Ce BM 021000

CEBM021000
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS A30049 and UP

With SDA12V160 Engine

Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-
sonnel 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 America Corp (KAC), and is not to be reproduced, used, or dis-
closed except in accordance with written authorization from KAC.
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 obli-
gation 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 Komatsu 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.
NON-OEM PARTS IN CRITICAL SYSTEMS
For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.
Replacement parts manufactured and supplied by unauthorized sources may not be

designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.
Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the
Komatsu product on the supplier and user. Komatsu will not in any case accept
responsibility for the failure or performance of non-OEM parts in its products,
including any damages or personal injury resulting from such use.
FOREWORD
This manual is written for use by the operator and/or the service technician and is designed to help these persons
to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
All operators and maintenance personnel must understand the content in this manual before maintaining or per-
forming operational checks on the truck. All safety notices, warnings and cautions must be understood before
repairing the truck.
This manual shows dimensioning of metric and (U.S. standard) units throughout. 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 Introduction section and individual torques are pro-
vided in the text in bold face type, such as 135 Nm (100 ft lbs). All torque specifications have 10% tolerance
unless otherwise specified.
The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of
what is found on the truck.
A product identification plate is located on the frame in front of the right side front wheel and designates the truck
model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW)
rating.
The product identification number (vehicle serial number) contains information which will identify the original manu-
facturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design
and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight. This is equal to
the empty vehicle weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty
truck. This includes all accessories, body liners, tailgates, etc. 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 must be removed as often as
practical.
Exceeding the allowable payload will reduce expected life of truck components.
A00036 Introduction A-1

This alert symbol is used with the signal words, cau-
tion, danger, and warning in this manual to alert the
reader to hazards arising from improper operating and
maintenance practices.
Danger identifies a specific potential hazard

which will result
in either injury or death
if proper precautions are not used.
Warning identifies a specific potential hazard

which may result
in either injury or death
if proper precautions are not used.
Caution is used for general reminders

of proper safety practices
or
to direct the readers attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
A-2 Introduction A00036

TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
TRANSMISSION AND TORQUE CONVERTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
DRIVE AXLE, SPINDLES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
SUSPENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
A00036 Introduction A-3

KOMATSU HD1500-7 TRUCK
A-4 Introduction A00036

SECTION A
GENERAL INFORMATION
INDEX
MAJOR COMPONENTS & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
GENERAL SAFETY AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
STANDARD TORQUE CHARTS AND CONVERSION TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
STORAGE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
A01001 02/94 Index A1-1

NOTES
A1-2 Index 02/94 A01001

MAJOR COMPONENTS AND SPECIFICATIONS
Engine Power Steering
The Komatsu HD1500-7 dump truck is powered by a The HD1500-7 truck is equipped with a full time
Komatsu SDA12V160 diesel engine. This engine is power steering system. The system provides positive
Tier 1 compliant. steering control with minimum effort by the operator.
Nitrogen-charged accumulators automatically pro-
vide emergency power if steering pressure is
reduced below an established minimum.
Transmission
The Torqflow transmission is a planetary gear, multi-
ple disc clutch transmission. The transmission is
Brake System
hydraulically actuated and force-lubricated for opti-
mum heat dissipation. A three-element, single-stage, Depressing the brake pedal, or operating the
two-phase torque converter is mounted to the front of retarder, actuates the hydraulic front and rear service
the transmission. brakes. Both front and rear service brakes are oil-
cooled, multiple-disc brakes. The brakes are auto-
The Torqflow transmission is capable of seven for-
matically applied when engine speed exceeds the
ward speeds and one reverse speed. Automatic
rated revolutions for the shift range. The system
shifting is controlled by an electronic shift control sys-
includes two nitrogen-charged accumulators for
tem with automatic clutch modulation in all gears. A
quick response. The accumulators provide emer-
lockup system consisting of a wet, double-disc
gency braking if a problem occurs in the primary
clutch, is activated in F1-F7 gears for increased fuel
braking circuit.
savings.
Retarder
Final Drive
The operator can manually apply both the front and
The final drive consists of a plug-in differential with
rear oil-cooled, multiple-disc brakes by actuating the
planetary wheel drive.
retarding system. The retarder control lever is
mounted on the steering column.
The retarding system is also equipped with an Auto-
matic Retard Speed Control (ARSC) system. The
Operators Cab system automatically applies the retarder to maintain
The HD1500-7 operator's cab has been engineered the set speed as initiated by the operator. Refer to
for maximum operator comfort and to allow for effi- Section 32, Operator Cab and Controls, for more
cient and safe operation of the truck. information on the ARSC system.
The cab provides for wide visibility, with an integral

four-post ROPS/FOPS, and an advanced analog
operator environment. It includes the following: tinted
safety-glass windshield, power-operated side win- Suspension
dows, deluxe interior with a fully adjustable seat with
Hydro-pneumatic suspension cylinders are mounted
lumbar support, fully adjustable tilt steering wheel,
at each wheel to reduce shock. The suspensions
controls mounted within easy reach of the operator,
provide riding comfort for the operator and machine
and an electronic display/monitoring panel to keep
stability for safe travel.
the operator informed of the truck's operating circuits.
Audible alarms and indicator lights warn the operator
of system malfunctions.
A02077 Major Components and Specifications A2-1

MAJOR COMPONENT LOCATION
A2-2 Major Components and Specifications A02077

SPECIFICATIONS
Engine Service Capacities
Komatsu . . . . . . . . . . . . . . . . . . . . . . . SDA12V160* . . . . . . . . . . . . . . . . . . . . . . . .Liters . . U.S Gallons
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 12 Engine . . . . . . . . . . . . . . . . . . 193 . . . . . . (51)
Operating Cycle (diesel) . . . . . . . . . . . . . . . 4-Stroke (Includes Lube Oil Filters)
Rated . 1109 kW (1487 SAE Brake HP) @ 1900 rpm Cooling System . . . . . . . . . . . 532 . . . . . . (141)
Flywheel . . . 1048 kW (1406 SAE HP) @ 1900 rpm Fuel Tank . . . . . . . . . . . . . . . . 2120 . . . . . (560)
Weight (dry) . . . . . . . . . . . . . . . .5813 kg (12,815 lbs) Transmission . . . . . . . . . . . . . 153 . . . . . . .(41)
* Tier 1 Compliant And Torque Converter
Hydraulic System . . . . . . . . . 900 . . . . . . (238)
Transmission
Differential . . . . . . . . . . . . . . . 297 . . . . . . .(78)
Automatic Electronic Shift Control with Automatic Final Drive (each planetary) . 120 . . . . . . .(32)
Clutch Modulation In All Gears.
Torque Converter. . . . . . . . 3-Element, Single-stage,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-phase Hydraulic System
Lockup Clutch . . . . . . . . . . . . . . . Wet, Double-disc, Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . (3)
. . . . . . . . . . . . . . . . . . . . . . Activated in F1-F7 gears. Hoist (Tandem Gear)
Transmission . . . . . . . 7 Forward Speeds, 1 Reverse . . . . 805 l/min. (213 gpm) @ 18 960 kPa (2,750 psi)
. . . . . . . . . . . . .Planetary Gear, Multiple Disc Clutch,
Steering (Piston)
. . . . . . . . . . Hydraulically Actuated, Force-lubricated
. . . 221 l/min. (58.5 gpm) @ 18 960 kPa (2,750 psi)
Gear . . . . . . . . . . . . . . . . . . . . . kph . . . . . . . . mph Brake (Tandem Gear) . . . . . 1512 l/min. (400 gpm)
1 . . . . . . . . . . . . . . . . . . . . . . 11.0 . . . . . . . . . 6.8 Hoist Control Valve . . . . . . . . . . . . . . . . . Spool Type
2 . . . . . . . . . . . . . . . . . . . . . . 14.6 . . . . . . . . . 9.1 Positions. . . . . . . . . . Raise, Hold, Float, and Lower
3 . . . . . . . . . . . . . . . . . . . . . . 19.5 . . . . . . . . 12.1 Hydraulic Cylinders
4 . . . . . . . . . . . . . . . . . . . . . . 24.5 . . . . . . . . 15.2 Hoist . . . . . . . . . . . . . 3-Stage Telescoping Piston
5 . . . . . . . . . . . . . . . . . . . . . . 32.6 . . . . . . . . 20.3 Steering . . . . . . . . . . . Twin - Double Acting Piston
6 . . . . . . . . . . . . . . . . . . . . . . 44.2 . . . . . . . . 27.5 Relief Valve Setting . . . . . . . .18 960 kPa (2,750 psi)
7 . . . . . . . . . . . . . . . . . . . . . . 58.0 . . . . . . . . 36.0 Filtration . . . . . . . . . . . In-line Replaceable Elements
Reverse . . . . . . . . . . . . . . . . . . . 10.6 . . . . . . . . . 6.6 Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Hoist & Steering . . . . . . . . . Dual, Full Flow, In-line
. . . . . . . . . . . . High Pressure. Beta 12 Rating = 200
Final Drive Transmission . . . . . . . . . . . . . .Dual, High Pressure
Final Drive . . . . . . . . . . . . . . . . . Plug-in Differential
Service Brakes
. . . . . . . . . . . . . . . . . . . . with Planetary Wheel Drive
Actuation: . . . . . . . . . . . . . . . . . . . . . . . All-Hydraulic
Reduction Ratios: Front . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Bevel Set . . . . . . . . . . . . . . . . . . . . . . . . . 2.647:1 Rear . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Planetary Final Drive . . . . . . . . . . . . . . . . . 7.235:1
. . . . . . . . . . Both act as service and retarder brakes
Total Reduction . . . . . . . . . . . . . . . . . . . 19.151:1
Retarder Brakes:
Normally Applied . . . . . . . . Manually By Operator.
. . . . . . . . . . . . . . . . . . . . . . . . . . (w/ ARSC control)
Electrical System
Automatically Actuated . . . . . . . . . . . . . . . . . . . . . .
Batteries (series-parallel). . 4 x 12V / 140 Amp-Hour when engine speed exceeds the rated revolutions
Alternator . . . . . . . . . . . . . . 24 Volt, 140 Amp Output of the shift position for the transmission.
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt Parking Brake: . . . . . . Spring-Applied, Oil Released
Cranking Motors . . . . . . . . . . . Two - 24 Volt Electric . . . . Dry Caliper Disc Actuates On Rear Drive Shaft
Emergency Brakes: Manual or automatic operation.
A02077 Major Components and Specifications A2-3

Steering Overall Truck Dimensions
Turning Circle Diameter (SAE) . . . . . . . 24.4 m (80 ft) Loading Height . . . . . . . . . . . . . . . . 4.965 m (16' 3")
Minimum Clearance Height . . . . . . . . 5.85 m (19' 2")
Automatic Emergency Steering . . . . 2 Accumulators
Overall Length . . . . . . . . . . . . . . . . . 11.37 m (37' 4")
Maximum Width. . . . . . . . . . . . . . . . . 6.62 m (21' 9")
Tires
Rock Service (E-3) . . . . . . . . . . . . . . . . . . . Tubeless Weight Distribution
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 33.00 R51 Empty . . . . . . . . . . . . . . . Kilograms . . . . .Pounds
Rim Size . . . . . 61x 12.95 x 12.7 cm (24 x 51 x 5 in.) Front Axle . . . . . . . . . . . . . . 51,714. . . . . . 114,008
Phase II Generation . . . . . . . Separable Tire Rims Rear Axle . . . . . . . . . . . . . . 54,041 . . . . . . . 119,140
Total . . . . . . . . . . . . . . . . . . 105,755 . . . . . 233,148
Loaded (150 Ton Payload)

Dump Body Capacity (Standard)
. . . . . . . . . . . . . . . . . . . . . Kilograms . . . . .Pounds
Struck . . . . . . . . . . . . . . . . . . . . . . . 54 m3 (71 yds3) Front Axle . . . . . . . . . . . . . . 83,824 . . . . . . .184,800
Heaped @ 2:1 (SAE) . . . . . . . . . . 78 m3 (102 yds3) Rear Axle . . . . . . . . . . . . . . 165,651 . . . . . .365,199
Total * . . . . . . . . . . . . . . . . . 249 475 . . . . . .550,000
*Not to Exceed 249 475 kg (550,000 lbs.).
Including Options, Fuel & Payload
A2-4 Major Components and Specifications A02077

SECTION A3
SAFETY
INDEX
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Leaving The Operators Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Precautions With High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Prevention Of Injury By Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
HAUL ROADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Ventilation In Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
In Operators Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Precautions For Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Ensure Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Operate Carefully On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Avoid Damage To Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Loading The Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
Battery Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
A03036 04/08 General Safety and Operating Instructions A3-1

Stopping The Engine Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Keep The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Rules To Follow When Adding Fuel Or Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Radiator Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Handling High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Precautions With High Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Precautions When Performing Maintenance Near High Temperature Or High Pressure . . . . A3-15
Rotating Fan And Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
Handling Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
Storing Tires After Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
Cold Weather Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-22
ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
AFTER THE ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
RETARDER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Raising the Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
TURNING OFF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
Secondary Steering And Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
DISABLED TRUCK DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Raising the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
Lowering the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
DISABLED TRUCK STEERING AND BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-37
A3-2 General Safety and Operating Instructions 04/08 A03036

SAFETY
Safety records from most organizations will show Clothing And Personal Items
that the greatest percentage of accidents are caused
by unsafe acts performed by people. The remainder
are caused by unsafe mechanical or physical condi-
tions. Report all unsafe conditions to the proper
authority.
The following safety rules are provided as a guide for
the operator. However, local conditions and regula-
tions may add many more to this list.
Avoid loose clothing, jewelry, and loose long hair.
Loose items can catch on controls or in moving
parts and cause serious injury or death.
Never wear oily clothes as they are flammable.
Wear a hard hat, safety glasses, safety shoes,
Read and follow all safety precautions. Failure to mask and gloves when operating or maintaining
do so may result in serious injury or death. a machine. Always wear safety goggles, hard hat
and heavy gloves if your job involves scattering
metal chips or minute materials--particularly
Safety Rules when driving pins with a hammer or when
cleaning air cleaner elements with compressed
Only trained and authorized personnel can air. Also, ensure that the work area is free from
operate and maintain the machine. other personnel during such tasks.
Follow all safety rules, precautions and
instructions when operating or performing
maintenance on the machine. Unauthorized Modification
Ensure all personnel understand all hand signals
Any modification made to this vehicle without
that are to be used during machine travel and
authorization from Komatsu America Corp. can
maintenance.
possibly create hazards.
Before making any modification, consult the
authorized regional Komatsu America Corp.
Safety Features distributor. Komatsu will not be responsible for
any injury or damage caused by any
Ensure all guards and covers are in their proper
unauthorized modification.
position. Repair damaged guards and covers.
Refer to Section 30, Operating Instructions -
Walk-Around Inspection.
Leaving The Operators Seat
Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. Use When preparing to leave the operator's seat, DO
these safety features properly. NOT touch any control lever that is not locked.
Never remove any safety features. Always keep Unexpected machine movement may result in
safety features in good operating condition. serious bodily injury or death. To prevent
accidental machine movement from occurring,
Improper use, or failure to maintain safety always perform the following:
features could result in serious bodily injury or
death. Move the shift control lever to NEUTRAL and
apply the parking brake.
Lower the dump body, set the dump lever to the
FLOAT position.
Stop the engine. When exiting the machine,
always lock compartments, and take the keys
with you.

Mounting And Dismounting Precautions With High Temperature Fluids
Never jump on or off the machine. Never climb on Immediately after machine operation, fluids are at
or off a machine while it is moving. high temperatures and are pressurized. If a
machine system is opened, there is danger of
When climbing on or off a machine, face the serious burns. Allow heat and pressure to
machine and use the hand-hold and steps. dissipate before performing such tasks and
Never hold any control levers when getting on or follow proper procedures as outlined in the
off a machine. service manual.
Always maintain three-point contact with the To prevent hot coolant from
hand-holds and steps to ensure proper support spraying:
and balance.
1. Stop the engine.
When bringing tools into the operator's 2. Wait for the coolant
compartment, always pass them by hand or pull
temperature to
them up by rope.
decrease.
If there is any oil, grease, or mud on the hand- 3. Depress the pressure
holds or steps, wipe them clean immediately.
release button on the
Always keep these areas clean. Repair any
cap to vent cooling system pressure.
damage and tighten any loose bolts.
4. Turn the radiator cap slowly to release the pres-
Properly use the handrails and steps when
sure before removing.
getting on or off the machine.
To prevent hot engine oil spray:
1. Stop the engine.
2. Wait for the oil temperature to cool down.
3. Turn the cap slowly to release the pressure
before removing the cap.
Fire Prevention For Fuel And Oil

Fuel, oil, and antifreeze can be ignited by a
flame. Fuel is extremely flammable and can be
hazardous.
Keep flames away from flammable fluids.
Stop the engine. Never smoke when refueling.
Tighten all fuel and oil tank caps securely.
Refueling and oiling must be done in well
ventilated areas.
Keep oil and fuel in a designated location and DO
NOT allow unauthorized persons to enter.

Asbestos Dust Hazard Prevention Precautions For ROPS
Asbestos dust is hazardous to The Rollover Protection Structure (ROPS) must
your health when inhaled. If be properly installed for machine operation.
you handle materials contain- The ROPS is intended to protect the operator if
ing asbestos fibers, follow the the machine should roll over. It is designed not
guidelines below: only to support the load of the machine, but also
to absorb the energy of the impact.
Never use compressed air
for cleaning. ROPS structures installed on equipment
manufactured and designed by Komatsu
Use water for cleaning to control dust.
America Corp. fulfills all of the regulations and
Operate the machine or perform tasks with the standards for all countries. If it is modified or
wind to your back, whenever possible. repaired without authorization from Komatsu, or
is damaged when the machine rolls over, the
Use an approved respirator when necessary. strength of the structure will be compromised
and will not be able to fulfill its intended purpose.
Optimum strength of the structure can only be
Prevention Of Injury By Work Equipment achieved if it is repaired or modified as specified
by Komatsu.
Never enter or put your hand, arm or any other
part of your body between movable parts such as When modifying or repairing the ROPS, always
the dump body, chassis or cylinders. If the work consult your nearest Komatsu distributor.
equipment is operated, clearances will change Even with the ROPS installed, the operator must
and may lead to serious bodily injury or death. always use the seat belt when operating the
machine.
Fire Extinguisher And First Aid Kit

Ensure fire extinguishers are Precautions For Attachments
accessible and proper usage When installing and using optional equipment,
techniques are known. read the instruction manual for the attachment
Periodically check fire and the information related to attachments in this
extinguishers. Verify that they manual.
are in working condition. DO NOT use attachments that are not authorized
Know what to do in the event of a fire. by Komatsu America Corp., or the authorized
regional Komatsu distributor. Use of
Provide a first aid kit at the storage point. Keep unauthorized attachments could create a safety
the kit fully stocked. problem and adversely affect the proper
Keep the phone numbers of persons you should operation and useful life of the machine.
contact in case of an emergency on hand. Any injuries, accidents, and product failures
resulting from the use of unauthorized
attachments will not be the responsibility of
Komatsu America Corp., or the authorized
regional Komatsu distributor.

HAUL ROADS PRECAUTIONS DURING OPERATION
Determining the travel road at the work site is an Prevention is the best safety program. Prevent a
important for safety, maintenance and speed. potential accident by knowing the employer's safety
When possible restrict travel to one direction. If it requirements and all necessary job site regulations.
is necessary to provide for traffic in both In addition, know the proper use and care of all the
directions, ensure the road is wide enough. safety equipment on the truck. Only qualified opera-
When creating haul roads, orient the road so the tors or technicians should attempt to operate or
loaded truck passes on the side closest to the hill maintain a Komatsu machine.
face. Keep the road as straight as possible. If Safe practices start before the operator gets to the
curves are necessary, make the curve radius and equipment!
road width as large as possible. Ramp the
outside of curves so they are higher than the
inside.
Limit intersections if possible. Design any BEFORE STARTING THE ENGINE
necessary intersections to provide safe When walking to and from a truck, maintain a
crossings. safe distance from all machines even when the
operator is visible.
Install mirrors at curves with poor visibility.
Before starting the engine, thoroughly check the
Install signs to warn of any dangers along the area for any unusual conditions that could be
road. dangerous.
Install adequate lighting and reflectors for safe Examine the road surface at the job site and
travel. determine the best and safest method of
Road grades should not exceed 10% and operation.
emergency ramps installed for brake failures. Choose an area where the ground is as
horizontal and firm as possible before performing
Properly maintain haul roads for safe travel. Use the operation.
a grader or a dozer to smooth rough roads and
strengthen where necessary. Spray the roads If it is necessary to operate the machine on or
with water to prevent excessive dust and poor near a public road, protect pedestrians and cars
visibility. by designating a person for work site traffic duty
or by installing fences around the work site.
The operator must personally check the work
area, the roads to be used, and existence of
obstacles before starting operations.
Always determine the travel roads at the work
site. Maintain roads to ensure machine and
operator safety.
If travel through wet areas is necessary, check
the depth and flow of water before crossing the
shallow parts. Never drive through water which
exceeds the permissible water depth.

Fire Prevention In Operators Cab - Before Starting The Engine
Thoroughly remove wood DO NOT leave tools or spare parts lying around
chips, leaves, paper and other or allow trash to accumulate in the cab of the
flammable items accumulated truck. Keep all unauthorized reading material out
in the engine compartment. of the truck cab.
Failure to do so could result in Keep the cab floor, controls, steps, and handrails
a fire. free of oil, grease, snow, and excess dirt.
Check fuel, lubrication, and hydraulic systems for Check the seat belt, buckle and hardware for
leaks. Repair any leaks. Clean any excess oil, damage or wear. Replace any worn or damaged
fuel or other flammable fluids, and dispose of parts. Always use the seat belts when operating
properly. a machine.
Ensure a fire extinguisher is present and in Read and understand the contents of this manual
proper working condition. pertaining to safety and operating instructions
DO NOT operate the machine near open flames. with special attention. Become thoroughly
acquainted with all gauges, instruments and
controls before attempting operation of the truck.
Preparing For Operation Read and understand the warning and caution
decals in the operator's cab.
Always mount and dismount while facing the
truck. Never attempt to mount or dismount the Ensure the steering wheel, horn, controls and
truck while it is in motion. Always use handrails pedals are free of any oil, grease or mud.
and ladders when mounting or dismounting the Check operation of the windshield wiper,
truck. condition of wiper blades, and check the washer
Check the deck areas for debris, loose hardware, fluid reservoir level.
and tools. Be familiar with all steering and brake system
Check for people and objects that might be in the controls, warning devices, road speeds and
area. Remove any obstructions and wait for any loading capabilities, before operating the truck.
personnel in the area to disperse.
Become familiar with and use all protective
equipment devices on the truck and ensure that Mirrors, Windows, And Lights
these items (anti-skid material, grab bars, seat
Remove any dirt from the surface of the
belts, etc.) are securely in place.
windshield, cab windows, mirrors and lights.
Good visibility may prevent an accident.
Adjust rear view mirrors to a position where the
operator can see best from the operator's seat.
Ventilation In Enclosed Areas If any glass or light should break, replace it with a
new part.
If it is necessary to start the
engine within an enclosed area, Ensure headlights, work lights and taillights are in
provide adequate ventilation. proper working order. Ensure that the machine is
Exhaust fumes from the engine equipped with the proper work lamps needed for
can kill. the operating conditions.

OPERATING THE MACHINE Check for flat tires periodically during a shift. If
the truck has been operating on a flat tire, DO
When Starting The Engine NOT park the machine inside of a building until
the tire cools. DO NOT stand in front of the rim
Never start the engine if a warning tag is attached and locking ring when inflating a tire mounted on
to the controls. the machine. DO NOT allow observers in the
When starting the engine, sound the horn as an area during tiring inflation and service.
alert.
Start and operate the machine only while seated
in the operators seat.
DO NOT allow unauthorized persons in the
operator's compartment or any other place on The tire and rim assembly may explode if sub-
the machine. jected to excessive heat. Move personnel to a
remote or protected location if there is evidence
of excessive heat in the wheel, brake and tire
Precautions For Starting Machine area.
Start the engine from the If the truck must be approached to extinguish a
operators seat, only. fire, those personnel should do so only while fac-
ing the tread area of the tire (front or back),
Never attempt to start the engine
unless protected by use of large heavy equip-
by shorting across the starter
terminals. This may cause fire, ment as a shield. Stay at least 15 m (50 ft) from
or serious injury or death to the tread of the tire.
anyone in machines path. In the event of fire in the tire and wheel area
(including brake fires), stay away from the truck
for at least eight hours or until the tire and wheel
Truck Operation - General are cool.
Wear seat belt at all times. Keep serviceable fire fighting equipment on
hand. Report empty extinguishers for
Only authorized persons are allowed to ride in replacement or refilling.
the truck. Riders must be in the cab and belted in
the passenger seat. Always have the parking brake applied when the
DO NOT allow anyone to ride on the decks or truck is parked and unattended. DO NOT leave
steps of the truck. the truck unattended while the engine is running.
DO NOT allow anyone to get on or off the truck Park the truck a safe distance away from other
while it is in motion. vehicles as determined by the supervisor.
DO NOT move the truck in or out of a building Stay alert at all times! In the event of an
without a signal person present. emergency, be prepared to react quickly and
Know and obey the hand signal communications avoid accidents. If an emergency arises, know
between operator and spotter. Use the direction where to get prompt assistance.
of a signal person to travel near buildings,
obstacles, people, etc. Courtesy at all times is a
safety precaution!
Immediately report any hazardous conditions at
the haul road, pit or dump area.

Traveling
Lower the dump body and set the dump lever to When operating in areas that may be hazardous
the FLOAT position before traveling. or have poor visibility, designate a person to
direct work site traffic.
When traveling on rough ground, travel at low
speeds. Do not exceed 27 kph (17 mph). When DO NOT allow anyone to enter the line of travel
changing direction, avoid turning suddenly. of the machine. This rule must be strictly
observed even with machines equipped with a
If the engine should stop while the machine is in back-up alarm or rear view mirror.
motion, secondary steering and braking enable
the truck to be steered and stopped. A fixed
amount of reserve oil provides temporary
steering and braking to briefly allow machine Traveling On Slopes
travel to a safe area. Apply the brakes Traveling on slopes could result in the machine
immediately and stop the machine as quickly and
tipping over or slipping.
safely as possible (off of the haul road, if
possible). DO NOT turn the truck around on a slope. To
ensure safety, drive to level ground before
turning around.
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. Avoid traveling sideways, and always
DO NOT move the shift lever to the N position keep travel speed low.
while the truck is in motion. If the selector is
shifted to N while in motion or while descending When traveling downhill, use the retarder or
a hill the following may occur: service brake pedal to reduce truck speed. Bring
the truck to a stop using the brake pedal and
Steering may be more difficult. then apply the parking brake. Use caution when
using the brake pedal. Excessive force when
A lack of cooling oil may cause the braking
applying the service brakes may cause a loss of
system to overheat and fail.
control of the truck.
Damage to the transmission may occur.
When turning, rotate the steering wheel gradually
The engine cannot provide braking when the to avoid losing control of the truck.
transmission is not in gear.
If the engine should fail while on a slope, apply
the service brakes and bring the truck to a stop.
Move the transmission range selector to
Traveling In Reverse NEUTRAL and apply the parking brake.
Before operating the machine or work equipment,
observe the following:
Ensure Good Visibility
Sound the horn to warn
people in the area. For When working in dark places, install work lamps
machines equipped with and head lamps. Set up extra lighting in the work
a back-up alarm, ensure area if necessary.
the alarm works Discontinue operations if visibility is poor, such as
properly. in mist, snow, or rain. Wait for the weather to
Check for personnel near the machine. Be improve to allow the operation to be performed
particularly careful to check behind the machine. safely.
When necessary, designate a person to watch
the area near the truck and signal the operator.
This is particularly necessary when traveling in
reverse.

Operate Carefully On Snow When Dumping
When working on snowy or icy roads, there is Before dumping, check that there is no person or
danger that the machine may slip to the side on objects behind the machine.
even the slightest slope. Always travel slowly
Stop the machine in the desired location. Check
and avoid sudden starting, turning, or stopping in
again for persons or objects behind the machine.
these conditions.
Give the determined signal, then slowly operate
Use extreme caution when clearing snow. The the dump body. If necessary, use blocks for the
road shoulder and other objects are buried in the wheels or position a flagman.
snow and cannot be seen. When traveling on
When dumping on slopes, machine stability is
snow-covered roads, always install tire chains.
poor and there is danger of tip over. Always
perform such operations using extreme care.
Never travel with the dump body raised.
Avoid Damage To Dump Body
Always use extreme caution when working in
tunnels, on bridges, under electric cables, or any Working On Loose Ground
other place where there are height limits. The
dump body must be completely lowered before Avoid operating the machine near cliffs,
driving the machine. overhangs, and deep ditches. If these areas
collapse, the machine could fall or tip over,
resulting in serious injury or death. Remember
that ground surfaces in these areas may be
Driving Near High Voltage Cables
weakened after heavy rain or blasting.
Driving near high-voltage cables can cause Freshly laid soil and soil near ditches is loose. It
electric shock. Always maintain safe distances
can collapse under the weight or vibration of the
between the machine and electric cables, as machine. Avoid these areas whenever possible.
listed below.
Voltage Minimum Safety Distance

Loading The Body
6.6 kv 3m 10 ft
33.0 kv 4m 14 ft Check that the surrounding area is safe, stop the
machine in the correct loading position, then
66.0 kv 5m 17 ft evenly load the body.
154.0 kv 8m 27 ft
DO NOT leave the operator's seat during loading.
275.0 kv 10 m 33 ft
The following actions are effective in preventing acci- Parking The Machine
dents while working near high voltages:
Choose a horizontal road surface to park the
Wear shoes with rubber or leather soles. machine. If the machine must be parked on a
Use a signal person to give a warning if the slope, always put blocks under all the wheels to
machine approaches an electric cable. prevent the machine from moving.
If the work equipment should touch an electric When parking on public roads, provide signals,
cable, the operator must remain in the cab. such as flags or lights, to warn pedestrians and
other vehicles. Ensure the machine, flags, or
When driving near high voltage cables, DO NOT lights do not obstruct the traffic.
allow anyone to approach the machine.
Before leaving the machine, fully lower the dump
Check with the electrical maintenance body, activate the parking brake, stop the engine,
department about the voltage of nearby cables and lock everything. Always take the key with
before operating. you.

TOWING Before working with batteries, stop the engine
and turn the key switch to the OFF position.
Improper towing methods may lead to serious
personal injury and/or damage. Avoid short-circuiting the battery terminals
through accidental contact with metallic objects,
Use a towing device with ample strength for the such as tools across the terminals.
weight of this machine.
When removing or installing, check which is the
Never tow a machine on a slope. positive (+) terminal and negative (-) terminal.
Inspect all towing apparatus for damage. DO Tighten battery caps securely.
NOT use tow rope that has kinks or is twisted.
Tighten the battery terminals securely. Loose
DO NOT stand near the towing cable during terminals can generate sparks and lead to an
towing. explosion.
When connecting a machine that is to be towed,
DO NOT allow anyone to go between the tow
machine and the machine that is being towed.
Set the coupling of the machine being towed in a
Starting With Booster Cables
straight line with the towing portion of the tow
machine, and secure it in position. Always wear safety
For towing methods, refer to Section 30, glasses or goggles when
Operating Instructions - Towing. starting the machine with
booster cables.
When using booster
cables, DO NOT allow the
two machines to touch.
WORKING NEAR BATTERIES Connect the positive (+) cable first when
installing booster cables. Disconnect the ground
Battery Hazard Prevention or negative (-) cable first during removal.
Battery electrolyte contains sulfuric acid and can If any tool touches between the positive (+)
quickly burn the skin and eat holes in clothing. If terminal and the chassis, it will cause sparks.
acid comes in contact with any part of the body, Always use caution when using tools near the
immediately flush the area with water. battery.
Battery acid can cause blindness if splashed into Connect the batteries in parallel: positive to
the eyes. If acid gets into the eyes, flush them positive and negative to negative.
immediately with large quantities of water and
see a doctor at once. When connecting the ground cable to the frame
of the machine to be started, connect it away
If acid is accidentally ingested, drink a large from the battery to minimize the risk of explosion.
quantity of water, milk, beaten eggs or vegetable
oil. Call a doctor or poison prevention center
immediately.
When working with batteries always wear safety
glasses or goggles.
Batteries generate hydrogen gas. Hydrogen gas
is very explosive and is easily ignited with a small
spark of flame.

MAINTENANCE PRECAUTIONS Stopping The Engine Before Service
Before performing inspections or maintenance,
Warning Tag stop the machine on firm, flat ground. Lower the
Starting the engine or operating the controls while dump body, stop the engine and apply the
others are performing maintenance on the truck parking brake.
can lead to serious injury and/or death. If the engine must be operated during service,
such as when cleaning the radiator, always move
the transmission control lever to the NEUTRAL
position and apply the parking brake. Always
perform this work with two people. One person
must sit in the operator's seat to stop the engine,
if necessary. Never move any controls, not
related to the task at hand, during these
situations.
Always attach the warning tag to the steering
When servicing the machine, DO NOT touch any
wheel in the operator's cab to alert others that
moving parts. Never wear loose clothing or
you are working on the machine. Attach
jewelry.
additional warning tags around the machine, if
necessary. Put wheel blocks under the wheels to prevent
machine movement.
Tags are available from your Komatsu distributor.
When performing service with the dump body
Warning tag part number (09963-03000) raised, always place the dump lever in the HOLD
position. Install the body-up retention cable,
securely.
Proper Tools
Use only tools suited to the
task. Using damaged, low
quality, faulty, or makeshift
tools can cause personal
injury. Securing The Dump Body
Any time personnel are required to perform main-

tenance on the vehicle with the dump body in the
raised position, the body-up retention cable must
be installed.
1. To hold the dump body in the raised position,

raise the body to it's maximum height. Refer to
Figure 20-1.
2. Remove cable (2) from its stored position on the
body and install between dump body (1) and
the axle housing ear.

3. Secure the cable clevis pins with cotter pins. 4. Gently move the hoist control lever to the
DOWN position until the dump body moves,
and then release the lever. The lever will now
default to the FLOAT position where the dump
body will be allowed to lower and pull the cable
It is very important to ensure that the cable is taut tight. When the cable is tight, the dump body is
before the dump body can be considered secure. secure, and maintenance can be performed.
Perform the following step in order to remove 5. After maintenance work has been completed,
any slack from the body retention cable. slightly raise the dump body to remove the ten-
sion in the body retention cable. Disconnect the
cable from the axle and place it in the stored
position.
FIGURE 3-1. SECURING THE DUMP BODY
1. Dump Body 2. Body Retention Cable

DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil
Personnel Spilled fuel and oil may cause

slipping. Always clean up spills,
Only authorized personnel may service and immediately. Failure to clean up
repair the machine. fuel or oil spills may lead to fires.
Always tighten the cap of the fuel and oil fillers
securely.
Attachments
Never use fuel to wash parts.
Place attachments that have
been removed from the machine Always add fuel and oil in a well-ventilated area.
in a safe place and manner to
prevent them from falling.
Working Under The Machine

Always lower all movable work
equipment to the ground or to their Radiator Water Level
lowest position before performing
service or repairs under the If it is necessary to add
machine. coolant to the radiator, stop
the engine, and allow the
Always block the tires of the machine securely. engine and radiator to cool.
Never work under the machine if the machine is Depress the pressure release
poorly supported. button on the cap to vent cooling system
pressure.
Keep The Machine Clean Slowly loosen the cap to relieve any remaining
pressure during removal.
Spilled oil or grease,
scattered tools, etc.
can cause you to slip or
Use Of Lighting
trip. Always keep the
machine clean and tidy. When checking fuel, oil, coolant, etc., always use
If water gets into the electrical system, there is lighting with anti-explosion specifications. If such
danger that the machine may move lighting equipment is not used, there is danger of
unexpectedly and/or damage to components explosion.
may occur. DO NOT use water or steam to clean
any sensors, connectors, or the inside of the
operator's compartment.

Precautions With The Battery Precautions When Performing Maintenance Near
High Temperature Or High Pressure
When repairing the
electrical system or when Immediately after stopping
performing electrical operation, engine coolant and
welding, remove the operating oils are at high
negative (-) terminal of temperature and under high
the battery to stop the pressure. In these conditions, if
flow of current. the cap is removed, the oil or
water drained, or the filters are replaced, it may
result in burns or other injury. Wait for the
temperature to cool and pressure to subside,
Handling High Pressure Hoses
before performing the inspection and/or
DO NOT bend high-pressure hoses or hit with maintenance as outlined in the service manual.
hard objects. DO NOT use any bent or cracked
piping, tubes or hoses. They may burst during
use. Rotating Fan And Belts
Always repair any loose or broken hoses. Fuel or
Stay away from rotating parts
oil leaks may result in a fire.
such as the radiator fan and fan
belts. Serious bodily injury may
result from direct or indirect
Precautions With High Pressure Oil contact with rotating parts and
flying objects.
Work equipment circuits are always under
pressure.
DO NOT add oil, drain oil, or perform
maintenance or inspections before completely
releasing the internal pressure. Waste Materials
Small, high pressure pin-hole leaks are extremely Never dump waste oil into a
dangerous. The jet of high-pressure oil can sewer system, river, etc.
pierce the skin and eyes. Always wear safety
glasses and thick gloves. Use a piece of Always put used oil in
cardboard or a sheet of wood to check for oil appropriate containers.
leakage. Never drain oil directly onto
the ground.
If you are hit by a jet of high-pressure oil, consult
a doctor immediately for medical attention. Obey appropriate laws and
regulations when disposing of harmful objects
such as oil, fuel, coolant, solvent, filters,
batteries, etc.

TIRES
Handling Tires
If tires are not used under the specified conditions, If the proper maintenance procedures are not used,
they may overheat and burst, or be cut and burst by the tire may burst and cause serious injury or dam-
sharp stones on rough road surfaces. This may lead age. When performing tire/wheel maintenance, con-
to serious injury or damage. sult your authorized regional Komatsu distributor, or
the tire manufacturer.
To maintain tire safety, always adhere to the following
conditions:
Inflate the tires to the specified pressure. Storing Tires After Removal
Abnormal heat is generated particularly when the
inflation pressure is too low. As a basic rule, store the tires in a warehouse
that unauthorized persons cannot enter. If the
Use the specified tires. tires are stored outside, erect a barrier around
the tires. Install a warning sign that young
children can understand.
The tire inflation pressure and permissible speeds
Stand the tire on level ground. Block the tire
are general values. The actual values may differ securely so that it cannot roll or fall over.
depending on the type of tire and operating condi-
tions. For details, please consult the tire manufac- If the tire should fall over, flee the area quickly.
turer. Tires for mining equipment are extremely heavy.
Never attempt to hold or support the tire.
When tires become hot, a flammable gas is produced Attempting to hold or support a tire may lead to
inside the tire, and may ignite. It is particularly dan- serious injury.
gerous if the tires become overheated while the tires
are pressurized. If the gas generated inside the tire
ignites, the internal pressure will suddenly rise, and
the tire will explode, resulting in danger to personnel
in the area. Explosions differ from punctures or tire
bursts because the destructive force is extremely
high. Therefore, the following actions are strictly pro-
hibited when the tire is pressurized:
Welding the rim
Welding near the wheel or tire.
Smoking or creating open flames

WHEN REPAIRS ARE NECESSARY
1. Only qualified maintenance personnel, who 9. If the truck is to be towed for any reason,
understand the systems being repaired, may always consider any special precautions. Refer
attempt repairs. to Section 30, Operating Instructions - Towing,
for instructions on how to properly tow the truck.
2. Many components on the truck are large and
heavy. Ensure that lifting equipment is of ade- 10. Drain, clean and ventilate fuel tanks and/or
quate capacity to handle the lift. hydraulic tanks before making any welding
repairs.
3. DO NOT stand under a suspended load. DO
NOT work under a raised body unless the body 11. Relieve pressure in lines or hoses before mak-
retention cable is in place to hold the body in ing any disconnects.
the raised position.
4. DO NOT repair or service the truck while the
engine is running, except when absolutely nec-
essary. Keep a safe distance from moving parts.
Any operating fluid, such as hydraulic oil escap-
5. When servicing an air conditioning system
ing under pressure, can have sufficient force to
charged with refrigerant, wear a face shield and
enter a person's body by penetrating the skin.
cold resistant gloves for protection against
Serious injury and possibly death may result if
freezing. Follow all current regulations for han-
proper medical treatment by a physician familiar
dling and recycling refrigerants.
with this injury is not received immediately.
6. Follow package directions carefully when using
cleaning solvents.
12. After adjustments or repairs, replace all shields,
7. If an auxiliary battery assist is needed, first use
screens and clamps.
one cable to connect the 24V positive (+) post
of the disabled truck batteries to the 24V posi- 13. Use extreme caution when working near tires
tive (+) post of the auxiliary assist. Use the sec- and rims.:
ond cable to connect the 24V negative (-) post
of the auxiliary assist battery to a frame ground
(-) on the disabled truck, away from the battery.
8. Always disconnect the positive and negative DO NOT stand in front of a rim and locking ring
battery cables of the vehicle before doing any when inflating a tire mounted on the machine.
welding on the unit. Failure to do so may seri- Observers must not be permitted in the area and
ously damage the battery and electrical equip- must be kept away from the sides of such tires.
ment. Disconnect the battery charging
alternator lead wire and isolate electronic con- DO NOT weld or heat the rim assembly with the
trol components before making weld repairs. tire mounted on the rim. Gases inside the tire
Always fasten the welding machine ground (-) may ignite, causing explosion of the tire and rim.
lead to the piece being welded. The grounding
clamp must be attached, as near as possible, to
the weld area. Never allow welding current to 14. Only a qualified operator may operate the truck
pass through ball bearings, roller bearings, sus- in the repair facility or during road testing after
pensions, or hydraulic cylinders. Avoid laying repairs are complete.
welding cables over or near the vehicle electri-
cal harnesses. Welding voltage could be
induced into the electrical harness and cause
damage to components.

ADDITIONAL JOB SITE RULES
Use this space to add any additional job site rules not covered in any of the previous discussions.
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OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
The safest trucks are those which have been prop- Walk Around Inspection
erly prepared for operation. At the beginning of each
shift, the operator must perform a careful check of At the beginning of each shift, perform a careful walk
the truck before starting the engine. around inspection on the truck before engine start-
up. A walk around inspection is a systematic inspec-
Safety Is Thinking Ahead tion of the truck and its components. The purpose is
to ensure that the truck is safe to operate.
Prevention is the best safety program. Prevent a
potential accident by knowing the employer's safety Start at the left front corner of the truck. Move in a
requirements and all necessary job site regulations. counterclockwise direction, from front to rear. Move
Be familiar with use and care of the safety equipment across the rear. and continue forward up the opposite
on the truck. Only qualified operators or technicians side of the truck to the original starting point. If these
may operate or maintain the truck. steps are performed in sequence, and are repeated
every shift, many potential problems can be avoided.
A safe work environment begins before the operator
boards the truck. If problems or potential problems are found during
the inspection, notify maintenance. Vehicle break-
Wear the proper clothing. Loose fitting clothing,
unbuttoned sleeves and jackets, jewelry, etc., are downs, unscheduled downtime and loss of produc-
a potential hazard. tion can be reduced.
Use personal safety equipment provided for the Local work practices may prevent an operator from
operator such as a hard hat, safety shoes, and performing all tasks suggested here. To the extent
safety glass. There are some conditions when permitted, the operator must follow this or a similar
protective hearing devices must also be worn for routine.
operator safety.
1. Start at the left front of the truck. Visually
When walking to and from the truck, maintain a inspect all lights and safety equipment for exter-
safe distance from all machines even if the nal damage from rocks or misuse. Ensure
operator is visible. lenses are clean and are not cracked or broken.
2. Move behind the front of the left front tire.
Inspect the hub and the oil disc brake assem-
blies for leaks and abnormalities.
Check that all suspension hardware is secure
and inspect for evidence of wear. Verify suspen-
sion extension is within the proper range. Check
for any leaks in the area.
3. Check the engine oil level. Verify engine oil fil-
ters or oil lines to filters are not leaking.

4. Inspect the fan and air conditioner belts for cor- 13. Check the axle housing breather. Replace the
rect tension, wear, and tracking. Inspect the fan breather if obstructed. Check for leakage
guard condition and secureness. around the final drive, brake, and connecting
5. Move outboard of the front wheel. Inspect hoses.
attaching lugs and clamps to ensure all are tight 14. While standing at the rear of the truck, verify the
and intact. Check the tire for damage. Ensure rear lights and back up horns are in good condi-
the tire is properly inflated. tion. Inspect the linkage rods to verify all loca-
6. Move behind the rear of the front wheel. Check tions are properly greased. Check both body
for leaks or any unusual conditions at the hub pivot pins. Ensure the pins are properly
and brakes. Inspect the suspension hardware. greased.
Ensure the tie rod and steering cylinder pivots 15. Perform the same inspection on the right rear
are properly greased. Check the secureness of suspension, as done on the left.
all parts. Check for hydraulic leaks. 16. Move to the right dual tires. Check between the
7. Check the transmission oil level. Check the tires for rocks. Check rock ejector condition.
pumps at the front of the transmission. Check Inspect the tires for damage, and proper infla-
for proper component mounting and ensure no tion.
leaks exist. 17. Check the wheel lugs and wedges, as done on
8. Move to the side of the hydraulic tank. Check the left dual wheels. Check for leaks.
the hydraulic fluid level for both the hydraulic 18. Move in front of the right dual tires. Inspect the
tank and brake cooling oil. Oil must be visible in hoist cylinder, as done on the left side.
the sight glass with the engine stopped and the
19. Move around the fuel tank, and inspect the fuel
body down.
gauge. Inspect the mounting hardware at the
9. Move around the hydraulic tank and in front of upper and lower mounts. Ensure the mounts
the rear dual tires. Inspect the hoist cylinder for are secure and in good condition.
damage or leaks. Inspect the upper and lower
20. Move behind the right front wheel. Ensure the
hoist cylinder pins for secureness. Ensure the
tie-rod and steering cylinder pivots are properly
pins are properly greased.
greased. Inspect the attaching hardware for the
10. Before leaving this position, verify there is no steering cylinder. Verify all parts are secure.
leakage or any other unusual condition with the Ensure the suspension protective cover is in
transmission or rear drive shaft. good condition. Check suspension hardware
11. Move around the dual tires. Verify all lugs and suspension extension. Ensure the mount-
clamps are intact and tight. Check the wheel for ing pins are properly greased.
leakage from inside of the wheel housing Fluid 21. Move around the right front wheel. Verify all lugs
may indicate planetary leakage. Check the dual and clamps are intact and tight.
tires damage and proper inflation. Check for 22. Move behind the right front wheel. Check the
rocks that might be lodged between the dual hub and brake for leaks or any unusual condi-
tires. Verify the rock ejector is in good condition tion. Inspect the engine compartment for leaks
and straight. or any unusual condition. Inspect the fan guard
12. Check the left rear suspension for damage, and belts. Check for debris from behind the
proper extension, and leaks. Ensure the sus- radiator. Remove any debris that is found.
pension pins are properly greased. Ensure the 23. Move to the right front of the truck. Check for
covers over the chrome piston rod are in good debris that might be trapped in front of the radi-
condition. ator. Remove any debris. Check for coolant
leaks. Inspect all head lamps and fog lights.

24. Ensure the ground level engine shut off switch Cold Weather Heating System
is ON.
Some trucks operating in cold weather climates may
25. Climb the ladder to the main deck. Always use be fitted with an optional cold weather heating sys-
the hand rails and ladder when mounting or dis- tem. The system includes heaters in the transmis-
mounting the truck. Clean the ladder and hand sion, hydraulic tank, engine oil pan, battery box,
rails of any foreign material, such as ice, snow, cooling system, and fuel system. Trucks fitted with -
oil or mud. 40C (-40F) equipment (or colder) may also contain
heaters in the rear axle.
The power receptacle (2, Figure 30-1) is mounted
inside the RH upright near the bottom of the radiator.
Face the truck when using the ladders. Never
mount or dismount the truck while the truck is in
motion.
26. Check the coolant in the radiator using the cool-

ant level sight gauge.
If the engine is hot, allow the coolant to cool

before removing the radiator fill cap. Serious
burns may be acquired from contact with hot
coolant. Depress the pressure relief before FIGURE 30-2. HEATING SYSTEM POWER
removing the cap. RECEPTACLE
27. Inspect the battery box cover for damage. 1. Radiator 2. Power Receptacle
Ensure the cover is secured, tightly.
28. Check the air cleaner indicators. If the indicator
is in the red area, the air filter must be cleaned The system operates on 220V and is controlled by
or replaced before operating the truck. various thermostats in the system. The thermostats
29. Clean the cab windows and mirrors. Clean the operate the heaters within a certain temperature
cab floor, as necessary. Ensure the steering range.
wheel, controls and pedals are free of foreign
substances such as oil.
30. Stow personal gear in the cab so that it does not
interfere with operation of the truck. Clean dirt
or trash buildup, specifically in the operator's
cab. DO NOT store tools or supplies in the cab
or on the deck. Do not operate the engine while the heater sys-
31. Adjust the seat and steering wheel so that it is tem is operating. Lack of coolant circulation in
comfortable for use. the heaters will burn out the heating elements.
32. Read and understand the information detailed in
Operator Controls and Instrument Panel.
Become familiar with all control locations and
functions before operating the truck.

ENGINE START-UP SAFETY PRACTICES NOTE: The engine is equipped with an oil prelube
system. A noticeable time delay will occur, while
Safety rules must be observed upon engine start-up.
engine oil passages are being filled, before cranking
motor engagement and engine cranking will begin.
The colder the engine oil temperature, the longer the
time delay will be. In addition, if the truck is also
equipped with an engine starting aid for cold weather
Ensure there is adequate ventilation before start- starting, allow the engine prelube system to operate,
up if the truck is in an enclosure. Exhaust fumes first for 5-10 seconds, or until the cranking motor is
are dangerous! engaged. Then activate the engine starting aid.
1. Ensure all personnel are clear of the truck

before starting the engine. Sound the horn as a Cold Weather Starting
warning before starting.
2. Ensure the transmission shift lever is in NEU-
TRAL and the parking brake is applied.
Starting fluid is extremely volatile and flammable!

Use extreme care when handling and using start-
ing fluid.
DO NOT attempt to start the engine while the cold
weather starting heater (if equipped) is operating. If the truck is equipped with cold weather starting aid
Damage to coolant heaters will result due to lack and the ambient temperature is below -5C (23F),
of circulation. push the engine starting aid switch in for three sec-
onds. Release the starting aid switch and turn the
key switch to START. If the engine does not start,
3. The key switch is a three position (OFF, RUN,
wait at least 15 seconds before repeating the proce-
START) switch.
dure.
When the key slot is in the vertical
position, the electrical system is off
and no electrical devices are ener-
gized.
Use this key position to stop the DO NOT crank the electric cranking motors for
engine when it is on. more than 30 seconds. Allow two minutes for the
4. When the switch is rotated one motor to cool before attempting to start the
position clockwise, it is in RUN and all electrical engine again. Severe damage to the cranking
circuits except START are energized. motors may result from overheating.
With the selector lever in NEU-
TRAL and the parking brake
applied, rotate the key switch
fully clockwise to the START
position. Hold this position until
the engine starts (see the follow-
ing note). The START position is
spring loaded to return to RUN
when the key is released.

Jump Starting AFTER THE ENGINE HAS STARTED
The truck cannot be push started. Transmission lube If coolant temperature is below 50 C (122 F), the
and control systems are inoperative when the engine engine will operate at 1000 rpm in order to reach nor-
is not on. mal operating temperature. When coolant tempera-
ture rises above 50 C (122 F), the engine will return
When jumping battery power from one truck to
to normal low idle speed, 650 rpm. Refer to Auto-
another, all switches must be OFF prior to making
matic Idle Selector Switch in Section 32 for related
any connections. Check connections for correct
information.
polarity.
Become thoroughly familiar with the steering, brak-
Connect one lead of the booster cable to the 24V
ing, and emergency controls. Perform the following
positive (+) post of battery needing assist, and the
checks to ensure safe truck operation before each
other lead of the booster cable to the 24V positive (+)
shift.
post of the auxiliary battery. Connect one lead of the
second booster cable to the 24V negative (-) post of
the auxiliary battery and then connect the other lead
of the booster cable to a good frame ground on the
disabled truck, away from the battery needing assist. During the following safety checks, if actuation
This procedure will avoid the possibility of causing or release of any steering, brake or emergency
sparks near the battery where explosive gases may control circuit does not appear normal, shut the
be present. engine off, immediately. Notify maintenance per-
sonnel. DO NOT operate the truck until the sys-
tem in question is fully operational. Ensure the
NOTE: HD1500 trucks are equipped with four 12 volt area around the truck is clear before testing.
batteries connected in series and parallel to provide
24 volt output. Maintain correct voltage and polarity
when connecting booster cables. Damage to
electrical components may result if voltage and Steering
polarity are not correct. 1. Test the truck steering in extreme right and left
directions. If the steering system is not operat-
ing properly, shut the engine off, immediately.
Determine the problem, and repair before
resuming operation.
NOTE: The steering and brake systems each have
two accumulators that store energy and provide
capability to steer and stop the truck in the event of
an unexpected engine or pump failure.
As part of the routine maintenance of the vehicle,
one requirement to ensure proper operation of each
system is to maintain proper accumulator nitrogen
pre-charge. Refer to the shop manual for proper
procedures when charging the accumulators.
Service Brake
2. With the truck on flat ground, check for normal
operation of the service brake:
a. Depress brake pedal (5, Figure 30-1).

Auxiliary Brake
b. Move transmission shift lever (2, Figure 30- 5. Check operation of the auxiliary brake:
2) to the 6 position and gradually increase a. Depress auxiliary brake switch (4, Figure 30-
engine speed to 1520 rpm. The truck must 1). Verify the internal red lamp illuminates.
remain stationary. Placing the shift lever in 6
ensures that the transmission will start in F1. b. Move the transmission shift lever to 6 and
gradually increase engine speed to full throt-
c. Reduce engine speed to low idle and release
tle. Placing the shift lever in 6 ensures the
the service brake. Place the shift lever in N.
transmission will start in F1. The truck must
remain stationary.
Retarder
3. With the truck on flat ground, check retarder
operation:
a. Move retarder lever (2, Figure 30-1) to the
If the truck moves, notify maintenance personnel
maximum retard position -lever down. Verify
to immediately repair the brakes. DO NOT oper-
the retarder pilot lamp in the electronic dis-
ate the truck until the auxiliary brake is fully oper-
play panel illuminates.
ational.
b. Move the transmission shift lever to the 6
position and gradually increase engine
speed to 1490 rpm. The truck must remain c. Reduce engine speed to low idle. Place the
stationary. Placing the shift lever in 6 shift lever in NEUTRAL. Switch the auxiliary
ensures the transmission will start in F1. brake OFF. Verify the red indicator lamp
turns off.
c. Reduce engine speed to low idle. Move the
retarder lever to OFF -lever up. The retarder
pilot lamp should turn off. Place the shift
lever in NEUTRAL. Brake Lock
6. Check the operation of the brake lock:
a. Depress brake lock switch (6, Figure 30-1).
Parking Brake Verify the brake lock indicator lamp illumi-
4. Check operation of the parking brake: nates.
a. Apply parking brake switch (3, Figure 30-2). b. With the F1 start switch OFF, move the
Verify the red parking brake lamp in the elec- transmission shift lever to D to enable the
tronic display panel illuminates. transmission to start in second gear. Gradu-
ally increase engine speed to 1410 rpm. The
b. Move transmission shift lever (2, Figure 30- truck must remain stationary.
2) to any position other than N. Verify the
central warning lamp on the electronic dis-
play panel flashes.
c. Move the transmission shift lever to the 6
position. Gradually increase engine speed to
1730 rpm. Placing the shift lever in 6 ensures If the truck moves, notify maintenance personnel
that the transmission will start in F1. The to immediately repair the rear brakes. DO NOT
truck must remain stationary. If the truck operate the truck until the brake lock is fully
moves, notify maintenance personnel to operational.
adjust the parking brake. DO NOT operate
the truck until the parking brake is fully oper- c. Reduce engine speed to low idle. Place the
ational. shift lever in NEUTRAL. Switch the brake
d. Reduce engine speed to low idle. Place the lock to OFF. Verify the brake lock indicator
selector lever in NEUTRAL. lamp is off.

7. Check the gauges, warning lights and instru-
ments before truck use to ensure proper system
operation. If any warning lights are illuminated,
shut off the engine immediately and determine
the cause.
8. Ensure headlights, work lights and taillights are
working properly. Good visibility may prevent an
accident. Check the operation of the windshield
wiper and washer.
FIGURE 30-4. CONSOLE CONTROLS
1. Center Console 3. Parking Brake Switch

2. Transmission Shift 4. Hoist Control Lever
Lever
FIGURE 30-3. BRAKE SYSTEM CONTROLS 9. When the body is raised, DO NOT allow anyone
1. Center Dash Panel 4. Auxiliary Brake Switch beneath unless the body-up retaining device is
2. Retarder Lever 5. Brake Pedal in place.
3. ARSC Lever 6. Brake Lock Switch 10. DO NOT use the fire extinguisher for any pur-
pose other than putting out a fire! If the extin-
guisher is discharged, refill or replace the
extinguisher.
11. DO NOT allow unauthorized personnel to ride in
the truck. DO NOT allow anyone to ride on the
ladder or on the deck of the truck.
12. DO NOT leave the truck unattended while the
engine is on. Shut off the engine before leaving
the cab.

MACHINE OPERATION SAFETY 7. Apply the brake lock switch at the shovel and
PRECAUTIONS dump areas.
Follow all local safety rules to ensure safe machine 8. Proceed slowly on rough terrain to avoid deep
operation. ruts or large obstacles. Do not travel along soft
edges or the edge of the fill area.
9. Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
operating the truck.
A malfunction exists if any of the red warning
10. When driving at night or when visibility is poor,
lights illuminate or if a gauge reads in the red
the headlights must be on. DO NOT travel in
area during truck operation. Safely stop the
these conditions if the headlights are inopera-
truck, and turn off the engine. Have the problem
tive.
repaired before resuming truck operation.
11. DO NOT travel in reverse if the back-up horn or
lights are inoperative.
1. Sound the warning horn before moving the
truck. When moving in reverse, honk the horn 12. When driving in reverse, signal with three honks
three times as a back up signal. When starting on the horn. When starting forward, signal with
forward, signal with two horn honks. Use these two honks on the horn. Signal each time the
signals each time the truck is moved forward or truck is moved forward or backward.
backward. Look to the rear before backing the 13. DO NOT stop or park on a haul road unless
truck. Watch and obey the ground spotter's unavoidable. If you must stop, move the truck to
hand signals before reversing. The spotter must a safe place. Apply the parking brake and turn
have a clear view of the total area at the rear of off the engine. Block the wheels securely and
the truck. notify maintenance personnel for assistance.
2. Operate the truck while properly seated with the
14. If the low steering pressure warning illuminates
seat belt fastened. Keep hands and feet inside
during operation, immediately steer the truck to
the cab compartment while driving. Keep a firm
a safe stopping area away from other traffic.
grip on the steering wheel at all times.
Refer to the previous item above.
3. Frequently check the gauges and instrument
panel for proper readings during operation. 15. Report adverse haul road conditions, immedi-
ately. Muddy or icy roads, pot holes or other
4. Observe all regulations pertaining to the job obstructions can present hazards.
site's traffic pattern. Be cautious of unusual traf-
fic patterns. Match the truck speed to haul road 16. Keep cab doors closed at all times while the
conditions and slow the truck in congested truck is in motion or unattended.
areas. Obey the spotter's signals at the shovel 17. Check for flat tires periodically during the shift. If
and dump. the truck has been operating on a flat tire, allow
5. DO NOT allow the engine to idle for extended the tire to cool before parking indoors.
periods of time.
6. Check the parking brake periodically during the
work shift. Use the parking brake for parking
only. DO NOT attempt to apply the parking
brake while the truck is moving!

LOADING HAULING
1. Approach the loading area with caution. 1. Stay alert and drive with extreme caution.
Remain at a safe distance while the truck ahead 2. Govern truck speed based on road conditions,
is being loaded. weather and visibility.
2. DO NOT drive over unprotected power cables. 3. Operate the truck with control at all times.
3. When near loading areas, watch for other vehi- 4. Use extreme caution when approaching an
cles and for personnel working in the area. intersection. Maintain a safe distance between
4. When approaching a loader or shovel, follow oncoming vehicles.
the spotter or shovel operator signals. The load- 5. Obey all road signs.
ing process may be shortened by following sim-
6. Always dim high beam headlights before
ilar patterns of the trucks that have already
approaching other vehicles in motion.
been loaded.
7. Maintain a safe distance of 15 m (50 ft) when
5. The operator must remain in the truck cab with
following another vehicle. When on a downhill
the engine on during loading. Place the trans-
grade, maintain a distance of 30 m (100 ft).
mission shift lever in NEUTRAL and apply the
brake lock switch. 8. When driving down a grade, maintain a safe
speed ensuring effective retarding.
When descending a known grade with a loaded
truck, adjust the speed of the truck to select the
proper transmission gear range. The truck must
If the operator must leave the truck cab during be maintained within the speeds listed on the
loading, the engine must be shut off and the retarding capacity decal. A version of the decal
parking brake applied. DO NOT use the emer- shown below is located inside the cab on the
gency brake for parking. Remain far enough left front cab post. Use either the retarder con-
away from the truck to avoid being struck by fly- trol lever or the foot-operated brake pedal to
ing material. control the speed of the truck.
6. When the truck is loaded, drive away from the

shovel as quickly as possible, but with extreme
caution.

RETARDER OPERATION If the maximum engine speed of 2100 rpm or the
brake oil temperature of 120C (248F) is about to be
Two lists are provided on the retarding capacity
exceeded, move the transmission shift lever to the
decal. One list is for a continuous rating. The second
next lower range. Adjust the retarder control to
list is for a short-length rating. Both lists are matched
reduce speed and allow the transmission to down-
to the truck at maximum Gross Vehicle Weight
shift into the selected gear range.
(GVW).
Continue this procedure to maintain engine speed at
The continuous numbers on the chart indicate the
2000 - 2100 rpm and brake oil temperature below
combination of speeds and grades the vehicle can
120C (248F). When the proper gear range is
safely negotiate for an unlimited time or distance.
attained, continue to use the retarder as needed to
The short-length numbers listed on the chart indicate maintain a safe speed.
the combination of speeds and grades the vehicle
If brake oil temperature exceeds 120C (248F), the
can safely negotiate for three minutes. These speeds
brake oil temperature warning will turn on. As quickly
are faster than the continuous values, reflecting the
as safety will permit, stop the truck away from traffic.
thermal capacity of various system components.
Move the transmission shift lever to NEUTRAL and
System components can accept heating at a higher-
apply the parking brake. Operate the engine at high
than-continuous rate for a short period of time.
idle.
Beyond this period, the system would become over-
heated. Keep the engine at high idle until the brake oil tem-
perature warning light turns off and brake oil temper-
The short-length rating, sometimes called the "three-
ature cools to below 120C (248F). If the
minute" limit, will successfully accommodate most
temperature does not return to this range within a
downhill hauls. It is necessary to divide the haul road
few minutes, immediately report the condition to
grade segment length by allowable speed to deter-
maintenance personnel. Wait for further instructions
mine actual time on the grade. If actual time on the
before moving the truck.
grade exceeds the allowable amount, travel speed
must be at continuous speed. Ambient temperature,
as well as the temperature of the brake cooling oil
can affect this number. (The brake cooling oil could PASSING
already be above the normal range from recent oper- 1. DO NOT pass another truck on a hill or at a
ating conditions). blind curve!
2. Before passing, ensure the road ahead is clear.
If a disabled truck is blocking your lane, slow
down and pass with extreme caution.
DO NOT exceed the recommended maximum 3. Use only the areas designated for passing.
speeds when descending grades with a loaded
truck.
For efficient retarder operation, adhere to the follow-
ing guidelines:
Maintain engine speed between 2000 - 2100 rpm
When descending a grade, apply the retarder
and observe both the tachometer and the brake
oil temperature gauge. Engine speed must be
maintained at 2000 - 2100 rpm. Brake oil
temperature must be maintained below 120C
(248F).

DUMPING Raising the Dump Body
1. Approach the dump area with extreme caution.
Ensure the area is clear of personnel and
obstructions such as overhead power lines.
Obey spotter signals, if present.
When dumping very large rocks or sticky mate-
Avoid unstable areas. Travel at a safe distance
rial, the material may exit the body too fast. This
from the edge of a dump area. Position the
may cause a violent jolt to the dump body and
truck on a solid, level surface before dumping.
cause possible injury to the operator. Damage to
the hoist cylinders, frame, and the dump body
hinge pins may also result. If it is necessary to
dump this kind of material, refer to the caution in
the following procedure.
As the body raises, the truck center of gravity will
move. The truck must be on a level surface to 4. Move hoist control lever (1, Figure 30-3) to
prevent tipping! POWER UP position (4) and release the lever.
Releasing the hoist lever anywhere in the lever
2. Carefully maneuver the truck into dump posi- stroke when raising will place the dump body in
tion. When backing the truck into dump position, HOLD at that position.
use the foot-operated brake pedal to stop and 5. Raise engine rpm to accelerate the hoist speed.
hold the truck.
Refer to the following caution note.
3. When in the dump position, place the transmis-
sion shift lever in NEUTRAL, and apply the When the body is near the maximum angle,
brake lock switch. reduce engine rpm in order to reduce the shock
load to the hydraulic system and hoist cylinders.
If dumping very large rocks or sticky material as

described in the warning above, slowly acceler-
ate engine rpm and raise the dump body. When
the material starts to move, release the hoist
lever to the HOLD position. If the material does
not continue out of the dump body, repeat this
procedure until the material has been dumped.
6. When the dump body rises to the desired posi-

tion, release the hoist control lever. The lever
will return to the HOLD position.
FIGURE 30-5. HOIST CONTROL
If necessary to raise the body further, move the
1. Hoist Control Lever 3. POWER DOWN Posi- dump lever to POWER UP. The dump body will
2. FLOAT/HOLD Posi- tion rise until the hoist cylinders are fully extended.
tion 4. POWER UP Position
5. Center Console

Lowering The Dump Body SAFE PARKING PROCEDURES
7. After the load clears the body, lower the body to The operator must continue to use safety precau-
the frame by moving the hoist control lever for- tions when parking and turning the engine off.
ward to the DOWN position. The dump body will
start to move downward. Any questionable truck performance must be
checked by maintenance before the truck is used for
8. Releasing the lever during the downstroke will
another shift.
return the lever to the FLOAT position. The
body will then float down under its own weight. 1. Park the truck on level ground when possible,
If dumped material builds up at the body tailgate and away from other vehicles. If parking on a
and the body cannot be lowered, shift the trans- grade, position the truck perpendicular to the
mission shift lever to DRIVE. Release the brake grade.
lock switch, and drive forward to clear the mate- Haul roads are not safe parking areas. In an
rial. Stop, and shift the transmission shift lever emergency, choose the safest spot most visible
to NEUTRAL. Apply the brake lock switch and to other machines in the area.
lower the dump body. See the note below.
2. Apply the parking brake. Verify that the parking
brake is operating properly and is capable of
holding the truck stationary.
DO NOT move the truck with the

dump body raised except in the
event of an emergency. Failure to
lower the dump body before moving Use the parking brake when parking the truck.
the truck may cause damage to the Verify the parking brake is capable of holding the
hoist cylinders, frame and body truck stationary before stopping the engine.
hinge pins. DO NOT use the brake lock to secure the truck
when parking. The brake lock will release when
NOTE: When traveling, always place the hoist hydraulic pressure dissipates after the engine is
control lever in the FLOAT position, regardless of turned off. This may result in truck movement,
whether or not the truck is loaded. damage to surrounding objects, and serious
If the transmission shift lever is moved to any position injury to personnel in the area.
other than NEUTRAL when the hoist control is not in
FLOAT, the central warning lamp will flash and the
3. Install wheel chocks.
alarm buzzer will sound intermittently.
4. If the truck is disabled and near operating
trucks, mark the truck with warning flags in day-
9. With the body on the frame, move the transmis- light, or with flares at night.
sion shift lever to DRIVE. Release the brake
lock switch, and carefully exit the dump area.

TURNING OFF THE ENGINE SUDDEN LOSS OF ENGINE POWER
Follow the sequence below at the end of machine If the engine suddenly stops, stored hydraulic pres-
use. sure in the brake and steering accumulators enables
temporary usage of steering and brake functions.
1. Stop the truck, and reduce engine rpm to low
Because accumulator oil supply is limited, it is impor-
idle. Place the transmission shift lever in NEU-
tant to stop the truck as quickly and safely as possi-
TRAL, and apply the parking brake. Refer to the
ble after the loss of engine power. When pressures
guidelines in Safe Parking Procedures for
drop to a pre-determined level, the low brake pres-
proper instructions when parking the truck.
sure and low steering pressure indicators will illumi-
2. Allow the engine to cool gradually by operating nate and a buzzer will sound. If the brake pressure
at low idle for three to five minutes. continues to decrease, the auto-apply feature will
3. Turn the key switch to the OFF position to stop activate and the service brakes will automatically
the engine. apply to stop the truck.
4. Close and lock all windows. Remove the key Bring the truck to a safe stop as quickly as possible
from the key switch and lock the cab to prevent by using the foot pedal to apply the service brakes. If
possible unauthorized truck operation. possible, steer the truck to the side of the road during
5. Dismount the truck, properly. braking. Apply the parking brake as soon as the truck
comes to a complete stop. Turn the key switch OFF
and notify maintenance personnel, immediately.
If the truck is disabled in a high-traffic area, mark the
truck with warning flags during daylight hours, and
flares at night.
Secondary Steering And Braking

The steering and brake systems each have accumu-
lators that store energy. The accumulators provide
hydraulic power in the event of an unexpected
engine failure or pump failure.
Checking the accumulator nitrogen charge is a
required routine maintenance item. Refer to the shop
manual for proper procedures when charging the
accumulators.
Audible and visual warnings will alert the operator if
accumulator pressures drop below the preset values
during operation.

DISABLED TRUCK DUMPING Hookup
Sometimes it is necessary to dump a load from the Ensure there is an adequate and safe area to dump
body of a disabled truck with an inoperable hoist sys- the loaded dump body.
tem. The following instructions describe the use of a
1. Safely park the good truck as close as possible
"good" truck to provide the hydraulic power required
to the disabled truck. When the good truck is in
to raise the body of a disabled truck to dump the
position next to the disabled truck, turn off the
load.
engine.
Figure 30-4 shows the quick disconnect fittings on a 2. Purge the pressure from the brake accumula-
hoist manifold for connecting the hoist circuits tors, steering accumulators, and hydraulic tanks
between trucks. on each truck.
3. Attach a hose from the power up quick discon-
nect on the good truck to the power down circuit
on the disabled truck. Hoses must be rated to
withstand 19,305 kPa (2800 psi) or greater
pressure.
NOTE: The power down circuit uses a smaller
diameter hose (tube) than the power up circuit.
4. Connect another hose from the power down
quick disconnect on the good truck to the power
up circuit on the disabled truck.
FIGURE 30-6. HOIST CIRCUIT QUICK DISCONNECT FITTINGS

1. Power Down Circuit 2. Power Up Circuit

Raising the Body Lowering the Body
5. Move the hoist control lever on the disabled 9. After the load has been emptied from the body,
truck to the HOLD position. Leave the lever in release the hoist control lever. The body of the
this position during the entire procedure. disabled truck should immediately begin floating
6. Adjust the power down relief setting on the downward.
good truck to the maximum setting. On HD1500 If any residual material left in the body prevents
trucks, the power down relief valve (1, Figure lowering, perform the following:
30- 5) is located on pilot valve (2) inside of the
brake cabinet. Gently, turn the adjustment a. Place the good truck hoist lever in the
screw clockwise until it bottoms out. Count the POWER UP position, and monitor the body
exact number of turns that the adjustment of the disabled truck for downward move-
screw is turned, and note for later adjustment. ment. The body of the good truck may rise a
small amount during this step.
7. Start the engine on the good truck, and adjust
the engine speed to 1000 rpm. b. Once the body of the disabled truck begins
downward, move the hoist control all the way
8. Place the hoist control in the POWER DOWN
forward. Then, release the lever to the
position. Continue to hold in this position until
FLOAT position.
the hoist cylinders reach full extension.
Increase engine speed as necessary. 10. Turn off the engine. Depressurize the brake
accumulators, steering accumulators, and the
hydraulic tanks on each truck.
11. Disconnect the hoses from each truck.
DO NOT move the hoist control from the POWER 12. Readjust the relief valve setting on the good
DOWN position until full extension is reached. truck. Turn the screw counter-clockwise the
DO NOT attempt to move the lever to the HOLD same number of turns as was noted earlier in
position during this procedure. this procedure. The power down relief valve set-
ting on an HD1500 is 10342 kPa (1500 psi).
FIGURE 30-7. POWER DOWN RELIEF VALVE

1. Power Down Relief 2. Hoist Pilot Valve

DISABLED TRUCK STEERING AND
BRAKING 11. If no problems are evident, begin moving the
During towing, it may be necessary to steer and stop machines.
a disabled truck using hydraulic power from the tow
Maintain a travel speed equal to normal human
truck. The following instructions describe the use of a
walking speed. Steer the machine slowly while
"good" truck to provide the hydraulic power required
keeping turns at 1/4 revolution/second or less.
to steer and stop a disabled truck.
NOTE: Use the brakes sparingly when possible.
Figure 30-7 illustrates a typical hookup with another
Each braking application and release on the
HD1500. Figure 30-6 shows the location of the quick
disabled truck transfers oil from the good truck
disconnects on the bleed-down manifold.
to the disabled truck. It may be necessary to
drain oil from the disabled truck if the hydraulic
tank inherits too much oil.
12. When the trucks have reached their destination,
Only install quick disconnects in the instance of apply the parking brake on each truck and shut
a truck failure. During normal truck operation, the the engine off.
fittings must be absent from the manifold, and
13. Depressurize the steering accumulators before
plugs installed.
removing the hoses. Attempt to steer each truck
1. When the good truck is in position in front of the to verify no pressure remains in the system.
disabled truck, turn off the engine, and apply the
parking brake.
2. Purge any pressure from the steering accumu-
lators on each truck. Verify no pressure exists
by attempting to steer each machine.
3. Connect the supply and return hoses to the
quick disconnects on each bleed-down mani-
fold. Route and secure the hoses in a safe man-
ner that will prevent hose damage during
machine movement.
4. Install pressure gauges in the brake supply cir-
cuit on both trucks for verification of proper
brake system pressures after machine start up.
5. Position the retarder lever on the bad truck in
the OFF position. DO NOT use the retarder
lever during machine towing.
6. Turn the disabled truck key switch to the ON
position. This prevents oil transfer between
trucks from the retarder command circuit.
7. Start the good truck, and allow the engine to
idle for a minimum of three minutes.
8. Verify proper brake system pressures on both
trucks. HD1500: 18, 960 kPa (2750 psi).
9. Slowly operate the steering wheel on each truck
to check steering function. Slow movement will
allow any trapped air to bleed out of the system.
10. Check all hydraulic connections for leakage
before machine travel.
FIGURE 30-8. STEERING QUICK DISCONNECTS
1. Bleed-down 2. Supply Port

Manifold 3. Return Port

A3-36
General Safety and Operating Instructions
FIGURE 30-9. GOOD TRUCK / DISABLED TRUCK STEERING AND BRAKING HOOKUP
04/08 A03036
TOWING
3. Determine the primary reason that the truck is
disabled.
a. If the truck is being towed because of engine
failure, certain precautions must be
Prior to towing a truck, many factors must be observed. The loss of hydraulic power due to
carefully considered. Serious personal injury engine failure requires the use of hydraulic
and/or significant property damage may result if power from another source. The tow
important safety practices and procedures are machine or an auxiliary power unit must be
not observed. Use extreme care when towing a used to supply hydraulic power. Hydraulic
disabled truck. power is necessary for dumping, steering
Towing a machine is only advised for short and braking. Hydraulic power is also neces-
distances. For longer distances, the machine sary to release the spring applied parking
must be hauled. brake. Refer to Disabled Truck Dumping and
Disabled Truck Steering and Braking in this
All precautions must be observed to protect chapter for more information on hookup.
the operators in the event of wire rope
breakage. b. If the truck is disabled because of a sus-
pected final drive problem, both right and left
Wire rope capable of towing 77,110 kg
(170,000 lbs) is required for the HD1500. drive axles must be removed before towing.
Refer to Section G, Final Drive, in the shop
An observer must be positioned in a safe manual for more information.
location during towing for signalling the
operators.
Towing speed must not exceed 2 kph (1 mph).
Tow rope angles must not exceed 10.
Observe all precautions outlined in this manual, Extensive secondary damage may occur
as well as local regulations. Refer to the follow- to final drive components and/or the
ing steps when towing is necessary: transmission, if the truck is towed with-
out first removing the drive axles.
Remove damaged components and any
1. Block the disabled truck to prevent movement
debris before moving the truck. Failure to
while preparing the truck for towing and attach-
remove debris or damaged components
ing the wire rope and other connections.
may result in further damage.
2. Verify the towing capacity of the wire rope (it
must be capable of towing 77,110 kg (170,000
lbs)). Verify the rope is in good condition show- c. If the truck is disabled because of a sus-
ing no indications of damage or wear. pected transmission problem, remove the
drive shaft between the transmission and the
differential case. If the drive axles were
removed, it is not necessary to remove the
drive shaft.
4. Use the tow eyes installed under the front
bumper for towing from the front of the disabled
truck. Both tow hooks must be used. Use the
tow pin on the rear axle when pulling the dis-
abled truck from the rear.

5. If the engine on the disabled truck is opera- 8. Remove all blocking, and release the disabled
tional, start the engine before towing to release truck brakes. Begin towing the disabled truck. A
the parking brake, and to enable steering and spotter must signal the operators to stop the
braking. tow if any signs of danger or damage are evi-
6. If the engine is inoperable, hydraulic power for dent.
steering, braking and transmission lubrication
will not be available.
Install the necessary hydraulic connections
between the tow vehicle and the disabled truck
to provide hydraulic power. Refer to Disabled DO NOT exceed 2 kph (1 mph) when towing
Truck Steering and Braking. another truck.
7. If the body of the disabled truck contains a load, Smooth and gradual truck movement is
dump the load before towing. If the engine is not essential during towing. Sudden movement
operational, refer to Disabled Truck Dumping. may cause wire rope failure leading to injury
and/or truck damage.
Minimize the tow angle at all times - Never
exceed 10 in any direction, vertically or
horizontally. The towed truck must be steered
in the direction of the wire rope.
Consult your customer support manager for any
questions or concerns about towing a disabled truck.

WARNINGS AND CAUTIONS
The following pages provide a brief explanation of the warning, caution, and service instruction plates and decals
attached to the truck. The plates and decals listed here are typical of this model. Because of customer options,
individual trucks may have plates and decals that are different from those shown here.
The plates and decals must be kept clean and legible. If any decal or plate is illegible or damaged, it must be
replaced with a new one.
WMC - Character positions 1, 2 and 3 identify the
Worldwide Manufacturer Code (WMC). The WMC
designates the manufacturer of the product. Komatsu
brand products are identified with the letters KMT.
MDS - Character positions 4, 5, 6, 7 and 8 identify

the Machine Descriptor Section (MDS). The MDS
code identifies general information regarding
machine specifications. The MDS is a code for the
machine type and model.
CL - Character position 9 identifies the Check Letter

(CL). The CL is used to verify the accuracy of the
A product identification plate is located on the frame
individual PIN.
in front of the right side front wheel. It shows the truck
model number, maximum Gross Vehicle Weight
(GVW) and Product Identification Number (PIN)
FC - Character positions 10 and 11 identify the Fac-
tory Code (FC). The FC identifies the Komatsu fac-
tory in charge of claims for the product. The FC for
electric drive trucks is 61.
SN - Character positions 12, 13, 14, 15, 16, and 17

identify the Serial Number (SN). The SN is a unique
sequential number.
The PIN consists of 19 total characters. The first and

last characters are tamper preventative symbols (*).
The remaining 17 alpha/numeric characters are used
to identify five characteristics of the machine. The
five characteristics are detailed below.
A04055 Warnings and Cautions A4-1

A warning decal surrounds the key switch. The warn-
ing stresses the importance of reading the operator's
manual before operation.
A grade/speed plate is located on the left front post of

the operator's cab. The decal provides the recom-
mended maximum speeds to be used when
descending various grades with a loaded truck.
Always refer to the decal in the operator's cab. This
decal may change with optional truck equipment.
A plate attached to the right rear corner of the cab

states the Roll-Over Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS) meet
various SAE performance requirements.
DO NOT modify these components. DO NOT

attempt to repair damage without written
When the auxiliary brake switch is activated, full, approval from the manufacturer. Unauthorized
unmodulated brake pressure is applied to all wheels. repairs will void certification.
The parking brake will also be applied.
Never actuate the auxiliary brake when the truck is
moving, except in the event of an emergency.
A plate is located next to the fill cap on the fuel tank

specifying diesel fuel only. Refer to the engine opera-
tion and maintenance manual for more information
on fuel requirements.
A4-2 Warnings and Cautions A04055

Warning plates are attached to the hydraulic tank
and the fuel tank. The decals alert technicians not to
work on the truck with the body raised unless the A plate is mounted on the left hand side of the trans-
body-up retention cable is in position. mission oil pan. The decal provides instructions for
properly checking the transmission oil level. Refer to
Section 40, Lubrication And Service, for more infor-
mation on filling the transmission.
Warning plates are mounted on the truck frame in

front of and to the rear of both front tires. The decal A warning plate is mounted on top of the radiator
alerts all persons to remain at a distance when the surge tank cover near the radiator cap. The engine
truck is being started. cooling system is pressurized when the engine is on
and/or when the system is hot. Turn the engine off
and allow the engine to cool before removing the
radiator cap. Release internal pressure by depress-
ing the pressure relief. Unless the pressure is first
released, removing the radiator cap will result in the
hot coolant being expelled from the radiator. Serious
scalding and burning can result.

A caution decal is attached below the hydraulic tank This danger plate is attached to each suspension
oil level sight gauge. Check the oil level with the body and steering accumulator. These plates warn that the
down, engine stopped, and the key switch OFF. suspension and accumulators are charged with high
Refer to the filling instructions outlined in Section 40, pressure nitrogen. Read the service manual and fol-
Lubrication And Service. Instructions are also out- low safety procedures when performing service on
lined on the following decal. these components.
A warning plate is attached to the frame above the

hydraulic system Auxiliary Power Unit (APU) quick
disconnect fittings. The plate alerts technicians that
high pressure hydraulic oil is present during opera-
A plate on the side of the hydraulic tank provides tion. Use caution when opening the hydraulic sys-
instructions for filling the hydraulic tank. tem. There is always a chance of residual pressure
being present. Loosen fittings slowly to allow pres-
Keep the system open to the atmosphere only as
sure to dissipate before removing any connections.
long as necessary to lessen the chances of system
contamination. Service the tank with clean type C-4
hydraulic oil. All oil being put into the hydraulic tank
must be filtered to 3 microns.
Pressurized operating fluids, such as hydraulic
oil, can have sufficient force to penetrate skin.
Serious injury and death may result if proper
medical treatment from a physician familiar with
this injury is not received immediately.

This plate is located on the battery box and near the
battery disconnect switches to indicate that the bat-
tery system is a negative ground system.
A warning decal is located on the rear compartment

in the operator cab. Use caution when working
around or in this compartment. Electrical potential
These decals are placed above the battery discon- may be present even when the battery disconnect
nect switches on the right side of the front bumper to has been switched to OFF.
indicate OFF and ON positions of the switches.
Attached to the exterior of the battery compartment is

a danger plate. This plate stresses the prevention of A caution plate is located on the side of the battery
sparks near the battery. When another battery or box. These instructions must be followed to avoid
24VDC power source is used for auxiliary power, all damage to electronic components when welding on
switches must be OFF prior to connecting. Maintain the truck.
correct polarity: connect the positive (+) posts
together and then connect the negative (-) lead of the
auxiliary power cable to a good frame ground. Do not
connect to the negative posts of the truck batteries.
Do not connect near the battery box. These precau-
tions minimize the danger of sparks near the batter-
ies.
Sulfuric acid is corrosive, toxic and explosive. Use
safety goggles, rubber gloves and a rubber apron
when working near batteries.
If battery electrolyte is splashed into the eyes or is
ingested, get the proper medical attention, immedi-
ately.

The lubrication chart is located on the LH side of the
radiator. The chart specifies some of the critical
maintenance items to be checked. Component loca-
tion and service intervals are specified on the chart.
The lube key lists the proper lubricants to be used.
Refer to Section 40, Lubrication and Service, for
more information on maintenance items.

STANDARD TABLES
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. Do not use standard values to replace specific torque values in assembly instructions.
For values not shown in any of the charts or tables, standard conversion factors for most commonly used measure-
ments are provided in Tables 1 and 17.
NOTE: Portions of this truck may be assembled with SAE (U.S.) hardware. Ensure the correct table is referenced
when determining the proper torque.
INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page TABLE1. Common Conversion Multipliers
Metric To English
TABLE 1 Common Conversions Multipliers
Metric -to- English . . . . . . . . . A5-1 Multiply
To Convert From To By
TABLE 2 Standard Tightening Torque For
millimeter (mm) inch (in.) 0.0394
Metric Capscrews and Nuts. . . . . . A5-2
centimeter (cm) inch (in.) 0.3937
TABLE 3 Standard Tightening Torque
meter (m) foot (ft) 3.2808
For Split Flange Bolts . . . A5-2
meter (m) yard (yd) 1.0936
TABLE 4 Tightening Torque For Flared kilometer (km) mile (mi) 0.6210
Tube And Hose Fittings . . . . . . . A5-2
square centimeters (cm2) sqare inch (in.2) 0.1550
TABLE 5 Temperature Conversions . . . . . A5-3 2)
square centimeters (cm sqare feet (ft2) 0.001
TABLE 6 Torque Conversions cubic centimeters (cm ) 3
cubic inch (in. ) 3 0.061
kgm to lb ft. . . . . . . . . . . A5-3
liters (l) cubic inch (in. ) 3 61.02
TABLE 7 Torque Conversions 3 3
cubic meters (m ) cubic feet (ft ) 35.314
kgm to Nm . . . . . . . . . . A5-3
liters (l) cubic feet (ft )3 0.0353
TABLE 8 Pressure Conversions
grams (g) ounce (oz) 0.0353
kg/cm2 to psi . . . . . . . . . . . A5-4
milliliter (ml) fluid ounce (fl oz) 0.0338
TABLE 9 Pressure Conversions kilogram (kg) pound (mass) 2.2046
kg/cm2 to kPa . . . . . . . . . . . A5-4 Newton (N) pounds (lbs) 0.2248
TABLE 10 Pressure Conversions Newton meters (Nm) kilogram meters (kgm) 0.102
psi to kPa . . . . . . . . . . . . . A5-4 Newton meters (Nm) foot pounds (lb fts) 0.7376
kilogram meters (Nm) foot pounds (lb ft) 7.2329
For SAE Cap Screws and Nuts . . . . A5-5 kilogram meters (Nm) Newton meters (Nm) 9.807
kilopascals (kPa) pounds/sqare inch (psi) 0.1450
megapascals (MPa) pounds/sqare inch (psi) 145.038
12-Pt, Grade 9, Cap Screws (SAE). . . . A5-5
kilograms/cm2 (kg/cm2) pounds/sqare inch (psi) 14.2231
TABLE 13 JIC 37 Swivel Nuts
Torque Chart (SAE) . . . . . . . . A5-6 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
kilogram (kg) short ton (tn) 0.0011
TABLE 14 Pipe Thread Torque Chart (SAE) . A5-6
metric ton short ton (tn) 1.1023
TABLE 15 O-Ring Boss Torque Chart (SAE) . A5-6 liters (l) quart (qt) 1.0567
TABLE 16 O-Ring Face Seal liters (l) gallon (gal) 0.2642
Torque Chart (SAE) . . . . . . . . . A5-6 Watts (W) horsepower (hp) 0.00134
TABLE 17 Common Conversions Multipliers kilowatts (kW) horsepower (hp) 1.3410

English -to- Metric . . . . . . . . . A5-7
TABLE 18 Sealants And Adhesives. . . . . . . A5-8
A05005 09/04 Standard Tables A5-1

TABLE 2. Standard Tightening Torque For
Metric Hex Head Cap Screws And Nut
Cap Screw Thread Width Kilogram meters Newton meters Foot Pounds
Diameter Across Flat (kgm) (Nm) (lb ft)
(mm) (mm) Tolerances 10% Tolerances 10% Tolerances 10%
6 10 1.35 13.2 10
8 13 3.2 31.4 23
10 17 6.7 65.7 48
12 19 11.5 112 83
14 22 18.0 177 130
16 24 28.5 279 206
18 27 39.0 383 282
20 30 56.0 549 405
22 32 76.0 745 550
24 36 94.5 927 684
27 41 135 1320 975
30 46 175 1720 1266
33 50 225 2210 1630
36 55 280 2750 2025
39 60 335 3280 2420
TABLE 3. Tightening Torque For

Split Flange Bolts
Cap Screw Thread Width Kilogram meters Newton meters Foot Pounds
Diameter Across Flat (kgm) (Nm) (lb ft)
10 14 6.7 65.7 48
12 17 11.5 112 83
16 22 28.5 279 206
TABLE 4. Tightening Torque For

Flared Tube And Hose Fittings
Thread Width Kilogram meters Newton meters Foot Pounds

Diameter of Nut Across Flat (kgm) (Nm) (lb ft)
14 19 2.5 25 18
18 24 5 50 36
22 27 8 80 58
24 32 14 140 101
30 36 18 175 130
33 41 20 195 145
36 46 25 245 180
42 55 30 295 215
A5-2 Standard Tables 09/04 A05005

TABLE 5. Temperature Conversions
Formula: F - 32 1.8 = C or C x 1.8 + 32 = F
Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit
C F C F C F
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 1 30 86
113 235 455 54 130 266 4 25 77
110 230 446 52 125 257 7 20 68
107 225 437 49 120 248 9 15 59
104 220 428 46 115 239 12 10 50
102 215 419 43 110 230 15 5 41
99 210 410 41 105 221 18 0 32
96 205 401 38 100 212 21 5 23
93 200 392 35 95 293 23 10 14
91 195 383 32 90 194 26 15 5
88 190 374 29 85 185 29 20 4
85 185 365 27 80 176 32 25 13
82 180 356 24 75 167 34 30 22
79 175 347 21 70 158 37 35 31
77 170 338 18 65 149 40 40 40
74 165 329 15 60 140 43 45 49
71 160 320 13 55 131 46 50 58
68 155 311 10 50 122 48 55 67
66 150 302 7 45 113 51 60 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C) or Fahrenheit (F). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C) or read to the right to convert to degrees Fahrenheit (F). If
starting with a known temperature (either C or F), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
TABLE 6. Torque Conversions

kilogram meter (kgm) to foot pounds - (lb ft)
1 kgm=7.2339 lb ft
kgm 0 1 2 3 4 5 6 7 8 9
0 (lb ft) 7.23 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.5 303.8 311.0 318.2 325.5 332.7 339.9 347.2 354.4
50 361.6 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
TABLE 7. Torque Conversions

kilogram meter - kgm To Newton meters (Nm)
1 kgm=9.807 Nm
kgm 0 1 2 3 4 5 6 7 8 9
0 (N.m) 9.8 19.6 29.4 39.2 49.0 58.8 68.6 78.5 88.3
10 98.1 107.9 117.7 127.5 137.3 147.1 156.9 166.7 176.5 186.3
20 196.1 205.9 215.8 225.6 235.4 245.2 255.0 264.8 274.6 284.4
30 294.2 304.0 313.8 323.6 333.4 343.2 353.1 362.9 372.7 382.5
40 392.3 402.1 411.9 421.7 431.5 441.3 451.1 460.9 470.7 480.5
50 490.4 500.2 510.0 519.8 529.6 539.4 549.2 559.0 568.8 578.6
60 588.4 598.2 608.0 617.8 627.6 637.5 647.3 657.1 666.9 676.7
70 686.5 696.3 706.1 716.0 725.7 735.5 745.3 755.1 764.9 774.8
80 784.6 794.4 804.2 814.0 823.8 833.6 843.4 853.2 863.0 872.8
90 882.6 892.4 902.2 912.1 921.9 931.7 941.5 951.3 961.1 970.9

TABLE 8. Pressure Conversions
kilograms per square centimeter (kg/cm2) to pounds per sqare inch (psi)
2
1 kg/cm =14.2231 psi
kg/cm2 0 1 2 3 4 5 6 7 8 9
0 (psi) 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 185.0 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.2 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.1 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.0 782.3 796.5 810.7 824.9 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 952.9 967.2 981.4
70 995.6 1009.8 1024.1 1038.3 1052.5 1066.7 1081.0 1095.2 1109.4 1123.6
80 1137.8 1152.1 1166.3 1180.5 1194.7 1209.0 1223.2 1237.4 1251.6 1265.9
90 1280.1 1294.3 1308.5 1322.7 1337.0 1351.2 1365.4 1379.6 1393.9 1408.1

2
kilograms per square centimeter (kg/cm ) to kilopascals (kPa)
2
1 kgcm =98.068 kPa
2 0 1 2 3 4 5 6 7 8 9
kg/cm
0 (kPa) 98 196 294 392 490 588 686 785 883
10 981 1079 1177 1275 1373 1471 1569 1667 1765 1863
20 1961 2059 2157 2256 2354 2452 2550 2648 2746 2844
30 2942 3040 3138 3236 3334 3432 3530 3629 3727 3825
40 3923 4021 4119 4217 4315 4413 4511 4609 4707 4805
50 4903 5001 5100 5198 5296 5394 5492 5590 5688 5786
60 5884 5982 6080 6178 6276 6374 6472 6571 6669 6767
70 6865 6963 7061 7159 7257 7355 7453 7551 7649 7747
80 7845 7944 8042 8140 8238 8336 8434 8532 8630 8728
90 8826 8924 9022 9120 9218 9316 9415 9513 9611 9709

pounds per sqare inch (psi) to kilopascals (kPa)
Formula: psi x 6.895 = kPa
0 1 2 3 4 5 6 7 8 9
psi
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
NOTE: Tables such as Table 6, 7, 8, 9 and 10 may be used as in the following example:
Example: Convert 955 kgm to foot pounds (lb ft). 950 kgm = 6871 lb ft
1. Select Table 6. 4. Go to kgm row 0, column 5; reads 49.0
5 kgm = 49 lb ft Add to step 3.
2. Go to kgm row 90, column 5; reads 687.1
95 kgm = 687.1 lb ft 5. 950 + 5 kgm = 6871 + 49 = 6920 lb ft
955 kgm = 6920 lb ft
3. Multiply by 10:

TABLE 11
Standar Torque Chart
SAE Hex Head Cap Screw And Nut Assembly
(Lubricated Threads)
Tolerances 10%
Cap Torque - Torque - Cap Torque - Torque -
Screw Grade 5 Grade 8 Screw Grade 5 Grade 8
Thread Thread
Size lb ft kgm Nm lb ft kgm Nm Size lb ft kgm Nm lb ft kgm Nm
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 lb ft = 0.138 Nm = 1.356 N.m
TABLE 12 - Standard Tightening Torque

TABLE 12 - Standard Tightening Torques For 12- for 12-Point, Grade 9 Cap Screws
Point, Grade 9, Cap Screws (SAE)
Torque Torque Torque
The following specifications apply to required assem- Cap Screw Size* lb ft Nm kgm
bly torques for all 12-Point, grade 9 (170,000 psi min- 0.250 - 20 12 16 1.7
imum tensile), cap screws. 0.312 - 18 24 33 3.3
Cap screw threads and seats shall be lubricated 0.375 - 16 42 57 5.8
when assembled. 0.438 -14 70 95 9.7
Unless instructions specifically recommend 0.500 -13 105 142 14.5
otherwise, these standard torque values are to be 0.562 - 12 150 203 20.7
used with simple lithium base chassis grease (multi-
0.625 - 11 205 278 28.3
purpose EP NLGI) or a rust- preventive grease (see
list, this page) on the threads. 0.750 - 10 360 488 49.7
0.875 - 9 575 780 79.4
Torques are calculated to give a clamping force
of approximately 75% of proof load. 1.000 - 8 860 1166 119
The maximum torque tolerance shall be 10% of 1.000 - 12 915 1240 126
the torque value shown. 1.125 - 7 1230 1670 170
1.125 - 12 1330 1800 184
1.250 - 7 1715 2325 237
1.250 - 12 1840 2495 254
1.375 - 6 2270 3080 313
1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
1.500 - 12 3225 4375 445
* Shank Diameter (in.) - Threads per inch

TABLE 13. TABLE 15.
Torque Chart For JIC 37 Swivel NutS Torque Chart For
With Or Without O-ring Seals O-ring Boss Fittings
Size Tube Size Threads Torque Size Tube Size Threads Torque
Code (OD) UNF-2B lb ft Code (OD) UNF-2B lb ft
2 0.125 0.312 24 4 1 2 0.125 0.312 24 4 2
3 0.188 0.375 24 8 3 3 0.188 0.375 24 5 2
4 0.250 0.438 20 12 3 4 0.250 0.438 20 8 3
5 0.312 0.500 20 15 3 5 0.312 0.500 20 10 3
6 0.375 0.562 18 18 5 6 0.375 0.562 18 13 3
8 0.500 0.750 16 30 5 8 0.500 0.750 16 24 5
10 0.625 0.875 14 40 5 10 0.625 0.875 14 32 5
12 0.750 1.062 12 55 5 12 0.750 1.062 12 48 5
14 0.875 1.188 12 65 5 14 0.875 1.188 12 54 5
16 1.000 1.312 12 80 5 16 1.000 1.312 12 72 5
20 1.250 1.625 12 100 10 20 1.250 1.625 12 80 5
24 1.500 1.875 12 120 10 24 1.500 1.875 12 80 5
32 2.000 2.500 12 230 20 32 2.000 2.500 12 96 10
TABLE 14 TABLE 16
Torque Chart For Torque Chart For
Pipe Thread Fittings O-ring Face Seal Fittings
With Without Size Tube Size Threads Torque

Size Pipe Thread Sealant Sealant CodeE (O.D.) UNF-2B lb ft
Code Size lb ft lb ft 4 0.250 0.438 20 11 1
2 0.125 27 15 3 20 5 6 0.375 0.562 18 18 2
4 0.250 18 20 5 25 5 8 0.500 0.750 16 35 4
6 0.375 18 25 5 35 5 10 0.625 0.875 14 51 5
8 0.500 14 35 5 45 5 12 0.750 1.062 12 71 7
12 0.750 14 45 5 55 5 16 1.000 1.312 12 98 6
16 1.000 11.50 55 5 65 5 20 1.250 1.625 12 132 7
20 1.250 11.50 70 5 80 5 24 1.500 1.875 12 165 15
24 1.500 11.50 80 5 95 10
32 2.000 11.50 95 10 120 10

TABLE 17 - Common Conversion Multipliers
English to Metric
To Convert To Multiply
From By
inch (in.) millimeter (mm) 25.40
inch (in.) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61
sqare inch (in. )2

sqare centimeters (cm )2 6.45
sqare feet (ft2) sqare centimeters (cm2) 929
cubic inches (in.3) cubic centimeters (cm3) 16.39
cubic inches (in.3) liters (l) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft.3) liters (l) 28.3
ounce (oz) kilogram (kg) 0.028

fluid ounce (fl oz) milliliter (ml) 29.573
pound (lbs) kilogram (kg) 0.454
pound (lbs) Newton (N) 4.448
inch pounds (lb in.) Newton meters (Nm) 0.113
foot pounds (lb ft) Newton meters (Nm) 1.356
foot pounds (lb ft) kilogram meters (kgm) 0.138
kilogram meters (kgm) Newton meters (Nm) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
pounds/square inch (psi) kilograms/sqare centimeter 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (l) 0.946
gallon (gal) liters (l) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745

TABLE 18. Sealants And Adhesives
Nomenclature Code Three Bond * Applications
LT-1A TB1521 Used to apply rubber pads, rubber gaskets and cork plugs.
LT-1B 1000B - 1000W Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
seal is needed.
LT-2 TB1374 Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-2A TB2411 Preventing bolts, nuts and plugs from loosening and leaking oil. (1)
Adhesives
LT-2B TB2403 Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
LT-2C TB2430 or Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
TB2440
LT-3 Main bond TB2001 Provides an airtight, electrically insulating seal. Used for aluminum surfaces.
Hardening agent
TB2105
LG-1 TB1108B Used with gaskets and packings to increase sealing effect.
LG-3 TB1107 Heat-resistant gasket for precombustion chambers and exhaust piping.
Liquid Gasket LG-4 TB1104 Used by itself on mounting surfaces on the final drive and transmission cases.
Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)
LG-5 TB1110 Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
tings in hydraulic circuits of less than 50 mm (2 in) in diameter.
Anti-friction LM-P - Applied to bearings and taper shafts to facilitate press-fitting and to prevent stick-
compound ing, burning or rusting.
Grease G2-LI - Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Vaseline - - Used for protecting battery electrode terminals from corrosion.
* NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations.
(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of
1965 kPa (285 psi) or less.
(2) Used for threaded areas (for example, stud, etc.) which are not removable, and a pressure of 1965 kPa
(285 psi) or less.
The sealants and adhesives listed below are manufactured

and sold by Three Bond U.S.A., Inc. For information concern- Part Numbers
ing Three Bond products, call or write to: Three Bond Komatsu
Three Bond U.S.A., Inc. TB1374 09940-00030

6184 Schumacher Park Drive TB1521 790-129-9030
West Chester, OH 45069 TB1104 790-129-9020
Telephone: (513) 779-7300 TB1108B 790-129-9010

Fax: (513) 779-7375

SECTION A7
STORAGE PROCEDURES
INDEX
STORAGE AND IDLE MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
SHORT TERM IDLE PERIODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
PREPARATION FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
REMOVAL FROM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-4
RECONDITIONING AN IDLE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-9
AFTER THE ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-9
SHORT TERM ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10
Preparing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10
Removing the Engine from Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
TRANSMISSION PRESERVATION AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Storage, New Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Storage, One Year- Without Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Storage, One Year - With Oil - Normally Installed On The Truck . . . . . . . . . . . . . . . . . . . . . . A7-13
Restoring The Transmission For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13
A07005 Storage Procedures A7-1

NOTES
A7-2 Storage Procedures A07005

STORAGE AND IDLE MACHINE PREPARATION
There may be times when it is necessary for a 3. Operate all hydraulic functions through their
machine to be idle for extended periods. Properly complete range of motion to ensure that cylin-
prepared, a stored machine may promptly and safely ders and all seals are fully lubricated.
be returned to operational service. Improper prepara- 4. Check and operate all systems.
tion can make the job of getting the vehicle back to
5. Maintain proper battery service.
operating status difficult.
6. Once a month, perform the 10 hour service
The following information outlines the essential steps items shown in Section P, Lubrication and Ser-
for preparing a unit for extended storage. Also listed vice.
are the necessary steps to bring it back to opera-
tional status. Additional information is given to help
restore those machines which were not properly pre-
pared for storage. PREPARATION FOR STORAGE
Much of this material is of a general nature. The stor- For long term idle periods, proper preparation will
age environment will play a big part in its overall con- pay large dividends in time and money when future
dition. Hot, humid climate will affect vehicle operation of the vehicle is scheduled.
components much differently than the dry desert
atmosphere or a cold arctic environment. Storage
1. Prepare the engine for storage according to
procedures must match the environmental condi-
instructions found in the engine manufacturers
tions.
manual.
These instructions only provide the minimum guide- 2. Prepare the transmission for storage. Refer to
lines. The final goal must be to provide the operator the instructions for storing a transmission later
with a safe, fully productive vehicle, that he can rely in this chapter.
on.
3. Repair all broken or improperly functioning
equipment.
4. Coat all exposed, machined or unpainted sur-
SHORT TERM IDLE PERIODS faces with a good rust preventative grease.
There will be periods when a vehicle may be idle Paint must be in good condition with no rust or
from 30-60 days, but must be ready for use at all corrosion.
times. 5. Park the vehicle in its storage location. Retract
The most effective method for this situation is to fol- all hydraulic cylinders, including the suspen-
low the procedure given below to prevent any deteri- sions, as much as possible. Center the steering
oration from beginning. cylinders. Wipe the exposed portion of all cylin-
der rods clean. Coat exposed rods and seals
1. Fully service and maintain the vehicle with a good preservative grease.
2. On a weekly basis, start and operate the engine 6. If long term storage is anticipated, block the
until both the engine and transmission are up to vehicle to remove the vehicle weight from the
operating temperature. Perform a visual check tires. Lower tire pressure to 103-172 kPa (15-25
of the vehicle before and after start-up. Move psi). Cover the tires with tarpaulins to minimize
the vehicle around the area for a few minutes to rubber oxidation and deterioration.
ensure that all internal gears and bearings are
freshly lubricated.

16. Close cab windows. Close and lock the cab
7. Clean the radiator. Refer to Section C, Cooling door to prevent vandalism and weather intru-
System, for proper cleaning instructions. sion.
Drain and flush the cooling system. Refill with 17. Drain the fuel tank. Fog the tank with preserva-
the proper water/antifreeze solution suitable for tive lubricant, ("Nox-Rust" Motorstor, SAE10)
the lowest temperature anticipated. Refer to and closed tightly. Replace fuel filters.
Section P, Lubrication and Service for anti- 18. Open the drain holes in the dump body.
freeze recommendations.
19. If possible, place all available service publica-
After refilling the system, operate the engine tions in a moisture proof package and place in
until the thermostats open to circulate the solu- the vehicle cab.
tion through the cooling system.
REMOVAL FROM STORAGE

If the vehicle was properly stored, getting it back to
operational status is a simple matter of reversing
Never store a vehicle with a dry cooling system. these steps.
NOTE: Before restoring a vehicle to operation, obtain
8. Install new hydraulic filters. all service and parts books for reference.
9. Service the hydraulic tank with type C-4 oil as 1. Inspect the entire vehicle carefully for rust and
specified in Section P, Lubrication and Service. corrosion. Repair as necessary.
10. Disconnect the batteries, if possible. Store bat- 2. Service the engine according to the engine
teries in a battery shop or a cool dry location. manufacturer's manual.
Clean the battery compartment. Remove all 3. Clean the radiator. Refer to Section C, Cooling
corrosion and paint the battery compartment System.
with acid-proof paint.
Drain and flush the cooling system. Refill with
11. Service wheel axle housings and final drives the proper water/antifreeze solution suitable for
with the recommended lubricants. Seal all the lowest temperature anticipated. Refer to
vents. Section P, Lubrication and Service for anti-
12. Tightly cover exhaust openings and air cleaners freeze recommendations.
with moisture barrier paper and sealing tape. After refilling the system, operate the engine
13. Grease all lubrication points with the recom- until the thermostats open to circulate the solu-
mended lubricants. tion through the cooling system.
4. Prepare the transmission for operation. Refer to
14. Relieve the tension from all drive belts. The
the instructions for transmission storage at the
engine manufacturer recommends insertion of
end of this chapter.
heavy kraft paper between belts and pulleys to
prevent sticking. 5. Thoroughly inspect drive belts, hydraulic hoses
and oil lines for evidence of damage, wear or
15. Put vandalism covers and locks in place and deterioration. Replace any worn components.
secure.

6. Install new hydraulic filters. 17. Adjust all drive belts to the specified tension.
7. Service the hydraulic tank with type C-4 oil as 18. Recharge fire protection equipment.
specified in Section P, Lubrication and Service.
19. Use the Operation and Maintenance Manual for
8. Open the drain on the fuel tank to remove mois- guidance on engine start and vehicle checkout.
ture or sediment that may have accumulated
while in storage. Close the drain and fill the fuel 20. Thoroughly check piping connections for leak-
tank with approved diesel fuel. age with the engine on.
21. Before moving the vehicle, cycle all hydraulic
controls including the steering wheel. Verify
proper operation.
22. Verify proper operation of the service brakes,
emergency braking system and parking brake.
Never blend gasoline, gasohol and/or alcohol
with diesel fuel. This practice creates an extreme 23. Check all system instruments to ensure that all
fire hazard and under certain conditions may systems are operational.
cause an explosion. 24. When all systems are operational and all dis-
crepancies are corrected, road test the vehicle
9. Ensure all hydraulic controls, steering linkage, on a smooth, level, unobstructed area. Check
and throttle linkage points are lubricated and steering response, transmission shifting, ser-
operate freely before engine start-up. vice brake efficiency, and hydraulic functions.
10. Clean all electrical connections and tighten. 25. If the vehicle is operating properly, the truck
Check the secureness of all ground straps and may be returned to service.
cables.
11. Install fully charged batteries. The battery com-
partment must be free of corrosion. Clean the
connections, then connect the battery cables.
Secure the batteries with the hold downs.
12. Check all electrical cables for weathering,
cracks and/or damage. Replace any defective
cables.
13. Check the tires for damage. Repair as neces-
sary.
14. Inflate the tires to the proper pressure.
15. If disconnected, reconnect the parking brake
linkage.
16. Completely service the vehicle as recom-
mended in Section P, Lubrication and Service,
10 and 100 hour inspections.

RECONDITIONING AN IDLE VEHICLE 3. Thoroughly inspect the tires for tread and side
wall wear, weathering, and damage.
Dismount suspect tires. Thoroughly inspect the
inside and outside of the tire before inflating.
Never attempt to operate a vehicle which has

been in storage for a long period until all systems
have been completely reconditioned. An unsafe
vehicle can cause serious injuries and/or major DO NOT disassemble an inflated tire. Slowly
property damage. remove the valve core. Allow pressure to dissi-
pate before attempting to remove the lockring.
At times, a vehicle is subjected to long idle periods Wear eye protection during tire deflation to pro-
without being properly serviced for storage. Recondi- tect against foreign objects being projected into
tioning of this vehicle can present a major expendi- the eyes.
ture of time and money.
Some of the conditions which might be encountered Do not mix rim parts of different rim manufactur-
after a machine has been exposed to the elements ers. Rim parts may resemble those of a different
for a long period may include: manufacturer, but the required tolerances may be
wrong. Use of mismatched rim parts is hazard-
Increased corrosion and fungus growth on ous.
electrical components in humid/tropical areas.
Accelerated rust formation in humid climates.
Increased sand and dust infiltration in windy, dry If tires are dismounted, all wheel components
dusty areas. These conditions can be similar to must be cleaned and inspected. Remove rust
sand blasting effects. and corrosion and repaint as necessary. Follow
the safety rules when mounting and inflating
Deterioration of rubber products in extreme cold tires.
areas. Cables, hoses, O-rings, seals and tires
may become weathered and brittle. Mount and inflate tires as detailed in Section G,
Animal or bird's nests in unsealed openings. Tires and Rims.
4. Inspect the service brakes.
1. Remove all trash and thoroughly clean the vehi-

cle before inspection and maintenance.
2. Remove the vehicle batteries. Move the batter-
ies to a battery shop for service and charging. Before disabling the brake circuit, chock the
wheels to prevent possible movement of the
vehicle.
The use of vapor degreasing or steam cleaning is

not recommended for the brake assemblies and
its component parts. Corrosion and rust may
result.

a. Clean all brake lines and connections. These f. Check and tighten the engine fan drive belt.
components must be free of rust and corro- Install a new belt if necessary.
sion.
b. Treadle valves must operate smoothly and
show no internal or external damage or con-
tamination. Leakage limitations are outlined
in Section J, Brake System.
c. The parking brake actuator must cycle To prevent injuries, always release spring ten-
smoothly when actuated by the parking sion before replacing the fan belt.
brake valve.
5. Inspect and service the engine. Refer to the
g. Check and tighten the engine mounts.
engine manual for instructions.
a. If water entry in the intake is suspected, dis-
connect the inlets at the turbochargers. 6. Inspect and service the transmission. Refer to
Check for water intrusion and damage. Section P, Lubrication and Service, for informa-
tion on oil and filter service.
b. Ensure the exhaust system is clear and
clean with no foreign materials. a. Check all transmission electrical connections
for corrosion, cleanliness and tightness.
c. Replace fuel filters. Fill filter cans with fresh Check electrical cables for damage and
fuel for engine priming. proper clamping.
d. Replace both the primary and safety filter b. Check drive lines for worn U-joints and
(secondary) elements in the air cleaners. proper hardware torque.
Refer to Section C, Air Filtration System.
Inspect all intake lines between the air clean- c. Check the condition of the transmission
ers and the engine. All clamps must be tight. mounts.
7. If fuel was left in the fuel tank, it must be
Inspect the tubes in the precleaner section of
removed. DO NOT attempt to use old diesel
the air cleaner assembly as specified in Sec-
fuel.
tion C. All tubes must be clear and clean. If
clogging is evident, the precleaner must be a. With the tank empty, remove the inspection
cleaned. Clean the precleaner according to plates and thoroughly check the interior of
instructions in Section C. the tank. Clean if necessary to remove sedi-
ment and contamination. If the fuel was con-
e. Drain and flush the cooling system. Check all
taminated, remove the lines and flush with
hoses and connections. Fill the cooling sys-
air.
tem with the proper blend of coolant. Refer to
Section P, Lubrication and Service, for anti- b. Check all fuel lines for deterioration or dam-
freeze recommendations. Radiator cores age. Replace lines as necessary.
must be clear of dirt and trash. c. Replace inspection covers, and install new
gaskets.
d. Fill the tank with specified diesel fuel.
e. Replace the fuel filters.

8. Drain the hydraulic tank. If oil is not contami- 11. Lubricate all grease fittings, not part of the auto-
nated and is stored in clean containers, it may matic lubrication system, with the specified
be reused. Before reuse, the oil must be filtered lubricants. All pivot points must be free of any
through filter elements with a 3-micron rating. binding.
Do not attempt to use contaminated hydraulic 12. Check the alternator for corrosion or deteriora-
oil, especially if water is present in the oil. tion. The alternator rotor must be free, with no
Refer to Section P, Lubrication and Service, for binding or roughness. Inspect, install and prop-
proper oil specifications. erly tension the alternator drive belt.
a. Replace hydraulic filter elements and clean 13. Check the secureness of the steering cylinder
suction strainer elements. While suction ball joints, link, and hydraulic connections.
strainers are removed, inspect and clean the 14. Examine the suspensions for signs of damage.
interior of the tank thoroughly to remove all
sediment and foreign material. a. Discharge the nitrogen from the suspensions
as outlined in Section H, Oiling and Charg-
b. Inspect all hydraulic lines for deterioration or ing. Check the condition of the suspension
damage. Replace any suspect lines. oil and the cylinder wiper seals. If the wipers
c. Check all hydraulic pumps, valves and cylin- are cracked or hardened, the suspension
ders for damage and corrosion. Secure all must be rebuilt. Recharge the suspension
mountings and connections. Control valves with new oil if the old oil is deteriorated.
in the cab must move freely without binding. b. Check the exposed chrome portions of the
d. Check exposed portions of all hydraulic cyl- cylinder for rust, pitting and corrosion. If the
inders for rust, pitting and corrosion. If plat- plating is deteriorated, the suspension must
ing is deteriorated, the cylinder must be be removed and overhauled or replaced. Pit-
removed and overhauled or replaced. Pitted ted or scored plating will rapidly cause leak-
or scored plating will cause leakage at the age at the seals.
cylinder seals. c. Recharge the suspensions as outlined in
9. Check the front wheel hub, final drive and rear Section H, Oiling and Charging.
axle lubricants. If contamination is suspected,
15. If not previously done, install fully charged bat-
drain the oil and service the component with the
teries into the battery box.
proper lubricant. If major contamination is
present, disassembly and overhaul is neces-
sary.
10. Inspect the parking brake. Since the parking
brake is spring-applied, the brake pads may be
stuck tightly to the disc. It may be necessary to
remove and overhaul the parking brake assem-
bly.

ENGINE OPERATION AFTER THE ENGINE HAS STARTED
Ensure all tools and loose equipment have been

removed prior to engine start-up. Sound the horn Any machine which is unsafe and/or not in top
prior to engine starting. Ensure the emergency operating condition must be repaired before use.
shut off switch is reset. Never start the engine in
a building unless the doors and windows are
open and ventilation is adequate. 1. Become thoroughly familiar with steering and
emergency controls. Test the steering in
After reconditioning the vehicle, a static check of the extreme right and left directions. If the steering
engine and various system checks must be per- system is not operating properly, shut the
formed before machine usage. engine off, immediately. Determine the steering
1. Ensure all personnel are clear of the machine system problem and repair before resuming
before starting the engine. Sound the horn as a operation.
warning before starting the engine. 2. Operate each of the brake circuits at least twice
prior to machine usage. These circuits include
2. Turn the key switch ON. The warning lights for
individual activation of the service brake and
low brake pressure and steering pressure
parking brake from the operator's cab.
should illuminate and the horn should sound. If
the horn does not sound, repair the circuit. Activate each circuit individually with the engine
3. Start the engine, and watch the engine oil pres- on and with the hydraulic circuit fully charged.
sure gauge. If pressure does not rise on the If brake circuit operation is sluggish or disabled,
gauge within 10 - 15 seconds, shut off the shut the engine off and notify maintenance per-
engine and repair the problem. sonnel. Do not operate the machine until the
4. While the engine is warming up, check the brake circuit in question is fully operational.
engine and related components for leakage. 3. Check gauges, warning lights and instruments
Check the hydraulic pump for leakage as well before moving the machine. Ensure the braking
as all hydraulic lines. and steering circuit warning lights are function-
5. Listen for abnormal engine noises. ing properly. If a warning light is illuminated,
6. Check the transmission and transmission piping shut off the engine immediately. Determine the
for leakage. If leakage is evident, shut off the cause and repair.
engine and repair before continuing the check- 4. Cycle the hoist controls and steering several
out. Listen for unusual sounds which may indi- times to remove trapped air. Steer in both direc-
cate component failure. tions to verify steering response, smoothness
7. When the engine reaches normal operating and reliability. Check seals and hoses for leaks.
temperature, check operation of the throttle cir-
cuit. Acceleration should be smooth. Watch the
gauges closely for any abnormal activity.
Proper temperatures and pressures are shown
in the engine manual.

5. After all discrepancies have been corrected, the SHORT TERM ENGINE STORAGE
vehicle is ready for a road test. This test must
This procedure describes the proper method for the
be performed by a capable and experienced
short term storage of an engine - one to six months.
operator. Road test in a large, open area where
plenty of maneuvering room is available. Road
test checks include:
Preparing the Engine
Repeated braking efficiency tests at
progressively higher speeds. Start at slow 1. Operate the engine at high idle until the coolant
speeds. Don't take chances with higher temperature reaches 70 C (160 F).
speeds until the machine has been 2. Turn the engine off.
determined to be completely safe.
3. Disconnect the fuel lines to the engine fuel filter.
Progressive upshifting and downshifting Disconnect the injector return line.
through all speed ranges to ensure proper
4. Use a preservative oil. Use Dauber T Chemical
transmission shifting and synchronization.
NoxRust No. 518, or equivalent. The oil must
meet Military Specification MIL-L-644, Type P-
6. After all tests have been performed and the 9.
vehicle is ready for use, perform a final visual 5. Fill two containers, one with diesel fuel, and the
check. second with preservative oil. Put both fuel lines
7. Check lubricant service items as outlined in in the container of diesel fuel.
Section P, Lubrication and Service. 6. Start the engine.
7. After the engine is operating smoothly, transfer
the fuel supply line to the container of preserva-
tive oil. Operate the engine until the preserva-
tive oil flows out of the injector return line.
8. Turn the engine off. Connect the fuel lines to
the fuel filter and the injector return line.
9. Drain the oil pan sump, oil filters, and fuel filters.
10. Install the drain plugs in the oil sump. The sump
can remain empty until the engine is ready to be
returned to service.
Put a warning tag on the engine. The tag must

indicate the following:
The engine does not contain oil.
DO NOT operate the engine.
11. Disconnect the electrical wiring from the fuel

pump solenoid.

12. Turn the fuel pump manual shutoff valve coun- LONG TERM ENGINE STORAGE
terclockwise until it stops.
This procedure describes the proper method for the
13. Crank the engine slowly. Spray lubricating oil long term storage of an engine - 6 to 24 months.
into the intake manifold and the inlet of the air
compressor.
14. Cover all of the openings with tape to prevent Prepare the Engine for Long Term Storage
dirt and moisture from entering the engine.
1. Operate the engine at high idle until the coolant
15. Drain the coolant. temperature reaches 70 C (160 F).
NOTE: It is not necessary to drain the coolant if it is a 2. Turn the engine off.
permanent type antifreeze with a rust inhibitor. 3. Drain the oil and install the drain plugs.
16. Store the engine in an area that is dry and has a Fill the engine to the "high" mark. Use Shell
constant, even temperature. 66202 or equivalent, preservative oil. The oil
17. Use a bar to turn the crankshaft two or three must meet Military Specification MIL-L-21260,
revolutions every three to four weeks. Type P-10, Grade 2, SAE 30.
4. Disconnect the fuel lines to the engine fuel filter
and the injector return line.
Removing the Engine from Short Term Storage 5. Use Daubert Chemical NoxRust No. 518, or an
equivalent preservative oil. The oil must meet
1. Prime the lubricating system. Refer to Cummins
Military Specification MIL- L- 644 Type P9.
Engine Shop Manual, Section 14-01, Engine
Run-in-Period. 6. Fill two containers, one with diesel fuel, the sec-
ond with preservative oil. Put both fuel lines in
2. Fill the coolant system if necessary.
the container of diesel fuel.
3. Adjust the injector and the valve clearance.
7. Start the engine.
Refer to Cummins Engine Shop Manual, Sec-
tion 00-02, Engine Assembly. 8. After the engine is operating smoothly, transfer
the fuel supply line to the container of preserva-
4. Tighten the intake manifold mounting cap
tive oil. Operate the engine until the preserva-
screws to the specified torques. Refer to the
tive oil flows out of the injector return line.
Cummins service manual for specifications.
9. Turn the engine off. Connect the fuel lines to
5. Fill the oil pan sump, oil filters, and fuel filters
the fuel filter and the injector return.
with the recommended lubricants and fuels.
10. Drain the preservative oil from the engine oil
pan sump and the oil filters.
11. Remove the intake and exhaust manifolds.
Spray preservative oil into the intake and
exhaust ports in the cylinder heads and in the
manifolds.
12. Use a rust preventative compound that meets
Military Specification MIL-C-16173C, Type P-2,
Grade 1 or 2. Brush or spray the compound on
all of the exposed surfaces that are not painted.

13. Remove the rocker lever covers. Spray the TRANSMISSION PRESERVATION AND
rocker levers, the valve stems, the springs, the STORAGE
valve guides, the crossheads, and the push
rods with preservative oil. Install the covers. Storage, New Transmission
14. Cover all the openings with heavy paper and Prior to installation- New transmissions are tested
tape to prevent dirt and moisture from entering with preservative oil and drained prior to shipment.
the engine. The residual oil in the transmission provides ade-
quate protection to safely store the transmission for
up to one year - stored inside, in a normal climate
and with all shipping plugs installed - without further
treatment.
When the transmission is to be stored or remain
Place a warning tag on the engine. The tag must inactive for more than one year, specific preservation
indicate the following: guidelines are recommended. These guidelines help
DO NOT operate the engine. prevent damage due to rust, corrosion, and organic
DO NOT turn the crankshaft. growth in the oil. Preservation guidelines are listed
The engine has been treated with for storage with transmission oil and without trans-
preservatives. mission oil.
The coolant has been removed.
The date of treatment.
Storage, One Year- Without Oil
15. Store the engine in an area that is dry and has a 1. Drain the oil.
constant, even temperature. 2. Spray 60 ml (2 oz) of VCI #10 through the fill
tube.
3. Seal all openings and the breather with mois-
Removing the Engine from Long Term Storage ture-proof tape.
1. Use clean diesel fuel. Flush the fuel system 4. Coat all exposed, unpainted surfaces with pre-
until all of the preservative oil is removed. servative grease such as petroleum - MIL-C-
11796, Class 2.
2. Remove the plug from the main oil rifle pas-
sage. Use a hot, lightweight mineral oil. Using a 5. If additional storage time is required, repeat
bar to rotate the engine crankshaft, flush the Steps 2, 3 and 4 at yearly intervals.
preservative oil from the engine. Rotate three to
four revolutions during the flushing procedure.
3. Fill the oil pan sump, oil filters, and fuel filters.
4. Drain the rust preventative compound from the
cooling system. Fill the cooling system with
coolant. Refer to Section P, Lubrication and
Service.
5. Prime the lubricating system. Refer to Cummins
Engine Shop Manual, Section 14-01, Engine
Run-in-Period.
6. Adjust the injector and the valve clearance.
Refer to Cummins Engine Shop Manual, Sec-
tion 00-02, Engine Assembly.
7. Tighten the intake manifold mounting cap
screws.

Storage, One Year - With Oil - Normally Installed Restoring The Transmission For Service
On The Truck 1. Remove the tape from the openings and the
1. Drain the oil and replace the oil filter elements. breather.
2. Fill the transmission to operating level. Fill with 2. Wash off all external grease with mineral spirits.
a mixture of one part VCI #10 (or equivalent) to 3. If the transmission is new, drain the residual
30 parts C-3 transmission fluid. Add 1/4 tea- preservative oil. Refill the transmission to the
spoon of Biobor JF (or equivalent) for every 11 proper level with C-4 transmission fluid.
liters (3 gal) of fluid in the system.
If the transmission was prepared for storage
NOTE: When calculating the amount of Biobor JF without oil, drain the residual oil and replace the
required, use the total volume of the system, not just oil filter elements. Refill the transmission to the
the quantity required to fill the transmission. Include proper level with C-4 transmission fluid.
external lines, filters, and the cooler.
If the transmission was prepared for storage
3. Operate the engine for approximately five min-
with oil, it is not necessary to drain the oil.
utes at 1500 rpm with the transmission in N.
Check the fluid level. Add or drain transmission
4. Drive the vehicle. Verify that the transmission fluid as required to obtain the proper level.
shifts through all ranges and the lockup clutch is
working.
5. Continue to operate the engine at 1500 rpm
with the transmission in N until the transmission
oil temperature stabilizes.
6. If the operating temperature is less than 107 C
(225 F), shift the transmission to the highest
forward range and stall the converter. When the
converter-out temperature reaches 107 C
(225 F), stop the engine. DO NOT exceed 107
C (225 F).
7. As soon as the transmission is cool enough to
touch, seal all openings and the breather with
moisture-proof tape.
8. Coat all exposed, unpainted surfaces with pre-
servative grease such as petrolatum MIL-C-
11796, Class 2.
9. If additional storage time is required, repeat
Steps 2 through 8 at yearly intervals.
NOTE: It is not necessary to drain the transmission
each year. It is only necessary to add Motorstor and
Biobor Jf (or equivalents).

NOTES

SECTION B
STRUCTURES
INDEX
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
DUMP BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
B01019 Index B1-1

NOTES
B1-2 Index B01019

SECTION B2
STRUCTURAL COMPONENTS
INDEX
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
GRILLE, HOOD AND LADDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
CENTER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
RIGHT DECK AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
LEFT DECK AND CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
B02030 Structural Components B2-1

NOTES
B2-2 Structural Components B02030

STRUCTURAL COMPONENTS
The deck structures and components are removable PREPARATION
in sections, as shown in Figure 2-1.
1. If installed, raise the body and install the body
Refer to Preparation for tasks to perform before the safety cable. Place the hoist lever in FLOAT.
ladders, decks, and hood can be removed. Additional Slowly lower the body until supported by the
steps may be required depending on optional equip- safety cable.
ment installed on the truck. 2. Reduce the engine speed to idle. Place the
Prior to component removal or repair, it may be nec- range selector in NEUTRAL and apply the park-
essary to remove the body to provide clearance for ing brake.
lifting equipment to be used. If body removal is not 3. Shut off the engine. Allow the steering accumu-
required, raise the body and install the safety cable. lators to bleed completely. Verify the steering
accumulators have bled down by attempting to
steer the machine.
4. Bleed the brake accumulators using the manual
bleed valves on the brake manifold.
5. Open the battery disconnect switch located on
battery box (11, Figure 2-1).
FIGURE 2-1. STRUCTURAL COMPONENTS

1. Left Deck 6. Center Deck 10. Engine/Transmission Access
2. Operator Cab 7. Right Deck Ladder
3. Left Deck Mounts 8. Right Deck Mounts 11. Battery Box
4. Anti-Slip Material 9. Center Deck Mounts 12. Hood & Grille
5. Operator Access Ladder

Ladders
Access ladders (5, Figure 2-1) are attached at lower
mount (3, Figure 2-2) and upper mount (5). Ladder
(10, Figure 2-1) is mounted at the rear of the center
Inspect the anti-slip material on the decks and deck area for access to the transmission/engine. Dis-
maintain for the safety of all personnel. connect wiring harnesses routed to the ladder lights,
ladder light switch, and ground level shut off switch
Cap all hoses and fittings as they are removed to before removal.
prevent possible system contamination.
Tag and verify that all cables, harnesses, hoses

etc. have been removed before the structure is
lifted off the truck. Ladders must be free of oil or dirt. Repair any
damage, and attach securely to the truck.
GRILLE, HOOD AND LADDERS

Grille
The grille must be removed for access to the air con-
ditioner condenser and fuel cooler. The grille is
removed in two sections by removing the cap screws
and washers retaining each section to the hood. The
weight of the upper grille is approximately 30 kg (66
lb). The weight of the lower grille is approximately 23
kg (51 lb).
Hood
The hood is retained by the cap screws securing it to
the brackets on the radiator assembly. Prior to
removal, remove any wire harnesses or hoses that
may be attached to the inside of the hood. The
weight of the hood is approximately 160 kg (353 lb).
Do not attach the lifting device to the hand rails.
FIGURE 2-2. RIGHT DECK & LADDERS

1. Clearance Lights 5. Ladder Upper Mount
2. Headlights 6. Handrail
3. Ladder Lower Mount 7. Battery Box
4. Ladder

DECKS RIGHT DECK AND COMPONENTS
The left, right and center decks are mounted to their Removal
supports using hardened flat washers and lock nuts.
Use the correct hardware when reinstalling. Domed 1. Follow the instructions outlined in Preparation
plugs are installed over each mounting cap screw to at the beginning of this chapter.
prevent dirt entry into the cap screw area. These
plugs must be replaced if damaged or missing.
To prevent damage to the battery equalizer cir-

CENTER DECK cuit when disconnecting the battery cables, dis-
connect the negative (-) lead first, then the
Removal positive (+) cable. When reinstalling battery
1. Follow the instructions outlined in Preparation cables, attach the positive (+) lead first, then the
at the beginning of this chapter. negative lead.
2. Remove any hoses, cables, pipe supports etc. 2. Tag and disconnect battery circuit cables and
from the center deck. wiring at battery box (7, Figure 2-2).
3. Attach lifting apparatus to each corner of the 3. Disconnect the wiring harness at clearance
center deck. The weight of the deck is approxi- lights (1) and head lights (2).
mately 250 kg (551 lb). 4. Remove ladder (4).
4. Remove the deck mounting hardware. 5. Inspect the underside of the deck and remove
5. Verify all wiring harnesses, cables and hoses any hoses or cables that remain.
have been removed. Using a hoist, carefully 6. Attach lifting apparatus to each corner of the
raise the deck and remove from the truck. right deck. The weight of the right deck (w/bat-
tery box) is approximately 850 kg (1874 lb).
Installation
1. Clean all mounting pad surfaces before installa-
tion. Do not attach the lifting device to the hand rails.
2. Clean contact surfaces before installing ground
cables. 7. Remove the deck mounting hardware at the
3. Attach lifting apparatus to each corner of the deck support and front upright.
center deck. The weight of the deck is approxi- 8. Verify all wiring harnesses, cables and hoses
mately 239 kg (527 lb). have been removed. Using a hoist, carefully
4. Using a hoist, carefully raise the deck into posi- raise the deck and remove from the truck.
tion on the truck.
5. Install the deck mounting hardware. Tighten all
hardware to the standard torque specifications Installation
listed in Section A.
6. Reattach any hoses, cables, pipe supports, etc. tion.
that were removed during deck removal.
Ensure all electrical connections and harness
cables.
clamps are installed and secure.

3. Attach lifting apparatus to each corner of the 5. Attach lifting apparatus to each corner of the left
right deck. The weight of the right deck (w/bat- deck. The weight of the left deck is approxi-
tery box) is approximately 850 kg (1874 lb). mately 420 kg (926 lb).

6. Remove the deck mounting hardware at the
4. Using a hoist, carefully raise the deck into posi- frame support and front upright.
tion on the truck.
7. Verify all wiring harnesses, cables and hoses
5. Install the deck mounting hardware at the deck have been removed. Using a hoist, carefully
support and front upright. Tighten all hardware raise the deck and remove from the truck.
to the standard torque specifications listed in
Section A.
6. Install ladder (4). Installation
7. Connect the wiring harnesses at clearance
lights (1) and head lights (2).
tion.
8. Reattach any other wiring, cables, or hoses that
were removed during deck removal. Ensure all
cables.
electrical connections and harness clamps are
installed and secure. 3. Attach lifting apparatus to each corner of the left
deck. The weight of the left deck is approxi-
mately 420 kg (926 lb).
LEFT DECK AND CAB

1. Follow the instructions outlined in Preparation
at the beginning of this chapter.
2. Remove the cab from the left deck. Refer to Do not attach the lifting device to the hand rails.
Section N for cab removal and installation
instructions.
4. Using a hoist, carefully raise the deck into posi-
tion on the truck.
5. Install the deck mounting hardware at the deck
support and front upright. Tighten all hardware
to the standard torque specifications listed in
3. Refer to Section N, Operator Comfort, for Section A.
instructions on discharging the air condi-
tioning system prior to disconnecting any 6. Reattach any other wiring, cables, or hoses that
air conditioning lines. were removed during deck removal. Ensure all
electrical connections and harness clamps are
installed and secure.
4. Tag and disconnect all hydraulic lines and elec- 7. Install the cab and charge the air conditioning
trical cables which will interfere with deck system with refrigerant. Refer to Section N for
removal. instructions.
8. Start the engine and allow systems to charge.
Check for oil leaks. Ensure all shields, covers
and clamps are in place.
9. Service the hydraulic reservoir if required.
Check for proper operation of the steering and
brake systems.

SECTION B3
DUMP BODY
INDEX
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Body Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
BODY-UP RETENTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
B03019 01/06 Dump Body B3-1

NOTES
B3-2 Dump Body 01/06 B03019

DUMP BODY
Removal
1. Park the truck on a hard, level surface and
chock the wheels. Attach appropriate lifting
cables and a hoist of sufficient capacity to the
Inspect all lifting devices. Slings, chains, and dump body. Ensure the lifting cables are taut. A
cables used for lifting components must be typical body, as shown in Figure 3-1, weighs
inspected daily for serviceable condition. approximately 20,000 kg (44,082 lb).
Refer to the manufacturers guidelines for
2. Remove the mud flaps and rock ejectors from
correct capacities and safety procedures
both sides of the body. Remove the electrical
when lifting components. Replace any
questionable items. cables, lubrication hoses, etc. attached to the
body.
Slings, chains and cables used for lifting
3. Use chains, or the equivalent, to secure the
must be rated for approximately two times the
intended load. upper portion of the hoist cylinders for pin
removal.
When in doubt as to the weight of
4. Remove pin retainer cap screws and washers
components or any assembly procedure,
contact your customer support manager for (2, Figure 3-2). Remove retainers (1) from each
further information. of the upper hoist cylinder mounting eyes. With
hoist cylinder supports in place, remove mount-
Lifting eyes and hooks must be fabricated ing pins (3).
from the proper materials and rated to lift the
intended load.
Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
positioning a suspended load.
Before lifting the body, ensure there is
adequate clearance between the body and
overhead structures or electric power lines.
Use a lifting device that is rated for at least a
25 ton capacity.
FIGURE 3-2. HOIST CYLINDER UPPER MOUNT

1. Retainer 4. Retainer Ring
2. Cap screws & Washers 5. Bearing
3. Pin 6. Hoist Cylinder
FIGURE 3-1. DUMP BODY REMOVAL
1. Lifting Cables 2. Guide Rope
B03019 01/06 Dump Body B3-3

5. Remove cap screws (5, Figure 3-3) from each
pivot pin.
6. Remove body pivot pins (1). The weight of the
pins is approximately 49 kg (108 lb). Shims and
spacers (2 & 3) will drop out as the pin is
removed.
7. Lift the dump body from the chassis and move
to a storage or work area. Block the body to
prevent damage to the body guides, etc.
8. Inspect bushings (4) and pivot pins (1). Replace
the bushings and/or body pivot pins if damaged
or worn excessively.
FIGURE 3-3. DUMP BODY PIVOT PIN

(Section B-B, Figure 3-4)
1. Body Pivot Pin 4. Pivot Bushing

2. Shim/Spacer 5. Cap screw
3. Shim/Spacer 6. Lock Nut
FIGURE 3-4. BODY COMPONENT LOCATIONS

1. Body Structure View A-A. Rock Ejector (See Figure 3-7)
2. Body-Up Retention (Safety) Cable View B-B. Body Pivot Pin (See Figure 3-3)
View C-C. Body Guide (See Figure 3-6)
View D-D. Body Pads (See Figure 3-5)
B3-4 Dump Body 01/06 B03019

Installation
3. Lift the pivot pin into position and align the pin
retainer cap screw hole. The weight of the pivot
pin is approximately 49 kg (108 lb). Push pivot
pin (1) through the shim(s) and into the pivot
bushings in each side of the frame.
Inspect all lifting devices. Slings, chains, and
cables used for lifting components must be 4. Install cap screw (5) through each pin. Install
inspected daily for serviceable condition. nut (6) and tighten.
Refer to the manufacturers guidelines for 5. Align the hoist cylinder upper mounting eye
correct capacities and safety procedures between the mounting ears. Align the retainer
when lifting components. Replace any slot in pin (3, Figure 3-2) with retainer (1) and
questionable items. install the pin.
Slings, chains and cables used for lifting 6. Install pin retainer (1) and cap screws (2). Posi-
must be rated for approximately two times the tion the retainer to obtain 0.5 mm (0.020 in)
intended load. clearance between the retainer and the bottom
When in doubt as to the weight of of the slot in body pin (3). Tighten the cap
components or any assembly procedure, screws to standard torque. Repeat for the
contact your customer support manager for remaining hoist cylinder.
further information. 7. Install the mud flaps, rock ejectors, electrical
Lifting eyes and hooks must be fabricated cables and lubrication hoses.
from the proper materials and rated to lift the
intended load.
Never stand beneath a suspended load. Guy
ropes are recommended for guiding and
BODY PADS
positioning a suspended load. Inspect the body pads during scheduled mainte-
Before lifting the body, ensure there is nance inspections. Replace if damaged or worn,
adequate clearance between the body and excessively.
overhead structures or electric power lines. 1. Raise the body to a height sufficient to allow
Use a lifting device that is rated for at least a access to all body pad mounts.
25 ton capacity.
1. Attach appropriate lifting cables and a hoist of

sufficient capacity to the dump body. A typical Place blocks between the body and the frame.
body, as shown in Figure 3-1, weighs approxi- Secure the blocks in place.
mately 20,000 kg (44,082 lb). Lift the body and 2. Remove the hardware attaching the pads to the
lower over the truck frame. Align the body pivot dump body. Refer to Figure 3-5.
and frame pivot holes.
3. Remove the body pads and shims, noting the
2. Install shims (2 & 3, Figure 3-3) in both body quantity of shims required at each pad. The rear
pivots as required to fill the gaps. Center the pads have one less shim than the other pads.
body on the frame pivot. A minimum of one
shim is required at the outside end of both 4. Install body pads using the same number of
frame pivots. shims as originally installed.
5. Install the mounting hardware and tighten.
6. Remove the blocks from between the body and
frame. Lower the body onto the frame.
B03019 01/06 Dump Body B3-5

BODY GUIDE
Inspect body guide wear points (2, Figure 3-6) each
time a body pad inspection is performed. If the gap
becomes excessive, replacement parts must be
installed.
FIGURE 3-5. BODY PAD INSTALLATION

1. Nut 6. Mounting Pad
2. Lock Washer 7. Shims (as required)
3. Cap screw 8. Body Pad
4. Flat Washer 9. Main Frame
5. Dump Body
FIGURE 3-6. BODY GUIDE

1. Body Guide 3. Body Rail
Body Pad Adjustment 2. Body Guide Wear Plug 4. Main Frame
NOTE: The truck must be parked on a flat, level

surface for this adjustment.
1. All pads, except the rear pads, should contact
the frame with approximately equal compres-
sion of the rubber.
2. A gap of approximately 1.5 mm (0.06 in.) is
required at each rear pad. This can be obtained
by using one less shim at each rear pad.
3. If pad contact appears to be unequal, repeat the
above procedure.
Proper body pad to frame contact is required to

ensure maximum pad life.
B3-6 Dump Body 01/06 B03019

BODY-UP RETENTION CABLE ROCK EJECTORS
Rock ejectors are placed between the rear dual
wheels to keep rocks and other material from lodging
between the tires. Failure to maintain the rock ejec-
tors could result in a build up of debris between the
dual wheels. Debris build up may lead to tire dam-
When performing maintenance on the vehicle age.
with the dump body raised, the body-up retention
cable must be installed. Inspection
1. To hold the dump body in the raised position, 1. The ejectors must be positioned on the center
raise the body to it's maximum height. Refer to line between the rear tires within 5 mm (0.20
Figure 3-4. in.).
2. Remove cable (2) from its stored position on the 2. With the truck parked on a level surface, the
body. Install between rear body (1) and the axle arm must be approximately 109 mm (4.3 in.)
housing ear. from the wheel spacer ring. Refer to Figure 3-7.
3. Secure the cable clevis pins with cotter pins. NOTE: With rock ejector arm (1, Figure 3-7) hanging
4. Allow the body to lower until supported by the vertical as shown in Figure 3-7, there must not be
cable. any gap between the arm and the stop on bracket
(2).
5. After maintenance is complete, reverse the
above procedure to remove the cable assembly 3. If arm (1) is bent, remove the arm and
and place it in the storage position. straighten.
4. Replace wear plates that are severely worn.
5. Inspect brackets (2) and pins (3) at each shift
change for wear and damage. Repair as neces-
sary.
FIGURE 3-7. ROCK EJECTORS

1. Rock Ejector Arm 4. Flat Washer
2. Rock Ejector Bracket 5. Cotter Pin
3. Pin
B03019 01/06 Dump Body B3-7

NOTES
B3-8 Dump Body 01/06 B03019

SECTION B4
FUEL TANK
INDEX
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
FUEL GAUGE AND SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
WIGGINS QUICK FILL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
FUEL RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
FUEL TANK BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
LEFT SIDE FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-7
B04027 5/07 Fuel Tank B4-1

NOTES
B4-2 Fuel Tank 5/07 B04027

FUEL TANK
Use extreme caution when working near fuel.

Perform repairs on fuel systems in a well venti-
lated area. Never smoke or create any sparks
near fuel. Risk of fire and explosion is very high.
Removal
apply the parking brake.
2. Raise the truck body and secure in position
with the safety cable. Shut the engine off.
3. Open drain cock (1, Figure 4-1) and drain the
fuel from the tank into clean containers. The
fuel tank has a capacity of 2120 l (560 gal).
4. Close shut off valve (2, Figure 4-1).
5. Disconnect fuel supply hose (2, Figure 4-2)
and return hose (3) from the tank. Cap the
hoses and tank fittings to prevent contamina-
tion.
6. Disconnect all electrical connections to the
tank.
7. Remove filter bracket bolts (3, Figure 4-1) and
tie the filters and hoses away from the fuel
tank. FIGURE 4-1. FUEL TANK
8. Attach an appropriate lifting device to the fuel
1. Drain Cock 6. Flat Washer
tank lift brackets (1, Figure 4-2). The weight of
2. Shut Off Valve 7. Rubber Dampener
the empty fuel tank is approximately 932 kg
3. Bolts 8. Flat Washer
(2055 lb).
4. Nut 9. Flat Washer
9. Remove nut (4, Figure 4-1), flat washer (8), 5. Cap Screw
cap screw (5), and flat washer (6) and flat
washer (9) from the lower mounts.
10. Remove two cap screws and washers (4,
Figure 4-2) from each trunnion cap on the
upper mounts. Remove the trunnion caps.
11. Lift the fuel tank from the truck and move it to a
safe work area.
12. Remove rubber dampener (7, Figure 4-1) from
each lower mount. Inspect the dampeners for
wear or damage. Discard the parts if any
defects are found.
B04027 5/07 Fuel Tank B4-3

Cleaning Repair
The fuel tank is equipped with a drain and a cleaning Clean the fuel tank before and after repairs are per-
port. These items enable steam or solvent to be used formed.
to clean tanks that have accumulated foreign mate-
rial.
It is not necessary to remove the tank from the truck
for cleaning of sediment. However, rust and scale on
the walls and baffles requires complete tank removal. If a tank is to be welded, special precautions are
Rotating the tank in various positions enables clean- necessary to prevent fire or explosion. Consult
ing solutions to contact all interior surfaces. local authorities for safety regulations before
proceeding.
Prior to a cleaning procedure of this type, remove the
fuel gauge, vents, and hose connections. The tank
must be completely sealed. After all scale, rust, and
Installation
foreign material has been removed, the temporary
plugs can be removed. 1. Thoroughly clean the fuel tank mounting
brackets and cap screw hole threads. Repair
When a tank is to remain idle for a long period of the threads if damaged. Install rubber damp-
time, spray a small amount of rust preventive oil into ener (7, Figure 4-1) in each mount.
the tank to prevent rust formation. Seal all openings
for rust prevention. 2. Attach an appropriate lifting device to the fuel
tank lift brackets. The weight of the empty fuel
tank is approximately 932 kg (2055 lb).
3. Lift the fuel tank into position over the trunnion
mounts and lower into position. Place the trun-
nion caps into position. Install cap screws and
washers (4, Figure 4-2), but do not torque at
this time.
4. Place lower mounting brackets into position.
Install cap screw (5, Figure 4-1), flat washer
(8), flat washer (9), flat washer (6), and nut (4).
Refer to Figure 4-1 for positioning. Tighten the
cap screws to standard torque.
5. Place the trunnion caps on the upper mounts.
There is a chamfer on one edge of each cap.
The chamfered edge must face the fuel tank.
Install the cap screws and washers (4,
Figure 4-2). Tighten the cap screws to stan-
dard torque.
FIGURE 4-2. FUEL TANK 6. Connect fuel supply hose (2) and return hose
(3).
1. Lift Brackets 5. Fuel Gauge and 7. Reconnect all electrical connections to the
2. Fuel Supply Hose Sending Unit tank.
3. Fuel Return Hose 6. RH Fuel Receiver
4. Trunnion Cap 7. Fuel Tank
Breather
B4-4 Fuel Tank 5/07 B04027

FUEL GAUGE AND SENDING UNIT WIGGINS QUICK FILL FUEL SYSTEM
Fuel gauge and sending unit (5, Figure 4-2) is
FUEL RECEIVER
mounted on the side of the fuel tank. The fuel gauge
device provides an on-tank display for fuel level. RH fuel receiver (6, Figure 4-2) is mounted on fuel
tank. Optional left side fuel receiver (6, Figure 4-4) is
The sending unit consists of a float arm that rises and mounted on the left hand frame rail. This remote
falls with the fuel level inside the fuel tank. A rotating receiver is for fueling the truck from the LH side.
shaft is driven by the float arm as it rises and falls. A
magnet is mounted on the shaft near the fuel gauge. Keep the cap on the receivers to prevent dirt build up
As the shaft is rotated, the magnet rotates. The rotat- in the valve area and nozzle grooves. If fuel leaks
ing magnet moves the fuel gauge needle to the cor- from the fuel tank breather, or if the tank does not
responding fuel level position. The potentiometer in completely fill, check the breather to see that the float
the transmitter portion of the gauge circuit is simulta- balls are in place and the outlet screen is clean. If the
neously moved with magnet rotation. The potentiom- breather is operating properly, the problem will most
eter varies electrical resistance to vary the electrical likely be with the fuel supply system.
output signal that is sent to the fuel gauge in the cab.
The output signal is translated into fuel volume by the
fuel gauge.
Removal
1. Partially drain the fuel until the fuel level is
below the on-tank fuel gauge.
2. Disconnect the wiring from the assembly.
3. Remove the two screws that secure the fuel
gauge to the sending unit. Remove the gauge
from the sending unit.
4. Remove the four cap screws that secure the
sending unit to the fuel tank. Remove the gas-
ket.
5. Cover the opening in the fuel tank.
Installation
1. Clean the mating surface on the fuel tank. Use
extreme care not to allow debris to enter the
fuel tank.
1. Install a new gasket.
2. Position the sending unit in the fuel tank.
Ensure the float is properly oriented and
moves freely in a vertical plane.
3. Install the four mounting cap screws and
tighten to standard torque.
4. Install the fuel gauge onto the sending unit.
Install the two screws.
5. Reconnect the wiring.
6. Refill the fuel tank. Verify proper operation of
the fuel gauges and check for fuel leaks.
B04027 5/07 Fuel Tank B4-5

FUEL TANK BREATHER
NOTE: The relief pressure of the breather valve is 70
- 89 kPa (10.2 - 12.9 psi).
Removal
1. Unscrew fuel tank breather (7, Figure 4-2)
from fuel tank.
Installation
1. Screw fuel tank breather (7, Figure 4-2) into
fuel tank.
Disassembly
1. Remove clamp (3, Figure 4-3).
2. Remove cover (2) and screen (1).
3. Remove ball cage (10), solid ball (11), and
float balls (12).
4. Unscrew end fitting (7) from body (4).
5. Remove stem (8) and valve spring (5).
Assembly
1. Clean and inspect all parts. If damaged com-
ponents are evident, replace the entire assem-
bly.
2. Place valve spring (5) into position in body (4).
3. Insert stem (8) into end fitting (7). FIGURE 4-3. BREATHER VALVE
4. Screw end fitting (7) into body (4). Ensure the
components are properly aligned and seated. 1. Screen 7. End Fitting
2. Cover 8. Stem
5. Place screen (1) and cover (2) into position on
3. Clamp 9. O-Ring
the breather. Install clamp (3).
4. Body 10. Ball Cage
6. Insert the balls into ball cage (10) with solid 5. Valve Spring 11. Solid Ball
ball (11) on top. 6. O-Ring 12. Float Ball
7. Insert the ball cage onto the stem. A minimum
of two cage coils must be seated in the groove
on the stem. Ensure the solid ball is able to
seat properly on the stem. If not, adjust the
cage, accordingly.
B4-6 Fuel Tank 5/07 B04027

LEFT SIDE FILL
This location permits fueling the truck from the left
side. The left side fill is an optional feature and might
not be included on all trucks.
FIGURE 4-4. LEFT SIDE FILL
1. Hydraulic Tank 4. Fuel Tank 7. Refueling Box

2. Filler Hose 5. Filler Cap 8. Cap Screw
3. Frame Rails 6. Receiver Assembly 9. Tapped Bar
NOTE: This illustration represents a typical installation. Installation may vary depending on truck model.
B04027 5/07 Fuel Tank B4-7

NOTES
B4-8 Fuel Tank 5/07 B04027

SECTION C
ENGINE
INDEX
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
AIR FILTRATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-1
C01022 Index C1-1

NOTES
C1-2 Index C01022

SECTION C3
COOLING SYSTEM
INDEX
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
LEAKS AND CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
RADIATOR FILL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
RADIATOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6
Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9
Additional Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9
RADIATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10
TRANSMISSION AND BRAKE COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-12
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-15
C03031 Cooling System C3-1

NOTES
C3-2 Cooling System C03031

COOLING SYSTEM
DESCRIPTION
The cooling system dissipates heat generated in the
engine, transmission and brake systems. Radiator
(1, Figure 3-1) is filled with a water/ethylene-glycol
coolant mixture. The coolant circulates through the
engine, transmission cooler (4), and brake cooler (5).
Engine water pump (6) circulates the coolant
throughout the system. Coolant temperature is con-
trolled by a thermostat located on the engine. A ther-
mostatically controlled, engine mounted fan draws air
through the grille and across the finned radiator
tubes, reducing coolant temperature. If coolant tem-
perature is low, fan clutch (7), mounted in the fan
hub, allows the fan to free-wheel. When coolant tem-
perature rises to a preset temperature, the fan clutch
engages the fan. A ribbed belt drives the fan clutch
assembly from a pulley on the front of the crankshaft.
Refer to Section C for additional information regard-
ing the fan clutch.
The radiator is mounted above the front bumper. The
radiator is attached to the truck frame near the bot-
tom tank. Support rods near the top tank attached
the radiator to the left and right uprights. Correct radi-
ator positioning is adjusted using shims at the lower
mounts and the upper mounts. Adjustable support
rods, near the top of the radiator, also allow radiator
adjustment.
FIGURE 3-1. COOLING SYSTEM
1. Radiator 5. Brake Cooler

2. Fuel Cooler 6. Engine Water Pump
3. A/C Condenser 7. Fan Clutch
4. Transmission Cooler

LEAKS AND CONTAMINATION RADIATOR FILL PROCEDURE
If a leak occurs in one of the coolers, antifreeze/cool-
ant may contaminate the transmission oil or brake oil
supply. Conversely, transmission oil or brake system
oil may contaminate the engine cooling system.
The cooling system is pressurized due to thermal
If the engine coolant is found to be contaminated with
expansion of coolant. DO NOT remove the radia-
oil, the system must be examined for leaks and
tor cap while the engine and is hot. Severe burns
repaired as necessary. The system must be flushed
may result.
to remove oil contamination and then refilled with a
clean coolant mixture.
1. With the engine and coolant at ambient temper-
If a leak has been found or is suspected in the trans-
ature, depress the pressure relief to remove
mission cooler, the transmission oil must be exam-
cooling system pressure. Slowly, remove the
ined immediately. Ethylene glycol, even in small
radiator cap.
amounts, will damage friction faced clutch plates.
NOTE: If coolant is added using the quick fill system,
the radiator cap must be removed prior to adding
coolant.
If ethylene glycol is detected in the transmission 2. Fill the radiator with the proper coolant mixture
oil, remove the transmission and disassemble. as specified by the engine manufacturer. Fill
Replace all friction-faced clutch plates. until coolant reaches the radiator cap area.
3. Install the radiator cap.
4. Allow the engine to idle for 5 minutes. Shut the
In the same manner, a defective brake cooler may engine off and wait for the engine to cool.
contaminate the hydraulic oil supply with ethylene
glycol. 5. Check the coolant level in the sight gauge. If the
radiator is not full, repeat the previous steps.
If a leak has been found or is suspected in the cooler, Any excess coolant will be discharged through
the hydraulic oil must be examined immediately. Eth- the vent hose after the engine reaches normal
ylene glycol, even in small amounts, will damage fric- operating temperature.
tion faced brake disc plates.
If ethylene glycol is detected in the hydraulic oil,

remove the wet disc brakes and disassemble.
Replace all friction-faced clutch plates.
Contact your truck distributor for ethylene glycol

detection kits.

RADIATOR REMOVAL
If the engine is to be removed, raise the truck body.
Secure the body in the up position with the body
retention cable.
Use caution when draining the coolant system or
1. Apply the parking brake, shut the engine off and removing hoses. Do not open the system until
allow the steering accumulators to bleed down. coolant temperature has reached a safe level.
Turn the steering wheel to ensure all pressure
has been released.
10. Drain the coolant from the radiator. The capac-
2. Open the battery disconnect switch.
ity of the cooling system is approximately 532 l
3. Remove the two grilles and the hood. Refer to (141 g). If the coolant is to be reused, ensure
Section B, Structural Components. the containers are clean. Remove the coolant
4. Disconnect the hoses at fuel cooler (2, Figure 3- filler cap and open drain cocks (5) to drain the
1). Remove any clamps that may interfere with system.
radiator removal.
11. Disconnect the wires from the sensors at the
5. Refer to Section N, Operator Comfort, and dis- top of the tank.
charge air conditioner system refrigerant.
12. Remove hoses (9, Figure 3-9) from the fittings
at the top of the tank. Cap all openings.
Federal regulations prohibit venting air condi-

tioner system refrigerant into the atmosphere. An
approved recovery/recycle station must be used
to remove refrigerant from the system.
6. Disconnect refrigerant hoses from condenser

(3, Figure 3-1) mounted in front of the radiator.
7. Remove the condenser mounting hardware.
Remove the condenser and move to a safe
storage area. Ensure all hoses and fittings are
plugged to prevent dirt entry.
8. Disconnect the hoses and wiring at the
receiver-drier (6, Figure 3-2).
FIGURE 3-2. RADIATOR (REAR VIEW)
1. Radiator Assembly 4. Cooler Assembly

2. Coolant Level Sensor 5. Drain Cock
3. Cooler Hoses 6. Receiver/Drier

13. Remove the hose clamps, loosen tube connec- External Cleaning
tors (5 & 8) and disconnect the coolant tubes Many radiator shops use a hot alkaline soap, caustic
from the top tank. Disconnect the hoses from soda, or chemical additives in their boil-out tanks
the brake and transmission oil cooler assembly. which can attack solders. These tanks are generally
14. Remove fan guard (12) from the right and left not recommended.
side of the shroud.
15. Attach an appropriate lifting device to the radia-
tor assembly. The weight of the radiator is 1191
kg (2626 lb).
Before such tanks are used for cleaning, ensure
16. Loosen cap screws (4) at the lower mounts
that the cleaning solutions are not harmful to sol-
17. Remove upper support rods (11). der. Otherwise, damage to the radiator will result.
18. Remove the cap screws from the lower mount.
Carefully slide the radiator forward until the Completely rinse the cleaned tube/core in clean
shroud is clear of the fan blades. Lift the radia- water after removing from the boil-out tank.
tor off the frame. Move the radiator to a storage
As an alternative to boil-out tanks, radiators can be
or repair area. Remove shims (2 & 3) and save
cleaned externally with a high pressure washer and
for use during radiator installation.
soap. In most cases, it may be best to blow out any
19. Inspect all hoses, clamps, tube connectors, etc. dry dirt with a high pressure air gun prior to washing
Replace damaged or worn parts. the core with the high pressure washer.
Pressure washers must not exceed 8274 kPa (1200
psi). Unlike conventional cores, it is recommended to
hold the spray nozzle directly next to the core. Start-
RADIATOR REPAIR ing from the air exit side, place the high pressure
washer nozzle next to the fins. Concentrate on a
Internal Inspection small area, slowly working from the top to the bottom.
Spray straight into the core, not at an angle. Con-
If desired, an internal inspection can be performed on tinue washing until the exit water is free of dirt.
the radiator before complete disassembly. The Repeat from the opposite side.
inspection entails removing tubes in the radiator core
and cutting them open. This type of inspection can
indicate overall radiator condition, as well as coolant
and additive breakdown.
To perform this inspection, remove about four ran-
dom tubes from the air inlet side of the radiator.
Remove tubes from both the top and bottom cores,
and near each end of the radiator. Refer to Disas-
sembly and Assembly in this section for proper
instructions for tube removal and installation. Ana-
lyze any contaminant residue inside the tube to
determine the cause. Flush the system before return-
ing the radiator to service. Contact your nearest L&M
Radiator facility for further instruction or visit the L&M
website for further information at www.mesabi.com.

Disassembly
To aid in removal of the tubes, clean the radiator

prior to disassembly. Heating the seals with hot
water helps to loosen the grip on the tubes.
Cleaning the radiator prior to disassembly also
reduces the risk of internal contamination. After
cleaning, spray lubricating oil at the top end of
the tubes.
FIGURE 3-4. INSTALLATION TOOL (VJ6567)
2. After the tube is loose, position the installation

tool (VJ6567) at the bottom of the tube to be
removed. Refer to Figure 3-4. Position the
upper jaw of the tool just below the rectangular
section of the tube. Rest the bottom jaw on the
seal. Squeeze the tool just enough to allow the
bottom of the tube to be removed from the bot-
tom seal.
NOTE: To ease in the removal of tubes, use the
breaker tool and installation tool simultaneously.
FIGURE 3-3. BREAKER TOOL (XA2307)
1. Start at the top row of tubes, first. Use the

breaker tool (XA2307) to loosen the tube to be
removed. When using the tool, position it at the
top or bottom of the tube. Never position it in the
middle of the tube or damage may result. Use
the tool to lightly twist the tube back and forth
within the seals to loosen the grip. Refer to Fig-
ure 3-3.
FIGURE 3-5. ANGLING TUBE DURING REMOVAL
3. Pull the tube from the top seal while simulta-

neously twisting the tube. Angle the tube only
far enough to clear the radiator during removal.
Refer to Figure 3-5. Removing the tube at an
excessive angle may cause damage to the
tube.

Assembly
4. Remove all the tubes at the top, before remov- NOTE: For easier installation, soak the seals in hot
ing the bottom tubes. water before installing.
5. After all of the tubes are removed, use pliers to 1. Install the new tube seals onto the bottom tank
remove the seals from the tanks. Discard all and the bottom side of the center tank. Do not
seals. New seals must be used for assembly. install the seals for the top core at this time.
Seals for the top of the tubes do not have lock-
ing grooves, bottom tube seals do. Ensure the
Cleaning and Inspection correct seals are installed in the proper position.
1. Clean the tube holes using a drill with a 19 mm The seal holes must be dry during installation.
(0.75 in.) wire brush. Use a rubber mallet and a flat metal plate to
2. Clean the holes of any foreign debris and wipe lightly tap the seals into place. Using excessive
clean. force will drive the seals in too far. Properly
3. Clean the inside of the tanks and tubes. In most installed seals are slightly convex in shape.
cases just flushing the inside with a high pres- Improperly installed seals are concave with a
sure hot water washer with soap, will suffice. If smaller diameter hole. Refer to Figure 3-6.
not, contact an L&M manufacturing facility or
visit the L&M website for further instruction at
www.mesabi.com.
4. Check for signs of internal blockage in the tubes
and tanks. If desired, you may cut open tubes
for inspection. If contamination is present, the
tube must be analyzed. The radiator must be
properly flushed of all contaminants and correc-
tive action must be taken to prevent such con-
tamination from occurring in the future. Refer to
Internal Inspection in this section.
5. Buff the tube ends with a polishing wheel and a
copper polishing compound. If any debris can
not be removed by buffing, emery cloth, steel FIGURE 3-6. PROPER SEAL INSTALLATION
wool, or a wire wheel (wire size 0.15 - 0.20 mm
(0.006 - 0.008 in.)) is acceptable for use. Use
extreme care not to mar the tube ends.
2. Use a 13 mm (0.5 in.) diameter brush to lubri-
cate the seals with lube/release agent
(XA2308).
3. Use a spray bottle to lubricate the tube ends
with the lube/release agent.

When installing tubes, start at one end and work
towards the center. After you reach the center,
move to the opposite end, and again, work
towards the center. If any of the tubes are diffi-
cult to install, do not proceed to force the tube.
Remove the tube and determine the problem.
Possible causes may be:
inadequate seal/tube lubrication
improperly installed seal
FIGURE 3-7. INSTALLING TUBE WITH TOOL
damaged seal or tube end
tube angle excessive during installation
and/or tube not centered in seal
Inspect seals for damage before trying to re-
install tube. Replace as necessary.
Ensure that all tube beads are seated in their
4. Move to the front of the radiator (opposite of fan respective bottom seals.
side). Install the bottom row of tubes starting
Align and straighten all tubes during the installa-
with the fan side row.
tion of each row to allow maximum air flow
When installing the tubes, center the top of the through the radiator.
tube in the top seal while angling the tube only
as much as necessary. Twist the tube while
6. Install the tube stay ends. Install the felt air baf-
applying upward force. Push the tube into the
fles behind the front and back rows while com-
seal until enough clearance is available to
pleting tube installation.
install the bottom end of the tube into the bot-
tom seal.
5. Center the bottom end of the tube in the bottom
seal. Push the tube downward until the formed Pressure Testing
bead on the tube is seated inside of the lock Pressure test radiators at 103 kPa (15 psi) for 30
ring groove in the seal. If necessary, use the minutes. Various methods of pressure testing include
installation tool (VJ6567) to pull the tube down- the following:
ward into the seal. The tool has a hooking
device on the end of one of the handles for aid- Pressurize the radiator and submerge into a test
tank. Watch for leaks.
ing in installation. Refer to Figure 3-7.
Lay the front side of the radiator on the floor. Cap
off ports, and fill the radiator with hot water.
Pressurize the radiator and check for leaks.
Cap off radiator ports. Install an air pressure
gauge and pressurize to 103 kPa (15 psi).
Remove the air source and monitor the pressure
gauge.
Pressurize the radiator with air, and spray sealed
joints with soapy water.
Additional Service Information

Additional service information can be found on the
L&M Radiator website located at www.mesabi.com.

RADIATOR INSTALLATION
1. Lift the radiator into position over the lower
mounts and the fan blades. 7. Install the hoses at the top tank. Connect the
2. Insert shims (2 & 3, Figure 3-9) between the wiring harnesses to the sensors.
frame mount block and the radiator mounting 8. If necessary, reinstall fuel cooler (7, Figure 3-9).
pad. Lower the radiator on the mounts and Install the fuel lines to the cooler.
insert cap screws and washers (4). 9. Install air conditioning condenser (6) to the
NOTE: If necessary, add or remove long shims (3) mounting brackets on the front of the radiator.
(two holes) to align the radiator outlet tube vertically 10. Connect the hoses to the condenser. Install
with the transmission cooler inlet. Use short shims receiver/drier (6, Figure 3-2) and attach the
(2) (one hole) to tilt the radiator until vertical. hoses.
11. Install the hood and the two grilles. Refer to
3. Tighten the lower mounting cap screws evenly. Section B, Structural Components.
Tighten the lower mounting cap screws to 549 12. Charge the air conditioning system with refriger-
Nm (405 lb ft). ant. Refer to Section N, Operator Comfort, for
4. Install support rods (11) between the radiator procedures on recharging the air conditioning
and uprights on the truck. system.
5. Install fan guard (12). 13. Fill the radiator with the proper coolant mixture
6. Install the upper and lower coolant piping tubes as specified in Section P, Lubrication And Ser-
and tube connectors. Position the tubes and vice.
install the hose clamps as shown in Figure 3-8.
14. Start the engine, and check for leaks. Repair as
necessary.
FIGURE 3-8. TUBE CONNECTOR CLAMPING

TRANSMISSION AND BRAKE COOLERS
Brake cooler (2, Figure 3-10) and transmission
cooler (1) are mounted behind the radiator lower
tank. The brake cooler reduces the oil temperature in
the wet disc brake (and hoist) oil circuit. This occurs
during service brake application and primarily during
retarder operation.
The transmission cooler reduces the temperature of
the transmission oil supply.
The coolers are manufactured as a single unit,
requiring removal of both coolers if service is
required.
FIGURE 3-9. RADIATOR (SIDE VIEW)

1. Coolers 7. Fuel Cooler
2. Short Shim 8. Tube Connector
3. Long Shim 9. Hose
4. Cap Screws & Washers 10. Coolant Tubes
5. Tube Connector 11. Support Rod FIGURE 3-10. OIL COOLERS
6. A/C Condenser 12. Fan Guard
1. Transmission Cooler 7. Transmission Oil

2. Brake Cooler Outlet Hose
3. Coolant Inlet 8. Transmission Oil Inlet
4. Coolant Outlet Hose
5. Orifice Check Valve 9. Brake Oil Outlet
6. Brake Oil Inlet Hoses Hoses

Removal
1. Apply the parking brake, and shut the engine
off. Allow steering accumulator pressure to dis-
sipate. Turn the steering wheel to ensure all
pressure has been released. Open the bleed
valves in the hydraulic cabinet, and bleed the
pressure from the brake accumulators. Close
the valves after all pressure has been released.
2. Drain the oil from the hydraulic tank. The capac-
ity of the hydraulic tank is 900 l (238 g).
3. Drain the oil from transmission sump. The FIGURE 3-11. SHORT END - LONG END
capacity of the transmission is 153 l (41 g).
4. Drain the coolant system as described previ- 2. Start at the long end of the cooler. Insert
ously in Radiator Removal. removal tool (XA2309) into one of the tubes.
Seat the shoulder of the tool against the end of
5. Remove the clamps and hoses connecting the tube. Squeeze the handle to lock the tool
coolant inlet (3, Figure 3-10) and outlet (4) to inside the tube. While twisting the tool, pull until
the coolers. the short end of the tube is pulled from its seal.
6. Remove brake oil inlet hoses (6) and outlet Repeat this step for each remaining tube.
hoses (9). Remove orifice check valve (5).
7. Disconnect transmission oil inlet hose (8) and
outlet hose (7) from the tubes. Cap all hoses
and oil cooler ports.
8. Support the cooler assembly with an appropri-
ate lifting device. The weight of the assembly is
approximately 397kg (875 lb). Remove the cap
screws and washers at the cooler mounting
brackets.
9. Lower the cooler assembly from the truck and
move to a clean repair area.
Disassembly FIGURE 3-12. REMOVAL TOOL

1. Remove the hardware securing the cooler end
caps, or tanks, to the main housing. Remove
each end. Ensure each end is properly identi-
fied for installation purposes. Clean the gasket
material from the end caps and from the hous-
ing.
DO NOT pull seals into the cooler housing. If a
Most coolers are stamped with an S for short seal is pulled into the housing, it must be
end, and an L for long end. The short end is removed.
the end that contains the shorter, smooth sec-
tion of the tubes. The long end contains the DO NOT attempt to remove the cap screw located
longer, smooth section of the tubes. Refer to at the center of each header plate. If it is neces-
Figure 3-11. sary to remove this cap screw, contact your near-
est L&M facility for instruction.

3. Remove all of the seals from the short end
header sheet, and discard.
4. After all seals have been removed from the
short end, insert the removal tool into a tube at
the short end of the cooler. Seat the shoulder of
the tool against the end of the tube. While twist-
ing, pull the tube from the cooler. Repeat this
step for each tube.
5. Remove all of the seals from the long end
header sheet, and discard.
Cleaning And Inspection FIGURE 3-13. INSTALLATION OF TUBES
1. Clean both header plates and all seal holes.

Prevent any debris from being pushed into the 5. Set up a plastic or a wood backstop behind the
shell. short end side of the cooler. DO NOT use a
2. Stand the cooler up in a vertical position. Flush metal backstop or damage to the tubes may
with a hot water, high pressure washer. Rinse result. The backstop will help prevent the tubes
clean. from being pushed out of the cooler during
installation.
3. Dry the inside of the cooler. Use a hot air
blower, if available.
4. Inspect the tube ends for burrs or damage.
Remove any burrs with a fine emery cloth.
Clean the inside and outside of each tube.
Assembly
1. Use cleaning solvent to wipe out the header
holes on the long end of the cooler before seal
installation. Verify that no damage exists.
2. Install new seals into the long end header plate.
DO NOT use any lubricant during installation.
Push the outer lip of each seal flush against the FIGURE 3-14. BACKSTOP AT SHORT END
header plate.
3. Use SAE 10 mineral oil to lubricate tube ends 6. Push the installation tool (XA2309) through one
and the inner portion of the long end seals. of the long end seals using a twisting motion.
When the shoulder of the tool makes contact
4. Insert the long end of a tube into the short end with the tube end, squeeze the handle to lock
side of the cooler. Slowly push the tube by hand the tube onto the tool. Gently twist the tool while
until it contacts the long end seal. Repeat this pulling the tube through the front end seal.
step for the remaining tubes. Ensure the seal remains flush with the header
plate. Repeat this step for each remaining tube.

12. Push the installation tool (XA2309) through one
of the short end seals using a twisting motion.
When the shoulder of the tool makes contact
with the tube end, squeeze the handle to lock
the tube onto the tool. Gently twist the tool while
pulling the tube through the short end seal.
Extend the tube about 6.35 mm (0.25 in.) from
the seal. Ensure the seal remains flush with the
header plate. Repeat this step for each remain-
ing tube.
FIGURE 3-15. PULLING TUBES THROUGH LONG

END SEALS
7. Remove the backstop from the short end.

8. Use cleaning solvent to wipe out the header
holes on the short end of the cooler before seal
installation.
FIGURE 3-16. PULLING TUBES THROUGH
9. Install new seals into the long end header plate. SHORT END SEALS
DO NOT use any lubricant during installation.
Push the outer lip of each seal flush against the
header plate.
Inspection
10. Use SAE 10 mineral oil to lubricate the inner
1. Inspect each tube end for any seal fragments. If
portion of the short end seals.
there is evidence of any seal damage, remove
11. Install the seal retaining tool (XA2310) onto the the corresponding tube. Install new seals, and
tube installation tool. install the tube.
2. Inspect all seals. The seals must be seated
flush against the header plates. If a gap of more
than 0.79 mm (0.031 in.) exists, the seal must
be removed, inspected and reinstalled.
Testing And Final Assembly

1. Connect an air source of 345 kPa (50 psi) to the
oil side fittings on the cooler for 15 minutes.
Submerge the cooler in water or use a spray
bottle to spray soapy water around each of the
seals. If any bubbles are evident, a leak exists
and must be repaired.

Installation
1. Move the cooler assembly under the truck.
Using an appropriate lifting device, raise the
assembly into position against the mounting
brackets on the frame. The weight of the
assembly is approximately 397kg (875 lb).
2. Install the mounting cap screws and lock wash-
ers. Tighten the cap screws to standard torque.
3. Install the coolant tube connectors at inlet (3,
Figure 3-10) and outlet (4). Refer to Figure 3-8
for tube connector clamp positioning recom-
mendations. Rotate the clamp adjusters to posi-
FIGURE 3-17. PRESSURE TESTING SEALS tion adjacent clamps 180 apart. Tighten the
clamps securely.
4. Using new O-rings on the flanges, install trans-
2. After successfully testing the seals, install the mission oil inlet hose (8, Figure 3-10), and out-
end caps. Apply a small amount of silicone rub- let hose (7). Tighten the flange clamp cap
ber to each side of the new gaskets. screws to standard torque.
3. Install the gaskets and the end caps. Ensure 5. Position orifice check valve (5) at the bottom
the notches on the end caps and the shell are brake oil inlet port. Using new O-rings on the
properly aligned. flanges, install brake oil inlet hoses (6), and out-
let hoses (9). Tighten the flange clamp cap
screws to standard torque.
6. Refill the radiator with the proper coolant mix-
ture as specified in Section P, Lubrication And
Service.
7. Refill the hydraulic tank. Refer to Section P,
Lubrication And Service for the proper proce-
dure.
8. Fill the transmission sump with hydraulic oil.
Refer to Section P, Lubrication And Service for
the proper procedure.
9. Start the engine and check for oil or coolant
FIGURE 3-18. GASKET INSTALLATION leaks. Repair leaks as required.
10. Recheck fluid levels and fill as necessary.
4. Tighten the cap screws to standard torque.
5. Hook up an air source of 1034 kPa (150 psi) to
the oil side fittings on the cooler for 15 minutes.
Submerge the cooler in water. If any bubbles
are evident, a leak exists and must be repaired.
If no leaks are present, the cooler assembly is
ready for use.

NOTES

SECTION C4
ENGINE
INDEX
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-7
DRIVE LINE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-10
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-18
Bearing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-19
C04031 05/08 Engine C4-1

NOTES
C4-2 Engine 05/08 C04031

ENGINE
The HD1500 truck is equipped with a turbocharged 3. Place the battery disconnect switch in the OFF
diesel engine. Engine power is transmitted to the position. Disconnect the negative battery
Torqflow transmission by a drive line adapter, cables, and then the positive battery cables.
damper assembly and drive shaft. 4. Remove the radiator. Refer to Section C, Cool-
ing System - Radiator Removal.
Removal
5. Disconnect the engine harness and ground
1. Park the truck in a work area with adequate cables from alternator (1, Figure 4-2).
overhead clearance to permit raising the body.
6. Close the fuel supply valve located on the left
2. Apply the parking brake and block the wheels. side of the engine. Close the valve located at
Raise the body, and install the safety cable. the fuel tank. Disconnect the fuel supply hose at
the engine. Cap all openings. Clean any spilled
fuel.
7. Disconnect the tubing for the air cleaner restric-
tion indicators at ports (7, Figure 4-1).
DO NOT work under a raised body unless the 8. Disconnect turbocharger inlet temperature sen-
safety cable is securely installed. sor (10).
9. Loosen intake pipe clamps (2). Remove the
support rods at clamps (6). Remove intake
pipes (4 and 5) from the rubber connector
hoses at the air cleaners and turbochargers.
Remove exhaust pipes (11).
Prior to removal, tag or mark all oil lines, fuel
lines and electrical connections to ensure correct
assembly during engine installation. Plug all
ports and cover all hose fittings or connections
when disconnected.
FIGURE 4-1. INTAKE/EXHAUST PIPING
1. Air Cleaner 7. Air Cleaner Restriction Indicator Port

2. Clamp 8. Hose
3. Hump Hose 9. Turbocharger
4. LH Intake Pipe 10. Turbocharger Inlet Temperature Sensor
5. RH Intake Pipe 11. Exhaust Pipes
6. Support Rod Clamp
C04031 05/08 Engine C4-3

FIGURE 4-3. AIR CONDITIONER COMPRESSOR
1. Belt Guard 4. Suction Hose

2. A/C Compressor 5. Clutch Connector
FIGURE 4-2. COOLER ASSEMBLY PIPING 3. Mounting Bracket 6. Harness Clamps
1. Alternator 5. Fan Clutch
2. Cooler Assembly 6. Heater Shutoff Valves
3. Water Pump Inlet Pipe
4. Coolant Temperature
Sensor
10. Remove water pump inlet pipe (3, Figure 4-2)

between the engine and cooler assembly (2).
11. Close heater shut-off valves (6) and disconnect
the hoses.
12. Disconnect the heater hoses and remove the
clamps to allow the hoses to be positioned
away from the engine.
13. Disconnect the suction and discharge hoses
from air conditioning compressor (2, Figure 4-
3).
14. Disconnect compressor clutch connector (5).
Remove harness clamps (6). Disconnect the tri-
nary switch from the receiver/drier.
15. Disconnect coolant temperature sensor (2, Fig-
ure 4-4) from the front right side of the engine. FIGURE 4-4. COOLANT TEMPERATURE
SENSOR
1. Right Front Cylinder 2. Coolant Temperature
Head Sensor
C4-4 Engine 05/08 C04031

FIGURE 4-5. REAR OF ENGINE
1. ECM Cables 3. Harness Clamps

2. Speed Sensors 4. Oil Pressure Switch
FIGURE 4-6. REAR ENGINE MOUNT
16. Disconnect the harness from oil pressure switch 1. Rear Engine Mount 4. Starter Cables
(4, Figure 4-5). Disconnect speed sensors (2). 2. Rubber Mount 5. Starter Motors
Disconnect the Electronic Control Module 3. Cap Screw 6. Exhaust Pipe
(ECM) connectors (1) and harness clamps (3).
17. Remove the battery supply and ground cables
from cranking motors (5, Figure 4-6). Discon-
nect the prelube timer and magnetic switches
connected to the main engine harness.
18. Disconnect the engine ground cables.
19. Verify all cable clamps are removed. Remove
the engine harness from the engine. Carefully
secure the harness to prevent interference
when the engine is removed.
20. Remove drive shaft guard (1, Figure 4-7), and
drive shaft (2). Refer to Section F, Drive Shafts
for instructions on removing the drive shaft.
21. Inspect the engine for any remaining hoses or
electrical wiring that must be removed prior to
engine removal.
FIGURE 4-7. DRIVE SHAFT
1. Guard 2. Drive Shaft
C04031 05/08 Engine C4-5

FIGURE 4-8. FRONT ENGINE MOUNTS
1. Alternator Guard
2. Fan
3. Fan Clutch
4. Mounting Hardware
5. Rubber Mount
Inspection
The complete engine (dry) weighs approximately Inspect rubber mounts (2, Figure 4-6, & 5,
5,813 kg (12,815 lbs). Ensure all lifting apparatus, Figure 4-8). If the mounts are deformed or
hoists, and spreader bars are of adequate capac- damaged, replace with new parts.
ity. During engine removal, ensure that the
Inspect all hoses for evidence of leakage,
engine removal path is clear of personnel and
damage, or deterioration.
equipment.
Inspect electrical harness connectors for
pin damage or corrosion.
22. Attach appropriate lifting apparatus to the Inspect electrical harnesses for damage.
engine.
Inspect the drive shaft cross and bearings.
23. Remove the mounting hardware from rear
engine mounts (1, Figure 4-6). Inspect the driveline adapter. Refer to
Driveline Adapter later in this chapter.
24. Remove mounting hardware (4, Figure 4-8)
from the front engine mounts. Repair or replace the above items as required.
25. Lift the engine from the frame. Move to a clean

work area and mount on work stands or crib-
bing.
C4-6 Engine 05/08 C04031

Installation
12. Connect all engine ground cables.
13. Install coolant pipe (3, Figure 4-2) between the
water pump inlet and cooler assembly (2).
The complete engine (dry) weighs approximately 14. Install the heater hoses onto shut-off valves (6).
5,813 kg (12,815 lbs). Ensure all lifting apparatus, Open the valves.
hoists, and spreader bars are of adequate capac- 15. Install exhaust pipes (11, Figure 4-1).
ity. During engine removal, ensure that the
engine removal path is clear of personnel and 16. Install the left and right air intake pipes between
equipment. the air cleaners and turbochargers.
1. Attach appropriate lifting apparatus to the 17. Install the support rods between the pipes and
engine. Lift the engine into position over the the deck. After the pipes are properly posi-
mounts. Install the rubber mounts on top of the tioned, tighten the clamps on hump hoses (3)
mount brackets. Lower the engine and install and turbocharger elbows (8), securely.
the bottom rubber mounts, mounting cap 18. Install air cleaner restriction indicator tubes to
screws, nuts, and washers. Tighten the cap ports (7).
screws to standard torque.
19. Connect the wiring harness to turbocharger inlet
2. Center the engine and transmission assembly. temperature sensor (10).
Refer to Section F, Transmission - Centering
the Engine and Transmission. 20. Connect the fuel supply hose to the shut-off
valve to the rear of the fuel filters. Open the
3. Install the drive line adapter if not already
shut-off valves at the filters and at the fuel tank.
installed. Refer to Driveline Adapter on the fol-
lowing pages for installation instructions. 21. Check installation to verify all hoses and wiring
have been reinstalled and all clamps are in
4. Install drive shaft (2, Figure 4-7), and drive shaft
place.
guard (1). Refer to Section F, Drive Shafts for
instructions on installing the drive shaft. 22. Install the radiator. Refer to Section C, Cooling
5. Route the engine harness into position on the System - Radiator Installation.
engine. 23. Connect the negative battery cables, then the
6. Install starter motor cables (4, Figure 4-6). positive battery cables. Close the battery dis-
7. Connect engine oil pressure switch (4, Figure 4- connect switch.
5), engine speed sensors (2) and three ECM 24. Fill the engine oil to the specified level. Refill the
cables (1). Install harness clamps (3) to secure radiator with coolant to the specified level.
the harness to the flywheel housing.
NOTE: Refer to Section P, Lubrication and Service
8. Connect coolant temperature sensor (2, Figure for the proper fluids and capacities.
4-4) to the engine harness.
25. Charge the air conditioning system with refriger-
9. Connect the harness wiring to the alternator R
ant. Refer to Section N, Operator Comfort for
terminal. Connect the alternator battery cable
instructions.
and ground cables.
26. Start the engine to circulate the oil and coolant
10. On the left side of the engine, install the air con-
through the system. Keep the engine on until
ditioner compressor suction and discharge
temperatures are stabilized. Then, turn the
hoses.
engine off and check fluid levels, again.
11. Install clutch connector (5, Figure 4-3). Route
27. Check for fluid leaks and repair as necessary.
the remaining wires to the receiver-drier. Install
harness clamps (6).
C04031 05/08 Engine C4-7

DRIVE LINE ADAPTER
FIGURE 4-9. DRIVELINE ADAPTER

1. Flywheel Housing 12. Cap Screw & Washer 23. Plug
2. Damper Assembly 13. Spacer 24. Cap Screws
3. Flange 14. Retainer Ring 25. Cap
4. Cap Screw & Washer 15. Retainer Ring 26. Retainer Ring
5. Outer Body 16. Bearing 27. Coupling Assembly
6. Rubber - Large 17. Spacer 28. Cap Screw & Washer
7. Rubber - Small 18. Bearing 29. Oil Seal
8. Retainer Ring 19. Cover 30. Output Shaft
9. Cover 20. Plug 31. Cover Assembly
10. Inner Body 21. Dowel Pin
11. Flange 22. Breather
C4-8 Engine 05/08 C04031

Removal
1. Park the truck in a work area with adequate
overhead clearance to permit raising the body.
DO NOT work under a raised body until the safety

cable is securely installed.
2. Apply the parking brake and chock the wheels.

Raise the body and install the safety cable.
3. Remove the front drive shaft. Refer to Section
F, Drive Shafts for instructions on removing the
drive shaft.
4. Remove coupling (3, Figure 4-11).
5. Attach a lifting device and guide bolts to damper
cover (1). The weight of the cover assembly is
approximately 140 kg (308 lbs). Remove cap
screws (2) from the damper cover. Lift the cover FIGURE 4-11. OUTPUT SHAFT
from the truck. 1. Damper Cover 3. Coupling
6. Attach a sling and a lifting device to damper (1, 2. Cap Screw
Figure 4-12). The weight of the assembly is
approximately 108 kg (238 lbs). Remove cap
screws (24, Figure 4-9) that secure the damper
to the flywheel housing (1).
7. Lift the damper assembly from the truck.
FIGURE 4-12. DAMPER ASSEMBLY
1. Damper 2. Housing
FIGURE 4-10. DRIVESHAFT

1. Drive Shaft 4. Damper Cover
2. Coupling and Bearing 5. Cap Screws
Assembly 6. Coupling
3. Plug(s) 7. Breather
C04031 05/08 Engine C4-9

Disassembly
NOTE: Bearing removal and installation tools allow

for easier disassembly and assembly of the driveline
adapter. The tools can be fabricated locally.
Manufacturing details are shown in Bearing Tools
located later in this chapter.
FIGURE 4-14. SHAFT REMOVAL

1. Press 2. Shaft
3. Set the assembly in a press stand as shown in

Figure 4-14. Place a blanket or other soft object
FIGURE 4-13. COVER DISASSEMBLY below the stand to prevent damage to shaft (2)
if it falls. The weight of the shaft is approxi-
1. Damper Cover 3. Snap Ring mately 37 kg (82 lb). Press shaft (2) from the
2. Snap Ring 4. Oil Seal cover.
1. Remove oil seal (4, Figure 4-13) from damper

cover (1).
2. Remove snap ring (2) and snap ring (3).
FIGURE 4-15. OIL SEAL REMOVAL
1. Oil Seal 2. Damper Cover
4. Turn the cover over and remove oil seal (1,

Figure 4-15).
C4-10 Engine 05/08 C04031

1. Press 2. Bearing Tool A
5. Use a press and bearing tool A to press bear-

ings (2, Figure 4-18) and spacer (3) from the
cover. Do not use excessive force when remov-
ing the bearings.
FIGURE 4-18. ADAPTER CROSS SECTION
1. Oil Seal** 8. Rubber - Small*
2. Bearing(s)** 9. Outer Body*
3. Spacer** 10. Cap Screw - Cover
4. Breather** 11. Cap Screw - Flange*
5. Flange(s)* 12. Plug(s)**
6. Inner Body* 13. Output Shaft**
7. Rubber - Large* 14. Cap Screw - Outer body
* Damper Assembly Components
**Cover Assembly Components
6. With the damper positioned as shown in

Figure 4-17, remove snap ring (2) and cap (1).
FIGURE 4-17. CAP REMOVAL
1. Cap 2. Snap Ring
C04031 05/08 Engine C4-11

9. Remove inner body (4) from outer body (3).
NOTE: Spacer (5) is not serviced separately. If either
the inner body or the spacer must be replaced, they
must be replaced as an assembly.
FIGURE 4-19. FLANGE REMOVAL
1. Cap Screw 2. Flange
7. Remove cap screws (1, Figure 4-19) from

flange (2). Separate the flange from the assem- FIGURE 4-21. FLANGE REMOVAL
bly.
1. Flange 2. Cap Screw
10. If necessary, remove flange (1, Figure 4-21).

Remove cap screws (2) and separate the flange
from the outer body.
Cleaning and Inspection

1. Clean and inspect all drive line adapter compo-
nents.
2. Replace any worn or damaged parts. Refer to
Figure 4-22 for wear limit specifications.
FIGURE 4-20. RUBBER REMOVAL

1. Large Rubber Damper 4. Inner Body
2. Small Rubber Damper 5. Spacer
3. Outer Body
8. Remove rubber dampers (1, Figure 4-20) and

rubber dampers (2) from outer body (3).
C4-12 Engine 05/08 C04031

FIGURE 4-22. WEAR
LIMITS
No. Check Item Criteria (Unit: mm) Remedy

Tolerance Standard Clearance
Nominal Size
Clearance between bearing Shaft Hole Clearance Limit
1
and shaft +0.018 0.000 -0.038~
120 0
+0.003 -0.020 -0.003
Replace
Clearance between bearing 0 -0.008 -0.037~
2 215 0.025
and housing -0.03 -0.037 0.0
Clearance between inner body +0.018 +0.077 -0.029~
3 120 0.1
and shaft +0.003 +0.047 0.074
Wear of coupling surface con- Nominal Size Tolerance Repair Limit
4 Repair by
tacting with oil seal 170 0 - 0.100 -0.160
Rechroming or
Wear of spacer surface con- Replace
5 180 0 - 0.100 -0.160
tacting with oil seal
Backlash of spline Standard Backlash Backlash Limit
6 between inner body Replace
0.080 ~ 0.243 0.4
and shaft
Backlash of spline Standard Backlash Backlash Limit
7 between coupling Replace
and shaft 0.080 ~ 0.246 0.4
Size Smallest Dimension: L L0 Repair Limit (L)

Original Dimension: L0
Deformation of 110 99
Large
8 rubber cushion Replace
Small 90 81
External No Cracks
C04031 05/08 Engine C4-13

Assembly
NOTE: Bearing removal and installation tools allow
for easier disassembly and assembly of the driveline
adapter. The tools can be fabricated locally.
Manufacturing details are shown in Bearing Tools
located later in this chapter.
FIGURE 4-24. DAMPER GREASE
FIGURE 4-23. OUTER BODY ASSEMBLY 1. Outer Body 4. Large Rubber Damper
2. Small Rubber Damper 5. Grease Area (shaded)
1. Outer Body 2. Dowel Pin 3. Inner Body
1. If removed, install dowel pins (1, Figure 4-23) to 6. Install the rubber dampers as illustrated in
outer body (1). Figure 4-24. Distribute the remaining grease to
2. If flange (1, Figure 4-21) was removed, apply grease area (5). Divide the grease evenly
Komatsu sealant (p/n 09940-00011 or 09920- among each damper chamber.
00150) to the mating surfaces of the flange and 7. Thoroughly clean any remaining grease from
the outer body. the outer body mating surface.
3. Align the dowel pins on the body with the holes 8. Apply a thin layer of Komatsu sealant (p/n
in flange (1). Place the flange into position on 09940-00011 or 09920-00150) to the mating
the body. Install cap screws (2) and the wash- surface of flange (2, Figure 4-19) and the outer
ers. Tighten the cap screws to 177 19 Nm body.
(130 15 lb ft). 9. Install cap screws (1) and the washers that
4. Place inner body (3, Figure 4-24) into position secure the flange to the outer body. Tighten the
in the outer body. cap screws to 177 19 Nm (130 15 lb ft).
5. Measure 700 cc (23 oz) of Komatsu grease (p/n 10. Turn over the assembly and fill the opening of
427-12-11871) and separate into a container. the inner body with 100 cc (3.8 oz.) of Komatsu
Use this supply of grease to lubricate the inner grease (p/n 427-12-11871).
surface of outer body (1), the outer surfaces of
inner body (3), and to all surfaces of rubber 11. Install cap (1, Figure 4-17) and snap-ring (2).
dampers (2 & 4).
C4-14 Engine 05/08 C04031

16. Turn the cover over on the press stand.
17. Press oil seal (1, Figure 4-26) into damper
cover (4) using a press and bearing tool C.
FIGURE 4-25. BEARING INSTALLATION

1. Press 3. Bearing Tool B FIGURE 4-26. GREASE AREA
2. Cover 4. Bearing
1. Oil Seal 3. Bearing
2. Grease Area 4. Cover
12. Set bearing tool B on a press stand. Lift the

damper cover onto the tool as shown in
Figure 4-25. Verify that the tool and cover are 18. Fill grease area (2), between oil seal (1) and
flat against the surface of the press stand. bearing (3), with 260 cc (9 oz) of Komatsu
grease (p/n 427-12-11871). Apply a small
13. Apply Loctite 648 to the outside circumfer-
amount of the grease to the lip of the oil seal.
ence of bearing (4) and press into damper
cover (2). Press the bearing until it is seated 19. Clean any grease from the inner circumference
against the bottom shoulder of the cover. of the bearing surfaces and the outer circumfer-
ences of output shaft (1, Figure 4-27).
14. Place spacer (17, Figure 4-9) into position on
the inner diameter of the bearing that was 20. Spray a dry type molybdenum disulfide lubricant
installed in the previous step. such as Dow Corning 321 on the splines of
the output shaft that mate with the inner body.
15. Apply Loctite 648 to the outside circumfer- Allow the lubricant to properly dry.
ence of bearing (16). Press the bearing into the
cover against spacer (17). 21. Apply Loctite 648 to the inner circumference
of the bearing surfaces.
C04031 05/08 Engine C4-15

24. Install snap ring (2, Figure 4-13) and snap ring
(3).
25. Apply Loctite 648 to the outer surface of oil
seal (4).
26. Install the oil seal into the cover using a press
and bearing tool D.
27. Fill the area between the oil seal and the
inboard bearing with 160 cc (5.5 oz) of Komatsu
grease (p/n 427-12-11871).
FIGURE 4-27. SHAFT INSTALLATION
1. Output Shaft 2. Bearing Tool A
22. Place bearing tool A below the inboard bearing

to support the assembly as shown in Figure 4-
27.
23. Press output shaft (1) into the cover assembly
until the shaft is seated against the outboard
bearing.
Do not allow the shaft to come in contact with
the oil seal.
Rotate the damper cover slowly while press fit-
ting the shaft to prevent the lip of the seal from
turning downward.
C4-16 Engine 05/08 C04031

FIGURE 4-28. GREASE MAP
C04031 05/08 Engine C4-17

Installation
NOTE: Refer to Figure 4-9 during assembly of the
drive line adapter.
1. Attach a sling and lifting device to damper
assembly (1, Figure 4-12). The weight of the
assembly is approximately 151 kg (333 lb). Lift
the damper onto the flywheel.
2. Apply Komatsu sealant (p/n 09940-00030) to
cap screws (24, Figure 4-9). Install and tighten
to 260 25 Nm (192 15 lb ft).
3. Apply a thin layer of Komatsu sealant to mating
surfaces of cover (19, Figure 4-9).
4. Install lifting device to damper cover. The weight
of the cover is approximately 140 kg (308 lbs).
Install guide bolts to aid in cover installation. Lift
the cover onto the assembly and install cap
screws (28). Remove the guide bolts. Tighten
the cap screws in a criss-cross pattern to 111
10 Nm (81 7 lb ft).
FIGURE 4-29. GREASE PLUGS
5. Remove both grease plugs (2, Figure 4-29) on
damper cover (1). Add Komatsu grease (p/n
1. Damper Cover 3. Coupling
427-12-11871) through one of the plug holes.
2. Grease Plug
Fill with grease until the grease is level with the
open plug hole.
6. Add 150 cc (5 oz) of Komatsu grease (p/n 427-
12-11871) to the inside of coupling (3). Install
the coupling onto the output shaft.
7. Install drive shaft (1, Figure 4-10). Refer to Sec-
tion F, Drive Shafts for instructions on installing
the drive shaft.
C4-18 Engine 05/08 C04031

Bearing Tools
FIGURE 4-30. BEARING TOOL A (88J-D562-212)
FIGURE 4-31. BEARING TOOL B (88J-D562-211)
C04031 05/08 Engine C4-19

FIGURE 3-32. BEARING TOOL C
FIGURE 3-33. BEARING TOOL D
C4-20 Engine 05/08 C04031

SECTION C5
AIR FILTRATION SYSTEM
INDEX
AIR FILTRATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
FILTER SERVICE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
MAIN FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
SAFETY FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
MAIN FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-6
PRECLEANER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7
AIR INTAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-8
C05014 Air Filtration System C5-1

NOTES
C5-2 Air Filtration System C05014

AIR FILTRATION SYSTEM
AIR CLEANER General Maintenance
Operation
The air cleaners are mounted on the uprights on
each side of the radiator. Intake air, required by the
engine, enters through the air cleaners. The air The engine must be off before servicing the air
cleaners discharge heavy particles of dust and dirt cleaner assemblies or opening the air intake sys-
using centrifugal action. Finer particles are removed tem.
by passing air through filter cartridges. 1. Inspect the dust collector cups at regular, daily
The engines demand for air creates a vacuum in the intervals. Do not allow the dust level to build up
air cleaners. This causes outside air to be drawn in to the Donaclone tube chamber.
through the air inlets on the air cleaners. Dirty air 2. Monitor the filter service indicators, mounted in
entering the cleaners is drawn through a series of the cab overhead panel, during truck operation.
tubes that are designed to produce a cyclonic action. Check the indicators each time the engine is
As the air passes through the outer portion of the shut off. If the red area is still indicated with the
tubes, the circular motion causes dust and dirt parti- engine off, filter service is required.
cles to be thrown from the air stream into the dust
The filter must be changed when the vacuum
collector cups. At the same time, the air stream turns
shown on the gauge is between 5 - 6.2 kPa (20
and is directed up through the center of the tubes into
- 25 in. of H2O) vacuum.
another chamber. Here the air passes through the
main filter element and safety filter element. The air Refer to the following pages for maintenance
then flows out of the clean air outlet to the engine air and cleaning instructions.
intake system.
3. After filter service, reset the service indicators
by pushing down on the button located on top of
each indicator.
4. Check the air inlets for obstructions or damage.
5. Check all connections between the air cleaner
outlets and the engine intake manifold. Connec-
tions must be tight and completely sealed.
6. Check all air cleaner housing cap screws to
ensure they are properly tightened.
FIGURE 5-1. AIR CLEANER

1. Dust Collector 3. Air Intake Cover
2. Precleaner Section 4. Element Section

FIGURE 5-2. TYPICAL AIR CLEANER ASSEMBLY
1. Dust Cup 6. Wing Nut Gasket 11. Main Element Gasket

2. Dust Cap Gasket 7. Safety Element Indicator Nut 12. Clean Air Outlet
3. Donaclone Tube 8. End Cover 13. Pre-Cleaner Gasket
4. Unfiltered Air Inlet 9. Safety Filter Element 14. Safety Filter Element Gasket
5. Wing Nut 10. Main Filter Element

FILTER SERVICE INDICATOR SAFETY FILTER ELEMENT
Filter restriction is metered by the service indicators Removal
located in the overhead panel inside the cab. As the
filters accumulate dirt, vacuum in the air intake sys-
tem increases. The engines demand for air will
cause the indicator float to rise due to the increase in
vacuum. As dirt buildup continues, the indicators
continue to rise toward the red area inside the indica- Keep new safety (secondary) filter elements in
tor. With the engine off and the indicator still showing stock for replacement. DO NOT clean the safety
red, filter service is required. element. Discard the used element and replace
with a new one.
DO NOT keep the intake system open to the

MAIN FILTER ELEMENT atmosphere for excessive lengths of time.
Removal The function of the safety filter is to increase overall
Remove and inspect the main filter element as out- reliability and engine protection. If the safety element
lined below. indicator is red, the element is clogged, and must be
discarded. Replace the filter with a new one.
1. Shut the engine off. Clean any dirt and dust off
the exterior of the air cleaner. 1. Shut the engine off. Clean the dirt and dust from
the element end cover.
2. Loosen wing nut (5, Figure 5-2) on the air
cleaner and remove cover (8). Remove main 2. Remove main element (10, Figure 5-2) as out-
element (10) from the assembly. lined in Main Filter Element - Removal.
3. Inspect the filter element carefully for possible 3. Remove indicator nut (7) holding the safety ele-
damage, holes, breaks, etc., which might effect ment in place. Remove safety element (9).
reuse of the element. If the element appears Inspect gasket (14) and replace if necessary.
serviceable, proceed with cleaning. If defects 4. Remove any dust lodged in the clean air outlet
are found in the filter element, remove wing nut and around the element sealing surface.
(5). Reuse the wing nut on the new filter ele-
ment. Installation
4. Check safety filter element nut (7). If the solid 1. Install the safety element and secure in place
red area is showing, safety filter service is with a new safety element indicating nut (7).
required. Refer to Safety Filter Element. 2. Reset the indicator from red to green by gently
blowing air through the threaded hole from the
Installation gasket end of the indicator wing nut. Tighten the
1. If the filter element is being reused, ensure the wing nut to 13 Nm (10 lb ft).
main element gasket (11) is not damaged. The 3. Install main element (10, Figure 5-2) as outlined
gasket must seal completely. in Main Filter Element - Installation.
2. Install a new or cleaned main filter element into
the air cleaner. Install the cover and secure with
the wing nut and gasket. Tighten the wing nut
hand tight. DO NOT use a wrench or pliers.

MAIN FILTER CLEANING
After inspection, determine the condition of the filter 2. Clean dust loaded elements with dry filtered
element. If the element may be reused, choose either compressed air:
the "washing" or "compressed air" method for clean- a. Maximum nozzle pressure must not exceed
ing the filter element. If washing the element, refer to 207 kPa (30 psi). Nozzle distance from the
Step 1. If using compressed air, refer to Step 2. filter element surface must be at least 25 mm
NOTE: Washing is best when an element is loaded (1 in.) to prevent damage to the filter mate-
with carbon, soot, oil or dust. rial.
b. As shown in Figure 5-4, direct a stream of air
from the nozzle against the inside of the filter
1. Wash elements with water and liquid detergent. element. This is the clean air side of the ele-
A 50/50 solution of Oakite 202 and warm water ment and air flow must be opposite of normal
may be used. air flow.
a. Soak the element in a solution of liquid deter-
gent and water for 15 to 30 minutes. Rotate
the element back and forth in the solution to
free the dirt deposits. DO NOT soak ele-
ments for more than 24 hours.
b. Rinse the element with a stream of fresh
water from the inside to the outside. Rinse
until the exit water appears clear. Maximum
permissible water pressure is 276 kPa (40
psi). A complete, thorough rinse is essential.
c. Dry the element thoroughly. If heated air is
used, the maximum temperature must not
exceed 60C (140F) and the air must be cir- FIGURE 5-4. CLEANING FILTER ELEMENT WITH
culated, continually. DO NOT use a light bulb COMPRESSED AIR
for drying filter elements.
d. After cleaning the element, inspect thor-
oughly for ruptures and gasket damage. A
good method to detect paper ruptures is to
place a light inside the filter element as c. Move air flow up and down vertically with the
shown in Figure 5-3. Inspect the outer sur- pleats in the filter material while slowly rotat-
face of the filter element. ing the filter element.
d. When cleaning is complete, inspect the filter
element as shown in Figure 5-3. If holes or
ruptures are observed, replace the element
with a new element.
FIGURE 5-3. FILTER ELEMENT INSPECTION

PRECLEANER CLEANING
Clean the Donaclone tubes in the precleaner section
of the air cleaner at least once annually. More fre-
quent cleaning may be necessary depending upon
operating conditions and local environment. The
tubes must also be cleaned at each engine overhaul.
To inspect the tubes in the precleaner section,
remove the main filter element. DO NOT remove the
safety element. Loosen the clamps and remove the
dust collector cup. Use a light to inspect the tubes. All
tubes must be clear and the light visible.
Clean the Donaclone tubes as follows if clogging is
evident.
Both the main element and safety element must

be installed in the air cleaner during Steps 1 and
2. The presence of the elements prevents dirt FIGURE 5-5. CLEANING DONACLONE TUBES
from being forced into the engine intake.
7. Loosen the clamps and remove dust cup (1,
1. Install the main filter element if removed. Refer Figure 5-2) from the precleaner section. Wash
to Main Filter Element - Installation. the dust cup with a water and liquid soap solu-
tion.
2. Use a stiff fiber brush to clean dust buildup, as
shown in Figure 5-5. DO NOT use a wire brush. 8. Submerge the precleaner section in a solution
Dust may also be cleaned effectively using of Donaldson D-1400 and warm water. Mix the
compressed air. solution according to the package directions.
Soak for 30 minutes, and remove from the solu-
3. Soak and wash the tubes if buildup is excessive tion. Rinse thoroughly with fresh water and blow
in the precleaner section. Proceed to the next dry.
step for cleaning instructions.
NOTE: The precleaner section may be separated
from the air cleaner assembly without removing the
complete air cleaner from the truck.
4. Remove air intake cover (3, Figure 5-1).
5. Remove the cap screws and lock nuts holding
the precleaner section to the cleaner assembly.
6. Remove the main filter element. The safety ele-
ment must remain in place to protect the engine
intake.
FIGURE 5-6. WASHING AND SOAKING OF PRE-

CLEANER SECTION

AIR INTAKE TROUBLESHOOTING
Severe plugging may require the use of an Oak- To ensure maximum engine protection, check all
ite 202 and water solution. Create the solution connections between the air cleaners and engine
with 50% Oakite 202 and 50% fresh water. intake. The connections must be tight and positively
Soak the precleaner section for 30 minutes. sealed. If air leaks are suspected, check the follow-
Rinse clean with fresh water and blow dry, coming:
pletely.
1. Check all intake lines, tubes and hump hoses
9. Check precleaner gaskets (13) carefully for any for breaks, cracks, holes, etc., which could
evidence of air leaks. Replace all suspect gas- allow an intake air leak.
kets.
2. Check all air cleaner gaskets for positive seal-
10. Install the precleaner section and gasket onto ing.
the air cleaner assembly. Install all mounting
3. Check air cleaner elements, main and safety,
hardware that was removed. Tighten the hard-
for ruptures, holes or cracks.
ware to standard torque.
4. Check the air cleaner assembly for structural
11. Install dust cup (1) and gasket (2) onto the pre- damage. Look for cracks, breaks or other
cleaner section. Secure the cup with the mount- defects which could allow air leakage. Check all
ing clamps. mounting hardware for proper tightening.

SECTION C7
FAN CLUTCH
INDEX
FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-3
REMOVAL & INSTALLATION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-3
FAN CLUTCH - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-6
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-16
ASSEMBLY - FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-20
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-34
C07002 Fan Clutch C7-1

NOTES
C7-2 Fan Clutch C07002

FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
TOOL A - FRONT SLEEVE BEARING INSTALLER
TOOL B - REAR SLEEVE BEARING INSTALLER

TOOL C - FRONT AND REAR SLEEVE BEARING REMOVER
TOOL D - WEAR SLEEVE AND RETAINER/SEAL ASSEMBLY INSTALLER;

BEARING REMOVER; ASSEMBLY PUSHER TOOL

TOOL E - BEARING INSTALLER
TOOL F - BEARING INSTALLER (LARGE)

FAN CLUTCH - DISASSEMBLY
FIGURE 7-1. FAN CLUTCH EXPLODED VIEW
1. Orifice Fitting 16. External Snapring (spacer) 31. Steel Clutch Plate
2. Dowel Pin (Rear) 17. Sealring (Hook type) 32. Internal Snapring
3. Pitot Tube 18. Bolt 33. Main Bearing (front)
4. Wear Sleeve 19. Washer 34. O-Ring Seal
5. Retainer/Seal Assembly 20. Pulley 35. Bearing Retainer (front)
6. Shaft Assembly 21. Pulley Adapter 36. Oil Seal
7. Nameplate Kit 22. Sealring (large) 37. Washer
8. Washer 23. Piston 38. Bolt
9. Bolt 24. Sealring (small) 39. Wear Sleeve
10. Oil Seal 25. Spring Washer 40. Retainer/Seal Assembly
11. Bearing Retainer (rear) 26. Shim 41. Sleeve Bearing (rear, short)
12. Bearing Spacer (External Snapring) 27. External Snapring 42. Fan Mounting Hub Assembly
13. O-Ring Seal 28. External Snapring 43. Dowel Pin (Front)
14. Main Bearing (rear) 29. Clutch Hub 44. Sleeve Bearing (front, long)
15. Internal Snapring 30. Facing Plate 45. End Cap

FIGURE 7-1. FAN CLUTCH CUTAWAY (Typical)
3. Pitot Tube 15. Internal Snapring 28. External Snapring 38. Bolt
4.Wear Sleeve 16. External Snapring 29. Clutch Hub 39. Wear Sleeve
5. Retainer/Seal Assembly 17. Sealring (Hook type) 30. Facing Plate 40. Retainer/Seal Assembly
6. Shaft Assembly 20. Pulley 31. Steel Clutch Plate 41. Sleeve Bearing
8. Washer 22. Sealring (large) 32. Internal Snapring (rear, short)
9. Bolt 23. Piston 33. Main Bearing 42. Fan Mounting Hub
10. Oil Seal 24. Sealring (small) 34. O-Ring Seal Assembly
11. Bearing Retainer 25. Spring Washer 35. Bearing Retainer 44. Sleeve Bearing
13. O-Ring Seal 26. Shim 36. Oil Seal (front, long)
14. Main Bearing 27. External Snapring 37. Washer 45. End Cap

FIGURE 7-4.
FIGURE 7-2.
1. Support the fan clutch on a bench with fan 3. Remove O-Ring seal (34).
mounting hub (42) facing upward. Support the
assembly beneath the pulley. Remove bolts
(38) and washers (37).
FIGURE 7-3. FIGURE 7-5.

2. Install lifting eyes, and attach a hoist and chains
to front bearing retainer (35). Use a small 4. Position the bearing retainer and hub assembly
screwdriver to separate the front bearing on the bench with clutch hub (29) up. Remove
retainer from pulley adapter (21), and set it external snap ring (28).
aside on a bench.

FIGURE 7-8.
FIGURE 7-6.
7. Remove front oil seal (36).
5. Remove clutch hub (29).
FIGURE 7-9.
FIGURE 7-7.
8. Remove internal snap ring (32).

6. Position the sub-assembly beneath the ram of a
press. Support the assembly beneath the bear-
ing retainer as close as possible to fan mount-
ing hub (42). Press the fan mounting hub out of
the front bearing using tooling (B).

FIGURE 7-10.
FIGURE 7-12.
11. Remove front retainer/seal assembly (40).

9. Turn bearing retainer (35) over on the press Wedge a large chisel or other appropriate tool
bed. Press front bearing (33) out of the bearing behind the retainer to force it off fan mounting
retainer using tooling (D). hub (42).
FIGURE 7-13.
FIGURE 7-11. Use a chisel to make three indentations in wear

sleeve (39) in order to loosen the sleeve. The inden-
tations should be approximately 120 apart from one
10. Support beneath the fan mounting hub with end another. Remove the wear sleeve.
cap (45) down, but approximately 2 in. (50 mm)
Use caution when using the chisel. Do not cut
above the press bed. Using a solid steel bar or
through the sleeve. Damage to the shaft can
equivalent, press the end cap from the fan
cause future leaks.
mounting hub.

FIGURE 7-14.
12. Inspect sleeve bearing (44) and sleeve bearing FIGURE 7-16.
(41). Compare the color of each bearing to the
chart below. The lighter the appearance of the 14. Remove the stack of facing plates (30) and
bearing, the more worn it is. If either bearing steel clutch plates (31) from inside the pulley.
needs replacing, proceed to the next step. If the
bearings are in good condition, skip the next
step.
FIGURE 7-17.
FIGURE 7-15.
15. Remove external snap ring (27), shim (26), and
13. Position tooling (C) against sleeve bearing (41). spring washer (25).
Press the front sleeve bearing downward to
press it out of the fan mounting hub. Rear
sleeve bearing (44) will be pressed out simulta-
neously.

FIGURE 7-20.
FIGURE 7-18.
18. Support beneath the pulley to prevent it from
dropping to the bench. Remove bolts (9) with
16. Attach wire lifting hooks to piston (23). Use the lockwashers (8).
lifting hooks to pull the piston from pulley
adapter (21).
FIGURE 7-19.
FIGURE 7-21.
17. Remove seal rings (22 & 24) from the piston.
19. Install lifting eyebolts to the shaft and bearing
retainer assembly. Use a suitable lifting device
to lift the assembly from the pulley. Remove O-
ring seal (13).
NOTE: It may be necessary to use a soft rubber
mallet to separate the shaft and bearing retainer from
the pulley.

FIGURE 7-22.
20. Position the shaft as shown. Insert a phillips-

FIGURE 7-24.
head screwdriver into pitot tubes (3) to loosen
and remove them from the shaft. Rotate the
pitot tube until the sealant holding it tight is bro-
ken loose. Then, grip the pitot tube with a pair of
pliers, and gently tap on the pliers to remove the 22. Remove external snap ring (16).
pitot tubes from the hole in the shaft.
21. Remove both seal rings (17).

23. Remove internal snap ring (15).

FIGURE 7-28.
FIGURE 7-26. 26. Use tooling (E) to press rear bearing (14) out of
rear bearing retainer (11).
24. Support the bearing retainer as close as possi-

ble to the bearing bore. Use care not to damage
the retainer/seal assembly. Press the shaft out
of bearing (14) using tooling (E).
FIGURE 7-29.
27. Use a chisel to make three indentations in wear

sleeve (4). The indentations should be approxi-
FIGURE 7-27. mately 120 apart from one another. Remove
the wear sleeve. Use caution when using the
chisel. Damage to the shaft can cause future
25. Remove oil seal (10) from bearing retainer (11). leaks.

FIGURE 7-30.
28. Remove rear retainer/seal assembly (5). Drive

the assembly off the shaft or wedge a large
chisel or other appropriate tool behind the
retainer to force it off.

CLEANING AND INSPECTION
Thoroughly clean all components before inspection.
Check each of the following components, and follow the guidelines for reuse.
Ball bearings - Replace at time of rebuild.
Internal snaprings - Must not be damaged or worn. Must be flat and have square edges at outer diameter.
External snaprings - Must not be damaged or worn. Must be flat and have square edges at inner diameter.
Sealrings - Replace during rebuild.
Oil seals - Replace during rebuild.
Bolts & washers - Reuse unless damaged or worn.
Retainer/Seal assemblies - Replace if damaged or worn.
Wear sleeves - Replace during rebuild.
Sleeve bearings - Inspect color of surface. Refer to Figure 7-14.
FIGURE 7-31. SHAFT ASSEMBLY WEAR DIMENSIONS
1. Check the shaft assembly for wear or damage. Refer to Figure 7-31 for dimensions.
NOTE: Some shafts were manufactured as two-piece assemblies. Do Not attempt to separate the shaft assembly.
2. Inspect and clean pitot tube holes in the shaft. Use a standard reamer, straight flute 0.3770 in. diameter.
Remove pipe plugs in the shaft for cleaning and reinstall using Loctite Primer N and #242.

FIGURE 7-32.
3. Check pulley and adapter dimensions.
FIGURE 7-34.
5. Check piston (23) dimensions.
FIGURE 7-33.
4. Check rear bearing retainer (11) dimensions.

FIGURE 7-35. PISTON REWORK
(For earlier pistons with the drilled orifice.)
6. Check the piston for a drilled orifice at the inside

face. If the piston contains the orifice, modify
the piston as shown in Figure 7-35.
7. Inspect clutch hub (29) for wear. Wear marks
that may be present on the teeth must not
restrict plate movement. If they have smooth
entry and exit ramps, the notches will not
restrict plate movement and the clutch hub may
be reused.
8. Check steel plates (31) for wear. The plates
must be smooth and free of grooves or heat
related damage. The plates are 0.121 in. mini-
mum thickness (new) and must be flat within
0.005 in.
9. Inspect facing plates (30). New minimum thick-
ness for facing plates is 0.109 in. Grooves are
0.006 in. deep. The plates must be flat within
0.005 in. Check teeth for excessive wear. When
new, the space between the teeth is approxi- FIGURE 7-36.
mately 0.280 in.
10. Inspect fan mounting hub (42).

FIGURE 7-37.
11. Inspect front bearing retainer (35).

12. Inspect end cap (45) for any wear or raised
nicks.

ASSEMBLY - FAN CLUTCH
NOTE: The fan clutch is reassembled using Loctite

(or equivalent) sealants. Follow manufacturer's
recommendations regarding minimum cure time to
prevent oil from washing the sealant from the sealing
surfaces.
1. Place end cap (45) in a freezer or on dry ice to

prepare for installation in the following steps.
FIGURE 7-39.
2. If removed, install dowel pin (43) into fan

mounting hub assembly (42). Refer to Figure 7-
38. Press the pin into the hub leaving 0.090 in.
(2.3 mm) exposed.
If the shaft did not originally come with
pinned bearings, install the dowel per
FIGURE 7-38. instructions in Figures 7-38 and 7-39.

FIGURE 7-40.
FIGURE 7-42.
4. Turn the hub over on the bed of the press.

Again using tooling (B), press rear sleeve bear-
ing (41) into the fan mounting hub until the tool
contacts the shoulder of the hub.
FIGURE 7-41.
3. Using tooling (A), press front (long) sleeve

bearing (44) into the fan mounting hub until the
tool contacts the shoulder of the hub. Ensure
the correct bearing is installed. There are two
sleeve bearings, and each one must be
installed in the proper area of the hub to ensure
the lube passage is not restricted. Refer to Fig-
ure 7-40.

FIGURE 7-44.
FIGURE 7-43.
5. Press front retainer/seal assembly (40) onto the

fan mounting hub (42) using tooling (D). The
inner race of the retainer should be recessed
0.040 in. (1.0 mm) below the shoulder.
Check carefully to insure the retainer/seal
assembly is installed straight, and not bent or
damaged in any way which will cause interfer-
ence between it and the bearing retainer after
assembly.
Front wear sleeve (39) is NOT

interchangeable with rear (notched) wear
sleeve (4). The ID of the front wear sleeve is
color coded red. FIGURE 7-45.
Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from 6. Coat the I.D. of front wear sleeve (39), and the
occurring. wear sleeve diameter of the shaft with Loctite
Primer N and #242 (or equivalent). Using tool-
Use extreme care when handling the wear ing (D), press the wear sleeve onto the shaft,
sleeve. The slightest nicks or scratches may
flush with the shoulder.
cause leakage.
NOTE: Some fan hubs may have a small hole on the
wear sleeve mounting journal. This hole is not used
and will be covered by the wear sleeve.

FIGURE 7-46.
FIGURE 7-48.
7. Coat the bore of the fan mounting hub (42) with
a thin coating of Loctite Primer N and #242. 9. Install internal snap ring (32).
Remove frozen end cap (45) from the freezer.

Do not apply Loctite to the end cap. Press the
end cap into the hub until the cap bottoms out.
FIGURE 7-47.
FIGURE 7-49.
8. Apply Loctite Primer N and #609 to the mating

surfaces of front bearing (33) and front bearing 10. Turn the retainer over on the press bed. Coat
retainer (35). Place the bearing into position on the O.D. of front oil seal (36) and mating surface
the retainer with the notch for the bearing pin on the bearing retainer with Loctite Primer N
facing downward. and #242 (or equivalent). Use tooling (E) to
press the oil seal into the front bearing retainer,
Press the front bearing into the bearing retainer flush with the front face. Ensure the lip of the
using tooling (E) or equivalent. Press ONLY on seal is dry. Wipe any excess Loctite from the
the outer race of the bearing until it seats at the seal area and remove any rubber strings from
bottom of the bore. the seal.

FIGURE 7-50.
11. Coat the bearing I.D.and the fan mounting hub

bearing journal with Loctite Primer N and #609
(or equivalent). Place the front bearing retainer FIGURE 7-51.
sub-assembly into position on the fan mounting
hub. (Ensure the notch in the bearing is aligned
with the bearing dowel pin.) Do not allow the 12. Install clutch hub (29) on the fan mounting hub
seal lip to come in contact with the Loctite. assembly (42) with the open end down. (No
Press the bearing onto the hub using tooling (D) special timing is necessary.)
until it contacts the wear sleeve.
Wipe any lubricant or sealer from the seal
lip. The seal lip is teflon and must remain
dry for proper sealing to occur.
Spin the bearing retainer at least 25 revolutions
to ensure proper rotation of the bearing and to
burnish the seal.
FIGURE 7-52.
13. Install external snap ring (28) to hold the clutch

hub in place.

FIGURE 7-53.
FIGURE 7-55.
15. Use tooling (D) to press the rear retainer/seal

assembly (5) onto shaft (6). The inner race of
the retainer should be recessed 0.040 in. (1.0
mm) below the shoulder.
Check carefully to insure the retainer/seal
assembly is installed straight, and not bent or
damaged in any way which will cause interfer-
ence between it and the bearing retainer after
FIGURE 7-54. assembly.
14. If removed, install rear dowel pin (2) in shaft

assembly (6). Press the pin until 0.080 in. (2.0
mm) is left exposed above the surface.
If the shaft did not originally come with
pinned bearings, install the dowel per
instructions in Figures 7-53 &7-54.

FIGURE 7-57.
FIGURE 7-56. 17. Coat the OD of rear bearing (14) and the mating
surface of bearing retainer (11) with Loctite
Primer N and #609 or equivalent.
The end of the bearing with the notch is
installed first. Press the bearing into the bearing
retainer using tooling (F) or equivalent. Press
only on the outer race of the bearing, until the
bearing bottoms out in the bore.
Rear (notched) wear sleeve (4) is NOT
interchangeable with front wear sleeve (39).
The ID of the rear wear sleeve is color coded
blue.
Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from
occurring.
Use extreme care when handling the wear
sleeve. The slightest nicks or scratches may
cause leakage.
16. Coat the I.D. of the rear, (notched) wear sleeve

(4), and the wear sleeve diameter of the fan
mounting hub with Loctite Primer N and #242
(or equivalent). Locate the sleeve so the notch
in the sleeve will be aligned with the small lube FIGURE 7-58.
hole in the shoulder. Press the wear sleeve
onto the fan mounting hub, flush with the shoul-
der using tooling (D).
18. Install internal snap ring (15).

FIGURE 7-59.
19. Some fan clutches were assembled with an external snapring that is used as a spacer between the bearing
and the oil seal. Newer models were assembled using a notched spacer. If an external snapring was used,
place the snapring (12) on top of the bearing (oil seal side). If a notched spacer was used, the spacer will be
installed in a later step. Proceed to the following step.
FIGURE 7-60.
FIGURE 7-61.
20. Coat the O.D. of rear oil seal (10) with Loctite 21. If a bearing spacer is used instead of a snapring
Primer N and #242 (or equivalent). Use tooling as explained in Step 19, place the spacer into
(E) or the equivalent to install the oil seal in the position in the groove on shaft assembly (6).
rear bearing retainer, flush with the rear face. Note the location of the spacer in Figure (7-61).
Do not lubricate the seal. The seal is made of
teflon and must be installed dry.

FIGURE 7-62.
FIGURE 7-63.
23. Install external snap ring (16). Ensure the

22. Place the shaft sub-assembly on the press bed. snapring is fully seated in the groove. It may be
Coat the bearing I.D., and bearing journal on necessary to tap on the snapring with a screw-
the shaft with Loctite Primer N and #609 (or driver to fully seat the snapring.
equivalent).
Carefully, lower the rear bearing retainer sub-
assembly in place on the shaft. Do not allow the
seal lip to come in contact with the Loctite.
Ensure the notch in the bearing and the dowel
pin are aligned. If external snapring (16) was
installed in the bearing retainer, ensure the
opening is aligned with the dowel pin.
Press the bearing onto the shaft until it reaches
the shoulder of the wear sleeve. Wipe any
excess Loctite from the assembly.
Ensure the seal lip is dry. The seal must
remain dry for proper sealing.
Spin the bearing retainer approximately 25
times to burnish the teflon seal on the wear
sleeve. Check for abnormal sounds or other
indications of contact between the retainer/seal
assembly and the bearing retainer. If interfer-
ence is found, remove the bearing retainer and
eliminate the point of interference.
FIGURE 7-64.
24. Be sure the pitot tube holes in the shaft are

clean and free of burrs and staking material, to
allow the pitot tubes to fit into the holes and seat
completely to the bottom. Apply a thin coating of
Loctite Primer N and #609 (or equivalent) on
the straight end of one pitot tube (3). Coat the

tube to approximately 0.75 in. (20 mm) from the
end.
Push the pitot tubes to the bottom of the hole.
The outer end of the tube should be located well
within the pulley-locating shoulder of the bear-
ing retainer. Rotate the tube so the open, bent
end faces in a counter-clockwise direction, and
is exactly parallel to the surface of the bearing
retainer. (A large phillips-head screwdriver
inserted in the end of the tube can be conve-
niently used as an alignment gage).
Install the second pitot tube in the same manner
as the first. Stake each pitot tube in three
places, (at the 9, 12, and 3 o'clock positions) to
prevent the tubes from rotating in operation.
FIGURE 7-66.
26. Install small seal ring (24) in the inside groove,

and large seal ring (22) in the outside groove of
piston (23). Lubricate the seal ring grooves with
an oil-soluble lubricant such as engine assem-
bly grease before installation. Refer to the Fig-
ure 7-66 for proper orientation.
FIGURE 7-65.
25. Install both hook-type seal rings (17) in the

grooves in the shaft. Rotate the rings so the slits FIGURE 7-67.
in the rings are 180 apart from one another.
27. Lubricate the external surfaces of seal rings (22

& 24) with an oil-soluble lubricant such as
engine assembly grease. Also, lubricate the
seal mating surfaces in the pulley adapter.

28. Carefully, place the piston in the pulley.
Do Not push the piston in place!
Without pressing down on the piston, rotate it
slowly clockwise-counterclockwise until it falls
into place. (Forcing the piston will usually cause
the seal rings to be cut.)
FIGURE 7-69.
30. Install spring washer (25), shim (26), and

spirolock ring (27). It will be necessary to press
downward to compress the spring washer,
while forcing the spirolock to properly seat in
the groove. The shim must then be centered on
the spring washer to prevent it from interfering
with the movement of the piston.
FIGURE 7-68.
29. Align the tangs of the piston for easy final

assembly of the fan clutch. Lift the front bearing
retainer sub-assembly in place on the pulley.
While doing so, the slots of the front bearing
retainer will engage the tangs of the piston, and
the retainer will rest against the pulley.
Then, rotate the bearing retainer (and piston)
until the bolt holes align in the bearing retainer
FIGURE 7-70.
and pulley. Carefully, remove the bearing
retainer sub-assembly. 31. Place the front bearing retainer sub-assembly
on the bench with the clutch hub up.
Install one steel clutch plate (31) in place in the
bearing retainer. Now dip a facing plate (30) in
new engine oil, allow the excess to drain off,
and place the plate on top of the steel plate.
Repeat this step until all 16 plates have been
installed.

32. Turn the pulley adapter assembly over and
install two lifting eyes 180 apart. Install a
guide-bolt in one bolt hole of the pulley. Refer to
Figure 7-71.
Coat front O-Ring seal (34) with petroleum jelly
or an oil-soluble grease. Place the seal in the
groove in the pulley. The grease should secure
the seal in the groove during installation.
Carefully lower the pulley. Ensure the guide bolt
is aligned with a bolt hole in the bearing retainer
assembly and the O-ring seal is still securely in
place. Lower the pulley until it rests on the front
bearing retainer.
FIGURE 7-71.
FIGURE 7-73.
33. Install at least four bolts (38) with lockwashers

(37) and snug. Insert the bolts 90 apart.
FIGURE 7-72.

FIGURE 7-76.
FIGURE 7-74.
36. Install bolts (9) with lockwashers (8), and torque
each one to 49-58 Nm (36-43 lb ft).
34. Lubricate O-Ring seal (13) with petroleum jelly

or an oil-soluble grease and install in the pulley
groove.
FIGURE 7-77.
FIGURE 7-75.
35. Lubricate the hook type sealrings (17) on the 37. If removed, install orifice fitting (1) in the "oil in"
shaft assembly. Carefully lower the shaft sub- port of the bracket.
assembly into the pulley bore and onto the pul-
ley until the retainer rests on the pulley. Use
caution when lowering. Damage to the sleeve
bearings may result if the shaft is cocked during
installation.

FIGURE 7-78.
38. Turn the assembly over on the bench. Install the remaining bolts (38) and lockwashers (37), and torque all to
49-58 Nm (36-43 lb ft).

TEST PROCEDURE
1. The fan clutch should be fully locked up with 40 psi oil pressure supplied at the control pressure port.
2. Operate the fan clutch with 180 F (82 C) oil supplied to the oil in port for 2 hours. Manually engage and dis-
engage the clutch during the test to operate seals in both modes. Restrict the fan mounting hub rotation while
the clutch is disengaged, but ensure the fan mounting hub is allowed to rotate freely while the clutch is
engaged.
The fan clutch rotation causes the pitot tubes to pump lubrication oil from inside the fan clutch,
maintaining low internal oil pressure. If lubricating oil is supplied to the fan clutch before it is rotating in
the proper direction, internal pressures will become excessive, causing the oil seals to leak.

SECTION D
ELECTRICAL SYSTEM
INDEX
BATTERIES AND STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-1
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-1
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D21-1
VHMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-1
D01043 05/08 Index D1-1

NOTES
D1-2 Index 05/08 D01043

SECTION D2
BATTERIES AND STARTING SYSTEM
INDEX
BATTERIES AND STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
MAINTENANCE AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Electrolyte Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Other Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-4
ENGINE PRELUB SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
Timer Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
Prelub System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
Prelub Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9
Timer Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9
PRELUB CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-10
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12
CRANKING MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13
Armature Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13
Field Coil Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-14
Field Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-14
D02036 Batteries And Starting System D2-1

Solenoid Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19
Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19
No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19
Interpreting The Results of The Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-20
MAGNETIC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-21
Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-21
D2-2 Batteries And Starting System D02036

BATTERIES AND STARTING SYSTEM
BATTERIES Electrolyte Levels
A 24VDC electrical system, generated by four 12 volt Check the electrolyte level of each battery cell at the
batteries, supplies power for the starting system. The interval specified in Section P, Lubrication and Ser-
batteries are wired in series and parallel. The four vice. Add water if necessary. The proper level to
batteries are a lead-acid type, each containing 6, 2- maintain is 10-13 mm (0.38 - 0.5 in.) above the
volt cells. With the key switch ON and the engine off, plates. To ensure maximum battery life, use only dis-
power is supplied by the batteries. When the engine tilled water or water recommended by the battery
is on, electrical power is supplied by a 24 volt alterna- manufacturer. After adding water in freezing weather,
tor. For information on the alternator, refer to the operate the engine for at least 30 minutes to thor-
charging system chapter later in this section. oughly mix the electrolyte.
The batteries function as an electrochemical device Excessive consumption of water indicates leakage or
for converting chemical energy into electrical energy. overcharging. Normal water usage for a unit operat-
This energy is required for operating the accessories ing eight hours per day is approximately 30 - 60 ml (1
when the engine is off. - 2 oz) per cell, per month. For heavy duty operation
(24 hour) normal consumption is approximately 30 -
60 ml (1 - 2 oz) per cell, per week. Any appreciable
increase over these figures is considered a sign that
a problem exists.
Lead-acid batteries contain sulfuric acid which Leakage can be detected by continual wetness of the
may cause burns and other serious injuries. battery or excessive corrosion of the terminals, bat-
Wear protective gloves, aprons and eye protec- tery carrier and surrounding area. (A slight amount of
tion when handling and servicing lead-acid bat- corrosion is normal in lead-acid batteries). Inspect
teries. See the precautions in Section A, Safety, the case, covers and sealing compound for holes,
to ensure proper handling of batteries and to pre- cracks or other signs of leakage. Check the tightness
vent accidents. of the battery hold down. Overtightening will crack
the battery, and under-tightening will allow vibration
to open the seams. A leaking battery must be
replaced.
MAINTENANCE AND SERVICE Cleaning
To remove corrosion, clean the battery with water,
baking soda and a stiff, non-wire brush. Flush with
clean water. Do not allow the baking soda solution
into the battery cells.
Ensure the battery terminals are clean and tight.
DO NOT smoke or allow flame around a dead bat- Clean terminals are very important in a voltage regu-
tery or during the recharging operation. The lated system. Corrosion creates resistance in the
expelled gas from a dead cell is extremely explo- charging circuit causing undercharging and gradual
sive. starvation of the battery.

Other Maintenance
Adding acid will be necessary if considerable electro- The rate of self-discharge of a battery kept at 38C
lyte has been lost through spillage. Before adding (100F) is about six times that of a battery kept at
acid, ensure the battery is fully charged. This is 19C (50F). Self-discharge of a battery kept at 27C
accomplished by putting the battery on a charger and (80F) is about four times that of one at 50F (10C).
taking hourly specific gravity readings on each cell. Over a thirty day period, the average self-discharge
When all the cells are gassing freely and three suc- is about 0.002 specific gravity per day at 27C
cessive hourly readings show no rise in specific grav- (80F).
ity, the battery is considered fully charged. Additional
To offset the results of self-discharge, booster-
acid may now be added. Continue charging for
charge idle batteries at least once every thirty days.
another hour and again check specific gravity.
Do not quick charge the batteries.
Repeat the above procedure until all cells indicate a
specific gravity of 1.260-1.265 corrected to 27C Idle batteries in a discharged state are attacked by a
(80F). crystallization of the lead sulfate on the plates. Such
batteries are called sulfated and are, in the majority
If the temperature of the electrolyte is not reasonably
of cases, irreparably damaged. In less severe cases,
close to 27C (80F) when the specific gravity is
the sulfated battery may be restored to limited ser-
taken, the temperature must be adjusted to 27C
vice by prolonged charging at a low rate (approxi-
(80F):
mately normal rate).
For every 5C (10F) below 27C (80F), subtract
An undercharged battery is extremely susceptible to
0.004 from the specific gravity reading.
freezing when left idle in cold weather. The electro-
For every 5C (10F) above 27C (80F), add lyte of a battery in various stages of charge will start
0.004 to the specific gravity reading. to freeze at temperatures indicated in Table 1. The
temperatures in Table I indicate the points at which
the first ice crystals appear. Lower temperatures
Use 1.400 strength sulfuric acid when making spe- must be reached for a solid freeze. Solid freezing of
cific gravity adjustments. Acid of higher strength will the electrolyte may crack the battery case and dam-
attack the plates and separators before it has a age the positive plates. A fully charged battery is not
chance to diffuse into the solution. susceptible to freezing. Therefore, keeping the bat-
Do not allow idle batteries to go unattended. If equip- tery fully charged is especially important during win-
ment is to go unused for more than two weeks, ter weather.
remove the batteries and place in a cool, dry place.
Periodically check the batteries and charge as
needed. Remember, all lead-acid batteries discharge
when not in use. Self discharge takes place even TABLE 1.
when the battery is not connected in a circuit. This Specific Gravity Freezing Temperature
phenomenon is more pronounced in warm weather Corrected to Degrees
than in cold. 80F (27C)
1.280 -70C (-90F)
1.250 -54C (-60F)
1.200 -27C (-16F)
1.150 -15C (+5F)
1.100 -7C (+19F)

The two most common problems that occur in the
charging system are undercharging and overcharg-
ing.
An undercharged battery is incapable of providing
sufficient power to the truck's electrical system.
Possible causes for an undercharged battery are:
Sulfated battery plates
Loose battery connections
Defective wire in electrical system
Loose alternator drive belt
A defective alternator
A defective battery equalizer
Overcharging, which causes battery overheating, is
first indicated by excessive use of water. If allowed to
continue, cell covers will push up at the positive ends
and in extreme cases the battery container will
become distorted and cracked.

ENGINE PRELUB SYSTEM
The engine is equipped with an pre-lubrication sys- When the pressure in the engine cam oil rifle reaches
tem designed to reduce wear that occurs during dry 17 kPa (2.5 psi), the pressure switch contacts open,
starts. disabling the circuit to the timer solenoid. The sole-
noid contacts for alternator power to the prelub pump
The Prelub system automatically fills engine oil fil- open, and current is directed to the magnetic
ters and oil passages prior to cranking at each switches that control the cranking motor solenoids.
engine startup. The system also prevents startup if The cranking motors will then be activated and the
oil pressure in the engine is insufficient. pinion gears will be engaged into the flywheel ring
The Prelub system includes: gear. Normal cranking will now occur with sufficient
lubrication to protect the engine bearings and other
Prelub pump components.
Timer solenoid NOTE: The power circuit from the alternator to the
Oil pressure switch pump is protected by a 400 amp fusible link. A
clamping diode in the circuit dissipates voltage
Oil suction line
spikes.
Oil outlet line
Check valve
Electrical harness.
OPERATION
Refer to the electrical schematic diagram in Figure 2-
3.
The Prelub system is activated when the operator
turns the key switch and holds it in the START posi-
tion. This allows current to flow to the timer solenoid.
Engine oil pressure switch (2, Figure 2-1) provides
the ground for the circuit. The switch contains nor-
mally closed contacts that open when oil pressure
reaches 17 kPa (2.5 psi). While the contacts are
closed, the timer solenoid closes the contacts that FIGURE 2-1. REMOTE MOUNT PRELUB PUMP
supply power from the alternator to the prelube
motor/pump. The pump, which has a dedicated 1. Prelub Pump 3. Outlet Line
frame ground, begins pumping oil into the engine. 2. Suction Line 4. Check Valve
During this time, the timer solenoid prevents the
cranking motors from operating.

FIGURE 2-2. PRELUB TIMER
1. Prelub Timer 3. Frame Ground
2. B+ From Alternator
FIGURE 2-3. PRELUB SCHEMATIC DIAGRAM
1. Prelub Pump 5. Diode

2. Oil Pressure Switch (N.C.) - 17 kPa (2.5 psi) 6. Prelub Timer Solenoid
3. Cranking Motors 7. Alternator
4. Magnetic Switch 8. 400 Amp Fusible Link

When the switch opens, current is redirected to the
starting system magnetic switches for engine crank-
ing.
DO NOT attempt to jump start the truck using the

terminals on the timer solenoid. Internal damage
to the timer will result.
MAINTENANCE
Prelub System Operation
FIGURE 2-4. ENGINE OIL PRESSURE SWITCH Verify the system operates according to the two
1. Oil Pressure Switch 2. Engine Damper phases of operation as listed in Prelub Circuit Trou-
bleshooting in this chapter. If a problem exists, refer
to the list of problems and possible causes for trou-
bleshooting system components.
Oil Pressure Switch If the system is operating properly, continue with the
Oil pressure switch (1 Figure 2-4) is a 17 kPa (2.5 inspection of component parts below:
psi), normally closed (NC) switch. The location of the
switch allows it to sense oil pressure after the engine Prelub Pump
oil has passed through the filters. Normally, this loca- 1. Open the battery disconnect switches to pre-
tion is the cam cover at the rear of the engine block vent engine startup.
just ahead of engine damper (2).
Check Valve
Check valve (4, Figure 2-1) is installed between the
prelub pump pressure hose and the engine. The oil
flow through the valve (arrow on valve) must be
toward the engine. The check valve prevents back-
flow from the engine back to the prelub pump after
the engine is started. Failure to prevent backflow to
the pump will result in pump failure.
Timer Solenoid
Timer solenoid (1, Figure 2-2) controls the prelubri-
cation cycle by completing the power supply circuit to
operate the prelub pump. Current is supplied to the
timer solenoid through the key switch. The ground FIGURE 2-5. MOTOR COVER
path is completed by the normally closed pressure 1. Cap Screw 2. Cover
switch (1, Figure 2-4) which is preset to open at 17
kPa (2.5 psi).
2. Remove a pump cap screw (1, Figure 2-5) from
the electric motor. Remove the cap screw that
is nearest the six oclock position.

3. Inspect the cap screw for any signs of oil. Oil Check Valve
may be present in large amounts or as a light
Verify no internal leakage exists in the check valve
mist. Oil in any quantity in the housing indicates
when the engine is on. Check valve leakage back to
a failed motor and repair or replacement is nec-
the pump will cause extensive damage to the pump.
essary. Proceed to the next step to determine
what components require repair. If check valve replacement is required, install the
valve with the arrow pointed toward the engine, not
toward the pump.
Timer Solenoid
Brush dust will be present in all motors. Do not Inspect the timer solenoid for physical damage. Ver-
confuse brush dust with oil. Brush dust will ify the wiring and connectors are in good condition.
appear as a black/brown, dry coating within the
motor.
4. If oil is present in the motor, disconnect output

line (3, Figure 2-1) from the pump. Place the
hose in a oil capture container, and secure. Use
caution when securing the hose. Oil may exit
the line at normal operating pressures.
Use extreme caution when performing the follow-

ing step. Hot oil can cause severe burns.
5. Start the engine, and observe the output line

while the engine is operating to verify that check
valve (4) is functioning properly.
a. If there is no oil flow from the hose, only the
pump must be replaced.
b. If there oil flow from the hose, the check
valve is faulty. The pump and check valve
must be replaced.

PRELUB CIRCUIT TROUBLESHOOTING
Two distinct phases are involved in a complete prelubrication cycle. The two phases are:
1. Prelubrication phase- Begins when the key switch is held in the start position. The circuit is completed by a
ground path through the normally closed pressure switch. The circuit is interrupted when oil pressure reaches 17
kPa (2.5 psi) and opens the contacts in the pressure switch.
2. Crank phase- Begins when the engine oil pressure switch opens, and cranking occurs.
PROBLEM POSSIBLE CAUSES

System lubricates only. Cranking is inoperable. Oil pressure is not sufficient to open the pressure
switch.
a. No oil or low oil in engine. The pump can not
build sufficient pressure to open switch.
b. Pump failure.
c. Pressure switch has failed (closed) and is
grounding circuit.
d. Oil pressure switch wire chafed and shorting
to block.
Possible timer failure, or a cranking motor problem.
a. Install a jumper cable to the cranking motor
solenoid S post. If the engine starts to crank,
replace the prelub timer solenoid.
b. If the engine fails to crank when the S post is
energized with voltage, check cranking motors
and solenoids.
System lubricates continuously regardless of key Indicates prelub timer solenoid contacts have welded.
switch position.
a. Low voltage can cause relay failure.
b. Jump starting of the vehicle with a voltage that
is higher than was designed for the system,
can cause solenoid contacts to weld.
Cranking motor bounces when cranking. Check for low or dead batteries.
Check alternator output.
Check for bad ground strap or missing ground wire
from the starter battery ground post to G terminal of
starting solenoid.
Check for bad starter safety relays.
System lubricates, but does not crank. Indication is either a timer failure, or a starter problem.
a. Place a jumper wire to the starter solenoid S
post. If the engine starts to crank, replace the
prelub timer solenoid.
b. If the engine fails to crank when the S post is
energized with voltage, check the starting
solenoid and pinion drive.

PROBLEM POSSIBLE CAUSES
No prelubrication mode, but cranking still operable. Indicates that a ground connection to the pressure
switch has been broken. Without a ground path, the
prelubrication unit will proceed to crank phase.
a. Check the wire to the pressure switch. If the
wire is removed or cut, replace it.
b. Check the ground strap to engine block. If the
ground strap is missing the block is not
grounded.
c. Check the pressure switch for an open circuit.
Remove the wire, then check for an open cir-
cuit between the switch terminal and the
switch base. If open, replace the pressure
switch.
System has very long prelubrication cycle. Except for severe cold weather starts, the prelub cycle
should not exceed 45 seconds.
a. Low oil pressure.
b. Verify oil of the proper viscosity is being used
in respect to outside temperature. Refer to
engine manufacturer's specifications.
c. Check for suction side air leaks, loose con-
nections, cracked fittings, pump casting, or
hose kinks and blockage.
d. Verify the suction hose is the correct diame-
ter. Reducing hose diameter will reduce pump
output, dramatically.
e. Check the oil pressure switch for the correct
location. Verify that it has not been moved into
a metered oil flow, as in a bypass filter or gov-
ernor assembly.
No prelubrication and no crank. Indicates a possible failure of the prelubrication timer

solenoid. Remove the wire from the pressure switch
(ground wire) and attempt to start the machine.
a. If the cranking motor now cranks, the prelub
timer solenoid is bad. Replace the timer sole-
noid assembly.
b. If the cranking motors do not crank, ensure all
relays, circuit breakers, switches, etc. are in
working condition. Repair as necessary.

STARTING SYSTEM CRANKING MOTORS
Heavy duty batteries supply 24VDC to each of the Removal
two cranking motors. Current from the batteries flow
1. Disconnect battery power:
through two magnetic switches that are activated by
the key switch. a. Open the battery disconnect switch to
remove power from the system.
When the key switch is moved to the START posi-
tion, the prelub system is activated. Refer to Prelub b. Remove the battery cables using the follow-
System. The prelub system lubricates internal engine ing sequence:
components with oil to prevent excessive wear due 1.) Remove the battery positive (+) cables
to dry starts. When oil pressure reaches 17 kPa (2.5 first.
psi), current flow is diverted to the cranking system
by the prelub timer solenoid. The magnetic switches 2.) Remove the negative (-) cables last.
close, connecting the motor solenoid "S" terminals to 2. Label all wiring at the cranking motor and the
the batteries. When the solenoid windings are ener- solenoid. Remove the wiring from the motor and
gized, plunger (56, Figure 2-7) is pulled in. Starter solenoid terminals.
drive (71) moves forward in the nose housing to 3. Remove motor mounting cap screws (1,
engage the engine flywheel ring gear. When the Figure 2-6).
solenoid plunger is pulled in, the main solenoid con-
tacts close to provide current to the cranking motor 4. Remove the cranking motor from the flywheel
armature and cranking occurs. After the engine housing. The weight of the cranking motor is
starts, an overrunning clutch in the drive assembly approximately 36 kg (80 lb).
protects the armature from excessive speed until the
key switch is released. When the key switch is
released, a return spring causes the drive pinion to
disengage.
After the engine has started, a normally closed pres-
sure switch senses engine oil pressure and opens
the electrical circuit. This prevents actuation of the
cranking motors with the engine on.
FIGURE 2-6. STARTER MOTORS
1. Mounting Cap Screws 3. Solenoid

2. Cranking Motor

Disassembly Armature Servicing
Only disassemble the cranking motor as far as nec- If the armature commutator is worn, dirty, out of
essary to repair or replace defective parts. round, or has elevated insulation, use a lathe to
machine armature (45). Machine the insulation to
1. Note the relative position of solenoid (53,
0.79 mm (0.031 in.) wide and 0.79 mm (0.031 in.)
Figure 2-7), lever housing (78), nose housing
deep. Clean the slots to remove any trace of dirt or
(69), and Commutator End (CE) frame (1). The
copper dust. As a final step in this procedure, lightly
motor must be reassembled in the same man-
sand the commutator with number 00 sandpaper to
ner.
remove any burrs resulting from machining.
2. Disconnect field coil connector (42) from the
solenoid motor terminal. Remove the lead from Check the armature for opens, short circuits and
the solenoid ground terminal. grounds as follows:
3. Remove brush inspection plates (52) and brush 1. Opens are usually caused by excessively long
lead screws (15). cranking periods. The most likely place for an
4. Remove bolts (34) and separate commutator open to occur is at the commutator riser bars.
end frame (1) from field frame (35). Inspect the points where the conductors are
joined to the commutator bars for loose connec-
5. Remove bolts (70). Separate nose housing (69)
tions. Poor connections cause arcing and burn-
and field frame (35) from lever housing (78).
ing of the commutator as the cranking motor is
6. Remove armature (45) and drive assembly (71) used. If the bars are not badly burned, repair
from lever housing (78). can often be effective by soldering or welding
7. Pull solenoid (53) from the lever housing. the leads in the riser bars (using rosin flux), and
machining the commutator in a lathe to remove
the burned material. The insulation must then
Cleaning and Inspection be undercut.
2. Short circuits in the armature are located by use
1. Drive (71, Figure 2-7), armature (45) and fields
of a growler. When the armature is revolved in
(46) can not be cleaned with degreaser or
the growler with a steel strip such as a hacksaw
grease dissolving solvents. Solvents would dis-
blade held above it, the blade will vibrate above
solve the lubricant in the drive and damage the
the area of the armature core in which the short
insulation in the armature and field coils.
circuit is located. Shorts between bars are
2. Clean all parts, except the drive, with mineral sometimes produced by brush dust or copper
spirits and a clean cloth. between the bars. These shorts can be elimi-
3. If the commutator is dirty, it may be cleaned nated by cleaning out the slots.
with number 00 sandpaper. 3. Grounds in the armature can be detected by the
NOTE: DO NOT use emery cloth to clean the use of a 110-volt test lamp and test points. If the
commutator. lamp lights when one test point is placed on the
commutator with the other point on the core or
4. Inspect brushes (13) for wear.
shaft, the armature is grounded. Grounds occur
a. Compare the brushes with a new brush. If as a result of insulation failures. These failures
worn excessively, replace with new brushes. are often caused by overheating of the cranking
b. Ensure brush holders (10) are clean and the motor produced by excessively long cranking
brushes are not binding in the holders. periods. Accumulation of brush dust between
the commutator bars and the steel commutator
c. The full brush surface should ride on the ring can also cause this type of failure.
commutator. Check by hand to ensure that
brush springs (16) are providing firm contact
for the brushes against the commutator.
d. If springs (16) are distorted or discolored,
replace with new springs.

Field Coil Checks
Field coils (46, Figure 2-5) can be checked for
grounds and opens by using a test lamp.
1. CE Frame 42. Connector
1. Grounds- The ground connections must be dis- 2. Washers 43. Lock Washer
connected during this check. Connect one lead 3. O-Ring 44. Nut
of the 110 volt test lamp to field frame (35) and 4. Insulator 45. Armature
the other lead to field connector (42). If the lamp 5. Support Plate 46. Field Coil (6 Coils)
lights, at least one field coil is grounded and 6. Brush Plate Insulator 47. Shoe
must be repaired or replaced. 7. Washers 48. Insulator
2. Opens- Connect test lamp leads to ends of field 8. Plate & Stud 49. Screw
coils (46). If the lamp does not light, the field 9. Plate 50. Washer
coils are open. 10. Brush Holder 51. O-Ring
11. Lock Washer 52. Inspection Plug
12. Screw 53. Solenoid Housing
Field Coil Removal 13. Brush (12 req'd) 54. Lock Washer
14. Lock Washer 55. Screw
Field coils can be removed from the field frame 15. Screw 56. Plunger
assembly by using a pole shoe screwdriver. Use a 16. Brush Spring 57. Washer
pole shoe spreader to prevent distortion of the field 17. Screw 58. Boot
frame. Careful installation of the field coils is neces- 18. Screw 59. Washer
sary to prevent shorting or grounding of the field coils 19. Screw 60. Spring
as the pole shoes are tightened into place. The pole 20. Lock Washers 61. Retainer
shoe has a long lip on one side and a short lip on the 21. Plate 62. Snap Ring
other. Assemble the long lip in the direction of arma- 22. Brush Holder Insulator 63. Shift Lever
ture rotation so it becomes the trailing (not leading) 23. Screw 64. Nut
edge of the pole shoe. 24. Lock Washer 65. O-Ring
25. Washer 66. O-Ring
26. O-Ring 67. Snap Ring
27. Bushing 68. Lever Shaft
28. Insulator 69. Drive Housing
29. Washer 70. Screw
30. Lock Washer 71. Drive Assembly
31. Nut 72. Gasket
32. Nut 73. Plug
33. Lock Washer 74. Gasket
34. Screw 75. Brake Washer
35. Field Frame 76. Screw
36. Stud Terminal 77. Lock Washer
37. Bushing 78. Lever Housing
38. Gasket 79. Washer
39. Washers 80. O-Ring
40. Washer
41. Nut

FIGURE 2-7. CRANKING MOTOR ASSEMBLY

Solenoid Checks
A basic solenoid circuit is shown in Figure 2-8. Sole-
noids can be checked electrically using the following
procedure.
Test
1. Disconnect all leads from the solenoid. Make
test connections as shown to the solenoid, the
switch terminal and the second switch terminal
"G", to check the hold-in winding (Figure 2-9).
2. Use the carbon pile to decrease battery voltage
to 20 volts. Close the switch and read current.
a. The ammeter should read 6.8 amps max.
3. To check the pull-in winding, connect from the
solenoid switch terminal "S" to the solenoid
FIGURE 2-8. SIMPLIFIED SOLENOID CIRCUIT
motor "M" or "MTR" terminal (Figure 2-10).
To prevent overheating, do not leave the pull-in

winding energized more than 15 seconds. The
current draw will decrease as the winding tem-
perature increases.
4. Use the carbon pile to decrease battery voltage

to 5 volts. Close the switch and read current.
a. The ammeter should read 9.0 to 11.5 amps.
NOTE: High readings indicate a shorted winding.
Low readings indicate excessive resistance.
5. To check for grounds, move the battery lead

from "G" and from "MTR" to the solenoid case.
The ammeter should read 0 amps. If not, the
winding is grounded.
FIGURE 2-9. SOLENOID HOLD-IN WINDING TEST

3. Do not cross-drill bearings. Because the bear-
ings are highly porous, oil from the wick touch-
ing the outside bearing surface will bleed
through and provide adequate lubrication.
4. The middle bearing is a support bearing used to
prevent armature deflection during cranking.
The clearance between this bearing and the
armature shaft is large compared to the end
frame bearings.
Motor Assembly
1. Install the end frame (with brushes) onto the
field frame as follows:
a. Insert armature (45, Figure 2-7) into field
frame (35). Pull the armature out of the field
frame just far enough to permit the brushes
to be placed over the commutator.
b. Place end frame (1) on the armature shaft.
Slide the end frame and armature into place
against the field frame.
c. Insert screws (34) and washers (33). Tighten
securely.
FIGURE 2-10. SOLENOID PULL-IN
2. Assemble lever (63) into lever housing (78), if
WINDING TEST
removed.
3. Place washer (79) on the armature shaft and
install new O-ring (80). Position drive assembly
(71) in lever (63) in the lever housing. Apply a
Assembly light coat of lubricant (Delco Remy Part No.
1960954) on washer (75) and install over the
Lubricate all bearings, wicks and oil reservoirs with armature shaft. Align the lever housing with the
SAE No. 20 oil during assembly. field frame and slide the assembly over the
armature shaft. Secure with screws (76) and
Bearing Replacement
washers (77).
1. If any of the bronze bearings are to be replaced, 4. Assemble and install the solenoid assembly
dip each bearing in SAE No. 20 oil before through the lever housing. Attach to the field
pressing into place. frame. Install nut (64) but do not tighten at this
Install the lubricated wick prior to installing the time. Install brush inspection plugs (52).
bearings.
2. Do not attempt to drill or ream sintered bear-
ings. These bearings are supplied to size. If
drilled or reamed, the I.D. will be too large and
the bearing pores will seal over.

5. Using a new gasket (72), install drive housing 2. Momentarily flash a jumper lead from terminal
(69) and secure with screws (70). "G to terminal "MTR". The drive will now shift
6. Assemble field coil connector (42) to the sole- into cranking position and remain so until the
noid. batteries are disconnected.
7. Adjust the pinion clearance per instructions in 3. Push the pinion or drive back towards the com-
Pinion Clearance. mutator end to eliminate endplay.
8. After pinion clearance has been adjusted, install 4. Measure the endplay with a feeler gauge, as
gasket (74) and plug (73). shown in Figure 2-12. The correct distance
between the drive pinion and housing is 8.3 -
9.9 mm (0.330 - 0.390 in.).
5. Adjust the clearance by turning shaft nut (64,
Figure 2-7).
Pinion Clearance
To adjust the pinion clearance, follow the steps listed
below.
1. Make connections as shown in Figure 2-11.
FIGURE 2-12. CHECKING PINION CLEARANCE
FIGURE 2-11. PINION CLEARANCE CHECK

CIRCUIT

Installation No-Load Test
1. Lift cranking motor (2, Figure 2-6) into position. Refer to Figure 2-13 for the following test setup.
The weight of the cranking motor is approxi-
2. Align the housing of the cranking motor with the
flywheel housing mounting holes. Slide the
motor into position. Ensure the switch is open before connecting or
3. Insert motor mounting cap screws (1). disconnecting test leads during the following
procedures.
4. Connect the labeled wires and cables to the
motor and solenoid terminals.
5. Connect the batteries in the following
sequence:
a. Install the battery negative (-) cables, first.
b. Install the battery positive (+) cables.
c. Close the battery disconnect switch.
TROUBLESHOOTING
If the cranking system is not functioning properly,
check the following to determine which part of the
system is at fault:
Batteries- Verify the condition of the batteries,
cables, connections and charging circuit. FIGURE 2-13. NO-LOAD TEST CIRCUIT
Wiring- Inspect all wiring for damage or loose
connections at the key switch, magnetic
switches, solenoids and cranking motors. Clean,
1. Setup the motor for test as follows:
repair or tighten as required.
a. Connect a voltmeter from the motor terminal
If the above inspection indicates the cranking motor
to the motor frame.
to be the cause of the problem, remove the motor
from the truck. Perform the following tests prior to b. Use an rpm indicator to measure armature
disassembly to determine the condition of the motor speed.
and solenoid. c. Connect a carbon pile across one battery to
limit battery voltage to 20 VDC.
Preliminary Inspection
1. Check the cranking motor to ensure the arma-
ture turns freely. Insert a flat blade screwdriver
through the opening in the nose housing. DO NOT apply voltages in excess of 20 volts.
2. Pry the pinion gear to rotate the armature. Excessive voltage may damage the windings.
If the armature does not turn freely, disassem-

ble the motor.
If the armature can be rotated, refer to No-Load
Test before disassembling.

d. Connect the motor and an ammeter in series 4. Failure to operate/no current draw:
with two fully charged 12 volt batteries. Open field circuit: This can be checked
e. Connect a switch in the open position from after disassembly by inspecting internal
the solenoid battery terminal to the solenoid connections and tracing the circuit with a
switch terminal. test lamp.
2. Close the switch and compare the rpm, current, Open armature coils: Inspect the
and voltage reading to the following specifica- commutator for badly burned bars after
tions: disassembly.
Broken brush springs, worn brushes, high
rpm: 5500 to 7500
insulation between the commutator bars or
amps: 95 to 120 other causes which would prevent good
contact between the brushes and
volts: 20 VDC
commutator.
5. Low no-load speed/low current draw:
Interpreting The Results of The Tests High internal resistance due to poor
connections, defective leads, dirty
1. Rated current draw and rated no-load speed commutator and malfunctions listed under
indicates normal condition of the cranking item 4.
motor. 6. High speed/high current draw:
2. Low speed/high current draw:
Shorted fields: If shorted fields are
Too much friction: tight, dirty, or worn suspected, replace the field coil assembly
bearings, bent armature shaft or loose pole and check for improved performance.
shoes allowing the armature to drag.
Shorted armature: This can be further
checked on a growler after disassembly.
Grounded armature or fields: Check further
after disassembly.
3. Failure to operate/high current draw:
A direct ground in the terminal or fields.
Seized bearings - determined by turning the
armature by hand.

MAGNETIC SWITCH Coil Test
The magnetic switch is a sealed unit and not repair- 1. Using an ohmmeter, measure the coil resis-
able. tance across the coil terminals.
Removal The coil should read approximately 28 ohms at

22 C (72F).
1. Remove battery power as described in Crank-
ing Motors - Removal. If the ohmmeter reads OL, the coil is open and
the switch must be replaced.
2. Disconnect the cables from the switch termi-
nals. Disconnect the wires from the coil termi- If the ohmmeter reads 0 ohms, the coil is
nals (Figure 2-14). shorted and the switch must be replaced.
NOTE: If the magnetic switch being removed has a 2. Place one of the ohmmeter probes on a coil ter-
diode across the coil terminals, mark the leads prior minal and another on the switch mounting
to removal. This is done to ensure correct polarity bracket. If the meter displays any resistance
during installation. reading, the coil is grounded and the switch
must be replaced.
3. Remove the mounting cap screws and wash-
ers. Remove the switch from the mounting 3. The ohmmeter should display OL when the
bracket. probes are placed across the switch terminals.
4. The switch coil circuit can be tested as NOTE: The switch terminals should have continuity
described in Coil Test. when 24 VDC is applied to the coil terminals.
However, high resistance across the internal switch
contacts due to arcing etc. could prevent the switch
Installation from delivering adequate current to the cranking
motor. If the coil tests are satisfactory, but the switch
1. Attach the magnetic switch to the mounting is still suspect, replace with a new part.
bracket using the cap screws and lock washers
previously removed.
2. Inspect the cables and the switch terminals.
Clean as required and install the cables.
3. Install the diode across the coil terminals, if
equipped. Ensure the diode polarity is correct.
Attach the wires from the truck harness to the
coil terminals shown in Figure 2-14.
4. Connect battery power as described in Crank-
ing Motors - Installation.
FIGURE 2-14. MAGNETIC SWITCH ASSEMBLY

NOTES

SECTION D3
ELECTRICAL SYSTEM COMPONENTS
INDEX
ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
CAB MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5
RELAY CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6
FUSE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-11
EXTERIOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
GROUND LEVEL SHUT OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
CONTROL POWER RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
BATTERY EQUALIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15
BODY POSITION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-17
Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-17
Body-Up Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-18
Hoist Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-18
SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-20
Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-21
GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-21
D03032 08/07 Electrical System Components D3-1

NOTES
D3-2 Electrical System Components 08/07 D03032

ELECTRICAL SYSTEM COMPONENTS
CAB MOUNTED COMPONENTS

Figure 3-1 illustrates electrical system components
and controllers mounted on the rear wall of the oper-
ator cab. The relay module and other electrical com-
ponents are located in the compartment under the
controllers. (Figure 3-2).
FIGURE 3-1. REAR ELECTRICAL COMPARTMENT
1. Automatic Transmission Controller (ATC) 6. Payload Meter Download Connector

2. Fuse Panel 7. CENSE Engine Download Connector -
3. Retard Control Module (RCM) (SDA12V160 Only)
4. Vehicle Health Monitoring System (VHMS) 8. Engine Maintenance Light
5. VHMS Download Connector 9. QSK Engine Communications Connector

(Enclosure Removed)
1. Automatic Lubrication System Timer 7. Relay Centers
2. Ground Bus Bars 8. Turn Signal Flasher
3. Power Bus # 1, 24V Battery Direct Power 9. Steering Bleeddown Timer
4. Power Bus # 2, 24V Battery Disconnect Power 10.Windshield Wiper Delay Timer
5. Power Bus # 3, 24V Key Controlled Power 11.External Harness Interface Connection Panel
6. Power Bus # 4, 12V Key Controlled Power 12.ORBCOMM Modem

CIRCUIT BREAKERS
Table 1 lists the truck circuit breakers located at the
battery box and on the AC/heater unit.
TABLE 1. CIRCUIT BREAKER CHART

CIRCUIT BREAKER IDENTIFICATION CIRCUIT NUMBER CONTROL DESCRIPTION
No. AMPS VOLTS IN OUT
LOCATION: BATTERY BOX
CB24V 50 +24 3 12 24 Volt Control Power (To Power Bus #3 on Cab Rear Wall)
CB12V 50 +12 4 12V 12 Volt Control Power (To Power Bus #4 on Cab Rear Wall)
LOCATION: AC/HEATER UNIT
A/C-CB 20 +24 12AC - Internal Automatic Reset Circuit Breaker
Always replace a circuit breaker with one of the

same amperage capacity as the one being
removed. Place the battery disconnect switch in
the OFF position before replacing circuit break-
ers.

RELAY CENTER
The relay center shown in Figure 3-3 contain a maxi- Additional circuits may be added by utilizing the
mum of 33 relays in its three convenience centers. available empty relays.
Circuit breakers are not used on this board.
The relay center is in the rear electrical compartment
behind the drivers seat. Refer to Table 2 and the fol-
lowing diagrams for identification of the relays and
circuits.
FIGURE 3-3. RELAY MODULE
1. Relay Center One

2. Relay Center Two
3. Relay Center Three

TABLE 2. RELAY BOARD CIRCUITS
RELAY COIL CIRCUITS CONTACT CIRCUITS FUNCTION
+ - COM. NO NC
Relay Center 1
L 39J 39A 39J RLNO 39AA Green PLM Light

M 39J 39B 39J RMNO 39BA Amber PLM Light
N 39J 39C 39J RNNO 39CA Red PLM Light
P 41H 11HA 41HA RPNC Left Hi Beam Headlight
R 41H 11HB 41HB RRNC Right Hi Beam Headlight
S 41 11LA 41LA RSNC Right Low Beam Headlight
T 48FS 48FP 48F RTNC Fog Lights
U Not Used
V 51R 51T RVNO 51S Steering Bleed Down
W Not Used
X 25N RXNO 25N1 VHMS Neutral Signal
Relay Center 2
L 41 11LB 41LB RLNC Left Low Beam Headlight

M 45L 11CLL 45LL 45LL2 Left Turn Signal
N 45R 11CLR 45RL 45RLZ Right Turn Signal
P 41TS 11T 41C RPNC Clearance Lights
R 44A1 44R1 44A1 44R RRNC Right Retard Light
S 44B1 44B4 44B1 44D RSNC Center Brake Light
T 52C1 52R1 52P 52C3 RTNC Front Brake Cooling Valve
U Not Used
V 52C2 5ZRZ 52P 52C4 RVNC Rear Brake Cooling Valve
W 43 11H 43 64 RWNC Front Horn
X 43 11H 43 64 RXNC Front Horn
Relay Center 3
L 44A1 44R4 44A1 44L RLNC Left Retard Light

M Not Used
N 45RR 46H 46 46A1 Hazard Light
P Not Used
R 25R 47A 47 RRNC Backup Light
S 28A1 68B 68C RSNC Ether Start
T 63L1 63 63L RTNC Low Windshield Wiper
U Not Used
V 63H1 63 63H RVNC High Windshield Wiper
W Not Used
X 25N 21S 21PT RXNC Engine Start

FIGURE 3-4. RELAY CENTER ONE

FIGURE 3-5. RELAY CENTER TWO

FIGURE 3-6. RELAY CENTER THREE

FUSE PANEL
The fuse panel is located in the rear electrical com-
partment behind the drivers seat (Figure 3-7). The
panel consists of three fuse blocks.
Refer to the following tables and diagrams for circuit
identification.
FIGURE 3-7. FUSE PANEL
1. Fuse Block 1
2. Fuse Block 2
3. Fuse Block 3

TABLE 3. FUSE BLOCK ONE
Battery Connections
1 Battery Direct Power
11 Battery Disconnect Power
Fuse Function Amperage
1 VHMS KEY SW SIG 5A
2 PLM LIghts 10A
3 SBDT 5A
4 Lincoln Lube 10A
5 Hoist Limit SW 5A
6 Brake Light 10A
7 Brake Controls 10A
8 Rear Retard Lt 10A
9 Komatsu Prog. Port (Key Switch) 10A
10 --- ---
11 --- ---
12 --- ---
13 Tier 1 Engine Power (Battery) 10A
14 VHMS/ORBCOMM 5A
15 Komatsu Prog. Port (Battery) 10A
16 Lube Fill Light 5A
17 Lo Beam HD LT Outside Position 15A
18 Hi Beam HD LT Outside Position 15A
19 Hi Beam HD LT Inside Position 15A
20 Service LTS 10A
21 Fog Lights 10A
22 SBDT 5A
23 --- ---
24 --- ---
FIGURE 3-8. FUSE BLOCK ONE

TABLE 4. FUSE BLOCK TWO
Battery Connections
12 Key Switch 24V Power
21 Key Switch Start Signal
Fuse Function Amperage
1 LT Aux Turn Sig 15a
2 RT Aux Turn SIg 15A
3 Head LT Controls 5A
4 LO BM HD LT Inside Position 15A
5 Clearance Lights 15A
6 ATC 10A
7 EDP 5A
8 FRT Horn & D-LTS 15A
9 Hazard Lights 10A
10 RCM 10A
11 --- ---
12 --- ---
13 Start Signal 5A
14 --- ---
15 --- ---
16 --- ---
17 --- ---
18 --- ---
19 --- ---
20 --- ---
21 Tier 2 Engine Power 10A
FIGURE 3-9. FUSE BLOCK TWO

TABLE 5. FUSE BLOCK THREE
Battery Connections
13 Key Switch ACC Power
12V Key Switch 12V Power
FUSE FUNCTION Amperage
1 A/C and Heater 20A
2 ATC 10A
3 Shifter 5A
4 EDP Signals 5A
5 --- ---
6 Turn Signals 5A
7 Rear BU LT & Horn 15A
8 Deck Backup LTS 10A
9 Windshield Wiper 15A
10 Drivers Seat 5A
11 Ether Start 5A
12 --- ---
13 Key SW Signal 5A
14 QSK Key Signal 5A
15 EDP 5A
16 Switch Lights 5A
17 AM/FM Radio 5A
18 Cigar Lighter 10A
19 12V AUX Power 10A
20 12V AUX Power #2 10a
21 LFT Window Motor 20A
22 RT Window Motor 20A
23 --- ---
24 --- ---
FIGURE 3-10. FUSE BLOCK THREE

EXTERIOR COMPONENTS
BATTERY BOX BATTERY EQUALIZER
Battery box (1, Figure 3-11), located on the right The majority of circuits on the truck operate on 24
deck, houses the four 220 amp hour, 12 volt heavy VDC. However, several components require 12 VDC
duty batteries (2). The following components are for operation. This requires tapping into the circuit
located on the outside of the enclosure: disconnect between two of the 12 volt batteries wired in series.
switch, circuit breakers, power relays, and battery The entire battery package is recharged by the 24
equalizer. volt alternator. To ensure all of the batteries are dis-
charged and recharged equally, battery equalizer (7,
All components except the disconnect switch are Figure 3-11) is utilized. The battery equalizer bal-
located under a protective cover. ances the charge and discharge rates of all four bat-
teries.
A circuit breaker mounted on the battery equalizer,
BATTERY DISCONNECT SWITCH near the hookup terminals protects its internal cir-
Battery disconnect (3, Figure 3-11) removes battery cuitry. If the breaker opens, the cause must be deter-
power from all truck power circuits when the switch is mined and corrected and the breaker reset to restore
open. The switch is for use during maintenance and normal operation.
repair procedures requiring removal of power from
the electrical circuits without the need to remove bat-
tery cables. Test
If the batteries are not being charged equally or other
problems are apparent, perform the following tests:
GROUND LEVEL SHUT OFF SWITCH
1. Check the circuit breaker on the end of the
The ground level shut off switch, mounted at the enclosure to see if it has opened. If so, press
base of the left access ladder, is connected in series the button to reset.
with the battery disconnect switch. The switch
2. Measure the voltage of each individual battery.
removes battery power from the key switch when
Each should measure approximately 12 volts. If
opened.
not, check voltages below:
a. Measure the voltage between the 24 volt ter-
minal and ground terminal on the battery
CONTROL POWER RELAYS
equalizer and record.
Control power relays connect the battery circuits to
b. Measure the voltage between the 12 volt ter-
the truck electrical circuits when the key switch is in
minal and ground terminal on the battery
RUN. Relay (8) is used in the 12 volt circuit and relay
equalizer and record.
(7) is used in the 24 volt circuit.
3. If the difference between the two voltage read-
ings in the previous step exceeds 0.75 volts, the
battery equalizer must be replaced.
CIRCUIT BREAKERS
Two, fifty amp circuit breakers protect the power cir-
cuits between the batteries and the power bus bars
located in the truck cab. Circuit breaker (4) is used in
the 24 volt circuit and circuit breaker (5) is used in the
12 volt circuit. When removing the battery equalizer, remove the
ground connection first. Then remove the 12 and
24 volt positive cables.
When installing the battery equalizer, Install the
12 and 24 volt cables first. Attach the ground
cable last.

FIGURE 3-11. BATTERY BOX AND EXTERNAL COMPONENTS
1. Battery Box 4. Circuit Breaker (24 Volt) 7. Power Relay (24 Volt)
2. Batteries 5. Circuit Breaker (12 Volt) 8. Power Relay (12 Volt)
3. Battery Disconnect Switch 6. Battery Equalizer

BODY POSITION SWITCHES
Two magnetically activated proximity switches sense Inside the body limit switch, there are two magnets of
the position of the truck dump body. Body-up switch slightly varying strengths in line with one another.
(5, Figure 3-13) is located inside the left frame rail, The magnets are located on separate ends of a
forward of the body pivot. This switch provides a rocker lever assembly which contains the functional
"body seated" signal to the transmission controller switch contacts. In the non-actuated or rest state, in
when the body is resting on the frame. When the which there is no disturbance in the internal switch
body is raised above the frame rail, the magnetic natural magnetic fields, the stronger magnet domi-
field is removed from the switch sensing area. The nates the rocker into the normal position. Refer to
switch sends a "body float" signal to the transmission Figure 3-12.
controller. A warning lamp in the left pod illuminates
When the field of the dominate magnet becomes dis-
to inform the operator.
tracted by a target, (a ferrous plate, or an opposite
NOTE: The body float lamp will also illuminate if the polarity magnet field (south pole)), the weaker mag-
hoist control is not in the FLOAT position or if there is net in the switch will then become more dominate
an open circuit between the switch and the and move the rocker lever. The switch is then consid-
transmission controller. ered to be actuated or in the sensed position.
Hoist limit switch (9) is located on the left frame rail

just behind the pivot. The hoist limit switch sends a
signal to the hoist limit solenoid in the hydraulic cabi-
net. The solenoid activates and blocks oil flow from
the hoist pilot valve to the hoist valve. The power up
oil supply is blocked to prevent full hoist cylinder
extension, and possible damage to the cylinders.
Proper switch adjustment ensures the hoist cylinder
travel stops slightly before full extension.
If either the body up switch or the hoist limit switch do
not function as described above, adjust the switches
according to the procedure on the following pages.
Proximity Switch Operation

The body position switches on these trucks are mag-
netic field change switches. The switches sense a
ferrous material target, as well as a specific pole
(south pole) magnet field. When a switch is activated
by ferrous material, the maximum sensing distance is
approximately 13 mm (0.5 in.). When a magnet is
used instead of ferrous material, maximum sensing
distance is approximately 95 mm (3.75 in.). There-
fore, use of a magnet target allows the switch to acti-
vate at greater sensing distances.
FIGURE 3-12. SWITCH CONTACTS - NORMAL

AND SENSED POSITIONS

Body-Up Switch Adjustment Hoist Limit Switch Adjustment
Figure 3-13 shows two views of body-up switch (5) Prior to adjustment, the body must be raised to the
and the magnet used to activate the switch. maximum hoist cylinder extension and supported.
If switch adjustment is necessary, follow the proce- 1. With the body fully raised, loosen proximity
dure below: switch adjustment cap screws (8, Figure 3-13).
Slide the switch up or down to position the top
1. With the body resting completely on the frame,
of the switch 25 mm (1 in.) away from the lower
loosen switch mounting cap screws (6) and/or
edge of magnet (10). Tighten the cap screws
the magnet adjustment cap screws (3).
when adjusted properly.
2. Position the lower edge of the magnet near the
upper edge of proximity switch (5), as shown in NOTE: Since a magnetic target is used to activate
view A-A. the switch, a larger initial distance in setting the
switch is required. This is due to the fact that
3. Adjust the proximity switch so the passing dis-
magnetic fields are not crisp 90 degree boxed fields
tance between the two targets is 15 mm (0.59
but are instead curved about the shape of the
in). Tighten cap screws (6) and recheck the ver-
magnet. The sensing field boundary limit takes on
tical adjustment. If necessary, readjust and
the same curved sensing area shape of the magnet
tighten cap screws (3).
field. The curved sensing area results in the
actuation of the switch approximately 25 mm (1 in.)
prior to reaching the edge of the magnet. Therefore,
it is crucial that the 25 mm (1 in.) is observed when
setting the body limit switch.
2. Loosen the cap screws securing the proximity

switch to the mounting bracket. Slide the switch
in or out until the passing distance between the
two targets is 45 mm (1.77 in.). Tighten the cap
screws after adjusting. Refer to Figure 3-14 for
an illustration of optimum setting of the switch.
3. Lower the body onto the frame.
4. Check the operation of the switch to verify that
the hoist cylinders stop before reaching maxi-
mum cylinder stroke. If the cylinders extend full
stroke, adjust the switch, as necessary, to pre-
vent full extension.

FIGURE 3-13. BODY-UP AND HOIST LIMIT SWITCHES
1. Body - Raised Position 6. Switch Mounting Cap Screws
2. Body - Resting on Frame 7. Mounting Bracket (On Frame)
3. Magnet Adjustment Cap Screws 8. Switch Mounting Cap Screws
4. Magnet 9. Proximity Switch (Body Limit)
5. Proximity Switch (Body-Up) 10. Magnet (Body Limit Switch)

SPEED SENSORS
A speed sensor (Figure 3-15), located in the brake
assembly in each rear wheel provides individual
wheel speed signals to the RCM. The speed signals
are used to determine truck speed and to monitor
wheel slip.
The sensors are mounted in the brake hub and
adjusted to provide a slight gap between the tip of the
sensor and the gear teeth on the periphery of the
seal carrier.
Each sensor is supplied with +18 volts through pin A.
Pin B is common (-) and grounded to the sensor
shell. Pin C provides the signal out.
No maintenance is required, normally. However, it is
necessary to adjust the sensor after brake rebuild.
FIGURE 3-14. HOIST LIMIT SWITCH

OPTIMUM SETTING
FIGURE 3-15. SPEED SENSOR ASSEMBLY
1. Sensor Body 3. Connector End

2. Lock Nut

Sensor Adjustment GENERAL TROUBLESHOOTING
NOTE: Sensor adjustment must be performed before When troubleshooting electrical system circuit and
the tires and rims are installed. component problems, it is necessary to follow a logi-
1. If the sensor is already installed, loosen locknut cal diagnosis procedure.
(2, Figure 3-16). Remove the sensor from the It is important to verify the batteries are fully charged,
tapped mounting hole. electrical harnesses and connectors have not been
2. Rotate the seal carrier until a gear tooth is physically damaged and all connectors are clean and
aligned with the center of the sensor mounting properly secured.
hole.
The following basic steps may eliminate many elec-
3. Carefully thread the sensor into the hole until trical problems:
the tip contacts the gear tooth.
1. Verify the batteries are fully charged and the
4. Back out the sensor 5/8 turn (counterclock-
battery disconnect switch is closed. Ensure the
wise).
control power relays for the 12 volt and 24 volt
5. Continue to rotate until the flats on the sensor power circuits are functioning.
housing are perpendicular to the direction of
2. Check all cable connections at the batteries in
rotation of the gear teeth. Refer to Figure 3-16.
the battery box. They must be clean, with no
DO NOT back out more than 1/2 turn.
corrosion. If necessary, open the battery dis-
6. Tighten the locknut. connect switch. Remove the cables and clean
7. Install the connector harness. the battery terminals and connectors with a bak-
ing soda/water solution using a stiff, non-wire
brush. Flush with clean water. Reinstall the
cables and tighten securely.
To prevent possible damage to the battery equal-

izer system, the following procedure must be fol-
lowed when the battery cables are removed or
installed.
When removing cables, disconnect and
remove the positive (+) cables first.
Remove the negative (-) cables last.
When installing the cables, install the
negative cables (-) first.
Install the positive cables (+) last.
FIGURE 3-16. SPEED SENSOR ADJUSTMENT
1. Speed Sensor 3. Brake Assembly

2. Locknut

3. Verify electrical connectors are properly
crimped onto the wires or cables. Improperly
crimped connectors can cause possible over-
heating of the circuit due to high resistance in
the connection. Discoloration of connector pins
and/or sockets indicate the possibility of an
improper crimp.
4. Connector pins must be properly locked into the
connector shell. If a pin does not extend far
enough into the connector shell, the pin may not
mate properly when the connector is assem-
bled.
5. If a harness must be repaired, use the proper
wire gauge and type. Use the proper crimping
tool if connector pins are replaced.
6. Verify the appropriate circuit breaker is function-
ing properly. If a circuit breaker must be
replaced, use a circuit breaker with the same
current rating as the part removed.
Always install a new circuit breaker with the

same current rating as the breaker being
replaced. A higher rated breaker could allow the
circuit to overheat and possibly result in a fire. A
circuit breaker with a lower rating will not allow
the circuit to operate properly.

SECTION D10
CHARGING SYSTEM
INDEX
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . D10-3
Excessive heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Dirt and dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-3
PREVENTIVE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-4
Alternator Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-4
Alternator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-4
Belt Tension And Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-4
ALTERNATOR PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-4
ALTERNATOR CABLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-5
VOLTAGE REGULATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-6
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10-8
D10004 04/08 Charging System D10-1

NOTES
D10-2 Charging System 04/08 D10004

CHARGING SYSTEM
The charging system is an important part of the elec- PRIMARY CAUSES OF CHARGING
trical system. It provides electrical current for the SYSTEM MALFUNCTION
lights, the radio, the engine electrical systems, and
There are several environmental and product appli-
all other electrical accessories. It also maintains the
cation factors that can cause the charging system to
batteries in a charged state, recharging them as nec-
malfunction. The most common factors are listed
essary.
below.
The charging system has three main components:
the alternator, the voltage regulator, and the batter- Excessive heat
ies. To properly service the charging system, a good Prolonged operation in excessive temperatures can
understanding of how each component works is nec- damage an alternator. Damaging heat levels can be
essary. generated in different ways. A build-up of dirt, either
The alternator generates electrical power to operate externally or internally, diminishes the ability to dissi-
accessories and to recharge the batteries. The alter- pate heat from the external surface and diminishes
nator is driven by a belt located off of an accessory airflow through the unit.
pulley. Mechanical energy from the drive pulley is Missing air ducts and heat shields can also lead to
converted by the alternator into electrical energy for overheating. Ensure any heat shields or air ducts are
the batteries and the electrical system. properly installed.
The alternator is a brushless alternator designed to
generate high output at low speeds. The alternator is Dirt and dust
also designed to withstand high heat exposure and Charging system components operate less efficiently
vibration. The 24 volt alternator is capable of gener- when a buildup of dirt particles forms around wire
ating 140 amps of electrical power. and cable connections. Dirty connection points
The voltage regulator controls alternator output and impair the flow of electrical current.
senses when the batteries need recharging, and
Vibration
increases in electrical demand. The voltage regulator
adjusts alternator output, accordingly. If charging system components are not securely
mounted to the truck, the resulting vibration can dam-
The batteries are a reservoir of chemical electrical
age sensitive internal components.
power. Their primary purpose is to provide electrical
energy for engine cranking. The batteries also supply Poorly mounted components will also diminish the
power to vehicle accessories when the electrical load performance of the belt drive. This is very important
is too great for the alternator, alone. on high powered engines.

PREVENTIVE MAINTENANCE TROUBLESHOOTING
PROCEDURES
Timely preventive maintenance of the charging sys-
The object of preventive maintenance is to identify tem will help keep it operating smoothly. However,
and correct potential problems before they occur. when a problem does occur, effective diagnostic pro-
There are three preventive maintenance procedures cedures will help you locate and correct the problem.
that can greatly enhance the efficiency of charging Before analyzing the charging system, ensure the
system functions. These three procedures also rep- batteries have been properly tested and are at least
resent the initial steps to follow when fully diagnosing 75% charged. Otherwise, any electrical tests con-
a problem in the charging system. Preventive main- ducted on the charging system will be inaccurate.
tenance procedures are as follows:
If the troubleshooting diagnosis points to a faulty
Alternator Cleanliness alternator, a new alternator must be installed. If the
vehicle has had a history of charging problems and
Ensure that all alternator surfaces are clean. A system failure has been eliminated, it may be neces-
buildup of dirt, grease or dust may result in poor per- sary to reevaluate the capacity of the alternator. The
formance and/or damage to the alternator. Air flow addition of add-on electrical devices also make it
passages must be clear of debris so that air can eas- necessary to reevaluate the capacity of the alterna-
ily pass through the unit. All electrical connection tor. Consult your area support manager for questions
points must be clean and free from corrosion. regarding this issue.
Alternator Mounting
Charging system components must be securely
mounted to their brackets. Mounting brackets must
ALTERNATOR PERFORMANCE TEST
be bolted securely to the engine. If charging system 1. Connect a voltmeter to the alternator output ter-
components are poorly mounted, damaging vibration minals and an ammeter to the positive output
and diminished belt drive performance will result. cable, as shown in Figure 10-1. Position the
ammeter at least 15 cm (6 in.) away from the
Ensure all components are securely mounted to the alternator to eliminate the possibility of faulty
truck. Verify that all mounting components are in readings. Ensure voltage is present at the out-
good condition and that the belt drive system is in put terminals.
proper alignment.
Belt Tension And Condition

Proper belt tension must be checked regularly. A
loose belt will slip on the pulley, and fail to turn the
rotor inside the alternator. This results in insufficient
charging.
Check the belt tension with a belt tension gauge.
Refer to the engine manufactures specifications for
proper belt tension.
Before checking the belt tension, inspect it for glaz-
ing, cracks or dryness. If the belt is worn or dam-
aged, replace the belt. If the belt is in good condition,
use a belt tension gauge and check the results. If belt
tension is below specifications, a new belt tensioner
must be installed.
FIGURE 10-1. ALTERNATOR PERFORMANCE
Check the alternator belt tension every 10,000 miles. TEST

ALTERNATOR CABLE TEST
2. Start the engine and operate at 1500 rpm. 1. To test the positive cable, connect the ammeter
Ensure that all vehicle loads, such as the radio, to the positive cable from the alternator. Ensure
are turned off and the reading on the ammeter the ammeter is at least 15 cm (6 in.) away from
is less than 20 amps. If the ammeter reading is the alternator to eliminate the possibility of
greater than 20 amps, double check that all faulty readings.
vehicle loads are turned off and that the batter- 2. Connect the negative lead of the voltmeter to
ies are fully charged. the positive terminal of the alternator. Connect
3. Record the voltage on the voltmeter. The read- the positive lead of the voltmeter to the positive
ing should be between 27.8 - 28.4 volts. terminal on the battery. Refer to Figure 10-2.
If the voltage is not within this ranges, adjust the
voltage regulator. Refer to Voltage Regulator -
Adjustment. If the regulator can not be adjusted
within this range, the alternator is defective.
ALTERNATOR PERFORMANCE TEST -

LOAD APPLIED
1. With the meters connected as shown in Figure
10-1, start the engine and operate at 1500 rpm.
2. Turn on vehicle loads until 75% of the rated out-
put (105 amps) is reached on the ammeter dis-
play. Record the voltage on the voltmeter.
An alternative method for applying a load is to
use a carbon pile tester. Connect a carbon pile
tester across the batteries, and adjust the car-
bon pile until the desired reading is obtained on
FIGURE 10-2. POSTIVE CABLE TEST
the ammeter. Record the voltage on the voltme-
ter.
3. Shut off the engine.
4. Compare the reading to that taken during the
alternator performance test. If the alternator
3. Start the engine and operate at 1500 rpm. Turn
voltage dropped more than 0.7 volts, the alter-
on vehicle loads, such as the radio, until 75% of
nator is defective.
the rated output (105 amps) is reached on the
ammeter display. If necessary use a carbon pile
tester to apply a load on the alternator. Record
the voltage on the voltmeter.
If the reading is greater than 0.5 volts, check all
wire connections between the alternator and
the battery. Check the condition of each cable.
Clean, repair or replace cables and connec-
tions, as necessary. If the reading is less than
0.5 volts, the cable is good. Turn off the vehicle
loads and shut off the engine.

VOLTAGE REGULATOR
4. To test the negative cable move the negative ADJUSTMENT
lead of the voltmeter to the negative terminal of
the battery. Connect the positive lead of the The voltage regulator is factory set to operate at 28.2
voltmeter to the negative terminal of the alterna- volts. If adjustment is necessary after performing the
tor. Refer to Figure 10-3. alternator performance test, follow the steps below.
5. Start the engine and operate at 1500 rpm. Turn 1. Access the voltage regulator adjustment screw.
on vehicle loads, such as the radio, until 75% of Refer to Figure 10-7 for the location of the
the rated output (105 amps) is reached on the adjustment screw.
ammeter display. If necessary use a carbon pile 2. Install a voltmeter across the positive and nega-
tester to apply a load on the alternator. Record tive output terminals of the alternator. Install an
the voltage on the voltmeter. ammeter at least 15 cm (6 in.) away on the pos-
itive output cable. Refer to Figure 10-1.
If the reading is greater than 0.5 volts, check all
wire connections between the alternator and 3. Start the engine and operate at approximately
the battery. Check the condition of each cable. 850 rpm (alternator @ 3000 rpm).
Clean, repair or replace cables and connec- 4. Create an electrical load of 10-15 amps by turn-
tions, as necessary. If the reading is less than ing on lights or other accessories.
0.5 volts, the cable is good. Turn off the vehicle 5. Check the voltage on the voltmeter. Acceptable
loads and shut off the engine. voltage ranges from 27.8 - 28.4 volts with the
desired voltage being 28.2 volts.
If it is necessary to adjust the voltage, turn the
adjustment screw clockwise to raise the volt-
age. Turn the screw counterclockwise to lower
the voltage.
If the voltage cannot be adjusted to within the
specifications, the alternator is defective and
must be replaced.
FIGURE 10-3. NEGATIVE CABLE TEST
FIGURE 10-4. VOLTAGE REGULATOR

ADJUSMENT SCREW

ALTERNATOR
Removal
1. Park the truck and shut off the engine. Discon-
nect the batteries with the battery disconnect
switch located on the battery box.
2. Tag all cable and wire connections at the rear of
the alternator and disconnect.
3. Remove the cap screws that secure belt guard
(2, Figure 10-5). Remove the belt guard assem-
bly from the engine.
FIGURE 10-6. ALTERNATOR PULLEY
1. Nut 2. Pulley
FIGURE 10-5. ALTERNATOR BELT GUARD
1. Capscrews 2. Belt Guard
4. Use a breaker bar to rotate the belt tensioner to

remove the tension from the alternator belt.
With the tensioner released, remove the belt
from the alternator pulley.
Inspect the alternator belt for glazing, cracks or
others signs of wear. If excessively worn, dis-
card the belt.
5. If it is necessary to remove the belt pulley,
remove pulley nut (1, Figure 10-6) and the
washer that secures pulley (2) to the alternator.
Remove the pulley.
6. Remove the mounting cap screws (2, Figure FIGURE 10-7. ALTERNATOR MOUNTING
10-7) from the alternator. 1. Alternator 2. Mounting Cap Screw
7. Lift the alternator from the mounting bracket.

Installation
1. Ensure the battery disconnect switch on the
battery box is open in order to isolate battery
power from the truck.
2. Place the alternator into position on the mount-
ing bracket. Install mounting cap screws (2, Fig-
ure 10-7)
3. If removed, install pulley (2, Figure 10-2), and
secure with nut (1) and the washer. Tighten to
102 7 Nm (75 5 lb ft).
4. Attach the cable and wire connections at the
rear of the alternator.
5. Use a breaker bar to rotate the belt tensioner to
allow installation of the drive belt. Install the belt
and ensure the belt is aligned and positioned
properly in the grooves.
6. Place belt guard (2, Figure 10-1) into position
over the alternator. Install the cap screws that
secure the guard to the engine.
7. Connect battery power to the truck by closing
the battery disconnect switch on the battery
box.
8. Verify the alternator is charging properly. Refer
to Alternator Performance Test.

FIGURE 10-8. ALTERNATOR - EXPLODED VIEW
1. Front Housing 9. Front Bearing Retainer 15. Terminal Stud Package 20. Terminal Block
2. Rotor Assembly 10. Rear Bearing Seal - Negative 21. Coil Assembly
3. Stator Assembly 11. Positive Diode Ring 16. Terminal Stud Package 22. Pulley Locknut
4. Rear Housing 12. Negative Diode Ring - Positive 23. Flat Washer
5. Fan 13. Rectifier Cable, Recti- 17. Terminal Stud Package 24. A/C Flag Terminal
6. Pulley fier-A/C Cable - A/C 25. Regulator
7. Front Bearing 14. Woodruff Key 18. Thru Bolt Package 26. Spacer
8. Rear Needle Bearing 19. Cover Shield 27. Hardware Package

FIGURE 10-9. ALTERNATOR WIRING DIAGRAM

SECTION D15
MACHINE MONITOR
INDEX
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-3
CHARACTER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-3
Mode Select Switches 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-4
Service Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-4
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-4
Operation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-4
Reverse Travel Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-5
Filter And Oil Change Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-5
Display Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-6
Resetting The Filter/Oil Replacement Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-6
Inputting Telephone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-7
Selecting A Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-7
ACTION CODE DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-8
E03 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-8
E02 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-9
E01 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-9
REAL TIME MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-10
USING REAL TIME MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-10
Viewing Two Streams of Data At Once . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-11
MACHINE MONITOR FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D15-16
D15002 Machine Monitor D15-1

NOTES
D15-2 Machine Monitor D15002

MACHINE MONITOR
CHARACTER DISPLAY
FIGURE 15-1. Electronic Display Panel
1. Electronic Display Panel 2. Character Display
Normally, the service meter/odometer is displayed on

the character display. Operator mode
If the machine experiences a failure or if it is neces- 1 Service meter, odometer display (default) *
sary to perform maintenance, an action code is dis- 2 Operation Information
played to recommend a suitable response.
3 Reverse travel distance display function
When filter replacement or an oil change is neces- Filter replacement, oil change interval display
4
sary, the maintenance monitor caution lamp will function
flash, and the filter or oil to be replaced is displayed. 5 Telephone number input function
This will occur after completion of the system check
6 Language selection function
with the key switch in the ON position. Refer to Filter
And Oil Change Display later in this chapter. 7 PLM setup function
8 Action code display function
Check the display to verify that there are no faults
before driving the truck. 9 Failure code display function
The following table lists the various displays of the * PLM information will override the default display when
character display while in Operator Mode. Service input is sent from VHMS. An active action code will also
related information can be obtained in the service override the default display.
modes.

Mode Select Switches 1 & 2
If the key switch is in the OFF position, the () por-
tion of mode select switch 1 can be pressed to dis-
play the service meter.
NOTE: If the service meter/odometer stays on while
the key switch in the OFF position, a failure has
occurred. Contact your Komatsu distributor for
inspection.
Odometer
FIGURE 15-2. MODE SELECT SWITCHES
Mode select switches 1 & 2 (Figure 3-2) are used to

scroll through the machine monitor character display.
The button commands are as follows:
1 Select, Run
2 Cancel, Release, Select (Yes/No Only)
3 Right, Next, Continue
4 Left, Previous, Return
This meter indicates the total distance traveled in
kilometers. The service meter/odometer is the default
display.
Service Meter
If the key switch is in the OFF position, the () por-
tion of mode select switch 1 can be pressed to dis-
play the odometer.
Operation Information
Operation information allows the operator to view the
total payload and dump counter.
To display operation information, the character dis-
play must be at the service meter/odometer display
(or an action code, if present). If another display is
This meter displays the total time that the machine showing, turn the key switch to OFF, then back to
has been operating. While the engine is on, the ser- ON. After the initial check and the service meter/
vice meter/odometer is the default display. The ser- odometer is displayed, press the () portion of mode
vice meter advances by one for each hour of engine select switch 1. The display should switch to operator
operation, regardless of engine speed. The service information.
meter advances even if the machine is not moving.
NOTE: PLM information will override the default
display when input is sent from VHMS. An active
action code will also override the default display.

Filter And Oil Change Display
After completion of the system check after turning the
key switch to ON, the character display will indicate
the filters and oil which are near the replacement
interval. When a maintenance interval reaches 30
hours before replacement, it will be displayed. The
maintenance caution lamp will flash or illuminate at
the same time. This will occur for 30 seconds.
As replacement intervals approach, the maintenance
caution lamp flashes. If a replacement interval has
been exceeded, the lamp illuminates steady.
Reverse Travel Odometer

This meter indicates the total distance traveled in
reverse.
1. To display the reverse travel odometer, the
character display must be at the service meter/
odometer display (or an action code, if present).
If another display is showing, turn the key The top line of the character display lists the name
switch to OFF, then back to ON. After the initial and ID number of the item needing replacement. The
check and the service meter/odometer is dis- bottom line displays the remaining time until replace-
played, press the () portion of mode select ment and the total number of times the item has been
switch 1. The display should switch to the oper- replaced. If there two or more items to be displayed,
ation information display. they alternate at three second intervals. If there are
more than 10 items to be displayed, all the items are
displayed once time.
The display will be active for 30 seconds, and will
switch back to the default display. The filter and oil
change display will return again only when the key
switch is turned to the ON position again.
If an action code is present however, the filter and oil
change display will not be displayed until the action
code has been removed.
After replacing the filter or changing the oil, reset the
replacement interval. Refer to Resetting The Filter/
Oil Replacement Meter.
2. Press (>) or (<) on mode select switch 2 to
scroll to the reverse odometer display.
3. To close the display, press the () portion of
mode select switch 1 or turn the key switch to
OFF.

Display Items
Item Interval Character ID

In Hours Display Number
Fuel filter 250 FUEL FILT 03
Engine oil filter 250 ENG FILT 02
Engine oil 250 ENG OIL 01
Transmission 500 TM FILT 13
oil filter
Corrosion 250 CORR RES 06
resistor
Torque converter, 2. Press the () portion of mode select switch 1.
transmission 1000 TC/TM/BKOIL 24 The display will show a component, the replace-
and brake cooling ment time and the number of times it has been
oil changed. For the following display the fuel filter
Brake cooling 1000 BK C FILT 16 replacement time is 500 hr. The filter has been
oil filter replaced 9 times.
Hydraulic 1000 HYD FILT 04
oil filter
Differential 2000 DIFF OIL 11
case oil
Final drive oil 2000 FNL OIL 08
Hydraulic oil 4000 HYD OIL 10
Refer to Section P2, Lubrication and Service, for

more information on maintenance items.
3. Press (>) or (<) on mode select switch 2 to dis-

play the item to be reset.
Resetting The Filter/Oil Replacement Meter
4. When the correct item is displayed, press the
The filter and oil replacement time is displayed on the () portion of mode select switch 1. The display
character display for items needing maintenance. If a will change to the reset display. The top line dis-
filter and/or oil have been replaced, reset the filter plays Reset and Item to be reset alternately.
and oil change time.
1. Beginning at the service meter, press the ()
portion of mode select switch 1 to display the
operation information. Press (>) or (<) on mode
select switch 2 until MAINTENANCE MONITOR
is displayed.

3. Press () on mode select switch 1. This will
change to the telephone input display. Up to 12
digits can be displayed for the telephone num-
ber. Input from the first digits.
5. When resetting the replacement time, press (>)

or (<) on mode select switch 2 to align the cur-
sor with YES, then press () on mode select
switch 1. It will reset and return to the previous
screen.
To abandon, align the cursor with NO, then
press () on mode select switch 1. 4. The cursor is displayed at the input position.
To reset the replacement time for another item, Press (>) or (<) on mode select switch 2 to
repeat this process. After all items are reset, scroll through numbers 0-9. To leave a blank,
press () on mode select switch 1 twice or turn select *. When the correct digit is displayed,
the key switch to OFF to exit. press () on mode select switch 1. The cursor
will advance to the next position.
Repeat the input process until all digits have
Inputting Telephone Numbers been entered. At the last digit, press () on
1. Beginning at the service meter display, press mode select switch 1 to input another telephone
the () on mode select switch 1 to display the number. If there is a mistake in the input or the
operation information. input is to be stopped, press () on mode select
switch 1 to return to the previous screen.
scroll to TEL. When complete, press () on mode select
switch 2 twice to exit or turn the key switch to
OFF. All input telephone numbers will be dis-
played next time this display is accessed.
Selecting A Language
This function can be used to change the default lan-
guage for the character display.
1. Beginning at the service meter display, press
the () on mode select switch 1 to display the
operation information.
scroll to the LANGUAGE display.

ACTION CODE DISPLAYS
Stop the machine immediately when E03 codes

are displayed. Contact your Komatsu distributor
for repairs.
If there is a machine failure or if maintenance is nec-

essary, an action code is displayed on the character
3. Press the () on mode select switch 1. The display to recommend a suitable response.
current default language is displayed.
If more than one failure is present, the most impor-
tant action code is displayed. The order of impor-
tance, starting from the highest, is E03, E02, and
E01. If failures of equal importance occur at the
same time, the latest one is displayed.
When action codes E02 or E03 occur, the alarm
buzzer sounds intermittently and the central warning
lamp illuminates.
E03 Codes
When E03 is displayed, stop the machine immedi-
4. Press (>) or (<) on mode select switch 2 to ately. Check the failure code, and contact your
select a different language. The available lan- Komatsu distributor for repairs. Refer to Checking
guages are: English, Japanese, German, Failure Codes later in this chapter.
French, Italian, Spanish, and Swedish.
5. Press the () on mode select switch 1 to acti-

vate the new language change. The display will
then return to the previous screen.
If the desired language has been set, press ()
on mode selector switch 2 twice or turn the key
switch to OFF to exit.

E01 Codes
When an E03 code is present, the top line displays When an E01 code is present, the top line of the
E03. The bottom line alternates between CHECK character display will display E01. The bottom line
RIGHT NOW and CALL. The display will alternate in will either display MAINTENANCE or another
3 second intervals. The telephone number is dis- description that indicates the affected system. E01
played to the right of CALL. If the telephone number codes do not require immediate attention. If desired,
has not been set, the spaces will be blank. Refer to the truck can operate until the end of the shift before
Character Display - Inputting Telephone Numbers. returning for service.
E02 Codes
When an E02 code is present, the top line of the
character display will indicate E02. The bottom line
indicates whether the condition of the machine is
related to overspeed or overheat.
When an E02 code is displayed, it is important to act
accordingly.
If an overspeed related fault is displayed, reduce
the engine speed and the speed of the machine. If MAINTENANCE is displayed, check the failure
code and contact your Komatsu distributor for
If an overheat related fault is displayed, safely repairs.
stop the machine and operate the engine under
no load at a mid-range speed.
If an action code is still displayed after altering the

operating conditions, check the failure code and con-
tact your Komatsu distributor for repairs.

REAL TIME MONITOR
The machine monitor can monitor and display the
condition of various circuits on the machine via sen-
sors and switches. This type of interaction, called
real time monitoring, can be used to troubleshoot the
truck. When the desired circuit is displayed, it will 4. Press (>) or (<) to scroll to the real time monitor
show whether the output is within the parameters display screen.
listed in Table 2.
5. Press () to advance to the real time monitor

menus. The different monitor menus are listed
in Table 1.
Menus 1-4 in Table 1 each contain several
items that can be monitored in real time. The
monitoring items are listed in Table 2.
FIGURE 19-3. MODE SELECT SWITCHES
Use mode select switch 1 & 2 (Figure 19-1) to scroll TABLE 1. REAL TIME MONITOR MENUS
through the machine monitor character display. The No. Display System And Function
switches are located on the lower left switch panel 1 Monitor Panel Machine monitor system
2 Transmission Transmission controller
3 Brake RCM controller
USING REAL TIME MONITOR
4 VHMS VHMS controller
5 2 Items 2 item simultaneous display
1. To access the real time monitor, access the ser-
vice menu screen. To do this, press () and (<)
simultaneously for approximately 6 seconds. 6. Press (>) or (<) to scroll through the list of mon-
itoring menus listed in Table 1.
Press () to advance to the individual monitor-
ing items listed in Table 2. Press (>) or (<) to
scroll through the list of monitored items for that
system. Hold the (>) or (<) to scroll at high
2. Enter the access ID number, 6491. Press (>) to speed.
increase the digit and (<) to decrease the digit.
Press () to move the cursor to the left and ()
to move the cursor to the right.
3. Once the code is entered, press () to advance
to the next display.

Example: Viewing Two Streams of Data At Once
It is possible to manually select two different items to
view on the machine monitor. This is done by finding
the desired items in Table 2, and entering the 5 digit
code for each item. Follow the steps below to simul-
taneously view two items.
For example, if you would like to monitor throttle
position, press (>) or (<) to scroll through the list
of monitoring menus until TRANSMISSION is
reached.
1. Choose the 2 ITEMS screen from the main

menu listed in Table 1.
Press () to advance to the monitoring items.

Press (>) or (<) to scroll through the list of mon-
itored items until THROTTLE POS is displayed.
The monitor should then show throttle position
displayed in voltage. 2. Press () to advance to the next display.
7. Press () to freeze the data. The () icon will 3. Determine which two items to view on the moni-
flash when the data is in hold mode. Press () tor. The item list and their five-digit codes are
again to make the data active. listed in Table 2.
8. Press () to return to the upper level and the 4. Enter the two, five-digit codes into the machine
menu items listed in Table 1. monitor.
Press (>) to increase the digit and (<) to
decrease the digit. Press () to move the cursor
to the left and () to move the cursor to the
right.
When the codes have been entered, press ()
to advance to the next display.
The display will now show data for the two

items.
5. Press () to move back to the code input dis-

play.
6. Continue to press () to navigate back to the
service menu.

TABLE 2. REAL TIME MONITORING CODES
No. Controller Description Code Output Unit
1 RCM Part number of software 20214 Part number --
2 RCM Application version 20231 Application --
3 RCM Data Version 20232 Version data --
4 RCM ARSC set switch 37701 0.00~5.00 V
5 RCM Front brake cooling valve 39800 ON [1] OFF [0] --
6 RCM Rear brake cooling valve 39801 ON [1] OFF [0] --
7 RCM Brake lock switch sense 39900 ON [1] OFF [0] --
8 RCM Front PPC valve output (command) 33700 0~1000 mA
9 RCM Rear left PPC valve output (command) 33802 0~1000 mA
10 RCM Rear right PPC valve output (command) 33804 0~1000 mA
11 RCM Front PPC valve output 33701 0~1000 mA
12 RCM Rear left PPC valve output 33803 0~1000 mA
13 RCM Rear right PPC valve output 33805 0~1000 mA
14 RCM Brake apply switch 35100 ON [1] OFF [0] --
15 RCM Front brake apply switch 35102 ON [1] OFF [0] --
16 RCM Retard cooling oil temp (front) 30201 0~160 C
17 RCM Retard cooling oil temp (front) 30204 0.00~5.00 V
18 RCM Retard cooling oil temp (rear left) 30207 0~160 C
19 RCM Retard cooling oil temp (rear left) 30209 0.00~5.00 V
20 RCM Retard cooling oil temp (rear right) 30208 0~160 C
21 RCM Retard cooling oil temp (rear right) 30210 0.00~5.00 V
22 RCM Brake pedal signal 44700 ON [1] OFF [0] --
23 RCM Front brake cooling filter 35701 ON [1] OFF [0] --
24 RCM Brake cooling filter - left 35702 ON [1] OFF [0] --
25 RCM Brake cooling filter - right 35703 ON [1] OFF [0] --
26 RCM Emergency auto apply switch 32101 ON [1] OFF [0] --
27 RCM Emergency Brake switch sense 32102 ON [1] OFF [0] --
28 RCM Empty or loaded 39400 Loaded [1] Empty [0] --
29 RCM Hydraulic filter 35700 ON [1] OFF [0] --
30 RCM PPC cut valve 34105 ON [1] OFF [0] --
31 RCM PPC cut valve switch 34106 ON [1] OFF [0] --
ON [1: Brake apply, PPC active] --
32 RCM Front retard apply switch 34102
OFF [0]
33 RCM Left retard apply switch 34103
OFF [0]
34 RCM Right retard apply switch 34104
OFF [0]
35 RCM Retard lever 33900 0.00~5.00 V
36 RCM Retard lever (off) 33901 0.00~5.00 V
37 RCM Retard lever (on) 33902 0.00~5.00 V
38 RCM Steering accumulator pressure 1 44800 ON [1] OFF [0] --
39 RCM Steering accumulator pressure 2 44801 ON [1] OFF [0] --

40 RCM Steering position sensor 35402 -90.0~90.0
41 RCM Steering position sensor 35400 0.00~5.00 V
42 RCM Left front suspension pressure 32803 0.00~20.10 MPa
43 RCM Left front suspension pressure 32809 0.00~5.00 V
44 RCM Right front suspension pressure 32802 0.00~20.10 MPa
45 RCM Right front suspension pressure 32808 0.00~5.00 V
46 RCM T/M output speed 31400 0~32767 rpm
47 RCM Left wheel speed (rear) 39705 0~32767 rpm
48 RCM Right wheel speed (rear) 39704 0~32767 rpm
49 T/M Part number of software 20201 Part number --
50 T/M Application version 20223 Application --
51 T/M Data Version 20224 Version data --
52 T/M Acceleration 38500 Quick [1] Normal [0] --
53 T/M Alternator R 4301 ON [1] OFF [0] --
54 T/M Body seated 34600 ON [1] OFF [0] --
55 T/M Front brake dir 44900 0~100 %
56 T/M Rear brake dir 44901 0~100 %
57 T/M Coolant temperature 04104 -40~210 C
58 T/M 1st (ECMV 1 dir) 31602 0~1000 mA
59 T/M 1st (ECMV 1) 31612 0~4000 mA
60 T/M 2nd (ECMV 2 dir) 31603 0~1000 mA
61 T/M 2nd (ECMV 2) 31613 0~4000 mA
62 T/M 3rd (ECMV 3 dir) 31604 0~1000 mA
63 T/M 3rd (ECMV 3) 31614 0~4000 mA
64 T/M H (ECMV H dir) 31600 0~1000 mA
65 T/M H (ECMV H) 31610 0~4000 mA
66 T/M ECMV L dir 31601 0~1000 mA
67 T/M ECMV L 31611 0~4000 mA
68 T/M ECMV LU dir 31609 0~1000 mA
69 T/M ECMV LU 31619 0~4000 mA
70 T/M ECMV M dir 31640 0~1000 mA
71 T/M ECMV M 31641 0~4000 mA
72 T/M ECMV R dir 31606 0~1000 mA
73 T/M ECMV R 31616 0~4000 mA
74 T/M Emergency travel 32400 ON [1] OFF [0] --
75 T/M Engine speed 01002 0~32767 rpm
76 T/M F1 switch 35200 ON [1] OFF [0] --
77 T/M Fill switch 31520 ON [1] OFF [0] --
78 T/M Fill time 1 41802 0~2550 mSec
79 T/M Fill time 2 41803 0~2550 mSec
80 T/M Fill time 3 41804 0~2550 mSec
81 T/M Fill time H 41801 0~2550 mSec

82 T/M Fill time L 41800 0~2550 mSec
83 T/M Fill time M 41809 0~2550 mSec
84 T/M Fill time R 41806 0~2550 mSec
85 T/M Fuel sensor 04201 0~250
86 T/M Fuel sensor 4200 0.00~5.00 V
87 T/M Key switch 32300 ON [1] OFF [0] --
88 T/M Torque converter in pressure 32601 0.00~5.00 MPa
89 T/M Torque converter in pressure 32602 0.00~5.00 V
90 T/M Torque converter oil temperature 30100 0~160 C
91 T/M Torque converter oil temperature 30101 0.00~5.00 V
92 T/M Torque converter out pressure 32603 0.00~5.00 MPa
93 T/M Torque converter out pressure 32604 0.00~5.00 V
94 T/M Transmission filter 33300 Clogged [1] Normal [0] --
95 T/M Transmission oil temperature 32500 0~160 C
96 T/M Transmission oil temperature 32501 0.00~5.00 V
97 T/M Transmission speed: in 31200 0~32767 rpm
98 T/M Transmission speed: mid 31300 0~32767 rpm
99 T/M Transmission speed: out 31400 0~32767 rpm
100 T/M Throttle mod 36000 -100~100 %
101 T/M Throttle position 31700 0.00~5.00 V
102 T/M Transmission shift mode 38700 0~17 --
103 T/M Transmission skip shift 38600 Keep [1] Normal [0] --
104 Monitor Part number of software 20200 Part number --
105 Monitor Application version 20221 Application --
106 Monitor Data Version 20222 Version data --
107 Monitor AISS switch 30400 ON [Close] OFF [Open] --
ON or OFF [1 of 0], --
108 Monitor Conn chk 1, 2 30700
ON or OFF [1 of 0]
109 Monitor Rheostat 30300 0.0~51.0 --
110 Monitor Sw1, Sw2, Sw3 30800 0~F, 0~F, 0~F --
111 Monitor Sw5-1, Sw5-2 30900
ON or OFF [1 of 0]
112 Monitor Sw5-3, Sw5-4 30901
ON or OFF [1 of 0]
113 Monitor Sw6-1, Sw6-2 30902
ON or OFF [1 of 0]
114 Monitor Sw6-3, Sw6-4 30903
ON or OFF [1 of 0]
ON [CN2B-2:close, CN2B-2:open] --
OFF [CN2B-2:open, CN2B-2:close]
115 Monitor ABS 37800
+++ [CN2B-2:close, CN2B-2:open]
--- [CN2B-2:open, CN2B-2:close]

116 Monitor ARSC 37700
117 Monitor ASR 37900
118 VHMS Body seated 34601 ON [1] OFF [0] --
119 VHMS Inclinometer 32901 -15.0~+15.0
120 VHMS Inclinometer 32902 0.00~5.10 V
121 VHMS Payload 42200 0.0~655.4 t
122 VHMS Rate weight 42201 0.0~655.4 t
123 VHMS Shift lever N 42500 ON [1] OFF [0] --
124 VHMS Stop run flag 45000 ON [1] OFF [0] --
125 VHMS Front left suspension pressure 32805 0.00~20.10 MPa
126 VHMS Front left suspension pressure 32811 0.00~5.00 V
127 VHMS Front right suspension pressure 32804 0.00~20.10 MPa
128 VHMS Front right suspension pressure 32810 0.00~5.00 V
129 VHMS Rear left suspension pressure 32807 0.00~20.10 MPa
130 VHMS Rear left suspension pressure 32813 0.00~5.00 V
131 VHMS Rear right suspension pressure 32806 0.00~20.10 MPa
132 VHMS Rear right suspension pressure 32812 0.00~5.00 V
133 VHMS Truck status 42400 0~8 --

MACHINE MONITOR FLOW CHART

NOTES

SECTION D20
FAILURE CODES
INDEX
FAILURE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20-3
ACTION CODE DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20-3
CHECKING FAILURE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20-4
LIMP HOME MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20-5
FAILURE CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20-6
D20001 Fault Codes D20-1

NOTES
D20-2 Fault Codes D20001

FAILURE CODES
ACTION CODE DISPLAYS
When an E03 code is present, the top line displays
E03. The bottom line alternates between CHECK
RIGHT NOW and CALL. The display will alternate in
3 second intervals. The telephone number is dis-
Stop the machine immediately when E03 codes played to the right of CALL. If the telephone number
are displayed. Contact your Komatsu distributor has not been set, the spaces will be blank. Refer to
for repairs. Character Display - Inputting Telephone Numbers.
If there is a machine failure or if maintenance is nec- E02 Codes

essary, an action code is displayed on the character
display to recommend a suitable response. When an E02 code is present, the top line of the
character display will indicate E02. The bottom line
If more than one failure is present, the most impor- indicates whether the condition of the machine is
tant action code is displayed. The order of impor- related to overspeed or overheat.
tance, starting from the highest, is E03, E02, and
E01. If failures of equal importance occur at the When an E02 code is displayed, it is important to act
same time, the latest one is displayed. accordingly.
When action codes E02 or E03 occur, the alarm If an overspeed related fault is displayed, reduce
the engine speed and the speed of the machine.
buzzer sounds intermittently and the central warning
lamp illuminates. If an overheat related fault is displayed, safely
stop the machine and operate the engine under
no load at a mid-range speed.
E03 Codes
When E03 is displayed, stop the machine immedi-
ately. Check the failure code, and contact your
Komatsu distributor for repairs. Refer to Checking
Failure Codes later in this chapter.
If an action code is still displayed after altering the

operating conditions, check the failure code and con-
tact your Komatsu distributor for repairs.
E01 Codes
When an E01 code is present, the top line of the
character display will display E01. The bottom line
will either display MAINTENANCE or another
description that indicates the affected system. E01
codes do not require immediate attention. If desired,
the truck can operate until the end of the shift before
returning for service.

The following failure code table is sorted in alphabet-
ical and numerical order.
The Applicable Controller column in the fault code
table indicates the controller that logged the failure.
Below are the controllers:
MON: Machine monitor system
ENG: Engine controller
TM: Transmission controller (ATC)
If MAINTENANCE is displayed, check the failure BK: Retarder controller (RCM)

code and contact your Komatsu distributor for VHMS Vehicle Health Monitoring System (VHMS)
repairs.
PLM Payload Meter - The payload meter system is
is a function of the VHMS controller. However, PLM
will be displayed on the machine monitor if a failure
CHECKING FAILURE CODES code is present.
If an action code is present on the character display, NOTE: Failure codes in parentheses are not
check the failure codes as follows: recorded in the failure history.
1. Press (>) on mode select switch 2 to display the
failure code. The failure code for that action
code will be displayed on the character display.
2. Press (>) on mode select switch 2 again to see
if any other codes are present. Check the failure
code for each action code present and note. If
no other codes are present, the character dis-
play will return to the service meter/odometer.
The six digit code displayed on the top line of the
character display is the failure code. The code dis-
played to the right of the failure code is the controller
that detected the fault. The bottom line on the char-
acter display lists the system where the failure was
generated.

LIMP HOME MODE
In some instances, electrical failures in the engine or
transmission systems may prevent the truck from
operating. If this occurs, the operator may be able to
operate the machine by following the limp home pro-
cedure.
FIGURE 20-1. LIMP HOME JUMPER
1. Move the shift lever to N and apply the parking

brake.
2. Locate connector CN041 in the operator cab
behind the electronic display panel (EDP).
3. The key switch must be in the ON position and/
or the engine must be on to switch into limp
home mode. Momentarily disconnect the limp
home jumper from connector CN041 to put the
machine in limp home mode. Plug the jumper
back into the connector.
4. Start the engine. The truck will stay in the limp
home mode until the key switch is turned OFF.
Fuse And Circuit Breakers

Before troubleshooting, verify that circuit breakers
and fuses are present and working properly.

FAILURE CODE TABLE
Failure Applicable Action History

Description
codes controller code classification
Mechanical
1500L0 Dual engagement of clutches TM E03
system
Mechanical
15B0NX Transmission oil filter: Restriction TM E01
system
Mechanical
15F0KM R to F shifting abuse 1: Operator Error TM
system
Mechanical
15F0MB R to F shifting abuse 2: Operator Error TM
system
Mechanical
15F7KM Forward clutch disc abuse: Operator Error TM
system
Electrical
15G0MW Reverse clutch: Slipping TM E03
system
Mechanical
15G7KM Reverse clutch disc abuse: Operator Error TM
system
Electrical
15H0MW High clutch: Slipping TM E03
system
Electrical
15J0MW Low clutch: Slipping TM E03
system
Electrical
15K0MW 1st clutch: Slipping TM E03
system
Electrical
15L0MW 2nd clutch: Slipping TM E03
system
Electrical
15M0MW 3rd clutch: Slipping TM E03
system
Electrical
15SBL1 Reverse clutch ECMV: Fill signal ON, command current OFF TM E03
system
Electrical
15SBMA Reverse clutch ECMV: Malfunction TM E03
system
Electrical
15SCL1 High clutch ECMV: Fill signal ON, command current OFF TM E03
system
Electrical
15SCMA High clutch ECMV: Malfunction TM E03
system
Electrical
15SDL1 Low clutch ECMV: Fill signal ON, command current OFF TM E03
system
Electrical
15SDMA Low clutch ECMV: Malfunction TM E03
system
Electrical
15SEL1 1st clutch ECMV: Fill signal ON, command current OFF TM E03
system
Electrical
15SEMA 1st clutch ECMV: Malfunction TM E03
system
Electrical
15SFL1 2nd clutch ECMV: Fill signal ON, command current OFF TM E03
system
Electrical
15SFMA 2nd clutch ECMV: Malfunction TM E03
system
Electrical
15SGL1 3rd clutch ECMV: Fill signal ON, command current OFF TM E03
system

Description
Electrical
15SGMA 3rd clutch ECMV: Malfunction TM E03
system
Electrical
15SJMA Lockup clutch ECMV: Malfunction TM E03
system
Electrical
15SSL1 Mid clutch ECMV: Fill signal ON, command current OFF TM E03
system
Electrical
15SSMA Mid clutch ECMV: Malfunction TM E03
system
Electrical
15X0MW Mid clutch: Slipping TM E03
system
Electrical
2G39MA Brake Vale: Malfunction BK E03
system
Electrical
2G3AMA Brake Relay Valve: Malfunction BK E03
system
Mechanical
2G41ZG Accumulator: Low oil pressure BK E03
system
Electrical
2J00MA Automatic Emergency Valve: Erratic Behavior BK E03
system
Mechanical
4A00ZG Steering system: Low oil pressure BK E03
system
Mechanical
4A5WZH Steering Accumulator 1: Low oil pressure BK E01
system
Mechanical
4A5XZH Steering Accumulator 2: Low oil pressure BK E01
system
Mechanical
6014NX Hydraulic filter: Restriction BK E01
system
Mechanical
989A00 Engine over-run protection: Activated TM E02
system
Electrical
AB00MA Alternator: Malfunction TM E03
system
Mechanical
B@BAZG Engine Oil: Low Engine Oil Pressure MON E03
system
Mechanical
B@BCNS Engine: Overheat MON E02
system
Mechanical
B@BFZK Fuel System: Fuel level low MON
system
Mechanical
B@C6NS Brake cooling oil: Overheating (Front) MON E02
system
Mechanical
B@C7NS Brake cooling oil: Overheating (Right Rear) MON E02
system
Mechanical
B@C8NS Brake cooling Oil: Overheating (Left Rear) MON E02
system
Mechanical
B@CENS Torque converter oil: Overheat ing MON E02
system
Mechanical
B@M6NX Brake cooling oil filter (front): Restriction BK E01
system
Mechanical
B@M7NX Brake cooling oil filter (#2 Rear): Restriction BK E01
system
Mechanical
B@M8NX Brake cooling oil filter (#1 Rear): Restriction BK E01
system

Description

C115 Speed Signal Lost ENG E03

C124 High Intake Man Press 1 ENG E02

C135 Oil Press Ckt Failed High ENG E02

C141 Oil Press Ckt Failed Low ENG E02

C143 Low Oil Press ENG E02

C144 Coolant Temp Ckt Failed High ENG E02

C145 Coolant Temp Ckt Failed Low ENG E02

C146 Coolant Temp Above Normal ENG E02

C151 High Coolant Temp ENG E03

C153 Intake Man Temp 1 Ckt Failed High ENG E02

C154 Intake Man Temp 1 Ckt Failed Low ENG E02

C155 High Intake Man Temp 1 ENG E03










C187 Sensor Supply 2 Ckt Failed Low ENG E02

C195 Coolant Level Ckt Failed High ENG E02

C196 Coolant Level Ckt Failed Low ENG E02

C197 Coolant Level Below Normal ENG E02

Description

C212 Oil Temp Ckt Failed High ENG E02

C213 Oil Temp Ckt Failed Low ENG E02

C221 Ambient Air Press Failed High ENG E02

C222 Ambient Air Press Failed Low ENG E02

C223 Centinel Burn Valve Below Normal ENG E02

C224 Centinel Burn Valve Above Normal ENG E02

C227 Sensor Supply 2 Ckt Failed High ENG E02

C228 Very Low Coolant Pressure ENG E03

C231 Coolant Press Ckt Failed High ENG E02

C232 Coolant Press Ckt Failed Low ENG E02

C234 Eng Overspeed ENG E03

C235 Low Coolant Level ENG E03

C237 Multi Unit Sync Error ENG E02


C245 Fan Control Circuit Failed Low ENG E02

C261 High Fuel Temp ENG E02

C263 Fuel Temp Ckt Failed High ENG E02

C265 Fuel Temp Ckt Failed Low ENG E02

C271 Fuel Pump Press 1 Ckt Failed Low ENG E02

C272 Fuel Pump Press 1 Ckt Failed High ENG E02

C285 J1939 PGN Timeout Error ENG E02

C286 J1939 Configuration Error ENG E02

C319 Real Time Clock - Data Erratic ENG E01

C322 Injector Sol Driver Cyl 1 Below Normal ENG E02


Description





C342 Calibration Incompatibility Error ENG E03

C343 ECM Hardware Issue Non Mission Disabling ENG E02

C349 Trans Output Shaft Speed Above Normal ENG E02

C351 Injector Power Supply Failed ENG E02


C386 Sensor Supply 1 Ckt Failed High ENG E02

C415 Very Low Oil Pressure ENG E03

C418 WIF Indicator Warning ENG E01

C421 Engine Oil Temp Above Normal ENG E02

C431 Idle Validation Invalid ENG E02

C432 Idle Validation Calibration Error ENG E03

C441 Low Battery Voltage ENG E02

C442 High Battery Voltage ENG E02

C449 High Rail Pressure ENG E03

C451 Rail Press Ckt Failed High ENG E02

C452 Rail Press Ckt Failed Low ENG E02

C487 Ether Bottle Empty ENG E02

C488 High Intake Manifold Temp ENG E02

C489 AXG Speed Low Error ENG E02

C497 Multi Unit Sync Error ENG E02

C527 Dual Output A Failed High ENG E02

Description

C529 Dual Output B Failed High ENG E02

C546 Fuel Del Pressure Ckt Failed High ENG E02

C547 Fuel Del Pressure Ckt Failed Low ENG E02

C556 High Crankcase Pressure ENG E03

C559 Rail Pressure 1 Below Normal ENG E02

C599 Aux Commanded Dual Output Shutdown ENG E03

C611 Engine Hot Shutdown ENG

C621 Low Power Cylinder 1 ENG E01
















C671 Exh Temp Ckt Failed Low Cylinder 1 ENG E01


Description







C689 Engine Crankshaft Speed Erratic ENG E02

C697 ECM Temp Ckt Failed High ENG E02

C698 ECM Temp Ckt Failed Low ENG E02









C731 Engine Speed Cam/Crank Misalignment ENG E02

C781 J1939 Datalink 2 Can Not Transmit ENG E02

C783 Rapid rise int man temp 1 ENG E03

C1117 Power Lost with Ignition On ENG

C1135 J1939 Datalink 2 Can Not Transmit ENG E03

C1256 Module ID Input State Error ENG E02

C1257 Module ID Input State Error ENG E03

C1357 Remote Oil Level Below Normal ENG E02

Description

C1358 Accel Pedal Sensor 1 Ckt Failed High ENG E02

C1359 Accel Pedal Sensor 1 Ckt Failed Low ENG E02

C1361 Remote Accel Pedal 1 Ckt Failed High ENG E02

C1362 High Lube Oil Filter Restriction ENG E02

C1363 Intake Man Press 1 Below Normal ENG E01

C1367 Pre Filter Oil Press Ckt Failed High ENG E01

C1368 Pre Filter Oil Press Ckt Failed Low ENG E01

C1369 Aux Temp Input 1 Ckt Failed High ENG E01

C1371 Aux Press Input 1 Ckt Failed High ENG E01

C1372 Aux Press Input 1 Ckt Failed Low ENG E01

C1373 Ether Injection Ckt Failed ENG E01

C1376 Engine Speed Cam/Crank data Erratic ENG E01

C1377 Post Filter Oil Press Ckt Failed High ENG E01

C1378 Post Filter Oil Press Ckt Failed Low ENG E01

C1381 Aux Temp Input 1 Ckt Exception ENG E01

C1383 Intake Man Press 1 Failed High ENG E01

C1384 Intake Man Press 1 Failed Low ENG E01

C1385 Intake Man Press 2 Failed High ENG E01

C1386 Intake Man Press 2 Failed Low ENG E01

C1387 J1939 Engine Commanded Shutdown ENG

C1514 Accel Pedal Pos Sensor Ckt 1 Freq Issue ENG E02

C1516 Engine Crankshaft Speed Above Normal ENG E01

C1517 ECM Detects Most Severe Fault ENG E03

C1518 ECM Detects Moderately Severe Fault ENG E02

C1519 ECM Detects Least Severe Fault ENG E01

Description

C1521 Exh Temp Ckt Failed High Cylinder 3 ENG E01
















C1544 Aux Pressure Sensor Input 1 Exception ENG E01

C1548 Injector Sol Driver 7 Below Normal ENG E02








Description




C1595 Remote Accel Pedal 1 Ckt Failed High ENG E02

C1596 Aux Temp Sensor Input 1 Ckt Failed Low ENG E01

C1597 ECM Criticial Internal Failure ENG E01




C1634 Intake Man Press 2 Above Normal ENG E02

C1638 Intake Man Press 2 Below Normal ENG E01

C1843 Crankcase Press Ckt Failed High ENG E02

C1844 Crankcase Press Ckt Failed Low ENG E02

C1845 WIF Indicator Ckt Failed High ENG E01

C1846 WIF Indicator Ckt Failed Low ENG E01

C1847 Engine Coolant Temp Exception ENG E03

C1852 WIF Indicator Above Normal ENG E02

C1888 J1939 Accel Pedal Error ENG E01

C1889 J1939 Remote Accel Pedal Error ENG E01

C1891 Engine Oil Change Interval Exceeded ENG E02

C1911 Inj Rail Pressure Above Normal ENG E02

C1984 Intake Man Temp 2 Above Normal ENG E02




Description


C2121 High Exhaust Temp Cyl 1 ENG E02






















C2157 Rapid Rise Intake Man Temp 2 ENG E03


Description

C2159 Rapid Rise Int Man Temp 4 ENG E03

C2185 Sensor Supply 4 Ckt Above Normal ENG E02

C2186 Sensor Supply 4 Ckt Below Normal ENG E02

C2215 Fuel Pump Pressure Below Normal ENG E02









C2261 Fuel Pump Del Pressure Above Normal ENG E01

C2262 Fuel Pump Del Pressure Below Normal ENG E01

C2265 Lift Pump Supply Ckt Failed High ENG E02

C2266 Lift Pump Supply Ckt Failed Low ENG E02

C2311 Fuel Injection Valve Ckt Error ENG E02

C2321 Engine Crankshaft Speed - Data Erratic ENG

C2322 Engine Camshaft Speed - Data Erratic ENG

C2377 Fan Control Ckt Failed High ENG E02

C2474 Turbocharger 1 Speed - Data Erratic ENG E02

C2557 Aux PWM Driver 1 Ckt Failed High ENG E02

C2558 Aux PWM Driver 1 Ckt Failed Low ENG E02

C2963 Engine Coolant Temp Above Normal ENG

C2964 Intake Man Temp 1 Above Normal ENG

Failure Description Applicable Action History
Electrical
DAF9KM Machine Monitor: Poor Connection MON E03
system
Electrical
DAFRKR Machine monitor: Communication error TM E03
system
Electrical
DAQ0KK Transmission controller power: Source voltage low TM E03
system
Electrical
DAQ2KK Transmission controller/ECMV power: Source voltage low TM E03
system

DAQ9KQ Transmission controller: Model Selection Error MON E03
Electrical
DAQRKR Transmission controller: Communication error MON E03
system

DAQRMA Transmission controller: Option Setting Error MON E03
Electrical
DASOMA Engine Malfunction: Red indicator light MON E03
system
Electrical
DASOMC Engine Malfunction: Amber indicator light MON E01
system
Electrical
DASRKR Engine: Communication error MON E03
system
Electrical
DB10KT Retarder controller non-volatile memory: Controller error BK E01
system
Electrical
DB12KK Retarder controller solenoid power source: Malfunction BK E03
system
Electrical
DB13KK Retarder controller battery direct power source: Source voltage low BK E03
system

DB19KQ Retarder controller: Model selection error MON E03
Electrical
DB1RKR Retarder controller: Communication error TM E03
system

DB1RMA Retarder controller: Option setting error MON E03
Electrical
dBBRKR VHMS Communication Error MON E01
system
Electrical
DDB4MA Brake Sensor: Open or short circuit BK E01
system
Electrical
DDD7KX ARSC switch: Input signal out of range BK E03
system
Electrical
DDD8KA ARSC switch: Open circuit BK E03
system
Electrical
DDD8KB ARSC switch: Short circuit BK E03
system
Electrical
DDDAKA ASR Cut switch: Open circuit BK E01
system
Electrical
DDDAKB ASR Cut switch: Short circuit BK E01
system
Electrical
DDP6MA Brake Switch: Open or short circuit BK E01
system
Electrical
DDTHKA High clutch fill switch: Open circuit TM E03
system

Description
Electrical
DDTJKA Low clutch fill switch: Open circuit TM E03
system
Electrical
DDTKKA 1st clutch fill switch: Open circuit TM E03
system
Electrical
DDTLKA 2nd clutch fill switch: Open circuit TM E03
system
Electrical
DDTMKA 3rd clutch fill switch: Open circuit TM E03
system
Electrical
DDTNKA Reverse clutch fill switch: Open circuit TM E03
system
Electrical
DDTRKA Middle clutch fill switch circuit: Open circuit TM E03
system
Electrical
DF10KA Shift lever: Open circuit TM E03
system
Electrical
DF10KB Shift lever: Short circuit TM E03
system
Electrical
DGF1KX Transmission oil temperature sensor: Input signal out of range TM E03
system
Electrical
DGR2KB Retarder oil temperature sensor (right rear): Short to ground BK E01
system
Electrical
DGR2KZ Retarder oil temperature sensor (right rear): Open or short circuit BK E01
system
Electrical
DGR3KB Retarder oil temperature sensor (left rear): Short to ground BK E01
system
Electrical
DGR3KZ Retarder oil temperature sensor (left rear): Open or short circuit BK E01
system
Electrical
DGR4KB Retarder oil temperature sensor (front wheel): Open or short circuit BK E01
system
Electrical
DGR4KZ Retarder oil temperature sensor (Front wheel): Short to ground BK E01
system
Electrical
DGT1KX Torque converter oil temperature sensor: Input signal out of range TM E01
system
Electrical
dHP4KX Right Front Suspension Pressure Sensor: Out of range BK E03
system
Electrical
DhP4KX Right Front Suspension Pressure Sensor: Out of range VHMS E03
system
Electrical
dHP5KX Front Left Suspension Pressure Sensor: Out of range BK E03
system
Electrical
DhP5KX Front Left Suspension Pressure Sensor: Out of range VHMS E03
system
Electrical
DHP6KX Right Rear Suspension Pressure Sensor: Out of Range VHMS E03
system
Electrical
DHP7KX Left Rear Suspension Pressure Sensor: Out of Range VHMS E03
system
Electrical
DHT5KX Torque converter inlet oil pressure sensor: Out of range TM E01
system
Electrical
DHT5L6 Torque converter inlet oil pressure sensor: Malfunction TM E01
system
Electrical
DHT7KX Torque converter outlet oil pressure sensor: Out of range TM E01
system

Description
Electrical
DHT7L6 Torque converter outlet oil pressure sensor: Malfunction TM E01
system
Electrical
DJF1KA Fuel level sensor: Open circuit TM E01
system
Electrical
DK11KX Accel Pedal Sensor Circuit: Out of range TM E03
system
Electrical
DK30KX Steering angle potentiometer: Open circuit BK E01
system
Electrical
DK51KX Retard Lever Potentiometer: Out of range BK E03
system
Electrical
DKH1KX Inclination Sensor: Out of Range VHMS E01
system
Electrical
DL10LC Wheel Speed Sensor Circuit: Malfunction BK E01
system
Electrical
DLE2KA Engine Speed Sensor: Open circuit TM E03
system
Electrical
DLE2LC Engine Speed Sensor: Malfunction TM E03
system
Electrical
DLF1KA Transmission input shaft speed sensor: Open circuit TM E03
system
Electrical
DLF1LC Transmission input shaft speed sensor: Malfunction TM E03
system
Electrical
DLF2KA Transmission intermediate shaft speed sensor: Open circuit TM E03
system
Electrical
DLF2LC Transmission intermediate shaft speed sensor: Malfunction TM E03
system
Electrical
DLF8LC Right rear wheel speed sensor: Malfunction BK E01
system
Electrical
DLF9LC Left rear wheel speed sensor: Malfunction BK E01
system
Electrical
dLt3KA Transmission output shaft speed sensor: Open circuit BK E03
system
Electrical
dLT3KA Transmission output shaft speed sensor: Open circuit BK E01
system
Electrical
DLT3KA Transmission output shaft speed sensor: Open circuit TM E03
system
Electrical
dLt3LC Transmission output shaft speed sensor: Malfunction BK E03
system
Electrical
dLT3LC Transmission output shaft speed sensor: Malfunction BK E01
system
Electrical
DLT3LC Transmission output shaft speed sensor: Malfunction TM E03
system
Electrical
DNCCMA Brake Pedal Proximity Switch: Short circuit BK E01
system
Electrical
DV00KB Warning alarm buzzer output: Short circuit MON E01
system
Electrical
DW78KZ Rear brake cooling valve: Open or short circuit BK E01
system
Electrical
DW79KZ Front brake cooling valve: Open or short circuit BK E01
system

Description
Electrical
DW7FMA Manual emergency brake valve: Malfunction BK E03
system
Electrical
DW7GMA Brake valve or brake lock valve: Malfunction BK E03
system
Electrical
DWA1K4 PPC cut valve: Malfunction (Valve Stuck On) BK E03
system
Electrical
DWA1KA PPC cut valve: Open circuit BK E03
system
Electrical
DWA1KB PPC cut valve: Short Circuit BK E03
system
Electrical
DWA1KY PPC cut valve: Short to Power BK E03
system
Electrical
DWA1MA PPC cut valve: Malfunction (Valve Does Not Operate) BK E03
system
Electrical
DX12K4 Front brake PPC solenoid valve: Malfunction (Valve stuck on) BK E03
system
Electrical
DX12KA Front brake PPC solenoid valve: Open circuit BK E03
system
Electrical
DX12KB Front brake PPC solenoid valve: Short circuit BK E03
system
Electrical
DX12KY Front brake PPC solenoid valve: Short to power BK E03
system
Electrical
DX12MA Front brake PPC solenoid valve: Malfunction (Valve does not operate) BK E03
system
Electrical
DX27K4 RIght rear PPC solenoid valve: Malfunction (Valve Stays On) BK E03
system
Electrical
DX27KA RIght rear PPC solenoid valve: Open ciruit BK E03
system
Electrical
DX27KB RIght rear PPC solenoid valve: Short Circuit BK E03
system
Electrical
DX27KY RIght rear PPC solenoid valve: Short to Power BK E03
system
Electrical
DX27MA RIght rear PPC solenoid valve: Malfunction (valve does not operate) BK E03
system
Electrical
DX28K4 Left rear PPC solenoid valve: Malfunction (valve is stuck on) BK E03
system
Electrical
DX28KA Left rear PPC solenoid valve: Open circuit BK E03
system
Electrical
DX28KB Left rear PPC solenoid valve: Short circuit BK E03
system
Electrical
DX28KY Left rear PPC solenoid valve: Short to power BK E03
system
Electrical
DX28MA Left rear PPC solenoid valve: Malfunction BK E03
system
Electrical
DXH1KA Lockup clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH1KB Lockup clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH1KY Lockup clutch ECMV output circuit: Short to power TM E03
system

Description
Electrical
DXH2KA High clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH2KB High clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH2KY High clutch ECMV output circuit: Short to power TM E03
system
Electrical
DXH3KA Low clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH3KB Low clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH3KY Low clutch ECMV output circuit: Short to power TM E03
system
Electrical
DXH4KA 1st clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH4KB 1st clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH4KY 1st clutch ECMV output circuit: Short to power TM E03
system
Electrical
DXH5KA 2nd clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH5KB 2nd clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH5KY 2nd clutch ECMV output circuit: Short to power TM E03
system
Electrical
DXH6KA 3rd clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH6KB 3rd clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH6KY 3rd clutch ECMV output circuit: Short to power TM E03
system
Electrical
DXH7KA R clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXH7KB R clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXH7KY R clutch ECMV output circuit: Short to power TM E03
system
Electrical
DXJ7KA Mid clutch ECMV output circuit: Open circuit TM E03
system
Electrical
DXJ7KB Mid clutch ECMV output circuit: Short circuit TM E03
system
Electrical
DXJ7KY Mid clutch ECMV output circuit: Short to power TM E03
system

TROUBLESHOOTING
If a failure code has been detected, use the following
failure code troubleshooting charts to determine the
problem. The tables are sorted numerically and
alphabetically in ascending order.
FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES
Action code Failure code Dual engagement of clutches

Description
E03 1500L0 (Transmission controller system)
Contents of
Fill switch signals have been inputted from 2 clutches that do not form a normal combination.
trouble
Controller Suddenly shifts to Neutral while traveling, and cannot move off again.
response Even after the repair, does not resume to normal unless starting switch is once turned OFF.
Problem that
appears on The gear speed is shifted to Neutral.
machine
Related
Other problem (clutch pressure control valve system failure code [15S*L1]) occurs at same time.
information
Cause Standard value in normal state/Remarks on troubleshooting

Clutch pressure control valve
1 system failure code (15S*L1) Troubleshooting by the active failure code.
Possible causes has occurred
and standard
value in normal Defective hydraulic or
Clutch ECMV may be malfunctioning. Perform troubleshooting of
state 2 mechanical system of clutch
hydraulic and mechanical systems.
ECMV
Defective transmission
3 Troubleshooting by the active failure code.
controller
D21003 08/07 Troubleshooting D21-1

FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION
Action code Failure code Transmission oil filter: restriction

Description
E01 15B0NX (Transmission controller system)
Contents of When the torque converter oil temperature is above 50C, the signal circuit of the transmission restriction
trouble sensor is opened (disconnected from GND).
Controller
None in particular.
response
Problem that
appears on If the machine is used without repairing, dust may enter the transmission circuit.
machine

Restriction of transmission
1 Clean or replace.
filter
1) Turn the starting switch OFF.
2) Disconnect connector 147 and 148.
3) Connect T-adapter.
2
Defective transmission filter Between 148 (male) Filter is normal Resistance Max. 1
restriction sensor (A) (B) Filter is clogged Resistance Min. 1 M
Between 147 (male) Filter is normal Resistance Max. 1
(A) (B) Filter is clogged Resistance Min. 1 M
2) Disconnect connectors ATC1, CN147 and CN148.
Wiring harness between ATC1 (female) (17)
Possible causes Disconnection in wiring Resistance Max. 1
148 (female) (A)
and standard harness
value in normal 3 (Disconnection or defective
Resistance Max. 1
state 147 (female) (A)
contact)
Wiring harness between 148 (female) (B)
Resistance Max. 1
ground
Wiring harness between 147 (female) (B)
Resistance Max. 1
ground
2) Disconnect connectors ATC1.
3) Insert T-adapter.
4) Connect conector.
5) Turn the starting switch ON.
Defective transmission con-
4 Between ATC1 Filter is normal Voltage Max. 1V
troller
(female) (17)
ground Filter is clogged Voltage 20 30 V
Between ATC1 Filter is normal Voltage Max. 1V

(female) (17)
ground Filter is clogged Voltage 20 30 V
D21-2 Troubleshooting 08/07 D21003

FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR
Action code Failure code R to F shifting abuse 1: Operator Error

Description
15F0KM (Transmission controller system)
Contents of When output shaft speed is 200 300 rpm (about 5 8 km/h), gear shifting from reverse to forward has
trouble been detected.
Controller
Non in particular.
response
Problem that
If the machine is operated in as-is condition, the machine may be damaged.
appears on
Only recorded in failure history.
machine
Related
Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 A forward-reverse shifting should be performed when the machine is
Abuse
state stationary. (Teach the proper operating method.)
FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR
Action
Failure code R to F shifting abuse 2: Operator Error
code Description
(Transmission controller system)
15F0MB
Contents of When output shaft speed is above 300 rpm (about 8 km/h), gear shifting from reverse to forward has been
trouble detected.
Controller
Non in particular.
response
Problem that
If the machine is operated in as-is condition, the machine may be damaged.
appears on
machine
Related
Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
information

and standard
value in normal 1 A forward-reverse shifting should be performed when the machine is sta-
Abuse
state tionary. (Teach the proper operating method.)

FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR
Action code Failure code Forward clutch disc abuse: Operator error
Description
15F7KM (Transmission controller system)
Contents of When the engine speed is above 1,800 rpm, gear shifting from neutral or reverse to forward has been
trouble detected.
Controller
Non in particular.
response
Problem that
Repeated abnormal operations may cause machine damage.
appears on
machine
Related
information

and standard
value in normal 1 A forward-reverse shifting should be performed when the machine is sta-
Abuse
state tionary. (Teach the proper operating method.)

FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING
Action code Failure code R clutch: Slipping

(R command is holding pressure, R clutch, fill switch is ON, and slipping
Description
E03 15G0MW detected)
When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission
Contents of
input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
trouble
speed sensor is abnormal.
Controller Sets gear in neutral.
response Turns lockup system OFF.
Machine cannot travel in reverse.
If gearshift lever is set in neutral, machine cannot start.
Operator can move the machine by following the limp home procedure.
1) Stop travel and set gearshift lever in N position.
Problem that
2) Momentarily disconnect the limp home jumper from connector CN041 to set the machine in limp home
appears on
mode. Plug the jumper back into the connector.
machine
3) Operate gearshift lever and start machine again.
a. When operating gearshift lever, release accelerator pedal.
b. Operate gearshift lever from N to D L or from N to R.
c. Machine is kept in limp home mode until starting switch is turned OFF.
Electric current of out put to ECMV can be checked with monitoring function (Code: 31606 (mA)).
Related
If electrical system is normal, check reverse clutch and mechanical/hydraulic system of pressure control
information
valve for defect.

2) Disconnect connector CN5 (R,PS).
1 Defective R clutch ECMV
Between CN5 (R,PS) (male) (1) (2) Resistance 5 15
Between CN5 (R,PS) (male) (1), (2)
Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN5 (R,PS).
Possible causes Disconnection in wiring 3) Connect T-adapter.
Resistance Max. 1
state CN5 (R,PS) (female) (1)
contact)
Resistance Max. 1
CN5 (R,PS) (female) (2)
Defective sensing by speed
3 Troubleshooting by the failure codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC3.
Defective transmission con- 3) Connect T-adapter.
4
troller
Resistance 5 15
ATC3 (female) (23)

FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR
Action code Failure code Reverse clutch disc abuse: Operator error
Description
15G7KM (Transmission controller system)
Contents of When the engine speed is above 1,800 rpm, gear shifting from neutral or forward to reverse has been
trouble detected.
Controller
None in particular.
response
Problem that
Repeated abusive operation may cause clutch damage.
appears on
machine
Related
information

and standard
value in normal 1 The machine must be stationary before the shift lever is moved into
Abuse
state REVERSE.

NOTES

FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING
Action code Failure code High clutch: Slipping

(High command is holding pressure, fill switch is ON, and slipping
Description
E03 15H0MW detected)
When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the transmission
Contents of
trouble
Controller Shifts up and keeps gear according to gear speed before trouble and Table 1.
Problem that
appears on If gearshift lever is set in neutral, machine cannot restart until it stops.
machine
Can be checked with monitoring function (Code: 31600 (mA)).
Related
If electrical system is normal, check Hi clutch and mechanical/hydraulic system of pressure control valve
information
for defect.

2) Disconnect connector CN13 (H,PS).
1 Defective Hi clutch ECMV
Between CN13 (H,PS) (male) (1) (2) Resistance 5 15
Between CN13 (H,PS) (male) (1), (2)
Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN13 (H,PS).
Resistance Max. 1
state CN13 (H,PS) (female) (1)
contact)
Resistance Max. 1
CN13 (H,PS) (female) (2)
sensor
4
troller
Resistance 5 15
ATC3 (female) (3)

TABLE 1
Remedy against trouble
Speed when trouble was
Failed clutch Action of controller ON/OFF state of
detected
(Selected clutch, gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F7
High High OFF NEUTRAL OFF
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
Reverse Reverse OFF NEUTRAL OFF
R
Low Low RM R* OFF
* Combination not normally used

FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING
Action code Failure code Low clutch: Slipping

(Low command is holding pressure, fill switch is ON, and slipping
Description
E03 15J0MW detected)
When a signal is output to the low clutch ECMV, the value calculated from the signals of the transmission
Contents of
trouble
Problem that
machine
Related
If electrical system is normal, check low clutch and mechanical/hydraulic system of pressure control valve
information
for defect.

2) Disconnect connector CN17.
1 Defective Low clutch ECMV
Between CN11 (L,PS) (male) (1) (2) Resistance 5 15
Between CN11 (L,PS) (male) (1), (2)
Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN11 (L,PS).
Resistance Max. 1
state CN11 (L,PS) (female) (1)
contact)
Resistance Max. 1
CN11 (L,PS) (female) (2)
sensor
4
troller
Resistance 5 15
ATC3 (female) (13)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING
Action code Failure code 1st clutch: Slipping

(1st command holding pressure, 1st clutch fill switch ON, slipping
Description
E03 15K0MW detected)
During an output to the 1st clutch ECMV, an abnormality exists in the value calculated from the
Contents of
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
trouble
and transmission output shaft speed sensor.
Controller Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in Table 1.
response Turns lock up to OFF.
Operator can move machine by following limp home procedure.
Problem that 2Momentarily disconnect the limp home jumper from connector CN041 to set the machine in limp home
appears on mode. Plug the jumper back into the connector.
machine 3) Operate gearshift lever and start machine again.
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D L or from N to R.
a Machine is kept in limp home mode until starting switch is turned OFF.
Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA))
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st clutch or
information
pressure control valve.

1) Turn starting switch OFF.
2) Connect T-adapter to connector CN7 (1,PS) (male).
1 Defective 1st clutch ECMV Between CN7 (1,PS) (male) (1) (2) Resistance 5 15
Between CN7 (1,PS) (male) (1), (2)
Resistance Min. 1 M
ground
2) Connect T-adapter to connectors ATC3 (female) and CN7 (1,PS)
Possible causes Disconnection in wiring (female).
Resistance Max. 1
state CN7 (1,PS) (female) (1)
contact)
Resistance Max. 1
CN7 (1,PS) (female) (2)
Defective speed sensor
3 Troubleshooting by failure code DL**KA, DL**LC
detection
Defective transmission 2) Connect T-adapter to connector ATC3 (female).
4
controller Wiring harness between ATC3 (female) (36)
Resistance 5 15
(3)

FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING
Action code Failure code 2nd clutch: Slipping

(2nd command holding pressure, 2nd clutch fill switch ON, slipping
Description
E03 15L0MW detected)
During an output to the 2nd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Problem that 2) Momentarily disconnect the limp home jumper from connector CN041 to set the machine in limp home
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd clutch or
information

1 Defective 2nd clutch ECMV Between CN9 (2,PS) (male) (1) (2) Resistance 5 15
Between CN9 (2,PS) (male) (1), (2) and
Resistance Min. 1 M
ground
Resistance Max. 1
contact)
Resistance Max. 1
detection
4
Resistance 5 15
(23)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING
Action code Failure code 3rd clutch: Slipping

(3rd command holding pressure, 3rd clutch fill switch ON, slipping
Description
E03 15M0MW detected)
During an output to the 3rd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Controller The controller sets the gear in neutral.
response Turns lockup system off.
The controller shifts to Neutral during travel.
Problem that 2) Momentarily disconnect the limp home jumper from connector CN041 to set the machine in limp home
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd clutch or
information

1 Defective 3rd clutch ECMV Between CN3 (3,PS) (male) (1) (2) Resistance 5 15
Resistance Min. 1 M
ground
Resistance Max. 1
contact)
Resistance Max. 1
detection
4
Resistance 5 15
(3)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code Failure code R clutch ECMV: Fill signal is ON, command current is OFF
Description
E03 15SBL1 (Transmission controller system)
Contents of Even when output to the R clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and the
trouble clutch is not released.
Controller The controller sets the gear is neutral.
Problem that
appears on Machine cannot restart until it stops.
machine
Related Fill switch input signal can be checked with code: 31520 (0: OFF, 1: ON).
information If electrical system is normal, check hydraulic and mechanical systems of R clutch or pressure control
valve for defect.

2) Connect T-adapter to connector CN6 (R,SW) (male).
When R
Defective for R clutch fill is disen- Resistance Min. 1 M
1
switch Between CN6 (R,SW) (male) (1) gaged
ground When R
is Resistance Max. 1
engaged
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect connectors ATC3 and CN6 (R,SW).
value in normal 2 Defective harness grounding 3) Connect T-adapter to ATC3 (female).
state (Contact with ground circuit)
Resistance Min. 1 M
CN6 (R,SW) (female) (1)
2) Connect T-adapter to connector ATC3 (female).
When R
Defective transmission is disen- Resistance Min. 1 M
3
controller Between ATC3 (female) (29) gaged
ground When R
engaged

FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION
Action code Failure code R clutch ECMV: Malfunction

Description (R command holding pressure, R clutch fill switch OFF, slipping detected)
E03 15SBMA (Transmission controller system)
The signal from the fill switch stays "OFF" during an output to the R clutch ECMV and an abnormality
Contents of
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission inter-
trouble
mediate shaft speed sensor and transmission output shaft speed sensor.
Controller The controller sets the gear is neutral.
Problem that
appears on Machine cannot restart until it stops.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for R clutch or
information

2) Connect T-adapter to connector CN12 (male).
1 Defective R clutch ECMV Between CN5 (R,PS) (male) (1) (2) Resistance 5 15
Resistance Min. 1 M
ground
2) Connect T-adapter to connectors ATC3 (female) and CN5 (R,PS)
Resistance Max. 1
state CN5 (R,PS) (female) (1)
contact)
Resistance Max. 1
detection
4
Resistance 5 15
(23)

FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT
OFF
Action code Failure code High clutch ECMV: Fill signal ON, command current OFF
Description
E03 15SCL1 (Transmission controller system)
Contents of Even when output to the Hi clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and the
trouble clutch is not released.
Problem that
Machine travels at gear speeds which use Hi clutch.
appears on
machine
information If electrical system is normal, check hydraulic and mechanical systems of high clutch or pressure control
valve for defect.

2) Connect T-adapter to connector CN14 (H,SW) (male).
When Hi
is disen- Resistance Min. 1 M
1 Defective Hi clutch fill switch
Between CN14 (H,SW) (male) gaged
(1) ground When Hi
engaged
Possible causes
2) Disconnect connectors ATC3 and CN14 (H,SW).
and standard
state (Contact with ground circuit) Between ground and wiring harness
between ATC3 (female) (30) CN14 Resistance Min. 1 M
(H,SW) (female) (1)
When Hi
Defective transmission is disen- Resistance Min. 1 M
3
controller Between ATC3 (female) (30) gaged
ground When Hi
engaged

TABLE 2
Speed when trouble was Failed clutch
detected (Fill switch ON) Action of controller ON/OFF state of
2nd OFF NEUTRAL* OFF
1st OFF NEUTRAL* OFF
3rd
F7 Reverse OFF NEUTRAL* OFF
High
Mid OFF NEUTRAL* OFF
Low OFF NEUTRAL* OFF
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
3rd OFF NEUTRAL* OFF
Reverse
R 1st OFF NEUTRAL* OFF
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

N 1st OFF NEUTRAL* OFF
Mid
HIgh OFF NEUTRAL* OFF

NOTES

FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION
Action code Failure code High clutch ECMV: Malfunction

(Hi command holding pressure, high clutch fill switch OFF, slipping
Description
E03 15SCMA detected)
The signal from the fill switch stays "OFF" during an output to the Hi clutch ECMV and an abnormality
Contents of
trouble
response Turns lock up system off.
Problem that
appears on Machine travels at gear speeds which do not use Hi clutch.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Hi clutch or
information

2) Connect T-adapter to connector CN13 (H,PS) (male).
1 Defective Hi clutch ECMV Between CN13 (H,PS) (male) (1) (2) Resistance 5 15
Resistance Min. 1 M
ground
2) Connect T-adapter to connectors ATC3 (female) and CN13 (H,PS)
Resistance Max. 1
state CN13 (H,PS) (female) (1)
contact)
Resistance Max. 1
CN13 (H,PS) (female) (2)
detection
4
Resistance 5 15
(3)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code Failure code Low clutch ECMV: Fill signal ON, command current OFF
Description
E03 15SDL1 (Transmission controller system)
Contents of Even when output to the Low clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
trouble the clutch is not released.
Controller Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Problem that
appears on Machine travels at gear speeds which use Low clutch.
machine
information If electrical system is normal, check hydraulic and mechanical systems of low clutch or pressure control
valve for defect.

2) Connect T-adapter to connector CN12 (L,SW) (male).
When
Defective Low clutch fill Low is Resistance Min. 1 M
1
switch Between CN12 (L,SW) (male) released
(1) ground When
Low is Resistance Max. 1
engaged
Possible causes
2) Disconnect connectors ATC3 and CN12 (L,SW).
and standard
between ATC3 (female) (10) CN12 (L,SW) Resistance Min. 1 M
(female) (1)
When
Defective transmission Low is Resistance Min. 1 M
3
controller Between ATC3 (female) (10) released
ground When
Low is Resistance Max. 1
engaged

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION
Action code Failure code Low clutch ECMV: Malfunction

(Low command holding pressure, low clutch fill switch OFF, slipping
Description
E03 15SDMA detected)
The signal from the fill switch stays "OFF" during an output to the Low clutch ECMV and an abnormality
Contents of
trouble
Problem that
appears on Machine travels at gear speeds which do not use Low clutch.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Low clutch or
information

2) Connect T-adapter to connector CN11 (L,PS) (male).
1 Defective Low clutch ECMV Between CN11 (L,PS) (male) (1) (2) Resistance 5 15
Resistance Min. 1 M
ground
2) Connect T-adapter to connectors ATC3 (female) and CN11 (L,PS)
Resistance Max. 1
state CN11 (L,PS) (female) (1)
contact)
Resistance Max. 1
detection
4
Resistance 5 15
(13)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code Failure code 1st clutch ECMV: Fill signal ON, command current OFF
Description
E03 15SEL1 (Transmission controller system)
Contents of Even when output to the 1st clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
Problem that
Machine travels at gear speeds which use 1st clutch.
appears on
Machine cannot travels in reverse.
machine
information If electrical system is normal, check hydraulic and mechanical systems of 1st clutch or pressure control
valve for defect.

2) Connect T-adapter to connector CN8 (1,SW) (male).
When 1st is
1 Defective 1st clutch fill switch Resistance Min. 1 M
Between CN8 (1,SW) (male) (1) released
ground When 1st is
Resistance Max. 1
engaged
and standard 2) Disconnect connectors ATC3 and CN8 (1,SW).
state (Contact with ground circuit)
Between ground and wiring harness between
Resistance Min. 1 M
ATC3 (female) (40) CN8 (1,SW) (female) (1)
Defective transmission When 1st is
3 Resistance Min. 1 M
ground When 1st is
Resistance Max. 1
engaged

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION
Action code Failure code 1st clutch ECMV: Malfunction

(1st command holding pressure, 1st clutch fill switch OFF, slipping
Description
E03 15SEMA detected)
The signal from the fill switch stays "OFF" during an output to the 1st clutch ECMV and an abnormality
Contents of
trouble
Problem that
appears on Machine travels at gear speeds which do not use 1st clutch.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st clutch or
information

Resistance Min. 1 M
ground
Resistance Max. 1
contact)
Resistance Max. 1
detection
4
Resistance 5 15
(3)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code Failure code 2nd clutch ECMV: Fill signal ON, command current is OFF
Description
E03 15SFL1 (Transmission controller system)
Contents of Even when output to the 2nd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
Problem that
Machine travels at gear speeds which use 2nd clutch.
appears on
machine
Related Fill switch input signal can be checked with code: 31520 (0: OFF, 1:ON).
information If electrical system is normal, check hydraulic and mechanical systems of 2nd clutch or pressure control
valve for defect.

When 2nd
Defective fill switch for 2nd is Resistance . 1
1
clutch Between CN10 (2,SW) (male) released
(1) ground When 2nd
engaged
Possible causes
2) Disconnect connectors ATC3 and CN10 (2,SW).
and standard
between ATC3 (female) (9) CN10 (2,SW) Resistance Min. 1 M
(female) (1)
When 2nd
Defective transmission is Resistance Min. 1 M
3
ground When 2nd
engaged

TABLE 2
detected (Fill switch ON)
Action of controller ON/OFF state of
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2
N
Mid 1st OFF NEUTRAL* OFF
* Combination not normally used, M clutch also off

NOTES

FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION
Action code Failure code 2nd clutch ECMV: Malfunction

(2nd command holding pressure, 2nd clutch fill switch OFF, slipping
Description
E03 15SFMA detected)
The signal from the fill switch stays "OFF" during an output to the 2nd clutch ECMV and an abnormality
Contents of
trouble
Problem that
appears on Machine travels at gear speeds which do not use 2nd clutch.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd clutch or
information

Resistance Min. 1 M
ground
Resistance Max. 1
contact)
Resistance Max. 1
detection
4
controller Wiring harness between ACT3 (female) (5)
Resistance 5 15
(23)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code Failure code 3rd clutch ECMV: Fill signal ON, command current OFF
Description
E03 15SGL1 (Transmission controller system)
Contents of Even when output to the 3rd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
Problem that
Machine travels at gear speeds which use 3rd clutch.
appears on
machine
Related Fill switch input signal can be checked with code: 31520 (0: OFF, 1:ON).
information If electrical system is normal, check hydraulic and mechanical systems of 3rd clutch or pressure control
valve for defect.

2) Connect T-adapter to connector CN4 (3,SW) (male).
When 3rd
Defective 3rd clutch fill is Resistance Min. 1 M
1
switch Between CN4 (3,SW) (male) (1) released
ground When 3rd
engaged
Possible causes
2) Disconnect connectors ATC3 and CN4 (3,SW).
and standard
between ATC3 (female) (19) CN4 (3,SW) Resistance Min. 1 M
(female) (1)
When 3rd
Defective transmission is Resistance Min. 1 M
3
ground When 3rd
engaged

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2
N

NOTES

FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION
Action code Failure code 3rd clutch ECMV: Malfunction

(3rd command holding pressure, 3rd clutch fill switch OFF, slipping
Description
E03 15SGMA detected)
The signal from the fill switch stays "OFF" during an output to the 3rd clutch ECMV and an abnormality
Contents of
trouble
Problem that
Machine travels at gear speeds which do not use 3rd clutch.
appears on
The gear is set in Neutral suddenly during travel.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd clutch or
information

Resistance Min. 1 M
ground
Resistance Max. 1
contact)
Resistance Max. 1
detection
4
Resistance 5 15
(13)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION
Action code Failure code Lockup clutch ECMV: Malfunction

Description (Lockup command holding pressure is applied and slipping detected)
E03 15SJMA (Transmission controller system)
During an output to the lockup clutch ECMV, an abnormality exists in the value calculated from the signals
Contents of
of engine speed sensor, transmission intermediated shaft speed sensor, and transmission output shaft
trouble
speed sensor.
Controller Holds gear speed during traveling and turns lock up to "OFF".
response Holds neutral when gear shift lever is set to "N".
Problem that
Lockup is released and gear shift is disabled.
appears on
If gear shift lever is shifted to "N", machine does not start unless it is stopped.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for lockup
information
clutch or pressure control valve.

Defective lockup clutch
1 Between CN17 (L/U,PS) (male) (1) (2) Resistance 5 15
ECMV
Between CN17 (L/U,PS) (male) (1), (2)
Resistance Min. 1 M
ground
Possible causes Disconnection in wiring 2) Connect T-adapter to connectors ATC3 (female) and CN16 (female).
and standard harness Wiring harness between ATC3 (female) (35)
value in normal 2 Resistance Max. 1
(Disconnection or defective CN17 (L/U,PS) (female) (1)
state contact) Wiring harness between ATC3 (female) (23)
Resistance Max. 1
CN17 (L/U,PS) (female) (2)
detection
4
Resistance 5 15
(23)

FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code Failure code Mid clutch ECMV: Fill signal ON, command signal OFF
Description
E03 15SSL1 (Transmission controller system)
Contents of Even when output to the Mid clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
Problem that
appears on Machine travels at gear speeds which use Mid clutch.
machine
information If electrical system is normal, check hydraulic and mechanical systems of high clutch or pressure control
valve for defect.

2) Connect T-adapter to connector CN16 (M,SW) (male).
When 3rd
1 Defective mid clutch fill switch Resistance Min. 1 M
Between CN4 (3,SW) (male) (1) is released
ground When 3rd
Resistance Max. 1
is engaged
Possible causes
2) Disconnect connectors ATC3 and CN16 (M,SW)
and standard
Defective harness grounding 3) Connect T-adapter to ATC3 (female).
value in normal 2
state (Contact with ground circuit) Between ground and wiring harness between
ATC3 (female) (20) CN16 (M,SW) (female) Resistance Min. 1 M
(1)
Defective transmission When 3rd
3 Resistance Min. 1 M
controller Between ATC3 (female) (20) is released
ground When 3rd
Resistance Max. 1
is engaged

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2
N

FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION
Action code Failure code Mid clutch ECMV: Malfunction

(Mid command holding pressure, Mid clutch fill switch OFF, slipping
Description
E03 15SSMA detected)
The signal from the fill switch stays "OFF" during an output to the Mid clutch ECMV and an abnormality
Contents of
trouble
Problem that
appears on Machine travels at gear speeds which do not use Mid clutch.
machine
Related
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Mid clutch or
information

2) Connect T-adapter to connector CN15 (M,PS) (male).
1 Defective mid clutch ECMV
Between CN15 (M,PS) (male) (1) (2) Resistance 5 15
Between CN15 (M,PS) (male) (1), (2) ground Resistance Min. 1 M
2) Connect T-adapter to connectors ATC3 (female) and CN15 (M,PS)
2 Wiring harness between ATC3 (female) (16)
value in normal (Disconnection or defective Resistance Max. 1
CN15 (M,PS) (female) (1)
state contact)
Resistance Max. 1
detection
4
Resistance 5 15
(03)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING
Action code Failure code Mid clutch: Slipping

(Mid command is holding pressure, fill switch is ON, and slipping
Description
E03 15X0MW detected)
When a signal is output to the Mid clutch ECMV, the value calculated from the signals of the transmission
Contents of
trouble
Problem that
machine
If electrical system is normal, check Mid clutch and mechanical/hydraulic system of pressure control valve
Related
for defect.
information
When carrying out emergency escape operation, see "Emergency escape method when electrical system
has trouble".

1 Defective mid clutch ECMV Between CN15 (M,PS) (male) (1) (2) Resistance 5 15
Between CN15 (M,PS) (male) (1), (2)
Resistance Min. 1 M
ground
Resistance Max. 1
state CN15 (M,PS) (female) (1)
contact)
Resistance Max. 1
Defective speed sensor detec-
tion
4
Resistance 5 15
(03)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION
Action code Failure code Brake valve: Malfunction

Description
E03 2G39MA (Retarder controller system)
Contents of
Brake does not operate even though the driver works the foot brake.
trouble
Controller
None in particular
response
Problem that
appears on Brake does not operate.
machine
Related
Input state can be checked with monitoring function (Code: 35102).
information
Refer to page 7 in the electrical schematic for reference.
Prepare with starting switch OFF, then turn starting switch ON and per-
1 Brake valve (front) form troubleshooting. Check front brake pressure. Disconnect CN027.
Between CN027 (female) (A) (C) Voltage 24 V
RCM2 (17) - RCM2 (39) Brake applied Voltage 0V
Brake apply and brake pedal RCM2 (17) - RCM2 (39) Brake not applied Voltage about 8V
2
proximity switches RCM1 (12) - RCM1 (21) Brake applied Voltage 0V
RCM1 (12) - RCM1 (21) Brake not applied Voltage about 8V
Prepare with starting switch OFF, then perform troubleshooting without
Disconnection in wiring turning starting switch ON.
harness
Wiring harness between CN027 (B) - RCM2
3 (Disconnection in wiring or Resistance Max. 1
(17)
Possible causes defective contact in connec-
and standard tor) Wiring harness between CN240 (female)
Resistance Max. 1
value in normal (C) RCM1 (12)
state Prepare with starting switch OFF, then perform troubleshooting without
turning starting switch ON.
Grounding fault in wiring
Wiring harness between CN027 (female)
4 harness Resistance Min. 1 M
(B) RCM2 (17)
(Contact with ground circuit)
Resistance Min. 1 M
(C) RCM1 (12)
form troubleshooting.
Defective hot short in wiring
5 harness Voltage Max. 1 V
(B) RCM2 (17)
(a contact with 24 V circuit)
Voltage Max. 1 V
(C) RCM1 (12)
6 Defective retarder controller If there were no faults found in the wiring, the controlller may be defective.

FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION
Action code Failure code Brake relay valve: Malfunction

Description
E03 2G3AMA (Retarder controller system)
Contents of
Brake (rear) does not operate even though the driver works the foot brake.
trouble
Controller
None in particular
response
Problem that
appears on Brake (rear) does not operate.
machine
Related
Input state can be checked with monitoring function (Code: 34103, 34104).
information
Check oil pressure output at the relay valve. Correct pressure with brake
1 Defective relay valve
depressed is 14,479 kPa (2100 psi).
Disconnection in wiring Prepare with starting switch OFF, then perform troubleshooting without
harness turning starting switch ON.
(Disconnection in wiring or Wiring harness between CN241 (female)
defective contact in connec- Resistance Max. 1
2 (B) RCM1 (18)
tor)
(Right retard apply switch Wiring harness between CN232 (female)
and left retard apply switch Resistance Max. 1
Possible causes (B) RCM1 (24)
failure)
and standard
value in normal Grounding fault in wiring Prepare with starting switch OFF, then perform troubleshooting without
state harness turning starting switch ON.
3
(Contact with ground circuit) Wiring harness between CN231 (female)
(Brake apply sw failure) Resistance Min. 1 M
(B) RCM3 (39)
Defective hot short in wiring Prepare with starting switch OFF, then turn starting switch ON and per-
harness form troubleshooting.
(a contact with 24 V circuit) Wiring harness between CN241 (female)
4 Voltage Max. 1 V
(Right retard apply switch (B) RCM1 (24)
and left retard apply switch Wiring harness between CN232 (female)
failure) Voltage Max. 1 V
(B) RCM1 (24)
5 Defective Retarder controller If no other problems were found, the controller may be defective.

FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE
Action code Failure code Accumulator: Low oil pressure

Description
E03 2G41ZG (Retarder controller system)
Contents of Oil pressure reduction (Max. 12.76 MPa {130 kg/cm2}) was detected by signal from accumulator oil pres-
trouble sure sensor (front).
Controller
Displays accumulator oil pressure monitor red.
response
Problem that
appears on Brake (Retarder) (front) does not work.
machine
Related

information
Hydraulic system (pump, relief valve or piping) may have trouble. If pres-
1 Trouble in hydraulic system
sure is reduced, remove cause of trouble.
Possible causes
Check resistance between CN220 (6) -
and standard 2 Open in harness Resistance Max.1
value in normal RCM3 (40).
state Defective accumulator (front) If no other problems are found, the oil pressure switch may be defec-
3
oil pressure switch tive.

FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR
Action code Failure code Auto emergency valve: erratic bahavior.

Description
E03 2J00MA (Retarder control system)
Contents of
Emergency brake operates although the driver does not work the emergency brake.
trouble
Controller
None in particular
response
Problem that
appears on Brake drags
machine
Related
information
Refer to page 7 & 8 in the electrical schematic for reference.
Defective auto emergency Check the emergency brake valve. If the valve is inoperable, replace with
1
valve a new valve.
(Disconnection in wiring or
2 defective contact in connec-
Wiring harness between CN222 (female) (1)
tor) Resistance Max. 1
Emergency auto apply sw RCM3 (30)
failure)
Possible causes Emergency brake sw failure Prepare with starting switch OFF and the emergency brake switch OFF.
and standard Grounding fault in wiring
value in normal harness
3 Disconnect the emergency brake switch.
state (Contact with ground circuit) Check the resistance between circuit 52EB Resistance Min. 1 M
(Emergency brake sw fail- and ground.
ure)
Defective hot short in wiring form troubleshooting.
harness
Wiring harness between CN169 (female) (1)
4 (a contact with 24 V circuit) Voltage Max. 1 V
RCM2 (25)
(Emergency auto apply sw
failure) Wiring harness between CN222 (female) (1)
Voltage Max. 1 V
RCM3 (30)
5 Defective retarder controller If no other problems are found, the controller may be defective.

FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE
Action code Failure code Steering System: Low oil pressure

Description
E03 4A00ZG (Retarder controller system)
Contents of Low oil pressure (less than 12.76 MPa {130 kg/cm2}) was detected by signal from low steering pressure
trouble sensor.
Controller
Displays steering oil pressure monitor red.
response
Problem that
appears on Poor or inoperable steering.
machine
Related
information
Possible causes 1 Trouble in hydraulic system
sure is reduced, remove cause of trouble.
and standard
Check continuity between CN184 (C) -
value in normal 2 Open in wiring harness Resistance Max. 1
state RCM3 (19).
Defective steering oil pres- If no other problems are found, the steering oil pressure sensor may be
3
sure sensor defective.

FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE
Action code Failure code Steering Accumulator 1: Low oil pressure

Description
E03 4A5WZH (Retarder controller system)
Contents of Oil pressure reduction (Max. 12.75 MPa {130 kg/cm2}) was detected by signal from accumulator1 oil pres-
trouble sure sensor (steering).
Controller
Displays accumulator1 oil pressure monitor red.
response
Problem that
appears on Steering (Retarder) does not work.
machine
Related
Input signal from oil pressure sensor can be checked with monitoring function (Code: 44800).
information
Possible causes sure is reduced, remove cause of trouble.
and standard Check wiring harness resistance between
value in normal 2 Open in wiring harness Resistance Max.1
RCM3 (10) - APCPS1.
state
Defective accumulator1
If cause 1 is not detected, accumulator (front) oil pressure sensor sys-
3 (steering) oil pressure sensor
tem may be defective.
system

FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE
Action code Failure code Steering Accumulator 2: Low oil pressure

Description
E03 4A5XZH (Retarder controller system)
Contents of Oil pressure reduction (Max. 12.75 (MPa) {130 (kg/cm2)}) was detected by signal from accumulator2 oil
trouble pressure sensor (steering).
Controller
Displays accumulator2 oil pressure monitor red.
response
Problem that
appears on Steering (Retarder) does not work.
machine
Related
Input signal from oil pressure sensor can be checked with monitoring function (Code: 44801).
information
Possible causes sure is reduced, remove cause of trouble.
and standard .Check wiring harness resistance
value in normal 2 Check for open in circuit. Resistance Max.1
between RCM3 (20) - APCPS2.
state
Defective accumulator2
3 (steering) oil pressure sensor If no other problems are found, the pressure sensor may be defective.
system

FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION
Action code Failure code Hydraulic filter: restriction

Description
E01 6014NX (Retarder controller system)
Contents of When the retarder brake oil temperature is above 70C, the signal circuit of the hydraulic restriction sensor
trouble is opened (disconnected from GND).
Controller
None in particular.
response
Problem that
appears on If the machine is used without repairing, dust may enter the hydraulic circuit.
machine
Related
This failure can be checked in the monitoring function (Code: 35700). (normal: 1, restricted: 0)
information
Restriction of hydraulic
1 Clean or replace.
filter
Defective hydraulic filter 3) Connect T-adapter.
2
restriction sensor
Between CN158 Filter is normal Resistance Max. 1
(male) (A) (B) Filter is clogged Resistance Min. 1 M
2) Disconnect connectors RCM2 and CN158.
Possible causes
Disconnection in wiring Wiring harness between RCM2 (female)
and standard Resistance Max. 1
harness (28) CN158 (female) (A)
value in normal 3
(Disconnection or defective
state Wiring harness between CN158 (female)
contact) Resistance Max. 1
(B) ground
Wiring harness between TMF2 (female) (2)
Resistance Max. 1
ground
2) Disconnect connectors RCM2.
4 Defective retarder controller 5) Turn the starting switch ON.
Between RCM2 Filter is normal Voltage Max. 1V
(female) (28)
ground Filter is clogged Voltage about 8 V

FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED
Action code Failure code Engine over run prevention command: Activated
Description
E02 989A00 (Machine monitor system)
Contents of When gear speed is set at the position other than neutral, transmission input shaft speed signal exceeds
trouble the input shaft speed which is set for each gear speed to prevent over run.
Controller
Send out command signal to retarder controller and activate brake.
response
Problem that
appears on Brake becomes activated and travel speed lowers.
machine
Input shaft speed can be checked in monitoring function (code: 31200 (rpm)).
Related
Information on operation of engine overrun prevention command is obtained from transmission controller
information
through network.

Possible causes If machine is so traveling that transmission input shaft speed signal
1 Engine over run
and standard exceeds 2,600 rpm (or 2,400 rpm at R2), engine is overrunning.
value in normal If machine is not so traveling that transmission input shaft speed signal
state Defective transmission
2 exceeds 2,600 rpm (or 2,400 rpm at R2), transmission controller is
controller
defective.

FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION
Action code Failure code Alternator: Malfunction

Description (Failure in battery charging circuit)
E03 AB00MA (Transmission controller system)
Contents of
A generation signal is not input from the alternator while the engine is running.
trouble
Controller
None in particular.
response
Problem that
If the machine is used without repairing, the source voltage may lower so much that the machine cannot
appears on
travel.
machine
Related
This failure can be checked in the monitoring function (Code: 04301 (0: OFF, 1:ON)).
information
Refer to sheet 2 of the electrical schematic for reference.
2) Disconnect connector alternator terminal R.
3) Start the engine.
1 Defective alternator
Between alternator R ground Voltage 27.5 29.5 V
If the battery is deteriorated or used in a cold district, the voltage may not
rise for a while after the engine is started.
and standard harness 4) Start the engine.
state Between ATC1 (female) (15) ground Voltage 27.5 29.5 V
contact)
Defective transmission con- 4) Start the engine.
3
troller
Between ATC1 (15) ground Voltage 20 30 V

FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE
Action code Failure code Engine oil: Low engine oil pressure
Description
E03 B@BAZG (Engine controller system)
Contents of
trouble
Controller
Illuminates the red engine caution lamp on the EDP.
response
Problem that
appears on Engine output drops.
machine
Related infor-
Contact the engine manufacturer.
mation

FAILURE CODE [B@BCNS] ENGINE: OVERHEAT
Action code Failure code Engine: overheat

Description
E02 B@BCNS (Engine controller system)
Contents of
trouble
Controller
Illuminates the red engine caution lamp on the EDP.
response
Problem that
appears on Engine output drops.
machine
Related infor-
Contact the engine manufacturer.
mation

FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW
Action code Failure code Fuel system: fuel level low

Description
B@BFZK (Machine monitor system)
Contents of
Fuel level sensor signal indicates lowering of fuel level (Resistance of 70 or higher is detected).
trouble
Controller Does not display this failure code, if DJF1KA is detected.
response Turns fuel level caution lamp ON.
Problem that
appears on None in particular.
machine
When fuel level is below LOW and fuel is added, if failure code disappears, fuel was insufficient.
Related Signal from fuel level sensor can be checked with monitoring function.
information (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200 (V) / 04201 ())
Method of reproducing failure code: Turn starting switch ON.

Possible causes
Lack of fuel (When system is
and standard 1 Fuel may be insufficient. Check and add fuel, if necessary.
normal)
value in normal
state When not recover by above 1,then perform troubleshooting for failure
2 Defective fuel level sensor
code [DJF1KA].

FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING
Action code Failure code Brake cooling oil (Front): Overheating

Description
E02 B@C6NS (Machine monitor system)
Contents of While engine was running, oil overheat was detected by signal from front brake (retarder) oil temperature
trouble sensor.
Controller
Turn on brake oil temperature caution lamp.
response
Problem that
Brake (Retarder) (front) comes not to work.
appears on
If machine is used as it is, brake (retarder) (front) may be damaged.
machine
Input signal from oil temperature sensor can be checked with monitoring function (Code: 30201 (C),
Related 30204 (V)).
information For troubleshooting for brake (retarder) (front) oil temperature sensor, see failure code [DGR4KZ].
If CNR02-T (BCV relay) primary side has trouble, error code [DW79KB] is displayed.
1) Open rear electrical compartment in the cab.
2) Turn starting switch ON (Do not start engine).
Defective CNR02-T (BCV 3) Turn retarder brake ON and OFF and perform troubleshooting.
1
relay)
CNR02-T (BCV
Operating sound of relay is heard.
relay)
Turn starting switch OFF and disconnect CN157, then perform trouble-
shooting without turning starting switch ON (Measure in diode check
mode).
2 Defective diode Forward direction:
Between CN157 There is continuity
Continuity
(male) (1) (2) Backward direction:
Possible causes There is not continuity
and standard 1) Open operator's cab door.
value in normal 2) Turn starting switch ON (Do not start engine).
state 3 Defective BCV solenoid 3) Turn retarder brake ON and OFF and perform troubleshooting.
Operating sound of front BCV solenoid
Front BCV solenoid
is heard.
Turn starting switch OFF and disconnect CNR02-T (BCV relay) and
CN156, then perform troubleshooting without turning starting switch ON.
Disconnection in wiring har-
ness (Disconnection in wiring Between CNR02-T (female) (43) CN156 Resistance Max. 1
4
or defective contact in con- (female) (1)
nector) Between (ground) CN156 (female) (2) Resistance Max. 1
Between CNR02-T (female) (1) FU1 (07) Resistance Max. 1
Grounding fault in wiring har- Turn starting switch OFF and disconnect CNR02-T, then perform trouble-
5 ness (Contact with ground shooting without turning starting switch ON.
circuit) Between CNR02-T (female) (1) ground Resistance Min. 1 M
Possible causes
Trouble in hydraulic system
and standard
6 (when electrical system is Hydraulic system may have trouble. Remove cause of trouble.
value in normal
normal)
state
If causes 1 6 are not detected, retarder controller may be defective.
7 Defective retarder controller
(Since trouble is in system, troubleshooting cannot be carried out.)

FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING
Action code Failure code Brake cooling oil (Right Rear): Overheating
Description
Contents of While engine was running, oil overheat was detected by signal from rear brake (retarder) oil temperature
trouble sensor.
Controller
response
Problem that
Brake (Retarder) (Rear) comes not to work.
appears on
If machine is used as it is, brake (retarder) (rear) may be damaged.
machine
Related 30210 (V)).
information For troubleshooting for brake (retarder) (right rear) oil temperature sensor, see failure code [DGR2KZ].
If CNR02-V (BCV relay) primary side has trouble, error code [DW78KZ] is displayed.
1) Remove relay cover.
Defective CNR02-V (Rear 3) Turn retarder brake ON and OFF and perform troubleshooting.
1
BCV relay)
CNR02-V (BCV
relay)
mode).
2 Defective diode
Forward direction: There is continuity
Between CN154
Continuity Backward direction: There is not conti-
(male) (1) (2)
nuity
1) Open rear panel.
Possible causes 3 Defective BCV solenoid 3) Turn retarder brake ON and OFF and perform troubleshooting.
and standard
value in normal Rear BCV solenoid Rear BCV solenoid actuation is heard.
state Turn starting switch OFF and disconnect CNR02-V (BCV relay) and
ness (Disconnection in wir- Between CNR02-V (female) (45) CN153
4 Resistance Max. 1
ing or defective contact in (female) (1)
connector) Between ground CN153 (female) (2) Resistance Max. 1
Between CNR02-V (female) (3) FU1 (07) Resistance Max. 1
Grounding fault in wiring har- Turn starting switch OFF and disconnect CN153, then perform trouble-
circuit) Between CNR02-V (female) (59) ground Resistance Min. 1 M
normal)

FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING
Action code Failure code Brake cooling oil (Left Rear): Overheating
Description
Contents of While engine was running, oil overheat was detected by signal from rear brake (retarder) oil temperature
trouble sensor.
Controller
response
Problem that
Brake (Retarder) (Rear) comes not to work.
appears on
If machine is used as it is, brake (retarder) (rear) may be damaged.
machine
Related 30209 (V)).
information For troubleshooting for brake (retarder) (left rear) oil temperature sensor, see failure code [DGR3KZ].
If CNR02-V (BCV relay) primary side has trouble, error code [DW78KZ] is displayed.
1) Remove relay cover.
Defective CNR02-V (Rear 3) Turn retarder brake ON and OFF and perform troubleshooting.
1
BCV relay)
CNR02-V (BCV
relay)
mode).
2 Defective diode
Forward direction: There is continuity
Between CN154
Continuity Backward direction: There is not conti-
(male) (1) (2)
nuity
1) Open rear panel.
Defective Rear BCV sole- 2) Turn starting switch ON (Do not start engine).
Possible causes 3 3) Turn retarder brake ON and OFF and perform troubleshooting.
noid
and standard
value in normal Rear BCV solenoid Rear BCV solenoid actuation is heard.
state Turn starting switch OFF and disconnect CNR02-V (BCV relay) and
ness (Disconnection in wir- Between CNR02-V (female) (45) CN153
4 Resistance Max. 1
ing or defective contact in (female) (1)
connector) Between ground CN153 (female) (2) Resistance Max. 1
Between CNR02-V (female) (3) FU1 (07) Resistance Max. 1
circuit) Between CNR02-V (female) (59) ground Resistance Min. 1 M
normal)

FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING
Action code Failure code Torque converter oil: Overheating

Description
E02 B@CENS (Machine monitor system)
Contents of
Torque converter oil is overheating.
trouble
Controller
Turns torque converter oil temperature caution lamp ON and sounds alarm buzzer.
response
Problem that
appears on If machine is used as it is, torque converter may be broken.
machine
Signal of torque converter oil temperature sensor is input to transmission controller and then its informa-
Related tion is transmitted to machine monitor through communication system.
information Power train oil temperature can be checked with monitoring function.
(Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100 (C) / 30101 (V))

Possible causes Overheating of torque con-
and standard 1 verter oil (When system is Torque converter oil may be overheating. Check for cause and repair.
value in normal normal)
state Defective torque converter oil If cause 1 is not detected, torque converter oil temperature sensor system
2
temperature sensor system may be defective. Perform troubleshooting for failure code [DGT1KX].

FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION
Action code Failure code Brake cooling oil filter (front): Restriction
Description
E01 B@M6NX (Retarder controller system)
Contents of When the brake oil (front) temperature is above 70C, the signal circuit of the front brake cooling restric-
trouble tion sensor is opened (disconnected from GND).
Controller
None in particular.
response
Problem that
appears on If the machine is used without repairing, dust may enter the brake cooling circuit.
machine
Related
information
Restriction of front brake
1 Clean or replace.
cooling filter
Defective front brake cooling 3) Connect T-adapter.
2
filter restriction sensor
Possible causes 2) Disconnect connectors RCM2 and CN122.
Disconnection in wiring 3) Connect T-adapter.
and standard
harness
value in normal 3 Wiring harness between RCM2 (female) (3)
(Disconnection or defective Resistance Max. 1
state CN122 (female) (A)
contact)
Resistance Max. 1
(B) ground
(female) (3) CN122
(A) Filter is clogged Voltage about 8 V

FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION
Action code Failure code Brake cooling oil filter (#2 Rear): Restriction
Description
E01 B@M7NX (Retarder controller system)
Contents of When the right rear brake oil temperature is above 70C, the signal circuit of the right rear brake cooling
trouble restriction sensor is opened (disconnected from GND).
Controller
None in particular.
response
Problem that
machine
Related
information
Restriction of right rear brake
1 Clean or replace.
cooling filter
Defective right rear brake 2) Disconnect connector CN150.
2 cooling filter restriction sen- 3) Connect T-adapter.
sor Between CN150 Filter is normal Resistance Max. 1
Disconnection in wiring 3) Connect T-adapter.
and standard
harness
value in normal 3 Wiring harness between RCM2 (female)
state (38) CN150 (female) (A)
contact)
Resistance Max. 1
(B) ground
Defective transmission con- 4) Connect conector.
4 5) Turn the starting switch ON.
troller
(female) (38)
ground Filter is clogged Voltage approx. 8 V

FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION
Action code Failure code Brake cooling oil filter (#1 Rear): Restriction
Description
E01 B@M8NX (Transmission controller system)
Contents of When the brake (left rear) oil temperature is above 70C, the signal circuit of the left rear brake cooling
trouble restriction sensor is opened (disconnected from GND).
Controller
None in particular.
response
Problem that
machine
Related
information
Restriction of left rear brake
1 Clean or replace.
cooling filter
Defective left brake cooling 3) Connect T-adapter.
2
filter restriction sensor
and standard Disconnection in wiring 3) Connect T-adapter.
value in normal 3 harness
Wiring harness between RCM2 (female) (2)
state (Disconnection or defective Resistance Max. 1
CN149 (female) (A)
contact)
Resistance Max. 1
(B) ground
4 Defective retarder controller 4) Connect conector.
(female) (2) ground Filter is clogged Voltage 20 30 V

FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION
Action code Failure code Monitor panel: Poor connection

Description
E03 DAF9KM (Machine monitor system)
Contents of
Check signal of connector is different from internal setting of machine monitor.
trouble
Controller Detects only at start.
response Keeps trouble condition until starting switch is turned OFF.
Problem that
Machine monitor mode selector switch cannot be selected.
appears on
Headlamp high beam pilot lamp, turn signal pilot lamp, and output mode pilot lamp do not operate.
machine
Related
information
Wrong connection of connec- Connector CN2A (female) may be connected to CN3A (male) by mistake.
1
tor Check and connect it correctly, if connected wrongly.
1) Starting switch OFF.
Disconnection in wiring har- 2) Connect T-adapter to CN2A.
Possible causes ness (Disconnection in wiring 3) Turn starting switch ON
2
and standard or defective contact in con-
CN2A Voltage
value in normal nector)
state Between (5) ground 20 30 V
Short circuit in wiring harness turning starting switch ON.
3
(with another wiring harness) Between CN3A (female) (5) pin other than
Resistance Min. 1 M
CN3A (5)
4 Defective machine monitor Check by replacing machine monitor.

NOTES

FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR
Action code Failure code Machine monitor: Communication error

Description
E03 DAFRKR (Machine monitor system)
Contents of
Transmission controller stops updating data received from machine monitor.
trouble
Controller Holds information at time when trouble occurs.
response Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on If network has error, data sent from each controller to machine monitor cannot be displayed normally.
machine
Related
Check that power source circuit of machine monitor is normal.
information
Defective CAN terminal turning starting switch ON.
1
resistor (Internal defect) CAN01-2 (male) Resistance
Between (A) (B) Approx. 120 12
SDA12V160 only:
Wiring harness between ATC2 -32 - CAN04-
3 (A), CAN04-2 (A), CAN04-1 (A);
Wiring harness between RCM2 (32)
CAN03-3 (A), CAN03-2 (A), CAN03-1 (A);
Wiring harness between HM4A (04)
Possible causes Resistance Max. 1
CAN02-3 (A), CAN02-2 (A), CAN02-1 (A);
and standard Wiring harness between CN062 (3)
value in normal Disconnection in wiring CAN08-3 (A), CAN08-2 (A), CAN08-1 (A);
state harness Wiring harness between CN4 (3) CAN01-
(Disconnection in wiring or 3 (A), CAN01-2 (A), CAN01-1 (A)
2
defective contact in connec-
tor) SDA12V160 only:
Wiring harness between ATC2 -22 - CAN04-
3 (B), CAN04-2 (B), CAN04-1 (B);
CAN03-3 (B), CAN03-2 (B), CAN03-1 (B);
Resistance Max. 1
CAN02-3 (B), CAN02-2 (B), CAN02-1 (B);
Wiring harness between CN062 (10)
CAN08-3 (B), CAN08-2 (B), CAN08-1 (B);
Wiring harness between CN4 (8) CAN01-
3 (B), CAN01-2 (B), CAN01-1 (B)

SSA16V159 only:
Wiring harness between CAN06 (A)
CAN05-3 (A), CAN05-2 (A), CAN05-1 (A);
Wiring harness between CAN07 (E)
CAN04-3 (A), CAN04-2 (A), CAN04-1 (A);
Wiring harness between ATC2 (32)
CAN03-3 (A), CAN03-2 (A), CAN03-1 (A);
Resistance Max. 1
CAN02-3 (A), CAN02-2 (A), CAN02-1 (A);
CAN08-3 (A), CAN08-2 (A), CAN08-1 (A);
Disconnection in wiring Wiring harness between CN062 (3)
harness CAN01-3 (A), CAN01-2 (A), CAN01-1 (A),
(Disconnection in wiring or CN4 (3)
2
defective contact in connec- SSA16V159 only:
tor) Wiring harness between CAN06 (B)
CAN05-3 (B), CAN05-2 (B), CAN05-1 (B);
Wiring harness between CAN07 (D)
CAN04-3 (B), CAN04-2 (B), CAN04-1 (B);
CAN03-3 (B), CAN03-2 (B), CAN03-1 (B);
Resistance Max. 1
Possible causes CAN02-3 (B), CAN02-2 (B), CAN02-1 (B);
and standard Wiring harness between HM4A (12)
value in normal CAN08-3 (B), CAN08-2 (B), CAN08-1 (B);
state Wiring harness between CN062 (10)
CAN01-3 (B), CAN01-2 (B), CAN01-1 (B),
CN4 (8)
SDA12V160 only:
Between ground and CAN05 (A), ATC2
Resistance Min. 1 M
(32), RCM2 (32), HM4A (04), CN062 (3),
CN4 (3)
SDA12V160 only:
Grounding fault in wiring Between ground and CAN05 (B), ATC2
Resistance Min. 1 M
harness (22), RCM2 (22), HM4A (12), CN062 (10),
3
(Contact with ground circuit) CN4 (8)
SSA16V159 only:
Between ground and CAN06 (A), CAN07
Resistance Min. 1 M
(E), ATC2 (32), RCM2 (32), HM4A (04),
CN062 (B), CN4 (3)
SSA16V159 only:
Between ground and CAN06 (B), CAN07
Resistance Min. 1 M
(D), ATC2 (22), RCM2 (22), HM4A (12),
CN062 (10), CN4 (8)

SDA12V160 only:
Between ground and CAN05 (A), ATC2
Voltage Max. 1V
(32), RCM2 (32), HM4A (04), CN062 (3),
CN4 (3)
SDA12V160 only:
Between ground and CAN05 (B), ATC2
Defective hot short in wiring Voltage Max. 1V
(22), RCM2 (22), HM4A (12), CN062 (10),
4 harness
CN4 (8)
Possible causes (a contact with 24 V circuit)
and standard SSA16V159 only:
value in normal Between ground and CAN06 (A), CAN07
Voltage Max. 1V
state (E), ATC2 (32), RCM2 (32), HM4A (04),
CN062 (B), CN4 (3)
SSA16V159 only:
Voltage Max. 1V
(D), ATC2 (22), RCM2 (22), HM4A (12),
CN062 (10), CN4 (8)
Defective machine monitor,
If causes 1 4 are not detected, machine monitor, engine controller,
engine controller, transmis-
transmission controller, VHMS & PLM controller or retarder controller or
5 sion controller, VHMS & PLM
may be defective. (Since trouble is in system, troubleshooting cannot be
controller, or retarder control-
carried out.)
ler

NOTES

FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE
LOW
Action code Failure code Transmission controller direct power supply: Lowering of source voltage
Description
E03 DAQ0KK (Transmission controller system)
Contents of
While engine was running, controller direct power supply circuit voltage lowered below 18 V.
trouble
Controller Keeps current gear speed.
response If gearshift lever is set in N, transmission is set in neutral.
If there is not power supply voltage (there is disconnection), transmission is set in neutral suddenly during
Problem that travel and machine cannot restart until voltage becomes normal.
appears on The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage rises
machine to the normal level.
If power supply voltage is low, machine can move but transmission may slip because of load.
Related If failure code "AB00MA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
information If the fuse is broken, check the line between the fuse and ATC3 (female) (1) and (11) for grounding fault.
Refer to pages 2 & 6 of the electrical schematic.
a Test the battery voltage and specific gravity of the battery fluid.
1 Defective battery Battery voltage Voltage Min. 24 V
Specific gravity of battery fluid Specific gravity Min. 1.26
2) Disconnect negative () terminal of battery and insert T-adapter in
ATC3.
3) Connect negative () terminal of battery.
Between battery relay terminal B ground Voltage 20 30 V
Between ATC3 (1), (11) ground Voltage 20 30 V
If there is voltage between battery relay terminal B and ground and there
is not voltage between ATC3 (1) and (11), wiring harness between them
Possible causes ness
2 has disconnection.
and standard (Disconnection or defective
value in normal contact) 1) Turn starting switch OFF.
state 2) Disconnect negative () terminal of battery and connect T-adapter to
ATC3 (female)
Wiring harness between ATC3 (female)
Resistance Max. 1
(21), (31), (32), (33) ground
If there is voltage between battery relay terminal B and ground but not
between ATC3 (1), (11), (14), (24) and ground, wiring harness or fuse is
broken.
2) Disconnect negative () terminal of battery and insert T-adapter in
ATC3.
Defective transmission con- 3) Connect negative () terminal of battery.
3
troller 4) Turn starting switch ON.
Between ATC3 (1), (11) (21), (31), (32),
Voltage 20 30 V
(33)

FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE
VOLTAGE LOW
Action code Failure code Transmission controller ECMV power source: Power source voltage too
Description low
E03 DAQ2KK (Transmission controller system)
Contents of Battery direct power source voltage of transmission controller has dropped to above 20 V, and
trouble ECMV power source voltage has dropped to below 18 V.
Controller Holds the gear speed.
response Keeps neutral with shift lever neutral.
Problem that
appears on Suddenly shifts to neutral while traveling, and the machine cannot move off again.
machine
Related
When the fuse is blown, check for ground fault of line from fuse ATC3 (female) (2), (12), (22).
information
1)Turn starting switch OFF.
2)Disconnect negative () terminal of battery and insert T-adapter in
ATC3.
3)Connect negative () terminal of battery.
Disconnection in wiring 4)Turn starting switch ON.
harness Between 24 V battery power relay terminal
1 Voltage 20 30 V
(Disconnection or defective (3) ground
Possible causes contact)
Between ATC3 (2), (12), (22) ground Voltage 20 30 V
and standard
value in normal If there is voltage between 24 V battery power relay terminal (3) and
state ground and there is not voltage between ATC3 (2), (12), (22) and ground,
wiring harness between them has disconnection.
ATC3.
Defective transmission 3)Connect negative () terminal of battery.
2
controller 4)Turn starting switch ON.
Between ATC3 (2), (12), (22) (21), (31),
Voltage 20 30 V
(32), (33)

FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR
Action code Failure code Transmission controller: Model selection error

Description
E03 DAQ9KQ (Machine monitor system)
Contents of Machine model information from machine monitor is different from machine model information saved in
trouble transmission controller.
Monitor
response
Problem that
appears on Machine cannot travel.
machine
Related
information
Failure code [DAQ9KQ] is not displayed (Code is not displayed).
Wrong setting of machine
1 When machine monitor or transmission controller is replaced, set them
model by machine monitor
according to Testing and adjusting.
SDA12V160 only:
Resistance Max. 1
Open circuit in wiring har- Between ATC2 (38) - GB10 ground
Possible causes 2
ness. SSA16V159 only:
Between ATC2 (28) - GB10 ground
value in normal
state SDA12V160 only:
Resistance Min. 1M
Short to ground in wiring har- Between ATC2 (28) - CNJ04 (23)
3
ness. SSA16V159 only:
Resistance Min. 1M
Between ATC2 (38) - CNJ04 (23)
Controller of correct part number is mounted.
Installation of wrong trans-
4 Check part number If it is wrong, replace transmission controller with
mission controller
correct one.

FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR
Action code Failure code Transmission controller: communication error

Description
E03 DAQRKR (Transmission controller system)
Contents of Machine monitor cannot obtain information from transmission controller through CAN communication cir-
trouble cuit.
Controller
Keeps information at time of occurrence of abnormality.
response
Problem that
System may not operate normally.
appears on
Information from transmission controller is not displayed.
machine
Related
information

and standard
value in normal Perform troubleshooting for failure code [DAFRKR]
state

FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR
Action code Failure code Transmission controller: option setting error

Description (Machine monitor-transmission controller)
E03 DAQRMA (Machine monitor system)
Contents of Option setting signals inputted from machine monitor with the starting switch ON are different from the
trouble option settings that controller memorizes.
Holds the gear speed in neutral.
Monitor
Controls with the option setting that the controller memorizes.
response
It does not return normal unless the starting switch is turned OFF.
Problem that
appears on The gear speed becomes neutral and the machine cannot move off again.
machine
Related
Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard
value in normal 1 Defective machine monitor Defective option setting of machine monitor or internal defect of monitor
state

FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT
Action code Failure code Engine malfunction: Red indicator light

Description
E03 DASOMA (Engine Controller)
Contents of
Engine controller detects an engine error code. The status of the code triggers the red stop light.
trouble
Monitor

response
Problem that
appears on
machine
Related
For more information, download VHMS or contact the engine manufacturer.
information

FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT
Action code Failure code Engine malfunction: Amber indicator light

Description
E03 DASOMC (Engine Controller)
Contents of
Engine controller detects an engine error code. The status of the code triggers the amber caution light.
trouble
Monitor

response
Problem that
appears on
machine
Related
For more information, download VHMS or contact the engine manufacturer.
information

FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR
Action code Failure code Engine malfunction: Communication error

Description
E03 DASRKR (Engine Controller)
Contents of Monitor does not receive engine coolant temperature information properly through the communication net-
trouble work.
Monitor
Turns on warning lamp and acitvates the warning alarm buzzer.
response
Problem that
appears on The monitor does not receive correct engine information related to coolant temperature and lamp status.
machine
Related

information

and standard
value in normal Perform troubleshooting for DAFRKR. If the failure code persists, contact the engine manufacturer.
state

FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY:
CONTROLLER ERROR
Action code Failure code Retarder controller nonvolatile memory: controller error
Description
E01 DB10KT (Retarder controller system)
Contents of
An abnormality has occurred in the nonvolatile memory inside the controller.
trouble
Control the model selection and option setting with default value.
Controller
Even if the cause of the failure has been eliminated automatically, the machine does not return to normal
response
unless once resetting the starting switch OFF.
Problem that
appears on Machine parameter may change and power may increase or decrease.
machine
Related
information

and standard
value in normal Since this is an internal defect, it cannot be diagnosed.
state Replace to controller.

FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MAL-
FUNCTION
Action code Failure code Retarder controller solenoid power source: Malfunction
Description
E03 DB12KK (Retarder controller system)
Contents of While controller direct power source voltage is normal, solenoid power source voltage has become below
trouble 18 V.
Controller Turn OFF all of output circuits.
response Turn OFF sensor 24 V power source.
Problem that
appears on All systems of retarder controller do not operate. (retarder, ARSC and ASR)
machine
If the fuse is blown, check for ground fault of line from fuse RCM3 (female) (2), (12), (22).
Related
If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, perform trou-
information
bleshooting for it first.
Refer to pages 2, 6 & 8 of the electrical schematic.
RCM3.
4)Turn starting switch ON.
Between terminal 3 on the 24V power
Voltage 20 30 V
relay (battery box) ground
Disconnection in wiring Between RCM3 (2), (12), (22) ground Voltage 20 30 V
harness If voltage at fuse FU1 (7) is normal and voltage at RCM3 (2), (12), (22)
1
(Disconnection or defective is abnormal, wiring harness between fuse FU1 (7) RCM3 (female)
Possible causes contact) (2), (12), (22) has disconnection.
and standard
value in normal 1)Turn starting switch OFF.
state 2)Disconnect negative () terminal of battery and connect T-adapter to
RCM3 (female).
Wiring harness between RCM3 (female)
Resistance Max. 1
(21), (31), (32), (33) ground
RCM3.
2 Defective retarder controller 3)Connect negative () terminal of battery.
Between RCM3 (2), (12), (22) ground Voltage 20 30 V

FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE:
SOURCE VOLTAGE LOW
Action code Failure code Retarder controller battery direct power source: Source voltage low
Description
E03 DB13KK (Retarder controller system)
Contents of
Controller source voltage is below 18 V.
trouble
Controller
Turns all output OFF.
response
Problem that
appears on Retarder does not operate.
machine
When the fuse is blown, check the short circuit of line from fuse RCM3 (female) (1), (11), (2), (12), (22).
Related
If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, perform trou-
information
bleshooting for it first.
Check battery voltage and electrolyte specific gravity.
Battery voltage Voltage Min. 24 V
1 Defective battery
Specific grav-
Battery electrolyte specific gravity Min. 1.26
ity
2) Disconnect battery () terminal and connect T-adapter to RCM3
(female).
Resistance Max. 1
(21), (31), (32), (33) ground
Possible causes Disconnection in wiring har- 2)Disconnect battery () terminal and insert T-adapter in RCM3 (female).
and standard ness 3)Connect battery () terminal.
value in normal 2 (Disconnection in wiring or
state Between battery relay terminal B ground Voltage 20 30 V
tor) Between RCM3 (1), (11) ground Voltage 20 30 V
2) Disconnect battery () terminal and connect T-adapter to RCM3
(female).
If there is voltage between battery 24V power relay circuits (1 & 3) and
ground but not between ATC3 (1), (11) and ground, wiring harness or fuse
is broken.
2)Disconnect battery () terminal and insert T-adapter in RCM3 (female).
3 Defective retarder controller 3)Connect battery () terminal.
Between RCM3 (1), (11) ground Voltage 20 30 V

FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR
Action code Failure code Retarder controller: Model selection error

Description
E03 DB19KQ (Machine monitor system)
Contents of Information of model selection input from machine monitor when starting switch is turned ON is different
trouble from model selection saved in retarder controller.
Monitor Turns all outputs OFF.
response Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on When operator performs starting operation, machine does not start.
machine
Related Perform initial setting and adjustment of retarder controller to be performed after replacement.
information Method of reproducing failure code: Turn starting switch ON.

Failure code [DB19KQ] is not displayed.
Possible causes
Wrong model selection in Machine model may not be set correctly in machine monitor. After
and standard 1
machine monitor replacing machine monitor or retarder controller, set them correctly
value in normal
according to Testing and adjusting volume.
state
Wrong reterder controller may be installed. Check its part No. and
install correct reterder controller.

FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR
Action code Failure code Retarder controller: Communication error

Description (Between retarder controller transmission controller)
E03 DB1RKR (Transmission controller system)
Contents of
Updating of received data from retarder controller has stopped.
trouble
AISS is locked in LOW. (until starting switch is turned OFF.)
Controller
Keep the information at the time when abnormality occurred.
repsonse Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on The information and special functions which are retrieved from retarder controller do not work or display.
machine
Related
information
Refer to pages 10 of the electrical schematic.
1
Wiring harness between CAN06 (A)
CAN05-3 (A), CAN05-2 (A), CAN05-1 (A);
Wiring harness between CAN07 (E)
CAN04-3 (A), CAN04-2 (A), CAN04-1 (A);
CAN03-3 (A), CAN03-2 (A), CAN03-1 (A);
Wiring harness between RCM2 (32) Resistance Max. 1
Possible causes CAN02-3 (A), CAN02-2 (A), CAN02-1 (A);
and standard Wiring harness between HM4A (04)
value in normal CAN08-3 (A), CAN08-2 (A), CAN08-1 (A);
state Disconnection in wiring
harness
CAN01-3 (A), CAN01-2 (A), CAN01-1 (A),
2 (Disconnection in wiring or
CN4 (3)
tor) Wiring harness between CAN06 (B)
CAN05-3 (B), CAN05-2 (B), CAN05-1 (B);
Wiring harness between CAN07 (D)
CAN04-3 (B), CAN04-2 (B), CAN04-1 (B);
CAN03-3 (B), CAN03-2 (B), CAN03-1 (B);
Wiring harness between RCM2 (22) Resistance Max. 1
CAN02-3 (B), CAN02-2 (B), CAN02-1 (B);
CAN08-3 (B), CAN08-2 (B), CAN08-1 (B);
CAN01-3 (B), CAN01-2 (B), CAN01-1 (B),
CN4 (8)

Grounding fault in wiring Between ground and CAN06 (A), CAN07
harness (E), ATC2 (32), RCM2 (32), HM4A (04), Resistance Min. 1 M
3
(Contact with ground circuit) CN062 (B), CN4 (3)
(D), ATC2 (22), RCM2 (22), HM4A (12), Resistance Min. 1 M
CN062 (10), CN4 (8)
Possible causes
and standard
value in normal Between ground and CAN06 (A), CAN07
state (E), ATC2 (32), RCM2 (32), HM4A (04), Voltage Max. 1V
4 harness
CN062 (B), CN4 (3)
(D), ATC2 (22), RCM2 (22), HM4A (12), Voltage Max. 1V
CN062 (10), CN4 (8)
transmission controller, VHMS & PLM controller or retarder controller or
may be defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
ler

FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR
Action code Failure code Retarder controller: Option setting error

Description
E03 DB1RMA (Machine monitor system)
Contents of Information of option setting sent from machine monitor when starting switch is turned ON is different from
trouble option setting saved in retarder controller.
Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Monitor
Controls with option setting saved in controller.
repsonse
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on None in particular.
machine
Related Perform initial setting and adjustment of retarder controller to be performed after replacement.
information Method of reproducing failure code: Turn starting switch ON.

Possible causes Option may be set wrongly in machine monitor. When machine monitor or
Wrong option setting in
and standard 1 retarder controller is replaced, set it correctly according to Testing and
machine monitor
value in normal adjusting.
state If cause 1 is not detected, machine monitor may be defective. (Since
2 Defective machine monitor
trouble is in system, troubleshooting cannot be carried out.)

FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR
Action code Failure code VHMS Communication Error

Description
E03 dBBRKR (Machine Monitor)
Contents of
Machine monitor cannot obtain information from the VHMS controller through the communication network.
trouble
Controller
Keeps information at time of occurrence of error.
Response
Problem that
The system may not operate normally.
appears on
Information from the VHMS controller is not displayed.
machine
Related
Method for reproducing failure codes: turn the key swithc ON.
information
and standard
value in normal Perform troubleshooting for DAFRKR.
state
1
Wiring harness between J2P (female) (46)
J2C (female) (46), CAN3 (female) (A),
CAN4 (female) (A), HM (female) (4), CAN2
Resistance Max. 1
(female) (A), DPC4 (female) (3), ATC2
(female) (32), BRC2 (female) (32), DL
(female) (3) or ABS2 (female) (32)
Possible causes Wiring harness between J2C (female) (46)
and standard J2P (female) (46), CAN3 (female) (A),
value in normal CAN4 (female) (A), DPC4 (female) (3), HM
state Disconnection in wiring (female) (4), CAN2 (female) (A), DPC4 Resistance Max. 1
harness (female) (3), ATC2 (female) (32), BRC2
2 (Disconnection in wiring or (female) (32), DL (female) (3) or ABS2
defective contact in connec- (female) (32)
tor)
Wiring harness between J2P (female) (47)
J2C (female) (47), CAN3 (female) (B),
CAN4 (female) (B), HM (female) (12), CAN2
Resistance Max. 1
(female) (B), DPC4 (female) (8), ATC2
Wiring harness between J2C (female) (47)
J2A (female) (47), CAN3 (female) (B),
CAN4 (female) (B), HM (female) (12), CAN2
Resistance Max. 1
(female) (B), DPC4 (female) (8), ATC2

Between ground and wiring harness
between J2P (female) (46) J2C (female)
(46), CAN3 (female) (A), CAN4 (female) (A),
HM (female) (4), CAN2 (female) (A), DPC4 Resistance Min. 1 M
(female) (3), ATC2 (female) (32), BRC2
(female) (32), DL (female) (3) or ABS2
(female) (32)
between J2C (female) (46) J2P (female)
DPC4 (female) (3), HM (female) (4), CAN2 Resistance Min. 1 M
Grounding fault in wiring (female) (A), DPC4 (female) (3), ATC2
harness (female) (32), BRC2 (female) (32), DL
3
(Contact with ground circuit) (female) (3) or ABS2 (female) (32)
(47), CAN3 (female) (B), CAN4 (female) (B),
HM (female) (12), CAN2 (female) (B), DPC4 Resistance Min. 1 M
(female) (22)
Possible causes between J2C (female) (47) J2A (female)
and standard (47), CAN3 (female) (B), CAN4 (female) (B),
value in normal HM (female) (12), CAN2 (female) (B), DPC4 Resistance Min. 1 M
state (female) (8), ATC2 (female) (22), BRC2
(female) (22)
Prepare with starting switch OFF, then turn starting switch ON and
perform troubleshooting.
HM (female) (4), CAN2 (female) (A), DPC4 Voltage Max. 1V
(female) (32)
Defective hot short in wiring between J2C (female) (46) J2P (female)
4 harness (46), CAN3 (female) (A), CAN4 (female) (A),
(a contact with 24 V circuit) DPC4 (female) (3), HM (female) (4), CAN2 Voltage Max. 1V
(female) (A), DPC4 (female) (3), ATC2
HM (female) (12), CAN2 (female) (B), DPC4 Voltage Max. 1V
(female) (22)

between J2C (female) (47) J2A (female)
harness
4 HM (female) (12), CAN2 (female) (B), DPC4 Voltage Max. 1V
Possible causes (a contact with 24 V circuit)
and standard (female) (22), DL (female) (10) or ABS2
value in normal (female) (22)
state
transmission controller, VHMS & PLM controller, retarder controller may
be defective. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
ler

FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT
Action code Failure code Suspension pressure sensor system: Brake pedal sw, front brake apply
Description
E01 DDB4MA sw, brake apply sw (Retarder controller system)
Contents of
Brake operates even though the driver does not work the foot brake.
trouble
Controller
None in particular
Response
Problem that
appears on Brake drags
machine
Related Input state can be checked with monitoring function (Code: 44700 (Brake pedal), 35102 (Front brake
information apply), 35700 (Brake apply)).
Between CN240 (A) - (B) Resistance Max. 1
Defective brake pedal, front Between CN240 (C) - (B) Resistance Min. 1 M
1 brake apply, or brake apply Between CN231 (A) - (B) Resistance Max. 1
sensor Between CN231 (C) - (B) Resistance Min. 1 M
Brake Pedal Applied Resistance Max. 1
Between CN027 (C) -
(B) Brake Pedal Not
Resistance Min. 1 M
Applied
(Disconnection in wiring or Wiring harness between CN231 (female)
Possible causes 2 Resistance Max. 1
defective contact in connec- (B) RCM3 (39)
and standard tor) Wiring harness between CN240 (female)
value in normal Brake pedal sw failure Resistance Max. 1
(C) RCM1 (12)
state
Grounding fault in wiring turning starting switch ON.
harness
3 (Contact with ground circuit) Resistance Min. 1 M
(B) RCM3 (39)
Front brake apply sw or
Brake apply sw failure Wiring harness between CN240 (female)
Resistance Min. 1 M
(C) RCM1 (12)
(a contact with 24 V circuit) Wiring harness between CN231 (female)
4 Voltage Max. 1 V
Front brake apply switch or (B) RCM3 (39)
brake apply switch failure Wiring harness between CN240 (female)
Voltage Max. 1 V
(C) RCM1 (12)
Defective Retarder
5 If no other problems were found, the controller may be defective..
controller

NOTES

FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE
Action code Failure code ARSC switch: input signal range out of range
Description (When ARSC is set and ARSC system switch is ON)
E03 DDD7KX (Retarder controller system)
Contents of
The input signal circuit voltage of the travel speed set switch is below 0.3 V.
trouble
Controller
When ARSC operates, the controller releases the brake gradually.
Response
Problem that
appears on This failure does not have a serious effect on the machine.
machine
Related
None in particular.
information
2) Replace the travel speed set switch (ARSC SET switch).
Defective travel speed set
1 Replace the travel Failure is not
switch (ARSC SET switch) Switch is normal
speed set switch repaired.
(ARSC SET switch). Failure is repaired. Switch is defective
2 Defective register (250 ) 3) Connect T-adapter.
Between CN034 (female) (1) (2) Resistance 250 25
Possible causes 2) Disconnect connector CN035.
and standard 3 Defective resistor (1,020 ) 3) Connect T-adapter.
value in normal Between CN035 (female) (1) (2) Resistance 1,020 102
state
2) Disconnect connectors RCM1, RCM3, CN092, and CN035, CN034.
Resistance Max. 1
Disconnection in wiring har- (34) CN034 (male) (2)
ness Wiring harness between RCM1 (female)
4
(Disconnection or defective (13) CN034 (male) (1) CN092 (female) Resistance Max. 1
contact) (1)
Wiring harness between CN035 (male) (1)
Resistance Max. 1
CN092 (female) (3)
Wiring harness between CN035 (male) (2)
Resistance Max. 1
CN092 (female) (2)

2) Disconnect connector RCM1 and RCM3.
Between RCM3 (34) RCM1 (21) Voltage Approx. 5 V
Possible causes 2) Disconnect connectors RCM1.
and standard 3) Insert T-adapter.
value in normal 5 Defective retarder controller
When set switch is
state Resistance 1,020 102
ON
When set switch is
Resistance 68 6.8
Between RCM1 TOUCH UP
(female) (13) (21) When set switch is
Resistance 198 19.8
TOUCH DOWN
When set switch is
Resistance 418 41.8
CANCEL

FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT
Action code Failure code ARSC switch: Open circuit

E03 DDD8KA (Retarder controller system)
Contents of
The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Controller
Response
Problem that
machine
Related
Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information
Disconnection in wiring har- 2) Disconnect connectors CN054 and CN2B.
ness 3) Connect T-adapter.
1
Wiring harness between CN2B (female) (1)
CN054 (female) (3)
2) Replace the ARSC system switch with normal one.
Defective ARSC system 3) Turn the starting switch ON.
2
Possible causes switch When the ARSC system switch No System switch is normal
and standard is replaced with normal one, is
value in normal failure repaired? Yes System switch is defective
state
2) Disconnect connector CN2B.
Turn the ARSC sys-
tem switch ON Voltage 20 30 V
Between CN2B (1) (Press it up).
ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).

FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT
Action code Failure code ARSC switch: Short circuit

E03 DDD8KB (Retarder controller system)
Contents of
The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Controller
Response
Problem that
machine
Related
Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information
2) Disconnect connectors CN2B and CN054.
1 Hot short in wiring harness
Voltage Max. 1 V
CN054 (female) (3)
Voltage Max. 1 V
CN054 (female) (2)
2) Replace the ARSC system switch with normal one.
Possible causes
ARSC system switch defec- 3) Turn the starting switch ON.
and standard 2
value in normal tive When the ARSC system switch No System switch is normal
state is replaced with normal one, is
failure repaired? Yes System switch is defective

Turn the ARSC sys-
3 Machine monitor defective
tem switch ON Voltage 20 30 V
Between CN2B (1) (Press it up).
ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).

FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT
Action code Failure code ASR cut switch: Open Circuit

Description
E01 DDDAKA (Machine monitor system)
Contents of
The ON input of the ASR system switch is OFF and the OFF input of the system switch is OFF.
trouble
Controller
Resets ASR control.
Response
Problem that
Machine is not affected seriously.
appears on
ASR control cannot be continued.
machine
Related
information
2) Disconnect connectors CN060 and CN2B.
Disconnection in wiring har- Wiring harness between CN2B (female) (3)
ness Resistance Max. 1
CN060 (female) (1)
defective contact in connec- 1) Turn starting switch OFF.
tor) 2) Disconnect connectors CN060 and CN2B.
Resistance Max. 1
CN060 (female) (2)
and standard 2) Replace ASR system switch with normal switch.
value in normal 3) Turn starting switch ON.
state 2 Defective ASR cut switch
When ASR system switch is No System switch is normal
replaced with normal switch,
does condition become normal? Yes System switch is abnormal

4) Turn starting switch ON.
3 Defective machine monitor Between CN2B (3) ASR cut switch ON Voltage 20 30 V
ground ASR cut switch OFF Voltage Max. 1 V
Between CN2B (9) ASR cut switch ON Voltage Max. 1 V
ground ASR cut switch OFF Voltage 20 30 V

FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT
Action code Failure code ASR cut switch: Short circuit

Description
E01 DDDAKB (Machine monitor system)
Contents of
ASR cut switch ON input is turned ON and system switch OFF input is turned ON.
trouble
Controller
Resets ASR control.
Response
Problem that
Machine is not affected particularly.
appears on
ASR control cannot be continued.
machine
Related
information
2) Disconnect connectors CN060 and CN2B.
1 Hot short in wiring harness
between CN2B (female) (3) CN060 Voltage Max. 1 V
(female) (3)
between CN2B (female) (9) CN060 Voltage Max. 1 V
(female) (2)
and standard 2) Replace ASR cut switch with normal switch.
value in normal 3) Turn starting switch ON.
state 2 Defective ASR cut switch
When ASR cut switch is No ASR cut switch is normal
replaced with normal switch, is
condition normal? Yes ASR cut switch is defective

3 Defective machine monitor Between CN2B (3) ASR cut switch OFF Voltage 20 30 V
ground ASR cut switch ON Voltage Max. 1 V
Between CN2B (9) ASR cut switch OFF Voltage Max. 1 V
ground ASR cut switch ON Voltage 20 30 V

FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT
Action code Failure code Brake switch: Open or short circuit

Description
E01 DDP6MA (Retarder controller system)
Contents of
Brake does not operate even though the driver works the emergency brake.
trouble
Controller
None in particular
Response
Problem that
appears on Emergency brake does not operate
machine
Related Input State can be checked with monitoring function (Code: 35102 (Front brake apply), 35100 (Brake
information apply)).
Defective front brake apply Between CN231 (female) Brake ON Max. 1

1 Resistance
or brake apply sensor (B) (C) Brake OFF Min. 1 M
Between CN240 (female) Brake ON Max. 1
Resistance
(B) (C) Brake OFF Min. 1 M
Possible causes harness turning starting switch ON.
and standard (Disconnection in wiring or Wiring harness between CN231 (female)
value in normal 2 defective contact in connec- Resistance Max. 1
(B) RCM3 (39)
state tor)
Front brake apply sw or Wiring harness between CN240 (female)
Resistance Max. 1
Brake apply sw failure (C) RCM1 (6)
Defective hot short in wiring form troubleshooting.
harness
3 (a contact with 24 V circuit) Voltage Max. 1 V
(B) RCM3 (39)
Front brake apply sw or
Brake apply sw failure Wiring harness between CN240 (female)
Voltage Max. 1 V
(C) RCM1 (6)
4 Defective retarder controller If no other problems have been found, the controller may be defective.

NOTES

FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code High clutch fill switch: Open Circuit
Description (Command is Holding pressure, fill switch is OFF, and slip is not sensed)
E03 DDTHKA (Transmission controller system)
Contents of When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
trouble switch is not turned ON.
Controller The controller keeps the current gear speed.
Response If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
The gear cannot be shifted.
appears on
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
machine
Related
This failure can be checked in the monitoring function (Code: 31520).
information

2) Disconnect connector CN14 (H, SW).
1 Defective Hi clutch fill switch When dis-
Resistance Min. 1 M
Between CN14 (H, SW) (male) engaged
(1) ground When
Resistance Max. 1
engaged
Possible causes 1) Turn the starting switch OFF.
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN14 (H, SW).
value in normal ness 3) Connect T-adapter.
2
state (Disconnection or defective
CN14 (H, SW) (female) (1)
3 When dis-
troller Resistance Min. 1 M
Between ATC3 (female) (30) engaged
ground When
Resistance Max. 1
engaged

FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code Low clutch fill switch: Open circuit
E03 DDTJKA (Transmission controller system)
Contents of When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Problem that
appears on
machine
Related
information

2) Disconnect connector CN12 (L,SW).
1 Defective Lo clutch fill switch When dis-
Resistance Min. 1 M
Between CN12 (L,SW) (male) engaged
(1) ground When
Resistance Max. 1
engaged
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN12 (L,SW).
2
CN12 (L,SW) (female) (1)
3 When dis-
ground When
Resistance Max. 1
engaged

FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code 1st clutch fill switch: Open circuit
E03 DDTKKA (Transmission controller system)
Contents of When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Response If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
machine
Related
information

2) Disconnect connector CN8 (1, SW).
1 Defective 1st clutch fill switch When dis-
Resistance Min. 1 M
Between CN8 (1, SW) (male) (1) engaged
ground When
Resistance Max. 1
engaged
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN8 (1, SW).
2
CN8 (1, SW) (female) (1)
3 When dis-
ground When
Resistance Max. 1
engaged

FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code 2nd clutch fill switch: Open circuit
E03 DDTLKA (Transmission controller system)
Contents of When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Problem that
appears on
machine
Related
information

2) Disconnect connector CN10 (2,SW).
Defective 2nd clutch fill
1 When dis-
switch Resistance Min. 1 M
Between CN10 (2,SW) (male) engaged
(1) ground When
Resistance Max. 1
engaged
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN10 (2,SW).
2
CN10 (2,SW) (female) (1)
3 When dis-
ground When
Resistance Max. 1
engaged

FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code 3rd clutch fill switch: Open circuit
E03 DDTMKA (Transmission controller system)
Contents of When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Problem that
appears on
machine
Related
information

2) Disconnect connector CN4 (3,SW).
Defective 3rd clutch fill
1 When dis-
switch Resistance Min. 1 M
Between CN4 (3,SW) (male) (1) engaged
ground When
Resistance Max. 1
engaged
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN4 (3,SW).
2
CN4 (3,SW) (female) (1)
3 When dis-
ground When
Resistance Max. 1
engaged

FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code R clutch fill switch: Open circuit

E03 DDTNKA (Transmission controller system)
Contents of When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Problem that
appears on
machine
Related
This failure can be checked in the monitoring function (Code: 31520)
information

2) Disconnect connector CN6 (R,SW).
1 Defective R clutch fill switch When dis-
Resistance Min. 1 M
Between CN6 (R,SW) (male) (1) engaged
ground When
Resistance Max. 1
engaged
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN6 (R,SW).
2
CN6 (R,SW) (female) (1)
3 When dis-
ground When
Resistance Max. 1
engaged

FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT
Action code Failure code Mid clutch fill switch: Open circuit
(Command is Holding pressure, fill switch is OFF, and slip is not
Description
E03 DDTRKA sensed)
Contents of When the output to the Mid clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Problem that
appears on
machine
Related
information

2) Disconnect connector CN16 (M,SW).
1 Defective R clutch fill switch When dis-
Resistance Min. 1 M
Between CN16 (M,SW) (male) (1) engaged
ground When
Resistance Max. 1
engaged
and standard Disconnection in wiring har- 2) Disconnect connectors ATC3 and CN16 (M,SW).
2
Wiring harness between ATC3 (female) (20) -
CN16 (M,SW) (female) (1)
3 When dis-
ground When
Resistance Max. 1
engaged

FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT
Action code Failure code Shift lever: Open circuit (No lever signal input)
Description
E03 DF10KA (Transmission controller system)
Contents of
Gear shift lever signal is not input at all.
trouble
Controller
Controls according to previous gear shift lever information before abnormality occurs.
Response
Problem that Gear speed is still in neutral and cannot start vehicle.
appears on Cannot shift between forward and reverse positions.
machine All gear shift lever position lamps go out.
Related infor-
Non in particular.
mation
Refer to pages 2, 5 & 6 of the electrical schematic for reference.
Gear shift lever is being pushed even though it is not operated.
1 Operational error Gear shift lever has been stopped at the midway point between each of
the gear positions.
2)Connect T-adapter to connector CN033A (male).
Harness between FU3 (3) CN033A (male)
Resistance Max. 1
(1)
Resistance Max. 1
CN033A (male) (3)
Resistance Max. 1
CN033A (male) (5)
Resistance Max. 1
CN033A (male) (4)
Disconnection in wiring Wiring harness between ATC2 (female) (15)
Resistance Max. 1
harness CN033A (male) (6)
2
(Disconnection or defective Wiring harness between ATC2 (female) (5)
contact of connectors) Resistance Max. 1
CN033A (male) (7)
Possible causes Wiring harness between ATC2 (female) (36)
CN033A (male) (8)
value in normal
state Resistance Max. 1
CN033A (male) (9)
Resistance Max. 1
CN033A (male) (10)
Resistance Max. 1
CN033A (male) (11)
Resistance Max. 1
(31), (32), (33) CN033A (male) (2)

2)Connect T-adapter to connectors ATC1 (female), ATC2 (female), and
CN033A (male).
Defective harness grounding
3 (Contact with ground circuit)
between ATC2 (female) (35) CN033A Resistance Min. 1 M
(male) (3)
(male) (5)

(male) (4)
(male) (6)
(male) (7)
Defective harness grounding Between ground and wiring harness
3 (Contact with ground circuit) between ATC2 (female) (36) CN033A Resistance Min. 1 M
(male) (8)
(male) (9)
between ATC2 (female) (16) SF1 (male) Resistance Min. 1 M
(10)
between ATC2 (female) (6) SF1 (male) Resistance Min. 1 M
(11)

2) Insert T-adapter in connector SF1.
Possible causes
and standard In shift range "R" Voltage 20 30 V
Between CN033A (3)
value in normal ground In shift range other
Voltage Max. 1 V
state than "R"
In shift range "N" Voltage 20 30 V
Between CN033A (4)
ground In shift range other
Voltage Max. 1 V
than "N"
In shift range "D" Voltage 20 30 V
Between CN033A (5)
Voltage Max. 1 V
than "D"
In shift range "6" Voltage 20 30 V
Between CN033A (6)
4 Defective gear shift lever Voltage Max. 1 V
than "6"
Between CN033A (7)
Voltage Max. 1 V
than "5"
Between CN033A (8)
Voltage Max. 1 V
than "4"
Between CN033A (9)
Voltage Max. 1 V
than "3"
Between CN033A
(10) ground In shift range other
Voltage Max. 1 V
than "2"
In shift range "L" Voltage 20 30 V
Between CN033A
Voltage Max. 1 V
than "L"

2) Insert T-adapter in connectors ATC1 and ATC2.
In shift range "R" Voltage 20 30 V
Between ATC2 (35)
Voltage Max. 1 V
than "R"
Between ATC2 (25)
Voltage Max. 1 V
than D
Between ATC1 (6)
Voltage Max. 1 V
than "N"
Possible causes Between ATC2 (15)
and standard Voltage Max. 1 V
Defective transmission than "6"
value in normal 5
state controller In shift range "5" Voltage 20 30 V
Between ATC2 (5)
Voltage Max. 1 V
than "5"
Between ATC2 (36)
Voltage Max. 1 V
than "4"
Between ATC2 (26)
Voltage Max. 1 V
than "3"
Between ATC2 (16)
Voltage Max. 1 V
than "2"
Between ATC2 (6)
Voltage Max. 1 V
than "L"

NOTES

FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT
Action code Failure code Shift lever: Short circuit

Description (Input of multiple lever signal)
E03 DF10KB (Transmission controller system)
Contents of
Gear shift lever signals have been inputted at the same time from 2 or more systems.
trouble
Controls according to high priority signal.
(1): N > D > 6> 5 > 4 > 3 > 2 > L
Controller
(2): N > R
Response
Shifts gear speed to neutral when signals have been inputted from system (1) and system (2) at the same
time.
There are cases where the gear speed is shifted to a higher gear speed than that which has been set by
Problem that
the gear shift lever.
appears on
Gear speed is still in neutral and cannot start vehicle.
machine
Gear shift lever position lamp does not indicate actual gear shift lever position.
Related
None in particular.
information
Refer to pages 2, 5 & 6 of the electrical schematic for reference.
2) Connect T-adapter to connectors ATC1 (female), ATC2 (female), and
CN033A (male).
Between ground and wiring harness When not at
between ATC2 (female) (35) CN033A Voltage R,
(male) (3) Max. 1 V
between ATC2 (female) (25) CN033A Voltage D,
(male) (5) Max. 1 V
between ATC1 (female) (6) CN033A Voltage N,
(male) (4) Max. 1 V
Possible causes Between ground and wiring harness When not at
and standard Defective hot short in wiring between ATC2 (female) (15) CN033A Voltage 6,
value in normal 1 harness (male) (6) Max. 1 V
state (a contact with 24 V circuit) Between ground and wiring harness When not at
between ATC2 (female) (5) CN033A Voltage 5,
(male) (7) Max. 1 V
(male) (8) Max. 1 V
(male) (9) Max. 1 V
(male) (10) Max. 1 V
between ATC2 (female) (6) CN033A Voltage L,
(male) (11) Max. 1 V

2) Insert T-adapter in connector SF1 (male).
Between CN033A (3)
Voltage Max. 1 V
than "R"
Between CN033A (4)
Voltage Max. 1 V
than "N"
In shift range"D" Voltage 20 30 V
Between CN033A (5)
Voltage Max. 1 V
than "D"
Between CN033A (6)
Voltage Max. 1 V
than "6"
2 Defective gear shift lever
Between CN033A (7)
Voltage Max. 1 V
than "5"
Between CN033A (8)
Voltage Max. 1 V
than "4"
Possible causes Between CN033A (9)
and standard Voltage Max. 1 V
than "3"
value in normal
state Between CN033A
Voltage Max. 1 V
than "2"
Between CN033A
Voltage Max. 1 V
than "L"
Turn the starting switch OFF.
Between ATC2 (35)
Voltage Max. 1 V
than "R"
Between ATC2 (25)
Voltage Max. 1 V
than "D"
In shift range"N" Voltage 20 30 V
Between ATC1 (6)
Defective transmission Voltage Max. 1 V
3 than N
controller
Between ATC2 (15)
Voltage Max. 1 V
than "6"
Between ATC2 (5)
Voltage Max. 1 V
than "5"
Between ATC2 (36)
Voltage Max. 1 V
than "4"

Between ATC2 (26)
Possible causes Voltage Max. 1 V
than "3"
and standard
value in normal Defective transmission Between ATC2 (16)
state 3 In shift range other
controller ground Voltage Max. 1 V
than "2"
Between ATC2 (6)
Voltage Max. 1 V
than "L"

FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL
OUT OF RANGE
Action code Failure code Transmission oil temperature sensor: Input signal out of range
Description
E03 DGF1KX (Transmission controller system)
The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V (above 150C)
Contents of or only transmission oil temperature is low (transmission oil temperature sensor signal circuit voltage is
trouble above 4.56 V (below 15 C) and torque converter and brake oil temperature sensor voltage is below 3.7 V
(above 55 C).
Controller
The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
Response
Problem that
appears on Gear shift shocks become large.
machine
Related
This failure can be checked in the monitoring function (Code: 32500 (C), 32501 (V)).
information
Refer to page 5 of the electrical schematic for reference.
2) Disconnect connector LUB,T.
Defective transmission oil
1 Between Oil temperature: Resis-
temperature sensor 37 50 k
LUB,T 25C tance
(male) (1) Oil temperature: Resis-
(2) 3.5 4.0 k
100C tance
2) Disconnect connectors ATC1 and LUB,T.
Disconnection in wiring har- 3) Connect T-adapter.
ness
LUB,T (female) (2)
contact)
Resistance Max. 1
LUB,T (female) (1)
and standard 2) Disconnect connectors ATC1 and LUB,T.
value in normal Grounding fault in wiring har- 3) Connect T-adapter.
3
state ness (Contact with ground)
Between ground and wiring harness ATC1
Resistance Min. 1 M
(female) (3) LUB,T (female) (1)
Hot short in wiring harness 3) Connect T-adapter.
(Contact with 24V)
Voltage Max. 5 V
(female) (3) LUB,T (female) (1)
Defective transmission con- 4) Turn the starting switch ON.
5
troller Between Oil temperature: Resis-
37 50 k
ATC1 25C tance
(female) Oil temperature: Resis-
(3) (21) 3.5 4.0 k
100C tance

FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT
TO GROUND
Action code Failure code Retarder oil temperature sensor (right rear ): Short to ground
Description
E01 DGR2KB (Retarder controller system)
Contents of
Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
trouble
Controller
None in particular.
Response
Problem that
appears on Oil temperature gauge does not work because of failure mode of sensor.
machine
Related Input signal from oil temperature sensor can be checked with monitoring function (codes: 30208 (C) and
information 30210 (V)).
Prepare with starting switch OFF, disconnect connector RTR and trouble-
shooting with starting switch still OFF.
Retarder oil tempera-
CN136 (male) Resistance (k)
ture (C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) (2) 80 6.556
90 4.925
100 3.75
Possible causes Prepare with starting switch OFF, disconnect connector RCM1 and trou-
and standard bleshooting with starting switch still OFF.
value in normal Retarder oil tempera-
state RCM1 (female) Resistance (k)
Short circuit of harness ture (C)
(Contact with ground circuit 25 42.7
2
or contact between har-
30 35.13
nesses)
Between (3) (21) 80 6.556
90 4.925
100 3.75
Prepare with the starting switch OFF. Turn the switch ON and perform the
troubleshooting.
3 Defective retarder controller Actual oil temperature
Check with monitoring
Oil temperature matches displayed
function code: 30208.
temperature

FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN
OR SHORT CIRCUIT
Action code Failure code Retarder oil temperature sensor (right rear): Open or short circuit
Description
E01 DGR2KZ (Retarder controller system)
Contents of
Signal circuit voltage of retarder oil temperature sensor is above 4.721 V.
trouble
Controller
None in particular.
Response
Problem that
machine
Prepare with starting switch OFF, disconnect connector CN136 and trou-
bleshooting with starting switch still OFF.
Retarder oil temperature
(C)
1
ature sensor
30 35.13
Between (1) (2) 80 6.556
90 4.925
100 3.75
Prepare with starting switch OFF, disconnect connector RCM1 and trou-
RCM1 (female) Resistance (k)
Disconnection in wiring (C)
harness 25 42.7
Possible causes 2
and standard 30 35.13
contact)
value in normal Between (3) (21) 80 6.556
state
90 4.925
100 3.75
Short circuit of harness (C)
3
30 35.13
nesses)
Between (3) (21) 80 6.556
90 4.925
100 3.75
Prepare with starting switch OFF and troubleshooting with starting switch
Defective retarder controller still ON.
4
(In normal system) Check with monitoring Oil Actual oil temperature and dis-
function code: 30208. temperature played temperature are same.

FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT
TO GROUND
Action code Failure code Retarder oil temperature sensor (left rear): Short to ground
Description
Contents of
trouble
Controller
None in particular.
Response
Problem that
machine
information 30209 (V))
Prepare with starting switch OFF, disconnect connector RTR and trouble-
shooting with starting switch still OFF.
(C)
Defective retarder oil tem- 25 42.7
1
perature sensor
30 35.13
Between (1) (2) 80 6.556
90 4.925
100 3.75
Possible causes
and standard
value in normal
state Retarder oil
Short circuit of harness temperature (C)
(Contact with ground cir- 25 42.7
2
cuit or contact between har-
30 35.13
nesses)
Between (9) (21) 80 6.556
90 4.925
100 3.75
Defective retarder control- still ON.
3 ler
(In normal system) Check with monitoring Actual oil temperature and dis-
Oil temperature
function code: 30207 played temperature are same.

FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN
OR SHORT CIRCUIT
Action code Failure code Retarder oil temperature sensor (left rear): Open or short circuit
Description
Contents of
Signal circuit voltage of retarder oil temperature sensor has become above 4.721 V.
trouble
Controller
None in particular.
Response
Problem that
machine
(C)
1
ature sensor
30 35.13
Between (1) (2) 80 6.556
90 4.925
100 3.75
Disconnection in wiring (C)
harness 25 42.7
Possible causes 2
contact)
state
90 4.925
100 3.75
Retarder oil
3
30 35.13
nesses)
Between (9) (21) 80 6.556
90 4.925
100 3.75
4
function code: 30207 temperature played temperature are same.

FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL):
OPEN OR SHORT CIRCUIT
Action code Failure code Retarder oil temperature sensor (front wheel): Open or short circuit
Description
Contents of
Signal circuit voltage of retarder oil temperature sensor has become above 4.721 V.
trouble
Controller
None in particular.
Response
Problem that
machine
Retarder oil
temperature (C)
1
ature sensor
30 35.13
Between (1) (2) 80 6.556
90 4.925
100 3.75
Retarder oil
Disconnection in wiring temperature (C)
harness 25 42.7
Possible causes 2
contact)
state
90 4.925
100 3.75
Retarder oil
3
30 35.13
nesses)
Between (20) (21) 80 6.556
90 4.925
100 3.75
4
(In normal system) Check with monitoring Actual oil temperature and dis-
Oil temperature
function code: 30201 played temperature are same.

FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL):
SHORT TO GROUND
Action code Failure code Retarder oil temperature sensor (front wheel): Short to ground fault
Description
Contents of
trouble
Controller
None in particular.
Response
Problem that
machine
Retarder oil
temperature (C)
1
ature sensor
30 35.13
Between (1) (2) 80 6.556
90 4.925
100 3.75
Possible causes
and standard
value in normal
state Retarder oil
2
30 35.13
nesses)
Between (20) (21) 80 6.556
90 4.925
100 3.75
3
function code: 30201 temperature played temperature are same.

FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT
SIGNAL OUT OF RANGE
Action code Failure code Torque converter oil temperature sensor: Input signal out of range
Description
E01 DGT1KX (Transmission controller system)
The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above
Contents of 150C) or when transmission valve oil temperature signal voltage is below 0.37 V (above 5C) and there is
trouble no abnormality, torque converter oil temperature sensor signal circuit voltage is above 4.56 V (below
15C).
Controller
None in particular.
Response
Problem that
appears on The torque converter oil temperature gauge does not indicate normally.
machine
Related
This failure can be checked in the monitoring function (Code: 30100 (C), 30101 (V)).
information
Defective torque converter
1 Between Oil temperature:
oil temperature sensor Resistance 37 50 k
CN152 25C
(male) (1) Oil temperature:
(2) Resistance 3.5 4.0 k
100C
2) Disconnect connectors ATC1 and CN152.
Disconnection in wiring har- 3) Connect T-adapter.
ness
CN152 (female) (2)
contact)
Resistance Max. 1
CN152 (female) (1)
and standard 2) Disconnect connectors ATC1 and CN152.
value in normal Grounding fault in wiring har- 3) Connect T-adapter.
3
state ness
Resistance Min. 1 M
(female) (9) CN152 (female) (1)
Defective hot short in wiring 3) Insert T-adapter.
harness
Voltage Max. 1 V
(female) (21) CN152 (female) (2)
5
troller Between Oil temperature:
Resistance 37 50 k
AT1 25C
(female) Oil temperature:
(9) (21) Resistance 3.5 4.0 k
100C

FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF
RANGE
Action code Failure code Failure in suspension pressure sensor system trouble: Out of input signal
Description range (right front)
E03 dHP4KX (Retarder controller)
Contents of The voltage of the signal circuit of the suspension pressure sensor (right front) is below1.0 V or above 4.7
trouble V.
Controller Does not operate ARSC.
Response When ARSC operates, the controller releases the brake gradually.
Problem that
appears on There is no great influence of machine.
machine
Related Input state from suspension pressure sensor (right front) can be checked with monitoring function (Code:
information 32802 (MPa), 32808 (V)).
Defective suspension form troubleshooting.
1
pressure sensor Between CN121 (female) (B) (A) Voltage 20 -30 V
Between CN121 (female) (C) (A) Voltage 1.0 - 4.6 V
Disconnection in wiring Resistance Max. 1
(A) HM2B (female) (9)
harness
Possible causes 2 (Disconnection in wiring or Resistance Max. 1
(B) HM1 (female) (2)
and standard defective contact in connec-
value in normal tor) Wiring harness between CN121 (female)
Resistance Max. 1
state (C) RCM1 (female) (1)
Resistance Max. 1
(C) HM2B (female) (8)
Grounding fault in wiring Resistance Min. 1 M
3 harness
(Contact with ground circuit) Wiring harness between CN121 (female) Resistance Min. 1 M
(C) RCM1 (female) (1)
Resistance Min. 1 M
Defective hot short in wiring Voltage Max. 1 V
Possible causes 4 harness
and standard (a contact with 24 V circuit) Voltage Max. 1 V
value in normal
Voltage Max. 1 V
5 Defective retarder controller form troubleshooting.
Between HM2B (1) (9) Voltage 1.0 4.6 V

FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF
RANGE
Description range (right front)
E03 DhP4KX (VHMS)
Contents of
Signal circuit voltage for the right front suspension pressure sensor is below1.0 V or above 4.7 V.
trouble
Problem that
machine
Related Input state from suspension pressure sensor (right front) can be checked with monitoring function (Code:
1
harness
Resistance Max. 1
Resistance Max. 1
3 harness
Resistance Min. 1 M
value in normal
Voltage Max. 1 V

FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF
RANGE
Action code Failure code Left front suspension pressure sensor system: Out of range
Description
E03 dHP5KX Retarder controller
Contents of
The voltage of the signal circuit of the suspension pressure sensor (left front) is below1.0 V or above 4.7 V.
trouble
Problem that
machine
Related Input state from suspension pressure sensor (left front) can be checked with monitoring function (Code:
1
Wiring harness between CN110 (female) (A)
HM2B (female) (9)
harness
Wiring harness between CN110 (female) (B)
HM1 (female) (2)
Resistance Max. 1
Resistance Max. 1
HM1 (female) (2)
3 harness
Resistance Min. 1 M
HM2B (female) (9)
value in normal
Voltage Max. 1 V
Between RCM1 (7) HM2B (9) Voltage 1.0 4.6 V

FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF
RANGE
Description range (left front)
E03 DhP5KX VHMS
Contents of
The voltage of the signal circuit of the suspension pressure sensor (left front) is below1.0 V or above 4.7 V.
trouble
Problem that
machine
Related Input state from suspension pressure sensor (left front) can be checked with monitoring function (Code:
1
HM2B (female) (9)
harness
HM1 (female) (2)
Resistance Max. 1
Resistance Max. 1
HM1 (female) (2)
3 harness
Resistance Min. 1 M
HM2B (female) (9)
value in normal
Voltage Max. 1 V

FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF
RANGE
Action code Failure code Right rear suspension pressure sensor: out of range
Description
E03 DHP6KX VHMS
Contents of
The voltage of the signal circuit of the suspension pressure sensor: is below 1.0 V or above 4.7 V.
trouble
Controller
The VHMS controller only monitors this information.
Response
Problem that
appears on There are no obvious symptoms.
machine
Related Input state from suspension pressure sensor: can be checked with monitoring function (Code: 32806
information (MPa), 32812 (V)).
Prepare with the starting switch OFF, then trun starting switch ON and
Defective suspension pres- perform troubleshooting.
1
sure sensor Between CN146 (female) (B) (A) Voltage 20 -30 V
Resistance Max. 1
2 Open in wiring harness
Resistance Max. 1
(B) HM1(female) (2)
Resistance Max. 1
Possible causes (C) HM2B (female) (7)
and standard Prepare with the starting switch OFF, then trun starting switch ON and
value in normal perform troubleshooting.
state Grounding fault in wiring
Resistance Min. 1 M
Voltage Max. 1 V
Defective transmission con- perform troubleshooting.
5
troller
Between HM2B (7) - (9) Voltage 1.4 - 4.6 V

FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE
Action code Failure code Left rear suspension pressure sensor: out of range
Description
E03 DHP7KX VHMS
Contents of
The voltage of the signal circuit of the suspension pressure sensor: is below 1.0 V or above 4.7 V.
trouble
Controller
The VHMS controller only monitors this information.
Response
Problem that
appears on There are no obvious symptoms.
machine
Related Input state from suspension pressure sensor: can be checked with monitoring function (Code: 32807
information (MPa), 32813 (V)).
Defective suspension pres- perform troubleshooting.
1
sure sensor Between CN143 (female) (B) (A) Voltage 20 -30 V
Resistance Max. 1
2 Open in wiring harness
Resistance Max. 1
(B) HM1(female) (2)
Resistance Max. 1
Possible causes (C) HM2B (female) (8)
and standard Prepare with the starting switch OFF, then trun starting switch ON and
value in normal perform troubleshooting.
Resistance Min. 1 M
Voltage Max. 1 V
Defective transmission con- perform troubleshooting.
5
troller
Between HM2B (8) - (9) Voltage 1.0 - 4.6 V

FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF
RANGE
Action code Failure code Torque converter inlet oil pressure sensor: Out of input signal range
Description
E01 DHT5KX (Transmission controller system)
Contents of The voltage of the signal circuit of the torque converter inlet oil pressure sensor is below 0.5 V or above
trouble 4.5 V.
Controller The controller controls the machine, fixing the torque converter inlet oil pressure to the set pressure in
Response itself.
Problem that
appears on Large shocks are made when the lockup system is operated.
machine
Related Input state from torque converter inlet oil pressure sensor can be checked with monitoring function (Code:
1. Turn the starting switch OFF.
2. Disconnect connectors ATC1 and the T/C IN connector.
Disconnection in wiring 3. Connect T-adapter.
harness Wiring harness between ATC1 (female) (7)
Resistance Max. 1
1 (Disconnection in wiring or TC IN (female) (3)
defective contact in connec- Wiring harness between ATC1 (female) (16)
TC IN (female) (2)
Resistance Max. 1
TC IN (female) (1)
Grounding fault in wiring 3. Connect T-adapter.
2 harness Wiring harness between ATC1 (female) (7)
(Contact with ground circuit) TC IN (female) (3) Resistance Min. 1
Possible causes
and standard Resistance Min. 1
value in normal (16) TC IN (female) (2)
state 1. Turn the starting switch OFF.
Defective hot short in wiring 2. Disconnect connectors ATC1 and the T/C IN connector.
3 harness 3. Connect T-adapter.
(a contact with 24 V circuit) Wiring harness between ATC1 (female) (7)
Resistance Max. 1
TC IN (female) (3)
2. Disconnect connector TC IN.
Defective torque converter 3. Connect T-adapter.
4
oil pressure sensor
Between TC IN (1) - (2) Voltage 20 - 30 V
Between TC IN (1) - (3) Voltage 0.8 - 2.0 V
2. Disconnect connectors ATC1.
Defective transmission con- 3. Connect T-adapter.
5
troller
Between ATC1 (7) - (21) Voltage 0.8 - 2.0 V
Between ATC1 (16) - (21) Voltage 20 - 30 V

FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR:
MALFUNCTION
Action code Failure code Torque converter inlet oil pressure sensor: Malfunction
Description
E01 DHT5L6 (Transmission controller system)
Contents of While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter inlet
trouble oil pressure sensor.
Controller The controller controls the machine, fixing the torque converter inlet oil pressure to the set pressure init-
Response self.
Problem that
machine
2. Disconnect connector ATC1 and TC IN.
3. Connect T-adapter.
1 harness
(a contact with 24 V circuit) 4. Turn the key switch to ON.
Wiring harness between ATC1 (female) (7) - TC
Voltage Max. 1.2 V
IN (female) (3)
Possible causes 2. Disconnect connector TC IN.
and standard 3. Connect T-adapter.
value in normal 2
inlet oil pressure sensor 4. Turn the key switch to ON.
state
Between TC IN (1) - (2) Voltage 20 - 30 V
Between TC IN (1) - (3) Voltage 0.8 - 2.0 V
2. Disconnect connector ATC1.
3
troller 4. Turn the key switch to ON.

FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT
OF RANGE
Action code Failure code Torque converter outlet oil pressure sensor: Out of input signal range
Description
E01 DHT7KX (Transmission controller system)
Contents of The voltage of the signal circuit of the torque converter outlet oil pressure sensor is below 0.5 V or above
trouble 4.5 V.
Controller The controller controls the machine, fixing the torque converter outlet oil pressure to the set pressure in
Response itself.
Problem that
machine
Related Input state from torque converter outlet oil pressure sensor can be checked with monitoring function
information (Code: 32603 (MPa), 32604 (V)).
2. Disconnect connectors ATC1 and the T/C OUT connector.
Disconnection in wiring
harness Resistance Max. 1
1 TC OUT (female) (3)
defective contact in connector) Wiring harness between ATC1 (female) (16) Resistance Max. 1
TC OUT (female) (2)
Resistance Max. 1
TC OUT (female) (1)
Grounding fault in wiring 3. Connect T-adapter.
2 harness Wiring harness between ATC1 (female) (1)
(Contact with ground circuit) Resistance Min. 1
TC OUT (female) (3)
Possible causes
and standard Resistance Min. 1
value in normal TC OUT (female) (2)
state 1. Turn the starting switch OFF.
Defective hot short in wiring 2. Disconnect connectors ATC1 and the T/C OUT connector.
3 harness 3. Connect T-adapter.
(a contact with 24 V circuit) Wiring harness between ATC1 (female) (16)
Resistance Max. 1
TC OUT (female) (2)
2. Disconnect connector TC OUT.
Defective torque converter oil 3. Connect T-adapter.
4
pressure sensor
Between TC OUT (1) - (2) Voltage 20 - 30 V
Between TC OUT (1) - (3) Voltage 0.8 - 2.0 V
2. Disconnect connectors ATC1.
Defective transmission control- 3. Connect T-adapter.
5
ler

FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR:
MALFUNCTION
Action code Failure code Torque converter outlet oil pressure sensor: Malfunction
Description
E01 DHT7L6 (Transmission controller system)
Contents of While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter out-
trouble let oil pressure sensor.
Controller The controller controls the machine, fixing the torque converter outlet oil pressure to the set pressure init-
Response self.
Problem that
machine
Related Input state from torque converter outlet oil pressure sensor can be checked with monitoring function
information (Code: 32603 (MPa), 32604 (V)).
2. Disconnect connector ATC1 and TC OUT.
1 harness
(a contact with 24 V circuit) 4. Turn the key switch to ON.
Wiring harness between ATC1 (female) (1) - TC
Voltage Max. 1.2 V
OUT (female) (3)
Possible causes 2. Disconnect connector TC OUT.
and standard 3. Connect T-adapter.
value in normal 2
inlet oil pressure sensor 4. Turn the key switch to ON.
state
Between TC OUT (1) - (2) Voltage 20 - 30 V
Between TC OUT (1) - (3) Voltage 0.8 - 2.0 V
2. Disconnect connector ATC1.
3
troller 4. Turn the key switch to ON.

FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT
Action code Failure code Fuel level sensor: Disconnection

Description
E01 DJF1KA (Transmission controller system)
Contents of
The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
trouble
Controller
None in particular.
Response
Problem that
appears on The fuel level gauge does not indicate normally.
machine
Related
This failure can be checked in the monitoring function (Code: 04200 (V)).
information
2) Disconnect connector FLVL.
1 Defective fuel level sensor Fuel level:
Resistance Max. 12
Between FLVL When full
(male) (1) (2) Fuel level:
Resistance 82 88
When empty
Disconnection in wiring 2) Disconnect connectors ATC1and FLVL.
harness 3) Connect T-adapter.
2 (Disconnection in wiring or Wiring harness between ATC1 (female) (8)
Resistance Max. 1
defective contact in connec- FLVL (female) (1)
Possible causes tor) Wiring harness between ATC1 (female) (21)
FLVL (female) (2)
value in normal
state
2) Disconnect connectors ATC1and FLVL.
Defective hot short in wiring 3) Connect T-adapter.
3 harness 4) Turn the starting switch ON.
(a contact with 24 V circuit) Between ground and wiring harness
between ATC1(female) (8) FLVL (female) Voltage Max. 1 V
(1)
4
troller Fuel level:
Resistance Max. 12
Between ATC1 When FULL
(female) (8) (21) Fuel level:
Resistance 82 88
When EMPTY

FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE
Action code Failure code Accelerator pedal sensor: Out of range

Description
E03 DK11KX (Transmission controller system)
Contents of
The voltage of the signal circuit of the accelerator sensor is below 0.6 V or above 4.7 V.
trouble
Controller
The controller controls ECMV assuming full throttle.
Response
Problem that
appears on Gear shift shocks become large.
machine
Related
information
2) Disconnect connectors CN028.
1 Defective Accelerator sensor
Pedal not
3.8 0.2 V
actuated
Check voltage between CN028 (A) - (B)
Pedal fully
1.2 0.2 V
actuated
2) Disconnect connectors CN028 and ATC1.
Disconnection in wiring har- 4) Perform troubleshooting with key switch OFF.
ness Check between CN028 (A) - ATC1 (21) Resistance Max. 1
2
(Disconnection or defective Check between CN028 (B) - ATC1 (14) Resistance Max. 1
contact)
Check between CN028 (C) - ATC1 (22) Resistance Max. 1
Possible causes
1) Turn the starting switch ON and perform troubleshooting.
and standard
value in normal Check between CN028 (A) - (C) Voltage 5V
state 1) Turn the starting switch OFF.
2) Disconnect connectors CN028 and ATC1.
Grounding fault in wiring har- 4) Perform troubleshooting with key switch OFF.
3 ness
Check between ground and harness
(Contact with ground) Resistance Min. 1 M
between CN028 (B) - ATC1 (14)
Check between ground and harness
Resistance Min. 1 M
between CN028 (C) - ATC1 (22)
Defective transmission con- Check between ATC1 (21) - (22) Voltage 5V
4
troller
Pedal not
3.8 0.2 V
Check accel pedal voltage with monitor actuated
function code: 31700 Pedal fully
1.2 0.2 V
actuated

FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT
Action code Failure code Steering angle potentiometer: Open circuit

Description
E01 DK30KX (Retarder controller system)
Contents of
There is no voltage in signal coming from steering angle potentiometer.
trouble
Controller
None in particular.
Response
Problem that
Since steering angle signal is not input to retarder controller, ASR may not operate normally and tires may
appears on
slip consequently.
machine
Related Input state from steering angle sensor can be checked with monitoring function (Code: 35400 (V), 35402
information ()).
shooting without turning starting switch ON.
CN228 (Male: Sensor side) Resistance
1 Defective sensor Between (A) (C) 5 k 20%
Between (A) (B) 0 5 k *1
Between (B) (C) 0 5 k *1
*1 Between (A) (B) + between (B) (C) = 5 k 20%
Possible causes
shooting without turning starting switch ON.
and standard
value in normal Disconnection in wiring har- Between CN228 (female) (B) RCM1
ness Resistance Max. 1
state (female) (2)
1) Turn starting switch OFF and disconnect CN228.
2) Turn starting switch ON and perform troubleshooting.
tor)
CN228 (Female) Voltage
Between (C) (A) 5V
3 ness shooting without turning starting switch ON.
(Contact with ground circuit) Between CN228 (female) (B) ground Resistance Min. 1 M

FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE
Action code Failure code Retarder lever potentiometer: Out of range

Description
E03 DK51KX (Retarder controller system)
Contents of
The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V.
trouble
Controller
Turns the output for the solenoid OFF.
Response
Problem that The following appear, depending on the action of the controller.
machine The retarder does not operate (The foot brake operates, however).
Related
information
2) Disconnect connectors RCM1 and RCM3.
harness Wiring harness between RCM1 (female) (14)
Resistance Max. 1
1 (Disconnection in wiring or CN023 (female) (B)
defective contact in connec- Wiring harness between RCM1 (female) (21)
CN023 (female) (A)
Wiring harness between RCM3 (female) (34)
Resistance Max. 1
CN023 (female) (3)
2) Disconnect connectors RCM1 and RCM3.
Possible causes 3) Connect T-adapter to RCM1 and RCM3.
and standard Between ground and wiring harness
value in normal between RCM1 (female) (14) CN023 Resistance Min. 1 M
state Grounding fault in wiring (female) (B)
2 harness
(Contact with ground circuit) Between ground and wiring harness
between RCM3 (female) (34) CN023 Resistance Min. 1 M
(female) (C)
(female) (A)
Defective hot short in wiring 3) Connect T-adapter to RCM1 and CN023.
between RCM1 (female) (14) CN023 Voltage Max. 1 V
(female) (B)

2) Disconnect connector CN023
4 Defective retarder lever 4) Turn the starting switch ON.
5) Check the potentiometer.
Possible causes Between CN023 (A) (C) Voltage 5V
and standard Between CN023 (A) (B) Voltage 0.25 4.75 V
value in normal
2) Disconnect connectors RCM1, and RCM3.
3) Insert T-adapters.
Between RCM3 (34) - RCM1 (21) Voltage 5V
Between RCM1 (21) - RCM1 (14) Voltage 0.25 4.75 V

FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE
Action code Failure code Pitch Inclination Sensor: Out of Range

Description
E01 DKH1KX VHMS
Contents of The signal circuit voltage is below 0.5 V or above 4.5 V.
trouble Open or short circuit detected in signal circuit
Controller None in particular.
Response Cannot detect tipping over.
Problem that
appears on Load weight is not displayed or recorded correctly.
machine
information 32901 (), 32902 (V))
2. Connect T adapter to AS3 (male).
1 Defective inclination sensor. 3. Turn the starting switch ON.
Between CN032 (C) (A) Voltage 20 - 30 V.
Between CN032 (B) (A) Voltage 0.5 - 4.5 V.
2. Disconnect HM2B, CN032 and HM1.
Wiring harness between HM2B (female) (3)
Resistance Max. 1
Open in wiring harness CN032 (female) (B)
2
Wiring harness between HM1 (female) (2)
Resistance Max. 1
CN032 (female) (C)
Resistance Max. 1
CN032 (female) (A)
Possible causes
and standard 1. Turn the starting switch OFF.
value in normal 2. Disconnect HM2B, CN032 and HM1.
3 harness Resistance Min. 1
(Contact with ground circuit) CN032 (female) (C)
Wiring harness between HM1 (female) (2)
Resistance Min. 1
CN032 (female) (C)
Defective hot short in wiring 2. Disconnect connector HM2B and CN032.
4 harness 3. Connect T-adapter to HM2B.
(a contact with 24 V circuit) 4. Turn starting switch ON.
Between HM2B (3) - CN032 (B) Voltage Max. 4.6 V
2. Connect T-adapter to HM2B and HM1.
5
troller
Between HM1 (2) - HM2B (9) Voltage 20 - 30 V
Between HM2B (3) - HM2B (9) Voltage 0.5 - 4.5 V

FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION
Action code Failure code Wheel speed sensor circuit: Malfunction

Description
E01 DL10LC (Retarder controller system)
Contents of
Both wheel speed signal (pulse) inputs to the retarder controller are abnormal.
trouble
Controller
Does not control ASR.
Response
Problem that
appears on ASR is not controlled normally.
machine
Related Input state from the wheel speed sensors can be checked with monitoring function (Codes: 39704, 39705
information (rpm)).
Turn starting switch OFF and remove the sensor from the brake housing.
Install a T-adapter to CN134 and CN137. Turn the key to ON.
Defective wheel speed sen- Pass a piece of metal in front of the right
1
sors rear sensor face while measuring the volt-
Voltage 0.4 - 5V
age between CN134 (3) - CN134 (2).
Repeat for left, CN137 (3) - CN137 (2).
Turn starting switch OFF and disconnect CN134, RCM1 and RCM2. Per-
form troubleshooting without turning starting switch ON.
Between CN134 (female) (1) RCM1
Resistance Max. 1
(female) (22)
Resistance Max. 1
(female) (39)
Disconnection in wiring Between CN134 (female) (3) RCM2
Possible causes harness Resistance Max. 1
and standard (female) (37)
2 (Disconnection in wiring
value in normal or defective contact in Turn starting switch OFF and disconnect CN137, RCM1 and RCM2. Per-
state connector) form troubleshooting without turning starting switch ON.
Resistance Max. 1
(female) (22)
Resistance Max. 1
(female) (39)
Resistance Max. 1
(female) (37)
Turn starting switch OFF and disconnect CN134 and CN137, then per-
Grounding fault in wiring form troubleshooting without turning starting switch ON.
3 harness
Between CN134 (female) (3) ground Resistance Min. 1 M
Between CN137 (female) (3) ground Resistance Min. 1 M
If causes 1 3 are not detected, retarder controller may be
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot be carried
out.)

FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT
Action code Failure code Engine speed sensor: Open circuit

Description
E03 DLE2KA (Transmission controller system)
Contents of
The signal circuit of the Engine speed sensor is disconnected and signals are not input.
trouble
Controller The controller keeps the current gear speed and turns the lockup operation OFF.
Problem that
The lockup system is reset and the gear cannot be shifted.
appears on
machine
Related
This failure can be checked in the monitoring function (Code: 01002 (rpm)).
information
Wrong adjustment of Press the sensor lightly against the revolution pickup gear, and then
1 transmission output shaft return it by 1/2 1 turn.
speed sensor
Defective transmission 3) Connect T-adapter.
2
output shaft speed sensor 500
Between CN178 (male) (1) (2) Resistance
1,000
Possible causes Between CN178 (male) (1), (2) ground Resistance Min. 1 M
and standard 1) Turn the starting switch OFF.
value in normal 2) Disconnect connectors ATC2 and CN178.
state Disconnection in wiring 3) Connect T-adapter to ATC2 (female) and CN178 (female).
harness
(Disconnection in wiring or Resistance Max. 1
CN178 (female) (1)
defective contact in connector)
Resistance Max. 1
CN178 (female) (2)
Defective retarder 3) Connect T-adapter to ATC2 (female).
4
controller
500
Between ATC2 (female) (10) (39) Resistance
1,000

FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION
Action code Failure code Engine speed sensor: Disagreement of revolution speed signal
Description
E03 DLE2LC (Transmission controller system)
The speed calculated from the transmission input shaft speed sensor signal, transmission intermediate
Contents of
shaft speed sensor signal, and transmission output shaft speed sensor signal is different from the signal
trouble
speed of the engine speed sensor.
Problem that
appears on
machine
Related
information
1
output shaft speed sensor 500
Between CN178 (male) (1) (2) Resistance
1,000
Between CN178 (male) (1), (2) chassis ground Resistance Min. 1 M
Grounding fault in wiring 2) Disconnect connectors ATC2 and CN178.
2 harness 3) Connect T-adapter.
Possible causes
(Contact with ground circuit) Between ground and wiring harness between
and standard Resistance Min. 1 M
value in normal ATC2 (female) (10) CN178 (female) (1)
Voltage Max. 1 V
CN178 (female) (1)
Defective retarder 3) Connect T-adapter.
4
controller
500
Between ATC2 (female) (10) (39) Resistance
1,000

FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
Action code Failure code Transmission input shaft speed sensor: Open circuit
Description
E03 DLF1KA (Transmission controller system)
Contents of
The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not input.
trouble
Problem that
appears on
machine
Related
information
Wrong adjustment of
Press the sensor lightly against the revolution pickup gear, and then
1 transmission input shaft
return it by 1/2 1 turn.
speed sensor
2) Disconnect connector N1.
Defective transmission input 3) Connect T-adapter.
2
shaft speed sensor
Between N1 (male) (1) (2) Resistance 500 1,000
Possible causes Between N1 (male) (1), (2) ground Resistance Min. 1 M
value in normal 2) Disconnect connectors ATC2 and N1.
state 3) Connect T-adapter.
harness
3 (Disconnection in wiring or Wiring harness between ATC2 (female)
Resistance Max. 1
defective contact in connec- (40) N1 (female) (1)
tor) Wiring harness between ATC2 (female)
Resistance Max. 1
(29) N1 (female) (2)
Defective transmission con- 2) Disconnect connector ATC2.
4 3) Connect T-adapter.
troller
Between ATC2 (female) (40) (29) Resistance 500 1,000

FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION
Action code Failure code Transmission input shaft speed sensor: Disagreement of revolution speed
Description signal
E03 DLF1LC (Transmission controller system)
The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sensor
Contents of
signal, and transmission output shaft speed sensor signal is different from the signal speed of the trans-
trouble
mission input shaft speed sensor.
Problem that
appears on
machine
Related
information
Defective transmission input 3) Connect T-adapter.
1
shaft speed sensor
Between N1 (male) (1), (2) ground Resistance Min. 1 M
2) Disconnect connectors ATC2 and N1.
Grounding fault in wiring 3) Connect T-adapter.
2 harness
Possible causes (Contact with ground circuit) Between ground and wiring harness
and standard between ATC2 (female) (40) N1 (female) Resistance Min. 1 M
value in normal (1)
between ATC2 (female) (40) N1 (female) Voltage Max. 1 V
(1)
troller

FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN
CIRCUIT
Action code Failure code Transmission intermediate shaft speed sensor: Disconnection
Description
E03 DLF2KA (Transmission controller system)
Contents of The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are not
trouble input.
Problem that
appears on
machine
Related
information
Wrong adjustment of
1 transmission intermediate
shaft speed sensor
Defective transmission inter- 3) Connect T-adapter.
2
mediate shaft speed sensor
state 3) Connect T-adapter.
harness
Resistance Max. 1
Resistance Max. 1
(39) N2 (female) (2)
troller

FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:
MALFUNCTION
Action code Failure code Transmission intermediate shaft speed sensor: Disagreement of revolu-
Description tion speed signal
E03 DLF2LC (Transmission controller system)
The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor signal,
Contents of
and transmission output shaft speed sensor signal is different from the signal speed of the transmission
trouble
intermediate shaft speed sensor.
Problem that
appears on
machine
Related
information
Transmission intermediate 3) Connect T-adapter.
1
shaft speed sensor defective
Between N2 (male) (1), (2) ground Resistance Min. 1 M
2) Disconnect connectors ATC2 N2.
2 harness
Possible causes (Contact with ground circuit) Between ground and wiring harness
and standard between ATC2 (female) (20) N2 (female) Resistance Min. 1 M
value in normal (1)
between ATC2 (female) (20) N2 (female) Voltage Max. 1 V
(1)
troller

FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION
Action code Failure code Wheel speed sensor: Trouble (Right rear)
Description
E01 DLF8LC (Retarder controller system)
Contents of
Wheel speed signal (pulse) input to retarder controller is abnormal.
trouble
Controller
Does not control retarder.
Response
Problem that
machine
Related Input state from wheel speed sensor (right rear) can be checked with monitoring function (Code: 39704
information (rpm)).
Refer to page 7 of the electrical schematic for refererence.
Disconnection in wiring har- Between CN134 (female) (1) RCM1
Resistance Max. 1
ness (female) (22)
1
(Disconnection in wiring or Between CN134 (female) (2) RCM2
defective contact in connector) Resistance Max. 1
(female) (39)
Possible causes Between CN134 (female) (3) RCM2
Resistance Max. 1
value in normal Grounding fault in wiring har- Turn starting switch OFF and disconnect CN134. Perform troubleshoot-
state 2 ness ing without turning starting switch ON.
(Contact with ground circuit) Between CN134 (female) (3) Ground Resistance Min. 1 M
Install a T-adapter to CN134 and turn the key to ON.
3 Defective wheel speed sensor Pass a piece of metal in front of the sensor
face while measuring the voltage between Voltage 0.4 - 5V
CN134 (3) - CN134 (2).
4 Defective retarder controller If causes 1 3 are not detected, retarder controller may be defective.

FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION
Action code Failure code Wheel speed sensor: Trouble (Left rear)
Description
E01 DLF9LC (Retarder controller system)
Contents of
Wheel speed signal (pulse) input to retarder controller is abnormal.
trouble
Controller
Does not control retarder.
Response
Problem that
machine
Related Input state from wheel speed sensor (right rear) can be checked with monitoring function (Code: 39705
information (rpm)).
Refer to page 7 of the electrical schematic for refererence.
Disconnection in wiring har- Between CN137 (female) (1) RCM1
Resistance Max. 1
ness (female) (22)
1
(Disconnection in wiring or Between CN137 (female) (2) RCM2
defective contact in connector) Resistance Max. 1
(female) (39)
Possible causes Between CN134 (female) (3) RCM2
Resistance Max. 1
value in normal Grounding fault in wiring har- Turn starting switch OFF and disconnect CN134. Perform troubleshoot-
state 2 ness ing without turning starting switch ON.
(Contact with ground circuit) Between CN137 (female) (3) Ground Resistance Min. 1 M
Install a T-adapter to CN137 and turn the key to ON.
3 Defective wheel speed sensor Pass a piece of metal in front of the sensor
face while measuring the voltage between Voltage 0.4 - 5V
CN137 (3) - CN137 (2)..
4 Defective retarder controller If causes 1 3 are not detected, retarder controller may be defective.

FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
Action code Failure code Transmission output shaft speed sensor: Open circuit
Description
E03 dLt3KA (Retarder controller system)
Contents of
The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input.
trouble
Controller When ARSC operates, the controller releases the brake gradually.
Response Stops controlled ASR
Problem that
ASR is not controlled normally
appears on
ARSC is not controlled normally
machine
Related
information
Refer to pages 5, 7, 8 & 9 of the electrical schematic for refererence.
Wrong adjustment of
1 transmission output shaft
a For details, see Testing and adjusting, "Adjustment of transmission
speed sensor
speed sensor".
2
output shaft speed sensor
and standard
value in normal 1) Turn the starting switch OFF.
state Disconnection in wiring 2) Disconnect connectors ATC2, RCM2, HM3A, and N3.
harness 3) Connect T-adapter to RCM2 (female) and N3 (female).
3 (Disconnection in wiring or Wiring harness between RCM2-30 (female)
Resistance Max. 1
tor) Wiring harness between RCM2 (female)
Resistance Max. 1
(29) N3 (female) (2)
Defective retarder 2) Disconnect connectors ATC2, RCM2, and HM3A.
4 3) Connect T-adapter to RCM2 (female).
controller
Between RCM2 (female) (30) (29) Resistance 500 1,000

FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
Description
E01 dLT3KA (Retarder controller system)
Contents of
The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input.
trouble
Controller When ARSC operates, the controller releases the brake gradually.
Problem that
appears on
ARSC is not controlled normally
machine
Related
information
Wrong adjustment of
a For details, see Testing and adjusting, "Adjustment of transmission
speed sensor
speed sensor".
2
and standard
value in normal 1) Turn the starting switch OFF.
state Disconnection in wiring 2) Disconnect connectors ATC2, RCM2, HM3A, and N3.
harness 3) Connect T-adapter to RCM2 (female) and N3 (female).
3 (Disconnection in wiring or Wiring harness between RCM2-30
Resistance Max. 1
defective contact in connec- (female) (30) N3 (female) (1)
tor) Wiring harness between RCM2 (female)
Resistance Max. 1
(29) N3 (female) (2)
Defective retarder 2) Disconnect connectors ATC2, RCM2, and HM3A.
4 3) Connect T-adapter to RCM2 (female).
controller

FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN
CIRCUIT
Description
E03 DLT3KA (Transmission controller system)
Contents of The signal circuit of the transmission output shaft speed sensor is open and signals are not received by the
trouble controller.
Keeps gear speed when a problem occurs.
Controller
If shift lever is set in neutral, the transmission will stay in neutral.
Response
Turns lockup system OFF.
Operator can move the machine by following the limp home procedure.
2) Momentarily disconnect the limp home jumper from connector CN041 to set the machine in limp home
Problem that
mode. Plug the jumper back into the connector.
appears on
3) Operate gearshift lever and start machine again.
machine
a. When operating gearshift lever, release accelerator pedal.
b. Operate gearshift lever from N to D L or from N to R.
c. Machine is kept in limp home mode until starting switch is turned OFF.
Related
This failure can be checked with monitor function code: 31400 (rpm).
information
Wrong adjustment of
speed sensor
2
state 3) Connect T-adapter to ATC2 (female) and N3 (female).
harness
Resistance Max. 1
Resistance Max. 1
(29) N3 (female) (2)
Defective retarder 2) Disconnect connector ATC2.
4 3) Connect T-adapter to ATC2 (female).
controller

FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION
Action code Failure code Transmission output shaft speed sensor: Disagreement of revolution
Description speed signal
E03 dLt3LC (Retarder controller system)
Contents of Left and right wheel speed sensor signals are different from the signal speed of the transmission output
trouble shaft speed sensor.
Controller When ARSC operates, the controller releases the brake normally.
Problem that
ASR is not controlled normally.
appears on
ARSC is not controlled normally.
machine
Related
information
Refer to pages 5,7, 8 & 9 of the electrical schematic for refererence.
1
output shaft speed sensor Between N3 (male) (1) (2) Resistance 500 1,000
Between N3 (male) (1), (2) chassis
Resistance Min. 1 M
ground
2) Disconnect connectors ATC2, RCM2, HM3A, and N2.
2 harness
Possible causes
and standard between RCM2 (female) (30) ATC2 Resistance Min. 1 M
value in normal (female) (30) N2 (female) (1), HM3A (6)
state
(a contact with 24 V circuit) Wiring harness between ATC2 (female)
(30) RCM2 (female) (30) N2 (female) Voltage Max. 1 V
(1) - HM3A (6)
Defective retarder 2) Disconnect connector RCM2.
controller

FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:
MALFUNCTION
E01 dLT3LC (Retarder controller system)
Contents of Left and right wheel speed sensor signals are different from the signal speed of the transmission output
trouble shaft speed sensor.
Controller When ARSC operates, the controller releases the brake normally.
Problem that
appears on
ARSC is not controlled normally.
machine
Related
information
1
Resistance Min. 1 M
ground
2 harness
Possible causes
and standard between RCM2 (female) (30) ATC2 Resistance Min. 1 M
value in normal (female) (30) N2 (female) (1), HM3A (6)
state
(a contact with 24 V circuit) Wiring harness between ATC2 (female)
(30) RCM2 (female) (30) N2 (female) Voltage Max. 1 V
(1) - HM3A (6)
Defective retarder 2) Disconnect connector RCM2.
controller

FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREE-
MENT OF REVOLUTION SPEED SIGNAL
E03 DLT3LC (Transmission controller system)
Contents of The engine speed sensor, transmission input shaft speed sensor, and transmission intermediate speed
trouble sensor does not match transmission output shaft speed.
Controller The controller keeps the current gear speed and truns the lockup operation OFF.
Response If the shift lever is set in the N position, the controller keeps the gear in NEUTRAL.
Problem that
appears on The operator can move the truck by following the limp home procedure outlined earlier in this section.
machine
Related
information
Refer to pages 5 of the electrical schematic for refererence.
1
Resistance Min. 1 M
ground
and standard (Contact with ground circuit) Between ground and wiring harness
value in normal between ATC2 (female) (30) N3 (female) Resistance Min. 1 M
state (1)
Voltage Max. 1 V
(30) N3 (female) (1)
Defective retarder 2) Disconnect connector ATC2.
controller

FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT
Action code Failure code Brake pedal proximity switch: Short circuit
Description
E01 DNCCMA (Retarder controller system)
Contents of
Brake does not work even though the driver works the foot brake.
trouble
Controller
None in particular
Response
Problem that
appears on Brake does not operate
machine
Related
information
Refer to pages 2, 7 & 8 of the electrical schematic for refererence.
Between CN027 (female) (B) ground -
1 Defective brake pedal sensor Voltage 0V
Pedal applied
Between CN027 (female) (B) ground -
Voltage about 8 V
Pedal not applied
Possible causes
and standard Grounding fault in wiring Prepare with starting switch OFF, then perform troubleshooting without
value in normal harness turning starting switch ON.
2
state (Contact with ground circuit) Wiring harness between CN027 (female)
Brake pedal sw failure Resistance Min. 1 M
(B) RCM2 (17)
Defective retarder Check with monitoring function code: 44700
3
controller
Brake pedal applied ON
Brake pedal not applied OFF

FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT
Action code Failure code Warning alarm buzzer output: Short circuit
Description
E01 DV00KB (Machine monitor system)
Contents of
When signal is output to buzzer circuit, abnormal current flows.
trouble
Monitor Keeps abnormality until starting switch is turned OFF.
Response Turns alarm buzzer output OFF.
Problem that
appears on Alarm buzzer does not sound.
machine
Related If buzzer sounds, buzzer (-) is Sink output (Normal).
information Controller cannot detect disconnection and ground fault of wiring harness.
1)Turn starting switch OFF, disconnect the buzzer connector, and remove
buzzer.
1 Defective buzzer
2)Connect +24 V to buzzer (+) and connect GND to buzzer (-).
If buzzer does not sound, buzzer is defective. Replace.
Grounding fault in wiring Turn starting switch OFF and disconnect the buzzer connector, then per-
harness form troubleshooting without turning starting switch ON.
2
(Reference) Between CN1 (male) (13) ground Resistance Min. 1 M
Possible causes
and standard 1)Turn starting switch OFF, disconnect CN1 and the buzzer connector,
value in normal Hot short and insert T-adapter in CN1 (female).
state 3 (Contact with 24V circuit) in 2)Turn starting switch ON and perform troubleshooting.
wiring harness
Between CN1 (male) (13) ground Voltage Max. 1 V
harness turning starting switch ON. (When voltage in Cause 1 is abnormal)
4 (Disconnection in wiring or Between CN1 (female) (13) buzzer (-) Resistance Max. 1
defective contact in
connector) (Reference) Between FU3 (15) buzzer (+) Resistance Max. 1
If causes 1 4 are not detected, machine monitor may be defective.

FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT
Action code Failure code Rear brake cooling valve: Open or short circuit
Description
E01 DW78KZ (Retarder controller system)
Contents of Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned ON/
trouble OFF. Accordingly, BCV solenoid cannot be driven.
Controller Stops supplying current when BCV circuit is disconnected.
Response Turns output to BCV relay (CNR02-V) primary side OFF.
Problem that
appears on Since retarder is not cooled, it may overheat.
machine
Related
For troubleshooting for BCV relay (CNR02-V) secondary side, see [B@C7NS] or [B@C8NS]..
information
Turn starting switch OFF and disconnect CNR02-V (BCV relay), then per-
Defective CNR02-V (BCV
1 CNR02-V
relay) Resistance
(female: Wiring harness side)
Between (59) (17) 100 500
Possible causes Turn starting switch OFF and disconnect CNR02-V (BCV relay), then per-
Grounding fault in wiring
and standard form troubleshooting without turning starting switch ON.
2 harness
value in normal
(Contact with ground circuit) Between CNR02-V (female) (59) ground Resistance Min. 1 M
state
Disconnection in wiring Turn starting switch OFF and disconnect CNR02-V (BCV relay) and
harness RCM3, then perform troubleshooting without turning starting switch ON.
3 (Disconnection in wiring Between RCM3 (female) (18) CNR02-V
Resistance Max. 1
or defective contact in (female) (59)
connector) Between CNR02-V (female) (17) (ground) Resistance Max. 1
4 Defective retarder controller If no other problems are found, the retarder controller may be defective.

FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT
Action code Failure code Front brake cooling valve: Open or short circuit
Description
E01 DW79KZ (Retarder controller system)
Contents of Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned ON/
trouble OFF. Accordingly, BCV solenoid cannot be driven.
Controller Stops supplying current when BCV circuit is disconnected.
Response Turns output to BCV relay (CNR02-T) primary side OFF.
Problem that
appears on Since retarder is not cooled, it may overheat.
machine
Related
For troubleshooting for BCV relay (CNR02-T) secondary side, see [B@C6NS].
information
Turn starting switch OFF and disconnect R14 (BCV relay), then perform
troubleshooting without turning starting switch ON.
Defective CNR02-T(BCV
1 CNR02
relay) Resistance
(female: Wiring harness side)
Between (15) (57) 100 500
Possible causes Grounding fault in wiring Turn starting switch OFF and disconnect R14 (BCV relay), then perform
and standard 2 harness troubleshooting without turning starting switch ON.
value in normal (Contact with ground circuit) Between R14 (female) (1) ground Resistance Min. 1 M
state
Disconnection in wiring Turn starting switch OFF and disconnect CNR02-T (BCV relay) and
harness RCM3, then perform troubleshooting without turning starting switch ON.
3 (Disconnection in wiring Between RCM3 (female) (8) CNR02
Resistance Max. 1
or defective contact in (female) (57)
connector) Between CNR02-15 RCM3 (female) (13) Resistance Max. 1

FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE
Action code Failure code Manual emergency brake valve: Failure

Description
E03 DW7FMA (Retarder controller system)
Contents of
Emergency brake does not operate even though the driver works the manual emergency brake.
trouble
Controller
None in particular
Response
Problem that
appears on Emergency brake does not operate
machine
Related
information
Refer to page 7 & 8 of the electrical schematic for reference.
Defective manual emergency Disconnect CN169. Connect CN169 (2) - The solenoid should ener-
1
valve ground. Connect 24V supply to CN169 (1). gize.
Grounding fault in wiring Prepare with starting switch OFF, then perform troubleshooting without
2 (Contact with ground circuit)
(Emergency auto apply sw Wiring harness between CN222 (female) (1)
Possible causes Resistance Min. 1 M
failure) RMC3 (30)
and standard
value in normal Defective hot short in wiring Prepare with starting switch OFF, then turn starting switch ON and per-
state harness form troubleshooting.
3 (a contact with 24 V circuit)
(Emergency brake sw sense Wiring harness between EBS (female) (3)
Voltage Max. 1 V
failure) RCM2 (25)
Check with monitoring function code: 32101.

Defective retarder
4 Emergency brake switch ON ON
controller
Emergency brake switch OFF OFF

FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT
CIRCUIT
Action code Failure code Brake value (rear) or brake lock value trouble
Description
E03 DW7GMA (Retarder controller system)
Contents of
Brake (rear) does not operate even though the driver works the foot brake or brake lock sw.
trouble
Controller
None in particular
Response
Problem that
appears on Brake (rear) does not operate.
machine
Related
information
Defective brake valve (rear) form troubleshooting.
1
or brake lock valve
Check the brake valve and brake lock.
Disconnection in wiring Wiring harness between CN232 (female)
harness Resistance Max. 1
(B) RCM1 (24)
2 defective contact in connec- Resistance Max. 1
(B) RCM1 (18)
tor)
(Brake lock sw or brake Wiring harness between CN005 (female) (1)
Possible causes Resistance Max. 1
apply sw failure) CN164 (1)
and standard
value in normal Wiring harness between CN231 (female)
Resistance Max. 1
state (B) RCM3 (39)
3
((Brake lock sw or brake Wiring harness between CN068 (female) (3)
apply sw failure) Voltage Max. 1 V
RCM2 (35)
4 Defective retarder controller Check with monitoring function code: 35100, 34103, and 34104.
Brake pedal applied. ON
Brake pedal not applied. OFF

FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)
Action code Failure code PPC cut valve: Malfunction (Valve stuck on)
Description
E03 DWA1K4 (Retarder controller system)
Contents of
PPC cut valve pressure sensor does not respond to PPC cut valve ON command of retarder controller.
trouble
Controller
None in particular
Response
Problem that
When rear retarder brake should be cut as treatment of DX27K4 and DX28K4, rear retarder brake is not
appears on
cut.
machine
Related
If PPC cut valve has electrical trouble, code [DWA1KA], [DWA1KB] or [DWA1KY] is output.
information
PPC cut valve may have mechanical trouble. Check it directly.
1. Turn starting switch ON.
1 Defective PPC cut valve
2. Turn ASR switch ON/OFF.
Operating sound of PPC cut valve solenoid is heard.
1. Turn starting switch OFF.
2. Disconnect CN238.
3. Install T adapter on CN238.
Defective PPC cut valve 4. Prepare and turn starting switch ON.
2
pressure sensor 5. Start the engine.
CN238 (male) (B) (C) Resistance
Possible causes Key ON Min. 1 M
and standard Engine ON Max. 1
value in normal
state Turn starting switch OFF and disconnect CN238, RCM1, RCM3 and
Between CN238 (female) (C) RCM1
harness (female) (6)
3 (Disconnection in wiring or Between RCM3 (female) (1) CN237
Resistance Max. 1
defective contact in connec- (female) (1)
tor) Between CN237 (female) (2) RCM3
Resistance Max. 1
(female) (3)
Between CN238 (female) (B) ground Resistance Max. 1
Grounding fault in wiring Turn starting switch OFF and disconnect ASR7, then perform trouble-
4 harness shooting without turning starting switch ON.
(Contact with ground circuit) Between CN238 (female) (C) ground Resistance Min. 1 M

FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT
Action code Failure code PPC cut valve output circuit: Open circuit
Description
E03 DWA1KA (Retarder controller system)
Contents of
When signal is output to PPC cut valve solenoid circuit, no current flows.
trouble
Controller
None in particular
Response
Problem that
appears on When DX27K4 or DX28K4 occurs, the brakes drag.
machine
Related
Signal is not output to PPC cut valve solenoid circuit until starting switch is turned OFF once.
information
Defective PPC cut valve turning starting switch ON.
1 solenoid
CN237 (male) Resistance
(Internal disconnection)
Possible causes Between (1) (2) 5 28
and standard
Open in wiring Prepare with starting switch OFF, then perform troubleshooting without
value in normal
harness turning starting switch ON. (When check result of Cause 1 is normal)
state
2 (Disconnection in wiring Between J02 (male) (10) (9) Resistance 5 28
or defective contact in
connector) Between RCM3 (female) (3) (27) Resistance 5 28
If causes 1 and 2 are not detected, retarder controller may be defective.

FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT
Action code Failure code PPC cut valve output circuit: Short circuit
Description
E03 DWA1KB (Retarder controller system)
Contents of
When signal is output to PPC cut valve solenoid circuit, abnormal current flows.
trouble
Controller
PPC cut valve output is OFF.
Response
Problem that
appears on When DX27K4 or DX28K4 occurs, the brakes drag.
machine
Related
Signal is not output to PPC cut valve solenoid circuit until starting switch is turned OFF once.
information
Turn starting switch OFF and disconnect ASR2, then perform trouble-
Defective PPC cut valve shooting without turning starting switch ON.
1 solenoid
(Internal short circuit)
Between (1) (2) 5 28
Possible causes
Grounding fault in wiring Turn starting switch OFF and disconnect RCM3, then perform trouble-
and standard
2 harness shooting without turning starting switch ON.
value in normal
state (Contact with ground circuit) Between RCM3 (female) (27) ground Resistance Min. 1 M
Turn starting switch OFF and disconnect RCM3 and CN239, then perform
Short circuit in wiring troubleshooting without turning starting switch ON.
3 harness
(with another wiring harness) Wiring harness between RCM3 (female)
Resistance Min. 1 M
(27) RCM (female) (pin other than (15))

FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER
Action code Failure code ASR shut-off valve output circuit: Hot short fault
Description
E03 DWA1KY (Retarder controller system)
Contents of
When signal is output to PPC cut valve solenoid circuit, abnormal current flows.
trouble
Controller
None in particular
Response
Problem that
machine
Related

information
Defective PPC cut valve shooting without turning starting switch ON.
Possible causes 1 solenoid
and standard (Internal short circuit)
Between (1) (2) 5 28
value in normal
state Turn starting switch OFF and insert T-adapter in RCM3, then turn starting
Hot short (Contact with 24 V switch ON and perform troubleshooting.
2
circuit) in wiring harness
Between RCM3 (female) (27) ground Voltage Max. 1 V

FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)
Action code Failure code PPC cut valve: Malfunction (Valve does not operate)
Description
E03 DWA1MA (Retarder controller system)
Contents of
Sensor does not respond to PPC cut valve OFF command of retarder controller.
trouble
Controller

Response
Problem that
Retarder is not controlled normally.
appears on
machine
Related
If PPC cut valve has electrical trouble, see code [DWA1KA], [DWA1KB] or [DWA1KY].
information

and standard
value in normal Perform troubleshooting for failure code [DWA1K4].
state

NOTES

FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE
STUCK ON)
Action code Failure code Front brake PPC solenoid valve: Malfunction (Valve stuck on)
Description
E03 DX12K4 (Retarder controller system)
Contents of Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not return
trouble or their condition cannot be judged normally because of defect in sensor switch after they return.
Controller
Continues control.
Response
Problem that If solenoid is defective, front brake drags.
appears on If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult and
machine gear shift-down operation becomes easy.
Related
Retarder oil pressure switch state can be checked with monitoring function (Code: 34102).
information
Refer to page 7, 8 & 12 of the electrical schematic for reference.
Defective front brake
Check front brake proportional pressure reducing solenoid valve. If
1 proportional pressure
there is an abnormality (mechanical failure), repair or replace it.
reducing solenoid valve
Oil
pressure is Resistance Max. 1
ON.
reducing solenoid Between CN230 (male) (1) (2)
Oil
pressure is Resistance Min. 1 M
OFF.
2) Connect T-adapter to connector CN236, CN027, CN222, CN231, and
CN240.
Possible causes 3) Start engine.
and standard CN236 Retarder Voltage
value in normal
When not operated 81V
state Between (B) (C)
When operated Max. 1 V
Defective retarder pressure CN240 Brake Voltage
switch applied 0V
Front retard apply sw Between (B) (C)
not applied 81V
3 Brake pedal signal
Emergency auto apply sw CN027 Brake Voltage
Brake apply sw applied 0V
Front brake apply sw Between (B) (C)
not applied 81V
CN222 Retarder Voltage
When operated 81V
Between (1) (2)
When not operated 0V
CN231 Brake Voltage
applied 0V
Between (B) (C)
not applied 81V

Defective harness grounding 2) Disconnect connectors RCM1, RCM3, CN222, and CN240.
(Contact with ground circuit) 3) Connect T-adapter to RCM1 (female).
4
Front retard apply sw
Emergency auto apply sw Between ground and wiring harness between
Resistance Min. 1 M
RCM1 (female) (12) CN240 (female) (C)
Possible causes
and standard
2) Connect T-adapter to connector RCM3 (female).
value in normal
state Oil
pressure is Voltage Max. 1 V
ON.
Between RCM3 (26) (13)
Oil
pressure is Voltage 81V
OFF.

FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT
Action code Failure code Front brake PPC solenoid valve: Open circuit
Description
E03 DX12KA (Retarder controller system)
Contents of When output to front brake proportional pressure reducing valve solenoid circuit is ON, current does not
trouble flow.
Controller
Turn output to front brake proportional pressure reducing valve solenoid OFF.
Response
Problem that
appears on Retarder (front brake) does not operate.
machine
Related
information
Defective front brake 2) Connect T-adapter to connector CN230 (male).
Between CN230 (male) (1) (2) Resistance 8.5 9.1
Between CN230 (female) (1), (2) ground Resistance Min. 1 M
Possible causes 1)Turn starting switch OFF.
and standard Disconnection in wiring 2)Connect T-adapter to connectors RCM3 (female) and CN230 (female).
value in normal harness Wiring harness between RCM3 (female)
state 2 Resistance Max. 1
(Disconnection or defective (26) CN230 (female) (1)
contact) Wiring harness between RCM3 (female)
Resistance Max. 1
(13) CN230 (female) (2)
3 Defective retarder controller 2) Connect T-adapter to connector RCM3 (female).
Between RCM3 (female) (26) (13) Resistance 8.5 9.1

FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT
Action code Failure code Front brake PPC solenoid valve: Short circuit
Description
E03 DX12KB (Retarder controller system)
Contents of When output to solenoid circuit of front brake proportional pressure reducing valve is turned ON, much
trouble current flows.
Controller
Turns output to solenoid circuit of front brake proportional pressure reducing valve OFF.
Response
Problem that
machine
Related
information
Between CN230 (male) (1), (2) ground Resistance Min. 1 M
Possible causes 3) Connect T-adapter to RCM3 (female).
and standard Short circuit of harness Between ground and wiring harness
value in normal (Contact with ground between RCM3 (female) (26) CN230 Resistance Min. 1 M
state 2
circuit or contact between (female) (1)
harnesses) Between wiring harness from RCM3
(female) (26) CN230 (female) (1) and wir-
Resistance Min. 1 M
ing harness from RCM3 (female) (13)
CN230 (female) (2)
3 Defective retarder controller 2) Connect T-adapter to RCM3 (female).

FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER
Action code Failure code Front brake PPC solenoid valve: Short to power
Description
E03 DX12KY (Retarder controller system)
Contents of When output to front brake proportional pressure reducing valve solenoid circuit is OFF, electric current
trouble flows.
Controller
Turn output to front brake proportional pressure reducing valve solenoid OFF.
Response
Problem that
machine
Related
information

and standard 2) Disconnect connectors RCM3 and CN230.
value in normal 3) Connect T-adapter to RCM3 (female).
Hot short in wiring harness 4) Turn starting switch ON.
state 2
(female) (1)

FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE
DOES NOT OPERATE)
Action code Failure code Front brake PPC solenoid valve: Malfunction (valve does not operate)
Description
E03 DX12MA (Retarder controller system)
Contents of Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not return
trouble or their condition cannot be judged normally because of defect in sensor switch after they return.
Controller
Continues control.
Response
Problem that
If solenoid is defective, front brake drags.
appears on
If switch is defective or switch input circuit has disconnection, condition does not change.
machine
Related
Condition of front retarder oil pressure switch can be checked with monitoring function (Code: 34102).
information
Check front brake proportional pressure reducing solenoid valve. If
2) Connect T-adapter to connector CN230.
Oil
pressure Resistance Max. 1
is ON.
Oil
pressure Resistance Min. 1 M
is OFF.
2) Insert T-adapter in connector CN230.
Defective retarder pressure 3) Start engine.
Possible causes 3 switch CN236 Retarder Voltage
and standard Front retard apply sw
value in normal When not operated 81V
Between (1) (2)
state When operated Max. 1 V
Disconnection in wiring har- 3) Connect T-adapter to RCM3.
4 ness
Front retard apply sw Between ground and wiring harness
(female) (1)
2) Insert T-adapter in connector RCM3.
Oil
5 Defective retarder controller pressure Voltage Max. 1 V
is ON.
Oil
pressure Voltage 81V
is OFF.

FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE
STUCK ON)
Action code Failure code Right rear PPC solenoid valve: Malfunction (Valve is stuck on)
Description
Contents of Rear right brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
trouble return or their condition cannot be judged normally because of defect in sensor switch after they return.
Controller Stops controlling ASR.
Response PPC cut valve ON
Problem that
If solenoid is defective, rear right brake drags.
appears on
machine
Related
Rear right retarder oil pressure switch state can be checked with monitoring function (Code: 34104).
information
Refer to page 7, 8 &12 of the electrical schematic for reference.
Defective rear right brake
Check rear brake proportional pressure reducing solenoid valve. If
Oil
pressure is Resistance Max. 1
ON.
Oil
pressure is Resistance Min. 1 M
OFF.
2) Connect T-adapter to connector CN242, CN231, CN222, CN236,
CN240 and CN027.
and standard
Right retard apply Retarder not operated 81V
value in normal
state Between CN242 (B) - (C) Retarder operated Max. 1 V
Defective rear right retarder Brake apply switch Brake not applied 81V
pressure switch Between CN231 (B) - (C) Brake applied Max. 1 V
Right retard apply sw
Emergency auto apply not applied Max. 1 V
Brake apply switch
3 Brake lock switch sense Between CN122 (1) - (2) applied 81V
Brake pedal signal Front retard apply Retarder not operated 81V
Emergency auto apply sw. Between CN236 (B) - (C) Retarder operated Max. 1 V
Front brake apply sw Front brake apply Brake not applied 81V
Between CN240 (B) - (C) Brake applied Max. 1 V
Brake pedal signal Brake applied 81V
Between CN027 (B) - (C) Brake not applied Min. 1 V
Brake lock Brake lock ON Pilot lamp on
Check with monitor func-
tion code: 39900 Brake lock OFF Pilot lamp off

Defective harness grounding 2) Disconnect connectors RCM1, CN242, CN232 and RCM3.
4
Right retard apply sw Between ground and wiring harness between
Resistance Min. 1 M
Emergency auto apply sw RCM1 (female) (24) CN242 (female) (B)
Possible causes Between RCM3 (30) CN222 (1) Resistance Min. 1 M
and standard
value in normal 1) Turn starting switch OFF.
state 2) Connect T-adapter to connector RCM3 (female).
Oil pres-
Voltage Max. 1 V
5 Defective retarder controller sure is ON.
Between RCM3 (6) (23) Oil pres-
sure is Voltage 81V
OFF.

FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT
Action code Failure code Right rear PPC solenoid valve: Open circuit
Description
Contents of When output to rear right brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Controller
Turn output to rear brake proportional pressure reducing valve solenoid OFF.
Response
Problem that
appears on Retarder (rear right brake) does not operate.
machine
Related
information
Defective rear right brake 2) Connect T-adapter to connector CN172 (male).
value in normal harness Wiring harness between RCM3 (female) (6)
(Disconnection or defective CN172 (female) (1)
Resistance Max. 1
(23) CN172 (female) (2)

FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT
Action code Failure code Rght rear PPC solenoid valve: Short circuit
Description
Contents of When output to solenoid circuit of rear right brake proportional pressure reducing valve is turned ON, much
Controller
Turns output to solenoid circuit of rear right brake proportional pressure reducing valve OFF.
Response
Problem that
machine
Related
information
state 2
(female) (6) CN172 (female) (1) and wiring
Resistance Min. 1 M
harness from RCM3 (female) (23) CN172
(female) (2)
Between BRC3 (female) (6) (23) Resistance 8.5 9.1

FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER
Action code Failure code Rght rear PPC solenoid valve: Short to power
Description
Contents of When output to rear right brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Controller
Turn output to rear brake proportional pressure reducing valve solenoid OFF.
Response
Problem that
machine
Related
information
Between CN172 (male) (1) (2) Resistance 10 30

state 2
(female) (1)
Between RCM3 (female) (6) (23) Resistance 10 30

FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION
Action code Failure code Rght rear PPC solenoid valve: Malfunction (valve does not operate)
Description
Contents of Rear right brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Controller
Continues control.
Response
Problem that
If solenoid is defective, rear right brake drags.
appears on
machine
Related
Condition of rear right retarder oil pressure switch can be checked with monitoring function (Code: 34104)
information
Oil
is ON.
Oil
is OFF.
Defective rear right retarder 3) Start engine.
Possible causes 3 pressure switch CN242 Retarder Voltage
and standard Right retard apply sw
Between (B) (C)
4 ness.
Right retard apply sw Between ground and wiring harness
between BRC1 (female) (24) CN242 Resistance Min. 1 M
(female) (B)
Oil
is ON.
Oil
is OFF.

FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION
Action code Failure code Left rear PPC solenoid valve: Malfunction (Valve is stuck on)
Description
Contents of Rear left brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Controller Stops controlling ASR.
Response PPC cut valve ON.
Problem that
appears on If solenoid is defective, rear left brake drags.
machine
Related
Rear left retarder oil pressure switch state can be checked with monitoring function (Code: 34103).
information
Refer to page 7, 8 & 12 of the electrical schematic for reference.
Defective rear left brake
Check rear brake proportional pressure reducing solenoid valve. If there
is an abnormality (mechanical failure), repair or replace it.
Oil
is ON.
Oil
is OFF.
2) Connect T-adapter to connector CN233, CN231, CN222, CN236,
CN240 and CN027.
and standard
Left retard apply Retarder not operated 81V
value in normal
state Between CN233 (B) - (C) Retarder operated Max. 1 V
Defective rear left retarder Brake apply switch Brake not applied 81V
pressure switch Between CN231 (B) - (C) Brake applied Max. 1 V
Left retard apply sw
Emergency auto apply not applied Max. 1 V
Brake apply sw
3 Brake lock sw sense Between CN122 (1) - (2) applied 81V
Brake pedal signal Front retard apply Retarder not operated 81V
Emergency auto apply sw Between CN236 (B) - (C) Retarder operated Max. 1 V
Front brake apply sw Front brake apply Brake not applied 81V
Between CN240 (B) - (C) Brake applied Max. 1 V
Brake pedal signal Brake applied 81V
Between CN027 (B) - (C) Brake not applied Min. 1 V
Brake lock Brake lock ON Pilot lamp on
Check with monitor func-
tion code: 39900 Brake lock OFF Pilot lamp off

Defective harness grounding 2) Disconnect connectors RCM1 and CN233.
4
Left retard apply sw
Emergency auto apply sw Between ground and wiring harness between
Resistance Min. 1 M
RCM1 (female) (5) CN233 (female) (B)
Possible causes
and standard
2) Connect T-adapter to connector RCM3 (female).
value in normal
state Oil
pressure Voltage Max. 1 V
is ON.
Oil
is OFF.

FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT
Action code Failure code Rear left brake proportional pressure reducing solenoid valve output cir-
Description cuit: Disconnection
Contents of When output to rear left brake proportional pressure reducing valve solenoid circuit is ON, current does not
trouble flow.
Controller
Turn output to rear left brake proportional pressure reducing valve solenoid OFF.
Response
Problem that
appears on Retarder (rear left brake) does not operate.
machine
Related
information
Defective rear left brake 2) Connect T-adapter to connector CN173 (male).
value in normal harness Wiring harness between RCM3 (female)
(Disconnection or defective (16) CN173 (female) (1)
Resistance Max. 1
(23) CN173 (female) (2)

FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT
Action code Failure code Left rear PPC solenoid valve: Short circuit
Description
Contents of When output to solenoid circuit of rear left brake proportional pressure reducing valve is turned ON, much
Controller
Turns output to solenoid circuit of rear left brake proportional pressure reducing valve OFF.
Response
Problem that
machine
Related
information
state 2
(female) (16) CN173 (female) (1) and wir-
Resistance Min. 1 M
ing harness from RCM3 (female) (23)
CN173 (female) (2)

FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER
Action code Failure code Left rear PPC solenoid valve: Short to power
Description
Contents of When output to rear left brake proportional pressure reducing valve solenoid circuit is OFF, electric current
trouble flows.
Controller
Turn output to rear left brake proportional pressure reducing valve solenoid OFF.
Response
Problem that
machine
Related
information

state 2
(female) (1)

FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE
DOES NOT OPERATE)
Action code Failure code Left rear PPC solenoid valve: Malfunction (Valve does not operate)
Description
Contents of Rear left brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Controller
Continues control.
Response
Problem that
If solenoid is defective, rear left brake drags.
appears on
machine
Related Condition of rear left retarder oil pressure switch can be checked with monitoring function (Code: 34103)
information (bit [3], 0:OFF, 1:ON).
Oil
is ON.
Oil
is OFF.
Defective rear left retarder 3) Start engine.
Possible causes 3 pressure switch CN233 Retarder Voltage
and standard Left retard apply sw
Between (1) (2)
4 ness
Left retard apply sw Between ground and wiring harness
(female) (1)
Oil
is ON.
Oil
is OFF.

FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code Lockup clutch ECMV output circuit: Open ciruit
Description
E03 DXH1KA (Transmission controller system)
Contents of
When signal is output to lockup clutch ECMV, no current flows.
trouble
Keeps gear speed used for travel.
Controller
Turns lockup operation OFF.
Response
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
Lockup system does not operate.
appears on
If gearshift lever is set in N, machine cannot restart until it stops.
machine
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Related infor- Output current to lockup ECMV can be checked with monitoring function (Code: 31609 (mA)).
mation Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
2) Connect T-adapter to connector CN17 (L/U,PS) (male).
ECMV
Resistance Min. 1 M
ground
and standard 2) Connect T-adapter to connectors ATC3 (female) and CN17 (L/U,PS)
value in normal Disconnection in wiring (female).
state harness
(Disconnection or improper Resistance Max. 1
contact)
Resistance Max. 1
3
controller
Between ATC3 (female) (35) (23) Resistance 5 15

FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code Lockup clutch ECMV output circuit: Short circuit
Description
E03 DXH1KB (Transmission controller system)
Contents of
Abnormally excessive current flows while output to lockup clutch ECMV is ON.
trouble
Controller Keeps gear speed used for travel and turns lockup operation OFF.
Response Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
Lockup system is kept OFF.
appears on
If gearshift lever is set in N, machine cannot restart until it stops.
machine
Related infor-
Output current to lockup ECMV can be checked with monitoring function (Code: 31609 (mA)).
mation
ECMV
Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN17 (L/U,PS).
Possible causes
3) Connect T-adapter to ATC3 (female).
and standard
value in normal Short circuit of harness Between ground and wiring harness
state (Contact with ground circuit between ATC3 (female) (35) CN17 (L/ Resistance Min. 1 M
2
or contact between har- U,PS) (female) (1)
nesses) Between wiring harness from ATC3 (female)
(35) CN17 (L/U,PS) (female) (1) and wir-
Resistance Min. 1 M
ing harness from ATC3 (female) (23)
3
controller

FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code Lockup clutch ECMV output circuit: Short to power
Description
E03 DXH1KY (Transmission controller system)
Contents of
While output to lock-up clutch ECMV is OFF, electric current flows.
trouble
Controller Keeps gear speed used for travel and turns lockup operation OFF.
Response Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that Cannot change gear speed.
appears on Keeps lockup OFF
machine When gear shift lever is operated to N, machine cannot move off.
Related infor-
Output current to lockup ECMV can be checked with monitoring function (Code: 31609 (mA))
mation
ECMV
Resistance Min. 1 M
ground
and standard 2) Disconnect connectors ATC3 and CN17 (L/U,PS).
value in normal 3) Connect T-adapter to ATC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
between ATC3 (female) (35) CN17 (L/ Voltage Max. 1 V
U,PS) (female) (1)
3
controller

FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code High clutch ECMV output circuit: Open circuit
Description
Contents of
No electric current flows when the output to Hi clutch ECMV is ON.
trouble
Response Turns lock up to OFF.
Problem that
appears on Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
machine
repair.
Related infor- Electric current of output to ECMV can be checked with monitoring function (code: 31600 (mA)).

2) Connect T-adapter to connector CN13(H,PS) (male).
1 Defective Hi clutch ECMV Between CN13(H,PS) (male) (1) (2) Resistance 5 15
Between CN13(H,PS) (male) (1), (2)
Resistance Min. 1 M
ground
and standard 2) Connect T-adapter to connectors ATC3 (female) and CN13(H,PS)
state harness
(Disconnection or Resistance Max. 1
CN13(H,PS) (female) (1)
defective contact)
Resistance Max. 1
CN13(H,PS) (female) (2)
Defective transmission con- 2) Connect T-adapter to connector ATC3 (female).
3
troller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code High clutch ECMV output circuit: Short circuit
Description
Contents of
Abnormally excessive current flows while output to Hi clutch ECMV is ON.
trouble
Problem that
machine
Related infor-
Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA)).
mation

Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN13 (H,PS).
Possible causes
and standard
state (Contact with ground circuit between ATC3 (female) (26) CN13 (H,PS) Resistance Min. 1 M
2
or contact between har- (female) (1)
(26) CN13 (H,PS) (female) (1) and wiring
Resistance Min. 1 M
harness from ATC3 (female) (13) CN13
(H,PS) (female) (2)
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF
*Combination not normally used

FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code High clutch ECMV output circuit: Short to power
Description
Contents of
When output to Hi clutch ECMV is OFF, electric current flows.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
and standard 2) Disconnect connectors ATC3 and CN3 (H,PS).
2
between ATC3 (female) (26) CN3 (H,PS) Voltage Max. 1V
(female) (1)
3
controller

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code Low clutch ECMV output circuit: Open circuit
Description
Contents of
Current does not flow when output to low clutch ECMV is ON.
trouble
Problem that
machine
repair.

1 Defective Lo clutch ECMV Between CN11 (L,PS) (male) (1) (2) Resistance 5 15
Resistance Min. 1 M
ground
Possible causes
2) Connect T-adapter to connectors ATC3 (female) and CN11 (L,PS)
and standard Disconnection in wiring (female).
state 2 Wiring harness between ATC3 (female) (6)
contact)
Resistance Max. 1
3
Resistance 5 15
(3)

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code Low clutch ECMV output circuit: Short circuit
Description
Contents of
Abnormally excessive current flows while output to low clutch ECMV is ON.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN11 (L,PS).
Possible causes
and standard
state (Contact with ground circuit between ATC3 (female) (6) CN11 (L,PS) Resistance Min. 1 M
2
(6) CN11 (L,PS) (female) (1) and wiring
Resistance Min. 1 M
(L,PS) (female) (2)
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code Low clutch ECMV output circuit: Short to power
Description
Contents of
When output to low clutch ECMV is turned OFF, current flows to circuit.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
Possible causes
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect connectors ATC3 and CN11 (L,PS).
state 3) Connect T-adapter to ATC3 (female).
2
between ATC3 (female) (6) CN11 (L,PS) Voltage Max. 1 V
(female) (1)
Defective transmission Turn starting switch OFF.
3
controller Between ATC3 (female) (6) (3) Resistance 5 15

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code 1st clutch ECMV output circuit: Disconnection
Description
Contents of
Current does not flow when output to 1st clutch ECMV is ON.
trouble
Problem that
machine
repair.

1 Defective 1st clutch ECMV Between CN7 (L,PS) (male) (1) (2) Resistance 5 15
Resistance Min. 1 M
ground
Possible causes
and standard
Disconnection in wiring 2) Connect T-adapter to ATC3 (female) and CN7 (L,PS) (female).
value in normal
state harness Wiring harness between ATC3 (female) (36)
2 Resistance Max. 1
(Disconnection or improper CN7 (L,PS) (female) (1)
contact) Wiring harness between ATC3 (female) (3)
Resistance Max. 1
Defective transmission 2) Connect T-adapter to ATC3 (female).
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code 1st clutch ECMV output circuit: Short circuit
Description
Contents of
Abnormally excessive current flows when output to 1st clutch ECMV is ON.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2) Disconnect connectors to ATC3 and CN7 (1,PS).
Possible causes
and standard
state (Contact with ground circuit between ATC3 (female) (36) CN7 (1,PS) Resistance Min. 1 M
2
(36) CN7 (1,PS) (female) (1) and wiring
Resistance Min. 1 M
(1,PS) (female) (2)
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code 1st clutch ECMV output circuit: Short to power
Description
Contents of
When output to 1st clutch ECMV is "OFF", current flows to circuit.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
and standard 2) Disconnect connectors ATC3 and CN7 (1,PS).
2
between ATC3 (female) (36) CN7 (1,PS) Voltage Max. 1 V
(female) (1)
3
controller

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code 2nd clutch ECMV output circuit: Open circuit
Description
Contents of
Current does not flow when output to 2nd clutch ECMV is ON.
trouble
Problem that
machine
repair.

Resistance Min. 1 M
ground
and standard 2) Connect T-adapter to connectors ATC3 (female) and CN9 (2,PS)
state harness
contact)
Resistance Max. 1
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code 2nd clutch ECMV output circuit: Short circuit
Description
Contents of
Abnormally excessive current flows while output to 2nd clutch ECMV is ON.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN2 (2,PS).
Possible causes
and standard
state (Contact with ground circuit between ATC3 (female) (5) CN8 (female) Resistance Min. 1 M
2
or contact between har- (1)
Resistance Min. 1 M
(2,PS) (female) (2)
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code 2nd clutch ECMV output circuit: Short to power
Description
Contents of
When output to 2nd clutch ECMV is "OFF", current flows to circuit.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2
(a contact with 24V circuit)
(female) (1)
3
controller

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code 3rd clutch ECMV output circuit: Open circuit
Description
Contents of
Current does not flow when output to 3rd clutch ECMV is ON.
trouble
Response Disengages the lockup circuit.
Problem that
appears on Machine cannot move off in any gear speeds.
machine
repair.

Resistance Min. 1 M
ground
and standard 2) Disconnect T-adapter connectors to ATC3 (female) and CN3 (3,PS)
value in normal Disconnection in wiring (male).
state harness
contact)
Resistance Max. 1
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code 3rd clutch ECMV output circuit: Short circuit
Description
Contents of
Abnormally excessive current flows while output to 3rd clutch ECMV is ON.
trouble
Response The controller disengages the lockup circuit.
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN3 (3,PS).
Possible causes
and standard
state (Contact with ground circuit between ATC3 (female) (15) CN3 (3,PS) Resistance Min. 1 M
2
Resistance Min. 1 M
(3,PS) (female) (2)
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code 3rd clutch ECMV output circuit: Short to power
Description
Contents of
When output to 3rd clutch ECMV is OFF, current flows to circuit.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2
(female) (1)
3
controller

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code R clutch ECMV output circuit: Open circuit
Description
Contents of
Current does not flow when output to R clutch ECMV is ON.
trouble
Problem that
appears on Machine can not move off in any gear speeds.
machine
repair.

2) Connect T-adapter to connector CN5 (R,PS) (male).
Resistance Min. 1 M
ground
and standard 2) Connect T-adapter to connectors ATC3 (female) and CN5 (R,PS)
state harness
contact)
Resistance Max. 1
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code R clutch ECMV output circuit: Short circuit
Description
Contents of
Abnormally excessive current flows while output to R clutch ECMV is ON.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
2) Disconnect connectors ATC3 and CN5 (R,PS).
Possible causes
and standard
state (Contact with ground circuit between ATC3 (female) (25) CN5 (R,PS) Resistance Min. 1 M
2
(25) CN5 (R,PS) (female) (1) and wiring
Resistance Min. 1 M
(R,PS) (female) (2)
3
controller

TABLE 1
detected
F7
F6
Mid Mid 3H F7 OFF
2nd 2nd 3M F6 OFF
F5
High High 3M F6 OFF
2nd 2nd 3M F6 OFF
F4
Mid Mid 2H F5 OFF
1st 1st 2M F4 OFF
F3
High High 2M F4 OFF
1st 1st 2M F4 OFF
F2
Mid Mid 1H F3 OFF
2nd 2nd 1M F2 OFF
F1
Low Low 1M F2 OFF
R
Low Low RM R* OFF

FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code R clutch ECMV output circuit: Short circuit to power source line
Description
Contents of
When output to R clutch ECMV is OFF, current flows to circuit.
trouble
Problem that
machine
Related infor-
mation

Resistance Min. 1 M
ground
and standard 2) Disconnect connectors ATC3 and CN5 (R,PS).
2
between ATC3 (female) (25) CN5 (R,PS) Voltage Max. 1 V
(female) (1)
3
controller

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

NOTES

FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code Failure code Mid clutch ECMV output circuit: Open circuit
Description
E03 DXJ7KA (Transmission controller system)
Contents of
Current does not flow when output to Mid clutch ECMV is ON.
trouble
Controller Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure
Problem that
appears on Once the gear shift lever is set to neutral, the machine cannot move off in any gear speeds.
machine
repair.

1 Defective Hi clutch ECMV
Possible causes
and standard Disconnection in wiring (female).
state 2 Wiring harness between ATC3 (female) (16)
(Disconnection or Resistance Max. 1
defective contact)
Resistance Max. 1
Defective transmission con- 2) Connect T-adapter to connector ATC3 (female).
3
troller

FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code Failure code Mid clutch ECMV output circuit: Short circuit
Description
E03 DXJ7KB (Transmission controller system)
Contents of
Excessive current flows while output to Mid clutch ECMV is ON.
trouble
Problem that
machine
Related infor-
mation

2) Disconnect connectors ATC3 and CN15 (M,PS).
Possible causes
and standard Short circuit of harness
value in normal Between ground and wiring harness between
(Contact with ground circuit Resistance Min. 1 M
state 2 ATC3 (female) (26) CN15 (M,PS) (female) (1)
(26) CN15 (M,PS) (female) (1) and wiring har-
Resistance Min. 1 M
ness from ATC3 (female) (03) CN15 (M,PS)
(female) (2)
3
controller

FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code Failure code Mid clutch ECMV output circuit: Short circuit to power source line
Description
E03 DXJ7KY (Transmission controller system)
Contents of
When output to Mid clutch ECMV is turned "OFF", current flows to circuit.
trouble
Problem that
machine
Related infor-
mation

and standard 2) Disconnect connectors ATC3 and CN15 (M,PS).
value in normal Hot short in wiring harness 3) Connect T-adapter to ATC3 (female).
state 2 4) Turn starting switch ON.
Between ground and wiring harness between
Voltage Max. 1V
ATC3 (female) (16) CN15 (M,PS) (female) (1)
3
controller

TABLE 2
3rd
High
3rd
Mid
High 3H F7 OFF
3rd 3M F6 OFF
2nd
High
Mid 3M F6 OFF
3rd 3M F6 OFF
2nd
Mid
High 2H F5 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
High
Mid 2M F4 OFF
3rd 3M F6 OFF
2nd 2M F4 OFF
1st
Mid
High 1H F3 OFF
3rd 3M F6 OFF
1st 1M F2 OFF
2nd
Low
High 1H F3 OFF
Mid 1M F2 OFF
Reverse
Low
High RH R* OFF
Mid RM R* OFF

TABLE 2

Mid

SECTION D30
VHMS INITIALIZATION
INDEX
INITIALIZATION OF VHMS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-3
Executing Quick PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-14
Downloading Existing VHMS Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-19
Confirmation of Downloaded Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-20
Disconnecting the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-20
Reporting to Komatsu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-20
REPLACING THE VHMS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-22
Prior to Removing VHMS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-22
Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1) . . . . . . . . . D30-22
Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1) . . . D30-26
Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer) . . . . . . . . . . . D30-28
Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer) . . . . . D30-29
FINAL VHMS PROCEDURES-POST INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-30
Correct the Load Weight Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30-32
D30003 VHMS D30-1

NOTES
D30-2 VHMS D30003

INITIALIZATION OF VHMS CONTROLLER 1. Confirm and record the machine information
specified in the table below.
Tools
Machine Information
Part Number Description
Model name
799-608-3211 Software Disc
Machine serial number
799-608-3220 Download Cable
Current service meter hour
Commercially Laptop PC - Windows 98/2000, ME,
Engine serial number
available XP - terminal RS232C
Transmission serial number
Initial setting of the VHMS controller must be VHMS controller serial number
done according to the following procedure. ORBCOMM terminal serial number
VHMS initialization is necessary prior to new
truck operation, and before resuming truck
operation after a long period in storage. 2. Turn the key switch to the OFF position. Con-
nect the download harness to the PCs RS232C
Machine data collected by the VHMS controller is terminal and the other end to download connec-
stored and managed on the WebCARE tor HM6VA. Download connector HM6VA is
database. In order to ensure smooth data located behind the passenger seat or at the
processing on WebCARE, consistency must be
ground level download box. Refer to Figures
maintained when setting the VHMS controller.
Inconsistencies in the settings cause WebCARE 30-1 and 30-2.
data loading problems, reducing the
effectiveness and accuracy of VHMS data.
Therefore, it is important to perform the VHMS
setting procedures correctly.
Refer to the help manual that comes with the
download software for help with installing the
VHMS initialization program.
In the procedure, service menus on the monitor
panel are used. Thus, it is advisable to
understand how to use the machine monitor
panel on the electronic display panel (EDP).
The initial setting procedures cover the
ORBCOMM Specification. When using the
ORBCOMM Specification, use only the
procedures needed for the VHMS. FIGURE 30-1. CAB DOWNLOAD PORT
During VHMS initialization, use the VHMS Initial
Setting Work Check Sheet located in this chapter.
D30003 VHMS D30-3

c. Verify that the ORBCOMM controller is cap-
turing the communication satellite from the
VHMS controller. This check must be done
within 3 minutes after the VHMS is powered.
Observe the LEDs situated in the right side
of VHMS controller. Refer to the decimal
point on the right hand digit to verify that the
ORBCOMM controller has captured the
communication satellite. If the decimal point
blinks slowly, the ORBCOMM controller is
operating normally. Communication between
the terminals is normal. The terminals have
transmission data and have captured the
satellite.
FIGURE 30-2. GROUND LEVEL DOWNLOAD

PORT
3. Confirm VHMS controller operation and satellite

capture. Confirmation of capturing of the satel-
lite is done for [ORBCOMM installation specifi- If the decimal point is not blinking slowly,
cation]. refer to the following list for status descrip-
a. Turn the key switch ON. tions.
b. Check the 7-segment LED on the VHMS OFF: The terminals cannot communicate
controller. The VHMS controller is powered with the ORBCOMM terminal.
with the accessory power supply. Accord-
ON (steady): Communication between the
ingly, when the key switch is turned ON, the
terminals is normal. The terminals have not
7-segment LED must blink to display rotation
captured the satellite.
and then count up in hexadecimal notation. If
the LED operates in this way, the VHMS con- Quick blink: Communication between the ter-
troller is operating normally. minals is normal. The terminals do not have
transmission data but have captured the sat-
ellite.
D30-4 VHMS D30003

4. Turn on the PC. Start up the VHMS initial set- 7. Click [OK] to proceed to the setup screen.
ting tool by clicking on the VHMS icon.
Appearance of the setup screen of the VHMS set-

ting tool depends its version.
When using a version older than 3.5.2.1 (CD-
ROM), the setting procedures must conform to
those described in steps 8 thru 21.
When using Version 3.5.2.1 or newer, the proce-
dures in steps 22 thru 31 must be used.
It is recommended to download the latest VHMS
version from WebCARE to update the currently
used version.
5. Enter the 10-digit service ID to [Service ID].
Service ID: 7826133000
6. Select [Data clear and Set up] from the [Select
Function] box.
D30003 VHMS D30-5

NOTE: For Version 3.5.2.1 and newer, proceed to b. After correcting the information, press the
step 22, all older versions proceed to the next step. [OK] button.
Versions older than 3.5.2.1:
8. Open the [Machine Information] tab. [Data clear
and Set up] menu displays [Machine Informa-
tion] tab first.
9. Check all data for correctness. The figure
shows the display of another model as an
example.
10. Select a [Variation Code] from Table 1.
12. When [Machine Information] information is not

appropriate, do the following:
a. Press the [Edit] button in the lower right side
of the [Machine Information] dialog box to
display the correction screen.
b. After correcting the information, press the
[OK] button.
11. To correct [Date/Time] information, do the fol-

lowing:
a. Press [Edit] in the lower right side of the
[Date/Time] box to display the correction
screen.
Table 1: VHMS Settings

Date/Time
Time Difference
VHMS Controller Engine Model Model Type Variation Code
(GMT)
Summertime
Installed SDA12V160 T1
HD1500 -7 Set Properly
Installed SSA16V159 T2
D30-6 VHMS D30003

13. After the data in [Machine Information] has been
checked and corrected, press the [Apply] button
to finalize the setting. After the [Apply] button is
pressed, a message confirming the setting will
appear on the screen. Check the setting again,
and if the setting is correct, press the [OK] but-
ton.
a. ORBCOMM installation requires the settle-
ment operation after [Communication Set-
ting] is completed.
16. When modifying the setting of [SHORT FAULT

HISTRY], use the following procedure:
a. Select [SHORT FAULT HISTRY] from the
screen. Press the [Edit] button in the lower
left side of [File Transfer Setting] block to dis-
play the setup screen.
b. Correct the setting and, press the [OK] but-
ton.
During the initial setting, select [Occurrence]
from the [Timing] box and then set the function
to ON.
14. [Communication Setting] [ORBCOMM installa-

tion specification only]
a. This setting shall be implemented after the
request for station opening has been made
and station of ORBCOMM has been opened.
15. Open the [Communication Setting] tab. Check
the data and verify that it is correct.
D30003 VHMS D30-7

17. When modifying the setting of [SHORT TREND GCC Codes & Applicable Regions
ANALYSIS], use the following procedure:
Code Applicable Region
a. Select [SHORT TREND ANALYSIS] from the 1 North and South America
screen and then press the [Edit] button in the
120 Italy
lower left side of the [File Transfer Setting]
block to display the setup screen. 121 Malaysia
b. Correct the setting and, press the [OK] but- 122 Korea
ton. 130 Japan
During the initial setting, enter [20] to [SMR] and

then set the function to ON.
19. After the data in [Communication Setting] has
been verified and corrected, press the [Apply]
button. After the [Apply] button is pressed, a
message confirming the setting will appear on
the screen. Check the settings again and, if cor-
rect, press the [OK] button.
18. When modifying the [Satellite Setting], use the

following procedure:
a. Press the [Edit] button in the [Satellite Set-
ting] block to display the correction screen.
b. Set the GCC code to the region applied and
press the [OK] button.
D30-8 VHMS D30003

20. After the data in [Machine Information] and NOTE: Version 3.5.2.1 or newer:
[Communication Setting] has been checked and 22. Select the [VHMS Setting] and then press the
corrected, press the [Exit] button to end the [Next] button.
[VHMS initial setting tool].
23. Select [Set up & All clear] and press the [Next]
21. Fill in the necessary information on the ORB- button.
COMM activation form later in this chapter.
Send by fax or by mail to Customer Support Gr.
Solution Division, Komatsu Ltd.
D30003 VHMS D30-9

24. Confirm the machine information and, if correct, 25. Enter the correct date and time information.
press the [Next] button. Selecting DST advances the clock by an hour.
Thus, correction of the time is needed again.
Click the [Next] button when complete.
D30-10 VHMS D30003

26. Set the GCC code to the target region of appli- 27. If all of the displayed information is correct, click
cation and, as setting is completed, press the the [Apply] button.
[Next] button.
GCC Codes & Applicable Regions

Code Applicable Region
1 North and South America
120 Italy
121 Malaysia
122 Korea
130 Japan
28. A screen message will ask whether or not a

copy of the data file is to be saved. If a copy of
the data is not necessary, select [NO].
D30003 VHMS D30-11

29. After the setting is complete, press the [OK] but-
ton to end the program.
30. Turn the key switch to OFF. The LED display on

the VHMS controller should remain lit for sev-
eral seconds before turning off.
31. Fill in the necessary information on the ORB-

COMM activation form on the following page.
Send by fax or by mail to Customer Support Gr.
Solution Division, Komatsu Ltd.
D30-12 VHMS D30003

D30003 VHMS D30-13
Executing Quick PM 6. Press mode switch [] to start the snapshot.
Quick PM denotes the PM clinic done by using the After the snapshot is started, the upper column
manual snapshot function on the machine monitor. It starts displaying the elapsed time.
stores 7 minutes and 30 seconds worth of data to the
The [] in the leftmost position of the lower col-
VHMS controller.
umn is replaced with [*] for every 30 seconds.
1. Park the machine on level ground. When two or more [*] signs are displayed, the
2. Start the engine. rightmost one flashes.
3. Switch the machine monitor to service menu. To stop the snapshot, press mode switch [].
4. Display the manual snapshot function screen
from the menu screen of service mode.
5. Press mode switch []. [READY] will be dis-

played on the screen and the monitor will switch
to standby mode. The lower column displays 15
[] symbols.
D30-14 VHMS D30003

7. After the snapshot has started, operate the
machine according to Table 2.
Verify that the engine coolant temperature and
the torque converter oil temperature are within
the operating range.
After the 10th [*] is displayed (5 minutes
elapsed from the start), [#] will be displayed for
11th through the 15th positions.
*: Indicates the data sampling interval is once
every 10 seconds.
#: Indicates the data sampling interval is once
every 1 second.
Table 2: Machine Operation For Snapshot

Measurement conditions
Start Finish Time Engine Speed AISS Shift Parking Hoist Remarks
Retarder
switch lever brake lever
1 0:00 2:00 120 sec Low idle (Low) Auto N ON ON HOLD
2 2:00 3:00 60 sec Low idle (Hi) Auto N OFF OFF HOLD (*1)
3 3:00 4:00 60 sec High idle (Stationary) Auto N ON ON FLOAT
4 4:00 5:00 60 sec Low idle (Hi) Auto N ON ON HOLD
5 5:00 5:30 30 sec High idle Auto N ON ON HOLD
6 5:30 6:00 30 sec Torque converter stall Auto D OFF ON HOLD (*2, *3)
High idle
7 6:00 6:30 30 sec & Auto N ON ON HOLD
20 pumps of foot brake
(*1) Press the brake pedal.

(*2) Monitor the torque converter oil temperature when stalling. DO NOT allow the oil to overheat. Stalling the torque converter
for 30 seconds is only a reference. If the oil temperature gauge reaches the top of the white range while the torque converter is
stalled, discontinue stalling. Allow the engine to idle, and return the shift lever to the N position.
(*3) Before moving the shift lever to the D position, return the engine speed to low idle.
D30003 VHMS D30-15

8. After 7 minutes and 30 seconds have elapsed Data from the Quick PM is recorded only once. Thus,
from the start of the snapshot, the following if another Quick PM is repeated, the current data will
screen appears. The initial screen is then be overwritten with the last one. Ensure that all data
restored in 5 seconds. is downloaded from the completed Quick PM to the
PC. For the procedure, refer to Downloading Existing
VHMS Data later in this chapter for more information.
9. Read the Quick PM data by using the analysis

tool.
D30-16 VHMS D30003

10. Apply a check mark to the Display graph value
at click position.
D30003 VHMS D30-17

11. Clicking the graph shows, below the graph, the
X-axis value of respective measurement items.
(An example of a graph displayed Not an
actual one)
D30-18 VHMS D30003

Downloading Existing VHMS Setting Data 3. When using the ground level download connec-
tor, move switch (2, FIGURE 30-4) to the ON
position. The green LED (3) will illuminate.
Before connecting or disconnecting the PC, turn

the key switch to the OFF position.
1. Use the download harness to connect the PC to

download connector (1, FIGURE 30-3) located
in the cab or download connector at the ground
level port.
2. When using the download connector in the cab,
move the key switch to the ON position.
FIGURE 30-4. GROUND LEVEL DOWNLOAD
PORT
4. Click on the VHMS icon to

start the VHMS analysis tool.
5. Enter [User Name] and [Password].
FIGURE 30-3. CAB DOWNLOAD PORT
D30003 VHMS D30-19

6. Using the [Download] function, download the Disconnecting the PC
data currently recorded in VHMS to the PC. Ver- 1. Turn the key switch to the OFF position.
ify that the download is complete and proceed
to the next step.
Before connecting or disconnecting the PC, turn

the key switch to the OFF position.
2. End all applications on the PC and turn off the

power.
3. Disconnect the harness from the download con-
nector and the PC.
Confirmation of Downloaded Data
1. Confirm the setting data using the [View] func-
tion. Reporting to Komatsu
a. Ensure that the [MFA0] code, which was Complete and send the VHMS/WebCARE report to
used in the quick snapshot, is indicated in the VHMS/WebCARE Support Center at Komatsu
[Fault History]. Headquarters.
b. Verify that the snapshot data was recorded. This report is for satellite communications to occur.
In this case, send VHMS data via Notes (LAN) or
E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
2. When finished, close out of the [VHMS analysis E-mail: webcare@komatsu.co.jp

tool].
D30-20 VHMS D30003

D30003 VHMS D30-21
REPLACING THE VHMS CONTROLLER Confirming and Saving VHMS Controller Settings
(Versions older than 3.5.2.1)
When it is required to replace a VHMS controller, the
new VHMS controller must be setup before and after 1. Before removing the VHMS controller, connect
the installation according to the following procedure. the PC to the existing VHMS controller and start
the VHMS initial setting tool. Refer to VHMS
Machine data collected by the VHMS controller are
Controller Initial Setting Procedure for this oper-
stored and managed on the WebCARE database. In
ation.
order to ensure smooth data processing on Web-
CARE, consistency must be maintained when setting 2. Select [Save/Load] and press the [OK] button.
the VHMS controller. Inconsistencies in the settings The VHMS setting information is saved from the
cause WebCARE data loading problems, reducing old VHMS controller to the PC. The saved infor-
the effectiveness and accuracy of VHMS data. mation is loaded to the new VHMS controller
Therefore, it is important to perform the VHMS set- after installation.
ting procedures correctly.
Check each step of the setting work referencing the
"VHMS Initial Setting Work Check Sheet".
Information such as models shown in the figures may
not be identical with actual ones.
Prior to Removing VHMS Controller

1. Download the remaining data from the existing
VHMS controller as explained earlier in this
chapter.
a. This work is done inside the cab (from PC).
b. Using the [Download] function, download the
currently recorded and remaining data from
the existing VHMS controller to the PC.
c. Refer to Downloading VHMS Data earlier in
this chapter for more information.
3. Confirm that all information is correct before

removing the old VHMS controller.
D30-22 VHMS D30003

4. Select [File] and then [Save] from the menu. 5. Confirm the information and then press the [OK]
button to save the information.
6. Select [File] and then [Exit] from the menu to

end the VHMS setting tool.
7. Disconnect the PC.
8. Refer to Disconnecting the PC earlier in this
chapter for more information.
9. Turn the PC power off.
10. Proceed to Loading Saved VHMS Settings To
New VHMS Settings (Versions older than
3.5.2.1).
D30003 VHMS D30-23

[For storage] Date of setting:
DB/branch
VHMS Initial Setting Work Check Sheet office name
Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller
Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the

8 Execution of Quick PM yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing from Snapshot? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
D30-24 VHMS D30003

[For storage] Date of setting:
DB/branch
ORBCOMM Station Opening Work office name
Check Sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data were stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
D30003 VHMS D30-25

Loading Saved VHMS Settings To New VHMS
Controller (Versions older than 3.5.2.1)
1. Connect the PC again and start the VHMS ini-
tial setting tool. Refer to VHMS Controller Initial
Setting Procedure for this operation.
2. Select [Save/Load] and press the [OK] button.
5. Display the saved information on another

screen.
6. Press the [Edit] button and adjust the time.
3. Select [File] and then [Load] from the menu.
4. Currently saved information will be displayed.

Press the [OK] button.
D30-26 VHMS D30003

7. After adjusting the time, press the [OK] button.
8. Press the [Apply] button to display contents of

the setting. Check the setting again and, if it is
correct, press the [OK] button.
9. The confirmation screen will ask whether or not

the data before the above setup is to be saved.
Press the [NO] button. It is not necessary to
save the data before the setting.
D30003 VHMS D30-27

10. The setup result is displayed. Confirm the con- 2. Select [When VHMS needs to be replaced] and
tents and press the [Close] button. press the [Next] button.
3. Select [Save current setting before replacement

of VHMS controller] and press the [Next] button.
The VHMS setting information is saved from the
old VHMS controller to the PC. The saved infor-
11. Select [File] and then [Exit] from the menu to mation is loaded to the new VHMS controller
end the VHMS initial setting tool. after installation.
Confirming and Saving VHMS Controller Settings

(Version 3.5.2.1 or newer)
1. Before removing the VHMS controller, connect
the PC to the existing VHMS controller and start
the VHMS initial setting tool. Refer to VHMS
Controller Initial Setting Procedure for this oper-
ation.
D30-28 VHMS D30003

4. Confirm that all information is correct before 2. Select [When VHMS needs to be replaced] and
removing the old VHMS controller. If all the press the [Next] button.
information is correct, press the [Save] button.
5. Select [File] and then [Exit] from the menu to 3. Select [Use previous setting after replacement
end the VHMS initial setting tool. of VHMS controller] and press the [Next] button.
6. Disconnect the PC.
7. Refer to Disconnecting the PC earlier in this
chapter if necessary.
8. Turn the PC power off.
9. Proceed to Loading Saved VHMS Settings To
New VHMS Controller (Version 3.5.2.1 or
newer).
Loading Saved VHMS Settings To New VHMS

Controller (Version 3.5.2.1 or newer)
1. Connect the PC again and start the VHMS ini-
tial setting tool. Refer to VHMS Controller Initial
Setting Procedure for this operation.
D30003 VHMS D30-29

4. Currently saved information will be displayed.
Press the [Next] button.
7. The above completes modification of the set-

ting. Press the [OK] button to end the VHMS ini-
tial setting tool.
5. Adjust the time and press the [Apply] button.
FINAL VHMS PROCEDURES-POST

INSTALLATION
1. Execute the Quick PM. Refer to Executing
Quick PM earlier in this chapter for more infor-
mation.
2. Download the VHMS data. Refer to Download-
ing VHMS Data earlier in this chapter for more
information.
3. After replacing the VHMS controller, send the
VHMS/WebCARE setting report sheet to
VHMS/WebCARE Support Center at Komatsu
Headquarters.
4. You will also need to send two sets of data, the
downloaded before and after the VHMS
replacement, via Notes (LAN) or E-mail (WAN).
6. The confirmation screen will ask whether or not
the data before the above setup is to be saved.
Press the [NO] button. It is not necessary to Komatsu VHMS/WebCARE Support Center
save the data before the setting.
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
D30-30 VHMS D30003

SETTING PAYLOAD METER USING VHMS
D30003 VHMS D30-31

Set various items of the payload meter (PLM) with Correct the Load Weight Calculation
the machine monitor.
Ensure that the weight measurements of the
1. Selection of service menu empty machine and of the fully loaded machine
are done as a set in order according to the
While the service menu selection screen is dis- following procedure.
played, select the PLM setting function (PLM).
The machine must travel for about 3 minutes
each after its empty weight and its fully loaded
weight are measured.
The relationship between the suspension
pressure and load weight corrected with this
function cannot be returned to the condition at
the time of shipment. Accordingly, perform the
following procedure very carefully.
1. Measure the weight of the empty machine with
the load meter and record it (Write it on a sheet
of paper, etc.)
2. Enter the measured weight of the empty
machine and drive the machine for about 3 min-
utes (at a speed higher than 8 km/h (5 mph)) to
settle the relationship between the weight of the
2. Setting of travel distance to recognize comple- machine and the suspension pressure under
tion of loading that weight.
Enter a travel distance to recognize completion

of loading by pressing the following buttons.
The setting range is 0 255 m (0.0 0.158
mile).
[ > ] : The number at the cursor increases in
value
[ < ] : The number at the cursor decreases in
value
[] : Accept the number at the cursor and go
to the next step
[ ] : Stop editing number
If the set value is too small, the system may rec-
ognize that loading is completed while the
machine is still being loaded.
D30-32 VHMS D30003

3. Select "EMPTY WEIGHT". 5. Enter the measured weight of the empty
machine.
[>], [<] : Select "EMPTY WEIGHT" or "LOADED

WEIGHT"
[] : Accept the selection and go to the next [>] : The number at the cursor increases in
step value
[] : Return to the previous screen [<] : The number at the cursor decreases in
If the weight of the empty machine has been value
entered and the machine has been driven for [] : Accept the number at the cursor and go to
about 3 minutes, "LOADED WEIGHT" is dis- the next step
played when the menu is selected.
[] : Return to the highest numerical place-
Confirm the unit of measurement. It is indicated holder to enter the value again. If this button is
in the ( ) on the right side of WEIGHT. pressed again, the editing data process data is
(METRIC): metric ton stopped and the previous screen appears.
(SHORT): short ton Input range

4. Confirm that the weight of the empty machine HD1500-7:
has been measured correctly.
105.3 [t] (Empty weight 13%)
(metric ton)
[] : Accept the weight measurement and go

to the next step
[] : Return to the previous screen
D30003 VHMS D30-33

6. Confirm the displayed weight. 8. Display the progress of the measurement.
[ > ] : Select "YES" if the displayed weight is cor- [] : Stop the measurement and return to the
rect previous screen
[ < ] : Select "NO" if the displayed weight is incor- As the measurement is executed, the number of
rect. "*" increases. When the measurement is fin-
ished, the next screen appears automatically.
[] : Accept the displayed weight and go to the
next step 9. Load the machine to measure its fully loaded
weight.
7. Move the machine to a place where you can

drive it for about 3 minutes.
[] : Return to the menu screen

When the loading has started, the menu screen
appears automatically. When indicating the cur-
rent load for reference while the machine is
[] : When ready to operate the machine, press being loaded, go out of "Service mode 1" tem-
this button and start driving porarily and return to "Display of load weight/
[] : Return to the weight editing screen integrated odometer". On this screen, you can
check the current load.
Drive the machine for about 3 minutes (at a
speed higher than 8 km/h (5 mph)) to settle the
relationship between the weight of the machine
and the suspension pressure under that weight.
D30-34 VHMS D30003

10. Measure the weight of the fully loaded machine 12. Confirm that the weight of the fully loaded
with the load meter and record it (Write it on a machine has been measured correctly.
sheet of paper, etc.)
11. Enter the measured weight of the fully loaded
machine and drive the machine for about 3 min-
utes.
a. Select "LOADED WEIGHT".
[] : Confirm that the measurement has been

completed and go to the next step
[>], [<] : Select "EMPTY WEIGHT" or "LOADED

WEIGHT"
[] : Accept the selection and go to the next
step
If the weight of the empty machine has been
entered and the machine has been driven for
about 3 minutes, "LOADED WEIGHT" is dis-
played when the menu is selected.
Confirm the unit of measurement. It is shown in
the ( ) on the right side of WEIGHT.
(METRIC): metric ton
(SHORT): short ton
D30003 VHMS D30-35

13. Enter the measured weight of the fully loaded 14. Confirm the displayed weight.
machine.
[>] : The number at the cursor increases in [ < ] : Select "YES" if the displayed weight is cor-
value rect
[<] : The number at the cursor decreases in [ > ] : Select "NO" if the displayed weight is incor-
value rect.
[] : Accept the number at the cursor and go to [] : Accept the displayed weight and go to the
the next step next step
[] : Return to the largest position of the num- 15. Move the machine to a place where you can
ber to input the value again. If this button is drive it for about 3 minutes.
pressed again, editing of the weight is stopped
and the previous screen appears.
Input range
HD1500-7:
A1 (A1 0.25) (metric ton)
However,
A1 = {105.3 [t] (Empty weight)
+ 144.1 [t] (Load capacity)}
HD1500-7:
A2 (A2 0.25) (metric ton)
However,
A2 = {105.3 [t] (Empty weight) [] : When ready to operate the machine, press
this button and start driving
+ 144.1 [t] (Load capacity)}
[] : Return to the weight editing screen
Drive the machine for about 3 minutes (at a
speed higher than 8 km/h (5 mph)) to settle the
relationship between the weight of the machine
and the suspension pressure under that weight.
D30-36 VHMS D30003

16. Display the progress of the measurement. 18. Correct the level of the inclinometer.
a. Drive the machine to a level area.
b. Enter the inclinometer reading (F) at the cur-
rent position and (R) after turning the
machine 180 degrees (stopping it in the
opposite direction) on the same position and
use the average value as the standard level.
c. Enter the value of (F).
[] : Stop the measurement and return to the

previous screen
As the measurement is executed, the number of
"*" increases. When the measurement is fin-
ished, the next screen appears automatically.
17. Dump the load in the dump area.
[] : Accept the blinking value

If the load is dumped with the dump lever, the
menu screen appears automatically.
If the load is dumped normally, correction is fin-
ished.
D30003 VHMS D30-37

The current standard level value is displayed on a. Enter the standard level value.
the upper line. The inclinometer value (F) at the
current position blinks. Enter it when it is stabi-
lized.
a. Turn the machine 180 degrees (Stop it in the
opposite direction).
b. Enter the value of (R).
[ < ] : Select "YES" if correct

[ > ] : Select "NO" if incorrect
[] : Accept selection and go to the next step
19. Set the maximum travel speed.
Enter a travel distance to recognize completion

of loading by pressing the following buttons.
The setting range is 0 255 m (0.0 0.158
mile).
[>] : The number at the cursor increases in
value
[<] : The number at the cursor decreases in
value
[] : Accept the blinking value
[] : Accept the blinking value Enter the maximum travel speed by pressing
[] : Return to the menu screen the following buttons.
The current standard level value is displayed on [ > ] : The number at the cursor increases in
the upper line. The inclinometer value at the value
current position blinks. Enter it when it has sta- [ < ] : The number at the cursor decreases in
bilized. value
[] : Accept the number at the cursor
[ ] : Stop editing data
The setting range is 0 99 km/h (0 62 mph).
(Default: 99 km/h (62 mph))
D30-38 VHMS D30003

20. Set the load weight to recognize start of loading 21. Set the indication range of the outside indicator
lamps
Enter a load weight to recognize start of loading

by pressing the following buttons.
Enter the indication range of the outside indica-
[ > ] : The number at the cursor increases in tor lamps by pressing the following buttons.
value
[ > ] : The number at cursor increases in value
[ < ] : The number at cursor decreases in value
value
[] : Accept the number at the cursor and go to
[] : Accept the number at the cursor and go to
the next step
the next step
% The setting range is 0 - 130% of the rated
The setting range is 6 25.5% of the rated load
load weight.
weight.
Set A (Yellow lamp) higher than G (Green lamp)
(Default: 15%)
and set R (Red lamp) higher than A (Yellow
This function does not ensure the operation lamp), however.
because of the contrary phenomena shown
below.
If the load weight value is not entered correctly,
the start of loading data will be inaccurate.
If the value is increased and a loader having a
small-capacity bucket is used, the forecast func-
tion of the outside indicator lamps and the MMS
communication may not operate normally.
D30003 VHMS D30-39

22. Set the offset range.
Enter an offset range by pressing the following

buttons.
[ > ] : The number at the cursor increases in
value
value
[] : Accept the number at cursor
The setting range is -5.0 +5.0 [t].
Check the unit of the input value by the previous
menu screen.
The unit is indicated in the ( ) on the right side of
the input value [t].
(METRIC): metric ton
(SHORT): short ton
D30-40 VHMS D30003

SECTION F
TRANSMISSION / TORQUE CONVERTER
INDEX
TORQUE CONVERTER AND TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
TRANSMISSION OIL COOLER AND STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
TORQUE CONVERTER REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1
TRANSMISSION REBUILD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1
F01014 Index F1-1

NOTES
F1-2 Index F01014

SECTION F2
TORQUE CONVERTER AND TRANSMISSION
INDEX
TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
TORQUE CONVERTER REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
LOCK-UP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-9
Lock-up Clutch Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-9
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10
TORQUE CONVERTER STALL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2-11
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12
LUBRICATION RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-14
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-14
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-15
ELECTRONIC CONTROL MODULATION VALVE (ECMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-17
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
Flow Sensor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
ECMV and Proportional Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
ECMV and Fill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
ECMV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-19
F02021 05/08 Torque Converter & Transmission F2-1

ECMV REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
Filter Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
ECMV Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-24
TRANSMISSION FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-26
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-26
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-27
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-28
TRANSMISSION OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-30
F2-2 Torque Converter & Transmission 05/08 F02021

TORQUE CONVERTER AND TRANSMISSION
TRANSMISSION
Torqflow transmission (9, Figure 2-1) has seven for- The transmission oil supply is filtered through wash-
ward speeds and one reverse speed. The transmis- able strainers located in the transmission sump.
sion contains planetary gears and hydraulically- Remove and clean the strainers every 1000 hours of
actuated multiple-disc clutches. The transmission is operation.
pressure lubricated for optimum heat dissipation. External, replaceable transmission filter elements are
Drive line adapter (2) containing rubber dampers, located at the front of the fuel tank. Replace the two
couples the engine to the transmission and torque transmission filter elements at 500 hour intervals. If
converter. The adapter reduces harmful engine the maintenance monitor indicates high restriction
shock and vibration to the transmission. A lock-up regardless of interval, the filters must be replaced.
system, consisting of a wet, triple-disc clutch, can be A control valve filter is located on top of the left side
actuated in all forward gears for higher fuel savings. of the transmission, next to the Electronic Control
Operation of the transmission is controlled electroni- Modulation Valves (ECMV). Replace this filter at 500
cally through inputs from the operator such as range hour intervals, also.
selector position, accelerator, etc. Various sensors Transmission maintenance intervals are outlined in
that monitor speeds and operating conditions also section P, Lubrication and Service.
contribute to transmission control.
FIGURE 2-1. POWERTRAIN
1. Engine 6. Steering & Brake Pump 11. Parking Brake

2. Driveline Adapter 7. Transmission Pump 12. Differential Gear
3. Front Drive Shaft 8. Torque Converter 13. Drive Shaft
4. Brake Cooling & Hoist Pump 9. Transmission 14. Brakes
5. Brake Cooling Pump 10. Rear Drive Shaft 15. Planetary Gears

TORQUE CONVERTER
The torque converter is a three element, single-
stage, two phase torque converter with lock-up
clutch.
Specifications are listed for the transmission and A water-to-oil type oil cooler is utilized to dissipate
torque converter components on the following heat from the oil supply.
pages. It is assumed the specified oil type and
viscosity is being used, the oil level is correct, Stall ratio:. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.99:1
and oil is at the normal operating temperature.
FIGURE 2-2. TORQUE CONVERTER PUMP DRIVES
FIGURE 2-3. TORQUE CONVERTER

1. Front Housing 3. Torque Converter Control Valve
2. Rear Housing 4. Torque Converter Regulator Valve

1. Rear Housing 6. Stator 11. Lock-Up Clutch Housing

2. One-Way Clutch 7. Coupling 12. Housing
3. Front Housing 8. Input Shaft 13. Pump
4. Disc 9. Turbine 14. Shaft
5. Plate 10. Piston

MAIN RELIEF VALVE
Function
The main relief valve maintains the main hydraulic
pressure in the transmission control circuits. The
valve also controls the oil flow to the transmission
clutches.
Operation
The oil from the hydraulic pump enters port (C,
Figure 2-5), then passes through orifice (B) to cham-
ber (A).
When hydraulic pressure in the circuit rises, the pres-
sure in chamber (A) also rises. This pushes main
relief spool (1) to the left through the movement of
piston (2). The oil at port (C) passes through (D) to
chamber (E) and to the torque converter circuit.
Actuating Pressure
Engine @ 2100 rpm,
Oil Temperature @ 70 - 90 C (158 - 194 F)
FIGURE 2-5. MAIN RELIEF VALVE
. . . . . . . . . . . . . . . . . .4316 145 kPa (626 21 psi)
1. Main Relief Spool 2. Main Relief Valve Pis-
ton
TORQUE CONVERTER RELIEF VALVE

Function
The torque converter relief valve protects the torque
converter oil circuit by preventing the oil pressure
from rising to an abnormally high pressure.
Operation
Oil from the main relief valve enters port (F, Figure 2-
6) and then passes through orifice (H) to chamber
(G).
When the hydraulic pressure in the circuit rises, the
pressure in chamber (G) also rises. This pushes
torque converter relief spool (4) to the right through
the movement of piston (3). As a result, the oil at port
(F) flows to port ( I ) into the transmission lubrication
circuit.
Actuating Pressure
Engine @ 2100 rpm FIGURE 2-6. TORQUE CONVERTER RELIEF
Oil Temperature @ 70 - 90 C (158 - 194 F) VALVE
. . . . . . . . . . . . . . . . . . . .961 98 kPa (139 14 psi) 3. Relief Valve Piston 4. Relief Valve Spool

FIGURE 2-7. MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
(Pressure specifications @ 2100 rpm, oil temperature 70 - 90 C (158 - 194 F)
1. Spring (Small) 9. Piston Spring

2. Spring (Large) 10. Torque Converter Relief Valve Piston
3. Valve Body 11. To Transmission Sump
4. Main Relief Valve 12. Transmission Pump
5. Main Relief Valve Piston 13. To Transmission Control Valve
6. Piston Spring 14. Torque Converter Inlet Test Port
7. Torque Converter Relief Valve Spring 15. To Torque Converter
8. Torque Converter Relief Valve 16. Main Pressure Test Port

TORQUE CONVERTER REGULATOR
VALVE
Torque converter regulator valve (Figure 2-8) is
installed in the output circuit of the torque converter.
The valve regulates the hydraulic pressure inside the
torque converter to 517 kPa (75 psi).
Operation
Oil from the torque converter flows from port (A,
Figure 2-9) to port (B). However, the hydraulic pres-
sure at port (B) is lower than the tension of spring (1).
Therefore, spool (2) does not move. FIGURE 2-9. BELOW REGULATED PRESSURE
1. Spring A: Inlet From Torque
When the hydraulic pressure at port (B, Figure 2-10) 2. Spool Converter
becomes higher than the tension of spring (1), it B: Chamber
pushes spool (2) in the direction of the arrow. The oil C: Outlet to Oil Cooler
at port (A) then flows to port (C).
Actuating Pressure
Engine @ 2100 rpm
. . . . . . . . . . . . . . . . . . . . .448 97 kPa (65 14 psi)
FIGURE 2-10. REGULATED PRESSURE

1. Spring A: Inlet From Torque
2. Spool Converter
B: Chamber
C: Outlet to Oil Cooler

REGULATOR VALVE
1. Valve Body 4. Pressure Tap

2. Spring 5. Inlet From Torque Con
3. Spool verter

LOCK-UP CLUTCH
The lock-up clutch is located in the torque converter.
Refer to Figure 2-4. The clutch is used to create a
direct mechanical connection from the engine to the
transmission. This direct drive connection helps mini-
mize energy loss that occurs while the engine is
hydraulically connected to the transmission via the
torque converter.
The operation of the lock-up clutch utilizes an ECMV
identical to those used to actuate the transmission
range clutches. At the correct rpm, the transmission
controller will provide the signal for lock-up clutch
engagement. Through the use of this valve and two
pressure sensors, the pressure in the apply piston
chamber is maintained at the same pressure as the
internal torque converter pressure instead of drop-
ping to zero pressure. This keeps the lock-up clutch FIGURE 2-11. LOCK-UP CLUTCH ACCUMULATOR
cavity filled with oil while waiting for the next lock-up
application. This method of lock-up clutch application 1. Transmission 2. Lock-up Clutch
greatly reduces the shift shock felt when the lock-up Accumulator
clutch is applied.
The pressure sensors monitor the inlet and outlet
pressures in the torque converter to actuate the
ECMV to control the pressure in the lock-up clutch
cavity. In addition, the input and output shaft speeds
are also monitored.
Lock-up Clutch Accumulator

Lock-up clutch accumulator (2, Figure 2-11) has
been added to the lock-up clutch circuit as a protec-
tive device. The function of the accumulator is to
dampen normal system pressure pulsations in the fill
switch hydraulic circuit. Repeated pulsations acting
on the switch can cause the switch to fail.

HYDRAULIC PUMP
Torque converter and transmission
Volume: . . . . . . . . 471 l/min (125 gpm) @ 2100 rpm
Pump Rotation . . . . . . . . . . . LH (Counterclockwise)
FIGURE 2-12. HYDRAULIC PUMP
1. Washer 7. Plug 13. Snap Ring 19. Backup Ring

2. Stud 8. Flange 14. Splined Coupling 20. O-Ring
3. Nut 9. Body 15. O-Ring 21. Ring Retainer
4. Drive Gear 10. Dowel Pin 16. Pressure Plate
5. Seal 11. O-Ring 17. Isolation Plate (Top)
6. Snap Ring 12. O-Ring 18. Isolation Plate (Bottom)

TORQUE CONVERTER STALL CHECK
8. After the engine and transmission reach normal
operating temperature, the stall test can be per-
formed.
Move the shift selector lever to D. Fully apply
the service brakes or move the retard lever to
The transmission oil temperature must not full ON to prevent machine movement. Slowly
exceed 120 C (248 F). accelerate the engine to full throttle for no more
than 30 seconds.
DO NOT stall the torque converter at full throttle
for more than 30 seconds at any one time. 9. Check and record engine rpm with an accurate
tachometer or a remote electronic measuring
Exceeding these limits may result in serious tachometer. Maximum engine rpm with the con-
damage to converter components. verter stalled is 1815 100 rpm.
10. If the stall rpm does not meet the listed require-
ments, refer to the service guidelines below.
Prior to performing a stall test, ensure that all sys-
tems such as exhaust piping, air intake piping, fuel
controls, and engine warning systems are all working Low rpm:
properly, and within specifications. Insufficient fuel or
Transmission oil viscosity high due to low
restricted piping can also effect stall speed.
temperature, wrong oil or bad oil
Engine power is not within specs
1. Install wheel chocks, and apply the parking Faulty torque converter assembly or components
brake.
2. Start the engine.
3. Apply and hold the service brakes fully to pre- High rpm:
vent movement of the machine. Transmission oil viscosity is low due to high
4. Ensure the F1 start switch is in the OFF posi- temperature, wrong oil, bad oil, or lack of oil flow
tion. Engine power is not within specs
5. Move the shift selector lever to D. Fully apply
Faulty torque converter assembly or components
the service brakes or move the retard lever to
full ON to prevent machine movement. Slowly
accelerate the engine to full throttle for no more
than 30 seconds.
6. Move the shift lever to NEUTRAL and allow the
engine to idle for 30 seconds.
7. Repeat the previous two steps until the engine
and transmission are at normal operating tem-
perature: engine 85 - 97 C (185 - 207 F),
transmission 70 - 90 C (158 - 194 F).

TRANSMISSION
FIGURE 2-13. TRANSMISSION AND TORQUE CONVERTER

1. Torque Converter 4. Transmission Control Valve
2. Lubrication Pressure Tap 5. Torque Converter Control Valve
3. Transmission

FIGURE 2-14. TRANSMISSION ASSEMBLY
1. Input Shaft 14. #5 Sun Gear 27. #4 Ring Gear

2. Hub 15. Output Shaft 28. #4 Clutch (2nd)
3. #1 Planetary Pinion Gear 16. #6 Sun Gear 29. #3 Clutch (Low Clutch)
4. Transmission Case 17. Coupling 30. #3 Ring Gear
5. #3 Sun Gear 18. Intermediate Shaft 31. #3 Planetary Carrier
6. #3 Planetary Pinion Gear 19. Case 32. #2 Clutch (High Clutch)
7. #4 Planetary Pinion Gear 20. Hub 33. #1 Planetary Carrier
8. #4 Sun Gear 21. #6 Planetary Pinion Gear 34. #1 Ring Gear
9. #5 Planetary Pinion Gear 22. #6 Ring Gear 35. #1 Clutch (Middle Clutch)
10. #6 Planetary Pinion Gear 23. #6 Clutch (Reverse) 36. Hub
11. Rear Case 24. #5 Ring Gear 37. #1 Sun Gear
12. #5, #6 Planetary Carrier 25. #5 Clutch (1st)
13. #7 Clutch (3rd) 26. #4 Planetary Carrier

LUBRICATION RELIEF VALVE
Function Operating Pressure
Engine @ 2100 rpm
Transmission lubrication relief valve (3, Figure 2-15)
is installed on the left side of transmission case (1).
This valve prevents abnormal pressure in the trans- . . . . . . . . . . . . . . . . . . . . 304 97 kPa (31 14 psi)
mission lubrication circuit. Cracking Pressure: . . . . . . . . . . . . . 343 kPa (50 psi)
FIGURE 2-15. TRANSMISSION LUBRICATION RELIEF VALVE
1. Transmission Case 7. Spring Guide

2. Lubrication Pressure Test Port 8. Spring
3. Lubrication Relief Valve 9. Plate
4. Cover 10. Spool
5. O-Ring 11. Gasket
6. Shim

TRANSMISSION CONTROL VALVE
FIGURE 2-16. TRANSMISSION CONTROL VALVE
1. ECMV (for T/C lock-up clutch)

2. ECMV (for medium clutch)
3. ECMV (for high clutch) SPEED ECMV RATIO
4. ECMV (for low clutch) RANGE R 1st 2nd 3rd L M H
5. ECMV (for 3rd clutch)
R n n 5.600
6. ECMV (for 2nd clutch)
7. ECMV (for 1st clutch) N n
8. ECMV (for reverse clutch) F1 n n 5.434
9. Valve Oil Filter
F2 n n 4.063
10. Valve Seat
11. Breather F3 n n 3.048
F4 n n 2.415
A. Lock-up Clutch Pressure Tap Port
B. Medium Clutch Pressure Tap Port F5 n n 1.811
C. High Clutch Pressure Tap Port F6 n n 1.333
D. Low Clutch Pressure Tap Port
F7 n n 1.000
E. 3rd Clutch Pressure Tap Port
F. 2nd Clutch Pressure Tap Port
G. 1st Clutch Pressure Tap Port
H. Reverse Clutch Pressure Tap Port

FIGURE 2-17. HYDRAULIC CIRCUIT DIAGRAM TRANSMISSION AND TORQUE CONVERTER
(*Engine @ 2100 rpm, Oil Temperature 70 C - 90 C (158 F - 194 F))
1. Torque Converter 16. ECMV (High Clutch): 1961 97 kPa (284 14 psi)
2. *Torque Converter Relief Valve: 961 kPa (139 psi) 17. High Clutch
3. *Main Relief Valve: 4316 kPa (626 psi) 18. ECMV (Low Clutch): 3434 145 kPa (498 21 psi)
4. *Torque Converter Regulator Valve: 517 97 kPa (75 14 psi) 19. Low Clutch
5. Oil Cooler 20. ECMV (2nd Clutch): 3434 145 kPa (498 21 psi)
6. *Lubrication Relief Valve: 304 97 kPa (44 14 psi) 21. 2nd Clutch
7. Filter Assemblies 22. ECMV (1st Clutch): 3434 145 kPa (498 21 psi)
8. Hydraulic Pump 23. 1st Clutch
9. Strainer 24. ECMV (Reverse Clutch): 3434 145 kPa (498 21 psi)
10. Transmission Oil Pan 25. Reverse Clutch
11. Fill Switch 26. ECMV (3rd Clutch): 1863 97 kPa (270 14 psi)
12. Proportional Solenoid: 1862 97 kPa (270 14 psi) 27. 3rd Clutch
13. Lock-up Clutch 28. ECMV Oil Filter
14. ECMV (Medium Clutch): 1863 97 kPa (270 14 psi) 29. Lock-up Clutch Accumulator
15. Medium Clutch

ELECTRONIC CONTROL MODULATION VALVE (ECMV)
FIGURE 2-18. ELECTRONIC CONTROL MODULATION VALVE
1. Connector 6. Proportional Solenoid A: To clutch

2. Spring 7. Pressure Control Valve Spool B: Drain
3. Flow Sensor Valve Spool 8. Load Piston C: From Pump
4. Spring 9. Spring a: Clutch Pressure
5. Fill Switch Measurement Port

ECMVs consists of two valves, a pressure control
valve and a flow sensor valve.
Pressure Control Valve

The pressure control valve contains a proportional
solenoid. The solenoid uses the current sent from the
transmission controller and converts it into hydraulic
pressure. Refer to Figure 2-19.
Flow Sensor Valve

The flow sensor valve is actuated by a trigger from
the pressure control valve. The flow sensor valve has
the following functions:
1. The valve is opened until the clutch is filled with
oil, reducing the time taken for oil to fill the
clutch.
2. When the clutch fills with oil, the valve closes. A
full signal is sent to the controller.
3. While there is hydraulic pressure applied to the
clutch, a full signal is sent to the controller to
indicate whether there is hydraulic pressure
present.
FIGURE 2-19.
ECMV and Proportional Solenoid
A range: Before Gear Shifting (drained)
Each ECMV is equipped with one proportional sole- B range: Filling Starts (trigger issued)
noid. C range: Filling Completed
D range: Regulation
The propulsion force shown in the diagram in
E range: Filling
Figure 2-20 is generated according to the command
signal from the controller.
The propulsion force generated by the proportional
solenoid acts on the pressure control valve spool.
This generates the hydraulic pressure shown in the
diagram. Therefore, by controlling the command cur-
rent, the propulsion force is changed. This acts on
the pressure control valve to control the oil flow and
hydraulic pressure.
ECMV and Fill Switch

Each ECMV is equipped with one fill switch. When
the clutch is completely filled, the flow sensor valve
sends a signal to turn the fill switch on. As a result of
this signal, the oil pressure starts to build up.

ECMV Operation
The ECMV is controlled by the command current
from the transmission controller to the proportional
solenoid, and the output signal of the fill switch. The
relationship between the ECMV proportional sole-
noid command current and clutch input pressure and
the output signal of the fill switch is shown in the dia-
gram in Figure 2-19.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
FIGURE 2-20.
Before shifting - drained - A range, Figure 2-19

1. Refer to Figure 2-21: When no current is being
sent to proportional solenoid (6), the reaction
force for spring (9) pushes pressure control
valve spool (7). As a result, proportional sole-
noid (6) is pushed back. Pressure control valve
spool (7) connects the oil at clutch port (C) to
drain port (E) and drains the oil.
In this condition, there is no hydraulic force act-
ing on spool (3). Therefore, the reaction force of
spring (4) moves flow sensor valve spool (3)
away from fill switch (5). The spool stops when
it is in balance with return spring (2).
FIGURE 2-21.

Starting to fill - trigger command input to pres-
sure control valve - B range, Figure 2-19
1. Refer to Figure 2-22: When there is no oil inside
the clutch and the trigger current is sent (maxi-
mum current is applied) to proportional solenoid
(6), the proportional solenoid moves the full
stroke. Pressure control valve spool (7) moves
to the left. As a result of this, pump port (A) and
pressure control valve output port (B) are
opened. Oil passes through orifice (a) and starts
to fill the clutch.
FIGURE 2-22.
2. Refer to Figure 2-22: When this happens, a

pressure difference is created between the
upstream and downstream sides of orifice (a).
Because of the difference in pressure, flow sen-
sor valve spool (3) moves to the left and com-
presses sensor valve return spring (2).
As a result, flow sensor valve spool (3) opens
pump port (D). Oil flows from here, through ori-
fice (a), to the clutch port.
FIGURE 2-23.
Filling completed - pressure control set to initial
pressure - C range, Figure 2-19
1. Refer to Figure 2-24: When pump port (D)
opens, a difference in pressure is created
between the upstream and downstream sides of
orifice (a). This continues to push flow sensor
valve spool (3) to the left. When this occurs, and
the current of proportional solenoid (6) is low-
ered momentarily to the initial pressure level,
almost the complete pump pressure acts on
load piston (8). As a result, pressure control
valve spool (7) is pushed to the right. A small
amount of oil flows from pressure control valve
outlet port (B) to drain port (E). Since most of
the oil from the pump flows to the clutch, flow
sensor valve spool (3) continues to be pushed
to the left.
FIGURE 2-24.

2. Refer to Figure 2-25: When the clutch is filled
with oil, the flow of oil from pump port (D) to
clutch port (C) stops. The area at the left side of
flow sensor valve spool (3) is larger than the
area on the right side. Therefore, with equal
pressure on both sides, the spool is moved by
hydraulic force to the right. When this happens,
port (D) and port (C) are closed. Because of this
difference in area and the force of return spring
(2), spool (3) compresses fill switch spring (4)
and is pushed to the right. It then signals fill
switch (5) and transmits the clutch filling com-
pleted signal to the shift controller. At this point,
the current for the initial pressure level is flow-
ing to proportional solenoid (6). Therefore, the
hydraulic pressure is set to the initial pressure
by pressure control valve spool (7).
FIGURE 2-25.
Regulating - D range, Figure 2-19

1. Refer to Figure 2-26: When current is sent to
proportional solenoid (6), the solenoid gener-
ates a force proportional to the current. This
propulsion force of the solenoid, and the sum of
the propulsion force produced by the hydraulic
pressure at the clutch port applied to load piston
(8), and the reaction force of pressure control
valve spring (9) are regulated so that they are in
balance. The difference in hydraulic pressure
applied to both sides of spool (3) pushes the
spool to the right. The fill signal continues to be
sent to the transmission controller.
FIGURE 2-26.

ECMV REPAIR PROCEDURE
1. Thoroughly wash and flush debris and dirt from
the transmission control valve mounted on top
of the transmission.
2. Thoroughly wash and flush the area surround-
ing filter assembly (5, Figure 2-27) to prevent
the intrusion of dirt and debris.
3. Remove nuts (2) and cover (1). Flush the area
under the cover. Do not allow dirt and debris to
enter the ECMV, valve seats, etc.
Filter Replacement Procedure

1. Remove cover (9, Figure 2-27). Prior to removal
of filter assembly (5), loosen filter case (8) from
filter head (6). Rotating the case counterclock-
wise, using the hex nut at the case tip.
2. Remove the complete filter assembly.
When the filter assembly is removed from the

valve seat, oil may flow from the case onto the
transmission. Capture any spillage.
FIGURE 2-27. TRANSMISSION CONTROL VALVE
ASSEMBLY
3. Remove case (3, Figure 2-28) from filter head
(1). 1. Cover 7. Filter Case
4. Remove filter element (2) from head (1). 2. Nut 8. Cover
Remove O-rings (4 & 5). 3. Harness 9. ECMV Assembly
5. Replace the element with a new element. 4. Filter Assembly 10. Bolt
6. Wash head (1) and case (3) with light oil. 5. Filter Head 11. Valve Plate
6. Filter Element
7. Install new O-rings (4 & 5). Insert element (2)
into case (3).
8. Install the case onto the head. Tighten the case
hand tight.
9. Install the assembled filter assembly onto the
valve seat. Tighten the mounting cap screws to
standard torque.
10. Tighten filter case (3) to 58 - 79 Nm (43 - 58 lb
ft).
FIGURE 2-28. FILTER ASSEMBLY

1. Filter Head 4. O-Ring
2. Filter Element 5. O-Ring
3. Filter Case

ECMV Removal
1. Remove the paint along the boundary between
fill switch assembly (16, Figure 2-29) and valve
body (1) at each ECMV to be removed.
2. Disconnect the electrical connectors for fill
switch assembly (16) and solenoid valve (9).
3. Remove the switch and solenoid connectors
from bracket (18).
Disassembly
1. Before disassembly, flush the ECMV and valve
seat. Paint at the corners of the mating surfaces
must be thoroughly removed.
Do not expose the solenoid connectors, fill

switch connectors, or harness to water, etc.
2. Remove bolts (8, Figure 2-30) from ECMV

assembly (10, Figure 2-27). Separate the
ECMV assembly from valve plate (12, Figure 2-
27). FIGURE 2-29. ECMV ASSEMBLY
3. Remove solenoid connector (2, Figure 2-30). 1. Valve Body 12. Spring
Remove fill switch connector (3) from the 2. Plug 13. Plug
bracket. Loosen bolts (17). Gently remove fill 3. Plug 14. O-ring
switch (16) and the bracket. Do not let spring 4. Pressure Control Valve 15. Spring
(15) fall out of place. 5. Piston 16. Fill Switch
4. Remove cover plate (21, Figure 2-29). Remove 6. Spring 17. O-ring
plug (13) by installing a cap screw in the tapped 7. Shim 18. Bracket
hole for easier removal. Then, remove valve 8. O-ring 19. Bolt
spring (12), valve spool (11), and spring (15). 9. Proportional Solenoid 20. Washer
Valve 21. Cover Plate
a. Examine valve body (1) spool (11) and 10. Bolt 22. O-ring
spring (15) for debris and other metallic parti- 11. Flow Detection Valve 23. Bolt
cles. Clean the parts. Spool
b. If foreign matter has lodged in the valves or
the pistons, or if their functional movement is
not smooth, recondition the valves with an oil
NOTE: Protect valve plate (12, Figure 2-27) and the
stone, etc.
valve mating surfaces by applying masking tape, etc.
5. Remove spring (6), shims (7), piston (5), and Prevent dirt from entering the transmission by
valve (4). Check for any trapped foreign matter, covering all openings. Place all removed parts in
a seized spool, or roughness during motion. Set storage. Do not scratch parts when handling.
shims (7) aside for installation.
6. Remove proportional solenoid valve (9).

Assembly
Inspect each part thoroughly and confirm that the
part is free from dirt, scratches, etc. Wash all parts
with solvent. Lubricate spools and plungers with a
small amount of transmission oil during assembly.
Spools and plungers must be reassembled into their
original valve body bores.
NOTE: When assembling the valve, ensure the valve
spools move smoothly in the bore.
Assemble the components in a clean room or at a

workstation free from dirt, dust, and other con-
taminents.
1. Insert pressure control valve spool (4, Figure 2-
30) into valve body (1). Ensure the valve move-
ment is smooth by pushing the valve at both
ends.
2. Install solenoid valve (9) together with O-ring (8,
Figure 2-29). Install four bolts (10). Tighten the
bolts to 12 - 15 Nm (9 - 11 lb ft).
3. Place piston (5) inside spool (4). Ensure piston
movement is smooth.
4. Install shims (7) and spring (6) in the pressure
control valve. Install O-ring (22, Figure 2-29) in
the valve body.
FIGURE 2-30. ECMV VALVE ASSEMBLY
1. Valve Body 10. Bolt The standard number of shims is: . . . . . . . . . . .3.
2. Solenoid Connector 11. Flow Sensor Valve
Standard shim pack thickness: 0.6 mm (0.023 in.)
3. Fill Switch Connector 12. Spring
4. Pressure Control 13. Plug Individual shim thickness: . . . .0.2 mm (0.008 in.)
Valve Spool 14. Pressure Test Port NOTE: - Refer to Figure 2-30. When parts (1), (6),
5. Load Piston 15. Spring (5), (4) and (9) are being reused, the same number of
6. Spring 16. Fill Switch shims removed during disassembly must be
7. Shims 17. Bolt reinstalled. When any of these parts have been
8. Bolt 18. Cover Plate replaced, install the standard number of shims (3
9. Proportional Solenoid ea.). The exact quantity required is determined when
the clutch pressure test is performed.
NOTE: - When only proportional solenoid valve (9) is
to be replaced, remove cover (18) and ensure spring
(6) has been positively set in place. There is a
possibility that the spring can be dislodged from the
valve end when the solenoid is removed.

5. Install flow sensor valve (11) in valve body (1). 11. Install all ECMV's onto the valve seat. Mounting
Ensure valve movement is smooth. surfaces must be free from dirt/dust, scratches,
6. Set spring (15, Figure 2-29) in place. Install O- etc. Secure all electrical connectors to the har-
ring (17) and position fill switch (16) and bracket ness.
(18) on the valve body. Install two bolts (19) and 12. Check clutch pressure for any ECMV that has
tighten to 27 34 Nm (20 - 25 lb ft). been disassembled for repairs.
7. Install spring (12) in the flow detecting valve.
Install O-ring (14) on plug (13) and install on the
valve body.
8. Install cover plate (21) with bolts (23) and wash-
ers (20). Tighten the bolts to standard torque. After disassembly and/or parts replacement in
9. Install connectors (2, Figure 2-30) and connec- the pressure control valve, clutch oil pressure
tors (3) onto the bracket. must be checked and adjusted if necessary.
10. For each ECMV assembly, install O-rings at
three places on the valve seats. Install using
four bolts (8). Tighten the bolts to 27 34 Nm
(20 - 25 lb ft).

TRANSMISSION FILTERS
The transmission filter elements must be replaced
every 500 hours of operation or sooner if the mainte-
nance monitor indicates high restriction. This mainte-
nance interval may be increased or reduced,
depending on operating conditions. The mainte-
nance monitor will alert the operator of a filter restric-
tion.
The two transmission filters are located on the out-
side of the right frame rail, ahead of the fuel tank. An
additional filter is located in the control valve assem-
bly. Refer to ECMV Repair Procedure - Filter Clean-
ing Procedure.
Relieve pressure before disconnecting hydraulic

lines. Tighten all connections before pressurizing
the system. Pressurized hydraulic fluid can have
sufficient force to enter a person's body by pene-
trating the skin. This can cause serious injury
and possible death. It is necessary to immedi-
ately get proper medical treatment by a physician
familiar with this injury.
Service
1. Remove plug (6, Figure 2-31) and drain the oil
from the housing into a suitable container.
Avoid contact with hot oil if the truck has been

operating. Avoid spillage and contamination!
2. Remove bowl (4) and element (5).

3. Replace seal (3) in filter head.
FIGURE 2-31. TRANSMISSION CIRCUIT FILTER

Installation
1. Install new element (5, Figure 2-31). Install bowl 1. Head Assembly 6. Plug
(4) and tighten. 2. Indicator Switch 7. O-Ring
2. Replace plug (6), and O-ring (7). 3. Seal 8. Core Assembly
4. Bowl 9. Bypass Valve
5. Filter Element 10. Anti-Backflow Valve
NOTE: Indicator switch (2, Figure 2-31) is not
repairable. If the indicator switch is inoperative,
replace as a unit. The actuation pressure of the
indicator switch is factory preset. Switch adjustment
is not necessary and not recommended.

TRANSMISSION REMOVAL
1. Thoroughly clean all components in the area of
the transmission, pumps and drivelines.
2. Park the truck on a hard, level surface. Chock
the wheels and apply the parking brake. Raise
the dump body and install the body retention
cable. Move the hoist lever to the FLOAT posi-
tion to put the weight of the dump body on the
cable. Place the lever in HOLD.
The dump body must be raised and the safety

cable in place. DO NOT work under a raised FIGURE 2-32. HYDRAULIC LINES
dump body unless the body safety cable is 1. PTO 2. Hydraulic Hoses
installed. If the hydraulic pump or engine is inop-
erative, raise the dump body with a crane to allow
retention cable installation.
3. Turn the key switch OFF. Allow the steering

accumulators to depressurize. Turn the steering
10. Remove the front and rear driveshaft guards.
wheel and verify no wheel movement occurs.
4. Bleed the brake system accumulators. Open 11. Remove the front and rear drive shaft assem-
the needle valves located on the brake manifold blies. Refer to Drive Shafts, in this section, for
in the hydraulic cabinet. Allow all pressure to instructions.
purge to the tank. Close the valves after pres- 12. Remove cap screws and washers (3) for the
sure has been relieved. front trunnion mounts.
5. Remove the transmission guard. 13. Remove cap screws and washers (5) at the rear
6. Drain the transmission oil. The capacity of the mounts.
hydraulic tank is 153 l (41 gal).
14. Attach an appropriate lifting device to the trans-
7. Drain the hydraulic tank. The capacity of the mission/torque converter. The weight of the
hydraulic tank is 900 l (238 gal). If the oil is to be assembly is approximately 3060 kg (6746 lb).
reused, use clean containers that are free of
contamination. 15. Verify that all wire harnesses and hydraulic lines
have been removed. Carefully lift the assembly
8. Tag and disconnect transmission control and from the truck.
sensor wiring connectors.
16. Remove the transmission filter elements and
9. Tag and remove hydraulic hoses (2, Figure 2-
inspect.
32) at the hydraulic pumps mounted on Power
Take-Off (PTO) (1) and the transmission. Cap
all hoses and ports to prevent contamination.
Secure loose hoses to the frame to allow clear-
ance for transmission removal.

TRANSMISSION INSTALLATION
NOTE: Check the vibration dampener for wear, 7. Align the engine and transmission. Refer to
damage or deterioration before transmission Section F5, Drive Shafts - Front Drive Shaft
installation. Replace any rubber cushions or Alignment.
dampeners in doubtful condition. Refer to Section C,
Engine for information on the driveline adapter and
dampener.
Proper alignment of the engine and transmission

is necessary to prevent premature driveline fail-
ures. The alignment must be checked whenever
Failure to properly secure the dump body may
the transmission, engine or engine damper has
cause serious injury or death. If it is necessary to
been removed or replaced. Other repairs that dis-
work beneath a raised dump body, install the
turb driveline alignment will require adjustment,
body retention cable. Inspect the cable regularly
as well.
and replace as necessary.
1. Clean the filter housings and install new ele-

ments.
2. Attach an appropriate lifting device to the trans-
mission/torque converter. The weight of the
assembly is approximately 3060 kg (6746 lb).
3. Install the cushions and mounting brackets to
the rear mounting pins if necessary.
Check the orientation of the rear mounting
brackets. The brackets must be properly ori-
ented to prevent damage to the powertrain.
The 46 mm (1.8 in.) dimension represents the
top of the bracket and must face upward during
installation as shown in Figure 2-34.
4. Install the cushions and pins at the front mounts
if necessary.
5. Lift the transmission into place on the truck.
6. Install four shims below each rear mounting
bracket. Install four shims below each each
front mounting pin.
Rear Shim (1 mm) - p/n (562-16-22140)
Front Shim (1 mm) - p/n (568-16-12120)
FIGURE 2-33. TRANSMISSION INSTALLATION

1. Front Drive Shaft 5. Cap Screw & Washer
2. Trunnion Support 6. Driveline Guard
3. Cap Screw & Washer 7. Rear Drive Shaft
4. Transmission
Assembly

FIGURE 2-34. TRANSMISSION REAR MOUNTING BRACKET
8. After aligning the front drive shaft, install cap 14. Remove the body retention cable and lower the
screws and washers (3, Figure 2-33) for the body to the frame. It may be necessary to
front trunnion. Tighten the cap screws to stan- slightly lift the body with an overhead crane to
dard torque. relieve tension on safety cable.
9. Install cap screws (5) at the rear mounts. 15. Verify new transmission filter elements have
Tighten the cap screws to standard torque. been installed.
10. Install front drive shafts (1) and rear drive shaft 16. Fill the transmission with oil. Refer to Section P,
(7). Refer to Section F, Drive Shafts, for instal- Lubrication and Service, for oil specifications.
lation instructions. Oil must be visible in the upper part of the sight
10. Install the front driveline guard and rear drive- gauge, between the H and L marks.
line guard (6).
NOTE: Check the oil level again after the engine has
11. Remove the protective caps from the transmis- been started and the oil has reached operating
sion hoses and ports. Install new O-rings for all temperature. Refer to Transmission Oil Level Check
fittings and hoses. Coat the O-rings with petro- in this chapter.
leum grease to secure in position during assem- 17. Loosen the suction lines on the hydraulic pumps
bly. Install the hoses. to purge trapped air. Refer to Section L,
12. Reconnect the wiring harness connectors to the Hydraulic System, for instructions. Tighten the
transmission controls and sensors. clamps securely after all air has been purged.
13. Verify all hoses and connectors have been 18. Start the engine and check for hydraulic leaks.
installed. Install the transmission guard under
19. Allow the transmission oil to reach normal oper-
the transmission.
ating temperature. Recheck the transmission oil
level. Refer to Refer to Transmission Oil Level
Check in this chapter.
20. Operate the truck to verify proper operation of
transmission and controls.

TRANSMISSION OIL LEVEL CHECK
1. Engine Off:
The oil level must be visible in the upper part of
the sight gauge (STOP) between H and L. This
level guarantees there is sufficient oil to safely
operate the transmission when the engine is off,
or when the transmission oil is cold.
Check the oil level again, as described below,
when the transmission oil reaches operating
temperature.
2. Engine On:
The oil level must be visible in the lower part of
the sight gauge (turtle) between H and L.
Check the transmission oil level with:
the truck parked on a level surface,
the engine at low idle,
the transmission in NEUTRAL
the transmission oil at normal operating
temperature
Add clean oil as required through the transmis-
sion oil filler tube at the left rear of the transmis-
sion.

SECTION F3
TRANSMISSION OIL COOLER & STRAINERS
INDEX
TRANSMISSION OIL COOLER & STRAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
TRANSMISSION OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
TRANSMISSION OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
F03009 Transmission Oil Cooler & Strainers F3-1

NOTES
F3-2 Transmission Oil Cooler & Strainers F03009

TRANSMISSION OIL COOLER & STRAINERS
TRANSMISSION OIL COOLER Removal and Installation
Transmission oil cooler (1, Figure 3-1) and brake cir- Refer to Section C, Cooling System for removal and
cuit oil cooler are contained in a combined unit. The installation procedures.
unit is located at the rear of the radiator.
If a leak occurs in the brake cooler, antifreeze may
contaminate the transmission oil and/or transmission Repair
oil may contaminate the engine cooling system. Repairs to Section C, Cooling System for information
If the engine coolant is contaminated with oil, the on oil cooler repair.
system must be examined for leaks and corrected.
The system must then be flushed to remove oil con-
tamination and refilled with a clean coolant solution.
If cross contamination is suspected in the brake TRANSMISSION OIL STRAINER
cooler, the transmission oil must be examined,
immediately. Ethylene glycol, even small amounts, The transmission oil pan contains magnetic strainers.
will damage clutch plates. Contact your Komatsu dis- They must be removed and cleaned every 1000
tributor for ethylene glycol detection test kits. hours of operation.
If ethylene glycol is found in the transmission oil, the

transmission must be removed and completely disas-
sembled. The transmission must be cleaned and
examined. All friction-faced clutch plates must be
replaced.
FIGURE 3-2. MAGNETIC STRAINER

INSTALLATION
1. Magnetic Strainer 4. Washer
2. O-ring 5. Cap Screw
3. Cover
FIGURE 3-1. OIL COOLERS

1. Transmission Cooler 7. Transmission Oil Out-
2. Brake Cooler let Hose
3. Coolant Inlet 8. Transmission Oil Inlet
4. Coolant Outlet Hose
5. Orifice Check Valve 9. Brake Oil Outlet Hoses
6. Brake Oil Inlet Hoses
F03009 Transmission Oil Cooler & Strainers F3-3

Removal
1. Drain the transmission oil. The capacity of the
transmission is approximately 153 liters (41
gal).
2. Remove cap screws (5, Figure 3-2) and cover
(3).
3. Remove magnetic strainer (1) and inspect.
FIGURE 3-3. MAGNETIC STRAINER

Careful inspection of the oil pan interior, drained 1. Screen Element 3. Magnets
oil, and screen/magnets immediately after 2. Black Foreign Matter 4. Iron Particles
removal can provide valuable information regard- (non-metallic)
ing the condition of the transmission internal
components. Perform the following inspections
prior to cleaning.
Inspection
Installation
Inspect the oil pan and drained oil. Check internal
1. Install each magnetic strainer (1, Figure 3-2)
metal parts in the screen for a clogged or fouled
condition with metallic particles. When the into the transmission oil pan.
amount of foreign material has significantly 2. Install new O-rings (2) in the cover. Install the
increased compared to previous inspections, an cover using cap screws (5) and washers (4).
internal failure probably exists. Immediate Tighten the cap screws to standard torque.
corrective action is required.
3. Fill the transmission with oil. Refer to Section P,
Black foreign material (2, Figure 3-3) in the Lubrication And Service, for oil specifications.
screen element* indicates clutch disc wear.
When the clogged area reaches approximately
10 mm (0.40 in) in width and about 60 mm (2.4
in) around the circumference, transmission repair
is considered necessary within 200 operating
hours. If the clogged area is more extensive,
immediate repair is necessary.
If all magnets are fouled with iron particles,
internal metal parts have worn excessively and
may be damaged. Immediate repair is necessary.
NOTE: Check the oil pan interior and drained oil for
foreign material or for metallic powder.
If a large amount of metallic debris is found in an
oil sample, immediate action is necessary.
Record small or trace amounts and check at the
next interval for a trend.
Contamination of oil by water or anti-freeze is
considered serious. Record trace amounts to
determine a trend. If a large percentage of
content is found in an oil sample, check the oil
cooler for leakage. Repair the source of the leak
and rebuild the transmission.
F3-4 Transmission Oil Cooler & Strainers F03009

SECTION F5
DRIVE SHAFTS
INDEX
DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-4
FRONT DRIVE SHAFT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-5
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
F05012 Drive Shafts F5-1

NOTES
F5-2 Drive Shafts F05012

DRIVE SHAFTS
The front drive shaft is located between the engine Disassembly
and the transmission. The rear drive shaft is located
1. Remove cap screws (4, Figure 5-1) securing
between the transmission and the rear axle. The two
the U-joints at each end of the drive shaft.
drive shafts differ in length and design. The front
drive shaft is a fixed length. The rear driveshaft has a 2. Remove the U-joints. Inspect the assemblies for
slip-joint to permit oscillation of the rear axle. seized and damaged bearings.
Removal and installation procedures for each drive NOTE: Do not disassemble the U-joints. If the
shaft are similar. bearings require replacement, replace the entire
assembly as a unit.
FRONT DRIVE SHAFT
Removal 3. Inspect all parts for wear and damage. If either
the tube or yoke must be replaced, replace with
a new, balanced drive shaft.
4. Remove the grease fittings. Ensure all grease
passages are clear.
Chock the wheels securely before removing the 5. Clean all parts (except the U-joint) in clean sol-
drive shafts. vent and blow dry with compressed air.
1. Remove the front drive shaft guards.
2. Remove and tag any wiring or hoses which may
interfere with removal. Assembly
3. Attach an appropriate lifting sling and a hoist to 1. Install each U-joint to the drive shaft ends.
the front drive shaft. The weight of the drive Install cap screws (4, Figure 5-1) and tighten to
shaft is approximately 80 kg (176 lb). 192 10 Nm (142 7 lb ft).
4. Remove four cap screws (3, Figure 5-1) at each NOTE: Due to limited space, these cap screws must
U-joint. Remove the drive shaft from the truck. be properly tightened before the drive shaft is
installed.
2. Install the grease fittings. Lubricate the bearings
with multi-purpose grease. Refer to Section P,
Lubrication and Service, for grease specifica-
tions.
FIGURE 5-1. FRONT DRIVE SHAFT

INSTALLATION
1. Front Drive Shaft 4. Cap Screws
2. Cap Screws 5. Transmission Input
3. Engine Output

Installation
When the engine, transmission, torque converter

or front drive shaft has been removed, it is nec-
essary to check the alignment between the
engine and the transmission. Refer to Front Drive
Shaft Alignment in this section for instructions.
NOTE: Ensure the U-joint to drive shaft cap screws

(4, Figure 5-1) have been properly tightened prior to
installing the drive shaft. Refer to Front Drive Shaft -
Assembly.
1. Attach an appropriate lifting sling and a hoist to
the front drive shaft. The weight of the drive
shaft is approximately 80 kg (176 lb).
2. Lift drive shaft (1, Figure 5-1) into position
between the engine and the transmission. Align
the U-joints with the drive flanges.
3. Install four cap screws (2) at each end. Tighten
the cap screws to 176 20 Nm (130 15 lb ft).
4. Install the drive shaft guards.
5. Install any wiring or hoses removed to gain
access to drive shaft.

FRONT DRIVE SHAFT ALIGNMENT
Proper alignment of the front drive shaft is necessary
to prevent premature driveline failures. The drive
shaft must be aligned whenever the transmission,
engine or engine damper has been removed or
replaced. Other repairs that disturb driveline align-
ment will require adjustment, as well.
A quantity of two alignment tools are necessary to
perform the procedure. One of the tools is to be
mounted on the torque converter input, and the other
on the engine output (damper). Refer to Section M,
Special Tools, for the appropriate part number.
FIGURE 5-3. ALIGNMENT TOOL INSTALLED ON

TORQUE CONVERTER
1. Alignment Tool 2. Torque Converter
2. Install the other alignment tool on the torque

converter input coupling. Refer to Figure 5-3. If
the transmission is not installed in the truck, the
tool may be installed before transmission instal-
lation.
FIGURE 5-2. ALIGNMENT TOOL INSTALLED ON

DAMPER
1. Engine Damper 2. Alignment Tool
1. Install alignment tool (2, Figure 5-2) on the

engine damper coupling. If the engine is not
installed in the truck, the tool may be installed
before engine installation.
FIGURE 5-4. ALIGNMENT TOOLS INSTALLED

1. Torque Converter Input 2. Engine Output

3. If not installed, install the transmission and/or
engine.
Install the hardware for the engine mounts and
tighten to standard torque before proceeding.
Keep the transmission mounts loose until
adjustments are complete.
4. The transmission must be properly shimmed
before measuring driveline angles. Verify that
four shims are installed at each rear mount and
four shims at each front mount. Install missing
shims as necessary.
Rear Shim (1 mm) - p/n (562-16-22140)
Front Shim (1 mm) - p/n (568-16-12120)
FIGURE 5-6. COUPLING ADJUSTMENT
1. Cover 2. Coupling
FIGURE 5-5. MEASURING MISALIGNMENT
5. Adjust the coupling so that the dust cover is no 7. Determine the necessary adjustments by using
more than 19 mm (0.75 in.) from the face of the the formulas below. There are two formulas, a
damper cover. Refer to Figure 5-6. top view formula and a side view formula. The
6. Obtain a straight edge long enough to span the top view formula is used to calculate the side-
gap between the two tools, as shown in Figure to-side adjustment. The side view formula is
5-5. Use a small ruler to measure the gap used to calculate the vertical adjustment. Refer
between the straight edge and the tools. Mea- to Figure 5-7 for reference.
sure in four places as specified in Figure 5-7.
Record the measurement at each location. Formulas -
Top View: (A + B) / 2 = 3 mm max.
Side View: (C - D) / 2 = 3 mm max.

Example -
Measurements: A = 3 mm B = 7 mm Side view formula: (20 - 6) / 2 = 7 mm
C = 20 mm D = 6 mm The quotient of 7 mm in this example is 4 mm
over the allowable maximum of 3 mm. Use a
hoist to lift the transmission enough to install
Top view formula: (3 + 7) / 2 = 5 mm shims (2, Figure 5-8) below mounting pins (1).
The quotient of 5 mm in this example is 2 mm A general guideline to follow is to divide the dif-
over the allowable maximum of 3 mm. Loosen ference by two. This is the number of shims to
the cap screws at the front transmission mounts install. Since the difference in this example is 4
and remove the locking plates. Use a hoist to mm, install two shims at each front mount.
move the transmission 2 to 5 mm towards the NOTE: DO NOT install additional shims at the rear
center of the truck. Moving the transmission 2 to mounts. Adjust the transmission height by shimming
5 mm would result in a quotient of 3 mm or less, the front mounts, only.
meeting the specification.
NOTE: Keep the shafts parallel when adjusting the
position of the transmission.
FIGURE 5-7. MEASURING DRIVE LINE ANGLES

REAR DRIVE SHAFT
Removal
Chock the wheels securely before removing the

drive shafts.
1. Remove the rear drive shaft guard.
2. Remove and tag any wiring or hoses which may
interfere with drive shaft removal.
3. Attach an appropriate lifting sling and a hoist to
the rear drive shaft. The weight of the drive
FIGURE 5-8. INSTALLING SHIMS - FRONT shaft is approximately 220 kg (485 lb).
1. Mounting Pins 2. Shims 4. Remove four cap screws (2, Figure 5-9) at each
U-joint. Remove the drive shaft from the truck.
8. Recheck the measurements. Adjust the position

of the transmission as necessary to meet the
specifications.
9. Install the locking plates to the transmission
mounts and tighten the cap screws to standard
torque.
10. Install the drive shaft. Refer to Front Drive Shaft
- Installation in this chapter.
FIGURE 5-9. REAR DRIVE SHAFT INSTALLATION
1. Rear Drive Shaft 4. Transmission Output

2. Cap Screws 5. Final Drive Input
3. Drive Shaft Cap
Screws

Disassembly Installation
1. Remove cap screws (3, Figure 5-9) securing NOTE: Ensure the U-joint to drive shaft cap screws
the U-joints to each end of the drive shaft. (3, Figure 5-9) have been properly tightened prior to
Inspect the assemblies for seized or damaged installing the drive shaft. Refer to Rear Drive Shaft -
bearings. Assembly.
NOTE: Do not disassemble the U-joints. If the 1. Attach an appropriate lifting sling and a hoist to
bearings require replacement, replace the entire the rear drive shaft. The weight of the drive
assembly as a unit. shaft is approximately 220 kg (485 lb).
2. Lift the rear drive shaft into position between the
transmission and the rear axle.
2. Match mark the drive shaft halves for proper ori-
entation during assembly. This is done to main- 3. Apply Three Bond TB1374 to cap screws (2).
tain the balance on the shaft. Install the eight cap screws and tighten to 382
38 Nm (282 28 lb ft).
3. Inspect all parts for wear and damage. If either
the tube or the yoke must be replaced, replace 4. Install the drive shaft guard.
with a new, balanced drive shaft. 5. Install any wiring or hoses that were removed to
4. Remove the grease fittings. Ensure all grease gain access to the drive shaft.
passages are clear.
5. Clean all parts (except the U-joints) in clean sol-
vent and blow dry with compressed air.
Assembly
1. Lubricate the splines of the drive shaft with
multi-purpose grease. Carefully slide both
shafts together using the alignment marks from
disassembly.
2. Install the U-joint at each end of the drive shaft.
Tighten cap screws (3, Figure 5-9) to 397 20
Nm (293 15 lb ft).
NOTE: Due to limited space, these cap screws must
be properly tightened before the drive shaft is
installed.
3. Install the grease fittings. Lubricate the bearings

with multi-purpose grease. Refer to Section P,
Lubrication and Service, for complete grease
specifications.

NOTES

SECTION F8
TORQUE CONVERTER REBUILD
INDEX
TORQUE CONVERTER REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-7
PTO COVER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
CLEANING & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16
TABLE I. COMPONENT WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
TABLE II. Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
ONE-WAY CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-19
STATOR BEARING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
PTO DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-24
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-30
F08003 Torque Converter Rebuild F8-1

NOTES
F8-2 Torque Converter Rebuild F08003

TORQUE CONVERTER REBUILD
The following information provides instructions for 3. If the transmission is to be disassembled,
removing the torque converter from the transmission, remove the cap screw on the output shaft and
torque converter rebuild, and reinstalling the torque remove drive shaft flange (5, Figure 8-2).
converter. Refer to Section F2, Torque Converter 4. Remove cover (4) from the ECMV valve assem-
and Transmission, for instructions on removing the bly.
transmission/torque converter from the truck.
5. Disconnect inlet pressure sensor (2) and outlet
Special tools for aiding in torque converter and pressure sensor (3).
transmission rebuild are listed at the end of this
chapter in Special Tools.
Unless otherwise specified, use standard torque
specifications for fasteners. Refer to Section A5
for standard torque specifications.
REMOVAL
1. Thoroughly clean the transmission and torque
converter to remove any dirt accumulation.
2. Remove hydraulic pumps (2, 3, 4, & 5, Figure 8-
1). Remove trunnion (6).
FIGURE 8-2. SENSOR WIRING
1. Torque Converter 4. ECMV Cover

2. Inlet Pressure Sensor 5. Output Flange
3. Outlet Pressure Sensor
6. Remove lubrication tubes (1, Figure 8-3) and

remove.
7. Remove cap screws (2) securing main relief
and regulator valve (3) and outlet relief valve
(4).
FIGURE 8-1. HYDRAULIC PUMPS
1. Torque Converter 4. Transmission Pump

2. Hoist Pump 5. Brake Cooling Pump
3. Steering/Brake 6. Trunnion
Pump

FIGURE 8-3. VALVES
1. Lubrication Tubes 3. Main Relief and
2. Cap Screws Regulator Valve
4. Outlet Relief Valve
8. Install lift plates (8, Figure 8-4) at each of the

three pump mounts. Refer to Special Tools at
the end of this chapter for instructions on fabri-
cating lift plates. Insert bolts (6) (p/n 01010-
81260) into the tapped pump mounting bosses
and tighten to 110 Nm (81 lb ft). Install a lift
eye (7) (p/n 04530-12438) in each lift plate and
attach to appropriate lifting chains and a hoist.
The weight of the assembly is approximately FIGURE 8-4. TORQUE CONVERTER REMOVAL
3160 kg (6967 lbs.).
9. Vertically lift the transmission/torque converter 1. Oil Drain Pan 6. Bolt
assembly over an oil drain pan. Install blocking 2. Blocking 7. Lift Eye
to support the assembly. 3. Transmission 8. Lift Plate
4. Torque Converter
10. Remove cap screws (5) securing the torque 5. Cap Screws and
converter to the transmission housing. Washers
11. Carefully lift the torque converter off of the
transmission input shaft. Move the torque con-
verter to a repair area.

INSTALLATION
1. Vertically position the transmission with the 3. Install seal rings (1, Figure 8-5) onto the trans-
input shaft upward, as shown in Figure 8-5. The mission input shaft at five locations. Apply
weight of the transmission is approximately petroleum jelly to the seals.
2270 kg (5000 lbs). 4. Install O-ring (6) onto the converter housing.
2. Install lift plates at each of the three pump Install O-rings (2, Figure 8-6) in the grooves of
mounts on the torque converter. Insert bolts (p/ the oil passages on the front face of transmis-
n 01010-81260) into the tapped pump mounting sion case (1). Apply petroleum jelly to the O-
bosses. and tighten to 110 Nm (81 lb ft). Install rings to aid in assembly.
a lift eye (p/n 04530-12438) in each lift plate
and attach to appropriate lifting chains and a
hoist. The weight of the torque converter is
approximately 842 kg (1856 lbs).
FIGURE 8-6. TRANSMISSION CASE FACE
1. Transmission Case 2. O-Rings
5. Raise torque converter (3, Figure 8-5) and posi-

tion over transmission input shaft (2). Carefully
lower the assembly while aligning the splines in
the converter stator with the splines on the
transmission shaft.
6. Install cap screws with washers (4). Install nuts
and washers (5) onto the studs.
NOTE: There are 10 nuts and 12 cap screws
required.
FIGURE 8-5. TORQUE CONVERTER 7. Install new O-rings (2, 3 & 4, Figure 8-7) into
INSTALLATION the grooves of the oil passages. Apply petro-
1. Seal Rings 4. Cap Screws and leum jelly to the O-rings.
2. Transmission Input Washers
Shaft 5. Nuts and Washers
3. Torque Converter 6. O-Ring

FIGURE 8-7. VALVE SEAT MOUNT
1. Torque Converter 3. O-rings

2. O-rings 4. O-rings FIGURE 8-9. MAIN RELIEF & REGULATOR
VALVE INSTALLATION
1. Main Relief and 3. Cap Screw
Regulator Valve 4. Washer
2. Gasket
8. Install valve seat (1, Figure 8-8) over the oil
passages on the top surface of the torque con-
verter housing. Ensure the O-rings remain in 10. Place torque converter main relief and regulator
place. valve assembly (1, Figure 8-9) and a new gas-
9. Install cap screws (2) that secure the valve seat ket into position. Install cap screws (3) and
to the torque converter. Tighten to 66 7 Nm washers (4) and tighten to 49 5 Nm (36 4 lb
(49 5 lb ft). ft).
11. Install outlet relief valve seat (5, Figure 8-10)
and a new O-ring (6) onto the torque converter
housing. Install cap screws (4) and tighten to
110 12 Nm (81 9 lb ft).
FIGURE 8-8. VALVE SEAT INSTALLATION
1. Valve Seat 3. Cap Screw and

2. Cap Screw and Washer
Washer 4. Cap Screw and
Washer

DISASSEMBLY
1. Place a container under the torque converter to
capture oil when the converter is drained.
Approximate capacity is 45 - 55 l (12 - 15 gal).
2. Remove two cap screws (2, Figure 8-11) and
drain oil from pump (1) and the stator.
FIGURE 8-11. DRAINING OIL
1. Pump 2. Cap Screws
3. Position the torque converter assembly with the

input flange upward. Remove the flange
FIGURE 8-10. OUTLET RELIEF VALVE
retainer cap screw. Remove holder (1, Figure 8-
ASSEMBLY
12). Lift input flange (2) off the input shaft
1. Outlet Relief Valve 4. Socket Head Cap splines.
2. Cap Screw and Screw
Washer 5. Valve Seat
3. O-Rings 6. O-ring
12. Install O-rings (3) between the valve seat and

the valve body. Apply petroleum jelly to the O-
rings. Place outlet relief valve (1) into position.
Install cap screws and washers (2). Tighten the
cap screws to 49 5 Nm (36 4 lb ft).
13. Install lubrication lines (5, Figure 8-8).
14. Connect the inlet and outlet pressure sensors to
the electrical harness.
FIGURE 8-12. DRIVE FLANGE REMOVAL
1. Holder 2. Input Drive Flange

10. Remove snap ring (1, Figure 8-13) securing
bearing retainer (2) to the housing.
11. Install pusher bolts into tapped holes (2).
Remove retainer (3) from the front housing.
FIGURE 8-14. PUMP DRIVE GEAR REMOVAL

1. Cover 4. Lift Eye
2. Cap Screw 5. Cap Screw and
3. Lift Plate Washer
FIGURE 8-13. RETAINER REMOVAL
1. Snap Ring 3. Bearing Retainer
2. Tapped Hole 4. Input Shaft 13. Repeat the previous step for the remaining
pump drives.
14. Remove cap screws (1, Figure 8-15) retaining
12. Remove pump drive cover (1, Figure 8-14) cap the front housing to the rear housing.
screws and washers (5). Install lift plate (3) on
pump mounting boss using p/n 01010-81260 NOTE: There are a total of 21 cap screws. Six cap
bolts. Install lift eye (p/n 04530-12438) and screws are located internally, as shown in Figure 8-
attach to lifting chains and a hoist. Lift the 16.
assembly out of the Power Take Off (PTO) 15. Remove cover (3). Loosen round nuts (4) on the
housing. gear shafts using tool - p/n 790-102-1891.
NOTE: Refer to Special Tools at the end of this
chapter for information on lift plate fabrication.
FIGURE 8-15. CASE DISASSEMBLY

1. Cap Screws & 3. Cover
Washers 4. Round Nut
2. Tapped Hole

16. Remove six cap screws (1, Figure 8-16) located 19. Install a lift eye in the tapped hole in input shaft
inside the housing. (1, Figure 8-18).
20. Attach lifting chains and a hoist and lift the
clutch assembly out of the rear housing.
FIGURE 8-16. INSIDE CAPSCREW REMOVAL
1. Cap Screws 2. Front Housing FIGURE 8-18. CLUTCH ASSEMBLY REMOVAL
1. Input Shaft 2. Clutch Housing
17. Insert pusher bolts in tapped holes (2, Figure 8- 21. Remove 14 cap screws (2, Figure 8-19). Insert
15). removed cap screws in tapped holes to push
18. Attach lift eyes to front housing (1, Figure 8-17). shaft (1) out of assembly.
Carefully lift the front housing off rear housing
(2) while tightening the pusher bolts.
1. Shaft 2. Cap Screws
FIGURE 8-17. FRONT HOUSING REMOVAL
1. Front Housing 2. Rear Housing

22. Remove snap ring (2, Figure 8-20).
23. Remove the spacer. Tap the end of turbine
shaft (1) to remove from the assembly.
FIGURE 8-22. PISTON REMOVAL
1. Piston 2. Housing
FIGURE 8-20. SNAP RING REMOVAL

27. Remove three lockup clutch discs (1, Figure 8-
23) and two plates (2).
1. Turbine Shaft 2. Snap Ring
24. Remove 36 cap screws (2, Figure 8-21).

25. Install lift eyes, lifting chains and a hoist to hous-
ing (1). Lift the housing from the case.
FIGURE 8-23. CLUTCH DISASSEMBLY
1. Clutch Disc 2. Clutch Plate

FIGURE 8-21. HOUSING REMOVAL
1. Housing 2. Cap Screws
28. Straighten the tabs on the nut retainer to unlock
the nuts.
29. Use special tool (p/n 792-335-1300) to remove
26. Lift piston (1, Figure 8-22) out of housing (2). the stator bearing retainer nuts.

FIGURE 8-24. NUT REMOVAL TOOL
1. Bearing Retainer 2. Special Tool

FIGURE 8-26. STATOR DISASSEMBLY
Nuts
1. Stator 2. Mounting Cap Screws
33. Install pusher bolts in tapped holes (1, Figure 8-

27). Tighten the bolts and remove retainer (2).
Remove the bearing outer race from the
retainer.
FIGURE 8-25. STATOR REMOVAL
1. Stator 2. Rear Housing
FIGURE 8-27. RETAINER REMOVAL

30. Grasp stator (1, Figure 8-25) and the bearing
assembly. Lift out while rotating clockwise. 1. Tapped Hole 2. Retainer
31. Remove 16 stator mounting cap screws (2,
Figure 8-26).
32. Remove stator (1).

34. Using an appropriate sized rubber mallet, lightly
tap the free-wheel assembly and remove.
FIGURE 8-30. INNER RACE REMOVAL
1. Inner Race 2. Retainer Nut
37. Use special tool (1, Figure 8-31) (p/n 792-335-

FIGURE 8-28. FREE-WHEEL REMOVAL
1400) to remove bearing retainer nut (2).
1. Driver Tool 2. Free-Wheel
35. Tap plate (3) with a mallet. Remove the plate

together with outer race (1, Figure 8-29).
FIGURE 8-31. NUT REMOVAL
FIGURE 8-29. OUTER RACE REMOVAL 1. Special Tool 2. Nut
1. Outer Race 3. Plate

2. Race
38. Remove two cap screws (1, Figure 8-32) from

the transmission end of the shaft.
36. Remover inner race (1, Figure 8-30) from the
splined shaft.

NOTE: Do not remove shaft (1, Figure 8-34) unless it
is necessary to replace the shaft or the rear housing.
43. If shaft removal is necessary, remove 13 cap
screws (2, Figure 8-34).
44. Support the rear housing on wooden blocks to
prevent damage to shaft threads. Use a ham-
mer to drive shaft (1) out.
FIGURE 8-32. BEARING ACCESS HOLES
1. Cap Screw 2. Shaft
39. Insert two bars into the bolt holes.

Bar dimensions: 8 mm (0.31 in.) diameter, 160 FIGURE 8-34. SHAFT REMOVAL
mm (6.3 in.) length (or longer)
1. Shaft 2. Cap Screws
40. Tap the end of the bars evenly to remove the
bearings from the shaft.
41. Remove 24 cap screws (1, Figure 8-33).
42. Remove retainer (3) and plate (2). Remove 45. Remove cover mounting cap screws (2,
outer bearing race (4) from the retainer. Figure 8-35) and remove cover (1). Discard the
O-ring sealing the cover to the housing.
FIGURE 8-33. PUMP DISASSEMBLY
1. Cap Screws 4. Bearing Outer Race

2. Plate 5. Pump FIGURE 8-35. COVER REMOVAL
3. Retainer 1. Cover (w/ O-ring) 4. Snap Ring
2. Cap Screws 5. Plate
3. Nut 6. Bearing
7. Gear

46. Remove mounting cap screw (1, Figure 8-36)
and remove holder (2) from the gear.
FIGURE 8-38. BEARING REMOVAL
1. Bearing 2. Front Housing

FIGURE 8-36. GEAR HOLDER REMOVAL
1. Cap Screw 2. Holder 49. Remove nut (3, Figure 8-35) using special
wrench, p/n 790-102-1891. Tap gear (7) out of
the bearing bore.
47. Use a rubber mallet to tap the end of the gear 50. Remove snap ring (4) and plate (5).
shaft. Remove from the bore of the bearings in
51. Remove bearing (6). Note the bearing markings
the front housing as shown in Figure 8-37.
as they are removed. Bearings are matched
and must be reassembled in the same order as
removed.
52. Remove nut (1, Figure 8-39) using special
wrench p/n 790-102-1891. Tap gear shaft (3) to
remove the gear from the bearing bore.
FIGURE 8-37. GEAR REMOVAL
48. Remove front bearing (1, Figure 8-38) from

front housing (2).

1. Nut 4. Plate
2. Snap Ring 5. Bearing
3. Gear Shaft

53. Remove snap ring (2) and plate (4).
54. Remove bearing (5). Note the bearing markings
as they are removed. Bearings are matched
and must be reassembled in the same order as
removed.
PTO COVER DISASSEMBLY

NOTE: Disassembly procedures for the right and left
PTO drives are identical.
55. Remove cap screws (1, Figure 8-40) and
remove gear (2).
FIGURE 8-41. BOSS REMOVAL

1. Cover 3. Snap Ring
2. Boss
58. Turn the boss and bearing assembly over.

Remove snap ring (2, Figure 8-42). Remove
bearing (1) from the boss.

1. Cap Screws 3. Cover
2. Gear
56. Remove snap ring (3, Figure 8-41).

57. Remove boss (2) and the bearing assembly
from cover (1).
FIGURE 8-42. BOSS DISASSEMBLY
1. Boss 2. Snap Ring
59. Repeat steps 55 through 58 for the remaining

PTO cover assembly.

CLEANING & INSPECTION
After disassembly, thoroughly clean all parts and Refer to Figure 8-43 for location of areas to be mea-
inspect. Determine whether the parts are within sured. The standard dimension of the item, and the
specifications. Refer to Table 1 - Component Wear maximum permissible wear is listed in Table I.
Limits. Install new O-rings during assembly. Inspect all cap
screws for cracks or thread damage. Replace any
damaged parts.
FIGURE 8-43. COMPONENT PARTS INSPECTION (SEE TABLE 1)
1. Clutch Housing/Piston Seal Ring 4. Input Shaft 7. Pump Bearing Retainer

2. Pump Seal Ring 5. Lockup Clutch Piston
3. Input Flange 6. One-Way Clutch Assembly

TABLE I. COMPONENT WEAR LIMITS
Dimension
Location/
DESCRIPTION Standard Size Max. Wear Limit Remedy
Item
mm Inches mm Inches
Outside diameter of input
Repair or replace
A flange (3) at oil seal contact 125 4.921 124.8 4.913
input flange.
area.
Inside diameter of input
Repair or replace
B shaft (4) at seal ring contact 35.0 1.378 35.1 1.382
input shaft.
area.
Inside diameter of one-way
D clutch (6) rotating face of 153.17 6.030 153.2 6.031
outer race. Replace one-way
Outside diameter of one- clutch
E way clutch (6) rotating face 134.17 5.282 134.14 5.281
of shaft.
Inside diameter of pump
Repair or replace
F bearing retainer (7) at seal 185 7.283 185.5 7.303
bearing retainer.
ring contact area.
Replace clutch
G Clutch disc thickness 5.4 .213 4.8 0.189
disk.
4.45 0.175 4.0 0.157
wide wide wide wide Replace seal ring
1 Pump seal ring dimensions
6.5 0.256 5.9 0.232
thick thick thick thick
2 Crack check of bolt No Crack Replace Bolt
TABLE II. Gear Backlash

Mating surfaces Backlash
Input shaft and lower idler gear 0.193~0.504
Lower idler gear and PTO gear 0.193~0.504
Input shaft and upper idler gear 0.204~0.538
Upper idler gear and PTO gears 0.204~0.538

ASSEMBLY 4. Install retainer (3, Figure 8-45) and tapped plate
(2) onto the pump. Apply thread lock (p/n
1. Place shaft (1, Figure 8-44) in dry ice to cool. 09940-00030) to 24 cap screws (1). Install the
After thoroughly chilled, place the shaft into cap screws and washers. Tighten the cap
position on the housing. Align the cap screw screws to 66 7 Nm (49 5 lb ft).
holes in the shaft with the holes in the housing.
2. Apply thread lock (p/n 09940-00030) to 13 cap
screws (2). Install the cap screws and washers.
Tighten to 110 12 Nm (81 9 lb ft).
FIGURE 8-45. PUMP SUBASSEMBLY
1. Cap Screws and 3. Retainer

Washers 4. Bearing Outer Race
FIGURE 8-44. SHAFT INSTALLATION 2. Retainer (tapped) 5. Pump
1. Shaft 2. Cap Screws and
Washers
5. Install seal ring (7, Figure 8-46) on shaft (1).
3. Press the outer race of bearing (5, Figure 8-46) Coat the seal ring with petroleum jelly.
into retainer (8). 6. Carefully lower the pump sub-assembly onto
the shaft.
FIGURE 8-46. PUMP ASSEMBLY

1. Shaft 5. Bearing
2. Inner Race 6. Pump
3. Nut 7. Seal Ring
4. Bearing 8. Retainer

7. Heat bearings (4 & 5) in an oven to 80 - 100C ONE-WAY CLUTCH ASSEMBLY
(175 - 212F). 14. Install plate (3, Figure 8-48) into the bore of
8. Press fit bearing (5) onto the shaft until seated race (2).
against the shoulder. Press fit bearing (4) onto
15. Place bearing race (1) in dry ice until chilled.
the shaft until seated against the pump bearing.
Use 19.6 - 29.4 kN (2 - 3 tons) force to press
Use 19.6 - 29.4 kN (2 - 3 tons) force when
bearing outer race (1) into the bore of race (2).
pressing the bearings.
Ensure the cup is properly seated with no clear-
10. Thread nut (3) onto the shaft. ance between the cup and the shoulder.
11. Use special tool (p/n 792-335-1400) to tighten
the nut to 466 24 Nm (344 18 lb ft) as
shown in Figure 8-47.
FIGURE 8-48. BEARING RACE INSTALLATION
1. Bearing Outer Race 3. Plate

2. Race
16. Turn the race over with the tapped holes posi-
tioned at the top.
FIGURE 8-47. TORQUEING SHAFT NUT
17. Position the free-wheel in the bore of the race
1. Special Tool 2. Bearing Retainer with the arrow pointing clockwise. Refer to
Nut Figure 8-49.
12. Apply approximately 7 ml (0.25 oz) power line

oil to the bearings and rotate the pump approxi-
mately 10 revolutions.
13. Install inner race (2, Figure 8-46) over shaft (1).
FIGURE 8-49. CLUTCH ROTATION DIRECTION
1. Drag Spring 2. Sprag

18. Use a mallet and installation tool (1, Figure 8- 19. Place bearing cup (4, Figure 8-51) in dry ice to
50) to tap the free-wheel into the bore of the chill. Use 19.6 - 29.4 kN (2 - 3 tons) force to
race. Use caution when installing. Damage to press the bearing cup into retainer (3). Verify
sprags or drag springs may result with too much the cup is properly seated with no clearance
force. between the cup and the shoulder.
20. Assemble stator (1), retainer (3), and race (10).
Apply thread lock (p/n 09940-00030) to cap
screws (2). Install the cap screws and the wash-
ers. Tighten to 110 12 Nm (81 9 lb ft).
21. Apply power line oil to the one-way clutch inner
race.
22. Lower stator assembly (1, Figure 8-52) over the
shaft. Position the stator into rear housing (2)
while rotating clockwise.
FIGURE 8-50. FREE-WHEEL INSTALLATION

1. Installation Tool 2. Free-Wheel
FIGURE 8-51. STATOR INSTALLATION
1. Stator 6. Nut
2. Cap Screw & Washer 7. Lock Plate
3. Retainer 8. Nut
4. Bearing Cup 9. Spacer
5. Bearing Cone 10. Race

27. Install nut (8). Use special tool (p/n 792-335-
1300) and tighten to 367 24 Nm (271 18 lb
ft).
28. Loosen nut (8) about 60 degrees. Install lock
plate (7) and outer nut (6). Tighten to 367 24
Nm (271 18 lb ft).
FIGURE 8-52. STATOR INSTALLATION
1. Stator Assembly 2. Rear Housing
23. After the stator is seated onto the bearing,

rotate the stator. Confirm the stator will turn
clockwise, but not counterclockwise.
FIGURE 8-53. BEARING PRE-LOAD CHECK
STATOR BEARING PRE-LOAD 1. Spring Scale 2. Stator Retainer Cap

ADJUSTMENT Screw
Reposition the assembly to place the torque con-
29. Repeat the measurement of force required to
verter axis horizontally.
rotate the one-way clutch. Use the same proce-
24. Rotate the stator 15 to 20 times. Tap the stator dure as before.
two or three times using a soft mallet.
30. Adjust the pre-load by loosening and tightening
25. Securely fasten one end of a small diameter the stator bearing retainer nuts until the proper
rope to one cap screw (2). Then wrap the rope tangential force is achieved. The proper tangen-
around the heads of the remaining cap screws tial force required to rotate the one-way clutch is
(2) for one revolution. 3.5 to 4.0 kg (7.7 to 8.8 lbs.)
NOTE: Figure 8-53 does not show the preferred rope Tangential force = Force required to rotate one-way
method of checking rolling resistance. clutch (from Step 25) + 2.2 to 3.6 kg (4.9 to 7.9 lbs.).
a. Hook a 10 kg (20 lb) spring scale to the other
end of the rope.
31. Repeat steps 29 and 30 until the correct force is
b. Pull the spring scale smoothly. Read and achieved.
record the force required to start the stator
rotating. The front stator bearing cone is not 32. After completing the preload adjustment, bend
installed. Take several measurements and locking plate (7, Figure 8-51) against the flats of
record the average value. nuts (6 & 8).
26. Install spacer (9, Figure 8-51) and bearing cone 33. Tighten two stator retainer cap screws (2,
(5). Coat the bearing with power line oil and Figure 8-53) to 110 12 Nm (81 9 lb ft).
rotate the stator several revolutions.

34. Confirm that all rollers of the stator bearing (5,
Figure 8-51) rotate. Verify that a 0.05 mm
(0.002 in.) feeler gauge cannot be inserted
between the end of the roller and the lip on the
outer race. Refer to Figure 8-54.
FIGURE 8-56. CASE INSTALLATION
1. Case 2. Turbine
38. Install a lock-up clutch disc (1, Figure 8-57) and

then a plate (2). Alternately install remainder of
discs (3 total) and plates (2 total). Coat the
discs and plates with clean power line oil during
installation.
FIGURE 8-54. BEARING CLEARANCE CHECK
35. Reposition the torque converter with the axis of

the shaft vertical.
36. Place the turbine on a work bench. Support the
turbine on a wood block, as shown in Figure 8-
55.
FIGURE 8-57. CLUTCH ASSEMBLY

1. Clutch Disc 2. Clutch Plate
39. Install piston seal rings (5) in the piston grooves

FIGURE 8-55. TURBINE ASSEMBLY as shown (cup positioned toward outside) in
Figure 8-58. Coat the piston seal ring with
petroleum jelly.
40. Chill new pins (4, Figure 8-58) in dry ice if
removed. After thoroughly chilled, tap the pins
37. Attach a lifting sling and a hoist to case (1, into the piston in three places.
Figure 8-56). Lower the case over turbine (2).

41. Install piston seal rings (3) into the groove in 44. Press fit bearing (2, Figure 8-60) into housing
housing (1). Coat the piston seal ring with petro- bore. Verify the bearing is installed parallel to
leum jelly. the face of piston housing (1) within 0.05 mm
(0.002 in.). Install spacer (3) and snap rings (4
& 5).
FIGURE 8-58. PISTON INSTALLATION 1. Piston Housing 4. Snap Ring

2. Bearing 5. Snap Ring
1. Piston Housing 4. Pin
3. Spacer
2. Piston 5. Piston Seal Ring
3. Housing Seal Ring
42. Carefully slide the piston into the housing. Invert 45. Press dowel pins (3, Figure 8-61) into the four
the assembly and lower onto the case top. holes in bottom of input shaft (1).
Ensure the piston remains in the housing bore. 46. Press bearing inner race (2) onto the shaft until
seated against the shoulder.
47. Align the dowel pins in the shaft with the holes
in piston housing (4). Tap the shaft until seated
on the housing.
FIGURE 8-59. CLUTCH HOUSING INSTALLATION
1. Piston Housing 2. Cap Screws
43. Apply thread lock (p/n 09940-00030) to cap

screws (2). Install the cap screws and washers
and tighten to 110 12 Nm (81 9 lb ft).

FIGURE 8-62. CLUTCH & PUMP ASSEMBLY
FIGURE 8-61. SHAFT INSTALLATION 1. Input Shaft 2. Clutch Sub-

Assembly
1. Input Shaft 4. Piston Housing
2. Bearing Inner Race 5. Cap Screw
3. Dowel Pin 6. Washer
PTO DRIVE ASSEMBLY

51. Press fit bearing outer race (2, Figure 8-63) for
48. Apply thread lock (p/n 09940-00030) to cap the right hand pump drive into the front housing.
screw (5). Install cap screws (5) and washers Install snap ring (1).
(6). Tighten to 292 18 Nm (215 13 lb ft).
52. Repeat the previous step for the left hand,
49. After assembly, check the turbine for smooth upper pump drive.
rotation.
NOTE: Pump drive assembly procedures are
50. Install a lift eye in the tapped hole of input shaft
identical for both the left and right, upper PTO pump
(1, Figure 8-62). Attach lifting chains and a
drives.
hoist. Lift the assembly over the pump in the
rear case sub-assembly and lower into position. 53. Install outer bearing race (4) for the upper idler
Install two cap screws to temporarily attach the gear in the front housing bore.
turbine case to the pump. 54. Press fit half of inner race (5) onto idler gear
shaft (10).
NOTE: Assemble bearing inner races (5 & 6)
according to match marks noted during disassembly
or match marks on new bearing assembly.
55. Install gear (10) through the front case bore
from the inside. Support the gear and press fit
the remaining inner race onto the shaft.
56. Install holder (9). Apply thread lock (p/n 09940-
00030) to cap screw (8). Install the cap screw
and washer. Tighten to 277 33 Nm (204 24
lb ft).

FIGURE 8-63. PTO UPPER PUMP DRIVE & IDLER GEAR ASSEMBLY
1. Snap Ring 7. Cover
2. Outer Race 8. Cap Screw
3. Snap Ring 9. Holder
4. Outer Race 10. Upper Idler Gear
5. Inner Race 11. O-ring
6. Inner Race
57. Apply approximately 7 ml (0.25 oz) of clean

power line oil to the tapered roller bearing
assembly. Rotate the gear approximately 10
revolutions to check for smooth operation.
58. Install new O-ring (11) and cover (7). Install the
cover cap screws and tighten to 110 12 Nm
(81 9 lb ft).
59. Press bearing outer race (2) into front housing
(1).
60. Press one inner race (3) onto gear shaft (4).
Refer to the match marks for proper bearing
assembly.
61. Insert gear (4) into the front housing bore. Press
the remaining inner race (8) onto the shaft. FIGURE 8-64. LOWER IDLER GEAR ASSEMBLY
Install plate (5) and snap ring (6). 1. Front Housing 5. Plate
2. Outer Race 6. Snap Ring
62. Apply thread lock (p/n 09940-00030) and install
3. Inner Race 7. Nut
nut (7). Use tool p/n 790-102-1891 to tighten to
4. Lower Idler Gear 8. Inner Race
353 39 Nm (260 29 lb ft).

revolutions to check for smooth operation.
64. Install a new O-ring (2, Figure 8-65) onto cover
(1). Place the cover over the lower idler gear.
Install cap screws (3) and the washers and
tighten to 110 12 Nm (81 9 lb ft).
FIGURE 8-66. LOWER PUMP DRIVE ASSEMBLY
1. Front Housing 6. Nut

3. Inner Race 8. Transmission Pump
4. Plate Drive Gear
5. Inner Race 9. Lower Idler Gear
66. Press one inner race (3) of the bearing onto

gear shaft (8). Refer to the match marks for
proper bearing assembly.
67. Install the gear in the front housing bore and
FIGURE 8-65. IDLER GEAR COVER press the remaining inner race (5) onto the
shaft.
1. Cover 3. Cap Screws 68. Install plate (4) and snap ring (7).
2. O-Ring
69. Apply thread lock (p/n 09940-00030) to the
threads of nut (6). Install the nut. Use tool p/n
790-102-1891 to tighten to 36 4 Nm (260
29 lb ft).
65. Press bearing outer race (2) into the bore in
front housing (1).
revolutions and check for smooth operation.
71. Attach lift eyes to front housing (1, Figure 8-67).
Attach appropriate lifting chains and a hoist to
the lift eyes.
72. Install a new O-ring in the groove of the front
housing flange. Install new O-rings at the oil
transfer holes. Coat the O-rings and mating sur-
faces with petroleum jelly.

FIGURE 8-69. MOUNTING CAP SCREWS
1. Cap Screws 2. Housing
FIGURE 8-67. HOUSING ASSEMBLY
1. Front Housing 2. Rear Housing
75. Tighten the cap screws to 277 33 Nm (204

24 lb ft).
76. Press fit bearing (1, Figure 8-70) to the pump
73. Carefully lower the front housing onto rear drive boss.
housing (2) while meshing the gears.
74. Coat the threads of cap screws (1, Figure 8-67)
with thread sealer p/n 790-129-9080. Install the
cap screws and washers.
FIGURE 8-70. BOSS & BEARING ASSEMBLY

1. Bearing 2. Snap Ring
FIGURE 8-68. HOUSING ASSEMBLY
1. Cap Screw 2. Washer
77. Press fit bearing and boss (2, Figure 8-71) into
cover (1). Install snap ring (3).
NOTE: Six of the cap screws must be accessed

through the pump drive cavity, as shown in Figure 8-
69. A special offset wrench may have to be
fabricated locally to reach below the gear to tighten
two of the cap screws.

80. Install gear (5) on boss (11).
threads of cap screws (1, Figure 8-73) Install
the cap screws and tighten to 110 12 Nm (81
9 lb ft).
FIGURE 8-71. COVER ASSEMBLY
1. Cover 3. Snap Ring

2. Bearing & Boss

power line oil to the ball bearing assembly. FIGURE 8-73. PUMP DRIVE GEAR
Rotate the boss approximately 10 revolutions to INSTALLATION
check for smooth operation. 1. Cap Screws 3. Cover
79. Press bearing inner race (7) onto pump drive 2. Gear
gear (5).
82. Install a new O-ring (14, Figure 8-72) in cover

(12). Coat the O-ring and mating bore in the
front housing with petroleum jelly.
83. Install the pump drive gear assembly into the
housing. Install cap screws (13) and the wash-
ers and tighten to 110 12 Nm (81 9 lb ft).
84. Install a new O-ring (6) onto cover (4). Install the
cover. (Applicable to the RH pump drive, only.)
85. Repeat the previous steps for the remaining,
upper pump drive components.
86. If previously removed, install dowel pin (3,
Figure 8-74).
87. Apply sealant p/n 790-129-9070 to the outer
diameter of oil seal (1). Install the seal in
retainer (5). Apply grease p/n 790-129-9080 to
FIGURE 8-72. UPPER PUMP DRIVE the seal lip and retainer bore in the front hous-
ing.
1. Snap Ring 8. Snap Ring
2. Bearing 9. Bearing
4. Cover 11. Boss
5. Pump Drive Gear 12. Cover
6. O-Ring 13. Cap Screw
7. Inner Race 14. O-Ring

88. Coat a new O-ring (2) with petroleum jelly and
install it onto retainer (5).
89. Position retainer (5) over the front housing.
Align the hole for dowel pin (3) and install the
retainer in the housing. Install snap ring (4).
90. Heat and install the collar (10).
91. Coat a new O-ring (9) with petroleum jelly and
install it onto input flange (6) and holder (7).
Place the assembly into position. Apply thread
lock (p/n 09940-00030) to the threads of cap
screw (8). Install the cap screw and the washer.
Tighten the cap screw to 696 34 Nm (514
25 lb ft). FIGURE 8-75. PUMP CAP SCREW INSTALLATION
1. Pump 2. Cap Screw
93. Install cap screws (1, Figure 8-76). Tighten the

FIGURE 8-74. INPUT SHAFT DETAIL

1. Oil Seal 7. Holder
2. O-Ring 8. Cap Screw
3. Dowel Pin 9. O-ring
4. Snap Ring 10. Collar FIGURE 8-76. CAPSCREW INSTALLATION
5. Retainer 11. Front Housing
6. Input Flange 1. Cap Screw 2. Shaft
92. Apply thread lock (p/n 09940-00030) to the 94. Refer to Torque Converter Installation at the
threads of cap screws (2). Install the cap beginning of this chapter for information on
screws and washers. Tighten to 54 5 Nm (40 mounting the torque converter to the transmis-
4 lb ft). sion.
Remove the two cap screws that were installed
temporarily. Apply thread lock (p/n 09940-
00030) to the threads of cap screws and install,
again. Tighten the cap screws to the specified
torque.

SPECIAL TOOLS
Special tools are available from Komatsu that have Wrench, p/n 792-335-1300
been designed to aid in torque converter rebuild.
Used for the torque converter stator bearing
Information is also provided to allow fabrication of lift- nut.
ing plates (see below) for lifting the torque converter
assembly off the transmission. Wrench, p/n 792-335-1400
Used for the torque converter pump/one-way
clutch bearing retainer nut.
Wrench, p/n 790-102-1891

Lift Plate - Fabricate Locally Used for the transmission pump drive gear and
Figure 8-77 lists the dimensions to fabricate lifting lower idler gear.
plates for torque converter removal and installation.
Three plates are necessary and can be used with
Figure 8-78 is a typical illustration of the type of
three lift eyes (p/n 04530-12438).
wrenches listed above.
Use a mild steel to fabricate the plates.
FIGURE 8-78. WRENCH (TYPICAL)
FIGURE 8-77. LIFT PLATE DIMENSIONS

SECTION F9
TRANSMISSION REBUILD
INDEX
TRANSMISSION REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
Number One Clutch Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7
Bearing Cage & Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-10
Number Four Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F9-11
Output Shaft Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-12
Rear Case Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-13
Output Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-13
Output Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-13
Number Five/Six Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-13
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-15
INSPECTION TABLE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-15
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
Number Five/Six Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-22
Number Seven Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-23
Rear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-24
Rear Case & Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-24
Number Six Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-26
Number Four Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-27
Number Four Carrier Bearing Cage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-28
Number Five Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-28
Number Four Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-29
Number Three Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-29
F09003 Transmission Rebuild F9-1

Clutch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-30
Number Two Clutch Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-30
Number Three Carrier & Number Two Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-31
Number One Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-31
Number One Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-34
Checks Prior to Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-36
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-36
Input Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-37
External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-39
F9-2 Transmission Rebuild F09003

TRANSMISSION REBUILD
Refer to Section F2 for the proper procedures for
removing and installing the transmission/torque con-
verter from the truck. Refer to Section F8 for the
proper procedures for removing and installing the
torque converter.
The transmission assembly weighs approxi-

mately 2294 kg (5057 lbs.). Use appropriate lifting
apparatus capable of lifting that weight.
TRANSMISSION DISASSEMBLY
1. Remove sheet metal covers (1, Figure 9-1).
2. Disconnect the wiring harness from input shaft
FIGURE 9-1. EXTERNAL COMPONENT
speed sensor (7), intermediate shaft speed sen-
REMOVAL
sor (6), output shaft speed sensor (3) and lube
oil temperature sensor (2). Remove the sen- 1. Covers 5. Wire Harness
sors. 2. Lube Oil Temperature 6. Intermediate Shaft
3. Disconnect the Electronic Control Modulated Sensor Speed Sensor
Valve (ECMV) valves and remove wiring har- 3. Output Shaft Speed 7. Input Shaft Speed
ness (3) from the transmission case. Remove Sensor Sensor
the ECMV valve mounting plate and filter 4. Output Flange
assembly.
4. If not previously removed, remove the cap
screw securing output flange (4). Remove the
flange, the cover, and the O-ring.
5. Remove sleeves (2, Figure 9-2) and discard the
O-rings.
6. With the transmission positioned vertically as
shown in Figure 9-3, remove cap screws (2)
and remove oil pan (1).
FIGURE 9-2. VALVE SEATS

1. Valve Seat 2. Sleeves
Mounting Surface

8. Remove cap screws (2) and remove plate (3)
from the input shaft. Check the dowel pins for
damage and remove if necessary.
9. Remove two 8 mm cap screws, the plate and
gasket (5). Remove nine 14 mm cap screws (4)
from the number one clutch housing to separate
it from transmission case (6).
10. Attach appropriate lifting apparatus and a hoist
to transmission case (1, Figure 9-5). Remove
21 cap screws (2) and six nuts securing the
transmission case to rear case (3).
11. Carefully lift the transmission case until it clears
the internal components, and set aside.
12. Remove and discard the O-rings sealing the two
cases together.
FIGURE 9-3. OIL PAN REMOVAL
1. Oil Pan Assembly 2. Cap Screws
7. Attach an overhead hoist to input shaft (1,

Figure 9-4). Lift the input shaft and plate (3) out
of the transmission assembly.
FIGURE 9-5. CASE SEPARATION
1. Transmission Case 3. Rear Case

2. Cap Screw
1. Input Shaft 5. Cap Screw (8 mm),

2. Cap Screw Plate & Gasket
3. Plate (Sensor Gear) 6. Transmission Case
4. Cap Screw (14 mm)

13. Before disassembling the clutches, check the
number one, three, four, five and six clutch pis-
tons for normal operation. Use pressurized air
at 380 104 kPa (55 15 psi) and oil leak
tester kit (p/n 799-301-1600), as shown below.
NOTE: This test will not work If the oil has drained
from the clutch cavities. The pistons will bypass air
and will not move.
FIGURE 9-6. CLUTCH OPERATION CHECK
1. Leak Tester 2. Clutch Pressure Port
14. Attach two 12 mm eye bolts, lifting chains and a FIGURE 9-7. CLUTCH & CARRIER ASSEMBLY
hoist. Lift out the number one and two clutches REMOVAL
and number three carrier assembly (1, Figure 9-
7). 1. Number One And 2. Rear Case
Two Clutch With
Number Three
Carrier

15. Disassemble the number one clutch as follows: 16. Remove discs (1, Figure 9-9), plates (2), piston
return springs (4), clutch plate separator springs
a. Remove cap screws (1, Figure 9-8). Remove
(3), and guide pins (5).
cover (2).
b. Remove internal snap ring (6).
c. Remove spacer (8).
d. Remove external snap ring (5) from the num-
ber one sun gear shaft.
e. Remove cover (7).
f. Remove cap screws (9).
g. Insert a 12 mm pusher bolt into the tapped
hole in clutch housing (10). Remove the
clutch housing, bearing and hub.
FIGURE 9-9. NUMBER ONE CLUTCH

DISASSEMBLY
1. Clutch Discs 4. Return Spring
2. Clutch Plates 5. Guide Pin
3. Separator Spring

DISASSEMBLY
1. Cap Screw 6. Snap Ring
2. Cover 7. Cover
3. Pin 8. Spacer
4. Number One Sun 9. Cap Screw
Gear 10. Clutch Housing
5. Snap Ring

17. Press hub (1, Figure 9-10) from the clutch hous-
ing bearing bore.
18. Remove snap ring (3). Turn the housing over
and press bearing (2) from clutch housing (4).
Use a bearing removal tool to press on the
outer race of the bearing during removal.
FIGURE 9-11. HOUSING REMOVAL

1. Number One Clutch 2. Snap Ring
Housing 3. Cap Screw
FIGURE 9-10. HUB REMOVAL

1. Hub 4. Clutch Housing Number One Clutch Housing Disassembly
2. Bearing 5. Support Blocks 22. Remove snap ring (2, Figure 9-12). Remove
3. Snap Ring bearing (3), bushing (4) and pin (5).
19. Remove snap ring (2, Figure 9-11) from the

bearing inner race.
20. Attach eye bolts, lifting chains and a hoist to
housing (1). Raise the assembly approximately
50 mm (2 in.) above the work surface.
21. Separate the number one clutch housing from
the number two clutch housing. Separate by
tapping the number two clutch housing with a
soft mallet or by inserting a pry bar.
FIGURE 9-12. CLUTCH HOUSING DISASSEMBLY
1. Number One Clutch 3. Bearing
Housing 4. Bushing
2. Snap Ring 5. Pin

23. Remove snap ring (3, Figure 9-13). 27. Disassemble the number two clutch as follows:
24. Attach lift eyes, lifting chains and a hoist to car- a. Remove piston (1, Figure 9-14). Remove
rier (2). Remove cap screws (1). separator plate (5) and plate (4).
25. Insert pusher bolts into the tapped holes and
b. Remove clutch discs and plates (6) and
remove the number one carrier assembly.
springs (21).
c. Remove spacer (3), hub (2), and number
three sun gear (14). Remove spacer (13).
28. Disassemble the number three carrier as fol-
lows:
a. Remove cap screws (9). Remove cover (8).
b. Push planet gear shafts (17) out of the car-
rier bores. Remove ball (18) when the shaft
is removed.
c. Remove gears (16), thrust washers (19), and
bearings (20).
d. If necessary, remove sleeves and balls (7).
NOTE: If sleeve removal is required, tap the sleeve

to gain access to the 10 x 1.5 mm threads. Insert a
FIGURE 9-13. NUMBER ONE CARRIER puller bolt to remove the sleeve.
DISASSEMBLY
1. Cap Screw 7. Bearing
2. Carrier 8. Number One e. Remove snap ring (10) and press bearing
3. Snap Ring Planetary Gear (11) out of the carrier bore.
4. Number One Sun 9. Ball f. Remove bearing inner race (15).
Gear 10. Cover
g. Remove seal ring (12).
5. Gear Shaft 11. Cap Screw
6. Thrust Washer 12. Snap Ring
26. Disassemble the number one carrier assembly

as follows:
a. Remove cap screws (11).
b. Remove cover (10).
c. Remove number one sun gear (4).
d. Push planetary gear shafts (5) out of the car-
rier bores. Remove ball (9) when the shaft is
removed.
e. Remove each shaft with gears (8), thrust
washers (6), and bearings (7).
f. Remove snap ring (12) and remove the ring
gear.

FIGURE 9-14. NUMBER TWO CLUTCH &
NUMBER THREE CARRIER DISASSEMBLY
1. Piston 13. Spacer
FIGURE 9-15. NUMBER THREE CLUTCH
2. Hub 14. Number Three Sun
DISASSEMBLY
3. Spacer Gear
1. Ring Gear 4. ClutchPlates, Discs,
4. Plate 15. Bearing Inner Race
2. Tie Bolt Springs
5. Separator Plate 16. Planetary Gear
3. Number Three
6. Clutch Discs & Plates 17. Gear Shaft
Clutch Housing
7. Sleeve & Ball 18. Ball
8. Cover 19. Thrust Washer
9. Cap Screw 20. Bearing
10. Snap Ring 21. Spring
11. Bearing 22. Number Three
12. Seal Ring Carrier
29. Remove tie bolts (2, Figure 9-15).

30. Remove number three clutch housing (3).
31. Remove ring gear (1). Remove the clutch
plates, discs, and springs.
32. Remove six cap screws (2, Figure 9-16).
Remove number three/four housing (1).
FIGURE 9-16. NUMBER FOUR CLUTCH

DISASSEMBLY
1. Number Three/Four 3. Guide Pin

Housing 4. Springs
2. Cap Screw 5. Discs & Plates

33. Remove clutch discs & plates (5), springs (4) Bearing Cage & Cover Disassembly
and guide pins (3). 40. Remove seal rings (2 & 9, Figure 9-18).
34. Use the hole in bearing cage (1, Figure 9-17) to
41. Remove snap ring (8). Separate bearing cage
access the cover mounting cap screws.
(1) from cover (6).
Remove the cap screws, the bearing cage and
the cover. 42. Remove seal ring (5).
35. Remove tie bolts (5) and housing (2). 43. Remove bearing (7) from the cover.
36. Remove the number four ring gear. 44. Remove snap ring (3). Remove bearing (4) from
the cage.
FIGURE 9-18. BEARING CAGE DISASSEMBLY

1. Bearing Cage 6. Cover
2. Seal Ring 7. Bearing
4. Bearing 9. Seal Ring
5. Seal Ring
FIGURE 9-17. NUMBER FOUR RING GEAR
REMOVAL
1. Bearing Cage 4. Springs
2. Housing 5. Tie Bolts
3. Discs & Plates 45. Attach lift eyes (M12 x 1.75), lifting chains and a
hoist to number four carrier (1, Figure 9-19).
Remove the carrier and the number five ring
gear.
37. Remove discs/plates (3) and springs (4).
46. Remove number five clutch housing (2).
38. Remove the snap ring retaining the number four
sun gear to the intermediate shaft.
39. Remove the number four sun gear.

FIGURE 9-20. NUMBER FOUR CARRIER
DISASSEMBLY
1. Number Five Ring 6. Planet Gear
Gear 7. Thrust Washer
2. Snap Ring 8. Shaft
3. Number Four Carrier 9. Ball
4. Sleeve 10. Bearing
5. Ball
FIGURE 9-19. NUMBER FOUR CARRIER

ASSEMBLY REMOVAL
1. Number Four Carrier 2. Number Five Clutch 50. Remove clutch discs, plates & springs (4,
Assembly Housing Figure 9-21).
3. Clutch Plates & Discs 51. Remove guide pins (1).
Number Four Carrier Disassembly

47. Remove snap ring (2, Figure 9-20). Remove
ring gear (1).
NOTE: Insert a tool through the holes in the ring gear
to compress the snap ring when disassembling.
48. If necessary, remove four sleeves (4) and
detent balls (5).
NOTE: If sleeve removal is required, tap the sleeve
for access to the 10 x 1.5 mm threads. Insert a puller
bolt and remove.
49. Remove four planet gear shafts (8) and detent
balls (9). Remove thrust washers (7) and bear-
ings (10). FIGURE 9-21. NUMBER SIX CLUTCH
DISASSEMBLY
1. Guide Pin 3. Number Six Clutch
2. Number Six Ring Housing
Gear 4. Clutch Discs, Plates,
& Springs

52. Remove number six ring gear (2). Remove
number six clutch housing (3).
53. Insert a lift eye (M16 x 2) into the tapped hole in
intermediate shaft (1, Figure 9-22). Attach a lift-
ing chain and a hoist. Lift the shaft out of the
assembly.
Use caution when inserting the lift eye. DO NOT

damage the seal ring contact area in the interme-
diate shaft bore.
54. Remove spacer and ball bearing (3). Remove FIGURE 9-23. SPEEDOMETER GEAR REMOVAL
the number five and number six sun gears. (Not Installed on Later Models)
55. Invert the rear case as shown in Figure 9-23. 1. Speedometer Gear 3. Cover
56. Remove cap screws (2). Use three pusher bolts 2. Cap Screw 4. Rear Case
(M12 x 1.75 x 150 mm) to remove cover (3).
Output Shaft Cover Disassembly

57. Remove cap screws (1, Figure 9-24). Remove
cover (2) and discard O-rings (3 & 4).
58. Remove oil seal (7).
59. Press bearing (6) from cover (5).
FIGURE 9-22. INTERMEDIATE SHAFT REMOVAL
1. Intermediate Shaft 3. Spacer & Bearing

2. Rear Case FIGURE 9-24. OUTPUT SHAFT COVER
DISASSEMBLY
1. Cap Screw 5. Cover
2. Cover 6. Bearing
3. O-ring 7. Oil Seal
4. O-ring

Rear Case Bearing Removal
60. Attach a hoist to the rear case and lift the case 65. Remove two plates (3)
off of the assembly. 66. Lift output shaft (1) out of the carrier assembly.
61. Remove collar (4, Figure 9-25) from rear case
(1).
62. Remove bearing (3). Output Shaft Disassembly
67. Remove spacer (3, Figure 9-27).
68. Remove cap screws (5) and cover (2).
69. Remove piston (1). Remove and discard seals
(6) from piston (1) and output shaft (11).
70. Remove worm gear (9), collar (7), and bearing
inner race (5). If damaged, remove dowel pins
(8).
71. Remove bearing (4).
Number Five/Six Carrier Disassembly

72. Remove the number seven clutch plates, discs,
FIGURE 9-25. REAR CASE BEARING and springs from the number five/six carrier.
1. Rear Case 4. Collar Remove the clutch hub.
2. Dowel Pin 5. Pin 73. Remove the planet shaft cover from the number
3. Bearing five/six carrier.
74. Remove each planet gear shaft (1 & 5,
Figure 9-28). Remove ball (3).
Output Shaft Removal 75. Remove planetary pinion gears (2). Remove the
63. Remove the output shaft speed sensor gear. bearings, collars, and thrust washers from the
carrier.
64. Remove cap screws (2, Figure 9-26).
76. If necessary, remove sleeve and ball (4) at four
locations. Tap the sleeves and install a puller
bolt to remove.
FIGURE 9-26. OUTPUT SHAFT REMOVAL
1. Output Shaft 4. Number Seven

2. Cap Screw Clutch Housing
3. Plates

FIGURE 9-27. OUTPUT SHAFT DISASSEMBLY
1. Piston 7. Bearing Inner Race
2. Cover 8. Pins
3. Spacer 9. Worm Gear
4. Bearing 10. Collar
5. Cap Screw 11. Output Shaft
6. Seals FIGURE 9-28. NUMBER FIVE/SIX CARRIER
DISASSEMBLY
1. Gear Shaft 4. Sleeve & Ball
2. Planetary Pinion Gear 5. Number Six Planetary
3. Ball Pinion Gear Shaft

CLEANING AND INSPECTION
Thoroughly clean all parts and inspect.

Discard gaskets and O-rings, and replace with new seals during reassembly. Inspect all cap screws for cracks
or thread damage. Replace any damaged parts.
Refer to Figure 9-29 and the following tables for new part specifications and maximum allowable wear limits for
used parts.
INSPECTION TABLE INDEX

Table 1 . . . . . . Piston Return Spring Specifications and Wear Limits
Table 2 . . . . . . Clutch Disc and Plate Specifications and Wear Limits
Table 3 . . . . . . Seal Ring Specifications and Wear Limits
Table 4 . . . . . . Gear Backlash Specifications
Table 5 . . . . . . Miscellaneous Components Inspection
NOTE: The column labelled No. in the following Tables refers to numbered components shown in Figure 9-29.
TABLE 1. PISTON RETURN SPRING SPECIFICATIONS AND WEAR LIMITS

(Non-Rotating Clutches)
Specifications
Standard - New Minimum - Used

No. Description Remedy
Free Installed Installed Free Installed
Length Length Load Length Load
No. 1 (M) clutch 91.0 mm 87.0 mm 3.6 kg 85.5 mm 3.1 kg
1
springs (10 ea.) (3.58 in.) (3.43 in.) (7.94 lbs.) (3.37 in.) (6.83 lbs.)
No. 3 (L) clutch 91 mm 69 mm 19.8 kg 85.5 mm 16.8 kg
2
No. 4 (2nd) clutch 91.0 mm 75 mm 14.4 kg 85.5 mm 12.2 kg
3 Replace
No. 5 (1st) clutch 91 mm 74.8 mm 14.6 kg 85.5 mm 12.4 kg
4
No. 6 (R) clutch 91 mm 71 mm 18.0 kg 85.5 mm 15.3 kg
5
NOTE: Discard all clutch spacer springs and replace with new parts during assembly.

TABLE 2. CLUTCH DISC AND PLATE SPECIFICATIONS AND WEAR LIMITS
Specifications
No. Description Standard - Minimum - Remedy
Tolerance
New Used
No. 1 clutch 70.1 mm 0.387 mm 67.7 mm
6
Total thickness: 8 discs + 7 plates (2.760 in.) (0.015 in.) (2.665 in.)
No. 2 clutch 37.2 mm 0.346 mm 34.8 mm
7
No. 3 clutch 42.6 mm 0.346 mm 40.2 mm
8
No. 4 clutch 55.0 mm 0.316 mm 52.0 mm
9
No. 5 clutch 55.0 mm 0.316 mm 52.0 mm
10
No. 6 clutch 60.2 mm 0.33 mm 56.6 mm
11
No. 7 clutch 37.2 mm 0.346 mm 34.8 mm
12
No. 1 clutch 5.0 mm 0.1 mm 4.4 mm
13
Single disc thickness (0.197 in.) (0.004 in.) (0.173 in.)
Replace
No. 2, 3 clutch 5.4 mm 0.15 mm 4.8 mm
14
Single disc thickness: (0.213 in.) (0.006 in.) (0.189 in.)
No. 4, 5 & 6 clutch 5.2 mm 0.1 mm 4.6 mm
15
16
17
Single plate thickness: (0.169 in.) (0.004 in.) (0.161 in.)
18
19
No. 4, 5 & 6 clutch 5.8 mm 0.1 mm 5.6 mm
20
21

TABLE 3. SEAL RING SPECIFICATIONS AND WEAR LIMITS
Specifications
No. Description Standard - Minimum - Remedy
Tolerance
New Used
Transmission input 2.56 mm -0.01 to -0.03 mm 2.30 mm
Width
shaft seal ring (0.101 in.) (-0.0004 to -0.0012 in.) (0.091 in.)
22
(34.5 mm dia. seal 1.70 mm 0.1 mm 1.55 mm
ring) Thickness
(0.067 in.) (0.004 in.) (0.061 in.)
3.00 mm -0.01 to -0.03 mm 2.70 mm
Transmission input Width
(0.118 in.) (-0.0004 to -0.0012 in.) (0.106 in.)
23 shaft seal ring (89
mm dia. seal ring) 3.70 mm 0.12 mm 3.55 mm
Thickness
(0.146 in.) (0.0047 in.) (0.140 in.)
4.00 mm -0.01 to -0.03 mm 3.60 mm
Width
No. 3 carrier seal (0.157 in.) (-0.0004 to -0.0012 in.) (0.118 in.)
24
ring 4.50 mm 0.12 mm 4.35 mm
Thickness
(0.177 in.) (0.0047 in.) (0.171 in.)
4.00 mm -0.01 to -0.04 mm 3.60 mm
Width
No. 4 carrier cover (0.157 in.) (-0.0004 to -0.0016 in.) (0.118 in.)
25
seal ring 5.00 mm 0.15 mm 4.85 mm
Thickness
(0.248 in.) (0.0059 in.) (0.191 in.)
4.00 mm -0.01 to -0.04 mm 3.60 mm Replace
Width
Bearing cage seal (0.157 in.) (-0.0004 to -0.0016 in.) (0.118 in.)
26
ring (front) 4.00 mm 0.15 mm 3.85 mm
Thickness
(0.157 in.) (0.0059 in.) (0.152 in.)
4.50 mm -0.01 to -0.03 mm 4.05 mm
Width
Bearing cage seal (0.177 in.) (-0.0004 to -0.0012 in. (0.159 in.)
27
ring (rear) 5.20 mm 0.12 mm 5.05 mm
Thickness
(0.157 in.) (0.0047 in.) (0.199 in.)
3.00 mm -0.01 to -0.03 mm 2.70 mm
Input shaft & inter- Width
(0.118 in.) (-0.0004 to -0.0012 in.) (0.106 in.)
28 mediate shaft seal
ring 1.70 mm 0.1 mm 1.55 mm
Thickness
(0.067 in.) (0.004 in.) (0.061 in.)
No 1 carrier collar 4.50 mm -0.01 to -0.03 mm 4.05 mm
Width
(2 ea.), No. 7 clutch (0.177 in.) (-0.0004 to -0.0012 in.) (0.159 in.)
29 hub (2 ea.) & Out-
put shaft collar (3 5.50 mm 0.15 mm 5.35 mm
Thickness
ea.) (0.217 in.) (0.0059 in.) (0.211 in.)

TABLE 4. GEAR BACKLASH SPECIFICATIONS
Specification
No. Description Remedy
Minimum Maximum
Backlash between No. 1 sun gear and plan- 0.15 mm 0.40 mm
30
etary gear (0.006 in.) (0.016 in.)
Backlash between No. 1 planetary gear and 0.17 mm 0.44 mm
31
ring gear (0.007 in.) (0.017 in.)
Backlash between No. 3 sun gear and plan- 0.14 mm 0.37mm
32
etary gear (0.006 in.) (0.015 in.)
33
ring gear (0.007 in.) (0.017 in.)
34
etary gear (0.006 in.) (0.016 in.)
35
ring gear (0.007 in.) (0.017 in.)
Replace
36
etary gear (0.006 in.) (0.015 in.)
Backlash between No. 5 planet gear and 0.16 mm 0.40 mm
37
ring gear (0.006 in.) (0.016 in.)
Backlash between No. 6 sun gear and 0.14 mm 0.37 mm
38
planet gear (0.006 in.) (0.015 in.)
39
planet gear (0.004 in.) (0.015 in.)
40
ring gear (0.006 in.) (0.016 in.)
Maximum wear of inside teeth of clutch 0.3 mm
41
discs (0.012 in.)

TABLE 5. MISCELLANEOUS COMPONENTS INSPECTION
No. Description Specification Remedy
Planet Gear Thrust Washers: Minimum -

Standard - New Tolerance
Used
No. 1, 4, 5 & 6 (outside) planet gear 3 mm 0.1 mm 2.5 mm
41 Replace
thrust washer thickness (0.118 in.) (0.004 in.) (0.098 in.)
thrust
No. 3 & 6 (inside) planet gear thrust 2 mm 0.1 mm 1.5 mm washer
42
washer thickness (0.079 in.) (0.002 in.) (0.059 in.)
NOTE: No flaws permissible on thrust washers.
Planet Gear Side Clearance: Maximum -

Standard - New
Used
No. 1 gear train
Replace
No. 3 gear train thrust
0.25 to 0.90 mm 1.5 mm
43 No. 4 gear train washer or
(0.010 to 0.035 in.) (0.059 in.)
No. 5 gear train replace
carrier
No. 6 gear train
Seal Ring Contact Area Wear: Maximum -

Used
0.05 mm
44 Seal ring sealing surface contact area (Max. groove depth.): Replace
(0.002 in.)
Oil Seal Contact Area Wear: Minimum

Standard Diameter - New
Diameter
Output shaft drive flange, oil seal 145 mm 144.8 mm
45 Replace
contact area (5.709 in.) (5.701 in.)

FIGURE 9-29. TRANSMISSION COMPONENT PARTS INSPECTION

TRANSMISSION ASSEMBLY
2. Position a thrust washer (2, Figure 9-31), two
GENERAL INSTRUCTIONS needle bearings (10), a number five planetary
Install new O-rings, seals, and gaskets when gear (9), and another thrust washer (2) in num-
components are assembled. ber five carrier (11).
During assembly, coat seal rings and grooves 3. Install a thrust washer (2) and two needle bear-
with petroleum jelly. ings (8) separated by a collar (3) in the number
six carrier planetary gear bore. Install a number
Apply clean power line oil to all rotating and six planetary gear (7) and another thrust washer
sliding components before assembly. (2). Repeat for the remaining three gears.
Freeze planetary gear shafts in dry ice before 4. After freezing in dry ice, carefully install each
installing in carriers. gear shaft (1). Properly align the bearings,
Use standard fastener torque values during washers, and collars. Insert detent ball (4) for
assembly unless otherwise specified. each shaft.
If oil passage plugs have been removed, apply
thread lock (p/n 09940-00030) to threads prior to
installation. Install plugs flush with the surface
and stake threads at two places.
Side clearance for all planetary pinion gears is
0.25 to 0.90 mm (0.010 to 0.035 in.).
Number Five/Six Carrier Assembly

1. If removed, insert sleeves and balls (4,
Figure 9-30) at four locations in the number six
carrier.
FIGURE 9-31. PLANETARY GEAR

INSTALLATION
1. Shaft 7. Number Six Planetary
2. Thrust Washer Pinion Gear
3. Collar 8. Needle Bearing
4. Ball 9. Number Five Plane-
5. Cap Screw tary Pinion Gear
6. Cover 10. Needle Bearing
11. Number Five/Six
Carrier
FIGURE 9-30. NUMBER FIVE/SIX CARRIER

ASSEMBLY
1. Gear Shaft 4. Sleeve & Ball
2. Planetary Pinion 5. Number Six
Gear Planetary Pinion
3. Ball Gear Shaft

5. Install a thrust washer and two needle bearings 11. Press bearing (4) into the output shaft until fully
separated by a collar in the remaining carrier seated against the shoulder of the bore.
bores. Install the number six planetary pinion
gear and another thrust washer.
6. Freeze the number six planetary pinion gear
shafts (5, Figure 9-30) in dry ice. Install the
shafts then install the detent balls. Press against the outer race of the bearing, only.
7. Install cover (6, Figure 9-31). Apply thread lock Applying force on the cage or the inner race will
(p/n 09940-00030) to the threads of cap screw damage the bearing.
(5) and install. Tighten to 66 7 Nm (49 5 lb
ft). 12. Coat the piston seals (3, Figure 9-33) with
petroleum jelly. Install the piston seals in the
Output Shaft Assembly
grooves in piston (1) and output shaft (2). Posi-
8. Press bearing inner race (7, Figure 9-32) onto tion the seal cup as shown in Figure 9-33.
output shaft (11) until fully seated against the
shoulder. 13. Apply power line oil to the seal contact area.
Install piston (1) into the output shaft.
9. Drive locating pins (8) into the output shaft
holes. 14. Install cover (2, Figure 9-32). Install cap screws
(5) and the washers. Tighten to standard
10. Install collar (10) and worm gear (9) over the torque.
locating pins and against the bearing inner race.
FIGURE 9-33. PISTON SEAL INSTALLATION
FIGURE 9-32. OUTPUT SHAFT ASSEMBLY 1. Piston 3. Seal

2. Output Shaft
1. Piston 7. Bearing Inner Race
2. Cover 8. Pins
3. Spacer 9. Worm Gear
4. Bearing 10. Collar
5. Cap Screw 11. Output Shaft
6. Seals

Number Seven Clutch Assembly
15. Install two seal rings (11, Figure 9-34) in the 18. Coat a new O-ring (13) with petroleum jelly.
grooves in number seven clutch hub (10). Coat Install the O-ring in the hub groove. Install
the seal rings with petroleum jelly. spacer (14).
16. Carefully lower the hub into number five carrier 19. Lift the output shaft assembly and lower it onto
assembly (12). the carrier assembly. Install plates (6).
NOTE: In the following step, apply TO-30 or TO-10 20. Apply thread lock (p/n 09940-00030) to cap
power line oil to the clutch discs as they are installed. screws (5). Install the cap screws and tighten to
110 12 Nm (81 9 lb ft).
17. Install a clutch disc (9) over the hub teeth until
seated in the carrier. Alternately install clutch 21. Install speed sensor gear (4). Apply thread lock
plates (8) and the remaining discs. Install wave (p/n 09940-00030) to cap screws (3). Install the
springs (7) around the discs. There are three cap screws and tighten to standard torque.
plates, four discs, and four springs. 22. Install seal rings (2) in the collar grooves. Coat
the seals with petroleum jelly to secure during
FIGURE 9-34. NUMBER SEVEN CLUTCH ASSEMBLY
1. Output Shaft 9. Clutch Disc (4 ea.)

2. Seal Rings 10. Hub
3. Cap Screw 11. Seal Ring
4. Speed Sensor Gear 12. Number Five Carrier
5. Cap Screw 13. O-ring
6. Plate 14. Spacer
7. Spring (4 ea.) 15. Bearing Inner Race
8. Clutch Plate (3 ea.)

Rear Case Assembly
23. If removed, install collar locating dowel pin (2,
Figure 9-35) into rear case (1).
24. Press bearing (3) into the case until seated
against the shoulder of the bore.
25. Align collar (4) with the dowel pin and install in
the case.
FIGURE 9-36. OUTPUT SHAFT COVER

ASSEMBLY
1. Cap Screw 5. Cover
2. Cover 6. Bearing
3. O-ring 7. Oil Seal
4. O-ring
FIGURE 9-35. REAR CASE ASSEMBLY 29. Coat a new O-ring (3) with petroleum jelly.
Install the O-ring in the groove of cover (2).
1. Rear Case 3. Bearing
Install cover (2) onto cover (5).
2. Dowel Pin 4. Collar
30. Install cap screws (1) and the washers. Tighten
to standard torque.
31. Install a new O-ring (7, Figure 9-37) in the
groove in cover (5).
Rear Case & Carrier Assembly 32. Place cover assembly (5) over output shaft (4)
26. Attach lifting apparatus and a hoist to the rear and align the mounting cap screw holes.
case. Carefully lower the case over the output 33. Temporarily install drive flange (1). Tap the
shaft to seat rear case bearing (3) on outer race flange to install bearing (2) onto the output shaft
(15, Figure 9-34). until fully seated against speedometer drive
27. Install bearing (6, Figure 9-36) in cover (5). gear (3).
28. Coat the outer diameter of seal (7) with sealant 34. Remove the drive flange.
(p/n 790-129-9080). Apply the sealant to the 35. Install cap screws (6) and the washers. Tighten
bore in cover (2). Press the seal into the cover. to standard torque.
Remove all traces of sealant after installation.

FIGURE 9-38. PREPARATION FOR
INTERMEDIATE SHAFT INSTALLATION
1. Intermediate Shaft 2. Dry Ice
38. Invert the rear case as shown in Figure 9-39.

39. When frozen, remove the intermediate shaft
FIGURE 9-37. COVER ASSEMBLY from the dry ice. Insert the shaft through the
INSTALLATION number five/six planetary assembly, and into
bearing (12, Figure 9-37). Seat the shaft
1. Drive Flange 7. O-Ring against spacer (11).
2. Bearing 8. Rear Case
3. Speedometer Drive 9. Seal Ring 40. Insert the number six sun gear, the spacer, and
Gear 10. Intermediate Shaft the number five sun gear. Insert spacer and
4. Output Shaft 11. Spacer bearing (3, Figure 9-39).
5. Cover 12. Bearing
6. Cap Screw
36. Install seal ring (9, Figure 9-37) onto the inter-
mediate shaft. Coat the seal with petroleum jelly
to aid in assembly.
37. Place intermediate shaft (1, Figure 9-38) in a
container of dry ice (2) to freeze the bearing
mounting area. Refer to Figure 9-38. Freeze for
20 minutes or more before installing.
FIGURE 9-39. INTERMEDIATE SHAFT

INSTALLATION
1. Intermediate Shaft 3. Spacer & Bearing
2. Rear Case

Number Six Clutch Assembly
41. Attach lifting apparatus and a hoist to number
six clutch housing (3, Figure 9-40). Lower the
housing onto the rear case, aligning the dowel
pins and the mating holes.
42. Install number six ring gear (2).
43. Install six guide pins (1).
44. Coat a new clutch piston seal (9, Figure 9-41)
with petroeum jelly. Install the clutch piston seal
in the housing groove. Position the seal as
shown in the illustration.
45. Install a new seal on the number six clutch pis-
ton. Position the seal with the open part posi-
tioned toward the clutch piston oil pressure
cavity.
NOTE: During the next step, apply TO-30 or TO-10 FIGURE 9-41. NUMBER SIX CLUTCH
power line oil to the clutch discs as the parts are COMPONENTS
installed.
1. Rear Case 6. Clutch Disc
2. Number Six 7. Clutch Plate
46. Install one clutch disc (6) against piston (3). Clutch Housing 8. Number Six Ring
Install the separator springs. Continue to alter- 3. Piston Gear
nately install the clutch discs, plates, and sepa- 4. Spring 9. Piston Seal
rator springs. Install a total of six discs and five 5. Dowel Pin
plates.
47. Install 12 piston return springs (4).
48. Install number five clutch housing (4, Figure 9-
42) over the dowel pins and firmly seat against
the number six clutch housing. Verify the
sleeves are installed in all 22 tie bolt holes.
FIGURE 9-40. NUMBER SIX CLUTCH

ASSEMBLY
1. Guide Pin 4. ClutchDiscs,Plates,
2. Number Six Ring & Springs
Gear
3. Number Six Clutch
Housing

FIGURE 9-43. PISTON SEAL INSTALLATION
Number Four Carrier Assembly

51. If removed, install four sleeves (4, Figure 9-44)
with detent balls (5).
52. Position thrust washers (7), needle bearings
(10), and a planetary gear in each carrier pinion
bore. With the parts aligned, insert frozen shaft
FIGURE 9-42. NUMBER FIVE CLUTCH (8) and detent ball (9).
ASSEMBLY
1. Number Six Clutch 8. Spring
Assembly 9. Number Four
2. Number Five Carrier
Clutch Piston 10. Cap Screw
3. Piston Seal 11. Bearing Cage
4. Number Five Assembly
Clutch Housing 12. Snap Ring
5. Housing Seal 13. Number Four Sun
6. Plate Gear
7. Number Five
Clutch Plates &
Discs FIGURE 9-44. NUMBER FOUR CARRIER
ASSEMBLY
1. Number Five Ring 5. Ball
49. Coat new piston seal rings (3 and 5, Figure 9- Gear 6. Planetary Gear
42) with petroluem jelly. Install seal (5) in the 2. Snap Ring 7. Thrust Washer
clutch housing groove. Install seal (3) in number 3. Number Four 8. Shaft
five clutch piston (2). Position the seal with the Carrier 9. Ball
cup opening toward the clutch oil pressure cav- 4. Sleeve 10. Bearing
ity as shown in Figure 9-43.
50. Install the piston in the clutch housing.

53. Install ring gear (1) as follows:
a. Insert snap ring (2) in carrier (3).
b. Align the external teeth of the carrier with the
internal teeth of the ring gear. Slide the parts
together until the snap ring aligns with the
ring gear groove and snaps into place.
c. Check for proper mating. The ring gear must
be stationary on the carrier.
d. Confirm a gap of approximately 3.2 mm
(0.12 in.) exists between the inner diameter
of the snap ring and the bottom of the carrier FIGURE 9-45. BEARING CAGE ASSEMBLY
teeth.
1. Bearing Cage 6. Cover
54. Install number four sun gear (13, Figure 9-42)
2. Seal Ring 7. Bearing
on the intermediate shaft. Install snap ring (12).
55. Attach lifting apparatus and a hoist to number 4. Bearing 9. Seal Ring
four carrier (9). Lower the carrier over the inter- 5. Seal Ring
mediate shaft.
Number Five Clutch Assembly

Number Four Carrier Bearing Cage Assembly
60. Install the number five clutch plates as follows:
NOTE: In the following assembly procedures, apply
a. Install plate (6, Figure 9-42) onto piston (2).
petroleum jelly to the seal ring grooves and seal
rings. NOTE: During the next step, apply TO-30 or TO-10
power line oil to the clutch discs as the parts are
56. Assemble the number four carrier retaining
installed.
cover and bearing cage (11) as follows:
b. Install a disc, then install a plate. Continue to
a. Install bearing (4, Figure 9-45) in bearing
alternately install a total of five discs and five
cage (1).
plates. Install a separator spring over the
b. Install snap ring (3). guide pins between the discs as they are
c. Install bearing (7) in cover (6). Install seal installed.
ring (5). c. Install piston return springs (8).
d. Assemble the cage to the cover and install
snap ring (8).
e. Install seal rings (2 & 9).
57. Install the assembled bearing cage on the num-
ber four carrier assembly.
threads of eight cap screws (10, Figure 9-42).
59. Install the cap screws through the access hole
in the bearing cage. Tighten to 110 12 Nm
(81 9 lb ft).

Number Four Clutch Assembly
61. Install number four clutch housing (3, Figure 9- 64. Assemble the number four clutch as follows:
46) over the dowel pins and seat against the
a. Install plate (5) on piston (1).
number five clutch housing.
b. Install a clutch disc, then install a plate. Con-
62. Coat new piston seals (2, Figure 9-46) with tinue to alternately install a total of five discs
petroleum jelly. Install the seals on the number and five plates. Lubricate the discs withTO-
four clutch piston and housing. Refer to 10 or TO-30 power line oil as they are
Figure 9-43 for proper seal orientation. The installed.
open end of the cup must be positioned toward
the clutch oil pressure cavity. c. Install a separator spring over the guide pins
between the discs as they are installed.
63. Install number four ring gear (9).
d. Install piston return springs (6).
65. Install housing (8). Install 22 washers (10) and
tie-bolts (11). Tighten to 385 42 Nm (284
31 lb ft).
Number Three Clutch Assembly

66. Install housing (4, Figure 9-47) over the dowel
pins.
threads of six cap screws (10). Insert the cap
screws through the housing and into bearing
cage assembly (11). Tighten to 110 12 Nm
(81 9 lb ft).
68. Coat new piston seals (1 and 3, Figure 9-47).
Install seal (1) on the housing. Install seal (3) on
piston (2). Refer to Figure 9-43 for seal orienta-
tion.
69. Install number three ring gear (9).
70. Assemble the number three clutch as follows:
a. Install plate (5) on the piston.
b. Install a clutch disc, then install a plate. Con-
tinue to alternately install a total of four discs
and three plates. Lubricate the discs with
TO-30 or TO-10 power line oil as they are
FIGURE 9-46. NUMBER FOUR CLUTCH
installed.
ASSEMBLY
1. Number Four Clutch 7. NumberFourClutch NOTE: The ear of the clutch plates for the number
Piston Assembly three clutch are stamped with the letter L.
2. Piston Seal 8. Housing c. Install a separator spring over the guide pins
3. Number Four Clutch 9. Number Four Ring between the discs as they are installed.
Housing Gear
d. Install piston return springs (8).
4. Housing Seal 10. Washer
5. Plate 11. Tie Bolt
6. Spring

71. Install plate (7) over the dowel pins in the num- Clutch Test
ber three clutch housing. Install 17 cap screws 72. Use 586 kPa (85 psi) of pressurized air and oil
and washers (12). Tighten to 385 42 Nm (284 leak tester (p/n 799-301-1600). Pressurize each
31 lb ft). clutch through the hydraulic oil port to 483 kPa
(70 psi) or more to check for normal operation.
Number Two Clutch Ring Gear Installation

73. Install snap ring (3, Figure 9-48) in the groove in
hub (2).
74. Align the teeth of ring gear (1) with the teeth on
the hub. Press the two parts together until the
snap ring fits into the groove on the ring gear.
75. Inspect the snap ring. Ensure a gap of 2.3 mm
(0.09 in.) exists between the inside diameter of
the snap ring and the hub. Refer to Figure 9-48.
76. Verify the ring gear is a tight fit on the hub and
the parts cannot be separated.
FIGURE 9-48. NUMBER TWO CLUTCH HUB RING

GEAR INSTALLATION
1. Ring Gear 3. Snap Ring

2. Hub
FIGURE 9-47. NUMBER THREE CLUTCH
ASSEMBLY
1. Housing Seal 8. Spring
2. Number Three 9. Number Three Ring
Clutch Piston Gear
3. Piston Seal 10. Cap Screw
4. Clutch Housing 11. Bearing Cage
5. Plate 12. Cap Screw &
6. Number Three Washer
Clutch Assembly
7. Plate

Number Three Carrier & Number Two Clutch
Assembly
77. Install bearing inner race (15, Figure 9-49) on
number two carrier (1).
78. Install bearing (11) and snap ring (10).
79. If removed, install sleeves (7) with detent balls.
80. Install thrust washers (19), needle bearings (20)
and gears (16). Align the parts, and install (fro-
zen) shafts (17) and detent balls (18).
81. Install cover (8). Apply thread lock (p/n 09940-
00030) to eight cap screws (9) Install the cap
screws and tighten to 66 7 Nm (49 5 lb ft).
82. Install spacer (13), number three sun gear (14),
and hub (4).
83. Install a number two clutch disc, then a plate.
Alternately install a total of four discs and three FIGURE 9-49. NUMBER THREE CARRIER
plates (6). Install a spring (5) at each disc. Place ASSEMBLY
plate (2) on top. 1. Number Three 11. Bearing
84. Install seal ring (12) in the carrier groove. Apply Carrier 12. Seal Ring
petroleum jelly to the seal ring and groove. 2. Plate 13. Spacer
3. Ring Gear 14. Number Three Sun
4. Hub Gear
5. Spring 15. Bearing Inner Race
6. Clutch Discs & Plates 16. Planetary Gear
7. Sleeve & Ball 17. Gear Shaft
8. Cover 18. Ball
9. Cap Screw 19. Thrust Washer
10. Snap Ring
Number One Carrier Assembly

85. Install thrust washers (3, Figure 9-50), needle
bearing (4), and planetary pinion gear (6). Insert
shaft (2) in carrier (1). Repeat for the remaining
gears.
86. Install cover (7). Apply thread lock (p/n 09940-
00030) to the threads of cap screws (8). Install
the cap screws and tighten to standard torque.

89. Coat the piston seals (Figure 9-52) with petro-
leum jelly. Install the piston seals as shown in
Figure 9-52.
FIGURE 9-50. NUMBER ONE PLANETARY

PINION INSTALLATION
1. Number One Carrier 6. Planetary Pinion
2. Shaft Gear FIGURE 9-52. PISTON SEAL INSTALLATION
3. Thrust Washer 7. Cover
4. Needle Bearing 8. Cap Screws
5. Ball
90. Coat carrier seal (3, Figure 9-54) with petroleum
jelly. Install the carrier seal. Position the seal
87. Using a tool as shown in Figure 9-51, align col- cup as shown in Figure 9-54.
lar (2) with pin (1) and press onto carrier (5).
88. Coat seal rings (4) and the collar grooves with
petroleum jelly. Install the seal rings.
FIGURE 9-53. NUMBER ONE CARRIER PISTON

INSTALLATION
FIGURE 9-51. COLLAR INSTALLATION 1. Separator Plate 4. Number One

2. Piston Carrier
1. Pin 4. Seal Rings 3. Carrier Seal
2. Collar 5. Number One
3. Tool Carrier
91. Align the guide hole in piston (2) with the lock
pin in carrier (4). Install the piston. Install sepa-
rator plate (1).

92. Install spacer (5, Figure 9-54) onto hub (7). 96. Install the bearing in the number one clutch
Install number one sun gear (4) in number three housing as follows:
carrier assembly (6). Align the splines in the a. If necessary, install pin (5, Figure 9-55) in
hub and the spacer. The hole in spacer (5) clutch housing (1).
should be aligned with the hole in the hub (7).
b. Align bushing (4) with the pin and install in
93. Attach lifting apparatus and a hoist to number
the carrier bore.
one carrier (2). Lower the carrier over the sun
gear shaft onto the number three carrier. c. Use a bearing installer and a press to install
bearing (3). Press the outer race of the bear-
94. Apply thread lock (p/n 09940-00030) to the ing into the bore until seated against the
threads of cap screws (1) and install. Tighten bushing.
d. Install snap ring (2).
95. Install snap ring (3).
FIGURE 9-55. NUMBER ONE CLUTCH HOUSING

BEARING INSTALLATION
1. Clutch Housing 4. Bushing
2. Snap Ring 5. Pin
3. Bearing
97. Using the proper diameter tool (3, Figure 9-56),

press the bearing inner race to assemble num-
FIGURE 9-54. NUMBER THREE AND NUMBER
ber one clutch housing (2) onto number three
ONE CARRIER ASSEMBLY
carrier (1).
1. Cap Screws 5. Spacer
2. Number One Carrier 6. Number Three
3. Snap Ring Carrier
4. Number One Sun 7. Hub
Gear

100. Install hub (4, Figure 9-58) over the splines on
the number one sun gear shaft.
101. Insert guide pins (2) in the number one housing.
102. Install the number one clutch assembly as fol-
lows:
NOTE: Apply TO-30 or TO-10 power line oil to the
clutch discs as they are installed.
a. Install a clutch disc on hub (4). Install springs
(7).
b. Install a clutch plate over the disc.
c. Alternately install the remaining discs,
plates, and springs. There are a total of eight
discs and seven plates.
d. Coat seal (6) with petroleum jelly. Install the
seal on piston (5) with the seal cup posi-
tioned as shown in Figure 9-58.
NOTE: The ear of each clutch plate is stamped 4.
FIGURE 9-56. HOUSING & CARRIER e. Install piston return springs (1).
ASSEMBLY
103. Coat seal (2, Figure 9-59) with petroleum jelly.
1. Number Three Carrier 3. Tool Install the seal in clutch housing (1) with the seal
2. Number One Clutch 4. Snap Ring cup positioned as shown in the illustration.
Housing 5. Bearing
104. Install clutch housing (1).
105. Install cap screws (9) and tighten to 177 20
98. After the bearing is seated against the collar, Nm (130 14 lb ft).
install snap ring (4) in the groove at the bearing
inner race. 106. Install cover (8) with dowel pin (3) over the sun
gear shaft splines. Install snap ring (5).
107. Install spacer (7) and snap ring (6).
Number One Clutch Assembly
99. Install bearing (2, Figure 9-57) in number one
clutch housing (1). Install snap ring (3).
FIGURE 9-57. HUB BEARING INSTALLATION
1. Number One Clutch 2. Bearing

Housing 3. Snap Ring

ASSEMBLY
1. Spring 4. Hub FIGURE 9-59. NUMBER ONE CLUTCH FINAL

2. Guide Pin 5. Piston ASSEMBLY
3. Clutch Discs & 6. Piston Seal
Plates 7. Spring 1. Clutch Housing 6. Snap Ring
2. Housing/Piston Seal 7. Spacer
3. Dowel Pin 8. Cover
4. Number One Sun 9. Cap Screw
Gear Shaft 10. Bearing Inner Race
5. Snap Ring 11. Carrier Seal Ring
108. Attach lifting apparatus and a hoist to the front

planetary and clutch assembly shown in
Figure 9-60. Lift the assembly. Lubricate seal
ring (11, Figure 9-59) and install. Lower the
assembly onto the transmission rear housing.
Refer to Figure 9-60. Ensure bearing inner race
(10, Figure 9-59) seats properly on the roller
bearing assembly.

FIGURE 9-61. CLEARANCE CHECK
1. Number Three 2. Number Three

Carrier Clutch Housing
Plate
111. Pressurize the number one and number two

clutches through the hydraulic oil port. Use a
shop air supply of 586 kPa (85 psi) and oil leak
tester (P/N 799-301-1600).
Number one clutch: Pressurize to 483 kPa (70
psi) or more to check for normal operation.
Number two clutch: Pressurize to 297 kPa (43
FIGURE 9-60. FRONT PLANETARY & CLUTCH
psi) or more to check for normal operation.
INSTALLATION
1. Front Planetary & 2. Rear Housing
Clutch Assembly Final Assembly
112. Install new O-rings in the hydraulic oil ports on
the face of the rear transmission case.
113. Attach lifting apparatus and a hoist to the trans-
Checks Prior to Final Assembly mission case. Coat a new O-ring (4, Figure 9-
109. After front planetary and clutch assembly (1, 62) with petroleum jelly. Install the O-ring in the
Figure 9-60) is installed, verify clearance exists groove at the rear of the case. Carefully lower
between the number three carrier and the num- the case over the power train.
ber three clutch housing plate. Refer to 114. Install 21 cap screws (2) and the washers that
Figure 9-61. secure the main case to the rear case. Install
110. Rotate the number three carrier by hand to the six nuts and washers. Tighten the cap
check for smooth rotation. screws and nuts to standard torque.

FIGURE 9-63. FRONT PLANETARY & CASE
ASSEMBLY
1. Cap Screw (8 mm), 4. Cover
Plate & Gasket 5. Clutch Housing
FIGURE 9-62. CASE INSTALLATION
2. Transmission Case 6. Cap Screw (14 mm)
1. Transmission Case 3. Rear Case 3. Cap Screw
2. Cap Screw 4. O-ring
Input Shaft Installation

117. Install two dowel pins (2, Figure 9-64) and the
115. Install two 8 mm cap screws, plate and gasket
plates.
(1, Figure 9-63) and the washers. Install nine 14
mm cap screws (6) and the washers. Tighten 118. Apply thread lock (p/n 09940-00030) to the
cap screws (1) to standard torque. Tighten cap threads of cap screws (3). Install the cap screws
screws (6) to 176 19 Nm (130 14 lb ft). and washers to attach speed sensor gear (4) to
transmission input shaft (1). Tighten the cap
116. Place cover (4) into position. Install cap screws
screws to 65 7 Nm (48 5 lb ft).
(3) and the washers.
119. Place the shaft in a container with dry ice to chill
the bearing mounting area as shown in
Figure 9-64. Chill for 45 minutes or more.

121. Align the internal splines of sun gear (2,
Figure 9-65), hub (3) and spacer (4). Coat the
spacers with petroleum jelly. Center spacer (1)
over the bore in bearing (5).
FIGURE 9-64. INPUT SHAFT PREPARATION
1. Input Shaft 4. Speed Sensor Gear

2. Dowel Pin 5. Dry Ice FIGURE 9-65. PREPARATION FOR INPUT SHAFT
3. Cap Screw 6. Seal Ring Groove INSTALLATION
1. Spacer 3. Hub
2. Number Three Sun 4. Spacer
Gear 5. Bearing
120. After the shaft has been chilled and is removed
for installation, install the seal ring in shaft
groove (6) and coat with petroleum jelly.
122. Carefully lower the input shaft into the front
NOTE: When the input shaft is installed, it is planetary and clutch assembly. Rotate the shaft
essential that the internal splines of number three as necessary to align the splines. If the align-
sun gear (2, Figure 9-65), hub (3), and spacer (4) are ment is correct, the shaft should drop into place.
in alignment. The splines must mate with the external
splines on the input shaft as it is lowered into the If the shaft does not drop into place, remove the
transmission. Ensure spacer (1) is aligned. Coat shaft and realign the splines of the spacer, hub,
spacers (1 & 4) with petroleum jelly to help keep and sun gear.
them aligned. When the dimension from the top of the speed
If properly aligned, the input shaft should slide in as sensor gear and the face of the case is 6 mm
far as bearing (5) without additonal force. If the shaft (0.236 in.) or less, the end of the shaft has
is forced, damage to bearing (5) may result. reached the bearing spacer chamfer as shown
in Figure 9-66.
123. Lightly tap the input shaft with a plastic mallet
(max. length - 40 cm (15.75 in.)) to seat the
shaft in the bearing bore and spacer.

FIGURE 9-67. INPUT SHAFT PROPERLY
FIGURE 9-66. INPUT SHAFT INSTALLATION INSTALLED
124. When the input shaft is properly seated, the External Components
dimension from the face of the transmission 125. Install oil pan (1, Figure 9-68) and a new gasket
case to the face of the speed sensor gear will be onto the transmission case. Install the magnet
approximately 30 mm (1.18 in.). Refer to assemblies and new O-rings.
Figure 9-67.
FIGURE 9-68. OIL PAN INSTALLATION

1. Oil Pan 2. Cap Screws

126. Install sleeves (2, Figure 9-69) and new O-rings
into the hydraulic oil ports on top of the trans-
mission. Coat the sleeve side of the O-rings with
petroleum jelly.
127. Install O-rings at the ports on valve seat mount-
ing surface (1).
FIGURE 9-70. SENSOR INSTALLATION

1. Covers 5. Wire Harness
FIGURE 9-69. SLEEVE INSTALLATION 2. Lube Oil Temp. 6. Intermediate Shaft
Sensor Speed Sensor
1. Valve Seat Mounting 2. Sleeves 3. Output Shaft Speed 7. Input Shaft Speed
Surface Sensor Sensor
4. Output Flange
128. Install the ECMV valve seat with ECMV valves.

Install the filter assembly. 133. Install output flange (4) onto the output shaft.
Install the cover and a new O-ring. Coat the O-
129. Install lube oil temperature sensor (2, Figure 9-
ring with petroleum jelly. Install the cap screw
70).
and washer. Tighten the cap screw to 2745
130. Install the speed sensors at input shaft (7), inter- 294 Nm (2025 217 lb ft).
mediate shaft (6), and output shaft (3).
134. Refer to Section F8 for torque converter installa-
131. Attach sensor wiring harness (5) and connect tion and final assembly.
the sensor plugs.
132. Install covers (1) over the sensors, ECMV
valves and filter.

SECTION G
DRIVE AXLE, SPINDLES AND WHEELS
INDEX
TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-1
FRONT WHEEL HUB AND SPINDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-1
FINAL DRIVE MOUNTING ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-1
FINAL DRIVE CENTER CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-1
FINAL DRIVE PLANETARIES AND WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-1
G01018 Index G1-1

NOTES
G1-2 Index G01018

SECTION G2
TIRES AND RIMS
INDEX
TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-3
FRONT TIRES AND RIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
REAR TIRE AND RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-7
TIRE MATCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-7
RIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-8
Tire Removal From Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-8
Tire Installation On Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-8
FRONT WHEEL STUD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-9
REAR WHEEL STUD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-10
G02023 11/05 Tires and Rims G2-1

NOTES
G2-2 Tires and Rims 11/05 G02023

TIRES AND RIMS
GENERAL INFORMATION
Truck tires must be inspected and the tire pressure Before storing used tires, clean thoroughly and
checked with an accurate pressure gauge before inspect for damage. Repair as necessary. When a
each working shift. Tire pressure may vary according truck is placed in storage, block the truck to remove
to manufacturer and local working conditions. Con- the weight from the deflated tires. If a stored truck
sult the tire manufacturer for recommended pres- cannot be blocked, check the air pressure and
sures. inspect the tires twice a month.
Install and securely tighten valve caps on each valve

stem. Caps protect valves from dirt build-up and
damage. DO NOT remove air from hot tires. It is nor-
mal for pressure to increase in the tire due to expan-
sion.
DO NOT weld or heat a rim with the tire
A bent or damaged rim that does not support the
mounted. Gases inside the tire may ignite
bead properly may cause abnormal strain on the tire causing an explosion of the tire and rim.
resulting in a malfunction. Rims must be repaired or
replaced if damaged. If a tire should obtain a deep When inflating tires, always use a safety
cut, it must be repaired. Neglected cuts cause many cage.
tire problems. Water, sand, grit, dirt and other foreign DO NOT inflate a tire until the lock ring is
materials can enter a tire through a cut eventually securely in place.
causing tread or ply separation.
DO NOT stand in front of or over the lockring
Whenever possible, store tires indoors. If stored out- during inflation procedures.
doors, cover the tires with tarpaulin to keep out dirt, DO NOT overinflate tires. Refer to the tire
water and other foreign materials. Long exposure to manufacturers recommendations.
the sun will cause ozone cracks. Store tires in a cool,
dry, dark, draft-free location. Tires may either be Keep personnel away from wheels and tires
during removal or installation.
stored vertically or laid horizontally. DO NOT exceed
stacks of more than three tires. Avoid contact with oil, If the truck has had a fire, DO NOT go near the
grease and other petroleum products. tires until the tires have cooled.
The tire/rim assembly weighs approximately
3180 kg (7010 lbs.). Ensure the tire handling
equipment is capable of lifting and
maneuvering the load.
Manual tire removal and installation is possible but,

due to the size and weight of the components, spe-
cial handling equipment such as a tire handler, as
shown in Figure 2-1, is desirable. Consult local tire
vendors for sources of equipment designed espe-
cially to remove, repair, and install large off-highway
truck tires.
FIGURE 2-1. TYPICAL TIRE HANDLER

FRONT TIRES AND RIMS
3. Release the air pressure from the tire.
Removal
4. Grasp the tire assembly with the tire handler.
1. Stop the machine on level ground, apply the
parking brake and chock the rear wheels.
2. Place a 45,360 kg (50 ton) capacity hydraulic
jack (1, Figure 2-2) under the suspension cylin-
der on the A-arm. Raise the front wheel assem- DO NOT damage the tire inflation stem during tire
bly and block securely. removal.
Due to its size and weight, keep personnel away

from the wheel and tire assembly during removal
and installation.
5. Remove air valve lock plate (3, Figure 2-3).

6. Remove wheel nuts (2) and clamps (1).
7. Move the wheel and tire assembly away from
the wheel hub and into a clean work area.
8. Inspect the brake components for damage or
wear. Inspect the hydraulic brake lines for leak-
ing fittings or damage.
FIGURE 2-2. JACK PLACEMENT

1. Jack (50 ton capacity) 2. A-Arm
When deflating tires, be cautious of flying dirt

and debris. Wear eye protection at all times.
FIGURE 2-3. FRONT WHEEL HUB

DO NOT completely deflate the tire. Keep the tire
inflated to 69 - 103 kPa (10-15 psi) to ensure the 1. Clamp 4. Capscrew
tire and rim components remain assembled dur- 2. Nut 5. Wheel Rim
ing tire handling. 3. Valve Lock Plate 6. Wheel Hub

Installation REAR TIRE AND RIM
1. Remove all dirt, debris and rust from mating
parts before installing the wheel. Removal
2. Grasp the wheel with the tire handler and posi- 1. Stop the machine on level ground. Apply the
tion the wheel on the wheel hub. Align the notch parking brake, and chock the front wheels.
in the wheel hub with the rim stopper. 2. Raise the final drive enough for the tires to clear
3. Install wheel clamps (1, Figure 2-3) and nuts the ground surface for removal. Block the final
(2). Moderately tighten the clamp nuts in the drive case, securely.
sequence specified in Figure 2-4. Rotate the 3. Remove air valve lock plate (2, Figure 2-5)
wheel, then check that the lateral runout of the 4. Remove clamp nuts (4) and clamps (3).
rim is within 5 mm (0.20 in.). Adjust the wheel
5. Remove wedge ring (7, Figure 2-7).
as necessary.
6. Move the tire handler into position on the out-
4. Continue tightening the nuts to 2210 245 Nm
side wheel.
(1630 181 lb ft) following the proper
sequence. 7. Remove spacer (2, Figure 2-6). Use the tire
handler or other lifting device to remove the
5. Adjust the tire inflation to the tire manufacturer's
spacer. The weight of the spacer is approxi-
recommended pressure.
6. Raise the truck and remove all blocking.
8. Remove nuts (12, Figure 2-7) and clamps (13).
7. Operate the truck for one haul cycle and tighten
the wheel nuts again. Use the same torque
specifications as previously outlined.
8. Check the torque daily until the specified torque
value listed above is maintained on each nut.
Check the torque intermittently, thereafter.
FIGURE 2-5. RIM AND CLAMPS

1. Rim 3. Clamp
2. Air Valve Lock Plate 4. Nut
Use caution when removing the wheel. Damage

to the air valve on the inboard wheel may occur.
9. Remove the inboard tire.

FIGURE 2-4. FRONT TIGHTENING SEQUENCE

10. Move the tires to a storage area and safely posi-
tion the tire so it cannot fall.
FIGURE 2-6. SPACER AND TIRE

1. Final Drive Housing 2. Spacer
FIGURE 2-7. REAR WHEEL RIM MOUNTING

1. Side Ring 5. Lock Ring 9. Nut 13. Clamp
2. Rim Base 6. Spacer 10. Clamp 14. Inflation Valve
3. Bead Seat Band 7. Wedge Ring 11. Hub Extension
4. O-Ring 8. Valve Extension 12. Nut

Installation
1. Clean all tire mounting surfaces. Ensure all con-
tact surfaces are free of damage and debris.
2. Move the tire handler into position and install
the inboard tire. Align the notched groove in the
wheel hub with the rim stopper.
NOTE: Use caution when installing the wheel. The
air valve is susceptible to damage.
3. Install three clamps (13, Figure 2-7) and nuts
(12). Tighten the clamp nuts to 2210 245 Nm
(1630 181 lb ft).
4. Install spacer (2, Figure 2-6). Use the tire han-
dler or other lifting device to lift the spacer. The
weight of the spacer is approximately 93 kg
(205 lb).
5. Move the tire handler into position and install
the outboard wheel. Align the notched groove in
the wheel hub with the rim stopper.
NOTE: Use caution when installing the wheel. The
air valve is susceptible to damage.
6. Install wedge ring (7). Position the wedge ring
FIGURE 2-8. REAR TIGHTENING SEQUENCE
so that the protrusion of the ring from the cover
surface is equal around the entire circumfer-
ence. Install clamps (10) and nuts (9). Only
tighten enough to prevent the tire/rim assembly
from moving.
7. Install air valve lock plate (2, Figure 2-5)
8. Remove the blocking and lower the truck to the
ground. TIRE MATCHING
10. Tighten clamp nuts (9, Figure 2-7) to 2210 The matching of tires on the drive axle and dual
245 Nm (1630 181 lb ft). Use the sequence wheel installations is very important. Tire matching is
shown in Figure 2-8 to tighten the clamps. necessary to achieve satisfactory life of the tires and
the final drive.
11. Rotate the wheel and verify the lateral runout of
the rim is within 5 mm. (0.20 in.) To check the match between the mounted dual
12. After installation, drive the truck approximately 5 wheels, use a large square. If one tire is too small, it
- 6 km (3 - 4 miles) to seat the wheels. Then becomes obvious as the square is laid across the
tighten the clamp nuts again to the specifica- dual tires. The square can be made from two 25 x 50
tions listed earlier in this procedure. mm (1 x 2 in.) wood strips. One piece must be long
enough to span the dual tires. The two wood strips
13. Check the torque periodically until the specified must be squared with a carpenter's square and rig-
torque is maintained. idly fastened to maintain a true 90 angle.

Matching of tire diameters from one side of an axle to RIM
the opposite side is important to prevent:
Tire Removal From Rim
unstable load shifting
excess load on structural members
rapid wear of the internal components of the final
drive
Side by side matching on dual wheel installations is When deflating tires, be cautious of flying dirt
necessary to prevent excess loading on the tire hav- and debris. Wear eye protection at all times.
ing the larger diameter. Mismatched tires on the dual
wheels causes unequal distribution of the load.
1. Remove the valve core to completely discharge
Rapid wear and/or tire blowout may result.
air pressure from the tire.
Exact limitations may not be specified by the tire
manufacturers, but a general rule is:
Unloaded, inflated tires, when standing side by
side, must not exceed a 1% maximum variation
in their diameters. Prying against the tire bead may cause damage
Measuring the tire size is most accurate during the to the bead resulting in air leaks.
following conditions:
2. Loosen the tire from bead seat band (3,
the tire is mounted on a rim
Figure 2-7).
inflated to the correct pressure 3. Force bead seat band (3), side ring (1) and the
unloaded (not mounted on the truck, or lifted off tire away from lock ring (5). Remove the lock
the ground, if mounted on a truck) ring.
Use a steel tape placed in the center of the tread and 4. Remove O-ring (4) from the rim.
measure the total circumference of the tire. Use the 5. Remove the bead seat band and the side ring.
formula below to calculate the diameter (d). 6. Loosen the tire bead from the back flange side
diameter (d) = measured circumference 3.1416 of the rim.
diameter (d) x 0.01 = allowable variation in size 7. Remove the tire from rim (2).
The tires used on opposite sides of Komatsu trucks

Tire Installation On Rim
are also limited to a 1% variation in the diameter of
the inflated, unloaded tires. 1. Clean all rim components. Remove any dirt and
rust from the O-ring groove and the bead seat
area. Coat all metal parts with a good anti-rust
paint to prevent bare metal from being exposed
to the weather. DO NOT allow paint, rust or
other contamination to cover the mating sur-
faces of lock ring (5, Figure 2-7) and rim (2).
Use only the proper rim parts for rim assembly.

Use of non-compatible parts may not properly
secure the assembly resulting in loose, flying
objects during inflation.

FRONT WHEEL STUD INSTALLATION
2. Check the inflation fittings. Replace, if neces- It is necessary to properly install wheel studs to
sary. ensure that correct thread engagement exists
3. Install inner side ring (1, Figure 2-7) onto the between the nut and the stud. Nuts must be fully
rim. Coat the beads of the tire with tire mounting threaded on the wheel studs with an allowable toler-
soap solution. ance of 17 mm (0.67 in.), as shown in Figure 2-9. If
4. Position the tire over the rim and work the tire thread engagement does not meet this criteria, the
on as far as possible without prying against the stud must be removed and checked for proper instal-
beads. Any damage to the tire bead will destroy lation.
the air seal and cause air leakage at these loca-
Verify correct wheel stud installation by checking the
tions.
distance from the end of the stud to the clamping sur-
5. Install the outer side ring in position and install face on the wheel hub. The proper distance is 89 2
bead seat band (3). Push in on the bead seat mm (3.5 0.08 in.), as shown in Figure 2-10. If this
band to expose the O-ring groove in the rim. dimension does not meet specifications, verify cor-
6. Lubricate the new O-ring with soap solution and rect orientation of the stud. The threads on the nut-
install into the groove. side of the stud measure 55 mm (2.17 in.) and must
7. Install lock ring (5) and tap into place with a lead be exposed for nut installation. The wheel hub-side
hammer. The lock ring lug must fit into the slot of the stud measures 51 mm (2.0 in.) and must be
on the rim. threaded into the hub. Refer to Figure 2-11. If the
stud is reversed, remove the stud and properly
8. Remove the valve core and inflate the tire to
install.
seat the beads of the tire and O-ring as speci-
fied by the tire manufacturer.
Use a safety cage whenever possible. Stand at

the front or back of the tire as it is being inflated.
DO NOT inflate the tire unless the lock ring is in
place. DO NOT stand in front or over the lock ring
when inflating.
9. If the beads of the tire and O-ring do not seat

within one minute, raise the tire slightly and tap
the bead seat band. This will help the air pres-
sure push the tire bead into position. FIGURE 2-9. NUT INSTALLATION
10. When the beads have seated, install the valve
1. Wheel Stud 2. Nut
core and inflate to the recommended tire pres-
sure.

REAR WHEEL STUD INSTALLATION
It is necessary to properly install wheel studs to
ensure that correct thread engagement exists
between the nut and the stud. Nuts must be fully
threaded on the wheel studs with an allowable toler-
ance of 17 mm (0.67 in.), as shown in Figure 2-12. If
thread engagement does not meet this criteria, the
stud must be removed and checked for proper instal-
lation.
Verify correct wheel stud installation by checking the
distance from the end of the stud to the clamping sur-
face on the wheel. The proper distance is 79 2 mm
(3.1 0.08 in.), as shown in Figure 2-13. If this
dimension does not meet specifications, verify cor-
rect orientation of the stud. The threads on the nut-
side of the stud measure 55 mm (2.17 in.) and must
be exposed for nut installation. The wheel hub-side
FIGURE 2-10. STUD INSTALLATION LENGTH of the stud measures 51 mm (2.0 in.) and must be
threaded into the wheel. Refer to Figure 2-14. If the
1. Wheel Hub 2. Wheel Stud stud is reversed, remove the stud and properly
install.
FIGURE 2-11. FRONT WHEEL STUD

FIGURE 2-12. NUT INSTALLATION

FIGURE 2-13. STUD INSTALLATION LENGTH
FIGURE 2-14. WHEEL STUD ORIENTATION

NOTES

SECTION G3
FRONT WHEEL HUB AND SPINDLE
INDEX
FRONT WHEEL HUB AND SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
FRONT WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-6
Front Wheel Hub Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-6
FRONT SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
CENTER TIE ROD PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-8
TOE IN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-9

Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-9
G03024 Front Wheel Hub and Spindle G3-1

NOTES
G3-2 Front Wheel Hub and Spindle G03024

FRONT WHEEL HUB AND SPINDLE
FRONT WHEEL HUB
Removal 10. Remove capscrews (9) and retainer (11).
Remove the shim pack. Note the number and
NOTE: The brake must be removed with the hub as a thickness of the shims behind the retainer.
single assembly and disassembled after removal. Keep the shims together in a safe place.
1. Park the truck on a hard, level surface and 11. Remove cap screws (1).
apply the parking brake. Chock the rear wheels.
12. Gently push the wheel hub from the rear to dis-
2. Drain the hydraulic tank. Refer to Section L, lodge the outer bearing. DO NOT allow the
Hydraulic System. bearing to fall.
3. Remove the front tire and rim. Refer to Front
Remove outer bearing (15) and pin (2).
Tire and Rim Removal in this section.
4. Thoroughly clean the wheel hub and the brake. 13. Lift the wheel hub and brake from the spindle.
Rotate plug (16, Figure 3-1) to the 6 oclock 14. Remove inner bearing (21) and pin (2).
position. Remove the plug and drain the oil from 15. Transport the wheel hub and brake to a clean
the wheel. work area for disassembly and inspection.
16. Position the assembly with the brake assembly
flat on the floor and the wheel hub facing
upward.
17. Remove the three bracket tools securing the
Drain the hydraulic tank before removing the wheel hub to the brake.
wheel hub plugs. Failure to do so may result in 18. Reattach the lifting apparatus to the wheel hub
pressurized oil being forced out of the wheel. and lift the hub straight off of the assembly. The
weight of the wheel hub is approximately 781 kg
5. Disconnect the brake apply and brake cooling (1722 lb).
lines. Cap all openings.
6. Disconnect drain tube (33) from the brake.
Remove clip (39). Disassembly
7. Install three bracket tools (EM5308) to secure 1. Remove the outer races for bearing (15, Figure
wheel hub (20) to the brake Use the tapped 3-1) and bearing (21).
holes in the wheel hub to mount the tools. 2. Remove bearing spacer (47).
Attach the other side of the tool to brake hub
(29).
8. Remove capscrews (18) and wheel cover (10). Inspection
Discard O-ring (17).
1. Clean all metal parts in cleaning solvent.
9. Attach lifting apparatus to the wheel hub to sup-
port the hub during removal. The wheel hub and 2. Inspect all seals and bearings and replace as
brake weigh approximately 1550 kg (3420 lb). required.
3. Check the seal ring mounting area on the wheel
hub and spindle for damage. Inspect the splined
areas for excessive wear.
4. Inspect the spindle bearing surfaces and the
radius under the spacer for distress or cracks.
Use a non-destructive method for crack detec-
tion such as dye penetrant or magnaflux.

Assembly
1. Clean all metal parts in cleaning solvent and FIGURE 3-1. FRONT WHEEL HUB & SPINDLE
lubricate all splines and bearing surfaces with
1. Capscrew & Washer
clean type C-4 hydraulic oil.
2. Pin
2. If removed, install bearing spacer (6). 3. Capscrew & Washer
3. Use a push tool and a press to install the outer 4. Capscrew & Washer
races for bearing (15, Figure 3-1) and bearing 5. Tapped Hole
(21). 6. Bearing Spacer
4. Position the assembly with the brake assembly 7. Stud
flat on the floor. 8. Pin
9. Capscrew & Washer
5. Install a new O-ring (25). Lightly lubricate the
10. Hub Cover
inner circumference of the O-ring with clean
11. Retainer
hydraulic oil.
12. Shim
6. Lubricate the inner circumference of seal rings 13. Shim
(23) with clean engine oil (SAE 30-40). 14. Shim
7. Check the position of the floating seals. Mea- 15. Bearing
sure dimension (C, Figure 3-2) in four places. 16. Plug & O-Ring
The distance must be 90 1 mm (3.54 0.039 17. O-Ring
in.). Adjust as necessary. 18. Capscrew & Washer
8. Check the alignment of the brake discs. Align 19. O-Ring
the discs as necessary to allow insertion of the 20. Front Wheel Hub
wheel hub. 21. Bearing
22. Retainer
9. Attach appropriate lifting apparatus to the wheel
23. Seal Ring
hub and slowly lift the hub straight onto the
24. O-Ring
assembly. The weight of the wheel hub is
25. O-Ring
approximately 781 kg (1722 lb).
26. Dowel Pin
When lowering the wheel hub, align the dowel 27. Retainer
pins in retainer (27) with the mating holes in the 28. Lip Seal
wheel hub. 29. Hub
30. O-Ring
Slowly lower the hub in through the floating
31. Elbow
seals. DO NOT disturb the seals during install-
32. Outer Gear
ion.
33. Tube
When the gear portion of the hub reaches the 34. Friction Disc (External Splines)
brake discs, it may be necessary to slightly 35. Separator Plate (Internal Splines)
rotate the hub to align the splines. 36. Damper
37. O-Ring
10. Inspect the assembly to ensure that the hub is
38. Bracket
evenly seated. If the assembly is properly
39. Clip
mated, install the three bracket tools (EM5308)
40. Bolt
to secure the wheel hub to the brake. Use the
41. Washer
tapped holes (5) in the wheel hub to mount the
42. Housing
tools. Attach the other side of the tool to the
43. Piston
brake.

FIGURE 3-1. FRONT WHEEL HUB & SPINDLE

5. Continue to lift the assembly onto the spindle.
Push the assembly onto the spindle until the
hub is properly seated on the inner bearing.
6. Install cap screws and washers (1). Tighten the
cap screws in an alternating pattern to 927
103 Nm (684 76 lb ft).
7. Install pin (8) and outer bearing (15) on the
spindle.
8. Place retainer (11) into position on the spindle
without the shims. Secure the retainer with cap
screws (9).
9. Remove the three bracket tools securing the
wheel hub to the brake.
10. Adjust the preload on the bearings. Refer to
Front Wheel Hub Bearing Adjustment.
Front Wheel Hub Bearing Adjustment

FIGURE 3-2. SEAL POSITION CHECK 1. Install retainer (11, Figure 3-1) with three evenly
spaced capscrews (9). DO NOT install the
1. Brake Hub 2. Seal Retainer
shims at this time. Tighten the capscrews
evenly and alternately to 109 5 Nm (80 4 lb
ft). Rotate the hub 20-30 times. Again, tighten
the cap screws to the specified torque.
Installation 2. Measure dimension (A, Figure 3-3) from the
retainer to the tip surface of the axle with depth
1. Install pin (2, Figure 3-1) and inner bearing (21) micrometer (2). Measure dimension "A" at two
onto the spindle. places on the retainer and use the average of
NOTE: Lubricate the bearings with clean hydraulic oil the measurements.
during assembly. Bearing adjustment will require
rotation of the hub prior to filling the hub with oil.
2. if not already installed, install the three bracket

tools (EM5308) to secure the wheel hub to the
brake. Use the tapped holes (5) in the wheel
hub to mount the tools. Attach the other side of
the tool to the brake.
3. Attach appropriate lifting apparatus to the wheel
hub for installation onto the spindle. The wheel
hub and brake weigh approximately 1550 kg
(3420 lb). Lift the assembly off the floor.
4. Install a new O-ring (19) onto the rear of the
brake. Lightly lubricate the O-ring with clean FIGURE 3-3. PRELOAD ADJUSTMENT
hydraulic oil.
1. Retainer 2. Depth Micrometer

3. Remove retainer (1), and measure retainer FRONT SPINDLE
thickness C. Then, select a shim thickness
The spindles are part of the front suspension cylinder
equal to B.
housings. To remove or install a spindle, refer to
B = (A-C) + 0.3 mm (0.012 in). Section H, Suspensions.
When removing the retainer, use caution to pre-
vent bearing (15, Figure 3-1) from being
removed.
NOTE: Select the combination of shims (12, 13, & A-ARM
14, Figure 3-1) that gives the minimum number of
shims. Removal
1. Refer to Section G, Front Tire and Rim
Removal and remove front tires.
4. Apply thread tightener, Three Bond #1374, to
cap screws (9). Install the shim pack and 2. Refer to Section H, Front Suspension Removal
retainer (11). Tighten the capscrews evenly, in and remove the front suspension.
an alternating pattern, to 929 98 Nm (685 3. Use a suitable lifting device and support the A-
72 lb ft). arm. Remove the retaining capscrew and pin (7,
5. Rotate the hub 20-30 times. Check the torque Figure 3-4) and spacers (3).
on the cap screws. If necessary, tighten the cap 4. Remove the A-arm from the frame.
screws again to the specified torqe. Repeat this
step until the proper torque is maintained.
6. install O-ring (17) into hub cover (10). Place the Inspection
hub cover into position and secure with cap 1. Inspect bushings (1, Figure 3-4). If damaged,
screws & washers (18). remove old bushings and install new parts.
7. Rotate plug (16) to the 12 o-clock position.
Remove the plug and fill the hub with clean NOTE: Bushings (1) are a tight fit in frame ears (2).
hydraulic oil. Install a new O-ring onto the plug When installing new bushings, apply a small amount
and install the plug. of heat to the frame ears and freeze the bushings
before attempting to press the new bushings into the
8. Connect the brake apply lines and brake cool- bores.
ing lines to brake assembly.
2. Inspect pin (7) and bearing (6). Replace if parts
9. Install the front tire and rim. Refer to Front Tire are damaged or wear is excessive.
and Rim Installation in this Section.
3. Inspect snap ring/seal (4). Replace if damaged
or if new bearing is installed.
Installation
Bleed the brakes before releasing the truck for
operation. Refer to Brake Bleeding, Section J. 1. Install new O-Rings (5, Figure 3-4) in bearing
(6).
10. After engine start-up, check the oil level in the 2. Position the A-arm onto the frame and install
hydraulic tank and fill. spacers (3) and pins (7). Install the retaining
capscrews, and tighten to standard torque.
3. Refer to Section H, Front Suspension Installa-
tion and install the front suspension.
4. Refer to Section G, Front Tire and Rim Installa-
tion and install the front tires.

CENTER TIE ROD PIVOT
Removal
1. Remove capscrews and washers (9, Figure 3-
5) and the grease lines connected to pins (3
and 10).
2. Slide tie rod (13) away from pivot link (7).
3. Remove snap ring (2), washer (1) and pivot pin
(3).
4. Remove the pivot link.
5. Remove seals (12), snap rings (14) and push
out ball joint assembly (16).
Inspection
1. Inspect all bushings (4, 6, and 11, Figure 3-5)
for wear.
2. Inspect all seals (12) and O-Rings (5, and 15).
3. Replace any worn or damaged parts.
Installation
FIGURE 3-4. A-ARM PIN 1. Press in bushings (4, 6, and 11, Figure 3-5).
1. Bushing 5. O-Ring 2. Place pivot link in frame with O-Rings (5) and
2. Frame 6. Bearing install pin (3). Install washer (1) and snap ring
3. Spacer 7. Pin (2).
4. Snap Ring\Seal 3. Install ball joint assembly (16), O-Rings (15),
and snap ring (14) onto the pivot link.
4. Install seals (12).
5. Position the tie rod in the pivot link and install
pin (10). Install the retaining capscrew and
washer (9).
6. Connect the grease lines to the pins and lubri-
cate all joints.

FIGURE 3-5. CENTER TIE ROD PIVOT
1. Washer 5. O-Ring 9. Capscrew and Washer 13. Tie Rod

2. Snap Ring 6. Bushing 10. Tie Rod Pin 14. Snap Ring
3. Pivot Pin 7. Pivot Link 11. Bushing 15. O-Ring
4. Bushing 8. Spacer 12. Seal 16. Ball Joint
TOE IN ADJUSTMENT
The correct toe-in specification for these model trucks is zero (0) with the truck at the empty vehicle weight. As the
truck is loaded, the geometry of the suspension and steering will result in minor toe-in angles.
Adjustment Procedure
3. Inspect steering and suspension components
and replace any damaged and/or worn parts.
chock the rear wheels.
4. Place a hydraulic jack below the front suspen-
2. Ensure the front and rear suspensions are oiled
sion to A-arm pin on both sides of the truck. Ele-
and charged according to shop manual specifi-
vate the truck until the lower portions of the tires
cations. Refer to Section H4, Oiling and Charg-
are no longer bulged, but allow for full tread
ing Procedures. The suspensions must be
contact with the ground across each tire.
properly charged and oiled to ensure accurate
Ensure the two jacks are at the same height.
toe adjustment.
Refer to Figure 3-6.

5. Measure the distance from the edge of the tire
rim to the flat face of the frame. Measure this
distance at both the front and the rear of the left
hand wheel. Refer to Figure 3-7.
6. Calculate the average distance from the two
measurements obtained in the previous step.
Record the measurement.
7. Start the truck and steer the wheels until the
average measurement is achieved at the front
and rear of the left hand tire.
DO NOT allow personnel near the truck when

operating the steering wheel. Personal injury
may result. Stand clear of the truck when poten-
tial energy exists in the steering circuit. Depres-
surize the accumulators before adjusting the
steering linkage.
FIGURE 3-6. RAISING THE TRUCK

FIGURE 3-7. TIRE TO FRAME DISTANCES
8. Mark the centerlines of the tires on the faces of 12. Remove the jacks and the wheel chocks from
the tread at the front and rear of each tire. The the truck. Operate the truck through several
vertical centerline should be a distance of 1220 complete turn cycles. Recheck the measure-
mm (48 in.) from the ground surface. The hori- ments, and readjust if necessary.
zontal centerline should be exactly half the
13. Check tire wear periodically. If abnormal wear is
width of the tire. Refer to Figure 3-8.
evident, check for damaged or worn steering
9. Measure the distances between centerlines at components, and verify the toe is properly
the front and rear of the wheels. Record the adjusted. Replace components as necessary,
measurements. and adjust the toe.
10. Adjust the length of the tie rods until the two
measurements obtained in the previous step
are within 3 mm (0.118 in.) of one another. The
tie rods must be adjusted equally. One full turn
of the tie rods is approximately equal to 25.4
mm (1 in.) of toe adjustment. Adjust the toe after replacing integral steering
11. Record the final distances between the front system components. Failure to adjust the toe
and rear centerlines for future reference. after replacing any components that may effect
the steering geometry may cause premature wear
to the tires and other components.

14. Check the toe adjustment at every 500 hour
interval. If abnormal tire wear is evident, check
the adjustment, immediately.
FIGURE 3-8. MARKING CENTERLINES ON THE TIRES

SECTION G4
REAR AXLE ATTACHMENTS
INDEX
REAR AXLE ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
CENTER LINK AND LOWER LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-4
Spherical Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-4
PANHARD ROD (DIAGONAL LINK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-6
G04017 Rear Axle Attachments G4-1

NOTES
G4-2 Rear Axle Attachments G04017

REAR AXLE ATTACHMENTS
The rear axle is attached to the truck frame by four
links (1, 4, & 5, Figure 4-1). Spherical bearings at 5. Place a jack under the rear suspension mount
each link end allow the drive axle to oscillate with the on the same side as the lower link to be
ground contour and maintain a positive wheel con- removed.
tact for maximum drive force.
The rear axle housing also provides the lower
mounts for the rear suspensions. Refer to Section H,
Suspensions, for information on removing the rear
suspensions. Secure the jack on the lower mount so it will not
The following chapter outlines the complete removal slide off as the jack is raised.
of the links and the removal of the spherical bearings
from the links. In some instances, it may not be nec-
essary to remove both ends of the links, or the bear-
ings. The service technician must determine the level
of disassembly required and proceed only to that
point.
If only one end of a link is to be disconnected, sup-
port the free end of the link so it cannot fall and
become a hazard to personnel.
CENTER LINK AND LOWER LINKS

Removal
1. Park the truck on a level surface and chock the
wheels.
2. Remove the rear drive shaft. Refer to Section F,
Drive Shafts, for the proper procedure. FIGURE 4-1. REAR AXLE ARRANGEMENT
3. Support the rear of the truck frame under the
hoist cylinder mount. 1. Panhard Rod 4. Lower Link (RH & LH)
(Diagonal Link) 5. Center Link
4. Support the front and rear side of the rear axle 2. Rear Suspension 6. Hoist Cylinder
housing. 3. Rear Axle Housing
NOTE: Center link (5, Figure 4-1) is slightly shorter

If more than one link is to be removed, extra sup- than lower links (4). Mark each link prior to removal
ports must be in place to prevent the frame and to ensure correct installation.
axle from moving out of position. Use adequate
supports and lifting devices. 6. Disconnect the grease lines.
7. Securely block the axle housing in this position.
8. Attach an appropriate lifting device to the link.
The weight of each link is approximately 120 kg
(265 lbs).

Inspection
1. Clean all parts.
2. Inspect bushings (2, Figure 4-2) and pin (1) for
wear, galling and cracks.
3. Inspect bearing (6) for wear and excessive
movement.
4. Inspect dirt seal (4) for cracks or damage.
Replace if necessary.
5. Replace any damaged or worn components
found during inspection.
Spherical Bearing Replacement

If the bearings are worn or damaged, replacement is
necessary. The bearings are a press fit in the links
and require a suitable press with the correct size
pusher plate for proper removal and installation. DO
NOT attempt to hammer directly on the bearings.
FIGURE 4-2. LINK PIN Installation

1. Install one snap ring (4, Figure 4-2) into the link.
1. Link Pin 5. Link
Press bearing (6) into the link until it contacts
2. Bushing 6. Spherical Bearing
the snap ring. Install the second snap ring on
3. Spacer 7. Retainer Plate
the other side of the link.
4. Dust Boot/Snap Ring 8. Cap Screw & Washer
NOTE: Orient the snap rings as shown in Figure 4-3.
9. Remove two cap screws & washers (8, Figure 2. Repeat the previous step for the opposite end
4-2). Remove retainer plate (7) and link pin (1). of the link.
10. Remove two spacers (3, Figure 4-2). 3. Install bushings (2, Figure 4-2), if removed.
11. If the link is to be removed completely from the 4. Attach an appropriate lifting device to the link.
truck, repeat the previous steps for the other The weight of each link is approximately 120 kg
end of the link. Lift the link from the truck. (265 lbs). Lift the link into position between the
12. If the spherical bearings are to be replaced, frame and the axle.
remove snap rings (4) and bearings (6). Refer 5. Install two spacers (3).
to Spherical Bearing Replacement. NOTE: If the center link and lower link(s) have been
removed, verify the correct link is installed in the
proper location. If in doubt, measure the distance
between the centerlines of the bearing bores. The
center link is 1190 mm (46.85 in.) in length. Each
lower link is 1220 mm (48.0 in.) in length.

6. Install pin (1). Install cap screws and washers PANHARD ROD (DIAGONAL LINK)
(8). Tighten the cap screws to standard torque.
Removal
Repeat the spacer and pin installation at the
other side of the link, if necessary. 1. Park the truck on a level surface and chock the
wheels.
7. Raise the rear of the frame. Remove the sup-
ports from under the lower hoist cylinder 2. Remove the rear drive shaft. Refer to Section F,
mounts and axle. Drive Shafts, for the proper procedure.
8. Install the rear drive shaft. Refer to Section F, 3. Support the frame on each side under the lower
Drive Shafts, for the proper procedure. hoist cylinder mounts. Raise the frame until the
weight is removed from the rear axle.
9. Connect the grease lines to the link bearings.
4. Attach an appropriate lifting device to panhard
rod (1, Figure 4-4). The weight of the rod is
approximately 95 kg (210 lbs).
5. Remove two cap screws and washers (8, Fig-
ure 4-2). Remove retainer plate (7) and link pin
(1).
FIGURE 4-3. SNAP RING ORIENTATION
1. Link 2. Snap Ring
FIGURE 4-4. PANHARD ROD (DIAGONAL LINK)

1. Rear Suspension 4. Panhard Rod
2. Frame Mount (Diagonal Link)
3. Rear Axle Mount
NOTE: Refer to Figure 4-2 for view A-A.

6. Remove two spacers. Installation
7. If the rod is to be removed from the truck, 1. Install one snap ring (4) into the bore of the rod.
repeat the previous steps for the other end of Press bearing (6) into the link until it contacts
the rod. Lift the rod from the truck. the snap ring. Install the second snap ring on
8. If the spherical bearings are to be replaced, the other side of the link.
remove snap rings (4) and bearings (6). Refer NOTE: Orient the snap rings as shown in Figure 4-3.
to Spherical Bearing Replacement.
2. Repeat the previous step for the opposite end

Inspection of the link.
1. Clean all parts.
2. Inspect bushings (2, Figure 4-2) and pin (1) for
wear, galling and cracks. Replace parts as nec-
essary.
3. Inspect bearing (6) for wear and excessive
movement. When installing the panhard rod, misalignment of
the second pin and bearing is likely to occur.
4. Inspect dirt seal (4) for cracks or damage.
Raise or lower each side of the frame with the
Replace the seal if necessary.
jacks or an adequate lifting device. DO NOT use
5. Replace any damaged or worn components the rear suspensions to raise the frame.
found during inspection.
3. Install bushings (2), if removed.
4. Attach an appropriate lifting device to the pan-
hard rod. The weight of the rod is approximately
95 kg (210 lbs). Lift the panhard rod into posi-
tion between the frame and the axle housing.
5. Install two spacers (3, Figure 4-2).
6. Install pin (1). Install cap screws and washers
(8). Tighten the cap screws to standard torque.
Repeat the spacer and pin installation at the
other side of the link, if necessary.
7. Raise the rear of the frame and remove the
supports from under the lower hoist cylinder
mounts and axle.
8. Install the rear drive shaft. Refer to Section F,
Drive Shafts, for the proper procedure.
9. Connect the grease lines to the rod bearings.

SECTION G5
REAR AXLE AND FINAL DRIVE ASSEMBLY
INDEX
REAR AXLE & FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
Straight-away-travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-3
REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-4
DIFFERENTIAL OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-5
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-7
Pinion Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-10
Differential Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-10
Differential Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-14
Differential Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-14
Assembly Of Differential Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-14
Installation Of Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-16
Input Pinion and Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-17
Adjusting Tooth Contact, Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G5-20
G05026 Rear Axle and Final Drive Assembly G5-1

NOTES
G5-2 Rear Axle and Final Drive Assembly G05026

REAR AXLE & FINAL DRIVE ASSEMBLY
The rear axle and final drive assembly contains the
differential assembly, rear oil-cooled disc brake
assemblies, drive axles, and the planetary drive
assemblies.
The rear axle and final drive assembly is attached to
the truck frame by four links with spherical bearings
at each link end. This allows the drive axle to oscil-
late with the ground contour and maintain a positive
wheel contact for maximum drive force. The assem-
bly also provides a mounting for the rear suspen-
sions and the parking brake assemblies.
DIFFERENTIAL OPERATION
Straight-away-travel
Power from the transmission to the input pinion
passes through the differential bevel gears to turn the
differential case. The differential pinions transfer this
rotation to the differential side gears where it turns
the drive shafts splined to the gears. During straight-
away travel, the resistance on the tires is equal,
same resistance on both left and right drive shafts,
so the differential pinions do not turn. Instead, the
rotation of the case is transferred directly to the side
gears. In this case, bevel and side gears rotate at the
same speeds, so the case and the shaft turn as a
single unit.
Turning
During a turn, the resistance on the inside tire is
greater than on the outside one so the resistances on
the drive shaft are not balanced. Consequently, the
side gears then rotate at different speeds. The differ-
ential pinions; therefore, rotate as they transmit the
rotation of the case to the side gears. This rotation
forces the two side gears to rotate in opposite direc-
tions. The net effect is that the outside wheel turns at
a rate equal to the sum of the bevel gear speed and
the differential pinion speed, while the inside one
turns at a rate equal to the difference.
Specifications:
Reduction Ratio:
Differential: 2.647
Final Drive: 7.235 FIGURE 5-1. REAR AXLE ASSEMBLY
Total: 19.15 1. Rear Suspension 5. Center Link Mount
Mount 6. Parking Brake Mount
Tire size: 33.00 - 51, 50 PR 2. Lower Link Mount 7. Rear Oil Disc Brakes
Rim size: 24.00 - 51 3. Panhard Rod Mount 8. Planetary Final Drive
4. Differential

REAR AXLE ASSEMBLY
Removal
10. Remove the rock ejectors from both sides of the
body.
11. Completely vent all nitrogen gas from both the
rear suspensions. Refer to Section H, Oiling
Ensure jacks, lifting equipment and rigging have
and Charging Procedures for safe discharging
adequate capacity and are securely attached to
of nitrogen gas.
raise and hold the rear of the truck until blocking
or support stands are securely installed. 12. Remove both suspensions. Refer to Section H,
Rear Suspension - Removal.
Total weight distribution (approximate):
13. Refer to Final Drive Attachment, in this Section,
Rear axle of empty truck (without body liners): for the Lower Link, Center Link, and Panhard
. . . . . . . . . . . . . . . . . . . . . . 51 865 kg (112,563 lbs.) Rod - Removal. Remove these components.
Rear Axle assembly with wheels & tires:
. . . . . . . . . . . . . . . . . . . . . . . 19 568 kg (43,140 lbs.) 14. Remove blocks from behind rear wheels.
Rear Axle assembly without wheels & tires: 15. Roll final drive assembly out from under frame.
. . . . . . . . . . . . . . . . . . . . . . .13 209 kg (29,120 lbs.)
1. Park the truck on a level surface. Installation

2. Securely block the front wheels.
3. Remove parking brake assembly. Refer to Sec-
tion J, Parking Brake.
4. Raise the rear of the frame high enough for the Ensure jacks, lifting equipment and rigging have
final drive case to clear as it is rolled from under adequate capacity and are securely attached to
the truck. raise and hold rear of truck until blocking or sup-
5. Securely block under both frame mounts at the port stands are securely installed.
lower end of the hoist cylinders. Total weight distribution (approximate):
6. Block the rear wheels to prevent the final drive
from moving when disconnected from the Rear axle of empty truck (without body liners):
frame. . . . . . . . . . . . . . . . . . . . . . 51 865 kg (112,563 lbs.)
Rear Axle assembly with wheels & tires:
7. Remove the drive shaft between the final drive . . . . . . . . . . . . . . . . . . . . . . 19 568 kg (43,140 lbs.)
and transmission. Slide the drive shaft out of Rear Axle assembly without wheels & tires:
the guard and set aside. . . . . . . . . . . . . . . . . . . . . . . 13 209 kg (29,120 lbs.)
8. Disconnect all hydraulic lines to both the oil disc
1. If necessary, raise the rear of the frame high
brake assemblies and the parking brake
enough for the final drive case to clear as it is
assembly. Cap/plug all ports and hoses to pre-
rolled under the truck. Securely block under
vent dirt entry. Identify or mark all connections
both frame mount structures at the lower end of
for easier reassembly.
the hoist cylinders. Align the final drive assem-
9. Remove any electrical wiring or lube lines that bly to the frame.
may interfere with removal of the final drive
2. Roll the final drive under the frame and block
assembly.
the wheels.

3. Install the axle links. Refer to Final Drive Attach- DIFFERENTIAL OIL LEVEL CHECK
ment in this section for link installation proce- 1. Park the truck on a level surface.
dures.
2. Remove plug (2, Figure 5-2) and check the oil
4. Raise the diagonal link to connect to the frame. level. If the oil level is not at, or near, the lower
Refer to Final Drive Attachment in this Section, end of the plug hole, fill with approved oil. Add
for diagonal link installation. oil through the plug hole until the oil reaches the
5. Install the rear suspensions. Refer to Section H, bottom of the hole.
Rear Suspension - Installation.
Oil capacity:
6. Install the driveshaft with the slip joint end near-
est the transmission. Tighten the companion Differential: . . . . . . . . . . . . . . . . 300 liters (79.0 gal)
flange capscrews to 392 20 Nm (289 14 lb Final Drive: . . . . . . . . 120 liters (31.7 gal) each side
ft). (Refer to Section P2 for oil specifications.)
7. Install all hydraulic lines to the parking brake NOTE:
assembly and both rear brake assemblies. a. Breather (6) must be open to atmosphere at all
8. Before releasing the truck for operation, the times. Check the breather before each shift of
brakes must be bled. Refer to Section J for the operation and remove any blockage of dirt/mud, etc.
proper brake bleeding procedures.
b. Clean the breather as necessary, or every 250
9. Install all electrical wiring and lube lines that hours of truck operation, to ensure proper venting.
were previously removed with the final drive
assembly. Install the rock ejectors on both sides c. Differential and Final Drive oil must be changed
of the body. every 2000 hours of truck operation.
10. Raise the rear of the truck frame and remove
the blocks or support stands from under the
hoist cylinder mount structures.
11. Install the parking brake assembly. Refer to
Section J, Parking Brake Installation for instruc-
tions.
12. Charge the front and rear suspensions. Refer to
Section H, Suspension Oiling and Charging
Procedure.
13. Fill the final drives with approved oil. Refer to
Planetary Final Drive in this section.
FIGURE 5-2. AXLE HOUSING, VIEW A-A, Fig. 5-1
1. Axle Housing 4. Pin

2. Fill/Level Plug 5. Drain Plug
3. Latch Assembly 6. Axle Housing Breather

DIFFERENTIAL ASSEMBLY 6. Install a lifting shackle to the differential mount-
ing surface, then fit a lever block to the pinion
The differential assembly is designed to transmit the
end to adjust the height when removing.
rotary power from the drive shaft to the left and right
wheels. It consists of a reduction unit and a differen-
tial unit which provides a difference in rotational
speed to the left and right wheels when turning.
Because of the design of the differential assembly,
the differential input pinion bearing is subject to both Ensure the lifting equipment is capable of lifting
thrust and radial forces. For this reason, a taper roller the drive shaft weight of 224 kg (494 lbs).
bearing is used. In order to adjust the bearings and
gear backlash, shims are used at the pinion end, and NOTE: Use caution when removing to prevent
adjusting nuts are used at the bevel gear end. damage to the seal surface of the differential
housing.
Specifications:
Splash-Type Lubrication
7. Remove differential assembly (2, Figure 5-3).
Ratio: 2.647
Removal
1. Place a container(s) into position and prepare Ensure the lifting equipment is capable of lifting
to recover 300 l (79.0 gal) of oil from the differ- 1780 kg (3,924 lbs).
ential gear case and 120 liters (31.7 gal) of oil
from each planetary final drive gear case.
Remove drain plug (5, Figure 5-2) and drain the
oil from the differential gear case.
2. Drain oil from each final drive assembly and for
removal of both drive axles. Refer to Planetary
Final Drive, in this Section, for instructions.
3. Disconnect all three parking brake spring cylin-
ders and hoses. Refer to Parking Brake
Removal, Section J.
4. Remove the center link, and panhard rod. Refer
to Final Drive Attachment, in this Section.
5. Remove the rear driveshaft. Refer to Transmis-
sion, Section F, Driveline - Removal.
FIGURE 5-3. DIFFERENTIAL ASSEMBLY
1. Lift Chain 2. Differential Assembly

Installation Disassembly
NOTE: The illustrations used in the following
Disassembly and Assembly procedures for the
differential assembly are typical of the installation,
but may not be an exact replica of the particular
Ensure the lifting equipment is capable of lifting part(s). Some parts, such as the parking brake
1780 kg (3,924 lbs). support, (the HD1500 has mounting surfaces for
three brake calipers) may actually appear different,
NOTE: Use caution when installing the differential to but their fit and function, as depicted in the
prevent damage to the seal surface of the differential illustrations, are similar.
housing.
1. Install a lifting shackle to the differential mount-
ing surface, then fit a lever block to the pinion 1. Set the differential assembly in a tool repair
end. Adjust the height when installing differen- stand (2, Figure 5-4).
tial assembly (2, Figure 5-3). Apply Three Bond
#1374 thread tightener to the mounting cap-
screws and tighten to 927 98 Nm (684 72
lb ft).
2. Apply Three Bond #1374 thread tightener to the
capscrews and install the drive shaft assembly.
Tighten the capscrews to 392 20 Nm (289
14 lb ft).
3. Install the center link and panhard rod. Refer to
Final Drive Attachment in this section.
4. Install both drive axles. Refer to Planetary Final
Drive in this section.
5. Install the rear driveshaft. Refer to Transmis- FIGURE 5-4. PARK BRAKE SPRING CYLINDER
sion, Section F, Drive Shafts.
1. Spring Cylinder 3. Connecting Pin
2. Tool 4. Lever
NOTE: The HD1500 has three brake caliper

assemblies.
Ensure the lifting equipment is capable of lifting
the drive shaft weight of 224 kg (494 lbs).
6. Connect all three parking brake spring cylinders 2. Using a portable power source, pump hydraulic
and hoses. Refer to Parking Brake Installation, oil into the park brake spring cylinder to retract
Section J. the rod, then pull out connecting pin (3) of
7. Add 300 liters (79.0 gal) of oil to the differential adjuster lever (4), and remove spring cylinder
gear case and 120 liters (31.7 gal) of oil to each (1).
planetary final drive gear case. Refer to Lubri-
cation and Service, Section P, for oil specifica-
tions. Check the differential and each final drive
for proper oil level.
If the hydraulic pressure in the spring cylinder is
released, the rod will suddenly extend. Keep
hands away from rod.

3. Remove all three parking brake assemblies.
Refer to Parking Brake Removal, Section J.
Remove brake disc (1, Figure 5-5).
4. Remove retaining capscrew (3, Figure 5-5), and
mounting capscrews (6). Then, remove cou-
pling (2) together with holder (4) and the O-ring.
5. Remove support (5).
FIGURE 5-6. PINION AND CARRIER

1. Lifting Device 2. Carrier Assembly
FIGURE 5-5. BRAKE COUPLING

1. Brake Disc 4. Holder
2. Coupling 5. Support
3. Capscrew 6. Capscrews
6. Install coupling and lifting device (1, Figure 5-6)

and screw in pusher bolts, then lift off pinion
and carrier assembly (2).
NOTE: Check the number and thickness of the
shims, and keep together in a safe place for
installation at re-assembly of pinion and carrier.

FIGURE 5-7. DIFFERENTIAL ASSEMBLY
1. Seal 10. Side Gear (28 Teeth) 19. Cage 28. Shim Assembly
2. Capscrew & Washer 11. Differential Gear Case 20. Cross Shaft 29. Park Brake Support
3. O-Ring 12. Ring Gear (45 Teeth) 21. Differential Case 30. Bearing
4. O-Ring 13. Capscrew & Washer 22. Retainer 31. Coupling
5. Input Pinion (17 Teeth) 14. Capscrew & Washer 23. Capscrew & Washer 32. Retainer
6. Capscrew & Washer 15. Plate 24. Bearing 33. Capscrew & Washer
7. Pinion Gear (22 Teeth) 16. Capscrew & Washer 25. Dowel Pin 34. O-Ring
8. Bearing 17. Lock 26. Ring
9. Adjusting Nut 18. Dowel Pin 27. Bearing Carrier Cage

Pinion Carrier Assembly Differential Gear Unit
1. Remove carrier (2, Figure 5-8) together with 1. Remove locks (1, Figure 5-10).
outer bearing (3) from pinion gear (1). 2. Using wrench (2), loosen the left and right side
bearing adjustment nuts (3) until they can be
turned by hand.
FIGURE 5-8. PINION BEARING

1. Pinion Gear 4. Inner Bearing
2. Carrier 5. Spacer
3. Outer Bearing
FIGURE 5-10. DIFFERENTIAL
2. Remove spacer (5), then remove inner bearing 1. Locks 3. Adjustment Nut
(4). 2. Wrench (790-425-1660)
3. Remove holder (4, Figure 5-9), then remove
center bearing inner race (5) from pinion gear
(6).
3. Remove capscrews (2, Figure 5-11). Remove
4. Remove bearing outer races (2) and (1) from
plates (5) and caps (1).
carrier (3).
4. Lift off differential gear assembly (4).
NOTE: The bearing is an adjustment-free bearing
5. Remove left and right side bearing adjustment
assembly with two tapered roller bearings and a
nuts (3).
spacer. Check the matching numbers, and keep
together as a set in a safe place.
FIGURE 5-11. DIFFERENTIAL MOUNTING

1. Cap 4. Gear Assembly
2. Capscrews 5. Plate
3. Adjustment Nuts
FIGURE 5-9. PINION GEAR AND RACES
1. Outer Race 4. Holder

2. Outer Race 5. Inner Race
3. Carrier 6. Pinion Gear

Differential Gear Unit
1. Using a knife edge type puller (1, Figure 5-12) 3. Remove thrust washer (1, Figure 5-14) from
and a porta-power cylinder, remove bearing (2). case (2).
4. Remove side gear (1, Figure 5-15).
5. Remove pinion gear assembly (1, Figure 5-16)
together with cross shaft (2).
FIGURE 5-12. BEARING PULLER

1. Puller 2. Bearing
FIGURE 5-14. THRUST WASHER
1. Thrust Washer 2. Case
2. Punch mark the case sections and remove
mounting capscrews (2, Figure 5-13). Remove
case (1).
FIGURE 5-13. DIFFERENTIAL CASE

1. Case 2. Capscrews FIGURE 5-15. SIDE GEAR
1. Side Gear 2. Gear

7. Push out shaft (4, Figure 5-18) with the press,
and remove pinion (1), bearing (2), and collar
(3).
8. Remove the bearing from the shaft.
FIGURE 5-16. PINION GEAR ASSEMBLY

1. Gear Assembly 2. Cross Shaft
6. Hold pinion gear assembly (3, Figure 5-17) with

a press. Use wrench (1) to remove ring nut (2).
FIGURE 5-18. GEAR AND SHAFT

1. Pinion Gear 3. Collar
2. Bearing 4. Shaft
9. Remove bearing outer races (1 & 2, Figure 5-

19) from pinion gear.
NOTE: The bearing is an adjustment-free bearing.
Check the matching numbers of the bearing, collar,
and outer race, and keep together as a set in a safe
place.
FIGURE 5-17. RING NUT AND GEAR
1. Wrench (09003-08290) 3. Pinion Gear

2. Ring Nut

11. Remove thrust washer (1, Figure 5-21).
FIGURE 5-21. BEVEL GEAR

FIGURE 5-19. GEAR BEARINGS
1. Thrust Washer 2. Bevel Gear
1. Outer Race 2. Outer Race
10. Remove side gear (1, Figure 5-20). 12. Remove bevel gear (3, Figure 5-22) from case
(2).
13. Remove bearing (1) from the case.
FIGURE 5-20.
1. Side Gear 2. Bevel Gear FIGURE 5-22. DIFFERENTIAL BEARING
1. Bearing 3. Bevel Gear
2. Case 4. Capscrews, Washers

14. Remove snap ring (2, Figure 5-23). Remove Assembly
bearing (1) from differential case (3).
Differential Bearing
1. Set the differential case in tool repair stand (2,
Figure 5-4).
2. Using a push tool, press fit bearing (1, Figure 5-
23) in differential case (3). Install snap ring (2).
Assembly Of Differential Gear Assembly

1. Align bevel gear (3, Figure 5-22) with dowel
pins on differential gear case (2) and install.
Apply Three Bond #1374 thread tightener to
mounting capscrews (4). Install the capscrews
and washers and tighten to 1322 Nm (975 lb
ft).
2. Install side bearing (1). Fit the bearing by heat-
ing to 100 C (212 F).
NOTE: Use heat lamps, an oil bath, or induction
heaters to heat the bearings. DO NOT use a torch or
heat greater than 176 C (350 F). After the bearing
FIGURE 5-23. DIFFERENTIAL BEARING cools, check that there is no clearance between the
end face of the case and the bearing.
1. Bearing 3. Differential Case
2. Snap Ring
3. Turn the case over. Align with dowel pins, and
install thrust washer (1, Figure 5-21).
a. Ensure the head of the dowel pin is 0.5
[+0.2/-0.0] mm (0.020 [+0.008/-0.00] in.)
15. If bevel gear (3, Figure 5-22) is to be replaced, lower than the surface of the washer.
remove gear retaining capscrews and separate
4. Install side gear (1, Figure 5-20).
the gear from case (2).
5. Assemble the differential pinion side gears.
NOTE: The bevel gear and pinion gear must be
replaced as a matched set. Using a press, install outer races (1 & 2, Figure 5-19)
into the pinion gear.
NOTE: The bearing is an adjustment-free bearing
assembly. Check the numbers on the bearings,
collar, and outer races, and use only as a matched
set.
b. Using a press, install bearing (1, Figure 5-
24) onto shaft (2).
c. Set pinion gear to shaft, then assemble col-
lar (3, Figure 5-18). Use a press to install
bearing (2).

d. Apply Three Bond #1374 thread tightener to
ring nut (2, Figure 5-17). Hold pinion gear
assembly (3) with a press, and using wrench
(1), tighten ring nut (2) to 927 Nm (684 lb
ft).
6. Assemble pinion gear assembly (1, Figure 5-
16) to cross shaft (2), then raise and install in
the case.
NOTE: Align the notched portion of the pinion gear
shaft with the case dowel pin and install. Move the
pinion gear, and verify gear assembly rotates easily.

1. Side Bearing 2. Case

1. Bearing 2. Shaft
7. Install side gear (1, Figure 5-15).

8. Align with dowel pin, and install thrust washer
(1, Figure 5-14).
Check that the head of the dowel pin is 0.5
[+0.2/-0.0] mm (0.020 [+0.008/-0.00] in.) lower
than the surface of the washer.
9. Heat side bearing (1, Figure 5-25) to 100C
(212F) and install in case (2).
heaters to heat the bearings. DO NOT use a torch or FIGURE 5-26. CASE INSTALLATION
heat greater than 176C (350F). After the bearing 1. Case 2. Capscrews
cools, check that there is no clearance between the
end face of the case and the bearing.
10. Fit case (1, Figure 5-26) to the housing. Apply
Three Bond #1374 thread tightener to mounting
capscrews (2) and tighten to 927 Nm (684 lb
ft).

Installation Of Differential Assembly
1. Tighten side bearing adjustment nuts (3, d. Fit spring balance (4, Figure 5-27) to the
Figure 5-11), and temporarily place differential bevel gear mounting bolt and measure the
gear (4) in the case. starting force in the tangential direction as
2. Align the match marks and install caps (1) on shown. Starting force should be 9 1.3 kg
the assembly. Rotate the bevel gear 20 - 30 (20 3 lb).
turns to seat the bearings, then tighten. Apply e. Tighten adjustment nuts (3, Figure 5-10)
Three Bond thread tightener #1374 to the from both ends, and continue to tighten with
mounting capscrews (2). Position plates (5) on wrench (2). Give attention to the groove that
caps and install the capscrews. Tighten to 1716 the lock enters. To seat the bearing properly,
Nm (1266 lb ft). rotate the bevel gear and tap the bearing cap
3. Adjust the bearing preload. and bevel gear with a soft-faced hammer,
a. Install measurement adapters (2, Figure 5- NOTE: If the increase in deflection caused by
27) to both ends of the cap. overtightening of the adjustment nut exceeds the
standard amount, return the adjustment nuts to the
b. Measure the dimension between the adapt-
condition before adjusting. When doing this, rotate
ers with depth micrometer (1).
the bevel gear and tap the bearing cap and bevel
NOTE: When measuring, hold the micrometer gear with a plastic hammer, check that there is no
securely with one hand, and put the probe in contact clearance at "A", Figure 5-28, and adjust again.
parallel to the measurement adapter.
c. Add 0.66 0.12 mm (0.025 0.005 in) to the
measured dimension, and set the scale of
the micrometer.
Use a light with a feeler gauge
NOTE: The added dimension becomes the amount to ensure there is no gap.
of deflection of the case before applying preload and
after applying preload.
FIGURE 5-28. BEARING ADJUSTMENT
FIGURE 5-27. BEARING PRELOAD

1. Micrometer (792- 3. Measuring Posts
525-3000) 4. Spring Balance
2. Adapter 5. Plates

Input Pinion and Carrier Assembly
When assembling the differential pinion carrier

assembly (Figure 5-29), if the coupling bolts are
not tightened while the pinion bearing is turning,
the bearing will be damaged in a short period of
operation. To prevent this, the following assem-
bly procedure must be followed.
1. Using a press, install outer races (1, Figure 5-
30) and (2) in carrier (3). Check that there is no
FIGURE 5-30.
clearance between the outer races and the car-
rier. 1. Outer Race 3. Carrier
2. Outer Race
2. Heat bearing inner race (2, Figure 5-31) to

100C (212F), then press the center bearing
inner race onto pinion gear (3). Install holder
(1). Apply Three Bond #1374 thread tightener to
the mounting bolts and tighten to 280 29 Nm
(206 22 lb ft).
heaters to heat the bearings. DO NOT use a torch or
heat greater than 176 C (350 F).
3. Heat bearing inner race (2, Figure 5-32) to

100C (212F). Press onto the pinion gear shaft
and install spacer (1).
Ensure the numbers match and keep together as a
set.
FIGURE 5-29. INPUT PINION ASSEMBLY 4. *Verify there is no clearance between the end
1. Capscrew & Washer 10. O-Ring face of the pinion gear and the inner race of the
2. Park Brake Disc 11. Capscrew & Washer bearing.
3. Coupling 12. Holder
4. Capscrew & Washer 13. Bearing Race
5. Holder 14. Pinion Gear (15 T)
6. O-Ring 15. Bearing Carrier
7. Park Brake Support 16. Shim Assembly
8. Oil Seal 17. Capscrew & Washer
9. O-Ring 18. Bearing Assembly

1. Holder 3. Pinion Gear 1. Bearing 3. Pinion Gear

2. Bearing Inner Race 2. Carrier
FIGURE 5-32.
1. Spacer 2. Bearing Inner Rac
FIGURE 5-34.
1. Cage Assembly
5. Set carrier (2, Figure 5-33) on pinion gear (3),
and install bearing (1).
6. Thoroughly coat the bearing rollers, as well as
8. Install oil seal (3, Figure 5-35) and O-ring (2) to
the running surfaces of the inner and outer
parking brake support (1). Install support (1) to
races, with oil.
the differential case. Apply Three Bond #1374
7. Fit O-ring (10, Figure 5-29) onto bearing carrier thread tightener to the mounting bolts and
(15), and assemble shims (16). Install pinion tighten to 549 59 Nm (405 45 lb ft).
and cage assembly (1, Figure 5-34) to differen-
tial case.
NOTE: Use the same amount of shims that were
removed at the time of pinion disassembly. If any
parts, such as the bearings, bearing carrier, pinion
gear, or housing have been replaced, refer to
Adjusting Tooth Contact - Backlash, later in this
procedure to determine the correct shim thickness.

10. After tightening bolt (3), turn the bearing 20 to
30 rotations, again Ensure the bearing is rotat-
ing smoothly and bolt (3) has been tightened to
the specified torque.
11. Using either of the following methods, confirm
that the bearing has been set normally.
Method #1:
a. Measure the starting torque in the tangential
direction with a spring scale (1, Figure 5-37)
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
FIGURE 5-35. kg. (11.2 lbs.) maximum. Perform this mea-
surement on the bevel gear side.
1. Park Brake Support 3. Oil Seal
2. O-Ring
9. Assemble coupling (4, Figure 5-36), the O-ring

and holder (2). Apply Three Bond thread tight-
ener #1374 to mounting bolt (3). Tighten bolt (3)
gradually to 2746 294 Nm (2025 217 lb ft)
while the bearing is turning (20 to 30 rotations).
If bolt (3) is tightened without the bearing being
turned, damage to the bearing may result.
FIGURE 5-37.
1. Spring Scale
FIGURE 5-36.
1. Park Brake Support 3. Bolt
2. O-Ring and Holder 4. Coupling

Method #2: Adjusting Tooth Contact, Backlash
b. Measure the axial bearing end play for: 0.0 - Adjust backlash and tooth contact at the same time.
0.118 mm (0.0 - 0.0046 in.)
1. Adjust backlash as follows.
Measuring method:
a. Move the bevel gear with adjustment nuts (1
1.) After 20 to 30 bearing revolutions, set a & 2, Figure 5-40).
dial gauge, as shown in Figure 5-38, to
align with point zero.
When adjusting the bevel gear, do not change the

preload of the bearing. Always turn the adjust-
ment nuts at both ends the same amount in the
same direction.
b. Put a dial Indicator (2, Figure 5-41) at right
angles in contact with the reverse face of the
tooth at the outside of the bevel gear. Turn
the adjustment nut and adjust the backlash.
c. Backlash: Adjust at 3 - 4 places. Keep the
pinion gear locked when measuring. Adjust
FIGURE 5-38.
to 0.46-0.66 mm (0.018 - 0.026 in) backlash.
2.) Oscillate the coupling 20 to 30 rotations

in its lifted condition (approximately 300
kg) and ensure the dial gauge reading
has stabilized. (See Figure 5-39)
3.) The dial gauge reading obtained in the
previous step will be equal to the end
play in the axial direction.
FIGURE 5-40. TOOTH CONTACT ADJUSTMENT

1. Adjustment Nut 2. Adjustment Nut
FIGURE 5-39.

2. Adjust tooth contact as follows.
a. Adjust the in and out movement of the bevel
pinion by changing the shims between the
differential case and bearing cage.
b. Adjust tooth contact in Step 3.
FIGURE 5-42. BRAKE COUPLING
1. Brake Disc 4. Holder

2. Coupling 5. Support
3. Capscrew 6. Capscrews
d. Install the plate on the other side and tighten.

Apply Three Bond #1374 thread tightener to
the plate mounting capscrews and tighten to
927 Nm (684 lb ft).
FIGURE 5-41. BACKLASH ADJUSTMENT
1. Bevel Gear 2. Dial Indicator
3. Adjusting tooth contact

Mix red lead in spindle oil to form a thin paste,
then coat the face of 7 or 8 teeth of the driven
gear. Hold down the driven gear by hand to act
as a brake, and rotate the drive pinion gear for-
ward and backward, then inspect the pattern left
on the teeth.
Adjust the tooth contact as shown in the following
illustrations and procedure.
4. Caliper assembly
a. Install brake disc (1, Figure 5-42). Apply FIGURE 5-43. CALIPER
Three Bond #1374 thread tightener to the
disc plate capscrews and tighten to 745 Nm 1. Plate 3. Caliper
(550 lb ft). 2. Pad
b. Install plate (1, Figure 5-43) on one side,
temporarily.
c. Fit pad (2) and install caliper (3).

FIGURE 5-44. PARK BRAKE SPRING CYLINDER
1. Spring Cylinder 3. Connecting Pin & Cl
2. Tool vis
4. Lever
NOTE: Adjust for a clearance of 0.1 mm (0.004 in)

between the plate and the caliper.
5. Install spring cylinder assembly (1, Figure 5-

44), and connect rod clevis with connecting pin
(3) to the lever of slack adjuster (4).
NOTE: To retract the rod, pump oil pressure into the
spring cylinder.
Refer to Parking Brake Adjustment, Section J, Brake
System, to adjust park brake assembly.

NOTES

SECTION G6
FINAL DRIVE PLANETARIES AND WHEEL HUBS
INDEX
FINAL DRIVE PLANETARIES AND WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-3
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-3
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-4
FINAL DRIVE CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-6
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6-9
G06012 Final Drive Planetaries and Wheel Hubs G6-1

NOTES
G6-2 Final Drive Planetaries and Wheel Hubs 11/05 G06012

FINAL DRIVE PLANETARIES AND WHEEL HUBS
FINAL DRIVE
The final drives are mounted on the outer ends of the
rear axle. Each final drive uses a planetary gear con-
figuration to reduce the rotation speed of the drive
train and produce a greater driving torque. Of all the
components in the drive train, the final drive bears
the greatest stress. Final drive lubrication must be
properly maintained to ensure the long life of the
gears and bearings.
FIGURE 6-1. FINAL DRIVE PLANETARY
1. Carrier 6. Cover 11. Drive Shaft

2. Planet Gear Shaft 7. Ring Gear (106 Teeth) 12. Wheel Hub
3. Planet Gear (43 Teeth) 8. Spacer 13. Seal Assembly
4. Sun Gear (17 teeth) 9. Retainer 14. Seal Drain Hose
5. Button 10. Inner Hub
SPECIFICATIONS: Splash-type Lubrication

Ratio: 7.235
Oil: 120 L (32 gal) - each side

Oil Level Check
Stop the truck with drain plug (3, Figure 6-2) rotated 3. Remove the cap screws that secure cover (1,
nearest the ground and casting line (1) horizontal. Figure 6-3). Remove the cover.
Remove fill plug (2) and check the oil level. If the oil
level is not near the lower edge of the plug hole, add
oil until it reaches this level. Refer to Section P, Lubri-
cation and Service, for oil specifications.
FIGURE 6-3. COVER

1. Cover 2. Button
FIGURE 6-2. OIL PLUG AND CASTING LINE 4. Install an eyebolt at the end of drive shaft (3,
Figure 6-4). Use a bar to pull the drive shaft
1. Casting Line 3. Drain Plug from the wheel. Attach a lifting device to the
2. Fill Plug shaft for support as it is pulled from the carrier.
The weight of the assembly is approximately
176 kg (388 lb). Lift the shaft from the truck.
FINAL DRIVE CARRIER ASSEMBLY

Removal
1. Remove drain plug (3, Figure 6-2) and drain the
oil from the final drive case. Oil capacity is 120 l
(31.7 gal).
NOTE: If the drain plug is not at the bottom, use a
hydraulic 51,000 kg (50 ton) jack to raise the truck.
Turn the hub to position the plug as shown in
Figure 6-2.
2. Remove the wheel assemblies. Refer to Sec-
tion G2, Tires and Rims, for instructions on
removing the rear wheels.
FIGURE 6-4. DRIVE SHAFT

1. Carrier Assembly 4. Snap Ring
2. Spacer 5. Sun Gear
3. Drive Shaft

5. Remove snap ring (4) from the drive shaft.
6. Remove sun gear (5). 5. Install snap ring (4).
7. Remove spacer (2). 6. Place cover (1) into position. Install the cap
8. Attach appropriate lifting apparatus to carrier screws and washers that secure the cover.
assembly (1). The weight of the carrier assem- 7. Add oil to the final drive case. Fill to the speci-
bly is approximately 630 kg (1,390 lbs). Lift the fied level and check the oil level again. Refer to
carrier from the truck. Section P, Lubrication and Service, for the
proper oil.
Disassembly
1. Remove nine cap screws (6, Figure 6-6) and six
cap screws (7). Remove plate (3).
2. Use a press to remove shaft (4).
FIGURE 6-5. CARRIER ASSEMBLY

1. Carrier Assembly 2. Rim
Installation
1. Attach appropriate lifting apparatus to carrier
assembly (1, Figure 6-5). The weight of the car- FIGURE 6-6. CARRIER
rier assembly is approximately 630 kg (1,390
lbs). Lift the carrier assembly into position on 1. Bearings 5. Gear Assembly
the truck. 2. Spacer 6. Cap Screws
3. Plate 7. Cap Screws
2. Attach a lifting device to the drive shaft. The 4. Shaft 8. Spacer
weight of the assembly is approximately 176 kg
(388 lb). Lift the shaft into position. Install an
eyebolt at the end of drive shaft (3). Insert a bar
through the eyebolt and use the bar to push the
drive shaft into the carrier.
3. Install spacer (2 Figure 6-4).
4. Install sun gear (5) on drive shaft (3).

Assembly
1. Install spacer (8, Figure 6-6) in the carrier.
2. Install snap ring (3, Figure 6-8).
3. Position spacer (2), and press fit outer race (1).
4. Set spacer (2, Figure 6-6) and bearing (1) into
position. Raise the planetary gear and assem-
ble. Install bearing (1) from the top.
5. Push planetary gear assembly (5) into the car-
rier.
6. Temporarily install plate (3) with cap screw (7).
Install two guide cap screws to shaft (4), and
press fit.
7. Apply Three Bond #1374 thread tightener to
FIGURE 6-7. BEARINGS cap screws (4, Figure 6-9). Tighten to 113 Nm
1. Bearings 2. Spacer (83 lb ft). Rotate the pinion gear five to six revo-
lutions. Again, tighten nine cap screws (4) and
six capscrews (3) to the specified torque.
3. Remove gear assembly (5). Remove two bear-
ings (1) and spacer (2). Refer to Figure 6-6 and
Figure 6-7.
4. Remove outer race (1, Figure 6-8) and spacer
(2).
Keep the bearing together as a set, in a safe place.
5. Remove snap ring (3).

6. Remove spacer (8, Figure 6-6) from the carrier.
FIGURE 6-9. PLANETARY SHAFT RETAINER
1. Carrier 3. Cap Screw, Washer

FIGURE 6-8. OUTER BEARING RACES 2. Retainer Plate 4. Cap Screw, Washer
2. Spacer

FINAL DRIVE ASSEMBLY
Disassembly
1. Remove the rear wheel. Refer to Section G2,
Tires and Rims, for instructions on removing the
rear wheel.
2. Remove the carrier assembly as outlined in this
chapter.
3. Remove the retainer and shims.
a. Use three fixture tools (562-99-3A120) (1,
Figure 6-10) to secure disc brake inner gear
(4) to outer gear (3). To install the tools,
remove three cap screws (2) from the outer
gear, and insert cap screws (5) into the three
tool mounting tapped holes in the inner gear.
FIGURE 6-11. RETAINER
1. Retainer 2. Cap Screws
To prevent damage to the floating seal, always

install the fixture tools before removing retainer 4. Attach appropriate lifting apparatus to ring gear
(1, Figure 6-10). assembly (1, Figure 6-12). The ring gear and
hub weighs approximately 325 kg (716 lbs). Lift
the gear from the assembly.
b. Remove mounting cap screws (2, Figure 6-
5. Disassemble the ring gear assembly as follows.
11). Remove retainer (1) and the shims.
a. Remove mounting cap screws (1, Figure 6-
NOTE: Note the number and thickness of the shims.
13), then remove holder (2).
Keep the shim pack together in a safe place.
b. Remove inner hub (3) from ring gear (4).
FIGURE 6-10. BRAKE GEAR TOOL INSTALLATION

1. Fixture Tool 4. Inner Gear FIGURE 6-12. RING GEAR
(562-99-3A120) 5. Temporary Cap Screw 1. Ring Gear Assembly 2. Hub
2. Cap Screw 6. Wheel Hub
3. Outer Gear

FIGURE 6-13. INNER GEAR AND RING GEAR
FIGURE 6-15. GEAR SUPPORT TOOL
1. Cap Screws 3. Inner Hub
2. Holder 4. Ring Gear 1. Tool (562-99-3A120) 4. Outer Gear
2. Nut 5. Wheel Hub
3. Cap Screw
b. Remove wheel hub assembly (2, Figure 6-

6. Remove the rear wheel hub assembly. 16) slowly until the outer bearing is
a. Attach an appropriate lifting sling to rear unseated. Remove outer bearing (1) and
wheel hub assembly (1, Figure 6-14) or sup- bearing inner race pin. The weight of the
port with a forklift. The weight of the assem- bearing is approximately 76 kg (168 lb).
bly is approximately 968 kg (2134 lbs).
NOTE: DO NOT allow the bearing to fall. The bearing
Remove nuts (2, Figure 6-15), except those
is easily dislodged.
on the seal retainer tools.
c. Remove the wheel hub assembly.

d. Remove outer races (2 & 3, Figure 6-17)
from the wheel hub assembly.
FIGURE 6-14. REAR WHEEL HUB

1. Hub Assembly 2. Housing

FIGURE 6-16. HUB AND BEARING
FIGURE 6-18. BEARING
1. Bearing 2. Hub Assembly
1. Bearing 3. Pin
2. Axle
Assembly
NOTE: Refer to Section J, Rear Wet Disc Brakes -
Floating Ring Seal Assembly/Installation for detailed
seal installation instructions.
1. Install floating seal assembly (13, Figure 6-1) to
the wheel hub seal carrier. Install a new O-ring
on the seal carrier.
2. Install inner bearing (1, Figure 6-18) and pin (3).
3. Assemble the wheel hub.
a. Use a bearing plate and press to install outer
races (2 & 3, Figure 6-17) into wheel hub (1).
FIGURE 6-17. HUB AND BEARING
1. Hub Assembly 3. Outer Race b. Raise the rear wheel hub assembly. Slide
2. Outer Race the assembly over the axle and against the
disc brake inner gear.
c. Install the outer bearing retainer pin onto the
axle. Install outer bearing (1, Figure 6-16).
7. Remove inner bearing (1, Figure 6-18 and bear-
ing inner race pin (3). The weight of the bearing d. Install nuts (2, Figure 6-15) and tighten to
is approximately 75 kg (165 lbs). 927 Nm (684 lb ft).
8. Remove floating seal carrier (13, Figure 6-1) NOTE: DO NOT remove tools (1, Figure 6-14) until
from the axle. the retainer has been completely secured.

4. Assemble the ring gear.
a. Place inner hub (3, Figure 6-13) into position
on ring gear (4).
b. Install holder (2). Apply Three Bond #1374
thread tightener to mounting cap screws (6)
and tighten to 113 Nm (83 lb ft).
c. Install ring gear assembly (1, Figure 6-12).
5. Adjust the bearing preload as follows.
a. Install retainer (2, Figure 6-19) with four
equally spaced cap screws (3). DO NOT
install any shims at this time.
b. Remove fixture tools (1, Figure 6-15) at three
places.
c. Rotate the wheel hub five to six times.
d. Tighten the cap screws evenly and alter-
nately to 167 10 Nm (123 7 lb ft).
FIGURE 6-19. SHIM ADJUSTMENT
1. Micrometer 3. Capscrew
2. Retainer
If the cap screws are tightened without rotating 6. Rotate the wheel hub five to six times. Tighten
the wheel hub, the bearing will not seat properly cap screws (2, Figure 6-19) evenly and alter-
and the correct preload cannot be obtained. nately until the tightening torque is constant.
After tightening the cap screws, rotate the
wheel hub and verify smooth rotation.
e. Using depth micrometer (1, Figure 6-19)
7. Install the carrier assembly. Refer to Final Drive
measure dimension (c) between the end of
Carrier Assembly - Installation in this section.
the shaft and the outer edge of retainer (2).
8. Install the rear wheel assembly. Refer to Sec-
f. Install tools (1, Figure 6-15) at three evenly tion G2, Tires and Rims for information on
spaced locations. installing the rear wheels.
g. Remove the retainer, and measure thickness
(a, Figure 6-19) of the retainer. Select a shim
thickness which is equal to dimension (b).
Use the formula below:
b = (c-a) + 0.3 mm (0.012 in.).
h. Insert the shim pack and install retainer (2,
Figure 6-19). Apply Three Bond #1374
thread tightener to cap screws (3) and
tighten to 927 Nm (684 lb ft).
i. Remove tools (1, Figure 6-15) at three
places. Install the absent cap screws (3) and
tighten to 549 Nm (405 lb ft).

SECTION H
SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
REAR SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
OILING AND CHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-1
H01017 Index H1-1

NOTES
H1-2 Index H01017

SECTION H2
FRONT SUSPENSION
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-8
DAMPING VALVE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-10
H02022 Front Suspensions H2-1

NOTES
H2-2 Front Suspensions H02022

FRONT SUSPENSION
The suspension system supports the weight of the

chassis and absorbs the shock from uneven road
surfaces to provide a comfortable ride for the opera-
tor. At the same time, it maintains the stability of the
machine by ensuring that all four wheels are always
in contact with the ground surface.
The suspensions are hydro-pneumatic components
containing oil and nitrogen gas. The oil and gas in the
four suspension cylinders carry the gross truck
weight less wheels, spindles and final drive assem-
bly.
The front suspension consists of two basic compo-
nents; a suspension cylinder and an A-arm.
DESCRIPTION
Front suspension cylinder (Figure 2-1) functions as a
shock absorber and spring, and is connected by
spherical bearings to the lower A-arm and main
frame. The wheels move up and down in accordance
with the retraction and extension of the suspension
cylinder to maintain the proper alignment for the
wheels and to improve the stability of the truck.
FIGURE 2-1. FRONT SUSPENSION

OPERATION
The inside of the suspension cylinder contains oil (B,
Figure 2-2), and is charged with nitrogen gas (A). Oil
(B) and oil chamber (C) are connected by tube (9)
and valve assembly (10).
When the machine is traveling, the wheels follow the
unevenness of the road surface, and an external,
vertical force is applied to the suspension cylinder.
When this happens, the volume of the nitrogen in the
gas chamber is compressed under the input force,
and absorbs the external force. The nitrogen gas is
sealed by a rod and oil, so it is always subjected to a
pressure corresponding to the external force, and
acts as a spring.
The damping force is produced inside valve assem-
bly (10) with orifice plate (12) and leaf springs (11).
They restrict the flow of oil between oil chamber (B)
and oil chamber (C), and create a damping force.
When retracting, the nitrogen gas is compressed
by the external force from the road surface. The
oil in chamber (B) flows through valve assembly
(10, Figure 2-2) in direction (Y) and tube (9) to oil
chamber (C). The oil flowing through the valve
from the tube to the orifice plate is throttled by
orifices to generate a damping force.
When extending, the external force from the road
surface weakens, the pressure of the nitrogen
gas extends the rod, and the oil in chamber (C)
passes through tube (9) and valve assembly (10)
to oil chamber (B). The oil flowing through the
valve flows in direction (Z) and passes through
orifices in the orifice plate to generate a damping
force.

1. Charging Valve 9. Tube
2. Retainer 10. Valve Assembly
3. Flange 11. Leaf Springs
4. Cylinder (with axle) 12. Orifice Plate
5. Rod
6. Wear Ring A. Gas Chamber
7. Discharge Plug B. Oil Chamber
8. Air Bleed Plug C. Oil Chamber

Removal
The suspension cylinders require only normal care 9. Remove capscrews (2, Figure 2-4) and lock
when handling as a unit. However, after being disas- washers (3). Rotate the knuckle arm as neces-
sembled these parts must be handled carefully to sary to gain access to all of the capscrews.
prevent damage to the machined surfaces. Surfaces 10. Steer the knuckle arm to the straight ahead
are machined to extremely close tolerances and are position.
precisely fitted. All parts must be completely clean
11. Lower the A-arm jack to disconnect the cylinder
during assembly.
from the steering knuckle.
1. Park the unloaded truck on a hard, level sur-
12. Attach a suitable lifting device to the suspen-
face. Block the wheels and apply the parking
sion. The weight of the suspension is approxi-
brake.
mately 1850 kg (4080 lbs). See Figure 2-5.
2. Remove the wheel hub and brake assemblies.
Refer to Section G for instructions. Position a 13. Remove pin (2) and the two spacers. Lift the
jack below the lower cylinder mount and a jack suspension from the truck
below the frame near the front of the machine
on the side being serviced.
3. Remove the cover from the top of the suspen-
sion cylinder, and disconnect the pressure sen-
sor connector.
4. Release the nitrogen pressure from the suspen-
sion. Refer to Oiling and Charging Procedures
later in this section for proper instructions.
FIGURE 2-3. STEERING LINKAGE REMOVAL

1. Tie Rod 4. Grease Tubes FIGURE 2-4. STEERING KNUCKLE
2. Pin 5. Pin 1. A-Arm 3. Lockwashers
3. Elbow 6. Steering Cylinder 2. Capscrews
5. Remove the two capscrews that secure the

brake cooling hose clamp to the cylinder.
6. Remove grease tubes (4, Figure 2-3) and
elbows (3).
7. Remove pins (2) and (5).
8. Move tie rod (1) and the rod of steering cylinder
(6) out from the steering knuckle.

Installation
1. Clean all paint and debris from the mounting 8. Position the brake hose clamping bracket in
surface of the suspension. Ensure the mounting place on the cylinder. Install the two capscrews
surfaces of the suspension and the A-arm are that secure the bracket.
smooth and free of any oil. 9. Install the front wheel hub and brake assem-
2. Attach a suitable lifting device to the suspen- blies. Refer to Section G for installation proce-
sion housing. The weight of the suspension is dures.
approximately 1850 kg (4080 lbs). 10. After installation of the suspension, it will be
3. Raise the suspension into position at the top necessary to check the oil level and charge with
cylinder mount. Install cylinder pin (2, Figure 2- nitrogen gas. Refer to Oiling and Charging Pro-
5) with the two spacers positioned on each side cedure, later in this section.
of the suspension.
4. Raise the A-arm into position at the lower cylin-
der mount. Install capscrews (2, Figure 2-4) and
lock washers (3).
Disassembly
If available, the suspension should be mounted in a
roll-over stand to retain the assembly and allow repo-
sitioning during disassembly and reassembly proce-
dures. Use extreme care when handling machined
surfaces and critical components.
1. Remove the top suspension cover, if installed.
2. Remove charging valve (3, Figure 2-6) and
pressure sensor (4) from the top of the cylinder.
3. Remove flange mounting bolts (2) and air bleed
plug (5).
4. Lift the cylinder rod assembly out of the housing
with plate (6), retainer (1), and flange (7)
installed.
After the rod assembly has been removed from
the housing, remove the plate, retainer, and
flange from rod.
FIGURE 2-5. FRONT SUSPENSION 5. Remove dust seal (11) and bushing (10) from
1. Suspension Cylinder 2. Cylinder Pin the retainer.
6. Remove seal (12), bushing (13) and buffer ring
(14) from the flange.
7. Remove wear ring (9) from cylinder rod (8).
8. Remove tube (9, Figure 2-2) and valve assem-
5. Connect steering cylinder (6, Figure 2-3) to the
bly (10) from the housing.
steering knuckle with pin (5).
9. If necessary, remove two snap rings (15, Figure
6. Connect tie rod (1) to the knuckle with pin (2).
2-6). Use a press and a step plate to remove
7. Install elbows (3) and grease tubes (4). bushing (16) from the rod eye.

FIGURE 2-6. FRONT SUSPENSION ASSEMBLY
1. Retainer 7. Flange 13. Bushing

2. Capscrew 8. Rod Assembly 14. Buffer Ring
3. Charging Valve 9. Wear Ring 15. Snap Ring
4. Pressure Sensor/Valve Assembly 10. Bushing 16. Bushing
5. Air Bleed Plug 11. Dust Seal
6. Plate 12. Seal

Inspection
If scratches or scores are found in housing or on sus-
pension tube, contact the nearest Komatsu distribu-
tor for additional information regarding repair
services or factory recommended repair procedures.
Assembly
Clean all components thoroughly. Lightly coat all O-
rings with petroleum jelly or suspension oil.
1. Install valve assembly (10, Figure 2-2) and tube
(9).
2. If removed, install bushing (16, Figure 2-6). Use
a press and a step plate to install the bushing to
the rod eye. Install two snap rings (15).
3. Install wear ring (9) to cylinder rod (8). Ensure
FIGURE 2-7. LIQUID GASKET SEAL AREA
the outside surface of the wear ring is lubricated
with clean suspension oil. 1. Retainer A - Sealant Area
2. Flange B - No Sealer in this area
NOTE: In the following steps, use caution not to
deform the bushings during installation.
4. Lubricate the inside surface of bushing (13) with
clean suspension oil. Press the bushing into
flange (7). 11. Refer to Figure 2-7. Coat the entire mating
5. Install seal (12) and buffer ring (14). face "A" of flange (2) and retainer (1) with a thin
6. Press bushing (10) to retainer (1), and install layer of Liquid Gasket LG-5. DO NOT allow
dust seal (11). sealant to contact seal bore area "B".
7. Install wear ring (9) to rod assembly (8). 10. Secure flange (7, Figure 2-6), retainer (1), and
8. Install flange (7), retainer (1), and plate (6) on plate (6) to the cylinder with capscrews (2).
cylinder rod. Tighten to 382 Nm (282 lb ft).
9. Position the suspension housing upright. Fill the 11. Install air bleed plug (5), discharge valve (4) and
cylinder with SAE 10W diesel engine oil. (Final charging valve (3). Tighten each item to 45 5
oil level is determined after the suspension is Nm (33 4 lb ft).
installed on the truck.)
10. Lift the cylinder rod assembly into the cylinder
housing.
NOTE: When installing the rod assembly in the
cylinder, if the rod assembly is inserted too far, the oil
will be forced out. If this occurs, do not attempt to
insert rod further into housing.

DAMPING VALVE REPAIR
If damping valve repairs are being performed

with the suspension assembly mounted on the
truck, relieve nitrogen pressure prior to removing
any components. Refer to Oiling and Charging
Procedures later in this section for information
on how to properly relieve the pressure. Use a
jack under the truck frame to prevent the suspen-
sion from retracting.
Disassembly
1. Place a container capable of capturing approxi-
mately 63 liters (17 gal) of oil into position
beneath valve body (2, Figure 2-8).
2. Remove the capscrews that secure tube (1) to
the valve body and cylinder. Remove the tube
and the O-rings.
3. Remove the four capscrews that secure valve
body (2) to the suspension. Remove the valve.
4. Remove orifice plate assembly (3) as a com-
plete unit.
5. Remove capscrew (4). Remove stopper plate
(5), plate (6), oblong leaf springs (7) and circu-
lar leaf springs (8) from orifice plate (9).
6. Remove pin (10) from orifice plate (9).
FIGURE 2-8. DAMPING VALVE
1. Tube 6. Plate
2. Valve Body 7. Oblong Leaf Spring
3. Orifice Plate Assembly 8. Circular Leaf Spring
4. Capscrew 9. Orifice Plate
5. Stopper Plate 10. Pin

Assembly
1. Install pin (10, Figure 2-8) to orifice plate (9).
NOTE: In the following step, assemble each oblong
leaf spring (7) and circular leaf spring (8) with the
chamfered side facing orifice plate (2). Refer to
Figure 2-8.
2. Assemble circular leaf springs (8), oblong leaf
springs (7) with plates (9), (6), and (5). Secure
the assembly with capscrew (4), and tighten to
66 Nm (49 lb ft).
3. Install orifice plate assembly (3) to valve body
(2). Tighten the capscrews to 66 Nm (49 lb ft).
4. Position the O-ring and valve body (2) into posi-
tion on the suspension. Coat the capscrew
threads with Three Bond TB1374. Install the
capscrew and tighten to 279 Nm (206 lb ft).
5. With new O-rings installed, place tube (1) into
position. Install the capscrews and tighten to
110 Nm (81 lb ft).
6. If damping valve repairs have been performed
while the suspension is still mounted on the
truck, fill the suspension assembly with oil and
recharge with nitrogen. Refer to Oiling and
Charging Procedures later in this section.

SECTION H3
REAR SUSPENSION
INDEX
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
SPHERICAL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
H03025 Rear Suspensions H3-1

NOTES
H3-2 Rear Suspensions H03025

REAR SUSPENSION
Suspensions are hydro-pneumatic cylinders contain-

ing oil and nitrogen gas. The oil and gas in the four
suspensions carry the gross weight of the truck
minus the wheels, spindles and rear axle. The rear
suspension cylinders consist of two basic compo-
nents, a suspension housing attached to the truck
frame and a suspension rod attached to the axle
housing.
Each rear suspension cylinder contains a charging
valve (1, Figure 3-1). The charging valve is used to
charge the suspension with pressurized nitrogen.
The suspension must be properly maintained with oil
and nitrogen for optimum performance. Refer to Sec-
tion H, Oiling and Charging Procedures, for proper
charging instructions.
The suspension is also equipped with a pressure
sensor. The sensor senses internal gas pressure and
sends that information to the VHMS controller. The
information is used to calculate payload data by the
payload meter.
The suspension cylinder requires only normal care
when handling as a unit. However, after being disas-
sembled these parts must be handled very carefully
to prevent damage to the machined surfaces. Sur-
faces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
FIGURE 3-1. REAR SUSPENSION ASSEMBLY

1. Charging Valve 2. Pressure Sensor

Operation
The suspension cylinder functions both as a shock
absorber (retracting) and a spring (extending).
Retracting: When the truck is in motion and hits a

bump or an object on the road, the wheels are
pushed up. The upward motion causes the
cylinder rod to retract into the cylinder. When this
happens, the nitrogen gas inside area (1) is
compressed and absorbs the shock from the
road. At the same time, oil is displaced from area
(6) and travels through orifices (2 & 3) to cavity
(5). The cavity is quickly filled.
Extending: After the truck has passed over a

bump or object on the road surface, the cylinder
is pulled down by the weight of the wheels and
axle. At the same time, the nitrogen pressure
inside the cylinder pushes down inside area (1)
and acts as a spring. As a result, the size of
cavity (5) is reduced, and pressurizes the oil in
the cavity. The pressurized oil closes the check
balls in orifices (2 & 3) limiting oil flow into oil area
(5). The restricted oil flow through orifice (4)
results in a slower extension as compared to
retraction. The slower extension provides a
smoother ride.
FIGURE 3-2. REAR SUSPENSION

1. Nitrogen Cavity 5. Oil Cavity
2. Check Ball Orifice 6. Oil Cavity
3. Check Ball Orifice 7. Piston Rod
4. Orifice

Removal
1. Park the unloaded truck on hard, level surface.
Apply the parking brake and chock the wheels.
2. Raise and support the rear of the truck frame.
3. Wear a face mask or goggles, and discharge
the nitrogen pressure from the suspension.
Refer to Section H, Oiling and Charging Proce-
dures, for the proper procedure for discharging
nitrogen.
4. Remove pressure sensor (5, Figure 3-3) and
remove the clamps securing the sensor har-
ness to the suspension.
5. Remove the upper pin retainer and remove
upper pin (1, Figure 3-3).
6. Attach an appropriate lifting device to the sus-
pension. The suspension weighs approximately
500 kg (1100 lbs.).
7. Remove the lower pin retainer and remove
lower pin (2, Figure 3-3). Lift the suspension
from the truck.
8. Move the suspension to a clean work area.

Installation
1. Attach an appropriate lifting device to the sus- 1. Upper Pin 4. Clamp
pension. The suspension weighs approximately 2. Lower Pin 5. Pressure Sensor
500 kg (1100 lbs.). 3. Cover 6. Charging Valve
2. Lift the suspension into position on the truck.
Lubricate lower pin (2, Figure 3-3) with multi-
purpose grease and install the pin. Install the
pin retainer and cap screws. Disassembly
3. Lubricate upper pin (1) with multi-purpose 1. If available, mount the suspension assembly in
grease and install the pin. Install the pin retainer a roll-over stand. Position the assembly upright
and cap screws. as installed on the truck.
4. If not done already, fill the suspension with oil, 2. Remove clamp (4, Figure 3-3) and cover (3).
and charge with nitrogen gas. Refer to Section 3. Remove charging valve (5) and the pressure
H, Suspension Oiling and Charging Proce- sensor schrader valve from the suspension.
dures, for more information. Drain the oil from the cylinder.
5. Install pressure sensor (5). Install the clamps 4. Rotate the assembly to position the flange on
that secure the sensor harness to the suspen- top. Remove cap screws (1, Figure 3-4) and the
sion. washers.

6. Attach a suitable lifting device to rod (1, Figure
3-6). The weight of the rod is approximately 177
kg (390 lb). Lift the rod out of the housing
FIGURE 3-4.
1. Cap Screw 2. Plate

FIGURE 3-6.
1. Rod 2. Cylinder Housing

5. Remove plate (1, Figure 3-5), retainer (4), and
flange (2).
7. Remove wear ring (2, Figure 3-7) from cylinder
rod (1).
FIGURE 3-7.
FIGURE 3-5.
1. Rod 2. Wear Ring
1. Plate 3. Cylinder Housing
2. Flange 4. Retainer

8. Remove seal (1, Figure 3-8) and bushing (2)
from retainer (3).
FIGURE 3-8.
1. Seal 3. Retainer FIGURE 3-9.

2. Bushing
1. Packing 4. O-Ring
2. Flange 5. Backup Ring
3. Bushing
9. Remove packing (1, Figure 3-9) and bushing
(3) from flange (2). Remove O-ring (4) and
backup ring (5).
10. If necessary, remove cover (8, 3-10) from the

cylinder housing.

FIGURE 3-10. SUSPENSION ASSEMBLY
1. Cap Screw 7. Charging Valve 13. Cap Screw 19. Plate

2. Washer 8. Cover 14. Washer 20. Retainer
3. Clamp 9. Cap Screw 15. Rod 21. Flange
4. Packing 10. Wear Ring 16. Packing 22. O-ring
5. Schrader Valve 11. Cylinder Housing 17. Bushing 23. Backup Ring
6. Pressure Sensor 12. Bushing 18. Seal

Assembly .
1. Clean all parts thoroughly. Remove any debris
or foreign objects from the cylinder housing and
other components.
2. Install wear ring (2, Figure 3-7) on rod (1).
3. Install packing (1, Figure 3-9) and bushing (3) in
flange (2). Install O-ring (4) and backup ring (5).
4. Install seal (1, Figure 3-8) and bushing (2) in
retainer (3).
5. Rotate the cylinder housing so flange mating
face is up.
6. Attach a suitable lifting device to rod (1, Figure
3-6). The weight of the rod is approximately 177
kg (390 lb). Lift the rod over the housing. Lubri-
cate the wear ring with clean suspension oil.
Lower the rod into the cylinder housing.
7. Apply a thin layer of Liquid Gasket to sealant
area (A, Figure 3-11) on retainer (1) and flange FIGURE 3-11. LIQUID GASKET SEAL AREA
(2). DO NOT allow the sealant to contact seal
area (B). 1. Retainer A - Sealant Area
2. Flange B - Seal Area
8. Lubricate bushing (3, Figure 3-9) with clean
suspension oil.
9. Lift flange (2, Figure 3-5) and retainer (4) onto
the cylinder housing.
10. Lift plate (1) onto the cylinder housing. 12. Secure the flange, retainer, and plate to the cyl-
11. Install temporary plugs in the charging valve inder with cap screws (1, Figure 3-4) and the
and pressure sensor ports. washers. Tighten the cap screws to 382 45
Nm (282 33 lb ft).
13. Install a new seal onto charging valve (7, Figure
3-10) and schrader valve (5). Install the valves
in the cylinder housing. Tighten the valves to 44
5 Nm (33 4 lb ft).
NOTE: The charging valves must be installed in the
outboard ports (as viewed while the suspension is
mounted on the truck).
14. If removed, install cover (8).
15. Install the spherical bearings, if necessary.
Refer to Spherical Bearings - Installation.
16. Adjust the suspension oil level and charge with
nitrogen. Refer to Section H, Suspension Oiling
and Charging Procedure.

LEAK TESTING Inspection
It is necessary to leak test the cylinder after rebuild 1. Inspect the bearing bores for damage. Inspect
and assembly to verify proper operation of the cylin- the retainer ring grooves. Repair or replace as
der. Use the pressure sensor port to charge the cylin- necessary.
der during the leak test. 2. Inspect the mounting pin, snap rings, and
spherical bearing. Replace if damaged.
Air Leak Test
Air Pressure . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Test Time . . . . . . . . . . . . . . . . . . . . . . . . . .2 minutes Installation
Apply soapy water to sealed joints and ports and 1. Install one snap ring (1, Figure 3-12) into one of
check for bubbles. If an air leak exists, the cylinder the snap ring grooves.
must be repaired as necessary before proceeding. 2. Use a press and a pusher plate to install the
spherical bearing in the bore.
Oil Leak Test 3. Install the remaining snap ring.
Oil Pressure . . . . . . . . . . . . . . 20,594 kPa (2987 psi)
Test Time . . . . . . . . . . . . . . . . . . . . . . . . .10 minutes
Check for oil leaks or cracks. If no leaks or damage is
evident, the cylinder may be charged and installed on
the truck
SPHERICAL BEARINGS
NOTE: If either the top or bottom spherical bearings
are to be replaced with the suspension mounted on
the truck, ensure the truck frame is securely
supported. Refer to Suspension Removal and
Installation for more information on suspension
removal. Securely support the suspension as the
bearing is being removed and installed.
FIGURE 3-12.
Removal
1. Snap Ring 2. Spherical Bearing
1. Remove two snap rings (1, Figure 3-12) from
the mounting eye.
2. Use a press and a pusher plate to remove bear-
ing (2).

SECTION H4
OILING AND CHARGING PROCEDURES
INDEX
OILING AND CHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-5
Front Suspension Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-5
Front Suspension Nitrogen Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-8
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-10
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-10
Rear Suspension Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-10
Rear Suspension Nitrogen Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-14
LENGTH ADJUSTMENT - FRONT AND REAR CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-14
H04020 Oiling and Charging Procedures H4-1

NOTES
H4-2 Oiling and Charging Procedures H04020

OILING AND CHARGING PROCEDURES
GENERAL INFORMATION Equipment List
These procedures detail the oiling and charging of 1. Service Kits:

the front and rear suspensions. Suspensions which a. EC6027 Oil Charging Kit (Figure 4-5)
have been properly charged will provide improved
b. EC3331Nitrogen Charging Kit (Figure 4-6)
handling and a better ride while improving the service
life of the suspensions, the truck main frame, and 2. Jacks and/or overhead crane
other main components. 3. Two oiling spacers: height - 95 mm (3.7 in.)
NOTE: Inflation pressures and oiling/charging 4. Jacks and/or overhead crane
dimensions are calculated for original truck Gross 5. Spacers (two) for oiling height; 95 mm (3.7 in.)
Vehicle Weight (GVW). Any accumulation of dirt/ 6. Oil - Refer to Tables 1 & 2
mud/debris on the truck or in the body must be
7. Dry nitrogen - Refer to Table 3
removed before starting these procedures. Additions
to the truck weight (tailgates, water tanks, etc.) must
be considered part of the payload. Keeping the truck
GVW within the specification will result in a better
ride and will extend the service life of the truck main
frame and suspensions.
Proper charging of suspensions requires three basic All suspensions are charged with compressed
conditions be established in the following order: nitrogen gas with sufficient pressure to cause
1. The oil level must be correct. injury or damage if improperly handled. Follow
all safety notes, cautions, and warnings in these
2. The suspension piston rod extension for nitro- procedures to prevent accidents during servicing
gen charging must be correct, and this dimen- and charging.
sion maintained during nitrogen charging.
3. Nitrogen charging pressure must be correct.
For best results, suspensions must be charged in
pairs (fronts together and rears together).
NOTE: Setup dimensions specified in the charts
must be maintained during oiling and charging
procedures. However, after the truck has been
operated, these dimensions will change.
It is extremely important to properly maintain oil

and nitrogen levels on the suspension cylinders.
The oil is not only used to provide dampening,
but also to lubricate internal parts. If an oil leak is
present, it must be repaired, immediately. Excess
nitrogen charging will not compensate for an oil
leak. The lack of oil will cause excess friction in
the cylinder leading to suspension cylinder fail-
ure.

TABLE 1. APPROVED SUSPENSION OILS AND FRICTION MODIFIER
Part Number Description Comments
VJ3911 Komatsu Suspension Oil - 19 liter (5 gal) container Add 6% friction modifier. See Table 2.
AK4063 Komatsu Suspension Oil - 19 liter (5 gal) container Already mixed with 6% friction modifier
AK4064 Komatsu Suspension Oil - 208 liter (55 gal) container Already mixed with 6% friction modifier
Not Available Mobil 424 Add 6% friction modifier. See Table 2.
Not Available Mobil DTE 15 Add 6% friction modifier. See Table 2.
Not Available Texaco TDH Oil Add 6% friction modifier. See Table 2.
Not Available Amoco Ultimate Motor Oil 5W-30 Add 6% friction modifier. See Table 2.
Not Available Sunfleet TH Universal Tractor Fluid Add 6% friction modifier. See Table 2.
Not Available Chevron Tractor Hydraulic Fluid Add 6% friction modifier. See Table 2.
Not Available Conoco Power Tran III Fluid Add 6% friction modifier. See Table 2.
Not Available Shell Donax TDL Add 6% friction modifier. See Table 2.
Not Available Citgo Transgard Tractor Hydraulic Fluid Add 6% friction modifier. See Table 2.
Not Available Duratran Fluid - Petro Add 6% friction modifier. See Table 2.
AK3761 100 % friction modifier - 19 liter (5 gal) container Mix with suspension oil. See Table 2.
TABLE 2 SUSPENSION OIL / FRICTION MODIFIER MIXING RATIO

Proper Ratio = 94% Suspension Oil : 6% Friction Modifier
Suspension Oil Quantity Friction Modifier Quantity
3.8 liter (1 gal) of suspension oil 237 ml (8 oz)
19 liter (5 gal) of suspension oil 1 liter (38 oz)
208 liter (55 gal) of suspension oil 11.4 liter (3 gal)
The following oils may be used as alternatives to those listed in Table 1. DO NOT mix these oils with friction modi-
fier.
HO-MVK (Koma-Hydro MV)
Shell Tellus T32
Shell Tellus 46
Castrol Hyspin AWS 46
TABLE 3. NITROGEN GAS SPECIFICATIONS

PROPERTY VALUE
Nitrogen 99.9% minimum
Nitrogen gas used in suspension cylinders must meet or Water 32 ppm maximum
exceed CGA Specification G-10.1 for Type 1, Grade F
Nitrogen Gas. Dew Point -55C(-68F) maximum
Oxygen 0.1% maximum

FRONT SUSPENSION Front Suspension Oiling
face. Apply the parking brake, and block the
wheels.
2. Verify that the bottom of each cylinder cover is
Lifting equipment (crane or hydraulic jacks) must
within the range designated by the arrows (Fig-
be capable of lifting the weight of the truck.
ure 4-1) signifying correct nitrogen charge.
Ensure that all personnel are clear of the lift area
3. If each suspension is within the area indicated before the lift is started.
by the arrows, no service is necessary for the
front suspensions. See the note below for
guidelines. If a suspension is not within the area
indicated by the arrows, the front suspensions
will have to be serviced.
NOTE: The oil level must be checked:
A common mistake when adjusting the oiling
Before charging or adding nitrogen. height is the failure to recognize and/or properly
When there are signs of oil leakage. react to oil that contains trapped nitrogen or
"foamy oil". Oil, such as this, is common when
After rebuild/repair and the suspension is
installed on the truck the truck has recently been operating and the
suspension oil and gas havent been allowed to
. settle and separate. This condition needs to be
handled properly to ensure that the suspension
receives the proper amount of oil. Failure to do
so may cause a low oil level resulting in prema-
ture component wear. Premature bearing and
seal wear can, in many cases, be attributed to
this occurrence.
If the truck has been operating, allow three to
four hours for the oil and nitrogen gas to sepa-
rate. An alternative is to purge the foamy oil and
replace with new oil. The wrong oiling height will
be observed if the oil level is checked/adjusted
with foamy oil or with air bubbles present.
FIGURE 4-1. FRONT SUSPENSION HEIGHT
Oil Quantity (approximate): 62.4 Liters (16.5 Gallons)
NOTE: DO NOT fill the suspension cylinder with oil

based on quantity alone. Oil quantities are given as
reference, only. Fill/adjust the oil level in the front
suspension to the oiling height listed in Figure 4-3.

face. Apply the parking brake, and block the
wheels.
2. Remove the outside suspension covers and
thoroughly clean the area around charging
valves (3, Figure 4-2).
3. Place a hydraulic jack (1, Figure 4-3) under the
main frame, and raise the jack until it contacts
the frame. The jack must be rated for a mini-
mum of 50 tons.
4. While wearing a face mask or goggles, dis-
charge the nitrogen pressure from the suspen-
sion by loosening pressure sensor valve
assembly (2, Figure 4-4) one revolution. DO
NOT exceed one revolution. Nitrogen pressure
cannot be released by loosening the pressure
sensor, itself. The schrader valve in the valve
assembly (2) will prevent nitrogen from being FIGURE 4-2. VALVE AND SENSOR LOCATION
released.
1. Air Bleed Valve 3. Charging Valve
2. Pressure Sensor
Releasing the nitrogen gas from the valve core of

charging valve (3, Figure 4-2) will damage the
valve core. Release the gas by loosening air
bleed valve (1, Figure 4-2) or sensor valve assem-
bly (2, Figure 4-4).
Loosening the pressure sensor valve assembly

more than three revolutions may result in the
component being forced out of the suspension
by the gas pressure inside. This can cause seri-
ous bodily injury. DO NOT exceed one revolution.
Wear a face mask or goggles while relieving
nitrogen pressure.
NOTE: If oil is discharged with the gas, tighten the
pressure sensor valve assembly slightly so only the FIGURE 4-3. OIL HEIGHT
gas will be discharged. If this is not possible, the
foamy oil will need to be purged from the suspension 1. Jack (50 ton min.) A: 97 3 mm
during the oiling procedure, prior to charging. 2. Frame (3.8 0.12 in.)

5. Adjust the hydraulic jack (1, Figure 4-3) so that
dimension "A" of the cylinder is 97 3 mm (3.8
0.12 in.).
6. After all nitrogen pressure has been relieved,
tighten valve assembly (2, FIgure 4-4).
FIGURE 4-4. PRESSURE SENSOR

1. Schrader Valve 3. Sensor
2. Valve Assembly
FIGURE 4-5. OIL CHARGING KIT (EC6027)
1. Hose 6. Pressure Sensor

2. Connector 7. Air Bleed Valve
3. Adapter 8. Air Bleed Hole
7. Remove charging valve (5, Figure 4-5), and 4. Fitting 9. Oil Pump Lever
install fitting (4). 5. Charging Valve 10. Oil Pump
8. Install adapter (3) to fitting (4), then connect the
hose and oil pump.
NOTE: Pressure sensor (6) must be installed, and
the air bleed valve (7) must be loose to ensure there
are no air pockets inside the suspension. Use caution when tightening the valves and fit-
9. Loosen air bleed valve (7), then pump oil into tings on the suspensions. DO NOT overtighten.
the cylinder until no air bubbles or foamy oil is Overtightening can damage the fittings or the
discharged from air bleed valve hole (8). suspension housing resulting in gas and oil
leaks. Tighten to the specified torque.
10. When no more air bubbles or foamy oil is dis-

charged, tighten air bleed valve (7) to 44 5
Nm (33 3 lb ft).
11. Remove pressure sensor valve assembly (6),
then operate the oil pump until no air bubbles or
foamy oil is discharged from the plug hole.
12. After all air and/or foamy oil is discharged,
install and tighten the pressure sensor valve
assembly to 44 5 Nm (33 3 lb ft).
13. After filling with oil, remove the oil pump and fit-
tings, then install charging valve (5) and tighten
the valve to 44 5 Nm (33 3 lb ft).

Front Suspension Nitrogen Charging
6. When the left and right cylinders reach the
specified length as shown in Figure 4-7, close
valve (4, Figure 4-6) to stop the flow of nitrogen
gas. Turn the handle of regulator (11) counter-
clockwise to close the valve.
Dry nitrogen is the only gas approved for use in
the suspensions. Charging the suspensions with
oxygen or other gases may result in an explosion
which could cause serious injuries, fatalities,
and/or major property damage. Refer to Nitrogen
Gas Specifications at the beginning of this chap-
ter.
1. Remove the caps from charging valves (3, Fig-

ure 4-2).
NOTE: Before installing regulator (11, Figure 4-6,

blow out the cylinder connector with nitrogen gas,
965 kPa (140 psi) or more, to clean out all dirt or
dust. Dirt or dust in the system can cause
suspension failures.
2. Connect the regulator to the nitrogen cylinder.

Open the valve on the gas cylinder, and check
the pressure reading on regulator gauge (1).
NOTE: The internal pressure of the gas cylinder must

be substantially higher than the suspension charging
pressure (refer to the chart in Figure 4-7).
FIGURE 4-6. NITROGEN CHARGING KIT

3. Install the nitrogen charging kit to the suspen- (EC3331)
sions, as shown in Figure 4-6.
4. Slowly turn the handle of regulator (11) clock- 1. Nitrogen Cylinder Gauge
wise. Adjust the pressure, shown on gauge (2), 2. Charging System Gauge
to the required charging pressure (refer to the 3. Manifold Outlet Valves (from gauge)
chart in Figure 4-7). Then, open valves (3 & 4, 4. Inlet Valve (from regulator)
Figure 4-6) to fill the suspension cylinders with 5. Connection Valve w/EC2253 Adapter Installed
nitrogen gas. 6. Valve "T" Handle
7. Pressure Sensor/Schrader Valve
5. Fill the left and right cylinders at the same time.
8. Air Bleed Valve
Verify the required charging pressure on gauge
9. Manifold
(10) by closing valve (4).
10. Charging Pressure Gauge (Suspensions)
11. Regulator Valve (Nitrogen Pressure)
12. Dry Nitrogen Gas
(see Nitrogen Gas Specifications at the begin-
ning of this chapter)
NOTE: Parts may vary from the illustration above
depending on the charging kit part number.

7. Turn handle (6) on valve adapter (5) fully coun- Dimension "A" is measured from the top of the cover
terclockwise to close the charging valve. Then, to the top of the suspension cylinder plate. DO NOT
remove the charging equipment, the hydraulic include the capscrews in the measurement. The
jack, and install the suspension covers. removal of an access panel on the top cover is
8. Use soapy water to check the charging valve, required.
the air bleed valve and the pressure sensor fit-
tings for leaks. Repair as necessary.
NOTE: Setup dimensions specified in the charts
9. Install the caps and O-rings onto charging
must be maintained during oiling and charging proce-
valves (3, Figure 4-2).
dures. However, after the truck has been operated,
these dimensions may vary. After charging the sus-
pensions, operate the empty truck over a short
course and then park the truck on a level surface.
Record the dimensions again and save for periodic
reference.
DIMENSION CHARGING CHARGING

HEIGHT PRESSURE
FRONT "A" 287 10 mm (11.3 2758 kPa

0.4 in.) (400 psi)

REAR SUSPENSION Rear Suspension Oiling
1. Check whether dimension "A" (Figure 4-11) on
each suspension cylinder is within the specified
GENERAL INFORMATION value listed in Table 4. If dimension A is within
specifications, no service is necessary for the
If the rear suspension is being filled with oil while rear suspensions. If a suspension is not within
installed on the truck, the angle in which the rear sus- the area indicated by the arrows, the front sus-
pension is positioned coupled with the location of the pensions must be serviced. Continue with this
charging valve port results in a significantly large vol- procedure.
ume of air being trapped inside the suspension. This
has the effect of lowering the oiling height since the NOTE: The oil level must be checked;
rear suspension can not be filled with the correct Before charging or adding nitrogen.
amount of oil. To compensate for this, all rear sus-
When there are signs of oil leakage.
pensions being filled with oil while installed on the
truck must use the "Installed On Truck" oiling heights After repair/rebuilds.
listed in Table 4.
When the suspension is in a vertical position while off
the truck, the oiling height will be different. All rear
suspensions being filled with oil while off the truck
should use the "On Bench" oiling heights listed in
Table 4. A common mistake when performing oiling pro-
NOTE: Refer to Table 4 for the approximate block cedures is the failure to recognize and/or prop-
height. The oiling height of the cylinder must always erly react to oil that contains trapped nitrogen or
be determined by using Dimensions A or C, only. "foamy oil". Oil, such as this, is common when
the truck has recently been operating and the
The final charging height in Table 4 is for suspen- suspension oil and gas havent been allowed to
sions at normal operating temperature and must not settle and separate. This condition must be han-
be exceeded. After charging a cold suspension, dled properly to ensure that the suspension
operate the truck for several hours and check/adjust receives the proper amount of oil. Failure to do
the charging height at normal operating temperature. so may cause a low oil level resulting in prema-
If the suspensions are not checked/adjusted at nor- ture component wear. Premature bearing and
mal operating temperature, the suspension height seal wear can, in many cases, be attributed to
may be incorrect, possibly causing excessive drive- this occurrence.
line angles that could result in damage to powertrain
If the truck has been operating, allow time for the
components.
oil and nitrogen gas to separate. This may take
several hours. An alternative action is to purge
the foamy oil from the cylinder during oiling.
Oil Quantity (approx.): . . . 36.3 Liters (9.6 Gallons)

NOTE: DO NOT fill a suspension cylinder with oil
based on quantity alone. Oil quantities are given as
reference, only. Always fill/adjust the oil level in the
suspension cylinders based on the oiling height
dimensions given in Table 4.

All suspensions are charged with compressed
nitrogen gas with sufficient pressure to cause
injury or damage if improperly handled. Follow
all safety notes, cautions, and warnings in these
procedures to prevent accidents during servicing
and charging.
1. Park the truck on a flat level surface. Apply the

parking brake, and chock the wheels.
2. Clean the area around charging valves (5, Fig-
ure 4-9).
3. Position the oiling spacer between the stopper
and the axle housing as shown in Figure 4-8 (if
servicing while on the truck). Dimension "A",
Figure 4-11, must be equal to the proper dimen-
sion listed in Table 4.
NOTE: The proper oiling block dimension is listed in
Table 4.
FIGURE 4-9. OIL CHARGING KIT (EC6027)
1. Hose 5. Charging Valve

2. Connector 6. Pressure Sensor
3. Adapter 7. Oil Pump
4. Fitting
FIGURE 4-8. OILING BLOCK INSTALLATION

1. Oiling Block 3. Dust Cover
2. Cylinder
FIGURE 4-10. PRESSURE SENSOR/VALVE ASSY.
1. Schrader Valve 3. Pressure Sensor

2. Valve Assembly

Dimension "A" is measured from the face of the
retainer to the bottom flat surface of the cylinder
rod. Do not measure from the cap screws or cap-
screw heads.
Dimension "B" is measured from the top of the
housing surface to the mating face for the flange.
Dimension "C" is measured from the center line
of the top pin to the center line of the bottom pin.

1. Housing 2. Retainer
TABLE 4. REAR SUSPENSION OILING & CHARGING DIMENSIONS
Housing Length (Dimension B) 510 mm (20.0 in.)
Installed On Truck 221 3 mm (8.7 0.1 in.)

Oiling Height (Dimension A)
On Bench 154 3 mm (6.1 0.1in.)
Installed On Truck 1148 3 mm (45.2 0.1 in.)

Oiling Height (Dimension C)
On Bench 1081 3 mm (42.6 0.1 in.)
Final Charge Height Dimension A 234 10 mm (9.2 0.4 in.)

(At Operating Temperature) Dimension C 1161 10 mm (45.7 0.4 in.)
Approximate Oiling Spacer Height 95 mm (3.7 in.)

4. Disconnect the pressure sensor harness con- 6. After all nitrogen pressure has been relieved,
nectors and remove the clamps securing the remove the pressure sensor/valve assembly.
harnesses. 7. Remove charging valve (5, Figure 4-9), and
install fitting (4).
8. Install adapter (3) to fitting (4). Connect the
hose and the oil pump.
9. Operate the pump until clear oil (containing no
air bubbles or foam) is discharged from the plug
Releasing the nitrogen gas from the valve core of hole.
charging valve (5, Figure 4-9) will damage the
10. After all air and foamy oil is discharged, install
valve core. Therefore, remove the gas by loosen-
the pressure sensor valve assembly.
ing pressure sensor/valve assembly (6) one revo-
lution.
Use caution when tightening the valves and fit-

tings on the suspensions. DO NOT overtighten.
Loosening the pressure sensor/valve assembly Overtightening can damage the fittings or the
more than three revolutions may result in the suspension housing resulting in gas and oil
component being forced out of the suspension leaks. Tighten to the specified torque.
by the gas pressure inside. DO NOT exceed one
revolution.
11. Tighten the pressure sensor valve assembly to
44 5 Nm (33 3 lb ft).
NOTE: If oil is discharged with the gas, tighten the 12. After the completion of oiling, remove the oil
valve slightly so only the gas will be discharged. If pump, and install charging valve (5). Tighten to
this is not possible, the foamy oil will need to be 44 5 Nm (33 3 lb ft).
purged from the suspension during the oiling
procedure, prior to charging.
Verify that all personnel are out of the area and

the support blocks are secure before releasing
the nitrogen. Use a face mask or goggles when
releasing the nitrogen.
5. While wearing a face mask or goggles, dis-

charge the nitrogen pressure from the suspen-
sion by loosening pressure sensor/valve
assembly (2, Figure 4-10) one revolution. DO
NOT loosen more than one revolution.

Rear Suspension Nitrogen Charging
6. When the left and right cylinders reach the
specified length, as shown in Figure 4-11 (Table
4), close valves (3 & 4, Figure 4-6) to stop the
flow of nitrogen gas. Turn the handle on regula-
tor (11) counterclockwise to close the valve.
Dry nitrogen is the only gas approved for use in
7. Turn handle (6) on valve adapter (5) counter-
suspensions. Charging of these components
clockwise to close the charging valve. After the
with oxygen or other gases may result in an
valve is completely closed, remove the charging
explosion which could cause serious injuries,
equipment.
fatalities and/or major property damage. Refer to
Nitrogen Gas Specifications at the beginning of 8. Use soapy water to check the charging valve
this chapter. and pressure sensor joints for leaks. Repair as
necessary.
1. Remove the caps from charging valves (5, Fig- 9. Install the caps and O-rings onto the charging
ure 4-9). valves.
NOTE: Before installing regulator (11, Figure 4-6),

blow out the connector with nitrogen gas at 965 kPa
(140 psi) or more, to clean out all dirt or dust. (Dirt or
dust in the system causes failures.) LENGTH ADJUSTMENT - FRONT AND
REAR CYLINDERS
2. Open the valve on the gas cylinder, and check
the pressure at regulator gauge (1).
NOTE: Adjust the installed length of the cylinder with
NOTE: Internal pressure of the gas cylinder must be the truck on level ground and the body empty.
substantially higher than the suspension charging
pressure, 1882 kPa (273 psi).
3. Slowly turn the handle of regulator (11, Figure

4-6) clockwise, and adjust the pressure at
gauge (2) to the required charging pressure, Depending on the ambient temperature, the gas
1882 kPa (273 psi). Open valves (3 & 4) to fill in the suspension may expand or contract
the suspension cylinders with nitrogen gas. changing the length of the cylinder. In locations
4. Fill the left and right cylinders at the same time. where there are wide differences in temperature
Verify the required charging pressure is present throughout the year, inspect the suspension
at gauge (10). height periodically and adjust to keep the length
within the specified range shown in Figures 4-7
5. When the left and right cylinders reach the and 4-11 (Table 4).
specified length, as shown in Figure 4-11, close
valve (4) to stop the flow of nitrogen gas. Turn
the handle of regulator (11) counterclockwise to 1. To reduce the sliding resistance of the cylinder,
close off nitrogen flow. drive the truck forward approximately 15 m (50
ft) and stop suddenly, then drive in reverse to
the original position and stop suddenly, again.
Repeat this cycle three to four times. Finally,
allow the truck to stop slowly without depressing
the brake. Then measure the installed length.

2. If the result of the check shows that the length is 3. After releasing nitrogen gas and adjusting the
too long, release nitrogen gas to adjust the length, repeat Step 1-2 to check the installed
length. Loosen the pressure sensor/valve length again.
assembly no more than one revolution to 4. Finally, check that there is no leakage of gas
release the nitrogen gas. When doing this, from the valve core, pressure sensor/valve
release only a small amount of gas. The cylin- assembly, and piston rod gland.
der should not move. If too much nitrogen gas is
released and the cylinder moves, the installed Use soapy water to check for leakage of gas. If
length may be below the specified length. The there is any leakage of gas from the valve core,
cylinders will need to be charged to the correct replace the valve core.
dimension. 5. The rear suspensions are now ready for opera-
tion. Visually check piston rod extensions both
with truck loaded and empty. Record extension
dimensions. Maximum downward travel is indi-
cated by the dirt ring at the base of the piston.
Operator comments on steering and suspen-
sion rebound should also be noted.
DO NOT release nitrogen pressure by depressing
the tip of the valve core. Damage to the valve
core may result.

NOTES

SECTION J
BRAKE SYSTEM
INDEX
BRAKE CIRCUIT COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-1
BRAKE CIRCUIT CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-1
FRONT WET DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-1
REAR WET DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
J01040 Index J1-1

NOTES
J1-2 Index J01040

SECTION J3
BRAKE CIRCUIT COMPONENT SERVICE
INDEX
BRAKE CIRCUIT COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J3-3
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-4

Rebuild Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Actuator Base Threaded Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Boot and Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Valve Body Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Regulator Sleeve O-Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-9
Actuator Plunger O-ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J3-10
Assembly of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
BENCH TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-12

Test Bench Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-12
Test Set Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-12
Brake Valve Output Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-14
Final Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-15
Proximity Switch Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-17
Installation Of Brake Pedal Actuator Assembly to Brake Valve . . . . . . . . . . . . . . . . . . . . . . . .J3-17
BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-18

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-19
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-21
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-23
ACCUMULATOR CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-24

Temperature During Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-26
J03039 Brake Circuit Component Service J3-1

ACCUMULATOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-27
BRAKE COOLING VALVE (BCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-28
RETARDER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-29

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-29
Disassembly and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-31
Potentiometer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-32
J3-2 Brake Circuit Component Service J03039

BRAKE CIRCUIT COMPONENT SERVICE

lines. Pressurized hydraulic fluid can have suffi-
cient force to enter a person's body by penetrat-
ing the skin. This can cause serious injury and
possibly death. If fluid has penetrated the skin,
seek medical treatment by a physician familiar
with this injury, immediately.
Depressurize system accumulators before open-

ing hydraulic circuits or installing test gauges.
For the steering circuit, turn the key switch to
OFF and allow 90 seconds for the accumulators FIGURE 3-1. BRAKE ACCUMULATOR
to depressurize. After 90 seconds, turn the steer- BLEEDDOWN VALVES
ing wheel to verify that pressure has been purged
from the circuit. If the wheels do not move, the 1. Rear Brake Accumulator
steering circuit is safe to service. 2. Front Brake Accumulator
3. Accumulator Bleed Down Valve (Rear)
For the brake circuit, first, chock the wheels. 4. Accumulator Bleed Down Valve (Front)
Then, open the shut-off valves on the brake man- 5. Brake Manifold
ifold. Opening the valves allows accumulator
pressure to be released to the hydraulic tank.

BRAKE VALVE Removal
The brake valve is a pressure modulating valve, If the brake valve is to be removed from the vehicle
actuated mechanically (brake pedal) or hydraulically for repair or adjustment, additional equipment will be
through the automatic apply valve. required as outlined in disassembly, assembly.
The brake valve controls the pressure delivered to
the front brake relay valve and rear brake dual relay
NOTE: Minor repairs and service adjustment may not
valve which provide the apply pressure for the front
require the removal of the brake valve.
wheel and rear wheel disc brake assemblies. Apply
pressure can be modulated from zero to maximum
braking effort by use of the foot pedal.
1. Park the truck on a hard level surface. Apply the
parking brake and turn the key switch to OFF.
Chock the wheels.
Rebuild Criteria 2. Open bleed down valve (3, Figure 3-1) and
If any one of the following conditions exist, the brake bleed down valve (4). The valves are located in
valve should be removed and repaired: the hydraulic cabinet on the brake manifold.
Opening the valves allows pressure in the brake
Excessive cam rock in pedal actuator. circuit to vent to the hydraulic tank.
Any sign of external leakage. 3. Remove the access panel at the front of the
Internal leakage at the tank port must be less operator's cab.
than 100 cc/minute with the valve in the released 4. Tag and remove all hydraulic lines from brake
position and system pressure supplied to the valve. Plug lines and ports to prevent possible
"P1" and "P2" inlet ports. contamination. Remove all valve fittings except
Tank port leakage must be less than 250 cc/ the fitting at port "PX". Disconnect wiring har-
minute with valve pilot or manual applied at 2750 ness at proximity switch connector.
psi (18.96 MPa) system pressure. 5. In the cab at the brake valve, remove cap-
Failure of the pedal to return to full release screws and lockwashers securing the brake
position. valve assembly to the mount.
Valve holds pressure when in the neutral 6. Slide the brake valve downward and remove
position. from the cab.
Varying output pressure with pedal fully 7. Move the brake valve assembly to a clean work
depressed. area for disassembly.

Installation
1. Place the brake valve assembly into position
and secure in place with capscrews and lock-
washers. Tighten capscrews to standard
torque.
2. Remove plugs from brake valve assembly and
hydraulic lines. Install fittings and connect lines
to brake valve assembly and tighten. Connect
proximity switch to harness.
NOTE: Prior to checking the brake valve operation,
the steering system must have the proper nitrogen
precharge in the steering accumulators (refer to
Section L, Hydraulic System, for steering
accumulator precharge procedure). In addition, the
brake system lines must be bled of air and the brake
accumulators must also be precharged with nitrogen
(refer to brake accumulator precharge procedures,
this section).
3. With the engine shut down and key switch OFF,

open both brake accumulator bleed down
valves (3 & 4, Figure 3-1). Precharge both
accumulators (1 & 2) mounted on brake mani-
fold to 1400 psi (9.6 MPa).
NOTE: For best performance, charge the
accumulators in the temperature conditions the
vehicle is expected to operate in. During the
precharge, allow temperature of the nitrogen gas to
come into equilibrium with the ambient temperature.
4. Close both accumulator bleed down valves

after accumulators have been properly charged.
5. Bleed air from brake apply circuit. Refer to Wet
Disc Brake Bleeding Procedure, in this section
of the manual.
6. Check for fluid leaks at the brake valve.
FIGURE 3-2. BRAKE VALVE ASSEMBLY
1. Brake Valve 8. Bolt

2. Capscrew 9. Lock Nut
3. Proximity Switch 10. Foot Pad
4. Retainer Clip 11. Pedal Actuator
5. Pivot Shaft 12. Pivot Stop
6. Nylon Bushing 13. Spring
7. Shim 14. Pivot Stop

Disassembly
NOTE: During disassembly, precision machined
parts should be ink marked or tagged to ensure
proper reassembly and minimize adjustment time. All
internal parts must be placed back into the bores
from which they were removed.
1. Match mark each section of the brake valve

prior to disassembly.
2. Drain oil from all ports of the valve by rotating
the valve over a suitable container.
3. Secure brake valve in an upright position in a
vice.
4. Remove the brake pedal actuator (11, Figure 3-
2) by removing the retaining clips (4), then
remove the pivot shaft (5) with a punch and
hammer.
5. Remove the four button head allen screws (3,
Figure 3-3) securing the boot retainer plate (4).
6. Remove the boot retainer plate (4), boot (2),
and actuator cap (1) as an assembly by grasp-
ing the boot and gently lifting from the valve
body. FIGURE 3-3. ACTUATOR CAP AND BOOT
7. Loosen the plunger locknuts (2, Figure 3-4). 1. Actuator Cap 5. Capscrew
Loosen the socket head capscrew from the 2. Boot 6. Actuator Base
adjustment collars (1). 3. Capscrew 7. Threaded Insert
10. Unscrew and remove the adjustment collars. 4. Retainer Plate
11. Remove the two socket head capscrews (5, Fig-

ure 3-3) that retain the actuator base (6) to the
valve body. 16. With the valve upright, the retaining plug (31)
should fall out. If the plug does not fall out,
12. Remove the actuator base from the valve body.
lightly tap to dislodge the plug.
13. Remove controller from vice.
NOTE: The spools (12), reaction plungers (21, 22)
14. Remove the four capscrews (28, Figure 3-4) and spool return springs (20) may fall out at this time.
and washers (27) from the base of the valve. Keep parts separate so they may be installed in the
15. Remove the base plate (32). same bores from which they were removed.
17. Remove and discard the O-ring (30) from the

counterbore in the base of the valve body.
18. With the controller upright on the work bench,
hold the valve with one hand and push the "B1"
actuator plunger (3) down with the other hand
until the regulator sleeve (19) pops loose.

19. Repeat the above procedure to loosen the "B2" Cleaning and Inspection
regulator sleeve. 1. Clean all metal parts with solvent and air dry.
20. Turn the valve on its side on the work bench 2. Inspect the plunger (3, Figure 3-4) for wear on
and remove the regulator sleeves (19) from the the sides where it moves through the seals. If
valve body. axial grooves are seen or if any wear is appar-
NOTE: Throughout the following steps, it is important ent, replace the plunger.
to keep the circuits and circuit components identified 3. Place the regulating spool (12) into its sleeve
as to which side of the unit they came from. For a (19). Push the spool lightly through the sleeve.
given circuit, all the components have a tolerance The spool must be able to move freely and
stack which could vary. Keep the "B1" and "B2" parts smoothly the entire length of the sleeve. If it
separate. cannot, it must be replaced. Never replace just
the spool or sleeve. They must be replaced as a
matched set.
21. Remove the spools (12), reaction plungers (21, 4. Inspect each spring carefully for cracks or
22) and spool return springs (20) from the regu- breaks. Any spring with a crack or break must
lator sleeves (19). be replaced. Also, if the valve was not reaching
22. Remove the plunger return springs (10), regula- proper regulated pressure, replace all regulator
tor springs (8 & 10), and spring seats (11) from springs.
the valve body. 5. Inspect the threaded inserts (7, Figure 3-3) in
23. Remove the actuator plungers (3) by pushing the actuator base. If any of the threads are
down (toward the bottom of the valve) on the damaged, the inserts must be replaced.
actuator plunger with your hand until the actua- 6. Lubricate all parts with a thin coat of clean
tor plunger slides out. hydraulic oil. Take care to keep components
protected from contamination.
24. Remove the staging seat (6). Remove and dis-
card packing (5).
25. Remove the Glyde ring assembly (7) from the
actuator plunger.
26. Remove the O-rings (14, 16 & 18) and teflon
back-up rings (13, 15 & 17) from the regulator
sleeves and discard.
27. Remove the wiper seals (23), poly-pak seals
(25), and the orange back-up rings (24) from
the actuator section of the valve and discard.

FIGURE 3-4. BRAKE VALVE
1. Adjustment Collar 9. Regulator Spring 17. Back-up Ring 25. Poly-Pak Seal
2. Nut 10. Plunger Return Spring 18. O-Ring 26. Valve Body
3. Actuator Plunger 11. Spring Seat 19. Regulator Sleeve 27. Washer
4. Stud 12. Regulator Spool 20. Spool Return Spring 28. Capscrew
5. Packing 13. Back-up Ring 21. Reaction Plunger (B1) 29. Set Screw Orifice Plug
6. Staging Seat 14. O-Ring 22. Reaction Plunger (B2) 30. O-Ring
7. Glyde Ring Assembly 15. Back-up Ring 23. Wiper Seal 31. Retaining Plug
8. Regulator Spring 16. O-Ring 24. Back-up Ring 32. Base Plate

Assembly Valve Body Seal Installation
1. Install the poly-pak seal (3, Figure 3-5) in the
Actuator Base Threaded Inserts
seal groove first. Position the seal in the groove
1. If any inserts (7, Figure 3-3) were removed from so that the internal O-ring inside the poly-pak
the actuator base (6), position the actuator base seal is facing down toward the bottom of the
upside down on the work bench and support valve.
directly under each of the four floor mounting 2. Make sure the internal O-ring is still seated
holes. inside the poly-pak seal (3) and did not get dis-
2. Install the threaded inserts into the actuator lodged during installation. Position the poly-pak
base by tapping lightly with a small hammer seal to the bottom of the groove.
until the insert flanges become flush with the 3. Install the orange back-up ring (4) on top of the
actuator base. Be sure the base is supported to poly-pak seal. Start by hand and then continue
avoid breaking the base. to work into the groove either by hand or by
3. Thoroughly clean the actuator base and set using an O-ring installation tool.
aside. 4. Install the wiper seal (5) in the top counterbore.
Position the seal in the groove so that the regis-
ter lip is facing up toward the actuator.
5. Repeat Steps 1- 4 for the second bore.
Boot and Cap
1. Examine the boot (2, Figure 3-3) for any cracks,
tears, or other damage. If damage is evident,
the boot must be replaced. To replace the boot, Regulator Sleeve O-Ring Installation
follow the procedure below.
1. Install an O-ring (2, Figure 3-6) onto the small-
2. Remove the boot from the actuator cap (1) and est groove (on the top) of the regulator sleeve
discard the old boot. Thoroughly clean the sides (3). Install O-ring (5) onto the middle groove on
of the cap by scraping the lip where the cap the regulator sleeve. Install O-ring (6) onto the
contacts the boot. Use a knife or suitable largest groove (on the bottom) on the regulator
scraper. Clean thoroughly to remove all adhe- sleeve.
sive or particles of the old boot.
2. Install a split nylon back-up ring (4) onto each
3. Apply a thin bead of Loctite Prism 410 onto side of the O-ring (5) located in the middle of
the upper sides of the cap. Apply the bead to the regulator sleeve.
the two long sides only. Do not apply it to the
rounded ends, these must not be sealed to 3. Install one split nylon back-up ring behind the
allow the boot to "breath". O-ring (2) located at the top end of the sleeve.
This O-ring is the smallest of the three O-rings.
4. Carefully position the cap into the new boot
Position the back-up ring so that it is next to the
groove wiping off the excess glue.
top of the regulator sleeve. The top of the
5. Position the boot such that it conforms to the sleeve is the end with the smallest O.D.
contour of the cap, then set aside. Adhesive
4. Repeat Steps 1-3 for the second regulator
requires about 30 minutes to cure.
sleeve.

FIGURE 3-6. SLEEVE SEAL PLACEMENT
1. Back-Up Ring 4. Back-Up Ring
2. O-Ring 5. O-Ring
3. Regulator Sleeve 6. O-Ring
FIGURE 3-5. VALVE BODY SEAL INSTALLATION

1. Actuator Plunger 4. Back-Up Ring
Actuator Plunger O-ring Installation
2. Valve Body 5. Wiper Seal
3. Poly - Pak Seal 6. Actuator Base 1. Install an O-ring (7, Figure 3-4) into the O-ring
groove located at the large diameter end of the
actuation plunger (3).
2. Install a split Glyde ring over the O-ring. (Twist
and squeeze the split Glyde ring into a small cir-
cle before installing to insure a tight fit over the
O-ring).
3. Repeat Steps 1 & 2 for the second plunger.

Assembly of Valve
NOTE: Start with either side (circuit) of the valve and 6. Install the plunger return spring (10, Figure 3-4),
build that side complete through Step 4 before regulator springs (8 & 9) and spring seat (11)
starting on the other side (circuit). Be careful to into the appropriate circuit. If spring seat does
assemble components into the circuit from which not seat correctly on top of the control spring,
they were removed. lightly shake the valve to correctly position the
spring seat.
1. If removed, install stud (4, Figure 3-4) in plunger
7. Lightly lubricate the regulator spool (12).
(3). Tighten nut (2).
8. Install the regulator spool into the regulator
2. Install new packing (5) on staging seat (6) and
sleeve (19). The spherical end of the spool
insert in plunger bore.
should be at the top of the regulator sleeve. The
3. Lightly lubricate the actuation plunger Glyde top of the sleeve is the end with the smallest
ring (7). O.D.
NOTE: Check to insure that the spool will slide
smoothly and freely. Replace the entire sleeve
assembly and spool, if the spool does not slide
smoothly and freely.
9. Remove spool from sleeve before installing

sleeve into body.
10. Lightly lubricate the O-rings (14, 16, & 18) on
the regulator sleeve.
11. Install the regulator sleeve assembly into the
correct circuit in the valve. Make sure the spring
seat is correctly seated in the regulator spring
before installing the regulator sleeve assembly.
Push sleeve into bore until sleeve retaining
FIGURE 3-7. GLYDE RING INSTALLATION
flange at the base of sleeve contacts the valve
1. Actuator Plunger 3. Glyde Ring body.
2. Valve Body 4. Sharp Edges
12. Install the spool return spring (20) into spool
(12).
13. Insert reaction plunger (21 or 22) into regulator
4. Install the "B1" actuation plunger (3) into the spool.
"B1" circuit. Be careful not to damage or cut the
Glyde ring during installation. Observe the 14. Install regulator spool (12) into regulator sleeve
Glyde ring assembly through the tank port as (19).
the plunger is being installed. (Refer to Figure 15. Repeat Steps 6 through 14 for the second cir-
3-7) It may be necessary to work the Glyde cuit.
rings past the sharp edge in the body to prevent
16. Lightly lubricate the large retainer plate O-ring
damage to the seal. Make sure the actuation
(30) and install into the counter bore in the bot-
plunger is completely seated and bottomed.
tom end of the valve.
5. Repeat Steps 1 through 4 for the "B2" actuation
plunger. 17. Install the retainer plug (31) into the counter
bore on the bottom of the valve. Make sure
steps on the retainer plug are facing the counter
bore or toward the top of the valve.

18. Install the base plate (32) on top of the retainer BENCH TEST AND ADJUSTMENT
plug. Tighten the four allen screws (28) evenly,
The following parts and test equipment will be
alternating diagonally, to evenly seat the regula-
required to completely bench test and adjust the
tor sleeve assembly. Tighten to 140 - 150 lb in.
brake valve.
(1.61 - 1.72 Nm).
Pressure gauges (3), 0-5000 psi (0-35 MPa).
19. Install the actuator base (6, Figure 3-3) on top of
the valve. Make sure to position properly for Hydraulic pressure supply, regulated to 2750 psi
correct port direction. Tighten the two socket (18.96 MPa).
head capscrews (5) and tighten to 180 - 190 lb Hydraulic test stand, Refer to Figure 3-9.
in. (2.1 - 2.2 Nm).
Hose fittings for valve ports:
20. Screw the adjustment collars (2, Figure 3-8) Port PX: . . . . . . . . . . . . . . . . . 7/16 in., # 4 SAE
onto the top of the actuation plungers. Screw all Ports P1, P2, B1 and B2: . . . . .3/4 in., #8 SAE
the way down until they bottom on the threads. Port T: . . . . . . . . . . . . . . . . 1 1/16 in., #12 SAE
Ohmmeter or continuity tester
NOTE: It is possible to check the pressures with the
brake valve installed and connected to the vehicle.
Remove the brake pedal assembly and actuator cap
and boot assembly to adjust individual brake circuit
pressures.
Test Bench Only
Test Set Up Procedure

1. Position the valve in the fixture to allow plung-
ers to be activated by hand using a lever (refer
to Figure 3-9).
2. Attach the pilot input supply pressure to the pilot
port labeled "PX" on the rear of the valve.
FIGURE 3-8. ADJUSTMENT COLLAR 3. Attach the main supply input pressure to the O-
ring ports on the rear of the valve labeled "P1"
1. Stud 3. Nut and "P2".
2. Adjustment Collar 4. Actuator Plunger 4. Attach the tank return line to the O-ring port
labeled "T" on the rear of the valve.

FIGURE 3-9. TEST BENCH SET-UP
1. Motor 5. Needle Valve 9. Simulated Brake Volume

2. Pump 6. Brake Valve 10. Rear Brake Pressure Gauge
3. System Pressure Gauge 7. Front Brake Pressure Gauge 11. Relief Valve
4. Needle Valve 8. Shut Off Valves
NOTE: Shut off valves (8) are for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1, B2 cylinders must be capable of a 10 cubic inch maximum displacement.

5. Attach the regulated output ports "B1" and "B2" Brake Valve Output Pressure Adjustment
to the test lines. Pressure monitoring devices in (Pedal Only)
these two lines must be capable of 3000 psi 1. Install the pedal pivot shaft pin in the actuator
(20.7 MPa) minimum. Connect all ports. The base by itself without installing the pedal
connections should be according to the diagram assembly.
shown in Figure 3-9. All ports must be used and
connected. 2. By taking a screw driver or pry bar and placing it
under the pivot pin and on top of the threaded
plunger assembly, each circuit can be actuated
individually. Refer to Figure 3-9.
3. Gradually apply pressure on each circuit (one at
a time) to check for leaks around the plunger.
All ports must be used. Relieve pressure before Make sure the adjustment collar is screwed all
disconnecting hydraulic and other lines. Tighten the way down on the threads.
all connections before applying pressure.
NOTE: The pressure gauges must be installed at the
Avoid spillage and contamination! Avoid contact
pedal as shown in Figure 3-9. Gauges must not be
with hot oil if the machine has been operating.
installed in the B1 or B2 test ports inside the brake
The oil will be at very high pressure.
cabinet or improper adjustment will result.
Hydraulic fluid escaping under pressure can
4. "B1" Adjustment: Adjust the adjustment collar
have sufficient force to enter a person's body by
up (counter-clockwise) starting with one turn
penetrating the skin and cause serious injury and
increments until the output pressure at port "B1"
possibly death if proper medical treatment by a
is 2200 75 psi (15.168 0.517 MPa) with the
physician familiar with this injury is not received
adjustment collar contacting the actuator base
immediately.
(fully actuated). Fine adjustment will require
turning the collar only in 1/8 turn increments.
6. Start hydraulic pump and regulate output pres- 5. "B2" Adjustment: Adjust the adjustment collar
sure to 2750 psi (18.96 MPa) at pressure gauge up (counter-clockwise) starting with one turn
(3). Pressure gauges (7 & 10) should read zero. increments until the output pressure at port "B2"
7. Pilot supply circuit pressure must also be 2750 is 2200 75 psi (15.168 0.517 MPa) with the
psi (18.96 MPa). adjustment collar contacting the actuator base
8. Return line pressure during this test is not to (fully actuated). Fine adjustment will require
exceed 5 psi (34.5 kPa). turning the collar only in 1/8 turn increments.
9. Test the valve with ISO 32 grade oil or hydraulic 6. Tighten the setscrews in the adjustment collars
oil meeting specifications listed in Section "P" at to 25 - 30 lb in. (0.28 - 0.35 Nm). The entire
120 10 F (49 3 C). plunger may have to be rotated to get to the
capscrews.
7. Check pressures again after tightening the set
screws. If the pressures have moved out of
specified range, loosen the appropriate set
screw and re-adjust.
8. Cycle each circuit 50 times using pilot apply.
This is done by closing needle valve (5) and
opening needle valve (4). Read pressure on
gauges (7 & 10). Close valve (4) and open
valve (5). The pressure gauges (7 & 10) should
read 0 psi.
9. Recheck pressures after cycling. If they have
changed, re-adjust pressures.

10. Shut down the test bench and relieve all 13. With test stand pump adjusted for 2750 psi
hydraulic pressure from the lines. (18.96 MPa) or with engine running and brake
system supply pressure at or above 2750 psi
(18.96 MPa), depress the pedal as quickly as
possible. The pressure on the output circuits
must reach the minimum pressure listed below
at port "B1" and port "B2" within 1.0 second.
Measurement of time begins the moment force
Avoid spillage and contamination! Avoid contact
is applied to move the pedal.
with hot oil if the machine has been operating.
The oil will be at very high pressure. Rear Brake - "B1":
Hydraulic fluid escaping under pressure can 2200 75 psi (15.168 0.517 MPa)
have sufficient force to enter a person's body by Front Brake - "B2":
penetrating the skin and cause serious injury and 2200 75 psi (15.168 0.517 MPa)
possibly death if proper medical treatment by a
physician familiar with this injury is not received 14. With "B1" and "B2" plugged into a strip chart
immediately. recorder, (if available) check the modulation by
slowly applying pressure until the maximum
pressure is reached. Make sure the pressure
11. Remove hoses from valve and remove valve increase is smooth and no sticking of the spools
from test stand. Refer to instructions below for is observed. Fully depress the pedal. Pressures
pedal actuator installation prior to final test. must remain within specification at "B1" and
"B2" for 20 seconds.
15. Adjust square head bolt (1, Figure 3-10) until
the bolt is not touching the actuator cap. Apply
Loctite 242 to the adjustment bolt prior to set-
Final Test and Adjustment
ting the deadband.
The brake pedal actuator must be installed on the 16. Set the deadband by placing a 0.010 in. (0.254
brake valve body prior to final test and adjustment. mm) thick shim at location shown in figure 3-10
Refer to "Installation of Brake Pedal Actuator to (between the pedal structure and return stop
Brake Valve". boss on pivot structure).
NOTE: The "Final Test and Adjustment" procedure 17. Adjust the bolt (1) until it is just touching the
can also be performed with the brake valve installed cap.
in the truck. To perform final test with brake valve
mounted in the truck, install valve per instructions in 18. Continue turning the adjustment bolt until pres-
"Installation". Install 0-5000 psi (0-35 MPa) gauges at sure begins to rise on one of the brake apply
the "B1" and "B2" diagnostic test connectors in the pressure gauges.
brake cabinet. 19. Back-off the adjustment bolt 1/8 turn.
Adhere to the following steps for the final test:
20. Tighten the jam nut (2) and remove the shim
stock inserted earlier in this procedure.
12. Reinstall brake valve (with actuator pedal
21. Fully stroke the brake pedal actuator to check
attached) on the test stand following steps 2
that output pressure at port "B1" and "B2" are
through 9 under "Test Setup Procedure".
within specifications.
NOTE: If pedal is adjusted properly, the spring and
spring pivots will not interfere with pedal travel.

22. If pressure is not within specifications, re-adjust.
If pressure is within specifications, apply a few
drops of Loctite #262 to the jam nut.
23. Check internal leakage at port "T". Leakage
must be less than 100 cc/minute with the valve
in the released position and system pressure
supplied to the "P1" and "P2" inlet ports.
24. "T" port leakage must be less than 250 cc/
minute with valve pilot pressure or manual
applied.
FIGURE 3-10. PEDAL ASSEMBLY ADJUSTMENTS

1. Square Head Bolt 3. Proximity Switch
2. Nut 4. Jam Nuts

Proximity Switch Installation and Adjustment
25. Install the proximity switch (3, Figure 3-10) in 5. Assemble spring assembly (13) and install com-
the actuator base until the switch is approxi- plete assembly to brake pedal actuator as
mately 6.35 mm (0.25 in.) below the boss on the shown.
actuator base.
26. Lock switch in position with the two jam nuts (4).
27. Connect an ohmmeter to the switch harness to
check continuity. Be sure to install spring assembly correctly, with
28. Slowly apply the brake pedal and note the pres- larger ball socket end pointing to the pedal struc-
sure on the gauge at which the ohmmeter indi- ture and smaller end toward the valve assembly.
cates continuity in the switch.
29. Readjust the switch if necessary to trip when
NOTE: When pedal is adjusted properly, the spring
the pressure reaches 517 kPa (75 psi).
assembly will not interfere with pedal travel.
30. Secure switch with jam nuts after adjustment is
complete.
Be certain the top section of the switch does not

contact the threads in the actuator base. If this
occurs, it will cause a short circuit, preventing
the switch from operating properly.
Installation Of Brake Pedal Actuator Assembly to

Brake Valve
1. Install jam nut (9, Figure 3-2) and square head

bolt (8) to brake pedal actuator (11).
2. Insert nylon bushings (6) into brake pedal actu-
ator.
3. Install one retaining clip (4) to one end of pivot
shaft.
4. Align pedal structure to brake valve (1) and par-
tially insert pivot pin. Move pedal structure to
the "B2" side of valve and insert shims (7)
between pedal structure and brake valve ear to
fill gap. Fully insert the pivot shaft (5). Install the
remaining retainer clip (4).

BRAKE ACCUMULATORS
There are two identical hydraulic brake accumulators
located on the brake manifold in the brake control
cabinet behind the operator's cab. The left accumula-
tor supplies the pressure necessary for actuation of
the rear service brakes. The right accumulator sup-
plies pressure to activate the front service brakes.
NOTE: If both accumulators are low on nitrogen,
charge both accumulators at the same time.

OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the steer-
from the circuit. If the wheels do not move, the
steering circuit is safe to service.
For the brake circuit, first, chock the wheels.

Then, open the shut-off valves on the brake man-
FIGURE 3-11. ACCUMULATOR ASSEMBLY
1. Hydraulic Port 8. Anti-Extrusion Ring

Assembly 9. Bladder Assembly
2. Bleed Plug 10. Shell
3. Locking Ring 11. Charging Valve
4. Spacer 12. O-Ring
5. O-Ring Backup 13. Lock Nut
6. O-Ring 14. Protective Cap
7. Metal Backup Washer 15. Port Protector

Removal Installation
1. Park the truck on a hard level surface. Apply the NOTE: DO NOT charge the accumulators to the
parking brake and turn the key switch to OFF. operating pressure before installation on the truck.
Chock the wheels.
1. Attach a hoist and lifting sling to the accumula-
2. Open bleed down valve (3, Figure 3-1) and tor. The weight of the accumulator is approxi-
bleed down valve (4). The valves are located in mately 58 kg (127 lb).
the hydraulic cabinet on the brake manifold.
2. Lift the accumulator into position on the brake
Opening the valves allows pressure in the brake
manifold. Tighten the fittings securely.
circuit to vent to the hydraulic tank.
3. Install the accumulator mounting brackets.
3. Remove the top lid from the hydraulic cabinet to
Secure the mounting brackets in place with the
allow access for a lifting device.
cap screws and the lock washers. Tighten the
4. Remove cap (14, Figure 3-11) from the accu- cap screws to standard torque.
mulator.
4. Charge the accumulator. Refer to Brake Accu-
5. Install charging valve adapter (6, Figure 3-23) mulator Charging in this section.
and slowly remove all nitrogen pressure.
NOTE: If the accumulator will be not be
disassembled immediately, allow 690 kPa (100 psi) Disassembly
to remain in the accumulator during storage.
1. Clean the exterior of the accumulator before
Discharge the remaining nitrogen pressure before
starting disassembly.
disassembling.
2. Securely clamp the accumulator body in a vise,
preferably a chain vise. Ensure the accumulator
shell is protected by strips of padding or soft
metal on the vise jaws.
3. With pressure relieved from the acumulator,
remove the valve core from the charging valve.
DO NOT release pressure by depressing the Refer to Figure 3-12.
valve core with a foreign object. High pressure
may rupture the rubber valve seat.
6. After nitrogen pressure has been relieved,

remove the charging manifold.
7. Attach a hoist and lifting sling to the accumula-
tor. The weight of the accumulator is approxi-
8. Remove the accumulator mounting bracket.
Loosen and remove the accumulator from the
brake manifold. Plug the opening on the brake
manifold to prevent contamination.
9. Transfer the accumulator to a clean work area.
FIGURE 3-12.

4. Remove bleed plug (2, Figure 3-11) from pop- 7. Push the port into the shell.
pet assembly (1). 8. Insert your hand into the shell and remove the
5. Remove locking ring (3) from the port assembly O-ring, washer, and anti-extrusion ring. Fold the
using two wrenches. Refer to Figure 3-13. anti-extrusion ring to enable removal. (Figure 3-
15)
FIGURE 3-15. ANTI-EXTRUSION RING

REMOVAL
FIGURE 3-13. LOCKNUT REMOVAL

9. Remove the hydraulic port from the shell. Refer
to Figure 3-16.
6. Remove the spacer (Figure 3-14).
FIGURE 3-16. PORT REMOVAL
FIGURE 3-14. SPACER REMOVAL

10. With the wrench on the valve stem flats, remove 5. Check the hydraulic port for proper functioning.
nut (13, Figure 3-11) from the charging valve.
11. Insert your hand into the accumulator shell fluid
opening. Depress the bag and eliminate as
much gas pressure as possible.
12. Fold the bladder and pull out of the accumulator
shell. Refer to Figure 3-17. A slight twisting Repair of the housing by welding, machining, or
motion, while pulling on the bladder, reduces plating to salvage a worn area is not approved.
the effort required to remove the bladder from These procedures may weaken the housing, and
the shell. If the bladder is slippery, grasp with a when pressurized, can result in serious injury to
cloth. personnel.
Assembly
1. Assemble the accumulator in a dust and lint-
free area. Maintain complete cleanliness during
assembly to prevent possible contamination.
2. If removed earlier, reclamp the accumulator in a
vise, preferably a chain vise. Ensure the accu-
mulator shell is protected by strips of padding or
soft metal on the vise jaws.
3. Thoroughly lubricate the inside of the accumu-
lator with clean C-4 hydraulic oil to cushion the
FIGURE 3-17. BLADDER REMOVAL bladder. Spray the entire inside surface of the
accumulator with 1 liter (32 oz).

1. After disassembly, clean all parts with an Failure to properly lubricate the shell during
approved cleaning solution. Blow all parts dry assembly will result in excessive scuffing of the
with air and keep free from foreign matter. bladder and can contribute to bladder failures.
Inspect the accumulator shell for nicks, pitting,
or damage that could destroy the bladder or
damage the new seals. 4. With the bladder assembly on the bench, expel
all air to completely collapse the bladder and
2. Check all the rubber items for deterioration, fold the bladder longitudinally into a compact
abrasion marks, cracks, holes, bubbles, or any roll. To maintain the rolled condition of the blad-
similar defects. der, install a gas valve core into the valve stem
3. Replace all O-rings and any other items to prevent air from entering the bladder.
deemed unsuitable for further usage. 5. Attach the bladder pull rod to the bladder valve
4. Inflate the bladder to normal size. Wash the stem.
bladder with a soap solution. If the soap solu-
tion bubbles, discard the bladder. After testing,
dry the bladder and deflate immediately.

6. Pass the bladder pull rod through the shell oil 9. Grasp the threaded section of hydraulic port
port and out through the valve stem opening. assembly (1, Figure 3-11) and insert the valve
Refer to Figure 3-18. end into the shell mouth.
. 10. Install anti-extrusion ring (8) inside the shell.
Fold the anti-extrusion ring to enable insertion
into the shell. Place the anti-extrusion ring on
port assembly (1) with its steel collar toward the
shell mouth.
FIGURE 3-18. BLADDER INSTALLATION
7. With one hand, pull the bladder pull rod while

feeding the bladder into the shell with the other
hand. Slight twisting of the bladder will assist in
this insertion.
FIGURE 3-20. PORT ASSEMBLY
8. Position the valve stem nut over the valve stem
and tighten the nut by hand. Refer to Figure 3-
19. Remove the bladder pull rod, and remove
the valve core to allow the bladder to expand to 11. Withdraw the threaded end of the port assembly
normal shape. through the shell mouth. Refer to Figure 3-20.
12. Pull the threaded end of the port assembly until
seated solidly into position on the shell mouth
opening.
13. Install the bladder valve core. Install the charg-
ing manifold. Slowly pressurize the bladder to
34 kPa (5 psi) to hold the port assembly in
place. Refer to Accumulator Charging in this
chapter.
14. Install washer (7, Figure 3-11) onto the port
assembly and push until seated against the
anti-extrusion ring. Refer to Figure 3-21
FIGURE 3-19. VALVE STEM INSTALLATION

Leak Testing
To perform leak testing, a source of nitrogen pres-
sure of 9653 kPa (1400 psi) and hydraulic pressure
of 24132 kPa (3500 psi) will be required. A water
tank large enough to hold the accumulator and a
method of safely securing the accumulator in a hold-
ing fixture will be necessary.
Securely mount the accumulator into a holding

fixture before high pressure testing. DO NOT
FIGURE 3-21. WASHER INSTALLATION handle the accumulator if nitrogen pressure
exceeds 827 kPa (120 psi). Sudden loss of accu-
15. Install O-ring (6) and O-ring backup (5) over the mulator pressure can result in a projectile hazard
port assembly and push until seated. that can cause serious injury or death.
1. Attach appropriate lifting apparatus to the accu-

mulator. The weight of the accumulator is
approximately 58 kg (127 lb). Lift the accumula-
DO NOT twist the O-ring. tor into the holding fixture and secure. Attach
the lifting apparatus to the holding fixture and lift
it into the test tank.
16. Install spacer (4) with the smaller diameter of 2. Cover the hydraulic port with a plastic cap to
the shoulder toward the shell. prevent water entry. DO NOT install a threaded
17. Install locking ring (3) on the port assembly and plug in the hydraulic port.
tighten securely. This will squeeze the O-ring 3. Charge the accumulator to 9653 kPa (1400 psi).
into place. Refer to Figure 3-22. Refer to Accumulator Charging in this chapter.
4. Fill the test tank so the accumulator is com-
pletely submerged and observe for 20 minutes.
No leakage (bubbling) is permitted. If leakage is
present, go to Step 8. If no leakage is present,
continue to the next step.
5. Drain the test tank. Remove the plastic plug
from the hydraulic port. Ensure no moisture is
present in the hydraulic port.
FIGURE 3-22. LOCKNUT INSTALLATION

18. Install bleed plug (2) into port assembly (1) and
tighten.

6. Connect a hydraulic power supply. Pressurize ACCUMULATOR CHARGING
the accumulator with oil to 24,132 kPa (3500
psi). Refill the test tank with water and observe
for 20 minutes. No oil or nitrogen leakage is per-
mitted.
7. Slowly release the oil pressure. Drain the test Depressurize system accumulators before open-
tank and remove the hydraulic power supply ing hydraulic circuits or installing test gauges.
connection. Ensure no moisture is present in For the steering circuit, turn the key switch to
hydraulic port assembly (1, Figure 3-11) and OFF and allow 90 seconds for the accumulators
install a plastic cap to prevent contamination. to depressurize. After 90 seconds, turn the steer-
DO NOT install a threaded plug in the hydraulic ing wheel to verify that pressure has been purged
port assembly. from the circuit. If the wheels do not move, the
8. If any nitrogen gas or oil leakage was present,
discharge all the nitrogen gas using the charg- For the brake circuit, first, chock the wheels.
ing equipment, and repair as necessary. Then, open the shut-off valves on the brake man-
9. If there are no leaks, charge the accumulator to ifold. Opening the valves allows accumulator
690-827 kPa (100-120 psi). Disconnect the pressure to be released to the hydraulic tank.
charging manifold.
10. Remove the accumulator from the test tank fix- Pure dry nitrogen is the only gas approved for
ture. use in the steering accumulator. The accidental
charging of oxygen, or any other gas in this com-
. ponent, may cause an explosion.
When charging or discharging nitrogen gas in

the accumulator, ensure the warning labels are
observed, and the instructions regarding the
When storing an accumulator, pressurize the
charging valve are carefully read and under-
accumulator to 690-827 kPa (100-120 psi). DO
stood.
NOT exceed 827 kPa (120 psi). Sudden loss of the
accumulator pressure can result in a projectile
Fully charge the accumulators while installed on
hazard that can cause serious injury or death.
the truck. DO NOT handle the accumulator with
lifting equipment when the accumulator pressure
is above 827 kPa (120 psi).
11. Verify all labels are attached and legible. Refer
to the parts book if replacements are required. NOTE: If one accumulator is low on nitrogen, it is
recommended that both accumulators be checked
and/or charged at the same time.
1. With the key switch OFF, allow at least 90 sec-

onds for the steering accumulators to depressur-
ize. Turn the steering wheel to ensure no oil
pressure remains in the accumulator. Open the
shut-off valves on the brake manifold.

2. Remove the valve guard from the accumulator 8. Turn the T handle clockwise to open the accu-
gas valve. Remove the dyna seal. mulator gas valve. Do not turn the T handle all
3. Close all shutoff valves on manifold (5, Figure the way down, as it will damage the valve core.
3-23). 9. Set the regulator for 25 psi (172 kPa), then
4. Connect the charging kit to the nitrogen supply slightly open the nitrogen bottle and slowly fill
tank, and open the valve on the tank. the accumulator. The proper fill rate for these
accumulators is 2 minutes.
5. Turn the T handle all the way out (counter-
clockwise) on charging valve adapter (6).
If the nitrogen is not added slowly, the bladder

may suffer permanent damage. A starburst
rupture in the lower end of the bladder is a char-
acteristic failure caused by charging too quickly.
10. After 25 psi (172kPa) is obtained, close the

nitrogen valve. Set the regulator for the operat-
ing pressure (refer to Table 2), based on the
current ambient temperature. Then, open the
nitrogen bottle and fill the accumulator.
If the accumulators are being charged for stor-

age, only charge to 100 - 120 psi (690 - 827 kPa).
FIGURE 3-23. NITROGEN CHARGING KIT Refer to Accumulator Storage later in this chap-
ter for more information.
1. Nitrogen Bottle 4. Pressure Gauge
2. Regulator 5. Manifold
3. Shut-Off Valve 6. Charging Valve 11. Let the accumulator set for 15 minutes. This will
Adaptor allow the gas temperature to stabilize. If the
desired pressure is exceeded, slowly purge
pressure from the accumulator.
6. Close any bleed valves.

7. Attach the charging valve adapter to the accu-
mulator gas valve. DO NOT loop or twist the Do not release pressure by depressing the valve
hose. core with a foreign object. High pressure may
rupture the rubber valve seat.

12. Close the valve on the nitrogen supply tank. Temperature During Precharge
Remove the charging manifold.
Temperature variation can affect the precharge pres-
13. Check for nitrogen leaks on the accumulator sure of an accumulator. As the temperature
using a common leak reactant. Repair leaks as increases, the pressure increases. Conversely,
necessary. decreasing temperature will decrease the pressure.
14. Install the valve cap on the charging valve. To ensure accuracy, it is necessary to adjust the
charging pressure to offset temperature variations.
15. Close the brake accumulator bleed-down The temperature variation is determined by the ambi-
valves. ent temperature at the time of charging. If the accu-
16. Check the hydraulic oil level. mulator is mounted on the truck, wait one hour after
shutting the engine off. After an hour, measure the
17. Operate the truck and check for normal opera- ambient temperature to determine the proper charg-
tion. ing pressure. Refer to Table 2.
Example: Assuming the ambient temperature is
10C (50F), charge the accumulator to 9294 kPa
(1348 psi).
TABLE 2. Relationship Between Charging

Pressure and Ambient Temperature
Ambient Charging Pressure
Temperature 70 kPa (10 psi)
-23C (-10F) and below 8232 kPa (1194 psi)
-17C (0F) 8412 kPa (1220 psi)
-12C (10F) 8584 kPa (1245 psi)
-7C (20F) 8763 kPa (1271 psi)
-1C (30F) 8943 kPa (1297 psi)
4C (40F) 9122 kPa (1323 psi)
10C (50F) 9294 kPa (1348 psi)
16C (60F) 9473 kPa (1374 psi)
21C (70F) 9653 kPa (1400 psi)
27C (80F) 9832 kPa (1426 psi)
32C (90F) 10011 kPa (1452 psi)
38C (100F) 10184 kPa (1477 psi)
43C (110F) 10363 kPa (1503 psi)
49C (120F) 10542 kPa (1529 psi)
NOTE: Pressures below 8232 kPa (1194 psi) are not

recommended. The low accumulator pressure warn-
ing switch activates at 7584 310 kPa (1100 45
psi).

ACCUMULATOR STORAGE Installation
The shelf life of bladders, under normal storage con-
ditions, is one year. Normal storage conditions con-
sist of the bladder being heat sealed in a black plastic
bag and placed in a cool, dry place away from the
sun, ultraviolet, and fluorescent lights, as well as
electrical equipment. Direct sunlight or fluorescent Follow this procedure when installing an accu-
light can cause the bladder to weather check and dry mulator that was in storage. This procedure also
rot, which appear on the bladder surface as cracks. applies to newly purchased accumulators.
1. Install the pressure gauges on the accumulator

and check the pressure. Refer to Accumulator
Charging in this chapter.
When storing an accumulator, pressurize the a. If the pressure is 165 kPa (24 psi) or less,
accumulator to 690-827 kPa (100-120 psi). DO slowly drain off any nitrogen and proceed to
NOT exceed 827 kPa (120 psi). Sudden loss of the Step 2.
accumulator pressure can result in a projectile b. If the pressure is between 172 kPa (25 psi)
hazard that can cause serious injury or death. and 690 kPa (100 psi), set the regulator to
Only charge the accumulators to operating pres- 690 kPa (100 psi) and slowly charge the
sure while installed on the truck. DO NOT handle accumulator to 690 kPa (100 psi). Discon-
the accumulator with a nitrogen charge greater nect the pressure gauges from the accumu-
than 827 kPa (120 psi). lator. Proceed to Step 7.
2. Remove the gauges from the accumulator.
1. If the accumulator has been rebuilt, ensure 3. Remove the plastic dust cap from the hydraulic
there is approximately 1 liter (32 oz) of oil inside port assembly.
the accumulator before pressurizing. 4. Lay the accumulator on a suitable work bench.
2. Charge the accumulator to 690-827 kPa (100- Pour 1 liter (32 oz) of clean C-4 hydraulic oil into
120 psi). Refer to Accumulator Charging in this the accumulator through the hydraulic port
chapter. assembly. Allow time for the oil to disperse
inside of the accumulator.
5. Lay the accumulator flat and slowly roll the
NOTE: Pressurizing the accumulator fully expands accumulator two complete revolutions. This pro-
the bladder and holds a film of oil against the inner vides the necessary lubrication for charging.
walls for lubrication and rust prevention. 6. Stand the accumulator upright and secure.
Install the pressure gauges and charge the
accumulator first to 172 kPa (25 psi), then to
3. The hydraulic port assembly must be covered 690 kPa (100 psi). Remove the gauges from the
with a plastic plug, without threads, to prevent accumulator and install a plastic dust cap over
contamination. DO NOT install a threaded plug the hydraulic port assembly. The fill time to
in the hydraulic port assembly. reach 172 kPa (25 psi) is approximately two
4. Store the accumulator in an upright position. minutes.
7. Install the accumulator on the truck.
8. Charge the accumulator to operating pressure.
Refer to Accumulator Charging in this chapter
to fully charge the accumulator to the correct
operating pressure.

BRAKE COOLING VALVE (BCV)
When the brakes are not applied, the brake cooling
valve (Figure 3-25) bypasses part of the brake cool-
ing oil to reduce power loss when traveling. This is
accomplished through activation of main spool valve
(4) by switching solenoid valve (3) on or off.
The truck is equipped with two brake cooling valves.
The BCV located on the front of the hydraulic tank
support bracket directs oil to the front brakes. The
BCV positioned inside the same support bracket
(with oil return lines coming from the hoist valve), is
for the rear brakes.
If any abnormal pressure is generated in the hydrau-
lic circuit, the pilot relief is actuated. This relief is
adjusted to 128 7 psi (883 48 kPa). One full turn of
the adjusting screw will change the pressure 34 psi
(234 kPa). This pilot relief valve will actuate the main
relief valve, acting as an unloader valve.
Specifications: SAE 10W oil . . . . @122 F 50 F

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (50C 10C)
Solenoid Valve Off:
Cracking Pressure: . . 128 7.1 psi @ 0.3 - 0.5 gpm)
. . . . . . . . . . . . . . . . . . .(883 48 kPa @ 1 - 2 l/min).
..........................................
Reseat Pressure (Min.). . . . .114 psi @ 0.3 - 0.5 gpm
. . . . . . . . . . . . . . . . . . . . . . . (786 kPa @ 1 - 2 l/min)
Oil Leakage (Max.) . . . . . . . 800 cc/min @ 6 kg/cm2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(85 psi)
FIGURE 3-24. BRAKE COOLING VALVE (BCV)
1. Pilot Relief Valve A: Pilot Port

2. Valve Body B: Pilot Port
3. Solenoid Valve C: Main Return to Tank
4. Main Valve Spool D: Pilot Port
5. Restrictor Plate E: From Pump
F: To Tank

RETARDER CONTROL LEVER
Due to frequent use and wear, retarder control lever
(5, Figure 3-26) may occasionally require adjustment
or repair.
Removal
Adjustment of the retarder control lever or replace-
ment of the potentiometer requires removal of the
assembly from the steering column.
1. Tilt the steering wheel downward, and tele-
scope the wheel towards the operator seat.
Remove the top cover from the steering col-
umn.
1. Remove capscrews (1, Figure 3-26) and lock-
washers (2) from steering column (4).
2. Disconnect the wiring harness from harness
connector (6) on the retarder control lever.
3. Remove the retarder control lever.
FIGURE 3-25. BCV SCHEMATIC
1. Main Spool Valve A: Pilot Port

2. Pilot Relief Valve B: Pilot Port Installation
3. Solenoid Valve C: Main Return to Tank 1. Connect the wiring harness to harness connec-
D: Pilot Port tor (6, Figure 3-26) on retarder control lever (5).
E: From Pump 2. Place the retarder control lever into position on
F: To Tank steering column (4).
3. Install capscrews (1) and lockwashers (2).
Tighten the capscrews to 4 Nm (36 lb in.).
4. Place the cover on the top of the steering col-
umn and return the steering wheel to its original
position.
5. Recalibrate the RCM.

FIGURE 3-26. RETARDER LEVER ASSEMBLY
1. Capscrew 7. Capscrew 13. Internal Tang Washer

2. Lockwasher 8. Lockwasher 14. Set Screw
3. Bracket 9. Potentiometer 15. Housing
4. Steering Column Assembly 10. Locknut 16. Shaft
5. Retarder Control Lever 11. Tanged Washer 17. Lever
6. Harness Connector 12. Disc Spring 18. Handle

Disassembly and Adjustment Potentiometer Check
1. Remove capscrews (7, Figure 3-27) and lock- Potentiometer (9, Figure 3-27) is spring-loaded to the
washers (8) from the retarder control lever. OFF position. With the switch assembly removed
2. Remove potentiometer (9). from the retarder control lever, make the following
checks:
3. Bend tangs on washer (11) away from slots in
locknut (10).
a. Lever Disassembly
If the retarder control lever is to be com-
pletely disassembled, loosen and remove
locknut (10). Remove tang washer (11),
spring (12), and washer (13).
Remove set screw (14).
Remove the lever and shaft assembly. If
necessary, unscrew lever (17) from shaft FIGURE 3-27. POTENTIOMETER CONNECTOR
(16) and handle (18).
1. Obtain a 10 volt power supply for testing the
Wash the mechanical parts in clean solvent potentiometer.
and inspect for excessive wear, burrs, or
scratches. Replace any defective parts. 2. Connect the positive lead to the supply terminal
on the potentiometer connector in Figure 3-28.
b. Lever Adjustments
3. Connect the negative lead to the ground termi-
Rotational Friction Adjustment: The lever nal on the connector.
must be adjusted so that frictional force will 4. Connect a voltmeter to the signal and ground
hold the lever firmly in the position selected connections.
by the operator. At the same time, the adjust-
5. Measure and record the OFF position signal
ment should not be so tight as to cause the
voltage.
operator to use undue force to move the
lever. Loosen or tighten locknut (10) to attain 6. Rotate the potentiometer clockwise to the full
the proper frictional force 0.23 - 0.34 Nm (2 ON position. Measure and record the signal
- 3 lb in.) at the handle. voltage.
7. Determine whether the potentiometer falls
The position of the lever should remain sta-
within the specifications. When the potentiome-
tionary without moving from its own weight or
ter is in the OFF position, the signal voltage
due to machine vibrations during truck oper-
must be within 5 - 15% of input voltage. When
ation.
the potentiometer is in the full ON position, the
When the desired adjustment is obtained, signal voltage must be within 75 - 95% of input
bend the tang on washer (11) into the slots voltage.
on locknut (10).
signal voltage
Detent Adjustment: The detent that holds the % of input voltage = ( input voltage ) x 100
lever in the OFF position can be adjusted, as
well. Loosen or tighten set screw (14) to
adjust the detent. The breakout force of the NOTE: With a 10 volt power supply, the
detent must be between 1.92 - 2.26 Nm (17 - potentiometer voltage specifications are as follows:
20 lb in.). OFF position . . . . . . . . . . . . . . . . . . . . 0.5 - 1.5 volts
Full ON position . . . . . . . . . . . . . . . . . . 7.5 - 9.5 volts
8. Replace the potentiometer if it does not meet

these specifications.

Assembly
1. Inspect the shaft bore and interior friction faces 5. Tighten and secure locknut (10) as described in
in housing (15, Figure 3-27). Remove any Step 3.b. of Disassembly and Adjustment.
scratches or burrs, or replace the housing. 6. Move the lever to the full OFF (up) position.
Lightly lubricate the surfaces with a Multi-Pur- Align the slot in potentiometer (9) with the key
pose EP NLGI Consistency #2 grease. on shaft (16) and rotate the potentiometer until
2. If handle (18) or lever (17) has been removed the capscrew holes line up with the housing.
from shaft (16), assemble as follows: Install washers (8) and capscrews (7) to secure
the potentiometer to the housing. Tighten the
a. Apply Loctite #271 to the threads on each socket head capscrews to 1.36 - 1.69 Nm (12 -
end of lever (17). 15 lb in.).
b. Install the lever onto shaft (16). Hand tighten, 7. Install set screw (14). Refer to Step 3.b. of Dis-
only! assembly and Adjustment for adjustment proce-
c. Install handle (18) onto the lever. Hand dures.
tighten, only! 8. Install the retarder control lever on the steering
3. Insert the lever, handle, and shaft assembly into column. Refer to Installation.
housing (15).
4. Install washer (13), new spring (12) [with the
outer spring diameter against washer (13), tang
washer (11), and locknut (10) onto shaft (16).

SECTION J4
BRAKE CIRCUIT CHECKOUT
INDEX
BRAKE CIRCUIT CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-3
REQUIRED EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-3
BRAKE CIRCUIT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-4
Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-4
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-5
Brake Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-6
Low-Brake Pressure and Auto-Apply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-6
Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-7
Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-7
BRAKE SYSTEM DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-8
BRAKE CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-11
J04039 04/08 Brake Circuit Checkout J4-1

NOTES
J4-2 Brake Circuit Checkout 04/08 J04039

BRAKE CIRCUIT CHECK-OUT
This chapter outlines a procedure to test the entire REQUIRED EQUIPMENT
functionality of the brake system. The outline lists cri-
The following equipment will be necessary to prop-
teria that must be duplicated for the braking system
erly check the hydraulic brake circuit:
to be considered operational. Follow the procedure
to check the system. Refer to Brake Circuit Trouble- Hydraulic brake schematic. Refer to Section R.
shooting in this chapter for help in diagnosing system Calibrated pressure gauges:
malfunctions. Four, 0 - 21, 000 kPa (0 - 3000 psi) range.
. Hoses long enough to reach from the brake
cabinet to the inside of the operator's cab for
each pressure gauge.
Clear plastic hose and a bucket for brake
bleeding.
Relieve pressure before disconnecting hydraulic Accumulator charging kit with gauges and dry
lines. Pressurized hydraulic fluid can have suffi- nitrogen. Refer to Section M, Special Tools
NOTE: A gas intensifier pump will be required, if
using "T type" nitrogen bottles.
possibly death. If fluid has penetrated the skin,
seek medical treatment by a physician familiar
with this injury, immediately.
PREPARATION
The following items must be performed before pro-
ceeding with brake system checks.
Depressurize system accumulators before open- 1. Perform the steering system check to verify
ing hydraulic circuits or installing test gauges. source pressure for the brake system is correct.
Refer to Section L, Hydraulic Checkout Proce-
For the steering circuit, turn the key switch to dure.
OFF and allow 90 seconds for the accumulators 2. The parking brake and slack adjusters must be
to depressurize. After 90 seconds, turn the steer- properly adjusted. Refer to Section J, Parking
ing wheel to verify that pressure has been purged Brake.
from the circuit. If the wheels do not move, the 3. The brake accumulators must be properly
steering circuit is safe to service. charged. Refer to Section J, Brake Circuit Com-
ponent Service.

BRAKE CIRCUIT TESTING
Perform the following steps to verify the brake sys- 2. Close both accumulator bleeddown valves.
tem is operating properly. 3. Check the position of the retarder lever and the
ARSC switch. Both devices must be off.
Included later in this chapter are data sheets to
record the test information. The data sheets can be 4. * Start the engine to fill the accumulators with
removed, copied, and used during the check. Steps oil. Observe the rising brake pressure as the
identified with an asterisk (*) must be recorded on the system charges. Brake pressure should begin
data sheet. to fall when the auto apply valve releases. The
proper pressure during auto apply release is
11,376 690 kPa (1650 100 psi). This specifi-
cation is applicable for both the front and rear
Initial System Setup
circuits. Record the brake pressures as the auto
1. Install pressure gauges at: apply releases.
a. Front brake test port (FB, Figure 4- 1) 5. At this point, the brakes must be bled to remove
trapped air. Refer to Section J, Brake Bleeding.
b. Rear brake test ports (RBL, RBR, Figure 4-
1)
c. Low accumulator pressure test port (LAP1,
Figure 4- 2)
FIGURE 4-1. TEST MANIFOLD
1. Pressure Test Port 2. Manifold

FIGURE 4-2. BRAKE MANIFOLD TEST PORTS
1. Test Ports 2. Brake Manifold
Parking Brake
NOTE: Move the pressure gauge from the LAP1 test 8. Cycle the parking brake switch several times to
port to the parking brake or PK2 port on the brake ensure crisp applications and release of the
manifold. brake (pressure). Verify proper functioning of
the pilot light.
9. * Release the brakes. Apply the auxiliary brake
6. Ensure the parking brake and automatic slack
switch. Ensure that the switch actuates both the
adjusters are properly adjusted. Refer to sec-
parking brake and the service brakes. Release
tion J, Brake System, Parking Brake.
the parking brake using the parking brake
7. * Apply the brake lock or depress the brake switch. Record the parking brake pressure (the
pedal to hold the truck stationary. Release the pressure should be zero), front brake pressure,
parking brake. Record the parking brake left rear brake pressure, and right rear brake
release pressure. The proper pressure is pressure. Apply the parking brake and release
18,961 345 kPa (2750 50 psi). Verify that the auxiliary brake.
the parking brake pilot light on the dash turns
off. Move the pressure gauge from the parking
brake circuit back to the LAP1 port.

10. * Quickly and completely depress the brake 16. * Brake pressures should begin to rise (auto
pedal. Check the front and rear brake pres- apply) when LAP1 reaches 9653 586 kPa
sures. The correct pressure for the front and (1400 85 psi). Record the front and rear brake
rear is 14,479 517 kPa (2100 75 psi) within pressures when auto apply is actuated.
one second. Record the front and rear brake 17. * Continue to allow the front accumulator to
pressures. Holding the pedal fully applied, both depressurize. When discharged, the brake
pressures must remain above 13,962 kPa lights and the retard lights should illuminate.
(2025 psi) for a minimum of 20 seconds. The illumination of the lights confirms operation
11. * Release the brake pedal. Brake pressure must of the normally closed pressure switch that
return to zero within two seconds with no resid- actuates at 6722 172 kPa (975 25 psi).
ual pressure trapped in the brakes. Record the Close the bleeddown valve for the front brake
pressures. accumulator.
18. * Start the engine to recharge the hydraulic sys-
tem. Verify that the low brake pressure warning
Brake Lock lamp and the warning buzzer turn off at the
12. * Apply the brake lock. Proper rear brake pres- same time. Record the LAP pressure when the
sure is 14,479 690 kPa (2100 100 psi). warning indicators turn off. Allow the engine to
Front brake pressure must be zero. Record the operate until the brake accumulator pressure
brake pressures. stabilizes at or above 18,616 kPa (2700 psi).
13. Cycle the brake lock several times to ensure 19. * Shut the engine off. Allow the steering accu-
crisp application and release of brake pressure. mulator to completely depressurize. Turn the
key switch to the ON position. Slightly open the
rear brake accumulator bleeddown valve and
observe the LAP1 pressure. Verify that the low
Low-Brake Pressure and Auto-Apply brake pressure warning lamp illuminates within
14. Shut the engine off. Allow the steering accumu- 690 kPa (100 psi) of the pressure recorded in
lators to completely depressurize. Locate the Step 15.
steering pressure switch beneath the steering 20. * Verify that the brake pressures begin to rise
accumulators on the LH frame rail. Place a (auto apply) when LAP1 is within 690 kPa (100
jumper wire across the pressure switch connec- psi) of the pressure recorded in Step 16. Record
tor to disable the switch. the front and rear brake pressures when auto
15. * Start the engine to fill the accumulators with apply is actuated.
oil. Allow the engine to operate until accumula- 21. Close the rear brake accumulator bleeddown
tor pressure stabilizes at or above 18,616 kPa valve. Remove the jumper from the steering
(2700 psi). Shut the engine off. Turn the key pressure switch connector. Connect the har-
switch back to the ON position. Slightly open ness connector to the pressure switch.
the front accumulator bleeddown valve to allow
the pressure to dissipate. Observe the pressure
at the LAP1 port while monitoring the dash
panel. The low brake pressure warning lamp
must illuminate at 12,755 517 kPa (1850 75
psi).
NOTE: The warning buzzer will not sound when the
engine is off.

Validation
22. Start the engine to recharge the hydraulic sys-
tem. Allow the engine to operate until the low
brake accumulator pressure stabilizes at or
above 18,616 kPa (2700 psi).
23. * Shut the engine off, but leave the key switch in
the ON position. Slowly depress the brake
pedal every 15 seconds until the low brake
accumulator pressure warning illuminates.
Record the number of brake applications before
the activation of the low brake accumulator
pressure warning. The warning should not illu-
minate before the sixth brake application.
Retarding
24. Install pressure gauges at:
a. Front brake test port (FB, Figure 4- 1)
b. Rear brake test ports (RBL, RBR, Figure 4-
1)
c. Low accumulator pressure test port (LAP1,
Figure 4- 2)
25. Start the engine to recharge the hydraulic sys-
tem. Allow the engine to operate until the low
brake accumulator pressure stabilizes at or
above 18,616 kPa (2700 psi).
26. * Move the retarder lever to full retard. Verify
that the front and rear brake pressures are at
14,479 869 kPa (2100 126 psi) within 1 sec-
ond. Record the front and rear brake pressures.
With the lever still at full retard, the brake pres-
sures should remain above their minimum val-
ues for a minimum of 20 seconds.
27. * Quickly return the retarder lever to OFF. The
front and rear brake pressures should return to
zero within 2 seconds. No residual pressure
trapped in the brakes is allowed. Record the
pressures.

BRAKE SYSTEM DATA SHEET
INITIAL SYSTEM SET UP
Step 4 _______________ Front brake pressure when auto apply releases: 11,376 690 kPa
(1650 100 psi)
_______________ Left rear brake pressure when auto apply releases: 11,376 690 kPa
(1650 100 psi)
_______________ Right rear brake pressure when auto apply releases: 11,376 690
kPa (1650 100 psi)
PARKING BRAKE SYSTEM
Step 7 _______________ Parking brake release pressure: 18,961 345 kPa (2750 50 psi)
Step 9 _______________ Parking brake pressure with emergency brake applied: 0 kPa (0 psi)
_______________ Front brake pressure with emergency brake applied: 0 kPa (0 psi)
_______________ Left rear brake pressure with emergency brake applied: 0 kPa (0 psi)
_______________ Right rear brake pressure with emergency brake applied: 0 kPa
(0 psi)
SERVICE BRAKE SYSTEM
Step 10 _______________ Front brake pressure (pedal applied): 14,479 517 kPa
(2100 75 psi)
_______________ Left rear brake pressure (pedal applied): 14,479 517 kPa
(2100 75 psi)
_______________ Right rear brake pressure (pedal applied): 14,479 517 kPa
(2100 75 psi)
Step 11 _______________ Front brake pressure (pedal released): 0 kPa (0 psi)
_______________ Left rear brake pressure (pedal released): 0 kPa (0 psi)
_______________ Right rear brake pressure (pedal released): 0 kPa (0 psi)

BRAKE LOCK
Step 12 _______________ Front brake pressure (brake lock applied): 0 kPa (0 psi)
_______________ Left rear brake pressure (brake lock applied): 14,479 690 kPa
(2100 100 psi)
_______________ Right rear brake pressure (brake lock applied): 14,479 690 kPa
(2100 100 psi)
LOW BRAKE PRESSURE AND AUTO APPLY
Step 15 _______________ LAP pressure when warning lamp illuminates: 12,755 517 kPa
(1850 75 psi)
Step 16 _______________ LAP pressure when auto apply occurs: 9653 586 kPa (1400 85
psi)
_______________ Front brake pressure after auto apply: 9653 586 kPa (1400 85 psi)
_______________ Right rear brake pressure after auto apply: 14,479 690 kPa (2100
100 psi)
_______________ Left rear brake pressure after auto apply: 14,479 690 kPa (2100
100 psi)
Step 17 _______________ LAP pressure when brake and retard lights illuminate: 6722 172
kPa (975 25 psi)
Step 18 _______________ LAP pressure when warning lamp and buzzer turn off
Step 19 _______________ LAP pressure when warning lamp turns on: within 690 kPa (100 psi)
of the pressure recorded in Step 15
Step 20 _______________ LAP pressure when auto apply occurs: within 690 kPa (100 psi)
of the pressure recorded in Step 16
_______________ Front brake pressure after auto apply: 14,479 690 kPa (2100 100
psi)
_______________ Right rear brake pressure after auto apply: 9653 586 kPa (1400 85
psi)
_______________ Left rear brake pressure after auto apply: 9653 586 kPa (1400 85
psi)

VALIDATION
Step 23 _______________ Number of applications to LAP pressure warning: 6 or more
RETARDING
Step 26 _______________ Front brake pressure (retarder applied): 14,479 869 kPa (2100 126
psi)
_______________ Left rear brake pressure (retarder applied): 14,479 869 kPa (2100
126 psi)
_______________ Right rear brake pressure (retarder applied): 14,479 869 kPa
(2100 126 psi)
Step 27 _______________ Front brake pressure (retarder off): 0 kPa (0 psi)
_______________ Left rear brake pressure (retarder off): 0 kPa (0 psi)
_______________ Right rear brake pressure (retarder off): 0 kPa (0 psi)
Machine __________________ Unit No. _______________ S/N ______________
Name of Inspector ___________________________________

BRAKE CIRCUIT TROUBLESHOOTING
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
PROBLEM: The Brakes are Locked, Service and/or Parking

Parking brake solenoid is de-energized. Check power to solenoid
Connections to tank and pressure ports reversed. Correct the plumbing.
Parking brake solenoid coil defective. Replace coil.
Parking brake solenoid valve defective. Replace solenoid valve.
Tank line is plugged or restricted. Remove restriction.
PROBLEM: Both Brake Circuits are Dragging

Tank line has back pressure. Ensure tank line has no back pressure.
Pedal set screw out of adjustment; residual pres- Adjust pedal deadband.
sure.
PROBLEM: One Brake Circuit is Dragging

Obstruction in the brake valve subassembly. Remove obstruction.
Brake valve is out of balance. Adjust balance according to instructions.
Actuator piston defective. Replace piston.
Brake valve is defective. Rebuild or replace brake valve assembly.
A relay valve is defective Rebuild or replace relay valve assembly.
PROBLEM: The Brakes are Not Going to Full Pressure

Internal malfunction of modulating section of brake Remove, disassemble, clean, and inspect brake
valve. valve.
Supply pressure is low. Check steering/brake pump system and accumula-
tors.
Improper collar adjustment on brake valve. Adjust collars according to instructions.
PROBLEM: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system. Check wiring.
Brake accumulator bleeding down. Bleeddown valve open; close valve.
Differential pressure switch defective. Check brake valve; replace switch assembly.

PROBLEM: A Low Brake Pressure Warning Occurs When Brakes are Applied
Leak or other malfunction in one brake circuit. Inspect brake system and repair leaks.
Brake valve balance is out of adjustment. Adjust collars according to instructions.
Differential pressure switch defective. Replace the switch.
A relay valve is defective Inspect and repair relay valve(s)
PROBLEM: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released
Brake valve out of balance (not tracking). Adjust collars according to instructions.
Differential pressure switch defective. Replace the switch.
Accumulator precharge/leak. Check accumulators and recharge if necessary.
Problem in brake valve subassembly. Remove, disassemble, clean, and inspect brake
valve assembly or replace it.
Relay valve defective Inspect and repair relay valve(s)
Air in one brake circuit. Bleed brakes.
Minor leak in one circuit. Inspect brake system and repair leaks.
PROBLEM: The Differential Pressure Warning Circuit is not Operating

Low brake pressure lamp is burned out. Replace bulb.
Electrical problem. Check switch circuit wiring.
Differential pressure switch is defective. Replace switch assembly.
Problem in brake valve assembly. Remove, disassemble, clean, and inspect, or
replace brake valve.
Retard Control Monitor defective Replace RCM.
PROBLEM: The Low Pressure Warning Circuit Not Operating Properly

The low brake pressure lamp is burned out. Replace the bulb.
The electrical circuit is open. Check switch circuit wiring.
Pressure switch defective. Replace the pressure switch.

PROBLEM: Trucks veers to Left (or Right) when brakes are applied.
Hoses between proportional pressure control valve Reconnect hoses to correct ports.
(PPC) and rear relay valve are crossed.
Malfunction in one proportional pressure control Rebuild or replace PPC valve.
valve circuit.
Malfunction in rear relay valve. Rebuild or replace relay valve.
RCM requires calibration. Calibrate. Refer to RCM Calibration in this chapter.
PROBLEM: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component. Check all steering and brake system components.
Steering accumulator precharge too high or too low. Check steering accumulator precharge.
Brake valve plumbed incorrectly. Correct plumbing.
Internal leakage in brake valve assembly. Replace brake valve assembly.
Internal leakage in relay valve assembly. Rebuild or replace relay valve
Steering/brake pump is worn. Rebuild or replace pump.
Pump compensator not adjusted correctly. Adjust pump pressure control.

PROBLEM: Low Pressure Warning is On Even Though System Pressure is Proper

Short in electrical system. Check wiring.
Pressure switch is defective. Replace the switch.
PROBLEM: Low Pressure Warning Comes On and Pressure is Low

Steering circuit is malfunctioning. Check steering circuit pressures.
The pump is worn. Rebuild or replace pump.
PROBLEM: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open. Close valve, check precharge.
Accumulator precharge is low. Recharge accumulator
Leak in one circuit. Check plumbing.
Malfunction in brake valve. Disassemble and clean, or replace.
PROBLEM: A "Squeal" is Heard When Controller is Operated

Rapid operation of controller. Normal
Brake Valve assembly is damaged. Replace the brake valve assembly.
Hydraulic oil is too hot. Check entire hydraulic system for restriction etc.
PROBLEM: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected. Check plumbing.
PROBLEM: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in brake valve assembly. Disassemble and clean, or replace.
Damage in brake valve assembly. Repair or replace brake valve assembly.
Relay valve malfunctioning Repair or replace relay valve assembly.
PROBLEM: Oil is Leaking Around the Pedal Base

Defective seal on top of brake valve. Replace the seal.

SECTION J5
FRONT WET DISC BRAKES
INDEX
FRONT WET DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-3
BRAKE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
Checking Disc Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
FRONT BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-8
Floating Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-11
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-14
J05022 Front Wet Disc Brakes J5-1

NOTES
J5-2 Front Wet Disc Brakes J05022

FRONT WET DISC BRAKES
The oil cooled wet disc brakes mounted on the front
wheels are similar in design and operation to the rear
wet disc brakes.
The front brake assembly uses the following major
components (refer to Figure 5-1):
Twelve friction discs (4)

Eleven separator plates (3)
Two damper discs (2)
Piston (1)
Cylinder (8)
Ring gear (7)
Wheel Hub (5)
Floating seal (6)
Ring gear (7) is internally splined to retain the damp-

ers (2) and separator plates (3). The separator plates
are alternately placed between the friction discs (4).
The friction discs are splined to wheel hub (5).
The inboard side of the assembly contains piston (1)
which is activated by hydraulic pressure supplied by
the brake valve through the front relay valve. As
hydraulic pressure is applied, the piston moves to
compress the rotating friction faced discs against the
stationary steel discs. The friction forces that are
generated resist the rotation of the wheel hub/wheel.
As hydraulic pressure increases, friction forces are
increased and wheel rotation is slowed until maxi-
mum force is reached and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic FIGURE 5-1. FRONT DISC BRAKE ASSEMBLY
oil. The low pressure cooling circuit is completely iso- (Installed on spindle with wheel hub)
lated from the high pressure, piston apply circuit.
Cooling oil flows from the hydraulic tank to the tan- 1. Piston 5. Front Wheel Hub
dem front and rear brake cooling pump. Cooling oil 2. Damper 6. Floating Seal
flows from one section of the pump to the front wet 3. Separator Plate 7. Ring Gear
disc brake cooling circuit. 4. Friction Disc 8. Cylinder

BRAKE MAINTENANCE
A Brake Cooling Valve (BCV) is located in the circuit. Brake disc wear must be checked every 1000 hours.
If activated (no brake apply signal) 50% of the cool- using the wear indicator tool. Refer to Section M,
ing oil will be routed directly back to tank. If the BCV Special Tools. The brake disc wear indicator tool is
is not activated (due to the presence of a brake sig- inserted in the wear gauge port on the inside of the
nal) then 100% of the oil is routed through the front brake assembly. Figure 5-2 shows the front brake
brake cooling oil circuit. location. Refer to Rear Wet Disc Brakes in this sec-
After the cooling oil has passed through the brake, tion for rear wheel plug location.
the oil is routed through a one way orifice check
Checking Disc Wear
valve. This valve provides a back pressure of 448
kPa (65 psi) in the front brake cooling circuit. Cooling 1. Place the shift lever in NEUTRAL, apply the
oil pressure returns the piston when the brakes are parking brake, and turn the key switch to OFF.
not applied. Allow the steering accumulators to depressur-
ize. Chock the wheels.
NOTE: If cooling oil pressure falls below 448 kPa (65
psi), the piston may not fully release the brake discs 2. Open the bleeddown valves on the brake mani-
causing premature wear. fold in the hydraulic cabinet to relieve pressure
from the brake accumulators. Close the valves
After passing throught the check valve, cooling oil after pressure is relieved.
flows through the heat exchanger and then back to
tank.
Before removing wear gauge plugs, depressurize

system accumulators before opening hydraulic
circuits or installing test gauges.


3. Thoroughly clean the exterior of the brakes,

especially the area surrounding the wear gauge
plugs.
4. Remove wear gauge plug (4, Figure 5-2) and
install the wear gauge as shown in Figure 5-3.
5. Start the engine and allow the steering system
to stabilize and the brake accumulators to fill.

6. While fully applying the service brake pedal,
check brake wear as follows:
a. Push the wear gauge in until it contacts the
brake piston. Check the position of front
brake marker (3, Figure 5-3). If the marker
goes in beyond the face of the case (5), the
disc pack is worn beyond maximum wear
limits. The brakes must be repaired.
b. If the marker does not go beyond the face of
the case, brake disc wear is still within allow-
able limits.
NOTE: If the mark is close to the face, perform more
frequent inspections.
7. Release the brakes. Shut off the engine, and

allow the steering accumulators to depressur-
ize. Open the brake accumulator bleeddown
valves to relieve pressure from the brake sys-
tem. Close the valves after all pressure is
relieved.
8. Remove the wear indicator tool and install wear
FIGURE 5-2. TOOL INSTALLATION LOCATION gauge plug (4, Figure 5-2).
1. Front Brake Assembly 3. Bleeder Plugs 9. Repeat this procedure for the remaining front
2. Cooling Oil Ports 4. Wear Gauge Plug brake. Refer to Section J, Rear Wet Disc
Brakes for instructions on checking rear brake
wear.
NOTE: Checking disc wear in all four brake
assemblies is recommended. Disc wear in one brake
assembly may be different from the other due to
dissimilar operation of parts and/or haul profiles.
10. Refill the hydraulic tank, as required.

11. If brake repairs are necessary, refer to the
rebuild instructions in this section and in section
J6 for the rear brakes.
Brake assemblies on the same axle must be

FIGURE 5-3. BRAKE WEAR TOOL rebuilt at the same time. DO NOT rebuild brake
assemblies individually.
1. Handle 4. Rear Brake Marker
2. Rod 5. Face of the Case
3. Front Brake Marker

FRONT BRAKE ASSEMBLY
Removal
1. The wheel hub and brake must be removed as
an assembly. Remove the front wheel hub and
brake, then remove the wheel hub. Refer to
Section G, Front Wheel Hub and Spindle.
2. Position the brake assembly on the floor as
shown in Figure 5-4 to prepare for disassembly.
Installation
1. The wheel hub and brake must be installed as
an assembly. Install the assembly onto the spin-
dle. Refer to Section G, Front Wheel Hub and
Spindle for instructions.
Disassembly
NOTE: Etch orientation marks onto the profile of
major exterior components before disassembly to
ensure correct assembly.
1. Position the brake assembly on a clean work
surface as shown in Figure 5-4.
2. Attach lifting apparatus to seal retainer (2). The
weight of the retainer is approximately 23 kg (51
lb). Lift the retainer off of the brake.
3. Remove lip seal (3), O-ring (15) and floating
seal (4) from the retainer.
FIGURE 5-4. BRAKE ASSEMBLY
4. Remove capscrews and flatwashers (5) from
brake hub (6). 1. O-Ring 10. Damper
5. Attach lifting apparatus to brake hub (6). The 2. Seal Retainer 11. Capscrew & Washer
weight of the hub is approximately 62 kg (137 3. Lip Seal 12. Piston
lb). Lift the hub off of the brake. 4. Floating Seal 13. O-Ring
5. Capscrew & Washer 14. Cylinder
6. Remove O-ring (1) and floating seal (4) from the
6. Brake Hub 15. O-Ring
brake hub.
7. Ring Gear 16. Piston Seals
8. Separator Plate 17. O-Ring
9. Friction Disc
7. Remove the brake discs. The brake contains

two dampers (10), eleven separator plates (8)
and twelve friction discs (9). Note the orienta-
tion and order of the discs for assembly. The
discs must be reassembled correctly to ensure
proper oil flow.

8. Remove capscrews and flatwashers (11). Cleaning and Inspection
9. Attach lifting apparatus to ring gear (7). The 1. Clean all parts thoroughly prior to inspection.
weight of the gear is approximately 99 kg (218 2. Remove and discard the O-rings from each
lb). Lift the gear off of cylinder (14). floating seal (4, Figure 5-4). Inspect the pol-
10. Remove piston (12). If piston removal is difficult, ished mating surfaces of the seal ring for
use air pressure to push the piston out of the scratches or other damage. Inspect the contact
cylinder bore. Remove two piston seals (16) band on the mating faces to determine the
from the piston. amount of wear.
11. Remove two O-rings (3, Figure 5-5) from the A new seal has a contact band (dimension "A",
bleeder ports. Figure 5-6) approximately 1.6 mm (0.06 in.)
12. Remove O-ring (13) and O-ring (17) from cylin- wide. As wear occurs, the contact band will
der (14). widen slightly as shown by dimension "B". The
band widens and migrates inward until the
13. Discard lip seal (3) and all O-rings. inside diameter is reached. At this point, the
entire seal assembly must be replaced.
Remaining seal life can be estimated by the
width of the contact band.
FIGURE 5-6. SEAL WEAR PROGRESSION
FIGURE 5-5. BLEEDER PORT O-RINGS
3. Inspect cylinder (14, Figure 5-4) for nicks or

1. Cylinder 3. O-Ring
scratches in the seal area. If nicks or scratches
2. Bleeder 4. Gear
cannot be removed by polishing, replace the
cylinder.
4. Inspect the piston and the seal grooves for
damage.
5. Inspect the friction discs, separator plates, and
damper plates for friction material wear, warp-
ing and tooth wear. Refer to Tables 1 for wear
limits.

Assembly
NOTE: Before assembling the floating seals, use
TABLE 1. FRONT BRAKE INSPECTION
alcohol to remove the white powder from the O-ring
ITEM NEW WEAR LIMIT surfaces.
Separator Plate 2.4 mm 2.15 mm
1. Refer to Floating Seal Installation in this chapter
(0.095 in) (0.085 in)
for proper seal installation instructions.
Disc 5.1 mm 4.6 mm
(0.201 in) (0.181 in) a. Install the floating seals in seal retainer (2,
Figure 5-4) and brake hub (6).
Damper 6.9 mm 5.1 mm
(0.272 in) (0.201 in) b. After installing the floating seal in the hub,
Disc 0.45 mm 0.7 mm measure dimension "A" (Figure 5-7). Mea-
Warping (0.018 in) (0.028 in) sure from the top of the hub to the top of the
seal ring at four places around the circumfer-
Warping (0.012 in) (0.028 in) ence. Verify that the measurement is within 1
mm (0.039 in). Adjust the seal as necessary
Assembled
to meet this criteria.
Thickness of Discs 101.4 mm 93.4 mm
And Plates (3.992 in) (3.667 in) c. Repeat this process for dimension "A" on the
seal retainer. The four measurements must
be within 1 mm (0.039 in). Adjust the seal as
necessary to meet this criteria.
FIGURE 5-7. SEAL INSTALLATION
NOTE: When assembling the brake, use the etch

marks made during disassembly to properly orient
components.
NOTE: Use new seals and O-rings during assembly.

FIGURE 5-8. ASSEMBLING THE BRAKE
1. Ring Gear 4. Wheel Hub

2. Brake Hub 5. Floating Seals
3. Seal Retainer 6. Cap Screw & Washer
2. Apply Loctite # 648 to the outside circumfer- 7. Attach lifting apparatus to seal retainer (3). The
ence of lip seal (3, Figure 5-4). Use a press and weight of the retainer is approximately 23 kg (51
pusher tool to install the lip seal in brake hub lb). Lift the retainer onto the wheel hub. Verify
(6). Lubricate the lip area with clean hydraulic that the retainer is properly seated in the hub.
oil. 8. Attach lifting apparatus to brake hub (2). The
3. Lubricate O-ring (1) with clean hydraulic oil and weight of the hub is approximately 62 kg (137
install onto brake hub (6). lb). Lift the hub into position on the assembly.
4. Lubricate O-ring (15) with clean hydraulic oil 9. Check the position of the floating seals. Mea-
and install into seal retainer (2). sure dimension (C, Figure 5-9) in four places.
5. Position wheel hub (4, Figure 5-8) on the floor The distance must be 90 1 mm (3.54 0.039
as shown. in.). Adjust as necessary.
6. Lubricate the sliding surfaces of the floating 10. Attach lifting apparatus to ring gear (1, Figure 5-
seals with clean engine oil (SAE 30-40). 8). The weight of the gear is approximately 99
kg (218 lb). Lift the gear into position onto brake
hub (2).

11. Install cap screws and washers (6). Tighten the
12. The front brake contains eleven separator discs,
twelve friction discs. and two dampers. Install
the discs in the following order:
a. Insert the first damper disc. Place the cork
face against the piston.
b. Insert a friction disc.
c. Insert one separator plate. Align the notches
with the damper disc notches as noted dur-
ing disassembly.
d. Continue installing separator plates sepa-
rated by friction discs. The internal teeth
must be kept in alignment when the friction
discs are installed.
e. Install the remaining damper disc. Place the
cork side facing upward against the brake FIGURE 5-9. SEAL POSITION CHECK
hub. Align the notches with the separator
1. Brake Hub 2. Seal Retainer
plates.
13. Lubricate piston seals (16, Figure 5-4) with
clean hydraulic oil and install onto piston (12).
14. Place piston (12) into position on the brake
discs.
15. Lubricate O-ring (17) with clean hydraulic fluid
and install onto cylinder (14).
16. Lubricate two O-rings (3, Figure 5-5) with clean
hydraulic oil and install onto ring gear (7, Figure
5-4). The two O-rings seal the ports between
the ring gear and the cylinder.
17. Install guide studs into the ring gear. Failure to
use guide studs could cause the O-rings
between the bleeder ports to be twisted during
assembly.
18. Attach lifting apparatus to cylinder (14). The
weight of the cylinder is approximately 132 kg
(291 lb). Lift the cylinder into position on the
brake.
19. Install cap screws and flatwashers (11). Tighten
20. Lubricate O-ring (13) with clean hydraulic fluid
and install onto cylinder (14).

Floating Seal Installation 1. Inspect the seal surfaces and mounting cavities
for scratches or nicks that may damage the
Failures are usually caused by combinations of fac-
seals. If scratches are present, hone and clean
tors rather than one single cause. Most failures are a
the damaged area.
result of assembly error.
Remove any oil, dust, protective coating or
other foreign matter from the metal seal rings,
the toric rings, and both the housing and seal
ring ramps. Use a non-petroleum base, rapid
drying solvent that leaves no film. Allow sur-
faces to dry completely. Use clean, lint-free
material such as "Micro-Wipes #05310" for
cleaning and wiping.
NOTE: Oil from adjacent bearing installations or seal
ring face lubrication must not get onto the ramp or
the toric. Oil is not allowed on the seals until after
both seal rings are together in their final assembled
position.
2. Install the rubber toric on the seal ring, and

ensure it is straight. Verify the toric ring is not
twisted and that it is seated against the retain-
ing lip of the seal ring ramp. Use the flash line
as a reference guide to eliminate twist. The
flash line must be straight and uniform around
the toric.
FIGURE 5-10. SEAL TERMINOLOGY
1. Seal Ring 6. Seal Ring Face
2. Rubber Toric 7. Seal Ring Ramp
3. Housing Retainer Lip 8. Seal Ring Retainer Lip
4. Housing Ramp 9. Installation Tool
5. Seal Ring Housing
Floating ring seals must be installed in matched

pairs. The seal rings must either be new or have
been previously mated together in operation. DO NO
mate a new ring with a used ring, or two used rings
that have not previously been mated together.
Always install new toric rings (O-rings).
Handle the seal carefully. Nicks and scratches on

the seal ring face cause leaks.

3. Place installation tool (9, Figure 5-10) onto the 5. Use a gauge to check the variation. Check the
seal ring. Lower the ring into a container of assembled height in four places, 90 apart.
clean solvent until all surfaces of the toric ring Height variation around the assembled ring
are wet. must be within 1.0 mm (0.0391 in).
DO NOT use Stanosol or any other liquid that
leaves an oily film or does not evaporate
quickly.
An alternative to dipping the ring in solvent is to
spray with solvent.
6. If small adjustments are necessary, DO NOT

push directly on the seal ring. Make any
required adjustments with the installation tool.
4. With all surfaces of the toric ring wet, use the

installation tool to position the seal ring and toric
ring squarely against the seal housing. Abruptly
apply even pressure to push the toric under the
housing retaining lip.
Toric rings can twist during adjustments or if

there are burrs or fins on the housing retaining
lip. Verify the rings are not twisted.
A bulging or cocked seal will lead to eventual
failure.

7. When properly assembled, toric rings will roll on 8. Wipe the polished metal seal surfaces with
the ramps during operation. The toric rings must clean solvent to remove any foreign material or
not be allowed to slip on the ramps of either the fingerprints. No foreign particles of any kind are
seal ring or the housing. To prevent slippage, allowed on the seal ring faces. Something as
wait at least two minutes. Let the solvent evapo- small as a paper towel fiber will hold the seal
rate before further assembly. If correct installa- faces apart and cause leakage.
tion is not obvious, repeat the installation.
9. Apply a thin film of clean engine oil (SAE 30-40)

on the seal faces. Use a lint-free applicator or a
clean finger to distribute the oil evenly. DO NOT
allow oil to come in contact with the rubber toric
rings or their mating surfaces.
Before assembling both the seals and housing
together, wait at least two minutes. Let all sol-
vent evaporate. Solvent may still be trapped
between the toric and the housing ramp.

BRAKE BLEEDING
1. Chock the wheels.
2. Verify that the brake hydraulic circuit is function-
ing properly. Refer to Section J, Brake Circuit
Checkout.
3. Verify that the bleed-down valves on the brake
manifold are closed.
4. Check the hydraulic tank oil level and fill, if nec-
essary.
5. Start the engine and allow the accumulators to
fill.
6. Install a clear hose onto a bleed valve on the
back of the brake housing. Route the hose to a
container.
7. With the brake pedal partially depressed, slowly
open the bleed valve. Bleed valve (2, Figure 5-
11) vents the cooling oil. Bleed valve (1) vents
the piston. Close the bleeder valve when clear
oil (free of air/bubbles) exits the bleeder. Repeat
at the remaining valve.
10. During assembly, ensure both housings are in
correct alignment, are square and concentric.
Move the parts slowly and carefully toward each
other. Do not slam, bump or drop the seals
together. High impact can damage the seal face
and cause leakage.
FIGURE 5-11. BLEEDER PORTS

1. Piston Bleed Valve 2. Brake Cooling Bleed
Valve
10. Repeat at the remaining brake housings.

11. Shut the engine off, and allow the steering accu-
mulators to depressurize.
12. Check the hydraulic tank oil level and fill as nec-
essary.

SECTION J6
REAR WET DISC BRAKES
INDEX
REAR WET DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-4
Checking Brake Disc Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J6-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-6
BRAKE REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-9
Floating Ring Seal Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-10
WET DISC BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-14
J06023 Rear Wet Disc Brakes J6-1

NOTES
J6-2 Rear Wet Disc Brakes J06023

REAR WET DISC BRAKES
DESCRIPTION
A wet disc brake assembly, similar to the front wheel Dynamic retarding is also a function of the brakes.
brakes, is mounted on both sides of the differential When the retarder lever is actuated, both the front
on the final drive housing, inboard from the wheel and rear wheel brakes apply. Dynamic retarding is
hub and planetary drive. This assembly contains the used to slow the truck during normal truck operation
following major components (refer to Figure 6-1): or to control speed while descending a grade.
Ring gear (4)

Inner gear (9)
Two damper discs (16)
Six separator plates (12)
Seven friction discs (13)
Piston assembly (3)
Floating seal assembly (5)
OPERATION
Housing (4, Figure 6-1) is internally splined to retain
steel damper (16) and separator discs (12). The sep-
arator discs are alternately placed between the fric-
tion faced discs (13) which are splined to rotating
inner gear (9). The inboard side of the assembly con-
tains piston assembly (3) which is actuated by
hydraulic pressure from either the service brake trea-
dle valve or the retarder. As hydraulic pressure is
applied, the piston moves and compresses the rotat-
ing friction faced discs against the stationary steel
discs. The friction forces that are generated resist the
rotation of the wheels. As hydraulic pressure
increases, friction forces are increased and wheel
rotation is slowed until maximum force is reached
and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The cooling oil circuit is a low-pressure circuit
which is completely isolated from the high-pressure
piston apply circuit. Cooling oil flows from the tank to
the brake cooling pump. Pump oil then flows to the
brake assembly housing (from the outside of the FIGURE 6-1. REAR DISC BRAKE ASSEMBLY
housing inward to the rotating hub for maximum cool- 1. Rear Axle 9. Inner Gear
ing). The oil then flows through a heat exchanger and 2. Cylinder 10. Seal Retainer
two filters, back to the hydraulic tank. Additional cool- 3. Piston 11. Hub
ing circuit oil is supplied by the hoist valve when the 4. Ring Gear 12. Separator Plate
body is not being raised. 5. Floating Seal 13. Friction Disc
Assembly 14. Housing Drain Plug
6. Wheel Hub 15. Piston Cavity Plug
7. Retainer 16. Damper
8. Floating Seal 17. Capscrews
Assembly 18. O-Ring

MAINTENANCE
Brake disc wear must be checked every 1000 hours
using the brake disc wear tool (refer to Section M,
Special Tools). The brake disc wear tool is inserted in
the wear gauge port on the brake assembly cylinder.
Figure 6-3 shows the rear brake wear tool port loca-
tion. Refer to Front Wet Disc Brakes, earlier in this
section, for the port location on front wheel brakes.
Checking Brake Disc Wear

FIGURE 6-2. BRAKE DISC WEAR TOOL
1. Handle 4. Rear Brake Marker
2. Indicator Rod 5. Face
3. Front Brake Marker
Before removing plugs or hydraulic connections,
depressurize the steering and brake accumula-
tors. The steering accumulators can be depres-
surized by turning the key switch OFF and
waiting 90 seconds. Confirm the steering pres-
sure is released by turning the steering wheel. No
front wheel movement should occur.
Open the bleed down valves located on the brake
manifold in the brake cabinet. This will allow both
accumulators for the rear brakes and front
brakes to depressurize.
Before disabling the brake circuit, chock the
wheels of the truck to prevent possible move-
ment.
1. Place the range selector in NEUTRAL, apply

the parking brake, and turn the key switch OFF.
Wait 90 seconds to allow the steering accumu-
lators to bleed down completely. Place wheel
chocks around the wheels of the truck.
2. Open the bleed-down valves on the brake man-
ifold in the brake cabinet and bleed all pressure
from the brake accumulators. Close the valves
after pressure is released.
3. Thoroughly clean the brake assemblies, espe-
cially the area surrounding the wear tool ports.
4. Remove wear tool plug (4, Figure 6-3) and
install the wear tool shown in Figure 6-2.
5. Start the engine and allow the steering system FIGURE 6-3. TOOL INSTALLATION LOCATION
to stabilize and the brake accumulators to fill.
1. Rear Brake Assembly 3. Bleeder Ports
2. Cooling Oil Ports 4. Wear Tool Port/Plug

6. While fully applying the service brake pedal, 11. Refill the hydraulic tank as required.
check brake wear as follows: 12. If brake repairs are necessary, refer to Brake
a. Push the wear gauge in until it contacts the Rebuild, later in this chapter.
brake piston. Check the position of the
stamped mark on rod (2, Figure 6-2). If the
stamped mark goes in beyond face (5), the
disc pack is worn past the maximum safe
wear limits. The brakes must be repaired, REMOVAL
immediately. 1. Remove the rear rims and tires, the planetary
NOTE: In the following procedures, observe the drive, and the wheel hubs. Refer to Section G,
correct mark on the wear tool indicator rod (2, Figure Drive Axle, Spindles and Wheels for instruc-
6-2). Marker (4) is used when measuring rear brake tions.
disc wear and marker (3) is used when measuring
front brake disc wear
b. If the stamped mark on the rod does not go
beyond the face of the case, disc wear is still Install floating seal assembly retainer tools (3,
within allowable limits. Figure 6-4), at three equal spaced locations. The
NOTE: If the mark is near the face, perform tools retain the floating seal assembly when the
inspections more frequently. brake is removed from the rear axle. If the
retainer tools are not installed, seal damage will
occur!
7. Release the brakes. Shut the engine off, and
allow the steering accumulators to bleed down.
2. If not done previously, use a suitable container
8. Open the brake accumulator bleed-down valves
to drain the brake cooling oil tank. The capacity
to remove all pressure from the brake system.
of the tank is 576 liters (152 gal).
Close the valves after all pressure is released.
3. Remove the drain plugs and drain the oil from
9. Remove the brake disc wear tool and reinstall
the brake housing and piston cavity. Open the
the port plug.
bleeder valves at the top of the brake assembly
10. Repeat this procedure at the remaining disc to facilitate oil removal.
assemblies.
4. Remove the cooling oil inlet and outlet tubes
from the inner side of the brake assembly.
Remove the brake apply line. Plug all openings
to prevent contamination.
5. Attach a suitable lifting device to the brake
assembly. The brake assembly weighs approxi-
Check disc wear in all four brake assemblies dur- mately 1100 kg (2424 lbs).
ing inspections. Disc wear in one brake assembly
may be different from the other due to dissimilar
operation of parts and/or haul profiles. Therefore,
one side may exceed maximum wear limits while
the other side may be within limits.
Brake assemblies on the same axle must be

rebuilt at the same time. Never rebuild brake
assemblies, individually.

INSTALLATION
1. Attach a suitable lifting device to the brake
assembly. The brake assembly weighs approxi-
mately 1100 kg (2425 lbs). The brake housing
must be properly oriented to align with the
hydraulic connections and mounting holes on
the inner side.
Place O-ring (18, Figure 6-5) into position and
ensure the O-ring remains in place during
installation.
2. Move the brake assembly into position against
the flange on the axle. Coat mounting capscrew
threads (17, Figure 6-5) with Three Bond (p/n
TB1374 or 09940-00030). Install the capscrews
and washers, and tighten to 1715 195 Nm
(1258 144 lb ft).
FIGURE 6-4. BRAKE ASSEMBLY REMOVAL 3. Measure the distance between the inner gear
and the hub, as shown in Figure 6-6. Measure
1. Brake Assembly 3. Floating Seal in four places 90 apart. Dimension "A" should
2. Lifting Device Retaining Tool be 118 1.0 mm (4.65 0.04 in.). Record the
measurement.
4. Install the cooling lines on the rear of the brake
6. Remove capscrews and washers (17, Figure 6- housing. Install the brake apply line.
5). Carefully lift the brake assembly outward 5. Install floating seal (8, Figure 6-5) and retainer
until it is clear of the rear axle. (7).
7. Move the brake assembly to a clean work area 6. Install the wheel hubs, the planetary drive, and
for disassembly. the rear rims and tires. Refer to Section G, Drive
Axle, Spindles and Wheels for instructions.
7. Fill the hydraulic tank.
8. Bleed the entire brake system. Refer to Wet
Disc Brake Bleeding Procedure later in this
chapter.

FIGURE 6-6. SEAL POSITION CHECK
1. Ring Gear 3. Inner Gear
2. Hub
FIGURE 6-5. REAR DISC BRAKE ASSEMBLY

1. Rear Axle 9. Inner Gear
2. Cylinder 10. Seal Retainer
3. Piston 11. Hub
4. Ring Gear 12. Separator Plate
5. Floating Seal 13. Friction Disc
Assembly 14. Housing Drain Plug
6. Wheel Hub 15. Piston Cavity Plug
7. Retainer 16. Damper
8. Floating Seal 17. Capscrews
Assembly 18. O-Ring

BRAKE REBUILD
Disassembly
NOTE: Match mark brake assembly components to
ensure correct orientation of parts during reassembly.
1. Position the brake assembly on a work surface,
as shown in Figure 6-7.
2. Install a suitable lifting device on inner gear (1,
Figure 6-7) or on the wheel hub. Remove seal
retainer tools (3, Figure 6-4).
3. Carefully, lift the inner gear from the assembly.
Damage to the floating seal may result when

removing the inner gear. Use caution and remove
the gear, slowly.
4. Remove capscrews and flatwashers (5) from

hub (6).
5. Lift the hub from ring gear (7).
6. Note the order of assembly of the discs.
Remove dampers (10), separator plates (8) and FIGURE 6-7. BRAKE ASSEMBLY COMPONENTS
friction discs (9). Also note the notches at seven 1. Inner Gear 10. Damper
locations on the periphery of the damper plates 2. Seal Carrier 11. Capscrew & Washer
and separator plates. The discs must be reas- 3. Lip Seal 12. Piston
sembled correctly to ensure proper oil flow. 4. Floating Seal 13. O-Ring
7. Remove capscrews and flatwashers (11). 5. Capscrew & Washer 14. Cylinder
Remove ring gear (7) from cylinder (14). 6. Hub 15. O-Ring
7. Ring Gear 16. Piston Seals
8. Remove piston (12).
8. Separator Plate 17. O-Ring
NOTE: If piston removal is difficult, plug any open 9. Friction Disc
ports at the piston apply pressure passages. Slowly
apply air pressure at one port to push the piston out
of the cylinder bore.
9. Remove the two halves of floating seal assem-

bly (4).
10. Remove and discard all O-ring seals.
11. Remove lip seal (3) from the bore of hub (6).

1. Clean all parts thoroughly prior to inspection.
TABLE 1. REAR BRAKE INSPECTION
2. Remove and discard the toric rings from floating
seal assembly (4, Figure 6-7) in the seal ITEM NEW WEAR LIMIT
retainer and the hub. Inspect the seal ring pol- Damper 7.6 mm 5.8 mm
ished (mating) surfaces for scratches or other (0.299 in.) (0.228 in.)
damage. Inspect the contact band on the mat-
ing faces for excessive wear. Replace damaged
(0.122 in.) (0.112 in.)
or excessively worn components.
NOTE: A new seal will have a contact band Warping (0.020 in.) (0.028 in.)
(dimension "A", Figure 6-8) approximately 1.6 mm
(0.06 in.) wide. As wear increases, the contact band Friction Disc 6.7 mm 6.2 mm
will widen slightly (dimension "B") and migrate inward (0.264 in.) (0.244 in.)
until the inside diameter is reached and the entire Friction Disc 0.70 mm 0.9 mm
seal assembly must be replaced. Remaining seal life Warping (0.028 in.) (0.004 in.)
can be estimated by the width of the contact band. Assembled
Thickness of 80.70 mm 75.2 mm
Plates and Discs (3.177 in.) (32.961 in.)
Assembly
Clean all parts, and check for dirt or damage. Coat
the sliding surfaces of all parts with hydraulic oil
before installing.
NOTE: When assembling the floating seals, use

alcohol to remove all of the white powder from the O-
ring surface before assembling.
1. Refer to Floating Ring Seal Assembly/Installa-
tion in this chapter for proper seal installation
procedures.
FIGURE 6-8. SEAL WEAR PROGRESSION
a. Install floating seal assembly (4, Figure 6-7)
to seal carrier (2) and hub (6).
b. After installing the floating seal, measure
3. Inspect piston cylinder (14, Figure 6-7) for nicks dimension "a" (Figure 6-9) between the hub
or scratches in the piston seal area. If nicks or and floating seal ring at four places around
scratches cannot be removed by polishing, the circumference. The measurements must
replace the cylinder. be within 1 mm (0.039 in) of one another.
4. Inspect the piston seal assembly grooves for
c. Measure dimension "a" (Figure 6-9) between
damage. Replace if necessary.
the seal carrier and the floating seal ring.
5. Inspect friction discs, separator plates, and The measurements must be within 1 mm
damper plates for friction material wear, warp- (0.039 in) of one another.
ing and tooth wear. Refer to Table 1 for wear
limits. NOTE: When assembling brake components, align
individual parts according to match marks made
during disassembly.

7. Install a new lip seal in hub (6). Apply Loctite
#648 to the outer diameter of the seal and press
into the hub. Coat the lip area with grease.
8. With a new O-ring and lip seal installed, install
hub (6) to ring gear (7). Tighten the capscrews
to 549 58 Nm (405 43 lb ft).
NOTE: Coat the sliding surfaces of the floating seals
with a small amount of engine oil. Assemble slowly
and cautiously to avoid damaging the floating seals.
FIGURE 6-9. SEAL INSTALLATION

10. Attach a lifting device to inner gear (1) and care-
fully lower the gear over the assembly. Align the
gear teeth with the disc teeth.
11. Install seal assembly retainer tools (3, Figure 6-
4) on the hub and inner gear. Position the tools
2. Position the cylinder on a work surface, as at three equally spaced holes to secure the
shown in Figure 6-7. Install new seals on piston floating seal until the brake assembly is
(12). Lubricate the seals and install the piston in installed.
cylinder (14).
3. Lubricate and install O-ring (17).
4. Install ring gear (7, Figure 6-7) onto cylinder Floating Ring Seal Assembly/Installation
housing (14).
Failures are usually caused by combinations of fac-
5. Install capscrews and flatwashers (11, Figure 6- tors rather than one single cause, but many failures
7). Tighten the capscrews to 549 58 Nm (405 have one common denominator - assembly error.
43 lb ft).
6. Install damper discs, friction discs, and separa- Floating ring seals must be installed in matched
tor plates in the following order: pairs. This means that two new rings or two rings that
have previously mated together in operation are to
a. Insert the first damper disc with the cork face be used. Never assemble one new ring and one
against the piston. used ring, or two used rings that have not previously
b. Insert a friction disc. been mated together.
c. Insert one separator plate, with notches Always use new toric rings.
aligned with damper disc notches (as noted
during disassembly).
1. Inspect seal surfaces and mounting cavities for
d. Continue installing the separator plates and rough tool marks or nicks that may damage rub-
friction discs. The rear wheel brake contains ber seal rings. Hone smooth and clean and
six separator plates and seven friction discs. repairs. Remove any oil, dust, protective coat-
The internal teeth must be kept in alignment ing or other foreign matter from the metal seal
when the friction discs are installed. Ensure rings, the toric rings, and both the housing and
the separator plate notches are aligned. seal ring ramps. Use a non-petroleum base,
e. Install the remaining damper disc with the rapid drying solvent that leaves no film. Allow
cork material facing up (against the hub) and surfaces to dry completely. Use clean, lint-free
the notches aligned with the separator material such as Micro-Wipes #05310 for clean-
plates. ing and wiping.
Both ramps must be dry. Use clean, lint-free
cloths or lint-free paper towels for wiping.

2. Install the rubber toric on the seal ring, and
ensure it is straight. Ensure the toric ring is not
twisted and that it is seated against the retain-
ing lip of the seal ring ramp. Use the flash line
as a reference guide to eliminate twist. The
flash line must be straight and uniform around
When using any solvent, avoid prolonged skin the toric.
contact. Use solvents only in well ventilated
areas and use approved respirators to avoid
breathing fumes. DO NOT use near open flame or
welding operations or other heated surfaces
exceeding 482 C (900 F). DO NOT smoke
around solvents.
NOTE: Oil from adjacent bearing installations or seal

ring face lubrication must not get onto the ramp or
the toric until after both seal rings are together in their
final assembled position.
Handle the seal carefully. Nicks and scratches on

the seal ring face cause leaks.
3. Place installation tool (9, Figure 6-10) onto the

seal ring with toric. Lower the rings into a con-
tainer of solvent until all surfaces of the toric
ring are wet.
Alternate lubrication method - After positioning
the seal squarely over the retaining lip, thor-
oughly lubricate the ring by spraying with sol-
vent. DO NOT use Stanosol or any other liquid
that leaves an oily film or does not evaporate
FIGURE 6-10. SEAL TERMINOLOGY quickly.
1. Seal Ring 6. Seal Ring Face
2. Rubber Toric 7. Seal Ring Ramp
3. Housing Retainer Lip 8. Seal Ring Retainer Lip
4. Housing Ramp 9. Installation Tool
5. Seal Ring Housing

4. With all surfaces of the toric ring wet, use the 6. If small adjustments are necessary, DO NOT
installation tool to position the seal ring and toric push directly on the seal ring. Make any
ring squarely against the seal housing. required adjustments with the installation tool.
Abruptly apply even pressure to push the toric
under the housing retaining lip.
5. Check the sight gauge. Check variation in the Toric rings can twist if dry on one spot or if there
seal ring assembled height in four places, 90 are burrs or fins on the housing retaining lip. A
apart. Height variation around the assembled bulging toric or cocked seal can contribute to
ring must be within 1.0 mm (0.0391 in). eventual failure.
The toric rings must not be allowed to slip on the

ramps of either the seal ring or the housing. To
prevent slippage, wait at least two minutes. Let
all solvent evaporate before further assembly.
Once in place, the toric ring must roll on the
ramps only. If correct installation is not obvious,
repeat Steps 3 through 6.

8. Apply a thin film of clean oil on the seal faces.
Use a lint-free applicator or a clean finger to dis-
tribute the oil evenly. DO NOT allow oil to come
in contact with the rubber toric rings or their
mating surfaces.
Before assembling both the seals and housing
together, wait at least two minutes. Let all sol-
vent evaporate. Solvent may still be trapped
between toric and housing ramp.
7. Wipe the polished metal seal surfaces with

clean solvent to remove any foreign material or
fingerprints. No foreign particles of any kind are
allowed on the seal ring faces. Something as
small as a paper towel fiber will hold the seal
faces apart and cause leakage.

10. Ensure both housings are in correct alignment WET DISC BRAKE BLEEDING
and are square and concentric. Move the parts
slowly and carefully toward each other.
Bleed the rear wheel brakes prior to rear tire

installation.
DO NOT slam, bump or drop the seals together.
High impact can damage the seal face and cause
leakage. 1. Ensure the hydraulic brake supply (steering cir-
cuit) is operating properly.
2. If necessary, charge the brake system accumu-
lators. Refer to Hydraulic Brake Accumulators,
earlier in this section of the manual.
3. Ensure the bleed-down valves on the brake
accumulator manifold are closed.
4. Check the hydraulic tank oil level and fill, if nec-
essary.
5. With the wheels securely blocked, start the
engine and allow the accumulators to fill.
6. Slowly depress the brake pedal until the service
brake is partially applied.
7. Slowly open the bleeder valves located at the
top of each brake cylinder. (The upper bleeder
vents the cooling oil and the lower bleeder vents
the piston.) Close the bleeder valve when clear
oil (free of air/bubbles) exits the bleeder.
8. Repeat for the remaining brake assemblies.
9. Shut the engine off, and allow the steering
accumulators to bleed-down.
10. Check the hydraulic tank oil level.

SECTION J7
PARKING BRAKE
INDEX
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Parking Brake Service Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
PARKING BRAKE SPRING CYLINDER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J7-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
AUTOMATIC SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-6
PARKING BRAKE CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-7
J07012 01/04 Parking Brake J7-1

NOTES
J7-2 Parking Brake 01/04 J07012

PARKING BRAKE
Description Parking Brake Service Criteria
The disc type parking brake, mounted on the final The following specifications should be used to deter-
drive input, utilizes three brake heads with spring mine the state of parking pads and the disc. Replace
cans (hydraulic cylinders) containing internal springs if any of the limits have been exceeded.
which apply the parking brake when hydraulic pres-
sure is released.
When the engine is running and the park brake Parking Brake Wear Limits
switch is in the OFF position, hydraulic oil is routed to
Item New Limit
the spring cans to extend the pistons and mechani-
cally retract the disc brake pads to release the park Disc Face Runout 0.4 mm 0.8 mm
brake. (0.016 in.) (0.032 in.)
A slack adjuster, mounted between each brake head Disc Thickness 25 mm 20 mm

and spring can, automatically maintains the correct (0.99 in.) (0.79 in.)
disc pad adjustment. Automatic adjustment occurs Pads 20.0 mm 12.2 mm
when the parking brake is applied. (Includes plate thickness) (0.787 in.) (0.48 in.)
Before removing any brake lines or brake circuit

components, be certain the steering system and
brake system accumulators are bled down. To
bleed down accumulators:
Block truck wheels
Turn the key switch OFF and wait
approximately 90 seconds for the steering
accumulators to bleed down. Rotate the
steering wheel; no wheel movement should
occur.
Bleed the brake accumulators (located in the
hydraulic components cabinet) by opening
(turning counterclockwise) the bleeddown
valves (NV1, NV2) located on the brake
manifold. Wait approximately 90 seconds to
let accumulators bleed down. When brake
accumulators are completely bled down,
close the bleeddown valves completely by
turning clockwise.

1. Place the range selector in NEUTRAL, apply 1. Install the brake disc (20, Figure 7-1) onto the
the park brake, turn the key switch OFF and companion flange with capscrews (10) and flat
allow the steering accumulators to bleed down washers (9). Tighten to standard torque.
completely. Block truck wheels. 2. Install dowel pins (23) into the parking brake
2. Open the bleeddown valves on the brake mani- cage.
fold (in the hydraulic components cabinet) and 3. Install each brake assembly (13) over the disc.
bleed all pressure from the brake accumulators.
4. Install the plates (19) onto the dowel pins and
Close valves after pressure is released.
align with slots in the brake assembly.
3. Thoroughly clean the brake assemblies, espe-
5. Assemble the springs (11& 12) onto the bracket
cially the area around any hose connections
(24). Take note of the left and right spring posi-
where dirt might enter the system.
tions. Attach brackets with springs to the plates
4. Remove the capscrews (6, Figure 7-1), lock with capscrews (25) and flat washers (17), pay-
washers (7) and brake line clamps (8). ing special attention that the springs are posi-
5. Disconnect the hoses (4, 5, and 14) from the tioned correctly between the brake pads.
spring cans. Tighten to standard torque.
6. Disconnect the three hoses at the junction block 6. Remove capscrews and flat washers and install
(1). bracket (15) using the longer capscrews (3) and
7. Remove fittings (2 & 26) at the junction block. re-using the same flat washers. Tighten to stan-
dard torque.
8. Remove the junction block from the bracket
(15) by removing the capscrews (16), washers 7. Install junction block (1) to bracket with cap-
(17), and nuts (18). screws (16), flat washers (17) and nuts (18).
Tighten to standard torque.
9. Remove the bracket (5) by removing capscrews
(3). (Re-Install capscrews and washers but do 8. Install fittings (12 & 10) into the junction block.
not tighten.) 9. Attach hoses (4, 5 & 14) onto the junction block.
NOTE: Repeat steps 10 through 13 for each of the 10. Attach the other end of the hoses to the spring
three brake assemblies. cans.
10. Remove brackets (24) with springs (11 and 12). 11. Install the hose clamps (8) onto the case with
capscrews (6) and lock washers (7). Tighten to
11. Remove capscrews (21) and flat washers (22).
standard torque.
Remove plates (19) from dowel pins (23).
12. Lift brake assembly (13) from brake disc (20).
13. Remove dowel pins (24) from assembly.
14. Loosen and remove capscrews (10) and flat
washers (28), then remove brake disc (20) from
companion flange.

FIGURE 7-1. PARKING BRAKE ASSEMBLY
1. Junction Block 8. Clamp 15. Bracket 22. Washer
2. Fitting 9. Washer 16. Capscrew 23. Dowel Pin
3. Capscrew 10. Capscrew 17. Washer 24. Bracket
4. Hose 11. Spring 18. Nut 25. Capscrew
5. Hose 12. Spring 19. Plate 26. Fitting
6. Capscrew 13. Brake Assembly 20. Disc
7. Washer 14. Hose 21. Capscrew

PARKING BRAKE SPRING CYLINDER AUTOMATIC SLACK ADJUSTER
REPLACEMENT
Adjustment Procedure
(Refer to Figure 7-2):
1. With the brake assembly in place as shown in
Figure 7-1, remove the pin (2, Figure 7-2) con-
necting the clevis (4) and slack adjuster (1).
Park the truck on level ground. Block the wheels 2. Remove the bolt (13) connecting the anchor
securely. Raise the dump body and lock in posi- bracket (11) and the slack adjuster control arm
tion. bracket (12). Position slack adjuster away from
clevis.
Removal
3. Pressurize the spring can (9) to fully extend the
1. Remove cotter pin (3, Figure 7-2), and pin (2). clevis. Verify cast arrow on the slack adjuster
2. Disconnect clevis (4) from slack adjuster (1). indicates the apply direction (towards spring
3. Loosen and remove the locking nut (6) on the can).
free end of the stud (5). 4. Turn adjuster nut (14) clockwise to align holes
4. Remove the stud from the threaded rod of the in slack adjuster and clevis.
spring can (9). 5. Rotate slack adjuster control arm bracket (12)
5. Loosen and remove the nuts (7) and flat wash- as far as possible following the radial direction
ers (8). of the cast arrow:
6. Disconnect the spring can from the brake head a. Align holes in anchor bracket and slack
(10). adjuster control arm bracket. (If necessary,
loosen nuts on anchor bracket and rotate
until holes align.)
Installation b. Install bolt (13) and tighten.
1. Install the spring can (9, Figure 7-2) securely to 6. Turn adjuster nut (14) clockwise until no clear-
the brake head (10) with flat washers (8) and ance exists between brake pads and disc.
nuts (7). 7. Turn adjuster nut counterclockwise to obtain
2. Install locking nut (5) on the stud (2). 0.040 - 0.060 in. (1.0 - 1.5 mm) between brake
3. Install the stud (5) into the threaded rod of the pads and disc. Note: a loud clicking noise will
spring can. be heard when adjuster nut is turned.
4. Place the locking nut (6) on the free end of the 8. Repeat steps 1 through 7 for the remaining
stud. Install the clevis (4) onto the stud. slack adjusters.
5. Attach the clevis to the slack adjuster (1) with 9. Start engine and allow hydraulic system to
pin (2) and cotter pin (3). reach normal operating pressure.
6. Position the slack adjuster perpendicular to the 10. Apply and release parking brake several times.
linkage by rotating the stud. Once the position is 11. With each application, the adjuster nuts will
achieved, lock the stud by tightening the two rotate a small amount. When no further rotation
locking nuts against the clevis and spring can occurs, the brake is properly adjusted. Shut
rod end. down engine.
7. Refer to Automatic Slack Adjuster, Adjustment
Procedure for final adjustment after installation
on truck.

12. Check the following:
a. Measure the stroke of the spring can push
rod. Stroke should be 1.73 - 1.89 in. (44.0 -
48.0 mm).
b. Using a feeler gauge, measure clearance
between brake pads and disc.
Minimum clearance should be 0.020 in.
(0.5 mm) per side [0.040 in. (1.0 mm)
total].
13. If clearance is less, repeat steps 1 through 12.
PARKING BRAKE CHECK-OUT

Refer to Brake Circuit Checkout in this section to
check and troubleshoot the parking brake hydraulic
circuit.

FIGURE 7-2. PARKING BRAKE ACTUATOR
1. Slack Adjuster 6. Locking Nut 11. Anchor Bracket
2. Pin 7. Nut 12. Slack Adjuster Control
3. Cotter Pin 8. Flat Washer Arm Bracket
4. Clevis 9. Spring Can 13. Bolt
5. Stud 10. Brake Head 14. Adjuster Nut

SECTION L
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-1
HYDRAULIC SYSTEM COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-1
STEERING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-1
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-1
STEERING CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-1
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-1
HOIST CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
HYDRAULIC SYSTEM FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-1
HYDRAULIC CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-1
L01033 Index L1-1

NOTES
L1-2 Index L01033

SECTION L2
HYDRAULIC SYSTEM OVERVIEW
INDEX
HYDRAULIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-3
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-3
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-3
BLEED-DOWN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-5
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-5
HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-5
BRAKE COOLING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-6
BRAKE CONTROL VALVE (BCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-6
L02040 Hydraulic System L2-1

NOTES
L2-2 Hydraulic System L02040

HYDRAULIC SYSTEM OVERVIEW
The following information describes the major com-
ponents of the hydraulic system including the hoist
circuit, steering circuit, and brake cooling circuit.
Detailed information for the hydraulic brake system
can be found in Section J of the manual. A hydraulic
system schematic can be found in Section R.
SYSTEM COMPONENTS
HYDRAULIC TANK
The hydraulic tank (Figure 2-1) is divided into two
sections. Front section (1) provides the oil supply for
the steering and brake circuits. Rear section (2) pro-
vides the oil supply for the hoist and wet disc brake
cooling oil. The total hydraulic system requires
approximately 710 liters (187.6 gal). Refer to Section
P, Lubrication and Service for the recommended oil
specification for use under various ambient tempera-
tures and tank refill capacity. The oil level should be
checked periodically with the body down, engine
stopped, and the truck parked on level ground.
FIGURE 2-2. HYDRAULIC PUMPS

1. PTO 4. Transmission Cooling
2. Hoist Pump Pump
3. Steering/Brake Pump 5. Brake Cooling Pump
In the front section of the tank, oil used for steering

and brakes flows from the bottom of the tank to the
inlet housing of the pump, mounted to the transmis-
sion pump on the lower left Power Take Off (PTO) on
the transmission.
In the rear section of the tank, oil flows from the bot-
tom of the tank to the inlet housing of hoist pump (2,
Figure 2-2), mounted on the left top of PTO (1) on the
transmission.
FIGURE 2-1. HYDRAULIC TANK

1. Tank Front Section 5. Breather Valve
2. Tank Rear Section 6. Pressure Release
3. Drain 7. Filter
4. Hoist Valve

As the truck body is raised and lowered, some tank Oil also flows from another port in the rear section of
pressurization occurs as the hoist cylinders are the tank to the inlet housing of pump (5) mounted on
retracted and oil returns to the tank. Excess pressure the right top PTO of the transmission for the brake
is relieved by breather valve (5, Figure 2-1) mounted cooling circuit.
on top of the tank.
FIGURE 2-3. STEERING CIRCUIT COMPONENTS
1. High Pressure Filter 3. Accumulators 5. Manifold

2. Bleeddown Manifold 4. Flow Amplifier Valve 6. Steering Cylinders

BLEED-DOWN MANIFOLD
Steering and brake pump (3, Figure 2-2) supplies oil
to high pressure filter (1, Figure 2-3). Filtered oil
passes through a one-way check valve, and into
bleed-down manifold (2), located on the inside left
frame rail just forward of the filter.
Oil within the bleed-down manifold is directed to
accumulators (3), flow amplifier (4), the steering con-
trol valve and steering cylinders (6), via flow amplifier
(4). Oil is also supplied from the bleed-down manifold
to the wet disc brake system for service brake appli-
cation.
The steering and brake pump has a compensator set
at 18, 961 kPa (2750 psi) to regulate the steering and
brake pressure. Oil returning from the steering and
brake circuits flows back to tank (1, Figure 2-4)
through diffuser (5) mounted in the bottom of the
tank.
FIGURE 2-4. HOIST VALVE

HOIST VALVE
1. Hydraulic Tank 4. To Hoist Pilot Valve
Hoist valve (2, Figure 2-4) is located on the rear of
2. Hoist Valve 5. Diffusers
the hydraulic tank, between the tank and the left
3. Hoist Pilot Valve (Inside Tank)
frame rail. The hoist valve is controlled by a hoist
Supply
pilot control valve that is located in the hydraulic cab-
inet on the center deck. The hoist valve controls oil
flow to the hoist cylinders to raise the dump body
when requested by the operator.
HOIST PUMP
Oil from tandem gear pump (2, Figure 2-2), mounted
on the left side of the transmission PTO, is directed
to the split spool hoist valve. Whenever the truck
body is not being raised, the oil is directed through
the rear brake cooling circuit before returning to tank.
On its path it will pass through a pair of filters and a
heat exchanger. This circuit also utilizes a Brake
Control Valve (BCV). If the rear brakes are not
applied, 50% of the oil returning from the hoist valve
will be bypassed around the rear brake cooling circuit
and flow directly to tank.
An internal, adjustable relief valve protects the hoist
circuit from pressures in excess of 18, 961 kPa (2750
psi).

BRAKE COOLING PUMP LOW PRESSURE FILTERS
Tandem gear pump (5, Figure 2-2), mounted on the The truck is also equipped with three low pressure fil-
right side of the transmission PTO, directs oil flow to ters, for the hoist and brake cooling circuits. All three
the front and rear brake cooling circuits. The front filters have a built in bypass system which also acti-
(drive shaft end) section provides oil for the front vates a display message on the EDP when the differ-
brake circuit while the other section provides oil for ential pressure indicates by-pass for any of the filters.
the rear brake circuit.
The filter elements must be changed as soon as pos-
sible after the indicator alert, before actual by-pass
occurs. For the regular filter service interval, refer to
BRAKE CONTROL VALVE (BCV) Lubrication and Service, Section P, or replace when
Each circuit has its own BCV. If the brakes are not the indicator light turns on.
applied, 50% of the cooling oil is bypassed around
the brakes and heat exchanger to be returned
directly to the tank. This reduces power loss caused
by excessive oil flowing through the brake housing.
Also built into the BCV's is a relief valve which will
activate at 883 kPa (128 psi). When actuated, the
pilot relief valve will cause the main relief valves to
open allowing the excess oil to return to tank.
HIGH PRESSURE FILTERS

The truck is equipped with one high pressure filter
with a Beta 12 = 200 rating, for the steering and
brake system. The filter assembly has a built-in
bypass system which activates a message on the
character display in the Electronic Display Panel
(EDP) when the differential pressure across the filter
exceeds 241 kPa (35 psi).
The filter must be changed as soon as possible after
the indication on the EDP, before actual by-pass
occurs. For the regular filter service interval, refer to
Lubrication and Service, Section P, or sooner if the
indicator light turns on.

SECTION L3
HYDRAULIC SYSTEM COMPONENT REPAIR
INDEX
HYDRAULIC COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
FILLING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-6
Gap Measurement - Hydraulic Tank Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-6
STRAINERS AND DIFFUSERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-8
HYDRAULIC TANK BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-9
HYDRAULIC SYSTEM FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-9
HYDRAULIC PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-11
PUMP REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-12
Inspection Of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-15
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-18
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-18
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-21
L03036 Hydraulic Component Repair L3-1

NOTES
L3-2 Hydraulic Component Repair L03036

HYDRAULIC COMPONENT REPAIR
HYDRAULIC TANK
FILLING INSTRUCTIONS
1. Lower the dump body, and turn the key switch
OFF.
The hydraulic tank may be pressurized! Depress

the hydraulic tank relief valve and slowly remove
the fill cap to remove any internal pressure.
2. Depress relief valve (2, Figure 3-1) for 30 - 45
seconds to release any internal tank pressure.
Slowly remove fill cap (4) to release any resid-
ual tank pressure.
3. Using a filtered (3 micron) filling apparatus, fill
the tank with the recommended oil, until oil is
visible in top sight glass (5). Refer to Section P,
Lubrication and Service, for oil specifications.
NOTE: The capacity of the hydraulic tank is 576 liters 1. Hydraulic Tank 5. Upper Sight Glass
(152 gal.) 2. Pressure Relief Valve 6. Lower Sight Glass
3. Breather 7. Drain Valves
4. Install the fill cap. 4. Filler Cap
5. Start the engine, and raise and lower the dump
body two to three times to circulate oil and fill
the system.
OFF. If the oil level falls below lower sight glass
(6), repeat the procedure. MAINTENANCE

the hydraulic tank relief valve and slowly remove
the fill cap to remove any internal pressure.
1. When servicing the tank or oil, inspect breather
(3, Figure 3-1). Clean accumulations of dirt,
mud, etc. from around the breather. Clean or
replace the breather element as necessary.
2. Whenever oil is drained from the tank, clean dif-
fusers (7 & 11, Figure 3-2) and strainers (8, 9, &
10).

Removal
DO NOT open the hydraulic system until the

engine is stopped and the key switch has been
OFF for at least 90 seconds.
Pressurized hydraulic fluid can have sufficient
force to enter a person's body by penetrating the
skin. This can cause serious injury and possibly
death. Seek proper medical treatment by a physi-
cian familiar with this type of injury, immediately.
Avoid contact with hot oil if truck has been oper-
ating. Properly contain oil and plug all openings.
1. Turn the key switch OFF and allow at least 90

seconds for the steering accumulators to
depressurize.
2. Thoroughly clean the outside of the hydraulic
tank and adjacent components.
3. Drain hydraulic tank (1, Figure 3-1) by opening
FIGURE 3-2. HYDRAULIC TANK (TOP VIEW)
drain valves (7) located in the bottom of the
tank. The capacity of the hydraulic tank is 1. Hydraulic Tank 7. Diffusers
approximately 576 liters (152 gal). 2. Pressure Relief Valve 8. Strainers
NOTE: If oil is to be re-used, clean containers must 3. Breather 9. Wire Mesh Strainer
be used with a filtering system available for refill. 4. Filler Cap 10. Strainer
5. Sight Glass Guard 11. Diffuser
6. Access Cover
4. Disconnect the hydraulic lines from the tank.
Plug the lines to prevent spillage and possible
contamination to the system. Tag each line for
proper identification during installation.
5. Attach appropriate lifting apparatus to the
hydraulic tank. The tank weighs approximately
700 kg (1543 lb).
6. Remove the cap screws and lockwashers
securing the hydraulic tank to the frame. Refer
to Figure 3-3.
7. Lift the hydraulic tank from the truck and move
to a clean work area for disassembly or repair.

FIGURE 3-3. HYDRAULIC TANK MOUNTING
1. Tank Mount 4. Cap Screw 7. Spacer
2. Nut 5. Hydraulic Tank 8. Cap Screw
3. Washer 6. Cap Screw 9. Shim

Installation 5. Install shims, accordingly.
1. Attach appropriate lifting apparatus to the 6. Install spacers (7, Figure 3-3) and the lower
hydraulic tank. The tank weighs approximately mounting hardware. Tighten the cap screws to
700 kg (1543 lb). 549 55 Nm (405 40 lb ft).
2. Lift the hydraulic tank into position on the truck. 7. Uncap the hydraulic lines and attach to the
Secure with the four upper cap screws and proper connections.
lockwashers, only. DO NOT install the lower 8. Fill the tank with hydraulic oil. The capacity of
cap screws at this time. the hydraulic tank is approximately 576 liters
(152 gal). Refer to Section P, Lubrication and
Gap Measurement - Hydraulic Tank Mounting Service for oil specifications.
3. TIghten the upper mounting capscrews to 549 9. Purge the air from the hydraulic pump suction
55 Nm (405 40 lb ft). lines before starting engine.
4. Measure the gaps (dimension X, Figure 3-4)
behind the two lower mounting cap screw holes.
If either of the gaps exceed 0.397 mm (0.0156
in.), shims are required. Use the larger of the
two gaps to determine a shim pack.
FIGURE 3-4. HYDRAULIC TANK MOUNTING - GAP MEASUREMENT

STRAINERS AND DIFFUSERS
Removal
seconds for the steering accumulators to
depressurize.
2. Thoroughly clean the outside of the hydraulic
tank and adjacent components.
tank. The capacity of the hydraulic tank is
approximately 576 liters (152 gal).
NOTE: If oil is to be re-used, clean containers must
be used with a filtering system available for refill.
4. Remove the nuts and lock washers securing

the pump inlet line and return line to the hydrau-
lic tank. Plug or cap the lines to prevent contam-
ination.
5. Remove cap screws (8 & 13). Remove covers
(8, 9, and 14) and the gaskets.
6. Remove strainers (9 & 11) and diffusers (6) FIGURE 3-5. STRAINER/DIFFUSER SERVICE
from the hydraulic tank. 1. Hydraulic Tank 9. Strainers
7. Remove diffuser (3, Figure 3-6) from the 2. Pressure Relief Valve 10. Wire Mesh Strainer
hydraulic tank. 3. Breather 11. Strainer
8. Remove cap screws and washers (1) securing 4. Filler Cap 12. Cover
cover (2) to the hydraulic tank. Remove the 5. Access Cover 13. Cap Screws
cover and gasket. 6. Diffusers 14. Oil Drain
7. Cover 15. Diffuser
9. Remove wire mesh strainer (10, Figure 3-5). 8. Cap Screws

1. Inspect the strainers and diffusers thoroughly
for metallic particles. The quantity and size of
any particles found may provide an indication of
excessive component wear in the hydraulic sys-
tem.
2. Clean the strainers with cleaning solvent. Clean
from the inside out.
3. Inspect the strainers for cracks or damage.
Replace, if necessary.
4. Clean the diffusers with cleaning solvent Clean
from the outside inward.
5. Inspect the diffusers for cracks or damage.
Replace, if necessary.
6. Clean any sediment from the bottom of the
hydraulic tank.

7. Fill the tank with hydraulic oil. The capacity of
the hydraulic tank is approximately 576 liters
(152 gal). Refer to Section P, Lubrication and
Service for oil specifications.
8. Loosen the connection at the hydraulic pump
inlets to purge trapped air from the inlet line and
make sure pump housing is filled with oil.
Tighten the pump inlet connections.
9. Start the engine, and raise and lower the dump
body two to three times to circulate oil and fill
the system.
OFF. If the oil level falls below the lower sight
glass, add oil and return to the previous step.
HYDRAULIC TANK BREATHER

The hydraulic tank breather is mounted on the top
cover of the hydraulic tank access cover. The
FIGURE 3-6. SIDE COVER AND DIFFUSER breather relieves internal tank pressure if pressure it
reaches 69 kPa (10 psi). A vacuum relief valve in the
1. Cap Screws & 2. Cover
breather allows the system pumps to pick up oil
Washers 3. Diffuser
when no pressure is present in the tank.
The breather must be serviced every 250 hours of
operation.
Installation
1. Install strainers (9 & 11, Figure 3-5) and diffus-
ers (6).
2. Install covers (7 & 12) and new gaskets. Install
cap screws (8 & 13). Tighten to standard
torque.
3. Install diffuser (3, Figure 3-6) into the hydraulic
tank.
4. Install strainer (10, Figure 3-5).
5. Place cover (2) and a new gasket into position
on the hydraulic tank. Install cap screws and
washers (1). Tighten the cap screws to stan-
dard torque.
FIGURE 3-7. HYDRAULIC TANK BREATHER
6. Connect the inlet and outlet lines to the proper
ports on the tank. 1. Snap Ring 3. Element
2. Cover

Service
1. Shut off the engine. Relieve internal pressure 6. Move all controls to the NEUTRAL position. Do
using the relief valve on top of the hydraulic not steer the truck or operate controls.
tank. 7. Start the engine, and operate at 1000 rpm for
2. Clean dirt accumulations from the area around four minutes. This will circulate oil with all of the
the breather. valves in the NEUTRAL position.
3. Remove the breather from the tank. 8. To increase flow and turbulence in the system,
increase engine speed to full throttle and main-
4. Remove snap ring (1 Figure 3-7), cover (2), and
tain for four minutes. This will carry contami-
filter element (3).
nates to the hydraulic tank.
5. Clean the breather in solvent and thoroughly
9. Shut the engine off. Allow at least 90 seconds
dry.
for the accumulators to depressurize. This will
6. Install a new filter element. Lubricate the O- return all contaminants in the accumulators to
rings with clean hydraulic oil during assembly. the hydraulic tank.
7. Install the breather onto the hydraulic tank.
NOTE: Normal hydraulic tank oil temperature is 43-
54C (110-130F). If the temperature is not in this
range, repeat Step 8 to increase oil temperature to
the proper operating range.
HYDRAULIC SYSTEM FLUSHING
The following instructions outline the procedure for 10. Start the engine and operate at 1000 rpm while
flushing the hydraulic system. performing the following:
NOTE: If a system component fails, perform an oil a. Steer the truck full left then full right and
analysis before replacing components. If foreign repeat four times.
particles are present, the system must be flushed. b. Steer full left, keeping pressure against the
Remove all flexible hoses and backflush with steering wheel at the stop. Hold for 10 sec-
cleaning solvent. Check for small particles which onds.
may be trapped inside the hoses.
c. Steer full right keeping pressure against the
1. Shut the engine off. Allow at least 90 seconds steering wheel at the stop. Hold for 10 sec-
for the accumulators to bleed down. Verify the onds.
system is void of pressure by turning the steer-
11. Increase engine speed to full throttle and steer
ing wheels. The wheels should not move.
full left, and then full right.
2. Thoroughly clean the exterior of the hydraulic
tank. Drain the tank and remove the top cover. 12. Return all controls to NEUTRAL.
Flush the interior of hydraulic tank with a clean- 13. Reduce engine speed to 1000 rpm and perform
ing solvent. the following:
3. Inspect all hydraulic hoses for deterioration or a. Fully extend the hoist cylinders, and then
damage. allow the cylinders to float down. Repeat four
4. Remove, clean and install the hydraulic tank times.
strainers. Replace the hydraulic filter elements.
NOTE: As the third stage exits the cylinder housing,
5. Fill the hydraulic tank with clean filtered hydrau- slowly decrease engine speed to prevent full
lic oil. Replace top cover. The final filter in the extension.
filling apparatus must be 3 micron.

b. Extend the hoist cylinders and hold at full HYDRAULIC PUMPS
extension for 10 seconds. The hoist control
lever must be held in the RAISE position. Hoist pump (2, Figure 3-8) and brake cooling pump
(7) are similar in design. The following removal,
c. Lower hoist cylinders and hold lever in the installation and rebuild procedures are applicable to
LOWER position for 10 seconds after cylin- both pumps. Pump rebuild instructions are also appli-
ders are fully retracted. cable to both pumps.
Removal
1. Turn key switch OFF and allow at least 90 sec-
onds for the accumulators to bleed down.
DO NOT continue to hold in RAISE/LOWER.
Excessive hydraulic oil heating can occur.
14. Increase engine speed to full throttle and per-
form the following:
a. Raise the cylinders to full extension, then
DO NOT open the hydraulic system until the
allow the body to float down.
engine is stopped and the key switch has been
b. Return the hoist control to NEUTRAL. OFF for at least 90 seconds.
15. Shut the engine off. Allow at least 90 seconds Pressurized hydraulic fluid can have sufficient
for the accumulators to depressurize. force to enter a person's body by penetrating the
16. Remove the hydraulic filters. Clean the hous-
death. Seek proper medical treatment by a physi-
ings and install new filters.
cian familiar with this type of injury, immediately.
17. With the hydraulic system charged, inspect all
connections and fittings for leaks. Tighten or Avoid contact with hot oil if truck has been oper-
repair any leaking connections. Refill the ating. Properly contain oil and plug all openings.
hydraulic tank if necessary.
tank. The capacity of the hydraulic tank is
approximately 576 liters (152 gal).
NOTE: If oil is to be re-used, clean containers must
be used with a filtering system available for refill.
3. Loosen the cap screws securing the pump suc-
tion hoses to the pump and allow the oil to
drain. Remove the suction hoses and cap to
prevent contamination of the hydraulic system.
4. Disconnect the pump outlet lines. Cap the lines.
5. Attach a suitable lifting device to the pump. The
weight of the pump is approximately 55 kg (121
lb).

Installation
6. Remove cap screws and lock washers securing 1. Install a new O-ring onto the pump.
the pump to the torque converter. Remove the 2. Attach a suitable lifting device to the pump. The
pump. weight of the pump is approximately 55 kg (121
7. Move the pump to a clean work area for disas- lb).
sembly. 3. Lift the pump into position onto the mounting
studs. Install the washers and nuts. Tighten the
nuts evenly to standard torque.
4. Install new O-rings onto the suction hoses and
outlet hoses. Place the hoses into position.
Install the cap screws and washers, but do not
tighten.
5. Refill the hydraulic tank.
6. Loosen the suction hose flange clamps until air
is discharged from the lines. Tighten all hose
flange clamp cap screws to standard torque.
7. Start the engine, and check for leaks. Ensure
the proper hydraulic tank oil level is maintained.
Refer to Filling Instructions earlier in this chap-
ter.
FIGURE 3-8. PUMP REMOVAL AND

INSTALLATION
1. Suction Hoses 5. Hoist Valve
2. Hoist Pump 6. PTO
3. Outlet Hoses 7. Brake Cooling Pump
4. Brake Control Valve
(BCV)

FIGURE 3-9. HYDRAULIC PUMP ASSEMBLY
(Hoist Pump Shown)
1. Front Drive Gear 7. O-Ring 13. Stud 19. O-Ring
2. Snap Ring 8. Bearing Plate 14. Nut 20. O-Ring
3. Seal 9. Splined Coupling 15. Flat washer 21. Steel Ball
4. Plug 10. Rear Drive Gear 16. Rear Idler Gear 22. Front Idler Gear
5. Flange Plate 11. Body (Rear) 17. O-Ring
6. Body (Front) 12. Cover Plate 18. Dowel Pin
PUMP REBUILD Disassembly

The following rebuild procedures are applicable to 1. Thoroughly clean the outside of the pump.
both the hoist circuit pump and the brake cooling cir- 2. Place the pump on a workbench and mark the
cuit pump. pump sections on the side nearest the drive
This rebuild procedure describes the disassembly, shaft extension. These marks will be used for
inspection, and reassembly for a typical gear type correct matching of parts during assembly.
pump as used on this truck. Slight design variations 3. Remove nuts (14, Figure 3-9) and washers
may be noted. Refer to the Parts Manual for actual (15).
parts installed and for seal service kits available. 4. Remove flange (5). If the flange is stuck, use a
plastic hammer or wooden mallet to tap the
edges of the flange.
NOTE: If shaft seal replacement only, is required,
further disassembly is not necessary. Refer to Seal
Replacement for instructions.

FIGURE 3-10. ISOLATION PLATE REMOVAL FIGURE 3-11. DRIVE GEAR REMOVAL
1. Isolation Plate 3. Backup Ring 1. Drive Gear 2. Pressure Plate

2. O-Ring 4. Ring Retainer
8. Examine the gear bores in body (1, Figure 3-

12):
5. Remove ring retainer (4, Figure 3-10), O-ring During the initial break-in at the factory the
(2), back-up ring (3), and isolation plate (1). gears cut into body. The nominal depth of this
6. Grasp the drive gear shaft extension (1, Figure cut is 0.20 mm (.008 in.) and should not exceed
3-11) and lift it upward to dislodge pressure 0.38 mm (.015 in.). As the gear teeth cut into
plate (2). Grasp the plate between thumb and the housing, metal is rolled against the pressure
forefinger and lift it straight off the shafts. plates.
NOTE: As parts are removed from each pump Using a knife or sharp pointed scraper, remove
section, lay out in separate groups and in the same the metal that was rolled against the top pres-
order in which removed. sure plate. Remove the metal that is rolled
against the pressure plate in the bottom of the
body. Blow out the metal chips that were broken
7. Lift the drive gear and the idler gear straight out loose. This will help to keep the pressure plate
of the bore of the body. from hanging as it is lifted from the bottom of
the gear bores.
When removing the rolled up metal, do not

attempt to remove gear track-in grooves.

10. Remove the ring retainer, O-ring, back-up ring,
and isolation plate located under the pressure
plate.
11. Lift the body straight off of the studs. If the body
is stuck on the dowels, use a plastic hammer or
wooden mallet to tap around the body.
12. Remove spline coupling (9, Figure 3-9) from the
rear drive shaft.
NOTE: Some pumps have O-rings (19) installed
around the studs in the top surface of bearing plate
(8). These O-rings are used to prevent vibration on
the studs during load conditions.
13. Remove the O-rings and lift the bearing plate
off. It may be necessary to tap the plate lightly
with a mallet to loosen it from the dowels.
14. To complete the disassembly of the pump
repeat previous steps as applicable for the rear
section.
FIGURE 3-12. GEAR BORE INSPECTION 15. Refer to Seal Replacement for flange plate seal
1. Body 2. Gear Track-in removal instructions.
Grooves
9. Insert an expandable bearing puller (1) in the

shaft bore of the plate to remove bottom pres-
sure plate (2, Figure 3-13). Tighten the puller.
a. Apply a light forward and back force to the
puller handle to dislodge the plate.
b. Lift the plate straight up and out.
NOTE: If a bearing puller is not available, grind a
screwdriver shape on the short end of an Allen
wrench. Insert the ground end of the wrench into the
shaft bore and lift the plate up. Move the wrench to
the opposite bore and lift up, repeating this action
until the plate has been dislodged. With thumbs in
the bores of the plate, lift it straight up and out.
Use extreme care when removing the plate. DO

NOT pry or force. If the plate is seized, work it up
and down until free. Then lift the plate out of the
bore. FIGURE 3-13. PRESSURE PLATE REMOVAL
1. Bearing Puller 2. Pressure Plate

Inspection Of Parts
1. Inspect the gear bores in the pump bodies. Dur-
ing initial break-in at the factory, the gears cut
into the housing. The nominal depth of this cut
is 0.20 mm (.008 in.) and should not exceed
0.38 mm (.015 in). Due to the hydraulic loading
of the gears, the cut will start on the suction side
of the body and will continue about one third of
the way around each gear bore. The cut should
be smooth with no deep grooves or deep
scratches. Reject the body if the depth of the
groove is greater than 0.38 mm (.015 in.), or if
the gear bores look like they have been sand
blasted. Reject the body if it is cracked or other-
wise damaged.
2. Examine the pressure plates The plates should
not have excessive wear on the bronze side. If
deep curved wear marks are visible, the plates
must be replaced.
3. Examine the gears. If excessive wear is visible FIGURE 3-14. ISOLATION PLATE INSTALLATION
on any part of the gear, replace with new parts.
1. Isolation Plate (Rounded Edge)
Assembly
1. Install the flange plate seal. Refer to Seal
Replacement for instructions.
2. Position rear pump body (11, Figure 3-9) so that
the orientation mark is visible. If a new body
must be used, ensure the same side is visible.
NOTE: Observe that the body has a wide and a
narrow boss. The side having the wide boss is
always the suction side of the body.
3. Coat the inside of pump body (11) with clean
hydraulic oil.
4. Examine the two isolation plates from the rear
section. The plates are slightly different.
Choose the plate with the rounded edge indi-
cated by the arrow in Figure 3-14. With the
rounded edge down, install the plate on the suc-
tion side in the bottom of the body.
5. Install back-up ring (7, Figure 3-15), O-ring (6),
and ring retainer (2). FIGURE 3-15. ISOLATION PLATE ASSEMBLY
1. Pump Body 5. Isolation Plate
2. Ring Retainer 6. O-Ring
3. Stud 7. Back-up Ring
4. Dowel Pin 8. Drive Gear

6. With the bronze side facing up and the rounded
trap slots toward the outlet side of the body,
slide pressure plate (2, Figure 3-16) down into
the gear bores. Position the plate so that it rests
firmly at the bottom of the pump body. Do not
force the plate into the gear bores. If the plate
binds, work it back and forth carefully until it
slides freely into position.
7. Coat rear drive gear (10, Figure 3-9) with clean
hydraulic oil. With the splined end up, install the
drive gear in the bore nearest the orientation
mark.
8. Coat rear idler gear (16) with clean hydraulic oil
and install it in the bore opposite the drive gear.
FIGURE 3-17. REAR DRIVE GEAR POSITIONING
1. Rear Drive Gear 2. Body Dowel Pin
9. Install dowels (18, Figure 3-9) in body (11).

10. Before continuing, the rear set of gears must be
positioned for proper timing with the front set of
gears. Refer to Figure 3-17.
a. Rotate the gears until the point of a tooth on
the drive gear is in line with the center of the
dowel nearest the drive gear. (See arrows)
b. This set of gears must remain in this position
until all remaining parts have been assem-
FIGURE 3-16. PRESSURE PLATE INSTALLATION bled.
1. Outlet Side (Body) 3. Trap Slots 11. With the bronze side facing down and the
2. Pressure Plate 4. Inlet Side(Body) rounded trap slots toward the discharge side of
the body, install the pressure plate over the rear
drive and idler gears.

12. Install the isolation plate on the suction side of
the pump body. Install the back-up ring, O-ring,
and the ring retainer.
13. Install the bearing plate. The side with the bear-
ing protrusion must face up. Install O-ring (7,
Figure 3-9). Use petroleum jelly to hold the O-
ring in the groove.
14. Align the orientation marks and install bearing
plate (8) with the O-ring facing downward. Slide
the bearing plate onto the shafts until the plate
contacts the dowels. Align the plate with the
dowels, and gently tap the plate with a plastic
hammer until the O-ring rests firmly against rear
pump body (11).
15. Install the spline coupling and snap ring (9).
16. Lubricate the threads of studs (13). Tighten the
studs until snug.
17. If equipped install stud O-rings (19).
FIGURE 3-18. FRONT DRIVE GEAR TIMING
18. Install O-ring (7) and dowels (18) in the bearing
plate. 1. Front Drive Gear 2. Tooth Valley
19. With the gear bores facing up and the orienta-

tion marks aligned, slide front pump body (6)
onto the studs. Position the body firmly onto the
O-ring in the bearing plate.
22. The rear set of gears was already positioned for
20. Install dowels (16) in body (3). timing. The drive gear in the front section must
21. Repeat the applicable steps to assemble the now be correctly positioned.
front section. Proceed to the next step for gear a. With the extension end of drive gear (1, Fig-
timing. ure 3-18) up, slide the gear down to the
splined coupling.
b. Before inserting the shaft spline into the cou-
pling, rotate the shaft until a valley (as shown
by the arrow in Figure 3-18) between two
gear teeth is lined up with the center of the
dowel nearest the gear.
c. If the spline will not enter the coupling with
the gear aligned, lift the shaft and rotate it to
the next valley. Continue to do this until the
proper alignment is achieved.

23. Install idler gear (22, Figure 3-9) and the pres- Bearing Replacement
sure plate. Position the bronze side of the plate
If the bearings are worn down to the bronze material,
downward and the traps facing the discharge
the complete flange or body housing must be
side of this body.
replaced. Installing a new bearing in an old flange or
24. Install the isolation plate, back ring, O-ring, and body is not recommended.
ring retainer over the pressure plate.
25. Install O-ring (20) in flange plate (5). Use petro-
leum jelly to hold the O-ring in the groove. Seal Replacement
26. If the drive shaft extension is keyed, cover the Seal kits are available for replacing the shaft seals
keyway with tape. If the drive shaft extension is only, if desired. If only the shaft seals are to be
splined, coat the spline with petroleum jelly. replaced, refer to disassembly and assembly instruc-
This will prevent damage to the sealing lips as tions for removal procedures for the flange plate only.
the flange plate and seals are installed. Complete pump disassembly is not required.
27. With the O-ring in flange plate (5) facing down-
ward, slide the flange plate over the studs and
1. Remove the snap ring from the bore. Lay the
shafts. Slide the plate until it contacts the dow-
flange plate on a work bench as shown in Fig-
els in the pump body. Use a plastic hammer to
ure 3-19. Position the input side down. To pre-
gently tap the flange plate into position.
vent the machined surfaces from being dented
28. Lubricate the threads on the two opposite studs. or scratched use a piece of clean wood, heavy
Install washers (15) and nuts (14). Tighten the cardboard, or other suitable material between
nuts to 217 - 237 Nm (160 - 175 lb ft). the plate and the work surface.
29. Use an adjustable wrench to turn the drive 2. Use a punch and mallet to tap the old seal(s)
shaft. The shaft should turn at a maximum of 7 - out of the bore. Refer to Figure 3-20.
14 Nm (5 - 10 lb ft).
30. If the shaft does not turn properly, disassemble
the pump and examine the parts. Check for
burrs or foreign material causing build-up or
interference between the parts. Remove the DO NOT scratch the bore surfaces. DO NOT
cause of the interference and reassemble the scratch the bearing surfaces and/or their end
pump. projections.
31. After verifying proper shaft rotation, lubricate
the threads on the studs. Install the remaining 3. Drive the seal out by moving the punch around
nuts and washers. Tighten the nuts to 217 - 237 the seal as it is pushed out of the bore.
Nm (160 - 175 lb ft) in an alternating, progres- 4. If the flange contains two (double) seals,
sive pattern. remove the outer seal completely before
attempting removal of the inner seal. After the
outer seal is out, remove the snap ring, and
then remove the inner seal.

5. Clean the bore thoroughly and inspect for
scratches or gouges which might interfere with
installation of the new seal.
6. If necessary, the bore may be smoothed with
No. 400 emery paper. Clean the bore again
afterwards.
7. Use a suitable seal press, and two wooden
blocks for installing the new seals. Use 25 mm x
100 mm (1 in. x 4 in.) blocks, approximately 250
mm (10 in.) long.
FIGURE 3-19. SEAL REMOVAL PREPARATION

1. Flange 3. Wooden Blocks
2. Bearings FIGURE 3-20. SHAFT SEAL REMOVAL
1. Flange 3. Bearings
2. Punch
8. The following procedures are outlined for use

with a vise, but they can be adapted to the use
of a press if an appropriate one is available.
9. Open the vise jaws wide enough to accept the
combined thickness dimensions of the flange,
the wood blocks and the press ring (or plug).
10. Place the two wood blocks flat against the fixed
jaw of the vise. Refer to Figure 3-21. Place
flange plate (1) against the blocks in such a
position that the bearing projections (3) are
between the blocks and clear of the vise jaw.

11. The flange requires two replacement seals.
Position the first seal so that the rubber face
enters the bore first; the second seal should
enter the same way.
12. Place the press ring in position, centered over
the seal. Ensure the seal stays centered with
the bore while applying pressure with the vise.
Continue until the seal just clears the snap-ring
groove in the bore.
13. Open the vise and remove the press ring. Install
the snap-ring in its groove in the bore so that
the weep-hole is directly over the gap in the
snap-ring.
14. Verify the snap-ring is seated properly in the
groove. Observe orientation and positioning
procedures outlined in Steps 11 and 12, and
install the second seal in the bore. Press the
seal in until it bottoms against the snap-ring.
FIGURE 3-21. SEAL INSTALLATION (VISE)
15. Remove the flange plate from the vise. Wash
the plate and blow it dry.
1. Flange Plate 3. Bearing Projection
2. Wooden Blocks

TROUBLESHOOTING GUIDE
Hoist Pump
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
1. Sandblasted band around pres- Was clean oil used?
sure plate bores
2. Angle groove on face of pressure Was filter element change period
plate correct?
3. Lube groove enlarged and edges Abrasive wear caused by fine parti- Were correct filter elements used?
rounded cles - dirt (fine contaminants, not
4. Dull area on shaft at root of tooth visible to the eye). Hoist cylinder rod wiper and seals in
good condition?
5. Dull finish on shaft in bearing area Cylinder rods dented or scored?
6. Sandblasted gear bore in housing Was system flushed properly after
previous failure?
1. Scored pressure plates Was system flushed properly after
previous failure?
2. Scored shafts Abrasive wear caused by metal par- Contaminants generated elsewhere
ticles - (coarse contaminants, visible in hydraulic system?
to the eye).
3. Scored gear bore Contaminants generated by wearing
pump components?
1. External damage to pump Interference between pump and
adjacent components?
2. Damage on rear of drive gear and Incorrect pump installation Did shaft bottom in mating part?
rear pressure plate only
1. Eroded pump housing Tank oil level correct?
2. Eroded pressure plates Oil viscosity correct?
Aeration-cavitation
a. Restricted oil flow to pump Restriction in pump inlet line?
b. Aerated oil Air leak in pump inlet line?
Loose hose or tube connection?
1. Heavy wear on pressure plate Was oil level correct?
2. Heavy wear on end of gear Lack of oil Tank strainers restricted?
1. Housing heavily scored Metal object left in system during ini-
tial assembly or previous repair?
2. Inlet peened and battered Damage caused by metal object Metal object generated by another
failure in system?
3. Foreign object caught in gear
teeth
1. Pressure plate black Metal object left in system during ini-
tial assembly or previous repair?
2. O-rings and seals brittle Excessive heat Was relief valve setting too low?
3. Gear and journals black Oil viscosity correct?
Oil level correct?
1. Broken shaft Overpressure Relief valve setting correct?
2. Broken housing or flange Relief valve functional?

NOTES

SECTION L4
STEERING CIRCUIT
INDEX
STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-3
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-3
Bleed-down Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-3
Bleed-down Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-4
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-5
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-5
High Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-5
Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-5
FLOW AMPLIFIER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-7
STEERING/BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-15
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-17
L04050 Steering Circuit L4-1

NOTES
L4-2 Steering Circuit L04050

STEERING CIRCUIT
OPERATION COMPONENT DESCRIPTION

The steering and brake pump supplies oil to bleed- Steering Control Valve
down manifold (2, Figure 4-1). The bleed-down man-
ifold supplies oil to steering accumulators (3) and the The steering control valve is mounted in the front
steering control valve via flow amplifier (4). Oil enter- compartment of the of the cab, behind the access
ing the accumulators pushes the floating pistons panel.
within the accumulators upward, compressing the Operation of the steering valve is both manual and
nitrogen on the opposite side of the pistons. The hydraulic. The steering valve incorporates a hydrau-
nitrogen pressure increases directly with steering cir- lic control valve. Manual steering effort applied to the
cuit pressure. The top side of the pistons are pre- steering wheel by the operator actuates the valve.
charged to 9,653 kPa (1400 psi) with pure dry nitro- The valve directs hydraulic oil through the flow ampli-
gen. When the steering circuit pressure reaches fier valve to the steering cylinders to provide the
18,961 kPa (2750 psi), each accumulator will contain operator with power steering.
approximately 23 l (4 gal.) of hydraulic oil. The accu-
mulators supply hydraulic oil to the steering circuit in
an emergency situation when steering pump pres-
sure is lost. Bleed-down Manifold
The steering circuit pressure is normally maintained
at 18,961 kPa (2750 psi) by the compensator located
in the steering/brake pump. Should a malfunction
occur and system pressure exceed this setting, the
bleed-down manifold relief valve will relieve the pres-
sure at 22,408 kPa (3250 psi).
If a loss in steering pressure occurs, stop the
truck, immediately. Pressure in the accumulators The bleed-down solenoid will relieve pressure con-
allows the operator to steer the truck only for a tained in the steering accumulators each time the key
short period. DO NOT attempt further operation switch is turned to the OFF position.
until the problem is located and corrected. The check valve in the supply port allows flow to
enter the bleed-down manifold, but blocks reverse
flow back to the pump in the event of pump failure.
Hydraulic oil from the bleed-down manifold flows to All check valves, relief valves and the bleed-down
the closed center steering control unit via the flow solenoid are replaceable. Valves and solenoids are
amplifier. Oil entering the steering control unit is replaced as a unit and are not repairable.
blocked until the steering wheel is turned. The steer-
ing control unit then directs oil to the flow amplifier
and then to the steering cylinders. Return oil from the
steering cylinders flows back through the flow ampli-
fier and bleed-down manifold. The oil then flows
through the low pressure filters to be cleaned before
returning to the hydraulic tank.

FIGURE 4-1. STEERING CIRCUIT COMPONENTS
1. High Pressure Filter 3. Accumulators 5. Manifold
2. Bleed-down Manifold 4. Flow Amplifier Valve 6. Steering Cylinder
Bleed-down Solenoid
Each time the key switch is turned OFF, it activates a After approximately 90 seconds, the timer will de-
timer that energizes the bleed-down solenoid. When energize to close the return port to tank. By this time
the bleed-down solenoid is energized, all hydraulic all the oil in the accumulators should have returned
steering pressure, including the accumulators, is to tank.
purged back to the hydraulic tank.

Accumulators High Pressure Filter
The accumulators are bladder type accumulators. The high pressure filter is a secondary filtering sys-
The top side of the accumulators are charged to tem, filtering oil for the steering and brake apply cir-
9653 kPa (1400 psi) with pure dry nitrogen. Oil enter- cuits. Oil is filtered through a Beta 12=200 filter to
ing the accumulators pushes the bladder upward reduce the possibility of contamination and subse-
compressing the nitrogen on the top side. The nitro- quent damage to the hydraulic system.
gen pressure increases directly with steering circuit
pressure. When steering circuit pressure reaches If flow through the steering filter is restricted, a switch
18,961 kPa (2750 psi), the accumulators will contain located on the filter housing will turn on the machine
approximately 23 l (4 gal.) of pressurized oil available monitor lamp. Steering circuit filter element restriction
for steering the truck. The accumulators also provide will be recorded and can be displayed on the Elec-
oil to be used in case of an emergency situation tronic Display Panel (EDP). The indicator may acti-
should the pump become inoperative. vate when oil in the system is cold. If this occurs, the
light should turn off when system oil warms. If the
A pressure switch for the steering oil is located above warning is active after the oil reaches normal operat-
the bleed-down manifold. The switch is normally ing temperature, notify maintenance personnel
closed and is used to activate a warning buzzer and immediately.
a red warning light when the key switch is turned to
the ON position. These alarms are used to alert the Change the high pressure filter element every 1000
operator that steering circuit pressure is less than hours or when notified by the warning indicator.
12,755 kPa (1850 psi).
At the top of each accumulator is another pressure
Warning Devices
switch. These pressure switches are used to activate
the accumulator warning light when the nitrogen Several methods are used to warn the operator of
pressure is below 5861 kPa (850 psi). If the warning impending problems in the hydraulic system.
light illuminates with the key switch ON, the nitrogen
Warning lamps on the EDP will illuminate if a prob-
must be charged to 9653 kPa (1400 psi).
lem occurs with low steering pressure or low accu-
mulator nitrogen precharge. If either or both of these
lights illuminate, the central warning lamp will illumi-
Flow Amplifier nate. The EDP will display a fault code indicating the
The flow amplifier (Figure 4-2) is located on the left exact problem, including the accumulator with the
frame rail forward of the front suspension. The flow low precharge or open switch circuit.
amplifier is necessary in the steering circuit due to
the large volume of oil required for steering. The flow
amplifier uses the amount of flow from the steering
control valve to determine the amount of amplified
flow to send from the bleed-down manifold to the
steering cylinders.

FIGURE 4-2. FLOW AMPLIFIER

FLOW AMPLIFIER OPERATION
Refer to Figures 4-3 through 4-6 for oil flow paths Neutral (No Steer)
during the following conditions:
Neutral (No steer)
High pressure oil from the steering pump and steer-
Steering left ing accumulators is available through the steering
Steering right bleed-down manifold to the HP port on the flow
amplifier.
External shock load
Upon entering the priority valve, oil flows past the
spool to the closed amplifier valve. Oil also flows out
port P through a hose to port P on the steering con-
trol unit. In the control unit, oil flows to a closed area
in the control valve. As pressure increases in these
two areas, oil passes through orifices in the end of
the priority valve. Pressure increases at the end of
the valve and port PP. When pressure reaches
approximately 3,447 kPa (500 psi), the spool com-
presses the spring and closes off oil supply through
area A resulting in high pressure at PP. Pressure
remains at 3447 kPa (500 psi) at the amplifier spool
and steering control unit.

(No Steer)

Steering Left
When the operator turns the steering wheel to the The oil inside sleeve E pushes valve F against its
left, the steering control unit valve is opened. This spring to give the oil access to a series of holes K
allows oil entering through port P to pass to the gero- that are in the same plane as hole G. The passage of
tor section of the control unit to turn the rotor. Oil in oil through holes K past the valve body is metered by
the other side of the gerotor flows through other pas- holes K being opened the same proportion as is hole
sages in the control unit valve and out steering con- G. The number of holes K (7) in sleeve E determine
trol unit port L. This oil enters port L in the flow the amount of additional oil that is added to the steer-
amplifier and flows to closed area B in the directional ing control unit oil passing through hole G.
valve.
This combined oil going to the center area Q of the
As pressure in this area increases, oil also flows into directional valve passes out port CL of the flow
the spool through orifice C to the spring area on the amplifier assembly and travels to the steering cylin-
end of the directional valve. The pressure then forces ders to steer the front wheels to the left. As the cylin-
the spool to compress the springs on the opposite ders move, oil is forced to return out the opposite
end. This movement allows the oil entering area B to ends, enter port CR of the flow amplifier assembly,
pass through the directional valve to area D of the pass through the directional valve to area M, passes
amplifier valve through sleeve E holes to a passage through the return check valve N, and exit port HT to
between sleeve E and valve F, through hole G in the hydraulic reservoir.
sleeve E where it initially is blocked by the valve
At the steering control unit when the operator turned
body.
the steering wheel, supply oil from port P was also
As pressure increases in this area, oil also flows from delivered through the control unit valve to port LS.
area D around the outside of sleeve E around pin H This oil enters the flow amplifier assembly through its
through orifice J to build pressure on the end of the LS port and builds pressure in the spring area of the
amplifier valve and opens hole G only enough to priority valve. This additional force on the spring end
allow the flow of oil coming from the steering control of the priority valve causes area A to open and allow
unit to pass to the control area of the directional the necessary flow and pressure to pass through the
valve. amplifier valve to operate the steering cylinders.
At the same time, the movement of sleeve E opened The flow amplifier includes a relief valve in the prior-
the holes near the spring end to allow the oil from the ity spring area that is used to control maximum steer-
priority valve to flow into the center of sleeve E. ing working pressure to 18,961 kPa (2750 psi) even
though supply pressure coming in to port HP is
higher. When 18,961 kPa (2750 psi) is obtained, the
relief valve prevents the LS pressure from going
higher and thereby allows the priority valve to com-
press the spring enough to close off the area A when
18,961 kPa (2750 psi) is present.

(Steering Left)

Steering Right
Only a few differences occur between steer left and
steer right. When the operator turns the steering
wheel right, oil is supplied out ports R and LS of the
steering control unit.
The oil enters the flow amplifier assembly at port R
and shifts the directional valve the opposite direction.
The oil flows through the amplifier valve exactly the
same. The combined oil from the amplifier valve
passes through the center area Q of the directional
valve to port CR where it goes to the opposite ends
of the steering cylinders to turn the wheels right.
The returning oil flows through port CL back to the
tank. The LS oil operates exactly the same as steer-
ing left.

(Steering Right)

No Steer, External Shock Load
When the operator is not turning the steering wheel, As the cylinders are allowed to move, the other ends
the steering control unit valve supply is closed. The will have less than atmospheric pressure on port CL.
directional valve remains centered by its springs thus This low pressure permits oil that is escaping through
closing the passages to ports CL and CR. This cre- the CR port relief valve to flow through the check
ates a hydraulic lock on the steering cylinders to pre- valve portion of the shock and suction relief valve
vent their movement. connected to port CL. The oil then flows to the low
pressure ends of the cylinders to keep the cylinders
If the truck hits an obstruction to cause a large shock
full of oil and prevent cavitation.
load to force the wheels to the left, increased pres-
sure will occur in the ends of the cylinders connected A shock load in the opposite direction reverses the
to port CR. The shock and suction relief valve inside above description.
the flow amplifier assembly at port CR will open at its
adjusted setting of 21,374 kPa (3100 psi) and allow
oil to escape from the pressurized ends of the cylin-
ders preventing a higher pressure.

(No Steer, External Shock Load)

STEERING/BRAKE PUMP COMPONENTS
Steering/brake pump (Figure 4-7) is mounted on the Drive shaft (1, Figure 4-7) is located through the cen-
rear of the transmission pump, located at the lower ter line of pump housing (5) and valve plate (31).
left side of the Power Take Off (PTO). The steering Pump cylinder barrel (30) is splined to the drive shaft.
pump drive shaft connects to the transmission pump Ball bearing (2) supports the driven end of the drive
driveshaft through a splined coupling. This pump shaft. A bushing supports the other end. The bushing
also provides the oil supply for the service brake is part of the valve plate assembly.
application circuits.
The pump cylinder barrel rotates on a journal type
The pump is a pressure-compensated, piston pump. cylinder bearing (35). Valve plate (31) has two cres-
The pump delivers oil through a high pressure filter to cent shaped ports. Piston/shoe assemblies (29) in
the bleed-down manifold. At the bleed-down mani- the cylinder barrel are held against swashblock (27)
fold, oil is directed to the steering circuit (accumula- by shoe retainer (34). The shoe retainer is held in
tors, flow amplifier, etc.) and to the brake system position by fulcrum ball (33) which is forced outward
components mounted in the hydraulic cabinet. by shoe retainer spring (32). The spring acts against
The pump pressure compensator is located in the the pump cylinder barrel forcing the piston shoes
control group and is mounted on the pump valve against the swashblock. The semi-cylindrical shaped
plate. The compensator maintains oil pressure in swashblock limits the piston stroke and can be swiv-
both circuits at 18,961 kPa (2750 psi). eled in an arc shaped saddle bearing (36). The angle
of the swashblock is controlled by the control group
(not shown). Refer to Operation later in this chapter.

FIGURE 4-7. STEERING/BRAKE PUMP (Cross Section)
1. Drive Shaft 14. Plug 27. Swashblock
2. Drive Shaft Bearing 15. O-Ring 28. Retainer Ring
3. Shaft Seal 16. Plug 29. Piston/Shoe Assembly
4. Roll Pin 17. O-ring 30. Cylinder Barrel
5. Housing 18. Roll Pin 31. Valve Plate
6. Gasket 19. O-Ring 32. Shoe Retainer Spring
7. Socket Head Screw 20. Seal Retainer 33. Fulcrum Ball
8. O-Ring Seal 21. Bearing Retainer Ring 34. Shoe Retainer
9. Rear Shaft Cover 22. Shaft Bearing Retainer Ring 35. Cylinder Bearing
10. Roll Pin 23. Roll Pin 36. Saddle Bearing
11. Socket Head Screw 24. Roll Pin 37. Roll Pin
12. Spline Cover 25. Guide Plate
13. Cap Screw 26. Flat Head Screw

OPERATION
Full Pump Volume (Figure 4-8):
Rotating the drive shaft turns the splined cylinder,
which contains the pistons. When the cylinder is
rotated, the pistons move in and out of their bores as
the shoes ride against the angled swashblock.
As the cylinder rotates, the individual piston bores
are connected, alternately, to Port A (upper) and Port
B (lower). While connected to the upper side (suc-
tion) Port A, each piston moves outward, drawing
fluid from Port A into the piston bore until it's outer- FIGURE 4-8. PUMP AT FULL VOLUME
most stroke is reached. At that point, the piston bore
passes from the upper crescent port to the lower
crescent port.
While rotating across the lower crescent, each piston
moves across the angled swashblock face. Thus,
each piston is forced inward. Each piston displaces
fluid through the lower crescent to Port B until it's
innermost stroke is reached. At that point, the piston
bore passes from the lower to the upper crescent
again, and the operating cycle is repeated.
Half Pump Volume (Figure 4-9):

Swashblock angle determines the length of piston
stroke thereby determining the amount of delivery
from the pump. In this illustration, the stroke angle is
one-half of the stroke angle shown in Figure 4-8. FIGURE 4-9. PUMP AT HALF VOLUME
Therefore, the piston stroke and pump delivery is one
half the delivery in Figure 4-8.
Neutral Position (Figure 4-10):

Neutral position results when the control centers the
swashblock. The swashblock angle is now zero and
the swashblock face is now parallel to the cylinder
face. Therefore, no inward or outward motion of the
pump pistons exist as the piston shoes rotate around
the swashblock face. The lack of inward and outward
motion results in no fluid being displaced from the
piston bores. Consequently, there is no delivery from
pump ports.
FIGURE 4-10. PUMP IN NEUTRAL POSITION

NOTES

SECTION L5
STEERING CONTROL VALVE
INDEX
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
REBUILD PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-8
L05032 Steering Control Valve L5-1

NOTES
L5-2 Steering Control Valve L05032

STEERING CONTROL VALVE
Removal
1. Shut off the engine. Wait 90 seconds for the 4. Remove cap screws (10, Figure 5-1) from the
steering circuit to depressurize. Turn the steer- steering valve mounting bracket. Remove steer-
ing wheel to verify that the pressure has been ing control valve (7).
relieved from the system.
2. Clean the steering control valve and surround-
ing area to prevent contamination.
3. Tag and disconnect the hydraulic lines from the
valve. Plug the lines to prevent spillage and
possible contamination to the system.
Remove pressure from the steering system

before removing hydraulic lines. Avoid contact
with hot oil. Properly contain oil and plug all
openings to prevent contamination.
FIGURE 5-2. STEERING CONTROL VALVE

1. Brake valve 5. "T" Port Hose
2. Steering Control Valve 6. "P" Port Hose
3. "LS" Port Hose 7. "R" Port Hose
4. "L" Port Hose
Installation
1. Lubricate the male splines on the end of the
steering column shaft.
2. Place steering control valve (7) into position.
FIGURE 5-1. STEERING CONTROL Install cap screws (10). Tighten the cap screws
VALVE INSTALLATION to standard torque.
1. Steering Wheel 7. Steering Control Valve
2. Button Horn 8. LH Bracket
3. Steering Column 9. RH Bracket
4. Cap Screw 10. Cap Screw
5. Flat Washer 11. Lock Washer
6. Lock Washer

3. Remove the plugs from the hydraulic lines. REBUILD PROCEDURE
Connect the hydraulic lines. Use the tags cre-
Tools required for disassembly and assembly:
ated during disassembly for reference.
2 screwdrivers (4-6 in. long, 1/8 in. flat blade)
1/2 inch socket (12 point)
1/2 inch breaker bar
Torque wrench, 120 Nm (90 lb ft) capacity.
Plastic hammer or rubber hammer
Serious damage and personal injury may occur if Retaining ring pliers
a truck is operated with the hydraulic steering Fabricated spring installation tool (Figure 5-4).
lines improperly installed. Improperly installed
hydraulic lines can result in uncontrolled steer- The steering control valve is a precision unit manu-
ing and/or sudden and rapid rotation of the steer- factured to very close tolerances. Complete cleanli-
ing wheel when turning. The steering wheel may ness is necessary when rebuilding the valve. Work in
turn rapidly and may not be stopped manually. a clean area and use lint free wiping materials or dry
After installing the steering control valve, check compressed air. Use a wire brush to remove foreign
the steering lines for correct installation before material and debris from around the exterior joints of
starting the engine. the unit before disassembly. Use clean solvent for
cleaning and clean hydraulic oil for initial lubrication.
FIGURE 5-4. SPRING INSTALLATION TOOL
NOTE: This tool is extremely helpful during

FIGURE 5-3. VALVE PORT IDENTIFICATION centering spring installation.
1. Steering Control Valve "R" - Right Steering
"T" - Return to Tank "LS" - Load Sensing
"P" - Supply from Pump
"L" - Left Steering
4. Check for proper steering wheel rotation without

binding. Rotate the wheel 1/4 turn to the left and
the right. The steering wheel should return to
the neutral position from each direction.

Disassembly
1. Clamp the valve in a vise with the metering end
up. Clamp lightly on the edges of the mounting
area, as shown in Figure 5-5.
Use protective material on the vise jaws. DO NOT

over-tighten the jaws.
FIGURE 5-6. MARKING VALVE COMPONENTS
1. Steering Control 3. Cap Screw With Roll

Valve Pin
2. Match Marks 4. Pin Location Mark
3. Remove the end cover cap screws and wash-

ers. Remove cap screw with rolled pin (3, Fig-
ure 5-6). Mark the location of the cap screw for
reassembly.
4. Remove end cover (1, Figure 5-7) and O-ring
(2). Remove gear wheel set (3).
5. Remove cardan shaft (11, Figure 5-10) distribu-
tion plate (15) and O-ring (14).
FIGURE 5-5. CLAMPING STEERING VALVE 6. Remove threaded bushing (4) and ball (3). Sep-
arate the spools from the housing. Remove O-
ring (5), kin ring (6) and bearing assembly (7).
7. Remove ring (8) and pin (9). Carefully push the
2. Mark the gear wheel set and end cover to inner spool out of the outer sleeve.
ensure proper orientation during assembly. 8. Press neutral position springs (10) out of their
Refer to Figure 5-6. slot in the inner spool. Note the orientation of
the centering springs.
NOTE: Although the illustrations do not show the unit
in a vise, it is recommended that the unit be kept in 9. Remove dust seal (2, Figure 5-8) using a
the vise during disassembly. screwdriver. DO NOT scratch the seal bore.

1. Clean all parts carefully with fresh cleaning sol-
vent.
2. Carefully inspect all parts and replace parts as
necessary. Replace all O-rings, seals and neu-
tral position springs with new parts.
3. Prior to assembly thoroughly lubricate all parts
with clean hydraulic oil.
FIGURE 5-7. END COVER REMOVAL

1. End Cover 3. Gear Wheel Set
2. O-ring 4. Housing
FIGURE 5-9. SPOOL AND SLEEVE ASSEMBLY

1. Slots 3. Spool
2. Hole 4. Sleeve
FIGURE 5-8. DUST SEAL REMOVAL

1. Screwdriver 3. Housing
2. Dust Seal

FIGURE 5-10. STEERING CONTROL VALVE
1. Dust Seal 9. Pin 17. O-ring
2. Housing & Spools 10. Neutral Position Springs 18. O-ring
3. Ball 11. Cardan Shaft 19. End Cover
4. Threaded Bushing 12. Spacer 20. Washers
5. O-ring 13. Tube 21. Rolled Pin
6. Kin Ring 14. O-ring 22. Cap Screw With Bore
7. Bearing Assembly 15. Distribution Plate 23. Cap Screws
8. Ring 16. Gear Wheel Set

Assembly
NOTE: When assembling the spool and sleeve, only
one of the two possible matching positions of the
spring slots can be used. The reason is that in the
other end of the sleeve and spool (opposite end of
the spring slots) there are three slots in the spool and
three holes in the sleeve. These must be opposite
each other during assembly so that the holes are
partly visible through the slots in the spool. Refer to
Figure 5-10.
1. Carefully assemble the spool and the sleeve so

the centering springs slots are aligned.
2. Apply a light film of clean oil to the outside
diameter of the spool. Rotate the spool while
sliding the parts together.
FIGURE 5-11. INSTALLING CENTERING SPRINGS
1. Spring Installation 2. Centering Springs

Tool
The spool and sleeve are machined to very close
tolerances. DO NOT use force when rotating the
parts during assembly. DO NOT scuff the sleeve
during assembly.
Alternate Method For Installing Centering
Springs
3. Test for free rotation. The spool should rotate
smoothly in the sleeve with finger tip force a. Place a screwdriver in the spool slot as
applied at the splined end. shown in Figure 5-12.
4. Align the springs slots in the spool and the b. Place one flat neutral position spring on each
sleeve. Stand the parts on the bench. Insert side of the screwdriver blade. Do not remove
spring installation tool (Figure 5-11) through the the screwdriver.
spring slots of both parts. c. Push two curved neutral position springs in
NOTE: If a spring installation tool is not available, between one side of the screwdriver blade
refer to Alternate Method For Installing Centering and a flat spring. Repeat for the opposite
Springs. side. Remove the screwdriver.
d. Slide the inner spool in the sleeve. Com-
5. Assemble the centering springs on the bench press the ends of the neutral position springs
Proper orientation of the springs is shown in and push the springs into place in the sleeve.
Figure 5-12. Install the cross pin.
6. Insert one end of the spring set into the installa-
tion tool (Figure 5-11).
7. Compress the end of the centering spring set
and push into the spool and sleeve assembly.
Keep pressure on the spring ends when with-
drawing the installation tool, pushing forward on
spring set.

FIGURE 5-12. NEUTRAL POSITION SPRING INSTALLATION
8. Install ring (1, Figure 5-13) rear bearing race

(2), bearing (3) and front bearing race (4) in
order. The chamfer on the rear bearing race
must be facing away from the bearing. Position
the O-ring and kin ring on the spool.
9. Place the dust seal in position. Position a flat,
iron block over the seal, and tap into position.
10. Rotate the steering control valve so the housing
is horizontal. While gently rotating the parts,
guide the spool and sleeve assembly into the
housing bore. Refer to Figure 5-14.
11. Install the check ball in the hole shown in Figure
5-15. Install the threaded bushing and lightly
tighten.
12. Grease the housing O-ring with petroleum jelly
and install in the housing groove. FIGURE 5-13. BEARING INSTALLATION
1. Ring 4. Front Bearing Race
2. Rear Bearing Race 5. Spool
3. Bearing 6. Sleeve

13. Install distribution plate (15, Figure 5-9), align-
ing the channel holes to match the correspond-
ing holes in the housing. Guide cardan shaft
(11) into the bore. The slot in the cardan shaft
must be parallel to the cross pin.
NOTE: Position the cardan shaft so that it is held up
and in position by a mounting fork. Refer to Figure 5-
16. The mounting fork can be fabricated from a small
piece of thin gauge metal.
FIGURE 5-15. CHECK BALL INSTALLATION

1. Housing 3. Check Ball Hole
2. Check Ball 4. O-ring
FIGURE 5-14. SPOOL AND SLEEVE

INSTALLATION
1. Housing 2. Spool & Sleeve
14. Grease the O-rings on both sides of the gear

wheel set with petroleum jelly and install.
15. Install the gear wheel set.
NOTE: The gear wheel (rotor) and cardan shaft must
be assembled with a tooth base in the rotor
positioned in alignment with the slot in the cardan
shaft. Refer to Figure 5-17.
FIGURE 5-16. CARDAN SHAFT INSTALLATION

FIGURE 5-18. GEAR WHEEL SET INSTALLATION
1. Gear Wheel Set 3. Rotor
2. Cross Pin (Outline) 4. Cardan Shaft
FIGURE 5-17. GEAR WHEEL ROTOR

INSTALLATION
NOTE: The rotor and cross pin must now be in the

position shown, in relation to each other. Refer to
Figure 5-18.
16. Place the end cover into position. Install the cap
screws with washers. Install the cap screw with
roll pin in the position shown in Figure 5-6.
Tighten the cover cap screws in a criss-cross
pattern to 3 0.5 Nm (24 5 lb in.).

NOTES

SECTION L6
STEERING CIRCUIT COMPONENT REPAIR
INDEX
STEERING CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
BLEED-DOWN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
Adjusting Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-4
FLOW AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-8
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-11
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-11
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-12
STEERING ACCUMULATOR CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-14
Temperature During Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-17
ACCUMULATOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-18
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-19
L06040 Steering Circuit Component Repair L6-1

STEERING CYLINDER REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-20
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
STEERING/BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-22
PUMP REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-23
Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-24
Valve Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-25
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-25
Drive Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-26
Swashblock Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-26
Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-26
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-28
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-29
Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-31
STEERING CIRCUIT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-32
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-33
L6-2 Steering Circuit Component Repair L06040

STEERING CIRCUIT COMPONENT REPAIR
BLEED-DOWN MANIFOLD
DO NOT loosen or disconnect hydraulic lines or

components until the engine is stopped and the
key switch has been OFF for at least 90 seconds.
death. Seek the proper medical treatment by a
physician familiar with this injury, immediately.
Removal
NOTE: It may not be necessary to remove the bleed-
down manifold from the truck to replace components.
If a problem area has been isolated, simply remove
the inoperative component and replace with a new
part.
FIGURE 6-1. BLEEDDOWN MANIFOLD

Adjusting Relief Valve 1. Brake Circuit Supply 8. To Flow Amplifier
2. Bleeddown Manifold 9. From Flow Amplifier
1. Depressurize the system and install a 34,474
3. Return to Tank 10. Accumulator Bleed-
kPa (5000 psi) pressure gauge in the pressure
4. Pressure Relief Valve Down Solenoid
test port (6, Figure 6-1) of the bleed-down man-
5. Supply From Steering 11. Low Steering
ifold.
Pump (Check Valve) Pressure Switch
2. Start the engine and operate at low idle. 6. Test Port 12. Auto-Lube Supply
3. Loosen the locknut on the compensator valve 7. From Accumulator
on the steering pump.
4. Adjust the pump compensator valve, raising the
pressure until the bleed-down manifold relief 6. Secure the system relief valve with the locknut.
valve opens at 22,408 kPa (3250 psi). Install the acorn nut.
5. If the bleed-down manifold relief valve setting is 7. Turn the steering pump pressure compensator
above or below 22,408 kPa (3250 psi), carefully adjustment screw counterclockwise to reduce
loosen the locknut on relief valve (4) and adjust pressure. Steer the truck and adjust to allow cir-
the pressure setting until 22,408 kPa (3250 psi) cuit pressure to drop to approximately 17,237
is obtained. kPa (2500 psi).
8. Turn the pressure compensator adjustment
screw clockwise to obtain 17,237 kPa (2750
NOTE: Each 1/16 turn of the adjusting screw is psi) on the gauge at the steering bleed-down
equivalent to a setting change of approximately 690 manifold test port. Tighten the jam nut to lock
kPa (100 psi). the adjustment screw when the correct pres-
sure is obtained.

Testing and Adjustment
1. Shut off the engine. Depressurize the steering
accumulators before opening the circuit.
2. Disconnect the return to tank line (3, Figure 6-1)
from the bleed-down manifold.
3. Start the engine and operate at low idle.
4. With the hydraulic oil at normal operating tem-
perature, check the leakage. Maximum allow-
able leakage is 32.8 ml (1 oz) per minute.
DO NOT turn the key switch to OFF to depressur-

ize the accumulators while the steering return
lines are open. The return lines will contain accu-
mulator oil flow during the depressurization
cycle.
5. If leakage is excessive, reconnect the return

line.
6. Turn the key switch to OFF and allow at least
90 seconds for the accumulators to depressur-
ize.
7. Remove bleed-down solenoid valve (10) and
relief valve (4). Replace the O-rings on both
valves and reinstall. FIGURE 6-2. BLEEDDOWN VALVE SCHEMATIC
8. Repeat the test procedure. 1. Accumulator Pressure Switch 5861 kPa (850 psi)
9. If leakage is still excessive, replace both the 2. Return From Automatic Lubrication System
bleed-down solenoid valve and the relief valve. 3. Accumulators
4. Steering Pressure Switch 12,755 kPa (1850 psi)
5. Differential Valve
6. Outlet to Flow Amplifier
7. Return from Flow Amplifier
8. Piloted Check Valve
9. Relief Valve: 3447 kPa (500 psi)
10. Accumulator Bleed-down Solenoid
11. Supply to Brake System
12. Return to Tank
13. Relief Valve 22,408 kPa (3250 psi)
14. Supply from Steering Pump / Check Valve
15. Pressure Test Port

FLOW AMPLIFIER Disassembly
Removal The flow amplifier valve is a precision unit manufac-

tured to close tolerances. Therefore, complete clean-
liness is a must when handling the flow amplifier
valve. Work in a clean area and use lint free wiping
materials or dry compressed air. Use a wire brush to
remove foreign material and debris from around the
DO NOT loosen or disconnect hydraulic lines or exterior of the valve before disassembly. Use clean
components until the engine is stopped and the solvent to ensure cleanliness and clean hydraulic oil
key switch has been OFF for at least 90 seconds. for initial lubrication.
Pressurized hydraulic fluid can have sufficient 1. Remove counterpressure valve plug (17, Figure
force to enter a person's body by penetrating the 6-3), and O-ring (16). Remove counterpressure
skin. This can cause serious injury and possibly valve assembly (15).
death. Seek the proper medical treatment by a 2. Remove relief valve plug (18) and seal (19).
physician familiar with this injury, immediately. Remove relief valve (20). Remove steel seal
(21).
1. Turn the key switch OFF and allow 90 seconds 3. Remove cap screw (37) and cap screws (36).
for the accumulators to depressurize. Discon- Remove lock washers (38 & 39). Remove end
nect each hydraulic line from the flow amplifier. cover (47).
Tag all hoses and plug all openings. 4. Remove spring stop (41) and spring (42).
2. Support the flow amplifier valve. The weight of Remove spring stop (34) and springs (32 & 33).
the flow amplifier is approximately 29 kg (69 lb). Remove O-rings (40 & 49) and seal plate (50).
Remove the mounting cap screws and remove 5. Remove spring control (31) and main spool
the valve from the machine. (29). Remove priority valve spool (43). Remove
3. Move the valve to a clean work area for disas- spring control (25), springs (23 & 24) and spring
sembly. stop (22).
6. Remove amplifier valve spool assembly (51).
Set amplifier valve spool assembly aside for fur-
Installation ther disassembly, if required.
7. Remove shock and suction valve (28). Set
1. Lift the flow amplifier into position. The weight of
shock and suction valve aside for further disas-
the flow amplifier is approximately 29 kg (69 lb).
sembly, if required.
2. Install the mounting cap screws and tighten to
8. Remove cap screws (1 & 3) and lock washers
standard torque.
(2 & 4). Remove end cover (5).
3. Identify hydraulic line location. Remove the
9. Remove O-rings (6, 7 & 8) and seal plate (9).
plugs from the hoses. Install new O-rings on the
Remove spring (55).
flange fittings and connect the lines to the
proper locations. Tighten the fittings securely. 10. Remove shock and suction valve assembly
(12). Set the shock and suction valve aside for
further disassembly, if required. Remove orifice
screw (13).
11. Remove orifice screw (53). Remove check valve
(54).
NOTE: If further disassembly is required for the

shock and suction valves refer to Figure 6-4.

FIGURE 6-3. FLOW AMPLIFIER VALVE

FIGURE 6-3. FLOW AMPLIFIER VALVE
1. Cap Screw
2. Lock Washer
3. Cap Screws
4. Lock Washer
5. Cover
6. O-ring
7. O-ring
8. O-ring
9. Seal Plate
10. O-ring
11. O-ring
12. Shock/Suction Valve (Complete)
13. Orifice Screw
14. Valve Housing
15. Counterpressure Valve (Complete) FIGURE 6-4. SHOCK AND SUCTION VALVE
16. O-ring
ASSEMBLY
17. Plug
18. Plug 1. O-Ring 3. O-Ring
19. Seal 2. Pilot Section
20. Relief Valve (Complete)
21. Steel Seal
22. Stop
23. Spring NOTE: The flow amplifier valve is equipped with two
24. Spring
identical shock and suction valves. The valves are
25. Spring Control
26. Orifice Screw
only serviced as complete assemblies. O-rings (1 &
27. O-ring 3, Figure 6-4) are replaceable. Relief valve (20,
28. Shock/Suction Valve (Complete) Figure 6-3) check valve (54) and counterpressure
29. Main Spool valve (15) are also serviced only as assemblies.
30. O-ring
31. Spring Control
32. Spring NOTE: Disassembly of the amplifier spool assembly
33. Spring is only necessary should O-ring (2, Figure 6-5),
34. Spring Stop spring (9) or orifice screw (11) require replacement.
35. Orifice Screw Otherwise, replace the amplifier spool assembly as a
36. Cap Screws
complete unit. For complete disassembly refer to
37. Cap Screw
38. Lock Washer
Steps 12 & 13.
39. Lock Washer
40. O-rings
41. Stop 12. Remove retaining ring (7, Figure 6-5), remove
42. Spring pin (5). Remove plug (10) and spring (9).
43. Spool Remove retaining ring (6) and pin (4). Remove
44. Name Plate inner spool (8).
45. Orifice Screw
13. Remove check valve (1). Remove O-ring (2).
46. Spring
47. Cover Remove orifice screw (11) from plug (10).
48. Pins 14. Clean and inspect all parts carefully. Replace
49. O-rings parts as necessary.
50. Seal Plate
51. Amplifier Spool Assembly (Complete)
52. O-ring
53. Orifice Screw
54. Check Valve
55. Spring

6. Install seal (21). Install relief valve (20), seal
(19), and plug (18). Tighten the plug to 2486
mNm (22 lb in.).
7. Install counterpressure valve (15). Install plug
(17) and new O-ring (16).
8. Install both shock and suction valves (12 & 28)
as complete units. Install spring stop (22)
springs (23 & 24) and spring control (25). Install
orifice screws (26 & 35) if removed from main
spool (29). Install main spool (29).
9. Install amplifier spool (51). Install priority valve
spool (43) and spring (42). Install spring (55).
10. Install spring control (31), springs (32 & 33) and
spring stop (34).
FIGURE 6-5. AMPLIFIER SPOOL ASSEMBLY
11. Lubricate O-rings (6, 7 & 8) with molycote
1. Check Valve 7. Retaining Ring grease and position on cover (5) with seal plate
2. O-Ring 8. Inner Spool (9). Install end cover (5). Install cap screws (3)
3. Spool 9. Spring and lock washers (4). Tighten the cap screws to
4. Pin 10. Plug 3 Nm (2 lb ft). Install cap screw (1) and lock
5. Pin 11. Orifice Screw washer (2). Tighten the cap screw to 8 Nm (6
6. Retaining Ring lb ft).
12. Lubricate O-rings (40 & 49) with molycote
grease and install on cover (47). Position seal
plate (5) on the end cover. Install end cover
Assembly (47). Install cap screws (36) and lock washers
1. Thoroughly clean all parts. Lubricate each part (39). Tighten the cap screws to 3 Nm (2 lb ft).
prior to installation with clean hydraulic oil. Install cap screw (37) and lock washer (38).
Tighten the cap screw to 8 Nm (6 lb ft).
2. Reassemble the amplifier spool assembly.
Install O-ring (2, Figure 6-5). Install check valve 13. To prevent contamination, install plastic plugs in
(1). Install orifice screw (11) in plug (10). Install each valve port.
pin (5) and retaining ring (7). Install spring (9)
and plug (10). Install pin (4) and retaining ring
(6). Install inner spool (8).
3. Install orifice screw (13, Figure 6-3). Tighten the
orifice screw to 452 mNm (4 lb in.).
4. Install check valve (54). Tighten the check valve
to 904 mNm (8 lb in.).
5. Install orifice screw (53). Tighten the orifice
screw to 904 mNm (8 lb in.).

ACCUMULATORS
Removal 1. Remove charging valve guard (5, Figure 6-6).
2. Loosen swivel nut (4, Figure 6-9) three com-
plete revolutions while holding the valve body
stationary.
3. Remove valve cap (1). Install the charging man-
ifold assembly and release all the nitrogen pres-
Depressurize the system accumulators before sure.
opening the hydraulic circuits or installing test
gauges.
DO NOT loosen the complete charging valve
assembly. Loosening the charging valve may
result in the valve being forced out of the accu-
For the brake circuit, first, chock the wheels. mulator by the nitrogen pressure.
Then, open the shut-off valves on the brake man- Wear a protective face mask when discharging
ifold. Opening the valves allows the accumulator nitrogen gas.
FIGURE 6-6. ACCUMULATOR VALVES

1. Valve Manifold 6. Valve Cap
2. O-Ring 7. Flat Gasket
3. Cap Screw 8. Valve Assembly
4. Lock Washer 9. Pressure Switch
5. Guard
FIGURE 6-7. ACCUMULATOR MOUNTING

1. Accumulators 3. Oil Pressure Switch
2. Clamp 4. Mounting Bracket

4. Disconnect the electrical leads at pressure Installation
switch (9, Figure 6-6). 1. Attach a lifting device to the top of the accumu-
5. Remove the oil lines from the bottom of the lator. The weight of the accumulator is 140 kg
accumulators. Plug all hoses and openings to (309 lb). Lift the accumulator into position onto
prevent contamination of the system. Discon- mounting bracket (4, Figure 6-7).
nect and label the electrical wiring to the pres- 2. Install the clamps (2) and hardware to secure
sure switch. the accumulator to the mounting bracket. Do
6. Attach a lifting device to the top of the accumu- not overtighten as this could distort the accumu-
lator to be removed. The weight of the accumulator.
lator is 140 kg (309 lb). 3. If necessary, install the pressure switches. Con-
7. Remove clamps (2, Figure 6-7) that secure the nect the wiring harness to the pressure
accumulator. switches.
8. Lift the accumulator from the truck and move to 4. Install the oil hoses to the bottom of the accu-
a clean work area for disassembly. mulators.
5. Charge both accumulators with pure dry nitro-
gen as outlined in Steering Accumulator Charg-
ing.
FIGURE 6-8. ACCUMULATOR ASSEMBLY

1. Bladder Assembly 7. O-Ring 13. Warning Plate
2. Hydraulic Port Assembly 8. O-Ring Back-Up 14. Gas Valve Manifold
3. Anti Extrusion Ring 9. Spacer 15. Pressure Switch
4. Shell 10. Lock Ring 16. O-Ring
5. Nut 11. Valve Assembly
6. O-Ring Back-Up (Metal) 12. Bleed plug

Disassembly
1. Secure the accumulator body in a vise (prefera- 5. Check the anti-extrusion ring and the soft seals
bly a chain vise). for damage or wear. Replace all worn or dam-
aged seals.
NOTE: If a standard jaw vise is used, copper inserts
6. After the shell has been cleaned with a cleaning
must be used to protect the hydraulic port from
solution, check the inside and outside of the
damage. Clamp against the wrench flats only when
shell. Carefully inspect the area where the gas
using a jaw vise to prevent the accumulator from
valve and hydraulic port assembly pass through
turning.
the shell. Any nicks or damages in this area
2. Remove bleed plug (12, Figure 6-8). could destroy the accumulator bladder or dam-
3. Using a spanner wrench, remove lock ring (10). age the new seals. If this area is pitted, consult
Use an adjustable wrench on the flats of your Komatsu service manager.
hydraulic port assembly (2) to prevent it from
rotating.
4. Remove spacer (9), then push hydraulic port
assembly (2) into the shell.
5. Remove O-ring back-up (8), O-ring (7), and
metal back-up washer (6). DO NOT attempt to repair the accumulator hous-
ing. Repairs may weaken the housing and result
6. Separate anti-extrusion ring (3) from the
in serious injury to personnel when pressurized.
hydraulic port assembly. Fold it to enable
Replace the accumulator housing if damaged.
removal from the shell.
7. Hold the bladder valve stem and remove gas
valve manifold (14).
Assembly
8. Remove nut (5).
9. Fold bladder (1) and remove. A slight twisting Assemble the accumulator in a dust and lint-free
motion, while pulling on the bladder, allows eas- area. Maintain complete cleanliness during assembly
ier removal. to prevent possible contamination of the hydraulic
system.
1. Place accumulator shell (4, Figure 6-8) in a vise
Cleaning and Inspection or on a table.
2. Lubricate the entire inside of the housing with
1. All metal parts must be cleaned with a cleaning
2.3 l (80 oz) of clean hydraulic fluid.
solution.
3. Fold the bladder longitudinally in a compact roll.
2. The seals and soft parts must be wiped clean.
4. Insert a bladder pull rod through the valve stem
3. Inflate the bladder to normal size using minimal
opening (nitrogen end) and out through the
pressure. Wash the bladder with a soap solu-
shell fluid port (hydraulic oil end). Attach the
tion. If the soap solution bubbles, discard the
bladder pull rod to the bladder valve stem.
bladder. After testing, deflate the bladder imme-
diately. 5. With one hand, pull the bladder pull rod while
inserting the bladder into the shell with the other
4. Inspect the hydraulic port assembly for dam-
hand. Slight twisting of the bladder will make
age. Ensure the poppet plunger spins freely and
this insertion easier.
functions properly.
6. Once the bladder valve stem has been pulled
through the valve stem opening in the shell,
install valve stem nut (5) by hand. Once the
valve stem nut is in place, remove the bladder
pull rod.

7. Hold the bladder valve stem on the flats with a 18. Install lock ring (10) onto the hydraulic port
wrench and tighten nut (5) securely. assembly and tighten securely. This will com-
8. If removed, install pressure switch (15) and press the O-ring into position. Use an appropri-
valve assembly (11). Install the charging valve ate wrench on the flats on the hydraulic port
onto gas valve manifold (14). Install new O-ring assembly to ensure the unit does not turn.
(16) on gas valve manifold (14). Hold the blad- 19. Install bleed plug (12).
der valve stem with a wrench and install gas
20. Charge the accumulator to 690-827 kPa (100-
valve manifold (14). Tighten securely.
120 psi). Refer to Steering Accumulator Charg-
10. Holding hydraulic port assembly (2) by the ing in this chapter. After charging, install a plas-
threaded end, insert the poppet end completely tic cover over the hydraulic port assembly to
inside the shell. prevent contamination. DO NOT use a screw-in
11. Fold anti-extrusion ring (3) and insert it into the type plug.
shell. Place the anti-extrusion ring on the
hydraulic port assembly with the steel collar fac-
ing the shell fluid port.
12. Pull the threaded end of the port assembly
through the shell until it seats solidly. When storing an accumulator, pressurize the
accumulator to 690-827 kPa (100-120 psi). DO
13. Connect the nitrogen charging kit to the charg- NOT exceed 827 kPa (120 psi). Sudden loss of
ing valve. Refer to Steering Accumulator Charg- accumulator pressure can result in a projectile
ing in this chapter to charge the accumulator. hazard that can cause serious injury or death.
With the hydraulic port assembly firmly in place,
slowly pressurize the bladder using dry nitrogen NOTE: Charge the accumulators to 690-827 kPa
to 172 kPa (25 psi). Continue to fill the bladder (100-120 psi) for storage. Pressurizing the
to 345 kPa (50 psi) until the hydraulic port accumulators expands the bladder and holds oil
assembly is firmly held in place. against the inner walls for lubrication and rust
prevention. Refer to Accumulator Storage in this
14. Install metal back-up washer (6) against the chapter.
anti-extrusion ring.
15. Install O-ring (7) against metal back-up washer (6).
Leak Testing
To perform leak testing, a source of nitrogen pres-
sure of 9653 kPa (1400 psi) and hydraulic pressure
of 24132 kPa (3500 psi) will be required. A water
DO NOT twist O-ring (7) during installation.
tank large enough to hold the accumulator and a
method of safely securing the accumulator in a hold-
ing fixture will be necessary.
16. Install O-ring back-up (8).
17. Insert spacer (9) with the smaller diameter of
the shoulder facing the accumulator shell.
Securely mount the accumulator into a holding

fixture before high pressure testing. DO NOT
handle the accumulator if nitrogen pressure
exceeds 827 kPa (120 psi). Sudden loss of accu-
mulator pressure can result in a projectile hazard
that can cause serious injury or death.

1. Attach the appropriate lifting apparatus to the 9. If there are no leaks, charge the accumulator to
accumulator. The weight of the accumulator is 690-827 kPa (100-120 psi). Disconnect the
approximately 140 kg (310 lb). Lift the accumu- charging manifold. Use a wrench to tighten
lator into the holding fixture and secure. Attach charging nut (5, Figure 6-5) to 7-11 Nm (5-8 lb
the lifting apparatus to the holding fixture and lift ft).
it into the test tank. 10. Remove the accumulator from the test tank fix-
2. Cover hydraulic port assembly (2, Figure 6-5) ture.
with a plastic cap to prevent water entry. DO
NOT install a threaded plug in the hydraulic port .
assembly. Install bleed plug (12).
3. Charge the accumulator to 9653 kPa (1400 psi).
Refer to Steering Accumulator Charging in this
chapter. When storing an accumulator, pressurize the
4. Fill the test tank so the accumulator is com- accumulator to 690-827 kPa (100-120 psi). DO
pletely submerged and observe for 20 minutes. NOT exceed 827 kPa (120 psi). Sudden loss of the
No leakage (bubbling) is permitted. If leakage is accumulator pressure can result in a projectile
present, go to Step 7. If no leakage is present, hazard that can cause serious injury or death.
continue to the next step.
5. Drain the test tank. Remove the plastic plug
from hydraulic port assembly (2). Ensure no 11. Verify all labels are attached and legible. Refer
moisture is present in the hydraulic port assem- to the parts book if replacements are required.
bly.
6. Connect a hydraulic power supply. Pressurize
the accumulator with oil to 24,132 kPa (3500
psi). Refill the test tank with water and observe
for 20 minutes. No oil or nitrogen leakage is per-
mitted.
7. Slowly release the oil pressure. Drain the test
tank and remove the hydraulic power supply
connection. Ensure no moisture is present in
hydraulic port assembly (2) and install a plastic
cap to prevent contamination. DO NOT install a
threaded plug in the hydraulic port assembly.
8. If any nitrogen gas or oil leakage was present,
discharge all the nitrogen gas using the charg-
ing equipment, and repair as necessary.

STEERING ACCUMULATOR CHARGING
2. Remove bleed plug (12, Figure 6-8) from each
accumulator being charged.
NOTE: If a new or rebuilt accumulator, or any bladder
accumulator with all the nitrogen discharged is being
precharged while installed on the truck and
connected to the hydraulic system, the oil side of the
accumulator must be vented to allow proper bladder
expansion. Release the trapped oil by removing the
bleeder plugs. Trapped air or oil on the hydraulic side
of the bladder will prevent the proper precharge
pressure.
For the brake circuit, first, chock the wheels. 3. Remove guard (5, Figure 6-6).
4. Close valves (1, 2, and 8, Figure 6-10).
pressure to be released to the hydraulic tank. 5. Install the charging manifold assembly onto the
nitrogen gas supply tank. Open the valve on the
Pure dry nitrogen is the only gas approved for nitrogen supply tank.
use in the steering accumulator. The accidental 6. Turn both T-handles (3) fully counterclockwise
charging of oxygen, or any other gas in this com- before attaching the charging hose to the accu-
ponent, may cause an explosion. mulator charging valve.
7. DO NOT loop or twist the hose. Attach swivel
When charging or discharging nitrogen gas in connector (4) to the charging valve and tighten
the accumulator, ensure the warning labels are to 1-2 Nm (10-15 lb in.).
observed, and the instructions regarding the
charging valve are carefully read and under-
stood.
Only precharge the accumulators while installed

on the truck. DO NOT handle the accumulator
with lifting equipment when the nitrogen pre-
charge is above 827 kPa (120 psi).
NOTE: If one accumulator is low on nitrogen, it is
recommended that both accumulators be checked
and/or charged at the same time.
1. With the key switch OFF, allow at least 90 sec-

onds for the accumulator to depressurize. Turn
the steering wheel to ensure no oil pressure
remains in the accumulator.
FIGURE 6-9. CHARGING VALVE
1. Valve Cap 6. Valve Body
2. Seal (Large Hex Nut)
3. Valve Core 7. O-Ring
4. Swivel Nut 8. Valve Stem
(Small Hex Nut) 9. O-Ring
5. Rubber Washer

FIGURE 6-10. CHARGING MANIFOLD ASSEMBLY
1. Valve 4. Swivel Connector 7. Adapter
2. Valve 5. Pressure Gauge (Regulated) 8. Valve
3. T-Handle 6. Regulator 9. Pressure Gauge
. 9. Turn T-handle (3, Figure 6-10) clockwise to

open the charging valve. Fill time for this accu-
mulator is four minutes.
Nitrogen pressure may be present in the accumu-

lator. Turning the complete valve assembly may
result in the valve assembly being forced out of
the accumulator by the nitrogen pressure inside. If the accumulator is not charged slowly, the
Ensure only swivel nut (4) is loosened. bladder may be permanently damaged. A star-
burst rupture in the lower end of the bladder is a
characteristic failure caused by charging too rap-
8. Hold the charging valve stationary using valve idly.
body (6, Figure 6-9) with one wrench and
loosen swivel nut (4) with a second wrench.
This will open the poppet inside the charging
valve.
NOTE: Three revolutions will fully open the valve.

10. If the pressure is greater than 172 kPa (25 psi), 15. Turn the T-handle fully counterclockwise. Hold
proceed to Step 12. If the pressure is less than valve body (6) and loosen the swivel connector
172 kPa (25 psi), set the regulator for 172 kPa to remove the charging hose assembly. Check
(25 psi). Completely open valve (1 or 8, Figure for nitrogen leaks.
6-10), whichever one is connected to the accu-
NOTE: If a new charging valve was installed, the
mulator. Then slightly open valve (2) and slowly
valve stem must be seated as follows:
fill the accumulator. Fill time for this accumulator
is four minutes. a. Tighten swivel nut (4, Figure 6-6) to 14 Nm
(11 lb ft).
11. When 172 kPa (25 psi) is obtained on pressure
gauge (9), close valve (2). b. Loosen the swivel nut.
12. If the accumulator is not installed on the truck, c. Retighten the swivel nut to 14 Nm (11 lb ft).
set the pressure regulator to 690 kPa (100 psi). d. Again, loosen the swivel nut.
If the accumulator is installed on the truck, set
regulator (6) for the pressure listed in Table 1 e. Finally, tighten the swivel nut to 5 Nm (4 lb
based on the ambient temperature. Open valve ft).
(2) and fill the accumulator.
13. After charging to the correct pressure, close 16. Install and tighten the valve cap to 1-2 Nm (10-
valve (2). Wait 15 minutes to allow the tempera- 15 lb in.). The valve cap serves as a secondary
ture and pressure of the nitrogen to stabilize. If seal. Install valve guard (5, Figure 6-6). Close
the desired pressure is low, adjust the regulator, the valve on the nitrogen supply tank.
open valve (2), and add more nitrogen to obtain
the correct pressure. If the pressure has 17. Install bleed plug(s) (12). If opened, close the
exceeded the recommended pressure, then brake accumulator bleed-down valves.
slowly release the nitrogen pressure to obtain 18. Operate the truck and check the steering for
the correct pressure. normal operation.
19. Check the hydraulic oil level and fill as neces-
sary.
DO NOT release pressure by depressing the

valve core with a foreign object. High-pressure
may rupture the rubber valve seat.
14. Tighten swivel nut (4, Figure 6-9) to 7-11 Nm

(5-8 lb ft) to close the internal poppet.

Temperature During Precharge ACCUMULATOR STORAGE
Temperature variation can affect the precharge pres- The shelf life of bladders, under normal storage con-
sure of an accumulator. As the temperature ditions, is one year. Normal storage conditions con-
increases, the pressure increases. Conversely, sist of the bladder being heat sealed in a black plastic
decreasing temperature will decrease the pressure. bag and placed in a cool, dry place away from the
To ensure accuracy, it is necessary to adjust the sun, ultraviolet, and fluorescent lights, as well as
charging pressure to offset temperature variations. electrical equipment. Direct sunlight or fluorescent
The temperature variation is determined by the ambi- light can cause the bladder to weather check and dry
ent temperature at the time of charging. If the accu- rot, which appear on the bladder surface as cracks.
mulator is mounted on the truck, wait one hour after
shutting the engine off. After an hour, measure the
ambient temperature to determine the proper charg-
ing pressure. Refer to Table 1.
Example: Assuming the ambient temperature is
10C (50F), charge the accumulator to 9294 kPa When storing an accumulator, pressurize the
(1348 psi). accumulator to 690-827 kPa (100-120 psi). DO
NOT exceed 827 kPa (120 psi). Sudden loss of the
accumulator pressure can result in a projectile
TABLE 1. Relationship Between Charging hazard that can cause serious injury or death.
Pressure and Ambient Temperature Only precharge the accumulators to operating
Ambient Charging Pressure
pressure while installed on the truck. DO NOT
Temperature 70 kPa (10 psi) handle the accumulator with a nitrogen pre-
charge greater than 827 kPa (120 psi).
-23C (-10F) and below 8232 kPa (1194 psi)
-17C (0F) 8412 kPa (1220 psi)

1. If the accumulator has been rebuilt, ensure
-12C (10F) 8584 kPa (1245 psi) there is approximately 2.3 l (80 oz) of oil inside
the accumulator before adding pressure.
-7C (20F) 8763 kPa (1271 psi)
2. Charge the accumulator to 690-827 kPa (100-
-1C (30F) 8943 kPa (1297 psi) 120 psi). Refer to Steering Accumulator Charg-
ing in this chapter.
4C (40F) 9122 kPa (1323 psi)
10C (50F) 9294 kPa (1348 psi)

NOTE: Pressurizing the accumulator fully expands
16C (60F) 9473 kPa (1374 psi) the bladder and holds a film of oil against the inner
21C (70F) 9653 kPa (1400 psi)
walls for lubrication and rust prevention.
27C (80F) 9832 kPa (1426 psi)

3. The hydraulic port assembly must be covered
32C (90F) 10011 kPa (1452 psi) with a plastic plug, without threads, to prevent
38C (100F) 10184 kPa (1477 psi)
contamination. DO NOT install a threaded plug
in the hydraulic port assembly.
43C (110F) 10363 kPa (1503 psi) 4. Store the accumulator in an upright position.
49C (120F) 10542 kPa (1529 psi)
NOTE: Pressures below 8232 kPa (1194 psi) are not

recommended. The low accumulator pressure warn-
ing switch activates at 7584 310 kPa (1100 45
psi).

Installation
6. Stand the accumulator upright and secure.
Install the pressure gauges and charge the
accumulator first to 172 kPa (25 psi), then to
690 kPa (100 psi). Remove the gauges from the
accumulator and install a plastic dust cap over
Follow this procedure when installing an accu- the hydraulic port assembly. The fill time to
mulator that was in storage. This procedure also reach 172 kPa (25 psi) is approximately four
applies to newly purchased accumulators. minutes.
1. Install the pressure gauges on the accumulator 7. Install the accumulator on the truck.
and check the pressure. Refer to Steering Accu- 8. Charge the accumulator to operating pressure.
mulator Charging in this chapter. Refer to Steering Accumulator Charging in this
a. If the pressure is 165 kPa (24 psi) or less, chapter to fully charge the accumulator to the
slowly drain off any nitrogen and proceed to correct operating precharge pressure.
Step 2.
b. If the pressure is between 172 kPa (25 psi)
and 690 kPa (100 psi), set the regulator to
690 kPa (100 psi) and slowly charge the
accumulator to 690 kPa (100 psi). Discon-
nect the pressure gauges from the accumu-
lator. Proceed to Step 7.
2. Remove the gauges from the accumulator.
3. Remove the plastic dust cap from the hydraulic
port assembly.
4. Lay the accumulator on a suitable work bench
and pour clean C-4 hydraulic oil, approximately
2.3 l (80 oz) into the accumulator through the
hydraulic port assembly. Allow time for the oil to
cover the inside of the accumulator.
5. Lay the accumulator flat and slowly roll the
accumulator two complete revolutions. This pro-
vides the necessary lubrication for charging.

STEERING CYLINDER
1. Disconnect the lubrication lines at the cylinder 1. Lift steering cylinder (5, Figure 6-11) into posi-
pins. tion. The weight of the steering cylinder is
2. Support the cylinder with a suitable lifting approximately 131 kg (289 lb).
device. The weight of the steering cylinder is 2. Position rubber boot (1, Figure 6-12) and install
approximately 131 kg (289 lb). pin (4, Figure 6-11). Install the pin retaining cap
3. Remove pin (4, Figure 6-11). screw and washer and tighten to standard
torque.
3. Move the piston rod eye into position. Install
NOTE: Support steering cylinder (5) with a suitable rubber boot (1) and the pin. Install the pin
jack. Start the engine and operate the steering to retaining cap screw and washer and tighten to
retract the piston rod, then disconnect the cylinder standard torque.
from the frame. 4. Connect the lubrication lines.
5. Install a new O-ring onto hose (3, Figure 6-11).
4. Remove hose (2). Connect the hose to the cylinder.
5. Remove hose (3). 6. Install a new O-ring onto hose (2). Connect the
hose to the cylinder.
6. Remove pin (1).
7. Remove the steering cylinder from the truck.
FIGURE 6-12. TYPICAL MOUNTING PIN

1. Rubber Boot 2. Pin
FIGURE 6-11. STEERING CYLINDER PIPING

1. Pin 4. Pin
2. Hose 5. Steering Cylinder
3. Hose

STEERING CYLINDER REBUILD
Disassembly Cleaning and Inspection
1. Remove cap screws (9, Figure 6-13). Clean parts thoroughly and inspect cylinder
2. Pull rod assembly (10) and gland out of cylinder housing (1, Figure 6-13), piston (3), piston rod
housing (1). (10), and gland (8) for evidence of scoring,
pitting, or excessive wear.
3. Remove locknut (2) and piston (3). Remove
bearing (4) and seal assembly (5) from the pis- Discard all seals, O-rings, backup rings, and
ton. bearings.
4. Slide the gland off the rod. Remove O-ring (6) Inspect bushing (16) and the bushing housing for
and backup ring (7) from the gland. excessive wear or damage. Replace if
necessary.
5. Remove rod wiper (11) and rod seal (12).
Remove bearing (13). Replace O-rings (15).
During assembly, coat sliding surfaces with
hydraulic oil.
FIGURE 6-13. STEERING CYLINDER ASSEMBLY
1. Housing 5. Seal Assembly 9. Cap Screw 13. Bearing

2. Locknut 6. O-Ring 10. Rod 14. Retaining Ring
3. Piston 7. Backup Ring 11. Wiper 15. O-Ring
4. Bearing 8. Gland 12. Seal 16. Bushing

Assembly STEERING/BRAKE PUMP
Piston Seal and Bearing Installation: Removal
1. Install new piston seal (5, Figure 6-13) onto pis-
ton (3) as follows:
a. Heat piston seal assembly (5) in boiling
water for 3 to 4 minutes.
b. Remove the piston seal from the water and DO NOT loosen or disconnect hydraulic lines or
assemble onto the piston. Install within 5 components until the engine is stopped and the
seconds before the seal hardens. Use piston key switch has been OFF for at least 90 seconds.
bearing (4) to position the seal assembly in
the groove. Apply pressure evenly to prevent
cocking the seal.
c. If the seal is loose on the piston, a belt type death. Seek the proper medical treatment by a
wrench or similar tool can be used to com- physician familiar with this injury, immediately.
press the OD of the seal until it fits tightly on
the piston.
2. Install bearing (4) in the piston groove. 1. Turn the key switch OFF and allow 90 seconds
for the accumulators to depressurize. Turn the
steering wheel to verify that pressure has been
Cylinder Assembly: relieved.
1. Install a new bearing (13), rod seal (12), rod 2. Drain the hydraulic tank by use of the drain
wiper (11), backup ring (7) and O-ring (6) in valves located at the bottom of the tank. The
gland (8). capacity of the hydraulic tank is approximately
576 liters (152 gal). If the oil is to be reused,
2. Push rod (10) through the top of the gland. clean containers must be used with a 3 micron
Slowly advance the rod over the seal and the filtering system available for refill.
rod wiper.
3. Clean the steering pump and surrounding area
3. Install piston assembly (3) onto the rod. Install to help prevent contamination of the hydraulic
locknut (2) and tighten to 2712 Nm (2000 lb ft). oil when the system is opened.
4. Carefully install the rod and the gland assembly 4. Disconnect suction hose (3, Figure 6-14) and
into cylinder housing (1). Ensure the O-ring and outlet hoses (6) at the steering pump. Discon-
the backup ring are not damaged during instal- nect pump case drain line (2) from fitting (4).
lation of the gland. Plug all hoses and fittings to prevent oil contam-
5. Install cap screws (9). Tighten to 420 Nm (310 ination.
lb ft).

Installation
1. Install a new O-ring onto the pump mounting
flange.
2. Inspect the splined coupler to verify the internal
snap ring is properly seated. Install the coupler
onto the transmission pump drive shaft.
3. Attach an appropriate lifting device to the steer-
ing pump. The pump weighs approximately 50
kg (110 lb). Lift the steering pump into position.
Engage the steering pump shaft with the trans-
mission pump splined coupler.
4. Align the cap screw holes and install the steer-
ing pump mounting cap screws. Tighten the
mounting cap screws to standard torque.
5. Remove the plugs from suction hose (3, Figure
6-14) and outlet hose and install new O-rings.
Connect the hoses to the steering pump.
Tighten the cap screws, securely.
6. Remove fitting (4) and add clean oil to the pump
until the housing is full. This may require 2 to 3
liters (2 to 3 qts) of oil.
7. Remove the cap from case drain line (2) and
connect to fitting (4).
8. Replace the hydraulic filter elements. Refer to
Hydraulic Filters, earlier in this section.
FIGURE 6-14. STEERING/BRAKE PUMP
1. Transmission Pump 4. Drain Line Fitting
2. Case Drain Line 5. Steering/Brake Pump
3. Suction Hose 6. Outlet Hose
NOTE: Use only Komatsu filter elements, or
elements that meet the Komatsu hydraulic filtration
specification of Beta 12 = 200.
5. Attach an appropriate lifting device to the steer- 10. With the body down and the engine off, fill the
ing pump. The pump weighs approximately 50 hydraulic tank with clean hydraulic oil. Fill until
kg (110 lb). Remove the two pump mounting oil is visible in the top sight glass. The capacity
cap screws. of the hydraulic is 576 liters (152 gal.).
6. Move the steering pump forward to disengage
the drive coupler splines from transmission
pump (1). Remove the pump.
7. Clean the exterior of the steering pump.
8. Move the steering pump to a clean work area
for disassembly.

17. Verify the oil level in the hydraulic tank is at the
upper sight glass when the engine is off and the
body is resting on the frame. If the oil level is not
at the upper sight glass, follow service manual
If trapped air is not purged from the steering instructions for adding oil.
pump, possible pump damage and pump failure 18. Start the engine and check for proper pump
may result. operation. If necessary, refer to Steering Circuit
Checkout Procedure, later in this section. Also,
refer to Troubleshooting Chart for additional
11. Loosen the cap screws that secure suction hose information.
(3) at the pump to purge trapped air. Loosen the
cap screws that secure outlet hose (6) at the
pump to purge trapped air. Retighten the cap
screws to standard torque. PUMP REBUILD
12. If necessary, add oil to the hydraulic tank up to When disassembling or assembling unit:
the upper sight glass. Choose a work area free of dust, sand or other
13. In the hydraulic brake cabinet, open both brake abrasive particles.
accumulator needle valves completely to allow Place all parts on a clean surface.
the steering pump to start under a minimal load.
Use clean solvents to clean parts.
14. Move the hoist pilot control valve to the FLOAT
All tools and gauges must be clean. Use new,
position. clean and threadless rags to handle and dry
15. Start the truck engine and operate at low idle for parts.
two minutes.
Disassembly
1. Drain the hydraulic oil from the pump inlet, dis-
charge and case drain ports.
Do not allow the engine to operate with the nee- 2. Thoroughly clean and dry the outside surface of
dle valves in the open position for longer than the pump housing.
this recommendation. Excessive hydraulic sys- NOTE: Depending upon what part or parts are to be
tem heating will occur. inspected, it may not be necessary to completely
Do not operate the hydraulic pumps for the first disassemble all assemblies.
time after an oil change, or pump replacement, 3. For complete pump disassembly, follow the
with the truck dump body raised. The oil level in instructions for each pump group on the follow-
the hydraulic tank may be below the level of the ing pages.
pump(s), causing premature pump wear during
initial start-up.
16. Shut off the engine and close both accumulator

needle valves in the brake cabinet.

Control Group
NOTE: Prior to removing the control group from the 6. Remove plugs (12 & 21) and orifice (30).
pump housing, loosen all external plugs for easier 7. Remove plug (28), spring (27), orifices (25 &
removal. 26) and four-way valve spool (24).
1. Remove cap screws (2, Figure 6-15). 8. Remove relief valve bonnet (14), spring (15),
shim (16), and poppet (17).
2. Lift control housing (1) off the pump housing.
9. Remove relief valve seat (18), O-ring (19), and
3. Remove gasket (8), O-Ring (9), plug (11) and
orifice (20).
piston control pin (10).
4. Remove cap screws (3). Remove end cap (23)
and gasket (31). Remove O-rings (4).
5. Carefully remove bias control piston (7), spring
(6), and main control piston (5) from the control
housing.
FIGURE 6-15. PUMP CONTROL GROUP

1. Control Housing 9. O-Ring 17. Relief Poppet 25. Orifice
2. Cap Screw 10. Control Piston Pin 18. Relief Valve Seat 26. Orifice
3. Cap Screw 11. Plug 19. O-Ring 27. Spring
4. O-Ring 12. Plug 20. Orifice 28. End Plug
5. Main Control Piston 13. O-Ring 21. Plug 29. O-Ring
6. Spring 14. Relief Valve Bonnet 22. O-Ring 30. Orifice
7. Bias Control Piston 15. Spring 23. End Cap 31. Gasket
8. Gasket 16. Shim 24. 4-Way Valve Spool

Valve Plate Group Rotating Group
10. Support the pump on the workbench with the
drive shaft facing downward. Remove the four
hex head cap screws (18, Figure 6-16).
11. Lift straight up to remove valve plate (17).
The rotating group weighs approximately 7 kg
12. Remove valve plate gasket (16) and O-ring (15 lb). Use extreme care when disassembling.
(10). DO NOT damage the cylinder wear plate face, the
bearings or the piston shoes. Assistance from
others and use of proper lifting techniques is
strongly recommended to prevent personal
injury and damage to the pump.
13. Place the pump in a horizontal position and

remove the rotating group by turning drive shaft
(6) slowly while pulling the cylinder/piston barrel
assembly (15) from the housing.
FIGURE 6-16. PUMP PISTON SECTION

1. Bearing Retainer Ring 7. Screw 13. Saddle Bearing 19. Plug
2. Shaft Retainer Ring 8. Guide Plate 14. Swashblock 20. O-Ring
3. Ball Bearing 9. Roll Pin 15. Cylinder/Piston Assembly 21. Plug
4. Seal Retainer 10. O-Ring 16. Gasket 22. O-Ring
5. Shaft Seal 11. Roll Pin 17. Plate
6. Drive Shaft 12. Roll Pin 18. Cap Screw

Drive Shaft Group
20. Remove the bearing retainer ring (1, Figure 6-
16).
21. Grasp the outboard end of the drive shaft and
pull shaft and bearing out from the pump hous-
ing.
22. Remove the shaft retaining ring (2) and bearing
(3).
23. Remove the shaft seal retainer (4) and the shaft
seal (5) from the housing only if necessary.
Swashblock Group
24. Remove the flat head screws (7, Figure 6-16)
and guide plate (8).
25. Reach inside the case and remove the swash-
FIGURE 6-17. PISTON/SHOE REMOVAL block (14) and the saddle bearings (13).
1. Cylinder Barrel 4. Piston/Shoe Assembly
2. Spring 5. Shoe Retainer
3. Fulcrum Ball Inspection
Always wear safety goggles when using solvents

or compressed air. Failure to wear safety goggles
14. Place the cylinder barrel on a clean, protective could result in serious personal injury.
surface with the piston shoes facing upward. 1. Clean all parts thoroughly.
15. Mark each piston, its cylinder bore and location 2. Replace all seals and O-rings with new parts.
in the shoe retainer for ease of inspection and 3. Check all locating pins for damage and all
assembly. springs for cracking or signs of fatigue.
16. Piston/shoe assemblies (4, Figure 6-17) can be
removed individually or as a group by pulling
upward on the shoe retainer (5). Control Group
17. Remove the fulcrum ball (3) and shoe retainer 4. Carefully check control piston pin (10, Figure 6-
spring (2). 15) for cracks and/or signs of fatigue. Check the
fit of the pin in the swashblock. The pin should
18. Remove the retaining ring (6, Figure 6-18) and
be a slip fit without any radial free-play.
pull the cylinder bearing (7) from the housing.
5. Verify all orifices and passages are free of
19. If necessary, remove roll pins (8) from the hous- obstructions.
ing. Note the position of the roll pins in the case.
6. Check main control piston (5), bias control pis-
ton (7), and housing (1) for excessive wear or
scoring.

FIGURE 6-18. ROTATING GROUP
1. Cylinder Barrel 4. Shoe Retainer 7. Cylinder Bearing

2. Spring 5. Piston & Shoe Assembly 8. Roll Pin
3. Fulcrum Ball 6. Retainer Ring
Valve Plate Group 11. Inspect cylinder bearing (7) for damage and
7. Inspect valve plate (17, Figure 6-16). Check the replace if necessary.
surface that mates with cylinder barrel (15) for 12. Check all piston and shoe assemblies (5) to be
excessive wear, scoring or grooves. If the faces sure they fit properly on the swashblock.
are not flat and smooth, the cylinder side will "lift
13. Check all pump piston assemblies for smooth
off" from the valve plate resulting in delivery
action in their bores.
loss and damage to the pump.
8. Remove minor defects on the face by lightly 14. Check the piston walls and bores for scratches
stoning the surface with a hard stone that is flat or other signs of excessive wear. Pistons should
within 0.03 mm (0.001 in.). Excessive stoning not have more than a few thousandths clear-
will remove the hardened surface. If wear or ance. Replace if necessary.
damage is extensive, replace the valve plate. 15. Check the end play of piston shoes (2, Figure 6-
19). The piston shoes must pivot smoothly, but
end play must not exceed 0.152 mm (0.006 in.).
Rotating Group 16. Measure each shoe at dimension (A) as shown
9. Inspect cylinder barrel (1, Figure 6-18). Check in Figure 6-19. All shoes must be equal within
the piston bores and the face that mates with 0.025 mm (0.001 in.) at this dimension.
the valve plate for wear and scoring.
17. Check each shoe contact face (3). Faces must
10. Remove minor defects on the face by lightly be free of nicks or scratches. If one or more pis-
stoning or lapping the surface. If defects can not ton/shoe assembly needs to be replaced,
be removed by this method, replace the cylinder replacement of all piston/shoe assemblies is
barrel. necessary.
18. When installing new piston/shoe assemblies or
the rotating group, verify that the pistons are
free in their bores.

Drive Shaft Group
24. Remove shaft seal (5, Figure 6-16).
25. Check shaft bearing (6) for galling, pitting, bind-
ing or roughness. Replace if necessary.
26. Check the rear shaft bushing in the valve plate.
27. Check the shaft and its splines for wear.
Replace any parts if necessary.
Assembly
The procedure for assembling the pump is basically
FIGURE 6-19. PISTON/SHOE INSPECTION the reverse order of the disassembly procedure. Dur-
ing assembly, install new gaskets, seals, and O-
1. Piston 3. Shoe Contact Face rings.
2. Shoe
1. Apply a thin film of clean grease or hydraulic oil
to sealing components to ease in assembly. If a
new rotating group is used, lubricate thoroughly
with clean hydraulic fluid. Apply oil generously
Swashblock Group
to all wear surfaces.
19. Inspect swashblock (14, Figure 6-16) for wear
and scoring. If defects are minor, stone the
swashblock, lightly. If damage is extensive,
Swashblock Group
replace the swashblock.
20. Check the small holes in the face of the swash-
block. These passageways are ports for the
hydrostatic balance fluid of the piston/shoe
assembly. The fluid is channelled through the
swashblock to the face of the saddle bearing Use extreme care when installing the saddle
providing lubrication. bearing into the pump housing. DO NOT damage
21. Inspect saddle bearing (13). Compare the thick- the bearing surfaces
ness in a wear area to the thickness in a non-
wear area. Replace the saddle bearing if the dif- 2. Press new shaft seal (5, Figure 6-16) into the
ference is greater than 0.40 mm (0.015 in.). front of the pump housing.
22. Check the mating surface of the swash block for 3. Place the housing on a workbench with the
cracks or excessive wear. Replace if necessary. mounting flange side down.
23. Swashblock movement in the saddle and the 4. If removed or replaced, press two roll pins (11)
saddle bearing must be smooth. Replace if nec- into the pump housing until the pins extend 1.3
essary. to 1.6 mm (0.050 to 0.065 in.) from the case.
5. Lubricate the back side of saddle bearings (13)
and place on the pins to orient the bearing in
the pump case. Do not allow the pin to protrude.

6. Partially insert swashblock (14) into the pump Rotating Group
housing. 18. Lubricate mating surfaces with grease or
7. Insert guide plate (8) into the case. Install hydraulic oil. Position cylinder barrel (1, Figure
screws (7) to secure the guide plate to the 6-20) downward on its wear surface, on a clean
housing. cloth.
8. Place the swashblock on the guide plate. The 19. Place shoe retainer spring (2) in the center of
guide plate must be positioned in the groove of the barrel. Place fulcrum ball (3) on top.
the swashblock.
20. Insert pistons (5). Install the pistons in shoe
9. Once in place, verify that the swashblock swiv-
retainer (4). Orient the pistons in their corre-
els in the saddle bearings. With new bearings,
sponding, numbered holes.
swivelling may be stiff and not always smooth.
21. As a unit, fit the pistons into their corresponding,
10. Verify roll pins (8, Figure 6-20) are inserted into
numbered, bores in the cylinder barrel. DO NOT
cylinder bearing (7).
force. If aligned properly, the pistons will fit
11. Position the cylinder bearing with the pins smoothly.
located nearest the control facing the outboard
end of the drive shaft. Position the bearing with
the "scarf" cuts positioned top and bottom with
pins (8) located on top of internal cast boss. The
bearing should fit into place with little difficulty The assembled rotating group weighs approxi-
and be square to the axis of the pump. mately 7 kg (15 lb). Assistance from others and
12. Tap the bearing into place, if necessary. Use proper use of proper lifting techniques is
extreme care. DO NOT damage the bearing. strongly recommended to prevent personal
injury and damage to the pump.
13. Install retaining ring (6).
22. Carefully install the rotating group over the end

Drive Shaft Group of the drive shaft and into the pump housing.
14. Place the housing on its side with the axis hori- When installing the rotating group, support the
zontal. Install seal retainer (4, Figure 6-16). weight of the cylinder barrel as the cylinder
spline is passed over the end of drive shaft to
15. Place front drive shaft bearing (3) onto drive avoid damage.
shaft (6) and lock in place with shaft retaining
ring (2). 23. Push the cylinder barrel forward until the cylin-
der spline reaches the drive shaft spline. Rotate
16. Lubricate shaft seal (5) and the shaft. the cylinder slightly to engage the shaft splines.
17. Insert the drive shaft and bearing assembly into 24. Continue to slide the cylinder barrel forward
the housing and lock in place with retainer ring until it encounters cylinder bearing (7). Slightly
(1). lifting the drive shaft helps cylinder barrel and
cylinder bearing engagement. Continue push-
ing the cylinder forward until the piston shoes
contact the swashblock.
25. At this point, the back of the cylinder barrel
should be located approximately 10.2 mm (0.4
in.) inside the back of the pump bearing.

Valve Plate Group
26. Place the pump housing on a bench with the 28. Install rear valve plate (17). Verify the end of the
open end facing up. drive shaft engages the bushing in the rear
valve plate while positioning the valve plate on
27. Install O-ring (10, Figure 6-16) and use assem-
pins (11) and on the housing.
bly grease to secure. Install gasket (16) over the
roll pins on the housing. 29. Install one cap screw (18) closest to O-ring (10)
first. Do not tighten the cap screw. Then, install
and alternately tighten the other cap screws.
FIGURE 6-20. ROTATING GROUP ASSEMBLY

1. Cylinder Barrel 4. Shoe Retainer 7. Cylinder Bearing
2. Spring 5. Piston & Shoe Assembly 8. Roll Pin
3. Fulcrum Ball 6. Retainer Ring

FIGURE 6-21. PUMP CONTROL GROUP
1. Control Housing 9. O-Ring 17. Relief Poppet 25. Orifice
2. Capscrew 10. Control Piston Pin 18. Relief Valve Seat 26. Orifice
3. Capscrew 11. Plug 19. O-Ring 27. Spring
4. O-Ring 12. Plug 20. Orifice 28. End Plug
5. Main Control Piston 13. O-Ring 21. Plug 29. O-Ring
6. Spring 14. Relief Valve Bonnet 22. O-Ring 30. Orifice
7. Bias Control Piston 15. Spring 23. End Cap 31. Gasket
8. Gasket 16. Shim 24. 4-Way Valve Spool
Control Group 35. Lubricate and install main control piston (5),
spring (6), and bias control piston (7) into hous-
30. Insert orifice (20, Figure 6-21). Install a new O-
ing (1).
ring (19) onto relief valve seat (18). Install and
tighten the seat, securely. 36. Install new O-rings (4), gasket (31), and place
end cap assembly (23) on the housing.
31. Install relief poppet (17), shim (16) and spring
(15). 37. install cap screws (3) and tighten evenly.
32. Install relief valve bonnet (14). 38. Install plugs (11 & 12).
33. Install orifice (30), plugs (21) and O-rings (22). 39. Place a new gasket (8) into position on the
pump housing. Install a new O-ring (9) onto the
34. Place four-way valve spool (24) in the bore.
control housing. Position the control group
Install orifices (25 & 26), spring (27), O-ring (29)
assembly over the pump housing. Insert control
and end plug (28).
piston pin (10) and align the control group over
the opening in the pump housing.
40. Install cap screws (2) and tighten evenly.

STEERING CIRCUIT FILTER
Removal
The steering circuit filter is located on the left frame
rail, forward of the hydraulic tank.

possibly death. Seek medical treatment by a phy-
sician familiar with this injury, immediately.

seconds for the accumulators to depressurize.
Operate the steering wheel to verify that system
pressure has been relieved.
Avoid contact with hot oil. Contain the oil when

draining and properly dispose. Do not contami-
nation!
3. Remove housing (8) and element (7).

4. Discard O-ring (4) and backup ring (5) in the fil-
ter head.
Installation
1. Install a new O-ring (4) and backup ring (5) in
the filter head.
2. Install a new element (7). Install housing (8) and
tighten.
3. Replace drain plug (10), and O-ring (9).
NOTE: The indicator switch (2, Figure 6-22) is preset FIGURE 6-22. STEERING CIRCUIT FILTER
to actuate at 241 kPa (35 psi). The switch is not
repairable or adjustable. If the indicator switch is 1. Head 6. Bypass Valve
inoperative, replace the complete switch. 2. Indicator Switch 7. Filter Element
3. O-Ring 8. Housing
4. O-Ring 9. O-Ring
5. Backup Ring 10. Plug

TROUBLESHOOTING CHART
SYMPTOM: Slow Steering, Hard Steering or Loss of Power Assist
Overloaded Steering Axle Reduce Axle Loading
Malfunctioning flow amplifier valve allowing system Repair or replace flow amplifier valve
pressure to be lower than specified
Worn or malfunctioning pump Replace pump
SYMPTOM: Drift - Truck Veers Slowly In One Direction.
Rod end of cylinder slowly extends without turning the A small rate of extension may be normal on a closed
steering wheel center system
Worn or damaged steering linkage Replace linkage and check alignment or toe-in of the
front wheels
SYMPTOM: Wander - Truck Will Not Stay In Straight Line
Air in system due to low oil level, pump cavitation, leak- Correct oil supply problem
ing fitting, pinched hoses, etc.
Loose cylinder piston Repair or replace defective components
Broken centering springs (Spool Valve, Steering Unit) Replace centering springs
Worn mechanical linkage Repair or replace
Bent linkage or cylinder rod Repair or replace defective components
Severe wear in steering control unit Repair steering control unit
SYMPTOM: Slip - A Slow Movement of Steering Wheel Fails To Cause Any Movement of the Steered
Wheels
Cylinder piston seal leakage Replace seals
Worn steering control unit meter Replace steering control unit
SYMPTOM: Spongy or Soft Steering
Low oil level. Service hydraulic tank and check for leakage
Air in hydraulic system. Most likely air trapped in cylin- Bleed air from system. Placing ports on top of cylinder
ders or lines will help avoid trapping air
SYMPTOM: Erratic Steering
Air in system due to low oil level, cavitating pump, Correct condition and add oil as necessary
leaky fittings, pinched hose, etc.
Loose cylinder piston Replace cylinder

TROUBLESHOOTING CHART
SYMPTOM: Free Wheeling - Steering Wheel Turns Freely with No Back Pressure or No Action of the
Front Wheels
Lower splines of steering column may be disengaged Repair or replace steering column
or damaged
No flow to steering unit can be caused by:

1. Low oil level 1. Add oil and check for leakage
2. Ruptured hose 2. Replace hose
3. Broken gerotor drive pin 3. Replace drive pin
SYMPTOM: Excessive Free Play at Steered Wheels
Broken or worn linkage between cylinder and steered Check for loose fitting bearings at anchor points in
wheels steering linkage between cylinder and steered wheels
Leaky cylinder seals Replace cylinder seals
SYMPTOM: Binding or Poor Centering of Steered Wheels
Binding or misalignment in steering column or splined Align column pilot and spline to steering control unit
column or splined input connection
High back pressure in tank can cause slow return to Reduce restriction in the lines or circuit by removing
center obstruction or pinched lines, etc.
Large particles can cause binding between the spool Clean the steering control unit and filter the oil. If
and sleeve in the steering control valve another component has malfunctioned generating con-
taminating materials, flush the entire hydraulic system
SYMPTOM: Steering Control Unit Locks Up
Large particles in meter section Clean the steering control unit
Insufficient hydraulic power Check hydraulic power supply
Severe wear and/or broken pin Replace the steering control unit
SYMPTOM: Steering Wheel Oscillates or Turns By Itself
Lines connected to wrong ports Check line routing and connections
Parts assembled wrong. Steering control unit improp- Reassemble correctly and time control unit
erly timed
SYMPTOM: Steered Wheels Turn in Opposite Direction When Operator Turns Steering Wheel
Lines connected to wrong cylinder ports Check proper line connections

SECTION L7
HOIST CIRCUIT
INDEX
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-3
HOIST CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hoist Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
Hoist Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-5
Power Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
Power Down Spool Limit Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-6
HOIST CIRCUIT HYDRAULIC FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-7
POWER UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-9
HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-11
POWER DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-13
FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-15
L07036 Hoist Circuit L7-1

NOTES
L7-2 Hoist Circuit L07036

HOIST CIRCUIT
HOIST CIRCUIT OPERATION

The following information describes the basic hoist Hydraulic oil from the pump is directed to hoist valve
circuit. Further circuit description is outlined under (12) mounted outboard of the left hand frame rail,
the individual component descriptions. behind the hydraulic tank.
Hydraulic fluid is supplied from the rear section of a The hoist valve directs oil to the body hoist cylinders
two section tank located on the left frame rail. Refer (15) for raising and lowering of the dump body. The
to Figure 7-1, Hoist Circuit Diagram. Hydraulic oil is hoist valve functions are controlled by the operator
routed to tandem gear pump (4). The pump is driven through a flexible cable to hoist pilot valve (8) in the
by a Power Take Off (PTO) gear case mounted on hydraulic component cabinet located to the right of
the front of the transmission. the operator's cab. Also in the hydraulic cabinet are
the power up hoist limit solenoid (10), piloted check
valve (11), and power down solenoid (9).
FIGURE 7-1. HOIST CIRCUIT DIAGRAM
1. Hydraulic Tank (Rear Section) 6. Manifold 11. Pilot Operated Check Valve
2. Heat Exchanger 7. Brake Control Valve (BCV) 12. Hoist Valve
3. Low Pressure Filters 8. Hoist Pilot Valve 13. Snubber Valve
4. Tandem Gear Pump (Hoist) 9. Power Down Hoist Limit Solenoid 14. Hoist Cylinders
5. Rear Disc Brakes 10. Power Up Hoist Limit Solenoid

COMPONENT DESCRIPTION
Hydraulic Tank Hoist Valve
The hydraulic tank supplies hydraulic oil for the hoist, Hoist valve (Figure 7-3) is mounted outboard of the
steering, and brake circuits. The tank is located on left hand frame rail, between the frame rail and
the left hand frame rail forward of the rear wheels. hydraulic tank. The hoist valve is a split spool design.
The service capacity of the tank is 576 L (152 gal). The term "split spool" describes the spool section of
Refer to Section P, Lubrication and Service for more the valve.
information on servicing the hydraulic system.
Separate spools control oil flow to each end of the
Oil used in the hoist circuit flows through two 100 cylinders. The valve consists of two identical inlet
mesh wire suction strainers to the inlet housing of the sections, a spool section, and a separator plate.
hoist pump. Air drawn into the tank during operation
The hoist valve precisely follows differential pressure
is filtered by a breather located on the top of the tank.
input signals generated by hoist pilot valve (1, Figure
Oil level can be checked visually at sight glasses
7-3).
located on the face of the tank. The oil level must be
maintained between the sight glasses with the body The inlet sections of the hoist valve consist of the fol-
down and the engine shut off. lowing components:
Flow control and main relief valve (system relief)
Hoist Pump Low pressure relief valve

Load check poppet
The hoist pump is a tandem gear type pump driven
by the transmission PTO gear case. The pump has a Anti-void poppet
total output of 845 l/min (224 gpm) at 2100 rpm. Max- The flow control portion of the flow control and main
imum hoist pump output pressure is 18, 961 kPa relief valve allows pump flow to the brake cooling cir-
(2750 psi). Pump output pressure is limited by relief cuit or return directly to tank through the inlet section
valves located within the hoist control valve. with low pressure loss. The relief portion of the valve
If the operator is not raising the truck body, hoist cir- is direct-acting, and has the capacity to limit the
cuit oil is routed to the rear disc brake cooling circuit working pressure at full pump flow.
and the rear brake control valve. If the brakes are not The low pressure relief is located between the low
applied, 50% of the oil will be routed directly back to pressure core and the outlet, and provides a con-
the hydraulic tank by the brake control valve and the trolled back pressure in the low pressure core when
remaining 50% is routed to the disc brake housings. oil is returning to tank.
Oil leaving the brake housings is routed through low
pressure filters and a heat exchanger before return- The load check allows free flow from the inlet to the
ing to the hydraulic tank. high pressure core and prevents flow from the high
pressure core to the inlet.
The anti-void check valve allows free flow from the
low pressure core to the high pressure core and pre-
vents flow from the high pressure core to the low
pressure core.

When there is flow through a pilot port to a spool, a
positive differential pressure at the top of the spool
will overcome the bottom spring bias causing the
spool to shift to connect the high pressure core to the
work port. When there is flow from the main valve
work port to the pilot port through the cross-holes, a
positive differential pressure at the bottom of the
spool will overcome the top spring bias and the spool
will shift to connect the work port to the low pressure
core.
The check poppets located in the main spools permit
free flow from the work port to the pilot port and
restrict flow from the pilot port to the work port. These
check poppets control spool response and spool
movements.
Hoist Pilot Valve

The hoist pilot valve is located in the hydraulic cabi-
net. (Refer to Figure 7-3.) The hoist pilot valve spool
FIGURE 7-2. HOIST VALVE
is spring centered to the HOLD position. The hoist
1. Inlet Section 3. Inlet Section pilot valve is controlled directly by the operator
2. Top Spool Section 4. Spool Section through a lever and cable arrangement. The control
Cover lever is located between the operator and center con-
sole. When the operator moves the lever, the pilot
valve spool moves and directs pilot flow to the appro-
priate pilot port on the hoist valve causing the main
spools to direct working pump flow to the hoist cylin-
ders.
The spool section of the hoist valve consists of the
The hoist pilot valve is equipped with a one way load
following components:
check valve which allows free flow from the center
Two pilot ports passage to bridge core and prevents reverse flow.
Two main spools The hoist pilot valve is also equipped with a power
down relief valve (1, Figure 7-3). The power down
Two work ports relief valve is located between the power down con-
Check poppets trol port and return galley. The power down relief
valve limits power down pressure at 10, 342 kPa
The pilot ports are located in the top spool section (1500 psi).
cover (2, Figure 7-3). These ports provide connec-
tions for pilot lines from the hoist pilot valve. Each
pilot port has a corresponding work port.
The work ports provide for line connections between
spool section (4) and the hoist cylinders. One main
spool for each work port is spring centered at both
ends to close the work port from the high and low
pressure cores when there is no flow to the pilot
ports.

Pilot Operated Check Valve
Pilot operated check valve (7, Figure 7-3) is opened
by the power down pilot pressure line to allow oil in
the raise port to bypass the power up solenoid. This
enables for initial power down operation while the
solenoid is activated by the hoist limit switch.
Power Down Spool Limit Solenoid

Power down valve (6, Figure 7-3) activates, along
with the power up solenoid, locking the power down
spool in the HOLD position. This solenoid is only acti-
vated when the body is raised and is positioned with
the hoist cylinders near full extension, in the hoist
limit zone.
Moving the hoist lever to the HOLD position prevents
the body from floating down after the body has been
raised. In addition, it prevents the body from floating
up and the cylinders fully extending if an external
force is applied to the tail of the body, such as if the
truck were backed into a berm.
FIGURE 7-3. HOIST PILOT CIRCUIT
1. Power Down Relief 4. Manifold

Valve 5. Control Cable
2. Hoist Pilot Valve 6. Power Down Solenoid
3. Power Up Solenoid 7. Piloted Check Valve
Power Up Solenoid
Power up solenoid (3, Figure 7-3) is used in the
hydraulic circuit to prevent maximum hoist cylinder
extension.
The solenoid valve is "normally closed" and is con-
trolled by a proximity switch (hoist limit switch). The
switch is located inside the rear frame rail near the
body pivot pin. When the solenoid is signalled to
open by the hoist limit switch, the raise pilot line is
opened to tank. This allows the hoist control spools
to shift to center stopping oil flow to the cylinders.
This locks the circuit in the HOLD position.

HOIST CIRCUIT HYDRAULIC FLOW
The following outline describes the hoist circuit oper-
ation in the FLOAT, POWER UP, HOLD, and
POWER DOWN positions. (Refer to Figures 7-4
through 7-8.)
FLOAT Position With Body On Frame

This is the proper position for truck travel. The pilot
valve spool position is illustrated in Figure 7-4. How-
ever, all hoist valve components are in position
shown in Figure 7-6. Oil from the hoist pumps enters
each inlet section of the hoist valve in port (11), FIGURE 7-4. HOIST CIRCUIT FLOAT POSITION
passes through check valve (18), and stops at the 1. Hoist Relief Valve 18, 961 kPa (2750 psi)
closed high pressure passage (19) at the two main 2. Flow Control Valve
spools. Pressure builds to approximately 414 kPa 3. Low Pressure Relief Valve 517 kPa (75 psi)
(60 psi) on the pilot of flow control valve (2) causing 4. Snubber Valve
the valve to compress the spring and open. This 5. Rod End Work Port
allows the oil to return to the tank through hoist valve 6. Hoist Cylinders
port (10) and (21). Oil also flows out hoist valve port 7. Rod End Spool
(12) to port (12) on the pilot valve, through the hoist 8. Head End Spool
pilot valve spool, and out pilot valve port (10) to the 9. Head End Work Port
tank. This oil flow is limited by orifices in the inlet sec- 10. Return to Tank Port
tions of the hoist valve and therefore has no pressure 11. Supply Port
buildup. 12. Pilot Supply Port
13. Power Up Limit Solenoid
14. Raise Pilot Port
15. Down Pilot Port
16. Power Down Relief Valve 10, 342 kPa (1500 psi)
17. Anti-void Check Valve
18. Load Check Valve
19. High Pressure Passage
20. Low Pressure Passage
21. Brake Cooling Oil/Return to Tank
22. Pilot Operated Check Valve
23. Power Down Hoist Limit Solenoid

FIGURE 7-4. HOIST CIRCUIT, FLOAT POSITION

POWER UP
Refer to Figure 7-5 for the following description. If the load passing over the tail of the body during
dumping attempts to cause the body to raise faster
The hoist pilot valve spool is moved to the POWER
than the oil being supplied by the pump, the oil
UP position when the operator moves the lever in the
returning from the annulus area of the hoist cylinders
cab. The pilot supply oil coming in port (12) is pre-
passing through the snubber valve (4) controls how
vented from returning to the tank and, instead, is
fast the hoist can extend because of the external
directed out port (14) and into port (14) of the hoist
force of the load. The speed is controlled by the
valve. There it goes to the top of head end spool (8),
restriction of the snubber valve. When the operator
builds pressure on the end of the spool, causes the
releases the lever, the valves change to the HOLD
spool to move down compressing the bottom spring,
position.
and connects the high pressure passage (19) to
head end port (9). Working oil flow in the high pres- If the body raises to the position that activates the
sure passage is now allowed to flow through the hoist limit switch before the operator releases the
spool and out port (9) to extend the hoist cylinders. lever, hoist limit solenoid (13) is energized. The sole-
Even though a small amount of oil flows through the noid valve opens and releases the raise pilot pres-
check poppet in the top of spool (8), raise pilot pressure at ports (14) to tank, allowing the head end
sure at ports (14) increases to slightly higher pres- spool (8) to center and shut off supply oil to the hoist
sure than the required hoist cylinder pressure. As a cylinders. This prevents maximum extension of the
result, the pilot supply pressure in port (12) also hoist cylinders.
increases causing back pressure to occur in the
spring area of flow control valve (2). This overcomes
the pilot pressure on the other end of the flow control
valve causing it to close and direct the incoming FIGURE 7-5. HOIST CIRCUIT, POWER UP
pump oil through head end spool (8) to the hoist cyl- POSITION
inders to extend them. 1. Hoist Relief Valve 18, 961 kPa (2750 psi)
2. Flow Control Valve
If at any time the resistance to the flow of the pump
3. Low Pressure Relief Valve 517 kPa (75 psi)
oil coming into the inlet section causes the pressure
4. Snubber Valve
to increase to 18, 961 kPa (2750 psi), the pilot pres-
5. Rod End Work Port
sure acting against hoist relief valve (1) causes it to
6. Hoist Cylinders
open and allow flow to exit out port (21) and return to
7. Rod End Spool
the tank.
8. Head End Spool
As the hoist cylinders extend, oil in the annulus area 9. Head End Work Port
of the second and third stages must exit from the cyl- 10. Return to Tank Port
inders. Initially, the rod end spool (7) ports are 11. Supply Port
closed. As the returning oil entering port (5) builds 12. Pilot Supply Port
low pressure, it flows through the check-poppet in the 13. Power Up Limit Solenoid
top of the spool, through ports (15), through the pilot 14. Raise Pilot Port
valve spool, and out port (10) of the pilot valve to the 15. Down Pilot Port
tank. No pressure is present on the top of spool (7). 16. Power Down Relief Valve 10, 342 kPa (1500 psi)
Cylinder return pressure passes through the check- 17. Anti-void Check Valve
poppet in the bottom of spool (7) to build pressure 18. Load Check Valve
under the spool which moves the spool upward com- 19. High Pressure Passage
pressing the top spring. This movement allows the 20. Low Pressure Passage
returning cylinder oil to flow into the low pressure 21. Brake Cooling Oil/Return to Tank
passage (20) to low pressure relief valve (3). Approx- 22. Pilot Operated Check Valve
imately 517 kPa (75 psi) causes this valve to open, 23. Power Down Hoist Limit Solenoid
allowing the oil to flow out port (10) to the tank.

FIGURE 7-5. HOIST CIRCUIT, POWER UP POSITION

HOLD
Refer to Figure 7-6 for the following description.
When the operator releases the lever as the body
travels upward, the hoist pilot valve spool returns to
the HOLD position. The pilot valve spool is posi-
tioned to allow the pilot supply oil entering port (12) to
return to the tank through port (10). Pilot supply pres-
sure in ports (12) then decreases to zero pressure
allowing flow control valve (2) to open and return the
incoming pump oil to the tank through port (10). Both
pilot ports (14 & 15) in the pilot valve are closed by
FIGURE 7-6. HOIST CIRCUIT, HOLD POSITION
the pilot valve spool. In this condition pressure is
1. Hoist Relief Valve 18, 961 kPa (2750 psi)
equalized on each end of each main spool allowing
the springs to center the spools and close all ports to
trap the oil in the cylinders and hold the body in its
4. Snubber Valve
current position.
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
9. Head End Work Port
10. Return to Tank Port
11. Supply Port
12. Pilot Supply Port
15. Down Pilot Port

FIGURE 7-6. HOIST CIRCUIT, HOLD POSITION

POWER DOWN
When the operator moves the lever to lower the
body, the hoist pilot valve is positioned to direct the
pilot supply oil in ports (12) through ports (15) to the
top of rod end spool (7). Pilot pressure increases to
move the spool down compressing the bottom
spring. Movement of the spool connects high pres-
FIGURE 7-7. HOIST CIRCUIT, POWER DOWN
sure passage (19) to the rod end (annulus area) of
the hoist cylinders. At the same time, flow control
valve (2) is forced to close as pilot pressure
increases thus directing the incoming pump oil to the
4. Snubber Valve
hoist cylinders through spool (7) and snubber valve
(4) rather than back to the tank.
6. Hoist Cylinders
The pilot pressure in port (14) is open to tank through 7. Rod End Spool
the pilot valve spool. As oil attempts to return from 8. Head End Spool
the head end of the hoist cylinders, it initially encoun- 9. Head End Work Port
ters the closed head end spool (8). Pressure 10. Return to Tank Port
increases on the bottom end of the spool causing it to 11. Supply Port
move upward. This allows the returning oil to go into 12. Pilot Supply Port
low pressure passage (20), build up 517 kPa (75 psi) 13. Power Up Limit Solenoid
to open low pressure relief (3), and exit the hoist 14. Raise Pilot Port
valve through port (10) to the tank. 15. Down Pilot Port

FIGURE 7-7. HOIST CIRCUIT, POWER DOWN

FLOAT
When the operator releases the lever as the body
travels downward, the hoist pilot valve spool returns
to the FLOAT position. In this position all ports (10,
12, 14, & 15) are common with each other. There-
fore, the pilot supply oil is returning to tank with no
pressure build-up thus allowing flow control valve (2)
to remain open to allow the pump oil to return to the
tank through hoist valve port (21). With no blockage
of either raise or down pilot ports (14 & 15) in the pilot
valve, there is no pressure on the top of either main
spool. The oil returning from the head end of the
hoist cylinders builds pressure on the bottom of the
head end spool (8) exactly like in power down allow-
4. Snubber Valve
ing the returning oil to transfer to the low pressure
passage (20). The back pressure in the low pressure
6. Hoist Cylinders
passage created by low pressure relief valve (3)
7. Rod End Spool
causes pressure under rod end spool (7) to move the
8. Head End Spool
spool upward. This connects the low pressure pas-
9. Head End Work Port
sage to the rod end of the hoist cylinders. The 517
10. Return to Tank Port
kPa (75 psi) in the low pressure passage causes oil
11. Supply Port
to flow to the rod end of the cylinders to keep them
12. Pilot Supply Port
full of oil as they retract. When the body reaches the
frame and there is no more oil flow from the cylin-
ders, the main spools center themselves and close
15. Down Pilot Port
the cylinder ports and the high and low pressure Pas-
sages.


SECTION L8
HOIST CIRCUIT COMPONENT REPAIR
INDEX
HOIST CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-3
O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-4
INLET SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6
SPOOL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-9
HOIST PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-11
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-12
HOIST CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-15
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-17
Assembly - Quill And Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-18
Quill Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-18
Installation Of Check Balls And Plugs In Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-19
Assembly of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-20
L08040 05/08 Hoist Circuit Component Repair L8-1

NOTES
L8-2 Hoist Circuit Component Repair 05/08 L08040

HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE Removal

1. Shut off the engine and turn the key switch to
OFF. Allow at least 90 seconds for the accumu-
lators to bleed down. Turn the steering wheel to
ensure hydraulic pressure has been relieved
before removing any hydraulic lines.
Relieve pressure before disconnecting hydraulic 2. Thoroughly clean the exterior of the hoist valve.
lines. Pressurized hydraulic fluid can enter a per- 3. Disconnect and plug all line connections to help
son's body by penetrating the skin, causing seri- prevent hydraulic oil contamination. Refer to
ous injury or death. Seek the proper medical Figure 8-1. Tag lines to ensure proper hookup
treatment by a physician familiar with this type of when the valve is re-installed.
injury if necessary. 4. Attach a suitable lifting device to the hoist valve
and remove from truck. The hoist valve weighs
5. Remove cap screws, washers and nuts (3, Fig-
ure 8-1) securing the hoist valve to its mounting
bracket.
6. Lift the hoist valve from the truck and move to a
clean work area for disassembly.
Installation
1. Attach a suitable lifting device to the hoist valve
and remove from truck. The hoist valve weighs
2. Lift the hoist valve into position and secure in
place with cap screws, nuts and washers (3,
Figure 8-1). Tighten the capscrews to standard
torque.
3. Install new O-rings at the flange fittings, and
connect the hydraulic lines. Tighten the flange
cap screws to standard torque. Refer to Figure
8-1 for hydraulic line location.
4. Connect the pilot supply lines and tighten the fit-
tings, securely.
5. Start the engine. Raise and lower the body to
check for proper operation. Observe for leaks.
6. Service the hydraulic tank if necessary.
FIGURE 8-1. HOIST VALVE REMOVAL
1. Supply From Pump 4. To Hydraulic Cabinet
2. Return To Manifold/ 5. To Hoist Cylinders
BCV 6. Return To Tank
3. Capscrews, Washers & 7. To Hoist Cylinders
Nuts 8. Snubber Valve

FIGURE 8-3. TIE ROD INSTALLATION
3. Lubricate the new O-rings lightly with multipur-

pose grease. Replace O-rings between sec-
tions. Stack the sections together. Ensure the
O-rings are properly positioned.
4. Install the four tie rods with the dished washer
between the nut and housing as shown in Fig-
ure 8-3.
5. Torque the nuts in the pattern shown in Figure
FIGURE 8-2. HOIST VALVE 8-4. Tighten the nuts evenly in the following
1. Inlet Section 7. Outlet Port sequence.
2. Spool Section Cover 8. Inlet Port a. Tighten evenly to 27 Nm (20 lb ft) - tighten-
3. Spool Section 9. Tie Rods ing order 1, 4, 2, 3.
4. Spacer 10. Nuts and Washers
b. Tighten evenly to 68 Nm (50 lb ft) - tighten-
5. Inlet Section 11. Inlet Section Cover
ing order 1, 4, 2, 3.
6. Relief Valve Cover
c. Torque evenly to 217 Nm (160 lb ft) - tight-
ening order 1, 4, 2, 3.
O-Ring Replacement
NOTE: It is not necessary to remove the individual
valve sections for repair unless emergency field
repair is required to replace leaking O-rings between
sections. Loosening and tightening of the main valve
tie rod nut could cause distortion resulting in binding
or severely sticking plungers, poppet and spools.
The following procedure is for replacing the O-rings
between the valve sections.
1. Remove four tie rod nuts (10, Figure 8-2) from
one end of the valve. Slide tie rods (9) from the
valve and separate the sections.
2. Inspect the machined sealing surfaces for
scratches or nicks. If scratches or nicks are
found, remove by lapping on a smooth flat steel FIGURE 8-4. TORQUE SEQUENCE
surface with fine lapping compound.

FIGURE 8-5. INLET SECTION DISASSEMBLY
1. Capscrew 5. Spring 9. Inlet Valve Body 13. Cover

2. Inlet Cover 6. Sleeve 10. O-Rings 14. Capscrews
3. Spring (Orange) 7. Low Pressure Relief 11. Poppets
4. Main Relief Valve 8. O-Rings 12. Springs
INLET SECTION
Disassembly
1. Match mark or identify each part when removed
in respect to its location or mating bore to aid
reassembly.
2. Disconnect the external tube at the cover end
and remove. Remove capscrews (14, Figure 8-
5), remove cover (13). Remove springs (12),
poppets (11) and O-rings (10).
NOTE: Figure 8-5 shows the inlet section removed
from the main valve body for clarity.
3. Remove capscrews (1) and cover (2). Remove
springs (3 & 5) and main relief valve (4).
Remove sleeve (6), low pressure relief (7) and
O-rings (8). DO NOT attempt to disassemble or
change the adjustment of main relief valve (4).
The main relief is factory preset at 18, 961 kPa
(2750 psi). Replace as a complete assembly
only.
4. Remove sleeve (9), backup ring (8), O-ring (7),
and backup ring (6). Remove backup ring (5),
O-ring (4), backup ring (3) and restrictor poppet
(2).
5. Repeat the previous steps for the opposite inlet FIGURE 8-6. RESTRICTOR POPPET REMOVAL
section, if required. 1. Inlet Cover 6. Backup Ring
2. Restrictor Poppet 7. O-ring
3. Backup Ring 8. Backup Ring
4. O-Ring 9. Sleeve
5. Backup Ring

Cleaning and Inspection SPOOL SECTION
1. Discard all O-rings and backup rings. Clean all Disassembly
parts in solvent and dry with compressed air.
2. Inspect all springs for breaks or distortion. NOTE: It is not necessary to remove inlet sections (1
Inspect poppet seating surfaces for nicks or & 5, Figure 8-2) for spool section (3) disassembly.
excessive wear. All seats must be sharp and 1. Match mark or identify each part when removed
free of nicks. in respect to its location or rmating bore to aid
3. Inspect all bores and surfaces of sliding parts during reassembly.
for nicks, scores or excessive wear. 2. Remove the capscrews that secure spool sec-
4. Inspect poppets in their respective bore for fit. tion cover (2, Figure 8-2). Remove the cover.
Poppets should move freely, without binding, 3. Remove poppet (1, Figure 8-7) from the cover.
through a complete revolution. Remove and discard O-ring (3).
5. Inspect fit and movement between sleeve and NOTE: Poppet (1) is equipped with a small steel ball
low pressure relief valve. (2). Do not misplace.
Assembly 4. Remove and discard seal ring (4, Figure 8-8)
and O-rings (5).
1. Coat all parts including housing bores with
5. Remove restrictor poppet (1). Remove and dis-
clean hydraulic oil. Lubricate O-rings lightly with
card O-ring (2) and backup ring (3), if used.
a multipurpose grease.
Note the position of the restrictor when removed
2. If restrictor poppet (2, Figure 8-6) was removed, to aid in correct assembly.
reassemble in the order shown.
6. Remove spool assembly (2, Figure 8-9). Note
3. Install poppets (11, Figure 8-5) in their respec- the color of the lower spring (blue) to aid in
tive bores. Install springs (12). proper assembly. Also note V groove (1) on the
4. Install O-rings (10), and cover (13). Install cap- end of the spool.
screws (14). Tighten capscrews to 81 Nm (60 7. Remove plug (3, Figure 8-10) from the end of
lb ft). spool (20). Remove spring seat (2) and spring
5. Install low pressure relief (7) in sleeve (6) and (11). Remove poppet (21) and spool end (15).
install assembly in housing (9). Install main
relief valve (4). Install springs (3 & 5). Install
cover (2). Install capscrews (1). Tighten the
capscrews to 81 Nm (60 lb ft).
6. Connect the external tube. Tighten the nuts to
34 Nm (25 lb ft).
FIGURE 8-7. POPPET AND BALL

1. Poppet 3. O-Ring
2. Steel Ball

NOTE: Pay special attention to poppets (12, 21 and
22, Figure 8-10) during removal to ensure proper
assembly. Poppets may be identified with a colored
dot: red, white or green.
8. Repeat the previous step for the opposite end
of the spool.
9. Remove spool assembly (14) from the adjacent
bore.
10. Remove plug (3) from the end of the spool.
Remove spring seat (2) and spring (11).
Remove poppet (12) and spool end (15).
11. Repeat the previous step to remove the spring,
spring seat, and spool end for the other end of
spool. Note there is no plug or poppet installed
in the lower end of this spool.
12. Remove cover (19). Remove O-rings (4, 5, &
10). FIGURE 8-9. SPOOL REMOVAL
1. V Groove 3. Spool
2. Spool Assembly

1. Discard all O-rings and backup rings. Clean all
parts in solvent and blow dry with compressed
air.
2. Inspect all springs for breaks or distortion.
Inspect poppet seating surfaces for nicks or
excessive wear. All seats must be sharp and
free of nicks.
FIGURE 8-8. RESTRICTOR POPPET REMOVAL 3. Inspect all bores and surfaces of sliding parts
1. Restrictor Poppet 4. Seal Ring for nicks, scores or excessive wear.
2. O-ring * 5. O-Ring 4. Inspect all poppets in their respective bore for
3. Backup Ring * fit. Poppets should move freely without binding
through a complete revolution.
* NOTE: Items 2 and 3 not used on all valves.

FIGURE 8-10. SPOOL SECTION ASSEMBLY
1. Cover 9. Restrictor Poppet 17. O-Ring
2. Spring Seat 10. O-Ring 18. Poppet
3. Plug 11. Spring 19. Spool Cover
4. O-Ring 12. Restrictor Poppet (Green) 20. Spool Assembly
5. O-Ring 13. Spool Housing 21. Restrictor Poppet (Red)
6. Poppet 14. Spool Assembly 22. Restrictor Poppet (White)
7. Ball 15. Spool End
8. O-Ring 16. Spring (Blue)

Assembly
1. Lubricate O-rings (4, 5 & 10, Figure 8-10) with 6. Repeat the previous step for the bottom end of
clean hydraulic oil. Install the O-rings in the spool (14). A poppet and plug are not installed
spool housing. Install poppet (18) and install in the lower end. Spring (16) is blue in color.
cover (19). Install the capscrews that secure the 7. Lubricate the assembled spool and install in the
cover. Tighten the capscrews to 81 Nm (60 lb spool housing. Make sure the V groove is in the
ft). up position, or toward cover (1).
2. Install spring (11) in spool (20). Install spring
seat (2). Apply Loctite to the threads of spool
end (15). Install the spool end and tighten to 34
Nm (25 lb ft). Install red poppet (21). Apply Dri-
loc #204 to the threads of plug (3). Install the
plug and tighten to 20 Nm (15 lb ft). Spools (14) and (20) are physically interchange-
able. Ensure spool (14) is installed toward the
NOTE: Poppets 12, 21 and 22 may be color coded base port of the spool housing.
and must be installed in their original location.
3. Repeat the previous step for the opposite end 8. If used, install a new O-ring and backup ring on
of spool (20). Ensure poppet (22) is white and restrictor poppet (1, Figure 8-8). Install the
spring (16) is blue in color. restrictor poppet in the housing.
4. Lubricate the spool assembly and carefully 9. Install new O-rings (4, 5 & 10, Figure 8-10).
install in spool housing (13). Make sure the V
groove in the spool is in the up position, or 10. Install a new O-ring on poppet (6). Ensure the
toward cover (1). small steel ball is installed in the poppet. Install
the poppet in cover (1).
5. Install spring (11) in remaining spool (14).
Install spring seat (2). Apply Loctite to the 11. Install the cover on housing (13). Secure the
threads of spool end (15). Install the spool end cover in place with the cover capscrews.
and tighten to 34 Nm (25 lb ft). Install green Tighten the capscrews to 81 Nm (60 lb ft).
poppet (12). Apply Dri-loc #204 to the threads
of plug (3). Install the plug and tighten to 20
Nm (15 lb ft).

HOIST PILOT VALVE
1. Shut off the engine and turn the key switch to 1. Place hoist pilot valve (1, Figure 8-11) into posi-
OFF. Allow at least 90 seconds for the accumu- tion on the mounting bracket. Secure the valve
lators to bleed down. Turn the steering wheel to in place with the mounting capscrews.
ensure hydraulic pressure has been relieved 2. Connect the hydraulic hoses to the correspond-
before removing any hydraulic lines. ing ports. Tighten the hydraulic line connec-
2. Place the hoist control lever in the POWER tions, securely.
DOWN position. Ensure the body is at rest on NOTE: Seal plate (16, Figure 8-13) must be in place
the frame. Release the hoist control lever to when installing the the hoist cable. Leakage will
return the hoist valve spool to the FLOAT posi- result if the plate is not properly installed during cable
tion. installation.
3. Disconnect the hydraulic hoses from hoist pilot 3. Place the hoist control lever in the FLOAT posi-
valve (1, Figure 8-11). tion. Adjust the pilot valve spool until the center-
4. Remove capscrews (6, Figure 8-12). line of the cable attachment hole extends 29.5
5. Loosen and unscrew jam nut (3). Unscrew mm (1.16 in.) from the face of the valve body.
sleeve (2) until cotter pin (7) and pin (1) are Refer to Figure 8-12.
exposed.
6. Remove the cotter pin and pin (1).
7. Remove the hoist pilot valve mounting cap-
screws. Remove the hoist pilot valve.
FIGURE 8-11. HOIST PILOT VALVE PIPING
1. Hoist Pilot Valve 4. Power Down Solenoid

2. Power Up Solenoid 5. Power Down Relief
3. Control Cable Valve
FIGURE 8-12. HOIST PILOT VALVE PIPING
1. Pin 5. Flange
2. Sleeve 6. Capscrew
3. Jam Nut 7. Cotter Pin
4. Control Cable

4. Align the control cable eye with the valve spool
hole and install pin (1, Figure 8-12). Secure the
pin in place with cotter pin (7).
5. Thread sleeve (2) upward until contact is made
with the valve body. Move flange (5) into posi-
tion and secure in place with capscrews (6).
6. Thread jam nut (3) against the sleeve. Tighten
the jam nut, securely.
7. Start the engine and check for proper hoist
operation. Check for leaks and repair as neces-
sary.
Disassembly
1. Thoroughly clean the exterior of the valve.
Place the valve in a clean work area for disas-
sembly.
2. Remove machine screw (15, Figure 8-13) seal
plate (16), wiper (13) and O-ring (12).
3. Remove snap ring (1), capscrews (6), cap (24),
spacer (23), and detent sleeve (22). Separate
cap (24), spacer (23) and detent sleeve (22).
Detent balls (2) and (21) will fall free when the
cap and detent sleeve are removed.
4. Carefully slide spool (14) out of spool housing
(17). Remove seal retainer (25), wiper (26) and
O-ring (27) from spool (14).
5. Insert a rod in the cross holes of detent pin (3)
and unscrew from spool (14). Slight pressure
should be exerted against the detent pin as it
disengages and spring tension is released.
6. Remove spring seats (19), spring (4) and
spacer (5).
7. Remove relief valve (5, Figure 8-11) from the
valve housing.
FIGURE 8-13. HOIST PILOT VALVE
8. Scribe identifying marks on the inlet and outlet
housings in relationship to the spool housing to 1. Snap Ring 15. Machine Screw
ensure correct assembly. 2. Ball (4) 16. Seal Plate
3. Detent Pin 17. Spool Housing
9. Remove nuts (8 Figure 8-13) and nuts (10).
4. Spring 18. Inlet Housing
Remove tie rods (9). Separate the valve hous-
5. Spacer 19. Spring Seat
ings. Remove O-ring (11). Remove check pop-
6. Capscrew 20. Spring
pet (2, Figure 8-14) and spring (3) from housing
7. Outlet Housing 21. Ball (1)
(1).
8. Nut 22. Detent Sleeve
9. Tie Rod 23. Spacer
10. Nut 24. Cap
11. O-Ring 25. Seal Retainer
12. O-Ring 26. Wiper
13. Wiper 27. O-Ring
14. Spool

1. Clean all parts, including housings, in solvent
and blow dry with compressed air.
2. Inspect seal counter bores. The bores must be
free of nicks or grooves.
3. Examine springs for breaks or distortion.
4. Inspect spool (14, Figure 8-13). The spool must
be free of longitudinal score marks, nicks or
grooves.
5. Install spool (14) in the spool housing to check
the fit. The spool must fit freely, without binding,
through a complete revolution.
Spool housing (17), spool (14), inlet housing (18) and
outlet housing (7) are not serviced separately.
Should any of these parts require replacement, the
entire control valve must be replaced.
Assembly
FIGURE 8-14. HOIST PILOT VALVE REASSEMBLY
1. Thoroughly coat all parts, including the housing
bores, with clean hydraulic oil. 1. Spool Housing 4. O-ring
2. Check Poppet 5. Outlet Housing
2. Install check poppet (2, Figure 8-14) and spring 3. Spring
(3) in spool housing (1).
3. Install new O-ring (4) in spool housing. Place
the inlet and outlet housings onto the spool
housing.
4. Install the tie rods, and the tie rod nuts. Tighten
the tie rod nuts to the torques shown in Figure
8-15.
5. Install a new O-ring (27, Figure 8-13) and wiper
(26). Install seal retainer (25).
6. Install spacer (5), spring seats (19), and spring
(4). Thread detent pin (3) into spool (14). Slight
pressure will be required to compress the
detent spring. Tighten the detent pin to 9-11
Nm (84-96 lb in.). Install spring (20). Carefully
install the spool into the spool housing.
FIGURE 8-15. TIE ROD NUT TORQUE

1. Nut 4. Tie Rod
2. Tie Rod 5. Outlet Housing
3. Nut

7. Apply grease to the cross holes of detent pin (3) HOIST CYLINDERS
to hold balls (21) and (2).
8. Slide detent sleeve (22) into cap (24) and place Removal
over a punch. Using the punch, depress ball
(21), and insert balls (2) in detent pin cross
holes.
10. While holding down on ball (21), slide detent
sleeve (22) and cap (24) as an assembly over Relieve pressure before disconnecting hydraulic
detent pin (3). Continue to insert detent sleeve lines. Hydraulic fluid escaping under pressure
(22) until it contacts spring seat (19). can have sufficient force to enter a person's body
11. Secure cap (24) in place with capscrews (6). by penetrating the skin and cause serious injury
Tighten capscrews (6) to 7 Nm (5 lb ft). Install and possibly death if proper medical treatment
spacer (23) and snap ring (1). by a physician familiar with this type of injury is
not received immediately.
12. Install a new O-ring (12) and wiper (13). Install
seal plate (16). Install machine screws (15).
13. Install new O-rings onto relief valve (5, Figure 8- 1. Turn the key switch OFF, and apply the parking
11) in the spool housing. brake. Wait at least 90 seconds to allow the
accumulators to bleed down.
FIGURE 8-16. HOIST CYLINDER UPPER MOUNT

2. Capscrews & Washers 5. Bearing
3. Pin 6. Hoist Cylinder

2. To relieve all pressure from the hydraulic circuit,
slowly move the hoist lever to the POWER
DOWN position and gently lower the body until
it rests completely on the frame.
3. Disconnect the lubrication lines to the upper
and lower bearings of the hoist cylinder. Discon-
nect the hydraulic lines from the hoist cylinder.
Cap and plug the lines and ports to prevent
excessive spillage and contamination. Secure
the cylinder to the frame to prevent movement
during the next step.
4. Attach a suitable lifting device to the hoist cylin-
der. The hoist cylinder weighs approximately
330 kg (730 lb.).
5. At the upper mount, remove capscrews and
washers (2, Figure 8-16). Remove retainer
plate (1). Use a brass drift and hammer to drive
pin (3) from the bore of the mounting bracket.
6. Carefully lower the cylinder until it lays against
the inside of the dual tire. Attach a suitable lift-
ing device to the upper cylinder mounting eye.
7. Install a retaining strap or chain to prevent the
cylinder from extending during handling.
8. At the lower mount, remove capscrews (3, Fig-
ure 8-17), locking plate (4) and retainer plate
(2).
9. Carefully remove the cylinder from the frame
pivot. Move the cylinder to a clean area for dis-
assembly.
FIGURE 8-17. HOIST CYLINDER LOWER MOUNT

1. Hoist Cylinder 4. Lock Plate
3. Capcsrew 6. Bearing

Installation
1. Install a retaining strap or chain to prevent the 4. Lift the cover straight up until quill assembly
cylinder from extending during handling. The (22) is clear. Remove O-ring (12) and backup
hoist cylinder weighs approximately 330 kg ring (23).
(730 lb.). Attach a suitable lifting device that can 5. Remove snap ring (9). Remove capscrews (7)
handle the load safely. and flatwashers (5) that secure rod bearing
2. Raise the cylinder into position over the pivot retainer (6) to rod (1). Remove seal (8).
point on the frame. The air bleed vent at the top 6. Fabricate a retainer bar using a 6 x 25 x 460
of the cylinder must be toward the front of the mm (1/4" x 1" x 18") steel flat. Drill holes in the
truck. Align the bearing eye with the pivot pin bar to align with a pair of tapped holes spaced
and push the cylinder into place. 180 apart in the housing. Attach the bar to the
3. Install retainer (2, Figure 8-17), lock plate (4), housing using capscrews (11).
and the capscrews. Tighten the capscrews to NOTE: A retainer bar is required to prevent the first
standard torque, and bend the lock plate tabs and second stage cylinders from dropping out when
over the capscrew flats. the housing is inverted.
4. Align the top hoist cylinder bearing eye with the
bore of the upper mounting bracket.
5. Install pin (3, Figure 8-16) and retaining plate 7. Rotate the cylinder assembly 180o to position
(1). Secure in place with capscrews and lock- the lower mounting eye at the top. Attach a lift-
washers (2). Tighten the capscrews to standard ing device to the eye on rod (1) and lift the rod
torque. and third stage cylinder assembly out of the cyl-
inder housing.
6. Install new O-rings in the grooves on the hose
flange connections and lubricate with clean
hydraulic oil. Position the flanges over the hoist
cylinder ports and install the flange clamps and
the mounting capscrews and lockwashers.
Tighten the capscrews to standard torque. As internal parts are exposed during disassem-
7. Reconnect the lubrication lines for the upper bly, protect machined surfaces from scratches or
and lower hoist cylinder bearings. nicks.
8. Start the engine, raise and lower the body sev-
eral times to bleed air from the cylinders. Check 8. Rotate the cylinder housing 180. Remove the
for proper operation and inspect for leaks. retainer installed in step 6.
9. Service the hydraulic tank if necessary. 9. Fabricate a round disc with a hole in the center.
Align the disc over second stage cylinder (2)
and first stage cylinder (3) at the bottom of the
Disassembly cylinder housing.
1. If removal of the hoist cylinder eye bearings is 10. Insert a 13 mm (.50 in.) dia. x 1350 mm (53 in.)
necessary, remove retainer ring (5, Figure 8-17) threaded rod through the top and through the
and press out bearing (6). hole in the disc. Thread a nut on the bottom end
2. Mount the hoist cylinder in a fixture which will of the threaded rod below the disc.
allow it to be rotated 180. 11. Screw a lifting eye on the top end of the rod.
3. Position cylinder head (10, Figure 8-18) at the Attach it to a lifting device and lift the second
top. Remove capscrews (11) and the lockwash- and first stage cylinders out of the housing.
ers.

1. Rod Eye 13. Bearing
2. Second Stage Cylinder 14. Seal
3. First Stage Cylinder 15. Bearing
4. Housing 16. Seal
5. Flatwasher 17. Bearing
6. Bearing Retainer 18. Buffer Seal
7. Capscrew 19. Bearing
8. Seal 20. Rod Seal
9. Snap Ring 21. Rod Wiper
10. Cylinder Head 22. Quill Assembly
11. Capscrews & Lockwashers 23. Backup Ring
12. O-Ring 24. Snap Ring
FIGURE 8-18. HOIST CYLINDER

12. Remove the lifting tools from the second and
first stage cylinder assembly.
13. Slide second stage cylinder (2) down inside first
stage cylinder (3). Remove snap ring (9) from
inside the first stage cylinder.
14. Remove the second stage cylinder from the first
stage cylinder by sliding it out the top.
15. Remove all old bearings, O-rings, and seals
from the hoist cylinder components.

NOTE: Use only fresh cleaning solvent, lint free
wiping cloths and dry filtered compressed air when
cleaning and handling hydraulic cylinder parts.
Immediately after cleaning and inspection, coat all
surfaces and parts with clean hydraulic oil.
1. Thoroughly clean and dry all parts.
FIGURE 8-19. QUILL INSTALLATION TOOL
2. Visually inspect all parts for damage or exces-
sive wear. 1. Cover 2. Quill Assembly
3. If the cylinder bores or plated surfaces are
excessively worn of grooved, the parts must be
NOTE: The SS1143 tightening tool can be fabricated
replaced or, if possible, replated and machined
locally. Request the following drawings from the
to original specifications.
Komatsu Distributor:
4. Check quill (2, Figure 8-19) for tightness if it has
not previously been tack welded. SS1143 Tightening Tool - Assembly Drawing
a. Check the quill for tightness by using special SS1144 - Square Tube (3.50" x 3.50" x 0.19" wall
tool SS1143 (Figure 8-19) and tightening to x 2.0" long)
1356 Nm (1000 lb ft). SS1145 - Plate (2.50" x 2.50" x 0.25" thick)
b. If the quill moves, remove the quill, clean the SS1146 - Square Tube (3.00" x 3.00" x 0.25"
threads in the cover assembly and quill, and wall)
reinstall. Follow instructions oulined in Quill SS1147 - Tube, Brass (1.75" O.D. x 1.50" I.D. x
Installation in this chapter. 13.50" long)
5. When a cylinder assembly is dismantled, care-
SS1148 - Square Cut (2.50" x 2.50" x 0.75" thick)
fully check capscrews (7, Figure 8-18) and
washers (5) for stress or damage. If in doubt, SS1149 - Hex Drive (1.75" hex stock x 2.50"
replace the hardware. long)
Note: All materials are 1020 steel except SS1147.

Assembly - Quill And Cylinder
Use only new seals, bearings and O-rings during
reassembly. Thoroughly lubricate all parts and seals
with hydraulic oil to aid in assembly and to provide
lubrication during initial operation.
Quill Installation
1. Check plugs (3, Figure 8-20) and check balls
(4) in the quill during any cylinder repair to
ensure the plugs are tight and the ball seats are
not damaged. Refer to Installation of Check
Balls and Plugs in Quill.
2. Secure cap assembly (1) in a sturdy fixture.
Ensure the threads in the cap and the threads
on the quill are clean and dry (free of oil and sol-
vent).
3. Using Loctite LOCQUIC Primer "T" (part num-
ber TL8753) or the equivalent, spray the mating
threads of both cap assembly (1) and quill
assembly (2). Allow the primer to dry three to
five minutes.
4. Apply Loctite Sealant #277 (part number
VJ6863) or the equivalent to the mating threads
of both the cap assembly and the quill assem-
bly.
5. Install the quill and use tool SS1143 to tighten
the quill to 1356 Nm (1000 lb ft). Allow the
parts to cure for two hours before exposing the
threaded areas to oil.
NOTE: If LOCQUIC primer "T" (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
6. Tack weld the quill in two places as shown in
Figure 8-20.
7. Remove all slag and foreign material from the
tack weld area before assembly of the cylinder.
During future cylinder rebuilds, removal of the quill
will not be necessary unless it has loosened or is
damaged. Removal, if necessary, will require a
break-loose force of at least 2712 Nm (2000 lb ft)
FIGURE 8-20. PLUG AND CHECK BALL
after the tack welds are ground off.
INSTALLATION
1. Cover Assembly 3. Plug

2. Quill Assembly 4. Check Ball

Installation Of Check Balls And Plugs In Quill
Check balls (4, Figure 8-20) in the side of quill 1. Ensure the threads in the quill tube and on the
assembly (2) are held in place with threaded plugs plugs are clean and dry (free of oil and solvent).
(3). 2. Use Loctite LOCQUIC Primer "T" (TL8753) or
If a plug is missing and the check ball is not found in equivalent and spray the mating threads of both
the cylinder, the opposite side hoist cylinder and the plugs (3, Figure 8-20) and quill assembly (2).
plumbing leading to the hoist valve should be exam- Allow the primer to dry three to five minutes.
ined for damage. The hoist valve itself should also be 3. Apply Loctite Sealant #277 (VJ6863) or equiva-
checked to see if the ball or plug has caused internal lent to the mating threads of both plugs and quill
damage to the spool. Peening of the necked down assembly.
sections of the spool may result. Spool sticking may 4. Place check balls (4) in quill tube (2) and install
also occur under these circumstances. plugs (3) with the concave side facing the ball.
Refer to Figure 8-21 for tool SS1158. The tool can be Using tool SS1158, tighten the plugs to 95 Nm
fabricated for installing or removing the check ball (70 lb ft). Allow parts to cure for two hours
plugs. before exposing the threaded areas to oil.
Check the plugs during any cylinder repair to ensure NOTE: If LOCQUIC primer "T" (TL8753) was not
they are tight. If found to have any movement, they used, the cure time will require 24 hours instead of 2
must be removed and the ball seat in the quill hours.
checked to see if it is deformed. If deformation of the 5. Stake the plug threads in two places (between
ball seat has occurred, the quill must be replaced. holes) as shown in Figure 8-20 to prevent loos-
ening of plug.
If removal of the plug is necessary in a later
rebuild, it will be necessary to carefully drill out
the stake marks and destroy the plug. A new
plug must be installed and staked as previously
detailed.
FIGURE 8-21. SS1158 PLUG INSTALLATION/REMOVAL TOOL

Assembly of Cylinder
1. Install seals (14, Figure 8-18) and bearings (15) NOTE: Carefully inspect the capscrews for stress or
on the second stage cylinder. Install bearings damage. If in doubt, replace with new parts.
(19), buffer seal (18), rod seal (20) and rod
12. Ensure the threads on capscrews (7) and the
wiper (21) on the first stage cylinder. Lubricate
threads in the rod are clean and dry (free of oil
all components with clean hydraulic oil.
and solvent).
2. Align and slide second stage cylinder (2) inside
first stage cylinder (3). Allow the second stage a. Use Loctite LOCQUIC Primer "T" (TL8753)
to protrude far enough to install snap ring (24) or the equivalent to spray the threads on the
on the inside of the first stage cylinder. capscrews and the threads in the rod. Allow
the primer to dry three to five minutes.
3. Mount housing (4) in the fixture with the cover
end positioned at the top. Install bearings (19) b. Apply Loctite Sealant #277 (VJ6863) or the
buffer seal (18), rod seal (20) and rod wiper (21) equivalent to the threads of the capscrews
in the housing. and the threads in the rod.
4. Install the lifting tool used during disassembly in 13. Install capscrews (7) with hardened washers
the second and first stage cylinder assembly. (5). Tighten the capscrews to 678 Nm (500 lb
5. Install bearings (13) on first stage cylinder (3). ft).
Lift and align this assembly over housing (4). NOTE: Allow parts to cure for two hours before
Lower the second and first stage cylinders into exposing the threaded areas to oil. If LOCQUIC
the housing. primer "T" (TL8753) was not used, the cure time will
6. Install the retainer used during disassembly to require 24 hours instead of 2 hours.
hold the second and first stage cylinder in place
14. Install snap ring (9).
when the housing is rotated. Rotate the housing
180 to position the lower mounting eye at the 15. Install O-ring (12) and backup ring (23) on cover
top. (10). Align and lower the cover onto housing
(4). Install capscrews (11) and the lockwashers.
7. Install the bearings, buffer seal, rod seal and
Tighten the capscrews to standard torque.
rod wiper in second stage cylinder (2).
8. Attach a lifting device to rod eye (1) and align it 16. Install hoist cylinder eye bearing (6, Figure 8-
over housing (4). Lubricate the rod with hydrau- 17) and retainer rings (5), if removed.
lic oil, and lower into the housing. .
9. Rotate the housing 180 to position the cover
end at the top. Remove the retainer installed in
Step 6. Install bearings (17) and seal (16) on
the rod bearing retainer (6).
10. Thread two guide bolts in the end of rod (1).
Install seal (8) on the end of the rod.
11. Align piston rod bearing retainer (6) over guide
bolts and lower it over the end of rod (1).
Remove the guide bolts.

SECTION L9
HYDRAULIC SYSTEM FILTERS
INDEX
HYDRAULIC SYSTEM FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
HIGH PRESSURE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
LOW PRESSURE FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
BRAKE COOLING & HOIST FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
TRANSMISSION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L9-5
L09010 Hydraulic System Filters L9-1

NOTES
L9-2 Hydraulic System Filters L09010

HYDRAULIC SYSTEM FILTERS
HIGH PRESSURE FILTER

A high pressure filter assembly filters the oil supply
from the steering/brake pump before it enters the
bleed-down manifold valve. The filter is located on
the left frame rail, forward of the hydraulic tank.
Refer to Section P, Lubrication and Service, for the
recommended filter element replacement interval.
Earlier replacement may be required if the mainte-
nance monitor lamp turns on and the Message for
Operation and Maintenance (MOM) display indicates
the element is restricted.
Removal
Relieve system pressure before disconnecting

hydraulic lines. Pressurized hydraulic fluid can
penetrating the skin. This can cause serious
injury and possibly death. Seek proper medical
treatment by a physician familiar with this injury,
immediately.

seconds for the accumulators to depressurize.
Verify that pressure has been released by turn-
ing the steering wheel. The wheels should not
turn.
Avoid contact with hot oil if the truck has been in

use. Properly contain oil and clean any spillage! FIGURE 9-1. STEERING CIRCUIT FILTER
1. Indicator Switch 6. Filter Element

2. Setscrew 7. Bowl
4. Replace O-ring (5) in the filter head. 3. Head 8. O-Ring
4. Bleed Plug 9. Drain Plug
5. O-Ring

Installation
1. Install new element (6). Install bowl (7) and
tighten. BRAKE COOLING & HOIST FILTERS
2. Replace drain plug (9), and O-ring (8). A filter, located near the brake cooler, filters brake
cooling oil after it leaves the front wheel brake hous-
NOTE: Indicator switch (1, Figure 9-1) is not ings. Two identical filters located on the inner side of
repairable. If the indicator switch is inoperative, the fuel tank, filter oil as it leaves the rear wheel
replace as a unit. Switch adjustment is not necessary brake housings.
or recommended.
If the maintenance monitor lamp illuminates, indicat-
ing a restricted filter element, use the MOM display to
determine the actual filter element(s) requiring ser-
vice.
LOW PRESSURE FILTERS
Low pressure hydraulic oil filters (Figure 9-2) are
used at multiple locations on the truck. The low pres-
TRANSMISSION FILTER
sure filters clean the hydraulic oil in the brake cooling Oil from the transmission pump flows through two fil-
circuit, hoist circuit, and the transmission oil supply. ters prior to entering the transmission. The filters are
located on the right frame rail, forward of the fuel
Indicator switch (2) provides an electrical signal to
tank.
the monitoring circuits to warn the operator if the filter
elements become restricted.
Refer to Section P, Lubrication and Service, for the
recommended filter element replacement interval.
Earlier replacement may be required if the mainte-
nance monitor lamp turns on and the MOM display
indicates one or more of the hydraulic system ele-
ments is restricted. A transmission oil filter lamp on
the instrument panel will flash and a buzzer will
sound if the transmission filter element becomes
restricted.
Premature filter restriction may indicate a system
component failure and signal a service requirement
before extensive secondary damage can occur.
NOTE: When the engine is initially started and the
hydraulic oil is cold, the restriction warning may
activate. Allow the hydraulic system oil to reach
operating temperature before using the warning as
an indicator to change the element. Cold, thick oil
may cause the monitor system to think the filters are
restricted.

Removal
Relieve system pressure before disconnecting

hydraulic lines. Pressurized hydraulic fluid can
penetrating the skin. This can cause serious
injury and possibly death. Seek proper medical
treatment by a physician familiar with this injury,
immediately.
1. Remove plug (6, Figure 9-2) and drain oil from

the housing into a suitable container.
Avoid contact with hot oil if the truck has been in

use. Properly contain oil and clean any spillage!

3. Replace seal (3) in the filter head.
Installation
1. Install new element (5, Figure 9-2). Install bowl
(4) and tighten.
2. Replace drain plug (6), and O-ring (7).
NOTE: Indicator switch (2, Figure 9-2) is not

repairable. If the indicator switch is inoperative,
replace as a unit. The actuation pressure of the
indicator switch is factory preset. Switch adjustment
is not necessary or recommended.
FIGURE 9-2. LOW PRESSURE FILTER ASSEMBLY

1. Head Assembly 6. Plug
2. Indicator Switch 7. O-Ring
3. Seal 8. Core Assembly
4. Bowl 9. Bypass Valve
5. Filter Element 10. Anti-Backflow Valve

NOTE

SECTION L10
HYDRAULIC CHECK-OUT PROCEDURE
INDEX
HYDRAULIC CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-3
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . .L10-3
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-4
Installation Of Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-4
Initial Startup And Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-4
Component Checkout And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-5
CHECKING HOIST SYSTEM PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-7
Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-7
Steering Components Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-9
HYDRAULIC SYSTEM CHECKOUT DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L10-10
L10030 05/08 Hydraulic Check-out Procedure L10-1

NOTES
L10-2 Hydraulic Check-out Procedure 05/08 L10030

HYDRAULIC CHECK-OUT PROCEDURE
GENERAL INFORMATION STEERING CIRCUIT CHECK-OUT &
The hydraulic check-out procedure is intended to
ADJUSTMENT PROCEDURE
help the technician check, adjust, and diagnose Steering circuit hydraulic pressure is supplied from
problems in the steering and hoist circuits. Read the the steering piston pump and accumulators. Some
entire check-out procedure prior to performing any steering system problems, such as spongy or slow
checks. It is important to become familiar with the steering or abnormal operation of the low steering
system before installing test equipment. pressure warning light can sometimes be traced to
internal leakage of steering components. If internal
The following procedures may be easier if the
leakage is suspected, refer to Steering Circuit Com-
gauges can be observed from the cab or where the
ponent Leakage Test in this chapter.
technician can communicate with the person operat-
ing the controls. NOTE: Excessive internal leakage within the brake
circuit may contribute to problems within the steering
circuit. Verify that brake circuit leakage is not
excessive before troubleshooting the steering circuit.
Refer to Section J, Brake System for information on
testing the brake system.
cient force to enter a person's body by penetrat- The steering circuit can be isolated from the brake
ing the skin. This can cause serious injury and circuit by relieving pressure from the brake accumu-
possibly death. If fluid has penetrated the skin, lators and removing the brake system supply line (1,
immediately seek medical treatment by a physi- Figure 10-2) from the fitting on the bleeddown mani-
cian familiar with this injury. fold. Plug the brake circuit supply hose and cap the
fitting at the bleeddown manifold to prevent leakage.
Depressurize system accumulators before open- Prior to checking the steering system, the hydraulic
ing hydraulic circuits or installing test gauges. steering and brake systems must have the correct
For the steering circuit, turn the key switch to accumulator charge and be at normal operating tem-
OFF and allow 90 seconds for the accumulators peratures. Refer to Section L, Steering Circuit Com-
to depressurize. After 90 seconds, turn the steer- ponent Repair, Steering Accumulator Charging for
ing wheel to verify that pressure has been purged steering accumulator charging instructions. Refer to
from the circuit. If the wheels do not move, the Section J, Brake Circuit Component Service, Accu-
steering circuit is safe to service. mulator Charging for brake accumulator charging
instructions

Equipment Requirements
The following equipment is necessary to properly
check the steering circuit
Hydraulic schematic, refer to Section R.
It is essential that the pump case is full of oil
Three 0-34,474 kPa (0-5000 psi) calibrated prior to starting the engine. Refer to Steering Cir-
pressure gauges and hoses. cuit Component Repair, Steering and Brake
Two 0-25,579 kPa (0-4000 psi) calibrated Pump in this section for instructions.
pressure gauges and hoses.
NOTE: A data sheet for recording test pressures is 6. Fill the hydraulic tank to the upper sight glass.
located at the rear of the chapter. Record all
7. Place the hoist control in the FLOAT position.
pressure checks on this sheet.
Installation Of Gauges
1. Install a 0-34,474 kPa (0-5000 psi) pressure
gauge at test port (6, Figure 10-1) on the bleed-
down manifold.
2. Install two 0-34,474 kPa (0-5000 psi) pressure
gauges onto the pressure ports on the steering
cylinder manifold (2, Figure 10-5) below the
horsecollar.
3. Install a 0-25,579 kPa (0-4000 psi) pressure
gauge onto the hoist pump outlet pressure port.
Install another 0-25,579 kPa (0-4000 psi) pres-
sure gauge at the brake cooling outlet pressure
port.
Initial Startup And Flushing

4. Disconnect the steering supply and return lines
from the bleeddown manifold. The supply hose
is connected to check valve (5, Figure 10-1)
and return to tank (3) is located directly below
the supply.
Using the necessary fittings, connect the supply FIGURE 10-1. BLEEDDOWN MANIFOLD
line to the return line to create a complete cir-
1. Brake Circuit Supply 8. To Flow Amplifier
cuit. Install a 6.4 mm (0.25 in.) orifice between
2. Bleeddown Manifold 9. From Flow Amplifier
the lines to create back pressure.
3. Return to Tank 10. Accumulator Bleed-
5. Remove the case drain line from the top of the 4. Pressure Relief Valve Down Solenoid
steering pump. Fill the pump with clean hydrau- 5. Supply From Steering 11. Low Steering
lic oil, and install the case drain back on the Pump (Check Valve) Pressure Switch
pump. 6. Test Port 12. Auto-Lube Supply
7. From Accumulator

8. Turn the key switch to the ON position, but do Component Checkout And Adjustment
not start the engine. Verify that the low steering 18. Adjust the steering pump compensator for test-
accumulator pressure warning is not displayed. ing of the steering shock valves. Compensator
If the indicator lamp illuminates, the accumula- (2, Figure 10-2) must be set to 22,753 689
tors are not properly charged. Charge the accu- kPa (3300 100 psi) for this test.
mulators accordingly. Refer to Section L,
Steering Circuit Component Repair, Steering
Accumulator Charging for steering accumulator
charging instructions.
9. Start the engine and allow it to operate at low
idle. Do not increase engine speed.
10. Check the pressure at the hoist and brake cool-
ing pumps. Pressure at both hoist pumps
should be 689 kPa (100 psi) with the oil temper-
ature at 21 C (70 F). Pressure at both brake
cooling pumps should be 241 kPa (35 psi) with
the oil temperature at 21 C (70 F).
11. If pressures are within range, increase engine
speed to 1500 rpm for 20 minutes to flush the
system.
12. After 20 minutes, stop the engine. Depressurize
all accumulators and return the steering circuit
hoses to their proper locations.
13. After the circuit is installed properly, start the
engine to flush the accumulators. Allow the
engine to operate until the pressure gauge at FIGURE 10-2. PUMP PRESSURE CONTROL
the bleeddown manifold reaches 18,100 862
1. Steering Pump 3. Case Drain Line
kPa (2625 125 psi). Do not apply the brakes
2. Compensator Adjust- 4. Hoist Pump
or move the steering wheel during accumulator
ment
flushing.
14. Stop the engine and depressurize all accumula-
tors. Verify no pressure exists on the pressure
gauge on the bleeddown manifold. Record the 19. Raise the steering relief valve setting to allow
pressure. testing of the shock valves. To adjust the relief
valve, perform the following:
15. Open the needle valves in the brake cabinet to
depressurize the brake accumulators. Check a. Remove plug (2, Figure 10-3) on flow ampli-
and record the pressure. fier (1) to access the relief valve.
Repeat Steps 14 and 15 four more times. b. Gently bottom out the adjustment screw by
Record the pressure after each cycle. turning clockwise.
16. Start the engine and allow the accumulators to 20. Start the engine and allow the steering system
fully charge. Rotate the steering wheel from to pressurize.
lock to lock a minimum of 10 times.
17. Stop the engine. Check the level of the hydrau-
lic tank and add oil if necessary.

FIGURE 10-3. FLOW AMPLIFIER RELIEF VALVE
1. Flow Amplifier 2. Plug
FIGURE 10-4. STEERING DISTRIBUTION
MANIFOLD
1. Steering Distribution 2. Steering Cylinder
21. While observing the two gauges installed on the Manifold
steering manifold, steer the truck against the left
stop. Pressure on one of the gauges should be
22,442 1069 kPa (3255 155 psi). Record the 23. After adjustment is complete, install plug (2).
measurement.
24. Record the relief valve adjustment pressure.
Steer the truck to the opposite stop. The other
25. Turn the steering pump pressure compensator
gauge should be 22,442 1069 kPa (3255
adjustment screw counterclockwise to reduce
155 psi). Record the measurement.
pressure while steering the truck to lower accu-
22. After checking the shock valves, lower the mulator pressure. Adjust the compensator to
steering relief valve setting back to 18,961 temporarily allow circuit pressure to drop to
345 kPa (2750 50 psi). approximately 17237 690 kPa (2500 100
a. Steer full left or right and maintain a slight psi).
pressure against the steering wheel. 26. After adjusting, steer the truck to verify the pres-
b. Adjust the steering relief valve until 18,961 sure is maintained at 17237 690 kPa (2500
kPa (2750 psi) is obtained on the pressure 100 psi).
gauge. 27. Without steering the wheels, turn the pressure
compensator adjustment screw clockwise to
obtain 18,961 345 kPa (2750 50 psi) on the
gauge at the bleeddown manifold test port.

28. Turn the steering wheel one revolution and CHECKING HOIST SYSTEM PRESSURES
stop. Wait at least 10 seconds and then check
the pressure. The pressure must be 18,961 Equipment Requirements
345 kPa (2750 50 psi). If the pressure is not The following equipment will be necessary to prop-
within range, repeat the adjustment. erly check the hoist relief and "power down" circuit
29. When properly adjusted, tighten the jam nut to pressures:
lock the adjustment screw. Hydraulic schematics, refer to Section R.
30. Turn the steering wheel one revolution and Two 0-34,474 kPa (0-5000 psi) range calibrated
stop. Wait at least 10 seconds and then check pressure gauges and hoses.
the pressure again. The pressure must be
18,961 345 kPa (2750 50 psi).
31. Record the pump compensator pressure. 33. Install two 0-34,474 kPa (0-5000 psi) pressure
gauges at each pressure port located on hoist
32. Verify the low steering accumulator pressure distribution manifold (2, Figure 10-5).
switch activates at 18,961 345 kPa (1850 50
psi). To check the switch perform the following:
a. Operate the engine to allow the accumula-
tors to charge. Turn the engine off.
b. Immediately turn the key switch to the ON
position without starting the engine. This pre-
vents the accumulators from depressurizing.
c. Open the needle valves in the brake cabinet
to allow the steering accumulator in the pres-
sure switch circuit to depressurize. Observe
the pressure gauge at the bleeddown mani-
fold to determine what pressure the buzzer is
activated.
d. Record the pressure when the buzzer
sounds.
e. If the buzzer does not sound within the spec-
ified range, the warning circuit must be
checked and repaired until it is within specifi-
cations.
FIGURE 10-5. HOIST DISTRIBUTION MANIFOLD

1. Hoist Cylinder 2. Hoist Distribution
Manifold
34. Disconnect the hoist cylinder lines at the distri-

bution manifold and cap the power up and
power down ports (four locations).
35. Start the engine and operate at high idle.

36. Place the hoist lever in the POWER UP posi- 38. Check the pressure again and verify that it is
tion. The pressure at the manifold must be within range.
18,961 1034 kPa (2750 150 psi). 39. With the engine at high idle, place the hoist
37. If the power up relief pressure is incorrect, lever in the POWER DOWN position.
adjust the pressures as follows:
40. Pressure must be 10,342 689 kPa (1500
a. Return hoist lever to the FLOAT position. 100 psi). If the power down pressure is not
within specifications, adjust the relief valve.
b. Relieve all hydraulic pressure from the hoist
system. a. To increase power down relief pressure, turn
the adjusting screw clockwise.
b. To decrease power down relief pressure,
turn the adjusting screw counter-clockwise.
NOTE: Power down relief valve (1, Figure 10-7) is
located on pilot control valve (2) in the hydraulic
cabinet.
41. If pressures are within specifications, shut off

the engine and move the hoist control lever to
the FLOAT position. Remove all gauges.
42. Connect the hoist lines to the distribution mani-
FIGURE 10-6. HOIST RELIEF VALVE fold.
43. Check the hydraulic tank oil level. Add oil if nec-
1. Capscrew 6. Sleeve essary.
2. Inlet Cover 7. Secondary Low
3. Spring Pressure Valve 44. If testing is complete, change all hydraulic filters
4. Main Relief Valve 8. O-Rings before returning the truck to operation.
5. Spring 9. Inlet Valve body
NOTE: Relief valve (4, Figure 10-6) is located under

inlet cover (2). The cover has a small external pipe
attached to it.
c. Remove the small external pipe and cap-
screws from inlet cover (2).
d. Remove the cover and spring (3) from the
relief valve.
e. Loosen the jam nut on relief valve (4) and
turn the screw clockwise to increase pres-
sure or counter-clockwise to decrease pres-
sure.
NOTE: Each 1/4 revolution of the adjustment screw
will cause approximately 1034 kPa (150 psi) change
in pressure.
f. Install spring (3), new O-rings (8) and cover
(2). Install and tighten cap screws (1). FIGURE 10-7. POWER DOWN RELIEF VALVE
1. Power Down Relief 2. Hoist Pilot Valve

Valve

Steering Components Leakage Test
9. Measure leakage at the steering return hose
removed in Step 1.
Maximum allowable leakage is 820 ml (50
in3) per minute.
10. If the leakage is excessive, the flow amplifier
Do not steer the truck while measuring leakage. must be repaired or replaced.
11. Disconnect tank return line (3, Figure 10-2) at
1. Check combined leakage from the steering con- the bleeddown manifold. Install a plug in end of
trol unit and flow amplifier. hose removed.
a. Disconnect hose (3, Figure 10-1) at the 12. Measure leakage from the tank return fitting on
bleeddown manifold port. the bleeddown manifold.
b. Cap the open fitting on the bleeddown mani- Maximum allowable leakage is 32.8 ml (2.0
fold. in3) per minute.
c. Place the end of the disconnected hose in a 13. If the leakage is excessive, the bleeddown sole-
graduated container. noid valve or the bleeddown manifold relief
2. Start the engine and allow the system to stabi- valve must be replaced.
lize at 18,961 1034 kPa (2750 150 psi). a. Verify the relief valve is set at 22,408 1034
3. Measure the leakage obtained in the graduated kPa (3250 150 psi).
container: b. Remove both valves and inspect the O-rings
Maximum allowable leakage is 984 ml (60 for damage.
in3) per minute. 14. Recheck the leakage. If leakage is still exces-
4. Shut off the engine. sive, replace the bleeddown solenoid.
5. If leakage exceeds the maximum, measure the If leakage is still excessive, replace the relief
leakage from the steering control valve as fol- valve.
lows:
15. After leakage tests are complete and leakage
a. Remove the steering control valve tank rates are acceptable, install all hoses and prop-
return line at the flow amplifier. erly tighten.
b. Plug the flow amplifier port. 16. Check the hydraulic tank oil level and refill if
c. Place the end of the disconnected hose in a necessary.
graduated container.
6. Start the engine and allow the system to stabi-
lize at 18,961 1034 kPa (2750 150 psi).
7. Check the leakage obtained in the graduated
container:
Maximum allowable leakage is 164 ml (10
in3) per minute.
8. If the leakage exceeds the maximum allowed,
repair or replace the steering control unit. If the
leakage rate is acceptable, perform the next
step to check flow amplifier leakage.

HYDRAULIC SYSTEM CHECKOUT DATA SHEET
8. Was accumulator precharge warning displayed before startup? ___________________
15. Pressure at bleeddown manifold test port after depressurizing accumulators

Pressure after 1st time ___________________
Pressure after 2nd time ___________________
Pressure after 3rd time ___________________
Pressure after 4th time ___________________
Pressure after 5th time ___________________
21.Left and right shock valve pressures

Left shock valve pressure ___________________
Right shock valve pressure ___________________
24. Flow amplifier relief valve pressure ___________________
31. Pump compensator pressure ___________________
32. Pressure at which low steering pressure indicator light illuminates and warning
buzzer sounds ___________________
36. Power up pressure at hoist cylinder manifold ___________________

40. Power down pressure at hoist cylinder manifold ___________________
Were all hydraulic filters changed after testing was completed? ___________________
Date of Checkout ___________________

Truck Unit: ___________________
Name of Technician ___________________

SECTION M
OPTIONS AND SPECIAL TOOLS
INDEX
SPECIAL TOOL GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8-1
M01048 Index M1-1

NOTES
M1-2 Index M01048

SPECIAL TOOLS
PART NO. DESCRIPTION USE

562-98-31301 Disc Gauge Brake Disc Wear
Tool

NItrogen Suspension &
EC3331 Charging Kit accumulator
nitrogen charging
NOTE: Not included with all trucks.

PC2061 Belt Tension A/C Belt Tension
Tester
569-86-87361 Download PLM Download

Harness Data
M08022 Special Tools M8-1

EL8868 V-Belt Align- Aligning A/C
ment Tool pulleys

SE21188 Driveshaft Aligning driveline
Alignment Tool components
M8-2 Special Tools M08022

SECTION N
OPERATOR CAB
INDEX
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-1
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-1
HEATER / AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1
OPERATOR CAB CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
N01027 Index N1-1

NOTES
N1-2 Index N01027

SECTION N2
OPERATOR CAB
INDEX
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
CAB DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-7
Door Striker Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-7
Door Handle Plunger Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-8
DOOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-9
DOOR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-12
WINDOW REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
DOOR HANDLE AND DOOR LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14
DOOR SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Door Opening Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15
GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16
WINDSHIELD AND REAR GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-18
N02022 Operator Cab N2-1

NOTES
N2-2 Operator Cab N02022

OPERATOR CAB
The operator cab is fully insulated for maximum oper- Components located in this compartment consist of:
ator comfort. The cab contains an integral Roll Over the steering valve, brake valve, heater valve, HVAC
Protection Structure (ROPS) for maximum operator plenum, HVAC relays, and other electrical connec-
safety. All gauges, switches, and controls have been tions.
designed to simplify operation and are within easy
reach of the operator. Servicing of the cab and asso-
ciated electrical systems is simplified by use of
heavy-duty connectors on the various wiring har-
nesses.
Hydraulic components and some electrical connec- DO NOT attempt to modify or repair damage to
tions are located outside of the interior and are the ROPS without written approval from
accessed through the large access cover on the front Komatsu. Unauthorized repairs to the ROPS will
of the cab. Refer to Figure 2-1. void certification. If modification or repairs are
required, contact your nearest Komatsu distribu-
tor.
FIGURE 2-1. CAB ASSEMBLY
1. Mounting Pad 6. Retard Light (Retarder Applied)

2. Access Covers 7. Lifting Eye
3. Filter Cover 8. Rear, Side Glass
4. Windshield Wiper Arms 9. Front, Side Glass
5. Stop Light (Service Brakes Applied)

Removal
Prior to cab removal or repairs, it may be necessary
to remove the body to provide clearance for lifting
equipment to be used. If body removal is not
required, raise the body and install the body retention
cable.
DO NOT work below a raised body until the body

retention cable has been installed.
NOTE: Label hoses and electrical connections

before disconnecting to ensure proper installation.
1. Park the truck on a hard, level surface. Apply FIGURE 2-2. HYDRAULIC & ELECTRICAL
the parking brake and chock the wheels.
1. Hydraulic Hoses 3. Ground Cable
2. Verify the steering accumulators are depressur- 2. Electrical Harnesses
ized by attempting to steer the truck.
3. Depressurize the brake accumulators using the 6. Remove the protective flaps from the hydraulic
manual bleed valves on the brake manifold. and electrical junctions at the rear of the cab.
4. Open the battery disconnect switch. Disconnect hydraulic hoses (1, Figure 2-2) from
the rear of the cab.
7. Disconnect electrical harnesses (2) and ground
cable (3).
Federal regulations prohibit venting air condi-

tioning system refrigerants into the atmosphere.
An approved recovery/recycle station must be
used to remove the refrigerant from the air condi-
tioning system.
5. Evacuate the air conditioning system. Attach a

recovery station to the air conditioning service
valves. Refer to Air Conditioning System in this
section for detailed instructions.
FIGURE 2-3. SHUTOFF VALVES

1. Shutoff Valve 2. Water Pump
8. Close the two heater hose shutoff valves (1,

Figure 2-3) located on the engine.

FIGURE 2-4. CAB HYDRAULIC AND HVAC FIGURE 2-6. RADIO ANTENNA
1. Hydraulic Hoses 4. Clamp 1. Radio Antenna 2. LH Front ROPS Beam

2. Heater Hoses 5. A/C Hoses
3. HVAC Drain
14. Remove the access cover from the exterior of

9. Disconnect two heater hoses (2, Figure 2-4)
the LH side of the cab. DIsconnect radio
from the fittings underneath the cab. Remove
antenna (1, Figure 2-6).
clamp (4) securing the hoses to the bottom of
the cab.
10. Disconnect five hydraulic hoses (1).
11. Disconnect two air conditioner hoses (5).
12. Cap all hoses and fittings to prevent contamina-
tion.
FIGURE 2-5. VACUUM HOSES

1. Vacuum Hoses 2. Filter Cover
13. Remove the access cover from the exterior of

the RH side of the cab. Disconnect two vacuum FIGURE 2-7. CAB MOUNT
hoses (1, Figure 2-5) from the front of the cab.
1. Cap Screw 2. Harness

15. Disconnect harness (2, Figure 2-7). Check for 8. Install HVAC drain hose (3, Figure 2-4).
any other hoses or harnesses which may inter- 9. Connect five hydraulic hoses (1) to the fittings
fere with cab removal. beneath the front of the cab.
16. Attach appropriate lifting apparatus and a hoist 10. Connect hydraulic hoses (1, Figure 2-2) to the
to the four lifting eyes on top of the cab. The cab rear of the cab.
weighs approximately 1690 kg (3726 lb).
11. Connect electrical harnesses (2) and ground
17. Remove cap screws (1) and the washers from cable (3). Install the protective flaps over the
each mounting pad. electrical and hydraulic junctions.
18. Lift the cab from the truck and move to an area 12. Check for any other remaining hoses and elec-
for further service. trical connections. Install as necessary.
19. Place blocks under each corner of the cab to 13. Charge the air conditioning system. Refer to Air
prevent damage to the floor pan and the fittings Conditioning System in Section N for detailed
below the cab. instructions.
14. Close the brake accumulator bleed-down
valves.
Installation
15. Close the battery disconnect switch.
1. Attach appropriate lifting apparatus and a hoist
to the lifting eyes on top of the cab. The cab 16. Service the hydraulic tank and the engine cool-
weighs approximately 2270 kg (5000 lb). ant as required.
2. Lift the cab into position on the truck and align 17. Start the engine and verify proper operation of
the mounting pad holes with the tapped pads. all systems.
Partially install at least one cap screw (1, Figure
2-7) and washer at each of the four mounting
pads prior to completely lowering the cab onto
the deck. This will aid in alignment.
3. After the cab is properly positioned, insert the CAB DOORS
remaining cap screws and washers. Tighten the For repairs on the door latches or window controls it
cap screws to 1288 Nm (700 lb ft). is usually better, but not necessary, to remove the
4. Connect harness (2). door from the cab and lower it to the floor for service.
5. Connect two vacuum hoses (1, Figure 2-5) to Instructions in this section are the same for both the
the fittings at the front of the cab. Connect radio LH and RH door.
antenna (1, Figure 2-6) at the front of the cab.
Install the outer access covers onto the front of Removal
the cab. 1. If overhead space is available, raise the body to
6. Connect two air conditioning hoses (5, Figure 2- allow access to the door with an overhead hoist.
4) to the fittings below the cab. The receiver Secure the body in the raised position with the
drier and the accumulator must be replaced and body retention cable.
oil added to the system. Refer to Air Condition- 2. Lower the door window far enough to allow
ing System in Section N for detailed instruc- installation of a lifting sling.
tions. 3. Disconnect window motor harness (4, Figure 2-
7. Install two heater hoses (2). Install clamp (4) 11) from the cab floor.
that secures the hoses to the cab. Open heater 4. Remove retainer clip (1) and bolt (2) from the
shutoff valves (1, Figure 2-3). travel limiting strap on the door.

5. Install a lifting sling through the door and attach If the door closes, but does not provide a good
it to a hoist. The weight of each door is approxi- seal:
mately 68 kg (150 lb). Remove the cap screws 1. Mark the location of washer (1, Figure 2-8) with
securing the door hinge to the cab. Lift the door a marker by circumscribing the outside edge of
from the cab. the washer onto the jamb.
6. Place the door on blocks or on a work bench. 2. Loosen striker bolt (2). Move the striker inwards
approximately 2 mm (0.078 in.) and tighten.
3. Hold a piece of paper between the door and the
Installation door seal. Close the door and verify that it is
1. Attach a lifting sling and a hoist to the door. The completely closed and latched.
weight of each door is approximately 68 kg (150 4. The door seal should firmly grip the paper all
lb). Lift the door into position on the cab. along the top, front, and bottom edge of the
2. Align the door hinges with the cab and install door. If the paper is loose all around, adjust the
the hinge cap screws. striker, again. If the paper is firmly gripped, but
can be removed without tearing, open the door.
3. Attach the travel limiting strap with bolt (2, Fig-
Tighten the striker bolt completely without
ure 2-11) and secure with retainer clip (1).
changing the adjustment and recheck.
4. Connect window motor harness (4) to the con-
nector in the cab floor. If the paper is tight near the top and loose at the
bottom then seal compression is not even. The
5. Verify proper operation of the power window
door must be adjusted as follows: Place a small
and the door latch adjustment.
block of wood at the top corner of the cab door
above the door handle. Then press firmly
inward on the lower corner of the door. Press in
Door Striker Adjustment one or two times, then remove the wood block
Door seals keep air, dust and moisture from entering and check seal compression, again. Seal com-
around the door openings. Over time, the door latch pression should be equal all the way around the
mechanism and the door seals may wear and allow door. If the seal is still loose at the bottom,
dirt and moisture to enter the cab. To ensure proper repeat the procedure again until seal compres-
sealing of the door seals, the door striker may need sion is equal all the way around.
to be adjusted periodically. If the paper is tight near the bottom and loose at
the top then seal compression is not even. The
door must be adjusted as follows: Place a small
block of wood at the bottom corner of the cab
door below the handle. Then press firmly inward
on the top corner of the door. Press in one or
two times, then remove the wood block and
check seal compression, again. Seal compres-
sion should be equal all the way around the
door. If the seal is still loose at the top, repeat
the procedure again until seal compression is
equal all the way around.
FIGURE 2-8. DOOR STRIKER ADJUSTMENT
1. Washer 3. Frame
2. Striker Bolt 4. Seal

If the door does not latch properly when trying to 8. Carefully close the door and determine if this
close, striker bolt (2, Figure 2-9) may not be has helped the problem. If the door latches, but
positioned where the latches can engage the does not provide a tight seal, follow previous
bolt. adjustment procedures. If the door latches do
5. Open the door and rotate latch (3) and latch (5) not catch, move the bolt outward and try again.
until they are both fully closed. When corrected, follow previous adjustment
6. Approximate the center of the latch opening procedures to ensure proper seal compression.
onto the door opening at the striker. Use a T-
square or other measuring equipment and mark
on the cab with a pencil. Door Handle Plunger Adjustment
NOTE: Release the door latches before trying to If the door handle becomes inoperative, it can either
close the door. be adjusted or replaced. The following is a procedure
for adjusting the exterior door handle plunger.
1. Determine the amount of free play in the door
release plunger by pushing in on the plunger
until it just contacts the door release mecha-
nism. Measure the distance that the plunger
travels (Figure 2-10).
FIGURE 2-10. TRAVEL DISTANCE OF PLUNGER
2. Remove the door panel. Refer to Door Panel -

Removal in this chapter.
3. Carefully lower the door panel a few centime-
ters. Hold the glass at the top to prevent it from
FIGURE 2-9. LATCH ASSEMBLY
dropping. Slide the door panel toward the cab to
1. Cab 4. Door disengage the window regulator roller (Figure 2-
2. Striker Bolt 5. Lower Latch 12) from the track on the bottom of the glass.
3. Upper Latch Slide the panel away from the cab to disengage
the other top roller and lower roller from its
tracks. Place the panel out of the way after
removal.
4. Lift the door glass and support at the top of the
7. Loosen and center the door striker with this
frame.
mark. Tighten the striker firmly enough to hold it
in place but still allow some slippage.

5. Remove two screws (Figure 2-13) holding the 6. Before removing all door panel mounting
roller track to the bottom of the door glass. screws, support the panel to prevent the
6. Remove cap screw and nut (1, Figure 2-19) assembly from dropping. Remove 15 mounting
from inside the release lever. screws (5). Remove the panel screws across
the top, last.
7. Remove four mounting screws (2) that hold the
latch mechanism in the door.
8. Remove door latch (4). Check to see if the door
latch works properly by performing the following
test.
Remove the top panel screws last. The window
a. Close the upper and lower latches. glass and internal door panel will drop when the
b. Operate the inside door release lever to see door panel screws are removed. Prevent the
if the latches open. If the latches do not panel from dropping during screw removal.
open, replace the assembly.
c. Close the latches, again. 7. Carefully lower the door panel a few centime-
ters (Figure 2-12). Hold the glass at the top to
d. Press the outside door button to see if the
prevent it from dropping. Slide the door panel
latches open. If the latches do not open,
toward the cab to disengage the window regula-
replace the assembly.
tor roller from the track on the bottom of the
9. Remove mounting screws (3) from the outside glass. Then, slide the panel away from the cab
door handle. With the door handle removed, to disengage the other top roller and the lower
adjust the plunger counterclockwise to increase roller from their tracks. Place the panel out of
the height of the door handle release button. the way after removal.
Apply a thread lock to prevent loosening of the
8. Secure the window.
screw. Tighten the nut to secure the adjust-
ment.
10. Reassemble the door.
Installation
1. Raise the door window a few inches from the
top of the door and secure. Move the door panel
into position and install the lower and upper reg-
DOOR PANEL ulator rollers in their tracks. Start by moving the
door panel and window regulator away from cab
Removal just far enough to allow the rollers to enter their
1. Remove hair pin clip (1, Figure 2-11) and bolt tracks. Then with the rollers in the tracks slide
(2) from the door check strap. the panel toward the cab. Move the panel just
2. Remove the two cap screws that secure door far enough to allow the upper regulator roller to
strap bracket (3) to the door. go into the track on the bottom of the glass.
3. Disconnect window motor harness (4). 2. Lift the door panel and window up to align the
4. Open the door as far as possible for removal of screw holes. Install 15 mounting screws (5, Fig-
the internal door panel. ure 2-11).
5. Lower the window about half way. This will posi- 3. Place strap bracket (3) into position on the door.
tion the rollers for easier removal of the panel. Install the two cap screws that secure the
bracket to the door.
4. Place the door check strap into position. Install
bolt (2) and hair pin clip (1).
5. Connect window motor harness (4).

DOOR WINDOW
Removal
1. Remove the door panel. Refer to Door Panel -
Removal for instructions.
2. Remove two screws (Figure 2-13) while holding
the bottom of the roller track.
FIGURE 2-11.
FIGURE 2-13.
1. Pin Clip 5. Panel Screws
2. Door Strap Bolt 6. Window Regulator
3. Strap Bracket Mounting Screw 3. Support the glass in the door frame as shown in
4. Wiring Harness Figure 2-14. Remove two screws (2) that hold
the adapter for the window regulator track.
Remove the adapter, the gaskets, the plate,
and the bushings.
FIGURE 2-14.
1. Support Blocks 2. Screws
FIGURE 2-12.

6. Lift the door glass up near the top of window
frame (1, Figure 2-17). Holding the glass in
place, tilt the frame out at the top. Lift the frame
and the glass straight up and out of the door.
Lift bracket (2, Figure 2-17) completely out of the

door before removing the assembly.
FIGURE 2-15.
1. Screws 2. Rubber Felt Insert
4. Remove the screw at the lower end of the win-

dow channels. It is necessary to pull rubber felt
insert (2, Figure 2-15) out of the channel in
order to be able to remove the screws.
5. Remove trim screws (1, Figure 2-16) that hold
the window frame to the door.
NOTE: Screws along the bottom of window frame
may be shorter than along the top and sides.
FIGURE 2-17.
1. Window Frame
10. Move the window and frame to an area where

the glass can be removed. Slide the glass down
and out of the window channels.
FIGURE 2-16.
1. Screws

Installation
11. Before installing a new window, first inspect the 14. Lower the glass in the frame and support it as
window frame. In each corner there is an L shown in Figure 2-14.
shaped bracket (1, Figure 2-18) with two screws
15. Reinstall screws (1, 2-16) that secure the win-
in it to hold the corners of the frame together.
dow frame to the door.
Verify the screws are tight to properly align the
angled joints. (The joints are welded on newer
frames.) Verify the rubber insert in the window
channels is in good condition. Replace, if nec-
essary.
12. Slide the new window glass into the window
frame channels. Move the glass to the top of the The screws along the bottom of the window
frame. frame may be shorter than the ones along the
sides and the top. These screws must be used in
13. Lift the window frame, holding the glass at the this area to prevent the window glass from being
top of the frame, and lower the assembly into scratched or cracked. Refer to Figure 2-16. DO
the door. NOT countersink the screws when installing.
Countersinking the screws may result in window
breakage.
16. Install the trim over the top of the screws that
secure the window frame to the door. Use a flat
Verify that the channel of window frame (5, Fig- blade screwdriver to assist with the installation
ure 2-19) is properly positioned to the inside of of the trim. Refer to Figure 2-20. DO NOT cut
latch assembly (4). the retainer lip on the trim.
17. Install two screws (1, Figure 2-15). Push rubber
insert (2) into position in the channel after instal-
lation of the screws.
Failure to install the two screws at the bottom of

the window channels may result in door rattles.
Install these screws and properly tighten before
proceeding.
18. Assemble the adapter bracket, gaskets, bush-

ings and the plate on the window, as shown in
Figure 2-19.
FIGURE 2-18.
1. L Shaped Brackets

19. Lift the window into the frame. Install the win-
dow regulator roller track to the adapter bracket
installed in the previous step. Refer to Figure 2-
13.
FIGURE 2-20.
1. Cap Screw & Nut 4. Latch Assembly

FIGURE 2-19. 2. Latch Screw 5. Window Frame
1. Adapter Bracket 6. Plate 3. Outside Door Handle
2. Bushing 7. Window Screw
3. Rubber Gasket 8. Rubber Gasket
4. Regulator Track
5. Screw 20. Holding the window glass as shown in Figure 2-
12 (a few centimeters from the top) install the
lower and upper regulator rollers in their tracks.
Start by moving the door panel (with window
regulator) away from the cab just far enough to
allow the rollers to enter their tracks. Then, with
the rollers in the tracks, slide the panel toward
the cab. Move the panel just far enough to allow
the upper regulator roller to go into the track on
the bottom of the glass.
21. Install the door panel. Refer to Door Panel -
Installation.

Installation
1. Move the window regulator to the up position.
Place the window regulator into position on the
door panel. Verify that the regulator gear and
the window motor gear are properly meshed.
2. Install four mounting screws (6, Figure 2-11).
Tighten the screws securely.
3. Install the door panel as outlined in Door Panel
- Installation.
DOOR HANDLE AND DOOR LATCH

Removal
The cab doors are equipped with serviceable latch
handles (inner and outer). If they become inopera-
tive, replace with a new assembly. The outer latch
handle on each door is furnished with a key-operated
lock to enable the operator to lock the truck cab while
the truck is unattended.
1. Remove the door panel from the door as out-
lined in Door Panel - Removal.
2. Remove cap screw and nut (1, Figure 2-20)
from inside door handle.
3. Remove four mounting screws (2) that secure
the latch. Remove the latch.
FIGURE 2-21.
4. If replacing the outside door handle, remove
three screws (3) that secure the handle to the
door panel.
NOTE: Two of the screws are hidden behind the
latch.
WINDOW REGULATOR
Removal
Installation
1. Remove the door panel from the door as out-
lined in Door Panel - Removal. 1. Place the outside door handle into position, if
removed. Install three screws (3, Figure 2-20)
2. Move the door panel to a work area to enable
that secure the door handle.
replacement of the window regulator. Remove
four mounting screws (6, Figure 2-11) and 1. Place the latch into position and align the
remove the regulator from the door panel. mounting holes. Install four mounting screws
(2).
2. Align the inside door handle and install cap
screw and nut (3).
3. Install the door panel. Refer to Door Panel -
Installation.

DOOR SEALS 4. Position both ends so that they are square.
Then, while holding the ends together, push
Removal them firmly into the center of the opening.
1. The three-sided door seal seals the two sides
and the top of the door. The seal is glued onto
the door and can be replaced by peeling the
seal away from the door frame. Use a suitable
cleaner to remove the remaining seal and glue
material.
Installation
1. Clean the mounting surface for the door seal.
The surface must be free of dirt and oil. Apply
weatherstrip adhesive onto the area where the
seal is to installed.
2. Install seal (3, Figure 22) so that the corners of
the seal fit up into the corners of the door frame.
NOTE: Repeat the previous steps for replacement of
door hinge seal (2, Figure 23).
FIGURE 2-22.
1. Door Opening Seal 3. Door Assembly Seal
DOOR OPENING SEAL
Removal
1. Starting at the lower center of the door opening,
pull up on one end of the seal. Remove the seal
from the opening.
Installation
1. Inspect the cab opening lip for damage, dirt, or
oil. Clean and repair the cab opening as neces-
sary. Remove any dirt and adhesive. Verify the
opening is clean and free of burrs.
2. Install the seal around the door opening in the
cab. Start at the bottom center of the cab open-
ing and work the seal lip over the edge of the
opening. Verify the seal fits tightly in the cor-
ners. A soft face tool may be used to work the
seal up into the corners.
3. Continue working all the around the opening.
When the ends of the seal meet at the starting
bottom center of the cab opening, it may be
necessary to trim off some of the seal.
NOTE: The ends of the seal must be square-cut to
FIGURE 2-23.
ensure a proper fit.
1. Door Opening Seal 2. Door Hinge Seal

GLASS REPLACEMENT Replacement
Recommended Tools
Pneumatic knife
Heavy protective gloves
Safety goggles The first concern with all glass replacement is
safety! Wear heavy protective gloves and safety
Glazing adhesive & application gun
goggles when working with glass.
SM2897 glass installation spacers
(quantity varies per window)
Window glass (Refer to Parts Catalog) 1. Use a cut-out tool to slice into the existing
Recommended adhesives: urethane adhesive and remove the window.
2. Carefully clean and remove all broken glass
SikaTack Ultrafast or Ultrafast II (both heated).
The vehicle can be put into service after four chips from any remaining window adhesive.
hours in optimum conditions. Heated adhesives The surface should be smooth and even. Use
require a Sika approved oven to heat adhesive to only clean water.
80 C (176 F). NOTE: Removal of all old adhesive is not required.
Sikaflex 255FC or Drive (unheated). The vehicle Remove just enough to provide an even bedding
can be put into service after eight hours in base.
optimum conditions.
Sika Corporation 3. Use a long knife to cut the remaining urethane
30800 Stephenson Hwy. from the opening, leaving a bed 2 - 4 mm (0.08 -
Madison Heights, MI 48071 0.15 in.) thick. If the existing urethane is loose,
Toll Free Number: 1-800-688-7452 completely remove it. Leave the installation
Fax number: 248-616-7452 bumpers in place, if possible.
http://www.sika.com or 4. Clean the metal with Sika Aktivator. Allow it to
http://www.sikasolutions.com dry for ten minutes. Then paint on a thin coat of
Sika Primer 206G+P and allow it to dry for ten
minutes.
5. Using only the new side window(s) which are to
be bonded in place, center the new glass over
the opening in the cab. Use a permanent
Due to the severe duty application of off-highway marker to mark on the cab skin along all the
vehicles, the cure times listed by the adhesive edges of the new glass that is to be installed. All
manufacturer must be doubled before truck edges must be marked on the cab in order to
operation can resume. If the cure time is not apply the adhesive in the proper location.
doubled, vibration or movement will weaken the 6. Use Sika Primer 206G+P to touch up any bright
adhesive bond, and the glass may fall off the cab. metal scratches on the metal frame of the truck.
Do not prime the existing urethane bed. Allow it
If another adhesive manufacturer is used, follow to dry for ten minutes.
that manufacturer's instructions for use,
including the use of any primers. Double the 7. Use a clean, lint free cloth to apply Sika
allowances for proper curing time. Aktivator to the black ceramic Frit surrounding
the new window. Use a clean, dry cloth and
wipe off the Sika Aktivator. Allow it to dry for ten
minutes.

8. For the side windows, use six or seven glass WINDSHIELD AND REAR GLASS
installation bumpers (SM2897). Space them
NOTE: Two people are required to remove and
equally around the previously marked glass
install the windshield or rear glass. One person
perimeter, approximately 19 mm (0.75 in.)
inside the cab, and the other person on the outside.
inboard from where the edge of the glass will be
when it installed. Special tools that are helpful in removing and
installing automotive glass are available from local
NOTE: DO NOT apply the adhesive too far inboard,
tool suppliers.
as it will make any future glass replacement more
difficult. Removal
9. Apply a continuous, even bead of adhesive
1. If the windshield is to be replaced, lift the
(approximately 10 mm (0.38 in.) in diameter) to
windshield wiper arms out of the way.
the cab skin at a distance of 13 - 16 mm (0.50 -
0.63 in.) inboard from the previously marked 2. Starting at the lower center of the glass, pull out
final location of the glass edges from Step 5. weatherstrip locking lip (2, Figure 2-24 or 2-25).
Use a non-oily rubber lubricant and a screw-
10. Immediately install the glass. Carefully locate driver to release the locking lip.
the glass in place with the black masking side
3. Remove glass (1) from weatherstrip (3) by
toward the adhesive. Press firmly, but not
pushing it out from inside the cab.
abruptly, into place to ensure that the glass is
properly seated. Do not pound the glass into 4. Clean all dirt and old sealant from the
place. weatherstrip grooves. Ensure that the perimeter
of the window opening is clean and free of
11. Use a wooden prop and duct tape to hold the burrs.
glass in place for at least two hours or double
the adhesive manufacturers curing time,
whichever time is longer.
12. Remove the tape or prop from the glass only
after the cure time has expired.
FIGURE 2-24. FRONT WINDSHIELD
1. Glass 3. Weatherstrip
2. Locking Lip 4. Sheet Metal

Installation
1. If the weatherstrip that was previously removed 5. After the glass is in place, go around the
is broken, weathered, or damaged in any way, weatherstrip and push in on locking lip (2) to
install a new rubber weatherstrip. secure the glass in the weatherstrip.
NOTE: Using a non-oily rubber lubricant on the 6. If the windshield was replaced, lower the
weatherstrip material and cab opening will make the windshield wiper arms back onto the glass.
following installation easier:
a. Install weatherstrip (3, Figure 2-24 or 2-25)
around the window opening. Start with one
end of the weatherstrip at the center, lower
part of the window opening and press the
weatherstrip over the edge of the opening.
b. Continue installing the weatherstrip all
around the opening. When the ends of the
weatherstrip meet at the lower, center part of
the window opening, there must be 12.7 mm
(0.5 in.) of overlapping material.
NOTE: The ends of the weatherstrip material need to
be square-cut to assure a proper fit.
c. Lift both ends so that they meet squarely.
Then, while holding the ends together, force
them back over the lip of the opening.
2. Lubricate the groove of the weatherstrip where
the glass is to be seated.
3. Lower the glass into the groove along the
bottom of the window opening.
4. Two people should be used for glass
installation. Have one person on the outside of FIGURE 2-25. REAR WINDOW
the cab pushing in on the glass against the
1. Glass 3. Weatherstrip
opening, while one person on the inside uses a
2. Locking Lip 4. Sheet Metal
soft flat tool (such as a plastic knife) to work the
weatherstrip over the edge of the glass all the
way around.

SECTION N3
CAB COMPONENTS
INDEX
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4
WIPER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
WINDSHIELD WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6
N03028 Cab Components N3-1

NOTES
N3-2 Cab Components N03028

CAB COMPONENTS
WIPER MOTOR 3. While holding the linkage stationary, remove
nut (10, Figure 3-1) and disconnect linkage (9)
The windshield wipers are operated by a 24 volt
from wiper motor (1).
electric motor. The wipers can be adjusted for a
variable intermittent delay or a constant low or high 4. Remove three capscrews (6) with flat washers
speed by the switch mounted on the turn signal lever. (7) and lockwashers (8) that secure the wiper
motor to plate (5). Remove the wiper motor
Removal assembly.
1. Remove the large access panel from the front
of the cab.
2. Disconnect the wiper motor harness connector. Installation
1. Place wiper motor (1, Figure 3-1) into position
on plate (5).
2. Install three capscrews (6) with flat washers (7)
and lockwashers (8). Tighten the capscrews to
8 - 9 Nm (71 - 79 lb in.).
3. Align the motor output shaft with linkage (9).
Install nut (10) while holding the linkage
stationary. Tighten the nut to 22 - 24 Nm (16 -
18 ft. lbs.).
4. Reconnect the wiper motor harness connector.
5. Verify that the wipers operate properly and park
in the proper position. Refer to Figure 3-3.
FIGURE 3-1. WINDSHIELD WIPER

INSTALLATION
1. Wiper Motor 6. Capscrew

2. Capscrew 7. Flat Washer
3. Flat Washer 8. Lockwasher
4. Lockwasher 9. Linkage
5. Plate 10. Nut

WIPER ARM
Removal
1. Note the parked position of wiper arm (1, Figure
3-2).
2. Lift the wiper arm cover and remove nut (2) and
spring washer (3).
3. Disconnect washer hose (9, Figure 3-3), and
remove the wiper arm.
FIGURE 3-2. WIPER ARM DETAIL

1. Wiper Arm 4. Cap FIGURE 3-3. PARK POSITION
2. Nut 5. Washer A. Park Position (7) 5. Flat Washer
3. Spring Washer 6. Nut 1. Wiper Motor 6. Wiper Arm
2. Wiper Blade 7. Nozzle
3. Capscrew 8. Retainer
4. Lockwasher 9. Hose
Installation
1. Place wiper arm (1, Figure 3-2) into the parked
position that was noted during removal. Install
spring washer (3) and nut (2). Tighten the nut to
16 - 20 Nm (142 - 177 lb in.). Close the cover.
2. Connect washer hose (9, Figure 3-3) to wiper
arm (6).
3. Verify that the wiper arms operate properly and
park in the proper position after installation is
complete. Refer to Figure 3-3.

WIPER LINKAGE WINDSHIELD WASHER
Removal Operation
1. Remove the wiper arms. Refer to Wiper Arm The windshield washer, which is mounted on the
Removal in this section. right side of the hydraulic cabinet, is a 3.8 liter (1 gal)
2. Remove retainer (8, Figure 3-3) and disconnect plastic reservoir (1, Figure 3-4) with a 24 volt electric
the wiper linkage from the wiper motor drive pump (2).
arm. The washer is controlled by the windshield wiper
3. Remove nut (6, Figure 3-2) and washer (5) from switch mounted on the turn signal lever. When the
each wiper shaft. switch is activated, washing solution is pumped
4. Remove capscrews (3, Figure 3-3) with through outlet hose (3) and fed to a jet located in
lockwashers (4) and flat washers (5). each of the windshield wiper arms.
5. Remove the wiper assembly from the cab.
Service
If windshield washer maintenance is required, check
Installation the strainer opening for obstructions and inspect the
hoses for damage. Check the voltage to the pump
1. Place the wiper assembly into position in the from the control switch. If the pump is inoperable,
wiper compartment. replace it with a new pump assembly.
2. Install capscrews (3, Figure 3-3) with
lockwashers (4) and flat washers (5) and tighten
the capscrews.
3. Install washer (5, Figure 3-2) and nut (6) on
each wiper shaft. Tighten the nuts to 18 - 20
Nm (160 - 177 lb in.). Install cap (4) over the
nuts.
NOTE: Do not overtighten the nuts. The threads on
the shafts are easily stripped when improperly
tightened.
4. Align the linkage and attach it to the wiper

motor drive arm using retainer (8, Figure 3-3).
NOTE: When the motor is parked, the drive arm will
be in the 3 oclock position, as shown in Figure 3-3.
5. Install the wiper arms. Refer to Wiper Arm

Installation in this section. Ensure that the
wiper arms operate properly and park in the
proper position after installation is complete.
FIGURE 3-4. WINDSHIELD WASHER FLUID

RESERVOIR AND PUMP
1. Reservoir 3. Outlet Hose
2. Pump 4. Filler Cap

OPERATOR SEAT .
The operator's seat provides a fully adjustable
cushioned ride for the driver's comfort and ease of
operation.
Adjustment
The following adjustments must be made while
sitting in the seat.
1. Headrest: Move headrest (1, Figure 3-5) up,
down, fore, or aft to the desired position.
2. Armrests: Rotate the adjusting knob until
armrest (2) is in the desired position.
3. Backrest: Lift handle (3) to release and select
backrest angle. Release control handle to set.
4. Seat Belt: The operator must always have seat
belt (4) buckled and properly adjusted
whenever the vehicle is in motion.
5. Seat Slope: Lift and hold lever (5) to adjust the
slope of the seat. Release the lever to lock the
position.
6. & 7 Air Lumbar Support: Switch (7) controls the
lower air pillow and switch (6) controls the
upper air pillow. To inflate, press and hold the
top of the switch, then release. To deflate, press
and hold the bottom of the switch, then release.
8. Seat Suspension: Move switch (8) up to
increase ride stiffness or down to decrease ride
stiffness.
9. Horizontal Adjustment: Lift and hold lever (9).
Bend your knees to move the seat back or forth.
Release the lever to lock the position.
12. Seat Height: Lift and hold lever (12) to adjust
the height of the seat. Release the lever to lock
the position.
FIGURE 3-5. OPERATORS SEAT ADJUSTMENT
Seat Removal
CONTROLS
1. Remove mounting hardware (10, Figure 3-5)
1. Headrest
that secures the seat base to the riser. Remove
2. Armrest
mounting hardware (11) that secures the tether
3. Backrest Adjustment Handle
to the floor.
4. Seat Belt
2. Remove the seat assembly from cab. 5. Seat Slope Adjustment Lever
6. Upper Air Pillow Lumbar Support Switch
Seat Installation 7. Lower Air Pillow Lumbar Support Switch
1. Mount the seat assembly to the riser. Install 8. Seat Suspension Adjustment Switch
mounting hardware (10, Figure 3-5). Tighten 9. Horizontal Adjustment Lever
the capscrews to the standard torque. 10. Seat Base Mounting Hardware
2. Fasten the tether straps to the floor with 11. Seat Tether Mounting Hardware
mounting hardware (11). Tighten the capscrews 12. Seat Height Adjustment Lever
to the standard torque

SECTION N4
OPERATOR COMFORT
INDEX
HEATER/AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
HEATER/AIR CONDITIONER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Fan Speed Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Air Flow Directional Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Fan Motor And Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
Cab Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
ENVIRONMENTAL IMPACT OF AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
PRINCIPLES OF REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8
Refrigeration - The Act Of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-9
The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-9
AIR CONDITIONER SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Compressor (Refrigerant Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10
Expansion Block Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-11
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-11
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-11
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12
Compressor Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12
Trinary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-13
SYSTEM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-14
SERVICE TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Recovery/Recycle Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-16
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-17
Installing Manifold Gauge Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-18
Purging Air From Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-18
N04038 Operator Comfort N4-1

SYSTEM PERFORMANCE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-19
SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20
Handling and Reusing PAG Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20
Oil Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20
Checking System Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20
REFRIGERANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-21
Recycled Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-21
Reclaimed Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-21
Refrigerant Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-21
R-134a Refrigerant Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22
SYSTEM LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22
Electronic Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Tracer Dyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Soap and Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
RECOVERING AND RECYCLING THE REFRIGERANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Draining Oil from the Previous Recovery Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Performing the Recovery Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23
Performing the Recycling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
Evacuating and Charging the A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
SYSTEM REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24
A/C DRIVE BELT CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
Belt Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25
COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27
Hoses and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28
Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28
Servicing the Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-29
Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-31
Clutch Coil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-32
Pulley Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-32
Clutch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-32
EVACUATING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-34
CHARGING THE A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-36
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-37
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-37
Diagnosis Of Gauge Readings And System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-37
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-38
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-44
N4-2 Operator Comfort N04038

OPERATOR COMFORT
HEATER/AIR CONDITIONER UNIT
The heater/air conditioner compartment contains
heater/air conditioner controls and some of the
heater/air conditioner components, such as the
blower motor assembly and the heater coil. Optimum
cab air climate can be selected by using the following
controls in various combinations.
Fan Speed Control Knob

Fan speed control knob (1, Figure 4-1) controls the
cab fan motor. The fan motor is a 3-speed motor
(low, medium and high). Speeds are selected by
rotating the control knob clockwise to the desired
position. OFF is in the full counterclockwise position.
The control knob must be switched ON for the air
conditioner to function.
Temperature Control Knob

Temperature control knob (2) allows the operator to
select a comfortable air temperature.
The control knob determines the operation of the air
conditioning and heater modes.
Rotating the control knob counterclockwise into blue
zone (3) will cause the A/C compressor to operate
and result in cooler air temperatures. Full counter-
clockwise position is the coldest air setting.
Rotating the control knob clockwise to red zone (4)
will allow coolant to flow through the heater core
resulting in warmer air temperatures. The full clock-
wise position is the warmest heater setting.
Air Flow Directional Knob

Air flow directional knob (5) controls the direction of
airflow as follows:
Provides airflow to floor vents, only.

FIGURE 4-1. A/C & HEATER CONTROLS
Provides airflow to upper vents and floor
vents. 1. Fan Speed Control 4. Red Zone
Knob 5. Air Flow Directional
Provides airflow to upper vents, only. 2. Temperature Knob
Control Knob 6. Vents
Defrost - Provides dehumidified air to the
3. Blue Zone
windshield.
Defrost - Provides dehumidified air to the
windshield as well as to floor vents.

Heater/Air Conditioner Vents
Heater/air conditioner vents (6) may be rotated 360. Relays
There are three vents in the heater/air conditioner
compartment, four vents across the top of the instru- Three relays (8, Figure 4-2) control the damper
ment panel, and one vent each in the RH and LH doors, A/C compressor clutch, temperature control
instrument panels. There are also an additional four switch, water (heater) valve and the actuator motors.
vents under the instrument panel. Air flow through
the vents is controlled by manually opening, closing Heater Core
or turning the louvers. Heater core (2, Figure 4-4) receives engine coolant
through water valve (33) when heat is selected. If
temperature control knob (2, Figure 4-1) is placed in
COMPONENTS between the red and blue area, or turned counter-
clockwise to the blue area, coolant flow will be
Figure 4-2 and Figure 4-4 illustrate both the heater blocked.
system and air conditioning system parts contained
in the cab mounted enclosure. Refer to the air condi- If temperature control knob (2) and water valve (33,
tioning system topics later in this section for addi- Figure 4-4) appear to be working properly, yet no
tional information regarding air conditioning system heat is apparent in heater core (2), the core may be
components, maintenance and repair. restricted. Remove and clean or replace the core.
Fuse
Before attempting to troubleshoot the electrical circuit
in the heater enclosure, turn the key switch ON and
verify that the fuse is good. The fuse is designated as
fuse 1 and is located in fuse panel 3 in the rear elec-
trical compartment. Refer to the electrical schematic
for more detailed information.
FIGURE 4-2. CAB HEATER/AIR

CONDITIONER COMPONENTS
1. Enclosure
2. Water (Heater) Valve
3. A/C Refrigerant Hoses
4. Water Outlet (To Engine)
5. Water Inlet (From Engine Water Pump)
6. Evaporator Core
7. Heater Core
8. Relays

Fan Motor And Speed Control Cab Air Filter
Fan speed is controlled by the position of the fan Recirculation air filter (5, Figure 4-4) and fresh air fil-
speed control knob (1, Figure 4-1). ter (2, Figure 4-3) in the front access panel of the cab
need periodic cleaning to prevent restrictions in air
If blower assembly (3, Figure 4-4) does not operate
circulation. Restricted filters will decrease the perfor-
at any of the speed selections, verify that battery
mance of the heater and air conditioner. The recom-
voltage is available at the switches and relays. Refer
mended interval for cleaning and inspection is 250
to the electrical schematic in Section R. If voltage is
hours, but in extremely dusty conditions the filters
present, the blower assembly is probably defective
may need daily service and inspection, especially the
and should be removed and replaced.
outer panel filter on the cab shell. The filter elements
should be cleaned with water and dried in a dust free
environment before reinstallation. Replace the filter
Actuators element every 2000 hours, or sooner if inspection
Two rotary actuator motors (9, Figure 4-4) are indicates a clogged or damaged filter.
installed inside the heater housing and are used to
actuate the damper doors for the following:
Defroster outlet
Bi-level or floor outlets
A failure to switch one of the above modes of
operation may be caused by a faulty actuator.
Visually inspect damper doors (35, 36) and the
linkage for the function being diagnosed. Ensure that
the damper door is not binding or obstructed,
preventing movement from one mode to the other.
Verify that 24 VDC is present at the actuator when air
flow directional knob (5, Figure 4-1) is moved
through its various positions of operation.
If the correct voltages are present during operation of
the switch, disconnect the actuator from the damper
door and verify that actuator force is comparable to a
known (new) actuator. If it is not, install a new
actuator.
FIGURE 4-3. CAB FILTER LOCATION
1. Access Cover 2. Cab Filter

FIGURE 4-4. HEATER/AIR CONDITIONER ASSEMBLY
1. Evaporator Core 10. Louver 21. Foam 32. Punched Strip

2. Heater Core 11. Thermostat 22. Bracket 33. Water Valve
3. Blower Assembly 12. LH Seal 23. Case 34. Drive Adapter
4. Outer Recirculation 13. Front Seal 24. Bracket 35. Damper Door (Up)
Grille 14. Top Seal 25. Control Panel Harness 36. Damper Door (Side)
5. Recirculation Filter 15. Screw 26. Main Unit Harness 37. Punched Strip
6. Inner Recirculation 16. Screw 27. Seal 38. Punched Strip
Grille 17. Cover 28. Screw 39. Blower Retainer
7. Expansion Block Valve 18. Knob 29. Screw 40. Control Panel
8. Relay 19. Seal 30. Bulb 41. Grommet
9. Actuator 20. Foam 31. Pivot Bushing 42. Duct Adapter

FIGURE 4-5. BASIC AIR CONDITIONING SYSTEM
1. Blower Switch 7. Evaporator 13. Magnetic Clutch
2. Thermostatic Switch 8. Expansion Valve 14. Compressor Drive Pulley
3. Battery Supply 9. Suction Line 15. Receiver-Drier
4. Circuit Breaker 10. Test Gauges & Manifold 16. Discharge Line
5. Blower 11. Compressor 17. Condenser
6. Temperature Sensor 12. Refrigerant Container 18. Accumulator

ENVIRONMENTAL IMPACT OF AIR The general cleanliness of the system and compo-
CONDITIONING nents is important. Dust or dirt collected in the con-
denser, evaporator, or air filters decreases the
Environmental studies have indicated a weakening of
system's cooling capacity.
the earths protective Ozone (O3) layer in the outer
stratosphere. Chloro-flouro-carbon compounds The compressor, condenser, evaporator units, hoses
(CFCs), such as R-12 refrigerant (Freon), commonly and fittings must be installed clean and tight and be
used in mobile equipment air conditioning systems, capable of withstanding the strain and abuse they
have been identified as a possible contributing factor are subjected to on off-highway vehicles.
of the Ozone depletion.
Equipment downtime costs are high enough to
Consequently, legislative bodies in more than 130 encourage service areas to perform preventative
countries have mandated that the production and maintenance at regular intervals on vehicle Air Con-
distribution of R-12 refrigerant be discontinued after ditioning (A/C) systems. (Cleaning, checking belt
1995. Therefore, a more environmentally-friendly tightness, and operation of electrical components).
hydro-flouro-carbon.
(HFC) refrigerant, commonly identified as HFC-134a
or R-134a, is being used in most current mobile air PRINCIPLES OF REFRIGERATION
conditioning systems. Additionally, the practice of A brief review of the principles of air conditioning is
releasing either refrigerant to the atmosphere during necessary to relate the function of the components,
the charging/recharging procedure is prohibited. the technique of troubleshooting and the corrective
These restrictions require the use of equipment and action necessary to put the A/C unit into top operat-
procedures which are significantly different from ing efficiency.
those traditionally used in air conditioning service Too frequently, the operator and the serviceman
techniques. The use of new equipment and tech- overlook the primary fact that no A/C system will
niques allows for complete recovery of refrigerants, function properly unless it is operated within a com-
which will not only help to protect the environment, pletely controlled cab environment. The circulation of
but through the recycling of the refrigerant will pre- air must be a directed flow. The cab must be sealed
serve the physical supply, and help to reduce the against seepage of ambient air. The cab interior must
cost of the refrigerant. be kept free of dust and dirt which, if picked up in the
air system, will clog the intake side of the evaporator
coil.
AIR CONDITIONING FOR OFF-HIGHWAY
VEHICLES
Mining and construction vehicles have unique char- Air Conditioning
acteristics of vibration, shock-loading, operator Air conditioning is a form of environmental control. As
changes, and climate conditions that present differ- applied to the cab, it refers to the control of tempera-
ent design and installation problems for air condition- ture, humidity, cleanliness, and circulation of air. In
ing systems. Off-highway equipment, in general, is the broad sense, a heating unit is as much an air
unique enough that normal automotive or highway conditioner as is a cooling unit. The term air condi-
truck engineering is not sufficient to provide the reli- tioner is commonly used to identify an air cooling
ability to endure the various work cycles encoun- unit. To be consistent with common usage, the term
tered. air conditioner will refer to the cooling unit utilizing
The cab tightness, insulation, and isolation from heat the principles of refrigeration; sometimes referred to
sources is very important to the efficiency of the sys- as the evaporator unit.
tem. It is advisable to close all vents, even the
intakes of pressurization systems, when there are
high humidity conditions.

Refrigeration - The Act Of Cooling Ambient air, passing through the condenser removes
heat from the circulating refrigerant resulting in the
There is no process for producing cold; there is
conversion of the refrigerant from gas to liquid.
only heat removal.
Heat always travels toward cooler temperatures. The liquid refrigerant moves on to the receiver drier
This principle is the basis for the operation of a where impurities are filtered out, and moisture
cooling unit. As long as one object has a removed. This component also serves as the tempo-
temperature lower than another, this heat transfer rary storage unit for some liquid refrigerant.
will occur.
The liquid refrigerant, still under high pressure, then
Temperature is the measurement of the intensity flows to the expansion valve. This valve meters the
of heat in degrees. The most common measuring amount of refrigerant entering the evaporator. As the
device is the thermometer. refrigerant passes through the valve, it becomes a
All liquids have a point at which they will turn to low temperature, low pressure liquid and saturated
vapor. Water boiling is the most common vapor. This causes the refrigerant to become cold.
example of heating until vapor is formed. Boiling
The remaining low pressure liquid immediately starts
is a rapid form of evaporation. Steam is a great
deal hotter than boiling water. The water will not to boil and vaporize as it approaches the evaporator,
increase in temperature once brought to a boil. adding to the cooling. The hot, humid air of the cab is
The heat energy is used in the vaporization pulled through the evaporator by the evaporator
process. The boiling point of a liquid is directly blower. Since the refrigerant is colder than the air, it
affected by pressure. By changing pressure, we absorbs the heat from the air producing cool air
can control the boiling point and temperature at which is pushed back into the cab. The moisture in
which a vapor will condense. When a liquid is the air condenses upon movement into the evapora-
heated and vaporizes, the gas will absorb heat tor and drops into the drain pan from which it drains
without changing pressure. out of the cab.
Reversing the process, when heat is removed Refrigerant leaving the evaporator enters the accu-
from water vapor, it will return to the liquid state.
mulator. The accumulator functions as a sump for liq-
Heat from air moves to a cooler object. Usually
the moisture in the cooled air will condense on uid refrigerant in the system. Because of its design,
the cooler object. the accumulator only allows vaporized refrigerant to
return to the compressor, preventing compressor
Refrigerant - Only R-134a should be used in the slugging from occurring. Desiccant is located at the
new mobile systems which are designed for this bottom of the accumulators to remove moisture that
refrigerant.
is trapped in the system.
The cycle is completed when the heated low pres-
sure gas is again drawn into the compressor through
the suction side.
The Refrigeration Cycle
This simplified explanation of the principles of refrig-
In an air conditioning system, the refrigerant is circu- eration does not call attention to the fine points of
lated under pressure through the five major compo- refrigeration technology. Some of these will be cov-
nents in a closed circuit. At these points in the ered in the following discussions of the components,
system, the refrigerant undergoes predetermined controls, and techniques involved in preparing the
pressure and temperature changes. unit for efficient operation.
The compressor (refrigerant pump) takes in low pres-
sure heat laden refrigerant gas through the suction
valve (low side), and as its name indicates, pressur-
izes the heat laden refrigerant and forces it through
the discharge valve (high side) on to the condenser.

AIR CONDITIONER SYSTEM Ram air condensers depend upon the vehicle move-
COMPONENTS ment to force a large volume of air past the fins and
tubes of the condenser. The condenser is usually
Compressor (Refrigerant Pump) located in front of the radiator or on the roof of the
The compressor is where the low pressure side of truck.
the system changes to high pressure. It concentrates Condensing of the refrigerant is the change of state
the refrigerant returning from the evaporator (low of the refrigerant from a vapor to a liquid. The action
side) creating high pressure and a temperature much is affected by the pressure of the refrigerant in the
higher than the outside air temperature. The high coil and air flow through the condenser. Condensing
temperature differential between the refrigerant and pressure in an A/C system is the controlled pressure
the outside air is necessary to aid rapid heat flow in of the refrigerant which affects the temperature at
the condenser from the hot refrigerant gas to much which it condenses to liquid, giving off large quanti-
cooler outside air. ties of heat in the process. The condensing point is
To create high pressure concentration, the compres- sufficiently high to create a wide temperature differ-
sor draws in refrigerant from the evaporator through ential between the hot refrigerant vapor and the air
the suction valve and during compression strokes, passing over the condenser fins and tubes. This dif-
forces it out through the discharge valve to the con- ference permits rapid heat transfer from the refriger-
denser. The pressure from the compressor action ant to ambient air.
moves the refrigerant through the condenser,
receiver-drier and connecting hoses to the expansion
valve. Receiver-Drier
The compressor is driven by the engine through a v- The receiver-drier is an important part of the air con-
belt driving an electrically operated clutch mounted ditioning system. The drier receives the liquid refrig-
on the compressor drive shaft. erant from the condenser and removes any moisture
and foreign matter present which may have entered
the system. The receiver section of the tank is
Service Valves designed to store extra refrigerant until it is needed
by the evaporator. The storage of this refrigerant is
Quick-connect hose end fittings with integral service temporary and is dependent on the demand of the
valves attach to system service ports for servicing expansion valve.
the unit. A manifold gauge set is connected into the
system at the service valve ports and all procedures, A desiccant is a solid substance capable of removing
such as discharging, evacuating and charging the moisture from gas, liquid or solid. It is held in place
system, are performed through the service valves. within the receiver between two screens, which also
act as strainers.
The receiver-drier is also equipped with a sight glass
Condenser and a moisture indicator. The sight glass can give a
good indication of the charge of the system. If the
The condenser receives the high pressure, high-tem- sight glass is not clear, the system is low on refriger-
perature refrigerant vapor from the compressor and ant.
condenses it to high pressure, hot liquid.
The moisture indicator is a device to notify service
It is designed to allow heat movement from the hot personnel that the drier is full of moisture and must
refrigerant vapor to the cooler outside air. The cool- be replaced. The indicator is blue when the compo-
ing of the refrigerant changes the vapor to liquid. nent is free from moisture. When the indicator turns
Heat exchange is accomplished using cooler air flow- beige or tan, the drier must be replaced.
ing through the condenser. Condenser cooling is
achieved by air flowing from the radiator fan along
with ram air provided by vehicle movement. The radi-
ator fan moves more than 50% of condenser air flow
unless travel speed is at least 25 mph.

Expansion Block Valve The storage of the liquid refrigerant is temporary.
When the liquid vaporizes into a gas it will be pulled
The expansion block valve controls the amount of
from the bottom of the accumulator into the compres-
refrigerant entering the evaporator coil. Both inter-
sor. This process not only allows the accumulator to
nally and externally equalized valves are used.
act as a storage device, but also protects the com-
The expansion valve is located near the inlet of the pressor from liquid slugging.
evaporator and provides the functions of throttling,
The low side service port is also located on the accu-
modulating, and controlling the liquid refrigerant to
mulator.
the evaporator coil.
The refrigerant flows through a restriction creating a
pressure drop across the valve. Since the expansion Evaporator
valve also separates the high side of the system from
the low side, the state of the refrigerant entering the The evaporator cools and dehumidifies the air before
valve is warm to hot high pressure liquid; exiting it is it enters the cab. Cooling a large area requires that
low pressure liquid and gas. The change to low pres- large volumes of air be passed through the evapora-
sure allows the flowing refrigerant to immediately tor coil for heat exchange. Therefore, a blower
begin changing to gas as it moves toward the evapo- becomes a vital part of the evaporator assembly. It
rator. This produces the desired cooling effect. not only draws heat laden air into the evaporator, but
also forces this air over the evaporator fins and coils
The amount of refrigerant metered into the evapora- where the heat is surrendered to the refrigerant. The
tor varies with different heat loads. The valve modu- blower forces the cooled air out of the evaporator into
lates from wide open to the nearly closed position, the cab.
seeking a point between for proper metering of the
refrigerant. Heat exchange, as explained under condenser oper-
ation, depends upon a temperature differential of the
As the load increases, the valve responds by open- air and the refrigerant. The greater the temperature
ing wider to allow more refrigerant to pass into the differential, the greater will be the amount of heat
evaporator. As the load decreases, the valve reacts exchanged between the air and the refrigerant. A
and allows less refrigerant into the evaporator. It is high heat load condition, as is generally encountered
this controlling action that provides the proper pres- when the air conditioning system is turned on, will
sure and temperature control in the evaporator. allow rapid heat transfer between the air and the
This system uses an internally equalized, block type cooler refrigerant.
expansion valve. With this type valve, the refrigerant The change of state of the refrigerant in and going
leaving the evaporator coil is also directed back through the evaporator coil is as important as that of
through the valve so the temperature of the refriger- the air flow over the coil.
ant is monitored internally rather than by a remote
sensing bulb. The expansion valve is controlled by All or most of the liquid that did not change to vapor
both the temperature of the power element bulb and in the expansion valve or connecting tubes boils
the pressure of the liquid in the evaporator. (expands) and vaporizes immediately in the evapora-
tor, becoming very cold. As the process of heat loss
NOTE: It is important that the sensing bulb, if from the air to the evaporator coil surface is taking
present, is tight against the output line and protected place, any moisture (humidity) in the air condenses
from ambient temperatures with insulation tape. on the cool outside surface of the evaporator coil and
is drained off as water.
At atmospheric pressure, refrigerant boils at a point
Accumulator
lower than water freezes. Therefore, the temperature
As the accumulator receives vaporized refrigerant in the evaporator must be controlled so that the water
from the evaporator, moisture and/or any residual liq- collecting on the coil surface does not freeze on and
uid refrigerant is collected at the bottom of the com- between the fins and restrict air flow. The evaporator
ponent. The moisture is absorbed by the desiccant temperature is controlled through pressure inside the
where it is safely isolated from the rest of the system. evaporator, and temperature and pressure at the out-
let of the evaporator.

ELECTRICAL CIRCUIT Compressor Clutch
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 cir- the thermostat to disengage the compressor when it
cuit breaker. is not needed, such as when a defrost cycle is indi-
cated in the evaporator, or when the system or
The blower control is a switch which provides a
blower is turned off.
range of blower speeds from fast to slow. When the
blower switch is turned on, current is available at the The stationary field clutch is the most desirable type
compressor clutch. Once the blower is turned on, fan since it has fewer parts to wear. The field is mounted
speeds may be changed without affecting the ther- to the compressor by mechanical means depending
mostat sensing level. on the type field and compressor. The rotor is held on
the armature by a bearing and snap rings. The arma-
The thermostat reacts to changing temperatures
ture is mounted on the compressor body.
which cause electrical contacts to open and close.
The thermostat has a capillary tube extended into the When no current is fed to the field, there is no mag-
evaporator coil to sense temperature. netic force applied to the clutch and the rotor is free
to rotate on the armature, which remains stationary
When the contacts are closed, current flows to the
on the crankshaft.
clutch field and energizes the clutch, causing the
swash plate inside the compressor to turn which When the thermostat or switch is closed, current is
starts the refrigeration cycle. When the temperature fed to the field. This sets up a magnetic force
of the evaporator coil drops to a predetermined point, between the field and armature, pulling it into the
the contacts open and the clutch disengages. rotor. When the armature becomes engaged with the
rotor, the complete unit rotates while the field
When the clutch is disengaged, the blower remains
remains stationary. This causes the compressor
at the set speed. After the evaporator temperature
crankshaft to turn, starting the refrigeration cycle.
rises about twelve degrees above the cutout point,
the contacts in the thermostat close and the refriger- When the switch or thermostat is opened, current is
ation cycle resumes. cut off. The armature snaps back out and stops while
the rotor continues to turn. Pumping action of the
compressor is stopped until current is again applied
Thermostat to the field. In addition, safety switches in the com-
pressor clutch electrical circuit control clutch opera-
An electromagnetic clutch is used on the compressor tion, disengaging the clutch if system pressures are
to provide a means of constant temperature control abnormal.
of the cab. The clutch is controlled by a thermostat in
the evaporator which is set initially by the driver to a
predetermined point. Evaporator temperature is then
maintained by the cycling action of the clutch.
The thermostat is simply a thermal device which con-
trols an electrical switch. When warm, the switch is
closed; when cold, it is open. Most thermostats have
a positive OFF position as a means to turn the clutch
off regardless of temperature.
The bellows type thermostat has a capillary tube con-
nected to it which is filled with refrigerant. The capil-
lary tube is attached to the bellows inside of the
thermostat. Expansion of the gases inside the capil-
lary tube exerts pressure on the bellows, which in
turn closes the contacts at a predetermined tempera-
ture.

Trinary Switch Fan Clutch - The mid-range function actuates the
engine fan clutch, if installed.
This switch is mounted on the receiver-drier and has
three functions, as implied by the name: High Pressure - This switch opens and
disengages the compressor clutch if system
1. Disengage the compressor clutch when system pressure rises above the 2068-2413 kPa (300-
pressure is too high. 350 psi) range. After system pressure drops to
2. Disengage the compressor clutch when system 1448-1724 kPa (210-250 psi), the switch contacts
pressure is too low. will close and the clutch will engage.
3. Engage and disengage the radiator fan drive The switch functions will automatically reset when
clutch during normal variation of system pres- system pressure returns to normal.
sure.
OPENS CLOSES
The Trinary switch performs three distinct func- Low 103-207 kPa 276 kPa
tions to monitor and control refrigerant pressure in Pressure (15-30 psi) (40 psi)
the system. This switch is installed on the receiver- descending rising pressure
drier. The switch functions are: pressure
Terminals 1 & 2 are connected internally through two, High 2068-2413 kPa 1448-1724 kPa
normally closed pressure switches in series, the low Pressure (300-350 psi) (210-250 psi)
pressure switch and the high pressure switch.
241-414 kPa 1379-1586 kPa
Fan Clutch (35-60 psi) (200-230 psi)
below closing rising pressure
pressure
The pressures listed above are typical of pres-

sures at the receiver-drier. Due to normal system
flow losses and the distance between the service
port and the receiver-drier, it is expected that
actual system pressure displayed on the gauge
will normally be approximately 20 psi higher. This
factor should be observed when checking for
proper operation of the switch.
Terminals 3 & 4 are connected internally through a
normally open switch that is used to control the NOTE: One other pressure controlling device is
clutch that drives the radiator fan. This switch closes installed within the compressor. A mechanical relief
and causes the cooling fan clutch to engage when valve is located on the back of the compressor. The
system pressure rises to 1379-1586 kPa (200-230 relief valve will open at 3447-3792 kPa (500 - 550
psi). When pressure falls to 965-1344 kPa (140-195 psi). The purpose of this valve is to protect the
psi), the switch contacts open, and the cooling fan compressor in the event that pressure should be
clutch disengages. allowed to rise to that level. Damage to the
compressor will occur if pressure exceeds 550 psi.
Low Pressure - This switch opens and
disengages the compressor clutch if system
pressure drops into the 103-207 kPa (15-30 psi)
range. When pressure rises above 276 kPa (40
psi), the switch contacts close, and the clutch
engages the compressor. Since temperature has
a direct effect on pressure, if the ambient
temperature is too cold, system pressure will
drop below the low range, and the pressure
switch will disengage the clutch.

SYSTEM SERVICING Ensure sufficient ventilation whenever refriger-
ant is being discharged from a system, keeping
Servicing an air conditioning system really means
in mind refrigerant is heavier than air and will fall
closely monitoring refrigerant flow. For this reason,
to low-lying areas.
the following procedures deal extensively with the
proper use, handling, care and safety factors When exposed to flames or sparks, the compo-
involved in the R-134a refrigerant quality and quan- nents of refrigerant change and become deadly
tity in an air conditioning system. phosgene gas. This poison gas will damage the
respiratory system if inhaled. NEVER smoke in
Because the refrigerant in an air conditioning system an area where refrigerant is used or stored.
must remain pressurized and sealed within the unit to
Never direct a steam cleaning hose or torch in
function properly, safety is a major consideration
direct contact with components in the air condi-
when anything causes this pressurized, sealed con-
tioning system. Localized heat can raise the
dition to change. The following warnings are pro-
pressure to a dangerous level.
vided here to alert service personnel to their
importance before learning the correct procedures. Do not heat or store refrigerant containers above
Read, remember, and observe each warning before 49 C (120 F).
beginning actual system servicing. Do not flush or pressure test the system using
shop air or another compressed air source. Cer-
NOTE: If the mine operates a fleet with some trucks
tain mixtures of air and R-134a refrigerant are
using R-12 and others using R-134a refrigerant, it is
combustible when slightly pressurized. Shop air
essential that servicing tools that come into contact
supplies also contain moisture and other con-
with the refrigerant (gauge sets, charging equipment,
taminants that could damage system compo-
recycle/recovery equipment etc.) be dedicated to one
nents.
type refrigerant only, to prevent cross contamination.
Federal regulations prohibit venting R-12 and

R-134a refrigerant into the atmosphere. An SAE Trucks operating in cold weather climates must
and UL approved recovery/recycle station must continue to keep the A/C system charged during
be used to remove refrigerant from the A/C sys- cold weather months. Keeping the system
tem. Refrigerant is stored in a container on the charged helps prevent moisture intrusion into
unit for recycling, reclaiming, or transporting. In system oil and desiccants.
addition, technicians servicing A/C systems
must be certified they have been properly trained
to service the system.
Although accidental release of refrigerant is a
remote possibility when proper procedures are
followed, the following warnings must be
observed when servicing A/C systems:
Provide appropriate protection for your eyes
(goggles or face shield) when working around
refrigerant.
A drop of the liquid refrigerant on your skin will
produce frostbite. Wear gloves and exercise
extreme care when handling refrigerant.
If even the slightest trace of refrigerant enters in
your eye, flood the eye immediately with cool
water and seek medical attention as soon as pos-
sible.

SERVICE TOOLS AND EQUIPMENT
Recovery/Recycle Station
Whenever refrigerant must be removed from the sys-
tem, a dual purpose station as shown in Figure 4-6, Mixing different types of refrigerant will damage
performs both recovery and recycle procedures equipment. Dedicate one recovery/recycle sta-
which follows the new guidelines for handling used tion to each type of refrigerant processing to
refrigerant. The recovered refrigerant is recycled to avoid equipment damage. DISPOSAL of the gas
reduce contaminants, and can then be reused in the removed requires laboratory or manufacturing
same machine or fleet. facilities.
To accomplish this, the recovery/recycle station sep- Test equipment is available to confirm the refrigerant
arates the oil from the refrigerant and filters the in the system is actually the type intended for the
refrigerant multiple times to reduce moisture, acidity, system and has not been contaminated by a mixture
and particulate matter found in a used refrigerant. of refrigerant types.
NOTE: To be re-sold, the gas must be reclaimed Recycling equipment must meet certain standards as
which leaves it as pure as new, but requires published by the Society of Automotive Engineers
equipment normally too expensive for all but the (SAE) and carry a UL approved label. The basic prin-
largest refrigeration shops. cipals of operation remain the same for all machines,
Equipment is also available to just remove or extract even if the details of operation differ somewhat.
the refrigerant. Extraction equipment does not clean
the refrigerant - it is used to recover the refrigerant
from an A/C system prior to servicing. Leak Detector
The electronic detector (Figure 4-7) is very accurate
and safe. It is a small hand-held device with a flexible
probe used to seek refrigerant leaks. A buzzer, alarm
or light will announce the presence of even the small-
est leak.
Some leak detectors are only applicable to one type
of refrigerant. Ensure the leak detector being used
applies to the refrigerant in the system.
FIGURE 4-6. RECOVERY/RECYCLE STATION FIGURE 4-7. TYPICAL ELECTRONIC LEAK

DETECTOR

FIGURE 4-9. VACUUM PUMP
FIGURE 4-8. R-134a SERVICE VALVE
1. System Service Port 3. Service Hose Co

Fitting nection
2. Quick Connect Vacuum Pump
The vacuum pump (Figure 4-9) is used to completely
evacuate all of the refrigerant, air, and moisture from
the system by deliberately lowering the pressure
within the system to the point where water turns to a
Service Valves vapor (boils) and together with all air and refrigerant
Because an air conditioning system is a sealed sys- is withdrawn (pumped) from the system.
tem, two service valves are provided on the com-
pressor to enable diagnostic tests, system charging
or evacuation. Connecting the applicable hoses from
the manifold gauge set to the compressor service
valves enables each of these to be readily per-
formed.
New and unique service hose fittings (Figure 4-8)
have been specified for R-134a systems. Their pur-
pose is to avoid accidental cross-mixing of refriger-
ants and lubricants with R-12 based systems. The
service ports on the system are quick disconnect
type with no external threads. They do contain a
Schrader type valve. The low side fitting has a
smaller diameter than the high side attachment.
Protective caps are provided for each service valve.
When not being used these caps should be in place
to prevent contamination or damage to the service
valves.

Manifold Gauge Set
A typical manifold gauge set (Figure 4-10) has two
screw type hand valves to control access to the sys-
tem, two gauges and three hoses. The gauges are
used to read system pressure or vacuum. The mani-
fold and hoses are for access to the inside of an air
conditioner, to remove air and moisture, and to put in,
or remove, refrigerant from the system. Shutoff
valves are required within 12 inches of the hose
end(s) to minimize refrigerant loss.
A gauge set for R-134a will have a blue hose with a
black stripe for the low side, a red hose with a black
stripe for the high side, and a yellow hose with a
black stripe for the utility (center) hose. The hoses
use a 1/2 in. ACME female nut on the gauge end.
Special quick disconnect couplings are normally
combined with a shutoff valve on the high and low
side hoses. The free end of the center hose contains
a 1/2 in. ACME female nut and a shutoff device
within 12 inches of the hose end. These special FIGURE 4-10. MANIFOLD GAUGE SET
hoses and fittings are designed to minimize refriger-
ant loss and to preclude putting the wrong refrigerant
in a system.
NOTE: When hose replacement becomes necessary, Low Side Gauge

the new hoses must be marked SAE J2916 R-
134a. The low side gauge, registers both vacuum and pres-
sure. The vacuum side of the scale is calibrated from
0 to 30 inches of mercury (in. Hg). The pressure side
Functions of the manifold gauge set are included in of the scale is calibrated to 150 psi.
many of the commercially available recovery or
recovery/recycle stations.
Never open the hand valve to the high side at

anytime when the air conditioning system is
operating. High side pressure, if allowed, may
rupture charging containers and potentially
cause personal injury.
High Side Gauge

The high side gauge is used to measure pressure
only on the discharge side of the compressor. The
scale is calibrated from 0 to 500 psi.

Installing Manifold Gauge Set 4. Connect the two service hoses from the mani-
fold to the correct service valves on the com-
Before attempting to service the air conditioning sys-
pressor and accumulator, as shown in Figure 4-
tem, a visual inspection of both the engine and A/C
11. (High side to compressor discharge valve
system components is recommended. Particular
and low side to accumulator.) Do not open the
attention should be given to the belts, hoses, tubing
service valves at this time.
and all attaching hardware as well as the radiator
cap, fan clutch, and thermostat. Inspect both the con-
denser and the radiator for any obstructions or poten-
This gauge hook-up process will be the same,
tial contamination. Minimize all the possibilities for
regardless of the gauge set being installed. Whether
error or malfunction of components in the air condi-
it is a recovery station or individual gauges, the con-
tioning system.
nections are the same. The procedures performed
next will vary depending what type of equipment is
being used. If a recovery/recycling station is being
used, complete servicing can be accomplished.
Shut off engine. DO NOT attempt to connect ser- Using only a set of gauges will limit the servicing to
vice equipment when the engine is running. only adding refrigerant or observing pressures.
1. Be sure all valves on the manifold are closed all

the way (turn them clockwise).
2. Check the hose connections on the manifold for Purging Air From Service Hoses
tightness. The purpose of this procedure is to remove all the air
3. Locate the low and high side system service fit- trapped in the hoses prior to actual system testing.
tings and remove their protective caps. Environmental regulations require that all service
hoses have a shutoff valve within 12 inches of the
service end. These valves are required to ensure
only a minimal amount of refrigerant is lost to the
atmosphere. R-134a gauge sets have a combination
quick disconnect and shutoff valve on the high and
low sides. The center hose also requires a valve.
The initial purging is best accomplished when con-
nected to recovery or recycle equipment. With the
center hose connected to the recovery station, ser-
vice hoses connected to the high and low sides of the
system, we can begin the purging. The manifold
valves and service valves should be closed. Activat-
ing the vacuum pump will now pull any air or mois-
ture out of the center hose. This will require only a
few minutes of time. The hose is the only area that is
being placed in a vacuum and this will not require a
lengthy process. Closing the valve will then insure
the hose is purged. It is now safe to open the other
manifold valves.
FIGURE 4-11. SERVICE HOSE HOOK-UP

SYSTEM PERFORMANCE TEST 8. Feel the hoses and components on the low
side. They should be cool to the touch. Check
This test is performed to establish the condition of all
connections near the expansion valve; the inlet
components in the system. Observe these conditions
side should be warm and the outlet side cold.
during testing:
9. After a minimum of 10 minutes has elapsed and
1. Place a fan in front of the condenser to simulate the system has stabilized, observe the gauge
normal ram air flow and allow the system to sta- readings. Compare the readings to the specifi-
bilize. cations in Table 1.
2. Install a thermometer into the air conditioning
vent closest to the evaporator.
NOTE: Pressures may be slightly higher in very
3. Start the engine and operate at 1000 rpm.
humid conditions and lower in very dry conditions.
4. Evaluate the readings obtained from the Pressures listed in Table 1 are during compressor
gauges to see if they match the readings for the clutch engagement.
ambient temperature.
5. Set air conditioning system at maximum cooling
and maximum blower speed operation. 10. Check the cab vents for cool air. Outlet air tem-
6. Close all windows and doors to the cab. perature should be approximately 16 - 22 C
(30 - 40 F) below ambient air temperature.
7. Carefully feel the hoses and components on the
high side. All should be warm-hot to the touch. 11. If pressures and temperatures are not within the
Check the inlet and outlet of receiver-drier for specified ranges, the system is not operating
even temperatures, if outlet is cooler than inlet, properly. Refer to Preliminary Checks near the
a restriction is indicated. end of this chapter for tips on diagnosing poor
system performance.
Use extreme caution when placing hands on high

side components and hoses. Under most normal
conditions these items can be extremely hot.
TABLE 1. NOMINAL R-134a PRESSURE RANGES
Ambient Air Temperature High Side Pressure Low Side Pressure
21 C (70 F) 820 - 1300 kPa (120 - 190 psi) 70 - 138 kPa (10 - 20 psi)
27 C (80 F) 950 - 1450 kPa (140 - 210 psi) 70 - 173 kPa (10 - 25 psi)
1175 - 1650 kPa (170 - 240

32 C (90 F) 105 - 210 kPa (15 - 30 psi)
psi)
1300 - 1850 kPa (190 - 270

38 C (100 F) 105 - 210 kPa (15 - 30 psi)
psi)
1450 - 2075 kPa (210 - 300

43 C (110 F) 105 - 210 kPa (15 - 30 psi)
psi)
NOTE: All pressures in this chart are for reference, only. Weight is the only absolute means of
determining proper refrigerant charge.

SYSTEM OIL Checking System Oil
R-134a air conditioning systems require the use of
Polyalkylene Glycol (PAG) lubricating oil. This is the
only oil recommended for use in this system. The
Komatsu PAG oil (PC2212) is the oil that is furnished
in the system on Komatsu trucks. The receiver-drier and accumulator must be
replaced each time the system is opened.
Handling and Reusing PAG Oil
1. Remove the compressor from the truck. With
Avoid skin contact and inhalation of PAG oil, as
the compressor positioned horizontally, remove
these are normal precautions with any chemical.
the drain plug, and capture the oil in a clear
PAG oil removed from new or old components graduated container. Rock the compressor back
must not be retained for re-use. It must be stored and forth, and rotate the shaft to facilitate oil
in a marked container and properly sealed. PAG removal.
oil is an environmental pollutant and must be
properly disposed of after use.
PAG oil in containers or in an air conditioning
system must not be left exposed to the
atmosphere any longer than necessary. PAG oil Under no circumstances should the A/C com-
absorbs moisture very rapidly, and therefore, any pressor be stood upright onto the clutch assem-
absorbed moisture could cause damage to an air bly. Damage to the compressor clutch will result,
conditioning system. leading to premature compressor failures.
2. Inspect the oil for any foreign particles. If parti-

Oil Quantity cles are found, further investigation and service
It is critical to keep the correct amount of lubricant in are necessary to determine the source. After
the air conditioning system at all times. Failure to do repair, the system will need to be flushed. Refer
so could result in damage to the compressor. to System Flushing. If no particles are found,
proceed to the next step.
Damage to the compressor can be a result from not 3. Add 207 ml (7oz.) of PAG oil to the compressor
only a lack of oil, but from too much oil, also. A lack sump. Add the oil through the drain port, and
of oil will cause excess friction and wear on moving install the drain plug. It is important to only add
parts. Excessive oil can result in slugging the com- the specified amount to ensure optimal system
pressor. This condition occurs when the compressor performance. Too much oil will result in a reduc-
attempts to compress liquid oil as opposed to vapor- tion in cooling. Too little oil will result in com-
ized refrigerant. Since liquid cannot be compressed, pressor failure.
damage to internal parts results.
4. Determine the correct amount of additional oil
to add to the system by using the Replacing Oil
listed in Table 2. Add this extra oil to the inlet
side of the receiver drier or accumulator.
NOTE: If truck is being assembled for the first time,
add 207 ml (7oz.) of PAG oil to the inlet side of the
receiver-drier or to the accumulator.
EXAMPLE - If only the accumulator and receiver
drier were replaced, then add 120 ml (4 oz.) of PAG
oil to the inlet side of the receiver-drier or to the accu-
mulator. If the evaporator was also replaced at this
time, then add 150 ml (5 oz.) of PAG oil to the inlet
side of the receiver-drier or to the accumulator.
NOTE: The proper quantity of oil may be injected into
the system during charging as an alternate method of
adding oil.

REFRIGERANT
Recycled Refrigerant
Recycled refrigerant has been extracted from a
mobile air conditioning system using a recovery unit.
When installing a new compressor, the compres- The refrigerant is cleaned by the recovery unit as it
sor must be completely drained of its oil before passes through filters located on the unit that meet
installation. Add 207 ml (7 oz.) of new PAG oil to specifications stipulated by Society of Automotive
the compressor to ensure proper system oil Engineers, SAE J2099. The refrigerant that has
level. Failure to adjust the amount of oil in the passed through the filtering process has only been
compressor will lead to excessive system oil and cleaned of contaminants that are associated with
poor A/C performance. Additionally, a new mobile systems. Therefore, recycled refrigerant from
receiver-drier and accumulator must be installed mobile systems is only acceptable for reuse in mobile
and oil added to both of these components. systems.
Reclaimed Refrigerant
TABLE 2. REPLACING OIL Reclaimed refrigerant has been filtered through a
more thorough filtering process and has been pro-
Component Oil to add
cessed to the same standards of purity as virgin
Condenser 60-90 ml (2-3 ounces) refrigerant. Because of this, reclaimed refrigerant is
acceptable for use in all systems, not just mobile.
Evaporator 30 ml (1 ounce) The reclaiming equipment used for this process is
expensive, and therefore, not common among nor-
Receiver-Drier 60 ml (2 ounces)
mal maintenance shops. Equipment such as this is
Accumulator 60 ml (2 ounces) more commonly found in air conditioning specialty
shops.
Compressor 207 ml (7 ounces)
Block Valve
Adding oil is not necessary
(Expansion)
Drain and measure amount Always use new, recycled, or reclaimed refriger-
Hoses
removed ant when charging a system. Failure to adhere to
this recommendation may result in premature
5. Connect all hoses and components in the sys-
wear or damage to air conditioning system com-
tem. Lubricate O-Rings with clean mineral oil
ponents and poor cooling performance.
before assembly.
NOTE: Do not use PAG oil to lubricate O-Rings or
fittings. PAG oil will attract moisture and will corrode
Refrigerant Quantity
fittings when used externally. Use only clean mineral
oil to lubricate fittings and O-Rings during assembly. If not enough refrigerant is charged into the system,
cooling ability will be diminished. If too much refriger-
ant is charged into the system, the system will oper-
6. Evacuate the system. Refer to Evacuating The ate at higher pressures, and in some cases, may
System. damage system components. Exceeding the speci-
fied refrigerant charge will not provide better cooling.

If an incorrect charge is suspected, recover the SYSTEM LEAK TESTING
refrigerant from the system, and charge the system
Refrigerant leaks are probably the most common
with the correct operating weight 3.4 kg (7.4 lb). This
cause of air conditioning problems, resulting from
is not only the recommended procedure, but it is also
improper or no cooling, to major internal component
the best way to ensure that the system is operating
damage. Leaks most commonly develop in two or
with the proper charge and providing optimum cool-
three places. The first is around the compressor shaft
ing. Using the sight glass to determine the charge is
seal, often accompanied by an indication of fresh
not an accurate method.
refrigerant oil. If a system is not operated for a while
(winter months), the shaft seal may dry out and leak
slightly. The centrifugal force of the clutch pulley
spinning can also cause the problem. When the sys-
tem is operated and lubricant wets the seal, the leak
may stop. Such leaks can often be located visually,
or by feeling with your fingers around the shaft for
An unclear sight glass on R-134a systems can
traces of oil. (The R-134a itself is invisible, odorless,
indicate that the system may be low on refriger-
and leaves no trace when it leaks, but has a great
ant. However, the sight glass should not be used
affinity for refrigerant oil.)
as a gauge for charging the system. Charging the
system must be done with a scale to ensure the A second common place for leaks is the nylon and
proper amount of refrigerant has been added. rubber hoses where they are crimped or clamped to
the fittings, or where routing allows abrasion. Other
threaded joints or areas where gaskets are used
should be visually and physically examined. Moving
your fingers along the bottom of the condenser and
R-134a Refrigerant Containers evaporator, particularly near the drain hole for the
Two basic, readily available containers are used to condensate will quickly indicate the condition of the
store R-134a: the 14 or 28 kg (30 or 60 lb) bulk canis- evaporator. Any trace of fresh oil here is a clear indi-
ters (Figure 4-12). cation of a leak.
Always read the container label to verify the contents Usually, a 50% charged system is enough to find
are correct for the system being serviced. Note the most leaks. If the system is empty, connect the mani-
containers for R-134a are painted light blue. fold gauge set to the system and charge at least 1.6
kg (3.5 lbs) of refrigerant into the system.
Use extreme caution when leak testing a system

while the engine is running.
In its natural state, refrigerant is a harmless, col-

orless gas, but when combined with an open
flame, it will generate toxic fumes (phosgene
gas), which can cause serious injuries or death.
NOTE: The refrigerant is heavier than air and will
move downward when it leaks. Apply pickup hose or
test probe on the under-surface of all components to
locate leaks.
FIGURE 4-12. R-134a CONTAINERS
1. 14 kg (30 lb) 2. 28 kg (60 lb)

Cylinder Cylinder

Electronic Leak Detector 6. When the pressure reaches 34-69 kPa (5-10
psi), open the oil drain valve, collect the oil in
(Refer to Figure 4-7). As the test probe is moved into
an appropriate container, and dispose of con-
an area where traces of refrigerant are present, a
tainer as indicated by local, state or federal reg-
visual or audible announcement indicates a leak.
ulation. The oil is not reusable due to
Audible units usually change tone or speed as inten-
contaminants absorbed during use.
sity changes.
Performing the Recovery Cycle
Tracer Dyes
1. Be sure the equipment being used is designed
Tracer dyes are available that can be added to the for the refrigerant you intend to recover.
system as refrigerant is added. The system is then
operated to thoroughly circulate the dye. As refriger- 2. Observe the sight glass oil level. Having
ant escapes, it leaves a trace of the dye at the point drained it, it should be zero.
of leakage, which is then detected using an ultravio- 3. Check the cylinder refrigerant level before
let light (black light), revealing a bright fluorescent beginning recovery to make sure you have
glow. enough capacity.
4. Confirm that all shut-off valves are closed
Soap and Water before connecting to the A/C system.
Soap and water can be mixed together and applied 5. Attach the appropriate hoses to the system
to system components. Bubbles will appear to pin- being recovered.
point the specific location of leaks. 6. Start the recovery process by operating the
After determining the location or source of leak(s), equipment as per the manufacturer's instruc-
repair or replace leaking component(s). tions.
7. Continue extraction until a vacuum exists in the
NOTE: The length of the hose will affect the
A/C system.
refrigerant capacity. When replacing hoses, always
use the same hose length, if possible. 8. If an abnormal amount of time elapses after the
system reaches 0 psi and does not drop
steadily into the vacuum range, close the mani-
fold valves and check the system pressure. If it
rises to 0 psi and stops, there is a major leak.
Before system assembly, check the compressor 9. Check the system pressure after the recovery
oil level and fill to specifications. equipment stops. After five minutes, system
pressure should not rise above 0 gauge pres-
sure. If the pressure continues to rise, restart
and begin the recovery sequence again. This
RECOVERING AND RECYCLING THE cycle should continue until the system is void of
REFRIGERANT refrigerant.
Draining Oil from the Previous Recovery Cycle 10. Check the sight glass oil level to determine the
1. Place the power switch and the controller on the amount of oil that needs to be replaced. (The
recovery unit in the OFF position. amount of oil that was lost during the recovery
cycle must be replaced back into the system).
2. Plug in the recovery station to the correct
power source. 11. Mark the cylinder with a RECOVERED (red)
magnetic label to reduce the chance of charging
3. Drain the recovered oil through the valve a system with contaminated refrigerant. Record
marked oil drain on the front of the machine. the amount of refrigerant recovered.
4. Place the controller knob in the ON position.
The low pressure gauge will show a rise.
5. Immediately switch to the OFF position and
allow the pressure to stabilize. If the pressure
does not rise to between 34-69 kPa (5-10 psi),
switch the controller ON and OFF again.

Performing the Recycling Procedure System Flushing
The recovered refrigerant contained in the cylinder If any contaminants are found in system hoses, com-
must undergo the recycle procedure before it can be ponents or oil, the entire system must be flushed.
reused. The recycle or clean mode is a continuous Major components such as the compressor are
loop design and cleans the refrigerant rapidly. Follow extremely susceptible to foreign particles and must
the equipment manufacturer's instructions for this be replaced. If contaminated, the evaporator and
procedure. condenser must also be replaced. The evaporator
and condenser are multi-pass units, and they can not
Evacuating and Charging the A/C System be properly cleaned by flushing.
Evacuate the system once the air conditioner compo-
nents are repaired or replacement parts are secured,
and the A/C system is reassembled. Evacuation
removes air and moisture from the system. Then, the
A/C system is ready for the charging process, which
adds new refrigerant to the system. Only SAE and/or Mobile Air Conditioning Society
(MACS) approved flushing methods with the
appropriate refrigerants are to be performed
when removing debris from the system. Other
SYSTEM REPAIR methods may be harmful to the environment, as
The following service and repair procedures are not well as air conditioning components.
any different than typical vehicle service work. How- 1. Remove the compressor, receiver-drier, expan-
ever, A/C system components are made of soft met- sion valve, and accumulator.
als (copper, aluminum, brass, etc.). Comments and
tips that follow will make the job easier and reduce 2. Inspect all other components such as the con-
unnecessary component replacement. denser, evaporator, hoses and fittings. If any of
these items are damaged or highly contami-
nated, replace the components.
3. Flush the remaining hoses with a flushing unit.
Use only R-134a as a flushing agent.
All of the service procedures described are only
performed after the system has been discharged. 4. After flushing, blow out the system with dry
Never use any lubricant or joint compound to shop air for 5 to 10 minutes.
lubricate or seal any A/C connections. 5. If the expansion valve has been removed of all
foreign contamination, it may be re-installed
NOTE: To help prevent air, moisture or debris from back into the system. If contamination is still
entering an open system, cap or plug open lines, present, replace the valve.
fittings, components and lubricant containers. Keep
6. Install a new compressor, receiver-drier, and
all connections, caps, and plugs clean.
accumulator.
7. Add oil to the system as outlined in Checking
System Oil.
Never leave a/c components, hoses, oil, etc.

exposed to the atmosphere. Always keep sealed
or plugged until the components are to be
installed and the system is ready for evacuation
and charging. PAG oil and receiver-drier desic-
cants attract moisture. Leaving system compo-
nents open to the atmosphere will allow moisture
to invade the system, resulting in component and
system failures.

A/C DRIVE BELT CHECKOUT PROCEDURE
This procedure must be performed each time any
component in the accessory drive is serviced, such
as replacing a belt or removing the compressor. In
addition, a 250 hour inspection of the AC drive belt is
mandatory. The belts must be inspected for
indications of wear and damage that may hinder
performance. Replace as necessary and perform the
following procedure.
Pulley Alignment
1. Install alignment tool (EL8868) onto the pulleys
to check the alignment. Refer to Figure 4-15. If
misalignment of the pulleys exceeds 3 mm
(0.13 in.), the position of the compressor must
be adjusted.
FIGURE 4-14. DEFLECTION MEASUREMENT
Belt Tension Check
NOTE: This procedure has been written for use with
4. Find the approximate center of the belt between
belt tension tool (XA3379), shown in Figure 4-13.
the two pulleys. Place the tip of the tool onto the
Other tension tools may differ in functionality.
outer face of the belt and apply pressure, as
shown in Figure 4-14. The tool must be
perpendicular to the belt. Push on the tool until
the bottom edge of the deflection scale O-Ring
is even with the outer face of the adjacent drive
belt. If only one belt is used, rest a straight edge
across both pulleys to serve as the indicating
plane.
5. The O-Ring on the force scale indicates the
force used to deflect the belt. The belt must
deflect 5.3 mm (0.21 in.) under a force of 1.6
0.1 kg f (3.44 0.11 lbf). If not, adjust the belt
accordingly and recheck the tension.
FIGURE 4-13. BELT TENSION TOOL - XA3379
2. Refer to Figure 4-16 for the proper distance

from the centerline of the drive pulley to the
centerline of the compressor pulley. Set the
tension tool accordingly on the deflection scale
by moving the deflection O-Ring to the
corresponding distance on the scale.
3. Slide the O-Ring for the "force" scale to zero.

FIGURE 4-15. BELT ALIGNMENT TOOL
1. AC Compressor Pulley 2. Drive Pulley 3. Alignment Tool
346 mm (13.63 in.)
FIGURE 4-16. BELT TENSION DIMENSIONS

COMPONENT REPLACEMENT
Hoses and Fittings Receiver-Drier
When replacing hoses, be sure to use the same type The receiver-drier can not be serviced or repaired. It
and ID hose you removed. When hoses or fittings are must be replaced whenever the system is opened for
shielded or clamped to prevent vibration damage, be any service. The receiver-drier has a pressure switch
sure these are in position or secured. to control the clutch, and should be removed and
installed onto the new unit.
Lines
Always use two wrenches when disconnecting or
connecting A/C fittings attached to metal lines. Cop- NOTE: Do not use PAG oil to lubricate O-Rings or fit-
per and aluminum tubing can kink or break very eas- tings. PAG oil will attract moisture and will corrode fit-
ily. When grommets or clamps are used to prevent tings when used externally. Use only clean mineral
line vibration, be certain these are in place and oil to lubricate fittings and O-Rings during assembly.
secure.
Thermostat
A thermostat can be stuck open or closed due to con-
tact point wear or fusion. The thermostat temperature
It is important to always tighten the fittings to the sensing element (capillary tube) may be broken or
proper torque. Failure to do this may result in kinked closed and therefore unable to sense evapo-
improper contact between mating parts and leak- rator temperature.
age may occur. Refer to the following torque When thermostat contact points are stuck open or
chart for tightening specifications. the sensing element can not sense temperature in
the evaporator, the clutch will not engage (no A/C
system operation). Causes are a loss of charge in
the capillary tube or a kink, burned thermostat con-
Fitting Size Foot Pounds Newton Meters tact or just no contact. When troubleshooting, bypass
the thermostat by hot wiring the clutch coil with a
6 10 - 15 ft.lbs. 14 - 20 Nm
fused lead. If the clutch engages, replace the thermo-
8 24 - 29 ft.lbs. 33 - 39 Nm stat.
10 26 - 31 ft.lbs. 36 - 42 Nm Thermostat contact points may be fused (burned)

closed and the clutch will not disengage. Causes are
12 30 - 35 ft.lbs. 41 - 47 Nm a faulty switch that could be due to fatigue. The ther-
mostat must be replaced. When the clutch will not
Installation torque for the single M10 or 3/8 in. cap disengage you may also note that condensate has
screws securing the inlet and outlet fittings onto the frozen on the evaporator fins and blocked air flow.
compressor ports is 15-34 Nm (11-25 ft lbs). There will also be below normal pressure on the low
side of the system. Side effects can be compressor
damage caused by oil accumulation (refrigeration oil
Expansion Valve tends to accumulate at the coldest spot inside the
system) and lower than normal suction pressure that
When removing the expansion valve from the sys- can starve the compressor of oil.
tem, remove the insulation, clean the area and dis-
connect 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 fil-
ter 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.

Compressor Clutch pulley bearing failure is indicated by bearing
noise when the A/C system is off or the clutch is not
The compressor can fail due to shaft seal leaks (no
engaged. Premature bearing failure may be caused
refrigerant in the system), defective valve plates,
by poor alignment of the clutch and clutch drive pul-
bearings, or other internal parts or problems associ-
ley.
ated with high or low pressure, heat, or lack of lubri-
cation. Be sure the compressor is securely mounted Sometimes it may be necessary to use shims or
and the clutch pulley is properly aligned with the enlarge the slots in the compressor mounting bracket
drive pulley. to achieve proper alignment.
Use a mechanic's stethoscope to listen for noises Excessive clutch plate wear is caused by the plate
inside the compressor. rubbing on the clutch pulley when the clutch is not
engaged or the clutch plate slipping when the clutch
coil is energized. A gap that is too small or too large
between the plate and clutch pulley or a loss of clutch
plate spring temper are possible causes. The ideal
When installing a new compressor, the compres- air gap between the clutch pulley and the clutch plate
sor must be completely drained of its oil before is 1.02 0.043 mm (0.023 to 0.057 in.). If the gap is
installation. Add 207 ml (7 oz.) of new PAG oil to too wide, the magnetic field created when the clutch
the compressor to ensure proper system oil coil is energized will not be strong enough to pull and
level. Failure to adjust the amount of oil in the lock the clutch plate to the clutch pulley.
compressor will lead to excessive system oil and
poor A/C performance.
NOTE: Some compressors may be discarded

because it is suspected that internal components
within the compressor have seized. Ensure that
Under no circumstances should the A/C com- the compressor clutch is working properly before
pressor be stood upright onto the clutch assem- discarding a compressor for internal seizure. The
bly. Damage to the compressor clutch will result, normal compressor life span should be about
leading to premature compressor failures. twice as long as the normal life span of the com-
pressor clutch.
It is important to note that often times a weak clutch
Accumulator coil may be mistaken for a seized compressor. When
The accumulator can not be serviced or repaired. It a coils resistance has increased over time and the
must be replaced whenever the system is opened for magnetic field weakens, the coil may not be able to
any service. pull the load of the compressor. Failure of the coil to
allow the compressor shaft to be turned, may appear
as though the compressor is locked up.
Clutch Before a compressor is dismissed as being seized, a

check for proper voltage to the coil should be per-
Clutch problems include electrical failure in the clutch formed. In addition, the coil should be ohm checked
coil or lead wire, clutch pulley bearing failure, worn or for proper electrical resistance. The coil should fall
warped clutch plate or loss of clutch plate spring tem- within the following range:
per. Defective clutch assembly parts may be
replaced or the whole assembly replaced. If the 12.0 0.37 Ohms @ 20 C (68 F)
clutch shows obvious signs of excessive heat dam- 16.1 0.62 Ohms @ 116 C (240 F)
age, replace the whole assembly. The temperatures specified above are roughly typical
The fast way to check electrical failure in the lead of a summer morning before first start-up and the
wire or clutch coil is to hot wire the coil with a fused heat beside an engine on a hot day. At temperatures
lead. This procedure enables you to bypass clutch in between those listed above, the correct resistance
circuit control devices. is proportionate to the difference in temperature.

Servicing the Compressor Clutch 1. Remove the belt guard from the front of the air
conditioning compressor.
* RECOMMENDED TOOLS FOR COMPRESSOR
CLUTCH REMOVAL AND INSTALLATION
J-9399 Thin Wall Socket
**J-9403 Spanner Wrench
**J-25030 Clutch Hub Holding Tool
Clutch Plate and Hub Assembly

J-9401
Remover
J-8433 Pulley Puller
J-9395 Puller Pilot

FIGURE 4-17.
***J-24092 Puller Legs
1. Belt Pulley 3. Shaft
J-8092 Universal Handle 2. Clutch Hub/Drive Plate 4. Locknut
J-9481 Pulley and Bearing Installer
J-9480-01 Drive Plate Installer
J-9480-02 Spacer, Drive Plate Installer

2. Remove the drive belt from compressor belt
pulley (1, Figure 4-17).
*Tools are available though your local Kent-Moore dealer.
3. Remove locknut (4, Figure 4-17) using thin wall
** These tools are interchangeable.
***For use on multiple groove pulleys. socket (1, Figure 4-18) or the equivalent.
Use the proper tools to remove and replace

clutch components. Using the recommended
tooling helps prevent damage to compressor
components during maintenance.
Do not drive or pound on the clutch plate, hub
assembly, or shaft. Internal damage to the com-
pressor may result.

4. Use clutch hub holding tool (2, Figure 4-18), 5. Thread clutch plate and hub assembly remover
spanner wrench (J-9403), or the equivalent to (2, Figure 4-19) into the hub of clutch assembly
hold clutch hub (3) while removing the locknut. (1). Hold the body of the remover with a wrench
It is recommended that the locknut be replaced and tighten the center screw to pull the clutch
after it has been removed. plate and hub assembly from the compressor.
FIGURE 4-19.
1. Clutch Assembly 2. Clutch Plate & Hub

Assembly Remover
FIGURE 4-18.
1. Thin Wall Socket

2. Clutch Hub Holding Tool 6. Remove square key (1, Figure 4-20) from the
3. Clutch Hub keyways.
FIGURE 4-20.
1. Square Key 2. Keyway in Shaft

7. Inspect the friction surface on the clutch hub Pulley Removal
and the friction surface on the pulley. Scoring on 8. Use retaining ring pliers (3, Figure 4-22) to
the friction surfaces is normal. DO NOT replace remove pulley retainer ring (2) from pulley (1).
these components for this condition only.
Inspect the steel friction surface on the clutch

and ensure that it is not damaged by excessive
heat. Inspect the other components near the
clutch for damage due to heat. If signs of exces-
sive heat are evident, it may be necessary to
replace the compressor. Excessive heat may
cause leakage in the seals and damage to inter-
nal components as well as external components.
FIGURE 4-22.
1. Pulley 3. Retaining Ring Pliers
2. Pulley Retainer Ring
9. Pry the absorbent sleeve retainer from the neck

of the compressor, and remove the sleeve.
10. Install pulley puller (1, Figure 4-23) and puller
pilot (3) onto the compressor, as shown. If a
multiple groove pulley is used, install puller legs
(J-24092) onto the puller in place of the stan-
dard legs. Extend the puller legs to the back
side of the pulley. DO NOT use the belt grooves
to pull the pulley from the compressor.
FIGURE 4-21.
1. Clutch Hub 2. Pulley
FIGURE 4-23.
1. Pulley Puller 3. Puller Pilot
2. Pulley Assembly

11. Tighten the center screw on the puller against 2. Ensure the pulley rotates freely. If the pulley
the shaft of the compressor to remove the pul- does not rotate freely, remove the pulley and
ley. check for damaged components. Replace any
damaged components and reinstall the pulley.
12. Clean the pulley and pulley bearing with sol-
vent. Inspect the assembly for damage. Check 3. Install the pulley retainer ring and ensure that
the bearing for brinneling, excessive looseness, the ring is properly seated.
noise, and lubricant leakage. Replace the
4. Install the absorbent sleeve into the neck of the
assembly if any of these warning signs are evi-
compressor. Install the sleeve retainer.
dent.
Clutch Coil Check

13. Use a multi-meter to ohm check the clutch coil.
The resistance should be as follows: Clutch Assembly Installation
12 0.37 ohms @ 20 C (68 F)
1. Insert square key (1, Figure 4-20) into the key-
16.1 0.62 ohms @ 115 C (239 F)
way in the clutch hub. Allow the key to protrude
If the resistance of the coil is not within the specifica- about 4.5 mm (0.18 in.) from the outer edge of
tions, the clutch will not operate properly. Remove the hub. Use petroleum jelly to hold the key in
the retaining ring and replace the coil. place.
Pulley Installation
FIGURE 4-24.
FIGURE 4-25.
1. Bearing Installer 2. Universal Handle
1. Drive Plate Installer 2. Spacer
1. Place the pulley assembly into position on the
compressor. Use bearing installer (1, Figure 4-
24), universal handle (2), and a hammer to
lightly tap the pulley assembly onto the com-
pressor until it seats. Use of the installer or the 2. Place the clutch assembly into position on the
equivalent ensures that the force driving the compressor. Align the square key with the key-
bearing into position acts on the inner race of way on the shaft.
the bearing. Applying force to the outer race of
3. Thread drive plate installer (1, Figure 4-24) onto
the bearing will result in bearing damage.
the shaft of the compressor. Spacer (2) should
be in place under the hex nut on the tool.

4. Press the clutch onto the compressor using 5. Install locknut (4, Figure 4-17) and tighten the
installer (1). Continue to press the clutch plate nut until it seats. The gap should now measure
until a 2 mm (0.079 in.) gap remains between 1.02 0.043 mm (0.040 0.017 in.). If the gap
the clutch friction surface and the pulley friction is not within the specification, check for proper
surface. Refer to Figure 4-26. installation of the square key.
NOTE: The outer threads of installer (J-9480-01) are 6. Install the drive belt onto the compressor.
left handed threads. Ensure that the proper tension on the belt is
attained. Refer to the belt tension chart in the
appropriate engine manual for the proper speci-
fications.
7. After assembly is complete, burnish the mating
parts of the clutch by operating the air condition-
ing system at maximum load conditions with the
engine at high idle. Turn the air conditioning
control ON and OFF at least 15 times for one
second intervals.
8. Install the belt guard if no further servicing is
required.
FIGURE 4-26. CLUTCH GAP

EVACUATING THE SYSTEM 2. Open the discharge valve on the vacuum pump
or remove the dust cap from the discharge out-
Evacuating the complete air conditioning system is
let. Turn the pump on and watch the low side
required in all new system installations, and when
gauge. The pump should pull the system into a
repairs are made on systems requiring a component
vacuum. If not, the system has a leak. Find the
replacement (system opened), or a major loss of
source of the leak, repair, and attempt to evacu-
refrigerant has occurred. All these conditions will
ate the system again.
require that a vacuum be pulled using a vacuum
pump that completely removes any moisture from the 3. Allow the vacuum pump to run for at least 45
system. Once properly evacuated, the system can be minutes.
recharged again.
Using a pump to create a vacuum in the air condition-
ing system effectively vaporizes any moisture, allow-
ing the water vapor to be easily drawn out by the
pump. The pump does this by reducing the point at
which water boils (100C, 212F at sea level with
14.7 psi). In a vacuum, water will boil at a lower tem-
perature depending upon how much of a vacuum is
created.
As an example, if the ambient air outside the truck is
24C (75F) at sea level, by creating a vacuum in the
system so that the pressure is below that of the out-
side air (in this case, at least 749.3 mm (29.5 in.) of
vacuum is needed), the boiling point of water will be
lowered to 22C (72F). Thus any moisture in the
system will vaporize and be drawn out by the pump if
the pump is run for approximately an hour. The fol-
lowing steps indicate the proper procedure for evacu-
ating all moisture from the heavy duty air conditioning
systems.
FIGURE 4-27. VACUUM PUMP HOOKUP
Do not attempt to use the air conditioning com-

pressor as a vacuum pump or the compressor
will be damaged.
NOTE: Refer to Table 3 for optimal vacuum
specifications at various altitudes.
1. With the manifold gauge set still connected
(after discharging the system), connect the cen-
ter hose to the inlet fitting of the vacuum pump
as shown in Figure 4-27. Then open both hand
valves to maximum.

4. Close both valves on the manifold gauge set. NOTE: In some cases, 45 minutes of evacuation may
Turn the vacuum pump off and observe the not be sufficient to vaporize all of the moisture and
gauges. The system should hold the vacuum draw it out of the system. If it has been verified that
within 5 cm Hg (2.0 in. Hg) of the optimal vac- no system leaks exist and gauge readings increase
uum for 5 minutes. If the vacuum does not hold, after 45 minutes, extend the evacuation time to
moisture may still be present in the system. ensure total moisture removal.
Repeat the previous step. If the vacuum still
does not hold, a leak may be present in the sys-
tem. Find the source of the leak, repair, and
evacuate the system, again.
TABLE 3. ALTITUDE VACUUM VARIATIONS
Altitude Optimal Vacuum
Meters (Feet) Above Sea Level Cm Hg. (In. Hg.)
0 76.0 (29.92)
305 (1000) 73.5 (28.92)
610 (2000) 70.7 (27.82)
914 (3000) 68.1 (26.82)
1219 (4000) 65.6 (25.82)
1524 (5000) 63.3 (24.92)
1829 (6000) 60.8 (23.92)
2134 (7000) 58.5 (23.02)
2438 (8000) 56.4 (22.22)
2743 (9000) 54.2 (21.32)
NOTE: The chart indicates the expected gauge readings at altitude to obtain the optimal
vacuum.

CHARGING THE A/C SYSTEM 1. Charge the A/C system with 3.4 kg (7.4 lbs) of
R-134a refrigerant.
The proper method for charging refrigerant into a R-
134a system is to first, recover all of the refrigerant NOTE: Charging is to be performed with the engine
from the system. The charging refrigerant should and compressor operating. Charge the A/C system
then be weighed on a scale to ensure the proper through the low side service port. Trucks equipped
amount is charged into the system. Most recovery with accumulators may charge the refrigerant as a
units include a scale within the apparatus, thus mak- liquid or as a vapor.
ing it very easy to charge the correct amount every
time. If equipment such as this is not available, a
2. Check the system for leaks. Refer to System
common scale can be used to determine the weight
Leak Testing.
of charge. Simply weigh the charging tank, subtract
the weight of the proper charge, and charge the sys- 3. If no leaks are found, verify the systems cooling
tem until the difference is shown on the scale. On capacity meets requirements. Refer to System
certain types of equipment, it is also possible to add Performance Testing.
any necessary lubricant when charging the system.
If a scale is not used when charging R-134a into a

system, it is difficult to tell if the correct charge has
been achieved. The sight glass can provide some
indication, but it is not a reliable tool for determining
proper charge.

TROUBLESHOOTING
Preliminary Checks Cab filters - Ensure the outside air filter and
inside recirculation filter are clean and free of
If the system indicates insufficient cooling, or no cool- restriction.
ing, the following points should be checked before
proceeding with the system diagnosis procedures. Condenser - Check the condenser for debris and
clogging. Air must be able to flow freely through
NOTE: If the truck being serviced is a model 830E- the condenser.
AC or a 930E, be certain the rest switch in the cab is
Evaporator - Check the evaporator for debris and
ON. Place the GF cutout switch in the CUTOUT clogging. Air must be able to flow freely through
position. the condenser.
Some simple, but effective checks can be performed
to help determine the cause of poor system perfor-
mance. Check the following to ensure proper system
operation.
Diagnosis Of Gauge Readings And System
Compressor belt - Must be tight, and aligned. Performance
Compressor clutch - The clutch must engage. If it Successfully servicing an air conditioning system,
does not, check fuses, wiring, and switches. beyond the basic procedures outlined in the previous
Oil leaks - Inspect all connection or components section, requires additional knowledge of system
for refrigeration oil leaks (especially in the area of testing and diagnosis.
the compressor shaft). A leak indicates a
A good working knowledge of the manifold gauge set
refrigerant leak.
is required to correctly test and diagnose an air con-
Electrical check - Check all wires and ditioning system. An accurate testing sequence is
connections for possible open circuits or shorts. usually the quickest way to diagnose an internal
Check all system fuses. problem. When correctly done, diagnosis becomes
Cooling system - Check for correct cooling an accurate procedure rather than guesswork.
system operation. Inspect the radiator hoses,
The following Troubleshooting Chart lists typical mal-
heater hoses, clamps, belts, water pump,
thermostat and radiator for condition or proper functions encountered in air conditioning systems.
operation. Indications and or problems may differ from one sys-
tem to the next. Read all applicable situations, ser-
Radiator shutters - Inspect for correct operation vice procedures, and explanations to gain a full
and controls, if equipped.
understanding of the system malfunction. Refer to
Fan and shroud - Check for proper operation of information listed under Suggested Corrective
fan clutch. Check installation of fan and shroud. Action for service procedures.
Heater/water valve - Check for malfunction or
leaking. With the heat switch set to COLD, the
heater hoses should be cool.
System ducts and doors - Check the ducts and
doors for proper function.
Refrigerant charge - Make sure system is
properly charged with the correct amount of
refrigerant.

TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PROBLEM: Insufficient Cooling

Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is only slightly cool.
Possible Causes Suggested Corrective Actions

- Low refrigerant charge, causing pressures to be Check for leaks by performing leak test.
slightly lower than normal.
If No Leaks Are Found:
Recover the refrigerant and use a scale to
charge the proper amount into the system.
Check system performance.
If Leaks Are Found:

After locating the source of the leak, recover the
refrigerant, and repair the leak. Evacuate the
system and recharge using a scale. Add oil as
necessary. Check A/C operation and perform-
ance test the system.
PROBLEM: Little or No Cooling
Indications:
Low side pressure - VERY LOW
High side pressure - VERY LOW
Discharge air is warm.
No bubbles observed in sight glass, may show oil
streaks.
- Pressure sensing switch may have compressor Add refrigerant (make sure system has at least
clutch disengaged. 50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
-
enable the compressor to operate, if the com-
- Refrigerant excessively low; leak in system. pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
A/C operation and do system performance test.

PROBLEM: Extremely Low Refrigerant Charge in the System
Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is warm.
The low pressure switch may have
shut off the compressor clutch.

- Extremely low or no refrigerant in the system. Check for leaks by performing leak test.
Possible leak in the system.
No Leaks Found:
Recover refrigerant from the system. Recharge
using a scale to ensure correct charge. Check
A/C operation and performance.
Leaks Found:
Add refrigerant (make sure system has at least
50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable the compressor to operate, if the com-
pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
AC operation and do system performance test.
PROBLEM: Air and/or Moisture in the System
Indications:
Low side pressure - Normal
High side pressure - Normal
(In a cycling type system with a
thermostatic switch, the switch may not cycle
the clutch on and off, so the low pressure
gauge will not fluctuate.)

Leaks in the system. Test for leaks, especially around the compressor shaft
seal area. When the leak is found, recover refrigerant
from the system and repair the leak. Replace the
receiver-drier or accumulator because the desiccant
may be saturated with moisture. Check the compressor
and replace any refrigerant oil lost due to leakage.
Evacuate and recharge the system with refrigerant
using a scale. Check A/C operation and performance.

PROBLEM: Air and/or Moisture in the System
Indications:
Low side pressure - HIGH
High side pressure - HIGH

- Leaks in system. Test for leaks, especially around the compressor
shaft seal area. After leaks are found, recover
refrigerant from the system and repair leaks. Re-
place the receiver-drier. Check the compressor
and replace any oil lost due to leakage. Evacuate
and recharge the system using a scale to ensure
proper quantity. Check A/C operation and perform-
ance.
PROBLEM: Expansion Valve Stuck or Plugged
Indications:
Low side pressure - VERY LOW or in a Vacuum
High side pressure - HIGH
Discharge air only slightly cool.
Expansion valve body is frosted or sweaty.

An expansion valve malfunction could mean Test: Warm diaphragm and valve body with your
the valve is stuck in the closed position, the filter hand, or very carefully with a heat gun. Activate
screen is clogged (block expansion valves do not the system and watch to see if the low pressure
have filter screens), moisture in the system has gauge rises. Next, carefully spray a little nitrogen,
frozen at the expansion valve orifice, or the or any substance below 32 F, on the capillary coil
sensing bulb is not operating. If the sensing bulb (bulb) or valve diaphragm. The low side gauge
is accessible, perform the following test. If not, needle should drop and read at a lower (suction)
proceed to the Repair Procedure. pressure on the gauge. This indicates the valve was
partially open and that your action closed it. Repeat
the test, but first warm the valve diaphragm or
capillary with your hand. If the low side gauge
drops again, the valve is not stuck.
Repair Procedure: Inspect the expansion valve

screen (except block type valves). To do this,
remove all refrigerant from the system. Disconnect
the inlet hose fitting from the expansion valve.
Remove, clean, and replace the screen. Reconnect
the hose and replace the receiver-drier. Evacuate
and recharge the system with refrigerant using a
scale. Check AC operation and performance. If the
expansion valve tests did not cause the low press-
ure gauge needle to rise and drop, and if the other
procedure described did not correct the problem,
the expansion valve is defective. Replace the valve.

PROBLEM: Expansion Valve Stuck Open
Indications:
Air from vents in the cab seems warm
or only slightly cool.

The expansion valve is stuck open and/or the Test: Operate the A/C system on it's coldest
capillary tube (bulb) is not making proper contact setting for a few minutes. Carefully spray
with the evaporator outlet tube. Liquid refrigerant nitrogen or another cold substance on the cap-
may be flooding the evaporator making it imposs- illary tube coil (bulb) or head of the valve. The low
ible for the refrigerant to vaporize and absorb pressure (suction) side gauge needle should now
heat normally. In vehicles where the expansion drop on the gauge. This indicates the valve has
valve sensing bulb is accessible, check the closed and is not stuck open. Repeat the test,
capillary tube for proper mounting and contact but first warm the valve diaphragm by warming
with the evaporator outlet tube. Then perform the with hands. If the low side gauge shows a drop
following test if the valve is accessible. If it is not, again, the valve is not stuck. Clean the surfaces of
proceed to the Repair Procedure. the evaporator outlet and the capillary coil or bulb.
Make sure the coil or bulb is securely fastened to
the evaporator outlet and covered with insulation
material. Operate the system and check perform-
ance.
Repair Procedure: If the test did not result in
proper operation of the expansion valve, the valve
is defective and must be replaced. Recover all
refrigerant from the system and replace the expan-
sion valve and the receiver-drier. Evacuate and
recharge the system with refrigerant using a
scale. Check A/C operation and performance.
PROBLEM: High Pressure Side Restriction
Indications:
Low side pressure - LOW
High side pressure - Normal to HIGH
Look for sweat or frost on high side hoses
and tubing. The line will be cool to the touch
near the restriction.

Kink in a line, collapsed hose liners, plugged Repair Procedure: After you locate the defective
receiver-drier or condenser, etc. component containing the restriction, recover all
of the refrigerant. Replace the defective compo-
nent and the receiver-drier. Evacuate and recharge
the system with refrigerant, then check A/C
operation and performance.

PROBLEM: Compressor Malfunction
Indications:
High side pressure - LOW
Compressor operates noisily.

- Defective reed valves or other internal Repair Procedure: If the belt is worn or loose,
components. replace or tighten it and recheck system perform-
ance and gauge readings. If inspection of the
compressor is required, all of the refrigerant must
be recovered and the compressor disassembled
to the point that inspection can be performed.
Replace defective components or replace the
compressor. If particles of desiccant are found in
the compressor, flushing of the system will be
required. It will also be necessary to replace the
receiver-drier. Always check the oil level in the
compressor, even if a new unit has been installed.
Rotary compressors have a limited oil reservoir.
Extra oil must be added for all truck installations.
Tighten all connections and evacuate the system.
Recharge the system with refrigerant using a scale.
Check system operation and performance.
PROBLEM: Thermostatic Switch Malfunction
Indications:
Low side pressure - Normal
Low side pressure may cycle within a smaller
range as the compressor clutch cycles
more frequently than normal. This may indicate
the thermostat is set too high.

- Thermostat malfunctioning possibly due to Replace the thermostatic switch. When removing
incorrect installation. the old thermostat, replace it with one of the same
type. Take care in removing and handling the
thermostat and the capillary tube that is attached
to it. Use care not to kink or break the tube.
Position the new thermostat capillary tube at or

close to the same location and seating depth
between the evaporator coil fins as the old one.
Connect the electrical leads

PROBLEM: Condenser Malfunction or System Overcharge
Indications:
Low Side High
High Side High
Discharge air may be warm.
High pressure hoses and lines are very hot.

- Lack of air flow through the condenser fins Repair Procedure: Check the engine cooling
system components, fan and drive belt, fan clutch
operation, and the radiator shutter. Inspect
condenser for dirt, bugs, or other debris, and
clean if necessary. Be sure the condenser
is securely mounted and there is adequate
clearance (about 38 mm) between it and
the radiator. Check the radiator pressure cap and
cooling system, including the fan, fan clutch, drive
belts and radiator shutter assembly. Replace any
defective parts and then recheck A/C system
operation, gauge readings, and performance.
If the problem continues, the system may be over-
charged. Recover the system refrigerant. Use a
scale to recharge the system using the correct
amount. Recheck A/C system operation, gauge
readings and performance. If the gauge readings
do not change, all of the refrigerant should be
recovered and the system flushed. The condenser
may be partially blocked -replace condenser. The
receiver-drier must also be replaced. Evacuate the
system, recharge, and check operation and
performance.

PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM
Truck Serial Number_________________________ Last Maintenance Check:_____________________
Site Unit Number____________________________ Name of Service Technician________________
Date:____________Hour Meter:________________
NOTE: Compressor should be run at least 5 minutes
(40F minimum ambient temperature) every month,
Maintenance Interval in order to circulate oil and lubricate components.
COMPONENT (months)
Maintenance Interval
3 6 12 Done
COMPONENT (months)
1. Compressor
3 6 12 Done
Check noise level
5. Expansion Valve X
Check clutch pulley
Inspect capillary tube (if
Check oil level used) for leakage, damage,
Run system 5 minutes looseness
Check belt tension 6. Evaporator
(80-100) lbs; V-belt
Clean dirt, bugs, leaves, etc.
Inspect shaft seal for leakage from fins (w/ compressed air)
Check mounting bracket Check solder joints on inlet/
(tighten bolts) outlet tubes (leakage)
Check clutch alignment w/ Inspect condensation drain
crankshaft pulley (within
7. Other Components
0.06 in.)
Check discharge lines
Perform manifold gauge
(hot to touch)
check
Check suction lines
Verify clutch is engaging
(cold to touch)
2. Condenser
Inspect fittings/clamps/hoses
Clean dirt, bugs, leaves, etc.
Check thermostatic switch for
from coils (w/compressed air)
proper operation
Verify engine fan clutch is
Outlets in cab: 40F to 50 F
engaging (if installed)
Inspect all wiring connections
Check inlet/outlet for
obstructions or damage Operate all manual controls
through full functions
3. Receiver-Drier
Check inlet line from
condenser (should be hot to
touch)
Replace, if system is opened
4. Accumulator
Check the inlet line from the
evaporator. It should be cool
to cold.
Replace the accumulator
each time the system is
opened.

SECTION N5
OPERATOR CAB AND CONTROLS
INDEX
OPERATOR CAB AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-3

STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
ARSC Set Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
Telescoping/Tilt Wheel Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
Multi-Function Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
RETARDER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5
SERVICE BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
HEATER / AIR CONDITIONER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
RETARDING CAPACITY CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
RADIO SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
AIR CLEANER VACUUM GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
WARNING ALARM BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
AM/FM RADIO / CD PLAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8
Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-9
Transmission Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-9
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
LH Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
RH Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
Auxiliary Power Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11
INSTRUMENT PANEL AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-12
UPPER RH SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
Brake Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
F1 Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
Hazard Warning Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13
LOWER RH SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14
Ether Starting Aid Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
ASR Cut Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
N05077 06/08 Operator Controls & Equipment N5-1

ARSC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
Automatic Idle Selector Switch (AISS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15
Auxiliary Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16
UPPER LH SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
Automatic Lubrication System Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17
LOWER LH SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
Head Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18
BackUp/Deck Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Mode Select Switches 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
Panel Light Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-19
ELECTRONIC DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20
PILOT DISPLAY ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21
METER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23
CAUTION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-25
EMERGENCY STOP ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-27
CHARACTER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-30
REAR ELECTRICAL COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-31
AUTOMATIC RETARD SPEED CONTROL (ARSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-34
AUTOMATIC SPIN REGULATOR (ASR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-37
N5-2 Operator Controls & Equipment 06/08 N05077

OPERATOR CAB AND CONTROLS
FIGURE 5-1. CAB INTERIOR - OPERATOR VIEW

1. Steering Wheel 7. Heater/Air Conditioner Vents
2. Retarder Control Lever 8. Retarding Capacity Chart
3. Service Brake Pedal 9. Radio Speakers
4. Accelerator Pedal 10. Air Cleaner Vacuum Gauges
5. Instrument Panel 11. Warning Alarm Buzzer
6. Heater/Air Conditioner Controls 12. Radio

STEERING WHEEL AND CONTROLS
Steering wheel (1, Figure 5-2) will telescope "in" and
"out" and adjust at a tilt angle to provide a comfort-
able wheel position for most operators.
Horn Button
Horn (2) is actuated by pushing the button in the cen-
ter of the steering wheel. Verify the operation of the
horn before moving the truck. Observe all local safety
rules regarding the use of the horn as a warning sig-
nal device before starting the engine and moving the
vehicle.
ARSC Set Lever

Automatic Retard Speed Control (ARSC) set lever
(3) is used to set, cancel, or make fine adjustments to FIGURE 5-2. STEERING WHEEL AND CONTROLS
the ARSC set speed.
1. Steering Wheel 5. Multi-Function Turn
(a) press this button to set 2. Horn Signal Lever
(b) increase speed (tap up) 3. ARSC Lever 6. Retarder Control
(c) decrease speed (tap down) 4. Telescope/Tilt Wheel Lever
(d) cancel Lever
Refer to ARSC later in this sec-

tion for more information.
Telescoping/Tilt Wheel Lever

Multi-Function Turn Signal Lever
Adjust the tilt angle of the steering wheel by pulling
tilt adjustment lever (4) toward the steering wheel
and moving the wheel to the desired angle. Releas-
ing the lever will lock the wheel in the desired loca-
tion. Push the lever towards the front of the truck to
telescope the column in and out. Release the lever to
lock the column adjustment.
Multi-function turn signal switch (5) is used to acti-

vate the turn signal lights, the windshield wipers, and
to select either high or low beam headlights.

Turn Signal Operation RETARDER CONTROL LEVER
Retarder control lever (6, Figure 5-2) is mounted on
Move the lever upward to signal a right turn.
the right side of the steering column. It can be used
to modulate the full range of retarding/braking effort
An indicator in the top, center of the instrument
being applied to both the front and rear oil disc
panel will illuminate to indicate turn direction
brakes. Any application of the retarder lever will
selected. Refer to Instrument Panel and Indicator
cause an indicator light to illuminate in the center
Lights in this section.
instrument panel Refer to Instrument Panel And Indi-
cators later in this chapter.
Move the lever downward to signal a left
turn. a. When the lever is rotated to the full "up"
(counterclockwise) position, it is in the OFF/
NOTE: The turn signal does not automatically NO RETARD position.
cancel after the turn has been completed. The b. When the lever is rotated "downward" (clock-
turn signal lever must be manually returned to wise), it is in the ON/RETARD position. The
the neutral position. ON position encompasses a full range of
motion that allows a variable retarding effort
High Beam Headlight Operation depending on the position of the lever. As the
lever is rotated further clockwise, more
Pulling the lever inward (toward the rear retarding effort will be applied.
of the cab) changes the headlights to
c. For long downhill hauls, the lever may be
high beam. When the high beams are
positioned anywhere to provide the desired
selected, the indicator in the top center of the
retarding effort. The lever will remain where it
instrument panel will illuminate. Moving the
is positioned until moved. Refer to Retarder
switch back to the original position will return the
Operation in the previous section for cau-
headlights to low beam.
tions when using the retarder on a downhill
Windshield Wiper Operation grade.
Windshield Wipers OFF
Intermittent - Long Delay
Intermittent -Medium Delay When retarding is completed, and acceleration is

resumed, return the lever to the full "up" (OFF/NO
Intermittent -Short Delay RETARD) position, to prevent rapid wear to brake
Low Speed discs and/or overheating of the brake cooling
system.
High Speed
The retarder lever and foot-operated service brake
Depressing the button at the end of the pedal can be used simultaneously or independently.
lever will activate the windshield washer. The Retard Control Module (RCM) will determine
which device is requesting the most retarding/braking
NOTE: The wipers will not come on automatically effort and apply that amount.
when activating the washer. This must be done
manually.

SERVICE BRAKE PEDAL
Service brake pedal (3, Figure 5-3) is a single func- The foot-operated treadle pedal contains an elec-
tion, foot-operated pedal which controls and modu- tronic sensor which sends signals to the Quantum
lates service brake pressure directly through a fuel control system. The movement of the fuel gover-
hydraulic valve. nor control arm corresponds directly to the travel of
the treadle pedal as it is applied by the operator.
When the pedal is depressed, the service brakes are
When the pedal is released, springs return the con-
actuated through a hydraulic valve, which modulates
trol arm and the pedal to their rest positions and the
pressure to the service brakes. Completely depress-
engine speed returns to low idle.
ing the pedal causes full application of both the front
and rear oil disc service brakes.
Refer to retarding capacity chart (8, Figure 5-1) to
determine maximum safe truck speeds for descend-
INSTRUMENT PANEL
ing various grades with a loaded truck. Instrument panel (5, Figure 5-1) includes a center
electronic display panel, and LH & RH switch panels
that contain a variety of switches.
ACCELERATOR PEDAL Refer to Instrument Panel And Indicators later in this
section for a detailed description of the function and
Accelerator pedal (4, Figure 5-3) is a foot-operated
location of each of these components.
pedal which allows the operator to control engine
rpm, depending on pedal depression.
HEATER / AIR CONDITIONER CONTROLS

The heater/air conditioner compartment contains
heater/air conditioner controls and some of the
heater/air conditioner components, such as the
blower motor assembly and the heater coil. Optimum
cab air climate can be selected by using the following
controls in various combinations. Refer to Section N4
for more information on the heater and air condi-
tioner.
FIGURE 5-3. PEDALS
3. Brake Pedal 4. Accelerator Pedal

RETARDING CAPACITY CHART RADIO SPEAKERS
Retarding capacity chart (8, Figure 5-1 & shown Radio speakers (9, Figure 5-1) for the AM/FM stereo
below) provides the recommended maximum truck radio are located at the far left and right of the over-
speeds for descending various grades with a fully head panel.
loaded truck.
AIR CLEANER VACUUM GAUGES

Air cleaner vacuum gauges (10, Figure 5-1) provide
a continuous reading of maximum air cleaner restric-
tion reached during operation. The air cleaner(s)
should be serviced when the gauge(s) reaches 25
inches of H2O vacuum.
NOTE: After service, push the reset pin on the face
of the gauge to allow the gauge to return to zero.
WARNING ALARM BUZZER

Warning alarm buzzer (11, Figure 5-1) will sound
when activated by any one of several truck functions.
Refer to Instrument Panel And Indicators for a
detailed description of functions and indicators that
will activate this alarm.
AM/FM RADIO / CD PLAYER

Reference the retarding capacity chart before
descending any grade with a loaded truck. Proper Radio (12, Figure 5-1) is an AM/FM radio with com-
selection of road grade, truck speed, transmission pact disc and MP3 capabilities.
gear range, and use of the retarder lever and/or Refer to Section 70, Cab Radio, in the operation and
brake pedal are required to maintain a safe speed. maintenance manual for a more complete description
Customer specified options may cause this decal to of the radio and its functions. Individual customers
change. Refer to the retarding capacity chart in the may use this area for other purposes, such as a two-
operator's cab, and follow the recommendations way communications radio.
there for safe truck operation.
DO NOT exceed these recommended maximum

speeds when descending grades with a loaded
truck.
Refer to Operating Instructions, Retarder Operation,
for more information on using the retarder function.
An automatic retard function is available on this
truck. For more information refer to Automatic Retard
Speed Control later in this chapter.

CENTER CONSOLE
Center console (1, Figure 5-4) located to the right of
the operator seat, is a housing which provides a
mounting surface for certain operator controls. The
passenger seat is located directly to the right of the
console.
FIGURE 5-4. CENTER CONSOLE

1. Center Console 5. Auxiliary Power Outlets
2. LH Window Control Switch 6. Parking Brake Switch
3. Hoist Control Lever 7. RH Window Control Switch
4. Transmission Shift Lever

Hoist Control Lever
Hoist control lever (3, Figure 5-4) is a four-function, 6, 5, 4, 3, 2 positions - Road and load conditions
three-position, hand-operated lever located between sometimes make it desirable to limit the automatic
the operator seat and the center console. up-shifting to a lower range. These positions provide
more effective retarding on grades. When the shift
Refer to Operating Instructions - Dumping, for more
lever is placed in any one of these positions, the
complete details concerning this control.
transmission starts in F1, and will not shift above the
highest gear range selected. As the truck ground
speed slows down, the transmission will automati-
Transmission Shift Lever cally downshift to the correct gear (including F1) for
Transmission shift lever (4, Figure 5-4) is mounted to grade/load/engine conditions. When conditions per-
the right of the operator's seat. mit, select position D for normal operation.
The transmission shift lever has nine positions (R, N, L - LOW position - Use this range position when
D, 6, 5, 4, 3, 2 and L). When moving the shift lever maneuvering in tight spaces and when pulling
from N to R, or from D to 6, press the lock button on through mud or deep snow. Use this range position
the end of the handle to release the lever and allow a also when driving up and down steep grades where
gear change. maximum driving power or maximum retarding is
required. When the shift lever is placed in L, the
R - REVERSE position - is used to move the truck transmission starts in F1, and will only upshift to F2.
backwards. Bring the truck to a complete stop before When conditions permit, select position D for normal
shifting from DRIVE to REVERSE or vice-versa. The operation.
Reverse warning horn is activated when the
REVERSE position is selected.
N - NEUTRAL position - is used when starting the
engine, during loading and parking the truck with the
engine on. The truck cannot be started unless the
shift lever is in the N - NEUTRAL position. DO NOT move the shift lever to the N position
D - DRIVE position (F1-F7) - When starting from a while the truck is in motion. If the selector is
stationary position, the transmission will shift auto- shifted to N while in motion or while descending
matically into second gear. As the truck ground a hill the following may occur:
speed increases, the transmission will automatically Steering may be more difficult.
upshift through each gear to seventh gear operation.
As the truck ground speed slows down, the transmis- A lack of cooling oil may cause the braking
sion will automatically downshift to the correct gear system to overheat and fail.
(including F1) for grade/load/engine conditions. Damage to the transmission may occur.
When conditions permit, select position D for normal
The engine cannot provide braking when the
operation. transmission is not in gear.

Parking Brake Switch
When parking brake switch (6,
Figure 5-4) is in the ON position, the
parking brake is applied.
When this switch is in the OFF posi-
tion, the parking brake is released.
The parking brake is spring applied and hydraulically
released. It will hold a stationary truck when the
engine is stopped and the key switch is in the OFF
position.
DO NOT apply the parking brake while the truck

is in motion. Damage to parking brake compo-
nents will occur.
When the key switch is ON and the parking brake is
applied, an indicator light in the center dash panel
will illuminate. Refer to Instrument Panel And Indica-
tors later in this chapter.
LH Window Control Switch

LH window control switch (2, Figure 5-4)
is spring-loaded to the center, OFF, posi-
tion. Pushing the front of the switch lowers
the left side cab window. Pushing the rear
of the switch raises the window.
RH Window Control Switch

RH window control switch (7, Figure 5-4)
is spring-loaded to the center, OFF posi-
tion. Pushing the front of the switch lowers
the right side cab window. Pushing the
rear of the switch raises the window.
Auxiliary Power Outlets

Auxiliary power outlets (5, Figure 5-4) can be used to
power accessory items. The outlets supply 12VDC.

OPERATOR SEAT
The operator's seat provides a fully adjustable cush-
ioned ride for driver comfort and easy operation.
Adjustment
The following adjustments must be made while sitting
in the seat.
1. Headrest: (1, Figure 5-5) will move up, down,
fore, or aft by moving headrest to desired posi-
tion.
2. Armrests: rotate adjusting knob until armrest is
in desired position.
3. Backrest: Lift handle (3) to release and select
backrest angle: release control handle to set.
4. Seat Belt: Operator should always have seat
belt (4) buckled in place and properly adjusted
whenever vehicle is in motion.
5. Seat Slope: Lift lever (5) and hold to adjust the
slope of the seat. Release lever to lock adjust-
ment.
6. & 7 Air Lumbar Support: Each rocker switch
(6 or 7) controls an air pillow. Switch (7) controls
the lower air pillow and switch (6) controls the
upper air pillow. To inflate, press on top of
rocker switch and hold for desired support, then
release. To deflate, press on bottom of rocker
switch and hold for desired support, then
release. Adjust each pillow for desired support.
8. Seat Suspension: Press rocker switch (8) on
top to increase ride firmness. Press on lower
part of rocker switch to decrease ride firmness.
9. Fore/Aft Location of Seat: Lift lever (9) and
hold. Bend knees to move seat to a comfortable
position: release control lever to lock adjust-
ment.
12. Seat Height: Lift lever (12) and hold to adjust FIGURE 5-5. OPERATORS SEAT ADJUSTMENT
the height of the seat. Release lever to lock CONTROLS
adjustment.
1. Headrest 8. Height Adjustment
2. Armrest Adjustment 9. Fore and Aft
3. Backrest Adjustment Adjustment
4. Seat Belt 10. Mounting Hardware
5. Seat Slope 11. Seat Tether
Adjustment Cap Screw
6. Upper Air Pillow 12. Seat Height
Lumbar Support Adjustment
7. Lower Air Pillow
Lumbar Support

INSTRUMENT PANEL AND
INDICATORS
FIGURE 5-6. INSTRUMENT PANEL
1. Upper LH Switch Panel 4. Lower LH Switch Panel

2. Center Electronic Display Panel (EDP) 5. Key Switch
3. Upper RH Switch Panel 6. Lower RH Switch Panel
The instrument panel consists of upper and lower RH

& LH switch panels, and a center display panel with
digital character display.
The center Electronic Display Panel (EDP) is
equipped with a microcomputer to process and dis-
play the signals from the sensors. The display is a
liquid crystal display.
The following pages will identify each element of the
instrument panel and detail its function and purpose.

UPPER RH SWITCH PANEL
Use the brake lock function only while at the

shovel or dump. The brake lock is to be used to
hold the truck stationary.
Do not use this switch to stop the truck. Use of
this switch applies the rear brakes at full, unmod-
ulated pressure!
Do not use the brake lock in place of the parking
brake. With the engine off, hydraulic pressure will
FIGURE 5-7. UPPER RH SWITCH PANEL
depressurize, allowing the brakes to release!
1. Brake Lock 3. Hazard Flasher
2. F1 Start Switch Switch
NOTE: If the truck is not equipped with the brake F1 Start Switch
lock option, slot (1) will contain a plug. F1 start switch (2, Figure 5-7) is used
to ensure that the transmission starts in
F1 when the transmission shift lever is
The upper RH switch panel, located to the right of the in D. When this switch is ON and the
steering wheel, contains the following: transmission shift lever is in the D posi-
tion, the transmission will shift to F1 to start. When
this switch is OFF and the shift lever is in D, the
transmission will start in second gear. Refer to Trans-
Brake Lock Switch mission Shift Lever, D - DRIVE. All other forward
Moving brake lock switch (1, Figure 5- gear ranges (L, F2, F3, F4, F5, F6) start out in F1
7) to the ON position, applies the brake regardless of the F1 start switch position.
lock. Depressing the bottom of the switch moves the
When this switch is in the OFF posi- switch to the ON position. Depressing the top moves
tion, the brake lock is released. the switch to the OFF position.
The brake lock can only be used with the engine on.
It is used for dumping and loading, only. The brake
lock switch actuates the hydraulic brake system Hazard Warning Lights Switch
which locks the rear wheel service brakes. Hazard warning light switch (3,
When approaching a shovel or dump area, select an Figure 5-7) causes all turn signal lights
area with a level surface. When the truck is com- to flash, simultaneously.
pletely stopped and in loading position, apply the The rocker switch is an ON/OFF type.
brake lock by moving the rocker switch to ON (up). Depressing the bottom moves the
To release, press the rocker switch to OFF (down). switch to the ON position. Depressing the top of the
switch moves the switch to the OFF position.
Use the hazard lights as a warning to alert other truck
operators that a problem exists.

LOWER RH SWITCH PANEL
FIGURE 5-8. LOWER RH SWITCH PANEL
1. Key Switch 4. ARSC Switch

2. Ether Starting Aid Switch (Optional) 5. AISS Switch
3. ASR Cut Switch 6. Auxiliary Brake Switch
The lower RH switch panel, located to the right of the START - With the transmis-
steering wheel, contains the following: sion selector lever in the NEU-
TRAL position, rotate the key
switch fully clockwise to the
Key Switch START position, and hold this
position until the engine starts
Key switch (1, Figure 5-8) is a three position (OFF, (see NOTE below). The
RUN, START) switch. START position is spring
OFF - Key insertion/withdrawal loaded to return to RUN when
position the key is released.
When the key slot is in the verti- NOTE: The engine start circuit is equipped with a
cal position, the electrical system engine prelube system. A noticeable time delay will
is off and no electrical devices are occur (while engine lube oil passages are being
energized. filled) before starter engagement and engine
cranking will begin. The colder the engine oil
Use this key position to stop the temperature, the longer the time delay will be. In
engine when it is operating. addition, if the truck is also equipped with an engine
RUN - When the switch is rotated one position starting aid for cold weather starting, the engine
clockwise, it is in the RUN position and all elec- prelube system should be engaged first for 5-10
trical circuits (except START) are energized. seconds, or until the starter is engaged, before
activating the engine starting aid.

ASR Cut Switch
ASR (Automatic Spin Regulator) cut
switch (3, Figure 5-8) is used to acti-
vate or de-activate the traction control
Starting fluid is extremely volatile and flammable! system.
Use with extreme care.
If the truck is equipped with an engine starting aid for The rocker switch is an ON/OFF type switch.
cold weather starting, and ambient temperature is Depressing the bottom turns the ASR system on. A
below -5C (23F), push the engine starting aid green light will illuminate the switch to notify the oper-
switch in for three seconds, then release. Turn the ator that ASR is active. Depressing the top of the
key switch to the START position. If the engine does switch turns the ASR system off. An amber light will
not start, wait at least 15 seconds before repeating. illuminate the switch notifying the operator that trac-
tion control is inactive.
When ASR is active, the system monitors individual
wheel speeds. If it determines one of the rear wheels
is slipping during acceleration, the brake is applied to
the rear wheel with the higher speed. Refer to Auto-
Do not crank an electric cranking motor for more
matic Spin Regulator later in this chapter for more
than 30 seconds. Allow two minutes for the
information on using this function.
cranking motor to cool before attempting to start
the engine again. Severe damage to the cranking
motor may result from overheating.
ARSC Switch
ARSC (Automatic Retard Speed Con-
Ether Starting Aid Switch trol) switch (4, Figure 5-8) is used to
Ether starting aid switch (2, Figure 5-8) enable and disable the automatic
is an ON/OFF type rocker switch that is retard speed control system. Press the
spring-loaded to the OFF position. This top of the switch to enable automatic
switch is optional equipment. retard. Press the bottom of the switch
to disable the automatic retard system. Refer to
When the outside temperature is below Automatic Retard Speed Control later in this section
-5C (23F), depress the top of this switch and hold for more information on this system.
for 2-3 seconds before starting the engine. The cold
starting aid atomizes ether into the engine intake
manifold.
Automatic Idle Selector Switch (AISS)
Refer to Key Switch - START for further details
regarding the use of this switch. AISS switch (5, Figure 5-8) controls the
idle speed of the engine. With the
accelerator pedal released, the monitor
panel sends a signal to the ECM for a
low idle rpm.
DO NOT push the ether injection switch after the This signal may be for either:
engine has started. Serious damage to the 650 rpm - normal-low idle, or
engine may occur. 1000 rpm - high-low idle, depending on the
following conditions:

1. Depressing the top of the switch Auxiliary Brake Switch
selects the OFF/AUTO position
Auxiliary brake switch (6, Figure 5-8) is used to apply
which is used for enhanced truck
the auxiliary braking system.
operation. When the AISS switch
is in this position, the idle speed Depress the button to apply the auxiliary brake sys-
will be determined by two condi- tem. When the switch is ON, the red lamp will illumi-
tions: engine coolant temperature, and brake nate.
application.
Pull the switch out to disable the auxiliary brake sys-
a. Engine Coolant Temperature - If the engine tem. The light will turn off.
coolant temperature is below 30C (47F),
the engine controller will signal for 1000 rpm,
regardless of other conditions. If the engine
coolant temperature is above 30C (47F),
the engine controller will signal for 650 rpm,
except as follows: When the auxiliary brake switch is activated, full,
unmodulated hydraulic brake pressure (or what-
b. Brake Application - If both the parking brake
ever pressure remains, if the system is failing) is
and service brake are released (acceleration
applied to all wheels. In addition, the parking
anticipated), the engine controller will signal
brake is also applied.
for 1000 rpm, regardless of other conditions.
Do not apply the auxiliary brake switch when the
NOTE: An amber light will illuminate the switch when truck is moving, except in an emergency.
the OFF/AUTO position is selected.
2. Depressing the bottom of the
switch selects the ON/LOW posi- NOTE: This switch is for the manual activation of the
tion. When the AISS switch is in auxiliary brake circuit by the operator. The auxiliary
this position, the engine control- brake circuit will apply automatically if the hydraulic
ler will signal for 650 rpm, regard- brake pressure decreases below a pre-set value.
less of other conditions. ON/LOW
position is used when fine control movements
are needed, such as parking in confined
spaces.
NOTE: A green light will illuminate the switch when
the ON/LOW position is selected.

UPPER LH SWITCH PANEL
FIGURE 5-9. UPPER LH SWITCH PANEL
1. Automatic Lubrication System Indicator
Upper LH switch panel (1, Figure 5-6), located to the

left of the steering wheel, currently does not contain
any switches (standard or optional). The panel con-
tains the following:
Automatic Lubrication System Indicator

Automatic lubrication system indica-
tor (1, Figure 5-9) illuminates when
lubrication system pressure fails to
reach 15168 kPa (2,000 psi) within
one minute after the lube timer ini-
tiates a cycle of grease. Notify main-
tenance personnel at the earliest
opportunity after the light comes on.

LOWER LH SWITCH PANEL
FIGURE 5-10. LH CONTROL/INDICATOR PANEL

1. Head Light Switch 5. Mode Select Switch # 1
2. Ladder Light Switch 6. Mode Select Switch # 2
3. Backup Light Switch 7. Panel Light Dimmer Switch
4. Fog Light Switch (Optional)
The lower LH switch panel, located to the left of the

steering wheel, contains the following:
Head Light Switch

Ladder Light Switch
Head light switch (1, Figure 5-10)
Ladder light switch (2, Figure 5-
is a three position rocker switch
10) turns the ladder lights on or
that controls the instrument panel
off. A similar switch is available at
lights, clearance lights, and the
the ground level to turn the ladder
head lights. Press the top of the
lights on or off. Depress the bot-
switch until it reaches the first
tom of the switch to turn the lad-
detent (middle) to select the
der lights on. Depress the top of
panel, clearance, and tail lights,
the switch to turn the ladder lights
only. Press the top of the switch again, until it
off.
reaches the second detent to select the headlights,
as well as panel, clearance, and tail lights. Press the
bottom of the switch to turn all of the lights off.

BackUp/Deck Light Switch Panel Light Dimmer Switch
Backup/deck light switch (3, Panel light dimmer switch (7,
Figure 5-10) allows the backup Figure 5-10) is used to adjust the
lights to be turned on regardless brightness of the machine monitor.
of the transmission shift lever Turn the knob clockwise to make
position. Depress the top of the the display brighter. Turn the knob
switch to turn the backup/deck counter-clockwise to dim the dis-
lights on. Depress the bottom of play.
the switch to turn the backup/
deck lights off.
Fog Light Switch

Fog light switch (4, Figure 5-10)
controls the fog lights. The fog
lights are optional and for use in
foggy conditions and heavy rain.
Pressing the bottom of the rocker
switch turns the lights on. Press-
ing the top of the switch turns the
lights off.
Mode Select Switches 1 & 2
Mode switch 1 & 2 (5, 6, Figure 5-10) are used to

scroll through the machine monitor character display.
The button commands are as follows:
1 Select, Run
2 Cancel, Release, Select (Yes/No Only)
3 Right, Next, Continue
4 Left, Previous, Return

ELECTRONIC DISPLAY PANEL
When the engine starting switch is turned to the ON The character display shows KOMATSU
position before starting the engine, a system check is SYSTEM CHECK for three seconds.
performed for 30 seconds. The following system If the lamps do not work, a failure in the circuit
checks occur: has occurred. Contact your Komatsu distributor
for inspection.
The central warning lamp illuminates for two
seconds, and then turns off. When the starting switch is turned ON, if the shift
lever is not in the NEUTRAL position, after
The alarm buzzer sounds for two seconds, and completion of the system check, the shift lever
then stops.
position pilot lamp and the central warning lamp
The monitor lamp alternately illuminates for two will illuminate, and the alarm buzzer will continue
seconds and then turns off for one second. to sound intermittently. When this happens, if the
shift lever is in NEUTRAL, N is displayed, the
The shift indicator alternately displays 88 for two central warning lamp turns off, and the buzzer
seconds and then turns off for one second. stops.
After a three second system check, the meters
start to function.
FIGURE 5-11. CENTER ELECTRONIC DISPLAY PANEL
A. Character Display D. Meter Display Portion

B. Caution Items E. Central Warning Lamp
C. Emergency Stop Items

PILOT DISPLAY ITEMS
When the key switch is in the ON position, controls
that have been activated will illuminate the corre-
sponding pilot display lamps.
FIGURE 5-12. EDP - PILOT DISPLAY ITEMS
1. Lock-up Pilot Lamp 6. Retarder Pilot Lamp

2. Turn Signal Directional Lamp 7. ARSC Pilot Lamp
3. High Beam Pilot Lamp 8. Shift Lever Position
4. ARSC Set Speed Indicator 9. Shift Indicator
5. ASR Actuation Lamp
Lockup Pilot Lamp Turn Signal Pilot Lamp

The lockup pilot lamp will illuminate
when the torque converter lockup is
engaged and the transmission is shifted
to direct drive.
The turn signal pilot lamp arrow will flash simulta-
neously as the exterior turn signal lamps flash. If a
right turn is selected using the turn signal lever, the
right arrow will flash. If a left turn is selected using the
turn signal lever, the left arrow will flash.

Head Lamp High Beam Pilot Lamp ASR Actuation Lamp
The high beam pilot lamp will illumi- When the ASR system is active, this
nate when the head lamps are set to lamp will illuminate when slipping from
high beam using the multi-function the rear wheels is detected. The lamp
turn signal lever. indicates that the ASR system has actu-
ated the brakes to prevent the slippage.
Retarder Pilot Lamp

Shift Lever Pilot Lamp
The retarder pilot lamp will illuminate
The shift lever pilot lamp displays the posi-
when the retarder control lever is actu-
tion of the shift lever.
ated and the retarding system is active.
The letter or number for the selected speed
range will be illuminated.
ARSC Pilot Lamp
The ARSC pilot lamp indicates that the
automatic retard system is active. The
system will maintain the truck at the set
speed.
The lamp will turn off when the ARSC system is
turned off.
Shift Indicator
The shift indicator displays the
transmission shift range (speed
range).
ARSC Set Speed Indicator
The ARSC set speed indicator displays the set travel

speed for the auto retarder speed control.
When the ARSC switch is off, the monitor turns off. If
the set travel speed has been canceled, 0 is dis-
played.

METER DISPLAYS
FIGURE 5-13. EDP - METERS
1. Torque Converter Oil Temperature Gauge 4. Speedometer

2. Engine Water Temperature Gauge 5. Retarder Oil Temperature Gauge
3. Engine tachometer 6. Fuel Gauge
Speedometer Engine Tachometer
The engine tachometer displays the engine speed.

The speedometer indicates the travel speed of the When engine speed exceeds 2500 rpm and moves
truck. into the red range on the meter, the alarm buzzer will
sound and the central warning lamp will illuminate.
Reduce engine speed to prevent damage to the
engine.

Fuel Gauge Torque Converter Oil Temperature Gauge
The fuel gauge displays the amount of fuel remaining The torque converter oil temperature gauge displays
in the fuel tank. The fuel level caution lamp will illumi- the torque converter oil temperature.
nate when the fuel level drops to 140 liters (37.0 US The white range indicates normal operating tempera-
gal). ture. If the temperature rises to the red range during
operation, the alarm buzzer will sound and the cen-
tral warning lamp will illuminate. E02 TC OVERHEAT
Coolant Temperature Gauge will simultaneously be displayed on the character dis-
play. Stop the truck and operate the engine under no
load at a mid-range speed until the meter enters the
white range.
Retarder Oil Temperature Gauge
The coolant temperature gauge displays the engine

coolant temperature.
The white range indicates normal operating tempera-
ture. If the temperature rises to the red range during
operation, the alarm buzzer will sound and the cen- The retarder oil temperature gauge displays the
tral warning lamp will illuminate. E02 ENGINE retarder oil temperature.
OVERHEAT will simultaneously be displayed on the
character display. Engine output will automatically be The white range indicates normal operating tempera-
limited. Stop the truck and operate the engine under ture. If the temperature rises to the red range during
no load at a mid-range speed until the meter enters operation, the alarm buzzer will sound and the cen-
the white range. tral warning lamp will illuminate. E02 BRAKE OVER-
HEAT will simultaneously be displayed on the
character display. Stop the truck and operate the
engine under no load at a mid-range speed until the
meter enters the white range.

CAUTION ITEMS
If a caution indicator icon illuminates during

machine operation, quickly assess the problem
to determine the necessary reaction.
FIGURE 5-14. EDP CAUTION LAMPS
1. Maintenance Caution Lamp 5. Emergency Steering Lamp

2. Parking Brake Pilot Lamp 6. Accumulator Charge Pressure Lamp
3. Dump Body Pilot Lamp 7. Fuel Level Caution Lamp
4. Check Engine Lamp
Maintenance Caution Lamp Clogged air cleaner

Clogged steering, hoist oil filter
The maintenance caution lamp illumi- Clogged transmission oil filter
nates if any of the following occur: Low coolant level
Clogged brake cooling oil filter
Low engine oil level Worn rear brake discs
Clogged engine oil filter Low battery electrolyte level
Low hydraulic oil level Low transmission oil level

When the maintenance caution lamp illuminates, Accumulator Charge Pressure Lamp
action code E01 is simultaneously displayed on the
The accumulator charge pressure lamp
character display. Service the truck at the next avail-
will illuminate if steering accumulator
able opportunity.
nitrogen pressure is below 5861 kPa
If a filter or oil replacement interval is displayed on (850 psi).
the character display, the maintenance caution lamp
will flash or illuminate. If the interval is approaching,
the lamp will flash. If the interval has been exceeded, Fuel Level Caution Lamp
the lamp will remain on. Refer to Character Display
later in this chapter for more information on mainte- The fuel level caution lamp
nance indicators. illuminates when the level of
the fuel in the fuel tank falls
below 140 liters (37 gal).
Parking Brake Pilot Lamp If the lamp is on, it will be nec-
essary to add fuel shortly.
The parking brake lamp illuminates
when the parking brake is applied.
Dump Body Pilot Lamp

The dump body lamp illuminates when
the dump body is raised or the dump
body lever is in any position other than
FLOAT.
Check Engine Lamp

The amber check engine lamp will illumi-
nate if a problem occurs in the engine
control system. The engine must be ser-
viced within 24 hours of the illumination of
the lamp.

EMERGENCY STOP ITEMS
If a fault occurs with an emergency stop item, the
alarm buzzer will sound intermittently and the lamp
for that item will illuminate. The central warning lamp
will illuminate simultaneously.
If one of the emergency stop lamps illuminate,
stop the truck immediately. Response instruc-
tions are documented on the following pages.
FIGURE 5-15. EDP - EMERGENCY STOP ITEMS
1. Coolant Temperature Caution Lamp 6. Central Warning Lamp

2. Charging System Caution Lamp 7. Retarder System Caution Lamp
3. Engine Oil pressure Caution Lamp 8. Transmission Caution Lamp
4. Brake Oil pressure Caution Lamp 9. Engine System Caution Lamp
(Accumulator Oil Pressure) 10. Machine Monitor Caution Lamp
5. Retarder Oil temperature Caution Lamp 11. Torque Converter Oil Temperature Caution Lamp

Coolant Temperature Caution Lamp Brake Oil Pressure Caution Lamp
The coolant temperature caution The brake oil pressure caution lamp will
lamp will illuminate when the illuminate if accumulator oil pressure
coolant temperature has risen to fails to reach the specified value 30 sec-
a critical level. onds after engine startup. If the brake
accumulator oil pressure has dropped
When the lamp is lit, E02
below the specified value during truck
ENGINE OVERHEAT will be
operation the lamp will also illuminate.
displayed on the character dis-
play simultaneously. Engine output will be automati- When the lamp is lit, E03 CHECK RIGHT NOW will
cally limited. Stop the truck and operate the engine simultaneously be displayed on the character dis-
under no load at a mid-range speed until the lamp play. Stop the truck immediately in a safe place, and
turns off. turn the engine off. Notify maintenance.
The central warning lamp and alarm buzzer are not
actuated when the engine is off.
Charging System Caution Lamp
The charging system caution lamp illu-
minates when an abnormality in the Retarder Oil Temperature Caution Lamp
charging system has occurred with the
The retarder oil temperature
engine on.
caution lamp will illuminate
When the lamp is lit, E03 CHECK RIGHT NOW will when the brake oil temperature
simultaneously be displayed on the character dis- has risen to a critical level.
play. Stop the machine immediately in a safe place,
When the lamp is lit, E02
and turn the engine off. Notify maintenance.
BRAKE OVERHEAT will simul-
taneously be displayed on the
character display. Stop the truck in a safe place.
Engine Oil Pressure Caution Lamp Move the shift lever to the N position, and operate
The engine oil pressure caution lamp the engine under no load at a mid-range speed until
will illuminate when the engine oil the lamp turns off.
pressure has dropped to a critical
level. Oil pressure is monitored only
when the engine is on.
When the lamp is lit, E03 CHECK RIGHT NOW will
simultaneously be displayed on the character display
and engine output automatically limited. Stop the
machine immediately in a safe place, and turn off the
engine. Notify maintenance.
Emergency Steering Lamp

The emergency steering lamp illumi-
nates when steering pressure drops
below 12, 800 kPa (1850 psi).

Central Warning Lamp
The central warning lamp and the When the lamp is lit, E02 TC OVERHEAT will simul-
alarm buzzer will sound intermit- taneously be displayed on the character display. Stop
tently to indicate that a failure is the truck in a safe place, and move the shift lever to
present. Any of the following will the N. Operate the engine under no load at a mid-
cause the central warning lamp to range speed until the lamp turns off.
light:
When an abnormality has occurred in any of
emergency stop items. Refer to Emergency Stop Transmission Caution Lamp
Items earlier in this chapter.
The transmission caution lamp will illumi-
When action code E02 or E03 is displayed on the nate when an abnormality has been
character display. detected by the transmission controller.
When the parking brake is applied, but the shift When the lamp is lit, E03 CHECK
lever is not in the N position. RIGHT NOW will simultaneously be displayed on the
When the hoist control lever is not in the FLOAT character display. Stop the truck and turn off the
position or the dump body is raised and the shift engine.
lever is not in the N position.
When the engine tachometer rises to the red
range. Engine System Caution Lamp
The red engine system caution lamp will
illuminate when an abnormality has
Retarder System Caution Lamp been detected by the engine controller.
The retarder system caution lamp will When the lamp is lit, E03 CHECK
illuminate when an abnormality has RIGHT NOW will simultaneously be dis-
been detected by the RCM. played on the character display. Stop the truck and
When the lamp is lit, E03 CHECK turn off the engine.
RIGHT NOW will simultaneously be displayed on the
character display. Stop the truck immediately in a
safe place, and turn off the engine. Notify mainte- Machine Monitor Caution Lamp
nance.
The machine monitor caution lamp will
illuminate when an abnormality has been
detected in the machine monitor. The
Torque Converter Oil Temperature Caution Lamp lamp will also monitor certain optional
equipment, if installed. If one of these
monitored systems fail, the lamp will illu-
minate.
When the lamp is lit, E03 CHECK RIGHT NOW will
simultaneously be displayed on the character dis-
play. Stop the truck and turn off the engine.
The torque converter oil temperature caution lamp

will illuminate when the torque converter oil tempera-
ture has risen to a critical level.

CHARACTER DISPLAY
FIGURE 5-16. Electronic Display Panel

1. Electronic Display Panel 2. Character Display
Normally, the service meter/odometer is displayed on

the character display. Operator mode
If the machine experiences a failure or if it is neces- 1 Service meter, odometer display (default) *
sary to perform maintenance, an action code is dis- 2 Operation Information
played to recommend a suitable response.
3 Reverse travel distance display function
When filter replacement or an oil change is neces- Filter replacement, oil change interval display
4
sary, the maintenance monitor caution lamp will function
flash, and the filter or oil to be replaced is displayed. 5 Telephone number input function
This will occur after completion of the system check
6 Language selection function
with the key switch in the ON position. Refer to Filter
And Oil Change Display later in this chapter. 7 PLM setup function
8 Action code display function
Check the display to verify that there are no faults
before driving the truck. 9 Failure code display function
The following table lists the various displays of the * PLM information will override the default display when
character display while in Operator Mode. Service input is sent from VHMS. An active action code will also
related information can be obtained in the service override the default display.
modes. Various service modes can be used to
extract fault code information as well as real time
monitoring of system information. Refer to Section D, Machine Monitor, for more infor-
mation on using the character display.

REAR ELECTRICAL COMPARTMENT
The following components are located behind the
operator and passenger seats across the back wall
of the operator cab (Refer to Figure 5-18):
1. ATC - Automatic Transmission Controller
The ATC controls and monitors the automatic
transmission. It controls the shift patterns and
lock-up clutch modulation and monitors numer-
ous other sensor inputs. Refer to Section D for
specific information regarding this device.
2. Fuse Panel
The fuse panel contains all of the electrical
fuses on the truck.
3. RCM - Retard Control Module
This panel controls and monitors the retarder
system. Refer to Section D for specific informa-
tion regarding this device.
4. Vehicle Health Monitoring System (VHMS)
The VHMS controller gathers data related to the
operational health of the machine from each of
the controllers and sensors. Refer to Section D,
VHMS, for more information.
5. VHMS Download Connector
6. Payload Meter (PLM) Download Connector
7. CENSE Engine Download Connector -
(SDA12V160 only)
8. Engine Maintenance Light -
The engine maintenance light will
illuminate when engine mainte-
nance is necessary. It is not nec-
essary to service the truck until
the next scheduled preventive maintenance.
9. Engine Communications Connector FIGURE 5-17. FUSE PANEL DESCRIPTIONS
TABLE I. CIRCUIT BREAKER CHART

CIRCUIT BREAKER IDENTIFICATION CIRCUIT NUMBER CONTROL DESCRIPTION
No. AMPS VOLTS IN OUT
LOCATION: BATTERY BOX
CB24V 50 +24 3 12 24 Volt Control Power (To Power Bus #3 on Cab Rear Wall)
CB12V 50 +12 4 12V 12 Volt Control Power (To Power Bus #4 on Cab Rear Wall)
LOCATION: AC/HEATER UNIT
A/C-CB 20 +24 12AC - Internal Automatic Reset Circuit Breaker

1. Automatic Transmission Controller (ATC) 6. Payload Meter Download Connector

2. Fuse Panel 7. CENSE Engine Download Connector -
3. Retard Control Module (RCM) (SDA12V160 Only)
4. Vehicle Health Monitoring System (VHMS) 8. Engine Maintenance Light
5. VHMS Download Connector 9. QSK Engine Communications Connector

(Enclosure Removed)
1. Automatic Lubrication System Timer 8. Turn Signal Flasher
2. Ground Bus Bars 9. Steering Bleeddown Timer
3. Power Bus # 1, 24V Battery Direct Power 10. Windshield Wiper Delay Timer
4. Power Bus # 2, 24V Battery Disconnect Power 11. External Harness Interface Connection Panel
5. Power Bus # 3, 24V Key Controlled Power 12. ORBCOMM Modem
6. Power Bus # 4, 12V Key Controlled Power
7. Relay Centers

AUTOMATIC RETARD SPEED
CONTROL (ARSC) If any failure in the system occurs during operation,
Automatic Retard Speed Control (ARSC) automati- the alarm sounds and the central warning lamp will
cally actuates the retard system to maintain the travel illuminate. The RCM will turn the ARSC system off.
speed at a set speed controlled by the operator. This Use the retarder control lever and/or the brake pedal
system is designed to make retarding easier and to stop the machine in a safe place. Turn the ARSC
more constant. switch off and notify maintenance.
For instance, if the ARSC is on, and the set speed is

set to 20 km/h (12 mph), the ARSC system will auto-
Set Speed Functionality
matically apply retarding effort to slow the truck. As
the truck descends a grade and attempts to exceed When setting the ARSC, vehicle speed cannot be set
20 km/h (12 mph), the ARSC maintains the set speed to less than 10 km/h (6 mph). If the set speed is set
without the operator having to use the brake pedal or while the truck is moving slower than 10 km/h (6
manual retard lever. mph) the ARSC will default to 10 km/h (6 mph).
Likewise, the set speed cannot be set higher than 60
km/h (37 mph). If the set speed is set while the truck
is moving faster than 60 km/h (37 mph), the set
speed will default back to 60 km/h (37 mph). In all
other instances, the speed will be set to the actual
Refer to the retarding capacity chart in the cab travel speed.
before setting the travel speed. If the set speed
exceeds the maximum permissible speed on the The time taken for the machine travel speed to match
chart, overheating and damage to the retarding the set speed may differ according to the grade of the
system may occur. slope.
If the set travel speed is near a transmission shifting
point or there is a change in the grade of the slope,
the transmission may shift (up or down) even during
retarding.
The ARSC system can be set in any gear range
When the ARSC is actuated on slippery road sur- except N or R.
faces, the wheels may lock. If this occurs, turn
the ARSC system off and use the manual retard The set speed will remain in memory when the
lever or brakes to safely control the truck. ARSC switch and/or the key switch is turned to OFF.
The only method for removing the set speed from the
memory is to cancel it using the ARSC lever. Refer to
The ARSC system will only apply retarding effort (d, Figure 5-20).
when the ARSC switch is on. If the switch is turned
off during retarding, the set speed indicator and
ARSC pilot lamp will turn off and the brakes will
release. Cancelling And Changing The Set Speed
The ARSC will only apply retarding effort when the Moving the lever to the cancel position (d, Figure 5-
accelerator pedal is not being depressed. If the 20) for more than 1 second cancels the set speed.
accelerator is pressed while the ARSC system is on, The set speed indicator will display a 0 when can-
the RCM will cancel the ARSC. The service brakes celled.
and the retarder lever will both continue to function If it is desired to increase the set speed, depress the
while the ARSC system is on. accelerator pedal to increase speed, and when the
The retard lever is more responsive when the ARSC desired set travel speed is reached, press the set
system is on. Use small increments when moving the switch on the auto retarder (ARSC) set lever. The set
lever to avoid locking the brakes. travel speed will be changed to the new speed.

FIGURE 5-20. ARSC CONTROLS
1. Retard Lever a. Set
2. ARSC Lever b. Increase Speed
3. ARSC Switch c. Decrease Speed
4. ARSC Pilot Lamp d. Cancel
5. ARSC Set Speed Indicator
6. Retarder Pilot Lamp
If it is desired to decrease the set speed, operate the If the set switch and cancel are operated at the same
retarder control lever to reduce speed, and when the time, cancel is given priority.
desired set travel speed is reached, press the set
If the set switch and tap up are operated at the same
switch on the auto retarder (ARSC) set lever. The set
time, tap up is given priority.
travel speed will be changed to the new speed.
If the set switch and tap down are operated at the
To change the speed without using the accelerator or
same time, tap down is given priority.
braking system, tap up (b, Figure 5-20) on the lever
to increase the speed. The speed will increase by 1
km/h (0.6 mph). To decrease the speed, tap down (c,
Figure 5-20) on the lever. The speed will decrease by
1 km/h (0.6 mph). The maximum speed change that
can occur using the tap up - tap down functions is 5
km/h (3.1 mph).

Recommended Set Speeds
Refer to the retarding capacity chart in the cab for the
maximum safe speeds for descending a grade.
Set the travel speed so that the engine speed is
above 1800 rpm. The retarder oil temperature gauge
must remain at normal operating temperature (in the
white range on the gauge). If the retarder oil is close
to overheating, the set speed is automatically
reduced 1 km/h (0.6 mph) every 3 seconds. The set
speed will not drop below 10 km/h (6 mph).
To set the ARSC:

1. Turn on ARSC switch (3, Figure 5-20) to turn
the system on. ARSC pilot lamp (4) will illumi-
nate to alert the operator that the system has
been activated. The ARSC set speed indicator
(5) will turn on and the previous set speed will
be displayed. If the previous speed was can-
celled, a 0 will be displayed.
2. When the truck speed reaches the desired set
speed, press button (a) on the ARSC lever to
set the travel speed. The set speed will be dis-
played on the ARSC set speed indicator (5).
The set speed indicator may differ slightly from
the speedometer display.
Refer to the retarding capacity chart in the cab
for the proper speed for descending a grade.
3. To adjust the set speed, tap up (b) on the lever
to increase the speed. The speed will increase
by 1 km/h (0.6 mph). To decrease the speed,
tap down (c) on the lever. The speed will
decrease by 1 km/h (0.6 mph). To cancel the set
speed, pull the lever towards the rear of the
cab. The set speed indicator will display a 0.
4. To turn the system off, turn ARSC switch (3) off.

AUTOMATIC SPIN REGULATOR (ASR)
Automatic Spin Regulator (ASR) is a traction control The ASR cut switch controls the
system that helps prevent slipping of the drive status of the system.
wheels caused by excessive torque. ASR also pro- A: ASR system OFF - amber lamp
vides traction on slippery road surfaces.
B: ASR system ON - green lamp
FIGURE 5-21. ASR OPERATION
1. ASR Cut Switch 4. Accelerator Pedal

2. ASR Actuation Lamp 5. Brake Pedal
3. Retarder Control Lever 6. Character Display

When the ASR switch is on, the system is active.
ASR monitors the individual rear wheel speeds. If it
determines one of the rear wheels is slipping during
acceleration, the brake is applied to the rear wheel
with the higher speed. ASR actuation lamp (2,
Figure 5-21) will illuminate when the system detects
slipping from the rear wheels and actuates the ASR.
If the brake pedal or retard lever are actuated during If a malfunction occurs in the system, an action
ASR actuation, ASR actuation will be cancelled. code is shown on the character display, and the
The ASR system is actuated only when the accelera- ASR function is canceled. Immediately drive the
tor pedal is being depressed and travel speed is 0 to truck to a safe area and turn the ASR cut switch
30 km/h (0 to 19 mph). If the pedal is released while off.
the ASR is being actuated, the actuation of the ASR On slick road surfaces or on steep slopes, it may
system is canceled. be impossible to drive safely even when the ASR
is actuated.
If any abnormality occurs in the ASR system, an
action code is shown on character display (6). If both rear wheels slip at the same speed, ASR
will not function. If this occurs, reduce the engine
Depressing the top of the switch turns the ASR sys- output with the accelerator pedal.
tem off. An amber light will illuminate the switch noti-
fying the operator that traction control is inactive.

SECTION P
LUBRICATION AND SERVICE
INDEX
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-1
AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-1
P01016 Index P1-1

NOTES
P1-2 Index P01016

SECTION P2
INDEX
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
RADIATOR FILL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3
HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
Filling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
TRANSMISSION OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4
PERIODIC REPLACEMENT OF CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-6
10 HOUR (DAILY) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-7
250 HOUR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-9
500 HOUR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P2-11
1000 HOUR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-12
P02056 Lubrication and Service P2-1

NOTES
P2-2 Lubrication and Service P02056

Preventive maintenance contributes to the long life
and dependability of the truck and its components. ANTI-FREEZE RECOMMENDATIONS
The use of proper lubricants and the performance of (Ethylene Glycol Permanent Type Anti-Freeze)
checks and adjustments at recommended intervals Percentage of Protection
are crucial. Anti-Freeze To:
Lubrication requirements reference the lube key 10 - 5 C + 23 F
found in the lubrication chart. For detailed service 20 - 9 C + 16 F
requirements for specific components, refer to the
25 - 11 C + 11 F
appropriate section in this book.
30 - 16 C + 4 F
The service intervals presented here are in hours of
35 - 19 C - 3 F
operation. Oil change intervals are recommended in
the absence of an oil analysis program which may 40 - 24 C - 12 F
determine different intervals. However, if the truck is 45 - 30 C - 23 F
being operated in extreme conditions, some or all of 50 - 36 C - 34 F
the intervals may need to be performed more fre-
55 - 44 C - 48 F
quently.
60 - 52 C - 62 F
Refer to the engine service manual when servicing
Use only anti-freeze that is compatible with engine as
the engine or any of its components.
specified by engine manufacturer.
RADIATOR FILL PROCEDURE
SERVICE CAPACITIES
The cooling system is pressurized due to thermal
Liters U.S. expansion of coolant. DO NOT remove the radia-
Engine Crankcase Gallons tor cap while the engine and is hot. Severe burns
(including lube oil filters) 193 51 may result.
Cooling System 532 141
Hydraulic System 1. With the engine and coolant at ambient temper-
Refer to Hydraulic Tank Ser- 900 238 ature, depress the pressure relief to remove
vice in this chapter cooling system pressure. Slowly, remove the
radiator cap.
Differential Case 297 78
NOTE: If coolant is added using the quick fill system,
Final Drive Case 120 32
the radiator cap must be removed prior to adding
(each planetary)
coolant.
Fuel Tank (diesel fuel only) 2120 560 2. Fill the radiator with the proper coolant mixture
Transmission Case 153 41 as specified by the engine manufacturer. Fill
including torque converter until coolant reaches the radiator cap area.
3. Install the radiator cap.
4. Allow the engine to idle for 5 minutes. Shut the
engine off and wait for the engine to cool.
5. Check the coolant level. If the radiator is not full,
repeat the previous steps. Any excess coolant
will be discharged through the vent hose after
the engine reaches normal operating tempera-
ture.

HYDRAULIC TANK SERVICE 4. Install the fill cap.
5. Start the engine. Raise and lower the dump
Filling Instructions
body three times to circulate oil and fill hoses
1. Lower the dump body and turn the key switch and components.
OFF. 6. Repeat the previous steps until oil level is again
in upper sight glass (5).
7. If oil level falls below lower sight glass (6) with
the engine on, repeat this procedure.
the relief valve on the tank before removing the
filler cap.
TRANSMISSION OIL LEVEL CHECK
1. With the engine off:
The oil level must be visible in the upper part of

the sight gauge between H and L. This sight
gauge is to be used when changing oil, before
engine start-up (engine off for eight hours or
more).
Add clean oil as required through the transmis-
sion oil filler tube at the left rear of the transmis-
sion.
When the engine is turned on and transmission
oil reaches normal operating temperature,
check the oil level again, as described below.
2. With the engine on:

1. Hydraulic Tank 5. Hydraulic Oil Level The oil level must be visible in the lower sight
2. Pressure Relief Valve Upper Sight Glass gauge between H and L.
3. Breather 6. Hydraulic Oil Level Use this sight gauge with the following guide-
4. Fill Cap Lower Sight Glass lines:
7. Hydraulic Oil Drain
truck parked on level surface
engine at low idle
shift lever in NEUTRAL
2. Depress relief valve (2, Figure 2-1) for 30 - 45
seconds to release any internal tank pressure. transmission oil at normal operating
Remove fill cap (4). Turn the cap slowly to temperature
release any residual tank pressure. Add clean oil as required through the transmis-
3. Refer to lube key C on the lubrication chart. Fill sion oil filler tube at the left rear of the transmis-
the tank with the recommended oil until oil is sion.
visible in upper sight glass (5). Hydraulic tank
capacity is: 576 l (152 gal).

FIGURE 2-2. LUBRICATION CHART

PERIODIC REPLACEMENT OF CRITICAL
PARTS
To ensure safe operation of the truck, it is necessary
to perform periodic maintenance for critical parts.
Fabrication of safety devices and other component
parts have been designed to high standards. How-
ever, all parts are subject to wear and gradual fatigue
during continuous use. Since it is difficult to deter-
mine accurately the process of change in quality,
wear, or fatigue, judgments must be made whether
or not some parts should be replaced even if they do
not show any faulty symptom at the time. Of course,
any part found to have an abnormality must be
repaired or replaced, regardless of the time it has
been used.
Replace the following parts every 4000 hours or

every two years, whichever comes first:
1. Fuel system hoses
2. Rubber hoses for brake piping
3. High pressure hoses in steering circuit
4. High pressure hoses in hoist circuit
5. Hoses at brake cooling inlet and outlet (wheel)
6. Hose at discharge side of brake cooling pump
7. Hose at discharge side of transmission pump
8. Accumulators
Replace the following parts every three years:

1. Seat belt

10 HOUR (DAILY) INSPECTION
Perform a walk around" inspection prior to each work shift. Check the general condition of the truck. Look for evi-
dence of hydraulic leaks. Check all lights and mirrors for dirt and damage. Check the operator's cab for dirty or
damaged accessories or controls. Inspect the frame, sheet metal and body for cracks. Notify the proper mainte-
nance authority if any discrepancies are found.
Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________
TASK COMMENTS CHECKED INITIALS

Check all fluid levels
1.
a. Engine Oil-
NOTE: Refer to engine manufacturer service manual
for oil recommendations.
b. Radiator - Check coolant level and fill with

proper mixture as shown in Anti-Freeze Rec-
ommendations at the beginning of this chap-
ter.
c. Batteries - Check electrolyte level and add

water if necessary.
d. Hydraulic Tank - Check oil level in tank, add if

necessary. Lube key C. Refer to Hydraulic
Tank Service, in this chapter.
NOTE: Check the oil level with the truck on a level
surface, engine stopped, body down, and oil warm.
Oil must be visible in sight glass. Do not overfill.
e. Transmission - Check oil level. Add oil if nec-

essary. Lube key C.
Refer to Transmission Oil Level Check in this
chapter.
f. Fuel Tank - Fill as required.
g. Differential - On a level surface, the oil level

must be even with the plug hole. Refill with
oil, as necessary. Lube key B.

10 HOUR (DAILY) INSPECTION (continued)


1. Air Cleaners
Check air cleaner vacuum gauges. Clean or replace
filter elements if restriction vacuum reaches 6.2 kPa
(25 in. H2O). Push the reset button on the face of the
gauge to return to zero.
2. Drive Belts
a. Check the condition of the alternator and fan
belts. Check for proper tension.
b. Inspect belt alignment.
3. Engine And Turbochargers

Inspect for leaks, vibrations or odd noises.
4. Tires
a. Check for proper inflation and wear.
b. Inspect for embedded debris, cuts or other
damage.

250 HOUR INSPECTION

INITIAL 250 HOUR SERVICE
1. Perform the following maintenance after operating the

machine for the first 250 hours. Thereafter, these ser-
vices are to be performed at the normal interval
schedules, as specified.
a. Transmission - change oil and filter elements.
b. Hydraulic System- change oil and filter ele-
ments.
c. Differential Case - change oil.
d. Final Drive Case - change oil.
EVERY 250 HOURS SERVICE
1. Lubrication -
a. Check the automatic lubrication system to
ensure an ample grease supply is reaching
pins and bearings.
- Dump body hinge pin - 2 points.
- Rear suspension - 4 points.
- Axle support pins - 8 points.
- Hoist cylinder pin - 4 points.
- Front suspension assembly - 8 points.
- Steering cylinder pin - 4 points.
- Steering linkage - 5 points.
- Front transmission mount - 1 point.
b. Refill grease reservoir - Lube key D. Reser-
voir capacity is approximately 29 l (7.7 gal) or
27 kg (60 lbs) of grease.
2 Engine - Refer to the engine service manual for oil

recommendations.
- change engine oil.
- change engine lube oil filter.

250 HOUR INSPECTION (continued)


3 Alternator Belt - Check the alternator belt for cracks,
cuts or glazing. Check for proper tension. Repair or
adjust as necessary.
4 Air Conditioner Compressor Belt- Check the com-

pressor belt for cracks, cuts or glazing. Check for
proper tension. Repair or adjust as necessary.
5 Fan Belt - Check the fan belt for cracks, cuts or glaz-
ing. Check for proper tension. Repair or adjust as
necessary.
6 Transmission Case Breathers - Remove breathers,

and disassemble. Remove the filter element, and
clean in solvent. Dry with pressurized air. Reassem-
ble and reinstall.
7 Hydraulic Tank Breather - Remove breather, and dis-

assemble. Remove the filter element and replace.
Reassemble and reinstall.
8 Differential Case - Check the oil level. Lube key B.
9 Differential Case Breather - Remove breather. Clean

the breather and reinstall.
10 Final Drive Case - Check the oil level in RH and LH

case. Lube key B.
11 Parking Brake - Measure brake pads for proper wear

and thickness. Refer to Section J, Parking Brake, for
limits and specifications.
Lube key D.
12 Fuel Filters
Remove and replace fuel filter elements.
13 Corrosion Resistors - Remove and replace corrosion

resistor elements.

500 HOUR INSPECTION
Perform the maintenance items for the 250 hour interval at this time, also.


1 Radiator - Check for clogged or damaged fins. Refer
to Section C, Cooling System, for more information on
radiator maintenance.
2 Transmission Oil Filter -

a. Remove and replace the two filter elements.
b. Remove and replace control valve filter.
Refer to Section F for transmission service informa-

tion.
3 Check Toe-In Adjustment - Check the steering toe-in

adjustment and inspect the tires for abnormal wear.
Adjust as necessary. Refer to Section G3 for the
adjustment procedure.
4 Bladder Accumulators - Pressure must be checked

every 500 hours. Failure to maintain correct pressure
may result in bladder failures. Refer to the appropriate
section for details on bladder accumulator repair.
Comprehensive instructions are outlined for properly
maintaining bladder accumulators.

1000 HOUR INSPECTION
Perform the maintenance items for the 250 and 500 hour intervals at this time, also.


1 Parking brake
-Manually lubricate the parking brake linkage at 6
points - Lube key D.
2 Transmission Oil -
a. Drain oil, remove and replace element.
Remove clean, and reinstall strainer. Refill
sump with oil - Capacity, approximately 153 l
(41 gal). Lube key C.
b. Remove and clean the three transmission
magnetic strainers.
Refer to Section F for more information on servicing
the transmission.
3 Steering, Brake, Hoist, & Rear Brake Cooling Oil Fil-

ters - Replace the filters.
4 Front & Rear Brake Wear - Refer to Section J for

proper inspection procedures.
5 Engine Breather - Remove and clean the engine

breather. Refer to the engine service manual.

Perform the maintenance items for the 250, 500 and

1000 hour intervals at this time, also.

1 Hydraulic Tank Oil -
a. Drain the oil from the tank and refill. Capacity
of the hydraulic tank is 576 l (152 gal). Refer
to the lubrication chart for type of oil to use.
Lube key C.
b. Remove and clean hydraulic tank strainers.
Refer to Hydraulic Tank Service in this chapter for
proper filling instructions. Instructions
2 Front Wheel Hubs - Drain the hydraulic oil from each

front wheel drain plug. Ensure the plugs are in the six
oclock position when draining.
Drain the hydraulic tank prior to removing the

drain plugs from the wheel hubs.
3 Final Drive - Position the machine so that the case

casting line is horizontal and the drain plug is at the
bottom. Drain the oil and reinstall the plug. Remove
the fill plug at casting line and fill until oil reaches the
plug hole. Service both final drives.
Capacity is 120 l (32 gal) on each side. Lube key B.
4 Differential Case - Drain the oil from the differential.

Refill until oil reaches the fill plug hole. Oil capacity is
300 l (79 gal). Lube key B.

Perform the maintenance items for the 250, 500, 1000 and 2000 hour intervals at this time, also.


1 Engine Driveline Adapter - Inspect driveline adapter
rubber dampers. If any defects are found, repair as
required.
2 Front And Rear Drive Shafts -

a. Grease the U-joints on each drive shaft.
Refer to lube key F on the lubrication chart.
b. Inspect both front and rear drive shafts for
binding, wear, vibration, etc. If U-joint dam-
age or roughness is noted, both U-joints on a
given shaft must be replaced.
Refer to Section F for replacement procedures.
3 Front Wheel Bearings - Check front wheel bearing

adjustments. Refer to Section G. Refill the hydraulic
tank. Refer to Hydraulic Tank Service in this chapter.
4 Front Suspensions - Drain the front suspension oil.

Disassemble and inspect the upper flange internal
bearing. Replace any worn parts. Refill the suspen-
sion with clean oil and recharge with nitrogen.
Refer to section H for service information on the sus-
pensions.
5 Prelub System - Inspect system components for

damage, leakage, etc.

SECTION P3
AUTOMATIC LUBRICATION SYSTEM
INDEX
AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-3

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-3
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-7
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9
INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-10
LUBRICANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P3-11
Pump Housing Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P3-11
Pump Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P3-11
INJECTORS (SL-1 Series H)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12
Injector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12
Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12
SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-13
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-13
SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-14
Lubrication Controller Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-14
Lubrication Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-14
Lubrication Controller Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-14
Lubrication Controller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-14
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-16
PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
Daily Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-18
1000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-19
PUMP REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-20
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-23
P03028 04/08 Automatic Lubrication System P3-1

NOTES
P3-2 Automatic Lubrication System 04/08 P03028

AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
The automatic lubrication system is a pressurized
lubricant delivery system which delivers a controlled
amount of lubricant to designated lube points. The
system is controlled by an electronic controller which
signals a solenoid valve to operate a hydraulic motor
powered grease pump. Hydraulic oil for pump opera-
tion is supplied by the truck steering circuit.
Grease output is proportional to the hydraulic motor
input flow. A pump control manifold, mounted on top
of the hydraulic motor, controls input flow and pres-
sure. A 24VDC solenoid mounted on the manifold
turns the pump on and off.
The pump is driven by the rotary motion of the
hydraulic motor, which is then converted to recipro-
cating motion through an eccentric crank mecha-
nism. The reciprocating action causes the pump
cylinder to move up and down. The pump is a posi-
tive displacement, double-acting type pump. Grease
output occurs on both the up and the down stroke.
FIGURE 3-1. PUMP & RESERVOIR COMPONENTS

1. Hose From Filter 7. Vent Valve
2. Outlet to Injectors 8. Pressure Gauge*
3. Hydraulic Motor 9. Pump Assembly
4. Pressure Reducing 10. Flow Control Valve
Valve 11. Pressure Switch
5. Solenoid Valve 12. Grease Reservoir
6. Test Switch 13. Vent Hose
NOTE: *Newer models do not come equipped with

a pressure gauge. A gauge may be installed in the
port if desired.

During the down stroke, the pump cylinder is
extended into the grease. Through the combination
of shovel action and vacuum generated in the pump
cylinder, the grease is forced into the pump cylinder.
Simultaneously, grease is discharged through the
outlet of the pump. The volume of grease during
intake is twice the amount of grease output during
one cycle. During the upstroke, the inlet check valve Over-pressurizing of the system, modifying
closes, and one half the grease taken in during the parts, using incompatible chemicals and fluids,
previous stroke is transferred through the outlet or using worn or damaged parts, may result in
check and discharged to the outlet port. equipment damage and/or serious personal
injury.
DO NOT exceed maximum working pressure
for any component in the system.
DO NOT alter or modify any part of this
system unless factory authorization.
DO NOT attempt to repair or disassemble the
equipment while the system is pressurized.
Ensure all fluid connections are securely
tightened before using this equipment.
Read and follow the fluid manufacturer's
recommendations regarding fluid
compatibility.
Check all equipment regularly and repair.
Replace worn or damaged parts immediately.
This equipment generates very high grease pres-

sure. Use extreme caution when operating this
equipment. Pressurized grease can pierce the
skin causing serious bodily injury. Adequate pro-
tection such as safety goggles and protective
clothing is recommended.
If fluid penetrates the skin, get medical care

immediately! Do not treat as a simple cut. Tell the
attending physician exactly what fluid was
injected.

FIGURE 3-2. AUTOMATIC LUBRICATION SYSTEM ARRANGEMENT
Group Lube Location A 3 Injectors Group Lube Location G 3 Injectors
Group Lube Location B 3 Injectors Group Lube Location H 3 Injectors
Group Lube Location C 3 Injectors Group Lube Location J 4 Injectors
Group Lube Location D 3 Injectors Group Lube Location K 3 Injectors
Group Lube Location E 5 Injectors Group Lube Location L 3 Injectors
Group Lube Location F 3 Injectors

FIGURE 3-2. LUBE INJECTOR GROUPS
Lube Group Number of Injectors Injector Point of Lubrication
RH front suspension, top
A 3 RH front suspension, rear A-arm
RH front suspension, front A-arm
LH front suspension, top
B 3 LH front suspension, rear A-arm
LH front suspension, front A-arm
RH steering cylinder, spindle
C 3 RH tie rod, spindle
RH front suspension, bottom A-arm
LH steering cylinder, spindle
D 3 LH tie rod, spindle
LH front suspension, bottom A-arm
RH steering cylinder, frame
LH steering cylinder, frame
E 5 LH tie rod, pivot
RH tie rod, pivot
Center steering pivot, frame
Rear axle, bottom LH bar frame
F 3 LH hoist cylinder, frame
Transmission, front mount
Rear axle, top front bar frame
G 3 Rear axle, bottom RH bar frame
RH hoist cylinder, frame
LH rear suspension, frame
H 3 LH hoist cylinder, body
LH body pivot
Rear axle, top sway bar, frame
J 4 RH rear suspension, frame
RH hoist cylinder, body
RH body pivot
LH rear suspension, axle
K 3 Rear axle, top front bar, axle
Rear axle, top sway bar, axle
Rear axle, bottom RH bar, axle
L 3 LH rear suspension, frame
RH rear suspension, axle

SYSTEM COMPONENTS
Filter Solenoid Valve
A filter assembly mounted on the grease reservoir fil- Solenoid valve (5), when energized, allows oil to flow
ters the grease from the shop supply. A bypass indi- to the hydraulic motor.
cator alerts service personnel when the filter requires
replacement.
Flow Control Valve
Flow control valve (10) mounted on the manifold,
Hydraulic Motor and Pump
controls the amount of oil flow to the hydraulic motor.
Hydraulic motor (3, Figure 3-1) and pump (9) The flow control valve has been factory adjusted. DO
together are a fully hydraulic grease pump. An inte- NOT attempt to adjust the setting.
grated pump control manifold is incorporated with the
motor to control input flow and pressure.
NOTE: The pump crankcase oil level must be Vent Valve
maintained to the level of the pipe plug port. If Vent valve (7, Figure 3-1) opens and closes to con-
necessary, refill with 10W-30 motor oil. trol the pressure in the system. With the valve
closed, the pump continues to operate until maxi-
mum grease pressure is achieved. As this occurs,
the vent valve opens and allows the grease pressure
to drop to 0, so the injectors can recharge for their
next output cycle.
Hydraulic oil supply inlet pressure must not
exceed 20 685 kPa (3000 psi). Exceeding the
rated pressure may result in damage to system Injectors
components and personal injury.
Each injector (Figure 3-2) delivers a controlled
amount of pressurized lubricant to a designated lube
point.
Grease Reservoir
Grease reservoir (12) has an approximate capacity of
41 kg (90 lbs) of grease. When the grease supply is Lubrication Timer
replenished, grease entering the system passes
through the filter to remove contaminants before set- Lubrication timer (1, Figure 3-3) is a solid state con-
tling into the reservoir. troller providing a 24 VDC timed-interval signal to
energize solenoid valve (5, Figure 3-1). Operation of
the solenoid valve controls the oil flow to operate the
hydraulic motor. This controller is mounted in the
Pressure Reducing Valve
electrical compartment in the rear of the cab.
Pressure reducing valve (4), located on the manifold,
reduces the hydraulic supply pressure from the truck
steering circuit. Hydraulic pressure is reduced to an Pump Cutoff Pressure Switch (Optional)
operating pressure of 2240 to 2415 kPa (325 to 350
psi). The hydraulic motor operates at this pressure to - Normally Open (N.O.), 17, 237 kPa (2500 psi)
drive the grease pump. The pressure reducing valve Pressure switch (11, Figure 3-1) de-energizes the
has been factory adjusted. DO NOT attempt to adjust pump solenoid relay when the grease line pressure
the setting. reaches the switch pressure setting. When the con-
tacts close, the motor and pump are actuated off.
This switch is used when the lubrication controller dip
switch is set to controller.

Pressure Gauge
Pressure gauge (8, Figure 3-1) monitors hydraulic oil
pressure to the inlet of the hydraulic motor.
NOTE: Newer models do not come equipped with a
pressure gauge. However, a gauge may be installed
in the port if desired.
Pump Cutoff Pressure Switch (Optional)

Pump cutoff pressure switch (11, Figure 3-1) de-
energizes the pump solenoid relay when the grease
pressure reaches the set pressure. This switch is
used when the lubrication controller dip switch is set
to controller.
Remote Fill Port

A remote fill port (1, Figure 3-4) is located on the RH
bumper. Indicator light (2) will illuminate when the
system grease level is full.
FIGURE 3-4. REMOTE FILL PORT

1. Fill Port 2. Indicator Light
FIGURE 3-3. LUBRICATION CONTROLLER

LOCATION
(Covers and controller panel, not shown.)
1. Lubrication Timer 2. Cab Rear Electrical

Compartment

SYSTEM OPERATION
1. During truck operation, the lubrication controller 5. During this period, the injectors will meter the
will energize the system at a preset time inter- appropriate amount of grease to each lubrica-
val. tion point.
2. The controller provides 24 VDC to energize the 6. When the timing period is complete, the control-
pump solenoid valve. The solenoid controls the ler will remove the power from the pump sole-
hydraulic oil provided by the steering circuit. noid valve.
The hydraulic oil drives the motor and pump. 7. After the pump solenoid is de-energized,
3. Hydraulic oil pressure from the steering circuit hydraulic pressure in the manifold drops and
is reduced to 2240 to 2413 kPa (325 to 350 psi) vent valve (11) will open. When the vent valve
by pressure reducing valve (4, Figure 3-5) opens, grease pressure in the lines is released
before entering the motor. The amount of oil to the injector banks. When this occurs, the
supplied to the pump is limited by flow control injectors are then able to recharge for the next
valve (6). Pump pressure can be read using lubrication cycle.
gauge (5) mounted on the manifold. 8. The system will remain at rest until the lubrica-
4. With oil flowing into the hydraulic motor, the tion controller turns on and initiates a new
grease pump suctions grease from the reser- grease cycle.
voir. Grease output from the pump flows
through check valve (10) to injectors (13) and to
vent valve (11).
FIGURE 3-5. HYDRAULIC SCHEMATIC
1. Hydraulic Oil Return 6. Flow Control Valve 11. Vent Valve

2. Hydraulic Oil Supply 7. Hydraulic Motor 12. Orifice
3. Pump Solenoid Valve 8. Grease Pump 13. Injector Bank
4. Pressure Reducing Valve 9. Pressure Switch
5. Motor Pressure Gauge 10. Check Valve

INJECTOR OPERATION
STAGE 1.
Injector piston (2) is in its normal or rest
position. Discharge chamber (3) is filled with
lubricant from the previous cycle. With pres-
sure applied from incoming lubricant (6),
slide valve (5) is about to open passage (4)
leading to measuring chamber (1).
STAGE 2.
When slide valve (5) opens to passage (4),
lubricant (6) is admitted to measuring cham-
ber (1). This forces lubricant from discharge
chamber (3) through outlet port (7) to the
lubrication destination.
STAGE 3.
As injector piston (2) completes its stroke, it
pushes slide valve (5) past passage (4). This
stops further admission of lubricant (6) to
passage (4) and measuring chamber (1).
Injector piston (2) and slide valve (5) remain
in this position until lubricant pressure in sup-
ply line (6) is vented.
STAGE 4.
After venting, the injector spring expands,
causing slide valve (5) to move. As the valve
moves, passage (4) and discharge chamber
(3) connect through valve port (8). Further
expansion of the spring causes the piston to
move upward. This forces the grease into
measuring chamber (1) through passage (4)
and valve port (8). Discharge chamber (3)
refills.
The injector is now ready for the next cycle.

LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Check the oil level at
1000 hour intervals. To add oil, remove plug (4, Fig-
ure 3-6) and fill the housing to the bottom of the plug
hole.
Pump Pressure Control

High pressure hydraulic fluid from the truck steering
system is reduced to 2240 to 2413 kPa (325 to 350
psi) by pressure reducing valve (1). The reducing
valve is located on the manifold on top of the pump
motor. Operating pressure can be read on the gauge
installed on the manifold. Occasionally check the
gauge to verify pressure is within the specified range.
The pressure reducing valve is not adjustable. If FIGURE 3-6. PUMP CONTROLS
operating pressure is not within limits, the pressure 1. Pressure Reducing 3. Pressure Gauge
reducing valve must be replaced. Valve 4. Oil Level Plug
2. Test Switch 5. Flow Control Valve

INJECTORS (SL-1 Series H))
Injector Specifications
Each lube injector services only one grease
point. In case of pump malfunction, each injector
is equipped with a covered grease fitting to allow
the use of manual lubrication equipment.
Injector output volume:
Maximum output = . . . . . . . 1.31 cc (0.08 in3)
Minimum output = . . . . . . . 0.13 cc (0.008 in3)
Operating Pressure:
Minimum - . . . . . . . . . . 12,755 kPa (1850 psi)
Maximum - . . . . . . . . . . 24,133 kPa (3500 psi)
Recommended - . . . . . 17,238 kPa (2500 psi)
Maximum Vent Pressure - (Recharge)
4,137 kPa (600 psi)
Injector Adjustment
FIGURE 3-7. TYPE SL-1 INJECTOR
The injectors may be adjusted to supply from 0.13 cc
to 1.31 cc (0.008 in3 to 0.08 in3) of lubricant per injec- 1. Adjusting Screw 11. Spring Seat
tion cycle. The injector piston travel distance deter- 2. Locknut 12. Plunger
mines the amount of lubricant supplied. Piston travel 3. Piston Stop Plug 13. Viton Packing
is controlled by an adjusting screw in the top of the 4. Gasket 14. Inlet Disc
injector housing. 5. Washer 15. Viton Packing
6. Viton O-Ring 16. Washer
Turn adjusting screw (1, Figure 3-7) counterclock- 7. Injector Body Assy. 17. Gasket
wise to increase injector output and clockwise to 8. Piston Assembly 18. Adapter Bolt
decrease injector output. 9. Fitting Assembly 19. Adapter
When the injector is not pressurized, maximum injec- 10. Plunger Spring 20. Viton Packing
tor delivery volume is attained by turning the adjust-
ing screw (1) fully counterclockwise. Turn until the
NOTE: Piston assembly (8) has a visible indicator
indicating pin (8) just touches the adjusting screw. At
pin at the top of the assembly to verify injector
the maximum delivery point, about 9.7 mm (0.38 in.)
operation.
of adjusting screw threads will be exposed. Decrease
the delivered lubricant amount by turning the adjust-
ing screw clockwise to limit injector piston travel. If
only half the lubricant is needed, turn the adjusting
screw to the point where about 4.8 mm (0.19 in.)
threads are exposed. The injector will be set at the
minimum delivery point with about 0.22 mm (0.009
in.) thread exposed.
NOTE: The information above relates only to the
adjustment of injector delivery volume. The timer
adjustment must also be changed if overall lubricant
delivery is inadequate or excessive. Do not adjust
Injector output to less than one-fourth capacity.

SYSTEM PRIMING
The system must be full of grease and free of air
pockets to function properly. After maintenance, if the
primary or secondary lubrication lines were replaced,
it will be necessary to prime the system to purge
entrapped air.
1. Fill the reservoir with lubricant, if necessary.
2. To purge air from the main supply line, remove
the main supply line at the reservoir and con-
nect an external grease supply to the line.
3. Remove plugs from each injector group in
sequence (right front, left front, and rear axle).
4. Using the external grease source, pump grease
until it reaches the injector group. Install the
pipe plug and repeat for the remaining injector
groups.
5. Remove the caps from each injector. Connect
an external grease supply to the zerk on the
injector. Pump until grease reaches the far end
of the individual grease hose or the joint being
greased.
Filter Assembly
Replace element (5, Figure 3-8) if bypass indicator
(2) indicates excessive element restriction.
FIGURE 3-8. FILTER ASSEMBLY
1. Housing 6. Spring
2. Bypass Indicator 7. Bowl
3. O-Ring 8. O-Ring
4. Backup Ring 9. Plug
5. Element

SYSTEM CHECK
To check system operation (not including timer), pro- The fourth dip switch is used to select memory off
ceed as follows: or memory on. When the switch is set to memory
1. Start the engine. off, a lube cycle will occur each time power is turned
on. The lube cycle will start at the beginning of the on
2. Actuate the lube system test switch at the reser- time setting.
voir/pump assembly.
3. The motor and pump should operate until the When the switch is set to memory on, the controller
system attains 17,237 kPa (2500 psi). will function as follows:
4. Once the required pressure is achieved, turn When power is turned off between lube cycles,
the pump motor off. The system should vent. the lube cycle will resume at the point of inter-
ruption after power is restored. In other
5. Check for pump, hose or injector damage.
words, the controller will remember its posi-
Check for leakage with the system pressurized.
tion in the cycle.
6. After checking the system, shut the engine off.
When power is turned off during a cycle, the
controller will reset to the beginning of the
lube cycle after power is restored.
Lubrication Controller Check
Pressing the manual lube button on the enclosure
cover will initiate a lube event. (See Figure 3-9). Off time switch (1) is used to select units of time.
Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or
30. The mode switch determines whether the off time
units will be minutes or hours.
Lubrication Controller Operation
Cover (3) contains three Light Emitting Diode (LED)
The time between lube events is determined by the windows and a manual lube switch. The LEDs indi-
setting of the rotary switch and the dip switch. The cate system operation and status. When power is on,
rotary switch selects the numeral setting, and the dip a green LED will illuminate. When the pump is on,
switch selects the units in either minutes or hours. another green LED will illuminate. A red LED will illu-
minate when an alarm condition occurs.
The manual lube switch, when depressed, will initiate
Lubrication Controller Components
a lube cycle.
Mode switch (2, Figure 3-9) consists of four dip
switches. The first dip switch controls the maximum
amount of on time, either 30 seconds or 120 sec-
onds.
Lubrication Controller Adjustment
The second dip switch controls the mode, either
timer mode or controller mode. When the switch is The lubrication controller is factory adjusted to the
set to the timer mode, the amount of time that the following switch settings:
pump is on will be determined by the setting of the Dip switch 1 . . . . . . . . . . . . . . . . . . . . . . 120 seconds
dip switch - 30 seconds or 120 seconds. When the
switch is set to the controller mode, a pressure Dip switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . timer
switch must be installed in the lube supply line. The Dip switch 3 . . . . . . . . . . . . . . . . . . . . . . . . . . minutes
pressure switch will detect supply line pressure, and
will reset the timer at a set pressure. If the pump fails Dip switch 4 . . . . . . . . . . . . . . . . . . . . . . . memory off
to reach the set pressure within the dip switch set
time, the controller will initiate an alarm.
Rotary Switch . . . . . . . . . . . . . . . . . . . . . 15 minutes
The third dip switch is for selecting the units for the
off time. This setting is to be used in conjunction
with off time switch (1). Hours or minutes may be
selected.

FIGURE 3-9. LUBRICATION TIMER
1. Off Time Switch 3. Cover

2. Mode Switch

SYSTEM TROUBLESHOOTING CHART
NOTE: If the following procedures do not correct the
problem, contact a factory authorized service center.
Symptom Possible Causes Corrective Action

Lube system not grounded. Correct grounding connections to pump assem-
bly and truck chassis.
Electrical power loss. Locate cause of power loss and repair. 24 VDC
power required. Ensure key switch is ON.
Pump Does Not Operate
Controller malfunction. Replace the controller assembly
Solenoid valve malfunctioning. Replace the solenoid valve assembly
Motor or pump malfunction. Repair or replace motor and/or pump assembly.
Refer to the service manual for rebuild instruc-
tions.
Pump Will Not Prime Low lubricant supply. Dirt in reservoir, pump inlet clogged, filter
clogged.
Air trapped in lubricant supply line. Prime system to remove trapped air.
Pump Will Not Build Lubricant supply line leaking. Check lines and connections to repair leakage.
Pressure
Vent valve leaking. Clean or replace vent valve.
Pump worn or scored. Repair or replace pump assembly. Refer to the
service manual for rebuild instructions.
NOTE: Normally during operation, the injector indicator stem will move into the
body of the injector when pressure builds. When the system vents and releases
pressure, the indicator stem will again move out into the adjusting yoke.
Malfunctioning injector - usually indi- Replace individual injector assembly.
Injector Indicator Stem cated by the pump building pressure
Does Not Operate and then venting.
All injectors inoperative - pump build up Service and/or replace pump assembly. Refer to
not sufficient to cycle injectors. the service manual for rebuild instructions.
No system pressure to the pump motor. Check hydraulic hose from steering system.
Pressure Gauge Does Not No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system.
Register Pressure
Pressure reducing valve not functioning Refer to Pump Pressure Control.
properly.

Symptom Possible Causes Corrective Action
Pump Pressure Builds Very No signal at solenoid. Check timer.

Slowly Or Not At All
Controller Does Not No electric power to controller. Turn on electric power to pump. POWER
Operate LED should light, PUMP ON LED should
light when MANUAL LUBE is pressed.
PUMP ON LED is lit, But Printed circuit board failure. Remove and replace.
Load Connected To Termi-
nals 3 & 4 Will Not Energize
Load Connected To Termi- Printed circuit board failure or key- Remove and replace.
nals 3 & 4 Energized, But pad failure.
PUMP ON LED Does Not
Light
Controller memory mode is off. Switch controller memory mode to ON.

Bearing Points
Excessively Lubricated
Injector output adjustment setting Readjust to lower setting.

too high.
Timer/controller cycle time setting Set to longer cycle time or reevaluate lube
too low. requirements.
Injector output adjustment setting Readjust injector output setting.

Bearing Points Are Not too low.
Sufficiently Lubricated
Timer/controller cycle time setting Set to shorter cycle time or reevaluate lube
does not deliver lubricant often requirements.
enough.
System too large for pump output. Calculate system requirements per plan-
ning manual.

PREVENTATIVE MAINTENANCE
Use the following maintenance procedures to ensure
proper system operation. 3. Check the grease reservoir level.
Daily Lubrication System Inspection a. Fill the reservoir as needed. Check the filter
bypass indicator when filling the reservoir.
1. Check grease reservoir level.
Replace the element if grease is bypassing.
Inspect grease level height after each shift of
operation. Grease usage should be consistent b. Check the reservoir for contaminants. Clean,
from day-to-day operations. if necessary.
Lack of lubricant usage would indicate an inop- c. Ensure all filler plugs, covers and breather
erative system. Excessive usage would indi- vents on the reservoir are intact and free of
cate a broken supply line. contaminants.
2. Check filter bypass indicator when filling reser- 4. Inspect all bearing points for a bead of lubricant
voir. Replace element if bypassing. around the bearing seal.
3. Check all grease feed line hoses from the SL-1 5. System Checkout
injectors to the lubrication points. a. Remove all SL-1 injector cover caps to allow
a. Repair or replace all damaged hoses. visual inspection of the injector cycle indica-
tor pins during system operation.
b. Ensure all air is purged and all new hoses
are filled with grease before truck operation. b. Start the engine.
4. Inspect key lubrication points for a bead of lubri- c. Actuate manual test switch (17, Figure 3-2).
cant around the seals. If a lubrication point The hydraulic motor and grease pump
appears dry, troubleshoot and repair the prob- should operate.
lem.
d. With the grease pressurized, check each SL-
NOTE: It is good practice to manually lube each 1 injector assembly.
bearing point at the grease fitting provided on each The cycle indicator pin should be retracted
Injector. This will indicate if there are any frozen or inside the injector body.
plugged bearings, and will help flush the bearings of
e. When the system reaches 17,237 kPa (2500
contaminants.
psi), the pump should shut off. The pressure
in the system should drop to zero, venting
back to the grease reservoir.
250 Hour Inspection
f. With the system vented, check all of the SL-1
1. Check all grease hoses from the SL-1 injectors injector indicator pins; all of the pins should
to the lubrication points. See Figure 3-2. be visible. Replace or repair injectors, if
a. Repair or replace all worn or broken hoses. defective.
b. Ensure all air is purged and all new hoses g. Reinstall all injector cover caps.
are filled with grease before truck operation. h. Check controller operation.
2. Check all grease hoses from the pump to the NOTE: With the engine on, the lube system should
SL-1 injectors. activate within 5 minutes. The system should build
a. Repair or replace all worn or broken hoses. 13,790 to 17,237 kPa (2000 to 2500 psi) within 25-40
seconds.
b. Ensure all air is purged and all new hoses
are filled with grease before truck operation.

i. If the system is working properly, the
machine is ready for operation.
j. If the system is malfunctioning, refer to the
troubleshooting chart.
1000 Hour Inspection

1. Check the pump housing oil level. Fill to the bot-
tom of the plug hole with SAE 10W-30 motor oil.

PUMP REBUILD
10. Remove the crankrod assembly (items 1
through 8) from the pump by unscrewing button
head screws (11) and pulling out wrist pin
bushings (12).
11. Remove check seat (27) from reciprocating tube
Be certain to bleed steering accumulators to (20).
relieve hydraulic pressure and to relieve pump
outlet grease pressure before removing any NOTE: There is a 3/8 in. allen head socket in the
hoses or fittings. throat of the check seat housing to facilitate removal.
Disassembly
12. Unscrew wrist pin anchor (13) from the
1. Remove four socket head screws (32, Figure 3-
reciprocating tube and pull the plunger
10). Separate manifold (37) from hydraulic
assembly (items 8 through 19) from the tube.
motor (42).
2. Remove pipe plug (45) and drain the crankcase 13. Using a 13 mm (0.50 in.) diameter wooden or
oil from pump housing (46). plastic rod, push cup seal (21) and pump
cylinder (23) from the reciprocating tube.
3. Remove six screws (28). Remove housing
cover (29) and cover gasket (30). 14. Remove pump plunger (19) from plunger rod
(16). A spanner wrench, which uses the holes in
4. Remove inlet screen (60), retaining ring (57)
the pump plunger, is required.
and pull shovel plug (56) from housing tube
(55). 15. Unscrew the plunger rod from plunger tube (10)
5. Remove two socket head screws (44). and slide off cup seal (15), backup washer (14)
Separate hydraulic motor (42) from pump and wrist pin anchor (13).
housing (46). 16. Unscrew the plunger tube from outlet pin (8).
6. Remove two outlet pin nuts (50) from the pump 17. To dismantle the crankrod assembly (items 1
housing. through 7), remove flat head screws (1) and
7. Remove the pump subassembly (items 1 counterweights (2).
through 27) from the pump housing. Pushing
18. Remove the small retaining rings (6) and press
the subassembly up with a 19 mm (0.75 in.)
the crank eccentric (7) out of the ball bearing
diameter wooden or plastic rod against check
(8). Support the ball bearing on the inner race.
seat housing (27) is helpful.
8. Remove housing tube (55) from the pump
housing by inserting a 19 mm (0.75 in.)
diameter rod through the inlet holes at the
bottom of the housing tube and unscrewing it.
9. Remove bronze bearing (51), O-ring (52),
backup washer (53), and O-ring (54) from the
housing tube.

FIGURE 3-10. LUBE PUMP ASSEMBLY
1. Screw
49. O-Ring
2. Counterweight
50. Outlet Pin Nut
3. Retaining Ring
51. Bronze Bearing
4. Crankrod
52. O-Ring
5. Retaining Ring
53. Backup Washer
6. Crank Eccentric
54. O-Ring
7. Ball Bearing
55. Housing Tube
8. Outlet Pin
56. Shovel Plug
9. O-Ring
57. Retaining Ring
10. Plunger Tube
58. Orifice Fitting
11. Screw
59. Gasket
12. Wrist Pin Bushing
60. Inlet Strainer
13. Wrist Pin Anchor
14. Backup Washer
15. Cup Seal
16. Plunger Rod
17. Spring
18. Steel Ball
19. Plunger
20. Reciprocating Tube
21. Cup Seal
22. O-Ring
23. Cylinder
24. Ball Cage
25. Steel Ball
26. O-Ring
27. Check Seat
28. Screw
29. Housing Cover
30. Cover Gasket
31. Gauge
32. Screw
33. Override Switch
34. Override Knob
35. Solenoid Valve
36. Connector
37. Manifold
38. Pressure Reducing Valve
40. O-Ring
41. Gasket
42. Hydraulic Motor
43. Washer
44. Screw
45. Pipe Plug
46. Pump Housing
47. Backup Ring
48. O-Ring

1. Discard all seals and gaskets. Repair kits are 4. Assemble wrist pin anchor (13), backup washer
available containing all the necessary seals and (14), cup seal (15) and plunger rod (16) onto the
gaskets for reassembly. Refer to the plunger tube. Tighten to 11 - 12 Nm (100 - 110
appropriate parts book. lb in.).
2. Clean and inspect the following parts. Replace 5. Assemble spring (17), ball (18), and plunger
if excessive wear is evident: (19) on the plunger rod. Tighten the plunger to
11 - 12 Nm (100 - 110 lb in.).
Ball bearing (7)
6. Install reciprocating tube (20) onto wrist pin
Crank eccentric (6) anchor (13). Tighten to 27 - 34 Nm (20 - 25 lb
Crankrod (4) ft).
7. Install cup seal (21), O-ring (22), cylinder (23),
Wrist pin bushings (12)
ball cage (24), ball (25), O-ring (26) and check
Plunger tube (10) seat (27) into reciprocating tube (20). Tighten
Pump plunger & upper check parts (19, 18 & 17) the check seat to 27 - 34 Nm (20 - 25 lb ft).
8. Assemble the crank rod assembly to the pump
Pump cylinder (23)
with bushings (12) and button head screws (11).
Check seat housing/lower check ball (27, 25) Tighten the screws to 11 - 14 Nm (100 - 125 lb
Upper bronze bearing (51) in.).
9. Place pump subassembly (items 1 through 26)
Housing tube (55)
into pump housing (46).
Shovel plug (56)
10. Install new O-ring (54), backup washer (53) and
Reciprocating tube (20) O-ring (52) and bronze bushing (51) into
housing tube (55).
11. Install housing tube assembly onto pump
Assembly housing (46). Make sure that reciprocating tube
Note: Use Loctite 242 (or equivalent) thread locker (21) is inserted through both bushings. Using a
on all torqued, threaded connections. Use extreme 19 mm (0.75 in.) diameter rod through the inlet
care to prevent thread locker from flowing into holes at bottom of tube, tighten to 27 - 34 Nm
adjacent areas such as clearance fits and ball check. (20 - 25 lb ft).
Allow a minimum of 30 minutes cure time before 12. Install shovel plug (56) and retainer (57).
operating pump.
13. Install new backup rings (47), O-rings (48 & 49),
1. Support ball bearing (7, Figure 3-10) inner race and outlet pin nuts (50). Tighten to 41 - 47 Nm
and press crank eccentric (6) into the bore. (30 - 35 lb ft).
Install small retaining rings (5).
14. Install gasket (41) and motor (42) on pump
2. Assemble the ball bearing assembly, large housing (46). Install washers (43) and socket
retaining rings (3), and counterweights (2) in head screws (44). Tighten to 68 - 75 Nm (50 -
crankrod (4), and install flat head screws (1). 55 lb ft).
Tighten to 11 - 12 Nm (100 - 110 lb in.).
15. Install shovel plug (56) in housing tube (55).
3. Using new O-ring (9), install plunger tube (10)
Install retaining ring (57).
on outlet pin (8). Tighten to 11 - 12 Nm (100 -
110 lb in.).

16. Install gasket (30), cover (29) and six self-
tapping screws (28) on the pump housing.
17. Using new O-rings (40), install manifold (37) on
motor (42). Install socket head screws (33).
Tighten to 27 - 34 Nm (20 - 25 lb ft).
18. If removed, install pressure reducing valve (38)
into manifold (37). Tighten to 27 - 34 Nm (20 -
25 lb ft).
19. If removed, install flow control valve (39) into
manifold (37). Tighten to 27 - 34 Nm (20 - 25 lb
ft).
20. If removed, install solenoid valve (34) into
manifold (37). Tighten to 20 - 27 Nm (15 - 20 lb
ft).
21. With the pump assembly in its normal operating
position, add SAE 10W-30 motor oil to the
pump housing until the oil is level with the
bottom of pipe plug (45) hole. Install the pipe
plug.

SECTION R
SYSTEM SCHEMATICS
INDEX
HYDRAULIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM3670
HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40C) . . . . . . . . . . . . . . . . . . . . . . . . . . EM7477
BRAKE SYSTEM SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EL5433
HOOKUP SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XS4490
ELECTRICAL WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XS4400
HVAC WIRING SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE484
R01095 Index R1-1

NOTES
R1-2 Index R01095

EM3670-1 FEB 08
HYDRAULIC SCHEMATIC
HD1500-7
A30001 & UP
EM7477-1 FEB 08
HYDRAULIC SCHEMATIC
COLD WEATHER (-40 C)
HD1500-7
A30035 & UP
EL5433-1 NOV 07
BRAKE SCHEMATIC
HD1500-7
A30001 & UP
XS4490-1 NOV 07
HOOKUP SCHEMATIC
SHEET 1 - PAGE 1
HD1500-7 w/ SDA12V160 ENGINE
A30001 and UP
XS4490-1 NOV 07
SHEET 1 - PAGE 2
XS4490-1 NOV 07
SHEET 1 - PAGE 3
XS4490-1 NOV 07
SHEET 1 - PAGE 4
XS4490-1 NOV 07
HOOKUP SCHEMATIC
SHEET 2 - PAGE 1
A30001 and UP
XS4490-1 NOV 07
SHEET 2 - PAGE 2
XS4490-1 NOV 07
SHEET 2 - PAGE 3
XS4490-1 NOV 07
SHEET 2 - PAGE 4
XS4401 JUNE 07
ELECTRICAL SCHEMATIC
INDEX AND SYMBOLS
A30001 and UP
SHEET 1 OF 21
XS4402 JUNE 07
MAIN POWER AND STARTER CIRCUITS
A30001 and UP
SHEET 2 OF 21
XS4403 JUNE 07
ELECTRONIC DISPLAY PNL I/O'S
A30001 and UP
SHEET 3 OF 21
XS4404 JUNE 07
ENGINE CONTROLS
A30001 and UP
SHEET 4 OF 21
XS4405 JUNE 07
TRANSMISSION INPUTS
A30001 and UP
SHEET 5 OF 21
XS4406 JUNE 07
TRANSMISSION CONTROLS
A30001 and UP
SHEET 6 OF 21
XS4407-1 NOV 07
RCM CONTROLLER INPUTS
A30001 and UP
SHEET 7 OF 21
XS4408 JUNE 07
BRAKE SOLENOID CONTROLS
A30001 and UP
SHEET 8 OF 21
XS4409 JUNE 07
VHMS CONTROLLER
A30001 and UP
SHEET 9 OF 21
XS4410 JUNE 07
CONTROLLER COMMUNICATIONS NETWORK
A30001 and UP
SHEET 10 OF 21
XS4411 JUNE 07
MISCELLANEOUS CONTROL CIRCUITS
A30001 and UP
SHEET 11 OF 21
XS4412-1 NOV 07
TURN SIGNAL, CLEARANCE & BRAKE LIGHTS
A30001 and UP
SHEET 12 OF 21
XS4413 JUNE 07
FOG AND HEAD LIGHTS
A30001 and UP
SHEET 13 OF 21
XS4414 JUNE 07
WORK LAMPS & MISC. CIRCUITS
A30001 and UP
SHEET 14 OF 21
-THIS UNIT ONLY APPLIES TO S/N 1-48. S/N 49 AND UP SEE HE484 SCHEMATIC, SECTION R.
XS4415 JUNE 07
AIR CONDITIONER & HEATER CIRCUITS
A30001 and UP
SHEET 15 OF 21
XS4416 JUNE 07
24VDC & 12VDC POWER CKT SUMMARY
A30001 and UP
SHEET 16 OF 21
XS4417 JUNE 07
24V POWER CIRCUIT SUMMARY
A30001 and UP
SHEET 17 OF 21
XS4418-1 NOV 07
GROUND CIRCUIT SUMMARY
A30001 and UP
SHEET 18 OF 21
XS4419 JUNE 07
FRAME & ISOLATED GRD. CKT SUMMARY
A30001 and UP
SHEET 19 OF 21
XS4420-1 NOV 07
COMPONENT LOCATOR
A30001 and UP
SHEET 20 OF 21
XS4421 JUNE 07
CIRCUIT NUMBER IDENTIFIER LOCATOR
A30001 and UP
SHEET 21 OF 21
HD1500-7 A30049 and UP
730E A30552 and UP
830E A30891 and UP
830E-AC A30174 and UP
930E-4 A30693 and UP
HE484 FEB 07
HEATER / AIR CONDITIONER CONTROLS
Sheet 1 of 1

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CEBM021000

SERIAL NUMBERS A30049 and UP

Replacement parts manufactured and supplied by unauthorized sources may not be

A00036 Introduction A-1

Danger identifies a specific potential hazard

Warning identifies a specific potential hazard

Caution is used for general reminders

A-2 Introduction A00036

TRANSMISSION AND TORQUE CONVERTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F

DRIVE AXLE, SPINDLES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G

OPTIONS AND SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P

A00036 Introduction A-3

A-4 Introduction A00036

MAJOR COMPONENTS & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

GENERAL SAFETY AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

STANDARD TORQUE CHARTS AND CONVERSION TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

A01001 02/94 Index A1-1

A1-2 Index 02/94 A01001

The cab provides for wide visibility, with an integral

A02077 Major Components and Specifications A2-1

A2-2 Major Components and Specifications A02077

A02077 Major Components and Specifications A2-3

Loaded (150 Ton Payload)

A2-4 Major Components and Specifications A02077

A03036 04/08 General Safety and Operating Instructions A3-1

A3-2 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-3

Fire Prevention For Fuel And Oil

A3-4 General Safety and Operating Instructions 04/08 A03036

Fire Extinguisher And First Aid Kit

A03036 04/08 General Safety and Operating Instructions A3-5

A3-6 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-7

A3-8 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-9

Voltage Minimum Safety Distance

A3-10 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-11

Any time personnel are required to perform main-

1. To hold the dump body in the raised position,

A3-12 General Safety and Operating Instructions 04/08 A03036

FIGURE 3-1. SECURING THE DUMP BODY

1. Dump Body 2. Body Retention Cable

A03036 04/08 General Safety and Operating Instructions A3-13

Personnel Spilled fuel and oil may cause

Working Under The Machine

A3-14 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-15

A3-16 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-17

A3-18 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-19

A03036 04/08 General Safety and Operating Instructions A3-21

26. Check the coolant in the radiator using the cool-

If the engine is hot, allow the coolant to cool

A3-22 General Safety and Operating Instructions 04/08 A03036

1. Ensure all personnel are clear of the truck

Starting fluid is extremely volatile and flammable!

A03036 04/08 General Safety and Operating Instructions A3-23

A3-24 General Safety and Operating Instructions 04/08 A03036

A03036 04/08 General Safety and Operating Instructions A3-25