Escolar Documentos
Profissional Documentos
Cultura Documentos
Operators and
maintenance personnel must read and understand this manual before operating
or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically
reviewed by all personnel who will come into contact with it.
This material is proprietary to Komatsu Mining Systems, Inc. and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Systems, Inc.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The Company
reserves the right to make changes or add improvements at any time without incurring any obligation to install
such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication. Customers
should contact their local distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and
lead compounds, chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
Wash hands after handling.
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 accomplishing 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 disassem-
bly, 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 drive train, 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:
Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories,
body liners, tailgates, etc.) and then weigh truck.
Record this value and subtract from the GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable
payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations
should be removed as often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
GENERAL INFORMATION
INDEX
TRANSMISSION
The TORQFLOW transmission assembly consists of BRAKE SYSTEM
a 3-element, single-stage, two-phase torque converter
Depressing the brake pedal actuates front and rear
driving a planetary gear, hydraulically-actuated multi-
air-over-hydraulic service brakes. The front service
ple disc clutch transmission which is force-lubricated
brakes are caliper disc type. The rear service brakes
for optimum heat dissipation.
are oil-cooled, multiple-disc brakes (acts also as re-
The TORQFLOW transmission is capable of seven (7) tarder).
forward speeds and one (1) reverse gear. Automatic
shifting is controlled by electronic shift control with
automatic clutch modulation in all gears.
A lockup system consisting of a wet, double-disc
clutch, is activated in F1–F7 gears for increased fuel
savings. RETARDER
The operator can manually apply the rear oil-cooled,
multiple-disc retarder brakes by moving the retarder
contol lever which is mounted on the steering column.
These brakes are automatically activated when the
FINAL DRIVE ASSEMBLY
engine speed exceeds the rated revolutions of the shift
The final drive consists of a plug-in differential with position.
planetary wheel drives.
This safety section also contains precautions for optional equipment and attachments.
SAFETY RULES
• ONLY trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
• When working with another operator or a person on worksite traffic duty, be sure all personnel understand all
hand signals that are to be used.
SAFETY FEATURES
• Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged. (See
Walk-Around Check, Page 3-17 )
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• NEVER remove any safety features. ALWAYS keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.
UNAUTHORIZED MODIFICATION
• Any modification made without authorization from Komatsu can create hazards.
• Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury
or damage caused by any unauthorized modification.
SAFETY AT WORKSITE
• Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
• Examine the road surface in the jobsite and determine the best and safest method of operation.
• Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
• If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty
or by installing fences around the worksite.
• Check the river bed condition, and depth and flow of water before crossing shallow parts of river. NEVER be in
water which is in excess of the permissible water depth.
• The operator must check personally the work position, roads to be used, and existence of obstacles before starting
operations.
• Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines
to travel.
FIRE PREVENTION
• Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compart-
ment. They could cause a fire.
• Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks
repaired. Wipe up any excess oil, fuel or other flammable fluids.
• Be sure a fire extinguisher is present and working.
• Do not operate the machine near any flame.
IN OPERATOR’S CAB
• Do not leave tools or spare parts lying around in the operator’s compartment. They may damage or break the
control levers or switches. Always put them in the tool box on the right side of the machine.
• Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
• Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use
seat belts when operating your machine.
TRAVELING
• When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is traveling, the steering wheel will not work, and it will be dangerous
to drive the machine. Apply the brakes immediately and stop the machine.
TRAVELING ON SLOPES
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, go down to level ground before turning.
• Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Take all possible steps to avoid traveling sideways, and always keep the travel
speed low.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly. Do
not use the foot brake except in an emergency.
• If the engine should stop on a slope, apply the brakes fully and apply the parking brake, also, to stop the machine.
WHEN LOADING
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
• Do not leave the operator’s seat during the loading operation.
WARNING TAG
• If others start the engine or operate the controls while you are performing service or lubrication, you could suffer
serious injury or death.
• ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working
on the machine. Attach additional warning tags around the machine, if necessary.
• These tags are available from your Komatsu distributor. (Part No. 09963-03000)
PROPER TOOLS
• Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools
could cause personal injury.
PERSONNEL
• Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.
ATTACHMENTS
• Place attachments that have been removed from the machine in a safe place so that they
do not fall. If they fall on you or others, serious injury could result.
• Spilled oil or grease, or scattered tools or broken pieces are dangerous because
they may cause you to slip or trip.
Always keep your machine clean and tidy.
• If water gets into the electrical system, there is danger that the machine may not
move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the
operator’s compartment.
USE OF LIGHTING
When checking fuel, oil, coolant, or battery electrolyte, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is
danger or explosion.
WASTE MATERIALS
HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones
on rough road surfaces. This may lead to serious injury or damage.
To maintain safety, always keep to the following conditions:
• Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
• Use the specified tires.
The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual
values may differ depending on the type of tire and the condition under which they are used. For details, please
contact your Komatsu distributor or tire maker.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly dangerous if the tires
become overheated when the tires are under pressure. If the gas generated inside the tire ignites, the internal pressure
will suddenly rise, and the tire will explode, and this may lead to serious personal injury. Explosions differ from
punctures or tire bursts, because the destructive force is extremely large. Therefore, the
following operations are strictly prohibited when the tire is under high internal pressure:
• Welding the rim
• Building fires or carrying out welding near the wheel or tire.
If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and
you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such
maintenance, please consult your Komatsu distributor or tire maker.
Prevention is the best safety program. Prevent a 2. Move behind the front of the left front tire, inspect
potential accident by knowing the employer’s safety the hub and brake assemblies for leaks and any
requirements and all necessary job site regulations, as abnormal conditions. Locate air system expan-
well as use and care of the safety equipment on the sion tank drain valve mounted on steering tubes,
truck. left frame rail and exhaust moisture by pulling
Only qualified operators or technicians should attempt chain toward tire.
to operate or maintain the truck. Check that all suspension attaching hardware is
secure and inspect for evidence of wear. Check
Safe practices start before the operator gets to that the suspension extension (exposed piston
the equipment! rod) is correct, and that there are no leaks.
• Wear the proper clothing. Loose fitting clothing, 3. Inspect fan and air conditioner belts for correct
unbuttoned sleeves and jackets, jewelry, etc., can tension, obvious wear, and tracking. Inspect fan
catch on a protrusion and cause a potential haz- guard for security and condition.
ard. 4. Look overhead at bottom of cab and check for
•Always use the personal safety equipment pro- steering control valve or hose leakage.
vided for the operator such as hard hat, safety 5. Move outboard of the front wheel, and inspect
shoes, safety glasses or goggles. There are some attaching lugs/wedges to be sure all are tight and
conditions when protective hearing devices complete. Check tires for cuts, damage or “bub-
should also be worn for operator safety. bles” and that inflation appears to be correct.
• When walking to and from the truck, maintain a 6. Move behind the rear of the front wheel, inspect
safe distance from all machines even if the opera- for leaks at hub or brakes or any unusual condi-
tor is visible. tions. Inspect suspension hardware to be sure it
is all in place. Inspect the tie-rod pivots and
steering cylinder for proper greasing, and for se-
At The Truck - Ground Level Walk Around curity of all parts. Inspect for any hydraulic leaks.
Inspection
7. Check pumps on front of transmission for leakage
At the beginning of each shift, a careful walk around and that all parts are secure.
inspection of the truck should be made before the Also check the transmission filter for leaks.
operator attempts engine start-up. A walk around in-
spection is a systematic ground level inspection of the 8. Inspect sight glass for transmission oil level. With
truck and its components to insure that the truck is safe engine stopped, hy-
to operate before entering the operator’s cab. draulic fluid should
be between the up-
Start at the left front corner of the truck (see illustration, per two marks.
next page), and move in a counter-clockwise direction, (Refer to decal on
front-to-rear, across the rear, and continuing forward t r an s mi s s i o n o i l
up the opposite side of the truck to the original starting pan.) Notify main-
point. If these steps are taken in sequence, and are tenance if oil ap-
repeated from the same point and in the same direction pears to be low.
before every shift, many potential problems may be
avoided.
If problems or potential problems are found during
the “walk-around”, be sure to notify maintenance.
16. Perform the same inspection on the right rear Check that the engine oil filters or oil lines to filters
suspension as done on the left. are not leaking.
3 1. Drain moisture
from tanks by
pulling chains (1)
on moisture drain
valves. Check air
tanks and lines
for leaks.
1. Insure all personnel are clear of truck before • The speedometer should display “88".
starting engine. • If the air pressure is below normal operating
Always sound the horn as a warning before actu- pressure, the central warning lamp should
ating any operational controls. flash and the buzzer should sound.
2. Check and insure Transmission Range Selector
is in the “Neutral” position before starting. • If the Shift Lever is not at the “N” position,
the central warning
3. In cold weather, if truck is equipped with auxiliary
lamp will flash and
heaters, do not attempt to start engine while
the alarm buzzer
heaters are in operation. Damage to coolant heat-
will sound intermit-
ers will result, due to lack of circulation.
tently. When the
4. The key switch has three positions: Off, On, Start. shift lever is moved
to the “N” position,
When the key switch is rotated one the lamp will go out and the buzzer will stop.
position clockwise, it is in the “On
(run)” position and all electrical cir-
cuits (except “start”) are activated. • When checking the
monitor, check all
Before Starting The Engine caution lamps and
pilot lamps at the
same time.
Press Lamp Check Switch -
During the following safety checks, if the alarm or Check to see that all caution lamps or pilot
red warning lamp does not turn “On” as required, lamps are illuminated.
OR, if the actuation or release of any emergency • Check the Manual Emergency Steering.
control, brake, or steering circuit does not appear With the key switch
normal, shut engine down immediately and notify in the ON position,
maintenance personnel. turn emergency
Do not operate truck until the circuit in question is steering switch ON
fully operational. (red light ON), and
c h e c k t ha t th e
steering wheel can
Perform the following checks to be certain that the be operated. If the
central warning system, alarm buzzer, and all steering wheel cannot be operated, notify
machine monitors and lamps are functional: maintenance personnel.
Do Not Operate truck.
• Turn the key switch to the “ON” position. • Check the Auto Emergency Steering.
(Do Not Start Engine). With the key switch in
t h e O N p os i t i on ,
NOTE: If the engine has been running, and then move Parking Brake
is stopped, the monitor cannot be checked until lever to the “OFF”
at least 30 seconds have passed. (unlocked) position.
Wait 1.5 seconds and
check that the emer-
gency steering is actuated and the steering can
be operated.
1. Test the truck steering in extreme right and left 5. Check for normal actuation of the Emergency
directions. Brake.
• With the machine on flat ground, verify the air
pressure gauge is indicating “normal” (green)
2. Check for normal actuation of the foot brake.
range.
• With the machine on flat ground,
• Move the Emergency Brake Lever to the
d e pr e ss Foot
BRAKE (“unlocked”) position.
Brake pedal.
• Set Shift Lever to the D position, and gradually
• Move Shift Lever
raise the engine
to the D position,
speed to full throt-
and gradually raise
tle. Check that the
the engine speed
machine does not
to 1680 rpm.
move.
If machine moves,
Check that the machine does not move. n ot i fy ma i nt e-
nance personnel immediately to repair brakes.
3. Check for normal actuation of the retarder. Do not operate truck until emergency brake
• With the machine is fully operational.
on flat ground,
pull Retarder
6. Check gauges, warning lights and instruments
Lever (1) fully.
before moving the truck to insure proper system
• Set Shift Lever operation and proper instrument functioning.
(2) to the D posi- Give special attention to braking and steering
tion, and gradu- circuit warning lights. If warning lights come on,
ally raise the engine speed to 1240 rpm. shut down the engine immediately and notify
Check that the machine does not move. maintenance personnel to determine the cause.
7. Insure headlights, worklights and taillights are in
proper working order. Good visibility may prevent
an accident. Check operation of windshield wiper
and washer.
If any of the red warning lights come “On” or if any 2. Do not drive over unprotected power cables.
gauge reads in the red area during truck operation, 3. When approaching or leaving a loading area,
a malfunction is indicated. Stop truck as soon as watch out for other vehicles and for personnel
safety permits, shut down engine if problem indi- working in the area.
cates and have problem corrected before resum-
ing truck operation. 4. When pulling in under a loader or shovel, follow
“Spotter” or “Shovel Operator” signals. The truck
operator may speed up loading operations by
1. Always sound the warning horn before moving the observing the location and loading cycle of the
truck. When backing the truck, give back-up sig- truck being loaded ahead, then follow a similar
nal (three blasts on air horn); when starting for- pattern.
ward, two blasts on air horn. These signals must
be given each time the truck is moved forward or 5. Operator should remain in truck cab with engine
backward. Look to the rear before backing the running while truck is being loaded. Place Trans-
truck. Watch for and obey ground spotter’s hand mission Range Selector in “Neutral” and apply
signals before making any reverse movements. Parking Brake lever.
Spotter should have a clear view of the total area
at the rear of the truck.
2. Operate the truck only while properly seated with
seat belt fastened. Keep hands and feet inside If operator must leave truck cab during loading,
the cab compartment while truck is in operation. engine must be shut down and parking brake ap-
Keep a firm grip on steering wheel at all times. plied. DO NOT use emergency brake for parking.
Remain far enough away from truck to avoid being
3. Check that all mirrors are not damaged, clean,
struck by flying material.
and are properly positioned for optimum view.
4. Check gauges and instruments frequently during
operation for proper readings. 6. When truck is loaded, pull away from shovel as
quickly as possible, but with extreme caution.
• Maintain engine RPM between 1800 - 2400 RPM, The rear brakes will not be released until engine speed
and falls below 2350 RPM.
The truck must not be towed except in emergen- Do not tow the truck any faster than 8 kph (5 MPH).
cies.
When towing becomes necessary, use the tow hook 8. Sudden movement may cause tow bar failure.
installed under the front frame and take the following Smooth and gradual truck movement is preferred.
precautions: 9. Minimize tow angle at all times - NEVER EXCEED
30o.
1. Block disabled truck to prevent movement while The towed truck must be steered in the direction
attaching tow bar. of the tow bar.
2. At the parking brake relay valve, remove both air If the emergency brake can not be released after its
hoses (4) connected to the air chambers of the emergency application – even if the emergency brake
parking brake spring cylinder assemblies (5). valve lever is put in RELEASE position – release the
emergency brake in the following manner:
Before releasing the air pressure from the emergency
brake reservoir, confirm safety in the surrounding area
and put chocks against the tires.
1. After making preparations to tow the machine, pull
rings (2) on the 4 drain valves on the front air tanks
to release the air pressure.
2. After exhausting all air pressure, release rings (2).
3. Drain the rear air tank by pulling and holding the
ring on the air drain valve mounted on the frame
in front of the right rear suspension. Keep drain
valve open until all air is exhausted from tank.
This will allow the emergency brake to release.
This warning plate is located inside the cab on the left-hand door panel under the arm rest. It contains (3) instructions
- Preparation for Operation, Precautions Prior to Moving Truck, and Hoist Control Lever operation. These decals
stress the importance of reading and understanding the operators manual prior to the operation of equipment.
This CAUTION plate is located on left hand side of the A plate is located next to filler cap on fuel cap which
radiator shroud. Extreme care should be taken when specifies Diesel Fuel Only. Care should be taken to
working around fan and belts. Hands and loose articles open cap slowly and bleed off pressure that may be in
of clothing should be kept away when machine is tank when removing filler cap.
operating. Operation and Maintenance Manual referred to is from
Engine Manufacturer.
This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard
units in parentheses. References throughout the manual to standard torques or other standard values will be to one
of the following Tables.
For values not shown in any of the charts or tables, standard conversion factors for most commonly used
measurements are provided in the conversion table below.
INDEX OF TABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
TABLE ISTANDARD TIGHTENING TORQUE COMMON CONVERSIONS
. . . . . . . For Capscrews and Nuts A5-2 TO CONVERT
MULTIPLY BY
FROM TO
millimeter (mm) inch -- in. 0.0394
TABLE IISTANDARD TIGHTENING TORQUE centimeter (cm) inch -- in. 0.3937
. . . . . . . . . . For Split Flange Bolts A5-2 meter (m) foot -- ft. 3.2808
meter (m) yard -- yd. 1.0936
kilometer (km) mile -- mi. 0.6210
TABLE III . . . . . TIGHTENING TORQUE FOR sq. centimeters (cm2) sq. in. -- in.2 0.1550
sq. centimeters (cm2) sq. ft. -- ft.2 0.001
. . Flared Tube And Hose Fittings A5-2 3
cu. centimeters (cm ) cu. in. -- in.3 0.061
liters (l) cu. in. -- in.3 61.02
3
cu. meters (m ) cu. ft. -- ft.3 35.314
TABLE IV TEMPERATURE CONVERSIONS A5-3 liters (l) cu. ft. -- ft.3 0.0353
grams (g) ounce -- oz. 0.0353
milliliter (ml) fluid ounce -- fl. oz. 0.0338
TABLE V . . . . . . TORQUE CONVERSIONS kilogram (kg) pound (mass) 2.2046
. . kilogram.meters To foot pounds A5-3 Newton (N) pound (force) -- lbs. 0.2248
Newton.meters (N.m) kilogram.meters (kg.m) 0.102
Newton.meters (N.m) ft. lbs. (force) 0.7376
TABLE VI . . . . . . TORQUE CONVERSIONS kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters To Newton.meters A5-3 kilogram.meters (kg.m) Newton.meters (N.m) 9.807
kilopascals (kPa) psi (pressure) 0.1450
megapascals (MPa) psi (pressure) 145.038
TABLE VII . . . . PRESSURE CONVERSIONS kilograms/cm2 (kg/cm2) psi (pressure) 14.2231
kilograms/cm2 (kg/cm2) kilopascals (kPa)
. . . . . . . . . . . kg/cm2 To (psi) A5-4 98.068
kilogram (kg) ton (short) 0.0011
metric ton ton (short) 1.1023
liters (l) quart -- qt. 1.0567
TABLEVIII . . . . PRESSURE CONVERSIONS liters (l) gallon -- gal. 0.2642
. . . . . . . . . . . . kg/cm2 To kPa A5-4 Watts HP (horsepower) 0.00134
kilowatts (kW) HP (horsepower) 1.3410
TABLE II
TIGHTENING TORQUE FOR SPLIT FLANGE BOLTS
TABLE III
TIGHTENING TORQUE FOR FLARED TUBE AND HOSE FITTINGS
NOTE: Tables such as Table V, VI, VII, VIII, and IX may be used as in the following example:
Example: Convert 955 kg.m to foot pounds (ft.lbs.).
(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable and a pressure of 20
kg/cm2 (285 psi) or less.
(2) Used for threaded areas (for example, stud, etc.) which are not removable and a pressure of 20 kg/cm2 (285
psi) or less.
PART NUMBERS
THREE BOND KOMATSU
TB1374 09940-00030
TB1521 790-129-9030
TB1104 790-129-9020
TB1108B 790-129-9010
High
Power 1450 ±50 1450 ±50
Control
RPM
Reset 2350 ±10 2350 ±10
clutch Engine @ low idle 16.5 ±1.5 (235 ±20) 16.5 ±1.5 (235 ±20)
Engine @ high idle 20.5 ±1.5 (290 ±20) 20.5 ±1.5 (290 ±20)
3RD clutch
Engine @ low idle
• Oil temperature: 20.5 ±1.5 (290 ±20) 20.5 ±1.5 (290 ±20)
Engine @ high idle 70° - 90°C (158° - 194°F) 31.5 ±1.5 (450 ±20) 31.5 ±1.5 (450 ±20)
1st, 2nd clutch
Engine @ low idle 2 31.5 ±1.5 (450 ±20) 31.5 ±1.5 (450 ±20)
• Engine water temperature: kg/cm
Engine @ high idle Within operating temperature (psi) 30 ±1.5 (435 ±20) 30 ±1.5 (435 ±20)
R clutch
Engine @ low idle 30 ±1.5 (435 ±20) 30 ±1.5 (435 ±20)
• Hydraulic oil temperature:
17 ±2 (242 ±28) 17 ±2 (242 ±28)
modulation Checker
STEERING VALVE
210 +15 210 +15
−0.0 −0.0
Engine @ Hi idle +215
• Oil temp.: 50° - 80°C (122° - 176°F) 2 (2986 ) (2986 +215 )
kg/cm −0.0 −0.0
Relief Pressure • Engine: Fulll throttle
(psi) +10
• Demand valve relief valve 185 185 +10
−0.0 −0.0
Engine @ Lo idle +140
(2630 ) (2630 +140 )
−0.0 −0.0
BRAKE PEDAL
kg
Operating Force Max 30 (Max. 66) Max 30 (Max. 66)
• Tip of pedal (lbs.)
Travel mm (in.) 78 ±8 (3 ±0.3) 78 ±15 (3 ±0.6)
RETARDER CONTROL LEVER
kg 1.0 - 4.0 0.5 - 6.0
Operating Force
• At point 10 mm (0.4 in) from tip of lever (lbs.) (2.2 - 8.8) (1.1 - 13.2)
Travel degrees 0 - 90 ±3 0 - 90 ±3
PARKING BRAKE LEVER
kg Max. 2.0 3.0
Operating Force • Tip of lever
(lbs.) (Max. 4.4) (6.6)
EMERGENCY BRAKE LEVER
kg 0.01 - 0.02 Max. 0.05
Operating Force • Tip of lever
(lbs.) (0.02 - 0.04) (Max. 0.10)
AIR GOVERNOR
• Pressure at which air is stored and 2
circuit is unloaded when air pressure is kg/cm 8.3 ±0.3 8.3 ±0.3
Set pressure
raised from 0 kg/cm2 (0 psi) with engine (psi) (120 ±4.3) (120 ±4.3)
at full throttle.
Shifter Lever SF (male) Between (4) - (2) [N] >1.0 V < 15.0 V
Between (5) - (2) [D] >1.0 V < 15.0 V
Between (6) - (2) [5] >1.0 V < 15.0 V
Between (7) - (2) [4] >1.0 V < 15.0 V
Between (8) - (2) [3] >1.0 V < 15.0 V
Between (9) - (2) [L] >1.0 V < 15.0 V
Between (1) - (2) 11.0 - 13.0 V
Relay
Emergency Steering
terminal 78 - Engine running: Minimum 20 V 1. Start engine.
Timer Relay
chassis
SUSPENSION CONTROLLER
1. Turn key switch
Verify normal conditions in circuit as listed below:
OFF.
Radiator Water Level 03 Radiator water level
Switch (male) Continuity 2. Disconnect 03.
normal
Between (1) - (2)
Radiator water level
No continuity
abnormal
1. Remove sensor
Verify normal resistances listed below: from suspension
cylinder.
FR Suspension 63 Between each connector -
500 - 1000Ω 2. Insert T-adapter.
Pressure Sensor (male) (3) - chassis
3. Verify there is no
FL Suspension 62 open or shorted
Pressure Sensor (male) circuit in wiring
harness.
4. Turn key switch ON.
AS5 2
Service Brake Switch Air pressure 0.6 kg/cm No continuity 2. Disconnect AS5.
(male) (8.5 psi) or above
Between (1) - (2)
2
Air pressure 0.2 kg/cm Continuity
(2.8 psi) or above
2
Emergency Brake AS4 Air pressure 4.9 kg/cm No continuity 2. Disconnect AS4.
Switch (male) (70 psi) or above
Between (1) - (2)
2
Air pressure 3.7 kg/cm Continuity
(52 psi) or above
1. Remove sensor
Verify normal voltage in circuit as listed below: from suspension
cylinder.
FL Suspension 13 Between (3) and chassis Approximately 0.45 - 1.50 V 2. Insert T-adapter.
Pressure Sensor (male)
3. Verify there is no
open or short circuit
in wiring harness.
4. Turn key switch ON.
STRUCTURES
INDEX
3. Disconnect all electrical wiring, air lines, and 3. Tighten capscrews to 35-43.5 kg.m (254-315
hydraulic lines that would interfer with the removal ft.lbs.) torque.
of the cab deck.
4. Attach lifting device with wood blocks (5,Figure
2-3) and lift deck section up and away from truck.
Removal
1. Lower deck section onto truck and align capscrew
mounting holes.
1. Disconnect the ground wire between the negative
2. Remove lifting device and
terminal of the batteries and the frame.
3. Install capscrews (2, Figure 2-4) and washers.
2. Disconnect all air hoses and electrical wiring
Tighten capscrews to standard torque.
leading from the right deck. Disconnect ground
strap between right deck and frame.
3. Attach a lifting device to the deck.
4. Remove the four (4) mounting capscrews (2,
Figure 2-4).
5. Remove deck from truck.
Removal Installation
1. Disconnect the ground wire between the negative 1. Install deck on truck and align mounting holes and
terminal of the batteries and the frame. the rear rubber mounting studs.
2. Remove the three plugs, capscrews and nuts from 2. Tighten all mounting hardware. Install the covers
the front of the center deck. over the front access holes.
3. Remove the two nuts (2, Figure 2-5) and lock- 3. Connect the ground wire between the negative
washers from the two rear rubber mounts. terminal of the batteries and the frame.
4. Remove deck from truck.
1. Park truck on hard level surface and block all 2. Remove mud flaps from both sides of the truck.
wheels. Using special sling (561-98-61350) con- Pin rock ejectors in the up position.
nect cables and lifting device to the dump body
3. On each side of the dump body, remove the hoist
and take up slack as illustrated in Figure 3-1.
cylinder pin retainer capscrew and washer (4 and
5, Figure 3-2) from the dump body brackets (1).
Before raising or lifting body be sure there is Some means of supporting hoist cylinders will be
adequate clearance between body and overhead necessary prior to removing hoist cylinder pin.
structures or electric power lines.
2. If not, adjust with shims (2). NOTE: Size of weld for body guide and wear plate is
0.31 inch (7.87 mm) unless otherwise specified. Use
AWS E 70 Series, Low Hydrogen Type Welding Rods,
such as E7016 or E7018.
BODY PIN
Inspection
Cleaning
The fuel tank is provided with a drain and a cleaning
port in the side that allows steam or solvent to be
utilized in cleaning tanks that have accumulated for-
eign material.
It is not necessary to remove the tank from the truck
for cleaning of sediment, however rust and scale on
the walls and baffles may require complete tank re-
moval. This allows cleaning solutions to be in contact
with all interior surfaces by rotating the tank in various
positions, etc.
Prior to a cleaning procedure of this type, all vents, fuel
gauges, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material have been removed, the temporary plugs can
be removed.
COOLING SYSTEM
RADIATOR
Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
BRAKE OIL COOLER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
FAN
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
FAN BELT
Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
ENGINE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-4
DRIVE LINE ADAPTER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
In addition, the air conditioning system condenser (2) 3. Remove grille. Remove steering oil cooler (4,
and a steering system oil cooler (4) are mounted in Figure 3-1).
front of the engine coolant radiator. A brake system 4. Remove the capscrews retaining the condenser
cooler is mounted below the rear of the radiator. core (2) to the radiator and rotate the condenser
core towards the left fender. Secure refrigerant
lines and condenser core away from radiator to
prevent possible damage during radiator re-
moval. If it is necessary to remove the condenser
Before removing any cooling system components, from the truck, refer to Section “M” and discharge
release cooling system pressure by turning radia- the refrigerant from the system, then remove the
tor cap counterclockwise to the first notch. Failure condenser.
to release pressure may result in hot coolant being
expelled causing serious injury.
Removal Removal
1. Drain engine coolant and the brake cooling oil. 1. Remove radiator, hood, grill, and water piping as
specified in Section “B” or earlier in this section.
2. Disconnect the two cooling water hoses (1, 2,
Figure 3-7) from the right side of the brake cooler. 2. The fan guard may be separated and removed or
can be moved back toward the engine clear of the
3. Disconnect the brake oil cooling lines (3, 5) from
fan hub.
the brake oil cooler.
3. Remove capscrews and lockwashers and lift fan
and spacer from pulley hub.
1. Fan Belt
2. Adjustment Nut
3. Tensioner Assembly
4. Tensioner Pulley
General Instructions
• Prior to disassembly or removal, tag or mark all air
lines, oil lines, fuel lines and electrical connections
to assure correct assembly at time of engine in-
stallation. Most electrical components have har-
ness connectors that can be disconnected quickly.
Refer to Section “D” for additional information
regarding connector types and disconnect instruc-
tions.
• Plug all ports and cover all hose fittings or connec-
tions when disconnected to prevent dirt or foreign
material from entering.
• Additional component disconnection and hookup
steps may be required during engine removal and FIGURE 4-1. HEATER RELAY
installation, depending on optional equipment in- 1. By-pass Filter 3. Heater Relay
stalled at the factory or by the end user. Refer to 2. Fuel Filter
Section “M” for additional information regarding
optional equipment.
2. Disconnect water pump pipes (1, Figure 4-2) and
hose (3).
3. Disconnect ground terminal (2) and alternator
Preparation For Engine Removal
output wire (4). Disconnect A/C compressor
Position the truck in work area with adequate clutch and heater relay at filters behind alternator.
overhead clearance to permit raising the dump
body.
Apply parking brake and block wheels to prevent
truck movement.
Raise body and install safety pin.
The temperatures in the table indicate the points at b. Place the positive lead of the voltmeter on the
which the first ice crystals appear. Lower temperatures positive battery post.
must be reached for a solid freeze. Solid freezing of c. Place the negative lead so that it touches the
the electrolyte may crack the battery case and damage battery case approximately one inch away from
the positive plates. As will be noted, a 3⁄4 charged the positive post.
battery is in no danger of freezing, therefore, a 3⁄4
d. The voltmeter should indicate 0.0 volts. If any
charge or better is desirable, especially during winter
voltage is indicated, there is a path that will dis-
weather.
charge the battery. The higher the voltage, the
quicker the discharge rate.
e. Move the negative probe to several locations
(near the positive post) to verify the test results.
Do not attempt to charge a frozen battery. Serious If voltage was detected in the previous test, the battery
injuries to service personnel can result! should be cleaned. The top of the battery may be wiped
off with a damp cloth or washed with a baking soda or
ammonia solution. If the battery is washed, be sure
Maintenance and Troubleshooting none of the cleaning solution is allowed into the battery
cells. Be sure terminals are clean and tight. Clean
Two most common troubles that occur in the charging terminals are very important in a voltage regulated
system are undercharging and overcharging of the system. Be sure to clean the entire battery compart-
truck’s batteries. ment thoroughly as it may contain acid residue. Be
An undercharged battery is incapable of providing careful not to splash any overspray onto surrounding
sufficient power to the truck’s electrical system. components. Rinse the area completely to remove all
traces of battery acid from machine.
Spillage
Addition of acid will be necessary if considerable elec-
trolyte has been lost through spillage. Before adding
acid, make sure battery is fully charged. This is accom-
plished by putting the battery on charge and taking
hourly specific gravity readings on each cell. When all
the cells are gassing freely and three successive
hourly readings show no rise in specific gravity, the
battery is considered charged. Additional acid may
now be added. Continue charging for another hour and
again check specific gravity. Repeat the above proce-
dure until all cells indicate a specific gravity of 1.260-
1.265 corrected to 80°F (27°C).
NOTE: Use 1.400 strength sulphuric acid when mak-
ing specific gravity adjustments. Acid of higher
strength will attack the plates and separators before it
has a chance to diffuse into the solution.
Check Valve
The Prelub starter is an electric starter motor which
has an extended armature shaft to drive an attached The oil pressure supply hose has a check valve in-
oil pump (1, Figure 2-4) at the brush end of the starter. stalled between the Prelub unit and the engine. The
check valve prevents the passage of oil from the
engine back to the pan after the engine is started. The
The Prelub Starter mounting is the same as that used oil flow through the valve is toward the engine as
for the standard starter. Engine oil is drawn through a indicated by an arrow on the valve.
suction hose attached to the oil pan, and then returned
to the engine through an outlet line attached to the Timer Solenoid
engine oil supply ahead of the filters.
The timer solenoid (6) controls the prelubrication cycle.
NOTE: Before starting engine in cold weather, refer to Current is supplied to the timer through the keyswitch.
the Operation & Maintenance Manual, Section 3 for The ground path is completed by the normally closed
proper starting procedure. pressure switch which is preset to open at 0.18 kg/cm2
(2.5 psi).
When the switch opens, current is redirected to the
standard starter solenoid for engine cranking, follow-
ing a 3 second delay.
OPERATION
The Prelub starter is activated when the operator
turns the key switch and holds it in the ‘‘start’’ position.
The normal starter solenoid is bypassed and the cur-
rent flows to the Prelub Starter Solenoid Timer.
When this Solenoid Timer is activated, current flows to
the Prelub Starter motor, but does not engage the
starter pinion gear. The motor drives the Prelub
pump assembly which will deliver approximately 57
liters (15 gallons) of oil per minute to the engine. DO NOT attempt to jump start the truck using the
terminals on the timer solenoid. INTERNAL DAM-
AGE TP THE TIMER WILL RESULT.
WH = White
OR = Orange
PK = Pink
RED = Red
PUR = Purple
BK = Black
YL = Yellow
GN = Green
WH/BK = White with black stripe
Prelub System Operation Brush dust will be present in all motors. Do not
Verify system operates according to the two phases of confuse brush dust with oil. Brush dust will appear
operation as listed in ‘‘Troubleshooting Prelub Starter as a black/brown, dry coating within the motor.
Circuit’’ on the following page. If a problem exists, refer
to the list of problems and possible causes for trou-
bleshooting system components. 4. If oil is present in the motor, install a 14 kg/cm2
(200 psi) gauge in the pump pressure test port (3)
If system is operating properly, continue with the in- located near the pump outlet hose.
spection of component parts below:
5. Close the battery disconnect switch or reconnect
Starter/Prelub Pump batteries and observe the pressure gauge while
the engine is started.
The starter motor (with the Prelub pump) should be
inspected as follows for possible oil leakage from the a. If there is any indication of pressure, remove
pump to the starter housing. and repair the the Prelub starting motor and
the check valve located between the pump
1. Disconnect batteries or open the battery discon- outlet and the engine/filters.
nect switch to prevent engine startup. b. If there is no indication of pressure, remove and
2. Remove the inspection plug (2, Figure 2-4). repair the Prelub starter motor only.
3. Using a flashlight (and mirror if necessary), in- 6. If no oil is present, carefully reinstall inspection
spect interior of starter motor housing for the plug (2).
presence of engine oil. Oil may be present in large
amounts or as a light mist. Oil in any quantity in
the housing indicates a failed motor and re-
pair or replacement is necessary. Perform
additional tests below to determine what compo- Check Valve
nents require repair. Verify no internal leakage exists in the check valve
when the engine is running. Check valve leakage back
to the Prelub pump will cause extensive damage to
the pump and starter motor.
If check valve replacement is required, be certain the
valve is installed with the arrow pointed toward the
engine, NOT toward the pump.
Timer Solenoid
Inspect Timer Solenoid for physical damage and to
verify wiring is in good condition.
1. Prelubrication Phase- Begins when the key 2. Delay and Crank Phase- Begins when the pres-
switch is held in the start position. A circuit is sure switch opens. A 3 second delay precedes
provided to ground through the normally closed the crank mode.
pressure switch. The circuit is interrupted upon
opening of the pressure switch when the Prelub
pressure reaches 0.18 kg/cm2 (2.5 psi).
Meters (speedometer, tachometer, service me- 11. Torque converter oil temperature display
ter, odometer). 12. Retarder oil temperature display
Gauges (air pressure, engine coolant tempera- 13. Fuel level display
ture, torque converter oil temperature, retarder oil
temperature, fuel level). 14. Caution/pilot lamp output
ENGINE WATER TEMPERATURE SENSOR The signal is sent from the transmission shift controller
through the network to the machine monitor panel, and
RETARDER OIL TEMPERATURE SENSOR the air pressure is displayed. If the air pressure goes
below the specified pressure (5.3 kg/cm2, 75 psi), the
TORQUE CONVERTER OIL TEMPERATURE monitor panel lamp flashes and the alarm buzzer
SENSOR sounds to warn the operator of the abnormality.
1. Magnet 4. Boot
2. Terminal 5. Connector
3. Case
This switch is used by the operator to control the idle When the switch is “out”, normal position, the light in
speed of the engine. The switch when pushed “in” the the switch “OFF”, this is the automatic position. In this
light in the switch will be “ON”, is in the manual position the engine is controlled automatically depend-
position. This provides for “LOW” engine idle speed. ing on operating status of the truck. The following chart
In this position the operator has greater control for outlines the conditions for the engine idle speed.
movement in confined spaces, such as parking or
driving in or out of service areas.
1. Disconnecting connectors
When disconnecting the connectors, hold the con-
nectors and not the wires (Figure 4-7). For con-
nectors held by a screw, loosen the screw fully,
then hold the male and female connectors in each
hand and pull apart. For connectors which have
FIGURE 4-7. DISCONNECTING CONNECTORS
a lock tab, press down the tab with your thumb
and pull the connectors apart.
NOTE: Never pull with one hand.
Sealing openings
• After any piping or component is removed, the
openings should be sealed with caps, plugs,
tapes, or vinyl bags to prevent any dirt or dust
form entering. If the opening is left open or is
blocked with a rag, there is danger of dirt enter-
ing or of the surrounding area becoming dirty
from the leaking oil.
• Do not simply drain oil out on to the ground, FIGURE 4-20. OIL PUMP WITH FILTER
collect it and dispose of it properly.
Flushing operations
• After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the system.
• Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and FIGURE 4-21. OIL FLUSHING
secondary flushing is carried out with the speci-
fied oil.
Cleaning operations
• After repairing the equipment (pump, control
valve, etc.) or when running the truck, carry out
oil cleaning to remove the sludge or contami-
nants in the oil circuit.
• The oil cleaning equipment is used to remove
the ultra fine (about 3µ) particles that the filters
installed on the truck are unable to remove.
Note: The following should be observed while performing steps 1 through 5, page 35.
FIGURE 4-37. FIRST FAULT OCCURED FIGURE 4-38. LAST FAULT OCCURED
• This shows that the fault first occured • Shows that the fault last occurred 1hour
1151hours ago. ago.
Shift to F2. L clutch (bit No. 1, Figure 4-43) and 2nd clutch (bit
Check that parking brake and
No. 5) are engaged and applicable portion lights up
retarder brake are applied, then
operate shift lever to D position
L clutch (bit No. 1 ) and 2nd clutch (bit No. 5) are disengaged
Return shift lever to N position
and applicable portion goes out
MONITOR PANEL
After the starting switch is turned ON, the monitor itself carries out self-diagnosis. After that, it goes to the normal
display.
Check the bulbs of the pilot and caution lamps by pressing the lamp check switch at the right edge of the panel.
For details of the service codes, see SERVICE CODE TABLE.
TRANSMISSION CONTROLLER
1. Self-diagnostic display, warning display
The content of the self-diagnosis and warning is displayed by a 2-digit LED code.
If any abnormality is detected during self-diagnosis, the fault occurrence data is sent to the network and the action
code is displayed on the monitor panel. The electronic controller display on the monitor panel may also light up. The
warning lamp and buzzer may also be actuated.
The warning display is the detection of a fault in the pilot lamp display sensor systems and warnings and warning
actuations. If problems are detected, the warning lamp and buzzer may also be actuated.
Explanation of symbols: [ ] 1 - 8: indicates that there are display patterns from 1 to 8 that appear in the [ ] portion.
1. : Lock - up clutch related parts
2. : H clutch related parts
3. : L clutch related parts
4. : 1st clutch related parts
5. : 2nd clutch related parts
6. : 3rd clutch related parts
7. : 4th clutch related
8. : R clutch related parts
|_| : Blank (no display)
NOTE: See the next page for explanation of the symbols used in the action of controller column.
- (intermediate shaft
1.2 F2
sensor)
2 Apply exhaust brake during travel test. (When traveling in lock - up, operate the exhaust brake switch
then the accelerator released)
6 If there is a fault in the sensor system, turn the key switch OFF - ON.
Display method: The code display starts with the faults that have occurred in order, and after completing the display
of the content of all the faults, the display returns to the first code display. It continues to repeat this order. If the fault
is repaired, it returns to the normal display 5 minutes after the repair.
To make full use of the memory function to clearly display when the failure occurred and what failures have already
been corrected, keep strictly to the procedure given below.
Deleting service code from memory
For details of the method of deletion, see Method of deleting trouble data from memory (page D4-48)
Carry out troubleshooting, and when the fault has been repaired, the self-diagnostic display returned to normal, to
delete the transmission controller service codes from memory, turn the starting switch OFF, then turn it ON again,
and check the past faults in memory have been deleted
For details, see MONITOR PANEL ACTION CODES AND SERVICE MODE FUNCTION, Method of deleting trouble
data from memory.
(if the data have been deleted, 8.8 is displayed for 3 seconds, then the display shows the part number, and after 3.5
seconds, the display returns to the normal display of 0.0 or 0.C)
Note 1: ‘‘Existing’’ means that the problem is still occurring; ‘‘history’’ means that the problem occurred in the past.
Note 2: If the problem is still existing, the alarm buzzer will also sound. (When the central warning lamp is ON).
FIGURE 4-50.
FIGURE 4-51.
Adjustment procedure
NOTE: Turn off the power, then remove the electronic
monitor and carry out adjustments at the rear of the
speedometer.
1. Remove the rubber cap from # 2 port at the rear FIGURE 4-52. ADJUSTING SPEEDOMETER
of the speedometer.
2. When the rubber cap is removed, a rotary switch
can be seen (See Figure 4-53).
3. Using a flat-headed screwdriver, turn this switch
and adjust to the values in the table below.
Switch position 0 1 2 3 4 5 6 7
Compensation (%) +7 +6 +5 +4 +3 +2 +1 0
Switch position 8 9 A B C D E F
Compensation (%) 0 -1 -2 -3 -4 -5 -6 -7
A. Outline
NOTE: If the transmission controller is going to be used
on another truck, delete the trouble data and other data
related to the current truck from the memory of the
transmission controller and PMC as follows. FIGURE 4-55. MODE SWITCHES
1. Bulb Check Switch 3. Mode Switch (Black)
1. This function is used to delete data from the 2. Mode Switch (Red)
memory of the transmission controller and PMC.
2. This function is effected by operating bulb check
switch (1, Figure 4-55) and mode change
switches (2) (the red switch at the front of the truck
and (3) (the black switch at the rear of the ma-
chine) and using the S-NET to send the command
from the monitor panel to each controller to delete
the data from memory.
3. The monitor panel accepts the operation for their
function only when the key switch is ON and the
engine is stopped.
In addition, each controller also accepts the op-
eration for this function only when the key switch
in ON and the engine is stopped.
4. To prevent the data from being deleted from the
memory of the wrong controller, an instrument
panel caution display (5, Figure 4-56) lights up to
make it possible to confirm the controller from FIGURE 4-56. CONFIRMING DATA DELETION
which the data is being deleted. 5. Caution Light
C. Method of operation
1. (Shown at location A in figure 4-57)
Operate bulb check switch (1, Figure 4-58) and
both mode change switches (2) & (3). Keep the
switches pressed to the ON position at the same
time for at least 2.5 seconds, then release them.
(When the switches are released, they will return
automatically to the OFF position).
2. (Shown at location B in Figure 4-57)
No particular operation is needed; after Step 1
and display (3) is shown, the display automat-
ically changes to display (4).
3. (Shown at location D in Figure 4-57)
Operate bulb check switch (1, Figure 4-58) and
FIGURE 4-58. MODE SWITCHES
both mode change switches (2) & (3). Keep the
switches pressed to the ON position at the same 1. Bulb Check Switch 3. Mode Switch (Black)
time for at least 5 seconds, then release them. 2. Mode Switch (Red)
(When the switches are released, they will return
automatically to the OFF position).
E. Remarks
The memory data deletion mode is also in the normal
mode except for the other mechatronics caution dis-
play (6).
Points to remember when carrying out troubleshooting of transmission controller system D5-4
Action taken by self-diagnostic device and problems on the truck D5-6
Table for transmission controller, transmission related parts D5-26
Details of fault Check the wiring harnesses and equipment given below :
Display Fault Conditions Disconnection, short circuit in wiring harness (+): Positive, (-): Negative
code Possible causes:
(E.C ↔ d.A) supply voltage and battery voltage: Min. 5V 1) Between alternator terminal B - emergency steering relay terminal
B - battery 4 (+)
2) Between alternator terminal E - chassis
When controller input voltage has become weak
1. Alternator output faulty
b0db Drop in main supply power voltage
2. Battery tends to become discharged
Difference in electric potential between
(E. ↔ 0.2)
is 500 rpm or more and input voltage is 20V 2. Between ATC (1), (12) - TMC (2) - R25 (5), (3) (transmission cut relay)
(E.C ↔ 0.2) or more: 18V - BT1 fuse No. 10
1. Defective handling of machine
2. Defective controller system
N safety 1) Looseness of J07, circuit breaker, battery (+)
With key switch "ON" Shift lever at position 2) Defective insertion of fuse BT1 fuse (No. 10)
b003 other than N 3) Defective contact of connectors ATC (9), (17), TMB (11)
(E. ↔ 0.3) There may also be sudden cut in power 4) Looseness of terminal J06, battery relay E
(E.C ↔ 0.3) (when there is defective contact of control 5) Defective contact of connectors ATC1 (8), (16), TMC (1)
power and power is momentarily cut and
comes on again)
The top code in th Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)
1. Defective controller
2. Defective fill switch
3. Between H SW - TM3 (3) - ATC5A (12)
Double engagement of clutch Between L SW - TM3 (6) - ATC5A (10)
With double engagement of clutch, Between R SW - TM3 (9) - ATC5A (13)
b005
input of fill sensor signal was Between 1 SW - TM4 (3) - ATC5A (14)
(E. ↔ 0.5)
detected Between 2 SW - TM4 (6) - ATC5A (15)
(E.C ↔ 0.5) Double engagement: Actuated for Between 3 SW - TM4 (9) - ATC5A (11)
2.1 - 4.7 sec Between 4 SW - TM4 (12) - ATC5A (16)
2. Between ATC1 (15) - TMC (3) - R25 (2), (1) (transmission cut relay) BT1 fuse
(E.C ↔ 0.6) terminal voltage No. 10
• When actuated: > 11V
• When not actuated: < 11V
Rear brake 3. Between (+) ATC1 (5) - TMC (10) - BT1 fuse No. 10
(E.C ↔ 0.8) • When actuated: > 11V 4. Defective rear brake solenoid
•When not actuated < 11V
Disconnection, short circuit, short
circuit with ground in exhaust brake 1. Between (+) ATC1 (14) - TMB (15) - RH4 (5) - GND ER
b009
solenoid 2. Between (-) SL5 (2) - RH4 (5) - GND ER
(E. ↔ 1.0)
Exhaust brake 3. Between (+) SL5 (1) RH4 (5) - BT1 fuse No. 10
(E.C ↔ 1.0) • When actuated: > 11V 4. Defective exhaust brake solenoid
• When not actuated: < 11V
1. Engine speed sensor
1) Between E12 (1) - J09M (9) - TMD (13) - ATC3A (13)
b010 Defective engine speed sensor output
2) Between E12 (2) - J09M (10) - TMD (14) - ATC3A (14)
Engine speed less than 350 rpm
b011
actuated but there is no sensor 1) Between N1 (1) - TM2 (1) - ATC3A (2)
(E. ↔ 1.1)
signal 2) Between N2 (2) - TM2 (2) - ATC3A (14)
(E.C ↔ 1.1) 2. Defective input shaft speed sensor
(E.C ↔ 1.2) actuated but there is no sensor 2) Between N2 (2) - TM2 (4) - ATC3A (14)
signal
The top code in the Display code column shows the monitor panel display and the bottom code (in [ ]) shows
the transmission controller LED display. (< less than - > greater than)
H SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (12) - chassis > 1M Ω or > 1 M Ω
between terminals
L SM (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (10) - chassis
Transmission suddenly
Actuates transmission
R SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (13) - chassis shifts to Neutral during
cut relay and shift to
1 SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (14) - chassis propel or truck cannot
Neutral
move again
2 SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (15) - chassis
3 SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (11) - chassis
4 SW (male) - chassis TM3 (male) (12) - chassis ATC5A (female) (16) - chassis
Transmission suddenly
AT1 TMC R25 (V) Ω shifts to Neutral during
Actuates transmission propel or truck cannot
(15) - chassis (1) - chassis (1) - chassis 20 - 30 V -
cut relay and shift to move again
- - Between relay - 100 - 500 Ω Neutral
(1) - (2)
1. Between ATC2 (14) - chassis (V): 12V 12V output circuit Transmission suddenly
2. Between TMB (1) - chassis (V): 12V OFF (does not give shifts to Neutral during
3. Between SF (1) - (2) (V): 12V +12V) propel or truck cannot
4. Each terminal of ATC2 (14), TMB (1), DF (1) - chassis: > 1MΩ Shifts to Neutral move again
Even when engine
Only gives self- speed exceeds 2,600
1. Between ATC2 (13) - chassis: 20 - 60 Ω
diagnostic display; rpm and engine
2. Between SL4 (male) (1) - (2): 20 - 60 Ω does nottake any overruns, brake to
3. Between ATC1 (13) - ATC1 (4) (V): 20 30 V action prevent overrun is not
actuated
Even when accelerator
pedal is released and
1. Between ATC1 (14) - chassis: 20 - 60 Ω
Operation of exhaust retarder lever is
2. Between SL4 (male) (1) - (2): L 20 - 60 Ω brake function stopped opeated, exhaust brake
3. Between ATC (5) - (14) (V): 20 - 30 V is not actuated.
1. gearshifting
Speed range used
1. Engine speed display on monitor panel is normal. becomes impossible.
during propel is
2. If shift lever is set to
2. Between ATC3A (13) - (14): 500 - 1,000 Ω, AC: > 0.5V maintained
Neutral, it becomes
3. Between each terminal ATC3A (13), (14) - chassis: > 1MΩ If shift lever is at
impossible to move
4. Between E12 (male) (1) - (2): 500 - 1,000Ω Neutral, transmission
truck again unless it is
is held in Neutral
stopped.
1. Gearshifting bec-
Speed range used omes impossible.
ATC3A (female) TM2 (male) N1 (male) Ω. during propel is 2. If shift lever is set
maintained to Neutral, it bec-
Between (2) - (14) Between (1) - (2) Between (1) - (2) 500 - 1,000 Ω
If shift lever is at omes impossible
Each terminal - chassis > 1MΩ. Neutral, transmission to move truck
is held in Neutral again unless it is
stopped.
1. Gearshifting be
comes impossi
Speed range used
ble.
ATC3A (female) TM2 (male) N2 (male) Ω during propel is
2. If shift lever is set
maintained
Between (14) - (12) Between (3) - (4) Between (1) - (2) 500 - 1,000 Ω to Neutral, it be
If shift lever is at
comes imposs
Each terminal - chassis > 1M Ω. Neutral, transmission
‘ ible to move
is held in Neutral
truck again un
less it is stopped.
Disconnection in transmission
output shaft speed ssensor
If disconnection detection is
b014
turned "ON", depending on 1. Between ATC5B (13) - ATC1 (8)
(E. ↔ 1.4)
the wiring harness, the 2. Defective contact of ATC5B, ATC1 connector
(E.C ↔ 1.4) model selection signal
does not match
Short circuit, short circuit with 1. R Between ATC5B (2) - TMB (2) - SF (3)
b015 ground in lever signal circuit N Between ATC5B (3) - TMB (3) - SF (4)
(E. ↔ 1.5) When two or more lever D Between ATC5B (4) - TMB (4) - SF (5)
(E.C ↔ 1.5) signals are generated, and 5 Between ATC5B (5) - TMB (5) - SF (6)
this continues for 3 seconds 4 Between ATC5B (6) - TMB (6) - SF (7)
3 Between ATC5B (7) - TMB (7) - SF (8)
L Between ATC5B (8) - TMB (8) - SF (9)
GND Between ATC5A (16) - TMB (9) - SF (2)
b016 Disconnection in lever signal circuit 2. Defective shift lever
(E. ↔ 1.6) When there is no lever
b028
(E. ↔ 2.2) speed, intermediate shaft Speed sensor 2) Between N1 (2) - TM2 (2) - ATC3A (14)
speed, output shaft speed 2. Output shaft 1) Between N3 (1) - TM2 (1) - ATC3A (5)
(E.C ↔ 2.2)
are converted and it is Speed sensor 2) Between N3 (2) - TM2 (6) - ATC3A (14)
found that there is an fault 3. One of following clutches worn or damaged: H, L, 1st, 2nd, 3rd, 4th, R
(E. ↔ 2.8) with either the HL clutch or
(E.C ↔ 2.8) speed clutch.
b022
Defective H clutch or input shaft See itmes for display codes b022 - b028
(E. ↔ 2.2)
speed sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.2)
b023
Defective L clutch or input shaft See items for display codes b022 - b028
(E. ↔ 2.3)
speed sensor system (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.3)
The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows
the transmission controller LED display. (< less than - > greater than)
1
1. Transmission
ATC3A (female) Ω suddenly shifts to
Neutral during propel
Between (2) - (14) 500 - 1,000 Ω. or truck cannot move
Between (12 - (14) again
Shift to Neutral
Between (3) - (14)
2. Power is lost when in
propel , and trans-
Each terminal - chassis > 1 MΩ mission repeatedly
shifts when going
2. See TESTING AND ADJUSTING OF TRANSMISSION
uphill
3. Transmission oil is not black enough to indicate problem
See items for display
1. Between ATC3A (female) (2) - (14): 500 - 1,000 Ω. codes b022 - b028
Shift to Neutral
2. See TESTING AND ADJUSTING OF TRANSMISSION, H clutch portion. (E. ↔ 2.2, E.C ↔ 2.2,
E. ↔ 2.8, E.C ↔ 2.8)
See items for display
1. Between ATC3A (female) (2) - (14): 500 - 1,000 Ω. codes b022 - b028
Shift to Neurtral
2. See TESTING AND ADJUSTING OF TRANSMISSION, L clutch portion. (E. ↔ 2.2, E.C ↔ 2.2,
E. ↔ 2.8, E.C ↔ 2.8)
b024
Defective 1st clutch or output shaft speed See items for display codes b022 - b028
(E. ↔ 2.4)
sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.4)
b025
Defective 2nd clutch or ouput shaft speed See items for display codes b022 - b028
(E. ↔ 2.5)
sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.5)
b026
See itmes for display codes b022 - b028
(E. ↔ 2.6) Defective 3rd clutch or output speed sensor
(E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.6)
b027
Defective 4th clutch or output shaft speed See items for display codes b022 - b028
(E. ↔ 2.7)
sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.7)
b028
Defective R clutch or output shaft speed See itmes for display codes b022 - b028
(E. ↔ 2.8)
sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.8)
b032
b038 1. Dirt caught in pressure control spool
(E. ↔ 3.2) 2. Short circuit, short circuit with ground in fill detection switch
(E.C ↔ 3.2) Defective pressure control valve 1) Between H SW - TM3 (3) - ATC5A (12)
ï When the controller is issuing the com 2) Between L SW - TM3 (6) - ATC5A (10)
(E. ↔ 3.8) mand to disengage the clutch, but the fill 3) Between R SW - TM3 (9) - ATC5A (16)
(E.C ↔ 3.8) signal is still being sent (clutch is en- 4) Between 1 SW - TM4 (3) - ATC5A (13)
gaged) 5) Between 2 SW - TM4 (6) - ATC5A (14)
6) Between 3 SW - TM4 (9) - ATC5A (15)
7) Between 4 SW - TM4 (12) - ATC5A (11)
b032
1. Dirt caught in H clutch pressure control spool
(E. ↔ 3.2) Defective H clutch pressure control valve
2. Between HSW - TM3 (3) - ATC5A (12)
(E.C ↔ 3.2)
b033
1. Dirt caught in L clutch pressure control spool
(E. ↔ 3.3) Defective L clutch pressure control valve
2. Between LSW - TM3 (6) - ATC5A (10)
(E.C ↔ 3.3)
b034
1. Dirt caught in 1 clutch pressure control spool
(E. ↔ 3.4) Defective 1st clutch pressure control valve
2. Between 1SW - TM4 (3) - ATC5A (13)
(E.C ↔ 3.4)
b035
1. Dirt caught in 2 clutch pressure control spool
(E. ↔ 3.5) Defective 2nd clutch pressure control valve
2. Between 2SW - TM4 (6) - ATC5A (14)
(E.C ↔ 3.5)
b036
1. Dirt caught in 3 clutch pressure control spool
(E. ↔ 3.6) Defective 3rd clutch pressure control valve
2. Between 3SW - Tm4 (9) - ATC5A (15)
(E.C ↔ 3.6)
b037
1. Dirt caught in 4 clutch pressure control spool
(E. ↔ 3.7) Defective 4th clutch pressure control valve
2. Between 4SW - TM4 (12) - ATC5A (11)
(E.C ↔ 3.7)
b038
1. Dirt caught in R clutch pressure control spool
(E. ↔ 3.8) Defective R clutch pressure control valve
2. Between RSW - TM3 (9) - ATC5A (16)
(E.C ↔ 3.8)
Action of
controller Symptoms that appear in truck when there is
Condition when normal: Check with tester
when fault Mechantronics display given, warning
Voltage (V), current (A), resistance value Ω
fault is actuated
detected
See items for display codes b022 - b028
1. Between ATC3A (female) (3) - (14): 500 - 1,000 Ω Shift to
(E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
2. SeeTESTING AND ADJUSTING OF TRANSMISSION, 1st clutch portion. Neurtral
H SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (12) - chassis >1MΩ
or
H SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (10) - chassis > 1M Ω
between Shift to Transmission suddenly shifts to Neutral during
H SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (16) - chassis
terminals
Neutral propel or truck cannot move again
H SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (13) - chassis
H SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (14) - chassis
H SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (15) - chassis
H SW (male) - chassis TM3 (male) (12) - chassis ATC5A (female) (11) - chassis
L SW (male) TM3 (female) ATC5A (female) > 1 M Ω or > 1 M Ω Shift to Transmission suddenly shifts to neutral during
(6) - chassis (10) - chassis between terminals Neutral propel or truck cannot move again
(E.C ↔ 5.2) issues the command, but the fill sensor signal is not 6) Between 2 SW - TM4 (9) - ATC5A (15)
given. However, the clutch is engaged. 7) Between 4 SW - TM4 (12) - ATC5A (11)
(E. ↔ 5.8) 2. Defective fill switch
(E.C ↔ 5.8)
The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows
the transmission controller LED display. (< less than - > greater than)
When each gear range is engaged using the shift checker, the fill
switch signal is given with the combinations shown in Table 1
F5 O O
F6 O O
F7 O O
When each gear range is engaged with the shift checker, the fill See items for display 1. Gearshifting during propel becomes
switch signal is issued for the combinations in Table 1 of the items codes b052 - b058 impossible.
for display codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, 2. If shift lever is in Neutral, it becomes
(E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8) E. ↔ 5.8, E.C ↔ 5.8) impossible to move truck
When each gear range is engaged with the shift checker, the fill
See items for display 1. Gearshifting during propel becomes
switch signal is issued for the combinations in Talbe 1 of the items
codes b052 - b058 impossible.
for display codes b052 - b058
(E. ↔ 5.2, E.C ↔ 5.2, 2. If shift lever is in Neutral, it becomes
(E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8)
E. ↔ 5.8, E.C ↔ 5.8) impossible to move truck
b055
1. Between 2SW - TM4 (6) - ATC5A (14)
(E. ↔ 5.5) Defective 2nd clutch flow control valve
2. Defective 2nd clutch fill switch
(E.C ↔ 5.5)
b056
1. Between 3SW - TM4 (9) - ATC5A (15)
(E. ↔ 5.6) Defective 3rd clutch flow control valve
2. Defective 3rd clutch fill switch
(E.C ↔ 5.6)
b057
1. Between 4SW - TM4 (12) - ASTC5A (11)
(E. ↔ 4.4) Defective 4th clutch flow control valve
2. Defective 4th clutch fill switch
(E.C ↔ 4.4)
b058
1. Between RSW - TM3 (9) - ATC5A (16)
(E. ↔ 5.8) Defective R clutch flow control valve
2. Defective R clutch fill switch
(E.C ↔ 5.8)
1. 1) Lock-up
Between (+) L/U.t (1) - ATC1 (1)
Between (-) L/U.T (2) - ATC1 (8), (16)
2) H clutch Between (+) H.PS (2) - ATC2 (9)
Between (-) H.PS (2) - ATC2 (19)
b071 Short cirucuit in pressure control 3) L clutch Between (+) L.PS (1) - ATC2 (7)
solenoid Between (-) L.PS (2) - ATC2 (17)
When it is tried to disengage the
b071
Short circuit in lock-up pressure control See items for display codes b071 - b078
(E. ↔ 7.1)
solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8)
(E.C ↔ 7.1)
b072
Short circuit in H clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.2)
solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8)
(E.C ↔ 7.2)
b073
Short circuit in L clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.3)
solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8)
(E.C ↔ 7.3)
b074
Short circuit in 1st clutch pressure See items for display codes b071 - b078
(E. ↔ 7.4)
control solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8)
(E.C ↔ 7.4)
b075
Short circuit in 2nd clutch pressure See items for display codes b071 - b078
(E. ↔ 7.5)
control solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8)
(E.C ↔ 5.5)
The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows
the transmission controller LED display. (< less than - > greater than)
Transmission suddenly
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to shifts to Neutral during
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral propel or truck cannot
move again
Transmission suddenly
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to shifts to Neutral during
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C↔ 7.8) Neutral propel or turck cannot
move again
Transmission suddenly
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to shifts to Neutral during
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral propel or truck cannot
move again
Transmission suddenly
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to shifts to Neutral during
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8) Neutral propel or truck cannot
move again
Transmission suddenly
Check with table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to shifts to Neutral during
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔7.8) Neutral propel or truck cannot
move again
b076
Short circuit in 3rd clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.6)
solenoid (E. ↔ 7.1, E.C ↔ 7.1- E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.6)
b0077
Short circuit in 4th clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.7)
solenoid (E. ↔ 7.1, E.C ↔ 7.1- E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.7)
b0078
Short circuit in R clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.7)
solenoid E. ↔ 7.1, E.C ↔ 7.1- E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.7)
1. 1) Lock - up Between (+) L/U.T (1) - ATC1 (1)
Between (-) L/U.T (2) - ATC1 (8), (16)
2) H clutch Between (+) H.PS (1) - ATC2 (9)
Between (-) H.PS (2) - ATC2 (19)
3) L clutch Between (+) L.PS (1) - ATC2 (7)
Between (-) L.PS (2) - ATC2 (17)
4) 1st clutch Between (+) 1.PS (1) - ATC2 (2)
b091 Between (-) 1.PS (2) - ATC2 (13)
5) 2nd clutch Between (+) 2.PS (1) - ATC2 (4)
b098 Disconnection in pressure control solenoid Between (-) 2.PS (2) - ATC2 (15)
(E. ↔ 9.1) When it is tried to disengage the clutch, the 6) 3rd clutch Between (+) 3.PS (1) - ATC2 (3)
(E.C ↔ 9.1) pressure control solenoid output is turned Between (-) 3.PS (2) - ATC2 (13)
ON, but the solenoid current does not flow 7) 4th clutch Between (+) 4.PS (1) - ATC2 (8)
(E. ↔ 9.8) Between (-) 4.PS (2) - ATC2 (18)
(E.C ↔ 9.8) 8) R clutch Between (+) R.PS (1) - ASTC2 (5)
Between (-) R.PS (2) - ATC2 (15)
2. Defective pressure control solenoid
b091
Disconnection in lock-up pressure control See items for display codes b091 - b098
(E. ↔ 9.1)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.1)
b092
Disconnection in H clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.2)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.2)
b093
Disconnection in L clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.3)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.3)
b094
Disconnection in 1st clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.4)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.4)
b095
Disconnection in 2nd clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.7)
soelnoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.7)
b096
Disconnection in 3rd clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.6)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.6)
b097
Disconnection in 4th clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.7)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.7)
b098
Disconnection in R clutch pressure control See tiems for display codes b091 - b098
(E. ↔ 9.8)
solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.8)
The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows
the transmission controller LED display. (< less than - > greater than)
When each gear range is engaged using the shift checker, the
fill switch signal is given with the combinations shown in
Table1.
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Tabel 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
See items for display codes See items for display codes
Check with Table 2 for the items for display codes b091 - b098
b091 - b098 (E. ↔ 9.1, E.C ↔ b091 - b098 (E. ↔ 9.1, E.C
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8)
9.1- E ↔ 9.8, E.C ↔ 9.8) ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
(E. ↔ 6.0)
transmission speed more thatn 500 2) Between E12 (2) - J09M (10) - TMD (14) - ATC3A (14)
(E.C ↔ 6.0) rpm continues for 10 sec. 2. Defective engine speed sensor
b062 ated shaft speed, and output shaft 2) Between N2 (2) - TM2 (4) - ATC3A (14)
(E. ↔ 6.2) speed are converted and it is found 2. Defective intermediate shaft speed sensor
(E.C ↔ 6.2) that there is a problem in HL clutch and
speed clutch (When disconnection de-
tection is actuated and there is no sen-
sor signal)
Defective output of transmission output
shaft speed sensor
1. Output shaft speed sensor
When the engine speed, input shaft
(E.C ↔ A.2) sensor signal is more than 150°C 2. Defective torque converter oil temperature sensor
b0A3
Disconnection in fuel level sensor 1. Between (+) ATC5B (5) - TMA (15) - J09M (12), (15) - J02 (1) - 26 (1)
(E. ↔ A.3)
Input voltage: > 4 V 2. Defective fuel sensor
(E.C ↔ A.3)
Short circuit with ground in cooling water
temperature sensor
b0b2 1. Between (+) ATC5B (5) - TMA (7) -J09M (12), (15) - J02 (1) - 26 (1)
When input resistance of cooling water
(E. ↔ b.2) Between (-) ATC5A (16) - TMB (9) - J09M (13), (16) - J02 (3) - 26 (2)
temperature sensor signal is more
(E.C ↔ b.2) 2. Defective coolant water temperature sensor
than 170 Ω
Between (-) ATC5A (16) - TMB (9) - RH4 (10) - SR5 (2)
(E.C ↔ b.3) pressure sensor signal is more than 2. Defective brake air pressure sensor
3,000 Ω
The top code in the Display code column shows the monitor panel display and the bottom code ( in [ ] ) shows
the transmission controller LED display. ( < less than - > greater than)
ATC3B TMD J02 61 (V) Only gives self-diagnostic No display at all is given
display; does not take any on fuel level gauge
(4) - chassis (7) - chassis (15) - chassis (1) - chassis 0.2 - 0.4 V
action display on monitor panel.
When engine water temperature is between 25°C (normal temperature) and 100°C, condition is as shown in
table below.
No display at all is given
Only gives self-diagnostic
ATC3B,3A (male) TMA, TMB (male) J09M J02 61 (V) on engine water
display; does not take any
Between (15) - (9) Between (12), (15) - Between (1) - (3) Between (1) - (2) 37 Ω
temperature gauge
Between (5) - (16) action
(13), (16) display on monitor panel.
4Ω
(5) - chassis (15) - chassis (12), (15) - chassis (1) - chassis (1) - chassis
ATC3B,3A (male) TMA, TMB (male) RH4, RH1 SR5 Ω Only gives self-diagnostic No display at all is given
Between (2) - (16) Between (7) - (9) Between (1) - (10) Between (1) - (2) 3 - 1,000 Ω
display; does not take any on air pressure gauge
action display on monitor panel.
(2) - chassis (7) - chassis (1) - chassis (10 - chassis
(E.C ↔ b.4) signal is more than 150°C 2. Defective retarder brake oil temperature sensor
(E. ↔ C1)
pending on the wiring harness, the model 2. Defective contact of ATC5A connector
(E.C ↔ C1) selection signal does not match
Short circuit with ground in BCV rear solenoid
b0C4 BCV output terminal voltage
(E.C ↔ d.5)
1. Between (+) ATC5B (15) - TMD (4) - J02 (7) - 01 (9) - 03 (1)
b0d6 Drop in radiator water level warning display Between (-) 03 (2) - GND.16
(E. ↔ d.6) When the engine cooling water level switch 2. Defective radiator water level sensor
The top code in the Display code column shows the monitor panel display and the bottom code ( in [ ] ) shows
the transmission controller LED display. ( < less than - > greater than)
ATC3B TMD J02 27 (V) Only gives self- Drop in engine oil
(12) - chassis (15) - chassis (2) - chassis (3) - chassis 0.4 - 4.6 V diagnostic display; does pressure cannot be
not take any action detected.
Between (2) - (3)
1. If operations are
continued, dirt will
When transmission filter is normal, condition is as shown in table below.
circulate in transmission
Only gives self-
ATC5A TMD J02 52 circuit.
diagnostic display; does
(6) - chassis (2) - chassis (13) - chassis (1) - chassis No continuity 2. Mechatronics display
not take any action
is not given.
Between (1) - (2)
3. Buzzer does not
sound.
1. If operations are
When machine tilt angle is ± 15°, condition is as shown in table below. Only gives self- continued, truck may roll
ATC5A TMD SR3 diagnostic display; does over.
not take any action 2. Mechatronics display
(5) - chassis (2) - chassis (1) - chassis, (1) - (2) Continuity
is not given.
1. If operations are
Only gives self- continued, there will be
When radiator water level is normal, condition is as shown in table below.
diagnostic display; does overheating.
ATC5B TMD J02 01 03 not take any action 2. Mechatronics display
(15) - chassis (4) - chassis (7) - chassis (8) - chassis (1) - chassis, (1) - (2) Continuity is not given.
b0d7 1. Between ATC3B (1) - TMD (1) - J01 (1) - alternaotor terminal R
Battery charge warning display
2. Defective charging circuit
(E. ↔ d.7) When battery charge switch is OFF with
1. Between (+) ATC5A (8) - TMC (12) - J)3 (2) - BLSL (1)
b0F6 Rear brake oil pressure warning display Between BLSL (2) - BLSR (1)
(E. ↔ F.6) When bralke stroke switch is ON for 2 Between (-) BLSR (2) - GND.67
The top code in the Display code column shows the monitor panel display and the bottom code ( in [ ] ) shows
When steering oil temperature is 25°C (normal temperature), condition is as shown in tabel below. 1. If operations are continued,
Only gives self-
oil may leak.
ATC3A TMA J01 21 . diagnostic display; does
2. Mechatronics display is not
not take any action
(11) - chassis (8) - chassis (6) - chassis (1) - chassis No continuity given.
When brake stroke is normal, condition is as shown in table below. 1. If operations are continued,
Only gives self-
ATC5A TMD J03 BLSL oil may leak.
diagnostic display; does
2. Mechatronics display is not
(8) - chassis (12) - chassis (2) - chassis (1) - chassis Continuity not take any action
given.
- - - (1) - (2), (2) - chassis
• When fuses BT1 (10) (19 - 20) and BT2 (8) (15 - 16) are normal.
If it is blown, check for a short circuit with the ground inside the controller and in the wiring harness between the
fuse and controller.
• When the battery is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the key switch is turned to ON with the shift lever at a position other than N, or when the power source is
momentarily cut when moving.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Displays disconnection, short circuit, or short circuit with chassis ground in transmission cut relay system.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
a)
Short circuit with ground in BCV rear solenoid is displayed
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that the mounting bolts of the input shaft speed sensor sre not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
a) -2
Disconnection in engine speed sensor [B] is displayed on truck
or
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that the mounting bolts of the input shaft speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that the mounting bolts of the intermediate shaft speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Table 1
• Check that the mounting bolts of the speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
• Always connect any disconnected connectors before going on to
the next step.
a)
or
• Check that the mounting bolts of the speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step
Table 1
ATC3A N3 Resistance
A-9 a) Related electrical circuit diagram Between (2) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (2) & chassis Between (1) & chassis > 1M Ω
• Check that the mounting bolts of the speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Table 1
ATC3A N3 Resistance
A-9 b) Related electrical circuit diagram Between (3) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (3) & chassis Between (1) & chassis > 1M Ω
Table 1
ATC5B ATC1 Voltage
(10) - (8) > 15 V
A-10 a) Related electrical circuit diagram (11) - (8) >1V
(12) - (8) >1V
(13) - (8) <1V
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Table 1
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Table 1
Connection of connector and fill
Fill switch
switch
Service code Corresponding Transmission When connected When open
display clutch controller
Fill switch
connector and pin Voltage Resistance Voltage Resistance
number
b042[E.↔ 4.2,
H clutch ATC5A (12) - H. SW <1V <1Ω 15 -25 V > 1 MΩ
E.C↔4.2]
b043[E.↔ 4.3,
L clutch ATC5A (10) - L. SW <1V <1Ω 15 - 25 V > 1 MΩ
E.C↔ 4.3]
b044[E.↔ 4.4,
1 clutch ATC5A (13) - 1. SW <1V <1Ω 15 - 25 V > 1 MΩ
E.C↔ 4.4]
b045[E.↔ 4.5,
2 clutch ATC5A (14) - 2. SW <1V <1Ω 15 - 25 V > 1 MΩ
E.C↔ 4.5]
b046[E↔ 4.6,
3 clutch ATC5A (15) - 3. SW <1V <1Ω 15 - 25 V > 1 MΩ
E.C↔ 4.6]
b047[E.↔ 4.7,
4 clutch ATC5A (11) - 4. SW <1V <1Ω 15 - 25 V > 1 MΩ
E.C↔ 4.7]
b048[E.↔ 4.8,
R clutch ATC5A (16) - R. SW <1V <1Ω 15 - 25 V > 1 MΩ
Ε.Χ ↔4.8]
• Measure the clutch oil pressure of the circuit where the fault is displayed. If the oil pressure is normal, carry out
the troubleshooting below.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Table 1
When
is displayed
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Go to Troubleshooting of A-7b).
b-3) Inspecting transmission output shaft speed signal system, 1-4, R clutch (check clutch slip)
When
is displayed
Go to Troubleshooting of A-7a).
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
5.2 ↔ 4.2
5.3 ↔ 4.3
5.4 ↔ 4.4
5.5 ↔ 4.5
5.6 ↔ 4.6
5.7 ↔ 4.7
5.8 ↔ 4.8
Disconnection in pressure
control valve solenoid is
displayed
Table 1 Table 2
Display Measurement location
Normal
7.2 ‘Trouble- Touble Measurement item value Display
Measurement Measurement Normal
9.2 shooting 1 shooting 2 location item value
Between Between Trouble Trouble Resistance
7.3 Resistance 30 - 80 Ω
ATC1 HPS 5 - 25 Ω shooting 1 shooting2 between (1) - (2)
9.3 between (1) - (2)
(9) - (19) (1) - (2) 7.1 Between
9.1 Between Resistance
Between Between ATC1
7.4 LCT between (2) - >1MΩ
ATC2 1 PS (1) - (8)
9.4 (1) - (2) chassis ground
(7) - (17) (1) - (2) (16)
Between Between
7.5
ATC2 2 PS
9.5 b0 [E., E.C] is omitted from the Display column.
(4) - (15) (1) - (2)
Resistance
Between Between between (2) -
7.6
ATC2 3 PS >1MΩ
9.6 chassis
(3) - (13) (1) - (2) ground
Between Between
7.7
ATC2 4 PS
9.7
(8) - (18) (1) - (2)
Between Between
7.8
ATC2 RPS
9.8
(5) - (15) (1) - (2)
(It takes 30 seconds for the fuel gauge to change 1 level. Take this into account when carrying out troubleshooting).
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that the transmission oil filter is not clogged.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that the cooling water level is not low.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check if the steering oil temperature is high.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check if the engine oil pressure is low.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check if the rear brake chamber has reached the end of its stroke.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• This shows that there had been an abnormal rise in the torque converter oil temperature.
• If the rise in the torque converter oil
• This shows that there has been an abnormal rise in the engine water temperature.
• If the rise in the engine water temperature is abnormal, see the engine Shop Manual.
• This shows that there has been an abnormal drop in the air pressure.
• If the drop in the air pressure is abnormal, carry out troubleshooting H-18.
• This shows that there had been an abnormal rise in the retarder brake oil temperature.
• If the rise in the retarder brake oil temperature is abnormal, see the Operation and Maintenance Manual.
• This shows that the engine overrun prevention had been actuated to protect the transmission.
• This shows that there has been engine overshoot (sudden spurt).
SERVICE
No. CODE FAILURE DESCRIPTION DISPLAY CONDITIONS
Display conditions, display in service code,
1 A000 Short circuit in output
trouble data display mode.
2 A001 Short circuit in lamp output
Display when lamp check switch is pressed
3 A002 Short circuit in central warning lamp output for at least 2.5 seconds and then released.
4 A003 Short circuit in alarm buzzer output
Display in service code, trouble data display
5 A011 Fault in network
mode
Network system connection data does not
6 A012
match
7 A013 Fault in network — transmission controller
8 A014 Fault in network — PMC Display when lamp check switch is pressed
for at least 2.5 seconds and then released.
9 A015 Fault in network — engine controller
10 A016 Fault in network — suspension controller
11 A018 Fault in model selection data
12 A019 Fault in option data
13 A021 Abnormal drop in air pressure
Engine cooling temperature overheat
14 A022
warning
Torque converter oil temperature overheat
15 A023
warning
16 A024 Brake oil temperature overheat warning
FAULT TROUBLESHOOTING
CODE FAULT CONDITION POSSIBLE CAUSE NOTE: Check wiring harness circuits and components listed below for
short circuit, open circuit, etc.
1. Fault between lamp (+) and monitor panel. (Refer to P-16, 18, 20, 22,
A001 Short circuit in lamp output Short circuit in output 24, 26, 28, 30, 32, 34, 36, 38, 40, 42 for troubleshooting details.)
2. Defective lamp
1. Between (+) DP08 pin 2 and WL pin 2.
Short circuit in Central
A002 Warning Lamp output Short circuit in output 2. Defective central warning lamp
1. Between (+) DP05 pin 3, TMD pin 10, and ATC4 pin 6.
2. Between (+) DP05 pin 4, TMD pin 12, and ATC4 pin 12.
3. Between (-) DP05 pin 5, TMD pin 9, and ATC4 pin 10.
Transmission 4. Between (-) DP05 pin 5, TMD pin 11, and ATC4 pin 10.
A013 Network system fault Controller system 5. Defective shift controller
NOTE: When troubleshooting the monitor panel, if the The following instructions must be followed when trou-
item in the troubleshooting flow chart or the item in the bleshooting the monitor panel and associated compo-
“remedy” column indicates “carry out check of wiring nents and wire harnesses:
harnesses between modules”, refer to the number
• Be certain all harnesses are properly inserted in
displayed in the following tables and check the female
the mating connectors.
connector of the wiring harnesses between modules.
• Before removing any harness connector, be cer-
tain the key switch is in the OFF position.
• The key switch must remain in the OFF position
when performing the following checks on the wir-
ing harnesses.
Be certain truck wheels are blocked to prevent • Visually inspect harnesses and connectors for
movement during troubleshooting procedures. physical damage, insulation cracks, pin damage
etc.
X Y
No. SIGNAL NAME
CONNECTOR PIN No. CONNECTOR PIN No.
DP11 1
A-1 1 VB (20V)
DP04 1
A-2 2 LCD TX OUT DP10 3
A-3 3 LCD TX IN DP04 4
DP10 4
A-4 4 SCK
DP04 5
DP10 5
A-5 5 LCD LOAD
DP02 DP04 6
DP10 6
A-6 6 LCD COM
DP04 7
DP10 7
A-7 7 RESET DP04 8
DP12 4
DP10 8
DP11 2
A-8 8 GND DP08 16
DP05 12
DP12 2
A-9 1 P/S DATE DP04 3
DP10
A-10 2 SHIFT/LOAD DP04 2
• Before troubleshooting,
verify all connectors related
to the wiring harnesses be-
tween the modules are
properly inserted.
• Always connect any discon-
nected connectors before
going on to the next step.
• Before troubleshooting, verify all connectors related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before troubleshooting, verify all connectors related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before troubleshooting, verify all connectors related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before troubleshooting, verify all connectors related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before troubleshooting, verify all connectors related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Before troubleshooting, verify all connectors related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• The monitor panel saves trouble data for problems detected as [A013], [A014], [A015], [A016], [A018], or [A019]
together as service code [A011].
• If [A013], [A014], [A015], [A016], [A018], or [A019] are currently being detected, carry out repairs according to
the respective troubleshooting.
• If [A013], [A014], [A015], [A016], [A018], or [A019] are not currently being detected, the system has been reset
so the condition is normal.
• The monitor panel saves trouble data for problems detected as [A001], [A002], or [A003] together as fault code
[A000].
• If [A001], [A002], or [A003] are currently being detected, carry out repairs according to the respective troubleshoot-
ing.
• If [A001], [A002], or [A003] are not currently being detected, the system has been reset so the condition is normal.
This diagram is provided as a diagnostic tool for trained, experienced technicians only. Improper trouble-
shooting or repair can result in severe personal injury or death or property damange. See important
instructions in the Shop Manual.
SENSOR SPECIFICATIONS
4 Truck does not move when oil temperature rises b. Defective transmission clutch seal ring, groove Replace
c. Defective speed clutch (oil leak) Replace
d. Defective shaft seal ring in speed clutch circuit Replace
a. Clogged strainer Clean
Low at every gear b. Air sucked in at suction side of pump Repair
5
range
c. Drop in pressure of main relief valve (torque converter Repair or
valve) replace
a. Defective ECMV Replace
Transmission oil
pressure is low Becomes lower at b. Defective transmission clutch seal ring, groove Replace
6
certain speed range
c. Defective speed clutch (oil leak) Replace
d. Defective shaft seal ring in speed clutch circuit Replace
Indicator is a. Clogged strainer Clean
unstable and
7
fluctuates b. Air sucked in at suction side of pump Repair
excessively
When pressure pickup port plug is removed and
8 a. Pump does not turn (defective PTO) Replace
engine is cranked, no oil comes out.
9 Modulation pressure is abnormal a. Defective ECMV Replace
a. Drop in pressure of main relief valve (torque converter Repair or
10 Hydraulic pressure at pump outlet port is low
valve) replace
F2
F3
F4
F5
F6
F7
CAUSE REMEDY
Drop in main relief pressure
Refer to H-6
Worn clutch seal ring
CAUSE REMEDY
Improper operation of ECMV for clutch which does not shift up Clean, repair, or replace
Defective piston seal ring, defective groove for clutch which does not shift up Replace
Drop in main relief pressure Adjust, clean, repair, or replace
CLUTCH
GEAR L 4th
H 3rd 2nd 1st R
RANGE (rotating) (rotating)
R
N
F1
F2
F3
F4
F5
F6
F7
TRANSMISSION
CONTROLLER
No. PROBLEM CAUSE REMEDY
SELF-DIAGNOSTIC
DISPLAY
a. 2nd clutch disc worn or seized, seal ring worn Replace
(1) F1 is normal, but F2 is defective 2.5 3.5 4.5 4.5
1 b. Improper operation of 2nd clutch ECMV Replace
Returns to normal when replaced
(2) a. Improper operation of 2nd clutch ECMV Replace
with any ECMV except 2nd.
a. 1st clutch disc worn or seized, seal ring worn Replace
(1) F2 is normal, but F1 is faulty 2.4 3.4 4.4 5.4
2 b. Improper operation of 1st clutch ECMV Replace
Returns to normal when replaced
(2) a. Improper operation of 1st clutch ECMV Replace
with any ECMV except 1st.
F1 and F2 are normal, but F3 is a. H clutch disc worn or seized, seal ring worn Replace
(1) 2.2 3.2 4.2 5.2
faulty b. Improper operation of H clutch ECMV Replace
3
Returns to normal when replaced
(2) a. Improper operation of H clutch ECMV Replace
with any ECMV except H.
F1, F2, and F3 are normal, but F4 a. 3rd clutch disc worn or seized, seal ring worn Replace
(1) 2.6 3.6 4.6 5.6
is faulty b. Improper operation of 3rd clutch ECMV Replace
4
Returns to normal when replaced
(2) a. Improper operation of 3rd clutch ECMV Replace
with any ECMV except 3rd.
a. 4th clutch disc worn or seized, seal ring worn Replace
(1) F1 - F5 are normal, but F6 is faulty 2.7 3.7 4.7 5.7
5 b. Improper operation of 4th clutch ECMV Replace
Returns to normal when replaced
(2) a. Improper operation of 4th clutch ECMV Replace
with any ECMV except 4th.
F3, F5, and F7 are normal, but a. L clutch disc worn or seized, seal ring worn Replace
(1) 2.3 3.3 4.3 5.3
others are faulty b. Improper operation of L clutch ECMV Replace
6
Returns to normal when replaced
(2) a. Improper operation of L clutch ECMV Replace
with any ECMV except 3rd.
a. R clutch disc worn or seized, seal ring worn Replace
(1) Only R is faulty 2.8 3.8 4.8 5.8
7 b. Improper operation of R clutch ECMV Replace
Returns to normal when replaced
(2) a. Improper operation of R clutch ECMV Replace
with any ECMV except 3rd.
NOTE:
> Remove all dirt and mud from around the ECMV, and clean it before replacing.
> After replacing, tighten ECMV mounting bolts to 2.8 - 3.5 kg.m (20 - 25 ft. lbs) torque
F2
F3
F4
F5
F6
F7
F2
F3
F4
F5
F6
F7
> NOTE: If oil temperature is normal but oil temperature gauge on truck goes above operating range, the
gauge is defective and should be replaced.
Oil pressure at master cylinder outlet port is low b. Defective relay valve Repair or replace
1
(outlet port hose disconnected) c. Clogged, crushed tube between relay valve and brake
Repair or replace
chamber
d. Defective brake chamber seal Replace
a. Defective brake chamber seal Replace
2 Air pressure at brake chamber inlet port is normal b. Clogged, crushed tube between relay valve and brake
Repair or replace
chamber
a. Defective brake valve Repair or replace
3 Air pressure at brake chamber inlet port is low b. Defective relay valve Repair or replace
c. Clogged, crushed tube between relay valve and brake
Repair or replace
chamber
4 Air leakage from brake chamber a. Defective brake chamber seal Replace
Items 1-4 are normal, but there is lack of hydraulic a. Clogged, crushed tube between relay valve and brake
5 Repair or replace
pressure in wheel cylinder chamber
Items 1-5 are normal, but brake is ineffective or
6 a. Excessive brake disc wear Replace
braking effect is poor
1 Hoist cylinder also does not work d. Defective steering pump Replace
e. Defective hoist pump Replace
f. Drop in demand valve relief valve pressure or defective Adjust, repair, or
seal replace
g. Improper operation of demand valve spool or stuck
Repair
spool
No oil comes out when pressure pickup port plug and
2 a. Defective pump drive (PTO) Repair
engine is cranked
Circuit pressure is too high at engine low idle, or
3 a. Improper operation of demand valve check valve Repair
pressure rises to relief pressure (item 2 normal)
a. Improper operation of demand valve spool or stuck
Repair
spool
4 Hoist is normal b. Improper operation of demand valve check valve Repair
c. Defective steering cylinder Replace
d. Defective steering valve Replace
a. Drop in demand valve relief valve pressure or defective Adjust, repair, or
Relief pressure is low at end of cylinder stroke (item 4 seal replace
5
normal) b. Defective steering cylinder Replace
c. Defective steering valve Replace
Item 5 is normal and sound of oil blowing through a. Drop in demand valve relief valve pressure or defective Adjust, repair, or
6
relief valve is heard seal replace
7 Abnormal noise comes from between pump and filter a. Air sucked in at suction end Repair
a. Crushed suction tube Repair
8 Steering wheel operates when engine is at low idle
b. Clogged strainer Clean
When steering wheel is turned to right (left) and hose
9 on opposite side is removed, rod does not move, but a. Defective steering cylinder Replace
oil flows out.
a. Defective steering pump Replace
10 Pump volume is too low
b. Defective hoist pump Replace
11 Excessive play in steering wheel a. Defective steering valve Replace
CAUSE REMEDY
Air in hydraulic oil Clean
Air leakage inside steering cylinder Repair or replace
Monitor
Panel
Display Controller Display Description
SP-1 d001 [All OFF or E.↔01] Power Source Fault Displayed D9-10
SP-2 d011 [E.↔11] Faulty Pressure Sensor (Right) DIsplayed D9-11
SP-3 d012 [E.↔12] Faulty Pressure Sensor (Left) DIsplayed D9-12
SP-4 d015 [E.↔15] Faulty Speed Sensor Displayed D9-13
SP-5 d016 [E.↔16] Fault in Steering Sensor Displayed D9-14
SP-6 d0C2 [E.↔C2] Defective Model Selection Data Displayed D9-15
SP-7 d021 [E.↔21] Fault in Solenoid 1 Displayed D9-16
SP-8 d022 [E.↔22] Fault in Solenoid 2 Displayed D9-17
SP-9 d023 [E.↔23] Fault in Solenoid 3 Displayed D9-18
SP-10 d0C1 [E.↔C1] Disconnection in Network Displayed D9-19
SP-11 d0C3 [E.↔C3] Defective Speed Compensation Displayed D9-20
NOTE:
Intermittent problems can be caused by an improperly crimped wire terminal, damaged wire insulation
etc. and may occur only when the truck is operating over rough haul roads or at full throttle. Therefore,
if the problem cannot be found during normal troubleshooting procedures described on the following
pages, it may be necessary to re-create the actual conditions under which the problem occurred.
Troubleshooting code when fault is displayed SP-1 SP-2 SP-3 SP-4 SP-5
NOTE: * Monitor Panel Display shown as: d0__ Suspension Controller display shown in brackets [ ].
• —
• • • • —
—
See “Testing &
Adjusting
Suspension”
See “Testing &
Adjusting
Suspension”
See “Testing &
• • Adjusting
Suspension”
See “Testing &
Adjusting
Suspension”
See “Testing &
• • Adjusting
Suspension”
Troubleshoot
applicable
F-1 F-2
monitor panel
SP-6 SP-7 SP-8 SP-9 SP-10 SP-11 item
Troubleshooting code when lamp
does not light when applicable
operation is performed
2. Between (-) N3 (2) - TM2 (6) - TMA (2) - SU3 (3) - SSP2B (12)
3. Output shaft speed sensor disconnected
d015 Detects open circuit
Defective speed sensor
[E.↔ 15] in sensor circuit
1. Between SSP1 (12) - SU3 (13) - TMD (12) - ATC4 (12), DP05 (4)
Unable to receive
2. Between SSP1 (1) - SU3 (9) - TMD (10) - ATC4 (6), DP05 (3)
model selection data
from Transmission 3. Between SSP2A (9) - SU3 (12) - TMD (9) - ATC4 (10), DP05 (5)
d0C2
Faulty model selection data Controller 4. Between SSP2A (9) - SU3 (14) - TMD (11) - ATC4 (10), DP05 (5)
[E.↔C2]
Model selection not 5. Improper setting of model selection in Transmission Controller
set in Transmission
Controller
Measure 500 to 1K ohms between each connector pin and 1. Does not switch mode (remains in
chassis ground as listed below: medium)
1. N3 (male): pins 2, 3 2. Truck sometimes rolls excessively
2. TM2 (male): pins 5, 6 3. Ride is uncomfortable
Remains in MEDIUM mode 4. Other mechatronics caution lamp on
3. TMA (female): pins 1, 2
monitor panel flashes 4
4. SU3 (male): pins 2, 3
1. Between SSP1 (12) - SU3 (13) - TMD (2) - ATC (12), DP05 (4)
Disconnection in 2. Between SSP1 (1) - SU3 (9) - TMD (10) - ATC (6), DP05 (3)
d0C1 3. Between SSP1 (9) - SU3 (12) - TMD (9) - ATC (10), DP05 (5)
Disconnection in network network
[E.↔C1]
communications 4. Between SSP2A (9) - SU3 (14) - TMD (11) - ATC (10), DP05 (5)
5. Defective monitor panel
1. Between SSP1 (12) - SU3 (13) - TMD (2) - ATC (12), DP05 (4)
2. Between SSP1 (1) - SU3 (9) - TMD (10) - ATC (6), DP05 (3)
3. Between SSP1 (9) - SU3 (12) - TMD (9) - ATC (10), DP05 (5)
Truck compensation 4. Between SSP2A (9) - SU3 (14) - TMD (11) - ATC (10), DP05 (5)
d0C3 Defective truck compensation data cannot be
[E.↔C3] data received from 5. Defective monitor panel
monitor panel
• When performing repairs or troubleshooting, check the direction of the solenoid diode.
• Before troubleshooting, verify all related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When performing repairs or troubleshooting, check the direction of the solenoid diode.
• Before troubleshooting, verify all related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When performing repairs or troubleshooting, check the direction of the solenoid diode.
• Before troubleshooting, verify all related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
TRANSMISSION
INDEX
The 330M Truck utilizes a remote mounted, 7 speed Operation of the transmission is controlled electroni-
transmission. The TORQFLOW transmission (8, Fig- cally through inputs from the operator (range selector
ure 2-1) consists of a water-cooled, 3-element, single- position, accelerator, etc.) and various sensors and
stage, two phase torque converter (7) and a switches monitoring speeds and operating conditions.
planetary-gear, multiple-disc clutch transmission
The transmission oil supply is filtered through a wash-
which is hydraulically actuated and pressure lubricated
able strainer located in the transmission sump and by
for optimum heat dissipation.
external, replaceable elements located at the front of
A rubber dampened drive line adapter (2), coupling the the hydraulic tank. The transmission filter element
engine to the transmission and torque converter, re- should be replaced at 500 hour intervals, or sooner, if
duces harmful engine shock and vibration to the trans- the warning light indicates high restriction. Refer to
mission. A lockup system, consisting of a wet, Section "P", Lubrication And Service. The transmis-
double-disc clutch, can be actuated in all forward gears sion oil should be drained, and the strainer removed
for higher fuel savings. and cleaned, every 1000 hours of operation.
FIGURE 2-5. TORQUE CONVERTER VALVE FIGURE 2-6. TORQUE CONVERTER VALVE
(External View) (Internal components)
Function
The main relief valve maintains the main hydraulic
pressure of the transmission valve, lockup valve, and
pilot pressure.
Operation
The oil from the hydraulic pump enters port (A, Figure
2-9), then passes through orifice (2) and goes to port
C.
When the hydraulic pressure in the circuit rises, the
pressure at port C also rises and pushes main relief
spool (1) to the left, in the direction of the arrow. The
oil at port A passes through port B and flows to the
torque converter circuit.
Actuating pressure:
Engine @ high idle RPM: . . . . . . . . 39 ± 2 kg/cm2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (555 ±29 psi)
Function
This valve acts to protect the torque converter circuit
from abnormally high pressure.
Operation
The oil from the main relief valve enters port B (Figure
2-10) and then passes through orifice (2) and goes to
port A. When the pressure in the circuit rises, the
pressure at port A also rises, and moves torque con-
verter relief spool (1) to the right in the direction of the
arrow. The oil at port B flows to port C and goes to the
transmission lubrication circuit.
Actuating pressure:
FIGURE 2-10. TORQUE CONVERTER RELIEF
Engine @ high idle RPM . . . . . . . . . . 8 ±1 kg/cm2 VALVE
1. Relief Spool 2. Orifice
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (113 ±15 psi)
Function
Operation
16 ±0.5 kg/cm2
(230 ±10 psi) 16.5 ±1.5 kg/cm2
(235 ±20 psi)
FIGURE 2-28.
FIGURE 2-29.
FIGURE 2-30.
FIGURE 2-31.
FIGURE 2-32.
Filling completed (pressure control set to in-
itial pressure) (C range of graph)
1. (Refer to Figure 2-33): When pump port D of the
flow sensor valve opens, and the oil flows out from
here, a difference in pressure is created between
the upstream and downstream sides of orifice “a”
of the flow sensor valve spool (3). This continues
to push flow sensor valve spool (3) to the left.
When this happens, and the current of propor-
tional solenoid (6) is lowered momentarily to the
initial pressure level, almost the complete pump
pressure comes to bear on load piston (8). As a
result, pressure control valve spool (7) is pushed
back to the right, and a small amount of oil leaks
from pressure control valve outlet port B to drain
port E. However, only a small amount of oil leaks,
so almost all of the oil from the pump flows to the FIGURE 2-33.
clutch, and flow sensor valve spool (3) continues
to be pushed to the left.
FIGURE 2-35.
Disassembly
1. Before disassembly, flush the ECMV and valve
seat (paint at corners of the mating surfaces must
be removed thoroughly).
NOTE: Do not allow the solenoid connectors, fill switch
connectors, or harness to be exposed directly to the
water, etc.
2. Remove the mounting bolts (8, Figure 2-39) from
the ECMV assembly (10), and separate the
ECMV assembly from valve plate (12). FIGURE 2-38. ECMV ASSEMBLY
3. Remove solenoid connector (2, Figure 2-39) and 1. Valve Body 13. Plug
fill switch connector (3) from bracket. Loosen 2. Plug 14. O-ring
bolts (17). Gently remove the flow sensor valve 3. Plug 15. Spring
fill switch (16) and bracket. Be careful not to let 4. Pressure Control Valve 16. Fill Switch
spring (15) fall out of place. 5. Piston 17. O-ring
6. Spring 18. Bracket
7. Shim 19. Bolt
8. O-ring 20. Washer
4. Remove cover plate (21, Figure 2-38). Remove 9. Solenoid Valve 21. Cover Plate
plug (13) by installing a capscrew in the tapped 10. Bolt 22. O-ring
hole for easier removal. Then, remove the flow 11. Flow Detection Valve 23. Bolt
detecting valve spring (12), valve spool (11), and 12. Spring
spring (15).
a. Examine valve body (1) and spool (11) as well
as spring (15) for the existence of plating film
pieces and other metallic particles. If found, NOTE: Protect the valve plate (12, Figure 2-36) and
remove them. the valve mating surfaces by applying masking tape,
etc. Prevent dirt/dust from entering the transmission
b. If foreign matter has lodged in the valves or the by covering all openings. Place all removed parts in
pistons, or if their functional movement is not storage, being careful not to scratch any part.
smooth, recondition them with an oil stone, etc.
5. Remove spring (6), shims (7), piston (5), and valve
(4) from the pressure control valve. Examine for
any trapped foreign matter, seized spool, or rough
movement. Be careful not to lose shims (7). Keep
shims in storage, after confirming their quantity.
6. Remove the proportional solenoid valve (9).
FIGURE 2-39. ECMV VALVE ASSEMBLY 4. Install shims (7) and spring (6) in the pressure
control valve. Install O-ring (22, Figure 2-38) in
the valve body.
1. Valve Body 10. Bolt
2. Solenoid Connector 11. Flow Sensor Valve
3. Fill Switch Connector 12. Spring • The standard number of shims is: 3 pcs.
4. Pressure Control Valve 13. Plug • Standard shim pack thickness: 0.6 mm
Spool 14. Pressure Test Port • Individual shim thickness: 0.2 mm
5. Load Piston 15. Spring
6. Spring 16. Fill Switch
7. Shims 17. Bolt NOTE 1: (Refer to Figure 2-39.) When parts (1), (6),
8. Mounting Bolt 18. Cover Plate (5), (4), and (9) are all being reused, the same number
9. Proportional Solenoid of shims removed during disassembly must be rein-
stalled. When any of these parts have been replaced,
the standard number of shims (3 ea.) should be in-
stalled. The exact quantity required is determined
when clutch pressure test is performed.
NOTE 2: When only the proportional solenoid valve (9)
is to be replaced, remove cover (18) and make sure
that spring (6) has been positively set in place. (There
is a possibility that the spring can get out of the valve
end when the proportional solenoid valve is removed.)
8. Repeat steps 4 through 7 as necessary to check NOTE: One shim (thickness: 0.2 mm) will result in
other clutch pressures. approximately 0.19 kg/cm2 (2.7 psi) variation in the oil
pressure.
9. Compare gauge readings obtained with chart in
(Add shims to increases oil pressure; remove shims to
Figure 2-42.
decrease oil pressure.)
10. If pressure is outside normal range, the pressure
11. If a different shim pack is installed, repeat pressure
control valve spool shim pack (7, Figure 2-39)
test to verify correct clutch pressure has been
must be increased or decreased.
achieved.
12. If no further tests are to be performed, the shift
checker (if installed) may be removed.
a. Disconnect harness connectors (5, Figure 2-
40) from chassis harness (6) and remove shift
PRESSURE checker.
CLUTCH
kg/cm2 PSI b. Reconnect chassis harness connectors to
H 16.5 ±1.5 235 ±20 transmission control box (4).
L 16.5 ±1.5 235 ±20 13. Be certain all pressure test port plugs are installed.
Install protective cover on transmission control
4th 16.5 ±1.5 235 ±20
valve.
3rd 20.5 ±1.5 290 ±20
R 30.5 ±1.5 435 ±20
2nd 31.5 ±1.5 450 ±20
1st 31.5 ±1.5 450 ±20
Function Specifications
This valve is installed on the left side of the transmis- Normal Operating Pressure:
sion and prevents abnormal pressure in the transmis- 1.25 ±.5 kg/cm2 (18 ±6 psi)
sion lubrication circuit.
Cracking pressure: 2.7 kg/cm2 (38 psi)
1. Park truck on a level surface, block wheels and 1. Electrical Connectors 2. Brake Cooling Valve
apply park brake. Raise dump body and install
body holding pins. Move hoist valve to “Float”
position to put weight of dump body on pins. Then
lock the hoist lever in the hold position.
FIGURE 2-47. BRAKE PUMP TUBES FIGURE 2-50. REAR DRIVE LINE
10. Disconnect pump tubes (1, Figure 2-48) and (2) 13. Remove front mount capscrews (1, Figure 2-51)
for the steering and hoist pump. for transmission assembly.
FIGURE 2-48. STEERING AND HOIST PUMP FIGURE 2-51. FRONT TRANSMISSION MOUNT
1. Tube 2. Tube 1. Transmission Mount 2. Torque Converter
Procedure For Centering The Engine Assembly 1. Engine End 3. Torque Converter End
And Transmission Assembly 2. Tool
NOTE: To raise transmission, place shims between FIGURE 2-55. SHAFT ALIGNMENT
the front mounts and the frame bracket. 1. Engine End 3. Torque Converter End
2. Tool
Service
If the engine coolant is found to be contaminated with 2. Remove capscrews (5, Figure 3-1) and cover (3).
oil, the system must be examined for leaks and cor- 3. Remove screen\magnet and clean. Replace if
rected. Then the system must be flushed to remove oil damaged.
contamination and refilled with a clean coolant solu-
tion.
If a leak has been found or suspected in the heat
exchanger, the transmission oil must be examined Installation
IMMEDIATELY. Ethylene glycol (even in small
1. Install screen\magnet into transmission oil pan.
amounts) will damage friction-faced clutch plates.
Contact your Komatsu distributor for ethylene glycol 2. Install new O- Rings (2) in cover and install cover
detection test kits. with capscrews (5).
If ethylene glycol is found in the transmission oil, the 3. Fill transmission with oil. Refer to fuel, coolant and
transmission should be removed, completely disas- lubricants table for type of oil to use.
sembled, cleaned and examined, and ALL friction-
faced clutch plates replaced.
Repair
FIGURE 3-1.
1. Screen\Magnet 4. Washer
2. O-Ring 5. Capscrew
3. Cover
Removal
1. Raise the dump body and lock with the safety pin.
2. Remove cover (2, Figure 3-2) and hose (1).
3. Disconnect lockup solenoid valve wiring connec-
tor (1, Figure 3-3).
4. Disconnect tube (3).
5. Remove torque converter control valve assembly
(2).
Disassembly
1. Remove plate (1, Figure 3-4), then remove pistons
(2) and (4), spring (3), and torque converter relief
valve (5).
2. Remove cover (6), then remove spring (7).
3. Remove cover (8), then remove spring (9).
4. Remove plate (10), then remove pistons (11) and
(13), spring (12), and main relief valve (14).
5. Remove cover (15), then remove piston (16),
spring (17), and ring (18).
6. Remove cover (19), then remove pistons (20) and
(22), spring (21), and lockup valve (23).
1. Hose 2. Cover
Removal
Removal and installation procedures for each driveline
are identical.
Economy Mode:
3. Lock-up
When the truck is operating with a light load, such as
traveling empty or when traveling on flat ground, the • Lock-up is not actuated in reverse.
shift-up and shift-down points are set lower to keep the • When coasting and decelerating (accelerator
engine speed low, improving fuel consumption, reduc- pedal released, and brake not applied), for
ing noise, and shock when shifting gears. In this mode, positions F7 - F4, the lock-up solenoid is mo-
engine output is limited to 85% of maximum engine mentarily turned off during the down-shift from
power. one gear to the next. For F3 and below, the
lock-up solenoid is turned OFF.
• When the truck descends a grade with the
accelerator pedal released, lock-up is not ac-
AUTOMATIC GEAR SHIFTING tuated until the accelerator pedal or the brake
The automatic shift-up/shift-down points, torque con- pedal is depressed.
verter lock-up ON/OFF points and auto brake ON/OFF
points are shown in Figure 6-5.
Note: F1, F2, etc. refers to 1st, 2nd etc. transmission
gear ranges.
AUTOMATIC SHIFTING SEQUENCE
When the operator moves the lever (1, Figure 6-7) to The shift position is also displayed on the monitor
select the travel conditions, such as FORWARD or panel digital display.
REVERSE, an electrical signal is sent from a photo The lock button (1, Figure 6-8) must be pressed when
interrupter (3, Figure 6-8) to the transmission shift moving the range selector lever from “N” to “R” or from
controller. The lever position is displayed on the indi- “D” to “5”.
cator (3, Figure 6-7) (with night lighting) to the left of
the shift lever.
FIGURE 6-7. TRANSMISSION RANGE SELECTOR FIGURE 6-8. TRANSMISSION RANGE SELECTOR
(Cross-sectional View)
1. Lever 3. Range Indicator
2. Detent
1. Lock Button 3. Photo Interrupter
2. Screening Plate
1. Connector 3. Sensor
2. Flange 4. Locknut
1. Terminal 3. Nut
2. Case 4. Connector
Solenoid Valves
If visual inspection of the above items does not reveal The table below lists the state of the transmission
an apparent reason for the problems, refer to Section solenoid valves (or fill sensor) for each of the transmis-
D, “Hydraulic and Mechanical Systems Troubleshoot- sion range selector positions.
ing” for detailed troubleshooting procedures.
Trans. Solenoid
Valve (Fill Sensor)
H L R 1 2 3 4
R H L L H H H H
N H H H H H H H
Shift 1 H L H L H H H
Indicator 2 H L H H L H H
Speed
Range 3 L H H H L H H
Display 4 H L H H H L H
5 L H H H H L H
6 H L H H H H L
7 L H H H H H L
H = Open or 24VDC
L = GND or 1.7VDC
CONNECTOR: ATC4
PIN No. SIGNAL
1 RS422 TX (+)
2 RS422 RX (+)
3 RS232C TX
4 RS232C RX
5 RS485 (+)
6 S-NET (+)
7 RS422 TX (-)
8 FLASH switch
9 RS422 RX (-)
10 GND (serial)
11 RS485 (-)
12 S-NET (-)
CONNECTOR: ATC6
PIN No. SIGNAL
1 RS232 TX
2 RS232 RX
3 Flasher switch ON/OFF
4 Signal GND
INDEX
DIFFERENTIAL ASSEMBLY -
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Disassembly of Pinion Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . G5-7
Differential Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-8
Disassembly of Differential Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . G5-8
Assembly of Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Differential Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Assembly of Differential Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . G5-11
Installation of Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . G5-12
Input Pinion and Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . G5-13
Adjusting Tooth Contact, Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . G5-16
Removal
1. Stop the machine on level ground, apply parking
brake and put blocks on both sides of the rear
wheels.
Do not damage the tire inflation stem during tire
2. Place a 50 ton capacity or larger hydraulic jack (1, removal.
Figure 2-2) under the suspension cylinder on the
A-Frame and jack up the front wheel assembly
and block up securely.
SUSPENSION A-FRAME
Both A-Frame mounting pins are the same.
Removal
FIGURE 3-9. A-ARM PIN
1. Refer to section "G", "Front Tire and Rim Removal"
and remove front tires. 1. Bushing 5. O-Ring
2. Refer to Section "H", "Front Suspension Removal" 2. Frame 6. Bearing
and remove the front suspension. 3. Spacer 7. Pin
4. Snap Ring\ Seal
3. Use a suitable lifting device and support the A-
Frame. Remove retaining capscrew and pin (7,
Figure 3-9) and spacers (3).
4. Remove A-Frame from frame.
1. Remove capscrews and washers (9, Figure 3-10) 1. Press in bushings (4, 6, and 11).
and the grease lines connected to pins (3 and 10). 2. Place pivot link in frame with O-Rings (5) and install
2. Slide tie rod (13) away from pivot link (7). pin (3). Install washer (1) and snap ring (2).
3. Remove snap ring (2), washer (1) and pivot pin (3). 3. Install ball joint assembly (16), O-Rings (15), and
snap ring (14) in pivot link.
4. Remove pivot link.
4. Install seals (12).
5. Remove seals (12), snap rings (14) and push out
ball joint assembly (16). 5. Position tie rod in pivot link and install pin (10).
Install retaining capscrew and washer (9).
6. Connect grease lines to pins and lubricate all
Inspection joints.
3. Inspect bearing for wear and freedom of move- 2. Securely support frame on each side under lower
ment. hoist cylinder mounts. Support frame so there is
not any weight being applied to the rear axle.
4. Inspect dirt seal for cracks or damage that could
allow dirt to enter. 3. Support panhard rod (1, Figure 4-4).
5. Replace any damaged or worn components found 4. Remove retainer capscrews from panhard rod
during inspection. pins (7).
5. Remove panhard rod pins and panhard rod from
Installation frame and final drive case.
1. Install one snap ring (4) and press bearing (6) in 6. Remove spacers (6, Figure 4-4) and O-Rings (2).
link until it contacts snap ring. Install second snap
ring. 7. Remove snap rings (7) and bearing (1).
NOTE: Install snap rings as shown in Figure 4-3. 4. Place panhard in position and install pin (5) and
retaining capscrew. Tighten to standard torque.
5. Install grease lines.
3. Remove holder (4, Figure 5-13), then remove 3. Loosen mounting capscrews (2, Figure 5-15), and
center bearing inner race (5) from pinion gear (6). remove cap (1).
4. Remove bearing outer races (2) and (1) from 4. Lift off differential gear assembly (4).
carrier (3).
5. Remove left and right side bearing adjustment nuts
NOTE: The bearing is an adjustment-free bearing (3).
assembly (2 tapered roller bearings and spacer),
so check the matching numbers, and keep as a set
in a safe place.
Disassembly Of Differential Gear Unit
Differential Gear Unit
1. Remove lock (1, Figure 5-14). 1. Using puller (1, Figure 5-16) remove bearing (2).
2. Using wrench 790-425-1660 (2), loosen left and
right side bearing adjustment nuts (3) until they
can be turned by hand.
FIGURE 5-19. SIDE GEAR FIGURE 5-21. RING NUT AND GEAR
1. Bearing 3. Collar 14. Remove snap ring (2, Figure 5-27), then remove
2. Bearing 4. Shaft bearing (1) from differential case (3).
3. Turn case over, then align with dowel pin, and 7. Install side gear (1, Figure 5-19).
install thrust washer (1, Figure 5-25). 8. Align with dowel pin, and install thrust washer (1,
NOTE: Check that the head of the dowel pin is 0.5 + 0.2 Figure 5-18).
-0.0 mm (0.02 + 0.0078 - 0.0 in) lower than the surface NOTE: Check that the head of the dowel pin is 0.5 + 0.2
of the washer. -0.0 mm (0.02 + 0.0078 - 0.0 in) lower than the surface
4. Install side gear (1, Figure 5-24). of the washer.
No Gap
FIGURE 5-36.
1. Bearing Inner Race 2. Spacer
FIGURE 5-38.
1. Cage Assembly
7. Install oil seal (3, Figure 5-39) and O-ring (2) to park
brake support (1). Install support (1) to differential
4. Set carrier (2, Figure 5-37) to pinion gear (3), and
case. Apply Three Bond thread tightener # 1374
install bearing (1).
to mounting bolts and tighten to 56 ± 6 kgm (405
± 45 ft.lbs) torque.
FIGURE 5-42.
FIGURE 5-40.
ii) Oscillate the coupling 20 to 30 rotations in its
1. Park Brake Support 3. Bolt lifted condition (approximately 300 kg) and
2. O-ring and Holder 4. Coupling make sure that the dial gauge reading has
been stabilized. (See Figure 5-43)
9. After tightening bolt (3), turn the bearing 20 to 30
rotations again, and make sure that the bearing is
running smoothly and that bolt (3) has been tight-
ened to the specified torque.
10. Using either of the following methods* , confirm that
the bearing has been set normally.
* 1) Measure the starting torque in the tangential
direction with a spring scale (1, Figure 5-41)
attached to a threaded hole in the coupling (396
mm [15.6 in.] bolt circle dia.). Starting torque
must not be greater than 5.1 kg. (11.2 lbs.)
FIGURE 5-43.
maximum.
Perform this measurement on the bevel gear
side.
iii) The dial gauge reading obtained in ii) above
will be equal to the end play in the axial
direction.
FIGURE 5-41.
1. Spring Scale
The tooth contact pattern Adjust the drive pinion by adjusting the shims at the
should start from about 5 mm drive pinion cage. Adjust the driven gear in the same
from the toe of the bevel gear way as when adjusting backlash.
and cover about 50% of the
length of the tooth. It should be
in the center of the tooth height.
FIGURE 5-46. BRAKE COUPLING FIGURE 5-48. PARK BRAKE SPRING CYLINDER
1. Brake Disc 4. Holder
5. Support 1. Spring Cylinder 3. Connecting Pin & Clevis
2. Coupling
6. Capscrews 2. Tool 4. Lever
3. Capscrew
FINAL DRIVE
To Check Oil Level
The final drive uses a planetary gear mechanism to
reduce the rotation speed and produce a greater driv- Stop the machine so that the casting line is horizontal
ing torque. Of all the components in the drive train, the and the drain plug is at the bottom. Remove the fill plug
final drive has to bear the greatest stresses. The and check the oil level. If the oil level is not near the
lubrication system should be maintained properly to lower edge of the plug hole, add oil until it reaches this
insure long life of the gears and bearings. level.
Removal
1. Drain 64 l (17 gal) of oil from the final drive case.
NOTE: If the drain plug is not at the bottom, use a
hydraulic jack (50t) to jack up the machine, then turn
the hub.
Assembly Disassembly
1. Install spacer (8, Figure 6-5) to carrier. 1. Remove rear wheel assembly. Refer to "Rear
Wheel Removal", this section.
2. Install snap ring (3, Figure 6-7).
2. Remove carrier assembly as previously de-
3. Fit spacer (2), and press fit outer race (1).
scribed.
4. Set spacer (2, Figure 6-5) and bearing (1) in
3. Shim retainer removal;
position, then raise pinion gear and assemble,
and install bearing (1) from top. a. Using three evenly spaced tools 790-438-1150
(3, Figure 6-8), secure inner gear (1) to outer
5. Push pinion gear assembly (5) into carrier. gear (2).
6. Fit plate (3) with capscrew (1) temporarily, then NOTE: To install the tool, remove capscrew (4) from
install 2 guide capscrews to shaft (4), and press the outer gear, and use the three tool mounting tap
fit. holes in the inner gear.
NOTE: Expand fit the shaft, of press fit with a press. NOTE: To prevent damage to the floating seal, always
remove before removing retainer (1, Figure 6-9).
4. Lift off ring gear assembly (1, Figure 6-10). Disas- 5. Rear wheel hub assembly.
semble ring gear assembly as follows. a. Sling rear wheel hub assembly (1, Figure 6-12)
a. Remove mounting capscrews (1, Figure 6-11), or support with forklift, then remove nuts (2,
then remove holder (2). Figure 6-13).
b. Remove inner hub (3) from ring gear (4).
SUSPENSIONS
INDEX
FRONT SUSPENSION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-7
Attenuation Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-8
REAR SUSPENSION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4
Spherical Bearing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
The suspension system supports the weight of the The front suspension consists of two basic com-
chassis, and absorbs the shock from uneven road ponents; a suspension cylinder and an A-arm.
surfaces to provide a comfortable ride for the operator.
In addition to these functions, the front suspension
At the same time, it maintains the stability of the ma-
employs an optional variable rate suspension system.
chine by ensuring that all four wheels are always in
In this system, the force of the suspension is automat-
contact with the ground surface. In this way, it allows
ically changed by selecting the damping force to match
the machine to demonstrate its full performance in
the travel conditions and load conditions. This further
items such as acceleration, braking, and turning, even
increases the stability and riding comfort of the ma-
when traveling at high speed.
chine.
The suspensions are hydro-pneumatic components
If a variable rate suspension system or the payload
containing oil and nitrogen gas. The oil and gas in the
meter is installed on the vehicle, both front suspension
four suspension cylinders carry the gross truck weight
cylinders will have a pressure sensor in place of the
less wheels, spindles and final drive assembly.
discharge plug.
FIGURE 2-4.
1. Leaf Springs 3. Orifice Plate
2. Leaf Springs
1. Capscrew 6. Plate
2. Orifice Plate Assembly 7. Oblong Leaf Spring
3. Valve Body 8. Circular Leaf Spring
4. Capscrew 9. Orifice Plate
5. Stopper Plate 10. Pin
The suspension cylinder has the function of both a 1. Park unloaded truck on hard level surface. Block
shock absorber and a spring. wheels and apply parking brake.
1. When a fixed amount of oil is sent from oil area 2. Raise and support the rear of the frame of the truck
(16, Figure 3-1) through orifices (5) and (A) to for rear suspension removal and installation.
cavity (17), the oil is throttled by the orifices and
3. Wearing face mask or goggles, crack open dis-
a shock-absorbing effect is obtained.
charge valve and discharge nitrogen pressure
2. Retracting action from suspension. If oil escapes with the nitrogen,
a. When the machine is traveling and it hits a tighten valve slightly. Tighten discharge valve
bump or object on the road, the wheels are after all nitrogen is released from suspension.
pushed up, and the cylinder rod is pushed 4. Remove suspension lower mount pin (2, Figure
inside the cylinder. 3-2) retainer bolt.
b. When this happens, the nitrogen gas inside
area (18) is compressed, the oil in area (16) is
sent through both orifices (5) and (A) to cavity
(17), and cavity (17) is filled quickly.
3. Extending action
a. After the machine has passed over any bump Suspension weighs approximately 240 kg. (530
or object on the road surface, the cylinder is lbs). Be certain that lifting device is of adequate
pulled down by the weight of the wheels and capacity.
axle and pushed down by the pressure of the
nitrogen inside area (18). 5. Attach lifting device to suspension. Suspension
b. As a result, the amount of oil in cavity (17) is weighs approximately 240 kg.(530 lbs.)
reduced, and pressure is applied to the oil
remaining in cavity (17). 6. Remove retaining capscrew and top mount pin (1,
Figure 3-2) and spacers and remove suspension
c. This pressurized oil closes orifice (5) with check from truck.
ball (5), and is sent to area (16) through only
orifice (A), so the flow of oil passing through the 7. Retract rod and move suspension to work area.
orifice is controlled so that it is slower than
during retraction. In this way, the amount of oil
returning to area (16) is restricted, providing a
shock absorbing effect.
FIGURE 3-4. ROD AND WEAR RING 4. Install seal (2, Figure 3-7) and bushing (3) to plate
(1).
1. Cylinder Rod 2. Wear Ring
1. Plate 3. Bushing
2. Seal
FIGURE 3-5. CYLINDER PACKINGS 5. Install plate (2, Figure 3-6) to rod (1).
6. Install backup ring (6, Figure 3-3) and O-ring (5)
1. Flange 3. U-Packing to flange.
2. Bushing
7. Install temporary plugs in charging and air bleed
valve ports.
Inspection
1. Inspect spacers and mounting eye bearing bores
for damage. Inspect retainer ring grooves. Repair
or replace as necessary.
2. Inspect mount pin. Replace pin if worn or dam-
aged.
Assembly
1. Install retainer ring in groove.
2. Press spherical bearing in mount eye bore.
FIGURE 3-8. LIQUID GASKET SEAL AREA 3. Install remaining retaining ring.
4. Refer to Suspension Installation.
1. Retainer A-Sealant Area
2. Flange B-No sealer this area 5. Be sure grease is applied to bearing before oper-
ating truck.
6. After suspension is installed on truck, it may be
necessary to charge suspension with nitrogen.
11. Install plate (2, Figure 3-6) together with flange (3)
Refer to Suspension Oiling and Charging proce-
with 16 mounting bolts. Tighten to 157 - 196 Nm
dure, this section.
(116 - 145 ft. lbs.) torque.
12. Fit packing to air bleed valve (1, Figure 3-1) and
install. Tighten to 4.5 ±0.5 kg.m (33 ±4 ft.lbs.)
torque.
13. Install charging valve (2, Figure 3-1). Tighten to
4.5 ±0.5 kg.m (33 ±4 ft.lbs.) torque.
NOTE: The charging valve and air bleed valve can be
installed in either place.
14. Install protective skirt to housing. Install cover over
charging and air bleed valves.
EQUIPMENT LIST
1. Service Kits:
a. EC6027 Oil Charging Kit (Figure 4-5)
b. EC3331 Nitrogen Charging Kit (Figure 4-6)
2. Jacks and/or Overhead Crane
3. Oil (MIL-L-2104C, SAE 10W)
4. Dry Nitrogen (See Nitrogen Specifications Chart)
Each suspension is equipped with a charging valve (3, FIGURE 4-2. VALVE AND SENSOR LOCATION
Figure 4-2), air bleed valve (1) and a discharge plug
1. Air Bleed Valve 3. Charging Valve
(2) or a pressure sensor assembly. The pressure
2. Discharge Plug
sensor assembly is used if the truck is equipped with
an on-board load weighing system or variable rate
suspension and takes the place of the discharge plug.
1. Park unloaded truck on a hard level surface.
Block wheels, apply parking brake.
2. Remove outside covers and thoroughly clean
area around charging valves (3, Figure 4-2) on
the suspensions.
3. If equipped with a pressure sensor, disconnect
the pressure sensor wire lead.
4. Set hydraulic jack (1, Figure 4-3) under the main
frame and raise jack to contact the frame.
NOTE: When releasing the nitrogen gas, there is
danger that releasing the gas from the valve core of
charging valve (3, Figure 4-2) will damage the valve
core, so remove the gas by loosening the discharge
plug (2) or sensor valve assembly (2, Figure 4-4).
10. Loosen air bleed valve (5), then pump oil into Dry nitrogen is the only gas approved for use in
cylinder until no bubbles come out with the oil from suspensions. Charging of these components with
air bleed valve hole (6). oxygen or other gases may result in an explosion
which could cause fatalities, serious injuries
11. When no bubbles come out with the oil, tighten air and/or major property damage. Use only nitrogen
bleed valve (5) to 4.5 ±0.5 k.gm (33 ±3 ft.lbs.) gas meeting the specifications shown on page
torque. H4-1.
1. Remove caps from charging valves (3, Figure
4-2).
NOTE: Before installing regulator (11, Figure 4-6, blow
out the cylinder connector with nitrogen gas at 10
kg/cm2 (140 psi) or more, to clean out all dirt or dust.
(Dirt or dust in the system can cause suspension
failures.)
Lifting equipment (crane or hydraulic jacks) must NOTE: Arrangement of parts may vary from illustration
be of sufficient capacity to lift the truck weight. Be above, depending on Charging Kit P/N.
certain that all personnel are clear of lift area be-
fore lift is started. 2. Remove caps from charging valves (3, Figure
1. Raise rear of truck with crane or jacks to provide 4-8).
dimensions shown in chart below figure 4-11 NOTE: Before installing regulator (11, Figure 4-10),
blow out the connector with nitrogen gas at 10 kg/cm2
(140 psi) or more, to clean out all dirt or dust. (Dirt or
dust in the system causes failures.)
BRAKE CIRCUIT
Brake Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
Emergency Relay Valve (RE-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-2
Hand Brake (Retarder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5
Parking Brake Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-7
Parking Brake Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-8
Brake Chamber (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-9
Brake Chamber (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-9
Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-10
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-12
Stop Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-12
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-13
Automatic Retarder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-13
Front Brake Cut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-14
Brake Cooling Valve (BCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-15
Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-16
Emergency Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-17
Brake Valve (Treadle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-21
REAR BRAKES
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-3
Inspection Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-4
PARKING BRAKE
Brake Pad
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
Parking Brake Caliper
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Parking Brake Spring Cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-5
Parking Brake Disc
Driveshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
Parking Brake Disc Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
Inspection Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-7
Parking Brake Disc Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-7
Driveshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-7
PARKING BRAKE RELEASE AFTER EMERGENCY APPLY
Release of Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-7
Release of Emergency Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-8
The operator of the truck applies the service brakes by If air system pressure decreases below 3.2 kg/cm2 (45
use of a foot operated treadle valve in the cab. The psi), the emergency brakes apply automatically. If air
brake circuit is an air controlled, hydraulically applied pressure continues to decrease, the parking brake will
dry and wet disc system. also apply.
During normal operation of the brake system Relay
Valve (RE-6), when the service brake pedal is de-
pressed, air is supplied from the air tank (dry) to the COMPONENT DESCRIPTION
pressure converters. The air pressure from the air tank
through the RE-6 valve should be equal to the air The main air system supplies air for actuation or
pressure from the service brake pedal. If a failure of release of all brake circuits. After the truck engine has
the air supply circuit or excessive air leakage from the been started, pressurized air flows through the wet air
(wet) air tank allows pressure to drop below 3.2 kg/cm2 tank to the dry air tanks to the emergency relay valves
(45 psi), it will cause the RE-6 valve to go into an mounted near the tanks. As circuit pressure increases,
“emergency mode”. This will apply the air pressure the RE-6 valve directs air to the pressure converters
stored in the (dry) air tanks (front and rear) to the which apply the brakes while air system pressure is
pressure converters. building. The service brakes will remain applied until
the pressure reaches approximately 7.0 kg/cm2 (100
To control truck speed without use of the service psi), at which point the exhaust valve of the RE-6 valve
brakes, the operator may use the hand operated con- will open and release the brakes.
trol valve lever to apply the rear wheel wet disc brakes.
This valve provides pressure to rear brakes only to
reduce truck speed. Use of only the rear brakes de- AIR TREADLE VALVE
creases the possibility of the truck skidding on slippery The brake circuit is controlled by a dual section treadle
roads. valve located on the floor of the cab. When the brake
For full braking power in an EMERGENCY situation, pedal is depressed, air pressure within the two sec-
the operator can manually apply the emergency brake. tions of the brake valve is directed to two separate
Located on the console next to the operator, the emer- brake circuits. One air circuit controls operation of a
gency brake control valve lever is to be used for brake circuit for actuation of the two brake actuators,
emergency application of the wheel brakes in an both front and one rear brake assemblies. The other
EMERGENCY ONLY. DO NOT use the emergency circuit actuates the other two brake actuators. If one
brake valve to stop the truck during normal operation! brake circuit should malfunction, the other circuit is still
available to apply the brakes. The flow of air from each
The parking brake toggle lever, mounted on the con- section of the dual brake valve passes through a valve
sole next to the operator, enables the operator to apply located in each circuit and then to the emergency relay
and release the parking brake. The parking brake is valves (RE-6) mounted on the front and rear dry tanks.
spring applied and air released. It should be used when The emergency relay valves regulate pressure from
parking the truck in a designated parking area. the dry air tanks to be applied to the pressure convert-
The Front Brake “OFF” switch changes the braking ers.
action of the system for operation under various road
surface conditions. The switch is located on the instru-
ment panel to the left of the steering wheel. When the
switch is in the “OFF” position (dry road conditions),
brake pressure is applied to both front and rear wheels.
If the switch is depressed to the “ON” position (slippery
road conditions), brake pressure is applied only to the
rear wheels. The pilot light inside the switch is illumi-
nated in this position.
FIGURE 2-1.
CHARGING-BRAKE APPLYING
Below 6.3 kg/cm2 (90 psi)
FIGURE 2-2.
SYSTEM CHARGING
6.3 - 7.0 kg/cm2 (90 - 100 psi)
FIGURE 2-4.
SYSTEM CHARGED-VALVE STATIC
7.0 kg/cm2 (100 psi)
FIGURE 2-6.
BRAKES APPLIED - VALVE BALANCED
When air pressure below the relay piston is equal to the
air pressure above it, the relay piston and emergency
piston will lift slightly and the inlet area of the inlet and
exhaust valve will close. The valve is then in a balanced
condition
NOTE: The brakes are not necessarily fully applied when
the valve is in a balanced position, but are applied only
to the extent of pressure applied by the operator at the
brake treadle valve. Should the operator continue to
depress the brake pedal, additional air pressure will open
the inlet passage in the RE-6 valve. Again the balanced
condition will occur if the operator stops and retains the
brake pedal in one position.
Releasing
When the operator releases the brake pedal, air in the
service port line is exhausted through the exhaust port of
the service brake valve. Upward movement of the relay
piston unseats the exhaust portion of the inlet and ex-
haust valve and air in the pressure converter is exhausted
through the RE-6 valves releasing the brakes.
FIGURE 2-7
FULL EMERGENCY
Whenever air pressure at the “Emergency” port drops
to 3.2 kg/cm2 (45 psi), the check valve in the RE-6 valve
closes and spring pressure lifts the emergency piston.
The inlet portion of the inlet and exhaust valve opens
and the exhaust portion closes, applying air tank pres-
sure out of the delivery ports to the pressure converters.
When air tank pressure equalizes the pressure at the
pressure converters, the RE-6 valve is in the full emer-
gency position.
FIGURE 2-7.
FIGURE 2-11.
FUNCTION
If the air for the emergency brake circuit is cut, the As a result, the parking brake is set to the “TRAVEL”
circuit between the parking brake valve and parking position.
relay valve is shut off and the parking brake is applied.
When no air is being sent to the emergency
OPERATION brake circuit ( Figure 2-16):
Piston (1) is moved up by the spring, the air from rear
When air is being sent to the emergency
air tank is shut off, and the air from the relay valve is
brake circuit (Figure 2-15):
released to the atmosphere, so the parking brake is
Piston (1) is moving down in the direction of the arrow, applied.
so the air from the rear air tank is sent to the relay valve.
FIGURE 2-14. PARK BRAKE RELEASED FIGURE 2-15. PARK BRAKE APPLIED
FUNCTION
Parking brake valve in “PARKING” (Figure
Parking brake valve in “TRAVELING” (Figure 2-19):
2-18):
The pressurized air in the piston upper section (A) will
Pressurized air will enter (A), the upper section of the be exhausted through the parking brake valve, reduc-
relay piston, causing the piston to lower. Then, the ing the pressure in (A).
exhaust valve seat (1) will close the exhaust port (C)
and open the valve (2). Consequently, the relay piston will be pushed up by
the pressurized air in the section (B), causing the
If the valve is opened, the pressurized air will be fed to exhaust port to open. Thus, the air in the section (B)
the parking brake chamber through the valve. will be exhausted.
FIGURE 2-18. PARK BRAKE RELEASE FIGURE 2-19. PARK BRAKE APPLIED
1. Exhaust Valve Seat A. From Parking Brake Pilot Valve D. To Parking Brake
2. Valve B. Chamber Chamber
C. Exhaust Port E. From Air Tank
FUNCTION
Indicates low air pressure below 75 psi. Turns on dash
light and warning buzzer.
If compressed air at a pressure higher than the speci-
fied pressure is applied to piston cup (7), the piston
cup is pushed up, and at the same time, contact disc
(4) is also pushed up.
When this happens, contact plate (8) and contact disc
(4) are separated, so the circuit is opened.
Specifications:
• Normally closed switch, opens at 75 psi.
• Measuring between pins 1 and 2 at:
8.3 kg/cm2 (120 psi) - 160 ohms or less
5.2 kg/cm2 (75 psi) - 640 - 800 ohms
FIGURE 2-26. PRESSURE SWITCH
1. Cover 5. Gasket
2. Contact Plate 6. Body
3. Spring 7. Piston Cup
4. Contact Disc 8. Contact Plate
FUNCTION
When the brake pedal is depressed, air pressure acts
on the switch to light up the stop lights.
Specifications:
Service brake switch
• Measuring between pins 1 and 2
above 0.6 kg/cm2 (8 psi) continuity
below 0.2 kg/cm2 (3 psi) no continuity
FUNCTION
If the parking brake is released, the compressed air
from the air tank acts on the diaphragm, and closes
the contacts of the switch.
FUNCTION
The input port and output port are connected by pass-
ing electricity through the coil of the solenoid valve.
When this happens, the auto retarder is applied.
Specifications:
Normally closed switch, actuates at 2500 ±10 RPM.
Opens and releases retarder at 2350 ±10 RPM.
• Measuring between pins 1 and 2, 20-60 ohms.
1. Core 8. Spring
2. Coil Assembly 9. Body
3. Spring 10. Connector
4. Plunger
5. Valve Seat A: Input Port
6. Rod B: Output
7. Valve C: Exhaust Port
Function
This valve is installed in the pilot circuit between the
brake valve and RE-6 valve. It is used to cancel the
actuation of the front brake according to the haul road
conditions .
When the Front Brake Off switch in the operator’s
compartment is pressed, current flows in the coil of the
solenoid valve, and the solenoid valve is actuated.
When this happens, the circuit from the brake valve to
the front brake RE-6 valves is shut off, and the front
brakes are released, if applied.
Specifications:
• Measuring between pins 1 and 2, 20-60 ohms.
Function
FUNCTION
When the lever is fully forward (“unlocked” position),
the emergency brake is released and in the correct
position for normal truck operation. Moving the lever
to the rear (“locked” position) provides a modulated FIGURE 2-36. VALVE CROSS SECTION
control to vary emergency brake application from fully
1. Handle 7. Valve Spring
released to fully applied.
2. Cam Ring 8. Main Spring
Figure 2-35 shows the emergency brake control valve 3. Head 9. Feed Valve
output pressure, with tank pressure at 8 kg/cm2 (114 4. Body 10. Feed Valve Seat
psi) in relation to the amount of handle rotation; be- 5. Piston 11. Return Spring
tween the full on position (0°) and full off position (55°). 6. Cover 12. Exhaust Valve Seat
FIGURE 2-37.
9. Feed Valve A. Exhaust Air
B. From Air Tank
C. From RE-6 Valve
FIGURE 2-38.
9. Feed Valve A. Exhaust Air
12. Exhaust Valve Seat B. From Air Tank
C. From RE-6 Valve
FIGURE 2-39.
5. Piston A. Exhaust Air
8. Main Spring B. From Air Tank
9. Feed Valve C. From RE-6 Valve
12. Exhaust Valve Seat
FIGURE 2-40.
5. Piston A. Exhaust Air
6. Cover B. From Air Tank
9. Feed Valve C. From RE-6 Valve
FIGURE 2-41.
9. Feed Valve A. Exhaust Air
11. Return Spring B. From Air Tank
12. Exhaust Valve Seat C. From RE-6 Valve
1. Plunger 7. Upper valve (upper inlet valve) 13. Lower valve return spring
2. Seat 8. Outer relay piston 14. Relay piston return spring
3. Pedal 9. Lower valve (lower inlet valve) 15. Upper ring retainer
4. Piston 10. Cover 16. Upper valve return spring
5. Stop bolt 11. Lower valve guide 17. Valve body
6. Piston return spring 12. Check valve 18. Rubber Spring
A: From Tank
B: From Tank
C: From Relay Valve
D: From Relay Valve
E: Exhaust Port
F: Package
G: Exhaust Port
3. Brake Pedal
4. Piston
8. Relay Piston
Removal
1. Depress brake pedal several times to bleed air
from air tank.
2. Remove cover from below pedal assemblies.
3. Disconnect lines (1, Figure 3-1) between air tank
and brake valve at valve end.
4. Disconnect lines (2) between relay valve and
brake valve at valve end.
5. Remove cover (1, Figure 3-2).
6. Remove pin (2), then remove brake pedal (3).
FIGURE 3-2. BRAKE TREADLE
7. Remove 3 mounting capscrews (2, Figure 3-3),
then leave mounting plate (1), and remove brake 1. Cover 3. Brake Pedal
valve assembly (3, Figure 3-1) from below. 2. Pin
4. Connect lines (1, Figure 3-1) between air tank and 6. Install cover below pedal assemblies.
brake valve.
Removal Disassembly
Installation
NOTE: When installing the brake chamber assembly,
be certain that the spacers support the chamber away
from the mounting plate. If the chamber is installed
touching the mounting plate, the chamber may crack FIGURE 3-12. OIL CYLINDER
when the mounting capscrews are tightened.
1. Capscrews 2. Oil Cylinder
Cover assembly
Oil cylinder
1. Install plug (6, Figure 3-18) with Three Bond
1. Install oil cylinder (2, Figure 3-12) to air cylinder
(TB2411) adhesive and tighten to 2.0 kg.m (14
assembly.
ft.lbs.) torque.
2. Tighten capscrews (1) to 3.85 kg.m (28 ft. lbs.)
2. Install filter (9) and snap ring (8).
torque.
3. Assemble bushing (7), secondary cup (2, Figure
3-17 or 3-18), spacer (4), secondary cup (2), cup
support (1) and stop ring (5) in order.
Checking
1. Bleed air from oil cylinder.
Air cylinder assembly 2. Check that at least 180 kg/cm2 (1680 psi) of oil
pressure is generated in the oil cylinder when 8
1. Install packing (15, Figure 3-13) to piston and rod
kg/cm2 (114 psi) of air pressure is applied to air
assembly (3).
cylinder.
3. Check that there is no leakage of air or oil.
REMOVAL
1. Open the drain valve to release the air inside the
tank.
2. Disconnect air lines (1, Figure 3-19).
3. Remove brake oil hoses (2 & 3, Figure 3-20).
4. Remove the four capscrews from the chamber
moutning plate and remove rear brake chamber
assembly (1) from the truck.
INSTALLATION
Carry out installation in the reverse order to removal.
1. Capscrews 2. Cover
150 mm (5.9 in)
Removal
1. Disconnect all hydraulic lines (1, Figure 3-24).
Installation
1. Install slack adjuster assembly with capscrews (2, Slack Adjuster Assembly
Figure 3-24). Tighten capscrews to 18.0 ±1.5
kg.m (130 ±10 ft. lbs.) torque.
2. Connect all hydraulic lines (1). When assembling, check carefully that there is no
3. Bleed the air from the brake circuit. dirt, dust or chips on the inside surface of the
Refer to Section “J”, “Brake Bleeding”. adjuster.
DIMENSION “C”
Standard Size Tolerance Standard Clearance
Clearance Limit
Clearance between Piston Housing
Cylionder Housing 80 mm
(3.15 in.) -0.030 to -0.076 mm +0.074 mm 0.03 - 0.15 mm 0.25 mm
and Piston (-0.001 to -0.003 in. (+0.003 in.) (0.001 - 0.006 in.) (0.098 in.)
TORQUE VALUES
6B. Tighten to 6.0 ±0.5 kgm (45 ±4 ft. lbs.) torque.
15. Tighten to 17.5 ±1.5 kgm (127 ±10 ft. lbs.) torque.
Removal Installation
1. With the engine shut down and the wheels se- 1. Position valve assembly (1, Figure 3-28) over
curely blocked, release air pressure from system. mounting plate holes in console and install cap-
screws (2). Tighten to standard torque.
2. Remove screws attaching cover (2, Figure 3-27)
to console base (1) and remove cover. Remove 2. Install air lines (3) at valve ports.
tray (5).
3. Pressurize air system and operate valve to verify
3. Remove access panel (4) on right side of console proper operation and inspect connections for pos-
and disconnect air line tubes (3, Figure 3-28) on sible air leaks.
emergency brake control valve ports.
4. Install cover (2, Figure 3-27) onto console base
4. Remove capscrews (2) and remove valve assem- (1). Install storage tray (5).
bly (1) from console.
5. Install access panel (4).
Inspection
Remove all O-Rings and discard. Thoroughly clean
parts and inspect valve body for cracks, scoring, and
port thread damage. Replace any part if damage or
excessive wear is evident. All O-ring seals, the feed
valve, and exhaust valve seat should be replaced
during rebuild. Refer to the appropriate parts book for
these parts in a pre-packaged kit.
Start the engine and wait for the air gauge to enter the
green range, then bleed the air from the circuit as
follows.
Rear brakes
1. Bleed the air at the slack adjuster end first. Depress FIGURE 4-5. SLACK ADJUSTER
the brake pedal, then loosen air bleed plugs (1 or
2, Figure 4-5) 3/4 turns. Tighten the plug again, 1. Air Bleed Plug 2. Air Bleed Plug
then release the pedal.
Front brakes
FIGURE 4-6. BRAKE HOUSING BLEED PLUG
1. The oil tank is separately installed, so always check 1. Air Bleed Plug 2. Brake Housing
the oil level while bleeding the air to avoid running
out of oil.
Removal
Installation
1. Install brake pads.
2. Install pin (1, Figure 5-1) and tighten capscrew (2)
to 5.25 ± 0.25 kg.m (38 ± 2 ft. lbs.) torque.
3. Bleed the air from the brake circuit. Refer to "Brake
Bleeding" this Section.
FIGURE 5-2. BRAKE PAD REPLACEMENT
Removal
1. Refer to "Tire Removal ", Section "G" and remove
front wheel assembly.
2. Disconnect the two brake lines (1, Figure 5-3).
3. Remove 13 mounting capscrews (3, Figure 5-4).
Use a suitable lifting device as support, remove
the remaining mounting capscrews, and remove
caliper assembly.
Disassembly
1. Loosen capscrews (1, Figure 5-5) and (2), remove
pins (3), (4), and (5), the remove pads (6).
2. Remove plate (7), then remove plug (8), backup
ring (9), and seal (10).
3. Remove dust seal (11), then remove piston (12).
4. Disassemble the other pistons in the same way.
TIGHTENING TORQUES
FIGURE 5-4. BRAKE CALIPER REMOVAL 2. 94.5 ± 10 kg.m (685 ± 72 ft. lbs.) torque.
1. Mounting Plate 4. Brake Disc 3. 94.5 ± 10 kg.m (685 ± 72 ft. lbs.) torque.
2. Brake Caliper 5. Capscrew 4. 21.0 ± 1 kg.m (150 ± 7 ft. lbs.) torque.
3. Capscrew 6. Bleeder Valve
7. Capscrew 5. 2.6 ± 0.3 kg.m (20 ± 2 ft. lbs.) torque.
NOTE: 2 Of thin pins (4) and (5), always install the short
pin (5) at the plate end.
4. Grease pins (3, 4, 5). Fit pads (6), and install pins
(3), (4), and (5), and tighten capscrews (2) and (1)
to 5.25 ± 0.25 kg.m (38 ± 2 ft. lbs.) torque.
A Wet Disc Brake Assembly is mounted on both sides The complete brake disc pack is cooled by hydraulic
of the differential on the final drive housing and inboard oil. The cooling oil circuit is a low-pressure circuit which
from the wheel hub and planetary drive. This assembly is completely separate from the high-pressure piston
contains a splined housing, two damper discs, fourteen apply circuit. The cooling oil flows from the tank to the
separator plates, fifteen friction discs, a spacer, and a pump, to the brake assembly housing (from the outside
piston assembly. of the housing inward to the rotating hub for maximum
cooling), through a heat exchanger, through two 30
The housing is internally splined to retain the steel
micron (absolute) filters, and then to the hydraulic tank.
damper and separator discs. The separator discs are
alternately placed between the friction faced discs Dynamic retarding is also provided by the wet disc
which are splined to the rotating hub. The inboard side brakes. When the operator’s retarder lever is actuated,
of the assembly contains the piston assembly which is the front wheel brakes are not used; only the rear wet
activated by hydraulic pressure from either the service disc brakes are applied. The dynamic retarding is used
brake treadle valve or the retarder valve. As hydraulic to slow the truck during normal truck operation or to
pressure is applied, the piston moves and compresses control speed coming down a grade.
the rotating friction faced discs against the stationary
steel discs. The friction forces generated resist the
rotation of the wheels. As hydraulic pressure increases,
friction forces are increased and wheel rotation is WET DISC BRAKE ASSEMBLY
slowed until maximum force is reached and the wheel
is stopped. Removal
1. Remove rear wheels and tires, planetary drive, and
wheel hubs. Refer to Section "G", Drive Axle, Spin-
dles and Wheels.
2. Drain brake cooling oil tank. Be prepared to catch
268 l (71 gal.) of oil.
3. Remove retainer (1, Figure 6-2) and floating seal
(2, figure 6-3).
J060009
FIGURE 6-6.
FIGURE 6-4. BRAKE LINES
1. Piston 2. Brake Disc Assembly
1. Hydraulic Hoses 2. Hydraulic Lines
Installation
For servicing any part of the parking brake, stop 4. Move plate (4) when removing pads (3) so that
the machine on level ground, and put blocks in the pads do not fall.
front of, and behind, the wheels. 5. After removing the rear pad, move the caliper to
Raise the dump body and lock with the safety pin. the front, and remove the front pad.
The parking brake is a dry disc brake mounted on the
rear drive shaft at the differential input with two (2) Pad Installation
spring-applied, air-released calipers. Each caliper is 1. Install and align the grooves of the pad and the
individually applied/released through separate air caliper with the plates on both sides.
chamber actuators (spring cylinder assemblies).
2. Coat the threads of the plate mounting capscrews
Inspection (2, Figure 7-1) with thread tightener Three Bond
(TB 1374). Tighten capscrews to 94.5 ±10 kg.m
PARKING BRAKE INSPECTION
(685 ±72 ft.lbs.) torque.
ITEM NEW LIMIT REMEDY
3. Refer to "Park Brake Adjustment", this section and
Disc Face Runout 0.4 mm 0.8 mm Replace adjust the parking brake.
(0.016 in) (0.032 in)
Disc 25 mm 20 mm Replace
Thickness (0.99 in) (0.79 in) PARKING BRAKE CALIPER
Pad (Includes Plate 21.5 mm 11.5 mm Replace
Thickness) (0.847 in) (0.45 in) Caliper Removal
FIGURE 7-1. BRAKE PAD REPLACEMENT FIGURE 7-2. BRAKE CALIPER ASSEMBLY
1. Adjusting Capscrew 3. Pad 1. Plate 3. Caliper
2. Mounting Capscrew 4. Plate 2. Brake Pads
The piston and support are under high pressure, Coat the sliding surfaces of all parts with grease and
so be careful when operating the press. be careful not to damage the rings when installing.
1. Coat ring (17, Figure 7-5) with engine oil. Install
5. Using press, support piston (10) and support (11), rings (18) and (17) to case (16).
and remove bolts (12). Then loosen press slowly, 2. Coat ring (15) with engine oil. Install rings (15) and
and remove support (11) and spring (13). (14) to piston (10), and set in case (16).
Also see Figure 7-6.
Dimension "a"
Rod Adjusted Length 128.0 mm (5.04 in.) Adjust
as
Dimension "b" 2.1 mm (0.08 in.)
Required
Axial Rod Play
Standard Size Standard
Clearance
Shaft Hole
Dimension "c"
Clearance between piston 38.04 mm 38.8 mm 0.76 mm
and insert center boss (1.50 in.) (1.53 in.) (0.03 in.) Replace
Parts
Dimension "d" as
Clearance between cylinder 158.65 mm 159 mm 0.35 mm Required.
and piston (6.25 in.) (6.26 in.) (0.014 in.)
Free Length Installed Load
Testing
Driveshaft Removal
1. Remove guard (1, Figure 7-13) and cover (2).
Driveshaft Installation
AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K2-1
Air Dyer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K2-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K2-2
Operational Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K2-2
AIR GOVERNOR
FIGURE 2-6. AIR GOVERNOR
The air governor (3, Figure 2-1) is located on the inside
of the expansion tank mounting bracket, under the
operator cab. As the pressure drops to 8.3 kg/cm2 (118 psi), force
exerted by air pressure on the bottom of the piston will
Air pressure from the expansion air tank enters the inlet
be reduced so that the spring force will move the piston
port of the governor (Figure 2-6), passes through a filter
down. The inlet valve closes and the exhaust valve
and acts on the bottom of the piston and valve.
opens allowing pressure in the unloader line to vent
When air pressure reaches 9.0 kg/cm2 (128), the piston through the exhaust ports. With pressure released in
moves upward unseating the valve. Air pressure flows the unloader line, the compressor will begin to pressur-
through the drilled passage in the piston and out the ize the air system.
unloader port to the compressor intake valve and the
At the same time, the exhaust port in the air dryers will
unloader valve port on each air dryer. The air compres-
close and cool, dry air will flow to the system air tanks.
sor intake valves are held open and air delivery stops.
In addition, the purge tanks will re-pressurize and store
At the same time, the air dryers will start their purge
a supply of air until needed for the next unload/purge
cycle, exhausting the air in the purge tanks through the
cycle.
desiccant bed and out the exhaust port.
Function
When the horn button on the steering wheel is pressed,
the electric circuit is closed and electricity flows to the
coil to form an electromagnet that raises the piston.
Compressed air then flows to sound the horn.
Removal
• The truck’s wheels must be chocked. 1. Drain the air system
Block the wheels and make sure the vehicle
2. Disconnect heater wiring.
will not roll, before releasing the brakes and
before performing any test and/or isolating 3. Mark the air lines for later reference and discon-
any air system component. nect from air dryer(s).
4. Remove the lock nuts, washers, and capscrews
• Stop the engine when working under a vehicle. that attach the air dryer to the mounting bracket.
Problem: The air compressor goes into the standby mode but cycles rapidly.
Problem: Air flows from the exhaust port when the air compressor is trying to build up pressure.
Problem: The air dryer does not unload when the air compressor goes into standby mode.
For air compressor service, refer to engine manufac- 1. Install an accurate air gauge to monitor system air
turer’s service manual. pressure.
2. Start engine and allow air system to fully charge.
AIR GOVERNOR Watch the air pressure gauge to determine the
point at which the compressor “cuts-out” (stops
Removal delivering compressed air):
1. With the wheels securely blocked, release all air Air pressure should be 9.0 kg/cm2 (128
pressure from the system. psi).
2. Disconnect air lines routed to the compressor (2, 3. Drain system air pressure and note at what pres-
Figure 3-2), air dryers (5) and governor inlet line sure the compressor “cuts-in” (delivers com-
(6). pressed air):
3. Remove mounting capscrews (3) and remove Air pressure should be 8.3 kg/cm2 (118
governor (4) from mount. psi).
4. If the above pressures are not at the recom-
Installation
mended levels, adjust air governor valve as fol-
1. Position governor (4, Figure 3-2) on mounting lows:
bracket. Install mounting hardware (3) and tighten a. Remove cover (17, Figure 3-3).
to standard torque.
b. Hold adjusting screw (11) with a screwdriver
2. Install air lines (2, 5, & 6). and loosen locknut (10).
3. After installation is complete, start engine, re- c. Turn the adjusting screw counterclockwise to
charge air system and check for leaks. Refer to raise the “cut-out” pressure, clockwise to lower
“Adjustment” to verify proper operation. the “cut-out” pressure. The “cut-in” pressure
should automatically follow to the correct level.
Hold adjusting screw and tighten the locknut to
secure. Cycle the compressor several times to
check the “cut-out” and “cut-in” pressures. One
turn of the adjusting screw changes pressure
settings approximately 1.1 kg/cm2 (16 psi).
d. Replace cover (17).
4. Place exhaust stem spring (14) over the exhaust 7. With exhaust stem (13) and spring (14) in place,
stem (13) and carefully press the stem into the install adjusting screw and spring assembly in the
stem bore of the piston. Make sure exhaust stem governor body.
moves up and down freely. 8. Install snap ring (12) to secure adjusting screw and
5. Install O-rings (18) in grooves of the piston and spring assembly.
install piston in body with largest bore of piston 9. Install top cover (17) and new filters (16).
facing up.
Installation
1. Hold the clamping area of the retarder valve body
(1, Figure 5-2) against the steering column so that
the lever extends to the right of the column.
2. Install clamp (5) opposite the valve body around
the steering column and install bolts (3) and lock-
washers (4).
3. Connect the three air hoses to the appropriate
ports in the bottom of the retarder valve body
(Figure 5-1).
NOTE: If the lever replacement kit has been installed, FIGURE 5-1. PORTS
it may be necessary to adjust the lever friction after
installation. If adjustment is required, proceed with the 1. Supply 3. Delivery
following steps. 2. Exhaust
HYDRAULIC SYSTEM
INDEX
1. Shaft 2. Lever
1. Power Down Line 8. Oil Cooler Inlet Hose 15. Steering and Hoist Filter
2. Power Up Line 9. LS Steering Line 16. Brake Cooling Filters
3. Suction Line 10. Steering Return Line 17. Oil Tank
4. Brake Cooling Pump 11. Steering Pressure Line 18. Hoist Valve Inlet Line
5. Steering and Hoist Pump 12. Demand Valve Inlet Lines 19. Orifice Plate
6. Flow Switch 13. Demand Valve 20. Hoist Valve Bleed Line
7. Oil Cooler Return Hose 14. Return Line To Tank 21. Hoist Valve
22. High Pressure Filters
Raise the dump body and lock with the safety pin
prior to working on components.
Removal
1. Remove tubes (1 & 2, Figure 3-2). Cap tubes and
pump ports.
2. Remove hoses (1 & 2, Figure 3-3). Cap hoses and
pump ports. FIGURE 3-2. HYDRAULIC PUMP PIPING
3. Remove hydraulic pump assembly (3, Figure 3-2). 1. Pump Inlet Tube 3. Hydraulic Pump
2. Pump Inlet Tube
HYDRAULIC TANK
Filling instructions (hoist oil supply) FIGURE 3-3. HYDRAULIC PUMP
1. Lower the dump body and shut down the engine. 1. Outlet Hose 3. Hydraulic Pump
2. Outlet Hose
Cleaning
Release hydraulic tank filler cap slowly to remove
1. With the brake cooling oil drained, remove the any internal pressure.
flange capscrews (3, Figure 3-7).
Hydraulic fluid escaping under pressure can have
2. Disassemble the tube coupling forward of the sufficient force to enter a person’s body by pene-
strainer or remove the flange capscrews at the oil trating the skin and cause serious injury and pos-
cooler inlet and remove tube (4). sibly death if proper medical treatment by a
3. Remove strainer (1) and clean thoroughly. Inspect physician familiar with this injury is not received
wire mesh for damage. immediately.
4. Reinstall strainer and tube using new O-ring seals.
5. Refer to Filling Instructions in this Section.
NOTE: Filter Elements should be replaced every 2000 hours* , and after
any debris-producing component failure within the hydraulic system.
* More frequent replacement may be required in very dusty/dirty environ-
ments.
FIGURE 4-2. DEMAND VALVE ASSEMBLY FIGURE 4-3. STEERING CONTROL VALVE
ASSEMBLY
The oil from the pump passes through the demand The oil from the steering pump enters port (A, Figure
valve and enters port P of the steering valve. 4-5). At the same time, the oil from the hoist pump
enters port B. When the steering valve is at neutral, port
Valve spool is at the neutral position, so port P and
P of the steering valve is closed, so the pressure at port
ports (RT and LT) to the cylinder are closed. No oil flows
P rises. The pressure from port P passes through orifice
to the cylinder, so the cylinder does not move.
“F” enters the chamber C, and moves spool (7) to the
At the same time, port LS is connected through port R right.
to the tank. As a result, there is no oil pressure at port
Port LS and chamber D are connected to the tank, and
LS, so all the oil from the pump at the demand valve
the force moving spool (7) to the left is the force of
flows to the hoist valve.
spool return spring (6). The pressure in chamber C
rises until it overcomes the set pressure of spool return
spring (6). As a result, spool (7) stops in the position
shown in the diagram, and all the oil from the steering
pump and hoist pump flows to the hoist valve.
When the steering wheel is turned slowly to the right The area of the opening of the steering valve orifice is
(Figure 4-6), input shaft rotates. When this happens, small, so the difference in pressure between the two
valve spool moves down. So when input shaft rotates, sides of the orifice is large. As a result, the movement
the oil from the demand valve flows into port P when the steering wheel is operated slowly to the right,
the spool moves a short distance to the left, and some
The oil inside the valve spool then passes between the
of the oil from the steering pump flows to the steering
stator and rotor in the metering portion of spool valve.
valve. The remaining oil from the steering pump and all
After the amount of oil flowing to the steering cylinder the oil from the hoist pump flows to the hoist valve.
is measured here, it enters the inside of the valve spool,
passes through a hole in the valve spool through port
RT and flows to the steering cylinders.
In this way, the two cylinders are actuated and the
wheels turn to the right.
The oil returning from the steering cylinder flows from
port LT and goes back to the tank.
The demand spool is actuated by the difference in
pressure between the oil pressure at port P end and
the oil pressure at the port LS end. As a result, only the
necessary amount of oil flows to the steering circuit,
and remaining oil flows from the demand valve to the
hoist valve.
When the steering wheel is turned quickly to the left The area of the opening of the steering valve orifice is
(Figure 4-7), input shaft rotates. When this happens, large, so the difference in pressure between the two
valve spool moves up. The oil from the demand valve sides of the orifice is small, therefor the difference at
flows into port P, through a hole in the valve spool, and chamber C and D is also small. As a result, spring (6)
enters the inside of the valve spool. moves spool (7) a long distance to the left, and all the
oil from the steering pump together with some of the
The oil inside the valve spool then passes between the
oil from the hoist pump passes through check valve (2)
stator and rotor in the metering portion of the valve.
and flows to the steering valve to provide a large
After the amount of oil flowing to the steering cylinder amount of oil to the steering valve.
is measured here, it flows through port LT and flows to
the steering cylinders.
In this way, two cylinders are actuated and the wheels
turn to the left.
The oil returning from the steering cylinder flows from
port RT and goes back to the tank.
The demand spool is actuated by the difference in
pressure between the oil pressure at port P end and
the oil pressure at the port LS end. As a result, only the
necessary amount of oil flows to the steering circuit,
and remaining oil flows from the demand valve to the
hoist circuit.
FLOW SWITCH
The flow switch (Figure 4-10) is installed in the steering
circuit piping to monitor steering circuit oil flow.
Operation
Refer to “A”, Figure 4-10:
When oil is flowing in the pipe, plate (4) is pushed to
the left, overcoming spring (3) force and the lever
pivots on pin (2). The magnet (5) mounted on the lever
moves away from the reed switch and opens the con-
tact.
Refer to “B”, Figure 4-10:
When oil flow is interrupted, the lever pivots in the
opposite direction due to spring (3). Magnet (5) moves
close to the reed switch contacts closing the electrical
circuit. This electrical signal is routed to the relay timer
below.
Relay Timer
The relay timer provides an electrical delay in the circuit
between the flow switch and the emergency steering
pump motor relay. The timer is adjusted to provide a 3
second delay to prevent accidental actuation of the
emergency steering system due to slight interruptions FIGURE 4-11. RELAY TIMER
in oil flow. Refer to Figure 4-12 for electrical schematic. 1. Timer Assembly 2. Delay Adjustment Knob
FIGURE 5-1.
1. Lock Bolt 3. Steering Valve Assy. FIGURE 5-2.
2. Hoses 4. Column Shaft 1. Yoke 3. Capscrews
2. Steering Valve Assy. 4. Mounting Bracket
Preparation
• Fit blind plugs to 5 ports of the valve body, clean
the outer parts, then remove the blind plugs.
• Install tube nut (2, Figure 5-3) to one of the ports.
• Install in vice (1) with the end cover facing up.
• Do not hold the valve body directly in the vice. This
may cause damage to the unit.
FIGURE 5-5.
1. Pin 2. Washer
3. Using 2 mounting bolts (1, Figure 5-6), remove 5. Insert screwdriver between sleeve (1, Figure 5-8)
commutator ring (2) and manifold (3). and valve body (2), and remove sleeve .
4. Using 2 mounting bolts, remove rotor set (4, Figure 6. Remove drive link (1, Figure 5-9).
5-7) and wear plate (1) in the same way as com-
mutator ring and manifold.
FIGURE 5-7. ROTOR SET REMOVAL FIGURE 5-9. DRIVE LINK REMOVAL
1. Wear Plate 3. Manifold 1. Drive Link 2. Valve Body
2. Commutator Ring 4. Rotor Set
FIGURE 5-11.
1. Rod 3. Rod
2. Roller 4. Spring
FIGURE 5-13.
1. Spool Assembly 2. Upper Cover
FIGURE 5-15.
1. Snap Ring 4. Seal Ring
2. Spacer 5. Upper Cover
3. Seal
12. Remove seal (6, Figure 5-15) and snap ring (1), then
remove spacer (2), seal (3), and seal ring (4) from
upper cover (5).
NOTE: Seal (3) and seal ring (4) may be combined into
one piece.
13. Remove snap ring (1, Figure 5-16), thrust washer
(2), thrust bearing (3), thrust washer (4), and wave
washer (5) from input shaft (6).
14. Using a punch (1, Figure 5-17) 3.0 mm dia., x 16
mm long (.12 in. dia. x .62 in. long), remove pin (2,
Figure 5-18) from input shaft. FIGURE 5-18. PIN DETAIL
1. Shaft 2. Pin
NOTE: To prevent damaging the input shaft, carry out
the operation on a wooden block.
17. Set valve spool (1, Figure 5-21) facing down, then
15. Set valve spool (1, Figure 5-19) facing down, then rotate input shaft (2) clockwise until ball (4) comes
remove torsion bar (2) and spacer (3) from input out.
shaft and valve spool assembly.
NOTE: Do not remove ball retaining spring (1, Figure
16. Set valve spool (1, Figure 5-20) facing down, then 5-22) unless replacing it. When removing it, make the
rotate input shaft (2) until drive link (3) comes out. end horizontal, grip it with pliers, then pull it up until it
comes completely away from valve spool (2). Be care-
ful not to damage the control edge or outside circum-
ference of the valve spool.
FIGURE 5-22.
1. Ball Retaining Spring 2. Valve Spool
FIGURE 5-23.
1. Thrust Washer 3. Input Shaft FIGURE 5-26. BALL INSTALLATION
2. Thrust Bearing 1. Ball 2. Valve Spool
2. Install wave washer (1, Figure 5-25) to thrust 4. Rotate counterclockwise so that ball and groove
bearing (3) and thrust washer (2). are meshed, and insert input shaft (1, Figure 5-27)
in valve spool (2).
3. Install ball (1, Figure 5-26) on inside of valve spool
(2).
NOTE: Keep the spool horizontal when carrying out the
operation.
FIGURE 5-24.
1. Thrust Washer 2. Snap Ring
FIGURE 5-29.
1. Drive Link 3. Spool
2. Input Shaft
8. Set spacer (3, Figure 5-32) to torsion bar (2), and 11. Install spacer (1, Figure 5-35) on input shaft and
insert valve spool and input shaft assembly (4). valve spool.
9. Using punch (1, Figure 5-33) (outside diameter: 3
mm (.12 in.)), align pin holes of torsion bar and
NOTE: If there is a lip at one end on the inside of the
input shaft (2).
spacer, install with the lip surface facing the wave
10 Using above punch, drive pin (2, Figure 5-34) in 0.8 washer.
mm (.031 in.) from end face of input shaft.
FIGURE 5-35.
1. Spacer 2. Spool Assembly
12. Install input shaft and valve spool assembly (1, 16. Measure width of groove of drive link (1, Figure
Figure 5-36) to valve body (2). 5-39) at several places, and check that the differ-
ence is less than 0.025 mm (.001 in.).
13. Set shim (3) on thrust washer, then fit seal, align
match mark of upper cover (2, Figure 5-37) and 17. Pull input shaft down, align drive link (1) with valve
install the mounting bolts (4) temporarily. spool spline, and install. Rotate spool so that valve
body is level with end face of spool.
14. Set tool (1, Figure 5-38) in position, and install so
that valve body and upper cover are centered.
15. Tighten mounting bolts (4, Figure 5-37), and re-
move special tool.
FIGURE 5-37. UPPER COVER INSTALLATION FIGURE 5-39. DRIVE LINK INSTALLATION
1. Valve Spool 3. Valve Body 1. Drive Link 2. Valve Body
2. Upper Cover 4. Bolt
18. Align drive link (1, Figure 5-40) and pin (2), then 20. Install ball (1, Figure 5-43).
install.
21. Set rod (2) to spring (3), and fit to valve body (6),
19. Using depth micrometer (1, Figure 5-42), measure then install roller (4) and rod (5).
mounting height “h” ( See Figure 5-41) of end face
22. Fit seal to valve body.
of valve spool and valve body.
• Mounting height “h” = Within 0.063 mm (.002 in.)
FIGURE 5-43.
FIGURE 5-41. 1. Ball 4. Roller
1. Drive Link 2. Valve Body 2. Rod 5. Rod
3. Spring 6. Valve Body
FIGURE 5-49.
1. Commutator 2. Valve Assembly
FIGURE 5-51. END COVER INSTALLATION
1. Bolt 3. Sleeve
2. End Cover 4. Valve Body
31. Set input shaft end facing up, then install seal ring 32. Using tool (1, Figure 5-53), install spacer (2) from
(1, Figure 5-52) and seal (2). small diameter end.
NOTE: Install the seal from the small diameter end. Seal 33. Install snap ring (3, Figure 5-52).
ring (1) and seal (2) are supplied stuck together as one
34. Fit seal (4) to input shaft, and install to upper cover.
unit. Coat the new seal with oil, and install it from the
lip end; - When doing this, coat thinly with grease.
Raise the dump body and lock with the safety pin.
Disconnect the cable from the negative (-) terminal
of the battery.
Installation
1. Lift emergency steering motor pump assembly
and bracket into position.
2. Install hose (3, Figure 6-2).
3. Install tube (2).
4. Connect motor wiring (1, Figure 6-1). FIGURE 6-2. PUMP PIPING
1. Steering Motor Pump 2. Tube
5. Refill oil to the specified level and run the engine
Assembly 3. Hose
to circulate the oil through the system. Then check
the oil level again.
Installation
1. Lift steering cylinder (1, Figure 6-4) into position.
Position rubber boot (1, Figure 6-5) and install
head pin (2, Figure 6-3). Install pin retaining cap-
screw with washer and tighten to standard torque.
2. Position piston rod eye in bracket bore. Install
rubber boot (1, Figure 6-5) and pin. Install pin
FIGURE 6-4. STEERING CYLINDER INSTALLATION
retaining capscrew with washer and tighten to
standard torque. 1. Steering Cylinder 3. Rod Pin
2. Grease Tube
3. Connect grease tubes (2, Figure 6-4 & 1, Figure
6-3).
4. Install rod hose (4, Figure 6-3).
5. Install head hose (3).
6. Disassembly of piston. a. Remove snap ring (7, Figure 6-11), then remove
a. Remove wear ring (1, Figure 6-10) from piston dust seal (6).
(2). b. Remove rod packing (4).
b. Remove piston ring (3) from piston (2). c. Remove bushing (5) from cylinder head (1).
7. Disassembly of cylinder head assembly d. Remove O-ring (3) and backup ring (2).
b. Remove piston ring from tool, and assemble to 3. Piston rod assembly
piston (2, Figure 6-15). a. Assemble cylinder head assembly (2, Figure
c. Set ring compressor (2, Figure 6-16) in position, 6-17) and piston assembly (1) to piston rod (3).
and using a hose clamp (1), compress piston b. Coat threads with Loctite and using 40 mm
ring. socket (3, Figure 6-18) tighten nut (4) to 405
d. Assemble wear ring (3, Figure 6-15). ± 40.5 kg.m (2929 ± 29.2 ft. lbs.) torque.
c. Remove piston rod assembly (3) from tool.
Raise the dump body and lock with the safety pin.
Loosen the oil filter cap slowly to release the pres-
sure inside the hydraulic tank.
NOTE: After disconnecting the piping, plug all open-
ings to prevent oil from leaking.
1. Remove tubes (1, Figure 6-20)
2. Remove hoses (2).
FIGURE 6-19. CYLINDER ASSEMBLY 3. Remove demand valve assembly (3).
1. Cylinder Assembly 3. Rebuild Stand
2. Cylinder Head 4. Wrench Assembly Installation
1. Install demand valve (3, Figure 6-20).
4. Set cylinder in rebuild stand (3, Figure 6-19).
2. Remove plugs and install hoses (2).
5. Assemble cylinder head (2) and piston rod assem-
3. Remove plugs and install tubes (1).
bly in cylinder (1).
4. Refill oil to the specified level and run the engine
6. Using wrench assembly (4), tighten cylinder head
to circulate the oil through the system. Then check
assembly (2). to 95 ± 9.5 kg.m (687 ± 68.7 ft.
the oil level again.
lbs.) torque.
5. Bleed air from system.
Disassembly Assembly
1. Remove cover (2, Figure 6-21) from valve body (1), 1. Fit backup ring and O-ring and install relief valve
then remove spring (3). assembly (12).
2. Fit backup ring and O-ring and assemble orifice
(11), then secure with plate (10).
3. Assemble demand spool (9), then fit O-ring and
tighten plug (8).
The spring (3) is under an installed load of 35 kg.
(77 lbs.). Remove slowly using several long bolts. 4. Assemble poppet (7) and spring (6), then fit
backup ring and O-ring and install plug (5), then
2. Remove plate (4), screw bolts into threaded end
secure with plate (4).
of plug (5), and pull out plug, then remove spring
(6) and poppet (7). 5. Assemble spring (3), then fit O-ring and install
cover (2).
3. Remove plug (8), and pull demand spool (9) out.
4. Remove plate (10), screw bolts into threaded end
of orifice (11), and remove orifice.
5. Remove relief valve assembly (12).
Hydraulic Filter
Oil is filtered through a 30 micron filter to reduce the
possibilities of contamination to the hydraulic system.
RAISE
Movement of the hoist lever to the “RAISE” position The load check valve prevents oil from flowing out of
moves the spool valve to the end of the hoist valve. the raise side of the cylinders when the spool is moved
Refer to Figure 7-1. into and out of the “RAISE” position, thus preventing
the body from dropping.
Oil from the hydraulic pump enters port “A”. Because
the spool has blocked any further flow, the oil pressure
builds up until it opens the spring-loaded load check
valve to port “D”. The spool in the “RAISE” position
opens port “D” so oil is directed to the hoist cylinders,
through the “RAISE” line to extend the cylinders. The
return oil from the hoist cylinders goes into port “C”
past the spool to port “B” and to the hydraulic tank.
HOLD
Located just below the raise position is the hold posi- The oil in the hoist cylinders is blocked at port “C” and
tion. Moving the hoist lever down from the raise posi- port “D” by the spool which prevents cylinder move-
tion, along with the centering spring, returns the spool ment.
to the “HOLD” position. Refer to Figure 7-2.
Oil from the hoist pump enters port “A” and goes
around the spool to port “B” and returns to the tank.
POWER DOWN
Movement of the hoist lever to the “DOWN” position Oil at port “D” returns from the hoist cylinders and is
moves the spool to the non-detent end of the hoist open to port “B” back to the tank.
valve. This moves the spool to the “POWER DOWN”
position. Refer to Figure 7-3.
Oil from the hoist pump enters PORT “A” and is di-
rected to port “C” by the spool. The oil going out port
“C” goes to the hoist cylinders to retract them.
FLOAT
Moving the hoist lever to the “FLOAT” position, the Hoist cylinder port “C” is open to port “A” to allow oil
centering spring returns the spool to the “FLOAT” to flow to the lower areas between the cylinder stages.
position where the detent stops it. Refer to Figure 7-4.
The truck should always be operated on the haul road
Oil from the hoist pump enters port “A” and is directed with hoist control valve in the “FLOAT” position.
to port “B” by the spool and returns to the tank. The oil
in the hoist cylinders is also returned back to the tank
from port “D” to port “B”, due to the spool location.
Raise the dump body and lock with the safety pin.
Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank.
Removal
1. Drain hydraulic oil.
2. Disconnect control cable (1, Figure 8-1)).
3. Remove bracket (2).
4. Disconnect positioner cable (3).
5. Remove spring (4).
6. Remove bracket (5). FIGURE 8-1. HOIST VALVE INSTALLATION
7. Remove hose (6). 1. Control Cable 6. Hose
2. Bracket 7. Tube
8. Remove tubes (7) and (8).
3. Positioner Cable 8. Tube
9. Remove hose (1, Figure 8-2). 4. Spring 9. Hoist Valve
5. Bracket
10. Remove hoist valve assembly (9, Figure 8-1).
Installation
1. Install hoist valve assembly.
2. Remove caps and plugs from hoses. Install hose
(1, Figure 8-2).
3. Install tubes (7 & 8, Figure 8-1).
4. Install hose (6).
5. Install bracket (5).
6. Install spring (4).
7. Install positioner cable (3).
8. Install bracket (2).
9. Install control cable (1).
10. Refill hydraulic tank oil to the specified level and FIGURE 8-2. HOSE REMOVAL & INSTALLATION
run the engine to circulate the oil through the 1. Hose 2. Bracket
system. Then check the oil level again.
Removal
The hoist cylinder weighs approximately 330 Kg.
(728 lbs.). Be certain lifting equipment is adequate
for handling the load.
1. Bolt
2. Cylinder Head Assembly
3. Cylinder
4. Cylinder
5. Cylinder
6. Piston Ring
7. Wear Ring
8. Wear Ring
9. Piston Mounting Nut
10. Snap Ring
11. Piston Assembly
12. O-Ring
13. Backup Ring
14. Bushing
15. Rod Packing
16. Dust Seal
17. Snap Ring
18. Dust Seal
19. Rod Packing
The hoist control lever and hoist control valve are This control system is equipped with a hoist limit sys-
connected by a mechanical control system consisting tem, so when the body is rising, the hoist limit is
of a push-pull cable. actuated when the body reaches the position set for
the limiter.
Hydraulic
Tank
FIGURE 10-2. HOIST VALVE ADJUSTMENT FIGURE 10-4. INTERMEDIATE LEVER ADJUSTMENT
1. Hoist Valve Lever A. 198.5 mm (7.8 in) 1. Intermediate Lever C. 203.5 (8.01 in)
2. Cable D. 15 mm (0.59 in) 2. Cable
STEERING CIRCUIT
HOIST CIRCUIT
Measuring Hydraulic Pressure In Hoist Circuit
1. Raise the hydraulic oil temperature to 45-55° C
(113-131° F)
2. Remove pressure measurement plug (1, Figure
10-7) and install a 400 kg.cm2 (or a 5000 psi)
pressure gauge.
3. Disconnect the body positioner cable.
4. Operate the hoist control lever, and move the
dump body to the maximum dump position to
relieve the circuit, then measure the hydraulic
pressure with the engine at full throttle.
5. The pressure should be 200 + 15 kg.cm2 (2885 +
213 psi).
Cause Remedy
Air in hydraulic oil AC
Oil leakage in steering cylinder X
INDEX
Installation
Screw breather valve (2, Figure 5-2) into tank (1).
Disassembly
1. Remove spring clamp (4, Figure 5-1) from outlet.
2. Pull off rubber cover and screen (3).
3. Unscrew nut (5) from top of breather valve. Re-
move cover (6), spring (7), and steel ball (8).
4. Slide valve assembly (9) from housing.
5. Disengage tapered spring (1) containing three
balls (2) from valve stem.
Assembly
1. Clean and inspect all parts. If valve, body, or
springs are damaged, replace complete breather
valve.
2. Install in order; tapered spring, one steel ball, one
cork ball and one hollow aluminum ball.
3. Engage three coils of spring on small end of valve
stem with hollow aluminum ball.
4. Install valve into housing.
5. Place steel ball (8) on top of valve. Install spring
(7).
6. Place cover (6) over spring. Screw on large nut (5).
7. Install screen and rubber cover (3) over outlet.
8. Install spring clamp (4).
FUEL RECEIVER
The fuel receiver (3, Figure 5-2) is normally mounted
on the fuel tank (1). Optional locations are the left hand FIGURE 5-1. BREATHER VALVE
frame rail or at the Service Center. 1. Tapered Spring 6. Cover
Keep the cap on the receiver to prevent dirt build up in 2. Float Balls 7. Spring
valve area and nozzle grooves. If fuel spills from tank 3. Cover and Screen 8. Steel Ball
breather valve or tank does not completely fill, check 4. Spring Clamp 9. Valve Assembly
breather valve to see that float balls are in place and 5. Nut
outlet screen is clean. If valve is operating properly, the
problem will be with the fuel supply system.
OPERATION MODES
(Refer to Figure 6-5): With no control pressure in the
pressure cavity, the fan clutch is always disengaged.
The thermal sensor (2) senses engine coolant tem-
perature through its thermal tip. The sensor is cali-
brated to respond within a specific coolant temperature
range by sending an electrical signal to drive the
solenoid (1). The operating range of the thermal sen-
FIGURE 6-3. OUTPUT COMPONENTS sor can be determined by the tag attached to the body.
1. Facing Plates 3. Fan Mounting Hub Engine lubrication oil enters the solenoid through the
2. Clutch Hub inlet (NO) port. The pressure out (COM) opening of the
solenoid valve is connected by a line to the “control
pressure” port of the fan clutch bracket. The solenoid
Stationary Components valve controls the speed of the vehicle cooling fan by
regulating the amount of oil pressure supplied to en-
(Refer to Figure 6-4): The shaft & bracket assembly (1) gage, modulate, and allow release of the fan clutch.
is bolted to the engine and supports the fan clutch Oil exiting the solenoid valve (and fan clutch) is di-
components. Pitot tubes (2) secured to the shaft pump rected to sump through the “oil out” (NC) port in the
oil from the clutch, directing it back to the oil reservoir solenoid valve.
(engine oil pan).
Fully Engaged
When engine coolant temperature at the thermal tip
reaches the top of the designed temperature range of
the thermal sensor, full oil pressure is directed by the
solenoid valve into the pressure cavity of the fan clutch.
The control pressure forces the piston against the
clutch plates, clamping the disc stack against the front
bearing retainer. When the clutch plates are fully
clamped, the input and output are fully connected
constituting a 1:1 drive through the clutch. The fan is
thus driven at pulley speed.
1. Solenoid Valve
2. Thermal Sensor
Fully Released
When engine coolant temperature is at or below the
lower limit of the designed temperature range of the
thermal sensor, no oil pressure is directed into the
pressure cavity. Existing pressure in the cavity vents
to sump through the solenoid valve. NO clamping force
is applied to the clutch plates, and the drive to the fan
is disconnected. At this time, the fan merely idles (at
less than 300 rpm) due to viscous oil drag of the cooling
oil passing between the facing plates and external
clutch plates.
3. Fan belts: Maintain proper belt tension. Refer to b. Clutch Plate Drive Slot Wear: With the engine
Section “C” for belt tension adjustment. off and the clutch locked up, rotate the fan with
a light force clockwise-counterclockwise.
4. Hoses and fittings: Check all hoses and fittings Movement at the tip of a fan blade should not
every 500 hours. Replace all soft, brittle or frayed exceed 22.4 mm (0.88 in.). Excess movement
hoses. Tighten all loose or leaking fittings. indicates excessive wear at the drive tangs.
5. Thermal sensor(s): Check corrosion buildup on c. Clutch Plate Wear: With the engine off, apply
thermal tip after each 5000 hours. Clean if neces- 275 kPa (40 psi) oil pressure to lockup the
sary and check for proper operation. clutch. Using a pull type scale connected to
the fan blade 610 mm (24 in.) from the center
DO NOT DISASSEMBLE OR DISTURB THERMAL
of fan, a pull of no less than 712 - 756 N (160
SENSOR SETTING.
- 170 lbs.) should be required to rotate the
blade independent of the pulley.
NOTE 1: Actual 0.0 kPa (psi) will not be attained if tested under normal operating conditons (connected to a fan
clutch). 0.0 - 55 kPa (0.0 - 8.0 psi) internal clutch pressure will read on the gauge.
NOTE 2: As water temperature increases or decreases within the temperature range of the thermal sensor,
voltage output from the thermal sensor and pressure output from solenoid valve should also increase or
decrease (although not in direct proportion). An increase in water temperature produces an increase in voltage
output and a decrease in pressure.
14. Setup fan mounting hub assembly (2, Figure 6-20) 16. Remove tool from bore of hub and remove assem-
on supports on bed of press. Insert tool #1D bly from press.
through bore and press end cap (3) out.
15. Remove tool #1D and insert tool #1A. (1, Figure
6-21). If necessary, add support blocks to allow
clearance for sleeve bearings to drop out. Press
both sleeve bearings (4 & 5) out at the same time.
LOCATIO DIMENSION
NOTES
N mm inches
A 38.029 φ Min. 1.4972 φ Min. No steps in surface
B 2.616 Max. Width 0.103 Max. Width Sealrings must fit free in grooves
C 57.836 φ Min. 2.277 φ Min.
D 60.000 φ Min. 2.3622 φ Min.
Must bee free of nicks that rise
E 63.449 φ Min. 2.498 φ Min.
above surface
Must bee free of nicks that rise
F 79.896 φ Min. 3.1455 φ Min.
above surface
NOTES:
• Some Shaft & Bracket Assemblies are constructed for manufacturing purposes as 2-piece units. DO NOT sepa-
rate the shaft from the bracket.
® ®
• Pipe plugs should be removed for cleaning, but must be reinstalled using Loctite Primer N and Loctite #242.
• Be certain shaft oil ports are free and clear.
• The orifice plug may be removed for cleaning. Be certain it is reinstalled in the “Oil In” port.
7. Setup the bearing retainer (1, Figure 6-48) on 8. Remove front bearing retainer from press bed and
supports as shown. invert as shown in Figure 6-49. Place supports
a. Apply Loctite® Primer N to bearing (2) outer under bearing bore area.
race and bore of bearing retainer. a. Apply Loctite® Primer N to O.D. of oil seal (2)
b. Apply Loctite® #609 to above parts. and bore in bearing retainer.
c. Using tool #5, press bearing to bottom of the b. Apply Loctite® #242 to above parts.
bore in the retainer.
d. Install snapring (4).
20. Setup shaft and bracket assembly (5, Figure 6-58) 22. Place pulley adapter on supports on press bed .
on bed of press. Using tools #2, #3 and #5, press a. Apply Loctite® Primer N to sides of bearing
seal retainer assembly (4) onto shaft until it stops bore in pulley adapter (1) and to outer race of
against the shoulder. Be certain seal retainer as- bearing (4) as shown in Figure 6-60.
sembly is straight.
b. Apply Loctite® #609 to same areas.
21. Install rear wear sleeve (3, Figure 6-59) on the c. Press the rear bearing into the pulley adapter.
shaft. Be certain correct wear sleeve is installed;
d. Install the internal snapring (2).
the I.D. should be color coded blue. (Refer to
Figure 6-45 for identification information.)
a. Apply Loctite® Primer N to I.D. of wear sleeve
and sleeve mounting area of shaft. as shown
in Figure 6-59.
b. Apply Loctite® #242 to same areas.
c. Using tools #2 and #5, carefully press until wear
sleeve stops against shoulder.
23. Invert the pulley adapter on the press and install FIGURE 6-62. PULLEY ADAPTER ASSEMBLY
the rear oil seal. INSTALLATION
a. Apply Loctite® Primer N to sides of seal bore 1. Tool #5 4. Rear Bearing
in pulley adapter (3) and to O.D. of the rear oil 2. Tool #2 5. Oil Seal
seal (2) as shown in Figure 6-61. 3. Pulley Adapter Assy. 6. Shaft & Bracket Assy.
b. Apply Loctite® #242 to same areas.
c. With tool #5 centered on oil seal, press into bore 24. Setup shaft and bracket assembly as shown in
until tool contacts face of pulley adapter. Figure 6-62.
a. Apply Loctite® Primer N to I.D. of rear bearing
(4) and the bearing seat area on the shaft.
b. Apply Loctite® #609 adequately but sparingly
to prevent Loctite from being spread onto the
The seal lip must remain dry. DO NOT allow Loctite
wear sleeve.
to contact seal lip.
d. Wipe off excess sealant and remove rubber
“strings” after installation.
Do not use a lubricant during assembly. Do not
allow seal lip to contact Loctite.
c. Carefully lower the pulley adapter assembly
onto the shaft assembly, making sure no Loc-
tite comes in contact with the seal lip. Press the
assembly into place until the bearing contacts
the wear sleeve.
d. After the components are assembled, spin the
pulley adapter on the shaft for approximately
25 revolutions (with the seal lip and mating
contact surface dry) to “burnish” the teflon seal
lip contact area on the wear sleeve.
Operational Test
Test for proper engagement, disengagement, and oil
leaks using OIL at both the “Oil IN” and “Control
Pressure” locations. DO NOT use air pressure.
1. The fan clutch should be fully locked up with 2.81
kg/cm2 (40 psi) oil pressure supplied to the “con-
trol pressure” port.
2. Run the fan clutch with 82°C (180°F) oil supplied
to the “oil in” port for 2 hours. Manually engage
and disengage the clutch during test to operate
seals in both modes. Restrict fan mounting hub
rotation while clutch is disengaged, but be sure
fan mounting hub is allowed to rotate freely
while clutch is engaged.
SECTION C
PART
DESCRIPTION USE
NUMBER
Transmission
790-501-2000 Repair Stand
and Engine
SECTION C
PART
DESCRIPTION USE
NUMBER
SECTION D
PART
DESCRIPTION USE
NUMBER
Electrical
799-601-7400 T-Adapter Kit
Troubleshooting
Electrical
799-601-7200 Harness
Troubleshooting
Electrical
799-601-7300 Harness
Troubleshooting
Plate Torque
790-901-5110
(Repair Stand) Converter
SECTION F
PART SERIAL RANGE RANGE
DESCRIPTION USE
NUMBER
799-607-2120 Harness Connector use with 799-607-2000 only BFP42-A & UP,(Unit A10190 & UP)
799-607-3000 Shift Checker Transmission BFP42-A & UP, (Unit A10190 & UP)
Drive Shaft
792-104-4501 Push Tool
Installation
SECTION G
PART
DESCRIPTION USE
NUMBER
SECTION G
PART
DESCRIPTION USE
NUMBER
Differential
792-525-3000 Micrometer
Preload
SECTION G
PART
DESCRIPTION USE
NUMBER
Differential
790-425-1660 Wrench
Preload
Differential
790-425-1670 Adapters
Preload
SECTION G
PART
DESCRIPTION USE
NUMBER
1. Plate 5. Plate
2. Arm 6. Capscrew
3. Stud 7. Wing Nut
4. Plate 8. Washer
SECTION G
PART
DESCRIPTION USE
NUMBER
Removal of
790-450-1120 Plates
Rod Assembly
SECTION H
PART
DESCRIPTION USE
NUMBER
SECTION J
PART
DESCRIPTION USE
NUMBER
SECTION L
PART
DESCRIPTION USE
NUMBER
PART
ITEM DESCRIPTION
NUMBER
Wrench
1 790-102-3791
Assembly
2 790-102-3811 Wrench
3 790-102-3840 Tooth
4 790-102-3850 Tooth
5 790-102-3830 Tooth
6 01010-31260 Capscrew
7 01580-01210 Nut
8 01643-31232 Washer
9 790-102-3980 Bar
10 790-102-3151 Frame
11 790-102-33140 Frame
12 01010-31650 Capscrew
13 01580-01613 Nut
14 01643-31645 Washer
15 01010-31245 Capscrew
16 01580-01245 Nut
Steering Valve
790-452-1200 Pilot Ring Tool
Installation
1. Ring 4. Knob
2. Shaft 5. Spring Pin
3. Collar 6. Spring Pin
SECTION L
PART
DESCRIPTION USE
NUMBER
790-502-1003 or Hydraulic
Rebuild Stand
790-502-2000 Cylinders
790-102-3802 or Wrench
Gland Nut
790-102-3791 Assembly
1. Hydraulic Cylinder 3. Rebuild Stand
2. Cylinder Head 4. Wrench Assembly
SECTION L
PART
DESCRIPTION USE
NUMBER
Hyd. Cylinders
Piston Ring
790-720-1000 (Hoist &
Expander
Steering)
1. Expander 3. Clamp
2. Ring (rubber band)
SECTION L
PART
DESCRIPTION USE
NUMBER
Digital
790-261-1102 Check Pressures
Hydraulic Tester
SECTION L
DESCRIPTION
PART
USE
NUMBER
FEMALE THREAD MALE THREAD
In order to adapt pressure test guages using the "NPT" type threads commonly PIPE THREAD ADAPTER - WB-1092
found in North America to the "PT" type threads used in the transmission and SHOWN
other areas of the truck, adapters are required.
EVAPORATOR
The evaporator cools and dehumidifies the air before
it enters the cab. Cooling a large area requires that
large volumes of air be passed through the evaporator
coil for heat exchange. Therefore, a blower becomes
a vital part of the evaporator assembly. It not only draws
heat laden air into the evaporator, but also forces this
air over the evaporator fins and coils where the heat is
surrendered to the refrigerant. The blower forces the
cooled air out of the evaporator into the cab.
Heat exchange, as explained under condenser opera-
tion, depends upon a temperature differential of the air
and the refrigerant. The greater the temperature differ-
ential, the greater will be the amount of heat exchanged
between the air and the refrigerant. A high heat load
condition, as is generally encountered when the air
conditioning system is turned on, will allow rapid heat
transfer between the air and the cooler refrigerant.
The change of state of the refrigerant in and going
through the evaporator coil is as important as that of
the air flow over the coil.
The air conditioner’s electrical circuit is fed from an An electromagnetic clutch is used in conjunction with
accessory circuit and is fused with a 30-ampere fuse the thermostat to disengage the compressor when it is
or circuit breaker. not needed, such as when a defrost cycle is indicated
in the evaporator, or when the system is turned off.
The blower control is a switch which provides a range
of blower speeds from fast to slow. When the blower The stationary field clutch is the most desirable type
switch is turned on, current is fed to the thermostat. since it has fewer parts to wear out. The field is mounted
Once the blower is turned on, fan speeds may be to the compressor by mechanical means depending
changed without affecting the thermostat sensing on the type field and compressor. The rotor is held on
level. the armature by a bearing and snap rings. The arma-
ture is mounted on the compressor crankshaft.
The thermostat reacts to changing temperatures which
cause electrical contacts to open and close. The When no current is fed to the field, there is no magnetic
thermostat has a capillary tube extended into the force applied to the clutch and the rotor is free to rotate
evaporator coil to sense temperature. on the armature, which remains stationary on the
crankshaft.
When the contacts are closed, current flows to the
clutch field and energizes the clutch, causing the When the thermostat or switch is closed, current is fed
crankshaft to turn which starts the refrigeration cycle. to the field. This sets up a magnetic force between the
When the temperature of the evaporator coil drops to field and armature, pulling it into the rotor. When the
a predetermined point, the contacts open and the armature becomes engaged with the rotor, the com-
clutch disengages. plete unit rotates while the field remains stationary. This
causes the compressor crankshaft to turn, starting the
When the clutch is disengaged, the blower remains at refrigeration cycle.
the set speed. After the evaporator temperature rises
about twelve degrees above the cutout point, the con- When the switch or thermostat is opened, current is cut
tacts in the thermostat close and the refrigeration cycle off. The armature snaps back out and stops while the
resumes. rotor continues to turn. Pumping action of the com-
pressor is stopped until current is again applied to the
field. In addition, safety switches in the compressor
clutch electrical circuit control clutch operation, disen-
THERMOSTAT gaging the clutch if system pressures are abnormal.
An electromagnetic clutch is used on the compressor
to provide a means of constant temperature control of SAFETY SWITCHES
the cab. The clutch is controlled by a thermostat in the
evaporator which is set initially by the driver to a pre- Trinary Switch
determined point. Coil temperature is then maintained The Trinary switch performs three distinct functions
by the cycling action of the clutch. to monitor and control refrigerant pressure in the sys-
The thermostat is simply a thermal device which con- tem. This switch is installed between the condenser
trols an electrical switch. When warm, the switch is and expansion valve, usually on the receiver-drier. The
closed; when cold, it is open. Most thermostats have a switch functions are:
positive OFF position as a means to turn the clutch OFF The low-pressure switch prevents compressor
regardless of temperature. operation if the refrigerant has been lost or the
The bellows type thermostat has a capillary tube con- ambient temperature is too low. Low ambient
nected to it which is filled with refrigerant. The capillary temperature results in very low system pressure.
tube is attached to the bellows inside of the thermostat. The mid-range function actuates the engine fan
Expansion of the gases inside the capillary tube exerts clutch if installed.
pressure on the bellows, which in turn closes the con-
tacts at a predetermined temperature. The high-range pressure function disengages
the compressor clutch if system pressure is too
high.
The switch functions will automatically reset when sys-
tem pressure returns to normal.
Lines
Always use two wrenches when disconnecting or con-
necting AC fittings attached to metal lines. You are
working with copper and aluminum tubing which can
kink or break easily. Tube O-ring type fittings require
only 18 ft. lbs. (24.4 N.m) of torque for correct sealing.
When grommets or clamps are used to prevent line
vibration, be certain these are in place and secured.
Expansion Valve
When removing the expansion valve from the system,
remove the insulation, clean the area and disconnect
the line from the receiver-drier. Detach the capillary
(bulb) and external equalizer tube (if present) from their
mounting locations. Remove the expansion valve from
the evaporator inlet. Expansion valve service is limited
to cleaning or replacing the filter screen. If this is not
the problem, replace the valve. Secure the capillary
and equalizer, if used, to clean surfaces and replace or
attach any insulating material.
No Leaks Found:
1. Charge System
2. Performance Test System
Leaks Found:
Leaks Found:
1. If a leak is present at a connection, tighten the
connection, then add refrigerant as required.
2. It may be necessary to use a jumper wire to en-
able the compressor to operate, if the compres-
sor has shut down due to faulty pressure
sensing switch.
3. If a system component needs to be replaced, re-
cover all refrigerant from the system. Replace
the defective part, then check the compressor
oil level; refill compressor oil as necessary.
4. Evacuate system.
5. Charge system with new / recycled refrigerant.
6. Check A/C operation and do system
performance test.
COMPONENTS PORTS
COMPONENTS PORTS
Problem: The air compressor goes into the standby mode but cycles rapidly.
Problem: Air flows from the exhaust port when the air compressor is trying to build up pressure.
Problem: The air dryer does not unload when the air compressor goes into standby mode.
Figure 20-3.
Figure 20-5.
Cycle Data
One cycle is considered to be from the point where a load is dumped to the point where the next load is dumped.
Data between these two points is recorded in memory. Examples of the data are shown below. The maximum
number of cycles that can be stored in memory is 2900 cycles.
Other Data
CONTENT ITEM UNIT RANGE REMARKS
Set Up Data That The Speed Limit Km/MPH 0 - 99
Operator Can Check Option Code Digital Number 0 - 13 Communication Mode
Year Year 0 - 99
Month Month 1 - 12
Calibration Data Day Day 1 - 31 Date and time when calibrated.
Hour Hour 24 Hour Clock
Minute Minute 0 - 59
Viewing the Operator Load Counter Dimming the Lights on the Display
1. Press the TOTAL/SFT switch once. There are a total of 10 brightness levels on the PLM
If there is a fault code present at this time: display.
2. The error code for that problem will be displayed.
This will be a flashing display. From the normal operation display:
3. Press the TOTAL/SFT switch again. If additional 1. Press the LIGHT/INC switch. The lighting will
faults or warnings exist, that fault code will be become one level dimmer. This will continue until
displayed as a flashing code. the lighting has reached its lowest level.
4. Repeat step #3 until no fault codes are displayed. 2. After reaching the lowest level, the display will
":" will show when no additional faults exist. The return to the brightest setting.
display will then show total tons hauled since the
last time the counter was cleared. The total is If the switch is held in the depressed position, the
displayed in hundreds of tons. brightness will change continuously.
5. Press the TOTAL/SFT switch again. The number
displayed is the number of haul cycles since the
last time the cycle counter was cleared.
6. Press the TOTAL/SFT switch again. ":" is dis-
played for 2 seconds before the display returns to
normal operations.
•Reception Pilot Lamp (2, Figure 20-1) 10. The display will show:
•Transmission Pilot Lamp (3, Figure 20-1)
This display indicates the Option code setting.
•Memory Card Pilot Lamp (4, Figure 20-1)
Refer to “Operator Check Mode, Setting the Op-
2. The display will show: tion Code” and to “Method of Operation” for more
information on this function.
The “xx” indicates the Truck Model. Refer to
"Initial Setup of Payload Meter" for code defini-
tions.
Setting The Operator I.D. Code 9. Press the LIGHT/INC switch to change the day.
1. Press and hold the MODE switch 10. Press the TOTAL/SFT switch and
until "Cd:dP" is displayed. the display will then indicate:
2. Press the MODE switch once. The 11. Press the LIGHT/INC switch to change the month.
display will show:
12. Press the TOTAL/SFT switch and
the display will then indicate:
3. Press the MODE switch once. The
display will show:
13. Press the LIGHT/INC switch to change the year.
4. Press the MODE switch repeatedly 14.Press the MODE switch to return to normal opera-
until "o.XXX" is displayed. tion.
Setting The Time and Date To begin, the shift lever should be in the “N”
position, the brake lock set, the hoist control lever
1. Press and hold the MODE switch should be in the “FLOAT” position and the body in
until "Cd:dP" is displayed. the down position.
2. Press the MODE switch once. The 1. Press and hold the MODE switch
display will show: until "Cd:dP" is displayed.
3. Press the MODE switch once. The 2. Press the MODE switch once. The
display will show: display will show:
4. Press the MODE switch repeatedly 3. Press and hold the CAL/CLR
until "XX:XX" is displayed. switch until "A.CLE" is flashing.
5. Press the LIGHT/INC switch to change the min- 4. Press the CAL/CLR switch again and the memory
utes. will be cleared. The meter will then return to
normal operation.
6. Press the TOTAL/SFT switch and
the display will then indicate: This does not clear the Operator Load Counter.
“ C1:oo” Shift selector is in "N". 4. Press the TOTAL/SFT switch to view faults again
or press the MODE switch to return to normal
“ C1:– –” Shift selector is not in "N’. operation.
Electric trucks
“ C1:oo” Brake lock is on.
“ C1:– –” Brake lock is off.
• Condition of the Body Up Switch signal.
The panel will display: “ C2:XX” for 3 seconds,
then indicate:
“ C2:oo” Body up switch is in up position.
“ C2:– –” Body up switch is in down position.
Payload meters sent from the factory are typically set Memory Storage - Same as above, the data is cap-
to "UP: 5" indicating a +5% gain in final load. tured at the last transition from 0 to 1 MPH prior to
traveling 160 meters from the shovel. The captured
This should be checked on all new meters and data is stored into memory when the body rises at the
changed to "UP: 0". dump. This load calculation will use the UP factor
percentage.
PL Mode - Load Calculation Timing
PL:01
Load Calculation Timing
Modular Mining Transmission - The data is captured
The PL mode controls when the payload meter takes at the last transition from 0 to 1 MPH prior to traveling
a sample of the data and calculates the load. There 160 meters from the shovel. The captured data is
are three modes available. There are two sets of data transmitted when the truck travels 160m from the
that are affected by the PL mode setting. shovel. This load calculation will use the UP factor
percentage.
• Modular Mining Transmission
Memory Storage - The data is captured and stored
• Memory Storage when the body rises from the frame. This calculation
will not use the UP factor percentage.
PL:10
The PL mode setting can have a significant impact on Modular Mining Transmission - The data is captured
the perceived accuracy of the payload meter. and transmitted when the truck travels 160 meters
from the shovel. This calculation will not use the UP
PL:00 is the only recommended setting. factor percentage.
Use of settings other than PL:00 Memory Storage - The data is captured and stored
is NOT recommended. when the body rises from the frame. This calculation
will not use the UP factor percentage.
INCLINOMETER
As the truck is tilted fore or aft, the weight distribution
between the front and rear axles changes. To compen- FIGURE 20-14. INCLINOMETER SIDE
sate for this, the inclinometer measures the ground CONNECTOR VIEW
angle at which the truck rests. This data is then sent
to the payload meter so it can calculate the correct Pin Number Wire Color Wire Function
payload weight. The inclinometer is located below the
operator’s center console (passenger seat structure). 1 Black Ground (GND)
2 White Signal
Removal 3 Red + Power
1. Disconnect inclinometer wire lead from harness.
Adjustment
2. Remove the three capscrews, nuts and lockwash-
ers (4, Figure 20-13) and inclinometer (3). 1. Park the truck on a 0% grade.
2. Loosen the three Inclinometer mounting cap-
screws (4, Figure 20-13) and rotate the Incli-
nometer until a voltage range of 2.6 ±0.1 Volts
can be measured (using aVolt/Ohm Meter) at pins
1 and 2 of the inclinometer electrical harness
connector.
3. Tighten all capscrews (4, Figure 20-13) to stand-
ard torque, after adjustment.
Making Connections
The Scoreboard connects to the RS232 port on the
Payload Meter. It must share this connection with other
dispatch systems like Modular Mining as well as the
PC download connection. This sharing of the single
port creates special circumstances when using a Per- Figure 20-15. Scoreboard
sonal Computer or dispatch system.
The Scoreboard is in constant communications with
The harness for the Scoreboard supplies two extra
the Payload Meter and must acknowledge every mes-
connections in the overhead compartment of the cab.
sage from the meter. In addition, the Scoreboard must
One is for the existing PC port and the other is for
also signal the Payload Meter that it is ready to receive
Modular Mining.
messages by supplying a 5vdc signal over the CTS
line. Installations that include Modular Mining or other When two Scoreboards are installed, the first sign
dispatch systems must take over the responsibility for transmits load information and power to the second
acknowledging messages from the Payload Meter. To sign. Note that the communications wire from the first
do this, the return communications line and the CTS sign connects to terminal 35L7. This is the retransmit
line from the Scoreboard must be cut and taped back. terminal. This wire then connects to the 35L4 terminal
When this is done, the Scoreboard simply monitors in the second sign. This is the receive terminal of the
communications between the Payload Meter and second sign.
Modular Mining. The Modular Mining system acknow-
The Payload Meter must be set to use OP12. Refer
ledges each message from the meter.
to "Setting the Option Code" for instructions.
Sharing this RS232 port with the Personal Computer
Once in this mode, the Payload Meter will look for the
for downloading can also create problems with com-
Scoreboard and attempt to communicate with it. If
munications. The Payload Meter can confuse mes-
there are communications problems the Payload Me-
sages from the PersonalComputer and Scoreboard.
ter may indicate a communications port error. Refer to
To eliminate this problem, the Scoreboard must be
"Fault Codes" for additional information.
turned off during downloading of the Payload Me-
ter. Using the circuit breaker to turn off the main power
to the Scoreboard is the best way to accomplish this.
The power to the Scoreboard must be turned off before
communications between a Personal Computer and
the Payload Meter can start. Once the download proc-
ess is finished, the power needs to be restored to the
Scoreboard to keep from receiving F99 or F93 error
codes.
CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins
No. Description Comments White (RS-232C Port)
CN2 - AMP 040 12 Pins Black Connector CN4 - AMP 040 8 Pins Black
(Optional Input, Reserved)
No. Description Comments
Running Open No. Description
1 Engine Oil Pressure Switch
Off - Closed 1 Optional Input GND
2 Sensor Power Out +18V 2 Analog Input 1
3 Sensor GND 3 Analog Input 2
4 Left FrontSuspension Pressure Sensor 1-5VDC Normal 4 Digital Input 1
Right Front Suspension PressureSensor 5 Digital Input 2
5 1-5VDC Normal
6
6 Left Rear Suspension Pressure Sensor 1-5VDC Normal 7
7 Right Rear Suspension Pressure Sensor 1-5VDC Normal
8 Inclinometer
Body Down - Open
9 Body Rise Signal
Body Up - Gnd
Lock Off - Open
10 Break Lock Signal/Neutral Signal
Lock On - Gnd
11
12
This procedure is necessary to fix a rare condition in 7. Set the time, date, OP, PL, and UP settings. All
the operation of the meter. Indication for this procedure other user settings should updated at this time.
is a repeated display of F.CAL on the meter despite
8. Calibrate the Payload Meter by holding the CAL
repeated calibration. If possible, download the Pay-
button until CAL flashes.
load Meter before performing this procedure. This
procedure will erase all memory and user settings. 9. Release the Brake Lock (Park Brake for 330M)
and begin driving 5-8 MPH on level ground and
NOTE:
press CAL.
This procedure should be performed before any
CAL should display until the meter finishes its
Payload Meter is returned for warranty or repair.
calibration.
10. Load the truck to rated load and drive through one
Before performing this procedure, be sure that the
haul cycle.
engine inputs into the payload meter can be manipu-
lated to indicate engine running and engine stopped. 11. After dumping the load, wait at least 15 seconds
Some payload meter installations have hard-wired and drive the truck to a safe location.
these inputs. These inputs must be accessible and
12. Stop the truck and shut down the engine.
able to produce the following input conditions:
13. Turn on the Payload Meter but leave the engine
off.
21C 21D
14. Hold MODE and LIGHT until CHEC flashes.
Condition Engine Oil Alternator "R"
Pressure Terminal 15. Hold LIGHT and CAL until A:CLE flashes.
Engine Running Open 24VDC 16. Press CAL to clear the service memory.
Engine Stopped Ground Open
17. When CHEC is displayed, press MODE to return
to normal operation.
1. Turn off all systems. 18. Clear the Haul Cycle Memory by holding MODE
until Cd:dP is displayed.
2. Turn on the Payload Meter but leave the engine
off. 19. Press MODE and A.CLE will be displayed.
3. Hold MODE and LIGHT until CHEC flashes. 20. Hold CAL until A.CLE flashed.
4. Hold the CAL, TOTAL and LIGHT buttons until 21. Press CAL once more to clear the haul cycle
00:00 is displayed. memory.
5. Press CAL for 2 seconds. 00 00 will flash and the 22. Clear the operator load counter by pressing the
meter will erase its memory and reset to its factory TOTAL button until ":" is displayed.
settings. This includes and OP, UP, PL, P.SEL,
23. Hold the CAL button until the display flashes.
and E.SEL settings.
The meter will restart and display F.CAL. 24. Hold the CAL button until 0000 is displayed to
clear the memory.
6. Start the engine.
25. The payload meter should now function normally.
L. G. HAGENBUCH holder of
U.S. Patent Numbers 4,831,539 and 4,839,835
1. Terminal 5. Block
2. Terminal 6. Diaphragm FIGURE 28-5. SOLENOID VALVE
3. Spring 7. Body
1. Core 8. Spring
4. Plate
2. Coil Assembly 9. Body
3. Spring 10. Connector
4. Plunger
Exhaust Brake Solenoid Valve
5. Valve Seat A: Inlet Port
When the exhaust brake solenoid valve (Figure 28-5) 6. Rod B: Outlet
is energized, air flows from the air tank into port ‘‘A’’, 7. Valve C: Exhaust Port
valve (7) is opened and air flows out port ‘‘B’’ to the
exhaust brake cylinders mounted on the turbocharger
outlets, activating the exhaust brake system. Exhaust
gasses are blocked.
When the solenoid is de-energized, valve (7) closes,
inlet port ‘‘A’’ closes, exhaust port ‘‘C’’ opens, and air
in the exhaust brake cylinders and cylinder supply
hoses is released as the cylinder springs return the
pistons to the top of the cylinders. Exhaust gasses are
then free to flow out to atmosphere through the ex-
haust pipes.
Gate Adjustment
The engine should be able to fully combust fuel at idle
and should not labor excessively when brake is ap-
plied. If problems are encountered, check gate adjust-
ment setting.
1. Measure dimension ‘‘A’’ as shown in Figure 28-8.
Dimension should be 32 ±1 mm (1.25 ±0.04 in.)
2. If necessary, loosen gate adjust screw locknut and
adjust screw to obtain correct dimension.
3. After adjustment, tighten locknut to 2.5 kg.m (18
ft. lbs.) torque.
NOTE: Note: If both rear wheels slip at the same speed, the
ASR function is not actuated. During this condition, the
• When the ABS is actuated on a slippery road operator must reduce the accelerator to control the
surface, the braking distance becomes slightly engine output.
longer.
• When traveling at extremely low speed, the
wheels may lock.
ABS
When not actuated under normal braking t7 : Because of the stepped increase, the wheel speed
conditions; again shows a tendency to lock. When the wheel
With normal brake operation, if it does not seem that acceleration speed passes a0, the ECU judges
the wheels will lock, the ABS pressure control valve is that the wheel is unstable and sends the decrease
not actuated, and air from the relay emergency valve signal.
is supplied directly to the brake chamber. t8 : When the brake pressure is reduced, the wheel
When actuated as shown in the graph on the next speed shows a tendency to recover. When it re-
page, the air pressure applied to the brakes is control- turns to a0, the ECU judges that the wheel has
led to automatically suppress any locking of the returned to the stable range, and sends a maintain
wheels. signal.
Refer to the graph in Figure 29-2 for various ABS t9 : Same as t6
system functions (inputs, controller calculations, and Stages t4 - t9 are repeated.
outputs) during operation over a theoretical time period
(t1 through t9 . . . ):
When actuated (when the truck starts to move): t3 : When the slippage starts to decrease, the ECU
gradually sends the signal to exhaust, and repeats
As shown in the graph in Figure 29-3, when the differ-
the control so that the speed of the left and right
ence in the rotating speed between the left and right
wheels is the same.
wheels is detected, the brake is applied to the wheel
that is slipping in order to reduce its speed until both
the left and the right wheel are rotating at the same
speed.
ABS/ASR CONTROLLER
The ABS/ASR Controller (ECU) (1, Figure 29-4) cal-
culates the wheel speed and dummy truck speed from
the signals sent by the wheel speed sensors installed
at each wheel. It then sends a control signal to the
control valve for the wheel which is slipping or where
there is a possibility of the wheel locking.
If the built-in troubleshooting function determines that
a fault has occurred in the system, it lights up the
warning lamp, and also disables the system and oper-
ates as the normal brake.
FIGURE 29-5. WHEEL SPEED SENSOR
1. Spring Spacer 3. Tube
WHEEL SPEED SENSOR 2. Sensor 4. Connector
The wheel speed sensor (Figure 29-5) is a non-contact
sensor. A pulse voltage is generated by the rotation of
the teeth of the gear installed to the outside of the pulse
wheel, and a signal is sent to the controller (ECU).
NOTE:
1. Lamp will flash 2 times if ABS is installed, but ASR is not installed.
2. Lamp will flash 4 times if both ABS and ASR are installed.
NOTE: This table is applicable to trucks equipped with ABS option only.
NOTE: This table is applicable to trucks equipped with both, ABS and ASR option.
1. Verify 10 amp fuses, FBX (1-7) and (2-8) are not blown. If blown, check for a short circuit with the ground
inside the controller and in the wiring harness between the fuse and controller.
Test Conditions:
Battery voltage is normal (21 — 29 volts)
ABS/ASR Main Switch turned ON
Key Switch turned ON
ABS/ASRMAIN
MEASURED
PASS/FAIL
SWITCH
VALUE
INDEX
CODE
STEP
MEASURED
PASS/FAIL
SWITCH
VALUE
INDEX
CODE
STEP
COMPONENT CHECKER BRAKE OPERATION/ SPECIFIED
INSPECTION HOOKUP CHECKER OPERATION VALUE
MEASURED
PASS/FAIL
BRAKE
SWITCH
VALUE
INDEX
CODE
STEP
MEASURED
PASS/ FAIL
BRAKE
SWITCH
VALUE
INDEX
CODE
STEP
COMPONENT CHECKER OPERATION/ SPECIFIED
INSPECTION HOOKUP CHECKER VALUE
OPERATION
NOTES:
Note 6: Before checking ASR valve function, jack up the rear wheels. During test, when checking the left (right) wheel, never rotate the right
(left) wheel at the same time.
NOTE 7:
CHECKER HOOKUP
The Table column labelled “Checker Hookup” lists the terminals for applying the checker leads to perform a particular
test and the type of test being performed. If the ohms symbol (Ω) appears between the arrows, a resistance
measurement must be made. If a “V” appears, a voltage reading must be made.
OPERATOR’S CAB
INDEX
Service
If windshield washer maintenance is required, check BODY DUMP CONTROL LINKAGE
the following; Figure 3-3 shows the body dump control lever and
associated linkage mounted in the cab.
1. Obstructions in the inlet to the pump.
The linkage should be lubricated at 2000 hour intervals
2. Kinked supply hose to the nozzle. as described in Section “P”, Lubrication and Service.
3. Check for system voltage at the pump terminals. Refer to Section L for linkage adjustment procedure.
If voltage is not OK, check the wire harness or the
wiper switch. If the voltage is OK at the pump,
replace the entire pump assembly.
Removal
1A. Steering Wheel 16. Cross & Bearing
1. Remove the four screws holding the top and 2A. Cup 17. Yoke
bottom plastic covers in place. 3A. Plunger 18. Capscrew
2. Remove wiper switch by removing two mounting 4A. Bushing 19. Washer
screws and unplugging the wire harness under 5A. Spring 20. Bracket
the dash. (Remove gauge cluster first.) 6A. Consent 21. Plate
7A. Wire 22. Capscrew
3. Remove turn signal switch by removing the two 8A. Spring 23. Hex Coupler
crews from the steering column clamp and un- 9A. Plate 24. Spring
plugging the harness on the column. 10A. Plate 25. Washer
4. Remove retarder lever by removing two cap- 11A. Insulator 26. Lever
screws from the clamp and disconnecting the 12A. Cushion 27. Capscrew
three air lines. 13A. Button 28. Washer
29. Spring
5. Remove four capscrews and cover plate on the left 1. Column 30. Spacer
side of steering column near the floor. 2. Bushing 31. Bushing
6. Remove two capscrews and cover from right side 3. Grommet 32. Pivot Bolt
of steering column. 4. Cover 33. Nut
5. Bearing 34. Washer
7. Remove capscrew (27, Figure 3-4) from tilt wheel 6. Ring 35. Nut
mechanism and remove lever. Remove special 7. Screw 36. Lockwasher
hex coupler (23), spring (24), washer (25), plate 8. Shaft 37. Flatwasher
(21), and capscrew (22) from tilt-lock mechanism. 9. Spider Assembly
8. Remove pivot bolt (32), washers (34), bushing 10. Yoke
(31), and spacer (30). Loosen capscrew (18) and 11. Yoke
slide yoke (17) from steering valve. Remove steer- 12. Seal
ing column (1). 13. Cover
14. Grease Fitting
Installation 15. Washer
1. Install steering column (1, Figure 3-4) by sliding
yoke (17) onto steering valve. Tighten capscrew
(18) to standard torque. Install pivot bolt (32),
washers (34), bushing (31), and spacer (30).
2. Install capscrew (22), plate (21), washer (25),
spring (24), and special hex coupler (23) to tiltlock
bracket (20). Install lever (26) and secure with
capscrew (27), washer (28).
3. Install two capscrews and cover on right side of
steering column.
4. Install four capscrews and cover plate on the left
side of steering column near the floor.
5. Install retarded lever control and connect the three
air lines.
6. Install turn signal switch and plug in the harness
on the column. Install wiper switch and plug in
wire harness under the dash.
7. Install the four screws holding the top and bottom
plastic cover in place.
Removal
1. Remove capscrews (3, Figure 4-2).
2. Lift seat assembly and disconnect air compressor
wiring harness.
3. Remove seat assembly (1) from cab.
Installation
1. Position spacers and seat in recessed area of cab
floor.
2. Connect air compressor wiring harness to truck
harness.
3. Install and tighten capscrews (3, Figure 4-2) to
standard torque.
4. Verify proper operation of air compressor and FIGURE 4-2. OPERATOR SEAT INSTALLATION
other seat functions.
1. Operator Seat 3. Capscrews
2. Cab Floor
1. Frame Assembly Kit 7. Recliner Cable Kit 13. Damper Kit 19. Valve Kit
2. Lumbar Support Kit 8. Headrest Kit 14. Air Spring Kit 20. Bearing Kit
3. Back Foam Kit 9. Height Riser Assy. Kit 15. Bump Stop Kit 21. Lever/Center Pivot Kit
4. Back Cover Kit 10. Height Riser Spring Kit 16. Harness Kit 22. Fore & Aft Adjust Kit
5. Seat Cover Kit 11. Handle Kit 17. Air Pipe Kit 23. Spacer Kit
6. Seat Foam Kit 12. Suspension Assy. Kit 18. Compressor Kit 24. Suspension Cover Kit
8. Remove control cable from coolant control valve. 2. Remove motor by removing three screws.
9. Remove two capscrews holding the mounting 3. Remove resistor by removing two screws.
brackets to the cab floor. 4. Remove heater core by disconnecting the water
10. Disconnect the two heater coolant hoses. pipes and lifting it out of the housing.
11. Slide heater/air conditioner unit out. While sliding, 5. Remove air conditioning core by removing tube
disconnect wiring harness from blower motor, support screw and lifting the core out of the
blower motor resistor and air conditioner sensor. housing.
Refer to Figure 4-4 for further disassembly of unit if
necessary, or for replacement of other components.
Refer to the appropriate Parts Book for component part
Installation numbers.
1. Slide heater/air conditioner unit in at the same
time with the access door on the left side. While
sliding unit in, connect wiring harness to blower Assembly
motor, blower motor resistor and air conditioner
1. Install air conditioning core and tube support
sensor.
screw in the housing.
2. Connect the two heater coolant hoses.
2. Install heater core and connect the water pipes.
3. Install two capscrews holding the mounting brack-
3. Install resistor with two screws.
ets to the cab floor.
4. Install motor with three screws.
4. Install control cable to coolant control valve. Ad-
just to ensure it travels to complete on and off 5. Join the two halves with ten screws (eight at the
positions. split and two on top).
5. Connect the two air conditioner lines to the core.
1. Cab (Front) 3. Wing Bolt 5. Close access door cover and latch in closed
2. Cover 4. Filter Element position.
5, 4, 3" positions -
FIGURE 5-2. CENTER CONSOLE Road and load conditions sometimes make it desirable
1. Transmission Range Selector (Shift Lever) to limit the automatic up-shifting to a lower range.
2. Shift Limiter Switch These positions provide more effective retarding on
3. Power Mode Selector Switch grades.
4. Emergency Steering Switch When the range selector is placed in any one of these
5. Emergency Brake Lever positions, the transmission will not shift above the
6. Parking Brake Valve Lever highest gear range selected.
7. Engine Shutdown Warning Light It will also downshift to first range when required by
8. Engine Maintenance Light grade/load/engine conditions.
9. Engine Maintenance Light When conditions permit, select position “D” for normal
10. PMC Display (Optional) operation.
11. Engine Fault Code Switch
“L” - LOW position - Use this range position when
12. Engine Diagnostic Switch
maneuvering in tight spaces and when pulling through
13. ABS/ASR Light
mud or deep snow. Use this range position also when
driving up and down steep grades where maximum
driving power or maximum retarding is required.
NOTE: The transmission will be locked into first gear
if the body is not seated on the frame.
Always lower the body when traveling.
STOPPING IN EMERGENCY
The following items (7, 8, 9, 11, & 12, Figure 5-2) relate Engine Shutdown Light (Stop Engine)
to the engine electronic fuel control system. (7, Figure 5-2)
If an abnormal engine condition develops, the control When illuminated, this red en-
system will record a “fault” code associated with that g i n e s hu t-
condition. By use of a series of indicator lamps and down light in-
switches, the system will display the numerical “fault” dicates a se-
code. rious engine
problem ex-
When the keyswitch is turned ists.
“On”, the lamps (7,8, 9) should
illuminate for about 2 seconds
and then turn “ Off” , if no The “fault” can be engine disabling. Stop the truck in
“faults” are detected in the sys- a safe area, as soon as possible. Shutdown the engine
tem. This is a system lamp test. and notify Maintenance personnel immediately.
TROUBLESHOOTING
If the ABS functions while traveling on a slippery
road, the braking distance may be slightly length-
When the key switch is turned on, if the warning lamp
ened. Even if the ABS is turned on, the tires may
(1, Figure 5-3) does not light up, it may be defective.
lock when the truck is braked when running at a
In this case, replace the lamp.
very low speed. Accordingly, take care when driv-
ing on slippery roads. If the ABS/ASR system malfunctions while being used,
the warning lamp (Red) will light up. In this case, stop
If the truck is braked while running at high speed
the truck at a safe place immediately, then notify the
or on a slippery road, more air is consumed by the
maintenance department.
ABS/ASR. If the air pressure drops and the warn-
ing buzzer sounds, stop the truck in a safe place. The positions of each switch and the status of the
Wait until the air pressure is restored sufficiently corresponding warning lamp are as follows:
in the safe zone, then proceed again.
Even with the ABS/ASR system installed, there Key ABS/ASR Warning Lamp
may be instances where the truck can not travel Switch Switch
safely such as on a road having an extremely low OFF OFF Turns OFF
coefficient of friction (a frozen road, etc.) or on a OFF ON Turns OFF
steep slope. In this case, repair the road surface
ON OFF ON (Normal)
before driving.
ON ON • Stays ON, until travel speed
rises above 10 km/h (6.2
• The truck can be driven normally even if the MPH), then turns OFF
ABS/ASR main switch is turned off. In this case, (Normal)
however, watch out for lateral skidding of the truck. • Turns ON when a fault
occurs
(Malfunction)
2. Raise engine RPM to accelerate hoist speed. When carrying out inspection on the machine with
When body is near the maximum angle, reduce the body raised, always lock the dump lever in the
engine RPM (reduce foot pressure on the accel- HOLD position, and then install the body up safety
erator pedal) to reduce shock load to the hydraulic pins.
system and hoist cylinders.
System Switch (1, Figure 5-4) ARSC Caution Light (4, Figure 5-4)
This is used to turn the ARSC system ON/OFF. This flashes if there is any abnormality in the ARSC
system when the system switch is ON. It lights up for
3 seconds when the key switch is turned ON to check
ARSC Set Lever (2, Figure 5-4) the bulb.
• Used when setting the travel speed.
Central Warning Lamp (5, Figure 5-4)
• Used when making fine adjustments up or down to
the set speed. (Tap up/tap down) This lights up together with the ARSC caution lights if
• Used when canceling the set speed. there is a serious abnormality in the ARSC system
when the system switch is ON.
To Increase Set Speed NOTE: The switch must be operated for at least 1
second (different from other switches) to cancel the
If it is desired to increase the set speed, depress the
control. This is to prevent any problem of the control
accelerator pedal to increase speed, and when the
being canceled if the switch is touched by mistake.
desired set travel speed is reached, press the set
switch on the ARSC set lever. The set travel speed will
be changed to the new speed.
Relationship With Exhaust Brake
If the exhaust brake switch is at the ON position, the
To Decrease Set Speed exhaust brake is actuated in the normal way when the
accelerator pedal is released if the torque converter
If it is desired to decrease the set speed, operate the
lock-up is ON. If the machine attempts to travel at a
retarder control lever to reduce speed, and when the
speed greater that the set speed, the ARSC is actu-
desired set travel speed is reached, press the set
ated.
switch on the ARSC set lever. The set travel speed will
be changed to the new speed. If the exhaust brake switch is at the OFF position, the
exhaust brake is not actuated when the ARSC is being
NOTE: After using the retarder control lever to reduce
operated. If the foot brake or retarder control lever are
the speed, return it to its original position.
operated, the exhaust brake is actuated in the same
way as normal.
If the downhill slope is not steep and the engine brake
Traveling Again At Set Speed
and exhaust brake have ample effect, the machine will
If the machine repeatedly travels on the same slope, not accelerate to the set travel speed, so the ARSC
once the travel speed has been set, it is possible to may not be actuated.
operate the ARSC without carrying out the setting
operation each time.
Before entering a downhill slope, if the travel speed Recommended Set Speed
has been adjusted to a speed lower that the set speed
Set the travel speed so that the engine speed is at least
displayed on the travel speed display, the READY
1800 rpm, and travel so that the retarder oil tempera-
lamp (green) lights and the ARSC is actuated when
ture gauge is in the green range.
the accelerator pedal is released.
If there is danger that the retarder oil may overheat,
the ARSC caution lamp will illuminate and the set
NOTE: When traveling at a speed greater than the set travel speed is automatically reduced.
speed displayed on the travel speed display, the ARSC
is not actuated even when the accelerator pedal is
released. When this happens, the READY lamp
(green) also does not light up. Always adjust the travel
speed to a speed lower that the set speed displayed
on the travel speed display, and check that the READY
lamp lights up.
Failure Warning
No. Code Details Pattern
1 0.1 Abnormality in power source 1
2 1.0 Disconnection, short circuit with ground, short circuit in engine speed sensor system 1
3 1.3 Disconnection, short circuit with ground, short circuit in trans. output shaft speed 1
sensor system
4 1.5 Short circuit with ground in retarder oil temperature sensor system 1
5 1.7 Disconnection, short circuit with ground, short circuit in accelerator signal system 1
6 1.8 Disconnection, short circuit with ground in suspension pressure sensor (left) system 1
7 1.9 Disconnection, short circuit with ground in suspension pressure sensor (right) system 1
8 4.2 Disconnection, short circuit in exhaust brake signal system 2
9 4.3 Disconnection, short circuit in ARSC caution lamp system 1
10 4.4 Disconnection in READY lamp system 2
11 4.5 Disconnection, short circuit in central warning lamp system or buzzer system 2
12 5.2 Short circuit with ground in exhaust brake signal system 2
13 5.3 Short circuit with ground in ARSC caution lamp system 1
14 5.4 Short circuit with ground in READY lamp system 2
15 5.5 Short circuit with ground in central warning lamp system or buzzer system 2
16 6.0 Failure in engine speed sensor system 1
17 7.0 Disconnection, short circuit in speed display up output 2
18 7.1 Disconnection, short circuit in speed display down output 2
19 7.2 Disconnection, short circuit in speed display clear output 2
20 7.3 Short circuit with ground in speed display up output 2
21 7.4 Short circuit with ground in speed display down output 2
22 7.5 Short circuit with ground in speed display clear output 2
23 8.1 Short circuit with ground in pressure control valve system 1
24 8.3 Disconnection, short circuit in pressure control valve system 1
25 8.5 Failure in pressure control valve system (retarder remains applied) or failure in pressure 1
switch 1 system
26 8.7 Failure in pressure control valve system (retarder has no affect) or failure in pressure 1
switch 1 system
27 8.9 Short circuit with ground in pressure cracking valve 1
28 9.0 Disconnection, short circuit in pressure cracking valve 1
29 9.1 Failure in pressure cracking valve (remains open) or failure in pressure switch 2 system 1
30 9.2 Failure in pressure cracking valve (does not open) or failure in pressure switch 2 system 1
31 9.3 Disconnection, short circuit in system switch system 1
32 9.4 Short circuit with ground in system switch system 1
33 9.5 Disconnection, short circuit with ground in travel speed set switch system 1
Turn the system switch OFF to stop use of the ARSC. 5. Failure code that occurred immediately before the
failure code in 4.
When the system switch is turned OFF, the ARSC
caution lamp will turn OFF. 6. Failure code that occurred immediately before the
failure code in 5.
In the case of warning patterns 1 and 2 above, turn the
system switch OFF quickly, stop use of the ARSC and Clearing The Failure Code
contact the maintenance department.
Turn the truck key switch to “ON” (the engine is not
started) and disconnect connectors CR1 and CR2
under the assistant’s seat.
Failure Codes
When this is done, “-” is displayed on the controller
The set travel speed display is also equipped with a LED.
self-diagnostic function, and a failure code is displayed
When the “-” changes from flashing and stays lighted
on the set travel speed display.
up (3 seconds), the failure code has been cleared.
E1 - Abnormality in CPU - Turn the key switch ON
again or turn the system switch ON again.
NOTE: When using the ARSC for the first time, always
E2 - Abnormality in memory - Turn key switch ON
clear the failure codes. After clearing the codes, con-
again or turn the system switch ON again.
nect connectors CR1 and CR2.
The gauge and monitor module and speedometer The following pages will identify each element of the
module each have a microcomputer to process and instrument panel and detail its function and purpose
display the signals from the sensors. Liquid crystal is for the operator.
used for the display area.
6. Torque Converter Oil Temperature 10. Left Turn Signal Pilot Lamp
Gauge
When the turn signal lever is moved down-
The Torque Converter Oil Tem- wards, the left turn signal pilot lamp (10)
perature Gauge (6) indicates flashes.
the temperature of the torque
converter oil. If the temperature
is normal during operation, the 11. Right Turn Signal Pilot Lamp
green range will light. If the red range lights during
operation, the alarm buzzer will sound, the central When the turn signal lever is moved up-
warning lamp will light up and the torque converter oil wards, the right turn signal pilot lamp (11)
temperature monitor lamp will flash at the same time. flashes.
If this occurs, stop the machine and run the engine with
no load at 1200-1500 RPM until the green range lights.
T h i s OPTIONAL suspension
feature automatically switches
29. Power Mode Indicator
the damping characteristics of
the suspension according to
whether the truck is carrying a
load, or whether the brake, The Power Mode indicator lights
steering, or dump controls are (29) indicate which of the two fuel
being operated. control modes is in use.
Normally, the SOFT mode (25) is used when traveling When the top light (P) is lit, the Power Mode Selector
empty, and MEDIUM (24) is used when traveling Switch on the console (3, Figure 3-2) is in “Power
loaded. When using the service brakes or turning Mode”.
sharply, or when operating the dump control, the sus-
When the bottom light (E) is lit, the Power Mode
pension mode is switched to HARD (23) to maintain
Selector Switch is in the “Economy Mode”.
the stability of the machine: front and rear, and left and
right. This indicator is present in all instrument panels,
but is inactive in trucks without this option.
31. Engine Oil Pressure Monitor This switch (35) is used to change the braking method
according to the road conditions.
The Engine Oil Pressure Monitor
(31) indicates low engine oil pres- This position (out/light “Off”) is used when
sure. traveling on normal road surfaces.
Braking force is applied to both front and
If the lamp flashes and alarm buzzer rear wheels.
sounds, stop the engine and carry
out inspection. This position (in/light “On”) is used when
Action code “04" will be indicated. traveling on slippery roads.
Braking force is applied only to the rear
wheels.
32. Charge Monitor
The Charge Monitor (32) indicates This switch is present in all instrument panels, but is
an abnormality in the charging sys- inactive in trucks without this option.
tem while the engine is running.
If the monitor lamp lights up, check
the charging circuit. 36. Panel Dimmer Switch
Action code “01" will be indicated. The Panel Dimmer Switch (36) is used to
adjust the brightness of the lighting inside
the monitor panel and pilot lamps.
33. Transmission Oil Filter Monitor
The Transmission Oil Filter Monitor
(33) warns of clogging of the trans- Adjust as follows:
mission oil filter. If the monitor light
To INCREASE brightness, turn CLOCKWISE.
lights up, replace the transmission
filters, and check for contamination To DECREASE brightness, turn COUNTER-
in the oil. CLOCKWISE.
Action code “01" will be indicated.
• – and High•
Move the lever to the left toward “VENT” to direct
“OFF” – Low• – Medium heated or cooled air through the front vents (59).
Move the lever to the center to “HEAT” to direct air to
Low, Medium, and High are indicated by circular marks
the foot vents and defroster vents for heating and
of increasing size.
dehumidifying.
When in the “OFF” position, the air conditioner com-
Move the lever to the right to “DEF” to direct air to the
pressor is de-activated.
defroster vents to remove and/or prevent mist from
forming inside the windshield.
INDEX
Refer to “Hydraulic
T a n k S e r v i c e” ,
page P2-14.
TIRES
Inspect all tires for proper inflation and wear;
Cuts, damage or “bubbles”;
Debris embedded in cuts or tread;
Rocks that might be lodged between dual tires.
Left Front Tire Pressure
Left Rear Outside Tire Pressure
Left Rear Inside Tire Pressure
Right Rear Outside Tire Pressure
Right Rear Inside Tire Pressure
Right Front Tire Pressure
Drain oil from tank and refill tank to specified level, COMMENTS √’d INITIALS
capacity 162 l (43 gal.). Refer to “Lubrication
Chart” for type of oil to use. Lube key “C”.
Refer to “Hydraulic Tank Service”, pageP2-14.
Remove / replace 2 high pressure filter elements.
Refer to "High Pressure Hydraulic Filters",
pageP2-16.
2. REAR BRAKE COOLING OIL TANK
Drain oil from tank and refill tank to specified level
capacity 268 l (71 gal.). Lube key “E”. To reduce
rear brake “squeal”, use only SHELL DONAX - TD
Oil or BP TRACTRAN UTH. If these oils are not
available, use Lube key “C”.
Refer to “Hydraulic Tank Service”, page P2-14.
3. FINAL DRIVE CASE
Position machine so that casting line is horizontal
and drain plug is at the bottom. Drain oil and
reinstall plug, remove fill plug at castline and fill to
specified level. This operation is performed on the
right and left hand final drives. Capacity is 64 l (17
gal.) each side.
Refer to “Lubrication Chart” for type of oil to use.
Lube key “B”.
4. DIFFERENTIAL CASE
Drain oil from differential and refill to the specified
level: capacity 130 l (34 gal.).
Refer to “Lubrication Chart” for type of oil to use.
Lube key B”.
5. VIBRATION DAMPER, ENGINE
Inspect damper for cracks or separation on rubber
surfaces. If any defects are noted, replace with
new vibration damper.
6. EMERGENCY RELAY VALVE
Disassemble emergency relay valve, clean and
inspect for damaged or worn parts. Replace all
rubber parts also any that were found defective,
then reassemble.
7. ENGINE FRONT TRUNNION
Apply grease. Lube Key “D”
8. DUMP CONTROL LINKAGE - 3 points
Apply grease. Lube key “D”
3. FRONT SUSPENSIONS
Drain Front suspension oil. Inspect upper flange
internal bearing. Replace worn parts.
Refill suspensions with clean oil and recharge with
nitrogen. Refer to Service Manual, Section “H” for
instructions and WARNINGS when servicing sus-
pensions.
5. RADIATOR
Inspect Air-to-Air aftercooler for damage. After-
cooler damage may result in air leaks causing
reduced engine performance due to low boost
pressure. Whistling noise due to air leakage may
also be present if aftercooler is cracked.
Filling Instructions
(Hoist Oil Supply)
1. Park the truck on a level surface, lower the dump
body, and shut down the engine.
2. Turn the oil filler cap (8, Figure 2-3) slowly coun-
terclockwise to release internal tank pressure.
3. Fill tank with recommended oil until oil is visible in
the sight glass (7).
To reduce rear brake “squeal”, use ONLY SHELL
DONAX - TD Oil or BP TRACTRAN UTH. If these
oils are not available, use Lube key “C”.
Rear Brake Oil tank refill capacity:
268 Liters (70.8 gal.)
Filter Replacement
1. Lower the dump body and shut down the engine.
Cleaning
1. Shut down the engine and open hydraulic tank filler
caps slowly to relieve any internal pressure.
2. Clean dirt accumulation from area of breather (9,
Figure 2-3).
3. Remove the breather from the tank.
4. Remove snap ring (1, Figure 2-5), cover (2) and
filter element (3).
5. Clean breather element in solvent and blow dry.
Clean remaining parts in solvent and dry thor-
oughly. Replace element, if element appears
damaged or doesn’t clean up thoroughly.
FIGURE 2-5. HYDRAULIC TANK BREATHER
6. Install element, cover and snap ring.
1. Snap Ring 3. Element
7. Install breather element on hydraulic tank.
2. Cover
Service
1. Remove drain plug (7, Figure 2-8) and drain the oil
from the filter housing. Tighten plug after all oil is
drained.
2. Unscrew filter bowl (4) from head assembly (1).
3. Remove the element and thoroughly clean and dry
all component parts.
4. Coat a new seal (9) with clean engine oil and
install.
5. Install a new element (5) and install the filter bowl
(4) into the head assembly (1).
6. Start the engine and let it idle for 5 minutes. Stop
engine and check for leaks. Check transmission
for proper oil level and adjust if necessary.
The following parts should be considered for repair or The following parts should be considered for repair or
replacement every 2000 hours, or every one year, replacement every 4000 hours, or every two years,
whichever comes first: whichever comes first:
1. Fuel Pump Screen Filter - Check and clean or
1. Brake valve parts. replace screen filter.
2. Parking brake valve parts. 2. Periodic Replacement Safety Parts Kit - Use the
periodic replacement safety parts service kit when
3. Relay valve parts.
replacing the parts.
4. Air governor parts.
3. High pressure hoses in steering circuit (to/from
5. Retarder control valve parts. pump, demand valve, steering valve, steering cyl-
inder). *
6. Emergency relay valve parts.
4. Outlet hose of retarder cooling oil pump. *
7. Emergency brake valve parts.
5. Outlet hose of steering oil pump. *
8. Quick release parts.
6. Outlet hose of transmission oil pump. *
9. Parking brake chamber parts.
7. Steering valve hose. *
10. Brake chamber parts (front and rear).
8. Hose of fuel filter. *
11. Engine Valve Clearance —
Refer to the engine manual for the proper inspec- 9. Fuel hose. *
tion, procedures, and tools.
12. Brake Discs - Refer to Section “J”, Brake System, * The replacement of these parts may be
“Brake Circuit Checkout And Adjustment”, for considered for Fire Prevention measures.
proper inspection, procedures and tools.
Other areas of the truck also require inspection and may require periodic replacement of parts due to environmental
and operating conditions. Rubber or plastic parts which are subjected to extreme heat or ultraviolet (sunlight)
conditions will deteriorate more rapidly than similar parts in less severe service.
Periodically check the following:
1. Air inlet piping elbows close to turbochargers and 5. Windshield washer bottle.
exhaust manifolds.
6. Plastic covers and caps.
2. Air cleaner plastic bonnets.
7. Water piping elbows and hoses.
3. Door seals.
8. Body cushion pads.
4. Windshield wiper blades.
9. Plastic tubing for air lines.
A C
Cab . . . . . . . . . . . . . . . . . . . . . . N2-1
Accelerator Pedal . . . . . . . . . . . . . . D3-12 Center Case Assembly (Rear Axle) . . . . . . G5-1
AISS Operation . . . . . . . . . . . . . . . D3-13 Charging Procedure
Air Cleaner . . . . . . . . . . . . . . . . . . . C5-1 Suspension . . . . . . . . . . . . . . . . . H4-2
Air Cleaner Indicator . . . . . . . . . . . . . . N3-2 Compressor, Air . . . . . . . . . . . . . . . . . K3-9
Air Compressor . . . . . . . . . . . . . . . . K3-9 Controller Troubleshooting
Air Conditioning System . . . . . . . . . . . . M9-1 Automatic Transmission . . . . . . . . . . D5-1
Component Service . . . . . . . . . . . . . M9-7 Engine . . . . . . . . . . . . . . . . . . . . D7-1
Air Dryer . . . . . . . . . . . . . . . . . . . . K2-2 Suspension (Optional) . . . . . . . . . . . D9-1
Air Filtration System . . . . . . . . . . . . . . C5-1 Converter, Pressure . . . . . . . . . . . . . . J3-4
General Service Information . . . . . . . . . C5-1 Cooling System . . . . . . . . . . . . . . . . C3-1
Air Governor . . . . . . . . . . . . . . . . . . K3-9 Crossover Relief Valve . . . . . . . . . . . . . L4-3
Adjustment . . . . . . . . . . . . . . . . . . K3-9 Cylinders
Air Intake Troubleshooting . . . . . . . . . . . C5-4 Hoist . . . . . . . . . . . . . . . . . . . . . . L8-4
Air System . . . . . . . . . . . . . . . . . . . K2-1 Steering
Air Governor . . . . . . . . . . . . . . . . . K2-5 Removal . . . . . . . . . . . . . . . . . . . L6-2
Safety Valve . . . . . . . . . . . . . . . . . K2-5 Disassembly . . . . . . . . . . . . . . . . . L6-3
Automatic Shift Control . . . . . . . . . . . . . F6-1 A-Frame . . . . . . . . . . . . . . . . . . G3-4
Alternator, 24VDC . . . . . . . . . . . . . . . D2-4
Antifreeze Recommendations . . . . . . . . . P2-1 D
Decals (Warnings & Cautions) . . . . . . . . . A4-1
Decks . . . . . . . . . . . . . . . . . . . . . . B2-1
B Demand Valve . . . . . . . . . . . . . . . . . L4-4
Batteries . . . . . . . . . . . . . . . . . . . . D2-1 Removal . . . . . . . . . . . . . . . . . . . L6-7
Maintenance and Service . . . . . . . . . . D2-2 Installation . . . . . . . . . . . . . . . . . . L6-7
Troubleshooting . . . . . . . . . . . . . . . D2-2 Differential Carrier . . . . . . . . . . . . . . G5-5
Battery Charging System . . . . . . . . . . . D2-4 Drivelines . . . . . . . . . . . . . . . . . . . . F5-1
Operation . . . . . . . . . . . . . . . . . . . D2-5 Dryer, Air . . . . . . . . . . . . . . . . . . . . K2-2
Battery Disconnect Switch . . . . . . . . . . . D2-3 Dump Body . . . . . . . . . . . . . . . . . . . B3-1
Belt, Fan . . . . . . . . . . . . . . . . . . . . C3-5
Body, Dump . . . . . . . . . . . . . . . . . . B3-1
Body Guide . . . . . . . . . . . . . . . . . . . B3-4
Body Pad . . . . . . . . . . . . . . . . . . . . B3-3
Brake, Emergency . . . . . . . . . . . . . . J2-17
Brake Circuit . . . . . . . . . . . . . . . . . . J2-1
Brake Oil Cooler . . . . . . . . . . . . . . . . C3-4
Brake Cooling Valve . . . . . . . . . . . . . J2-15
Bleeding Procedure
Front . . . . . . . . . . . . . . . . . . . . J4-3
Rear . . . . . . . . . . . . . . . . . . . . J4-3
Brake, Parking . . . . . . . . . . . . . . . . . J7-1
Brake Treadle Valve Operation . . . . . . . J2-21
Brake Treadle Valve Repair . . . . . . . . . . J3-1
G
General Safety Rules . . . . . . . . . . . . . . A3-1
Governor, Air . . . . . . . . . . . . . . . . . . K3-9
Grille . . . . . . . . . . . . . . . . . . . . . . B2-1
SYSTEM SCHEMATICS
INDEX
NOTE
* 10
1
RT R 5 6 7
LS
LT P
28
27
29
11
12
26 20 19
30 13
25 14
A B C D
Tube
18 Hose ( Flange )
Hose ( Low Pressure )
Block
24 23 22 21
Coupling
17 16 15
HH346
May 2000
HD785-5LC
UNIT 224, 228 & UP
Hydraulic Piping
( Steering, Hoist
& Brake Cooling )
Komatsu Mining Systems, Inc.
Peoria Operations
2300 N. E. Adams Street
Peoria, IL 61639
Printed in U.S.A. 092800