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630E
DUMP TRUCK
SERIAL SUFFIX
AFE42-M
and up
AFE46-U
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.
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.
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.
CEHQ000700 - Komatsu America International Company 12/99
EMISSION CONTROL WARRANTY
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)
1. Products Warranted
Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively Komatsu) produce and/or
market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the
Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to
these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.
2. Coverage
Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the
time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in
workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as
measured from the date of delivery of the engine to the ultimate purchaser.
3. Limitations
Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for
failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant
or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in
or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water,
dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, downtime expense, related damage, fines, all business
costs or other losses resulting from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.
GARANTIE SUR LE CONTRLE DES MISSIONS
NONC DE GARANTIE SUR LE CONTRLE DES MISSIONS (APPLICABLE AU CANADA SEULEMENT):
1. Produits garantis:
Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la
mise en march de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les missions sapplique tous les
nouveaux moteurs portant le nom Komatsu, installs dans ces produits et utiliss au Canada dans des machines conues pour utilisation industrielle non-
routire. Cette garantie sapplique seulement sur les moteurs produits partir du 1er Janvier 2000. Cette garantie sera administre par la distribution de
Komatsu au Canada.
2. Couverture:
Komatsu garantit lacheteur ultime et chaque acheteur subsquent que le moteur est conu, construit et quip en toute conformit, au moment de la vente
par Komatsu, avec toutes les Rglementations fdrales amricaines sur les missions applicables au moment de la fabrication et quil est exempt de dfauts
de construction ou de matriaux qui auraient pour effet de contrevenir ces rglementations en dedans de 5 ans ou 3000 heures dopration, mesur partir
de la date de livraison du moteur au client ultime.
3. Limitations:
Les bris, autres que ceux rsultant de dfauts de matriaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu nest pas responsable pour
bris ou dommages rsultant de ce que Komatsu dtermine comme tant de labus ou ngligence, incluant mais ne se limitant pas : lopration sans
lubrifiants ou agent refroidissants adquats; la suralimentation dessence; la survitesse; le manque dentretien des systmes de lubrification, de
refroidissement ou dentre; de pratiques non-propices dentreposage, de mise en marche, de rchauffement, de conditionnement ou darrt; les
modifications non-autorises du moteur. De plus, Komatsu nest pas responsable de bris causs par de lessence inadquate ou de leau, des salets ou autres
contaminants dans lessence. Komatsu nest pas responsable des rparations non-relies au moteur, des dpenses encourues suite aux temps darrts, des
dommages relatifs, amendes, et de tout autre cot daffaires ou autres pertes rsultant dun bris couvert par la garantie.
KOMATSU NEST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSQUENTS.
Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL NY A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIRE.
INFORMATION IMPORTANTE SUR LE MOTEUR
CE MOTEUR EST CONFORME AUX NORMES AMRICAINES DELEPA (ANNE DU
MODLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI-
TION PAR COMPRESSION. CE MOTEUR EST CERTIFI POUR OPERATION ESSENCE
DISEL.
AVERTISSEMENT
DES BLESSURES PEUVENT RSULTER ET LA GARANTIE
SANNULER SI LES RPM DU TAUX DESSENCE OU LALTITUDE
EXCDENT LES VALEURS MAXIMALES PUBLIES POUR CE
MODLE ET SON APPLICATION.
IMPORTANT ENGINE INFORMATION
THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
MODLE DU MOTEUR
WARNING
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.
NO. SRIE
FAMILLE DU MOTEUR
ENGINE MODEL SERIAL NO.
DPLACEMENT
SYSTME DE
CONTROLE DES
MISSIONS DCHAPPEMENT
ENGINE FAMILY DISPLACEMENT LITERS
EXHAUST EMISSION
CONTROL SYSTEM
FIRING ORDER 1 - 5 - 3 - 6 - 2 - 4 LITRES
CHARGE DE SORTIE ADV.
ADV. LOAD OUTPUT
Kw ( HP) RPM
SQUENCE DE MISE FEU
PORTE DE VALVE FROID
(mm)
VALVE LASH
COLD (mm)
IN. EX. FUEL RATE
AT ADV.
mm
3
/STROKE
mm
3
/BATTEMENT
TAUX DESSENCE ADV.
VITESSE STATIQUE
IDLE SPEED RPM FAMILY EMISSION LIMIT
INITIAL INJECTION
TIMING
DEG. BTDC DATE OF MANUFACTURE
LIMITE DMISSION DE
LA FAMILLE
RGLAGE DE LALLUMAGE -
INJECTION INITIALE
_____________________________________________ KOMATSU LTD.
MADE IN JAPAN
DATE
DE FABRICATION
DEG. BTDC
KOMATSU LTE
FABRIQU AU JAPON
ENGINE DATAPLATE - ENGLISH / FRENCH
A00004 7/95 Introduction A-1
FOREWORD
This Service Manual is written for use by the service technician and is designed to help the technician become fully
knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per-
sonnel should read and understand the materials in this manual before performing maintenance and/or operational
checks on the truck. All safety notices, warnings and cautions should be understood and followed when accom-
plishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well as other gen-
eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major ser-
viceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator
group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire
mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed
repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict
a specific model.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to "Right",
"Left", "Front", or "Rear" are made with respect to the operators normal seated position, unless specifically stated
otherwise.
Standard torque requirements are shown in torque charts in the general information section and individual torques
are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have 10%
tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig-
nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
(Gross Vehicle Weight) rating.
The HAULPAKModel designation consists of three numbers and one letter (i.e. 630E). The three numbers repre-
sent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an Electrical
propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the original man-
ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and othercompo-
nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
(GVW) and this means the total weight: the Empty Vehicle Weight +the fuel &lubricants +the payload.
To determine allowable payload:
Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners,
tailgates, etc.) and then weigh truck.
Record this value and subtract from the GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often
as practical.
Exceeding the allowable payload will reduce expected life of truck components.
For Model 630E HAULPAKTrucks, optional heavy duty components may be required to utilize the630,000 lbs.
(286 020 kg) GVW. Contact factory if clarification is needed.
A-2 Introduction A00004 7/95
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.
WARNING identifies a specific potential hazard
WHICH MAY RESULT in either INJ URY OR DEATH if
proper precautions are not taken.
DANGER identifies a specific potential hazard
WHICH WILL RESULT in either INJ URY OR DEATH if
proper precautions are not taken.
This ALERT symbol is used with the signal words,
CAUTION, DANGER, and WARNING in this
manual to alert the reader to hazards arising from
improper operating and maintenance practices.
A00004 7/95 Introduction A-3
TABLE OF CONTENTS
SUBJ ECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE, FUEL, COOLING AND AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRIC SYSTEM (24 VDC. NON-PROPULSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
ELECTRIC PROPULSION AND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
DRIVE AXLE, SPINDLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
HYDRAIR
II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M
OPERATORS CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
A-4 Introduction A00004 7/95
KOMATSU 630E HAULPAK TRUCK
A01001 02/94 Index A1-1
SECTION A
GENERAL INFORMATION
INDEX
MAJ OR COMPONENTS & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1
GENERAL SAFETY AND TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1
WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1
STANDARD TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1
STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-1
A1-2 Index 02/94 A01001
NOTES
A2-1 Major Component Description A02028
MAJ OR COMPONENT DESCRIPTION
ENGINE
The 630E HAULPAK
.
Safe practices start before the operator gets to
the equipment!
1. Wear the proper clothing. Loose fitting clothing,
unbuttoned sleeves and jackets, jewelry, etc.,
can catch on a protrusion and cause a potential
hazard.
2. Always use the personal safety equipment pro-
vided for the operator such as hard hat, safety
shoes, safety glasses or goggles. There are
some conditions when protective hearing
devices should also be worn for operator safety.
PREPARING FOR OPERATION
The safest trucks are those which have been prop-
erly prepared for operation. At the beginning of each
shift, a careful check of the truck should be made
before the operator attempts engine start-up.
1. When walking to and from the truck, BE ALERT,
remain a safe distance from all other machines
even if the operator is visible.
2. Check for any oil or coolant leaks. When check-
ing coolant in radiator, use coolant level sight
gauge (if equipped). If necessary to remove
radiator cap, shut down engine, and relieve
coolant pressure SLOWLY before removing
radiator cap.
If engine has been running, allow coolant to cool,
before removing the fill cap or draining radiator.
Serious burns may result if coolant is not allowed
to cool.
Any operating fluid, such as hydraulic oil, or
engine coolant escaping under pressure, can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death, if proper medical treatment by a
physician who is familiar with this type of injury
is not received immediately.
3. Check tires for cuts, damage or "bubbles". Check
tires for proper inflation before beginning shift and
periodically during shift. If tire is warm from opera-
tion, allow tire to cool before adjusting tire
pressure. If inflation is needed, use an air chuck
with extension hose clipped on the tire inflation
valve to allow service from behind the tread of the
tire and away from front of wheel.
Do not stand in front of rim and locking ring
when inflating tire.
4. Visually inspect all headlights, worklights and
taillights and safety equipment for external dam-
age from rocks or misuse. Make sure lenses
are clean.
5. Always use hand rails and ladder when mounting
or dismounting from the truck. Clean your shoes,
ladder, and hand rails of all accumulations, such
as ice, snow, oil, or mud before climbing.
Always mount and dismount the truck facing the
truck. Never attempt to mount or dismount the
truck while it is in motion.
6. Check the deck areas for debris, loose hard-
ware or tools. Become familiar with all protec-
tive equipment devices on the truck and insure
that these items (anti-skid material, grab bars,
seat belts, etc.) are securely in place.
A3-2 General Safety & Operation A03004 7/95
7. Read and understand the contents of the Oper-
ator's Handbook. Give particular attention to
safety material and operating instructions.
Read and understand CAUTION and WARN-
ING decals in the operator's cab.
8. Become thoroughly acquainted with all gauges,
instruments and controls. Be familiar with all
brake and steering system controls and warning
devices, road speeds, and loading capabilities,
before operating the truck.
9. Keep all unauthorized reading material out of
truck cab.
10. Dirt or trash buildup, specifically in the opera-
tor's cab, should be cleared. Do not carry tools
or supplies in cab of truck or on the deck.
11. Insure steering wheel, controls and pedals are
free of any oil, grease or mud.
12. Insure headlights, worklights and taillights are in
proper working order.
13. Insure windshield and all cab windows are clean
and unbroken. Good visibility may prevent an
accident.
14. Check operation of windshield wiper, condition
of wiper blades, and windshield washer reser-
voir for fluid level.
15. Insure adequate ventilation before start-up if the
truck is in an enclosure.
Exhaust fumes are dangerous!
ENGINE START-UP SAFETY PRACTICES
1. Insure all personnel are clear of truck before
starting engine. Always sound the horn as a
warning before actuating any operational con-
trols.
2. Check and insure Selector Switch is in "Neutral"
before starting.
3. If truck is equipped with auxiliary cold weather
heater system(s), do not attempt to start engine
while heaters are in operation.
Damage to coolant heaters will result.
NOTE: If truck is equipped with HMS control system,
refer to Operator Handbook for starting procedures
4. The keyswitch is a three position (Off, Run,
Start) switch. When switch is rotated one posi-
tion clockwise, it is in the "Run" position and all
electrical circuits (except "Start") are activated.
With Selector Switch in "Neutral", rotate key-
switch fully clockwise to "Start" position and
hold this position until engine starts. "Start" posi-
tion is spring loaded to return to "Run" when key
is released.
NOTE: If truck is equipped with the Cummins
Engine Prelube System, a noticeable time delay
will occur (while engine lube oil passages are
being filled) before starter engagement and
engine cranking will begin. The colder the
engine oil temperature, the longer the time
delay will be. In addition, if truck is also
equipped with Engine Starting Aid for cold
weather starting, the Engine Prelube System
should be engaged FIRST for 5-10 seconds, or
until starter is engaged, BEFORE activating the
Engine Starting Aid.
Starting fluid is extremely volatile and flammable!
Use with extreme care.
If truck is equipped with optional Engine Starting Aid
and ambient temperature is below 50F (10C), turn
the keyswitch to the "Start" position, and while crank-
ing engine, move the Engine Starting Aid switch to
the "On" position for three (3) seconds MAXIMUM;
then release Engine Starting Aid. If engine does not
start, wait at least fifteen (15) seconds before repeat-
ing the procedure.
Do not crank an electric starter for more than 30
seconds.
Allow at least two minutes for starter cooling before
attempting to start engine again.
Severe damage to starter motor can result from over-
heating.
A03004 7/95 General Safety & Operation A3-3
AFTER ENGINE HAS STARTED
1. Become thoroughly familiar with steering and
emergency controls. After engine has started
and low pressure and warning systems are nor-
mal, test the truck steering in extreme right and
left directions. If the steering system is not oper-
ating properly, shut engine down immediately.
Determine the steering system problem and
have repairs made before resuming operation.
2. Operate each of the truck's brake circuits at
least twice prior to operating and moving the
truck. These circuits include individual activa-
tion from the operator's cab of the service
brake, parking brake, and brake lock (also
emergency brake, if equipped). With the engine
running and with the hydraulic circuit fully
charged, activate each circuit individually. If any
application or release of any brake circuit
appears sluggish or improper, or if warning
alarms are activated on application or release,
shut the engine down and notify maintenance
personnel. Do not operate truck until brake
circuit in question is fully operational.
3. Check gauges, warning lights and instruments
before moving the truck to insure proper system
operation and proper instrument functioning.
Give special attention to braking and steering
circuit hydraulic warning lights. If warning lights
come on, shut down the engine immediately
and determine the cause.
4. Insure headlights, worklights and taillights are in
proper working order. Good visibility may pre-
vent an accident. Check operation of windshield
wiper.
5. When truck body is in dump position, do not
allow anyone beneath it unless body-up retain-
ing pin or cable is in place.
6. Do not use the fire extinguisher for any purpose
other than putting out a fire! If extinguisher is
discharged, report the occurrence, so the used
unit can be refilled or replaced.
7. Do not leave truck unattended while engine is
running. Shut down engine before getting out of
cab.
SAFETY PRECAUTIONS
DURING TRUCK OPERATION
After the truck engine is started and all systems are
functioning properly, the operator must follow all local
safety rules to insure safe machine operation.
If any of the red warning lights come "On" or if
any gauge reads in the red area during truck
operation, a malfunction is indicated. Stop truck
as soon as safety permits, shut down engine if
problem indicates and have problem corrected
before resuming truck operation.
Operating truck with stalled or free spinning
wheel motors may cause serious damage to
wheel motors! If truck does not begin to move
within 10 seconds after depressing throttle pedal
(Selector Switch in a drive position), release
throttle pedal and allow wheels to regain traction
before accelerating engine again.
At the beginning of each shift, check the automatic
emergency steering for proper operation. This can be
accomplished as follows:
With engine running and steering system fully
charged, no red warning lights or buzzer should
be "on" (HMS trucks should have no warnings
displayed.).
Shut down engine and leave keyswitch in "Run"
position (leave HMS "On").
Turn steering wheel one full turn left and right; if
front wheels turn, system is operating properly.
Restart engine.
NOTE: Automatic Emergency Steering ability is lim-
ited by the capacity of the steering accumulators.
This function is intended to allow the operator only
enough time to steer the HAULPAK
to a safe stop
during an emergency situation.
1. WEAR SEAT BELTS AT ALL TIMES! Operate
the truck only while properly seated with seat
belt fastened. Keep hands and feet inside the
cab compartment while truck is in operation.
2. Do not allow unauthorized personnel to ride in
the truck. Only authorized persons are allowed
to ride in truck cab, and they should have seat
belts fastened. Do not allow anyone to get on or
off truck while it is in motion, or to ride on the
deck or the ladder of the truck.
A3-4 General Safety & Operation A03004 7/95
3. Do not move truck into or out of a building with-
out a signal person present. Know and obey the
hand signal communications between operator
and spotter. When other machines and person-
nel are present, the operator should move in
and out of buildings, loading areas and through
traffic, under the direction of a signalman. Cour-
tesy at all times is a safety precaution!
Always look to the rear before backing the
truck. Watch for and obey ground spotter's hand
signals before making any reverse movements.
Sound the warning horn (3 blasts). Spotter
should have a clear view of the total area at the
rear of the truck.
4. Check gauges and instruments frequently dur-
ing operation for proper readings.
5. DO NOT leave truck unattended while engine is
running. Do not allow engine to run at "Idle" for
extended periods of time. When parking, always
apply parking brake, and park a safe distance
from other vehicles, as determined by supervisor.
6. Report immediately to supervisor any condi-
tions on haul road, pit or dump area that may
present an operating hazard.
7. Observe all regulations pertaining to the job
site's traffic pattern. Be alert to any unusual traf-
fic pattern. Obey the spotter's signals.
8. Match the truck speed to haul road conditions
and slow the truck in any congested area. Keep
a firm grip on steering wheel at all times.
9. Check parking brake periodically during shift.
Use parking brake ONLY for parking. Do not
use park brake for loading / dumping.
Do not attempt to apply parking brake while
truck is moving!
Do not use "Brake Lock" or "Emergency Brake"
(if equipped) for parking.
10. Check brake lock performance periodically for
safe loading and dump operation.
11. Proceed slowly on rough terrain to avoid deep
ruts or large obstacles. Avoid traveling close to
soft edges and the edge of fill area.
12. Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
operating the truck.
13. Keep serviceable fire fighting equipment at hand.
If extinguisher is discharged, report the occur-
rence, so the used unit can be refilled or replaced.
In the event of fire in the tire and wheel area
(including brake fires), stay away from the truck
at least 8 hours until the tire and wheel are cool.
Tire and rim assembly may explode if subjected
to excessive heat. Personnel should move to a
remote or protected location if sensing exces-
sively hot brakes, smell of burning rubber or evi-
dence of fire near tire and wheel area.
If the truck must be approached, such as to fight
a fire, those personnel should do so only while
facing the tread area of the tire (front or back),
unless protected by use of large heavy equip-
ment as a shield. Stay at least 50 ft. (15 m) from
the tread of the tire.
14. Stay alert at all times! In the event of an emer-
gency, be prepared to react quickly and avoid
accidents. If an emergency arises, know where
to get prompt assistance.
LOADING
1. Pull into the loading area with caution. Remain at
a safe distance while truck ahead is being loaded.
2. Do not drive over unprotected power cables.
3. When approaching or leaving a loading area,
watch out for other vehicles and for personnel
working in the area.
4. When pulling in under a loader or shovel, follow
"Spotter" or "Shovel Operator" signals. The
truck operator may speed up loading operations
by observing the location and loading cycle of
the truck being loaded ahead, then follow a sim-
ilar pattern.
5. When being loaded, operator should stay in
truck cab. Place Selector Switch in "Neutral"
and apply brake lock with engine running.
If operator must leave truck cab during loading,
engine must be shut down and parking brake
applied. DO NOT use brake lock or emergency
brake (if equipped) for parking.
Remain far enough away from truck to avoid
being struck by flying material.
6. When loaded, pull away from shovel as quickly
as possible but with extreme caution.
A03004 7/95 General Safety & Operation A3-5
HAULING
1. Always stay alert! If unfamiliar with the road,
drive with extreme caution.
Cab doors should remain closed at all times if
truck is in motion or unattended.
2. Obey all road signs. Operate truck so it is under
control at all times. Govern truck speed by the
road conditions, weather and visibility. Report
haul road conditions immediately. Muddy or icy
roads, pot holes or other obstructions can
present hazards.
3. When backing the truck, give back-up signal
(three blasts on the horn); when starting for-
ward, two blasts on the horn. Sound these
alarms each time the truck is moved forward or
backward.
4. Use extreme caution when approaching a haul
road intersection. Maintain a safe distance from
oncoming vehicles.
5. Maintain a safe distance when following
another vehicle. Never approach another vehi-
cle from the rear, in the same lane, closer than
50 ft. (15 m). When driving on a down grade,
this distance should not be less than 100 ft.
(30 m).
6. Do not stop or park on a haul road unless
unavoidable. If you must stop, move truck to a
safe place, apply parking brake, block wheels
securely, shut down engine and notify mainte-
nance personnel for assistance.
7. Before starting up or down a grade, maintain a
speed that will insure safe driving and provide
effective retarding under all conditions. Refer to
Grade/Speed decal in operator's cab.
8. When operating truck in darkness, or when visi-
bility is poor, do not move truck unless head-
lights are on. Do not back truck if back-up horn
or lights are inoperative. Always dim headlights
when meeting oncoming vehicles.
9. If the "Emergency Steering" light and/or "Low
Brake Pressure Warning" light (if equipped) illu-
minate during operation, steer the truck imme-
diately to a safe stopping area, away from
other traffic, if possible. Refer to item 6 above.
10. The Statex III w/Fuel Enhancement system
monitors wheel motor, ambient, and static
exciter temperatures. If any one of these values
is outside the limits established, the Statex III
controls will cause the engine to increase to
1650 RPM.
(Normal engine RPM for haul road/retarding
operation is 1250 RPM.)
11. When maximum truck speed is reached, haul
trucks equipped with Statex III w/Fuel Enhance-
ment system will experience a DECREASE in
engine RPM.
NOTE: This is different from trucks equipped
with Statex II or Statex III without Fuel Enhance-
ment, which increase RPM upon reaching
speed limit.
12. Check tires for proper inflation periodically dur-
ing shift. If truck has been run on a "flat", or
under-inflated tire, it must not be parked in a
building until the tire cools.
PASSING
1. Do not pass another truck on a hill or blind
curve!
2. Before passing, make sure the road ahead is
clear. If a disabled truck is blocking your lane,
slow down and pass with extreme caution.
3. Use only the areas designated for passing.
DUMPING
1. Pull into dump area with extreme caution. Make
sure area is clear of persons and obstructions,
including overhead utility lines. Carefully
maneuver truck into dump position. Obey sig-
nals directed by the spotter, if present.
2. Avoid unstable areas. Stay a safe distance from
edge of dump area. Position truck on a solid,
level surface before dumping.
As body raises, the truck Center of Gravity (CG)
will move. Truck must be on level surface to pre-
vent tipping / rolling!
3. When in dump position, apply Brake Lock and
move Selector Switch to the "Neutral" position.
A3-6 General Safety & Operation A03004 7/95
To Raise dump body:
The dumping of very large rocks (10% of payload,
or greater) or sticky material (loads that do not
flow freely from the body) may allow the material
to move too fast and cause the body to move
RAPIDLY and SUDDENLY. This sudden move-
ment may jolt the truck violently and cause pos-
sible injury to the operator, and/or damage to the
hoist cylinders, frame, and/or body hinge pins. If
it is necessary to dump this kind of material, refer
to the CAUTION in the following procedure:
4. Pull the lever to the rear to actuate hoist circuit.
(Releasing the lever anywhere during "hoist up"
will place the body in "hold" at that position.)
5. Raise engine RPM to accelerate hoist speed.
Refer to the CAUTION below.
If dumping very large rocks or sticky material as
described in WARNING above, slowly accelerate
engine RPM to raise body. When the material
starts to move, release hoist lever to "HOLD"
position. If material does not continue moving
and clear body, repeat this procedure until mate-
rial has cleared body.
6. Reduce engine RPM as last stage of hoist cylin-
der begins to extend and let engine go to low
idle as last stage reaches half-extension.
7. Release hoist lever as last stage of hoist cylin-
der reaches full extension.
8. After material being dumped clears body, lower
body to frame.
To Lower Body:
Move hoist lever forward to "down" position and
release. Releasing the lever places hoist control
valve in the "float" position allowing the body to
return to frame.
NOTE: If dumped material builds up at the rear of the
body and the body cannot be lowered, shift Selector
Switch to "Forward", release Brake Lock, depress
Override button and drive forward to clear material.
Stop, shift Selector Switch to "Neutral", apply Brake
Lock and lower body.
The HAULPAK
are large
and heavy. Insure that lifting equipment (hoists,
slings, chains, lifting eyes) are of adequate
capacity to handle the lift.
10. Relieve pressure in lines or hoses by shutting
engine down, activating the system to relieve
accumulator pressure, and place all system
controls in neutral before making the discon-
nects.
Any operating fluid, such as hydraulic oil, escap-
ing under pressure can have sufficient force to
enter a person's body by penetrating the skin.
Serious injury and possibly death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
11. Drain, clean and ventilate fuel tanks and/or
hydraulic tanks before making any welding
repairs on these structures.
12. After adjustments or repairs, replace all shields,
screens and clamps.
13. Tire Care:
Mounting and demounting a multi-piece tire and
rim assembly can be extremely dangerous. An
incorrect assembly can blow apart leading to
extensive property damage, severe injury, or
even death for anyone in its trajectory path.
Before servicing tire and rim assemblies, read
all available publications on proper tire handling
and safety instructions.
Do not stand in front of rim and locking ring
when inflating/deflating tire mounted on vehicle.
Inflate ONLY to tire manufacturer's recommenda-
tion.
Use an air chuck with extension hose clipped on
the tire inflation valve to allow service from
behind the tread of the tire.
DO NOT weld or apply heat on the rim assembly
with the tire mounted on the rim. Resulting gases
inside the tire may ignite, causing explosion of
tire and rim.
When jacking a vehicle, DO NOT rely entirely on
vehicle braking system; use chocks to block the
wheels on opposite side from jack.
DO NOT remove any rim or wheel mounting
hardware, such as nuts or clamps, before
COMPLETELY exhausting all air from the tire, or
both tires on a dual assembly.
DO NOT reuse cracked, damaged, or worn rim
parts. Replace with new parts.
DO NOT mix/assemble rim parts of different
designs. If in doubt of compatibility, consult rim
manufacturer.
DO NOT use a steel hammer to aid assembly.
Use soft mallets only.
14. Only a qualified operator or experienced main-
tenance personnel who are also qualified in
operation should move the truck under its own
power to the repair facility or in road testing
after repairs are complete.
A3-8 General Safety & Operation A03004 7/95
SAFE PARKING PROCEDURES
The operator must continue the use of safety precau-
tions when preparing for parking and engine shut-
down.
In the event that the equipment is being worked in
consecutive shifts, any questionable truck perfor-
mance the operator may have noticed must be
checked by maintenance personnel before the truck
is released to another operator.
1. The truck should be parked on level ground, if
at all possible. If parking must be done on a
grade, the truck should be positioned at right
angles to the grade.
2. The parking brake must be applied and/or
chocks placed fore/aft of wheels so that the
truck cannot roll. Each truck should be parked
at a reasonable distance from another.
3. Haul roads are not safe parking areas. In an
emergency, pick the safest spot most visible to
other machines in the area. If the truck
becomes disabled where traffic is heavy, mark
the truck with warning flags in daylight or flares
at night.
SHUTDOWN PROCEDURE
The following procedure (1. - 4.) should be followed
at each engine shutdown.
1. Stop truck. Reduce engine RPM to low idle.
Place Selector Switch in "Neutral" and apply
parking brake.
2. Allow engine to cool gradually by running at low
idle for 3 to 5 minutes.
NOTE: If truck is equipped with HMS control
system, refer to Operator Handbook for shut-
down procedure.
3. With truck stopped and engine cooled down,
turn keyswitch counterclockwise to "Off" for nor-
mal shutdown of engines equipped with elec-
tronic engine controls (MTU, Detroit Diesel w/
DDEC, or Cummins w/Centry Fuel Control).
If engine does not shutdown with keyswitch,
use engine shutdown switch (*) and hold switch
down until engine stops.
* For 445E - 685E, this is the Engine Shutdown
Switch on center console (see "Operator Con-
trols" in Operator Handbook).
* For 830E, this is the instrument panel Emer-
gency Engine Shutdown switch (see "Instru-
ments and Indicators" in Operator Handbook).
4. With keyswitch "Off", and engine stopped, wait
at least 90 seconds. Insure steering circuit is
completely bled down by turning steering wheel
back and forth several times. No front wheel
movement will occur when hydraulic pressure is
relieved.
NOTE: A switch is located at lower left front of truck
for ground level engine shutdown.
5. Close and lock all windows, remove key from
keyswitch and lock cab to prevent possible
unauthorized truck operation. Dismount truck
properly.
A04015 1/91 Warnings and Cautions A4-1
WARNINGS AND CAUTIONS
A plate is located on the front left corner by the lad-
der. This plate indicates the location of the ground
level engine shutdown switch.
A warning plate is mounted around the key switch on
the instrument panel. The warning stresses the
importance of reading and understanding the opera-
tor's manual before operation.
A warning plate is mounted on top of the instrument
panel above the voltmeter and ammeter.
The voltmeter indicates the condition of the batteries.
Normal indicated voltage at high RPM is 27 to 28
volts with batteries in fully charged condition.
The ammeter indicates the charging or discharging
rate of the batteries.
A warning plate is mounted directly under the red
warning lights in the instrument panel and warns that
the truck should not be operated if any red warning
lights on. If any of the red warning lights come on,
safely stop truck, shut down engine, notify mainte-
nance.
A warning plate is mounted on the instrument panel
around the Parking Brake switch and the Wheel
Brake Lock switch.
The Parking Brake switch is for parking only. Truck
must be completely stopped before applying parking
brake or damage may occur to parking brake. Park-
ing brake is not designed to stop a moving truck.
NOTE: Do not use parking brake at shovel or dump.
The Wheel Brake Lock should be used only with
engine running during dumping and loading
operations, or when brake pedal is inoperative.
Wheel Brake Lock must NOT be used for parking
truck with engine shut down. Under these conditions,
pressure will bleed down and wheel brakes will NOT
hold truck.
The following paragraphs give an explanation of the Warning, Caution, and Service Instruction plates and decals
attached to the HAULPAK
truck. The plates and decals listed are typical of this model HAULPAK
, but 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 can no longer be read because of
deterioration or damage, it should be replaced with a new one.
A4-2 Warnings and Cautions A04015 1/91
A warning plate is mounted on the instrument panel
around the "Dry/Slippery Road" switch on the instru-
ment panel. It warns that the slippery road position
reduces front wheel braking effort while maintaining
full braking of the rear wheels. Reduced braking of
the front wheels assists in steering control on slip-
pery roads but increases stopping distance.
The Dry / Slippery road control switch permits the
operator to select either full braking capability at all
wheels for "dry" road or reduced braking at the front
wheels for "slippery" road.
A warning plate is located inside the operator's cab to
define maximum speed to be used when descending
various grades with a loaded truck. This chart will
vary depending on tire size and wheel motors.
Attached to the exterior of the battery compartment is
a danger plate. This plate stresses the need to keep
from making any sparks near the battery. When
another battery or 24VDC power source is used for
auxiliary power, all switches must be Off prior to mak-
ing any connections. When connecting auxiliary
power cables, positively maintain correct polarity;
connect the positive (+) posts together and then con-
nect the negative (-) lead of the auxiliary power cable
to a good frame ground. Do not connect to the neg-
ative posts of the truck battery or near the battery
box. This hookup completes the circuit but minimizes
danger of sparks near the batteries.
Sulfuric acid is corrosive and toxic. Use proper safety
gear, goggles, rubber gloves and rubber apron when
handling and servicing batteries.
A04015 1/91 Warnings and Cautions A4-3
A danger plate and a warning plate are attached to
the hydraulic brake accumulators mounted on deck
at rear of cab. The danger plate provides instructions
on how to relieve hydraulic pressure prior to loosen-
ing or disconnecting any hydraulic lines or compo-
nents while accumulators are under pressure. These
plates are also located on the cabinet behind cab.
The warning plate is also located on the inside of the
box cover.
The engine cooling system is controlled by thermo-
stats which keep coolant temperature between 160-
190F (71-89C) during operation. Unless the pres-
sure is first released, removing the radiator cap after
engine has been running for a time will result in the
hot coolant being expelled from the radiator. Serious
scalding and burning can result. The warning plate is
mounted on top of the radiator grille near the radiator
cap.
Warning plates are mounted on the frame just in front
of and to the rear of the front tires. Technicians mak-
ing adjustments while the truck is being steered are
warned the clearances change when the truck is
steered and could cause serious injury.
An instruction plate is applied to the side of the
hydraulic tank. This plate furnishes instructions for
filling of the hydraulic tank.
Keep the system open to the atmosphere only as long
as absolutely necessary to lessen chances of system
contamination. Service the tank with clean Type C-4
hydraulic oil. All oil being put into the hydraulic tank
should be filtered through 3 micron filters.
A caution decal is attached under the hydraulic tank
oil level sight gauge. With body down, engine
stopped, and oil level below top of sight glass, add oil
per filling instructions.
A4-4 Warnings and Cautions A04015 1/91
The dump procedure for a disabled truck is located
on the left side of the torque tube near the hoist
valve. This decal provides the operator or technician
with the proper hook-up procedure for dumping a
loaded disabled truck.
A warning plate is attached to the hydraulic tank to
alert technicians that hydraulic oil becomes heated
during operation and care must be taken to avoid
burns when it is necessary to open the hydraulic sys-
tem. There is always a chance of residual pressure
being present. Open fittings slowly to allow any pres-
sure to bleed off before removing any connections.
Any operating fluid, such as hydraulic oil or
brake fluid escaping under pressure, can have
sufficient force to enter a person's body by pene-
trating the skin. Serious injury and possibly
death may result if proper medical treatment by a
physician familiar with this injury is not received
immediately.
Warning plates are attached to both the hydraulic
and fuel tank to alert technicians not to work on the
truck with the body in the raised position unless
body-up safety devices are in position.
A steering procedure for a disabled truck is located
on the left frame rail near the unloader valve. This
decal provides the operator or technician with the
proper hookup procedure for steering on a disabled
truck. Quick disconnects are located at the bottom of
the bleeddown manifold.
A warning decal is located on the left top corner of
the operator's cab. This decal states that the cab
assembly must not be lifted by using the handrail.
A04015 1/91 Warnings and Cautions A4-5
High Voltage Danger Plates and Caution Plates are
attached to both doors of the Electrical Control Cabi-
net. The High Voltage Plate is also attached to the
blown grid housing, extended range housing, rectifier
housing, inlet duct structure and rear hatch cover.
A wheel motor oil level decal is attached to the gear
cover on both electric wheel motors. This decal
stresses the fact that the truck must be on a level
surface and parked for 20 minutes prior to checking
the oil level. This is necessary in order to get an
accurate reading.
A warning plate is located near the HOT START con-
nection which is attached to the back side of the front
bumper on the left side of the truck. This warning
plate states that the engine should not be started
while the optional HOT START is in operation. Oper-
ators should observe this area during Ground Level
Inspection and be certain that this option is discon-
nected from the truck before starting engine.
A decal is attached to the frame rail near the hoist
cylinder creep down valve which is located on the
hydraulic tank. This decal states that the body may
be lowered in a controlled manner by opening the
valve and allowing the hoist cylinders to slowly
retract.
A danger plate is attached to or near the steering
accumulator mounting bracket. This plate alerts tech-
nicians to read the warning label attached to the top
of the steering accumulator prior to releasing internal
nitrogen pressure or disconnecting any hydraulic
lines or hardware.
A4-6 Warnings and Cautions A04015 1/91
A danger plate is attached to each suspension cylin-
der and steering accumulator. The plate contains
instructions for releasing internal pressure prior to
disconnecting any hydraulic lines or hardware.
A Product Identification plate is located on the frame
in front of the right side front wheel and gives Model
Number, Maximum G.V.W. and the Product Identifi-
cation Number.
The Lubrication Chart is located on the left hand side of the radiator grille. Refer to the Lubrication Sec-
tion in this service manual for more complete lubrication instructions.
A05001 12/99 Standard Torque Chart and Tables A5-1
STANDARD CHARTS AND TABLES
This manual provides dual dimensioning for most spec-
ifications. U.S. standard units are specified first, with
metric (SI) units in parentheses. References through-
out the manual to standard torques or other standard
values will be to one of the following Charts or Tables.
For values not shown in any of the charts or tables,
standard conversion factors for most commonly used
measurements are provided in TABLE XIII, page 1-14.
INDEX OF TABLES
TABLE I . . . . . . . Standard Torque Chart (SAE) . . A5-1
TABLE II . Standard Torque, 12-Point, Grade 9 . . A5-2
TABLE III . . Standard Metric Assembly Torque . . A5-2
TABLE IV. . . . . . J IC Swivel Nuts Torque Chart . . A5-3
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . A5-3
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . A5-3
TABLEVII . . . . O-Ring Face Seal Torque Chart . . A5-3
TABLE VIII . Torque Conversions (ft.lbs. - N.m) . . A5-4
TABLE IX. . Torque Conversions (ft.lbs. - kg.m) . . A5-4
TABLE X . . . Pressure Conversions (psi - kPa) . . A5-4
TABLE XI . . Pressure Conversions (psi - MPa) . . A5-5
TABLE XII . . . . . . . .Temperature Conversions . . A5-5
TABLE XIII . . .Common Conversion Multipliers . . A5-6
EFFECT OF SPECIAL LUBRICANTS
On Fasteners and Standard Torque Values
KOMATSU engineering department does NOT recom-
mend the use of special friction-reducing lubricants
such as, Copper Coat, Never Seize, and other simi-
lar products on the threads of standard fasteners
where standard torque values are applied.
The use of special friction-reducing lubricants will sig-
nificantly alter the clamping force being applied to fas-
teners during the tightening process.
If special friction-reducing lubricants are used with the
Standard Torque values listed below in Table I (and
in Komatsu shop manuals), excessive stress and pos-
sible breakage of the fasteners may result.
Where Torque Tables specify Lubricated Threads for
the Standard Torque values listed, these standard
torque values are to be used with simple lithium
base chassis grease (multi-purpose EP NLGI) or a
rust- preventive grease (see list, page 1-10) on the
threads and seats, unless specified otherwise.
NOTE: Always be sure threads of fasteners and
tapped holes are free of burrs and other imperfec-
tions before assembling.
Standard torque values are not to be used when
Turn-of-the-Nut tightening procedures are rec-
ommended.
TABLE I. -STANDARD TORQUE CHART
SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
(LUBRICATED THREADS) - TOLERANCES 10%
Cap-
screw
Thread
Size
TORQUE -
GRADE 5
TORQUE -
GRADE 8
Cap-
screw
Thread
Size
TORQUE -
GRADE 5
TORQUE -
GRADE 8
ft. lbs. kg.m N.m ft. lbs. kg.m N.m ft. lbs. kg.m N.m ft. lbs. kg.m N.m
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 ft. lbs. =0.138 kg.m =1.356 N.m
Grade 5
Grade 8
A5-2 Standard Torque Chart and Tables 12/99 A05001
Standard Assembly Torques For 12-Point, Grade 9,
Capscrews (SAE)
The following specifications apply to required assembly
torques for all 12-Point, Grade 9 (170,000 psi minimum
tensile), Capscrews.
Capscrew threads and seats SHALL be lubri-
cated when assembled.
Unless instructions specifically recommend other-
wise, these standard torque values are to be used
with simple lithium base chassis grease (multi-pur-
pose EP NLGI) or a rust-preventive grease (see list,
this page) on the threads.
Torques are calculated to give a clamping force
of approximately 75% of proof load.
The maximum torque tolerance shall be 10% of
the torque value shown.
Standard Metric Assembly Torque For Class 10.9
Capscrews & Class 10 Nuts
The following specifications apply to required assembly
torques for all metric Class 10.9 finished hexagon head
capscrews and Class 10 nuts.
Capscrew threads and seats SHALL NOT be
lubricated when assembled. These specifications
are based on all capscrews, nuts, and hardened
washers being phosphate and oil coated.NOTE:
If zinc-plated hardware is used, each piece must
be lubricated with a Rust Preventive Grease or
Lithium-base grease to achieve the same clamp-
ing forces provided below.
Torques are calculated to give a clamping force
of approximately 75% of proof load.
The maximum torque tolerance shall be within
10% of the torque value shown.
Suggested* Sources for Rust Preventive Grease:
AMERICAN ANTI-RUST GREASE #3-X from Stan-
dard Oil Company (also American Oil Co.)
GULF NORUST #3 from Gulf Oil Company.
MOBILARMA 355, Product No. 66705 from Mobil
Oil Corporation.
RUST BAN 326 from Humble Oil Company.
RUSTOLENE B GREASE from Sinclair Oil Com-
pany.
RUST PREVENTIVE GREASE - CODE 312 from
the Southwest Grease and Oil Company.
* NOTE: This list represents the current Engineer-
ing approved sources for use in Komatsu manufac-
ture. It is not exclusive. Other products may meet
the same specifications of this list.
TABLE II. - STANDARD ASSEMBLY TORQUE
for 12-Point, Grade 9 Capscrews
CAPSCREW
SIZE*
TORQUE
ft. lbs.
TORQUE
N.m
TORQUE
kg.m
0.250 - 20 12 16 1.7
0.312 - 18 24 33 3.3
0.375 - 16 42 57 5.8
0.438 -14 70 95 9.7
0.500 -13 105 142 14.5
0.562 - 12 150 203 20.7
0.625 - 11 205 278 28.3
0.750 - 10 360 488 49.7
0.875 - 9 575 780 79.4
1.000 - 8 860 1166 119
1.000 - 12 915 1240 126
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
This table represents standard values only. Do not use these val-
ues to replace torque values which are specified in assembly
instructions.
TABLE III. - STANDARD METRIC ASSEMBLY TORQUE
CAPSCREW
SIZE*
TORQUE
N.m
TORQUE
ft.lbs.
TORQUE
kg.m
M6 x1 12 9 1.22
M8 x 1.25 30 22 3.06
M10 x 1.5 55 40 5.61
M12 x 1.75 95 70 9.69
M14 x 2 155 114 15.81
M16 x 2 240 177 24.48
M20 x 2.25 465 343 47.43
M24 x 3 800 590 81.6
M30 x 3.5 1600 1180 163.2
M36 x 4 2750 2028 280.5
* Shank Diameter (mm) - Threads per millimeter
This table represents standard values only. Do not use these val-
ues to replace torque values which are specified in assembly
instructions.
A05001 12/99 Standard Torque Chart and Tables A5-3
TABLE IV.
TORQUE CHART FOR JIC 37 SWIVEL NUTS
WITH OR WITHOUT O-RING SEALS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
2 0.125 0.312 24 4 1
3 0.188 0.375 24 8 3
4 0.250 0.438 20 12 3
5 0.312 0.500 20 15 3
6 0.375 0.562 18 18 5
8 0.500 0.750 16 30 5
10 0.625 0.875 14 40 5
12 0.750 1.062 12 55 5
14 0.875 1.188 12 65 5
16 1.000 1.312 12 80 5
20 1.250 1.625 12 100 10
24 1.500 1.875 12 120 10
32 2.000 2.500 12 230 20
TABLE V.
TORQUE CHART FOR
PIPE THREAD FITTINGS
SIZE
CODE
PIPE
THREAD
SIZE
WITH
SEALANT
FT. LBS.
WITHOUT
SEALANT
FT. LBS.
2 0.125 27 15 3 20 5
4 0.250 18 20 5 25 5
6 0.375 18 25 5 35 5
8 0.500 14 35 5 45 5
12 0.750 14 45 5 55 5
16 1.000 11.50 55 5 65 5
20 1.250 11.50 70 5 80 5
24 1.500 11.50 80 5 95 10
32 2.000 11.50 95 10 120 10
TABLE VI.
TORQUE CHART FOR
O-RING BOSS FITTINGS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
2 0.125 0.312 24 4 2
3 0.188 0.375 24 5 2
4 0.250 0.438 20 8 3
5 0.312 0.500 20 10 3
6 0.375 0.562 18 13 3
8 0.500 0.750 16 24 5
10 0.625 0.875 14 32 5
12 0.750 1.062 12 48 5
14 0.875 1.188 12 54 5
16 1.000 1.312 12 72 5
20 1.250 1.625 12 80 5
24 1.500 1.875 12 80 5
32 2.000 2.500 12 96 10
TABLE VII.
TORQUE CHART FOR
O-RING FACE SEAL FITTINGS
SIZE
CODE
TUBE SIZE
(O.D.)
THREADS
UNF-2B
TORQUE
FT. LBS.
4 0.250 0.438 20 11 1
6 0.375 0.562 18 18 2
8 0.500 0.750 16 35 4
10 0.625 0.875 14 51 5
12 0.750 1.062 12 71 7
16 1.000 1.312 12 98 6
20 1.250 1.625 12 132 7
24 1.500 1.875 12 165 15
A5-4 Standard Torque Chart and Tables 12/99 A05001
TABLE VIII. TORQUE CONVERSIONS
Foot Pounds ft. lbs. To Newton-meters (N.m)
FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page A5-5 regarding Table usage
TABLE IX. TORQUE CONVERSIONS
Foot Pounds ft. lbs. To kilogram-meters (kg.m)
FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page A5-5 regarding Table usage
TABLE X. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
PSI 0 1 2 3 4 5 6 7 8 9
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
See NOTE on page A5-5 regarding Table usage
A05001 12/99 Standard Torque Chart and Tables A5-5
TABLE XI. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa
PSI 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage
TABLE XII. TEMPERATURE CONVERSIONS
Formula: F - 32 / 1.8 = C or C x 1.8 + 32 = F
CELSIUS
C
FAHRENHEIT
F
CELSIUS
C
FAHRENHEIT
F
CELSIUS
C
FAHRENHEIT
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.
NOTE: Tables such as Table VIII, IX, X, and XI may
be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa).
1. Select Table X.
2. Go to PSI row 90, column 7; read 668.8
97 psi =668.8 kPa.
3. Multiply by 10:
970 psi =6688 kPa.
4. Go to PSI row 0, column 5; read 34.475
psi =34.47 kPa. Add to step 3.
5. 970 +5 psi =6688 +34 =6722 kPa.
A5-6 Standard Torque Chart and Tables 12/99 A05001
TABLE XIII
COMMON CONVERSION MULTIPLIERS
COMMON CONVERSION MULTIPLIERS
ENGLISH To METRIC
To Convert From TO
Multiply
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
sq. in. in.
2
sq. centimeters (cm
2
)
6.45
sq. ft. ft.
2
sq. centimeters (cm
2
)
929
cu. in. in.
3
cu. centimeters (cm
3
)
16.39
cu. in. in.
3
liters (l) 0.016
cu. ft. ft.
3
cu. meters (m
3
)
0.028
cu. ft. ft.
3
liters (l) 28.3
ounce oz. kilogram (kg) 0.028
fluid ounce fl. oz. milliliter (ml) 29.573
pound (mass) kilogram (kg) 0.454
pound (force) lbs. Newton (N) 4.448
in. lbs. (force) Newton.meters (N.m) 0.113
ft. lbs. (force) Newton.meters (N.m) 1.356
ft. lbs. (force) kilogram.meters (kg.m) 0.138
kilogram.meters
(kg.m)
Newton.meters (N.m) 9.807
psi (pressure) kilopascals (kPa) 6.895
psi (pressure) megapascals (MPa) 0.007
psi (pressure)
kilograms/cm
2
(kg/cm
2
)
0.0704
ton (short) kilogram (kg) 907.2
ton (short) metric ton 0.0907
quart qt. liters (l) 0.946
gallon gal. liters (l) 3.785
HP (horsepower) Watts 745.7
HP (horsepower) kilowatts (kw) 0.745
COMMON CONVERSION MULTIPLIERS
METRIC To ENGLISH
To Convert From TO
Multiply
By
millimeter (mm) inch in. 0.0394
centimeter (cm) inch in. 0.3937
meter (m) foot ft. 3.2808
meter (m) yard yd. 1.0936
kilometer (km) mile mi. 0.6210
sq. centimeters (cm
2
) sq. in. in.
2
0.1550
sq. centimeters (cm
2
) sq. ft. ft.
2
0.001
cu. centimeters (cm
3
) cu. in. in.
3
0.061
liters (l)
cu. in. in.
3
61.02
cu. meters (m
3
) cu. ft. ft.
3
35.314
liters (l)
cu. ft. ft.
3
0.0353
grams (g) ounce oz. 0.0353
milliliter (ml) fluid ounce fl. oz. 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pound (force) lbs. 0.2248
Newton.meters (N.m) kilogram.meters (kg.m) 0.102
Newton.meters (N.m) ft. lbs. (force) 0.7376
kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters (kg.m) Newton.meters (N.m) 9.807
Kilopascals (kPa) psi (pressure) 0.1450
megapascals (MPa) psi (pressure) 145.038
kilograms/cm
2
(kg/cm
2
)
psi (pressure) 14.2231
kilograms/cm
2
(kg/cm
2
)
kilopascals (kPa) 98.068
kilogram (kg) ton (short) 0.0011
metric ton ton (short) 1.1023
liters (l) quart qt. 1.0567
liters (l) gallon gal. 0.2642
Watts HP (horsepower) 0.00134
kilowatts (kw) HP (horsepower) 1.3410
A07002 01/98 Storage Procedures A7-1
STORAGE AND IDLE MACHINE PREPARATION
There may be periods when it is necessary for a
machine to be idle for an extended period of time.
Properly prepared, a stored machine may promptly
and safely be put back into operational service.
mproper preparation, or complete lack of prepara-
tion, can make the job of getting the vehicle back to
operating status difficult.
The following information outlines the essential
proper steps for preparing a unit for extended stor-
age, and the necessary steps to bring it back to oper-
ational status - these are the ideals. Additional
information is given to help restore those machines
which were not put into storage, merely shut down
and left idle for a long period of time.
Much of this material is of a general nature since the
environment, where the machine has been standing
idle, will play a big part in its overall condition. Hot,
humid climate will affect vehicle components much
differently than the dry desert atmosphere or a cold
arctic environment. These climatic aspects must be
considered, and appropriate actions taken when
restoring a long term idle vehicle.
These instructions are not intended to be all inclu-
sive, but are furnished to provide the minimum guide
lines. The final aim should always be to provide the
operator with a safe, fully productive vehicle, that he
can rely on.
SHORT TERM IDLE PERIODS
There will be periods when a vehicle may be idle
from 30-60 days, but must be ready for use at all
times.
The most effective handling of this type situation is to
follow the procedure given below to prevent any
deterioration from beginning.
1. Keep the vehicle fully serviced.
2. On a weekly schedule, perform a visual check of
the vehicle, start and run the engine until both
the engine and transmission are up to operating
temperature. Move the vehicle around the yard
for a few minutes to insure that all internal gears
and bearings are freshly lubricated.
3. Operate all hydraulic functions through complete
range to insure that cylinder rams and all seals
are fully lubricated.
4. Check and operate all systems.
5. After shutdown, drain air tank (if so equipped) to
expel any accumulated moisture.
6. Once a month, perform the 10 hour service
items shown in the Operation and Maintenance
Manuals. Keep batteries properly serviced.
A7-2 Storage Procedures 01/98 A07002
PREPARATION FOR STORAGE
For long term idle periods, proper preparation will
pay large dividends in time and money when future
operation of the vehicle is scheduled.
1. Engine should be prepared for storage accord-
ing to instructions found in the engine manufac-
turers manual.
2. Transmission should be prepared for storage.
nstruction will be found in the transmission Ser-
vice Manual. Several storage variations are
given.
3. The vehicle should be in top operating condition
with all discrepancies corrected. Paint should
be in good condition, no rust or corrosion, all
exposed, machined or unpainted surfaces
should be coated with a good rust preventative
grease.
4. After the vehicle has been parked in its storage
location, all hydraulic cylinders, including Hyd-
rair suspensions (Trucks), should be retracted
as much as possible (steering cylinders cen-
tered). Wipe the exposed portion of all cylinder
rams clean and, coat (including seals on ends
of barrel) with good preservative grease.
5. f long term storage is anticipated, the vehicle
should be blocked up with the tires clear of the
ground or floor to remove vehicle weight from
the tires. Lower air pressure in the tires to 15-25
psi (103-172 kPa). Completely cover the tires
with tarpolins to minimize rubber oxidation and
deterioration.
6. (Trucks equipped with air-actuated park brake)
With air tanks pressurized and parking brake
valve "Off", remove a clevis pin from the brake
actuator linkage. This will relieve spring pres-
sure from applying the parking brake while the
vehicle is idle. Replace clevis pin in link to pre-
vent loss. Tag steering wheel with a parking
brake disconnected tag.
7. Drain air tank(s) completely (if equipped). When
tank compartments are empty, fog the inside of
each tank compartment with a light application
of preservative oil to deter rust and corrosion.
8. Clean the radiator; refer to Engine Service Man-
ual and the Vehicle Service Manual for the
proper cleaning instructions.
9. The cooling system should be completely
drained, chemically flushed, and refilled with a
conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
Section "P", Fluid Specifications and Charts, of
the Shop Manual for the proper anti-freeze and
conditioner concentrations. After refilling the
system, always operate the engine until the
thermostats open to circulate the solution
through the cooling system.
NOTE: NEVER store a vehicle with a dry cooling
system.
10. New hydraulic filters should be installed and the
hydraulic tank fully serviced with Type C-4 oil as
specified in Section "P", Lubrication and Ser-
vice, of the Shop Manual.
Any operating fluid, such as hydraulic oil, escap-
ing under pressure can have sufficient force to
enter a person's body by penetrating the skin.
Serious injury and possible death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
11. Disconnect batteries, f possible, batteries
should be removed and stored in a battery shop
or a cool dry location on wooden blocks. Do not
store batteries on a concrete floor. Clean bat-
tery compartment, remove all corrosion and
paint compartment with acid proof paint.
12. Wheel axle housings and final drives should be
fully serviced with prescribed lubricants. Seal all
vents.
A07002 01/98 Storage Procedures A7-3
13. Exhaust openings and air cleaners should be
covered tightly with moisture barrier paper and
sealing tape.
14. All lubrication points (grease fittings) should be
serviced with the prescribed lubricants.
15. Relieve tension from all drive belts. The engine
manufacturer recommends insertion of heavy
kraft paper between belts and pulleys to prevent
sticking.
16. All vandalism covers and locks should be in
place and secured.
17. f so equipped, cab windows should be closed,
locked and sealed and the cab door locked to
prevent vandalism and weather effects.
18. The vehicle fuel tanks should be completely
drained of fuel, fogged with preservative lubri-
cant, ("NOX-RUST" MOTOR STOR., SAE10)
and closed tightly. All fuel filters should be
replaced.
19. f at all possible, to aid those who will eventually
place the unit back in operation, all available
service publications (vehicle, engine and trans-
mission) and a current parts catalog should be
packaged in a moisture proof package and
placed in the vehicle cab.
20. Be certain water drain holes in body (trucks) are
open.
REMOVAL FROM STORAGE
f the foregoing preparations were conscientiously
followed in placing the vehicle into storage, getting it
back to operational status is a simple matter of
reversing these steps.
NOTE: Before starting the job or restoring a vehicle
to operation, obtain copies of the Operation and
Maintenance Manual, Shop Manual, Engine and
Transmission Manuals and/or the Parts Book and
follow ALL special instructions regarding servicing
the vehicle and its components.
n addition to removing the storage materials, the fol-
lowing actions should be taken.
1. nspect the entire vehicle carefully for rust and
corrosion, correct as necessary.
2. Service the engine according to the Engine
Manufacturer's Operation and Maintenance
Manual.
3. Clean the radiator; refer Engine Manufacturer's
Operation and Maintenance Manual.
4. The cooling system should be completely
drained, chemically flushed, and refilled with a
conditioned water/antifreeze solution suitable
for the lowest temperature anticipated. Refer to
Fluid Specifications in Section "P", Lubrication
and Service, of the Shop Manual for the proper
anti-freeze and conditioner concentrations.
After refilling the system, always operate the
engine until the thermostats open to circulate
the solution through the cooling system.
5. Refer to the proper transmission service manual
for returning the transmission to operation.
6. Thoroughly inspect all drive belts, hydraulic, air
and oil lines for evidence of damage, wear or
deterioration. Replace any suspected lines.
Don't take chances on ruptures or blow-outs.
7. New hydraulic filters should be installed and the
hydraulic tank (reservoir) checked and serviced
with Type C-4 oil as specified in Section "P",
Lubrication and Service, of the Shop Manual.
8. Drain on fuel tank should be opened to remove
any build up of moisture or sediment that may
have accumulated while in storage. Close drain
then fill the fuel tank with approved diesel fuel.
NEVER blend gasoline, gasohol and/or alcohol
with diesel fuel. This practice creates an extreme
FIRE HAZARD and under certain conditions may
cause an EXPLOSION.
9. Make certain that all hydraulic controls, steering
linkage and throttle linkage points are lubricated
and operate freely before engine start up.
10. All electrical connections must be clean and
tight. Check security of all ground straps and
cables.
A7-4 Storage Procedures 01/98 A07002
11. nstall fully charged batteries in unit. Clean con-
nectors and connect battery cables. Compart-
ment must be free of corrosion. Secure
batteries with hold downs.
12. Check all electrical cables for weathering, cracks
and/or damage. Replace any defective cables.
Air pressure must be released from tires with bad
cuts or wear that extends into the plies, before
removal from the vehicle. Also, do not allow per-
sonnel to stand in removal path of tires.
13. Check all tires carefully for serviceability and
inflate to proper pressure.
14. f disconnected, reconnect the parking brake
linkage.
15. Completely service the vehicle as recommended
in Section "P", Lubrication and Service, of the
Shop Manual for both 10 and 100 hour inspec-
tions.
16. Adjust all drive belts to specified tension.
17. Make certain that all hydraulic controls, steering
linkage and throttle linkage points are free
before engine start up.
18. Use the Operation and Maintenance Manual for
guidance on engine start and vehicle checkout.
Make a thorough check of all hose and line con-
nections for leakage when the engine is run-
ning.
19. Before moving the vehicle, cycle all hydraulic
controls and steering to verify proper operation.
Verify proper operation of service brakes, emer-
gency braking system and parking brake.
Check ALL system instruments to insure that all
systems are operational. (Trucks with air-over-
hydraulic brakes.) Bleed air system down with
brake pedal applications to insure that the air
governor is functioning properly.
Consult the service manual for the specific
truck being serviced. Verify proper operation of
the air compressor, the air governor, and the air
tank safety valve. f any of these components
do not function as prescribed in the service
manual, shut down engine and correct any dis-
crepancy before continuing operation.
20. When all systems are operational and all dis-
crepancies are corrected, road test the vehicle
in a smooth, level, unobstructed area (with qual-
ified, experienced operator only) to check steer-
ing response, transmission shifting, service
brake efficiency, and hydraulic functions. Only
when it is assured that the vehicle is in safe
operational condition should it be turned over to
an operator.
21. Fire protection equipment on a machine which
has been in storage should be recharged before
the machine is returned to service.
A07002 01/98 Storage Procedures A7-5
RECONDITIONING AN IDLE VEHICLE
NEVER attempt operation of a vehicle which has
been standing idle for a long period until all sys-
tems which affect steering, brakes, engine, trans-
mission and running gear have been completely
reconditioned. An unsafe vehicle can cause seri-
ous injuries and/or major property damage -
DON'T TAKE CHANCES!
At times a vehicle is subjected to long idle periods
without being properly serviced for storage - merely
shut down and left to the elements for an extended
period. Reconditioning of this vehicle can and does
present a major expenditure of time and money when
it is to be put into operating condition.
1. Remove all trash and thoroughly clean the vehi-
cle before starting any inspection or mainte-
nance.
2. Remove vehicle batteries and move to battery
shop for service and charging or replacement
as necessary.
Do not disassemble an inflated tire. Remove
valve core slowly, and allow pressure to bleed
off, before attempting to remove lockring. Also,
eye protection should be worn during tire defla-
tion to protect against any foreign object being
projected into the eyes.
3. nspect tires thoroughly for tread and side wall
condition, weathering, cuts and cracks.
a. Any tire suspected of being unserviceable
should be dismounted and thoroughly
inspected inside and out before being
inflated.
Do not mix rim parts of different rim manufactur-
ers. Rim parts may resemble those of a different
manufacturer, but the required tolerances may be
wrong. Use of mismatched rim parts is hazard-
ous.
b. f tires are dismounted, all wheel compo-
nents must be cleaned, inspected, all rust
and corrosion removed and parts repainted
as applicable before remounting the tires.
Follow the safety rules when mounting and
inflating tires.
c. Mount and inflate tires as shown in Opera-
tion and Maintenance Manual or service
manual.
4. nspect vehicle service brakes carefully.
Before disabling the brake circuit, block all
wheels to prevent possible movement of the
vehicle.
a. f dust covers are installed on the inboard
side of the wheels, remove the covers to
allow for inspection of brake calipers/shoes
and/or brake discs/drums.
The use of vapor degreasing or steam cleaning is
not recommended, either for brake assemblies or
the component parts. Corrosion and rusting may
occur.
b. All brake lines, connections and pressure
converters must be clean, serviced and free
of rust and corrosion.
c. Check condition of brake fluid; fill or replace
fluid as necessary.
A7-6 Storage Procedures 01/98 A07002
5. nspect air system components (if equipped) for
corrosion and deterioration.
a. Safety valve plunger must be free. Remove
rubber cap from air governor to check for any
corrosion and rust. Governor should be
replaced if any defect is suspected.
b. Air compressor should turn by hand without
appreciable binding. Check and tighten drive
belts to prescribed tension; if one belt of a
set is unserviceable, replace the set.
c. f internal air tank corrosion is suspected, the
drain cocks of the dual air tank should be
opened or removed and the automatic mois-
ture ejector removed from the tank.
d. Disconnect the tank line from the compres-
sor and connect a shop air line to the tank
line. Slowly apply shop pressure to the sys-
tem while observing the openings in the
tanks. f excess moisture, dirt, rust or other
foreign material is ejected from tanks, the
complete air system should be recondi-
tioned, including replacement of suspect
components. Air tanks cannot be easily
checked for wall thickness; if rust or corro-
sion is present in the tank, replacement of
the tank should be considered.
e. f contamination is eliminated as a possible
problem, shop air may be used to charge air
system and check all air operated compo-
nents except the compressor and governor.
f. Treadle valves must operate smoothly and
show no internal or external damage or con-
tamination. Leakage limitations are shown in
Section "J", Brake System, of the Shop Man-
ual.
g. The throttle cylinder and parking brake actu-
ator must cycle smoothly when actuated by
the treadle valves or parking brake valve.
h. When air system servicing is complete and
all defective components repaired or
replaced, the service brake hydraulic circuits
should be bled according to instructions in
Section "J", Brake System, of the Shop Man-
ual.
6. The vehicle engine should be inspected and ser-
viced according to the Engine Manufacturer's
Operation And Maintenance Manuals.
a. nsure that exhaust is clear and clean, no for-
eign materials. f water entry is suspected,
disconnect air tubes at the turbochargers to
check for water damage before attempting
startup.
b. Replace fuel filters, fill filter cans with fresh
fuel for engine priming.
Have a new safety filter (secondary) filter element
on hand before removing old one. Do not keep
intake system open to atmosphere any longer
than absolutely necessary.
c. Remove and replace both the primary and
safety filter (secondary) elements in the air
cleaners. Check all intake lines between air
cleaners and engine. All clamps must be
tight. ndicating plunger in filter condition
indicators must be free.
d. The tubes in precleaner section of air
cleaner assembly should be inspected, all
tubes should be clear and clean. Use a light
to inspect the tubes. The light should be visi-
ble. f clogging is evident, precleaner must
be cleaned. Clean precleaner according to
instructions in Section "C", of the Shop Man-
ual.
e. Drain and flush engine cooling system. Fill
with coolant and inhibitors after checking all
lines, hoses and connections. Refer to Sec-
tion "P", Lubrication and Service, of the Shop
Manual, for anti-freeze recommendations.
Radiator cores must be clear of dirt and
trash.
To prevent injuries, always release spring ten-
sion before replacing the fan belt.
f. Check and tighten engine fan drive belts,
install new belt set if necessary.
g. Check and tighten engine mounts.
7. nspect and service the transmission (mechani-
cal drive vehicles) according to the Transmis-
sion manufacturer's service manual.
NOTE: If hydraulic pump or engine is inoperative,
dump body (trucks) should be raised with a crane so
body holding devices can be installed.
a. Check all transmission electrical connections
for corrosion, cleanliness and tightness.
Check electrical cables for weathering, dam-
age and proper clamping.
A07002 01/98 Storage Procedures A7-7
b. Check drive lines for tightness of hardware
and worn U-joints.
c. Check transmission mounts for condition
and security.
8. f fuel was left in the tanks, it must be removed.
Do not attempt to use old diesel fuel.
a. With tanks empty, remove inspection plates
and thoroughly check interior of tanks; clean
if necessary to remove sediment and con-
tamination. f fuel was contaminated, lines
should be disconnected and blown clear.
b. Check all fuel lines for deterioration or dam-
age. Replace lines as necessary.
c. Replace inspection covers, use new gas-
kets.
d. Service tanks with specified diesel fuel.
e. Replace fuel filters.
Any operating fluid, such as hydraulic oil or
brake fluid escaping under pressure, can have
sufficient force to enter a person's body by pene-
trating the skin. Serious injury and possible
death may result if proper medical treatment by a
physician familiar with this injury is not received
immediately.
9. Hydraulic tank should be drained. f oil is not
contaminated and is stored in clean containers,
it may be reused if filtered through 3-micron fil-
ter elements when being pumped back into the
tank. Do not attempt to use contaminated
hydraulic oil, especially if water entry into the
system is suspected.
NOTE: If filling is required, use clean hydraulic oil
only. Refer to the Lubrication chart in Section "P",
Lubrication and Service, of the Shop Manual for
proper oil specifications.
a. Replace hydraulic filter elements and clean
suction strainer elements. While suction
strainers are removed, inspect and clean
interior of tank thoroughly to remove all sedi-
ment and foreign material.
b. nspect all hydraulic lines for deterioration or
damage. Replace suspected lines - don't risk
hose ruptures or blow outs.
c. Check all hydraulic components - pumps,
valves and cylinders for damage and corro-
sion. Secure all mountings and connections.
Control valves in the cab must be free mov-
ing with no binding.
d. Check exposed portions of all hydraulic cyl-
inder rams for rust, pitting and corrosion. f
plating is deteriorated, the cylinder should be
removed and overhauled or replaced; pitted
or scored plating will cause leakage at the
cylinder seals.
10. Check front wheel hub, final drive and wheel
axle lubricant. f contamination is suspected, oil
should be drained completely and the compo-
nent serviced with clean prescribed lubricant. f
major contamination is present, disassembly
and overhaul will be in order.
11. Check parking brake. Since it is spring applied,
the brake shoes/pads may be stuck tightly to
the drum/disc, it may be necessary to remove
and overhaul the parking brake assembly.
12. Lubricate all grease fittings with prescribed lubri-
cants which are not part of the automatic lubri-
cation system. Pay particular attention to the
steering linkage connections. All pivot points
must be free of any binding.
13. Check generator/alternator for corrosion or dete-
rioration. Generator/alternator rotor must be
free, with no binding or roughness. nspect,
install and properly tension the generator/alter-
nator drive belts.
14. Check security of steering cylinder ball joints link
and hydraulic connections.
15. Examine Hydrair suspensions damage.
a. Discharge nitrogen from suspensions as out-
lined in the service manual. Check condition
of suspension oil and cylinder wipers. f wip-
ers are cracked or hardened, the suspension
must be rebuilt. Recharge suspension with
new oil if old oil is deteriorated.
b. Check exposed chrome portions of cylinder
for rust, pitting and corrosion. f plating is
deteriorated the suspension should be
removed and overhauled or replaced; pitted
or scored plating will rapidly cause leakage
at the seals.
c. Recharge suspensions as outlined in the
service manual.
16. f not previously done, install fully charged bat-
teries and completely charge air tank (if
equipped) with shop air.
A7-8 Storage Procedures 01/98 A07002
ENGINE OPERATION
Insure that all tools and loose equipment have
been removed prior to engine start-up. Sound
horn prior to engine start. Make sure emergency
shut down is reset. Cables must be free moving
in their housings.
When all reconditioning operations have been com-
pleted, a static check of engine operation along with
operation of systems as well as verification of braking
and steering must be done before the vehicle is
moved.
1. nsure all personnel are clear of Equipment
before starting engine. Always sound the horn
as a warning before actuating any operational
controls.
Before starting engine, clear the immediate area
of personnel and obstructions.
Never start the engine in a building unless the
doors and windows are open and ventilation is
adequate.
2. Turn key switch "On". Warning lights for low air,
brake, and steering pressure should illuminate
and the horn should sound. f it does not, check
all components in the circuit (both air and elec-
trical) and correct the discrepancy before con-
tinuing.
3. Turn key switch to start position to crank engine,
release switch when engine fires. Watch engine
oil pressure gauge; if pressure does not show in
10 - 15 seconds, shut down and locate problem.
On air throttle engines, there will be no throttle
control until air pressure builds, engine should
run about 1000 RPM.
4. While engine is warming up, make a careful
inspection of engine coolant, oil and fuel lines
for leaks. Check hydraulic pump for leakage as
well as all hydraulic lines. Mechanical Drive
vehicles - Check transmission and retarder
cooler lines and aftercooler for leakage. f leak-
age is evident, shut down and correct before
continuing checkout. Listen for unusual sounds,
which may indicate problems in components.
5. When engine is up to operating temperature,
check operation of throttle circuit; acceleration
should be smooth. Keep a close watch on the
gauges for any abnormal activity. Proper tem-
peratures and pressures are shown in the Oper-
ation and Maintenance Manual.
A07002 01/98 Storage Procedures A7-9
AFTER ENGINE HAS STARTED
Any machine which is unsafe and/or not in top oper-
ating condition should not be assigned to an operator
for production use.
1. Become thoroughly familiar with steering and
emergency controls. Test the steering in
extreme right and left directions. f the steering
system is not operating properly, shut engine
down immediately. Determine the steering sys-
tem problem and have repairs made before
resuming operation.
2. Operate each of the brake circuits at least twice
prior to operating and moving the machine.
These circuits include individual activation of
the service brake and parking brake from the
operator's cab.
a. Activate each circuit individually with the
engine running and with hydraulic circuit fully
charged.
b. f any application or release of any brake cir-
cuit does not appear proper or if sluggish-
ness is apparent on application or release,
shut the engine down and notify mainte-
nance personnel. Do not operate machine
until brake circuit in question is fully opera-
tional.
3. Check gauges, warning lights and instruments
before moving the machine to insure proper
system operation and proper gauge functioning.
Give special attention to braking and steering
circuit warning lights. f warning lights come on,
shut down the engine immediately and deter-
mine the cause.
4. Cycle hoist controls and steering several times
to remove trapped air. Complete steering cycles
in both directions to verify steering response,
smoothness and reliability. Check seals and
lines for leaks.
5. When satisfied that all discrepancies have been
corrected, the vehicle is ready for a road test.
This test should be done only by a capable and
experienced operator and should be accom-
plished in a large open area where plenty of
maneuvering room is available. Some of the
road test items which should be covered will
include:
a. Repeated test of braking efficiency at pro-
gressively higher speeds. Start at slow
speeds. Don't take chances with higher
speeds until the machine is determined to be
completely safe.
b. Mechanical Drive vehicles - Progressive
upshifting and downshifting through all
speed ranges to insure proper transmission
shifting and synchronization.
6. When all tests and checks have been made and
the vehicle is ready for work, it should be visu-
ally rechecked and fully serviced according to
Section "P", Lubrication and Service, of the
Shop Manual.
A few of the conditions (others may be found) which
might be encountered after a machine has been
exposed to the elements for a long period would
include:
ncreased corrosion and fungus growth on
electrical components in humid/tropical areas.
Accelerated rust formation in humid climates.
ncreased sand and dust infiltration in windy, dry
dusty areas. (These conditions can approach
sand blasting effects.)
Deterioration of rubber products in extreme cold
areas. Cables, hoses, O- rings, seals and tires
may become weather checked and brittle.
Animal or bird's nests in unsealed openings.
A7-10 Storage Procedures 01/98 A07002
ENGINE STORAGE-CUMMINS
Engine Storage-(Short Term)
1 Month to 6 Months
This procedure describes the proper method for the
short term storage of an engine.
Prepare the Engine for Short Term
Storage
1. Operate the engine at "HGH DLE" until the
coolant temperature is 160 F (70 C).
2. Turn the engine "OFF".
3. Disconnect the fuel lines to the engine fuel filter
and the injector return line.
4. Use a preservative oil. Use Dauber T Chemical
NoxRust No. 518, or equivalent. The oil must
meet Military Specification ML-L-644, Type P-
9.
5. Fill two containers, one with diesel fuel, and the
second with preservative oil. Put both fuel lines
in the container of diesel fuel.
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. nstall 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 engine does not contain oiI.
Do not operate the engine.
11. Disconnect the electrical wiring from the fuel
pump solenoid.
12. Turn the fuel pump manual shutoff valve coun-
tercIockwise until it stops.
13. Crank the engine slowly. Spray lubricating oil
into the intake manifold and the inlet of the air
compressor.
14. Cover all of the openings with tape to prevent
dirt and moisture from entering the engine.
15. Drain the coolant.
NOTE: It is not necessary to drain the coolant if it is a
permanent type antifreeze with a rust inhibitor.
16. Store the engine in an area that is dry and has a
uniform temperature.
17. Bar turn the Crankshaft two or three revolutions
every 3 to 4 weeks.
Remove the Engine from Short Term
Storage
1. Prime the lubricating system. Refer to Cummins
Engine Shop Manual, (Section 14-01, Engine
Run-in-Period).
2. Fill the coolant system if necessary.
3. Adjust the injector and the valve clearance.
Refer to Cummins Engine Shop Manual, (Sec-
tion 00-02, Engine Assembly).
4. Tighten the intake manifold mounting capscrews
to specified torques, refer to the Cummins Ser-
vice Manual for specifications.
5. Fill the oil pan sump, oil filters, and fuel filters
with recommended lubricants and fuels.
A07002 01/98 Storage Procedures A7-11
Engine Storage- (Long Term)
6 Months to 24 Months
This procedure describes the proper method for the
long term storage of an engine.
Prepare the Engine for Long Term Stor-
age
1. Operate the engine at "HGH DLE" until the
coolant temperature is 160 F (70 C).
2. Turn engine "OFF".
3. Drain the oil. nstall the drain plugs. Use Shell
66202 or equivalent, preservative oil. The oil
must meet Military Specification ML-L-21260,
Type P-10, Grade 2, SAE 30. Fill the engine to
the "HGH" mark.
4. Disconnect the fuel lines to the engine fuel filter
and the injector return line.
5. Use Daubert Chemical NoxRust No. 518, or an
equivalent preservative oil. The oil must meet
Military Specification ML- L- 644 Type P9.
6. Fill two (2) containers, one with diesel fuel, the
second with preservative oil. Put both fuel lines
in the container of diesel fuel.
7. "START" engine.
8. 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.
9. Turn the engine "OFF". Connect the fuel lines to
the fuel filter and the injector return.
10. Drain the preservative oil from the engine oil pan
sump, the air compressor 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. Spray preservative oil in the intake port on the
air compressor.
13. Use a rust preventative compound that meets
Military Specification ML-C-16173C, Type P-2,
Grade 1 or 2. Brush or spray the compound on
all of the exposed surfaces that are not painted.
14. Remove the rocker lever covers. Spray the
rocker levers, the valve stems, the springs, the
valve guides, the crossheads, and the push
rods with preservative oil. nstall the covers.
15. Cover all the openings with heavy paper and
tape to prevent dirt and moisture from entering
the engine.
Put a WARNING tag on the engine. The tag must
indicate:
-The engine has been treated with preservatives.
-Do not bar turn the crankshaft.
-The coolant has been removed.
-The date of treatment.
-Do not operate the engine.
16. Store the engine in an area that is dry and has a
uniform temperature.
Remove the Engine from Long Term
Storage
1. Use clean diesel fuel. Flush the fuel system until
all of the preservative oil is removed.
2. Remove the plug from the main oil rifle passage.
Use a hot, lightweight mineral oil. To flush all of
the preservative oil from the engine: Bar the
engine crankshaft three to four revolutions dur-
ing 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.
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.
A7-12 Storage Procedures 01/98 A07002
ENGINE STORAGE - DETROIT DIESEL
Preparing Engine For Storage
When an engine is to be stored or removed from
operation for a period of time, special precautions
should be taken to protect the interior and exterior of
the engine and other parts from rust accumulation
and corrosion. The parts requiring attention and the
recommended preparations are given below.
t will be necessary to remove all rust or corrosion
completely from any exposed part before applying a
rust preventative compound.
Therefore, it is recommended that the engine be pro-
cessed for storage as soon as possible after removal
from operation.
The engine should be stored in a building which is
dry and can be heated during the winter months.
Moisture absorbing chemicals are available commer-
cially for use when excessive damage prevail in the
storage area.
Temporary Storage (30 Days Or Less)
To protect an engine for a temporary period of time,
proceed as follows:
1. Drain the engine crankcase.
2. Fill the crankcase to proper level with the recom-
mended viscosity and grade of oil.
3. Fill the fuel tank with the recommended grade of
fuel oil. Operate the engine for two minutes at
1,200 rpm and no load. Shut down engine, do
not drain the fuel system or the crankcase after
this run.
4. Check the air cleaner and service it, if neces-
sary, as outlined in Detroit Diesel Service Man-
ual.
5. f freezing weather is expected during the stor-
age period, add an ethylene glycol base anti-
freeze solution in accordance with the
manufacturer's recommendations.
6. Clean the entire exterior of the engine (except
the electrical system) with fuel oil and dry it with
compressed air.
To prevent possible personal injury, wear ade-
quate eye protection and do not exceed 40 psi
(276 kPa) compressed air pressure.
7. Seal all of the engine openings. The material
used for this purpose must be waterproof,
vaporproof and possess sufficient physical
strength to resist puncture and damage from
the expansion of entrapped air.
An engine prepared in this manner can be returned
to service in a short period of time by removing the
seals at the engine openings, checking the engine
coolant, fuel oil, lubricating oil, transmission oil and
priming the raw water pump (if used).
Extended Storage (more Than 30 Days)
To prepare an engine for extended storage, (more
than 30 days), follow this procedure:
1. Drain the cooling system and flush with clean,
soft water. Refill with clean, soft water and add
a rust inhibitor to the cooling system (refer to
Corrosion nhibitor under Coolant Specifica-
tions in Detroit Diesel Service Manual .
2. Remove, check and recondition the injectors, if
necessary, to make sure they will be ready to
operate when the engine is restored to service.
3. Reinstall the injectors, time them and adjust the
exhaust valve clearance.
4. Circulate the coolant by operating the engine
until normal operating temperature is reached
160 - 185 F ( 71 - 85 C).
5. Stop the engine.
6. Drain the engine crankcase, then reinstall and
tighten the drain plug. nstall new lubricating oil
filter elements and gaskets.
7. Fill the crankcase to the proper level with a 30-
weight preservative lubricating oil ML-L-
21260C, Grade 2.
A07002 01/98 Storage Procedures A7-13
8. Drain the fuel tank. Refill with enough clean No.
1 diesel fuel or pure kerosene to permit the
engine to operate for about ten (10) minutes. f
it isn't convenient to drain the fuel tank use a
separate portable supply of the recommended
fuel.
If engines in vehicle are stored where condensa-
tion of water in the fuel tank may be a problem,
add pure, waterless isopropyl alcohol (isopro-
panol) to the fuel at a ratio of one pint to 125 gal-
lons(473 L) of fuel, or 0.010% by volume. Where
biological contamination of fuel may be a prob-
lem, add a biocide such as Biobor JF, or equiva-
lent to the fuel. When using a biocide, follow the
manufacturer's concentration recommenda-
tions, and observe all cautions and warnings.
9. Drain and disassemble the fuel filter and
strainer. Discard the used elements and gas-
kets. Fill the cavity between the element and
shell with No. 1 diesel fuel or pure kerosene,
and reinstall on the engine. f spin-on fuel filters
and strainers are used, discard the used car-
tridges, fill the new ones with No. 1 diesel fuel
or pure kerosene, and reinstall on the engine.
10. Operate the engine for five (5) minutes to circu-
late the clean fuel oil throughout the fuel sys-
tem.
11. Refer to Detroit Diesel Service Manual and ser-
vice the air cleaner.
12. Turbocharger bearings are pressure lubricated
through the external oil line leading from the
engine cylinder block while the engine is operat-
ing. However, the turbocharger air inlet and tur-
bine outlet connections should be sealed off
with moisture resistant tape.
13. Apply a rust preventive compound to all exposed
non-painted surfaces.
14. Drain the engine cooling system.
15. Drain the preservative oil from the engine crank-
case. Reinstall and tighten the drain plug.
16. Remove and clean the batteries and battery
cables with baking soda-water solution and
rinse them with fresh water. Do not allow the
soda solution to enter the battery. Add distilled
water to the electrolyte, if necessary, and fully
charge the battery. Store the battery in a cool
(never below 32 F or 0 C) dry place. Keep the
battery fully charged and check the level and
the specific gravity of the electrolyte regularly.
Never set batteries on concrete floor. Place on
wooded blocks.
17. nsert heavy paper strips between the pulleys
and belts to prevent sticking.
18. Seal all engine openings, including the exhaust
outlet, with moisture resistant tape. Use card-
board, plywood or metal covers where practical.
19. Clean and dry the exterior painted surfaces of
the engine and spray with a suitable liquid auto-
motive body wax, a synthetic resin varnish or a
rust preventive compound.
20. Protect the engine with a good weather-resistant
tarpaulin and store it under cover, preferably in
a dry building with temperatures above freez-
ing.
Detroit Diesel Corporation does not recommend the
outdoor storage of engines. However, in some cases
outdoor storage may be unavoidable. f units must be
kept out-off-doors, follow the preparation and storage
instructions already given. Protect units with quality,
weather-resistant tarpaulins (or other suitable cov-
ers) arranged to provide air circulation.
Do not use plastic sheeting for outdoor storage.
Plastic may be used for indoor storage. However,
when used outdoors, moisture can condense on
the inside of the plastic and cause ferrous metal
surfaces to rust and/or pit aluminum surfaces. If
a unit is stored outside for any extended period
of time, severe corrosion damage can result.
The stored engine should be inspected periodically. f
there are any indication of rust or corrosion, correc-
tive steps must be taken to prevent damage to the
engine parts. Perform a complete inspection at the
end of one year and apply additional treatment, as
required.
A7-14 Storage Procedures 01/98 A07002
PROCEDURE FOR RESTORING AN
ENGINE TO SERVICE WHICH HAS BEEN
IN EXTENDED STORAGE
1. Remove the covers and tape from all of the
openings of the engine, fuel tank and electrical
equipment. Do not overlook the exhaust outlet
or the intake system.
2. Wash the exterior of the engine with fuel oil to
remove the rust preventive.
3. Remove the rust preventive from the flywheel.
4. Remove the paper strips from between the pul-
leys and the belts.
5. Remove the drain plug and drain the preserva-
tive oil from the crankcase. Reinstall the drain
plug. Then, refer to Lubrication System in
Detroit Diesel Service Manual and fill the crank-
case to proper level, using a pressure prelubri-
cator, with the recommended grade of
lubricating oil.
6. Fill the fuel tank with the fuel specified under
Fuel Oil in Detroit Diesel Service Manual.
7. Close all of the drain cocks and fill the engine
cooling system with clean soft water and a rust
inhibitor. f the engine is to be exposed to freez-
ing temperatures, fill the cooling system with an
ethylene glycol base antifreeze solution refer to
Coolant Specifications in Detroit Diesel Service
Manual.
8. nstall and connect the fully charged batteries.
9. Service the air cleaner as outlined in Detroit Die-
sel Service Manual.
10. Remove the covers from the turbocharger air
inlet and turbine outlet connections. Refer to the
lubricating procedure outlined in Preparation for
Starting Engine First Time in Detroit Diesel Ser-
vice Manual.
11. After all of the preparations have been com-
pleted, start the engine. The small amount of
rust preventive compound which remains in the
fuel system will cause a smoky exhaust for a
few minutes.
NOTE: Before subjecting the engine to a load or high
speed, it is advisable to check the engine tune-up.
A07002 01/98 Storage Procedures A7-15
ELECTRIC DRIVE TRUCKS
Storage Instructions and Procedures
This instruction provides the recommended proce-
dures for protecting equipment from damage during
both short-term and long-term storage periods and
for maintaining adequate protection while in storage.
Also included are instructions for placing this equip-
ment into service after having been stored.
For the purposes of this instruction, a short-term stor-
age period is considered to be less than three
months; a long-term storage period is considered to
be three months or longer.
General Electric recommends a maximum storage
period of three years, with these storage procedures
being repeated after each year. After a storage
period of three years or more, the Motorized Wheels
should be removed and sent to an overhaul facility
for teardown and inspection of seals and bearings.
These should be replaced if necessary.
Periodic (every three months) inspections should be
made to determine the lasting qualities of long-term
storage protection measures. Such inspections will
indicate the need for renewing protective measures
when necessary to prevent equipment deterioration.
Proper storage of this equipment is vital to equipment
life. Bearings, gears, and insulation may deteriorate
unless adequate protective measures are taken to
protect against the elements. For example, bearings
and gears in the Motorized Wheel gear case are sus-
ceptible to the formation of rust; insulation in rotating
electrical equipment can accumulate moisture; and
bearings may become pitted.
NEVER APPLY ANY SPRAY, COATING OR OTHER
PROTECTIVE MATERIALS TO AREAS NOT SPE-
CIFICALLY RECOMMENDED.
t is also important to note that these instructions
cannot possibly anticipate every type of storage con-
dition and, therefore, cannot prevent all equipment
deterioration problems caused by inadequate stor-
age. However, these instructions should be consid-
ered as a minimum procedure to achieve the best
possible equipment life and the lowest operating cost
when the equipment is returned to service.
NOTE: Local conditions and/or experience may
require ADDITIONAL procedures and/or additional
storage precautions.
PIacing Equipment Into Storage
Perform the following instructions when preparing
General Electric equipment for storage. There are
three main equipment categories to consider:
1. When storing a truck that is operational.
2. When storing a truck that is not operational.
3. When storing major components (Motorized
Wheel, alternator, etc.).
These three major categories are the basis for deter-
mining required protective measures.
NOTE: In addition to these instructions, refer to truck
storage instructions.
When Storing A Truck That Is Opera-
tionaI
When a fully operational truck is being placed into
storage for less than three months, the best protec-
tive measure which can be taken is to drive the truck
once a week for at least 30 minutes. Prior to driving
the truck, the rotating equipment should be Meg-
gered and:
1. f greater than 2 megohms, run normally.
2. f less than 2 megohms, isolate condition and
correct before running.
Driving the truck circulates oil in the gear case to
keep gears and bearings lubricated and free from
rust. t also prevents deterioration of the brushes,
commutators and slip rings.
When a fully operational truck is being placed into
storage for three months or longer, and the truck
cannot be operated weekly throughout the storage
period as indicated above, perform the following
instructions:
1. Drain oil from the gear case and install rust pre-
ventive 4161 (product of Van Straaten Chemi-
cal Co.)or equivalent. Fill per General Electric
Motorized Wheel Service Manual.
2. Megger the wheels as indicated in the instruc-
tions above. Operate the truck for at least 30
minutes to insure that the rust preventive com-
pound has been thoroughly circulated through-
out the gear case. Stop the truck and drain the
rust preventive compound.
NOTE: Do not run a LOADED truck with rust
preventive compound in Motorized Wheel gear
cases.
A7-16 Storage Procedures 01/98 A07002
Do not operate trucks without oil in the Motorized
Wheel gear cases.
3. Perform a megohmmeter test. Refer to the
truck's Vehicle Test instructions for the correct
procedure. Record the Megger readings for
future reference. They will be helpful in deter-
mining if deterioration is being experienced
when additional Megger tests are made as part
of the periodic inspection.
4. Lift all brushes in the Motorized Wheels, blowers
and the alternator. They must be removed from
the brush holder. Disconnecting brush pigtails is
not required.
5. Cover any open ductwork with screening mate-
rial to prevent rodents from entering. Then tape
over the screen to prevent the entry of water
and dirt (allow breathing).
6. Examine all exposed machined surfaces for rust
or other dirt accumulation. Remove all dirt as
necessary. Remove rust by using a fine abra-
sive paper. Old flushing compound can be
removed with mineral spirits (GE-D5B8). Meth-
anol should be used to remove all residue.
When clean, coat with Tarp B rust preventive.
Refer to General Electric Motorized Wheel Ser-
vice Manual for specifications.
7. Loosen exciter drive belts (where applicable).
8. Open all switches in the control compartment.
9. nstall a 500 watt heat source inside all control
groups which house electronic control equip-
ment. These heat sources are to be energized
below 32 F (0 C) and de-energized above 41
F (5 C).
10. nstall a 500 watt heat source inside the commu-
tator chamber of both Motorized Wheels and
inside the alternator slip ring chamber. This will
minimize the accumulation of moisture. A hole
in the bottom of the hubcap will accommodate
the electrical cord for the heat source in the
Motorized Wheels. These heat sources are to
be energized continuously.
11. Seal compartment doors with a weatherproof
tape to prevent entry of rain, snow and dirt
(allow breathing).
When Storing A Truck That Is Not Opera-
tionaI
When a truck which is not fully operational is being
stored for a period of any length, perform the follow-
ing:
1. Drain the oil from the gear case and install rust
preventive compound 4161 (or equivalent). Fill
per General Electric Motorized Wheel Service
Manual.
2. Jack each side of the truck (one side at a time)
enough to rotate the tires.
3. Connect a D-C welder as described in the Vehi-
cle Test nstructions (Wheel Motor inst. 400A,
arm & field in stress 900- 1000 rpm arm).
4. Rotate each Motorized Wheel (one at a time) for
at least 30 minutes to insure that the rust pre-
ventive compound has been thoroughly circu-
lated throughout the gear case. Disconnect the
welder. Remove the jacks. Drain the gear case.
5. f the truck is partially dismantled, pay careful
attention to ductwork, blower shrouds, etc.,
which may be exposed to weather conditions as
a consequence. These areas will require the
same sealing measures as in Step 5 above
which deals with protecting ductwork. Cover
exposed blower housings to prevent entry of
water and dirt.
6. Perform Steps 3 through 11 under When Stor-
ing a Truck that is OperationaI.
When Storing A Major Component
When storing a Motorized Wheel, alternator, blower
or control group for a period of any length, always
store it inside a warm, climate-controlled environ-
ment. Do not attempt to store individual components
where they would be exposed to inclement weather,
climatic changes, high humidity and/or temperature
extremes.
A07002 01/98 Storage Procedures A7-17
Periodic Inspections
t is important that periodic inspections (every three
months) of stored equipment be performed to insure
the continued serviceability of all protective mea-
sures initially taken when the storage period began.
tems which should be checked at each inspection
interval are listed as follows:
1. Remove the weatherproof tape from the com-
partment doors and preform a Megger test as
described in the Vehicle Test nstructions.
Record the test results and compare them with
the recorded Megger readings taken when stor-
age first began, and those taken throughout the
storage period. Remove all test equipment and
close up the compartment. Reseal the compart-
ment doors with new weatherproof tape. f
Megger readings indicate a deterioration of
insulation quality, to below 2.0 megohms then
consideration should be given to providing
more protection.
2. Check all other weatherproofing tape. Replace
any that has become loose or is missing com-
pletely.
3. Check all heat sources. Replace or repair any
units which have become inoperative.
4. Check all machine surfaces which were coated
with flushing compound when storage began. f
compound appears to be deteriorating, it must
be cleaned off and renewed.
PIacing Equipment Into Service After
Storage
When taking equipment out of storage, perform the
following procedures:
When A Truck Is OperationaI
f a truck has been operated weekly throughout the
storage period, perform a complete visual inspection
of the Motorized Wheels, blowers, alternator and
control compartments. Repair any defects found,
then place the truck directly into service.
When A Truck Is Not OperationaI
f the truck was not operated weekly throughout the
storage period, perform the following procedures:
1. Remove all weatherproofing tape from control
compartment doors and ductworks.
2. Remove all screening material from ductwork.
3. Remove all heat sources from Motorized
Wheels, control compartments and the alterna-
tor.
4. Fill with recommended oil. Refer to the Motor-
ized Wheel Service Manual for the type and
amount oil to be used. This oil should be
drained and new oil should be added after 500
hours of operation.
5. Clean all Motorized Wheel grease fittings in the
axle box. nsure that all grease lines are com-
pletely full of grease. Then add the recom-
mended amount of grease to all fittings.
6. nstall brushes in the Motorized Wheels, blowers
and the alternator. Make sure that brushes
move freely in their carbonways and that they
have enough length to serve until the truck's
next inspection period. nstall new brushes if
necessary. nsure that all brush pigtail screws
are tight.
7. Perform a megohmmeter test. Refer to the
truck's Vehicle Test nstructions for the correct
procedure. f Megger readings are less than 2.0
megohms, the problem could be an accumula-
tion of moisture in motor or alternator. f this is
the case, the faulty component will have to be
isolated and dried out using procedures recom-
mended in the G.E.Service Manual.
8. Perform a thorough inspection of the Motorized
Wheels, alternator, blowers and control com-
partments. Look for:
a. Rust or dirt accumulation on machine sur-
faces
b. Damaged insulation
c. An accumulation of moisture or debris
d. Loose wiring and cables
e. Any rust on electrical connectors in the con-
trol compartment
f. Any loose cards in the card panels
g. Any accumulation of moisture or debris in
ductwork.
Clean and make repairs as necessary.
9. Check retarding grids and insulators for loose
connections and dirt accumulation. Clean and
make corrections as necessary.
10. Where applicable, check exciter drive belts for
cracks, and deterioration. f acceptable, set belt
tension to specification.
11. Before starting engine, turn on control power.
Check that contactors and relays pick up and
drop out normally.
A7-18 Storage Procedures 01/98 A07002
12. Perform a start-up procedure on the complete
system to insure maximum performance during
service. Refer to the truck's Vehicle Test
nstructions for the complete test procedure.
For The First Hour
After all storage protection has been removed, the
truck has been cleaned and inspected and repairs
made as necessary, the Motorized Wheel gear case
has been filled with new oil, the dirt seals have been
completely purged with new grease and the system
completely checked, the truck can be placed into ser-
vice. t is recommended, however, that the truck be
driven unIoaded at a low speed (10 mph) for the
first hour of operation.
A07002 01/98 Storage Procedures A7-19
PRESERVATION AND STORAGE
ALLISON TRANSMISSION
Storage, New Transmission
(Prior to installation). New transmissions are tested
at Allison with preservative oil and drained prior to
shipment. The residual oil remaining in the transmis-
sion provides adequate protection to safely store the
transmission for up to one year (stored inside the
conditions of normal climate and with all shipping
plugs installed) without further treatment.
Preservation Methods. When the transmission is to
be stored or remain inactive for an extended period
(one or more years), specific preservation methods
are recommended to prevent damage due to rust,
corrosion, and organic growth in the oil. Preservation
methods are presented for storage with and without
transmission fluid.
Storage, One Year -- Without OiI
1. Drain the oil.
2. Spray two ounces (60 milliliters) of VC #10
through the fill tube.
3. Seal all openings and the breather with mois-
ture-proof tape.
4. Coat all exposed, unpainted surfaces with pre-
servative grease such as petroleum (ML-C-
11796, Class 2).
5. f additional storage time is required, repeat
steps (2), (3) and (4) at yearly intervals.
Storage, One Year With OiI (normaIIy in a vehicIe
chassis)
1. Drain the oil and replace the oil filter element(s).
2. Fill the transmission to operating level with a
mixture of one part VC #10 (or equivalent) to
30 parts C-3 transmission fluid. Add 1/4 tea-
spoon of Biobor JF (or equivalent) for each 3
gallons (11 liters) of fluid in the system.
NOTE: When calculating the amount of Biobor JF
required, use the total volume of the system, not just
the quantity required to fill the transmission. Include
external lines, filters, and the cooler.
3. Run the engine for approximately five minutes at
1500 rpm with the transmission in neutral.
4. Drive the vehicle. Make sure the transmission
shifts through all ranges. Make sure the lockup
clutch is working.
5. Continue running the engine at 1500 rpm with
the transmission in neutral until normal operat-
ing temperature is reached.
f the unit does not have a converter-out tempera-
ture gage, do not stall the converter.
6. f normal operating temperature is less than
225 F (107 C), shift the transmission to the
highest forward range and stall the con-
verter.When the converter-out temperature
reaches 225 F (107 C), stop the engine. Do
not exceed 225 F (107 C).
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 (ML-C-
11796, Class 2).
9. f additional storage time is required, repeat
steps (2) through (8) at yearly intervals; except,
it is not necessary to drain the transmission
each year. Just add Motorstor and Biobor Jf (or
equivalents).
Restoring Transmission to Service
1. Remove all tape from openings and the
breather.
2. Wash off all external grease with mineral spirits.
3. f the transmission is new, drain the residual pre-
servative oil. Refill the transmission to the
proper level with C-4 transmission fluid.
4. f the transmission was prepared for storage
without oil, drain the residual oil and replace the
oil filter elements. Refill the transmission to the
proper level with C-4 transmission fluid.
5. f the transmission was prepared for storage
with oil, it is not necessary to drain and refill the
transmission with new transmission fluid. Check
for proper fluid level. Add or drain transmission
fluid as required to obtain to proper level.
A7-20 Storage Procedures 01/98 A07002
NOTES
B01007 Index B1-1
SECTION B
STRUCTURES
INDEX
STRUCTURAL COMPONENTS
GRILLE AND HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2
Right Deck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2
Left Deck and Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Right Deck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Left Deck and Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
BODY PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
Body Pad Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
BODY POSITION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
BODY SLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Body Sling Hook-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
ROCK EJ ECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
BODY-UP LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Indicator Arm Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
BREATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
B1-2 Index B01007
NOTES:
B02008 Structural Components B2-1
STRUCTURAL COMPONENTS
GRILLE AND HOOD
Removal
1. Attach lifting device to the hood and grille
assembly (1, Figure 2-1).
2. Remove upper mounting capscrews (3) from
the hood and grille assembly.
3. Remove all side mounting capscrews (2) from
the hood and grille assembly.
4. Disconnect upper hood mounted headlights, if
equipped.
5. Lift hood and grille assembly from truck and
move to work area.
Installation
1. Move hood and grille assembly from work area
to truck and lift into place.
2. Install side mounting capscrews (2).
3. Install upper mounting capscrews (3).
4. Connect hood mounted headlights, if equipped.
DECKS
The HAULPAK
F (27
C).
NOTE: Use 1.400 strength sulfuric acid when making
specific gravity adjustments. Acid of higher strength
will attack the plates and separators before it has a
chance to diffuse into the solution.
If the temperature of the electrolyte is not reasonably
close to 80
F (27
F (27
C):
For every 10
F (5
C) below 80
F (27
C), 0.004
should be SUBTRACTED from the specific
gravity reading.
For every 10
F (5
C) above 80
F (27
C), 0.004
should be ADDED to the reading.
Idle batteries should not be allowed to stand unat-
tended. If equipment is to stand unused for more than
two weeks, the batteries should be removed and
placed in a cool, dry place where they may be
checked periodically and charged when necessary.
Remember, all lead-acid batteries discharge slowly
when not in use. This self discharge takes place even
though the battery is not connected in a circuit and is
more pronounced in warm weather than in cold.
The rate of self-discharge of a battery kept at 100
F
(38
F
(19
F
(27
F (10
C).
Over a thirty day period, the average self-discharge
runs about 0.002 specific gravity per day at 80
F
(27
C).
To offset the results of self-discharge, idle batteries
should receive a booster charge (not a quick charge)
at least once every thirty days. Batteries allowed to
stand for long periods in a discharged condition are
attacked by a crystallization of the lead sulfate on the
plates. Such batteries are called sulfated and are, in
the majority of cases, irreparably damaged. In less
severe cases, the sulfated battery may be restored to
limited service by prolonged charging at a low rate
(approximately 1/2 normal rate).
An undercharged battery is extremely susceptible to
freezing when allowed to stand in cold weather.
The electrolyte of a battery in various stages of
charge will start to freeze at temperatures indicated
in the table.
The temperatures in the table indicate the points at
which the first ice crystals appear. Lower tempera-
tures must be reached for a solid freeze. Solid freez-
ing of the electrolyte may crack the battery case and
damage the positive plates. As will be noted, a 3/4
charged battery is in no danger of freezing; therefore,
a 3/4 charge or better is desirable, especially during
winter weather.
BATTERY CHARGING SYSTEM
(Used with DDC and Cummins Engines)
NOTE: If the truck is equipped with the MTU engine,
service for the 24 volt alternator must be obtained
from the engine manufacturers dealer.
However, some MTU engine-equipped trucks have
been converted to use the 30-SI Series Delcotron
alternator for use, either as the main 24 volt source,
or as a charging system for auxililary batteries.
General Description
The 30-SI Series Delcotron Integral Charging System
(Figure 2-2) is a heavy-duty 24 VDC unit rated at 100
amps. An integral, solid state Voltage regulator that is
mounted inside the end frame provides Voltage output
control. The 30-SI Series uses one wire with an ade-
quate ground return to charge the vehicle battery.
Specific Gravity Cor-
rected to 80
F (27
C)
Freezing Temperature
Degrees
1.280
-90F (-70
C)
1.250
-60F (-54
C)
1.200
-16F (-27
C)
1.150
+5F (-15
C)
1.100
+19F (-7
C)
D02012 11/94 24 VDC Electric Supply System D2-3
with 100 Amp. Delcotron Alternator
Operating Principles
A typical wiring diagram is shown in Figure 2-3. The
basic operating principles are explained as follows:
The base-emitter of transistors TR3 and TR1 is con-
nected to the battery through resistor R5, thus turn-
ing these transistors on. Also, resistors R2 and R3
are connected to the battery, but the discharge cur-
rent of the battery is very low because of the resis-
tance values of R2, R3, R5, TR1, and TR3.
With the system operating, A.C. voltages initially are
generated in the stator windings by residual magne-
tism in the rotor. The diodes in the rectifier bridge
change the stator A.C. voltages to a D.C. voltage
which appears between ground and the "BAT" termi-
nal. As speed increases, current is provided for
charging the battery and operating electrical acces-
sories.
The stator also supplies D.C. field current through
the diode trio, the field, TR1, and then through the
diodes in the rectifier bridge back to the stator.
As the speed and voltage increase the voltage
between R2 and R3 increases to the value where
Zener diode D1 conducts. Transistor TR2 then turns
"ON" and TR1 and TR3 turn "OFF". With TR1 "OFF",
the field current and system voltage decrease and
D1 then blocks current flow causing TR1 and TR3 to
turn back "ON".
Capacitor C1 smooths out the voltage across R3,
resistor R4 prevents excessive current through TR1
at high temperatures, and diode D2 prevents high-
induced voltages in the field windings when TR1
turns OFF.
FIGURE 2-1. TYPICAL ALTERNATOR INSTALLATION
1. Alternator
2. Pivot Capscrew
3. Belt Tension Adjuster
4. Drive Belt
NOTE: Belt tension adjuster gauges are available
from Detroit Diesel (Part No. J 23586-B) and
Cummins (Part No. ST-1293).
FIGURE 2-2. 30-SI SERIES ALTERNATOR
1. End Plate
2. Output Terminal
3. Ground Screw
FIGURE 2-3. TYPICAL 30-SI CIRCUIT
D2-4 24 VDC Electric Supply System D02012 11/94
with 100 Amp. Delcotron Alternator
Energizing Speed
The energizing speed is the RPM at which the regu-
lator turns ON to energize the field coil. This speed is
higher than some speeds at which output can be
obtained. Therefore, when checking output at low
speeds, increase the speed until the regulator turns
ON, then reduce the speed to check the output. No
output can be obtained until the regulator turns ON.
Once the regulator turns ON, it will remain turned on
until the engine is stopped.
Rated Voltage
The integral, battery charging system output should
be checked at the "Rated Voltage":
However, it is permissible to check the output in
amperes at any voltage within the "Operating Range"
listed, since the current output will be quite close to
the value that would be obtained at "Rated Voltage."
The voltage should never be allowed to rise above
the "Operating Range" for any length of time. It
should be noted that the voltage may be below the
"Operating Range" if the battery is in a low state of
charge. However, as the battery receives a charge,
the voltage will rise to some value within the "Operat-
ing Range."
Magnetizing The Rotor
The rotor normally retains magnetism to provide volt-
age build-up when the engine is started. After disas-
sembly or servicing, however, it may be necessary to
reestablish the magnetism. To restore the normal
residual magnetism in the rotor, connect the unit to
the battery in a normal manner, then momentarily
connect a jumper lead from the battery positive (+)
post to the relay terminal, (1, Figure 2-4).
System
Voltage
Rated
Voltage
Operating
Range
24 28.0 26.0-30.0
FIGURE 2-4. TYPICAL 30-SI CROSS SECTIONAL VIEW
1. Relay Terminal R
2. Rectifier Bridge
3. Output Terminal
4. Stationary Field Coil
(Brushless)
5. Front Seal
6. Ball Bearing
7. Rotor
8. Stator
9. Roller Bearing
10. Integrated
Circuit Regulator
11. Grease Reservoir
D02012 11/94 24 VDC Electric Supply System D2-5
with 100 Amp. Delcotron Alternator
INTEGRAL CHARGING SYSTEM
(Battery Charging Alternator)
Troubleshooting Procedures
A typical 30-SI cross-sectional view is shown in Figure
2-4. A basic wiring diagram is shown in Figure 2-5.
1. Check the drive belt for proper tension.
2. Insure that an undercharged battery condition
has not been caused by accessories having
been left ON for extended periods.
3. If a battery defect is suspected, check battery
as specified in "Battery - Troubleshooting".
4. Inspect the wiring for defects. Check all connec-
tions for tightness and cleanliness, including
battery connectors.
5. Connect a voltmeter from the battery charging
alternator output terminal ("BAT") to ground (-).
A zero reading indicates an open between volt-
meter connection and battery.
6. With all accessories turned OFF, increase
engine speed as required to obtain maximum
voltage reading.
7. If voltage is not within the 26 - 30 Volts operat-
ing range, remove the unit for repair as covered
under heading of "Integral Charging System
Repair", as there is no voltage adjustment on
this model.
8. If previous Steps 1 through 7 check satisfacto-
rily, check generator as follows:
a. Disconnect battery ground cable.
b. Connect an ammeter in the circuit at the out-
put terminal of the battery charging alternator.
c. Reconnect battery ground cable.
d. Turn on accessories. Connect a carbon pile
across the battery.
e. Operate engine at moderate speed, and
adjust carbon pile as required, to obtain max-
imum current output.
IMPORTANT: Initial Voltage build-up is by resid-
ual magnetism in the rotor. Increase the speed as
required to obtain maximum current output.
f. If ampere output IS within 10 amperes of
rated output as stamped on the battery charg-
ing alternator frame, unit is not defective.
g. If ampere output IS NOT within 10 amperes
of rated output as stamped on the battery
charging alternator frame, remove the unit
for repair as covered in "Integral Charging
System Repair".
Integral Charging System Repair
Component parts and connections are shown in
Figure 2-6.
FIGURE 2-5. TYPICAL CHARGING CIRCUIT
FIGURE 2-6. 30-SI COMPONENT PARTS
1. Relay Terminal R
2. Reg. Stud Connector
3. R Terminal
Connector
4. Rectifier Bridge
5. Stator Leads
6. Output Term.
Connector
7. Diode Trio
8. Output Terminal
9. Capacitor
10. Field Leads (Insu-
lated Screws)
11. Ground Screw
12. Regulator
D2-6 24 VDC Electric Supply System D02012 11/94
with 100 Amp. Delcotron Alternator
Insulated battery charging alternators have both recti-
fier bridge heat sinks insulated, and the lower heat sink
is connected to the second output terminal located
where the "R" terminal is shown (3, Figure 2-6).
NOTE: Some digital ohmmeters cannot be used to
check diodes. Consult ohmmeter manufacturers to
determine ohmmeter capabilities.
NOTE: The Diode Trio (7, Figure 2-6) has been
removed in Figure 2-7, along with the end plate. Note
also that the rectifier end frame has been dipped in
clear electric grade varnish.
Regulator Check
The regulator cannot be checked with an ohmmeter.
Use an approved regulator tester available from vari-
ous test equipment manufacturers.
Rectifier Bridge Check
(Omit for Overcharged Battery)
To check the rectifier bridge, connect the ohmmeter
to a heat sink and one of the three terminals (1, Fig-
ure 2-7). Then reverse lead connections to the same
heat sink and same terminal.
If both readings are the same, replace the rectifier
bridge by detaching the necessary screws and nuts.
A good rectifier bridge will give one high and one low
reading. Repeat this same test between the same
heat sink and the other two terminals, and between
the other heat sink and each of the three terminals.
This makes a total of six checks, with two readings
taken for each check on each rectifier bridge.
IMPORTANT: If rectifier bridge is constructed
with flat metal clips at the three studs, press
down firmly onto flat metal clips and not onto
threaded stud.
Field Coil Checks
To check for grounds, connect an ohmmeter to one
field coil lead and to the end frame as illustrated in 2,
Figure 2-7. If ohmmeter reading is low, the field coil is
grounded.
To check for opens, connect an ohmmeter to the two
field coil leads as shown in 3, Figure 2-7. If ohmmeter
reading is high (infinite), the field coil is open.
The winding is checked for short-circuits by connect-
ing a 24 Volt battery and ammeter in series with the
field coil. Note the ammeter reading. An ammeter
reading above 2.7 - 3.4 amps indicates shorted wind-
ings. An alternate method is to check the resistance
of the field by connecting an ohmmeter to the field
coil. If the resistance reading is below 7.0 - 9.0 ohms,
the winding is shorted. To replace the field coil, see
"Disassembly."
FIGURE 2-7. OHMMETER CHECKS
1. Ohmmeter Connected to Heat Sink and one
Rectifier Bridge Terminal
2. Ohmmeter Connected to one Field Coil Lead and
End Frame.
3. Ohmmeter Connected to both Field Coil Leads.
4. Ohmmeter Connected to one Stator Lead and End
Frame.
D02012 11/94 24 VDC Electric Supply System D2-7
with 100 Amp. Delcotron Alternator
Diode Trio Check
To check the diode trio, remove it from the end frame
assembly by detaching the nuts and attaching screw.
NOTE: The insulating washer on the screw is
assembled over the top of the diode trio connector.
Connect an ohmmeter having a 1 1/2-Volt cell, and
using the lowest range scale, to the single connector
and to one of the three connectors, (Figure 2-8).
Observe the reading. Then reverse the ohmmeter
leads to the same two connectors. If both readings
are the same, replace the diode trio. A good diode
trio will give one high and one low reading. Repeat
this same test between the single connector and
each of the other two connectors.
Stator Checks (Omit for Overcharged Battery)
Most stators are delta wound and only a check for
grounds can be made with an ohmmeter. Connect
from either lead to the frame (4, Figure 2-7). The
reading should be infinite. If not, replace the stator.
See "Disassembly."
If the regulator checks good and the unit does not
supply rated output, replace the stator if it is badly
discolored.
Disassembly (Refer to Figure 2-10)
1. Remove screws (1) and end plate (2).
2. Remove pulley (40) and fan (39).
3. Remove 4 thru-bolts (37).
4. Separate rotor and Drive End frame (36) from
stator and Rectifier End frame (27).
5. Press rotor (32) from end frame.
6. Remove inside collar (34) from end frame.
7. Remove outside collar from rotor shaft, if
present. Early models may have a collar and
fabricated metal fan; later models have a one-
piece cast aluminum fan (39) whose hub
replaces the former outside collar.
8. To replace Drive End Frame Bearing (Figure 2-9):
a. Remove retaining plate attaching screws (5).
b. Remove retainer plate (6).
c. Push on inner race to remove bearing (2).
d. Press in new bearing against outer race.
e. Assemble retainer with screws.
f. Assemble inside collar(1) over shaft.
g. Press rotor into drive end frame.
h. Assemble outer collar (4).
FIGURE 2-8. DIODE TRIO CHECK
1. Single Connector 2. Three Connectors
FIGURE 2-9. DRIVE END FRAME BEARING
1. Inside Collar
2. Sealed Bearing
3. Drive End Frame
4. Outer Collar/Fan Hub
5. Capscrew
6. Retainer Plate
7. Seal
D2-8 24 VDC Electric Supply System D02012 11/94
with 100 Amp. Delcotron Alternator
9. To replace Rectifier End Frame bearing:
a. Pull inner race from shaft and bearing from
end frame.
b. Assemble new inner race and bearing as
shown in Figure 4 with bearing seal away
from grease reservoir.
c. Use Delco Remy lubricant P/No. 1948791
and fill reservoir half full. Arrange lubricant
so a portion will touch bearing when assem-
bled.
10. To replace field coil:
a. Remove attaching bolts.
b. Install new field coil and torque bolts to 55
inch-lbs.
Reassembly
Assemble parts as shown in Figure 2-10. Before
attaching end plate, dip rectifier end frame about one
inch (1") deep into clear electric grade varnish, or use
spray can, to restore assembly to new condition.
FIGURE 2-10. 30-SI PARTS ILLUSTRATION
1. Screw
2. Plate
3. Plug, Bearing Well (1)
4. Screw
5. Washer, Plain
6. Nut & Washer
7. Diode
8. Screw
9. Bridge, Rectifier
10. Screw
11. Screw
12. Connector, Rectifier Bridge to Regulator
13. Nut & Washer
14. Regulator
15. Cap, Relay Terminal
16. Connector, Rectifier Bridge to Relay
17. Relay Terminal Package Contains: Boot, "R" Ter-
minal, Insulating Washer, Metal Washer, Connector,
Washer, Nut
18. Lockwasher, Ground
19. Screw, Ground Terminal
20. Output Terminal Package Contains: Output Termi-
nal, Insulator, Insulating Washer, Metal Washer,
Lock Washer (two), Nut (two)
21. Screw
22. Capacitor
23. Bracket
24. Bushing, Mounting Hinge (1)
25. Bearing, Outer Race (1)
26. Roller Bearing, Inner Race
27. Housing, Rectifier End
28. Clip - Stator Leads (2)
29. 29. Grommet (2)
30. Stator
31. Coil
32. Rotor
33. Retainer, Drive End Bearing (Includes Seal)
34. Collar, Inside
35. Ball Bearing, Sealed
36. Housing, Drive End
37. Thru Bolt
38. Screw
39. Fan, Cast Aluminum
40. Pulley (from engine manufacturer)
41. Washer, Shaft Nut
42. Nut, Shaft
NOTES:
(1) Included In Item 27, Housing, Rectifier End
(2) Included In Item 30, Stator.
D02012 11/94 24 VDC Electric Supply System D2-9
with 100 Amp. Delcotron Alternator
FIGURE 2-10. 30-SI PARTS ILLUSTRATION
D2-10 24 VDC Electric Supply System D02012 11/94
with 100 Amp. Delcotron Alternator
NOTES:
D03013 24 VDC System Components D3-1
24 VDC ELECTRICAL SYSTEM COMPONENTS
ALARM INDICATING DEVICE (AID)
SYSTEM
The Alarm Indicating Device (AID) used on HAUL-
PAK
F (85
C) and 500
ohms at 250
oF (122
F
(96
C).
FIGURE 3-1. AID SYSTEM
1. Diode Matrix With Sound
2. Diode Matrix Without Sound
3. Hot Switch Inverter
4. Cover
5. Housing
6. Electrical Hook-Up Terminal
7. Temperature & Latch
8. Coolant Level & Flasher
D3-2 24 VDC System Components D03013
When the temperature is low and the resistance is
high, Q1 is off and there is no high temperature indi-
cation. When the water gets hot and resistance
decreases, Q1 will turn on and ground the flasher
through D8, the alarm horn through D12, and the
High Temperature Light through terminal D8. R14
can adjust the temperature (resistance) at which the
circuit is activated. The Latch Circuit monitors the
accumulator precharge pressure switches. When
one of the pressure switches closes, Q5 will be
turned off which supplies power to the gate of SCR
Q7. With Q7 turned on Q9 will supply the ground
path to turn on the Low Accumulator Precharge Indi-
cator Light and sound the alarm horn. The Indicator
Light is connected to 12F and will flash off and on.
The SCR will remain on until power is removed from
the card by turning the key switch "Off".
The Hot Switch Inverter Card (Slot 3) is used to
operate and test the Service Brake and Motor Blower
(green) Indicator Lights. In normal conditions Q4 and
Q7 transistors are off and the Indicator Lights are off.
When the stoplight switch or the blower switch is acti-
vated, 24 Volts is sent to pins "E" or "J " of the Hot
Switch Inverter Card. Transistor Q4 or Q7 is turned
on by this Voltage and, in turn, grounds the appropri-
ate Indicator Light. There is no alarm horn operation
with this card.
The Hot Switch Inverter Card (Slot 4) is used to
operate and test the Body Up and Engine Monitor
Indicator Lights. In normal conditions Q4 and Q7
transistors are off and the Indicator Lights are off.
When Body Up Switch or the Engine Monitor Switch
closes, 24 Volts is sent to pins "E" or "J " of the Hot
Switch Inventor Card. Transistor Q4 or Q7 is turned
on by this Voltage and, in turn, grounds the appropri-
ate indicator light. There is no alarm horn operation
with this card.
The Oil Level Card (Optional) is used to turn on the
Low Oil Level Indicator Light to warn the operator
engine oil level is below acceptable levels. The
engine oil float is connected to a variable resistor. As
the oil level decreases, the resistance goes down
causing Q3 to turn on grounding the indicator light
and alarm horn.
The Temperature Card (Optional) is used to turn on
the High Oil Temperature Indicator Light. The indica-
tor light tells the operator hydraulic tank oil tempera-
ture has exceeded acceptable levels. Normal
temperature setting is 250F (121C). As the tem-
perature goes up the resistance in the probe
decreases providing a ground path for the indicator
light and alarm horn.
The Diode Matrix Without Sound Card consists of a
series of diodes capable of working with eight differ-
ent indicator circuits. The indicator light can be a
flashing light by connecting it to 12F wire or a steady
light by connecting it to 12M wire. When an indicator
circuit is not activated there is no ground for the bulb.
When the Indicator Detecting Switch activates the
circuit, it grounds the lamp and grounds the flasher
circuit through the diodes. Any circuits connected to
terminals C1 through C8 will operate the same. The
alarm horn is not activated by this card.
The Diode Matrix With Sound Card works very
much like the other Diode Matrix Card, except that it
contains extra diodes to activate the alarm horn in
addition to the flasher. The circuits connected to ter-
minals A1 through A8 operate in the same manner.
All of the cards circuits are connected to the Lamp
Test Switch on the instrument panel. In normal oper-
ation, these circuits are open and do nothing. When
the operator pushes the Lamp Test Switch, it acti-
vates all the indicator circuits by grounding them.
This is used to verify that all lamps are functional.
D03013 24 VDC System Components D3-3
BODY-UP SWITCH
The body-up switch is located on the left frame rail above
the hydraulic tank and must be adjusted to within limits.
The body-up switch is designed to prevent propulsion in
"Reverse" when the dump body is not resting on frame
rails. The switch also prevents forward propulsion
unless the override button is depressed and held.
The body-up switch should be checked daily and the
sensing area cleaned of any dirt or metallic dust
accumulation. Improper adjustment or loose mount-
ing bolts may cause false signals or damage to the
body-up switch assembly.
Adjustment
Adjust proximity switch bracket to maintain an air gap
(4), between sensing and body bracket, of between
0.50 in. (12.7 mm) minimum and 0.62 in. (15.7 mm)
maximum. Set up measurement (5) should be 2.12
0.06 in. (53.8 1.5 mm).
Set up measurement (6) should be 4.62 0.03 in.
(117.3 0.76 mm).
Service
Keep sensing area clean, free of metallic dust and
other debris that may damage or inhibit operation of
the proximity switch. If the switch is not functioning or
damaged the unit must be replaced.
HOIST LIMIT SWITCH
The hoist limit switch is located inside the left frame
rail above the rear suspension (near the body pivot
pin). The hoist limit switch is designed to stop the
hoist cylinders short of full extension and prevent
possible damage to the dump body or hoist cylinders.
The hoist limit switch should be checked daily and
the sensing area cleaned of any dirt or metallic dust
accumulation. The switch must be properly adjusted
at all times. Improper adjustment or loose mounting
bolts may cause false signals or damage to the
switch assembly.
Adjustment
With body raised and hoist cylinders within 6 in. (152
mm) of maximum travel, make the following adjust-
ments. Adjust limit switch bracket to maintain an air
gap of 0.56 in. (14.2 mm) (1) between sensing area
and body activator. Set-up measurement (2) should
be 1.50 in. (38.1 mm).
Service
Keep sensing area clean, free of metallic dust and
other debris that may damage or inhibit operation of
the limit switch. If the switch is not functioning or
damaged the unit must be replaced.
FIGURE 3-2. BODY-UP SWITCH ADJ USTMENT
1. Body-Up Switch
2. Sensing Area
3. Actuator
4. Air Gap
5. Set Up Measurement
6. Set Up Measurement
FIGURE 3-3. HOIST LIMIT SWITCH
1. Air Gap
2. Set Up Measurement
3. Hoist Limit Switch
4. Sensing Area
5. Actuator
D3-4 24 VDC System Components D03013
GROUND LEVEL SHUTDOWN
For Detroit Diesel (Without DDEC).
The Ground Level Shutdown switch is located on the
left side of the truck on the up-right near the ladder.
The switch is a spring return push button switch.
The switch is connected to the engine shutdown
solenoid. The engine shutdown solenoid is normally
open (N.O.). When Ground Level Shutdown switch is
depressed, solenoid energizes, allowing engine oil
pressure to the hydraulic governor to return to engine
oil sump. With no oil pressure, the spring loaded gov-
ernor closes, shutting off fuel to the engine.
The Ground Level Shutdown button must be
depressed until engine comes to a complete stop.
For Detroit Diesel (With DDEC II or DDEC III).
The Ground Level Shutdown switch is located on the
left side of the truck on the up-right near the ladder.
The switch is a two position rotary switch.
The ground level shutdown switch is connected in
series between the battery supply and the ignition
switch. Turning the switch to the "OFF" position will
stop all power going to the key switch.
To shut down the engine, turn ground level shutdown
switch to the "OFF" position. Turn the switch to the
"ON" position before starting engine.
For Cummins Engines (With air throttle).
The Ground Level Shutdown system consists of a
switch and a fuel valve. The switch is located on the
left side of the truck on the up-right near the ladder. It
is a spring return, push button switch.
The fuel valve is located on the engine and is con-
nected between the injection pump and the injectors.
The fuel valve contains two electric solenoids. The
"open" solenoid is energized only when the ignition
switch is in the start position. The "close" solenoid is
only energized when the shutdown switch in the cab
or the ground level shutdown switch is activated. The
solenoids move the valve to either the open or closed
position. The valve will remain in its current position
until the other solenoid is energized.
The ground level shutdown switch is connected in
parallel with the shutdown switch located in the cab.
When the ground level shutdown switch is activated,
it will send 24 Volts to the fuel valve close solenoid,
moving the valve to the closed position, and stopping
the engine.
For Cummins Engines (With Centry throttle con-
trol).
The Ground Level Shutdown switch is located on the
left side of the truck on the up-right near the ladder.
The switch is a two position rotary switch.
The ground level shutdown switch is connected in
series between the battery supply and the ignition
switch. Turning the switch to the "OFF" position will
stop all power going to the key switch.
With the shutdown switch and the key switch in the
run position, the key switch sends 24 Volts to the fuel
solenoid. The fuel solenoid needs to be energized to
start and run the engine. When there is no Voltage at
the fuel solenoid, the fuel solenoid shuts off the fuel
to the engine.
To shut down the engine (at the ground level), turn
the ground level shutdown switch to the "OFF" posi-
tion. Turn the switch to the "ON" position before start-
ing engine.
To shut down the engine (inside the cab), turn the
key switch to the "OFF" position.
D03013 24 VDC System Components D3-5
24 VOLT RELAY BOARDS
The truck is equipped with 5 relay boards and 2 diode
boards to control the 24 Volt electrical system. If a truck
is equipped with the optional Payload Meter System,
there will be a sixth relay board.Each relay board con-
tains 4 relays, all of which are interchangeable.
Each relay board also contains circuit breakers,
which are also interchangeable between the relay
boards. DO NOT interchange or replace any circuit
breaker with one of a different capacity than specified
for that circuit. Serious damage or fire may result if
the wrong capacity circuit breaker is used.
The six relay boards are identified as follows:
Relay Board 1 Turn Signal (1, Figure 3-5)
Relay Board 2 Payload Meter (5, Figure 3-4)
Relay Board 3 Stop Lights (2, Figure 3-5)
Relay Board 4 Parking Brake (7, Figure 3-4)
Relay Board 5 Head Lights (3, Figure 3-5)
Relay Board 6 Auxiliary Panel (6, Figure 3-4)
The truck is also equipped with two diode boards:
Diode Board 1 (4, Figure 3-4)
Diode Board 2 (1, Figure 3-6)
Refer to Circuit Breaker chart for the circuits each cir-
cuit breaker protects.
NOTE: All references to item location (Right or Left
side) in the control cabinet will be as a person is
facing towards the front of the control cabinet.
FIGURE 3-5. RELAY BOARD LOCATION
(J UNCTION BOX BEHIND CONTROL CABINET)
1. Relay Board 1
2. Relay Board 3
3. Relay Board 5
4. J unction Box
FIGURE 3-4. RELAY BOARD LOCATION
1. Control Cabinet
2. Statex III FL 275 Panel
3. Control Panel
4. Diode Board 1
5. Relay Board 2 (Pay-
load Meter
6. Relay Board 6 (Aux.)
7. Relay Board 4
(Park Brake)
D3-6 24 VDC System Components D03013
Description
Each relay board is equipped with four green lights
(9, Figure 3-7) and one red light (7). The four green
lights are labeled K1, K2, K3, or K4. These lights will
be "ON" only when that particular control circuit has
been switched "ON" and the relay coil is being ener-
gized. The light will not turn on if the relay board does
not receive the 24 Volt signal to turn "ON" a compo-
nent, or if the relay coil has an "open" circuit.
The red "Breaker Open" light (if "ON") indicates that
a circuit breaker (on that relay board) is in the "OFF"
position. A light on the instrument panel will also turn
"ON" telling the operator that a circuit breaker is in
the "OFF" position. The red breaker open light will
turn "ON" whenever there is a Voltage difference
across the two terminals of a circuit breaker.
If a control switch has been turned "ON" and a green
(K) light is "ON", but that component is not operating,
check the following on the relay board for that circuit:
1. Check for a circuit breaker that is in the "OFF"
position or a red (breaker open) light is "ON". If
a circuit breaker is "OFF", turn it "ON". Check
operation of component. If it trips again, check
the wiring or component for defects that could
be causing the circuit to be overloaded.
2. The contacts inside the relay may not be clos-
ing and not causing an electrical connection.
Swap relays and check again. Replace defec-
tive relays.
3. Check the wiring and all of the connections
between the relay board and the component for
an "open" circuit.
4. Defective component. Replace component.
5. Poor ground at the component. Repair the
ground connection.
Service
To replace a relay:
1. Remove one screw (10, Figure 3-7) holding the
crossbar in place and loosen the other screw.
2. Swing crossbar away.
3. Gently wiggle and pull upward to remove relay
(11).
4. Line up tabs and install new relay.
5. Place crossbar in original position and install
screw (10) that was removed and tighten both
screws.
To replace a circuit breaker:
NOTE: Always replace a circuit breaker with one of
the same amperage capacity as the one being
removed.
1. Place battery disconnect switch(s) in the "OFF"
position.
2. Unplug all wiring harness(s) from relay board.
Remove four relay mounting screws and
remove relay board from truck.
3. Remove four hold down screws (3) (one in each
corner) in circuit breaker cover plate and all cir-
cuit breaker screws. Remove cover plate from
circuit breakers.
4. Remove nuts and star washer from back side of
circuit board that holds the breaker in place.
5. Lift out circuit breaker. Retain flat washers that
were between inner circuit breaker nut and
relay board.
6. Install one nut and two flat washers to each
pole on the circuit breaker. Nuts must be
FIGURE 3-6 DIODE BOARD 2 LOCATION
(BELOW INSTRUMENT PANEL)
1. Diode Board 2 2. Steering Wheel
Column
D03013 24 VDC System Components D3-7
adjusted to the same height as on the other cir-
cuit breakers. This is necessary so when cover
plate is installed, it will not press circuit breaker
into, or pull up on, the circuit board. Install new
circuit breaker of the same capacity rating as
the one removed.
7. Install star washer and nut to circuit breaker
poles (on the back side) and tighten nuts.
8. Install cover plate and all screws removed dur-
ing disassembly.
To replace a circuit panel card:
DO NOT remove the small screws that hold the
cover plate to the circuit panel. Replace circuit panel
as a complete assembly.
1. Place battery disconnect switch(s) in the "OFF"
position.
2. Remove the two mounting screws (6, Figure 3-7)
and carefully remove the circuit panel card from
the relay board.
3. Line up the new circuit panel in slots and with
the socket on the relay board and install gently.
4. Install two mounting screws (6).
FIGURE 3-7. TYPICAL RELAY BOARD
1. Relay Board
2. Main Harness
Connector
3. Screw
4. Circuit Breaker
5. Circuit Panel Card
6. Screw
7. Breaker Open Light
(RED)
8. Bleed Down Light
(GREEN)
9. K1,K2,K3,K4 Lights
(GREEN)
10. Screw
11. Relay
12. Circuit Harness
Connector
13. Circuit Harness
Connector
D3-8 24 VDC System Components D03013
RELAY BOARD DESCRIPTIONS
Relay Board 1 Turn Signal
The top relay board located in the junction box on the
rear of the control cabinet.
1 - Flasher Power Light (Green): This light will
be "ON" when the turn signals or hazard lights
are activated.
K1 light will be "ON" during right turn signal
operation
K2 light will be "ON" during left turn signal oper-
ation
K4 light will be flashing when the turn signals or
hazard lights are in operation.
NOTE: If circuit breakers (CB13 & CB15) are in the
off position, no warning will be noticed until the
clearance light switch is turned "ON".
1 - Flasher Module card.
3 - 15 amp circuit breakers (CB13, CB14, CB15)
4 - Relays
Right Turn/Clear Light Relay
Left Turn/Clear Light Relay
Clearance Lights Relay
Flasher Relay
Relay Board 2 Payload Meter (Optional)
Located on right wall of control cabinet. Only installed
if truck is equipped with Payload Meter System.
1 - Data Storage Module card
1 - Payload Stored Light (Green): This light is
ON for one second when the payload meter
actually stores the load data into memory.
1 - 5 amp circuit breakers (CB29) (To payload
meter)
1 - 15 amp circuit breaker (CB28) (To all light
relays)
4 - Relays
Light Relay 1 (Green)
Light Relay 2 (Amber)
Light Relay 3 (Red)
Light Control Relay
Relay Board 3 Stop Lights
Located in the center of the three relay boards in the
junction box on the rear of the control cabinet.
1 - Light Module Display card
1 - Rev Light (Green): This light is "ON" whenever
the selector switch is in the "reverse" position,
and the key switch is in the "ON" position.
4 - 15 amp circuit breakers
(CB16, CB17, CB18, CB19)
4 - Relays
Manual Back-up Lights Relay
Stop Light Relay
Retard Light Relay
Slippery Road Relay
Relay Board 4 Parking Brake
Located on the floor of control cabinet behind the
right hand door.
1 - Steering Pressure Bleed Down Timer Module
card.
1 - Bleed Down Light (Green): This light in ON
when the bleeddown solenoid is being energized.
The bleeddown timer will energize the solenoid for
two to three minutes after key switch is turned
OFF.
2 - 5 amp circuit breakers (CB20, CB22)
1 - 15 amp circuit breakers (CB21)
4 - Relays
Park Brake Failure
Cranking Oil Pressure Interlock Relay
Horn Relay
Body Up Relay
D03013 24 VDC System Components D3-9
Relay Board 5Head Lights
The bottom relay board of the three located in the
junction box on the rear of the control cabinet.
1 - Light Display Module card
1 - Lights Control Light (Green): This light is
"ON" when there is 24 volts being supplied to
the battery terminal of the light switch.
5 - 15 amp circuit breakers
(CB23, CB24, CB25, CB26, CB27)
4 - Relays
Left Low Beam Relay
Right Low Beam Relay
Left High Beam Relay
Right High Beam Relay
Relay Board 6 Auxiliary Panel
The auxiliary panel is located on the floor of control
cabinet behind the right hand door. Additional circuits
may be added by utilizing the empty relay terminals
provided.
To add an additional circuit with a relay, connect the
wires as described below:
Control circuit for the relay are the "+" and "-" termi-
nals.
"+" terminal is for positive voltage.
"-" terminal is for grounding of the control circuit.
Either circuit can be switched "open" or "closed" to
control the position of the relay.
The terminals of the switched circuit from the relay
contacts are labeled as follows
NC - Normally Closed
COM - Common
NO - Normally Open
"COM" terminal is for the voltage source
(protected by a circuit breaker) coming into
the relay which will supply the electrical
power for the component being controlled.
"NC" terminal is connected (through the
relay) to the "COM" terminal when the relay
is not energized (when the control circuit ter-
minals "+" & "-") are not activated).
"NO" terminal is connected (through the
relay) to the "COM" terminal when the relay
is energized (by the control circuits "+" & "-")
being energized).
D3-10 24 VDC System Components D03013
DIODE BOARDS
The truck is equipped with two diode boards. Each
board contains replaceable diodes.
Diode Board 1
Diode board 1 is located on right wall on control cabi-
net and contains 23 replaceable diodes.
DIODE BOARD 1
DIODE DESCRIPTION WIRE #
1 ENGINE MONITOR CIRCUIT (NOT USED THIS APPLICATION) 31MTR - 509R2
2 ENGINE MONITOR CIRCUIT (NOT USED THIS APPLICATION) 509R2 - 509RB
3 ENGINE MONITOR CIRCUIT - SECONDARY ECM ON ENGINE 31MTR - 509R1
4 ENGINE MONITOR CIRCUIT SECONDARY AID ALARM GROUND 509R1 - 509RA
5 ENGINE MONITOR CIRCUIT - MAIN ECM ON ENGINE 31MTR - 509M
6 ENGINE MONITOR CIRCUIT - MAIN AID ALARM TO GROUND 509M - 509MA
7 ENGINE MONITOR CIRCUIT (NOT USED THIS APPLICATION) 31MTR - 31MT
8 CHECK ENGINE CIRCUIT (NOT USED THIS APPLICATION) 419I - 419R2
9 CHECK ENGINE CIRCUIT - SECONDARY ECM ON ENGINE 419I - 419R1
10 CHECK ENGINE CIRCUIT - MAIN ECM ON ENGINE 419I - 419M
11 CHECK ENGINE CIRCUIT - LAMP TEST 419I - 419
12 PARK BRAKE SOLENOID - SUPPRESSION 52CS - 71
13 LINCOLN LUBE SOLENOID - SUPPRESSION 68-710
14 HOIST LIMIT SOLENOID - SUPPRESSION 53H - 710
15 ACCUMULATOR BLEEDDOWN SOLENOID - SUPPRESSION 33J - 710
16 THROTTLE SOLENOID - SUPPRESSION (IF EQUIPPED) 76MM - 439E
17 LOW IDLE SOLENOID - SUPPRESSION (IF EQUIPPED) 76L - 439
18 FAULT DETECTION PANEL - ELECTRICAL SYSTEM FAULT 79V - 79VD
19 SYSTEM FAULT - ELECTRICAL SYSTEM FAULT 79V - 79VS
20 GROUND FAULT - ELECTRICAL SYSTEM FAULT 79V - 79VG
21 LOW STEERING PRESSURE INDICATOR LIGHT CIRCUIT 33F - 33A
22 PREVENTS LOW STEERING PRESSURE INDICATOR LIGHT
FROM TURNING ON WHEN THERE IS LOW PRESSURE IN
BRAKE CIRCUIT
FF3 - 33
23 LOW BRAKE PRESSURE INDICATOR LIGHT CIRCUIT 33F - 33L
DB1P7 SPARE
DB1P8 SPARE
DB1P9 SPARE
DB1P10 SPARE
DB1P11 SPARE
DB1P12 SPARE
D03013 24 VDC System Components D3-11
Diode Board 2
Diode board 2 is located inside the cab on steering
column bracket, and contains 7 replaceable diodes.
DIODE BOARD 2
DIODE DESCRIPTION WIRE #
1 NOT USED THIS APPLICATION 12T - 712
2 BODY UP ALARM 31A - 63L
3 LOW FUEL ALARM 31A - 38
4 BRAKE LOCK SOLENOID - SUPPRESSION 52D - 710
5 PREVENTS BRAKE LOCK SOLENOID BEING ENERGIZED WHEN
USING SECONDARY BRAKE SWITCH OR AUTOMATIC APPLY OF
BRAKES
52D - 52B
6
PROVIDES PATH FOR SLIPPERY ROAD RELAY AND SOLENOID TO
BE ENERGIZED:
WHEN USING BRAKE LOCK SWITCH
WHEN USING SECONDARY BRAKE SWITCH
DURING AUTOMATIC BRAKE APPLY
ALSO PREVENTS ENERGIZING OF THE AUXILIARY BRAKE SOLE-
NOID WITH THE SLIPPERY ROAD SWITCH IN THE ON POSITION.
52B - 52S
7 AUXILIARY BRAKE SOLENOID - SUPPRESSION
DP2P4 SPARE
DB2P5 SPARE
BD2P6 SPARE
D3-12 24 VDC System Components D03013
CIRCUIT BREAKERS
AMPS DEVICE(S) PROTECTED LOCATION
CB13 15 Turn Signal & Clearance Lights RB1, Control Cabinet
CB14 15 Flashing Lights RB1, Control Cabinet
CB15 15 RD1, RD2, & Tail Lights RB1, Control Cabinet
CB16 15 Dynamic Retard Lights RB3, Control Cabinet
CB17 15 Manual Back-up Lights RB3, Control Cabinet
CB18 15 Stop Lights RB3, Control Cabinet
CB19 15 Back-up Horn RB3, Control Cabinet
CB20 5 Parking Brake Failure Relay RB4, Control Cabinet
CB21 15 Fluid Components Cabinet Service Lights, Rear Axle
Service Light, Horn Solenoid, Steering Accumulator
Bleed Down Solenoid, Hourmeter
RB4, Control Cabinet
CB22 5 DDEC Master ECM Control Power (DDEC Engine Only) RB4, Control Cabinet
CB23 15 Low Beam Headlight, L.H. RB5, Control Cabinet
CB24 15 Low Beam Headlight, R.H. RB5, Control Cabinet
CB25 15 High Beam Headlight, L.H. RB5, Control Cabinet
CB26 15 High Beam Headlight, R.H. RB5, Control Cabinet
CB27 15 Clearance Light Relay, Panel Lights, High Beam Indica-
tor
RB5, Control Cabinet
CB28 15 Payload Meter (Lights and Light Relays) RB2, Control Cabinet
CB29 5 Payload Meter ECU RB2, Control Cabinet
DB30 15 Ladder, Engine Service, & (Optional) Fog Lights Operator Cab, Instrument Panel
CB31 15 Heater/AC Blower Motor Operator Cab, Instrument Panel
CB32 15 Warning Lights, A.I.D. Module, Voltmeter, Turn Signal
Relays, & Indicator Lights
Operator Cab, Instrument Panel
CB33 15 Hoist Solenoid Operator Cab, Instrument Panel
CB34 10 Air Dryer Heater Operator Cab, Instrument Panel
CB35 10 Lincoln Lube Solenoid (Optional) Operator Cab, Instrument Panel
CB37 10 Windshield Washer & Wiper Operator Cab, Instrument Panel
CB38 5 Fuel Gauge, Engine Temperature Gauge Operator Cab, Instrument Panel
CB339 5 Radiator Pressure Solenoid Operator Cab, Instrument Panel
CB40 5 12 VDC Accessory Receptacle (DDEC Engine Only) Operator Cab, Instrument Panel
CB42 5 Slippery Road Solenoid & Relay Operator Cab, Instrument Panel
CB43 10 Starter Solenoid, Oil Pressure Latch Relay Operator Cab, Instrument Panel
CB44 20 DDR Connections, Coolant Level Module (DDEC Engine
Only)
Vanner Box
CB45 20 DDEC Main ECM 12 VDC Power (DDEC Engine Only) Vanner Box
CB46 20 DDEC Main ECM 12 VDC Power (DDEC Engine Only) Vanner Box
CB47 20 DDEC Receiver ECM 12 VDC Power (DDEC Engine Only) Vanner Box
CB48 20 DDEC Receiver ECM 12 VDC Power (DDEC Engine Only) Vanner Box
E01009 3/98 Index E1-1
SECTION E
ELECTRICAL PROPULSION COMPONENTS
INDEX
ELECTRICAL PROPULSION COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1
General System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1
17FL275 Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-3
Computer Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-5
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-5
2-Digit Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-8
Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-8
Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-9
Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-9
Event Code Descriptions (Table I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E2-11
Subcode Descriptions (Table II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-18
Portable Test Unit (PTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-20
Software Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-22
The Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-23
PTU Software Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-24
Configuration (CFG) File Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-25
Statex Configuration Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-31
Programming the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-42
PTU Hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-42
Download Configuration Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-44
Event Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-46
Statistical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-48
Statistical Data Codes - Counters (Table III). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-50
Statistical Data Codes - Profiles (Table IV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-55
Truck Specific Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-59
Temporary Truck Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-60
Miscellaneous Software Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-61
Saving Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-61
PTU Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-61
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . E2-63
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-63
Electric Wheel Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-63
Retarding Grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-63
Acceleration Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-63
Electronic Accelerator and Retard Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-66
Cooling Blower Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-67
Electrical Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-68
STATEX III Electric Drive Components Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-74
Detroit Diesel Electronic Engine Controls Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-75
ELECTRICAL CHECKOUT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-1
See pages E3-1 and E3-2 for index of Checkout Procedure
E1-2 Index E01009 3/98
1. Electric shock can cause serious of fatal injury. Only qualified electrical maintenance person-
nel should perform electrical testing. Use caution during test procedures to protect personnel
from injury. All potential testing should be considered hazardous and proper precautions are
necessary.
2. General Electric DOES NOT recommend removing control cards or panel connectors prior to
welding. When welding on a truck, connect the welders ground cable directly to, or as close
as possible to the part being welded. Welder cables should not be placed near truck system
power cables or wiring harnesses.
3. Any tim one of the plug-in circuit cards must be removed or reinstalled, be certain that the
control power switch is Off. Wear a properly grounded wrist strap when removing a card to
prevent damage caused by static electricity. After card removal, place in a static proof bag or
container.
4. Extreme care should be exercised to prevent damage to the various semi-conductor devices
and low impedance circuits under test. When using an ohmmeter to check diodes, transis-
tors, and low power conductors, care must be used when using the ohms x 1 scale. Exces-
sive current can damage the meter.When using the Hi-pot tester or megger, disconnect the
104 pin connectors CNA, CNB, CND, and CNE located at the top of the 17FL275 panel. Refer
to the GE publication VEHICLE TEST INSTRUCTIONS FOR OHV STATEX III SYSTEMS for
additional instructions.
5. Do not make open circuit Voltage checks in propulsion mode.
6. Parking brakes and service brakes have to be released for some tests. When this occurs,
make sure wheels are blocked.
E02011C1 1/96 Electrical Propulsion Components E2-1
ELECTRICAL PROPULSION COMPONENTS
GENERAL SYSTEM DESCRIPTION
The electric propulsion and control system of the
HAULPAK
Distributor
under the GE Unit Exchange Program.
Cards should be packed in a special shipping con-
tainer, designed specifically for shipping these cards.
Contact your HAULPAK
truck model.
The CFG program is also used to set values which
are specific to a particular mine, such as overspeed
settings.
Configuration software, also sometimes referred to
as configuration download software, allows the end
user (mine) or HAULPAK
on
3.5" floppy disks must be transferred to the PTU hard
disk drive prior to transferring the Control Program to
the truck.
All adjustments, setup procedures and diagnostic trou-
bleshooting of the truck's control system can be made
via this PTU. Most of the procedures are menu driven,
with function screens provided as part of the operating
software. Figure 2-2. illustrates the Main Menu which
appears when the software program opens. Figure 2-3
illustrates the menu tree showing the various screen
menus available from the main menu and the path
required to reach the next level sub-menu.
Sample PTU screens illustrated on the following pages
show menus and data screens as they appear in the
version 11, J uly 1994 STATEX III software release.
Earlier and later versions of the software may differ.
The information that follows is presented in the
sequence that it would most likely be used at a mine
site that was receiving new Statex III trucks or a mine
that was updating software from previous release
versions. It is assumed the technician is familiar with
the basic operation of a laptop computer.
OPERATIONAL HINTS
Here are a few things to remember about the use of
the PTU and software:
Some instructions in this manual call for the user to
type certain operating commands. These commands
are shown in a typewriter style type font within quota-
tion marks to indicate the characters to be typed from
the keyboard. The operating commands should be
typed in lower case letters. Do not type the quotation
marks when entering commands on the PTU. (Refer
to the chart below.)
Other operations require pressing an individual key
on the keyboard; these keys are shown in square
brackets. For example, if an operation requires
pressing the key labelled Enter, it will be shown as
[ENTER]. Keys shown as [F1] through [F10] refer to
the Function keys across the top of the keyboard.
Note that many portable computers require pressing
another key (usually labelled Fn) in conjunction with
each Function key.
Keep the PTU plugged into its charger
when possible to maintain a full charge on
the battery.
There is an indicator light on the PTU
which, when lit, indicates low battery power.
If this light should come on while using the
PTU, continue until you reach a convenient
break point. Return to the main menu and
turn off the PTU. Then, replace the battery
with a spare and continue.
If a spare battery pack is available, switch
the PTU battery occasionally to ensure that
both batteries are kept fully charged.
Battery life can be extended by fully
discharging and recharging every 3
months.
CONVENTION APPLIES TO: SAMPLE
Bold Type Menu & Screen Titles GE OHV STATEX III MENU
Quotation Marks Menu Selection Choice PTU TALK TO TRUCK
Typewriter Font in Quotes Command to be typed from keyboard gemenu
[Brackets] Keyboard Key to Press [ENTER], [CTRL], [ALT], [F1] etc.
E02011C1 1/96 Electrical Propulsion Components E2-21
SOFTWARE INSTALLATION
PREPARATION
There are four diskettes in a software code release.
The diskettes are labelled as follows:
Statex Utilities
Statex PTU Screens
Statex Object Code
Statex Configuration Code
Statex Object Code is code that is common to all
trucks.
Statex Configuration Code is code that is unique to
each truck.
When first received, they should all be installed in
numerical sequence. Once all diskettes of a release
have been installed, any single diskette may be
installed at any time.
The following instructions describe the procedures
for initial installation of the GE software on the PTU
or procedures to update the PTU with the latest ver-
sion software code. It is not necessary to connect the
PTU to the truck during software installation.
NOTE: To determine the latest version of software
code, contact your HAULPAK
Distributor. If new
code is required, the current diskettes can be
obtained.
Deleting Prior Software Versions
Software installation will require approximately 4
megabytes of disk space on the PTU hard disk. Prior
to performing the installation procedure (when disk
#1 is installed), a message will be displayed listing
the space required for software installation and the
actual space available on the hard disk. If insufficient
space is available, the installation procedure should
be aborted and unnecessary files should be deleted
until the required amount of space is available or the
installation procedure can be continued and an auto-
mated provision is available to delete older versions
of software code. The J une 1992 and later software
releases allow deletion of older versions of the soft-
ware previously installed on the PTU hard disk.
The installation program will sequentially display all
older versions of GE software code that may be
deleted, pausing to allow time to decide which (if any)
versions to delete. It is not necessary to delete older
versions of software, however if it will no longer be
used, the files should be deleted to recover disk
space.
WARNING! If older software versions are to be
deleted, statistical data, files, directories and
subdirectories used with the older version will be
deleted automatically!
Computer Boot File Editing
In some cases it may be necessary to modify the
DOS files AUTOEXEC.BAT and CONFIG.SYS to
allow the GE software to operate properly. These
files are normally located in the root directory of the
hard drive and are used by the PTU when it is initially
turned on.
At the end of diskette #1, the installation program will
pause to ask whether you will permit automatic edit-
ing of the AUTOEXEC.BAT and CONFIG.SYS files. If
automatic editing of these files is not permitted, the
installation program will display changes (if any)
which should be made but will not make the changes
for you. If changes are not allowed, the recom-
mended changes should be made by manually edit-
ing the AUTOEXEC.BAT and CONFIG.SYS after
completion of the GE software installation.
If permission was given to automatically edit the
AUTOEXEC.BAT and CONFIG.SYS files, the
changes will be made and displayed for viewing. The
original files will then be saved under the names
AUTOEXEC.BAK and CONFIG.BAK respectively.
The .BAK files are saved to the hard disk as backup
copies of the files prior to any changes being made. If
a problem should arise with the newly modified files,
the original AUTOEXEC.BAT and CONFIG.SYS files
can be restored by using DOS to delete the modified
files and then renaming the backup files from
AUTOEXEC.BAK to AUTOEXEC.BAT and CON-
FIG.BAK to CONFIG.SYS.
NOTE: Whenever changes are made to the
AUTOEXEC.BAT and CONFIG.SYS files, the PTU
must be re-booted for any changes to take effect.
The computer can be re-booted by simultaneously
pressing the [CTRL], [ALT] and [DEL] keys or by
turning the power switch Off and then On again.
E2-22 Electrical Propulsion Components E02011C1 1/96
SOFTWARE INSTALLATION ON PTU
Use the following procedure when initially installing
the GE software on the PTU hard drive or if updating
the current software to a new release version.
1. The computer must be at any DOS prompt prior
to installing the software.
2. Insert the #1 diskette into the computer diskette
drive.
3. If the floppy disk drive containing diskette #1 is
designated drive A, type a:installa and press
[ENTER] key. If the floppy disk drive containing
diskette #1 is designated drive B, type
b:installb and press [ENTER] key.
4. When all diskette #1 files have been copied to
the hard drive, a message to insert the next dis-
kette will appear on the screen.
5. Remove diskette #1, insert diskette #2 and
repeat step 3.
Before diskette #2 files are copied to the hard
disk, an option is presented to indicate which
serial port is to be used for communication with
the truck. If the PTU uses serial port #1, enter
the number 1 at the prompt. If the PTU uses
serial port number 2, enter the number 2 at the
prompt.
NOTE: Serial port #1 is normally used for
communication and should be chosen if uncertain. If
after software is installed and problems are
encountered in communicating with the truck, repeat
step 5 and select number 2 instead of 1.
6. Install the remaining software files on diskettes
#3 & #4 using the above procedures.
7. Reboot the PTU before opening the main
menu.
If a new version of software has just been installed
and truck configuration files have been created using
earlier software versions, refer to Configuration
(CFG) File Conversion which follows to update the
files for use with the new software release.
E02011C1 1/96 Electrical Propulsion Components E2-23
THE MAIN MENU
The main menu, titled GE OHV STATEX III MENU as
shown in Figure 2-2, illustrates the major selections
available. Note the software release date also
appears in the title. This menu is used to access all
other operating menus. Options on this menu are
selected by using the arrow keys or typing the first
letter of the name of the selection.
To view the main menu, turn the PTU power switch
on. After the PTU performs a self-test startup proce-
dure, the DOS C:>> prompt will appear.
Type gemenu and press the [ENTER] key. The
main menu will appear on the PTU screen.
The following identifies each of the options listed on
the main menu:
QUIT MENU
When selected, the PTU exits the GE software
and returns to the DOS C:>> prompt. When
the C:>> prompt appears, the PTU is function-
ing as a standard laptop computer.
PTU TALK TO TRUCK
Used to talk to the CPU (Central Processing
Unit) in the 17FL275 panel. All PTU/CPU com-
munication is done through this selection. To
enter this selection, a log-on with an appropriate
password is required and the serial communica-
tion cable should be attached.
VIEW PTU SAVED FILES
Used to examine the contents of saved event
files in the PTU. No password is required. Can
only be used to playback events already stored
n a filename.
LIST STAT DATA FILES
Used to examine the statistical data from a
truck's CPU which has been stored on the PTU.
TRUCK SETUP (CFG)
Used to edit or create CFG files. Refer to PRO-
GRAM TRUCK, for a procedure for download-
ing configuration files to the CPU in the
17FL275 panel.
SELECT TRUCK SETUP
Used to view the current list of configuration
files and to select a configuration file for down-
loading to the CPU. Refer to PROGRAMMING
TRUCK for additional information.
UPDATE CFG VERSION
Permits conversion of truck configurations from
older versions of software to be compatible with
newer versions without requiring retyping val-
ues for overspeed, serial numbers, etc.
NOTE: configuration files from versions prior to
March 1992 can not be converted. Older ver-
sions must be retyped.
CHANGE PTU PASSWORD
Used to set passwords which permit different
levels of access to the operating screens in the
software.
FIGURE 2-2. MAIN MENU
Software Release Date
E2-24 Electrical Propulsion Components E02011C1 1/96
FIGURE 2-3. PTU SOFTWARE MENU TREE
E02011C1 1/96 Electrical Propulsion Components E2-25
CONFIGURATION (CFG)
FILE CONVERSION
When new GE software code is installed on the PTU
to replace older versions of software, it will not con-
tain the existing truck configuration data (over-
speeds, serial numbers, option choices, etc.) already
in current truck files. Previously, you were required to
retype all of this information, one file for each truck
into newly created configuration files.
The Configuration Conversion Tool (UPDATE CFG
VERSION option on the main menu) eliminates the
need for any truck configuration data retyping. It will
convert this truck data from the existing August 1993
configuration files. If March 1992 CFG files are to be
used with the J uly 1994 release, it is necessary to
first convert the CFG files to the August 1994
release. The August 1994 CFG files can then be con-
verted for use with the J uly 1994 release.
NOTE: For the configuration conversion tool to work
properly, the OEM must have saved their OEM file in
both the \GEOHV\CFG\STXJ UL94 directory and the
\GEOHV\CFG\STXJ UL94\TRUCK directory on
diskette #4.
Conversion Procedure
Use the following procedure to convert configuration
files used with previous versions of software for use
in the current version:
Search for old CFG filenames:
1. Select the previous software version by typing
oldge at the DOS C:>> prompt.
2. Select TRUCK SETUP (CFG) from the GE
OHV STATEX III MENU and press [ENTER].
3. The cursor should be at number 1. Press
[ENTER]. The screen shown in Figure 2-4 is a
typical example. Make a list of the files listed on
your screen.
NOTE: Refer to Figure 2-5 for an explanation of the
elements of a GE file name. This information can be
used to determine the release version of files stored
on the PTU.
4. Exit back to the GEOHV STATEX III Menu, use
the arrow keys to highlight QUIT MENU and
press [ENTER] to return to DOS.
FIGURE 2-5. ELEMENTS OF A GE FILE NAME
FIGURE 2-4. CFG FILE CREATED IN EARLIER SOFTWARE RELEASE
E2-26 Electrical Propulsion Components E02011C1 1/96
5. Open the main menu for the current software
release by typing gemenu and press
[ENTER]. The main menu (Figure 2-3) should
appear. (Note the software release date in the
menu title.)
Convert old CFG files for new software:
6. Select UPDATE CFG VERSION by typing [u]
or move the cursor with the arrow keys and
press [ENTER]. The screen shown in Figure 2-6
will appear.
7. Note the screen shows a series of options
labelled F1 through F9, referring to the Func-
tion Keys [F1] through [F9] and provides a
description of each.
[F1] provides a Help Screen to assist you directly
on the screen.
[F2] names the new configuration file in column
NEWCFG with the old configuration file name in
column OLDCFG (only at the line where the
cursor is).
[F3] names the new configuration file with no
configuration file name.
[F4] creates a new configuration file with a new
configuration file name (only at the line where the
cursor is).
[F5] creates multiple configuration files with new
configuration file names for all files in the
NEWCFG column.
[F6] resets all new file names to their original
OLDCFG names.
[F7] sorts the old configuration files in the
NEWCFG column by file names.
[F8] sorts the old configuration files by their
extensions.
Note: The description of [F7] or [F8] will be
capitalized, depending on which sort has been used.
[F9] exits the Configuration Converter Tool and
returns to the GEOHV Main Menu.
8. Note in Figure 2-6 the four columns headed by
OLDCFG, OLDOEMCFG, NEWOEMCFG
and NEWCFG. These are described as fol-
lows:
Files listed under OLDCFG are the old truck
configuration files created by the mine using the
August 1993 software release which is displayed
for possible conversion.
Files listed under OLDOEMCFG are the old
OEM files created by HAULPAK
and given to
the mine to create the August 1993 configuration
files.
FIGURE 2-6. CONFIGURATION CONVERSION INITIAL SCREEN
E02011C1 1/96 Electrical Propulsion Components E2-27
Files listed under NEWOEMCFG are the new
OEM files created by HAULPAK
and given to
the mine for the current software release version
to create the new configuration files.
Files listed under NEWCFG are the names of
the new configuration files to be created by the
Configuration Conversion Tool. The cursor is
there, blinking in front of the first file name in the
last column to indicate that the computer is ready
to edit these file names. The numbers which
precede each column heading indicate the
number of different files listed.
9. Note equal (=) signs appear at the beginning
and the end of the first file name line, and fol-
lows the cursor up and down the list of files.
10. Using the RIGHT arrow key, move the cursor to
the right. The cursor will fall under the first letter
of the first file name in the last column. The UP,
DOWN and LEFT arrow keys are now ineffec-
tive. See Figure 2-7.
11. Type in the name for the new file over the old
name.
If an error is made in naming this file, the operation
can be cancelled any time before [ENTER] is
pressed by first pressing [ESC]. This returns the cur-
sor to its original starting position where it can once
again be moved with the arrow keys. A note to this
effect is displayed at the bottom of the screen.
The example shows the new file name to be TEST1
There is room for eight characters. If there are more
letters in the old name than in the new, simply erase
them using the space bar.
Note the asterisk (*) which appears in front of the
new name, and another asterisk appears in front of
the column heading when you begin typing. This
means the file name is being changed, but the file
has not yet been created. The asterisks disappear if
[ESC] is pressed to cancel the renaming operation.
12. After the new name has been typed in, press
[ENTER]. This records the new file name. Note
the cursor moves back to its starting position at
the left of the file name asterisk.
This operation can be cancelled, even after [ENTER]
has been pressed by pressing [F6]. This resets the
file back to its original name.
FIGURE 2-7. TYPING IN NEW FILE NAME IN COLUMN FOUR
E2-28 Electrical Propulsion Components E02011C1 1/96
13. Press [F4] to create the new file. The mine data
from the file in the first column is copied and put
into the OEM file in the third column to create
the name you entered in the fourth column. See
Figure 2-8. Note that both asterisks (*) have
changed to plus signs (+), indicating the file has
been created and copied to the hard disk.
14. Use the DOWN arrow to move the cursor to the
next file name. Note the equal (=) signs move
with the cursor.
15. Use the RIGHT arrow key and move the cursor
to the right.
16. Type in the new file name.
17. Press [ENTER]. The example in Figure 2-9
shows the new file name to be TEST2.
18. Use the DOWN arrow key and move the cursor
to the next file name.
19. Move the cursor to the right to position the cur-
sor on the name.
FIGURE 2-8. NEW FILE NAME CREATED AFTER F4 IS PRESSED
FIGURE 2-9. TEST2 FILE NAME TYPED IN
E02011C1 1/96 Electrical Propulsion Components E2-29
20. Type in the new file name (TEST3) and press
[ENTER].
Note an asterisk appears in front of both
TEST2 and TEST3, indicating the names
have been changed but the files have not yet
been created.
21. You can now press [F5] to create all new files at
once. See Figure 2-10.
a. Note the screen prompts you to make a deci-
sion; (O) for Overwrite the file name, (S)
for Skip creation of the noted file & continue
with the remaining files, (A) for Abort cre-
ation of any new files. This is because the
[F5] key tries to create all of the new files,
and the first file has already been created.
The computer is looking at the first file and
is asking which of these three options to
apply. Since the first file has already been
created, the correct option is (S) for Skip &
continue.
NOTE: This feature can be used to change a file
name which was already created by selecting (O),
or abort the last changes made by selecting (A).
22. Press [S]. Note the computer went directly to
the second file and created it, and went on to
the third file and created it. Note also that all
asterisks (*) are now changed to plus signs (+).
23. Press [F9] or [ESC] to exit this screen and
return to the GE OHV STATEX III MENU.
24. Select TRUCK SETUP (CFG) and press
[ENTER].
25. Select No. [1] to view the current truck configu-
rations on file. The sample screen shown in Fig-
ure 2-11 will appear. Note that the three new
configuration files are listed and are available
for use. These new files contain the latest
release of GE software and all of the truck con-
figuration data from the previous files.
FIGURE 2-10. CONVERTING REMAINING FILES
E2-30 Electrical Propulsion Components E02011C1 1/96
FIGURE 2-11. CONVERTED TRUCK CONFIGURATION FILE LIST
E02011C1 1/96 Electrical Propulsion Components E2-31
STATEX CONFIGURATION FILES
Truck Configuration files must be properly setup and
the correct file selected prior to programming the
FB101 card in the FL275 Panel.
The following examples illustrate the various selec-
tions available from the TRUCK SETUP CONFIGU-
RATION MINE MENU and the procedure required to
create and save a configuration file for a specific
truck.
1. Turn on the PTU. When the DOS C:>> prompt
appears, type gemenu and press [ENTER].
2. With the GE OHV STATEX III MENU displayed,
use the arrow keys to move the cursor to
TRUCK SETUP (CFG) and press [ENTER].
The TRUCK SETUP CONFIGURATION MINE
MENU shown in Figure 2-12 will appear.
3. The first line under the heading indicates the
number of configuration files stored on the PTU
(hard drive) source directory shown in the sec-
ond (A) line. The example in Figure 2-12 lists
one configuration file stored in the directory
named C:\GEOHV\CFG\STXJ UL94\TRUCK.
Each time a new configuration file is created and
saved it will be added to the list of files available and
the number of STATEX truck configurations will
increase.
A) Source Directory: . . .
When the TRUCK SETUP CONFIGURATION MINE
MENU first appears, a default source directory used
to store truck configuration files will appear in line A).
In some cases it may be beneficial to create other
directories for storing truck configuration files. For
example, a mine operating several models of trucks
may prefer to create directories named 510E,
685E, and 830E to separate configuration files.
NOTE: If additional directories as described above
are desired, the new directories MUST be created
using DOS, prior to using the GE software.
If configuration files are to be retrieved from a differ-
ent directory, use the following procedure:
1. Move the cursor to line A) and press [ENTER].
2. With the cursor on A, type in the full DOS path
name of the alternate directory used to store
configuration files. Press [ENTER].
3. The alternate directory name will appear and the
number of configuration files stored in the alter-
nate directory will be displayed above line A).
If all configuration files are stored in the default direc-
tory that appears when the TRUCK SETUP CON-
FIGURATION MINE MENU appears, no change to
line A) is necessary.
FIGURE 2-12. TRUCK CONFIGURATION FILE MAIN MENU
E2-32 Electrical Propulsion Components E02011C1 1/96
0) Select A Truck Configuration . . .
NOTE: A truck configuration must be selected before
menu choices 1 through 8 can be used.
1. With the TRUCK SETUP CONFIGURATION
MINE MENU displayed, press [0] or move the
cursor to 0) and press [ENTER] to select
Select a truck configuration, . . ..
2. A listing of the configuration files stored in the
source directory (line A), will appear as shown
in Figure 2-13.
NOTE: Normally, the display would show the base
configuration that was provided by the OEM, to
define the specific truck model options plus a
configuration that was made by the mine specifically
for each truck. In the examples that follow, it will be
assumed the single file listed in Figure 2-13 is the
OEM configuration file provided by HAULPAK
and
the following procedures will create a configuration
file for a specific truck.
3. Note that across the bottom of the screen six
different file list sort options are available.
1 =DOS file name
2 =DOS filename.extension
3 =Truck ID
4 =Date that the file was created
5 =GE file name
6 =GE filename.extension
DEL = Choosing delete will prompt for a Y/N
input to delete the selected file or not.
When many files are listed, it is helpful to sort the file
names in a different order from what they appear. For
example, to sort the files by truck ID, press the [3]
key. If the Delete key [DEL] is chosen, the file next to
the cursor will be deleted after the prompt appears
and [Y] is chosen. If the file should not be deleted,
press [N] to return the cursor to the file list.
When many files are listed, [Page Up] and [Page
Down] keys help move the cursor around the screen
faster. Otherwise use the UP arrow and DOWN
arrow keys.
4. Move the cursor to the desired configuration
and press [ENTER] to select the filename and
return to the TRUCK CONFIGURATION MINE
MENU.
NOTE: Press [ESCAPE] if leaving the screen without
making a selection.
The sample file X11HBTAC.214 will then appear in
line 0) of the TRUCK SETUP CONFIGURATION
MINE MENU.
FIGURE 2-13. TRUCK CONFIGURATION FILE SELECTION SCREEN
E02011C1 1/96 Electrical Propulsion Components E2-33
1) View Truck Configuration: Data Curves . . .
NOTE: The following screens are view only. No
changes can be made.
1. With the sample configuration file selected and
displayed at the end of line 0) of the TRUCK
SETUP CONFIGURATION MINE MENU, use
the Down arrow to move the cursor to the menu
position VIEW TRUCK CONFIGURATION
SCREEN; DATA CURVES SCREEN and press
[ENTER], or press [1]. An example of a model
830E truck configuration is shown in Figure 2-
14.
2. Press any key to view the second screen:
TRUCK CONFIGURATION DATA CURVES
SCREEN. An example of the data curves is pro-
vided in Figure 2-15.
3. Press any key to return to the TRUCK CON-
FIGURATION MINE MENU.
FIGURE 2-14. TRUCK CONFIGURATIONS SCREEN
(Sample 830E Information)
FIGURE 2-15. DATA CURVES SCREEN
(Sample 830E Information)
E2-34 Electrical Propulsion Components E02011C1 1/96
2) Change/View Serial and Model Numbers . . .
1. Use the down arrow key to move the cursor to
the menu position CHANGE/VIEW SERIAL
AND MODEL NUMBERS SCREEN, or press
[2]. All of the major component serial numbers
will be displayed, or serial number information
can be typed in. Refer to the screen shown in
Figure 2-16. If a serial number is changed, an
asterisk (*) will appear next to it.
2. To insert new serial numbers, move the cursor
to the desired location, type in the information,
and press [ENTER]. When finished entering
serial numbers, exit the screen by moving the
cursor to the leave truck serial numbers
screen selection and press [ENTER].
3) View OEM Options
NOTE: The options on this screen can be changed
only by the manufacturer.
1. Use the Down arrow to move the cursor to the
menu position VIEW OEM OPTIONS and
press [ENTER], or press [3]. The screen shown
in Figure 2-17 will appear.
2. Several codes are used to indicate the status of
various options and equipment.
The Y, N, and X codes are described as follows:
Y =OEM has selected YES
N =OEM has selected NO
X =Not available to OEM
FIGURE 2-16. TRUCK COMPONENT SERIAL NUMBERS SCREEN
FIGURE 2-17. OPTIONS ENTRY SCREEN (VIEW ONLY)
E02011C1 1/96 Electrical Propulsion Components E2-35
The following list defines each option:
a. GE engine control
Y: Fuel Saver option is installed. The
engine, accelerator, and retard pedals
interface with the FL275 panel.
N: Accelerator and retard pedals interfaced
with ACC/RET panel.
b. Engine Status (Voltage signal from engine
system fault which inhibits propel):
Y: 0 v trip
N: 28 v trip
NOTE: Y is used for DDEC and MTU engine system
interface for Engine Service and Engine Shutdown
digital inputs.
c. Engine crankcase pressure sensor installed
Y: Analog engine crankcase pressure
sensor has been installed on the engine.
N: Pressure sensor not installed.
d. Engine coolant temperature sensor installed
Y: Engine coolant temperature sensor has
been installed on the engine.
N: Temperature sensor not installed.
e. Engine coolant pressure sensor installed
Y: Analog engine coolant pressure sensor
has been installed on the engine.
N: Pressure sensor not installed.
f. Engine oil pressure sensor installed
Y: Analog engine oil pressure sensor has
been installed on the engine.
N: Pressure sensor not installed.
g. APS (Accelerator Pedal Switch) accel inhibit:
Y: 28 v at the accinh digital input will inhibit
acceleration.
N: 0 v at the accinh digital input will inhibit
acceleration.
h. Two speed overspeed system installed
Y: Loaded/empty load weighing system is
operating on the truck.
N: System not installed on the truck.
i. Optional motor 1 temperature sensor
installed
Y: Motor 1 temperature sensor option is
installed.
N: Temperature sensor not installed.
j. Optional motor 2 temperature sensor
installed
Y: Motor 2 temperature sensor option is
installed.
N: Temperature sensor not installed.
k. AS switch overrides retard speed control
Y: Pressing the accelerator pedal will
override the retard speed control
system and allow acceleration with the
retard speed control system turned on.
N: Pressing the accelerator pedal does not
ride the retard speed control system.
l. Retard speed control system installed
Y: FL275 panel accepts the retard speed
control system input.
N: Control computer ignores this input.
m.Spin/stall option
Y: Spin stall system is active.
N: Function is turned off.
n. Wheelmotor stall protection active
Y: Total stall (both motors) control function is
active.
N: Function is not computed.
o. mph OEM option
The number entered is the value in miles per
hour at which the digital output OEM SPEED
EVENT is turned On. When the truck slows
to a speed below this setting, the OEM
SPEED EVENT is turned Off.
4) View GE Product Service Data . . .
This screen is normally used to enter information for
a specific truck by GE or the manufacturer during
truck test, delivery, and startup checkout procedures.
E2-36 Electrical Propulsion Components E02011C1 1/96
5) Change/View Truck Specifics . . .
NOTE: If values are changed on the TRUCK
SPECIFICS SCREEN, the truck MUST be re-
programmed before the changes will be in effect.
The TRUCK SPECIFICS SCREEN is used to enter
the desired values of engine horsepower, engine
load rpm, accelerator and retard pedal calibration,
the blower pressure fault time delay, the fault data
collection interval, statistical data quarter start month,
and the mine truck identification.
1. Use the Down arrow to move the cursor to the
menu position CHANGE\VIEW TRUCK SPE-
CIFICS and press [ENTER], or press [5].
2. The TRUCK SPECIFICS SCREEN, Figure 2-
18, will be displayed. Move the cursor to the line
where a change is desired. Enter the values
desired as a permanent value in the truck code.
(Type the value and press [ENTER].) A note at
the bottom of the screen shows the range of
values that may be entered.
a. Manual horsepower limit set
Used to select manual or automatic
horsepower limit.
Y: Manual
N: Automatic
NOTE: It is recommended that this value is always
set to N to select automatic. In this condition the
system will automatically adjust the electrical system
load to maintain the ENGINE FULL LOAD RPM
value specified in step d.
b. Ignore high idle switch when empty
Y: Operator request for high idle is ignored if
sensors indicate truck is empty.
N: Load weighing sensors do not affect idle
selection.
c. Engine horsepower output adjust
This line allows entering the reducer or
adder to the nominal horsepower that was
determined in the manual load box screen.
For example, if in the manual mode load box
screen the nominal HP is set at 2350 NHP,
use the increment/decrement keys to load
the engine to the point where it starts to bog
the engine. The horsepower output adjust
value shown at the bottom of the screen is
entered here. The available range is
displayed at the bottom of the screen when
this line is selected with the cursor. This
allows modification of the value of the
horsepower pre-programmed in the
configuration data tables.
d. Engine full load rpm value
Used when the manual horsepower limit set
is N. Sets the engine rpm value that the
control system will maintain by automatically
adjusting the load. The available range is
displayed at the bottom of the screen when
this line is selected with the cursor. This
generally is set to the rated RPM of the
engine.
FIGURE 2-18. TRUCK SPECIFICS SCREEN
E02011C1 1/96 Electrical Propulsion Components E2-37
e. Retard current demand adjust
This line allows entering the value deter-
mined using the TEMPORARY RETARD
CURRENT ADJUST SCREEN for inclusion
in the permanent settings in the truck config-
uration file. Refer to page TEMPORARY
TRUCK SETTINGS for instructions for
obtaining this value.
NOTE: Items f. through j. are applicable only if truck
is equipped with Fuel Saver option and GE engine
control on the OEM-ONLY SETTABLE OPTIONS
ENTRY SCREEN is set to Y.
f. Percent accel pedal travel off request
Used to enter the percent of pot reference
volts at which the accelerator pedal is cali-
brated to have zero accel request.
g. Percent accel pedal travel full request.
Used to enter the percent of pot reference
volts at which the accelerator pedal is cali-
brated to have full accel request.
NOTE: Refer to Statex III Electrical System
Checkout Procedure, Throttle System Check and
Adjustment for accelerator pedal calibration.
h. Percent retard pedal travel Off request
Used to enter the percent of pot reference
volts at which the retard pedal is calibrated to
have zero retard request.
i. Percent retard pedal travel full request
Used to enter the percent of pot reference
volts at which the retard pedal is calibrated to
have full retard request.
NOTE: Refer to Statex III Electrical System
Checkout Procedure, Retard System Check and
Adjustment for retard pedal calibration.
j. Blower pressure fault time delay
Use to set the blower fault time delay in sec-
onds. A value between 30 seconds and 101
seconds may be entered if a delay other than
the default setting of 101 seconds is desired.
k. Event data collection interval (sec)
Used to set the time interval in seconds that
the CPU collects fault data. A value between
0.012 to 1.00 seconds may be entered. The
default value is 0.204 seconds.
l. Stopped advance engine idle
For future use.
m.Statistical quarter start month (0=jan, 1=feb,
2=mar)
Used to set the starting month for the active
calendar quarters on the CPU clock.
Example:
0=J an, Apr, J ul, Oct
1=Feb, May, Aug, Nov
2=Mar, J un, Sept, Dec
n. Truck identification number
For use by the mine to enter the truck identi-
fication number. Truck ID shows up with the
event data and must be unique for each
truck.
3. When changes are completed, move the cursor
to LEAVE TRUCK SPECIFICS SCREEN and
press [ENTER]. This automatically returns the
program to the TRUCK SETUP CONFIGURA-
TION MINE MENU.
E2-38 Electrical Propulsion Components E02011C1 1/96
6) Change/View Overspeeds . . .
The OVERSPEEDS ENTRY SCREEN is used to
enter the desired speed settings for overspeed
pickup, overspeed dropout, speed override, and the
maximum retard speed control speed.
Initially, empty and loaded truck overspeed settings
from the HAULPAK
or the mine.
Level 3 has several privilege levels to allow or
prevent access to the screens listed. The
password privilege must be equal to or greater
than the value indicated. The upper limit for level
3 is 14899.
Selections listed at the bottom of the screen allow
passwords to be added, changed and deleted. Addi-
tional help is available by pressing [F1].
It is recommended that supervisors assign pass-
words and privilege levels below their own.
NOTE: On some PTUs, some difficulty has been
experienced if passwords were entered which have
zeros. The problem was found to be caused by the
PTU being in the Numlock mode (or Keypad mode
on some PCs). This interprets a section of the normal
keypad as a numeric keypad and hence produces
the wrong characters.
PTU USER PRIVILEGE LEVELS
LEVEL PRIVILEGE SCREEN TITLE LEVEL PRIVILEGE SCREEN TITLE
1 200
GE OHV Statex III Menu
2 1000
Upload Statistical Data Menu
Normal Operation Menu Temporary Truck Settings Menu
Monitor Real Time Data
Screen
Temporary Speed Set Screen
Automatic Load Box Test
Screen
Retard Current Adjust Screen
Manual Load Test Box
Screen
Truck Specific Information Menu
Accelerate State Logic
Screen
OEM Option Screen
2 1000
Monitor Analog Input Chan-
nels Screen
Mine Option Screen
Retard State Logic Screen View Speed Settings Screen
Special Operation Menu Serial Numbers Screen
Event Data Menu GE Version Information Screen
Event Summary Screen Special Control Engine Stopped
Test Menu
Event Data Display Screen Manual Digital Output Test
Screen
Special F1 Help Screen View Program Truck File
Upload GE Event Data Yes/
No Screen
3
1100 Reset All Yes/No Menu (Erase
Event Data)
Statistical Data Menu 2990 Date and Time Set Screen
Stat Parameter Counters
Screen
4990 Program Truck Yes/No Menu
Profiles Screen
E2-42 Electrical Propulsion Components E02011C1 1/96
PROGRAMMING THE TRUCK
The following procedures should be followed to pro-
gram a new truck or reprogram an operational truck
when necessary. Reprogramming is required if the
FB101 card is replaced, equipment is added or
removed, or if changes are made to the Truck Con-
figuration File.
It is assumed the correct Truck Configuration File is
available for programming the truck. If not available,
or if changes are required, refer to previous informa-
tion in STATEX CONFIGURATION FILES and
make the required changes before proceeding.
Perform the following steps to program the truck:
Connect PTU to the Truck
1. Connect the PTU to the control system on the
truck:
a. Connect the PTU cable male plug to the A
receptacle located at the Two-Digit Display
panel in the control cabinet or in the cab.
Plug the female connector end of the cable
into the serial port receptacle at the back of
the PTU.
NOTE: Connector A is used for communication with
the truck CPU. Connector B uses a cable with a
female connector on both ends and is used for
communicating with a mine dispatch computer.
b. Provide 110 vac to the work area on the
truck. Connect the portable battery charger
for the PTU to 110 vac and the PTU. This will
maintain the charge on the PTU battery.
2. Turn on the PTU. After warm-up and self-test,
the DOS C:>> prompt will appear.
3. Type gemenu and press [ENTER]. The main
menu titled GE OHV STATEX III MENU will
appear.
NOTE: There may be two available GE OHV menus
on the portable computer. If installed, a previous
software version can be accessed by typing oldge
at the DOS prompt.
Select Configuration File
1. Use the arrow keys to move the cursor to select
SELECT TRUCK SETUP.
2. Select the proper Truck Configuration file by
moving the cursor to the correct file and press-
ing [ENTER].
3. The GE OHV STATEX III MENU will reappear.
Activate The PTU Mode
1. Use the arrow keys to move the cursor to the
PTU TALK TO TRUCK selection on the main
menu and press [ENTER].
2. Logon by responding to the prompts shown in
Figure 2-22, typing in your name (initials will
suffice) and password.
3. A menu titled GE STATEX III PTU MAIN MENU
(Figure 2-23) will appear after the PTU goes
through necessary loading (about 10 seconds).
NOTE: Various screens may display caution
statements about contactors moving. This is to
protect maintenance personnel who may be working
in the control cabinet while the PTU is being used to
perform test and set-up functions.
NOTE: If a PTU lock-up occurs at any time during
communications with the truck, it may necessary to
start over. Perform the following:
1. If the PTU screen has a message at the bot-
tom of the screen, press the [SPACE] bar and
wait for the message to clear.
2. If the PTU still does not communicate, turn the
Control Power switch Off. (Sometimes it may
be necessary to turn the battery disconnect
switch off to insure a complete cycle of power.)
3. If this doesn't work, press the [CTRL], [ALT]
and [DEL] keys simultaneously. This reboots
the PTU and takes the PTU to the DOS C:>>
prompt. Then, type gemenu to reopen the
main menu.
FIGURE 2-22. PTU LOGON INFORMATION ENTRY
PTU LOGON
1. Enter your name:
2. Enter your password:
Your Privilege level is: 10000
E02011C1 1/96 Electrical Propulsion Components E2-43
Check Object Code Version
Before downloading configuration files to the truck
CPU, use the cursor to select OBJ CODE V0.00 (or
whatever number is displayed on the screen) as
shown in Fig. 2-23. When selected, one of two
events will take place:
1. If a number appears on the screen, code has
been installed into the truck CPU, and the
downloading selection on the PROGRAM
TRUCK YES/NO MENU will be YES, RELOAD
INTO TRUCK.
2. If code has not been installed, the truck CPU is
not programmed, and an error message will
appear as shown in Figure 2-24. If this hap-
pens, the downloading selection will be YES,
INSTALL PROGRAM INTO TRUCK.
FIGURE 2-23. PTU MAIN MENU
FIGURE 2-24. PTU/CPU COMMUNICATION ERROR MESSAGE
PROBLEMS COMMUNICATING W/VEHICLE
Unable to successfully communicate
with target after 1 attempt
Press C to continue attempts,
R to re-initialize Serial Port,
Anything else to abort this packet
Overrun error: 0
Parity error: 0
Framing error: 0
TOTAL ERRORS: 1
E2-44 Electrical Propulsion Components E02011C1 1/96
Download Configuration Files
Download configuration files into the CPU on the
truck as follows:
1. From the GE STATEX III PTU MAIN MENU
(Figure 2-23) use the arrow keys to move the
cursor to the SPECIAL OPERATION WITH
ENGINE STOPPED selection and press
[ENTER]. An intermediate screen will appear
asking yes or no. With the cursor on yes press
[ENTER]. The SPECIAL CONTROL ENGINE
STOPPED TEST MENU screen appears.
2. Use the arrow keys to move the cursor to the
VIEW PROGRAM TRUCK FILE selection and
press [ENTER]. The screen will show the CFG
and OBJ file to be downloaded.
3. Press [ESC] to return to the previous menu.
4. Use the arrow keys to move the cursor to the
program truck yes/no menu selection and
press [ENTER]. The PROGRAM TRUCK YES/
NO MENU screen appears.
5. Use the arrow keys to move the cursor to
desired program truck selection.
a. NO, Return to Engine Stopped Test Menu
This selection will take the computer back to
the SPECIAL CONTROL ENGINE
STOPPED TEST MENU.
If, for some reason programming is not
desired, select this choice.
b. YES, RELOAD PROGRAM INTO TRUCK
Use whenever the truck CPU has already
been programmed and re-programming is
desired. This selection is appropriate if, for
example, the truck configuration file has
been modified. The configuration file must be
reloaded for the changes to become effec-
tive.
NOTE: From power on, it takes about 15 seconds
for the computer to be talking PTU language.
c. YES, INSTALL PROGRAM INTO TRUCK
Use to install a program into the truck CPU
for the first time or into a new or modified
FB101 card. For example, if the FB101 card
EPROM's are updated.
6. Press [ENTER] to begin programming the truck.
The programming will take approximately 10
minutes to complete.
7. During the downloading operation, various
messages are displayed on the PTU screen as
the procedure progresses. At completion, press
[SPACE] per instruction on the screen.
E02011C1 1/96 Electrical Propulsion Components E2-45
Date And Time
When the initial programming of a truck is completed,
the date and time should be set.
Selecting SPECIAL OPERATION in the following
procedure may present a safety hazard if the
engine is running. Control of the propulsion sys-
tem may transfer from the truck driver to the PTU
operator with this software operation. See step 1.
below for details.
1. Use the arrow keys to move the cursor to the
SPECIAL OPERATION selection on the GE
STATEX III PTU MAIN MENU and press
[ENTER]. The message shown in the lower half
of screen shown in Figure 2-25. will be dis-
played. This warning notifies the operator when
control of the truck is being transferred from the
truck driver to the PTU, based on the PTU
selection of SPECIAL OPERATION.
When finished and the PTU is returned to the
PTU MAIN MENU, control of the propulsion
system is returned to the truck driver. Before
activating this command, the screen shown in
Figure 2-26 will be displayed.
The PTU user should always keep the truck
driver appraised of this control.
2. Select Yes on the caution screen and press
[ENTER].
3. Use the arrow keys to move the cursor to the
SET DATE & TIME selection and press
[ENTER]. The DATE & TIME SET SCREEN
screen will be displayed.
4. If the date and time displayed is correct, press
[ENTER] at the No, Do not reset date and time
selection.
5. Use the arrow keys to move the cursor to the
various other selections.
6. Type the day of the month, 1 thru 31, and press
[ENTER].
7. Press the Down arrow key. Type the month as a
two-digit number, 01 thru 12, and press
[ENTER].
8. Press the Down arrow key. Type the year as a
two-digit number, 00 thru 99, and press
[ENTER].
9. Press the Down arrow key. Type the hour based
on a 24 hour clock, 0 to 23, and press [ENTER].
10. Press the Down arrow key. Type minute, 0 thru
59, and press [ENTER].
11. Press the Down arrow key to the RESET
CLOCK selection and press [ENTER] at the
moment you want the clock to be set to the time
setting you have entered. The DATE & TIME
SET SCREEN is automatically displayed. Verify
that the time displayed is correct. If not, repeat
Steps 5 thru 11.
12. Use the Up arrow to move the cursor to the No,
Do not reset date and time selection and press
[ENTER]. The SPECIAL OPERATION MENU is
displayed.
13. Use the Page Down key to move the cursor
directly to the EXIT selection and press
[ENTER] to return to the PTU MAIN MENU.
FIGURE 2-25. CAUTION SCREEN FOR PTU
OPERATOR
(Entering NORMAL or SPECIAL OPERATION menu)
Selection of NORMAL OPERATION gives truck
control to the driver.
Continue? ( ) Yes
( ) No
OR
Selection of SPECIAL OPERATION will override
truck driver controls until you exit to the PTU
main menu.
Continue? ( ) Yes
( ) No
FIGURE 2-26. CAUTION SCREEN FOR PTU
OPERATOR
(Leaving SPECIAL OPERATION menu)
Return to PTU Main Menu gives truck control to
the driver. CAUTION: Contactors may move!
Continue? ( ) Yes
( ) No
E2-46 Electrical Propulsion Components E02011C1 1/96
Event Data
The EVENT DATA MENU selection from the SPE-
CIAL OPERATION MENU allows the technician to
view event data stored in the CPU, save the event
data to a file and to erase event data when storage of
the information is no longer necessary. Event data is
used to troubleshoot system problems and is nor-
mally erased after the problem has been corrected
and the information is no longer needed.
The event data is accessed by initially selecting PTU
TALK TO TRUCK from the GE OHV STATEX III
MENU and following the procedure below:
Selecting SPECIAL OPERATION in the following
procedure may present a safety hazard if the
engine is running. Control of the propulsion sys-
tem may transfer to the PTU operator from the
truck driver with this software operation. Refer to
Step 1. below:
1. When the GE STATEX III PTU MAIN MENU
appears, select EVENT DATA MENU and
press [ENTER].
The screen shown in Figure 2-25 will be dis-
played to alert the operator about the state of
the truck software.
This warning notifies the operator when control
of the truck is being transferred from the truck
driver to the PTU, based on the PTU selection
of SPECIAL OPERATION.
When finished and the PTU is returned to the
GE STATEX III PTU MAIN MENU, control of the
propulsion system is returned to the truck driver.
Before activating this command, the screen
shown in Figure 2-26 will be displayed. The
PTU user should always keep the truck driver
appraised of this control.
2. Select YES on the caution screen (Figure 2-
25) and press [ENTER]. The SPECIAL OPER-
ATION MENU will be displayed.
3. Use the arrow keys to move the cursor to the
EVENT DATA MENU selection and press
[ENTER]. The Event Data Menu screens will be
displayed.
a. If no event data has been stored, the screen
will indicate 0 (zero) events stored. If no
events have been stored, the cursor will be
positioned on EXIT. Press the [ENTER] key
to return to the previous menu.
4. If one or more events have been stored, a
screen as shown in either Figure 2-27 or 2-28
will be displayed.
5. If Figure 2-27 is displayed, select reset hard-
ware startup event with the cursor and press
[ENTER].
a. The screen shown in Figure 2-29 will appear.
Follow the on-screen instructions to cycle
power to the control system.
b. After the system is powered up, repeat steps
1 through 3 to view the event data.
6. If Figure 2-28 is displayed, select VIEW
EVENT DATA and press [ENTER]. A screen
displaying a list of stored events appears.
a. To view a particular event, type in the num-
ber of the event desired and press [ENTER].
The EVENT DATA DISPLAY SCREEN will
appear showing the status of system compo-
nents at the time the event occurred.
FIGURE 2-27. EVENT DATA MENU
(Requires Control System Reset)
PTUSTX: 1.2.1 EVENT DATA MENU
Special Operation
5 Events stored
( ) VIEW EVENT DATA
Event Summary and Details
( ) reset hardware startup event
( ) GE engineering format event data
( ) EXIT
FIGURE 2-28. EVENT DATA MENU
(All Menu Choices Available)
PTUSTX: 1.2.1 EVENT DATA MENU
Special Operation
5 Events stored
( ) VIEW EVENT DATA
Event Summary and Details
( ) erase event data yes/no menu
( ) GE engineering format event data
( ) EXIT
E02011C1 1/96 Electrical Propulsion Components E2-47
b. When the EVENT DATA DISPLAY SCREEN
is displayed, press the help key [F1] for addi-
tional information regarding the event
description and troubleshooting tips.
7. To upload event data for future review, return to
the EVENT DATA MENU and move the cursor
to select GE engineering format event data
and press [ENTER]. A screen titled UPLOAD
GE EVENT DATA YES/NO MENU will appear.
a. Select YES, UPLOAD GE FORMAT EVENT
DATA to a File. Press [ENTER]. A screen
asking for a path name will appear.
1.) If only the file name is entered, the data
will be saved, under the file name typed,
to the GE default directory.
2.) If a specific directory has been setup on
the PTU hard drive for storing event data
files, type in the full path name followed
by the file name chosen. For example, if
a directory named EVENTDAT has been
setup on drive C for storing event data
files, and the name of the file is to be
EV001, this entry would be typed as:
C:\eventdat\ev001
3.) If the event data is to be stored on a floppy
disk, insert a formatted floppy disk in drive
A. If the file name used above is chosen,
the entry would be typed as:
A:ev00120
b. After entering the appropriate name, press
[ENTER]. The information will then be trans-
ferred from the CPU to the PTU and stored
under the file name assigned. The transfer
may take several minutes to complete
depending on the number of events being
saved to the file. After the file transfer is com-
plete, a message will appear stating
Received xxxxxx bytes. . . Returning to
PTU. Press Space. Press [SPACE] bar to
return to the UPLOAD GE EVENT DATA
YES/NO MENU.
8. When the recorded events are no longer
needed, they may be erased by selecting
erase event data yes/no menu from the
EVENT DATA MENU.
NOTE: ALL EVENTS WILL BE ERASED! Only
certain privilege levels are authorized to erase event
data.
a. With the cursor on erase event data yes/no
menu, press [ENTER]. A screen titled
RESET ALLYES/NO MENU appears.
b. To erase the event data, move the cursor to
YES, Erase Truck Events and press
[ENTER].
c. Exit back to the desired menu following
screen instructions as they appear.
FIGURE 2-29. RESET HARDWARE STARTUP EVENT INSTRUCTIONS
PTUSTX: 1.2.H RESET HARDWARE STARTUP EVENT
To reset the hardware startup event,
control power must first be cycled.
Please exit this screen,
and then turn off the control power
while the PTU is at the PTU MAIN MENU screen.
Observe the normal 2 second shutdown sequence.
Remember to wait about 20 seconds after the panel
powers up before attempting to use the PTU to
communicate with the GE control system.
Once PTU communication is established,
you may reset and erase all events including the
HARDWARE STARTUP event.
E2-48 Electrical Propulsion Components E02011C1 1/96
STATISTICAL DATA
The Statistical Data Collector uses the memory capa-
bility of the computer to record and store hundreds of
system parameters unique to each individual truck.
These parameters are divided into two types;
Counters and Profiles.
Detailed information concerning the Statistical Data
Collector is discussed on the following pages. Tables
III and IV list parameter code numbers, descriptions,
units of measure, count conditions, etc. The informa-
tion below outlines the procedures required to view
Statistical Data on the PTU and save the information
to a file.
Selecting SPECIAL OPERATION in the follow-
ing procedure may present a safety hazard if the
engine is running. Control of the propulsion sys-
tem may transfer to the PTU operator from the
truck driver with this software operation. Refer to
Step 1. below:
1. Use the arrow keys to move the cursor to the
SPECIAL OPERATION selection on the GE
STATEX III PTU MAIN MENU and press
[ENTER]. The screen shown in Figure 2-25 will
be displayed to alert the operator about the
state of the truck software.
This warning notifies the operator when control
of the truck is being transferred from the truck
driver to the PTU, based on the PTU selection
of SPECIAL OPERATION.
When finished and the PTU is returned to the
GE STATEX III PTU MAIN MENU, control of the
propulsion system is returned to the truck driver.
Before activating this command, the screen
shown in Figure 2-26 will be displayed.
The PTU user should always keep the truck
driver appraised of this control.
2. Select YES on the caution screen (Figure 2-
25) and press [ENTER]. The SPECIAL OPER-
ATION MENU will be displayed.
3. Use the arrow keys to move the cursor to the
STATISTICAL DATA MENU selection and
press [ENTER]. The STATISTICAL DATA
MENU screen will be displayed. Selections
available on this menu are as follows:
View Counters
The STATISTICAL COUNTERS SCREEN displays
the number of times various operations have
occurred in the history of the truck operation or in
how many seconds or miles the event has lasted.
Refer to Table III, for a listing of all active counters.
1. While the STATISTICAL DATA MENU is dis-
played, use the arrow keys to move the cursor
to the VIEW COUNTERS selection and press
[ENTER]. The STATISTICAL COUNTERS
SCREEN will be displayed.
2. Use the up and down arrow keys to scroll
through the counters. Press [ESC] to return to
the exit choice.
3. When finished viewing the information, press
[ENTER] again to exit this screen.
View Profiles
This screen displays currents, voltages and speeds
as a history of truck operation. Each profile is broken
into a number of Bins and each Bin has a range of
values. In this manner, the entire range of the param-
eter from minimum to maximum is covered. The
result is a histogram for each parameter covered by a
profile. Refer to Table IV for a listing of all active pro-
files.
1. Use the arrow keys to move the cursor to the
VIEW PARAMETER PROFILES selection and
press [ENTER]. The PROFILE screen will be
displayed. Use [F3] and [F4] to move through all
profiles.
2. When finished viewing this screen, press
[ENTER] again to exit this screen.
Upload Statistical Data To A File
Use the arrow keys to move the cursor to the
UPLOAD STATISTICAL DATA TO A FILE selection
and press [ENTER]. The UPLOAD STATISTICAL
DATA MENU screen will be displayed. Use the direc-
tions on this screen to upload data from the truck
CPU to your PTU.
E02011C1 1/96 Electrical Propulsion Components E2-49
Statistical Data Codes - Counters
The Statistical Data Collector uses Parameter
Counters and Parameter Profiles to record operating
conditions for various occurrences on the truck.
To make data most useful, there are four counters for
every statistical counter and five for every statistical
profile. These counts are named by the method used
to reset the count to zero. For the counter, there is a
lifetime count, LCount, which is associated with its
date, LCount Start. Then there are three other
counters, Last Qtr, This Qtr, and This Day.
A parameter is a defined occurrence. Each parame-
ter has an identification number called Par #, and a
short name called Description. Each parameter is
an occurrence that is counted in some unit such as
hours or the number of times the conditions have
been correct to declare that the occurrence hap-
pened.
The units for which the counters count is listed under
Units in Table III. The tables contain additional
explanation of the conditions which define a statisti-
cal parameter as having occurred. This column is
entitled Count Conditions.
There are two types of parameters; Counter (Table
III, and Profile (Table IV). The profile parameters
have one more characteristic, Range Counted,
which sorts the actual value of the parameter and
then counts time of the parameter-at-the-value.
When examining the number of counts for a parame-
ter, it is often useful to know over what period of time
the counts occurred. To aid in determining how long it
took to get a certain number of counts for a Statistical
Data Counter parameter, the Statistical Data is pre-
sented in the form of four counters. The first counter,
LCount, indicates how many counts have occurred
since the LCount Start date. This is intended to be
lifetime counter. It can be reset to zero by a privileged
user, and the LCount Start will automatically be set
to the date on the CPU board when the user per-
formed the reset.
The second counter, Last Qtr is just the total num-
ber of counts for the parameter over the last-fiscal-
quarter, also known as the last-three-months. This
counter has the same value in it all quarter long. At
midnight on a quarter change, this counter is over-
written by the This Qtr value as this-quarter
becomes last-quarter.
The third counter, This Qtr, keeps a moment by
moment count of occurrences of the parameter. The
counts are not reset to zero until midnight of the next
quarter.
The fourth counter, This Day, keeps a moment by
moment count of occurrences of the parameter just
as This Qtr, except the This Day count is reset to
zero every midnight whether it is a quarter change or
not.
If the GE control panel is shut off during midnight,
any necessary resetting of counters is done when the
panel next powers up after midnight.
Whenever the truck is programmed, that is, the CPU
Card has the contents of the flash proms changed,
the LCount, Last Qtr, and This Qtr counts are not
changed. However, the This Day count will be reset
to zero.
In order to use the Statistical Data Collector to moni-
tor maintenance of the vehicle, it is recommended
that an office spread sheet or data base computer
program be used to keep quarterly records of the sta-
tistical data. To aid in getting the data off the CPU
card and into the office computer, a feature called
UPLOAD STATISTICAL DATA TO A FILE has been
provided in the PTU. This feature puts all the col-
lected statistical data in an ASCII file which can then
be processed in the office to keep records on truck
use. The [F2] feature of the PTU can be used to cap-
ture statistical data playback on the PTU in the office.
NOTE: The Statistical Data Collector is a part of the
program run by the CPU board. If the CPU board
does not have power, or if the code is stopped (as
when looking at event and statistical data via the
(PTU), then the Statistical Data Collector is also
stopped. Hence, the Statistical Data Collector cannot
count occurrences of, for example, toggling the AS
pedal, while the code is stopped.
Also note that the Statistical Data Collector is initial-
ized at power-up. The counter conditions are initial-
ized to their respective inactive states, usually false.
If, again for example, the AS pedal is depressed
while power is cycled, then the Statistical Data Col-
lector will be initialized to AS not depressed at
power-up. Momentarily after power-up however, the
Statistical Data Collector will detect that AS is
depressed and increment the count. Thus, cycling
power has resulted in the Statistical Data Collector
counting an occurrence of AS depressed even
though AS has been depressed for some time and
has not really been released and depressed again.
E2-50 Electrical Propulsion Components E02011C1 1/96
TABLE III. STATISTICAL DATA CODES - COUNTERS
PAR
No.
DESCRIPTION UNITS COUNT CONDITIONS
1 Engine Operating Hours Hours Number of hours engine has operated above 450 RPM
2 Wheel #1 Operating Hours Hours
Number of hours wheel was powered in either propulsion or retard mode and:
. . . Speed is above 50 RPM
. . . Current is above 50 amps (absolute value)
3 Wheel #2 Operating Hours Hours
Number of hours wheel was powered in either propulsion or retard mode and:
. . . Speed is above 50 RPM
. . . Current is above 50 amps (absolute value)
4 Alternator Operating Hours Hours Number of hours alternator has been rotating at or above 450 RPM
5 Propulsion Mode Hours Hours
Number of hours in propulsion mode when propulsion mode is active and:
. . . Wheel #1 or wheel #2 speed is above 50 RPM and
. . . Motor #1 or motor #2 current is above 50 amps (absolute value)
6 Retard Mode Hours Hours
Number of hours in retarding mode when propulsion mode is active and:
. . . Wheel #1 or wheel #2 speed is above 50 RPM and
. . . Motor #1 or motor #2 current is above 50 amps (absolute value)
7 Coast Mode Hours Hours
Number of hours in coast mode when propulsion mode is active and:
. . . Wheel #1 or wheel #2 speed is above 50 RPM and
. . . Motor #1 or motor #2 current is above 50 amps (absolute value)
8 Idle Hours Hours
Number of hours engine is idling, truck is stationary and:
. . . Engine speed is above 450 RPM
. . . Wheel #1 and wheel #2 speeds are both less than 50 RPM
9 Fault Down Time Hours Hours
Number of hours truck has propulsion system faults and the accelerator pedal is
depressed.
. . . Clock will start anytime a fault is recorded that restricts propulsion and
. . . the propulsion mode is requested.
. . . Clock will stop when propulsion mode is no longer requested or
. . . when all restrictive faults are reset
10 Truck Operating Hours Hours Sum of propulsion mode, retard mode, coast mode and idle hours
11
Propulsion Mode Net
Operating Hours
Hours Net KW hours generated by the alternator in propulsion mode
12 Retard Mode KW Hours Hours Net KW hours generated by the alternator in retard mode
13 Truck Distance Travelled Miles
Value is calculated by integrating the higher of the two wheel speed signals and
displaying the cumulative value in miles
. . . Active when control power (CPR) is on
. . . Not sensitive to vehicle direction
14 Truck Distance Travelled Kilometers
Value is calculated by integrating the higher of the two wheel speed signals and
displaying the cumulative value in kilometers
. . . Active when control power (CPR) is on
. . . Not sensitive to vehicle direction
20 Speed Override Occurrences Number of times Speed Override mode condition has changed from false to true
21 Body Up Switch Occurrences Number of times Dump Body Switch input has changed from false to true
22 RS Switch Occurrences Number of times Retard Switch input has changed from false to true
23 AS Switch Occurrences Number of times Accel Switch input has changed from false to true
24 Override Switch Occurrences Number of times Override Switch input has changed from false to true
25 Forward Switch Occurrences Number of times Selector Switch was moved to FORWARD position
26 Reverse Switch Occurrences Number of times Selector Switch was moved to REVERSE position
27 Neutral Switch Occurrences Number of times Selector Switch was moved to NEUTRAL position
28 Retard Mode Occurrences
Number of times Retard Contactor sequence has been completed or Retard
mode entered
E02011C1 1/96 Electrical Propulsion Components E2-51
TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.)
PAR
No.
DESCRIPTION UNITS COUNT CONDITIONS
29 Propel Mode Occurrences
Number of times Propel Contactor sequence has been completed or Propel
mode entered
30 Coast Mode Occurrences Number of times Coast mode entered
31 P1 Pickup Occurrences Number of times P1 feedback has changed from false to true
32 P2 Pickup Occurrences Number of times P2 feedback has changed from false to true
33 RP1 Pickup Occurrences Number of times RP1 feedback has changed from false to true
34 RP2 Pickup Occurrences Number of times RP2 feedback has changed from false to true
35 RP3 Pickup Occurrences Number of times RP3 feedback has changed from false to true
36 RP4 Pickup Occurrences Number of times RP4 feedback has changed from false to true
37 RP5 Pickup Occurrences Number of times RP5 feedback has changed from false to true
38 RP6 Pickup Occurrences Number of times RP6 feedback has changed from false to true
39 RP7 Pickup Occurrences Number of times RP7 feedback has changed from false to true
40 RP8 Pickup Occurrences Number of times RP8 feedback has changed from false to true
41 RP9 Pickup Occurrences Number of times RP9 feedback has changed from false to true
42 GF Pickup Occurrences Number of times GF feedback has changed from false to true
43 GFR Pickup Occurrences Number of times GFR feedback has changed from false to true
44 MF Pickup Occurrences Number of times MF feedback has changed from false to true
49 Srv Brk >8 MPH Occurrences Number of times service brake has been applied with truck speed above 8 MPH
50 Park Brake Occurrences Number of times Park Brake Off has changed from false to true
51 Service Brake Occurrences Number of times Service Brake Pressure Switch has changed from false to true
52 Loaded Switch Occurrences
Number of times Two-Speed Overspeed has changed from false to true
. . . (empty to loaded)
53 Reverser Moves Occurrences
Number of times Reverser feedback has changed from FORWARD to REVERSE
or REVERSE to FORWARD
54 SS Move >2 MPH Occurrences
Number of times Selector Switch was moved with truck speed greater than no
motion (2 MPH)
55 CPR Pickup Occurrences Number of times CPR feedback has changed from false to true
56 Engine Starts Occurrences Number of times engine speed goes from <450 RPM to >450 RPM
57 2dd Reset Switch Occurrences Number of times reset button on 2 Digit Display has been pushed
58 Both AS & RS Occurrences Number of times AS & RS activated at same time
59 AS & Service Brake Occurrences Number of times AS and service brake activated at same time
60 RS & Service Brake Occurrences Number of times RS and service brake activated at same time
61 AS & Temp >220C Occurrences
Number of times AS is activated with either motor temperature greater than
220C
62 RS & nomotion Occurrences Number of times RS is activated at truck speeds below no motion (2 MPH)
63 RSC Switch On Occurrences Number of times Retard Speed Control switch is turned On
64 RSC Pot Moved Occurrences
Number of times Retard Speed Control pot is moved more than 1 MPH while
RSC is On.
65 Test Digital Output Occurrences
Number of times MANUAL DIGITAL OUTPUT TEST screen has been selected
at the SPECIAL OPERATION WITH ENGINE STOPPED TEST menu
66 Program Truck Occurrences Number of times PTU has been used to program the truck
E2-52 Electrical Propulsion Components E02011C1 1/96
TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.)
PAR
No.
DESCRIPTION UNITS COUNT CONDITIONS
67 Special Operation Occurrences
Number of times SPECIAL OPERATION menu has been selected at PTU
MAIN MENU
68 Events Erased Occurrences Number of times PTU has been used to erase event data
69 Normal Operation Occurrences
Number of times NORMAL OPERATION menu has been selected at PTU
MAIN MENU
70
AS & Park Brake
Applied
Occurrences
Number of times AS and Park Brake have been activated at the same time. New
counts will be recorded when a state change occurs. If both signals are present
for 2 hours, only one count is recorded.
71
Park Brake Switch >0.3
MPH
Occurrences
Number of times Park Brake switch has been turned On when truck speed is
above 0.3 MPH.
72 Alternator Field Too Hot Occurrences Number of times (estimated) alternator field temperature has exceeded 220C
80 M1 Amps Propel Seconds
Refer to Table IV, PROFILES
81 M2 Amps Propel Seconds
82 M1 Amps Retard Seconds
83 M2 Amps Retard Seconds
84 MF Amps Propel Seconds
85 MF Amps Retard Seconds
86 Net Input Engine HP Hours
87 Net Input Engine KW Hours
88 M1 Temp Degrees C Seconds
89 M2 Temp Degrees C Seconds
90 Truck Speed MPH Seconds
91 Engine Speed RPM Seconds
98 AFSE Temp Degrees C Seconds
99 MFSE Temp Degrees C Seconds
101 Low Level Ground Fault Occurrences
Refer to Table I, TWO-DIGIT DISPLAY CODES
102 High Level Ground Fault Occurrences
108 Accelerator Pedal Occurrences
109 Retard Pedal Occurrences
110 GF Occurrences
111 GFR Occurrences
112 MF Occurrences
113 P1 Occurrences
114 P2 Occurrences
115 RF1 Occurrences
116 RF2 Occurrences
117 RP1 Occurrences
118 RP2 Occurrences
119 RP3 Occurrences
E02011C1 1/96 Electrical Propulsion Components E2-53
TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.)
PAR
No.
DESCRIPTION UNITS COUNT CONDITIONS
120 RP4 Occurrences
Refer to Table I, TWO-DIGIT DISPLAY CODES
121 RP5 Occurrences
122 RP6 Occurrences
123 RP7 Occurrences
124 RP8 Occurrences
125 RP9 Occurrences
126 FORWARD Occurrences
127 REVERSE Occurrences
130 Analog Output Occurrences
131 Analog Read Back Occurrences
132 Analog Input Occurrences
133 Frequency Input Occurrences
137 Startup Fault Occurrences
145 Diode Fault Occurrences
146
Motor 1
Overcurrent
Occurrences
147
Motor 2
Overcurrent
Occurrences
148 MFld Marm Occurrences
149 MF Overcurrent Occurrences
150 Motor Stall Occurrences
151 Motor Spin Occurrences
152
Alternator Tertiary
Overcurrent
Occurrences
153
Motor Tertiary
Overcurrent
Occurrences
154 +15V Power Occurrences
155 -15V Power Occurrences
156 +19V Power Occurrences
157 Motor Polarity Occurrences
161 Retard Grid 1 Occurrences
162 Retard Grid 2 Occurrences
163 Blower Fault Occurrences
164 M1 Overtemp Occurrences
165 M2 Overtemp Occurrences
E2-54 Electrical Propulsion Components E02011C1 1/96
TABLE III. STATISTICAL DATA CODES - COUNTERS (Cont.)
PAR
No.
DESCRIPTION UNITS COUNT CONDITIONS
166 Overspeed Occurrences
Refer to Table I, TWO-DIGIT DISPLAY CODES
167
Speed Retard
Exceeded
Occurrences
168 Retard Overcurrent Occurrences
169 Horsepower Low Occurrences
170 HP Limit Exceeded Occurrences
171
Engine Overspeed
Exceeded
Occurrences
172
Engine Oil Pres-
sure Warning
Occurrences
173
Engine Oil Pres-
sure Shutdown
Occurrences
174
Engine Coolant
Pressure Warning
Occurrences
175
Engine Coolant
Press Shutdown
Occurrences
176
Engine Crankcase
Pressure
Occurrences
177
Engine Coolant
Temperature
Occurrences
178 Engine Service Occurrences
179 Engine Shutdown Occurrences
180
Engine Speed
Retard
Occurrences
181
Motor 1 Voltage
Limit
Occurrences
182
Motor 2 Voltage
Limit
Occurrences
183
Alternator Field
Amps
Occurrences
190
Battery Voltage
Low
Occurrences
191
Battery Voltage
High
Occurrences
192
Engine Speed Sen-
sor
Occurrences
193
Motor Speed Sen-
sor
Occurrences
198 Datastore Occurrences
199 Software Occurrences
E02011C1 1/96 Electrical Propulsion Components E2-55
STATISTICAL DATA CODES - PROFILES
TABLE IV. STATISTICAL DATA CODES - PROFILES
PAR
No.
DESCRIPTION COUNT CONDITIONS BUCKET No.
CURRENT
VALUE
(AMPS)
80
M1 Amps Propel
(In seconds)
This is a histogram of Motor #1 armature current in propulsion
mode.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever propulsion mode is selected.
The histogram breaks the current spectrum into 17 buckets defined
at right, and displays the time spent in each bucket.
1 below 500
2 501 to 750
3 751 to 850
4 851 to 950
5 951 to 1050
6 1051 to 1150
7 1151 to 1250
8 1251 to 1350
81
M2 Amps Propel
(In seconds)
This is a histogram of Motor #2 armature current in propulsion
mode.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever propulsion mode is selected.
The histogram breaks the current spectrum into 17 buckets defined
at right, and displays the time spent in each bucket.
9 1351 to 1450
10 1451 to 1550
11 1551 to 1800
12 1801 to 2150
13 2151 to 2300
14 2301 to 2600
15 2601 to 2900
16 2901 to 3200
17 above 3201
PAR
No.
DESCRIPTION COUNT CONDITIONS BUCKET No.
CURRENT
VALUE
(AMPS)
82
M1 Amps Retard
(in seconds)
This is a histogram of Motor #1 armature current in retard mode.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever retard mode is selected.
The histogram breaks the current spectrum into 17 buckets defined
at right, and displays the time spent in each bucket.
1 below 200
2 201 to 300
3 301 to 400
4 401 to 500
5 501 to 600
6 601 to 700
7 701 to 800
8 801 to 900
83
M2 Amps Retard
(in seconds)
This is a histogram of Motor #2 armature current in retard mode.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever retard mode is selected.
The histogram breaks the current spectrum into 17 buckets defined
at right, and displays the time spent in each bucket.
9 901 to 1000
10 1001 to 1100
11 1101 to 1200
12 1201 to 1350
13 1351 to 1450
14 1451 to 1550
15 1551 to 1650
16 1651 to 1750
17 above 1751
E2-56 Electrical Propulsion Components E02011C1 1/96
TABLE IV. STATISTICAL DATA CODES - PROFILES (Cont.)
PAR
No.
DESCRIPTION COUNT CONDITIONS BUCKET No.
CURRENT
VALUE
(AMPS)
84
MF Amps Propel
(in seconds)
This is a histogram of Motor Field current in propulsion mode.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever propulsion mode is selected.
The histogram breaks the current spectrum into 17 buckets defined
at right, and displays the time spent in each bucket.
1 0 to 100
2 101 to 125
3 126 to 150
4 151 to 175
5 176 to 200
6 201 to 225
7 226 to 250
8 251 to 275
85
MF Amps Retard
(in seconds)
This is a histogram of Motor Field current in retard mode.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever retard mode is selected.
The histogram breaks the current spectrum into 17 buckets defined
at right, and displays the time spent in each bucket.
9 276 to 300
10 301 to 325
11 326 to 375
12 376 to 450
13 451 to 550
14 551 to 650
15 651 to 800
16 801 to 950
17 951 to 9999
PAR
No.
DESCRIPTION COUNT CONDITIONS BUCKET No.
NET INPUT
HP RANGE
86
Net Input Engine
Horsepower
(in minutes)
This is a histogram of net input horsepower.
It is a calculated value, calculated as follows:
HP=(I
a
x V
a
) (746 x Load Box Efficiency in %)
1 below 200
2 201 to 400
3 401 to 600
4 601 to 800
5 801 to 1000
6 1001 to 1200
7 1201 to 1400
8 1401 to 1600
87
Net Input Engine
Kilowatts
(in minutes)
This is a histogram of net input horsepower.
It is a calculated value, calculated as follows:
HP=(I
a
x V
a
) (1000 x Load Box Efficiency in %)
9 1601 to 1800
10 1801 to 2000
11 2001 to 2200
12 2201 to 2400
13 2401 to 2600
14 2601 to 2800
15 2801 to 3000
16 3001 to 3200
17 above 3201
E02011C1 1/96 Electrical Propulsion Components E2-57
TABLE IV. STATISTICAL DATA CODES - PROFILES (Cont.)
PAR
No.
DESCRIPTION COUNT CONDITIONS BUCKET No.
TEMP RANGE
(C)
88
M1 Temp C
(in seconds)
This is a histogram of Motor #1 temperature.
. . . . Sample time is 60.0 seconds
. . . . The clock will start whenever control power (CPR) is on.
The histogram breaks the temperature spectrum into 17 buckets
defined at right, and displays the time spent in each bucket.
1 -40 to 100
2 101 to 110
3 111 to 120
4 121 to 130
5 131 to 140
6 141 to 150
7 151 to 160
8 161 to 170
89
M2 Temp C
(in seconds)
This is a histogram of Motor #2 temperature.
. . . . Sample time is 60.0 seconds
. . . . The clock will start whenever control power (CPR) is on.
The histogram breaks the temperature spectrum into 17 buckets
defined at right, and displays the time spent in each bucket.
9 171 to 180
10 181 to 190
11 191 to 200
12 201 to 210
13 211 to 220
14 221 to 230
15 231 to 240
16 241 to 250
17 251 to 9999
PAR
No.
DESCRIPTION COUNT CONDITIONS
BUCKET
No.
TRUCK
SPEED
MPH
ENGINE SPD
RPM
90
Truck Speed
MPH
(in seconds)
This is a histogram of truck speed for all modes of operation.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever control power (CPR) is
on.
The buckets are defined in the Truck Speed column at right:
1 0 to 1 below 600
2 2 to 3 601 to 800
3 4 to 6 801 to 900
4 7 to 9 901 to 1000
5 10 to 12 1001 to 1100
6 13 to 15 1101 to 1200
7 16 to 18 1201 to 1300
8 19 to 21 1301 to 1400
91
Engine Speed
RPM
(in seconds)
This is a histogram of engine speed in RPM for all modes of
operation.
. . . . Sample time is 1.0 second
. . . . The clock will start whenever control power (CPR) is
on.
The buckets are defined in the Engine Speed column at
right:
9 22 to 24 1401 to 1500
10 25 to 27 1501 to 1600
11 28 to 30 1601 to 1700
12 31 to 33 1701 to 1800
13 34 to 36 1801 to 1900
14 37 to 39 1901 to 2000
15 40 to 42 2001 to 2100
16 43 to 45 2101 to 2200
17 45 & above above 2200
E2-58 Electrical Propulsion Components E02011C1 1/96
TABLE IV. STATISTICAL DATA CODES - PROFILES (Cont.)
PAR
No.
DESCRIPTION COUNT CONDITIONS BUCKET No.
TEMP RANGE
(C)
98
AFSE Temp C
(in seconds)
This is a histogram of Alternator Field Static Exciter temperature.
. . . . Sample time is 60.0 seconds
. . . . The clock will start whenever control power (CPR) is on.
The histogram breaks the temperature spectrum into 17 buckets
defined at right, and displays the time spent in each bucket.
1 below 20
2 21 to 40
3 41 to 50
4 51 to 60
5 61 to 70
6 71 to 80
7 81 to 90
8 91 to 100
99
MFSE Temp C
(in seconds)
This is a histogram of Motor Field Static Exciter temperature.
. . . . Sample time is 60.0 seconds
. . . . The clock will start whenever control power (CPR) is on.
The histogram breaks the temperature spectrum into 17 buckets
defined at right, and displays the time spent in each bucket.
9 101 to 105
10 106 to 110
11 111 to 120
12 121 to 125
13 126 to 130
14 131 to 135
15 136 to 140
16 141 to 145
17 above 146
E02011C1 1/96 Electrical Propulsion Components E2-59
Truck Specific Information
To quickly review the various options on the current
truck, the TRUCK SPECIFIC INFORMATION MENU
can be used to view configuration options, speed set-
tings, serial numbers, etc. Information accessed
through this menu is for viewing only and cannot be
changed. If changes are required, use the TRUCK
SETUP (CFG) selection from the GE OHV STATEX
III MENU.
Selecting SPECIAL OPERATION in the follow-
ing procedure may present a safety hazard if the
engine is running. Control of the propulsion sys-
tem may transfer to the PTU operator from the
truck driver with this software operation. Refer to
Step 1. below:
1. With the GE STATEX III PTU MAIN MENU dis-
played, select SPECIAL OPERATION and
press [ENTER].
The screen shown in Figure 2-30 will be dis-
played to alert the operator about the state of
the truck software.
This warning notifies the operator when control
of the truck is being transferred from the truck
driver to the PTU, based on the PTU selection
of SPECIAL OPERATION.
When finished and the PTU is returned to the
GE STATEX III PTU MAIN MENU, control of the
propulsion system is returned to the truck driver.
Before activating this command, the screen
shown in Figure 2-31 will be displayed.
The PTU user should always keep the truck
driver appraised of this control.
2. Select YES on the caution screen (Figure 2-
30) and press [ENTER]. The SPECIAL OPER-
ATION MENU will be displayed.
3. Use the arrow keys to move the cursor to the
TRUCK SPECIFIC INFORMATION MENU
selection and press [ENTER].
Selections available on this menu are:
VIEW OEM CONFIGURATION OPTIONS
This selection permits reviewing the setup infor-
mation programmed into the truck configuration
file by HAULPAK
apart and
adjacent to the 0.50 in. diameter holes to 60 ft.
lbs. (81 N.m) torque. Rotate wheel or hub 3
revolutions. Tighten same 2 capscrews to 110
ft. lbs. (149 N.m) torque and rotate wheel or
hub at least 3 revolutions while tightening.
While rotating wheel or hub at least 3 revolu-
tions, tighten same 2 capscrews again to 110 ft.
lbs. (149 N.m) torque.
13. Using a depth micrometer, measure and record
the depth to the end of the spindle through the 2
holes adjacent to the 2 capscrews.
14. Average the 2 measured depths. Subtract the
retainer (1) thickness, (etched on surface of
retainer) from the average depth. The result is
the required shim pack dimension.
15. Measure each shim individually to arrive at a total
shim pack thickness of 0.001 in. (0.025 mm) of
the required shim pack determined in Step 14.
NOTE: This procedure will provide the required
assembled bearing preload of 0.007 in. (0.178 mm)
nominal.
16. Install wheel support chains. Refer to Steps 5 & 6.
17. Remove capscrews and retainer. Install shim
pack (20, Figure 3-4). Install retainer (1) and
capscrews (2). Tighten all capscrews (2, Figure
3-9) to 100 ft. lbs. (135.6 N.m) torque.
18. Remove tire retaining chains (2 & 3, Figure 3-10).
19. Tighten capscrews (2, Figure 3-9) in four equal
increments while rotating wheel at least 3 revo-
lutions at each increment. Final capscrew
torque is 750 75 ft. lbs. (1017 102 N.m).
20. Using new O-ring (20, Figure 3-4) install cover
(3). Secure cover in place with capscrews and
washers. Tighten capscrews to standard torque.
21. Remove support chain (1, Figure 3-10) and all
cribbing.
22. Add oil (SAE 80W-90) per instructions under
Installation, Step 8.
23. Check bearing adjustment after first 500 hours
of operation and at each 5000 hour mainte-
nance interval thereafter.
FIGURE 3-10. WHEEL SUPPORT CHAIN
INSTALLATION
1. Support Chain
2. Chain & Chain Binder
3. Chain & Chain
Binder
G3-8 Front Wheel Hub and Spindle G03006 6/98
STEERING CYLINDERS AND TIE ROD
The steering cylinders and tie rod are mounted in the
same manner. The removal and installation instruc-
tions can be used for both.
Removal
1. With engine shut down and key switch Off,
allow at least 90 seconds for accumulators to
bleed down. Block front and back of rear
wheels.
2. Disconnect oil supply lines at the steering cylin-
ders. Plug all line connections and cylinder ports
to prevent contamination of hydraulic system.
3. Remove nut (1, Figure 3-11) and washer from
both ends of assembly.
FIGURE 3-11. STEERING CYLINDER REMOVAL
1. Nut
2. Pin
3. Steering Cylinder
4. Spindle
5. Tie Rod
FIGURE 3-12. STEERING CYLINDER AND TIE ROD INSTALLATION
1. Steering Cylinder
2. Tie Rod Assembly
3. Bearing
4. Bearing Retainer
5. Capscrew
6. Lockwasher
7. Rod End
8. Capscrew
9. Slotted Nut
10. Cotter Pin
11. Tie Rod
12. Bearing Spacer
13. Grease Fitting
14. Pin
15. Flat Washer
16. Nut
G03006 6/98 Front Wheel Hub and Spindle G3-9
4. Remove pins from each end of assembly and
move assembly to clean work area.
Bearing spacers will be free when pin is
removed. Insure bearing spacers do not drop out
and become damaged when removing pin.
Installation
1. Align bearing spacers (12, Figure 3-12) and rod
end (7) with pin openings on spindle and frame.
2. Install pin (14) and washers (15) and secure
with nut (16). Tighten to 1000 ft. lbs. (1350
N.m) torque.
3. Connect oil lines to their respective ports. Oper-
ate steering and check for leaks and proper
operation.
NOTE: Tie rod is to be installed with clamping bolts
toward the rear of the truck. (Reference Figure 3-11).
Bearing Replacement
1. Remove capscrew (2, Figure 3-13) and lock-
washer (3). Remove bearing retainer (4).
2. Press bearing (1) out of bore in steering cylin-
der or tie rod end.
3. Press new bearing into bore.
4. Install bearing retainers with capscrews and
lockwashers. Tighten capscrews to standard
torque.
FIGURE 3-13. STEERING
1. Bearing
2. Capscrew
3. Lockwasher
4. Bearing Retainer
5. Rod End
G3-10 Front Wheel Hub and Spindle G03006 6/98
TOE-IN ADJUSTMENT
(Bias Ply Tires)
1. Check toe-in by measuring the distance
between front wheels at the inside edge of the
tire rim in two places. These measurements
should be taken on a horizontal center line at
front and rear of rim. Refer Figure 3-14.
2. The front measurement should be 0.75 in.
0.25 in. (19.1 mm 1.9 mm) less than rear
(Dimension A) measurement.
3. Adjust as necessary on adjustable tie rod end
by loosening clamp nuts and turning rod end in
or out. When dimension required is attained,
tighten clamp nuts on tie rod to 208 ft. lbs. (282
N.m) torque. Install cotter pins. (Figure 3-11).
NOTE: If the original Grade 5 pinch bolts with
castellated nuts and cotter pins have been replaced
with 3/4"-10 UNC x 4.0" long, Grade 8 capscrews
and Grade 8 self-locking nuts, then the specified
torque should be 310 31 ft.lbs. (420 42 N.m)
torque.
4. Install tie rod retaining nut and tighten to 1000
100 ft.lbs. (1356 136 N.m) torque. Install cot-
ter pin.
5. Install lubrication line to pin ends.
6. Remove blocks from rear wheels.
(Radial Tires)
NOTE: Set toe-in to zero with the truck fully loaded.
If inconvenient or impractical to make adjustments on
a fully loaded truck, proceed as follows with the truck
empty:
1. Partially release the nitrogen pressure in the
front suspensions to achieve the loaded
extension of 5.58 in. (141 mm).
2. Adjust front toe-in to zero. Refer to toe-in
adjustment Steps 1, 3, 4, 5, and 6 for bias ply
tires.
3. When toe-in adjustment is complete, recharge
front suspensions. Refer to Section H, Oiling
and Charging procedure.
FIGURE 3-14. MEASURING TOE-IN
G04004 10/98 Rear Axle Housing Attachment G4-1
REAR AXLE HOUSING ATTACHMENT
HITCH PIN
Removal
1. Park truck on firm level surface and block front
and rear of all tires.
Truck body must be empty and down against
frame before attempting this procedure.
2. Release all brakes.
3. Charge rear suspensions with nitrogen until pis-
tons are fully extended.
4. Place blocks or stands under each frame mem-
ber beneath the hoist cylinders.
Blocks must be securely in place before lowering
the frame. Check blocks on wheels to make sure
they are in place.
5. Release nitrogen out of front suspensions.
6. Release nitrogen out of rear suspensions.
7. Place a jack below the nose cone to control any
downward movement of nose cone.
8. Disconnect nose cone bearing lube line.
Remove ground wire between hitch structure
and frame.
9. Remove capscrew and lockwashers (1, Figure
4-1). Remove capscrews (2). Remove retainer
plate (3) Remove pin (10).
10. Remove clamps (15), separate and remove
seals (11 and 14).
NOTE: Placement of a pry bar or jack between
mounting structure and nose cone may be necessary
to push nose cone down and away from mount
structure. Spacers (4 and 7) will fall free.
Installation
1. Raise nose cone into position.
2. Install spacers (4 and 7, Figure 4-1). Install pin
(10). Install seals (11 and 14) and secure in
place with clamps (15).
3. Position retainer plate (3) by lining up capscrew
holes with capscrew holes in pin (10). Install
capscrews (2).
4. Rotate pin and retainer plate and align cap-
screw holes in mounting structure.
a. Install capscrews and lockwashers (1).
Tighten capscrews (1) to 125 ft. lbs. (169.5
N.m) torque.
b. Tighten capscrews (2) to 750 ft. lbs. (1017
N.m) torque, and lockwire capscrews in pairs
with 0.080 in. (0.020 mm) lockwire.
c. Install ground wire and lubrication line.
d. Pressurize lube line and be certain bearing
(9) receives adequate grease.
5. Remove jacks if used in nose cone area.
6. Charge front suspension as described in "Oiling
and Charging Procedure", Section "H".
FIGURE 4-1. PIVOT PIN INSTALLATION
Refer to NOTE: and Figure 4-1A on page G4-2 for
information regarding later style Retainer Plate (2).
1. Capscrew &
Lockwasher
2. Capscrew
3. Retainer Plate
4. Spacer
5. Drive Axle Nose
Cone
6. Bearing Retainer
7. Spacer
8. Mounting Structure
9. Bearing
10. Pin
11. Seal
12. Capscrew
13. Nut
14. Seal
15. Clamp
G4-2 Rear Axle Housing Attachment G04004 10/98
7. Charge rear suspensions with nitrogen to fully
extend pistons.
8. Remove blocks or stands from beneath the frame.
9. Release nitrogen from rear suspension and
charge according to procedure in "Oiling and
Charging Procedure", Section "H".
Before removing blocks from the wheels, make
sure parking brake is applied.
10. Remove blocks from wheels.
NOTE: Later model trucks, or trucks that have
been retro-fitted, will have a thicker retainer plate
(3, Figure 4-1A) with new, longer capscrews (1 &
2). These capscrews must be tightened to a
higher torque.
Follow "Pivot Pin Installation" procedure on previous
page, except as follows:
4. Rotate pin and retainer plate and align cap-
screw holes in mounting structure. Install cap-
screws and lockwashers (1, Figure 4-1A).
a. Tighten capscrews (1) to 175 ft. lbs. (237
N.m) torque.
b. Tighten capscrews (2) to 1715 ft. lbs. (2325
N.m) torque.
c. Install ground wire and lubrication line.
d. Pressurize lube line and be certain bearing
(9) receives adequate grease.
PIVOT PIN BEARING
Disassembly
1. Remove capscrews and nuts (12 and 13, Figure
4-2). Remove bearing retainer (6). Remove
bearing (9).
2. Inspect all parts and bearings for wear or dam-
age. Replace parts showing excessive wear or
damage.
Assembly
1. Install spherical bearing (9) into bore of Pivot
Eye Structure (5).
Be sure that outer race of bearing (9) is seated
against inner lip of pivot eye bore.
2. Install bearing retainer (6) with capscrews and
locknuts (12 and 13).
Tighten capscrews to 310 ft. lbs. (420 N.m)
torque.
FIGURE 4-1A. PIVOT PIN INSTALLATION
1. Capscrew (Gr8) &
Lockwasher
2. Capscrew (12 pt. -
Gr9)
3. Retainer Plate
(Thicker)
4. Spacer
5. Drive Axle Nose Cone
6. Bearing Retainer
7. Spacer
8. Mounting Structure
9. Bearing
10. Pin
11. Seal
12. Capscrew
13. Nut
14. Seal
15. Clamp
FIGURE 4-2. PIVOT PIN INSTALLATION
5. Pivot Eye Structure
6. Bearing Retainer
9. Bearing
12. Capscrew
13. Nut
G04004 10/98 Rear Axle Housing Attachment G4-3
PIVOT EYE REPAIR
If damage occurs to the pivot eye (Drive Axle Nose
Cone), it may be necessary to remove this compo-
nent from the rear axle structure to facilitate repair
and bearing replacement.
Removal
To remove the axle housing pivot eye (5, Figure 4-2),
follow the instructions on the preceding page for
Pivot Pin Removal.
Be certain axle housing is blocked securely.
1. Attach a lifting device to the pivot eye (4, Figure
4-3).
2. Remove capscrews (2) and flatwashers (3).
Remove pivot eye.
Installation
1. Be certain mating surfaces of axle housing (1,
Figure 4-3), and pivot eye (4) are clean and not
damaged.
2. Lift pivot eye into position on front of axle hous-
ing. Insert several capscrews (2) and flatwash-
ers (3) to align the parts. Remove the lifting
device.
3. Install the remaining capscrews and flatwash-
ers. Tighten alternately until the pivot eye is
properly seated.
Tighten capscrews to 1480 ft. lbs. (2007 N.m)
final torque.
FIGURE 4-3. PIVOT EYE ATTACHMENT
1. Rear Axle Structure
2. Capscrew
3. Flatwasher
4. Pivot Eye
G4-4 Rear Axle Housing Attachment G04004 10/98
ANTI-SWAY BAR
Removal
1. Position frame and rear axle housing so force
can be applied to end of anti- sway bar pin (13,
Figure 4-4) on the rear axle housing.
2. Block securely between frame and axle housing.
3. Disconnect lubrication lines (4 and 14, Figure 4-
4) and attach lifting device to anti-sway bar (15).
4. Remove capscrews and lockwashers (9) and
retainer bar (8).
5. Bend tabs away from capscrew heads, and
remove capscrews (3), retainer plate (2) from
stub shaft (7) on frame.
6. Remove pin (13) from end of anti-sway bar (15).
7. Remove anti-sway bar from frame stub shaft (7).
8. Remove bearing spacer (6).
Installation
1. Install spacer (6, Figure 4-4) on frame stub
shaft (7).
2. Raise anti-sway bar and slide onto frame stub
shaft. Place anti-sway bar so retainer rings (5 &
11) are toward front of truck.
3. Position opposite end of anti-sway bar in axle
housing mounting structure (10).
4. Install spacers (17) and pin (13).
5. Install retainer bar (8) with capscrews and lock-
washers (9). Tighten capscrews to 750 ft. lbs.
(1018 N.m) torque.
6. Install retainer plate (2). Install lock plate (16).
Install capscrews (3). Tighten capscrews to 220
22 ft. lbs. (298 29.8 N.m) torque.
7. Attach lubrication lines.
8. Remove blocks between frame and axle hous-
ing.
9. Charge suspensions if necessary. Refer to Sec-
tion H for suspension charging.
Disassembly
1. Remove snap rings (11 & 5, Figure 4-4) from
bores of both ends of anti-sway bar (15).
2. Drive out spherical bearings (1 & 12).
Cleaning and Inspection
1. Inspect bearing bores of anti-sway bar. If bores
are damaged, repair or replace anti-sway bar.
2. Inspect bearing spacer (6 & 17) for damage or
wear.
Assembly
1. Press in new bearings.
2. Install snap ring.
FIGURE 4-4. ANTI-SWAY BAR ASSEMBLY
1. Bearing
2. Retainer
3. Capscrew
4. Lube Line
5. Retainer Ring
6. Spacer
7. Stub Shaft
8. Retainer Bar
9. Capscrew and
Lockwashers
10. Mount Structure
11. Retainer Ring
12. Bearing
13. Pin
14. Lube Line
15. Anti-Sway Bar
16. Lock Plate
17. Spacer
G05004 06/03 Rear Axle Housing G5-1
REAR AXLE HOUSING
REAR AXLE HOUSING
Removal
1. Remove the dump body as outlined earlier in
Section "B".
NOTE: It is not necessary to remove the rear axle
housing to service the anti- sway bar or hitch pin.
2. Loosen hose clamps and disconnect large flexi-
ble air tube from connection on rear axle hous-
ing.
3. Mark and disconnect air, lube and brake lines
from rear axle housing.
4. Mark electrical cables for identification and dis-
connect at wheel motors. Loosen cable grips
and pull cables free.
5. Remove rear tires as covered in this Section.
6. Remove wheel motors as covered in this Sec-
tion.
7. Block up truck frame and remove rear HYD-
RAIR
II SUSPENSIONS
INDEX
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-4
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-4
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-5
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-2
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4
OILING AND CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-1
Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-1
HYDRAIR
II suspension weighs
approximately 5140 pounds (2330 kg). Be certain
the lifting device to be used is of sufficient capac-
ity to handle load.
8. Remove capscrews and washers (1, Figure 2-
4) and nuts and washers (2).
9. Remove capscrews and washers (8), and nuts
and washers (10).
10. Remove capscrews and washers (6), and spac-
ers (9).
11. Move suspension to a clean work area for disas-
sembly.
Installation
Use the following procedure for preparing mounting
surfaces and mounting hardware.
1. The mounting surface of both the suspension
and the frame must be clean and dry. Use a
cleaning agent that does not leave a film after
evaporation, such as trichlorethylene, tetrachlo-
rethylene, acetone, or lacquer thinner.
When using a cleaning agent, follow the manu-
facturer's instructions for use, proper ventilation
and/or use of breathing apparatus.
2. Inspect suspension and frame mounting sur-
faces and spotfaces for flatness. Surface finish
not to exceed 250 (RMS). Surface flatness to
be within 0.010 in. (0.254 mm).
3. Clean and dry all capscrews, nuts and washers
as stated in Step 1, above.
NOTE: The use of dry threads in this application is
not recommended. Due to the high tightening forces
required to load these capscrews, dry threads may
cause damage to tools.
FIGURE 2-4. SUSPENSION INSTALLATION
1. Capscrew & Washers
2. Nuts & Washers
3. Housing
4. Mounting Surface
5. Shear Bar
6. Capscrew & Washers
7. Piston
8. Capscrews & Wash-
ers
9. Spacer
10. Nuts & Washers
H02005 3/94 Front Suspensions H2-3
4. Lubricate capscrew threads, capscrew head
seats, washer face, and nut seats with a rust
preventive compound. Approved sources are:
AMERICAN ANTI-RUST GREASE #3-X
from Standard Oil Company,
also American Oil Company.
RUSTOLENE D grease
from Sinclair Oil Company.
GULF NORUST #3 from Gulf Oil Company.
RUST BAN 326 from Humble Oil Company.
1973 RUSTPROOF from the Texas Company.
RUST PREVENTIVE GREASE-CODE 312
from the Southwest Grease and Oil Company.
NOTE: If none of the rust preventive greases listed
above are available for field assembly, use one of the
following lubricants:
SAE 30 weight oil.
3% Molybdenum - Disulphide Grease
High tightening force is required to load front
suspension mounting capscrews. Repeated
tightening operations will cause capscrew mate-
rial to fatigue and break. DO NOT reuse mounting
hardware (capscrews, hardened washers, and
nuts) more than twice after original installation (3
total see NOTE below). Replace capscrews,
washers and nuts after third use.
NOTE: The following method is suggested to control
the "3 - Use" maximum:
Punch mark the capscrew heads with a center punch
after each tightening as follows:
Initial Installation - No (0) marks.
Second Installation - One (1) punch mark.
Third Installation - Two (2) punch marks.
Suspension mounting capscrews are specially
hardened bolts to meet or exceed Grade 8
specifications. Replace only with bolts of correct
hardness. Refer to Haulpak Parts Catalog for correct
part number.
Before installation, inspect each capscrew for any
defects and number of punch marks. Replace
capscrew and related hardware if two punch marks
are evident; do not reuse if any defect is suspected.
Hardware showing signs of rust, corrosion, galling or
local yielding on any seat or thread surfaces should
be replaced. Replace all suspension mounting
hardware, if the truck was operated with the
suspension mounting in a loose joint condition.
5. Attach fork truck or lifting device to suspension
and mount suspension to the truck frame making
sure shear bar (5, Figure 2-4) is in place. Install
fourteen capscrews (1, 6, 8) with hardened
washers and nuts. Four bottom holes tapped into
suspension housing require capscrews (6) with
hardened washers, and spacers (9) only.
6. The capscrews are now ready for the first step
of preloading using "TURN-OF-THE-NUT"
Tightening Procedure.
NOTE: The "Turn-of-the-Nut" tightening
procedure was developed for high strength 1 1/2"
UNC capscrews (grade 8 or better). Do not use
this tightening method for capscrews of lesser
grade/size.
NOTE: Special hardened flat washers are punched
during the manufacturing process; therefore, when
used under the capscrew head they must be
assembled with the inside diameter radius of the hole
toward the head (punch lip away from head) to
prevent damage to the fillet between capscrew head
and shank. See illustration above.
FIGURE 2-5. INSTALLATION OF HARDENED FLAT
WASHER
1. Hardened Flat
Washer
2. Capscrew
H2-4 Front Suspensions H02005 3/94
" TURN-OF-THE-NUT" Tightening Procedure
a. Tighten all fourteen capscrews (1, 6, 8, Fig-
ure 2-4) to 400 40 ft. lbs. (542 5 N.m)
torque. Use a torque wrench of known cali-
bration.
b. Maintain this torque on the top two corner
capscrews and the bottom outer two cap-
screws (8) on each side (the 4 bottom cap-
screws with nuts).
c. Loosen the 8 remaining capscrews and then
tighten again using "TURN-OF-THE-NUT"
Tightening Procedure as follows:
d. For the 6.0 in. (15 cm) long capscrews (1,
Figure 2-4), tighten capscrews initially to 70
ft. lbs. (95 N.m) torque; then advance 60
using Steps d1. through d3. Refer to Figure
2-5.
For the 0.75 in. (27.3 cm) long capscrews (6, 8, Fig-
ure 2-4), tighten capscrews initially to 150 ft. lbs.
(203 N.m) torque; then advance 90
using Steps d
1
.
through d
3
. Refer to Figure 2-6.
d
1.
Mark a reference line on a corner of the hex-
agonal capscrew head or nut and the
mounting surface opposite this corner as
shown. Then mark the position located 60
or 90
Distributor for
HYDRAIR
.
NOTE: Steel balls (13) will fall free when the housing
is rotated.
4. Attach lifting device to the piston (11, Figure 2-
7) and carefully lift out of housing (12).
5. Remove capscrews and washers (24, 28, Fig-
ure 2-8) and remove bearing retainer (20).
6. Remove and discard rod seal (21) step seal
(22) and rod wiper (23). Remove and discard O-
ring and backup ring (9 and 10).
Cleaning and Inspection
When using cleaning agents follow the solvent
manufacturer's instructions.
1. Clean all parts thoroughly in fresh cleaning sol-
vent. Use a solvent that does not leave a film
after evaporation such as Trichlorethylene, Ace-
tone, or Lacquer Thinner.
2. Inspect all parts for evidence of wear or dam-
age. Inspect plated surfaces for scratches,
nicks, or other defects. Replace or repair defec-
tive parts.
FIGURE 2-8. PISTON ROD REMOVAL
1. Capscrews
2. O-Ring & Backup
Ring
3. End Cap
4. Bearing Retainer
5. Capscrew
6. Ring
7. Bearing
8. Spacer
9. Nut
10. Roll Pin
11. Piston
12. Housing
13. Steel Ball
14. Hardened Washer
H2-6 Front Suspensions H02005 3/94
Assembly
NOTE: All parts must be completely dry and free of
foreign material. Lubricate all interior parts with clean
HYDRAIR
II FRONT SUSPENSION
1. Plug
2. Guard Cap
3. Charging Valve Assy.
4. Gasket
5. End Cap
6. Plug
7. Capscrew
8. Hardened Washer
9. O-Ring
10. Backup Ring
11. Capscrew
12. Hardened Washer
13. Upper Bearing
Retainer
14. Housing
15. Steel Check Ball
16. Spacer
17. Locknut
18. Roll Pin
19. Piston
20. Lower
Bearing Retainer
21. Rod Seal
22. Step Seal
23. Rod Wiper
24. Capscrew
25. Suspension Oil
26. Upper Bearing
27. Lower Bearing
28. Hardened Washer
FIGURE 2-9. FRONT SUSPENSION
H02005 3/94 Front Suspensions H2-7
2. Install new bearing (27), rod seal (21), step seal
(22), and rod wiper (23). Install new O-rings (9)
and backup rings (10) in their appropriate
grooves in the bearing retainer (20).
NOTE: Backup rings must be positioned toward
flange at bearing retainer. (See Figure 2-10).
3. Install lower bearing retainer (20, Figure 2-8)
into lubricated suspension housing. Install cap-
screws and hardened lockwashers (24 & 28)
into lower bearing retainer and tighten to 175 ft.
lbs. (237 N.m) torque.
4. Install new bearing (7, Figure 2-7) onto upper
bearing retainer (4). Slide upper bearing
retainer (4) over end cap rod (3).
5. Install spacer (3, Figure 2-9). Make sure spacer
is fully seated against the rod shoulder. Install
locknut (4) snugly against spacer (3). Turn lock-
nut one half turn until hole for the roll pin (5) is in
alignment. Install roll pin (5).
6. Install upper bearing retainer (4, Figure 2-7)
onto piston rod (11). Secure retainer in place
with ring (6) and NEW capscrews (5). Tighten
capscrews to 500 ft. lbs. (678 N.m) torque.
NOTE: ALWAYS use new capscrews (5, Figure 2-7)
during assembly. Used capscrews will be stressed
and fatigued because of loads imposed on these
capscrews during operation.
NOTE: Backup rings must be positioned toward the
flange on the end cap (3).
7. Install two ball checks (13, Figure 2-7) into pis-
ton rod receptacles. A small amount of petro-
leum jelly will prevent balls from dropping out
during assembly.
8. With suspension housing in a vertical position
carefully install the piston rod (19, Figure 2-8),
bearing retainer (13), and end cap (5) into the
lubricated bore of the cylinder housing to its fully
retracted position
9. Rotate suspension housing and install cap-
screw and hardened washers (7 & 8) and
tighten to 175 ft. lbs. (237 N.m) torque.
10. Install bottom plug (6) and tighten to 13 ft. lbs.
(17.5 N.m) torque.
11. Install charging valve (3) and new O-ring (4).
Lubricate O-rings with clean HYDRAIR
oil
before threading into end cap. Tighten large hex
of charging valve to 16.5 ft. lbs. (27.4 N.m)
torque.
FIGURE 2-10. END CAP ASSEMBLY
1. End Cap
2. Upper Bearing
Retainer
3. Spacer
4. Locknut
5. Roll Pin
6. Wrench
FIGURE 2-11. BACK-UP RING PLACEMENT
H2-8 Front Suspensions H02005 3/94
NOTES:
H03001 9/90 Rear Suspensions H3-1
REAR SUSPENSION
REAR SUSPENSION
The HYDRAIR
Suspension
2. Anti-Rotational
Cable
3. Lubrication Lines
4. Upper Locknut
5. Lower Locknut
H03001 9/90 Rear Suspensions H3-3
3. Remove capscrew and hardened washer (19 &
4, Figure 3-4) and pull suspension piston
assembly (14) from housing.
4. Slide lower bearing (16) from piston (14).
Remove capscrew and hardened washers (11 &
12), remove upper bearing (13) from piston rod.
Remove ball checks (21) from piston.
5. Remove and discard wiper (17), rod seal (15),
O-rings (6) and backup rings (7) from lower
bearing.
6. Using spanner wrench (VN1392), remove lock-
nut (23) and retainer plate (22).
7. Using spanner wrench (VN1388), remove ball
retainer (27), remove and discard O-ring (25).
Remove ball stud (26) and ball liner (20).
8. Remove capscrews and hardened washer (3 &
4), remove ball stud housing (5) from suspen-
sion housing (8). Remove and discard O-rings
(6) and backup rings (7).
9. Using spanner wrench (VN1392), remove lock-
nut (23) and ball retainer (22).
10. Using spanner wrench (VN1388), remove ball
retainer (27), remove and discard O-ring (25).
Remove ball stud (26) and ball liner (20).
FIGURE 3-4. HYDRAIR
II REAR SUSPENSION
1. Pipe Plug
2. Charging Valve
Assembly.
3. Capscrew
4. Hardened Washer
5. Ball Stud Housing
6. O-Ring
7. Backup Ring
8. Housing Suspension
9. Gasket
10. Pipe Plug
11. Capscrew
12. Hardened Washer
13. Upper Bearing
14. Piston
15. Rod Seal
16. Lower Bearing
17. Rod Wiper
18. Suspension Oil
19. Capscrew
20. Ball Liner
21. Check Ball
22. Retainer Plate
23. Locknut
24. Grease Fitting
25. O-Ring
26. Ball Stud
27. Ball Retainer
FIGURE 3-5. REAR SUSPENSION HOUSING
1. Charging Valve
2. End Cap
3. Lifting Holes
4. Lockwasher
5. Locknut
6. Retainer
7. Ball Stud
H3-4 Rear Suspensions H03001 9/90
When using cleaning agents follow the solvent
manufacturer's instructions.
Cleaning and Inspection
1. Clean all parts thoroughly in fresh cleaning sol-
vent. Use a solvent that does not leave a film
after evaporation, such as Trichlorethylene,
Acetone, or Lacquer Thinner.
2. Dry all parts completely using only dry, filtered
compressed air and lint free wiping materials.
3. Inspect all parts for evidence of wear or dam-
age. Inspect plated surfaces for scratches,
nicks or other defects. Replace or repair any
damaged parts.
NOTE: If other repairs are necessary, refer to your
local HAULPAK
II suspensions on HAULPAK
trucks.
HYDRAIR
II
suspensions to produce a comfortable ride.
All HYDRAIR
II suspensions
requires that three (3) basic conditions be estab-
lished in the following order:
1. Oil level must be correct.
2. Suspension piston rod extension for nitrogen
charging must be correct and this dimension be
maintained during nitrogen charging.
3. Nitrogen charge pressure must be correct.
For best results, HYDRAIR
II suspensions should be
charged in pairs (fronts together and rears together).
If rears are to be charged, the fronts should be
charged first.
NOTE: Set up dimensions specified in the charts
must be maintained during oiling and charging
procedures. However, after truck has been operated,
these dimensions may vary.
EQUIPMENT LIST
HYDRAIR
Charging Kit
J acks and/or Overhead Crane
Support Blocks (Front and Rear) for:
Oiling height
Nitrogen Charging height
HYDRAIR
CHARGING KIT
Assemble service kit as shown in Figure 4-1 and
attach to container of pure dry nitrogen (8).
Installation of Charging Kit
1. Remove protective covers and charging valve
caps from suspensions to be charged.
2. Turn "T" handles (1, Figure 4-1) of adapters (2)
completely counterclockwise.
3. Be certain outlet valves (3) and inlet valve (4)
are closed (turned completely clockwise).
FIGURE 4-1. HYDRAIR
CHARGING KIT
1. T Handle Valve
2. Charging Valve Adapter
3. Manifold Outer Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
1. T Handle Valve
2. Charging Valve Adapter
3. Manifold Outer Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas (Specifications Figure 4-6)
NOTE: Arrangement of parts may vary from
illustration above, depending on Charging Kit P/N.
H4-2 Oiling and Charging Procedures H04004 10/96
445E/510E/630E/685E
4. Turn swivel nut (small hex) on charging valve 3
full turns counterclockwise to unseat valve (DO
NOT turn more than three turns).
5. Attach charging valve adapters (2) to each sus-
pension charging valve stem.
6. Turn "T" handles (1) clockwise (this will depress
core of charging valve and open gas chamber
of suspension).
7. Open both outlet valves (3).
By selective opening and closing of outlet valves (3),
and inlet valve (4), suspensions may be charged
separately or together.
Removal of Charging Kit
1. Close both outlet valves (3).
2. Turn "T" handles (1) counterclockwise to
release charging valve cores.
3. Remove charging valve adapters (2) from
charging valves.
4. Tighten swivel nut (small hex) on charging
valve.
5. Install charging valve caps and protective cov-
ers on both suspensions.
SUPPORT BLOCKS FOR OILING AND
CHARGING DIMENSIONS
Prior to starting oiling and charging procedures, sup-
ports should be fabricated which will maintain the
correct exposed piston rod extensions.
Exposed piston rod extensions are specified for both
oil level and nitrogen charging for HYDRAIR
II sus-
pensions. These dimensions are listed in tables
below Figures 4-3, 4-5, and 4-6. Measure dimen-
sions from face of cylinder gland to machined surface
on spindle or to top of bottom support bracket as
shown. Do NOT include capscrew heads in mea-
surements.
Support blocks may be made in various forms. Mild
steel materials are recommended. For front suspen-
sions, square stock or pipe segments [1 in. (25 mm)
minimum] may be used. Blocks must be capable of
supporting the weight of the truck during oiling and
charging procedures. Refer to Figure 4-3 for front
suspension support block placement and Figures 4-5
or 4-6 for rear support block placement.
Figure 4-2 shows support blocks for rear suspen-
sions which are placed between the truck frame and
final drive centercase and which fit over the bumper
pads. Dimension "A" must be determined to produce
the Rod Extensions listed in the chart.
To establish Dimension " A" :
a. Park empty truck on a hard level surface.
Block wheels, apply parking brake. Vent any
existing nitrogen charge from rear suspen-
sions.
b. Using overhead crane or jacks of sufficient
capacity to support weight of truck, lift rear of
truck to expose correct suspension exten-
sion for OILING HEIGHT.
c. Measure distance between frame and center
case. See NOTE below.
Record the measurements as Dimension "A"
for OILING HEIGHT.
d. Lift truck higher to expose correct suspen-
sion extension for NITROGEN CHARGING.
e. Measure distance between frame and rear
axle housing. See NOTE below.
Record the measurements as Dimension "A"
for NITROGEN CHARGING.
f. Lower truck and fabricate blocks using
dimensions recorded.
NOTE: Blocks must straddle rubber pad on axle
stops. Due to the pivot point geometry of the final
drive assembly, the surfaces between the bottom
frame rail and final drive bumper pad mount will not
remain parallel as dimension "A" changes. When
recording Dimension "A", make two measurements:
A1 at the rear of the bumper pad, and
A2 at the front of the bumper pad.
Fabricate support blocks to fit this space (Figure 4-2).
As an aid for identification for next use, support
blocks may be color coded to mark them as used for:
Truck Model; Oiling, or Charging for Front or Rear
suspensions.
FIGURE4-2. REAR SUSPENSION SUPPORT
BLOCKS
H04004 10/96 Oiling and Charging Procedures H4-3
445E/510E/630E/685E
FRONT SUSPENSION
1. Park unloaded truck on a hard level surface.
Block wheels, apply parking brake.
2. Thoroughly clean area around charging valve
on the suspensions. Remove protective covers
from charging valves.
All HYDRAIR
oil.
Front Suspension Nitrogen Charging
Lifting equipment (crane or hydraulic jacks) must
be of sufficient capacity to lift the truck weight.
Be certain that all personnel are clear of lift area
before lift is started.
1. With nitrogen charging blocks at hand (Figure
4-2), use crane or jacks to raise the truck to pro-
vide clearance for the blocks.
2. Remove oiling blocks and install nitrogen charg-
ing blocks. Secure blocks so they will not fly
free. Lower truck frame until the blocks are
firmly and squarely seated between the spindle
and the cylinder housing.
NOTE: Use caution to prevent damage to plated
cylinder surfaces and oil seals.
3. If removed, install charging valve with new lubri-
cated "O" ring (9, Figure 4-4), use clean HYD-
RAIR
oil.
4. Tighten valve body (large hex, 6) to 16.5 ft. lbs.
(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated counterclockwise
three full turns.
Dry nitrogen is the only gas approved for use in
HYDRAIR
oil.
4. Tighten valve body (large hex, 6) to 16.5 ft. lbs.
(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated counterclockwise
three full turns.
Dry nitrogen is the only gas approved for use in
HYDRAIR
II OIL SPECIFICATIONS
Ambient Temperature Range Part No. Approved Sources
-30
F above (-34.5
II
Suspension Cylinders must meet or
exceed CGA specification G-10.1 for
Type 1, Grade F Nitrogen Gas
Nitrogen
Water
Dew Point
Oxygen
99.9% Minimum
32 PPM Maximum
-68
F (-55
C) Maximum
0.1% Maximum
FIGURE 4-7. SPECIFICATIONS CHART
H4-8 Oiling and Charging Procedures H04004 10/96
445E/510E/630E/685E
NOTES:
J 01023 Index J 1-1
with Both Carlisle and Rockwell Brakes
SECTION J
BRAKE CIRCUIT
INDEX
BRAKE CIRCUIT (J 02016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 2-1
Brake Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 2-1
Brake Circuit and Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 2-1
BRAKE CIRCUIT COMPONENT SERVICE (J 03001). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-1
Dual Hydraulic Brake Controller (J 03001A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-1
Hydraulic Brake Accumulators (J 03001B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-17
Differential Pressure Manifold (J 03001C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-21
Piloted Single Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-23
Dry/Slippery Road Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-26
BRAKE CIRCUIT CHECKOUT AND ADJ USTMENT (J 04016). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 4-1
BRAKE CIRCUIT COMPONENT LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 4-1
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 4-1
Dual Controller and Piloted Single Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 4-2
Dry/Slippery Road Valver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 4-2
BRAKE CIRCUIT CHECKOUT AND ADJ USTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 4-3
FRONT WHEEL SPEED DISC BRAKES
CARLISLE FRONT BRAKES (J 05005) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-1
Brake Lining Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-1
Brake Caliper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-2
Brake Caliper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-2
Brake Caliper Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-3
Brake Caliper Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-4
Brake Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-5
Brake Conditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-5
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-6
ROCKWELL FRONT BRAKES (J 05007) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-1
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-1
Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-5
Brake Pad Conditioning (Burnishing) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-6
Temporary Brake Disconnect (Disable) Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-6
Brake Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 5-8
J 1-2 Index J 01023
with Both Carlisle and Rockwell Brakes
REAR ARMATURE SPEED DISC BRAKES
CARLISLE REAR BRAKES (J 06005). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-1
Brake Lining Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-1
Brake Caliper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-2
Brake Caliper Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-6
Brake Caliper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-7
Brake Caliper Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-10
Brake Conditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-10
ROCKWELL REAR BRAKES (J 06001)
Brake Caliper, Disc and Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-1
Caliper Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-4
Functional Test of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-5
Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J 6-11
Brake Pad Conditioning (Burnishing) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-13
Brake Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 6-14
REAR DISC PARKING BRAKES
CARLISLE PARKING BRAKE (J 07005)
Caliper Removal (With Rockwell service brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-1
Caliper Installation (With Rockwell service brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-1
Caliper Removal (With Carlisle service brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-3
Caliper Installation (With Carlisle service brakes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-3
Lining Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-4
Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-5
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-6
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-6
Brake Conditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-6
500 Hour Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-7
ROCKWELL PARKING BRAKE (J 07004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-1
Caliper Style Identification (SCL15 vs. SCL70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-2
Parking Brake Adjustment (SCL70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-2
Parking Brake Adjustment (SCL15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-4
Park Brake Caliper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-5
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-6
Park Brake Caliper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-7
PARK BRAKE LINING
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-7
Conditioning (Burnish Procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-7
BRAKE BLEEDING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J 7-7
J 02016 Brake Circuit J 2-1
with Payload Meter
BRAKE CIRCUIT
Operation
The HAULPAK
truck supplies
oil for actuation or release of all brake circuits.
As hydraulic fluid enters the bleeddown manifold, it is
divided between the steering and brake circuit. Two
brake accumulators supply reserve pressure for the
service brakes, the third brake accumulator supplies
pilot pressure for the brake lock and secondary brake.
Service brake pressure is directed from the bleed-
down manifold to the piloted single controller valve
and the dual controller treadle valve assemblies at the
same time. Hydraulic pressure directed to the dual
controller treadle valve is divided and enters the valve
through Ports "P". "PA" and "PPK". (Refer to Hydraulic
Brake Schematic). Port "AA" supplies oil to pressurize
the auxiliary accumulator [1 qt. (0.9 l) capacity] to
2500 psi (17.3 MPa) and supplies oil to the auxiliary
brake solenoid. Port "P" is the main pressure supply
for the rear service brakes and the rear service brake
accumulators. Ports A1 and A2 supply full pressure to
brake accumulators 2500 psi (17.2 MPa).
Normal Brake Application
Depression of the treadle valve will send a modulated
pressure from ports B1 and B2 of 0-1425 75 psi (9.8
0.5 MPa) from the dual controller treadle valve
through the pressure differential manifold to the rear
brakes. At the same time (in Dry Road position), pres-
sure is directed from the pressure differential manifold
through the front brake cut-out solenoid and through
the Dry/Slippery Road Valve to actuate the piloted sin-
gle controller valve assembly, causing a modulated
pressure of 0-2100 psi (0-14.7 MPa) minimum, 2500
psi (17.5 MPa) maximum, to be supplied to the front
brake system. Maximum front brake pressure is con-
trolled by the pilot unloading valve, located on the
unloading valve.
J 2-2 Brake Circuit J 02016
with Payload Meter
FIGURE 2-1. HYDRAULIC CABINET (Behind Operator Cab)
1. Pressure Differential Manifold
2. Piloted Single Controller
3. Dry/Slippery Road Valve
4. Front Brake Cut-Out Solenoid
5. Auxiliary Accumulator
6. Accumulators
7. Accumulator Bleed Down Valves
J 02016 Brake Circuit J 2-3
with Payload Meter
Slippery Road Operation
When the Dry/Slippery road switch is placed in the
slippery road position, the slippery road solenoid is
energized, changing the pilot supply to the piloted
single controller which reduces the delivery pressure
to the front brakes. When the treadle valve is
depressed, the front brake pressure will be modu-
lated between 0-1425 75 psi (9.8 0.5 MPa) while
rear brake pressure will remain unchanged.
Wheel Brake Lock Operation
With the brake lock switch in the "On" position, the
auxiliary brake solenoid and the front brake cut-out
solenoid will be energized. The auxiliary brake sole-
noid allows system pressure from port "PA" and the
auxiliary accumulator to depress the treadle valve
plungers applying full unmodulated pressure [1425
75 psi (9.8 0.5 MPa)] to the rear brake system. The
front brake cut-out solenoid will be energized and
prevent pilot oil from flowing to the piloted single con-
troller resulting in no oil to the front brakes.
NOTE: When wheel brake lock or secondary brake is
used, rear brake pressures may read 50-100 psi
(0.3-0.7 MPa) higher than brake pressures recorded
during brake treadle application.
Secondary Brake Switch Operation
When the secondary brake switch is moved to the
"On" position, all service brakes will be applied. The
brake treadle will not be responsive to operator con-
trol.
Automatic Emergency Brake Application
When an emergency situation caused by a loss of
brake supply pressure occurs and circuit pressure
drops to 1850 psi (13 MPa), the low brake pressure
warning light and low steering pressure warning light
and warning buzzer will sound.
As pressure decreases to 1600 psi (11.2 MPa), the
emergency automatic apply pressure switch will
close, energizing the auxiliary brake solenoid and the
slippery road solenoid. When this occurs, all service
brakes will be applied and the brake treadle will not
be responsive to operator control. Front brake pres-
sure is at "Slippery Road" pressure.
When the brake supply pressure further decreases to
approximately 1375 psi (9.6 MPa), the parking brake
will begin to apply. As supply pressure continues to
drop, parking brake will be fully applied at approxi-
mately 900 psi (6.3 MPa).
Parking Brake
The parking brake is spring applied and hydraulically
released by oil from port "PK" at 2100-2500 psi (14.7-
17.2 MPa). When the parking brake switch is in the
"On" position, the parking brake solenoid is de-ener-
gized. The oil pressure in the parking brake lines will
bleed back to tank. The parking brake pressure
switch will close, illuminating the parking brake light
on the instrument panel.
FIGURE 2-2. BRAKE LOCK HOOK-UP WITH PAYLOAD METER (next page)
1. Wire
2. Toggle Switch
3. Wire
4. Wire
5. Diode
6. Housing
7. Park Brake/Sec. Brake
Lexan Overlay
8. Dry Road/Slippery Road
Wheel Brake Lexan Overlay
9. Disconnect
10. Wire
11. Solenoid Valve
12. Wire
13. Wire
J 2-4 Brake Circuit J 02016
with Payload Meter
FIGURE 2-2. BRAKE LOCK HOOK-UP WITH PAYLOAD METER
J 03001A 2/90 Brake Circuit Component Service J 3-1
BRAKE CIRCUIT COMPONENT SERVICE
DUAL CONTROLLER
The Dual Controller is a pressure modulating valve
actuated mechanically or hydraulically. It consists of:
1. Pedal Subassembly
2. Park Brake Solenoid
3. Auxiliary Brake Solenoid
4. Two Actuator Assemblies
5. Various Pressure Switches
The Dual Controller independently controls the pres-
sure of the service brakes on each rear wheel. Apply
pressure can be modulated from zero to maximum
braking effort by use of foot pedal. Use of the auxiliary
solenoid will provide maximum apply pressure to the
brakes. When brake wheel lock switch or emergency
brake switch (located on instrument panel) is switched
on, maximum apply pressure is delivered to the rear
brakes with reduced pressure to the front brakes.
The dual controller contains a parking brake solenoid
which controls oil pressure to release the spring-
applied parking brake. When parking brake switch is
"On", the parking brake solenoid is de-energized.
Operation Of Brake Controller Components
1. Pedal Subassembly (1, Figure 3-2) is mounted
to the actuator cam assembly and can be
mounted at four different angles. The actuator
cam transfers pedal force to pressure regula-
tors in dual controller subassembly. The travel
of the pedal is limited by a return stop (2) and
pedal stop (3). Both stops are adjustable.
2. The parking brake solenoid (4) is energized
when the parking brake switch is in the "Off"
position. Full hydraulic system pressure is
applied to release the parking brake assem-
blies. When de-energized, the solenoid valve
ports parking brake oil pressure to the tank.
3. The auxiliary brake solenoid (5) may be ener-
gized under any of the following conditions:
a. Hydraulic system supply pressure falls below
1600 psi (11.2 MPa).
b. Wheel brake lock switch is "On".
c. Emergency brake switch is "On"
When the solenoid is energized, the pres-
sure regulators allow the maximum regu-
lated pressure to be applied to the rear
brakes. The maximum regulated pressure
should be 1425 75 psi (9.8 0.5 MPa).
NOTE: This pressure is 1050 50 psi (7240 345)
kPa if truck is equipped with 772 wheelmotors.
NOTE: When wheel brake lock or emergency brake
is used, rear brake pressures may read 50-100 psi
(0.3-0.7 MPa) higher than brake pressures recorded
during brake treadle application.
4. The low brake pressure switch (6) will cause the
"Low Brake Pressure" light to illuminate if the
pressure within auxiliary accumulator goes
below 1850 psi (11.2 MPa).
5. The parking brake switch (7) serves two func-
tions. When "On", it closes a circuit connected
to the brake interlock relay in the drive control
system. Truck cannot be moved until parking
brakes are released. When switch is "On", it illu-
minates parking brake light.
6. The rear differential pressure switch (8) is actu-
ated by a differential in rear brake pressure. If
rear brake pressures differ by more than 350
50 psi (2.4 0.34 MPa), switch will close and
illuminate the "Low Brake Pressure" light.
7. The stop light and brake interlock switch (9)
serves two functions. When activated by 50 psi
(345 kPa) or more rear brake apply pressure, it
turns on the truck's rear brake lights and service
brake indicator light. When deactivated, it
closes a circuit connected to the brake interlock
relay to allow propulsion only when brakes are
released or override button is depressed.
8. The parking brake interlock switch (10) is con-
nected into a parking brake interlock circuit.
When activated by 50 psi (345 kPa) or more
rear brake apply pressure and speed of truck is
above 3 MPH (5 km/hr), switch prevents park-
ing brake from being applied.
Application of service and parking brake circuits
at the same time, over 3 MPH could cause seri-
ous damage to brake and drive train compo-
nents. The parking brake should be applied only
after the vehicle has come to a complete stop.
J 3-2 Brake Circuit Component Service J 03001A 2/90
9. The emergency automatic supply pressure
switch (11) is connected to the auxiliary brake
solenoid circuit. If the brake supply pressure
falls below 1600 psi (11.2 MPa), the switch
actuates the auxiliary brake solenoid applying
service brakes through the dual controller.
Removal
If the dual hydraulic brake controller is to be removed
from the vehicle for repair or adjustment, additional
equipment will be required as outlined in disassem-
bly, assembly and adjustment procedures.
NOTE: Minor repairs and service adjustment may not
require the removal of the dual hydraulic brake
controller.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits or installing
test gauges always bleed down hydraulic steer-
ing and brake accumulators. The steering accu-
mulators can be bled down with engine shut
down, turning the key switch " Off" and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur. Open " T" handles
at bottom of accumulators to bleed down brake
accumulators.
Before disabling brake circuit, be sure truck
wheels are blocked to prevent possible rollaway.
1. Bleed down hydraulic system.
2. From below the left center deck release the
brake controller foot box door to expose the
brake controller.
3. Tag and remove all electrical connections.
4. Remove all pressure lines and install protective
plugs and caps in all pressure fittings.
5. In the cab at the brake controller pedal (1, Fig-
ure 3-1), remove capscrews (2) securing the
two piece floor plate (3) surrounding brake con-
troller.
6. Remove capscrews (4) retaining brake control-
ler to floor plate and remove lower floor plate
section.
7. Slide brake controller downward from upper
floor plate section and remove brake controller
from the console area.
8. Move brake controller to a clean work area for
repair and disassembly.
Installation
1. Slide the front portion of brake controller (1, Fig-
ure 3-1) into the upper section of the floor plate
and install upper capscrews.
2. Slide lower floor plate onto brake controller and
install lower capscrews (4).
3. Install capscrews (2) securing the upper and
lower floor plates and tighten to standard
torque.
4. In the foot box beneath the cab, install all elec-
trical leads to the correct terminal post.
5. Remove protective plug or caps and install each
hose to its designated port.
6. Start engine and check for leaks after hydraulic
pressure has been stabilized.
FIGURE 3-1. BRAKE CONTROLLER PEDAL
1. Pedal Assembly
2. Capscrew
3. Floor Plate
4. Capscrew
J 03001A 2/90 Brake Circuit Component Service J 3-3
FIGURE 3-2. DUAL CONTROLLER
1. Pedal Subassembly
2. Return Stop
3. Pedal Stop
4. Parking Brake Solenoid
5. Auxiliary Brake Solenoid
6. Low Pressure Switch (Small
Accumulator)
7. Park Brake Light Switch
8. Rear Differential Pressure
Switch
9. Stop Light and Brake
Interlock Switch
10. Parking Brake Interlock
Switch
11. Automatic Emergency
Apply Switch
J 3-4 Brake Circuit Component Service J 03001A 2/90
FIGURE 3-3. DUAL CONTROLLER (Front View) FIGURE 3-3. DUAL CONTROLLER (Front View)
J 03001A 2/90 Brake Circuit Component Service J 3-5
FIGURE 3-4. DUAL CONTROLLER (Rear View)
J 3-6 Brake Circuit Component Service J 03001A 2/90
FIGURE 3-5. DUAL CONTROLLER
1. Adjuster Lug Lockscrew
2. Adjuster Lug
3. Conical Spring
4. Sleeve Retainer
5. Actuator Plunger and Spring
Seat Assembly
6. Aluminum Flat Washer
7. Emergency Apply Piston
(Sleeve)
8. Plastic Flatwasher
9. Primary Spring
10. Snap Ring
11. BL2
12. Shims
13. Primary Spring Seat
14. Regulator Sleeve
15. Secondary Spring Seat
16. Regulator Spool
17. Secondary Spool
18. Plunger
19. Isolation Check Valve/Seat
20. Check Valve Seat
21. O-Ring
22. Check Valve
23. Check Valve Spring
24. Controller Section
25. Differential Switch (DR1)
26. BL1
27. Auxiliary Brake Solenoid
28. Park Brake Solenoid
29. Solenoid Section
J 03001A 2/90 Brake Circuit Component Service J 3-7
Service
Figures 3-3 & 3-4 show the location of all electrical
components and port identification for the dual
hydraulic brake controller. The port identifications are
stamped on the valve body sections and will be used
in these maintenance instructions.
Disassembly
NOTE: During disassembly, precision machined
parts such as valve spools, sleeves, check valves,
etc. should be ink-marked or tagged for reassembly
into their original positions to assure best possible fit.
1. Remove capscrews (1, Figure 3-3) securing the
pedal to actuator cam assembly and remove
pedal.
2. Remove capscrews (2, Figure 3-3) and remove
actuator cam assembly and base plate.
Remove aluminum flat washers (6, Figure 3-5).
3. Loosen both adjuster lug lockscrews (1, Figure
3-5) and remove the adjuster lugs (2). Remove
conical return springs (3).
NOTE: In the following step, solenoid section will
drop free. To avoid damage be prepared to catch this
section.
4. Invert the remaining assembly. Support the
inverted assembly by grasping the controller
section (24). Tapping downward with a plastic
mallet on solenoid section (29), remove the sec-
tion from over the actuator sleeve retainers (4).
5. Remove plastic flat washers (8). Use a 7/8 inch
open end wrench on the flats of the sleeve
retainers and remove both retainers (4).
6. Remove the primary springs (9) and spring
seats (13).
NOTE: Do not lose small brass secondary spring
seat (15) located inside plunger.
7. Remove both regulating spools (16), secondary
springs (17), secondary spring seats (15), and
plungers (18) from controller housing (24).
8. A special tool (Figure 3-6) is required to remove
the regulating spool sleeve. Remove sleeve
only if necessary to replace the sleeve or "O"
rings. Using a screwdriver and special tool as
shown in Figure 3-7, remove regulator spool
sleeve (14, Figure 3-4). NOTE: There are duplicate electrical components
that have different wire numbers and plugs. Label
each component before removal to facilitate
installation at their proper location.
FIGURE 3-6. SPOOL SLEEVE REMOVAL TOOL
FIGURE 3-7. SPOOL SLEEVE REMOVAL
J 3-8 Brake Circuit Component Service J 03001A 2/90
9. Remove all electrical switches and solenoid
coils after labeling.
NOTE: Remove BL2 switch (11, Figure 3-5) before
BL1 switch (26) to prevent seal damage on
differential spool.
10. Remove differential spool from BL2 port by
pushing on BL1 end of spool. (See Figure 3-8).
11. Inspect differential spool for distress from con-
tact with DR1 Switch. Replace if excessive wear
is evident.
12. Remove supply pressure fitting from Port "PA"
(Figure 3-4). Remove check valve and spring
(See Figure 3-12).
13. Remove supply pressure fitting and orifice from
Port "P" (Figure 3-3).
14. Remove both solenoid valves (27 & 28, Figure
3-5) from solenoid section (24).
15. Remove snap ring (10) and shims (12) from bot-
tom of sleeve retainer (4) and inspect for signs
of wear.
NOTE: Controllers before Serial Number 1287
originally did not have split and dark colored
hardened shims. Controllers found to have early
style shims should be reassembled with a new shim
kit.
16. Push actuator plunger (5) and piston sleeve (7)
out bottom of sleeve retainer (4).
17. Remove all seals and O-rings and replace with
new seals and O- rings during assembly.
Cleaning and Inspection
1. Clean and inspect all parts for evidence of wear
or scoring. Replace any damaged parts.
2. Inspect actuator plunger assembly (5, Figure 3-
5) for a loose spring seat. Seat may be retained
by either a swaged method or a capscrew
secured with Loctite; neither is designed to be
serviced. If spring seat is loose, replace
entire actuator plunger assembly.
3. Inspect primary spring seat (13). If steel ball on
bottom of seat has become loose, primary
spring seat (13) regulating spool (16), plunger
(18), and sleeve (14) must be replaced. Later
styles have a tip on regulator spool that mates
with spring seat. (Figure 3-5).
4. Examine spring-loaded ball on end of DR1
switch. Ball must be free to rotate, slide back
into body and extend completely when
released. Switch must be replaced if not in good
working condition.
5. Use an Ohmmeter to check continuity between
ball and brass stud on opposite end of switch.
There should be less than 1.0 Ohm resistance
(Figure 3-9). Check resistance between steel
switch body and brass stud. It should be greater
than 100,000 Ohms. If either condition is not
met, switch should be replaced.
FIGURE 3-8. REMOVAL DIFFERENTIAL SPOOL
FIGURE 3-9. TESTING CONTINUITY
J 03001A 2/90 Brake Circuit Component Service J 3-9
Assembly
NOTE: Cleanliness during assembly is very
important to assure proper operation of dual
hydraulic brake controller. Lightly lubricate all parts
with clean C-3 oil during assembly. All fittings,
switches and plugs use an O-ring seal, therefore,
these parts do not require a high torque to seal.
1. Position controller section upside down and
install isolation check valve spring (23), check
valve (22), and seat (20) with new O-rings and
tighten.
2. Install Switch BL1 (26) with new seals.
3. Install a new seal on differential spool. Place a
spring on each end of spool and carefully install
assembly thru BL2 port with the non-sealed end
of the spool toward BL1.
4. Install Switch BL2 with new seals and tighten.
5. Assemble DR1 switch as shown in Figure 3-10.
Carefully thread this assembly into controller
section, but do not tighten at this time.
6. Connect an ohmmeter between Differential
Switch (DR1) terminal and ground terminal.
Thread switch into controller section until conti-
nuity through switch is indicated. Back switch
body out 1/4 turn which should cause an open
circuit and tighten locknut.
7. Install Switch DB2 with new O-ring into control-
ler section and install Switches PAA and PKS
with new "O" rings into solenoid section.
NOTE: The Parking Brake Solenoid (4, Figure 3-2)
and Auxiliary Brake Solenoid (5) have similar
appearance but function differently. The Parking
Brake Solenoid is the longer of the two.
8. Install new O-rings and back-up rings onto
Parking Brake Solenoid and Auxiliary Brake
Solenoid as shown in Figure 3-11.
9. Install Parking Brake Solenoid Valve (5, Figure
3-3) into bore of solenoid section and install
solenoid coil onto valve with a lockwasher and
nut.
10. Install new O-rings only (no back-up rings) on
Auxiliary Brake Solenoid (6, Figure 3-3) and
install into bore of the solenoid section. Install
solenoid coil onto valve with lockwasher and
nut.
11. Install fittings "PA" and "P" into their proper port
as shown in Figure 3- 12 and 3-3).
12. Install new O-ring seals on sleeve retainer (4,
Figure 3-5).
13. Assemble piston sleeve (7) onto actuator
plunger (5). Check for free fit.
FIGURE 3-10. DR1 SWITCH
1. Switch Body
2. O-Ring
3. Teflon Washer
4. Aluminum Washer
5. Controller Section
FIGURE 3-11. PARK BRAKE AND AUXILIARY
BRAKE SOLENOID
FIGURE 3-12. FITTINGS FOR PORTS P and PA
J 3-10 Brake Circuit Component Service J 03001A 2/90
14. Insert assembly into bore of sleeve retainer (4)
being careful not to damage the seals.
15. Insert shims as shown in Figure 3-13.
16. Install snap ring with radius toward actuator
plunger.
17. Push actuator plunger down to seat all shims
tight against snap ring.
18. Repeat Steps 12 through 17 for other sleeve
retainer assembly.
NOTE: A hardened shim should always be against
snap ring.
19. If regulator sleeve was removed, place new O-
rings on sleeve and insert into bore of Controller
Section.
Sleeve and spool are machined as a matched set
and cannot be interchanged. Assembly must be
replaced as a unit.
20. Insert small brass secondary spring seat (15)
into bore of regulating spool (16) with round pin
into bore first. Install secondary spring into bore
making sure spring seat is properly seated.
Insert small end of plunger into spring and into
bore of regulator spool.
NOTE: If spring seat is properly installed, plunger will
just begin to engage spool bore.
21. Position the controller section on its side and
insert regulator spool assembly into bore of reg-
ulator sleeve. Be careful to keep plunger from
dropping out of regulator spool (16). When
properly installed, the spool can be depressed
completely until flush with regulator sleeve (14).
22. Repeat Steps 19 thru 21 for other regulating
valve assembly.
23. Position controller section upright. Install a pri-
mary spring seat (13) making sure recess of
seat fits properly onto spool (16). Install primary
spring (9).
24. Carefully install sleeve retainer assembly over
spring (9) and into bore of controller section.
Do not force sleeve retainer down. Thread
assembly into controller section. If spring resis-
tance is felt before thread engagement, parts
are not properly assembled. Screw sleeve
retainer in controller section until tight.
25. Install new O-rings over sleeve retainer. Install a
plastic flat washer (8) over retainer and seat
against controller body. (Figure 3-5).
26. Repeat Steps 23 thru 25 for installation of other
sleeve retainer assembly.
27. Install solenoid section over sleeve retainers
and lightly tap with plastic mallet, until seated
against controller section. Undue force will
damage O- rings and resulting in leakage.
28. Install aluminum flatwashers (6) over the sleeve
retainers.
29. Install the conical springs (3) over actuator
plungers with large end against sleeve retainer.
30. Install adjuster lugs (2) onto actuator plungers
at least 5 revolutions. Do Not tighten adjuster
lug lockscrews at this time.
31. Install the actuator cam and base plate assem-
bly over adjusting lugs.
32. Install capscrews and tighten.
BENCH ADJ USTMENT
Equipment Required:
1. A temporary mount for Dual Hydraulic Brake
Controller.
2. An adjustable hydraulic power supply with an
operating pressure between 1900- 2500 psi
(13.3-17.5 MPa) but capable of being reduced
to 1400 psi (9.8 MPa).
FIGURE 3-13. SHIM PLACEMENT
J 03001A 2/90 Brake Circuit Component Service J 3-11
3. Four calibrated 0-3000 psi (0.21 MPa) pressure
gauges adapted to fit 9/16-18 SAE O-ring ports.
4. Small bleedoff valve and hoses to connect into
port AA.
5. An ohmmeter.
6. Miscellaneous hand tools.
7. 24 volt D.C. power source capable of supplying
2 amps.
Set-Up
1. Mount the dual hydraulic controller for easy
access to all hydraulic ports and switches.
2. Connect ports "P", "PPK" and "PA" to hydraulic
supply. Do not pressurize these ports until pro-
cedure requires it.
3. Connect ports "T" and "PT" to return to hydrau-
lic tank.
4. Install pressure gauges into ports "A3", "B1",
"B2" and "PK".
5. Plug ports "A1" and "A2".
6. Connect bleedoff valve and hose to port "AA"
and close valve.
7. Gradually apply hydraulic supply pressure and
check for leaks.
8. Connect solenoids to 24V source and energize
solenoids to check for further leakage.
9. De-energize solenoids and shut off hydraulic
supply.
10. Work is more easily done with the pedal
removed from the actuator cam.
Adjustments
1. Apply hydraulic supply pressure, the gauge in
port "A3" (Figure 3-4) shows supply pressure.
2. Connect 24VDC power supply to auxiliary brake
solenoid coil (5, Figure 3-2). The adjuster plung-
ers should move downward and pressures on
gauges in ports "B1" and "B2" should go to the
maximum pressure of 1425 75 psi (9.8 0.5
MPa).
3. Record pressures on "B1" and "B2" gauges. If
not within specifications, shut off hydraulic sup-
ply and electrical supply. It is necessary to dis-
assemble dual controller far enough to access
snap ring and shims to adjust pressure. (See
Disassembly of Dual Controller).
A change of 0.010 in. (0.254 mm) in shim stack
will change the output pressure approximately
100 psi (0.69 MPa). Reducing shim thickness
increases output pressure. Reassemble per
Assembly Instructions.
4. Repeat Steps 1 thru 3 until proper maximum
pressures are obtained on "B1" and "B2".
5. With auxiliary brake solenoid de-energized,
apply hydraulic supply pressure.
6. Check output pressures at "B1" and "B2" while
moving the actuator cam through its range. The
two pressures should remain within 100 psi (0.69
MPa) of each other. If they do not:
a. Turn adjuster lug of the power pressure circuit
counterclockwise (as viewed from top) to
increase pressure until both circuits are bal-
anced.
b. If they cannot be balanced, there is an inter-
nal problem within the controller and it will
need to be rebuilt or replaced.
c. Tighten adjuster lug lockscrews.
7. Depress actuator cam to maximum travel. The
pressures on "B1" and "B2" gauges should be
within 100 psi (0.67 MPa) of final pressures set
in Step 4. If pressures are low, adjust pedal front
stop clockwise until maximum pressure is
obtained.
8. Energize auxiliary brake solenoid (5, Figure 3-2).
Depress actuator cam to maximum travel. Adjust
pedal front stop to have 0.03 in. (0.76 mm) clear-
ance to actuator cam. Tighten front pedal stop
locknut. De-energize auxiliary brake solenoid.
9. Release actuator cam completely. The pres-
sures at "B1" and "B2" should both go to zero
and there should be 0.01-0.03 in. (0.254-0.762
mm) clearance between adjuster lugs and their
contact points on actuator cam. Adjust pedal
return stop to obtain proper clearance and
tighten pedal return stop locknut. If there is out-
put pressure and clearance at top of the
adjuster lug, there is an internal problem in dual
controller. Be certain there is no pressure on
return-to-tank lines.
10. Place a screwdriver blade or other flat object on
top of one adjuster lug and depress the actuator
plunger. When pressure difference between
"B1" and "B2" reaches 300 50 psi (2.1 0.34
MPa), the differential switch should close (conti-
nuity on ohmmeter). Below 300 50 psi (2.1
0.34 MPa) differential pressure, switch should
open. Repeat procedure on other adjuster lug.
J 3-12 Brake Circuit Component Service J 03001A 2/90
11. If differential switch (8, Figure 3-2) does not
operate at proper pressure in Step 10, shut off
all hydraulic pressure, loosen locknut on switch
and turn switch clockwise slightly to decrease
the differential pressure at which it opens and
closes or counterclockwise to increase the dif-
ferential pressure. Tighten locknut.
Never apply brakes with locknut loose.
12. Repeat Steps 10 and 11 until proper operating
pressure is obtained.
13. Energize parking brake solenoid (4, Figure 3-2)
with 24VDC. Port "PK" pressure gauge should
indicate the same pressure as shown on
hydraulic supply gauge port "A3". De-energize
solenoid. Port "PK" pressure should go to zero.
If this does not happen, there is an electrical or
mechanical problem in parking brake solenoid.
14. Connect ohmmeter to switch "PAA" between
red wire (33) and black wire (710). With hydrau-
lic supply above 2100 psi (144.8 MPa), the
switch should be open. Reduce hydraulic sup-
ply and slowly bleed down pressure by use of
bleedoff valve on port "AA". When supply pres-
sure drops to 1850 psi (12.95 MPa), the switch
should close. The switch should be replaced if it
does not operate within these specifications.
15. Energize parking brake solenoid (4, Figure 3-2)
to check operation of "PKS" switch. Pressure
reading of switch is shown on gauge connected
to port "PK". Using hydraulic supply slowly
increase and decrease supply pressure and the
following conditions should occur:
a. Red (52A) wire to black (710) wire:
1). Increasing pressure - open at 1650 psi
(11.5 MPa)
2). Decreasing pressure - close at 1400 psi
(9.8 MPa)
b. Brown (73S) wire to black (710) wire:
1). Increasing pressure - open at 1650 psi
(11.5 MPa)
2). Decreasing pressure - close at 1400 psi
(9.8 MPa)
c. If the switch does not perform properly, it
should be replaced.
16. Check operation of "DB2" switch (11, Figure 3-
2) by slowly raising and lowering the hydraulic
supply pressure.
a. Red (52b) wire to black (712) wire:
1). Increasing pressure - open at 1850 psi
(13 MPa)
2). Decreasing pressure - close at 1600 psi
(11.2 MPa)
No other circuits are used on this switch. If the
switch does not perform properly, the switch
should be replaced.
17. Check operation of "BL1" (9) and "BL2" (10)
switches by operating the pedal mechanism to
modulate pressure on switches. The gauges in
ports "B1" and "B2" indicate pressure on
respective switch.
a. Red (73N) wire to black (712) wire:
1). Increasing pressure - open at 50 psi (0.35
MPa)
2). Decreasing pressure - close at 30 psi
(0.21 MPa)
b. Brown (44R) to black (712) wire:
1). Increasing pressure - close at 50 psi (0.35
MPa)
2). Decreasing pressure - open at 30 psi
(0.21 MPa)
c. "BL2" brown (52C) wire to black (52X) wire:
1). Increasing pressure - close at 50 psi
(0.35 MPa)
2). Decreasing pressure - open at 30 psi
(0.21 MPa)
d. If either switch fails to operate properly, it
should be replaced.
18. Remove gauges and bleedoff hose installed for
bench test. Disconnect hydraulic supply and
return hoses.
19. Remove plugs from ports "A1" and "A2". Plug
port "A3".
20. Remove dual controller from bench mount.
Install pedal onto actuator cam assembly with
capscrews.
21. Plug all open ports with plastic caps or plugs.
22. Place assembly into a suitable package to pro-
tect it from dirt and damage.
J 03001A 2/90 Brake Circuit Component Service J 3-13
HYDRAULIC BRAKE CONTROLLER TROUBLESHOOTING
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: The Brakes are Locked, Service and/or Parking
Parking brake solenoid is de-energized. Check power to solenoid.
Auxiliary solenoid is activated. Check switches for possible shorted contacts.
Connections to tank and pressure ports reversed. Correct the plumbing.
Parking brake solenoid coil defective. Replace coil.
Auxiliary or parking brake solenoid valve defective. Flush valve body or replace it.
Tank line is plugged or restricted. Remove restriction.
TROUBLE: Both Brake Circuits are Dragging
Tank line has back pressure. Insure tank line has no back pressure.
Return stop out of adjustment, residual pressure. Adjust return stop.
Auxiliary solenoid valve is sticking (Parking brake
solenoid if parking brakes are dragging).
TROUBLE: One Brake Circuit is Dragging
Flush the valve body or replace it.
There is an obstruction in the pedal subassembly. Remove it.
Controller is out of balance. Adjust balance per instructions.
One regulator is contaminated. Flush per instructions.
Actuator plunger return spring defective or missing. Replace it.
One regulator is defective. Replace dual controller subassembly.
TROUBLE: The Brakes are Not Going to Full Pressure
Pedal stop out of adjustment. Adjust pedal front stop.
Internal malfunction of regulators. Remove, disassemble, clean, and reassemble dual
subassembly.
The supply pressure is low. Check pump system and accumulators.
Improper shimming inside controller. Reshim controller.
TROUBLE: The Brake Circuits are Operating at Different Pressures
Obstruction between actuating cam and adjusting lugs. Remove obstruction.
Actuating cam defective. Replace pedal base assembly.
Regulators contaminated or damaged. Remove, disassemble, clean, and reassemble dual
subassembly, or replace it.
J 3-14 Brake Circuit Component Service J 03001A 2/90
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system. Check wiring.
One of the brake circuits is not releasing completely. Refer to previous Steps.
Brake accumulators bleed down. Valve Open.
Differential switch shorted or out of adjustment. Test per instructions and adjust if necessary.
TROUBLE: A Low Brake Pressure Warning Occurs When Brakes are Applied
There is a leak or other malfunction in one brake
circuit.
The controller balance is out of adjustment. Adjust per instructions.
Differential pressure warning switch out of adjustment. Adjust per instructions.
Inspect brake system.
TROUBLE: A Differential Pressure Warning Occurs Briefly When Brakes are Applied or Released
Controller out of balance (not tracking). Refer to previous Step.
The differential pressure out of adjustment. Adjust per instructions.
Accumulator precharge/leak. Check accumulators.
Problem in dual subassembly Remove, disassemble, clean, and reassemble dual
subassembly or replace it.
Air in one brake circuit. Bleed brakes.
Brake adjustment. Adjust brakes (if required).
Small leak in one circuit. Inspect brake system.
TROUBLE: The Differential Pressure Warning is Not Operating
The bulb is burned out. Replace bulb.
Electrical problem. Check wiring.
The differential pressure switch is out of adjustment. Adjust per instructions.
Problem in dual subassembly. Remove, disassemble, clean, and reassemble, or
replace it.
The differential pressure warning switch is defective. Test per instructions.
TROUBLE: Differential Pressure Warning On and Off While Maintaining Brake Pressure When Pump
Cycles in an Unloading Type System
Leak in one brake circuit. Inspect brake system.
J 03001A 2/90 Brake Circuit Component Service J 3-15
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: The Low Pressure Warning Not Operating Properly
The bulb is burned out. Replace the bulb.
The circuit is open. Check the wiring.
Pressure switch defective. Replace the pressure switch
TROUBLE: Low Pressure Warning is On Even Though System Pressure is Proper
Short in electrical system. Check wiring.
Pressure switch is defective. Replace it.
TROUBLE: Low Pressure Warning Comes On and Pressure is Low
Charging circuit is malfunctioning. Check charging circuit.
The pump is worn. Rebuild or replace pump.
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator leakdown valve is open. Check plumbing.
Accumulator precharge is low. Close valve.
Leak in one circuit. Check plumbing.
Check valve is contaminated. Flush dual subassembly.
The check seat or check poppet is damaged. Replace.
TROUBLE: A "Squeal" is Heard When Controller is Operated
Rapid operation of controller. Normal.
Return stop misadjusted - too much "deadband". Adjust return stop.
Dual controller subassembly is damaged. Replace the dual controller subassembly.
Hydraulic oil is too hot. Check hydraulic system cooling.
TROUBLE: Controller Squeals or Chatters When Pedal is "Held"
Excessive flow is indicated. Check brakes and lines for leakage.
Extreme heat. Check hydraulic system cooling apparatus.
TROUBLE: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected. Check plumbing.
J 3-16 Brake Circuit Component Service J 03001A 2/90
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in dual controller subassembly. Will require disassembly and cleaning.
Damage in dual controller subassembly. Replace dual controller subassembly.
TROUBLE: Oil is Leaking Around the Pedal Base
Defective seal on the top of dual subassembly. Replace the O-rings.
The bore in park/auxiliary body is scored. Replace park/auxiliary body.
TROUBLE: Oil is Leaking Out Below the Adjusting Lugs
There is a damaged seal in dual controller
subassembly.
Replace dual controller subassembly.
TROUBLE: Oil is Leaking Between the Park/Auxiliary Body and Dual Controller Subassembly
Controller not bolted tightly. Tighten the three bolts at pedal base.
A defective seal on top of dual controller subassembly. Replace the O-rings.
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Leak in charge system. Check charge system.
Accumulators precharge too high or too low. Check accumulator precharge.
Controller plumbed incorrectly. Correct plumbing.
Internal leakage in dual subassembly. Replace dual controller subassembly.
Pump is worn. Rebuild or replace pump.
J 03001B 10/89 Brake Circuit Component Service J 3-17
HYDRAULIC BRAKE ACCUMULATORS
There are three hydraulic brake accumulators
located in the bottom portion of the brake control
cabinet behind the operator's cab on the left hand
deck assembly. The two larger accumulators [1 gal.
(3.79 l) capacity] supply the pressure necessary for
actuation of the rear service brakes. The small accu-
mulator [1 qt. (0.9 l) capacity] is called the auxiliary
accumulator and supplies pressure to activate the
actuator plungers (regulators) of the dual controller
when the Brake Lock or Emergency Brake or auto-
matic emergency apply switch is applied.
The disassembly, assembly, and repair of all three
accumulators will be the same.
Accumulators maintain high pressure at all
times. DO NOT disconnect any hydraulic line
from the accumulators or rear brake system until
all hydraulic pressure has been manually drained
from accumulators. Open manual drain valves
located at bottom of each accumulator to drain
pressurized oil.
Brake Accumulator Bleed Down Procedure
The brake accumulators can be bled down by open-
ing the three "T" handles on the bleed down valves.
The valves are located below the accumulators in the
hydraulic cabinet.
1. Turn handles counterclockwise to open valves.
2. Confirm accumulators are bled down by apply-
ing the "Brake Lock" switch (key switch "On",
engine shut down) and applying service brake
pedal. The service brake light should not come
on.
3. Close the bleed down valves by turning "T" han-
dles clockwise.
Removal
1. Shut down engine and exhaust all hydraulic
pressure from the system by opening accumu-
lator manual drain valves.
2. Remove the valve guard and "Dyna-seal" from
top of accumulators.
3. Depress valve core to release gas precharge
pressure from accumulator bladder. (Refer to
Figure 3-13).
4. Disconnect lines and remove complete accu-
mulator from mounting bracket. Cover lines to
prevent contamination.
5. Transfer accumulator to work area.
Installation
1. After service repairs or bench test has been
completed, move the accumulators to the brake
control cabinet. DO NOT precharge accumula-
tors on the bench test.
2. Position the accumulators in the brake control
cabinet and secure the accumulators with
mounting brackets and capscrews.
3. Remove protective plugs and connect pressure
lines to bottom of accumulators.
4. Refer to "Charging Procedure" in this section.
5. Replace "Dyna-seal" and valve guard on top of
accumulators.
Disassembly
1. Securely clamp accumulator (preferably in a
chain vise). Make sure accumulator shell is suit-
ably protected by strips of padding or soft metal
on vise base.
2. Remove core from gas valve using valve core
tool. (Refer to Figure 3-13).
3. Remove pipe plug from plug and poppet
assembly.
4. Remove locknut from plug and poppet assem-
bly using a spanner wrench and an adjustable
wrench. One for torque and one for counter-
torque. (Refer to Figure 3-14).
5. Remove spacer, Figure 3-15.
FIGURE 3-13. VALVE CORE REMOVAL
J 3-18 Brake Circuit Component Service J 03001B 10/89
6. With palm of hand, push plug and poppet
assembly into the shell.
7. Insert hand into shell and remove O-ring,
washer, and anti-extrusion ring from plug. Fold
anti-extrusion ring to enable removal. (Refer to
Figure 3-16).
8. Remove plug and poppet assembly from shell.
(Refer to Figure 3-17.)
9. With wrench on valve stem flats, remove the nut
from the valve stem.
10. Insert hand into shell fluid opening. Depress
bag and eliminate as much gas pressure as
possible.
11. Grasp heel of the bladder and withdraw from
shell. (Refer to Figure 3-18).
Cleaning and Inspection
1. After disassembly, clean all parts with an
approved cleaning solution.
2. Blow all parts dry with air and keep free from
foreign matter.
3. Check all rubber items for deterioration, abra-
sion marks, cracks, holes, bubbles, or any simi-
lar defects.
4. Replace all O-rings and any other items
deemed unsuitable for further usage.
FIGURE 3-14. LOCKNUT REMOVAL
FIGURE 3-15. SPACER REMOVAL
FIGURE 3-16. ANTI-EXTRUSION RING REMOVAL
FIGURE 3-17. PLUG AND POPPET REMOVAL
FIGURE 3-18. BLADDER REMOVAL
J 03001B 10/89 Brake Circuit Component Service J 3-19
5. Bladder may be checked by inflating to normal
size and checking with a soapy solution. After
testing, deflate immediately.
6. Check plug and poppet valve for proper func-
tioning.
Assembly
1. Replace shell in vise, if removed.
2. Pour a liberal amount of clean C-3 hydraulic oil
into shell to serve as a cushion.
3. With bladder assembly on bench, expel all air to
completely collapse bladder and fold bladder
longitudinally into a compact roll. To maintain
rolled condition of bladder, install gas valve core
into the valve stem, thereby preventing air from
entering the bladder.
4. Attach bladder pull rod to bladder valve stem.
5. Pass bladder pull rod through shell oil port and
out through valve stem opening. (Refer to Fig-
ure 3-19).
6. Pull bladder pull rod out of shell with one hand
while feeding bladder into shell with other hand.
7. Position name plate over valve stem and install
valve stem nut by hand (Figure 3-20). Remove
bladder pull rod.
8. Grasp threaded section of plug and insert pop-
pet end into shell mouth.
9. Install anti-extrusion ring inside shell. Fold anti-
extrusion ring to enable insertion into shell.
Place anti-extrusion ring on plug and poppet
assembly with its steel collar toward shell
mouth.
10. Withdraw threaded end of plug through shell
mouth. (Refer to Figure 3-21).
11. Pull plug until seated solidly into position on
shell mouth opening.
12. Install valve core. Using dry nitrogen, slowly
pressurize bladder with sufficient pressure
[approximately 5 psi (34 kPa)] to hold plug and
poppet assembly in place.
13. Install washer onto plug and poppet assembly
and push until seated against anti-extrusion
ring. (Refer to Figure 3-22).
FIGURE 3-19. BLADDER INSTALLATION
FIGURE 3-20. VALVE STEM NUT INSTALLATION
FIGURE 3-21. PLUG ASSEMBLY
FIGURE 3-22. WASHER INSTALLATION
J 3-20 Brake Circuit Component Service J 03001B 10/89
14. Install O-ring over plug and poppet assembly
and push until seated.
DO NOT TWIST O-RING.
15. Install spacer with smaller diameter of the
shoulder toward shell.
16. Install locknut on plug and poppet assembly and
tighten securely. This will squeeze O-ring into
place. (Refer to Figure 3-23).
17. Replace pipe plug into plug and poppet assem-
bly.
18. Install accumulator on truck and charge accord-
ing to "Charging Procedure".
Charging Procedure
1. Mount hose assembly gland nut on pressure
regulator.
Pure dry nitrogen is the only gas approved for
use in brake accumulators. Accidental charging
of oxygen or any other gas in this component
may cause an explosion. Be sure pure dry nitro-
gen gas is being used to charge accumulators.
NOTE: Remove "Dyna-seal" or "O-ring (if equipped)
prior to attaching connector to accumulator gas
valve. Refer to Figure 3-23A.
2. Attach swivel connector of hose assembly to
gas valve. Hand tighten sufficiently to compress
gasket swivel connector in order to prevent gas
leakage.
NOTE: If leakage is still present, replacement of the
small copper washer in swivel connector may be
necessary.
3. Precharge bladder slowly to about 10 psi (69
kPa) before completely tightening the valve
stem nut. With wrench on valve stem flats,
tighten valve stem nut.
4. Proceed to inflate accumulator to 1250 25 psi
(8.6 0.17 MPa) pressure by slowly opening the
pressure regulator valve on nitrogen cylinder,
closing it occasionally to allow needle on pres-
sure gauge to stabilize (thus giving accurate
reading of precharge pressure). When correct
precharge has been reached, close pressure
regulator valve on nitrogen cylinder securely.
5. Bleeder valve can be used to release any gas
pressure in excess of desired precharge.
6. Replace "Dyna-seal" and valve guard over
valve stem.
NOTE: For recharging only:
Exhaust all hydraulic pressure from the system.
Remove valve guard and seal. Then, follow
"Charging Procedure", Steps 1 thru 6.
FIGURE 3-23. LOCKNUT INSTALLATION
FIGURE 3-23A. INSTALLATION/REMOVAL OF
"DYNA-SEAL"
1. Dyna-seal
2. Accumulator
Charging Valve
3. Accumulator
J 03001C Brake Circuit Component Service J 3-21
DIFFERENTIAL PRESSURE MANIFOLD
Brake apply pressure from the dual controller is
ported through the differential pressure manifold to
the rear brakes. The pressure differential manifold
also sends rear brake apply pressures to the piloted
single controller and detects an unbalance between
the front and rear brake apply pressure. The differen-
tial pressure manifold is mounted in the upper left
side of the brake circuit control cabinet mounted
directly behind the operator's station.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or install-
ing test gauges, ALWAYS bleed down hydraulic
steering and brake accumulators. The steering
accumulators can be bled down with engine shut
down, turning the keyswitch " Off" and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur. Open " T" handles
at bottom of accumulators to bleed down brake
accumulators.
Before disabling brake circuit, be sure truck
wheels are blocked to prevent possible rollaway.
Removal
If the differential pressure manifold is to be removed
from the cabinet for bench test or repair, tag or mark
all lines to be removed. The manifold is coded at
each port location which will be used in the assembly
and adjustment procedure. (Refer to Figure 3-24).
1. Release pressure from brake accumulator as
per "Caution" instructions.
2. Disconnect the electrical leads and tag
switches. (Refer to Figure 3-24).
3. Disconnect and plug ends of all hoses and fit-
tings. Move lines clear of the pressure manifold.
4. Remove capscrews securing pressure manifold
to the cabinet and remove manifold to a clean
work area for disassembly. Refer to "Disassem-
bly, Cleaning and Service".
Installation
1. Install the pressure manifold to the control cabi-
net using two capscrews. Tighten capscrews to
standard torque. DO NOT remove protective
plugs until each line connection is completed.
2. Connect all pressure fittings to their respective
location (Figure 3-25).
3. Connect the electrical leads to the correct termi-
nals.
4. Close brake accumulator bleeddown valves.
5. Start engine to charge brake accumulators and
check pressure manifold for leaks.
Disassembly
1. Remove two electrical switches (7, Figure 3-25)
from ports DF and DR 2.
2. Remove plugs (1 & 13) and remove plunger
assembly thru port "A".
NOTE: Remove sleeve (10) only if replacement is
necessary. Sleeve is made from soft material and
can be easily damaged during disassembly if care is
not taken.
FIGURE 3-24. BRAKE CONTROL CABINET
1. Capscrew
2. Differential Pressure
Manifold
3. Electrical Lead
4. Ground Wire
5. Test Port BF
6. Test Port B2
7. Test Port B1
J 3-22 Brake Circuit Component Service J 03001C
3. Remove plug (13), shuttle check seat (14),
spring (16) and shuttle poppet (17).
Be careful not to damage shuttle check seat dur-
ing removal.
Cleaning and Inspection
1. Check seat of shuttle check valve (14) for wear.
Replace if necessary.
2. Replace seals or plunger assembly, also
replace O-rings (11, 15, 20, & 19).
3. Clean all parts in clean solvent and blow dry.
Assembly and Initial Adjustment
1. Install shuttle poppet (17), spring (16) and shut-
tle check seat (14).
NOTE: When installing check seat, insert seat into bore
and use plug (13) to position seat to appropriate depth.
2. Install plug (13) and tighten.
When installing plugs (1, 12, & 13), do not over-
tighten. These plugs are sealed by O-rings to pre-
vent leaking.
FIGURE 3-25. DIFFERENTIAL PRESSURE MANIFOLD
1. Plug Assembly
2. Differential Plunger
Assembly
3. Lockwasher
4. Washer
5. Nut
6. Stud (Ground)
7. Switch Assembly
8. Backup Ring
9. O-Ring
10. Sleeve
11. O-Ring
12. Plug
13. Plug Assembly
14. Shuttle Check Seat
15. O-Ring
16. Spring
17. Shuttle Poppet
18. Body
19. O-Ring
20. Spring
21. Backup Ring
22. O-Ring
23. Port A
J 03001C Brake Circuit Component Service J 3-23
3. If removed, install sleeve (10) and seat in place
by threading plug (12) into valve body.
4. Install plunger with seals but no springs into
valve body until end of plunger is flush with end
of body at Port "A".
5. Install two switches in port openings "DF" and
"DR2".
NOTE: If switches have O-rings or teflon washers,
remove and replace. Do not reinstall.
6. Connect an ohmmeter to end of plunger and the
brass stud on the "DF" switch. Use the wrench
flats to screw the switch in or out, until slight
contact is made.
7. Back out "DR2" switch until no contact is made.
"DR2" switch is not used on HAULPAK
truck,
but can be used as a spare switch to replace
defective "DR" switch.
8. Place springs on each end of plunger, install
both plugs (1 & 12) and tighten.
9. Turn switch into the body 1/8 to 1/4 turn. Hold
switches by the wrench flats and tighten locking
nuts.
Final Adjustment
Final adjustment of the front brake differential switch
"DF" can be performed on a bench test if an adjust-
able pressure source is available. Adjustment can
also be made on the machine, as outlined in the
"Brake Circuit Check-Out and Adjustment Proce-
dure". Switch "DR2" is not used on HAULPAK
truck.
For bench adjustment, plug "PLF", both "B2" ports
and one "B1" port. Do not plug "BF" port. Attach an
adjustable hydraulic source and an accurate gauge
to the open "B1" port. Connect an ohmmeter
between the brass stud on "DF" switch and the
ground stud. Loosen locknut on "DF" switch. Slowly
increase pressure on "B1" port and adjust "DF"
switch inward or outward so the switch closes when
the pressure reaches 588 60 psi (4.1 0.4 MPa).
Tighten locknut and check for repeatability.
PILOTED SINGLE CONTROLLER
The piloted single controller utilizes a signal from the
rear brake apply pressure. This signal keeps the
pressure delivered to the front brakes in relation with
the pressure delivered to the rear brakes. The piloted
single controller also works with the dry/slippery road
solenoid to deliver two different pressure ranges to
the front brakes. The piloted controller is mounted in
the center section of the brake circuit control cabinet
located directly behind the operator's cab.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits or installing
test gauges, always bleed down hydraulic steer-
ing and brake accumulators. The steering accu-
mulators can be bled down with engine shut
down, turning keyswitch " Off" and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur. Open " T" handles
at bottom of accumulators to bleed down brake
accumulators.
Before disabling brake circuit, be sure truck
wheels are blocked to prevent possible rollaway.
Removal
If the piloted single controller is to be removed from
the cabinet for bench test or repair, tag or mark all
lines to be removed.
1. Release pressure from the brake accumulators.
2. Disconnect all pressure lines and plug ends of
all fittings removed. Move pressure lines clear
of the controller.
3. Remove capscrews securing the controller to
the cabinet and remove the controller to a clean
work area for disassembly. (Refer to Disassem-
bly, Cleaning and Service).
J 3-24 Brake Circuit Component Service J 03001C
Installation
1. Install the piloted single controller to the brake
control cabinet and secure controller using
three capscrews. Tighten capscrews to stan-
dard torque values. DO NOT remove protective
plugs until each line connection is completed.
2. Connect all pressure fittings to their respective
locations (Figure 3-26).
3. Close brake accumulator bleeddown valves.
4. Start engine to charge the brake accumulators
and check controller for leaks.
Disassembly
1. Remove primary actuator "PLT2" (1), piston (3)
and O-ring (2). (Refer to Figure 3-27).
NOTE: Scribe a mark down the side of controller to
make sure ports are in proper relation to each other
during assembly.
2. Remove nut (20) and washer (19) from top of
controller. Do not remove studs at this time.
3. Remove secondary actuator assembly (4) and
remove piston (5).
4. Remove tank assembly (6). Remove O-ring (9),
actuator spring cap (10), spring (11), and spring
seat (7).
5. Remove regulator assembly (13). Remove reg-
ulator spool (12), reaction plunger (14), and
spring (15). Remove O-rings (16 & 18).
Cleaning and Inspection
1. Clean all parts in clean solvent.
2. Inspect plungers and spool (3, 5, & 12) for wear.
If spools or valve bodies are worn, spool and
valve must be replaced as an assembly.
3. Replace shims if worn or damaged.
4. Replace all O-rings.
5. Make sure all ports and oil passages are free of
foreign materials.
Assembly
1. Install O-ring (18) into cover assembly (17).
Place nut and washer (19 & 20) on stud and
install through cover section.
2. Install spring (15) and plunger (14) into regula-
tor spool (12). Install spool into regulator
assembly (13). Carefully place assembly down
over studs and seat onto cover assembly mak-
ing sure plunger (14) does not come out of reg-
ulating spool.
3. Install O-ring (16).
4. Install tank body (6) over studs.
5. Install shims (8), seat (7), spring (11), spring
cap (10), and O-ring (9).
6. Install plunger (5) into actuator body (4).
7. Install actuator assembly (4) over studs. Install
washers and nuts and tighten.
8. Install plunger (3) and O-ring (2) on primary
actuator and install into secondary actuator.
Sealing of actuator is done by the O-ring and
high torque is not required to prevent leakage.
9. After controller is assembled, perform "Bench
Test" to make sure regulated pressure is cor-
rect.
Bench Test
After piloted single controller has been serviced per-
form the following test to make sure regulated pres-
sure is accurate.
FIGURE 3-26. SINGLE PILOTED CONTROLLER
1. Controller
2. Port PLT2
3. Port PL1
4. Port T
5. Port REG
6. Port PR
J 03001C Brake Circuit Component Service J 3-25
Equipment Needed:
1. One 5000 psi gauge.
2. Hydraulic supply source capable of 1700 psi
(18.9 MPa) pressure.
3. Line with regulator to limit supply pressure to
1500 psi (10.5 MPa).
Set-Up
1. Plug port "PL2" in top of controller
.
Do not apply pressure to " PL1" without a plug in
" PL2" .
2. Connect line with regulator into port "PL1".
3. Connect line capable of supplying 2700 psi
(18.9 MPa) to port "PR".
4. Connect a line to port "T" to return oil to tank.
5. Install 5000 psi gauge in port marked "REG".
Adjustment
1. Apply 1500 psi (10.5 MPa) to port "PL1" and at
the same time apply 2700 psi (18.9 MPa) to port
"PR".
2. Observe pressure reading on gauge installed in
port marked "REG". The correct pressure
should not exceed 2500 psi (17.5 MPa). Shut
off hydraulic source and release pressure.
3. If pressure exceeds 2500 psi (17.5 MPa) on
gauge, controller will have to be disassembled
and have shims added. If pressure is less than
2500 psi (17.5 MPa), disassemble and remove
shims.
4. Repeat Steps 1, 2 and 3 until 2500 psi (17.5
MPa) pressure reading is obtained.
5. Disconnect lines and gauges. Return controller
to service.
FIGURE 3-27. SINGLE PILOTED CONTROLLER
1.
2.
1. Primary Actuator
2. O-Ring
3. Pilot Plunger
4. Secondary Actuator
5. Pilot Plunger
6. Tank Assembly
7. Spring Seat
8. Shim Kit
9. O-Ring
10. Actuator Spring Cap
11. Spring
12. Regulator Spool
13. Regulator Assembly
14. Reaction Plunger
15. Spring
16. O-Ring
17. Cover Assembly
18. O-Ring
19. Washer
20. Hex Nut
J 3-26 Brake Circuit Component Service J 03001C
DRY/SLIPPERY ROAD SOLENOID VALVE
The slippery road solenoid valve is controlled by an
instrument panel mounted switch (Dry/Slippery
Road). The valve directs rear brake apply signal from
the differential pressure manifold to the piloted single
controller. The switch is open in the "Dry Road" posi-
tion allowing the solenoid valve to be de- energized.
The result is a modulated pressure range of 0-2500
psi (0-17.5 MPa) for the front brakes. When the
switch is moved to "Slippery Road" position, the
modulated front brake pressure through the piloted
single controller is a 1:1 ratio of the rear brake pres-
sure. The solenoid valve is located in the upper left
corner of the brake control cabinet located directly
behind the operator's station. (Refer to Figure 3-28).
Before disconnecting pressure lines, replacing
components in the hydraulic circuits or installing
test gauges, always bleed down hydraulic steer-
ing and brake accumulators. The steering accu-
mulators can be bled down with engine shut
down, turning the keyswitch " Off" and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur. Open " T" handles
on accumulators to bleed down brake accumula-
tors.
Before disabling brake circuit, be sure truck
wheels are blocked to prevent possible rollaway.
Removal
If the solenoid valve is to be removed from the cabi-
net for bench test or repair, tag or mark all lines to be
removed.
1. Release the pressure from the brake accumula-
tors.
2. Disconnect all electrical leads, hydraulic lines,
and plug lines and cap fittings.
3. Move all electrical lines and hydraulic lines
clear of the solenoid valve.
4. Remove the two capscrews securing the sole-
noid valve to the cabinet and remove the sole-
noid valve to a clean work area for disassembly.
(Refer to Disassembly, Cleaning and Service).
Installation
1. Install the solenoid valve to the brake control
cabinet and secure the solenoid using two cap-
screws. Tighten capscrews to standard torque.
DO NOT remove the protective plugs until each
line connection is completed.
2. Connect all pressure fittings to their respective
locations (Figure 3-28).
3. Connect all electrical leads to their respective
terminals (Figure 3-28 ).
4. Close brake accumulator bleeddown valves.
5. Start engine to charge the brake accumulators
and check solenoid for leaks.
FIGURE 3-28. DRY/SLIPPERY SOLENOID VALVE
1. Solenoid Valve
2. Hydraulic Lines
3. Electrical Leads
4. Capscrews
J 03001C Brake Circuit Component Service J 3-27
Disassembly
1. Remove nut (3, Figure 3-29) and washer (4).
2. Remove coil (2) and valve (5).
Cleaning and Inspection
1. Clean valve body (1) and valve (5) in clean sol-
vent.
2. Replace solenoid coil if damaged. Replace O-
rings and backup rings.
Assembly
1. Install new O-rings and backup rings on valve
(5). Install valve into valve body (1) and tighten.
2. Install solenoid coil (2) with washer (4) and nut
(3) and tighten.
FIGURE 3-29. SOLENOID VALVE ASSEMBLY
1. Valve Body
2. Coil
3. Nut
4. Washer
5. Valve
6. O-Ring
7. Backup Ring
8. Electrical Leads
J 3-28 Brake Circuit Component Service J 03001C
NOTES:
J 04016 3/97 Brake Checkout & Adjustment J 4-1
BRAKE CIRCUIT CHECK OUT AND ADJUSTMENT PROCEDURE
The brake circuit hydraulic pressure is supplied from
the steering circuit at the bleeddown manifold.
Excessive leakage in the steering system can cause
problems with the brake system. Some brake system
problems such as spongy brakes or slow brake apply
or release can sometimes be traced to internal leak-
age of brake components. If internal leakage is sus-
pected, refer to Brake Circuit Component Leakage
Test.
NOTE: If internal leakage within the steering circuit is
excessive, this also may contribute to problems
within the brake circuit. Be certain that steering circuit
leakage is not excessive before troubleshooting
brake circuit. For Steering Circuit Test Procedure,
refer to Section L, Hydraulic System.
The steering circuit can be isolated from the brake
circuit by removing the supply line from the bottom
side of the bleeddown manifold (see WARNING).
Plug the supply line and cap the port in the bleed-
down manifold.
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury,
and possibly death, if proper medical treatment
by a physician familiar with this type of injury is
not received immediately.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or install-
ing test gauges, ALWAYS bleed down hydraulic
steering and brake accumulators.
NOTE: The following paragraphs refer to the Models
630E/685E only (does not apply to 445/510E
Models).
The hoist control valve receives pressure oil from a
Tee fitting located on the brake circuit supply line.
Excessive leakage in the hoist control valve or in the
steering system can cause problems with the brake
system.
To test the hoist control valve for leakage, remove
and cap the return line for this valve at the valve
return port next to the operator seat.
Start engine and at low idle, measure the leakage
from the hoist control valve. It should not exceed
16.6 oz. (491 ml) per minute. If leakage is excessive,
rebuild or replace the hoist control valve as outlined
in Section L, Hydraulic System.
BRAKE CIRCUIT COMPONENT
LEAKAGE TEST
Note: The steering accumulators can be bled
down with engine shut down, turning the key
switch Off and waiting 90 seconds. Confirm the
steering pressure is released by turning steering
wheel - No front wheel movement should occur.
Before disabling brake circuit, be sure truck
wheels are blocked to prevent possible roll away.
Accumulators
1. Open T handles on accumulators to bleed
down brake accumulators.
2. Close the accumulator manual drain valves by
turning T handles clockwise (CW). Remove
drain lines from brake accumulator manual
drain valves, and cap lines. The valves are
located at the bottom of each accumulator in
the hydraulic brake cabinet.
3. Start engine and idle at low RPM until brake accu-
mulators are charged to 2500 psi (17.2 MPa).
4. No leakage should occur from accumulator
manual drain valves.
5. If leakage is present, correct the cause of leakage.
6. Shutdown engine. Turn key switch to Off and
wait 90 seconds. Reconnect the drain lines to
the accumulator drain valves.
7. If leakage in the brake circuit is still excessive,
lower the foot box cover. Disconnect the pres-
sure supply line at the port marked P on the
left lower side of the dual controller. Check for
excessive leakage from this port. The Maximum
leakage rate should be 2 oz/min (66ml).
a. If leakage is excessive, manually drain the
brake accumulators by turning the T han-
dles counterclockwise (CCW) on the drain
valves.
b. Remove check valves on bottom of dual con-
troller.
c. Visually check for cause of leakage from
valves.
d. Replace valves when corrected and recon-
nect pressure line removed in Step 7.
e. Check accumulator check valves again for
leaks by referring back to Step 7.
J 4-2 Brake Checkout & Adjustment J 04016 3/97
Dual Controller and Piloted Single Controller
1. Shutdown engine, bleed down steering and
brake accumulators.
2. In foot box, under cab, disconnect large brake
controller return line (Port T) and the brake
controller auxiliary/park brake return line (Port
PT) and cap Tee fittings.
3. In the hydraulic cabinet behind operators cab,
disconnect the return line from the Piloted Sin-
gle Controller and cap Tee Fitting.
4. Start engine to charge hydraulic system.
DO NOT make any brake applications.
5. With the engine at low idle (750 RPM) check
leakage from Port T. The maximum allowable
leakage from the brake controller is 2.6 oz./min.
(77 ml). If excessive leakage is present, it will
be necessary to replace or rebuild the brake
controller.
6. With engine at low idle, check leakage from
Port PT. The maximum allowable leakage
from the brake controller auxiliary/park brake
line is 2.6 oz./min. (77 ml). If excessive leakage
is present it may be coming from either of the
solenoids mounted in the upper section of the
brake controller valve. Check solenoids as fol-
lows:
When actuating these solenoids, a small amount
of oil will come out of Port PT. Provisions must
be made to contain this oil.
a. Remove both solenoid valves and replace O-
ring seals. Recheck leakage.
b. If leakage is still excessive, apply Brake
Lock. If leakage is reduced, replace Brake
Lock solenoid.
c. If leakage is still excessive, release Park
Brake. If leakage rate is increased, replace
Park Brake solenoid.
7. With engine at low idle, check leakage from
Piloted Single Controller (8. Figure 4-1) in
hydraulic brake cabinet behind operator's cab.
Do not reconnect return lines in foot box. Make
sure both sides of tee in foot box are capped.
With the engine running, measure leakage from
Single Piloted Controller at T port (9). Maxi-
mum leakage allowed is 1.3 oz./min. (38 ml). If
excessive leakage is found, replace or rebuild
the Piloted Single Controller
8. Shut engine down and bleed steering and brake
accumulators.
9. Connect all lines previously disconnected for
the leakage tests.
Dry/Slippery Road Valve
NOTE: This valve will not cause the steering cycle
time to be affected if leakage is excessive. This
leakage occurs only while brakes are being applied.
1. Shut engine Off to bleed down hydraulic sys-
tem and bleed down brake accumulators.
2. Remove return line from bottom of Dry/Slippery
Road solenoid (10, Figure 4-1) and plug tank
line.
3. Move slippery road switch to Slippery.
4. Start engine to charge brake accumulators.
5. Move Wheel Brake Lock to On position.
6. Slight leakage may be present.
7. Move Wheel Brake Lock to Off position.
8. Move Dry/Slippery switch to Dry. Slight leak-
age may occur.
9. If continued excessive leakage occurs, replace
seal rings and recheck for leakage. If leakage
continues the valve should be replaced.
10. Cap fitting on Dry/Slippery Road valve and
leave return line Off. Connect line later in this
procedure.
J 04016 3/97 Brake Checkout & Adjustment J 4-3
BRAKE CIRCUIT CHECKOUT AND
ADJUSTMENT
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury,
and possibly death, if proper medical treatment
by a physician familiar with this type of injury is
not received immediately.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or install-
ing test gauges, ALWAYS bleed down hydraulic
steering and brake accumulators.
The steering accumulators can be bled down
with engine shut down, turning the key switch
Off and waiting 90 seconds. Confirm the steer-
ing pressure is released by turning the steering
wheel - No front wheel movement should occur.
Open T handles on all brake accumulators to
bleed down accumulators.
Before disabling the brake circuit, be sure the
truck wheels are blocked to prevent possible roll-
away.
NOTE: The following procedures will be easier if six
gauges are connected such that they can be read in
the cab, where technician can communicate with
person operating controls.
1. Install reliable pressure gauges at the following
locations:
a. One 3000 psi (21 MPa) gauge in front brake
circuit. Install a pressure gauge in the T fit-
ting (5, Figure 4-1), Port BF on the pressure
differential manifold.
b. Two 3000 psi (21 MPa) gauges in each of
the rear brake circuits. Install pressure
gauges in the fittings (6 & 7), Port B1 and B2
on the pressure differential manifold.
c. One 5000 psi (35 MPa) gauge in steering
bleeddown manifold test port to observe
brake supply pressure.
d. One 5000 psi (35 MPa) gauge in park brake
circuit, connected to Port PK on the Dual
Hydraulic Brake Controller located in foot
box.
e. Install a Tee fitting in the hose to tube con-
nection at the Hydra-Zorb clamp of line AA
and install a 3000 psi (21 MPa) gauge lead-
ing to Port AA of the Dual Hydraulic Brake
Controller Auxiliary Accumulator.
2. Fill hydraulic tank to proper oil level. Check,
and, if necessary, precharge brake accumula-
tors with approved nitrogen to proper pressure
level, 1250 psi (8.8 MPa). Refer to Charging
Procedure.
3. Start engine. Turn steering wheel until unloader
valve has cycled five or more times. Perform
the following checkout procedure at low idle
with no steering.
4. Apply and release the Wheel Brake Lock sev-
eral times. Both front and rear brake pressure
maximums should be 1425 75 psi (9.8 0.5
MPa) with the Wheel Brake Lock On.
FIGURE 4-1. BRAKE CONTROL CABINET
1. Capscrew
2. Differential Pressure
Manifold
3. Electrical Lead
4. Ground Wire
5. Test Port BF
6. Test Port B2
7. Test Port B1
8. Piloted Single
Controller
9. T Port
10. Dry/Slippery
Road Solenoid Valve
11. PL1 Port
12. PL2 Port
13. Front Brake Cut-out
Solenoid
14. Accumulator Shut-off
Valves
J 4-4 Brake Checkout & Adjustment J 04016 3/97
NOTE 1: When truck is equipped with 772
wheelmotors, the pressure to the rear wheels should
be 1100 psi 50 psi (7.24 0.35 MPa).
NOTE 2: If truck is equipped with the Payload Meter,
the Wheel Brake Lock will actuate only the rear
brakes.
a. If rear brake pressures are not acceptable,
dual controller requires re-shimming which is
best done on a test bench facility.
b. After rear brake pressures are acceptable, if
front brake pressure is not acceptable, check
system supply pressure. Front brake pres-
sure must be within 200 psi (1.4 MPa) of
supply pressure.
5. If system pressure is correct but front brake
pressure is low, check pressure at port PL2
(12, Figure 4-1) on piloted single controller.
Pressure should be the same as highest pres-
sure of ports B1 and B2 (rear brake pres-
sures). If not, check piping and electrical
operation of slippery road relay and slippery
road solenoid valve. If pressure on PL2 is cor-
rect but front pressure is low, replace or rebuild
the piloted single controller.
NOTE: Conditions in Step 5 must be met before
proceeding.
6. With engine running at low idle, wheel brake
lock Off, Slippery Road valve in Dry position,
slowly cycle brake pedal up and down. Both
rear brake pressures should remain within 100
psi (689 kPa) of one another. If the pressure
does not remain within 100 psi (689 kPa)
throughout the full range, loosen the adjuster
lug lockscrews on the dual controller. Turn
adjuster lug of circuit with lowest pressure coun-
terclockwise until both circuits are equal.
Tighten setscrews.
a. Depress pedal fully. The front brake pressure
should be 2100-2500 psi (14.7-17.2 MPa).
The rear brake pressures should be 1425
75 psi (9.8 0.5 MPa). Refer to Bench
Adjustment if pressures are not within speci-
fications.
NOTE: When truck is equipped with 772
wheelmotors, pressure to rear wheels should be
1050 psi 50 psi (7.24 0.35 MPa).
b. If pressures are correct, verify that front
pedal stop is adjusted to contact pedal when
fully depressed. (Internal shims limit total
travel of actuation plungers).
c. If pressures are low, adjust the front pedal
stop to obtain maximum pressure and meet
the requirements in paragraph (a.).
d. When brake pedal is released, pressure on
both rear and front brakes should be 0 psi (0
kPa). If brake pressure is not released, make
sure pedal rear adjustment screw is not pre-
venting pedal from releasing plungers. Pedal
return stop should be adjusted such that
there is 0.01-0.03 in. (0.25-0.76 mm) clear-
ance between adjusting lug and spherical
portion of actuator cam.
e. If pressure is still too high, check tank return
pressure.
7. Move emergency brake switch (if equipped) to
On. Both front and rear brake pressures should
be 1425 75 psi (9.8 0.5 MPa). Move switch to
Off position. If either of the rear brake circuits
are not within the allowable limits, major internal
adjustments must be made to the brake control-
ler.
NOTE: When truck is equipped with 772 wheelmotors,
pressure to rear wheels should be 1100 psi 50 psi
(7.24 0.35 MPa).
8. Actuate wheel brake lock switch on instrument
panel. Both rear brake circuits and front circuit
pressures should be 1425 75 psi (9.8 0.5
MPa). Move switch to Off position. If either of
rear brake circuits are not within the allowable
range, major internal adjustments must be made
to the dual controller.
NOTE: If truck is equipped with the optional Payload
Meter, the Wheel Brake Lock will actuate only the
rear brakes.
9. Reach under brake pedal and depress one
adjusting lug/actuator plunger with flat of screw-
driver. The low brake pressure warning indicator
should illuminate when one rear brake pressure
is 300 50 psi (2.1 0.35 MPa) higher than the
other. Repeat on opposite actuator.
NOTE: When truck is equipped with 772 wheelmotors,
the low brake pressure warning indicator should
illuminate when one rear brake pressure is 250 50 psi
(1724 345 kPa) higher than the other.
10. If warning indicator does not operate within speci-
fied limits, adjust the rear differential pressure
switch (DR1) as follows:
a. Remove pressure from dual controller by
bleeding down all steering and brake accu-
mulators.
J 04016 3/97 Brake Checkout & Adjustment J 4-5
b. Loosen locknut on switch and turn switch
clockwise to decrease pressure differential
required to activate switch or counterclock-
wise to increase differential pressure.
Retighten the locknut.
Never apply brakes with locknut loose.
c. Recharge the hydraulic system by starting
the engine and repeat the test. Make adjust-
ments until the indicator operates at the
specified differential.
11. Check the front to rear brake differential switch
by first disabling SRR (Slippery Road Relay).
This can be done by placing a jumper wire
across 33 and 33Z inside the junction box.
a. Place the Slippery Road Switch in Slippery
Road position. Slowly apply service brakes
and observe pressure in front brake circuit
as the treadle is applied. As the front brake
pressure slowly increases to 588 60 psi (4.1
0.4 MPa) the front to rear brake differential
switch should close, causing the Low Brake
Pressure Warning Light on the instrument
panel to light.
NOTE: When truck is equipped with 772
wheelmotors, the front to rear brake differential
switch should close as the front brake pressure
slowly increases to 500 50 psi (3.5 0.35 MPa),
causing the Low Brake Pressure Warning Light on
the instrument panel to light.
b. If warning light does not come on, adjust the
switch located on the pressure differential
manifold. Loosen switch terminal wire only
enough so that switch can be rotated. Using
the low brake pressure light as indicator of
switch closing, turn the switch in slightly for
contact at a lower pressure or out for contact
at a higher pressure. When adjustment is
made between 530-650 psi (3.7- 4.6 MPa)
tighten the locknut and check repeatability.
Tighten nut holding ring terminal on switch
stud.
c. Remove jumper wire installed between 33
and 33Z.
12. With system charged, move parking brake
switch to Off. The parking brake pressure
should increase to system supply pressure and
parking brake light should turn off.
13. Move parking brake switch to the On position.
The parking brake pressure should decrease to
0 psi (0 kPa) and the parking brake light should
come On. If pressure does not respond accord-
ingly, check for proper operation of the switch or
replace parking brake solenoid.
14. With system charged and parking brake Off,
stop engine without turning the key switch Off.
Slowly steer the front wheels to reduce the sys-
tem supply pressure. The low steering pressure
light and buzzer and low brake pressure light
should all actuate at 1850 50 psi (12.95 0.35
MPa). If not within specified range, the steering
accumulator switch must be replaced.
a. Continue to decrease the system supply
pressure by steering slowly. The brakes
should automatically apply when system
supply pressure decreased to 1600 50 psi
(11 0.35 MPa). If not within specifications,
the automatic apply pressure switch (DB2)
must be replaced.
b. Continue to decrease system supply pres-
sure. At 1400 50 psi (9.8 0.35 MPa) the
parking brake light should go on.
15. To check the Auxiliary Accumulator Switch use
the following procedure:
a. Remove electrical connector 33F from Low
Steering Pressure Switch at bottom of steer-
ing accumulator.
b. Remove wire 33 at Accumulator Leak Switch
in hydraulic brake cabinet.
c. Start engine to charge the steering accumu-
lators. Wait 90 seconds and shut engine
Off without turning Off key switch.
d. With key switch On, slowly reduce brake
supply pressure to 1750 psi (12.2 MPa) by
turning front wheels. Stop wheel movement.
e. Slowly open manual drain valve on the auxil-
iary accumulator.
f. As accumulator pressure is reduced to
approximately 1850 75 psi (12.9 0.53
MPa), the Auxiliary Accumulator Pressure
Switch will close turning on low brake pres-
sure light.
g. If low brake pressure light fails to light, check
the indicator light and the accumulator
switch.
h. Connect the electrical terminals 33 and 33F.
J 4-6 Brake Checkout & Adjustment J 04016 3/97
16. Recharge system. With engine at low idle,
slowly open each service brake and auxiliary
brake accumulator manual drain valves one at a
time. Each open valve should cause the accu-
mulator leak detector switch (DB1) to detect the
leak and illuminate low brake pressure indicator
on instrument panel.
a. If switch does not function, check for proper
wiring and operation of the DB1 pressure
switch in the accumulator leak/down mani-
fold. Also check for flow coming out of bleed-
down valve from accumulator.
b. If indicator is still not working, remove fitting
from top of manifold and check orifice. A
0.060 in. (1.53 mm) diameter wire should not
pass through orifice.
17. After all tests are completed, shutdown engine.
Bleed down all accumulators.
18. Remove all gauges and fittings used for check-
ing. Connect all lines previously removed.
J 05005 9/95 Carlisle Wheel Speed Disc Brakes J 5-1
CARLISLE WHEEL SPEED DISC BRAKES
The front wheel speed brake assemblies have two,
three or four brake calipers on each wheel assembly.
Each brake caliper contains six pistons (12, Figure 5-
1). Oil pressure pushes the pistons against the car-
rier and lining assemblies (5) which transmit force
against the brake disc causing a braking action. The
reaction to the braking effort is supplied by the thrust
plates (4) which also retains the carrier and lining
assemblies when brake pressure is released.
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
Relieve pressure before disconnecting hydraulic
lines. Tighten all connections securely before
applying pressure.
NOTE: The parking brake is released and the service
brakes are applied with high pressure oil. Before
disconnecting any brake lines, be sure keyswitch has
been off at least 90 seconds in order to bleed down
steering accumulators. To assure that service brakes
are not accidentally applied, open all manual drain
valves and bleed down all brake accumulators.
Failure to take above precautions may result in high
pressure fluid spraying from brake lines.
BRAKE CALIPERS
Lining Replacement
Linings MUST BE REPLACED when worn to rec-
ommended limits. Failure to replace linings worn
beyond limits, will result in loss of braking effort
and possible complete loss of the truck's service
brake capability.
Carrier and lining assemblies should be replaced
when the friction material is worn to 0.125 in. (0.317
cm) thickness. Replace carrier and lining assemblies
as follows:
1. Open all manual drain valves and bleed down
all brake accumulators.
2. Inspect disc for excessive or uneven wear. If
thickness of disc is less than 0.700 in. (17.8
mm) replace disc as covered in "Spindle and
Wheels", Section "G".
3. Remove wheel and tire assembly according to
the "Front Wheel Removal" instructions, Sec-
tion "G".
4. Remove capscrews (1, Figure 5-1), washers (2)
and thrust plates (3 & 4) from both ends of brake.
5. Attach a bleeder hose to top bleeder valve (6)
and place loose end of hose in a clean con-
tainer to catch the oil at each brake.
6. Open bleeder valve (6) to vent oil cavity behind
pistons.
When using pry bar, do not damage disc.
NOTE: If tool not available, insert a smooth ended
pry bar between worn lining and disc.
7. Using Carrier and Lining Retraction Tool (Figure
5-6), pry carrier and lining assembly (5) back
until all six pistons are retracted as follows:
a. Insert flat face of small end of tool between
brake disc and carrier/liner assembly.
b. Use wrench on tool flats and rotate tool until
carrier and liner have retracted to limit of tool
width.
c. Remove tool and insert large end of tool
between brake disc and carrier/liner assem-
bly. Again, use wrench on tool flats and rotate
tool until carrier and liner have retracted to
limit of tool width. Pistons should be com-
pletely retracted for lining replacement.
8. Slide lining and carrier assemblies out.
9. Insert new carrier and lining assemblies (5) in
each side of brake, making sure that the friction
surface of lining is toward the disc.
10. Close bleeder screw (6) and remove bleeder hose.
11. Install thrust plates (3 & 4) with capscrews (1)
and flat washers (2) engaging tang of lining car-
riers into slot in thrust plates. Tighten capscrew
(1) to 730-750 ft. lbs. (990-1017 N.m) torque.
12. Close manual drain valves. Actuate brakes. If
inspection indicates further disassembly or
repair of brake calipers, refer to the following
instructions on "Removal, Disassembly, and
Installation".
J 5-2 Carlisle Wheel Speed Disc Brakes J 05005 9/95
13. Install front wheel and tire assembly according
to "Front Wheels and Tires" installation.
14. Refer to "Service Brake Conditioning (Burnish-
ing) Procedure" and burnish the new brake lin-
ings.
All new brake linings should be burnished prior
to truck being put in service. Refer to " Service
Brake Conditioning" .
Brake Caliper Removal
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
Relieve pressure before disconnecting hydraulic
lines. Tighten all connections securely before
applying pressure.
1. Be sure keyswitch has been off at least 90 sec-
onds. Open all manual drain valves and bleed
down all brake accumulators in the brake cabi-
net.
NOTE: Before disconnecting any brake lines, be sure
keyswitch has been off at least 90 seconds in order
to bleed down steering accumulators. To assure that
service brakes are not accidentally applied, open all
manual drain valves and bleed down all brake
accumulators. Failure to take these precautions may
result in high pressure fluid spraying from brake
lines.
2. Remove brake line junction block and mounting
bracket.
3. Remove wheel and tire assembly according to
"Front Wheel Removal" instructions, Section
"G".
4. Disconnect and cap brake lines to prevent con-
tamination of brake system.
Brake caliper weighs approximately 150 lbs. (68.1
kg). Use a suitable lifting device that can handle
the load safely.
5. Attach lifting device to brake caliper assembly
(1, Figure 5-2). Brake caliper weighs approxi-
mately 150 lbs. (68.1 kg). Remove capscrews
attaching brake caliper to brake support. Slide
brake caliper from disc. Repeat for remaining
calipers.
FIGURE 5-1. FRONT DISC BRAKE
1. Capscrew
2. Washer
3. Thrust Plate
4. Thrust Plate
5. Carrier & Lining
Assembly
6. Bleeder Valve
7. Washer
8. Capscrew
9. Cap
10. Retainer
11. Packing
12. Piston
13. Packing
14. Retainer
15. Boot
16. Torque Plate
Assembly
J 05005 9/95 Carlisle Wheel Speed Disc Brakes J 5-3
Brake Caliper Installation
1. Test caliper for piston seal leakage using "Brake
Caliper Bench Test" before installing calipers
onto truck.
2. Apply simple lithium base chassis grease (multi-
purpose EP NLGI) or a rust - preventive grease
(as specified in the "Standard Charts And
Tables" from Section "A") to the internal threads
of each brake. Thoroughly clean mounting sur-
face of brake, calipers and brake support.
Brake caliper weighs approximately 150 lbs. (68.1
kg). Use a suitable lifting device that can handle
the load safely.
3. Attach lifting device to the brake caliper and
install over disc. Attach brake caliper to support
with capscrews and flat washers. Lubricate flat
washers with rust preventative grease. Tighten
mounting capscrews to 1580 158 ft. lbs. (2142
214 N.m) torque. Repeat for all brake calipers.
4. Install brake line junction block and brake lines.
5. Install new linings per "Lining Replacement"
instructions.
6. Bleed the air from all brake calipers. Refer to
"Brake Bleeding Procedure".
7. Install wheel and tire assembly according to
"Front Wheel Installation" instructions, Section
"G".
8. Refer to "Service Brake Conditioning (Burnish-
ing) Procedure" and burnish the new brake lin-
ings.
All new brake linings must be burnished prior to
being put in service. Refer to " Service Brake
Conditioning (Burnishing) Procedure" .
Brake Caliper Disassembly
1. Inspect brake calipers to insure that all boots
(15, Figure 5-1) are tight and there are no leaks.
Check boots for deterioration and the carrier
and lining assemblies (5) for excessive wear.
2. Mark each thrust plate (4) before removal so
thrust plate will be installed in same location
during assembly. Remove capscrews (1), wash-
ers (2) and thrust plates (4).
Linings MUST BE REPLACED when worn to rec-
ommended limits. Failure to replace linings worn
beyond limits, will result in loss of braking effort
and possible complete loss of the truck's service
brake capability.
NOTE: Removal of piston caps (9) is not necessary
to remove pistons (12). Remove piston from area
where brake linings were removed.
3. Using Piston Removal Tool (Figure 5-7),
remove pistons (12) from torque plate assembly
(16) as follows:
a. Install 3/8-16 capscrew in threaded hole in
piston face.
b. Slide slotted end of Piston Removal Tool,
over capscrew shaft. Install 0.500-13 UNC-6
capscrew through threaded hole in tool shaft.
c. As capscrew is screwed through tool, it will
pull piston from housing.
Inspection
1. Inspect pistons (12, Figure 5-1) for minor
scratches and nicks. If piston is badly nicked or
scratched, or if the chrome plating is worn off,
replace piston.
FIGURE 5-2. BRAKE HEAD REMOVAL
1. Brake Caliper
2. Brake Caliper
Support
3. Disc
J 5-4 Carlisle Wheel Speed Disc Brakes J 05005 9/95
2. Scratches, nicks, and other slight surface dam-
age may be smoothed with fine crocus cloth.
Replace damaged parts that affect proper brake
operation.
3. Inspect piston and housing for wear:
Piston - Minimum O.D. 3.4945 in. (8.876 cm)
Housing - Maximum I.D. 3.505 in. (8.903 cm)
4. Carrier and lining assemblies (5) should be
replaced with new if cracks or damage is
present. Carrier and lining assemblies should
also be replaced when the friction material is
worn to 0.125 in (0.318 cm) thickness.
5. Inspect thrust plates for wear, cracks, or dam-
age. Replace worn or defective thrust plates.
Brake Caliper Assembly
1. Replace all retainers, packings, and boots.
Refer to Figure 5-3.
When replacing rubber components the type of
brake actuating oil must be identified. Rubber
components for C-4 Hydraulic Fluid (mineral oil)
and ABF (brake fluid) are not interchangeable.
Use only rubber replacement components com-
patible with the HAULPAK
F - 650
F (315
- 345
C).
NOTE: Heavy smoke and foul odor from brake
linings is normal during burnishing procedures.
3. Permit brake discs to cool to 350
F (177
C) or
below. (This can require up to 30 minutes
depending on the ambient air temperature and
beginning surface temperature of the disc.)
4. For the second "burn in", repeat Step 2 above to
achieve a disc temperature of 700
F - 750
F
(371
C - 400
F (121
C) or
below before running any brake performance
tests.
Temporary Disconnect Procedures For
Rear Brakes
Before disabling any brake circuit, insure truck
wheels are blocked to prevent possible rollaway.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or install-
ing test gauges, ALWAYS bleed down hydraulic
steering and brake accumulators. The steering
accumulators can be bled down with engine shut
down, turning the keyswitch " Off" and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur. Open the two
valves at the bottom of the brake accumulators
(inside brake cabinet) to bleed down the two
brake accumulators.
The location for disconnecting the rear brakes is dif-
ferent for the model 830E than for the 445E, 510E,
630E, and 685E HAULPAK
Truck Models.
Refer to next page for these locations.
J 05005 9/95 Carlisle Wheel Speed Disc Brakes J 5-7
Temporary Disconnect Procedures
for Disabling Rear Brakes For Models 445E,
510E, 630E, and 685E HAULPAK
Trucks
1. Relieve pressure in hydraulic system according
to the previous "WARNING" instructions.
2. Disconnect lines (2, Figure 5-4) and (3) from
"B1" and "B2" tee fittings on differential pres-
sure manifold inside brake control cabinet.
3. Install a #8, 0.75 X 16, 37
Trucks
1. Relieve stored pressure in hydraulic system
according to the previous "WARNING" instruc-
tions.
2. Disconnect "BR" hydraulic tube (1, Figure 5-5)
at both ends inside brake control cabinet. Install
a #8, 0.75 x 16UNF-2B, 37
F (190
C).
4. Remove capscrews (19) and piston housings
(16) from torque plates (2 or 5).
5. Remove dust boot (9), piston O-ring (10) and
housing O-ring (21) from piston.
Inspection
1. Replace seals (10 & 21) and boots (9) when-
ever brake is disassembled.
2. Inspect adjuster guides (15) for surface damage
and tightness in piston housing (16). If guide
surface has nicks or other surface damage,
replace guide. If guides are loose, remove,
clean and dry threads. Apply non-permanent
thread adhesive (such as 3M's Scotch Weld #
2158 B/A) to threads of guide and install.
Tighten to 130-145 in. lbs. (14.7-16.4 N.m)
torque. Allow the appropriate time for adhesive
to set. Refer to manufacturer's instructions.
NOTE: The thread adhesive must withstand
temperature up to 350
F (177
truck system.
1. Thoroughly clean all parts and lubricate with the
appropriate brake actuating fluid (C-4 hydraulic
oil for mineral oil system; ABF for brake fluid
system).
2. Install insulators (7, Figure 6-8) on pistons (8)
with machine screws (6) as follows:
a. Clean threads of machine screws to remove
old adhesive and other foreign material from
threads.
b. Apply a non-permanent thread adhesive
(such as 3M's Scotch Weld #2158 B/A) to
threads of machine screws (6).
NOTE: The thread adhesive must withstand
temperature up to 350
F (177
C).
c. Install machine screws (6) and tighten
securely. For best results allow adhesive to
cure per manufacturer's instructions.
3. Install adjuster sleeve (11), compression spring
(12) and flatwasher (13) into piston. Retain the
above parts in piston (8) with retainer ring (14).
4. If adjuster guide (15) was removed, replace
according to "Inspection", Step 2.
J 06005 9/95 Carlisle Armature Speed J 6-9
Rear Disc Brakes
5. Lubricate and install new piston O-rings (10)
into each piston housing (16). Make sure O-ring
grooves are clean.
NOTE: Lubricate seals with the appropriate brake
actuating fluid (C-4 hydraulic oil for mineral oil
system; ABF for brake fluid system).
6. Lubricate piston and insert piston into housing
(16), being careful not to damage piston seal
(10). Use a vise clamp or arbor press to force
adjuster sleeve (11) onto adjuster guide (15)
and push piston to bottom of housing.
7. Install boot (9) over piston and into grooves on
piston (8) and housing (16).
8. Install O-ring (21) into groove in housing (16).
9. Install piston and housing assemblies on torque
plate (2 or 5), making sure that the fluid port of
piston housing (16) are aligned with the fluid
ports of torque plates. Apply sealant to threads
of capscrews (19) and attach housings (16) with
capscrews (19) and flat washers (20). Tighten
capscrews to 24-26 ft. lbs. (32-35 N.m) torque.
BRAKE CALIPER BENCH TEST
The purpose of this test is to verify that overhaul of
the calipers was performed satisfactorily. If any leak-
age occurs during this test, the caliper assembly
must be rebuilt.
A hydraulic supply with sufficient volume and pres-
sure capacity to extend piston assemblies will be
necessary. A gauge of 0-2000 psi (0-13,790 kPa)
should be placed in the output line of the hydraulic
source.
Fabricate a block using rear lining backing plate as a
template. Thickness of plate for rear caliper should
be 1.0 in. (25.4 mm) thick.
1. If necessary, bolt caliper halves together with
mounting hardware or Grade 8 capscrews and
nuts of adequate diameter and length to
securely retain caliper halves together during
testing. Tighten capscrews and/or nuts to stan-
dard torque.
2. Install new lining assemblies and test block.
Be sure test block is securely retained in caliper
head before applying pressure.
3. Connect oil lines between two caliper halves.
Oil used in the hydraulic source must be of the
same type as used in the Brake Circuit on the
HAULPAK
Truck
is put into operational service. A surface pyrometer is
required to measure brake disc temperatures during
the conditioning procedures.
If "Brake Certification" type tests are to be run, all lin-
ings and discs should be new and the factory should
be notified. For in-service testing of service brakes,
new linings or discs are not necessary.
Front discs should be in serviceable condition with no
metal smearing or metal buildup from previous use
and not extensively rough or grooved. Inspect discs
for wear limits.
Rear discs will operate at higher temperatures and
can be dark blue in color and show periodic spots
[approximately 1.5 in. (3.8 cm) in size] and still be
serviceable. A disc that is extremely heat-checked
with radial cracks open to show a gap should not be
used.
IMPORTANT! To prevent lining damage during
burnishing, as well as for stop distance tests, release
the brakes as quickly as possible at the end of each
cycle or stop.
The burnish procedure consists of:
1. Alternately applying and releasing the service
brakes until the recommended brake disc sur-
face temperature is reached: then allow brakes
to cool. Cool brakes, if necessary, by driving
machine. (Rear brakes will normally cool faster
than fronts.) Repeat cycle 3 - 4 more times.
2. To expedite the burnishing cycles of heating
and cooling, operate the brakes on only one
axle at a time, so that the other system will be
cooling (operate front brakes with rear brakes
disconnected, or rear brakes with front brakes
disconnected).
3. The recommended order for burnishing is:
Front, Rear, Front, Rear, Front, Rear, and Front.
Carlisle Armature Speed Disc Brakes
Conditioning (Burnishing) Rear Brakes
Extreme safety precautions should be used when
making high-energy/high-speed brake stops on
any downgrade. Safety berms or adequate run off
ramps are necessary for any stopping perfor-
mance tests.
1. Front brakes will require burnishing indepen-
dently from rear brakes in order to control disc
temperatures Refer to Temporary Disconnect
Procedures on the following pages.
NOTE: Heavy smoke, flames, and foul odor
from brake linings is normal during burnishing
procedures.
2. Temporarily disconnect the FRONT brakes
(refer to Temporary Disconnect Procedures).
Electric Propulsion drops out when rear brake
pressure is sensed, therefore burnish by bring-
ing the truck speed up to about 18 mph and
snubbing the brakes to slow truck to about 8
mph. Continue until a pyrometer applied to the
disc on the lining rubbing surface indicates
700
F - 750
F (371
C - 400
C).
NOTE: The Override Switch on the instrument
panel must be depressed and held by the oper-
ator in order to propel the truck with the brakes
applied.
3. Permit brake discs to cool to 350
F (177
C) or
below. (This can require up to 30 minutes
depending on the ambient air temperature and
beginning surface temperature of the disc.)
4. Repeat the above as necessary to achieve a
disc temperature of 800
F - 850
F (427
C -
455
F (121
C) or below
before running any brake performance tests or
placing truck into operation.
J 06005 9/95 Carlisle Armature Speed J 6-11
Rear Disc Brakes
BLEEDING PROCEDURE
Attach brake lines and bleed brake calipers accord-
ing to the following instructions:
1. Fill hydraulic tank per procedure and close
brake accumulator drain valves, if open.
2. Securely attach bleeder hose to highest bleeder
valve of each caliper, direct hose away from
brake assembly and into a container to catch
excess oil.
3. With engine at idle, make partial brake applica-
tion of dual brake controller, maintain partial
application, open bleeder valve until a clean
stream of oil is discharged from caliper. Close
bleeder valve.
4. Repeat above Steps until all air is bled from all
calipers.
5. Check hydraulic reservoir level as bleeding
takes place, maintain correct level.
All new brake linings should be burnished prior
to being put in service. Refer to " Service Brake
Conditioning" .
6. Before returning truck to production, brake lin-
ing must be burnished.
TEMPORARY DISCONNECT PROCE-
DURES FOR DISABLING FRONT
BRAKES
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or install-
ing test gauges, ALWAYS bleed down hydraulic
steering and brake accumulators. The steering
accumulators can be bled down with engine shut
down, turning the keyswitch " Off" and waiting 90
seconds. Confirm the steering pressure is
released by turning the steering wheel - No front
wheel movement should occur. Open " T" handles
at bottom of accumulators to bleed down brake
accumulators.
Before disabling any brake circuit, insure truck
wheels are blocked to prevent possible rollaway.
The location for disconnecting the front brakes is dif-
ferent for the model 830E than for the 445E, 510E,
630E, and 685E HAULPAK
Truck Models.
Refer to next page for these locations.
J 6-12 Carlisle Armature Speed J 06005 9/95
Rear Disc Brakes
Temporary Disconnect Procedures
for Disabling Front Brakes For Models
445E, 510E, 630E, and 685E HAULPAK
Trucks
1. Relieve pressure in hydraulic system according
to the previous "WARNING" instructions.
2. Disconnect "BF" line (1, Figure 5-9) from tee fit-
ting on differential pressure manifold inside the
brake control cabinet.
3. Install a #8, 0.75 x 16UNF-2B, 37
Trucks
1. Relieve stored pressure in hydraulic system
according to the previous "WARNING" instruc-
tions.
2. Disconnect "BF" hydraulic tube (5, Figure 5-10)
at both ends inside brake control cabinet. Install
a #8, 0.75 x 16UNF-2B, 37
F (177
C)
maximum] applied to screw heads will help loosen
screws.
3. Prior to attaching new carrier and lining assem-
blies (7), clean screws (6) with a solvent to
remove old adhesive and other foreign material.
Apply a liberal coat of an epoxy adhesive to
threads of screws (6).
NOTE: Thread adhesive must tolerate temperatures
up to 350
F (177
truck.
2. Lubricate packings (14 & 16) and backup rings
(15 & 17) with clean hydraulic oil.
3. Install packings (14 & 16) and backup rings (15
& 17) in grooves of housings (19 & 20) with
rounded surfaces of backup rings against the
packings and flat surface of backup rings
against the piston housing as shown in Figure
7-5.
NOTE: Make sure packings and backup rings are
properly seated in grooves before continuing
assembly.
4. Install piston and lining assemblies (13 & 7, Fig-
ure 7-4) into housings (19 & 20), being careful
not to damage packings. Make sure thread
holes are free of lubricant, clean and dry.
5. Install capscrews (8) and flat washer (9) into
caps (10). Install springs (11 & 12) over cap-
screws (6) protruding through cap (10).
FIGURE 7-4. DISC PARKING BRAKE ASSEMBLY
1. 12 pt. Capscrew
2. Special Flatwasher
3. 0.060 in. Shim
4. 0.020 in. Shim
5. 0.030 in. Shim
6. Flat Head Screw
7. Carrier & Lining
8. 12 pt. Capscrew
9. Flatwasher
10. Cap
11. Spring
12. Compression Spring
13. Piston
14. Backing
15. Backup Ring
16. Packing
17. Backup Ring
18. Bleeder Screw
19. Piston
Housing (Inboard)
20. Piston Housing
(Outboard)
FIGURE 7-5. CORRECT INSTALLATION OF
PACKINGS AND BACKUP RINGS IN PISTON
HOUSING
1. Housing
2. Packing
3. Backup Ring
J 7-6 Carlisle Disc Parking Brake J 07005 7/94
6. Install assembly from Step 5 onto each housing
(19 & 20). Tighten capscrews (8) evenly to a dry
torque of 110-120 ft. lbs. (149-163 N.m) torque.
BRAKE CALIPER BENCH TEST
The purpose of this test is to verify that overhaul of
the calipers was performed satisfactorily. If any leak-
age occurs during this test the caliper assembly must
be rebuilt.
A hydraulic supply with sufficient volume and pres-
sure capacity to extend piston assemblies will be
necessary. A gauge of 0-3000 psi (0-20,685 kPa)
should be placed in the output line of the hydraulic
source.
Oil used in the hydraulic source must be of the
same type as used in the Brake Circuit on the
HAULPAK
truck.
1. Attach hydraulic source to inlet port of caliper
half.
2. Bleed air from caliper half.
During testing or bleeding procedure, DO NOT
allow oil to come into contact with brake linings.
3. Gradually increase hydraulic pressure to 2500
psi (17,237 kPa), observing piston assembly for
leakage.
4. Reduce pressure to 0 psi (0 kPa) and repeat
Step 3 and Step 4 three times.
5. If no leakage has been observed, reduce pres-
sure to 0 psi (0 kPa) and disconnect hydraulic
source.
6. Follow "Installation" instructions to install brake
halves.
PARKING BRAKE BLEEDING
1. Run engine at low idle and apply the wheel
brake lock.
2. Place Parking Brake Switch in the "Off" posi-
tion.
3. Open bleeder valve on parking brake and allow
oil to flow until free of air.
4. Close bleeder valve while oil is still flowing.
CONDITIONING PROCEDURE FOR DISC
PARKING BRAKE
Conditioning or burnishing of new parking brake lin-
ings is not necessary.
J 07005 7/94 Carlisle Disc Parking Brake J 7-7
500 HOUR SERVICE GUIDE
FOR DISC PARKING BRAKE
The following procedures should be performed every
500 hours of operation.
1. Park truck on level ground and block the wheels
to prevent the truck from rolling.
2. With parking brake applied, measure clearance
between disc outer edge and the lining carrier
with a feeler gauge. (Refer to Figure 7-6). Mea-
sure carefully, being sure to include any lip
which may exist at the O.D. of the disc.
3. Measure the disc thickness at the most worn
surface.
4. If the clearance dimension found in Step 2 is
greater than 0.040 in. (0.102cm) and the disc
thickness found in Step 3 is greater than 0.750
in. (1.905 cm) skip items 5 thru 7.
5. If the clearance dimension is less than 0.040 in.
(0.102 cm), or if the disc thickness is less than
0.750 in. (1.905 cm), either the disc or lining
must be replaced. Remove the parking brake
and measure the lining thickness remaining.
NOTE: While the parking brake is removed,
disassemble and inspect springs for damage. If
broken springs are found, replace all springs in that
brake as a set. Inspect brake linings for damage and
replace if broken.
6. Based upon the clearance dimension and disc
thickness, use the following table to decide
which components require replacement:
7. Install brake assembly and continue to step 8.
8. With parking brake released, measure the
clearance between the parking brake lining and
disc with a feeler gauge. Refer to Figure 7-7.
NOTE: Even if disc and/or lining may have been
replaced, this clearance should be checked before
returning machine to service. Refer to Table 1.
FIGURE 7-6. DISC AND CARRIER CLEARANCE
1. Brake Disc 2. Lining Carrier
CONDITION ACTION
A. Disc thickness is less
than 0.750 in. (1.9 cm)
A. Replace disc.
B. Disc has a lip at the outer
edge and remaining lining
is thicker than 0.165 in.
(04.2 mm).
B. Replace disc.
C. Disc has no lip. C. Replace linings
and crossover
tube.
D. Disc has a lip at the outer
edge and the disc
thickness is greater than
0.750 in. (1.9 cm).
D. Replace linings
and crossover
tube.
FIGURE 7-7. DISC AND LINING CLEARANCE
1. Brake Disc
2. Lining Carrier
3. Lining
J 7-8 Carlisle Disc Parking Brake J 07005 7/94
9. If clearance dimension is within the limits listed
in Table 1, return truck to service.
10. If clearance dimension is not within limits, the
brake requires adjustment. Remove or add
shims to establish 0.020 - 0.050 in. (0.508 -
1.27 mm) clearance.
TABLE 1
TRUCK
MODEL
CLEARANCE DIMENSION IN
STEP 9
120C,445E Less than 0.200 in. (0.508 cm)
510E Less than 0.150 in. (0.381 cm)
170C/D Greater than 0.020 in. (0.051 cm)
Less than 0.065 in. (0.165 cm)
630E w/776
wheel motors
Less than 0.065 in. (0.165 cm)
630E w/788
wheel motors
Less than 0.120 in. (0.305 cm)
685E Less than 0.065 in. (0.165 cm)
830E Less than 0.065 in. (0.165 cm)
ROCKWELL DISC PARKING BRAKE
A park brake assembly is mounted to each wheel motor
on each outboard disc and is intended for parking only.
The park brake caliper is a dual piston, spring applied,
hydraulically released type brake designed for petro-
leum base fluid.
NOTE: Some trucks may be equipped with with TWO
(2) Park Brake Calipers per wheel. Service and adjust-
ment for these calipers are the same as presented
here.
The parking brake housing contains two spring loaded,
lining faced, pistons. The spring preload is controlled
by an adjustment bolt. A yoke, which fits over the
housing, contains the adjustment bolt and is secured
to the housing with a clamping bolt.
The springs are held in place by spring retainers. The
spring retainers are grooved to receive the inside di-
ameter of the piston dust boot, and the housing is
grooved to receive the outside diameter of the piston
dust boot.
CALIPER STYLE IDENTIFICATION
There are two basic styles of Rockwell Park Brake
calipers (Figures 7-1 & 7-1A) in use on Komatsu trucks.
Either style may be used, but different styles SHOULD
NOT be used on the same truck.
Adjustment procedures for each style are different!
As seen in the illustrations, the the SCL-70 style has a
broader, thicker yoke than the SCL-15, and the SCL-15
has four bleeders per caliper (two/piston) compared to
the SCL-70 which has two bleeders per caliper
(one/piston). n addition, the SCL-15 has a hex-head
adjustment bolt (5), compared with a socket-head ad-
justment bolt (drilled for safety wire) in the SCL-70.
nternally, the SCL-15 has only 2 springs/piston, where
the SCL-70 has 4 springs/piston.
Before servicing or adjusting, it is very important
to correctly identify the style of Park Brake Caliper
being used.
FGURE 7-1A. PARK BRAKE ASSEMBLY (SCL-15)
1. Parking Brake Caliper 4. Jam Nut
2. Capscrew 5. Adjustment Bolt
3. Mounting Bracket 6. Clamping Capscrew
FGURE 7-1. PARK BRAKE ASSEMBLY (SCL-70)
1. Parking Brake Caliper 4. Jam Nut
2. Capscrew 5. Adjustment Bolt
3. Mounting Bracket 6. Clamping Capscrew
J07004 1/01 Rockwell Parking Brake J7-1
PARK BRAKE CALIPER
Park Brake CaIiper RemovaI
The park brake caliper may be removed from wheel
without disassembling other brake components.
1. Securely block truck to prevent movement.
Do not loosen or disconnect any hydraulic brake
line or component until engine is stopped, key
switch is 'Off" and drain valves on brake accumu-
lators are opened and steering accumulators are
bled down.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person's body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
2. Disconnect brake line connected to caliper.
3. Loosen jam nut (4, Figure 7-1) on adjustment bolt
(5). Loosen clamping capscrew (6) one turn and
back out adjustment bolt (5) six turns to release
park brake linings from outer disc.
4. Support park brake caliper and remove capscrews
(2) securing caliper to mounting bracket (3).
5. Remove caliper from disc and set aside for repairs
or replacement.
Park Brake CaIiper InstaIIation
Do not start the truck engine until the parking brake
has been installed, adjusted, and the hydraulic
brake lines are tightly connected.
Before installing the park brake caliper, the caliper
mounting must be checked to determine that caliper is
centered over the disc.
Refer to "Caliper, Disc, And Parking Brake nstallation,
(determination of Dimension "B), in Armature Speed
Rear Disc Brakes section. Shim disc as necessary.
NOTE: Do not apply any hydraulic pressure to release
the parking brake until installation and adjustment are
completed.
1. Loosen clamp capscrew (3, Figure 7-2) on yoke of
parking brake caliper. Loosen jam nut (17) on
adjuster capscrew (16).
2. Open bleeder to each piston and push linings back
to obtain disc clearance. Retighten bleeders.
3. nstall park brake caliper onto park brake adapter.
Lubricate the threads of mounting capscrews (2,
Figure 7-1) with rust preventative grease and
tighten to 310 ft.Ibs. (420 N.m) torque.
4. nstall hydraulic supply line to park brake caliper.
Parking Brake Adjustment (SCL70)
Do not start truck engine until both parking brake
assemblies have been installed, adjusted, and all
hydraulic brake lines are tightly connected.
1. Block all wheels, front and rear, to prevent truck
from moving.
2. Loosen clamp capscrew (3, Figure 7-2) which
secures the yoke to the housing.
3. Loosen the jam nut (17).
4. Loosen adjusting bolt (16) until the bolt does not
contact the spring retainer (15).
5. Tighten clamp capscrew (3) finger tight until no
gap exists between yoke (1) and housing (2), but
yoke must be free to slide on housing.
6. Be sure the yoke is positioned inside housing
groove and the end of the adjuster bolt are cen-
tered on the spring retainers (15).
7. Turn adjusting bolt (16) IN (clockwise) until both
the inboard and outboard linings (5) just
touch the brake disc. Use long feeler gauge
[ 0.001 0.002 in. (0.0002 0.0005 mm)] to be sure
linings are in contact with disc; gauge should not
slide in between disc and lining.
8. Turn adjusting bolt (16) IN (clockwise) an addi-
tional 4 1/4 turns to obtain proper brake force.
NOTE: The torque to obtain 4 1/4 turns should NOT
exceed 220 ft. lbs. (298 N.m). If torque exceeds this
value, repeat steps 2 8. If torque to obtain 4 1/4 turns
still exceeds 220 ft. lbs. (298 N.m), remove park brake
caliper and check for improper assembly. Rebuild
caliper assembly correctly and reinstall following ALL
specified procedures. Repeat steps 1 8 above.
J7-2 Rockwell Parking Brake J07004 1/01
9. Tighten clamp capscrew (3) to 125 ft.Ibs. (170
N.m) torque to lock yoke (1) to housing (2).
10. Turn adjusting bolt (16) OUT (counterclockwise)
1/4 turn.
11. Hold adjusting bolt (16) to prevent turning in either
direction and tighten jam nut (17).
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person's body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
12. With truck engine running, apply and release park
brake three (3) times. Check for leaks. f caliper
leaks, refer to "Caliper Removal and Disassemby
procedures and repair leaking caliper.
NOTE: If another source of hydraulic power (such as
"porta-power") is used for this check, install a gauge
in line. Use 2200 2500 psi (10.3 MPa 17.2 MPa)
pressure for adjustment.
Exceeding MAXIMUM pressure of 3000 psi (20.7
MPa) may rupture seals in park brake caliper and
cause leakage.
13. Tighten clamp capscrew (3) to 125 ft.Ibs. (170
N.m) torque and insure parking brake lines are
tightly connected. Lockwire clamp capscrew (3)
to adjusting bolt (16) as shown to prevent loosen-
ing.
14. Bleed park brake after starting engine. Refer to
"Brake Bleeding Procedure.
15. With engine running and park brake switch "OFF
(brake released* ), check the lining-to-disc clear-
ance for both inboard and outboard linings with a
long feeler gauge. Clearance should be 0.025 in.
- 0.060 in. (0.635 mm - 1.524 mm) for both
inboard and outboard linings.
* NOTE: If another source of hydraulic power (such as
"porta-power") is used for this check, install a gauge
in line and use 2200 2500 psi (10.3 MPa 17.2 MPa)
pressure for adjustment.
Exceeding MAXIMUM pressure of 3000 psi (20.7
MPa) may rupture seals in park brake caliper and
cause leakage.
16. f the lining-to-disc clearance is not as specified,
repeat steps 2 through 14 and also refer to deter-
mination of Dimension "B, "Caliper, Disc, And
Park Brake nstallation, in Armature Speed Rear
Disc Brakes section. Reshim disc if necessary.
17. Condition park brake linings according to "Lining
Conditioning procedure before releasing truck to
production.
FGURE 7-2. PARK BRAKE ASSEMBLY (SCL70-4)
1. Yoke 10. Piston
2. Housing 11. Bleed Screw
3. Clamping Capscrew 12. Seal Assembly
4. Washer 13. Backup Ring
5. Lining 14. Screw
6. Seal Assembly 15. Spring Retainers (2)
7. Backup Ring 16. Adjustment Bolt
8. Dust Boot 17. Jam Nut
9. Spring (4/piston)
NOTE: Earlier version (SCL70-3) had a different style
Seal Assembly, 6 & 12, and did not have Backup Rings,
7 & 13.
J07004 1/01 Rockwell Parking Brake J7-3
Parking Brake Adjustment (SCL15)
Do not start truck engine until both parking brake
assemblies have been installed, adjusted, and all
hydraulic brake lines are tightly connected.
1. Block all wheels, front and rear, to prevent truck
from moving.
2. Loosen clamp capscrew (3, Figure 7-2A) which
secures the yoke to the housing.
3. Loosen the jam nut (17).
4. Loosen adjusting bolt (16) until the bolt does not
contact the spring retainer (15).
5. Tighten clamp capscrew (3) finger tight until no
gap exists between yoke (1) and housing (2), but
yoke must be free to slide on housing.
6. Be sure the yoke is positioned inside housing
groove and the end of the adjuster bolt are cen-
tered on the spring retainers (15).
7. Turn adjusting bolt (16) IN (clockwise) until both
the inboard and outboard linings (5) just
touch the brake disc. Use long feeler gauge
[ 0.001 0.002 in. (0.0002 0.0005 mm)] to be sure
linings are in contact with disc; gauge should not
slide in between disc and lining.
8. Turn adjusting bolt (16) IN (clockwise) an addi-
tional 4 1/4 turns to obtain proper brake force.
NOTE: The torque to obtain 4 1/4 turns should NOT
exceed 220 ft. lbs. (298 N.m). If torque exceeds this
value, repeat steps 2 8. If torque to obtain 4 1/4 turns
still exceeds 220 ft. lbs. (298 N.m), remove park brake
caliper and check for improper assembly. Rebuild
caliper assembly correctly and reinstall following ALL
specified procedures. Repeat steps 1 8 above.
9. Hold adjusting bolt (16) to prevent turning in either
direction and tighten jam nut (17).
10. Tighten clamp capscrew (3) to 125 ft.Ibs. (170
N.m) torque to lock yoke (1) to housing (2 and
insure parking brake lines are tightly connected).
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person's body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
11. Bleed park brake caliper after starting engine.
Refer to "Brake Bleeding Procedure.
NOTE: The inboard lining-to-disc clearance must be
adjusted before the outboard lining-to-disc clearance
is adjusted.
12. With truck engine running, apply and release park
brake three (3) times. Check for leaks. f caliper
leaks, refer to "Caliper Removal and Disassemby
procedures and repair leaking caliper.
NOTE: If another source of hydraulic power (such as
"porta-power") is used for this check, install a gauge
in line.
Use 2200 psi (10.3 MPa) MINIMUM 2500 psi (17.2
MPa) MAXIMUM pressure for adjustment.
FGURE 7-2A. PARK BRAKE ASSEMBLY (SCL15)
1. Yoke 10. Piston
2. Housing 11. Bleed Screw
3. Clamping Capscrew 12. O-Ring
4. Washer 13. Backup Ring
5. Lining 14. Screw
6. O-Ring 15. Spring Retainers (2)
7. Backup Ring 16. Adjustment Bolt
8. Dust Boot 17. Jam Nut
9. Spring (2/piston)
J7-4 Rockwell Parking Brake J07004 1/01
13. Check the Inboard lining-to-disc clearance with
the engine running and the Park Brake Switch
" OFF (brake released). Using a long feeler
gauge, clearance should be 0.030 - 0.040 in.
(0.762 - 1.016 mm).
14. f the inboard lining-to-disc clearance is not as
specified in step 13. above, record clearance
measurement and:
a. With truck engine not running, apply parking
brake.
b. Loosen clamp capscrew (3).
c. Turn adjusting bolt (16) to obtain the correct
clearance specified in step 13. above. Turning
adjusting bolt cIockwise decreases clearance
while turning countercIockwise increases
clearance. Each
1
/4 turn of adjusting boIt
changes cIearance 0.009 in. (0.228 mm).
d. Tighten clamp capscrew (3) to 125 ft.Ibs. (170
N.m) torque.
e. With truck engine running, apply and release
parking brake three (3) times.
f. Release parking brake and repeat step 13. f
clearance is not correct, repeat step 14. (a.-f.)
until correct clearance is established.
15. nsure clamp capscrew (3) is tightened to 125
ft.Ibs. (170 N.m) torque.
16. Check the outboard lining-to-disc clearance with
truck engine running and park brake switch OFF
(brake released). Using feeler gauge, clearance
should be 0.030-0.040 in. (0.762-1.016 mm).
17. f the outboard lining-to-disc clearance is not as
specified in step 16. above, record clearance
measurement and:
a. With truck engine not running, apply parking
brake.
NOTE: The clamp capscrew (3) is NOT loosened in
this procedure.
b. nsure clamp capscrew (3) is tightened to 125
ft.Ibs. (170 N.m) torque.
c. Turn adjusting bolt (16) to obtain the correct
clearance specified in step 13 above. Turning
adjusting bolt cIockwise decreases clearance
while turning countercIockwise increases
clearance. Each
1
/8 (one eighth) turn of ad-
justing boIt changes cIearance 0.009 in.
(0.228 mm).
d. With truck engine running, apply and release
parking brake three (3) times.
e. Release parking brake and repeat step 16. f
clearance is not correct, repeat step 17. (a.-e.)
until correct clearance is established.
18. With engine running, turn park brake switch OFF
(brake released).
19. Check the lining-to-disc clearance for both in-
board and outboard linings with feeler gauge.
Clearance should be 0.030-0.040 in. (0.762-
1.016 mm) for both inboard and outboard linings.
f the lining-to-disc clearance is not as specified,
repeat steps 2 through 19.
20. Hold adjusting bolt (16) to prevent turning in either
direction and tighten jam nut (17) to 210 ft.Ibs.
(285 N.m) torque.
21. Condition park brake linings according to "Lining
Conditioning procedure before releasing truck to
production.
Park Brake CaIiper DisassembIy
NOTE: To assure that tension on springs (9, Figure 7-2
& 2A) has been released, be certain that jam nut (17)
has been loosened on adjustment bolt (16) and that
clamping capscrew (3) has been loosened one turn.
Be sure that adjustment bolt (16) has been loosened
six turns.
1. Remove bleeder screws (11, Figure 7-2 / 2A) from
housing (2) and drain fluid from brake caliper.
2. Loosen jam nut (17) and remove adjustment bolt
(16) from yoke (1).
3. Remove clamp capscrew (3) and washer (4) to
release housing (2) from yoke (1).
4. Remove piston dust boots (8) from spring retain-
ers (15).
5. Remove spring retainers (15) and springs (9). Note
order and orientation of springs.
6. Remove pistons (10) from housing.
7. Remove seal and backup ring (6 &7, Figure 2) or
O-ring & backup ring (6 &7,Figure 2A) from pis-
tons and discard these parts.
8. Remove screws (14) releasing the lining (5) from
pistons.
9. Remove seal and backup ring (6 &7, Figure 2) or
O-ring & backup ring (6 &7,Figure 2A) from hous-
ing and discard these parts.
J07004 1/01 Rockwell Parking Brake J7-5
CIeaning and Inspection
Petroleum base cleaning solvents are flammable.
DO NOT USE NEAR OPEN FLAME.
1. Clean all metal parts of brake assembly in cleaning
solvent.
2. nspect all metal parts for breaks or cracks. Re-
place all cracked parts.
3. Measure pistons and housing bores. Replace the
parts if they are worn beyond the following limits:
Piston:
(SCL70) large O.D. 4.494 in. (114.1 mm)
(SCL15) large O.D. 4.495 in. (114.2 mm)
(SCL70) small O.D. 2.493 in. (63.3 mm)
(SCL15) small O.D. 2.495 in. (63.4 mm)
(ETHER) seal groove 4.126 in. (104.8 mm)
Housing Bore:
large .D. 4.503 in. (114.4 mm)
small .D. 2.504 in. (63.6 mm)
(SCL70) seal groove 2.869 in. (73.6 mm)
(SCL15) seal groove 2.872 in. (72.9 mm)
4. nspect inlet and bleeder holes in housing (2) for
thread damage.
If rethreading is necessary, use the following taps:
Lining bolt hole in piston - 10-24 UNC-2B tap
Inlet hole - 7/16-20 UNF-2B tap
Bleeder hole - 1/4-28 UNF-2B tap
After tapping, be certain all metal chips and resi-
due are removed from openings and hydraulic
passages. If threads are not serviceable, replace
housing.
5. nspect housing cylinder walls for damage.
Scratches or corrosion to a depth of 0.002 in.
(0.005 cm) or less on the cylinder wall can be
blended out with 300-500 grit wet-or dry sandpa-
per or emery cloth. Replace housing if damage is
beyond these limits.
Excessive localized polishing of the cylinder wall
may result in fluid leakage.
6. nspect spring washers (9) for cracks or corrosion.
Replace parts that are cracked or severely cor-
roded.
7. nspect capscrews (3 & 16) for cracks, corrosion,
or thread damage. Replace damaged bolts.
8. nspect threaded hole (for adjustment bolt) in
yoke. The threaded hole in yoke for adjustment
bolt can be cleaned up with a 1-14 UNS-2B tap. f
threads are not serviceable, replace yoke.
9. nspect threaded hole (for clamping capscrews)
in housing. The threaded hole in housing for
clamping bolt can be cleaned up with a 5/8-
11UNC-2B tap. f threads are not serviceable,
replace housing.
J7-6 Rockwell Parking Brake J07004 1/01
Park Brake CaIiper AssembIy
1. Using all new seal assemblies, lubricate seals (6 &
12, Figure 7-2) with clean hydraulic oil as used in
brake circuit. Lubricate cylinder walls with Dow
Corning # 4 (or equivalent).
2. nstall lubricated seals and backup ring (12 & 13,
Figure 2) or O-ring & backup ring (12 &13,Figure
2A) in housing.
3. nstall lubricated seals and backup ring (6 &7,
Figure 2) or O-rings & backup ring (6 &7,Figure
2A) on pistons.
4. Attach lining (5) to pistons with screws (14). (Refer
to "Lining Replacement Procedure).
5. nstall piston in housing.
6. Lubricate spring washers (9) with anti-seize com-
pound.
7. Place spring retainers (15) on a flat surface with
the largest diameter on the bottom. nstall piston
dust boots (8) in groove of spring retainer (15).
Place lubricated spring washers (9) on spring
retainer so that the concave surface of each pair
of springs face one another.
8. nstall spring retainers (15) with spring washers on
pistons.
9. nstall the outer edge of dust boot (8) in grooves
of housing.
10. Place yoke (1) over housing (2) and align hole in
yoke with the hole in housing.
11. Place washer (4) on clamping bolt (3) and install
bolt and washer loosely. Attach yoke to housing.
12. Screw jam nut (17) all the way on adjustment bolt
(16) and apply anti-seize compound to threads
and end of bolt. Screw bolt in yoke part way,
approximately five (5) turns.
13. nstall bleeder valves (11) on housing.
PARK BRAKE LINING REPLACEMENT
nspect park brake linings periodically for wear. Linings
must be replaced before lining material has been worn
to the top of the retaining screws. Use of linings beyond
this wear limit will result in decrease of braking action,
and possible damage to disc.
1. Change linings. Refer to "Park Brake Caliper Re-
moval and "Disassembly procedure.
2. Remove screws (14, Figure 7-2) releasing the
lining (5) from the piston (10).
3. nstall new lining and secure lining to piston with
screws (14).
NOTE: If lining mounts screws are reused,
use Loctite
.
COMPONENT DESCRIPTION
Treadle Valve
The treadle valve is pressure compensating, the
valve is a pressure regulator with a pedal to control it.
When the pedal is depressed, air flow enters the inlet
port and due to a compensating spring in the valve
and the pressure applied at the pedal, metered air
pressure is directed out the cylinder port to actuate
the throttle air cylinder. A booster spring located
under the pedal increases pedal effort and provides
feel for the operator. Maximum air pressure from
valve is 90 psi (620 kPa).
Service
1. Every month or after 500 hours of operation,
lubricate treadle roller and hinge pins with
engine oil. Lift boot from mounting place and
apply a few drops of SAE20 grade engine oil
between mounting plate and plunger. Replace
boot.
2. After two years of operation, disassemble trea-
dle valve and clean all parts. Install new inlet
valve. U-cups and all O-rings.
COMPONENT REPAIR
The following procedure should be used for service
of the throttle treadle valve.
Removal
1. Relieve air pressure, tag and disconnect air
lines from throttle treadle valve. Cover ends of
lines and cap inlet and outlet ports of valve to
prevent entry of foreign material.
2. Remove capscrews and lockwashers securing
valve assembly to cab floor. Remove valve
assembly.
Installation
1. Install treadle valve assembly and attach the air
lines. If necessary, adjust capscrew under heel
of pedal to eliminate any free play.
2. Completely check valve for proper operation
before putting truck to work. Charge air system
and check valve completely.
Disassembly
1. Remove clips (5) from ends of push rod pin (10,
Figure 5-2) and treadle pin (4). Remove pins (4
& 10) from mounting bosses of pedal assembly,
roller (9), spring (3) and separate pedal from
valve assembly.
2. Remove push rod (11, Figure 5-2) and dust
boot (12) from inlet portion of valve body (15).
Match mark relationship of mounting plate (8) to
the valve body. Remove nut (13) and separate
mounting plate from valve.
3. Match mark inlet (2, Figure 5-3) and outlet (14)
portion of valve. Remove the machine screws
(16) and separate outlet body from inlet body.
Remove barrier plate assembly (8) and O-ring
(6). Remove small O-ring (7) from inlet body (2).
FIGURE 5-1. THROTTLE VALVE
1. Pedal
2. Mounting Plate
3. Inlet Port
4. Outlet Port
5. Breather
K5-2 Throttle Treadle Valve K05004
4. Remove balance piston (11, Figure 5-3) from
body (14). Remove thrust ring (10) and U cup
(9) from piston and remove spring from body.
5. To disassemble barrier plate assembly, remove
spiral retainer ring (14, Figure 5-4). Use caution
as spring pressure will force out disc ring (13),
exhaust poppet (12), poppet support plate (11)
and spring (10) from cage (6).
6. Push piston (2) down until fully depressed and
remove retainer ring (9) from groove in end of
piston. Remove cage (6) from barrier plate (5)
and tap cage on a block of wood to remove sup-
port disc (8) and inlet poppet (7). Remove
sleeve (3), O-ring (4), piston (2) and U cup (1)
from the barrier plate.
Inspection
Discard O-rings, U cups and poppet seals and
replace with new. Check all parts for wear, cracks or
breakage and replace if necessary.
FIGURE 5-2. PEDAL ASSEMBLY
1. Pedal Cover
2. Pedal
3. Spring
4. Treadle Pin
5. E-Clip
6. Capscrew
7. J am Nut
8. Mounting Plate
9. Roller
10. Push Rod Pin
11. Push Rod
12. Dust Boot
13. Nut
14. Air Filter
15. Valve Assembly
FIGURE 5-3. VALVE ASSEMBLY
1. Guide Rod
2. Inlet Body
3. Screen
4. Seal Washer
5. Capscrew
6. Large O-Ring
7. Small O-Ring
8. Barrier Plate
9. U-Cup Seal
10. Thrust Ring
11. Balance Piston
12. Spring
13. Shim
14. Outlet Body
15. Plug
K05004 Throttle Treadle Valve K5-3
Assembly
1. Lightly coat all moving parts with moly grease
2. Install piston sleeve (3) with new O-ring (4) into
top of barrier plate (5). Install piston (2) and U-
cup (1), open side down, into piston sleeve (3)
making sure U-cup seal is properly seated.
Place cage assembly (6) over the piston rod
end and into the barrier plate. Install inlet pop-
pet (7) and support disc (8) on the piston rod
end (2). Fully depress piston into cage and
install retaining ring (14) into the groove on the
bottom of the piston rod end.
3. Install spring (10), small end up, poppet support
plate (11), exhaust poppet (12) and disc ring
(13) and spring (12) into outlet portion of valve
body (14).
4. Install thrust ring (10, Figure 5-3) and U-cup (9),
open side up, on balance piston (11). Install
shim (13) and spring (12) into outlet portion of
valve body (14).
5. Install new O-rings (6 & 7, Figure 5-3) into the
inlet housing (2). Install new seal washer (4)
under capscrew (5).
6. Install barrier plate assembly into inlet housing
(2).
7. Place inlet body and barrier plate assembly
over outlet body. Match the marks on the inlet
and outlet body and align barrier plate assembly
and balance piston prior to assembling inlet and
outlet bodies.
8. Install capscrews (5) and tighten.
9. Attach valve body assembly to the mounting
plate (8, Figure 5-2) with nut (13). Match marks
on body and plate must align.
10. Install push rod (11) into top of valve assemblies
and install dust boot (12) around push rod.
11. Install push rod pin (10) and roller (9) on pedal
(2) and retain with E-clip (5).
12. Install spring ends (3) in holes of mounting plate
(8) and align spring with bores in the mounting
plate bosses. Using the pedal (2) to compress
spring, install treadle pin (4) through mounting
plate bosses, pedal bosses and spring eyes.
Secure pin in place with an E-clip (5).
FIGURE 5-4. BARRIER PLATE ASSEMBLY
1. U-Cup Seal
2. Piston
3. Sleeve
4. O-Ring
5. Barrier Plate
6. Cage
7. Inlet Poppet
8. Support Disc
9. Retainer Ring
10. Spring
11. Poppet Plate
12. Exhaust Poppet
13. Disc Ring
14. Retainer Ring
K5-4 Throttle Treadle Valve K05004
NOTES:
L01016 Index L1-1
SECTION L
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-1
HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-1
COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L2-1
HYDRAULIC SYSTEM COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-1
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-2
Pump Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-2
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-3
Cartridge Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-6
Cartridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-7
TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-9
HYDRAULIC TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-10
Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-11
STRAINER AND DIFFUSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-11
Inspect and Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-12
HYDRAULIC SYSTEM FLUSHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L3-13
STEERING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-1
STEERING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-1
COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L4-1
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-2
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-3
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L5-5
L1-2 Index L01016
STEERING CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-1
UNLOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-1
BLEEDDOWN MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-3
FLOW AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-5
STEERING ACCUMULATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-9
STEERING ACCUMULATOR CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-11
STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-12
HIGH PRESSURE STEERING FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-14
STEERING CIRCUIT TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-15
PRESSURE ADJ USTMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-15
COMPONENT LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-17
TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L6-18
HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-1
CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-1
COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-2
HOIST PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-3
BODY UP LIMIT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
PILOT OPERATED CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
FLOW SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L7-4
HOIST CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-2
HOIST PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-7
HOIST CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-9
HIGH PRESSURE HOIST CIRCUIT FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-16
HOIST CIRCUIT CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-17
L02014 Hydraulic System L2-1
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OPERATION
The steering, hoist, and brake circuits use a common
hydraulic tank (5, Figure 2-1). The tank is located on
the left frame in front of the rear wheel. If filling is
required, type C-4 hydraulic oil should be used.
Hydraulic oil flows from the bottom of the hydraulic
tank to the inlet housing of the hydraulic pump (3,
Figure 2-2). The shaft end of the double cartridge
pump supplies oil to the hoist valve (6). The cover
end of the double cartridge pump supplies oil to the
unloader valve (4, Figure 2-1).
The unloader valve directs oil to the accumulator
supply manifold which supplies oil to the two accu-
mulators (2, Figure 2-1). The accumulators supply oil
to the bleeddown manifold (10) which supplies oil to
the steering and brake circuits.
After requirements for the steering and brake circuits
are met, the excess oil flow is directed (by the
unloader valve) to the hoist valve. If the hoist valve is
in the "float" position, the oil is returned to the tank.
COMPONENT DESCRIPTION
High Pressure Filters
The truck is equipped with two high pressure, 7
micron filters (1 & 10, Figure 2-2). Both filter assem-
blies have a built-in bypass system which activates a
light on instrument panel when differential pressure
across the filter exceeds 40 psi (275 kPa). Actual by-
pass will occur at a pressure differential of 60 psi
(413 kPa). The filter should be changed as soon as
possible after the indicator light has turned on before
actual by-pass occurs. For the regular filter service
interval, refer to the "Lubrication and Service" Sec-
tion, or replace when indicator light turns on.
Hydraulic Pump
The truck is equipped with a Vickers vane pump (3,
Figure 2-2) which supplies oil for the steering, hoist,
and brake circuits. The hydraulic pump is mounted
behind the alternator, and is driven by a drive shaft
connection between the pump and the output of the
alternator.
FIGURE 2-1. HYDRAULIC COMPONENT LOCATION (SIDE VIEW)
1. Hydraulic Lines
(To & From Steering
Control Valve)
2. Accumulators
3. To Brake Circuit
4. Unloader Valve
5. Hydraulic Tank
6. Breather (Air Filter)
7. Hoist Cylinder
8. Body Creep Down
Valve
9. High Pressure Filter
(Steering & Brake)
10. Bleeddown Valve
11. Flow Amplifier Valve
12. Hydraulic Lines
(To & From Steering
Cylinders)
L2-2 Hydraulic System L02014
The pump is a double cartridge vane type, with a
total output of 143 GPM (541 l/min). The shaft end
cartridge supplies 88 GPM (333 l/min.), the cover
end cartridge supplies 55 GPM (208 l/min.) @ 1900
RPM and 2500 psi (17,238 kPa).
Hydraulic Tank
The hydraulic tank holds approximately 134 gallons
(507 l) of hydraulic oil for use in the hydraulic system.
Oil level should be checked periodically and be visi-
ble in the lower sight glass when the body is down
and the engine running. If filling is required, use Type
C-4 hydraulic oil only.
Oil leaving the hydraulic tank passes through a 100
mesh outlet strainer before being delivered to the
hydraulic pump.
The outlet strainer acts as the final filtering action
before the hydraulic oil enters the hydraulic pump.
For the regular outlet strainer service interval, refer to
the "Lubrication and Service" Section. Clean filter
after any oil change or major component failure.
The hydraulic tank is also equipped with a breather
element (6, Figure 2-1). For regular breather service
interval, refer to the "Lubrication and Service" Sec-
tion, or replace when plugged.
Always maintain complete cleanliness when
opening any hydraulic connection. Insure that all
system lines and components are capped while
the component is removed from the truck.
FIGURE 2-2. HYDRAULIC COMPONENT LOCATION (TOP VIEW)
1. High Pressure Filter
(Hoist)
2. Hose
3. Hydraulic Pump
4. Suction Hose
5. Capscrew
6. Hoist Valve
7. Hoist Inlet
(From Unloader)
8. Bleeddown Manifold
9. Unloader Valve
10. High Pressure Filter
(Steering & Brakes)
11. Hydraulic Tank
12. Hoist Cylinder
13. Hoist Cylinder Lines
14. Snubber Valve
15. Manifold
16. Pressure Line
(To Hoist Valve)
L02014 Hydraulic System L2-3
HYDRAULIC SYSTEM
(With Trolley Assisted Option)
HYDRAULIC SYSTEM DESCRIPTION
The following information describes the basic opera-
tion of the Haulpak
-130
F (43
-54
F (49
C) oil tempera-
ture. If leakage is excessive, refer to Step 3. for
steering control valve leakage.
3. The steering control valve can be isolated for
leakage by disconnecting the steering control
valve return hose at the flow amplifier valve.
Plug flow amplifier port. Use container to
receive oil leakage. The maximum allowable
leakage from the steering control valve return
hose is 5.5 oz (163 ml) per minute. If excessive
leakage from the steering control valve is found,
turn steering wheel and let valve recenter itself
again. Check leakage rate again. If l leakage is
still excessive, rebuild unit as per instructions in
this Section.
4. Measure leakage from the flow amplifier return
hose. Leakage is not to exceed 27.7 oz (820 ml)
per minute. If leakage is excessive, replace the
flow amplifier valve.
5. To check for leakage from the bleeddown mani-
fold:
a. Disconnect the tank line from the unloader
valve to the bleeddown manifold at the mani-
fold. Cap the port on the manifold and place
the line from the unloader valve in a con-
tainer. Some leakage from the line will occur
while the steering circuit is charged.
b. Disconnect the return hose connection from
the bleeddown manifold (3, Figure 6-16).
NOTE: Plug the connection at the hoist valve during
the bleeddown manifold leakage test.
c. Maximum allowable leakage from the return
hose is 1.1 oz (33ml) per minute.
6. If excessive leakage from the bleeddown mani-
fold is found, it may be caused by the bleed-
down solenoid valve (10, Figure 6-16) or the
3000 psi (21 MPa) relief valve (4). Verify 3000
psi (21 MPa) relief setting. The excessive leak-
age may be caused by the O-rings on these
valves. Remove valves and replace O-rings.
Recheck for leakage.
7. If excessive internal leakage from the bleed-
down manifold is still present, remove the steer-
ing bleeddown solenoid valve and replace valve
assembly. If internal leakage is still excessive,
replace 3000 psi (21 MPa) relief valve.
8. Check the unloader valve for leakage. This can
be done by shutting down engine (without turn-
ing off the key switch) and listening at the
unloader valve for sounds of leakage. If valve is
determined to be leaking, repair according to
instructions in this section.
NOTE: Trucks equipped with DDEC engines,
disconnect the 33J wire in the steering bleeddown
timer during the test for leakage of the unloader
valve. After test is completed, reconnect wire 33J in
the bleeddown timer.
9. After the leakage tests are complete and the
leakage rates are satisfactory, be sure all return
hoses which were disconnected are recon-
nected properly and tightened securely.
10. Fill the hydraulic tank, if required.
L6-18 Steering Circuit Component Repair L06003 3/99
TROUBLESHOOTING CHART
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Slow Steering, Hard Steering, or Loss of Power Assist.
Overloaded Steering Axle. Reduce Axle Loading.
Malfunctioning flow amplifier valve allowing system
pressure to be lower than specified.
Repair or replace flow amplifier valve.
Worn or malfunctioning pump. Replace pump.
TROUBLE: Drift - Truck Veers Slowly In One Direction
Rod end of cylinder slowly extends without turning the
steering wheel.
A small rate of extension may be normal on a closed cen-
ter system.
Worm or damaged steering linkage. Replace linkage and check alignment or toe-in of the
front wheels.
TROUBLE: Wander - Truck Will Not Stay in Straight Line
Air in system due to low oil level, pump cavitation,
leaking fitting, pinched hoses, etc.
Correct oil supply problem and/or oil linkage.
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.
TROUBLE: Slip - A Slow Movement of Steering Wheel Fails to Cause Any Movement of the Steered
Wheels
Leakage of cylinder piston seals. Replace seals.
Worn steering control unit meter. Replace steering control unit.
TROUBLE: Spongy or Soft Steering Replace the solenoid valve assembly.
Low oil level. Service hydraulic tank and check for leakage.
Air in hydraulic system. Most likely air trapped in cylin-
ders or lines.
Bleed air from system. Placing ports on top of cylinder
will help avoid trapping air.
L06003 3/99 Steering Circuit Component Repair L6-19
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Erratic Steering
Air in system due to low oil level, cavitating pump,
leaky fittings, pinched hose, etc.
Correct condition and add oil as necessary.
Loose cylinder piston. Replace cylinder.
TROUBLE: Free Wheeling - Steering Wheel Turns Freely with No Back Pressure of No Action of the Front
Wheels
Lower splines of steering column may be disengaged
or damaged.
Repair or replace steering column.
No flow to steering unit can be caused by:
1. Low oil level.
2. Ruptured hose.
3. Broken gerotor drive pin.
1. Add oil and check for leakage.
2. Replace hose.
3. Replace drive pin.
TROUBLE: Excessive Free Play at Steered Wheels
Broken or worn linkage between cylinder and steered
wheels.
Check for loose fitting bearings at anchor points in steer-
ing linkage between cylinder and steered wheels.
Leaky cylinder seals. Replace cylinder seals.
TROUBLE: Binding or Poor Centering of Steered Wheels
Binding or misalignment in steering column or splined
column or splined input connection.
Align column pilot and spline to steering control unit.
High back pressure in tank can cause slow return to
center. Should not exceed 300 psi (2068 kPa).
Reduce restriction in the lines or circuit by removing
obstruction or pinched lines, etc.
Large particles can cause binding between the spool
and sleeve in the steering control valve.
Clean the steering control unit and filter the oil. If another
component has malfunctioned generating contaminating
materials, flush the entire hydraulic system.
TROUBLE: 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.
L6-20 Steering Circuit Component Repair L06003 3/99
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Steering Wheel Oscillates or Turns By Itself
Lines connected to wrong ports. Check line routing and connections.
Parts assembled wrong. Steering control unit improp-
erly timed.
Reassemble correctly and retime control unit.
TROUBLE: Steered Wheels Turn in Opposite Direction When Operator Turns Steering Wheel
Lines connected to wrong cylinder ports. Check proper line connections.
L07014 Hoist Circuit L7-1
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
The following hoist circuit operation description
describes the basic hoist circuit. Further circuit
description is outlined under the individual compo-
nent descriptions.
Hydraulic fluid is supplied by a tank located on the left
frame rail. The tank's service capacity is approximately
134 gal. (507 L). Refer to (10, Figure 7-1), Hoist Circuit
Schematic. Hydraulic oil is routed to a tandem vane
type pump, (9). The pump is driven by an accessory
drive at the end of the traction alternator.
Pump output is directed to two high pressure filters
(5), one mounted to the inboard side of the right hand
frame rail near hydraulic pump, and the other on the
outside of the left frame rail near the hydraulic tank.
Hydraulic oil from the filters is directed to the hoist
valve (2) which is mounted to the inboard side of the
left hand frame rail.
The hoist valve directs oil to the body hoist cylinders
(1) for raising and lowering of the dump body. The
hoist valve functions are controlled by the operator
through the lever connected to the hoist pilot valve (6)
located below the floor of the operators cab. There is
also a hoist limit solenoid located to the inboard side
of the left hand frame rail near the hydraulic tank. The
hoist-up limit solenoid prevents the hoist cylinders
from extending to maximum physical limit.
Hydraulic hoses deteriorate with age and use.
Prevent possible malfunctions by inspecting all
hoses periodically. Replace any hose showing
wear, damage, or deterioration.
FIGURE 7-1. HOIST CIRCUIT SCHEMATIC
1. Hoist Cylinder
2. Hoist Valve
3. Pilot Operated Check
Valve
4. Hoist Up Limit
Solenoid
5. High Pressure Filter
6. Hoist Pilot Valve
7. Unloader Valve
8. Return From Brake &
Flow Amplifier Valve
9. Pump
10. Hydraulic Tank
11. Quick Disconnect
12. Snubber Valve
13. Bleeddown Manifold
14. To Steering & Brake
Accumulator
L7-2 Hoist Circuit L07014
COMPONENT DESCRIPTION
Hydraulic Tank
The hydraulic tank supplies hydraulic oil for the hoist,
steering and brake circuits. The tank is located on the
left hand frame rail forward of the rear wheels. The
service capacity of the tank is 134 gal. (507 l). Type
C-4 hydraulic oil is recommended for use in the
hydraulic system. Oil used in the hoist circuit flows
through a 100 mesh wire suction strainer to the inlet
housing of the pump. Air drawn into the tank during
operation is filtered by dual air filters located on the
top of the tank. Oil level can be checked visually at
sight glasses located on the front face of the tank.
Hydraulic Pump
The hydraulic pump is a tandem, vane type pump
driven by a drive shaft passing through the end of the
alternator. The pump has a total output of 143 GPM
(541 l) at 1900 RPM. The front (shaft end) cartridge
delivers oil to the hoist valve and the rear (cover end)
cartridge supplies oil to the unloader valve. The
unloader valve directs priority oil for use in the steer-
ing and brake circuits and the remaining oil to the
hoist valve.
Hoist pressure is regulated by relief valves located
within the hoist control valve. Pressure test ports are
located at the outlet port of each pump cartridge.
High Pressure Filters
Hoist pump output oil is directed to the high pressure,
7 micron filters, one mounted to the inboard side of
the right hand frame rail near hydraulic pump, and
the other on the outside of the left frame rail near the
hydraulic tank. The filter assemblies are equipped
with a bypass valve which permits oil flow should the
filter element become plugged.
Flow restriction through the filter element is sensed
by an indicator switch. This switch will turn on an
instrument panel mounted red warning light to indi-
cate filter service is required. The indicator light will
illuminate when restriction reaches approximately 40
psid (276 kPa). Actual filter bypass will result when
the filter element restriction reaches approximately
60 psid (414 kPa).
Hoist Valve
The hoist valve (Figure 7-2) is mounted to the
inboard side of the left hand frame rail. Hydraulic oil
from the shaft end of the hydraulic pump and the
unloader valve is routed to the hoist valve (or through
the high pressure filter from the pump).
The hoist valve is a split spool design. (The term
split spool describes the spool section of the valve.)
The spools operate in synchronization with, or in
opposition to its mate. The main valve precisely fol-
lows differential pressure input signals generated by
the hoist pilot valve.
The inlet section of the hoist valve consists of the fol-
lowing components: (Refer to Figure 7-3.)
Flow control and main relief valve
(system relief) (1)
Low pressure relief valve (3)
Load check poppet (18)
Anti-void poppet (17)
The flow control portion of the flow control and main
relief valve allows pump flow to return directly to tank
through the inlet section with low pressure loss. The
relief portion of the valve is direct acting and has the
capacity to limit the working pressure at full pump
flow.
The low pressure relief is located between the low
pressure core and the outlet, and provides a con-
trolled back pressure in the low pressure core when
oil is returning to tank.
FIGURE 7-2. HOIST VALVE
1. Outlet Section
2. Spool Section Cover
3. Spool Section
4. Inlet Section
L07014 Hoist Circuit L7-3
The load check allows free flow from the inlet to the
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 and prevents flow from the high
pressure core to the low pressure core.
The spool section of the hoist valve consists of the
following components:
Pilot ports
Main spools
Work ports
Check poppets
The pilot ports are located in the spool section cover.
These ports provide connections for a pilot line to the
hoist pilot valve. Each work port has a corresponding
pilot port.
The work ports provide for a line connection between
the spool section and the hoist cylinders. One main
spool for each work port is spring biased at both ends
to block the work port from the high and low pressure
cores when there is no flow through the spool cross
holes. When there is flow through the pilot ports to
the spools, a positive differential pressure at the top
of the spool will overcome the bottom spring bias and
the spool will shift to connect the work port to the
high pressure core. 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
spool section 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 during void condi-
tions.
Hoist Pilot Valve
The hoist pilot valve is mounted on the cab floor, on
the left side of the operator's seat. The hoist pilot
valve spool is spring centered to the neutral position.
The hoist valve is controlled directly by the operator
through a lever mounted on the valve assembly.
When the operator pulls the lever to the rear, the pilot
valve spool moves and transfers the small pilot flow
from the main valve into control signals which cause
the main valve spools to direct the working flow.
The hoist pilot valve is equipped with a one way load
check valve which allows free flow from the center
passage to bridge core and prevents reverse flow.
L7-4 Hoist Circuit L07014
Hoist-up Limit Solenoid
The hoist-up limit solenoid (13, Figure 7-3) is used in
the hydraulic circuit to prevent maximum hoist cylin-
der extension.
The solenoid valve is "normally open", allowing pilot
pressure oil to pass through the valve. When the
body is nearly fully raised, the body activates the
magnetic proximity switch (located on the right frame
rail near the body pivot). The proximity switch then
sends 24 volts to the body up solenoid valve. The
solenoid valve is actuated and diverts the flow of pilot
oil (from the pilot valve) to the tank. The pilot port (on
the solenoid valve) that is connected to the hoist
valve is closed, and the pilot pressure area in the
hoist valve neutralizes, allowing the main spools (7 &
8) to center, and shuting off hydraulic flow to the hoist
cylinders (6).
Pilot Operated Check Valve
The Pilot Operated Check Valve (21, Figure 7-3) is
opened by power down pilot pressure to allow oil in
the raise port to by-pass the hoist up limit solenoid for
initial power down operation while the solenoid is
activated by the hoist limit switch.
Hoist Valve Operation
The following outline describes the hoist circuit oper-
ation in the float, power up, hold, and power down
positions. (Refer to Figures 7-3 through 7-7.)
Float Operation
Figure 7-3 shows float operation when pilot valve is
in float and body is coming down. Once body is com-
pletely down and resting on the frame rails, the Hoist
Valve components (3, 7 & 8) are in position shown in
Figure 7-5. Oil from the hoist pump enters the inlet
section of the Hoist Valve in Port (11), passes
through check valve (18), and stops at the closed
High Pressure Passage (19) at the two main spools.
Pressure builds to approximately 60 psi (414 kPa) on
the pilot of the Flow Control Valve (2) causing the
valve to compress the spring and open, allowing the
oil to return to the tank through Hoist Valve Port (10).
Oil also flows out Hoist Valve Port (12) to Port (12) on
the Pilot Valve, through the Hoist Pilot Valve spool,
and out Pilot Valve Port (10) to the tank. This oil flow
is limited by orifices in the inlet sections of the Hoist
Valve and therefore has no pressure buildup.
L07014 Hoist Circuit L7-5
FIGURE 7-3. FLOAT POSITION
1. Hoist Relief Valve 2500
psi (17,238 kPa)
2. Flow Control Valve
3. Low Pressure Relief
Valve 75 psi (517 kPa)
4. Snubber Valve
5. Rod End Work Port
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
9. Head End Work Port
10. Return Port
11. Supply Port
12. Pilot Supply Port
13. Hoist Limit Solenoid
14. Raise Pilot Port
15. Down Pilot Port
16. Hoist Pilot Valve
17. Anti-void Check Valve
18. Load Check Valve
19. High Pressure
Passage
20. Low Pressure
Passage
21. Pilot Operated Check
Valve
L7-6 Hoist Circuit L07014
Power Up Operation (Figure 7-4)
The Hoist Pilot Valve spool is moved to the Power Up
position when the operator moves the lever in the
cab. The pilot supply oil coming in Port (12) is pre-
vented from returning to the tank and, instead, is
directed out Port (14) through hoist limit solenoid (13)
and into Port (14) of the Hoist Valve. There it goes to
the top of the Head End Spool (8), builds pressure on
the end of the spool, causes the spool to move down
compressing the bottom spring, and connects the
High Pressure Passage (19) to Head End Port (9).
Working oil flow in the High Pressure Passage is now
allowed to flow through the spool and out Port (9) to
extend the hoist cylinders. Even though a small
amount of oil flows through the check poppet in the
top of Spool (8), raise pilot pressure at Ports (14)
increases to slightly higher pressure than the
required hoist cylinder pressure. As a result, the pilot
supply pressure in Ports (12) also 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 pump oil through
Head End Spool (8) to the hoist cylinders to extend
them.
If at any time the resistance to the flow of the pump
oil coming into the inlet section causes the pressure
to increase to 2500 psi (17,238 kPa), the pilot pres-
sure against Hoist Relief Valve (1) causes it to open
and allow flow to exit out Port (10) and return to the
tank.
As the hoist cylinders extend, oil in the annulus area
of the second and third stages must exit from the cyl-
inders. Initially, the Rod End Spool (7) ports are
closed. As the returning oil entering Port (5) builds
low pressure, it flows through the check-poppet in the
top of the spool, through Ports (15), through the Pilot
Valve spool, and out Port (10) of the Pilot Valve to the
tank. No pressure is present on the top of Spool (7).
Cylinder return pressure passes through the check-
poppet in the bottom of Spool (7) to build pressure
under the spool which moves the spool upward com-
pressing the top spring. This movement allows the
returning cylinder oil to flow into the Low Pressure
Passage (20) to the Low Pressure Relief Valve (3).
Approximately 75 psi (517 kPa) causes this valve to
open, allowing the oil to flow out Port (10) to the tank.
If the load passing over the tail of the body during
dumping attempts to cause the body to raise faster
than the oil being supplied by the pump, the oil
returning from the annulus area of the hoist cylinders
passing through the Snubber Valve (4) controls how
fast the hoist can extend because of the external
force of the load. The speed is controlled by the
restriction of the Snubber Valve. When the operator
releases the lever, the valves change to the HOLD
position.
If the body raises to the position that activates the
Hoist Limit Switch located above the right rear sus-
pension before the operator releases the lever, the
Hoist Limit Solenoid (13) is energized. The solenoid
valve closes the raise pilot Port (14) on the hoist and
releases the Hoist Pilot Valve raise pilot pressure at
Port (14) to tank, allowing the Head End Spool (8) to
center and shut off supply of oil to the hoist cylinders.
This prevents maximum extension of the hoist cylin-
ders.
L07014 Hoist Circuit L7-7
FIGURE 7-4. POWER UP POSITION
1. Hoist Relief Valve 2500
psi (17,238 kPa)
2. Flow Control Valve
3. Low Pressure Relief
Valve 75 psi (517 kPa)
4. Snubber Valve
5. Rod End Work Port
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
9. Head End Work Port
10. Return Port
11. Supply Port
12. Pilot Supply Port
13. Hoist Limit Solenoid
14. Raise Pilot Port
15. Down Pilot Port
16. Hoist Pilot Valve
17. Anti-void Check Valve
18. Load Check Valve
19. High Pressure
Passage
20. Low Pressure
21. Pilot Operated Check
Valve
L7-8 Hoist Circuit L07014
Hold Operation (Figure 7-5)
The Pilot Valve spool is positioned to allow the pilot
supply oil entering Port (12) to return to the tank
through Port (10). Pilot supply pressure in Ports (12)
then decreases to no 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 the Pilot Valve spool. In
this condition pressure is 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 cylin-
ders and hold the body in its current position.
L07014 Hoist Circuit L7-9
FIGURE 7-5. HOLD POSITION
1. Hoist Relief Valve 2500
psi (17,238 kPa)
2. Flow Control Valve
3. Low Pressure Relief
Valve 75 psi (517 kPa)
4. Snubber Valve
5. Rod End Work Port
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
9. Head End Work Port
10. Return Port
11. Supply Port
12. Pilot Supply Port
13. Hoist Limit Solenoid
14. Raise Pilot Port
15. Down Pilot Port
16. Hoist Pilot Valve
17. Anti-void Check Valve
18. Load Check Valve
19. High Pressure
Passage
20. Low Pressure
Passage
21. Pilot Operated Check
Valve
L7-10 Hoist Circuit L07014
Power Down Operation (Figure 7-6)
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 the Rod End Spool (7). Pilot pressure
increases to move the spool down compressing the
bottom spring. Movement of the spool connects the
High Pressure Passage (19) to the rod end (annulus
area) of the hoist cylinders. At the same time, the
Flow Control Valve (2) is forced to close as pilot pres-
sure increases thus directing the incoming pump oil
to the hoist cylinders through Spool (7) and Snubber
Valve (4) rather than back to the tank.
If the body is at the maximum up position, the hoist
limit switch has the hoist limit solenoid activated,
therefore closing the raise port (14) on the hoist
valve. Power down pilot pressure in Ports (15)
pushes open the pilot operated check valve (21) so
the pilot pressure in Ports (14) is open to tank
through the Pilot Valve spool. As oil attempts to
return from the head end of the hoist cylinders, it ini-
tially encounters the closed Head End Spool (8).
Pressure increases on the bottom end of the spool
causing it to move upward. This allows the returning
oil to go into the Low Pressure Passage (20), build
up 75 psi (517 kPa) to open the Low Pressure Relief
(3), and exit the Hoist Valve through Port (10) to the
tank. As the body descends and the hoist limit sole-
noid is no longer activated, the pilot operated check
valve is no longer necessary.
L07014 Hoist Circuit L7-11
FIGURE 7-6. POWER DOWN POSITION
1. Hoist Relief Valve 2500
psi (17,238 kPa)
2. Flow Control Valve
3. Low Pressure Relief
Valve 75 psi (517 kPa)
4. Snubber Valve
5. Rod End Work Port
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
9. Head End Work Port
10. Return Port
11. Supply Port
12. Pilot Supply Port
13. Hoist Limit Solenoid
14. Raise Pilot Port
15. Down Pilot Port
16. Hoist Pilot Valve
17. Anti-void Check Valve
18. Load Check Valve
19. High Pressure
Passage
20. Low Pressure
Passage
21. Pilot Operated Check
Valve
L7-12 Hoist Circuit L07014
Float Operation (Figure 7-7)
When the operator releases the lever as the body
travels down, The Hoist Pilot Valve spool returns to
the FLOAT position. In this position all ports (10, 12,
14, & 15) are common with each other. Therefore,
the pilot supply oil is returning to tank with no pres-
sure build-up thus allowing the Flow Control Valve (2)
to remain open to allow the pump oil to return to the
tank through Hoist Valve Port (10). 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
allowing the returning oil to transfer to the Low Pres-
sure Passage (20). The back pressure in the Low
Pressure Passage created by the Low Pressure
Relief Valve (3) causes pressure under the Rod End
Spool (7) to move the spool upward. This connects
the Low Pressure Passage to the Rod End of the
hoist cylinders. The 75 psi (517 kPa) in the Low Pres-
sure Passage causes oil to flow to the rod end of the
cylinders to keep them full of oil as they retract.
When the body reaches the frame and there is no
more oil flow from the cylinders, the Main Spools
center themselves and close the cylinder ports and
the High and Low Pressure Passages.
L07014 Hoist Circuit L7-13
FIGURE 7-7. FLOAT POSITION
1. Hoist Relief Valve 2500
psi (17,238 kPa)
2. Flow Control Valve
3. Low Pressure Relief
Valve 75 psi (517 kPa)
4. Snubber Valve
5. Rod End Work Port
6. Hoist Cylinders
7. Rod End Spool
8. Head End Spool
9. Head End Work Port
10. Return Port
11. Supply Port
12. Pilot Supply Port
13. Hoist Limit Solenoid
14. Raise Pilot Port
15. Down Pilot Port
16. Hoist Pilot Valve
17. Anti-void Check Valve
18. Load Check Valve
19. High Pressure
Passage
20. Low Pressure
Passage
21. Pilot Operated Check
Valve
L7-14 Hoist Circuit L07014
NOTES :
L08012 7/95 Hoist Circuit Component Repair L8-1
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
Removal
Relieve pressure before disconnecting hydraulic
lines. Tighten all connections securely before
applying pressure.
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
1. Be certain the area above the truck is clear of
all obstacles so body can be fully raised without
hitting anything. Raise the body and install the
body sling cable and locking pin.
2. Shut down engine and turn key switch to the
Off position. Relieve hydraulic pressure in
hoist system by slowly moving hoist control
lever to the "lower" position and gently lower
body so body lock pin and/or sling cable is hold-
ing body up.
3. Drain hydraulic tank.
4. Thoroughly clean the exterior of the hoist valve.
5. Disconnect and cap (or plug) all connections
from hoist valve to prevent contamination.
6. Remove capscrews and lockwashers securing
the hoist valve to its mounting bracket.
FIGURE 8-1. HYDRAULIC COMPONENT LOCATION (TOP VIEW)
1. High Pressure Filter
(Hoist)
2. Hose
3. Hydraulic Pump
4. Suction Hose
5. Capscrew
6. Hoist Valve
7. Hoist Inlet (From
Unloader)
8. Bleeddown Manifold
9. Unloader Valve
10. High Pressure Filter
(Steering & Brakes)
11. Hydraulic Tank
12. Hoist Cylinder
13. Hoist Cylinder Lines
14. Snubber Valve
15. Manifold
16. Pressure Line
(to Hoist Valve)
L8-2 Hoist Circuit Component Repair L08012 7/95
NOTE: The hoist valve weighs approximately 320
lbs. (145 Kg). Use a suitable lifting device that can
handle the load safely.
7. Attach a suitable lifting device to the hoist valve
and remove from truck.
Installation
1. Move the hoist valve into position and secure in
place with capscrews, nuts and lockwashers.
Alternately tighten capscrews to standard
torque.
2. Using new O-rings at the flange fittings, connect
hydraulic lines. Tighten flange capscrews to
standard torque. Refer to Figure 8-1 for hydrau-
lic line location.
3. Connect pilot supply lines, tighten fittings
securely. Close body creep down valve on
hydraulic tank.
4. If hydraulic tank was drained, add type C-4 oil.
5. Start the engine. Raise the body to remove the
body sling cable. Lower and raise body to check
for proper operation. Observe for leaks.
6. Service hydraulic tank if necessary.
Disassembly
NOTE: It is not necessary to remove the individual
valve sections to accomplish repair, unless
emergency field repair is required to replace the O-
rings between sections to prevent leakage.
Loosening and retorqueing 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 the four tie rod nuts and washers (7, Fig-
ure 8-2) from one end of the valve. Slide the tie
rods 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
surface with fine lapping compound.
3. Lubricate the new O-rings lightly with multipur-
pose grease. Replace O-rings between sections.
Stack the sections together making sure O-rings
between the sections 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.
FIGURE 8-2. HOIST VALVE
1. Outlet Section
2. Spool Section Cover
3. Spool Section
4. Inlet Section
5. Tube
6. Tie Rods
7. Nuts and Washers
8. Inlet Section Cover
FIGURE 8-3. TIE ROD INSTALLATION
FIGURE 8-4. TORQUE SEQUENCE
L08012 7/95 Hoist Circuit Component Repair L8-3
5. A torque wrench should be used to torque the
nuts in the pattern shown in Figure 8-4. The tie
rods should be torqued evenly to 105 ft. lbs.
(217 N.m) torque in the following sequence.
a. Torque nuts evenly to 15 ft. lbs. (20 N.m)
torque in order 1, 4, 2, 3.
b. Torque nuts evenly to 32 ft. lbs. (43 N.m)
torque in order 1, 4, 2, 3.
c. Torque nuts evenly to 105 ft. lbs. (142 N.m)
torque in order 1, 4, 2, 3.
INLET SECTION
Disassembly
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Disconnect the external tube at the cover end
and remove. Remove capscrews (14, Figure 8-
5), and cover (13). Remove springs (12), pop-
pets (11) and O-rings (10).
NOTE: Inlet section shown removed from 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). The main relief valve (4) is factory
preset at 2500 psi (17,238 kPa). Replace only
as a complete assembly. If adjustment is neces-
sary, refer to "Checking Hoist System Pressure
Relief Valve" later in this section.
NOTE: If restrictor poppet removal in cover (2) is
required, refer to step 4 and Figure 8-6.
4. Remove sleeve (6, Figure 8-6), backup ring (5),
O-ring (4), and backup ring (3). Remove restric-
tor poppet (2).
FIGURE 8-6. RESTRICTOR POPPET REMOVAL
1. Inlet Cover
2. Restrictor Poppet
3. Backup Ring
4. O-Ring
5. Backup Ring
6. Sleeve
FIGURE 8-5. INLET SECTION DISASSEMBLY
1. Capscrew
2. Inlet Cover
3. Spring
4. Main Relief Valve
5. Spring
6. Sleeve
7. Low Pressure Relief
8. O-Rings
9. Inlet Valve Body
10. O-Rings
11. Poppets
12. Springs
13. Cover
14. Capscrews
L8-4 Hoist Circuit Component Repair L08012 7/95
Cleaning and Inspection
1. Discard all O-rings and backup rings. Clean all
parts in solvent and 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.
3. Inspect all bores and surfaces of sliding parts
for nicks, scores or excessive wear.
4. Inspect poppets in their respective bore for fit.
Poppets should move freely, without binding,
through a complete revolution.
5. Inspect fit and movement between sleeve and
low pressure relief valve.
Reassembly
1. Coat all parts including housing bores with
clean type C-4 hydraulic oil. Lubricate O-rings
lightly with a multipurpose grease.
2. If restrictor poppet (2, Figure 8-6) was removed,
reassemble in the order shown.
3. Install poppets (11, Figure 8-5) in their respec-
tive bores. Install springs (12).
4. Install O-rings (10), and cover (13). Install cap-
screws (14). Tighten capscrews to 60 ft. lbs.
(81 N.m) torque.
5. Install low pressure relief (7) in sleeve (6) and
install assembly in housing (9). Install main
relief valve (4), and springs (3 & 5). Install cover
(2) Install capscrews (1). Tighten capscrews to
60 ft. lbs. (81 N.m) torque. Connect external
tube, tighten nuts to 25 ft. lbs. (34 N.m) torque.
SPOOL SECTION
Disassembly
NOTE: It is not necessary to remove the inlet or
outlet sections to accomplish spool section
disassembly.
1. Match mark or identify each part when removed
in respect to its location or respect to its mating
bore to aid reassembly.
2. Remove capscrews and remove spool section
cover (2, Figure 8-2). Remove and discard O-
rings (4 & 5, Figure 8-8).
3. Remove poppet (1, Figure 8-7). Remove and
discard O-ring (2).
NOTE: The poppet (1) is equipped with a small steel
ball (2). Do not misplace.
4. Remove restrictor poppet (1, Figure 8-8).
Remove and discard O-ring (2) and backup ring
(3). Note the position of the restrictor when
removed to insure correct reassembly.
5. Remove springs (4, Figure 8-9) and spool
assemblies (15). Note location of V groove on
end of spools.
6. Remove the spool washers and restrictor pop-
pets.
FIGURE 8-7. POPPET AND BALL
1. Poppet
2. Steel Ball
3. O-Ring
FIGURE 8-8. RESTRICTOR POPPET REMOVAL
1. Restrictor Poppet
2. O-Ring
3. Backup Ring
4. O-Ring
5. O-Ring
L08012 7/95 Hoist Circuit Component Repair L8-5
FIGURE 8-9. SPOOL SECTION ASSEMBLY
1. Poppet
2. O-Ring
3. Backup Ring
4. Spring (4)
5. Spool Housing
6. Restrictor Poppet (Blue)
7. O-Ring
8. Spool Washer (4)
9. O-Ring (4)
10. Spool Cover
11. Poppet
12. O-Ring (2)
13. O-Ring
14. Plug
15. Spool (2)
16. Poppet (White)
17. Poppet (White)
18. Spool Cover
19. Restrictor Poppet
20. O-Ring
21. Ball
L8-6 Hoist Circuit Component Repair L08012 7/95
NOTE: Pay special attention to poppets (6, 16, and
17, Figure 8-9) during removal to ensure proper
location during reassembly. Poppets may be
identified with a colored dot; white or blue. If poppets
are not color coded, use the chart in Figure 8-11 for
identification.
7. Remove cover (10), and O-rings (9 & 12).
8. Remove Poppet (11) from spool section hous-
ing.
9. Remove plug (14) and O-ring (13).
Cleaning and Inspection
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.
3. Inspect all bores and surfaces of sliding parts
for nicks, scores or excessive wear.
4. Inspect all poppets in their respective bore for
fit. Poppets should move freely, without binding,
through a complete revolution.
Reassembly
1. Using a new O-ring, install plug (14, Figure 8-9)
in cover (10).
2. Install poppet (11). Lubricate O-rings (9 & 12)
with clean hydraulic oil and install cover (10) on
the spool housing (5). Secure cover in place
with capscrews. Tighten capscrews to 60 ft.
lbs. (81 N.m) torque.
3. Lubricate O-rings (7) and install on spool wash-
ers (8). Insert poppets (6, 16, & 17) in the
proper location in each spool (15) and insert the
spool washers to hold in place.
NOTE: Poppets 6, 16 and 17 may be color coded
and must be installed in their original location.
Refer to the chart, Figure 8-11 for identification
information.
4. Install spool springs (4). Carefully insert lubri-
cated spool assemblies into their original bores
in the spool housing (15), with the V groove
positioned as shown in Figure 8-9.
5. Install new O-ring (2, Figure 8-8) and backup
ring (3) on restrictor poppet (1). Install restrictor
poppet in housing.
6. Install new O-rings (9 & 12, Figure 8-10).
7. Install new O-ring (20, Figure 8-9) on poppet
(1). Make sure the small steel ball (21) is
installed in poppet. Install poppet in cover (18,
Figure 8-9).
8. Install cover (18, Figure 8-9). Secure cover in
place with capscrews. Tighten capscrews to 60
ft. lbs. (81 N.m) torque.
POPPET
COLOR
ORIFICE
DIAMETER
DRILL
SIZE
Red .140 in. (3.556 mm) 9/64
Green .093 in. (2.362 mm) #35
Black .078 in. (1.981 mm) #42
White .063 in. (1.600 mm) #52
Blue .046 in. (1.168 mm) #56
Gray .035 in. (0.889 mm) #65
FIGURE 8-10. SPOOL ASSEMBLY REMOVAL
1. V Groove
2. Spool Assembly
3. Spool Section
FIGURE 8-11. POPPET IDENTIFICATION
L08012 7/95 Hoist Circuit Component Repair L8-7
HOIST PILOT VALVE
Removal
1. Place the hoist control lever in the body down
position. Make sure the body is in the full down
position. Release the hoist control lever to return
the hoist valve spool to the neutral position.
2. Disconnect hydraulic lines at the hoist pilot
valve. Tag all hydraulic lines for identification
and cap openings to prevent contamination.
3. In the operator cab, remove capscrews & wash-
ers (3 & 4, Figure 8-11) and plate/gasket (2).
4. Remove the hoist pilot valve mounting cap-
screws, washers, and nuts (5, 6, 7, 8). Remove
hoist pilot valve (10). Handle Assembly (1) will
come with valve.
Installation
1. Move the hoist pilot valve (10, Figure 8-11) into
position on the mounting bracket. Secure valve
in place with capscrews. Tighten capscrews (5)
to standard torque. Install plate/gasket (2).
Tighten capscrews (3) to standard torque.
2. Attach hydraulic lines into correct ports. Tighten
hydraulic line connections securely.
3. Start the engine and check for proper hoist
operation. Observe for leaks.
Disassembly
1. Thoroughly clean the exterior of the valve. Place
the valve in a clean work area for disassembly.
2. Remove the handle assembly, seal plate (25,
Figure 8-12), wiper (13) and O-ring (12).
FIGURE 8-11. HOIST CONTROL/PILOT VALVE
1. Handle Assembly
2. Plate & Gasket
3. Capscrew
4. Flatwasher
5. Capscrew
6. Flatwasher
7. Lockwasher
8. Nut
9. Floor Plate
10. Pilot Valve Body
FIGURE 8-12. HOIST PILOT VALVE
1. Snap Ring
2. Ball (4)
3. Detent Pin
4. Spring
5. Spacer
6. Capscrew
7. Housing
8. Nut
9. Tie Rod
10. Nut
11. O-Ring
12. O-Ring
13. Wiper
14. Spool
15. Housing
16. O-Ring
17. Wiper
18. Seal Retainer
19. Spring Seat
20. Spring
21. Ball (1)
22. Detent Sleeve
23. Spacer
24. Cap
25. Seal Plate
L8-8 Hoist Circuit Component Repair L08012 7/95
3. Remove snap ring (1), capscrews (6), cap (24),
spacer (23), and detent sleeve (22). Detent
Balls (2) and (21) will fall free when the cap and
detent sleeve are removed. Separate cap (24),
spacer (23) and detent sleeve (22), as this will
be necessary for reassembly.
4. Carefully slide the spool (14) out of the spool
housing. Remove seal retainer (18), wiper (17)
and O-ring (16) from spool (14).
5. Insert a rod in the cross holes of the detent pin
(3) and unscrew from spool (14). Slight pres-
sure 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 plugs from the spool housing.
8. Match mark the housings (7 & 15) in relation-
ship to the spool housing to insure correct loca-
tion during reassembly.
9. Remove nuts (8) and (10) and remove tie rods
(9). Separate the valve housings. Remove O-
rings (11). Remove the check poppet (2, Figure
8-13) and spring (3) from the spool housing.
Cleaning and Inspection
1. Clean all parts including housings in solvent
and blow dry with compressed air.
2. Inspect seal counter bores, they must be free of
nicks or grooves.
3. Examine springs for breaks or distortion
.
4. Inspect spool (14, Figure 8-12). The spool must
be free of longitudinal score marks, nicks or
grooves.
5. Test spool (14) in spool housing for fit. Spool
must fit freely, without binding when rotated
through a complete revolution.
NOTE: The spool housing, spool, and side housings
are not serviced separately. Should any of these
parts require replacement, the entire control valve
must be replaced.
Reassembly
1. Thoroughly coat all parts including housing
bores with clean type C-4 hydraulic oil.
2. Install check poppet (2, Figure 8-13) and spring
(3) in spool housing (1).
3. Install new O-ring (4) in spool housing. Align the
housing (5), spool housing (1) and opposite
side housing and insert the tie rods (9, Figure 8-
12) through all three housings.
4. Install tie rod nuts. Tighten tie rod nuts to the
torques shown in Figure 8-14.
5. Install a new O-ring (16, Figure 8-12) and wiper
(17). Install seal retainer (18).
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 detent pin 84-96 in. lbs.
(9-11 N.m) torque. Install spring (20). Carefully
install spool into spool housing.
7. Apply grease to the cross holes of the detent
pin (3) to hold balls (21) and (2).
FIGURE 8-13. CHECK POPPET LOCATION
1. Spool Housing
2. Check Poppet
3. Spring
4. O-Ring
5. Housing
FIGURE 8-14. TIE ROD NUT TORQUE
1. Nut
2. Tie Rod
3. Nut
4. Tie Rod
5. Housing
L08012 7/95 Hoist Circuit Component Repair L8-9
8. Slide detent sleeve (22) into cap (24) and place
over a punch. Using this punch, depress ball (21)
and insert balls (2) in detent pin cross holes.
9. While holding down on ball (21), slide detent
sleeve (22) and cap (24) as an assembly over
the detent pin (3). Continue to insert detent
sleeve (22) until it contacts spring seat (19).
10. Secure cap (24) in place with capscrews (6).
Tighten capscrews to 5 ft. lbs. (7 N.m) torque.
Install spacer (23) and snap ring (1).
11. Install a new O-ring (12) and wiper (13). Install
seal plate. Using new O-rings, install plugs.
HOIST CYLINDERS
Removal
1. Be certain engine and key switch has been Off
for at least 90 seconds to allow accumulators to
bleed down.
Relieve pressure before disconnecting hydraulic
lines. Tighten all connections securely before
applying pressure.
Hydraulic fluid escaping under pressure can
have sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
The hoist cylinder weighs approximately 1700 lbs
(772 kg). Make sure lifting device is adequate and
provide support to prevent cylinder from falling
or causing injury when cylinder is removed from
truck.
2. To relieve all hydraulic pressure form the hoist
circuit, slowly move hoist control lever to the
"lower" position and gently lower body so it is
completely resting on frame rails.
3. Disconnect hydraulic lines from connection on
hoist cylinders. Cap and plug lines and ports to
prevent excessive spillage and contamination.
Strap cylinder in place to prevent movement.
FIGURE 8-15. HOIST CYLINDER MOUNT (TOP)
1. Retainer Plate
2. Capscrew &
Lockwasher
3. Pin
4. Snap Ring
5. Bearing
6. Hoist Cylinder
FIGURE 8-16. HOIST CYLINDER MOUNT
(LOWER)
1. Capscrew &
Lockwasher
2. Retainer Plate
3. Locking Plate
4. Snap Ring
5. Bearing
6. Spacer
L8-10 Hoist Circuit Component Repair L08012 7/95
4. At the pivot point under the body, remove cap-
screws and lockwashers (2, Figure 8-15).
Remove retainer plate (1). Using a brass drift,
drive pin (3) from bore of mounting bracket.
5. Carefully lower cylinder until it lays against the
inside dual tire. Attach a lifting device to the
upper cylinder mounting eye.
6. At the pivot point on the frame, remove cap-
screws and lockwasher (1, Figure 8-16) secur-
ing retainer (2). Remove locking plate (3).
7. Install retaining strap or chains to prevent
extension of hoist cylinder while handling.
8. Pull cylinder from the pivot point on the frame
and remove from machine
.
NOTE: Do not lose spacer (6) between cylinder
bearing and frame.
9. Clean the exterior of the cylinder thoroughly
and move to a clean work area for disassembly.
Installation
The hoist cylinder weighs approximately 1700 lbs
(772 kg). Make sure lifting device is adequate and
provide support to prevent cylinder from falling
or causing injury when cylinder is removed from
truck.
Use chain or strap to prevent cylinder extension
during installation.
1. Raise the hoist cylinder into position. Install
spacer (6, Figure 8-16) and lower hoist eye over
the frame pivot.
2. Install retainer plate (2) and secure in place with
capscrews and lockwashers (1). Tighten cap-
screws to 220 ft. lbs. (298 N.m) torque.
3. Align the top hoist eye with the bore of the body
mounting bracket. (See Figure 8-15).
NOTE: Make sure air bleed vent located on top of
hoist cylinder is toward front of truck.
4. Install pin (3, Figure 8-15) and retaining plate
(1). Secure retaining plate in place with cap-
screws and lockwashers (2). Tighten capscrews
to standard torque.
5. Close body creep down valve. Start engine and
raise and lower body several times. Observe for
leaks.
6. Service hydraulic tank if necessary.
Disassembly
1. If removal of the hoist cylinder eye bearings is
necessary, remove retainer ring (4, Figure 8-15)
and press out bearing (5).
2. Mount the hoist cylinder in a fixture which will
allow it to be rotated 180
.
3. Position cylinder with the cover (10, Figure 8-
17) mounting eye on top. Remove capscrews
(11) and lockwashers retaining cover to housing
(4).
4. Using two 0.88 in. dia. x 9 in. long, threaded
capscrews, thread them into the two threaded
holes in the cover. Screw the capscrews in
evenly until the cover can be removed. Lift
cover (10) straight up until quill assembly (22) is
clear. Remove O-ring (12) and backup ring (23).
5. Remove capscrews (7) and flatwashers (5)
attaching the rod bearing retainer (6) to the rod
(1). Remove the seal (8).
6. Fabricate a retainer bar using a 1/4" x 1" x 18"
(6 x 25 x 460 mm) steel flat. Drill holes in the
bar to align with a pair of tapped holes spaced
180
, until the
lower mounting eye is at the top. Hook a lifting
device to the eye on the rod (1) and lift the rod
and third stage cylinder assembly out of cylin-
der housing.
NOTE: As internal parts are exposed
8. Rotate the cylinder housing 180
. Remove the
retainer installed in step 6.
9. Fabricate a round disc 12.5 in. (318 mm) in
diameter 0.38 in. (10 mm) thick with a 0.56 in.
(14 mm) hole in the center. Align the disc over
the second (2) and first (3) stage cylinders at
the bottom of the cylinder housing.
L08012 7/95 Hoist Circuit Component Repair L8-11
FIGURE 8-17. HOIST CYLINDER
1. Rod & Third Stage
2. Second Stage
Cylinder
3. First Stage Cylinder
4. Housing
5. Flatwasher
6. Piston Bearing
Retainer
7. Capscrew
8. Seal
9. Snap Ring
10. Cover
11. Capscrews
12. O-Ring
13. Bearing
14. Bearing
15. Seal
16. Seal
17. Bearing
18. Buffer Seal
19. Bearing
20. Rod Seal
21. Rod Wiper
22. Quill Assembly
L8-12 Hoist Circuit Component Repair L08012 7/95
10. Insert a 0.50 in. (13mm) dia. X 52 in. (1320 mm)
threaded rod through the top and through the
hole in the disc. Thread a nut on the bottom end
of the threaded rod below the disc.
11. Screw a lifting eye on the top end of the rod.
Attach it to a lifting device and lift the second
and first stage cylinders out of the housing.
12. Remove lifting tools from the second and first
stage cylinder assembly.
13. Slide the second stage cylinder (2) down inside
the first stage cylinder (3). Remove snap ring
(9) from inside the first stage cylinder.
14. Remove second stage cylinder from first stage
cylinder by sliding it out the top.
15. Remove all old bearings, O-rings, and seals
from the hoist cylinder parts.
Cleaning and Inspection
NOTE: Use only fresh cleaning solvent, lint free
wiping cloth 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 (Type C-4).
1. Thoroughly clean and dry all parts.
2. Visually inspect all parts for damage or exces-
sive wear.
3. If cylinder bores or plated surfaces are exces-
sively worn or grooved, the parts must be
replaced or, if possible, replated and machined
to original specifications.
4. The quill (2, Figure 8-18) should be checked for
tightness if it has not previously been tack
welded.
a. Check the quill for tightness by using special
tool SS1143 (Figure 8-18) and applying a
tightening torque of 1000 ft. lb. (1356 N.m).
b. If the quill moves, remove quill, clean
threads in cover assembly and quill, and
reinstall using the procedure in "Quill Instal-
lation".
5. When a cylinder assembly is dismantled, the
capscrews (7, Figure 8-17) should be checked
carefully for distress and, if in doubt, replace
them. New washers (5) are to be used. The new
washer can be distinguished from the previous
washer by the thickness and fit to the bolt:
New Washer 5/32" Thick; Plated; Close Fit;
Old Washer 3/32" Thick; Non-plated; Loose Fit.
NOTE: SS1143 Tightening Tool can be made locally.
Request the following drawings from your Area or
Regional Service Manager.
SS1143 Tightening Tool - Assembly Drawing
SS1144-Square Tube (3.50 x 3.50 x 0.19 wall
x2.0 long)
SS1145-Plate (2.50 x 2.50 x 0.25 thick)
SS1146-Square Tube (3.00 x 3.00 x 0.25 wall
x 15.50 long)
SS1147-Tube, Brass (1.75 O.D. x 1.50 I.D.
x 13.50 long)
SS1148-Square Cut (2.50 x 2.50 x 0.75 thick)
SS1149-Hex Drive (1.75 Hex stock x 2.50 long)
All materials are 1020 Steel except SS1147.
FIGURE 8-18. QUILL INSTALLATION
1. Cap Assembly 2. Quill Assembly
L08012 7/95 Hoist Circuit Component Repair L8-13
ASSEMBLY OF QUILL AND CYLINDER
NOTE: 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. The plugs (3, Figure 8-19) and the check balls
(4) in the quill should be checked during any
cylinder repair to insure the plugs are tight and
ball seats are not damaged. Refer to "Installa-
tion of Check Balls and Plugs in Quill".
2. Secure cap assembly (1, Figure 18) in a sturdy
fixture. Make certain threads in cap and threads
on quill are clean and dry (free of oil and sol-
vent).
3. Using Loctite "LOCQUIC" Primer "T" (TL8753,
or equivalent), spray mating threads of both cap
assembly (1) and quill assembly (2).
Allow primer to dry 3 to 5 minutes.
4. Apply Loctite Sealant #277 (VJ 6863, or equiva-
lent) to mating threads of both cap assembly
and quill assembly.
5. Install quill and use SS1143 tool to tighten quill
to 1000 ft. lbs. (1356 N.m) torque. Allow parts
to cure for 2* hours before exposing 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 quill in 2 places as shown in Figure 8-
19.
7. Remove all slag and foreign material from tack
weld area before assembly of 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 2000 ft. lbs. (2712 N.m)
torque after the tack welds are ground off.
FIGURE 8-19. PLUG AND CHECK BALL
INSTALLATION
1. Cover Assembly
2. Quill Assembly
3. Plug
4. Check Ball
L8-14 Hoist Circuit Component Repair L08012 7/95
Installation Of Check Balls And Plugs In Quill
The check balls (4, Figure 8-19) in the side of the
quill assembly (2) are held in place with threaded
plugs (3).
If a plug is missing and the check ball is not found in
the cylinder, the opposite side hoist cylinder and the
plumbing leading to the hoist valve should be exam-
ined for damage. The hoist valve itself should also be
checked to see if the ball or plug has caused internal
damage to the spool. Peening of the necked down
sections of the spool may result. Spool sticking may
also occur under these circumstances.
Refer to Figure 8-20 for SS1158 tool that can be
made for installing or removing the check ball plugs.
Plugs should be checked during any cylinder repair
to be sure they are tight. If found to have any move-
ment, they should be removed and the ball seat in
the quill checked to see if it is deformed.
If deformation of the ball seat has occurred, the
quill should be replaced.
If the ball seat area is not deformed, measure the
plug thickness as shown in Figure 19:
Older Plug is 0.25 0.02 in. thick.
Newer plug is 0.38 0.02 in. thick.
1. Use the newer plugs and make certain threads
in quill tube and on plugs are clean and dry
(free of oil and solvent).
2. Use Loctite "LOCQUIC" Primer "T" (TL8753, or
equivalent), and spray mating threads of both
plugs (3, Figure 8-19) and quill assembly (2).
Allow primer to dry 3 to 5 minutes.
3. Apply Loctite Sealant #277 (VJ 6863, or equiva-
lent) to mating threads of both plugs and quill
assembly.
4. Place check balls (4) in quill tube (2) and install
plugs (3) with concave side facing ball. Using
SS1158 tool, tighten plugs to 70 ft. lbs. (95
N.m) torque. Allow parts to cure for 2* hours
before exposing threaded areas to oil.
* NOTE: If "LOCQUIC" primer "T" (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
5. Stake plug threads in two places (between
holes) as shown in Figure 8-19 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 should be installed
and staked as previously detailed.
FIGURE 8-20. SS1158 TOOL PLUG
INSTALLATION/REMOVAL
L08012 7/95 Hoist Circuit Component Repair L8-15
Assembly of Cylinder
1. Install seals (15, Figure 8-17) and bearing (14)
on second stage cylinder. Install bearings (19)
and buffer seal (18), rod seal (20) and rod wiper
(21) on first stage cylinder. Lubricate with clean
hydraulic oil (Type C-4).
2. Align and slide the second stage cylinder (2)
inside the first stage cylinder (3). Allow the second
stage to protrude far enough to install the snap
ring (9) on the inside of the first stage cylinder.
3. Mount the housing (4) in the fixture with the
cover end positioned at the top. Install bearings
(19) and buffer seal (18), rod seal (20) and rod
wiper (21) in the housing.
4. Install lifting tool used during disassembly in the
second and first stage cylinder assembly.
5. Install bearings (13) on the first stage cylinder
(3). Lift and align this assembly over the hous-
ing (4). Lower the second and first stage cylin-
ders into the housing.
6. Install retainer used during disassembly to hold
the second and first stage cylinder in place
when the housing is rotated. Rotate housing
180
F to 131
F
(-29
C to 55
F (32
to 90
F (-32
to 32
F (-32
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M06001 Fan Drive Clutch M6-15
FAN CLUTCH DISASSEMBLY INSTRUCTIONS
Refer to page M6-14 for individual parts referenced in the following instructions:
1. Support the fan clutch on a bench with the fan
mounting hub (2) up. Support beneath the pul-
ley. Remove bolts (14) with lockwashers (15).
2. Separate the front bearing retainer from the pul-
ley, lift it off, and set it aside on the bench. (A
small screwdriver may be used at the split-line
to break the bearing retainer loose from the pul-
ley).
3. Remove O-Ring seal (13).
4. Support the bearing retainer sub-assembly on
the bench with the clutch hub (7) up. Remove
external snap ring (8).
M6-16 Fan Drive Clutch M06001
5. Remove clutch hub (7).
6. Position the sub-assembly beneath the ram of a
press. Support beneath the bearing retainer (as
close as possible to the fan mounting hub).
Press the fan mounting hub out of the front
bearing.
7. Remove the front oil seal (11).
8. Remove internal snap ring (28).
M06001 Fan Drive Clutch M6-17
9. Turn the bearing retainer over on the press bed.
Press the front bearing (5) out of the bearing
retainer.
10. Remove the wear sleeve (4). Split the wear
sleeve with a chisel to loosen it.
NOTE: IF THE RETAINER/SEAL ASSEMBLY IS
NOT DAMAGED, WORN OR OTHERWISE IN
NEED OF REPLACEMENT, REMOVAL MAY BE
OMITTED.
11. Remove the front retainer/seal assembly (3).
Wedge a large chisel or other appropriate tool
behind the retainer to force it off the fan mount-
ing hub.
12. Support beneath the fan mounting hub with the
end cap (1) down, but approximately 2 in. (50
mm) above the press bed. Using a piece of bar
stock 1.5 in. -2.5 in. (38-64 mm) dia. x 7 in. (175
mm) long resting on the end cap, press or drive
the end cap out of the fan mounting hub.
M6-18 Fan Drive Clutch M06001
13. Place a piece of bar stock 2.93 in. (74.4 mm)
dia. against sleeve bearing (9). Press the
sleeve bearing downward to press it out of the
fan mounting hub. The second sleeve bearing
(10) will be pressed out at the same time.
NOTE: A #4 arbor press or a small hydraulic
press will be needed to press the sleeve bearings
out.
14. Remove the stack of facing plates (6) and steel
clutch plates (16) from inside the pulley.
15. Remove external snap ring (29), shim (30), and
spring washer (27).
16. Turn the pulley/shaft sub-assembly over on the
bench. The piston (17) will usually fall out when
the pulley is turned over on the bench. Remove
it.
M06001 Fan Drive Clutch M6-19
17. Remove the seal rings (18 and 26) from the pis-
ton.
18. Support beneath the pulley to prevent it from
dropping to the bench. Remove bolts (21) with
lockwashers (20). The pulley should not be
allowed to drop to the bench when the supports
are removed, but if it is not free of the bearing
retainer, stand the unit on the bench resting on
the nose of the shaft. Rap the pulley with a soft,
but heavy mallet to break it loose from the rear
bearing retainer.
19. Remove the shaft and rest it on the mounting
bracket with the nose up. Insert a phillips-head
screwdriver into the pitot tubes (33) 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
pitot tubes from the hole in the shaft.
20. Remove both seal rings (32).
M6-20 Fan Drive Clutch M06001
21. Remove external snap ring (38).
22. Remove internal snap ring (25).
23. Support beneath the bearing retainer (as close
as possible to the bearing bore, but not so close
as to damage the retainer/seal assembly).
Press the shaft out of bearing (37).
24. Remove oil seal (24).
M06001 Fan Drive Clutch M6-21
25. Press the rear bearing (37) out of the rear bear-
ing retainer (23).
26. Remove the wear sleeve (34). Split the wear
sleeve with a chisel to loosen it. Use care not to
damage shaft.
NOTE: IF THE RETAINER/SEAL ASSEMBLY IS
NOT DAMAGED, WORN OR OTHERWISE IN
NEED OF REPLACEMENT, REMOVAL MAY BE
OMITTED.
27. Remove the rear retainer/seal assembly (36).
Drive the assembly off the shaft or wedge a
large chisel or other appropriate tool behind the
retainer to force it off.
DISASSEMBLY OF THE FAN CLUTCH IS
COMPLETE.
DO NOT ATTEMPT TO DISASSEMBLE FURTHER.
M6-22 Fan Drive Clutch M06001
REASSEMBLY OF THE 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.
28. Press the front retainer/seal assembly (3) onto
the fan mounting hub (2). 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.
29. Coat the I.D. of the front wear sleeve (4), and the
wear sleeve diameter of the shaft with Loctite
#290 (or equivalent). NOTE: The front wear
sleeve (4) is NOT interchangeable with rear
(notched) wear sleeve (34). Press the wear
sleeve onto the shaft, flush with the shoulder.
30. Using a proper installation tool, press the rear
sleeve bearing (9) into the fan mounting hub
until the rear end of the sleeve is just below the
chamfer.
31. Turn the fan mounting hub over on the bed of the
press. Again using a proper installation tool,
press the front sleeve bearing (10) into the fan
mounting hub until the front end of the sleeve is
0.25 in.- 0.28 in. (6.3 - 7.1 mm) below the shoul-
der.
M06001 Fan Drive Clutch M6-23
32. Coat the bore of the fan mounting hub (2) with a
thin coating of Loctite#290 (or equivalent).
FREEZE THE END CAP IN A FREEZER OR
DRY ICE FOR 15 MINUTES TO 1/2 HOUR.
When frozen, press the end cap (1) into the fan
mounting hub, to the bottom of the bore.
Note: When the end cap is properly seated, it's O.D.
will be tight against the fan mounting hub.
33. Press the rear retainer/seal assembly (36) onto
the shaft (31). 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.
34. Coat the I.D. of the rear, (notched) wear sleeve
(34), and the wear sleeve diameter of the fan
mounting hub with Loctite#290 (or equiva-
lent). Locate the sleeve so the notch in the
sleeve will be aligned with the small lube hole in
the shoulder. Press the wear sleeve onto the
fan mounting hub, flush with the shoulder.
NOTE: The rear wear sleeve (34) is notched to
allow oil to flow from the shaft. This notch
MUST BE ALIGNED with the hole in the shaft!
35. Install the rear bearing (37) in the rear bearing
retainer (23). Press ONLY on the outer race of
the bearing, and press it to the bottom of the
bore.
M6-24 Fan Drive Clutch M06001
36. Install internal snap ring (25).
37. Turn the retainer over on the press bed. Coat the
O.D. of rear oil seal (24) with Loctite#290 (or
equivalent). Install the oil seal in the rear bear-
ing retainer, flush with the rear face.
38. Place the shaft sub-assembly on the press bed.
Coat the bearing I.D., O.D., shaft, and bearing
retainer bore with Loctite#609 (or equivalent).
Install the rear bearing retainer sub-assembly in
place on the shaft. Press the bearing onto the
shaft until it stops at the bottom of the shoulder.
Spin the bearing retainer to be sure there is no
sound or other indication of contact between the
retainer/seal assembly and the bearing retainer.
If interference is found, remove the bearing
retainer and eliminate the point of interference.
39. Install external snap ring (38).
M06001 Fan Drive Clutch M6-25
40. 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#609 (or equivalent) on the straight
end of one pitot tube (33). 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 bear-
ing 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.
41. Install both hook-type seal rings (32) in the
grooves in the shaft.
42. Install the front bearing (5) in the front bearing
retainer (12). Press ONLY on the outer race of
the bearing, and press it to the bottom of the
bore.
43. Install internal snap ring (28).
M6-26 Fan Drive Clutch M06001
44. Turn the retainer over on the press bed. Coat the
O.D. of front oil seal (11) with Loctite#290 (or
equivalent). Install the oil seal in the front bear-
ing retainer, flush with the front face.
45. Place the fan mounting hub sub-assembly on
the press bed.
Coat the bearing O.D., I.D., fan mounting hub
bearing journal and front bearing retainer bore
with Loctite#609 (or equivalent). Install the
front bearing retainer sub-assembly in place on
the fan mounting hub. Press the bearing down
until it stops at the bottom of the shoulder.
Spin the bearing retainer to be sure there is no
sound or other indication of contact between the
retainer/seal assembly and the bearing retainer.
If interference is found, remove the bearing
retainer and eliminate the point of interference.
46. Install the clutch hub (7) on the fan mounting hub
splines with the open end down.
47. Install external snap ring (8) to hold the clutch
hub in place.
M06001 Fan Drive Clutch M6-27
48. Install the small seal ring (26) in the piston (17).
Lubricate the seal ring groove with an oil-solu-
ble lubricant. Squeeze the "L shaped" seal ring
to form it into a tight "V" shape all the way
around its diameter. Then install the seal ring
into the groove.
Note the shape of the groove. It will properly
accept the seal ring in only one way.
49. Install the large seal ring (18) in the piston (17),
as was done with the small seal ring.
Lubricate the seal ring groove with an oil-solu-
ble lubricant. (petroleum jelly or a 50%-50%
mixture of engine oil and STP work well).
Squeeze the "L shaped" seal ring to form it into
a tight "V" shape all the way around its diame-
ter. Then install the seal ring into the groove.
Note the shape of the groove. It will properly
accept the seal ring in only one way.
50. Install the piston in the pulley. First lubricate the
internal and external surfaces the seal rings (18
& 26) will contact, with an oil-soluble lubricant
such as was described above. Carefully place
the piston in the pulley.
DO NOT PUSH THE PISTON INTO 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.
51. Align the tangs of the piston for easy final
assembly of the fan clutch. Place the front bear-
ing retainer sub-assembly in place on the pul-
ley. While doing so, the slots of the front bearing
retainer will engage the tangs, and the retainer
will rest against the pulley.
Then, rotate the bearing retainer (and therefore,
the piston) until the bolt holes align in the bear-
ing retainer and pulley. Remove the bearing
retainer sub-assembly.
M6-28 Fan Drive Clutch M06001
52. Install spring washer (27). Then install shim (30)
on the spring washer. Install the spirolock ring
(29) in the groove. 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.
53. Place the front bearing retainer sub-assembly on
the bench with the clutch hub up. Dip the fac-
ing plates (6) in engine oil to get them wet.
Install one steel clutch plate (16) in place in the
bearing retainer. Then place one facing plate on
top of the steel clutch plate. Alternately stack
the remaining plates until a total of 7 of each
have been placed on the stack, and the top
plate is a facing plate.
54. Using petroleum jelly or an oil-soluble grease,
"stick" the front O-Ring seal (13) in the pulley
groove.
55. Install a guide-bolt in one bolt hole of the pulley.
Turn the pulley over on the bench and lift with a
hoist. Carefully lower the pulley until it rests on
the front bearing retainer.
M06001 Fan Drive Clutch M6-29
56. Install and snug 3 or 4 bolts (14) with lockwash-
ers (15).
57. Using petroleum jelly or an oil-soluble grease,
"stick" the rear O-Ring seal (22) in the pulley
groove.
58. Lubricate the bore of the pulley, and carefully
lower the shaft sub-assembly into the pulley
bore and onto the pulley until the retainer rests
on the pulley.
59. Install bolts (21) with lockwashers (20), and
torque each one to 38-42 ft. lbs. (5-57 N-m).
M6-30 Fan Drive Clutch M06001
60. Install orifice fitting (35) in the "oil in" port of the
bracket.
61. Turn the assembly over on the bench. Install the
remaining bolts (14) with lockwashers (15), and
torque all to 38-42 ft. lbs. (51-57 N.m).
ASSEMBLY OF THE FAN CLUTCH IS COMPLETE
M06001 Fan Drive Clutch M6-31
REF. DESCRIPTION
20 Lockwasher
21 Bolt
22 O-Ring Seal
23 Rear Bearing Retainer
24 Rear Oil Seal
25 Internal Snap Ring
31 Shaft / Bracket Assembly
REF. DESCRIPTION
32 Seal Rings
33 Pitot Tubes
34 Rear Wear Sleeve
35 Orifice
36 Rear Retainer / Seal Assembly
37 Rear Bearing
38 External Snap Ring
REF. DESCRIPTION
17 Piston
18 Seal Ring (large)
19 Pulley
26 Seal Ring (small)
REF. DESCRIPTION
27 Spring Washer
29 External Snap Ring
30 Shim
M6-32 Fan Drive Clutch M06001
REF. DESCRIPTION
5 Front Bearing
6 Facing Clutch Plate
7 Clutch Hub
8 External Snap Ring
11 Front Oil Seal
12 Front Bearing Retainer
REF. DESCRIPTION
13 O-Ring Seal
14 Bolt
15 Lockwasher
16 Steel Clutch Plate
28 Internal Snap Ring
REF. DESCRIPTION
1 End Cap
2 Fan Mounting Hub
3 Front Retainer / Seal Assembly
REF. DESCRIPTION
4 Front Wear Sleeve
9 Sleeve Bearing
10 Sleeve Bearing
M06001 Fan Drive Clutch M6-33
INSPECTION OF PARTS
(31): Shaft & Bracket Assembly
Bearing journal for bearings (10) and (9)
Bearing journal for rear bearing (37)
Groove width for snap ring (38)
General:
2.7480 in. (69.799 mm) minimum-no steps in surface
3.7398 in. (94.991 mm) minimum
0.145 in. (3.683 mm) maximum
Do not separate shaft from bracket.
Do not remove tube from center bore.
Pipe plugs may be removed for cleaning.
Replace with sealant on threads.
Snap ring grooves must have straight sides and
square corners.
(35): Orifice
Re-use
(4), (34): Wear Sleeve
Replace if damaged or worn.
(11), (24): Oil Seal
Replace
(19): Pulley
Pilot bore for bearing retainer must be free of nicks
that extend above the pilot surface.
Flat surface(s) that mate with bearing retainer must be
free of nicks that extend above the surface.
Pulley grooves must not be severely worn or dam-
aged.
(23): Rear Bearing Retainer
Bore For Bearing (37)
Bore for rear oil seal (24)
General:
5.7088 in. (145.004 mm) maximum
5.1265 in. (130.213 mm) maximum
Bearing bore must have straight sides, square bottom,
and not be oval due to wear.
Oil seal bore must not have nicks that extend above
the bore surface. All sealants must be removed.
Pilot diameter for pulley must be free of nicks that
extend above the pilot surface.
Flat surface that mates with pulley must be free of
nicks that extend above the surface.
PART INSPECTION WEAR LIMITS
M6-34 Fan Drive Clutch M06001
(14), (15), (20), (21): Bolts and Lockwashers
Re-use if not damaged.
(5), (37): Bearing Assembly
Replace
(8), (29), (38): External Snap Ring
Re-use unless worn, damaged, or distorted.
(32): Seal Rings
Replace
(17): Piston
General: Should be free of nicks.
Sealing grooves must be smooth so as not to cut seal
rings.
O.D. must not have nicks which extend above the
O.D. surface.
I.D. must not be elongated from wear.
(18), (26): Piston Seal Rings
Replace
(7): Clutch Hub
Replace if I.D. teeth are severely worn.
Replace if wear notches made by facing plates have
straight sides.
If the wear marks have smooth entry and exit marks
the notches will not restrict plate movement and the
clutch hub can be re-used.
(6): Facing Clutch Plates
Must pass between two plate surfaces 11 x 11 in. (280
x 280 mm) spaced 0.188 in. (4.78 mm) apart set at
45 angle. Facing grooves are 0.005 in. (0.127 mm)
minimum deep when new. Plate is worn out at the bot-
tom of the grooves.
Internal teeth must not be worn in excess of 0.005 in.
(0.127 mm) per side and the tooth driving contact sur-
face must not be worn to a point or to a wedge shape.
PART INSPECTION WEAR LIMITS
M06001 Fan Drive Clutch M6-35
(16): Steel Clutch Plates
Must pass between two plate surfaces 11 x 11 in. (280
x 280 mm) spaced 0.130 in. (3.30 mm) apart, set at a
45 angle.
Replace if wear on drive surfaces of the external
tangs exceeds 0.005 in. (0.127 mm) per side.
Minimum thickness: 0.121 in. (3.07 mm).
Replace if "tracked" with grooves, darkened or discol-
ored by heat, damaged, or warped.
(2): Fan Mounting Hub
Groove for snap ring (8)
Wear Sleeve Diameter
Bore for bearings (9) and (10)
Bearing journal for (5) bearing
End Cap Bore
General:
0.145 in. (3.683 mm) maximum
Free of Nicks above surface.
2.9370 in. (74.600 mm)
3.7401 in. (94.999 mm) minimum
Free of nicks, 3.378 in. (85.80 mm)
Snap ring grooves must have straight sides and
square edges.
Bearing bore must not have nicks or scratches which
extend above the bore surface.
Splines must not be excessively worn.
Bolt holes must not be worn or damaged severely.
(9), (10): Sleeve Bearings
Replace if necessary.
See Figure 6-8 for information concerning determina-
tion of amount of wear.
(1): End Cap
O.D. free of nicks above the surface.
PART INSPECTION WEAR LIMITS
M6-36 Fan Drive Clutch M06001
(12): Bearing Retainer
Bore for bearing (5)
Bore for oil seal (11)
General:
5.7088 in. (145.004 mm) maximum
5.1265 in. (130.213 mm) maximum
Bearing bore must have straight sides, square bottom,
and not be oval due to wear.
Oil seal bore must not have nicks that extend above
the bore surface. All sealants must be removed.
Pilot diameter for pulley must be free of nicks that
extend above the pilot surface.
Flat surface that mates with the pulley must be free of
nicks that extend above the surface.
Slots in the bearing retainer must not have worn
notches with straight sides. Maximum depth of the
wear mark should not exceed 0.020 in.(0.51 mm), but
if the notches have smooth entry and exit sides the
notch will not resist movement of the steel plate (16).
PART INSPECTION WEAR LIMITS
(3), (36): Retainer / Seal Assembly
Replace if damaged, worn, or distorted.
(25), (28): Internal Snap Ring
Re-use unless damaged, worn, or distorted.
(33): Pitot Tubes
Replace
(13), (22): O-Ring Seal
Replace
(27): Spring Washer
Replace
(30): Shim
Replace
M06001 Fan Drive Clutch M6-37
FIGURE 6-8. SLEEVE BEARING WEAR
Condition of bearing surface:
Running in completed.
Low wear rate starts when
bronze is exposed.
Typical appearance
after half useful life.
Bronze beginning
to smear near end
of useful life.
M6-38 Fan Drive Clutch M06001
REBUILD TOOLS
The tools illustrated below are necessary for proper
installation of the Retainer/Seal Assembly, Sleeve Bearings,
and Wear Sleeves. These tools can be fabricated from locally.
FIGURE 6-9. SLEEVE BEARING (9), (10) REMOVAL AND INSTALLATION TOOL
FIGURE 6-10. RETAINER / SEAL ASSEMBLY (3), (36) INSTALLATION TOOL
FIGURE 6-11. WEAR SLEEVE (4), (34) INSTALLATION TOOL
M07001 03/95 Engine Coolant Heater M7-1
ENGINE COOLANT HEATER
To aid in cold weather starting, the truck can be
equipped with cooling system heaters. Two high
capacity coolant heating units are mounted under the
engine on the power module subframe. The system
includes:
Heaters
Thermostats
Coolant Shutoff Valves and Hoses
220 volt Receptacle
Power Cables, Thermostat Wiring, and J unction
Box
Heater operation is controlled by a thermostat
mounted on the intake end of the heating units. The
thermostat turns the heater ON at 120F (48C) and
OFF at 140F (60C). Shutoff valves allow heater
element or thermostat sensor replacement without
loss of engine coolant.
Do not operate engine while the cooling system
heater is plugged in. The flow check valve elimi-
nates coolant flow through the heater while the
engine is running. This will cause a lack of circu-
lation in the heater and burn out the heating ele-
ments.
Maintenance
To check for operation of the heating units, the outlet
water hoses should feel warm to the touch.
1. Check all electrical connections to insure proper
connections are made.
2. Check for a burned out heating element. (Do not
remove heating unit from the truck.)
a. Remove the two Phillips head screws and
slide end cover out of the way.
b. Connect a voltmeter at the two electrical ter-
minals and check for operating voltage (220
to 230 volts) while coolant temperature is
below 120F (48C). If correct voltage is
present, the heating element is defective and
should be replaced.
3. If correct voltage (measured above) is not read
at heating element terminals, the thermostat is
defective and should be replaced.
HEATING ELEMENT
Removal
1. Disconnect the external power source at the
plug-in receptacle.
2. Close the shut-off valves located at the inlet and
outlet ports.
3. Remove heating element.
a. Remove the two Phillips head screws from
cover at power cable entry. Slide cover out of
the way.
b. Disconnect the two electrical leads and
remove heating element from the cartridge.
Installation
1. Install new heating element.
a. Cover the new heating element threads with
an anti-seize thread compound.
FIGURE 7-1. COOLANT HEATER
1. Thermostat
2. Heater Assembly
3. Water Outlet Port
4. Heating Element
5. Cover
6. Terminals
M7-2 Engine Coolant Heater 03/95 M07001
b. Screw heating element into cartridge and
tighten securely to insure against leaks.
2. Connect the electrical leads.
3. Slide element cover into position and secure
with screws.
4. Open shut-off valves.
5. Plug in the external power source. After allowing
time for the element to warm up, outlet hoses
should feel warm to the touch.
6. Check for leaks and proper coolant level.
THERMOSTAT
Removal
1. Disconnect the external power source at the
plug in receptacle.
NOTE: It is not necessary to remove the thermostat
assembly from the heater.
2. Remove the two screws and slide cover out of
the way.
3. Disconnect the two electrical leads.
4. Loosen the two setscrews and remove the tem-
perature sensing unit.
Installation
1. Install a new temperature sensing unit and
secure in place with two setscrews.
2. Connect the electrical leads.
3. Move cover into position and secure in place
with screws.
4. Plug in the external power source.
After allowing time for the element to warm up, outlet
hoses should feel warm to the touch.
FIGURE 7-2. THERMOSTAT ASSEMBLY
1. Cover
2. Temperature
Sensing Unit
3. Housing
4. Setscrew
M07003 Engine Oil Heaters M7-1
ENGINE OIL HEATERS
Three engine oil heaters, located in the engine oil
pans, are provided for Detroit Diesel engines. The
front pan has a 230 volt, 300 watt heater installed in
the left side and another of the same rating in the
right side. The rear pan contains one 230 volt, 600
watt heater located on the left side. Operation of the
heaters is controlled by the coolant system heater
thermostats.
Cummins engines utilize two 230 volt, 600 watt heat-
ers in a single oil pan.
Troubleshooting
Operation of the heaters can be checked by touching
each mounting boss (3, Figure 7-1) on the oil pan
after allowing time for the heaters to warm up:
1. If the boss feels warm to the touch, the heater is
functioning.
2. If no heat is detected, verify proper operating
voltage (220 to 230 volts) at the heating ele-
ment leads.
3. If voltage is not present, check the thermostat
circuit at the engine coolant heaters. (Refer to
"Engine Coolant Heaters".) Also check circuits
between heaters and the plug-in receptacle.
4. If no heat is detected, but voltage is correct, the
heating element must be replaced.
HEATING ELEMENT
Removal
1. Disconnect the external power source at the
plug-in receptacle.
NOTE: Heater element replacement can be
accomplished without draining the crankcase oil by
disassembling all parts from the element cover.
Figures 7-2 and 7-3 show the complete heater
assembly removed from the pan.
2. Remove cap (7, Figure 7-2), remove connectors
(9) and disconnect wires (8).
3. Remove cord grip cap (2) and remove power
cord from the housing.
4. Remove the heater housing from the element
cover.
5. Loosen the setscrew (3, Figure 7-3) and remove
the heater element from the cover.
FIGURE 7-1. ENGINE OIL HEATER
1. Heater Assembly
2. Power Cord
3. Oil Pan Mounting
Boss
FIGURE 7-2. HEATER ASSEMBLY
1. Power Cord
2. Cover
3. Washer
4. Rubber Bushing
5. Housing
6. Element Cover
7. Housing Cap
8. Electrical Leads
9. Wire Connectors
M7-2 Engine Oil Heaters M07003
Installation
1. Install a new heater element and secure in
place with the setscrew (3, Figure 7-3).
The Detroit Diesel front pan requires 300 watt ele-
ments. The rear requires one 600 watt element.
Do not interchange.
2. Coat the threads of the element cover with an
anti-seize compound and install the housing (5,
Figure 7-2).
3. Insert the power cord (1), cord grip bushing (4),
washer (3) and cap (2) into the housing.
4. Twist the wires together and place a screw-on
connecter on each pair.
5. Adjust the power cord and tighten the cord grip
cover.
6. Replace the housing cap.
7. IIf engine oil was drained, refill the crankcase
with fresh oil.
FIGURE 7-3. HEATING ELEMENT REMOVAL
1. Element Cover
2. Heating Element
3. Element Retaining
Setscrew
M07004 Engine Coolant and Oil Heaters, 440 Volt M7-1
ENGINE COOLANT & OIL HEATERS, 440 VOLT
To aid in cold weather starting, the truck can be
equipped with optional cooling system and engine oil
heaters. Two high capacity coolant heating units are
mounted under the engine on the power module sub-
frame. Engine Oil heaters are mounted in each oil
pan.
The system includes:
Heaters
Thermostats
Coolant Shutoff Valves and Hoses
Power Receptacle
Magnetic Contactor
Power Cables, Thermostat Wiring, and J unction
Box
The 440 volt engine oil and coolant heater system
utilizes a magnetic contactor in the electrical circuit to
apply line voltage to the heater elements when cool-
ing system temperature drops below 120F (48C)
and the thermostats close. Thermostat contact clo-
sure energizes the magnetic contactor and supplies
line voltage to the heating elements. When coolant
temperature exceeeds 140F (60C), the thermostat
contacts open and de-energize the magnetic contac-
tor. The thermostats are located at the inlet of each
coolant heater assembly.
Shut-off valves allow coolant heater element or ther-
mostat sensor replacement without loss of engine
coolant. Engine oil heater elements can be replaced
without draining the engine oil.
Do not operate engine while the heater system is
operating. Lack of coolant circulation in the heat-
ers will burn out the heating elements.
FIGURE 7-1. ENGINE HEATERS INSTALLATION
1. Power Module
2. Contactor J unction Box
3. Coolant Shut-Off Valve
4. RH Oil Heater
5. Lower Coolant Heater
6. Upper Coolant Heater
7. LH Oil Heater
8. Thermostat
9. Mounting Bracket
10. Outlet Hose
M7-2 Engine Coolant and Oil Heaters, 440 Volt M07004
Troubleshooting
To check for proper operation of the heating units,
the coolant outlet water hoses (10, Figure 7-1) and
the oil pan heater mounting bosses (3, Figure 7-4)
should feel warm to the touch.
If none or only several of the heaters feel warm to the
touch after allowing sufficient time for warm-up, per-
form the following checks:
1. Open the magnetic contactor box located on the
lower left of the radiator shroud (2, Figure 7-1).
Visually check all electrical connections in the
box and to the heating units.
2. With line voltage applied to the system, verify a
nominal 440 volts across terminals "84" and
"87" at the magnetic contactor (3, Figure 7-2).
3. With the coolant temperature below 120F
(48C), verify a nominal 440 volts across termi-
nals "85" and "86".
4. If voltage is not present on terminals "85" and
"86", disconnect the power cable at the junction
box receptacle and check the thermostat con-
tacts using an ohmmeter. Verify continuity
across terminals "87" and "88" at the magnetic
contactor.
5. If the circuit between terminals "87" and "88" is
open:
a. Remove each of the thermostat covers 1,
Figure 7-7) and check for continuity between
the terminals.
b. If no continuity exists and coolant tempera-
ture is below 120 (48C), the thermostat is
defective and should be replaced. (Refer to
"Thermostat".)
6. If the circuit between terminals "87" and "88" at
the magnetic contactor is closed, but operating
voltage was not present at terminals "85" and
"86", the magnetic contactor is defective and
must be replaced.
FIGURE 7-2. HEATER SYSTEM ELECTRICAL HOOKUP
1. Line Power Receptacle
2. Contactor J unction Box
3. Magnetic Contactor
4. Cord Grip
M07004 Engine Coolant and Oil Heaters, 440 Volt M7-3
7. If the circuit between terminals "87" and "88" at
the magnetic contactor is closed, and operating
voltage was present at terminals "85" and "86",
check for burned out heating elements:
Coolant Heaters:
a. Remove the two Phillips head screws and
slide end cover (5, Figure 7-3) out of the way.
b. With the power cable connected, attach a
voltmeter at the two electrical terminals (6)
and check for operating voltage (nominal
440 volts) while coolant temperature is below
120F (48C). If correct voltage is present,
the heating element is defective and should
be replaced. Refer to "Coolant Heater Ele-
ment".
Oil Heaters:
a. Disconnect the power cable at the junction
box.
b. Remove the housing cap and wire connec-
tors at each heater assembly. Reconnect the
power cable and apply power. Measure the
voltage at the wires and verify approximately
440 volts.
c. If voltage is present but no heat is detected,
the heating element must be replaced. Refer
to "Oil Heater Element".
COOLANT HEATER ELEMENT
Removal
1. Disconnect the external power source at the
plug-in receptacle.
2. Close the shut-off valves (3, Figure 7-1).
3. Remove heating element (4, Figure 7-3).
a. Remove the two Phillips head screws from
cover at power cable entry. Slide cover (5)
out of the way.
b. Disconnect the two electrical leads and
remove heating element from the cartridge.
Installation
1. Install new heating element (4, Figure 7-3).
a. Cover the new heating element threads with
an anti-seize thread compound.
b. Screw heating element into cartridge and
tighten securely to insure against leaks.
2. Connect the electrical leads.
3. Slide element cover into position and secure
with screws.
4. Open shut-off valves (3, Figure 7-1).
5. Plug in the external power source. After allowing
time for the element to warm up, outlet hoses
should feel warm to the touch.
6. Check for leaks and proper coolant level.
FIGURE 7-3. ENGINE COOLANT HEATER
1. Thermostat
2. Heater Assembly
3. Water Outlet Port
4. Heating Element
5. Cover
6. Terminals
FIGURE 7-4. ENGINE OIL HEATER
1. Heater Assembly
2. Power Cord
3. Oil Pan Mounting
Boss
M7-4 Engine Coolant and Oil Heaters, 440 Volt M07004
OIL HEATER ELEMENT
Removal
1. Disconnect the external power source at the
plug-in receptacle.
NOTE: Heater element replacement can be
accomplished without draining the crankcase oil by
disassembling all parts from the element cover.
Figures 7-5 and 7-6 show the complete heater
assembly removed from the pan.
2. Remove cap (7, Figure 7-5), remove connectors
(9) and disconnect wires (8).
3. Remove cord grip cap (2) and remove power
cord (1) from the housing (5).
4. Remove the heater housing from the element
cover (6).
5. Loosen the setscrew (3, Figure 7-6) and remove
the heater element (2) from the cover.
Installation
1. Install a new heater element and secure in
place with the setscrew (3, Figure 7-6).
2. Coat the threads of the element cover with an
anti-seize compound and install the housing (5,
Figure 7-5).
3. Insert the power cord (1), cord grip bushing (4),
washer (3) and cap (2) into the housing.
4. Twist the wires together and place a screw-on
connecter on each pair.
5. Adjust the power cord and tighten the cord grip
cover.
6. Replace the housing cap (7).
7. If engine oil was drained, refill the crankcase
with fresh oil.
8. Plug in the external power source. After allowing
time for the element to warm up, the heater
mounting boss on the oil pan should feel warm
to the touch.
FIGURE 7-5. ENGINE OIL HEATER ASSEMBLY
1. Power Cord
2. Cover
3. Washer
4. Rubber Bushing
5. Housing
6. Element Cover
7. Housing Cap
8. Electrical Leads
9. Wire Connectors
FIGURE 7-6. OIL HEATER ELEMENT
1. Element Cover
2. Heating Element
3. Element Retaining
Setscrew
M07004 Engine Coolant and Oil Heaters, 440 Volt M7-5
THERMOSTAT
Removal
1. Disconnect the external power source at the
plug-in receptacle.
NOTE: It is not necessary to remove the thermostat
assembly from the heater.
2. Remove the two screws and slide cover (1, Fig-
ure 7-7) out of the way.
3. Disconnect the two electrical leads.
4. Loosen the two setscrews (4) and remove the
temperature sensing unit (2).
Installation
1. Install a new temperature sensing unit (2, Figure
7-7) and secure in place with two setscrews (4).
2. Connect the electrical leads.
3. Move cover (1) into position and secure in place
with screws.
4. Plug in the external power source.
5. After allowing time for the elements to warm up,
coolant outlet hoses and oil heater mounting
bosses should feel warm to the touch.
FIGURE 7-7. THERMOSTAT ASSEMBLY
1. Cover
2. Temperature Sensing
Unit
3. Housing
4. Setscrew
M7-6 Engine Coolant and Oil Heaters, 440 Volt M07004
NOTES
M08006 Special Tools M8-1
SPECIAL TOOLS
PART
NUMBER DESCRIPTION USE
VD4665 Nitrogen
Charging Kit
Suspension and
accumulator nitro-
gen charging
PART
NUMBER DESCRIPTION USE
FA4429 Roll-Out
Assembly
Power module
removal
PART
NUMBER DESCRIPTION USE
TG1106 Lifting Eye Miscellaneous
M8-2 Special Tools M08006
PART
NUMBER DESCRIPTION USE
PB6039 Female
Coupling
Hydraulic brake
system diagnostics
PART
NUMBER DESCRIPTION USE
TA8545
TA8546
Seal Installa-
tion Tool
Installation of front
wheel bearing face
seals
PART
NUMBER DESCRIPTION USE
TW9425 Wrench Accumulator rebuild
M08006 Special Tools M8-3
PART
NUMBER DESCRIPTION USE
VN1388
VN1392
Special
Wrench
Rear suspension
ball stud retaining
ring and locknut
PART
NUMBER DESCRIPTION USE
VL0293 Chain Wrench Miscellaneous
PART
NUMBER DESCRIPTION USE
TL9422 Box End
Wrench
Rear suspension
ball stud lock nut
M8-4 Special Tools M08006
PART
NUMBER DESCRIPTION USE
TB2555
TB2557
TB2559
TB2561
TY0026
Spanner
Wrench
Hoist cylinder
glands
PART
NUMBER DESCRIPTION USE
TB2575
TB2829
TB2832
Clamp
Hoist cylinder stage
removal and
installation
PART
NUMBER DESCRIPTION USE
SS1134 Special
Wrench
Unloader valve,
check valve
removal, and instal-
lation
M08006 Special Tools M8-5
PART
NUMBER DESCRIPTION USE
VS5386 Puller Steering wheel
removal
PART
NUMBER DESCRIPTION USE
VS5388 Lock plate
compressor
Steering column
lock plate removal
PART
NUMBER DESCRIPTION USE
VS5389 Pivot pin tool Removal and
installation of
steering column tilt
pivot pin
PART
NUMBER DESCRIPTION USE
VS5387 Clamp tool Support steering
column in bench
vise during rebuild
M8-6 Special Tools M08006
NOTES:
M09003 11/95 Air Conditioning System M9-1
for R-12 Refrigerant
AIR CONDITIONING SYSTEM
ENVIRONMENTAL IMPACT
Environmental studies have indicated a weakening of
the earth's protective Ozone (O
3
) layer in the outer
stratosphere. Chloro-flouro-carbon compounds
(CFC's), such as R-12 refrigerant (Freon
), com-
monly used in mobile equipment air conditioning sys-
tems, has been identified as a possible contributing
factor to the Ozone depletion.
Consequently, legislative bodies in more than 130
countries have mandated that the production and
distribution of R-12 refrigerant be discontinued after
1995. In addition, the practice of releasing refrigerant
to the atmosphere during the charging/recharging
procedure is now prohibited.
FIGURE 9-1. BASIC AIR CONDITIONING SYSTEM (TYPICAL)
1. Blower Switch
2. Thermostatic Switch
3. Battery Supply
4. Circuit Breaker
5. Blower
6. Temperature Sensor
91.Evaporator
2. Expansion Valve
3. Suction Line
10. Test Gauges &
Manifold
11. Compressor
12. Refrigerant Container
13. Magnetic Clutch
14. Compressor
Drive Pulley
15. Receiver/Drier
16. Discharge Line
17. Condenser
M9-2 Air Conditioning System M09003 11/95
for R-12 Refrigerant
These new restrictions require the use of new equip-
ment and new procedures which are significantly dif-
ferent from those traditionally used in air conditioning
service techniques. The use of new equipment and
techniques permits the complete recovery of refriger-
ant, which will not only help to protect the environ-
ment, but through the re-cycling of the refrigerant,
will preserve the physical supply as well as help to
reduce the cost of the refrigerant.
OPERATOR CAB AIR CONDITIONING
Mining and construction vehicles have unique char-
acteristics of vibration, shock-loading, operator
changes, and climate conditions that present differ-
ent design and installation problems for Air Condi-
tioning systems. Off-highway equipment, in general,
is unique enough that normal automotive or highway
truck engineering is not sufficient to provide the reli-
ability to endure the various work cycles encoun-
tered.
Air conditioning is a form of environmental control. As
applied to the cab, it refers to the control of tempera-
ture, humidity, cleanliness, and circulation of air. In
the broad sense, a heating unit is as much an air
conditioner as is a cooling unit. The term Air Condi-
tioner is commonly used to identify an air cooling
unit. To be consistent with common usage, the term
Air Conditioner will refer to the cooling unit utilizing
the principles of refrigeration; sometimes referred to
as the evaporator unit.
The cab tightness, insulation, and isolation from heat
sources is very important to the efficiency of the sys-
tem. It is advisable to close all vents, even the
intakes of pressurization systems, when there are
high humidity conditions.
The general cleanliness of the system and compo-
nents is important. Dust or dirt collected in the con-
denser, evaporator, or air filters decreases the
system's cooling capacity.
The refrigerant pump (compressor), condenser,
evaporator units, hoses and fittings must be installed
clean and tight and be capable of withstanding the
strain and abuse they are subjected to from off-high-
way vehicles.
Equipment downtime costs are high enough to
encourage service areas to perform preventive main-
tenance at regular intervals on vehicle air-condition-
ing systems. (Cleaning, checking belt tightness, and
operation of electrical components).
PRINCIPLES OF REFRIGERATION
A review of the principles of air conditioning will
relate the function of the components, the technique
of trouble shooting and the corrective action neces-
sary to keep the A/C unit into top operating efficiency.
Too frequently, the operator and the serviceman
overlook the primary fact that no A/C system will
function properly unless it is operated within a com-
pletely controlled cab environment. The circulation of
air must be a directed flow. The cab must be sealed
against seepage of ambient air. The cab interior must
be maintained for cleanliness, dust, and dirt which, if
picked up in the air system, will clog the intake side of
the evaporator coil.
Refrigeration - The Act Of Cooling
There is no process for producing cold; there is
only heat removal.
Heat is always drawn toward cold objects. This
principle is the basis for the operation of a cooling
unit. As long as one object has a temperature
lower than another, this heat transfer will occur.
Temperature is the measurement of the intensity
of heat in degrees. The most common measuring
device is the thermometer.
All objects have a point at which they will turn to
vapor. Water boiling is the most common
example of heating until vapor is formed. Boiling
is a rapid form of evaporation. Steam is a great
deal hotter than boiling water. The water will not
increase in temperature once brought to a boil.
The heat energy is used in the vaporization
process. The boiling point of a liquid is directly
affected by pressure. By changing pressure, we
can control the boiling point and temperature at
which a vapor will condense. When a liquid is
heated and vaporizes, the gas will absorb heat
without changing pressure. This gas is in a
superheated condition.
Reversing the process, when heat is removed
from water vapor, it will return to the liquid state.
Heat from air is attracted to a cooler object.
Usually the moisture in the cooled air will
condense on the cooler object.
Refrigerant: Only R-12 refrigerant should be used
in mobile systems designed for R-12.
Do not mix refrigerants! Damage to
equipment and components will result!
M09003 11/95 Air Conditioning System M9-3
for R-12 Refrigerant
R-12 refrigerant has a boiling point of -21F
(atmospheric pressure). If released in a room, it
would absorb heat from the air and immediately
vaporize. R-12, because of its low boiling point,
has a great capacity for heat absorption.
The Refrigeration Cycle
In an air conditioning system, the refrigerant is circu-
lated under pressure through the five major compo-
nents in a closed circuit. At these points in the
system, the refrigerant undergoes predetermined
pressure and temperature changes.
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.
Ambient air, passing through the condenser removes
the heat from the circulating refrigerant resulting in
the conversion of the refrigerant from gas to liquid.
The liquid refrigerant moves on to the filter-receiver
drier where impurities are filtered out, and moisture
removed. This component also serves as the tempo-
rary storage unit for the liquid refrigerant.
The liquid refrigerant, still under high pressure, then
flows to the expansion valve. This valve meters the
amount of refrigerant entering the evaporator. As the
refrigerant passes through the valve, it becomes a
low temperature, low pressure liquid and saturated
vapor.
The remaining low pressure liquid immediately starts
to boil and vaporize as it approaches the evaporator,
causing it to become cold. The hot, humid air of the
cab is pulled through the evaporator by the evapora-
tor blower. Since the refrigerant is colder than the air,
it absorbs the heat from the air producing cool air
which is pushed back into the cab. The moisture in
the air condenses upon movement into the evapora-
tor and drops into the drain pan from which it drains
out of the cab.
The cycle is completed when the heated low pres-
sure gas is again drawn into the compressor through
the suction side.
This simplified explanation of the principles of refrig-
eration does not call attention to the fine points of
refrigeration technology and the design of air condi-
tioning systems. Some of these will be covered in the
following discussion of the components, controls,
and techniques involved in preparing the unit for effi-
cient operation.
AIR CONDITIONER SYSTEM
COMPONENTS
Compressor (Refrigerant Pump)
The compressor separates the low pressure and the
high pressure sides of the system. It concentrates
the refrigerant returning from the evaporator (low
side) creating a temperature much higher than the
outside air temperature. The high temperature differ-
ential between the refrigerant and the outside air is
necessary to aid rapid heat flow in the condenser
from the hot refrigerant gas to much cooler outside
air.
To create high pressure concentration, the compres-
sor draws in refrigerant through the suction valve and
forces it out through the discharge valve. During the
suction part of the cycle, the reed valve is opened to
allow low pressure gas to enter. During discharge,
refrigerant is forced through the discharge valve.
The compressor is driven by the engine through a v-
belt driving an electrically operated clutch mounted
on the compressor drive shaft.
Service Valves
Service valves are provided for servicing the unit. A
manifold gauge set is connected into the system at
the service valve ports and all procedures, such as
discharging, evacuating and charging the system,
are performed through the service valves.
Condenser
The condenser receives the high pressure, high-tem-
perature refrigerant vapor from the compressor and
condenses it to high pressure, hot liquid.
It is designed to allow heat movement from the hot
refrigerant vapor to the cooler outside air. The cool-
ing of the refrigerant changes the vapor to liquid.
Heat exchange is accomplished using cooler air flow-
ing through the condenser. The condenser can be
cooled with ram air provided by vehicle movement
and sometimes aided by electric or hydraulic fans or
by using the air movement provided by the radiator
fan.
Ram air condensers depend upon the vehicle move-
ment to force a large volume of air past the fins and
tubes of the condenser. The condenser is usually
located in front of the radiator or on the roof of the
truck. Refrigerant temperature in the condenser var-
ies from 120
to 170
F (49
to 77
C) with pressure
ranging from 150 to 300 psi. (27 to 54 kg/cm).
M9-4 Air Conditioning System M09003 11/95
for R-12 Refrigerant
Condensing of the refrigerant is the change of state
of the refrigerant from a vapor to a liquid. The action
is affected by the pressure of the refrigerant in the
coil and air flow through the condenser. Condensing
pressure in an A/C system is the controlled pressure
of the refrigerant which affects the temperature at
which it condenses to liquid, giving off large quanti-
ties of heat in the process. The condensing point is
sufficiently high to create a wide temperature differ-
ential between the hot refrigerant vapor and the air
passing over the condenser fins and tubes. This dif-
ference permits rapid heat transfer from the refriger-
ant to ambient air.
Filter Receiver-drier
The receiver-drier is an important part of the air con-
ditioning system. The drier receives the liquid refrig-
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
designed to store extra refrigerant until it is needed
by the evaporator. The storage of this refrigerant is
temporary and is dependent on the demand of the
expansion valve.
A desiccant is a solid substance capable of removing
moisture from gas, liquid or solid. It is held in place
within the receiver between two screens, which also
act as strainers. Sometimes it is simply placed in a
metal mesh or wool felt bag. Filtering is accom-
plished by a separate strainer screen on the pickup
tube.
Some systems may utilize an accumulator instead of
a receiver-drier. If an accumulator is used, an expan-
sion (fixed-orifice) tube is used instead of the thermo-
static expansion valve described below. When used,
the expansion tube is located inside the inlet tube of
the evaporator and is used to restrict, but still allow a
continuous flow of refrigerant to the evaporator coil.
Fusible Pressure Relief Plug
Some receiver driers have a fusible plug which melts
between 218
- 230
F (103
- 110
F (3
F (88
F
(111
F (88
F (66
C).
Refrigerant Loss (Low Pressure) Switch
The refrigerant loss switch prevents the clutch from
engaging in the event the system loses its refrigerant
charge, or if the refrigerant pressure drops below 5
psi (0.89 Kg /cm).This is a simple breaker-type
switch at 5 psi (0.89 Kg/cm).
M09003 11/95 Air Conditioning System M9-7
for R-12 Refrigerant
SYSTEM SERVICING
Servicing an air conditioning system really means
closely monitoring refrigerant flow. For this reason,
the following procedures deal extensively with the
proper use, handling, care and safety factors
involved in the refrigerant quality and quantity in an
air conditioning system.
Because the refrigerant in an air conditioning system
must remain pressurized and sealed within the unit to
function properly, safety is a major consideration
when anything causes this pressurized, sealed con-
dition to change. The following warnings are pro-
vided here to alert you to their importance BEFORE
you begin learning the correct procedures. Read,
remember, and observe each warning as you begin
actual system servicing.
NOTE: If the mine operates a fleet with some trucks
using R-12 and others using the new R-134a
refrigerant, it is essential that servicing tools (gauge
sets, charging equipment, recovery/recycle
equipment etc.) be dedicated to one type refrigerant
only to prevent cross contamination.
Federal regulations prohibit venting R-12 or other
refrigerants into the atmosphere. An SAE and UL
approved recovery/recycle station must be used
to remove refrigerant from the AC system.
Although accidental release of refrigerant is a
remote possibility when correct service proce-
dures are followed, the following warnings must
be observed when servicing AC systems:
Provide appropriate protection for your eyes
(goggles or face shield) when working around air
conditioning refrigerant.
Because R-12 refrigerant boils at a normal sea
level temperature of -21.6
F (-30
F (49
C).
Do not flush or pressure test the system using
shop air or other compressed air sources. Shop
air supplies contain moisture and other contami-
nants that could damage system components.
R-12 Containers
Two basic, readily available containers are used to
store R-12 refrigerant: the 30 or 60 pound bulk canis-
ters (Figure 9-2).
Always read the container label to verify the contents
are correct for the system being serviced. R-12 and
R-134a refrigerants must not be mixed.
FIGURE 9-2. REFRIGERANT CONTAINERS
1. 30 Pound Cylinder 2. 60 Pound Cylinder
M9-8 Air Conditioning System M09003 11/95
for R-12 Refrigerant
SERVICE TOOLS AND EQUIPMENT
Recovery/recycle Station
Whenever refrigerant must be removed from the sys-
tem, a dual purpose station (Figure 9-3) performs
both recovery and recycle procedures which follows
the new guidelines for handling used refrigerant. The
recovered refrigerant can then be recycled to reduce
contaminants, and reused in the same machine or
fleet.
NOTE: To be re-sold, the gas must be re-claimed
which leaves it as pure as new, but requires
equipment normally too expensive for all but the
largest refrigeration shops.
Equipment is also available to just remove or extract
the refrigerant. Extraction equipment does not clean
the refrigerant. It is used to recover the refrigerant
from an AC system prior to servicing.
To accomplish this, the recovery/recycle station sep-
arates the oil from the refrigerant and filters the
refrigerant multiple times to reduce moisture, acidity,
and particulate matter found in a used refrigerant.
Mixing different types of refrigerant will damage
equipment. Dedicate one recovery/recycle sta-
tion to each type of refrigerant processing to
avoid equipment damage.
Disposal of the gas removed requires laboratory
or manufacturing facilities.
Recycle equipment must meet certain standards as
published by the Society of Automotive Engineers
and carry a UL approved label. The basic principals
of operation remain the same for all machines, even
if the details of operation differ somewhat.
Leak Detector
Two basic types of leak detectors are used on air
conditioning systems today to locate suspected
leaks. The propane, or halide type detector (Figure 9-
4) uses a flame which changes colors (from pale blue
- normal to purple/blue/violet for a large leak to light
green/yellow for a small leak) to successfully detect
leaks.
The halide type consists of a hose for leak searching,
a burner, tank, and a control valve. Safety is a vital
concern with this type, as the fumes can be poison-
ous. Refer to WARNING on page M9-7.
FIGURE 9-3 RECYCLE/RECOVERY UNIT
FIGURE 9-4 HALIDE (PROPANE) LEAK
DETECTOR
1. Burner
2. Search Hose
3. Cylinder
4. Shut-off Valve
M09003 11/95 Air Conditioning System M9-9
for R-12 Refrigerant
One of the most common types is the electronic
detector (Figure 9-5) which tends to be safer and
more accurate. It is a small hand-held device with a
flexible probe used to seek leaks. A buzzer, alarm or
light will announce the presence of even the smallest
leak.
Note that electronic leak detectors are available for
use only with R-12 or only with R-134a, while other
models are suitable for use with either.
Vacuum Pump
The vacuum pump is used to completely evacuate all
refrigerant, air, and moisture from the system by
deliberately lowering the pressure within the system
to the point where water turns to a vapor (boils) and
together with all air and refrigerant is withdrawn
(pumped) from the system. Normally the vacuum
pump is only used when a system has completely
lost its charge of refrigerant.
FIGURE 9-5 TYPICAL ELECTRONIC LEAK
DETECTOR
FIGURE 9-6 TYPICAL VACUUM PUMP
M9-10 Air Conditioning System M09003 11/95
for R-12 Refrigerant
SERVICE VALVES
Because an air conditioning system is a sealed sys-
tem, two service valves are provided on the compres-
sor 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 performed.
Air conditioning systems designed for R-134a
refrigerant are equipped with a different type ser-
vice valve designed to prevent accidental use of
R-12 in the system. Be certain the servicing
equipment is compatible with R-12 refrigerant.
Stem Type
Service valves may be one of two types. The stem
type valve (Figure 9-7) is capable of being placed in
three positions: front seat; intermediate (mid); and
back seat. Each position represents a specific func-
tion desired when testing the system.
Schrader Type
The Schrader type service valve (Figure 9-8), similar
in appearance and function to the valve in a truck tire
(the rubber compound and spring pressures being
quite different) is becoming more common due to its
capacity for easier accessibility. The Schrader valve
can be mounted almost anywhere in the system. Two
positions are possible with this valve: Closed and
Open, each serves a specific function during testing.
Protective caps are provided for each service valve
when not being used for servicing purposes. These
caps must be kept on each valve to prevent contami-
nation or damage to the valve core.
FIGURE 9-7 STEM TYPE SERVICE VALVE
FIGURE 9-8
M09003 11/95 Air Conditioning System M9-11
for R-12 Refrigerant
MANIFOLD GAUGE SET
The manifold gauge set consists of a manifold with
two screw-type hand valves, one for low side and
one for the high side of an air conditioning system,
located at each end of the manifold (Figure 9-9).
Three fittings are provided between these two
valves. The first fitting connects the low side hose to
the suction side of the compressor or the evaporator
outlet. The second (center) fitting is provided to con-
nect to the servicing canister to charge the system or
for other service procedures. The third fitting con-
nects to the system high side (discharge) hose lead-
ing from the compressor. Shut-off valves are required
within 12 in. of the hose ends to minimize refrigerant
loss.
Low Side Gauge
The Low Side Gauge, registers both vacuum and
pressure. The vacuum side of the scale is calibrated
from 0 to 30 inches of mercury (in. Hg). The pressure
side of the scale is calibrated to 150 psi, however,
normal pressures seldom exceed 75 - 80 psi.
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, though normal
pressures are usually 300 psi or less.
Installing Manifold Gauge Set
Before attempting to service the air conditioning sys-
tem, a visual inspection of both the engine and sys-
tem components is recommended. Particular
attention should be paid to the belts, hoses, tubing
and all attaching hardware plus the radiator cap, fan
clutch, and thermostat. Inspect both the condenser
and the radiator for any obstructions or potential con-
tamination. Minimize all the possibilities for error or
malfunction of components in the air conditioning
system.
Shut off engine. DO NOT attempt to connect ser-
vicing equipment when the engine is running.
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
tightness.
3. Locate the low and high side system service fit-
tings, clean and remove their protective caps.
(See Figure 9-10)
4. Connect the two service hoses from the mani-
fold to the correct service valves on the com-
pressor. (High side to compressor discharge
valve and low side to compressor suction side.)
The gauge hook-up process will be the same,
regardless of the gauge set being installed. Whether
it is a recovery station or individual gauges, the con-
nections are the same. The procedures performed
next will vary depending on what type of equipment
is being used. If a recovery/recycling station is being
used, complete servicing can be accomplished.
Using only a set of gauges will limit the servicing to
adding refrigerant or observing pressures.
FIGURE 9-9 MANIFOLD GAUGE SET
M9-12 Air Conditioning System M09003 11/95
for R-12 Refrigerant
Purging Air From Service Hoses
The purpose of this procedure is to remove all the air
trapped in the hoses prior to actual system testing.
Environmental regulations require that all service
hoses have a shutoff valve within 12 in. of the service
end. These valves are required to ensure only a min-
imal amount of refrigerant is lost to the atmosphere.
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, purging of the system can begin. (See Fig.
9-11.)
The manifold valves should be closed. Activating the
vacuum pump will now evacuate any air or moisture
out of the center hose. This will require only a few
minutes of time as the hose is the only component
being placed in a vacuum. Closing the valve will then
insure the hose is purged. It is now safe to open the
other manifold valves.
FIGURE 9-10 SERVICE HOSE HOOK-UP
FIGURE 9-11 PURGING SYSTEM
M09003 11/95 Air Conditioning System M9-13
for R-12 Refrigerant
Adding Refrigerant to the System
(without a charging station)
After determining that the system is low and addi-
tional refrigerant is required, perform the following:
1. Connect the center hose from the manifold
gauge set to the refrigerant dispensing valve on
the container as shown in Figure 9-12.
2. Start the engine and set the idle at 1200 to 1500
RPM and then turn on the air conditioning.
3. Open the refrigerant dispensing valve on the
container and then the low pressure hand valve
on the manifold. This will allow the refrigerant to
enter the system as a gas on the low pressure
or suction side of the compressor. The com-
pressor will pull refrigerant into the system.
4. Continue adding refrigerant until the gauge
reads in the normal range and/or the sight glass
(if equipped) is clear. The sight glass may not
be clear for a moment just before or after the
clutch cycles on and off, but should generally be
clear. Gauge readings will fluctuate as the com-
pressor cycles on and off.
Pressures within the air conditioning system
vary with ambient temperature. A normal pres-
sure range is defined as follows:
Low side - 15 - 30 PSI
High side - 150 - 280 PSI
5. When the gauges show a normal reading and/
or the sight glass (if equipped) is clear, close the
hand valve on the refrigerant container.
FIGURE 9-12 TYPICAL CANISTER HOOKUP
1. Gauge Manifold
2. Low Side Hand Valve
3. High Side Hand Valve
4. High Side Service Valve
5. Low Side Service Valve
6. Service Hose
7. Refrigerant Charging Container
8. Shut-Off Valves
9. Compressor
M9-14 Air Conditioning System M09003 11/95
for R-12 Refrigerant
Stabilizing the AC System
Operating the system at full cooling capacity for a few
minutes after purging ensures that temperatures and
pressures within the system will stabilize, allowing
system testing.
During this stabilization period, do not open
hand valves on manifold for any reason. Equip-
ment damage and personal injury may result.
1. Leave test equipment attached to the system
but ensure it is clear of any moving compo-
nents.
2. Start engine. Allow to operate approximately
1200 - 1500 RPM.
3. Set air conditioning system to maximum cooling
capacity (blower at full speed, temperature set-
ting at coldest point).
4. Open all truck windows and doors briefly to
exhaust any buildup heat in cab. Close windows
and doors.
5. Allow to operate in this manner for a minimum
of five minutes. System should stabilize.
NOTE: If necessary, provide a fan in front of
condenser coils large enough to develop air flow
comparable to normal ram air.
6. Place a thermometer in the air conditioning vent
closest to the evaporator. Wait five minutes to
establish that thermometer reflects tempera-
ture inside cab, then check thermometer. At out-
side ambient temperature of 80
to 100
F,
reading should be between 38
and 45
F.
7. Check sight glass; bubbles may indicate system
is low on refrigerant.
NOTE: If low refrigerant is indicated by lower than
normal pressure readings and bubbles in sight glass,
add refrigerant to enable adequate system testing
Adding Refrigerant and Stabilizing the System
(with a recovery/recycling station)
When using a recovery/recycling station, the proce-
dure is the same as previously described. The differ-
ence is that instead of just opening the refrigerant
container, the refrigerant should be added 0.5 to 1
pound at a time. After each instance of adding the
refrigerant, pause long enough to observe the gauge
reading and/or the sight glass (if equipped) to deter-
mine if the system is full. Use the pressures listed on
the previous page.
Do not open high side hand valve. High side sys-
tem pressure is greater than refrigerant con-
tainer. Serious personal injury may result if the
container explodes.
Use hand valve to regulate low side reading dur-
ing charging. DO NOT EXCEED 40 psi maximum.
Exceeding this pressure may cause compressor
failure.
RECOVERING AND RECYCLING THE
REFRIGERANT
Draining the Oil from the Previous Recovery Cycle
1. Place the power switch and the controller on the
recovery unit in the OFF position.
2. Plug in the recovery station to the correct power
source.
3. Drain the recovered oil through the valve
marked OIL DRAIN on the front of the machine.
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 5 psi and 10 psi,
switch the controller ON and OFF again.
6. When the pressure reaches 5 to 10 psi open
the OIL DRAIN valve, collect oil in an appropri-
ate container, and dispose of container as indi-
cated by local, state or Federal Regulation.
THE OIL IS NOT REUSABLE, DUE TO CON-
TAMINANTS ABSORBED DURING ITS PREVI-
OUS USE.
M09003 11/95 Air Conditioning System M9-15
for R-12 Refrigerant
Performing the Recovery Cycle
1. Be certain the equipment being used is
designed for the refrigerant intended to be
recovered.
2. Observe the sight glass oil level. Having
drained it, it should be zero.
3. Check the cylinder refrigerant level before
beginning recovery to make sure you have
enough capacity.
4. Confirm that all shut-off valves are closed
before connecting to the AC system.
5. Attach the appropriate hoses to the system
being recovered.
6. Start the recovery process by operating the
equipment as per the manufacturer's instruc-
tions.
7. Continue extraction until a vacuum exists in the
AC system.
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.
9. Check the system pressure after the recovery
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
cycle should continue until the system is void of
refrigerant.
10. Check the sight glass oil level to determine the
amount of oil that needs to be replaced. (The
amount of oil that was lost during the recovery
cycle must be replaced back into the system).
11. Mark the cylinder with a RECOVERED (red)
magnetic label to reduce the chance of charging
a system with contaminated refrigerant. Keep a
record of the amount of refrigerant recovered, if
possible.
Performing the Recycling Procedure
The recovered refrigerant contained in the cylinder
must undergo the recycle procedure before it can be
reused. The recycle or clean mode is a continuous
loop design and cleans the refrigerant rapidly. Follow
equipment manufacturer's instructions for this proce-
dure.
Evacuating and Charging the AC System
Evacuate the system once the air conditioner compo-
nents are repaired or replacement parts are secured,
and the AC system is reassembled. Evacuation
removes air and moisture from the system. Then, the
AC system is ready for the charging process, which
adds new refrigerant to the system.
Evacuating the System
1. Attach the high and low side hoses to the
appropriate connections.
2. Start the vacuum pump and run it for five min-
utes.
3. Check the gauge readings for five minutes. If
the gauge needle moves up, the system is not
sealed. The vacuum that was just created did
not hold, air and moisture are being sucked into
the system by that same vacuum.
4. Tighten any loose connections. Re-start the
pump, and open the hand valves on the gauges
again. Repeat the vacuum test.
5. If the leak has been repaired, run the vacuum
pump for at least an hour to remove any mois-
ture from the system.
The moisture must turn to gas before the pump can
pull it out. The moisture takes time to boil away, so
that it can be drawn out of the system. The vacuum
pump can draw most of the air out quickly, but a deep
vacuum requires more time; the deeper the vacuum,
the more time required.
Charging the AC System
When adding a full charge of refrigerant, it is possible
to put it in as a gas or as a liquid. Adding refrigerant
as a liquid is faster but can damage the compressor if
not done correctly. The procedure used, and where
the refrigerant is added in the AC system makes a
difference. When using refrigerant as a liquid, never
add more than two thirds of system requirements as
a liquid. Finish charging the system using gas.
M9-16 Air Conditioning System M09003 11/95
for R-12 Refrigerant
SYSTEM PERFORMANCE TEST
This test is performed to establish the condition of all
components in the system. Observe these conditions
during testing:
1. Start engine and operate at 1200 - 1500 RPM.
2. Place fan in front of condenser to simulate nor-
mal ram air flow and allow system to stabilize.
3. Place a thermometer in air conditioning vent
closest to evaporator.
4. Evaluate the readings obtained from the
gauges against those in Figure 9-19. In addi-
tion, consult each applicable diagnosis situa-
tion in this section.
As preliminary steps to begin checkout of the system,
perform the following:
1. Close all windows and doors in the cab.
2. Set air conditioning system at maximum cooling
and blower to high speed operation.
3. Read indication on the two manifold gauges.
Readings should be within normal range,
adjusted for current ambient temperature.
4. Observe sight glass. It should be clear of bub-
bles.
5. Compare evaporator discharge air temperature
reading against specifications shown in Figure
9-19.
6. Carefully feel the hoses and components on the
high side. All should be warm-hot to the touch.
Check the inlet and outlet of receiver-drier for
even temperatures, if outlet is cooler than inlet,
a restriction is indicated.
7. Feel the hoses and components on the low
side. They should be cool to the touch. Check
connections near the expansion valve, inlet side
should be warm and cold-cool on the outlet
side.
8. Check the operation of the temperature control
switch to ensure the compressor drive clutch
engages and disengages. A 5
_
10
F evaporator
air temperature rise between the cut-off and
cut-in points of control switch is not uncommon.
9. If these conditions are met, the system is con-
sidered normal. Shut down engine. Backseat
service valves, if used. Remove gauges and
install the caps on the service valves.
10. If conditions are not met, refer to Diagnosis
section.
SYSTEM LEAK TESTING
Refrigerant leaks are probably the most common
cause of air conditioning problems, resulting in inad-
equate or no cooling, to major internal component
damage. Leaks most commonly develop in two or
three places. The first is around the compressor shaft
seal, often accompanied by an indication of fresh
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
traces of oil. (The R-12 itself is invisible, odorless,
and leaves no trace when it leaks, but has a great
affinity for refrigerant oil.)
A second common place for leaks is the nylon or rub-
ber 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
evaporator, particularly near the drain hole for the
condensate will quickly indicate the condition of the
evaporator. Any trace of fresh oil here is a clear indi-
cation of a leak.
To locate a leak, four common types of leak detectors
are used. Usually, a 50% charged system is enough
to find most leaks. If the system is empty, connect the
manifold gauge set to the system and charge at least
one (1) lb. of refrigerant into the system.
Use extreme caution leak testing a system while
the engine is running. Stay clear of all moving
components, and don't allow high side pressure
to exceed 300 psi.
In its natural state, R-12 refrigerant is a harmless,
colorless gas, but when combined with an open
flame, it will generate toxic fumes (phosgene
gas), which can cause serious injuries or death.
When using a halide torch for detecting air condi-
tioning system leaks, always insure that the area
is adequately ventilated. Do not breathe fumes
from the torch and keep flames away from flam-
mable material.
NOTE: R-12 refrigerant is heavier than air and will
move downward when it leaks. Apply pickup hose or
test probe on the undersurface of all components to
locate leak.
M09003 11/95 Air Conditioning System M9-17
for R-12 Refrigerant
Electronic leak detector
(Refer to Figure 9-5). As the test probe is moved into
an area where traces of R-12 are present, a visual or
audible announcement indicates a leak. Audible units
usually change tone or speed as intensity changes.
Halide (propane) Torch
1. Light the torch (Figure 9-4) by opening the pro-
pane can and igniting the flame; carefully adjust
the flame to a height sufficient to heat the reac-
tion plate to a cherry red color.
2. As plate turns red, adjust flame to a height
slightly above the plate and high enough to sus-
tain the cherry red color.
Too high a flame will overheat and destroy the
reaction plate.
3. Slowly and carefully move the pickup hose
around the various components of the system.
Don't rush testing as R-12 must travel length of
hose to reach flame.
4. Observe the flame for any noticeable change in
color.
Tracer dyes
Tracer dyes are available that can be added to the
system as R-12 is added. The system is then oper-
ated to thoroughly circulate the dye. As R-12
escapes, it leaves a trace of the dye at the point of
leakage, which is then detected using an ultraviolet
light, revealing a bright fluorescent glow.
Soap and water
Soap and water can be mixed together and applied
to system components. Bubbles will appear to pin-
point the specific location of leaks.
After determining the location or source of leak(s),
repair or replace leaking component(s).
Engine must not be running during this proce-
dure. Supply adequate ventilation and extinguish
any nearby flame sources.
FLUSHING AIR CONDITIONER COMPO-
NENTS
The flushing process is used to remove contaminants
from hoses, lines and some of the other system com-
ponents. DO NOT flush the compressor, expansion
valve or metering device or screens. These are
bench checked, cleaned and repaired or replaced. A
receiver-drier, accumulator, expansion valve and
tube are never flushed, they are replaced. When you
disassemble and flush components and hoses
(lines), it is best to REVERSE FLUSH. Flush in the
opposite direction of R-12 flow. Flush the system
using R-11 or R-13 or other commercial solvent sold
for that purpose. Figure 9-13 illustrates the use of a
flushing kit.
Always wear protective goggles and provide ade-
quate ventilation when flushing components.
Never use R-12 as a flushing agent.
When opening the AC system, plug any open lines
except when flushing. Fill the cylinder of the flushing
gun with solvent. Insert the rubber gun probe into the
outlet of each component and dispense solvent
(reverse flush). Unless there is a serious blockage,
the solvent will appear at the other end of the compo-
nents. Flush the next component in turn until all parts
are flushed.
FIGURE 9-13 FLUSHING COMPONENTS
M9-18 Air Conditioning System M09003 11/95
for R-12 Refrigerant
Allow solvent to evaporate completely (about 30 min-
utes) and then assemble the system replacing parts
where necessary.
NOTE: The length of the hose will affect the
refrigerant capacity. When replacing hoses, always
use the same hose length, if possible. Always
replace the receiver-drier when assembling the AC
system after flushing.
Before system assembly, check the compressor
oil level and fill to manufacturer specifications.
SYSTEM REPAIR
The following service and repair procedures are not
any different than typical vehicle service work. How-
ever, AC system components are made of soft met-
als (copper, aluminum, brass, etc.). Comments and
tips that follow will make the job easier and reduce
unnecessary component replacement.
All of the service procedures described are only
performed after the system has been discharged.
Never use regular shop oil or joint compound to
lubricate or seal any AC connections.
NOTE: To help prevent air, moisture or debris from
entering an open system, cap or plug open lines,
fittings or components as soon as they are
disconnected. Keep all connections clean (also caps
and plugs used) so debris can't enter accidentally. As
a general rule, replace any gaskets and O-rings with
new ones. Use fresh refrigeration oil to lubricate
connections, gaskets and O-rings.
Hoses and Fittings
When replacing hoses, be sure to use the same type
and ID hose you removed. After lubricating the hose
and fitting, slide the hose over the fitting. The hose
clamp should be on the hose before it is pushed onto
the fitting and seated. The hose should be fully
seated or pushed in to a locating bead if present.
When hoses or fittings are shielded or clamped to
prevent vibration damage, be sure these are in posi-
tion or secured.
Lines
Always use two wrenches when disconnecting or
connecting AC fittings attached to metal lines. You
are working with copper and aluminum tubing which
can kink or break easily. Tube O-ring type fittings
require only 18 ft. lbs. (24.4 N.m) of torque for cor-
rect sealing. When grommets or clamps are used to
prevent line vibration, be certain these are in place
and secured.
M09003 11/95 Air Conditioning System M9-19
for R-12 Refrigerant
Expansion Valve
When removing the expansion valve from the sys-
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.
Receiver-Drier
The receiver-drier can not be serviced or repaired. It
should be replaced whenever the system is opened
for any service. If the receiver-drier has a pressure
switch to control the clutch, it should be removed and
installed on the new unit.
Thermostat
A thermostat can be stuck open or closed due to con-
tact point wear or fusion. The thermostat temperature
sensing element (capillary tube) may be broken or
kinked closed and therefore unable to sense evapo-
rator temperature.
When thermostat contact points are stuck open or
the sensing element can not sense temperature in
the evaporator, the clutch will not engage (no AC
system operation). Causes are a loss of charge in
the capillary tube or a kink, burned thermostat con-
tact or just no contact. A quick method of trouble-
shooting is to bypass the thermostat by hot wiring the
clutch coil with a fused lead. If the clutch engages,
replace the thermostat.
Thermostat contact points may be fused (burned)
closed and the clutch will not disengage. Causes are
a faulty switch that could be due to fatigue. The ther-
mostat must be replaced. When the clutch will not
disengage you may also note that condensate has
frozen on the evaporator fins and blocked air flow.
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 tends to accumu-
late at the coolest spot inside the system) and lower
than normal suction pressure that can starve the
compressor of oil.
Clutch
Clutch problems include electrical failure in the clutch
coil or lead wire, clutch pulley bearing failure, worn or
warped clutch plate or loss of clutch plate spring tem-
per. Defective clutch assembly parts may be
replaced or the whole assembly replaced. If the
clutch shows obvious signs of excessive heat dam-
age, replace the whole assembly.
The fast way to check electrical failure in the lead
wire or clutch coil is to hot wire the coil with a fused
lead. This procedure bypasses clutch circuit control
devices.
Clutch pulley bearing failure is indicated by bearing
noise when the AC system is off or the clutch is not
engaged. Premature bearing failure may be caused
by poor alignment of the clutch and clutch drive pul-
ley. Sometimes it may be necessary to use shims or
enlarge the slots in the compressor mounting bracket
to achieve proper alignment.
Excessive clutch plate wear is caused by the plate
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
gap between the clutch pulley and the clutch plate is
0.030 to 0.040 in., with 0.060 in. maximum. If the gap
is too wide, the magnetic field created when the
clutch coil is energized will not be strong enough to
pull and lock the clutch plate to the clutch pulley.
Compressor
The compressor can fail due to shaft seal leaks (no
R-12 in the system), defective valve plates, bearings,
other internal parts or problems associated with high
or low pressure, heat or lack of lubrication. Be sure
the compressor is securely mounted and the clutch
pulley is properly aligned with the drive pulley.
You may use a mechanics stethoscope to listen for
noises inside the compressor, loose wrist pins, piston
slap, noisy valves or bearings. Feel the compressor
body and note if the lower part of the crankcase is
extremely hot. This indicates the compressor is low
on or may be starved for oil. Compressor lockup is an
indication of a broken piston or connecting rod.
M9-20 Air Conditioning System M09003 11/95
for R-12 Refrigerant
CHECKING COMPRESSOR OIL LEVEL
Every air conditioning system and compressor
depends on refrigeration oil for lubrication and safe
operation.
Refrigerant oil, under normal circumstances inside
the sealed system, cannot go anywhere, and there is
no need to check the oil at such times. It is a highly
refined, pure mineral oil, containing no additives,
waxfree and contained in a dehydrated form. For this
reason, always keep a cap on an oil container except
when in use. Moisture is quickly absorbed by the oil.
Whenever a system is opened for service, the com-
pressor oil level should be checked and clean refrig-
eration oil added as required by the manufacturer's
specifications (usually located on compressor).
York Compressor Oil Level Check
(2 cylinder model)
NOTE: The York compressor need not be removed
from the system to be checked. If system has been
discharged, steps 1 through 3 will not apply.
1. Run compressor for 10 to 15 minutes to allow
oil to thoroughly circulate through the system.
Stop engine.
2. Connect manifold gage set to compressor ser-
vice valves.
3. Refer to Performing the Recovery Cycle.
4. Unscrew oil check plug five full turns to bleed off
remaining pressure until gauge reads 0.
NOTE: Suction pressure may rise slowly to 5 psi
gauge pressure after both valves are closed.
5. Remove oil check plug and O-ring to check oil
level with dipstick. (See Figure 9-14 for details
and Figure 9-15 for location.)
6. Check the findings against the values in the
table in Figure 9-14.
7. If necessary to add oil, add only the type speci-
fied by the system manufacturer (never more
than 10 ounces).
8. Slip the O-ring over the oil fill plug threads,
being careful not to twist the O-ring. Insert oil
plug in oil filler opening and snug-tighten.
Sanden Compressor Oil Level Check
(5-Cylinder)
NOTE: This check can be better performed with the
compressor out of the system and on the bench. If
system has been discharged, steps 1 and 2 will not
apply.
OIL CHARGE VS. DIPSTICK DEPTH
Oil Charge
Ounces 6 8 10 12 16
Horizontal
Mount
13/16 1 1-3/16 1-5/8 1-15/16
Vertical
Mount
7/8 1 1-1/8 1-7/16 1-7/8
FIGURE 9-14 OIL LEVEL CHECK
(York Compressor)
FIGURE 9-14. DIPSTICK DIMENSIONS & DETAILS
(2 Cylinder York)
M09003 11/95 Air Conditioning System M9-21
for R-12 Refrigerant
1. Run compressor for 10 minutes to allow oil to
thoroughly circulate through the system.
2. Stop engine; recover refrigerant.
3. Remove compressor from the system by loos-
ening mounting bolts and removing drive belt.
Place compressor on bench with oil fill plug at
top dead center.
4. Using an angle gage, determine the mounting
angle across the two mounting ears flat sur-
faces. After centering the bubble on the gage,
check the angle of mounting to the closest
degree.
5. Remove oil filler plug slowly to release pres-
sure. Using figure 9-16 as a guide, peer through
oil filler hole to rotate the clutch front plate to
place internal parts of compressor as shown in
illustration.
6. If the compressor is right-mounted (facing
clutch) (See Figure 9-17), position the parts as
though they were moving toward the rear of the
compressor (equal to the discharge stroke of
piston).
7. If the compressor is left-mounted (facing the
clutch) (See Figure 9-17), position the parts as
though they were moving to the front of the
compressor (equal to the suction stroke of pis-
ton).
NOTE: Either step will clear the path of internal parts
so as to allow dipstick insertion to its full depth.
8. Insert dipstick (Sanden p/n 32447) through oil
filler hole until stop point is reached. (See Fig-
ure 9-17). Use the following as a guide to deter-
mining the correct angle of the dipstick for each
type of mounting (right or left):
If mounting angle is to the RIGHT, point of
angle should be to LEFT.
If mounting angle is to the LEFT, point of
angle should be to RIGHT.
In both, bottom surface of angle must be
flush with surface of oil filler hole.
Remove the dipstick and count the increments of oil
(numbers on dipstick). (Refer to Figure 9-18 for cor-
rect mounting angle/oil level determination.)
10. Add or subtract oil to reach a mid-range of value
if the actual reading is not exactly on the dip-
stick increment.
Exercise care not to overtighten plug to stop a
leak in step 11. Remove plug instead and install
new O-ring.
11. Insert the oil filler plug, checking that O-ring is
not twisted. Torque the plug to 6 to 9 ft. lbs. (8 -
12 N.m).
FIGURE 9-15 LOCATING INTERNAL PARTS
FIGURE 9-16 MOUNTING ANGLE FOR DIPSTICK
INSERTION
M9-22 Air Conditioning System M09003 11/95
for R-12 Refrigerant
EVACUATING THE SYSTEM
Evacuating the complete air conditioning system is
required in all new system installation. Also, when
repairs are made on systems requiring a component
replacement (system opened) or a major loss of
refrigerant has occurred. All will require that a vac-
uum be pulled using a vacuum pump that completely
removes any moisture from the system. Once prop-
erly evacuated, the system can be recharged with
refrigerant 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 (212
F)
Low Side High Side
EVAPORATOR
OUTLET TEMP.
(F)
60 0-4 95-115
65 4-8 105-125
70 8-12 115-135
35-55
75 12-14 130-150
80 12-18 150-170
85 16-20 165-185
90 18-22 175-195
95 22-24 185-205
100 24-27 210-230
105 25-29 230-250
110 26-32 250-270
115 30-36 265-285
120 32-42 285-310
FIGURE 9-20. TEMPERATURE/PRESSURE RELATIONSHIP
NOTE: The pressures shown in this table are representative. They will vary depending upon system configuration,
components, and operating conditions. Evaporator outlet temperatures will vary depending upon thermometer
placement location, blower fan speed, and system conditions.
M09004 Heater/Air Conditioner Service M9-1
HEATER/AIR CONDITIONER SERVICE
COMPONENT SERVICE
When a component connected to the refrigerant cir-
cuit, other than the compressor head gasket, requires
replacement, the proper procedures must be followed
to release the refrigerant charge in the system before
removal of any hoses. After component replacement,
follow the procedure described under Evacuation and
Charging to remove the moisture from the system,
check for leaks, and to replace the refrigerant. Keep all
hoses and components capped to prevent entry of
moisture and foreign material during repair. If the com-
pressor head gasket is the only component to be
removed, adjust the service valves to the front seated
position as shown in Figure 9-5 in Air Conditioning
System. This position isolates the compressor from
the rest of the system and prevents loss of refrigerant.
To remove the refrigerant charge prior to removing any
other component or hose, follow the procedure below:
Refrigerant Discharge
1. Attach the gauge manifold to the compressor
service valves as shown in Figure 9-12 in Air
Conditioning System. Do not install a refriger-
ant container on the center hose.
2. Turn the gauge manifold valves fully clockwise
to the closed position.
3. Adjust the service valves to the mid position as
shown in Figure 9-5 in Air Conditioning Sys-
tem.
4. Connect the gauge manifold center hose to a
recovery/recycle station as shown in Air Condi-
tioning System to permit discharge of the refrig-
erant.
5. Slowly de-pressurize the system by opening the
low pressure valve a slight amount and allowing
the refrigerant to discharge slowly from the system.
FIGURE 9-1. AIR CONDITIONER COMPRESSOR MOUNTING
1. Compressor
2. Compressor Driven
Pulley and Clutch
3. Mounting Bracket
4. Shims
5. Low Pressure Inlet
Hose
6. High Pressure
Discharge Hose
7. Adjustment Locking
Capscrew
8. Engine Mount Bracket
9. Compressor Drive
Belt
10. Belt Tension Adjuster
11. J am Nut
M9-2 Heater/Air Conditioner Service M09004
6. After the system is nearly discharged, open the
high pressure valve very slowly and allow any
refrigerant remaining in the compressor and
high pressure line to discharge.
COMPRESSOR
A defective compressor will cause insufficient cooling
and/or loss of refrigerant. Refrigerant loss past the
head gaskets or shaft seal can easily be detected by
using a leak detector. If the manifold gauges indicate
high suction and low discharge pressures, the trou-
ble can probably be traced to a defective head gas-
ket or valve assembly in the compressor. Additional
compressor repair information can be found in Air
Conditioning System.
Cylinder Head (Gasket) Removal
1. Adjust the compressor service valves to the
front seated position.
2. Remove the cylinder head capscrews and lift
cylinder head off.
3. Inspect compressor and replace parts as
required.
Installation
1. Install new gasket and position cylinder head
over compressor.
2. Install capscrews.
3. Torque capscrews to proper torque and in the
correct sequence as recommended by the com-
pressor manufacturer.
Compressor Removal
1. Discharge refrigerant per instructions described
earlier.
2. Remove gauge manifold and refrigerant system
hoses and disconnect clutch wire from com-
pressor.
3. Remove hardware attaching compressor drive
belt guard and remove guard structure.
4. Loosen compressor mount pivot and belt
adjustment capscrews.
a. Loosen belt tension adjuster to relieve ten-
sion on belt.
b. Remove belt from compressor clutch
pulley.
5. Remove hardware loosened in step 4 and
remove compressor from the engine brackets.
Note position of any shims removed for pulley
alignment during reinstallation.
Installation
1. Align compressor with brackets on engine and
install attaching hardware.
2. Using a straight edge, check alignment of
engine drive pulley and compressor clutch
driven pulley. Shim if necessary for proper
alignment.
3. Install compressor drive belt and adjust belt ten-
sion adjuster to allow .50 in. (12.7 mm) maxi-
mum belt deflection measured at the middle of
the belt span. Tighten adjuster jam nut.
4. Tighten all compressor mounting hardware and
recheck belt tension.
5. Attach refrigerant system hoses and clutch
wire.
6. Install belt guard and verify proper clearance to
prevent contact with the belt or pulley.
7. Evacuate and recharge the system as
described in Air Conditioning System.
CONDENSER
A dirty or clogged condenser through which air flow is
restricted will cause high head pressure in the com-
pressor. The condenser usually may be cleaned by
using a fiber bristled brush and compressed air.
Extensive clogging may require use of soapy water
and brush wash and complete flushing with fresh
water to remove all foreign materials. If the condenser
has been damaged and is leaking, remove the con-
denser assembly and install a new component.
FIGURE 9-2. CONDENSER INSTALLATION
1. Outlet Hose
2. Inlet Hose
3. High Temperature
Switch
4. Mounting Hardware
M09004 Heater/Air Conditioner Service M9-3
Removal
1. Discharge system refrigerant as described ear-
lier.
2. Remove grille covering condenser assembly.
3. Loosen hose fittings at condenser hose inlet
and outlet bulkhead fittings. (Refer to Figure 9-
2.)
4. Disconnect wires attached to the high tempera-
ture switch (3)
5. Remove the six capscrews, washers, and nuts
attaching the condenser to the vertical mount-
ing brackets. Remove the condenser assembly.
6. Remove the short hoses connected to the coil
tubes for reuse if condition is acceptable.
Installation
1. Install new condenser assembly with hardware
removed above. Tighten to 65 ft. lbs (88.1 N-m)
torque.
2. Install inlet and outlet hoses.
3. Connect wires to high temperature switch.
4. Check system for leaks and evacuate and
recharge system as described in Air Condi-
tioning System.
5. Install grille over condenser assembly.
RECEIVER/DRYER
A dirty or restricted receiver/dryer will cause a sys-
tem malfunction and will be indicated by loss of cool-
ing, low suction and discharge pressures. When the
system is in operation, a defective receiver/dryer
may be detected by the outlet fitting being cooler
than the inlet fitting. Replace any unit which is sus-
pected of being restricted.
Removal
1. Discharge refrigerant from system.
2. Disconnect wires from low pressure switch.
3. Loosen and remove hoses at inlet and outlet
ports.
4. Remove clamps securing receiver/dryer to the
mounting brackets and remove assembly.
Installation
1. Attach receiver/dryer to shroud brackets with
mounting clamps.
2. Attach hoses at inlet and outlet ports.
3. Connect wires to the low pressure switch.
4. Check hose connections for leaks and evacuate
and recharge the system per instructions in Air
Conditioning System.
EVAPORATOR COIL, THERMOSTAT
SWITCH, AND EXPANSION VALVE
A dirty or plugged evaporator coil will restrict flow of
air and reduce cooling. Clean the coil in the same
manner as for the condenser coil. if ice forms on the
evaporator coil (restricting air flow) the thermostat
should be checked for serviceability and proper loca-
tion and mounting. A defective unit should be
replaced with a new component.
The thermostat switch controls the temperature of
the air entering the truck cab. If the unit is not cool-
ing, make sure the control lever is adjusted past the
OFF position. Also check that the switch capillary
tube is properly mounted in the evaporator coil fins. If
cooling still is not proper, perform the following
check:
1. Disconnect the thermostat leads and attach an
ohmmeter. There should be no continuity
between these terminals.
2. Rotate the thermostat arm towards the MAX
position and note the continuity. The resistance
value should change as the arm is moved. If
not, the thermostat switch must be replaced.
FIGURE 9-3. RECEIVER/DRYER INSTALLATION
1. Receiver/Dryer
2. Outlet Hose
3. Sight Glass
4. Low Pressure Switch
5. Inlet Hose
6. Radiator Shroud
M9-4 Heater/Air Conditioner Service M09004
EXPANSION VALVE
A faulty expansion valve could cause the evaporator
coil to be starved for, or flooded with refrigerant.
If the manifold gauge shows low suction pressure or
a vacuum, the evaporator coil is being starved of
refrigerant. To check the expansion valve, remove
the sensing bulb from the evaporator coil discharge
tube and warm it by holding it in your hand. If suction
pressure does not return to normal, the expansion
valve is probably defective and should be replaced.
Before replacing the expansion valve though, run
your hand the length of the tube between the con-
denser and the receiver/dryer, if the tube is warm
along its length the expansion valve definitely is
defective. If the receiver/dryer is cooler than the
hose, the receiver/dryer is restricted or defective and
should be replaced.
If the manifold gauge shows high suction pressure,
the evaporator coil is being flooded with refrigerant.
Check the sensing bulb to be sure it is rigidly con-
nected to the evaporator coil discharge tube and is
properly insulated. If the proper bulb mounting does
not correct the problem, the expansion valve is prob-
ably contaminated internally and should be replaced.
For a further check of the operation of the expansion
valve, insert the sensing bulb in a container of ice
water. If the suction pressure does not return to nor-
mal, replace the expansion valve.
Removal
Refer to Figures 9-4 and 9-5 for the following proce-
dure:
1. Discharge refrigerant from system as described
earlier.
FIGURE 9-4. EVAPORATOR COIL INSTALLATION
1. Cabinet
2. Blower Motor Assembly
3. Heater Core
4. Thermostat Switch
5. Evaporator Outlet
6. Extension Fitting
7. Expansion Valve
8. Capillary Tube
9. Evaporator Coil
M09004 Heater/Air Conditioner Service M9-5
2. Remove covers from heater/air conditioner cab-
inet (1, Figure 9-4) for access to components.
3. Remove hoses from expansion valve extension
(7) and evaporator coil outlet (5).
4. Remove heater hoses per instructions in Blower
Removal.
5. Remove thermostat control cable (1, Figure 9-
5) and wires from thermostat switch (3).
6. Loosen and remove thermostat mounting
screws.
Use extreme care in removing the thermostat
switch sensing capillary tube. If tube is damaged
or kinked, it must be replaced.
7. Carefully pull the end of the thermostat switch
capillary tube (8, Figure 9-4) from bottom of
evaporator coil (9) and bend and straighten just
enough to allow removal from top side of coil.
Remove thermostat switch and capillary tube.
8. Slide evaporator coil assembly out of heater/air
conditioner cabinet.
9. Remove insulating tape from expansion valve
and bulb.
10. Replace components as required.
Installation
1. Mount inlet extension (6, Figure 9-4) to expan-
sion valve (7), parallel to outlet tube (5).
2. Connect pressure equalizing capillary tube (5,
Figure 9-5) to outlet line.
3. Clamp the sensing bulb (4) to outlet manifold.
4. Wrap expansion valve and expansion valve
bulb with insulating tape to prevent condensa-
tion and freeze-up of valve.
5. Slide evaporator coil assembly into cabinet
bracket slots.
6. Feed thermostat switch capillary tube through
grommet in side of cabinet.
a. Route capillary tube above and to the center
of the evaporator coil.
b. Route tube down through the fins at a point 5
in. (127 mm) from the right side of the cabi-
net.
c. Bend the tube and route it horizontally and
insert tip up through evaporator lower sur-
face. (Refer to Figure 9-4.)
7. Reinstall cables, hoses and covers.
8. Check for leaks, evacuate and recharge the
system per instructions in Air Conditioning
System.
BLOWER MOTOR ASSEMBLY
The engine cooling system is pressurized by sys-
tem air pressure and by thermal expansion of
coolant during operation. DO NOT remove the
radiator cap while the engine is hot. Severe
scalding burns can result.
FIGURE 9-5. EVAPORATOR ASSEMBLY
COMPONENTS
1. Thermostat Control
Cable
2. Capillary Tube
3. Thermostat Switch
4. Sensing Bulb
5. Pressure Equalizing
Capillary Tube
6. Expansion Valve
M9-6 Heater/Air Conditioner Service M09004
Removal
1. Relieve radiator pressure by loosening the radi-
ator cap slowly.
2. To minimize spillage of antifreeze in the truck
cab, set the temperature control to OFF. Close
shut-off valve on engine block. Disconnect
heater hose from shut-off valve.
3. Remove access cover from outer right front of
the truck cab.
4. Loosen clamp securing heater return line (line
without valve) to heater core. Loosen line until it
starts to leak, then move temperature control
lever to ON position. Heater core will drain
through hose removed from the shut-off valve
on the engine block.
NOTE: Make certain return line loosened in Step 4 is
sucking air to prevent siphoning coolant from radiator
and engine.
FIGURE 9-6. HEATER/AIR CONDITIONER ASSEMBLY
1. Cover Assembly
2. Inlet Ring
3. Wheel
4. Housing (Right Side)
5. Blower Mounting
Bracket
6. Heater Core Support
7. Heater Core
8. Evaporator Coil
9. Cabinet
10. Damper Assembly
11. Evaporator Closeout
12. Thermostat Switch
13. Grommet
14. Grommet
15. Evaporator
Plate Assembly
16. Extension Tube
17. Expansion Valve
18. Heater Core
Connector
19. Housing (Left Side)
20. Gasket
21. Motor Assembly
M09004 Heater/Air Conditioner Service M9-7
5. Remove cover (1, Figure 9-6) from heater
assembly by removing two screws on each side
and two screws at lower front of the cover.
6. Remove both hoses and clamps from heater
core fittings.
7. Remove air conditioner thermostat switch (12,)
by removing two mounting screws and discon-
necting operating cable.
Use care removing upper screw from the thermo-
stat switch to prevent bending of capillary tube in
switch area. Bending or cracking of the capillary
tube will cause the sensing switch to be inopera-
tive.
8. Carefully pull capillary tube from unit.
9. Remove fittings from heater core (7).
10. Slide heater core from unit.
11. Disconnect electrical wiring from blower motor.
Wires are color coded for easy identification,
note the proper connection locations.
12. Remove motor blower assembly (2, Figure 9-4)
by removing mounting screws on each side of
cabinet (1). Inside the cabinet, raise end of
blower assembly on right side and lower left end
to remove blower from the cabinet.
Installation
1. Reassemble, if necessary, and install motor
blower assembly into the casing assembly (23).
Secure with machine screws removed at disas-
sembly.
2. Using notes made at removal, reconnect all
electrical wiring to the blower motor.
3. Slide heater core into the casing assembly and
seat fully.
NOTE: Cores being installed should be sealed with
silicone rubber sealant (Part Number VJ6937). DO
NOT overtighten the heater core fittings to prevent
possible distortion of the core end shell.
4. Install fittings on the heater core tubes.
5. Carefully install thermostat switch and capillary
tube. Take care not to kink or otherwise damage
the capillary tube. Connect operating cable to
the sensing switch.
6. Connect coolant lines from engine to the heater
core fittings and tighten securely. Do not over-
tighten.
7. Install cover assembly (1, Figure 9-6).
8. Replace outer access cover on right front of
truck cab.
9. If removed, reconnect heater hose to shut-off
valve on engine block. Open the shut-off valve.
10. Check coolant level in radiator and service with
appropriate mix of antifreeze as necessary.
11. Start engine and move temperature control to
the ON position. Run engine for a short time
for coolant to completely fill the heater circuit
and lines. Shut down engine, recheck coolant
level and add coolant mix if necessary.
Blower Disassembly
1. Remove screws holding blower housing (4, 19,
Figure 9-6) to blower mounting plate (5).
2. Remove two nuts securing each end of motor to
blower housings.
NOTE: Mark position of blower housing and fan with
respect to motor to insure proper fan rotation at
assembly.
3. With blower motor held securely, bring blower
housing evenly in contact with rear of fan and
apply pressure on blower housing forcing fan
from motor shaft.
NOTE: It is not necessary to remove snap ring from
fan hub for assembly or disassembly.
4. Unplug motor wire and repeat fan removal pro-
cedure at other end of the motor shaft.
Blower Assembly
1. Install gasket (5) and blower housing (3) on
blower mount (4).
NOTE: To insure proper fan rotation, reassembly unit
using match marks made at disassembly.
2. Press fan (6) onto motor shaft Install two nuts
securing blower housing to end of motor.
3. Repeat Steps 1 & 2 for the other fan and hous-
ing assembly.
4. Install both fan housing assemblies on the
blower mounting plate and secure with machine
screws.
M9-8 Heater/Air Conditioner Service M09004
NOTES:
M10002 Aftercooler Operation and Repair M10-1
AFTERCOOLER OPERATION AND REPAIR
OPERATION
The aftercooler is designed to remove suspended
water and oil particles from air before going to the air
tank. Air from the compressor enters the aftercooler
inlet port and is directed upward between the deflec-
tor and the outer shell. The air cools as it moves
upward condensing water and oil droplets which drop
to the sump of the aftercooler housing. Air then
passes through the filter media which removes dirt
particles. As the air moves up through the filter, the
moisture content is progressively decreased. Cool air
then flows through the cap, check valve and into the
air tank.
When the air tank is fully charged, air pressure from
the governor unloader line is ported to the after-
cooler. This pilot pressure opens the purge valve,
discharging accumulated oil and water from the
sump. Each time the governor cuts out, the air dryer
is purged of oil and water which has accumulated in
the deflector. When air compression resumes, the
unloader line is exhausted to the atmosphere, the
purge valve closes and the cooling process is
repeated.
MAINTENANCE
Removal
1. Tag or mark air lines before disconnecting.
NOTE: If replacement of the filter assembly is the
only service required, the aftercooler does not have
to be removed from the truck. Proceed to the
disassembly procedure for filter replacement
2. Remove outlet air line leading to air tank.
3. Remove air line from inlet port.
4. Remove electrical connection from heater
assembly if aftercooler is equipped with this
option.
5. Remove nuts securing aftercooler assembly to
mounting bracket. Remove aftercooler and
place in a clean work area for disassembly.
Installation
1. Install aftercooler assembly on mounting
bracket and secure in place.
2. Connect air lines and electrical heater wire, if
equipped.
3. Charge air system and check for leaks.
FIGURE 10-1. AFTERCOOLER
M10-2 Aftercooler Operation and Repair M10002
Disassembly
1. Unscrew nut (13, Figure 10-2) from aftercooler
bottom cap (12)
.
2. Remove O-ring (14). Remove sleeve (15), cup
(16) and piston (17). Remove large spring (18).
3. Pull spindle assembly from aftercooler bottom
cap (12) and remove retaining ring (19), spring
(20), seat ring (21) and spindle (22).
4. Remove capscrews (5) securing aftercooler
upper cap (4) to aftercooler body.
5. Remove cap (1, Figure 10-3), spring (2) and
gasket (3) from aftercooler.
6. Remove filter (1, Figure 10-4).
FIGURE 10-2. AFTERCOOLER ASSEMBLY
1. Body
2. Deflector Assembly
3. Spring
4. Top Cap
5. Capscrew
6. Gasket
7. Filter Cup
8. Filter
9. Seal Ring
10. Gasket
11. Gasket
12. Bottom Cap
13. Nut
14. O-Ring
15. Sleeve
16. Cup
17. Piston
18. Spring
19. Retainer
20. Spring
21. Seat Ring
22. Spindle
23. Capscrews
FIGURE 10-3. TOP CAP REMOVAL
1. Top Cap
2. Spring
3. Gasket
FIGURE 10-4. FILTER REMOVAL
1. Filter Assembly 2. Body
M10002 Aftercooler Operation and Repair M10-3
7. Remove seal ring (1, Figure 10-5).
8. If replacement of the bottom cap (12, Figure 10-
2) or deflector (2) is necessary, remove cap-
screws (23), bottom cap (12) gaskets (10 and
11) and deflector (2).
Cleaning and Inspection
1. Disassemble filter assembly (1, Figure 10-4)
wash stainless steel filter element in cleaning
solvent. Blow dry with compressed air. Wipe
nylon parts of assembly to remove dirt etc.
2. Inspect body for damage.
3. Clean the body fins. Inspect fins for damage.
NOTE: Never paint or cover the exterior of the
aftercooler. Cooling capacity will be reduced.
Assembly
1. If removed, install deflector (2, Figure 10-2).
2. Install new gaskets (10 and 11) and end cap
(12).
3. Install capscrews (23). Tighten capscrews to 12
to 15 ft. lbs. (16.2 to 20.3 N.m) torque.
4. Install new seal ring (1, Figure 10-5).
5. Install filter assembly (1, Figure 10-3).
6. Install new gasket (3, Figure 10-3). Install spring
(2) and cap (1). Secure cap in place with cap-
screws tightened to 12 - 15 ft.lbs. (16.2 - 20.3
N.m) torque.
7. Install spindle (22, Figure 10-2) in seat ring (21).
Install spring (20) and retainer ring (19).
8. Install spindle assembly in bottom cap (12).
Install large spring (18), piston (17), cup (16)
and sleeve (15).
9. Install O-ring (14) on nut (13). Install nut (13)
and tighten securely.
FIGURE 10-5. SEAL RING REMOVAL
1. Seal Ring 2. Body
M10-4 Aftercooler Operation and Repair M10002
NOTES:
M10003 6/97 AEROFINER III M10-1
AIR DRYER (AEROFINER III)
AIR DRYER
The AEROFINER III air dryer removes moisture from
the air system by passing the air through a desiccant
medium.
The air dryer is designed to remove suspended water
and oil particles from air before going to the main air
tank. Air from the compressor enters the air dryer inlet
port and is directed downward between the desiccant
canister and the outer shell. The air cools as it moves
downward, condensing water and oil droplets which
drop to the sump of the air dryer housing. Air then
passes through the oil separator which removes dirt
particles, oil and water mist. As the air moves up
through the desiccant material, the moisture content
is progressively decreased. Dry air then flows through
the cap, check valve and into the main air tank.
When the main air tank is fully charged, air pressure
from the governor unloader line is ported to the Air
port on the air dryer. This pilot pressure opens the
purge valve discharging accumulated oil and water
from the sump. As long as the compressor is not deliv-
ering compressed air, the purge valve remains open. A
small amount of air that was trapped in the cap is now
metered down through the purge plate forcing oil and
water down through the desiccant material and out the
purge port. Each time the governor cuts out, the desic-
cant material in the air dryer is purged of oil and water
which has accumulated in the canister assembly.
When air compression resumes, the unloader line is
exhausted to the atmosphere, the purge valve closes
and the drying process is repeated.
Service
The Aerofiner III air dryer does not normally require fre-
quent service. The service interval will vary dependent
on the average atmospheric relative humidity of the
locality where the unit is in operation. Areas with high
humidity conditions (rainy) will require the desiccant
material to be changed more often than dry climates.
Indications To Change Desiccant
Fresh desiccant material is a light brown color. As the
desiccant material absorbs moisture, the color
becomes a very dark brown and its consistency
thickens. Change desiccant.
In addition, as the desiccant material absorbs mois-
ture, there will be a noticeable increase in the time
required to charge the air system.
Desiccant replacement, check valve service and
purge valve and heater service can all be performed
with the dryer still mounted on the truck.
FIGURE 10-1. AIR DRYER OPERATION
M10-2 AEROFINER III M10003 6/97
Removal
1. Discharge air pressure from main air tank. Tag
or mark air lines before disconnecting.
2. Remove outlet air line from discharge port (33,
Figure 10-2) leading to main air tank.
3. Remove air line from inlet port (23). Remove air
line from purge line port (24).
4. If air dryer is equipped with heater, remove
electrical connection.
5. Remove capscrews securing air dryer assembly
to truck. Remove air dryer and place in a clean
work area for disassembly.
Installation
1. Install air dryer assembly on truck and secure in
place with capscrews.
2. Connect air lines and electrical heater wire, if
equipped.
3. Charge main air system and check for leaks.
Disassembly
The AEROFINER III air dryer can be serviced with
the unit installed on the truck.
1. Release any air pressure which may be trapped
by slowly loosening the hose fitting at the outlet
port (33, Figure 10-2).
2. Disconnect purge control line from port (24) and
heater wires if equipped.
3. Loosen V-band coupling nut (18) far enough
that coupling will clear flanges and remove V-
band from air dryer.
4. Twist and pull down on housing (1) and remove
housing from cap (17).
5. Remove purge cap nut (15), purge plate (13)
and spring (12). Complete desiccant canister
assembly (11) can now be removed from hous-
ing (1).
6. With the desiccant canister upright, remove the
inner tube retaining ring (35) with a screwdriver.
The retainer screen and cloth filter pad can then
be removed, exposing the desiccant. Discard
old desiccant in a suitable manner.
7. Invert the canister and remove retaining ring
(34) which holds tube assembly in the canister.
Remove tube assembly, lower retainer screen,
and filter pad. Remove mesh oil separator pad
and discard.
8. Wash all metal components with solvent and
allow to dry.
FIGURE 10-2. AIR DRIER
M10003 6/97 AEROFINER III M10-3
Assembly
1. Install new mesh separator pad on bottom of
tube assembly. Insert in canister and secure
with retaining ring (34, Figure 10-2). Install
lower retainer plate and new cloth filter pad. Be
sure that cloth filter pad lays flat against retainer
screen.
2. Set canister upright and pour in new desiccant.
Gently tap side of canister several times with
rubber mallet to settle the desiccant. Fill only up
to the inner tube retaining ring groove. Any
excess desiccant may be discarded.
3. Install upper retainer screen and new cloth filter
pad over the inner tube, cloth pad against the
desiccant. Push the retainer screen down until
the small retaining ring (35) can be inserted in
groove on inner tube.
4. Insert recharged desiccant canister (11) into
lower housing (1). Replace all O-rings. with new
O-rings and lubricate them.
5. Stack desiccant spring (12) and purge plate
(13) on top of canister and reassemble with
purge plate nut (15) with new (and lubricated)
seal washer (14). Tighten purge plate nut (15)
to 200 in. lbs. (22.6 N.m) maximum torque.
6. Install new O-ring (20) in cap (17).
7. Be certain large thin O-ring (16) is seated in
groove on housing (1). Push lower housing
assembly with recharged canister up into cap
assembly (17) with a twisting motion. Replace
V-band coupling over flanges and tighten nut to
35 in lbs. (4 N.m) torque.
CHECK VALVE
Removal
1. Discharge air pressure from main air tank.
2. Disconnect the hose from the air dryer outlet
port (33, Figure 10-2).
3. Remove retaining ring (32) with snap ring pliers.
Remove spring (27) and poppet assembly (21)
with O-ring (19).
Installation
1. Install new O-ring (19, Figure 10-2) onto the
poppet (21) and coat the entire O-ring poppet
assembly with a light petroleum grease. The
sealing surface in the valve body must be
smooth and clean. Inspect thoroughly before
installing new check valve components.
2. Place the O-ring/poppet assembly into the
check valve body, O-ring end first. Needle nose
pliers may be used to guide the poppet into
place.
3. Place new spring (27) in back of the poppet with
small end of spring facing poppet.
4. Install retaining ring (32) in groove behind the
spring.
5. To check valve operation, remove cap assem-
bly and push the nose of the poppet several
times. Free movement with a positive return
should be observed. After functional testing, the
spring must still be retained fully by the retaining
ring.
M10-4 AEROFINER III M10003 6/97
PURGE VALVE & HEATER
Removal
1. Disconnect purge control line and heater wires.
2. Loosen V-band coupling nut far enough that
coupling will clear flanges and remove coupling
from unit.
3. Twist and pull down on housing (1, Figure 10-2)
and remove assembly from cap (17).
4. Remove purge cap nut (15), purge plate and
spring (12). Complete desiccant canister
assembly (11) can now be removed from hous-
ing and set aside.
5. Place purge valve body in vise so that vise jaws
engage with flats on valve body. Turn housing
counterclockwise to remove housing from purge
valve body.
6. Unscrew threaded shaft assembly from valve
body exposing springs and valve.
7. Remove purge valve (5), springs (7 & 8) and U-
cup seal (6) from valve body and discard.
Inspection
The inside of valve body must be wiped clean and be
free from burrs and scratches before assembly.
Installation
1. Lubricate new valve O-ring (4, Figure 10-2) and
U-cup (6). Insert U-cup (6) into valve body first.
Care must be taken not to damage the seal lips.
2. Install O-ring (4) onto the new valve and insert
into the valve body. Place new springs (7 & 8)
on top of valve.
Care must be taken not to damage the seal lips
during installation.
3. Lubricate new O-ring (4) on center shaft assem-
bly. Thread center shaft assembly into valve
body, wrench tight. Do not over tighten.
The valve body is aluminum and care must be
taken not to cross thread the shaft assembly
when starting threads against the spring pres-
sure.
4. Lubricate threads inside housing (1). Thread
housing onto valve body (3).
5. Insert recharged desiccant canister into lower
housing. Replace all O-rings with new ones and
lubricate them.
6. Stack desiccant spring (12) and purge plate
(13) on top of canister and reassemble with
purge plate nut (15) with new (and lubricated)
seal washer (14). Tighten purge plate nut (15)
to 200 in. lbs. (22.6 N.m) maximum torque.
7. Be certain large thin O-ring is seated on groove
on housing. Push lower housing assembly with
canister up into cap assembly with a twisting
motion. Replace V-band coupling over flanges
and tighten nut to 35 in lbs. (4 N.m) torque.
8. Reconnect all air lines and heater wires. Check
for air leaks.
FIGURE 10-3. END VIEW OF AIR DRIER
1. Purge Valve Cover
Plate
2. Drive Screw
3. Heater & Thermostat
Assembly
4. Aerofiner Housing
M10004 Salem Aftercooler M10-1
SALEM AFTERCOOLER (AIR DRYER)
AFTERCOOLER/AIR DRYER
The aftercooler (commonly called an air dryer) is
designed to remove moisture and heat from the truck
air system. Air, leaving the compressor, enters at the
top of the dryer and heat is dissipated through the
body fins. As the air cools, the moisture condenses
and collects in the bottom of the dryer. Air passes
through a steel mesh unit, which collects any oil in
the air. The cool, filtered air passes through the
scrubber through the outlet port of the dryer.
The moisture drain valve is actuated by control air
from the air governor. Control air enters the drain
valve and forces a piston off its seat. Moisture in the
bottom of the dryer is then forced past a valve seat
and out a drain port. The air dryer is also equipped
with a heater to prevent freezing of the moisture.
Removal
1. Relieve the system air pressure and disconnect
the air lines on the dryer. Disconnect heater
wire. Remove the capscrews securing the dryer
to its support bracket and remove from truck.
2. Clean the exterior thoroughly with quality clean-
ing solvent. Place the assembly in a clean work
area.
Disassembly
1. Remove heater (7, Figure 1) from moisture
drain valve (18), Port "A".
2. Remove capscrews securing drain valve to
lower body half. Remove drain valve (18).
3. Remove nuts and lockwashers (2 & 3) from
studs and separate body cap from lower body
half.
4. Remove center scrubber (8) from upper halve
of body.
5. Remove bottom cap (16), seat bolt (17), seat
washer (19), seat spacer (20), and valve seat
(21) from valve body (18).
6. Remove capscrews (31) from the spring cap
(27) and remove cap from body.
7. Remove piston (23) from valve body (18) and
discard seal (24) and O-rings (22). Replace
these with new seals and O-rings during reas-
sembly.
8. Remove valve seat (21) from body.
Cleaning and Inspection
1. Disassemble scrubber (8) and clean steel ele-
ment (9) with quality cleaning solvent.
2. Inspect scrubber poppet for damage. Replace if
necessary.
3. Check air inlet and outlet flange for damage.
Replace outlet flange if necessary.
4. Clean moisture drain valve with cleaning sol-
vent. Replace piston seal and O-rings.
5. Clean hardware and check for cross-threading
and damage. Replace as necessary.
Reassembly and Installation
1. Place scrubber (8) in body and assemble body
halves.
2. Reassemble moisture drain valve and mount on
body.
3. Install outlet flange and gasket on body.
4. Secure drain valve heater (7) to moisture drain
valve (18).
5. Install air dryer on truck and connect air lines
and heater wire.
M10-2 Salem Aftercooler M10004
FIGURE M10-1. SALEM AFTERCOOLER
1. Mounting Bracket
2. Capscrew - 3/8
3. Lockwasher - 3/8
4. Seal
5. Flange
6. Separator Body
7. Heater
8. Scrubber
9. Coalescer
10. Retainer
11. Seal
12. Lockwasher - 5/16
13. Nut - 5/16 - 24NF
14. Bottom Cap
15. Gasket
16. Bottom Cap
17. Seat Bolt
18. Moisture Drain Valve
19. Seat Washer
20. Seat Spacer
21. Valve Seat
22. Piston Seal
23. Piston
24. O-Rings
25. Spring Seat Washer
26. Spring (Large, outer)
Spring (Small, inner)
27. Spring Cap
28. Shoulder Bolt
29. Dust Cap
30. Seal
31. Capscrew
M14001 Isringhausen Operator Seat M14-1
OPTIONAL OPERATOR SEAT
The optional operators seat provides a fully adjust-
able cushioned ride for the drivers comfort and ease
of operation.
The seat is independently mounted from the cab for
easy removal for repair or maintenance.
SEAT
Removal
1. Relieve system air pressure.
2. Disconnect air supply tube routed to rear of seat
base at the union.
3. Remove four capscrews, washers and nuts
securing seat base to riser.
4. Remove seat for further maintenance.
Installation
1. Install seat assembly on riser and align mount-
ing capscrew holes.
2. Install capscrews, lockwashers, and nuts and
tighten to 21 ft. lbs. (28.5 N.m) torque.
3. Connect air supply tube from seat base to union
fitting.
ARMRESTS
Rotate control knob at end of
armrest to change angle.
Pivot up and back for entering
and exiting seat.
SEAT ADJ USTMENT INSTRUCTIONS
SLIDE, FRONT TO REAR
Lift lever and hold while slid-
ing seat to desired position.
Release handle to lock.
AIR SUSPENSION
The seat will automatically
adjust to a mid-ride position
after several seconds when
occupied,
HEADREST
Pull up or push down for vertical
adjustment. Pivot forward or
rearward for horizontal adjust-
ment.
BACKREST
Rotate control handle upward
and hold, select desired back-
rest angle, release handle.
CAUTION!
Do not attempt to adjust until
operator is seated.
SEAT HEIGHT ADJ USTENT,
FRONT OR REAR
Lift front or rear handle up and
hold to release lock for spring
loaded seat. Adjust by shifting
body weight at front or rear of
cushion. Release handle to
lock.
LUMBAR SUPPORT
Each rocker switch controls an
air pillow. To inflate, press on
top of rocker switch. To deflate,
press on bottom of rocker
switch.
M14-2 Isringhausen Operator Seat M14001
Disassembly
1. Remove capscrew securing the backrest in
place, refer to Figure 14-1. Access to the cap-
screw can be gained by compressing the lower
left corner of the backrest cushion.
2. Remove seat cushion by removing the retaining
screws at the front lower edge of the seat cush-
ion. Lift the cushion up and out.
3. Slide the seat frame forward and remove the
capscrews securing the seat frame to the sus-
pension assembly, refer to Figures 14-2 and 14-
3. Slide the seat frame rearward and remove
the two remaining capscrews, separate seat
frame from suspension assembly.
4. If backrest spring replacement is necessary,
remove the backrest handle (1, Figure 14-4).
Handle can be removed by carefully pulling han-
dle off control arm. Remove locking clip and
remove cover (2). Install new spring as shown in
Figure 14-5. Replace cover and handle.
FIGURE 14-1. BACKREST REMOVAL
1. Capscrew
2. Backrest Cushion
3. Seat Frame
FIGURE 14-2. SEAT FRAME REMOVAL
1. Seat Frame
2. Capscrew
3. Rubber Boot
FIGURE 14-3. REMOVING SEAT FRAME
1. Seat Frame
2. Suspension
Assembly
3. Rubber Boot
FIGURE 14-4. BACKREST SPRING REMOVAL
1. Handle 2. Cover
M14001 Isringhausen Operator Seat M14-3
5. If height and tilt handles or slide springs require
replacement, proceed as follows:
a. Remove connector spring (1, Figure 14-6).
Remove both handle springs (5).
b. Remove slide spring (2).
c. Remove height and tilt handles (3 and 4).
Handles are press fit.
d. Remove handle arms if replacement is nec-
essary by removing handle arm retainer (1,
Figure 14-7). Use care during retainer
removal to prevent retainer breakage.
6. Remove "E" washer from pins (1, Figure 14-8).
Remove slide stop (2). Remove slide assembly
(3).
FIGURE 14-5. BACKREST SPRING INSTALLATION
FIGURE 14-6. SPRING REMOVAL
1. Connector Spring
2. Fore and Aft Slide
Springs
3. Height Handle
4. Tilt Handle
5. Handle Springs
FIGURE 14-7. HANDLE ARM REMOVAL
1. Handle Arm Retainer
2. Height Handle
3. Tilt Handle
FIGURE 14-8. SLIDE REMOVAL
1. Pins
2. Slide Stop
3. Slide Rail
M14-4 Isringhausen Operator Seat M14001
7. Remove and inspect the nylon slide assem-
blies, replace if required, refer to Figures 1 4-9
and 14-10.
8. Carefully pry button plugs securing the rubber
boot to the suspension assembly.
9. Cam removal can be accomplished by remov-
ing "E" washer (1, Figure 14-11). Pull cam (2)
off support shaft (3).
10. Disconnect air lines (6, Figure 14-11). Remove
nuts securing air regulator (4) to suspension
assembly. Remove air regulator. Further disas-
sembly of the air regulator is not required.
Replace air regulator as a unit.
11. Disconnect air line (6) to air spring (5). Remove
air line fitting. Remove capscrew (7), spread the
suspension assembly and remove air spring
(5). Further disassembly of the air spring is not
required. Replace air spring as a unit. If shock
absorber (8) replacement is necessary, remove
mounting hardware and remove shock
absorber.
Assembly
1. If removed, replace shock absorber. Extend the
shock fully, and spread the suspension frame
so shock will fit. Place the shock with the yellow
sticker facing toward the top of the seat. Tighten
mounting capscrews to standard torque.
2. If removed, replace air spring. Extend the sus-
pension frame and install air spring. Install air
spring retaining capscrew with lockwasher.
Tighten capscrew to standard torque. Connect
air line and fitting to air spring.
3. If removed, install air regulator valve. Install
retaining nuts and tighten. Connect air lines.
4. If removed, install cam. Secure cam on support
shaft with "E" washer.
NOTE: If a new cam is being installed, adjustment
may be necessary. Refer to Air Suspension Cam
Adjustment Procedure.
FIGURE 14-9. NYLON SLIDE REMOVAL
1. Nylon Slide 2. Slide Rail
FIGURE 14-10. NYLON SLIDE REMOVAL
1. Nylon Slide 2. Seat Frame
FIGURE 14-11. CAM REMOVAL
1. E Washer
2. Cam
3. Support Shaft
4. Air Regulator
5. Air Spring
6. Air Lines
7. Capscrew
8. Shock Absorber
M14001 Isringhausen Operator Seat M14-5
5. Install rubber boot and secure in place with but-
ton plugs.
6. Install slide rails if removed. Install slide rail
stops. Secure slide rail stops in place with "E"
washers.
7. Position seat frame on suspension assembly.
Secure seat frame in place with capscrews.
Tighten capscrews to standard torque.
8. Install seat cushion. Secure cushion in place
with screws. Tighten screws securely. Install
backrest. Secure backrest in position with cap-
screw and lockwasher (1, Figure 14-12). Apply
Loctite #242 or equivalent to threads. Tighten
capscrew to standard torque.
9. Replace slide springs, tilt and height springs
and connector spring if removed. Replace tilt
and height handle if removed.
Air Suspension Cam Adjustment
1. Connect air supply.
2. Turn adjustment screws (4 and 5, Figure 14-13)
counterclockwise until the end of the screws are
flush with the inside diameter of the cam.
3. Compress and hold the suspension height to
4.13 inches (105 mm). Refer to Figure 14-13.
4. Rotate screw (4) clockwise very slowly and stop
when the suspension valve is opened and air
starts flowing into the air spring.
5. Measure the overall height of the suspension. If
the height is less than 6.69 inches (170 mm)
compress the suspension to a height of 3.54
inches (90 mm) to allow air to enter the air
spring. Repeat this procedure until the height of
the suspension is greater than 6.69 inches,
(170 mm).
6. Compress and hold the suspension height to
6.38 inches (162 mm), refer to Figure 14-13.
7. Turn screw (5) clockwise very slowly and stop
when air begins to exhaust through the air regu-
lator valve.
FIGURE 14-12. BACKREST INSTALLATION
1. Capscrew
2. Backrest Cushion
3. Seat Frame
FIGURE 14-13. CAM ADJ USTMENT PROCEDURE
1. Suspension
Assembly
2. Cam
3. Air Regulator
4. Adjusting Screw
5. Adjusting Screw
M14-6 Isringhausen Operator Seat M14001
SEAT MAINTENANCE AND REPAIR
Headrest
1. Check upholstery covering for tears.
2. Check for proper headrest vertical and pivot
adjustments.
3. If operation or condition is unsatisfactory, head-
rest must be replaced as a complete assembly.
Backrest
1. Check upholstery and foam condition and seat
backrest angle adjustment operation.
2. If repairs are required:
a. Remove side plate cover (5, Figure 14-14)
covering backrest angle adjustment assem-
bly.
b. Remove attachment bolt (4) located inside
angle adjustment support plate.
c. Remove armrests. Remove upholstery from
frame.
1.) Widen upholstery tuck groove slightly by
prying open with a flat blade screwdriver.
2.) Remove upholstery and foam from frame
and replace parts as required.
d. Attach upholstery to frame and reinsert nylon
tuck strip into tuck groove.
1.) Gently hammer edges of tuck groove to
pinch tuck strip in place.
3. Re-install backrest assembly on frame if no fur-
ther repairs are required.
a. Apply Loctite #242 (or equivalent) Thread-
locker to threads and install bolt (4) at back-
rest support plate.
b. Apply dry lubricant between the sliding lock
toothed plate and the guide support plate.
c. Replace side plate cover.
Armrests
1. Check for excessive wear and proper move-
ment.
2. If replacement is required, remove screws
attaching armrest bracket to the seat back.
3. Install new armrests with new hardware sup-
plied with parts kit.
Seat Cushion
1. Check condition of upholstery and foam.
2. Remove cushion by removing two screws at
front and detaching from the rear mounting
brackets.
3. Replace parts as required.
Seat Frame
1. Inspect seat frame (6) for excessive wear in the
seat height and slope adjustment nylon bush-
ings.
2. If repairs are required, remove seat backrest
and seat cushion according to above instruc-
tions.
3. Remove seat frame from static spacer.
4. Inspect bushings, springs, sideplate assembly
and replace parts as required.
5. Reinstall seat frame to static spacer.
a. Insert rear swivel bolts (Bolts must be facing
out from static spacer).
b. Insert front bolts. Use self-locking nuts
only.
FIGURE 14-14. SEAT COMPONENTS
1. Mounting Hardware
2. Union Fitting
3. Air Supply Tube
4. Backrest Mounting
Bolt
5. Slide Plate Cover
6. Seat Frame
7. Static Spacer
8. Slide Assembly
9. Suspension
Assembly
10. Boot
M14001 Isringhausen Operator Seat M14-7
Slides
1. Inspect for excessive wear or binding.
2. Lubricate the slide rails (8, Figure 14-14) and
nylon slides/rollers and the handle pivot post on
the inside of both rails.
3. If replacement is necessary, install slide assem-
bly replacement parts kit. Individual parts are
not serviced.
a. Install slide rails, making certain the left and
right rails are aligned parallel.
b. Check fore and aft alignment to be certain
the handle locks rail securely.
Suspension
1. Remove boot (10) and inspect suspension
assembly (9).
2. Inspect air valve and cam, shock absorber, air
spring, rollers and bushings.
3. Replace parts as required.
4. Apply automotive or white grease to vertical
section only of the inside of the frame rails. DO
NOT GREASE THE SURFACE THAT THE
ROLLERS ROLL ON. Grease the posts used to
mount the rollers.
5. Use a dry lubricant at the intersection of the
suspension scissor's shoulder bolts.
6. Check air hose connections and routing to pre-
vent damage during suspension travel.
7. Re-install boot (10) and assemble slides, static
spacer, seat frame, seat cushion, and backrest.
M14-8 Isringhausen Operator Seat M14001
NOTES:
M15001TC TDI AIR STARTER TABLE OF CONTENTS M15.TC-1
M15001 - TDI AIR STARTER
TABLE OF CONTENTS
MODEL DIFFERENTIATION
The TDI Air Starter may be either a single-stage, or a two-stage model. Determine whether the unit is the
single-stage or two-stage model by viewing the overall external appearance of the unit.
Figure 15TC-1 illustrates the single-stage model. Figure 15TC-2 illustrates the two-stage model.
FIGURE 15TC-1. SINGLE-STAGE AIR STARTER
FIGURE 15TC-2. TWO-STAGE AIR STARTER
SINGLE STAGE AIR STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-5
Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-5
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-8
M15.TC-2 TDI AIR STARTER TABLE OF CONTENTS M15001TC
SINGLE STAGE AIR STARTER (CONTINUED)
Automatic Trip Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-12
Operation Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-13
TWO-STAGE AIR STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-15
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-15
Description of Basic Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-18
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-20
Parts Inspection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-20
Parts Dimensions Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-21
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-22
Torque Values Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-22
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M15-28
M15001 6/97 TDI Air Starter M15-1
TDI SINGLE STAGE AIR STARTER
STARTER
The optional TDI starter utilizes a single stage, tur-
bine driven air motor design to reduce air consump-
tion and improve cranking power at lower air
pressures than vane motor type starters. No external
lubrication is required resulting in reduced mainte-
nance requirements. An automatic trip valve,
mounted at the air supply inlet, shuts off air flow if the
cranking speed exceeds 4200 RPM to prevent
excessive starter speed. The starter assembly
weighs approximately 55 lbs (25 kg).
The following instructions provide information for ser-
vicing, parts replacement and reassembly of the
starter. The parts illustration (Figure 15-2) identifies
parts which can be disassembled and replaced by
field service personnel. Parts that are identified as
assemblies should not be disassembled as individual
replacement parts are not available.
Removal
1. Disconnect the air inlet hose at the relay valve.
2. Disconnect the hoses routed to the starter sole-
noid valve.
3. Cap all hoses to prevent entrance of dirt.
4. Mark the starter mounting flange and the
engine mounting boss to ensure proper align-
ment when reinstalling.
5. Remove the three capscrews and lockwashers
attaching the starter to the engine and remove
assembly.
Installation
1. Apply a liberal coat of molybdenum disulphide
grease on the starter pinion teeth.
2. Lower starter assembly into position and align
the mounting flange holes using match marks
made during removal with the tapped holes in
the engine.
3. Install the three capscrews and lockwashers
and tighten to 100 ft. lbs. (136 N.m) torque.
4. Install starter relay valve (if removed) at the inlet
port and attach hoses.
5. Install the main air inlet hose. Tighten all hoses
securely.
Disassembly
NOTE: Note the number and thickness of any shims
removed during disassembly.
1. Remove the six screws (1, Figure 15-2) attach-
ing the exhaust closure plate (2) to the air motor
assembly and remove.
2. Remove the six screws (3, Figure 15-1), auto-
matic trip valve inlet housing(2), and gasket.
The automatic trip valve is doweled to the turbine
housing. The valve housing must be lifted off ver-
tically to prevent damage to the nylon trip rod.
3. Match mark the Bendix drive housing relative to
the gearbox housing. Remove the six cap-
screws (52, Figure 15-2) and nuts (51) and pull
the drive housing from the gearbox.
FIGURE 15-1. ATV REMOVAL
1. Motor Housing
2. Automatic Trip Valve
3. Mounting Screw
M15-2 TDI Air Starter M15001 6/97
FIGURE 15-2. AIR STARTER
1. Screw
2. Exhaust Plate
Assembly
3. Screw
4. Washer
5. Turbine Wheel
6. Spacer
7. Bearing
8. O-Ring
9. Spring Seat
10. Spring
11. Spacer
12. Plug
13. Screw
14. Dowel
15. Screw
16. Automatic Trip Valve
17. Screw
18. Gasket
19. Setscrew
20. Motor Housing
21. Bearing
22. Key
23. Sungear & Shaft
24. Ring Gear
25. Retainer Plate
26. Screw
27. Plug
28. Screw
29. Hammer Assembly
30. Retainer Ring
31. Planet Gear Carrier
32. Thrust Washer
33. Planet Gear
34. Needle Bearing
35. Planet Shaft
36. Bearing
37. Spring Washer
38. Gearbox Housing
39. Screw
40. Lockwasher
41. Spacer
42. Bearing
43. Retainer Plate
44. Screw
45. Retainer Nut
46. Spring
47. Keys
48. Set Screw
49. Bendix Assembly
50. Needle Bearing
51. Nut
52. Screw
53. Bendix Drive Housing
M15001 6/97 TDI Air Starter M15-3
4. Locate the bendix assembly setscrew (2, Figure
15-3) and remove. Pull the bendix assembly
from the starter carrier output shaft.
5. Remove the spring (46, Figure 15-2) and keys
(47).
6. Inspect the bendix drive for excessive wear etc.
If broken springs, gear teeth etc. are found,
replace the entire bendix assembly. Do not
attempt to disassemble further.
7. If the drive housing needle bearing requires
replacement, tap out the welch plug and press
the bearing out.
8. Remove the six bolts (39) attaching the gearbox
(38) to the air motor housing. Remove the gear
housing.
9. To remove the hammer assembly (29, Figure
15-2), apply a small amount of heat to the
mounting screws (28) and remove. NOTE: Tem-
perature should not exceed 180
F. Do not
attempt further disassembly of the hammer
assembly.
NOTE: Special tool, part number SS1136 is available
to aid in removal of the shaft nut in the following
disassembly procedure. Refer to Figure 15-4
10. Secure the gearbox assembly to a workbench.
Bend the tab of the lockwasher (3, Figure 15-4)
away from the slot in the nut (2). Place the nut
removal tool (1) over the nut. Remove the shaft
nut and lockwasher.
FIGURE 15-3. BENDIX ASSEMBLY
1. Bendix Assembly
2. Set Screw
3. Gear Box
FIGURE 15-4. SHAFT NUT REMOVAL
1. SS1136 Tool
2. Nut
3. Lockwasher
4. Gearbox
FIGURE 15-5. CARRIER SHAFT REMOVAL
1. Shaft 2. Gearbox Housing
M15-4 TDI Air Starter M15001 6/97
11. Support the gearbox housing as shown in Fig-
ure 15-5 and press the carrier shaft from the
housing. Remove spring washer (37, Figure 15-
2) and spacer (41). Attach a puller and remove
the bearing (36).
12. If the front bearing (42) requires replacement,
remove the six screws (44) and remove the
retainer plate (43). Tap the bearing out of the
bore.
13. To disassemble the planet gears, remove the
snap ring (30) at each gear pin (35) and press the
pins out by hand. Remove the planet gears (33)
and washers (32). If the planet gear bearings (34)
require removal, press the bearings out.
NOTE: Special tools are available to aid in removal
of the turbine wheel. Tool part No. SS1137 is used for
removal of the turbine wheel mounting screw. Tool
No. SS1135 is used to remove the turbine wheel from
the shaft. Refer to Figures 15-6 and 15-7.
14. Mount the special tool (5) onto the turbine wheel
as shown in Figure 15-6 using #6-32 screws.
Hold the tool with a wrench and insert a 1/4"
allen wrench (4) to remove the screw (3).
Remove the washer (2) and tool
15. Install the special tool as shown in Figure 15-7
using #6-32 screws. Grip the tool with a wrench
and rotate the T-bar to remove the turbine.
Remove the turbine shaft key (22, Figure 15-2)
and spacer (6).
FIGURE 15-6. TURBINE RETAINER SCREW
REMOVAL
1. Turbine Wheel
2. Washer
3. Screw
4. Allen Wrench
5. Special Tool SS1137
6. #6-32 Screws
FIGURE 15-7. TURBINE ROTOR REMOVAL
1. Turbine Wheel 2. Special Tool SS1135
FIGURE 15-8. TURBINE SHAFT REMOVAL
1. Shaft
2. Round Stock
3. Arbor Press
M15001 6/97 TDI Air Starter M15-5
Do not allow the shaft to drop out during the next
procedure. Be prepared to catch the shaft to pre-
vent damage to the sungear.
16. Remove six screws (26) and retainer plate (25).
Support the turbine housing and using a .650 in.
(16.5 mm) maximum dia. round, press the tur-
bine shaft (1, Figure 15-8) out of the bearing.
17. Using a puller, remove the bearing (3) and
spacer (4).
18. Tap the bearing (7, Figure 15-2) lightly to
remove. Remove the spring seat (9), spring (10)
and O-ring (8).
Do not attempt further disassembly of the follow-
ing parts:
Internal ring gear (24)
Set Screw (19)
Turbine nozzle from housing
Cleaning
NOTE: Do not wash the bendix assembly or shielded
ball bearings in solvents.
1. Clean all metal parts thoroughly using commer-
cially approved solvents such as acetone or
trichloroethylene.
2. Clean aluminum parts using a solvent suitable
for aluminum alloys. Follow manufacturer's rec-
ommendations and cautions. Corroded alumi-
num parts may be cleaned further by immersing
in the following chromic-nitric-phosphoric acid
pickling solution:
8 lbs (3.63 kg) chromic acid
1.9 gallons (7.2 liters) phosphoric acid
1.5 gallons (5.7 liters) nitric acid
Add water to make a total of 10 gallons (37.9
liters) of solution.
After parts are soaked, rinse in hot water and
blow dry with clean compressed air.
3. Clean corroded steel parts with a commercially
approved stripper.
Parts Inspection
NOTE: Refer to the chart which follows for detailed
inspection information.
1. In general, inspect all threaded parts for galled,
stripped, crossed, or broken threads. Inspect all
parts for cracks, corrosion, distortion, scoring or
damage.
2. Inspect all bearing bores for wear and scoring.
Maximum permissible scoring:
0.005 in. (0.13 mm) wide and
0.005 in. (0.13 mm) deep.
3. Check gear teeth for excessive wear (Figure
15-9). Also inspect teeth for spalling, fretting,
surface flaking, splitting, rubbing, and corrosion.
Nicks and dents that cannot be felt with a .020
in. (.50 mm) radius scribe are acceptable for re-
use.
FIGURE 15-9. GEAR TOOTH WEAR LIMITS
M15-6 TDI Air Starter M15001 6/97
PARTS INSPECTION
(Refer to Figure 15-2 for reference to parts)
PART INSPECTION WEAR LIMITS
Bendix (49)
Check for loose, worn, missing or damaged parts. If any part is unacceptable, replace complete assembly.
Refer to Figure 15-9 for acceptable pinion wear.
Drive Housing (53)
Check for cracks, damage, or breakage. No cracking is acceptable.
Planet Gear (33)
Check for cracked, chipped or galled teeth.
Measure tooth wear.
External measurement over two .0864 in. (2.1496 mm)
dia pins: 2.6399 in. (67.0535 mm) minimum.
Carrier Shaft (31)
Check for cracks, scoring or raised metal in
planet shaft holes and keyways. Measure bearing
journal and bore dimensions.
Deformation or smearing in planet pin holes and keyways
not acceptable.
Scoring on bearing diameter not to exceed .005 in. (.13
mm) deep.
Bearing journal: 1.1800 in. (29.9720 mm) minimum diam-
eter.
Planet pin bore: 0.8750 in. (22.2250 mm) maximum
diameter.
Planet Pins (35)
Check for grooves, flat spots, and diameter. Bearing diameter: 0.873 in. (22.1742 mm) minimum.
No grooves or flat spots acceptable.
Thrust Washers (32)
Check for grooving and thickness dimension. Washer thickness: 0.055 in. (1.397 mm) minimum.
Sungear/shaft (23)
Check for cracks, scoring, grooves, chipped or
broken gear teeth. Check for galling or scoring
on bearing journal. Check keyway.
Bearing journal: 0.6690 in. (16.9926 mm) minimum diam-
eter.
External measurement over two .096 in. (2.4384 mm) dia.
pins: 0.808 in. (20.5232 mm) minimum.
Turbine Housing (20)
Check for corrosion, erosion or broken nozzle
edges, or cracks.
Minor damage permissible if function is not impaired.
Cracks not permitted.
M15001 6/97 TDI Air Starter M15-7
PART INSPECTION WEAR LIMITS
Turbine Wheel (5)
Check for cracks, corrosion, erosion,
broken edges, bore and keyway wear.
Minor damage acceptable.
Bore and keyway wear not acceptable.
Spacer (11)
Check parallelism of end surfaces. Ends to be parallel within .0005 in. (.0127 mm).
No scoring or dents on end surfaces permitted.
Needle Bearings (34, 50)
Check freedom of needle rollers. Replace bearings as required.
Ball Bearings (7, 21, 36, 42)
Check for freedom of rotation without
excessive play between races.
Reuse bearings (36, 42) if acceptable.
Replace bearings (7, 21).
M15-8 TDI Air Starter M15001 6/97
Assembly
NOTE: Always replace seals, gaskets, and O-rings
during reassembly. Lubricate all O-rings prior to
installation. Always replace Nylock screws (3, 26,
and 44, Figure 15-2). Always replace turbine
bearings (7, 21).
1. Press bearing (21, Figure 15-2) on sungear
shaft (23) until bearing is seated on shaft shoul-
der. (Press on bearing inner race only.)
2. Install O-ring (8) into groove in housing without
lubricant. Install shaft and bearing assembly (1,
Figure 15-10) into bore of the motor housing. If
bearing cannot be seated by hand pressure,
setup assembly in arbor press and press on
outer race only.
3. Install bearing retainer plate in housing with
notch aligned with vent hole as shown in Figure
15-11. Tighten screws (26, Figure 15-2) to 40
in. lbs. (4.52 N.m) torque.
4. Setup housing in a press as shown in Figure
15-12. Install the bearing spacer (4) over the
shaft.
FIGURE 15-10. TURBINE SHAFT INSTALLATION
1. Sungear, Shaft, &
Bearing
2. Motor Housing
FIGURE 15-11. BEARING RETAINER
INSTALLATION
1. Bearing Retainer
2. Sungear
3. Motor Housing
FIGURE 15-12. BEARING INSTALLATION
1. Bearing
2. Spring Seat
3. O-Ring
4. Spacer
5. Spring
6. Turbine Shaft
M15001 6/97 TDI Air Starter M15-9
During the next step, use care to prevent damage
to O-ring. Carefully align spring seat with hous-
ing prior pressing bearing.
5. Install spring (5) and spring seat (2). Press
bearing (1) until seated against bearing spacer.
6. Install spacer (6, Figure 15-2) and key (22) on
shaft (23).
7. Support turbine housing on press bed. Position
the turbine wheel with the lettering facing up,
align the key slot with the shaft key, and press
the turbine on the shaft until seated against the
spacer as shown in Figure 15-13.
8. Install washer and a new, nylock screw (3).
Hand tighten the screw.
9. Install special tool SS1137 to hold the turbine
wheel as the retaining screw is tightened. (See
Figure 15-14.) Insert a 1/4 in. allen wrench and
tighten to 130 in. lbs. (14.7 N.m) torque.
10. Remove the tool used above. Insert a feeler
gauge between the tips of the turbine blades
and the inner housing wall and verify proper
clearance at 90
F max.) to break
Loctite bond. Remove the lever arm assembly.
5. Press out the Teflon bearing (2) and, using a
sharp tool, remove bearing (1).
6. If lever arm is to be completely disassembled,
remove the snap ring (15) and remove arm (16).
Reassembly
NOTE: Clean Loctite residue off all parts prior to
reassembly.
1. Assemble arm (16) and snap ring (15) on lever
arm assembly.
2. Reassemble the butterfly shaft by installing a
new O-ring (2, Figure 15-23). Apply petroleum
jelly to the seal surface.
3. Mount the spring (1) with the long end pointed
downward.
4. Press Teflon bearings (1, Figure 15-22) then (2)
into the housing until flush with side walls.
Lubricate bearings with petroleum jelly.
5. Slide trip rod (4) into bottom hole of housing.
6. Place Loctite #680 on threads of lever arm stud
(17) and on threads in housing.
FIGURE 15-22. AUTOMATIC TRIP VALVE ASSEMBLY
1. Bearing
2. Bearing
3. Nut
4. Trip Rod
5. Dowel Pin
6. Screw
7. Butterfly Plate
8. Camshaft
Spring
9. O-ring
10. CamShaft
11. Gasket
12. Cover Plate
13. Screw
14. Nut
15. Retainer
16. Lever Arm
17. Stud
18. Lever
Arm Spring
19. Screw
20. Screw
21. Gasket
22. Dowel Pin
M15001 6/97 TDI Air Starter M15-13
7. Mount spring (18) over stud with short end in
the lever arm hole. Tighten stud firmly. Place a
drop of Loctite Super Bonder 495" into small
spring hole in the housing.
8. Mount the butterfly shaft assembly, aligning
spring (8) end into small hole in housing. Place
long end of spring (18) in the same hole.
9. Push lever arm toward top and rotate cam
counterclockwise. Mount the butterfly plate on
the large flat of the shaft with the bevelled edge
up. Coat screws (6) and nuts (11) with Loctite
680 and tighten to 5 in. lbs. (.57 N.m) torque.
Operation Check
1. Push the trip rod up several times and release.
The lever arm should move back and forth eas-
ily.
2. Push up on the trip rod and hold:
a. Slowly close the butterfly and slowly allow it
to open. There should be resistance to
movement.
b. Close the butterfly and allow it to snap open.
It should open quickly and smoothly.
3. Close butterfly and release the trip rod, allowing
butterfly to snap open.
a. The lever arm should drop against the cam.
4. Press on butterfly plate with two fingers and try
to close it. The lever arm should hold the butter-
fly open.
FIGURE 15-23. BUTTERFLY SHAFT ASSEMBLY
1. Spring
2. O-Ring Seal
3. Shaft
M15-14 TDI Air Starter M15001 6/97
NOTES:
M15001 6/97 TDI Air Starter M15-15
TDI TWO-STAGE AIR STARTER
AIR STARTER
The optional two-stage TDI starter provides distinct
advantages of size and efficiency as compared to
electric motor, vane-type or other turbine-type air
starters. It is a turbine driven air starter with a pre-
engage starter drive and is designed for use with
compressed air. Small amounts of foreign matter or
liquid in the air stream will normally not adversely
affect it. No lubrication is required in the air supply.
The unit has a pilot air solenoid valve installed. The
exclusive electronic control module reads output
shaft speed and shuts off air to the inlet in case of an
over speed condition. This prevents excessive crank-
ing speeds, which could damage the starter or waste
compressed air.
The following instructions provide information for ser-
vicing, parts replacement and reassembly of the
starter. The parts illustrations (Figure 15-24 & 25)
identify parts which can be disassembled and
replaced by field service personnel. Parts that are
identified as assemblies should not be disassembled
as individual replacement parts are not available.
Removal
1. Disconnect the air inlet hose at the relay valve.
2. Disconnect the hoses routed to the starter sole-
noid valve.
3. Cap all hoses to prevent entrance of dirt.
4. Mark the starter mounting flange and the
engine mounting boss to ensure proper align-
ment when reinstalling.
5. Remove the three capscrews and lockwashers
attaching the starter to the engine and remove
assembly.
Installation
1. Apply a liberal coat of molybdenum disulphide
grease on the starter pinion teeth.
2. Lower starter assembly into position and align
the mounting flange holes using match marks
made during removal with the tapped holes in
the engine.
3. Install the three capscrews and lockwashers
and tighten to 100 ft. lbs. (136 N.m) torque.
4. Install starter relay valve (if removed) at the inlet
port and attach hoses.
5. Install the main air inlet hose. Tighten all hoses
securely.
The TDI two-stage air starter must be installed
and operated in accordance with the instructions
given in the installation and operating manuals.
Failure to properly install the starter, or failure to
operate it according to these instructions may
result in damage to the starter or engine, or per-
sonal injury.
Description of Basic Groups
The unit can descriptively be grouped into four basic
segments: (1) Inlet Housing - Nozzle/Valve Seat; (2)
Turbine Housing; (3) Stage One Gear Carrier; and (4)
Gearbox - Drive Housing. The following Disassembly
and Assembly sections will generally follow the
above mentioned groups for instruction.
The Inlet Housing-Nozzle/Valve Seat area generally
includes items (1) through (25) in Figure 15-24. It
should be noted, however, that some items, such as
control lines and muffler parts, are addressed where
they are best removed and assembled.
The Turbine Housing includes items (26) through
(38) in Figure 15-24.
The Stage One Gear Carrier area includes items (39)
through (47), plus the Ring Gear pieces (48, 49, 50)
in Figure 15-25.
The Gearbox Drive Housing area includes items (51)
through (102) in Figure 15-25. It should be noted,
however, that some items, such as control lines, are
addressed where they are best removed and assem-
bled.
M15-16 TDI Air Starter M15001 6/97
FIGURE 15-24. INLET HOUSING - NOZZLE/VALVE SEAT & TURBINE HOUSING
1. Capscrew
2. Threaded Inlet Flange
3. O-Ring
4. Hex Plug
5. Inlet Housing
6. Capscrew
7. Capscrew
8. O-Ring
9. No longer required
10. Compression Spring
11. O-Ring Cap
12. Spool Valve
13. O-Ring
14. O-Ring
15. O-Ring
16. Nozzle/Valve Seat
17. Liner
18. Containment Ring
19. Long Male Elbow
20. Hose Assembly
21. See FIG. 15-25
22. Muffler Element
23. Button Head Screw
24. Muffler Retainer Plate
25. Muffler Retainer
26. Socket Screw
27. Rotor Washer
28. Turbine Rotor
29. Square Key
30. Labyrinth Spacer
31. No longer required
32. Turbine Housing
33. Ball Bearing
34. Retainer Ring
35. Compression Spring
36. Bearing Spacer
37. O-Ring
38. Turbine Shaft
M15001 6/97 TDI Air Starter M15-17
FIGURE 15-25. STAGE ONE GEAR CARRIER & GEARBOX - DRIVE HOUSING
21. Male Elbow
39. Button Head Screw
40. Shaft Retention Plate
41. Roll Pin
41A.Roll Pin
42. Planet Gear Shaft
43. Gear Shim
44. Gear Spacer
45. Needle Bearing
46. Planet Gear
47. Gear Carrier
48. O-Ring
49. Ring Gear
50. O-Ring
51. Gear Spacer
52. Needle Bearing
53. Planet Gear
54. Planet Gear Shaft
55. Carrier/Output Shaft
56. Shaft Retention Plate
57. Button Head Screw
58. Bronze Bearing
59. Hose Assembly
60. Controller
61. Capscrew
62. Capscrew
63. Solenoid Valve
64. Capscrew
65. O-Ring
66. Gearbox Housing
67. Capscrew
68. O-Ring
69. Bearing Hub
70. O-Ring
71. Lip Seal
72. Thrust Washer
73. Retainer Ring
74. O-Ring
75. Pre-Engage Piston
76. O-Ring
77. Split Ring
78. Drive
79. Compression Spring
80. Retaining Ring
81. Bearing
82. Seal
83. O-ring
84. Pinion Housing
85. O-Ring
86. Mounting Flange
87. Capscrew
88. Pinion Collar
89. Pinion
90. Split Washer
91. Capscrew
92. Gasket
93. Dowel Pin
94. Magnet
95. Connector
96. Connector Gasket
97. Connector Screw
98. Connector
99. Security Cap
100.Terminal
101.wire Seal
102.Capscrew
M15-18 TDI Air Starter M15001 6/97
Disassembly
1. Mark each section of the starter for reference
during assembly: mounting flange (86), gearbox
housing (66), ring gear (49), containment ring
(18), and inlet housing (5). Note the location of
the long male elbow (19) in the nozzle/valve
seat (16). Note that the control line access hole
in the containment ring (18) and the port in the
nozzle/valve seat (16) must line up when re-
assembled.
2. Mark the turbine rotor (28) and note its direction
of rotation.
3. Have a complete set of o-rings, seals, screws
and miscellaneous hardware available for
assembly.
Do not wash bearings (33, 45, 52, 81) or the
starter drive (78) in cleaning solvents.
4. Remove the two control line hoses (20, 59) and
four elbows (19, 21).
5. Disconnect the solenoid valve (63) from the
control module (60). Remove the three screws
(62) and the solenoid valve (63).
6. Remove the four screws (61) and the control
module (60) and the gasket (92).
The drive housing - gearbox housing is spring
loaded. Exercise caution when separating the
pinion housing (84) from the gearbox housing
(66).
7. Remove screw (91) and separate pinion collar
(88), pinion (89), split washer (90) and screw
(91) from drive (78).
8. Remove the twelve screws (102) and separate
the pinion housing (84) from the gearbox hous-
ing (66). Remove retaining ring (80).
9. Check the condition of the roller bearing (81).
Press out if damaged or suspect.
10. Remove the compression spring (79) and the
starter drive (78) from the gearbox housing (66).
The two split rings (77) will come out with the
starter drive (78).
11. Remove twelve screws (87) and separate
mounting flange (86) and o-ring (85) from pinion
housing (84).
12. Check condition of lip seal (82). If damaged,
press out of pinion housing (84).
Hold a rag over the output shaft (55) and gearbox
housing (66) to stop the pre-engaged piston (75)
when applying low pressure air to remove it from
the gearbox housing (66).
13. Apply low pressure air to the solenoid port on
the gearbox housing (66) to force the pre-
engage piston (75) out of the gearbox housing
(66). Refer to WARNING above.
14. Remove the seven screws (67) and separate
the gearbox housing (66), ring gear (49), stage
one gear carrier (47), turbine housing (32) and
inlet housing - nozzle/valve seat (5, 16). Anti-
rotation pin (93) should remain pressed into
gearbox housing (66).
15. Remove the retainer ring (73) and two thrust
washers (72) from the output shaft (55).
16. Remove the gear carrier/output shaft (55) from
the gearbox housing (66).
17. Remove the four screws (64) and the bearing
hub (69). Press out the lip seal (71).
18. Check the condition of the bronze bearing (58).
Press out if damaged or suspect.
19. Remove the three screws (57) and gear shaft
retainer plate (56).
20. Press out the three stage two planet gear shafts
(54) and remove the gears (53) and gear spac-
ers (51).
21. Check the condition of the needle bearings (52).
Press out if damaged or suspect.
22. Remove the two shims (43) from the sun gear.
23. Remove the three screws (39) and the stage
one planet gear shaft retention plate (40). Press
out the three shafts (42) and remove the gears
(46) and gear spacers (44).
24. Check the condition of the needle bearings (45).
Press out if damaged or suspect.
M15001 6/97 TDI Air Starter M15-19
25. Remove the six screws (23), three retainer
plates (24), and muffler retainer (25) from the
containment ring (18). Remove the three muffler
elements (22) and discard.
26. Remove the turbine housing assembly (32)
from the containment ring (18).
27. Remove the rotor retention screw (26) and rotor
washer (27) from the turbine shaft (38).
NOTE: It is suggested that you hold the sun gear end
of the turbine shaft (38) in a soft-jawed (aluminum)
vise while removing the rotor retention screw (26).
28. Remove the turbine rotor (28) from the turbine
shaft as shown in Figure 15-26. Hold on to the
puller tool with an open end wrench.
NOTE: Install the three puller screws hand tight to
the turbine rotor (28). Before installing the puller tool,
check to make sure that the face of the t-screw is
smaller than the diameter of the turbine shaft (38).
29. Remove the 1/8" key (29) from the turbine shaft
(38).
30. Press the turbine shaft (38) from the turbine
housing (32). The bearing spacer (36) should
come out also. Remove the bearing spacer (36)
from the turbine shaft (38).
The shaft pressing tool must be smaller in diame-
ter than the turbine shaft (1/2" ).
31. Press the ball bearing (33) from the turbine
shaft (38).
32. Remove the compression spring (35) from the
turbine housing (32).
33. Remove the o-ring (37) from the turbine housing
(32).
34. Remove the retainer ring (34) from the turbine
housing (32).
35. Remove the ball bearing (33) from the turbine
housing (32).
NOTE: You should be able to push the ball bearing
(33) out by pressing on the seal spacer (30) with your
finger.
36. Support the turbine housing (32) and remove
the labyrinth spacer (30).
37. If the threaded inlet (2A) is used, remove the
four screws (1). Remove the threaded inlet (2A)
from the inlet housing (5).
38. Remove the four screws (7) and separate the
inlet housing (5) from the containment ring (18).
On units after serial number 9307-181, the liner
(17) should slide out of the containment ring
(18).
39. Remove the five screws (6) and separate the
nozzle/valve seat (16) from the inlet housing
(5).
The spool valve - nozzle is spring loaded. Exer-
cise caution when separating the inlet housing
(5) from the nozzle/valve seat (16).
40. Remove the spring (10) from the spool valve
(12). Remove the o-ring cap (11) from the spool
valve (12). Remove the shock dampener from
the spool valve (12), if present.
FIGURE 15-26. TURBINE ROTOR REMOVAL
1. T-Handle
2. Turbine Rotor Tool
3. Screw
M15-20 TDI Air Starter M15001 6/97
41. Remove and discard the o-rings (3, 8, 13, 14,
15, 37, 48, 50, 65, 68, 70, 74, 76, 83, 85) from
the threaded inlet (2), inlet housing (5), spool
valve (12), nozzle/valve seat (16), turbine hous-
ing (32), ring gear (49), gearbox housing (66),
bearing hub (69), pre-engage piston (75) and
pinion housing (84).
Cleaning and Inspection
1. Degrease all metal parts except bearings and
the starter drive (78) using commercially
approved solvents. Dry parts thoroughly.
Never wash the starter drive (78) or shielded
bearings (33, 81) in cleaning solvents.
2. Clean aluminum parts using an approved alumi-
num cleaning solution. Soak for five minutes.
Remove parts, rinse in hot water, and dry thor-
oughly.
3. Clean corroded steel parts with commercially
approved stripper.
TABLE 15-1 - PARTS INSPECTION
PART DESCRIPTION CHECK FOR
REQUIREMENTS
Defective Parts Must be Replaced
Starter Drive (78) Worn, loose, missing, or damaged
parts.
Use Table 15-2 for acceptable wear
guidelines.
Pinion Housing (84) Cracks and breakage. Cracks and breakage not acceptable.
Carrier Shaft (55) & Gear Carrier
(47)
Wear-created grooves or flat spots.
Wear beyond limits per Table 15-2.
Deformation or metal smearing in
planet shaft holes not acceptable.
Scoring on bearing journal not to
exceed .005 (0.127 mm) depth.
Stage One and Stage Two Planet
Gears (46) and (53)
Cracked, chipped, or galled teeth.
Wear beyond limits per Table 15-2.
There shall be no evidence of wear
beyond limits per Table 15-2.
Turbine Shaft (38) Cracks, scoring, grooves, chipped or
broken teeth; galling or scoring on
shaft bearing journals. Raised metal
in keyway.
There shall be no evidence of wear
beyond limits per Table 15-2.
Turbine Housing (32) and Nozzle-
Valve Seat (16)
Corrosion, cracks, and erosion on
nozzle edges.
Cracks not permitted. Minor wear or
erosion acceptable if operation not
impaired.
Turbine Rotor (28) Corrosion, erosion, broken edges,
bore and keyway wear. Tip wear.
Minor tip rub acceptable. Bore and
keyway wear not acceptable. Play
exceeding 0.005 (0.127 mm) radial
and 0.005 (0.127 mm) axial not
acceptable.
Lip Seals (31) and (71) Wear and cracks. None permitted.
Labyrinth Spacer (30) Grooves and scoring. Wear groove not acceptable over
0.002 (0.051 mm).
Needle Bearings (45) and (52) and
Roller Bearings (81)
Rotation, scoring, or flat spots. Bearings should rotate freely.
Bearing Spacer (36) and Bronze
Bearing (58)
Parallelism of end surfaces. Ends shall be parallel within 0.0005
(0.0127 mm). Dented surfaces not
acceptable.
Ball Bearings (33) Freedom of rotation. Excessive play
between races.
Replace bearings if play is excessive.
M15001 6/97 TDI Air Starter M15-21
4. Clean corroded aluminum parts by cleaning as
stated in item 2 above and then immersing the
parts in a chromic-nitric- phosphoric acid-pickle
solution [Mix 8 lb. (3.6 kg) of chromic acid, 1.9
gallon (7.19 l) of phosphoric acid, 1.5 gallon
(5.67 l) of nitric acid with enough water to make
10 gallons (37.85 l).] Rinse in hot water and dry
thoroughly.
5. Use Table 15-1 as a guide to check for accept-
able condition of the parts listed.
6. Check all threaded parts for galled, crossed,
stripped, or broken threads.
7. Check all parts for cracks, corrosion, distortion,
scoring or general damage.
8. Check the nozzles (16) for wear, chipping, or
breakage, especially on the trailing edges.
9. Check the spool valve (12) and valve seat in the
nozzle (16) for wear.
10. Check all bearing bores for wear and scoring.
Bearing bores shall be free of scoring lines not
to exceed .005 in. (0.127 mm) width and .005
in. (0.127 mm) depth.
TABLE 15-2 - PARTS DIMENSIONS
DIMENSIONS
PART DESCRIPTION
NEW
Inches (Millimeters)
MAX. ALLOWABLE WEAR
Inches (Millimeters)
PLANET GEAR STAGE 1 & STAGE 2 (20:1)
(46) & (53)
Measurement over two 0.1080 diameter pins 1.391-1.388 (35.33-35.26) 1.387 (35.23)
PLANET GEAR STAGE 2 (16:1) (53)
Measurement over two 0.1080 diameter pins 1.202-1.199 (30.53 - 30.45) 1.198 (30.43)
PLANET GEAR SHAFT
Outside Diameter - Stage 1 (42)
Stage 2 (54)
0.6299-0.6296 (16.000-15.992)
0.5003-0.5001 (12.708-12.703)
0.6294 (15.987)
0.4999 (12.697)
TURBINE SHAFT (38)
Bearing J ournal - O.D. 0.5119-0.5116 (13.002-12.995) 0.5114 (12.990)
SUN GEAR - STAGE 1
Measurement over two 0.1080 diameter pins 1.144-1.141 (29.06-28.98) 1.140 (28.96)
SUN GEAR - STAGE 2 (47)
Measurement over two 0.1080 diameter pins
(20:1)
(16:1)
1.144-1.141 (29.06-28.98)
1.520 - 1.517 (38.61-38.53)
1.140 (28.96)
1.516 (38.51)
RING GEAR (49)
Measurement between two 0.1050 diameter
pins 3.3654-3.3632 (85.481-85.425) 3.3664 (85.507)
OUTPUT SHAFT (55)
Sleeve Bearing J ournal - O.D.
Roller Bearing J ournal - O.D.
0.8712-0.8707 (22.128-22.116)
0.747-0.746 (18.974-18.948)
0.8697 (22.090)
0.745 (18.923)
CARRIERS (47) AND (55)
Planet Pin Bore - Stage 1
- Stage 2
0.6301-0.6306 (16.005-16.017)
0.5005-0.5010 (12.713-12.725)
0.6307 (16.020)
0.5011 (12.728)
PINION SHAFT BEARING J OURNAL (78) 1.5000-1.4994 (38.100-38.085) 1.4984 (38.059)
M15-22 TDI Air Starter M15001 6/97
11. Check gear teeth for wear. If wear is apparent,
check gear teeth dimensions in accordance
with Table 15-2.
Assembly
Always press the inner race of ball bearings when
installing onto a shaft. Always press the outer race of
ball bearings when installing into a housing.
The rotor retention screw (26) must be replaced each
time the turbine rotor (28) is removed.
Degrease all parts (EXCEPT BEARINGS) and clean
aluminum parts per the cleaning and inspection pro-
cedures earlier in this section.
NOTE: It is recommended to use NYE 377AL grease
on all gears and bearings in the turbine carrier
sections and gear carrier sections. Aeroshell #6 is
recommended for use on all parts on the output side
of the gearbox - drive housing and the sliding o-rings
on the pre-engage piston and spool valve. Pre-lube
all stationary o-rings with Parker o-ring lube or
petroleum jelly.
The turbine housing o-ring (37) must not be lubri-
cated. It is to be installed dry.
For overhaul, the turbine ball bearings (33) should be
replaced.
For torque values, refer to Table 15-3.
All screw threads are treated at the factory with a
fastener retention compound. Every screw, 1/4
inch diameter or larger, must have a drop of Loc-
tite 290 applied to the threads before being re-
used; screws smaller than 1/4 inch diameter
must have a drop of Loctite 222 applied to the
threads.
1. Lube with Aeroshell #6 and install o-ring (8)
onto the inlet housing (5).
2. Lube with Aeroshell #6 and install the o-rings
(13) and (14) onto the spool valve (12).
3. Lube with o-ring lube and install o-ring (15) onto
the nozzle/valve seat (16).
4. Lube the ID of the spool valve (12) and the ID of
the nozzle/valve seat (16) with Aeroshell #6.
Insert the spool valve (12) into nozzle/valve
seat (16). Push, by hand, until seated.
5. Install the o-ring cap (11) onto the spool valve (12).
6. The lip on the o-ring cap (11) must extend over
o-ring (13). Set the compression spring (10)
onto the o-ring cap (11).
NOTE: Visually align the inlet housing (5) with the
nozzle/valve seat (16) so the piston hose port will
align with the containment ring (18) in the proper
orientation. (Refer to Disassembly #1).
TABLE 15-3 - TORQUE VALUES
PART DESCRIPTION
TORQUE
Lb-In (Lb-Ft) Nm
Screw, inlet housing to valve
seat (6)
64 (5) 7.2
Screw, inlet housing to con-
tainment ring (7)
150 (12) 16.9
Screw, inlet flange to inlet
housing (1)
840 (70) 94.9
Screw, rotor retention (26) 100 (8) 11.3
Screw, control module to
gearbox housing (61)
15 1.69
Screw, bearing hub to gear-
box housing (64)
64 (5) 7.2
Screw, mounting flange to
pinion housing (87)
170 (14) 19.2
Screw, stage two retention
plate (57)
45 (4) 5.1
Screw, gearbox housing to
containment ring (67)
150 (12) 16.9
Screw, muffler retainer (23) 45 (4) 5.1
Screw, stage one retention
plate to gear carrier (39)
45 (4) 5.1
Screw, solenoid valve to
gearbox housing 62)
64 (5) 7.2
Screw, pinion to pinion drive
shaft (91)
1590 (133) 179.6
Screw, pinion housing to
gearbox housing (102)
150 (12) 16.9
M15001 6/97 TDI Air Starter M15-23
7. Install the inlet housing (5) onto the nozzle/
valve seat (16). Push together to compress the
spring (10). While holding these pieces
together, line up the five screw holes and install
the five screws (6).
NOTE: It is recommended to alternately tighten two
opposite screws to ensure a straight pull before
tightening all five screws (6).
8. Tighten the five screws (6) to 64 Lb-in (7.2 Nm)
torque.
9. Position the nozzle liner (17) in the containment
ring (18) so that the holes through one wall align.
NOTE: Visually align the control line access hole in
the containment ring (18) with port in the nozzle/
valve seat (16). (Refer to Disassembly #1.) It is
recommended to alternately tighten two opposite
screws to ensure a straight pull before tightening all
four screws (7).
10. Install the inlet housing (5) onto the containment
ring (18). Install the four screws (7) and tighten
to 12 Lb-Ft. (16.9 Nm) torque. Start the long
male elbow (19) into the nozzle/valve seat (16)
port to prevent the nozzle liner from rotating.
11. Lube with o-ring lube and install the o-ring (3)
into the inlet (5). Install the inlet insert (2) onto
the inlet housing (5). Install the four screws (1)
and tighten to 70 Lb- Ft (94.9 Nm) torque.
NOTE: Apply pipe thread sealant to fittings before re-
assembly.
12. Install the long male elbow (19) into the port in the
nozzle/valve seat (16) and install the male elbow
(21) into the inlet housing (5). Be sure to put these
into the correct ports. (Refer to Disassembly #1.)
13. Install the ball bearing (33) into the turbine
housing (32) by hand. Install the retainer ring
(34) into the turbine housing (32) to secure the
bearing (33).
The turbine housing o-ring (37) must not be lubri-
cated. It is to be installed dry.
14. Install the o-ring (37) into the turbine housing (32).
15. Install the compression spring (35) into the tur-
bine housing (32).
NOTE: The compression spring (35) must be shoved
past the o-ring (37) as far as possible.
16. Press the ball bearing (33) onto the turbine shaft
(38) as shown in Figure 15-27.
17. Install the bearing spacer (36) onto the turbine
shaft (38).
18. Place the turbine housing (32) onto the turbine
shaft (38) and press into position until seated as
shown in Figure 15-28.
19. Install the labyrinth spacer (30) over the turbine
shaft (38).
20. Install the 1/8" key (29) into the turbine shaft
keyway (38).
21. Press the turbine rotor (28) onto the turbine
shaft (38) until seated.
FIGURE 15-27. BALL BEARING INSTALLATION
1. Ram
2. Bearing Pressing
Tool
3. Table
FIGURE 15-28. TURBINE SHAFT INSTALLATION
1. Ram
2. Bearing Pressing
Tool
3. Table
M15-24 TDI Air Starter M15001 6/97
Be sure to check the rotation of the starter motor
and the correct installation of the turbine rotor
(28). Turbine rotor buckets must flow in the same
direction as the nozzles on the nozzle/valve seat
(16).
Be sure to check the alignment of the turbine
rotor (28) and key (29).
22. Install the rotor washer (27) and rotor retention
screw (26) into the turbine shaft (38). Tighten to
8 Lb-Ft (11.3 Nm) torque.
NOTE: It is suggested that you hold the sun gear end
of the turbine shaft (38) in a soft-jawed (aluminum)
vise while torquing the rotor retention screw (26).
23. Slide the three needle bearings (45) into the
three stage one planet gears (46). Use NYE
377AL to grease the bearings (45).
24. Install one gear spacer (44) on each side of the
three gears (46).
25. Install three anti-rotation roll pins (41) into the
three stage one planet gear shafts (42). Tap the
pins (41) into position with a small hammer.
26. Insert the three gears (46) into the stage one
gear carrier (47) and align the shaft bores.
27. Hand install the three gear shafts (42) into the
gear carrier (47) and tap into position.
The gear shafts (42) must be inserted from the
stage one sun gear (38) side of the gear carrier
(47). Be sure to align the anti-rotation pins on the
gear shafts (42) with the slots in the gear carrier
(47).
28. Set the shaft retention plate (40) on the gear
carrier (47). Be sure to properly align the screw
holes.
29. Install the three screws (39); tighten to 45 Lb-in
(5.1 Nm) torque.
Check gear rotation. The gears (46) must rotate
freely in the gear carrier (47).
30. Press the oil impregnated bronze bearing (58)
into the bearing hub (69) until seated.
31. Press the lip seal (71) into the bearing hub (69)
until seated as shown in Figure 15-29.
Be sure that the lip on the seal (71) faces down
into the hub (69).
32. Lube with o-ring lube and install the o-ring (68)
into the recess on the internal face of the gear-
box housing (66).
33. Lube with Aeroshell #6 and set the o-ring (70)
onto the bearing hub (69). Roll the o-ring (70)
into position on the bearing hub (69).
34. Set the bearing hub (69) into the gearbox hous-
ing. Take care to line up the four screw holes.
35. Install the four screws (64) to secure the bearing
hub; tighten to 64 Lb-in (7.2 Nm) torque.
Be sure to hold the bearing hub (69) and the gear-
box housing (66) firmly together while installing
the screws (64) to prevent the o-ring (68) from
shifting out of position.
FIGURE 15-29. HUB LIP SEAL INSTALLATION
1. Ram
2. Seal Pressing Tool
3. Table
M15001 6/97 TDI Air Starter M15-25
36. Lube with Aeroshell #6 and install the o-rings
(74) and (76) onto the pre-engage piston (75).
37. Use Aeroshell #6 to grease the inside of the
gearbox housing (66) and the inside and out-
side of the pre-engage piston (75).
38. Hand press the pre-engage piston (75) into the
gearbox housing (66) and onto the bearing hub
(69). Set the gearbox housing (66) aside.
The more deeply recessed end of the pre-engage
piston (75) must be fitted onto the bearing hub
(69).
39. Press the three needle bearings (52) flush into
the three stage two planet gears (53).
The bearings (52) have a flat end and a radius
end. Be certain to press against the flat end.
Press each bearing (52) flush with the face of the
gear (53).
40. Install three anti-rotation roll pins (41A) into
three stage two planet gear shafts (54). Tap the
pins (41A) into position with a small hammer.
41. Place one of the gear spacers (51) on each side
of the stage two planet gears (53).
42. Insert the three gears (53), with spacers (51),
into the gear carrier (55) and align the shaft
bores.
43. Hand install the three gear shafts (54) into the
gear carrier (55) and tap into position.
The gear shafts (54) must be inserted from the
output shaft side of the gear carrier (55). Be sure
to align the anti-rotation pins on the gear shafts
(54) with the slots in the gear carrier (55).
Check gear rotation. The gears (53) must rotate
freely in the gear carrier (55).
44. Set the shaft retention plate (56) onto the gear
carrier (55). Be sure to properly align the screw
holes.
45. Install the three screws (57) and tighten to 45
LB-in (5.1 Nm) torque.
NOTE: Coat the bronze bearing (58) with NYE
377AL Grease.
46. Insert the seal positioning tool through the lip of
the seal (71).
47. Install the gearbox housing (66) onto the output
shaft of the gear carrier (55).
48. With the gearbox housing (66) in place, remove
the seal positioning tool.
While handling the gearbox housing/gear carrier,
do not let the gear carrier (55) fall out of the gear-
box housing (66) or the lip seal procedure on seal
(71) will have to be repeated. If the lip on the lip
seal (71) becomes reversed during assembly of
the gearbox housing (66) onto the output shaft
(55), the lip seal (71) must be replaced.
49. Install the two thrust washers (72) onto the out-
put shaft (55).
50. Install the retainer ring (73) onto the output shaft
(55).
51. Set the inlet housing - containment ring (5, 18)
assembly on the inlet housing (5).
52. Install the turbine assembly (32) into the con-
tainment ring (18).
NOTE: Since the major components must attach to
each other, be sure to align the components for both
the proper general orientation and for screw holes.
53. Lube with o-ring lube and install the o-rings (48,
50) onto the ring gear (49). Install the ring gear
(49) onto the turbine housing (32).
54. Install the two shims (43) onto the sun gear pin
of the stage one gear carrier (47). One shim
(43) goes on each end.
NOTE: NYE 377AL grease can be used to hold these
shims (43) in position during assembly.
Use NYE 377AL grease to coat the interior of the
ring gear (49), the stage one gear carrier/second
stage sun gear (47) and the stage two gear carrier
(55).
M15-26 TDI Air Starter M15001 6/97
55. Install the stage one gear carrier (47) into the
ring gear (49) and onto the turbine shaft sun
gear (38). Rotate the carrier (47) until fully
seated.
56. Check that the anti-rotation pin (93) is firmly
secured in the gearbox housing (66).
57. Install the gearbox housing - gear carrier
(66,55) onto the ring gear (49) and onto the sun
gear of the carrier (47). Rotate fully to seat.
NOTE: Recheck component orientation and screw
hole alignment.
58. Install the seven screws (67) to secure the gear-
box housing (66) through to the containment
ring (18).
NOTE: It is recommended to alternately tighten two
opposite screws, to ensure a straight pull, before
tightening all seven screws (67).
59. Carefully tighten the seven screws (67) to
ensure that the o-rings (48, 50) on the ring gear
(49) are not cut. Tighten the four screws (67) to
12 LB-Ft (16.9 Nm) torque.
60. Using Aeroshell #6, grease inner diameter of
split rings (77) and inside diameter of starter
drive spline (78). Install the two split rings (77)
onto the starter drive (78).
61. Install the starter drive (78) onto the output shaft
(55) and into the pre-engage piston (75).
Ensure that the split rings (77) remain in position
so that the starter drive (78) seats into the pre-
engage piston (75).
62. Install the compression spring (79) onto the
starter drive (78).
63. Press the lip seal (82) into the pinion housing
(84). The lip must be face down, or toward the
pinion (89).
64. Press the roller bearing (81) into the pinion
housing (84) until seated. Use NYE 377AL to
grease the roller bearing (81).
65. Install the retainer ring (80) in the pinion housing
(84).
66. Lube with Aeroshell #6 and install the o-ring
(83) onto the pinion housing (84).
67. Attach the pinion housing (84) to the gearbox
housing (66).
NOTE: It is recommended to alternately tighten two
opposite screws, to ensure a straight pull, before
tightening all twelve screws (102).
68. Hold the pinion housing (84) firmly against the
gearbox housing (66) and install the twelve
screws (102).
69. Carefully tighten the twelve screws (102) to
ensure that the o-ring (83) is not cut. Tighten
the twelve screws to 12 Lb-Ft (16.9 Nm)
torque.
NOTE: Align the mounting flange (86) with the pinion
housing (84) so that component orientation is correct
for final assembly and installation. (Refer to
Disassembly #1)
70. Lube with Aeroshell #6 and install o-ring (85)
onto the pinion housing (84).
71. Attach the mounting flange (86) to the pinion
housing (84) using twelve screws (87).
72. Carefully tighten the twelve screws (87) to
ensure that the o-ring (85) is not cut. Tighten
the twelve screws (87) to 14 Lb-Ft (19.2 Nm)
torque.
73. Place the pinion collar (88) and the pinion (89)
onto the drive (78). Attach the pinion (89) to the
drive (78) with the split washer (90) and screw
(91). Hold the pinion (89) in a soft-jaw vise and
tighten the screw (91) to 133 Lb-Ft (179.6 Nm)
torque.
Check the rotation of the gear carrier/output
shaft (55). The gear carrier (55) and gears (53)
should all rotate freely.
74. Install three new muffler elements (22) into the
containment ring (18). Position the muffler
retainer (25) and install the three muffler
retainer plates (24) with the six screws (23).
Tighten the six screws (23) to 45 LB-In (5.1
Nm) torque.
75. Position the gasket (92) on the gearbox housing
so that the four holes align with the four tapped
holes.
76. Install the control module (60) onto the gearbox
housing (66).
M15001 6/97 TDI Air Starter M15-27
Ensure that the speed sensor probe on the con-
trol module (60) seats into the counterbore in the
gearbox housing (66).
77. Install the four screws (61) to secure the control
module (60). Tighten to 15 Lb-In (1.69 Nm)
torque.
78. Lube with o-ring lube and install o-ring (65) onto
the gearbox housing (66). Set the solenoid
valve (63) onto the gearbox housing (66) and
secure with the three screws (62). Tighten to 64
Lb-In (7.2 Nm) torque.
79. Install the two male elbows (19 and 21). Item 19
goes into the gearbox housing (66) and Item 21
goes into the solenoid valve (63).
NOTE: Apply pipe thread sealant to fittings before re-
assembly.
80. Install the inlet-to-solenoid hose (59) and the
piston-to-valve hose (20).
81. Attach the solenoid leads to the control module
(60) unmarked terminal strip screws or reattach
the Hirschmann Connector (95) using the con-
nector screw (97). Place the connector gasket
(96) between the male and female Hirschmann
connectors before securing the screw. There is
no positive or negative for these leads.
M15-28 TDI Air Starter M15001 6/97
TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE
Release all system air pressure before attempt-
ing to work on starter system components.
TROUBLE PROBABLE CAUSE SOLUTION
1. Air always flows through
starter.
A. Spool Valve is not sealing cor-
rectly.
A. Check for damaged or contaminated valve seat, dam-
aged O-ring, or damaged spring.
B. Solenoid is not sealing correctly. B. Check solenoid potential at solenoid lead to ground;
should be zero. If not, see 2.C below. Check hose connec-
tions; supply air connects to NC, COM connects to pis-
ton air port on gearbox housing. Check function of solenoid
by disconnecting from control module and applying 12
VDC. Check for damaged or contaminated valve seat.
2. Starter doesnt run; no air
flow from exhaust.
A. Low air pressure; pinion doesnt
engage.
A. Check air pressure at air tank. Air pressure must be in
the 150-80 PSIG range.
B. No power to control module. B. Check electrical system powering control module; bat-
tery, keyswitch, start switch, wire continuity, fuse.
C. Power to control module; sole-
noid doesnt open.
C. Check voltage potential at solenoid lead to ground;
should be 12 VDC after power is applied to control module.
If not, disconnect solenoid from control module. Apply 12
VDC to solenoid; should click open. Verify by applying air to
NC. If solenoid functions correctly, replace control mod-
ule.
D. Air pressure correct; pinion
doesnt engage.
D. Replace damaged piston O-rings. Manually check for
correct piston operation. Check for obstructions in air pas-
sages.
3. Starter doesnt run; normal
air flow from exhaust.
A. Broken turbine rotor. A. Replace turbine rotor. If turbine hoop failed due to over-
speed, reason for overspeed must be determined. Examine
gear train and control module functions.
B. Obstruction or damage in gear
train.
B. Repair or replace.
4. Starter runs; engine cranks
slowly or not at all.
A. Low inlet pressure. A. Inlet air pressure must be in 150-80 PSIG range.
B. Excessive back pressure. B. Replace muffler elements.
C. Damaged turbine nozzles. C. Replace nozzle/valve seat.
D. Broken pinion. D. Replace starter drive.
5. Engine cranks too quickly,
causing premature starter cut-
out.
A. Inlet pressure too high. A. Inlet air pressure must be in 150-80 PSIG range.
6. Starter continues to operate
after starter button is released.
A. Solenoid is stuck open. A. See 1.B above.
B. Spool Valve is not sealing cor-
rectly.
B. See 1.A above.
7. Tank pressure decays after
extended shutdown.
A. Air connections are not tight. A. Disconnect fittings at tank, starter, and solenoid. Inspect
for damage. Repair or replace. Reconnect; use pipe joint
compound at all connections.
B. Air lines are damaged. B. Replace damaged lines.
C. Spool Valve is not sealing cor-
rectly.
C. See 1.A above.
D. Solenoid is open. D. See 1.B above.
M15002 Ingersoll-Rand Turbine Powered Starter M15-1
INGERSOLL-RAND TURBINE POWERED STARTER
The Ingersoll-Rand Pre-engaged Turbine Powered
Air Starter is supplied as a customer specified option.
It requires a dry air supply providing 70 -150 PSI (483
- 1034 kPa) operating pressure.
The dry weight of the starter assembly is approx-
imately 70 lbs. (32 kg). Be certain that adequate
lifting devices are available when Removing or
Installing starter.
MAINTENANCE
Removal
1. Mark or tag all air supply lines.
2. Discharge system air pressure completely.
3. Remove all air lines connected to starter
assembly. Cap all connectors to prevent
entrance of dirt.
4. Mark the starter mounting flange and the
engine mounting boss to ensure proper align-
ment when reinstalling.
5. Remove capscrews securing starter to engine
flywheel housing. Remove starter from the truck
and move to work area for repair.
Installation
1. Lower starter assembly into position and align
the mounting flange holes using match marks
made during removal, with the tapped holes in
the engine.
2. Install the capscrews with lockwashers and
torque to standard torque.
3. On all thread connections throughout the sys-
tem, use non hardening No. 2 Permatex or Loc-
tite Pipe Sealant.
4. Connect all previously removed air lines and
tighten securely.
5. Charge air system and check for leaks.
Disassembly Tips
The following are a few recommended procedures
which will help avoid unnecessary delay in assembly
of the air starter.
1. Always punch mark or scribe adjacent parts on
the motor housing cover, motor housing, gear
case and drive housing, so these members can
be located in the same relative position when
the starter is reassembled.
NOTE: The relative assembled position of the motor
housing cover (6, Figure 15-1), motor housing (13),
gear case (29), and drive housing (58), may vary with
different starter models. If for some reason (parts
replaced), original orientation is lost, refer to Figure
15-22. This starter model orientation code is 1H.
2. Do not remove any part which is a press fit in or
on a sub assembly, unless the removal of that
part is necessary for replacement or repairs.
3. Never save old seals or O-rings for reuse.
4. When grasping a part in a vise, always use
leather covered or copper covered vise jaws to
protect the surface of the part and help prevent
distortion. This is particularly true of threaded
members.
5. Do not press any needle bearings from a part,
unless new needle bearings are to be installed.
Needle bearings are always damaged during
the removal process.
M15-2 Ingersoll-Rand Turbine Powered Starter M15002
FIGURE 15-1. STARTER ASSEMBLY
1. Deflector Retaining Screw
2. Deflector Return Spring
3. Splash Deflector
4. Starter Assembly Cap Screw
5. Cap Screw Washer
6. Housing Exhaust Cover
7. Housing Exhaust Cover Seal
8. Motor Assembly Cylinder O-ring Seal
9. Motor Assembly Housing O-ring Seal
10. Motor Assembly
11. Motor Housing Plug Inlet Boss
12. Motor Housing Plug
12A.Motor Housing Plug
13. Motor Housing
14. Rear Gear Frame Bearing
15. Gear Shaft Retaining Washer
16. Planet Gear Frame
17. Planet Gear Shaft
18. Bearing Spacer
19. Planet Gear
20. Planet Gear Needle Roller
21. Front Bearing Spacer
22. Planet Gear Frame Shaft Seal
23. Front Gear Frame Bearing
24. Rear Gear Case O-ring
25. Intermediate Gear Case
26. Front Gear Case O-ring
27. Intermediate Pinion
28. Intermediate Pinion Retaining Screw
29. Gear Case
30. Drive Gear Shaft Bearing Retainer
31. Rear Drive Gear Bearing
32. Drive Gear Bearing Retainer
33. Drive Gear
34. Bulkhead Retainer
35. Outer Bulkhead O-ring
36. Bulkhead Kit
37. Inner Bulkhead O-ring
38. Piston O-ring
39. Spacer Ring
40. Piston
41. Clutch Spring Cup Retainer
42. Clutch Spring Cup
43. Clutch Spring
44. Clutch J aws
45. Front Drive Gear Bearing
46. Drive Gear Screw O-ring
47. Drive Gear Cup
48. Drive Gear Lock Washer
49. Drive Gear Screw
50. Drive Shaft
51. Rear Drive Shaft Bearing
52. Large Drive Shaft Bearing Retainer
53. Piston Return Spring
54. Spring Seat
55. Front Drive Shaft Bearing
56. Drive Housing Seal
57. Drive Housing O-ring
58. Drive Housing
59. Drive Housing Cap Screw Lock Washer
60. Drive Housing Cap Screw
61. 61. Drive Housing Vent Plug
62. Pinion Spring
63. Pinion Spring Sleeve
64. Drive Pinion
65. Drive Pinion Washer
66. Drive Pinion Retaining Screw
M15002 Ingersoll-Rand Turbine Powered Starter M15-3
FIGURE 15-1. STARTER ASSEMBLY
M15-4 Ingersoll-Rand Turbine Powered Starter M15002
Disassembly -
Housing Exhaust Cover, Motor Assembly, and
Motor Housing
Punch or scribe marks on each housing section
for proper alignment and orientation of compo-
nents during re-assembly.
1. If replacing the motor assembly (10, Figure 15-
1), remove both housing plugs (11) and (12)
and drain the oil from the gearing before begin-
ning disassembly of the starter. Inspect the
magnetic housing plugs (11) and (12) for metal
particles. Very fine metal particles are normal.
Remove particles and reinstall plugs. Large par-
ticles or chips are an indication of a problem
requiring disassembly and inspection of gear
case (29).
2. Using a 8 mm hex head wrench, loosen and
remove capscrews (4, Figure 15-2) and wash-
ers (5).
3. Pull the housing exhaust cover (6) from the
motor housing (13). To dislodge the housing
exhaust cover, rotate it until the ears clear the
motor housing. Using a plastic hammer, tap the
ears alternately until the housing exhaust cover
can be removed from the motor housing.
4. Remove the deflector retaining screw (1, Figure
15-3), deflector retaining spring (2) and the
splash deflector (3) from the housing exhaust
cover (6).
5. Tap the motor housing (13, Figure 15 4) with a
plastic hammer to dislodge it from the interme-
diate gear case (25).
FIGURE 15-2. STARTER DISASSEMBLY
FIGURE 15-3.
FIGURE 15-4.
FIGURE 15-5.
M15002 Ingersoll-Rand Turbine Powered Starter M15-5
6. Grasp the rear of the motor assembly (10, Fig-
ure 15-5) and pull it from the rear of the motor
housing. If the motor assembly is difficult to
remove, lightly push the motor pinion which is
on the front of the motor assembly toward the
exhaust side of the motor housing in order to
free motor assembly.
7. Tap the intermediate gear case (25, Figure 15-
6) with a plastic hammer to dislodge it from the
gear case (29).
8. Position the intermediate gear case on a bench
in a copper faced vise so that the intermediate
pinion (27, Figure 15-7) is secured in the jaws of
the vise. Tighten the vise only enough to hold
the intermediate pinion securely.
9. Loosen the intermediate pinion retaining screw
(28) 1 1/2 turns only. Do not remove.
If the intermediate gear case is not supported on
a bench and if the intermediate pinion retaining
screw is completely removed, the intermediate
gear case and components could fall causing
injury to personnel and/or damage to part.
Tap the intermediate pinion lightly to back the
planet gear frame assembly (Figure 15-8) out of
the intermediate gear case (25).
10. Remove the intermediate gear case assembly
from the vise and remove the intermediate pin-
ion (27). Remove the rear case O-ring (24, Fig-
ure 15-1) and front gear case O-ring (26) from
the intermediate gear case.
11. Remove the planet gear frame assembly (Fig-
ure 15-8) from the intermediate gear case (25).
Using a sleeve that contacts the outer race of
the front gear frame bearing (23), press the
planet gear frame shaft seal (22) and the front
gear frame bearing (23) from the front end and
out of the rear of the intermediate gear case
(25).
FIGURE 15-6.
FIGURE 15-7.
FIGURE 15-8.
M15-6 Ingersoll-Rand Turbine Powered Starter M15002
12. Using a bearing puller, remove the rear gear
frame bearing (14, Figure 15-9) from the planet
gear frame (16) and remove the gear shaft
retaining washer (15).
13. Remove the planet gear shafts (17), planet
gears (19), planet gear bearings (20) and bear-
ing spacers (18).
14. Using a bearing puller, remove the front bearing
spacer (21) and the gear shaft retaining washer
(15) from the front of the planet gear frame by
pressing on the front of the planet gear shaft.
Remove the gear shaft retaining washer only if
the washer or front bearing spacer is damaged.
Disassembly - Drive Housing
Punch or scribe marks on each housing section
for proper alignment and orientation of compo-
nents during re-assembly.
1. Grasp the drive pinion (64, Figure 15-1) in a
copper faced vise with the starter supported on
the workbench.
2. Remove the drive pinion retaining screw (66).
NOTE: This model uses a left-hand thread.
3. Remove the starter from the vise.
4. Remove the drive pinion washer (65) and the
drive pinion (64).
5. Slide the pinion spring sleeve (63) and the pin-
ion spring (62) off the drive shaft (50).
6. Using an impact wrench with a 5/16" x 8" long
(8 mm x 203 mm) hex inserted into the end of
the drive shaft screw (49), loosen and remove
the drive housing cap screws (60) and lock
washers (59).
7. Tap the drive housing (58) with a plastic ham-
mer to help dislodge it from the gear case (29).
Failure to follow this procedure could result in
injury to personnel because of unexpected sepa-
ration of the components.
8. Place the drive housing in an arbor press, pin-
ion end up. Apply a load to the piston (40) using
the arbor press to compress the piston return
spring (53) before removing the bulkhead
retainer (34).
(Do not use compressed air to load the piston.)
9. Using a screwdriver, remove the bulkhead
retainer while the component is still mounted on
the arbor press.
Make sure the tension of the spring pushes the
bulkhead out of the drive housing before remov-
ing the drive housing from the arbor press.
10. Remove the bulkhead (36) from the piston (40).
11. Remove the outer bulkhead ring (35) and the
inner bulkhead ring (37).
12. Slide the drive shaft (50) from the drive housing.
13. Pull the piston return spring (53) off the drive
shaft.
Do not remove the front drive shaft bearing (55)
or the drive housing seal (56) unless replacement
is necessary and new parts are available. The
bearing and/or the seal will always be damaged
when removed from the drive housing.
FIGURE 15-9.
M15002 Ingersoll-Rand Turbine Powered Starter M15-7
14. Remove the piston ring (38, Figure 15-1) from
the piston.
This operation will damage the piston seal.
Therefore, a replacement piston seal must be on
hand.
15. Press the clutch spring cup (42) down and
remove the clutch spring cup retainer (41).
16. Remove the clutch spring cup and clutch spring
(43).
17. Remove the two clutch jaws (43).
18. Remove the front drive gear bearing (45), drive
gear cup (47), drive gear lock washer (48), drive
gear screw ring (46) and drive gear screw (49).
19. Using a screwdriver, remove the large drive
shaft bearing retainer (52).
20. Press the rear drive shaft bearing (51) and drive
shaft (50) out of the piston. If the rear drive shaft
bearing needs to be replaced, proceed as follows:
a. Using a small chisel, cut and remove the
small drive shaft bearing retained in the drive
shaft.
b. Press the rear drive shaft bearing (51) off the
drive shaft.
21. Place the gear case (29) on a workbench.
22. Using retaining ring pliers and working through
the access holes in the gear web, remove the
drive gear bearing retainer (32, Figure 15-10).
23. Pull the drive gear (33, Figure 15-1) out of the
gear case (29).
Do not disassemble the drive gear and clutch
parts for this starter. If the drive shaft is defec-
tive, install a new or rebuilt unit.
24. Using retaining ring pliers, remove the drive
gear shaft bearing retainer (30).
25. Remove the rear drive gear bearing (31) from
the drive gear (33).
FIGURE 15-10.
M15-8 Ingersoll-Rand Turbine Powered Starter M15002
Assembly Tips
1. Always press on the inner ring of a ball type
bearing when installing the bearing on a shaft.
2. Always press on the outer ring of a ball type
bearing when pressing the bearing into a bear-
ing recess.
3. Whenever grasping a starter or part in a vise,
always use leather covered or copper covered
vise jaws. Take extra care with threaded parts
or housings.
4. Except for bearings, always clean every part,
and wipe every part, with a thin film of oil before
installation.
5. Check every bearing for roughness. If an open
bearing must be cleaned, wash it thoroughly in
a suitable cleaning solution and dry with a clean
cloth. Sealed or shielded bearings should never
be cleaned. Work grease thoroughly into every
open bearing before installation.
6. Apply a film of O-ring lubricant to all O-rings
before final assembly.
7. Unless otherwise noted, always press on the
stamped end of a needle bearing when install-
ing the needle bearing in a recess. Use a bear-
ing inserting tool similar to the one shown in
Figure 15-11.
8. Always look for punch or scribe marks on the
motor housing cover, motor housing, gear case
and drive housing, so these members can be
located in the same relative position when the
starter is reassembled.
NOTE: The relative assembled position of the motor
housing cover (6, Figure 15-1), motor housing (13),
gear case (29), and drive housing (58), may vary with
different starter models. If for some reason (parts
replaced), original orientation is lost, refer to Figure
15-22. This starter model orientation code is 1H.
Lubrication
1. Lubricate all O-rings with O-ring lubricant.
2. Coat the front bearing spacer (21, Figure 15-1)
with gear lube before installing.
3. Add approximately 1/3 pint (175 ml) of Dextron
II Automatic Transmission Fluid through the
side plug hole in the motor housing (13).
4. Lubricate the front drive gear (33) with Mobil Oil
Company - Mobilith SHC 007.
5. Lubricate the inside diameter of the drive shaft
(50) with Mobil Oil Company - Mobilith SHC
007.
6. Lubricate the pinion end of the drive shaft with
Tenneco Chemicals - Andersol 786.
7. Wipe a thin film of Mobil Oil Company - Mobilith
SHC 007 in the drive housing (58).
8. Roll the pinion return spring (53) in Mobil Oil
Company - Mobilith SHC 007.
9. Coat the outside of the piston (40) with Mobil Oil
Company - Mobilith SHC 007.
FIGURE 15-11.
M15002 Ingersoll-Rand Turbine Powered Starter M15-9
Assembly - Gear Case and Drive Housing
1. Place the drive gear bearing retainer over the
rear end of the drive gear.
2. Using an arbor press, press the rear drive gear
bearing (31, Figure 15-1) onto the rear end of
the drive gear (33).
3. Using a plastic hammer, seat the rear drive gear
bearing into the gear case (29) by tapping the
opposite end of the drive gear.
4. Using retaining ring pliers install the drive gear
shaft bearing retainer (30).
5. Using retaining ring pliers and working through
the access holes in the gear web, install the
drive gear bearing retainer (32, Figure 15-12).
6. Lubricate the drive gear with Mobil Oil Com-
pany - Mobilith SHC 007.
7. Press the rear drive shaft bearing (51, Figure
15-1) onto the drive shaft.
8. Slide the small bearing retainer convex side
first, onto the drive shaft. Press it into position.
9. Assemble the drive gear screw (49), drive gear
lock washer (48), drive gear cup (47) and drive
gear screw O-ring (46).
10. Grasp the drive shaft (50) in a vise, external
splined end down. Place assembled drive shaft
screw unit into the drive shaft, screwhead down.
Lubricate the inside diameter of the drive shaft
with Mobil Oil Company - Mobilith SHC 007.
11. Slide the front drive gear bearing (45) into the
drive shaft (50).
12. Lubricate with Mobil Oil Company - Mobilith
SHC 007 grease and install the driving clutch
jaw teeth (44) facing up and driven clutch jaw
teeth facing down into the drive shaft (50).
13. Insert the clutch spring (43) into the drive shaft
(50).
14. Insert the clutch spring cup (42) into the drive
shaft (50).
15. Press the inserted parts into the drive shaft (50),
and install the clutch spring cup retainer (41).
If it is necessary to replace the drive housing (58)
and drive components, make sure that the piston
seal has been removed from the rear of the new
piston (40). The piston seal must be removed to
prevent pressure build up which will cause
movement of the planet gear frame shaft seal
(22). If this condition occurs, the piston cannot
retract and the drive pinion (64) will remain in
engagement with the flywheel, causing damage
to the starter drive train and/or starter motor. To
remove the piston seal, insert a screwdriver
inside the lip of the seal and pry it loose from the
piston.
16. Install the piston (40) onto the drive shaft (50)
until the rear drive shaft bearing (51) seats into
the piston.
17. Using a thin flat blade screwdriver to assist in
this operation, coil the large drive shaft bearing
retainer (52) into the groove of the piston to
retain the outer race of the drive shaft bearing
(51).
18. Using O-ring lubricant, lubricate the piston O-
ring (38) and install it in the groove of the Piston.
19. Position the drive housing (58) in an arbor
press, pinion end down. Using a pressing
sleeve of the proper size, press the seal (56)
into the drive housing (58) so that the lip of the
seal faces away from the drive pinion.
20. Using a sleeve that contacts the outer race of
the front drive shaft bearing (55), press the
bearing into the drive housing until it seats.
Drop the piston return spring seat (54) on top of
the front drive shaft bearing (55).
FIGURE 15-12.
M15-10 Ingersoll-Rand Turbine Powered Starter M15002
21. Slide the piston return spring (53) onto the drive
shaft and snap it into the front of the piston so
that it is against the large drive shaft bearing
retainer (52).
22. Lubricate and insert the assembled drive shaft
into the drive housing.
23. Using O-ring lubricant, lubricate and install the
outer bulkhead O-ring (35) and the inner bulk-
head O-ring (37) on the bulkhead (36).
24. Slide the bulkhead onto the piston.
25. With the drive housing in the arbor press, press
down on the rear face of the piston.
Feel the underside of the drive housing to make
sure the drive shaft passes through the bearing.
26. Using a screwdriver, install the bulkhead
retainer (34).
Make sure the bulkhead retainer (34) is properly
seated in the drive housing groove before easing
off the arbor press. Improperly retained parts will
allow parts to separate when removed from the
arbor press causing possible injury to personnel.
27. Remove the drive housing (58) from the arbor
press.
28. Using O-ring lubricant, lubricate and install the
drive housing O-ring (57) in the groove of the
drive housing.
29. Position the assembled gear case (29) on a
workbench. The assembled unit must be
upright to accept the drive housing (58).
30. Carefully position the assembled drive housing
(58) onto the gear case (29) so as not to dam-
age the piston seal. Align the punch marks of
the gear case and drive housing.
31. Install the drive housing capscrew lock washers
(59) and the drive housing capscrews (60) and
tighten to 28 ft. lb. (38 N.m) torque.
32. Using an impact wrench with a 5/16" x 8" (8 mm
x 203 mm) long hex inserted into the end of
drive shaft, tighten the drive gear screw (49) to
57 ft. lb. (77.3 N.m) torque.
33. Lubricate using Tenneco Chemicals - Andersol
786 grease, slide the pinion spring (62) and pin-
ion spring sleeve (63) over pinion end of drive
shaft.
34. Lubricate the pinion end of the drive shaft with
Tenneco Chemicals - Andersol 786 grease and
install the drive pinion (64).
35. Grasp the drive pinion in a leather covered or
copper covered vise with the starter supported
on a workbench.
36. Place the drive pinion washer (65) onto drive
pinion retaining screw (66).
This starter model has a left hand thread. Install
the drive pinion retaining screw (66) into the end
of the drive shaft and tighten to 80 ft. lb. (108.5
N.m) torque.
Assembly -
Intermediate Gear Case, Motor Housing, Motor
Assembly, and Housing Exhaust Cover
1. Using a bearing pressing tool of the proper size,
press the front gear frame bearing (23, Figure
15-13) into the rear of the intermediate gear
case (25). Place spacer ring (39) on bearing.
2. Using sleeve which contacts the outer ring of
the seal, press the planet gear frame seal (22)
into the rear of the intermediate gear case over
the front gear frame bearing.
Make sure that the flat side of the seal is installed
against the bearing.
FIGURE 15-13.
M15002 Ingersoll-Rand Turbine Powered Starter M15-11
3. Install the rear gear case O-ring (24) in the
groove at the rear of the Intermediate gear case
and the front gear case O-ring (26) in the
groove at the front of the intermediate gear
case. Coat both O-rings with O-ring lubricant.
4. Install one gear shaft retaining washer (15, Fig-
ure 15-14) on the front of the planet gear frame
(16). Press the front bearing spacer (21) on the
front shaft of the planet gear frame to hold the
gear shaft retaining washer firmly in position.
Coat the front bearing spacer with gear lube
before installing it. Be careful not to gouge or
scratch the front bearing spacer during installa-
tion as this could result in leakage between the
planet gear frame and gear case
5. Place planet gear frame on a bench, shaft side
down. Place the planet gear bearing (20) inside
the planet gear (19). Place bearing spacer (18)
on top and bottom of bearing and gear. Slide
the components into the slots in the side of the
planet gear frame. Align holes in spacers and
bearings with holes in planet gear frame and
insert planet gear shaft (17), integral keyed end
down, through the spacers and bearing so that
the larger portion of the keyed end of the shaft
contacts the planet gear shaft retaining washer.
Repeat the procedure for the two remaining
planet gears and components.
Do not move or turn over the planet gear frame
until steps 6 and 7 have been completed. Move-
ment of the planet gear frame assembly could
dislodge assembled components, making it nec-
essary to repeat step 5.
6. Install the other planet gear shaft retaining
washer over the shaft at the rear of the planet
gear.
7. Using the proper size bearing inserting tool,
press the rear gear frame bearing (14) on the
shaft at the rear of the planet gear frame.
8. Slide the planet gear frame assembly, coupling
end first, into the rear of the intermediate gear
case (25, Figure 15-15), making sure that the
planet gears mesh with the ring gear. Use care
so as to not damage the seal.
FIGURE 15-14.
FIGURE 15-15.
FIGURE 15-16.
M15-12 Ingersoll-Rand Turbine Powered Starter M15002
9. Install the intermediate pinion (27, Figure 15-
16) making sure that the notches at the rear of
the pinion align with the notches and tangs in
the shaft of the planet gear frame.
10. Clean the threads of the intermediate pinion
retaining screw (28) and apply 2-3 drops of
Permabond HM118 to the threads approxi-
mately 3 mm from the end of the screw and
tighten enough to hold assembly together.
11. For final tightening, position the intermediate
gear case so the intermediate pinion is secured
in the jaws of a leather-covered or copper-faced
vise. Tighten the intermediate pinion retaining
screw to 90 ft. lb. (122 N.m) torque.
12. Remove the intermediate gear case from the
vise and set it on a bench.
The intermediate gear case will work in only one
orientation.
Align the punch marks on the intermediate gear
case (25, Figure 15-17) and the gear case (29)
and using a plastic hammer, tap the intermedi-
ate gear case until it seats in the rear of the
gear case. Make sure the intermediate pinion
meshes with the drive gear.
13. Before installing the motor assembly, coat the
O-rings on the motor assembly and the inside of
the cylinder with O-ring lubricant. Install the
motor assembly through the rear of the motor
housing with the geared end of the rotor toward
the front. Refer to Figure 15-18.
Turn the intermediate pinion so that the gear on
the rotor meshes with the planet gears. Make
sure that the rotor of the motor assembly is
installed flush with the rear of the cylinder.
14. Align the punch marks on the motor housing
(13, Figure 15-19) with the punch marks on the
intermediate gear case (25) and using a plastic
hammer, tap the motor housing until it seats on
the rear of the intermediate gear case.
FIGURE 15-17.
FIGURE 15-18.
FIGURE 15-19.
M15002 Ingersoll-Rand Turbine Powered Starter M15-13
15. Install the splash deflector (3, Figure 15-20),
deflector retaining spring (2) and deflector
retaining screw (1) in the rear of the housing
exhaust cover (6).
Coat the threads of the deflector retaining screws
with non hardening No. 2 Permatex or Locktite
Pipe Sealant.
16. Coat the exhaust cover seal (7, Figure 15-1)
with O-ring lubricant and install in the groove on
the housing exhaust cover.
17. Align the punch marks on the housing exhaust
cover (6, Figure 15-21) with the punch marks on
the motor housing (13) and using a plastic ham-
mer, tap the housing exhaust cover until it
seats.
18. Install the housing exhaust cover (6) on the rear
of the motor housing (13) using the starter
assembly cap screws (4) and cap screw wash-
ers (5). Use an 8 mm hex head wrench to
tighten each gradually to a final torque of 45 to
50 ft. lb. (61 to 68 N.m).
Use non hardening No. 2 Permatex or Locktite
Pipe Sealant.
19. Install the bottom housing plug (12A, Figure 15-
1) and the housing plug inlet boss (11). Put the
starter on its side with the side plug (12) hole
upward. Be certain to keep starter level. Using
Dextron II Automatic Transmission Fluid, add 1/3
pint (175 ml) [or until fluid just begins to come out
of hole] through the side plug (12) hole in the
motor housing (13).
CAUTION - Do not overfill!
Install the side housing plug (12) and tighten all
plugs to 5 to 10 ft. lb. (6.8 to 13.6 N.m) torque.
FIGURE 15-20.
FIGURE 15-21.
M15-14 Ingersoll-Rand Turbine Powered Starter M15002
FIGURE 15-22. STARTER CASE ORIENTATION CODES
M15002 Ingersoll-Rand Turbine Powered Starter M15-15
TEST AND INSPECTION PROCEDURE
Inadvertent application of air pressure to the
" OUT" port will result in drive malfunction (Pin-
ion will fail to retract). If this condition occurs,
loosen the drive housing cap screws (60, Figure
15-1) to vent the gear case (29). Also, loosen
housing plugs (11) and (12) to vent the motor.
1. Clutch Ratcheting - Turn the drive shaft pinion
(64, Figure 15-1) by hand in the direction of
starter rotation. The clutch should ratchet
smoothly with a slight clicking action.
2. Motor and Gearing Freeness - Turn the drive
shaft pinion (64, Figure 15-1) opposite the
direction of starter rotation. The drive shaft pin-
ion should turn by hand.
3. Pinion Engagement - Plug the "OUT" port in the
drive housing (58, Figure 15-1). Apply 70 psi
(483 kPa) as needed. In its normal position, the
distance from the mounting flange to the end of
the drive shaft (50) should be 1-3/4". In its
extended position, the distance from the mount-
ing flange to the end of the drive shaft should be
2-7/8". While the drive shaft is extended, push
the drive pinion (64) back on the helical splined
shaft. The rear face of the drive pinion must
move back 0.47" 0.035".
4. Motor Action - Secure the starter in a vise and
apply 90 psi (620 kPa) pressure using a 3/8" (9
mm) supply line to the inlet of the motor. Starter
should run smoothly.
5. Motor Seals - Plug the exhaust and slowly apply
20 psi (138 kPa) pressure to the inlet of the
motor. Immerse the starter for 30 seconds in a
nonflammable, bubble producing liquid. If the
starter is properly sealed, no bubbles will
appear.
6. Gear Case Seals - Plug the exhaust and slowly
apply 20 psi (138 kPa) pressure to the inlet of
the motor. Immerse the starter for 30 seconds in
a nonflammable, bubble-producing liquid. There
should be no leakage in the housing joints in the
gear case area or in the shaft seal in the inter-
mediate gear system. If the starter is properly
sealed, no bubbles will appear.
7. Confirm Motor Rotation - Remove housing plug
(12, Figure 15-1). Use a 1/4" hex drive to rotate
the motor to verify proper motor adjustment.
Intermediate gearing output should rotate oppo-
site the required starter rotation while observing
from the pinion side. Replace the housing plug
when finished.
8. Confirm Drive Rotation - Apply low pressure to
the motor and observe rotation. The drive pinion
(64, Figure 15-1) must rotate in the direction
stamped on the nameplate. Chamfer on pinion
teeth should be on the trailing edge of the gear
tooth.
9. Drive Housing Function - Apply 150 psi (1034
kPa) to the "IN" port of the drive housing (58,
Figure 15-1). Cycle five times. Air should
exhaust through the "OUT" port during each
cycle.
10. Exhaust Deflector Operation - Install starter on
testing fixture. Apply low air pressure to the
motor and observe. The deflector must return to
its normal position after operation of the starter.
11. Drive Housing Leakage - Plug the drive housing
(58, Figure 15-1) "OUT" port and apply 150 psi
(1034 kPa) to the "IN" port to extend the drive
shaft (50). There should be no leakage.
12. Drive Shaft Seal Leakage - Plug the "OUT" port
on the drive housing (58, Figure 15-1). Apply 90
psi (620 kPa) to the "IN" port and 20 psi (138
kPa) to the vent hole. After five seconds, there
should be no leakage.
M15-16 Ingersoll-Rand Turbine Powered Starter M15002
TROUBLESHOOTING CHART
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Motor will not run.
No air supply. Check for blockage or damage to air supply lines or tank.
Damaged motor assembly. Inspect motor assembly and power train and repair or
replace if necessary.
Foreign material in motor and/or piping. Remove motor assembly and/or piping and remove
blockage.
Blocked exhaust system. Remove housing exhaust cover and check for blockage.
Defective control valve or relay valve. Replace control valve or relay valve.
TROUBLE: Loss of Power.
Low air pressure to starter. Check air supply.
Restricted air supply line. Check for blockage or damage to air lines.
Relay valve malfunctioning. Clean or replace lines or relay valve. Lube relay valve.
Exhaust flow restricted. Check for blocked or damaged piping. Clean or replace
piping. Check for dirt or foreign material and clean or
remove. Check for ice build-up. Melt ice and reduce
moisture build-up to starter.
Damaged motor assembly. Replace motor assembly.
TROUBLE: Drive will not engage.
No pressure to drive housing port. Check air supply.
Internal drive housing ports blocked. Remove blockage.
Fluid in drive unit components. Remove fluid.
Damaged or worn piston assembly, O-rings, or seals. Replace damaged or worn parts.
O-rings and seals dry. Re-lube O-rings and seals.
Severe wear in steering control unit. Repair steering control unit.
TROUBLE: Motor runs, pinion engages, but does not rotate flywheel.
Damaged or broken drive train. Disassemble drive train and replace worn or damaged
parts.
M15002 Ingersoll-Rand Turbine Powered Starter M15-17
TROUBLESHOOTING CHART (Continued)
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Excessive butt engagement.
Damaged drive pinion or flywheel. Inspect drive pinion and flywheel and replace if neces-
sary.
Damaged starter drive or components. Inspect drive components and replace worn or damaged
parts.
Low air pressure. Check air supply.
Wrong drive pinion. Replace with proper drive pinion.
TROUBLE: Oil blowing out of exhaust.
Oil in air supply line. Inspect air line and remove source of oil.
Splash deflector retaining screw or pipe plug missing. Install splash deflector retaining screw or pipe plug.
Worn or damaged rotor seals or static O rings. Replace static seals on outside of motor.
TROUBLE: Oil leaking from gear case.
Worn or damaged O rings. Replace O-rings.
Loose joints. Make sure that joints fit properly and that starter assem-
bly cap screws are tightened to 60 ft lb. Make sure that all
seals and O rings fit and seal properly at their perimeters.
If they do not, replace with new seals and o rings.
Excessive high speed operation. Operate according to recommendations.
High number of start cycles. Replace worn components.
Loose or leaking pipe plugs. Tighten or replace pipe plugs using proper pipe sealant.
Splash deflector retaining screw or pipe plug missing. Tighten splash deflector retaining screw or replace pipe
plugs.
M15-18 Ingersoll-Rand Turbine Powered Starter M15002
TROUBLESHOOTING CHART (Continued)
.
.
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Air or gas leakage.
Loose joints. Insure that joints fit properly and that starter assembly
capscrews are tightened to 60 ft lb. Make sure that all
seals and O rings fit and seal properly at their perimeters.
If not, replace with new seals and O rings.
Excessive high speed operation. Operate according to recommendations.
High number of start cycles. Replace worn components.
Loose or leaking pipe plugs. Tighten or replace pipe plugs using proper pipe sealant.
Splash deflector retaining screw loose or pipe
plug missing.
Tighten splash deflector retaining screw or replace pipe
plug.
M17001 8/91 24 VDC Electric Start System M17-1
24 VDC ELECTRIC START SYSTEM
The 140M, 210M, 325M, and 385M model trucks use
a single cranking motor and magnetic switch. All
other models use two cranking motors and two mag-
netic switches. Refer to pages M17-9 and M17-10 for
the appropriate schematic.
OPERATION
Heavy duty batteries supply 24VDC to each of the
cranking motors through magnetic switches activated
by the key switch on the instrument panel.
When the keyswitch is placed in the Start position,
the magnetic switches close, connecting the motor
solenoid S terminals to the batteries. When the
solenoid windings are energized, the plunger (56,
Figure 17-3) is pulled in, moving the starter drive (71)
assembly forward in the nose housing to engage the
engine flywheel ring gear. Also, when the solenoid
plunger is pulled in, the main solenoid contacts close
to provide current to the motor armature and crank-
ing takes place. When the engine starts, an overrun-
ning clutch in the drive assembly protects the
armature from excessive speed until the keyswitch is
released. When the keyswitch is released, a return
spring causes the drive pinion to disengage.
After the engine is running, a normally closed pres-
sure switch senses engine oil pressure and opens
the electrical circuit to prevent actuation of the
motor(s) after the engine has started.
CRANKING MOTOR
Removal
1. Disconnect battery power using the appropriate
procedure below:
a. If truck is equipped with a battery equalizer,
place the ATEC or DDEC power switch in the
Off position.
b. Open the battery disconnect switch to
remove power from the system.
c. If not equipped with a battery disconnect
switch, remove battery cables using the fol-
lowing sequence if equipped with battery
equalizer:
1.) Remove the battery positive (+) cables
first.
2.) Remove the negative (-) cables last.
2. Mark wires and cables and remove from motor
(1, Figure 17-1) and solenoid (3) terminals.
3. Remove motor mounting capscrews and lock
washers (2).
4. Remove motor assembly from flywheel hous-
ing.
Installation
1. Align motor (1, Figure 17-1) housing with the
flywheel housing adaptor mounting holes and
slide into position.
2. Insert motor mounting capscrews and lock
washers (2).
3. Connect marked wires and cables to motor and
solenoid terminals.
4. If the truck is equipped with a battery equalizer,
no battery disconnect and the battery cables
were removed, reinstall in the following
sequence:
a. Install the negative (-) cables first.
b. Install the positive (+) cables.
c. Turn the ATEC or DDEC switch On.
5. On other models, close battery disconnect
switch or connect battery cables to the battery if
not equipped with a battery disconnect switch.
FIGURE 17-1. TYPICAL STARTER INSTALLATION
1. Cranking Motor
2. Capscrews &
Washers
3. Solenoid
M17-2 24 VDC Electric Start System M17001 8/91
CRANKING MOTOR
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. Refer to Section D for additional
information.
Wiring - Inspect all wiring for damage or
loose connections at the keyswitch,
magnetic switches, solenoids and cranking
motor(s). Clean, repair or tighten as
required.
If the above inspection indicates the starter motor to
be the cause of the problem, remove the motor and
perform the following tests prior to disassembly to
determine the condition of the motor and solenoid
and repairs required.
Preliminary Inspection
1. Check the starter to be certain the armature
turns freely.
a. Insert a flat blade screwdriver through the
opening in the nose housing.
b. Pry the pinion gear to be certain the arma-
ture can be rotated.
2. If the armature does not turn freely, the starter
should be disassembled immediately.
3. If the armature can be rotated, perform the No-
Load Test before disassembly.
No-Load Test
Refer to Figure 17-2 for the following test setup.
Be certain switch is open before connections or
disconnections are made during the following
procedures.
1. Setup the motor for test as follows:
a. Connect a voltmeter from the motor terminal
to the motor frame.
b. Use an RPM indicator to measure armature
speed.
c. Connect a carbon pile across one battery to
limit battery voltage to 20 VDC.
Do not apply voltages in excess of 20 volts.
Excessive voltage may cause the armature to
throw windings.
d. Connect the motor and an ammeter in series
with two fully charged 12 volt batteries.
e. Connect a switch in the open position from
the solenoid battery terminal to the solenoid
switch terminal.
2. Close the switch and compare the RPM, cur-
rent, and voltage reading to the following speci-
fications:
RPM: 5500 Minimum to 7500 Maximum
AMPS: 95 Minimum to 120 Maximum
VOLTS: 20 VDC
Interpreting Results of Tests
1. Rated current draw and no-load speed indi-
cates normal condition of the cranking motor.
2. Low free speed and high current draw indi-
cates:
a. Too much friction; tight, dirty, or worn bear-
ings, bent armature shaft or loose pole shoes
allowing armature to drag.
b. Shorted armature. This can be further
checked on a growler after disassembly.
c. Grounded armature or fields. Check Further
after disassembly.
FIGURE 17-2. NO-LOAD TEST CIRCUIT
M17001 8/91 24 VDC Electric Start System M17-3
3. Failure to operate with high current draw indi-
cates:
a. A direct ground in the terminal or fields.
b. Frozen bearings (this should have been
determined by turning the armature by hand).
4. Failure to operate with no current draw indi-
cates:
a. Open field circuit. This can be checked after
disassembly by inspecting internal connec-
tions and tracing circuit with a test lamp.
b. Open armature coils. Inspect the commuta-
tor for badly burned bars after disassembly.
c. Broken brush springs, worn brushes, high
insulation between the commutator bars or
other causes which would prevent good con-
tact between the brushes and commutator.
5. Low no-load speed and low current draw indi-
cates:
a. High internal resistance due to poor connec-
tions, defective leads, dirty commutator and
causes listed under Number 4.
6. High free speed and high current draw indicates
shorted fields. If shorted fields are suspected,
replace the field coil assembly and check for
improved performance.
Disassembly
Normally the cranking motor should be disassembled
only as far as necessary to repair or replace defec-
tive parts.
1. Note the relative position of the solenoid (53,
Figure 17-3), lever housing (78), nose housing
(69), and C.E. frame (1) so the motor can be
reassembled in the same manner.
2. Disconnect field coil connector (42) from sole-
noid motor terminal, and lead from solenoid
ground terminal.
3. Remove the brush inspection plates (52), and
brush lead screws(15).
4. Remove the attaching bolts (34) and separate
the commutator end frame (1) from the field
frame (35).
5. Separate the nose housing (69) and field frame
(35) from lever housing (78) by removing
attaching bolts (70).
6. Remove armature (45) and drive assembly (71)
from lever housing (78).
7. Separate solenoid (53) from lever housing by
pulling apart.
Cleaning and Inspection
1. The drive (71), armature (45) and fields (46)
should not be cleaned in any degreasing tank,
or with grease dissolving solvents, since these
would dissolve the lubricant in the drive and
damage the insulation in the armature and field
coils.
2. All parts except the drive should be cleaned
with mineral spirits and a clean cloth.
3. If the commutator is dirty, it may be cleaned with
No. 00 sandpaper.
NOTE: Never use emery cloth to clean commutator.
4. Inspect the brushes (13, Figure 17-3) for wear.
a. If worn excessively when compared with a
new brush, they should be replaced.
b. Make sure the brush holders (10) are clean
and the brushes are not binding in the holders.
c. The full brush surface should ride on the
commutator to give proper performance.
Check by hand to insure that the brush
springs (16) are giving firm contact between
the brushes (13) and commutator.
d. If the springs (16) are distorted or discolored,
they should be replaced.
Armature Servicing
If the armature commutator is worn, dirty, out of
round, or has high insulation, the armature (45)
should be put on a lathe and the commutator turned
down. The insulation should then be undercut .031
in. (.79 mm) wide and .031 in. (.79 mm) deep, and
the slots cleaned out to remove any trace of dirt or
copper dust. As a final step in this procedure, the
commutator should be sanded lightly with No. 00
sandpaper to remove any burrs left as a result of the
undercutting procedure.
The armature should be checked for opens, short cir-
cuits and grounds as follows:
1. Opens are usually caused by excessively long
cranking periods. The most likely place for an
open to occur is at the commutator riser bars.
Inspect the points where the conductors are
joined to the commutator bars for loose connec-
tions. Poor connections cause arcing and burn-
ing of the commutator as the cranking motor is
used. If the bars are not too badly burned,
repair can often be effected by resoldering or
welding the leads in the riser bars (using rosin
flux), and turning down the commutator in a
lathe to remove the burned material. The insula-
tion should then be undercut.
M17-4 24 VDC Electric Start System M17001 8/91
2. Short circuits in the armature are located by use
of a growler. When the armature is revolved in
the growler with a steel strip such as a hacksaw
blade held above it, the blade will vibrate above
the area of the armature core in which the short
circuit is located. Shorts between bars are
sometimes produced by brush dust or copper
between the bars. These shorts can be elimi-
nated by cleaning out the slots.
3. Grounds in the armature can be detected by the
use of a 110-volt test lamp and test points. If the
lamp lights when one test point is placed on the
commutator with the other point on the core or
shaft, the armature is grounded. Grounds occur
as a result of insulation failure which is often
brought about by overheating of the cranking
motor produced by excessively long cranking
periods or by accumulation of brush dust
between the commutator bars and the steel
commutator ring.
Field Coil Checks
The field coils (46, figure 17-3) can be checked for
grounds and opens by using a test lamp.
1. Grounds - The ground connections must be dis-
connected during this check. Connect one lead
of the 110 volt test lamp to the field frame (35)
and the other lead to the field connector (42). If
the lamp lights, at least one field coil is
grounded and must be repaired or replaced.
2. Opens - Connect test lamp leads to ends of
field coils (46). If lamp does not light, the field
coils are open.
Field Coil Removal
Field coils can be removed from the field frame
assembly by using a pole shoe screwdriver. A pole
shoe spreader should also be used to prevent distor-
tion of the field frame. Careful installation of the field
coils is necessary to prevent shorting or grounding of
the field coils as the pole shoes are tightened into
place. Where the pole shoe has a long lip on one
side and a short lip on the other, the long lip should
be assembled in the direction of armature rotation so
it becomes the trailing (not leading) edge of the pole
shoe.
M17001 8/91 24 VDC Electric Start System M17-5
FIGURE 17-3. CRANKING MOTOR ASSEMBLY
1. C.E. Frame
2. Washers
3. O-Ring
4. Insulator
5. Support Plate
6. Brush Plate
Insulator
7. Washers
8. Plate & Stud
9. Plate
10. Brush Holder
11. Lockwasher
12. Screw
13. Brush
(12 required)
14. Lockwasher
15. Screw
16. Brush Spring
17. Screw
18. Screw
19. Screw
20. Lockwasher
21. Plate
22. Brush
Holder Insulator
23. Screw
24. Lockwasher
25. Washer
26. O-Ring
27. Bushing
28. Insulator
29. Washer
30. Lockwasher
31. Nut
32. Nut
33. Lockwasher
34. Screw
35. Field Frame
36. Stud Terminal
37. Bushing
38. Gasket
39. Washers
40. Washer
41. Nut
42. Connector
43. Lockwasher
44. Nut
45. Armature
46. Field Coil
(6 Coils)
47. Shoe
48. Insulator
49. Screw
50. Washer
51. O-Ring
52. Inspection Plug
53. Solenoid
Housing
54. Lockwasher
55. Screw
56. Plunger
57. Washer
58. Boot
59. Washer
60. Spring
61. Retainer
62. Snap Ring
63. Shift Lever
64. Nut
65. O-Ring
66. O-Ring
67. Snap Ring
68. Lever Shaft
69. Drive Housing
70. Screw
71. Drive Assembly
72. Gasket
73. Plug
74. Gasket
75. Brake Washer
76. Screw
77. Lockwasher
78. Lever Housing
79. Washer
80. O-Ring
M17-6 24 VDC Electric Start System M17001 8/91
Solenoid Checks
A basic solenoid circuit is shown in Figure 17-4.
Solenoids can be checked electrically using the fol-
lowing procedure.
Test
1. With all leads disconnected from the solenoid,
make test connections as shown to the sole-
noid, switch terminal and to the second switch
terminal G, to check the hold-in winding (Fig-
ure 17-5).
2. Use the carbon pile to decrease the battery volt-
age to 20 volts. Close the switch and read current.
a. The ammeter should read 6.8 amps maximum.
3. To check the pull-in winding, connect from the
solenoid switch terminal S to the solenoid
motor M or MTR terminal (Figure 17-6).
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 the battery volt-
age 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 battery lead from
G (Figure 17-5) and from MTR (Figure 17-6)
to the solenoid case. Ammeter should read
zero. If not, the winding is grounded.
FIGURE 17-4. SIMPLIFIED SOLENOID CIRCUIT
FIGURE 17-5. SOLENOID HOLD-IN WINDING
TEST
FIGURE 17-6. SOLENOID PULL-IN WINDING TEST
M17001 8/91 24 VDC Electric Start System M17-7
Assembly
Lubricate all bearings, wicks, and oil reservoirs with
SAE No. 20 oil during assembly.
Bearing Replacement:
1. If any of the bronze bearings are to be replaced,
dip each bearing in SAE No. 20 oil before
pressing into place.
2. Install wick, soaked in oil, prior to installing
bearings.
3. 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.
4. Do not cross-drill bearings. Because the bear-
ing is so highly porous, oil from the wick touch-
ing the outside bearing surface will bleed
through and provide adequate lubrication.
5. 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 the armature (45, Figure 17-3) into the
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 the end frame (1) on the armature
shaft. Slide end frame and armature into
place against the field frame.
c. Insert screws (34) and washers (33) and
tighten securely.
2. Assemble lever (63) into lever housing (78) If
removed.
3. Place washer (79) on armature shaft and install
new O-ring (80). Position drive assembly (71) in
lever (63) in lever housing. Apply a light coat of
lubricant (Delco Remy Part No. 1960954) on
washer(75) and install over armature shaft.
Align lever housing with field frame and slide
assembly over armature shaft. Secure with
screws (76) and washers (77).
4. Assemble and install solenoid assembly
through lever housing and attach to field frame.
Install nut (64) but do not tighten at this time.
Install brush inspection plugs (52).
5. Using a new gasket (72), install drive housing
(69) and secure with screws (70).
6. Assemble field coil connector (42) to solenoid.
7. Adjust pinion clearance per instructions on the
following page.
8. After pinion clearance has been adjusted, install
gasket (74) and plug(73).
Pinion Clearance
To adjust pinion clearance, follow the steps listed
below.
1. Make connections as shown in Figure 17-7.
2. Momentarily flash a jumper lead from terminal
G to terminal MTR. The drive will now shift
into cranking position and remain so until the
batteries are disconnected.
3. Push the pinion or drive back towards the com-
mutator end to eliminate slack movement.
4. The distance between the drive pinion and
housing should be between .330 in. to .390 in.
(8.3 mm to 9.9 mm) as shown in Figure 17-8.
5. Adjust clearance by turning shaft nut (64, Fig-
ure 17-3).
FIGURE 17-7. PINION CLEARANCE CHECK
CIRCUIT
M17-8 24 VDC Electric Start System M17001 8/91
Magnetic Switch
The magnetic switch is a sealed unit and not repair-
able.
Removal
1. Remove battery power as described in Crank-
ing Motor Removal, page M17-1.
2. Disconnect cables from the switch terminals
and wires from coil terminals (Figure 17-9).
NOTE: If the magnetic switch has a diode across the
coil terminals, mark the leads prior to removal to
ensure correct polarity during installation.
3. Remove mounting capscrews and washers.
Remove switch from mounting bracket.
4. The switch coil circuit can be tested as
described below.
Installation
1. Attach magnetic switch to the mounting bracket
using the capscrews and lockwashers removed
previously.
2. Inspect cables and switch terminals. Clean as
required and install cables.
3. Install the diode across the coil terminals if
required. Be certain diode polarity is correct.
(Refer to the wiring diagrams on the following
pages.) Attach wires from the truck harness to
the coil terminals (See Figure 17-9).
4. Connect battery power as described in Canking
Motor Installation, page M17-1.
Coil Test
1. Using an ohmmeter, measure the coil resis-
tance across the coil terminals.
a. The coil should read approximately 28W at
72
F (22.2
C).
b. If the ohmeter reads , the coil is open and
the switch must be replaced.
c. If the ohmmeter reads 0 W, the coil is
shorted and the switch must be replaced.
2. Place one of the ohmmeter probes on a coil ter-
minal and another on the switch mounting
bracket. If the meter displays any resistance
reading, the coil is grounded and the switch
must be replaced.
3. The ohmmeter should display when the
probes are placed across the switch terminals.
NOTE: The switch terminals should show continuity
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
from delivering adequate current to the cranking
motor. If the coil tests are satisfactory but the switch
is still suspect, it should be replaced with a new part.
FIGURE 17-8. CHECKING PINION CLEARANCE
FIGURE 17-9. MAGNETIC SWITCH ASSEMBLY
M17001 8/91 24 VDC Electric Start System M17-9
ELECTRIC START SYSTEM WIRING DIAGRAMS
The following wiring diagrams represent the starter system hookup for various
truck models. Refer to the schematics in Section R for additional components
and wiring information.
M17-10 24 VDC Electric Start System M17001 8/91
M20001TC 6/96 Index M20-1
ON-BOARD WEIGHING SYSTEM
ON-BOARD WEIGHING SYSTEM INDEX
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-3
TIPS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-3
DECK MOUNTED LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-4
OPERATIONS AND FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-4
DISPLAY LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-4
METRIC/SHORT TON SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-4
DATA STORAGE LOGIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-4
DATA PRINT OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5
CLEAR MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5
SETTING THE TIME OF DAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-5
CALIBRATING THE PAYLOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
DIMMING THE PAYLOAD METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
SERVICING THE PAYLOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
REPLACING PRINTER PAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-6
To Replace Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Troubleshooting Paper Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
REPLACEMENT OF PRINTER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Printer Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-7
Printer Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-8
M20-2 Index M20001TC 6/96
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
PRESSURE SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
To Perform Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
INCLINOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
RELAYS and Data Storage Trigger Module (DSTM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-10
PAYLOAD METER SELF TEST FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-11
CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-12
ON-BOARD WEIGHING SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20-14
TROUBLESHOOTING THE HAULPAK
. Normal.
Open or short in circuit 39FE. Examine wiring on inclinometer and housing for opens.
Open in circuit 39F at inclinometer. Examine wiring for opens.
Faulty inclinometer. Replace if no shorts or opens in wiring are found.
Broken inclinometer mounting. Repair mount.
POSSIBLE CAUSES CORRECTION
Operators not using brake lock switch at loading area. Remind operators to use brake lock switch at loading
area and at dumping area.
Memory is full. Clear memory if "FULL" error code is displayed.
Excess carryback in body. Remove carryback to allow system to reset to record
next load.
Fault in DSTM wiring or module. Check for proper operation of DSTM, check wiring, and
replace module if necessary.
Fault in TR1 wiring. Troubleshoot wiring and replace relay if necessary.
Fault in body up circuit (63L) from AID module. Troubleshoot wiring.
Material in body is less than 50% of rated payload. Normal.
M20-18 Troubleshooting the On-Board Weighing System M20001C2 6/96
PROBLEM: Readings are suspected of being inaccurate.
PROBLEM: Printing is faint or blotchy.
PROBLEM: Lights are not working.
PROBLEM: System is not working, display is blank.
POSSIBLE CAUSES CORRECTION
Computer in need of calibration. Calibrate computer.
Loading area uneven or rutted. Grade loading area to provide a smooth level surface.
Low charge in suspension, especially oil level in rears. Recharge suspension and recalibrate computer.
Operators are backing truck up on rocks, berms, or
bank at loading area.
Remind operators not to back up on such obstacles.
Operators releasing brake lock switch too soon after
last pass is dropped in body.
Remind operators to wait several seconds after last
pass before releasing brake lock to allow suspension
pressures to stabilize.
Inclinometer out of adjustment.
Adjust inclinometer to read 0.0 0.1
on level surface.
Operators are not using brake lock switch properly. Remind operators of proper use of switch.
Unit is set for metric tons when short tons are desired. Check to see if jumper wire structure is installed in har-
ness inside payload meter housing.
Malfunction in brake lock hydraulics, allowing front and
rear brakes to energize during brake lock (all trucks
except 830E).
Troubleshoot system.
Pressure sensors wired in incorrect sequence. Verify proper sequence as outlined in checkout proce-
dure.
POSSIBLE CAUSES CORRECTION
Printer paper exposed to bright sunlight, heat, or cold
and has become inactive.
Replace paper with fresh roll.
Printer is cold. Warm up cab interior to warm up the printer.
Foreign material in printer. Carefully clean printer assembly.
Printer paper inserted upside-down. Remove and insert paper correctly.
Defective printer assembly. Replace printer cartridge.
POSSIBLE CAUSES CORRECTION
Burned out light bulbs. Replace burned out bulbs.
15 amp circuit breaker in circuit 39A is tripped. Look for shorts and reset circuit breaker.
POSSIBLE CAUSES CORRECTION
5 amp circuit breaker in circuit 39G is tripped. Look for shorts and reset circuit breaker.
Open circuit to computer. Verify +24V on 39G when key and control power are on,
and verify ground (710) connections.
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-19
On-Board Weighing System
ON-BOARD WEIGHING SYSTEM EXPANDED MEMORY BOX
The On-Board Weighing System expanded memory
box provides additional storage space for payload
data recorded by the payload meter. As the payload
meter records each load, the payload data is simulta-
neously transferred to the expanded memory box by
means of a cable. Every payload is recorded in both
places, but only the data in the expanded memory
box is accessible by using a personal computer (PC).
Load data for 3000 loads can be stored in the
expanded memory box.
To access the payload data, a personal computer
(IBM compatible), a special serial cable, and a disc
copy of the expanded memory box software pro-
grams is needed. The expanded memory box soft-
ware programs can be operated from a floppy disc or
from a hard drive. It is recommended that the pro-
grams are copied to and operated from a hard drive,
as the storage space for the payload data is limited
on a floppy disc.
Before a truck is placed in service, the expanded
memory box must be "set-up" in order to record the
payload data correctly. The payload data contains a
truck identification number, payload weight and the
date and time of each payload. Refer to "INITIAL
START UP OF THE EXPANDED MEMORY BOX" for
start up instructions.
The customer must choose a method to store and
analyze all the data that is collected from the
expanded memory box from the fleet of trucks. There
are several options available depending on the use
of the payload data. For more information on storing
payload data, refer to "PAYLOAD DATA".
The On-Board Weighing System expanded memory
software has two programs that perform different
functions. One is called DOWNLOAD and the other
is ANALYSIS.
DOWNLOAD
This program provides a means to view and/or down-
load data that is stored in the expanded memory box.
The payload data can be downloaded from the box
and into a PC and stored into a new file, or added to
an existing file.
ANALYSIS
The analysis program is used to view or print payload
data that has already been downloaded and stored in
a file on the PC. The payload data can be viewed as
a data table or as a graph. The Data Table will dis-
play a complete payload history of a particular file.
The Graph Data will display payload data in bar
graphs. To print payload data, in either table or graph
form, the correct printer must be selected in the
"SETUP" option in the Analysis program. Refer to the
"SETUP" option for more information on printers.
Tips For Operation
To leave a screen and return to the previous
screen without saving any changes, just press
the "ESC" key.
Use the "TAB" and "ARROW" keys to highlight
the desired command, then press "ENTER" to
execute the command.
If directions say type "download", type on the key
board only the letters between the " " and not the
parenthesis.
To exit either program and return to the DOS
prompt, hold down the "ALT" key and press the
"X" key.
Press the F1 key at any time for help. Can be
used before selecting a menu option for general
information or, after selecting a menu option for
more detailed information on that selection.
The expanded memory box program disc
contains two sample payload data files called
"ATEST" and "BTEST". These files were included
so personnel can examine them and become
familiar with payload data files ahead of time.
Before the expanded memory box system is
placed into service for the first time, the box must
be "set up" in order to record data correctly. Refer
to "Initial Start Up Of The Expanded Memory
Box".
A method of recording and storing payload data
must be determined. Refer to "Payload Data" for
more information.
Refer to the Analysis program for printing
options.
M20-20 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
GETTING STARTED
Determine if the program has been loaded onto the
PC hard drive or if the program is located on an aux-
iliary disc.
Installing The Software
1. Power up (turn on) the personal computer.
2. Insert the floppy disc containing the expanded
memory box program into the drive bay.
3. The screen prompt should be the "C:\". Change
the C:\>>to A:\>>by typing "A:", then press
"ENTER". The prompt should now be "A:\>>".
4. At the A:\>>, type "install", then press "ENTER".
This will create a new subdirectory on the hard
drive called "PAYLOAD". The entire program
will be copied from the floppy disc to the pay-
load subdirectory on the internal hard disc.
When the transfer is complete, the prompt on
the screen should be "C:\>>".
5. Using the special serial cable supplied with the
unit, connect the personal computer to the
expanded memory box.
6. With the ignition key switch and the PC turned
on, the system is ready for use.
7. To start the program, type "DOWNLOAD" or
"ANALYSIS".
NOTE: To start the program on the floppy drive, omit
step 4 completely.
INITIAL START UP OF THE EXPANDED
MEMORY BOX
When the expanded memory box is placed into ser-
vice for the first time, the box must be "set up" in
order to record data correctly. Obtain a PC with the
expanded memory program on it and perform steps
5-7 in "Getting Started". Then perform steps 1-4 to
"set up" the expanded memory box.
1. Communication Port
Tells the PC which serial communication port to use
to communicate to the expanded memory box.
a. At the C:\>> prompt, type "download" and
press "ENTER".
b. Hold down the "Alt" key and press "S".
c. Use the arrow keys to highlight "Set Comm
Port" and press "ENTER". Use the tab and
arrow keys to select the proper comm port
that the cable (from the expanded memory
box) is connected to and press "ENTER".
NOTE: If incorrect comm port is selected, an error
message will appear in the next step. Change the
comm port selection, quit the program, open
download program again and try again to access the
box.
2. Set Truck Number
This is the vehicle identification number that will
appear in all payload data that is stored or printed
out.
a. Hold down the "Alt" key and press "S".
b. Use the arrow keys to highlight "Set Truck
Number" and press "ENTER".
c. Press the tab key to highlight the truck num-
ber box. Type the appropriate truck number
in the empty box and press "ENTER".
3. Set Maximum Loads
This should be set at 199 loads.
a. Hold down the "Alt" key and press "S".
b. Use the arrow keys to highlight "Set Max
Loads" and press "ENTER".
c. Type "199" in the box and press "ENTER" to
save the desired selection.
4. Set Date & Time
This is for setting the date and time. This information
is stored in the expanded memory box for document-
ing each payload.
a. Hold down the "Alt" key and press "P".
b. Use the arrow keys to highlight "Set Date &
Time" and press "ENTER".
c. Use the tab key to highlight the date and time
boxes and type in the appropriate informa-
tion. Press "ENTER" to save and store the
information.
NOTE: The day of the week is determined by Sunday
being day 1, Monday is day 2, etc.
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-21
On-Board Weighing System
COMMON PROCEDURES
The following steps are the most common proce-
dures that will be used. A short cut method for per-
forming these procedures are given by using the
function keys. It will be assumed that a PC with this
program is already connected to the expanded mem-
ory box and both devices are turned on.
For additional information covering these proce-
dures, refer to the appropriate program description.
To download data from the expanded memory
box to a PC.
1. Type "download", press "ENTER" two times.
2. Press "F3".
3. Type in a new file name in the window or, use
the "tab" and "arrow" keys to select a file to add
data to. Press "ENTER". Press "ENTER" again
to down-load data. Screen will display the
downloaded data.
NOTE: For more information on selecting a file name
and file management, refer to "Payload Data".
To view current box set up information.
1. Type "download", press "ENTER" two times.
2. Press "F5".
To view payload data stored in expanded memory
box.
1. Type "download", press "ENTER" two times.
2. Press "F7".
To view data in a file. (Not in expanded memory
box.)
1. Type "analysis", press "ENTER" two times.
2. Press "F3".
3. Use "tab" key and "arrow" keys to select (high-
light) desired file. Press "ENTER".
To view a file in graph form. (Not in expanded
memory box.)
1. Type "analysis", press "ENTER" two times.
2. Press "F5".
3. Use "tab" key and "arrow" keys to select (high-
light) desired file. Press "ENTER".
To print data in a file.
1. Type "analysis", press "ENTER" two times.
2. Press "F7".
3. Use "tab" key and "arrow" keys to select (high-
light) desired file. Press "ENTER".
M20-22 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
DOWNLOAD PROGRAM
This program provides a means to view and/or download data that is stored in the expanded memory box. The
payload data can be downloaded from the box and into a PC and stored into a new file, or added to an existing file.
1. At the C:\>>prompt, type "download" and press the "ENTER" key two times.
The download screen will appear as shown in Figure 20-17. Any of the functions across the top can be selected by
holding down the "ALT" key and pressing the first letter that appears in the desired selection.
Payload Box
To select the payload box menu, hold down the "Alt" key and press "P". The payload menu screen will appear as
shown in Figure 20-18. Use the arrow keys to select (highlight) the desired menu item and press "ENTER".
FIGURE 20-17. PAYLOAD SCREEN
FIGURE 20-18. PAYLOAD MENU OPTIONS
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-23
On-Board Weighing System
Download from Box F3 - This selection will allow downloading of payload data from the expanded memory
box to a PC. Two options are available to download payload data. One is to make a new file name to store the
payload data into and the other is to add the payload data to an existing file. Can also press "F3".
NOTE: When the expanded memory is downloaded into a file, all the data in the expanded memory box will be
erased. The data in the payload meter memory will not be erased, but is no longer accessible electronically. A
printout from the payload meter can provide data since the last CLEAR of the meter.
1. The computer screen will ask for a file name to save the data under. If the data is to be added into an existing
file, go to Step 2. If the data is to be stored under a new name, go to Step 3.
2. If the data is to be added into an existing file, press the "TAB" key. Then use the arrow keys to highlight the file
that the data is to be added to, then press "ENTER". Now go to Step 4.
3. The data can be given a file name using letters or numbers up to eight characters long. Do not add a period
and any characters after the eight character file name. The program will automatically assign a .DB extension
to the file name. After selecting a file name, press "ENTER".
4. The screen will provide the approximate time that will be required to download the data.
5. Press "ENTER" again to download the data. The screen will then display the data just retrieved from the
memory box and is now stored in a file.
6. Push "Esc" key to return to main menu screen.
Set Date & Time
This selection is for setting or changing the date and time. The Set Date & Time menu screen will appear as shown
in Figure 20-19. This information is stored in the expanded memory box for documenting each payload.
1. Arrow down to highlight "Setting Date and Time". Press "ENTER".
2. Using the "TAB" key, highlight date or time to be changed. Type in new information if desired.
3. Press "ESC" to cancel the command and return to the previous screen, or press "ENTER" to execute the
command and save any changes.
NOTE: The day of the week is determined by Sunday being day 1, Monday is day 2, etc.
FIGURE 20-19. PAYLOAD SET DATE & TIME INPUT SCREEN
M20-24 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
Clear Box Data
Selecting this option from the download screen will clear all memory stored in the expanded memory box. It will not
clear data stored in the payload meter.
NOTE: Once this is selected, a confirmation screen will appear. Be sure this information has been downloaded into
a file before clearing the memory. The data in the payload meter memory will not be erased, but is no longer
accessible electronically. A printout from the payload meter can provide data since the last CLEAR of the payload
meter.
1. Arrow down to highlight "Clear Box Data ". Press "ENTER".
2. Using the "tab" key, select "YES", "NO" or "CANCEL" and press "ENTER".
FIGURE 20-20. PAYLOAD CLEAR DATA MENU OPTIONS
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-25
On-Board Weighing System
SPECIAL
To select the special menu, hold down the "Alt" key and press "S". The Special menu screen will appear as shown
in Figure 20-21. Use the arrow keys to select the desired menu items listed below and press "ENTER".
Set Max Loads - The payload meter will only store 200 haul cycles. If the payload meter is allowed to record
200 haul cycles, it will stop sending data to the expanded memory box. By setting maximum loads at 199, the
payload meter will clear its memory and start counting at 0 again. All the loads recorded by the payload meter
are sent to the expanded memory box when the payload is first recorded. No payload data already stored in the
expanded memory box will be lost when the payload meter memory is cleared.
1. Highlight "Set Max Loads". Press "ENTER". The "Set Max Loads" screen will appear as shown in Figure 20-22.
2. Press "tab" key once to highlight the number box and set number of loads with number keys.
3. Press "ESC" to cancel the command or press "ENTER" to execute the command and save any changes.
FIGURE 20-21. SPECIAL MENU OPTIONS
FIGURE 20-22. SPECIAL SET MAX LOADS SCREEN
M20-26 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
Clear Meter - This selection will clear all payload data stored in the Payload Meter memory.
NOTE: The data in the expanded memory box will not be cleared.
1. Arrow down to highlight "Clear Meter". Press "ENTER".
Box Info - This selection will allow you to view the stored information in the expanded memory box. This
information can also be viewed at any time by pushing the "F5" key.
1. Arrow down to highlight "Box Info". Press "ENTER". The screen will appear as shown in Figure 20-23.
NOTE: The battery voltage refers to the memory backup battery in the expanded memory box.
FIGURE 20-23. SPECIAL BOX INFO SCREEN
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-27
On-Board Weighing System
Set Truck Number - This selection allows you to enter the truck identification for storage into the expanded
memory box. All future download information retrieved from this payload system will be identified by the
number you enter here.
1. Arrow down to highlight "Set Truck Number". Press "ENTER".
2. Press tab key to select the change box and then enter the truck identification number.
3. Press "ESC" to cancel the command or press "ENTER" to execute the command and save any changes.
View Data in Box - This selection will allow you to view payload data stored in the expanded memory box without
erasing the information.
1. Arrow down to highlight "View Data in Box". Press "ENTER".
2. The screen will display a message indicating the amount of time to download the information for viewing.
3. Press "ENTER" to view the data. Use the arrow keys to scroll up or down through the data.
4. Press "ESC" to return to the main menu screen.
FIGURE 20-24. SPECIAL SET TRUCK NUMBER SCREEN
M20-28 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
Set Comm Port - This option tells the PC which serial communication port to use to communicate to the
expanded memory box.
1. Arrow down to highlight "Set Comm Port". Press "ENTER". The screen will appear as shown in Figure 20-25.
2. Press tab key.
3. Use the arrow keys to select the comm port desired. Press "ENTER" to select the comm port.
NOTE: If the incorrect communication port is selected, an error message will appear the next time the PC tries to
access the expanded memory box. Change communication port selection, close out of the PAYLOAD PROGRAM,
open the PAYLOAD program and try again.
Help
This selection will provide help information or general information about the download program. Use the arrow keys
to move the text.
1. Arrow down to highlight "About". Press "ENTER".
2. Press "ESC" key to return to the main menu screen.
FIGURE 20-25. SPECIAL COMM PORT SCREEN
FIGURE 20-26. SPECIAL HELP SCREEN
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-29
On-Board Weighing System
ANALYSIS PROGRAM
The analysis program is used to view or print payload data that has already been downloaded and stored in a file
on the PC. The payload data can be viewed or printed as a data table or as a graph. The Data Table will display a
complete payload history of a particular file. The Graph will display payload data in bar graphs. To print payload
data, in either table or graph form, the correct printer must be selected in the "SETUP" option in the Analysis pro-
gram. Refer to the "SETUP" option for more information on printers.
To start the Analysis program:
1. At the C:\>>disc drive prompt, type "analysis" and press the "ENTER" key The analysis screen will appear as
shown in Figure 20-27.
Analysis Menu
To select the "Analysis" menu, hold down the "Alt" key and press "A". See Figure 20-28. Use the arrow keys to
highlight one of the desired menu items and press "ENTER".
FIGURE 20-27. ANALYSIS SCREEN
FIGURE 20-28. ANALYSIS MENU SCREEN
M20-30 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
Data Tables - This selection will allow you to view any stored data file for analysis. This function is also directly
accessible from the main menu screen by pressing "F3".
1. Arrow down to highlight "Data Tables". Press "ENTER". The screen will appear as shown in Figure 20-29.
2. Press the "TAB" key and then use the "ARROW" keys to highlight the desired file.
3. After selecting a file, press "ENTER" to display the stored information in the file. Use the arrow (or pg down or
pg up) keys to move through and view the file. For more information on data files, refer to "PAYLOAD DATA"
in this section.
4. Press "ESC" key to return to the main menu screen.
Graphics - This selection will provide a bar graph view of any selected data file.
1. Arrow down to highlight "Graphics". Press "ENTER". The screen will appear as shown in Figure 20-29.
2. Press the "TAB" key and then use the "ARROW" keys to highlight the desired file.
3. After highlighting a file, press "ENTER" to display the stored information in graph form. All of the data stored in
the file will be displayed in graph form. The vertical column (Number of Loads) indicates the number of loads
hauled for each payload range. The horizontal column (Payload, Tons) indicates the payload ranges in tons.
The bar graph scales will automatically adjust based on the amount of data stored in the file. For more infor-
mation on data files, refer to "PAYLOAD DATA" in this section.
4. (OPTIONAL) To print the graph, connect a compatible printer to the PC and press "P" while the graph is dis-
played on the screen.
NOTE: Refer to the "Setup" menu to select the correct printer before printing. If an attempt to print is made without
a printer connected, the program will "lock up" and a warm boot (press "ctrl", "alt" and "del" at the same time) will
be required to reset the PC.
5. Press "ESC" key to return to the main menu screen.
FIGURE 20-29. ANALYSIS DATA TABLE MENU SCREEN
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-31
On-Board Weighing System
Print Report - This selection will allow you to print a report identical to the screen display seen in "Data Tables"
in this section for the selected file. Refer to the "Setup" menu to select the correct printer before printing. For
more information on printed reports, refer to "Load Data ".
NOTE: Refer to the "Setup" menu to select the correct printer before printing. If an attempt to print is made without
a printer connected, the program will "lock up" and a warm boot (press "ctrl", "alt" and "del" at the same time) will
be required to reset the PC.
1. Arrow down to highlight "Print Report". Press "ENTER".
2. Use "tab" key to highlight the file selection box and use "arrow" keys to highlight the desired file to print. Press
"ENTER" to send file data to the printer.
Setup Menu
Setup Printer - To print payload data, in either table or graph form, the correct printer must be selected. Only
those printers listed or 100% compatible printers to those listed will be able to print payload data. Use the
PRINTER CHART to select the appropriate printer.
1. Hold down the "Alt" key and press "S". A screen will appear as shown in Figure 20-30.
2. Press "ENTER". A screen will appear as shown in Figure 20-31.
3. Press the "tab" key once and the selected printer option will become highlighted. The selection that becomes
highlighted is the one with the period inside the ().
4. Use the "arrow" keys to select the appropriate printer and press "ENTER" to save the change.
NOTE: The printer option can also be selected by holding down the "alt" key and pressing the same letter key that
is highlighted in the desired printer description.
FIGURE 20-30. ANALYSIS SETUP SCREEN
M20-32 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
Refer to the Printer Chart below for additional printers that do not appear on the menu screen in Figure 20-31.
PRINTER CHART
Selection Printers
Epson MX All Epson MX;
Okidata;
IBM proprinter;
IBM Graphics printer;
Star Gemini;
Epson FX Epson FX
Epson LQ Epson 24 pin;
Star Gemini 24 pin;
Panasonic 24 pin printers
HP Laser J et/
HP Desk J et
All HP Laser J ets and
Emulators
HP Desk J et
Toshiba 24 pin Toshiba 24 pin printers
FIGURE 20-31. SPECIAL PRINTER MENU SCREEN
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-33
On-Board Weighing System
HELP MENU
This selection provides information about the analysis program.
Help - Access information about the program.
1. Hold down the "Alt" key and press "H".
2. Select Help and press "ENTER".
3. Press "ESC" key to return to the main menu screen.
About - Access information about the program.
1. Arrow down to highlight "About". Press "ENTER". Version and date of software is displayed.
2. Press "ESC" key to return to the main menu screen.
FIGURE 20-32. ANALYSIS SETUP SCREEN
M20-34 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
PAYLOAD DATA
The customer must choose a method to store and analyze all the data that is collected from the expanded memory
box from the fleet of trucks. There are several options available depending on the use of the payload data.
Each truck that is equipped with an expanded memory box must be given a truck identification number containing
10 characters or less (done during initial setup). The truck I.D. number is stored in the expanded memory box and
is part of the payload data information. When the payload data is downloaded into a PC, a computer file name must
be chosen containing 8 characters or less.
Payload data records can be maintained separately for each truck in one particular computer file, and can be
added to at any time by downloading more data from the same truck into the same computer file. In this case, a
computer file name that reflects that particular truck may work best for record keeping.
OR, over a given time span, (one week for example) the payload data from all trucks can be added together into
one file. In this case, a file name that reflects that particular week may work the best. Several truck I.D. numbers
will show up in the payload data file. (See Figure 20-17, sample print out of ATEST.DB data file.) If this method is
used, it is recommended that only the same size of trucks have their data added together into one file. Otherwise,
the payload data in a particular file will not accurately reflect the possibility of the trucks being underloaded or over-
loaded because different truck payload capacities are represented.
The payload data stored in a file is not sorted by payload size or date. It will appear in the order that the data was
transferred into the file. If the payload data needs to be sorted by date, payload size, etc, the "PARADOX Data
Base Program" is compatible with the payload data files created by the expanded memory box program. The PAR-
ADOX Data Base Program is available at most computer retail outlets or mail order companies.
When the data file is viewed, a summary of the file is shown in the upper left corner. The data file name is also
shown.
FIGURE 20-33. LOAD DATA IN TABLE FORM (File ATEST.DB)
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-35
On-Board Weighing System
When a payload data file is viewed in the graph form, it will appear as shown in Figure 20-18. All payloads are
sorted by payload tons across the bottom and the number of loads carried along the side. The scales for tons and
the number of loads carried automatically adjust to best suit the size and volume of data in the file.
FIGURE 20-34. LOAD DATA IN GRAPH FORM (File ATEST.DB)
M20-36 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
SERVICE
NOTE: Download all payload data from the
expanded memory box to a PC before making any
repairs to avoid loosing payload data. If the battery
goes dead or is unplugged from the payload memory
card, all payload data, truck I.D. number and date will
be erased. Refer to "Initial Start Up Of The Expanded
Memory Box" to reset the truck I.D. number and date.
Removal
1. Turn key switch off. Disconnect all wire har-
nesses from expanded memory box.
2. Remove mounting screws and expanded mem-
ory box.
Installation
1. Be certain that mounting surface on the
expanded memory box and on the truck is clean
and free of foreign material.
NOTE: Foreign material between the box and
mounting surface can distort the box as the mounting
hardware is tightened, and can cause damage to the
payload memory card.
2. Install box and tighten mounting hardware.
3. Connect wire harnesses to appropriate connec-
tors.
Disassembly
1. Loosen the four corner screws on end cover (1,
Figure 20-19). Do not remove screws from end
cover as they are held in place by the gasket.
2. Remove end cover (1) and carefully unplug wire
connector from the payload memory card (6).
3. Unlock lever (5) and carefully pull payload
memory card from the box using handle (1, Fig-
ure 20-20).
4. Loosen the four corner screws retaining end
cover (4, Figure 20-19). Do not remove screws
from end cover as they are held in place by the
gasket. Remove end cover.
FIGURE 20-35. EXPANDED MEMORY BOX
1. End Cover
2. Connector (To PC)
3. Box
4. End Cover
5. Lever
6. Payload Memory
M20001C3 4/92 Expanded Memory Box (Version 1.00) M20-37
On-Board Weighing System
Battery Replacement
NOTE: If the battery goes dead or is unplugged from
the payload memory card, all payload data, truck I.D.
number and date will be erased. Refer to "Initial Start
Up Of The Expanded Memory Box" to reset the truck
I.D. number and date.
1. Carefully unplug battery connector (5, Figure
20-20) from payload memory card (3).
2. Remove nut, screw and washer and remove
battery (2) from clamp.
3. Install new battery in clamp and attach to pay-
load memory card with screw, washer and nut.
4. Carefully plug battery connector (5) into pay-
load memory card (3).
Assembly
1. Install end cover (4, Figure 20-19) with gasket
and four screws.
2. With lever (5, Figure 20-19) in the unlocked
position, carefully install payload memory card
(6) into box using slots highlighted with white
paint. Wiggle the card slightly to engage the
card pins into the receptacle. Be certain that the
card is fully seated and the pins are fully
engaged. Press lever (5) over to lock card into
place.
3. Connect wire lead from end cover (1) to card
(6).
4. Install end cover (1) with gasket and four
screws.
Wire Connections
Refer to Figure 20-21 for wire connections made on
the expanded memory box.
FIGURE 20-36. PAYLOAD MEMORY CARD
1. Handle
2. Battery
3. Payload Memory
Card
4. Pin Connector
5. Battery Connector
FIGURE 20-37. END PLATE
1. End Plate
2. Power Connector
3. Dust Cap
4. Connector (To
Modular Mining or
Truck Harness
5. Connector (To
Payload Meter)
M20-38 Expanded Memory Box (Version 1.00) M20001C3 4/92
On-Board Weighing System
TROUBLESHOOTING EXPANDED MEMORY BOX
PC Will Not Communicate To Expanded Memory
Box
The expanded memory box must have 24 volt power
to function and be connected to a PC.
1. Check truck key switch. Should be in the "on"
position.
2. Check the special serial cable and the connec-
tions that link the PC to the expanded memory
box.
3. Check the communication port on the PC to
which the special serial cable is connected to.
The software program DOWNLOAD must have
the same communication port selected as the
one the special serial cable is connected to.
Refer to the Special menu selection and select
"Set Comm Port" to determine which port the
Download program is using for communica-
tions.
4. Check truck harness terminal for proper voltage
(24-28 Volts) at the expanded memory box.
5. Check circuit breaker.
PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE
MANUFACTURED UNDER LICENSE FROM
L. G. HAGENBUCH holder of
U.S. Patent Numbers 4,831,539 and 4,839,835
DDEC II ELECTRONIC ENGINE CONTROL
GENERAL DESCRIPTION
The Electronic Engine Control system provides an
electronic method for determining engine fuel require-
ments and controlling engine speed. Engine perform-
ance is continuously monitored by various sensor
inputs to microprocessors and compared to operating
parameters stored in memory to provide engine opera-
tion controls. Operator demand for power is provided
by an electronic foot pedal while engine mounted
sensors provide information on engine crankshaft po-
sition and RPM. Extensive operation and diagnostic
information is stored and made available for trou-
bleshooting engine problems and monitoring engine
performance.
Electronic engine control eliminates the need for air
operated throttle pedals, cylinders, and mechanical or
hydraulic governors.
The following major components are required for the
system:
Electronic Control Module
Electronic Unit Injectors
Engine and cooling system sensors
Operator input controls
Engine protection indicator lights
Wire harness/connector assemblies
Diagnostic Data Reader
91466
FIGURE 21-1. ELECTRONIC CONTROL MODULE (ECM)
1. Fuel (Cooler) Ports
2. Injector Harness Connectors
3. Power Harness Connector
4. Truck Harness Connector
5. Engine Harness Connector
M21001 Electronic Engine Control M21-1
COMPONENT DESCRIPTION
Electronic Control Module
The ECM contains the microprocessor which receives
information from the various system sensors and op-
erator input. All sensor circuits are constantly moni-
tored during operation for correct voltage levels,
sensor failure, and open or shorted electrical circuits.
The incoming information is compared to stored infor-
mation which determines acceptable operating pa-
rameters for oil pressure, coolant level, etc. for current
operating conditions. If all conditions are acceptable,
calculated information is then sent to driver circuits to
control the fuel injectors for controlling engine perform-
ance. If conditions are not within the programmed
operation limits, a warning system alerts the driver of
possible problems and, depending on the malfunction
and vehicle application, may initiate an engine protec-
tion sequence.
Various forms of information storage memory are used
to store engine operation parameters and diagnostic
data. Performance information for a particular applica-
tion is programmed into the system memory by the
manufacturer prior to final testing. Information regard-
ing accumulated engine operation hours, fuel con-
sumption, and engine idle hours is stored for retrieval
by service personnel. Various functions can be re-pro-
grammed by the user through the use of a portable
diagnostic data readout device. Unauthorized re-pro-
gramming is prevented by use of a security password
prior to re-programming.
If a malfunction occurs in the main fuel control circuits
or power supply, a backup fuel control system will
maintain engine operation at a reduced performance
level. If the system is operating in the backup mode,
the amber Check Engine Light (CEL) on the instrument
panel will illuminate.
Two ECMs are required for the 12V149 and 16V149
engines, a master and a secondary unit. The master
(front) ECM controls fuelling in the front 6-8 cylinders
and the secondary (rear) ECM controls fuelling in the
rear 6-8 cylinders. Fuel control information is sent
across an electrical harness (data link) from the main
to the secondary unit.
Since the ECM is designed to operate from a 12 volt
DC supply, a battery equalizer system is required to
provide the proper voltage and extend the life of the
batteries. The battery equalizer is mounted on the right
hand deck next to the battery box. The equalizer sys-
tem also incorporates a device to warn the operator of
a failure of the equalizer system by illuminating a warn-
ing light on the instrument panel.
The ECM electronics are cooled by passing engine fuel
through a plate mounted on the ECM. Internal elec-
tronic components are attached to this plate which acts
as a heat sink to remove excessive heat.
Electronic Unit Injectors
Fuel is delivered to the cylinders by the electronic unit
injectors (EUI). Fuel is pressurized by a mechanical
cam and controlled electronically by the ECM through
a solenoid operated valve on each injector. The ECM
computes fuel timing and quantity and actuates the
solenoids through high current, pulse width modulated
drivers located inside the ECM.
When the ECM begins sending a pulsed signal to the
injector, the solenoid valve closes, pressurization of the
fuel occurs and the injection cycle begins. The pulse
width (length of time energized) delivered to the sole-
noid determines the quantity of fuel injected. When the
pulse is removed and the solenoid valve opens, fuel
pressure decays and the injection cycle ends.
91468
FIGURE 21-2. ELECTRONIC UNIT INJECTOR (EUI)
1. Connector Terminal
2. Solenoid
3. Fuel Return
4. Fuel Inlet
M21-2 Electronic Engine Control M21001
System Sensors and Operator inputs
SRS
The synchronous reference sensor (SRS) monitors
camshaft revolutions and is used for cylinder sequenc-
ing by determining when cylinder # 1 is about to fire.
TRS
The timing reference sensor (TRS) monitors crankshaft
rotation and determines when any cylinder is about to
fire.
OTS
The oil temperature sensor (OTS) monitors oil tem-
perature in the turbocharger supply line.
CLS
The coolant level system (CLS) monitors coolant level
through a level sensor (Figure 21-3) mounted in the
cooling system top tank. This sensor provides a signal
to an interface module, located in the electrical cabinet
junction box, which conditions the signal for use by the
ECM.
EFPA
The electronic foot pedal assembly (EFPA) (Figure
21-4) is the accelerator pedal controlled by the opera-
tor to vary the power demand.
TPS (PTO Counts)
NOTE: The TPS signal enters the ECM on the PTO
(Power Take-Off) pin. To check TPS counts using the
DDR, select PTO Counts.
The throttle position sensor (TPS) (Figure 21-4) is con-
tained in the electronic foot pedal. When the operator
depresses the accelerator pedal, a variable voltage
signal is sent to the ACC/RET interface ACC card
located in the control cabinet and then to the ECM. The
ACC card also provides the ECM with a fixed voltage
signal for increased engine RPM during dynamic re-
tarding and when truck speed is over 3 MPH (4.83
km/h) if the engine idle switch is placed in the high idle
position.
TBS
The turbo boost pressure sensor (TBS) (Figure 21-5)
monitors turbocharger boost pressure and sends a
voltage signal porportional to pressure to the ECM.
OPS
The oil pressure sensor (OPS) monitors engine oil
pressure.
91470
FIGURE 21-3. COOLANT LEVEL SENSOR (CLS)
91471
FIGURE 21-4. ELECTRONIC FOOT PEDAL
ASSEMBLY (EFPA)
91467
FIGURE 21-5. TURBOCHARGER BOOST
PRESSURE SENSOR (TBS)
M21001 Electronic Engine Control M21-3
ENGINE PROTECTION SYSTEM
Engine Check Main
Engine Check Second
The amber "Engine Check Main" or "Engine Check
Second" indicator light will illuminate if a malfunction is
detected in the electronic engine control system. If this
indicator illuminates, alert maintenance personnel
as soon as possible.
If this light illuminates, a code is stored in the ECM
memory describing the fault.
This light will remain on for approximately five seconds
after the key switch is turned on. If the light remains on,
a problem exists within the system. If a problem occurs
but clears itself (for example, a loose connection), an
error code will be stored in the ECM memory which can
be recalled by using the diagnostic data reader.
Engine Monitor Main
Engine Monitor Second
The red "Engine Monitor Main" or "Engine Monitor
Second" indicator light will illuminate and an alarm horn
will sound if a serious engine malfunction is detected
by the electronic engine control system. Electric pro-
pulsion to the wheelmotors will be discontinued. Dy-
namic Retarding will still be available to slow or stop
the truck. The maximum engine speed will be reduced
to 1675 RPM. Stop the truck as quickly and safely as
possible. Apply parking brake. SHUT DOWN THE
ENGINE IMMEDIATELY. Additional engine damage is
likely to occur if operation is continued.
Low coolant level, low engine oil pressure, high crank-
case pressure, and/or high oil temperature can cause
this to occur. If one of these conditions is detected,
both lights are illuminated, the error code is logged,
and the ECM begins a programmed engine protection
sequence. High idle speed is reduced to 1675 RPM and
the "AS" signal is interupted to stop propulsion.
The red "Engine Monitor Main" or "Engine Monitor
Second" light will illuminate for approximately five sec-
onds after the key switch is turned on.
NOTE: The amber and red "Main" lights receive input
from the master ECM while the amber and red "Sec-
ond" lights receive input from the receiver ECM.
DIAGNOSTICS
The ECM continuously monitors itself and other system
components including sensors, injectors and associ-
ated wiring and connectors. If a fault is detected, the
ECM illuminates the Check Engine light and stores a
malfunction code. These codes can be read out by
using a Diagnostic Data Reader (DDR) as shown in
Figure 21-6.
Whenever a fault is detected, the ECM will substitute a
default value for the component or circuit that has
failed. If the fault clears up, the actual sensor value is
again used.
If the ECM detects a potential engine damaging condi-
tion (low oil pressure, low coolant, high crankcase
pressure, or high oil temperature), both the Check
Engine and Stop Engine lights are illuminated. In addi-
tion, an associated malfunction code is logged.
When using the DDR, codes are broken down into two
types:
Active Codes These codes are currently
causing the Check Engine light to illuminate.
Historical Codes These codes can be either
currently active or active in the past. Certain
codes on the DDR will also display an audit trail
of their occurrence(s).
FIGURE 21-6. DIAGNOSTIC DATA READER (DDR)
M21-4 Electronic Engine Control M21001
In addition to displaying codes, the DDR is capable of:
Displaying sensor values and switch positions
Simultaneous display of current operating pa-
rameters such as engine RPM, injector timing,
fuel rate and turbocharger boost pressure.
Cutting out cylinders to detect weak cylinders
Erasing codes
Limited data logging as an aid to intermittent fault
diagnosis
Programming the EEPROM (Electrically Eras-
able Programmable Read Only Memory) in the
ECM for specific operation requirements.
The DDR includes a customer replaceable PROM (Pro-
grammable Read Only Memory). As new diagnostic
techniques are developed which make use of the DDR,
they can be programmed on a PROM by the manufac-
turer and installed in the field by DDR users.
The DDR is attached to the diagnostic connector lo-
cated below the instrument panel. Refer to the DDEC
II Diagnostic Troubleshooting Guide for complete in-
formation on its use and procedures to follow for sys-
t emat i cal l y t roubl eshoot i ng engi ne probl ems,
retrieving stored data, etc.
BATTERY EQUALIZER
The majority of the accessory and control circuits
operate at 24VDC. The Electronic Engine Controls
however, require 12VDC. A battery equalizer system is
utilized to obtain the required 12VDC and insure that
the two 12 volt, series wired batteries are charged and
discharged equally. A monitoring device warns the
operator of a malfunction in the battery equalizer sys-
tem or the battery charging alternator by illuminating
an amber light on the instrument panel.
The battery equalizer is mounted in a box on the right
hand deck. This box also contains the battery equalizer
monitor, circuit breakers, and the main battery discon-
nect switch. (See Figure 21-7.)
FIGURE 21-7. BATTERY EQUALIZER BOX
1. Battery Equalizer Box
Assembly
2. Battery Equalizer
3. Battery Equalizer
Monitor
4. Circuit Breakers
5. Battery Disconnect
Switch
6. Disconnect Switch
Handles
M21001 Electronic Engine Control M21-5
Troubleshooting
Normal battery maintenance procedures should be
followed according to the intervals specified in the
Lubrication and Service section of this manual. Refer
to the Battery information in this section for detailed
instructions regarding proper battery maintenance and
service procedures. Prior to troubleshooting the bat-
tery equalizer system, inspect all battery circuit con-
nections for excessive corrosion, loose cables, ground
connections etc. Use the following procedure to check
the system if the warning light on the instrument panel
illuminates during truck operation:
1. Check the circuit breakers.
a. If a circuit breaker has opened, check circuits
and repair cause.
b. Reset circuit breaker.
2. Check battery voltage with the battery equalizer
connected and the engine running.
a. Verify battery charging alternator output is 27.8
to 28.2 volts.
3. If alternator voltage is outside above limits, adjust
voltage regulator as described in Battery Charg-
ing System.
4. With the engine running, verify voltages at the
battery equalizer terminals.
a. Measure the voltage between the 24 volt and
12 volt terminals.
b. Measure the voltage between the 12 volt
terminal and ground.
5. If the difference between the voltage measure-
ments above exceeds 0.75 volts, the battery
equalizer is defective and should be replaced.
6. If the alternator voltage regulator is operating
within limits and the voltage measured in step 2.
is within limits, the Battery Equalizer monitor is
defective and should be replaced.
Always open main battery disconnect switch prior
to removing or connecting any wires or cables in
the Battery Equalizer box.
Always open main battery disconnect switch prior to
welding on the truck.
.
M21-6 Electronic Engine Control M21001
DDEC III ELECTRONIC ENGINE CONTROL
GENERAL DESCRIPTION
The Detroit Diesel Electronic Control (DDEC III) system
provides an electronic method for determining engine
fuel requirements and controlling engine speed.
Engine performance is continuously monitored by vari-
ous sensor inputs to microprocessors and compared
to operating parameters stored in memory to provide
engine operation controls. Operator demand for power
is provided by an electronic foot pedal and/or the
Statex III engine control system while engine mounted
sensors provide information on engine crankshaft po-
sition and RPM. Extensive operation and diagnostic
information is stored and made available for trou-
bleshooting engine problems and monitoring engine
performance.
Electronic engine control eliminates the need for air
operated throttle pedals, cylinders, and mechanical or
hydraulic governors.
The following major components are required for the
system:
Electronic Control Module
Electronic Unit Injectors
Engine and cooling system sensors
Operator input controls
Engine protection indicator lights/circuits
Wire harness/connector assemblies
Diagnostic Data Reader
FIGURE 21-1. ELECTRONIC CONTROL MODULE (ECM)
1. Electronic Control Module
2. Vehicle Interface Harness Connector
3. Optional Communication Harness Connector
4. Power Harness Connector
5. Sensor Harness Connector
6. Injector Harness Connector (2)
M21002 DDEC III Electronic Engine Control M21-1
COMPONENT DESCRIPTION
Electronic Control Module
The ECM contains the microprocessor which receives
information from the various system sensors and op-
erator input. All sensor circuits are constantly moni-
tored during operation for correct voltage levels,
sensor failure, and open or shorted electrical circuits.
The incoming information is compared to stored infor-
mation which determines acceptable operating pa-
rameters for oil pressure, coolant level, etc. for current
operating conditions. If all conditions are acceptable,
calculated information is then sent to driver circuits to
control the fuel injectors for controlling engine perform-
ance. If conditions are not within the programmed
operation limits, a warning system alerts the driver of
possible problems and, depending on the malfunction
and vehicle application, may initiate an engine protec-
tion sequence.
Various forms of information storage memory are used
to store engine operation parameters and diagnostic
data. Performance information for a particular applica-
tion is programmed into the system memory by the
manufacturer prior to final testing. Information regard-
ing accumulated engine operation hours, fuel con-
sumption, and engine idle hours is stored for retrieval
by service personnel. Various functions can be re-pro-
grammed by the user through the use of a portable
diagnostic data readout device. Unauthorized re-pro-
gramming is prevented by use of a security password
prior to re-programming.
If a malfunction occurs in the main fuel control circuits
or power supply, a backup fuel control system will
maintain engine operation at a reduced performance
level. If the system is operating in the backup mode,
the amber Check Engine Light (CEL) on the instrument
panel will illuminate or a Check Engine message will be
displayed on the HMS overhead display panel. The two
digit Statex III display will display code 78.
Two ECMs are required for the 16V149 engine, a main
and a secondary unit. The front (main) ECM controls
fueling in the front 8 cylinders and the rear ECM con-
trols fueling in the rear 8 cylinders. Fuel control infor-
mation is sent across an electrical harness (data link)
from the main to the secondary unit. The 20V149 en-
gine has three ECMs.
The ECM electronics are cooled by passing engine fuel
through a plate mounted on the ECM. Internal elec-
tronic components are attached to this side of the ECM
which acts as a heat sink to remove excessive heat.
Electronic Unit Injectors
Fuel is delivered to the cylinders by the electronic unit
injectors (EUI). Fuel is pressurized by a mechanical
cam and controlled electronically by the ECM through
a solenoid operated valve on each injector. The ECM
computes fuel timing and quantity and actuates the
solenoids through high current, pulse width modulated
drivers located inside the ECM.
When the ECM begins sending a pulsed signal to the
injector, the solenoid valve closes, pressurization of the
fuel occurs and the injection cycle begins. The pulse
width (length of time energized) delivered to the sole-
noid determines the quantity of fuel injected. When the
pulse is removed and the solenoid valve opens, fuel
pressure decays and the injection cycle ends.
System Sensors and Operator inputs
SRS
The Synchronous Reference Sensor (SRS) monitors
camshaft revolutions and is used for cylinder sequenc-
ing by determining when cylinder # 1 is about to fire.
91468
FIGURE 21-2. ELECTRONIC UNIT INJECTOR (EUI)
1. Connector Terminal
2. Solenoid
3. Fuel Return
4. Fuel Inlet
M21-2 DDEC III Electronic Engine Control M21002
TRS
The Timing Reference Sensor (TRS) monitors crank-
shaft rotation and determines when any cylinder is
about to fire.
OTS
The Oil Temperature Sensor (OTS) monitors oil tem-
perature in the turbocharger supply line.
PTO Counts
WITH OUT FUEL - SAVER:
NOTE: The throttle signal enters the ECM on the PTO
(Power Take-Off) pin. To check throttle input counts
using the DDR, select PTO Counts.
The Throttle Position Sensor (Figure 21-4) is contained
in the electronic foot pedal. When the operator de-
presses the accelerator pedal, a variable voltage signal
is sent to the ACC/RET interface ACC card located in
the control cabinet and then to the ECM. The ACC card
also provides the ECM with a fixed voltage signal for
increased engine RPM during dynamic retarding and
when truck speed is over 3 MPH (4.83 km/h) if the
engine idle switch is placed in the high idle position.
WITH FUEL SAVER
The Throttle Position Sensor (Figure 21-4) is contained
in the electronic foot pedal control. When the operator
depresses the accelerator pedal, a variable voltage
signal is sent to the Statex III Card Panel (FL 275) and
based on other truck operating conditions inputs to the
panel (temperature, truck speed, idle switch position)
the panel will provide a frequency signal to the DDEC
ECMs to control engine speed. The Statex III system
will control the engine RPM for all operating conditions.
CLS
The Coolant Level System (CLS) monitors coolant level
through a level sensor (Figure 21-3) mounted in the
cooling system top tank. This sensor provides a signal
to an interface module, located in the electrical cabinet
junction box, which conditions the signal for use by the
ECM.
EFPA
The Electronic Foot Pedal Assembly (EFPA) (Figure
21-4) is the accelerator pedal controlled by the opera-
tor to vary the power demand.
91470
FIGURE 21-3. COOLANT LEVEL SENSOR (CLS)
FIGURE 21-4. ELECTRONIC FOOT PEDAL
ASSEMBLY (EFPA)
M21002 DDEC III Electronic Engine Control M21-3
TBS
The Turbo Boost Pressure Sensor (TBS) (Figure 21-5)
monitors turbocharger boost pressure and sends a
voltage signal proportional to pressure to the ECM.
OPS
The Oil Pressure Sensor (OPS) monitors engine oil
pressure.
ENGINE PROTECTION SYSTEM
CEL
The amber Check Engine Light (or Check Engine mes-
sage on HMS equipped trucks) is used to inform the
operator that a problem has occurred in the DDEC
system and the problem should be investigated. If this
light illuminates (or message occurs), a code is stored
in the ECM and Statex III memory describing the fault.
If this indicator illuminates (or message occurs),
alert maintenance personnel as soon as possible.
On standard truck control systems (with out HMS), this
light on the instrument panel will remain on for approxi-
mately five seconds after the key switch is turned on.
If the light remains on, a problem exists within the
system. If a problem occurs but clears itself (for exam-
ple, a loose connection), an error code will be stored
in the ECM memory which can be recalled by using the
diagnostic data reader.
SEL
On standard truck control systems (with out HMS), the
red Stop Engine Light will illuminate for approximately
five seconds after the key switch is turned on. If the
Stop Engine light and Check Engine light turn on during
operation, a potentially damaging condition has been
detected. Stop the truck as quickly as possible in a safe
area. Apply parking brake. SHUT DOWN THE EN-
GINE IMMEDIATELY.
On HMS equipped trucks, if the Stop Engine message
occurs during operation, a potentially damaging con-
dition has been detected. Stop the truck as quickly as
possible in a safe area. Apply parking brake. SHUT
DOWN THE ENGINE IMMEDIATELY.
Low coolant level, low engine oil pressure, high crank-
case pressure, high oil temperature, high coolant tem-
perature, high intercooler temperature, low coolant
pressure can cause this to occur.
If one of the above conditions is detected, both lights
are illuminated and an alarm horn will sound (or on
HMS equipped trucks, the check engine and stop
engine message will be displayed), the error code is
logged and the ECM begins a programmed engine
protection sequence. Maximum engine speed is re-
duced to 1675 RPM and the "AS" signal is interrupted
to stop propulsion. Retarding is available if it is needed
to slow or stop the truck.
The DDR should be used to determine which system
caused fault. The problem should then be corrected.
91467
FIGURE 21-5. TURBOCHARGER BOOST
PRESSURE SENSOR (TBS)
FIGURE 21-6. DIAGNOSTIC DATA READER (DDR)
M21-4 DDEC III Electronic Engine Control M21002
DIAGNOSTICS
The ECM continuously monitors itself and other system
components including sensors, injectors and associ-
ated wiring and connectors. If a fault is detected, the
ECM illuminates the Check Engine light (or a check
engine message on the HMS overhead display) and
stores a malfunction code. These codes can be read
out by using a Diagnostic Data Reader (DDR) as shown
in Figure 21-6.
Whenever a fault is detected, the ECM will substitute a
default value for the component or circuit that has
failed. If the fault clears up, the actual sensor value is
again used.
When using the DDR, codes are broken down into two
types:
Active Codes These codes are currently
causing the Check Engine or Stop Engine lights
to illuminate (or Check Engine or Stop Engine
message on the HMS overhead display).
Historical Codes These codes can be either
currently active or active in the past. Certain
codes on the DDR will also display an audit trail
of their occurrence(s).
In addition to displaying codes, the DDR is capable of:
Displaying sensor values and switch positions
Simultaneous display of current operating pa-
rameters such as engine RPM, injector timing,
fuel rate and turbocharger boost pressure.
Cutting out cylinders to detect weak cylinders
Erasing codes
Limited data logging as an aid to intermittent fault
diagnosis
Programming the EEPROM (Electrically Eras-
able Programmable Read Only Memory) in the
ECM for specific operation requirements.
The DDR includes a customer replaceable PROM (Pro-
grammable Read Only Memory). As new diagnostic
techniques are developed which make use of the DDR,
they can be programmed on a PROM by the manufac-
turer and installed in the field by DDR users.
The DDR is attached to the diagnostic connector lo-
cated on the panel behind the passenger seat and in
the electrical cabinet.
Refer to the DDEC III Diagnostic Troubleshooting
Guide, 6SE492, for complete information on its use and
procedures to follow for systematically troubleshoot-
ing engine problems, retrieving stored data etc.
M21002 DDEC III Electronic Engine Control M21-5
NOTES
M21-6 DDEC III Electronic Engine Control M21002
N01007 Index N1-1
SECTION N
OPERATORS CAB
INDEX
TRUCK CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-1
DOOR WINDOW SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-2
CAB DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3
WINDSHIELD AND REAR WINDOW SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-5
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-3
WINDSHIELD WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-1
WINDSHIELD WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-2
WIPER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3
OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1
Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1
SEAT MAINTENANCE AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-2
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-5
HEATER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-6
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-6
OPERATING CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5
STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
SELECTOR SWITCH CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
DYNAMIC RETARDING PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
HOIST CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
THROTTLE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8
N1-2 Index N01007
NOTES:
N02005 Truck Cab N2-1
TRUCK CAB
TRUCK CAB
Removal
The operators cab shell is removable as an assembly
to provide clearance for all interior cab components if
this is desirable.
1. To remove the cab shell, disconnect electrical
wiring to dome lights and/or fans if these are
installed. Disconnect windshield wiper and
remove windshield washer bottle.
2. Remove the threshold plate (2, Figure 2-1) from
both door openings. Remove capscrews, flat
washers and lockwashers securing the cab
shell perimeter to the truck deck.
3. Loosen the lower heater mounting hardware
and bracket to break the seal between the
heater and filter plenum.
4. Position a wide, (6 in. [150 mm] minimum) nylon
lifting strap through both door openings and
attach to an overhead crane, have the doors
open, do not lift on top edges of the doors. Mak-
ing sure all necessary disconnects have been
made, lift cab shell carefully straight up until
clear of the instrument panel and seats. Move
cab shell clear of truck and move to work area
for necessary service.
Installation
1. When service procedures are complete, lift cab
back into position on the truck deck, making
sure the rubber sealing strips are in good condi-
tion and properly located.
2. Position the two threshold plates in the door
openings. Secure the cab to the truck deck with
capscrews. Tighten capscrews to 25 ft. lbs. (34
N.m) torque.
3. Reconnect all wiring and air lines disconnected
at removal. Install windshield washer bottle.
FIGURE 2-1. CAB ASSEMBLY
1. Door Assembly
2. Threshold Plate
3. Side Glass
4. Cover
5. Air Filter Element
6. Windshield Wiper
7. Sliding Window
N2-2 Truck Cab N02005
OPTIONAL R-8 INSULATION EQUIPPED CABS
If cab is equipped with the optional R-8 insulation
package, the glass assemblies for the windshield,
back window, and right side window must be
replaced as a complete unit.
When servicing this cab, damaged glass and
frames are removed and replaced by removing the
mounting capscrews and acorn nuts. Replacement
assemblies are then bolted into the original open-
ing
Left door glass replacement procedures are identi-
cal to the standard cab instructions.
DOOR WINDOW SERVICE
The repair procedures for the right and left sliding glass
windows are identical. (See the special note which fol-
lows concerning the optional R-8 insulation cab.)
The sliding glass window assembly in the door
should be removed from the door assembly if either
of the glass panels are to be replaced.
NOTE: The door sliding glass window is available as
an assembly or individual parts can be replaced.
FIGURE 2-2. DOOR WINDOW ASSEMBLY
1. Handle
2. Catch
3. Weather Strip
4. Glass & Channel
5. Glass & Channel
6. Window Locking Knob
7. Rivet
8. Machine Screw
9. Machine Screw
N02005 Truck Cab N2-3
Removal
1. Remove capscrews, washers and acorn nuts
securing the window assembly in the door.
Remove window assembly (7, Figure 2-1).
Installation
1. Install window assembly (7, Figure 2-1) into
door opening, secure with capscrews, flat wash-
ers and acorn nuts. Tighten nuts to 7 ft. lbs.
(9.5 N.m) torque.
Disassembly
1. The inside rear surface of the window assembly
is riveted together. These rivets (7, Figure 2-2)
must be removed to remove the window panes.
At the forward edge of the stationary glass pane
there is a screw, top and bottom. Remove these
two screws to free the stationary pane.
2. The outer window frame may now be spread
sufficiently at the rear to allow removal of both
the sliding and stationary window panes.
3. On one edge of each window pane assembly
are two screws (8) which secure the inner frame
of the assembly. Remove these screws. The
broken or defective glass may now be removed
from the inner frame along with the rubber seal.
Insure that the frame channel is completely
clear and clean before attempting to install new
glass and/or rubber seal.
NOTE: Windows are available with or without the
outside channel.
Assembly
1. After the glass panes have been replaced and
the two window assemblies are complete, install
the stationary window into the frame in the outer
channel.
2. Install sliding pane into inner channel.
3. Install the two square recess drive screws at top
and bottom of stationary window and install stiff-
ening block and two square recess drive screws
to secure open end of frame assembly together.
CAB DOOR
The cab door assemblies are similar except for the
hinge side, each is hinged on the rear edge with
three heavy duty hinges. For repairs on the door
latches or sliding windows it is usually best to remove
the door from the cab and lower it to the floor for ser-
vice (the cab does not need to be removed to remove
either door assembly).
Removal
1. Remove the screw and spring retainer clip from
the travel limiting rod at the top of the door and
unhook the limiting rod.
2. Remove acorn nut from the center hinge pin on
the door.
3. Attach sling and hoist to door assembly, lift door
vertically until clear of the hinge pins and lower
to floor for service. Place door on blocks or on a
work bench to protect the window glass and/or
foam insulating material in the lower section.
Installation
1. Attach sling and hoist to door assembly, lift door
up to the deck and position door hinges to cab
hinges.
2. Align door on hinges and install hinge pins,
install acorn nut on the center hinge.
3. Attach the travel limiting rod at the top of the
door and fix in place with the screw and spring
retainer clip.
Door Adjustment
If adjustment is necessary to insure tight closure of
door, loosen mounting capscrews and reposition
striker as necessary.
A rubber sealer strip is mounted with adhesive
around the perimeter of the door assembly to
exclude dirt and drafts. This sealer strip should be
kept in good condition and replaced if it becomes
torn or otherwise damaged.
Door Latch
The cab doors are equipped with recessed, lockable
latches for cab security both during operation and
while the truck is parked unattended. The latch han-
dle assemblies (inner and outer) and the latch
assembly are not serviceable. If they become inoper-
ative, they should be replaced by a new part. The
outer latch handle assembly on each door is fur-
nished with a key operated lock to enable the opera-
tor to lock the truck.
Removal
1. Removing the access panel in the door allows
removal of latch handle assembly.
N2-4 Truck Cab N02005
Installation
1. The latch handle assembly components may be
installed exactly as removed. For ease of instal-
lation, leave mounting screws and nuts slightly
loose until all actuating rods are installed into
their lever assembly. Tighten all fasteners
securely. Check for operation of both the inner
and outer handles and locks to insure that oper-
ation is proper and the door is secure when
closed. Install access panel using machine
screws.
Disassembly
1. Unclip locking clips from lock and actuator rods
(3, 5, & 6, Figure 2-3). These rods need only to
be disconnected at one end. Pull rod ends from
their respective levers.
2. Remove machine screws to remove inner latch
handle assembly and armrest which is attached
to the same panel. The armrest need not be
removed from the panel unless it must be
repaired. Note the nut retaining the inner latch
handle assembly in the panel like the one that
secures the outer latch assembly. Remove this
nut to free the inner latch handle assembly from
the panel. Do not attempt to disassemble latch
handle assembly. If defective or inoperative
after checking and lubricating the pivot points, it
should be replaced with a new assembly.
3. If outer locking latch assembly is defective,
remove by removing retaining nut and sliding
latch assembly from door. Do not attempt to dis-
assemble latch assembly. Replace if defective.
4. If door latch assembly is broken or inoperative,
remove capscrews and lockwashers and lift
latch from the door (the actuator rod must be
disconnected).
Assembly
1. If door latch assembly is replaced, attach with
capscrews and lockwashers. Reconnect the
actuator rod.
2. If outer locking latch assembly is replaced,
attach with retaining nut.
3. If the inner latch handle assembly has been
replaced, lubricate and attach to panel with
retaining nut.
4. Attach panel to door with machine screws.
5. Assemble rod ends into the proper levers (3, 5,
& 6) and attach with locking clips.
FIGURE 2-3. DOOR LATCH LINKAGE
1. Latch
2. Clip/Rod Retainer
3. Rod
4. Handle
5. Rod
6. Rod
7. Lever
8. Housing
9. Handle
10.Retaining Ring
N02005 Truck Cab N2-5
WINDSHIELD AND REAR WINDOW
SERVICE
NOTE: Rear window glass replacement procedures
are the same as windshield replacement. See
special note on page N2-2 regarding optional cabs
equipped with the R-8 insulation package.
Removal
1. Remove windshield wiper arm (6, Figure 2-1).
2. Remove the insert from the channel around the
glass.
3. Remove glass from channel.
4. Inspect channel and replace if damaged or
cracked.
Installation
1. Install new window channel if required.
2. Install glass into channel and press insert into
place.
3. Install wiper arm and blade.
N2-6 Truck Cab N02005
NOTES:
N03004 Cab Components N3-1
CAB COMPONENTS
WINDSHIELD WIPER - AIR OPERATED
Early model HAULPAK
F (10
-195
F (74
-91
C)
(12) ENGINE OIL PRESSURE GAUGE
The engine oil pressure gauge indicates pressure in
the engine lubrication system in pounds per square
inch (psi). Normal operating pressure after engine
warm up should be:
Idle: 20 psi (138 kPa)
Rated Speed: 45 to 70 psi (310 to 483 kPa)
(13) AIR PRESSURE GAUGE
The air pressure gauge indicates the pressure in the
air tank. A pressure reading of 115-135 psi (790-930
kPa) should be indicated on the gauge before operat-
ing the truck. Until air pressure reaches or drops
below 90 psi (621 kPa), a warning buzzer will sound,
indicating low air pressure.
(14) SPEEDOMETER
The speedometer indicates the truck speed in miles
per hour (MPH). A speedometer that displays kilome-
ters per hour (KM/H) is available.
(15) LEFT TURN SIGNAL INDICATOR
This indicator illuminates to indicate the left turn sig-
nals are operating when the turn signal lever on the
steering column is moved downward. Moving the
lever to its center position will turn indicator "Off".
N5-12 Operator Controls N05019 7/95
(16) HIGH BEAM INDICATOR
The high beam indicator when lit, indicates that the
truck headlights are on High beam. To switch head-
lights to High or Low beam, depress dimmer
switch located on the floor between service brake
and retard pedals.
(17) RIGHT TURN SIGNAL INDICATOR
This indicator illuminates to indicate the right turn sig-
nals are operating when the turn signal lever on the
steering column is moved upward. Moving the lever
to its center position will turn indicator "Off".
(18) VOLTMETER
The voltmeter indicates the voltage of the 24V battery
system. Normal indicated voltage at high RPM is 27
to 28 volts with batteries in fully charged condition.
When key switch (1) is "On" and engine NOT running,
the voltmeter indicates battery charge condition.
(19) WARNING DECAL
A warning is mounted on top of the instrument panel
above the voltmeter and ammeter. This decal warns
operator that operating truck with less than 26 volts
may result in a loss of dynamic retarding.
(20) BLANK
This space not currently used. Reserved for future
use.
(21) TACHOMETER
The tachometer registers engine crankshaft speed in
revolutions per minute (RPM).
Governed RPM:
Low Idle: 750 RPM (650 RPM with DDEC Fuel
Saver)
Detroit Diesel: High Idle, No load - 2040 20
RPM (1920 RPM with DDEC option)
Cummins: High Idle, No load - 2150 RPM
Maximum
CAUTION INDICATOR LIGHTS
Indicator lights (22) through (33) are amber in color
and alert the operator of the status of truck functions
and that some precaution may be required when
lighted.
(22) DYNAMIC RETARDING
The dynamic retarding indicator light glows when the
retarder pedal is operated, RSC (Retarder Speed
Control) is activated or the automatic overspeed
retarding circuit is energized, indicating the dynamic
retarding function of the truck is operating.
(23) BODY UP
The Body Up indicator, when lit, shows that the body
is not completely down on the frame. Truck should
not be driven until body is down and light is off.
(24) SERVICE BRAKE
The service brake indicator light will glow when the
service brake pedal is applied or when wheel brake
lock (or emergency brake, if equipped) is applied. Do
not attempt to drive truck from stopped position with
service brakes applied.
(25) PARKING BRAKE
The parking brake indicator will glow when the park-
ing brake is applied. Do not attempt to drive truck
with parking brake applied.
(26) ACCUMULATOR BOOSTER
(OPTIONAL)
Indicates the accumulator booster system is function-
ing.
(27) MANUAL BACK UP LIGHT
Indicates backup lights are On. Works with Manual
Backup Light switch.
(28) LOW FUEL (OPTIONAL)
Indicates low fuel in fuel tank. Light will come on and
buzzer will sound. Approximately 25 gal. (95 l) of
usable fuel is left when light comes on.
N05019 7/95 Operator Controls N5-13
(29) HIGH PRESSURE FILTER (Optional)
This light indicates a restriction in the high pressure
filter assembly for either the steering or hoist circuit.
This light will come on before filters start to bypass.
Notify maintenance personnel at earliest opportunity
after light comes on.
(30) ENGINE CHECK MAIN ("DDEC"
Electronic Engine Controls or Cummins
Engines Equipped With Centry
Fuel
Control)
When the keyswitch is turned "On" (before starting
engine), this amber "Engine Check Main" indicator
light will illuminate for about 2 seconds and then turn
off, if no "faults" are detected in the system. If this
indicator remains "On" (or flashes with Cummins
Centry
Fuel Control -
If truck is equipped with a Cummins engine and Cen-
try
F (107
Diagnostic Test Switch (if equipped)
This switch may be used for
Lamp Test, or for diagnostic tests
of a Cummins Centry
Fuel Con-
trol system (if equipped).
The Lamp Test Switch is provided for the operator
to test the warning and indicator lights before engine
startup. To test lamps, turn key switch to "run" posi-
tion and move switch lever to the right for the "On"
position. This action will complete a circuit to the
warning and indicator lights. The warning horn will
also sound. All red warning lights and amber indica-
tor lights should light up except those that are
"BLANK" and not currently used (see description of
indicators and warning lights in this section also see
"NOTE:" following Indicator #47). Releasing the
spring-loaded switch will allow the lever to return left
to the "Off" position.
For diagnostic tests of a Cummins engine equipped
with Centry Fuel Control, refer to "Centry
Diagnos-
tics" at the end of this section.
(60) HEATER TEMPERATURE CONTROL
LEVER
The heater temperature control lever is provided for
the operator to select a comfortable temperature.
The far left position turns heat off for warm weather
operation (or air conditioning if so equipped). Milder
temperatures can be regulated by moving the control
lever to the right. Moving the control lever to the far
right selects the warmest temperature for cold
weather operation.
(61) DEFROSTER/HEAT CONTROL
LEVER
The defroster/heater control lever permits the opera-
tor to select either defroster or heater.
Moving the control lever to the far left position directs
heated air to the cab floor for most efficient heating of
cab air.
Moving the lever to the far right selects the defroster
function. This directs heated air to the windshield.
Selecting a center position for the control lever
divides the air to both floor heat and defroster.
(62) OUTSIDE/INSIDE AIR CONTROL
LEVER
The outside/inside air control lever is connected to a
vent which allows either outside or inside air to be cir-
culated through the cab heater assembly.
Moving the lever to the left directs outside air to be
circulated through the heater assembly.
Moving the lever to the right directs inside air to be
recirculated through the heater assembly.
(63) AIR CONDITIONER CONTROL
(OPTIONAL)
The Air Conditioner control lever is moved from left
(off) to right to cool the cab air.
Full right position is coldest setting.
(64) FAN CONTROL KNOB
The fan control knob is provided to control the cab air
fan motor. The fan motor is a 3-speed motor (low,
medium and high) which are selected by rotating the
control knob clockwise to the desired position. Off
position is marked by symbol on panel.
N05019 7/95 Operator Controls N5-19
(65) AIR CLEANER SERVICE VACUUM
GAUGE
The air cleaner service gauge provides a continuous
reading of maximum air cleaner restriction reached
during operation. The air cleaner(s) should be ser-
viced when the gauge(s) shows the following maxi-
mum recommended restriction:
20 inches H
2
O vacuum for Detroit Diesel engine.
25 inches H
2
O vacuum for Cummins engine.
After service, push the reset pin on face of gauge to
allow the gauge to reset to zero.
When truck is equipped with a Cummins engine of
LESS THAN 2000 HP (1491 kW), the instrument
panel will contain only two (2) Air Cleaner Service
gauges.
(66) FUEL LEVEL GAUGE (OPTIONAL)
Allows operator to be aware of fuel status without
viewing fuel tank at ground level.
(67) HOURMETER
The hourmeter registers the total number of hours
the engine has been in operation.
(68) OVERSPEED ALARM HORN
(OPTIONAL)
This alarm will sound when truck speed reaches
overspeed setting. Dynamic Retarding and Dynamic
Retard Indicator light will also come on. Refer to
speed grade decal in operator's cab for downhill
hauling speeds.
(69) CIRCUIT BREAKERS
The circuit breakers are provided to protect various
circuits from an excess current condition. If a mal-
function in the circuitry occurs, the appropriate circuit
breaker will open the circuit. After the circuit breaker
cools, it can be reset by pushing the button.
Report any faulty circuit that is protected by a cir-
cuit breaker, as serious damage may result from
overcurrent conditions.
FIGURE 5-12. CIRCUIT BREAKER PANEL
1. Hoist Limit (15 amp.)
2. Volt Meter/Turn Signal/Relay
Coils/Status Lights (15 amp.)
3. Heater Blower (15 amp.)
4. Dry/Slippery
Road (5 amp.)
5. Rad. Pre-Charge Solenoid
(5 amp.)
6. Eng. Temp. & Fuel Gauges
(5 amp.)
7. Heater Drain Valve and Air Dryer
(5 amp.)
8. Lincoln Lube Timer (10 amp.)
9. 12VDC Power Supply (Lower
Right Side Center of Console)
(10 amp.)
10. Keyswitch to Starter Solenoid
(10 amp.)
11. Windshield Washer (10 amp.)
12. Alarm (see NOTE)
13. Engine Service, Ladder Lights, &
Opt. Fog Lights (15 amp.)
14. Cigar Lighter (20 amp. Fuse)
NOTE: Alarm Horn (12) alerts the operator of a malfunction within a system. When the alarm horn sounds during
operation, a warning light will flash to provide a visual aid for determining which system is malfunctioning.
N5-20 Operator Controls N05019 7/95
CENTRY
Fuel Sys-
tem diagnostic codes. When the Centry
fuel system
detects a "fault" and the ENGINE CHECK MAIN indi-
cator light (30, FIGURE 5-10) illuminates as
described above, this switch will permit determination
of the kind of "fault(s)" detected.
DETERMINING "FAULT" CODES
Centry
SUSPENSION BALL
J OINTS - Add one or two applications of
grease to each grease fitting for the upper and
lower suspension mount pins. Use Lube Key
E.
6. HYDRAULIC PUMP & U-J OINT - Add one or
two applications of grease to each grease fit-
ting on the cross and bearing assemblies and
splines. Use Lube Key F.
7. STEERING COLUMN - Add one or two appli-
cations of grease to each grease fitting on the
cross and bearing assemblies and splines.
Use Lube Key E.
8. FRONT WHEEL BEARINGS - Check oil level.
9. FUEL TANK - Drain H
2
O and sediment.
P02017 1/95 Lubrication and Service P2-7
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
Maintenance for every 10, 50, & 100 hour Lubrication
Checks should also be carried out at this time.
NOTE: Lube Key references are to the Lubrication
Specification Chart.
Truck Serial Number _________________________
Site Unit Number ____________________________
Date: __________ Hour Meter _________________
Name of Service Person ______________________
COMMENTS CHECKED INITIALS
1. ENGINE - Change engine oil and spin-on lube
oil filters. Use Lube Key A.
NOTE: When installing spin-on filter elements,
thread onto base until the seal touches the base and
then tighten only 1/2 to 3/4 additional turn by hand to
seat element fully. Do not use a wrench or strap
to tighten filter elements.
2. FUEL FILTER AND STRAINER - Change filter
and strainer element.
3. STEERING CONTROL LINKAGE - Add one or
two applications of grease to each grease fit-
ting for pin and bearing. Check torque on steer-
ing pin nuts 1000 ft. lbs. (1346 N.m) torque.
Use Lube Key E.
4. AIR SYSTEM LUBRICATOR - (May not be on
later trucks.) - If equipped, fill with oil, use Lube
Key D.
5. HYDRAULIC SYSTEM OIL FILTERS - Change
filter elements after the initial 250 hours of
operation; then at each 500 hours of operation
thereafter.
6. COOLING SYSTEM DCA WATER FILTER -
Change spin-off filter. Check cooling system for
proper coolant mixture. Add water mixture as
required.
7. CAB AIR FILTER (NOT SHOWN) - Under nor-
mal operation conditions, clean every 250
hours. In extremely dusty conditions, service as
frequently as required. Clean filter element with
mild soap and water, rinse completely clean
and air dry with maximum of 40 psi (275 kPa).
Reinstall filter.
P2-8 Lubrication and Service P02017 1/95
500 HOUR LUBRICATION AND MAINTENANCE CHECKS
Maintenance for every 10, 50, 100, & 250 hour Lubri-
cation and Maintenance Checks should also be car-
ried out at this time.
NOTE: Lube Key references are to the Lubrication
Specification Chart.
Truck Serial Number _________________________
Site Unit Number ____________________________
Date: __________ Hour Meter _________________
Name of Service Person ______________________
COMMENTS CHECKED INITIALS
1. REAR AXLE CASE BREATHERS - Remove
breather elements for motorized wheels and
clean or replace elements.
2. HYDRAULIC SYSTEM FILTERS - Replace fil-
ter elements. Check oil level in tank. Oil should
be visible in sight glass, add oil if necessary.
Refer to Hydraulic Tank Service. DO NOT
OVERFILL. Lube Key D.
3. HYDRAIR
II . . . . . . . . H4-1
Clutch, Fan Drive . . . . . . . . . . . . . . . . . . . . . .M6-1
Compressor, Air . . . . . . . . . . . . . . . . . . . . . . . K3-1
Conditioner, Air. . . . . . . . . . . . . . . . . . . . . . . .M9-1
Cooling Blower Warning System . . . . . . . . . . E2-4
Cooling System . . . . . . . . . . . . . . . . . . . . . . . C3-1
Creep Down Valve . . . . . . . . . . . . . . . . . . . . . L7-1
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . L6-10
Throttle Control . . . . . . . . . . . . . . . . . . . . C6-1
D
Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
Differential Pressure Manifold . . . . . . . . . . . J 3-21
Disc Brakes
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . J 5-1
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . J 7-1
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . J 6-1
Door, Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-2
Drain Valve (Automatic/Manual). . . . . . . . . . . K3-3
Drive Case Bumper Pad. . . . . . . . . . . . . . . . .G5-2
Dry/Slippery Road Solenoid. . . . . . . . . . . . . N5-13
Dual Hydraulic Brake Controller. . . . . . . . . . . J 3-1
Dump Body. . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . K4-3
Q1-2 Alphabetical Index Q01011
E
Electrical Checkout Procedure
FL191 (PLCP) . . . . . . . . . . . . . . . . . . . . . E3-1
Electrical System Schematics . . . . . . . . . . . . R1-1
Ejector, Rock . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4-1
Engine - Alternator Mating . . . . . . . . . . . . . . . C4-2
Engine Coolant Heater. . . . . . . . . . . . . . . . . .M7-1
Engine Coolant & Oil Heaters, 440V . . . . . . .M7-1
Engine Monitor . . . . . . . . . . . . . . . . . . . . . . .M13-1
Engine Oil Heater. . . . . . . . . . . . . . . . . . . . . .M7-1
Engine Specifications . . . . . . . . . . . . . . . . . . . A2-3
F
Fan Drive Clutch. . . . . . . . . . . . . . . . . . . . . . .M6-1
Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-6
Filters
Air (Hydraulic Tank) . . . . . . . . . . . . . . . . L3-10
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-2
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . L8-10
Final Drive Attachment. . . . . . . . . . . . . . . . . .G4-1
Fire Control (Manual) . . . . . . . . . . . . . . . . . . .M2-1
Fire Control (Pneumatic) . . . . . . . . . . . . . . M2.2-1
Fire Control (Electric) . . . . . . . . . . . . . . . . . M2.3-1
Float Control (Creep Down) . . . . . . . . . . . . . . L7-1
Flow Amplifier Valve. . . . . . . . . . . . . . . . . . . . L6-3
Flushing, Hydraulic System . . . . . . . . . . . . . L3-13
Front Suspension, HYDRAIR
II . . . . . . . . . . H2-1
Front Wheel Brakes . . . . . . . . . . . . . . . . . . . . J 5-1
Front Wheel Hub and Spindle. . . . . . . . . . . . .G3-1
Front Wheel and Tires . . . . . . . . . . . . . . . . . .G2-1
Fuel Filter - Water Separator (Optional) . . . .M16-1
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
G
Gauge (Fuel Tank) . . . . . . . . . . . . . . . . . . . . . B4-2
Generator (Battery Charging). . . . . . . . . . . . . D2-3
Governor, Air . . . . . . . . . . . . . . . . . . . . . . . . . K3-4
Grille & Hood . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
Ground Level Shut Down. . . . . . . . . . . . . . . .D3-3
Guide (Body) . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
H
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Blower & Core. . . . . . . . . . . . . . . . . . . . . N4-4
Water Control Valve . . . . . . . . . . . . . . . . N4-4
Hitch Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . G4-1
Hoist Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
Hoist Control Valve . . . . . . . . . . . . . . . . . . . . .L8-4
Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . . .L8-6
Hoist Relief Valve . . . . . . . . . . . . . . . . . . . . . .L8-3
Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . D3-4
Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
Hub, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . G3-1
HYDRAIR
II Suspensions
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
Oil and Nitrogen Specifications. . . . . . . . H4-6
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
HYDRAIR
II . . . . . . . . . . . H4-6
Oiling and Charging Procedure, HYDRAIR
IIH4-1
Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . N4-1
Outlet Strainer (Hydraulic) . . . . . . . . . . . . . . .L3-11
Optional Operator Seat . . . . . . . . . . . . . . . . M14-1
P
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . .J 7-1
Pedal, Brake . . . . . . . . . . . . . . . . . . . . . . . . . .J 3-1
Plates, Warning and Caution. . . . . . . . . . . . . A4-1
Power Module . . . . . . . . . . . . . . . . . . . . . . . . C2-1
Q
Quick Fill Fuel System (Optional) . . . . . . . . . M5-1
R
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
Rear HYDRAIR
II Suspension. . . . . . . . . . . H3-1
Rear Wheel Disc Brakes . . . . . . . . . . . . . . . . .J 6-1
Rear Tire and Rim. . . . . . . . . . . . . . . . . . . . . G2-3
Retard Pedal, Electronic . . . . . . . . . . . . . . . . E2-3
Regulator Valve Radiator. . . . . . . . . . . . . . . . K3-6
Rims (Tire Removal) . . . . . . . . . . . . . . . . . . . G2-4
Rock Ejector . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Rod, Tie. . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-7
S
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . A3-1
Safety Valve (Air) . . . . . . . . . . . . . . . . . . . . . . K2-3
Seat (Operator) . . . . . . . . . . . . . . . . . . . . . . . N4-1
Service Kit, HYDRAIR
II . . . . . . . . . . . . . . . . H4-1
Solenoid
Bleeddown. . . . . . . . . . . . . . . . . . . . . . . . L6-2
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . C6-2
Specifications
HYDRAIR
II Nitrogen . . . . . . . . . . . . . . . H4-6
HYDRAIR
II Oil. . . . . . . . . . . . . . . . . . . . H4-6
Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .M8-1
Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G3-1
Starter, Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . K4-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator Charging Procedure . . . . . . L6-9
Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-1
Circuit Test Procedure . . . . . . . . . . . . . . L6-13
Control Unit . . . . . . . . . . . . . . . . . . . . . . . L5-1
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . L6-10
Troubleshooting. . . . . . . . . . . . . . . . . . . L6-16
Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1
Suspension, HYDRAIR
II
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-1
Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1
Body Up. . . . . . . . . . . . . . . . . . . . . . . . . . D3-3
Hoist Limit . . . . . . . . . . . . . . . . . . . . . . . . D3-4
Selector . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6
Q1-4 Alphabetical Index Q01011
T
Table of Contents . . . . . . . . . . . . . . . . . . . . . . A3-1
Tank
Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K2-2
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . L3-11
Throttle Control Air Cylinder. . . . . . . . . . . . . . C6-1
Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . C6-3
Throttle Treadle Valve. . . . . . . . . . . . . . . . . . . K5-1
Tie Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G3-7
Tires
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . .G2-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G2-3
Toe-In Adjustment. . . . . . . . . . . . . . . . . . . . .G3-10
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M8-1
Torque Table (Standard) . . . . . . . . . . . . . . . . . A5-1
Troubleshooting
Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . C5-1
Air Starter. . . . . . . . . . . . . . . . . . . . . . . . . K4-4
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . L3-1
Steering Control Unit . . . . . . . . . . . . . . . . L5-1
U
Unloader Valve. . . . . . . . . . . . . . . . . . . . . . . . L6-1
V
Valves
Bleeddown Manifold . . . . . . . . . . . . . . . . .L6-2
Creep Down . . . . . . . . . . . . . . . . . . . . . . .L7-1
Drain (Automatic/Manual). . . . . . . . . . . . K3-3
Dual Hydraulic Control . . . . . . . . . . . . . . .J 3-1
Flow Amplifier . . . . . . . . . . . . . . . . . . . . . .L6-3
Heater Control. . . . . . . . . . . . . . . . . . . . N5-16
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L8-1
Hoist Control . . . . . . . . . . . . . . . . . . . . . . .L8-4
Hoist Relief . . . . . . . . . . . . . . . . . . . . . . . .L8-3
Moisture Ejection . . . . . . . . . . . . . . . . . . K3-3
Regulator . . . . . . . . . . . . . . . . . . . . . . . . K3-6
Retarder Treadle. . . . . . . . . . . . . . . . . . . N5-6
Safety (Air) . . . . . . . . . . . . . . . . . . . . . . . K3-2
Solenoid (Air Start) . . . . . . . . . . . . . . . . . K4-3
Solenoid (Dry/Slippery Road) . . . . . . . . N5-13
Throttle Treadle. . . . . . . . . . . . . . . . . . . . K5-1
Unloader . . . . . . . . . . . . . . . . . . . . . . . . . .L6-1
Wiper Control . . . . . . . . . . . . . . . . . . . . . N3-1
W
Weights (Truck) . . . . . . . . . . . . . . . . . . . . . . . A2-3
Wheel Bearing Adjustment (Field). . . . . . . . . G3-6
Wheel Cylinders (Steering) . . . . . . . . . . . . . . G3-7
Wheel Hub and Spindle. . . . . . . . . . . . . . . . . G3-1
Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . G5-1
Wheels and Tires
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-3
Wiggins
Fuel Receiver . . . . . . . . . . . . . . . . . . . . . M5-1
Tank Vent . . . . . . . . . . . . . . . . . . . . . . . . M5-1
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-2
Windshield Washer . . . . . . . . . . . . . . . . . . . . N3-2
Windshield Wiper . . . . . . . . . . . . . . . . . . . . . N3-1
R01022 7/94 Schematics R1-1
w/Statex III & 24 VDC Relay Circuit Boards
SECTION R
SYSTEM SCHEMATICS
INDEX
AIR SYSTEM (All Hydraulic Brake w/Air Throttle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HA195
AIR SYSTEM (All Hydraulic Brake w/DDEC or CUMMINS CENTRY
). . . . . . . . . . . . . . . . . . . . . . .HA198
HYDRAULIC BRAKE SYSTEM SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HH313
HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HH309
RETARD CONTROL PANEL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HE378
DDEC ACCELERATION INTERFACE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HE379
STATEX III POWER & EXCITATION SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HE376
TRUCK ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HE400
R1-2 Schematics R01022 7/94
w/Statex III & 24 VDC Relay Circuit Boards
NOTES:
-A-
ACCELERATOR BOX 70
ACCELERATOR INTERFACE CARD 70, 77
ACCUMULATOR BLEEDDOWN SOLENOID 36
ACCUMULATOR LEAK DETECTION SWITCH 66
ACCUMULATOR PRE-CHARGE INDICATOR LIGHT 50
ACCUMULATOR PRE-CHARGE PRESSURE SWITCH 51
ALARMHORN 48
AIR CONDITIONER COMPRESSOR 20
AIR CONDITIONER CONDENSOR 20
AIR CONDITIONER RECEIVER DRYER 20
AIR PRESSURE SWITCH 35
AIR START SOLENOID 7
AIR TANK DRAIN VALVE HEATER 34
ALTERNATOR 24V DC 5
AREOFINER HEATER 35
AUTOMATIC APPLY SWITCH 31
AUXILIARY BRAKE SOLENOID 31
-B-
BACK-UP HORN 27
BACK-UP INDICATOR LIGHT (MANUAL) 45
BACK-UP LIGHTS 28
BACK-UP LIGHT RELAY (MANUAL) 28
BACK-UP LIGHT SWITCH (MANUAL) 28
BATTERIES 4
BATTERY CHECK INDICATOR LIGHT 67
BATTERY EQUALIZER 3
BATTERY EQUALIZER MONITOR 3
BODY-UP INDICATOR LIGHT 62
BODY-UP RELAY 62
BODY-UP SWITCH 62
BRAKE CABINET SERVICE LIGHT 38
BRAKE LOCK LOCK-OUT RELAY 32
BRAKE LOCK SOLENOID 31
BRAKE LOCK SWITCH 31
-C-
CAB DOME LIGHTS 22
CABINET SERVICE LIGHT SWITCH (CSLS) 22
CAB THERMOSTAT 20
CHECK ENGINE MAIN INDICATOR LIGHT 67
CHECK ENGINE RECEIVER 1INDICATOR LIGHT 67
CIGAR LIGHTER 19
CIRCUIT BREAKER - 13(CB-13) 14
CIRCUIT BREAKER - 14(CB-14) 16
CIRCUIT BREAKER - 15(CB-15) 14
CIRCUIT BREAKER - 16(CB-16) 28
CIRCUIT BREAKER - 17(CB-17) 28
CIRCUIT BREAKER - 18(CB-18) 29
CIRCUIT BREAKER - 19(CB-19) 27
CIRCUIT BREAKER - 20(CB-20) 36
CIRCUIT BREAKER - 21(CB-21) 36
CIRCUIT BREAKER - 22(CB-22) 35
CIRCUIT BREAKER - 23(CB-23) 9
CIRCUIT BREAKER - 24(CB-24) 9
CIRCUIT BREAKER - 25(CB-25) 10
CIRCUIT BREAKER - 26(CB-26) 10
CIRCUIT BREAKER - 27(CB-27) 11
CIRCUIT BREAKER - 28(CB-28) 97
CIRCUIT BREAKER - 29(CB-29) 97
CIRCUIT BREAKER - 30(CB-30) 17
CIRCUIT BREAKER - 31(CB-31) 19
CIRCUIT BREAKER - 32(CB-32) 44
CIRCUIT BREAKER - 33(CB-33) 25
CIRCUIT BREAKER - 34(CB-34) 34
CIRCUIT BREAKER - 35(CB-35) 33
CIRCUIT BREAKER - 37(CB-37) 42
CIRCUIT BREAKER - 38(CB-38) 23
CIRCUIT BREAKER - 39(CB-39) 23
CIRCUIT BREAKER - 40(CB-40) 1
CIRCUIT BREAKER - 42(CB-42) 30
CIRCUIT BREAKER - 43(CB-43) 7
CIRCUIT BREAKER - 44(CB-44) 2
CIRCUIT BREAKER - 45(CB-45) 2
CIRCUIT BREAKER - 46(CB-46) 3
CIRCUIT BREAKER - 47(CB-47) 3
CIRCUIT BREAKER - 48(CB-48) 3
CLEARANCE LIGHT RELAY 14
CONTROL CABINET DIAGN. CONNECTOR (DDEC) 1, 75
CONTROL POWER RELAY (CPR) 26, 68
CONTROL POWER RELAY COIL 26
CONTROL POWER RELAY LIGHT 26
CONTROL POWER SWITCH (CPS) 26
COOLANT HIGH TEMPERATURE LIGHT 50
COOLANT LEVEL INDICATOR LIGHT 48
COOLANT LEVEL MODULE 1
COOLANT LEVEL PROBE 47
COOLANT LEVEL SENDER 2
CRANKING OIL PRESSURE INTERLOCK RELAY 8
-D-
DASH LIGHT RHEOSTAT 13
DASH LIGHTS 13
DATA STORAGE TRIGGER MODULE (DSTM) 97
DATA STORE SWITCH 39
DDEC DIAGNOSTIC CONNECTOR 1, 75
DDEC 12V DC POWER 2
DIFFERENTIAL PRESSURE SWITCH FRONT 30
DIGITAL SPEEDOMETER 13
DIGITAL TACHOMETER 13
DIMMER SWITCH 12
DIODE BOARDI (DBI)
25, 33, 37,
41
"
65, 68, 71,
74
HE400 SCHEMATIC COMPONENT INDEX AND LOCATOR
" 82, 100
DIODE BOARD2(DB2) 31, 62
DISCONNECT SWITCH 12V 3
DISCONNECT SWITCH 24V 4
DYNAMIC RETARDINDICATOR LIGHT 29, 45
-E-
ELECTRICAL SYSTEMFAILURE INDICATOR LIGHT 72
EMERGENCY ENGINE SHUTDOWN SWITCH 35
ENGINE CONTROL MONITOR (ECM) MAIN 76
ENGINE CONTROL MONITOR (ECM) RECEIVER 1 77
ENGINE HOURS OIL PRESSURE SWITCH 39
ENGINE OIL PRESSURE SWITCH (STARTER) 7
ENGINE SERVICE DASH INDICATOR LIGHT 67
ENGINE SERVICE LIGHT 17
ENGINE TEMPERATURE GAUGE 24
ENGINE TEMPERATURE SENDER 24
ENGINE WATER TEMPERATURE SENSOR 50
-F-
FAN CLUTCH SOLENOID 21
FAN SWITCH - COOLANT 21
FAN SWITCH - HEATER/AC MOTOR 19
FAN SWITCH - HEAT EXCHANGER 21
FLASHER RELAY 16
FOG LIGHTS 17
FOG LIGHT S WITCH 17
FUEL GAUGE 23
FUSE (CIGAR LIGHTER) 19
-G-
GF CONTACTOR 83
GFR CONTACTOR 84
-H-
HAZARDSWITCH 16
HEADLIGHT SWITCH 12
HIGH BEAMHEADLIGHTS 10
HIGH BEAMINDICATOR LIGHT 12
HIGH HYDRAULIC OIL TEMP.INDICATOR LIGHT 54
HIGH MOUNT HIGH BEAMHEADLIGHTS 10
HIGH MOUNT LOWBEAMHEADLIGHTS 9
HIGH PRESSURE FILTER INDICATOR LIGHT 63
HOIST LIMIT SOLENOID&SWITCH 25
HORN BUTTON 37
HORN RELAY 37
HORN SOLENOID 37
HOUR METER 39
HYDRAULIC FILTER PRESSURE SWITCH 63
-I-
ICLINOMETER 99
INTERCOOLER SOLENOID 21
INTERCOOLER SWITCH 21
-K-
KEY SWITCH 7
-L-
LADDER LIGHTS 18
LADDER LIGHT SWITCH - GROUNDLEVEL &DASH 18
LAMP TEST 46
LIGHT CONTROL RELAY 98
LEFT HIGH BEAMHEADLIGHT RELAY 10
LEFT LOWBEAMHEADLIGHT RELAY 9
LINCOLN LUBE SOLENOID 33
LINCOLN LUBE TIMER 33
LOWAUXILIARY BRAKE ACCUM. PRESSURE SWITCH 66
LOWBEAMHEADLIGHTS 9
LOWBRAKE PRESSURE INDICATOR LIGHT 66
LOWBRAKE PRESSURE WARNING BUZZER 66
LOWFUEL INDICATOR LIGHT 64
LOWFUEL LEVEL TRANSMITTER 64
LOWIDLE SOLENOID 68
LOWIDLE SWITCH 40
LOWMOUNT HIGH BEAMHEADLIGHTS 10
LOWMOUNT LOWBEAMHEADLIGHTS 9
LOWOIL LEVEL INDICATOR LIGHT 52
LOWSTEERING PRESSURE BUZZER 65
LOWSTEERING PRESSURE INDICATOR LIGHT 65
LOWSTEERING PRESSURE SWITCH 65
-M-
MFC CONTACTOR 85
MOTOR BLOWER OFF INDICATOR LIGHT 70
MOTOR BLOWER PRESSURE SWITCH 70
-O-
OIL PRESSURE GAUGE &SENDER 24
OPERATOR CAB DIAGNOSTIC CONNECTOR - DDEC 1
OVERRIDE SWITCH 40
-P-
PARKING BRAKE FAILURE RELAY (PBFR) 36
PARKING BRAKE INDICATOR LIGHT 63
PARKING BRAKE PRESSURE SWITCH 36
PARKING BRAKE SOLENOID 41
PARKING BRAKE SWITCH 42
PAYLOADLIGHTS 98
PAYLOADMETER 98
PAYLOADMETER CONTROLLER 98
POWER RECEPTACLE ACCESSORY 12V DC 1
PROPEL/LOCKOUT SWITCH 5
P1CONTACTOR 82
P2CONTACTOR 83
-R-
RADIATOR AIR PRE-CHARGE SOLONOID 23
RD1&RD2 14
REAR AXLE LIGHT &SWITCH 38
REAR BRAKE PRESS. DIFF. WARNING SWITCH (DR1) 65
REAR DYNAMIC RETARDLIGHT 28
RELAY 1(RY1) (ACC) 70
Optional components are shown in BOLDITALIC type
R E LAY 2 (R Y2) (ACC) 69
R E LAY BOAR D 1 (R B1) 15
R E LAY BOAR D 2 (R B2) 98
R E LAY BOAR D 3 (R B3) 28
R E LAY BOAR D 4 (R B4) 8, 36, 62
R E LAY BOAR D 5 (R B5) 10
R E LAY BOAR D 6 (R B6) 32
R E TAR D INTE R FACE CAR D 81
R E TAR D LIGHT R E LAY 28
R E TAR D POWE R CONTACTOR 1 (R P1) 86
R E TAR D POWE R CONTACTOR 2 (R P2) 87
R E TAR D POWE R CONTACTOR 3 (R P3) 87
R E TAR D POWE R CONTACTOR 4 (R P4) 88
R E TAR D POWE R CONTACTOR 5 (R P5) 89
R E TAR D POWE R CONTACTOR 6 (R P6) 89
R E TAR D POWE R CONTACTOR 7 (R P7) 90
R E TAR D POWE R CONTACTOR 8 (R P8) 91
R E TAR D POWE R CONTACTOR 9 (R P9) 91
R E TAR D S PE E D CONTR OL DIAL 79
R E TAR D S PE E D CONTR OL INDICATOR LIGHT 78
R E TAR D S PE E D CONTR OL S WITCH 78
R E VE R S E R 27
R E VE R S E R COILS 85
R IGHT HIGH BE AM HE ADLIGHT R E LAY 11
R IGHT LOW BE AM HE ADLIGHT R E LAY 10
-S -
S E CONDAR Y BR AKE LOCK S WITCH 31
S E LE CTOR S WITCH 7, 41
S E R IAL POR T CONNE CTOR 100, 102
S E R VICE BR AKE INDICATOR LIGHT 60
S HUTTE R S OLE NOID 19
S LIPPE R Y R OAD R E LAY 29
S LIPPE R Y R OAD S OLE NOID 30
S LIPPE R Y R OAD S WITCH 30
S TAR TE R S OLE NOIDS (E LE CTR ICAL) 5
S TAR TE R S , (E LE CTR ICAL) 5
S TE E R ING BLE E DDOWN TIME R & S OLE NOID 36
S TOP E NGINE MAIN INDICATOR LIGHT 73
S TOP E NGINE R E CE IVE R 1 INDICATOR LIGHT 74
S TOP LIGHT R E LAY 29
S TOP LIGHTS 14
S TOP LIGHT S WITCHE S 59
-T-
TAIL LIGHTS 14
THR OTTLE S OLE NOID 69
TUR N/CLE AR ANCE LIGHT R E AR 15
TUR N/CLE AR ANCE LIGHT R E LAY LE FT 15
TUR N/CLE AR ANCE LIGHT R E LAY R IGHT 16
TUR N/CLE AR ANCE LIGHTS 15
TUR N INDICATOR LIGHT LE FT 15
TUR N INDICATOR LIGHT R IGHT 16
TUR N S IGNAL FLAS HE R 16
TUR N S IGNAL S WITCH 14
TWO S PE E D S WITCH 44
-V-
VOLTME TE R 44
-W-
WAS HE R MOTOR 42
WATE R TE MPE R ATUR E GAUGE INDICATOR LIGHT 50
WE IGHT S E NS OR LE FT FR ONT 98
WE IGHT S E NS OR LE FT R E AR 98
WE IGHT S E NS OR R IGHT FR ONT 98
WE IGHT S E NS OR R IGHT R E AR 98
WHE E L MOTOR TE MPE R ATUR E INDICATOR LIGHT 72
WINDS HIE LD WAS HE R /WIPE R S WITCH 43
WIPE R MOTOR 43
HE400 JUNE 94
SECTION 1