EH1700-3 Workshop Manual

Manual No: W8R6-E-01
WORKSHOP MANUAL
EH1700-3
8R6AA
RIGID DUMP TRUCK
Service Manual consists of the following separate Part No;

Workshop Manual W8R6-E-01
TITLE / Introduction
TO THE READER MANUAL COMPOSITION

This manual is written for an experienced technician This manual consists of three portions; the Technical
to provide technical information needed to maintain Manual (Operational Principle) the Technical Manual
and repair this rigid dump truck. (Troubleshooting) and the Workshop Manual.
The Technical Manual (Operational Principle) con-

Be sure to thoroughly read this manual for correct
tains the information necessary for delivery, operation
product information and service procedures.
and activation of all devices and systems.
If you have any questions or comments, or if you
The Technical Manual (Troubleshooting) contains the
found any errors regarding the contents of this man-
information about operational performance tests, and
ual, please contact us using the “PLEASE TELL US”
troubleshooting procedures.
form. The form follows this INTRODUCTION section.
The Workshop Manual contains the information nec-
essary for maintenance and repair of the rigid dump
ADDITIONAL REFERENCES truck, tools and devices necessary for maintenance
and repair, maintenance standards, and re-
Please refer to the materials listed below in addition
moval/installation and disassembly/assembly proce-
to this manual:
dures.
• Operators Manual
• Parts Catalog
• Operation Manual of the Engine
o Detroit Diesel 16V2000 Service Manual
• Operation Manual of the Transmission
o 8000-9000 Series Transmissions Commer-
cial Electronic Controls 2 (CEC2) Manual
o Allison Transmission 8610-9610 Series Ser-
vice Manual
• Hitachi Weld Repair Manual KO-111-00
TS41154
IN-01
PAGE NUMBER
The Manuals have the page number located on the
center lower part of the page, as well as, additional
numbers on the page to help the technician locate
specific information:
W2-1-3
Consecutive Page Number for each
group
Group Number
Section Number
T = Technical Manual
W = Workshop Manual
SAFETY ALERT SYMBOL AND HEAD-

LINE NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the po-
tential for personal injury or rigid dump truck damage.
This is the safety alert symbol. When you see

this symbol, be alert to the potential for personal
injury. Always follow the safety instructions that ac-
company the safety alert symbol.
The safety alert symbol is also used to draw attention

to the weight of component parts.
To avoid injury and damage, be sure to use appropri-

ate lifting techniques and equipment when lifting
heavy parts.
WARNING: Indicates a potentially hazardous

situation that could, if not avoided, result in per-
sonal injury or death.
NOTE: Indicates supplementary technical infor-

mation or know-how.
IN-02
UNITS USED
Example: 24.5 MPa (3550 psi)
SI system units and English units are used in this
manual. English units are in parentheses behind SI A table for conversion from SI units to other system
units. units is shown below for reference purposes.
To Convert
Quantity From Into Multiply by
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m³ yd³ 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N٠m kgf٠m 1.0197
N٠m lbf٠ft 0.7375
To Convert
Quantity From Into Multiply by
Pressure MPa kgf/cm² 10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
Flow Rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
IN-03
MEMO
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IN-04
SAFETY
RECOGNIZE SAFETY INFORMATION
• SAFETY ALERT SYMBOL
• This symbol, which will appear at various points in the

manual and on the rigid dump truck together with a
warning statement, means: “Warning, be alert! Your
safety is involved!” Carefully read the message
that follows. It is the obligation of the operator to
make sure that all warning decals are in place on
the rigid dump truck and that they are readable.
Accidents may otherwise occur.
• Follow recommended precautions and safe operating
practices.
• Every country (Jurisdiction) has its own safety
regulations. It is the obligation of the operator to know
and follow these. This also applies to local regulations
covering different types of work. Should the
recommendations in this manual deviate from those of
your country (State), your local safety regulations
should be followed.
UNDERSTAND SIGNAL WORD
• On the rigid dump truck safety signs, signal words

designating the degree or level of hazard –
DANGER, WARNING, or CAUTION – are used with
the safety alert symbol.
• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death or
serious injury.
• WARNING indicates a potential hazardous
situation which, if not avoided, could result in death
or serious injury.
• CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listed on CAUTION safety signs.
• These signal words also call attention to safety
messages in this manual.
To avoid confusing rigid dump truck protection with
personal safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could result
in damage to the rigid dump truck.
NOTE: indicates an additional explanation for an

element of information.
S-1
SAFETY
OPERATOR’S QUALIFICATIONS
• Only trained personnel should operate the rigid dump

truck.
• Operator should be of legal operating age according

to country (Jurisdiction) regulations and familiar with
the operation and maintenance of the rigid dump
truck.
• Operator must be licensed if required by National

Rules and Regulations.
DUTIES OF THE OPERATOR
• Before operating the rigid dump truck, this manual

must be read and understood. Contact your
supervisor if you do not understand any portion of
this manual. By reading and understanding the
manual, you will become aware of and observe
how to avoid injury and damage.
• Know the work area and the company rules and
regulations
• Never operate any vehicle while under the

influence of alcohol, medicine or other drugs.
Due to the position of the cab and size of the rigid

dump truck, the operator has limited visibility to areas
close to or near the rigid dump truck. No person
should enter the operating area of the rigid dump
truck when it is in operation without first notifying the
operator. If a person has to enter the operating area
of the rigid dump truck, they should signal the
operator and wait for an acknowledgement of
recognition by the operator.
During rigid dump truck operation no one should be

allowed to get any closer than 7m (23 ft.). Any closer
will limit one’s time to react and move away from the
vehicle when it starts.
INSPECT RIGID DUMP TRUCK
• Inspect your rigid dump truck carefully each day or shift

by walking around it before you start it to avoid personal
injury.
• Be sure to cover all points described under “INSPECT

RIGID DUMP TRUCK DAILY BEFORE STARTING”
found in the OPERATING THE RIGID DUMP TRUCK
section in this operator’s manual.
SA-435
S-2
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the rigid

dump truck and all safety messages in this manual.
• Safety signs should be installed, maintained and

replaced when necessary.
• If a safety sign or this manual is damaged or missing,

order a replacement from your authorized Hitachi
dealer in the same way you order other replacement
parts (be sure to state rigid dump truck model and
serial number when ordering).
• Learn how to operate the rigid dump truck and its

SA-003
controls correctly and safely.
• Allow only trained qualified, authorized personnel to

operate the rigid dump truck.
• Keep your rigid dump truck in proper working condition.

• Unauthorized modifications of the rigid dump truck
may impair its function and/or safety and affect its life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of the rigid
dump truck. However it is impossible for these safety
messages to cover every hazardous situation you may
encounter. If you have any questions, you should first
consult your supervisor and/or your authorized Hitachi
dealer before operating or performing maintenance work
on the rigid dump truck.
PREPARE FOR EMERGENCIES
• Be prepared if fire starts or if an accident occurs.
• It is recommended that a first aid kit and fire

extinguisher be kept on hand.
• Thoroughly read and understand the label attached
on the fire extinguisher to use it properly.
• To ensure that a fire extinguisher can be always
used when necessary, check and service the fire SA-437
extinguisher at the recommended intervals as

specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to cope
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.
S-3
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other parts
of the rigid dump truck.
• Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating the rigid dump truck.
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises. This
may be necessary when working outside of the
cab, during the Pre-Operation Inspection, for
example.
SA-434
PROTECT AGAINST FLYING DEBRIS
• If flying debris hits eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
SA-432
S-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal are operated with dirt
and/or oil on the soles of the operator’s work boots
the operator’s foot may slip off the pedal, possibly
resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified
locations.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations on
the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to a radio or music with
headphones or mobile telephones in the cab while
operating the rigid dump truck.
• Keep all flammable objects and/or explosives away
from the rigid dump truck.
• After using the ashtray, always cover it to
extinguish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
• When operating the rigid dump truck, both doors
should be closed at all times.
S-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When entering or leaving the rigid dump truck,

always use the steps and the handrails.
• Do not use any controls as handholds.
• When you get on and off the rigid dump truck,
always face it and maintain a three-point grip with
the steps and handrails. (i.e., two hands and one
foot or one hand and two feet.)
• DO NOT JUMP on or off the rigid dump truck. SA-439
Never mount or dismount a moving rigid dump

truck.
• Do not step or climb on surfaces, which are not
intended for walking. Step only on the areas
provided with slip resistant surfaces.
• Be careful of slippery conditions on platforms,
steps, and handrails when leaving the rigid dump
truck.
• All steps, ladders, stairways, handholds, platforms,
walkways, and guardrails must be free of dirt,
snow, and ice.
• All steps, ladders, stairways, platforms, walkways,
and non-skid deck strips must be replaced if EL20273
damaged.
• The use of a rope is recommended to bring up to
the deck or cab lunch box, tools, etc so as to
maintain a three-point grip when entering or
leaving the rigid dump truck.
ADJUST THE OPERATOR’S SEAT

• A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator.
• The seat should be adjusted whenever changing

rigid dump truck operator.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
SA-378
check again.
S-6
SAFETY
FASTEN YOUR SEAT BELT
• If the rigid dump truck should overturn, the operator

may become injured and/or thrown from the cab.
Additionally the overturning rigid dump truck may
crush the operator, resulting in serious injury or
death.
• Prior to operating the rigid dump truck, thoroughly

examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component immediately before operating
the rigid dump truck.
• Be sure to remain seated with the seat belt
securely fastened at all times when the rigid dump
truck is in operation to minimize the chance of SA-237
injury from an accident.

• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
S-7
SAFETY
OPERATE ONLY FROM OPERATOR’S SEAT
• Inappropriate engine starting procedures may cause

the rigid dump truck to runaway, possibly resulting in
serious injury or death.
• Start the engine ONLY from the operator’s seat.

• NEVER start the engine while standing on the
ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral, and the park brake switch is
activated.
EL20368
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump-started, be sure to

follow the instructions shown under Starting with
Auxiliary Batteries in the OPERATING
INSTRUCTIONS section of the Operator’s Manual.
• The operator must be in the operator’s seat so that
the rigid dump truck will be under control when the
engine starts. Jump-starting is a two-person
operation. SA-032
• Never use a frozen battery.

• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
rigid dump truck.
KEEP RIDERS OFF RIGID DUMP TRUCK
• Riders on rigid dump truck are subject to injury

such as being struck by foreign objects and being
thrown off the rigid dump truck.
• Do not allow riders other than on the

passenger's seat. Riders must also have their
seat belt fastened.
• Riders also obstruct the operator’s view,
resulting in the rigid dump truck being operated EL20369
in an unsafe manner.
S-8
SAFETY
PROTECT AGAINST FALLING STONES

AND DEBRIS
• Stay in your cab while your rigid dump truck is
being loaded. Stepping out of the cab could result
in possible injury.
• Do not place your head and/or arms outside of the
window.
EL20380-1
PROVIDE SIGNALS FOR JOBS INVOLVING

MULTIPLE NUMBERS OF VEHICLES
• For jobs involving multiple numbers of vehicles,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person’s directions.
SA-481
S-9
SAFETY
OPERATE THE RIGID DUMP TRUCK

SAFELY
• When pulling out of the loading area, avoid hitting

debris, rocks and loading rigid dump truck overflow
that can cause tire damage. Allow the clean-up dozer
sufficient time to clear the loading area.
• Watch where you are going. Stay away from people,

the edge of cliffs, slide areas, other machines and
vehicles, etc.
• While traveling on the haul road, maintain a sufficient

distance behind the vehicle ahead (depending on
roads, speeds, and haul road conditions). This
practice should always be followed to allow sufficient EL14019
safe maneuvering and stopping room.
• During all operations, the rigid dump truck may

vibrate or shake to some extent. Therefore, operate
the rigid dump truck in such a way that your body is
exposed to as little vibration as possible.
• Have the operator’s seat properly adjusted and

wear the seat belt.
• Pick the smoothest path for the rigid dump truck.
• Adjust the speed of the rigid dump truck to the
terrain, and driving conditions.
S-10
SAFETY
AVOID INJURY FROM RUNNING OVER,

FRONT AND BACK, AND FROM FRONT
WHEEL CRUSH AREA
• If any person is present near the rigid dump truck
when backing or moving forward, the rigid dump truck
may hit or run over that person, resulting in serious
injury or death. If any person is present in the area
between the engine and the front wheel, the person
could be crushed when the front wheels are turned.
To avoid these situations:

• Always look around BEFORE YOU MOVE THE
RIGID DUMP TRUCK. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the back-up alarm in working condition.
ALWAYS BE ALERT FOR BYSTANDERS MOVING
EL20370
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS
BEFORE MOVING RIGID DUMP TRUCK.
• USE A SIGNAL PERSON IF YOUR VIEW IS
OBSTRUCTED. ALWAYS KEEP THE SIGNAL
PERSON IN VIEW.
• No rigid dump truck motions shall be made unless
signals are clearly understood by both signalman
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has the
responsibility for signaling.
EL20371
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in
the operator’s manual.
EL20372
S-11
SAFETY
AVOID TIPPING
• Keep the rigid dump truck at safe distance from the

edge of cliffs and slide areas. There is the danger of
tipping or roll over.
• Avoid operating on the side of slopes.
• Use the seat belt during operation.
• When operating the rigid dump truck, both doors should

be closed at all times.
• The cab is for the protection of the operator and it

meets the requirements for rollover protection
structures (ROPS) according to the adopted standard
for this rigid dump truck.
EL20373
THE OPERATOR AND PASSENGER SHOULD NOT
ATTEMPT TO JUMP CLEAR OF A TIPPING RIGID
DUMP TRUCK --- SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT.
A RIGID DUMP TRUCK WILL TIP OVER FASTER
THAN YOU CAN JUMP FREE. THEREFORE, HOLD
FIRMLY ONTO THE STEERING WHEEL IF THE RIGID
DUMP TRUCK SHOULD TIP OR ROLL OVER. DO
NOT JUMP.
IMPORTANT Never make any unauthorized modifications
or alterations to the Rollover Protective
Structure (ROPS) such as; welding on fire
extinguisher brackets, CB antenna
brackets, or fire suppression systems. Such
unauthorized modifications will affect the
structural limits of the ROPS and will void
the certification and could result in loss of
protection to the operator.
The Rollover Protective Structure (ROPS) has been

certified to meet specified requirements according to SAE
J1040C, ISO 3471 and ISO 3449.
Any planned modification or change must be reviewed in

advance by our Engineering Department to determine if
the modification or change can be made within the limits of
the certified tests.
IMPORTANT Each person in your organization,

including management should be made aware of
these rules involving the Rollover Protective
Structure (ROPS). Whenever anyone sees a rigid
dump truck’s ROPS with unauthorized modifications
or changes both the customer and manufacturer
should be notified in writing.
S-12
SAFETY
AVOID INJURY FROM ROLLAWAY

ACCIDENTS
• Death or serious injury may result if you attempt to

mount or stop a moving rigid dump truck.
To avoid rollaways:
• Select level ground when possible to park rigid dump
truck.
• Do not park the rigid dump truck on a grade.
• Reference: PARK RIGID DUMP TRUCK SAFELY in
this section.
• Chock the wheels if you must park on a grade.
• Position the rigid dump truck to prevent rolling.
• Park a reasonable distance from other vehicles.
EL20374
S-13
SAFETY
NEVER TRAVEL WITH THE BODY OFF THE

FRAME
• Make sure the body is resting on the frame prior to
moving the rigid dump truck.
• If the raised body hits against an overhead
obstacle, both the rigid dump truck and the
overhead obstacle will be damaged, and personal
injury may result as well. This includes overhead
wires, cables and power lines.
• Traveling with a raised body places greater stress
to the body pivot pins, hydraulic cylinders and the
frame.
• Never “jump dump” by bouncing the rear wheels EL20375
against a stop rail or by jerking the body control

lever.
EL20376
S-14
SAFETY
OPERATING THE RIGID DUMP TRUCK

NEAR OVERHEAD WIRES OR CABLES
• Before operating the rigid dump truck, check with
employer/supervisor to find out if there are any
overhead cables or wires on the work site.
• The rigid dump truck operator must be given clear
information about this. Make sure that all relevant
and practical measures to help detect such lines are
taken.
• Local authorities and/or communication and power
companies should be contacted for guidance and
advice.
• Overhead wires and cables must be protected
against damage in a suitable way. The electricity EL20377
should be turned off when practical.
OPERATING THE RIGID DUMP TRUCK

NEAR HIGH VOLTAGE, OVERHEAD
POWER LINES
• A power line is a single conductor suspended on or
from poles or other supports as well as accessories
such as insulators, hooks, and bars.
• Serious injury or death can result if the rigid dump
truck is not kept a safe distance from electric lines.
• When operating near an electric line, NEVER move

any part of the rigid dump truck or load closer than
3 m (10 ft.) plus twice the line insulator length.
• Never operate the rigid dump truck with the dump
body in the raised position.
• Check and comply with any local regulations that
may apply.
• If the rigid dump truck comes into contact with a
high voltage line, the operator must remain in the
operator’s seat and not leave the cab; if the line is
live and the operator tries to reach the ground his
or her life is in danger. Call for help by signaling in
some way, sounding the horn or mobile telephone,
so that the power can be turned off.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
• If the rigid dump truck is used in potentially
dangerous environments, e.g. explosive
atmosphere, areas with dust including asbestos,
special safety regulations must be followed and the
rigid dump truck shall be equipped for such
operations.
S-15
SAFETY
PARK RIGID DUMP TRUCK SAFELY
• Park rigid dump truck on a level surface.

• Lower the body to the frame.
• Move the shift controller lever to the N (Neutral)
position.
• Apply the parking brake and release the service
brakes to insure that the parking brake is holding
• Let the engine run at idle for three to five minutes
for cool down.
• Make sure the body hoist control lever is in the
Float position.
• Check that all switches and controls are in the OFF
position.
• Turn the Key Switch to the OFF position.
EL20378
• Turn the Battery Disconnect Switch to the OFF

position.
• Fill the fuel tank to minimize water condensation in
the tank.
NOTE: Running out of fuel with the engine running,

especially under load, is very detrimental to
engine life and requires a time consuming
restart procedure.
• Perform a walk around inspection and fill out the

required Preventative Maintenance form or other
required operator report forms. Be sure to report
any adjustments of service required to those
responsible for maintenance.
• When leaving the rigid dump truck unattended,
remove the key. Lock the doors and any vandalism
guards to prevent theft or damage.
S-16
SAFETY
SAFE HANDLING OF OFF ROAD TIRES
• When doing any tire service, especially tire inflation,

NEVER stand in the TRAJECTORY PATH. Serious
injury or death can result if an explosion should occur.
• Use a self-attaching air chuck with a hose long

enough to be out of the trajectory path when filling
a tire with air.
• Use an inflation cage, safety cables, or chains
when inflating tires.
• Never use air from a compressed air system, to
inflate a tire if alcohol has been used as antifreeze.
• Inspect all rims, wheels and components.
• Replace any worn or damaged rims, wheels and

components.
• Do not remove any wheel nuts; rim clamps or dagger
clamps until the tire is deflated.
• No personnel should be touching the rim, rim

clamp, or tire when dislodging the rim clamps or
dagger clamps on larger dumps.
• Never stand in front of rim clamps or dagger
clamps during removal.
• Trained and certified personnel should only do the
dismounting and mounting of tires. It is EL20379
recommended that a certified tire repair service be

hired to perform the dismounting and mounting of
tires from rims.
DISCHARGE ACCUMULATORS
• Before removing and disassembling brake or

steering accumulators, they must be discharged to
prevent serious injury. Refer to the appropriate
Maintenance Manual section for BRAKE
ACCUMULATOR and STEERING
ACCUMULATOR.
S-17
SAFETY
HANDLE FLUIDS SAFELY; AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the rigid dump truck while smoking

or when near open flame or sparks.
• Always stop the engine before refueling the rigid
dump truck.
• Fill the fuel tank outdoors.
SA-018
• All fuels, most lubricants, and some coolants are

flammable.
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler caps. SA-019
S-18
SAFETY
A FEW SIMPLE RULES WHEN
SERVICING
Before working on the rigid dump truck, park it on a

level surface and put it in the SERVICE POSITION:
1. Engine stopped, ignition key removed (except

when service requires engine operation).
2. Tag the rigid dump truck following local lockout
and tag procedure. Identify rigid dump truck as
“Out of Service”.
3. If the body is raised, use body prop pins, or
body prop cable.
4. The wheels blocked.
5. Body control lever in “FLOAT” position.
6. Parking brake applied.
7. Allow the rigid dump truck to cool down.
EL20300R
8. Pressure released from all lines, tanks, and
accumulators.
• If work must be done on a warm rigid dump
truck, beware of hot fluids and components.
• Do not perform any work on the rigid dump

truck unless you are authorized to do so.
• Maintenance can be dangerous unless

performed properly. Be satisfied that you have
the necessary skills, information, correct tools,
and equipment to do the job correctly.
• Standard maintenance procedures should

always be observed. Read the manufacturer's
manual or find assistance if you do not
understand what you are doing.
• Failure to perform the Basic Preventive

Maintenance as outlined may void rigid dump
truck warranty.
• Deflate tires before loosening any rim clamp
bolts.
• Always stop the engine before removing
inspection covers. Do not let tools or parts fall
into the opening. SA-020
• Before you work on the rigid dump truck

always lower the body. If you must work on the
rigid dump truck with the body raised, always
securely support the body.
S-19
SAFETY
A FEW SIMPLE RULES WHEN
SERVICING (continued)
• Be sure the rigid dump truck is in the “SERVICE

POSITION" before lifting or jacking up the rigid
dump truck. Always support an elevated rigid
dump truck using proper blocks and/or cribbing
before beginning work on it.
• Be sure the body prop pins or body prop cable

are engaged when working beneath a raised
dump body.
• Inspect recommended parts periodically and repair

or replace as necessary. Refer to the maintenance
section of the manual.
• Keep all parts in good condition and properly

installed.
• Fix damage immediately. Replace worn or broken

parts. Remove any buildup of grease, oil, or
debris.
• Take care to ensure that hands, feet, clothing,

jewelry and hair do not become entangled when
working around rotating parts.
• Do not wear loose fitting clothing or jewelry when

working on a rigid dump truck. SA-026
• When cleaning parts, always use nonflammable

detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Sufficiently illuminate the work site. Use a

maintenance work light when working under or
inside the rigid dump truck.
• Always use a work light protected with a guard. In

case the light bulb is broken, spilled fuel, oil,
antifreeze fluid, or window washer fluid may catch
fire.
• Polymer materials such as rubber and certain

kinds of plastics can, when heated, give off gases SA-037
that may be dangerous to health and environment.
• Do not weld or cut near polymer materials

without first having protected them from the
heat.
• Never burn polymer materials when scrapping
them.
S-20
SAFETY
USE TOOLS PROPERLY
• Use tool(s) appropriate for the work to be done.
• Use the correct tool(s) for the job. Repair or

replace broken or defective equipment or tool(s).
• Makeshift tools, parts, and procedures can
create safety hazards.
• For loosening and tightening hardware, use the
correct size tool to avoid injury caused by
slipping wrenches for example.
• Make sure that no tool(s) or other object(s) are
left inside the rigid dump truck where they may
cause damage.
SA-034
• When lifting or supporting components, use

equipment with a weight capacity as great or
greater then the weight of the component.
EL20380
S-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.

DO NOT remove the pressure cap from the
surge tank for the cooling system until the SA-039
engine is cool. When removing, depress the red

button on top of the pressure cap to relieve
system pressure. Then turn and remove the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.
• Wait for the oil and components to cool before

starting any maintenance or inspection work.
SA-225
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and abrasion.
It is very difficult to gauge the extent of deterioration due
to aging, fatigue, and abrasion of rubber hoses by
inspection alone.
• Periodically replace the rubber hoses.
• Failure to periodically replace rubber hoses may cause a

SA-019
fire, fluid injection into skin, or the dump body to fall,

which may result in severe burns, infection, or other
serious injury.
S-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under pressure
can penetrate the skin or eyes causing serious injury,
blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Remove all pressure caps carefully.
• Tighten all connections before applying pressure. SA-031
• Never adjust a pressure relief valve above the

manufacturer’s recommendations.
• Be careful of hot fluid when changing oil in the engine,
hydraulic system, etc.
• Search for leaks with a piece of cardboard or wood,
not your hand. Take care to protect hands and body
from high-pressure fluids. Wear a face shield or
goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-292
skin must be surgically removed within a few hours or

gangrene may result.
SA-044
S-23
SAFETY
FIRE PREVENTION MEASURES
• Fire prevention features provided by the manufacturer
should be maintained in operational condition and
should be used to supplement operator’s fire prevention
efforts. In no case should the features be used or
assumed as replacement for diligent operator efforts at
preventing fires.
• Keep the work place clean. Oil and water on the floor
makes it slippery and particularly dangerous in
connection with electrical equipment or electrically
powered tools. Oily clothes are a serious fire hazard.
SA-019
• Keep the rigid dump truck and all equipment free of dirt
and oil. This will decrease possible fire hazards and
make it easier to find loose or defective parts. This is
especially important when working with combustible
materials.
• Rigid dump trucks should be clean of debris particularly

around the engine, exhaust, and drive shaft
components. Keep the rigid dump truck extra clean
when working in a sensitive environment.
NOTE: If a high-pressure jet is used for cleaning, take

great care as the insulation of electrical wires
can become damaged even at moderately high
pressure and temperature. Protect electrical
wires in a suitable way.
• Gasoline is highly flammable and should never be used

as a cleaning fluid. Use an approved solvent for
cleaning.
SA-028
• Some solvents can cause skin rashes and or fire

dangers. Do not inhale solvent vapors.
• Store flammable starting aids in a cool, well-ventilated

location.
• Smoking, open flames, etc. should not be permitted

around any rigid dump truck during fueling operations
and/or when the fuel system is open to the atmosphere.
• Prior to welding or brazing on any part of the rigid dump

truck, the part and the surrounding area should be
cleaned and a fire extinguisher should be made readily
available.
• Hydraulic fluid is flammable. Do not weld on pipes or

tubes that are filled with fluid. Be careful when welding
next to filled pipes or tubes.
• There is always a risk of fire. Find out which type of fire

extinguisher to use, where it is and how to use it.
S-24
SAFETY
FIRE PREVENTION MEASURES (continued)
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps,

kinked hoses lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-cooler
flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check electrical wiring connections every 250 hours
of operation. Check for loose, kinked, hardened or
frayed electrical cables and wires.
• DO NOT OPERATE RIGID DUMP TRUCK if cable or
wires are loose, kinked, etc.
Clean up Flammables:
• Spilled fuel, oil, antifreeze fluid and window washer fluid,

and trash, grease, debris, accumulated coal dust, and
other flammables may cause fires.
• Prevent fires by inspecting and cleaning the rigid

dump truck daily, and by removing spilled or
accumulated flammables immediately.
S-25
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the rigid dump truck in the
following way:
• Lower the hauler body all the way down.
• Set parking brake.
• Stop the engine by turning the key switch to the OFF
position.
• Exit and get away from the rigid dump truck. If
possible take a hand-held portable extinguisher along.
• Call for help SA-393
• Stand by with a hand-held portable extinguisher and

use it if possible.
BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
• Stand away from the rear exhaust area when the

engine is running.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe SA-016
extension to remove the exhaust fumes or open doors

and windows to bring enough outside air into the
area.
• Diesel engine exhaust and some of its constituents

are known to cause cancer, birth defects and other
reproductive harm.
S-26
SAFETY
PRECAUTIONS FOR WELDING, CUTTING,

AND GRINDING
• When performing any welding operation on a rigid dump
truck, specific electrical components must be disconnected.
Refer to Electrical Disconnects Before Welding in the
MAINTENANCE section of this manual.
• Grinding on the rigid dump truck may create fire hazards.

Store flammable objects in a safe place before starting
grinding.
NOTE: A high speed-grinding rigid dump truck will

SA-818
heat the paint and must only be used in a well-ventilated
area.
• Be sure to perform welding in a well ventilated and
prepared area. Store flammable materials in a safe place
before starting welding.
• Protect the working areas with flame retardant blankets.
• Welding should be done by a qualified person.
• After completing the weld repair, check the surrounding

area for possible smoldering spots.
REMOVE PAINT BEFORE WELDING OR

CUTTING
Paint must be removed up to a distance of 10 cm (4 in) from
the welding or cutting point.
• Remove the paint from the area where work is to be

performed through sand blasting.
• If you sand blast or grind paint, avoid breathing the dust.

Wear an approved respirator.
• Work outside or in a well-ventilated area.
• If the paint cannot be removed by sand blasting, it must be
removed in some other way e.g., with paint stripper.
SA-029
• Wear protective gloves and work either outside or in a well-

ventilated area.
• Dispose of paint and solvent properly.
• If you use solvent or paint stripper, remove stripper with soap
and water before welding.
• Remove solvent or paint stripper containers and other
flammable material from area. Allow fumes to disperse at
least 15 minutes before welding or cutting.
S-27
SAFETY
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch near

pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary fire-
resistant guards to protect hoses or other materials SA-030
before engaging in welding, soldering, etc.
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Clean them thoroughly with nonflammable solvent before
welding or flame cutting them.
S-28
SAFETY
PREVENT BATTERY EXPLOSIONS
• Battery gas is explosive.
• Keep sparks, lighted matches, and flame away from the

top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the
battery to 16 ºC (60 ºF) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
• Loose terminals may produce sparks. Securely tighten all SA-032
terminals.
• Battery electrolyte is acidic and poisonous. If the battery

should explode battery electrolyte may be splashed onto
the skin or into eyes, possibly resulting in burns or
blindness.
• Be sure to wear eye protection when checking electrolyte

specific gravity.
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.
SERVICE AIR CONDITIONING SYSTEM

SAFELY
NOTE: Only certified technicians should be allowed to
service air conditioning systems.
• If spilled onto skin, refrigerant may cause a cold contact

burn (frostbite).
• Refer to the Freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid venting
Freon into the atmosphere. SA-405
• Never let the Freon stream make contact with the skin.
S-29
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your rigid dump truck include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques (MSDS may be known by other names in
different jurisdictions).
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment. SA-309
• See your authorized Hitachi dealer for MSDS (available

only in English) on chemical products used with your rigid
dump truck.
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with Hitachi rigid dump trucks includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.
• Use leak proof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source. SA-226
• Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerant.
• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center.
S-30
SECTION
CONTENTS SECTION 1 GENERAL
SECTION 2 SERVICE & MAINTENANCE
WORKSHOP SECTION 3 ENGINE

MANUAL
SECTION 4 ELECTRICAL & INSTRUMENTS
All information, illustrations

SECTION 5 POWER TRANSMISSION
and specifications in this
manual are based on the
latest product information
available at the time of SECTION 6 BRAKE SYSTEM
publication. The right is
reserved to make changes at
any time without notice.
SECTION 7 STEERING
SECTION 8 FRAME SUSPENSION & WHEEL

COPYRIGHT(C) 2008
Hitachi Construction Truck
Manufacturing Ltd. SECTION 9 CAB
Guelph, Canada
All rights reserved
SECTION 10 HOIST ATTACHMENT

<BLANK>
SECTION 1
GENERAL
—CONTENTS—
Group 1 Precautions for Disassembling

and Assembling
Precautions for Disassembling
and Assembling................................. W1-1-1
Bleeding Air from Hydraulic System............ W1-1-2
Floating Seal Precautions (Wheel Seal) ..... W1-1-3
Precautions for Using Nylon Sling .............. W1-1-4
Maintenance Standard Terminology............ W1-1-6
Group 2 Tightening Torque

Tightening Torque Specifications ................ W1-2-1
Torque Charts.............................................. W1-2-2
Bolt Tightening Order .................................. W1-2-5
Nut and Bolt Locking ................................... W1-2-6
Torque Formula T-FL................................... W1-2-6
Piping Joint.................................................. W1-2-7
O-ring Seal Joint ......................................... W1-2-8
Split Flange Clamp Torque Values .............. W1-2-9
Seal Tape Application................................ W1-2-10
Low-Pressure Hose Clamp
Torque Value ...................................... W1-2-10
Connecting Hose....................................... W1-2-11
Periodic Replacement of Parts.................. W1-2-12
W1-0
<BLANK>
W1-0
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING • Precautions for Disassembling

AND ASSEMBLING
• To prevent dirt from entering, cap or plug the
Precautions for Disassembling and Assembling removed pipes, hoses and ports.
• Before disassembling, clean the exterior of the
• Clean the rigid dump truck components.
• Before disassembling, drain all fluids into
Thoroughly wash the rigid dump truck before appropriate containers for draining fluids and
bringing it into the shop. Bringing a dirty rigid dump make available for the remainder of the
truck into the shop may cause rigid dump truck disassembly.
components to be contaminated during • Use matching marks for easier reassembling.
disassembling/assembling, resulting in damage to • Be sure to use the specified special tools, when
the components, as well as decreased efficiency in instructed.
servicing the rigid dump truck. • If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
• Inspect the rigid dump truck then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
Be sure to thoroughly understand all disassembling/ tag them as necessary.
assembling procedures beforehand, to help avoid • Store common parts, such as bolts and nuts with
incorrect disassembly of components as well as reference to where they are to be used and in a
personal injury. Check and record the items listed manner that will prevent loss.
below to prevent problems from occurring in the • Inspect the contact or sliding surfaces of
future. disassembled parts for abnormal wear, sticking, or
other damage.
• The rigid dump truck model, serial number, and • Measure and record the amount/degree of wear
hour meter reading. and clearances.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if any.
• Levels and condition of lubricants.
• Loose, worn or damaged parts.
• Prepare/Clean Tools and Disassembly Area
Prepare the necessary tools to be used in the area

for disassembly work, and the required personal
protective equipment.
W1-1-1
• Precautions for Assembling • Bleeding Air from Hydraulic Pump
• Be sure to clean all parts and inspect them for any • Loosen the inlet hose connection or bleeding plug
damage. If any damage is found, repair or replace from the top of the pump and fill the pump hous-
part. ing with hydraulic oil. Oil will flow by gravity into
• Dirt or debris on the contact or sliding surfaces pump housing.
may shorten the service life of the component or • After the pump housing is filled with hydraulic oil,
secondary component. Take care not to temporarily tighten the plug. Check and adjust
contaminate any contact or sliding surfaces. hydraulic tank oil level before engine starting.
• Be sure to replace O-rings, backup rings, and oil Then, start the engine and run at low idle speed.
seals with new ones once they are assembled. • After bleeding all the air, securely tighten all plugs
Apply a film of grease before installing, unless and connections.
otherwise stated.
• Be sure that liquid-gasket-applied surfaces are
• Bleeding Air from Hoist Cylinder
clean and dry.
• If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to • Remove bleed plug from top of hoist cylinder. Run
remove the agent. engine with hoist controller in float position when
• Utilize matching marks when assembling. oil flows from port install plug.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals. • Bleeding Air from Hydraulic Circuit
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is • After refilling the hydraulic oil to the proper level,
complete, count the number of tools, so as to start the engine and cycle the hoist and steering
make sure that no forgotten tools remain in the cylinders evenly. Operate the rigid dump truck
assembled rigid dump truck. under light load for 10 to 15 minutes. Slowly start
• Record new component serial numbers and hour each operation and don’t fully stroke the cylinders
meter reading, if required. during initial operation stage.
• Lower the body to the chassis rails.
• Stop the engine. Recheck the hydraulic oil level in
Bleeding Air from Hydraulic System both the steering and hoist oil tanks. Replenish oil
as necessary to the proper levels.
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and installa-
tion of the pump, or cylinder is done, bleed air from the NOTE: Ensure the body is in full contact with the
hydraulic system in the following procedures: chassis, and the oil in the steering accu-
mulator has completely returned to tank.
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic system is operated
with air trapped inside major com-
ponents, damage may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage
to the seal or cylinder may result.
Be sure to bleed air before starting
the engine.
W1-1-2
Floating Seal Precautions (Wheel Seals)

A
1. In general, replace the floating seal with a new
one after disassembling. If the floating seal is to
be reused, follow these procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of clean
cardboard between the contact surfaces to
protect the surfaces.
(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019
uneven wear.
(3) Check toric O-ring (B) for tears, breaks,

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent that does not leave
a residue. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect
(2) Inspect the floating seal mounting bores.

Check the bore surface for scuffing or scoring. W105-03-05-020
Seal bore surface machining must be smooth

and uniform. Correct Incorrect
C
(3) Check that the O-ring is not twisted, and that it a a
is installed correctly on the seal ring. A
(4) Throughly wet the seal toric O-ring and seal
bore immediately before installation using a B
aerosol brake cleaner solvent or alcohol wash.
After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating face
(C) by measuring the distances (A) and (C) at
point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
W110-03-05-004
a=b a≠b
W1-1-3
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners Correct Eyehole
of the load so that the nylon sling does not di- Lifting Method
rectly contact the corners. This will prevent the
nylon sling from being damaged and the lifted
load from slipping.
• Lower the temperature of the lifted load to lower
than 100°C (212°F). If unavoidably lifting a load
with a temperature of 100°C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
Do not use wet or oil soaked slings. The load
may slip.
• When required to use more than one sling, use W102-04-02-016
matched slings with the same width and length Incorrect Eyehole
to keep the lifted load balanced. Lifting Method
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
The sling should grasp the load tightly in a
choke hold. Reduce the load weight so that it is
less than 80 % of the sling breaking force.
• Avoid using twisted, bound, connected, or
hitched slings. Do not use a visually damaged
sling to hoist load.
• Do not hoist any object with twisted or bent
slings. (Refer to the right illustration.) A sling that
is cut creased or kinked should not be used.
• When removing the slings from under the load, W105-04-01-008
take care not to damage the nylon slings. Avoid

contact with protrusions.
• Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal object.
• When using with other types of slings (wire
rope) or accessories (shackle), protect the joint
so that the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t de-
teriorate with heat, sun light, or chemicals.
W1-1-4
Damaged Appearance
Broken Sewing Thread
CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-

lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut sling apart and discard the sling. Even if no
W162-01-01-003
damage is found, do not use slings older than
7-years. Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Scoring Separation of W162-01-01-006
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
Bent Sling
W1-1-5
MAINTENANCE STANDARD
TERMINOLOGY
“Standard”
1. Dimension for parts on a new rigid dump truck.
2. Dimension of new components or assemblies ad-

justed to specification.
“Allowable Limit”
1. Normal rigid dump truck performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.
W1-1-6
GENERAL / Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
Wrench Torque
Descriptions Bolt Dia. Qty
Size N٠m (kgf٠m) (lbf٠ft)
Axle, front trunnion mount 1½ 8 2¼ 3644 (371.6) (2687)
Brake, caliper front 1¼ 24 1 7/8 1291 (131.6) (952)
Brake, parking head mount ¾ 8 1 1/8 307 (31.3) (226)
Brake, rear mount 1 36 1½ 1048 (106.9) (773)
Cab, mount 1½ 3 2¼ 950 (97) (700)
Differential mount ¾ 24 1 1/8 433 (44.2) (319)
5 15
Driveline, front mount /8 8 /16 244 (24.9) (180)
Driveline, rear mount to transmission M22x2.5 8 32 mm 780 (79.5) (575)
Driveline, rear mount to differential M22x2.5 8 32 mm 750 (76.5) (553)
Engine, A/C compressor mount M16x2 4 24 mm 270 (27.5) (199)
3 9
Engine, A/C condenser mount /8 4 /16 36 (3.7) (26)
5 15
Engine, coupler to flywheel /8 6 /16 244 (24.9) (180)
Engine, fan M12x1.75 6 18 mm 110 (11.2) (81)
Engine, front bracket mount to engine M16x2 8 24 mm 270 (27.5) (199)
Engine, front bracket mount to chassis 1 4 1 1/2 1232 (125.6) (909)
Engine, radiator mount 1 2 1 1/2 742 (75.7) (547)
Engine, rear bracket mount to engine M16x2 12 24 mm 270 (27.5) (199)
Engine, rear bracket mount to chassis 1 4 1 1/2 1232 (125.6) (909)
3 9
Engine, shroud to radiator /8 11 /16 36 (3.7) (26)
5 15
Engine, starter mount /8 3 /16 244 (24.9) (180)
7 5
Power Take Off, mount /16 8 /8 60 (6.1) (44)
3
Pump, hoist /4 4 1 1/8 433 (44.2) (319)
5 15
Pump, hoist to transmission /8 4 /16 244 (24.9) 180
Tank, fuel 1 5 1½ 742 (75.7) (547)
Tank, hydraulic 1¼ 3 1 7/8 2094 (213.5) (1544)
Transmission, bracket mount to chassis 1 6 1½ 1232 (125.6) (909)
5 15
Transmission, bracket mount to transmission /8 12 /16 241 24.6 178
Wheel Lug Nut (front) 1 54 1 1/2 942 (96.1) (695)
Wheel Lug Nut (rear) 1 48 1 1/2 942 (96.1) (695)
NOTE: Make sure bolt and nut threads are clean

and lubricated with oil (or coated with NOTE: The above torque specifications are criti-
Loctite, if required) before installing. Do cal to the operation of the hauler and
not use oil on a bolt that requires Loctite. should be used at all times. Use a
torque wrench as opposed to an air gun
to ensure precise torquing on critical
bolts.
W1-2-1
TORQUE CHARTS
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Many different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them
correctly when assembling the rigid dump truck or
components.
CAUTION: Use tools appropriate for the work

to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size
tools. Otherwise, tightening tools may slip,
potentially causing personal injury. Use only
properly calibrated torque wrenches / tools
during final assembly.
SA-040
CAUTION: Some assemblies on the rigid

dump truck use Nylock type bolts. It is
important that these bolts are discarded af-
ter each use. Ensure that new hardware is
used when replacing these types of bolts.
W1-2-2
Standard Imperial Tightening Torque Chart, Plain Finish with Oil (35511, 1)
Fastener De-
Hex Head, 12 pt Flange Head, Hex Sckt Head, Hex Sckt Button Head, L9 Hex Cap
scription
Grade 2 Bolt Alloy Steel LAMALLOY
Grade 5 Grade 8 1960 Series
Classification or Stud F835 L9
by strength
category
Standard
tightening The torque applied irrespective of whether the screw thread is fine or coarse
torque
Bolt Size ft.lb Nm ft.lb Nm ft.lb Nm ft.lb Nm ft.lb Nm ft.lb Nm
1
/4 6 8 7 10 10 14 12 16 12 16 15 20
5
/16 13 18 15 20 21 28 24 33 24 33 26 35
3
/8 23 31 26 36 37 50 43 59 43 59 40 53
7
/16 37 50 42 57 59 80 69 94 65 86
1
/2 56 76 64 87 90 123 106 143 106 143 115 153
9
/16 81 109 92 125 131 177 147 199 155 206
5
/8 111 150 128 173 180 244 203 275 210 285 215 286
3
/4 197 266 226 307 319 433 359 487 340 452
7
/8 208 281 365 495 515 699 580 786 560 745
1 313 423 547 742 773 1048 869 1179 860 1144
1 1/4 625 844 952 1291 1544 2094 1737 2356 1700 2261
1 1/2 819 1106 1657 2247 2687 3644 3023 4099 3000 3990
W1-2-3
Standard Metric Tightening Torque Chart, Plain Finish with Oil (35511, 1)
Description Hexagon head bolt

Classification by strength
4.8 bolt 8.8 bolt 10.9 bolt
category
Classification by identifi-
M Bolt H Bolt T Bolt
cation mark (Obsolete
style)
Standard tight- M8 10 (7) 20 (15) 30 (22)

ening torque by
bolt size M10 20 (15) 50 (37) 65 (48)
N-m (ft.lb) M12 35 (26) 90 (66) 110 (81)
M14 55 (41) 140 (103) 180 (133)
M16 80 (59) 210 (155) 270 (199)
M18 120 (89) 300 (221) 400 (295)
M20 170 (125) 400 (295) 550 (406)
M22 220 (162) 550 (406) 750 (553)
M24 280 (207) 700 (516) 950 (701)
M27 400 (295) 1050 (774) 1400 (1033)
M30 550 (406) 1450 (1069) 1950 (1438)
M33 750 (553) 1950 (1438) 2600 (1918)
M36 950 (701) 2450 (1807) 3200 (2360)
W1-2-4
Fastener
Hex Nut Flange Nut
Description
Grade8 Grade 8
Classification by strength
category
Fastener Size and Part

Tightening Torque
Number
Nut Size Part Number ft.lbs Nm ft.lbs Nm

3
/4 6231046 319 433
1 4034827 773 1048
1 13814033 866 1174
1 1/4 12621516 1544 2093
1 1/4 12632032 1710 2319
The Deviation of the torque in table shall be +/- 10%
Torque Sequence:
Unless the bolt tightening sequence is specified on the drawing or by the Service Manual, the fasteners should
be tightened in a cross pattern. Use Steps 1 through 5 unless the tightening procedure is specified.
1. Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench.
2. Torque all fasteners to 40% of full torque.
3. Torque fasteners to 70% of full torque.
4. Torque all fasteners to full torque by using cross pattern. Large flanges may require additional passes.
5. Apply at least one final full torque to all fasteners in a clockwise direction until all torque is uniform.
Larger flanges may require additional passes.
Tightening Conditions:
a. When tightening bolts, lubricants must be used to keep friction coefficient constant.
b. Anti-seize is not recommended as a lubricant, however, if it is used, reduce the torque values by 20%.
Note:
i. Do not use sealants and compounds that are not specified on the drawing or in the Service Manual. Clean old
compound from the bolt and hole before installation.
ii. For fasteners used with tapped holes and “no lock nut”, use Loctite as specified in the Shop Manual.
W1-2-5
SPLIT FLANGE CLAMP TORQUE

VALUES
Recommended Bolt Torque Values for Zinc and

Plain Finish Flanges
ZINC PLATED
FLANGE TORQUE FLANGE SIZE STAMPED
IN THIS LOCATION
DASH
N٠m lbf٠ft kgf٠m
SIZE
-8 23 17 2.4
-12 43 32 4.4
-16 43 32 4.4
-20 72 53 7.3
-24 106 78 10.8
-32 106 78 10.8
-40 106 78 10.8
-48 207 153 21.2
-56 207 153 21.2
-64 207 153 21.2
-80 207 153 21.2 W8DX-01-70-005
CAPSCREW TORQUE SEQUENCE: Tighten cap

screws in a diagonal sequence in small increments un-
ALUMINUM HYDRAULIC PUMP OR VALVE til the appropriate torque is obtained for the specific
HOUSING ONLY nominal flange size.
FLANGE TORQUE
DASH
N٠m lbf٠ft kgf٠m
SIZE
-20 45 33 4.6
-24 66 48 6.6
-32 66 48 6.6
-40 38 28 3.9
-48 38 28 3.9
W1-2-6
Bolt Tightening Order
When tightening two or more bolts, tighten them alter-

nately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally
1 12 9 4 1 6 7 14
1-3
6 3
4 5
2-4 13 5 10 11
2 8 2 3
W105-01-01-003
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches or
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the component.
W105-01-01-015
2. Be sure to use only specified O O
WRONG
O-rings. Inspect O-rings for any
damage. Take care not to cut
O-ring surfaces. When installing
an O-ring into a groove, use O
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to the
port. Hand-tighten bolts to hold
parts in place. Take care not to W105-01-01-016
pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tight- O
ening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven W105-01-01-008
tightening of bolts.
W1-2-7
Nut and Bolt Locking

RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend at the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply Do not bend it round
holes in the bolt and nut while tight- W105-01-01-009
ening, not while loosening. RIGHT RIGHT WRONG
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Bend along edge sharply W105-01-01-010
RIGHT RIGHT WRONG
RIGHT Loosen WRONG
Tighten
Torque Formula: T-FL To find Torque Setting required to produce a desired

amount of torque at adapter, use the following formula.
T=Torque
F=Force (Pounds) TE x L1
TS=
L=Lever Arm Length L
TE To find Torque Exerted at adapter use the following

formula.
TS x L
TE=
L1 L1
L2
L L =Overall length as shown (center of hand grip to
center of open end, etc.
L1 = Effective torque wrench length
When crowfoot adapters are used with a click or dial L2 = Effective torque adapter length
torque wrench, it is necessary to compensate for the TE = Torque exerted at adapter
additional length of the crowfoot adapter. To find the TS = Torque setting or reading of wrench
effective torque difference when using crowfoot
adapter a basic formula may be used.
W1-2-8
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are for

general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressurized oil. Union joints
are used to join small diameter lines. 37°
IMPORTANT: 1. Do not over-tighten nut (3). Ex- 30°

cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
W105-01-01-017
cations.
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size mm Tightening Torque

Description mm
Union Nut Hose Fittings N٠m (kgf٠m, lbf٠ft)
30º male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 93 (9.5, 69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37º female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 93 (9.5, 69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37º male coupling without union is similar

to tightening torque of 37º female.
W1-2-9
O-ring Seal Joint 7 6 9

O-ring (6) seats against the end face of adapter (7) to
seal pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with a

new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10 M104-07-033
in O-ring groove (e). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface (10). mm mm
Damage to O-ring (6) will cause Union Nut Hose Fittings N٠m (kgf٠m, lbf٠ft)
oil leakage. 19 17 29.5 (3.0, 21.5)
4. If nut (9) is loose and oil is leak- 22 19 69 (7.0, 51)
ing, do not re-tighten nut (9). Re- 27 22 93 (9.5, 69)
place O-ring (6) with a new one 32 27 137 (14.0,101)
and check that O-ring (6) is cor- 36 30, 32 175 (18.0,129)
rectly seated in place, tighten nut 41 36 205 (21.0,151)
(9). 46 41 205 (21.0,151)
W1-2-10
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018
Male Tapered Thread

Seal Tape Application Wrench Size Tightening Torque
mm Flat Carbon Steel Stainless Steel
Seal tape is used to seal clearances between male and Hose Fittings N٠m (kgf٠m, lbf٠ft) N٠m (kgf٠m, lbf٠ft)
female threads, so as to prevent any leaks between
19 14.5 (1.5,10.5) 34 (3.5, 25)
threads.
22 29.5 (3.0, 21.5) 49 (5.0, 36)
Be sure to apply just enough seal tape to fill up thread
27 49 (5.0, 36) 93 (9.5, 69)
clearances. Do not over wrap.
36 69 (7.0, 51) 157 (16,116)
• Application Procedure 41 108 (11, 80) 205 (21,151)
50 157 (16,116) 320 (33, 235)
Confirm that the thread surface is clean and, free of dirt 60 195 (20,144)
or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads. Internal Thread
Low-Pressure-Hose Clamp Tightening Torque

External Thread
Clearance
Low-pressure-hose clamp tightening torque differs de-
pending on the type of clamp. W105-01-01-019
T-Bolt Type Band Clamp:

4.4 N٠m (0.45 kgf٠m, 3.25 lbf٠ft) Leave one to two pitch threads uncovered
Worm Gear Type Band Clamp:
5.9 to 6.9 N٠m (0.6 to 0.7 kgf٠m, 4.3 to 5.1 lbf٠ft)
T-Bolt Type Worm Gear TypeM114-07-041
M114-07-043 M114-07-042
W1-2-11
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the rigid
dump truck.
Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose rup-
ture or separation of fitting. Utilize Print marks WRONG RIGHT
on hoses when installing to prevent hose from Rubbing Against
being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-12
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic

inspection of the rigid dump truck. In addition, the parts
listed below, if defective, may pose serious safety / fire
hazards. It is very difficult to gauge the extent of dete-
rioration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace as
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine fuel system hose Every 2 years
Engine Engine cooling system hose Every 2 years
Engine air inlet hose Every 2 years
Heater hose (engine to heater unit) Every 2 years
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Base Machine
Brake apply and cooling hose Every 2 years
Air conditioner hose Every 2 years
Hydraulic
Transmission cooling hose Every 2 years
System
Hoist cylinder line hose Every 2 years
Steer cylinder hose Every 2 years
Attachments Accumulator hose Every 2 years
Grease or auto lube hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-13
MEMO
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W1-2-14
SECTION 2
SERVICE AND MAINTENANCE
—CONTENTS—
Group 1 Service Position Group 4 Special Tools

Prepare Rigid Dump Truck for Service........ W2-1-1 Special Tools Recommended
Installing Body Prop Cable.......................... W2-1-2 for EH1700-3 ......................................W2-4-1
Removal and Storage of
Body Prop Cable ............................ W2-1-4
Group 2 Maintenance
Correct Maintenance and Inspection
Procedures ....................................... W2-2-1
Service Your Rigid Dump Truck at
Specified Intervals ............................ W2-2-2
Check Hour Meter Regularly....................... W2-2-2
Recommended Lubricants .......................... W2-2-3
Recommended Fuel.................................... W2-2-4
Electrical Disconnects Before Welding
On Rigid Dump Truck....................... W2-2-5
Maintenance Interval Guide ........................ W2-2-7
Memo ........................................................ W2-2-16
Group 3 Lifting and Jacking

Introduction.................................................. W2-3-1
Service Position........................................... W2-3-2
Front Axle Jacking....................................... W2-3-3
Lifting at the Front ....................................... W2-3-5
Rear Axle Jacking ....................................... W2-3-7
W2-0
<BLANK>
W2-0
SERVICE AND MAINTENANCE / Service Position
PREPARE RIGID DUMP TRUCK FOR SERVICE
Before working on the rigid dump truck, park it on a level surface and put it in the SERVICE POSITION:
Figure 1
EL20300
1. Engine stopped, ignition key removed (except when service requires engine operation).
2. Tag the rigid dump truck following local lockout and tag procedure. Identify rigid dump truck as “Out of
Service”.
3. If body is raised, install the body prop cable.
4. The wheels blocked.
5. Hoist lever in FLOAT position.
6. Parking brake applied.
7. Allow the rigid dump truck fluid systems to cool down.
8. Pressure released from all lines, tanks and accumulators.
W2-1-1
INSTALLING BODY PROP CABLE
WARNING: It is recommended that three

people be involved when installing the body
prop cable:
I. a rigid dump truck operator, sitting in
the operator’s seat,
II. the person installing the body prop ca-
ble
III. and a signal person, coordinating be-
tween the operator and the installer.
Signals used must be commonly known by
all personnel involved.
Figure 2
WARNING: An area directly below the rear
EL20364
of the body should be designated and
marked as a restricted area whenever the
body is secured in the raised position. No
personnel should enter this area as al-
though the body should be empty, material 1
may be stuck in the bed. This material could
dislodge and fall while the body is in the
raised position.
1. The operator can now start the engine. With

the parking brake applied, apply the load/dump
brake.
2. Move the hoist lever all the way back to the

RAISE position and fully raise the body. Place
the hoist lever in the HOLD position.
3. Undo the lock pin, Figure 3 item (1), from driver

Figure 3
side end of the body prop cable. Carefully re-
move the end from where it is stored in the
body.
CAUTION: Body prop cable weighs 57 kg
(125 lbs).
WARNING: The cable installer should enter
the hinge area from the cab side of the rigid
dump truck only, not from the rear, re-
stricted area.
4. Inspect the condition of the body prop cable.
5. Align the eye of the body prop cable to the des-

ignated lug on the rear axle casting and insert
the pin. Insert the lock pin.
W2-1-2
6. The installer moves out from the area between

the rear axle and the body to a safe distance
7. The operator will then place the hoist lever in

the FLOAT position so the body is now sup-
ported by the body prop cable. Place the hoist
lever in the HOLD position. Release the load
dump brake and verify parking brake holds and
wheel chocks are in place. Shut off the engine
and before exiting the cab, make sure the “Out
of Service” tag is in place on the steering wheel
and the key is removed.
OM21154
Figure 4
W2-1-3
REMOVAL AND STORAGE OF BODY PROP

CABLE
WARNING: Follow all WARNINGS and

CAUTIONS listed under INSTALLING BODY
PROP CABLE. (BODY Raised with BODY
PROP CABLE)
1. The operator starts the engine. Make sure that

both the parking brake and the load/dump
brake are applied.
2. The operator then moves the hoist lever slowly

to the RAISE position. There may have been
some bleed off of hydraulic fluid in the hoist cyl-
inders while the body was in the locked posi-
tion. Raise the body to full extension, then
place the hoist lever in the HOLD position.
3. The person removing the body prop cable will

then go to the rear axle area, undo the lock pin
Figure 5
(1) on the body prop cable end attached to the
rear axle lug, then pull the pin from the aligned
holes in the cable eye and rear axle lug.
4. The installer can now attach the end of the

body prop cable to its storage location on the
dump body, securing it with the lock pin, figure
3 item (1).
5. The installer moves out from the area between

the rear axle and the body to a safe distance
6. The operator is signaled that the body can be

lowered, and moves the hoist lever to the
FLOAT position. If the body remains in the
raised position after moving to FLOAT, it will be
necessary to momentarily shift the hoist lever
to the POWER DOWN position.
7. With the body completely down, resting on the

frame, the operator shuts off the engine.
IMPORTANT: Be sure the body prop cable is in

proper storage location.
W2-1-4
SERVICE AND MAINTENANCE / Maintenance
CORRECT MAINTENANCE AND

INSPECTION PROCEDURES
Learn how to service your rigid dump truck correctly.

Follow the correct maintenance and inspection pro-
cedures shown in this manual.
Inspect the rigid dump truck daily before starting. See

Daily Walk Around Inspection Check Sheet in the
OPERATING THE RIGID DUMP TRUCK section of
the Operator’s Manual.
• Check coolant, fuel, engine oil and other fluid lev-

els. SA435
• Check for leaks, kinked, frayed or damaged hoses

and lines.
• During the walk around inspection check the gen-

eral appearance, check for noise, heat, etc.
• Check for loose or missing parts.
It there is any problem with your rigid dump truck,

have it fixed or repaired before operating or contact
your authorized Hitachi dealer.
IMPORTANT:
y Use only recommended fuel and lubricants.
y Use only genuine Hitachi replacement parts.
y Failure to use recommended fuel, lubricants,
and genuine Hitachi replacement parts will
result in the loss of Hitachi product warranty.
y Never adjust the engine governor or hydraulic
system relief valves.
y Protect electrical parts from water and steam.
y Never disassemble electrical components
such as engine controller, sensors, etc.
W2-2-1
SERVICE YOUR RIGID DUMP TRUCK AT

SPECIFIED INTERVALS
Perform all service procedures described in this

maintenance guide.
Make service checks, and adjustments at intervals

shown in the Maintenance Interval Guides on the
following pages.
CHECK THE HOUR METER

REGULARLY
Check the hour meter to determine when your rigid

dump truck needs periodic maintenance.
Intervals in the Maintenance Interval Guides are for

operating in normal conditions. If your rigid dump Odo XXXXXXX.X mile
truck is operated in more adverse conditions, you Machine XXXXXX h
should service it more often at SHORTER INTER- Loads XXX
VALS between scheduled maintenance.
ELI20141
USE CORRECT FUELS AND LUBRICANTS
IMPORTANT: Always use recommended fuels

and lubricants. Failure to do so will
result in rigid dump truck damage
and loss of Hitachi product war-
ranty.
W2-2-2
RECOMMENDED LUBRICANTS
NOTE: The rigid dump truck was filled at the factory to capacity with recommended lubricants meeting ambient
temperatures or -18 °C to 43°C (0°F to 110°F).
W2-2-3
NOTE 1: For ambient temperatures below -18 °C (0 °F) oil viscosity should not exceed 5000 CST (2,250
SUS) at start up. Higher viscosities may cause pump damage from cavitation and/or insufficient
bearing lubrication. Optimum viscosity at system operating temperature is 16-40 CST (80-180 SUS).
NOTE 2: Select an Allison C-4 fluid that is not a qualified Dexron III® automotive transmission fluid.
NOTE 3: Can substitute Cat T02 qualified oil, DO NOT USE CAT T04 qualified oil.
DO NOT USE OILS WITH EXTREME PRESSURE (EP) ADDITIVES. EP additives are known to
react negatively with friction materials in brake systems.
NOTE 4: When using a conventional Allison C-4 fluid, fluid preheat is required when operating below
-15 ˚C (5 ˚F). If preheating equipment is not available, run the transmission a minimum of 20 min-
utes prior to range operation.
NOTE 5: A complete listing of approved C-4 fluids is available at www.allisontransmission.com
When start-up conditions are colder than specified in the Recommended Lubricants chart, anti-wear hydraulic oil
with Viscosity Index (VI) improvers or synthesized hydrocarbon oil should be used to obtain the desired viscosities.
During start-up, when the oil is at atmospheric temperature, the viscosity should not exceed 4,600 SUS or 1,000
centistokes (mm 2/s). Higher viscosities may cause pump damage from cavitations and/or incomplete bearing
lubrication. At the same time the viscosity should be maintained between 80-280 SUS or 16-60 CST when the sys-
tem has reached operating temperature. Consult your local lubrication specialist to obtain an oil to meet these re-
quirements. If suitable oil cannot be identified, consult the factory for preheating system.
RECOMMENDED FUEL
Number 2 Diesel Fuel
Grade C for ambient temperature above -18 °C (0 °F)
Grade B for ambient temperature below -18 °C (0 °F)
W2-2-4
ELECTRICAL DISCONNECTS BEFORE

WELDING ON THE RIGID DUMP TRUCK Disconnect
Disconnect
Disconnect the following before performing any
welding operation on the rigid dump truck.
Turn the battery disconnect switch to the OFF posi-

tion.
OM21155
Disconnect the battery cables.
Main Electrical Compartment
1. At the Central Control Unit (CCU) disconnect all

connections as shown in the illustration, 2A, 2B,
1A, 1B, 1C, 1D, 3B, and 3A.
OM21156
2. At the transmission’s CEC2 unit, disconnect all

connections as shown in the illustration, S
(black), T (blue), and V (gray).
EL20396
W2-2-5
Engine Compartment
3. At the engine’s Electronic Control Module

(ECM), disconnect the 3 Connectors labeled
ENG-1, ENG-2 and J1939 as shown in the illus-
tration.
4. When welding is completed, reconnect all ca-

bles and wires as illustrated. Turn the battery
disconnect switch to the ON position.
W2-2-6
MAINTENANCE INTERVAL GUIDE
NOTE: Disposal of used lubricants, filters, and batteries should be done in accordance with the
rules and regulations of the local governing agencies.
BASIC PREVENTIVE MAINTENANCE REPLACEMENT PARTS

Interval (hours)
Parts Quantity Daily 6 Months As

250 500 1000 1200
or or 2500 Required
Every 10
Engine Oil Filter 3
Transmission Filter 1 Upon Indication
Axle Breather Element 1
Hydraulic Filter Element, Steer- 1
ing/Brake Apply
Hydraulic Filter Element, 1
Hoist/Brake Cooling
Hydraulic Tank Breather Ele- 1
ment
Fuel Filter 2
Fuel-Water Separator 2 Every 1500 Hours or 1 Year
Air Cleaner, Primary Element 2
Air Cleaner, Safety Element 2 Replace at third servicing of Primary Element
or as indicated by service indicator nut
Cooling System, Supplemental
* To be done by the engine manufacturer’s recommendations
Coolant Additive (SCA)
Cooling Fan 1
Fan Belt 1
Filter, Air Conditioner Unit 1
Seat Belt 2 Replace every three years
Filter, Cab 1
Windshield Wiper Blade 1
Alternator Belt 1
NOTE: * Supplemental Coolant Additive is to be added as per Engine Manufacturers Requirements
NOTE: Refer to the rigid dump truck’s Operator’s Manual for detailed maintenance intervals of major sys-
tems.
W2-2-7
A. GREASING
Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
A. Tie Rod Ends 2
B. Trailing Arm Bushings 4
C. Steering Cylinder 2
D. King Pin 2
E. Front Drive Line Universal Joint 4
F. Front Drive Line Slip Joint 2
G. Hoist Cylinder Pin Upper and Lower 4
H. Body Hinge Pin 2
J. Track Rod and A-Frame 7
K. Rear Axle Ride Strut 4
L. Front Axle Ride Strut 4
M. Steering Column Driveshaft 2
W2-2-8
B. ENGINE
Interval (hours)
6
Parts Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Engine Oil Level, Check 1
See
2. Engine Oil, Change 118.3L(31.3 US gal)
Note
See
3. Engine Oil Filter, Replace 3
Note
4. Crankcase Breather Tube,
Check/ Clean
a) EH1700-3 DD 6
b) EH1700-3 Cummins 1
After the first 1000 hours,
5. Valve Lash 16 After the first 4000 hours,
Every 4000 hours thereafter
6. Injector Nozzle Every 4000 hours
16
Replacement Refer to the engine manufacturer’s manual
NOTE: With a new or rebuilt engine, oil and filters have to be changed after the initial 150 hours of operation,
and every 500 hours thereafter.
NOTE: For a 500 hour oil drain interval, an oil meeting Category 2 requirements is necessary. Refer to the
Fluids and Lubricants Specifications manual supplied with the rigid dump truck.
W2-2-9
C. TRANSMISSION
Interval (hours)
Daily
Parts Quantity 6 Months As
or 250 500 1000 1200
or 2500 Required
Every
10
1. Transmission Fluid Level, Check 1
2. Transmission Fluid, Change 99.0 L (26.0 US gal) *
3. Transmission Filter, Replace 1 Upon Indication

4. Transmission Sump Strainer, Clean 1 **
5. Transmission Cooling Line Strainer,
1
Clean
6. Transmission Breather Element, Check 1
7. Differential Lubricant, Level Check 1
8. Differential Lubricant, Change 148 L (39.0 US gal)
9. Planetary Hubs Lubricant Level, Check 1
10. Planetary Hubs Lubricant, Change 87 L (23.0 US gal)

11. Axle Breather Element, Check 1
12. Axle Breather Element, Change 1
NOTE: * Transmission fluid should be changed every 1200 hours.
NOTE: * Mineral based transmission fluid should be changed every 1200 hours.
NOTE: * A complete listing of approved C-4 fluids can be found

at www.allisontransmission.com
NOTE: ** Change at transmission overhaul
OM21170
W2-2-10
D. HYDRAULIC STEERING/BRAKE APPLY SYSTEM

Interval (hours)
Daily or 250 500 1000 1200
or 2500 Required
Every 10
1. Hydraulic Fluid Level, Check 1
2. Hydraulic Fluid, Change 117 L (31 gal)
3. Hydraulic Filter, Replace 1
4. Accumulator, Steering, Check 1
5. Accumulator, Brake, Check 2
6. Brake Pressure, Check
7. Check Hoses and Lines All
E. HYDRAULIC HOIST/BRAKE COOLING SYSTEM

Interval (hours)
Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Hydraulic Fluid Level, Check
2. Hydraulic Fluid, Change 342 L (90 US gal)
3. Hydraulic Filter, Replace 1
4. Hydraulic Tank Breather Ele-
1
ment, Check
5. Hydraulic Tank Breather Ele-
1
ment, Change
6. Check Hoses and Lines All
W2-2-11
F. BRAKES
Interval (hours)
Parts Quantity Daily or 6 Months As

250 500 1000 1200
10
1. Brake/Retarder Operation,
Check
2. Parking Brake, Check
3. Steering Operation, Check
4. Brake Visual Inspection, Check
5. Front Brake Wear, Check
6. Rear Brake Wear, Check Every 5000 hours
7. Brake System Complete Inspec-
1
tion and Function, Check
G. FUEL SYSTEM
Interval (hours)
6
Parts Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Fuel Tank Sediment, Drain 1
2. Fuel-Water Separator, Drain 2
3. Fuel-Water Separator, Replace 2 As Required
4. Fuel Tank Mounting, Check 1
5. Hoses and Lines, Check All
6. Fuel Filter, Replace 2
H. AIR CLEANER
Interval (hours)
Daily or 250 500 1000 1200
or 2500 Required
Every 10
1. Vacuator Valve, Check 2
2. Dust Cup, Check/Clean 2
3. Primary Filter Element, Change 2
Replace at third cleaning of
4. Safety Filter Element, Change 2 Primary Filter Element
or as indicated by service indicator nut
5. Intake Lines & Clamps, Check All
W2-2-12
I. COOLING SYSTEM
Interval (hours)
6
Item Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Coolant Level, Check
2. Supplemental Coolant To be done by the engine manufacturer’s
*
Additive (SCA), Check recommendations
3. Coolant, Change Drain and Flush After 6000 Hours or
408L (108 US gal)
3 Years of Service
Every 250 Hours
4. Coolant Filter, Replace 2 (EH1700-3 Cummins)
Always After the System has been Flushed
5. Cooling Fan, Check 1
6. Radiator, Clean 1
7. Fan Belt, Check 1
NOTE: The cooling system of the rigid dump truck was shipped with a mixture of 55% ethylene glycol and 45%
water. A supplemental coolant additive (SCA), anti-corrosive agent, was also added to protect the cooling
system components. Check the coolant concentration to protect the system to -37° C (-34° F) year round.
NOTE: * Supplemental Coolant Additive is to be added as per Engine Manufacturers Requirements.
J. ELECTRICAL SYSTEM
Interval (hours)
Quantity Daily or 6 Months As

Item 250 500 1000 1200
10
1. Battery Condition, Check All
2. Battery Cables and Con-
All
nections, Check
3. Electrical Wiring and Con-
All
nections, Check
4. Fuse/Relay, Check All
5. Neutral Start Circuit, Check
6. Exterior Lights, Check All
7. Back-up Alarm, Check 1
8. Horn, Check 4
9. Gauges, Check All
10. Indicator Lights, Check All
11. Headlight Aiming, Check All
12. Alternator A/C Belt, Check 1
W2-2-13
K. SUSPENSION, WHEELS & TIRES

Interval (hours)
Item Quantity Daily or 6 Months As

250 500 1000 1200
10
1. Struts, (X) Dimension,
4
Check
2. Wheels, Check *
3. Front Wheel Lubricant,
2 Every 15000 hours or at major service
Check
4. Front Wheel Lubricant, 7.6L (2.0 US gal)
Every 15000 hours or at major service
Change (per wheel) per wheel
Refer to following
5. Tire Inflation, Check **
chart
6. Tire Condition, Check 6
7. Wheel Alignment, Check ***
TIRE INFLATION CHART

Michelin
Bridgestone Goodyear
Tire Make and Size 27.00 R 49
27.00 R 49 27.00 R 49
EH1700-3 Quarry Transport
Tire inflation pressure
650 (94) 700 (102) 700 (102)
kPa (psi)
NOTE: * After wheel removal, check torque of bolts at 5 and 10 hours of operation.
NOTE: ** The tires are inflated at the factory to a minimum inflation pressure for shipping. Before placing the
rigid dump truck in service the tires must be inflated to the pressure shown which is for standard tires
for rigid dump truck operation at maximum 48 km/h (30 mph). Check tire manufacturer’s information
for proper inflation.
NOTE: *** See your authorized Hitachi Dealer.
W2-2-14
L. CAB
Interval (hours)
Item Quantity Daily or 6 As

250 500 1000 1200
Every Months Required
10 or 2500
1. Air Filter, Clean/Change 1
2. Air Conditioner Filter,
2
Clean/Change
3. Mounts, Check 3
4. Wiper Blade Condition, Check 1
5. Windshield Washer Fluid
5.7 L (1.5 US gal)
Level
6. Seat Belt & Mounting, Check 2
7. Seat Belt, Replace 2 Every 3 Years
8. Air Conditioner, Check
9. Heater & Defroster, Check
M. GENERAL
Interval (hours)
6
Item Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Leaks, Check
2. Body Prop Cable, Check 1
3. Main Rail, Strut and Axle Lug
Welds, Check
4. Frame Assembly, Check
5. Tightening Torque of Bolts and
Nuts, Check
6. Loose Bolts & Fittings, Check
NOTE: Some jobsites may require more frequent checks (i.e. heavy dust, rough roads, & etc.).
W2-2-15
MEMO
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W2-2-16
SERVICE AND MAINTENANCE / Lifting and Jacking
INTRODUCTION
When it is necessary to use a lifting device for mainte-
nance, the use of an air-powered-hydraulic jack or
overhead crane of sufficient capacity is recommended.
This section covers:

A. Front Axle-Jacking
B. Lifting at the Front
Chains/cables, overhead crane
C. Rear Axle-Jacking
WARNING: Lifting eyelets incorporated on
both sides of the dump body are to be used
for lifting and removing only the empty dump
body NOT the entire rigid dump truck.
The following jacking and lifting procedures are to be

used as a guide line and for reference only. Weather,
working conditions, expertise of service personnel, job
location, and available equipment will affect and pos- ELI20442
sibly change the procedures. Figure 1 – Lifting eyelets for lifting and removing the
body. NOT to be used for lifting the entire rigid dump
Once the rigid dump truck has been lifted or jacked up, truck.
a safety jack stand(s), See Figure 2, must be properly
positioned under the rigid dump truck for security. Ap-
propriate wood and/or steel cribbing, See Figure 3,
can be used for security if a jack stand(s) is not avail-
able.
NOTE: The term “cribbing” is used throughout this

section to describe the support used to se-
cure or block the rigid dump truck after it
has been jacked up or lifted. Refer to Fig-
ure 3 for sample cribbing.
NOTE: Service personnel should review the

information contained in this section so as
to be familiar with the use of jacking, lifting,
and cribbing equipment. Service personnel EL20097
should also be familiar with the rigid dump Figure 2 – Safety Jack Stand
truck. Reference the appropriate Opera-
tor’s Manual, Technical Manual and Work-
shop Manual and other literature that may
be provided with your rigid dump truck.
WARNING: Read and follow all cautions,

warnings, and instructions provided by the
equipment manufacturer of the jacking/lifting
devices being used.
W2-3-1
NOTE: Turn the steering wheel to remove residual

steering pressure, if any.
The work environment, situation, and specific reason

for raising the rigid dump truck may dictate the proper
selection of equipment needed. Examples of various
lifting equipment are: cables, slings, shackles, blocks,
clevis, jacks, and mobile or overhead cranes.
Special consideration must be made in the selection of

a site where a rigid dump truck is to be jacked or lifted.
Ground conditions must be assessed so that jacks and
support stands can adequately support the load for an
extended length of time. If the rigid dump truck is out-
side inclement weather must be taken into considera-
tion when selecting a site. It is recommended to have
EL20095
a specially designated area for jacking and lifting a
Figure 3 – Sample Cribbing (Blocking)
rigid dump truck. The base of the area should be at a
minimum of 609 mm (24 in) properly compacted rock.
Never lift a rigid dump truck on un-compacted earth.
SERVICE POSITION
Never lift a rigid dump truck on a grade or incline, lift
only on level ground. Area must also have proper
WARNING: Before working on the rigid dump drainage. Concrete pavement designed to support the
truck, park it on a level surface and put it in load may also be used.
the Service Position. Refer to Section W2-1,
SERVICE AND MAINTENANCE / Service Posi-
tion.
SERVICE POSITION:
Chart 1 EH1700-3
1. Put the rigid dump truck on a level, firm and Chassis with Hoists 54557 kg
large enough area that is clear of anything that Body 16443 kg
would interfere with the jacking or lifting proce- Net Weight with Body 71000 kg
dure. Inspect ground condition and compaction
to be sure it is stable and capable of supporting
jacks and stands. Chart 1 - Weight of Rigid Dump Truck with Standard
Tires and Standard Body Mounted
2. Turn the ignition key switch to the OFF position.
3. Put the rigid dump truck in the

SERVICE POSITION:
y Engine stopped
y Ignition key removed (except when service
requires engine operation)
y DO NOT OPERATE warning tag placed on the
steering wheel
y Body down and resting on frame
y Wheels chocked
y Hoist lever in the float position
y Parking brake applied
W2-3-2
EL20408
Figure 5 – Jacking Points, Typical Frame
EL20562 NOTE: It may or may not be necessary to jack

both sides of the rigid dump truck. It de-
Figure 4 - Wheels Chocked pends on the situation or the type of repairs
being made. For example, removing a
tire/rim assembly. Jack up only the side of
the rigid dump truck necessary to make the
A. FRONT AXLE- JACKING
repairs.
Minimum Jacking Device Capacity:
45 Tonnes (50 Tons)
1. After the rigid dump truck has been jacked up to
the desired height, place a safety jack stand(s)
WARNING: Read and follow all cautions, or cribbing in position to support the rigid dump
warnings and instructions provided by the truck.
equipment manufacturer of the lifting devices
being used. 2. After checking the jack stand(s) or cribbing to
make sure that the rigid dump truck will be
blocked properly and the rigid dump truck's
WARNING: Always chock tire and wheel on weight is supported and balanced, carefully
the opposite side of the rigid dump truck lower the rigid dump truck onto the jack stand(s)
prior to lifting or cribbing.
WARNING: The jacking device must be WARNING: ALWAYS support the rigid dump
placed on a level and firm surface truck with a safety jack stand(s) or cribbing.
NEVER work or crawl under a rigid dump
NOTE: The rigid dump truck must be empty prior truck that is only supported by a jack.
to being lifted for repairs.
3. With the rigid dump truck stable the jacking
equipment can be removed if necessary.
NOTE: Some jacking devices have a safety lock

which allows them to be used as a jack
stand. For safety purposes also use a jack
stand(s) or cribbing.
W2-3-3
REMOVAL OF CRIBBING/BLOCKING
1. Reposition the jacking device and carefully jack
the front of the rigid dump truck high enough to
remove the jack stand(s) or cribbing.
2. With the jack stand(s) or cribbing removed and

all other personnel at a safe distance from the
rigid dump truck carefully lower the rigid dump
truck to the ground.
EL20409
INSPECTION Figure 6 – Air-Over-Hydraulic Jack,

At the Front of the Rigid dump truck
1. Inspect the rigid dump truck and clean up the
work area. Make sure all equipment, tools and
other materials used in the service process have
been removed. Check to see that there are no
obstacles in the path of the rigid dump truck.
2. After all safety checks have been made take the

rigid dump truck out of the SERVICE POSITON.
Refer to Section W2, SERVICE POSITION.
EL20406
Figure 7– Cribbing Placed Under the Front Bumper
W2-3-4
B. LIFTING AT THE FRONT

Minimum Lifting Device Capacity:
45 Tonnes (50 Tons)

warnings and instructions provided by the
being used.
WARNING: Always chock tire and wheel on

the opposite side of the rigid dump truck
prior to lifting
NOTE: The rigid dump truck must be empty prior

1. Position the lifting device with the proper lifting

capacity at the front of the rigid dump truck.
2. Check the lifting/tow eyelets, Figure 8, for any EL20308
damage. Figure 8 – Lifting/Tow Eyelets, Front Frame
3. Attach the chains or cable of proper lifting ca-

pacity to the crane or other lifting device.
4. Secure the other end of the chains or nylon ca-

bles to shackles at the lifting/tow eyelets (see
Figure 8). Then lift the rigid dump truck to the
desired height.
NOTE: Place a block of wood between the chain or

cables and the front bumper of the rigid
dump truck. This will avoid damage to the
bumper that could be caused by the chain
or cables.
5. With the rigid dump truck lifted to the desired

height, place a safety jack stand(s) or cribbing in
position to support the front of the rigid dump
truck. Refer to Figure 9 and Figure 10.
NOTE: DO NOT place supports in the center of the

bumper. Cribbing should be done to the left EL20406
or right of the appropriate lifting/tow eyelet. Figure 9– Cribbing Placed Under the Front Bumper
Refer to Figure 9.
W2-3-5
WARNING: ALWAYS support the rigid dump

truck with a safety jack stand(s) or cribbing.
truck that is only supported with chains or
cables attached to a crane or other lifting de-
vice.
6. After checking the jack stand(s) or cribbing to

weight is supported and balanced, carefully
lower the rigid dump truck onto the jack stand(s)
or cribbing. The cable or chain can stay attached
to the eyelets if needed.
NOTE: It may or may not be necessary to block

pends on the situation or the type of repairs
being made. For example: the removal of a
tire or rim assembly. Block only the side of
repairs.
NOTE: Depending on the type of repairs, it may be

necessary to place the cribbing under the
trailing arms. Refer to Figure 10.
EL20407
1. With the work completed lift the rigid dump truck Figure 10 – Cribbing Placed Under the Trailing Arms
high enough to remove the jack stand(s) or crib-
bing.

rigid dump truck, carefully lower the rigid dump
INSPECTION

been removed. Check to see that there are no
obstacles in the path of the rigid dump truck.
2. After all safety checks have been made take the

W2-3-6
C. REAR AXLE - JACKING

Minimum Jacking Device Capacity:
45 Tonnes (50 Tons)

warnings and instructions provided by the
being used.
WARNING: Always chock tire and wheel on
the opposite side of the rigid dump truck
prior to lifting.
EL20412
WARNING: The jacking device must be Figure 11 – Rear Axle Jacking Points
placed on a level and firm surface.
NOTE: The rigid dump truck must be empty prior

NOTE: The rear axle has pads specifically de-

signed for the placement of the jack. Refer
to Figure 11.
1. Using a proper capacity jacking device, place a

jack underneath both sides of the rear axle to lift
the entire rear end of the rigid dump truck.
NOTE: It may or may not be necessary to jack

pends on the situation or the type of repairs
being made. For example: removing a
tire/rim assembly. Jack up only the side of
repairs.
2. After the rigid dump truck has been jacked up to

the desired height, place a safety stand(s) or
EL20413
cribbing in position to support the rigid dump
Figure 12 – Air-Over-Hydraulic Jack,
truck. Refer to Figure 13.
Rear Axle of the Rigid dump truck
3. After checking the jack stand(s) or cribbing to
weight is supported and balanced, carefully
lower the rigid dump truck onto the jack stand(s)
or cribbing.
WARNING: ALWAYS support the rigid dump

truck with a safety jack stand(s) or cribbing.
truck that is only supported by a jack.
W2-3-7
4. With the rigid dump truck stable the jacking

equipment can be removed if necessary.
NOTE: Some jacking devices have a safety lock

which allows them to be used as a jack
stand. For safety purposes also use a jack
stand(s) or cribbing.
1. Reposition the jacking device and carefully jack

the rear of the rigid dump truck high enough to
remove the jack stand(s) or cribbing.

rigid dump truck carefully lower the rigid dump
EL20414
Figure 13 – Rear Axle Cribbing Area

INSPECTION

been removed. Check that there are no obsta-
cles in the path of the rigid dump truck.
2. After all safety checks have been made, take the

W2-3-8
SERVICE AND MAINTENANCE / Special Tools
Recommended for EH1700-3

E12641387 Fig.1 Accumulator Inflation Kit Charge Brake and Steering Accumulators
E4082333 Fig.2 Neocon Charging Kit Charging Neocon Struts
E12977820 Fig.3 Digital Multimeter Electrical Testing
E12977829 Fig.4 Flow meter Kit Troubleshooting Hydraulic Systems
E12679919 Fig.5 Pressure Testing Kit Pressure Test Hydraulic Steer/Brake/Hoist System
E12977823 Fig.6 A/C Charging Kit Air Conditioning Charge and Test Kit
E12977845 Fig.7 Seal Installer/Outer Installing Wheel and Brake Seals - Outer
E12977792 Fig.8 Seal Installer/Inner Installing Wheel and Brake Seals - Inner
E12977851 Fig.10 King Pin Removal/Align Tool Used to Remove King Pin and Align King Pin
E12977824 Fig.11 Ring Gear Tool Used to Support Rear Axle Planetary Ring Gear
E12977826 Fig.12 Puller Transmission Flange Removal
E12977982 Fig.13, 39 Transmission Lift Bracket Transmission
E12650885 Fig.14 HTM Software Kit Used to troubleshoot the Hitachi CCU
E12977849 Fig.15 Side Bearing Removal Tool Used to Remove Flange Half Case Side Bearing
E12659700 Fig.16 Electrical Repair Kit Repair Electrical System Components
E12977832 Fig.17 Filtration Cart Reclaim Silicone and Neocon Strut Fluids
E12977833 Fig.18 Differential Lifting Tool Used to Lift Differential Retainer and Pinion Shaft
E12977848 Fig.19, 38 Differential Centerline Fixture Used in Differential Assembly
E12977841 Fig.20 Axle/Spindle Align Tool Assembly of Spindle/Axle Housing
E12592281 Fig.21 Tool Kit Basic Hand Tools
E12977852 Fig.22 Shaft Bearing Remove/Install Removing Steering Pump Shaft
E12977855 Fig.23 Bearing Race Removal Removing Bearing Race from Steering Pump
E12977853 Fig.24 Bearing Race Installation Installing Bearing Race in Steering Pump
E12977854 Fig.25 Shaft Seal Driver Installing Seal in Steering Pump
E12978878 Fig.26 Vacuum Pump Air Conditioning Tool
E12978884 Fig.27 Manifold Gauge Set Air Conditioning Tool
E12978880 Fig.28 Charging Cylinder Air Conditioning Tool
E12978882 Fig.29 Thermometer Air Conditioning Tool
E12978883 Fig.30 Dual R-12/R134 Leak Detector Air Conditioning Tool
(F) Fig.31 Cylinder Block Tool Steering Pump
E12978611 Fig.32 Seal Installation Tool Hoist Control Valve
E12978612 Fig.33 Seal Installation Tool Hoist Control Valve
E12977685 Fig.34 Notched Socket Remove Solenoid from ATC Retarder Valve
(F) Fig.35 Spring Installation Tool Steering Valve Assembly
E12628029 Fig.36 Crowfoot Tool Torquing Rear Driveline Bolts
E12677843 Fig.37 Disc Alignment Tool Aligns Rear Brake Discs
No Image Transmission Diagnostics Allison Doc Diagnostic Package
No Image Steering Wheel Puller Automotive Steering Wheel Puller Set
The tools listed are recommended for the care and

maintenance of the EH1700-3 rigid dump trucks. They may be ordered through your HITACHI
CONSTRUCTION TRUCK MANUFACTURING
NOTE: For additional special tools necessary Distributor.
to service the engine and the transmis-
sion, refer to the applicable engine or NOTE: (F) denotes fabricated tools that can
transmission maintenance manual. be fabricated locally.
W2-4-1
The Nitrogen accumulator inflation kit shown in

Figure 1 is used to check gas pressure and to gas
charge the brake and steering accumulators.
EL 20684
Figure 1 – Inflation Kit, E12641387
The charging kit shown in Figure 2 is used to

charge the Neocon ride struts with Helium gas.
EL 20685
Figure 2 – Neocon Charging Kit, E4082333
The Digital Multimeter shown in Figure 3 is used to

perform various electrical tests.
EL 20686
Figure 3 – Digital Multimeter, E12977820
W2-4-2
The flow meters illustrated in Figure 4 are used in

troubleshooting the steering system, hydraulic
system, and the hydraulic brake system.
.
EL 20687
Figure 4 – Flow meter Kit, E12977829
The pressure testing kit, shown in Figure 5 is for

checking and setting of pressures within the steer-
ing, hoist, brake and transmission systems.
INCLUDES:
QTY. DESCRIPTION
2 Plastic cases
2 Foam insert
6 SMD20-1/4-NPT-V
2 SMK20-1/8-NPT-VD
3 SMK20-1/4-NPT-VD
2 SMK20-7/16-UNF-VE
2 SMK20-9/16-UNF-VE EL 20688
3 SMS20-024-B Figure 5 – Pressure Testing Kit, E12679919
2 SMD20-096-B
1 BBV20040001M
1 WPG-63-1530-1/4-NPT
1 WPG-63-0300-1/4-NPT
3 WPG-63-3000-1/4-NPT
1 WPG-63-5000-1/4-NPT
6 SSV-20/20
W2-4-3
The Recovery / Recycler in Figure 6 is used to remove

and capture the used refrigerant from the air condition-
ing system. Refrigerant is recycled and then used again
to recharge the air conditioning system.
INCLUDES:
1 – Ratchet for compressor valve

1 – Thermometer
1 – Leak detector
EL 20689
Figure 6 – Air Conditioning Recovery/Recycler Kit
E12977823
The seal Installer tool shown in Figure 7 is used to

install the outer rear wheel brake seal.
EL 20690
Figure 7 – Outer Seal Installer, E12977845
The seal Installer tool shown in Figure 8 is used to

install the inner rear wheel brake seal.
EL 20691
Figure 8 – Inner Seal Installer, E12977792
W2-4-4
Figure 10 – Fabricated Tool for Removing Kingpin – E12977851
1. Bolt 5. Nut
2. Vertical Member 6. Eye Bolt
3. Horizontal Members 7. Jack
4. Horizontal Members
8. Tube and Base
and Tapped Boss
W2-4-5
The tool shown in Figure 11 is used to hoist the rear

axle planetary internal ring gear.
EL 20692
Figure 11 – Rear Axle Planetary Ring Gear Tool
E12977824
The heavy duty puller illustrated in Figure 12 is used to

remove the transmission output shaft flange from the
transmission.
EL 20695
Figure 12 – Improvised Heavy Duty Puller,
E12977826
W2-4-6
The fabricated tool shown in Figure 13 is used to assist

in the removal of the transmission.
ELI12977982
Figure 13 – E12977982 Transmission Lifting Bracket
A laptop with an HTM Software Kit is used to trouble-

shoot the Hitachi CCU. The Kit includes a CD-ROM
disc, a copy of the engineering standard for trouble-
shooting the CCU, and two computer cables.
Figure 14 – Laptop with HTM Software Kit E12650910
W2-4-7
The fabricated tool shown in Figure 15 is used with a

standard bearing puller set in removing the bearing
cones from the case halves of the differential.
EL 20696
Figure 15 – Side Bearing Removal Tool, E12977849
The kit shown in Figure 16 is used for the repair of

electrical system components.
EL 20697
Figure 16 – Electrical Repair Kit, E12659700
W2-4-8
The Silicone and Neocon Filtration Cart in Figure 17

is used to reclaim suspension strut dampening fluid.
Special filter media is used to filter the fluid and re-
move trace water. Use new replacement filter ele-
ment Hitachi part number E12980564 when reclaim-
ing Neocon fluid.
EL 20698
Figure 17 – Silicone and Neocon Filtration Cart
E12977832
The tool shown in Figure 18 is used to aid in the lifting

during disassembly or assembly of the differential.
Figure 18 – Differential Lifting Tool

E12977833
W2-4-9
”Centerline Fixture Tool” shown in Figure 19 is used for

taking pinion gear depth measurements during assem-
bly. Tool position is referenced from the side bearing
bores as shown.
W8DX-04-65-013
Figure 19 – Install Centerline Fixture Tool Parallel
E12977848
The tool shown in Figure 20 is used to align and clamp

a replacement spindle to the axle housing for welding.
It supports the joint alignment between the axle hous-
ing and the spindle.
EL 20700
Figure 20 – Fabricated Tool, Axle Housing and Spindle,
E12977841
W2-4-10
EL 20699
Figure 21 – Basic Hand Tool Kit, E12592281
1. E12992142 Wrench Set – Standard 11. El 2592150 Feeler Gauges

2. E12593568 Open-End Metric Wrenches 12. E12592151 Bar
3. E12592143 Adjustable Wrench 13. E12592152 Tool Bag
4. E12592144 Strap Wrench 14. E12592153 Air Gauge
5. E12592145 Standard, 12 Pt. Socket Set 15. E12592154 U.S. Hex Wrench Set
6. E12593569 Metric, 12 Pt. Socket Set 16. E12592155 Grease Gun
7. E12592146 Breaker Bar 17. E12592156 Socket
8. E12592147 Screwdriver 18. E12592157 Accumulator Gauge
9. E12592148 Pliers 19. E4086789 Brake Wear Kit
10. El 2592149 Hammer
The Basic Hand Tool kit shown in Figure 21 contains basic tools required to service the rigid dump truck. They are
supplied in a bag to assist the operator with minor maintenance items or adjustments.
W2-4-11
The driver tools shown in table are used in the disassembly and assembly of the steering pump.
EL 20702
Figure 22 – Fabricated Shaft Bearing Removal and Installation Tool, E12977852
Table
USE FOR “A”
Intermediate shaft bearing installation 101.6 mm (4 in)
Drive shaft bearing installation 152.4 mm (6 in)
Drive shaft bearing removal 228.6 mm (9 in)
38.1 mm (1.5 in)
W2-4-12
Use a 5 in long ½ in – 13 hex head driver screw
Bearing Race Puller

Description A B C
Valve Block 42.545 mm 33.02 mm 31.75 mm
(1.675 in) (1.300 in) (1.250 in)
Housing 53.975 mm 41.275 mm 38.100 mm
(2.125 in) (1.625 in) (1.500 in)
EL 20703
Figure 23- Bearing Race Removal Tool E12977855
W2-4-13
NOMINAL
PIPE “A” “B” “C”
SIZE
38.1 mm 101.6 mm 41.275 mm 48.26 mm
(1.50 in) (4 in) (1.625 in) (1.900 in)
50.8 mm 101.6 mm 53.975 mm 60.325 mm
(2 in) (4 in) (2.125 in) (2.375 in)
SCHEDULE 80 (extra heavy)
EL 20704
Figure 24 – Special Bearing Race Installation Tool, E12977853
EL 20705
Figure 25 – Shaft Seal Driver, E12977854
W2-4-14
The tools illustrated in Figure 26 through Figure 30 are

used by individuals trained and qualified to service air
conditioning systems.
Vacuum pump is used to evacuate air conditioning

system and leakage testing.
EL 20706
Figure 26 – Vacuum Pump E12978878.
Manifold gauge set is used to charge air conditioning

system with refrigerant.
EL 20707
Figure 27 – Manifold Gauge Set E12978884.
W2-4-15
Charge cylinder in Figure 28 is a pressurized cylinder

of replacement refrigerant. Cylinder has heating ele-
ment to maintain positive pressure in charge cylinder.
Tool is designed to aid air conditioning system re-
charging where temperature may cause fluctuations in
refrigerant volume.
EL 20709
Figure 28 – Charging Cylinder E12978880
Temperature sensing thermometer used to check per-

formance of both heating and air conditioning system.
EL 20711
Figure 29 – Thermometer E12978882
W2-4-16
Figure 30–Dual R-12/R-134 Leak Detector E12978883

is used to detect refrigerant leakage from hose con-
nections and air conditioning components.
ELI E12978883
Figure 30 – E12978883 Dual R-12 or R134
Leak Detector
The cylinder block subassembly tool in Figure 31 is

used to compress the cylinder block internal spring in
the steering pump for snap ring removal and installa-
tion.
ELI E16502
Figure 31 – Cylinder Block Subassembly Tool
W2-4-17
EL 20712
Figure 32 – E12978611 Seal Installation Tool
Hoist control valve spool seal installation tools are
shown in Figure 32-33.
EL 20713
Figure 33 – E12978612 Seal Installation Tool
The notched socket shown in Figure 34 is used to

remove the solenoid from ATC Retarder Control
Valve.
Figure 34 – E12977685 Notched Socket
W2-4-18
Figure 35 – Steer Valve Spring Installation Tool
The tool in Figure 35 is used to ease the installation of steering control valve spool centering springs.
The crowfoot tool is used to torque the bolts on the

rear driveline’s flange yokes.
Figure 36 – Crowfoot Tool - E12628029
W2-4-19
The Disc Alignment Tool is used to ensure alignment

of the rear brake discs during the rebuilding of the rear
brakes.
Figure 37 – Disc Alignment Tool - E12677843
Figure 38 – Centerline Fixture Tool
W2-4-20
Figure 39 – Transmission Lifting Bracket
W2-4-21
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W2-4-22
SECTION 3
ENGINE
—CONTENTS—
Group 1 Engine Removal Group 4 Air Cleaner

Service Position .......................................... W3-1-1 Service Position .......................................... W3-4-1
Removal...................................................... W3-1-1 Removal...................................................... W3-4-2
Installation................................................... W3-1-8 Installation................................................... W3-4-5
Disassembly................................................ W3-1-8 Disassembly................................................ W3-4-5
Inspection.................................................... W3-1-8 Inspection.................................................... W3-4-7
Assembly .................................................... W3-1-8 Assembly .................................................... W3-4-7
Maintenance Standard................................ W3-1-8 Maintenance Standard .............................. W3-4-10
Group 2 Drive Coupling Group 5 Radiator

Removal...................................................... W3-2-1 Removal...................................................... W3-5-1
Installation................................................... W3-2-3 Inspection.................................................... W3-5-6
Inspection.................................................... W3-2-3 Installation................................................... W3-5-6
Maintenance Standard................................ W3-2-3 Maintenance Standard ................................ W3-5-8
Memo…………………………………………..W3-2-4
Group 3 Exhaust System

Service Position .......................................... W3-3-2
Removal...................................................... W3-3-2
Installation................................................... W3-3-2
Inspection.................................................... W3-3-3
Maintenance Standard................................ W3-3-3
Memo…………………………………………..W3-3-4
W3-0
<BLANK>
W3-0
ENGINE / Engine Removal
Figure 1 – Right Side of Typical Detroit Diesel 16V2000 Engine
SERVICE POSITION
CAUTION: A lifting device and chains rated
Before checking and/or servicing the rigid dump truck, to hoist at least 3500 kg. (7700 lbs.) will be
park it on a level solid surface and put it in the “Ser- required for removal.
vice Position.” Refer to Section W2-3.
CAUTION: Use a hoist or get assistance
REMOVAL when lifting components that weigh 23 kg (50
lbs.) or more. Be sure all chains, cables,
When it is necessary to remove the engine, a hoist will hooks, and slings are in good condition and
be required to lift the engine from the rigid dump truck. are of the correct capacity. Be sure that all
The following procedures for preparation to remove chains are positioned correctly. Always use a
the engine should be used only as a guide, since they spreader bar when possible.
do not include the removal of additional optional
equipment that may not have been installed by the
factory. Cables, hoses, and wire harness that have CAUTION: Do not attempt to lift the engine
been removed from the engine connections should be with an apparatus that allows side loading of
tagged to facilitate installation, and should be tied the lifting brackets, or allows the chain or
away from the engine so as not to interfere with the cable to apply force to other parts on the en-
removal. All hose openings should be capped, and all gine. The lifting brackets or parts can break,
openings left by the removal of components on the causing the engine to fall. Personal injury or
engine should be plugged to keep dirt from entering. engine damage may result.
W3-1-1
IMPORTANT: Special care should be used to pro- 4

tect engine components from envi-
ronmental damage during repair
when part is removed. Use protec-
tive caps and place tarp over com-
ponents. Dirt or water entry may
freeze or corrode the inside of the
assembly during storage.
1. Raise the body and install the body prop cable.
2. Follow all steps for radiator removal given in Sec-

tion W3-5, RADIATOR REMOVAL.
3. Remove the radiator fan shroud.
4. Remove bolts (1) and washers (2) that mount the

fan to the engine, and then remove the fan (3) 1
2
and fan spacer (4). Refer to Figure 2.
: 18 mm
Figure 2
1
2
3
5. Remove exhaust support brackets (4) from the

engine. Loosen exhaust system clamps (1, 2) to
rotate tubing, before removing the tubing (3) from
the engine. Refer to Figure 3. Cover the turbo-
charger exposed openings to prevent dirt entry. 4
Refer to Section W3-3, EXHAUST SYSTEM.
9
: /16 in, 13 mm
Figure 3
W3-1-2
6. Disconnect the heater hoses from the engine.

Have a suitable container set up to collect cool-
ant leakage. Refer to Figure 4.
Figure 4
7. Disconnect the starter relays and grounds on

both starters. Refer to Figure 5.
3 3
: /8 in, /4 in
Figure 5
W3-1-3
8. Disconnect the alternator charging and ground

terminals. Connectors are labeled “POS”, “I”
and “GND”. Refer to Figure 6.
3 7
: /8 in, /16 in
9. Disconnect the electrical connector at the air

conditioning compressor electric clutch. Con-
nector is labeled “COMP”. Refer to Figure 6.
Figure 6
10. Disconnect the engine harness connector on top

of the engine. These connectors are labeled
ENG-1, ENG-2, J1939 and RES-120. Refer to
Figure 7.
Figure 7
W3-1-4
2
11. Close the fuel supply shut-off valve at the fuel
tank. Disconnect the fuel supply (1) and drain
connections (2). Have a suitable container set
up to collect any fuel leakage. It is advisable to
remove the fuel/water separator and bracket (3)
to avoid damage. Do not leave the filter hanging
from the hose. Refer to Figure 8.
7 5 3 9
: 1 /16, 1 /16 in, 1 /4 in, /16 in
1
3
12. Remove the front driveline cover and drive cou-

pling cover, and then disconnect the front drive-
line from the drive coupling. Secure driveline
away from engine. Refer to section W5-4,
Figure 8
FRONT DRIVELINE.
13. Remove A/C compressor belt guard by remov-

ing bolts (1,2). Slacken the air conditioning com-
pressor drive-belt by loosening the nut on the
tension screw (3). Remove the two bolt and
washer assemblies mounting the air condition-
ing compressor to the engine and support the
compressor away from the engine. Refer to
Figure 9. It is not necessary to disconnect the
lines to the compressor if the compressor is
supported. Do not allow the compressor weight
to hang by the air conditioning hoses.
9 15
: /16 in, /16 in
3 2
Figure 9
W3-1-5
14. Attach shackles or lift hooks with hook latches to

engine lifting lugs. Refer to Figures 10 and 11.
Figure 10
17. Remove the bolts (5), nuts (7), and washers (6)
from the rear engine mounts. Refer to Figure 12.
1
: 1 /2 in
18. Remove the front mount bolts (5), nuts (7), and
washers (6). Refer to Figure 12.
1
: 1 /2 in
CAUTION: Approximate Engine weight: 3500

Kg (7700 lbs)
19. Support engine with hoist and remove washers

and rubber mounts that could not be removed ini-
tially.
20. Carefully lift engine out of frame.
21. Mount the engine on a suitable work stand.
22. Remove the drive coupling. Refer to Section

W3-2, DRIVE COUPLING.
EL 20578
Figure 11
W3-1-6
Figure 12
2. Front Bracket Weldment 8. Washer

4. Rear Bracket Weldment 9. Mount
5. Bolt 10. Washer
6. Washer 11. Bolt
7. Lock Nut 12. Bolt
W3-1-7
INSTALLATION to engine operation manual. Do not pressurize

the fuel tank over 34 kPa (5 psi).
Use new seals, gaskets, hose and o-rings when in-
stalling components or making connections. Check 5. Perform the recommended checks indicated in
for damaged threads on all fittings before connecting Detroit Diesel Engine Manual for preparing to
them to the engine. Replace any engine mounting start a new or rebuilt engine for the first time.
part that shows signs of deterioration or is damaged.
Install the engine by reversing the removal proce- 6. During the run-in period, check for leaks in the
dures, and by following the additional steps given air system, the cooling system, the fuel system,
below. the oil filter, the oil cooling systems, and the en-
gine oil lubricating system. Immediately correct
1. Inspect the engine mounting hardware and re- any defect reported.
place if necessary. Tighten all bolts and nuts to
the torque value specified in Section W1-2, 7. Monitor the gauges for proper engine perform-
GENERAL / Tightening Torque, except as indi- ance. Repeatedly check fluid level of the engine,
cated. Refer to Section W3-5 RADIATOR for transmission, and hydraulic oil tank and add oil if
wrench sizes and torques for vent lines and necessary.
hose clamps.
8. Monitor engine coolant level and adjust freeze
Front Mount Bolts (5, Figure 12) protection. Add fluid if needed. Inspect that
1
: 1 /2 in freeze protection is adequate with each fluid
: 1232 N·m (909 Ibf·ft) level adjustment.
Rear Mount Bolts (5, Figure 12)
1 DISASSEMBLY
: 1 /2 in
: 1232 N·m (909 Ibf·ft)
Refer to Detroit Diesel “16V2000 Engine Service
A/C Compressor Bolts (1, 2, Figure 9) Manual (6SE2000)” for engine disassembly proce-
9
: /16 in dures.
: 70 N·m (52 Ibf·ft)
Fan Bolts (1, Figure 2) INSPECTION
: 18 mm
: 110 N·m (81 Ibf·ft) 1. Inspect the rubber mounts (9, Figure 13) for de-
terioration or wear. Replace with new parts as
Engine Bracket Mounting Bolts (11,12,Figure 12)
necessary.
A/C Compressor Mounting Bolts
: 24 mm 2. Inspect the mounting brackets (2, 4, Figure 13)
: 270 N·m (199 Ibf·ft) for distortion or cracks. Replace as necessary.
Exhaust Support Bracket Mountings (4, Figure 3)
: 24 mm 3. Refer to Detroit Diesel “16V2000 Engine Service
: 43 N·m (32 Ibf·ft) Manual” for inspection procedures.
2. Fill the engine crankcase with lubricant and ASSEMBLY

check the transmission oil level. Refer to Op-
erators Manual, Basic Preventive Maintenance. Refer to Detroit Diesel “16V2000 Engine Service
Manual” for engine assembly procedures.
3. Fill the cooling system with anti-freeze engine
coolant and bleed trapped air from cooling sys- MAINTENANCE STANDARD
tem. Rubber Mounts Recommended replace
(9, Figure 13) at engine overhaul
4. Check fuel condition, fuel tank level, and fluid Fuel, Air Intake, Cooling Recommended replace
flow from tank to engine and return to tank fuel System Hoses every 2 years and at en-
circuit. Bleed trapped air from fuel system. Refer gine overhaul
W3-1-8
ENGINE / Drive Coupling
4
5
2
3
Figure 1
1. Coupling 3. Washer 5. Flywheel Housing

2. Bolt 4. Engine Flywheel
SERVICE POSITION 4. Support coupling. Remove bolts (2) and washers

(3) securing coupling (1) to engine flywheel (4).
Before checking and/or servicing the rigid dump truck, Remove coupling (1).
park it on a level solid surface and put it in the “Service : 15/16 in
Position”. Refer to Section W2-1.
5. Check that the engine crankshaft endplay and
REMOVAL flywheel runout are within recommended operat-
ing tolerances as specified by the engine manu-
1. Remove the front driveline cover and drive cou- facturer.
pling cover.
2. Remove the front driveshaft. Refer to Group W5-4,

FRONT DRIVELINE.
3. Inspect the engine flywheel housing for accumu-

lated dirt or debris. Clean off accumulated mate-
rial before removal of drive coupling (1).
CAUTION: Coupling weight: 86 Kg (190 lb)
W3-2-1
2
3
Inner Member
Pilot Bore Flywheel
EL 20580
Figure 2
1. Coupling 2. Bolt 3. Washer
W3-2-2
INSTALLATION INSPECTION
1. Install coupling (1) to engine flywheel (4) with 8 1. Inspect the outer diameter pilot of engine drive
bolts (2) and washers (3). Seat coupling into pilot coupling for ridges or burrs that may prevent
by tightening opposite bolts in a cross pattern. proper mounting to flywheel.
: 15/16 in
2. Inspect the coupling inner member for fatigue
2. After all bolts have been seated using the alter- cracks. Inspect drive shaft mounting face for
nating cross pattern, tighten to torque specified, damage. Inspect driveshaft pilot fit and ensure no
again in a cross pattern. damage to driveshaft mounting threads.
: 15/16 in
: 244 N٠m (180 Ibf٠ft) 3. Inspect the rubber element for damage. Check for
missing pieces of rubber and cracks. Inspect the
3. Install the front driveline. Refer to Section W5-4, outer diameter of the drive coupling element
FRONT DRIVELINE. Install the drive coupling where it meets the outer steel member. Check for
cover and the front driveline cover. signs of element slip or rubber movement. This is
evident by signs of heat, cracking, rubber flow,
etc. Replace a suspect drive coupler.
4. Inspect the rubber drive coupling element to en-

sure that it is still properly seated. The driveshaft
mounting face must be square to the outer di-
ameter of the coupling.
5. Remove any grease/oil buildup from rubber ele-

ment. This can cause slip or vibration.
Criteria Limit
Rubber condition No evidence of slippage or material deterioration
Balance 0.03 N٠m [4 oz٠in] @ 2100 min-1 (rpm)
Engine Crankshaft endplay and flywheel run out must be within recom-
mended tolerance. Engine crankshaft balancer must be within tol-
erance. Consult local engine distributor for maintenance and
specifications.
W3-2-3
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W3-2-4
ENGINE / Exhaust System
Figure 1
1. Right Hand Bracket 9. Flex Tube 17. Yoke

2. Left Hand Bracket 10. Flex Tube 18. Clevis Pin
3. Screw 11. Exhaust Collector 19. Cotter Pin
4. Washer 12. Sleeve 20. Clevis
5. Exhaust Tube 13. U-Bolt 21. Clamp
6. U-Bolt 14. Exhaust Tube 22. Screw
7. Lock Nut 15. Flex Tube 23. Washer
8. Clamp 16. Collector Box 24. Lock Nut
W3-3-1
SERVICE POSITION 10. Remove the U-Bolt (13), nuts (24) and washers
(23) from the exhaust tube (14) and the support
Before checking and/or servicing the rigid dump truck, plate located above the rear axle.
park the rigid dump truck on a level solid surface and : 9/16 in
put it in the “Service Position.” Refer to Section W2-1.
11. Remove the double clamp from the connection
REMOVAL
between the flex tube (15) and the collector box
Numbers in parentheses refer to Figure 1.
(16).
1. Remove the exhaust blankets. : 9/16 in
12. Remove cotter pin (18) from clevis pin (19), then
2. Disconnect the Marmon clamp at the connection
remove clevis pin (19) from clevis (20). Rotate
between the exhaust tube and the engine turbo-
collector box (16) to allow removal of exhaust
charger.
tube (14) and flex tube (15).
: 7/16 in
3. Remove U-Bolts (6), nuts (7) and washers (4) 13. Remove the flex tube (15) and then exhaust tube
holding the exhaust tubes in place on the left (14).
hand bracket (2) and right hand bracket (1).
: 9/16 in INSTALLATION
4. Remove band clamp (8) if separation of the ex-
haust tube (5) from the flex tube (10) is neces- 1. Scrape any corrosion or particles of gaskets off of
sary. the mating surfaces of reused parts.
: 9/16 in 2. All clamps and U-Bolts should be assembled loose
until final fit-up of all tube assemblies and flex
5. Remove band clamp (8) from the connection be- tubes.
tween the flex tube (10) and the exhaust collector
(11). 3. Insert the adaptor end of flex tube (15) over the
: 9/16 in collector box connection and secure with double
clamp (21). Refer to Figure 2.
6. Remove the flex tube (10). Repeat steps 1 – 5
for flex tube (9). 4. Slide flex tube (15) over exhaust tube (14) up to
the raised radius in exhaust tube (14). Refer to
Figure 2. Secure with double clamp (21).
7. Remove the double clamp (21) from the exhaust
tube (14) and the support plate located above the
5. Secure exhaust tube (14) with U-bolt (13), washer
transmission.
(23), and locknut (24). Do not torque, wait for final
: 9/16 in fit-up of all exhaust tubes and flex tubes.
: 9/16 in
8. Remove the U-Bolt (13), nuts (24) and washers
(23) from the connection between the exhaust
tube (14) and the exhaust collector (11).
: 9/16 in
9. Remove the double clamp (21) from the connec-

tion between the flex tube (15) and the exhaust
tube (14).
: 9/16 in EL 20582
Figure 2
W3-3-2
6. Slide exhaust collector (11) onto exhaust tube (14) MAINTENANCE STANDARD
and secure connection with double clamp (21).
: 9/16 in
NOTE: The connection between item 16 (Figure 1)
and the rigid dump truck body is not gas
7. Slide flex tube (10) over the inlet of exhaust col-
tight. Leakage at this rotating swivel con-
lector (11) and secure with clamp (8).
nection is normal.
: 9/16 in
Inspect the exhaust system to make Check every
8. Slide flex tube (10) over exhaust tube (5) up to sure that the tubing is gas tight. 250 hrs. / “As
where the flex tube touches the raised radius in Required”
exhaust tube assembly (5). Secure tube assembly Check the condition of mounting Check every
with U-bolt (6), washers (4) and locknuts (7). hardware. Repair or replace any 250 hrs / “As
Refer to Figure 2. Attach clamp (8) to secure con- components that are found defective. Required”
nection between flex tube (10) and exhaust tube Check and adjust alignment of ex-
(5). Assemble loose until final fit-up. Check every
haust system tubing periodically when
: 9/16 in 250 hrs / “As
rubbing or wear pattern is noticed on
Required”
parts.
9. Attach Marmon Clamp to exhaust tube (5) as Inspect the inside of the body for
shown in Figure 1. Remember to assemble loose through cracks. Cracks in the body
until final fit-up. can lead to water entrance into the
: 7/16 in exhaust system. Refer to Figure 3 for
a diagram of exhaust system flow.
10. Repeat steps 9 – 11 for flex tube (9). Water draining back inside the engine 6 Months /
or accumulating in the exhaust system 2500 hrs
11. After fit-up of all exhaust tubes, flex tubes and can cause engine damage. Improper
tube assemblies, tighten all bolts and lock nuts storage may cause exhaust blockage
according to the following table. due to ice formation inside of exhaust
duct. Exhaust system blockage can
Torque prevent engine from starting.
Item
U-Bolt (6, 13) 22 N⋅m (16 lbf.ft)

Double clamp Tighten until 2 halves are
(21) forced together
Tighten until 2 faces are
Band clamp (8)
forced together
Marmon clamp 23 N⋅m (200 lbf.in)
INSPECTION
Inspect each component for corrosion or perforation.

Replace parts as necessary.
EL 20584
Figure 3
W3-3-3
MEMO
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W3-3-4
ENGINE / Air Cleaner
Figure 1
1. Air Cleaner Assembly 5. Elbow

3. Clamp 6. Clamp
4. Tube 7. Clamp
SERVICE POSITION
Before checking and/or servicing the rigid dump truck,

park it on a level solid surface and put it in the “Ser-
W3-4-1
REMOVAL
Tubing Removal
1. Pressure wash any dirt off the exterior of the tub-

ing and elbows. Allow parts to dry or blow off
moisture before removal.
2. Support tube (4) with a suitable hoist.
3. Loosen the clamp (3) holding the tube (4) to the

elbow (5) at the air cleaner assembly (1).
7
: /16 in
4. Loosen the clamp (7) holding the elbow (5) to the

engine turbocharger, and then remove the tube
(4) and elbow (5).
7
: /16 in
5. Cap the turbocharger connection to prevent dirt

entry into the engine air intake system. EL 20586
Air Cleaner Assembly Removal Figure 2
Numbers in parentheses refer to Figure 1 unless oth-

erwise noted.
1. Secure the air cleaner with a suitable lifting de-

vice and a nylon scrape. Refer to Figure 3.
CAUTION: Approximate Air Cleaner As-

sembly weight: 227 kg (500 lb)
2. Wipe any dirt off the exterior of the air cleaner

assembly and loosen the clamp (3) which se-
cures the elbow (5) to the air cleaner outlet.
3. Remove the elbow (5) from the air cleaner as-

sembly. If necessary, loosen the clamp that
secures the elbow to the tube.
Figure 3
W3-4-2
4. Disconnect the wire harness (12) from the filter

restriction switch (11) at the air cleaner outlet.
Refer to Figure 4.
5. Apply a slight tension to the lifting device to sup-

port the weight of the air cleaner (1). Remove
the bolts (2) and washers (3, 4) and nuts (5) that
secure the air cleaner assembly (1) to the plate
assembly (7). Refer to Figure 5.
: 9/16 in EL20587
Figure 4
6. Remove the air cleaner assembly (1) from the

rigid dump truck. Refer to Figure 6.
7. Cap the outlet tube port to prevent dirt from en-

tering the air cleaner.
NOTE: When removing the air cleaner assembly

(1), do not permit dust or dirt to fall into EL20588
Figure 5
the air tube. Cap the tube immediately.
Figure 6
W3-4-3
INSTALLATION
Numbers in parenthesis refer to Figures 1 and 7,

CAUTION: The cap on the turbocharger
unless otherwise noted.
inlet and the wrapping on the safety ele-
1. Inspect all components for cleanliness prior to ment must be removed prior to engine
installation. start-up. Failure to do so may cause en-
gine damage.
2. Install air cleaner in the reverse order of re-
moval. Tighten bolts to torque specified.
: 9/16 in DISASSEMBLY
: 50 N·m (37 Ibf·ft)
Numbers in parentheses refer to Figure 7 unless oth-
3. Install tubing in the reverse order of removal. erwise noted.
: 9/16 in
1. Carefully remove the filter elements as outlined
: 9 N·m (75 Ibf·in)
under the heading “CHANGING THE ELE-
MENTS” in this section.
4. Once the air intake system is installed, it should
be checked for leaks. Remove the elbow (22) 2. The body (1) can be separated from the lower
at the turbocharger inlet, cap the turbocharger body (14) by loosening clamp (10) and sepa-
inlet, and re-install the elbow (22). rating the body halves.
5. Remove the primary (16, Figure 7) and safety

(15, Figure 7) air cleaner elements. Carefully
create an air tight seal over the safety element
(15, Figure 7) by wrapping it with plastic and re-
inforced tape. Re-install the safety element.
6. Remove the filter restriction switch at the air

cleaner outlet and apply 34 kPa (5 psi) clean
regulated air pressure to the switch port.
7. Use a foaming detergent soap and water solu-

tion to inspect the air intake system for leaks.
Apply generous amount of soap solution to all
connections and tubing. Check for bubble for-
mation that indicates leakage. Pay particular at-
tention to elbows and connections. Tighten
connections and/or replace components where
leaking is evident.
8. Remove regulated air supply. Allow parts to dry.

Re-install the air cleaner filter restriction switch
(11, Figure 3).
9. Remove the elbow at the turbocharger inlet,

remove the cap at the turbocharger inlet, and
re-install the elbow.
10. Remove the wrapping from the secondary ele-

ment, and then re-install the secondary element
and primary elements.
W3-4-4
19
ELI15064
Figure 7 - Exploded View of Air Cleaner
5. Nut (Service
1. Body 9. Gasket 13. Clamp 17. Vacuator Valve
Indicator)
18. Filter Elements
2. Cap 6. Cotter Pin 10. Clamp 14. Lower Body
Kit
3. Filter 7. Nut 11. O-Ring 15. Safety Filter 19. Clamp (3x)
4. Gasket 8. Cover 12. Cup 16. Primary Filter
W3-4-5
CAUTION: When using regulated com-

pressed air, wear proper clothing and
equipment. Use extreme caution to avoid
injury.
5. Check the vacuator valve (7, Figure 8) attached

to the dust cup (1, Figure 8). Replace the valve
if it is missing, cracked, torn, or outlet remains
open.
6. All parts must be clean and dry for assembling.
ASSEMBLY
1. Assembly of the air cleaner is in reverse order

of disassembly.
2. Make sure that all components are clean.
3. Use new O-rings and seals.
Figure 8 - Section View of Typical Air Cleaner 4. Inspect the air cleaner elements. Inspect for
holes and tears in the pleats by looking
through the element toward a bright light.
1. Dust Cup 5. Primary Filter Element Any obvious damage will cause light to show
2. Tubes 6. Air Inlet Screen through. Check for absent, torn, loose or par-
3. Safety Filter Element 7. Vacuator Valve tially-compressed gaskets, and for dented
metal parts. Make sure that elements are dry.
4. Lower Body
Replace any element that is suspected to
leak when installed.
INSPECTION
1. Check the elbows, tubes, and clamps that run

between the air cleaner and engine. Replace any
components that are cracked or damaged.
2. Check all air cleaner assembly components for

damage or corrosion. Pay particular attention to
gasket sealing surfaces.
3. Check the pre-cleaner tubes in the body assembly

(10, Figure 9). Light dust plugging the tubes can
be removed with a stiff fiber brush (Figure 9).
4. If heavy plugging of tubes with compacted mate-

rial is evident, clean the lower body assembly with
o
compressed air or water not exceeding 71 C
o
(160 F). EL 20592
Figure 9
W3-4-6
SERVICING THE AIR CLEANERS

1. The safety filter element (15) is not intended to 5. To remove the safety filter element (15), first re-
be cleaned. For maximum engine protection move the cotter pin (6) then remove the safety
and air cleaner service life, replace the safety signal service indicator (5). Carefully remove the
element every third primary element change or safety filter element (15) from the upper body (1).
cleaning - or as indicated by the safety signal
service indicator (5). NOTE: Do not operate the machine without a
safety filter element (15). Also, do not at-
2. The service indicator nut (5) accurately moni- tempt to clean the safety filter element;
tors the restriction level of the safety element. service by replacement only.
The service indicator installs like an ordinary
wing nut down over the center bolt of the air 6. Use a clean, damp cloth to wipe the surface of
cleaner holding the safety filter element (15) in the upper body (1) clean. Always clean the gas-
place. The window in the nut is green when ket sealing surface of the upper body. Check it
the service filter element is OK. When all of visually to make sure it is clean before putting in
the green in the window disappears and the a new safety filter element (15).
window is entirely red, a safety filter element
change is required. To reset the nut, apply air 7. Installation of elements is basically in the reverse
suction to the window. order of removal. Use a new cotter pin (6) if the
safety filter element (15) was replaced. Install
CHANGING THE ELEMENTS new gaskets (4) and (9). Also, ensure that the
Numbers in parentheses refer to Figure 7. gaskets on the lips of the safety filter element,
and in the access cover (8) provide a good seal.
1. Shut the engine down and wipe the dirt off the
entire air cleaner.
SERVICING THE LOWER BODY ASSEMBLY
2. Release the three clamps (19) on the upper Numbers in parentheses refer to Figure 8.
body (1) that secures access cover (8) and
remove. Remove gasket (9) from access cover As part of the daily walk around inspection and main-
(8). tenance, the air cleaner vacuator valve (7) is
checked and any dirt removed by squeezing the
3. Loosen and remove wing nut (7) and remove the vacuator valve.
primary element (16) carefully. Remove gasket
(4) as the element is being removed. Normal servicing of the lower body assembly (4)
should be done at intervals as recommended in the
NOTE: Remove the primary filter element (16) as Operators Manual.
carefully as possible. Accidentally bump-
ing it prior to removal can result in 1. Squeeze the dust collecting cup (7) to remove
dropped dirt and dust that may contami- any contaminates.
nate the clean side of your filter housing.
2. Light dust that is plugging tubes can be removed
4. Replace the primary filter element (16) if needed. with a stiff fiber brush. If heavy plugging with fi-
brous material is evident, remove lower body
section (4) for cleaning with compressed air or
water. Temperature of the water is not to ex-
NOTE: In order to keep machine downtime to a
ceed 71° C (160° F).
minimum, install a new or clean, primary
element. If the primary filter element is
to be serviced for immediate re-use, re- NOTE: Never clean tubes with compressed air
install the access cover (8) to protect the unless both primary (5) and safety filter
induction system while cleaning the elements (3) are installed in the air
element. cleaner. Do not steam-clean tubes.
W3-4-7
3. If a heavily plugged condition is encountered,

clean the body (4). The manufacturer recom-
mends cleaning the inside of the housing care-
fully. Use a clean, damp cloth to wipe every sur-
face clean. Check it visually to make sure it’s
clean before putting in new filters.
4. Always clean the gasket sealing surfaces of the

housing. Make sure that all hardened dirt ridges
are completely removed, both on the bottom and
top of the air cleaner.
Item Limit
System Integrity Test No leaking evident when system is pressurized with 34 kPa (5 psi)
clean air pressure and tested with soapy water solution.
W3-4-8
ENGINE / Radiator
REMOVE AND INSTALL RADIATOR
SERVICE POSITION
Before checking and/or servicing the rigid dump

truck, park the rigid dump truck on a level, solid sur-
face and put it in the “Service Position.” Refer to
Section W2-1.
CAUTION: Use extreme care when remov-

ing the radiator cap from the surge tank
(Figure 1) while the engine is hot. When
the engine is hot, the pressure in the ra-
diator may be sufficient to expel hot wa-
ter and steam if the radiator cap is sud-
denly removed. This can cause serious Figure 1
burns.
NOTE: When necessary to remove the radiator,

a hoist will be required to lift the radiator
from the rigid dump truck. The following
procedures for preparation to remove the
radiator should be used as a guide, since
they do not include the removal of any
optional equipment that may have been
installed. Cables, hoses, and wires that
have been removed from the radiator
should be tied away from the radiator so
as not to interfere with the removal. All
hose openings should be capped and all
openings on the radiator should be
plugged to keep dirt from entering.
REMOVAL Figure 2
1. Remove plugs at the bottom of the brake cooler,

transmission cooler and radiator. Drain coolant
into a suitable container for storage or disposal
per local regulations. Refer to Figure 2.
NOTE: The transmission cooler is located below

the radiator, and the brake cooler is lo-
cated behind the engine.
2. Remove battery cover and disconnect the battery

cables from the battery. Figure 3.
Figure 3
W3-5-1
ENGINE / Radiator
3. Remove bolts (1) that secure the center handrail

(2) to the hood, and to other hand rails (3). Use a 2 3
suitable crane to remove the center hand rail sec-
tion. Refer to Figure 4.
: 3/4 in
5. Disconnect and remove the horns to prevent

damage when removing the hood.
1
Figure 4
6. Remove bolts from the grille, remove the grille

sections and set them aside.
: 3/4 in
7. Remove the bolts (2, Figure 5) that secure the

hood to the frame of the hauler. Also remove the 2
bolts (3, Figure 5) that secure the hood to the
center deck.
: 11/8 in, 3/4 in
: 3/8 in
8. Locate lifting holes (1) in the hood and insert

eyebolts (3/4 -10 UNRC-2) (3 places). Refer to
Figure 5. Attach chains to the eyebolts and take
up the slack in the chains using a crane. Slowly 1
lift the hood free of the truck with the crane and
set aside. 2 3
Figure 5
CAUTION: Hood weight: 156 kg (343 Ib)
W3-5-2
ENGINE / Radiator
9. Disconnect the fluid level sensor and all the

hoses that run to the surge tank. Refer to Figure
6.
: 1/2, 1 1/8, 1 3/8 in
Figure 6
1
2
10. Remove the hose clamps from the radiator inlet

and outlet cooling tubes (1, 2, 3, 4, Figure 7) and
then remove the tubes from the ports. Control
contamination and limit entry of dirt by capping all
open ports.
: 7/16 in
3 4
Figure 7
11. Remove air conditioning hose mount clamps from

circumference of fan shroud. Tie back both the air
conditioning hoses and cab heater hoses with
elastic cord or cable. Refer to Figure 8.
Figure 8
W3-5-3
ENGINE / Radiator
Side
12. Remove the fan guard by removing the bolts from Mount
around the circumference of the fan shroud and
bolts on the fan guard. Remove all segments of
the fan guard (1) and alternator guard (2). Refer
1
to Figure 9.
: 9/16 in
2
Figure 9
13. Remove any clamps which may be holding wires
or hoses to the radiator or fan shroud.
14. Remove the radiator lower mount. Refer to Figure

10.
: 1 1/8 in
Figure 10
1
15. Remove bolts (1) that attach the head lamp
bracket to the side member. Place the headlamp
bracket assembly out of the way so that it is not
damaged during radiator removal. Repeat proc-
ess for the other head lamp. Reference Figure
11.
: 9/16 in
Figure 11
W3-5-4
ENGINE / Radiator
16. Unbolt the air conditioning condenser from the

front of the radiator and set it aside. It is not rec-
ommended to disconnect the lines if the con-
denser is supported properly. Discharge air condi-
tioner system if hoses are to be removed. Refer
to Figure 12.
: 9/16 in Air Baffles
17. Remove the air baffles from the front of the ra-
diator. Refer to Figure 12.
: 9/16 in
18. Drain the fuel system and remove the fuel

cooler. Refer to Figure 12.
: 1/2 in
19. Locate the 3 tapped holes in the lifting pads on

each side of the surge tank and insert 6 eyebolts
(1/2 -13UNC). Refer to Figure 13. Attach chains
to the eyebolts and take up the slack in the Condenser Fuel Cooler
chains.
Figure 12
20. Locate the radiator side mounts behind the air
baffles. Remove the nuts, bolts, washers and
mounting pads and set them aside. Refer to
Figure 9 for location of side mounts. Carefully lift
the radiator out of the rigid hauler.
: 1½ in
21. After the radiator has been lifted clear of the

hauler, place on a suitable stand. Be careful not
to get tangled in any wires or hoses while lifting.
Also avoid banging the radiator against the fan,
engine or any structure which could damage the
radiator or be damaged by the radiator. If it is a
concern, remove the fan from the engine.
CAUTION: Radiator weight: 1500 kg (3307

Ib)
22. Support radiator vertically on the floor during

storage to avoid damage.
NOTE: Protect radiator by installing caps and

Figure 13 – Lifting Pad
plugs into ports. Do not store where
temperature may drop below freezing.
Protect radiator core fins from impact
damage by covering with wood or metal
covers.
W3-5-5
ENGINE / Radiator
INSPECTION 3. Install the air conditioning condenser and the fuel

cooler. Refer to Figure 12.
1. Inspect all mounts for wear and cracks, replace or : 9/16 in
repair if necessary. Also check all brackets and : 36 N·m (26 Ibf·ft)
gussets for distortion, stress cracks, and broken : 1/2 in
frame welds. : 20 N·m (15 Ibf·ft)
2. Inspect cooling hoses and lines for cracks, brit- 4. Install the headlamp bracket assemblies. Refer to
tleness, and lack of flexibility. Replace as needed. Figure 11.
: 9/16 in
3. Inspect radiator core for large areas of bent or : 50 N·m (37 Ibf·ft)
damaged fins, straighten fins as needed.
5. Install the radiator lower mount. Refer to Figure
4. Inspect radiator core for leakage. 10.
: 1 1/8 in
5. Inspect radiator tanks for internal corrosion and : 307 N·m (226 Ibf·ft)
scale.
6. Inspect coolant by pH test. Contact your engine 6. Install the fan shroud, fan ring and fan guard. Re-
manufacturer’s representative to acquire a pH fer to Figure 9.
testing kit. : 9/16 in
: 36 N·m (26 Ibf·ft)
7. Pressure test radiator to 0.17 MPa (25 psi) and
verify no leakage before installation. 7. Attach the air conditioning and heater hose
mountings to the fan shroud. Refer to Figure 8.
INSTALLATION
8. Install the cooling tubes on to the appropriate ra-
NOTE: All brackets and clamps must be relo- diator inlet/outlet ports. Attach the hose clamps
cated in their original position. All coolant to the tubes and tighten. Refer to Figure 7.
and hydraulic oil drained must be put : 7/16 in
back into respective systems or replaced. : 10 N·m (90 Ibf·in)
After completion check all systems and
make sure the work area is cleared of all 9. Install the fluid level sensor and all the vent lines
tools and obstructions. on the back of the surge tank. Refer to Figure 6.
: 1/2 in
1. Using a crane, hoist the radiator into position on : 15 - 16 N·m (135 - 145 Ibf·in)
to the frame. Fasten the radiator in place with the : 1 1/8 in
side mounts. Refer to Figure 9 for side mount lo- : 97 - 107 N·m (71 - 79 Ibf·ft)
cation. : 1 3/8 in
: 1 1/2 in : 129 - 142 N·m (95 - 105 Ibf·ft)
: 742N·m (547 Ibf·ft)
10. Using a crane, position the hood on to the rigid
hauler and install the bolts to secure it to the
CAUTION: Radiator weight: 1500 kg (3307
frame. Also install the bolts that attach it to the
Ib)
center deck. Refer to Figure 5.
: 1 1/8 in
2. Install the air baffles on the front and bottom of the : 433 N·m (319 Ibf·ft)
radiator. Refer to Figure 12. : 3/8 in
: 9/16 in : 173 N·m (128 Ibf·ft)
: 50 N·m (37 Ibf·ft)
CAUTION: Hood weight: 156 kg (343 Ib)
W3-5-6
ENGINE / Radiator
11. Install and connect the horns.

14. Connect the battery cables to the battery and se-
12. Install the grille. cure the battery cover. Refer to Figure 3.
: 3/4 in
: 123 N·m (90 Ibf·ft) NOTE: Verify that all of the drain plugs that were
removed previously are secure and tight
13. Using a crane, position the center handrail section before filling the anti-freeze. Refer to Fig-
over the hood. Install the bolts that secure the ure 2 for the locations of the drain plugs.
handrail to the hood. Refer to Figure 4.
: 3/4 in 15. Fill the radiator with pre-mix anti-freeze coolant.
: 123 N·m (90 Ibf·ft)
W3-5-7
ENGINE / Radiator
Time
Component Notes
Interval
Inspect and test SCA, follow engine manufacturer’s recom-
Coolant 6 months
mendations.
Inspect for leakage, cracks, or deterioration of rubber material,
Hoses and Tubes 1 yr
replace as required.
Mounts/Brackets/Gussets 1 yr Inspect, repair or replace if damaged, or as required.
Coolant 3 yr/6000 hr Drain and flush cooling system.
Check torque, inspect for excessive corrosion, replace as re-
Clamps As Required
quired.
Radiator Core As Required Clean and inspect, straighten bent fins, paint as required.
Maximum of 10% of cooling tubes may be clogged or sealed
Radiator Tubes As Required
closed.
W3-5-8
SECTION 4
ELECTRICAL AND INSTRUMENTS
—CONTENTS—
Group 1 Starter Mounting

Removal...................................................... W4-1-1
Installation................................................... W4-1-2
Disassembly................................................ W4-1-2
Inspection.................................................... W4-1-2
Assembly .................................................... W4-1-2
Memo .......................................................... W4-1-4
Group 2 Transmission Shift Control

Removal...................................................... W4-2-1
Installation................................................... W4-2-2
Disassembly, Inspection, and Assembly..... W4-2-2
Group 3 Accelerator Controls

Removal/ Disassembly ............................... W4-3-1
Installation................................................... W4-3-2
Inspection.................................................... W4-3-3
Assembly .................................................... W4-3-3
Memo .......................................................... W4-3-4
W4-0
<BLANK>
W4-0
ELECTRICAL AND INSTRUMENTS / Starter Mounting
4
3
2
5
1
EL16758
Figure 1 – Starter Motor
1. Battery Terminal 4. Motor Terminal (M)

2. Ground Terminal (G)Solenoid 5. Switch Terminal (S)
3. Ground Terminal (G1)
SERVICE POSITION shock occurring through whatever tool may

be in use. This can result in injury. Isolation
Before checking and/or servicing the rigid dump truck, of the start circuit can most easily be done at
park the rigid dump truck on a level solid surface and the batteries by disconnecting the ground
put it in the “Service Position.” Refer to Section W2-1. cable from the NEGATIVE BATTERY TERMI-
NAL.
NOTE: The rigid hauler comes with 2 starter mo-
tors. In addition to the wiring shown in Fig- 2. Remove electrical connections from the ground,
ure 1, there are jumper connections be- switch, and battery terminals of the starter. Refer
tween the two motors on terminals 1, 2 and to Figure 1.
5. Also note the two motors are wired : 3/8 in
identically. : 3/4 in
REMOVAL
CAUTION: Starter weight: 36 kg (80Ib)
1. Disconnect batteries.
: 1/2 in 3. Remove capscrews which attach starter to en-
gine.
: 5/8 in
CAUTION: Before attempting to do any work
on the starter itself, be sure the electrical cir- 4. Remove starter from engine.
cuit from the batteries is disconnected. If this
is not done, there is danger of electrical
W4-1-1
INSTALLATION the engine. Engine should rotate only when the

transmission shift selector is in Neutral (N) range.
1. Inspect flywheel ring gear teeth. Replace if teeth
are broken or show excessive wear. INSPECTION
2. Install starting motor and capscrews. 1. Inspect starter pinion teeth for excessive wear,
5
: /8 in broken or chipped teeth.
: 244 N·m (180 Ibf·ft) 2. Inspect starter housing for evidence of excessive
corrosion, water damage or oil contamination.
3. Install electrical connections to ground, switch,
and battery terminals of starter. Refer to Figure 3. Check armature for freedom of rotation.
1.
: 3/8 in 4. Check pinion drive for excess radial movement.
: 1.8 – 3.4 N·m (1.3 – 2.5 Ibf·ft)
: 3/4 in
ASSEMBLY
: 27 - 34 N·m (19.9 – 25.1 Ibf·ft)
Starter is not a serviceable part. Replace starter as an
4. Connect batteries. assembly.
: 1/2 in
DISASSEMBLY
5. Confirm starter operation. Engine should start
normally. Inspect neutral start circuit by first Starter is not a serviceable part.
stopping engine (engine off). Place transmission
shift selector in drive position (D) and try to start
Pull-in Coil Resistance “S” Terminal to “M” Terminal

0.094 – 0.124 ohms at 20 oC (68 oF)
Pull-in Voltage “S” Terminal to “M” Terminal
16V maximum
Hold-in Coil Resistance “S” Terminal to “G1” Terminal
1.483 - 1.707 ohms at 20 oC (68 oF)
Hold-in Voltage “S” Terminal to “G1” Terminal
8V maximum
Insulation Test Must be ≥ 200 M ohm when 500 VAC is applied between “S” terminal and case
with megger
Free Speed Station Tests Apply 24 volts to battery terminal and verify the solenoid contacts are open be-
tween the battery and motor terminals
With 24 volts applied to the battery and switch terminals, free speed the motor for
4 seconds and measure the following parameters:
Check Limit
Pinion Free Speed 4600 - 6500 Min-1(rpm)
Free Speed Current at “M” terminal 70-160 amps
W4-1-2
Figure 2 – Starter Motor Wiring
W4-1-3
MEMO
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W4-1-4
ELECTRICAL AND INSTRUMENTS / Transmission Shift Control
1
2
3
10
6 4
5
11 12 15 13 16 14
8
9
TRANSMISSION
EL 20617
Figure 1 – Transmission Control Unit with Vehicle Electrical Center
1. Shift Selector 6. Transmission Control Unit (TCU) 11. Main Valve Body
2. Screws (4x) 7. Vehicle Electrical Center (VEC) 12. Trim Boost Valve Body
3. Shift Tower 8. To Central Control Unit (CCU) and 13. Lockup Port Valve Body
Engine Control Unit (ECU)
4. Cab Harness (S) 9. Secondary Harness (V) 14. Output Speed Sensor
5. Diagnostic Data Reader
(DDR) Connector 10. Chassis Harness (T) 15. Input Speed Sensor
16. Turbine Speed Sensor
SERVICE POSITION
1. Disconnect the batteries.
park the rigid dump truck on a level solid surface and 2. Remove the four screws (2) that secure the shift
put it in the “Service Position.” Refer to section W2-1. selector (1) to the center console.
REMOVAL 3. Lift the shift selector (1) and disconnect the wire
harness (4) from its base, and then remove the
Removal of Shift Selector shift selector (1).
Numbers in parentheses refer to Figures 1 and 2.
W4-2-1
ELECTRICAL AND INSTRUMENTS / Transmission Shift Control
Removal of Transmission Control Unit (TCU)
1. Loosen the four capscrews that hold the rear

cover panel that covers the electrical compartment,
and then remove the cover. Refer to Figure 2.
2. Locate the transmission TCU (6), behind the op-

erator’s seat. Refer to Figure 3.
3. Disconnect the 3 wire harness connectors from

the TCU.
4. Remove the 3 screws (1) holding the TCU (6), and

then remove the TCU. Refer to Figure 3. Cover removed
Figure 2 exposing electrical
components
INSTALLATION
1. Reinstall all items in the reverse order of their

removal.
2. Perform operational inspection of transmission.
NOTE: Replacement TCU’s are pre-programmed.
DISASSEMBLY, INSPECTION, AND

ASSEMBLY
Refer to Allison “5000, 6000, 8000, 9000 Series Trans-

missions Commercial Electronic Controls 2 (CEC2)” 1
Manual TS3353EN for a description and explanation of
the electronic shift control, operation, disassembly, in-
spection and reassembly. Refer to Section 1.
6
Figure 3
W4-2-2
ELECTRICAL AND INSTRUMENTS / Accelerator Controls
Pin Description
(A) – WHITE – APS Ground
(B) – BLACK – APS Signal
(C) – RED – APS Supply (5V)
(APS – Accelerator Position Sensor)
EL 20621
Figure 1
SERVICE POSITION

park it on a level solid surface and put it in the “Service
Position.” Refer to Section W2-1.
REMOVAL / DISASSEMBLY
1. Disconnect the accelerator’s electrical connector.

Refer to Figure 1.
: 7/16 in
EL 20624
2. Remove the 2 bolts that attach the pedal to the Figure 2

mounting plate. Refer to Figure 3.
: 1/2 in
W4-3-1
INSTALLATION
Install the pedal in the reverse order of removal.
Tightening Torque
Tool Size
(kgf. Remarks
(in) N.m Ibf.ft
m)
1
: /2 28 (2.8) 21 Bolt
INSPECTION
1. Inspect all mounting hardware for stripped threads

or other damage, and replace as required.
2. Inspect the electrical connector for cracks, breaks,

or deterioration. Replace if necessary.
W4-3-2
ASSEMBLY
1. Connect the accelerator pedal’s harness.
2. Attach the pedal to the pedal mounting plate using

2 bolts.
: 1/2 in
EL 20625
Figure 3
NOTE: Remember to clamp the wire back on to

the pedal mounting plate as shown in
Figures 2 and 3.
APS, PIN A TO PIN C 2000 – 3000 Ω RESISTANCE
PEDAL RELEASED AND DEPRESSED
(LOW IDLE) & (MAXIMUM THROTTLE)
APS, PIN A TO PIN B 1500 – 3000 Ω RESISTANCE
PEDAL RELEASED
(LOW IDLE)
APS, PIN A TO PIN B 200 – 1500 Ω RESISTANCE
PEDAL DEPRESSED VALUE MUST BE 1000 Ω
(MAXIMUM THROTTLE) LOWER THAN PEDAL RELEASED READING
Ω = ohms
* = Voltage must be removed from circuit when resis- NOTE: Disconnect wire harness at APS and take
tance checks are made. measurements directly from APS. Refer to
Service Bulletin 2710 - 03.
W4-3-3
MEMO
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W4-3-4
SECTION 5
POWER TRANSMISSION
—CONTENTS—
Group 1 Transmission Oil Lines Group 4 Front Driveline

Removal ...................................................... W5-1-2 Removal ...................................................... W5-4-1
Installation ................................................... W5-1-2 Installation ................................................... W5-4-4
Disassembly................................................ W5-1-2 Disassembly................................................ W5-4-5
Inspection.................................................... W5-1-3 • Inspection Prior to Disassembly..... W5-4-5
Assembly..................................................... W5-1-3 • Disassembly .................................. W5-4-6
Maintenance Standard ................................ W5-1-3 Inspection.................................................... W5-4-6
Memo .......................................................... W5-1-4 Assembly..................................................... W5-4-7
Maintenance Standard ................................ W5-4-8
Group 2 Transmission Mounting
Service Position .......................................... W5-2-1 Group 5 Rear Driveline
Removal ...................................................... W5-2-1 Service Position .......................................... W5-5-2
Installation ................................................... W5-2-7 Removal ...................................................... W5-5-2
Disassembly................................................ W5-2-8 Inspection after Removal ............................ W5-5-2
Inspection.................................................... W5-2-8 Universal Joint Kit Removal ........................ W5-5-3
Assembly..................................................... W5-2-8 Inspection.................................................... W5-5-3
Maintenance Standard ................................ W5-2-8 Universal Joint Kit Installation ..................... W5-5-3
Installation/Run-Out Inspection................... W5-5-5
Group 3 Power Take Off Maintenance................................................ W5-5-5
Service Position .......................................... W5-3-1 Memo .......................................................... W5-5-6
Removal ...................................................... W5-3-3
Installation ................................................... W5-3-3
Disassembly................................................ W5-3-7
Inspection.................................................... W5-3-7
Assembly..................................................... W5-3-7
Memo ........................................................ W5-3-10
W5-0
<BLANK>
W5-0
Group 6 Rear Axle Group 8 Planetary
Service Position ......................................... W5-6-2 Service Position .......................................... W5-8-1
Removal-Axle Shaft .................................... W5-6-2 Removal ...................................................... W5-8-1
Disassembly-Axle Shaft .............................. W5-6-3 Disassembly................................................ W5-8-4
Inspection-Axle Shaft .................................. W5-6-3 Inspection.................................................... W5-8-6
Assembly-Axle Shaft ................................... W5-6-3 Assembly..................................................... W5-8-7
Installation-Axle Shaft ................................. W5-6-3 Installation ................................................... W5-8-8
Checking Axle Shaft Endplay ..................... W5-6-4 Maintenance Standard ................................ W5-8-9
Service Position .......................................... W5-6-7 Memo ........................................................ W5-8-10
Removal-Rear Axle ..................................... W5-6-7
Disassembly-Spindle from Axle Housing .... W5-6-9
Inspection-Axle Housing ........................... W5-6-10
Assembly-Spindle to Axle Housing ........... W5-6-11
Installation-Rear Axle Housing.................. W5-6-12
Memo ........................................................ W5-6-14
Group 7 Differential
Removal ...................................................... W5-7-2
Disassembly................................................ W5-7-3
Inspection.................................................... W5-7-6
Assembly..................................................... W5-7-6
• Drive Pinion.................................... W5-7-8
• Body ............................................. W5-7-12
Tooth Contact Patterns ............................. W5-7-16
Installation ................................................. W5-7-18
Differential Assembly Worksheet .............. W5-7-24
Torque Specifications ................................ W5-7-25
Memo ........................................................ W5-7-26
W5-0
<BLANK>
W5-0
POWER TRANSMISSION / Transmission Oil Lines
5
4 9
11
14
14
6 8
7 3
2
1
13 12 10
Figure 1. Transmission Radiator Lines and Mounting
1. Transmission 8. Tube Assembly, Cooler to Transmission

2. Hose Assembly, Transmission to Strainer 9. Hose Assembly, Transmission to Filter
3. Tube Assembly, Transmission to Strainer 10. Filter
4. Strainer 11. Hose Assembly, Filter to Transmission
5. Hose Assembly, Strainer to Cooler 12. Filler Hose
6. Transmission Cooler 13. Filler Cap
7. Hose Assembly, Cooler to Transmission 14. Oil Drain Plug
W5-1-1
SERVICE POSITION

park the rigid dump truck on a level solid surface and
REMOVAL INSTALLATION
1. Thoroughly clean the hoses to be removed. 1. Make sure that hose assemblies are clean.
2. Remove the transmission drain plug and drain the 2. Install hose assemblies, using torques given in
oil from the transmission into a suitable container. Section W1-2.
: 1 1/2 in
NOTE: When installing hose assemblies, apply
wrench at end connectors only. Do not twist
hoses.
NOTE: Do not use Teflon® tape. Loose slivers of

tape can plug orifices, cause valves to stick,
or interfere with check ball operation. An-
aerobic sealant may be used on threaded
connections.
Drain Plug 3. Reinstall supporting clamps.
4. Be sure the transmission drain plug and transmis-

sion cooler drain plugs have been installed and fill
Strainer
the transmission with the prescribed oil. Refer to
Figure 2 Section W2-2.
3. Remove the plugs (14, Figure 1) from the bottom of 5. Run the engine and check the lines for leaks.
the transmission cooler and drain the oil from the Check the transmission oil pressure level and
transmission cooler into a suitable container. converter temperature.
4. Label all hose assemblies to facilitate installation. 6. Perform operational check of hauler power trans-
mission system. Inspect and verify proper opera-
5. Remove supporting clamps, and then remove hose tion and satisfactory shift quality.
assemblies.
NOTE: When removing hose assemblies, apply DISASSEMBLY

wrench at end connectors only. Do not twist
hoses. 1. For hose assemblies with field-attachable end fit-
tings, refer to manufacturer’s instructions for dis-
6. Cap all hose openings and plug all openings on assembly.
transmission to prevent dirt from entering.
W5-1-2
INSPECTION
1. Inspect all hose assemblies for cracks or deteriora-

tion, and replace if necessary.
2. Inspect all tubes for cracks, bends, or other dam-

age, and replace if necessary.
3. Inspect fittings for wear or other damage, and re-

place as required.
4. Replace all O-rings with new ones before recon-

necting.
5. Inspect all attaching hardware for stripped threads

or other damage. Replace if damaged.
6. It is important that the strainer (4, Figure 1) located

in the line from the transmission to the transmission
cooler should be cleaned periodically and always
checked after a transmission failure to prevent a
build-up of contaminants. Lack of proper mainte-
nance can cause transmission damage.
ASSEMBLY
1. For hose assemblies with field-attachable end fit-

tings, refer to manufacturer’s instructions for as-
sembly.
Recommended replace
every 2 years and at
Transmission Hoses
transmission overhaul.
Refer to section W1-2.
Radiator, Pressure
690 kPa (100 psi)
Check
Zero Glycol contamination
allowed. Refer to current
Transmission
HTM service bulletin on
Fluid Analysis
Fluid Analysis Recom-
mendations.
Replace suspect hose
immediately if connection
Transmission Hoses
is wet or noticeable leak-
age is present.
W5-1-3
MEMO
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W5-1-4
POWER TRANSMISSION / Transmission Mounting
6
4
1 5
3
EL 20628
2
Figure 1
1. Electric Control Valve Body 4. Main Pressure Hose

2. Power Take-Off Mount Flange Cover 5. Input Charging & Scavenge Oil Pump
3. Lockup Valve 6. Breather Protective Cap
SERVICE POSITION
Special tooling needed is the transmission lifting fix-
Before checking and/or servicing the rigid dump truck, ture. Refer to Section W2-4, SPECIAL TOOLS.
put it in the “Service Position.” Refer to Section W2–1. Depending on the type of hoist available to remove the
transmission, the hauler body may have to be re-
REMOVAL moved for crane access. If the body is to be removed,
refer to Section W10-6, BODY AND MOUNTING.
The following procedures for preparation to remove
the transmission should be used as a guide, since NOTE: When towing or pushing vehicle with an
they do not include the removal of any additional op- automatic transmission, the transmission
tional equipment that may have been installed on your output shaft must be disconnected regard-
rigid dump truck. Cables, hoses, and wires that have less of distance or speed traveled. Trans-
been removed from the transmission should be la- mission damage may occur because
beled and tied away from the transmission so as not to transmission oil pressure for bearing lubri-
interfere with the removal. All hose openings should cation is available only when engine is run-
be capped and all openings on the transmission ning and transmission input shaft is rotat-
should be plugged to keep dirt from entering. ing.
NOTE: A hoist and suitable rigging rated to lift a

transmission of 1848 kg (4075 lb) will be
needed for this procedure.
W5-2-1
Figure 2
1. Transmission 8. Bolt (6x)

2. Front Mount 9. Lock Nut (6x)
3. Bracket 10. Washer (6x)
4. Rear Mount 11. Mount (12x)
5. Rear Mount 12. Washer (4x)
6. Washer (10x) 13. Lock Nut (4x)
7. Screw (4x) 14. Bolt (10x)
W5-2-2
Numbers in parentheses refer to Figure 4, unless oth-

erwise noted
1. Hoist body to raised position; install body prop

cable to secure. Refer to section W2-1.
2. Thoroughly clean the transmission, power

take-off, and attaching hoses.
3. Remove the transmission drain plug and drain Strainer

the oil from the transmission into a suitable con-
tainer.
: 1 1/4 in Drain Plug
Figure 3
4. Remove hose assemblies with all necessary el-
12
bows and connectors. Install caps into all open
ports of transmission and chassis hoses to avoid
entry of dirt and contamination.
5. Disconnect the oil cooler inlet hose assembly

(11) and outlet hose assembly (10) from the el- 15
bows at the left side of the transmission. Dis-
connect transmission filter hose assemblies (12)
from the elbows at the top of the transmission at
the main regulator valve.
: 9/16 in
16
6. Disconnect the power take-off lubrication hose
assembly (13) from the elbow at the side of the 11 13 10
14
transmission. Cap the hose and plug the elbow
to prevent the entrance of dirt. Remove the two
clamps (14) securing hose assembly (13) to the Figure 4
transmission.
: 3/4, 11/16 in 10. Hose Assembly to Cooler 14. Clamp
11. Hose Assembly from Cooler 15. Power Take-Off Assembly
12. Filter Hose Assembly 16. Transmission Fill Hose
CAUTION: PTO, Hoist Pump, Steer Pump 13. Lubrication Hose Assembly
Combined Weight: 163 kg (360 Ib)
7. Drain the hydraulic tank and remove the suction

and pressure lines from the steer pump and the
hoist/brake cooling pump. Refer to the Mainte-
nance section in the Operator’s Manual
(EM8R6-1-2) for instructions on draining the hy-
draulic tank.
: 3/4, 9/16 in
15
18
Hoist/Brake EL 20632
19 Steer
Cooling Pump
Pump
Figure 5
W5-2-3
8. Support the power take-off (15, Figure 5), hoist

and steer pumps. Remove the bolts (18, Figure
5) and washers (19, Figure 5) that attach the
PTO to the transmission. Support the PTO,
hoist pump, and steer pump away from the
transmission. Clean and inspect PTO housing
and gears. Cover the opening on the PTO to Fill
prevent entrance of dirt. Cover the PTO opening Hose
at the transmission to prevent entrance of dirt.
: 5/8 in socket
EL 20633
Figure 6 - Transmission Fill Hose
9. Remove the fill hose (16, Figure 4) from the el-

bow. Plug the elbow and cap the hose to prevent
the entrance of dirt. Refer to Figure 6.
: 2 in
10. Disconnect all of the electrical connections from

the transmission: output speed sensor
(OUT-SP), turbine speed sensor (TUR-SP),
transmission fluid pressure sensor (TM-PR),
lockup clutch connector (LOCK), transmission
temperature sensor (TM-TEMP), trim boost
connector (TRIM), transmission connector
(TRANS) and the engine speed sensor
(ENG-SP). Refer to Figure 7.
EL20634
Figure 7
11. Remove the engine exhaust tubes to gain ac-

cess to the area over the transmission. Refer
to section W3-3 for instructions on removing the
exhaust tubes.
12. Install the transmission lifting fixture on the

transmission body. Place the crane hook into
the clevis and apply slight hoist pressure to the
chain. EL 20635
: 15/16 in Figure 8 - Install Lifting Fixture
W5-2-4
13. Remove the front driveline from the transmis- 24

sion. See Section W5-4, FRONT DRIVELINE.
Remove the rear driveline from the transmission. EL 20628
See Section W5-5, REAR DRIVELINE.

Figure 9 - Standard Transmission H8610A
14. Loosen and remove the bolts (8, Figure 2),

nuts (9, Figure 2), and washers (10, Figure 2)
from the front transmission mount assembly (2,
Figure 2) and frame brackets. Refer to Figure
12.
: 1½ in
EL 20636
Figure 10 - Optional Transmission H9610A
W5-2-5
15. Loosen and remove the bolts (8, Figure 2), nuts
(9, Figure 2), and washers (10, Figure 2) from
the rear transmission bracket assemblies (4, 5,
Figure 2). Refer to Figure 13.
: 1½ in
CAUTION: Transmission and mounting

assembly weight: 1848 kg (4075 lb)
16. Loosen and remove the bolts (14, Figure 2) and

washers (6, Figure 2) that attach bracket assem- Figure 11 - Front Transmission Mount
blies (4, 5, Figure 2) to the transmission.
: 15/16 in
17. Remove bracket (3, Figure 2) and mount assem-

bly (2, Figure 2) from the front of the transmis-
sion.
: 3/4 in
18. Carefully lower the transmission out the bottom of

the frame on to a suitable stand or cart that can
be used to slide the transmission out from under
19. Refer to Allison Service Manual SM1228EN (for

the H8610A) or SM1833EN (for the H9610A) for
EL20638
instructions on input flange removal. Figure 12 - Rear Transmission Mount
20. Move the transmission to a clean work area for

further disassembly.
W5-2-6
INSTALLATION 11. Remove the protective plug from the connection

for the transmission filler hose. Install the trans-
1. Install front mounting bracket (2, Figure 2) and mission filler hose.
bracket (3, Figure 2) on to the transmission. : 2 in
: 172 N·m (127 Ibf·ft)
CAUTION: Front mounting bracket weight:
12. Secure the PTO lubrication hose assembly (13,
74 kg (163 lb) Figure 4) to the transmission with two clamps (14,
Figure 4). Remove the cap from lubrication hose
2. Refer to Allison Service Manual SM1228EN (for assembly (13, Figure 4) and the plug from the el-
the H8610A) or SM1833EN (for the H9610A) for bow it connects to at the side of the transmission
instructions on input flange installation. and install.
: 11/16 in
3. Install the rear mounting bracket (4, Figure 2) : 15 N·m (135 Ibf·in) (lubrication hose)
with the PTO and pumps on to the transmission. : 3/4 in
Replace the mounting hardware every 5 years or : 172 N·m (127 Ibf·ft) (hose clamps)
at transmission overhaul.
: 15/16 in
13. Remove the protective caps from the transmis-
: 244 N·m (180 Ibf·ft)
sion filter hose assemblies (12, Figure 4). Re-
move the protective plugs from the elbows that
4. Install the transmission in the reverse order of
the main regulator valve filter hose assemblies
removal. Install the other rear mounting bracket
(12, Figure 4) connect to and install.
(5, Figure 2) once the transmission is in position
: 2 in
on the frame. Tighten bolts (8, Figure 2) to torque
: 172 N·m (127 Ibf·ft)
specified.
: 1½ in
14. Remove the caps from hose assemblies leading
: 1232 N·m (909 Ibf·ft)
to and from the oil cooler (10 and 11, Figure 4).
Remove the plugs on the side of the transmission
CAUTION: Transmission and mounting these hoses connect to and install.
assembly weight: 1848 kg (4075 lb) : 5/8 in
: 68 - 75 N·m (50 - 55 Ibf·ft)
5. Install the front driveline to the transmission. See
Section W5-4, FRONT DRIVELINE. Install the 15. Be sure the transmission drain plug has been in-
rear driveline to the transmission. See Section stalled and fill the transmission with the pre-
W5-5, REAR DRIVELINE. scribed oil. See section W2-2 Maintenance.
6. Remove the transmission lifting fixture. Refer to 16. Install the engine exhaust pipes. Refer to section
Figure 8. W3-3 for more information.
: 15/16 in
17. Install the suction and pressure hoses to the
7. Connect the output speed sensor (OUT-SP), tur- pumps.
bine speed sensor (TUR-SP), transmission fluid : 3/4
pressure sensor (TM-PR), lockup clutch connec- : 102 - 108 N·m (75 - 80 Ibf·ft)
tor (LOCK), transmission temperature sensor : 9/16 in
(TM-TEMP), trim boost connector (TRIM), trans- : 102 - 108 N·m (75 - 80 Ibf·ft)
mission connector (TRANS) and the engine
speed sensor (ENG-SP). Refer to Figure 7. 18. Fill the hydraulic tank. Refer to the Maintenance
section in the Operator’s Manual (EM8R6-1-3) for
10. Install the power take-off (PTO) (15, Figure 5) instructions on draining the hydraulic tank.
check or adjust the backlash as required. Refer
to Section W5-3, POWER TAKE-OFF. 19. Bleed the steering pump and the hoist/brake
cooling pump. Refer to the applicable sections
for more information.
W5-2-7
20. Run the engine and check the lines for leaks.
Check the transmission oil pressure and con-
verter temperature using the Hitachi Controller
Tool Software. Refer to the appropriate stan-
dard for information on this reader.
21. Perform operational check of hauler power

transmission system. Inspect and verify proper
operation and satisfactory shift quality.
22. Record start up date, transmission serial number,

hour meter reading.
23. After one shift of operation, take an initial oil

analysis test sample.
NOTE: Oil sample results may be used as base-

line for comparison of future oil samples.
DISASSEMBLY
Refer to Allison Service Manual SM1228EN (for the

H8610A) or SM1833EN (for the H9610A) for trans-
mission disassembly procedure.
INSPECTION
1. Inspect the front mount assembly (2, Figure 2)

and rear bracket assemblies (5, Figure 2) for dis-
tortion or cracks. Replace, if necessary.
2. Inspect the rubber mounts (11, Figure 2) for de-

terioration and wear. Replace with new parts, if
necessary.

mission inspection procedure.
ASSEMBLY

mission assembly procedure.
Criteria Limit
Transmission Mounts At time of transmission overhaul or every 5 yrs.
Hoses Refer to Section W5-1
W5-2-8
POWER TRANSMISSION / Power Take Off
2
1
EL 20640
Figure 1
1. Power Take Off 3. Transmission

2. Hoist Pump Mount Flange 4. Steer Pump Mount Flange
SERVICE POSITION

put it in the “Service Position.” Refer to section W2-1
W5-3-1
EL 20641
2
5
3 9
7
10 6
8
Figure 2
1. Adapter 6. Hose Assembly

2. Tee 7. Shim
3. Elbow 8. Shim
4. Plug 9. Bolt (8x)
5. Hose Assembly 10. Washer (8x)
W5-3-2
REMOVAL INSTALLATION
Numbers in parentheses refer to Figure 2. The gear backlash between the transmission output
gear and the power take off input gear is shim ad-
1. Drain both sumps of the combination hydraulic justed during assembly using shims (7, 8) between
tank of both the steering and hoist system fluid. the transmission flange and the power take off.
2. Remove steering pump from front side of power Numbers in parentheses refer to Figure 2 unless
take off. Refer to section W7-5. otherwise noted.
3. Remove hoist pump from rear of power take off. 1. Clamp driveline input yoke of transmission tight
Refer to Section W10-5. so it cannot rotate. This can be done by using
adjustable clamps or a fabricated bracket bolted
4. Drain transmission fluid. Refer to Section W5-1. between the yoke and transmission front hous-
ing.
5. Remove hose assemblies (5, 6) and fittings (1, 2,
and 3) from power take off housing. 2. Use a dial indicator inside the power take off
: 1 in mounting flange on side of transmission to
measure the backlash of the transmission output
gear. See Figure 3. The measurement must be
6. Loosen, do not remove, bolts (9) and break loose taken from center flank of the tooth. Dial indicator
seal between power take off and transmission movement must be perpendicular to tooth sur-
housing. face. Record measurement on line L1 of chart.
: 5/8 in
3. Assemble stack of trial shims (7, 8) that are ap-
proximately .050 inches thick. Record measure-
CAUTION: Power take off weight: 71 kg (157 ment on line L2 of chart.
lb).
4. Hoist power take off (1, Figure 1) into place on
7. Support power take off, remove bolts (9), washers transmission flange (3, Figure 1) using the trial
(10). Slide unit out carefully to separate gear shims selected in previous step between the
mesh. Shims (7, 8) may be used again if not mount flanges. Install bolts (9) and washers (10).
damaged during removal. : 5/8 in
8. Inspect the transmission output gear. If gear is Numbers in parentheses refer to Figure 5 unless
damaged, repair transmission. otherwise noted.
9. To control contamination and dirt entry over time, 5. Slowly tighten bolts (9, Figure 2) to recom-
seal all open ports. Close all open disconnected mended torque value while checking for clear-
hoses left in chassis by installing cap plugs. Cover ance between gears through plug (15, Figure 6).
and seal power take off mounting flange on trans- If gears bind tightly together, stop tightening bolts
mission. and inspect for cause.
6. Measure the system backlash with a dial indica-

tor through the hole of plug (11) and record on
line L3 of chart. See Figure 4.
7. The backlash between the transmission output

gear and idler pinion (2) inside the power take off
is equal to the system backlash minus the back-
lash measured at the transmission output gear.
Compute Line L4.
W5-3-3
8. If L4 measurement is equal to value L5 of chart,

then shim thickness selection is correct. If L4
measurement does not equal L5, change shim-
stack thickness following instruction in lines L6
and L7 of chart.
9. At final installation of power take off use the

proper thickness shim stack (7, 8, Figure 2),
coating both sides of shims with red gasket elimi-
nator.
10. Secure power take off using bolts (9, Figure 2).
Tighten bolts to standard torque.
: 5/8 in
: 52 - 68 N·m (32 – 50 Ibf·ft)
11. Connect all hydraulic lines removed.
12. Install hoist pump. Refer to Section W10-5.
13. Install steer pump. Refer to Section W7-5.
14. Replace all drained fluids.
15. Bleed air from pump inlet lines.
W5-3-4
EL 20642 EL 20643
Figure 3 Output Gear Lash Figure 4 System Backlash
BACKLASH MEASUREMENT AND SHIM PACK THICKNESS SELECTION

MEASUREMENT
LINE DESCRIPTION METRIC ENGLISH NOTES
L1 Transmission output gear Lock transmission input yoke, record
Trial shim pack is 0.050 (+0.003 / -0),
L2 Shim pack thickness record thickness
L3 System assembly backlash Record
L4 Power take off backlash Backlash = LINE (L3 – L1)
Final assembly specification with red
+ 0.25 + 0.010 gasket eliminator applied on shims,
Specification, Power Take
0.51mm ________ .020 in ________ PTO installed and cap screws tight-
L5 Off Backlash
- 0.13 - 0.005 ened to torque specification.
Remove shim from L2 and retest
L6 L4 is greater than (>) 0.635mm .025in
backlash
Add shim to L2 stack and retest back-
L7 L4 is less than (<) 0.381mm .015in
lash
NOTE: “Gasket Eliminator” can add 0 to 0.005 mm (0 to 0.002 in) to thickness of shim pack.
W5-3-5
Figure 5 – Exploded View of Power Take-Off Assembly
1. Plug 11. Bearing 21. Orfice

2. Bolt 12. Bearing 22. Snap Ring
3. Washer 13. Hose Assembly 23. Output Shaft
4. Housing 14. Clip 24. Bearing
5. Shims 15. Elbow 25. Snap Ring
6. Idler Shaft 16. Plug 26. Spacer
7. O-Ring 17. Retainer Ring 27. Spacer
8. Washer 18. Hose Assembly 28. Bolt
9. Driven Gear 19. Tee 29. Plate
10. Idler Gear 20. O-Ring 30. Shims
W5-3-6
DISASSEMBLY
1. Remove plug (16) from housing (4).

4. Check the idler shaft (6) and output shaft (23) for
2. Remove bolt (28), from the end of the idler shaft (6). cracks, warpage, or excessive wear, and replace if
Remove plate (29) and shims (30). Drive the idler necessary. Be sure to inspect both the internal and
shaft (6), and the O-rings (7 and 20) from the hous- external splines of the output shaft (23).
ing (4). Remove and discard the O-rings (7 and 20)
from the idler shaft (6). NOTE: The threaded hole in the end of idler shaft (6)
should accept bolt (28) with a finger torque.
3. Remove the idler gear (10) and bearings (11) from
the housing (4) as an assembly. Remove washer 5. Inspect the bearings (11, 12 and 24) to make sure
(8). Remove the inner races in bearings (11) from they are not binding or excessively worn. Replace
the idler gear (10). Remove the spacer (26) and them if necessary.
harden washer (8) from inside the housing (4).
6. Inspect the ends of the spacers (26 and 27) for
4. Drive the outer races of the bearings (11) out of the wear and replace if necessary.
idler gear (10). Remove retainer ring (17) from in-
side idler gear (10). Remove spacer (27) from in-
NOTE: The length of spacer (27) should be 54.180 -
side idler gear (10).
54.58 mm (2.1569 - 2.149 in) and length of
5. Remove snap ring (25) which retains bearing (24) in spacer (26) should be 55.48 - 55.42 mm
housing (4). (2.1841 - 2.1821 in)
6. Place housing (4) in an arbor press with bearing 7. Inspect the underside of plate (29) for wear and re-
(24) facing down. Place a soft drift against the end place if necessary.
of the output shaft (23) and press the output shaft
(23) and bearing (24) out of the housing (4). Be 8. Replace all worn or broken parts as required.
certain there is enough clearance between the
housing (4) and the arbor press to allow the output
shaft (23) and bearing (24) to be removed. Press
the outer race, of bearing (12), out of the housing
(4). Care should be taken to prevent the bearings
(24) and the output shaft (23) from falling and being ASSEMBLY
damaged during removal. Numbers in parentheses refer to Figure 5.
7. Remove the driven gear (9), and bearing (12) from NOTE: Prior to assembly a special tool must be fab-
the housing (4). Remove the snap ring (22) and ricated, to replace the plate (29) in assembly
bearing (24) from the output shaft (23). procedure. Use mild steel to fabricate. Refer
to Figure 4 for dimensions.
INSPECTION 1. Install snap ring (22) on the output shaft (23).

Numbers in parentheses refer to Figure 5. Press the inner race of bearing (24) on the output
shaft (23).
1. Clean all the parts thoroughly in a suitable solvent.
2. Place the housing (4) in an arbor press with the
2. Inspect the lubrication hose assembly for deteriora- opening for the bearing (24) facing up. Through
tion, cracks, or ruptures, and replace them if nec- the opening in the bottom of the housing (4),
essary. place the outer race of the bearing (12) over its
bore in the housing (4) and tap it into place using
3. Check the idler gear (10) and driven gear (9) for a suitable driver.
cracks, chipped teeth, or excessive wear, and re-
place them if necessary.
W5-3-7
Figure 6 – Bearing Assembly
1. Inner Race 2. Outer Race
3. Through the opening in the bottom of the housing 7. When the stack- up of tolerances for either the
(4), place the inner race of bearing (12) into its outer driven gear (9) or the idler gear (10) assemblies is
race. Slide the driven gear (9) into the housing (4) such that the end play is near the lower limit of its
and center it on the bearing (12). If the driven gear allowable range, the gears (9 and 10) may be very
(9) has been previously used, it is acceptable to difficult to turn by hand. This should not be a cause
turn it over so as to load the sides of the teeth that for concern as long as the end play requirements
were previously unloaded. have been met.
4. Insert the output shaft assembly (23) into the hous- NOTE: If either of the gears (9 and 10) cannot be
ing (4) and carefully align the output shaft’s (23) turned by hand or are excessively loose, fur-
splines with the driven gear (9) splines. Push the ther inspection of the assembly is required.
output shaft (23) through the driven gear (9) and Items that have been found to affect end play
start the end of the output shaft (23) into the bearing includes improper shimming of idler shaft (6),
(12). Finish the installation of the output shaft (23) worn housing (4) worn spacers (26 and 27),
into the bearing (12) using the press and a suitable improperly seated bearings (11, 12 or 24),
driver. Use sufficient force to fully seat the bearing use of non-OEM bearings, or use of improp-
(12) against the shoulder on the shaft (23). Exces- erly remanufactured parts.
sive force, however, may damage the bearing (12).
8. Install the retainer ring (17) into the idler gear (10).
5. Install the outer race of bearing (24) into the hous- Press the outer race of bearing (11) against the re-
ing (4) using a suitable driver. Install snap ring (25) tainer ring (17). Insert the spacer (27) from the op-
into the housing (4). Turn the housing (4) over and posite side with the stepped end of the spacer (27)
push on the opposite end of the shaft to seat the towards the retainer ring (17). Press the remaining
outer race of bearing (24) firmly against the snap outer race of bearing (11) firmly against the spacer
ring (25). (27).
6. Position the housing (4) so the gear opening is up 9. Lay the housing (4) on its side with the opening for
and rotate the driven gear (9) several times to align the bearing (24) facing down. Insert one of the
the rollers in the bearings. It may be helpful to se- harden washers (8) into the counter-bore in the
cure the housing (4) in this position with a suitable housing (4). Insert the inner races of bearing (11),
clamp arrangement. Install a magnetic base dial in- spacer (26) and the remaining harden washers (8)
dicator on the housing (4) with the stem resting on into the idler gear (10), and slide the assembly into
the end of the output shaft (23). the housing (4). While looking down through the
bore in the housing (4) for the idler pin (6), align the
bores in the harden washers (8), bearing (11) and
spacer (27) with the housing bore.
W5-3-8
Figure 7 – Special Tool
10. Install O-rings (7 and 20) on the idler shaft (6). NOTE: If either of the gears (9 and 10) cannot be
Lubricate the idler shaft (6) and carefully tap it turned by hand or are excessively loose, fur-
into the housing (4) until it is seated against the ther inspection of the assembly is required.
first hardened washer. Items that have been found to affect end play
includes improper shimming of idler shaft (6),
11. Measure the thickness of the special tool with a mi- worn housing (4) worn spacers (26 and 27),
crometer. Install the special tool in place of plate improperly seated bearings (11, 12 or 24),
(29), using bolt (28) but without using any shims. use of non-OEM bearings, or use of improp-
The “cupped” portion of the tool should be towards erly remanufactured parts.
the outside. Using a half inch drive socket, torque
bolt (28) 156 N⋅m (115 ft⋅lbs.). Rotate the idler gear
NOTE: The axial end play of the idler gear (10)
(10) several times and check the bolt torque. Using
a depth micrometer, measure the distance from the should be 0.0127 - 0.203mm (0.0005 -
outer end of the special tool to the end of the idler 0.0080 in) with a force of 34 - 47 N⋅m (25 -
shaft (6). Subtract the thickness of the plate and the 35 ft⋅lbs.) applied to the idler gear (10).
spacer to obtain the gap between the end of the pin
and the plate. Add 0.0254 - 0.0508 mm (0.001 -
0.002 in) to the measured gap to determine the 12. Position the housing (4) so that the gear opening is
shim pack thickness. Remove the special tooling up and rotate the idler gear (10) several times to
pieces. Install plate (29), bolt (28), shims (30) and align the rollers in the bearings. It may be helpful to
torque the bolts to 156 N⋅m (115 ft⋅lbs). secure the housing (4) in this position with a suit-
able clamping arrangement. Install a magnetic base
dial indicator on the housing (4) with the stem rest-
ing on the side of the idler gear (10).
W5-3-9
Figure 6
1. P.T.O. Housing 8. Bearing Assembly 15. Plug 22. O-Ring

2. Output Shaft 9. Bearing Assembly 16. Screw 23. Plate
3. Gear 10. Bearing Assembly 17. Washer 24. Oil Seal
4. Gear 11. Plate 18. Shim 25. Screw
5. Spacer 12. Snap Ring 19. Shim 26. Washer
6. Spacer 13. Retaining Ring 20. Shim 27. Sealant
7. Idler Shaft 14. Ring 21. O-Ring 28. Kit, Bearing Assembly
W5-3-10
CHECKING AXIAL END PLAY
Apply the force to the gear while rotating the gear

back and forth several times to fully seat the gear in
one direction. Set the dial indicator to zero. Apply the
force in the opposite direction, while rotating the gear
back and forth several times to fully seat the gear in
the opposite direction. The dial indicator will show the
amount of end play present.
NOTE: The axial end play of the output shaft

(23) should be 0.0254 - 0.4267 mm
(0.0010 - 0.0168 in) with a force of 34 -
47 N•m (25 - 35 ft⋅lbs) applied to the
shaft.
Criteria Limit
Backlash – Transmission output to PTO input
assembled gear backlash. + 0.25
_________
0.51mm
- 0.13
+ 0.010
__________
0.020 in
- 0.005
PTO inspection/rebuild • At time of engine overhaul
• At time of transmission overhaul or major repair
• At time of hydraulic pump failure
• At time of driveline or driveshaft failure
Water truck with PTO drive for H2O pumps Inspect every 1yr. (option equipment)
W5-3-11
MEMO
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W5-3-12
POWER TRANSMISSION / Front Driveline
6 4
3 5
2
2
1
EL20646
FORWARD
Figure 1
1. Cross Assembly (2x) 4. Seal Assembly

2. Bolt (8x) 5. Shaft Assembly
3. Sleeve Assembly 6. Bolt (8x)
SERVICE POSITION

REMOVAL
A lifting device capable of lifting 227 kg (500 lbs) is re-

quired to perform this procedure.
NOTE: The only serviceable component of the

front driveshaft is the U-joint, which is
available as a replacement kit. Do not
disassemble the U-joint, the slip joint or
the propeller tube. Figure 2 – Recommended Hoist Arrangement for
Driveshaft Installation and Removal
W5-4-1
1. Remove bolts (5) holding the lower cover (2) and

the upper weldment guard (1) together and re- 4. Remove the upper and lower plates at the en-
move lower cover (2). gine by loosening and removing the bolts (9, 11,
: 9/16 in 13).
: 9/16 in, 18 mm
2. Remove bolts (5) holding strap brackets (4), then
remove brackets. 5. Punch mark the driveline yokes, the transmis-
: 9/16 in sion input yoke, and the engine output yoke to
indicate the correct component relationship.
3. Remove bolts (5) holding lower rear cover (3),
then remove lower rear cover (3).
: 9/16 in
Figure 3
1. Weldment Guard 6. Washer 11. Bolt

2. Cover 7. Lock Nut 12. Washer
3. Plate 8. Upper Plate 13. Bolt
4. Weldment Bracket 9. Bolt 14. Lower Plate
5. Bolt 10. Washer
W5-4-2
CAUTION: Driveline weight: 148 Kg (325 lb)
6. Support the driveline to prevent it from falling.

1
7. Remove the bolts (5) from the driveline cross as-
semblies (1) at the engine drive coupling. Refer to
Figure 4.
: 15/16 in
EL 20650
Figure 4
8. Remove the bolts (4) from the driveline cross as- 1

semblies (1) at the transmission input yoke. Refer
to Figure 5.
: 15/16 in
9. Use hoist to lower and remove the driveline from

NOTE: Incorrect handling of a driveline, espe-

cially impacts and shocks, may cause se-
EL 20651
rious damage. The driveline must always
be handled horizontally.
Figure 5
W5-4-3
INSTALLATION
NOTE: Always use new mounting hardware.
1. Align the punch marks made during removal and

place the tube end of the driveline against the en-
gine coupler. Before inserting bolts (5), make sure
that the bearing caps of the U-joint are fitted in
their final position. To ensure that they are, tap
with a light rubber or wooden hammer. Secure
the cross assembly (1) with the bolts (5). Refer
to Figure 4.
: 15/16 in
: 244 N·m (180 Ibf·ft)
2. Align the punch marks made during removal and

place the shaft end of the driveline against the trans-
mission input yoke. Before inserting bolts (4), make
sure that the bearing caps of the U-joint are fitted in
their final position. To ensure that they are, tap with a
light rubber or wooden hammer. Secure the cross
bearing assembly (1) with the bolts (4). Refer to Fig-
ure 5.
: 15/16 in
: 244 N·m (180 Ibf·ft)
Figure 6 – Seating Bearing Caps with Light Hammer
3. Set up a dial indicator and check the driveline run-out
on a machined surface near each universal joint.
Run-out cannot exceed 0.508 mm (0.02 in) total in-
dicator reading.
4. If the run-out exceeds 0.508 mm (0.02 in) total indi-

cator reading, inspect the bearing assembly mating
faces to assure that they are properly seated.
NOTE: Engine crankshaft bearings and drive cou-

pler may also affect total run out measure-
ment. If problem still exists, measure
driveshaft when removed from machine on
vee blocks.
5. If problem still exists, inspection of differential input

and transmission output flange splines is necessary.
Replace worn spline members and repeat step 3.
NOTE: Greasing of the shaft is not required since both

the crosses and the slip spline are lubricated
for life.
W5-4-4
DISASSEMBLY 4. Check the slip spline for excessive wear. With the
driveline extended to near mid-slip, mount a dial
Inspection Prior to Disassembly indicator base on the top of the driveline on one
side of the slip joint, 6.4 mm [0.25 in] from the
Numbers in parentheses refer to Figure 1. weld, with the dial indicator on the other side, 6.4
mm [0.25 in] from the shaft seal. Push vertically
1. Before disassembly, the driveline should be near the slip joint. If the dial indicator measures
checked for run-out. Place the driveline in two vee more than 0.30 mm [0.012 in] movement, replace
blocks. The driveline should rest in the vee block the driveline. Reference Figure 7. Rotate drive-
o
on a smooth surface near each end. line 45 , and repeat. Rotate the driveline another
o
45 , and repeat.
2. Set up a dial indicator to the center of the driveline
and rotate the driveline in the vee blocks. Refer 5. Check universal joints for excessive movement.
to Figure 7 for allowable run-out. Try moving the driveline parallel to the cross di-
rections (side to side AND up and down). If the
3. If the run-out exceeds values given in Figure 7, driveline moves more than 0.15 mm (.006 in) rela-
the driveshaft requires replacement. tive to the mating flanges, replace the universal
joint kit. Reference Figure 8.
0.30
(0.012) MAX
6.4 6.4
[.25] [.25]
Figure 7
W5-4-5
INSPECTION
1. Inspect the splines in the end of the sleeve as-

sembly (3) and on the shaft assembly (5) for nicks,
burrs or excessive wear. Nicks and burrs may be
removed with a fine stone. Worn splines require
replacement of driveline assembly.
2. Check the condition of the seal assembly (4).
PHOTO COURTESY OF SPICER® EL 20657 3. Clean U-joints thoroughly in solvent.
Figure 8 4. Inspect U-joints for burrs, score marks or exces-

sive wear. Replace any worn, damaged or cor-
roded universal joint.
6. Check the sleeve assembly (3) and shaft assembly
(5) for cracks, weld breaks, warpage, metal fatigue 5. Check the U-joint (1) for free movement. Replace
or other damage. Replace driveline as necessary. the U-joint kit if there is no free movement.
NOTE: The driveline should be checked on a cali- NOTE: Replacement of only one part of assembly will
brated balancing machine designed only for cause excessive wear in the newer part; there-
this purpose. Balance test at 2500 fore, universal joints are only available in kit
min-1(rpm) to ISO 1940 grade G-16 specifi- form.
cation.
6. Inspect the sleeve (3) end and shaft (5) end yokes
Disassembly for burrs or any obstructions that would prevent
proper bearing cap seating. Replace driveline if
Numbers in parentheses refer to Figure 1 unless oth- necessary.
erwise noted.
7. Visually check the sleeve assembly (3), shaft as-
NOTE: Before the driveline is disassembled, it sembly (5) and the flanges on these components
should be checked for run-out as described for fretting damage, twist or loss of straightness.
in the inspection portion of the disassembly Replace driveline if necessary.
section.
1. Remove the four bolts (6) that attach the universal

joint kit (1) to the shaft assembly (5) and remove
the universal joint kit.
2. Remove the four bolts (6) that attach the universal

joint kit (1) to the sleeve assembly (3) and remove
the universal joint kit.
NOTE: Do not disassemble the universal joint kit.
3. Install universal joint kits in reverse order.
W5-4-6
ASSEMBLY
NOTE: Always use new mounting hardware.
1. Ensure that the yoke faces, bearing mounting

faces, circular pilots and keyways are free of for-
eign material, burrs and nicks prior to assembly to
ensure proper seating of the bearings.
2. To assemble a joint to a yoke, insert the key and

pilot of one bearing in to the keyway and pilot of
the yoke. Refer to Figure 9.
3. Insert the key and pilot of the opposite bearing into

the yoke. The fit is intended to be tight and some
compression of the seals and/or thrust washers
may be required to seat the second bearing. This Photo courtesy of Rockford Powertrain®
can be done with a “C” clamp, a tap with a soft Figure 9 – Inserting Key and Pilot into the Yoke
hammer, or with hand pressure. DO NOT use the
bolts to seat the bearings. Refer to Figure 10.
4. Once the bearings are properly seated, insert the

bolts and uniformly torque them to the proper level
as indicated below. Make sure the bolts are clean
prior to insertion.
: 15/16 in
: 312 – 325 N·m (230 - 240 Ibf·ft)
NOTE: The driveline components must be aligned

correctly to ensure proper balance.
Photo courtesy of Rockford Powertrain®

Figure 10 – Using a Hammer to Seat Bearing
W5-4-7
Criteria Limit
U-joint movement parallel to cross directions 0.15 mm [0.006 in] maximum
(side to side AND up, down) Refer to Figure 8
Run-out Refer to Figure 7
Slip spline wear 0.30 mm [0.012 in] maximum. Refer to Figure 7
Balance ISO 1940 Grade G-16 Specification @ 2500 min-1(rpm)
Torque tube of shaft assembly (5) No visible dents or deformities
W5-4-8
POWER TRANSMISSION / Rear Driveline
15 1
2 16 6
8
9
10
FORWARD
17
14
11 12 5
4
A 1
C 18
19
3 13
B
A
EL 20661
Figure 1
1. Cross Assembly (2x) 7. Grease Fitting (2x) 13. Flange Yoke, Differential 19. Nut (8x)
2. Flange Yoke, Transmission 8. Sleeve Assembly 14. Seal (2x) A. U - Joint
3. Grease Seal (8x) 9. Cork Washer 15. Bolt (8x) B. Slip Joint
4. Capscrew (8x) 10. Steel Washer 16. Nut (8x) C. Propeller Tube
5. Bearing Cap Assembly (8x) 11. Dust Cap 17. Weld Yoke (2x)
6. Sleeve Yoke Plug 12. Shaft Assembly 18. Bolt (8x)
W5-5-1
SERVICE POSITION 4. Support the driveline near the differential flange

and remove the nuts (19) and bolts (18) from the
Before checking and/or servicing the rigid dump truck, differential flange yoke (13). Remove the drive-
park the rigid dump truck on a level solid surface and line from the rigid dump truck.
put it in the “Service Position.” Refer to Section W2-1. : 32 mm
REMOVAL 5. Support drive shaft and slowly lower to the ground.

CAUTION: When the rear driveline is dis-

connected, the parking brake is inoperative;
therefore, block the wheels to prevent rigid
dump truck movement while removing or re-
placing the rear driveline.
NOTE: Incorrect handling of a driveline, especially

impacts and shocks, may cause serious
damage. The driveline must always be
handled horizontally, and precautions
must be taken to avoid unexpected sepa-
ration. If you have to sling the driveline,
do so as shown in Figure 2 using ade-
quate ropes or nylon straps.
NOTE: The only serviceable component of the Figure 2 – Recommended Arrangement for Removing
rear driveline is the U-joint, which is and Installing Rear Driveline
available as a replacement kit. Do not
disassemble the U-joint, the slip joint or
the propeller tube.
INSPECTION AFTER REMOVAL
1. Apply the parking brake to hold the parking brake
disc in place while the driveline is removed.
1. Before removing the flange yokes (2,13) and the
universal joint kit assemblies, the driveline should
2. Punch mark the driveline flange yokes (2 and 13), the be checked for run-out. Place the driveline in two
differential flange, and the transmission flange to in- v-blocks. The driveline should rest in the v-block
dicate the correct component relationship. on a smooth surface near each end. Refer to Fig-
ure 3.
3. Support the driveline to prevent it from falling and
remove the bolts (15) and nuts (16) from the
transmission flange yoke (2).
: 30 mm
CAUTION: Driveline approximate weight: 181

kg (400 lb)
NOTE: Bolts (18) retain the park brake disc to the

differential flange. Once these bolts are
removed, the park brake is ineffective in
holding the rigid dump truck.
Figure 3 – Rear Driveline in V-Blocks
W5-5-2
2. Set up a dial indicator to the center of the driveline UNIVERSAL JOINT KIT INSTALLATION
and rotate the driveline in the v-blocks. Run-out
should not exceed 0.51mm (.020”) total indicator
1. Install universal joint kits in reverse order of re-
reading. If the run-out does exceed 0.51mm (.020”)
moval.
replace the entire rear driveline.
3. Check the driveline, flange yokes (2,13), weld yoke NOTE: Replacement universal joint kits contain only
(17), tube (10, Figure 5), spline shaft (11, Figure enough grease to provide needle bearing
5), and sleeve yoke (8), for cracks, weld breaks, protection during storage. It is therefore
warpage, metal fatigue or other damage. Repair or necessary to completely lubricate each re-
replace as necessary. placement kit prior to assembly into the
driveline yokes. Each journal cross lube
reservoir should be fully packed with a rec-
NOTE: The sleeve and shaft are replaced as an
ommended grease and each bearing as-
assembly. sembly should also be wiped with the same
grease; filling all the cavities between the
rollers and applying a liberal grease coating
on the bottom of each race. After the kits are
UNIVERSAL JOINT KIT REMOVAL installed into the driveline yokes and prior to
Numbers in parentheses refer to Figure 5. placing into service, they should be relubri-
cated, through the zerks, using the same
1. Loosen and remove the cap bolts (4) securing the grease. The slip joint should be re-lubricated
bearing caps to the flange yokes (6). whenever the U-joints are lubed. Fill the spline
: 27 mm with grease until it purges out the dust cap and
grease relief at the sleeve plug.
2. Loosen and remove the cap bolts (4) securing
the bearing caps (5) to the weld yoke (8). Re-
move the universal joint kit.
: 27 mm
3. Loosen and remove the cap bolts (4) securing

the bearing caps (5) to the sleeve yoke (15).
Remove the universal joint kit.
: 27 mm
INSPECTION
1. Clean the bearing assemblies (1) in a suitable sol-

vent and dry with compressed air, being careful not
to damage the thrust washer (1C). Work a small
amount of lubricant into each needle bearing (1A),
inside the bearing case (1B).
2. Place the bearing assemblies (1) on the cross (2) Figure 4 – Lubrication of Cross
and rotate to check for excessive bearing wear.
3. Replace the complete universal joint kit if either

or both the bearing assembly and cross assem-
bly are worn.
W5-5-3
Figure 5 – Exploded View of Rear Driveline
Universal Joint Kit 4. Cap Bolt 11. Spline Shaft

1. Bearing Assembly 5. Bearing Cap 12. Dust Cap
1A. Needle Bearing 6. Flange Yoke 13. Packing
1B. Bearing Case 7. End Plate 14. Side Plate
1C. Thrust Washer 8. Weld Yoke 15. Sleeve Yoke
2. Cross 9. Weld Ring 16. Seal Plate
3. Grease Fitting 10. Tube
W5-5-4
INSTALLATION / RUN-OUT INSPECTION 3. Install and torque the bolts (15) and locknuts (16)
Numbers in parentheses refer to Figure 1. on the transmission flange yoke.
: 30 mm
NOTE: Before beginning the installation procedures, : 780 N⋅m (575 lbf⋅ft)
clean all the mating surfaces with brake
4. Set up a dial indicator and check the driveline
cleaner or an equivalent solvent and all bolts
runout on a machined surface near each universal
holes must be free of paint, oil, and grease.
joint kit (1). Run out should not exceed 0.51mm
CAUTION: Driveline approximate weight: 181 (.020”) total indicator reading.
kg (400 lb)
5. If the run-out exceeds 0.51mm (.020”) total indica-
1. Match marks are stamped on the shaft assembly tor reading, inspect the flange yoke and the bear-
(12) and sleeve assembly (8). Be sure the marks ing cap assemblies to determine if they are prop-
are aligned to each other. Refer to Figure 5. erly seated. Adjust as required.
6. Position the dial indicator to the middle of the

driveline and check for run-out. If run-out at the
middle of the driveline exceeds 1.27mm (.050”)
total-indicator reading and all components are
properly seated, a bent driveline is evident and
replacement will be necessary.
NOTE: When using the Special Tool (Crowfoot

Tool E12628029) to tighten the nuts/bolts
on the differential flange yoke or the trans-
mission flange yoke, use the following for-
mula to calculate the appropriate wrench
setting (wrench length is in inches):
Figure 6 – Match Marks
Wrench Setting = Bolt Torque x Wrench Length
2. Install the driveline and (disc type) parking brake ------------------------------------------
disc on the differential flange yoke. Install the Wrench Length + 3
bolts (18) and locknuts (19) and torque.
: 32 mm For more information on this torque formula, see Sec-
: 750 N⋅m (553 lbf⋅ft) tion W1-2, TIGHTENING TORQUE.
MAINTENANCE
NOTE: Improper lubrication procedure is one of the

most frequent causes of driveline failure.
Refer to Section W2-2 MAINTENANCE for
recommended lubricant. Lubricate every 250
hours. There may exist applications of se-
vere operating conditions where this interval
is not adequate. If such a situation exists,
reduce the interval to fit the condition.
1. Clean the grease fitting (3) at the cross (2). Do

not insert high pressure grease. Pump grease
into the universal joint kit until the old grease
overflows through the bearing seals at the four
Figure 7 - Installation bearing locations.
W5-5-5
MEMO
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W5-5-6
POWER TRANSMISSION / Rear Axle
17 21,22 40 23 24 25
19 11 26,27
3 34
18
32 20
16 42
43
15
1
13
12
14
10
7
8
9
38 36
33
30
37 2 35 39 41 28 29 31
Figure 1 – Section View of Rear Axle and Planetary Assembly
1. Axle Shaft 13. Pin (3x) 25. Inner Wheel Bearing 37. O-Ring
2. Internal Ring Gear Hub 14. Bolt/Washer (3x) 26. Face Seal 38. Bolt (24x)
3. Retainer Plate 15. Bearing (3x) 27. O-Ring (2x) 39. Ring
4. Bolt (12x) 16. Planet Gear 28. Spacer 40. Outer O-Ring
5. Sun Gear 17. Internal Ring Gear 29. Brake Assembly 41. Inner O-Ring
6. Bolt (4x) 18. Planetary Carrier 30. Tube 42. Spindle
7. Gasket 19. O-Ring 31. O-Ring 43. Carrier
8. Ring 20. Dowel Pin (2x) 32. Toric Seal
9. Snap Ring 21. Bolt with Lockwire (12x) 33. Bolt/Washer (24x)
10. Flange Cover 22. Plate (6x) 34. Hub
11. Retainer (3x) 23. Outer Wheel Bearing 35. Shim(s)
12. O-Ring 24. Wheel 36. Axle Housing
W5-6-1
SERVICE POSITION
NOTE: Support axle assembly during removal to
Before checking and/or servicing the rigid dump truck prevent damage to planetary gears and
Refer to Section W2-1 splines on axle shaft. Sun gear may be
difficult to remove because of how the
REMOVAL – AXLE SHAFT gears were loaded during parking brake
application. If axle is difficult to remove,
Numbers in parentheses refer to Figure 1. start unit and release both park and load
dump brake. Inspect that wheel chocks
first are holding, then apply load dump
The inner end of the axle shaft (1) is splined into the
brake and slide axle out.
differential side gear and is driven by the differential.
The outer end of the axle shaft is splined into the sun
gear (5). The axle shaft (1) can be removed without
jacking up the rigid dump truck, or removing the tires. Fill
1. Drain the lubricant from the planetary gear

reservoir by turning the wheel until the drain plug
is at the lowest point of travel (6 o’clock) and
remove the drain plug. Refer to Figure 2. Drain
NOTE: Immediately remove any lubricant spilled

EL 20671
on the tire to prevent deterioration of the
rubber. Wash tire with soap and water, or
use a degreasing solution that is not Figure 2 – Planetary Drain Plug
harmful to rubber.
NOTE: If rigid dump truck is equipped with Active

Traction Control (ATC/EDSC), speed
sensors (Refer to Figure 3) must be
removed before the removal of the axle
shaft.
3
: /16 in
2. Remove the cover bolts (6) from the cover (10).

Remove the cover (10) and gasket (7). Discard EL 20672
gasket (7).
15
: /16 in
Figure 3 – Speed Sensors for Optional ATC/EDSC
CAUTION: Removal of a planetary sun
gear disables the parking brake. Inspect
wheel chocks and secure hauler from
rolling during service.
3. Remove snap ring (9), sun gear (5) and axle

shaft (1) as an assembly by sliding the shaft out
slowly. See Figure 4.
CAUTION: Axle shaft weight 93 kg (204

lbs).
EL 20673
Figure 4 – Removing Sun Gear and Axle Shaft
W5-6-2
DISASSEMBLY – AXLE SHAFT 1. Insert Axle Shaft (1) through the planetary
Numbers in parentheses refer to Figure 1. assembly into the tube (30) of the Spindle (42)
and Axle Housing (36) until it makes contact with
1. Remove the Snap Ring (9) that retains the Sun the differential side gear.
Gear (5) on the Axle Shaft (1). Remove the Sun
Gear (5). NOTE: Support the shaft during installation to
prevent damage to Planet Gears (16)
INSPECTION – AXLE SHAFT and Axle Shaft (1) splines.
1. Thoroughly clean all parts, including the Axle 2. Rotate the Axle Shaft (1) until the splines on the
Shaft (1) with a suitable solvent. Dry with end of the axle shaft align with the internal
compressed air. splines in the differential side gear.
2. Inspect the splines of the Axle Shaft (1) for 3. Slide the Axle Shaft (1) into the differential side
burrs, broken teeth, excessive wear and/or other gear inner teeth and the teeth of Sun Gear (5)
damage. mesh.
3. Inspect the outer end of the Axle Shaft (1) for 4. Check the axle shaft endplay. Refer to Checking
excessive wear. Axle Shaft End Play procedure in this section.
4. Check the central portion of the Axle Shaft (1) 5. Install the Cover (10) with new Gasket (7) and
for indications of torsional stress (small fractures secure the cover with Bolts (6). Tighten Bolts
in surface finish). Use magnetic particle (6).
inspection method (MPI) for this purpose. : 15/16 in
: 173 N·m (128 lbf·ft).
5. Inspect the center of Cover (10) for wear pattern
that could have been caused from contact with 6. Turn rear wheel assembly until the oil level line
the Axle Shaft (1). Replace worn cover. cast on the outer face of the Planet Carrier (18)
is parallel with the ground. See Figure 2.
6. Repair or replace any defective, damaged or Replace the drain plug and fill the planetary
suspect parts. reservoir to the indicated level (flows from cover
bolt hole) through the fill plughole. Refer to
7. Inspect the Sun Gear (5) using magnetic particle section W2-2 for recommended lubricants.
inspection method (MPI). Replace any defective
parts. NOTE: Immediately remove any lubricant that
contacts the tire to prevent deterioration
ASSEMBLY – AXLE SHAFT of the rubber. Wash tire with soap and
water, or use a degreasing solution that
Numbers in parentheses refer to Figure 1. is not harmful to the rubber.
1. Install the Sun Gear (5) on the Axle Shaft (1). 7. If required, install the optional ATC/EDSC axle
shaft speed sensors in the axle housing on each
2. Install the Snap Ring (9). side of the differential. Refer to Figure 3 and
Section W6-5, NEW SENSOR ADJUSTMENT
INSTALLATION – AXLE SHAFT AND INSTALLATION.
3
Numbers in parentheses refer to Figure 1. : /16 in
The Axle Shaft (1) and Sun Gear (5) are installed as
an assembly.
CAUTION: Axle shaft weight 93 kg (204

lbs), sun gear weight 10 kg (22 lbs).
W5-6-3
CHECKING AXLE SHAFT ENDPLAY
The axle shaft endplay is determined by measuring

the distance between the Axle Shaft (1) and the
Cover (10).
1. Remove the flange cover Bolts (6) from the

flange Cover (10). Remove the Cover (10) and
Gasket (7).
15
: /16 in
2. Push the Axle Shaft (1) in as far as it will go.

Place a straight edge across the flange cover
mounting surface on the Planetary Carrier (18),
as shown in Figure 5. Using a scale, measure
the distance from the outer surface of the carrier
to the axle shaft thrust surface, and record this
as dimension 1 in Table 1 – Axle Shaft Endplay.
EL 20674
3. Place a straight edge across the inside surface Figure 5 – Measuring Dimension 1
of the Cover (10), at the point the Axle Shaft (1)
contacts the flange cover, as shown in Figure 6.
Use a scale and measure the distance from the
lower edge of the straight edge to the inner
surface of the flange cover. Subtract 1.52 mm
(0.060 in), the thickness of the cover Gasket (7),
and record this as dimension 2 in Table 1 – Axle
Shaft Endplay.
4. In Table 1, subtract dimension 2 from dimension

1. The resulting dimension is the actual axle
shaft endplay and should be 3 - 7 mm (0.120 -
0.275 in). If the endplay is less than 3 mm
(0.120 in), check for obstructions within the axle
assembly that would prevent the axle
components from mating properly. If the
measured dimension is greater than 7 mm EL 20675
(0.275 in), check for worn or broken axle Figure 6 – Measuring Dimension 2
assembly components. Replace any worn,
damaged or broken parts.
5. Install the Cover (10) and Gasket (7) and secure

the Cover (10) with Bolts (6).
15
: /16 in Dimension 1 [ ]
: 173 N·m (128 lbf·in).
Dimension 2 [ ] 1.52 mm (0.060in)
Endplay Dim 1 - Dim 2
Table 1 – Axle Shaft Endplay
W5-6-4
EL 20676
Figure 7 – Rear Axle Mounting Parts
W5-6-5
Figure 7 Continued – Rear Axle Mounting Parts
1. Axle Housing 16. Ring 44. Screw 70. Ring

2. Snap Ring 17. Machining Pin 45. O-Ring 71. Screw
3. Snap Ring 18. Stud 57. Spacer 72. Pin
4. Spherical Bushing 19. Pad 58. Tube 73. Spherical Bushing
5. Breather Vent 29. Washer 59. Washer 74. Plate
6. Bracket Assembly 31. Snap Ring 60. Grease Fitting 75. Cotter Pin
7. Bushing 35. O-Ring 61. Cap 76. Screw
8. Hose Assembly 36. Axle Shaft 62. Spacer 77. Snap Ring
9. Connector 37. Axle Shaft 63. Pin Assembly 79. Washer
10. Elbow 38. Magnetic Plug 64. Grease Fitting 80. Link
11. Plug 39. Retaining Ring 65. Nut 81. A-Frame
12. Cover Plate 40. Bearing, Assembly 66. Gasket 82. Plug
13. Screw 41. Plate 67. Screw
14. Sealant 42. Pin 68. Pin
15. Spherical Bushing 43. Plug 69. Lock Nut
W5-6-6
SERVICE POSITION 7. Drain both sections of the hydraulic tank. Refer

to the Maintenance section in the Operator’s
1. Park the rigid dump truck on a level surface and Manual (EM8R6-1-2) for instructions on
put it in the Service Position. Refer to Section draining the hydraulic tank.
W2-1.
8. With the Rear Axle Housing (1) well supported,
REMOVAL – REAR AXLE remove the rear wheels. Refer to Section W8-
Numbers in parentheses refer to Figure 7, unless 5.
otherwise noted.
9. Remove the Rear Brake Assemblies (29,
CAUTION: The components that make up Figure 1). Refer to Section W6-2. Remove
the rear axle and suspension are heavy; brake lines clamped to Axle Housing (1) by
use care when disassembling or removing the nuts and washers.
removing these components. Misuse of
lifting equipment or improper support of
components may result in possible injury
or damage.
NOTE: The body should be removed from the

rigid dump truck prior to removing the 14
rear axle. A spreader bar should be
used in the removal of the rear axle
because it prevents the chains from
hitting the frame. It should be noted
however that a spreader bar increases
the stresses in the chains, so chain
selection should reflect the required extra
strength.
1. Drain the oil from the differential by removing

the drain plug (18) located at the bottom of
Axle Housing (1). Refer to Figure 8. 1 18
2. Remove the Rear Axle Shaft (36, 37). Refer to EL 20677
Axle Shaft Removal. Figure 8 – Rear Axle Drain and Fill Plugs
3. Disconnect the rear driveline from the

differential. Refer to Section W5-5.
10. Position wheeled platforms under the rear axle
4. Disconnect and remove the differential assembly and lower the rigid dump truck so
Breather Hose (8) from the Rear Axle Housing that the axle assembly is resting on them.
(1). Block the rear housing on the wheeled
platforms so that it cannot rotate when the rear
5. Using suitable equipment, jack up the rear of suspension is disconnected.
the rigid dump truck until the tires clear the
ground. Refer to Section W2-3. Remove the 11. Remove the rear ride struts from the frame and
tires and rim assemblies. Refer to Section W8- rear axle assembly. Refer to Section W8-3.
6.
6. Remove the rear axle planetary assemblies.

Refer to Section W5-8.
W5-6-7
Numbers in parentheses refer also to Figure 9.

29 28 30
12. Secure the end of the track rod (25) where it
attaches to Axle Housing (1, Figure 7) with a 26 27
chain and hoist. Remove Bolt (29) and Washer
(28) from the Pin (27) at Axle Housing (1, 23
Figure 7). Remove Retaining Ring (31) from
pin (27) and tap out the pin (27) from Axle 24
Housing (17) and Track Rod (25).
: ¾ in
13. If the Track Rod (25) needs to be removed

from the frame (17) of the rigid dump truck,
remove the other Bolt (29), Washer (28) and
Retaining Ring (31) from Pin (27) at the frame 31
(17) of the rigid dump truck. Tap out the Pin
(27) from the rigid dump truck frame (17) and
Track Rod (25). Lay the Track Rod (25) and its 25 17
mounting hardware aside.
: ¾ in
14. If the bearings (24) are to be removed from the

frame (17) and the Rear Axle Housing (1, EL 20678
Figure 7), remove the Snap Rings (23) and use

a suitable puller.
15. Lift and support the A-Frame (81, Figure 7)

away from the rear axle. Figure 9 – Section View of Track Rod Assembly
16. Using a hoist of suitable capacity, raise the

frame to facilitate removal of the rear axle 17. Frame 27. Pin
housing assembly. Remove the assembly from
23. Snap Ring 28. Washer
under the rigid dump truck.
24. Bearing 29. Bolt
25. Track Rod 30. Fitting
CAUTION: Rear Axle weight 3827 kg (8437 26. Spacer 31. Retaining Ring
lbs), Differential weight 818 kg (1805 lbs).
17. Remove the differential. Refer to Section W5-7.
W5-6-8
DISASSEMBLY–SPINDLE FROM AXLE

HOUSING
To replace the Spindle (42) of rear axle without the

need to replace Axle Housing (36), use the following
method. Since the Spindle (42) is welded to axle
housing, the following procedures for spindle
replacement should be followed to insure proper
assembly and operation of the affected components.
1. Thread puller bolts into the holes of ring (39). Pull

ring (39) out of spindle. Remove and discard
outer O-ring (40) and inner O-ring (41) from ring
(39).
NOTE: Remove one spindle at a time.
2. Carefully remove tube (30) from spindle (42) and

axle housing (36). Figure 10 – Dimension B
CAUTION: It is important that the spindle

be adequately supported to prevent injury
to personnel when it is separated from the
axle housing.
3. Before cutting off the spindle, pass a tape

measure through the axle. Measure the axle from
outside to outside of the spindles. Record the
length in Table 1, “OLD A”. Also, in 3 places
about the old spindle (2, 6, and 10 O’clock),
measure from the brake flange to the main
housing and mark (with paint) the housing. In the
table mark “B, C, and D”. Be sure to place the
mark far enough away from the weld so it will not
be affected by the pre-heat operation. Record the
dimension of “B, C, and D” in Table 2. These
dimensions will ensure the new spindle is straight
before welding.
4. Refer to Figure 12 for location of weld.

Figure 11
5. Support the rear axle (36) and using an air arc or
suitable tool, remove the weld. Since the spindle
will not be reused, cutting through the pilot aids 6. After the assemblies are separated, clean the old
in the removal. weld off of the axle housing (36) and remove the
pilot section of the spindle.
7. After removing the pilot section of the spindle,

dress the housing back as shown in Figure 11.
W5-6-9
Figure 12
INSPECTION OF THE AXLE HOUSING
1. Clean rear axle housing (36) and spindle (42)

with a suitable cleaning solvent.
2. Inspect for cracks, deterioration or other damage.

Use dye penetrant if available.
3. Inspect the new splined end of spindle (42) for

damage.
4. Inspect new Spindle (42) and Axle Housing (36)

for scoring, burrs or pits. Inspect all threaded
holes for damage.
NOTE: 381 mm (15 in.) from B, C and D to

the brake flange is recommended.
W5-6-10
42 42
36
EL 20681
Figure 13 – Spindle and Axle Housing
42. Spindle 36. Axle Housing
ASSEMBLY – SPINDLE TO AXLE

HOUSING
Numbers in parentheses refer to Figure 13. Temperature measurement should be taken
at a distance of 100 mm (4 in) from centerline
1. Make sure the areas to be welded are clean and of groove or prepared area.
free of old weld, grease, oil and any other
substances that would contaminate the weld Weld with E-7018 electrodes. Make sure the
process. weld area does not cool below 95 °C (200
°F) during welding.
2. Before proceeding to weld the following notes
should be read and considered throughout the Allow to cool below 200 °C (400 °F) then
welding process. post heat weld area to 260 °C (500 °F)
minimum for 30 minutes at completion of
welding.
NOTE: No welding should be done when ambient
temperature is below 10 °C (50 °F). Cover the repaired area with welding blanket.
Locally preheat prepared area to 150 °C - Allow repaired components to air cool slowly
232 °C (300 °F - 450 °F) minimum. to room temperature after post weld heat
treatment.
W5-6-11
3. Secure the components after they are prepared for INSTALLATION – REAR AXLE HOUSING
welding in a suitable fixture, preferably one that Numbers in parentheses refer to Figure 7.
will allow axle assembly and spindle to rotate. A
special tool (E12977841) is required to correctly 1. Installation of the rear axle housing (1) is in the
assemble the spindle to the axle. Refer to Section reverse order of removal. Refer to each
W2-4. components section in this manual for the
proper installation procedures.
4. The purpose of this tool (E12977841) is to
maintain the proper dimensions between the axle 2. Fill the planetary drives with lubricant. Fill the
housing and the new spindle. This dimension is differential at the fill plug (11). Refer to the
critical to ensure proper operation of all Section W2-2 for the recommended lubricant.
components that make up the rear axle area.
Figure 13 should be referenced throughout the 3. Fill the hydraulic tanks. Refer to the
Maintenance section in the Operator’s Manual
welding process for detail on the above mentioned
(EM8R6-1-2) for instructions on draining the
areas. Install the fabricated tool by passing the
hydraulic tank.
threaded rod through the rear axle housing,
positioning the spindle and attaching the plates.
CAUTION: Disable the Traction Control
Tighten the nuts on the rod until the proper
System (ATC). Failure to do so will result
dimensions from Table 2 are met. Only after the
in machine damage and/or bodily injury.
correct dimensions have been obtained can the
welding process begin.
4. Jack up the rear axle housing (1) until both
wheels are lifted off the ground and test run the
5. When dimensions are met, weld the Spindle (42) machine for noises. Wheel brakes should be
to Axle Housing (36) per the welding notes free, allowing both wheels to rotate at the same
included in this group. Also reference Hitachi speed.
Repair Welding Manual KO-111-00 and Service
Bulletin 4600-03R2 for more information on this NOTE: Never test run hauler with one wheel
welding process. jacked up. Torque transfer to opposite
wheel on ground could cause hauler to
6. After pieces have been properly welded, allow part unexpectedly move and fall from
to slowly cool and normalize before final support stands.
inspection. Then proceed to install the Rear Axle
Housing (36).
W5-6-12
POWER TRANSMISSION / Differential
EL 20723
Figure 1 – Section View of Differential
1. Bolt 13. Retainer 25. Bearing Cone 37. Dowel Pin

2. Plate 14. Bearing Cone 26. Bearing Cup 38. Case, Flanged Half
3. O-Ring 15. Bearing Cup 27. Bearing Cone 39. Case. Plain Half
4. Flange 16. Oil Seal 28. Bearing Cup 40. Thrust Washer
5. Collar 17. Lock Adjuster 29. Shims 41. Spider
6. Housing, Carrier 18. Washer 30. Shield 42. Pinion Gear Set
7. Cap, Bearing 19. Drive Pinion 31. Shield, Thread 43. Washer (Not Shown)
8. Dowel Bushing 20. Ring Gear 32. Pin 44. Nut (Not Shown)
9. Bolt 21. Shims 33. Bolt 45. Bearing, Caged Roller
10. Washer 22. Lock Nut 34. Bolt (Not Shown) 46. Washer, Case
11. Bearing Adjuster 23. Bolt 35. Gear 47. Axle Shaft (Reference)
12. O-Ring 24. Bolt 36. Thrust Washer 48. Bolt, Differential Mounting
W5-7-1
REMOVAL
1. Before working on the rigid dump truck, park it on a

level surface and put it in the Service Position.
2. Drain the differential housing and rear axle

planetary drive assemblies. Refer to Section
W5-6.
3. If applicable, remove the two ATC/EDSC speed

sensors located on the front side of the differential.
The two speed sensors must be removed from the
axle housing before the axle shafts are removed.
3
: /16 in
NOTE: Failure to remove the “Active Traction

Control” speed sensors before removing EL 20724
the axle shafts may result in sensor

damage. Figure 2 – Removing Sun Gear and Axle Shaft
4. Remove the center cover from the planetary carrier

on each rear wheel. Refer to section W5-6.
34
5. Slide the axle shaft, with the sun gear attached, at
least 0.30 m (1ft) out of each rear wheel. This will
disengage the axle shaft from the differential.
Cover the shaft and sun gear and plug the hole to
prevent dirt from entering.
6. Disconnect the rear driveline from the differential.

Refer to section W5-5.
7. Remove parking brake assembly. Refer to section

W6-8. 35
8. Support the weight of differential housing with a

suitable service jack from underneath or hoist from
above or combination of both to remove differential.
CAUTION: Differential weight 818 kg (1805 EL 20725
lbs). Figure 3 – Differential to Rear Axle Housing Mounting
9. Remove the twenty-four Bolts (34) which secure

differential housing in axle housing. See Figure 3.
1
: 1 /8 in
W5-7-2
10. Remove the thread protectors from the tapped

holes in the outer flange of the differential housing.
Insert bolts into the tapped holes and use them as
jacks to break the differential loose from the axle
housing. Pull the differential out of the axle housing
and lower it to the floor. Wrap the differential with
clean tarp to control dirt entry and contamination.
Remove the differential from beneath the rigid
dump truck.
11. Install the differential on a work stand before

removing any differential components. Refer to
Figure 4.
DISASSEMBLY EL 20726

Figure 4 – Differential Assembly in Work Stand
1. Remove the Flange (4) from the Drive Pinion (19).
15
: /16 in 7. Remove the Bolts (23) that secure the Bearing
Adjuster Locks (17) to the Bearing Caps (7).
2. Use special lifting tool (E12977833) and hoist Remove the Bearing Adjuster Locks (17).
9
differential. Refer to Figure 7 & 8. Mount : /16 in
differential to suitable work stand that allows easy
rotation of differential. Refer to Figure 4. 8. Rotate counter-clockwise to remove the Bearing
Adjusters (11) that are threaded into the Bearing
CAUTION: Differential weight 818 kg (1805 Caps (7) and differential housing.
lbs).
9. Remove the bolts (9) and washers (10) from
3. Secure the housing in a position where the Drive Bearing Caps (7). Remove Bearing Caps (7) from
Pinion (19) faces downward. differential housing. If necessary, remove dowel
bushings.
4. Punch-mark both Bearing Caps (7) and differential : 1½ in
housing so that the caps can be returned to their
original positions when re-assembled. 10. Using a hoist, raise the Ring Gear (2) and case
: Punch assembly to free it from the differential housing.
Remove Bearing Cups (26, 28).
5. If the differential assembly is disassembled for
inspection purposes only, scribe an identifying line 11. Punch-mark the Plain Case (39) and Flanged Case
on the Bearing Adjusters (11) and Bearing Caps (7). (38) to indicate their relationship to
This scribed line will be of assistance when each other.
adjusting the pre-load on the differential side ; Punch
bearings and setting the backlash. If a new spiral
bevel gear set, half cases or side bearings are 12. Stand the Flanged Case (38) on end with the Ring
used, disregard the scribed line. Gear (20) teeth facing up. Use caution not to
damage the bearing cages of the cone. Block the
6. Loosen, but do not remove, the bolts (9) that secure assembly to prevent it from tipping.
the Bearing Caps (7) to the differential housing.
This will facilitate removal of the Bearing Adjusters 13. Remove the nuts (44), washers (43) and bolts (34)
(11). It may be necessary to heat the bolts to that secure the Plain Case (39) to the Flanged
loosen them. Case (38). Discard the nuts. Lift off the Plain Case
: 1½ in (39).
15
: /16 in
NOTE: Replace any bolt that is heated to remove.
W5-7-3
14. Remove the Thrust Washer (36) and Dowel Pins

(37) from the Plain Case (39).
15. Remove the Side Gears (35), Pinion gears (42),

Thrust Washers (36) and Spider (41) from the
Flanged Case (38). Remove the Dowel Pins (37)
from the Flanged Case (38).
16. If spider roller bearings (45) are worn, replace the

spider pinion gears (42), roller bearings (45) and
spider (41) as an assembly. The spider pinion
gears (42) and Bushing (41) assemblies are
supplied in a kit.
EL 20728
17. Turn Ring Gear (20) and Flanged Half Case (38)
Figure 6 – Use of Puller and Round Disc (E12977849)
over so that the Ring Gear (20) teeth are facing
downward. Support the Flanged Half Case (38) so
20. Rotate differential housing in a position where the
that the gear teeth are above the
Drive Pinion (19) is upward. Remove Bolts (24)
work surface.
from the Seal Retainer (13).
15
18. Remove the Bolts (33), Nuts (22) and Washers : /16 in
(18). Separate the Flanged Half Case (38) from the
21. Remove thread protectors (30) from the tapped
Ring Gear (20) by tapping the edge of the Ring
holes in the retainer (13). Insert puller bolts into the
Gear (20) with a soft-faced hammer. Refer to
tapped holes and use them to assist in removing
Figure 5. Be careful so as not to chip the teeth of
the retainer (13) from the carrier housing (6).
the Ring Gear (20).
5
: 1 /16 in
22. Utilize Lifting Tool, as shown in Figure 7, to lift the
: Hammer Drive Pinion (19) assembly from the housing (6).
CAUTION: Pinion assembly weight 139 kg

(306 lbs).
23. Remove the Shim(s) (21).
24. Remove the Retainer (13) with the Oil Seal (16) and
O-Ring (12) attached. Tap out the Oil Seal (16) and
remove the O-Ring (12) from the Seal Retainer
(13). Discard the Oil Seal (16) and O-Ring (12).
EL 20727
Figure 5 – Removing Ring Gear

CAUTION: Retainer weight 21 kg (46 lbs).
NOTE: The dowel pin (37) will stay in either the

NOTE: Do not disassemble the drive pinion
Ring Gear (20) or the Flanged Half Case
assembly any further unless the bearings
(38).
need to be replaced. The double row
pinion bearing is a matched set and has
19. Remove both Bearing Cones (27) from the Plain
been pre-adjusted at the factory. Do not
Half Case (39) and Flanged Half Case (38) as
mix parts from different pinion bearing
necessary. A round steel disc (E12977849) should
assemblies.
be used as a center for the puller screw. Refer to
Figure 6 and Section W2-4.
W5-7-4
25. Using a soft drift, tap the bearing cup (26) out of the
Retainer (13).
26. Use a bearing puller to remove the bearing cones

(14, 25) from the Drive Pinion (19) shaft.
27. Using a soft drift, tap the bearing cup (15) out of the
carrier housing (6), and remove the shims (29).
Figure 8 – Lifting Tool
Figure 7 – Lifting Tool
W5-7-5
INSPECTION ASSEMBLY
Before starting assembly, make sure that all
1. Clean all parts in a suitable cleaning solvent. Use components are clean and free of rust. Clean and
special attention to ensure that the pinion bearing inspect all tapped internal holes for dirt, grease or
lube oil passages in the housing (6) and Retainer hardened locking compounds. Inspect threads for
(13) free of debris. damage. During reassembly and installation, make
sure that mated, punch-marked, or otherwise identified
2. Inspect all gears for excessive wear or cracked or serviceable parts are returned to their original
broken teeth. Used gears should be inspected positions. Lubricate all parts during assembly. Refer
using wet magnetic particle inspection method. to section W2-2.
NOTE: The Drive Pinion (19) and Ring Gear (20) NOTE: A worksheet is provided to provide
are a matched set. If either the Drive assistance during assembly. Reference
Pinion (19) or Ring Gear (20) is worn or will be made to this worksheet throughout
damaged, then both must be replaced. the text of the assembly procedure.
3. Check the housings, shafts, threads and splines for NOTE: The Ring Gear (20) and Drive Pinion (19)
abnormal wear and damage and replace parts as gear set must be used together. The
required. matched set is identified by a serial
number etched on the Ring Gear (20) and
4. If the tail bearing and pinion bearing assembly have identical number etched on the Drive
been removed, they should be replaced since they Pinion (19).
often sustain unnoticeable damage during removal.
5. Check the Side Bearing Cups (28) and Side

Bearing Cones (27) for pitting, bruising, excessive
wear or other damage. Replace if necessary.
NOTE: If either the outer cup or inner cone is worn

or damaged, then bearing cup and cone
must be replaced as a set.
6. Inspect the thrust washers and dowel pins for wear

or damage and replace if necessary.
W5-7-6
A
19
16
13
12
6 21
EL 20731
Figure 9 – Section View of Drive Pinion Assembly
6. Housing, Differential 16. Seal, Oil A. 12.7 mm (0.50 in)

12. O-Ring 19. Drive Pinion B. < 0.0127 mm (0.0005in)
13. Retainer 21. Shim
W5-7-7
ASSEMBLY – DRIVE PINION Preliminary Outer Bearing Shim Pack

Numbers in parentheses refer to Figure 1. Procedure
Torque specifications can be found at the end of this 1. Record the gauging distance to the ring gear
section. center line, etched on the end of the drive pinion
(19) on the worksheet, Table 1, Line 1.
1. Install the bearing caps (7) to the carrier housing
(6) at the punch marks made at disassembly. 2. Use a micrometer to measure the thickness of the
Install and tighten bolts. retainer plate (13). Take measurements at 4
: 1 1/2 in different places and average them. Fill out Lines 2
and 3 in Table 1 on the worksheet.
2. Using an OD micrometer, measure the distance
across the bearing caps (7). Record the distance NOTE: The special lifting device (E12977833)
on the worksheet in Table 2 on Line 1. shown in Figure 7, should be used to lift
and install the drive pinion (19). Refer to
3. Using the proper bearing driver, install bearing cup Section W2-4, SPECIAL TOOLS.
(15) in carrier housing (6). DO NOT install any
shims at this time. 3. Install the retainer (13) less shims (21) and O-ring
(12) onto the end shaft of the drive pinion (19).
NOTE: Freezing the bearing cup (15) may assist
in assembly. An alternate method is to 4. Install the assembled drive pinion (19) into the
heat the retainer (13) to 93°C (200°F) carrier housing (6). Refer to Figure 10.
and install bearing cup (15).
CAUTION: Pinion assembly weight 139 kg
NOTE: If using the heat method to install bearing (306 lbs).
cup (15), use temperature markers to
assure 93°C (200°F) is not exceeded.
NOTE: During the normalizing process, check

the back face of bearing cup (15) with a
.0127 mm (.0005 in.) feeler gage to
ensure the cup is properly seated.
4. Install bearing cup (26) into the retainer (13).
NOTE: As an alternate method, lightly heat the

bearing cones (25 & 14) to 93°C (200°F)
and install onto the drive pinion (19).
NOTE: If using the heat method to install bearing

cones (25 & 14), use temperature
markers to assure 93°C (200°F) is not
exceeded. If 93°C (200°F) is exceeded,
the metallurgical structure of the metal is Figure 10 – Installing Drive Pinion (19) Assembly
changed and the component may fail
prematurely. 5. Install two bolts (24) positioned 180° apart from
each other next to the puller holes in the retainer
5. Press bearing cone (14) and bearing cone (25) (13).
onto the end shafts of drive pinion (19). Check
with a .0127 mm (.0005 in.) feeler gage to assure 6. Apply a light coat of gear oil to bearing cone (25),
proper seating. bearing cup (26), bearing cone (14) and bearing
cup (15).
W5-7-8
NOTE: It will become very difficult to rotate the 8. Loosen the bolts (24) and spin drive pinion (19) at
drive pinion (19). To assist in turning the least eight complete rotations. Retighten the bolts
drive pinion install two of three bolts into (24) finger tight (10 lbf.ft.). Refer to Figure 13.
the drive pinion (19). Use a bar between : Hand Tighten
the two bolts to assist in rotating the
drive pinion (19).
7. While rotating the drive pinion (19), tighten the two

bolts (24) to 68 N⋅m (50 lbf.ft.) in increments of 34
N⋅m (25 lbf.ft.). Continue to rotate the drive pinion
while applying the torque to the bolts. Refer to
Figures 11 and 12.
: 15/16 in
: 68N٠m (50 Ibf٠ft)
Figure 13 – Loosen Bolts and Retighten Hand Tight
9. Using a depth micrometer, measure the depth

through the puller holes in the retainer plate (13).
Record the results on Lines 4 and 5 in Table 1 of
the worksheet.
Inner Bearing Shim Pack Procedure

Figure 11 – Torque-In Increments 1. While rotating the drive pinion (19), impact it with
a dead blow hammer ten times to ensure it is
properly seated against the bearing cup (26).
Etched dimension must be visible.
2. Record the flat bar thickness (if used) on Line 2 of

Table 3.
3. Using the centerline fixture tool (or a flat bar) and

the depth micrometer, measure the depth to the
drive pinion (19). Record the measured depth on
Line 3 of Table 3, then complete the calculations.
4. Build up a shim pack using shims (29). The shim

pack must be within +0.0254/-0.0508 mm
(+0.001/-0.002 in) of the calculated shim pack on
Line 4 of Table 3. Record each shim used on
Lines 5 of Table 3. Add all of the shims to obtain
the total actual shim pack.
Figure 12 – Rotate Drive Pinion (19) While Tightening
W5-7-9
Final Outer Bearing Shim Pack Procedure Preliminary Pinion Depth Check
2. Fill out Table 4 in the worksheet to determine the 1. Rotate the pinion eight times. Impact the end of
final outer bearing shim pack thickness. Build the pinion shaft with a rubber mallet to help seat
the actual shim pack to be within +0.000/-0.003” the bearings. Install the center line fixture tool or
of the final shim pack value recorded on Line 4 in flat bar. Take a depth micrometer reading to the
Table 4. end of the pinion shaft and complete Table 6 in
the work sheet to determine the preliminary pinion
depth dimension. The preliminary pinion depth
Preliminary End Play Check dimension should be within -0.001 to -0.003
inches of the etched dimension. If it is not, add or
1. Rotate the housing and remove the two bolts subtract shims from the inner shim pack as
(24), the drive pinion (19) assembly and the necessary. Be sure to make the same change to
retainer (13). the outer shim pack as well.
2. Weigh the drive pinion (19) with both inner and Final End Play Check
outer bearings to determine the required lifting
force that is required for the procedure. Take 1. Insert the O-ring (12) onto the retainer (13).
note of the weight and install the drive pinion (19) Lubricate with petroleum jelly or grease. Use the
with bearings, inner and outer shim packs (21, proper seal driver and install the oil seal (16) into
29), and retainer (13) without O-ring (12). Install the retainer (13).
the retainer bolts (24) and torque in a star
pattern. 2. Coat each shim of the outer shim pack (21) with a
: 15/16 in sealant such as Loctite Gasket Eliminator 573
: 259 N٠m (191 lbf٠ft) (green) or equivalent. Install the two shim packs
(21, 29) and the retainer (13) with the park brake
3. Prepare a lifting device capable of applying a mounting plate.
lifting force of 50 lbs plus the weight of the drive
pinion/bearing assembly to the drive pinion (19). 3. Install all bolts (24) and torque in a star pattern.
Ensure that the inner and outer shim packs, the Rotate the drive pinion (19) while applying torque
retainer and retainer bolts have been installed. to the bolts (24) to assure the proper torque has
Rotate the pinion ten times. Ensure that the been achieved. The drive pinion (19) should
bearing cup (26) is totally seated in the retainer rotate with slight resistance when the bolts (24)
(13) before proceeding. have been properly torqued. Refer to Figure 17.
: 15/16 in
4. Take depth micrometer readings in three places : 259 N٠m (191 Ibf٠ft)
(120° apart) from the lifting device down to the
bearing retainer. Record this data in Table 5, 4. Perform the final end play check. Record the data
Lines 1. Lift the pinion with the force previously in Table 7 of the worksheet. The final end play
calculated. Rotate the pinion ten times. Take range is 0.0005 to 0.004 inches.
depth micrometer readings in the same three
places and record in Table 5, Lines 3. Release NOTE: All but a few of the rollers should be
the lifting force. Rotate the pinion ten times. Take turning when the drive pinion shaft is
depth micrometer readings in the same three rotated after being properly torqued.
places and record in Table 5, Lines 6. Repeat When the proper procedure is followed,
the lifting procedure and record the results in the pinion bearings will have an endplay
Table 5, Lines 8. Complete the calculations in setting of 0.0127 - 0.0508 mm (0.0005 -
Table 5 for the preliminary end play. The two end 0.004 in). Setting the bearings tighter
play values from Line 5 and Line 10 in Table 5 than recommended may cause
should be within 0.001 inches of each other. If premature bearing failure and setting
they are not, the measurements must be taken them looser than recommended will
again. The actual value of the preliminary end cause pinion seal leaks during operation.
play should be 0.0005 to 0.002 inches. If the
endplay is not within range, add or subtract
shims from the outer shim pack to correct it.
W5-7-10
Final Pinion Depth Check
1. Install the center line fixture tool or flat bar. Take

a depth micrometer reading to the end of the
pinion shaft and complete Table 8 in the work
sheet to determine the preliminary pinion depth
dimension. The final pinion depth dimension
should be within -0.001 to -0.003 inches of the
etched dimension. If it is not, add or subtract
shims from the inner shim pack and make the
corresponding changes to the outer shim pack.
Figure 14 – Centerline Fixture Tool E12977848
Figure 16 - Measure Drive Pinion (19) Depth
Figure 15 - Install Centerline Fixture Tool

(E12977848) Parallel
Figure 17 - Reinstall Pinion Retainer Bolts
W5-7-11
BODY ASSEMBLY c. Place the case washers (46) onto the spider
Numbers in parentheses refer to Figure 1. (41) crosses. Refer to Figure 18.
NOTE: The cases, flanged half (38) and plain

half (39), are machined as a match and
each half must remain with its mate. It is
very important to keep the halves aligned
in their original position as the holes for
the spider cross are machined with the
cases bolted together.
1. Press the side bearing cones (27) onto each of

the half cases (38 & 49). An alternate method is to
heat the bearing cones to a temperature of 90°C
(200°F) maximum and install on the half cases.
Check with a 0.0127 mm (.0005 in.) feeler gage
behind the back face of each cone as the
temperature cones normalizes to ensure it stays
firmly seated against the shoulder. Use a soft drift
and hammer to re-seat, if necessary, during the
normalizing process.
2. Beginning with the flanged half case (38), install Figure 18 - Assembled Spider
two dowel pins (37). Refer to Figure 19.
6. Install the other gear (35) onto the assembled
3. Coat one of the bronze thrust washers (36) with a spider. Coat gear (35) in gear oil, especially if
petroleum jelly or grease. Align the holes in the the differential will not be installed, to prevent
thrust washer (36) over the two dowel pins (37) rust during storage.
and install into the flanged half case (38).
7. Install two dowels (37) into holes in the plain half
4. Install one of the gears (35). Coat in gear oil, case (39). Refer to Figure 19.
especially if the differential will not be installed, to
prevent rust during storage.
NOTE: The pinion gear set (42) is a matched set

and must be replaced as a set of four. If
there is any pitting on the spider (41),
pinion gear set (42), or caged roller
bearings (45); all of these components
will need to be replaced.
NOTE: Never mate a new half case with a used

half case. They must always be replaced
in pairs.
5. Build the spider assembly on a bench before

installation:
a. Lubricate each caged roller bearing (45) with
petroleum jelly or grease and install onto the
crosses of spider (41)
b. Place the pinion gear set (42) of the spider Figure 19 – Drive-In Dowel Pins (37)
onto the spider (41) crosses and over the
caged roller bearing (45). 8. Coat the other bronze thrust washer (40) with
petroleum jelly or grease. Align the holes in the
W5-7-12
thrust washer (40) over the two dowel pins and 12. Insert bolts (33) and washers (18) into and
install into the plain half case (39). through the ring gear (20) and flanged half case
(38). Install nuts (22) to the threaded ends of bolts
9. Coat the spider (41) cross ends and the mating (33). Tighten in a star pattern.
surface between the flange half case and the : 1 5/16 in
plain half case with Gasket Eliminator. Refer to : 576 - 712 N٠m (425 - 525 Ibf٠ft)
Figure 20.
13. Coat bearing cones (27) with gear oil.
DIFFERENTIAL CASE INSTALLATION

1. If used half cases which have been re-machined

are being used, proceed with step 2. If new half
cases are being used go to step 9.
Used Half Cases
2. Place bearing cups (28) on bearing cones (27).
3. Install the assembled body assembly into carrier

housing (6). Check that dowel bushings (8) are in
their holes in the carrier housing. They may have
remained in the bearing caps (7) at time of
disassembly. Replace any missing dowel
Figure 20 - Apply Gasket Eliminator bushings.
(Assembled Spider Shown Prior to Cross Ends
Installed into Bore of Half Case) CAUTION: Differential body weight 269 kg
(592 lbs).
10. Align the bolt holes and spider bores of the plain
half case (39) with those in the flanged half case 4. Match the identifying punch marks made at
(38). Install the plain half case (39) to and disassembly on bearing caps (7) with the punch
against the flanged half case (38). marks made on the carrier housing (6). Install the
bearing caps (7) over dowel bushings (8) in the
NOTE: It may be easier to finish torquing the carrier housing (6). Refer to Figure 22. Install
bolts (34) with the assembly installed in bolts (9) and washers (10) through bearing caps
the carrier housing (6). (7) and into the carrier housing (6). Do not tighten
the bolts (9) at this time.
11. Install bolts (34) and washers (43) into and
through the plain half case (39) and flanged half 5. Install the bearing adjusters (11). The bearing
case (38). Install washers (43) and nuts (44) to adjusters (11) thread into bearing caps (7) and
the threaded ends of bolts (34). Tighten in a star the bearing cap mounts on the carrier housing
pattern. (6). Tighten the bearing adjusters (11) until all but
: 15/16 in a few rollers in bearing cones (27) are rolling.
: 251 N٠m (185 Ibf٠ft) Rotate the body assembly 5-10 times in the
carrier housing (6) to seat the bearings.
NOTE: If pin (32) was removed, insert it into ring
6. Set up a dial indicator on the carrier housing (6),
gear (20) at this time.
Figure 21, and place the dial against the surface
to which the ring gear (20) bolts. Rotate the body
NOTE: It may be easier to finish torquing the
bolts (33) with the assembly installed in assembly. The runout must not exceed ± 0.076
the carrier housing (6). mm (± 0.003 in.). If the runout is in excess of that
range, the half case should be removed and re-
machined. Excessive runout may cause a poor
contact pattern between the ring (20) and pinion
W5-7-13
gear (19), thereby decreasing the service life of

the gearset. It may also cause premature side 12. If dowel pin (32) is not in either the ring gear (20)
bearing failure. or flanged half case (38), first seat the ring gear,
then install bolts (33), washers (18) and nuts (22)
with light torque. The heads of the bolts (33) and
the washers (18) are against the ring gear (20)
with the nuts (22) installed on the flanged half
case (38).
13. Drive dowel pin (32) in from the flanged half case
(38) side using a brass hammer. It would be
advantageous to “freeze” the dowel pin (32)
before hand. Use a pointed punch to deform the
metal in two places around the dowel pin hole in
the flanged half case (38) to prevent the dowel
pin (32) from coming out. This operation is not
required on the ring gear (20) side because the
dowel pin hole in the ring gear is “stepped”.
Tighten the bolts (33) in a star pattern.
: 1 5/16 in
: 576 - 712 N٠m (425 - 525 Ibf٠ft)
14. Place bearing cups (28) on bearing cones (27)

Figure 21 - Flanged Half Runout and install the body assembly into the carrier
housing (6). Refer to Figure 22.
7. Remove the bearing adjusters (11) and remove
the end caps (7). Lift body assembly out from
carrier housing (6) and place on a table with the
flanged end down.
8. Continue with the installation of Used Half

Cases with step 9.
New Half Cases
9. Install ring gear (20) onto the flanged half case

(38), being sure to align the pin (32).
10. If dowel pin (32) is already in either the ring gear

(20) or flanged half case (38), align the dowel pin
(32) with its corresponding hole and carefully
seat the ring gear against the flanged half case
(38).
11. Insert bolts (33) and washers (18) into and

through the ring gear (20) and flanged half case
(38). Install nuts (22) to the threaded ends of
bolts (33). Tighten in a star pattern. Figure 22 - Install Body Assembly and Bearing Caps
: 1 5/16 in
: 576 - 712 N٠m (425 - 525 Ibf٠ft)
W5-7-14
15. Match the identifying punch marks on the bearing 18. Set the bearing adjuster (11) on the side of the
caps (7) with the punch marks made on carrier flanged half case (38) so that there is a small
housing (6) during disassembly. Install the amount of backlash, seen visually. Set the other
bearing caps (7) over dowel bushings (8) on the bearing adjuster on the side of the plain half case
carrier housing (6). Install bolts (9) and washers (39) to approximately zero bearing end play.
(10). Do not tighten the bolts (19) at this time. Watch the rollers in bearing cones (27) as ring
gear (20) is turned. At zero end play most of the
16. Install the two bearing adjusters (11). The rollers will be rotating with only one or two sliding.
bearing adjusters thread into bearing caps (7) All rollers turning indicates a preload.
and the bearing cap mounts on the carrier
housing (6). Tighten bolts (9) until the bearing 19. Preload bearing cones (27) and cups (28) by
adjusters cannot be turned. tightening each bearing adjuster (11) until the
expansion between bearing caps (7) is 0.0254 to
17. Using a large Outside Diameter Micrometer, take 0.102 mm (.001 to .004 in) over the ”relaxed”
a measurement across the sides of bearing caps dimension as recorded under Line 1 in Table 9 of
(7). Refer to Figure 23. Record the measured the worksheet. Record the preload expansion on
value on the worksheet in Table 9 on Line 2. Line 3. Be sure when adjusting the preload that a
Back the bolts (9) off until each bearing adjuster groove in the bearing adjuster (11) is in position
can be turned in and out easily. for the installation of lock adjuster (17). Maintain a
small amount of ring gear backlash at all times.
NOTE: The measurement on Line 1 should be Refer to Figure 24.
within ± .025 mm (± .001”) of Line 2.
Figure 23 - Preload Side Bearings Figure 24 - Adjusting Ring Gear Backlash
NOTE: For a specific gear set, the backlash will

change slightly as different teeth on the
drive pinion (19) mate with different teeth
on the ring gear (20).
W5-7-15
20. Install a dial indicator as shown in Figure 25 and set, deviations from the specified pinion location
check the runout of ring gear (20). The ring gear are not normally necessary and the tooth contact
runout must not exceed ± 0.102 mm (± 0.004 in.). pattern check is used to confirm that the pinion
If the runout exceeds ± 0.102 mm (± 0.004 in), location shim packs and backlash adjustments
check for improper seating between the flanged have been made correctly.
half case (38) and the plain half case (39), and
also between the ring gear (20) and the flanged NOTE: The use of the centerline fixture tool
half case (38). (E12977848) will increase accuracy and
is recommended in the ASSEMBLY of
21. Install a dial indicator as shown in Figure 24. It the differential. The use of a flat bar may
must be rigidly mounted with the stem require more pinion adjustments to
perpendicular to the tooth surface at the extreme achieve proper gear patterns.
outside diameter. Clamp the shaft of the drive
pinion (19) so it will not rotate. (A flat bar bolted 2. When a differential is assembled using a spiral
to the end of the pinion and C-clamped to the bevel gear set that has a degree of normal wear,
supporting fixture will prevent rotation). Check it may be necessary to deviate from the ”Etched
the backlash and record on the work sheet in Dimension” and the backlash range in order to
Table 10 on Line 2. Adjust the backlash to be arrive at a favorable tooth contact pattern. As a
within 0.406 to 0.558 mm (0.016 to 0.022 in) by starting point it is always best to assemble all
rotating both side bearing adjusters (11) in and differentials as if a new gear set was being used
out the same amount and direction. Record the and then make adjustments to obtain the
backlash etched on the ring gear on the work optimum contact pattern.
sheet.
3. Before starting the tooth contact pattern, check
and tighten bolts (9) in the bearing caps (7).
4. Paint the drive and coast side of several teeth in

three locations on ring gear (20) with a suitable
marking compound such as Prussian Blue.
5. With the ring gear (20) under load, rotate the

drive pinion (19) at least five times in each
direction.
NOTE: In order to develop a true tooth contact

pattern, it is necessary to apply a
significant load to the gear set. A drive
pinion (19) load of 271 N⋅m (200 lbf.ft) is
necessary to impart a representative
tooth contact pattern. An acceptable
method is to anchor a lifting strap to the
rebuild fixture. Wrap the strap 1/2 to 3/4
Figure 25 - Checking Ring Gear (20) Runout of a turn around the splines on the drive
1. Ring Gear 2. Dial Indicator pinion’s shaft and connect the other end
of the strap to a crane. Tension the strap
until it is just possible to turn the ring gear
TOOTH CONTACT PATTERNS (20) with a 610 mm (24 in.) breaker bar.
This will provide a good contact pattern
1. When a differential is assembled using a new indication.
spiral bevel gear set or one with minimal wear,
the best tooth contact pattern will be obtained 6. Figure 31A and 31B shows various tooth contact
when the drive pinion (19) is set to the ”Etched patterns. To determine which chart to use,
Dimension” and the backlash is at a mid range examine the ring gear (20). If the tooth depth
value. Therefore, with a new or nearly new gear varies from the inside diameter to the outside
W5-7-16
diameter, use the chart in Figure 31A for

Gleason Cut gears. If the tooth depth remains
constant, use chart in Figure 31B for
Klingelnberg Cut gears.
NOTE: Always strive to have the drive side set

to the preferred pattern as shown in
Figure 31A & 31B.
7. When changing backlash, advance one bearing

adjuster (11) in as many notches as the opposite
adjuster is being withdrawn out in order to
maintain bearing preload.
8. When changing pinion (19) position, equal

amounts of shim pack must be added or Figure 26 - Flange Assembly
removed from the inner and outer shim packs in 4. Flange 5. Collar
order to maintain pinion bearing end play.
5. Lubricate a new O-ring (3) with NLGI#2 grease

and install it in flange (4). Install plate (2) in the
FINAL ASSEMBLY flange (4). Apply a suitable thread locking
compound to bolts (1) and install.
: 15/16 in
1. Remove bolts (9), one at a time. Apply Loctite
: 244 N٠m (180 Ibf٠ft)
Thread Adhesive (permanent) or equivalent to
the thread of the bolt removed, and reinstall.
: 1 1/2 in 6. Install thread shield (31) in carrier housing (6).
: 942 N٠m (695 Ibf٠ft)
2. Apply Loctite Thread Adhesive (permanent) or

equivalent, to the threads of bolts (23) and install
lock adjusters (17).
: 9/16 in
: 33 N٠m (24 Ibf٠ft)
3. Secure carrier housing (6) in a position where

drive pinion (19) is upward.
4. Slide flange (4) down onto the splines of drive

pinion (19). (Collar (5) should be welded to the
flange, See Figure 26.) It may be necessary to
tap the flange lightly with a hammer. Refer to
Figure 27. Orange sealant 504 can be applied to
the splines.
Figure 27 - Install Flange
W5-7-17
INSTALLATION 5. Install the two axle shafts. Reinstall and secure

the center cover on the planetary carrier. Refer to
1. Using an ID micrometer, measure the inside of Section W5-6, REAR AXLE.
the axle housing differential supports. The
tolerance is 682.523/682.625 mm (26.871/26.875 6. Install the two speed sensors in the rear axle
in). Refer to Figure 28. Repair, if necessary. housing if the hauler is equipped with ”Active
Traction Control” (optional equipment). Refer to
Section W6-5 for installation instructions.
7. Install the drain plug in the axle assembly and fill

the differential through the level check plug with
the recommended lubricant. Refer to Figure 29.
Refer to the Recommended Lubricant Chart in
Section W2-2, MAINTENANCE.
: 13/16 in
Figure 28 - Axle Housing Differential Supports
2. Clean the mounting flanges on both the

differential and axle housing and apply a suitable
sealing compound to the flange on the axle
housing to insure an oil-tight seal. Position an O-
ring around the pilot diameter on carrier housing
(6). Install two studs approximately 100 mm (4
in.) long into the threaded holes in the axle
housing to assist in aligning the differential.
NOTE: The axle housing cavity must be

thoroughly clean before installing the differential.
3. Using a suitable hoist, lift the differential onto the

axle housing using the studs to align and hold Figure 29 - Rear Axle Drain and Fill Plugs
the differential in position. Apply a mild strength
thread locking compound to the mounting bolts
(34, Figure 3) and tighten. Refer to Figure 3. 8. Replace the axle breather filter element. Refer to
Remove the two studs used for alignment and MAINTENANCE in the Operator’s Manual.
install the mounting bolts (34, Figure 3). Allow
the thread locking compound to cure by following
the manufacturer’s recommendations.
: 1 1/8 in
: 433 N٠m (319 Ibf٠ft)
CAUTION: Differential weight 818 kg (1805

lbs).
4. Connect the rear driveline. Refer to Section W5-

5, REAR DRIVELINE.
W5-7-18
MAINTENANCE
Inspect the yoke mounting bolts (1, Figure 1), NOTE: Plan your oil sampling program carefully.
retainer bolts (24, Figure 1) and the differential It is necessary to use the same test lab
mounting bolts (48, Figure 1) for tightness. Retighten (and preferably the same test equipment)
if necessary. for every oil sampling test. Trend analysis
is the most important part of oil sampling.
Changing labs or equipment introduces
CAUTION: Never test run with one wheel error and may make the oil sampling data
jacked up. Excessive operation in this meaningless.
manner will cause overheating of the
differential spider and pitting of the spider Tests to Perform
bearings. A rigid dump truck equipped with Viscosity @ 40°C
an ATC system will lunge forward during Specto-Analysis (Wear Metal ppm)
testing, so the ATC sensors must be Macro-particle examination if abnormal sample or
disconnected prior to testing. Failure to trend spike is observed. *See note above.
remove the connections may result in
damage to equipment or serious injury.
Tests Procedure
TOOLS REQUIRED:
Jack up the drive axle and test run the machine. A
Three NEW plastic tubes
noisy differential will indicate the need for adjustment
Three NEW sample bottles
or replacement of worn parts. Both wheels must be
A Vampire pump
lifted off the ground during the test run, and the
brakes should be free to allow both wheels to rotate
1. Make sure that the final drive is at operating
at the same speed. The differential is splash-
temperature and has run for at least five hours of
lubricated. The fill-level plug (Refer to Figure 29) is
continuous productive operation. Final drive
located in the rear center of the axle housing. Every
operating temperatures are between 40 - 70°C
1,000 hours remove the magnetic drain plug (Refer
to Figure 29) in the bottom of the axle housing and (100 - 160 °F).
drain the differential oil. Remove any particles
adhering to the magnetic drain plug. Replace the 2. Within five minutes of bringing the unit to the
differential oil as outlined in your Operators Manual. servicing location, remove the differential level
Refer to Section W2-2, MAINTENANCE. The drain check plug (Figure 29). Remove the planetary fill
interval for differential oil can be extended by plug from each of the two planetaries (Figure 30).
following an Oil Sampling Program.
: 13/16 in
Oil Sampling Program

Oil sampling programs are very beneficial for
lowering maintenance costs through extending oil
change intervals and for catching problems before
they cause major component rework and machine
downtime.
Oil Sample Procedure

FREQUENCY:
Initial Sample Five (5) Hours after an oil change
Periodic Sample Every 250 Hours *
Final Sample Just prior to an oil change
*Retest immediately if abnormal trends or spikes in

wear metals occurs. This will determine whether the
abnormal reading was due to an error of the previous Figure 30 - Rear Planetary Drain Check, and Fill
oil sample or due to abnormal wear. Plugs
W5-7-19
3. At each planetary and differential fill plug insert a analysis test burns the oil and any tiny element
NEW tube and draw enough oil to fill a NEW particles (< 6 microns). The flame is analyzed by a
sample bottle. Immediately label each sample computer to determine which elements, and the
bottle as to; left planetary, right planetary or quantity of those elements, that are present. This test
differential. will not find the presence of large particles. If you can
see quantities of metal, perform a visual macro-
4. Note the machine hours, number of hours since particle test coupled with the spectra-analysis.
last oil change, serial number of machine, date
and any important notes such as if a brake failure As with the viscosity test, trends are most important. It
occurred, a seal leaked, type of oil, etc. is very difficult for a manufacturer of axles to predict
the wear rate of the gearing and bearings for all
5. Send the oil samples to the test facility chosen, applications as loading, temperatures, maintenance
requesting the Tests to Perform. practices, oil quality, and operator habits differ greatly
from site to site. Therefore, it is best to follow the
Sample Results and Trend Analysis recommended oil sample procedure with one test lab.
The particle counting test reveals the type of wear
VISCOSITY TRENDS: debris in the oil and the distribution of particle sizes.
Checking the viscosity is important with gear oils. It is The current standard for the particle counting test is
one of the easiest ways to determine when the ISO 4406. The test results have a lower limit of zero
additive package has been exhausted and the oil is ppm, but no upper limit exists. It is important to
ready for a change. Typically, the oil will have a monitor these levels regularly and trend them over
higher viscosity when it is new. As the oil ages, the time, as a single test result on its own is not a good
additive and viscosity improvers are used up. As this indication of the performance of the differential or the
happens, the viscosity of the oil begins to drop quality of the oil. Brand new oil should be tested as
(slightly). When the oil is worn out, the viscosity rises well to determine baseline values for the analysis.
rapidly and the oil loses most of its lubricative The metals to be concerned with and their warning
properties. Operating the unit with oil in this condition level concentrations are:
will cause extensive gear and bearing damage.
1. Iron (Fe) 1000 ppm
2. Chromium (Cr) 20 ppm
3. Nickel (Ni) 10 ppm
4. Aluminum (Al) 25 ppm
5. Silicon (Si) 150 ppm
6. Tin (Sn) 20 ppm
7. Copper (Cu) 75 ppm
8. Lead (Pb) 50 ppm
All other metals and elements are part of the viscosity

modifier and the extreme pressure package from the
oil manufacturer. The additive packages will vary by
manufacturer - therefore, changing to a new brand of
oil may cause a difference in the oil sample results.
Additive package elements include:
Based on this set of operating conditions, the proper Calcium (Ca)

time to change the oil was at 1500 operating hours. Magnesium (Mg)
The graph illustrated here is only a representation – it Phosphorous (P)
should not be used to base a specific change interval Sodium (Na)
for the site the unit is working at. Each individual site Zinc (Zn).
must determine the rate at which the viscosity
changes. The rate of change is determined by the The ppm in the oil sample of these elements should
operating temperatures, haul cycle and duty factor, drop as the oil ages. A good means of measuring the
and quality of oil. Work with your oil sample lab and concentration of additives in the oil is by using the
lubrication supplier to determine the proper point total acid number test. The test measures the total
based on BOTH Viscosity and Particle Count Data. amount of oxidation that is present in the oil. It is
SPECTRA-ANALYSIS TRENDS: The spectra-
W5-7-20
important to determine a baseline total acid number TROUBLE SHOOTING

for your fresh oil because the additives in the oil raise Noises and vibrations originating in the tires,
the total acid number. Over time, the additives in the transmission, planetaries, and driveshafts are easily
oil will deteriorate and the total acid number will drop transmitted to the differential and may be erroneously
to a minimum value, and then rise again. This attributed to the differential. Therefore, all possible
represents the depletion of the additives in the oil, sources of noise should be thoroughly investigated.
followed by a rise in harmful acids in the oil. The oil
viscosity follows a similar trend, diminishing in value
until the additives are gone, and then rising again as CAUTION: Never test run with one wheel
the harmful acids and sludge form in the oil. It is very
important to try to service your oil prior to that jacked up. Excessive operation in this
minimum acid number being reached. Replace the manner will cause overheating of the
oil completely or refortify it with more additives. If you differential spider and pitting of the spider
miss the minimum total acid number and acids have bearings. Machine equipped with the ATC
formed in your oil, a simple oil change will not solve system will lunge forward. Disconnect the
the problem. Acids remaining in the system after the ATC sensors before testing in this manner.
oil change will quickly deteriorate the oil additives in Failure to remove the connections may
the new oil and the problem will continue to surface. result in damage to equipment or serious
Flush out the system thoroughly before replacing the injury.
oil to prevent rapid oil deterioration in subsequent oil
Differential noises may be located by jacking up the
changes.
drive axle of the machine with the tires off the ground.
Run the power train in fourth gear at a moderate
Change intervals will differ by site and by
types/brands of oil used. Some oils may last only engine speed. Be sure to jack up both drive wheels to
1000 hours or less while some may last more than prevent damage to the differential. If noises, such as
grating or rattle are heard in the differential, stop the
2000 hours. Hitachi recommends using high quality
oils to best protect your equipment investment and to machine immediately. One broken ring gear tooth can
get the maximum benefit from your oil sampling cause damage to all gears and bearings. If the
differential is suspect of requiring repair, the axle
process. Low quality oils will wear out faster than
high quality oils. Experiment with brands or types shafts should be removed and the machine towed to
within a brand to determine which one provides the prevent additional internal damage.
longest service using the oil sampling procedure.
As a recommendation, extending drain intervals on

axle oil over 2000 hours may cause increased gear
and bearing wear. If synthetic oil is used, it may be
drained, filtered, and re-used for up to 4000 hours -
by oil sample results.
NOTE: If extended drain intervals are used

during the warranty period, keep your oil
sample records as they will aid in any
warranty claim process.
W5-7-21
W8DX-04-65-01
Figure 31A – Spiral Bevel Ring Gear Tooth Bearing Contact Chart – Gleason Cut
W5-7-22
Figure 31B – Spiral Bevel Ring Gear Tooth Bearing Contact Chart – Klingelnberg Cut
W5-7-23
DIFFERENTIAL ASSEMBLY WORK SHEET

(Make copies as needed for assembly and record)
MODEL 2650 SERIES
Preliminary Outer Bearing Shim Pack
1) Etched Dimension on Drive Pinion _______________________________
2) Retainer Plate Thickness Measurements _______________________________
_______________________________
______________________________
______________________________
3) Total ÷ 4 (average) ______________________________
4) Puller Hole Depth Measurements ______________________________
______________________________
5) Total ÷ 2 (average) ______________________________
6) Subtract Line 5 – Line 3 ______________________________

(Preliminary Shim Pack Measurement)
Table 1
Side Bearing Pre-Load
1) Measurement Over Bearing End Caps ______________________________

(no load)
Table 2
W5-7-24
Inner Bearing Shim Pack
1) Dimension Etched on Pinion Shaft ______________________________
2) Flat Bar Thickness (use 0 if not used) ______________________________
3) Reading from Centerline Fixture Tool ______________________________
4) Subtract Line 1 – Line 3, Add Line 2 ______________________________

(Calculated Inner Bearing Shim Pack)
5) Shims Actually Used _____________ _____________
_____________ _____________
_____________ _____________
_____________ _____________
6) Total Inner Shim Pack

(to be within (-0.001/+0.002” of Line 4) _______________________________
Table 3
Final Outer Bearing Shim Pack
1) Recall Line 6 from Table 1 ______________________________
3) Constant (to ensure endplay) 0.003”
4) Add Line 1 + Line 2 + Line 3 ______________________________

(Calculated Outer Bearing Shim Pack)
5) Shims Actually Used _____________ _____________
_____________ _____________
_____________ _____________
_____________ _____________
6) Total Outer Shim Pack

(to be within -0.003/+0.000” of Line 4) _______________________________
Table 4
W5-7-25
Preliminary Endplay Check
1st Measurement
1) Micrometer Readings (no force) _______________________________
_______________________________
_______________________________
2) Total ÷ 3 (average) _______________________________
3) Micrometer Readings (with force) _______________________________
_______________________________
_______________________________
4) Total ÷ 3 (average) _______________________________
5) Subtract Line 4 – Line 2 _______________________________

(Drive Pinion Endplay)
2nd Measurement
_______________________________
_______________________________
7) Total ÷ 3 (average) _______________________________
_______________________________
_______________________________
9) Total ÷ 3 (average) _______________________________

Table 5
W5-7-26
Preliminary Pinion Depth Check
2) Measured Pinion Dimension ______________________________
Table 6
Final Endplay Check
1st Measurement
_______________________________
_______________________________
2) Total ÷ 3 (average) _______________________________
_______________________________
_______________________________
4) Total ÷ 3 (average) _______________________________

2nd Measurement
_______________________________
_______________________________
7) Total ÷ 3 (average) _______________________________
_______________________________
_______________________________
9) Total ÷ 3 (average) _______________________________

Table 7
W5-7-27
Final Pinion Depth Check
2) Measured Pinion Dimension ______________________________
Table 8
Side Bearing Pre-Load

(with bearings)

(with pre-load)
Table 9
Backlash
1) Required Backlash 0.016 – 0.022”
2) Measured Backlash ______________________________
3) Backlash Etched on Ring Gear ______________________________
Table 10
TORQUE SPECIFICATIONS
Figure 1 Description Specification

23 Adjuster Lock Bolts 33 N·m (24 lbf·ft) + Thread lock compound
33 Ring Gear Bolts 576 - 712 N·m (425 - 525 lbf·ft)
24 Retainer Bolts 259 N·m (191 lbf·ft)
48 Differential Mounting Bolts 433 N·m (319 lbf·ft) + Thread lock compound
34 Half Case Bolts 251 N٠m (185 Ibf٠ft)
9 Bearing Cap Bolts 942 N·m (695 lbf·ft) + Thread lock compound
1 Yoke Mounting Bolts 244 N·m (180 lbf·ft) + Thread lock compound
W5-7-28
POWER TRANSMISSION / Planetary
SERVICE POSITION

park the rigid dump truck on a level solid surface and Fill Plug
Oil Level
REMOVAL
1. Remove the rear tires and rims as outlined in Sec-

tion W8-6.
2. Drain the lubricant from the planetary gear reser-

voir by turning the wheel until the drain plug is at
the lowest point of travel, and remove the drain
plug. Refer to Figure 2.
: 1 in Cover
Drain
Plug
3. If the rigid dump truck is equipped with the optional
ATC system, remove the two speed sensors lo-
cated on the front side of the differential. Refer to W8DX-04-66-001
Figure 2. The two speed sensors must be removed

from the axle housing before the axle shafts are Figure 1 - Planetary Drain Plug
removed.
3
: /16 in
Speed Sensor
W8DX-04-66-002
Figure 2 - Speed Sensors

Optional Active Traction Control
W5-8-1
15
19 18 10
3 14 2
16
23
24
11
22
4
20
21
27
31 5
29
26 12
28 5 6 6 17
25
1 30
13
8 7
9
W8DX-04-66-003
Figure 3 - Exploded View of Planetary Assembly

1. Internal Ring Gear 11. O-Ring (3x) 21. Washer (3x)
2. Axle Shaft 12. Shim(s) 22. Bolt (4x)
3. Pin (3x) 13. Plate 23. Cover
4. Bearing Assembly includes items 5,6,8,9 (3x) 14. Bolt (12x) 24. Gasket
5. Cone (6x) 15. Ring Spacer 25. Set Screw (3x)
6. Cup (6x) 16. Sun Gear 26. Spacer (11x)
7. Retaining Ring (3x) 17. Snap Ring 27. Bolt (11x)
8. Spacer (3x) 18. O-Ring 28. Plug, Magnetic (2x)
9. Spacer (3x) 19. Planet Carrier 29. Dowel Pin (3x)
10. Planet Gear (3x) 20. Bolt (3x) 30. Hub
31. Washer (11x)
8 7
Figure 4 – Section View of Pin (3) from Figure 3 6
3
3. Pin 8. Spacer
29
5. Cone (2x) 9. Spacer
6. Cup (2x) 11. O-Ring
7. Retaining Ring 29. Dowel Pin
11
5
9
W5-8-2
NOTE: Failure to remove the “Active Traction

Control” speed sensors before removing
CAUTION: Support and retain wheel hub in
the axle shafts may result in sensor dam-
age. position with hoist when the bolts (14) are
removed. The wheel hub could move unex-
4. Remove the bolts (22) from the cover (23). Re- pectedly causing injury or damage.
move cover (23) and gasket (24) from the plane-
tary carrier (19). Discard the gasket (24).
: 15/16 in
5. Remove the sun gear (16) and axle shaft (2) as

an assembly. See Figure 6.
CAUTION: Axle Shaft & Sun Gear weight:

103 kg (226 lbs.)
NOTE: Support the sun gear and axle shaft as-

sembly during removal to prevent dam-
age to the splines on the axle shaft and
planetary gears.
6. Remove the planetary carrier (19) spacers (26)

and washers (31) that secure the planetary as-
sembly to the wheel.
: 1 1/2 in
7. Remove set screws (25) from the planetary car-

rier (19) and thread puller bolts into the holes.
Evenly separate carrier from wheel. Catch ex- Figure 5 – Use of Planetary Ring Gear Tool
cess planetary fluid in drain pan. (E12977824). Refer to Section W2-4.
: 5/8 in
: 1 1/8 in NOTE: Make sure the internal ring gear is sup-
ported to prevent damage to the splines
8. Attach a shackle and suitable hoist to the planet on the axle spindle.
carrier (19), apply slight tension and remove the
planetary assembly from the rigid dump truck.
Remove and discard the O-ring (18).
CAUTION: Planetary weight: 899 kg (1982 lbs)
9. Loosen the bolts (14), while supporting the

wheel with a suitable hoist. Remove bolts (14),
plate (13) and shim(s) (12) from the spindle.
1
: 1 /2 in
10. Use the rear axle planetary ring gear tool

(E12977824) to remove internal ring gear (1) us-
ing the special tool. Pull the internal ring gear (1)
straight out, away from the spindle, and remove
it from the rigid dump truck. Refer to Figure 5. W8DX-04-66-004
CAUTION: Ring Gear weight: 359 kg (791 lbs)

Figure 6 - Removing Sun Gear and Axle Shaft
W5-8-3
DISASSEMBLY
NOTE: Keep planetary bearings and spacers
Numbers in parentheses refer to Figure 7, unless organized so they can be returned to
otherwise noted. their original location if being used
again. Do not mix bearing cup and
1. Remove the bolts (20) and washers (21) which cone or select spacers between plane-
retain the planetary pins (3) to the planetary car- tary bearing kits.
rier (19).
: 1½ in 7. Remove the snap ring (17) from the axle
shaft (2). Remove the sun gear (16) from the
2. Remove the planetary pin (3) from one planetary axle shaft (2).
gear (10). Use a soft drift pin to tap or push the
pin out. Capture the dowel pin (29, Figure 3). 8. Remove the bolts, plates (25) and lockwire
Remove and discard the O-ring (11). from the ring gear assembly. Separate the
ring gear (1) from the hub (26).
3. Slide the planetary gear (10) out of the planetary : 3/4 in
carrier (19).
CAUTION: Planetary Gear weight: 76 kg

(168 lbs)
4. To remove the bearing assembly (4) first remove

the cones (5) and the inner spacer (8).
5. Use a drift to drive either of the cups (6) from the

planetary gear (10). Remove the outer spacer
(9). Drive out the remaining cup (6). Snap ring
(7) is removed only if replacement is required.
6. Repeat steps 2 through 5 to remove the other

planetary pins (3), planetary gears (10) and
bearing assemblies (4).
W5-8-4
19 25
10 7
8
11
26
9
20 13
21
3
4
16
23
24
2
17
14
12
DX-04-66-005
Figure 7 - Section View of Planetary Assembly
1. Internal Ring Gear 9. Spacer (3x) 17. Snap Ring

2. Axle Shaft 10. Planet Gear (3x) 19. Planet Carrier
3. Planet Pin (3x) 11. O-Ring (3x) 20. Bolt (3x)
4. Bearing Assembly (3x) 12. Shim(s) 21. Washer (3x)
5. Cone (See Figure 4) 13. Plate 23. Cover
6. Cup (See Figure 4) 14. Bolt (12x) 24. Gasket
7. Retaining Ring (3x) 16. Sun Gear 25. Bolt (12x), Plate (6x), Lockwire
8. Spacer (3x) 26. Hub, Ring Gear
W5-8-5
INSPECTION running clearance. Therefore bearing components

are not serviced separately and supplied in kit
Numbers in parentheses refer to Figure 7, unless oth- form only. Do not mix parts between bearing kits
erwise noted. during assembly.
1. Thoroughly clean all parts with a suitable solvent; 10. If planetary fluid is found heavily contaminated
dry with compressed air. the wheel hub should also be removed. Inspect
the wheel bearings and inner rotating seals con-
2. Inspect all machined surfaces for scoring and pit- currently with planetary repair (refer to Section
ting. W8-5). Inspect the differential sump fluid and
opposite planetary fluid (refer to Section W5-7) if
3. Inspect the planetary carrier (19) for cracks, elon- this condition is found.
gated bolt holes, worn pin holes or other damage.
11. Minor fretting on the spindle end or the retainer
4. Inspect the teeth on the planetary gears (10) and plate (13) can be made smooth using a file or a
the sun gear (16) for burrs, cracks, nicks, and ex- stone. These surfaces should also be free from
cessive wear. dirt, nicks, burrs and corrosion. Minor wear, less
than 0.076 mm (0.003 in), on the internal gear
5. Inspect gears and shafts using a non-destructive hub, the seal retainer, or the seal spacer where
test method UT, MPI or PT. Minimum requirement contact is made with the bearing shoulder can be
should be to Penetrant Test (PT) all gears and tolerated. Parts with excessive wear should be re-
shafts to be used again. Measure Penetrant bleed paired or replaced. On the rear axle any change in
pattern size after Penetrant dwell time has elapse- the width of the seal retainer will result in a corre-
d. Visually inspect for indications of defect closely. sponding change in the squeeze on the wheel ro-
Confirm suspect indications with additional testing tating face seals. Inspect the wheels for burrs on
using either Magnetic Particle Inspection or Ultra- the bearing shoulders if the bearing cups have
sonic Test Methods. Replace parts as required. been removed. The burrs, which often result after
a punch has been used to drive the cups out,
6. A new ring gear can be installed on a used inter- should be removed. The burrs could crush later,
nal gear hub if it is in good condition. Check ring allowing the cups to shift, resulting in a loss of
gear hub for wear to the splines and the surfaces preload. Carefully inspect the wheel bearing re-
where direct contact is made with wheel bearing taining bolts (14). Look for galling under the head
and (acro-set retainer) plate (13, Figure 3). Re- and on the threads. Use new bolts (14) if there is
move light fretting indications by hand polishing any doubt about their condition. Excess galling will
with a large flat surface stone. New parts will have disturb the relationship between the torque and
a light press fit between ring gear (26) and hub. the applied clamp resulting in shim pack errors.
The ring gear (26) can be driven on the hub with a Inspect the threaded holes in the spindle ends.
plastic or brass hammer. Clean the holes of any debris. Lubricate the
threads with oil. The bolts (14) should be able to
7. Inspect the ring spacer (15, Figure 3). It must be be threaded in by hand.
absolutely flat and free of burrs. Replace if re-
quired.
8. Inspect all threaded components. Replace plane-

tary mounting bolts if necessary,
9. Inspect the bearing assembly cup raceways and

cone rollers (4) for excess bruising, pitting, scor-
ing, or wear. Replace the bearing only as an as-
sembly kit of two cups, two cones and two select
spacers (Figure 4 items 8, 9). The precision
ground spacers are selected during bearing
manufacture to control the assembled bearing
W5-8-6
ASSEMBLY
Numbers in parentheses refer to Figure 7, unless oth- 7. Check for smooth free rotation of planet gear (10).
erwise noted.
8. Repeat steps 2-6 for each planet gear (10).
1. All parts must be clean and dry during assembly.
Control contamination and dirt entry by lubricating 9. Install a new O-ring (18, Figure 3) onto planet car-
parts and wrapping with protective paper and plastic rier (19).
if assembly progress is delayed.
10. Install the sun gear (16) and the snap ring (17) on
2. Install the retaining ring (7) into the groove in the the axle shaft (2).
planetary gear (10). Note that the groove is off-
center in the gear. Measure the distance from both 11. Assemble the internal gear to the gear hub. Install
sides of the gear to the retaining ring. bolts and plates (25) using both thread locking
compound and lock wire. Refer to Figure 8.
3. Install the bearing cups (6, Figure 4) on the side : 3/4 in
with the smaller dimension, using an arbor press or : 123 N·m (90 lbf·ft)
a soft drift. Install the large diameter spacer (9) with
the groove facing the retaining ring (7). Install the
remaining cup (6, Figure 4). Refer to Figure 3 & 4.
: Punch or soft drift
: Arbor press
4. Install the cones (5, Figure 4) and small diameter

spacer (8) into the cups (6, Figure 4) aligning the
bores.
5. Lay the planet carrier (19) flat with outside surface

face down. Install the planet gear assembly (10) in
the planet carrier (19), aligning the pin bore (3) with
the bearings (4).
CAUTION: Planetary Carrier weight: 298 kg

(658 lbs)
6. Install a new O-ring (11) on the planet pin (3) and

lubricate the O-ring and bearing rollers with clean
oil. Align the dowel pin hole in pin (3) with the dowel
pin hole in the planet carrier (19). Install the dowel
pin (29, Figure 3) into the pin (3) and hold in place.
Insert the planet pin (3) through the planet gear (10)
and into the pin seat in the planet carrier (19). Se-
cure the pin with the bolt (20) and washer (21).
Tighten the bolt.
: 1 ½ in
: 1048 N·m (773 lbf·ft)
Figure 8 – Ring Gear to Hub Connection
W5-8-7
INSTALLATION

erwise noted.
1. Remove any foreign matter from all components. 8. Rotate the rear wheel assembly until the oil level
line cast on the outer face of the planet carrier (19)
2. Attach the planetary ring gear tool (E12977824) to is parallel with ground. This will orient or clock the
the internal ring gear (1) and hub (26). Slide the planetary in the correct position for filling with oil
hub gear (26) onto the spindle of the axle. Refer to later.
Figure 5.
9. Install the axle shaft (2) and sun gear (16) assem-
NOTE: Make certain the internal ring gear is ade- bly.
quately supported to prevent damage to
the splines. CAUTION: Axle Shaft & Sun Gear weight:
103 kg (226 lbs.)
3. Install the shim(s) (12, Figure 3) and plate (13,
Figure 3) over the ring gear hub (26) and secure to 10. Check the axle shaft end play. Refer to
the spindle with the bolts (14, Figure 3). Refer to Section W5-6.
Section W8-5 for procedure to check and adjust
shim pack to pre-load the wheel bearings. After 11. Fill the planetary with the majority of lubricant be-
proper shim pack thickness is determined, tighten fore installing axle shaft cover (23). Fill through the
bolts (14). open center port till fluid flows from center cover
: 1 1/2 in bolt holes.
: 1048 N·m (773 lbf·ft)
12. Install gasket (24) and the drive axle cover (23),
4. When installing the ring spacer (15, Figure 3), the and secure with bolts (22, Figure 3). Tighten the
beveled side must face out towards the sun gear bolts (22, Figure 3).
(16). : 15/16 in
: 173 N·m (128 lbf·ft)
5. Coat contact face of planet carrier (19) with purple
sealant. 13. Operate unit to rotate the rear wheel assembly
several times and stop rotation when the oil level
6. Attach a shackle and suitable hoist to the planet line cast on the outer face of the planet carrier (19)
carrier (19) and lift into position. Slide the planet is parallel with ground. Again check and adjust the
carrier assembly in to internal ring gear. Align slot planetary reservoir to the indicated level (flows
in carrier outside diameter (19) with mating slot in from cover bolt hole) using the fill plug. Refer to
wheel hub. Inspect and ensure that the O-ring (18, Section W2-2 for recommended lubricants.
Figure 3) is properly aligned and seated during in-
stallation.
NOTE: Immediately remove any lubricant that
contacts the tire to prevent deterioration
CAUTION: Planetary Carrier weight: 541 kg of the rubber. Wash the tire with soap
(1193 lbs) and water or use a degreasing solution
that is not harmful to rubber.
7. Install the set screws (25, Figure 3).
: 5/8 in 14. Install the rear tires and rims as outlined in Section
W8-6.
W5-8-8
Description Metric(mm) English(in)
Bore Diameter Part Number Surface Minimum Maximum Minimum Maximum
Planet Pin Di- 12615420 1.6, 63√ 74.953 74.971 2.9509 2.9516
ameter Small
Planet Pin Di- 12615420 1.6, 63√ 95.25 95.28 3.750 3.751
ameter Large
Carrier Planet 12613735 3.2, 125√ 74.945 75.004 2.9506 2.9529
Pin Small 4035239
Carrier Planet 12613735 3.2, 125√ 73.20 73.25 2.882 2.884
Pin Large 4035239
Ring Gear Hub 12613735 3.2, 125√ 95.275 95.326 3.751 3.753
Thickness 4035239
W5-8-9
MEMO
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W5-8-10
SECTION 6
BRAKE SYSTEM
—CONTENTS—
Group 1 Front Brake Group 3 Brake Control Valve
Service Position .......................................... W6-1-4 Service Position ...........................................W6-3-1
Removal...................................................... W6-1-4 Isolate Stored Energy ..................................W6-3-1
• Brake Head .................................... W6-1-4 Removal.......................................................W6-3-2
• Lining ............................................. W6-1-4 Installation....................................................W6-3-2
• Brake Disc...................................... W6-1-4 Disassembly ................................................W6-3-5
Installation ................................................... W6-1-5 Inspection ..................................................W6-3-10
• Brake Disc...................................... W6-1-5 Assembly ...................................................W6-3-10
• Lining ............................................. W6-1-5 Adjustments ...............................................W6-3-14
• Brake Head .................................... W6-1-5
Disassembly Brake Head............................ W6-1-6 Group 4 Retarder Control Valve
Inspection.................................................... W6-1-6 Service Position ...........................................W6-4-1
• Brake Disc...................................... W6-1-6 Isolate Stored Energy ..................................W6-4-1
• Brake Lining ................................... W6-1-6 Removal.......................................................W6-4-2
• Brake Head .................................... W6-1-6 Installation....................................................W6-4-3
Assembly Brake Head ................................ W6-1-7 Disassembly ................................................W6-4-4
Maintenance Standard ................................ W6-1-8 Inspection ....................................................W6-4-7
Assembly .....................................................W6-4-8
Group 2 Rear Brake Memo…………………………………………...
Removal...................................................... W6-2-7 Group 5 Retarder Control Valve (ATC)
Installation ................................................... W6-2-8 Service Position ...........................................W6-5-1
Disassembly................................................ W6-2-9 Isolate Stored Energy ..................................W6-5-1
Inspection.................................................. W6-2-10 Removal.......................................................W6-5-2
Assembly ...................................................W6-2-11 Installation....................................................W6-5-2
Toric Face Seal Installation ....................... W6-2-13 Disassembly ................................................W6-5-4
Rear Brake Assembly Installation ............. W6-2-15 Inspection ..................................................W6-5-10
Bleeding .................................................... W6-2-16 Assembly ...................................................W6-5-10
Maintenance Standard .............................. W6-2-16 Adjustments ...............................................W6-5-12
Removal – Speed Sensor………………….W6-5-13
Installation – Speed Sensor…...…………..W6-5-13
New Sensor Adjustment/Installation…...…W6-5-13
Memo………………………………………...W6-5-14
W6-0
<BLANK>
W6-0
Group 6 Brake Accumulator Group 8 Parking Brake
Service Position .......................................... W6-6-1 Service Position ...........................................W6-8-2
Isolate Stored Energy.................................. W6-6-1 Removal of Lining and Carrier.....................W6-8-4
Removal...................................................... W6-6-2 Inspection ...................................................W6-8-5
Installation ................................................... W6-6-4 Installation-Lining and Carrier .....................W6-8-5
Disassembly................................................ W6-6-6 Maintenance Standard.................................W6-8-6
Inspection.................................................... W6-6-6
Assembly .................................................... W6-6-7
Group 7 Brake Cooling Lines

Removal...................................................... W6-7-4
• Supply Piping
Removal................................ W6-7-4
• Return Piping
Removal................................ W6-7-4
• Relief Valve Cover and Components
Removal.................................. W6-7-5
• Return Diffuser Cover
Removal................................ W6-7-5
Inspection .................................................... W6-7-6
• Supply and Return Piping
Inspection............................... W6-7-6
• Relief Manifold Cover and Diffuser
Inspection .............................. W6-7-6
• Relief Check Valve
Inspection ............................. W6-7-6
Installation………………………………...…. W6-7-7
• Supply and Return Piping
Installation………………....... W6-7-7
• Return Diffuser Cover
Installation............................. W6-7-7
• Check Valve
Installation ............................. W6-7-7
• Hydraulic Tank Connections
Installation ............................. W6-7-8
Final Assembly ........................................... W6-7-8
W6-0
<BLANK>
W6-0
BRAKE SYSTEM / Front Brakes
EL16579
Figure 1 - Exploded View of Brake and Brake Mounting
1. Bolt 10. Bolt 19. Backup Ring

2. Washer 11. Washer 20. Packing Ring
3. Brake Head 12. Thrust Plate 21. Boot
4. Spindle 13. Bleeder Valve 22. Tube Assembly
5. Brake Disc 14. Bolt 23. Bolt
6. Wheel 15. Washer 24. Washer
7. Shim 16. Cap 25. Tee
8. Lining and Carrier Assembly 17. Backup Ring 26. Tube Assembly
9. Piston 18. Packing Ring
W6-1-1
EL 20719
Figure 2 - Section View of Front Brake and Mounting

(Front Brake Shown Rotated 90º)
1. Bolt 6. Wheel 12. Thrust Plate

2. Washer 7. Shims (as required) 13. Bleeder Valve
3A. Brake Head 8. Lining and Carrier Assembly 14. Bolt
3B. Brake Head Cutaway View 9. Piston 15. Washer
4. Spindle 10. Bolt 16. Cap
5. Brake Disc 11. Washer
W6-1-2
SERVICE POSITION REMOVAL, BRAKE LINING

Before checking and/or servicing the machine, park
the machine on a level solid surface and put it in the Numbers in parentheses refer to Figure 1 thru 4.
“Service Position.” Refer to Section W2-1.
1. Loosen the bolts (10) securing the upper thrust
CAUTION: Prior to any service work, the plate (12).
brake accumulators must be manually bled : 1 1/2 in
down to remove any hydraulic system pres-
sure in the brake supply system. By con-
necting drain lines to the test ports "Rear" 2. Attach a bleeder hose to the bleeder valve (13)
and "TP1", located on the Brake Control and slowly open the bleed valve (13). Carefully
Valve, the brake accumulators can be bled press the pistons (9) into the brake head (3) using
down by repeatedly depressing the service a pry bar inserted between carrier lining (8) and
brake. Capture any fluid that escapes from brake disc (5). Capture fluid that is exhausted
the bleed-down process and dispose of from open bleeder valve. Once the pistons (9) are
properly. fully retracted, close the bleed valve (13).
: 7/16 in
REMOVAL, BRAKE HEAD
3. Remove upper thrust plate (12) and hardware (10
CAUTION: A hoist capable of at least 135 kg
and 11).
(300 lbs.) lift force will be required.
4. Slide the carrier and lining assemblies (8) out of

Before removing the brake head, the front tire and rim
brake head (3).
must be removed first. Refer to Section W8-6.
Numbers in parentheses refer to Figure 1 thru 3.
REMOVAL, BRAKE DISC
1. Slowly open brake bleeder screw (13) to relieve
trapped pressure. Capture any fluid that escapes
Before removing the brake disc, the front tire and rim
and dispose of properly.
must be removed first. Refer to Section W8-6.
: 7/16 in
2. Place a clean container under the brake line con-
nection and disconnect tube assembly (22 and 1. Remove brake head, refer to the Removal, Brake
26) from tee (25) and at the brake head assembly. Head section in this section.
Plug all ports to keep dirt out.
2. Remove the front wheel (6). Refer to Section
W8-4.
3. Support the brake head assembly (3) with a hoist
3. After the front wheel (6) is removed, loosen and
before removing mounting bolts (1). The upper
remove bolts (23) and washers (24). Lift off brake
thrust plates (12) can be removed to allow the
disc (5).
use of lifting brackets or threaded bolts.
: 1 7/8 in
4. Loosen bolts (1) securing the brake head assem-

bly (3) to the mounting flange of spindle (4).
: 1 7/8 in
5. Remove bolts (1), washers (2), and hoist brake

head assembly (3) to remove. Ensure shims (7)
do not fall during the removal of the brake head
(3).
W6-1-3
INSTALLATION, BRAKE DISC INSTALLATION, BRAKE HEAD

CAUTION: Brake Head Weight 120 kg (265 lb).
Installation of the brake disc is in the reverse order of
the removal procedure. 1. The brake head assembly (3) is mounted with the
bleeder valve (13) positioned above the fluid inlet
1. Install and tighten washer (24) and bolt (23) to port.
torque specified.
: 1 7/8 in 2. Ensure all pistons (9) are fully retracted and lift
brake head (3) in place with hoist. Insert a few
: 2094 N·m (1544 Ibf·ft)
bolts (1) and washers (2) and tighten.
2. Install front wheel. Refer to Section W8-4. : 1 7/8 in
3. Install brake head and linings; refer to the Installa-
tion, Brake Head and Installation, Brake Lining 3. Insert carrier and linings (8); refer to Installation,
sections in this section. Brake Lining in this section.
4. Install tires and rims. Refer to section W8-6.
4. Install the thrust plates (12), bolts (10) and wash-
ers (11).
INSTALLATION, BRAKE LINING : 1 1/2 in
: 990 - 1017 N·m (730 - 750 Ibf·ft)
5. Using a feeler gauge, measure the gap between
1. Install new or reusable carrier and lining assem-
the brake disc (5) and the liner & carrier (8) as-
blies (8) by placing the friction material next to
sembly. If the gaps are not the same to within
the disc and sliding them into brake head (3).
0.76mm (0.030”), remove the brake head (3) and
2. Insert the thrust plate (12) into brake head (3) install shims (7) between the brake head (3) and
and around the tabs of the new lining (8). the mounting flange on the spindle (4). Recheck
the gap.
3. Install bolts (10) and washers (11). Lubricate the
bolt threads with SAE 10W or 30W oil. Tighten : 1 7/8 in
the bolts.
: 1 1/2 in 6. After the brake head (3) has been centered over
: 990 - 1017 N·m (730 - 750 Ibf·ft) the brake disc (5), install all bolts (1) and washers
(2), tighten and torque.
4. Install tires and rims; refer to Section W8-6.
: 1 1/2 in
: 990 - 1017 N·m (730 - 750 Ibf·ft)
NOTE: Maximum braking performance with new
lining is only achieved after the lining has 7. Reconnect the brake lines (22, 25, & 26). Bleed
been properly seated to the disc with the entire hydraulic brake system to remove
aggressive braking (Burnish). In most trapped air using the bleeder valves (13).
cases normal use is sufficient for burnish
and provides adequate performance. If, NOTE: Do not allow hydraulic oil to spill on car-
however the front brakes will be only rier and linings (8) or brake disc (5). Use
infrequently used and maximum a bleeder hose pressed over bleed
performance is required due to screw (13) to direct fluid away during
conditions or regulatory testing, brake bleeding of brake system. Capture
burnishing may be required. waste fluid and dispose of properly.
8. Install tires and rims; refer to Section W8-6.
W6-1-4
INSPECTION, BRAKE DISC

CAUTION: After servicing brake system, Numbers in parentheses refer to Figure 1 thru 3.
Start the engine and let it run until pressure
readings are normal. Ensure brake perform- 1. Thoroughly clean all metal parts in a suitable sol-
ance by operating the machine under con- vent.
trolled conditions before returning it to ser-
vice. 2. Inspect disc (5), Replace when worn to a mini-
mum thickness.
DISASSEMBLY, BRAKE HEAD CAUTION: If the disc is to be resurfaced, the

machined thickness must be maintained
Numbers in parentheses refer to Figure 3
above 18.0 mm (0.71 in). The disc must be
resurfaced evenly on both sides and the re-
1. Remove carrier and lining (8) as instructed pre-
viously in this section under Removal, Brake Lin- surfaced area should be limited to the lining
ing. contact area. Do not resurface the entire disc,
especially the area around the mounting bolt
2. Remove bolts (14), washers (15), cover (16), and holes. Use of brake disc worn below 18.0 mm
two bleeder valves (13) from the brake head (3). (0.71 in) will result in hazardous braking!
: 3/4 in
: 7/16 in INSPECTION, BRAKE LINING
NOTE: Pistons (9) are easily damaged; do not pry
1. Inspect the carrier and lining assemblies (8) for
them out of the brake head (3). Place a
wear or damage. Install new linings if lining mate-
wood slat inside the caliper between the
pistons (9) and apply air pressure to caliper rial thickness (without metal backing) is worn
inlet in small, short bursts until all pistons down. Refer to Maintenance Standards this sec-
(9) are extended out of the brake head (3). tion.
Remove the wooden block or spacer then
remove the pistons (9) by hand. CAUTION: Use of brakes with lining material
worn below minimum thickness will result in
CAUTION: Eye protection must be worn diminished braking. Never mix new and
when using air pressure to force pistons (9) used carrier linings (8) in brake head (3).
out of the housing (3). When using air pres-
sure, hands must be kept clear of area be-
tween the pistons. Failure to do so may result INSPECTION, BRAKE HEAD
in injury.
3. Remove packing ring (20), back-up rings (19) and 1. Thoroughly clean all metal parts in a suitable sol-
pistons (9) from brake head (3). Discard packing vent.
rings (20) and backup rings (19).
2. Inspect outside diameter sealing surfaces of pis-
4. Remove boots (21) from brake head (3) and dis- tons (9), for pitting, deep scratches and wear.
card. Clean up minor surface damage by polishing with
crocus cloth or replace parts as necessary. Re-
5. Remove packing rings (18) and backup rings (17) place pistons (9) if chrome plating is worn, pitted
and discard.
or otherwise damaged. Measure diameter of pis-
tons (9) and compare with the specification given
in the Maintenance Standard in this section.
W6-1-5
3. Inspect all threaded parts for damage and repair 4. Install the packing ring (18) and retaining ring (17)
or replace parts as necessary. into the outside diameter groove on cover (16).
4. Inspect piston bores of brake head for pitting, 5. Install the cover (16) with bolts (14) and washers
deep scratches and wear (not out-of-round). (15). Tighten the bolts.
3
Reference the maximum allowable brake piston : /4 in
bore diameter specification in the Maintenance
: 142 - 156 N·m (105 - 115 Ibf·ft)
Standard in this section.
6. Install the bleeder valves (13) into the brake head
(3).
ASSEMBLY, BRAKE HEAD 7
: /16 in
Numbers in parentheses refer to Figure 1 thru 3. : 5 N·m (42 Ibf·in)
1. Lightly lubricate all hydraulic parts with clean hy-

7. Install linings (8) into the brake head (3). Refer to
draulic fluid to ease assembly.
Installation, Brake Lining and Installation, Brake
Head.
2. Install packing ring (20), back-up ring (19) and
boot (21) into the piston bore of the brake head
(3). Refer to Figure 3 for seal orientation.
NOTE: Careful attention must be noted to proper

alignment of Packing Ring (20) and
Back-up ring (19). Refer to Figure 3.
3. Install pistons (9) into brake head (3) as follows

(refer to Figure 3):
a. Position piston (9) inside dust boot (21). Holding

the piston (9) at a slight angle, insert forefinger
between the piston outer diameter, lifting the
dust boot (21) over the piston (9). Make certain
that the anchor lip of dust boot (21) remains in EL 20722
the groove (A) of the piston bore in brake head
(3). Figure 3 - Boot, Packing, and Back-Up Ring Installation
b. After piston (9) is started through dust boot (21),
center the piston over packings (20). While
3. Brake Head 20. Packing Ring
slowly rotating piston, press the piston through
the packing ring (20) using hand pressure only. 9. Piston 21. Boot
No additional force is required when parts are 19. Back-Up Ring A. Groove
properly aligned.
c. After the piston (9) passes packing ring (20),
carefully slip the piston (9) down into the bore.
When properly assembled, the pistons (9) will
slide into place by hand without use of addi-
tional force.
d. Stretch and insert the open end of boot (21) into
the groove (B) on piston (9).
W6-1-6
DESCRIPTION SPECIFICATION
Minimum allowable brake piston diameter (9) 89.03 mm (3.505 in)
Maximum allowable brake piston bore diameter in brake head (3) 88.77 mm (3.495 in)
Brake disc minimum thickness at lining contact surface (5) * 18.0 mm (0.71 in)
Brake disc surface roughness specification 6.3, 250√
Minimum thickness of lining material on carrier (8) * 3.0 mm (0.12 in)
Difference in material thickness between used linings on brake head (8) Not greater than: 3 mm (0.12 in)
* Should be performed every 1000 hours
W6-1-7
MEMO
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W6-1-8
BRAKE SYSTEM / Rear Brake
A
1
32
36
Figure 1 - Brake Assembly and Spindle
1. Housing 36. Spindle

32. Hub Adapter A. Rear Axle Housing
W6-2-1
14
41
Figure 2 - Section View of Rear Brake Assembly and Attaching Parts
1. Brake Housing 10. Spring (8x) 19. Gage Pin 28. Sealant
2. Cover 11. Retainer (8x) 20. Bleeder Screw 29. Screw (24x)
3. Pressure Plate 12. Snap Ring (8x) 21. Loctite Adhesive 30. O-Ring
4. Friction Disc (8x) 13. T Seal (8x) 22. Plug, Drain 31. Toric Face Seal
5. Reaction Disc (7x) 14. Reaction Plate – Corked (2x) 23. Set Screw (Fig. 3) 32. Hub Adapter
6. Screw (20x) 15. Wear Compensator (8x) 24. Wear Ring (8x) 33. Washer (24x)
7. Washer (20x) 16. Post (8x) 25. Washer (8x) 34. Retainer Ring
8. Piston (8x) 17. O-Ring 26. Spacer (8x) 35. Carrier, Disc
9. Screw (8x) 18. Plug 27. Solvent 41. Bolt
W6-2-2
Figure 3 – Back View of Rear Brake Assembly
22. Plug, Drain 38. Supply Port

23. Set Screw (2x) 39. Wear Indicator Port
36. Plug 40. Bleed Port
37. Cooling Port
W6-2-3
23 2 20
6, 7 14
29, 33 14 4 5
3
1
18
24
10
8 12
19
11
34, 35
32 31 13
17 9, 21, 25
26
15
16, 21 22
27, 30
Figure 4 - Exploded View of Brake Assembly
1. Brake Housing 13. T Seal (8x) 25. Washer (8x)

2. Cover 14. Reaction Plate – Corked (2x) 26. Spacer (8x)
3. Pressure Plate 15. Wear Compensator (8x) 27. Solvent (as required)
4. Friction Disc (8x) 16. Post (8x) 28. Sealant (as required) (Fig. 2)
5. Reaction Plate (7x) 17. O-Ring 29. Screw (24x)
6. Screw (20x) 18. Plug 30. O-Ring
7. Washer (20x) 19. Gage Pin 31. Toric Face Seal
8. Piston (8x) 20. Bleeder Screw 32. Hub Adapter
9. Screw (8x) 21. Loctite (as required) 33. Washer (24x)
10. Spring (8x) 22. Plug 34. Retainer Ring
11. Retainer (8x) 23. Set Screw (2x) 35. Carrier, Disc
12. Snap Ring (8x) 24. Wear Ring (8x)
W6-2-4
14, 16, 17
14, 16, 17
1, 10, 13, 15
14, 16, 17
2
12 12 3
18
7
4, 10, 13, 15
10, 13, 15
18
10, 13, 15
8 9 5 10, 13, 15
12
Figure 5 – Brake Cooling Pipe and Tubing Connections
1. Tube Assembly 7. Tube Assembly 14. Screw

2. Tube Assembly 8. Tube Assembly 15. Screw
3. Tube Assembly 9. Tube Assembly 16. Washer
4. Tube Assembly 10. Split Flange 17. Lock Nut
5. Tube Assembly 12. O-Ring 18. Brake Assembly
6. Tube Assembly 13. O-Ring
W6-2-5
Figure 6 - Brake Apply Lines
1. Hose Assembly 10. Tube Assembly

2. Hose Assembly 11. Tube Assembly
8. Screw 12. Tee
9. Clamp 13. Connector
W6-2-6
SERVICE POSITION CAUTION: The components which make up

Before checking and/or servicing the rigid dump truck, the rear brake assembly are heavy. Use care
park the rigid dump truck on a level solid surface and when disassembling or removing these
put it in the “Service Position”. Refer to Section W2 components. Misuse of lifting equipment or
-1. improper support of components may result
in possible injury or damage.
BRAKE WEAR INSPECTION
Numbers in parentheses refer to Figure 2. 1. Remove the tires and rims from the rear wheels.
Refer to applicable Removal Section in W8-6.
To determine if the wet disc brake assembly requires
rebuilding due to wear, the following steps should be 2. Drain the hoist system hydraulic fluid tank.
taken as part of routine maintenance.
1. Ensure that the brake accumulators are charged Reclaim or Dispose of Oil Properly
and the engine is shut down. 3. Place a suitable container, at least 7.5 L (2 gal),
under brake housing (1) and remove drain plug
2. Remove the wear indicator plug (18). (22) to drain the cooling oil from the brake hous-
: 11/16 in ing (1). Reinstall the drain plug. Refer to Fig-
ure 3.
3. Turn the key switch ON and apply the Load/Dump
brake Place a DO NOT START tag on the : 6.2 mm (0.24in)
steering wheel.
4. Remove the rear wheel and hub adapter to-
4. Insert a depth micrometer into the wear indicator
gether (32, Figure 2). Refer to the applicable
port and force the gage pin (19) against the pres-
Removal sections in Section W8-5.
sure plate. Measure the distance from gage pin
(19) to the back face of brake housing (1). NOTE: Use caution to avoid damage to toric
face seals (31). When the wheel is re-
5. Compare this dimension to the original dimension moved, half of the toric face seal will re-
stamped on the brake housing (1) at the time of main in the wheel, and half of the toric
assembly (stamped dimension is in inches). face seal will remain in the seal retainer.
Half of the other toric seal (31) will re-
6. If the measured dimension is larger by 6.35 mm main in hub adapter (32) and the other
(0.250”) or more, then the wet disc brake assem- half will remain in end cover (2). Gently
bly will require rebuild. ALWAYS rebuild both remove the wheel to avoid seals (31)
rear wet disc brake assemblies at the same time. from becoming dislodged causing dam-
age to parts. Refer to Figure 2.
7. Reinstall the wear indicator plug (18).
: 11/16 in 5. Remove toric face seals (31) from their bores
: 37 N·m (27 lbf·ft) after marking steel face rings of seal, stationary
side and rotating side, to facilitate reassembly.
8. Release the Load/Dump Brake, turn the key
switch OFF and remove the DO NOT START tag 6. Discard the rubber torics, the large O-Ring por-
from the steering wheel. tion of seal assembly (31).
REMOVAL- REAR BRAKE 7. Remove the brake cooling tube assemblies (1-6)
at brake housing (18). Cap the tube assemblies
to prevent contamination from entering. Refer to
Figure 5.
CAUTION: A lifting device with capacity of : ¾ in
2268 kg (5000 lb) is required.
W6-2-7
8. At brake housing (18, Figure 5), remove brake

apply tube assemblies (10, 11, Figure 6) from Bleeder
Brake Cooling
their connectors (13). Cap the tube assemblies Outlet Port Port
to prevent contamination from entering. Refer to
Figure 6.
: 13/16 in, 15/16 in
9. Remove the seal retainer for the inner wheel

seal and O-ring (30). Discard O-ring (30). Refer
to Figure 2.
10. Support the brake assembly with a suitable lifting

device.
CAUTION: Rear Brake weight 668 kg (1472

lb).
11. Loosen bolts (41) that secure the rear brake as-
sembly (18, Figure 5) to spindle (36, Figure 1).
: 1 1/2 in Figure 7 - Align Brake Assembly to Rear Axle
Spindle
12. Ensure proper balance by slowly hoisting the
brake assembly (18, Figure 5) before completely
removing bolts (41).
: 1 1/2 in 2. Attach the brake assembly (18, Figure 5) to a
suitable lifting device and position it on the rear
axle spindle assembly (36, Figure 1) with brake
CAUTION: Carrier (35) is loose when wheel cooling outlet port aligned at the upper most
is removed from spindle (36, Figure 1). Car- position. Refer to Figure 7. Carefully slide
rier weight is 60 Kg (132 lb). Retain Carrier brake assembly (18, Figure 5) against the
with wire before removing brake assembly mounting flange of spindle (36, Figure 1).
(18, Figure 5) from the spindle (36, Figure 1).
13. With the suitable lifting device, remove the brake CAUTION: Rear Brake weight 668 kg (1472
assembly (18, Figure 5) from the spindle (36, lb).
Figure 1).
CAUTION: Carrier (35) is loose when wheel
14. Remove and discard O-ring (30, Figure 2). is removed from spindle (36). Carrier weight
is 60 Kg (132 lb). Retain Carrier with wire
before removing brake assembly from spin-
INSTALLATION-REAR BRAKE dle.
Numbers in parentheses refer to Figure 1 thru 12. 3. Align holes in brake housing (1) and insert
mounting bolts (41, Figure 2) and tighten.
1. Install O-ring (30) in brake housing (1) and lu- : 1 1/2 in
bricate with petroleum jelly.
: 1048 N·m (733 lbf·ft)
4. Install O-ring (30) on the seal retainer for the

inner wheel seal and install on spindle (36, Fig-
ure 1). Use petroleum jelly or light grease to
hold O-ring in groove during installation.
W6-2-8
5. Install Toric face seals (31, Figure 2). Refer to 2. Remove bolts (6) and washers (7). Use set
Toric Face Seal Installation in this section. screws (28) to force cover (2) off housing (1).
Remove end cover (2). Lift off O-ring (17) and
6. Hoist the wheel in place over spindle (36, Fig- discard. (Figure 2).
ure 1). Refer to the applicable Installation sec- : 15/16 in
tion in Section W8-5 Rear Wheel and Section : ½ in
W5-8 Planetary.
3. Remove disc carrier (35) by pulling upward. Car-
7. Remove caps from the brake inlet and outlet rier (35) may bind on the teeth of friction discs (4)
cooling tube assemblies (1 – 6, Figure 5). In- if not pulled straight out of friction disc pack.
stall new O-rings and attach to ports in brake
housing (18). Refer to Figure 5 and Section 4. Remove reaction plates (5) and friction discs (4)
W6-7 Brake Cooling Lines. from housing (1).
: ¾ in
: 106 N·m (78 lbf·ft) CAUTION: Pressure plate weight 66 kg (145
lb).
8. Remove caps from brake apply tube assem-
blies (10, 11, Figure 6) and install at their con- NOTE: There should be seven reaction plates (5),
nectors (13). Refer to Figure 6. eight friction discs (4), and two damper
: 13/16 in plates (14).
: 26 N·m (19 lbf·ft)
5. Removal of pressure plate (3): Using a wrench
: 15/16 in on the retaining screw (9), rotate the piston (8)
: 45 N·m (33 lbf·ft) until the anti-rotation notch on the piston (8) is
aligned with the access hole in the pressure
9. Fill and check the hydraulic fluid reservoir, both plate (3). Insert a punch or appropriate tool to
sides (steer/hoist). restrict the rotation of the piston (8). Remove
screw (9), washer (25) and spacer (26). Re-
10. Bleed Brake apply system. Refer to applicable peat this procedure for the remaining pistons
Section W6-3. (8). Carefully remove pressure plate (3).
: 1/2 in
11. Start engine, check the system for proper op-
eration. Check for leakage. Check hydraulic
fluid level and correct fluid level if necessary. NOTE: Refer to step 15 of the assembly in-
structions for pressure checking actua-
tion. Do NOT remove pistons (8) unless
DISASSEMBLY-REAR BRAKE leakage or damage is suspected. If re-
moval of pistons (8) is required, all pis-
Numbers in parentheses refer to Figure 2. ton assembly components should be
marked for installation into the same
bore as removed.
NOTE: When disassembling the brake assembly
all seals and O-rings should be discarded
and replaced. 6. Removal and disassembly of piston assembly:
a) To remove piston assemblies from the
1. Install six 1 1/2 inch UNC bolts 152 - 203 mm (six housing (1), insert screw (9) into piston (8)
to eight inch) long equally spaced into brake for several threads of engagement. Using
housing (1) to act as a support stand. (The six the screw (9) as a pull point, carefully re-
bolts are installed in the threaded holes where move the piston assembly from the housing
(1). Once free from the housing (1) remove
bolts (41) were removed from.) Place the brake
screw (9) from the assembly.
assembly on a work table with end cover (2) fac-
ing up.
W6-2-9
INSPECTION-REAR BRAKE
NOTE: All parts should be thoroughly inspected

for damage and replaced if necessary.
1. Inspect the face seals (31, Figure 2). The sealing

faces must not be nicked, pitted or scored. It is
normal for the sealing surface to progress toward
the inner diameter with wear. If the face seal (31)
or outer seal is exposed to external dirt; it is nor-
mal for the outer diameter of this seal face to
show signs of abrasion. This condition is accept-
able provided a clean sealing face still exists to-
ward the inside diameter.
2. The face seals (31, Figure 2) must be replaced

if the face wear path is not concentric with the
outside diameter or is worn into the inner half of
the seal ring (See Figure 9).
Figure 8 – Piston Assembly
b) To disassemble the piston assembly, spring

(10) is to be compressed using either a
socket or pipe against the retainer (11).
While compressed, remove the snap ring
(12) and then carefully remove the com-
pressive force on the retainer (11) and
spring (10).
c) Remove spring (10), retainer (11) and wear

compensator (15) from inside the piston (8). Figure 9
d) From the piston bore of the housing (1), 3. The face seal (31, Figure 2) rubber Torics
remove the wear ring (24) and the T-Seal should be replaced if over 100 hours. Inspect
(13) and discard. the Toric for compression set or nicks.
4. Clean all metal components of the brake system

e) Loosen and remove the alignment post (16) in mineral spirits or equivalent solvent.
from the housing (1). Allow parts to air dry.
f) Repeat for each piston assembly to be re- 5. Inspect machined surfaces of all parts for scoring,
moved and inspected. pitting, burring or excessive wear.
7. Remove the bleeder screw (20). 6. Inspect all threaded components for stripped or
: 7/16 in damaged threads and replace if necessary.
7. Inspect reaction plates (5) for coning or waving.

Plates must be flat within 0.75 mm (0.030 in).
Minor warpage is acceptable provided the plate
W6-2-10
lies flat under its own weight. Surface finish must

be smooth across face from inside diameter to
outside diameter. Minor wear pattern is accept-
able where friction material makes contact.
A B
REACTION FRICTION
PLATE (5) DISC (4)
A – Diametrical Scoring
B – Radial Scoring
Notch Figure 11 – Brake Reaction Plate (5)
Twisted Tooth 11. Inspect friction disc (4) for heat damage. Discol-
oration or darkening of the friction material is
Figure 10 - Checking for Cracks in normal as is a slight glazed appearance. Re-
Reaction Plates and Friction Discs place if the friction material is blackened, charred
or crumbling.
8. Inspect reaction plates (5) for wear. Measure the
plate thickness at tooth and again in the brake NOTE: The frictional characteristics of the mate-
surface contact area. Replace if more than 0.25 rial can degrade with elevated tempera-
mm (0.010 in) thickness reduction is measured. ture due to cooling oil carbon deposits.
Minor diametrical score lines are acceptable if This condition can only be verified with
coverage is less than 20% of braking surface. specialized lab testing. If reduction in
No radial score lines or scratches are permissi- brake torque has been reported without
ble in brake surface. Wear pattern must be even application system faults or visible dam-
and balanced on both sides of plate, otherwise age to friction discs, replace all friction
replace plate. Refer to Figure 11. discs (4) in brake.
9. Remove piston assemblies. The piston assem- 12. Inspect brake housing (1) and carrier (35) for
bly consists of: piston (8), spring (10), retainer excessive wear. Localized spline wear is ac-
(11), snap ring (12) and the wear compensator ceptable but must not impede friction disc (4) or
(15). reaction plate (5) motion. Replace worn or dam-
aged parts.
10. Inspect friction disc (4) for wear, replace if any oil
grooves are less than 0.25 mm (0.010 in) in 13. Inspect the teeth on friction discs (4) and reac-
depth. Replace if the friction material on either tion plates (5) for notching caused by excessive
face is less than 0.5 mm (0.020 in) thick. Wear wear. Inspect tooth base for cracks. Look for
pattern must be evenly balanced on both sides of twisted or missing teeth. Refer to Figure 10.
plate, otherwise replace plate.
14. Inspect apply piston (8) for scoring, pitting, burrs,
and excessive wear.
15. Inspect the retainer (34) and snap ring (12) for
deformation.
16. Inspect the snap ring groove in the piston (8) for
deformation.
17. Inspect the piston bores and annular connecting

passages of the housing (1) for contamination.
W6-2-11
Inspect the piston bore seal grooves for burrs

or damage.
18. Place piston (8) into brake housing (1) without

seals (13, 24) to check for concentricity and twist
or for any sign of binding. Piston should rotate
free and slide inside piston bore without restric-
tion. All seal surfaces of brake piston (8) must be
highly polished and smooth. Replace a damaged
brake apply piston (8).
ASSEMBLY-REAR BRAKE
NOTE: When rebuilding the brake assembly (18,

Figure 5) all seals and O-rings should be Figure 12 – T Seal (13)
replaced.
9. Install the T-seals (13) into their grooves. Ob-
1. Install the bleeder screw (20) in the housing (1). serve the proper orientation of the backup ring
7
: /16 in
radii and chamfer overlap. Refer to Figure 12.
: 5 N·m (42 lbf·in)
10. Clean and dry the threaded holes in the piston
bores of the housing (1). Apply the thread adhe-
2. Build up the piston assemblies as follows:
sive to the threads on the new post (16) and in-
stall.
3. Install a new wear compensator (15) into piston
(8).
11. Torque the post (16).
4. Place the spring (10) into the piston (8) and over : 68 N·m (50 lbf·ft)
(flathead screwdriver)
the wear compensator (15).
12. Lubricate the post (16), the T-Seal (13) and
5. Place the retainer (11) on the spring (10) and
the wear ring (24) with petroleum jelly.
carefully compress the spring (10) and the re-
tainer (11) until the snap ring groove is accessi-
ble. Use caution, refer to Figure 8. 13. Carefully hand press the piston assembly into
the housing (1) until the piston (8) passes the T
6. While compressed, install the snap ring (12) into seal (13). The piston assembly will make con-
the groove and slowly release the spring (10). tact with the post (16) and stop. Use a rubber
Ensure that the snap ring (12) is properly seated. mallet and a wood block and carefully drive the
piston assembly on the post (16) until the top of
7. Repeat the above procedure for all the piston the piston (8) is flush with the housing (1).
assemblies. : Rubber Mallet
8. Install the wear rings (24) into the piston bores. 14. After all the pistons (8) are assembled in the
Ensure that the wear rings (24) are properly housing (1), their operation can be checked
seated. before further assembly of the brake.
NOTE: The wear compensator (15) and the post

(16) must be replaced with new parts if CAUTION: DO NOT pressurize the brake
the piston assemblies were removed. assembly when disassembled. Pressure in
Any scoring on the post (16) and com- excess of 345 kPa (50psi) will cause the
pensator (15) mating surfaces will im- pistons to fly out of the housing bore caus-
pede proper operation of the adjustment ing potential injury.
feature.
W6-2-12
15. Install an eye bolt into the threaded hole in the 27. Install the outer damper plate (14) into the hous-
piston (8). Use a pry bar to extend the piston as- ing (1), with the damper material exposed, steel
sembly and note the stroke. The piston should side against the friction disc (4).
extend against the spring tension approximately
6mm (.250”) before contacting a noticeable stop. 28. Install the brake cover (2) using the required lift-
ing device.
: Pry Tool
16. Install the gage pin (19) into the housing (1). CAUTION: Brake cover weight 108 kg (239
lb).
17. With the required lifting device, carefully lift and
place the pressure plate (3) into the housing (1), 29. Install the cover bolts (6) and washer (7) and
aligning the bolt holes in the pressure plate with torque the bolts as follows.
the threaded holes in the piston (8). : 15/16 in
: 173 N·m (128 lbf·ft)
CAUTION: Pressure plate weight 66 kg (145
30. Apply 13790 kPa (2000 psi) to the brake apply
lb).
port. This will pre-adjust the pistons and com-
press the friction pack. Several audible “clunks”
18. Insert the washers (25) and spacer (26) on bolts
will be observed as the pistons “stickslip” on the
(9).
posts (16).
19. Apply adhesive to the clean and dry threads of
the screw (9) and install them through the pres-
sure plate (3) into the piston (8). CAUTION: Keep your fingers clear of the
: 1/2 in friction pack while applying the brakes. The
friction pack will compress and could cause
20. Rotate the piston (8) until the anti-rotation slot is injury.
visible through the access hole in the pressure
plate (3). Insert a punch or similar tool and 31. Exercise the brake several times and observe
torque the screw (9). that the pressure plate applies and retracts freely.
: 1/2 in Check for any leakage.
: 20 N·m (15 lbf·ft)
32. Release the applied pressure and remove the
21. Remove punch tool and rotate each piston (8) brake cover (2) by removing bolts (6) and wash-
ers (7).
clockwise approximately 180°.
: 1/2 in
33. Remove the outermost damper plate (14) and
friction disc (4). There is now a friction disc (4)
22. Install the damper plate (14) in the housing (1)
showing.
with the damper material against the pressure
plate (3).
34. Install the last reaction plate (5) and friction disc
(4).
23. Install a friction disc (4) into the housing (1).
35. Install the outer damper plate (14) into the hous-
24. Install a reaction plate (5) into the housing (1).
ing (1) with the damper material exposed, with
the steel side against the friction disc (4).
25. Alternate installing the friction disc (4) and the
reaction plates (5) until the total installed is one
36. The friction pack consists now of two damper
damper plate (14), eight friction discs (4), and six
plates (14), eight friction discs (4), and seven
reaction plates (5).
reaction plates (5), refer to Figure 2. Ensure
proper installation sequence; improper order
26. There is now a friction disc (4) showing. To pre-
will cause immediate failure.
adjust the brake assembly, it will be necessary to
install, temporarily, another friction disc (4) omit-
37. Lubricate the O-ring (17) with petroleum jelly or
ting one reaction plate (5).
equivalent and install the housing (1).
W6-2-13
38. Install the cover (2) with the required lifting de- NOTE: Do not use any solvent that leaves a film
vice. and/or does not evaporate quickly. Never
use oil or kerosene.
39. Install bolts (6) and washers (7) into the cover (2)
and torque the bolts as follows. 3. Seat one rubber toric (41) on one seal ring (40).
: 15/16 in The rubber toric (41) must not be twisted. The
: 173 N·m (128 lbf·ft) rubber toric (41) must be uniformly seated on the
retaining lip of seal ring (40).
40. Reapply 13790 kPa (2000 psi) to the brake apply
port. Using a depth micrometer measure the dis-
tance from the housing (1) face to the gage pin
(19).
41. Obliterate existing number (if it exists) and metal

stamp this dimension close to the gage pin (19)
port.
42. Install plug (18) into measuring pin port.

: 11/16 in
: 37 N·m (27 lbf·ft)
Figure 14 - Toric Installation
TORIC FACE SEAL INSTALLATION
40. Seal Ring 42. Installation Tool
Numbers in parentheses refer to Figure 13 to 17. 41. Rubber Toric
NOTE: Always remove the Toric seals from their

bores anytime the faces are separated.
4. Place the assembled face seal into the proper in-

stallation tool (42, Figure 14). The seal installa-
tion tools can be found in Section W2-4, Special
Tools.
5. Dip the rubber toric (41, Figure 14) in Trichloro-

ethane. Most aerosol brake cleaners are also
acceptable. Spray the rubber toric (41) and the
bore of seal ring (40, Figure 14) until they are
completely wet.
Figure 13 - Section View of Toric Face Seal
40. Seal Ring NOTE: If Trichloroethane III is not available or

41. Rubber Toric permitted due to local regulations, some
brake cleaners are Trichloroethane III free
1. The toric face seals (31, Figure 2) consists of two and are acceptable substitutes. A 10%
seal rings (40, Figure 13), and two rubber torics mixture of dishwasher soap and water is
(41, Figure 13). an acceptable substitute.
2. Clean all parts with a non-filming solvent and a

clean lint-free cloth. Seal ring (40), rubber toric
(41) and the area in the housing the seal will seat
must be free of all oil and dirt.
W6-2-14
6. With rubber toric (41) still wet, set seal ring (40)
and installation tool (42) square against seal
housing (43). Use sudden and even pressure
against the tool (42) to push the toric (41) under
the retaining lip (44) of seal housing (43).
7. Ensure that rubber toric (41) is uniformly captured

under retaining lip (44). Ensure that the face of
seal ring (40) is parallel to seal housing (43)
within 1.0 mm (0.040”). Ensure that rubber toric
Figure 15 – Toric Installation (41) is not twisted or pinched.
40. Seal Ring 43. Seal Housing

NOTE: Improper wetting of the toric (41) or burrs
41. Rubber Toric 44. Retaining Lip on the housing seat can cause the toric
42. Installation Tool (41) to twist. The toric (41) must slide
uniformly into the housing (43). Improper
installation will cause eventual seal failure.
8. Repeat procedure for installation of the other toric

face seal half.
9. Wait at least two minutes to ensure complete

evaporation of solvent from torics (41).
10. Just prior to assembly, wipe the seal faces of seal

ring (40) with a lint-free cloth and moisten the
Figure 16 – Installed Toric Face Seal faces with oil. Do not get oil on rubber torics (41).
40. Seal Ring 43. Seal Housing

41. Rubber Toric 44. Retaining Lip CAUTION: Any contamination, even a piece of
42. Installation Tool lint is sufficient to cause leakage of the seal
assembly!
CAUTION: Do not allow faces to impact each

other. Seal Rings (40) are brittle and may
scratch or fracture. Move mating pieces
slowly and carefully together.
REAR BRAKE ASSEMBLY INSTALLATION

Numbers in parentheses refer to Figure 2 and 3.
1. Install O-ring (30) into housing (1) groove. Apply

Figure 17 – Section View of Toric Installed, in a continuous bead of liquid gasket to retain the
Compression O-ring.
2. Attach the brake assembly to the required lifting

40. Seal Ring 43. Seal Housing device. Lift the brake assembly and position it
41. Rubber Toric on the spindle (36, Figure 1), with the bleeder
screw (20) on top of the assembly.
3. Carefully push the brake assembly on the spindle

(36, Figure 1) against the flange.
W6-2-15
4. Insert mounting bolts (41) securing the brake as- 14. Install the rear wheel. Refer to Section W8-5,
sembly to the spindle (36, Figure 1). Torque REAR WHEEL. Be sure that the hub adapter
bolts (41) to the following value. (35) engages all the friction discs (4).
: 1 1/2 in
: 1048 N·m (773 lbf·ft)
NOTE: Do not force the wheel into the friction
5. Remove lifting device. plates (4) or damage to the wheel seal or
friction discs may result.
NOTE: The friction discs (4) must be perfectly 15. Release the applied pressure from the brake as-
aligned and centered in the brake housing sembly.
(1) to facilitate the wheel installation. It is
therefore recommended that the disc 16. Remove the caps from the brake cooling inlet and
alignmen ttool is to be utilized. Refer to outlet lines (1 – 6, Figure 5) and connect them to
Section 2-4, SPECIAL TOOLS. the brake housing (1) with the spilt flanges (10,
Figure 5). Remove the cap from the brake apply
6. The disc alignment tool (E12977843) pilots on the lines (10, 11, Figure 6) and install them at the
outer diameter of the seal retainer assembly connectors (13, Figure 6) at the brake housing
(bearing spacer). (1).
7. Guide the alignment tool (E12977843) into the 17. Refill the hydraulic reservoir. Refer to the Main-
brake while lifting the friction disc (4) on to the tenance section in the Operator’s Manual
tool guides until all the discs (4) are aligned. (EM8R6-1-3).
8. Slowly apply at least 345kPa (500 psi) to the 18. Brakes must be bled any time a connection in the
brake apply circuit to compress the friction system has been loosened. See BLEEDING in
pack. this section.
CAUTION: Keep your fingers clear of the 19. Start the engine and check the system for
friction pack while applying the brakes. The proper operation. Check for leakage. Check
friction pack will compress and could cause hydraulic fluid level and add if necessary.
injury.
9. Remove the alignment tool (E12977843). The

friction pack is now held into place by applied
pressure.
NOTE: If the disc alignment tool (E12977843) is

not available, follow steps 10 – 13.
10. Using the hydraulic power sourced attached to

the supply port (38, Figure 3), pressurize the
brake to 690 kPa (100 psi). Make sure the oil
used is the same type as recommended for the
system. Reference applicable sections.
11. Align the friction discs with a pry bar.
12. Increase the pressure to clamp the friction discs

(4) tight.
13. Verify the proper alignment before attempting

the wheel installation.
W6-2-16
BLEEDING
1. Attach a bleeder hose to the bleeder valve (20,

Figure 1) with the other end in a container for
drainage.
2. Check the oil level in the steering tank and add

hydraulic oil as necessary to bring it to the correct
level.
3. Start the engine and let it idle. Monitor the brake

pressure on the LCD display until the brake pres-
sure reads a normal level.
4. While a second person gently depresses the re-

tarder pedal, loosen the bleeder valve (13), with
hose attached, and bleed fluid until it flows free of
air bubbles. Tighten the bleeder valve (13) and
remove hose. Repeat at the other rear brake to
completely eliminate air in the system.
5. Replace the oil as necessary to bring the hydrau-

lic reservoir to the correct oil level.
6. Check the brake performance by operating the

machine under controlled conditions before re-
turning it to service.
W6-2-17
DESCRIPTION SPECIFICATION
Brake Reaction Plate (5) Minimum thickness 2.75mm (0.11 in)
Brake Reaction Plate (5) Flat within 0.75mm (0.030 in)
Brake Reaction Plate (5) Surface diametrical scoring (Figure
< 20 % of brake surface area
14A), maximum allowance over contact area
Brake Reaction Plate (5) Radial scoring (Figure 11B) 0, None
Brake Friction Disc (4) Minimum lubrication groove depth 0.25 mm (0.01in)
Brake Friction Disc (4) Minimum lining material thickness
0.5mm (0.020 in)
each side
Piston Seal (13) Leakage Check Zero leakage after 15 minutes
0 - 13790 ± 173 kPa
Rear Brake Apply Pressure
(0 - 2000 ± 25 psi)
W6-2-18
BRAKE SYSTEM / Brake Valve
SERVICE POSITION
Park rigid dump truck on a level solid surface and CAUTION: Escaping fluid under pressure
place in “Service Position” Refer to Section W2-1. can penetrate the skin and eyes, causing
serious injury.
Isolate Stored Energy Hydraulic oil may be hot after operation.
Hot hydraulic oil may spurt out, possibly
The hydraulic accumulators automatically apply causing severe burns.
stored energy to the brake circuits during normal
engine shutdown. Verify this stored energy is re- Assure that open end of test hose is se-
cured in a fluid holding container.
leased from the accumulators before service is per-
formed to the brake system. Eye Protection is required.
3. Secure one end of two test hoses, (see pressure
1. Be sure to apply wheel blocks to both sides of test kit E12979919, Figure 2), inside a fluid hold-
the tire to prevent vehicle movement. ing container. Use a tie wrap or wire to retain the
hose end inside container. Direct the fluid dis-
charge towards bottom of container.
2. Allow the steering accumulator time to drain to
4. Carefully connect one test hose to the front test
zero pressure. Verify accumulator is bled down
port and another test hose to the rear test port of
by rotation of steering wheel left and right until
the brake valve by removing the test port caps
you cannot turn the steering wheel further.
and slowly threading the test hoses onto the test
fittings.
5. Depress the brake pedal multiple times to relieve
brake accumulator pressure. When the pressure
in both accumulators falls below 9650 kPa [1400
psi], the brake valve will shift the Low Pressure
Rear TP Sensor Valve (LPS) spool and remain in the ap-
Supply TP plied position until the pressure has dropped to
near zero. Pedal effort will be dramatically re-
duced when pressure falls below 1400 psi and
the LPS spool is shifted.
Front TP 6. Remove the test hoses and replace the caps on
the test port connectors, once the oil stops flow-
ing from both test hoses.
EL 20738
Figure 1 - Test Ports
EL 20739
Figure 2 - Pressure Test Kit (E12979919)
W6-3-1
7. Verify there is no pressure in the accumulators by

connecting a hydraulic pressure test gauge to the
front and rear brake apply test ports and de-
pressing the brake pedal. There should be no
pressure showing on the test gauges with the
brake pedal depressed.
8. Clean the area of the cab where the brake valve
is located to remove dirt and dust.
9. Plug all open lines during service. If plug is un-
available use plastic film or tin foil to cover tubing
end and retain covering with tie wrap.
CAUTION: Contamination can interfere with

proper operation of the brake system.
REMOVAL
Figure 3 – Brake Valve Standard
CAUTION: Brake Valve Assembly weight
18.5 kg (41 lb). 1. Load Dump Solenoid Connection
2. Front Brake Apply Tube (WBF)
1. With rigid dump truck off, in “Service Position”, 3. Accumulator Tube Connection (AR)
and all accumulator pressures released to zero 4. Brake Valve Return Tube (R)
(refer to Isolate Stored Energy, this section), dis- 5. Rear Brake Tube (BR)
connect the load dump solenoid electrical con- 6. Pressure Inlet Tube (P)
nection (1). 7. Mounting Screw
8. Accumulator Tube Connection (AF)
2. Remove the front brake apply tube (2). 9. Front Brake Cut-off Solenoid Connection
: 11/8 in
3. Remove accumulator tubes (3) and (8) 7 4

: 15/16 in 9
4. Remove Brake Valve Return Tube (4).

: 11/8 in
5. Remove BR port tube (5).
: 15/16 in
6. Remove Pressure inlet line (6).
: 15/16 in
: 11/8 in
7. Remove six mounting screws (7).
: 9/16 in
8. Disconnect the front brake cut-off solenoid con-

nection. 5 1 3
2 8 6
9. Disconnect the brake switch electrical connection

near the top of the brake pedal inside the cab
(not illustrated). Figure 4 - Brake Valve with ATC / EDSC (Optional)
W6-3-2
INSTALLATION
1. Attach brake valve assembly to cab using six

mounting screws (7).
: 9/16 in
: 36 N·m (26 Ibf·ft)
2. Attach Pressure inlet line (6) with new O-rings.

Torque tube ends and swivel nut connections.
: 15/16 in
: 45 N·m (33 Ibf·ft)
: 11/8 in
: 65 N·m (48 Ibf·ft)
3. Attach BR port tube (5) with new O-rings. Torque

tube and swivel nut connections.
: 15/16 in
: 45 N·m (33 Ibf·ft)
4. Attach Brake Valve Return Tube (4) with new

O-rings. Torque tube and swivel nut connec-
tions.
: 1 1/8 in
: 65 N·m (48 Ibf·ft)
5. Install accumulator tubes (3) and (8) with new

O-rings. Torque tube ends and swivel nut con-
nections.
: 15/16 in
: 45 N·m (33 Ibf·ft)
6. Install front brake apply tube (2) with new

O-rings. Torque tube ends and swivel nut con-
nections.
: 11/8 in
: 65 N·m (48 Ibf·ft)
7. Connect load dump brake solenoid electrical

connection (1).
8. Connect front brake cut-off solenoid electrical

connection (9).
9. Connect brake switch electrical connection near

top of pedal inside cab (not illustrated).
W6-3-3
Supply TP
Front TP
Rear TP
Figure 5 – Retarder and Brake Valve Test Ports
(Standard Equipment)
Retarder CAUTION: TEST PORTS HOLD HIGH PRES-

Test Port Retarder SURE HYDRAULIC FLUID.
(TPR) Test Port Escaping fluid under pressure can pene-
(TPL) trate the skin and eyes, causing serious
injury.
Hydraulic oil may be hot after operation.
causing severe burns.
Assure that open end of test hose is se-
cured in holding container.
Eye Protection is required.
10. Assure that the area around the hauler is clear,

and start the engine.
Figure 6 – Retarder Valve Test Ports ATC/EDSC 11. With the engine running, secure one end of a
(Optional) test hose, (see pressure test kit E12979919, Fig-
ure 2), into a fluid holding container.
CAUTION: Verify that all personnel have 12. Remove the cap from the Supply TP (supply test
moved away from the unit before proceed- port) of the brake valve and slowly thread the
ing. free end of the test hose onto the test port, (refer
to Figure 5).
W6-3-4
DISASSEMBLY
NOTE: The further the test hose fitting is CAUTION: Contamination can cause im-
threaded onto the test port, the more proper valve operation.
flow will be expelled from the test hose.
Attach the test hose slowly.
NOTE: Service valve in a clean work area on a
clean surface.
13. Allow fluid to flow into the container until there is
no evidence of air in the line. NOTE: Use lint-free cloths and filtered cleaning
fluids when handling and cleaning
14. Remove the test hose connection from port components.
Supply TP and replace the test port cap.
15. Remove the cap from the retarder test port (Re-
2
tarder TP) and thread on one end of the test
hose. Refer to Figure 5.
16. Slowly apply the retarder pedal until fluid starts

to flow into the container and hold until there is
no evidence of air in the line.
17. Remove the test hose connection from port Re-

tarder TP and replace the test port cap. 5
4
18. For units with the optional ATC / EDSC, perform
these steps for both test ports TPL and TPR.
Refer to Figure 6.
3
19. Repeat steps 15 thru 17 for the rear brake apply
test port (Rear TP) and the front brake apply test
port (Front TP) on the brake valve. Refer to
Figure 5. 6
7
20. Bleed the front and rear hydraulic circuits at
each individual front and rear brake head.
1
21. Verify brake valve operation. Check and adjust
operational pressures, and if necessary, adjust
brake apply pressures using section W6-3, Ad-
justments.
Figure 7 – Brake Valve and Fittings
1. Brake Valve Assembly

2. Test Fitting
3. Elbow
4. Adaptor
5. Tee Connector
6. Plug
7. O-Ring
W6-3-5

1. Move assembly to a clean area.
6. Remove fitting (4) and discard O-rings.
7
2. Remove test fittings (2). : /8 in
: 11/16 in
7. Remove screws (3).
3. Remove fitting (3). : 5/16 in
: 1 1/16 in
4. Remove fitting (5).
: 7/8 in 8. Lift front brake cut-off assembly (1) from brake
valve (2) and discard O-rings (4) and (5).
: 1 3/8 in
5. Remove plug (6) and discard O-ring (7).
7
: /8 in
EL 20745
Figure 8 – Brake Valve and Front Brake Cut-off

Valve
1. Front Brake Cutoff Valve

2. Brake Valve
3. Screw
4. O-Ring
5. O-ring
W6-3-6
Rear
Front
Figure 9 – Brake Valve
1 Manifold 8.2 O-ring 20 Spring, extension 31 O-ring

2 Valve, Cartridge 9 Spring, Compression 21 Pin 32 Backup Ring
3 Valve, Cartridge 10 Poppet 22 Retainer, E-ring 33 Plug
4 Pedal Assembly 11 LPS Valve 23 Washer 34 Plug
4.1 Pedal 12 Valve, Solenoid 24 Plug 35 O-ring
4.2 Bushing 13 Plug 24.1 O-ring 36 Sealant
4.3 Pin 14 Bracket 25 Pin 37 Elbow
5 Mounting Plate 15 Screw 26 Retainer, E-ring 37.1 O-ring
6 Ball 16 Set Screw 27 Set Screw 37.2 O-ring
7 Cover 17 Nut 28 Nut 38 O-ring
8 Elbow 18 Screw 29 Screw 39 Kit, seal
8.1 O-ring 19 Nut 30 Screw
W6-3-7
Numbers in parentheses refer to Figure 9. 19. Discard O-rings (31) and backup rings (32).
NOTE: If the pedal and mounting components 20. Remove plug (24).
are not in need of service, skip to step 8. : 11/4 in
9. Loosen nut (28) from set screw (29) and remove
the setscrew.
NOTE: Plug (13) and ball (6) cannot be removed
: 9/16 in from the manifold (1). Those three
pieces must be replaced at the same
10. Remove one e-ring (26) from pin (25). Push out
time.
pin (25) and let spring (20) drop free.
11. Remove e-ring (22) from pin (21). Push out pin NOTE: Plugs (34) are factory installed with per-
(21) and nylon washers (23) to remove pedal manent thread sealer (36) and their re-
assembly (4). moval will be difficult and is discouraged.
12. Remove nuts (19) and eye screw (18).
21. If there are signs of seal leakage around plugs
: 3/8 in (34), remove the plug and discard the O-ring
13. Remove nut (17) from set screw (16) and re- (35).
move from bracket (14). : 1/8 in
: 9/16 in 22. Remove plugs (33), and discard O-ring (38).
: 3/16 in : 3/16 in
14. Remove screws (15) from mounting (5).
: 7/16 in 23. Remove the load dump solenoid valve (12) by
first removing the coil nut and coil.
15. Remove pedal cover (7).
16. Remove screws (29 and 30) securing mounting NOTE: Do not discard coil O-rings (not illus-
plate (5) to manifold (1). trated) as they are not available sepa-
: 9/16 in rately.
: ¾ in
17. Place a pry block (approximately 10mm [0.39 in] : 7/8 in
thick) on the manifold (1) held against the car-
tridge (2) to protect the manifold (1) surface. In- 24. Remove sequence valve (11). Tag the cartridge
sert the pry tool tip under the cartridge (2) guide “LPS” (Low Pressure Sensor) for later identifica-
lip, (refer to Figure 10), use the block as a ful- tion.
crum, and pry the cartridge (2) from the mani- : 1 in
fold (1). Tag the cartridge (2) to note which
side of the manifold it was removed from, (front 25. Remove fitting (37).
or rear; the word “REAR” or “FRONT” is : 13/8 in
stamped on the rear side of the manifold).
18. Repeat step 9 for the rear brake cartridge (3). 26. Remove special hardened elbow fittings (8),
springs (9), and poppet (10).
: 15/16 in
Spool Area
Carefully place pry
NOTE: Internal components of the Brake valve
tool tip here to
cartridges (2 and 3) are not serviceable.
remove cartridge
The outer valve cartridge seals are
(2 and 3) from
available and should be replaced.
manifold (1).
Plunger Face
EL 20747
Figure 10 – Cartridge (2 and 3) Removal
W6-3-8
5 Numbers in parentheses refer to Figure 12.

29. Remove O-Rings (1), (3), and (5) and discard.
4
1 30. Remove Backup rings (2) and (4) and discard.
3 31. Do not discard coil O-rings as they are not

available separately (not illustrated).
EL 20747
Figure 11 - Cartridge Assembly
Description *
1. O-Ring
2. Backup Ring *
3. O-Ring *
4. Backup Ring
5. O-Ring
EL 20749
27. Remove O-Rings (1), (3), and (5) and discard.

Figure 13 - Low Pressure (Sequence) Valve (LPS)
28. Remove Backup rings (2) and (4) and discard.
Description
2. O-Ring
Spool Area 3. O-Ring
4. O-Ring
5. O-Ring
6. Backup Ring
7. Backup Ring
8. Backup Ring
32. Remove backup rings (8), and O-ring (5) and

discard.
EL 20748 33. Remove backup rings (7) and O-ring (4) and
Figure 12 - Load Dump Cartridge discard.
1. O-Ring 34. Remove O-ring 3 and backup ring (6) and dis-
card.
2. Backup Ring
3. O-Ring 35. Remove O-ring (2) and discard.
4. Backup Ring
5. O-Ring
W6-3-9
38. Remove check valve (6).

: 1 in
39. Remove plugs (3) and O-rings (11).
: 5/16 in
40. Remove plug (4) and discard O-ring (10).
: ¼ in
41. Remove plugs (7) and discard O-rings (9).
: 3/16 in
EL 20750
Install This Plug After

Sequence Valve (1)
Figure 14 - Front Brake Cutoff (FBCO) Valve

Assembly EL 20751
Figure 15 - FBCO Solenoid Valve

1. Valve, Sequence (FBCO)
2. Valve, Solenoid (FBCO)
1 Coil
3. Plug
4. Plug 2 Valve, cartridge
5. Manifold
2.1 O-ring
6. Valve, Check
7. Plug 2.2 Backup Ring
8. Kit, Seal
2.3 O-ring
9. O-Ring
10. O-Ring 2.4 O-ring
11. O-Ring
2.5 Backup Ring

36. Remove solenoid valve (2) by first removing
the coil nut and coil.
42. Remove O-rings (2.1), (2.3), and (2.4) and
NOTE: Do not discard coil O-rings as they are not discard.
sold separately (not illustrated).
: 1 in 43. Remove backup rings (2.2) and (2.5) and dis-
: ¾ in card.
37. Remove sequence valve (1). Tag the sequence NOTE: Do not discard coil O-rings as they are not
valve (1) “FBCO” to identify that it was re- available separately (not illustrated).
moved from the front brake cutoff manifold.
: 1 in
W6-3-10
INSPECTION
1. Inspect brake valve cartridges (2 and 3) for signs
of obvious damage. Look for signs of leakage
from the cartridge plunger face (refer to Figure
10).
2. Examine small cross holes of the valve car-
tridges (2 and 3) for signs of contamination
within the spool area, (see Figure 10, Figure 12,
Figure 13, and Figure 15 through Figure 17).
Contamination in this area may result in sticking
EL 20752 of the valve spool and will require replacement
Figure 16 - FBCO Sequence Valve of the cartridge (2 or 3).
3. Inspect elbow fitting (8) for damage on the
1. O-Ring spring face. Excessive wear may indicate that
2 Backup Ring the incorrect fitting (8) has been used. The
3. O-Ring proper fitting (8) is special hardened steel. This
4. Backup Ring can be verified as the component part number is
5. O-Ring stamped onto the flat of the correct part.
Numbers in parentheses refer to Figure 16. 4. Inspect manifold (1) bores for deep scratches,
gouges or excessive wear, particularly in the
44. Remove O-rings (1), (3), and (5) and discard. areas were cartridge o-rings seal. Inspect the
45. Remove backup rings (2) and (4) and discard. seat area of the poppet (10) bores for gouges or
scratches. If any of these conditions exist re-
place that part.
5. Inspect removed seals for signs of swelling or
degradation that may be a result of incompatible
fluids.
6. Inspect pedal cover (7) for excess wear. Inspect
manifold (5) (refer to Figure 14), bores for deep
scratches, gouges or excessive wear, particu-
larly in the areas were cartridge O-rings seal.
7. Thoroughly clean all parts prior to assembly.
8. Discard all used seals, O-rings and backup rings
EXCEPT FOR COIL O-RINGS. Re-assemble
EL 20753 with new seals, O-rings and backup rings
Figure 17 - FBCO Check Valve
1. O-Ring ASSEMBLY
2. O-Ring
3. Backup Ring CAUTION: Contamination can cause im-
proper valve operation.
46. Remove O-rings (1) and (2) and discard. clean surface.
47. Remove backup rings (3) and discard.
NOTE: Use lint-free cloths and filtered cleaning
fluids when handling and cleaning com-
ponents.
W6-3-11
4. Install sequence valve (1) into manifold (5).

NOTE: Clean all components with filtered
cleaning solution prior to assembly. : 1 in
: 34 N·m (25 Ibf·ft)
NOTE: Lubricate cartridge seals with filtered 5. Install solenoid valve (2) into manifold (5). Do
hydraulic oil prior to installation. not install the coil assembly on to the valve stem
yet.
NOTE: Carefully coat cartridge threads with : 1 in
thread lock compound prior to : 34 N·m (25 Ibf·ft)
installation. 6. Install plugs (7) with new O-rings (9) in manifold
(5).
NOTE: The use of grease to hold seals in place : 3/16 in
is NOT RECOMMENDED for brake and : 5 N·m (40 Ibf·in)
retarder valve assemblies and
components. 7. Install the solenoid coil on solenoid valve stem
(2) that was installed in step 2.
: ¾ in
Front Brake Cutoff Assembly
: 7 N·m (5 Ibf⋅ft)
8. Install check valve (6) in manifold (5).
: 1 in
1. Install O-ring (1), O-ring (2), and backup ring (3) : 34 N·m (25 Ibf·ft)
on the front brake cutoff check valve (item 6 on
9. Install plug (4) and new O-ring (10) in manifold
Figure 14).
(5).
: ¼ in
: 9 N·m (75 Ibf·in)
2. Install O-ring (1), backup ring (2), O-ring (3),
10. Install plugs (3) and new O-rings (11) into mani-
backup ring (4), and O-ring (5) on the front brake
fold (5).
cutoff sequence valve (item 1 on Figure 14).
: 5/16 in
: 18 N·m (155 Ibf·in)
3. Install O-ring (2.1), backup rings (2.2), O-ring Pedal Assembly
(2.3), backup ring (2.5), and O-ring (2.4) on the Numbers in parentheses refer to Figure 9.
front brake cutoff solenoid valve (item 2 on Fig-
ure 14). 1. Assemble bracket (14) on mounting plate (5)
using screws (15).
Numbers in parentheses refer to Figure 15. : 7/16 in
: 10 N·m (86 Ibf·in)
2. Install set screw (16) and nuts (17) on bracket
NOTE: Plug (7) located on the drivers side of the (14), DO NOT TORQUE NUTS UNTIL VALVE
front brake cutoff manifold, (see Figure 14), IS INSTALLED ON UNIT, and final adjustment
should be installed after the sequence car- has been made.
tridge (1).
: 9/16 in
NOTE: The WBF port or the TP ports (see Figure
1) should be open to atmosphere when
the check valve (6) and the solenoid valve 3. Install pedal cover (7) on to pedal (4).
(2) are installed.
4. Thread set screw (27) into pedal (4) until it is
visually level with the pedal button pin (4.3). In-
W6-3-12
stall nut (28) to set screw (27). DO NOT Brake Assembly

TORQUE UNTIL VALVE IS INSTALLED ON Numbers in parentheses refer to Figure 9.
UNIT.
: 9/16 in 1. Install plugs (33) and O-rings (38) in manifold
: 26 N·m (19 Ibf·ft) (1).
5. Install one e-ring retainer (22) on pin (21). : 3/16 in
: 14 - 16 N·m (125 - 145 Ibf·in)
6. Apply a small spot of clean bearing or lithium
grease to the inside faces of the mounting plate
(5) where the pin (21) will pass. Use the grease 2. Install plugs (34) and O-rings (35) in manifold
to hold the plastic washers (23) in place and (1) using thread sealant (36).
aligned to the holes in the mounting plate (5) : 1/8 in
face. : 4 N·m (35 Ibf·in)
7. Hold the pedal (4) in line with the holes in the
mounting plate (5), and using care to keep the 3. Coin the ball (6) into the plug (13) and into the
plastic washers (23) in line, install pin (21) manifold (1) using a steel punch and a small
through the mounting plate holes, pedal holes, hammer. Use one impact from selected weight
and washer holes until it is approximately cen- hammer to (coin) ball seat.
tered. : ¼ Kg (8 ounce)
8. Install the second e-ring retainer (22) on to pin : Steel Punch
(21).
9. Install the eye screw (18) and nuts (19) on to 4. Install plug (13).
mounting plate (5). : 5/16 in
: 3/8 in : 36 N·m (27 Ibf·ft)
10. Install one end of spring (20) through eye screw

(18). 5. Install plug (24) and new O-ring (24.1).
: 1 ¼ in
11. Install one e-ring (26) on pin (25) and feed the : 34 N·m (25 Ibf·ft)
pin (25) through the one hole in pedal (4),
through spring (20), and through the opposing
hole in pedal (4). 6. Coin the poppets (10) into the manifold (1) using
a steel punch and a small hammer. Use one
12. Install the remaining e-ring retainer (26) on to impact from selected weight hammer to (coin)
the pin (25). poppet seat.
: ¼ kg (8 ounce)
: Steel Punch
Brake Apply Cartridge Assembly
7. Install springs (9) and elbow fittings (8) with new
1. Install new O-ring (1) on to cartridge. O-rings (8.1) and (8.2). DO NOT TORQUE THE
ELBOW FITTING (8) LOCK NUTS UNTIL
2. Install new backup ring (2), and new O-ring (3). VALVE IS ASSEMBLED ON UNIT.
3. Install new backup ring (4) and new O-ring (5). : 15/16 in
: 58 N·m (43 Ibf·ft)
CAUTION: Elbow fittings (8) have been

specially designed for this application. Use
of standard fittings could cause excess
system contamination and ultimately valve
failure.
W6-3-13
8. Install fitting (37) and new O-ring (37.1).

16. Install fitting (3) with new O-rings.
: 1 3/8 in
: 72 N·m (53 Ibf·ft) : 1 1/16 in
: 50 N·m (37 Ibf·ft)
NOTE: DO NOT tighten any of the fitting’s lock 17. Install fitting (4) with new O-rings.
nuts until the valve has been installed and : 7/8 in
each of the metal tubes installed. : 43 N·m (32 Ibf·ft)
9. Install sequence cartridge (11).

: 1 in 18. Install fitting (5) with new O-rings.
: 31 N·m (23 Ibf·ft) : 13/8 in
: 72 N·m (53 Ibf·ft)
10. Install load dump solenoid cartridge and coil
(12). 19. Install plug (6) with new O-ring (7).
: 7/8 in : 7/8 in
: 25 N·m (18 Ibf·ft) : 43 N·m (32 Ibf·in)
: ¾ in
: 7 N·m (60 lbf·in)
11. Install new backup rings (32) followed by new
O-rings (31) into manifold (1).
12. Install rear cartridge (3) and front cartridge (2) in
manifold (1). Refer to Figure 9 for proper in-
stallation orientation.
13. Install pedal assembly (from previous steps)
onto manifold (1) using bolts (29) and (30).
: 9/16 in
: 37 N·m (27 Ibf·ft)
14. Install front brake cutoff assembly (1) onto the

brake valve (2) with O-rings 4 and (5) using
screws (3).
: 5/16 in
: 32 N·m (24 Ibf·ft)
15. Install test fittings (2).

: 11/16 in
: 5 N·m (40 Ibf·in).
W6-3-14
ADJUSTMENTS 5. Adjust pedal 'up stop' screw (16) so that the

pedal free travel, measured at the pedal cover
NOTE: Adjustments should only be performed (7), is 13 to 15mm (0.5 to 0.6 in) before pres-
using tools and equipment that are sure is observed at the brake valve test ports.
known to be in proper functional condi- Tighten nuts (17) after final adjustment is made.
tion and properly calibrated.
: 3/16 in
: 9/16 in
Numbers in parentheses refer to Figure 9, unless : 26 N·m (19 Ibf·ft)
otherwise noted. 6. Verify proper operation of the brake valve.
Check load dump switch operation. Check op-
eration of LPS while bleeding down brake ac-
1. Attach 0–34500 kPa (0–5000 psi) pressure cumulators with engine off.
gauges from the pressure test kit (refer to Fig-
ure 2) to the TP and Rear TP test ports. Refer
to Figure 1.
2. Loosen nut (28), adjust the set screw (27) out
and then apply the brake pedal fully so that one
brake cartridge plunger achieves the maximum
plunger travel. Check that cartridge pressure
achieved is to specification.
3. Adjust the set screw (27) in (with a flat screw-
driver) and then apply the brake pedal fully so
that opposite plunger achieves the maximum
plunger travel. Check that cartridge pressure
4. Adjust set screw (27) (with a flat screwdriver)
now so that both plungers have zero gap be-
tween the adjustment collar and face of car-
tridge when pedal is fully depressed. Check that
pressures front and rear are to specification.
Tighten nut (28).
: Pry Tool
: 9/16 in
: 26 N·m (19 Ibf·ft)
Zero gap when

pedal is depressed
EL 20754
Figure 18 – Brake Pedal Applied
W6-3-15
Brake Valve Cartridge Pressure Range
Front Brake 0 - 18.96 ± 0.173 MPa (0 - 2750 ± 25 psi)
Retarder 0 - 13.78 ± 0.173 MPa (0 - 2000 ± 25 psi)
NOTE: After an application of the brake or retarder

pedal, there should be no pressure re-
maining in the brake circuit. Any residual
pressure could indicate a problem with the
brakes.
W6-3-16
BRAKE SYSTEM / Retarder Valve
Service Position
Park rigid dump truck on a level solid surface and CAUTION: Escaping fluid under pressure can
place in “Service Position” Refer to Section W2-1. penetrate the skin and eyes, causing serious
injury.
Isolate Stored Energy Hydraulic oil may be hot after operation. Hot
hydraulic oil may spurt out, possibly causing
The hydraulic accumulators automatically apply severe burns.
engine shutdown. Verify this stored energy is re- Assure that open end of test hose is secured
in a fluid holding container.
leased from the accumulators before service is
performed to the brake system. Eye Protection is required.
1. Be sure to apply wheel blocks to both sides of test kit E12979919, Figure 2), inside a fluid holding
the tire to prevent vehicle movement. container. Use a tie wrap or wire to retain the hose
end inside container. Direct the fluid discharge to-
wards bottom of container.
zero pressure. Verify accumulator is bled
down by rotation of steering wheel left and
the brake valve by removing the test port caps and
right until you cannot turn the steering wheel
slowly threading the test hoses onto the test fit-
further.
tings.
brake accumulator pressure. When the pressure in
both accumulators falls below 9650 kPa [1400 psi],
the brake valve will shift the Low Pressure Sensor
Valve (LPS) spool and remain in the applied posi-
Rear TP tion until the pressure has dropped to near zero.
Supply TP Pedal effort will be dramatically reduced when
pressure falls below 1400 psi and the LPS spool is
shifted.
6. Remove the test hoses and replace the caps on
Front TP the test port connectors, once the oil stops flowing
from both test hoses.
EL 20738
EL 20739
W6-4-1
7. Verify there is no pressure in the accumula-

tors by connecting a hydraulic pressure test 4 6
gauge to the front and rear brake apply test
ports and depressing the brake pedal. There
should be no pressure showing on the test
gauges with the brake pedal depressed.
8. Clean the area of the cab where the brake
valve is located to remove dirt and dust.
9. Plug all open lines during service. If plug is
unavailable use plastic film or tin foil to cover
tubing end and retain covering with tie wrap.
CAUTION: Contamination can interfere

with proper operation of the brake sys-
tem.
REMOVAL
Numbers in parentheses refer to Figure 3. 5 3
1
2
CAUTION: Retarder Valve Assembly
weight 9 kg (20 lb).
Figure 3 – Retarder Valve
1. With rigid dump truck off, in “Service Posi-

tion”, and all accumulator pressures released 1. Brake Apply Pressure Tube
to zero (refer to Isolate Stored Energy, this 2. Inlet Pressure Tube
section), remove the brake apply pressure 3. BR Port Tube
tube (1). 4. Brake Valve Return Tube
5. Return Tube
: 15/16 in
6. Mounting Screw
: 11/8 in
2. Remove inlet pressure tube (2).

: 15/16 in
3. Remove BR port tube (3).

: 15/16 in
4. Remove Brake Valve Return Tube (4).
: 1 in
: 11/8 in
5. Remove return tube (5).
: 11/8 in
: 13/8 in
6. Remove six mounting screws (6).

: 9/16 in
W6-4-2
INSTALLATION CAUTION: Verify that all personnel have

Numbers in parentheses refer to Figure 3 moved away from the unit before proceed-
ing.
1. Attach retarder valve assembly to cab using
six mounting screws (6). CAUTION: TEST PORTS HOLD HIGH PRES-
9
: /16 in SURE HYDRAULIC FLUID.
: 36 N·m (26 Ibf·ft) Escaping fluid under pressure can penetrate
the skin and eyes, causing serious injury.
2. Attach return tube (5).
Hydraulic oil may be hot after operation. Hot
: 11/8 in
hydraulic oil may spurt out, possibly causing
: 65 N·m (48 Ibf·ft)
severe burns.
: 13/8 in
Assure that open end of test hose is secured
: 92 N·m (68 Ibf·ft)
in holding container.
3. Attach Brake Valve Return Tube (4). Torque Eye Protection is required.
tube and swivel nut connection.
: 11/8 in 7. Assure that area around unit is clear, and start the
: 65 N·m (48 Ibf·ft) engine.
4. Attach BR port tube (3). Torque tube and

8. With the engine running, secure one end of a test
swivel nut connection.
hose, (see pressure test kit E12979919 Figure 2),
: 15/16 in into a fluid holding container.
: 45 N·m (33 Ibf·ft)
9. Remove the cap from the Supply TP Test Port of
5. Install inlet pressure tube (2). Torque tube and the brake valve and slowly thread the free end of
swivel nut connection. the test hose onto the test port, (see Figure 4).
: 15/16 in NOTE: The further the test hose fitting is threaded
: 45 N·m (33 Ibf·ft) onto the test port, the more flow will be
expelled from the test hose. Attach the
6. Install brake apply pressure tube (1). test hose slowly.
: 15/16 in
: 45 N·m (33 Ibf·ft) 10. Allow fluid to flow into the container until there is
no evidence of air in the line.
: 11/8 in
: 65 N·m (48 Ibf·ft) 11. Remove the hose and replace the test port cap.
12. Remove the cap from the Retarder TP Test Port

STP RTP and thread on one end of the test hose.
FTP Retarder
Test Port 13. Slowly apply the retarder pedal until fluid starts to
flow into the container and hold until there is no
evidence of air in the line.
14. Remove the hose and replace the test port cap.
15. Remove the cap from the Rear TP Test Port on

the brake valve and thread on one end of the test
hose. Refer to Figure 4.
Figure 4 - Valve Bleed Ports
W6-4-3
16. Slowly apply the brake until fluid starts to

flow into the container and hold until there is 2
no evidence of air in the line. 2.1
17. Remove the hose and replace the test port

6
cap.
4 6.1
4.1 6.2
18. Bleed the rear brake circuit at each rear
brake assembly. 4.2
5
5.1
5.2
DISASSEMBLY 3
3.1
3.2
CAUTION: Contamination can cause im-
Figure 5 - Retarder Valve Fittings

NOTE: Service valve in a clean work area on
a clean surface. Item Description Item Description
1 Valve, Retarder 5 Connector
NOTE: Use lint-free cloths and filtered clean- 2 Fitting 5.1 O-Ring
ing fluids when handling and cleaning 2.1 O-Ring 5.2 O-Ring
components. 3 Tee 6 Elbow
3.1 O-Ring 6.1 O-Ring
3.2 O-Ring 6.2 O-Ring
4 Tee
4.1 O-Ring
4.2 O-Ring

2. Remove Fitting (4).
: 15/16 in
: 7/8 in
4. Remove Fittings (3) and (6).
: ¾ in

: 11/16 in
W6-4-4
Figure 6 - Retarder Valve Assembly
1 Manifold 16 Pin
2 Valve, Cartridge 17 Washer
3 Mounting Plate 18 Retainer, E-Ring
4 Pedal Assembly 19 Pin
5 Cover, Pedal 20 Retainer, E-Ring
6 O-Ring 21 Screw
7 Ball 22 Screw
8 Bracket 23 Set Screw
9 Screw 24 Nut
10 Fitting 25 Plug
11 Screw, Set 25.1 O-Ring
12 Nut 27 Plug
13 Screw, Eye 28 O-Ring
14 Nut 29 Kit-Seal
15 Spring
W6-4-5

10. Remove fitting (10), and ball (7). O-Ring (6)
should be removed and replaced.
NOTE: If the pedal and mounting components : 7/8 in
are not in need of service, skip to step 8. 11. Remove plug 25 and replace O-Ring 25.1.
: 11/16 in
1. Loosen nut (24) from set screw (23) and remove
12. Remove plug (27), if present, and replace
the set screw.
O-Ring (28).
: 9/16 in
: 3/16 in
2. Remove one E-ring (20) from pin (19). Push out
pin (19) and let spring (16) drop free.
NOTE: Internal components of the Retarder
3. Remove E-ring (18) from pin (19). Push out pin valve cartridge (2) are not serviceable.
(16) and nylon washers (17) to remove pedal The outer valve cartridge seals are
assembly (4). available and should be replaced.
4. Remove nuts (14) and eye screw (13)
: 3/8 in
5. Remove nuts (12) from set screw (11) and re- 13. Remove O-Rings (1), (3), and (5) and discard.
move from bracket (8). 14. Remove Back-up rings (2) and (4) and discard.
9
: /16 in
: 3/16 in
6. Remove screws (9) from mounting (3).
: 7/16 in
8. Remove screws (21 and 22) securing mounting
plate (3) to manifold (1).
: 9/16 in
9. Place a pry block (approximately 10mm [0.39 in]
thick) on the manifold (1) held against the car-
tridge (2) to protect the manifold surface. Insert
the pry tool tip under the cartridge guide lip, (re-
fer to Figure 7), use the block as a fulcrum, and
pry the cartridge (2) from the manifold (1).
Spool Area
Carefully place pry
tool tip here to
remove cartridge
from manifold (1)
EL 20747
Figure 7 – Cartridge (2) Removal
W6-4-6
INSPECTION may result in sticking of the valve spool and will

require replacement of the cartridge (2).
4. Inspect seals removed for signs of swelling or
degradation that may be a result of incompatible
1. Inspect retarder valve cartridge (2), ball (7) and
fluids.
manifold (1) bores for deep scratches, gouges
or excessive wear. If any of these conditions ex- 5. Thoroughly clean all parts prior to assembly.
ist, replace part.
6. Discard all used seals, O-rings and backup rings.
2. Examine machined surfaces of the valve hous- Reassemble with new seals, O-rings and backup
ing for nicks or burrs that could cause leakage. rings.
3. Examine small cross holes of cartridge (2) for
signs of contamination within the spool area
(refer to Figure 8). Contamination in this area
Cross Drilled
Holes
Figure 8 – Retarder Cartridge Assembly
1. O-Ring
2. Ring
3. O-Ring
4. Ring
5. O-Ring
W6-4-7
ASSEMBLY 6. Apply a small spot of clean bearing or lithium

grease to the inside faces of the mounting (3)
where the pin (16) will pass. Use the grease to
proper valve operation. hold the plastic washers (17) in place and
aligned to the holes in the mounting plate (3)
face.
clean surface.
NOTE: Use lint-free cloths and filtered cleaning mounting plate (3), and using care to keep the
fluids when handling and cleaning plastic washers (17) in line, install pin (16)
components. through the mounting holes, pedal holes, and
washer holes until it is approximately centered.
Retarder Cartridge Assembly
Numbers in parentheses refer to Figure 8. 8. Install the second E-ring retainer (18) on pin (16).
9. Install the eye screw (13) and nuts (14) on
1. Clean all components with filtered cleaning solu- mounting plate (3).
tion prior to assembly.
: 3/8 in
2. Install O-ring (1), backup ring (2), O-ring (3),
backup ring (4), and O-ring (5) on the retarder 10. Install one end of spring (15) through eye screw
cartridge. (13).
3. If pedal and mounting assembly was not disas- 11. Install one E-ring (20) on pin (19) and feed
sembled, skip to assembly step 16. through the one hole on pedal (4), through spring
(15), and through the opposing hole on pedal (4).
Retarder Valve and Pedal Assembly 12. Install the remaining E-ring retainer (20).
13. Install a new O-ring (25.1) on plug (25) and
1. Assemble bracket (8) on to mounting plate (3) thread into manifold (1).
using screws (9). : 11/16 in
: 7/16 in : 8.5 N·m (75 Ibf·in)
: 10 N·m (86 Ibf·in)
14. Install a new O-ring (28) on plug (27) and thread
2. Install set screw (11) and nuts (12) on bracket (8). into manifold (1).
Final adjustment will be done in step 19. Do not : 3/16 in
torque nuts until final adjustment is made. : 4.5 N·m (40 Ibf·in)
: 9/16 in
: 3/16 in 15. Install a new O-ring (6) on fitting (10).
3. Install pedal cover (5) on pedal (4). 16. Place ball (7) into manifold (1) port, and thread
fitting (10) into manifold (1).
4. Thread set screw (23) into pedal (4) (with flat : 7/8 in
screwdriver) until it is visually level with the pedal : 17 N·m (150 Ibf·in)
button (4.3). Lock in place with nut (24).
: 9/16 in 17. Lubricate the seals on the cartridge (2) with clean
: 26 N·m (19 Ibf·ft) hydraulic fluid, and slide into manifold (1).
5. Install one E-ring retainer (18) on pin (16). 18. Assemble mounting plate assembly (3) to mani-
fold (1) using screws (21) and (22). Tighten
screws slowly in a cross pattern to compress the
cartridge (2) into the manifold (1) port.
: 9/16 in
: 37 N·m (27 Ibf·ft)
W6-4-8
19. Adjust set screw (11) such that 0.25 – 0.76 mm ADJUSTMENTS
(0.01 – 0.03 in) in travel exists between the face
of set screw (23) and the cartridge (2) plunger NOTE: Adjustments should only be performed
face. Torque nut (12). using tools and equipment that are
: 3/8 in known to be in proper functional condi-
: 9/16 in tion and properly calibrated.
: 26 N·m (19 Ibf·ft) Numbers in parentheses refer to Figure 6, unless
otherwise noted.
Numbers in parentheses refer to Figure 5. 1. Attach 0–34500 kPa (0–5000 psi) pressure
gauges from the pressure test kit (refer to Figure
20. Install new O-rings on fittings (2), (3), (4), (5) and 2) to the Retarder TP test port. Refer to Figure
(6). 4.
21. Install fittings (4) and (5). DO NOT TORQUE “T” 2. Loosen nut (24), adjust the set screw (23) out
FITTING (4) UNTIL VALVE IS ASSEMBLED ON and then apply the brake pedal fully so that the
UNIT AND TUBES HAVE BEEN INSTALLED. brake cartridge plunger achieves the maximum
(Fitting (5) should be torqued.) plunger travel. Check that cartridge pressure
: 15/16 in
: 42 N·m (31 Ibf·ft) 3. Adjust set screw (23) (with a flat screwdriver)
now so that the plunger has zero gap between
: 7/8 in the adjustment collar and face of cartridge when
: 32 N·m (24 Ibf·ft) pedal is fully depressed. Check that pressure is
to specification. Tighten nut (24).
22. Install fittings (3) and (6). DO NOT TORQUE FIT- : Pry Tool
TINGS UNTIL VALVE IS ASSEMBLED ON UNIT : 9/16 in
AND TUBES HAVE BEEN INSTALLED. : 26 N·m (19 Ibf·ft)
: ¾ in
: 24 N·m (18 Ibf·ft)
23. Install test fitting (2).

: 11/16 in
: 4.5 N·m (40 Ibf·in)
Zero gap when

pedal is depressed
EL 20754
Figure 18 – Retarder Brake Pedal Applied
4. Adjust pedal 'up stop' screw (11) so that the

(5), is 13 to 15 mm (0.5 to 0.6 in) before pres-
sure is observed at the brake valve test ports.
Tighten nuts (12) after final adjustment is made.
: 3/16 in
: 9/16 in
: 26 N·m (19 Ibf·ft)
5. Verify proper operation of the brake valve.
W6-4-9
Retarder 0 - 13.78 ± 0.173 MPa (0 - 2000 ± 25 psi)
NOTE: After an application of the brake or retarder

pedal, there should be no pressure re-
maining in the brake circuit. Any residual
pressure could indicate a problem with the
brakes.
W6-4-10
BRAKE SYSTEM / Retarder Valve (ATC)
Service Position
Park rigid dump truck on a level solid surface and CAUTION: Escaping fluid under pressure
place in “Service Position” Refer to Section W2-1. can penetrate the skin and eyes, causing
serious injury.
Isolate Stored Energy Hydraulic oil may be hot after operation.
The hydraulic accumulators automatically apply causing severe burns.
engine shutdown. Verify this stored energy is re- Assure that open end of test hose is se-
cured in a fluid holding container.
leased from the accumulators before service is per-
formed to the brake system. Eye Protection is required.
1. Be sure to apply wheel blocks to both sides of test kit E12979919, Figure 2), inside a fluid hold-
the tire to prevent vehicle movement. ing container. Use a tie wrap or wire to retain the
hose end inside container. Direct the fluid dis-
charge towards bottom of container.
zero pressure. Verify accumulator is bled down
by rotation of steering wheel left and right until
the brake valve by removing the test port caps
you cannot turn the steering wheel further.
and slowly threading the test hoses onto the test
fittings.
brake accumulator pressure. When the pressure
in both accumulators falls below 9650 kPa [1400
psi], the brake valve will shift the Low Pressure
Rear TP Sensor Valve (LPS) spool and remain in the ap-
Supply TP plied position until the pressure has dropped to
near zero. Pedal effort will be dramatically re-
duced when pressure falls below 1400 psi and
the LPS spool is shifted.
Front TP 6. Remove the test hoses and replace the caps on
the test port connectors, once the oil stops flow-
ing from both test hoses.
EL 20738
EL 20739
W6-5-1
REMOVAL
5. Remove tube (5).
CAUTION: Retarder Valve Assembly weight : 15/16 in
18 kg (40 lb).
6. Remove brake valve return tube (7).
1. With rigid dump truck off, in “Service Position”, : 11/8 in
and all accumulator pressures released to zero,
disconnect the solenoid electrical connections
(9). 7. Remove six mounting screws (8).
2. Remove the return tube (1). : 9/16 in
: 11/8 in
: 13/8 in
INSTALLATION
8 7
9 1. Attach valve assembly to cab using six mounting
screws (8).
: 9/16 in
: 36 N·m (26 Ibf·ft)
2. Attach return tube (1).
: 11/8 in
: 13/8 in
: 65 N·m (48 Ibf·ft)
: 92 N·m (68 Ibf·ft)
3. Attach Brake Valve Return Tube (7). Torque tube

and swivel nut connections.
1 : 11/8 in
6 3 5 4 2 : 65 N·m (48 Ibf·ft)
Figure 3 – Retarder Valve – ATC (Optional) 4. Attach tubes (2), (4), and (6). Torque tube and
swivel nut connections.
1. Return Tube
2. Left Rear Brake Tube : 11/8 in
3. Pressure Inlet Tube : 65 N·m (48 Ibf·ft)
4. Right Rear Brake Tube 5. Connect solenoid electrical connections (9).
5. Rear Brake Apply Tube (BR)
6. Attach tube (3).
6. Retarder Valve Pressure Inlet Tube (R)
7. Brake Valve Return Tube : 15/16 in
8. Mounting Screw : 11/8 in
9. Solenoid Electrical Connections : 45 N·m (33 Ibf·ft)
: 65 N·m (48 Ibf·ft)
7. Attach tube (5).
3. Remove tubes (2), (4) and (6).
: 11/8 in : 15/16 in
: 45 N·m (26 Ibf·ft)
4. Remove tube (3).
: 15/16 in
: 11/8 in
W6-5-2
NOTE: The further the test hose fitting is

Rear TP TPR threaded onto the test port, the more
flow will be expelled from the test hose.
Attach the test hose slowly.
Supply TP TPL 11. Allow fluid to flow into the container until there is
no evidence of air in the oil flow from the line.
12. Remove the hose and replace the test port cap.
TP (front) 13. Repeat steps 7 thru 10 for the Rear TP and TP

(front) ports on the brake valve with the brake
pedal lightly applied (refer to Figure 4).
14. Remove the caps from the retarder test ports
(TPR and TPL) and thread on one end of the
test hoses. Refer to Figure 4.
15. Slowly apply the retarder pedal until fluid starts
to flow into the container and hold until there is
no evidence of air in the lines.
16. Remove the hoses and replace the test port
Figure 4 – Brake and Retarder Valve Test Ports ATC caps.
(Option)
17. Bleed the front and rear brake circuits at each
CAUTION: Verify that all personnel have individual brake head.
moved away from the unit before proceed-
ing.
8. Assure that area around unit is clear, and start
the engine.
CAUTION: TEST PORTS HOLD HIGH PRES-

SURE HYDRAULIC FLUID
Escaping fluid under pressure can pene-
trate the skin and eyes, causing serious
injury.
causing severe burns.
Assure that open end of test hose is se-
cured in holding container.
9. With the engine running, secure one end of a

test hose, (from pressure test kit E12979919,
Figure 2) into a fluid holding container.
10. Remove the cap from the Supply TP Test Port of
the brake valve and slowly thread the free end of
the test hose onto the test port, (refer to Figure
4).
W6-5-3
DISASSEMBLY


clean surface.
fluids when handling and cleaning
components.

2. Remove test fittings (2).
: 11/16 in
3. Remove Fittings (3) and (5).
2
: 15/16 in
4. Remove fittings (4).
: 7/8 in
EL 20758
Figure 5 – Retarder Valve ATC (Option) & Fittings
1 Valve, Retarder (ATC)

2 Test Fitting
3 Tee Fitting
3.1 Elbow
3.2 Elbow
4 Plug
4.1 O-Ring
4.2 O-Ring
5 Tee Fitting
5.1 O-Ring
5.2 O-Ring
W6-5-4
EL 20759
Figure 6 – Retarder Valve ATC (Option)
1 Manifold 10 Nut 22 Spring, Extension

2 Valve 11 Screw 23 Pin
3 Manifold, ATC 12 Screw 24 Washer
4 Ball 13 O-Ring 25 Retainer, E-Ring
5 Mounting Plate 14 Plug 26 Plug
6 Pedal Assembly 15 Bracket 26.1 O-Ring
6.1 Pedal 16 Screw 27 Pin
6.2 Bushing 17 Backup Ring 28 Retainer
6.3 Button 18 Set Screw 29 Set Screw
7 Cover, Pedal 19 Nut 30 Kit-Seal, ATC
8 Screw 20 Eye Screw
9 O-Ring 21 Nut
W6-5-5
Numbers in parentheses refer to Figure 6. Spool Area

Carefully place pry
NOTE: If the pedal and mounting components tool tip here to
are not in need of service, skip to step 8. remove cartridge
5. Loosen nut (10) from set screw (29) and remove (2) from manifold
the setscrew. (1).
: 9/16 in
Plunger Face
6. Remove one E-ring (28) from pin (27). Push out
the pin (27) and let spring (22) drop free. EL 20747
7. Remove E-ring (25) from pin (23). Push out the Figure 7 – Cartridge Removal
pin (23) and nylon washers (24) to remove pedal
assembly (6). 15. Discard O-rings (13) and backup rings (17).
8. Remove nuts (21) and eye screw (20).
16. Remove plugs (26).
: 3/8 in
: 1¼ in
9. Remove nut (19) from set screw (18) and remove
from bracket (15).
NOTE: Plugs (14) and balls (4) cannot be
: 9/16 in
removed from the manifold (1). These
10. Remove screws (16) from bracket (15). three pieces must be replaced at the
same time.
: 7/16 in
12. Remove screws (11) and (12) securing mounting
plate (5) to manifold (1).
: 9/16 in
13. Remove screws (8) and ATC manifold (3). Dis-
card O-rings (9).
1. Manifold
14. Place a pry block (approximately 10mm [0.39 in] 2. Plug
thick) on the manifold (1) held against each car-
3. Plug
tridge (2) to protect the manifold (1) surface. In-
sert the pry tool tip under the cartridge (2) guide 4. O-Ring
lip (refer to Figure 7), use the block as a fulcrum, 5. O-Ring
and pry the cartridge (2) from the manifold (1).
Figure 8 - Manifold Assembly
W6-5-6

5
NOTE: Plugs (2, 3) are factory installed with 4
permanent thread sealer and their
removal will be difficult and is 1
discouraged. 3
17. If there are signs of seal leakage around plugs (3),

remove the plug (3) and discard the O-ring (5). 2
1
: /8 in
18. Remove plugs (2), and discard o-rings (4).

: 3/16 in
EL 20747
Figure 9 - Cartridge Assembly (2)

NOTE: Internal components of the Retarder
valve cartridges (2) are not serviceable. 1. O-Ring
The valve cartridge seals are available 2. Backup Ring
and should be replaced.
3. O-Ring
4. Backup Ring
Numbers in parentheses refer to Figure 9. 5. O-Ring
19. Remove O-Rings (1), (3), and (5).
20. Remove Backup rings (2) and (4).
W6-5-7
Coil
Retaining
Nut
Coil
EL 20761
Figure 10 - ATC Valve Assembly
1. Valve
2. Ball
3. Spring
4. Valve, Pressure Reducing
5. Plug
6. Plug
7. O-Ring
8. Kit, Seal
W6-5-8
21. Remove PWM (Pulse Width Modulating) valve

cartridges (1). The coils must first be removed
by removing the coil retaining nuts. Slide coil off
Adjusting
end of solenoid valve. Next remove body of car-
Screw
tridge (1) by unscrewing from manifold (3, Figure
6). Use care to catch balls (2) and springs (3)
when the cartridges (1) are removed. Lock Nut
: 7/8 in
22. Remove reducing cartridge (4).
: 7/8 in
23. Remove plugs (5) and (6).
: 3/16 in
: 1/8 in
EL 20763
Figure 12 - Reducing Valve Cartridge
1 O-Ring
2 O-Ring
3 O-Ring
4 O-Ring
5 Backup Ring
25. Remove O-ring (3), backup ring (5), O-ring (4),

EL 20762 and O-ring (2).
Figure 11 – PWM Valve Cartridge
26. Mark the adjusting screw location on the top of
the cartridge. Mark adjusting screw to lock nut
1 O-Ring reference mark also.
2 O-Ring 27. Remove the adjustment locking nut and o-ring

(1). Use care not to move the adjusting screw
3 O-Ring as the pressure setting will change and the
4 Coil valve may not function correctly.
: 9/16 in
: 5/32 in
24. Remove and discard O-rings (1), (2), and (3).
W6-5-9
INSPECTION ASSEMBLY
Numbers in parentheses refer to Figure 6.. CAUTION: Contamination can cause im-
1. Inspect retarder valve cartridges (2) for signs of
obvious damage. Look for signs of leakage
from the cartridge plunger face (refer to Figure NOTE: Service valve in a clean work area on a
7). clean surface.
2. Examine small cross holes of the valve car- NOTE: Use lint-free cloths and filtered cleaning
tridges (2) for signs of contamination within the fluids when handling and cleaning
spool area, (refer to Figure 7). Contamination in
components.
this area may result in sticking of the valve
spool and will require replacement of the car- NOTE: Clean all components with filtered
tridge (2). cleaning solution prior to assembly.
3. Inspect manifold (1) bores for deep scratches, NOTE: Lubricate cartridge seals with filtered
gouges or excessive wear, particularly in the hydraulic oil prior to installation.
areas were cartridge o-rings seal. View top face
NOTE: The use of grease to hold seals in place is
of manifold (1), (where the ATC manifold (3)
mounts), for scratches or damage. If any of NOT RECOMMENDED for brake and
these conditions exist replace the manifold (1). retarder valve assemblies and other
brake components.
4. Inspect seals for signs of swelling or degrada-
tion that may be a result of incompatible fluids.
ATC / EDSC Valve Assembly
5. Inspect pedal cover (7) for excess wear.
6. Inspect manifold (3) bores for deep scratches, Numbers in parentheses refer to Figure 12.
gouges or excessive wear, particularly in the 1. Install new O-ring (3), backup ring (5), O-ring (4),
areas where cartridge O-rings seal. Search and O-ring (2).
manifold base (3) for damage where face seal
O-rings seal. 2. Install the adjustment locking nut and O-ring (1).
Use care not to move the adjusting screw as the
7. Thoroughly clean all parts prior to assembly. pressure setting will change and the reducing
8. Discard all used seals, O-rings and back-up valve (4, Figure 10) may not function correctly.
9
rings EXCEPT FOR COIL O-RINGS. During : /16 in
reassembly use new seals, O-rings and backup : 5/32 in
rings.
3. Install O-rings (1), (2), and (3).

4. Place springs (3) and balls (2) in manifold (3, Fig-
ure 6).
5. Install PWM valve cartridges (1). The coils must
then be installed and the coil retaining nuts tight-
ened hand tight only, (do not use a wrench on the
coil nuts).
: 7/8 in
: 20 N·m (15 Ibf·ft)
6. Install pressure reducing cartridge (4).
: 7/8 in
: 36 N·m (27 Ibf·ft)
W6-5-10
9. Install the eye screw (20) and nuts (21) on to

7. Install plugs (5) and (6) with a thread locking mounting plate (5).
compound. : 3/8 in
: 3/16 in
10. Install one end of spring (22) through eye screw
: 16 N·m (140 Ibf·in)
(20).
: 1/8 in 11. Install one E-ring (28) on to pin (27) and feed
: 4 N·m (35 Ibf·in) through the one hole in pedal (6), through spring
(22), and through the opposing hole in pedal (6).
Pedal Assembly 12. Install the remaining E-ring retainer (28) on to

pin (27).
1. Assemble bracket (15) on to mounting plate (5) Cartridge Assemblies
using screws (16).
: 7/16 in Numbers in parentheses refer to Figure 9.
: 10 N·m (86 Ibf·in) 1. Install new O-ring (1)
2. Install set screw (18) and nuts (19) on bracket 2. Install new backup ring (2) and O-ring (3).
(15), DO NOT TORQUE NUTS UNTIL VALVE
IS INSTALLED ON UNIT AND FINAL AD- 3. Install new backup ring (4) and O-ring (5).
JUSTMENT HAS BEEN MADE.
: 9/16 in Manifold Assembly
3. Install pedal cover (7) on to pedal (6).
4. Thread set screw (29) into pedal (6) until it is
visually level with the pedal button (6.3). Install 1. Install plugs (2) and new O-rings (4) in manifold
nut (10) to set screw (29). DO NOT TORQUE (1) using a thread locking compound.
UNTIL VALVE IS INSTALLED ON UNIT. : 3/16 in
: 9/16 in : 16 N·m (140 Ibf·in)
5. Install one E-ring retainer (25) on pin (23). 2. Install plugs (3) and O-rings (5) in manifold (1)
using a thread locking compound.
6. Apply a small spot of clean bearing or lithium
grease to the inside faces of the mounting plate : 1/8 in
(5) where the pin (23) will pass. Use the grease : 4 N·m (35 Ibf·in)
to hold the plastic washers (24) in place and
aligned to the holes in the mounting plate (5)
face.
mounting plate (5), and using care to keep the
plastic washers (24) in line, install pin (23)
through the mounting plate holes, pedal holes,
and washer holes until it is approximately cen-
tered.
8. Install the second E-ring retainer (25) on to pin
(23).
W6-5-11
Numbers in parentheses refer to Figure 6. Numbers in parentheses refer to Figure 5.

1. Coin the balls (4) into the plugs (14) and into NOTE: DO NOT TORQUE NUTS ON SWIVEL
each side of manifold (1) using a steel punch FITTINGS UNTIL VALVE IS
and a small hammer. Use a single strike of INSTALLED ON UNIT AND ALL TUBES
rated size hammer to coin ball seat. Once ARE POSITIONED IN PLACE.
complete, insert the balls (4) into the manifold
(1). 1. Install test fittings (2).
: 11/16 in
: ¼ Kg (8 ounce) : 4.5 N·m (40 Ibf·in)
: Steel Punch
2. Install Fitting (3). .
2. Install Plugs (14).
: 15/16 in
5
: /16 in : 42 N·m (31 Ibf·in)
: 36 N·m (27 Ibf·ft)
3. Install fitting (5).
3. Install Plugs (26) and O-rings (26.1).
: 15/16 in
: 1 ¼ in : 42 N·m (31 Ibf·in)
: 34 N·m (25 Ibf·ft)
4. Install Fittings (4).
4. Install new backup rings (17) followed by new : 7/8 in
O-rings (13) into manifold (1). : 32 N·m (24 Ibf·in)
5. Lubricate the O-rings on cartridges (2) with
clean hydraulic oil and install in manifold (1).
6. Install pedal assembly (5) (from previous ADJUSTMENTS
steps) onto manifold (1) using bolts (11) and Numbers in parentheses refer to Figure 6.
(12).
: 9/16 in 1. Attach 0 - 34500 KPa (0 - 5000 psi) pressure
: 37 N·m (27 Ibf·ft) gauges from the pressure test kit (E12979919,
Figure 2) to the TPL and TPR test ports.
NOTE: The use of grease to hold seals in place 2. Loosen nut (10), adjust the set screw (29) out
is NOT RECOMENDED for brake and and then apply the brake pedal fully so that one
retarder valve assemblies and any brake cartridge plunger achieves the maximum
brake components. If necessary, tip the plunger travel. Check that cartridge pressure
assembly on end or turn the valves achieved is to specification.
upside-down for step 24. 3. Adjust the set screw (29) in (with a flat screw-
. driver) and then apply the brake pedal fully so
7. Install ATC manifold (3) onto the manifold (1) that opposite plunger achieves the maximum
with new O-rings (9) using screws (8). Make plunger travel. Check that cartridge pressure
sure O-rings seat in ATC manifold (3) grooves achieved is to specification.
during installation. 4. Adjust set screw (29) (with a flat screwdriver)
: 5/16 in now so that both plungers have zero gap be-
: 32 N·m (24 Ibf⋅ft) tween the adjustment collar and face of car-
tridge when pedal is fully depressed. Check that
pressures are to specification. Tighten nut (10).
: Pry Tool
: 9/16 in
: 26 N·m (19 Ibf·ft)
W6-5-12
Zero gap when

pedal is depressed
EL 20754
Figure 13 – Retarder Pedal Applied
5. Adjust pedal 'up stop' screw (18) so that the

(7), is 13 to 15mm (0.5 to 0.6 in) before pres-
sure is observed at the brake valve test ports.
Tighten nuts (19) after final adjustment is
made.
: 3/16 in Figure 14 – ATC Speed Sensor Assembly
: 9/16 in
: 26 N·m (19 Ibf·ft)
1. Adaptor 4. Nut
6. Verify proper operation of the brake valve.
2. Sensor 5. O-Ring
3. Washer 6. O-Ring
Left ATC
Speed
Right ATC Sensor
Speed
Sensor
Differential
Figure 15 – Speed Sensor Location
W6-5-13
REMOVAL NEW SENSOR ADJUSTMENT AND

ATC Speed Sensor Assembly INSTALLATION
1. Disconnect electrical harness from ATC speed
sensor assembly. 1. A new ATC speed sensor assembly comes with
the retaining nut (4) being hand tight.
2. Remove two bolts.
: 7/16 in 2. Loosen nut (4) and unscrew sensor (2) from the
adaptor (1).
3. Carefully remove ATC speed sensor assembly
from rear axle housing. 3. Install the adaptor (1) into the rear axle housing.
INSTALLATION 4. Install and torque the two ATC speed sensor

mounting bolts.
1. Carefully install ATC speed sensor assembly : 7/16 in

into the rear axle housing. : 14 N·m (122 Ibf·in)
2. Install and torque the two ATC speed sensor 5. Apply thread sealant to the threaded portion of
mounting bolts (not illustrated). the sensor (2) and screw it into adaptor (1) until
it touches the axle shaft.
: 7/16 in
: 14 N·m (122 Ibf·in) 6. Back the sensor (2) out 13/4 threads (approx. 2.5
mm [0.10 in]) and tighten nut (4).
3. Reconnect electrical harness to the ATC speed
sensor assembly. : 15/16 in
: 40 N·m (30 Ibf·ft)
7. Connect electrical harness.
Retarder 0 - 13.78 ± 0.173 MPa (0 - 2000 ± 25 psi)
NOTE: After an application of the brake or re-

tarder pedal, there should be no pressure
remaining in the brake circuit. Any re-
sidual pressure could indicate a problem
with the brakes.
W6-5-14
BRAKE SYSTEM / Brake Accumulator
SERVICE POSITION Isolate Stored Energy

Park rigid dump truck on a level solid surface and The hydraulic accumulators automatically apply stored
place in “Service Position” Refer to Section W2-1. energy to the brake circuit during normal engine
shutdown. Verify this stored energy is released before
service is performed to the brake system. Refer to
Section W6-3 Isolate Stored Energy.
1 7
10 9
3 8 4 2 6 5
4
Figure 1 – Brake Accumulator System
1. TP (Front) Test Port 5. Rear Brake Apply Tube 9. Rear TP Test Port
2. Accumulator - Rear 6. Brake Valve Return Tube 10. Pressure Test Port
3. Accumulator - Front 7. Retarder Test Port
4. Inlet Pressure Tube 8. Retarder Inlet Pressure Tube
W6-6-1
REMOVAL
Numbers in parentheses refer to Figure 2 and Figure 3,
1. The Brake Accumulators are located on the right-

hand side of the cabs’ deck, one for the front brake
circuit and one for the rear. The accumulators (1)
are mounted on bracket assembly (4). The air
cleaners (3) and the windshield washer reservoir (5)
are also mounted to the bracket assembly (4). The
steer accumulator (2) is located on the right-hand
side of the cab’s deck, next to the air cleaner (3).
Figure 3
Figure 2 – Brake Accumulator Location
1. Brake Accumulators
2. Steer Accumulator
3. Air Cleaner
4. Bracket Assembly
5. Windshield Washer Reservoir
2. Remove the two bolts (20) and U-strap (19) that

protects the charging valve on top of each
accumulator. Reference Figure 3.
: ½ in
3. Remove the valve stem cap (16) and turn the upper
nut (15) of the charge valve (21) counter-clockwise
until it’s loose. Continue to turn the upper nut (15)
until it’s hand tight, then using a wrench, turn it
counter-clockwise 1 complete turn to open the
charge valve (21) and release the dry nitrogen gas
pre-charge. Figure 4
: ¾ in
3
: /8 in
W6-6-2
16
15
14
EL 20765
Figure 5 - Charge Valve (21)

Figure 7 - Accumulator Connector
14. Lower Nut 16. Cap
15. Upper Nut 5. Disconnect the brake lines from the adaptors on
both accumulators (1). The adaptors are located at
Port “A”, on the base of each brake accumulator
(1). Remove and discard the O-rings from the
adaptors. Plug hose assemblies to prevent dirt
and contamination from entering.
15
: /16 in
Figure 6 – Windshield Washer Reservoir (5)
4. Remove the four screws from the tabs on the

windshield washer reservoir (5) and lift the
reservoir (5) out of the bracket. Do not disconnect Figure 8 - U-Bolt Nuts
the windshield washer reservoir pump, if possible.
6. Loosen the nuts on the four U-bolts.
9
: /16 in
W6-6-3
INSTALLATION
1. Mount rear brake accumulator in position using U-

bolts. Tighten locknuts to secure the brake
accumulator.
9
: /16 in
: 36 N٠m (26 Ibf٠ft)
2. Place new O-rings on adaptor and install into rear

accumulator.
15
: /16 in
: 58 N٠m (43 Ibf٠ft)
3. Connect hose assembly to adaptor on rear

accumulator.
15
: /16 in
: 45 N٠m (33 Ibf٠ft)
Figure 9 – Accumulator Removal
4. Mount front brake accumulator in position using U-
7. Remove the accumulators (1) from the bracket bolts. Tighten locknuts to secure the brake
assembly (4) and move it to a clean area for accumulator.
disassembly.
9
: /16 in
5. Place new O-rings on adaptors and install into front

CAUTION: accumulator.
Front Accumulator Weight – 20 kg (45 lb).
15
Rear Accumulator Weight – 26 kg (57 lb). : /16 in
: 58 N٠m (43 Ibf٠ft)
6. Connect hose assembly to adaptor on front

accumulator.
15
: /16 in
: 45 N٠m (33 Ibf٠ft)
7. Pre-charge the accumulators (1) using service tool

and nitrogen gas. Refer to Section W2-4 SPECIAL
TOOLS. Refer to Section W7-6 INSTALLATION for
information about charging nitrogen accumulators.
W6-6-4
16 27 25
23
19 26
18
28
17 24
22
13
15
14
20 21
Figure 10 - Section View of Brake Accumulator

T8DX-05-27-002
13. Housing 18. *AQ Seal 23. End Cap 28. Valve Cap
14. Wear Ring 19. *Quad Ring 24. O-Ring
15. Piston 20. O-Ring 25. Charge Valve A. Oil Inlet Port
16. Seal Assembly 21. Back-Up Ring 26. Plate B. Hydraulic Oil
17. *Square Ring 22. Friction Plug 27. Bolt C. Nitrogen Gas
W6-6-5
DISASSEMBLY INSPECTION
1. Inspect all threaded areas of housing (13) and

CAUTION:
end cap (23) for damage, replace if necessary.
Front Accumulator Weight – 20 kg (45 lb).
Rear Accumulator Weight – 26 kg (57 lb). 2. Inspect housing (13) inside diameter near end
cap O-ring (20) interface for damage. Polish
1. Remove the valve stem cap (28) and turn the with crocus cloth if required. Seal surface must
upper nut (15, Figure 5) of the charge valve (25) be smooth and polished.
counter-clockwise until it’s loose. Continue to
turn the upper nut (15, Figure 5) counter- 3. Inspect inside bore diameter of housing (13) and
clockwise until it’s hand-tight, then using a outer surface of piston (15) for scuffing or
wrench, turn it counter clockwise 1 complete turn scratches. Remove any ridge, nick, or scratch
to open the charge valve (25) and release the with crocus cloth. Replace any component part
dry nitrogen gas pre-charge. Remove charge when sealing surface is damaged, rough or
valve (25) and O-ring (24). Discard O-ring (24). corroded.
: ¾ in
3 4. Check housing (13) inside diameter, tube should
: /8 in be round without taper from top to bottom of
bore.
2. Remove end cap (23) using a spanner wrench.
If a spanner wrench (3.0 in) is unavailable, insert
5. Outside diameter of housing (13) should be free
bolts in the tapped holes in end cap (23) and use
of dents, deep scratches or gouges. Replace
a pry bar as lever. Turn counter-clockwise to
housing (13) if defect is found in outside surface.
remove.
3. Remove and discard friction plug (22), O-ring

(20) and back-up ring (21).
4. Insert a small rod through Oil Port (A) and press

piston (15) out by lightly tapping the end of the
rod with a hammer.
5. Remove and discard wear ring (14) and seal

assembly (16) from piston (15).
W6-6-6
ASSEMBLY
CAUTION: Exercise care when installing
piston (15) into housing (13) so not to
CAUTION: damage piston seal (16) on housing (13)
Front Accumulator Weight – 20 kg (45 lb). internal threads.
Rear Accumulator Weight – 26 kg (57 lb).
7. Push piston (15) into housing (13) with piston
NOTE: Tube inside diameter should be cleaned wear ring (14) going in first. Push piston (15)
with filtered clean solvent prior to into middle position inside housing (13).
following steps.
8. Install back-up ring (21) and O-ring (20) over
1. Install split Wear Ring (14) into larger groove on unthreaded end of end cap (23). Note that the
Piston (15). concave side of back-up ring (21) faces O-ring
(20).
2. Install square ring (17) rubber piston seal
energizer into piston seal groove. 9. Insert new friction plug (22) into side of end cap
(23).
3. To make piston seal (18, 19) more pliable, place
seal in heated oil bath of 82 °C (180 °F) for 10 10. Apply a light coat of clean hydraulic oil on both
minutes. O-ring (20) and back-up ring (21) only.
4. Remove seal (18, 19) from heated oil and 11. Install end cap (23) and carefully rotate
immediately press seal over lead-in taper on clockwise until threads bottom out. Do not
piston (15), and down into the seal groove where tighten.
the square ring (17) rubber energizer ring has
been previously installed. Screw drivers or blunt 12. Install a new O-ring (24) on face of charge valve
tools are not recommended to install seal (16), (25) and thread into end cap (23), torque lower
as they may damage sealing surfaces. nut and upper nut (14, 15, Figure 5) only.
: ¾ in
5. While seal (16) is still warm, slide piston (15) into
: 11 - 12 N٠m (100-110 lbf٠in) (lower nut)
sizing ring or ring compressor compressing seal
: 6 - 8 N٠m (50 - 70 lbf٠in) (upper nut)
(16), until piston (15) has cooled.
13. Close port A to prevent against
6. Apply a light coating of clean hydraulic oil to the contamination entering the accumulator.
inside walls of housing (13) and onto the lead-in
at threads to bore diameter. : 3 in spanner
W6-6-7
Part Description Service Limit Metric Service Limit Imperial

Housing (13) inside diameter 102.24-102.36 mm 4.025-4.029 in
Housing (13) inside surface finish 0.25-0.40 μ m 10-16 μ in
Precharge Specifications 8275 kPa 1200 psi
Dry filtered Nitrogen gas only
Extended Storage of Accumulator Drain all residual fluid from accumulator. Cap plug ports air tight.
Store inside on rack in vertical position, as mounted on hauler.
DO NOT STORE ACCUMULATOR WITH NITROGEN GAS
CHARGE INSTALLED
W6-6-8
BRAKE SYSTEM / Brake Cooling Lines
FRONT OF
UNIT
6
10
3
6
8
8 3
2
9
7
5
11
1
4
8
8
Figure 1 – Brake Cooling System
1. Supply to Cooler 5. Heat Exchanger (Cooler) 9. Supply from Cooler

2. Return Hose from Brakes 6. Hydraulic Tank Assembly 10. Check Valve
3. Return Diffuser Port 7. Return Tube at Wheel Brakes 11. Cooler Bypass Hose
4. Supply Brake Cooling Pump 8. Supply Tube at Wheel Brakes
W6-7-1
5 Tube Movement
2 7 3
4 2
6
6
Figure 2 – Rear Axle Brake Cooling Lines
1. Split Flange 5. Manifold/Tube Holding Bolts

2. Return Tube 6. Supply Tube Manifold
3. Return Tube Manifold 7. Manifold Mounting Hardware
4. Supply Tubes 8. Manifold O-Ring Seals
W6-7-2
7 5
11
10
9
3
4
1
Figure 3 – Hydraulic Tank Brake Cooling Connections
1. Supply to Cooler, Hose 7. Relief Check Valve

3. Cooling Pump Supply 8. Hoist Return Filter Assembly
4. Return from Brakes, Hose 9. Cooler By Pass Hose
5. Return Diffuser Manifold 10. Bypass Manifold
6. Hoist Filter Outlet Tube 11. Cooling Return Manifold
W6-7-3
SERVICE POSITION Supply Piping Removal
1. Before checking and/or servicing the rigid dump Number in parentheses refers to Figure 2.
truck, park it on a level solid surface and put it in
the “Service Position”. Refer to Section W2-1. 1. Remove supply hoses (9, Figure 1) from tube
manifolds (6) as indicated and cap hose ends (9)
2. For access, raise body to maximum position and to prevent contamination.
secure body to frame with body prop cable : ¾ in
provided. Refer to Figure 4.
2. Remove Nuts (5) and slide bolts (4 places) out of
manifold (6), which secure tubes (4) inside
manifold (6).
7
: /16 in
3. Remove split flanges (1) from supply tubes (4).

3
: /4 in
4. Gently slide opposite end of tube (4) out of its

seat in manifold (6).
5. Loosen and remove manifold mounting nuts and

washers (7) from axle assembly. Remove
manifold (6).
9
: /16 In
Figure 4- Attach Body Prop Cable
3. Stop engine, move control lever several times to Return Piping Removal
release pressure.
REMOVAL CAUTION: Wet Disc Brake cooling

chambers and tubes will be filled with oil.
1. Power wash clean backside of hydraulic tank and
cooling tube on top of axle and their line Number in parentheses refers to Figure 2.
connection points.
1. Place a suitable large container under connector
2. Place an oil drain pan under the hydraulic tank fittings of brake to Tube (2) to collect trapped fluid
with a minimum capacity of 380 liters (100 when tube is removed.
gallons).
2. Remove nuts (5) and slide bolts (2 places) out of
3. Remove hex plug under hoist/brake cooling manifold (3) which secures tubes (2) inside
chamber on hydraulic tank to drain oil (rear manifold (3)
7
section). : /16 in
: 1 ¼ in
3. Remove split flanges from Return Tubes (2) at top
4. After oil is drained, reinstall drain plug. of each rear brake assembly housing.
3
: 1 ¼ in : /4 in
: 60 N٠m (44 lbf٠ft)
4. Gently slide Tubes (2) out from manifold (3).
5. Remove mounting washers and nuts (7) at

manifold (3) to axle mounting. Remove manifold
Reclaim or Dispose of Oil Properly (3) from rear axle.
9
: /16 in
W6-7-4
Relief Check Valve Removal Return Diffuser Cover Removal
Number in parentheses refers to Figure 3. Number in parentheses refers to Figure 3.
1. Place a suitable large container under connector 1. Remove Brake Cooling Hose (4) from Cover
fittings at back of hydraulic tank to collect trapped Plate (5) and cover open hose end.
fluid when connectors are removed. : ¾ in
2. Remove eight bolts, which hold cover plate (5) to

hydraulic tank.
Reclaim or Dispose of Oil Properly 9
: /16 in
3. Slide cover plate (5) from hydraulic tank and

2. Remove the cooler by-pass hose (9).
3 place on a clean dry work area.
: /4 in
4. Remove diffuser by turning diffuser counter-
3. Remove the filter outlet tube (6).
7 clockwise and unthreading from cover plate (5).
: 1 /8 in 7
3 : 2 /8 in
: /4 in
4. Remove eight bolts which hold manifold (10) to

the hydraulic tank.
9
: /16 in
5. Remove check valve (7).
W6-7-5
INSPECTION Diffuser Inspection
Number in parentheses refers to Figure 2, unless Number in parentheses refers to Figure 3.

otherwise noted.
1. Inspect the weld of the perforated cover seam on
Supply and Return Piping Inspection the Diffuser. Any cracks must be repaired. Check
inside for large debris. Remove diffuser and
1. Inspect end fittings of all tubes at connection of clean.
tube to brake housing connector for cracking in
the silver brazed zone. Replace tube if cracks 2. Inspect end cap seam weld to perforated cover
are found. Refer to Figure 5. for cracks or possible separation. Repair a
cracked weld with similar size and length weld
2. Inspect tubes (2, 4) for damage, dents or before re-using. If diffuser has separated or come
deformed bends and replace damaged parts if apart, replace diffuser.
found.
3. Replace all O-rings used at mounting flanges.
3. Inspect all O-rings removed for abnormal
condition. Look for seal swelling, misalignment
wear pattern or extrusion cuts and tears. Discard Relief Check Valve Inspection
the o rings and replace with new seals. Correct
any deficiency found during assembly of 1. Inspect relief check valve for integrity and that
replacement parts. poppet is in place. Replace O-rings.
1 2
SILVER BRAZE
Figure 5- Hydraulic Tube Assembly Typical
1. Tube 2. Flange O-ring
W6-7-6
INSTALLATION Return Diffuser Cover Installation
Supply and Return Piping Installation Number in parentheses refers to Figure 3.
Numbers in parentheses refer to Figure 2. 1. Install new O-ring in groove at the port opening
ring on back of hydraulic tank. Slide diffuser with
1. Clean all tubes with clean/new solvent and dry mounting plate (5) into tank, as shown, and install
with compressed air. the eight cover bolts.
9
: /16 in
2. Install manifolds (3, 6) on rear axle but do not : 50 N٠m (37 lbf٠ft)
tighten mounting bolts (7).
9
: /16 in 2. Install new O-ring in open end of hose (4) and
attach hose (4) to cooling return manifold (11)
3. Install new Viton O-rings (8) in their grooves on all with split flange clamps.
tube ends, as shown. : ¾ in
: 106 N٠m (78 lbf٠ft)
4. Lube O-ring surface with light grease and insert
tubes (2) (right-hand and left-hand) into return
tube (3) manifold. Check Valve Installation
5. Insert bolts (5), as shown, into manifold (3). 1. Install new O-ring in groove at the port opening
ring on back of the hydraulic tank (6, Figure 1).
6. Install locknuts to bolts (5) as shown and torque.
7
: /16 in 2. Install new O-ring in groove on the check valve
: 14 N٠m (122 lbf٠in) (7) and loosely assemble with manifold (10) and
cover bolts.
7. Align opposite end of tube (2) with proper location
on rear brake housing and install split flanges 3. Slide check valve (7) and manifold (10) into
carefully. reservoir as shown and install eight cover bolts.
9
: ¾ in : /16 in
: 106 N٠m (78 lbf٠ft) : 50 N٠m (37 lbf٠ft)
8. Lube O-ring surface with light grease and Insert

Tubes (4) into Manifold (6).
9. Insert bolts (5), as shown, into manifold.
10. Install locknuts to bolts (5), as shown, and torque.

7
: /16 in
: 14 N٠m (122 lbf٠in)
11. Align opposite end of tube (4) with proper location

on rear brake housing and install split flanges (1)
carefully until seated together.
: ¾ in
: 106 N٠m (78 lbf٠ft)
12. Torque mounting bolts (7) on manifolds (3, 6).

9
: /16 in
: 36 N٠m (26 lbf٠ft)
W6-7-7
Hydraulic Tank Connections Installation
Number in parentheses refers to Figure 3.
1. Install new O-ring on end of cooler bypass hose

(9) and attach it to manifold (10) with split flange
clamps.
3
: /4 in
: 106 N٠m (78 lbf٠ft)
2. Install new O-ring on end of return from brakes

hose (4) and attach it to manifold (5) with split
flange clamps.
3
: /4 in
: 106 N٠m (78 lbf٠ft)
3. Install new O-ring on end of filter output tube (6)

and attach it to manifold (10) with split flange
clamps.
3
: /4 in
: 106 N٠m (78 lbf٠ft)
FINAL ASSEMBLY INSTALLATION
1. Inspect or replace hoist system hydraulic filter

element as indicated by the Filter Indicator Light
on the dash of the cab.
2. Fill hydraulic tank to the high level with approved

hydraulic fluid.
3. Start engine and recheck oil level after short idle

time.
4. Cycle hoist system by raising body several times.

Shut engine off with body resting on frame and
again check hoist system tank oil level. Adjust
level as required.
W6-7-8
BRAKE SYSTEM / Park Brake
27 12
8 7
23
26
25 24
6
15
20
14 11
13
10 16
21
4
30 3
17
1
18
32
22
31
19
29
9
2 28
EL118967
Figure 1 - Exploded View of Parking Brake and Mounting
1. Disc 9. Screw (4x) 17. Washer (2x) 25. Bracket

2. Screw (16x) 10. Washer (4x) 18. Nut (2x) 26. Screw
3. Brake Support Plate (2x) 11. Nut (2x) 19. Block (2x) 27. Nut
4. Plate 12. Washer (2x) 20. Washer (2x) 28. Brake Mounting Plate
5. Plate 13. Spring (2x) 21. Screw (2x) 29. Screw (4x)
6. Brake Caliper Assembly 14. Spring (4x) 22. Nut (2x) 30. Spacer (4x)
7. Brake Chamber 15. Shoulder Screw (2x) 23. Screw (2x) 31. Cable Tie (2x)
8. Yoke Assembly 16. Dowel Pin (2x) 24. Washer (2x) 32. Spring
W6-8-1
SERVICE POSITION The yoke (8, Figure 1) attaches the slack adjuster
Before checking and/or servicing the rigid dump (15) to the actuator (7, Figure 1) with a yoke pin
truck, park it on a level solid surface and put it in the which is secured by a cotter pin.
“Service Position”. Refer to Section W2-1.
NOTE: The parking brake is for static holding
DESCRIPTION only. It is not designed for dynamic
Numbers in parentheses refer to Figure 1 unless braking. The park brake apply logic
otherwise noted. contains safety interlocks to prevent
application while the rigid dump truck
The rigid dump truck parking brake is located at the is in motion and to lock the transmis-
input shaft of the rear axle differential. The brake is sion in Neutral if the park brake is ap-
operated by an actuator (7) that uses the “spring
plied.
applied and hydraulic released” principle explained
in the next paragraph. The hydraulic fluid to the
brake actuator (7) is controlled by the park brake NOTE: To release the park brake on a rigid
switch on the right hand side of the instrument panel dump truck that cannot be started, in-
in the cab. The brake disc (1) is secured to the input stall wheel chocks and use a remote
flange of the rear axle differential. The caliper and pump or Porta-Power in the actuator
the linings produce the braking force. The parking supply line to release the brake
brake can be manually adjusted to compensate for heads.
wear on the brake linings (4, Figure 2). Return
springs (13,14,32) provide additional lining (4, Fig- OPERATION
ure 2) wear protection. Numbers in parentheses refer to Figure 2 unless
otherwise noted.
The parking brake head assembly consists of a cali- CAUTION: Do not attempt to remove
per (7), a manual slack adjuster (15), and a springs from actuator (13, Figure 1), they
spring/oil actuator (13, Figure 1). The caliper (7) are not serviceable. Do not cut, saw,
houses two lining and carrier assemblies (4), a pis- torch or modify the spring chamber of
ton assembly (6) threaded to a power screw shaft actuator (13, Figure 1). Serious injury
(19), and a piston seal (5) installed in an ID groove may result. This is not a serviceable item.
in the caliper (7). The seal (5) helps to align the pis-
ton assembly (6) in the caliper (7) and prevents 1. When the parking brake switch in the rigid
contamination of the piston bore area. The caliper dump truck cab is placed in the “ON”
(7) is mounted to brake mounting plate (28, Figure position, the park brake solenoid in the RCB
1), which is attached to the differential carrier hous- valve (Relief Check Bleed Valve) exhausts
ing. the hydraulic pressure in the parking brake
actuator (13, Figure 1).
The cap assembly (9) is fastened to the caliper (7)
with 4 bolts (2), and washers (3). It supports the 2. The park brake apply is initiated by dumping
power screw shaft (19) seated on a thrust bearing the hydraulic oil from the spring/oil actuator
(20) and a press fitted journal bearing (10). A (13, Figure 1) inlet port, releasing the
welded bracket (21) on the cap assembly supports compressed spring in the actuator (13,
the actuator (7, Figure 1) secured with 2 nuts (11, Figure 1).
Figure 1) and flat washers (12, Figure 1).
3. The spring pulls the yoke (8, Figure 1) and
The slack adjuster (15) is attached to the splined the slack adjuster (15) arm down, turning
end of the power screw shaft (19) which protrudes the attached power screw shaft (19) that is
from the cap assembly (9). A packing (18) is seated threaded into the piston assembly (6)
against the journal bearing (10) in the cap assembly housed in the caliper (7). This transmitted
(9). A flat washer (16) and a wave spring washer force moves the piston assembly (6) forward
(17) are installed on the power screw shaft (19) be- against the lining and carrier assembly (4)
tween the cap assembly (9) and the slack adjuster until it presses against the disc (1, Figure 1).
(15). A retaining ring (14) secures the slack adjuster The park brake is now applied.
(15) on the splined end of the power screw shaft
(19).
W6-8-2
4. Placing the park brake switch to the “OFF”

position causes the park brake solenoid to
pressurize the actuator with hydraulic oil
which compresses the spring inside the
actuator chamber, causing the actuator rod
and yoke (8, Figure 1) to extend.
5. The actuator rod extends to retract the piston

assembly (6), releasing the park brake.
6. Additionally, external return springs (13,14,32,

Figure 1) prevent the free floating linings (4)
from contacting the brake disc (1, Figure 1)
when the park brake is released.
EL118968
Figure 2 - Exploded View of Parking Brake Head Assembly
1. Brake Head Assembly 8. Gasket 15. Slack Adjuster

2. Screw 9. Cap 16. Washer
3. Washer 10. Bearing 17. Washer
4. Lining 11. Fitting 18. Packing
5. Seal 12. Fitting 19. Power Screw Shaft
6. Piston 13. Spacer 20. Bearing
7. Caliper 14. Ring 22. Repair Kit
W6-8-3
REMOVAL OF THE LINING AND

Release
CARRIER
1. Put the rigid dump truck in the Service Position

and include blocking the wheels and securing
the body in the raised position. Refer to “Ser-
vice Position” in Section W2-1. Apply
2. Disconnect the hose at the park brake actuator 5

3
(7). Connect a hydraulic pump to the actuator
(7) and apply pressure until the actuator rod is 1
fully extended. 4
3. Remove the cotter pin and pin from the yoke (8).
4. Release the pressure from the actuator (7) to

allow the actuator rod to fully retract.
5. Remove the shoulder screw (15), washers

(17,20), nut (18), spacers (30) and springs from
the left side support plate (4) to remove spring
tension from the linings (4, Figure 2).
2
6. Remove the spring (32) from the cable ties (31).
EL118969
7. Swing bracket (25) out of the way by removing

screw (23) and washer (24) from the left side
support plate (4) and loosen the screw (23) on Figure 3 - Park Brake Head View
the right side support plate (5).
1. Brake Head Assembly 4. Spacer
8. Remove the screws (9) and washers (10) that 2. Carrier and Lining 5. Adjustment Nut
mount the block (19) on the left side support 3. Slack Adjuster
plate (4). Remove the screw (9) closest the
spring (13), then loosen and remove the other.
11. Loosen shoulder screws (16, Figure 1) to permit
9. While supporting the park brake head assembly return springs (14, Figure 1) to be rotated free of
(1, Figure 2), loosen and remove the screws the lining.
(29) and washers (10) from the left side support
plate (4). Carefully remove the left side support 12. Remove the caliper (7, Figure 2) from the dif-
plate (4) while supporting the park brake head ferential input flange.
assembly (1, Figure 2), the linings (4, Figure 2)
and spacer (13, Figure 2). 13. Remove worn lining and carrier assemblies (4)
and replace.
CAUTION: Park brake head assembly weight
is 34 kg (75 lb).
10. Remove the worn linings (4, Figure 2) and

spacer (13, Figure 2).
W6-8-4
INSPECTION NOTE: There should not be any paint, grease, dirt,

Numbers in parentheses refer to Figure 2. etc. on the mating surfaces of the differen-
tial input flange, park brake disc (1, Figure
1) and driveline flange. Thoroughly clean
1. Inspect the brakes for loose or missing attach-
these mating surfaces prior to installation.
ing hardware (bolts, nuts, retaining rings, etc.).
Tighten and replace when necessary.
9. Measure the differential pinion endplay. The
total pinion endplay must not exceed 0.127 mm
2. Clean the parts in a suitable solvent. Blow dirt
(0.005 in). If pinion endplay is out of specifica-
and cleaning fluid off parts with compressed air.
tion, re-shim the differential pinion to attain an
endplay of 0.025 – 0.127 mm (0.001 – 0.005 in).
3. Inspect the lining and carrier assemblies (4) for
worn lining material. Replace the lining if it has
worn to the point where the parking brake will NOTE: Replace with new parts where necessary.
not hold the rigid dump truck stationary on the
steepest hill it is required to traverse. Caliper Overhaul and Seal Replacement
CAUTION: The park brake requires manual
adjustment as the linings wear. Park the 1. Apply brake pressure to extend the actuator
machine fully loaded on the steepest ac- (7, Figure 1), and then remove the caliper
tive grade available at the start of each (7) from the rigid dump truck.
shift. If the park brake will not hold the
hauler, perform the Manual Slack Adjust- 2. Separate the yoke (8, Figure 1) from the
ment, found in this section. If the hauler slack adjuster (15) by removing the cotter
still does not hold under the above condi- pin and the yoke pin.
tions, replace the linings.
3. Dismount the actuator (7, Figure 1) from the
4. Check the studs on the actuator and the power cap assembly (9) bracket by removing the
screw shaft (19) for nicked or sheared threads. nuts (11, Figure 1) and washers (12, Figure
1) from the actuator (7, Figure 1) studs.
5. Inspect the mounting holes on the cap assembly
(9) and the input flange on the differential hous- 4. Remove the retainer ring (14) from the
ing. power screw shaft (19).
5. Slide the slack adjuster (15) from the power

6. Inspect the caliper (7) mounting grooves for
screw shaft (19).
wear.
6. Remove and discard the packing (18), flat
7. Measure total disc (1, Figure 1) runout by washer (16), and the wave spring washer
measuring it near the outer edge of the disc (1, (17) from the power screw shaft (19).
Figure 1). If total runout of the disc (1, Figure
1) is greater than 0.406 mm (0.016 in), replace 7. Remove the bolts (2) and washers (3) from
the park brake disc (1, Figure 1). the cap assembly (9).
8. If total disc (1, Figure 1) is out of specification, 8. Remove as a unit the power screw (19), the
remove the disc (1, Figure 1) and measure total piston assembly (6), and the cap assembly
flange runout near the outer edge of the disc (1, (9) (with the welded on bracket) from the
Figure 1) mounting surface. If total runout of caliper (7).
flange is greater than 0.127 mm (0.005 in), re-
place the flange. 9. Slide the power screw shaft (19) and the pis-
ton assembly (6) from the cap assembly (9).
10. Unscrew the piston assembly (6) from the

power screw shaft (19).
W6-8-5
11. Remove and discard the thrust bearing (20)

CAUTION: Do not push the piston seal (5) out
from the power screw shaft (19).
of the seal groove in the caliper (7) when
12. Remove and discard the piston seal (5) assembling the cap assembly (9) with the
from the caliper (7). piston assembly (6) and the power screw
shaft (19).
13. Thoroughly clean all the parts. Inspect the
journal bearing (10) in the cap assembly (9) 21. Install the new flat washer (16), the wave spring
for wear. washer (17), and a packing (18) over the power
screw shaft (19) with the packing (18) in front
14. Inspect all brake parts for damage, cracks, and the flat washer (16) in the middle.
excessive wear, or scoring. Replace all
parts as required. 22. Mount the brake actuator (7, Figure 1) on the
cap assembly (9) bracket with the nuts (11) and
15. Install a new piston seal (5) into the caliper the washers (12). Torque to the values listed in
(7). the Torque Value table below.
16. Apply grease (Lubriplate Aero or equivalent) NOTE: The torque value depends on the finish
to the flat face of the new thrust bearing on the studs of the actuator.
(20).
17. Install and seat all the new thrust bearing Torque Value
(20) over the splined end of the power
screw shaft (19) with the greased side of Wrench Size Phosphate/Oil Cad. Plate/Wax
the thrust bearing against the thrust collar of 107 N٠m 150 N٠m
the power screw shaft (19). 19 mm
(79 lbf٠ft) (111 lbf٠ft)
CAUTION: Ensure the correct installation of 23. Apply a coat of Lubriplate Aero or equivalent
the thrust bearing (20) by verifying that the grease to the mounting spline of the slack ad-
installation was made over the larger di- juster (15).
ameter end of the power screw shaft (19)
and the thrust bearing (20) inside diameter 24. Slide the slack adjuster (15) on the power
lip is toward the splined end of the power screw shaft (19), aligning the slack adjuster
screw shaft (19). arm with the yoke (8, Figure 1).
18. Screw the power screw shaft (19) into the 25. Install the retainer ring (14) on the power screw
piston assembly (6) after lubricating the shaft (19).
threads with an application of Lubriplate
Aero or equivalent grease. 26. Secure the yoke (8, Figure 1) to the slack ad-
juster (15) with the yoke pin and the cotter pin.
19. Coat the outside of the piston assembly (6)
27. Adjust and check the operation of the caliper.
with Lubriplate Aero or equivalent grease
then slide the assembled power screw shaft
(19) and the piston assembly (6) into the
cap assembly (9), shaft end first.
20. Bolt the cap assembly (9), with the assem-

bled power screw shaft (19) and piston as-
sembly (6), to the caliper (7) using bolt (2)
and washers (3). Torque the bolts.
: 183 N٠m (135 lbf٠ft)
W6-8-6
INSTALLATION OF THE LINING AND

CARRIER 8. Proceed to MANUAL SLACK ADJUSTMENT,
this section, to properly set up the park brake.
Numbers in parentheses refer to Figure 1, unless
otherwise noted.
MANUAL SLACK ADJUSTMENT
1. After following the REMOVAL OF THE LINING
AND CARRIER procedure, this section, ensure Numbers in parentheses refer to Figure 2, unless
the park brake head assembly (1, Figure 2) is otherwise noted.
fully supported and secure.
CAUTION: Park brake head assembly weight CAUTION: It is very important that the initial
is 34 kg (75 lb). adjustment procedures are properly fol-
lowed.
2. Install new linings (4, Figure 2) with the spacer
(13, Figure 2) positioned correctly and the re-
traction springs (14) properly positioned against CAUTION: The rod on the actuator (7, Fig-
the new lining (4, Figure 2). Refer to Figure 3 ure 1) is under spring tension. Keep clear
for proper component positioning. of the rod until it is fully retracted.
NOTE: To achieve the required space when in-

stalling the new linings (4, Figure 2), it
may be necessary to back off the slack
adjuster (15, Figure 2) by turning the
adjustment screw (5, Figure 3)
counter-clockwise until it stops turning.
3. Re-install the left side support plate (4) and the

screws (29) and washers (10). Align the sup-
port plate (4) square to the grooves in the park
brake caliper (7, Figure 2). Tighten and torque
the screws (29).
1
: 1 /8 in
: 307 N٠m (226 lbf·ft)
1
4. Install the spring (32) and cable ties (31) around
the front lining (4, Figure 2) Figure 4: Park Brake-Applied position
5. Properly position the springs (14) and install the 1. Put the rigid dump truck in the Service Position.
shoulder bolt (15), washers (17, 20), nut (18) Refer to Service Position in Section W2-1.
and spacers (30) on to the support plate (4).
7
: /16 in 2. In the applied position, Turn the yoke assembly
: 10 N٠m (7 lbf·ft) (8, Figure 1) so that the slack adjuster (15) is
positioned about 90º with respect to the actua-
6. Install and align the block (19) square to the tor and lock the yoke assembly (8, Figure 1)
support plate (4) using screws (9) and washers with the jam nut. Refer to Figure 4
(10).
1
: 1 /8 in 3. Start engine and apply the Load/Dump brake.
Release the parking brake.
: 309 N٠m (226 lbf·ft)
7. Install the bracket (25) to the support plate (4) 4. To set to fully released position, a hydraulic
using screw (23) and washer (24). pressure of 13790 – 20690 (2000-3000 psi)
3
: /4 in must be applied to the actuator (7, Figure 1).
: 87 N٠m (64 lbf·ft)
W6-8-7
5. The actuator (7, Figure 1) must be in the re-

CAUTION: This park brake assembly uses
leased position (extended). Refer to Figure 3.
a manual slack adjuster. It will need
adjustment as the linings (4) wear. Park
6. Turn stop screw (1, Figure 5) counter clock-
the machine fully loaded on the steepest
wise until it is not touching the caliper (7) cast-
available active grade at the start of
ing. The rear lining (4) must contact the disc
each shift. If the park brake does not
(1, Figure 1).
hold, perform the Manual Slack Adjust-
ment procedure. Replace the linings (4)
7. Turn the adjustment screw (1, Figure 4) on the
if the brake does not hold after adjust-
slack adjuster (15) to give 1.27 mm (0.050 in) ment.
clearance between the disc (1, Figure 1) and
the front lining (4), with the rear lining (4) in
contact with the disc (1, Figure 1).
NOTE: When the rigid dump truck is first started
8. Turn the stop screw (26, Figure 1) clockwise
the parking brake light on the dash will
until it touches the caliper (7) casting and then
stay illuminated even if the parking
turn it ½ turn more, or 0.64 mm (0.025 in).
brake switch is in the OFF position. The
rigid dump truck will not shift into range
9. Verify there is 0.64 mm (0.025 in) lining (4)
until the engine oil, steering and brake
clearance on each side of the disc (1, Figure 1).
systems reach normal operating pres-
Adjust set screw (26, Figure 1) as needed.
sure.
10. Lock the stop screw (26, Figure 1) with the jam
nut (27, Figure 1). NOTE: Make certain the rod moves out of the
parking brake actuator when the control
11. Cycle the park brake a few times to verify switch is in the “OFF” position.
proper operation and lining (4) clearances.
Repeat steps 1-11 if necessary.
Maintenance Specification
Stop loaded truck on steepest active grade on-site daily (loaded Hold stationary with no
truck not to exceed maximum published Target GMOW) other brakes applied
Park brake caliper lining to disc clearance – both sides 0.635 mm (0.025 mm)
Total allowable runout on disc (near outer edge) 0.406 mm (0.016 in)
Total allowable runout on differential input flange (near outer

0.127 mm (0.005 in)
edge)
Maximum allowable endplay of differential pinion 0.127 mm (0.005 in)
W6-8-8
SECTION 7
STEERING
—CONTENTS—
Group 1 Front Axle Group 4 Steering Cylinder

Service Position.......................................... W7-1-1 Service Position .......................................... W7-4-1
Checking Play in Front Axle Assembly....... W7-1-3 Removal...................................................... W7-4-1
Tools and Equipment Required .................. W7-1-3 Installation................................................... W7-4-4
Removal ..................................................... W7-1-3 Disassembly ............................................... W7-4-5
Installation .................................................. W7-1-7 Inspection ................................................... W7-4-6
Disassembly Trailing Arm .......................... W7-1-9 Assembly .................................................... W7-4-7
Inspection ................................................... W7-1-9 Maintenance Standard.............................. W7-4-12
Assembly Trailing Arm.............................. W7-1-11
Shimming Procedure................................ W7-1-11 Group 5 Steering Pump
Alignment.................................................. W7-1-13 Removal ...................................................... W7-5-1
Maintenance Standard ............................. W7-1-14 Installation ................................................... W7-5-2
Disassembly................................................ W7-5-2
Group 2 Steering Column Disassembly Load Sensing Control ............ W7-5-5
Removal ..................................................... W7-2-1 Inspection.................................................... W7-5-9
Installation .................................................. W7-2-2 Assembly................................................... W7-5-10
Disassembly ............................................... W7-2-3 Pressure Checks and Adjustment............. W7-5-15
Assembly .................................................... W7-2-6 Maintenance Standard .............................. W7-5-16
Group 3 Steering Control Valve

Service Position.......................................... W7-3-1
Removal ..................................................... W7-3-1
Installation .................................................. W7-3-2
Disassembly ............................................... W7-3-4
Inspection ................................................... W7-3-7
Assembly .................................................... W7-3-8
W7-0
<BLANK>
W7-0
Group 6 Steering Accumulator Group 7 Relief Check Bleed Valve
Service Position .......................................... W7-6-3 Removal ...................................................... W7-7-1
Removal ..................................................... W7-6-3 Installation ................................................... W7-7-4
Installation................................................... W7-6-4 Disassembly................................................ W7-7-7
Disassembly ............................................... W7-6-7 Inspection.................................................... W7-7-7
Assembly .................................................... W7-6-8 Assembly..................................................... W7-7-7
Inspection.................................................... W7-6-9
Maintenance Standard.............................. W7-6-10
W7-0
BLANK
W7-0
STEERING / Front Axle
T8DX-06-10-001
Figure 1 - Front Axle Assembly
1. Spindle Assembly 4. Tie Rod Assembly

2. Trailing Arm Assembly 5. Kingpin
3. Torque Tube 6. Front Ride Strut
SERVICE POSITION

W7-1-1
T8DX-06-10-003
Figure 2 - Section View of Front Axle (Left Side Shown)
1. Spindle Assembly 9. Gasket 14. Set Screws

3. Trailing Arm Assembly 10. Bolt 15. Shims
4. Kingpin 11. Washer 16. Bushing
8. Cover Plate (bottom) 12. Grease Fitting
8A. Cover Plate (top) 13. Spherical Thrust Bearing
W7-1-2
CHECKING PLAY IN FRONT TOOLS AND EQUIPMENT REQUIRED

AXLE ASSEMBLY
The following tools and equipment will be required for the
Prior to checking for play in the front axle assembly, the disassembly and assembly of the trailing arm and king-
rigid dump truck must be empty and a hydraulic tire pin:
handler, rated for the tire and wheel assembly, will be
needed. Disassembly
• Boring mill with a 120 to 160 mm (5 to 6 in.) spindle
Numbers in parentheses refer to Figure 4. • Welding Equipment and Supplies
• Hammer and driving tool or 45-55 metric ton (50-60
1. Apply the parking brake and block the rear wheels. ton) Hydraulic jack and Kingpin Removal Tool
Using a jack or similar lifting device, lift the front end of Refer to Section W2-4, SPECIAL TOOLS
the rigid dump truck until the front tires clear the
ground. See Section W2-3, LIFTING AND JACKING. Assembly
• Liquid Nitrogen, 76 L (20 gal) each Kingpin
2. While an assistant operates the tire handler, rotate the • Approved 19 L (5 gal) Submersion Vessel
top of the tire inwards towards the hauler chassis on • Protective Safety Equipment (PPE)
horizontal axis. Visually inspect the point where the • Heating Torch
thrust bearing (13) and spindle (1) meet. Any appre- • 121°C (250 °F) Temperature Stick
ciable wear in the kingpin (4) or its bushings (16) will • Alignment Tool, Refer to Section W2-5, SPECIAL
be seen at this point. TOOLS
• Required replacement parts from Hitachi
3. While an assistant operates the tire handler, rotate the
tire on vertical axis. Visually inspect the point where
the tie rod ball socket and the spindle assembly arm REMOVAL
meet. Any appreciable play will be seen.
CAUTION: A lifting device capable of lifting 45
4. The spindle bushings (16) should be replaced when
Metric Tons [50 Tons] will be required for lifting
1.5 mm (0.060 in) wear is measured on the inside
the front of rigid dump truck.
surface of the bushing (16), through its full length. At
this point, the grease groove in the bushing (16) would
be completely worn through which would accelerate CAUTION: A lifting device capable of lifting
the wear on both the kingpin (4) and bushings (16). 5650 kg (12500 lb) will be required for the re-
moval of the front axle assembly.
5. This spindle bushing wear can be checked by using a
round 1.5 mm (0.060 in) feeler gauge. Loosen and Numbers in parentheses refer to Figure 4.
remove bolts (12), washers (10, 11) and plate (8) from
the bottom of kingpin (4). With the unit empty, push 1. Put the rigid dump truck in the Service Position.
the feeler gauge in at various points around the di- Reference Section W2-1.
ameter of the king pin between the bottom bushing
(16) and kingpin (4). To have 1.5 mm (0.060 in ) wear, 2. Using the required lifting device, lift the front end until
feeler gauge must extend into the gap between both tires clear the ground, and crib the front of the
bushing (16) and the kingpin (4) at least 64 mm (2.50 rigid dump truck’s frame with heavy timbers. Refer to
in). Section W2-3, LIFTING AND JACKING. Remove
: 3/4 in tires and rims. See Section W8-6, TIRES / RIMS /
INFLATION.
W7-1-3
3. Ensure there is no hydraulic oil pressure in the brake

accumulators. Disconnect the brake lines and remove
the brake heads. Refer to Section W6-1, FRONT
BRAKES. Remove the wheels. Refer to Section W8-4,
FRONT WHEELS.
4. Disconnect the brake lines from the connections at the

front engine mount and plug and cap the hose and fitting
connections.
5. Disconnect the steer lines from the connections at the

front engine mount and plug and cap the hose and fitting
connections.
CAUTION: The front brake disc is bolted to

the wheel. Do not remove the bolts securing
disc to the wheel until the wheel is removed 25
from the unit and placed in a clear work area.
Removing these bolts prior to pulling the
wheel could result in personal injury.
24
6. Remove the steering cylinders from the spindle assembly
(1) and trailing arm assembly (3). Refer to Section W7-4, 1
STEERING CYLINDER.
26
7. Disconnect and remove the ride struts from the kingpin (5).
Refer to Section W8-2, FRONT SUSPENSION. 4
8. Remove the cotter pins (18) and lock nuts (19) which W8DX-06-10-001
secure the tie rod assembly (2). Loosen the socket

assemblies (17) from the spindle assembly (1), and Figure 3 – Tie Rod Assembly Removal
remove the tie rod assembly (2). If necessary, use a
tie rod fork to separate the tie rod ball socket assembly 1. Spindle 25. Lock Nut
(17) from the tapered seat. 4. Tie Rod Assembly 26. Socket Assembly
: 2 1/4 in 24. Cotter Pin
CAUTION: Tie Rod Assembly Weight: 90 kg

(200Ib)
W7-1-4
W8DX-06-10-002
Figure 4 – Exploded View of Front Axle (Left Side Shown)
1. Spindle 15. Shims 28. Grease Fitting

2. Tie Rod 16. Bushing 29. Relief Valve
3. Trailing Arm 17. Ball Socket Assembly 30. Nut
4. Kingpin 18. Cotter Pin 31. Washer
7. Torque Tube 19. Nut 32. Plate
8. Cover Plate 20. Bolt 33. Thrust Washer
8A. Cover Weldment 21. Nut 34. Shims
9. Gasket 22. Trunnion Cap 35. Plate
10. Bolt 23. Bolt 36. Washer
11. Washer 24. Washer 37. Lock Nut
12. Grease Fitting 25. Seal Ring 38. Bolt
13. Spherical Thrust Bearing 26. Bushing 39. Bar
14. Set Screws 27. Plug
W7-1-5
9. If necessary, the socket assemblies (17) can be re- 14. Using the required lifting device, position a bridge
moved from the tie rod (2) by loosening the nut (21) press assembly at the back side of the spindle (1) as
and bolt (20) on the clamp and then unscrewing the shown in Figure 5. Place a 406mm (16 in) tube
socket assembly (17) from the tie rod (2). between the top of the lower horizontal members of
: 1 1/8 in the bridge press assembly and the bottom of the
spindle. This will support the spindle (1) and also
10. Use the required lifting device to support the spindle retain the kingpin (4) when it’s pressed out of the
(1) and trailing arm (3). spindle. Place a 45 Tonne (50 ton) 355mm (14 in)
jack in a vertical position between the upper hori-
zontal members of the press assembly and the top
CAUTION: One Side Spindle and Trailing Arm
side of the king pin. Press the king pin (4) out of the
Weight: 1800kg (4000 Ib)
spindle (1) and trailing arm (3) until the pin (4) drops
into the 406mm (16 in) tube. Refer to Section W2-4,
11. Place a wheeled platform under the trailing arm
SPECIAL TOOLS for fabrication of a typical bridge.
assemblies (3) and spindle assemblies (1). Install
blocking as necessary to secure them to the platform. 14. Slide spindle (1) off the trailing arm (3) and remove
the thrust bearing (13) and shims (15). If necessary,
12. Use the required lifting device to support the spindle press or drive bushing (16) out of the spindle (1),
(1) and trailing arm (3). The approximate weight of using a driver with an outside diameter 0.79mm
the spindle assembly (1) and the trailing arm (3) is (.0312 in) smaller than the bushing’s outside di-
1800 kg. (4000 lbs.). Remove the bolts (10), washers ameter.
(11), cover plates (8) and gaskets (9) from the top
and bottom of the spindle (1). Discard gaskets (9).
: 3/4 in NOTE: If bushings (16) are removed they should be
discarded and new bushings (16) should be
installed along with a new spherical thrust
13. Loosen and remove set screws (14) from the trailing
bearing (13) and kingpin (4).
arm (3), it locks the king pin (4) in position.
3
: /4 in 15. If the trailing arm (3) on the opposite side of the
machine is to be removed, repeat steps 2 through
11.
16. Place a dolly under the trailing arms (3) and the
torque tube (7), and install blocking as necessary to
secure them to the dolly.
17. Remove the front ride struts from the trailing arms
(3). See Section W8-2, FRONT SUSPENSION.
18. Punch mark the trunnion caps (22) and the frame to
enable installation of the caps on the same mating
surfaces they were removed from. Loosen and
remove the four bolts (24) and washers (23) which
secure the trunnion caps (22) to the frame. Remove
the trunnion caps (22) from the frame. Lower the
spindle assemblies (1) and trailing arm assemblies
(3) to the ground.
: 2 1/4 in
CAUTION: Trunnion Cap Weight: 1800kg (4000

Ib)
Figure 5 - Removing Kingpin (4) with a Fabricated
Bridge Press
W7-1-6
INSTALLATION around the king pin bore in the trailing arm (3) and the
Numbers in parentheses refer to Figure 4. spindle assembly (1) to expand it.
1. With the trailing arm (3) and the torque tube (7) se- NOTE: DO NOT heat the bore above 121°C (250°F).
cured to a dolly with blocking as necessary, move the Check the temperature frequently with a
assembly into position under the machines frame. Tempstick.
CAUTION: Front Axle Assembly Without 9. Align the locking flat in the king pin (4) with the set
Wheels Weighs Approximately: 5650kg (12500 screw (14) holes in the trailing arm (3). Guide the king
Ib) pin (4) through the spindle arm into the trailing arm (3)
until the flat in the king pin is aligned with the set screw
2. Using the required lifting device lift the assembled holes in the trailing arm (3).
trailing arm (3) and the torque tube (7) into position.
Align the punch marks on the trunnion caps (22) with 10. Install the set screws (14) into the holes in the trailing
those marks made on the frame mounts and secure arm (3) until they bottom on the king pin’s (4) flat spot.
bolts (24) and washers (23). Tighten bolts (24) to the The set screws (14) must be properly seated to pre-
following specifications: vent excessive king pin (4) wear.
: 2 1/4 in
: 2034 N·m (1500 Ibf٠ft) 11. Install the cover plate (8) and new gaskets (9) over the
top and bottom of the king pin (4). Secure the cover
plate (8) to the spindle (1) with bolts (10) and washers
CAUTION: Trunnion Cap Weight: 91kg (200 Ib) (11).
: 3/4 in
3. Install the front ride struts. Reference Section W8-2,
FRONT SUSPENSION. 12. Install grease fittings (12) into the cover plates (8) and
lubricate to ensure the bushings (16) and king pin (4)
4. With the front ride struts installed between the frame are properly lubricated. Reference Section W2-2,
and the trailing arm assembly (3), remove the dolly MAINTENANCE in this manual.
and any blocking used from the trailing arm assem-
blies (3). 13. If the ball socket assembly (17) was removed from the
tie rod (2), reassemble and install by threading the ball
5. If the bushings (16) were removed from the spindle socket into the tie rod (2) until the assembly length is
(1), press new bushings (16) into the spindle (1) until 2864mm (112.75”) measured between the rod end
they are flush with the inner wear surface. stud center lines. This dimension is a reference only.
Do not tighten the clamping bolt (20) and nut (21) until
6. Using the required lifting device, lift and support the the toe-in adjustment is made. Reference ALIGN-
spindle assembly (1) on the trailing arm (3). Install the MENT, this section, for toe-in adjustment.
thrust bearing (13) between the trailing arm (3) and the
lower arm of the spindle (1). Measure the clearance 14. Install tie rod (2) into the spindle (1) and secure it with
between the upper arm of the spindle (1) and the nut (19) and the cotter pin (18). Torque nut (19) to
trailing arm (3). Insert sufficient shims (15) to obtain a recommended value, properly preloading the socket
clearance of 0.127-0.432 mm (.005 - .017 in). ball joint. Retorque again until required value re-
mains constant. Do not back off nut to insert cotter
CAUTION: Spindle Weight is approximately: pin (18). Apply additional torque to align nut and
550kg (1200 Ib) taper pin in order to insert cotter pin (18) if necessary.
Secure nut with cotter pin.
7. Prior to kingpin (4) installation, use the kingpin : 2 1/4 in
: 678 - 698 N·m (500 - 515 Ibf·ft)
alignment tool to position and align the bores between
the spindle (1) and trailing arm (3). Reference Spe-
15. Install the brake head assemblies. See Section W6-1,
cial Tools, section W2-4.
FRONT BRAKES. Secure the hydraulic steering
hose assembly to the trailing arm at the stud weld-
8. Pack the king pin (4) in dry ice or liquid nitrogen for one
to one and a half hours to shrink it. Heat the area
W7-1-7
ments with the clamps, washers, and nuts removed at TIRES/RIMS/INFLATION. Using required lifting de-
disassembly. vice, raise the front of the machine and remove the
blocking. Lower the machine to the ground.
16. Install the steering cylinder. See Section W7-4,
STEERING CYLINDER. Secure the hydraulic steering 18. Adjust the toe-in. Reference ALIGNMENT in this
hose assembly to the trailing arm at the stud weld- Section.
ments with the clamps, washers, and nuts removed at
disassembly.
17. Install the wheels. See Section W8-4, FRONT

WHEEL. Install the tires and rims. See Section W8-6,
33
25
26
26
28 33
25 W8DX-06-10-015
Figure 6 - Trailing Arm Assembly
3. Trailing Arm 28. Grease Fitting

25. Seal Ring 33. Thrust Washer
26. Bushing
2864 mm (112.75 in)
6.35 mm ± 1.50 mm
144 mm (0.25 in ± 0.06 in)
(5.66 in) Both Ends Minimum thread depth of socket
Reference into tie rod is 32 mm (1.25 in)
: 244 N·m (180 Ibf٠ft)
W8DX-06-10-016
Figure 7 - Tie Rod Assembly
W7-1-8
DISASSEMBLY, TRAILING ARM INSPECTION

1. Using the required lifting device, remove the trailing 1. Clean all parts thoroughly. Insure that all bushing
arm (3) from the torque tube (7). Remove the seal bores and grease journals are properly cleaned.
rings (25) from the groove in the inside diameter of
the bushing (26). Using a bearing puller, remove the 2. Inspect all threaded surfaces for damaged threads.
bushings (26) from the trailing arm (3). If necessary, Visually inspect all parts. Magnetic particle inspec-
remove the grease fittings (28), plugs (27), and relief tion may be performed by a qualified and experi-
valve (29) from the trailing arm (3). enced test technician if visual inspection alone
cannot adequately define the extent of suspected
CAUTION: Trailing Arm (3) Without Spindle (1, cracks in the surface.
Figure 4) Weight is approximately: 1050kg
(2300 Ib). Torque tube weight is approxi- 3. Replace or repair any component that is damaged or
mately 320 kg (700 lb). excessively worn.
2. Repeat step 1 to remove the opposite trailing arm 4. If the trunnion cap (22) shows significant wear, more
(3) from the torque tube (7). than 3.175mm (0.125 in), reclaim by using an E7018
electrode to build up material and machine back to
the original specifications. Reference Figure 9 and
SB0000-17R3.
5. If the trailing arm (3) shows significant wear at the top

and bottom surfaces at the kingpin area, machine
face flat and shim appropriately. See SHIMMING
PROCEDURE in this section.
6. If the torque tube (7) shows wear (grooves between

the trailing arms) DO NOT repair. This component
must be replaced.
7. Reference SB6100-26 or its latest revision for more

detailed trailing arm inspection.
Figure 8 – Trailing Arm
3. Trailing Arm 26. Bushing

7. Torque Tube 27. Plug
25. Seal 28. Grease Fitting
29. Relief Valve
W7-1-9
Figure 9 – Trunnion Cap Machining Specification
W7-1-10
ASSEMBLY, TRAILING ARM NOTE: Items listed in Figure 11 must be of the

correct thickness for the desired gap.
3. Using the required lifting device lift the front end of
1. If the grease fittings (28), plugs (27), and the relief the rigid dump truck until the front tires clear the
valve (29) were removed from the trailing arm (3) ground.
during disassembly, install these parts at this time.
4. Place cribbing under the front of the rigid dump
2. Install bushings (26) in the trailing arm (3). Install truck (empty), to relieve the weight off of the trailing
new seals (25) in the groove of bushing (26). Ref- arms and to support the rigid dump truck. Refer to
erence Figure 10. With the required lifting device Section W2-3, LIFTING/JACKING PROCEDURE.
install the trailing arm (3) on the torque tube (7).
5. Force the trailing arms (3, Figure 4) towards the
3. Repeat for other trailing arm (3). trunnion caps (22, Figure 4). If necessary, a hy-
draulic ram (port-a-power) of sufficient size can be
used to separate or force the trailing arms against
the trunnion caps.
6. With the rigid dump truck properly cribbed and the

weight off of the trailing arms (3, Figure 4), measure
the gap between the trailing arms (3, Figure 4).
Refer to Figure 11.
7. To determine the correct shim pack, measure and

record the gap between the trailing arms (3, Figure
4). The maximum allowable gap is 6 mm (0.25 in)
8. If the gap is greater than 6 mm (0.25 in), the

maximum allowable, the trailing arms must be
shimmed.
9. Place the shims (1) in the center of the torque tube.

Refer to Figure 11.
Figure 10 – Seal (25) Orientation
10. Locate plates (2) on both sides of the shims (1),
then insert the bolts (5), washers (3) and nuts (4)
SHIMMING PROCEDURE through the shims (1) and plates (2).
: 9/16 in
(A lifting device capable of lifting 45 Metric Tons : 36 N٠m (26 lbf٠ft)
[50 Tons] is required to perform this procedure.)
11. Using the dimension in Figure 12, locate and weld
Numbers in parentheses refer to Figure 11. the bar stock (6) on the same trailing arm (3,
Figure 4) to keep the shims (1) from rotating on the
1. With the rigid dump truck empty and on level torque tube (7, Figure 4).
ground, turn the steering wheel back and forth
against the stops. The trailing arms will work apart NOTE: Prior to welding on the rigid dump truck,
and a visual inspection of the gap between the follow the procedure in Section W8-1,
trailing arms can be performed. If the gap is ex- ELECTRICAL DISCONNECTIONS BE-
cessive, shim accordingly. Maximum allowable gap FORE WELDING ON THE RIGID DUMP
6 mm (0.25 in) TRUCK.
2. Put the rigid dump truck in the Service Position. 12. Lower rigid dump truck to the ground.
Reference Section W2-1.
W7-1-11
CL
13 mm (1/2 in)
5 mm (3/16
6 in)
115.8 mm C Trailing Arm

Gap between (4.56 in) L
trailing arms
58 mm
(2.28 in)
W8DX-06-10-013
Figure 13– Weld Shim Stops
Trailing
Arms
W8DX-06-10-011
Figure 11 - Shimming Areas
3, 4, & 5 3, 4, & 5
6
2 2 Trailing
Arm
1
6 1 2
W8DX-06-10-012
View A - A
Figure 12 - Shimming Areas
1. Shims 4. Nut
2. Plates 5. Bolt
3. Washer 6. Bar Stock
W7-1-12
ALIGNMENT
Correct front end alignment depends upon three basic

fundamentals which describe the geometry of the
steering system: the angles of caster, camber and
toe-in. The relationship among the three is very criti-
cal; changes in any one directly affects the other two,
and also affects the steering of the vehicle; caster and
camber are not adjustable; toe-in is adjustable.
Frequency of adjustments is largely dependent upon
road conditions… the rougher the terrain, the greater
the necessity for adjustments.
ELI1596
Figure 15 – Toe-In Measurement
Measure toe-in at the tire bulge, as close to the hori-

zontal center line as possible. The wheels should be
closer in the front of the axle than in the rear of the axle.
If an adjustment to the toe-in must be made, loosen
both the clamping bolts and nuts (20, 21, Figure 4),
EL853 and rotate the tie rod in the direction to increase or
Figure 14 - Alignment decrease the toe-in dimension. Tighten and torque
the clamping bolts and nuts once the correct toe-in
dimension is achieved.
: 1 1/8 in
: 244 N٠m (180 Ibf٠ft)
W7-1-13
DESCRIPTION SPECIFICATION ACCEPTANCE NOTES

CRITERIA
Spindle (1) Wet magnetic particle in- ASTM 125 Inspect at time of major
Inspect General Area spection method (MPI) Linear / Welds service when wheel hub
Refer to Figure 17 Degree 3 is removed
Discontinuity
Spindle (1) Wet magnetic particle in- ASTM 125 Inspect at time of major
Inspect Special Attention spection method (MPI) Linear / Welds service when wheel hub
Area Refer to Figure 17 Degree 1 is removed.
Discontinuity
Spindle (1) 133.320-133.345 mm
Small Bearing Journal (5.2488-5.2498 in)
Diameter
Spindle (1) 237.300-237.325 mm
Large Bearing Journal (9.3425-9.3435 in)
Diameter
Kingpin Bushing (16) 1.52 mm Replace bushing when Refer to CHECKING
Maximum Gap Clearance (0.06 in) specification is exceeded PLAY IN FRONT AXLE
ASSEMBLY.
Trailing Arms (3) 6 mm Install shim when specifi- Refer to Figure 12
Maximum Gap Between T (0.25 in) cation is exceeded SHIMMING PROCE-
Arms Before Shimming DURE.
Toe In Adjustment Bias Tires: 19 – 25 mm Refer to Figure 14
(0.75 – 1.00 in) ALIGNMENT
Radial Tires: 0 – 3 mm
(0 – 0.12 in)
Trailing Arm Inspection and Refer to Service Bulletin
Minor Repair 6100-26R1
Kingpin Bore Specifications Refer to Figure 16
W7-1-14
Figure 16 – King Pin Machining Specifications
W7-1-15
General Area
Special Attention Area
End Side
Figure 17 – Wheel Spindle General and Special Attention Area
W7-1-16
STEERING / Steering Column
REMOVAL
31
1. Park rigid dump truck on a level solid surface

and place in “Service Position”. Refer to Sec-
tion W2-1 SERVICE POSITION.
2. Allow steering accumulator time to drain to zero 30

pressure.
3. Turn steering wheel full left and full right several

times to assure any pressure trapped in the
lines or a cylinder is relieved to tank.
NOTE: The hose assemblies attached to the

steering control valve (28) can remain
attached during the removal unless the
steering control valve (28) is to be dis-
assembled. See Section W7-3 for re-
moval instructions.
4. Clean underside of cab in the area of the steer-

ing control valve (28) to remove dirt and dust
from work area.
5. Loosen and remove bolt (6) and nut (7), which

secures the splined yoke on the driveshaft (8) to
the spline on the steering column assembly (1).
: 5/8 in T8DX-06-41-001
6. Disconnect the steering column wire harness (A). Figure 1 - Steering Column and Mounting
Refer to Figure 2.
1. Steering Column As- 17. Screw
7. Remove screw (3), lock nut (5), and washers (4),
sembly
and pull steering column (1) from drive shaft (8).
2. Dash (Reference) 18. Washer
: 9/16 in
3. Screw 19. Cab Frame (Reference)
4. Washer 20. Bracket
CAUTION: Steering wheel (30) and Steering 5. Lock Nut 21. Lock Nut
Column (1) approximate weight: 23 Kg (50 lb) 6. Bolt 22. Washer
7. Nut 23. Mount
8. Loosen and remove screw (9), washer (10), that 8. Driveshaft 24. Washer
secures two half plates (12) and boot (13) to cab 9. Screw 25. Washer
floor (14). Remove the two half plates (12). Re- 10. Washer 26. Screw
fer to Figure 3. 11. Cover 27. Washer
: 7/16 in 12. Plate 28. Steering Control Valve
13. Boot 29. Steering Column
9. With the steering column assembly (1) removed,
14. Cab Floor (Reference) 30. Steering Wheel
loosen and remove bolt (15) and nut (16) which
15. Bolt 31. Horn Button
secures the splined yoke on the driveshaft (8), to
the spline on the steering column (29) of steer- 16. Nut A. Steering Column Wire
ing control valve (28). Harness
: 9/16 in
W7-2-1
12. Carefully remove and lower the steering control

valve (28) and steering column (29) from the
bracket (20). Pull the steering column (29) from
the splines on the steering control valve (28). If
the steering control valve is not to be disassem-
bled secure it off to the side using elastic straps
or wire to support the weight. Do not allow the
steering valve to hang free supported only by
the hydraulic hoses attached. If the hose as-
semblies were removed from the steering con-
trol valve (28) and disassembly is required,
move it to a clean work area.
Figure 2 - Disconnect Wire Harness CAUTION: Steering Control Valve and Steering
Column weight: 15 Kg (35 lb)
W8DX-06-41-001
17
18
Cover
20
Plates
Boot
W8DX-06-41-004
Figure 3 - Removal of Half Plates and Boot
Figure 4 – Steering Column and Steering Control

10. Carefully pull the driveshaft (8) from the spline
end of the steering column (29). Be careful not Valve
to damage the splines of the yoke at the end of
the driveshaft (8) or those at the end of the
steering column (29).
INSTALLATION
11. With the steering column assembly (1) and
driveshaft (8) removed, and a support under the Numbers in parentheses refer to Figure 1.
steering control valve (28), loosen and remove
screws (17) and washers (18). Screws (17) and
NOTE: Components should be clean and free of
washers (18) secure the steering column (29)
dirt and dust prior to installation.
and steering control valve (28) to bracket (20).
Refer to Figure 4. 1. Lubricate the spline section of the steering col-
: 9/16 in umn (29) with grease and slide into the steering
valve (28).
W7-2-2
2. Install screws (17) and washers (18) through 12. Rotate steering wheel and inspect for interfer-
mounting bracket (20) and into valve (28). ence or rubbing. Make adjustment as required.
: 9/16 in Reference INSTALLATION step 6.
: 36 N٠m (26 Ibf٠ft)
CAUTION: Steering Control Valve and Steering

Column approximate weight: 15 Kg (35 lb)
1
3. If the hose assemblies were removed from the
steering control valve (28), attach at connectors
using new O-rings. (Refer to Section W7-3).
4. Install the cover (11) and boot (13) around the
driveshaft (8) and carefully slide into the spline
end of the steering column (29).
5. Secure the two half plates (12) using Screws (9),
and washers (10). Reference Figure 3. 3
4
: 7/16 in 5
: 14 N٠m (10 Ibf٠ft)
6. Inspect alignment of steering valve driveshaft (8)
with hole in floor of cab. Adjust the valve mount-
ing position by loosening screws (26) and lock-
nut (21), and sliding plate (20) until the drive-
shaft (8) is centered in the hole. Rotate steering
column 720° to ensure smooth steering. Adjust
alignment as required. Tighten when complete. Figure 5 - Steering Column Assembly
: 9/16 in
: 36 N٠m (26 Ibf٠ft)
1. Steer Column Assembly
7. Install bolt (15) and nut (16), then tighten. 3. Screw
: 9/16 in 4. Washer
: 54 - 65 N٠m (40 - 48 Ibf٠ft) 5. Lock Nut
8. Install steering column assembly (1) on drive
shaft (8) and secure to cab with screws (3),
washers (4), and lock nuts (5). See Figure 6. DISASSEMBLY
: 9/16 in
: 50 N٠m (37 Ibf٠ft) Numbers in parentheses refer to Figure 1, unless
otherwise noted.
CAUTION: Steering wheel (30) and steering
column (1) approximate weight: 23 kg (50 lb) 1. Press horn button (31) inward, rotate, and re-
9. Install bolt (6) and nut (7), then tighten. move horn button.
: 5/8 in 2. Remove steering wheel retaining nut (32, Figure
: 85 - 102 N٠m (63 - 75 Ibf٠ft) 6).
: 1 5/16 in
10. Connect the steering column wire harness (A).
Refer to Figure 2. 3. Remove steering wheel (30) using an automo-
tive steering wheel puller tool.
11. Start the rigid dump truck and check the opera-
tion of all steering column and steering control 4. Remove spring (36), contact (33), ring (34), and
valve components. horn brush (35). Refer to Figure 6.
W7-2-3
5. Remove screw (39), lock washer (40), lever (38),

33 35 and turn signal switch (37). Refer to Figure 8.
36 6. Remove wire harness (41). Refer to Figure 9.
32
34
Figure 6 – Horn Brush Removal
32. Jam Nut

33. Contact
34. Ring
35. Horn Brush 41
36. Spring
Figure 8 – Wire Harness
41. Wire Harness

37

7. Loosen nut (43) and remove knob (42).
8. Remove retaining ring (50), washer (51).
40 9. Remove spring (48).
39 10. Remove pins (46) and (47), lever (52), pawl (49),
38
and rod & pawl assembly (45).
Figure 7 – Turn Signal 11. Remove springs (44).
37. Turn Signal

38. Lever
39. Screw
40. Lock Washer
W7-2-4
48
47 50
49 51
46 44
45
52
44 43
42
Figure 9 – Tilt Rod & Pawl
42. Knob 48. Spring

43. Lock Nut 49. Pawl
44. Spring 50. Retaining Ring
45. Rod & Pawl Assembly 51. Washer
46. Pin 52. Lever
47. Pin
W7-2-5
ASSEMBLY

erwise noted.
1. Install springs (44), rod & pawl (45), pin (46).

2. Install Pawl (49), washer (51), and ring (50).
3. Install Lever (52), Pin (47), nut (43), and knob
(42).
4. Install wire harness (41). Refer to Figure 8.
5. Install turn signal switch (37), screw (39), lock
washer (40), and lever (38). Refer to Figure 7.
6. Install spring (36), contact (33), ring (34), and
brush (35). Refer to Figure 6.
7. Install Steering wheel (30), steering wheel retain-
ing nut (32). Refer to Figure 1 and 6.
: 1 5/16 in
: 41 N٠m (30 Ibf٠ft)
8. Install horn button (31), press and rotate in place.
Refer to Figure 1.
W7-2-6
STEERING / Steering Control Valve
SERVICE POSITION
Before checking and/or servicing the rigid dump truck, 8. Slide steering control valve assembly away from
park it on a level solid surface and put it in the “Service steering shaft spline and place valve on clean
Position.” Refer to Section W2-1. work area.
REMOVAL
1. Park the rigid dump truck on a level solid surface

and apply park brake.
2. Stop engine and with key switch in “off” position,

place tag on steering wheel that rigid dump truck
is “out of service.”
3. Allow steering accumulator to automatically re-

lease hydraulic pressure. Turn steering wheel
right and left to release any trapped oil pressure.
All oil pressure is released when you can’t turn
the steering wheel.
Figure 1- Chock Wheels Tight
4. Power wash and clean steering control valve
assembly and related hose connections.
5. Block both sides of a wheel with chocks to pre-

vent rigid dump truck movement.
CAUTION: Escaping fluid under pressure

can penetrate the skin and eyes, causing
serious injury. Avoid this hazard by reliev-
ing pressure before disconnecting hydrau-
lic lines. Hydraulic oil may be hot after op-
eration. Hot hydraulic oil may spray out,
possibly causing severe burns. Be sure to
wait for oil to cool before starting any repair
work.
IMPORTANT: Attach identification tags on all four Mounting

steering hoses to aid in reassembly. Bolts
6. Disconnect hoses (total 4) and plug/cap connec-

tions and fitting to prevent contamination.
: 36 mm
: 41 mm
W8DX-06-41-006
7. Remove four mounting bolts on bracket while Figure 2- Steering Control Valve
supporting steering control valve assembly.
Discard bolts.
: 9/16 in
CAUTION: Steering Control Valve approximate

weight: 14 Kg (30 lb)
W7-3-1
INSTALLATION
1. Clean steering control valve mounting flange and
spline shaft of rust and scale. Refer to Figures 2
and 3.
2. Coat spline of steering shaft coupling area with a

thin coating of grease or never seize.
3. Install steering control valve onto its mounting

flange and spline shaft. Rotate steering control
valve to align mounting holes to original location
and install the four mounting bolts.
: 9/16 in
: 47 N٠m (35 Ibf٠ft)
Spline
Shaft Mounting
CAUTION: Steering Control Valve approximate
weight: 14 Kg (30 lb)
Flange
4. Remove the plugs and caps from the hoses and Figure 3 – Steering Column Adapter
fittings and install hoses on labeled connections.
5. Torque hose swivel nuts.

: 36 mm
: 92 N٠m (68 Ibf٠ft)
: 41 mm
: 130 N٠m (96 Ibf٠ft)
IMPORTANT: Be sure to check the hydraulic oil

level is at the correct level in the
steering tank after assembly. Start
engine and visually inspect each part
for signs of oil leakage.
W7-3-2
15
30
31
29
28
Steering Control Valve
27 Schematics
20
19
Figure 4 – Section View of the Steering Control Valve
1. Seal Retainer 12. End Cap 29. Cylinder Port Reliefs (3120 psi)
2. Snap Ring 13. Rotor 30. Manual Steering Check Valve (Fig. 13)
3. Dust Seal 14. Stator 31. Thermal Bleed
4. Spool 15. Inlet Check Valve
5. Seal (2 piece) 16. Pin
6. O-Ring 17. Centering Springs (total 4) A. Control Section
7. Bearing Assembly 18. Screw (illustrated in Figure 6) B. Metering Section
8. Driveshaft 19. Wear Plate L. Left Turn Port
9. Sleeve 20. Housing R. Right Turn Port
10. O-Ring 27. Drive Spacer P. Pressure Port
11. O-Ring 28. Anti-Cavitation Valves (Fig. 8) T. Tank Port
W7-3-3
DISASSEMBLY
12
NOTE: Cleanliness is extremely important as clear- Punch 14
ance of rotation sleeves and housing is very
small and any contamination in these areas Mark
will permanently damage this area. 20

erwise noted.
1. Clamp the steering control valve in a vise, with the

meter end up. Clamp lightly on edges of mounting
area. Use protective material on the vise jaws. Do
not over tighten the vise jaws. Refer to Figure 5. W8DX-06-45-034
NOTE: Although not all the illustrations show the Figure 5 - Steering Control Valve Clamped in Vise
unit in a vise, it is recommended that the
valve be kept in a vise during disassembly.
18
2. Remove the cap screws (18) from the end cap (12).
Remove the end cap (12) and O-ring (11) from the
end cap. Refer to Figure 6. 12
11
W8DX-06-45-035
Figure 6
14
11
3. Remove the stator (14) and rotor (13) as a unit. Be

careful not to drop the rotor (13). Remove the 13
O-ring (11) from the stator (14). Refer to Figure 7.
W8DX-06-45-036
Figure 7
W7-3-4
4. Remove the wear plate (19), and O-ring (10) from

the housing (20). Remove the driveshaft (8). Refer
to Figure 8.
Figure 8
5. Remove the housing (20) from the vise. Place the

housing (20) on a clean, soft cloth to protect the
surface finish. Use the retaining ring ratchet pliers to
remove the snap ring (2) from the housing (20).
Refer to Figure 9.
Figure 9
6. Position the two flat blade screwdrivers 180° apart

in the groove of the seal retainer (1), reference Fig-
ure 10. Pry the seal retainer (1) upward until it’s
flush with the housing. Be careful not to damage the
ring groove of the front retainer. Remove the
screwdrivers. Push the spool (4) down while re-
moving the seal retainer (1) from the housing (20)
by hand.
Figure 10
7. Remove the seal (5, Figure 4), O-ring (6, Figure 4)

and dust seal (3, Figure 4) from the seal retainer (1,
Figure 4). Use a thin blade screwdriver to pry dust
seal (3, Figure 4) from seal retainer (1, Figure 4). Be
careful not to damage seal retainer (1, Figure 4).
8. Remove the two bearing races (7B) and the nee-

dle thrust bearing (7A) from the spool (4) and
sleeve (9) assembly. Refer to Figure 11.
Figure 11
W7-3-5
NOTE: Avoid binding the spool (4) and sleeve (9) in

the housing. Limited alternate rotation of the
spool (4) and sleeve (9) helps reduce binding.
Keep the pin (16) in a nearly horizontal posi-
tion when removing the spool (4) and sleeve
(9) from the housing (20). If the pin (16) be-
comes vertical during removal, it may drop
from the spool (4) and sleeve (9) into an oil
passage inside the housing (20).
9. Remove spool (4) and sleeve (9) assembly from the

end of the housing (20), see Figure 12.
10. Push the pin (16) from the spool (4) and sleeve (9)
assembly. Refer to Figure 12.
11. Remove the spool (4) from sleeve (9), see Figure
13. Remove the four or six centering springs (17)
from spool (4) carefully by hand.
12. Remove the plugs (21, Figure 4) from housing (20,

Figure 4). Remove the O-rings (22, Figure 4) and
valves (23, Figure 4).
Figure 12
INSPECTION
NOTE: If the spool (4), sleeve (9) or the housing as-

sembly (20) need replacement, the complete
steering control valve must be replaced.
Also, if the stator (14) or rotor (13) need to be
replaced, they must be replaced as an as-
sembly.
1. Rinse all the parts carefully in clean solvent and dry

with compressed air.
2. Inspect the bore and ends of the housing assembly

(20) for excessive wear, scoring, or damage.
3. Inspect the outside diameter, control edges and the

inside splines of spool (4) for excessive wear, scor- Figure 13
ing, or damage.
4. Inspect the outside diameter, edges, and the inside

diameter of sleeve (9) for damage.
5. Inspect the needle thrust bearing (7A) and bearing

races (7B) for pitting or wear.
6. Inspect the teeth of the drive shaft (8) and the

splines in the rotor (13) for excessive wear or dam-
age.
W7-3-6
7. Inspect the lobes of the rotor (13) and inside of sta-

tor (14) for excessive wear scoring or damage.
8. Inspect the springs on the valve (23) for damage

and replace if necessary.
9. Replace the O--rings (6, 10, 11 and 22); seals (3

and 5) and snap ring (2) before reassembling the
valve.
10. Replace any parts that have scratches or burrs that

could cause leakage.
ASSEMBLY
Numbers in parentheses refer to Figure 4 unless other-
wise noted. Figure 14
Clean all mating surfaces. Clean all metal parts in clean
solvent. Blow dry parts with compressed air. Do not
wipe dry with cloth or paper towel because lint or other
matter can get into the hydraulic system and cause
damage. Do not use grit, or try to file or grind steering
control unit parts.
NOTE: Lubricate all the seals (with exception of seal

5) with clean petroleum jelly. Do not use ex-
cessive lubricant on O-rings (10 and 11).
1. Refer to Figure 14. Insert control end of spool (4) in

sleeve (9). Assemble the spool (4) and sleeve (9)
carefully so that the centering spring slots line up at
the same end. Apply a light film of clean oil to the Figure 15
outside diameter (O.D.) of spool (4).
2. Rotate spool (4) while sliding parts together. Be-

cause of close tolerance between the spool (4) and
sleeve (9), do not use force when rotating parts to-
gether. Be careful not to burr spool (4). Test for free
rotation. The spool (4) should rotate smoothly in
sleeve (9) with finger tip force applied at the splined
end.
NOTE: The spring installation, fabricated, tool illus-

trated in Figure 15 is not required for assem-
bly, but is helpful.
Figure 16
W7-3-7
Spring Installation with Tool
3. Align the spring slots of spool (4) and sleeve (9),

then stand the parts on the bench. Insert the spring
installation tool (illustrated in Figure 17) through the
spring slots of both the spool (4) and sleeve (9).
Refer to Figure 16.
4. Position the centering springs (item 17, two sets of

three each) on bench so that the extended edge is
down and the center section is together. In this
position, insert one end of the entire spring set into
the spring installation tool.
5. Compress the expanded end of the centering spring

(17) set and push it into the spool (4) and the sleeve
(9) assembly. Keep the pressure on the spring ends
when withdrawing the installation tool, push forward
on the springs at the same time.
6. Center the centering spring set (17) in the spring

slots. Seat the springs down evenly and flush with
the upper surface of the spring and sleeve (9).
Spring Installation without Tool Figure 17

7. Insert one centering spring (17), with the extended
edge down, in the spring slot of the spool (4). Raise
the spool (4) from sleeve (9) slightly for more spring
clearance. Refer to Figure 17.
8. Insert one centering spring (17) opposite the spring

located in the slot of spool (4). Make sure the center
sections of both springs are together, and that the
extended edges of the springs are down.
9. Push one set of the two centering springs (17) be-

tween the two springs in the spool (4), reference
Figure 17.
10. Push the remaining set of the two centering springs

(17) opposite the three centering springs in the
spool (4).
11. Push the spool (4) into sleeve (9) until the springs
(17) seat flush with the top and sides of the sleeve
(9).
12. Install the pin (16) the through spool (4) and sleeve
(9) assembly until the pin (16) becomes flush at
both sides of the sleeve. Refer to Figure 18. Figure 18
13. Position the spool (4) and sleeve (9) assembly so

the splined end of the spool enters the meter end of
the housing (20) first.
W7-3-8
NOTE: Be extremely careful that the spool (4) and

sleeve (9) don’t tilt out of position while in-
serting them in the housing (20). Lubricate
the outside diameter (O.D.) of the sleeve (9).
Push the parts gently into the plate with slight
rotation. Keep the pin (16) horizontal. Bring
the spool (4) sleeve (9) assembly entirely
within the bore of the housing (20) until the
parts are flush at the meter end of the hous-
ing. Do not pull the spool (4) sleeve (9) as-
sembly beyond this point to prevent the cross
pin (16) from dropping into the discharge
groove of the housing (20). With the spool (4) Figure 19
sleeve (9) assembly in this flush position,
check for free rotation within the housing by
turning with light finger force at the splined
end.
14. Place the housing (20) on a clean shop towel. Install

the two bearing races (7B) and the needle thrust
bearing (7A) in the order shown in Figure 19.
15. Install the dust seal (3) in the seal retainer (1), flat or Figure 20
smooth side of dust seal must face down toward the
retainer. Refer to Figure 20.
16. Install the seal (5) into the seal retainer (1). Seat the
seal (5) in place with your finger. Do not use and
seal that falls freely into pocket of seal retainer (1).
Refer to Figure 20.
17. Install O-ring (6, Figure 20) on the front of the seal
retainer (1).
18. Install the front part of the seal retainer (1) over the
spool (4) end with a twisting motion. Tap seal re-
tainer (1) into the housing (20) with a rubber ham-
mer. Make sure the seal retainer (1) is flush against Figure 21
the bearing race (7B).
19. With the retaining ring ratchet pliers, install the snap
ring (item 2, Figure 20 & 21) in the housing (20).
After installing the snap ring (2), tap on the ring to
properly seat the snap ring (2) in groove of the
housing (20).
20. Clamp the housing (20) in a vise as shown in Figure

22. Clamp it lightly on the edges of the mounting
area. Do not over tighten jaws. Install the O-ring
(10) in the housing (20).
Figure 22
W7-3-9
NOTE: Check to ensure that the spool (4) and sleeve

(9) are flush or slightly below the meter end of
the housing (20). Clean the upper surface of
the housing (20) by wiping it with the palm of
your (clean) hand. Clean each of the flat sur-
faces of the meter end parts in a similar way
when ready for assembly. Do not use cloth or
paper towel to clean surfaces.
21. Refer to Figure 23. Rotate the spool (4) and sleeve
(9) assembly until the pin (16) is parallel with the
port face. Install the driveshaft (8) and make sure
you engage with the pin (16). To assure a proper
alignment, mark one of the two drive tooth slots that
are parallel with the slot in the end of the drive, see Figure 23
Figure 26, reference B & C.
22. The wear plate (19) oil feed holes are larger on one
side than the other. When assembling the unit,
make sure the side with the smaller diameter holes
is against the housing (20). Install O-ring (10) on the
stator (14). Refer to Figure 24.
23. With the O-ring (10) side of the stator (14) down, in-
stall it on the driveshaft (8). If the rotor (13) has a
counter bore, install it with the counterbore facing
end cap (12).
NOTE: The drive mark on the driveshaft (8) must fall

on the parallel line between two rotor (13)
star valleys.
24. Note the parallel relationships of the reference lines

A, B, C and D, Figures 24 and 25. Align the bolt Figure 24
holes in the stator (14), wear plate (19) and housing
(20) without disengaging the stator (14) from the
driveshaft (8). Be careful when adjusting the stator
(14) on the housing (20), excessive turning of the
stator (14) may disrupt the O-ring (10) between the
stator (14) and housing (20).
25. Install O-ring (11) in the end cap (12). Place the end
cap (12) on the housing (20), aligning the bolt holes.
Do not dislodge the O-ring (11) from end cap (12).
Refer to Figure 26.
26. Install the seven cap screws (18), see Figure 28.
Pre-tighten the cap screws (18) to 20 - 27 N·m (15 -
20 lbf·ft), then torque cap screws to 100 N·m (75
lbf·ft) in the sequence shown in Figure 27.
Figure 25
W7-3-10
27. Install the valves (23, Figure 4) in the cavity of the

housing (20). Install new the O--rings (22) on plugs
(21). Install and tighten the plugs in the housing
(20).
INSTALLATION
1. Refer to Section 7-2 STEERING COLUMN for in-
stallation of the steering control valve.
2. Check the steering system fluid level, fill as needed.
3. Start the engine and let it idle. Rotate the steering Figure 26
wheel left and right from stop to stop to bleed out air
from the system. Do not operate the machine until
all the air is bled out of the steering system and the
steering is functioning properly.
4. Recheck the oil level in the tank.
Figure 27
W7-3-11
W7-3-12
STEERING / Steering Cylinder
SERVICE POSITION
Before checking and/or servicing the rigid dump truck, Numbers in parentheses refer to Figure 1.
park it on a level solid surface and put it in the “Ser- 6. Disconnect hoses (1) and (2). Plug hose ends
vice Position”. Refer to Section W2-1. to reduce fluid loss and prevent contamination
from entering.
REMOVAL : 24 mm
1. Park the rigid dump truck on a level solid surface CAUTION: Steer Cylinder weight: 41Kg (90lb)
and apply park brake.
2. Stop engine and with engine in “off” position, tag 7. Remove fittings (3) from cylinders. Cap cylinder
the steering wheel that rigid dump truck is “Out of ports to reduce fluid loss and prevent contami-
Service.” nation from entering.
3. Allow steering accumulator to automatically re- : 15/16 in
lease hydraulic pressure. Turn steering wheel
right and left several times to release any trapped
oil pressure. All oil pressure is relieved when you 2
can’t turn the steering wheel.
4. Block both sides of a wheel with approved chocks
to prevent rigid dump truck movement.
5. Power wash and clean steering cylinders and re-
lated hose connections.

can penetrate the skin and eyes, causing
serious injury. Avoid this hazard by re-
lieving pressure before disconnecting hy-
draulic lines. 1
Hot hydraulic oil may spray out, possibly 3
causing severe burns. Be sure to wait for
oil to cool before starting any repair work.
Figure 1 - Steer Cylinder Hoses
1 Hose, Cylinder Rod End (2x)

2 Hose, Cylinder Base End (2x)
3 Fitting (4x)
W7-4-1
24, 25, 27
19
26
W8DX-06-45-012
Figure 4 - Base End Mounting
20, 21
W8DX-06-45-011 Numbers in parentheses refer to Figures 2, 4 and 5.
Figure 2 – Rod End Mounting
9. Remove bolt (24), washer (25) and tube (27)

Numbers in parentheses refer to Figure 2. from pin assembly (26) at the base end tube
clevis.
8. Support the steering cylinder assembly with the
required lifting device. Remove cotter pin (20) and : 3/4 in
loosen nut (21), which secures the steering cylinder 10. Remove pin (26) from cylinder base (1) and
socket assembly (19) in the spindle. Leave approxi- bushing (30) in trailing arm.
mately 6 mm (1/4 in) gap between loosened nut and
spindle. 11. Use a picklefork (refer to Figure 3) or hydraulic
1 press to loosen socket (19) taper seat from
: 2 /4 in spindle counterbore. After socket is free, re-
move nut (21).
12. With the steering cylinder supported with the
required lifting device, pull the cylinder assembly
free of the spindle. Do not rest or support the
cylinder on the exposed cylinder rod chrome
plated surface.
NOTE: The ball stud is a taper connection in the

spindle and may require application of
heat to spindle for release to occur.
13. Carefully remove the steering cylinder assem-
bly from the rigid dump truck, and drain the hy-
draulic oil trapped inside the cylinder. Place the
steering cylinder in a clean work area for dis-
assembly.
Reclaim or Dispose of Oil Properly

Figure 3 – Use of Pickle Fork
W7-4-2
INSTALLATION
8. Remove the protective caps, from the hose as-
1. Clean socket (19) tapered hole in spindle to be semblies, and install the hoses (1) and (2) on the
certain it is free of dirt and debris. fittings (3).
2. Support the steering cylinder with the required lift- : 24 mm
ing device and install it on the trailing arm and : 45 N٠m (33 Ibf٠ft)
wheel spindle.
9. Grease the fittings at the trailing arm and socket
3. Insert the socket assembly (19) into the mounting assembly. See the OPERATOR’S MANUAL:
hole in the steering spindle. Make certain seal is RECOMMENDED LUBRICANTS, for the rec-
in place. ommended lubricant.
Numbers in parentheses refer to Figures 4 and 5. 10. Check the oil level in the steering oil tank and add
4. Align the mounting holes at base of the tube oil as necessary. Operate the engine and turn the
weldment (1) with the mounting hole in the trailing rigid dump truck steering wheel several times left
arm. Place one spacer (36) on top of the spheri- to right from steer stop to steer stop to purge all
cal bushing (30). Partially install the pin assem- the air from the steering cylinders while checking
bly (26), and before completely installing it, place for proper operation of the steering system. In-
the second spacer (36) between spherical bush- spect for leaks at the hose connections and at the
ing (30) and the steer cylinder. Completely in- steering cylinder rod and gland.
stall the pin (26), and secure the pin (26) to cyl- 11. Operate unit and inspect steering system travel to
inder (1) with bolt (24), washer (25), and tube verify minimum turning radius is obtained in both
(27). directions. Check steering linkage condition for
: 3/4 in proper function and visually inspect that steer
: 87 N٠m (64 Ibf٠ft) stops are in good functioning condition. Steering
system operation should be smooth and con-
trolled.
5. Install and tighten nut (21) on socket assembly
(19). Rap top of socket assembly (19) several 12. Recheck the oil level in the steering oil compart-
times with a mallet to insure taper is seated in the ment of the hydraulic oil tank. Check when en-
spindle, Tighten nut (21) to finally assure seating gine is running and again with the engine not
of the taper. Continue to tighten the nut (21) to running and only after steering system accumu-
align the slot in the nut (21) with the cotter pin lator has completely bled down.
hole in the stud (19); never loosen the nut (21) to
achieve cotter pin-hole alignment.
: 2 1/4 in
: 678 - 698 N٠m (500 - 515 Ibf٠ft)
6. Install cotter pin (20) and bend over open ends.
7. Remove the protective plugs installed in the cyl-

inders at removal, and install the fittings (3).
: 15/16 in
: 56 N٠m (41 Ibf٠ft)
W7-4-3
Figure 5 – Exploded View of Steering Cylinder
1. Tube Weldment 13. Rod Wiper 25. Flat Washer

2. Rod 14. U-Cup Seal 26. Pin Assembly
3. Piston 15. Buffer Ring Assembly 27. Tube
4. Dowel Pin 16. Wear Ring 28. Grease Fitting
5. Locking Screw 17. O-Ring 29. Snap Ring
6. Washer 18. Back-Up Ring 30. Spherical Bushing
7. Wear Ring 19. Socket Assembly 31. Hose Assembly
8. Inner Seal Ring 20. Cotter Pin 32. 45° Adapter
9. Outer Seal Ring 21. Nut 33. O-Ring
10. O-Ring 22. Bolt 34. Hose Assembly
11. Cap 23. Nut 35. 90° Adapter
12. Locking Plug 24. Screw 36. Spacer
W7-4-4
3. Remove snap ring (38) and cover (39) from the

DISASSEMBLY socket assembly (19).
4. Remove seal (42) from the threaded end of the
NOTE: Service cylinders in a clean work area on a stud (41).
clean surface. 5. Place assembly in an arbor press and apply
pressure to the threaded end of the stud (41) to
NOTE: Use lint-free cloths and filtered cleaning force the bearing (40) and stud (41) from the
fluids when handling and cleaning com- housing.
ponents.
: Arbor Press
41
42
19
40
37
38
22
39 23
Figure 6 - Socket Assembly
37. Grease Fitting 40. Bearing

38. Snap Ring 41. Stud
39. Cover 42. Seal
Figure 7 - Cylinder Base End Detail
1. Tube Weldment 29. Snap Ring
24. Screw 30. Spherical Bushing
1. Remove bolt (22) from ball stud clamp (19) by 25. Flat Washer 31. Hose Assembly
removing locknut (23).
26. Pin Assembly 32. 45° Adapter
1
: 1 /8 in 27. Tube 33. O-Ring
28. Grease Fitting 36. Spacer
2. Thread socket assembly (19) from cylinder rod
(2). It may be necessary to place a wrench on
the rod flats.
: 1½ in
W7-4-5
6. To remove bushing (30) from trailing arm, push

or gently tap outer race of ball bushing (30) from INSPECTION
trailing arm.
IMPORTANT: Clean all cylinder components, stud
: Hammer
(41), and bushing (30) in clean sol-
: Punch
vent so they can be thoroughly in-
Numbers in parentheses refer to Figure 5. spected.
7. Secure the cylinder base end clevis in a vise and
support the rod end of the cylinder tube (1). Numbers in parentheses refer to Figure 5 and 6.
8. Remove cap (11) from tube (1) with a spanner

wrench. Completely remove the cap (11) from 1. Inspect bearing race (40) for scoring and dam-
the tube (1) at this time. age to surface.
9. Slide the rod (2) and piston (3) from the tube (1). 2. Inspect stud (41) for scoring, damage, and
cracks to taper and ball surfaces.
10. Clamp the wrench flat portion of rod (2) in a vise,
(the threaded end of the rod). Support piston end 3. Inspect machined contact area of taper ball stud
of rod on a non-metallic surface. to spindle. Minimum satisfactory area of contact
between parts is 60% when inspected using
machinist blue dye. Either repair machined ta-
11. Remove the locking screw (5) and the washer (6) pered bore in spindle or replace the spindle if
from the piston (3). Pull the dowel pin (4) out of bore contact pattern is less than specification.
the piston (3). The dowel pin (4) has a tang with a Refer to Figure 12.
hole. Insert a hooked wire through the hole in the
tang and remove the dowel pin (4). NOTE: Damage to stud ball or taper surface
requires replacement of entire socket
12. Remove the piston (3) from the rod (2) by turning assembly. Magnetic particle inspect
it counterclockwise. A span wrench can be used (MPI) all socket assembly parts that
to assist in the removal of the piston (3). are accessible when disassembled.
13. Remove and discard the outer seal ring (9), inner 4. Inspect the inner and outer bearing race of
seal ring (8), and the wear ring (7) from the, out- bushing (30) for scoring or excessive move-
side diameter, outer grooves of piston (3). ment.
5. Inspect the bushing (30) lube groove for cracks.
14. Remove and discard O-ring (10) from the, inside
diameter, inner grooves of piston (3). 6. Inspect the cylinder rod (2) for wear, cracks or
damage to the chromed surfaces. Inspect rod
15. Remove and discard the locking plug (12) from for straightness; run-out greater than 1.0mm [.04
the cap (11). Remove and discard the O-ring (17) in] T.I.R. over the full length of the rod would
and the back-up ring (18) from the outside di- require replacement.
ameter of the outer groove of the cap (11). 7. Inspect tube (1) bore for scoring or deep
scratches in the sealing areas. Use Crocus
16. Slide the cap (11) off at the threaded piston (3) cloth or India Stone to remove minor scratches
end of the rod (2). or burrs. Replace if there are signs of deep
scoring or scratching.
17. Remove and discard the wear ring (16) and the
buffer ring assembly (15) from the inside diame- 8. Inspect cap (11) for signs of burrs or rust on the
ter of the inner grooves of cap (11). machined surfaces of the bores. Use Crocus
cloth or India Stone to remove minor scratches
18. Remove and discard the rod wiper ring (13) and or burrs.
the U-cup rod seal (14) from inside diameter of
the inner grooves of the cap (11).
W7-4-6
ASSEMBLY
NOTE: Service cylinders in a clean work area on a

clean surface.
NOTE: Use lint-free cloths and filtered cleaning flu-

ids when handling and cleaning compo-
nents.
NOTE: Lubricate all sliding surfaces with clean

hydraulic oil to facilitate assembly and to
prevent damage.
1. Install the U-cup seal (14) in the cap (11) with the
lips toward the inside of the tube weldment (1).
Reference Figure 8.
2. Install the rod wiper (13) in the cap (11) with

Figure 8 – Cap Seal Locations
the wiper lip pointing away from the cap (11).
Reference Figure 8.
2. Rod 15. Buffer Ring
3. Install the square rubber of buffer ring assembly 11. Cap 16. Wear Ring
(15) in the inside diameter of the inner groove of 12. Locking Plug 17. O-Ring
the cap (11). Reference Figure 8. 13. Rod Wiper 18. Back-Up Ring
14. U-Cup Seal
4. Heat the outer bronze Teflon of the buffer ring
assembly (15) in warm oil. Push the top (A,
Figure 9) of the buffer ring (15) down while
holding the sides (B, Figure 10) together. Slide
the buffer ring (15) into the inside diameter, of
the inner groove of the cap (11), refer to Figure
8 & 9. Insert the buffer ring (15) into the bore of
the cap (11) with the sealing lip as shown in
Figure 8. Release the shape per Figure 9, al-
lowing bronze Teflon ring to seat into the
groove.
5. Apply hydraulic fluid to the new wear ring (16).

Overlap one end of wear ring (16) over the
other end. Compress the wear ring (16) and
slide it into the cap (11). Expand the wear ring
(16) until the end that is overlapped slides off
and the wear ring (16) sets in the inside di-
ameter, of the inner groove of the cap (11).
6. Install a new back-up ring (18) in the outside di-

ameter of the cap (11).
7. Install a new O-ring (17) in the outside diameter

Figure 9 – Seal Installation
of the cap (11).
W7-4-7
8. Install new locking plug (12) in the cap (11). 14. Turn the piston (3) clockwise to install it on the
threaded end of the rod (2). Turn the piston until
Numbers in parentheses refer to Figure 5 and 10. it bottoms out on the rod, and then back it off un-
til the slot in the piston (3) aligns with the closest
9. Install a new O-ring (10) in the inner groove, in- slot in rod (2). Install the dowel pin (4).
side diameter of piston (3).
15. Install washer (6) and locking screw (5). Torque
10. Install a new inner seal ring (8) in the outer the locking screw (5) as follows.
groove of the piston (3), the outside diameter.
: 1/2 in
: 24 - 27 N٠m (18 - 20 Ibf٠ft)
11. Install a new outer seal ring (9) in the outer
groove of the piston (3). A piston ring compres-
16. Apply oil to the outside of the piston (3) and its
sor may be used to retain the previous shape.
assembled ring and seals. Push the piston (3)
into the tube weldment base (1). Do not dam-
12. Install a new wear ring (7) in the outer groove
age the seals or wear rings. A piece of shim
of the piston (3).
stock (37) may be used to the cover the port
hole, refer to Figure 11.
Figure 10 – Piston Assembly
2. Rod 7. Wear Ring Figure 11 – Piston Installation

3. Piston 8. Inner Seal Ring
4. Dowel Pin 9. Outer Seal Ring 1. Tube Weldment 3. Piston 37. Shim Stock
5. Locking Screw 10. O-Ring
6. Washer
17. Install cap (11) with its assembled seal, rings and
wiper into tube weldment (1). Turn cap (11)
Numbers in parentheses refer to Figure 5. clockwise until it seats in tube weldment (1). A
spanner wrench can be used to assist in this
13. Slide the cap (11) with the assembled seal, rings, step.
and wiper on the rod (2) at the piston end of the
rod only. Numbers in parentheses refer to Figure 5.
W7-4-8
18. Thread the socket assembly (19) on the rod (2)

of the assembled steering cylinder until 57mm
(2.25”) minimum thread engagement is achieved.
Install bolt (22) in socket assembly (19) and se-
cure with nut (23). Torque nut and bolt.
: 1 1/8 in
: 244 N٠m (180 Ibf٠ft)
19. Install the adapters (32 and 35, Figure 9) with

new O-rings (33) at the base and rod end of
the steering cylinder assembly.
Pressure Test
1. Mount the steering cylinder in a hydraulic

component test stand. Connect a hydraulic oil 6. Check the extended and retracted cylinder
supply to the elbow at the rod end port (the length. The stroke of the cylinder is 533 mm
port nearest the cap). Connect a drain hose to (21 in.). Reference MAINTENANCE STAN-
the elbow at the base end port. Remove ex- DARD table, this section. Cylinder assembly
cess oil from all surfaces, including wiper, end length must be between 1061.7 mm (41.80 in)
cap to tube seams and castings. minimum, and 1551.9 mm (61.10 in) maxi-
mum with socket assembly (19) installed on
hauler.
NOTE: Hydraulic oil temperature should be ap-
proximately 71 ºC (160 ºF) during test 7. Disconnect the test hoses, and drain excess
with an oil viscosity of 130 – 155 @ 30°C fluid from the cylinder ports. Retract cylinder
(100°F). rod during storage.
8. Plug the ports to prevent internal contamina-
2. Using hydraulic pressure, compress the steer- tion. Coat external exposed rod surface with
ing cylinder and hold it at 20700 kPa (207 bar, protective coating or paste wax prior to ex-
3000 psi). Check for leaks between the weld tended storage. Store cylinder in vertical posi-
joints of the casting. Using a “black light”, tion.
check for oil leaking between the cap (11) and
the rod assembly (2), the cap (11) and tube
(1), and from the end port connections. Any
evidence of leakage is reason for rejection,
with the exception of a narrow moisture ring at
the rod wiper (13) lip (no formation of a drop
permitted).
3. Repeat Step 2 with the cylinder fully extended.
4. Connect the cylinder to a 4-way valve on the
test stand so that it may be cycled between
extend and retract.
5. Cycle the steering cylinder 6 times at a pres-
sure of 345 kPa (50 psi) maximum and make
sure the cylinder does not bind or leak.
W7-4-9
Figure 12 – Socket Assembly (41, Figure 6) Taper Inspection
NOTE: The black on the steering knuckle stud

(41, Figure 6) in Figure 12 indicates
“Contact Area”, blue dye removed by
contact with the inside bore of the spin-
dle assembly. The white on the steering
knuckle stud (41, Figure 6) indicates
“Dye Remaining”, blue dye visible on
the steering knuckle stud (41, Figure 6).
W7-4-10
DESCRIPTION NEW USED NOTES

Tube (1) Inside diameter 0.2– 0.4√ 0.1– 0.4√ Polish chrome surface to specification.
surface finish down to bot- 8–16 RMS 4–16 RMS
tom of cylinder bore
Tube (1) 102.24 – 102.36 ~ Lengthwise grooves not permissible in
Bore inside diameter mm surface
(4.025 – 4.030 in)
Rod (2) 50.77 – 50.80 mm ~ Lengthwise grooves not permissible in
Outside diameter (1.999 – 2.000 in) surface
Rod (2) 0.02 – 0.4 mm 0.02 – 0.4 mm Grind to remove chrome surface. Plate
Chrome depth (0.001 – 0.0015 in) (0.001 – surface and return to “NEW” rod diame-
0.0015 in) ter. Do not extend chrome treatment be-
yond chamfer at piston end of rod
Rod (2) 0.2 – 0.4√ 0.15 – 0.4√ Polish chrome surface to specification
Surface finish 8–16 RMS 6 - 16 RMS
Rod (2) 0 – 0.25 mm 1.0 mm Total indicator run out
Straightness (0.010 in) (0.040 in) T.I.R. over full length
Pressure Test Specifications 20684 kPa 20684 kPa See Pressure Test procedure, this sec-
3000 psi 3000 psi tion.
Socket Assembly (19) ≥ 70% ≥ 60% Refer to Figure 12
Taper Bore Seat Contact
Area
Mounting Pin (26) ~ ~ Coat both pin and inside of bore with
Installation “SILVER” grade never seize compound
Mounting Pin Hardware (24, ~ ~ Use “Blue” thread lock compound
25)
Extended Storage of Cylin- ~ ~ Plug ports with air tight plugs. Store on
der rack in vertical position. Store indoors
only. Coat exposed surface of rod with
paste wax.
Cylinder length, retracted 1019.30 mm 1019.30 mm Socket assembly (19) installed with 57.2
(40.13 in) (40.13 in) mm (2.25 in) thread engagement on rod
(2). Measurement taken from centerline
of tube weldment (1) pin bore to center-
line of socket assembly (19) stud (41,
Figure 6).
Cylinder length, extended 1552.70 mm 1552.70 mm Same as note above
(61.13 in) (61.13 in)
Cylinder length, stroke 533.40 mm 533.40 mm Same as note above
(21.00 in) (21.00 in)
W7-4-11
MEMO
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W7-4-12
STEERING / Steering Pump
REMOVAL
8. Remove four flange bolts on pump outlet port
CAUTION: Steering Pump weight: 42 Kg (93 lb) remove hose from pump end.
: 9/16 in
9. Cap/plug outlet hose to prevent leakage and
1. Place rigid dump truck in “Service Position”. contamination.
10. Disconnect case drain hose from pump end.
2. Drain fluid from steering tank, 117 L [30.9 gal], : 24 mm
then re-install drain plug once fluid has com- 11. Disconnect pump control hose from pump end.
pletely drained. : 5/8 in
: 1¼ in 12. Cap/plug drain and control hoses to prevent
: 92 N٠m (68 Ibf٠ft) leakage and contamination.
• Alternative Method: Apply vacuum to steer 13. Secure lifting devise to pump.
tank inlet with sufficient force to prevent fluid 14. Remove the pump mounting bolts. Refer to
from leaking when lines are removed. Figure 1.
: ¾ in
NOTE: Run the vacuum pump continuously
while working on the hydraulic system. 15. Slide pump away from PTO assembly.
Clean all connections prior to disas-
sembly to prevent contamination in-
gression with the applied vacuum.
3. Clean the pump and attached hoses to remove
as much contamination as possible from the
work area.
4. Place drain pan underneath power take off
(PTO) and pump to capture escaping fluid.
5. Cap or plug all lines and ports as removed to
limit leakage and contamination ingression.
Mounting Bolt
Wrench Size Tightening Torque

Remarks
(in) N٠m (kgf٠m) Ibf٠ft
9
: /16 43 (4.4) 32 Outlet Hose
: 22 mm 26 (2.7) 19 Control Hose
3
: /4 87 (8.8) 64 Mounting
3
: /4 105 (11) 77 Inlet Hose
: 24 mm 45 (4.6) 33 Case Drain
Figure 1 - Steering Pump Installation
Hose
: 1¼ 92 (9.4) 68 Tank Drain
Table 1
6. Remove four flange bolts on pump inlet hose

and remove hose from pump end.
: 3/4 in
7. Cap/plug inlet hose to prevent leakage and
contamination.
W7-5-1
INSTALLATION DISASSEMBLY
Items listed in this section refer to Figure 6.

NOTE: Repair of this unit is intricate and should
not be attempted without proper tools.
1. Clean mounting flange of PTO.
2. Apply sealant to mounting face around pilot In most cases, the steering pump will not require a
diameter. See Parts Manual for sealant detail. complete rebuild as described within this section. In
general, pump disassembly is accomplished ac-
3. Using a secure lifting device, raise and slide the cording to the item number sequence as shown in
pump into the PTO. Assure the pump mounting Figure 6.
face is flush with PTO mounting face. For pump assembly, reverse the item sequence.
The item number sequence can also be used as a
4. Secure with two mounting bolts.
guide for partial disassembly and assembly. If the
: ¾ in
pump needs a complete rebuild, obtain the following
: 87 N٠m (64 Ibf٠ft)
Standard and Special service tools.
5. Clean inlet, outlet, pilot and drain line hose
ends to reduce the possibility of introducing Standard Tools:
contamination during assembly. a. Torque wrench 68 N•m (50 lbf·ft maximum) with
a short extension.
6. If the tank has not been drained, apply suffi- b. One standard socket set 5/8 in to 1 in.
cient vacuum to the hydraulic tank fill port to c. Set of hex key wrenches with a socket adaptor.
prevent hose leakage during connection of hy- d. 6 inch crescent wrench.
draulic hoses. e. Feeler gauge.
7. Connect the pump outlet hose assembly using f. Medium size screwdriver.
a new O-ring, the split flange connection and g. Rubber tip hammer
four mounting bolts. Verify O-ring seal is in h. Needle nose pliers
place when tightening. i. Vice grip pliers
: 9/16 in j. Large nut wrench that opens to 51 mm (2 in)
: 43 N٠m (32 Ibf٠ft) k. Internal Truarc pliers
l. Petroleum jelly lubricant or equivalent that is
8. Attach the pump inlet hose using a new O-ring, compatible with the system fluid.
the split flange connection and four mounting m. Cleaning solvent that is compatible with system
bolts. fluid.
: ¾ in n. Small hammer
: 106 N٠m (78 Ibf٠ft)
9. Connect pump control line. Special Tools:
: 22 mm a. Dial indicator and accessories
: 26 N٠m (19 Ibf٠ft) b. Bearing race remover tool and shim stock (Ref-
erence Figure 10.)
10. Fill the pump casing with filtered hydraulic oil c. Cylinder block spring decompression tool (Ref-
through the case drain pump port. erence Figure 12).
d. Two studs 203.20 mm x 10.92 mm - 14 dia.(8 in
NOTE: Failure to pre-fill pump case with clean long x 0.437in-14) /C1-2A thread class
hydraulic oil will result in premature e. Shaft seal assembly tool.
pump failure. f. Force indicator tool that will read up to 11 kilo-
11. Connect case drain hose assembly. grams (25 lb).
: 24 mm g. Bearing race installation tool. (Reference Figure
: 45 N٠m (33 Ibf٠ft) 8.)
h. In addition to the above tools, an arbor press is
12. Fill steering tank to the proper level with filtered required to assemble the bearings. A chain fall
hydraulic oil. is also required to handle the pump.
i. A piece of shim stock or Teflon material 203 mm
x 76 mm x 0.076 mm (8 in x 3 in x .003 in).
W7-5-2
CAUTION: Before breaking the circuit NOTE: To dislodge the valve block (28) from
connection, make sure power is off and the pump housing (74), tap on the
the system pressure is released. Lower side of the valve block (28) with a
all vertical cylinders, discharge accumula- rubber hammer. Slowly remove the
valve block (28) away from the hous-
tors and block any load that could generate
ing (74). The studs will act as a guide
pressure.
during this procedure. The valve plate
(46) may stick to the cylinder block
1. Put the pump on a clean work table that will
(54) or the valve block (28) during
support its weight.
removal of the valve block (28). Be
careful not to damage the valve plate
NOTE: If control rod (41) or bias rod (38) needs (46) or the valve block (28) during this
to be removed from the valve block (28), operation. Once the valve block (28)
secure the valve block (28) in a sturdy moves away, do not allow the valve
vise. Make sure the vise jaws do not block (28) to move back against the
damage the valve block (28) face. In- pump housing (74) because the valve
sert a hex key wrench into the stem plate (46) may get damaged.
and turn the wrench counterclockwise.
It may be necessary to use an exten- 7. Remove the valve plate (46) and the housing
sion on the wrench because the control gasket (44). Discard the housing gasket (44).
and bias stem are secured to the valve
block (28) with Loctite 270 cement. 8. Remove pins (34, 35) from the valve block (28).
Remove O-ring (42) and O-ring (39)
from the bias rod (38) and the control 9. Remove control piston (40), bias piston (36) and
rod (41). bias spring (37). Do not remove control rod (41),
O-ring (42), bias rod (38) and O-ring (39) from
2. Remove the drain plug (29) from the pump’s valve block (28) unless they are damaged.
valve block (28) and drain the fluid from the
pump into a suitable container.
NOTE: If control rod (41) or bias rod (38) needs
to be removed from the valve block (28),
3. Loosen the six screws (26 and 27) that attach
secure the valve block (28) in a sturdy
the valve block (28) to the pump housing (74).
vise. Make sure the vise jaws do not
damage the valve block (28) face. Insert
4. At this time, remove two screws (26 and 27) that
a hex key wrench into the stem and turn
are opposite each other and replace them with
the wrench counterclockwise. It may be
two studs 203 mm x 11 mm - 14 dia. (8 in long x
necessary to use an extension on the
0.437in-14) /C1-2A thread class.
wrench because the control and bias
stem are secured to the valve block (28)
5. Remove the remaining four screws (26 and 27)
with Loctite 270 thread locking com-
from the valve block (28).
pound. Remove O-ring (42) and O-ring
(39) from the bias rod (38) and the con-
6. Remove the valve block (28) from the pump
trol rod (41).
housing (74).
10. Take a blunt screwdriver and push down the
valve (32). The valve (32) is located in the valve
block face underneath seat (31). Release the
screwdriver from the valve (32) and check to see
if the valve (32) returns against the seat (31).
DO NOT remove the seat (31), valve (32) and
spring (33) from the valve block (28) if the valve
(32) returns against the seat (31).
11. Remove tail roller bearing (43) and shim (45)

from ends of the driveshaft (57).
W7-5-3
Rotating Group Removal

Numbers in parentheses refer to Figure 6. 2. Remove the four screws (48) and limiter plates
(49) so that the rotating group can be separated
1. Remove the three screws (61) that hold the from the yoke (64).
lower bearing cover (62) to the pump housing
(74). Remove lower bearing cover (62) and 3. Secure the housing (74) in a vise so the drive-
O-ring (63). Discard O-ring (63). Remove upper shaft (57) is in a horizontal position.
bearing plug (59) and O-ring (60).
2. Reach in with both hands and remove the com-

plete rotating group from the housing (74). The
complete rotating group consists of items 54
through 64.
3. Remove 4 screws (48) and limiter plates (49) to

remove the rotating group from the yoke (64).
The yoke assembly consists of 2 limiter
plates (49), 2 spacers (58) and 4 screws (48).
CAUTION: Do not remove the retaining

ring (50) from the cylinder block (54) be-
cause the spring (52) is under high com-
pression. Bodily harm may result if the re- Figure 2 – Shaft Seal Removal
taining ring is removed without adequate
caution. In most cases, the parts inside
the cylinder block (54) will not require re- 4. Remove the retaining ring (69) and shaft seal
moval. However, if the spring (52) is dam- (70). Refer to Figure 8.
aged, the parts within the cylinder block
(54) must be removed. 5. Remove the shaft (57) from housing (74) by tap-
ping on the spline end of the shaft (57) with a
Shaft and Yoke Removal rubber hammer.
6. Remove the yoke (64) from the housing (74) and
Removal of the driveshaft (57) would be necessary if wash in clean solvent.
any of the following conditions are noted:
a. Damage at the bearing surface or spline area of Bearing and Shaft Seal Removal
the driveshaft (57). Numbers in parentheses refer to Figure 6.
b. The yoke (64) binds and does not move freely
back and forth within the pump housing. 1. Remove the roller bearing (68) from the yoke
c. The yoke (64) shows evidence of heavy wear or (64). Also remove the saddle bearing (66 and
cracks. 67) and inspect for wear.
d. The yoke saddle bearings (66 and 67) surfaces 2. Inspect the roller bearings (43 and 68) for pitting
are worn, scored or defective. and cracks. Turn the roller bearings (43 and 68)
in their associated bearing races and check for
e. If the shaft seal (70) shows leakage during roughness and binding. The roller bearings (43
pumping operation. If any of the above condi- and 68) just turn freely within the bearing race
tions exist, follow the procedure noted below for with no sign of bind. If a roller bearing (43 or 68)
removal of the shaft. shows evidence of binding, wash the bearing
(43 or 68) in a clean solvent and recheck for
1. Remove the three screws (61) from the lower binding. If binding persists, replace the roller
bearing cover (62), and then remove the bearing bearing (43 or 68) and bearing race. Refer to
cover (62) and upper bearing plugs (59). Figure 10 for bearing race removal procedure.
W7-5-4
3. Remove the retaining ring (69) from housing

(74) with a pair of Truarc pliers.
DISASSEMBLING LOAD SENSING / PRES-
4. Remove the shaft seal (70) from housing (74). SURE LIMITING CONTROL
Refer to Figure 2. Numbers in parentheses refer to Figure 6.
CAUTION: Do not attempt to disassemble

or remove the load/sensing limiting control
while the engine is running. Make sure the
power is “OFF” and the hydraulic cylinders
are lowered. Discharge accumulators and
block any load whose movement could
generate pressure.
NOTE: In the following step if the pump control

is mounted at the twelve (12) o’clock
position, complete draining of the pump
will not be required. Some draining will
occur until fluid level reaches the drain
port level of the control.
1. Remove plug (18) and O-ring (19) from the

pump body (1) and drain fluid from the pump.
2. Remove the load sensing/pressure (3) control by

Figure 3 – Removal of Bearing Race from Valve loosening four screws (2) that holds the pump
Block body (1) to the valve block (28). Remove three
O-rings (24) and discard.
3. Place the pump body (1) in a vise with the jaws

resting on the outside of the pump’s body (1).
4. Remove parts (4 through 17) then remove the

plugs (20) and O-rings (21). Slide spools (22,
23) from the body. Discard all O-rings.
Figure 4 – Removal of Front Bearing Race
W7-5-5
Figure 5 – Section View of Steering Pump
1. Drive Shaft 4. Valve Block

2. Yoke 5. Bias Piston
3. Control Piston 6. Piston
W7-5-6
W7-5-7
Figure 6 – Exploded View of Steering Pump
1. Pump Body 30. O-Ring 58. Spacer

2. Screw 31. Seat 59. Upper Bearing Plug
3. Control Kit 32. Valve 60. O-Ring
4. Nut 33. Spring 61. Screw
5. Plug 34. Pin 62. Lower Bearing Cover
6. O-Ring 35. Pin 63. O-Ring
7. Compensator Adj. Screw 36. Bias Piston 64. Yoke
8. Spring 37. Bias Spring 65. Screw
9. Spring 38. Bias Rod 66. Saddle Bearing
10. Spring Guide 39. O-Ring 67. Saddle Bearing
11. Plug 40. Control Piston 68. Roller Bearing
12. O-Ring 41. Control Rod 69. Retaining Ring
13. Adjusting Screw 42. O-Ring 70. Shaft Seal
14. Spring Guide 43. Roller Bearing 71. Plug
15. Pin 44. Housing Gasket 72. O-Ring
16. Spring 45. Spacer Kit (Shim) 73. O-Ring
17. Spring Guide 46. Valve Plate 74. Pump Housing
18. Plug 47. Rotating Kit 75. *Unloading Valve
19. O-Ring 48. Screw 76. Valve
20. Plug 49. Limiter Plate 77. Plug
21. O-Ring 50. Retaining Ring 78. O-Ring
22. Spool 51. Guide 79. Plug
23. Spool 52. Spring 80. Plug
24. O-Ring 53. Guide 81. Nameplate
25. Body 54. Cylinder Block 82. Rivet
26. Screw 55. Piston Kit 83. O-Ring
27. Screw 56. Cage 84. Tube
28. Valve Block 57. Drive Shaft 85. Elbow
29. Plug
W7-5-8
INSPECTION
Load Sensing/Pressure Limiting Control

NOTE: Before inspection of parts, clean parts with

a solvent that is compatible with the sys-
tem fluid.
1. Inspect all parts for wear and/or erosion.
2. Inspect plugs (5, 11 and 20) and screws for dam-

aged threads, burrs, etc. Replace any plugs (5, 11
and 20) or screws that have damaged threads.
3. Inspect springs (9 and 16) for squareness. The

spring ends must be parallel within 76 mm (3 in).
4. Check each spool (22 and 23) for proper move- Figure 7 – Piston Subassemblies Tolerances
ment within the body subassemblies. A lubri-
cated spool (22 and 23) must move freely under 4. Inspect the cage (56) for heavy wear and cracks.
the influence of gravity. Check the spool orifice If heavy wear and/or cracks are found replace the
for restriction. To clean the spool (22 and 23) cage (56).
orifice, pour some clean solvent in a squeeze
bottle, then apply the solvent to the nose end of
the spool (22 and 23) and observe the flow of Valve Block and Associated Parts
solvent from the spool (22 and 23) orifice. Numbers in parentheses refer to Figure 6.
Rotating Group Parts 1. Inspect the valve block (28) for erosion, cracks
Numbers in parentheses refer to Figure 6. and burrs. Clean up minor burrs with an India
stone. If erosion or cracks are noted, replace the
1. Inspect valve block face (28) for wear, scratches valve block (28).
and/or erosion. If cylinder block condition is ques-
tionable, replace the entire rotating group (48 2. Inspect the roller bearing and bearing race (43) for
through 58 and item 64). nicks and pitting. Make sure the roller bearing (43)
turns freely within the bearing race. If the roller
2. Check each cylinder block bore for excessive bearing (43) needs replacing, both the roller bear-
wear. Use the piston and cage subassemblies (55 ing (43) and the bearing race must be replaced. To
and 56) for that purpose. The pistons (55) should remove the bearing race from the valve block (28),
be very close fit and slide in and out of the cylinder refer to Figure 3.
block (54) bores. NO BINDING CAN BE TOLER-
ATED. If binding occurs, clean the cylinder block 3. Inspect valve plate (46) for erosion, excessive
(54) and pistons (55). Lubricate the cylinder block wear, heavy scratches and cracks. If any of the
bores with clean fluid and try again. Even minor above conditions are found replace the value plate
contamination of the fluid may cause a piston (55) (46).
to freeze up in a cylinder bore.
4. Inspect control and bias piston parts (36 through
3. Inspect each of the nine piston and cage sub- 42) for burrs, scratches and cracks. Clean up
assemblies (55 and 56) for a maximum end play minor scratches with 500 grit paper. Remove
of 0.130 mm (0.005 in) between the piston and burrs with an India stone. The control and bias
shoe. Also check the face dimension of each pistons (36 and 40) should move freely over the
shoe. The face dimension must be within 0.030 respective control rod (41) and bias rod (38).
mm (0.001 in). See Figure 7.
W7-5-9
Yoke Parts
Numbers in parentheses refer to Figure 6. ASSEMBLY
1. Inspect yoke (64) face for wear, roughness or Assembly is generally performed in reverse order of
scoring. Check the yoke hubs and bearing sur- disassembly. Numbers in parentheses refer to Figure
faces for wear and cracks. Replace yoke (64) if 6.
defective.
Assembly Piston Pump
2. Inspect the limiter plate (49) and spacers (58) for
heavy ware and cracks. Replace if defective.
1. If the shaft seal (70) was removed, install a new
shaft seal (70) in the pump housing (74). Lubricate
3. Inspect the saddle bearing surfaces (66 and 67)
the shaft seal (70) and pump housing (74) bore
for wear, pitting and smooth operation.
with petroleum jelly before assembly. Use an arbor
press and the shaft seal (70) assembly tool. Re-
Shaft/Housing Parts fer to Figure 16. Make sure that the spring
Numbers in parentheses refer to Figure 6. member of the shaft seal (70) is face up during
assembly.
1. Inspect the driveshaft (57) for wear, stripped
splines and burrs. Remove burrs with an India 2. Install retaining ring (69) into the second groove
stone. Inspect the contact area of the roller within the pump housing (74) bore next to the shaft
bearing (68) and the shaft seal (70). Replace the seal (70). Use a pair of Truarc pliers for this opera-
driveshaft (57) if wear or scoring is greater than tion.
0.130mm (0.005 in) T.I.R. (total indicator read-
ing).
NOTE: Bearings (race and rollers) are to be treated
as one part. Therefore, when replacing
NOTE: Apply a light film of clean hydraulic fluid to bearings, install new rollers and races. Do
the new seals. This will make assembly not try to use old races over again.
easier and also provide initial lubrication of
moving parts. 3. If the roller bearing’s race (68) was removed
from the pump housing (74) install a new roller
2. Inspect the driveshaft (57) for roughness, pitting of bearing’s race (68) into the pump housing (74)
rollers and excessive end play. Replace, if defec- with an arbor press. Make sure the roller bear-
tive. If the roller bearing (68) needs to be re- ing’s race (68) is face up to accommodate the
placed, the bearing race inside the pump housing matching roller bearing. Press the roller bear-
(74) must also be replaced. To remove the bearing ing’s race until it rests at the bottom of the pump
race from the pump housing (74), refer to Figure 4. housing (74). Use the roller bearing race tool as
described in Figure 8 and shown in Figure 9. After
3. Inspect the pump housing (74) mounting flange for the roller bearing’s race (68) is installed, apply a
nicks and burrs. Remove minor nicks and burrs liberal amount of petroleum jelly to the matching
with an India stone. Also check the pump housing roller bearing. Install the roller bearing into the
(74) for damaged or stripped threads. If any thread bearing race (68).
is damaged, replace the pump housing (74).
4. Check remaining pump housing parts for exces-

sive wear, damaged threads, burrs, cracks and
erosion.
W7-5-10
Figure 8 – Bearing Race Installation Tool
Table 1 – Dimensions of Bearing Race Installation Tool
Figure 9 – Installation of the Bearing Race into the Valve Block
W7-5-11
6. If the yoke (64) was removed from the pump

housing (74), assemble the yoke (64) into the
pump housing (74) as follows:
a. Place the pump housing (74) on its side with
the saddle bearings (66 and 67) area of the
pump housing (74) face up.
b. Insert the yoke (64) into the pump housing
(74).
c. Lubricate the yoke’s (64) saddle bearing sur-
faces (66 and 67) with clean hydraulic fluid.
Orient the saddle bearings (66 and 67) to
match the bearing race. Carefully insert the
yoke (64) into the pump housing (74). DO
NOT force the yoke (64) into place if it does
not fit properly. Align the yoke’s (64) bearing
surfaces with the saddle bearings (66 and 67).
Shaft and End Play Procedure
NOTE: The following steps describes the driveshaft

(57) and end play procedure. This proce-
dure is necessary to ensure proper pump
Figure 10 - Valve Block Bearing Race Removal operation. Final drive shaft (57) end play
Tool and Shim Stock must be 0.030mm - 0.100mm (0.001in -
0.004 in).
7. Obtain a spacer kit as shown in Figure 6, item 45.

Installation of Shaft
a. If the bias rod (38) and control rod (41) parts
(36 through 39) are attached to the valve block
NOTE: Steps 5 through 6c describes the assembly (28), remove these parts.
of the drive shaft (57) and housing (74).
NOTE: The bias rod (38) and control rods (41) must
4. Apply a thin coat of clean hydraulic fluid to the lim- be bonded to the valve block (28) during
iter plate (49), spacer (58) and piston/cage subassembly, using a suitable bonding com-
assemblies (55 and 56). Align the piston/cage pound.
subassemblies (55 and 56) with the yoke (64), and
install using screws (48). b. If the pins (34 and 35) were removed, install
two new pins (34 and 35) into the valve block
5. Install the driveshaft (57) as follows: (28) and also install the pump housing gasket
a. Lubricate roller bearing (68) and driveshaft (44) against the valve block (28).
(57). Assemble the roller bearing (68) and c. Install the roller bearing (43) on the end of the
driveshaft (57). driveshaft (57), so the roller bearing (43)
b. Take a piece of shim stock or Teflon material matches up with the bearing race within the
203mm x 76mm x 0.076mm (8 in x 3 in x .003 valve block (28).
in) and roll it into a funnel shape. Insert the
Teflon material into the shaft seal (70) as
shown in Figure 11. NOTE: If the bearing race (43) was removed from
c. Install the drive shaft (57) into housing (74). the valve block (28), install a new bearing
race into the valve block (28). DO NOT re-
use bearing races with new rollers. Refer to
NOTE: The Teflon material will be forced out of the Figure 9 for instructions.
shaft seal (70) during this procedure.
W7-5-12
d. Position the valve block (28) on the two

studs and carefully slide the valve block (28)
against the pump housing (74). Make sure
the mounting pins (34 and 35) engage prop-
erly into the valve block (28).
e. Apply a small amount of hydraulic fluid to
screws (26 and 27) threads. Secure the valve
block (28) to the pump housing (74) with 6
screws (26 and 27).
: 64 - 78 N•m (47 - 57 lbf·ft)
f. Position the pump housing (74) so that the
driveshaft (57) is straight up (vertical). Push
down on the driveshaft (57) to ensure the
roller bearings (43 and 68) are seated.
g. Place a dial indicator at the end of the drive-
shaft (57). Set the dial to 0.00 in.
Figure 12 – Cylinder Block Subassembly Disassembly

Tool
j. Remove valve block (28) from the pump

housing (74). Remove roller bearing (43) from
end of shaft (57).
k. Install shim (45) to end of the shaft drive (57)
according to the measurement obtained in
step ”i”.
l. Install roller bearing (43) on the end of the
drive shaft (57) next to shim (45).
m. Repeat steps ”a” through ”j”. If 0.030mm -
0.100mm (0.001 in - 0.004 in) shaft end play is
obtained, proceed to step ”n”.
n. Remove valve block (28), roller bearing (43)
and shim (45) from the pump. Set these parts
aside for the final assembly.
Figure 11 – Shaft Installation
8. Remove the lower bearing cover (62) and upper
h. Place a pair of vise grip pliers underneath the bearing plug (59) from pump housing (74).
driveshaft’s (57) spline and lift up on the
driveshaft (57). 9. If required, assemble the rotating group (48
i. Observe the dial indicator reading to deter- through 58 and item 64) into the cylinder block
mine the amount of shaft movement. For (54). Use the spring decompression tool as shown
example, if the dial indicator needle reads in Figures 12 and 13.
1.016mm (0.040 in), a 0.910mm - 0.990mm
(0.036 in - 0.039 in) shim (45) thickness 10. Lubricate the cylinder block (54) with clean hy-
must be added to the end shaft to obtain a draulic fluid. Install the nine piston subassem-
0.030mm - 0.100mm (0.001 in - 0.004 in) blies (55) into cage (56) as shown in Figure 6.
shaft end play [1.016mm minus 0.910mm -
0.990mm equals 0.030mm - 0.100mm]
(0.040 in minus 0.036 in - 0.039 in equals
0.001 in - 0.004 in). Repeat this step 2 times to
ensure proper measurement.
W7-5-13
19. Place the valve plate (46) on the valve block (28)
face with the bronze side up.
20. Carefully assemble the valve block (28) onto the

pump housing (74). Make sure the bias spring (37)
and the bias piston (36) are in place against the
yoke (28) subassembly during the assembly pro-
cedure. If the bias spring (37) or bias piston (36)
falls off the bias rod (38), apply a liberal amount of
petroleum jelly to the bias spring (37) and bias
piston (36) to hold them in place.
21. Install 4 screws (26 and 27) and hand tighten.

Remove the two 203mm (8 in) alignment studs
from the pump housing (74) and install the re-
maining two screws (26 and 27). Cross tighten the
screws (26 and 27).
: 64 - 77 N•m (47 - 57 lbf·ft)
Figure 13 - Cylinder Block Subassembly Parts
22. Assemble O-rings (30) on plugs (29). Install the
plug (29, see * in Figure 6)
11. Feed the nine pistons (55) into the cylinder bores. : 54 - 59 N•m (40 - 44 lbf·ft)
Then install rotating parts (48 through 58 and item and torque the other plug into the valve block
64). (28).
: 15 - 16 N•m (11 - 12 lbf·ft)
12. Align the rotating parts with the yoke (64) subas- For the operating parameters, tighten the plugs
sembly. Add spacers (58) and limiter plates (49) to the following specification.
and attach them to the yoke (64) with four screws : 12.6 - 13 N•m (9.3 – 9.5 lbf·ft)
(48). Seat the yoke (64) on the saddle bearings
(66 and 67).
ASSEMBLY
13. Install the upper bearing plug (59) and lower bear-
ing cover (62) and tighten three of the screws (48)
to 7.50 - 9.50 N•m (5.50 - 7 lbf·ft). Load Sensing Control
14. Install roller bearing (43) on driveshaft (57) next to
shim (45). NOTE: Replace all seals with new ones from the
Control Seal Kit. Assembly of parts will be
15. If required, assemble the O-ring (39) on the bias in reverse item number sequence. Special
rod (38) and O-ring (42) on control rod (41). Apply assembly procedure will be noted in the
one drop of Loctite 270 thread locking compound step by step procedure.
to the bias rod (38) and control rod (41) threads.
Install the bias rod (38) and control rod (41) into 1. Assemble spools (22 and 23) into the pump body
valve block (28). Secure the stems with a hex (1) with the rounded end of the spools (22 and 23)
key wrench. pointing toward the adjustment plug end of the
load sensing control valve. The pressure com-
16. Assemble the spring (37) and piston (36) on the pensating spool (23) has five grooves versus three
bias rod (38). Install the bias piston (40) on the on the load sensing assembly (22). Assemble
control rod (41). O-rings (21) on plugs (20) and on plugs (5 and 11)
and torque the plugs.
17. Insert pins (34 and 35) into the valve block (28). : 9.80 - 10.20 N•m (7 - 7.50 lbf·ft).
18. Lubricate the valve block (28) face with a light film 2. Install all parts in order as shown in Figure 14.
of clean hydraulic fluid.
W7-5-14
3. Install plugs (5 and 11) with their O-rings over the

spring guides (8 and 10). Make sure the compen-
sator and the load sensing adjusting screws (7
and 13) are threaded through plugs (5 and 11).
Make sure the compensator adjusting screw and
the load sensing adjusting screws (7 and 13) are
lubricated.
NOTE: Final adjustment of the load sensing valve

will be accomplished after installation of MAINTENANCE
the load sensing control (3) to the piston
pumps. All the parts within the pump must be kept clean
during the overhaul process. Handle each part with
care and always work in a clean area. The close tol-
erance of the pump parts makes cleanliness very
important. Clean all the parts that are removed with
a commercial solvent that is compatible with the
system’s fluid. Compressed air may be used in the
cleaning process; however, it must be filtered to re-
move any water and any other contamination.
PRESSURE CHECKS AND ADJUSTMENT

1. Check the oil level of the steering tank. It must
be at the correct level, adjust as required.
2. Install a calibrated 34500 kPa (5000 psi) hydrau-

lic oil pressure test gauge on to the test fitting at
the RCB valve (refer to Section W7-7).
Figure 14 – Load Sensing Control Exploded View 3. Start the engine and check the pressure on the
test gauge. The oil pressure should cycle be-
tween the increasing maximum system pressure
13. Load Sensing of 19000 ± 350 kPa (2750 ± 50 psi) and de-
1. Pump Body
Adjusting Screw creasing recycle pressure of approximately
2. Screw 14. Spring Guide 15800 kPa (2450 psi).
3. Control Kit 15. Pin 4. Set the maximum system pressure to 19000 ±
4. Nut 16. Spring 350 kPa (2750 ± 50 psi) by removing the protec-
tive cap from the unloading valve (76), loosening
5. Plug 17. Spring Guide the jam nut and turning the unloading valve
6. O-Ring 18. Plug (76) adjustment screw clockwise to increase
pressure and counterclockwise to decrease
7. Compensator Adjusting pressure. After attaining the proper pressure set-
19. O-Ring
Screw ting, tighten the jam nut while holding the ad-
8. Spring Guide 20. Plug justment screw, then re-install the protective cap.
9. Spring 21. O-Ring
NOTE: Decreasing recycle pressure, of approxi-
10. Spring Guide 22. Spool mately 16900 kPa (2450 psi), is
11. Plug 23. Spool non-adjustable.
12. O-Ring 24. O-Ring
W7-5-15
Standby Pressure Adjustment
Unloading Valve Adjustment
Figure 15 – Steer Pump Adjustment
5. Warm the steering oil temperature to approxi-

mately 70 ºC (160 ºF), then re-check the unload- 8. Set the standby pressure by first stopping the
ing valve (76) maximum system pressure setting. engine. Turn the standby pressure adjustment
Adjust as required, as outlined in step 4. 1
plug in /4 turn increments clockwise to increase
the pressure setting and counterclockwise to
6. With the engine stopped and the hauler in the
decrease the pressure setting.
service position, install a calibrated 34500 kPa
(5000 psi) hydraulic oil pressure test gauge in
9. Start the engine and verify the standby pressure
the steer pump pressure port. Refer to Figure
setting is correct.
17.
7. Start the engine and watch the pressure test

NOTE: An SAE -4 O-ring boss fitting is required to
gauge. The oil pressure in the gauge will in-
tap into the steer pump pressure port. The
crease to the unloading valve maximum system
port specification is SAE -4 straight, 7/16 -20
pressure setting, then drop to the standby pres-
UNF-2B, O-ring boss.
sure setting of 1930 ± 172 kPa (280 ± 25 psi).
W7-5-16
Figure 16 – Shaft Seal Driver
Figure 17 – Steer Pump Pressure Port
W7-5-17
DESCRIPTION SPECIFICATION NOTES

Main System Pressure 19000 ± 345 kPa Oil temperature must be at operating temperature.
(Unloading Valve) (2750 ± 50 psi)
Standby Pressure 1930 ± 172 Oil temperature must be at operating temperature.
(280 ± 25 psi)
W7-5-18
STEERING / Steering Accumulator
20
Figure 1 - Service Platform
20. Steering Accumulator

5. Battery Box
6. Air Cleaner
W7-6-1
20
18
19 19
A
C
17
16
Figure 3 – RCB Valve Mounting

Figure 2 – Accumulator Mounting
16. Screw (4x) long 17. Half Flange (6x)
19. RCB Valve A. Hose 18. Hose (center) D. Screw (8x) short
20. Steering Accumulator C. Hose 19. RCB Valve
W7-6-2
SERVICE POSITION
1 2
20
CAUTION: Hydraulic oil may be hot after op-
eration. Hot hydraulic oil may spray out,
possibly causing severe burns. Be sure to
wait for oil to cool before starting work.
REMOVAL
1. Park rigid dump truck on solid level surface and

apply parking brake.
2. Stop engine and with engine in “off” position, tag

the steering wheel that rigid dump truck is “Out of
Service.”
3. Stop engine and after steering accumulator has

automatically bled down, rotate steering wheel, if
possible, to ensure all pressure is released. All oil
pressure is relieved when you can’t turn the steer-
ing wheel.
4. Block both sides of a wheel with approved chocks Figure 4 – Steering Accumulator
to prevent rigid dump truck movement.
1. Screw 20. Accumulator
5. Power wash accumulator, RCB valve and hose 2. Plate
connections removing all loose dirt and grease.
CAUTION: Lifting device with lifting capacity 7. Remove the protective cap (6C) from charge valve
of at least 226 kg (500 lb) is required. Use (3, Figure 8) and loosen outer lock nut (6B) slowly
care when handling accumulator pressure counter-clockwise to allow the Nitrogen gas pre-
vessel housing to avoid damage. charge to release. Refer to Figures 4 & 5.
11
: /16 in
6. Discharge Nitrogen pre-charge by first removing 7
: /16 in
protective plate (2) from top of accumulator (20).
Remove screws (1). Refer to Figure 4. 8. The Relief-Check-Bleed (RCB) valve (19) is se-
: ¾ in cured to the accumulator (20) via four hex head
cap screws (16) that retain the center split flange
clamp (17) and hose connection (18). Refer to
Figures 2 & 3.
9. While supporting the RCB valve (19), remove hex

head cap screws (16) and clamp halves (17) that
clamp hose (18) in place. Refer to Figure 3.
5
: /8 in
10. Remove center hose (18) and cap hose to prevent

the entry of contamination. Refer to Figure 3.
W7-6-3
11. Place plastic bag covering over the RCB valve (19) 14. Apply a slight lift force to the strap and remove the
to prevent contamination entry. torque hex nut from the upper U-bolt (22) mounting.
Refer to Figure 6.
: ¾ in
15. Use lifting device to move the accumulator (20,

Figure 6) to a work bench for disassembly.
6C
6B
6A
INSTALLATION
Figure 5 - Charge Valve
1. Remove storage caps and plugs to facilitate as-
6A. Lower Nut 6C. Cap sembly.
6B. Outer Lock Nut
2. With hoist sling placed around the accumulator
: 6A ¾ in body (20) or eyebolts (1/2 – 20 UNF-2B) threaded
: 11 - 12 N٠m (100 - 110 lbf٠in) into the end cap (2, Figure 8) with lifting chains or
11
: 6B /16 in slings, raise and position the accumulator body to
: 6 - 8 N٠m (50 - 70 lbf٠in) the mounting bracket. Refer to Figure 6.
7
: 6C /16 in
3. Lower the accumulator (20) until the mounting ring
NOTE: Tighten Lower Valve (6A) to 11 - 12 N٠m on the accumulator (20) aligns with the lower
(100 - 110 lbf٠in) and Outer Lock Nut (6B) mounting bracket. Refer to Figure 2 and 6.
to 6 - 8 N٠m (50 - 70 lbf٠in). Do not over
tighten them. Assemble and test the steer 4. Install the upper and lower U-bolts (22) and install
accumulator per Hitachi standard 35252, nuts (21) loosely because accumulator may have
72 to be rotated slightly to align the RCB valve (19).
Refer to Figure 2 and 7.
12. Remove bottom U-bolt (22), which holds accumu-
: ¾ in
lator to chassis mounting support. This U-bolt is
located just below the upper mount U-bolt. Refer to
Figures 2 & 6.
: ¾ in
13. Wrap a hoist sling around the steering accumulator

(20, Figure 6) and attach other end to overhead
hoist or crane. Another method of lifting the
steering accumulator (20, Figure 6) is to thread two
eyebolts (1/2 – 20 UNF-2B) into the end cap (5,
Figure 8) mounting holes for the protective plate (2,
Figure 8). Then attach suitable chains or slings to
the overhead hoist or crane.
CAUTION: Steer accumulator weight is 223 kg

(500 lb).
W7-6-4
O
9. Replace O-ring on the hose assembly (18) and
slide the hose flange in place under the first clamp
half (17) previously installed. Refer to Figure 3.
10. Install the second clamp half (17) and bolts (16),
20 inspect installation of O-ring for proper alignment
and torque screws (16) in a crossing pattern to
achieve even clamp force across the two clamp
halves.
5
: /8 in
21 : 72 N٠m (53 Ibf٠ft)
11. Torque the upper and lower “U”-bolt (22) nuts (21)
mounting the accumulator (20) to chassis. Refer to
Figure 2 and 6.
: ¾ in
: 87 N٠m (64 Ibf٠ft)
12. To pre-charge the steering accumulator (20), ob-

tain a sufficient amount of dry Nitrogen and accu-
mulator charge kit. Refer to SPECIAL TOOLS,
22 Section W2-4, Accumulator Inflation Kit
(E12641387).
NOTE: ENGINE MUST REMAIN OFF (0 RPM)

AND ALL OIL PRESSURE RELEASED
FROM THE ACCUMULATOR (20, FIG-
URE 6) DURING NITROGEN CHARG-
ING PROCESS. Charging tools are
Figure 6 - Accumulator Mounting – Upper available for the steering accumulator,
refer to Section W2-4, Special Tools.
20. Accumulator 22. U - Bolt
21. Nut, Upper
Center Thru Hole
5. Remove protective plastic covering from the RCB
valve (19) and cap plugs from hose.
6. Replace O-ring from center thru port on the top of

RCB valve (19) with new O-ring. Refer to Figure
7.
7. Align the RCB valve (19) so that the center port

thru hole lines up with the accumulator (20) port. 19
The accumulator (20) may have to be rotated to
achieve proper alignment. Refer to Figure 7.
8. Install one split flange half clamp (17) and two of Figure 7 - RCB Valve (19)
the long screws (16) to hold the RCB valve as-
sembly to the bottom of accumulator (20) (Do not
tighten screws down). Refer to Figure 3.
W7-6-5
13. Remove the charge valve cap (6C) and connect 20. Open charge kit bleed valve to exhaust charge
the accumulator charging kit adaptor making all the hose of pressurized gas. After removing connec-
pre-charge connections. Bleed the dry Nitrogen tions to the Nitrogen gas supply, replace the
charge hose of trapped air using a small volume charge valve cap. Refer to Figure 5.
7
burst of low pressure Nitrogen gas flow (690 kPa, : /16 in
100 psi) while tightening charge kit hose connec-
tion to charge valve. 21. Position protective plate (2) over top of charge
valve, install two bolts (1) and tighten. Refer to
14. Loosen the charge valve swivel nut (6B, Figure 5) Figure 4.
to allow dry Nitrogen to now flow into the accumu- : ¾ in
lator (20) and precharge the accumulator. : 87 N٠m (64 Ibf٠ft)
11
: /16 in
15. Check for Nitrogen gas leaks using a pump spray 22. Start hauler and allow engine to idle while in-
bottle with detergent and water mixture. Soak specting for hydraulic oil leaks at RCB valve (19,
area around charge valve (3, Figure 8) and joint Figure 2) and related connections.
between end cap (5, Figure 8) and hose housing
(15). Visually inspect that bubbles do not form
and grow in size which is indication of a Nitrogen
gas leak.
16. Increase dry Nitrogen pressure tank valve setting

until dry Nitrogen flow stops and equalizes at sup-
ply bottle pressure indicated on calibrated gauge.
Allow two minutes dwell time for gas pressure to
stabilize between pressure vessels.
17. Shut off the Nitrogen gas supply valve at gas stor-
age bottle. Observe and record the Nitrogen gas
pressure reading on charge kit gauge. Allow dwell
time of 10 minutes and again check gauge reading.
Gauge reading should equal first reading. If read-
ing has changed (decrease), gas leakage has oc-
curred. Correct any cause of gas leakage before
proceeding to next step.
18. Bleed down excess Nitrogen gas pressure by

opening bleed down valve on side of charge kit
manifold. (Nitrogen bottle supply valve is now
closed). Stop bleeding off Nitrogen gas when
gauge reading is at correct value. The trapped
volume of gas is now at the correct set pressure.
Refer to “Precharge Specifications” in Maintenance
Standard for the correct dry nitrogen precharge
pressure.
19. After pre-charging the accumulator (20) and before

disconnecting the hose connection to the dry Ni-
trogen source, tighten the charge swivel nut (6B)
trapping the gas charge inside the accumulator.
11
: /16 in
: 6 - 8 N٠m (50 - 70 Ibf٠in)
W7-6-6
10
11 9
15 8 12
7 13
14
4
B
1
2 3
6
Figure 8 - Section View of Accumulator
1. Bolt (Not Shown) 7. Back-Up Ring 13. Wear Ring

2. Protective Plate 8. O-Ring 14. Piston
3. Charge Valve 9. Seal Assembly 15. Housing
4. O-Ring 10. Quad Ring A. Hydraulic Oil Port
5. End Cap 11. Seal B. Hydraulic Oil
6. Friction Plug 12. Square Ring C. Dry Nitrogen
DISASSEMBLY

erwise noted.
1. Place steer accumulator in a hydraulic work sta- 3. Insert the spanner wrench in the removal holes in
tion cylinder vise or secure it on a clean work- the top of the end cap (5) and remove the end cap
bench to prevent it from moving. (5). If a spanner wrench is not available, insert
bolts in the tapped holes in the top of the end cap
CAUTION: Steer accumulator weight is 223 (5), and using a pry bar as a lever, turn the pry bar
kg (500 lb). counter-clockwise to remove the end cap (5).
2. Remove the protective plate (2) over charge valve 4. Remove and discard the friction plug (6), back-up
(3). ring (7), and the O-ring (8).
3
: /4 in
1
5. Install a lifting eye with a ( /2 – 13UNC-2B)
threaded end into the tapped hole in the counter-
CAUTION: Slowly open charge valve upper sunk end of the piston (14). Pull the lifting eye
charge swivel nut (6B Figure 5) to release and piston (14) out of the housing (15).
and vent Nitrogen gas charge. Remove
charge valve (3) from accumulator hose 6. Remove and discard the wear rings (13) and seal
housing (15) before proceeding. assembly (9) from the piston (14).
W7-6-7
ASSEMBLY 10. With housing (15) standing vertical lower piston

(14) into housing (15) with the seal assembly (9)
Numbers in parentheses refer to Figure 8, unless oth- facing outwards, towards the charge valve (3).
1
erwise noted. Thread a long cap screw ( /2 – 13 UNC-2B) tem-
porarily into piston to ease assembly.
1. Open seal kit for this accumulator (20, Figure 2)
and familiarize yourself with the various seal com- 11. Apply a light coat of clean hydraulic oil to back-up
ponents. Refer to Figure 8 thru 10. ring (7) and O-ring (8) before installing them over
the unthreaded end of the end cap (5).
2. Place Items (10) and (11) of seal assembly (9) in
heated oil 65˚C (150 ˚F) for ten minutes, to make NOTE: The concave side of the back-up ring (7)
them flexible. faces O-ring (8).
3. Install the square ring (12) in groove around pis-

ton (14). Refer to Figure 9 and 10. Detail in Figure 10.
CAUTION: Remove outer Teflon seal (11)

with quad ring (10) from heated oil. With
your hands or a blunt tool (no sharp edges)
carefully work seal set over taper end of
B
piston (14) and slide in groove over top of
energizer square ring (12).
4. While seal set is still warm, resize to bore diame-

ter of accumulator using sizing ring or ring com-
pressor.
Figure 9 – Section View of Accumulator
5. Allow to cool to ambient temperature before re-
moving from sizing equipment.
6. Place black nylon wear rings (13, 2pc) into their

10
grooves on the piston (14), as shown in Figure 8.
11
7. Inspect the piston assembly (14) and make certain 12
quad ring (10) has not twisted or been damaged.
8. Wipe inside bore of housing (15) with clean lint

free cloth moistened with filtered hydraulic fluid.
Wipe inside of bore until cloth, when removed, is
clean when inspected.
9. Apply a light coat of clean hydraulic oil to inside

diameter of housing (15) (including the lead-in ta-
per) and also to piston seal assembly (9). Figure 10 - Detail of Seal Assembly (9)
10 . Quad Ring 12. Square Ring
CAUTION: Exercise extreme care when in- 11 . Seal
stalling piston (14) assembly in housing (15)
and when passing wear ring (13) and seal 12. Insert a new friction plug (6) into the end cap (5).
assembly (9) past the entrance threads on The friction plug (6) assists with locking the end
the housing (15). Contact with threads may cap (5) in the housing (15) and will resist moisture
damage sealing components. from wicking down the threaded connection.
W7-6-8
13. Apply grease to threads of cap (5) using Molykote

#111 (Dow Corning Corp.) or Mobiltemp #SHC32 INSPECTION
(Mobile Oil Corp.)
14. Install the end cap (5) in the top of the hose hous- erwise noted.
ing (15). Carefully turn the end cap (5) clockwise
until the threads bottom out firmly. No specific 1. Wash parts clean removing all oil and carbon de-
torque is specified because the friction plug will posits before inspection.
increase turning torque significantly during final
assembly. Make sure cap (5) is completely seated. 2. Inspect weld area of base end cap to housing (15)
using non destructive test method. PT or MPI in-
15. Install new O-ring on the charge valve (3) and inspect (Penetrant Test or Magnetic Particle In-
stall the charge valve (3) into the port in end cap spect) 100 % of weld joint between housing (15)
(5). Tighten the lower nut (6A) of charge valve. and hydraulic oil port (A).
Refer to Figure 5.
3
: /4 in 3. Insert a high intensity light into the housing (15)
: 11 - 12 N٠m (100 - 110 Ibf٠in) and look for any ridges, nicks, or scratches. Re-
move any imperfection with a stone and re-clean.
16. Lightly seat upper charge swivel nut (6B Figure 3)
on charge valve (3) clockwise to store accumula- 4. Clean all corrosion and dirt from end cap threads
tor until the proper dry Nitrogen pre-charge can be (5) using rotating wire brush or glass bead proc-
added. Install cap (6C) on end of charge valve. ess. Repeat same process to mating threads
7
: /16 in leading in to housing (15).
11
: /16 in
: 6 - 8 N٠m (50 - 70 Ibf٠in) 5. Inspect the external surface of accumulator
housing for damage. Reject any housing (15) that
17. Install charge valve protective plate (2, Figure 4) has been dented, deeply scored, or damaged.
using screws (1, Figure 4). Reject any tubing housing that has been altered,
3
: /4 in modified or welded upon. Replace any component
: 87 N٠m (64 Ibf·ft) that cannot be repaired.
18. Plug accumulator discharge port (A).
W7-6-9
Housing (15) 0.2 – 0.8√ 0.2 – 0.8√
Inside diameter surface finish from (8–16 RMS) (8–16 RMS)
lead in chamfer to bottom of bore
Housing (15) 204.2–204.3 mm 204.4 mm Maximum oversize
Bore inside diameter (8.040–8.045 in) (8.047 in)
Dry Nitrogen Pre-charge Specifications 8275 kPa 8275 kPa Dry filtered Nitrogen gas only
(1000 psi) (1000 psi)
Bench Test Accumulator – STEP 1 19000 kPa 19000 kPa Step 1. Pressurize (C) cavity
Hydraulic Component Flow Test Bench 2750 psi 2750 psi with (160°F) hydraulic fluid to
Hold 5 min Hold 5 min 2500 psi. Check for fluid leak-
age at open port (A). Dwell for 5
minutes with no leakage de-
tected.
Bench Test Accumulator – STEP 2 19000 kPa 19000 kPa Step 2. Pressurize port (A)
Hydraulic Component Flow Test Bench 2750 psi 2750 psi SLOWLY with hydraulic fluid,
Hold 5 min Hold 5 min exhaust fluid left from Step 1 out
of cavity (C). Dwell for 5 minutes
with no leakage detected.
Extended Storage of Accumulator ~ ~ Drain all residual fluid from ac-
cumulator. Cap/plug ports air
tight. Store inside on rack in ver-
tical position as mounted on
hauler. DO NOT STORE AC-
CUMULATOR WITH NITRO-
GEN GAS CHARGE IN-
STALLED.
W7-6-10
STEERING / Relief Check Bleed Valve
REMOVAL
1. Park rigid dump truck on a level solid surface

and place in “Service Position” Refer to Section
W2-1.
2. Apply wheel blocks to both sides of the tire to
prevent vehicle movement.
zero pressure.
4. Turn the steering wheel left and right as far as it
will travel to assure that all oil pressure within
the system has been released. All oil pressure
is relieved when you can’t turn the steering
Figure 1 - Pressure Test Kit E12979919
wheel.

can penetrate the skin and eyes, causing CAUTION: Contamination can interfere with
serious injury. proper operation of the steering and brake
systems.
Hot hydraulic oil may spray out, possibly
causing severe burns. Tightening Torque
Wrench Size
Remarks
(in)
Eye Protection is required. N٠m (kgf٠m) Ibf٠ft
5. Tag all the electrical and hydraulic connections : 5/8 72 (7.3) 53 Flange
to facilitate installation. 15
: /16 17 (1.7) 150 lbf٠in Switch
6. Secure one end of a test hose, (see pressure
3
test kit Figure 1), to a fluid holding container. : /4 32 (3.3) 24 Fitting
7. Carefully connect the other end of the test hose : 22mm 26 (2.7) 19 Hose
to the test fitting (3, Figure 4) on the Re- 3
lief-Check-Bleed (RCB) valve to assure that all : /4 6.8 (0.7) 60 lbf٠in Coil Nuts
pressure has been released from the system. 7
: /8 48 (4.9) 35 Cartridge
8. Clean the steering accumulator and the area :1 34 (3.5) 25 Cartridge
around the RCB valve to remove dirt and dust.
1
: 1 /2 68 (6.9) 50 Cartridge
: 3/16 4.5 (0.5) 40 lbf٠in Plug

3
: /8 23 (2.4) 17 Plug
Table 1
W7-7-1

10. Remove the brake apply hose (6) and fitting
(5).
: 3/4 in
Steer accumulator
11. Remove pump control hose (8) and fitting (7).
: 3/4 in
12. Remove the parking brake hose (10) and fit-
ting (9).
1 : 3/4 in
2
3
Figure 2 - RCB Valve Electrical
1. Brake/Steer Pressure 3. Bleed Down Solenoid

Transducer Valve 7
2. Parking Brake Pres- 4. Park Brake Solenoid
sure Switch Valve 9
NOTE: Loose hoses should be plugged to re-

duce leakage issues and prevent con-
tamination ingression. 5
6
Numbers in parentheses refer to Figure 2. RCB

8
9. Disconnect the electrical connectors at; the ac-
cumulator bleed down solenoid (3), the parking 10
brake solenoid (4), the brake/steering pressure
transducer (1), and the parking brake pressure
switch (2). Figure 3 - Control & Brake Connections
5. Adapter 8. Pump Control Hose

6. Brake Apply Hose 9. Adapter
7. Elbow 10. Parking Brake Hose
W7-7-2
7
9
10
Figure 4 - RCB Valve Lines
1. Steer Accumulator 6. Hose, Return

2. Relief Check Bleed Valve 7. Flange (6x)
3. Test Fitting 8. O-Ring (3x)
4. Hose, Steering Valve 9. Screw, Short (8x)
5. Hose, Pump 10. Screw, Long (4x)
W7-7-3

6. Install pump control hose (8) and fitting (7).
13. Remove hoses (5) and (6) by removing the : ¾ in Fitting
flange bolts (9) and flanges (7). Remove and : 32 N٠m (24 Ibf٠ft) Fitting
discard O-Ring (8). : 22 mm Hose
: 5/8 in : 26 N٠m (19 Ibf٠ft) Hose
14. Disconnect the steering hose (4) by removing
the flange bolts (10) and flanges (7). The RCB 7. Install the brake apply hose (6) and fitting (5).
valve (2) is connected to the Accumulator by : ¾ in Fitting
these flange bolts (10), so it will drop when dis- : 32 N٠m (24 Ibf٠ft) Fitting
connected. Remove and discard O-Ring (8). : 22 mm Hose
: 5/8 in : 26 N٠m (19 Ibf٠ft) Hose
15. Carefully remove the RCB valve from the rigid CAUTION: Verify that all personnel have
dump truck and move to a clean work area for moved away from the unit before proceed-
disassembly. Cap/plug all open hose connec- ing.
tions and ports on chassis and steer accumula-
tor (1) to control contamination. CAUTION: TEST PORTS HOLD HIGH
PRESSURE HYDRAULIC FLUID
INSTALLATION Escaping fluid under pressure can pene-
Numbers in parentheses refer to Figure 4. trate the skin and eyes, causing serious in-
jury.
1. Install new O-rings (8) in the valve grooves and
on the hose ends (4), (5), and (6). Using two CAUTION: Hydraulic oil may be hot after
screws (10) and one flange half (7), loosely bolt operation. Hot hydraulic oil may spurt out,
the RCB valve (2) to the steering accumulator possibly causing severe burns.
(1). The screws (10) should be loose enough to
slide a hose under the flange lip (7). Assure that open end of test hose is
: 5/8 in secured in holding container.
: Loose
2. Slide steering hose (4) under the flange half (7),
and install the remaining flange half (7) and re- 8. Assure that area around unit is clear, and start
maining two screws (10) to secure the hose and the engine.
RCB valve (2) to the steering accumulator (1).
: 5/8 in 9. With the engine running, secure one end of a
: 72 N٠m (53 Ibf٠ft) test hose, (see pressure test kit, Figure 1), into a
fluid holding container.
3. Loosely connect one flange half (7) for each port
using screws (9) on the tank and inlet ports of 10. Remove the cap from the test fitting (3), (see
RCB valve. Figure 4), of the RCB valve (2) and slowly
: 5/8 in
thread the free end of the test hose onto the test
: Loose
port (3).
4. Connect tank hoses (5) and (6) with the remain-
ing flange half (7) and screws (9). NOTE: The further the test hose fitting is
: 5/8 in threaded onto the test port (3), the
: 72 N٠m (53 Ibf٠ft) more flow will be expelled from the test
hose. Attach the test hose slowly.
5. Install the parking brake hose (10) and fitting (9). 11. Allow fluid to flow into the container until there is
: ¾ in Fitting no evidence of air in the line.
: 32 N٠m (24 Ibf·ft) Fitting
: 22 mm Hose 12. Remove the hose and replace the test port cap
: 26 N٠m (19 Ibf٠ft) Hose to the test fitting (3).
W7-7-4
13. Remove the cap from the brake valve test fit-
ting (1, Figure 5), and thread on one end of
the test hose into a container. Thread the
other end of the test hose onto the test fitting
(1) until fluid starts to flow into the container
and continue until there is no evidence of air in
the line.
Figure 5 - Brake Valve
14. Remove the hose and replace the test port

cap on to the test fitting (1, Figure 5).
W7-7-5
Figure 6 - RCB Valve Exploded View
ITEM PART NAME ITEM PART NAME

1 Manifold 7.2 O-ring
2 O-ring 7.3 Backup Ring
3 Cartridge, Bleed Down 7.4 Kit, seal
3.1 O-ring 8 Cartridge, Relief
3.2 Backup Ring 8.1 O-ring
3.3 O-ring 8.2 O-ring
3.4 Kit, seal 8.3 Backup Ring
4 Cartridge, Park Brake 8.4 Kit, seal
4.1 O-ring 9 Fuse, Velocity
4.2 Backup Ring 9.1 O-ring
4.3 O-ring 9.2 O-ring
4.4 Backup Ring 9.3 Backup Ring
4.5 O-ring 9.4 Backup Ring
4.6 Kit, seal 9.5 Kit, seal
5 Coil, Bleed Down 10 Plug
6 Coil, Park Brake 11 O-ring
7 Cartridge, Check 12 Plug
7.1 O-ring 13 O-ring
W7-7-6
DISASSEMBLY
INSPECTION
Numbers in parentheses refer to figure 6.
1. Inspect manifold (1) for obvious signs of dam-
NOTE: Service valve in a clean work area on a age, cracking, or deformity.
clean surface.
NOTE: Use lint-free cloths and filtered cleaning 2. Inspect cartridge ports and O-ring grooves in
fluids when handling and cleaning com- manifold (1) for gouges or scratches.
ponents.
Numbers in parentheses refer to Figure 6. ASSEMBLY
1. Remove coil (5) and cartridge (3). Replace all CAUTION: Contamination can cause im-
external cartridge o-rings and backup rings. Coil proper valve operation.
seals should be reused.
: 1 in
2. Remove Coil (6) and cartridge (4). Replace all clean surface.
external cartridge O-rings and backup rings. Coil
seals should be reused. NOTE: Use lint-free cloths and filtered cleaning
: 7/8 in fluids when handling and cleaning com-
ponents.
3. Remove cartridge (7). Replace all external car-
tridge O-rings and backup rings. Numbers in parentheses refer to Figure 2.
: 1 ½ in
1. Install parking brake switch (2) and O-ring.
4. Remove cartridge (8). Replace all external car- : 15/16 in
tridge O-rings and backup rings. : 17 N⋅m (150 Ibf⋅in)
: 1 in
2. Install brake/steer pressure transducer (1) and
5. Remove velocity fuse (9). Replace all external O-ring.
cartridge O-rings and backup rings.
: 7/8 in : 27 mm
: 4.5 N٠m (40 Ibf٠in)
6. Remove plug (10). Replace O-ring (13). Numbers in parentheses refer to Figure 6.
: 3/8 in
7. Remove plugs (12). Replace O-rings (11). 3. Install coil (5) and cartridge (3). Replace all ex-
: 3/16 in ternal cartridge O-rings and backup rings. Coil
seals should be reused.
: 1 in
Numbers in parentheses refer to Figure 2. : 34 N٠m (25 Ibf٠ft)
: ¾ in
8. Remove parking brake switch (2) and discard : 6.8 N٠m (60 Ibf٠in)
O-ring.
: 15/16 in 4. Install Coil (6) and cartridge (4). Replace all ex-
ternal cartridge O-rings and backup rings. Coil
9. Remove brake/steer pressure transducer (1) seals should be reused.
and discard O-ring. : 7/8 in
: 27 mm : 27 N٠m (19 Ibf٠ft)
: ¾ in
: 6.8 N٠m (60 Ibf٠in)
W7-7-7
5. Install cartridge (7). Replace all external car-

tridge O-rings and backup rings.
: 1½ in
: 68 N٠m (50 Ibf٠ft)
6. Install cartridge (8). Replace all external car-

: 1 in
: 34 N٠m (25 Ibf٠ft)
7. Install velocity fuse (9). Replace all external car-

: 7/8 in
: 48 N٠m (35 Ibf٠ft)
8. Install plug (10) and O-ring (13).

: 3/8 in
: 23 N٠m (17 Ibf٠ft)
9. Install plugs (12) and O-rings (11).

: 3/16 in
: 4.5 N٠m (40 Ibf٠in)
W7-7-8
PRESSURE ADJUSTMENT
Numbers in parentheses refer to Figures 7 and 8,

1. Check the oil level of the steering tank. It

must be at the correct level, adjust as re- 5. If the system pressure increases past the
quired. pressure specification of the RCB relief car-
tridge (1), 22070 ± 173 kPa (3200 ± 25 psi),
loosen the adjustment screw jam nut on the
2. Install a calibrated 35000 kPa (5000 psi) hy- RCB relief cartridge (1) and turn the adjust-
draulic oil pressure test gauge onto the test fit- ment screw counter-clockwise until the oil
ting (3) at the RCB valve. pressure in the test gauge lowers to approxi-
mately 20700 kPa (3000 psi), then increase
3. Start the engine and check the pressure on the the pressure setting by turning the adjustment
gauge. The oil pressure should increase to a screw clockwise to the pressure setting of the
maximum 19000 kPa (2750 psi), the pressure RCB relief cartridge (1), 22070 ± 173 kPa
setting of the unloading valve (2) on the steer (3200 ± 25 psi).
pump. : 3/4 in
: 3/8 in
NOTE: Steering oil temperature should be
warmed to approximately 70°C (160°F) when 6. While holding the RCB relief cartridge (1) ad-
checking/adjusting relief cartridges. justment screw, tighten the jam nut.
4. Remove the protective cap from the unloading 7. Shutdown the engine.
valve (2) on the steering pump. Loosen the
unloading valve (2) adjustment screw jam nut. 8. Turn the unloading valve (2) adjustment screw
While watching the pressure test gauge, counter-clockwise the amount of turns used to
slowly turn the adjustment screw clockwise to increase the system pressure in step 4.
increase the maximum pressure setting of the
system (take notice of the amount of turns
made to the unloading valve (2) adjustment 9. Start the engine and watch the oil pressure in
screw). Increase the system pressure to the the test gauge. Using the unloading valve (2)
pressure setting of the RCB valve relief car- adjustment screw, increase or decrease the
tridge, 22070 ± 173 kPa (3200 ± 25 psi). maximum system pressure to the unloading
: 3/4 in valve (2) maximum system pressure setting,
: 3/8 in 19000 ± 173 kPa (2750 ± 25 psi).
: 3/4 in
: 3/8 in
10. While holding the unloading valve (2) adjust-

ment screw, tighten the jam nut then replace
and tighten the protective cap.
11. Shutdown the engine. Remove the pressure

test gauge and install the protective cap to the
test fitting (3).
W7-7-9
Figure 7 – RCB Relief Cartridge
1. RCB Relief Cartridge

3. Test Fitting
Figure 8 – Unloading Valve (2)
W7-7-10
MAINTENANCE SPECIFICATION
22070 ± 173 kPa (3200 ± 25 psi)

RCB Valve Relief Cartridge (1, Figure 7)
NOTE: at operating temperature
W7-7-11
MEMO
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W7-7-12
SECTION 8
FRAME SUSPENSION AND WHEEL
—CONTENTS—
Group 1 Frame General

Group 3 Rear Suspension
Removal ......................................................W8-3-3
Inspection .................................................... W8-1-2
Installation ...................................................W8-3-5
Cleaning ......................................................W8-1-2
Disassembly ................................................W8-3-5
Frame Reinforcement.................................. W8-1-2
Inspection ....................................................W8-3-7
Straightening ............................................... W8-1-2
Assembly .....................................................W8-3-8
Welding........................................................ W8-1-3
Liquid Fill .....................................................W8-3-8
Painting........................................................W8-1-3
Gas Inflation ..............................................W8-3-12
Trunnion Cap............................................... W8-1-3
Servicing Procedure ..................................W8-3-14
Electrical Disconnects Before Welding
Storage of Struts ........................................W8-3-14
on the Rigid Dump Truck.................... W8-1-4
Maintenance Standard ..............................W8-3-15
Maintenance Standard ................................. W8-1-8
Memo ........................................................W8-3-16
Group 2 Front Suspension

Group 4 Front Wheel
Removal ......................................................W8-4-2
Removal ....................................................... W8-2-3
Installation ...................................................W8-4-3
Installation ................................................... W8-2-5
Disassembly ................................................W8-4-5
Disassembly ..............................................W8-2-10
Inspection ....................................................W8-4-5
Inspection ..................................................W8-2-10
Assembly .....................................................W8-4-6
Assembly ................................................... W8-2-11
Lubricating Front Wheel Bearings...............W8-4-6
Maintenance Standard ..............................W8-2-13
Maintenance Standard ................................W8-4-7
Memo ........................................................W8-2-14
Memo ..........................................................W8-4-8
W8-0
<BLANK>
W8-0
Group 5 Rear Wheel Group 6 Tires/Rims/Inflation
Removal ......................................................W8-5-2 Service Position...........................................W8-6-1
Installation ................................................... W8-5-4 Removal
Disassembly................................................ W8-5-4 • Front Rim and Tire ....................W8-6-2
Inspection.................................................... W8-5-4 • Rear Rim and Tire.....................W8-6-5
Assembly..................................................... W8-5-5 Installation ...................................................W8-6-6
Bearing Adjustment .....................................W8-5-6 Disassembly ................................................W8-6-7
Toric Face Seal Inspection .......................... W8-5-8 Inspection ....................................................W8-6-7
Toric Face Seal Installation ......................... W8-5-9 Assembly .....................................................W8-6-8
Memo ........................................................W8-5-12 Maintenance Standard ................................W8-6-9
Inflation ........................................................W8-6-9
Memo ........................................................W8-6-10
W8-0
<BLANK>
W8-0
FRAME SUSPENSION AND WHEEL / Frame General
6
12
9
4
00
3
14
11
2
13
15
5
7
10
16
1
Figure 1 – Frame
1. Radiator Mounting 6. Body Pivots (2x) 11. Tow Hooks (2x)

Bracket
2. Bumper 7. Hoist Cylinder Mtg. 12. Lower Fuel Tank Mount

Shaft
3. Engine Support Lugs- 8. Hydraulic Tank Support 13. Lower Hydraulic Tank
Front (2x) (not shown) Mount
4. Cab Support (High Arch) 9. Fuel Tank Support 14. Engine Support-Rear (2x)
5. Transmission Support 10. Transmission Guard 15. Transmission Support

Lugs-Front (2x) Bracket Lugs-rear (4x)
16. Trunnion Caps (2x)
W8-1-1
SERVICE POSITION Reclaim or Dispose of Oil Properly

FRAME REINFORCEMENT
No specific set rules apply to shape, length, or kind of
INSPECTION reinforcement to be installed on frames that have been
damaged. In the event that the frame has been dam-
Inspect the frame for cracks approximately every 1000
aged, contact your nearest HTM dealer for the correct
hours of operation. Perform the inspection in accor-
method for reinforcing the damaged frame.
dance with the criteria listed in steps
1 through 6.
1. Obtain a copy of HITACHI REPAIR WELDING

STRAIGHTENING
MANUAL, K0-111-00.
If the frame is not badly sprung or twisted, use hydrau-
2. Clean the entire frame. The preferred method is to lic straightening and aligning equipment to straighten
use pressurized steam, if available. the frame without dismantling the unit. However, if the
frame is severely damaged, it will be necessary to
3. Consult HITACHI REPAIR WELDING MANUAL,
disassemble the unit in order to repair or replace the
K0-111-00, and refer to Section 05 for inspection of
frame. Remove the component parts in large subas-
cracks. Visually inspect all welds that are reasona-
semblies if possible, such as: the radiator assembly,
bly accessible.
engine assembly, cab assembly, etc.
4. Magnetic Particle (MT) inspect or Dye Penetrant All straightening operations should be performed with-
(PT) inspect any welds where cracking is sus- out application of heat if possible. If heat has to be
pected. Where cracks are found, record the specific applied, DO NOT heat surface beyond a dull cherry
location(s), length, and depth of these cracks. red color. Excessive heat will result in serious weaken-
ing of the frame by decreasing the tensile strength of
5. Photograph crack(s) before, during, and after re-
the steel. If it is necessary to apply heat, use an oxya-
pairs. Send the photographs and the records from
cetylene torch to heat the entire area. Apply a neutral
step 4, above, to HTM Service Personnel if assis-
flame until the metal reaches a uniform dull cherry red
tance is required.
color. Protect the heated area of the frame from cold
6. Contact HTM service personnel for availability of drafts to prevent sudden cooling of the metal. If frame
specific repair procedures. Consult HITACHI RE- parts cannot be straightened to correct the bent,
PAIR WELDING MANUAL K0-111-00 for general twisted or buckled condition, the part or parts must be
repair procedures. replaced.
CLEANING
Clean the entire frame periodically and before each
frame inspection. The preferred method is to use pres-
surized steam. Care must be taken to direct high pres-
sure wash stream away from delicate materials. Use
care not to damage safety decals, radiator cooling fins,
lights, window glass, electrical harnesses etc. Direct
large pieces of caked mud and stone away from rigid
dump truck with pressure wash stream to avoid dam-
age to hauler. Material rinsed from hauler may be con-
sidered hazardous. Control rinse water run off follow-
ing local environmental regulations.
W8-1-2
WELDING
Refer to information in OPERATORS MANUAL,
MAINTENANCE section before doing any welding on
your rigid dump truck. Also refer to ELECTRICAL
DISCONNECTS BEFORE WELDING ON THE RIGID
DUMP TRUCK later in this section.
CAUTION: Prior to welding on rigid dump

truck review Precautions for Welding, Cut-
ting, and Grinding in the SAFETY section of
this manual. Refer to Section W2-3.
NOTE: Reference Hitachi Repair Welding Manual

K0-111-00 and HTM Service Bulletin
7100-18 for a list of service bulletins re-
leased that detail repair procedures for
specific areas on the rigid dump truck.
PAINTING
A check of the condition of the paint should be made
approximately twice a year. The frame should be re-
painted if necessary. Painting is required to control
corrosion, make the frame highly visible and for gen-
eral cosmetic reasons. The paint process should in-
clude good preparation prior to painting (clean, sand-
blast, clean, masking) followed by a base coat of Syn-
thetic Red Oxide Primer; and multiple top coats of a
high quality Synthetic Enamel.
TRUNNION CAP
If Trunnion caps (16, Figure 1) show significant wear,
more than 3.1 mm (0.125 in), reclaim surface by using
an E10018 electrode to build up worn away material
and then machine profile to the original specification.
Refer to Section W7-1 FRONT AXLE.
W8-1-3
ELECTRICAL DISCONNECTS BEFORE

WELDING ON THE RIGID DUMP TRUCK Disconnect Disconnect
Disconnect the following before performing any weld-
ing operation on the rigid dump truck. Each on board
controller should be isolated from chassis wiring and
rigid dump truck electrical ground before performing
any method of welding on the hauler.
1. Turn the battery disconnect switch to the OFF po-

OM21086
sition.
Figure 2 - Battery Cables
2. Disconnect Battery Cables, refer to Figure 2.
3. At the Central Control Unit (CCU) disconnect all

connections labeled 2A, 2B, 1A, 1B, 1C, 1D, 3B,
and 3A shown in Figures 3, 6 and 7.
OM21196
Figure 3 - Central Control Unit
4. At the CEC2 Transmission Control Unit (TCU),

disconnect all connections labeled S (Black), T
(Blue), and V (Gray) as shown in Figures 4, 8 and
9.
EL20396
Figure 4 – CECII TCU
W8-1-4
Engine Compartment
5. At the engine’s Electronic Control Module (ECM),

disconnect the connectors labeled ENG-1, ENG-2
and J1939 as shown in Figures 5 and 10.
OM21261
Figure 5 – Engine ECM Disconnect
6. The welding machine’s ground cable must be in

close proximity to the welding location.
7. When welding is completed, reconnect all cables

and wires as illustrated in Figures 2 through 5.
Turn the battery disconnect switch to the ON posi-
tion.
W8-1-5
CCU
Figure 6 – Location of CCU (Central Control Unit) in rear of cab
Figure 7 – Detailed View of CCU
W8-1-6
TCU
Figure 8 – Location of TCU on Unit
Figure 9 – Detailed View of TCU
W8-1-7
ECU
Figure 10 – Location of ECU harness ports on Engine
DESCRIPTION LIMIT
Frame Inspect frame every 1000 hours of use.
Frame Linear crack not exceeding 75 mm (3 in) in length may be repaired using reference material
K0-111-00 HTM Weld Repair Manual and HTM Service Bulletin 7100-18.
Frame Linear crack exceeding 150 mm (6 in) in length, consult your local HTM distributor.
Weld Repairs Only a skilled welder qualified to meet or exceed AWS (American Welding Society) specification
D1.1 or D14.3; ASME Pressure Vessel Code, Section II or IX; or Canadian Standards Associa-
tion W59 should complete structural welding on rigid dump truck frame. For countries not
listed, the equivalent applicable standard may be applied.
W8-1-8
FRAME SUSPENSION AND WHEEL / Front Suspension
T8DX-07-25-001
Figure 1 - Front Suspension Components
1. Spindle (2x) 3. Suspension Tube 5. Ride Strut (2x)

2. Trailing Arm (2x) 4. Tie Rod 6. King Pin (2x)
W8-2-1
T8DX-07-25-002
Figure 2 - Exploded View Suspension and Mounting
1. Damper 13. O-ring 25. Bolt

2. Rod Assembly 14. Warning Decal 26. Washer
3. Cap Screw 15. Check Ball 27. Valve Cover Plate
4. Washer 16. Ring Bearing 28. Bolt
5. Guide Gland 17. Rod Seal 29. Washer
6. Ring Seal 18. Back-up Ring 30. Pin
7. Guide Piston 19. U-cup Rod Seal 31. Spacer
8. Ring Bearing 20. Rod Wiper 32. Grease Fitting
9. Washer 21. Inflation Valve 33. Snap Ring
10. Cap Screw 22. Collar Spacer Assembly 34. Bearing
11. Tube Assembly 23. Cap Screw
12. Plug 24. Lock Washer
W8-2-2
SERVICE POSITION 4. Remove the bolt (1), washer (2) and valve cover
Before checking and/or servicing the rigid dump truck, plate (3).
9
park it on a level solid surface and put it in the “Ser- : /16 in
3
REMOVAL
A lifting device capable of lifting 45 Metric Ton-

nes (50 Tons) will be required for removal.
CAUTION: The components which make up

the suspension system are heavy; use care
when removing and disassembling these
components. Do not jeopardize the safety of
service personnel and that of the rigid dump
truck.
Numbers in parentheses refer to Figure 2, unless W8DX-07-25-002
otherwise noted.
Figure 4 – Removal of Valve Cover Plate (3)
1. Put the rigid dump truck in the “Service Position”.
Refer to Section W2-1. 5. Remove the cap (6C) on the charge valve (6)
and slowly turn the outer locknut (6B) counter-
2. With a suitable lifting device, raise the front of clockwise releasing the helium charge. When
the rigid dump truck until the suspension strut is the strut is completely deflated, close the valve
in the fully extended position. Secure chassis at and replace the cap (6C). Refer to Figure 5.
3 3
raised height with blocking or support stands. : /8 in, /4 in
Refer to Section W2-3, LIFTING AND JACKING.
3. Remove grease fittings (23, Figure 3).

7
: /16 in
6C
23
6A 6B
Figure 5 - Charge Valve (6)
W8DX-07-25-003
23 6A. Lower Nut 6C. Cap
6B. Outer Lock Nut
3
: 6A /4 in
: 46 - 50 N٠m (34 - 37 lbf٠ft)
3
: 6B /4 in
W8DX-07-25-001 : 6 - 8 N٠m (50 - 70 lbf٠in)
Figure 3 - Removal of Grease Fittings (23) 3
: 6C /8 in (do not torque)
W8-2-3
6. Loosen the plug (4) with O-ring (5) attached,

Figure 6.
3
: /4 in
W8DX-07-25-005
Figure 7 – Removing bolts (26) from the Pin Assem-

bly
W8DX-07-25-004
Figure 6 - Loosening the Plug
7. Attach a suitable lifting device to the tube as-

sembly (8) and apply a slight tension in order to
relieve the weight of the strut at the frame
mounting.
CAUTION: Once the pin assembly (28) has

been removed, the strut is free of the cross
member and unless securely bound as out-
lined in step 7 above, could swing down
harming personnel and damaging equip-
ment within its path. Be sure to keep per-
sonnel and equipment away from the area
while removing the strut. Do not stand be-
hind the strut as it is being lowered.
W8DX-07-25-006
8. Remove the bolts (26), washers (27) and collar Figure 8 – Removing the Pin Assemblies (28)
spacer (29) which secure the pin assemblies
(28) to the upper ride strut mounting and the
axle assembly. Refer to Figure 7.
3
: /4 in 10. Compress the cylinder and replace the plug (4)
and O-ring (5).
3
: /4 in
9. With a soft drift and hammer, carefully tap out
and remove the pin (28) as shown in Figure 8.
: Hammer
: Punch
W8-2-4
11. With the strut still secured by a suitable lifting

device, apply a slight tension to relieve the
weight of the strut at the trailing arm. Remove 12. Remove the snap rings (9) and spherical bush-
the bolt (26), washer (27) and collar spacer (29) ings (10) from the eye in the frame and the eye
which secure the lower strut mounting on the in the trailing arm.
trailing arm mounting. With a soft drift and
hammer tap out and remove the pin (28). Re- 13. Repeat steps 3 through 9 to remove the oppo-
move and lower the strut assembly. site strut from the rigid dump truck.
3
: /4 in
W8DX-07-26-011
Figure 9 – Helium / Neocon Inflation Schematic
INSTALLATION 1. With a suitable lifting device, hold the strut in a ver-

tical position, rod end down.
2. Remove the plug (4) and O-ring (5) and allow the
NOTE: Refer to Figure 9 – Helium/Neocon Inflation strut to extend fully. Verify that strut dimension fully
Schematic. Neocon fluid should be filtered extended is X-1 dimension covered in Strut Charg-
through 3 micron absolute filter media that ing Data. Refer to Figure 10.
3
traps and removes water during fill process. : /4 in
W8-2-5
FILL CAPACITY:
15.65L (4.13 Gal)
Figure 10 – Strut Charging Data
MODEL 1700-3
METRIC IMPERIAL
PRESSURE DESCRIPTION
MPa PSI
Initial inflation pressure with
5.76 835
P-1 Initial new Neocon-E fluid and struts ± .003 ±5
fully extended
Inflation pressure after first 48
Operat- 5.24 760
P-1A hours of operation with struts
ing ± .003 ±5
fully extended (X-1)
METRIC IMPERIAL
X-DIMENSION DESCRIPTION
MM In
The stroke of strut fully ex-
Rod 406 16.00
X-1 tended, the rod exposed
length ± 6.35 ± 0.25
length (adjust gas pressure)
Strut installed on empty vehi-
Rod 260 10.25
X-2 cle after first 48 hours of vehi-
length ± 38 ± 1.50
cle operation.
Rod exposed length when
Rod strut is bled down to liquid fill 89 3.5
X-4
length volume (fluid fill height of ±6 ± 0.25
Neocon-E)
W8-2-6
3. Connect the fill line to the plug (4) port and open 9. Utilizing a suitable lifting device, adjust and hold
the charge valve (6). the height of the frame to align the opposite pin
bore of the strut with the bearing. Apply LOCTITE®
4. Fill the strut with Neocon until it flows through the Silver Grade anti-seize lubricant to pin (28) and in-
charge valve (6) clearly with no bubbles. Capture side diameter of bushing (10). Install the pin (28)
excess fluid that escapes. and secure it with collar spacer (29), bolt (26), and
washer (27). Apply LOCTITE® Product 242 thread
5. Disconnect the fill line and replace the plug (4) and adhesive to the threads of bolt (26) before install-
O-ring (5). Take care not to lose additional Neo- ing.
3
con liquid and ensure that the strut is accurately : /4 in
bled of all air. : 123 N٠m (90 lbf٠ft)
3
: /4 in
: 46 - 50 N٠m (34 - 37 lbf٠ft) 10. If grease fittings (23) were removed from the pins
(28), reinstall at this time.
6. Close the charge valve (6).
3
: /4 in Liquid Level Procedure
: 6 - 8 N٠m (50 - 70 lbf٠in)
11. Using a ¾” wrench, crack open the inflation valve
7. If the spherical bushings (10) were removed from at the top of the struts to bleed off any trapped
the trailing arm and the frame cross member, in- pressure then continue opening by turning the
stall new bushings noting that the outer race frac- lock-nut counterclockwise until hand tight.
3
ture of the bushing must be positioned 90 degrees : /4 in
out of the load zone. The fractures must be
mounted in a horizontal position. Refer to Figure 12. Allow the struts to drain of compressed helium gas.
11.
13. Remove liquid fill plug. On trucks equipped with
Haultronic, remove the strut transducer and
Point Of Load one-way check valve assembly.
14. Fully extend the struts to the X-1 dimension.
15. With the struts completely extended, verify the X-1

dimension to be 406 ± 6.35 mm (16 ± 0.25 in).
16. Connect the liquid fill lines into the plug port on
90° From both struts using the “T” provided, allowing both
Point Of Load struts to be filled simultaneously.
Fracture
W8DX-07-25-009 17. Ensure the inflation valves are open to bleed-off
Figure 11 - Ride Strut Bushing Mounting Position trapped air.
8. With a suitable lifting device, secure the Neocon 18. Attach hoses to the inflation valves and run to a
filled strut in a vertical position, rod end down. clean container.
Position the strut assembly over the bushing (10)
of the mount cross member. Align the bores. Ap- 19. Begin filling the struts with Neocon-E fluid.
ply LOCTITE® Silver Grade anti-seize lubricant
to pin (28) and inside diameter of bushing (10). 20. Continue filling the struts with Neocon-E fluid until
Install the pin (28) and secure with collar spacer the struts are completely full and the fluid flowing
(29), bolt (26) and washer (27). Apply LOC- out of the inflation valves into the container is free
TITE® Product 242 thread adhesive to the of air bubbles.
threads of bolt (26) before installing.
3
: /4 in 21. Close the inflation valves.
: 123 N٠m (90 lbf٠ft)
W8-2-7
22. Disconnect the liquid fill line at the pump and place water solution on all connections to detect bub-
pump end in a clean container. bles.
23. Lower the truck allowing the struts to collapse to 30. Close the charge kit valves on each line.
the X-4 dimension, confirm it is 89 ± 6 mm (3.5 ±
0.25 in). 31. Using a ¾” wrench, open the inflation valve at the
top of the struts by turning the lock-nut counter-
24. Remove all lines and fittings, replace plugs or strut clockwise until hand tight.
3
transducer and one-way check valve assemblies : /4 in
and torque.
: 42 - 46 N٠m (31 - 34 lbf٠ft) 32. Open the charge kit valves on each line.
Gas Charging Procedure 33. While maintaining the 100 psi pre-charge, fully ex-
tend the struts to the X-1 dimension.
NOTE: Helium bottle selected should have volume
and pressure greater than the combined CAUTION: DO NOT extend the struts without
volume and pressure requirement for filling the 100 psi pre-charge as it is possible for
two struts. air to enter the strut and cause damage to
internal components.
CAUTION: Struts must only be charged with
helium. For best ride quality, both struts CAUTION: If there is a question as to the
should be inflated simultaneously with helium possibility of air entering the struts you
using the inflation kit. Confirm gauge calibra- must repeat the liquid fill procedure.
tion before use. Refer to Section W2-5 Spe-
cial Tools. 34. With the struts completely extended to X-1, inflate
them simultaneously by adjusting the regulator
NOTE: During strut liquid fill height adjustment, valve on the helium tank to the proper pressure of
Neocon-E fluid may become trapped in- 5757 ± 34 kPa (835 ± 5 psi).
side inflation kit hoses. Purge the inflation
hoses to clear Neocon fluid from lines with 35. Once again check the X-1 dimension to ensure
short burst of helium gas. Direct the dis- struts are fully extended.
charge from hoses into container and
wear safety glasses and gloves during 36. After verifying the X-1, allow the helium pressure to
purge process. normalize for approximately 1 minute. Once the
pressure has normalized, close the strut inflation
25. Adjust the helium gas pressure to 100 psi valves to and torque.
3
pre-charge using the regulator on the supply tank. : /4 in
: 6 - 8 N٠m (50 - 70 lbf٠in)
26. Connect the gas inflation lines to the inflation
37. Close the supply valve on the helium tank.
valves on both struts - but leave loose.
27. Open the charge kit valves on each line and purge 38. Evacuate the gas inflation lines using the bleed
the inflation lines with short bursts of helium gas. valve located on the charging kit manifold.
28. Tighten the inflation lines after purging with helium 39. Turn gas regulator to low value before storage of
gas. gas regulator.
29. Check all connections for gas leakage. Listen for 40. Disconnect the inflation lines and fittings.
gas leakage closely or use glycerin detergent and
41. Remove cribbing and lower the truck.
W8-2-8
W8DX-07-25-007
Figure 12 - Section View of Ride Strut
1. Damper 8. Ring 15. Check Ball

2. Rod Assembly 9. Washer 16. Ring Bearing
3. Cap Screw 10. Cap Screw 17. Rod Seal
4. Washer 11. Tube Assembly 18. Back-up Ring
5. Guide Gland 12. Plug 19. U-cup Rod Seal
6. T-seal 13. O-ring 20. Rod Wiper
7. Guide Piston 14. Warning Decal 21. Inflation Valve
W8-2-9
DISASSEMBLY INSPECTION
Numbers in the parentheses refer to Figure 12. Numbers in parentheses refer to Figure 12.
1. Open the inflation valve (21) to confirm that the 1. Wash all parts in suitable clean filtered solvent.
ride struts are completely deflated of the helium Dry with compressed air. Make sure that the pis-
precharge. Once this has been done, remove the ton (16) and guide gland (11) are thoroughly
inflation valve plug (12) and O-ring (13). cleaned.
3
: /4 in
2. Inspect all threaded surfaces for damage. In-
2. Using the required lifting device, hold the ride spect tubes, bushings and bearings for scoring,
strut in a vertical position, with the rod end up. pitting or excessive wear.
3. Drain the liquid into a suitable container.

NOTE: Normally seal damage is caused by a fail-
4. Remove the cap screws (3) and washers (4) ure of the rod wiper (9) allowing contami-
from the guide gland (5) and lift the rod assembly nation to destroy the seals or excessive
(2) from the tube assembly (11). wear of the bearing rings which results in
: 5/8 in seal deformation. Damaged or worn parts
must be replaced.
5. Place and hold the rod assembly (2) in a hori-
zontal position. Remove the bearing ring (16) 3. The rod assembly (17) diameter should be
from the guide piston (7). 126.94 - 127.00 mm (4.998-5.000 in) with a mi-
cro finish of 8-12 RMS. If the rod assembly (17)
6. Remove cap screws (10) and washers (9) from does not meet these specifications, considera-
guide piston (7). As the guide piston is being re- tion should be given to replacing the rod.
moved and separated from the guide gland (5),
be careful not to lose the check balls (15). 4. The tube assembly (1) inner diameter should be
: 7/16 in 203.2 - 203.28 (8.000 – 8.003 in) with a micro
finish of 10-16 RMS. If the tube assembly (1)
7. Slide the guide gland (5) from the rod assembly does not meet these specifications, considera-
(2). Remove the ring (8), the U-cup rod seal (19), tion should be given to replacing the part.
the rod seals (17), back-up ring (18), rod wiper
(20), and T-seal (6).
5. Inspect the trailing arms and suspension tube for
cracks, warping or signs of stress. Repair or re-
8. Slide the damper (1) from the rod assembly (2).
Remove the cap screws (23) and lock washers place as necessary. Magnetic Particle Inspect
(24) securing the two halves of the collar (MPI) or Dye Penetrant (PT) parts being used
spacer assembly (22) together. Remove the again.
collar spacer from the rod assembly.
6. Inspect the front axle and the front wheel com-
ponents.
7. Inspect the tubes, eye assemblies, and guides

for cracks or distortion. Repair or replace worn
or damaged parts as necessary.
Figure 13 – Removing the Piston and Retaining

Rings
W8-2-10
ASSEMBLY 7. Install the four check balls (15) into the rod as-
sembly (2).
8. Slide the guide piston (7) down the rod assembly
(2). Make sure the check balls (15) remain in
NOTE: When a strut is disassembled, all seals
their seats.
should be replaced. Coat lightly with
clean and filtered Neocon strut fluid dur-
9. Coat threads of cap screws (10) with a medium
ing assembly. locking adhesive. Install the cap screws and
washers (9) into guide piston (7). Torque cap
1. Before assembly, all threaded areas must be screws to 163 N·m (120 lbf٠ft) to secure the
clean and free of grease. guide piston to the rod assembly (2).
: 7/16 in
2. Install rubber damper (1) and spacer on to rod : 163 N٠m (120 lbf٠ft)
assembly (2).
NOTE: Follow locking adhesive manufactures in-
NOTE: When the ride strut has been disassem-
structions for cure time.
bled, all the seals must be replaced and
coated lightly with strut fluid (Neocon).
10. Make sure that there are no sharp edges on
ring (8) and install on guide piston (7).
3. Install the new back up ring (18). Refer to
enlarged area in Figure 12 for position of
11. Prior to the final assembly, coat the inside of the
chamfer.
tube assembly (11) and all the seals with a thin
layer of Neocon. (Same as used in the ride
4. Install the T-seal (6), ring bearing (16), the two
struts.)
rod seals (17), the U-cup rod seal (19) and the
rod wiper (20).
12. Secure the tube assembly (11) in an upright posi-
tion. With the lifting device attached to the clevis
end of the rod assembly (2) lift and gently slide
the rod assembly into the tube assembly.
13. Coat the cap screws (3) with lubricant. Install

the cap screws and washers (4) in the guide
gland (5). Torque cap screws to 393 N·m (290
lbf٠ft) to secure the guide gland to the tube
Seal Seal
Free Form Collapsed Form
assembly (11).
: 5/8 in
: 393 N٠m (290 lbf٠ft)
W8DX-07-25-008
Figure 14 - Seal Installation 14. Install plug (12) and O-ring (13). Torque the plug
to 46 - 50 N·m (34 - 37 lbf٠ft). Install the
NOTE: When collapsing the rod seal (17), do not inflation valve (21). Tighten the outer lock nut
bend sharply, doing so will cause damage (21B) to 6 - 8 N·m (50 - 70 in. lbs.) and the lower
to the lip of the seal. Seals may be warmed lock nut (21A) to 11 - 12 N·m (100 - 110 in. lbs.).
3
in oil to ease with the assembly. See Fig- : Plug /4 in
ure 11 for seal installation. : 46 - 50 N٠m (34 - 37 lbf٠ft)
3
: 21A /4 in
5. Hold the rod assembly (2) firmly in a vertical po- : 46 - 50 N٠m (34 - 37 lbf٠ft)
3
sition. Slide the damper (1) onto the rod assem- : 21B /4 in
bly. : 6 - 8 N٠m (50 - 70 lbf٠in)
3
: Cap /8 in (do not torque)
6. Carefully slide the guide gland (5), with the in-
stalled rod wiper (20) towards the clevis of the
rod assembly (2).
W8-2-11
Servicing Procedure
During the first 48 hours of operation the helium gas If, for any reason, the strut is to be stored for an ex-
and the Neocon-E in the struts will mix in a dissolu- tended duration, it must remain in a vertical position,
tion process. As dissolution occurs, the strut rod ex- rod end down, completely filled with Neocon fluid. If
posed length will change and a reduction in the strut strut will be put in extended storage use steel band-
height is to be expected. After the initial 48 hours op- ing wrapped between clevis ears and between mount
erating period, the struts should be checked at regu- ears to hold strut retracted. Store strut in vertical po-
lar intervals. To visually monitor the condition of the sition to maximize seal life. A strut stored for ex-
strut, there is only one dimension to be checked. tended time in a horizontal position could develop
That is the X-2 space between the cylinder gland leak due to seal deforming and compression set.
assembly and the top of the rod assembly. This
check is to be accomplished only with the rigid dump NOTE: Struts may be stored retracted with
truck empty and parked on level ground. Prior to the volume of fluid equal to X-4 fill height.
check being performed, the rigid dump truck should Either method is acceptable. The ex-
be operated a minimum of one hour. (When parking posed rod should be protected with a
unit for visual check, allow empty unit to coast in light coating of grease or equivalent
neutral to a stop without using the brakes. Apply protective surface coating during ex-
parking brake when stopped then make inspection.) tended storage.
Failure to follow the described method may result in
false X-2 readings.
When the strut dimension is out of tolerance, check

the following:
1. Sign of Neocon-E fluid or Helium gas leakage.
2. Excess carry back or payload material stuck in

corner of hauler body.
3. External damage to strut. Scratched or dented

strut rod chrome, dented tube or other obvious
damage.
4. Broken suspension.
5. Verify pressure of fully extended strut to P-1A

pressure level using calibrated gauge. If strut
P-1A pressure is dramatically low, remedy ap-
parent problem and charge strut according to
the charging procedure.
Storage of Struts
Store the ride strut with the required amount of fluid

and all ports closed. All machined surfaces should be
protected against corrosion and the chrome-plated
area of the rod must be protected against possible
damage.
W8-2-12

Tube (8) 0.4√ 0.4√ Open end of tube to 76 mm
Inside diameter surface finish lead to 16 RMS 16 RMS (3 in) deep in bore
76 mm (3 in) deep in bore
Tube (8) 0.25√ 0.25√ 76 mm (3 in), to bottom of
Inside diameter surface finish from 10 RMS 10RMS cylinder bore
76 mm (3 in) depth to bottom of bore
Tube (8) 203.20 – 203.28 mm 203.2 – 203.33 mm
Bore inside diameter (8.000 - 8.003 in) (8.000 - 8.005 in)
Rod (25) 126.94 - 127.00 mm 126.85 - 127.00 mm
Outside diameter (4.998 - 5.000 in) (4.994 - 5.000 in)
Rod (25) 0.0254 - 0.0381 mm ~ Plate surface to “NEW” di-
Chrome depth (0.0010 - 0.0015 in) ameter. Do not extend
chrome to check ball seats
Rod (25) 0.2 - 0.3√ 0.15 - 0.3√ Polish chrome surface to
Surface finish 8 - 12 RMS 6 - 12 RMS specification
Recharge Specifications ~ ~ See Figure 10
Mounting Pin (28) ~ ~ Coat both pin and inside of
Installation bore with “SILVER” grade
never seize compound
Mounting Pin Hardware (26) ~ ~ Use “BLUE” thread lock
compound
Strut Fluid ~ ~ Genuine Hitachi Neocon E
Fluid only Fluid filtered
through 3 micron element
with water trap
Extended Storage of Strut ~ ~ Store in rack in vertical po-
sition as mounted on hauler
W8-2-13
MEMO
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W8-2-14
FRAME SUSPENSION AND WHEEL / Rear Suspension
Figure 1 - Rear Suspension Components
1. “A” Frame 2. Track Rod (2x) 3. Ride Strut, Rear (2x)
W8-3-1
T8DX-07-26-002
Figure 2 - Exploded View of Rear Suspension
1. Damper 10. Cap Screw 19. U-cup Rod Seal 28. Bolt
2. Rod Assembly 11. Tube Assembly 20. Rod Wiper 29. Washer
3. Cap Screw 12. Plug 21. Inflation Valve 30. Pin
4. Washer 13. O-ring 22. Bolt 31. Spacer
5. Guide Gland 14. Warning Decal 23. Washer 32. Grease Fitting
6. T-seal 15. Check Ball 24. Valve Cover Plate 33. Snap Ring
7. Guide Piston 16. Ring Bearing 25. Screw 34. Bearing
8. Ring 17. Rod Seal 26. Washer
9. Washer 18. Back-up Ring 27. Guard
W8-3-2
REMOVAL
20, 21, 22
A lifting device capable of lifting 45 Metric Ton-
nes (50 Tons) will be required for removal
Numbers in parentheses refer to Figure 2 unless

otherwise noted.
1. Park the rigid dump truck on a level, solid surface

and put it in the Service Position. Refer to SER-
VICE POSITION, Section W2-1.
CAUTION: The components which make up

the suspension system are heavy; use care
when removing and disassembling these
components. Do not jeopardize the safety of W8DX-07-26-002
service personnel and that of the rigid dump Figure 4 – Inflation Valve Cover Plate
truck.
5. Remove the cap (23C) on the inflation valve (23)
2. With a suitable lifting device, raise the rear of the and slowly turn the outer locknut (23B) counter-
rigid dump truck until the suspension strut is in a clockwise releasing the helium charge. When
fully extended position. Secure chassis in raised the strut is completely deflated, close the valve
position with support stands or blocking. and replace the cap. Refer to Figure 5.
: 3/8 in
3. Remove grease fittings (32). Refer to Figure 3. : 3/4 in
: 7/16 in
23C
26
23B
23A W8DX-07-26-003
Figure 5 - Inflation Valve
23A. Lower Nut 23C. Cap

23B. Outer Lock Nut
3
: 23A /4 in
W8DX-07-26-001
: 46 – 50 N٠m (34 - 37 lbf٠ft)
Figure 3 – Grease Fitting Removal 3
: 23B /4 in
: 6 - 8 N٠m (50 - 70 lbf٠in)
3
4. Remove the bolt (20), washer (21) and valve : 23C /8 in (do not torque)
cover plate (22). Refer to Figure 4.
6. Loosen the plug (10). Refer to Figure 6.
: 9/16 in
: 3/4 in
W8-3-3
8. Attach a suitable lifting device to the tube as-

sembly (11) and apply a slight tension in order to
relieve the weight of the strut at the cross member
mounting. Remove bolt (24, Figure 8) and washer
(25, Figure 8) which secures the pin (28, Figure 8)
to the upper ride strut mounting. Refer to Figure
8.
: 3/4 in
10
CAUTION: Rear Strut Weight: 730 kg (1600
lb)
CAUTION: Once the pin (28) has been re-

moved, the strut is free of the cross member
and unless securely bound as outlined in
W8DX-07-26-004 Step 8, could swing down harming person-
nel and damaging equipment within its path.
Figure 6 – Plug Be sure to keep personnel and equipment
away from the area while removing the strut.
NOTE: Before removing the guard (19, Figure 7), Do not stand behind the strut as it is being
mark the guard (19, Figure 7) and the cyl- lowered. Be sure to tighten plug (10, Figure
inder where the four bolts are located. This 6) after strut is removed from hauler.
will ensure proper assembly. If the guard
(19, Figure 7) is not assembled correctly
the strut can be damaged.
24, 25, 28
7. Remove the screws (30) and washers (31) from
the guard (19). Refer to Figure 7.
: 3/4 in
W8DX-07-26-006
30 Figure 8 – Ride Strut Pin Retainer Removal
19
9. With a soft drift and hammer, tap out and remove

pin (28, Figure 8) and spacer (31). Remove
grease fitting (32) from the pin (30) if necessary.
W8DX-07-26-005
Remove and lower the strut assembly. Refer to
Figure 7 – Guard Removal
Figure 9.
: Hammer
W8-3-4
2. Install new snap rings (33) in place. Inspect that

snap ring is seated completely in bottom of ma-
chined groove around bearing bore.

lb)
3. With a suitable lifting device, secure the strut in a

vertical position, rod end down. Position the strut
assembly over the flange of the cross member.
Align the pin bores, then apply LOCTITE® Silver
Grade, anti-seize lubricant to pin (30) and bearing
(17) inside diameter. Install pin (30), and secure
with spacer (31), washer (29) and bolt (28). Apply
W8DX-07-26-007 LOCTITE® Product 242 thread adhesive to the
Figure 9 – Pin Removal threads of bolt (28) before installation.
: 3/4 in
10. Compress the strut, retracting the rod assembly : 123 N٠m (90 lbf٠ft)
(2) and tighten plug (10, Figure 6).
: 3/4 in 4. If grease fittings (32) were removed from the pins
: 47N٠m (35 Ibf٠ft) (30), reinstall at this time. Lubricate pins with
grease until grease flows from bearing.
: 7/16 in
11. Using suitable tools, remove the snap rings (33)
and bearings (34) from the mounting eye in the 5. Inflate the struts as recommended under “Gas
frame. Remove snap rings (33) and bearing (34) Procedure” in this section.
from the mounting eye in the rear axle.
12. Repeat Steps 3 through 11 to remove the oppo- 6. Lower the rigid dump truck.
site strut from the rigid dump truck.
DISASSEMBLY
INSTALLATION Numbers in parentheses refer to Figure 10.
Numbers in parentheses refer to Figure 2. 1. Open the inflation valve (21) to confirm that the
ride strut is completely deflated of helium pre-
1. If the bearings (34) were removed from the rear charge. Once this has been done, remove infla-
axle, install in reverse order of disassembly noting tion valve (21), plug (12) and O-ring (13).
that the bearing outside diameter fracture line : 3/4 in
(outer race fracture) of the bearing must be posi-
tioned out of the load zone. The fracture line is to 2. Using the required lifting device, hold the ride strut
be mounted in the horizontal position. This will in a vertical position, rod end up.
allow the fracture to be positioned away from the
load zone. Refer to Figure 12 for proper orienta-
tion of bearing. The bearing must be pressed in
lb)
place using a driver that applies force evenly
across the outside race of the bearing. A universal
3. Drain the Neocon-E liquid into suitable container.
hydraulic ram with a through hole may be used to The fluid can be filtered for reuse.
pull bearing in place. Freezing of the bearing prior
to installation may also ease installation.
W8-3-5
4. Remove the cap screws (3) and washers (4) from

the guide gland (5) and lift the rod assembly (2)
and guide gland (5) from the tube assembly (11).
: 5/8 in
5. Place and hold the rod assembly (2) in a hori-

zontal position. Remove the bearing ring (16) from
the guide piston (7).
6. Remove the cap screws (10) and washers (9)

from the guide piston (7). As the guide piston (7)
is being removed and separated from the guide
gland (5), be careful not to lose the check balls
(15).
: 7/16 in
7. Slide the guide gland (5) from the rod assembly

(2). Remove the bearing ring (16), U-Cup rod seal
(19), rod seal (17), back up ring (18), the other rod
seal (17), rod wiper (20), and T-seal (6).
8. Slide the damper (1) from the rod assembly (2).
W8-3-6
W8DX-07-26-008
Figure 10 - Section View of Ride Strut
1. Damper 8. Ring 15. Check Ball

2. Rod Assembly 9. Washer 16. Ring Bearing
3. Cap Screw 10. Cap Screw 17. Rod Seal
4. Washer 11. Tube Assembly 18. Back-up Ring
5. Guide Gland 12. Plug 19. U-cup Rod Seal
6. T-seal 13. O-ring 20. Rod Wiper
7. Guide Piston 14. Warning Decal 21. Inflation Valve
W8-3-7
INSPECTION
4. Hold the rod assembly (2) firmly in a vertical posi-
Numbers in parentheses refer to Figure 10. tion.
1. Wash all parts in a suitable solvent. Dry with 5. Carefully slide the guide gland assembly (5) with
compressed air. Make sure that the guide piston the rod seal (17) towards the clevis of the rod
(7) and guide glands (5) are thoroughly cleaned. assembly (2).
2. Inspect all threaded surfaces for damage. Inspect 6. Install the four check balls (15) in the rod assem-
tubes, bushings and bearings for scoring, pitting bly (2), making sure the check balls (15) remain
or excessive wear. seated.
NOTE: Normally seal damage is caused by a fail- 7. Place the guide piston (7) on the rod assembly
(2), making sure that the check balls (15) remain
ure of the wiper allowing contamination to
seated. Coat the threads of the cap screws (20)
destroy the seals or excessive wear of the
with a medium locking adhesive. Install the cap
bearing rings which result in seal deforma-
screws (10) and washers (9) in the guide piston
tion. Damaged or worn parts must be re-
(7). Torque the cap screws (10) to 163 N•m (120
placed.
lbf٠ft). Make sure there are no sharp edges on
the ring bearing (16) and install the guide piston
3. The rod diameter should be 152.40 - 152.35 mm
(7).
(6.00 - 5.998 in) with a micro finish of 8 – 12 RMS.
: 7/16 in
If the rod assembly (2) does not meet these
specifications, consideration should be given to : 163 N٠m (120 lbf٠ft)
replacing the rod.
8. Prior to final assembly, coat the inside of the tube
4. Inspect the rear axle and the frame strut connec- assembly (11) and all the seals with a thin layer of
tion points. the Neocon-E liquid. The same liquid used to coat
the ride strut can be used to coat the seals.
5. Inspect the tube assemblies, the rod assem-
blies, and the guides for cracks or distortion. 9. Secure the tube assembly (11) in an upright posi-
Repair or replace as necessary. tion. With the lifting device attached to the clevis
end of the rod assembly (2) lift and gently slide the
rod assembly (2) into the tube assembly (11).
ASSEMBLY
10. Coat the cap screws (3) and washers (4) with a
lubricated liquid coating. Install and tighten to 393
NOTE: When a strut has been disassembled, all N•m (290 ft. lbs.).
seals should be replaced. Coat lightly with : 5/8 in
Neocon strut fluid prior to assembly. : 393 N٠m (290 lbf٠ft)
1. Before assembly, all threaded areas must be 11. Install plug (12) and new O-ring (13), torque
clean and free of grease. lubricated to 46 – 50 N•m (34 – 37 lbf٠ft). Install
the inflation valve (21). Tighten the outer lock
2. First install the damper (1) and rod assembly (2), nut (23B, Figure 5) to 6 - 8 N•m (50 – 70 lbf٠in)
the new back up ring (18) with the chamfered side and the lower lock nut (23A, Figure 5) to 11 - 12
of the ring facing toward the U-cup rod seal (19) N•m (100 – 110 lbf٠in) torque lubricated.
and rod seal (17) in the guide gland (5).
3
: Plug (12) /4 in
NOTE: When collapsing the rod seal (17), do not : 46 - 50 N٠m (34 - 37 lbf٠ft)
3
bend sharply. Doing so will cause damage : 23A /4 in
to the lip of the seal. Heating the seals : 46 - 50 N٠m (34 - 37 lbf٠ft)
with oil will aid in installation. 3
: 23B /4 in
: 6 - 8 N٠m (50 - 70 lbf٠in)
3. Install the T-seal (6), rod seal (17), and the ring 3
: 23C /8 in (do not torque)
bearing (16).
W8-3-8
LIQUID FILL
NOTE: Once the ride strut has been filled with
Numbers in parentheses refer to Figure 10. liquid, the plug (2) and inflation valve (3)
closed, the strut must not be extended
1. Using a ¾” wrench, crack open the inflation valve until charging with helium. Extending the
at the top of the struts to bleed off any trapped strut will cause air to enter the strut being
pressure then continue opening by turning the drawn in past the seals. If strut is stored
lock-nut counterclockwise until hand tight. for extended time, wrap a steel band or
3
: /4 in wire rope through mounting eyes and
clamp tightly to keep strut in retracted
2. Allow the struts to drain of compressed helium position. Put protective coating on ex-
gas. posed rod surface and mounting pin holes.
Store strut in vertical position in rack de-
3. Remove liquid fill plug. On trucks equipped with signed to hold strut securely.
Haultronic, remove the strut transducer and
one-way check valve assembly.
4. Fully extend the struts to the X-1 dimension.
5. With the struts completely extended, verify the X-1

dimension to be 406 ± 6.35 mm (16 ± 0.25 in).
6. Connect the liquid fill lines into the plug port on

both struts using the “T” provided with the kit, al-
lowing both struts to be filled simultaneously.
Seal Seal
7. Ensure the inflation valves are open to bleed-off Free Form Collapsed Form
trapped air.
W8DX-07-26-009
8. Attach hoses to the inflation valves and run to a

Figure 11 – Compressing Seal for Installation
clean container.
9. Begin filling the struts with Neocon-E fluid.
10. Continue filling the struts with Neocon-E fluid until

the struts are completely full and the fluid flowing
out of the inflation valves into the container is free Point of Load
of air bubbles.
11. Close the inflation valves.
12. Disconnect the liquid fill line at the pump and place
pump end in a clean container.
13. Lower the truck allowing the struts to collapse to 90° From
Point of Load
the X-4 dimension, confirm it is 89 ± 6 mm (3.5 ±
0.25 in). Fracture
14. Remove all lines and fittings, replace plugs or strut W8DX-07-26-010
transducer and one-way check valve assemblies

and torque. Figure 12 - Ride Strut Bushing Mounting Position
: 42 - 46 N٠m (31 - 34 lbf٠ft)
W8-3-9
W8DX-07-26-011
Figure 13 – Helium / Neocon Inflation Schematic
W8-3-10
Fill capacity Neocon – E

12.6 L (3.33 gal)
W8DX-07-26-012
Figure 14 - Strut Charging Data
MODEL 1700-3
METRIC IMPERIAL
PRESSURE DESCRIPTION
MPa PSI
Initial inflation pressure with new
3.00 435
P-1 Initial Neocon-E fluid and struts fully
± .003 ±5
extended
Inflation pressure after first 48
2.48 360
P-1A Operating hours of operation with struts fully
± .003 ±5
extended (X-1)
METRIC IMPERIAL
X-DIMENSION DESCRIPTION
MM IN
The stroke of strut fully extended,
165 6.50
X-1 Rod length the rod exposed length (adjust
±6 ± 0.25
gas pressure)
Strut installed on empty vehicle
127.0 5.00
X-2 Rod length after first 48 hours of vehicle
±6 ± 0.25
operation.
Rod exposed length when strut is
86 3.375
X-4 Rod length bled down to liquid fill volume
±6 ± 0.25
(fluid fill height of Neocon-E)
W8-3-11
GAS INFLATION 3. First install the charge kit adaptor to the closed
inflation valves (21) on both struts at Port A. See
Refer to Figures 2, 10, 13, 14. “Gas Inflation” illustration in Figure 13. Open he-
lium bottle gas valve and set regulator to 690 kPa
NOTE: When inflating rear struts, both struts (100 psi) gas flow. Loosen connector at left strut
should be inflated simultaneously with inflation valve and bleed off small volume (1-2
helium gas using the inflation kit. Proper seconds) of helium gas to purge hose of air.
use of this tool will pressure balance the Repeat process for right strut.
ride struts for best performance. See
Section W2-4, SPECIAL TOOLS. Bleed Inflation Kit Hoses of Air
Helium supply tank Open
Liquid Level Check Procedure valve
1. Lower the rear of the rigid dump truck. And com- Manifold gas bleed Closed
press the strut to the X-4 dimension, allowing the valve
Neocon-E liquid to flow from plug (12, Figure 10)
port, Port B, through the fill line to a suitable Helium regulator Set to 690 kPa (100
container. See “Liquid Fill” illustration in Figure 13. psi)
If strut was previously filled and bled, fluid should Left ball valve Open
just begin to flow when X-4 dimension is obtained Right ball valve Open
using crane to control chassis height.
Strut inflation valves Closed
NOTE: The strut must not be extended until 4. Check all connections using foaming detergent
charged with helium. Extending the strut and water mix solution. Use lint free cloth dipped
will cause air to enter the strut past the in solution to wet all hose connector locations of
seals. inflation kit. Any formation of bubbles indicates a
leaking gas connection. Correct leaks before
2. Disconnect the fill line and install O-ring (13) and proceeding with strut inflation.
plug (12). Take care not to lose liquid and ensure
that strut is accurately bled of all air. 5. Close both left and right ball valves.
3
: /4 in
: 46 - 50 N٠m (34 – 37 Ibf٠ft) Hoses Purged Close Ball Valves
Helium supply tank Open
CAUTION: Struts must only be charged with valve
helium gas. Manifold gas bleed Closed
valve
NOTE: Purge the inflation lines with flow of low Helium regulator Set to 690 kPa
pressure helium gas while hose connec-
(100 psi)
tors are tightened. This will create leak
free helium connection to strut via inflation Left ball valve Closed
valves. Purge hoses prior to step 3. Right ball valve Closed
Refer to Figure 13. Strut inflation valves Closed
Helium supply tank valve Closed 6. Turn the outer lock nut (23B, Figure 5) on the in-
Manifold gas bleed valve Closed flation valve (21) counter-clockwise to open
valve. Repeat for opposite strut inflation valve.
Helium regulator Closed 0 kPa (0 psi) 3
: /4 in
Left ball valve Closed
Right ball valve Closed
W8-3-12
Open Inflation Valves Inflate Strut While Extending

Helium supply tank Open Helium supply tank Open
valve valve
Manifold gas bleed Closed Manifold gas bleed Closed
valve valve
Helium regulator Set to 690 kPa Helium regulator Set to 690 kPa
(100 psi) (100 psi)
Left ball valve Closed Left ball valve Open
Right ball valve Closed Right ball valve Open
Strut inflation valves Open Strut inflation valves Open
7. Utilizing a suitable lifting device, prepare to raise 9. With the struts now fully extended and the rigid
the rear of the rigid dump truck as the struts are dump truck blocked and secured, measure ex-
being inflated. Slowly open the ball valves while tended dimension, X-1 as illustrated in Figure 14 -
watching gauge on manifold valve. If pressure Strut Charging Data. Both rear struts exposed rod
increases dramatically, close ball valve and raise length must measure to this dimension.
chassis a small amount 6 mm (1/4 in).
10. Increase helium gas regulator pressure setting to
Begin Inflation the P-1 pressure value. Balance the strut pres-
Helium supply tank Open sures by allowing gas to flow for two minutes.
valve
Increase Gas Pressure to P1 Value
Manifold gas bleed Closed
valve Helium supply tank valve Open
Helium regulator Set to 690 kPa Manifold gas bleed valve Closed
(100 psi) Helium regulator Set to P-1
Left ball valve Slowly open specification
Right ball valve Slowly open Left ball valve Open
Strut inflation valves Open Right ball valve Open
Strut inflation valves Open
8. Adjust the gas regulator to a minimum pressure of
690 kPa (100 psi). Open fully both the right and 11. Check the helium supply pressure. The supply
left ball valves at the manifold. Simultaneously lift (tank) pressure must be greater than P1 value
the rear of the rigid dump truck slowly to full strut when gas charging is complete.
extension while inflating struts, maintaining a
minimum of 690 kPa (100 psi) gas regulated 12. Close the strut inflation valves at Port A, Figure
pressure inside the struts as they are being ex- 13, by turning the outer lock nut (23B, Figure 5) in
tended. This process ensures that no air will be a clockwise rotation. Shut off helium gas supply
drawn into the strut past the seals. valve. Open the gas bleed valve slowly on the
manifold to discharge trapped pressure in the
hoses. Return helium gas regulator setting to
zero. Torque gas inflation valves (Refer to 23B
Figure 5), disconnect the charge kit hose adap-
tors from the inflation valves and replace the
protection caps (23C, Figure 5).
W8-3-13
Discharge Inflation Kit Hoses

Helium supply tank valve Closed STORAGE OF STRUTS
Manifold gas bleed valve Open slowly
Store the ride strut with the required amount of Neo-
Helium regulator Set to zero psi con fluid inside and all ports sealed. All machined
Left ball valve Open surfaces should be protected against corrosion and
the exposed chrome-plated area of the rod must be
Right ball valve Open
protected against impact or corrosive damage.
If, for any reason, the strut is to be stored, it must
13. Install valve cover plate (22) to the tube as- remain in a vertical position, rod end down, completely
sembly (2), securing with washers (21) and filled with Neocon fluid. Store strut in vertical position
bolts (20). in rack designed to hold strut securely.
: 9/16 in
Do not install gas charge in strut removed from rigid
14. Remove blocking and slowly lower the rigid dump truck.
dump truck and verify the X-2 dimension,
Figure 14.
SERVICING PROCEDURE
During the first 48 hours of operation the helium gas

and the Neocon-E in the struts will mix in a dissolution
process. As dissolution occurs, the strut rod exposed
lengths will change and a reduction in the strut height
is to be expected. After the initial 48 hour operating
period, the strut should be checked at regular intervals.
To visually monitor the condition of the strut gas
charge, there is only one dimension to check. That
dimension is the X-2 exposed rod length between the
cylinder gland assembly and the top of the rod as-
sembly. This inspection is to be accomplished only
with the rigid dump truck empty and parked on level
ground. Before checking, the rigid dump truck should
be operated a minimum of one hour. (When parking
unit for visual check, allow the empty unit to coast in
neutral to a complete stop without using the brakes.
Only apply parking brake when stopped, and then
make the inspection.) Failure to follow this process as
described may result in inaccurate X-2 readings.
When the strut dimension is out of tolerance, check

the following:
1. Look for signs of Neocon-E fluid leak or gas

leakage.
2. Check pressure of fully extended strut and

compare value with P-1A pressure specification.
Remedy any apparent problem first and then
proceed according to the charging procedure to
refill strut gas charge.
W8-3-14

Tube (2) 0.40√ 0.40√
Inside diameter surface finish down to 16 RMS 16 RMS
bottom of cylinder bore
203.20 – 203.28 mm 203.20 – 203.33 mm
Tube (2)
Bore inside diameter (8.000 - 8.003 in) (8.000 - 8.005 in)
152.349 - 152.400 mm 152.248 – 152.400 mm
Rod (1)
Outside diameter (5.998 - 6.000 in) (5.994 - 6.000 in)
Rod (1) 0.0254 - 0.0381 mm Plate surface to “NEW”

Chrome depth (0.0010 – 0.0015 in) ~ diameter. Do not extend
chrome to check ball seats
Rod (1) 0.2 - 0.3√ 0.15 - 0.3√ Polish chrome surface to
Surface finish 8 - 12 RMS 6 - 12 RMS specification
Recharge Specifications ~ ~ See Figure 14
Mounting Pin (27) ~ ~ Coat both pin and inside of
Installation bore with “SILVER” grade
never seize compound
Mounting Pin Hardware (24, 25, 28) ~ ~ Use “BLUE” thread lock
compound
Strut Fluid ~ ~ Genuine Hitachi Neocon-E
fluid filtered through 3 mi-
cron element with water
trap
Extended Storage of Strut ~ ~ Store in rack in vertical
position as mounted on
hauler
W8-3-15
MEMO
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W8-3-16
FRAME SUSPENSION AND WHEEL / Front Wheel
Figure 1 - Section View of Left Hand Front Wheel
1. Cup 7. Cone 13. Shim

2. Cup 8. Cone 14. Cover
3. Spacer 9. Screw 15. Gasket
4. O - Ring 10. Plate 16. Screw
5. Seal 11. Shim 17. Wheel
6. Washer 12. Shim
W8-4-1
10 2 3
11
12
8
Front Brake 9
1 16
5 4
13
7 15
6 14
Figure 2 - Exploded View of Front Wheel

1. Oil Seal 5. Washer 9. Gasket 13. Cover Plate
2. Spacer 6. Wheel 10. Spindle Assembly 14. Retainer Plate
3. Inner Bearing Cone 7. Outer Bearing Cup 11. Screw (8x) 15. Shims
4. Inner Bearing Cup 8. Outer Bearing Cone 12. Screw (6x) 16. O-Ring
REMOVAL
1. Remove the front tires and rims. Refer to Section
Before checking and/or servicing the rigid dump truck, W8-6, TIRES/RIMS/INFLATION.
Position.” Refer to Section W2-1. 2. Remove brake heads. Refer to Section W6-1,
FRONT BRAKES.
CAUTION: Wheel assembly weight: 750 kg
3. Remove the bolts (11), the cover plate (13), and the
(1650 lb).
gasket (9). Discard the gasket (9).
3
CAUTION: Before performing any type of : /4 in
service on the tires or rims, always remove
the valve core and exhaust all the air from a 4. Attach a hoist to the wheel (6) assembly in such a
single tire and both tires of a dual assembly manner that it will remain plumb during removal.
prior to loosening the first rim clamp nut.
Check the valve stem by running a piece of
wire through the stem to make sure it is not
plugged.
W8-4-2
5. Remove the bolts (12), then remove the retainer 6. This process will make certain that the inner and
plate (14) and shim pack (15). Keep the shim pack outer bearing cones (3 & 8) and bearing cups (4 &
(15) together for reference during assembly. 7) are seated properly while bearing rollers align.
1
: 1 /8 in Loosen and back out 3 mm (0.125 in) the two bolts
adjacent to the measuring holes. Completely
6. Apply tension with hoist and slide the wheel (6) remove the other bolts. Rotate the wheel to “re-
assembly out to the end of the spindle (10). Do not lease” the bearing preload.
1
allow the wheel (6) assembly to rest or contact : 1 /8 in
spindle (10). Remove the outer bearing cone (8).
Remove the wheel (6) assembly from the rigid NOTE: The wheel should move outward. There
dump truck. usually is a noise when this bearing pre-
load is released. The noise indicates that
INSTALLATION movement has taken place. If there is not
Numbers in parentheses refer to Figure 1. an audible noise, check for a reduction in
the 3 mm (0.125 in) gap under the bolt
CAUTION: Wheel assembly weight: 750 kg head. It may sometimes be necessary to
(1650 lb). force the outward movement of the wheel
with a bar or other suitable device.
1. Attach a suitable hoist to the wheel (6) assembly.
Attach the hoist so that the wheel (6) assembly will 7. Retighten the two remaining bolts (12) next to the
remain vertical during installation. Use care when two small measuring holes in the retainer plate (14)
hoisting wheel (6) in place to avoid damage to while rotating the wheel. The wheel must be rotated
brake rotor disc, oil seal surfaces and bearings. as the bolts are being tightened. Retighten each bolt
five times until it no longer turns at the specified
2. Slide the wheel (6) assembly over the spindle (10). torque value. Bump the wheel several times in an
axial direction with a steel bar, rotate the wheel, and
3. Coat the outer bearing cone (8) with lubricant and re-torque the bolts (12).
1
install it into the outer bearing cup (7) : 1 /8 in
: 135N٠m (100 lbf٠ft), lubricated
4. Use a micrometer and measure the thickness of
the retainer plate (14) in two places in the location 8. Using a depth micrometer, take a measurement
where the shims (15) sit. Add the two measure- from the surface of the retainer plate (14) to the end
ments together and then average them by dividing of the spindle (10) at each measuring hole. Record
the sum by two. This dimension will be required in the two dimensions as “Depth No. 1” and “Depth No.
Step 11. Record this dimension as the “retainer 2” in Chart 1, Reference Data Table. If the meas-
plate thickness.” (Refer to the data table Chart 1). urements differ by more than 0.127 mm (0.005 in),
the rotating wheel and complete torque procedure
5. Install the retainer plate (14) on the spindle (10) should be repeated.
end with the two measuring holes located near the
12:00 o’clock and 6 o’clock position using all six 9. Add the two depth dimensions, Depth No. 1 and
lubricated bolts (12) and without installing shims Depth No. 2, together and record as the “Sub-Total”.
(15). Tighten the bolts (12) uniformly using a cross
pattern while rotating the wheel. Re-tighten each 10. Divide the Depth, Sub-Total dimension by 2 to obtain
bolt five times until it no longer turns at the speci- the average of the two depth readings. Record this
fied torque value. Bump the wheel several times in as the “Average Depth” in Chart 1.
an axial direction with a heavy steel bar, and again
rotate the wheel (6), repeat torque the bolts (12) till 11. Subtract the “retainer plate thickness” (refer to Step
bolt torque is stable. 4) from the “Average Depth”. Record this as the
1
: 1 /8 in “Average Gap” in Chart 1.
: 183 N٠m (135 lbf٠ft), lubricated
12. Add 0.051 mm (0.002 in), the constant, to the av-
erage gap to obtain the required shim pack thickness.
NOTE: Do not tighten bolts (12) to a value higher
Record this as the “Total Shim Pack Requirement” in
than specified as damage to bearings could
Chart 1.
result.
W8-4-3
13. Make up a shim pack using clean flat shims. As- NOTE: The inner and outer bearing cones (3 & 8)
semble the shim pack by individually measuring and inner and outer bearing cups (4 & 7)
each shim, then adding the individual shims to attain must be free from contamination. If they are
the Total Shim Pack Requirement. not properly cleaned, the rollers will not
rotate freely.
14. The “Actual Pack Now Used” must be less than or
equal to 0.051 mm (≤ 0.002 in) of the “Total Shim 17. Fill front wheel hub with lubricant. Refer to section
Pack Requirement”. LUBRICATE FRONT WHEEL BEARINGS later in
this section.
15. Record the “Actual Shim Pack Now Used” in Chart
1. 18. Install the cover plate assembly (13) and a new
gasket (9) on the wheel (6) and secure it with bolts
16. Secure the wheel (6) with the lifting device, and (11).
remove the bolts (12) and retainer plate (14). 3
: /4 in
Position plate retainer (14) with the “Actual Shim : 123 N٠m (90 lbf٠ft)
Pack Now Used” on the spindle (10) and secure
with the bolts (12). Tighten the bolts slowly in a 19. Install the tire and rim. Refer to Group W8-6, TIRES
star pattern to specified torque. / RIMS / INFLATION.
1
: 1 /8 in
: 433 N٠m (319 lbf٠ft), lubricated
NOTE: Before installing the cover plate (13), turn

the wheel and observe the rotation of the
bearing rollers in the outside bearing cone
(9). All of the rollers should rotate con-
tinuously while the wheel is turning. This
rotation is the result of the preload on the
bearings. If all of the rollers are not rotating,
repeat the Acro-Set bearing adjustment
(Steps 4-15).
Left Wheel Right Wheel

Depth No. 1
Depth No. 2
Depth Subtotal = (Depth 1 + Depth 2)
Avg. Depth = (Depth Subtotal ÷ 2)
Retainer Plate Thickness = (From step 4)
Average Gap = (Avg. Depth - Retainer Thickness)
Add Constant (+) 0.051 mm (0.002 in) 0.051 mm (0.002 in)
Total Shim Pack Requirement = (Gap + Constant)
Actual Shim Pack Used Previously (Record)
Actual Shim Pack Now Used (Record)
Chart 1 - Reference Data Table
W8-4-4
DISASSEMBLY 4. Inspect the wheels (6) for burrs or displaced

metal on the bearing shoulder edge if the inner
Numbers in parentheses refer to Figure 2. and outer bearing cups (4 & 7) have been re-
moved from wheel (6). The burrs, often occur
1. If necessary, remove the brake disc. Refer to when a punch has been used to drive the inner
Section W6-1, FRONT BRAKES. and outer bearing cups (4 & 7) out, and should be
removed. The burrs may interfere with proper
2. Remove oil seal (1), washer (5) and inner bear- assembly and seating of bearing parts, allowing
ing cone (3) from the wheel (6). Discard the oil the inner and outer bearing cups (4 & 7) to shift
seal (1). after assembly, resulting in a loss of bearing
pre-load.
3. The bearing cups (4 & 7) need not be removed
from the wheel (6) unless new bearings are to be 5. Inspect the wheels (6) for cracks or impact
installed. Use a soft punch or drift to remove the damage. Inspect the tapered seat where the rim
bearing cups (4 & 7). seats against the wheel. Remove rough edges
and polish away minor imperfections. Replace
4. If the spacer (2) must be removed, use a pry bar any wheel that is cracked or damaged from ac-
in the slots provided, or tap it from the spindle cident or abuse.
assembly (10) with a brass hammer and remove.
Care should be taken to avoid hitting the spindle 6. Remove and replace all seals, orings and gas-
assembly (10). kets.
NOTE: The outside diameter of the spacer (2) 7. Inspect all threaded components for stripped or
serves as a sealing surface for the oil seal damaged threads, and replace as necessary.
(1). The spacer (2) should therefore be Carefully inspect wheel bearing retaining bolts
replaced if its outside diameter is nicked, use wet magnetic particle inspection method.
pitted, scored or grooved. Replace bolts if there is any doubt about their
condition. Damaged bolt threads will disturb the
relationship between the tightening torque and
INSPECTION the applied mechanical clamp load, resulting in
Numbers in parentheses refer to Figure 2. shim pack selection thickness errors. Inspect the
threaded holes in the spindle assembly (10)
1. Thoroughly clean all metal parts, except the ends. Clean the holes of any debris and lubricate
bearing cones (3 & 8) and bearing cups (4 & 7) the threads. You should be able to thread bolts
with a suitable solvent. Dry the parts with com- (11) in to spindle (10) by hand before bearing
pressed air and coat with light oil to facilitate adjustments are made.
assembly.
8. Check the cover plate (13) to insure it will main-
2. Clean the inner and outer bearing cones (3 & 8) tain an oil tight seal.
and the inner and outer bearing cups (4 & 7) in
volatile mineral spirits. Dry with a clean, lint-free
cloth or dry filtered compressed air. If drying with
compressed air, restrain bearing from rotating.
Lubricate with light oil and rotate to check for
wear or roughness. Visually inspect bearing cone
inner raceway surface finish and each bearing
roller surface. Replace bearing cones (3 & 8) and
the bearing cups (4 & 7) together as a bearing set
if excessive wear is found on any component of
the bearing set, or if rough or noisy operation is
noted.
3. Inspect the machined surfaces of all parts for

excessive wear, scoring, pitting or burring. Re-
surface or replace parts with excessive wear as
necessary. W8DX-07-71-002
Figure 3 - Front Wheel
W8-4-5
ASSEMBLY 4. Apply a thin uniform coat of anaerobic sealant to

the O.D. of the oil seal (1) and the inside diameter
Numbers in parentheses refer to Figure 2. of seal bore in the wheel (6) to cover 100% of
both surfaces. Press in the oil seal (1) flush with
1. If the spacer (2) was removed from the spindle the face of the wheel (6) so that the seal lips face
(10), install the spacer (2) and the O-ring (16). the outboard end of the spindle (10). Wipe clean
Lubricate the O-ring (16) and install it in the any excess sealant remaining exposed on sur-
groove in the spacer (2). Place the spacer (2) on face.
the spindle (10) with the beveled edge facing the
backing plate. Push the spacer (2) onto the 5. If the brake disc was removed from the wheel (6)
spindle (10). Be careful not to damage the O-ring assembly, reinstall it. Refer to Section W6-1,
(16) or the oil seal (1) surface on the outside FRONT BRAKES.
diameter of the spacer (2).
2. If the inner and outer bearing cups (4 & 7) were LUBRICATING FRONT WHEEL BEAR-
removed, use a suitable driver and install new INGS
bearing cups into the bores of the wheel (6).
1. Place the rigid dump truck in the “Service Posi-
NOTE: If inner bearing cups (4 & 7) were chilled tion”. Refer to W2-1.
prior to installation, check for clearance
behind the shoulder with a 0.05 mm 2. Remove bolts (11) cover plate (13) and gasket
(0.002 in) feeler gauge after they have (9). Capture drained grease from the front hubs.
returned to normal temperature. It may be Discard used lubricant in accordance with local
necessary to reseat them. environmental regulations.
3. Coat the inner bearing cone (3) with lubricant and 3. Rotate wheel until drain port is at 6:00 o’clock
install it in the inner bearing cup (4). Install the position. Allow enough time for viscous fluid to
washer (5) in the wheel (6). stop flowing.
4. Rotate wheel until drain hole is at the 3:00 or 9:00

o’clock position.
5. Pump metered volume of grease in through the

drain port to the center cavity of wheel hub.
Watch for grease flowing outward between
bearing rollers of outer bearing. Allow enough
time for grease to flow from center cavity of wheel
(6).
6. Quickly replace gasket (9) and install cover plate

(13). Install bolts (11) and tighten.
3
: /4 in
: 123 N٠m (90 lbf٠ft)
7. Manually rotate the wheel 10 revolutions in each

direction to allow the grease to flow between
bearing rollers. If this is not possible because
rims are mounted operate the rigid dump truck
for three minutes SLOWLY WITHOUT PAY-
LOAD (< 8 kph, < 5 mph).
W8-4-6
Wheel hub (6) Lubricant capacity Refer to Section W2-2, MAINTENANCE

Lubricant replace Every 15000 hours or when wheel (6) is removed for service
Acro set seating torque 183 N٠m
Six bolts (12) (135 lbf٠ft)
Acro set preload 135 N٠m
Two bolts (12) (100 lbf٠ft)
Acro set constant value 0.051 mm
0.002 in
Acro set bolt (12) 433 N٠m
Final assembly torque value 319 lbf٠ft
Wheel Hub 336.42 – 336.47 mm
Inner Bearing bore diameter (13.245 – 13.247 in)
Wheel Hub 234.85 – 234.90 mm
Outer Bearing bore diameter (9.246 – 9.248 in)
Wheel Hub
√3.2 (125)
Bearing bore machine finish
Figure 4 – Front Wheel Machining Specifications
W8-4-7
MEMO
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W8-4-8
FRAME SUSPENSION AND WHEEL / Rear Wheel
9 7, 8 5, 6
14 13 22 23, 24, 25 21
18 20 27
28
19
15
10 11 12 T8DX-07-71-002
26 4
1 16 2, 3 17
Figure 1 - Section View of Rear Wheel Assembly
1. Wheel 8. Inner Bearing Cup 15. Spindle 22. Dowel Pin

2. Shims 9. O-Ring 16. Outer Toric Face Seal 23. Ring
3. Retainer Plate 10. Wet Disc Brake Assy. 17. Internal Ring Gear Assy. 24. O-ring
4. Bolts (12x) 11. Brake Cover Plate 18. Carrier 25. O-ring
5. Outer Bearing Cone 12. Inner Toric Face Seal 19. Planetary Assembly 26. Retainer Plate
6. Outer Bearing Cup 13. Hub 20. Seal Retainer 27. Ring
7. Inner Bearing Cone 14. Bolts (12x) 21. Bolt 28. Dowel Pin
W8-5-1
REMOVAL

NOTE: Support the sun gear and axle shaft as-

sembly during removal to prevent damage
to the splines on the axle shaft and planet
gears.
1. Remove the tires and rims. Refer to the instruc-

tions provided in Group W8-6,
TIRES/RIMS/INFLATION.
2. Drain the host system hydraulic fluid tank. W8DX-04-66-004
Reclaim or Dispose of Oil Properly Figure 2 - Removing Sun Gear and Axle Shaft
Place a suitable container, at least 7.5L (2 gal)

under brake housing and remove drain plug to
drain the cooling oil from the brake housing. CAUTION: Weight of the wheel (1) assembly
Reinstall the drain plug. is: 1825 kg (4000 Ib).
: Square Bit 6.2 mm (0.24 in) 6. While supporting the wheel (1) with the lifting de-
vice, remove the ring (27), bolts (4), retainer plate
(3), wheel bearing adjustment shims (2), ring (23),
3. Drain the planetary and remove the axle shaft and O-rings (24, 25) and then remove the planetary
sun gear. Refer to Group W5-6, REAR AXLE and ring gear. Refer to Group W5-8, PLANETARY for
W5-8 PLANETARY for instructions on removal of ring gear removal. Discard O-rings (24, 25).
these components. : 1 1/2 in
A Minimum lifting device of 2.7 Metric Tonnes (3 7. Using the lifting device, carefully slide the wheel
Tons) is required to perform this procedure. (1) along the spindle toward the end of the spindle
(13). After the outer bearing cone (5) is loose, lift it
away and remove it from the spindle (15). Care-
CAUTION: Axle shaft and Sun Gear weight: fully slide the wheel (1) off the end of spindle (15)
115 kg (250 Ib). and hoist the wheel (1) away from the rigid dump
truck. The inner bearing cup (8), the outer bearing
4. Remove the planetary assembly. Refer to Sec- cup (6), and the inner toric face seal (12) will re-
tion W5-8, PLANETARY for removal instructions. main in the wheel (1) when it is removed from the
rigid dump truck. Place the wheel (1) in a clean
NOTE: Bolts (21) hold wheel assembly in place. work area.
Restrain wheel (1) anytime bolts (21) are
removed. 8. Do not remove the toric face seals (12 and 16)
unless they are worn or damaged.
5. Attach a lifting device of sufficient capacity to the
wheel (1). Support the weight of the wheel (1) so NOTE: If the toric face seals (12 and 16) are
it doesn’t drop when the retainer plate (3) is re- removed they must be reinstalled using
moved. new rubber torics.
W8-5-2
9. If it is necessary to remove the outer toric face seal 6. Insert outer bearing cone (5) aligned with retainer
(16), slide the seal retainer (20) off the spindle (13) plate (26) and dowel pin (22), ring (23) with new
and remove and discard the O-ring (9). O-rings (24, 25), planetary ring gear, retainer plate
(3) and bolts (4) to retain wheel (1) on spindle. Do
10. If replacement of the inner and outer bearing not tighten bolts (4) until shims (2) are properly
cones (5 and 7) is indicated by inspection, the selected and bearing adjustment is complete.
inner and outer bearing cups (6 and 8) should be Avoid rotation of wheel (1) unless wheel bearings
driven from the wheel (6) with a soft drift. Re- are properly seated. Refer to Section W5-8,
move dowel pin (22) from outer bearing cone (5) PLANETARY for planetary ring gear installation.
and dowel pin (28) from inner bearing cone (7). : 1 1/2 in
7. Refer to section BEARING ADJUSTMENT for

INSTALLATION proper selection of wheel bearing shim pack.
8. Install the planetary and fill with the correct
1. Install the O-ring (9) into the seal retainer (20). amount of the recommended fluid. Refer to
Lubricate the O-ring (9) with petroleum jelly or Section W5-8, PLANETARY.
something similar and carefully guide the seal
retainer (20) over the spindle splines and against
the spindle shoulder. Note that the dowel pins DISASSEMBLY
must align with the holes in the spindle face.
Reference Figure 1. Numbers in parentheses refer to Figure 1.
2. Coat the inner bearing cone (7) with oil and install 1. Do not remove the toric face seals (12 and 16)
it on the spindle with dowel pin (28) aligned with unless they are worn or damaged. Refer to toric
the seal retainer (20). face seal inspection at the end of this section.
3. Install the toric face seals (12 and 16) into their NOTE: If the Toric Face seals (12 and 16) are
respective bores in wheel (1), retainer (20) and removed they must be reinstalled using
brake cover plate (11). new rubber torics.
NOTE: The toric bore must be clean and oil free. 2. If it is necessary to remove the inner toric face
Refer to INSTALLATION TORIC FACE seal (12), slide the seal retainer (20) off the
SEAL. spindle (15) and remove and discard the O-ring
(9).
4. Lightly lubricate the mating surfaces of the toric
face seals (9 and 12) with clean hydraulic fluid. 3. If replacement of the inner and outer bearing cone
Support the wheel assembly (1) with the required is indicated by inspection, the inner and outer
lifting device. Ensure that the wheel is level and bearing cups (6 and 8) should be driven from the
centered over the spindle. The wheel assembly (1) wheel (1) with a soft drift.
splines must engage with the wet disc carrier,
refer to the wet disc brake assembly. Refer to
Section W6-2, REAR BRAKE. INSPECTION
5. Slowly guide the wheel assembly (1) along the Numbers in parentheses refer to Figure 1.
spindle (15) and into the splined teeth of wet disc
brake carrier. Rock or rotate the wheel (6) side to 1. Clean all metal components, except the bearing
side to align the splines in the disc carrier. Use cones (5 and 7) and the bearing cups (6 and 8) in
caution to prevent the face seals (12 and 16) from a suitable solvent. Large parts can be quickly
impacting each other as the properly aligned pressure washed clean. To prevent corrosion
wheel (6) will easily slide into place. Refer to damage of metal parts and to facilitate reassembly,
Section W6-2, REAR BRAKES. blow parts dry using dry compressed air. Coat all
the small parts with light oil. Clean the bearing
W8-5-3
cones (5 and 7) and bearing cups (6 and 8) in threaded holes in the spindle (15) ends. Clean the
volatile mineral spirits. Dry them with a clean, holes of any debris and lubricate the threads. Bolts
lint-free cloth. Lubricate bearings with light oil and (4) should thread into spindle (15) by hand prior to
rotate to check for damage, excessive wear or bearing adjustment and final assembly.
roughness. Replace both the bearing cups (6 and
8) and cones (5 and 7) if excessive wear is ap- 9. Visually inspect spindle (15), wheel (1) and
parent on either component. planetary for damage or cracks. If flaw or crack is
noticed, follow the visual inspection with a mag-
2. If toric seals are removed, inspect the seal groove netic particle inspection of entire assembly. Repair
beneath toric seals (12 and 16). If grooves are or replace any part found to be defective.
contaminated with hard packed material either
wire brush groove clean to bare metal or use lo- 10. Inspect the toric seal assemblies. Refer to
calized medium grit glass bead blast to clear TORIC FACE SEAL INSPECTION, this section,
grooves. for general guidelines.
3. Inspect the machined surfaces of all the parts for

excessive wear, scoring, pitting or burring. Re- ASSEMBLY
surface or replace parts with excessive wear as
necessary. Numbers in parentheses refer to Figure 1.
4. Inspect the wheels (1) for burrs on the bearing 1. Using a soft drift, drive the inner bearing cup (8)
shoulders if the bearing cups (6 and 8) have been and outer bearing cup (6) into their respective
removed. The burrs, which may occur when a counter bores in the wheel (1). Ensure both bear-
punch has been used to drive the bearing cups (6 ing cups (6 and 8) are fully seated against their
and 8) out, should be removed. Any burr could shoulders. Use a 0.025 mm (0.001 in) feeler
crush later, allowing the bearing cups (6 or 8) to gauge slid between parts to check seating of parts.
shift, resulting in a loss of pre-load. If gauge slips between the parts remove and
correct interference.
5. Minor fretting on the spindle end (15) or the re-
tainer plate (3) can be made smooth using a file or 2. Install the O-ring (9) into the seal retainer (20).
a stone. These surfaces should also be free from Lubricate the O-ring (9) with petroleum jelly or
dirt, nicks, burrs and corrosion. something similar and carefully guide the seal
retainer (20) over the spindle spline and against
6. Minor wear, less than 0.003 mm (0.076 in), on the the spindle shoulder. Note that the dowel pins
internal gear hub, the seal retainer (20), where must align with the holes in the spindle face.
contact is made with the bearing shoulder can be
tolerated. Parts with excessive wear should be 5. Coat the inner bearing cone (7) with oil and install
repaired or replaced. it on the spindle (15) with dowel pin (28) aligned
with the seal retainer (20).
7. On the rear axle any change in the width of the
seal retainer (20) will result in a corresponding 6. Install the toric face seals (12 and 16) into their
change in the squeeze on the face seals. Replace respective bores.
a worn seal retainer (20). Do not machine material
off to reclaim part. NOTE: The toric bore must be clean and oil free,
refer to Toric Face Seal Installation.
8. Inspect all threaded components for stripped or
damaged threads, and replace as necessary. 7. Lubricate the mating surfaces of the toric face
Carefully inspect the wheel bearing retaining bolts. seals (12 and 16). Proceed with INSTALLATION.
Use new bolts if there is any doubt about their
condition. Damaged threads will disturb the rela-
tionship between the tightening torque and the
applied clamp force, resulting in wheel bearing
shim selection calculation errors. Inspect the
W8-5-4
BEARING ADJUSTMENT place. If there is no noise, check for a reduction in

the 3 mm (0.125 in.) gap under the bolt (2) head. It
Numbers in parentheses refer to Figure 1. may sometimes be necessary to force the outward
movement of the wheel (6) with a bar or other
NOTE: For spindle references see Figure 1. suitable device. Failure of the movement to take
place will result in an incorrect shim pack selec-
1. Measure the thickness of the retainer plate (3), in tion.
the location where the shims (2) sit, in two places : 1 1/2 in
with a micrometer and then divide by two to obtain
the Average Thickness. Record this dimension as 5. Re-torque the four bolts (4) again. Tighten these
the “Retainer Plate Thickness” in Chart 1 (Ref- bolts alternately increasing increments to a value
erence Data Table). of 217 N⋅m (160 lbf ft). The wheel must be rotated
as the bolts are being tightened. Retighten each
2. Assemble all the parts on the spindle (15), in- bolt (4) five times until the bolt no longer turns at
cluding the wheel seals, but without using shims the specified torque value.
(2). Install the seal retainer plate (3) on the spindle : 1 1/2 in
(15) end with the two measuring holes located : 217 N٠m (160 Ibf٠ft)
near the 12:00 and 6:00 o’clock positions. Install
the six bolts (4) into the threaded holes in the 6. Using a depth micrometer, take a measurement
spindle (15), evenly spaced around the spindle from the surface of the retainer plate (3) to the end
(15). of the spindle (15) at each measuring hole. The
: 1 1/2 in measuring holes should be near the 12:00 and
6:00 o’clock positions and adjacent to a tightened
bolt (4). Record the two dimensions as “Depth No.
NOTE: Using a calibrated torque wrench, tighten
1 and Depth No. 2”. If the measurements differ by
bolts (4). Do not apply the torque with
more than 0.13 mm (0.005 in), the tightening
jerky movements. Use uniform pressure
and continue to re-torque the bolts at least procedure should again be repeated (steps 2 – 5).
five times to ensure that they have the
correct torque. 7. Add the two depth dimensions, Depth No. 1 and
Depth No. 2, together and record as the
“Sub-Total” in chart, refer to Chart 1.
NOTE: While tightening and torquing the bolts (4),
continually rotate and bump the wheel (1)
8. Divide the sub total dimension by 2 to obtain the
or the internal gear hub several times in an
average of the two depth readings. Record this as
axial direction with a steel bar.
the “Average Depth” in Chart 1.
3. Tighten the six bolts (4) uniformly in increments,
9. Subtract the “retainer plate (3) thickness” (refer to
using a crisscross pattern, slowly increasing to a
step 1) from the “Average Depth”. Record this as
final torque of 203 N⋅m (150 lbf⋅ft). The wheel (1)
the “Average Gap” in Chart 1.
must be rotated as the bolts (4) are being tight-
ened to ensure proper seating of the parts. Re-
10. Add the appropriate correction factor from Chart 1
tighten each bolt five times until it no longer turns
(Add Constant) to the “Average Gap” to obtain the
at the specified torque value.
required shim pack thickness. Record this as the
: 1 1/2 in
“Total Shim Pack Requirement” in Chart 1.
: 203 N٠m (150 Ibf٠ft)
11. Make up the shim pack using clean flat shims.
4. Loosen then remove all of the retainer bolts (4)
Assemble the Shim Pack by individually meas-
except four evenly spaced around the spindle (15).
uring each shim, then adding the individual shims
Loosen and retract these two bolts out approxi-
to attain the “Total Shim Pack Requirement”.
mately 3 mm (0.125 in). Rotate the wheel (1). The
wheel (1) and/or the internal gear hub should
12. Record the “Actual Shim Pack Now Used” in Chart
move outward. There may or may not be a noise.
1.
The noise indicates that the movement has taken
W8-5-5
NOTE: The “Actual Shim Pack Now Used” must and position it with the shim pack on the spindle
be equal to or up to 0.050 mm (0.002 in) (15) and secure with the bolts (4). Tighten the bolts
less than the “Total Shim Pack Re- lubed to the specified torque.
quirement”. : 1 1/2 in
: 1048 N٠m (773 Ibf٠ft)
13. Secure the wheel (1) with the lifting device, and
remove the four bolts (2) from the retainer plate (1)
Left Wheel Right Wheel

Depth No. 1
Depth No. 2
Depth Subtotal = (Depth 1 + Depth 2)
Average Depth (Depth Subtotal ÷ 2)
Retainer Plate Thickness (subtract)
Average Gap = (Avg. Depth – Retainer Thickness)
Add Constant (+) 0.127 mm (0.005 in) 0.127 mm (0.005 in)
Total Shim Pack Requirement = (Gap + Constant)
Actual Shim Pack Used Previously (Record)
Actual Shim Pack Now Used (Record)
Chart 1 – Reference Data Table
W8-5-6
TORIC FACE SEAL INSPECTION
A - A slightly used seal will have a witness pattern close to the outside
diameter of the seal face. If contact surface is highly polished and does
not have radial surface scratches, seal is acceptable for reuse.
B - A seal with a non-concentric witness pattern must be replaced.
C - As a seal wears, the witness pattern decreases in diameter. A seal wit-

ness pattern that is concentric and has worn past the center of the seal
face width must be replaced.
A B C
W8DX-05-12-004
Figure 3 - Face Seal Wear Pattern
W8-5-7
Numbers in parentheses refer to Figure 1. 3. Seat one rubber toric (53) on one seal ring (52). The
rubber toric (53) must not be twisted. The rubber
toric (53) must be uniformly seated on the retaining
NOTE: All parts should be thoroughly inspected for lip of seal ring (52).
damage and replaced if necessary.
4. Place the assembled face seal into the proper in-
1. Inspect the toric face seals (12 and 16). The sealing stallation tool (54), Figure 5. Refer to W2-4, SPE-
faces must not be nicked, pitted, scored or corroded. CIAL TOOLS.
It is normal for the sealing surface to progress to-
ward the inner diameter with wear. Outer toric face 5. Dip the rubber toric (53), Figure 6 in Trichloroethane
seal (12) is exposed to external dirt; it is normal for to aid in assembly. Or use alternate of aerosol brake
the outer diameter of this seal face to show signs of cleaner to rinse and wet the toric seals. Spray the
abrasion. This condition is acceptable provided a rubber toric (53) and the bore of seal ring (52) until
clean sealing face still exists toward the inside di- they are completely soaked wet.
ameter.
CAUTION: Trichloroethane III - Avoid pro-
2. The Toric face seals (12 and 16) must be replaced if longed skin contact. Use in adequate ventila-
the sealing face wear pattern is not concentric with tion. Follow manufacturer’s instructions on
the outside diameter or is worn beyond the inner half label and warnings.
of the seal ring. Refer to Figure 3.
3. The rubber torics should be replaced if seals have

over 500 hours operational use at time of disas- 53
52
sembly or if the seal was removed from the bore.
Never displace and reinstall a used rubber toric.
4. Clean all metal components in mineral spirits or

equivalent solvent. Allow parts to air dry.
5. Inspect machined surfaces of all parts for scoring,

pitting, burring or excessive wear.
TORIC FACE SEAL INSTALLATION
Numbers in parentheses refer to Figures 4 through 9,

1. The toric face seals (12 and 16, Figure 1) consist of W8DX-05-12-007
two seal rings (52, Figure 5), and two rubber torics
(53). Figure 4 - Section View of Toric Face Seal.
52. Face Seal Ring 53. Rubber Toric

2. Clean all parts with a non-filming solvent and a clean
lint-free cloth. Seal ring (52), rubber toric (53) and
the area in the housing the seal will seat must be free
of all oil and dirt.
NOTE: Do not use any solvent that leaves behind a

film or does not evaporate quickly. Never use
oil or kerosene.
W8-5-8
54
52
53 NOTE: Any contamination, even a piece of lint is
sufficient to cause leakage of the seal as-
sembly.
NOTE: Do not allow faces to impact together. Seal

rings are brittle and may scratch or fracture.
W8DX-05-12-008
Move mating pieces slowly and carefully
Figure 5 - Toric Installation when aligning together during assembly.
52. Face Seal Ring (Steel) 54. Installation Tool

53. Rubber Toric
54
52
NOTE: If Trichloroethane III is not available or per-
mitted due to local regulations, some brake 53
cleaners are Trichloroethane III free and
56 56
are acceptable substitutes. A 10% mixture
of mild dishwashing soap and water can be
used as an assembly substitute lubricant.
Avoid wetting metal face seal with water as
highly polished metal seal surface is easily
corrosion etched. 55
W8DX-05-12-009
6. With rubber toric (53) still wet, set seal ring (53) and Figure 6 - Toric Installation
installation tool (54) held square against seal
housing (55). Refer to Figure 6. Use sudden and 52. Seal Ring 55. Seal Housing
even pressure against the tool to push the toric 53. Rubber Toric 56. Retaining Lip
under the retaining lip (56) of seal housing 54. Installation Tool
7. Ensure that rubber toric (53) is uniformly captured

under retaining lip (56, Figure 6). Ensure that the
face of seal ring (52) is parallel to seal housing (55)
within 1.0 mm (0.040 in.). Ensure that rubber toric is
not twisted or pined. (Refer to Figure 10).
NOTE: Improper wetting of the toric or burrs on the

housing seat can cause the toric to twist or
tear. The toric must slide uniformly into the
housing. Improper installation will cause
premature seal leakage.
8. Repeat procedure for installation of the other toric

face seal half.
9. Wait at least two minutes before mating seals and

housings to ensure complete evaporation of sol-
vent from the torics.
10. Just prior to assembly, wipe the seal faces of seal

ring (52) with a lint-free cloth moistened with clean
hydraulic oil. Do not get oil on rubber torics (53).
W8-5-9
55
54 52
53
53
56 56
52
55
W8DX-05-12-010 W8DX-05-12-011
Figure 7 - Section View of Toric Face Seal. Figure 8 - Section View of Toric Installed
52. Face Seal Ring 55. Seal Housing 52 . Face Seal Ring 55. Seal Housing
53. Rubber Toric 56. Retaining Lip 53 . Rubber Toric
54. Installation Tool
SURF. “B”
SURF. “A”
SEAL RING
SURFACE “B” PARALLEL CORRECT

TO SURFACE “A”
HOUSING (WHEEL, SPACER,

BRAKE, COVER, HUB ADAPTER)
SEAL TORIC SEAT
SURF. “B”
SURF. “A”
SURFACE “B” NOT

PARALLEL TO SURFACE “A”
INCORRECT
TORIC TWISTED
W8DX-05-12-012
Figure 9 - Correct and Incorrect Indication
W8-5-10
Description Specification
Wheel Hub 447.573 - 447.624 mm
Inner bearing bore diameter (17.6210 - 17.6230 in)
Wheel Hub 447.573 - 447.624 mm
Outer bearing bore diameter (17.6210 - 17.6230 in)
Wheel Hub
12.7 (500)
Machine finish - bearing bores
Wheel spindle (rear) 317.470 - 317.495 mm
Inner bearing seat diameter (12.4988 - 12.4998 in)
Wheel spindle (rear) 317.470 - 317.495 mm
Outer bearing seat diameter (12.4988 - 12.4998 in)
Wheel spindle (rear)
1.6 (63)
Machine finish - bearing seat
Acro-set seating torque
203 N٠m (150 Ibf٠ft)
(total six bolts installed)
Acro-set pre-load torque
217 N٠m (160 Ibf٠ft)
(total four bolts installed)
Acro-set constant (add) 0.127 mm (0.005 in)
Acro-set plate bolt torque

1048 N٠m (773 Ibf٠ft)
(final assembly torque value)
W8-5-11
W8-5-12
W8-5-13
MEMO
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W8-5-14
FRAME SUSPENSION AND WHEEL / Tires/Rims/Inflation
11
12
5
9
10
8
4
6 3 2
W8DX-07-72-011
Figure 1 - Section View of Rim Assembly Typical Front Axle Installation
1. Valve Cap 5. Spacer 9. Rim Clamp

2. Flange, Rim 6. Flange, Rim 10. Clamp Nut
3. Rim Base 7. Bead Seat Band 11. Valve Assembly
4. O-Ring 8. Lock Ring 12. Wheel
SERVICE POSITION

W8-6-1
REMOVAL Numbers in parentheses refer to Figure 1.
FRONT RIM & TIRE 1. Apply the parking brake and chock the front and
rear of all wheels except the one to be raised. Re-
fer to Figure 2.
CAUTION: Before performing any type of
service on the tires or rims, always remove
2. Jack up the rigid dump truck until the tire & rim
the valve core and exhaust all the air from a
that is to be removed clears the ground by ap-
single tire and both tires of a dual assembly
proximately 150 mm (6 in). Then place a stand
prior to loosening the first rim clamp nut. If
under the frame (block if necessary).
air does not escape when valve core is re-
Refer to Section W2-3, LIFTING AND JACKING.
moved check the valve stem by running a
piece of wire through the valve stem. This is
3. As shown in Figure 4, remove the valve cap (11c)
done to make sure it is not plugged with ice,
and the valve core (11b) from the valve (11a) to
tire sealant or dirt.
completely deflate the tire.
3
: /8 in
: 0.6 - 1.7 N٠m (0.4 - 1.2 lbf٠ft)
: Valve Core Tool (Figure 5)

: 0.3 - 0.6 N٠m (0.3 - 0.4 lbf٠ft)
CAUTION: Control tire valve core when re-
moving. Escaping air is under pressure and
valve core (11B) may eject if not trapped caus-
ing injury.
Figure 2 - Wheels Chocked W8DX-07-72-001
11B
11A
11C
Figure 4 – Removing Valve Cap and Core
11A. Valve 11C. Valve Cap

11B. Valve Core
W8DX-07-72-002
Figure 3 - Cribbing at the Front Bumper

/ Frame for Tire remove
Figure 5 – Tire Valve Core Removal Tool
W8-6-2
4. Loosen the clamp nuts (10) just enough to facili-

tate their removal after the rigid dump truck is
jacked up and the tires are completely deflated.
: 1 ½ in
W8DX-07-72-005
Figure 7 – Removing the Clamp Nuts and Rim Clamps

W8DX-07-72-004
Figure 6 – Loosening the clamp nuts
NOTE: Special equipment designed specifically for

handling, moving, and repair of large earth-
mover tires is available. Consult tire manu-
facturer for additional information.
5. Rotate wheel so tire valve is located at 6:00

o’clock position. Support the tire & rim with tire
sling of sufficient strength attached to a suitable
lifting device. Remove the clamp nuts (10) and rim
clamps (9) from the wheel (12) assembly as
shown in Figure 6, and hoist the tire and rim as-
sembly free. Use care not to impact damage tire
valve while hoisting tire & rim.
W8-6-3
ELI12620547
Figure 7- Cutaway View of Typical Dual Rear Wheel Assembly
1- Wheel Nut 5- Valve 9- Flange 13 - Spacer Band

2- Dagger Clamp 6- Lock Ring 10 - Rim Base 14 - Extension
3- Stud 7- Bead Seat Band 11 - Tire 15 - Bolt
4- Cap 8- O-Ring 12 - Wheel 16 - Valve Stem Bracket
W8-6-4
REAR RIM & TIRE
1. Apply the parking brake and block the front and

rear wheels, except the wheel to be raised.
Chock wheels as necessary. Refer to Figure 2.
2. Crib the rear axle nearest the tire to be removed.

Jack up the rigid dump truck until the tire that is
to be removed clears the ground by approxi-
mately 150 mm (6 in), use blocks if necessary.
Refer to Figure 9 and Section W2-3, LIFTING
AND JACKING.
3. Remove the valve stem bracket. Then remove

the valve cap (11C, Figure 4) and valve core
(11B, Figure 4) from each valve stem (11A, Fig- W8DX-07-72-008
ure 4) to completely deflate inner and outer tire of

dual rear wheel assembly. Figure 9 - Cribbing at Rear Axle for Tire Removal
3
: /8 in
: 0.6 - 1.7 N٠m (0.4 - 1.2 lbf٠ft) 5. Rotate tire and rim so valve stem is located in
6:00 o’clock position. Support the outer tire with a
: Valve Core Tool (Figure 5) tire sling attached to the lifting device. Remove
: 0.3 - 0.6 N٠m (0.3 - 0.4 lbf٠ft) the outer clamp nuts (14) and dagger clamps (13)
from the wheel studs (15), and lift the tire and rim
4. Loosen the outer wheel clamp nuts (14), just assembly free. Use care not to impact damage
enough to facilitate their removal, after the rigid tire valves during hoisting of tire & rim.
dump truck is jacked up and the tires are com-
pletely deflated. 6. If the inner rim assembly is being removed, again
: 1 ½ in check the condition of the rim assembly. If ques-
tionable, ensure tire is completely deflated and
remove the band spacer. Attach the lifting device
to the tire and rim assembly, and remove it from
W8-6-5
INSTALLATION NOTE: Mating contact surface of rim base to wheel

hub, rim base to clamp or dagger and rim
Install the tire and rim by reversing the removal pro- base to spacer band must be clean,
cedure. The recommended installation procedure is smooth and free of paint, grease, oil, etc.
as follows; refer to Figure 10. Inspect this area on inside diameter of rim
and outside diameter of wheel hub before
assembly. Refer to Figure 10, surface “A”.
4. Install the dagger clamps (2) and clamp nuts (1).

Follow the torque sequence shown in Figure 11.
Repeat pattern until applied tightening torque is
achieved and fastener no longer rotates. Ensure
the dagger clamp is wedging straight during the
torquing process.
: 1½ in
: 942 N٠m (695 lbf٠ft)
W8DX-07-72-014
Figure 10 - Wheel, Rim and Clamp Assembly
1. Thoroughly clean the stud (3) and hole threads

using thread lock solvent removing all dirt and
grease.
2. Apply a thread locking compound comparable to

Green Loctite 680 to both thread surfaces, using Figure 11- Nut Tightening Sequence for Rear Wheels
sufficient quantity to ensure full coverage on a
minimum of 4 threads of each component. 5. The rim clamp nuts (1) should be checked for the
proper torque after one trip then re-torque again
3. Install the studs to exposed length dimension as after 3 loads, and continue the re-torque every 3
shown in Figure 10. loads until the tightening torque has been
achieved and maintained. Check all around the
rim for proper component seating. If necessary,
NOTE: Allow full curing of the thread lock com- deflate the tire and adjust the components if
pound before full torque is applied to the needed.
clamp nuts. At room temperature, full cur-
: 1½ in
ing will occur in 1-2 hours. Addition of : 942 N٠m (695 lbf٠ft)
heat will affect full cure. Consult the
manufacturer’s instructions on accelerat-
ing the curing process.
W8-6-6
6. Always inflate the cold tires as recommended by NOTE: Consult tire manufacturer’s maintenance
tire manufacturer before operation. guide for specific tire inspection guide-
lines. Because operating conditions for
CAUTION: Before performing any type of Off-the-Road tires is extremely severe,
service on the tires or rims, always remove frequent inspection of the tires is neces-
the valve core and exhaust all the air from a sary. The external appearance of tire
single tire and both tires of a dual assembly sidewalls and tread, valves, rims and in-
prior to loosening the first rim clamp nut. flation pressure should be inspected on a
Check the valve stem by running a piece of daily basis before operation of rigid dump
wire through the stem to make sure it is not truck.
plugged.
DISASSEMBLY 1. Inspect the tire for deep cuts. The tire should be
removed if deep cuts reaching the casing ply (9)
For complete information pertaining to dismounting are present. The tire should be destroyed and
the tires from the rims, refer to the tire manufacturer’s disposed if cuts or breaks in the sidewall (5) can-
tire maintenance manual. It is recommended that a not be repaired.
certified tire repair service perform dismount-
ing/mounting operation of tires from the rims. Reclaim or Dispose of Tires Properly
INSPECTION NOTE: Determine root cause of tire cut and take

corrective action to alleviate problem.
Example is a bent or broken rock ejector
6 7 puncturing a tire sidewall, or a sharp rock
protruding from haul road. Minor tread
8 cuts can be excavated open to minimize
tearing of tread. Consult with distributor
of tire manufacturer for specialized tire
repair services.
6
2. Inspect the tread (7) for separation from the cas-
5 ing ply (9). If separation is found or if there is ex-
cessive peeling of the tread, the tire should be
4 9 scrapped.
3
3. Inspect the beads (10) and sidewalls (5) for rim
4
flange chaffing. If chaffing is present, continue to
2 1 12 11 10 use with monitoring of tire.
T8DX-07-72-001
4. Inspect the tread (7) grooves for cracking. If

Figure 12 - Section View of Typical Tubeless Tire deep cracks are found, consult the tire manufac-
and Rim Assembly turer.
1. Bead Seat Band 7. Tread 5. If abnormal wear of the tire such as feathering or
2. O-Ring 8. Breakers quick wear of the center or a shoulder of tread (7)
3. Lock Ring 9. Plies is observed, the tires should be rotated or re-
versed. Additionally the inflation pressure and
4. Side Flange 10. Beads
payload size should be monitored.
5. Sidewalls 11. Rim Base
6. Carcass 12. Inner Liner
W8-6-7
6. If irregular wear or the wearing of one tread (7) 8. The rim parts should be inspected individually for
shoulder is found on the tire, the brakes, wheels, any damage to the rim base (11), bead seat band
bearings and alignment should be checked. (1) and side flanges, (4) which are common areas
of fracture, as shown in Figure 13. Fretting can
7. Clean all of the rim components of dirt, rust, etc also occur at the side flange (4), rim base (11) in-
during servicing. Repaint rim parts as required to terface. If there are any signs of fracture or fret-
control corrosion. Additives have been developed ting, the affected rim component should be
to control corrosion inside tire and rim. Consult scrapped.
with tire manufacturer before using these types
of products in hauler tires.
CAUTION: Do not mix similar components

from different rim manufacturers. Do not use
any visibly damaged rim components. Doing
so could result in failure of the rim assembly.
Figure 13 – Areas of Rim Fracture
ASSEMBLY
For complete information pertaining to mounting tires

on rims, refer to the tire manufacturer’s applicable tire
maintenance manual. It is recommended that certified
tire repair service perform tire repair or dismount-
ing/mounting of tires from the rims.
W8-6-8
NOTE: Select replacement tires carefully. Re-
To obtain maximum service from off-highway tires, the placement tires must be rated to operate
precautions outlined below should be followed. at rigid dump truck gross weight, esti-
mated speed, and capable for distance of
INFLATION haul road. Consult with tire manufacturer
for recommendations on replacement tire
Inflation pressures are established to fit the load and selection.
speed of the rigid dump truck. Off-highway tires are
designed and built to permit deflection for the type of
NOTE: If excess loads are encountered, cold infla-
service required of them. The tire is a working mem-
tion pressures must be increased to com-
ber of the overall suspension system of the hauler.
pensate for higher loading. For each 1%
increase in the load, cold inflation pressure
Over inflation may result in high cord stress which
must be increased 2% up to the maximum
reduces resistance to blowout from impact and in-
inflation pressure of tire. Consult tire manu-
creases the potential of rock cuts. Hauler ride quality
facturer for recommendations.
also is affected with complaints of harsh hauler ride.
Under inflated tires are subject to an increased per- NOTE: For 65 km/h (40 mph) maximum travel
centage of deflection which results in excessive cyclic speed, payload must be reduced 12%
flexing of the tire side wall and tread. Operation under with no change to inflation pressure.
these conditions results in uneven or localized tread
wear, sidewall radial cracks, ply separation and loose NOTE: Never exceed tire manufacturers Maximum
or broken cords inside the tire. Suspension and steer- Excess Load Rating for tire or Maximum
ing is affected with complaints of slow steering re- Excess Load Pressure recommendation.
sponse or difficulty in holding a straight line without Beyond these values load may exceed the
corrective steering. tire’s capability resulting in reduced tire per-
formance.
Select correct tire inflation pressure for various tire
loads. Refer to tire manufactures general data for tire NOTE: Majority of rim equipment fretting or fracture
pressures for your rigid dump truck and specific tire damage is result of operation at low infla-
selection. Standard method is to start with recom- tion pressure or excessive payload. Monitor
mended inflation value for operation to maximum tire inflation and hauler payload daily.
speed of 50 km/h (31 mph). Use this general data
value until enough site data is available to optimize
inflation pressure for your hauler.
NOTE: Refer to your tire manufacturer’s recom-

mendations for inflation pressures which
may differ depending on the tire construc-
tion, size and ply rating.
NOTE: When “roading” a rigid dump truck between

jobs, it is important to contact your tire dis-
tributor for the recommended highway
operating pressure and maintain that
pressure. Do not allow tires or drive com-
ponents to overheat during high speed
travel.
W8-6-9
MEMO
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W8-6-10
SECTION 9
CAB
—CONTENTS—
Group 1 Cab Mounting

Removal ...................................................... W9-1-1
Installation ................................................... W9-1-1
Inspection.................................................... W9-1-2
Group 2 Air Conditioning

Servicing ..................................................... W9-2-4
Special Tools ............................................... W9-2-6
Repair Procedures .................................... W9-2-17
Maintenance Standard .............................. W9-2-23
W9-0
<BLANK>
W9-0
CAB / Cab Mounting
SERVICE POSITION and lock nut (11). Lift the cab using the four lifting lugs
at the four top corners of the cab.
Before checking and/or servicing the rigid dump truck, : 2¼ in
park it on a level solid surface and put it in the “Service : 3/4 in
NOTE: Before hoisting cab, check hose connec-
tion clearance at air conditioner, cab
heater, brake valve and steering valve.
As cab is raised, check hoses frequently
so hose damage does not occur. If hose
connection does not have adequate
clearance to raise cab, remove hose
connection before raising cab. Same rule
applies to electrical harnesses that are
connected to cab assembly.
Reclaim or Dispose of Oil Properly
INSTALLATION
If the cab mounts are being replaced, they are to be
assembled in the same orientation as shown in Figure
2.
NOTE: None of the screws (1, 5) should be tight-

ened before all cab mounting parts are in
place and cab is resting, aligned on frame.
1. Insert new cab mounts (2) into hole on frame.

Figure 1 – Cab Mounting
2. Lower cab in place down over new cab
REMOVAL mounts (2). Check alignment of cab mount is
centered in both hole in frame and hole in
cab.
CAUTION: Cab approximate weight: 1500 kg
(3300 lb)
3. Place snubber washer (3) over top of cab
mount (2) protruding through hole in cab
bracket.
The cab is held in place by a three point cab mounting
4. Install hardware in sequence: washer (6),
system using semi-rigid mounts (2) located beneath
screw (1, 5), washer (6, 8) and locknut (4).
the floor of the cab. Each mount consists of screws (1,
Apply thread locking compound (12) Loctite
5), washers (6, 8), snubbing washer (3), cab mount (2),
Product 242 (blue) to threads of screws (1, 5)
nut (11) and cotter pin (7). Replacement of the cab
before installation.
mounts does not require the cab to be removed from
the chassis. The semi rigid mounts can be replaced by
5. Torque all mounting screws (1, 5).
raising the cab just enough to remove and replace the : 2¼ in
semi- rigid mount (2) and snubbing washer (3). Prior
to lifting the cab, remove pin assembly (9), screw (10) : 813 - 1085 N٠m (600 - 800 Ibf٠ft)
W9-1-1
CAB / Cab Mounting
6. Install cotter pins (7).
7. Install any additional hose connections or

electrical connections removed to gain ac-
cess or additional clearance.
8. Install pin assembly (9), screw (10) and lock

nut (11).
: 3/4 in
: 123 N٠m (90 Ibf٠ft)
Figure 2- Cab Mounting Parts
1. Screw 5. Screw 9. Pin Assembly

2. Cab Mount 6. Washer 10. Screw
3. Snubbing Washer 7. Cotter Pin 11. Lock Nut
4. Lock Nut 8. Washer 12. Adhesive
INSPECTION MAINTENANCE STANDARD
Inspect the face of snubbing washer (3) for wear or Visually inspect cab Every 1500 hours of op-
tearing of the bonded rubber element. Check the mounting screws (1,5) eration or 6 months
bonded rubber of cab mount (2) for wear or missing and cotter pin (7) installa- (1500hrs / 6 months)
material. If these parts have taken a compression set tion
where the mounting surface is distorted or has a deep Check cab mounting Every (3000 hrs / 1yr)
impression witness mark from contact with the surface screw (1, 5) torque
they should be replaced. If the rubber elements have Remove and inspect cab If excessive vibration or
decayed because of chemical reaction with leaking mounts (2) unusual noise complaint
coolant or oil, replace. The cab mounting is part of the occurs
ROPS system and only genuine replacement parts are Remove and replace all At time of high energy
recommended for installation. Periodically check and cab mounting parts. impact, roll over, intense
tighten cab mounting screws during maintenance fire or accident
inspection.
W9-1-2
CAB / Air Conditioning
SERVICE POSITION
put it in the “Service Position.” Refer to W2-1.
Figure 1- Component Location
1. A / C Air Conditioning Compressor 2. Receiver Dryer 3. Condenser
NOTE: All maintenance and service work to the

air conditioning system should be per-
formed by qualified personnel. Local or
National rules and regulations may require
the specific licensing or certification of
personnel performing air conditioning sys-
tem maintenance and service work.
W9-2-1
Figure 2- Major Components of Typical Air Conditioning System
Figure 4 – Cab Filter
1. Cab Outside Filter 2. Outside Airflow

Figure 3 – A/C Compressor Mounting
W9-2-2
1 7
1
5
4
2
Figure 5- Air Conditioning Unit
3
1. Inside Filter Figure 7 – Air Conditioning Unit (Outside View)
1. Outside Filter 2. Heater Valve

3. Refrigerant hose to 4. Evaporator, Expansion
Compressor Valve
5. Tube to Evaporator 6. Tube from Evaporator
7. Tube from Condenser 8. Receiver / Dryer
Figure 6 – Air Conditioning (Inside View)
Figure 8 – Dashboard Air Flow (Inside View)
7A. Defrost Vents, Wind- 7C. Face Vents, Opera-

shield tor and Passenger
7B. Defrost Vents, Side 7D. Floor Vents
Windows
W9-2-3
SERVICING
Before servicing the air conditioning system, it is im-
portant to know the rigid dump trucks system; R-12
or R-134a refrigerant. A label attached to the com-
pressor will identify R-134a air conditioning systems
on Hitachi rigid dump trucks. See Figure 13.
1. Do not mistake refrigerants. If an R-134a air

conditioner system is mistakenly charged with EL153
R-12, serious problems, such as compressor Figure 13 – A/C System Plate

seizure can result. Confirm before charging with
refrigerant that the type of air conditioner sys-
tem is in fact an R-134a system. Countermea-
sures to avoid charging with the wrong refrig-
erant have been taken. These include different
shaped service valves, different service tool
thread sizes, and caution stickers and labels.
WARNING: Direct contact with refrigerant

can cause frostbite or blindness. Always
wear safety glasses and protective gloves.
Do not work with refrigerant close to the
face.
Figure 14
2. Always wear eye and hand protection when
working with any refrigerant or air conditioning
system. Extreme care should be used when
handling R-134a in order to prevent freezing of
body tissues. Refer to Figure 15.
3. The air conditioning system is under high pres-

sure whenever refrigerant is present in the sys-
tem. Take necessary precautions when servic-
ing the system while under pressure, and avoid
releasing refrigerant into the atmosphere. Al-
though R-134a is not subject to CHLORO- Figure 15
FLUROCARON (CFC) regulations, it can have
an effect on global warming, and must not be
released into the air. When removing refrigerant
from the air conditioning system, always use a
refrigerant recovery unit made especially for
R134a, meeting SAE/UL Standards. Refer to
Figure 16.
Figure 16
W9-2-4
4. To avoid injury, never introduce compressed air

or oxygen to any refrigerant container or com-
ponent. R-134a in the presence of air or oxygen
above atmospheric pressure may form a com-
bustible mixture.
5. If accidental discharge occurs, avoid breathing

refrigerant/lubricant vapor or mist. Ventilate the
work area before resuming service. You may
be required by local regulations to document
the accidental release.
6. Use only approved and calibrated recovery and

recharge equipment (Figure 24) or weight scale
(Figure 31) in order to avoid venting refrigerant
into the atmosphere when charging with R-134a.
Proper charge determination is critical for air
conditioning system performance.
7. Use only approved recovery and recharge

equipment for dispensing R-134a. Do not store
or heat refrigerant container or recovery equip-
ment at temperatures above 525 ºC (1255 ºF).
8. Only the manufacturer's specified lubricants for Figure 17 – Cap to Minimize Moisture Absorption
R-134a air conditioning system and compo-
nents should be used. If a lubricant other than
specified is used, air conditioning system failure
can occur. R-134a systems use Polyalkylene
Glycol (PAG) or ester oil lubricants.
9. PAG oil will absorb moisture from the atmos-

phere at an extremely rapid rate. When remov-
ing or installing air conditioning system compo-
nents, cap all fittings and keep them capped un-
til the moment of connection in order to mini-
mize moisture absorption.
W9-2-5
SPECIAL TOOLS
NOTE: R-134a and R-12 service tools are not

interchangeable.
In order to distinguish R-134a service tools from

those for R-12 systems, the service tools for R-134a
systems have been changed according to SAE stan-
dards. Refer to Figures 18 and 19.
NOTE: R-12 service tools are specified with

imperial sizes.
A compressor oil testing kit should be made available

in the event that the compressor oil is of question-
able quality and needs to be tested for contaminants.
Figure 18 – R-12 Manifold Gauge (Top) and R-134a

Manifold Gauge (Bottom)
Figure 19 – R-12 Charging Hoses (Top) and R-134a

Charging Hoses (Bottom)
W9-2-6
For R-134a identification purposes the hoses are

color-coded. See Figure 20.
Low pressure test hose Blue

Center test hose Yellow
High pressure test hose Red
NOTE: Do not use any hose if defects are found.
Check each hose for cracks or bulging. If these signs

are noticed, discard the hose. Check the rubber
EL15327
packing. If deteriorated or cracked, replace it. Figure 20 – Manifold Gauge Set
Part Number: OEM 1419
The high and low pressure hoses are color coded for
identification. A linear stripe may be printed on the
R-134a service hoses for proper identification.
Figure 21 – Charging Hoses
To prevent refrigerant from escaping during installa-

tion and removal of charging hoses from the vehicle's
charging valves, quick connect type fittings are used.
Refer to Figure 22.
Figure 22 – Quick Connect
W9-2-7
NOTE: The shape of the charge valve has been

changed on R-134a systems in order to
distinguish them from the charge valves
used in R-12 systems. See Figure 23.
Push quick connect on firmly until a “clicking" sound

is heard, indicating quick connect is locked to charge
valve. To remove, hold the quick connect grip ring
and pull. Refer to Figure 23.
Figure 23 – Charging Valve/Quick Joint Connection
EL15328
Figure 24 – Charging Cylinder

Part Number: OEM-1425
EL15329
Figure 25 – Ratchet for Compressor Valve

W9-2-8
EL15330
Figure 26 – Thermometer
Part Number: OEM=1256
A leak detector specifically for R-134a must be used

or a suitable dual R-12/R-134a detector.
NOTE: R-12 leak detector sensitivity is low,

therefore it cannot be used to detect
R-134a.
Figure 27 – Dual R-12/R-134a Leak Detector

Figure 28 – Dual R-12/R-134a Vacuum Pump

W9-2-9
NOTE: Mineral based oil used in R-12 systems is

not compatible with R-134a systems. It is
critical that only the specified oil be used
in an air conditioning system.
PAG 100 (Poly Alkylene Glycol) oil, the type used in

the R-134a system, absorbs moisture very quickly.
Special care must be taken when handling PAG 100
oil and the components which require PAG oil lubri-
cation.
EL15333
Figure 29 – Compressor Oil

Sight Glass
Sight Glass
A sight glass is provided on the receiver-drier. It pro-
vides a visual check of the refrigerant passing
through the system. Refer to Figure 30.
Figure 30 –Receiver/Drier
The scale shown in Figure 31 is used to measure the
weight of the refrigerant during charging of air condi-
tioning system.
NOTE: These tools and additional air condition-

ing tools are available from OTC. Address
and phone number for OTC is in SPE-
CIAL TOOLS, Group 1 in this manual.
Figure 31 – Scale
W9-2-10
Manifold Gauge
The manifold gauge, Figure 32, is used to measure The manifold gauge is designed to control refrigerant
the operating system's high and low side operational flow. When the manifold gauge is connected into the
system pressures, monitor correct refrigerant charge, system, pressure is registered on both gauges at all
as well as for system diagnosis and operating effi- times during normal conditions. During testing both
ciency. The manifold gauge allows monitoring both the low and high side hand valves are in the closed
the high and low side pressures at the same time, position (turned inward until the valve is seated). Re-
because they must be compared to determine sys- frigerant will flow around the valve stem to the re-
tem operation. spective gauge and register the system low side
pressure on the low side gauge, and the system high
Gauge Port A: BLUE side pressure on the high side gauge. The hand
Connects to the system's low pressure side service valves isolate the low and high side from the central
valve. Gauge reads from 0 to 150 psi (0-10.4 portion of the manifold.
bar/0-10.5 kg/cm2) (pressure scale) in a clockwise
direction, and from 0 to 30 in of mercury (vacuum
scale) in a counterclockwise direction.
Gauge Port B: YELLOW

System service
Gauge Port C: RED

Connects to the system's high pressure side service
valve. Pressure only reading from 0 to 3450 kPa (0 -
500 psi) in a clockwise direction.
WARNING: Direct contact with refrigerant

can cause frostbite or blindness. Always Figure 32 – Manifold Gauge
wear safety glasses and protective gloves.
Do not work with refrigerant close to the
face.
NOTE: With both hand valves closed or with ei-

ther the low or high side valve open, the
low and high side gauges will give accu-
rate readings. With both hand valves
open gauge readings are not reliable as
high side pressure will flow into the low
side of system causing inaccurate gauge
readings. Refer to gauge manifold oper-
ating instructions.
W9-2-11
Inspect Air Conditioning System Manifold Gauge, Connection

The first step is to correct any conditions that may System pressures and refrigerant flow are checked
adversely be affecting system operation. with the manifold gauge. Making a check of the sys-
tem's overall performance will assist in properly di-
NOTE: Read and follow all safety precautions. agnosing problems in the air conditioning system.
Check and inspect the following: 1. Put on safety goggles and cover the rigid dump
truck's interior and painted surfaces to protect
1. Inspect cooling system. Inspect all hoses and them from damage during all service opera-
water pump for leaks. Check coolant level and tions.
mixture. See Operators Instruction Manual,
Check Coolant Level and Coolant System Addi- 2. Remove the protective caps from the service
tives. valves on the compressor. Be sure that the
hand valves on the manifold gauge are closed
2. Air conditioner compressor and engine fan belts before attaching test hoses to the service
must be in good condition and tightened to valves.
correct tension.
3. Connect the low side service hose (blue) to the
3. Check for proper installation of fan blade and low (suction) side of the a/c compressor. Con-
shroud. nect the high side service hose (red) to the high
(discharge) side of the compressor. The center
4. Condenser fins must not be bent, damaged or service hose (yellow) connected to recycler.
clogged. See Figure 33.
5. Check for mechanical failures.
6. Inspect air conditioner compressor front seal

and pressure relief valve for leakage. Look for
damp or wet areas around rotating seals.
Figure 33 – Manifold Gauge Connection
W9-2-12
4. Air must be purged from test connection hoses Manifold Gauge Readings
before proceeding with any system testing.
Crack the high side hand valve for about four Normal operating pressure range of the low side is
seconds. Purging of air will take place as the 15 to 20 PSIG. Normal operating pressure range of
R-134a from the system forces air out of the the high side is 110 to 125 PSIG. The operating pres-
center hose at the manifold gauge set. Close sures will vary depending on the ambient outside
the high side hand valve. temperature and internal cab temperature. These are
normal pressure gauge readings assuming an en-
5. Repeat step 4 for the low side hand valve. gine idle speed of approximately 600 RPM.
6. The air conditioning system must now be oper-

ated for a few minutes to stabilize the system. Normal Functioning Air Conditioning System
Make sure all test hoses, gauges, and other test Low Side Gauge Normal
equipment is away from moving engine parts. (15-20 psi) @ idle rpm
Also, make sure that hoses are not touching hot High Side Gauge Normal, with cold discharge air
manifolds. from vents in cab.
(110-125 psi) @ idle min-1 (rpm)
7. Start engine, run at high idle. Place air condi- Diagnosis Normal functioning air
tioning control in the “ON" position and turn fan conditioning system
control speed to high. Operate air conditioning
system for 5-10 minutes. Corrective Action:
1. None
NOTE: On R-134a systems, “topping off" system
refrigerant should never be done. If an
R-134a system is suspected of not having Some Moisture in Air Conditioning System
a complete charge, first check for leaks Low Side Gauge Normal, then occasionally drops
and repair system as necessary. Evacu- to below zero
ate system and refill with correct amount High Side Gauge Normal, then occasionally goes
of refrigerant as identified on air condi- high
tioning system label. R-134a systems are Diagnosis Moisture in system freezes
to be filled by weight method only. temporarily stopping cooling cy-
cle. Normal operation returns
when ice formation melts.
Corrective Action:
1. Evacuate air conditioning system.
2. Replace receiver-drier.
3. Remove moisture by pulling a vacuum on the
system with the use of a vacuum pump.
4. Charge system with R-134a. Test compressor
oil with test kit (replace if necessary).
5. Operate system and check performance.
W9-2-13
Insufficient Cooling of Condenser or Refrigerant

Low R-134a System Charge Overcharge
Low Side Gauge Low Low Side Gauge High reading
High Side Gauge Low High Side Gauge High
Diagnosis System low on R134a due to Diagnosis Refrigerant overcharge or con-
leak or incorrect system denser cooling fins bent or
charging clogged with dirt. Condenser
cooling fan or air flow malfunc-
Corrective Action: tion.
1. Leak test air conditioning system.
2. Evacuate air conditioning system. Corrective Action:
3. Repair system leaks. 1. Clean condenser cooling fans.
4. Charge system with R-134a. 2. Check engine cooling fan operation.
5. Operate system and check performance. 3. Evacuate air conditioning system.
4. Charge system with R-134a.
Poor Refrigerant Circulation
Low Side Gauge Zero or negative reading
High Side Gauge Low, with frost on tubes from Air in System
receiver drier to evaporator Low Side Gauge High reading
unit High Side Gauge High, also low pressure pipes
Diagnosis Refrigerant flow is obstructed are hot to the touch
by dirt, debris, or receiver drier Diagnosis Air is present in refrigerant
clogged. lines. Possible from improper
evacuation procedure during
Correction Action system charging.
1. Evacuate Air conditioning system.
2. Replace receiver-drier. Corrective Action:
3. Charge system with R-134a. 1. Evacuate air conditioning system.
4. Operate system and check performance 2. Check compressor oil for contamination using
an oil test kit. Check compressor for proper oil
amount. Correct if necessary. Pull a vacuum
No Refrigerant Circulation on the system with the use of a vacuum pump.
Low Side Gauge Zero to negative reading 3. Charge system with R-134a.
High Side Gauge Low, with frost or moisture on 4. Operate system and check performance.
tubes before and after re-
ceiver drier
Diagnosis Refrigerant flow is obstructed
by dirt or moisture or refrig-
erant flow obstructed by faulty
expansion valve
Corrective Action:
1. Evacuate air conditioning system.
2. Check heat sensing tube at expansion valve.
Replace expansion valve if necessary
3. Remove expansion valve and attempt removal
of dirt. If dirt cannot be removed, replace ex-
pansion valve.
4. Replace receiver-drier.
W9-2-14
Expansion Valve Improperly Mounted or Heat Leak Testing

Sensing Tube Defective
Low Side Gauge High reading Electronic detectors, like the one illustrated, are the
High Side Gauge High reading, with large most sensitive of the leak detectors available. The
amount of frost or moisture on instrument will draw in any leaking refrigerant
low pressure piping. through a test probe, and then sound an alarm or
Diagnosis Excessive refrigerant in low create a flashing light if refrigerant is found.
side piping possibly from ex-
pansion valve malfunction NOTE: Be sure you are familiar with your test
with valve opening wide. equipment. Read and follow manufactur-
ers' instructions.
Corrective Action:
1. Check heat sensing tube for proper installation. Electronic leak detectors should be used in
2. If heat sensing tube is properly positioned, well-ventilated areas. Avoid using them around ex-
evacuate air conditioning system. plosive gases. A basic procedure for electronic leak
3. Check expansion valve and replace if defective. detectors follows.
5. Operate system and check performance. 1. Turn all controls and sensitivity knob to the OFF
position or zero setting. Plug the leak detector
into an approved source of voltage if not battery
Compressor Malfunction operated. Turn the switch ON, and allow the unit
Low Side Gauge High reading dwell time to warm up, approximately five min-
High Side Gauge Low reading utes.
Diagnosis Internal compressor leak or
compressor mechanically bro- 2. Check operation of the tester by positioning the
ken. probe in a reference area where refrigerant is
known to be present in small amounts. Adjust
Corrective Action: the controls and sensitivity knob until detector
1. Evacuate air conditioning system. reacts properly. Remove the probe and the re-
2. Repair or replace compressor. action should stop. If it continues, adjust the
3. Flush system. sensitivity knob to a lower setting.
5. Operate system and check performance. 3. When the tester calibration is correct and it re-
acts properly, move the probe UNDER all sys-
NOTE: Repairs are made with system DIS- tem controls, seals and connections. Discon-
CHARGED. Repairs must be performed nect and check vacuum hoses. Keep the probe
(connections tightened, components removing. Do not hold it in constant contact with
placed, etc.) before system can be re- refrigerant. When leaks are found, repair them
stored to operating condition. as necessary. Keep in mind, that there may be
more than one leak.
NOTE: Never place the probe in areas where

severe leaks are known to exist, as the
detectors sensitivity components can be
damaged. Once a leak is found, move the
probe out of the area.
W9-2-15
Discharging the System
To eliminate system contaminants from an air condi-

tioning system requires discharging the entire system.
Foreign substances interfere with refrigerant move-
ment, or may chemically react to form corrosive ac-
ids and contaminate the refrigerant. After removal of
the refrigerant the air conditioning system is then
evacuated by vacuum pump to remove all traces of
air, moisture, and contaminated refrigerant. Air condi-
tioning performance will degrade if the system is not
properly evacuated prior to installation of refrigerant.
The system is discharged whenever it is necessary

to open any connection to the system for repair or
replacement of components.
NOTE: DO NOT discharge refrigerant into the

atmosphere. As of January 1992, the use
of a recycling machine is required by law.
Follow all local regulation regarding re-
frigerant use, storage and disposal.
An air conditioning refrigerant recycling machine is

listed in the special tools Section W2-5. This tool is to
be used to discharge and prepare the system before
servicing.
A recycling machine removes and stores refrigerant

from the vehicle's air conditioning system without
polluting the atmosphere. Recycling machines and
hoses used on R-12 systems cannot be used on
R-134a systems. Within the recycling machine, the Figure 34 – Connections for Refrigerant Recycling
refrigerant is filtered, processed by a dryer and then
stored in a tank. The refrigerant is stored until the
technician pumps it back into an air conditioning sys-
tem.
To recycle refrigerant, connect the center hose from

the manifold gauge set to the recycling machine. See
illustration. Using the instructions provided with the
recycling machine, remove refrigerant from the air
conditioning system.
W9-2-16
REPAIR PROCEDURES
NOTE: Repairs are made with system DIS-

CHARGED of refrigerant. Repairs must
be performed (connections tightened,
components replaced, etc.) before system
can be restored to operating condition.
Reclaim or Dispose of Refrigerant &

Oil Properly
Leak Connection
Repair minor leaks at connections by tightening con-

nection or by replacing O-ring sealing. To avoid
strains on hose or tubing assemblies, always use a
back-up wrench and a torque wrench on the fitting
being tightened. Refer to Figure 35. Figure 35 – Fitting Tightening Procedure
Hose Repair
Compressor Oil Check
Check each hose assembly for deterioration, cracks
or bulging. If these signs are noticed, discard the If the system does not contain the specified amount
hose. On R-134a systems, hose repair should not be of oil, the following problems may occur;
done. If a hose on the R-134a system is damaged,
replace the hose. Insufficient Oil
• Poor Lubrication
• Compressor seizure
Hose Replacement
Excessive Oil
Keep refrigerant hose assemblies and connections • Poor cooling performance (excessive oil ad-
clean and dry. When a connection is being opened, hered to system components that hinder heat
first clean the area thoroughly. To avoid strains on exchange).
hose assemblies, always use a back-up wrench and
a torque wrench on the fitting being tightened. Cap Therefore, as with refrigerant, the specified charge
off hose assemblies immediately to keep out water must always be maintained.
vapor and contaminants.
The oil must be replaced or replenished in the fol-
lowing cases:
Receiver-Drier Replacement
• When refrigerant or oil leaks from the system.
The receiver-dryer is a sealed unit, and cannot be • When refrigerant is suddenly discharged from
repaired. It must be replaced if the system has be- the system.
come saturated with moisture or left exposed to at- • When system components are replaced.
mosphere for a prolonged period. Since the re-
ceiver-dryer is located on the high side of the system, NOTE: As the compressor oil blends with the re-
it should be hot to the touch while the system is op- frigerant and circulates through the sys-
erating. A cool receiver-drier or lines which show tem, it adheres to and accumulates inside
condensation will indicate a malfunction such as a of the system components.
restriction at this point.
W9-2-17
Unlike engine oil, no detergent is added to the com- Only new moisture-free refrigeration oil should be
pressor oil. Even if the compressor is run for a long used in the air conditioning system. Refrigeration oil
period (approximately 1 season), the oil never be- is highly refined and dehydrated. Therefore, the oil
comes turbid as long as there is nothing wrong with container must always be kept tightly closed when
the compressor or its method of use. Inspect the ex- not in use. If the container is left uncapped, even for
tracted oil for any of the following. a short time, moisture will be absorbed from the at-
mosphere by the oil, and then introduced into the air
• Increased opacity of the oil. conditioning system.
• Color change to red.
• Presence of foreign matter, metal fillings, etc.
The compressor oil must be checked as follows when

being charged into a used system.
1. Perform the oil return operation.
2. Remove the compressor from the vehicle.
3. Drain the oil through the oil plug/or the high low
pressure connectors. Refer to Figure 36.
4. Check the oil for contamination.
5. Fill the compressor with the specified amount of

oil. Secure a suitable dipstick or fabricate one
according to Figure 37. Clean and cool the dip- Figure 36
stick with R-134a prior to checking. Insert dip-
stick, and check oil level, Figure 38. It may be
necessary to rotate dipstick to be sure it clears
the crankshaft.
6. Install the oil plug and tighten it to the specified

torque.
NOTE: The oil plug O-Ring must be replaced with

a new one.
When servicing refrigerant oil, ensure correct oil is

used. Current mineral oil lubricants used with R-12
systems do not provide adequate lubrication for
R-134a systems. Synthetic oils, made from Polyal-
kylene Glycol (PAG), have been developed for use in
systems using R134a refrigerant.
W9-2-18
Maintenance Precautions
1. Use protective covers to protect the rigid dump

truck's interior and painted surfaces from dam-
age during service operations.
2. Cap or cover all vehicle components (radiator,

etc.) to prevent the entry of dirt and dust.
3. Maintain clearances between air conditioner

components and vehicle components.
4. Prior to installing the compressor, turn the mag-

netic clutch, Figure 39, 2 or 3 times by hand to
prevent any liquid compression.
Figure 37
5. Do not remove any plugs or caps from the air
conditioner components until just before con-
necting.
NOTE: This is particularly important for R-134a

systems as PAG oil tends to absorb mois-
ture quickly when exposed to the atmos-
phere.
6. Handle the air conditioner components carefully.

Do not knock or drop them.
7. Be careful not to damage any of the surrounding

rigid dump truck parts during removal and in-
stallation.
Figure 38
8. Piping, reference Figure 40.
a.) Position the O-ring against the bulge in the
pipe when connecting hoses and pipes.
b.) Coat the piping connections and the O-ring
with PAG 100 oil.
NOTE: Always use oil specified for system to coat

the O-Rings.
c.) Fit the nuts and unions tightly, Figure 41,

against the base of the companion pieces,
then hand tighten the nut as much as
possible to prevent cross-threading.
9. Always use a back-up wrench, Figure 35, and

tighten fittings to the specified torque. THE Figure 39
TORQUE WRENCH SHOULD BE USED ON
THE FITTING THAT IS BEING TIGHTENED.
W9-2-19
Evacuating the System
Moisture, in any quantity, is extremely harmful to an

air conditioning system. The purpose of the re-
ceiver-dryer is to trap and retain any moisture that
may enter the system. Air contains moisture, there-
fore a leak in the system will allow air and moisture to
enter.
Moisture can collect and freeze in the orifice of the

expansion valve, causing restricted refrigerant flow.
Similarly, it can block flow through any orifice in the
system. For these reasons, moisture must be kept
from entering the system. If moisture has entered, the
desiccant in the receiver-dryer must be able to re-
move it.
Unwanted air and moisture are removed from the Figure 40 – Compressor/Condenser Connections
system by a vacuum pump. The recycling machine
illustrated in Figure 42 incorporates a vacuum pump
as part of the machine. A vacuum pump controls the
pressure inside the system. By lowering the pressure
inside the system into a vacuum condition, the boiling
point of water (moisture) is also lowered to a point
where evaporation will easily occur. This vaporized
moisture can then easily be drawn out by the vacuum
pump. Use the instructions provided with the recy-
cling machine for more information on the vacuum
pump.
1. With the system fully discharged the test

manifold is connected to the system as be-
fore but with the yellow service hose con-
nected to the inlet of a vacuum pump or re-
cycling machine. Open the discharge valve
on the vacuum pump (if equipped) or remove
Figure 41
the dust cap from the discharge outlet. Start
the vacuum pump or recycling machine.
2. Open the low and high side manifold hand

valves to their maximum position, and watch
the low side gauge to be certain the pump
pulls the system into a vacuum.
NOTE: The use of heat lamps placed at the com-

pressor, condenser and evaporator during
the evacuation procedure can assist in
the removal of the moisture. Be sure not
to place the lamps too close to plastic
components as they can be damaged by
the heat.
W9-2-20
3. Pull a vacuum to 1 mm Hg (39.37 in Hg,

1000 microns). Break the vacuum with dry
nitrogen and sweep the system. Pressurize
to a minimum of 5 psi.
4. Pull a vacuum to 0.5 mm Hg (19.69 in Hg,

500 microns). Break the vacuum with dry
nitrogen and sweep the system. Pressurize
to a minimum of 5 psi.
5. Pull the system down to 0.25 mm Hg (9.84 in

Hg, 250 microns). When 250 microns has
been achieved, allow the vacuum pump to
run for 30 minutes.
6. Perform a leak test by charging the system

with an inert gas and using a leak detector.
If a leak is detected, remedy the problem be-
fore the system is recharged with refrigerant.
7. Fully charge the system with R-134a.
8. Operate the A/C system to ensure proper

operation. Figure 42 – Connections for Evacuation
W9-2-21
Complete System Charge
1. With the system fully discharged and evacuated,

the test manifold is connected to the system as
before but with the yellow service hose con-
nected to refrigerant supply. See Figure 43. In
this illustration, the refrigerant tank is placed on
a scale. Weight is recorded so charging can
stop when reading decreases by the amount of
charge specified.
TOTAL CHARGE FOR RIGID DUMP TRUCK IS 1.4

KG (3.1 LB).
2. Make sure manifold gauge valves are fully

closed.
3. Purge air from yellow service, charging, hose.

Loosen yellow service hose connection at test
manifold. Slowly open the refrigerant supply
valve, and allow refrigerant to escape through
the loose connection for a few seconds. Re-
member, refrigerant is harmful to the atmos-
phere so keep refrigerant loss to a minimum.
Retighten the connection and close the supply
valve.
NOTE: Care should be taken when purging lines

to avoid unnecessary release of refriger-
ant to atmosphere.
Figure 43 – Connections for Complete System
4. With both manifold gauge valves fully closed. Charge
Start the engine and stabilize the air condition-
ing system, control set at maximum cooling, fan
blower on high. Run engine at 1250 RPM for 5
minutes.
NOTE: Do not open high side hand valve.
5. Open the refrigerants supply valve and manifold

gauge's low side hand valve, and begin charg-
ing the system with vaporous refrigerant. Close
the hand valve and supply valve when the
proper amount or refrigerant (determined by
weight indicated on scale in our illustration) has
entered the system.
6. Remove the yellow service hose from the refrig-

erant supply container. Take gauge readings as
described in this section to check system. Re-
move manifold gauge and replace all protective
caps.
W9-2-22
Low Pressure Gauge 103-137 kPa

Normal Reading 15-20 psi @ 600 min-1(rpm)
High Pressure Gauge 758-862 kPa
Normal Reading 110-125 psi @ 600 min-1(rpm)
Refrigerant R134a
Refrigerant System Capacity 1.4kg (3.1lbs) Test, DO NOT CHARGE
System Evacuation Draw system down to 20 in Hg with vacuum pump
Compressor Oil ZXL100 (PAG 100)(Poly Alkylene Glycol)
A/C Compressor Drive Belt Ribbed serpentine with automatic tensioner
Replace every 2yrs/6000hrs
W9-2-23
MEMO
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W9-2-24
SECTION 10
HOIST ATTACHMENT
—CONTENTS—
Group 1 Hoist System Group 4 Motion Control Valve

Removal.................................................... W10-1-1 Removal ....................................................W10-4-1
Inspection.................................................. W10-1-2 Installation .................................................W10-4-2
Installation................................................. W10-1-2 Disassembly ..............................................W10-4-2
Assembly ...................................................W10-4-4
Group 2 Hoist Cylinder Pressure Check and Adjustment ...............W10-4-4
Removal.................................................... W10-2-1 Maintenance Standard ..............................W10-4-4
Installation................................................. W10-2-3
Disassembly.............................................. W10-2-5 Group 5 Hoist Pump
Inspection.................................................. W10-2-6 Removal ....................................................W10-5-1
Assembly .................................................. W10-2-7 Installation .................................................W10-5-2
Testing....................................................... W10-2-8 Disassembly ..............................................W10-5-5
Maintenance Standard.............................. W10-2-9 Inspection ..................................................W10-5-6
Memo ...................................................... W10-2-10 Assembly ...................................................W10-5-7

Maintenance Standard ............................ W10-5-11
Group 3 Hoist Valve Memo.......................................................W10-5-12
Removal.................................................... W10-3-2
Installation................................................. W10-3-3
Group 6 Body Mounting
Disassembly.............................................. W10-3-5 Removal ........................................................W10-6-2
Assembly .................................................. W10-3-7 Installation .....................................................W10-6-2
Pressure Check and Adjustment .............. W10-3-8 Disassembly ..................................................W10-6-5
Maintenance Standard.............................. W10-3-9 Inspection ......................................................W10-6-6
Memo ...................................................... W10-3-10 Maintenance..................................................W10-6-6
W10-0
<BLANK>
W10-0
HOIST ATTACHMENT / Hoist System
Steer Tank
Hoist Tank Cylinder
Figure 1 - Hoist System
REMOVAL CAUTION: Escaping fluid under pres-

sure can penetrate the skin and eyes,
1. Park rigid dump truck on a level solid surface and causing serious injury.
place it in “Service Position”. Refer to Section
W2-1.
Hot hydraulic oil may spurt out, possi-
2. It is critical to apply wheel blocks to both sides of bly causing severe burns.
the tire to prevent vehicle movement.
Steering accumulator hydraulic pres-
3. Allow the steering accumulator time to drain to sure must be zero prior to servicing the
zero pressure. hoist system as the hoist valve is pi-
loted by steer system fluid.
4. Drain fluid from hydraulic tank, 342L (90.3 gal)
from the hoist tank and 117L (31 gal) from the Eye Protection is required.
steer tank, prior to servicing any lines or compo-
nents located or connected below the oil level in
the hydraulic tank.
: 1¼ in Reclaim or Dispose of Oil Properly
W10-1-1
HOIST ATTACHMENT / Hoist System
INSPECTION
1. Visually check hoses, tubes and components for
signs of external damage or leakage.
2. Hoses should be inspected for abrasion, cuts,
bulging, or separation from end fittings.
NOTE: Hose assemblies should be replaced every

two years. Only original HITACHI equip-
ment hose assemblies should be used.
3. O-rings should be replaced each time an o-ring
flanged connection is disassembled.
4. Hydraulic oil samples should be collected and
analyzed after every 250 hrs of operation to estab-
lish a fluid trend analysis. Also sample new un-
used replacement fluid when the hydraulic fluid
Pump type or brand is changed to provide a new oil
Hoist Inlet baseline.
Pump
Figure 2 - Hoist Pump CAUTION: Use of non-HITACHI replacement

hoses, O-rings and seals can result in pre-
mature leakage and system failure.
INSTALLATION
Hoist
Reference individual component sections for detailed
Control
installation instructions.
Valve
Motion
Control
Valve
Pressure
Reducing Valve
(Steer system oil for
Hoist Control)
Figure 3 - Hoist Control
See individual component sections for removal in-

structions.
W10-1-2
HOIST ATTACHMENT / Hoist Cylinder
REMOVAL CAUTION: Contamination can interfere with

otherwise noted. proper operation of the hydraulic system.
1. Park the unit on a level, solid surface and ap-

ply the parking brake.
2. Raise the machine body approximately 0.6 m
(2 ft) and install wood blocking on top of frame
rails to secure the body in this position to allow
clearance for the removal of the hoist cylinder
(1).
3. Place the hoist lever in the “FLOAT” position
and check to make sure the body is fully rest-
ing on the wood blocking, then place the hoist
lever in the “HOLD” position.
4. Shut down the engine and allow steering ac-
cumulator time to drain to zero pressure.
5. Put the machine in the Service Position. Re-
fer to SERVICE POSITION, Section W2-1.
6. Clean (power wash) the hoist cylinder(s) (1)
and related hoses to remove dirt and debris
that may contaminate the hydraulic system.
Tightening Torque
Wrench Size
Remarks
T8DX-09-15-002
37 (3.8) 27
: 9/16 Plug Figure 1 - Hoist Cylinder Mounting
43 (4.4) 32
: 9/16 Hose 1. Hoist Cylinder 8. Washer
50 (5.1) 37 2. Snap Ring 9. Tube
: 9/16 Screw
3. Grease Fitting 10. Grease Fitting
120 (12.4) 90
:¾ Screw 4. Spherical Bushing 11. Pin Assembly
24 - 27 (2.5 – 2.8) 18 - 20 5. Snap Ring 12. Spacer
:¼ Screw
6. Washer 13. Snap Ring
Table 1 7. Bolt 14. Spherical Bearing
Port A. Base End Port B. Rod End
CAUTION: A lifting device with a lifting
capacity of 1.8 Tonnes (2 Tons) will be re- Numbers in parentheses refer to Figure 1, unless
quired. otherwise noted.
CAUTION: Hydraulic oil may be hot after 7. Remove grease fittings (3 and 10) from the hoist
operation. Hot hydraulic oil may spray out, cylinder (1) base end and from the hoist cylinder
possibly causing severe burns. (1) rod end. Refer to Figure 2.
: 7/16 in
W10-2-1
Hoist cylinder rod end NOTE: Refer to Figure 5. Secure the piston rod
assembly (16) to the hoist cylinder tube
Hoist cylinder base end (1) by looping a strap around the piston
rod assembly (16) and attaching it to the
hoist cylinder (1) tube or lifting device.
This will prevent the piston rod assembly
3 (16) from extending and being damaged
while the hoist cylinder (1, Figure 1) is
being removed from the machine.
10 11. Hold the hoist cylinder (1) in a vertical position,
and lift slightly to relieve weight from the lower
Figure 2 - Grease Fitting Location frame mount assembly (see Figure 4). Re-
move snap ring (2) from the hoist support.
12. Slide the hoist cylinder (1) off the lower frame
8. Support the hoist cylinder (1) with a suitable lift-
mount (see Figure 4). Lift the hoist cylinder (1)
ing device.
from the machine and move it to a clean work
9. Remove bolt (7) and washer (8) from pin (11), area for disassembly.
and remove tube (9). Remove pin (11) and
13. Remove the spherical bushing (4) and washer
spacers (12). Open the Emergency Body
(6) from the lower frame mount, (see Figure
Down Valve that is located on the brake accu-
4).
mulator mounting bracket (refer to Figure 3). Al-
low the hoist cylinder (1) to compress by care-
fully relieving the tension of the lifting device.
: 3/4 in
Lower
frame mount
assembly
Emergency
Air Body Down 6
Cleaner Valve
4
Figure 3 - Body Down Valve
Figure 4 – Hoist Cylinder Frame Mounting

NOTE: The hoist cylinder (1) may not compress
completely because of the Retract
Cushion device built into the hoist cyl- 1. Cylinder 4. Spherical Bushing 6. Washer
inder (1).
10. Disconnect the hydraulic hoses (ports A and B)
and allow oil to drain into a suitable container.
Plug the lines and cap the hoist cylinder (1) 14. Remove snap ring (13) and spherical bearing
ports (A and B) to reduce contamination in- (14) from the body.
gression.
: 9/16 in
W10-2-2
INSTALLATION 7. Apply Loctite Product 242 thread locking

compound to the threads of screw (7). Install
Numbers in parentheses refer to Figure 1, unless screw (7), washer (8) and tube (9) into the
otherwise noted. hoist cylinder through pin (11).
: 3/4 in
: 87 N٠m (64 Ibf٠ft)
1. If the bearing (14) was removed from the body,
install bearing (14) into the body mounting 8. Insert grease fitting (10) into pin (11).
bore. The bearing (14) diameter fracture line : 7/16 in
(outer race fracture) of the bearing must be : Two full turns after finger tight
positioned out of the load zone. The fracture
line is to be mounted in the horizontal position. 9. Connect hydraulic lines to hoist cylinder ports
This will allow the fracture to be positioned 90º (A and B) with new O-rings in the flange fit-
away from the load zone. Refer to Figure 1 for tings.
proper orientation of bearing (14). The bearing : 9/16 in
(14) must be pressed in place using a driver : 43 N٠m (32 Ibf٠ft)
that applies force evenly across the outside
race of the bearing. A universal hydraulic ram 10. Remove strap used to secure piston rod as-
with a through hole may be used to pull bear- sembly (16, Figure 5) to hoist cylinder tube (1,
ing (14) in place. Freezing of the bearing (14) Figure 5). Install grease fitting (3) into cylinder
prior to installation may also ease installation. (1).
Install snap ring (13). : 7/16 in
2. Install washer (6) onto lower frame mount with : Two full turns after finger tight
the large diameter of the washer against the 11. Check oil level in hydraulic tank and adjust as
lower frame mount assembly as illustrated in required, Refer to section W2-2 Maintenance
Figure 4. for tank capacity.
12. Make sure the area around the truck is clear
and no one else is working on the machine.
CAUTION: Secure piston rod assembly (16,
13. Place hoist lever in the “FLOAT” position.
Figure 5) to hoist cylinder body (1). See
removal instructions and Figure 5. 14. Start the engine and allow engine to idle.
15. Carefully loosen air bleed plug (3, Figure 5)
just slightly until a steady flow of oil appears
3. Using a suitable lifting device, slide cylinder
with no sign of trapped air remaining in the
(1) onto lower frame mount (see Figure 4).
hoist cylinder (1), and tighten the plug (3).
4. Install snap ring (2). : 9/16 in
5. Rotate cylinder housing (1) and position under : 37 N٠m (27 Ibf٠ft)
body mount. Raise hoist cylinder (1) to align 16. Raise the body slightly to allow removal of the
cylinder base end pin holes with body bearing wood blocking on the frame rails. Remove the
(14). wood blocking and lower the body to the
6. Install and position spacers (12) on either side frame.
of the bearing (14), with the smaller diameter 17. Re-check hydraulic tank oil level and adjust as
mating surface against the bearing (14). required.
Align the pin bores, then apply Loctite Silver
Grade anti-seize lubricant to pin (11) and the 18. Grease body pin bushing (14) and lower frame
inside diameter of bearing (14). Install pin mount spherical bushing (4).
(11) through the hoist cylinder (1), body bear-
ing (14) and spacers (12).
W10-2-3
Figure 5 - Section View of Hoist Cylinder with Cushioning (Retract Only)
1. Tube Base and Assembly 16. Piston Rod Assembly 31. Split Flange
2. Snap Ring 17. U-Cup Rod Seal 32. Bolt
3. Plug 18. Wiper Seal 33. Lock Washer
4. Wear Ring 19. Buffer Ring Assembly 34. O-ring
5. Inner Seal Ring 20. O-Ring 35. Plug, Flange
6. Outer Seal Ring 21. Back-Up Ring 36. Split Flange
7. O-Ring 22. Wear Ring 37. O-Ring
8. Check Ball 23. Piston 38. Plug, Flange
9. Socket Head Screw 24. Wear Ring 39. Snap Ring
10. Washer 25. U-Cup Rod Seal 40. Plug
11. Adhesive 26. Wiper Rod 41. O-Ring
12. Intermediate Tube Assembly 27. Buffer Ring 42. Pin
13. Gland Cap 28. Dowel Pin 43. Spool
14. Cap Bolts 29. Wear Ring 44. Disc
15. Washer 30. Spherical Bushing
Port A. (Raise) Port B. (Return)
W10-2-4
DISASSEMBLY 4. Remove bolts (14), and washers (15) from the

cap (13).
: 3/4 in
CAUTION: Contamination can cause wear
5. Remove the caps installed during the removal
and premature seal failure. stage from the inlet (Port A) and outlet ports
(Port B).
CAUTION: Safety glasses are required. : 9/16 in
NOTE: Service hoist cylinder in a clean work
area on a clean surface.
CAUTION: Cover cylinder ports (A and B)
NOTE: Use lint-free cloths and filtered cleaning with a rag or towel as oil may spray from
fluids when handling and cleaning com- the ports if the piston rod (16) is moved up
ponents. or down.
Numbers in parentheses refer to Figures 5 and 6, Cap

unless otherwise noted. Puller
Holes
45
46
47 Figure 7 - Cap Puller Holes
Figure 6 - Rock Guards 6. Attach a strap to the piston rod assembly (16)
45. Shield 47. Washer through bushing (30) and to a lifting device.
46. Screw 7. Using the lifting device, start to extend the cyl-
inder. About 150 mm (6 in) would be ade-
quate.
1. Secure hoist cylinder vertically, piston rod (16)
8. Install screws, (1/2-13 UNC thread x 56 mm
up, to a mounting fixture, table or post. The hoist
(2.2 in) minimum thread length), into the cap
cylinder should be sitting in some sort of con-
puller holes on cap (13), refer to Figure 7.
tainer that will collect oil remaining in the hoist
cylinder. 9. Evenly tighten the screws until the cap (13) is
separated from the tube base (1).
CAUTION: Hoist Cylinder Assembly weight:
10. Using the lifting device, pull the cylinder inter-
750 kg (1655 lb). nal components out of the tube base (1).
2. Remove screws (46), washers (47), and shield NOTE: The lifting device will need a lifting range
(45) from the cylinder. Refer to Figure 6. of about 2.3 meters (92 in).
: 9/16 in 11. Lower the internal components onto a clean
3. Punch mark relationship of gland cap (13) to work surface to collapse the stages. Lay the
tube base assembly (1). parts in the horizontal position and use blocks
to support and control movement.
W10-2-5
INSPECTION
1. Wash all of the parts thoroughly in a suitable

cleaning solvent and dry with a clean, lint free
cloth. Clean all of the seal and ring grooves
carefully to insure that any foreign material is
removed.
2. Blow out the passages in the tube base assem-
Figure 8 – Hoist Cylinder Details
bly (1) and the piston rod assembly (16) with
compressed air to remove any foreign material.
17. U-Cup Rod Seal 24. Wear Ring
18. Wiper Seal 25. U-Cup Rod Seal 3. Inspect the cylinder, the tube base assembly (1),
19. Buffer Ring Assembly 26. Wiper Rod the piston rod assembly (16) and the pistons
22. Wear Ring 27. Buffer Ring (23) for cracked welds or deep grooves. Shine a
light inside the tubes to inspect for damage.
Remove ridges, nicks and scratches with a fine
12. Slide small stage piston (23) into the bore of stone and clean. Replace any components that
the intermediate stage (12) a sufficient dis- cannot be repaired.
tance to clear snap ring (4), refer to Figure 8. 4. Inspect pin (11, Figure 1) for wear in bearing
13. Using two pry tools, or large screw drivers, area, replace if necessary.
compress snap ring (2) and lift it from the 5. Inspect bushing (4, Figure 1) insert in piston rod
groove with a prying motion. eye (16) for excessive wear and scoring, replace
: Pry tool or screwdrivers if necessary.
14. Hold piston rod assembly (16) at the eye end, 6. Inspect piston rod (16) in transition area to cast
and remove piston (23) using a spanner port end eye (see Figure 10) for cracks, replace
wrench. if necessary.
15. Separate the assemblies (1), (12) and (16)

with care and place them on a clean work sur-
face for inspection.
2 12
16. Remove plug (40) with O-ring (41) from tube
base assembly (1). Using a hammer and
punch, remove pin (42) that secures spool (43)
and disc (44) to plug (40). Be careful not to 16
damage the threads of the plug (40). The
spool (43) and disc (44) can now be removed
from tube base assembly (1). Refer to Figure
9.
17. Remove and discard all wear rings, rod seals,
rod wipers, O-rings, back-up rings, and cast
iron piston seals. Figure 8 – Hoist Cylinder Details
2. Snap Ring
12. Intermediate Tube Assembly
16. Piston Rod Assembly
W10-2-6

41 44 43 otherwise noted.
1
40
1. Wash all components in clean, filtered solvent
and dry with compressed air.
2. Install O-ring (20) and backup ring (21) on the

outer diameter of the gland cap (13). Install the
buffer ring assembly (19), U-cup rod seal (17),
and the wiper seal (18) with the wear ring (22)
as shown in view “B” in the inner diameter of
42 gland cap (13).
Figure 9 – Cushion Pin Assembly 3. Assembly of the Intermediate tube section is as

follows:
A. Install the wear ring (4) on the piston’s O.D.
1. Tube Base Assembly 42. Pin as indicated.
40. Plug 43. Pin B. Install a new rod wear ring (24) in the inner
diameter.
41. O-Ring 44. Orifice Disc C. Install a new buffer ring (27) as shown in
view “B”.
D. Install a new U-cup rod seal (25) as shown
10 in view “B”.
Transition E. Install a new wiper seal (26) as shown in
Area view “B”.
4. Slide the gland cap (13) onto the open end of

the intermediate tube assembly (12) as shown
in Figure 5.
5. Slide the piston rod assembly (16) into the in-

side diameter of the intermediate tube assem-
bly (12), taking extra effort not to damage seal-
ing lips as the orifice spot face passes through
it.
Figure 10 – Piston Rod Eye
6. Coat the check balls (8) with grease and insert
them into their seat in the rod assembly (16), as
ASSEMBLY shown in Figure 5. Install O-ring (7) into
groove location in the pilot diameter of piston
(23). Install the piston inner seal (5) in groove
CAUTION: Contamination can cause wear as shown. Preheat the outer seal ring (6) in 49
and premature seal failure. °C (120°F) oil (to ease in assembly). Slide the
outer seal ring (6) over the piston (23) into the
NOTE: Service hoist cylinder in a clean work groove where the inner seal (5) has been pre-
area on a clean surface. viously located. A ring resizing sleeve or ring
compressor to restore the seal to its original
NOTE: Use lint-free cloths and filtered cleaning diameter would be very beneficial before pro-
fluids when handling and cleaning com- ceeding to the next step.
ponents.
7. Install the piston wear rings (29) onto the piston
NOTE: Lubricate all components with filtered hy- (23), as shown in Figure 5.
draulic fluid as they are being installed.
W10-2-7
8. Coat the outside and inside diameter of the TESTING

piston (23), including the threads, with hydraulic
oil and insert the piston (23) into the intermedi- Numbers in parentheses refer to Figure 5.
ate tube assembly (12). Thread the piston (23) 1. Mount the hoist cylinder in a hydraulic compo-
on the piston rod assembly (16) with a spanner nent test stand. Connect a hydraulic oil supply
wrench or hold the piston to keep it from rotat- to the rod end port. Connect a drain hose to the
ing and turn the rod eye (16). Thread the piston base end port. Remove excess oil from all
(23) until it is flush with the end of intermediate surfaces, including wipers, gland cap, tube
tube (12). Align to nearest dowel slot and insert seams and castings.
locking dowel pin (28). Apply adhesive (11) to
the threads of the socket head screw (9), then
install and torque the socket head screw (9) NOTE: Hydraulic oil temperature should be ap-
with washer (10). proximately 71° C (160 ° F).
: 1/4 in
: 24 - 27 N٠m (18 - 20 Ibf٠ft) 2. Using hydraulic pressure, compress the hoist
cylinder and hold it at 20700 kPa (207 bar,
9. Slide the piston (23) and the rod assembly (16) 3000 psi). Check for leaks between the weld
into the bore of intermediate tube (12) ap- joints of the casting. Check for oil leaking be-
proximately 150 mm (6 in). tween the gland cap (13) and the tube base
assembly (1), the cap (13) and intermediate
10. Insert one end of snap ring (2) into the groove tube (12), and the intermediate tube (12) and
on intermediate tube (12). Using a pry tool or the piston rod (16). Any evidence of leakage is
flat blade screwdriver, compress the snap ring reason for rejection.
(2) and pry it into the groove on the tube (12).
Refer to Figure 8. 3. Connect the cylinder to a 4-way valve on the
test stand so that it may be cycled between
: Pry tool or screwdriver extend and retract.
11. Check for raised metal or burrs caused by 4. Cycle the hoist cylinder 6 times and make sure
above snap ring installation, and remove as the cylinder does not bind or leak.
required. 5. Check the retracted cylinder length and the
stroke of each cylinder stage. Refer to Table 2.
12. Collapse rod assembly (16) completely into the
intermediate tube (12) to verify the engagement
of the snap ring (2) and piston (23), and to ver- CYLINDER STAGE STROKE
ify complete retraction of the assembly. Refer
to Figure 8. Large Stage 1141.47 mm (44.94 in)
13. Slide the tube base and assembly (1) on the Small Stage 1194.05 mm (47.01 in)
internal components. Align the punch marks
made during disassembly on the cylinder and Fully Collapsed Length -
gland cap (13). Install the cap bolts (14) with center to center of hoist 1426.5 mm (56.16 in)
washers (15) and torque. cylinder mounting bores
: 3/4 in
: 120 N٠m (90 Ibf٠ft) Fully Collapsed Length -
center to center of hoist 4070.60 mm (160.26 in)
cylinder mounting bores
14. Install shield (45) on cap (13) with washers (47)
and screws (46). Refer to Figure 6.
Table 2 – Hoist Cylinder Stroke
: 9/16 in
6. Disconnect the test hoses, and drain excess
: 50 N٠m (37 Ibf٠ft)
fluid from the cylinder ports.
7. Plug the ports to prevent internal contamina-
tion.
W10-2-8
Numbers in parentheses refer to Figure 5, unless otherwise noted.

Tube Base (1) 203.20–203.30 mm 203.20 – 203.35 mm
Bore inside diameter (8.000– 8.004 in) (8.000–8.006 in)
Tube Base (1) 0.1 - 0.4√ 0.1 –0.4√
Inside diameter surface finish down 4 - 16 RMS 4 - 16 RMS
to bottom of tube bore
Intermediate Tube (12) 177.72 – 177.80 mm 177.67 – 177.80 mm
Outside diameter (6.997 – 7.000 in) (6.995– 7.000 in)
Intermediate Tube (12) 0.025– 0.038 mm 0.025– 0.038 mm Plate surface to “NEW” di-
Chrome depth (0.001– 0.0015 in) (0.001– 0.0015 in) ameter. Plate up to stage
porting, but don’t plate past
stage porting. Chrome
build-up must not create
sharp edges on stage port-
ing and must be free from
chrome deposits.
Intermediate Tube (12) 0.1 – 0.4√ 0.1 – 0.4√ Polish chrome surface to
Surface finish 4 – 16 RMS 4 – 16 RMS specification
Piston Rod (16) 101.52–101.60 mm 101.47–101.60 mm
Outside diameter (3.997–4.000 in) (3.995–4.000 in)
Piston Rod (16) 0.025–0.038 mm 0.025–0.038 mm Plate surface to “NEW” di-
Chrome depth (0.001– 0.0015 in) (0.001– 0.0015 in) ameter. Plate up to stage
porting, but don’t plate past
stage porting. Chrome
build-up must not create
sharp edges on stage port-
ing and must be free from
chrome deposits.
Piston Rod (16) 0.2–0.4√ 0.15–0.4√ Polish chrome surface to
Surface finish 8–16 RMS 6–16 RMS specification
Mounting Pin (11, Figure 1) ~ ~ Coat both pin and inside of
Installation bushing bore with “SILVER”
grade never seize com-
pound.
Mounting Pin Bolt (7) ~ ~ Use “Blue” thread lock com-
pound.
Extended Storage of Hoist Cylinder ~ ~ Store in rack in vertical posi-
tion / collapsed as mounted
on hauler.
Upper pin bore diameter of tube 76.25 – 76.35 mm 76.25 – 76.35 mm
base (1) (3.002 – 3.006 in) (3.002 – 3.006 in)
Bushing bore diameter of piston rod 177.75 – 177.77 mm 177.75 – 177.77 mm
(16) (6.998 – 6.999 in) (6.998 – 6.999 in)
W10-2-9
MEMO
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W10-2-10
HOIST ATTACHMENT / Hoist Valve
16
8 9
15 7 20
18 19
14
17
11
13
10
12
Figure 1 – Hoist Control System
1. Motion Control Valve 9. Pulse Width Modulating Pilot Solenoid 16. Hydraulic Tank
2. Return Tube 10. Inlet Tube 17. Motion Control Pilot Tube
3. Pilot Supply Hose 11. Tube “Raise” 18. Nut
5. Pilot Drain Hose 12. Tube “Lower” 19. Pilot Drain Tube
6. Hoist Filter 13. Body Down Valve Hose 20. Pilot Supply Tube
7. Hoist Valve 14. Main Relief Valve
8. Mounting Bolts 15. Washer
W10-3-1
REMOVAL 4. Disconnect inlet tube (10) from hoist valve (7)

and remove it from the clamp at the back of the
Numbers in parentheses refer to Figure 1 unless hydraulic tank (16) so tube can be moved out of
otherwise noted. the way.
3
: /4 in (tube flange)
9
1. Before checking and/or servicing the rigid dump : /16 in (clamp)
truck, park the rigid dump truck on a level solid
surface and put it in the “Service Position.” Refer 5. Disconnect pilot supply hose (3), pilot drain hose
to Section W2-1. (5), pilot supply tube (20), and pilot drain tube
(19) at each PWM valve (9). Tag line location to
aid in assembly.
NOTE: A lifting device capable of lifting 80 kg (175
: 22 mm (hose)
lb) will be required. 13
: /16 in (tube)
CAUTION: When removing any hydraulic 6. Remove tube “Lower” (12) from motion control
connection from the hoist valve (7), valve (1) and remove it from the support clamp
immediately cap or plug ports to prevent so it can be moved out of the way. Remove the
contamination entry. motion control valve (1) from the hoist valve (7)
and cover open ports.
9
: /16 in
Tightening Torque
Wrench Size
Remarks 7. Remove motion control pilot tube (17).
(in)
N٠m (kgf٠m) Ibf٠ft 13
: /16 in
: 9/16 50 (5.1) 37 Screw 8. Remove tube “Raise” (11) and support clamp on
the back of the tank.
:¾ 106 (10.8) 78 Screw 5
9
: /16 in (clamp)
:¾ 115 (11.7) 85 Locknut
9. Remove body down valve tube hose (13).
: 15/16 244 (24.9) 180 Screw 13
: /16 in
: 1½ 59 (6.0) 44 Cartridge 10. Remove mounting bolts (8) which hold the hoist
valve (7) to the hydraulic tank (16).
15
: 3/8 13.5 (1.4) 10 Screw : /16 in
: 5/8 72 (7.3) 53 Screw 11. With a suitable lifting device, place a hoist sling
around each PWM valve (9) end cap and gently
: 13/16 Tube lift hoist valve (7) from the hydraulic tank (16).
26 (2.7) 19
: 22 mm 26 (2.7) 19 Hose
Table 1
2. Disconnect electrical connectors from pulse

width modulating (PWM) solenoids (9) at each
end of the hoist valve (7).
3. Disconnect return tube (2) from hoist valve (7)

and hoist filter (6).
: ¾ in
W10-3-2
INSTALLATION 7. Install tube “Lower” (12) and the motion control

valve (1). Install support bracket to tube
Numbers in parentheses refer to Figure 1. “Lower” (12) and tighten bolts.
5
9
: /16 in (clamp)
CAUTION: Before installing hoist valve (7) on : 72 N٠m (53 Ibf٠ft) (tube flange)
hydraulic tank, clean mounting surface and
all hydraulic tubes and lines to be installed. 8. Install tube “Raise” (11).
The mounting surfaces on both hydraulic 5
: /8 in
tank and bottom of hoist valve (7) must be : 72 N٠m (53 Ibf٠ft)
flat and clean to prevent valve distortion.
9. Install the motion control pilot tube (17).
13
NOTE: Replace all O-Rings used to connect : /16 in
hydraulic connections at hoist valve (7) : 26 N٠m (19 Ibf٠ft)
with new O-rings.
10. Install pilot supply hose (3), pilot drain hose (5),
pilot supply tube (20), and pilot drain tube (19)
NOTE: A lifting device capable of lifting 80 kg to both PWM solenoid valves (9), as indicated
(175 lb) will be required. by the tags installed at disassembly.
13
: /16 in
1. With suitable lifting device, place a hoist sling : 26 N٠m (19 Ibf٠ft)
around PWM valve (9) end caps and position : 22 mm
hoist valve (7) on top of hydraulic tank (16). : 26 N٠m (19 Ibf٠ft)
2. Install mounting bolts (8), washers (15), and 11. Connect the electrical connectors of both PWM
nuts (18), but do not tighten, as the hoist valve solenoids (9).
(7) may require some movement to install
tubes. 12. Check the oil level in the hydraulic tank and fill
15
: /16 in to the proper level, if required.
3. Install body down valve hose (13). 13. Start engine and allow it to idle 5 minutes to
13
: /16 in remove air from the neutral hydraulic circuit.
: 26 N٠m (19 Ibf٠ft) Check for oil leakage around the hoist valve (7)
and related components.
4. Install return tube (2) to hoist valve (7) and
hoist filter (6). 14. Install 34500 kPa (5000 psi) calibrated
: ¾ in pressure gauge in the test port and check the
: 106 N٠m (78 Ibf٠ft) maximum system pressure setting. Refer to
PRESSURE CHECKS AND ADJUSTMENT,
5. Install inlet tube (10) to hoist valve (7) and this section.
install the support clamp around the inlet tube
(10) at rear of hydraulic tank (16).
: ¾ in (tube flange)
9
: /16 in (clamp)
: 106 N٠m (78 Ibf٠ft) (tube flange)
6. Torque mounting bolts (8) to hydraulic tank

(16) previously installed.
15
: /16 in
: 244 N٠m (180 Ibf٠ft)
W10-3-3
6 7
39
40
11 41 28
2 14
12 8 38
9
13 1
10
44
26
27 42 43
25 32 24
38
31
17
21
33
16 15 22
24
17 20
20 18
18
31 19 30
30
28 21
34
37 32
35 22
36
23 3
29
4, 5
28
Figure 2 – Hoist Valve System
1. Control Housing 12. Back-up Ring 23. Spacer 34. Spool

2. Inlet Housing 13. O-Ring 24. Spring 35. Spring
3. Outlet Housing 14. Bleed off Plug 25. Spacer 36. Body
4. Stud 15. O-Ring, Bridge 26. Bolt 37. O-Ring Seals
5. Locknut 16. O-Ring, Pressure 27. Spring 38. Allen Screws
6. Plugs 17. O-Ring, Tank 28. Pilot Housing 39. Load Check Plug
7. O-Ring 18. O-Ring 29. Plug (Test) 40. Spring
8. Fitting - Test Port 19. Spool, Directional 30. PWM Solenoid 41. Poppet
9. O-Ring 20. Spacer 31. Retainer 42. Spring
10. Main Relief Valve 21. Teflon Spool Seal 32. Stop 43. Washers
11. O-Ring 22. O-Ring 33. Plug 44. Bolt
W10-3-4
DISASSEMBLY D. With directional spool (19) still in control

housing (1), place an Allen head wrench
Numbers in parentheses refer to Figure 2 and 3. on bolt (26) and rotate bolt (44) counter-
clockwise to remove bolt (44) from the
directional spool (19).
CAUTION: Hoist valve (7, Figure 1) contains
highly machined and close tolerance parts. E. Remove springs (24 and 42), washers
Exterior must be free of any dirt and oil. (43), and stop (32) and note location.
NOTE: The directional spool (19) has four distinct F. Gently slide directional spool (19) from
positions and is not symmetrical with the control housing (1) via the opposite
control housing (1) passages. This spring assembly which remains in place.
means that all pieces in the control
housing (1) as well as springs on the G. Remove all spacers and seals that
directional spool (19) must be kept in the remain in place.
same relationship; at the same end of
control housing (1) and directional spool H. Protect directional spool (19) from
(19) location during the next step. damage and place in a vise, which grips
the small diameter valley area between
1. Remove locknuts (5) from the studs (4) and the highly polished outside diameters.
separate the three sections (1, 2 and 3).
I. Remove bolt (26) from direction spool
2. From the inlet housing (2) remove the main (19) and remaining springs, spacers, and
relief valve (10) and discard O-ring seals (11, seals.
12 and 13). Note that the relief valve is
serviced as assembly or seals only. J. Remove bleed off plug (33) from control
: 1½ in housing (1) and discard O-rings.
3. Control housing (1) disassembly: 4. Inlet housing (2) disassembly:
A. Mark the location of the pilot housing A. Remove studs (4) and locknuts (5) and
(28) and spacer (20) as it relates to the separate the inlet housing (2) and outlet
mounting location on control housing (1). housing (3) from the control housing (1).
Discard all O-rings (15, 16, and 17) that
B. Remove the screws (38), which secure are between the housings.
each pilot housing (28) and spacer (20)
to the control housing (1). Gently slide B. Remove main relief valve assembly (10)
each from the control housing (1) and and discard O-rings (11 and 13) and
directional spool spring (27) assembly. backup rings (12).
C. Remove load check plug (39), spring C. Remove plugs (6) and discard O-rings
(40) and poppet (41). (7).
D. Remove fitting (8) and discard O-ring (9).

NOTE: Refer to Figure 3 and note directional
spool (19) design and how it relates to
location in control housing (1); also,
spring (24) and spacer type and
location to control housing (1) and
directional spool (19).
W10-3-5
40
39
41 30
30
1
33
28
28
44 27
43 Hydraulic
42 21 26
24 Pump
32 18 25
21 Hydraulic
19 32 24 23
Tank
Figure 3 – Hoist Control Section
1. Control Housing 24. Spring 30. Solenoid PWM 41. Poppet

18. O-Ring 25. Spacer 32. Stop 42. Spring
19. Spool, Directional 26. Bolt 33. Plug, Bleed 43. Washers
21. Teflon Spool Seal 27. Spring 39. Load Check Plug 44. Bolt
23. Spacer 28. Pilot Housing 40. Spring
W10-3-6
ASSEMBLY

A B
CAUTION: Hoist valve (7, Figure 1) contains

highly machined and close tolerance parts.
Exterior must be free of any dirt and oil.
Also, all housings (1, 2, 3) and directional
spool (19) must be cleaned in new filtered
solvent and dried before assembly.
1. Insert main relief valve (10) with new O-rings

and back-up ring (11, 12, 13) into inlet housing 21 19
(2).
: 1½ in
: 59 N٠m (44 Ibf٠ft) 19
2. Install load check poppet (41), spring (40); plug

(39) with new O-ring into control housing (1).
: 1½ in
: 59 N٠m (44 Ibf٠ft)
Figure 4 – Teflon Spool Seal (21) Installation
3. Install directional spool (19) only in control
housing (1). Make certain that direction spool A. Seal Installer B. Seal Driver
(19) is in correct position. 1. Control Housing 19. Directional Spool
21. Teflon Spool Seal (2 piece)
4. Teflon spool seal installation (21), refer to
Figure 4:
5. Install seal retainer washer (31) over directional
A. Lube interface of directional spool (19) to spool (19) at each end.
control housing (1) with clean hydraulic
oil. 6. Install spool stop (32) over directional spool
(19) at each end to hold seal retainer (31) in
B. Place seal installer (A) (Special tool place.
number E12978611) on control housing
(1) face. 7. Install O-ring (18) in place over the outside
diameter of seal retainer (31).
C. Slide the two piece teflon seal (21) over
directional spool (19). 8. Install spacer (20) over spool stop (32). Light
coating of grease may be required to hold O-
D. Slide seal driver tool (B) (Special tool rings and retainers in place.
number E12978612) over directional
spool (19) and gently tap teflon spool 9. Install springs and spacer as required over the
seal (21) into position. hex head or socket head bolts as determined in
disassembly.
E. Repeat procedure for other end of
directional spool (19). 10. Thread bolts (26, 44) into directional spool (19)
and torque.
NOTE: Failure to use the seal installer and seal : 34 N٠m (25 Ibf٠ft)
driver tools (A and B) will result in a
damaged seal.
W10-3-7
PRESSURE CHECK AND ADJUSTMENT

NOTE: Bolt (44) with inner centering spring (24)
and shims (43) is on “Lower” port side (B). 1. Check the oil level of the hoist tank. It must be
Also, bolt (26) with spacer (23) over spring at the correct level, adjust as required.
(24) and additional spring (27) at socket
head is on “Raise” port side (A). 2. Install 34500 kPa (5000 psi) calibrated oil
pressure test gauge to the test port.
11. Install end cap to spacer O-Ring (22) and hold
in place via light coating of grease. 3. Start the engine and raise the body so the hoist
cylinders are at full extension. While watching
12. Slide pilot housings (28) over springs/spacers the pressure test gauge, increase the engine
and note previous orientation markings made rpm to full (100%) throttle. The pressure in the
on the pilot housings (28) and control housing test gauge should reach the pressure setting of
(1). the main relief cartridge 20340 ± 172 kPa
(2950 ± 25 psi) with the oil temp 71°C (160°F)
A. “Raise” port PWM solenoid (30) is minimum.
pointed towards the outlet housing (3).
4. If pressure setting is correct, proceed to step 6.
B. “Lower” port PWM solenoid (30) is
pointed towards the outlet housing (3). 5. If the pressure setting is not correct, loosen the
adjustment screw jam nut and turn the
13. Install four allen head bolts (38) on each pilot adjustment screw clockwise to increase the
housing (28) and torque evenly. main relief valve (10) pressure setting and
: 13.5 N٠m (10 Ibf٠ft)
counterclockwise to decrease the pressure
setting. After attaining the proper pressure
14. Bolting all three housing (1, 2, 3) together:
setting of 20340 ± 172 kPa (2950 ± 25 psi),
tighten the jam nut while holding the
A. The inlet housing (2) and control housing
adjustment screw.
(1) contain four grooves for trapping O- 9
: /16 in
rings on one face only. 5
: /32 in
B. With a light coating of grease to retain O-
rings, install O-rings (15, 16, 17) in the NOTE: The pressure adjustment should be made
proper grooves. in small, increasing pressure, increments.
15. On a flat surface, stand each housing (1, 2, 3) 6. Warm the hoist oil to approximately 70 ºC (160
upright on its mounting surface and gently slide ºF), then recheck the main relief cartridge
together (side by side). pressure setting as outlined in step 3.
16. Slide the four studs (4) into each hole as

shown. CAUTION: It is recommended that the hoist
control lever not be held in the “Raise”
17. Install locknuts (5) at each end of the studs (4) position, with the hoist cylinders at full
and tighten locknuts (5). Ensure the locknuts extension for a period longer than 10
fully engage the studs (4). seconds without release.
: ¾ in
: 115 N٠m (85 Ibf٠ft)
W10-3-8

Main Relief Valve (10) Pressure 20340 ± 172 kPa Oil temperature must be at operating
(2950 ± 25 psi) temperature.
Check pressure setting each time a major

component of the rigid dump truck hoist system
has been replaced or serviced.
Teflon Spool Seal (21) (Refer to ~ Seal Installer (E12978611) and Seal Driver
Figure 4) Seal Installer and Seal (E12978612) must be used when installing
Driver Teflon Spool Seal (21).
W10-3-9
MEMO
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W10-3-10
HOIST ATTACHMENT / Motion Control Valve
REMOVAL
CAUTION: Hydraulic oil may be hot after

operation. Hot hydraulic oil may spurt out,
possibly causing severe burns.
9
CAUTION: Contamination can interfere
with proper operation of the hydraulic 1
system. 12
4
1. With the engine running, place the hoist 5
lever in the “FLOAT” position and make 6
sure the body is fully lowered to the frame.
2. Park rigid dump truck on a level solid sur- 3
face and place in “Service Position”, Refer 10
2
to Section W2-1. 7 11
3. Allow steering accumulator time to drain to
zero pressure. Turn steering wheel full left Figure 1- Motion Control Valve Removal
and full right several times to assure any
hydraulic pressure trapped in the lines or
cylinders is relieved. 1. Motion Control Valve 7. Fitting
4. Open the manual body-down valve (lo- 2. Pilot Tube (Raise) 9. Relief Car-
tridge
cated on the air cleaner mounting bracket) 3. Tube (Lower) 10. Screw
by pulling out and holding the red knob.
4. Screw 11. Clamp
This will relieve any pressure in the base
5. Split Flange 12. O-ring
end of the hoist cylinder back to tank and
6. O-Ring
ensure the body is fully lowered to the
frame.
5. Clean top area of the hydraulic tank and
around the motion control valve (1) to re- 6. Remove screws (10) from clamp (11) to free
move dirt and dust from work area. tube (3).
: 9/16 in
Tightening Torque 7. Remove the pilot tube (2) at the motion control
Wrench Size valve (1).
Remarks
(in)
N٠m (kgf٠m) Ibf٠ft : 22 mm
:¾ 97 (9.9) 72 Fitting 8. Remove fitting (7) from motion control valve (1).
: 3/4 in
: 9/16 11 (1.5) 8 Screws
9. Remove screws (4), split flange (5), O-ring (6),
: 5/8 72 (7.3) 53 Screws and tube (3).
: 13/16 26 (2.7) 19 Tube : 5/8 in
: 1¼ 210 (21) 155 Cartridge
Table 1
W10-4-1
INSTALLATION DISASSEMBLY
Numbers in parentheses refer to Figure 1. Numbers in parentheses refer to Figure 2, unless

otherwise noted.
NOTE: Components should be clean and free
of dirt and dust prior to installation.
proper motion control valve (1, Figure 1)
1. Place O-ring (12) in groove of motion control operation.
valve (1) and position on the hoist valve.
NOTE: Service motion control valve (1, Figure 1)
2. Place O-ring (6) on tube (3) and install on the in a clean work area on a clean surface.
motion control valve (1) using screws (4) and
split flange (5). NOTE: Use lint-free cloths and filtered cleaning
5 fluids when handling and cleaning com-
: /8 in
ponents.
: 72 N٠m (53 Ibf٠ft)
1. Remove motion control relief cartridge (9) from

3. Install fitting (7) and attach pilot tube (2). manifold (1).
: 3/4 in : 1¼ in
: 97 N٠m (72 Ibf٠ft)
2. Remove and discard all external O-rings and
: 13/16 in back-up rings from motion control relief car-
: 26 N٠m (19 Ibf٠ft) tridge (9).
4. Assemble clamp (11) on tube (3) using

screws (10). NOTE: Motion control relief cartridge (9) is ser-
9
: /16 in viced as an assembly only. External
: 11 N٠m (8 Ibf٠ft) O-rings and backup rings can be re-
placed.
W10-4-2
14
13 9
9.4
9.1
9.2
9.5
9.6
9.3
9.6
Figure 2 - Motion Control Valve
1 Manifold
9 Relief Cartridge
9.1 O-ring
9.2 O-ring
9.3 O-ring
9.4 Backup Ring
9.5 Backup Ring
9.6 Backup Ring
13 Jam Nut
14 Adjustment Screw
W10-4-3
ASSEMBLY 34500 kPa (5000 psi) calibrated oil pressure

gauge into the rod end test port.
otherwise noted. 4. Start the engine and raise the body, increasing
the speed from idle to full (100%) throttle.
Watch the pressure test gauge and note the
CAUTION: Contamination can cause im- pressure as the hoist cylinders enter the last
proper valve operation. stage of extension. The pressure should be
20700 ± 172 kPa (3000 ± 25 psi) at full (100%)
NOTE: Service motion control valve in a throttle with the hoist cylinders in the last stage
clean work area on a clean surface. of extension.
NOTE: Use lint-free cloths and filtered cleaning 5. If the pressure setting of the motion control re-
fluids when handling and cleaning com- lief cartridge is not correct, loosen the jam nut
ponents. (13), and turn the adjustment screw (14)
counterclockwise to increase the pressure set-
ting and clockwise to decrease the pressure
1. Install new O-rings and back-up rings (9.1 setting.
through 9.6) on relief cartridge (9) and install 9
: /16 in
in manifold (1).
: 5/32 in
: 1¼ in
: 210 N٠m (155 Ibf٠ft)
NOTE: The pressure adjustment should be
made in small, increasing pressure in-
PRESSURE CHECK AND ADJUSTMENT crements.
Number in parentheses refers to Figure 1 and 2.
6. After attaining the proper pressure setting,
tighten the jam nut (13) while holding the ad-
1. Check the oil level of the hoist tank. It must
justment screw (14).
be at the correct level, adjust as required. 9
: /16 in
2. Remove the pilot tube (2) from the fitting on : 5/32 in
the motion control valve (1). Plug the pilot
tube (2) connection and leave the fitting (7) 7. Warm the hoist oil temperature to approxi-
on the motion control valve (1) open to at- mately 70 ºC (160 ºF) and recheck the motion
mosphere. control valve pressure setting as outlined in
step 4.
3. Remove the plug from the rod end test port
on the motion control valve. If a test port is 8. Reconnect pilot tube (2) to fitting (7). Remove
not available, a tee fitting can be used to cre- pressure test gauge and install plug at rod end
ate a test port so the rod end pressure will be test port.
available for an oil pressure gauge. Install a

Motion Control Relief Cartridge 20700 ± 172 kPa Oil temperature must be at operating temperature.
Pressure Setting (3000 ± 25 psi)
W10-4-4
HOIST ATTACHMENT / Hoist Pump
CAUTION: Pump weight: 80 kg (175 lb)

5. Remove the screws (13) from the split flanges
REMOVAL (12) on hose assembly (17).
1. Before checking and/or servicing the rigid dump : 3/4 in
truck, park it on a level solid surface and put it in
6. Remove the screws (8) from the split flanges (9)
the Service Position. Refer to Section W2-1.
on hose assembly (16).
2. Drain fluid from hydraulic tank, 459 L (121 gal).
: ¾ in
That includes both hoist tank and steer tank.
Refer to the maintenance section of Operator’s 7. Remove the screws (8) from the split flanges
Manual. (14) on tube assemblies (15).
: 1 ¼ in
: ¾ in
• Alternative Method: Apply vacuum to Tank 8. Cap/plug drain and control hoses to prevent
inlet with sufficient force to prevent fluid from leakage and contamination.
leaking when lines are removed.
9. Secure lifting device to pump.
NOTE: Run the vacuum pump continuously 10. Remove front and rear pump mounting bolts and
while working on the hydraulic system. mounting bracket (19).
Clean all connections prior to disas- : 1 1/8 in
sembly to prevent contamination in- : ¾ in
gression with the applied vacuum.
11. Slide pump away from PTO assembly.
3. Clean the pump and attached hoses to remove
as much contamination as possible from the
work area.
4. Cap or plug all lines as removed to limit leakage
and contamination ingression.
Wrench Size Tightening Torque

Remarks
: 3/4 106 (11) 78 Suction Tube
: 3/4 123 (12.4) 90 Rear Mounting
: 3/4 106 (11.0) 78 Hose
: 1 1/4 97 (9.9) 72 Tank Drain
: 1 1/8 433 (44.2) 319 Front Mounting
Table 1
W10-5-1
11,12,13 5 INSTALLATION
16
17 Items listed in this section refer to Figure 1.
19 7,8,9
1. Clean the pump mounting flange.

2. Apply sealant (5) to mounting face around pilot
diameter. See Parts Manual for sealant detail.
3. Using a secure lifting device, raise and slide the
pump into the PTO. Assure the pump mounting
face is seated flush with the other mounting
face.
4. Secure four mounting screws (2), washers (3)
and nuts (4).
: 1 1/8 in
15 2,3,4,6
1 7,8,10,14 : 433 N٠m (319 lbf٠ft)
7,8,10,14 W8DX-09-13-001
5. Install mounting bracket (19) with screws, wash-
Figure 1 - Hydraulic Pump Mounted to PTO ers and nuts.
: ¾ in
1. Hydraulic Pump 10. O-Ring : 123 N٠m (90 lbf٠ft)
2. Screw 11. O-Ring 6. Clean inlet and outlet hose ends to reduce the
3. Washer 12. Flange possibility of introducing contamination during
4. Lock Nut 13. Screw assembly.
5. Sealant, Orange 14. Flange
7. Install the screws (13) for the split flanges (12)
6. Adhesive, Red 15. Inlet Tube and hose assembly (17).
7. O-Ring 16. Hoist Hose : ¾ in
8. Screw 17. Cooling Hose : 106 N٠m (78 lbf٠ft)
9. Flange 18. PTO Assembly
19. Mounting Bracket 8. Install the screws (8) for the split flanges (9) and
hose assembly (16).
: ¾ in
: 106 N٠m (78 lbf٠ft)
9. Install the screws (8) for the split flanges (14)
and tube assemblies (15).
: ¾ in
: 106 N٠m (78 lbf٠ft)
10. Replace tank plug and fill with filtered hydraulic
oil.
: 1¼ in
: 97 N٠m (72 lbf٠ft)
W10-5-2
Figure 2 - Section View of Typical Tandem Hydraulic Pump
A. Cavity D. Passage G. Cavity

B. Passage E. Cavity H. Passage
C. Cavity F. Passage J. Passage
W10-5-3
Figure 3 - Exploded View of Hoist Pump
1. Flange 15. Front Idler Gear 29. Back-up Ring

2. Seal 16. Pressure Plate 30. O- Ring
3. Snap Ring 17. Lower Isolation Plate 31. Retainer Ring
4. Nut 18. Back-up Ring 32. Pressure Plate
5. Washer 19. O- Ring 33. Rear Drive Gear
6. Ball 20. Retainer Ring 34. Rear Idler Gear
7. Plug 21. Dowel 35. Pressure Plate
8. O- Ring 22. Body 36. Back-up Ring
9. Upper Isolation Plate 23. Stud 37. O- Ring
10. Back-up Ring 24. Spline Coupling 38. Retainer Ring
11. O- Ring 25. O- Ring 39. Lower Isolation Plate
12. Retainer Ring 26. O- Ring 40. Body
13. Pressure Plate 27. Bearing Plate 41. Cover Plate
14. Front Drive Gear 28. Upper Isolation Plate
W10-5-4
DISASSEMBLY 8. Remove the remaining O-ring (19), back-up ring (18),

Numbers in parentheses refer to Figure 3. ring retainer (29) and lower isolation plate (17). Dis-
Use rubber or brass hammer for disassembly. card the O- ring and back-up ring.
1. Mark the flange (1), front body (22), center housing 9. Lightly tap the front body (22) with a soft hammer to
(27) and the rear body (40) and rear cover plate (4) loosen it from the dowel pins (21), and remove the
to facilitate correct assembly. front body. Remove and discard the O- ring (26).
Slide the coupling (24) off the rear drive gear (33).
2. Set the pump assembly on the rear cover plate (41) Remove and discard stud stabilizer O- rings (25).
with the front drive gear (14) facing up. Remove the
nuts (4) and the washers (5) from the studs (23). Tap 10. Lightly tap the center housing (27) with a soft ham-
the edges of the flange (1) with a soft hammer to mer to loosen it from the dowel pins (21), and re-
loosen the flange from the dowel pins (21), and lift move the center housing. Remove and discard the
the flange straight off of the drive gear shaft. Remove O- ring (8).
and discard the O-ring (8).
11. Remove the exposed ring retainer (31), upper isola-
3. Remove the snap ring (3) from the flange (1). Using a tion plate (28), O-ring (30) and back-up ring (29) from
hammer and soft drift, remove and discard the seal the rear body (40). Discard the O-ring and back-up
(2) from the split flange (1). Be careful not to scratch ring.
or score the seal bore in the flange. Do not remove
the plug (7), from the flange (1). The plug (7) is a 12. Remove the upper pressure plate (32) from the rear
press fit in the flange (1) and should only be replaced body (40) by lifting slightly on the rear drive gear (33)
if loose. Mark the flange (1) to ensure proper installa- to dislodge the pressure plate from the inside bore of
tion of the plug later replaced if loose. Mark the the front body. Then hold the raised pressure plate,
flange to ensure proper installation of the plug (7) lower the drive gear and lift out the pressure plate.
later.
NOTE: To prevent damage to the body bore, use ex-
4. Remove the exposed ring retainer (12), upper isola- treme care in removal; do not pry or force
tion plate (9), O-ring (11), and back-up ring (10) from this plate out.
the front body (22). Discard the O-ring and back-up
ring. 13. For reassembly alignment, mark gear teeth with felt
tip marker. Lift the rear drive gear (33) and idler gear
5. Remove the upper pressure plate (13) from the front (34) straight up and out of the rear body (40).
body (22) by lifting slightly on the front drive gear (14)
to dislodge the pressure plate from the inside bore of 14. Place a thumb into each hole of lower pressure plate
the front body. Then hold the raised pressure plate, (35) and lift it up and out of the rear body. The plate
lower the drive gear and lift out the pressure plate. can be removed most easily by tilting the plate
slightly.
NOTE: To prevent damage to the body bore, use ex-
treme care in removal; do not pry or force 15. Remove the remaining O-ring (37), back-up ring (36),
this plate out. ring retainer (38) and lower isolation plate (39). Dis-
card the O- ring and back-up ring.
6. For reassembly alignment, mark gear teeth with felt
tip marker. Lift the front drive gear (14) and idler gear 16. Lightly tap the rear housing (40) with a soft hammer
(15) straight up and out of the front body (22). to loosen the housing from the rear cover plate (41).
Remove the rear housing and discard O-ring (26).
7. Place a thumb into each hole of the lower pressure Remove the studs (23) washers (5) and nuts (4) from
plate (16), and lift it up and out of the front body. The the rear cover plate.
plate can be removed most easily by tilting the plate
slightly. 17. If necessary, remove the dowel pins (21) from the
front and rear bodies (22 & 40) and center housing
NOTE: To prevent damage to the body bore, use (27).
extreme care in removal; do not pry or
force this plate out.
W10-5-5
INSPECTION
1. Wash all parts in a suitable cleaning solvent and dry

with clean, lint-free cloths and compressed air.
2. Use an India stone to remove all nicks and burrs from

pump mating surfaces.
3. Use an India stone to remove any light scoring or

burring from the gear faces and teeth.
4. The pressure plates (13, 16, 32, and 35) should be

carefully examined. If they are scored or gouged,
they should be replaced. Replacement is also nec-
essary if erosion is evident at the high pressure
pocket or at any other point that connects the high
pressure side of the pump to the shaft clearance
holes. Erosion on the path in this area is usually
caused by contaminated oil.
5. The inlet side of the pressure plates (13, 16, 32, and Figure 4 – Check Bushing to Shaft Clearance
35) should also be carefully examined for scoring,
pitting or evidence of cavitation. If signs of cavitation 9. Check the bushing to shaft clearance in the bodies
are present, the pressure plates must be replaced. (22 and 40), center housing (27) and the flange (1)
Also, the source of the cavitation should be detected as shown in Figure 4. The bushings are not serviced
and eliminated. separately; therefore, the flange, center housing and
bodies must be replaced if the clearance exceeds
6. Measure the thickness of the pressure plates at the 0.203 mm (.008”) due to bushing wear. If the exces-
edges of the bearing bores and at the outer edge of sive clearance is due to worn gears, then the gears
the plate. Taper must not exceed 0.050 mm (.002”). must be replaced as a set. To determine how much
the gears are worn, measure the shaft diameter
7. Examine the gears carefully for excessive wear or within 8.89 mm (.350”) of the gear faces. This section
scoring on the face of the gear teeth. If either of of the gear shafts will be unworn. Compare the di-
these conditions exists, the gears must be replaced mension with the measurement obtained on the worn
as a set. portion of the shafts to determine the amount of shaft
wear. Subtract the amount of wear from the total
8. Measure the width of the gears at the tip of the clearance between the shaft and bushings to deter-
gear teeth and at the intersection of the gear face mine if a new set of gears will bring the clearance
and journal. The gear must be at least 0.051 mm between the shaft and bushings within 0.203 mm
(.002”) wider at the tips of the teeth than at the (.008”) maximum limit.
journal intersection.
10. Measure the clearance between the bodies (22 and
40) and the gears, using the method shown in Figure
5. The shim should be thick enough to take up the
clearance between the gear tip and body bore with
the gear at rest in the pump body. The clearance
between the gear tips and body bore must not ex-
ceed 0.381 mm (.015”) per side.
W10-5-6
NOTE: When determining clearance, be sure the

proper thickness shim is used to help sup-
port the gear. If the shim used is too thick, it
will tip the gear toward the side of the body
where the clearance is being checked, giving
a false clearance which is less than the ac-
tual clearance. If the shim used is too small,
it will allow the gear to tip away from the
body where the clearance is being checked,
giving a false clearance that is more than the
actual clearance.
Figure 6 – Reverse Rotation Lube Hole Plugged
ASSEMBLY
NOTE: Coat all parts lightly with clean, (filtered),

hydraulic oil as they are assembled.
NOTE: Service only in a clean work area on a

clean surface.

Figure 5 – Checking Gear Tip to Body Clearance fluids when handling and cleaning com-
ponents.
11. Visually inspect the front and rear bodies (22 and NOTE: Pump rotation is clockwise as viewing in-
40), center housing (27) rear cover (40) and the put drive gear from the front. Refer to Fig-
flange (1) for cracks or other physical damage. Re- ure 7. Care must be exercised in the re-
place components if necessary. assembly of the pump to obtain proper
pump rotation. Pump rotation can be re-
12. Inspect the studs (23) for damage and replace if versed by interchanging the drive and
necessary. idler gear locations in the front and rear
bodies (22 & 40) and moving the plug (7)
to the hole on the opposite side of the
flange (1). See Figure 6. When reas-
sembling, the flange and center housing
(27) would have to be rotated 180° from
their original position on the bodies.
W10-5-7
1. Place the rear cover plate (41) on a clean work- 3. Install the lower isolation plate (39) into the rear
bench and install studs (23), washers (5) and body (40) on the inlet port (large side) side of the
nuts (4). pump with the rounded edge of the isolation plate
against the bottom of the rear body. Refer to Fig-
2. Install new O- rings (26) on body (40) and with ure 8.
O-ring face down, carefully slide body down
over studs, being careful not to damage the
NOTE: Examine the isolation plates (9, 17, 28,
O-rings.
& 39). The plate with the rounded edge
is the lower isolation plate. The plate
with the square edge is the upper isola-
tion plate. See Figure 9.
4. Place a new back-up ring (36) into position on

the opposite side of the bore from the lower iso-
lation plate (39). Refer to Figure 8.
5. Place a new O- ring (37) in position next to the

back-up ring, being sure it seats against the
groove in the back-up ring (36). Refer to Figure
8.
6. Insert the ring retainer (38) between the O-ring

(37) and the side of the rear body (40) with the
rounded edge against the bottom of the rear
body. Refer to Figure 8.
7. Install the lower pressure plate (35) so the

bronze side will be up against the gears and the
counterbored relief is on the outlet port (small
port) side of the pump. Do not force this plate.
Figure 7 – Clockwise Rotation
8. While facing the inlet port in the body (40) install
the rear drive gear (33) in the left-hand bore and
the idler gear (34) in the right-hand bore.
NOTE: Do not drop the gears into place. The

gears should be placed in the bores
carefully to avoid damage to the bronze
pressure plate surface. If the drive gear
and the idler gear are being reused,
align the identification marks made at
disassembly and install the gears into
their respective locations.
9. Install the upper pressure plate (32) with the

bronze side towards the gears and the counter-
bored relief on the outlet port (small port) side of
the pump.
10. Install the upper isolation plate (28) in place on

the inlet (large port) side of the pump. Either side
up is correct.
Figure 8 – Lower Isolation Plate and Seal Assembly 11. Install a new back-up ring (29) as in Step 4.
W10-5-8
12. Install a new O-ring (30) ensuring that it seats 13. Install the ring retainer (31) as in Step 6. Either
in the backup ring as in Step 5. side up is correct.
14. If the dowel pins (21) were removed, install

them in the rear body. Align the marks on the
center housing (27) and the rear body (40)
made during disassembly, and install the cen-
ter housing on the rear body. Make sure the O-
ring (8) remains in place in its groove.
15. Install the coupling on the rear drive gear (33).

Place another new O- ring (26) into the groove in
the center housing (27) using an oil soluble
grease the hold the O- ring in place.
16. Before installing the front body (22) on the center

housing (27), it is important that the front drive
gear (14) and rear drive gear (33) be properly
timed. This is accomplished by placing the front
drive gear (14) in position and lining up the two
gears as seen through a port in the center hous-
ing. A tooth of the rear drive gear (33) should
correspond to a valley on the front drive gear
(14) as shown in Figure 10. Mark the position,
remove the front drive gear (14) and proceed to
Figure 9 – Identifying Lower Isolation Plate the next step.
17. If the dowel pins (21) were removed, install them

in the front body (22). Install O-rings (25) on the
studs (23). Align the marks on the front body and
center housing (27) made during disassembly,
and install the front body on the center housing.
Make sure the O-ring (26) remains in place in its
groove.
18. Install the lower isolation plate (17) into the front
body (22) on the inlet port (large side) side of the
pump with the rounded edge of the isolation plate
against the bottom of the rear body. Refer to Fig-
ure 8.
19. Place a new back-up ring (18) into position on

the opposite side of the bore from the lower iso-
lation plate (17). Refer to Figure 8.
20. Place a new O- ring (19) in position next to the

back-up ring, being sure it seats against the
groove in the back-up ring (18). Refer to Figure
8.
Figure 10 – Drive Gear Alignment
21. Insert the ring retainer (20) between the O-ring
A. Valley 1. Front Drive Gear (19) and the side of the rear body (22) with the
B. Tooth 2. Coupling rounded edge against the bottom of the rear
body. Refer to Figure 8.
3. Rear Drive Gear
W10-5-9
22. Install the lower pressure plate (16) so the 32. Coat the splines of the front drive gear (14) with
bronze side will be up against the gears and the oil soluble grease to prevent damaging the seal
counterbored relief is on the outlet port (small (2) when installing the flange (1).
port) side of the pump. Do not force this plate.
33. Align the marks on the flange (1) and front body
23. While facing the inlet port in the body (22), install (22) made during disassembly and slide the
the front drive gear (14) in the left hand bore and flange over the front drive gear shaft (14) and
the idler gear (15) in the right hand bore. seat it against the front body. Make certain the O-
ring (8) remains in place in the groove in the
flange.
NOTE: Do not drop the gears into place. The
gears should be placed in the bores
34. Install the washers (5) and nuts (4) on the
carefully to avoid damage to the bronze
studs (23) and tighten the nuts to 122 N·m (90
pressure plate surface. If the drive gear
lbf·ft) torque lubricated. Tighten the nuts in a
and idler gear are being reused, align the
star pattern to draw the flange down evenly.
identification marks made at disassembly
and install the gears into their respective
locations. NOTE: While tightening the nuts to the specified
torque value, check for freeness of gear
24. Install the upper pressure plate (13) with the rotation several times by turning the front
bronze side towards the gears and the counter- drive gear shaft. The maximum torque
bored relief on the outlet port (small port) side of required to rotate the drive gear should
the pump. not exceed 14 N·m (10 lbf·ft)
25. Install the upper isolation plate (9) in place on the 35. If the torque required to rotate the drive gear
inlet (large port) side of the pump. Either side up exceeds 14 N·m (10 lbf·ft), disassemble and
is correct. inspect for burrs or dirty particles. Recheck
clearances and assembly procedures. Reas-
26. Install a new back-up ring (10) as in Step 19. semble and tighten to the specified torque.
27. Install a new O- ring (11), ensuring that it seats in

the back-up ring as in Step 20.
28. Install the ring retainer (12) as in Step 21. Either

side up is correct.
29. If the dowel pins (21) were removed, install them

in the front body. If the plug was removed from
the flange at disassembly, determine the proper
relationship of the flange to the front body and
install the plug in the threaded hole in the flange
on the outlet side of the pump. See Figure 6.
30. Using an arbor press and a sleeve that will press

only on the metal portion of the seal (2), press a
new seal into the flange (1) until it is seated in its
bore as shown in Figure 1. Install the snap ring
(3) in the flange to secure the seal in place.
31. Install a new O-ring (8) in the groove in the

flange (1) using oil soluble grease to hold the
O-ring in place.
W10-5-10

Hoist Pump System Pressure 20300 kPa Oil temperature must be at operating
20.3 bar temperature.
(2950psi)
Pump Hoist Section Flow @2100 min-1(rpm) 472 L /min Oil temperature must be at operating
(125 gal/min) temperature.
Pump Brake Section Flow @2100 min-1(rpm) 472 L /min Oil temperature must be at operating
(125 gal/min) temperature.
Gear 6, 7, 28, 32 ≤ 0.38 mm Per side
Gear to housing clearance ≤ 0.015 in
Gear 6, 7, 28, 32 ≤ 0.203 mm Total
Gear to bushing clearance ≤ 0.008 in
W10-5-11
MEMO
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W10-5-12
HOIST ATTACHMENT / Body Mounting
EL20064
Figure 1 - Exploded View of Body
1. L.H Body Assembly 15. Shim 30. Rock Ejector

2. R.H Body Assembly 16. Bolt 31. Body Down Indicator
3. Body Prop Cable 17. Shim 32. Nut
4. Shim 18. Shim 33. Washer
5. Cotter Pin 19. Shim 34. Spacer
6. Shim 20. Body Pad Assembly 35. Bolt
7. Shim 21. Shim 36. Nut
8. Pin Assembly 22. Plate Assembly 37. Mud Flap
9. Snap Ring 23. Body Guide Plate 44. Bolt
10. Pivot Pin 24. Screw 45. Plate
11. Bolt 25. Bolt 46. Body Guide Bracket
12. Grease Fitting 26. Lock Nut 49. Plate
13. Bushing 27. Bolt 51. Plate
14. Nut 28. Lock Nut 52. Nut
53. Washer
W10-6-1
REMOVAL
CAUTION: Standard Body (1) weight: 15650

CAUTION: When driving pin with hammer,
kg (34500 Ib)
metal debris may fly, causing personal injury.
Be sure to use proper safety equipment
CAUTION: The addition of body options can (PPE).
significantly increase this weight.
CAUTION: Body tare weight is used to select CAUTION: Pivot Pin (10) weight: 15 kg (34 Ib)
hoist and rigging of adequate size and capac-
ity to hoist body assembly. Add to body tare 6. Drive the pivot pins (10) out of the hinge brackets
weight the estimated weight for stuck mate- and remove the shims (15), and bushings (13).
rial left in body, optional attached accessories,
wire rope lifting slings and shackles. Calcu- 7. Remove the body assembly (1,2) using a four part
late the total weight of the load being hoisted hoist sling of chain or wire rope with lift hooks at
when selecting crane and rigging. the end of each part. The hooks should be at-
tached to each corner of the body at the body lift-
Numbers in parentheses refer to Figure 1. ing eyes. Hoist the body off rigid dump truck chas-
sis and lower on to wooden blocks or support
Select a crane with sufficient lifting capacity to hoist the stands. Inspect that ground condition is stable
body assembly (1) from hauler chassis. compacted earth, rock or concrete that body will
be stored on.
NOTE: The body assembly should only be re-
moved when it is down and resting on the NOTE: Do not store the body assembly (1,2) for
frame. extended time period with the body pads
(20) mounted.
CAUTION: Rock Ejector (30) weight: 43 kg
INSTALLATION
(95 Ib)
CAUTION: Mud Guard (37) weight: 20 kg (45
Ib) 1. Attach an overhead crane to the body assembly
(1, 2) in similar manner that was used to lift the
1. Remove the rock ejectors (30) and rear wheel body from the rigid dump truck. Adjust the lift
mud guards (37). chains so body will raise level from left to right
: 1 7/8 in side and inclined slightly front to rear with the for-
: 9/16 in ward end 6-12 inches higher than the rear. This
will ease installation as the body is lowered over
2. Remove the body prop cable (3), if necessary. the chassis because the pin bosses will engage
first when lowering the body onto the frame.
3. Disconnect and secure the hoist cylinders away
from the body (1, 2). Refer to Section W10-2 2. Park the hauler on level ground before installation
HOIST CYLINDER. of body hinge pins. This will ease alignment of the
body to chassis.
4. Disconnect the body exhaust connection from the
body assembly (1, 2). 3. Sub-assemble the body installing mounting pads
(20) without shims (21).
5. Remove the grease fittings (12), nuts (14) and
bolts (11) from the body pivot pins (10). Remove 4. Lower the body assembly (1, 2) into position and
the snap rings (9) from the pivot pins (10). align the holes in the body hinge brackets with the
: 1 1/8 in holes in the frame hinge brackets.
W10-6-2
CAUTION: When driving the pin with a ham-

mer, metal debris may fly, causing personal
injury. Be sure to use proper safety equip- 13
ment. 9
CAUTION: Pivot Pin (10) weight: 10 kg (22 Ib)
6 13
10
W8DX-09-51-002
7
Figure 3 - Body Pivot Pin and Bushing Gap
NOTE: The body pivot pins (10) are free floating by

design. This is why there is approximately
7 - 9 mm (0.276 – 0.354 in) gap between
4 the body pivot pin (10) and the bushing (9)
at the 6 o’clock position. It is very impor-
tant to maintain the body pad wear toler-
35 8
ances in order to deter shock and wear to
the body pivot pins (10).
W8DX-09-51-001 6. Place the selected shims in position on both sides

Figure 2 - Body Shimming Details of the body hinge bracket and install the pivot pins
(10). Locate the shims in positions that best align
4. Snap Ring 10. Pivot Pin body straight on hauler chassis.
6. Bolt 13. Bushing
7. Grease Fitting 35. Nut
7. Align the bolt holes of the pivot pins (10) with the
8. Shims
bolt holes of the body hinge brackets and install
bolts (11) and nuts (14).
: 1 1/8 in
5. Measure and select the shims (15) as necessary
to provide a 0.00 - 2.30 mm (0.00 - 0.09 in) maxi-
8. Install the snap rings (9) and grease fittings (12).
mum clearance at four locations between the
body hinge brackets and the frame hinge brackets.
9. Install the hoist cylinders as outlined in Section
No more than a 13 mm (0.5 in) total shim pack
W10-2 HOIST CYLINDER.
should be used. Liberally coat the inside diame-
ter of the body pin bores in hinge brackets, bush-
10. Connect the body exhaust inlet assembly to the
ings (13) and body pivot pins (10) with a good
body (1, 2).
anti-seize compound. Refer to Figure 2.
NOTE: Refer to Figure 2 for Body Shimming details,

Steps 5 – 7.
W10-6-3
4, 6, 7
13. Place an equal amount of shims at all six locations
until the hinge pin sits at the top of the hinge bore
16 with the body lowered. Using a square, position
17, 18, 19 one of the straight edges of the square against the
outside surface of the right side tail lug of the
16 frame. Slide the square to position the other
46 straight edge of the square against the hinge right
side outer hinge ear. Locate the straight edge of
the square as close to the bottom of the hinge ear
as visually possible. Then mark the position of the
23 square on the tail lug. Repeat step on the left
side of the frame.
24
Figure 4 - Body Pad and Body Guide Installation
4. Shim 18. Shim

6. Shim 19. Shim
14. Raise the body; this will cause the hinge pin to
7. Shim 23. Body Guide Plate drop to the bottom of the frame bore. Once again
16. Bolt 24. Bolt use the square and marker to indicate the raised
position of the body to the frame.
17. Shim 46. Body Guide Bracket
CAUTION: Body Guide Bracket (46) weight:

19 kg (41 Ib)
11. When the body guide brackets (46) are installed,

install shims as necessary until the gap between
the body guide bracket (46) and the body guide
plate (29) is 3.1 – 6.4 mm (0.12 - 0.25 in). Refer
to Figure 4. Tighten bolts (24).
: 1 1/8 in
: 307 N٠m (226 Ibf٠ft)
12. Place 2 body pads on the frame rails at both the

left and right rearmost positions and 1 body pad
at both the left and right front positions. 15. After making two marks on the outer side of each
of the tail lugs, lower the body in the FLOAT posi-
tion only. Watch for the pivot pins to move up-
ward when all body pads come to rest on the
frame rails. Use a ruler to measure the distance
between the two lines marked on each frame tail
lug.
W10-6-4
16. Measured movement should be 7 - 9 mm (0.276 –

0.354 in). If the measured movement is not
enough, the body will need to have shims added
(refer to step 6). If the measurement is too high,
remove the hinge pins to inspect condition of the EL20066
hinge pins and frame hinge bore bushings. If the
hinge pins appear worn (grooved or wallowed) re- Figure 5 - Body Pad and Body Guide Location
place them. Ensure the hinge bore bushings are
not split and are not creeping out of the bore. Re- 20. Body Pad Assembly 21E. Shim
place or reposition the bushings as necessary
21A. Shim 21F. Shim
17. If the pivot pins do not move the required distance, 21B. Shim 54. Bolt
raise the body and install the body prop cable. 21C. Shim 55. Washer
Place an equal amount of test body shims on the 20A. Body Pad Assembly 56. Locknut
frame rail where the 2 rear body pads and the front 21D. Shim
body pads are located on each frame rail.
18. Remove body prop cable and lower the body in the CAUTION: Body Pad (20) weight: 17 kg (40
FLOAT position only. Redo measurement and add Ib)
or remove test shims until desired movement of 7
– 9 mm (0.276 – 0.354 in) is established. After 20. After selecting the proper number of shims, bolt
obtaining the specified amount of movement with the rear body pads (20) with shims into position
the test shims in place, raise the body and install
on the body rails with washers (55), lock nuts (56)
the body prop cable. Permanently install the body
and bolts (54).
pads and the test shims used to establish the
: 3/4 in
specified amount of hinge pin movement. Install
the remainder of the required body pads with an : 80 - 89 N٠m (59 - 66 Ibf٠ft)
equal amount of shims.
: 3/4 in 21. Hoist the body several times slowly. During each
hoist cycle, inspect the exhaust system connector
: 80 - 89 N٠m (59 - 66 Ibf٠ft)
alignment and body guide bracket alignment. The
19. Remove body prop cable and lower the body in the body must lower down easily lying flat and cen-
FLOAT position only. Using a ruler or set of feeler tered between the frame rails supported by the
gauges determine the amount of gap between the body pads. The hinge pins must be tight against
body pads and the frame. Record the amount of the top of the frame bushing bore (Refer to Figure
gap on the right side as well as the left side. All 3) without crushing the rear body pad. When
body pads must be in contact or within 1.5 mm shimmed correctly the pins will appear to float
(0.059 in) of contacting the chassis rail when when the body is just raised off the frame or when
empty. Shim individual body pads accordingly. the body just starts to rest on the frame when be-
ing lowered.
W10-6-5
22. Reattach body prop cable (3). 3. The body guide striker plates (23) can be re-
moved from the frame by removing the bolts (24)
which attach them.
CAUTION: Rock Ejector (39) weight: 43 kg : 1 1/8 in
(95 Ib). Mud Guard (37) weight: 20 kg (45 Ib).
4. The body down indicator (33) can be removed
23. Install rock ejectors (30). Position spacers (34) from the body (1,2) by removing the bolts (44) that
so that there is clearance between the rock attach it to the canopy of the body.
ejector (30) and the tires. Rock ejectors should be : 7/16 in
centered between the rear tires.
: 1 7/8 in
INSPECTION
24. Attach the body down indicator (31) to the body (1,
2). Numbers in parentheses refer to Figure 1.
7
: /16 in
NOTE: Inspect the frame and body for cracks ap-
25. Attach mudguards (37). proximately every 1000 hours of operation.
9
: /16 in
1. Obtain a copy of Hitachi REPAIR WELDING MAN-
UAL, K0-111-00.
DISASSEMBLY
2. Clean the body assembly (1,2) thoroughly. The
Numbers in parentheses refer to Figure 1. preferred method is to use pressurized steam, if
available. Clean all small components in a suitable
solvent.
CAUTION: Body Pad (20) weight: 17 kg (40
Ib)
3. Inspect the condition of each body pad (20). Re-
place pads (20) if deteriorated and/or cracked and
1. The body pad assemblies (20) can be removed, if
pitted.
necessary by unbolting them from the body stiff-
eners. Remove bolts (54), washers (55), and nuts
4. Measure the gaps between the body guide brackets
(56).
(46) and the body guide plate (23). Each gap must
: 3/4 in
be between 3.1 to 6.4 mm (0.12 to 0.25 in) with the
body centered and resting on the frame. Re-shim
NOTE: If the body pad assemblies (20) are to be as necessary. Refer to figure 4.
removed, mark the location on the frame
rail at each pad to facilitate assembly, us- 5. Consult Hitachi REPAIR WELDING MANUAL,
ing a marking pen or chalk. K0-111-00, Section 05 for inspection of cracks.
Visually inspect all welds for cracks and breaks. In-
NOTE: Do not place body assembly in long term spect the inside of the body for damage or weld
storage (1,2) with the body pads (20) cracks.
mounted.
6. Magnetic Particle (MT) inspect or Dye Penetrant
(PT) inspect any welds where cracking is suspected.
CAUTION: Body Guide Bracket (46) weight: Where cracks are found, record the specific loca-
19 kg (41 Ib) tion(s), length, and depth of these cracks.
2. The body guide brackets (46) can be removed, if 7. Photograph crack(s) before, during, and after re-
necessary, by removing bolts (16) and shims (17, pairs. Send the photographs and the records from
18, 19, 4, 6 & 7) which attach the body guide step 6 to Hitachi Service Personnel if assistance is
brackets (46) to the body assembly (1,2). required.
: 1 1/8 in
W10-6-6
8. Repair as necessary according to instructions under

MAINTENANCE in this Group. Contact Hitachi ser-
vice personnel for availability of specific repair pro-
cedures. Consult Hitachi REPAIR WELDING WARNING!
MANUAL for general repair procedures. Follow in- The body prop cable (3) must be inspected on a
struction in hauler operators manual to prepare unit daily basis. Any cable that is broken, kinked,
by isolation of rigid dump truck electrical system rusted, or damaged must be removed from service
prior to welding on rigid dump truck. and replaced.
9. Inspect all wear surfaces for excessive wear. Check Do not use the body prop cable (3) for towing a
plate thickness annually to gauge wear rate. machine. Damage to the prop cable (3) may occur
and possibly result in injury.
10. Inspect the entire body assembly (1) for bent plates
and channels. Replace parts, straighten, patch or
paint, according to the instructions outlined under
the heading MAINTENANCE in this Group.
11. Inspect the pivot pins (5) and steel bushings (9).
Replace if wear is excessive.
12. Inspect the body prop cable (3) daily for broken or
worn parts. Replace or repair if necessary.
13. Inspect the rock ejector (39) for damage or sharp

edges. Replace if necessary. Do not operate
hauler if rock ejector is bent or broken.
MAINTENANCE
BODY PROP CABLE ASSEMBLY
OM21154

Figure 6 - Installed Body Prop cable
The body prop cable assembly must be put in place
when working on the rigid dump truck with the body in
the raised position. As an added safety measure, the
body should be shored up with hard wood timbers or
blocks. Never work around a raised body without
proper support or body prop installed. The body prop
cable assemblies are stored in the lower hole in the
bracket when not in use.
W10-6-7
MAINTENANCE (CONTINUED) welding 400 Brinell steel must be kept within the
maximum recommended limits. These limits are
WELDING ON RIGID DUMP TRUCKS WITH available from your Hitachi distributor.
TRANSMISSION CONTROL UNIT SYSTEM AND
CENTRAL CONTROL UNIT SYSTEM Preheat 400 Brinell steel to a maximum of 38 °C (100
°F) before welding if ambient temperature is below 16
When performing any welding operation on the rigid °C (60 °F). Although preheating is the standard pro-
dump truck, follow these precautions: Be sure to iso- cedure for welding other structural steel, it can be very
late rigid dump truck electrical system before welding harmful when welding 400 Brinell steel since the best
on hauler. Refer to electrical disconnect before welding 400 Brinell steel weld results from rapid cooling of the
on the rigid dump truck Section W8-1 Frame. weld.
Welding Procedure
Welding – General
Considerable emphasis has been placed on the need
Special arc welding methods must be used since the
for using low hydrogen electrodes, and preventing ex-
floor plate is made of 400 Brinell steel. Although 400
cessive heat input during welding however faulty weld-
Brinell steel is weldable, the materials and procedure
ing techniques can also cause low strength welds and
required for welding this metal are different from those
stress cracks.
for welding plain structural steels. 400 Brinell steel
chemical and physical properties are different. If your
When laying beads, the straight “stringer bead” method
welder has no previous experience welding 400 Brinell
is recommended for welding 400 Brinell steel as op-
steel, consult your Hitachi distributor.
posed to the “full weave” method. The “full weave”
method decreases the welding speed and thereby puts
NOTE: Never weld the body assembly (1,2) when more heat into the weld.
ambient temperature is below (0 ° F).
A good fillet-welding technique is perhaps more im-
Three general rules to be followed when welding 400 portant when welding 400 Brinell steel than with steels
Brinell steel are: of lower strength, because high-strength rods are often
required and because the joints are usually expected
to withstand greater forces. Therefore, more care
Correct Electrodes should be taken when making this type of weld.
Only electrodes with low-hydrogen coatings should be When welding 400 Brinell steel. In cases where multi-
used. It is also important that low-hydrogen elec- ple passes must be make which heats the metal plates,
trodes be kept dry. Their coatings absorb moisture and it is impossible to wait until the work cools to a
when exposed to air, and damp rods will cause unsafe welding temperature, the welding current amper-
derbead weld cracking even though they are classified age should be lowered a little at a time so that the heat
as “low-hydrogen”. input value is with in the allowable limits. The factors
that always result in the fastest welding are those that
NOTE: When welding 400 Brinell steel to lower supply heat input close to (but not exceeding) the al-
strength steel, the electrode strength lowable limits.
should be the same as that recommended
for the lower-strength steel. When welding with body in the raised position, thor-
oughly coat the exposed sections of the hoist cylinder
Welding Temperature exposed rods with heavy grease and wrap with water-
proof paper or welding blankets to prevent possible
The best welds when joining 400 Brinell steel results damage or pitting by falling pieces of hot metal during
when the welding heat remains below a specified welding.
maximum value so that the weld will cool down quickly.
The only practical way to control the cooling time of the No definite repair procedures can be established be-
weld is to control the amount of heat generated during cause the nature and extent of damages to the body
welding. Thus, the amount of heat developed when will vary. As a general rule, except for major repairs, it
W10-6-8
will not be necessary to remove the body from the unit. 8. Bead width should not exceed 4 times the elec-
Successful repair of the body will depend to great ex- trode diameter.
tent upon the use of proper welding equipment, mate-
rial used, and upon the ability and skills of the welder. 9. Thoroughly remove the slag from each bead
before depositing the subsequent bead.
Welding – 400 BHN Steel
The interior body surfaces and liner plates are made Straightening
from 400 BHN abrasion resistant steel. Strict adher-
ence to the following welding procedures will prevent Heat should not be used when straightening parts of
weld cracking and prolong weld service life of this the body. Heat weakens the structural characteris-
steel. tics of metal; therefore, all straightening should be
done with parts cold. Any parts bent or buckled suf-
1. Preheat all weld joints to 93 °C (200 °F) if am- ficiently to show strains or cracks after straightening
bient temperature is below 16 °C (60 °F). should be replaced or reinforced. Joints should be
properly fit before welding. Do not build stress into
2. Measure pre-heat at 76 mm (3.00 in) on each joint with the use of jacks or pullers to force parts
side of the weld joint centerline. together before welding.
3. No welding when ambient temperature is below Patching

–18 °C (0 °F).
Prepare the hole or break for patching by trimming
4. Use E7018 (AWS A5.1, Class E7018) electrode. off the curled edges with a cutting torch. When
The FCAW (Flux cored arc welding) process patching the body, the patch should be the same
with CO2 gas shielding can be substituted. thickness as the panel that is being patched. The
Please contact Product Support for approval patch must be of sufficient size to overlap at least 51
and procedures. mm (2.00in) all around the hole. Form the patch to
fit the contour of the mating part. Position the patch
5. The electrode size should be suited to the thick- over the hole and tack weld the patch to one side of
ness of the material, type of groove, the welding the panel, at several evenly spaced points. On the
position and other circumstance attending the other side of the panel burn a continuous fillet weld
work. The maximum size of electrode and cur- all around the hole. When welding body side panels
rent shall be as follows: the patch should be welded to the outside so that the
inside of the body well be as smooth as possible.
1 5 3
Position /8 /32 /16 ¼ The edges of the fracture inside the body should be
Flat/Horiz. 100/150 175/225 225/275 350 hammered smooth to fit against patch and the
Vertical 120/140 140/160 X X welded solidly to the patch.
Overhead 110/135 140/170 X X
Painting
6. Electrodes should be supplied in hermetically
sealed containers. They may be used directly The condition of the paint should be checked ap-
from the container within (4) hours after the con- proximately twice a year. Repaint the exterior of the
tainer has been opened. After (4) hours the body when necessary. The first coat should consist
electrodes are to be stored in a heated oven at of a Zinc Chromate Primer, and a Synthetic Enamel
121˚C (250 ˚F). If after (4) hours they are not should be used for the second coat.
stored at 121˚C (250 ˚F) they can be reclaimed
for use by baking at 427˚C (800 ˚F) for 1 hour. If the rigid dump truck is to be stored for any length
of time, it is suggested that the interior of the body
7. The welding surface must be free of moisture, be cleaned and painted to prevent it from rusting.
scale, slag, heavy rust, paint, grease, oil, or
other foreign matter.
W10-6-9
Optional Body Wear Plates:
Numbers in parenthesis refer to Figure 16.
The body wear plates, illustrated in Figure 16, pro- 2

tect the body against the abrasion and minor impact 5
of rocks. The plates are welded to the body as 6 RH
shown, and extend the body’s life. The body sides 7 LH
wear plates (2), floor wear plates (3), end wear plate
(4), and front wear plate (1) should be installed with
a maximum gap of 3 mm (0.12 in at the welding 1
points.
The wear plates should be replaced when excessive

wear is present or they have large deformations to 4
8
the point that the main plates may also be damaged.
Dump body structural integrity can be compromised 3
if excessive wear of the main plates is permitted on
unlined bodies. Figure 16 – Body Rock Protection Plates
Proper maintenance of the body liners is required so 1. Front Wear Plate 5. Front Valley Plate
main plates of the body are not prematurely dam-
aged. Damaged main body plates can allow the liner 2. Side Wear Plate 6. Rear Valley Plate RH
plates to come loose and fall out of the body. 3. Floor Wear Plate 7. Rear Valley Plate LH
Therefore, it is important that the user inspects the 4. End Cap Plate 8. Rock Cap Plate
condition of the inside of the body at regular main-
tenance intervals.
Perforation of the body interior either by weld cracks,

impact damage or tearing should be immediately in-
spected. The heated body assembly has exhaust
system channels throughout which can be contami-
nated by fluid leaking into engine exhaust system.
Excess leakage into exhaust system can cause en-
gine damage.
W10-6-10
Canopy Spill Guard
The canopy spill guard, illustrated in Figure 17, pre-

vents rocks from falling on the hood of the cab and
air cleaner. The spill guard and supports are bolted
to the canopy.
2
1
Figure 17 – Canopy Spill Guard
1. LH Canopy Guard Bracket 6. Screw

2. RH Canopy Guard Bracket 7. Washer
3. LH Support 8. Lock Nut
4. RH Support 9. Screw
5. Plate 10. Washer
W10-6-11
Replace all body pads when the rubber layer becomes less than 38 mm (1.5 in) in
Body Pads
thickness on any body pad.
Perform body shimming procedure at time of body mounting and whenever the
Body Shimming
body pads are replaced.
Replace cable immediately upon discovery of wear or damage during visual in-
Body Prop Cable
spection.
Replace rock ejectors immediately if either rock ejector is found to be bent or bro-
Rock Ejectors
ken. Do not operate the rigid dump truck without both rock ejectors.
W10-6-12
Hitachi Construction Truck Manufacturing Ltd. Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 519-823-2000 Email: TechPubs@hitachitruck.com
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If you need more space, please use another sheet.
REPLY:
(Copy this form for usage)

Hitachi Construction Truck Manufacturing Ltd. Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 519-823-2000 Email: TechPubs@hitachitruck.com
SERVICE MANUAL REVISION REQUEST FORM
(Copy this form for usage)

Hitachi Construction Machinery Co. Ltd.
Head Office: 5-1, Koraku 2-chome, Bunkyo-ku
Tokyo 112-0004 Japan
Hitachi Construction Truck Manufacturing Ltd.

200 Woodlawn St. West
Guelph, Ontario, Canada
N1H 1B6

EH1700-3 Workshop Manual

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Manual No: W8R6-E-01

RIGID DUMP TRUCK

Service Manual consists of the following separate Part No;

TO THE READER MANUAL COMPOSITION

The Technical Manual (Operational Principle) con-

SAFETY ALERT SYMBOL AND HEAD-

This is the safety alert symbol. When you see

The safety alert symbol is also used to draw attention

To avoid injury and damage, be sure to use appropri-

WARNING: Indicates a potentially hazardous

NOTE: Indicates supplementary technical infor-

RECOGNIZE SAFETY INFORMATION

• SAFETY ALERT SYMBOL

• This symbol, which will appear at various points in the

UNDERSTAND SIGNAL WORD

• On the rigid dump truck safety signs, signal words

• DANGER indicates an imminently hazardous

NOTE: indicates an additional explanation for an

• Only trained personnel should operate the rigid dump

• Operator should be of legal operating age according

• Operator must be licensed if required by National

DUTIES OF THE OPERATOR

• Before operating the rigid dump truck, this manual

• Never operate any vehicle while under the

Due to the position of the cab and size of the rigid

During rigid dump truck operation no one should be

INSPECT RIGID DUMP TRUCK

• Inspect your rigid dump truck carefully each day or shift

• Be sure to cover all points described under “INSPECT

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the rigid

• Safety signs should be installed, maintained and

• If a safety sign or this manual is damaged or missing,

• Learn how to operate the rigid dump truck and its

controls correctly and safely.

• Allow only trained qualified, authorized personnel to

• Keep your rigid dump truck in proper working condition.

PREPARE FOR EMERGENCIES

• Be prepared if fire starts or if an accident occurs.

• It is recommended that a first aid kit and fire

extinguisher at the recommended intervals as

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

You may need:

Respirator or filter mask.

• Avoid wearing loose clothing, jewelry, or other

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

PROTECT AGAINST FLYING DEBRIS

• If flying debris hits eyes or any other part of the body,

• Guard against injury from flying pieces of metal or

GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When entering or leaving the rigid dump truck,

Never mount or dismount a moving rigid dump

ADJUST THE OPERATOR’S SEAT

• The seat should be adjusted whenever changing

• If the rigid dump truck should overturn, the operator

• Prior to operating the rigid dump truck, thoroughly

injury from an accident.