Professional Documents
Culture Documents
and is not
to be reproduced, used, or disclosed except in accordance with written
authorization from Komatsu Mining Systems, Inc.
It is the policy of the Company to improve products whenever it is possible
and practical to do so. The Company reserves the right to make changes
or add improvements at any time without incurring any obligation to install
such changes on products sold previously.
Because of continuous research and development, periodic revisions
may be made to this publication. Customers should contact their local
distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects and other
reproductive harm.
Unsafe use of this machine may cause serious injury or death.
Operators and maintenance personnel must read and understand
this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference,
and periodically reviewed by all personnel who will come into
contact with it.
FOREWORD
This Service Manual is written for use by the service technician and is designed to help the technician
become fully knowledgeable of the truck and all its systems in order to keep it running and in
production. All maintenance personnel should read and understand the materials in this manual
before performing maintenance and/or operational checks on the truck. All safety notices, warnings
and cautions should be understood and followed when accomplishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as well
as other general information. The major portion of the manual pertains to disassembly, service and
reassembly. Each major serviceable area is dealt with individually. For example: The disassembly,
service and reassembly of the radiator group is discussed as a unit. The same is true of the engine
and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly
should be carried only as far as necessary to accomplish needed repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not
necessarily depict a specific model.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references
to "Right", "Left", "Front", or "Rear" are made with respect to the operators normal seated position,
unless specifically stated otherwise.
Standard torque requirements are shown in torque charts in the general information section and
individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All
torque specifications have 10% tolerance unless otherwise specified.
A Product Identification plate is normally located on the truck frame in front of the right side front
wheel and designates the Truck Model Number, Product Identification Number (vehicle serial
number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
The HAULPAK
Model designation consists of three numbers and one letter (i.e. 210M). The three
numbers represent the basic truck model. The letter "M" designates a Mechanical drive and the letter
"E" designates an Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will identify the
original manufacturing bill of material for this unit. This complete number will be necessary for proper
ordering of many service parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other
components. The vehicle design and application guidelines are sensitive to the total maximum Gross
Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel &
lubricants + the payload.
To determine allowable payload:
Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories,
body liners, tailgates, etc.) and then weigh truck.
Record this value and subtract from the GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable
payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations
should be removed as often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
A00010 8/95 Introduction A-1
"DANGER" IDENTIFIES A SPECIFIC POTENTIAL HAZARD
WHICH WILL RESULT
IN EITHER INJURY OR DEATH
IF PROPER PRECAUTIONS ARE NOT TAKEN.
"WARNING" IDENTIFIES A SPECIFIC POTENTIAL HAZARD
WHICH MAY RESULT
IN EITHER INJURY OR DEATH
IF PROPER PRECAUTIONS ARE NOT TAKEN.
"CAUTION" IS USED FOR GENERAL REMINDERS
OF PROPER SAFETY PRACTICES
OR
TO DIRECT THE READERS ATTENTION TO AVOID UNSAFE
OR IMPROPER PRACTICES WHICH MAY RESULT
IN DAMAGE TO THE EQUIPMENT.
THIS "ALERT" SYMBOL IS USED WITH THE SIGNAL WORDS,
"CAUTION", "DANGER", AND "WARNING" IN THIS MANUAL TO
ALERT THE READER TO HAZARDS ARISING FROM IMPROPER
OPERATING AND MAINTENANCE PRACTICES.
A-2 Introduction A00010 8/95
TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE, FUEL, COOLING AND AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . . . D
TRANSMISSION AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
DRIVE AXLE, SPINDLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
HYDRAIR
II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M
OPERATORS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
A00010 8/95 Introduction A-3
210M HAULPAK
TRUCK
A-4 Introduction A00010 8/95
SECTION A
GENERAL INFORMATION
INDEX
TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . A2-1
GENERAL SAFETY AND TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . A3-1
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1
CHARTS AND TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1
STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-1
A01001 2/94 Index A1-1
NOTES
A1-2 Index A01001 2/94
COMPONENT DESCRIPTION AND SPECIFICATIONS
ENGINE
The 210M HAULPAK
is powered by a Cummins
KTTA--19C diesel engine. The truck is capable of
speeds up to 35 MPH (56.7 km/h).
TRANSMISSION
The diesel engine drives a remote-mounted Allison
CLT-6062 transmission incorporating a TC683 torque
converter. The transmission has six speeds "Forward"
and one "Reverse" and uses Allison Transmission Elec-
tronic Control (ATEC) for complete automatic shift
sequencing. By moving the operators Range Selector
in the cab, the operator may select "R" for Reverse, "N"
for Neutral or any one of six Forward driving ranges.
The Range Selector is an electronic-mechanical con-
trol unit. Each position (R,N,D,5,4,3,2,1) is selected by
releasing a range locking mechanism on the lever and
choosing the desired range. "D" will permit completely
automatic up and down shifts through all six ranges.
"5" will limit upshifts to 5th range only. "4" will limit
upshifts to 4th range only. "3" will limit upshifts to 3rd
range only. "2" will limit upshifts to 2nd range only. "1"
is a first range hold position and no upshifts are permit-
ted.
DYNAMIC RETARDING
Dynamic retarding is actuated by depressing the op-
erators retarder pedal which applies oil-cooled, rear
mounted, wet disc brakes only; the front brakes are not
applied.
Application of the retarder pedal may be fully modu-
lated and should be used to slow the truck during
normal truck operation, to control speed coming down
a grade or to make non-emergency stops. Use of the
retarder pedal saves wear on the front brakes and
provides better steering control.
SERVICE BRAKE SYSTEM
The service brakes are controlled by an all hydraulic
actuation system. Depressing the service brake pedal
actuates front dry disc brakes and rear wet disc brakes.
Automatic Emergency Braking is provided if system
pressure falls below a preset value. All functioning
wheel brakes will be automatically applied by accumu-
lators.
POWER STEERING
The HAULPAK
II
Stroke (Front & Rear) . . . . . . 10.88 in. (276 mm)
FINAL DRIVE
Ratios:
Bevel Set (differential) . . . . . . . . . . . 3.85:1
Planetary . . . . . . . . . . . . . . . . . . 5.70:1
Total Reduction . . . . . . . . . . . . . . . . 21.93:1
Maximum Speed . . . . . . . . 35 MPH (56.7 km/h)
TIRES (Standard) 24.00-35, 36 PR(E-3)
Rating Ton-MPH (m/ton-km/h) . . . . . . 180 (262.8)
24 VDC ELECTRIC SYSTEM
Batteries . . . . . . . Two 12 Volt Batteries in Series
Capacity . . . . . . . . . . . . . 200 Ampere-Hour
Alternator . . . . . . . . 24 Volt, 75 Amperes Output
Starter . . . . . . . . . . . . . . . . . DELCO-REMY
Lighting . . . . . . . . . . . . . . . . . . 24 Volt-DC
SERVICE CAPACITIES U.S. Gallons Liters
Engine Lube Oil:
Cummins . . . . . . . . . . . . . . 13 49.2
Cooling System . . . . . . . . . . . . 48 181.7
Fuel Tank . . . . . . . . . . . . . . 154 583.7
Hydraulic System (incl. tank) . . . . 144 545.0
Hydraulic Tank . . . . . . . . . . . 95 359.6
Transmission . . . . . . . . . . . . . 20 75.6
Final Drive . . . . . . . . . . . . . . . 56 212.2
Front Spindle . . . . . . . . . . . . . 1 3.8
HOIST SYSTEM
Tandem Pump Capacity:
Shaft End . . . . 94 gpm (355 l/min.) @ 2100 RPM
Cover End . . . . 80 gpm (303 l/min.) @ 2100 RPM
Relief Valve Pressure Setting 2750 psi (18961 kPa)
Hoist Cylinders . . . . 2 - Stage Hydraulic Cylinders
Filtration . . . . . Full-Flow, Remote-Mounted Filter
Return . . . . . . Full Flow, 12 Micron - Absolute
SERVICE BRAKES
Actuation . . . . . . . . . . . . . . . . All Hydraulic
Type:
(Front) Single Dry Disc with 2 Caliper Assy./Wheel
Total Braking Surface . . . 408 in.
2
(2 632 cm
2
)
(Rear) . . . . . . Dual Wet Disc Brake Assemblies
Total Braking Surface . . 9020 in.
2
(58 193 cm
2
)
STEERING
Turning Circle . . . . . . . . . . . . 69 ft. (21.0 m)
Pump Capacity . . . . . . . . . 22.7 gpm (85.9 lpm)
System Pressure . . . . . . . . 2750 psi (19.0 MPa)
DUMP BODY CAPACITIES
PAYLOAD (Rated) 55 Ton (49.9 mt)
Capacitiy:
Struck . . . . . . . . . . 31.1
cu. yds. (23.8 m
3
)
Heaped @ 2:1 (SAE) . . 44.0 cu. yds. (33.7 m
3
)
BODY
Material [Yield Strength] . . . . . . . . . Thickness
Floor [125,000 psi (862 mPa)Steel] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 in. (19 mm)
Front [90,000 psi (620 mPa)Steel] 0.50 in. (13 mm)
Sides [90,000 psi (620 mPa)Steel] 0.38 in. (10 mm)
WEIGHT DISTRIBUTION
EMPTY - STANDARD . . . . Pounds Kilograms
Front Axle . . . . . . . . . . . 44,390 20 135
Rear Axle . . . . . . . . . . . 45,910 20 824
Total . . . . . . . . . . . . . . 90,300 40 959
LOADED . . . . . . . . . . Pounds Kilograms
Front Axle . . . . . . . . . . . 66,700 30 255
Rear Axle . . . . . . . . . . 133,600 60 600
Total . . . . . . . . . . . . . 200,300 90 855
MAXIMUM ALLOWABLE GVW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210,000 95 340
A02015 01/92 Component Description and Specifications A2-3
OVERALL TRUCK DIMENSIONS
A2-4 Component Description and Specifications A02015
GENERAL SAFETY
This safety section also contains precautions for optional equipment and attachments.
SAFETY RULES
ONLY trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
When working with another operator or a person on worksite traffic duty, be sure all personnel understand all
hand signals that are to be used.
SAFETY FEATURES
Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.
(See Walk-Around Inspection, Operating Instructions later in this section.)
Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
NEVER remove any safety features. ALWAYS keep them in good operating condition.
Improper use of safety features could result in serious bodily injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause
serious injury or death. Also, do not wear oily clothes because they are
flammable.
Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine. Always wear safety goggles, hard
hat and heavy gloves if your job involves scattering metal chips or minute
materials----this is so particularly when driving pins with a hammer and
when cleaning the air cleaner element with compressed air. Check also
that there is no one near the machine.
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards.
Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury
or damage caused by any unauthorized modification.
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
A03002 4/98 General Safety & Operation A3-1
STANDING UP FROM THE SEAT
To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the
following before standing up from the operators seat.
Place the shift control lever at neutral (N) and set the parking lever to the PARKING position.
Lower the dump body, set the dump lever to the HOLD position, then apply the lock.
Stop the engine. When leaving the machine, always lock everything. Always remember to take the key with you.
If the machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or
death.
MOUNTING AND DISMOUNTING
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When getting on or off the machine, face the machine and use the handhold and steps.
Never hold any control levers when getting on or off the machine.
Always maintain three-point contact with the handholds and steps to ensure that you support yourself.
When bringing tools to the operators compartment, always pass them by hand or pull them up by rope.
If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
A: For use when getting on or off the machine from the left door.
B: For use when getting on or off the machine from the engine hood or right door.
FIRE PREVENTION FOR FUEL AND OIL
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
Keep flame away from flammable fluids.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil tank caps securely.
Refueling and oiling should be made in well ventilated areas.
Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
A3-2 General Safety & Operation A03002 4/98
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature and
are under pressure. If the cap is removed or the oil or water is drained or the filters are replaced, there is danger
of serious burns. Always wait for the temperature to go down, and carry out the operation according to the specified
procedure.
To prevent hot water from spurting out:
1) Stop the engine.
2) Wait for the water temperature to go down.
3) Turn the cap slowly to release the pressure before removing the cap.
To prevent hot oil from spurting out:
1) Stop the engine.
2) Wait for the oil temperature to go down.
3) Turn the cap slowly to release the pressure before removing the cap.
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given
below:
NEVER use compressed air for cleaning.
Use water for cleaning to keep down the dust.
Operate the machine with the wind to your back, whenever possible.
Use an approved respirator if necessary.
PREVENTION OF INJURY BY WORK EQUIPMENT
Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead
to serious bodily injury or death.
FIRE EXTINGUISHER AND FIRST AID KIT
Be sure fire extinguishers have been provided and know how to use them.
Provide a first aid kit at the storage point.
Know what to do in the event of a fire.
Be sure you know the phone numbers of persons you should contact in case of
an emergency.
A03002 4/98 General Safety & Operation A3-3
PRECAUTIONS WHEN USING ROPS
If ROPS is installed, the ROPS must never be removed when operating the machine.
The ROPS is installed to protect the operator if the machine should roll over. If is designed not only to support
the load if the machine should roll over, but also to absorb the impact energy.
The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without
authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its
function properly. It can only display its performance if it is repaired or modified in the specified way.
When modifying or repairing the ROPS, always contact your Komatsu distributor.
Even if the ROPS is installed, it cannot show its full effect if the operator does not fasten the seat belt properly.
Always fasten the seat belt when operating.
PRECAUTIONS FOR ATTACHMENTS
When installing and using an optional attachment, read the instruction manual for the attachment and the
information related to attachments in this manual.
Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized
attachments could create a safety problem and adversely affect the proper operation and useful life of the
machine.
Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the
responsibility of Komatsu.
A3-4 General Safety & Operation A03002 4/98
PRECAUTIONS DURING OPERATION
BEFORE STARTING ENGINE
SAFETY AT WORKSITE
Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
Examine the road surface in the jobsite and determine the best and safest method of operation.
Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty
or by installing fences around the worksite.
Check the river bed condition, and depth and flow of water before crossing shallow parts of river. NEVER be in
water which is in excess of the permissible water depth.
The operator must check personally the work position, roads to be used, and existence of obstacles before starting
operations.
Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines
to travel.
FIRE PREVENTION
Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compart-
ment. They could cause a fire.
Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks
repaired. Wipe up any excess oil, fuel or other flammable fluids.
Be sure a fire extinguisher is present and working.
Do not operate the machine near any flame.
IN OPERATORS CAB
Do not leave tools or spare parts lying around in the operators compartment. They may damage or break the
control levers or switches. Always put them in the tool box on the right side of the machine.
Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use
seat belts when operating your machine.
VENTILATION FOR ENCLOSED AREAS
If it is necessary to start the engine within an enclosed area, provide adequate ventilation.
Exhaust fumes from the engine can KILL.
A03002 4/98 General Safety & Operation A3-5
KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN
Remove any dirt from the surface of the windows or lights to ensure good visibility.
Adjust the rear view mirror to a position where the operator can see best from the operators seat, and keep the
surface of the mirror clean. If any glass should break, replace it with a new part.
Check that the machine is equipped with the head lamps and working lamps needed for the operating conditions.
Check that all the lamps light up properly.
A3-6 General Safety & Operation A03002 4/98
OPERATING MACHINE
WHEN STARTING ENGINE
Walk around your machine again just before mounting it, checking for people and objects that might be in the
way.
NEVER start the engine if a warning tag has been attached to the control.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Do not allow any person other than the operator in the operators compartment or any other place on the machine.
For machines equipped with a back-up alarm buzzer, check that the alarm buzzer works properly.
CHECK WHEN TRAVELING IN REVERSE
Before operating the machine or work equipment, do as follows:
Sound the horn to warn people in the area.
Check that there is no one near the machine. Be particularly careful to check
behind the machine.
If necessary, designate a person to check the safety. This is particularly
necessary when traveling in reverse.
When operating in areas that may be hazardous or have poor visibility,
designate a person to direct worksite traffic.
Do not allow any one to enter the line of travel of the machine. This rule must
be strictly observed even on machines equipped with a back-up alarm or rear view mirror.
TRAVELING
When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
Lower the dump body and set the dump lever to the FLOAT position when traveling.
If the engine should stop when the machine is traveling, the steering wheel will not work, and it will be dangerous
to drive the machine. Apply the brakes immediately and stop the machine.
TRAVELING ON SLOPES
Traveling on slopes could result in the machine tipping over or slipping.
Do not change direction on slopes. To ensure safety, go down to level ground before turning.
Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Take all possible steps to avoid traveling sideways, and always keep the travel
speed low.
When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly. Do
not use the foot brake except in an emergency.
If the engine should stop on a slope, apply the brakes fully and apply the parking brake, also, to stop the machine.
A03002 4/98 General Safety & Operation A3-7
ENSURE GOOD VISIBILITY
When working in dark places, install working lamps and head lamps, and set up lighting in the work area if
necessary.
Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a
condition that allows the operation to be carried out safely.
OPERATE CAREFULLY ON SNOW
When working on snowy or icy roads, there is danger that the machine may slip to the side on even the slightest
slope, so always travel slowly and avoid sudden starting, turning, or stopping.
Be extremely careful when carrying out snow-clearing operations. The road shoulder and other objects are buried
in the snow and cannot be seen.
When traveling on snow-covered roads, always install tire chains.
AVOID DAMAGE TO DUMP BODY
When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits, always drive extremely carefully and lower the dump body completely before driving
the machine.
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below
between the machine and the electric cable.
The following actions are effective in preventing accidents:
1) Wear shoes with rubber or leather soles.
2) Use a signalman to give warning if the machine approaches too close to the electric cable.
If the work equipment should touch the electric cable, the operator should not leave the operators compartment.
When carrying out operations near high voltage cables, do not let anyone come close to the machine.
Check with the electricity company about the voltage of the cables before starting operations.
Voltage Min. Safety Distance
6.6 kV 3 m 10 ft
33.0 kV 4 m 14 ft
66.0 kV 5 m 17 ft
154.0 kV 8 m 27 ft
275.0 kV 10 m 33 ft
A3-8 General Safety & Operation A03002 4/98
WHEN DUMPING
Before starting the dumping operation, check that there is no person or object behind the machine.
Stop the machine in the correct position, and check again that there is no person or object behind the machine.
Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position
a flagman.
When carrying out dumping operations on slopes, the machine stability will become poor and there is danger
that it may tip over. Always carry out such operations extremely carefully.
Do not travel with the dump body raised.
WORKING ON LOOSE GROUND
Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse,
your machine could fall or tip over and result in serious injury or death. Remember that the soil after heavy rain
or blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight or vibration of
your machine.
When operating in places where there is danger of falling rocks or danger of the machine turning over, always
install ROPS and a seat belt.
WHEN LOADING
Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
Do not leave the operators seat during the loading operation.
PARKING THE MACHINE
Choose a horizontal road surface to park the machine. If the machine has to be parked on a slope, always put
blocks under all the wheels to prevent the machine from moving.
When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn
pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
Before leaving the machine, lower the dump body fully, set the parking lever to the PARKING position, stop the
engine, then lock everything. Always take the key with you.
A03002 4/98 General Safety & Operation A3-9
BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or
poison prevention center immediately.
When working with batteries ALWAYS wear safety glasses or goggles.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark of
flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across
the terminals.
When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
Tighten the battery cap securely.
Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.
STARTING WITH BOOSTER CABLES
ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
When starting from another machine, do not allow the two machines to touch.
Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the ground or negative
(-) cable first when removing them.
If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. This is dangerous, so
be sure to work carefully.
Connect the batteries in parallel: positive to positive and negative to negative.
When connecting the ground cable to the frame of the machine to be started, be sure to connect it as far as
possible from the battery.
A3-10 General Safety & Operation A03002 4/98
TOWING
WHEN TOWING, FIX WIRE TO HOOK
Towing in the wrong way may lead to serious personal injury or damage.
When using another machine to tow this machine, use a wire rope with ample strength for the weight of this
machine.
Never tow a machine on a slope.
Do not use any towing rope that has kinks or is twisted.
Do not stand astride the towing cable or wire rope.
When connecting a machine that is to be towed, do not let any one come between the towing machine and the
machine that is being towed.
Set the coupling of the machine being towed in a straight line with the towing portion of the machine, and secure
it in position.
(For towing method, see "Operating Instructions" later in this section or in Section 3 in the Operation &
Maintenance Manual.)
A03002 4/98 General Safety & Operation A3-11
PRECAUTIONS FOR MAINTENANCE
BEFORE CARRYING OUT MAINTENANCE
WARNING TAG
If others start the engine or operate the controls while you are performing service or lubrication, you could suffer
serious injury or death.
ALWAYS attach the WARNING TAG to the control lever in the operators cab to alert others that you are working
on the machine. Attach additional warning tags around the machine, if necessary.
These tags are available from your Komatsu distributor. (Part No. 09963-03000)
PROPER TOOLS
Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools
could cause personal injury.
PERIODIC REPLACEMENT OF CRITICAL PARTS
Periodically replace parts used to insure safety or prevent accident. (See PERIODIC REPLACEMENT OF
COMPONENT PARTS FOR SAFETY DEVICES, Section 4.)
Replace these components periodically with new ones, regardless of whether or not they appear to be defective.
These components deteriorate over time.
Replace or repair any such components if any defect is found, even though they have not reached the time
specified.
STOPPING THE ENGINE BEFORE SERVICE
When carrying out inspection or maintenance, always stop the machine on firm flat ground, lower the dump body,
then stop the engine.
If the engine must be run during service, such as when cleaning the radiator, always set the shift control lever to
the neutral position (N) and the parking brake lever to the PARKING position. Always carry out the work with two
people. One person should sit on the operators seat so that he can stop the engine if necessary. NEVER move
any controls you do not need to operate.
When servicing the machine, be careful not to touch any moving part or get your clothes caught.
Put blocks under the wheels.
When carrying out service with the dump body raised, always place the dump lever at the HOLD position, apply
the lock, and insert the safety pins securely.
A3-12 General Safety & Operation A03002 4/98
DURING MAINTENANCE
PERSONNEL
Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.
ATTACHMENTS
Place attachments that have been removed from the machine in a safe place so that they
do not fall. If they fall on you or others, serious injury could result.
WORK UNDER THE MACHINE
Always lower all movable work equipment to the ground or to their lowest position before
performing service or repairs under the machine.
Always block the tires of the machine securely.
Never work under the machine if the machine is poorly supported.
KEEP THE MACHINE CLEAN
Spilled oil or grease, or scattered tools or broken pieces are dangerous because
they may cause you to slip or trip.
Always keep your machine clean and tidy.
If water gets into the electrical system, there is danger that the machine may not
move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the
operators compartment.
RULES TO FOLLOW WHEN ADDING FUEL OR OIL
Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
Always tighten the cap of the fuel and oil fillers securely.
Never use fuel for washing any parts.
Always add fuel and oil in a well-ventilated place.
A03002 4/98 General Safety & Operation A3-13
RADIATOR WATER LEVEL
If it is necessary to add water to the radiator, stop the engine and allow the engine
and radiator to cool down before adding the water.
Slowly loosen the cap to relieve pressure before removing the cap.
USE OF LIGHTING
When checking fuel, oil, coolant, or battery electrolyte, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is
danger or explosion.
PRECAUTIONS WITH BATTERY
When repairing the electrical system or when carrying out electrical welding,
remove the negative (-) terminal of the battery to stop the flow of current.
HANDLING HIGH-PRESSURE HOSES
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
PRECAUTIONS WITH HIGH PRESSURE OIL
Do not forget that the work equipment circuits are always under pressure.
Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin
or enters your eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of
wood to check for oil leakage.
If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
A3-14 General Safety & Operation A03002 4/98
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE
Immediately after stopping operations, the engine cooling water and oil at all parts
are at high temperature and under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters
are replaced, it may result in burns or other injury. Wait for the temperature to go
down, then carry out the inspection and maintenance in accordance with the
procedures given in this manual.
ROTATING FAN AND BELT
Keep away from rotating parts and be careful not to let anything get caught in them.
If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying,
so never touch any rotating parts.
WASTE MATERIALS
Never dump waste oil in a sewer system, rivers, etc.
Always put oil drained from your machine in containers. Never drain oil directly
on the ground.
Obey appropriate laws and regulations when disposing of harmful objects such
as oil, fuel, coolant, solvent, filters, batteries, and others.
A03002 4/98 General Safety & Operation A3-15
TIRES
HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones
on rough road surfaces. This may lead to serious injury or damage.
To maintain safety, always keep to the following conditions:
Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
Use the specified tires.
The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual
values may differ depending on the type of tire and the condition under which they are used. For details, please
contact your Komatsu distributor or tire maker.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly dangerous if the tires
become overheated when the tires are under pressure. If the gas generated inside the tire ignites, the internal pressure
will suddenly rise, and the tire will explode, and this may lead to serious personal injury. Explosions differ from
punctures or tire bursts, because the destructive force is extremely large. Therefore, the
following operations are strictly prohibited when the tire is under high internal pressure:
Welding the rim
Building fires or carrying out welding near the wheel or tire.
If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and
you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such
maintenance, please consult your Komatsu distributor or tire maker.
STORING TIRES AFTER REMOVAL
As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored
outside, always erect a fence around the tires and put up No Entry and other warning signs that even young
children can understand.
Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy,
so trying to hold the tire may lead to serious injury.
A3-16 General Safety & Operation A03002 4/98
SAFETY RULES
Safety records of most organizations will show that the
greatest percentage of accidents are caused by un-
safe acts of persons while the remainder are caused
by unsafe mechanical or physical conditions.
The following safety rules are intended to instruct the
truck operator on what to do and not to do while
operating the truck. However, all situations cannot be
covered by these safety rules; local conditions and
regulations may add many more to this list.
GENERAL
1. Prevention is the best safety program. Prevent
accidents by knowing all the safety regulations
required by the employer, all necessary precau-
tions at the job site, and the manufacturers rec-
ommendati ons for the truck. Report any
conditions that need attention to the proper
authorities.
2. Wear proper clothing. Loose fitting clothing, un-
buttoned jackets and sleeves, jewelery, etc. can
catch on a protrusion and cause a potential haz-
zard.
3. Always use personal safety equipment such as
safety shoes, safety glasses and hard hat. There
may be conditions when ear protective devices
should also be worn.
4. When walking to or from the truck, keep a safe
distance from all machines even if the operator is
visible.
Before Starting Engine
1. Carefully study the Operator Handbook before
starting engine or driving truck. Give particular
attention to safety material and caution and warn-
ing decals. Only qualified operators or techni-
cians should attempt to operate the truck.
2. Before operating truck, a careful visual inspection
as well as operational checks should be com-
pleted. Report any items that need attention to the
proper authority.
a. Inspect entire truck for oil or coolant leaks.
If engine has been running, allow coolant to cool
before removing the fill cap or draining radiator.
Any operating fluid, such as hydraulic oil, or en-
gine coolant escaping under pressure, can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury and pos-
sibly death, if proper medical treatment by a
physician who is familiar with this type of injury is
not received immediately.
b. When checking coolant in radiator, relieve
pressure before removing radiator cap.
c. Check tires for cuts, damage or "bubbles".
Check tires for proper inflation. If tire is warm
from operation, allow tire to cool before adjust-
ing tire pressure. If inflation is needed, use an
air chuck with extension hose clipped on the
tire inflation valve to allow service away from
front of wheel.
d. Visually inspect all headlights, worklights, clear-
ance lights, and taillights for damage and be
certain lenses are clean. Good visibility may
prevent an accident.
e. Upon completion of an exterior inspection of
the truck, clean mud, grease, ice or snow from
shoes and ladder before climbing access lad-
der.
f. Always use handrails and ladder when mount-
ing or dismounting truck.
Always mount and dismount facing the truck.
Never attempt to mount or dismount while the
truck is in motion.
g. Check the deck areas for debris or loose hard-
ware.
h. When getting in or out of truck cab, face the
cab and use handrails provided.
A03002 4/98 Safety Rules A3-17
i. Become familiar with all protective equipment
devices on the truck and insure that these
items (seat belts, grab bars, anti-skid material,
canopies, etc.) are securely in place.
j. Check on-board fire extinguishers. Do not use
a fire extinguisher for any purpose other than
extinguishing a fire. If extinguisher is used,
report the occurrence so it may be refilled or
replaced.
Starting Engine And General Operation
1. Make sure all persons are clear of truck before
starting engine. Always sound the horn as a
warning device before activating any controls.
When backing the truck, give backup signal (three
blasts on horn); when starting forward, two blasts
on horn. These signals must be given each time
the truck is moved forward or backward.
2. Insure adequate ventilation before startup if the
truck is in an enclosure. Exhaust fumes are dan-
gerous.
3. If a cold weather starting aid is used, read and
follow the manufacturers instructions for use and
disposal.
Starting fluid is highly flammable. Use with ex-
treme care.
4. Check windshield wipers, lights, windows and
horn for proper operation and cleanliness.
5. Operate each of the truck brake circuits at least
twice prior to operating and moving the truck.
These checks should include individual activa-
tions of the service brake, parking brake, and
brake lock with the engine running. If any appli-
cation/release of any brake circuit does not ap-
pear proper, or if sluggishness is apparent on
application/release, shut the truck down and no-
tify maintenance personnel. DO NOT operate
truck until brake circuit in question is fully opera-
tional.
Use brake lock at dump or loading site ONLY. DO
NOT use brake lock to park the truck with engine
shut down or to stop the truck during routine
operation.
6. Check parking brake periodically during shift. Use
parking brake for parking only.
7. Observe safety and warning decals on the truck
at all times.
8. Keep all unauthorized reading material out of truck
cab.
9. Do not carry tools and supplies in cab of truck or
allow trash to accumulate in cab.
10. Do not allow anyone to ride on decks or steps of
truck. Riders should be in cab only.
11. Only authorized persons are allowed to ride in the
truck cab. Wear seat belts at all times.
12. Do not allow anyone to get on or off truck while it
is in motion.
13. Do not move truck into or out of a building without
a signal person present.
14. DO NOT leave truck unattended while engine is
running.
15. Check for flat tires periodically during shift. If truck
has been run on a "flat", it must not be parked in
a building until the tire cools.
If tire must be changed, do not stand in front of
rim and locking ring when inflating tire mounted
on the machine. Initial inflation to required pres-
sure must be done with a safety cage or rack
enclosing the tire and rim assembly. Observers
should not be permitted in the area and should be
kept at least 1500 ft. (457 m) away from the side
of such tires.
Do not weld or apply heat on the rim assembly with
the tire mounted on the rim. Resulting gases inside
the tire may ignite causing explosion of tire and
rim.
In the event of fire in the tire and wheel area
(including brake fires), stay away from the truck
until the tire and wheel are cool. Tire and rim
assembly may explode if subjected to excessive
heat. Personnel should move to a remote or pro-
tected location if sensing excessively hot brakes,
smell of rubber burning or evidence of fire near tire
and wheel area.
A3-18 Safety Rules A03002 4/98
If the truck must be approached to extinguish a
fire, those personnel should do so only from the
front or the back of the tire, unless protected by
use of large heavy equipment as a shield. Stay at
least 50 feet (15 m) from the tread of the tire.
16. Report haul road, pit or dump conditions which
may present hazzards (muddy roads, ice, snow,
pot holes, spilled debris, etc.) immediately to su-
pervisor.
Loading
1. Pull into the loading area with caution. Remain at
a safe distance while truck ahead of you is being
loaded.
2. Do not drive over unprotected power cables.
3. When approaching or leaving a loading area,
watch out for other trucks and for personnel work-
ing in the area.
4. When positioning truck under shovel, follow
"Spotter" or "Shovel Operator" signals. Operator
may speed up loading operations by watching
truck position ahead of him in order to judge
where he is to place his unit.
5. While truck is being loaded, operator should stay
in cab of truck. Apply brake lock during loading
operation.
6. After truck is loaded, pull away from shovel with
caution.
Hauling
1. Stay alert! Govern truck speed by the road condi-
tions, weather and visibility.
2. Always operate truck so it is under control at all
times.
3. Use extreme caution when approaching a haul
road intersection. Be prepared to avoid collisions
with other vehicles. Watch for oncoming vehicles
and be prepared to slow down and move aside if
haul road is restricted.
4. Obey all road signs.
5. If unfamiliar with the road, drive with extra caution.
6. Always dim headlights when meeting oncoming
vehicles.
7. Maintain a safe distance when following another
truck. Never approach another truck from the
rear, in the same lane, closer than 50 ft. (15 m).
When operating on a down grade, this distance
should be no closer than 100 ft. (30 m).
8. Before starting up or down a grade, maintain a
speed that will insure safe driving and provide
effective retarding under all conditions. Refer to
speed/grade decal in operator cab.
9. When operating truck in darkness or when visibil-
ity is poor, do not move truck unless headlights
are on. Do not back truck without a spotter if
backup horn or lights are inoperative.
10. When backing the truck, give backup signal (three
blasts on horn); when starting forward, two blasts
on horn. These signals must be given each time
the truck is moved forward or backward.
11. Do not stop or park on a haul road unless unavoid-
able. If you must stop, move truck to a safe place,
apply parking brake, block wheels securely and
notify maintenance personnel for assistance.
12. Cab doors should remain closed at all times while
truck is in motion or unattended.
A03002 4/98 Safety Rules A3-19
Passing
1. Use only the areas designated for passing. Before
passing, make sure the road ahead is clear.
2. Do not pass another vehicle on a hill or blind curve.
3. If a disabled truck is blocking your lane, slow down
and pass with extreme caution.
Dumping
1. Pull into dump area using caution. Carefully ma-
neuver truck into dump position. Obey signals as
directed by the spotter, if present.
2. When in dump position, apply wheel brake lock
and move selector switch to "Neutral" position.
3. Put hoist control lever in "Hoist" position and
depress throttle pedal.
4. Remove foot from throttle pedal as last stage of
hoist cylinder starts to extend.
5. After load has been dumped, place hoist control
lever in the down position and release the lever
allowing the body to return to the frame.
6. With body completely down against frame, leave
the dump area.
The truck is not to be moved with the dump body
raised EXCEPT IN EMERGENCIES.
Failure to follow this CAUTION may result in hoist
cylinder, frame, and/or body hinge pin damage.
Parking
1. When parking, park only in designated parking
areas and at a safe distance from other vehicles
as determined by supervisor.
2. If parking truck in other than designated parking
area is necessary, select a level area, apply
parking brake and block wheels front and rear. Do
not use brake lock as a parking brake.
3. If necessary to park on a slope, park at right angles
to the incline and block wheels securely.
4. When parking do not leave truck unattended if
engine is left running or if dump body is raised.
5. If engine is to be shut down, follow procedure
outlined under "Shutting Down Engine".
Shutting Down Engine
1. Bring truck to complete stop, move range selector
to the "Neutral" position and apply parking brake.
2. Allow engine to run from 3 to 5 minutes at idle to
provide cooling of the engine.
Do not leave truck unattended during engine idle
cool down period.
3. Turn off all lights and accessories.
4. Engine shutdown may be activated when key-
switch is moved to the "Off" position on some
trucks; other trucks may require depressing and
holding a shutdown button until the engine stops.
Refer to the Operator Handbook for specific
model information. Some trucks may include an
optional "Ground Level Shutdown" button .
5. Close and lock all windows, remove key from
key-switch and lock cab to prevent unauthorized
truck operation. Dismount truck properly.
A3-20 Safety Rules A03002 4/98
When Service Is Necessary
1. If truck is to be towed for any reason, use a rigid
tow bar. Check truck cab for decal recommending
special towing precautions. Refer to "Towing"
instructions for further precautions.
2. When truck body is in the dump position, do not
allow anyone beneath it unless "body-up" retain-
ing cable or pins are installed.
3. Do not repair or service truck while engine is
running, except when adjustments can only be
made under such conditions. Keep a safe dis-
tance from moving parts.
4. When servicing air conditioning system with re-
frigerant, wear a face shield and cold resistant
gloves for protection against freezing.
5. Follow package directions carefully when using
cleaning solvents.
6. If an auxiliary battery assist is needed, turn off all
accessories and be sure area is well ventilated.
NOTE: HAULPAK Trucks are generally equipped with
two 12 volt batteries connected in series to provide 24
volt output. Be sure to maintain correct voltage and
polarity when connecting booster cables. Damage to
electrical components may result if voltage and polarity
are not correct.
Lead-sulphate batteries will give off hydrogen gas!
Sparks or flame near these batteries may cause a
violent explosion which will expel debris and ex-
tremely toxic and corrosive sulphuric acid!
Use the following procedure to minimize the pos-
sibility of sparks in the vicinity of the battery:
a. Connect one lead of booster cable to 24V
positive (+) post of battery needing assist, and
other lead of the booster cable to the 24V
positive (+) post of auxiliary battery.
b. Connect one lead of second booster cable to
24V negative (-) post of auxiliary battery and
then connect other lead of the booster cable to
a good frame ground on the disabled truck
away from the battery needing assist.
Towing
Prior to towing a truck, many factors must be carefully
considered. Serious personal injury and/or significant
property damage may result if important safety prac-
tices, procedures and preparation for moving heavy
equipment are not observed.
Both right and left planetary sun gears/drive axles
should be removed before any towing. Refer to
Section "G" for these instructions. Extensive sec-
ondary damage can occur to final drive compo-
nents and/or transmission, if truck is towed
without first removing sun gears/drive axles.
A disabled truck may be towed after the following
MINIMUM precautions have been taken.
1. Shut down engine.
2. Refer to operators cab for towing decal for any
special instructions.
3. If truck is equipped, install hydraulic connections
for steering and dumping between towing and
towed vehicles.
4. Inspect tow bar for adequacy (approximately 1.5
times the gross vehicle weight of truck being
towed).
5. Determine that towing vehicle has adequate ca-
pacity to both move and stop the towed truck
under all conditions.
6. Protect both operators in the event of tow bar
failure.
7. Block disabled truck to prevent movement while
attaching tow bar.
8. Release disabled truck brakes and remove block-
ing.
Do not tow the truck any faster than 5 MPH (8 kph).
9. Sudden movement may cause tow bar failure.
Smooth and gradual truck movement is preferred.
10. Minimize tow angle at all times - NEVER EXCEED
30
o
. The towed truck must be steered in the direc-
tion of the tow bar.
A03002 4/98 Safety Rules A3-21
NOTES
A3-22 Safety Rules A03002 4/98
WARNINGS AND CAUTIONS
The following paragraphs give an explanation of the
Warning, Caution, Danger and Service Instruction
plates and decals attached to the truck. The plates and
decals listed here are typical of this model HAULPAK
,
but because of customer options, individual trucks
may have plates and decals that are different from
those shown here.
The plates and decals must be kept clean and legible.
If any decal or plate becomes worn or unable to be
read, it should be replaced with a new one. Order
replacements by the part number shown at the bottom
of the plate or decal.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine idle decal WA9706 is located in the cab, above
the windshield. The operator is cautioned that damage
can occur to the turbocharger if the engine is not
properly idled for three minutes before shutdown.
These instructions are very important.
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
The WA9721 towing "Caution" decal is located to the
right of operator, above the windshield. Do not tow the
truck without first removing the sun gears and sun
shafts from the planetary drive. If these parts are not
removed, damage to the transmission and/or final drive
will result when the truck is towed. Refer to Section "G",
Planetary Drive, for instructions.
Do not tow the truck faster than 5 MPH (8 KPH).
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
WA9741Caution decal is located inside the cab above
the windshield. It cautions the operator that the maxi-
mum brake oil temperature is 250
o
F (121
o
C) and maxi-
mum engine speed is 2350 RPM. Exceeding these
limits may result in vehicle damage. The graph pro-
vides speed guide lines to be used to maintain these
limits when descending various grades with a loaded
truck.
When descending a grade and applying the retarder
pedal, the operator should observe both the Tachome-
ter and the Brake Oil Temperature Gauge. The engine
RPM must be maintained at 1650 -- 2350 RPM (green
area on tachometer) and the Brake Oil Temperature
must be maintained below 250
o
F (121
o
C).
If the operator observes that either of these values are
about to be exceeded, the operator should immedi-
ately move the transmission range selector to the next
lower range and apply the service brakes until the truck
is slowed to a speed which will permit the transmission
to downshift to the gear range selected.
A04017 1/92 Warnings and Cautions A4-1
The welding "Caution" plate WA9713 is located in the
cab above the windshield. These instructions MUST be
followed when welding is done on the truck to avoid
damage to the ATEC components.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A ROPS/FOPS Warning plate is located on the right
side of the cab above the windshield. It specifies that
the structure as manufactured meets SAE specifica-
tions and warns that these specifications may be im-
paired if subjected to any modifications or damage.
WA9779 Caution decal is located in the cab on the back
of the sunvisor and specifies that during first four hours
of operation, the Truck Speed SHOULD NOT Exceed
25 MPH (40 KPH) in order to properly break-in the oil
brake seals.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On the right side of the operators instument panel is a
series of three Warnings.
The Warning on the left specifies that wheel brake lock
is not to be used for parking. If engine is not running,
brake pressure may bleed down allowing brakes to be
released. It should be used only at the shovel or dump,
or for emergency.
A4-2 Warnings and Cautions A04017 1/92
The center Warning specifies that if any of the red lights
on the instrument panel are "ON" (during truck opera-
tion), the truck should not be operated. The switch in
this panel is a manual test switch to check all indicator
lights for operation.
The Warning on the right specifies that when the slip-
pery road control is in use, braking power to the front
wheels is reduced. The Slippery Road switch will not
be present on Haulpak
Distributor
for information on type of material required.
The addition of sideboards to increase payload is not
recommended without factory approval.
BODY-UP LIMIT SWITCH
The Body-Up Limit Switch is designed to stop hoist
cylinder extension before maximum travel (complete
extension) occurs. The body-up limit switch is a mag-
netic proximity switch mounted on the inboard side of
the right frame rail near the upper rear suspension
mount. The limit switch is installed in the wiring circuit
for the hoist control.
When the indicator arm (mounted on the body pivot
ear) moves near the body-up limit switch, the circuit to
the hoist up solenoid is interrupted; this limits body-up
travel by preventing additional oil flow to the hoist
cylinders.
Body-Up Limit Switch Adjustment
NOTE: Prior to adjusting the Body-Up Limit Switch, a
thorough inspection of the body pivot pins, spacers,
and bushings should be made.
Excessive wear of these parts may allow the body to
shift during operation and cause damage to the Body-
Up Limit Switch. Refer to Dump Body Pivot Pins, for
information regarding these components.
1. Park truck on level surface, apply park brake and
block wheels. Check for sufficient overhead clear-
ance to allow body to be raised. Remove Indicator
Arm Plate (2, Figure 3-8) from body.
2. Start engine and operate at low idle. Place hoist
control switch in "Raise" position and allow body
to be raised to maximum hoist cylinder extension.
FIGURE 3-7. ROCK EJECTOR INSTALLATION
1. Rock Ejector Arm 2. Rear Wheel Spacer Ring
B3-4 Dump Body B03007 10/90
3. Measure length of lower hoist cylinder rod shown
as "A", Figure 3-8. Record measurement.
4. Lower body to frame. Subtract 4 in. (10.16 cm.)
from dimension found in Step 3 and record as
dimension "B".
5. Raise body until exposed length of lower hoist
cylinder rod equals dimension "B".
6. Install indicator arm plate (2, Figure 3-9). Loosen
capscrews and nuts (4, Figure 3-10) and adjust
gap between body-up limit switch (2) and indica-
tor arm plate (1) to 0.25 in. (6.35 mm.) Tighten nuts
(4) to standard torque.
7. Loosen capscrews (1, Figure 3-9) on indicator arm
plate (2). Adjust arm to overlap end of switch (5)
by 0.75 0.25 in. (19.05 6.35 mm). Tighten
capscrews to standard torque.
8. Place hoist control switch in "Power Down" posi-
tion and lower body to frame.
FIGURE 3-8. HOIST CYLINDER MEASUREMENT
A. Length of Cylinder Rod @ Complete Extension
B. Complete Extension less 4 in. (10.16 cm).
FIGURE 3-9. BODY-UP LIMIT SWITCH ADJUSTMENT
1. Tapped Pads and Capscrews 4. Mounting Bracket with Mounting Hardware
2. Indicator Arm Plate 5. Body-Up Limit Switch with Mounting Hardware
3. R.H. Frame (Inboard Rear)
B03007 10/90 Dump Body B3-5
9. Place hoist control switch in "Raise" position and
operate engine at approximately 1200 RPM.
Observe body as it raises, when indicator arm (5)
passes by body-up limit switch the hoist valve
should shift and stop flow of hydraulic oil to hoist
cylinders, preventing hoist cylinders from fully
extending.
10. If cylinders continue to go to full extension, adjust-
ment procedures of body-up limit switch must be
repeated until full cylinder extension is prevented.
Maintenance
1. Before each operating shift remove any accumu-
lated debris from indicator arm and body-up
switch (1 and 2, Figure 3-10).
2. Inspect for any damage to indicator arm, body-up,
switch, and electrical connections.
NOTE: If capscrews are found to be loose or replace-
ment of components is necessary, an adjustment of
body-up switch will be required.
3. Inspect body pivot pins, spacers, and bushings for
wear. Refer to "Dump Body Pivot Pins".
FIGURE 3-10. INDICATOR ARM ADJUSTMENT
1. Indicator Arm Plate 3. Mounting Bracket
2. Body-Up Limit Switch 4. Capscrews and Nuts
B3-6 Dump Body B03007 10/90
FUEL TANK
Removal
1. Drain all fuel from tank to reduce the weight to be
handled. Disconnect all fuel and hydraulic hoses
and cap to prevent contamination.
The empty fuel tank weighs approximately 622 lbs.
(282 Kg.). Be sure lifting device is capable of lifting
the load.
2. Loosen the bottom mount capscrew (9, Figure 4-1)
and top U-bolts, nuts and washers (3) and take up
slack of hoist or fork lift. Remove capscrews and
move tank to safe working area.
NOTE:
Hoist valve weights approximately 40 lbs.(18.2 Kg).
3. Remove hoist valve, fuel gauge (5) and vent (2)
from tank, and other fittings as required to carry
out interior cleaning or repair.
FIGURE 4-1. FUEL TANK INSTALLATION
1. Fuel Cap
2. Vent
3. U-Bolts, Nuts and Washers
4. Lifting Eye
5. Fuel Gauge
6. Fuel Tank
7. Drain Petcock
8. Cover
9. Rubber Mount, Capscrew,
and Nut
B04003 3/92 Fuel Tank B4-1
Installation
1. Thoroughly clean the frame mounting brackets.
Inspect the lower rubber mount for wear or dam-
age and replace if necessary.
2. Install hoist valve to fuel tank using three cap-
screws and washers. Tighten capscrews to 65
ft. ils. (88 N.m.) torque.
3. Lift the fuel tank into position being carefull not to
damage the hoist valve. Install the rubber mount,
capscrew and lockwashers (9), but do not tighten.
4. Install the U-bolts, washers and nuts (3). Tighten
nuts to 125 ft.lbs. (170 N.m) torque.
5. Tighten lower mount capscwew to 200 ft.lbs. (271
N.m) torque.
6. Connect hoses removed during removal proce-
dure.
If a tank is to be weld repaired, special precautions
are necessary to prevent fire or explosion. Consult
local authorities if necessary, on safety regulations
before proceeding.
Cleaning
The fuel tank is provided with a drain (7, figure 4-1) and
a cleaning port (8) in the side that allows steam or
solvent to be utilized in cleaning tanks that have accu-
mulated foreign material.
It is not necessary to remove the tank from the truck
for cleaning of sediment, however rust and scale on the
walls and baffles may require complete tank removal.
This allows cleaning solutions to be in contact with all
interior surfaces by rotating the tank in various posi-
tions, etc.
Prior to a cleaning procedure of this type, all vents, fuel
gauges, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material has been removed, the temporary plugs can
be removed.
If a tank has been damaged and requires structural
repair, carry out such repairs before final cleaning. A
small amount of light oil should be sprayed into the tank
to prevent rust if the tank is to remain out of service. All
openings should be sealed for rust prevention.
VENT
The fuel tank is vented through a small mesh type filter
(2, Figure 4-1) installed in a port on the top of the tank.
This filter should be cleaned periodically and can be
blown out with solvent and reused. The area around
the vent must be free of caked mud and debris that
would cover the vent and prevent proper fuel suction
and return.
Refer to Section M for information on various quick
fill systems.
GAUGE
A direct readout type gauge (5, Figure 4-1) is mounted
in an opening in the side of the tank. The gauge is a
magnetic arm type with a float inside the tank.
Removal
1. Drain fuel below level of gauge.
2. Loosen the small screws holding the dial face in
the fuel gauge sender unit and remove.
3. Loosen four socket head screws in sender unit and
remove from tank.
Installation
1. Install new gasket.
2. Reinstall the sender unit in tank. Take care to
insure that float is oriented properly and works
freely in vertical plane during installation.
3. Reinstall four socket head capscrews and tighten
to standard torque.
4. Reinstall dial face in sender. If a remote readout in
the cab is utilized, reconnect wire(s).
5. Refill tank and check for leaks.
B4-2 Fuel Tank B04003 3/92
SECTION C
ENGINE, FUEL, COOLING AND AIR CLEANER
INDEX
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5
AIR FILTRATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
MAIN FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
Main Filter Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
Precleaner Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-4
Cleaning Precleaner Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-4
Air Intake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-1
THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-1
THROTTLE CONTROL PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-1
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-1
THROTTLE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-1
Throttle Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-3
ATEC THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-4
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-5
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-5
FAN BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-5
ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6-6
C01006 8/94 Index C1-1
NOTES
C1-2 Index C01006 8/94
COOLING SYSTEM
RADIATOR
Both sides of the radiator are mounted with rubber
mounts to the radiator support structures. On top of
the radiator is an adjustable rod, rubber mounted to the
cowl, to position radiator core parallel to engine fan.
The bottom radiator tank is also used as the transmis-
sion oil cooler. A separate heat exchanger for the rear
oil-cooled disc brakes is mounted below the radiator
bottom tank.
Radiator Removal
If necessary to remove engine, raise body and install
body-up retaining pin (1, Figure 3-1) to secure body in
full raised position.
1. Disconnect cables from battery terminals. Remove
cable from negative terminal first. Refer to Section
"D", Electrical System "Battery Equalizer".
2. Remove capscrews and retainer (5, Figure 3-2).
Remove grille (6).
3. Disconnect horn wires, remove horn.
Serious personal injury may result if hoses at con-
denser are disconnected prior to properly dis-
charging the air conditioning system. Refer to
Section "M" for proper discharging procedure.
4. If radiator is being removed only for repair of the
radiator, remove condenser mounting bracket
capscrews (4, Figure 3-2). Secure condenser as-
sembly to allow enough room for radiator re-
moval.
5. If radiator is being removed to permit engine
removal, refer to Section "M" for procedures to
discharge the air conditioning system. Discon-
nect hoses at condenser, tightly cap hoses and
fittings to prevent moisture entry, and remove
condenser assembly (3, Figure 3-2).
6. If coolant is to be reused, provide a clean container
to hold approximately 48 gal. (182 l) of coolant.
FIGURE 3-1. BODY-UP PIN INSTALLATION
1. Body Up Retaining Pin 3. Body Pivot Pin
2. Body 4. Main Frame
FIGURE 3-2. RADIATOR REMOVAL
1. Cowl 5. Capscrews
2. Capscrews 6. Grille
3. Condenser 7. Radiator
4. Capscrews
C03011 Cooling System C3-1
Before removing any cooling system components,
release cooling system pressure by turning radia-
tor cap counterclockwise to the first notch. Failure
to release pressure may result in hot coolant being
expelled causing serious injury.
7. Remove radiator cap. To drain radiator, open drain
cock on bottom of large coolant tube to bottom
tank on right side of radiator.
8. Remove adjustment rod nut (2, Figure 3-3) on top
tank.
9. Remove capscrews (1, Figure 3-4) and hood struc-
tures (2).
10. Remove capscrews (2, Figure 3-2) and cowl (1).
11. Disconnect wire from low coolant level probe in top
tank.
12. Disconnect and cap all hoses from top and bottom
tank of radiator.
13. Disconnect and cap hoses from transmission at
bottom tank.
14. Remove fan guard (7, Figure 3-3) from radiator
shroud (6).
Heat exchanger weighs approximately 280 lbs (127
kg). Use adequate lifting device.
15. Remove capscrews attaching lower coolant tube
to support bracket.
16. Support heat exchanger. Remove four capscrews
and lower heat exchanger onto supports and se-
cure safely.
17. Attach lifting device to tapped blocks on radiator
top tank and take up slack.
18. Remove radiator mount capscrews securing radia-
tor to support structures (1, Figure 3-5). Maneuver
radiator away from fan, taking care not to damage
fan or radiator.
19. Set radiator aside for repair, if required.
20. Inspect hoses and clamps, rubber mounts at radia-
tor supports, adjustment rod, and condenser
bracket. Replace as necessary.
FIGURE 3-3. RADIATOR REMOVAL
1. Adjustment Rod 6. Radiator Shroud
2. Adjustment Rod Nut 7. Fan Guard
3. Top Radiator Tank 8. O-Ring
4. Lower Radiator Tank 9. Coolant Flange
(Transmission Cooler) (To Engine Block)
5. Heat Exchanger (Rear
Oil-Cooled Disc Brakes)
FIGURE 3-4. HOOD REMOVAL
1. Capscrews 2. Hood Structure
C3-2 Cooling System C03011
Radiator Installation
1. Place radiator rubber mount (2, Figure 3-5) in each
radiator support structure (1).
2. Raise radiator into position, taking care not to
damage fan or radiator.
3. Install capscrew (3), washer (4) and nut (5).
Tighten to standard torque.
4. Install adjustment rod (1, Figure 3-6) washers,
rubber mount and nuts to cowl.
5. Raise cowl into position, install adjustment rod (1,
Figure 3-6) into bracket on top tank (3).
6. Install cowl mounting capscrews (2, Figure 3-2)
and tighten to standard torque.
7. Adjust rod, if necessary, so radiator core is parallel
to fan. Tighten nuts to standard torque.
8. Install fan guard (7, Figure 3-6). Tighten capscrews
to 25 ft.lbs. (35 N.m) torque.
9. Remove caps and connect all hoses to top and
bottom tanks to engine. Tighten clamps securely
to prevent leaks.
10. Install new O-rings and connect transmission
cooler lines. Tighten split flange capscrews to
standard torque.
11. Install new O-ring (8, Figure 3-6) on radiator mount-
ing surface (use a non-petroleum base lubricant).
Install heat exchanger and capscrews. Tighten to
90 ft.lbs. (122 N.m) torque.
12. Connect coolant line to heat exchanger, tighten
clamps securely to prevent leaks.
13. Install capscrews into lower coolant tube support
bracket. Tighten to standard torque.
14. Connect wire to low coolant probe.
15. Install hood structures and capscrews (Figure 3-4).
16. Position air conditioner condenser (1, Figure 3-7)
and mount bracket to support structures. Install
rubber mounts, capscrews, washers and nuts.
Tighten to standard torque.
17. Connect air conditioner hoses to condenser, if
removed. Refer to Section"M" for evacuation and
charging procedures.
FIGURE 3-7. CONDENSER INSTALLATION
1. Condenser 3.Rubber Mount
2. Mount Bracket
FIGURE 3-6. RADIATOR REMOVAL
1. Adjustment Rod 6. Radiator Shroud
2. Adjustment Rod Nut 7. Fan Guard
3. Top Radiator Tank 8. O-Ring
4. Lower Radiator Tank 9. Coolant Flange
(Transmission Cooler) (To Engine Block)
5. Heat Exchanger (Rear
Oil-Cooled Disc Brakes)
FIGURE 3-5. RADIATOR MOUNTING
1. Radiator Support 4. Washer
2. Rubber Mount 5. Nut
3. Capscrew
C03011 Cooling System C3-3
18. Install horn and connect wires. Install grille.
19. Add approximately 48 gal. (182 l) of coolant. Refer
to Section "P", Lubrication And Service, for anti-
freeze recommendations.
Radiator Repair
Radiator core repairs should be performed by a quali-
fied repair facility. The core, top and bottom tanks, and
gaskets are available as replacement components.
Contact your HAULPAK
distributor.
The bottom tank of the radiator contains the heat
exchanger for the transmission. If a leak occurs in the
heat exchanger, antifreeze/coolant may contaminate
the transmission oil and/or transmission oil may con-
taminate the engine cooling system.
If the engine coolant is found to be contaminated with
oil, the system must be examined for leaks and cor-
rected. Then the system must be flushed to remove oil
contamination, and finally, refilled with a clean coolant
solution.
If a leak has been found or suspected in the heat
exchanger, the transmission oil must be examined
IMMEDIATELY. Ethylene glycol (even in small
amounts) will damage friction-faced clutch plates.
Contact your HAULPAK
distributor.
The heat exchanger for the rear oil-cooled disc brakes
is mounted to the bottom tank of the radiator. If a leak
occurs in the heat exchanger, antifreeze/coolant may
contaminate the hydraulic oil and/or hydraulic oil may
contaminate the engine cooling system, and entire
hydraulic system.
If the engine coolant is found to be contaminated with
oil, the system must be examined for leaks and cor-
rected. The system must then be flushed to remove oil
contamination, and finally, refilled with a clean coolant
solution.
If a leak is found or suspected in the heat exchanger,
the hydraulic oil must be analyzed IMMEDIATELY.
Ethylene glycol (even in small amounts) will damage
friction-faced disc plates used in the rear wet disc brake
assemblies.
If ethylene glycol is found in the hydraulic oil, the
hydraulic system must be drained and flushed to re-
move all contamination, and finally, refilled with clean
hydraulic oil. Both rear wet disc brake assemblies
should be removed, completely disassembled,
cleaned and examined, and ALL friction-faced disc
plates replaced. Contact your HAULPAK
distributor
for ethylene glycol detection test kits.
C03011 Cooling System C3-5
NOTES
C3-6 Cooling System C03011
ENGINE
The 210M HAULPAK
truck is controlled
by the operator through a range selector located in the
cab. Included is a Do Not Shift light and a Check
Transmission light to alert the operator of any potential
problems at startup or during operation of the truck.
Range Selector
The lever-type range selector has eight positions (1, 2,
3, 4, 5, D, N, & R). To change positions, release the
range holding mechanism (below knob) on the lever,
and move lever to the desired range.
1 - Use this gear when pulling through mud and deep
snow, or when maneuvering in tight spaces, when
driving up or down steep grades where maximum
driving power and maximum engine braking is needed.
2, 3, 4, 5 - positions. Road and load conditions some-
times make it desirable to limit the automatic shifting
to a lower range. These positions provide greater en-
gine braking on grades. The transmission will not shift
above the highest gear selected. When conditions
improve, select position "D" for full range operation.
"D" DRIVE - position. The transmission will start in first
gear and as the speed increases, the transmission will
automatically upshift through each gear to sixth gear
operation. As the truck slows down, the transmission
will automatically downshift to the correct gear.
"N" NEUTRAL - used when truck is stopped/parked
with engine operating, and when starting engine.
The truck cannot be started unless the Range Selector
is in NEUTRAL position.
"R" REVERSE - use this position to back up the truck.
Completely stop the vehicle before shifting from For-
ward to Reverse or vice-versa. The Reverse Warning
Horn is activated when Reverse range is selected.
DO NOT SHIFT Light
The Do Not Shift lights come on anytime the on-
board computer finds a potentially serious problem in
the system. The computer will cause the transmission
to lock-in-gear and also to disengage the lockup
clutch. These actions by the computer reduce the
possibility of damage to the vehicle and transmission.
The hold-in-range feature prevents upshifts and down-
shifts when a problem is detected in the operation of
the transmission. The hold-in-gear circuit permits the
transmission to continue to operate in the gear it was
in at the time the Do Not Shift light and buzzer turned
On. Selection of a different gear range will have no
effect on the transmission. The hold-in-gear circuit is
released when the engine is shut-off. If the problem
causing the Do Not Shift light is still present when the
engine is restarted, the transmission will be shifted to
Neutral and will remain in Neutral until the problem
is corrected.
RESET PROCEDURE: When the Do Not Shift light
and/or Check Trans lights come On, the system
can be cleared or reset. To reset, bring the vehicle to
a stop at a safe location and shut down the engine. Wait
about 10 seconds and restart engine. If the problem is
temporary, the Do Not Shift and Check Trans lights
will not come back On and the truck can be operated
in a normal manner.
CHECK TRANS Light
The ATEC system has a built in computer that monitors
various functions and performances. The Check
Trans light will come On when the ignition is turned
On. After the engine is started, the engine oil pressure
switch closes and the light will go Off. This provides
a light bulb check and a system check. When the
computer senses that the system is not performing
properly, the Check Trans light comes On to warn
and alert the operator that a problem has occurred.
Bring the truck to a safe stop, apply the parking brake
when the light comes "ON" place the ATEC test switch
(11, Figure 4-7) in the test position and read the blinking
light error code. Refer to Allison "Off-Highway ATEC
Troubleshooting Manual" for a description of the error
code meanings (refer to Figure 4-8). The vehicle should
be serviced as soon as possible.
FIGURE 4-1. RANGE SELECTOR
D04003 8/95 Allison Transmission Electronic Control (ATEC) D4-1
In cold weather, when the temperature of the transmis-
sion oil is below -10F (-23C), the Do Not Shift light
on the Range Selector and the Check Trans light will
stay On after the engine is started. The transmission
will stay in Neutral, regardless of which range is
selected until the oil is warmer than -10F (-23C). When
the transmission oil warms up, the Check Trans and
Do Not Shift lights will turn Off and the transmission
will operate in first gear or reverse only. At 20F (- 7C),
the transmission may be operated safely in all ranges.
If the transmission oil temperature reaches 250F
(121C), the Check Trans indicator light will come
On. The ECU (Electronic Control Unit) will inhibit
operation of the truck above 4th range.
NOTE: The Transmission Temperature Gauge on the
instrument panel indicates the temperature of oil com-
ing out of the converter. The ECU senses oil tempera-
ture in the sump.
SYSTEM DESCRIPTION
The HAULPAK
truck circuits.
Therefore, a Battery Equalizer (Figure 4-5) is provided
to maintain equal charge on both truck batteries. The
external 24VDC. functions of the truck related to the
transmission system are controlled by relays which are
controlled by the ECU or range selector. The ECU also
monitors the system for abnormal fault conditions.
When such a fault condition is detected, the ECU
automatically responds in a manner which is safe for
the operator, the truck, and the transmission. It also
records an appropriate malfunction code in its mem-
ory. When the abnormal condition occurs, the Check
Transmission light is turned on. Additionally, with
some conditions, the Do Not Shift light and a buzzer
is activated in the Range Selector alerting the operator
to the potential problem.
Before welding on truck, be sure alternator and
battery equalizer are completely disconnected.
Remove equalizer ground first, then disconnect 12
and 24 volt positive terminals. When connecting
back in system, connect 24 and 12 volt positive
terminals first, ground terminal last.
When disconnecting the truck batteries, the follow-
ing procedure MUST be followed in the sequence
shown to prevent damage to the ATEC system
components:
1. Turn ATEC power switch OFF.
2. Remove the battery 12V positive (+ ) terminal.
DO NOT LET TERMINAL TOUCH CHASSIS
GROUND!
3. Remove the battery 24V positive (+ ) terminal.
4. Remove the battery 24V negative (-) terminal.
5. Disconnect harness connectors at the ECU after
disconnecting battery power.
6. Cover ATEC components and wiring to protect
from hot sparks, etc. Do not connect welding
cables to ATEC components. Do not weld on
ATEC components. Remove ATEC components
if welding within 10 in. (25 cm) of component.
7. When reconnecting components, reverse the or-
der of steps 1 through 6. Check wiring and cables
for proper routing and termination.
TRANSMISSION CONTROL CIRCUITS
The following circuits can be affected by a problem in
either the HAULPAK
or ATEC circuit.
For example; the engine will not crank. If the problem
is in the ATEC circuit, the Off-Highway ATEC Trou-
bleshooting Manual should be used to determine
component causing problem.
Battery Charging Circuit
Two 12 volt batteries connected in series, supply 24
volts to the system. The batteries are recharged from
an engine driven alternator with built-in voltage regula-
tor. The voltmeter indicates the output voltage of the
battery charging alternator. Normal indicated voltage
at high idle is 27 -- 28 volts. When the key switch is On
and engine is not running, the voltmeter indicates
battery voltage.
One 12 volt battery supplies the transmission control
circuit. To prevent unequal charge and discharge of the
batteries, a battery equalizer is provided in the charge
circuit. The battery equalizer balances charge and
discharge of both batteries. Refer to Electrical Sche-
matic in Section R.
The equalizer is equipped with a circuit breaker for
internal protection. If the breaker is activated, it must
be reset to prevent one battery running down. The fault
causing the breaker to activate must be corrected also.
FIGURE 4-5. BATTERY EQUALIZER
D04003 8/95 Allison Transmission Electronic Control (ATEC) D4-3
FIGURE 4-6. ATEC SYSTEM DIAGRAM
D4-4 Allison Transmission Electronic Control (ATEC) D04003 8/95
Control Power and Memory Circuits
One battery supplies the switch side of two normally
open (N/O) relays with 12 volts. This signal is also
continuously supplied to the ATEC Electronic Control
Unit (ECU) for memory power. When keyswitch is in
Start or Run position, the coil side of the Switch
Power Relay is supplied with 24 volts. The relay closes
supplying 12 volts to the ECU and range selector.
When engine is started, engine oil pressure closes a
normally open (N/O) pressure switch supplying 24
volts to the oil Pressure Switch Relay (PSR) coil. The
relay closes supplying the ECU with 12 volts. This
control circuit configuration maintains power to ATEC
if the keyswitch should be turned Off during truck
operation.
Start Circuit
When the keyswitch is moved to Start position, a
Neutral Relay coil will be energized through a 5 amp
circuit breaker. The ground will be completed for the
relay coil when the transmission shift selector is in the
Neutral position. When neutral relay (NSR) closes,
the coil of the start solenoid is energized, providing
power to the starter for cranking the engine.
Check Transmission Warning Light Circuit
When the keyswitch is in Run position, the Check
Transmission light will be grounded through normally
closed (N/C) switch side of Check Transmission relay
(CTR). When the engine is started or running, engine
oil pressure closes the normally open (N/O) oil pres-
sure switch supplying 24 volts to the coil side of the
Check Transmission Relay (CTR). When the coil is
grounded through the ECU, the relay opens turning
Off the Check Transmission light. If during opera-
tion the ECU detects a fault condition, the relay coil
ground will open, turning On the Check Transmis-
sion light.
When the Check Transmission light comes On,
activating the normally open (N/O) test switch will
cause the Check Transmission light to flash a fault
condition code. Refer to Allison Off-Highway ATEC
Troubleshooting Manual for a description of the code
meaning.
Backup Horn and Light Circuit
The backup horn and lights are supplied with 24 volts
by a normally open (N/O) relay. The coil side of Re-
verse relay (RWR) is supplied with 24 volts from the
keyswitch. The ground for the coil is provided by the
ECU. When the range selector is moved to Reverse
position, ECU completes the ground of Reverse Relay
(RWR) coil, relay closes supplying backup horn and
lights with 24 volts.
Hoist Interlock Circuit
This circuit prevents the truck from moving backwards
if shift selector is in Reverse position and body hoist
circuit is actuated. A circuit is completed through a
normally closed (N/C) hoist pressure switch for Re-
verse range to be applied. The hoist interlock pressure
switch is opened when the hoist control lever is in the
Power Up position. If the range selector is in Re-
verse, the transmission will be shifted to Neutral by
the ECU. If selector is in Neutral and is moved to
Reverse, shift will not occur. When the hoist control
lever is released and the range selector was in Re-
verse, the range selector must be moved to Neutral
and back to Reverse for shift to occur. All forward
shifts will occur even if the hoist switch is actuated.
Auto/Manual Circuit
In normal operation, shifts are made automatically, but
situations occur that require manual shifts be made,
such as making engine stall speed check. A toggle
switch is available in the ATEC system to allow manual
shifts to occur for maintenance reasons. For normal
operation, the toggle switch is left open to provide
automatic shifts. With toggle switch in closed or Man-
ual position, transmission will shift to range selected
by lever.
Overspeed Relay Circuit (Not Used)
The coil side of the overspeed relay is supplied with 24
volts and grounded by ECU. The normally open (N/O)
switch side of the overspeed relay (OR) is supplied with
24 volts, but the output is not connected. This relay is
not used in the current HAULPAK
truck.
Speedometer Circuit
The speedometer is supplied with 24 volts from the
keyswitch and is grounded to the system. A signal
originating at the magnetic pickup is supplied to the
ECU. The ECU provides a signal to the gauge which
provides a MPH or KPH reading on the speedometer.
D04003 8/95 Allison Transmission Electronic Control (ATEC) D4-5
TRANSMISSION CIRCUIT
COMPONENTS
Keyswitch - is mounted in instrument panel and com-
pletes the Start Circuit when moved to Start posi-
tion and the transmission range selector is in the N,
Neutral position.
1. Auxilary Seat Support (refer to Figure 4-7) - The
auxiliary seat is located behind the operator seat
and contains the following components:
2. Electronic Control Unit (ECU) - processes input
signals from the various components to control
the operation of the transmission.
3. Battery Equalizer Monitor - Monitors the battery
equalizer for correct charge and discharge of the
batteries.
4. Scanner Receptacle - Provides connection for a
Display Data Line scanner (DDL) for use in trou-
bleshooting the ATEC system.
5. Start Solenoid - The start solenoid is normally
open (N/O) with 24 volts to coil and 24 volts to
switch side.
6. Auto/Manual Test Switch - Located in relay box
for diagnostic test work and engine stall tests;
requires knowledge of transmission electrical wir-
ing.
Circuit Breakers (7 - 10) - four manual reset circuit
breakers are provided for the protection of the
various ATEC relay switches:
7. Circuit Breaker No. 4 (CB-4)- 5 amp - Keyswitch
supplies 24 volts through wire 25f to Battery
Equalizer Monitor and normally (N/O) switch side
of overspeed relay.
8. Circuit Breaker No. 3 (CB-3) - 5 amp - Keyswitch
supplies 24 volts to coil side of neutral, reverse,
and overspeed relays. Also wire 235/pin2A.
9. Circuit Breaker No. 2 (CB-2) - 5 amp - With
engine running, alternator supplies 24 volts to
engine oil pressure switch, coil side of oil pressure
indicator relay, pressure switch relay, and CHECK
TRANS relay; also to wire 215/pin 3h.
10. Circuit Breaker No. 1 (CB-1) - 10 amp - Supplied
12 volts from 12 volt side of Battery Equalizer to
normally open (N/O) switch side of Pressure
Switch and Switch Power Relays also wire 203/pin
3A.
11. ATEC Test Switch - The test switch is a toggle
switch located on the relay box. It is used in locat-
ing and clearing diagnostic codes in the ATEC
system.
12. Check Transmission Relay (CTR) - normally
closed (N/C), with 24 volts to coil side, and 24 volts
to switch side; provides a ground for CHECK
TRANS light.
13. Pressure Switch Relay (PSR) - normally open
(N/O), with 24 volts to coil side, and 12 volts to
switch side.
14. Switch Power Relay (SPR) - normally open (N/O),
with 24 volts to coil side, and 12 volts to switch
side.
15. Neutral Relay (NSR) - normally open (N/O), with
24 volts to coil side, and 24 volts to switch side.
Refer to Backup Horn and Light Circuit.
16. Reverse Relay (RWR) - normally open (N/O), with
24 volts to coil side, and 24 volts to switch side.
17. Overspeed Relay (OR) - not used
18. Hoist Relay - normally closed (N/C), with 24 volts
to coil side, and 12 volts to switch side.
19. Relay Box contains ATEC components indicated.
FIGURE 4-7. CAB MOUNTED RELAY BOX
D4-6 Allison Transmission Electronic Control (ATEC) D04003 8/95
CIRCUIT DESCRIPTION AND CHECKOUT
The following procedure is designed to aid in the un-
derstanding of the ATEC electrical schematic. The
procedure also contains circuit checkouts which aid in
isolating problems between the HAULPAK
truck cir-
cuit and the ATEC circuit. Refer to Electrical Schematic,
Section R, when performing circuit voltage and con-
tinuity checks.
Improper use of the Maintenance/Test Terminals
can cause damage to the drive train. Specific
knowledge of the complete ATEC system is re-
quired for these diagnostic checks.
1. Electric power (12 volts) is supplied to the ATEC
system wires (202A) & (233A) through two relays:
one controlled by the key switch and one control-
led by engine oil pressure. If the engine will not
crank:
a. Place transmission range selector in Neutral
position.
b. Battery disconnect (if equipped) must be
closed.
c. Move key switch to "Start" position. With a VOM,
make following voltage checks:
1). 24 volts at the starter solenoid; wire (25R).
2). 24 volts at the neutral start relay; wire (25R).
3). 24 volts at the neutral start relay; wire (21).
4). If voltage readings are not acceptable, cor-
rect the cause before proceeding.
d. Remove wire (25R) from start solenoid.
1). Connect a VOM from terminal (25R) of start
solenoid to ground.
2). Move keyswitch to Start position.
3). If VOM indicates 24 volts, the HAULPAK
and
ATEC circuit are correct. Begin voltage
checks with the electric starter, check wiring
from start solenoid to starter wire (25A). Re-
fer to manufacturers Service Manual for
electric starter checkout.
4). If VOM does not indicate 24 volts at (25R) of
start solenoid, proceed to the following
steps:
e. Connect a VOM at terminal 25C of terminal strip
in relay box. Move key switch to Start posi-
tion.
1). If a reading of 12 volts at 25C is not found,
correct HAULPAK
circuit problem.
2). If a reading of 12 volts at 25C is present,
proceed to following steps:
f. Connect a jumper from terminal 25, to the
ground terminal on relay box.
1). Move keyswitch to Start position, if VOM
does not read 24 volts at 25A of start sole-
noid, correct HAULPAK
circuit problem.
2). If a reading of 24 volt at wire (25A) of start
solenoid is obtained, check ATEC circuit.
Refer to ATEC Off-Highway Troubleshoot-
ing Manual.
g. Reconnect wire (25R) to start solenoid.
2. 12 V.D.C. is also supplied directly to the ECU wire
(203) to provide for the continuous memory of any
malfunction codes and TPS calibration values.
Maximum current draw is 10 Ma and will not
appreciably drain the batteries.
3. A battery ground is provided to the ECU wires
(208), (209) and the Range Selector wire (234).
Power for the illumination of Range Selector lights
is supplied to wire (230) through the instrument
panel dimmer rheostat.
4. When the ECU detects an abnormal condition, it
turns On the Check Transmission light and
records the malfunction code. If the malfunction
is serious, the ECU turns On the Do Not Shift
lights and prevents further shifting of the transmis-
sion. The transmission remains in the gear it was
in at the time of the malfunction.
Turning On the ATEC Diagnostic Switch grounds
wire (216) causing the ECU to turn the Check
Transmission light On and Off indicating a
malfunction code stored in the memory of the ECU
identifying the location of the malfunction.
a. To clear the ECU memory of codes after the
fault condition has been corrected:
1). Shut down the engine.
2). Turn keyswitch Off then On.
3). Turn the Test Transmission Switch On.
4). Move Range Selector to Reverse and hold
for several seconds.
5). Move Range Selector to Neutral.
b. To check for proper operation of the Check
Transmission Test Switch:
D04003 8/95 Allison Transmission Electronic Control (ATEC) D4-7
1). Turn keyswitch to Run position. Move test
switch to Test position; switch should be
closed.
2). Check transmission light will flash On and
Off.
3). If light does not flash, make sure switch is
closed when in the Test position If switch
is not closed, correct problem.
4). If switch does close in Test position and
light does not flash, refer to ATEC Off-High-
way Troubleshooting Manual.
5. The Check Transmission light is controlled by a
relay wire (215) that will energize only when the
engine is running, the oil pressure switch is
closed, and the ECU detects a malfunction in the
ATEC system.
a. If Check Transmission light does not turn
On:
1). Check bulb.
2). Check that switch side of Check Transmis-
sion Relay is closed.
b. Light does not go out after engine starts:
1). Check for 24 volts at terminal 25B on terminal
strip in relay box.
2). If 24 volts are not present,
correct HAULPAK
circuit.
3). If 24 volts are present and light does not go
out, connect a jumper from 25B to ground.
4). If light does not go out, correct HAULPAK
circuit problem.
5). If light goes out, refer to ATEC Off-Highway
Troubleshooting Manual.
6. The neutral start circuit is controlled by a relay wire
(231) that is energized only when the Range Se-
lector is positioned in Neutral. A Park Brake
Pressure Switch is also connected to this Neu-
tral circuit, preventing the transmission from be-
ing shifted into Forward or Reverse range as
long as the Park Brake is applied.
7. Wire (222) is connected to wire (309). This circuit
is used in conjunction with the parking brake.
When the circuit is opened, the transmission will
not shift into Forward or Reverse.
The backup lights and horn are controlled by a
relay wire (214) which is grounded by the ECU
when the transmission is in Reverse.
a. If the backup horn and lights do not turn On
when shift selector is in Reverse:
1). Shut down engine, turn keyswitch to Run
position.
2). Connect a jumper from terminal 25E on the
terminal strip in relay box to a ground.
3). If horn and lights do not operate, correct
HAULPAK
circuit problem.
4). If horn and lights operate, refer to ATEC
Off-Highway Troubleshooting Manual.
b. Backup horn and lights will not turn Off when
shift selector is moved to Neutral or For-
ward range.
1). If horn and light are On, with keyswitch"Off",
correct HAULPAK
circuit problem.
2). If horn and lights are On, with keyswitch
On, disconnect and isolate wires from ter-
minal 25E of the relay box terminal strip.
If horn and lights turn Off, refer to ATEC
Off-Highway Troubleshooting Manual.
8. An optional function is available that can be acti-
vated if the ECU senses an overspeed of the drive
train. This function is controlled by a relay wire
(213).
9.The ECU utilizes the output speed sensor to pro-
vide a signal to the speedometer wire (205) indi-
cating the speed of the truck.
a. If the speedometer is not functioning:
1). With engine shutdown, place keyswitch in the
Run position.
2). Check for a 24 volt reading at "B" terminal on
the back side of speedometer. If no reading
is indicated, refer to Section R", Electrical
Schematic, when performing circuit voltage
and continuity checks.
3). If 24 volts is present, refer to ATEC Off-High-
way Troubleshooting Manual for output
speed sensor adjustment.
NOTE: Initial adjustment for output speed
sensor is:screw sensor all the way in to just
touch the center of a gear tooth and then turn
out (counterclockwise) 3/4 turn.
10. Hoist Interlock wire (309) is a logic return circuit for
the ECU. The hoist relay controlled by the hoist
control lever opens wire (305) to wire (309) when
the body is being raised, which immediately tells
the ECU to shift the transmission to Neutral if it
is in Reverse. While the hoist lever is in the Body
Up position, Reverse cannot be obtained. Re-
verse can be obtained only by having the Range
Selector in Neutral after the hoist lever is re-
leased from the Body Up position.
D4-8 Allison Transmission Electronic Control (ATEC) D04003 8/95
The purpose of this feature is to prevent accidental
rearward movement of the truck when the operator
begins to raise the body. There is no body interlock
function to inhibit Forward operation.
a. If the truck moves in reverse when the hoist
control lever is held in Power Up position:
1). Shut down engine and turn key switch Off.
2). Remove ATEC plug J3 from ECU.
3). Connect an ohmmeter between pin J and E
of the J3 harness.
4). Ohmmeter should indicate continuity
through relay of hoist interlock circuit.
5). Turn keyswitch On, move hoist control
lever to Power Up position. Ohmmeter
should indicate infinity.
6). If ohmmeter does not indicate hoist relay
opening when hoist control lever is moved to
Power Up position, repair wiring to relay or
replace relay.
7). If ohmmeter indicates hoist relay opens when
hoist switch is moved to Power Up posi-
tion, refer to ATEC Off-Highway Trou-
bleshooting Manual.
8). Install J3 plug into ECU.
b. Transmission will not shift to Reverse range
when range selector is moved to Reverse
position.
1). Turn keyswitch Off.
2). Remove J3 plug from ECU.
3). Check for continuity between pins J and E of
J3 harness plug with an ohmmeter.
4). If ohmmeter reads infinity, correct circuit
problem in HAULPAK
wiring.
5). If ohmmeter indicates continuity, refer to
ATEC Off-Highway Troubleshooting Man-
ual.
11. The Battery Equalizer is connected from the batter-
ies to the ATEC battery disconnct (on left side of
engine) and to the 24 volt terminal on the Battery
Equalizer by wire (2T). The 12V terminal is con-
nected to the ECU by going through CB-1 using
wire (1T). Wire (1T) is also connected to one of the
two batteries through the ATEC battery discon-
nect.
Before welding on truck, be sure alternator and
battery equalizer are completely disconnected.
Remove equalizer ground first, then disconnect 12
and 24 volt positive terminals. When connecting
back in system, connect 24 and 12 volt positive
terminals first, ground terminal last.
12. If the battery equalizer is not functioning properly:
a. Check circuit breaker; if the button is out, reset
by depressing button.
b. Check each battery for a 12 volt full charge
condition.
NOTE: Replace batteries in PAIRS only - otherwise
Equalizer and ATEC problems are sure to exist!
c. Check voltage between 12 volt and 24 volt
terminals with a voltmeter and record the read-
ing.
d. Check voltage between 12 volt terminal and
ground terminal and record the reading.
e. If difference between the two voltage readings
is more than 0.75 volts, replace equalizer. Refer
to Electrical Schematic, Section R.
NOTE: Transmission shift problems, as well as reduced
Battery Equalizer life may be experienced if external 12
volt devices are connected to the 12 volt power supply
for the ATEC system. If such devices are to be used, it
is highly recommended the power supply is taken from
the 24 volt system and converted to isolate the ATEC
supply as much as possible.
D04003 8/95 Allison Transmission Electronic Control (ATEC) D4-9
OFF - HIGHWAY HAULING
TRANSMISSIONS
ATEC DIAGNOSTIC CODES
13 - LOW BATTERY VOLTAGE
21 - THROTTLE SENSOR
22 - SPEED SENSOR
23 - PRIMARY RANGE SELECTOR
24 - OIL TEMPERATURE
33 - OIL TEMPERATURE SENSOR
34 - PROM CHECK
41 - A SOLENOID / CIRCUITRY
42 - B SOLENOID / CIRCUITRY
43 - C SOLENOID / CIRCUITRY
44 - D SOLENOID / CIRCUITRY
45 - E SOLENOID / CIRCUITRY
51 - K (LOCKUP) SOLENOID / CIRCUITRY
54 - SOLENOID CHAIN (A-E)
61 - G (SPLITER OVERDRIVE) SOLENOID / CIRCUITRY
62 - F (SPLITTER DIRECT) SOLENOID / CIRCUITRY
63 - G (SPLITTER OVERDRIVE) SOLENOID / CIRCUITRY
69 - ELECRONIC CONTROL UNIT ERROR
Range Solenoids
Energized
Clutches
Engaged
1 C, F Splitter-Direct, Low
2 C, G Splitter-Overdrive, Low
3 D, F Splitter-Direct,
Intermediate
4 D, G Splitter-Overdrive,
Intermediate
5 E, F Splitter-Direct, High
6 E, G Splitter-Overdrive, High
N A, F Splitter-Direct
R A, B, F Splitter-Direct,
Reverse
FIGURE 4-8. ATEC DIAGNOSIC CODES
D4-10 Allison Transmission Electronic Control (ATEC) D04003 8/95
SECTION F
TRANSMISSION AND PTO
INDEX
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Transmission Fill Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
TRANSMISSION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
TRANSMISSION OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
POWER TAKE OFF (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
PTO GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
DRIVELINES & U-JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-2
F01003 5/92 Index F1-1
NOTES
F1-2 Index F01003 5/92
TRANSMISSION
The HAULKPAK
distributor.
The bottom tank of the radiator contains the heat
exchanger for the transmission. If a leak occurs in the
heat exchanger, antifreeze/coolant may contaminate
the transmission oil and/or transmission oil may con-
taminate the engine cooling system.
If the engine coolant is found to be contaminated with
oil, the system must be examined for leaks and cor-
rected. Then the system must be flushed to remove oil
contamination and refilled with a clean coolant solu-
tion.
If a leak has been found or suspected in the heat
exchanger, the transmission oil must be examined
IMMEDIATELY. Ethylene glycol (even in small
amounts) will damage friction-faced clutch plates.
Contact your HAULPAK
Trucks
should also be limited to a 1% variation in diameter of
the inflated, unloaded tires.
G02007 3/92 Tires and Rims G2-5
NOTES
G2-6 Tires and Rims G02007 3/92
FRONT WHEEL HUB AND SPINDLES
FRONT WHEEL HUB
Removal
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleed down accumulators:
BLOCK WHEELS OF TRUCK!
Turn key switch "Off", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Brake accumulator bleeder valves are lo-
cated on the Low Pressure Detection Mod-
ule beneath the accumulators on the right
side of the truck.
Bleed down brake accumulators by turn-
ing Bleeder Valve handles counterclock-
wise to open. When accumulators are
completely bled down, close bleeder
valves by turning Bleeder Valve handles
clockwise. Do not leave open.
1. Refer to Front Tire and Rim Removal, this Section,
and remove front tire and rim assembly.
2. Rotate wheel hub (4, Figure 3-1) so drain plug (9)
is down. Drain oil into a suitable container. Hub
holds approximately 1 gal. (3.8 l).
3. Disconnect and cap brake lines at brake calipers
(10).
Each Brake Caliper weighs approximately 140 lbs.
(63.4 kg).
The Wheel Hub Assembly weighs approximately
900 lbs. (408 kg).
Use adequate lifting devices when lifting these
components.
4. Support one brake caliper and remove caliper
mount capscrews (11). Remove caliper. Repeat
for other caliper.
5. Support wheel hub with an adequate lifting device.
6. Remove wheel hub cap (7), roll pin (6) and wheel
nut (8).
7. Slide outboard bearing cone (5) from spindle.
8. Remove wheel hub (4) from spindle.
9. Remove seal runner (1) if necessary.
10. Remove brake disc capscrews (2) and brake disc
(3) if necessary. Refer to Front Disc Brakes, Sec-
tion "J" for brake disc wear limits.
FIGURE 3-1. FRONT WHEEL REMOVAL
1. Seal Runner 6. Roll Pin
2. Capscrew 7. Wheel Hub Cap
3. Brake disc 8. Wheel Nut
4. Wheel hub 9. Drain Plug
5. Bearing Cone, 10. Brake Calipers
Outboard 11. Capscrews
NOTE: For illustration clarity, the brake caliper is shown
in a top mounted position. The 210M has two brake
calipers per front wheel, mounted in a fore-aft position.
The 140M has one brake caliper per front wheel,
mounted in the aft position.
G03009 8/91 Front Wheel Hub and Spindles G3-1
Front Wheel Hub Bearing
And Brake Disc Replacement
1. Remove seal (4, Figure 3-2), seal spacer (5), inner
bearing cone (3) and bearing cups (2 and 1).
2. Clean all metal parts in cleaning solvent.
3. Inspect all seals and bearings and replace as
required.
4. Check seal ring mounting area on wheel hub,
brake adaptor, and spindle for damage that could
cause leakage.
5. Inspect spindle in area of bearing surfaces and
radius (under seal runner) for distress or cracks.
Non-destructive methods of crack detection (dye
penetrant or magnaflux) should be used.
6. Nominal Clearance Dimensions:
Wheel hub bearing cup O.D.
to wheel hub bore I.D.
+ 0.002 in. to + 0.0050 in.
(+ 0.05 mm to + 0.127 mm)
Outboard bearing cone I.D. to spindle O.D.
0.000 in. to + 0.0015 in. (0.0 to + 0.038 mm)
Inboard bearing cone I.D. to spindle O.D.
0.000 in. to + 0.0002 in. (0.0 to + 0.050 mm)
Spindle O.D. to seal runner I.D.
0.000 in. to + 0.0040 in. (0.0 to + 0.101 mm)
7. Install bearing cups in wheel hub. Be sure bearing
cups are tight against shoulder.
8. Install brake disc (7, Figure 3-2) and disc mounting
capscrews (6). Tighten to standard torque.
Front Wheel Hub Installation
And Bearing Adjustment
1. Place inner bearing cone in cup (2, Figure 3-2),
install seal spacer (5) and seal (4).
2. Install seal runner (1, Figure 3-3) if removed. Be
sure seal runner is tight against shoulder.
3. Install wheel hub (4) on spindle. Maintain support
on wheel hub until next step is completed.
4. Install outer bearing cone (6) and retaining nut (9).
FIGURE 3-2. FRONT WHEEL HUB
1. Bearing Cups 5. Seal Spacer
2. Bearing Cups 6. Capscrews
3. Inner Bearing Cone 7. Brake disc
4. Seal
FIGURE 3-3. FRONT SPINDLE AND HUB ASSEMBLY
1. Seal Runner 8. Cap
2. Capscrew 9. Retaining Nut
3. Brake disc 10. Gasket
4. Wheel Hub 11. Brake Calipers
5. Capscrews 12. Capscrews
6. Outer Bearing Cone 13. Brake Lines
7. Roll Pin
G3-2 Front Wheel Hub and Spindles G03009 8/91
5. Tighten wheel hub retaining nut (9) until all bearing
rollers rotate, while rotating wheel hub, then
tighten to next notch and install roll pin (7).
6. Install gasket (10, Figure 3-3), cap (8) and cap-
screws. Tighten capscrews to standard torque.
7. Install brake calipers (11) and capscrews (2).
Tighten capscrews to 1050 ft. lbs. (1423 N.m)
torque.
8. Connect brake lines (13) to calipers.
9. Rotate wheel hub until one fill/drain plug (1, Figure
3-4) is horizontal and one plug is up. Fill with
proper lube. Refer to Lubrication and Service,
Section "P" for lube specifications.
Bleed brakes before placing truck in production. If
new linings and discs were installed, burnish
brakes. Refer to Brake Bleeding and Burnishing,
Section "J ".
Front Wheel Spindle Removal
1. Park truck on level surface. Apply park brake and
securely block rear wheels. Shut down engine.
2. Refer to Front Tire and Rim Removal and remove
these components.
3. The spindle and wheel hub may be removed from
the suspension tube as an assembly. If the wheel
hub assembly or brake disc does not require
service, go to "WARNING" ahead of step 5.
4. Refer to "Front Wheel Hub Removal" and remove
these components if the wheel hub assembly or
brake disc requires service; then go to step 6.
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleed down accumulators:
Turn key switch "Off", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Bleeder Valve handles counterclock-
wise to open. When accumulators are
completely bled down, close bleeder
valves by turning Bleeder Valve handles
clockwise. Do not leave open.
5. Disconnect and cap brake lines.
6. Support tie rod (2, Figure 3-5), steering cylinder
(4) and spindle arm (13) near spindle (11).
7. Remove six capscrews (12).
NOTE: If all or part of the steering linkage requires
service, Refer to "Steering Linkage Ball Stud Removal",
this section.
8. Remove splined nut (1, Figure 3-6) from suspen-
sion tube (2). Refer to Section "M" for Spline Nut
Wrench.
9. Sharply strike the spindle to loosen spindle from
suspension tube. If spindle wont come off, apply
heat in a narrow band, vertically on spindle.
10. Carefully remove spindle assembly.
FIGURE 3-4. WHEEL HUB/DRAIN HOLES
1. Fill/drain Plug 2. Wheel Hub
G03009 8/91 Front Wheel Hub and Spindles G3-3
Front Wheel Spindle Installation
1. Be certain taper of spindle bore and suspension
tube are clean and dry and free of any surface
imperfections or roughness.
2. Raise spindle assembly onto taper of suspension
tube. Install splined nut (1, Figure 3-5).
3. Tighten splined nut to 1100 100 ft. lbs. (1491
135 N.m) torque.
4. Install spindle arm (13, Figure 3-6) on spindle
assembly (11) with six capscrews (12). Tighten
capscrews to 750 ft.lbs. (1017 N.m) torque.
5. Remove supports from tie rod (2), steering cylin-
der (4) and spindle arm (13).
6. Refer to "Front Wheel Hub Installation" and install
these components, if removed.
7. Connect brake lines to calipers.
8. Rotate wheel hub until one drain/fill plug is hori-
zontal and one plug is up. Fill with proper lube.
Refer to Lubrication and Service, Section "P".
9. Install front tire. Refer to "Front Tire Installation".
10. Remove blocks or support stand.
11. Repeat Step 3.
12. Measure toe-in. Toe-in should be 0.0 to 0.625 in.
(0.0 to 15.8 mm). Refer to Toe-In Adjustment
procedure if necessary.
FIGURE 3-5. WHEEL SPINDLE
AND SUSPENSION TUBE
1. Splined Nut 3. Spindle Assembly
2. Suspension Tube
FIGURE 3-6. TIE ROD REMOVAL
1. Cotter Pin 7. Cover
2. Tie Rod 8. Grommet
3. Ball Studs 9. Race
4. Steering Cylinder 10. Boot
5. Nut 11.Spindle
6. Capscrews 12. Capscrews
13.Spindle Arm
Bleed brakes before placing truck in production. If
new linings and discs were installed, burnish
brakes. Refer to Section "J " for Brake Bleeding and
Burnishing.
G3-4 Front Wheel Hub and Spindles G03009 8/91
13. Drive truck empty. Repeat Step 3.
14. Drive truck loaded. Repeat Step 3 until torque is
maintained.
Steering Linkage Removal
1. Park truck on level surface, securely block rear
wheels.
Before removing any steering lines or steering
circuit components be sure steering accumulator
is bled down. To bleed down accumulator:
Turn key switch "Off" to shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no movement
should occur.
NOTE: It may not be necessary to remove both ends
of tie rod or steering cylinder to make ball stud and
bearing repair. If steering cylinder is removed, cap and
plug hose ends and cylinder ports to prevent dirt from
entering hydraulic system. When ball studs are in-
stalled in tapered bores, be sure that nuts are properly
torqued to prevent movement of ball stud.
2. Support tie rod (2, Figure 3-6) or steering cylinder
(4).
3. Remove cotter pin (1), loosen nut (5) on ball stud.
4. Drive wedge between mount and tie rod end or
steering cylinder end to loosen tapered stud.
5. Remove nut, pull out ball stud.
Steering Cylinder Ball Stud/Bearing Removal
1. Remove capscrews (6, Figure 3-6) cover (7) and
grommet (8).
2. Remove ball stud (3) and race (9) from the cylinder
end.
Steering Cylinder Ball Stud/Bearing Installation
1. Place two halves of ball stud bearing race (9,
Figure 3-6) on ball. Install snap ring.
2. Install bearing race into end of cylinder.
3. Lubricate ball and race.
4. Install grommet (8) cover (7) and capscrews (6).
Tighten to standard torque.
5. Install tapered end of ball stud into mount. Tighten
nut (5) to 800 50 ft. lbs. (1084 67 N.m)
torque.
Tie Rod Ball Stud/Bearing Removal
1. Remove snap ring (11, Figure 3-7) and retainer
(10).
2. Push ball stud (1) and race (8) through rod end.
Tie Rod Ball Stud/Bearing Installation
1. Place two halves of ball stud bearing race (8,
Figure 3-7) on ball. Install snap ring.
2. Install ball stud and bearing race into tie rod end.
3. Lubricate ball and race. Install dirt seal (9).
4. Install tapered end of ball stud into mount. Tighten
nut (12) to 800 50 ft. lbs. (1084 67 N.m)
torque.
FIGURE 3-7. TIE ROD ASSEMBLY
1. Ball Stud 4. Capscrew 7. Link 10. Retainer
2. Socket, R.H. Thread 5. Locknut 8. Bearing Race, Split 11. Snap Ring
3. Socket, L.H. Thread 6. Clamp 9. Dirt Seal 12. Nut
13. Cotter Pin
G03009 8/91 Front Wheel Hub and Spindles G3-5
Front Wheel Toe-in Adjustment
(Bias Ply Tires)
1. Park empty truck on a level surface. Check toe-in
by measuring the distance between front wheels
(centerline to centerline). These measurements
should be taken on a horizontal center line at front
and rear of tire (Figure 3-8).
2. The front measurement, Dimension "A", should be
0.0 to 0.625 in. (0.0 to 15.8 mm) less than rear
measurement, Dimension "B".
3. If adjustment is necessary, loosen clamp bolt nuts
(1, Figure 3-9) on both ends of tie rod eyes.
4. Rotate tie rod (2) until 0.0 to 0.625 in. (0.0 to 15.8
mm) of toe-in is obtained (Figure 3-8).
5. Tighten clamp bolt nuts (1) to standard torque.
NOTE: Be certain clamp and hardware is positioned
"up" as shown in Figure 3-9. This is necessary to avoid
linkage interference during steering.
6. Remove blocks from rear wheels.
(Radial Tires)
NOTE: Set toe-in to zero with the truck fully loaded.
1. Park fully loaded truck on a level surface. Check
toe-in by measuring the distance between front
wheels (centerline to centerline). These measure-
ments should be taken on a horizontal center line
at front and rear of tire (Figure 3-8).
2. The front measurement, Dimension "A", should be
equal to rear measurement, Dimension "B".
3. If adjustment is necessary, loosen clamp bolt nuts
(1, Figure 3-9) on both ends of tie rod eyes.
4. Rotate tie rod (2) until zero toe-in (Dimension "A"
= Dimension "B") is obtained (Figure 3-8).
5. Tighten clamp bolt nuts (1) to standard torque.
NOTE: Be certain clamp and hardware is positioned
"up" as shown in Figure 3-9. This is necessary to avoid
linkage interference during steering.
6. Remove blocks from rear wheels.
FIGURE 3-8. TOE-IN DIMENSIONS
FIGURE 3-9. TIE ROD ADJUSTMENT
1. Clamp, Capscrew & Nut 3. Spindle Arm
2. Tie Rod 4. Frame Member
G3-6 Front Wheel Hub and Spindles G03009 8/91
FINAL DRIVE ATTACHMENTS
FINAL DRIVE ANCHOR
The final drive anchor pin bearing may be replaced
without removing the complete final drive from truck.
Pin Removal
1. Securely block front wheels.
2. Vent all nitrogen from both front suspensions to
allow front of truck to lower when blocked under
hoist cylinder mounts (Step 5). Refer to Section
"H", Oiling and Charging Procedures.
3. Remove drive line (2, Figure 4-1) between final
drive and transmission and set aside.
4. Raise rear of frame until rear suspension are 1 in.
(25.4 mm) from full extension.
5. Securely block under lower hoist cylinder mount
structure (3) of both sides.
6. Securely block rear wheels.
7. Vent nitrogen from rear suspensions to allow the
final drive anchor structure to be lowered (step 13)
when the anchor pin is removed. Refer to Section
"H", Oiling and Charging Procedures.
8. Support anchor structure (1) so that when anchor
pin is removed (step 12) it will not drop, but can
be lowered in a controlled manner far enough for
anchor pin assembly to clear frame mounts.
9. Place jack under either rear suspension lower
mount.
Be sure jack is secure to lower mount so it will not
slide off as jack is extended.
10. Remove lock plug (1, Figure 4-2), splined nut (3)
and electrical ground strap. Refer to Section "M",
Special Tools, for Splined Nut Wrench.
11. Remove retainer bar (8).
12. Remove anchor pin (2).
13. As jack under rear suspension is raised, let off on
anchor structure support until anchor bearing as-
sembly clears frame. As anchor structure comes
down, spacer (4) can be removed.
14. Block final drive securely in this position.
FIGURE 4-1. FINAL DRIVE ANCHOR ATTACHMENT
1. Anchor Structure 3. Hoist Cylinder Mount
2. Drive Line
FIGURE 4-2. FINAL DRIVE ANCHOR PIN ASSEMBLY
1. Lock Plug 6. Capscrew
2. Anchor Pin 7. Final Drive Anchor
3. Splined Nut Structure
4. Spacer 8. Retainer Bar
5. Anchor Bearing Inner Race
G04007 Final Drive Attachments G4-1
Pin Installation
1. Raise anchor structure into position between
frame mounts as jack under rear suspension is
lowered.
2. Install spacer (4, Figure 4-2).
3. Install anchor pin (2).
4. Install retainer bar (8) and capscrews (6). Tighten
to standard torque.
5. Install splined nut (3), tighten to 1500 ft. lbs. (2034
N.m) torque. If lock plug holes do not align,
tighten to next hole. Install lock plug (1). Refer to
Section "M", Special Tools, for Splined Nut
Wrench.
6. Connect electrical ground strap.
7. Install drive line. Tighten capscrews to 100 5 ft.
lbs. (136 7 N.m) torque.
8. Raise rear of frame and remove support from
under lower hoist cylinder mounts.
9. Charge both front and rear suspensions with nitro-
gen. Refer to Section "H", Oiling and Charging
Procedures.
Bearing Removal and Inspection
1. Remove nuts (1, Figure 4-3), capscrews (2) and
retainer (3) from anchor structure.
2. Remove bearing carrier (6) from anchor structure.
3. Remove bearing (4) from carrier.
4. Inspect anchor pin, bearing, bearing carrier, and
bore of anchor structure. Replace any damaged
or worn component.
5. Nominal Clearance Dimensions:
Bearing carrier O.D. to anchor structure bore I.D.
+ 0.0010 to + 0.0030 in.
(0.025 mm to 0.076 mm).
Bearing O.D. to carrier I.D.
+ 0.0005 to + 0.0015 in.
(0.013 mm to 0.038 mm).
Bearing I.D. to pin O.D.
+ 0.0008 to 0.002 in
(0.020 mm to 0.050 mm).
Bearing Installation
1. Clean all parts.
2. Install bearing assembly (4, Figure 4-3) into carrier
(6). Be certain outer race is against shoulder of
carrier.
3. Install carrier into bore of anchor structure (5).
4. Install bearing retainer (3), capscrews (2) and nuts
(1). Tighten to standard torque.
PANHARD ROD
Removal
1. Park truck on level surface and securely block
wheels.
2. Securely support frame on each side under lower
hoist cylinder mounts (3, Figure 4-1).
3. Support panhard rod (1, Figure 4-4).
4. Remove nuts (3), capscrews (2) and retainers (4)
from both panhard rod pins (5).
5. Remove panhard rod pins and panhard rod from
frame and final drive case.
Installation
1. Raise panhard rod into position.
2. Install pins
When installing panhard rod, misalignment of sec-
ond pin and bearing will probably occur. Raise or
lower frame with jacks or adequate lifting device
ON EACH SIDE OF FRAME.
DO NOT use rear suspensions, because there is no
restraint to keep frame from shifting to one side or
the other.
FIGURE 4-3. ANCHOR PIN BEARING
1. Nut 4. Bearing Assembly
2. Capscrew 5. Anchor Structure
3. Bearing Retainer 6. Bearing Carrier
G4-2 Final Drive Attachments G04007
3. Install retainers (4), capscrews (2) and nuts (3).
Tighten capscrews to standard torque.
Bearing Replacement
1. Remove one snap ring (1, Figure 4-5) from each
end of panhard rod bores.
2. Remove bearing (2) from each end of panhard rod.
3. Inspect panhard rod pin bearing bores. Replace
any component damaged or worn beyond the
following limits:
Nominal Clearance Dimensions:
Bearing O.D. to panhard rod bore I.D.
0.0004 in. to + 0.0018 in.
(0.010 mm to 0.045 mm).
Bearing I.D. to pin O.D.
0.0000 in to + o.0006 in.
(0.000 mm to 0.015 mm).
Panhard rod pin mount bores I.D. to pin O.D.
+ 0.0010 in. to + 0.0040 in.
(0.025 mm to 0.101 mm).
4. Clean all parts being reused.
5. Install bearing (2) in each end of panhard rod
bearing bore firmly against snap ring.
6. Install other snap ring (1) for both bearings.
FIGURE 4-4. PANHARD ROD ATTACHMENT
1. Panhard Rod 4. Retainers
2. Capscrew 5. Panhard Rod Pin
3. Nut
FIGURE 4-5. PANHARD ROD BEARING
1. Snap Rings 2. Bearing Assembly
G04007 Final Drive Attachments G4-3
NOTES
G4-4 Final Drive Attachments G04007
FINAL DRIVE ASSEMBLY
The 210M HAULPAK
Dis-
tributor.
2. Maximum clearance between new upper bearing
and housing is 0.020 in. (0.50 mm).
3. Maximum clearance between new lower bearing
to suspension tube is 0.020 in. (0.50 mm).
FIGURE 2-4. LOWER BEARING RETAINER SEALS
1. Lower Bearing 3. Double Lip Rod Seal
2. Step Seal and 4. Wiper
Step Seal O-Ring
H02007 Front Suspensions H2-3
Assembly
1. Clean all components thoroughly.
2. Lightly coat all O-rings, backup rings, seals and
wiper with petroleum jelly or suspension oil.
3. Install O-rings and backup rings (1, Figure 2-5) to
pilot of suspension cap (2).
4. Install step seal O-ring (3) and step seal (4).
Position step seal lip toward bearing of lower
retainer.
5. Install rod seal (6) with lip toward bearing of lower
retainer (Figure 2-5).
6. Install wiper (7) with lip pointing away from bear-
ing.
7. Install bearing (8).
8. Install backup rings and O-ring on O.D. of lower
bearing retainer.
9. Install lower retainer (9) into housing. Install wash-
ers and capscrews (5). Tighten to standard
torque.
10. If removed, install retainer cap, washer (10) and nut
to suspension cap. Tighten nut to 800 ft. lbs.
(1084 N.m) torque.
11. Place two 3/4 in. (19 mm) balls (11) in pockets of
tube. Install upper bearing retainer.
12. Install retainer cap (12), washers and capscrews
(13). Tighten to standard torque.
13. Install upper bearing (14) on upper retainer (18).
14. Insert tube (15) and cap (2) into housing. Install
capscrews (16). Tighten to standard torque.
15. Install plug (17) in bottom of tube. Tighten to 13 ft.
lbs. (17.5 N.m) torque.
16. Add 3.5 gal. (13.25 l) of suspension oil thru charg-
ing valve hole in cap of suspension.
17. Install charging valve assembly (Figure 2-1) with
new O-ring (9). Tighten 3/4 in. (19 mm) nut of
charging valve to 16.5 ft. lbs. (22.4 N.m) torque.
18. If new charging valve is used, tighten 5/8 in. (16
mm) nut to 10.5 ft. lbs. (14 N.m) torque, loosen,
retighten to 10.5 ft. lbs. (14 N.m) torque, loosen,
retighten to 4 ft. lbs. (5.5 N.m) torque. If old valve
is reused, tighten 5/8 in. (16 mm) nut to 4 ft. lbs.
(5.5 N.m) torque.
19. Correct oil level will be established when suspen-
sion is mounted on truck. Refer to Suspension
Oiling and Charging procedure, this section.
FIGURE 2-5. SUSPENSION ASSEMBLY
1. O-Rings/Backup Rings 10. Washer
2. Cap 11. Steel Ball
3. Step Seal O-Ring 12. Bearing Retainer Cap
4. Step Seal 13. Capscrews & Washers
5. Capscrews & Washers 14. Upper Bearing
6. Double Lip Rod Seal 15. Tube
7. Wiper 16. Capscrews
8. Lower Bearing 17. Drain Plug
9. Lower Bearing 18. Upper Bearing Retainer
Retainer
H2-4 Front Suspensions H02007
REAR SUSPENSIONS
The HYDRAIR
Distributor.
11. Maximum clearance between new bearing and
housing is 0.020 in. (0.50 mm).
12. Maximum clearance between lower retainer and
tube is 0.020 in. (0.50 mm).
FIGURE 3-2. REAR SUSPENSION MOUNTING
1. Retainer Bolt 2. Mount Pin
And Nut 3. Spacers
H3-2 Rear Suspensions H03006
Assembly
1. Clean all parts thoroughly.
2. Lightly coat all O-rings, backup rings, seals and
wipers with petroleum jelly or suspension oil.
3. Install O-ring/back-up ring and step seal (12, Fig-
ure 3-4) in seal retainer. Position lip of step seal
toward inside of suspension.
4. Install double lip rod seal (11) in retainer.
5. Install wiper seal (10) in retainer.
6. Install backup rings and O-rings (13) on O.D. of
retainer.
7. If bearing retainer (6) was removed from piston
tube (14), install two balls (15) and bearing re-
tainer to piston tube. Tighten capscrews to stand-
ard torque.
8. Place bearing (7) on retainer (6).
9. Install piston tube and retainer assembly into sus-
pension housing (4).
10. Install seal retainer (8) over tube. Tighten cap-
screws (9) to standard torque.
11. Pour 2 gal. (7.5 l) of suspension oil into suspension
through charging valve hole.
12. Install charging valve (Figure 3-1) using new O-ring
(9). Tighten 3/4 in. (19 mm) nut to 16.5 ft. lbs. (22.3
N.m) torque.
13. If a new charging valve is used, tighten 5/8 in. (16
mm) swivel nut (3, Figure 3-3) to 10.5 ft. lbs. (14
N.m), release and retighten to 10.5 ft. lbs. (14
N.m) and release, retighten to 4.0 ft. lbs. (5.5
N.m). If the old charging valve is reused, tighten
swivel nut to 4.0 ft. lbs. (5.5 N.m) torque.
14. Install valve cap (2) and valve guard (1).
FIGURE 3-3. REAR SUSPENSION ASSEMBLY
1. Charging Valve Guard 9. Capscrews & Washers
2. Charging Valve Cap 10. Wiper Seal
3. Swivel Nut (Small Hex) 11. Double Lip Rod Seal
4. Suspension Housing 12. O-Ring/Back-up Ring
5. Capscrews & Washers 13. O-Rings/Back-up Rings
6. Upper Brng. Retainer 14. Piston Rod Tube
7. Upper Bearing 15. Steel Ball
8. Lower Seal Retainer 16. Gease Fitting
H03006 Rear Suspensions H3-3
REAR SUSPENSION
SPHERICAL BEARING REPAIR
NOTE: If either top or bottom spherical bearings (2,
Figure 3-5) are to be replaced with suspension
mounted on truck, be sure truck frame is securely
supported. Refer to Suspension Removal and Installa-
tion for procedure. Securely support suspension as
bearing is being removed and installed.
Disassembly
1. Remove retaining ring (2, Figure 3-5) from mount-
ing eye of housing or tube.
2. Remove bearing (2).
Inspection
1. Inspect mount pin (3), spacers (4) and mounting
eye bearing bores for damage.
Replace as necessary.
2. Tolerance Dimensions:
Suspension frame and final drive mount pin bores
I.D. to mount pin O.D.:
+ 0.005 in. (0.012 mm) to 0.0035 in. (0.088 mm).
Spherical bearing O.D. to suspension mount
bearing bore I.D.:
-0.0002 in. (0.005 mm) to + 0.0018 in. (0.045 mm).
Spherical bearing I.D. to mount pin O.D.:
-0.0001 in. (0.002 mm) to + 0.0015 (0.038 mm).
Assembly
1. Install spherical bearing (2) in mount eye bore.
2. Install retaining ring (1).
3. Refer to Suspension Installation. Be sure grease is
applied to bearing before operating truck.
4. After suspension is installed on truck, it may be
necessary to charge suspension with nitrogen.
Refer to Suspension Oiling and Charging proce-
dure, this section.
FIGURE 3-4. SPHERICAL BEARING INSTALLATION
1. Retaining Ring 3. Mount Pin
2. Spherical Bearing 4. Spacers
Assembly
H3-4 Rear Suspensions H03006
OILING AND CHARGING PROCEDURES
GENERAL
These procedures cover Oiling and Charging of HY-
DRAIR
II suspensions on HAULPAK
trucks. HY-
DRAIR
II suspensions.
All HYDRAIR
II suspensions requires
that three (3) basic conditions be established in the
following order:
1. Oil level must be correct.
2. Suspension piston rod extension for nitrogen
charging must be correct and this dimension be
maintained during nitrogen charging.
3. Nitrogen charge pressure must be correct.
For best results, HYDRAIR
II suspensions should be
charged in pairs (fronts together and rears together).
If rears are to be charged, the fronts should be charged
first.
NOTE: Set up dimensions specified in the charts must
be maintained during oiling and charging procedures.
However, after truck has been operated, these dimen-
sions may vary.
EQUIPMENT LIST
HYDRAIR
Charging Kit
Jacks and/or Overhead Crane
Support Blocks for Oiling height - Front
Support Blocks for Nitrogen Charging height- Front
HYDRAIR
Oil (See Specifications Chart)
Dry Nitrogen (See Specifications Chart)
HYDRAIR
CHARGING KIT
Assemble service kit as shown in Figure 4-1 and attach
to container of pure dry nitrogen (8).
Installation of Charging Kit
1. Remove protective covers and charging valve
caps from suspensions to be charged.
2. Turn "T" handles (1, Figure 4-1) of adapters (2)
completely counterclockwise.
FIGURE 4-1. HYDRAIR CHARGING KIT
1. "T" Handle
2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (to gauge)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas (Specifications Chart)
NOTE: Arrangement of parts may vary from illustration
above, depending on Charging Kit P/N.
H04008 8/96 Oiling and Charging Procedures H4-1
140M/210M
3. Be certain outlet valves (3) and inlet valve (4) are
closed (turned completely clockwise).
4. Attach charging valve adapters (2) to each sus-
pension charging valve stem.
5. Turn "T" handles (1) clockwise (this will depress
core of charging valve and open gas chamber of
suspension).
6. Open both outlet valves (3).
By selective opening and closing of outlet valves (3),
and inlet valve (4), suspensions may be charged sepa-
rately or together.
Removal of Charging Kit
1. Close both outlet valves (3).
2. Turn "T" handles (1) counterclockwise to release
charging valve cores.
3. Remove charging valve adapters (2) from charg-
ing valves.
4. Install charging valve caps and protective covers
on both suspensions.
SUPPORT BLOCKS FOR OILING AND
CHARGING DIMENSIONS
Prior to starting oiling and charging procedures, sup-
ports should be fabricated which will maintain the
correct exposed piston rod extensions.
Exposed piston rod extensions are specified for both
oil level and nitrogen charging for HYDRAIR
II sus-
pensions. These dimensions are listed in tables below
Figures 4-2 and 4-4. Measure dimensions from face of
cylinder gland to machined surface on spindle or to top
of bottom support bracket as shown. Do NOT include
capscrew heads in measurements.
Support blocks may be made in various forms. Mild
steel materials of 0.5 in. (13mm) minimum thickness is
recommended. Square bar stock or pipe segments
may be used. Blocks must be capable of supporting
the weight of the truck during oiling and charging
procedures while avoiding contact with plated surfaces
and seals on the suspension.
Refer to Figure 4-2 for front suspension support block
placement.
As an aid for identification for next use, some opera-
tions color code the support blocks to mark them as
used for: Truck Model, Oiling, or Charging for Front
or Rear suspensions.
FRONT SUSPENSION
1. Park unloaded truck on a hard level surface. Block
wheels, apply parking brake.
2. Thoroughly clean area around charging valve on
the suspensions. Remove protective covers from
charging valves.
All HYDRAIR
oil until
the cylinder is full to top of charging valve bore.
Drip pans should be used and all spillage cleaned
from outside of suspension.
Allow suspension to stand for at least 15 minutes to
clear any trapped nitrogen and/or bubbles from the oil.
Add more suspension oil if necessary. Loosely install
charging valve.
Front Suspension Nitrogen Charging
Lifting equipment (crane or hydraulic jacks) must
be of sufficient capacity to lift the truck weight. Be
certain that all personnel are clear of lift area
before lift is started.
1. With nitrogen charging blocks at hand (Figure
4-2), use crane or jacks to raise the truck to
provide clearance for the blocks.
2. Remove oiling blocks and install nitrogen charging
blocks. Secure blocks so they will not fly free.
Lower truck frame until the blocks are firmly and
squarely seated between the spindle and the cyl-
inder housing.
NOTE: Use caution to prevent damage to plated cylin-
der surfaces and oil seals.
3. Install charging valve with new lubricated "O" ring
(9, Figure 4-3), use clean HYDRAIR
oil.
4. Tighten valve body (large hex, 6) to 16.5 ft. lbs.
(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated counterclockwise three
full turns.
FIGURE 4-2. FRONT SUSPENSION DIMENSIONS
TRUCK
MODEL
SIZE
OILING
HEIGHT
in. (mm)
CHARGING
HEIGHT
in. (mm)
CHARGING
PRESSURE
psi (kPa)
140M 2.0 (50.8) 7.88 (200) 335 (2309)
210M 2.0 (50.8) 7.88 (200) 410 (2826)
FIGURE 4-3. CHARGING VALVE
1. Valve Cap
2. Seal
3. Valve Core
4. Swivel Nut
(small hex, 0.625 in.)
5. Rubber Washer
6. Valve Body (large
hex nut - 0.75 in.)
7. O-Ring
8. Valve Stem
9. O-ring
H04008 8/96 Oiling and Charging Procedures H4-3
140M/210M
Dry nitrogen is the only gas approved for use in
HYDRAIR
oil until
the cylinder is full to top of fill plug bore. Drip pans
should be used and all spillage cleaned from
outside of suspension. Allow suspension to stand
for at least 15 minutes to clear any trapped nitro-
gen and/or air bubbles from the oil. Add oil if
necessary. Loosely install charging valve.
Rear Suspension Nitrogen Charging
Lifting equipment (crane or hydraulic jacks) must
be of sufficient capacity to lift the truck weight. Be
certain that all personnel are clear of lift area
before lift is started.
1. Raise rear of truck with crane or jacks to provide
dimensions shown in chart below Figure 4-4.
2. Install charging valve with new lubricated "O" ring
(9, Figure 4-3). Use clean HYDRAIR
oil.
3. Tighten valve body (large hex, 6) to 16.5 ft. lbs.
(22.4 N.m) torque. The valve swivel nut (small
hex, 4) must be unseated counterclockwise three
full turns.
Dry nitrogen is the only gas approved for use in
HYDRAIR
II OIL SPECIFICATIONS
Ambient Temperature Range Part No. Approved Sources
-30F & above (-34.5C & above) VJ3911
Mobil 424
Mobil D.T.E. 15
Texaco TDH Oil
AMOCO ULTIMATE
Motor Oil 5W--30
Sunfleet TH Universal Tractor Fluid
Chevron Tractor Hydraulic Fluid
Conoco Power Tran III Fluid
Petro Canada Duratran Fluid
Shell Canada Donax TDL
-55F & above (-48.5C & above) VJ5925
Emery 2811, SG-CD,
5W--30
Mobil Delvac I, 5W--30
Petro Canada Super Arctic
Motor Oil, 0W--30
Conoco High Performance
Synthetic Motor Oil, 5W--30
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.
VJ3911 and VJ5925 oils are supplied in 5 gallon (19 Liter) cans.
NITROGEN GAS (N2) SPECIFICATIONS
Nitrogen gas used in HYDRAIR
II
Suspension Cylinders must meet or
exceed CGA specification G--10.1 for
Type 1, Grade F Nitrogen Gas
Property Value
Nitrogen
Water
Dew Point
Oxygen
99.9% Minimum
32 PPM Maximum
-68F (-55C) Maximum
0.1% Maximum
FIGURE 4-5. SPECIFICATIONS CHART
H4-6 Oiling and Charging Procedures H04008 8/96
140M/210M
SECTION J
BRAKE CIRCUIT
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
Manual Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1
HYDRAULIC OIL MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-2
BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-2
ACCUMULATOR PRECHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-2
LOW-PRESSURE BRAKE DETECTION MODULE . . . . . . . . . . . . . . . . . . . . . . J2-2
Low-Pressure Sensing Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . J2-2
Brake Accumulator Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . J2-2
Accumulator Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
Accumulator Discharge Valves (Bleeddown Valves) . . . . . . . . . . . . . . . . . . J2-3
Emergency Apply Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
Brake Pressure Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
BRAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
Brake Lock Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-3
Brake Lock Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-4
Brake Manifold Shuttle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-4
Steering Bleeddown Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . J2-4
Steering Accumulator Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . J2-4
SERVICE BRAKE TREADLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-4
RETARDER TREADLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-4
SERVICE BRAKE/RETARDER SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . J2-5
STOP LIGHT MANIFOLD AND TEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5
REAR BRAKE SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5
WET DISC BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-5
BRAKE CIRCUIT COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-1
LOW-PRESSURE BRAKE DETECTION MODULE . . . . . . . . . . . . . . . . . . . . . . J3-1
BRAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-1
BRAKE ACCUMULATOR REPAIR (Refer To Section "L", Hydraulic System) . . . . . . . J3-2
SERVICE BRAKE TREADLE VALVE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . J3-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
DISASSEMBLY OF TREADLE VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . J3-3
Removal of Brake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-3
Brake Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5
ASSEMBLY OF TREADLE VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . J3-5
Brake Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-5
Installation of Brake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-7
ADJUSTMENT FOR MAXIMUM DELIVERY PRESSURE . . . . . . . . . . . . . . . . J3-7
BRAKE PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-8
SERVICE BRAKE TREADLE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-10
Pedal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-10
Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-10
J01006 8/90 Brake System Index J1-1
RETARDER TREADLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-12
Retarder Treadle Pedal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . J3-13
Retarder Treadle Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-13
BRAKE CIRCUIT CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . J4-1
CIRCUIT TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-1
INITIAL SYSTEM SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-2
CHECK OF BRAKE CIRCUIT SHUTTLE VALVES . . . . . . . . . . . . . . . . . . . . . . J4-2
BRAKE SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-3
FAILURE MODE CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-4
BRAKE VALVE LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-5
CHECKOUT DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-9
FRONT WHEEL SPEED DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-1
Lining Replacement On Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-1
BRAKE CALIPER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-2
Piston and Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-2
Piston and Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-3
BRAKE CALIPER BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-3
FRONT BRAKE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . J5-4
FRONT SERVICE BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . J5-4
REAR WET DISC BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-2
Wet Disc Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-3
Brake Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-6
Brake Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-6
Brake Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-6
Floating Ring Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-7
Wet Disc Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6-11
REAR WET DISC BRAKE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . J6-13
REAR BRAKE DISC WEAR INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . J6-14
Removal/Installation From One Brake To Another . . . . . . . . . . . . . . . . . . J6-14
PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
Park Brake Lining Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
Park Brake Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-1
PARK BRAKE ACTUATOR ASSEMBLY REPAIR . . . . . . . . . . . . . . . . . . . . . . J7-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Actuator Spring Pod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-3
Actuator Spring Pod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
PARK BRAKE BURNISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J7-4
J1-2 Brake System Index J01006 8/90
BRAKE CIRCUIT
The brake circuit is an all-hydraulic-actuated mineral oil
system, normally operating at 2750 psi (19.25 MPa)
pressure. The manual apply system is controlled by the
operator through the Service Brake Treadle Valve (5,
Figure 2-1). The operator can modulate applied pres-
sure to the front and rear brakes.
The separate Retarder Treadle Valve (7, Figure 2-1),
controls the rear brakes only. This pressure is also
modulated by the operator.
Two separate circuits; one from the front (right) brake
treadle valve/retarder circuit, and one from the rear
(left) brake treadle valve circuit, provide a means of
applying the rear brakes in the event pressure is re-
duced or lost in one of the circuits.
The system also features an automatic emergency
apply. If the system pressure decreases to 1650 psi
(11.6 MPa) or lower, all four wheel brakes will be
applied automatically. Refer to Hydraulic Schematic,
Section "R" for details of circuit operation.
CIRCUIT OPERATION
Charging
When the engine is started with the brake circuit com-
pletely bled down, oil from the steering/brake pump
(11, Figure 2-1) enters the Oil Manifold (1) and then to
each of two brake circuit accumulators (4). From the
accumulators the oil enters the Low-Pressure Brake
Detection Module (2) and all of its components. From
there, the oil enters the brake manifold (6) and its
components. The oil then enters the service brake
treadle valve (5) and the retarder treadle valve (7).
As brake circuit pressure continues to increase, the
signal from the low pressure sensing shuttle valve
releases the emergency apply valve, blocking the
emergency apply pilot signal to the pilot piston of the
service treadle valves, releasing the brakes. When sys-
tem pressure reaches approximately 2000 psi (14
MPa), the brake pressure warning switch opens, turn-
ing off the instrument panel warning light.
Anytime the emergency apply valve is activated, the
brake pedal will move freely through its normal travel
with little or no effort. If the emergency apply valve
deactivates while the pedal is depressed a slight "kick"
of the pedal will be felt.
FIGURE 2-1. BRAKE CIRCUIT
1. Hydraulic Oil Manifold 8. Service Brake/Retarder Shuttle Valve
2. Low-Pressure Brake Detection Module 9. Wet Disc Brakes
3. Accumulator Discharge Valves 10. Stop Light Manifold
4. Accumulators (Front and Rear Brakes) 11. Steering/Brake Hydraulic Pump
5. Service Brake Treadle Valve 12. Front Brake Calipers
6. Brake Manifold 13. Rear Brake Shuttle Valves
7. Retarder Treadle Valve (Rear Brakes Only) 14. Tee
J02008 8/90 Brake Circuit J2-1
Manual Application
With the system fully charged, apply pressure from the
Service Brake Treadle Valve to the brakes can be
modulated from 0 -- 1350 100 psi (0 -- 9.45 0.7 MPa)
by depressing the brake pedal. The Retarder Treadle
Valve can also be modulated from 0 -- 1150 100 psi
(0 -- 7.9 0.7 MPa) by depressing the retarder pedal.
HYDRAULIC OIL MANIFOLD
The hydraulic oil manifold (1, Figure 2-1) is used as an
oil distribution center for charging the steering and
both brake accumulators. Each of three outlet ports
has a check valve that allows oil to flow only to the
accumulator it supplies.
BRAKE ACCUMULATORS
There are two brake accumulators (4, Figure 2-1) in the
brake circuit to supply pressure for emergency opera-
tion and during normal application (an additional in-
board mounted large accumulator is used for the
steering circuit).
The accumulators are floating piston type with nitrogen
gas on the top side of piston. The nitrogen gas end of
each accumulator contains a precharge pressure
switch and charging valve. The outlet port directs oil to
the low-pressure brake detection module (2), and the
brake manifold (6). The accumulators are located on
the back of the right front deck support. The smaller
outboard accumulator supplies pressure to the front
brakes and also supplies an alternate apply line to the
rear brakes. The retarder circuit is also supplied from
this accumulator. The larger (middle) accumulator sup-
plies pressure to the rear brakes only. Refer to Section
"R", Schematics.
ACCUMULATOR PRECHARGE
When the key switch is first turned on before starting
the engine, the accumulator nitrogen precharge warn-
ing light on instrument panel should be "Off". If the light
is "On", the nitrogen charge on both accumulators
should be checked; correct precharge is 1050 psi (7.3
MPa).
LOW-PRESSURE BRAKE DETECTION
MODULE
The low-pressure brake detection module (2, Figure
2-1) is located under the accumulators on the right side
of the truck between the accumulators and the brake
manifold in the brake circuit. Figure 2-2 outlines the
internal circuitry and components.
Low-Pressure Sensing Shuttle Valve
The Low-Pressure Sensing Shuttle Valve (1, Figure 2-2)
is a replaceable cartridge spool-type valve that senses
pressure from each accumulator. The lower of the two
accumulator pressures will be directed to the pilot end
of the emergency apply valve (5) and brake pressure
warning switch (7). When accumulator pressures are
equal, the shuttle is balanced, supplying oil to the
circuits mentioned above.
Brake Accumulator Pressure Checks
Two quick disconnect pressure check points (2 & 6,
Figure 2-2) are provided for testing brake accumulator
pressures. Refer to "Brake Circuit Checkout", this sec-
tion, for testing procedures.
FIGURE 2-2. LOW-PRESSURE BRAKE DETECTION
MODULE
1. Low-Pressure Sensing Shuttle Valve
2. Front Brake Accumulator Pressure Check
3. Accumulator Shuttle Valve
4. Brake Accumulator Discharge Valves
(Manual Bleeddown Valves)
5. Emergency Brake Apply Valve -
1650 psi (11.4 MPa)
6. Rear Brake Accumulator Pressure Check
7. Brake Warning Pressure Switch -
2000 psi (13.8 MPa)
J2-2 Brake Circuit J02008 8/90
Accumulator Shuttle Valve
The accumulator shuttle (3, Figure 2-2) valve is a re-
placeable cartridge ball type valve that senses pres-
sure from each accumulator. The higher of the two
pressures is directed to the supply port of the emer-
gency apply valve.
Accumulator Discharge Valves
(Manual Bleeddown Valves)
Two accumulator discharge valves (4, Figure 2-2) are
located on top of the low-pressure detection module
and are used for draining the brake accumulator(s).
The right valve controls the front accumulator; the left
valve controls the rear accumulator. Turning the valve
handles counterclockwise will allow stored accumula-
tor oil pressure to return to tank. Turning the valves
clockwise will close the drains and allow the accumu-
lators to charge when the engine is started.
Emergency Apply Valve
The emergency apply valve (5, Figure 2-2) is a replace-
able cartridge, spring operated, normally open (N.O.)
spool type directional valve. When the pilot pressure
from the low pressure sensing shuttle valve (1) is higher
than the spring pressure of the emergency apply valve,
the valve will be held in the normal operating position
(pilot port to brake manifold is blocked).
When the pilot pressure on the spool of the emergency
valve (5) decreases to approximately 1650 psi (11.5
MPa) the spring moves the spool to the open position
directing accumulator pressure to the pilot ports of the
service brake treadle valves applying the brakes at all
wheels.
Brake Pressure Warning Switch
The brake pressure warning switch (7, Figure 2-2) is a
normally closed, double pole, single throw switch lo-
cated in the pilot circuit between the low pressure
sensing shuttle valve (1) and emergency apply valve
(5). If emergency apply pilot pressure decreases to
2000 psi (14 MPa) or below, the switch closes, turning
on the brake pressure warning light and alarm on the
instrument panel.
BRAKE MANIFOLD
The brake manifold valve (6, Figure 2-1) is mounted to
the service brake treadle valve (5, Figure 2-1). Figure
2-3 outlines the internal circuitry and components.
Refer to "Brake Circuit Component Service", this sec-
tion, for more information.
Brake Lock Shuttle Valve
The Brake Lock Shuttle Valve (5, Figure 2-3) is located
between the brake lock solenoid (6) and the emer-
gency apply valve port (1) from the low-pressure brake
detection module.
When the brake lock solenoid is energized, accu-
mulator oil pressure will shift the shuttle ball to
block the pilot port to the right (front) brake valve.
The pilot port to the left brake valve will be open
and allow the oil pressure to apply the rear brakes
only.
When the emergency apply valve is energized,
accumulator oil pressure will shift the shuttle ball
to block the brake lock pilot port and allow both
pilot ports of the service brake valves to be open
to the oil pressure to apply all wheel brakes.
FIGURE 2-3. BRAKE MANIFOLD
1. Emergency Apply Valve Port
2. Return to Tank
3. Steering Bleeddown Solenoid Valve
4. Steering Accumulator Pressure Check
5. Brake Lock Shuttle Valve
6. Brake Lock Solenoid Valve
7. Brake Manifold Shuttle Valve
J02008 8/90 Brake Circuit J2-3
Brake Lock Solenoid Valve
The brake lock valve (6, Figure 2-3) is a replaceable
cartridge, solenoid operated, normally closed (N.C.)
directional spool valve. The valve receives a supply of
oil from the accumulator shuttle valve. The solenoid is
energized by the instrument panel mounted brake lock
switch. When energized, the solenoid moves the spool,
directing oil to the left pilot through a shuttle valve (5)
which then applies the rear brakes. When the solenoid
is not energized, the rear brake pilot port is open to
tank, releasing the rear brakes.
Brake Manifold Shuttle Valve
The brake manifold shuttle valve (7, Figure 2-3) is
located between the two accumulator circuits. It will
sense the higher of the two accumulator pressures,
allowing oil to pass to the Brake Lock Solenoid Valve.
This will act as a pilot when Brake Lock is applied,
allowing oil to close shuttle valve (5) in the emergency
apply circuit to the brake treadle valve pilot.
Steering Bleeddown Solenoid Valve
The Steering Bleeddown Solenoid Valve is a replace-
able assembly. Refer to "Steering Bleeddown Solenoid
Valve and Low Steering Pressure Switch", Section "L"
for more information.
Steering Accumulator Pressure Check
A quick-disconnect (4, Figure 2-3) is provided for
checking steering accumulator pressure. Refer to
"Steering Circuit Test Procedure", Section "L".
SERVICE BRAKE TREADLE VALVE
The Service Brake Treadle Valve (5, Figure 2-1) con-
tains two valves for brake application. A single pedal
operates both valves for manual brake application. The
left valve operates rear brakes only; the right operates
the front brakes and also supplies an alternate apply
line to the rear brakes. Each valve is a pressure modu-
lating directional valve made up of two sections; an
apply section and a modulating section.
The apply section is either pilot or manually operated.
The modulating section will deliver oil from accumula-
tor circuits to brake circuits. When a manual applica-
tion is made, the delivery pressure will be modulated
by pedal travel. The delivery pressure will be main-
tained as long as the pedal is held at that position.
Maximum apply pressure is delivered when the pedal
is completely depressed.
Pilot application of treadle valves is available from two
sources; the brake lock valve and the emergency apply
valve.
When the brake lock valve is activated, a pilot
signal enters the pilot section of the left treadle
valve. The pilot piston applies only the rear brakes
to maximum brake apply pressure.
When approximately 1650 psi (11.4 MPa) or less
is sensed by the emergency apply valve, a pilot
signal enters the pilot section of both brake
treadle valves and opens both accumulator cir-
cuits to supply oil to apply all wheel brakes at
accumulator circuit pressure.
The service brake treadle pedal is non-respon-
sive when this occurs.
RETARDER TREADLE VALVE
The retarder treadle valve (7, Figure 2-1) is located to
the left of the service brake treadle valve and applies
the rear brakes only. It is a manually operated pressure
modulating directional valve which delivers oil from the
front brake accumulator circuit to the rear brakes.
When an application is made, the delivery pressure will
be modulated by pedal travel. This delivery pressure
will be maintained as long as the pedal is held at that
position. Maximum apply pressure is 1150 psi (8.05
MPa) when the pedal is completely depressed.
J2-4 Brake Circuit J02008 8/90
SERVICE BRAKE/RETARDER
SHUTTLE VALVE
The Service Brake/Retarder Shuttle Valve (8, Figure
2-1), is a two way valve mounted under the cab on a
cross member near the brake and retarder treadle
valves. It is located between the service brake treadle
valve and the retarder treadle valve circuit. The purpose
of the shuttle valve is to separate the oil flow from either
the service brake treadle valve or the retarder treadle
valve from flowing into the other valve.
When the service brake treadle valve is applied, hy-
draulic pressure from the small accumulator, through
the right side brake controller valve will cause the
shuttle valve to shift, blocking the flow of oil to the
retarder treadle valve, but allowing oil to apply the front
and rear brakes.
When the retarder valve is applied, the shuttle valve will
shift to the other side, preventing oil from entering the
service brake treadle valve, but will allow oil from the
same small accumulator circuit to apply the rear brakes
only.
STOP LIGHT MANIFOLD AND TEE
A manifold (10, Figure 2-1) is mounted on the final drive
anchor structure which contains the stop light pressure
switch. It receives brake apply pressure from the front
(right) brake treadle valve/retarder circuit (small brake
accumulator) and activates the rear stop lights. It also
distributes the apply pressure to one port of each rear
brake shuttle valve.
A tee (14, Figure 2-1) is mounted above the manifold
and receives brake apply pressure from the rear (left)
brake treadle valve and distributes apply pressure to
the other port of each rear brake shuttle valve.
REAR BRAKE SHUTTLE VALVES
A Shuttle Valve (13, Figure 2-1) is mounted at each rear
brake assembly. These shuttle valves normally receive
brake apply pressures from two separate circuits as
described above; one from the front (right) brake
treadle valve/retarder circuit through the stop light
manifold, and one from the rear (left) brake treadle
valve circuit and through the tee. Having two separate
circuits provides a means of applying the rear brakes
in the event pressure is reduced or lost in one of the
circuits. The shuttle valves will move and close off the
lower pressure side and the rear brakes will be applied
through the higher pressure line.
WET DISC BRAKE ASSEMBLY
A Wet Disc Brake Assembly (9, Figure 2-1) is mounted
on both sides of the differential on the final drive hous-
ing and inboard from the wheel hub and planetary
drive. The assembly contains a shuttle valve assembly,
a splined housing, two damper discs, ten separator
plates, eleven friction discs, a spacer, a piston assem-
bly, and a splined rotating hub.
The housing is internally splined to retain the steel
damper and separator discs. The separator discs are
alternately placed between the friction faced discs
which are splined to the rotating hub. The inboard side
of the assembly contains the piston assembly which is
activated by hydraulic pressure from either the service
brake treadle valve or the retarder treadle valve. As
hydraulic pressure is applied, the piston moves and
compresses the rotating friction faced discs against the
stationary steel discs. The friction forces generated
resist the rotation of the wheels. As hydraulic pressure
increases, friction forces are increased and wheel ro-
tation is slowed until maximum force is reached and
the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The cooling oil circuit is a low-pressure circuit which
is completely separate from the high-pressure piston
apply circuit. The cooling oil flows from the pump,
through two 12 micron (absolute) filters, through a heat
exchanger, to the brake assembly housing (from the
outside of the housing inward to the rotating hub for
maximum cooling) and then to the hydraulic tank.
Dynamic retarding is also provided by the wet disc
brakes. The dynamic retarding is used to slow the truck
during normal truck operation or to control speed
coming down a grade. When the operators retarder
pedal is depresed, front wheel brakes are not used;
only the rear wet disc brakes are applied.
J02008 8/90 Brake Circuit J2-5
NOTES
J2-6 Brake Circuit J02008 8/90
BRAKE CIRCUIT COMPONENT SERVICE
Before removing any brake lines or brake circuit
components, be sure brake accumulators are bled
down. To bleeddown accumulators:
BLOCK WHEELS OF TRUCK!
Turn key switch "OFF", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Accumulator Discharge Valve handles
counterclockwise to open. Wait at least 90
seconds to let accumulators bleed down.
When brake accumulators are completely
bled down, close accumulator discharge
valves by turning handles clockwise.
Do not leave open.
LOW PRESSURE BRAKE DETECTION
MODULE
The low-pressure brake detection module ( Figure 3-1)
is a serviceable component and is mounted under the
accumulators on the right side of the truck. Refer to
"Brake Circuit Checkout", this section, for testing and
troubleshooting this valve and its internal components.
All components are individually serviceable without
removing the complete module from the truck.
Low-Pressure Sensing Shuttle Valve
The Low-Pressure Sensing Shuttle Valve (7, Figure 3-1)
is replaceable as a cartridge assembly.
Accumulator Shuttle Valve
The accumulator shuttle (6, Figure 3-1) valve is replace-
able as a cartridge assembly.
Accumulator Discharge Valves (Bleeddown
Valves)
The Accumulator Discharge Valves (Manual Bleed-
down Valves) are replaceable as a cartridge assem-
blies.
Emergency Apply Valve
The emergency apply valve (2, Figure 3-1) is replace-
able as a cartridge assembly.
Brake Pressure Warning Switch
The brake pressure warning switch (11, Figure 3-1) is
a normally closed, double pole, single throw switch and
is replaceable as an assembly.
BRAKE MANIFOLD
The brake manifold is mounted to the service brake
treadle valves under the cab of the truck. It contains the
following components which are individually service-
able without removing the complete manifold from the
truck:
Steering Bleeddown Solenoid Valve
Steering Accumulator Pressure Check
Brake Lock Shuttle Valve
Brake Lock Solenoid Valve
Brake Manifold Shuttle Valve
FIGURE 3-1. LOW-PRESSURE BRAKE DETECTION
MODULE
1. Rear Accumulator Discharge Valve
(Manual Bleeddown Valve)
2. Emergency Brake Apply Valve -
1650 psi (11.4 MPa)
3. Front Accumulator Discharge Valve
(Manual Bleeddown Valve)
4. From Front Brake Accumulator
5. Mounting Capscrew
6. Accumulator Shuttle Valve
7. Low-Pressure Sensing Shuttle Valve
8. Front Brake Accumulator Pressure Check
9. Return to Tank
10. Rear Brake Accumulator Pressure Check
11. Brake Warning Pressure Switch -
2000 psi (13.8 MPa)
12. From Rear Brake Accumulator
13. Manifold Housing
J03011 8/90 Brake Circuit Component Service J3-1
Refer to "Service Brake Treadle Valve" for removal or
installation.
BRAKE ACCUMULATOR REPAIR
Refer to "Accumulator Repair", Section "L".
SERVICE BRAKE TREADLE VALVE
The Service Brake Treadle Valve Assembly (Figure 3-2)
consists of a pedal assembly and two modulating, pilot
applied valves to apply the front and rear brakes of the
truck. The right valve (as assembly is mounted in
cab) controls the front and rear brakes and the left
valve controls the rear brakes only. It receives oil sup-
ply from the two brake accumulators, allowing the
pressure to be modulated from 0 - 1350 psi (0 - 9.3
MPa).
The bushing mounted pedal is attached to a base using
two threaded studs, which allows the pedal to move
when depressed by the operator for brake application.
Two trunnion mounted rollers are centered over the
two piston apply rods. When the pedal is depressed for
brake application, the piston apply rods push the pis-
tons in the valve body down, allowing pressurized oil
to pass to the front and rear brake assemblies.
Removal
Before removing any brake lines or brake circuit
components, be sure brake accumulators are bled
down. To bleeddown accumulators:
Turn key switch "OFF", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Accumulator Discharge Valve handles
counterclockwise to open. Wait at least 90
seconds to let accumulators bleed down.
When brake accumulators are completely
bled down, close accumulator discharge
valves by turning handles clockwise.
Do not leave open.
FIGURE 3-2. SERVICE BRAKE TREADLE VALVE
(As Viewed From Front Of Truck)
1. Pedal 8. Rear Brake Apply Port
2. Roller 9. Capscrews (eight)
3. Snap Ring 10. Plug (two)
4. Threaded Stud 11. Front Brake Apply Port
5. Push Rod Assembly 12. Capscrews (four)
6. Valve Body 13. Pedal Stop
7. Brake Manifold 14. Pin
J3-2 Brake Circuit Component Service J03011 8/90
1. After draining accumulators, indentify and tag all
hose and wire connections to brake manifold and
service brake treadle valve assembly for correct
installation during assembly.
2. Disconnect all hoses and wires from assembly.
Cap and plug all hoses and ports to prevent entry
of contamination.
3. Support treadle valve assembly. Remove all cap-
screws, nuts and washers used to mount treadle
valve assembly to the cab deck. Lower valve and
brake treadle valve as an assembly. Move assem-
bly to a clean work area.
Installation
Brake pedal must be properly adjusted and deliv-
ery pressure must be checked before placing truck
in service. Refer to "Adjustment for Maximum De-
livery Pressure" procedure.
1. Position service brake treadle valve assembly onto
cab deck. Install capscrews, washers and nuts
securing valve assembly to cab deck. Tighten
capscrews to standard torque.
2. Connect wires to solenoids as previously tagged.
3. Uncap and connect hoses to all ports. Tighten
securely to prevent high pressure leakage.
4. Refer to steps 14 and 15, "Brake Circuit Checkout
Procedure", this section.
5. Start engine and allow system to fully charge.
Bleed both front and rear brakes. Refer to "Brake
Bleeding" procedures, this section.
6. Check brake circuit apply pressures. Refer to
steps 23 -- 27, "Brake Circuit Checkout Proce-
dure", this section.
DISASSEMBLY OF TREADLE VALVE ASSEMBLY
Removal of Brake Manifold
1. Before any disassembly and with Treadle Valve
Assembly positioned as mounted in cab (pedal
toe pointing up and away), mark both valves and
their positions on the treadle base plate. Mark
valves as Right and Left.
2. Remove the eight capscrews (9, Figure 3-2)
mounting treadle valve assembly (6) to brake
manifold (7). Place manifold in a clean work area.
FIGURE 3-3. REMOVING TREADLE ASSEMBLY
1. Capscrews and Washers
2. Brake Manifold 3. O-Rings
J03011 8/90 Brake Circuit Component Service J3-3
FIGURE 3-4 . VALVE DISASSEMBLY
1. Boot 3. Pushrod
2. Spring
FIGURE 3-5. VALVE DISASSEMBLY
1. Pilot Housing 3. Capscrews
2. Modulating Housing 4. O-Ring
FIGURE 3-6. VALVE DISASSEMBLY
1. Pilot Piston 3. O-Rings
2. Pilot Housing 4. Back-Up Rings
FIGURE 3-7. VALVE DISASSEMBLY
1. Apply Plunger 4. Modulation Housing
2. O-Ring 5. Shims
3. Spring
FIGURE 3-8. VALVE DISASSEMBLY
1. Snap Ring 4. Regulating Piston
2. Spring Retainer 5. Sleeve
3. Snap Ring 6. Spring
J3-4 Brake Circuit Component Service J03011 8/90
NOTE: O-rings (3, Figure 3-3) are placed between the
brake mainfold and treadle valve bodies. Remove and
discard.
3. Remove threaded studs (4) and pedal (1). Inspect
for worn or damaged parts, particularly pedal
bushings.
4. Remove four capscrews (12) and separate valve
bodies from pedal assembly.
5. Brake valve(s) can now be serviced.
Brake Valve Disassembly
During servicing, the right and left brake valves should
be serviced separately and their components should
not be interchanged.
NOTE: During disassembly, do not scratch or mar
housing or O-ring grooves.
1. Remove boot (1, Figure 3-4) pushrod (3) and
spring (2).
2. Match mark pilot housing (1, Figure 3-5) and
modulation housing (2).
3. Remove capscrews (3) connecting the pilot hous-
ing to modulating housing and separate the hous-
ings.
4. Push pilot piston (1, Figure 3-6) from pilot hous-
ing(2).
5. Remove O-rings (3) and backup rings (4) from pilot
housing.
6. Remove apply plunger (1, Figure 3-7) O-ring (2)
and spring (3) from the modulation housing (4).
Observe shims (5) between spring and plunger
and maintain this arrangement.
7. Depress spring retainer (2, Figure 3-8), remove
snap ring (1), remove spring retainer.
8. Remove snap ring (3), regulating piston (4), sleeve
(5) and spring (6).
9. Remove plug (1, Figure 3-9), guide (4), washer (6)
and spring (3).
10. Pull out cage spacer (5) and ball assembly (9).
11. Remove all seals, O-rings and backup rings from
all pieces and discard.
ASSEMBLY OF TREADLE VALVE ASSEMBLY
Brake Valve Assembly
If repair of valve requires replacement of internal
components other than seals, test equipment will
be required for proper adjustment of maximum
delivery pressure.
NOTE: In following assembly, do not scratch or mar
housing or O-ring grooves.
1. Clean and inspect all parts for wear; replace any
damaged parts. Use all new O-rings and backup
rings. Lubricate all parts with clean C-3 hydraulic
oil.
2. Install O-ring (2, Figure 3-10) on ball assembly
guide (1). Install ball assembly into housing.
FIGURE 3-9. VALVE DISASSEMBLY
1. Plug 6. Washer
2. O-Ring 7. Seal
3. Spring 8. Backup Ring
4. Guide 9. Ball Assembly
5. Cage Spacer
J03011 8/90 Brake Circuit Component Service J3-5
3. Install backup ring (4) on regulating piston toward
roll pin (7). Install seal (3) with lip pointing away
from roll pin.
4. Install regulating piston (6) inside of regulating
piston sleeve (5).
5. Place backup ring (8) and O-ring (9) on regulating
piston sleeve. Backup ring toward shoulder of
sleeve. Install spring (10) and regulating piston
assembly in housing. Retain assembly by install-
ing snap ring (1, Figure 3-11).
6. Install backup ring (8, Figure 3-9) toward head of
plug (1). Install seal (7) with lip pointing away from
head of plug.
7. Place O-ring (2, Figure 3-9) on O.D. of plug (1).
8. Place washer, (6) spring (3) and guide (4) in plug
(1).
9. Insert cage (5) into housing. Install plug assembly
in housing.
10. Place washer (2, Figure 3-11) on regulating piston,
depress against spring, install snap ring (3).
11. Install O-ring (7) in housing (8).
FIGURE 3-10. VALVE ASSEMBLY
1. Ball Assembly Guide 6. Regulating Piston
2. O-Ring 7. Roll Pin
3. Seal 8. Backup Ring
4. Backup Ring 9. O-Ring
5. Reg. Piston Sleeve 10. Spring
FIGURE 3-11. VALVE ASSEMBLY
1. Snap Ring 5. Shims
2. Washer 6. Apply Plunger
3. Snap Ring 7. O-Ring
4. Spring 8. Housing
FIGURE 3-12. VALVE DISASSEMBLY
1. Pilot Piston 3. O-Rings
2. Pilot Housing 4. Back-Up Rings
J3-6 Brake Circuit Component Service J03011 8/90
If no valve components are replaced other than
seals, use same shim pack that came out of apply
plunger. If springs or components were replaced,
refer to "Adjustment for Maximum Delivery Pres-
sure" procedure to determine a new shim pack.
12. Place spring (4) shims (5) and apply plunger (6) in
housing (8).
13. Install backup rings (4, Figure 3-12) and O-rings
(3) in bore of pilot housing (2) and on pilot piston
(1) as shown.
14. Install pilot piston (1) in housing.
15. Install O-rings (4, Figure 3-13) in pilot housing.
Align match marks so pilot port from modulating
housing (2) matches pilot port of pilot housing (1).
16. Install the capscrews through pilot housing into
modulation housing. Tighten capscrews to 32-37
ft. lbs. (43.4-50.2 N.m) torque.
17. Install push rod (3, Figure 3-14), spring (2) and
rubber boot (1).
Installation of Brake Manifold
1. Install both brake valves onto treadle assembly.
Install capscrews and washers (12, Figure 3-2).
Tighten capscrews to 35-40 ft. lbs. (47.5-54.2
N.m) torque.
2. Install brake pedal (1), if removed. Install threaded
studs (4). Tighten capscrews to 30-50 ft. lbs.
(40.7- 67.8 N.m) torque. Do not over tighten.
3. Brake pedal should travel freely and must be
properly adjusted. Refer to "Brake Pedal Adjust-
ment" procedure, this section.
4. Install new O-rings (3, Figure 3-3) between brake
valves and brake manifold (2).
5. Install the eight capscrews (9, Figure 3-2) securing
brake manifold to brake valves. Tighten cap-
screws to standard torque.
ADJUSTMENT FOR MAXIMUM
DELIVERY PRESSURE
If any valve components other than seals are re-
placed, a new shim pack must be determined.
NOTE: A 2250-2400 psi (15.7-16.8 MPa) regulated hy-
draulic pressure source is required for this procedure.
FIGURE 3-13. VALVE DISASSEMBLY
1. Pilot Housing 3. Capscrews
2. Modulating Housing 4. O-Ring
FIGURE 3-14 . VALVE DISASSEMBLY
1. Boot 3. Pushrod
2. Spring
J03011 8/90 Brake Circuit Component Service J3-7
1. Install original shim pack (2, Figure 3-15) between
spring (4) and plunger (3).
2. Bolt an adapter block (5) and O-rings (7) to modu-
lation section of valve. Refer to Section "M" for
adapter block.
3. Attach pressure source to supply port (8) and a
return line to return port (6).
4. Using a C-clamp, vise or other means, apply valve
so that plunger (3) bottoms on valve section hous-
ing.
5. Install a 0-3000 psi (0-21 MPa) pressure gauge in
delivery port (1).
6. Direct supply pressure to brake valve. Observe
pressure in delivery port. Delivery port pressure
should be 1300 -- 1400 psi (9.1 -- 9.8 MPa) for either
right or left valve. Pressures for both valves must
be within 100 psi (0.7 MPa) of each other.
7. If delivery pressure is below these ranges, add
shims. If delivery pressure is above these ranges,
remove shims. Each 0.005 in. (0.127 mm) shim will
change the pressure approximately 100 psi (0.7
MPa).
FIGURE 3-15. VALVE PRESSURE ADJUSTMENT
1. Delivery Port 5. Adapter Block
2. Shim Pack 6. Return Port
3. Plunger 7. O-Ring
4. Spring 8. Supply Port
FIGURE 3-16. VALVE ASSEMBLY
1. Plug 6. Washer
2. O-Ring 7. Seal
3. Spring 8. Backup Ring
4. Guide 9. Ball Assembly
5. Cage Spacer
J3-8 Brake Circuit Component Service J03011 8/90
BRAKE PEDAL ADJUSTMENT
Brake pedal must be properly adjusted and deliv-
ery pressure must be checked before placing truck
in service.
1. Remove plug (1, Figure 3-16), spring (3) and guide
(4) from both valves. Do not allow parts to become
intermixed between valves.
NOTE: Pedal free travel must be set if maximum deliv-
ery pressure has been adjusted. Approximately 0.094
in. (2.4 mm) must be available before piston contacts
ball assembly with pedal in non-apply position. This
distance can be determined by measuring the dis-
tance the apply stem moves before the piston contacts
the ball assembly. By removing apply line, the free
travel can be observed and measured through the
brake apply port.
2. Hold the ball (1, Figure 3-17) against the seat (2)
of one valve.
3. Depress pedal until internal contact is felt against
ball.
4. Through the open brake apply port, measure the
distance the apply stem (3) travels. It should travel
0.094 in. (2.4 mm) before contact is felt.
5. To make apply stem adjustment, unlock locknut
on stop screw located under heel of brake pedal.
Turning the stop screw in will increase the free
play; turning the stop screw out will decrease the
free play.
6. Repeat Steps 1 through 5 for other valve.
7. Install the plugs, springs, and guides into their
respective valves.
8. Hold pedal in fully apply position and maintain
pedal position. Observe both plungers through
brake apply ports.
NOTE: When pedal is applied, both plungers must
bottom out together to be sure that full brake pressure
will be achieved.
FIGURE 3-17. BRAKE PEDAL ADJUSTMENT
1. Ball 3. Apply Stem
2. Seat
J03011 8/90 Brake Circuit Component Service J3-9
SERVICE BRAKE TREADLE PEDAL
Pedal Disassembly
NOTE: If any components in the service brake treadle
pedal are replaced. maximum delivery pressure
should be checked and adjusted.
Refer to "ADJUSTMENT FOR MAXIMUM DELIVERY
PRESSURE", this section.
1. Separate the pedal (9, Figure 3-18) and base (1)
by removing both studs (17) from base.
Thoroughly inspect pedal assembly for worn or
damaged parts. Pay particular attention to the
bushings (8). If further disassembly is necessary,
continue with pedal disassembly procedures.
2. Loosen the set screw (6), but do not remove.
Remove shoulder bolt (7). Trunnion assembly
(11) and washers (10) can then be removed.
3. Remove the retaining rings (14) and rollers (13)
from pin (12). Remove pin (12) from trunnion (11).
4. Use an arbor press to replace bushings (8) with
new bushings.
5. It is not necessary to loosen or remove cap screw
(15) or jam nut (16).
6. Remove the push rod (5), and boots, (4) from main
assembly.
Pedal Assembly
NOTE: During assembly, coat the following parts with
a clean multi-purpose grease; push rods (5, Figure
3-18), bushing (8), shoulder bolt (7), washers (10), and
pin (12).
1. Install new boots (4), push rod (5), in the valve
assembly.
2. Insert pin (12) into the trunnion (11). Attach rollers
(13) and the retaining rings (14) to both ends of
pin (12).
3. Attach trunnion assembly (11) and washers (10)
to pedal (9) using shoulder bolt (7).
NOTE: Shoulder bolt (7) must not be over tightened.
Trunnion (11) must be free to move.
4. Tighten set screw (6) locking the shoulder bolt in
place.
5. Use an arbor press to replace bushings (8) with
new bushings.
6. Apply a medium strength Loctite to threads of
studs (17).
7. Align pedal (9) between ears of base (1) and install
studs (17). Tighten capscrews to 30-50 ft.lbs.
(40.7-68 N.m) torque.
FIGURE 3-18. SERVICE BRAKE TREADLE
PEDAL ASSEMBLY
1. Base 10. Washer (Two)
2. Washer (Four) 11. Trunnion
3. Capscrew (Four) 12. Pin
4. Rubber Boot (Two) 13. Rollers (Two)
5. Push Rod (Two) 14. Retaining Rings (Two)
6. Set Screw 15. Capscrew
7. Shoulder Bolt 16. Jam Nut
8. Bushing (Two) 17. Studs (Two)
9. Pedal
J3-10 Brake Circuit Component Service J03011 8/90
RETARDER TREADLE VALVE
The retarder treadle valve (Figure 3-19) is a single
modulating hydraulic valve used to apply rear brakes
only. When the pedal is depressed, the operator can
modulate applied pressure from 0 -- 1150 psi (0 --8.05
MPa). Oil from the small brake accumulator will shift
the service brake treadle valve/retarder shuttle valve
(blocking off passage of oil back to the service brake
treadle valve) and apply the rear brakes only.
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleeddown accumulators:
Turn key switch "OFF" and shut down en-
gine and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no movement
should occur.
Bleed down brake accumulators by turn-
ing Accumulator Discharge Valve handles
counterclockwise to open. Wait at least 90
seconds to let accumulators bleed down.
When brake accumulators are completely
bled down, close accumulator discharge
valves by turning handles clockwise.
Do not leave open.
Removal
1. Be certain accumulators have been bleddown.
2. Tag all hydraulic lines and their ports (35, 36, 37,
Figure 3-19).
3. Remove and cap hydraulic lines to prevent dirt
entry.
4. Support the valve from below cab, and remove
capscrews (30) from pedal mounting plate.
5. Carefully remove valve from pedal assembly.
NOTE: Maintain the shim stack as found and remove
from top of apply spring.
6. Shim stack can be reused, if only O-rings and
backup rings are being replaced.
Installation
1. Support valve body and align holes with pedal
assembly base. Valve ports (35, 36, 37, Figure
3-19) will be facing towards the rear of truck.
2. Place capscrews and washers (30) into valve body
and tighten to 35-40 ft.lbs. (47.5-54.2 N.m)
torque.
3. Uncap hydraulic lines and connect to proper
ports. Tighten securely to prevent leakage.
4. Bleed rear brakes. Refer to "Rear Brake Bleeding
Procedure", this section.
5. Refer to Step 10. in "Check-out Procedure" for
retarder apply pressure setting.
Disassembly
1. Remove ring (1, Figure 3-20) and boot (2) from
housing (16).
2. Remove piston (3), shim or shims (4) and spring
(5) from housing bore. Note the number of shims
being removed from housing.
3. Remove O-ring (6) from housing bore.
NOTE: Do not scratch or mar housing bore.
4. Remove retaining ring (7), retainer (8), and retain-
ing ring (9) from housing bore.
5. Remove the piston and sleeve assembly (10 &
14)from housing bore. Separate piston (14) from
sleeve (10).
6. Remove O-ring (12) and the backup ring (11) from
sleeve (10).
7. Remove spring (15) from the piston (14).
8. Remove cup (13) from the piston (14).
A check ball is located inside the piston (14). Make
sure ball is clean and moving freely.
9. Remove plug (26) from the housing (16).
10. Remove O-ring (25), cup (23) and back-up ring
(24) from the plug (26).
11. Remove washer (22), spacer (21), spring (20) and
guide (19) from the housing bore.
12. Remove valve & ball assembly (18) from the hous-
ing bore.
13. Remove O-ring (17) from the valve & ball assembly
(18).
J03011 8/90 Brake Circuit Component Service J3-11
FIGURE 3-19.
RETARDER TREADLE VALVE
1. Shims
2. O-Ring
3. O-Ring
4. Retaining Ring
5. Piston
6. Sleeve
7. Backup Ring
8. O-Ring
9. Spring
10. O-Ring
11. Sleeve
12. Spring
13. Cup
14. O-Ring
15. Plug
16. Backup Ring
17. Housing
18. Washer
19. Guide
20. Ball
21. Seat
22. Guide
23. Stem
24. Cup
25. Pin
26. Ball
27. Retainer Ring
28. Retainer
29. Spring
30. Capscrew and Washer
31. Apply Plunger
32. Pin and Retainer Ring
33. Pedal
34. Stopscrew and Locknut
35. Drain Port
36. Brake Apply Port
37. Accumulator Port
J3-12 Brake Circuit Component Service J03011 8/90
Assembly
1. Install O-ring (17, Figure 3-20) on the valve & ball
assembly (18) and insert into the housing bore.
Note the direction of valve & ball assembly.
2. Install spacer (21)into the housing bore.
3. Install O-ring (25) on plug (26).
4. Insert back-up ring (24) and cup (23) inside end of
plug (26). Note the order of back-up ring and cup.
5. Install guide (19), spring (20) and washer (22) in
plug (26). Place plug in the housing bore.
6. Install cup (13) on piston (14) and insert into sleeve
(10). Note direction of piston and sleeve.
7. Install back-up ring (11) and O-ring (12) on sleeve
(10).
8. Install spring (15) on the piston (14).
9. Install piston and sleeve assembly (10 & 14) into
housing bore. Note the direction of assembly.
10. Install retaining ring (9),retainer (8), and retaining
ring (7) in the housing bore.
NOTE: Do not mar or scratch housing bore.
11. Install O-ring (6) into housing bore.
12. Install spring (5), shim or shims (4) and piston (3)
in housing bore.
For proper brake pressure setting, install the same
number of shims that were removed during disas-
sembly.
13. Install boot (2) and ring (1) into housing (16).
FIGURE 3-20. RETARDER TREADLE VALVE
1. Ring 14. Piston
2. Boot 15. Spring
3 . Piston 16. Housing
4. Shims (as required) 17. O-Ring
5. Spring 18. Valve & Ball Assembly
6. O-Ring 19. Guide
7. Retaining Ring 20. Spring
8. Retainer 21. Spacer
9. Retaining Ring 22. Washer
10 . Sleeve 23. Cup
11. Back-up Ring 24. Backup Ring
12. O-Ring 25. O-Ring
13. Cup 26. Plug
J03011 8/90 Brake Circuit Component Service J3-13
Retarder Treadle Pedal Disassembly
1. Separate the pedal (6, Figure 3-21) and base (11)
by removing one E-ring (4) from pin (5) and sliding
the pin from base.
2. Loosen the set screw (2) enough to slide pin (1)
from the pedal (6). Do not drop the roller (3) while
removing pin.
3. It is not necessary to loosen or remove cap screw
(9) or locknut (10) from base.
Retarder Treadle Pedal Assembly
NOTE: Lightly coat pins (1 & 5, Figure 3-21) and roller
(3) with a clean multi-purpose grease.
1. Align the roller (3) between ears of the pedal (6)
and insert pin (1). Note direction of the pin.
Grooved end of pin should line up with set screw
(2).
2. Tighten set screw (2) so it holds pin (1) in place.
3. Align pedal (6) between the ears of base (11) and
insert pin (5). Install E-ring (4).
4. Assemble pedal assembly and valve assembly
using cap screws (7) and washers (8). Tighten
capscrews to 35-40 ft.lbs. (47.5-54.2 N.m)
torque.
FIGURE 3-21. RETARDER TREADLE PEDAL
1. Pin 7. Capscrews
2. Set screw 8. Washers
3. Roller 9. Capscrew
4. E-ring 10. Locknut
5. Pin 11. Base
6. Pedal
J3-14 Brake Circuit Component Service J03011 8/90
BRAKE CIRCUIT CHECKOUT PROCEDURE
The brake circuit hydraulic pressure is supplied from
the steering pump and brake accumulators. Some
brake system problems, such as spongy brakes, slow
brake release, or abnormal operation of the instrument
panel mounted "Low Brake Pressure" warning light can
sometimes be traced to internal leakage of brake com-
ponents. If internal leakage is suspected, refer to Brake
Circuit Component Leakage Test.
NOTE: If internal leakage within the steering circuit is
excessive, this also may contribute to problems within
the brake circuit. Be certain that steering circuit leak-
age is not excessive before troubleshooting brake
circuit. For Steering Circuit Test Procedure, refer to
Section "L", Hydraulic System.
The steering circuit can be isolated from the brake
circuit by removing the brake supply line from the
distribution manifold to the brake accumulators (see
WARNING). Plug the brake supply lines and cap the
port in the distribution manifold.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury, and pos-
sibly death, if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or installing
test gauges, ALWAYS bleed down hydraulic steer-
ing and brake accumulators.
The steering accumulator can be bled down with en-
gine shut down, turning key switch "Off", and waiting
90 seconds. Confirm the steering pressure is released
by turning the steering wheel - No front wheel move-
ment should occur. Open both bleeddown valves on
low pressure brake detection module to bleed down
brake accumulators.
Before disabling brake circuit, be sure truck wheels are
blocked to prevent possible rollaway.
Included as the last page of this Checkout Procedure
is a Data Sheet to record the information observed
during the hydraulic brake system checkout proce-
dure. The data sheet is designed to be removed, cop-
ied, and used during the checkout procedure.
* Steps indicated in this manner should be
Recorded on the Data Sheet for reference.
The following equipment will be necessary to properly
check out the hydraulic brake circuit.
a. Hydraulic schematic, refer to Section "R".
b. Calibrated pressure gauges:
Three 0-5000 psi (0-35 mPa) range.
One 0-2000 psi (0-14 mPa) range.
c. One female quick disconnect and hose long
enough to reach from rear brake housing to a
clean container.
d. Accumulator charging kit with gauges and dry
nitrogen.
Circuit "Tracking"
In any hydraulic circuit, it is important that hydraulic
lines be connected to the correct ports, connections
and fittings are free of leaks, valves operate correctly,
and in some cases, in a given sequence. The checking
of these points, along with flow, direction, and timing
of events in a circuit is referenced as "tracking".
J04008 1/93 Brake Circuit Checkout J4-1
INITIAL SYSTEM SET-UP
Prior to checking the brake system, the hydraulic sys-
tem must have proper accumulator nitrogen precharge
pressure and hydraulic oil must be at normal operating
temperature. Refer to Section "L" this manual for steer-
ing system operation procedures and specifications.
Also prior to checking the brake system make sure the
parking brake is properly adjusted. Refer to parking
brake adjustment this section.
With the steering system functioning properly and the
parking brake adjusted, proceed as follows:
1. Turn engine and key switch "Off". Wait 90 seconds
for the steering accumulator to bleed down.
2. Open both brake accumulator bleed down valves.
Verify nitrogen precharge in each accumulator.
Accumulator precharge should be 1050 psi (7.35
mPa). Charge accumulators if necessary.
* Record on data sheet.
NOTE: Always allow nitrogen gas temperature to ap-
proach ambient temperatures before completing pre-
charge procedure. For best resul t s, charge
accumulator in the ambient temperature conditions in
which the truck will be operating.
3. Close both accumulator bleeddown valves.
Brake Valve Leakage
4. Install a 5000 psi (35 mPa) gauge onto the right
hand quick disconnect on the low pressure brake
detection module.
5. Connect a 5000 psi (35 mPa) gauge to the left hand
quick disconnect on the low pressure brake de-
tection module.
6. Install a 5000 psi (35 mPa) gauge to the quick
disconnect on the left (rear) brake valve of the
service brake treadle.
7. Install a 2000 psi (35 mPa) gauge to the quick
disconnect on the right (front) brake valve of the
service brake treadle.
NOTE: The 5000 psi (35 mPa) gauges attached in steps
4 and 5 are measuring front and rear brake accumula-
tor pressures.
7. Set park brake.
8. Release brake lock.
9. Start engine and allow accumulators to charge to
full system pressure.
10. Shut down engine.
* Record brake accumulator pressure readings on
data sheet.
11. Do not operate any controls for 10 minutes. Record
brake accumulator pressure again. Maximum
pressure drop in 10 minutes should not exceed
450 psi (3.1 mPa).
* Record pressure readings on data sheet.
Emergency Brakes
12. At this point, slowly bleed-off pressure from the
front brake accumulator, using the right hand man-
ual bleeddown valve. As front accumulator pres-
sure reaches 2000 50 psi (14 0.3 mPa), the low
brake warning light should illuminate and buzzer
should sound.
* Record pressure reading on data sheet.
13. Continue slowly bleeding-off pressure from the
front brake accumulator. As front brake accumu-
lator reaches 1650 50 psi (11.6 0.3 mPa), the
emergency apply valve should activate.
14. Front and rear brakes should be fully applied
holding a steady 1275 to 1425 psi (8.8 to 9.8 mPa).
* Record pressure readings on data sheet.
NOTE: The brakes can only be released by bleeding
off the brake accumulators or establishing a safe work-
ing pressure in each brake accumulator circuit.
15. Start engine and charge the system.
16. Shut down engine and repeat steps 12 throught 14
bleeding-off the rear brake accumulator using the
left hand manual bleeddown valve. When the
emergency trigger pressure is reached, the front
brakes will be fully applied, holding a steady pres-
sure of 1275 to 1425 psi (8.8 to 9.8 mPa).
* Record pressure readings on data sheet.
Brake Lock
17. Start engine and charge the system.
18. Cycle brake lock several times to assure crisp shift
of solenoid valve and release of pressure.
J4-2 Brake Circuit Checkout J04008 1/93
19. Apply brake lock and read brake pressures. Front
pressure should be zero, and rear brake pressure
should be 1275 to 1425 psi (8.8 to 9.8 mPa) with
brake lock status light illuminated.
20. Turn off brake lock switch and rear brakes should
release with pressure reducing to 0 psi (0 mPa).
* Record pressure readings on data sheet.
BRAKE SYSTEM - FUNCTIONAL
Service Brakes
NOTE: Unless otherwise instructed, perform the fol-
lowing checks with the engine running at half throttle,
park brake applied, and brake lock released.
21. Very slowly depress the service brake pedal and
check circuit tracking. The gauges installed in
steps 6 and 7 should begin to rise simultaneously.
22. With the service brake treadle fully applied, brake
apply pressure to both front and rear brakes
should be 1275 to 1425 psi (8.8 to 9.8 mPa).
Release service brakes and the gauge readings
should return to 0 psi (0 mPa).
* Record pressure readings on data sheet.
NOTE: Brake pedal "feel" should be smooth with no
abnormal noise or mechanical roughness.
23. Slowly depress brake pedal and check to see that
stop lights come on at 100 5 psi (0.7 0.03 mPa).
* Record pressure on data sheet.
24. Quickly and completely depress the brake pedal
and check to see that front and rear brake pres-
sures read pressure obtained in step 22 within
approximately one second and maintain that pres-
sure fora minimum of 20 seconds. Release pedal
and make sure that each circuits pressure is zero.
* Record gauge readings on data sheet.
25. Check to see that all front pads are not tight against
disc. Pads should be loose and moveable by hand.
26. Check brake pedal free play. Refer to "Brake Pedal
Adjustment", Brake Circuit Component Service,
this section.
Retarder
27. Shut down engine and open both brake accumu-
lator bleeddown valves and allow both accumula-
tors to bleed down. Close both bleeddown valves
after pressure in accumulators has been reduced
to zero.
28. Remove both 5000 psi (35 mPa) gauges from the
low pressure brake detection module.
29. Install one 5000 psi (35 mPa) gauge onto pressure
tap provided on retarder treadle valve.
30. Install one 5000 psi (35 mPa) gauge in the park
brake circuit at the auxiliary manifold.
31. Start engine and charge the system.
32. With engine running at half throttle very slowly
depress the retarder treadle valve and check cir-
cuit tracking.
33. Retarder pedal fully depressed brake apply pres-
sure to rear brakes should be 1100 to 1200 psi (7.7
to 8.4 mPa).
* Record pressure reading on data sheet.
NOTE: The pressure gauges on the service brake
treadle valves should remain at 0. If not one of the three
shuttle valves in the circuit may not be functioning
properly.
34. Release the brakes and the brake apply pressure
in the retarder circuit should return to 0 psi (0 mPa).
* Record on data sheet.
Park Brake
35. With engine running and park brake switch in the
"off" position, the park brake should be released
and the warning light off. Read the pressure on the
5000 psi (35 mPa) gauge which was installed with
step 30. Park brake pressure should be 2750 50
psi (9.1 0.4 mPa).
* Record pressure on data sheet.
36. Check park brake to make sure there is a gap
between park brake lining and drum.
* Record gap measurement on data sheet.
NOTE: If park brake is not released, refer to "Parking
Brake Adjustment", this section, and repeat steps 35
and 36.
J04008 1/93 Brake Circuit Checkout J4-3
37. Shut down engine and turn off key switch with the
park brake switch in the "OFF" position. The Steer-
ing bleeddown circuit is activated, discharging the
steering accumulator and the pump outlet pres-
sure which automatically will apply the park brake.
38. Start the engine with the park brake in the "ON"
position. The park brake will remain "ON" along
with the indicator as pressure builds.
39. At low idle, apply the service brakes and slowly shift
the transmission into forward and/or reverse
gears. With the park brake switch in the "ON"
position forward and/or reverse will be inhibited.
40. Turn the park brake switch "OFF" and forward
and/or reverse gears should function after shifting
through neutral.
41. Shut down engine and open both brake accumu-
lator bleeddown valves.
42. Remove all pressure gauges from system.
43. Install a 5000 psi (35 mPa) gauge in the quick
disconnects on both rear brake housings.
44. Close both brake accumulator bleeddown valves,
start engine and charge system.
45. Apply service brake treadle valve and observe
pressure at full apply.
46. Apply retarder brake treadle valve and observe
pressure at full apply.
47. If pressures observed in steps 45 and 46 corre-
spond to pressure previously recorded, then op-
eration of circuit shuttle valves is correct.
NOTE: Defective shuttle valves may affect circuit track-
ing and pressures. Isolating individual valves will aid
in locating a malfunction in that particular circuit.
48. If any readings specified in the preceeding proce-
dure were not within specifications, the reason(s)
for the incorrect pressure(s) must be identified,
corrected and checkout again verified. All read-
ings must be correct and proper circuit operation
present before releasing truck for production.
49. Shut down truck and open manual bleeddown
valves on both brake accumulators.
50. Remove all pressure gauges and fittings which
were installed for brake checkout procedures.
J4-4 Brake Circuit Checkout J04008 1/93
BRAKE CIRCUIT AND SERVICE BRAKE TREADLE VALVE TROUBLESHOOTING
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: The Service Brakes are Locked
Connections to tank and pressure ports reversed.
Tank line is plugged or restricted.
Brake Lock Valve defective.
Emergency Apply Valve defective.
Correct the plumbing.
Remove restriction.
Replace solenoid valve
Replace valve.
TROUBLE: Both Brake Circuits are Dragging
Tank line has back pressure.
Pedal return stop out of adjustment, residual pressure.
Service Brake Treadle Valve pilot port pressurized.
Insure tank line has no back pressure.
Adjust pedal return stop.
Verify proper operation of emergency apply valve.
TROUBLE: One Brake Circuit is Dragging
There is an obstruction in the dual control treadle
subassembly.
Service Brake Treadle Valve is out of balance.
Actuator piston defective.
Service Brake Treadle Valve is defective.
Remove obstruction.
Adjust balance according to instructions.
Replace actuator piston.
Repair or replace Service Brake Treadle Valve.
TROUBLE: The Brakes are Not Going to Full Pressure
Pedal stop out of adjustment.
Internal malfunction of modulating section of Service
Brake Treadle Valve.
The supply pressure is low.
Improper shimming inside Service Brake Treadle
Valve.
Shuttle valve(s) in retarder/rear brake circuit defective.
Adjust pedal stop.
Remove, disassemble, clean, and reassemble Service
Brake Treadle Valve.
Check pump system and accumulators.
Reshim Service Brake Treadle Valve according to
instructions.
Obstruction in shuttle valve. Isolate shuttle valves to
determine defective valve. Disassemble and clean or
replace valve.
J04008 1/93 Brake Circuit Checkout J4-5
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system.
Brake accumulators bleed down.
Low pressure sensing shuttle valve defective.
Check wiring.
Valve Open.
Replace valve.
TROUBLE: A Low Brake Pressure Warning Occurs When Brakes are Applied
There is a leak or other malfunction in one brake circuit.
Low pressure sensing shuttle valve defective.
Shuttle valve(s) in retarder/rear brake circuit defective.
Inspect brake system.
Replace valve.
Obstruction in shuttle valve. Isolate shuttle valves to
determine defective valve. Disassemble and clean or
replace valve.
TROUBLE: Low Retarder Brake Pressure
Retarder pedal stop out of adjustment.
Internal malfunction of modulating section of retarder
valve.
Supply pressure low.
Improper shimming inside retarder valve.
Shuttle valve(s) in retarder/rear brake circuit defective.
Adjust pedal stop.
Remove, disassemble, clean and reassemble retarder
control valve.
Check pump system and accumulators.
Reshim retarder valve according to instructions.
Obstruction in shuttle valve. Isolate shuttle valves to
determine defective valve. Disassemble and clean or
replace valve.
TROUBLE: Indication of Excessive Brake Temperature (Warning Light On or Gauge Reading High)
Brakes dragging.
Low oil level in hydraulic tank.
High oil level in hydraulic tank.
Restriction in heat exchanger.
Truck being operated in improper transmission range.
See Trouble/Cause/Action previous page.
Fill hydraulic tank to proper level.
Drain hydraulic tank to proper level.
Repair or replace heat exchanger.
Refer to Grade/Speed Chart and select proper trans-
mission operating range.
TROUBLE: Low Pressure Warning Light Not Operating Properly
The bulb is burned out.
The circuit is open.
Pressure switch defective.
Low pressure sensing shuttle valve defective.
Replace the bulb.
Check the wiring.
Replace the pressure switch.
Replace valve.
J4-6 Brake Circuit Checkout J04008 1/93
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Low Pressure Warning Light is On Even Though System Pressure is Proper
Short in electrical system.
Pressure switch is defective.
Check wiring.
Replace pressure switch.
TROUBLE: Low Pressure Warning Light Comes On and Pressure is Low
Accumulator Bleeddown valves open.
Charging circuit is malfunctioning.
Restriction in hydraulic filter(s)/heat exchanger.
The pump is worn.
Close Valves.
Check charging circuit.
Repair or replace hydraulic filter(s)/heat exchanger.
Rebuild or replace pump.
TROUBLE: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open.
Accumulator precharge is low.
Leak in one circuit, external or internal.
Malfunction in Service Brake Treadle Valve .
Accumulator check valves leaking.
Check plumbing.
Close valve, check precharge.
Check plumbing; circuit leakage.
Remove, disassemble, clean, reassemble; or replace.
Replace check valve.
TROUBLE: A "Squeal" is Heard When Retarder or Service Brake Treadle Valve is Operated
Rapid operation of controller.
Service Brake Treadle Valve assembly is damaged.
Hydraulic oil is too hot.
Normal.
Replace the Service Brake Treadle Valve assembly.
Check hydraulic system cooling.
TROUBLE: The Output Pressure At Controller is Correct but Brakes are Not Applying
Shuttle valve(s) in Retarder/Brake Circuit defective.
Brake lines are blocked or improperly connected.
Obstruction in shuttle valve. Isolate shuttle valves to
determine defective valve. Disassemble and clean or
replace valve.
Check plumbing.
TROUBLE: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in Service Brake Treadle Valve.
Damage in Service Brake Treadle Valve assembly.
Will require disassembly and cleaning.
Replace Service Brake Treadle Valve assembly.
J04008 1/93 Brake Circuit Checkout J4-7
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Oil is Leaking Around the Pedal Base
Defective seal on the top of treadle valve. Replace the seal.
TROUBLE: Oil is Leaking Between the Service Brake Treadle Valve Body Sections
Service Brake Treadle Valve pilot and modulating
sections not bolted tightly together.
Defective O-ring(s) between valve sections and brake
manifold.
Remove mounting plate from valve body and tighten
capscrews joining pilot and modulating sections to-
gether.
Replace the O-ring(s).
TROUBLE: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Leak in hydraulic system.
Accumulators precharge too high or too low.
Service Brake Treadle Valve plumbed incorrectly.
Internal leakage in Service Brake Treadle Valve
assembly.
Pump is worn.
Check hydraulic system for leaks.
Check accumulator precharge.
Correct plumbing.
Replace Service Brake Treadle Valve assembly.
Rebuild or replace pump.
TROUBLE: The Parking Brake is Locked
Parking brake solenoid is de-energized.
Parking brake solenoid coil defective.
Parking brake solenoid valve defective.
Park brake linkage improperly adjusted.
Check power to solenoid.
Replace coil.
Replace solenoid valve.
Adjust park brake linkage according to instructions in
service manual.
J4-8 Brake Circuit Checkout J04008 1/93
HAULPAK
CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
MACHINE MODEL UNIT NUMBER SERIAL NUMBER
I. INITIAL SYSTEM SET-UP
Operate Hydraulic System to obtain normal operating temperature.
Refer to Check-out Procedures.
STEP 2 Brake Accumulators charged to 1050 psi (7.3 mPa).
II. SERVICE BRAKE SYSTEM CHECK-OUT
Refer to appropriate Service Manual procedures and Bleed brakes.
Brake Valve Leakage
STEP 10 Front brake accumulator pressure.
Rear brake accumulator pressure.
STEP 11 Front brake accumulator pressure after 10 minutes.
Rear brake accumulator pressure after 10 minutes.
STEP 12 Front accumulator- pressure for warning light.
STEP 14 Front accumulator- pressure for emergency apply.
Front brakes- apply pressure.
Rear brakes- apply pressure.
STEP 16 Rear accumulator- pressure for warning light.
Rear accumulator- pressure for emergency apply.
Front brakes- apply pressure.
Brake Lock
STEP 19 Brake lock applied- front brake circuit.
Brake lock applied- rear brake circuit.
Brake lock off- front brake circuit.
Brake lock off- rear brake circuit.
J04008 1/93 Brake Circuit Checkout J4-9
HAULPAK
CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
(Continued)
Service Brakes
STEP 22 Front brake circuit- full apply.
Rear brake circuit- full apply.
Front brake circuit- pedal released.
Rear brake circuit- pedal released.
STEP 23 Pressure at which stop lights come on.
STEP 24 Front brake pressure within one second.
Rear brake pressure within one second.
Retarder
STEP 33 Retarder circuit- full apply.
Retarder circuit- pedal released.
Park Brake
STEP 35 Park brake circuit- released.
Park brake indicator light off- released.
STEP 36 Gap between park brake lining and drum.
Name of Mechanic or Inspector Doing Check-Out
J4-10 Brake Circuit Checkout J04008 1/93
FRONT WHEEL SPEED DISC BRAKES
The front brakes consist of two brake calipers per
wheel. Each caliper has two lining assemblies. There
are no adjusters in the caliper piston assemblies. Each
brake caliper has three bleeders. The brake calipers
with the linings, weigh approximately 140 lbs. (63.6 kg).
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleeddown accumulators:
Turn key switch "Off", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Accumulator Discharge Valve handles
counterclockwise to open. Wait at least 90
seconds to let accumulators bleed down.
When brake accumulators are completely
bled down, close accumulator discharge
valves by turning handles clockwise.
Do not leave open.
Lining Replacement On Truck
1. Remove tires. Refer to "Tire Removal", Section "G".
2. Inspect brake linings (1, Figure 5-1) for wear.
Linings must be replaced when worn to minimum
of 0.100 in. (2.5 mm) from back plate.
3. Observe brake disc wear. Refer to Figure 5-2 for
maximum disc wear. To replace brake disc, refer
to Section "G", Front Wheel Hub Removal.
4. Remove lining retainer capscrews (1, Figure 5-3)
and retainer (2) on each side of disc.
5. Pry against linings to force pistons back into cali-
per.
6. Remove linings from caliper.
7. After linings have been removed, check wiper
seals, they should be soft and pliable. If hard or
torn, caliper must be removed for rebuild.
8. Install new linings.
9. Install retainer (2), apply Loctite 271 to retainer
capscrews (1). Tighten capscrews to 170 ft.lbs.
(230 N.m) torque.
10. Check that linings move freely between retainers.
11. Install tires. Refer to Section "G" for tire installation.
Before placing truck in production, linings must be
burnished. Refer to "Service Brake Burnishing"
Procedure.
FIGURE 5-1. DISC BRAKE LININGS
FIGURE 5-2.DISC WEAR SPECIFICATIONS
FIGURE 5-3. BRAKE CALIPER ASSEMBLY
1. Capscrew 3. Bleeder Valve
2. Lining Retainer
J05008 8/90 Front Disc Brakes J5-1
BRAKE CALIPER REPAIR
Removal
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleeddown accumulators:
BLOCK WHEELS OF TRUCK!
Turn key switch "Off", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Bleeder Valve handles counterclock-
wise to open. When accumulators are
completely bled down, close bleeder
valves by turning Bleeder Valve handles
clockwise. Do not leave open.
1. Clean brake caliper and spindle area thoroughly
before tire removal.
2. Remove tires. Refer to Section "G" for Tire Removal
Procedure.
3. Be sure brake accumulators are bled down. Dis-
connect brake line to caliper and plug line to
prevent contamination.
4. Remove lining retainer capscrews (1, Figure 5-4)
and retainers (2). Remove linings (4).
5. Install a lift eye bolt into retainer capscrew hole.
6. Brake calipers weigh approximately 140 lbs.
(63.6 kg). Attach lifting device to eye bolt which
was previously placed in retainer capscrew hole.
Take up slack.
7. Remove caliper mounting capscrews (5).
8. Lift caliper away from disc and take to work bench.
Installation
1. Install caliper without lining onto mounting struc-
ture. Tighten mount capscrews (5, Figure 5-4) to
1050 ft.lbs. (1424 N.m) torque. Remove eye bolt.
2. Pry pistons back completely into caliper housing.
Do not damage dust covers.
3. Install lining assemblies (4) retainers (2) and apply
Loctite 271 to retainer capscrews (1). Tighten to
170 ft.lbs. (230 N.m) torque.
4. Check that linings move freely in retainers and
caliper assembly.
5. Connect brake lines to brake caliper.
6. Bleed brakes, refer to "Front Brake Bleeding Pro-
cedure", this section.
7. Install tires. Refer to "Tire Removal", Section "G".
8. If new linings replaced the old linings, the new
linings must be burnished before placing truck
back into service. See "Brake Burnishing Proce-
dure" in this section.
Piston And Seal Removal
1. Brake calipers must be removed for Piston and
Seal Removal. See "Brake Caliper Repair" for re-
moval procedure.
2. Remove cylinder heads (1, Figure 5-5) and pistons
(2).
3. Remove O-rings (3), from cylinder heads (1).
4. Remove all wipers (4), O-rings (5) and back up
rings (6) from each piston bore of caliper and
discard.
FIGURE 5-4.BRAKE CALIPER INSTALLATION
1. Capscrew 4. Lining
2. Lining Retainer 5. Capscrew
3. Bleeder Valve
J5-2 Front Disc Brakes J05008 8/90
Piston and Seal Installation
1. Clean all parts thoroughly and inspect for service-
ability.
2. Polish any minor scratches from pistons and cali-
per bores.
3. Using new O-rings, backup rings and wipers,
lightly coat all parts with clean C-3 hydraulic oil.
4. Install O-rings (5, Figure 5-5), backup rings (6) and
wipers (4) into each bore of caliper. Install backup
rings toward lining side of seal grooves.
5. Lightly coat pistons (2) with clean C-3 hydraulic oil
and install from lining side of bores.
6. Install O-rings (3) on cylinder heads.
7. Install cylinder heads (1) and tighten to 75 ft.lbs.
(101 N.m) torque.
8. Install bleeder valves (7), if removed.
BRAKE CALIPER BENCH TEST
The purpose of this test is to be certain that overhaul
of the calipers was performed satisfactorily. Any leak-
age found during this test must be corrected before
installing on truck.
A hydraulic supply with sufficient volume and pressure
capacity to extend piston assemblies will be necessary.
A gauge of 0-2000 psi (0-14MPa) should be placed in
the output line of the hydraulic source.
Fabricate a block to simulate brake disc. Use lining
backing plate as a template. Thickness of test block
should be 0.625 in. (18.8 mm) thick.
1. Secure brake caliper assembly in vise or other
holding fixture.
2. Install new linings and brake disc block.
Be sure test block is securely retained in caliper
head before applying pressure.
3. Attach hydraulic source to inlet port of caliper
assembly.
Oil used in the hydraulic source must be of the
same type as used in the Brake Circuit on the
HAULPAK
truck.
4. Bleed air from caliper assembly.
During testing or bleeding procedure, DO NOT
allow oil to come into contact with brake linings.
5. Gradually increase hydraulic pressure to 1200 psi
(8.4 MPa), observing piston assembly for leakage.
6. Reduce pressure to 0 psi (0 MPa).
7. Repeat Step 5 and 6 three times. If no leakage has
been observed, reduce pressure to 0 psi (0 MPa)
and disconnect hydraulic source and remove test
block.
FIGURE 5-5. BRAKE CALIPER ASSEMBLY
1. Cylinder Heads 5. O-Rings
2. Pistons 6. Backup Rings
3. O-Rings 7. Bleeder Valve
4. Wipers
J05008 8/90 Front Disc Brakes J5-3
8. Use adequate force to pry each piston fully into
caliper housing. Do not damage O-rings, wipers,
or backup rings.
9. Install brake calipers on truck. Refer to "Installa-
tion" instructions.
FRONT BRAKE BLEEDING PROCEDURE
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
Eye protection such as goggles or a face shield
should be used while performing the following
procedures.
1. Start engine and allow brake accumulators to
charge. After accumulators have charged, oper-
ate engine at 1000 RPM.
2. Install a hose to top bleeder valve of caliper to drain
hydraulic oil into a container.
3. Depress service brake pedal and hold down.
Open bleeder only one turn maximum to prevent
hose from blowing off bleeder valve and oil spilling
onto ground. DO NOT allow oil to come into con-
tact with brake linings.
4. Open bleeder valve for one minute or until a clear,
steady air-free flow of oil comes from bleeder
hose.
5. After air-free oil is observed, close bleeder and
release treadle valve. Remove hose.
6. Repeat above procedure for each caliper.
7. After all calipers are bled, make three complete
brake applications by depressing treadle valve
down completely. Be certain the brake lining does
not bind, and that it works properly. Check for
leakage after three applications have been made.
FRONT SERVICE BRAKE
BURNISHING PROCEDURE
During normal truck operation, the rear wet disc brakes
provide 70% of the braking effort. Therefore, to burnish
the front brakes, it will be necessary to TEMPORARILY
disconnect the rear wet disc brakes from the Service
Brake Treadle Valve.
The Retarder pedal will still be operative.
Braking effort is seriously reduced without the rear
wet disc brakes. Prior to disconnecting rear
brakes, be certain truck body is unloaded and a
level area free of obstacles and other equipment is
selected to operate truck while burnishing front
brakes. Serious injury to personnel and property
damage may result if these precautions are not
followed.
1. Park truck in a level area, block wheels and apply
parking brake.
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleeddown accumulators:
Turn key switch "Off", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Accumulator Discharge Valve handles
counterclockwise to open. Wait at least 90
seconds to let accumulators bleed down.
When brake accumulators are completely
bled down, close accumulator discharge
valves by turning handles clockwise.
Do not leave open.
2. Bleed down accumulators and disconnect the rear
brake apply line at the left service brake treadle
valve. Refer to Brake Circuit Component Service,
this Section, for location of brake apply port.
3. Install an O-ring plug in the left brake apply port
of the service brake treadle valve and cap "tee"
connection on right service brake treadle valve
going to the Service Brake/Retarder Shuttle valve.
Tighten all caps, plugs and brake lines securely to
prevent high pressure leakage.
J5-4 Front Disc Brakes J05008 8/90
4. Remove wheel blocks and start engine. Be certain
truck body is unloaded and a level area free of
obstacles and other equipment is selected to op-
erate truck while burnishing front brakes. Do not
exceed 15 mph (24 kph).
5. Drive truck while applying brakes until disc surface
reaches temperature of 450
o
- 550
o
F (232
o
- 287
o
).
Measure front brake disc temperatures with a
hand held pyrometer.
NOTE: During the burnishing procedure, the retarder
pedal may be used to apply the rear brakes if safety or
other circumstances require quick stoppage of truck.
6. Let discs cool to 200
o
F (93
o
C).
7. Repeat Steps 4, 5, and 6 three times to complete
burnishing procedure.
8. Repeat Step 1 and bleeddown accumulators.
9. Remove O-ring plug (installed at step 3.) in brake
apply port of left service brake treadle valve and
remove cap from "tee" connection on right service
brake treadle valve. Connect rear brake apply line
to the left service brake treadle valve. Connect
brake apply line going from "tee" on right service
brake treadle valve to the Service Brake/Retarder
Shuttle valve. Tighten all brake lines securely to
prevent high pressure leakage.
10. Refer to Rear Brake Bleeding Procedures, this
Section, and bleed rear brakes to clear any air
trapped during brake line removal/installation.
11. Be sure ALL steps outlined above have been
completed before releasing truck for operation.
J05008 8/90 Front Disc Brakes J5-5
NOTES
J5-6 Front Disc Brakes J05008 8/90
REAR WET DISC BRAKE ASSEMBLY
A Wet Disc Brake Assembly is mounted on both sides
of the differential on the final drive housing and inboard
from the wheel hub and planetary drive. This assembly
contains a splined housing, two damper discs, ten
separator plates, eleven friction discs, a spacer, a
piston assembly, and a splined rotating hub.
The housing is internally splined to retain the steel
damper and separator discs. The separator discs are
alternately placed between the friction faced discs
which are splined to the rotating hub. The inboard side
of the assembly contains the piston assembly which is
activated by hydraulic pressure from either the service
brake treadle valve or the retarder treadle valve. As
hydraulic pressure is applied, the piston moves and
compresses the rotating friction faced discs against the
stationary steel discs. The friction forces generated
resist the rotation of the wheels. As hydraulic pressure
increases, friction forces are increased and wheel ro-
tation is slowed until maximum force is reached and
the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The cooling oil circuit is a low-pressure circuit which
is completely separate from the high-pressure piston
apply circuit. The cooling oil flows from the pump,
through two 12 micron (absolute) filters, through a heat
exchanger, to the brake assembly housing (from the
outside of the housing inward to the rotating hub for
maximum cooling) and then to the hydraulic tank.
Dynamic retarding is also provided by the wet disc
brakes. When the operators retarder pedal is depre-
sed, front wheel brakes are not used; only the rear wet
disc brakes are applied. The dynamic retarding is used
to slow the truck during normal truck operation or to
control speed coming down a grade.
WET DISC BRAKE ASSEMBLY
Removal
Before removing any brake lines or brake circuit
components be sure brake accumulators are bled
down. To bleeddown accumulators:
BLOCK WHEELS OF TRUCK!
Turn key switch "Off", shut down engine
and wait at least 90 seconds to bleed
down steering accumulator. Rotate steer-
ing wheel back and forth; no front wheel
movement should occur.
Bleed down brake accumulators by turn-
ing Accumulator Discharge Valve handles
counterclockwise to open. Wait at least 90
seconds to let accumulators bleed down.
When brake accumulators are completely
bled down, close accumulator discharge
valves by turning handles clockwise.
Do not leave open.
1. Remove rear wheels and tires, planetary drive, and
wheel hubs. Refer to Section "G", Drive Axle, Spin-
dles and Wheels.
WET DISC BRAKE ASSEMBLY
J06008 9/90 Rear Wet Disc Brake Assembly J6-1
2. Install retaining brackets and capscrews (1, Figure
6-1), if not previously installed. Refer to Special
Tools, Section "M" for bracket description. Re-
move seal carrier (11, Figure 6-1) and floating ring
seal (12), if not previously removed after wheel
hub removal.
3. To prevent hydraulic oil from siphoning from tank,
loosen the plug above the return tube in the top
cover of the hydraulic tank. Refer to Hydraulic
Tank, Section "L". Remove one of two drain plugs
(2) to drain excess oil into container.
4. Punch-mark final drive housing and brake assem-
bly housing to aid in proper positioning during
assembly.
5. Remove capscrews holding lower cooling-oil line
(inlet), upper cooling-oil line (outlet) and rear
brake shuttle valve to brake housing. Cap/plug all
open lines and ports to prevent contamination.
Brake Assembly weighs approximately 1200 lbs.
(545 kg.). Use adequate lifting devices.
6. Install lifting device and take up slack. Remove
capscrews (6) and carefully slide brake assembly
off of final drive housing.
7. Move assembly to a clean, dry working area. Place
on wooden blocks for disassembly/storage.
Installation
1. Inspect and clean brake mounting surface (4,
Figure 6-1), particularly around O-ring (5) sealing
surface. If O-ring sealing surface is nicked or
scratched, repair area before installing brake as-
sembly.
2. Install O-ring (5) into brake assembly.
3. Attach lifting device (see WARNING above) and
lift assembly into position. Slide onto final drive
mounting surface, taking care not to damage
O-ring.
4. Position housing assembly so match-marks line
up and hydraulic ports are in correct position.
Install capscrews (6). Tighten capscrews to
standard torque.
5. Remove caps and plugs from lines and ports and
install new O-rings on fittings. Connect lower cool-
ing-oil line (inlet), upper cooling-oil line (outlet)
and rear brake shuttle valve to brake housing.
Tighten capscrews to standard torque.Tighten
plug above the return tube in the top cover of the
hydraulic tank.
6. Inspect floating ring seal (12). Replace if nicked or
scratched . Refer to "Floating Ring Seal Assembly/
Installation", this Section.
FIGURE 6-1. WET DISC BRAKE ASSEMBLY
1. Retaining Bracket & 6. Capscrew
Capscrews 7. Floating Ring Seal
2. Drain Plug 8. O-Ring
3. Cooling Oil Port 9. Pin
4. Axle Housing Mount 10. O-Ring
Surface 11. Seal Carrier
5. O-Ring 12. Floating Ring Seal
J6-2 Rear Wet Disc Brake Assembly J06008 9/90
7. Install O-ring (10) and pin (9) into seal carrier (11).
Slide carrier onto housing. Pin must engage into
slot of case structure. To determine correct pin
engagement, measure distance from face of seal
structure to face of housing (Figure 6-2). Dimen-
sion should be 16.06 0.06 in. (40.79 0.15 cm).
8. Refer to Section "G", for installation of Wheel Hub,
Planetary Drive, Wheels and Tires.
NOTE: If new seal rings were installed in oil brake
housing, truck speed must not exceed 25 MPH (40
KPH) during the first 4 hours of operation. See "Break-
In Procedure" CAUTION decal in cab.
Wet Disc Brake Disassembly
1. Disassemble rear brake assembly in a clean and
dry work area. Match mark all components.
2. Place assembly (Figure 6-3), piston (1) side up and
hub (8) down on wooden blocking.
FIGURE 6-3. WET DISC BRAKE ASSEMBLY
1. Piston Assembly 5. Damper 9. Floating Ring Seal Assembly
2. Brake Housing 6. Retaining Bracket & Capscrews 10. Spacer
3. Damper 7. O-Ring Seal Bore 11. Capscrews
4. Disc Pack 8. Rotating Hub
FIGURE 6-2. SEAL CARRIER DIMENSION
J06008 9/90 Rear Wet Disc Brake Assembly J6-3
3. Remove capscrews (11, Figure 6-3) and install two
threaded eyebolts (1, Figure 6-4) for lifting.
4. Attach lifting device and lift piston assembly (2)
out. Set off to one side on wood blocks or work-
bench.
5. Remove disc pack (1, Figure 6-5) and spacer (2).
Note the order of pack assembly. Place pack off
to one side for cleaning and further inspection.
FIGURE 6-5. DISC PACK REMOVAL/INSTALLATION
1. Disc Pack 3. Housing 5. Retaining Brackets and Capscrews
2. Spacer 4. Rotating Hub
FIGURE 6-4. PISTON REMOVAL/INSTALLATION
1. Eyebolt 4. Retaining Bracket & Capscrews 7. Disc Pack
2. Piston Assembly 5. O-Ring Seal Bore 8. O-Ring
3. Brake Housing 6. Rotating Hub 9. Capscrews
J6-4 Rear Wet Disc Brake Assembly J06008 9/90
6. Lift brake housing and invert housing so hub (2,
Figure 6-6) is facing up. Remove capscrews (7)
holding the three retaining brackets (6).
7. Attach lifting device to hub and lift hub and ring
seal (3) away from brake housing (5). Be careful
not to damage ring seal (4).
8. Inspect seals (3 & 4). Clean mounting areas and
seals thoroughly. If any damage is found, seal
assembly must be replaced. Install new seals
according to "Floating Ring Seal Installation", this
section.
FIGURE 6-6. HUB AND BRAKE HOUSING ASSEMBLY
1. O-Ring Bore 4. Floating Ring Seal 6. Retaining Bracket
2. Rotating Hub 5. Brake Housing 7. Capscrews
3. Floating Ring Seal
J06008 9/90 Rear Wet Disc Brake Assembly J6-5
Brake Piston Disassembly
1. Position piston with hydraulic ports (6, Figure 6-7)
down, onto a wooden or padded work area.
2. Remove eight capscrews(1), springs (3) and
spring guides (2). Separate piston (4) from piston
housing.
3. Remove seal rings and O-rings (8 & 9) and discard.
Brake Piston Inspection
The work area must be clean! All parts must be
carefully handled so that no damage occurs to
polished sealing surfaces.
1. Check housing bore (5, Figure 6-7) to be sure that
no nicks or scratches are present. If nicks or
scratches cannot be removed by polishing, re-
place piston housing.
NOTE: Inboard and outboard O-ring grooves are dif-
ferent diameters.
2. Inspect piston seal ring grooves for any nicks or
scratches. If nicks or scratches cannot be re-
moved by polishing, replace piston.
3. Check piston return springs for wear as follows:
Wire Size: 0.177 0.001 in. (4.50 0.025 mm)
Coil I.D.: 0.646 0.020 in. (16.40 0.508 mm)
Coil O.D.: 1.00 0.020 in. (25.40 0.508 mm)
Total Number of Coils: 9.93
Free Length:
2.825 in. 0.283 in. (71.75 7.20 mm)
Working Length Under Load:
2.380 in. (60.45 mm) @ 142 14 lbs. (64.5 6 kg)
1.758 in. (44.7 mm) @ 340 34 lbs. (154 15 kg)
Replace springs if they do not meet specifications.
Weak springs may not allow complete return of
the piston, causing rapid wear of the brake discs
and overheating of hydraulic oil.
Brake Piston Assembly
1. Install O-rings (8 & 9, Figure 6-7) into grooves of
piston (4), then insert seal rings (see detail # 9).
Using fingers or a smooth, rounded object, work
seal assembly into piston grooves. Do not nick or
scratch seal ring.
2. Lubricate piston and O-ring/seal ring assembly
with clean C-3 hydraulic oil.
3. Lubricate housing bore (5) with clean C-3 hydrau-
lic oil. Install two equally spaced 6.0 " long x 3/8"
- 16NC guide studs in piston return spring holes
to properly position piston.
FIGURE 6-7. PISTON ASSEMBLY
1. Capscrews with Washers 4. Piston 7. O-Ring
2. Spring Guide 5. Piston Housing Bore 8. O-Ring/Seal Ring (see detail # 9)
3. Spring 6. Apply Port 9. O-Ring/Seal Ring
J6-6 Rear Wet Disc Brake Assembly J06008 9/90
4. Place piston carefully (O-ring side down) into
piston housing. Align holes of piston with guide
studs in the housing. Firmly tap piston into hous-
ing (using nonmetallic mallet) until seated or bot-
tomed out. Remove guide studs.
5. Assemble spring guides (2, Figure 6-7) into
springs (3). Apply LOCTITE to threads of 3/8-
16NC capscrews with washers (1). Insert cap-
screws/washers into spring assemblies and place
into guide holes of piston and piston housing.
Tighten capscrews to standard torque.
6. Pressure check piston assembly by attaching a
clean, C-3 hydraulic oil supply to one apply port
(6) and a pressure gauge to the other. Apply 100
psi. (0.69MPa) of hydraulic pressure. Check for
leaks and proper operation of piston before final
assembly.
Floating Ring Seal Assembly/Installation
Failures are usually caused by combinations of factors
rather than one single cause, but many failures have
one common denominator: -- ASSEMBLY ERROR!
Floating ring seals should ALWAYS be installed in
MATCHED pairs: that is, two new rings OR two rings
that have previously run together. NEVER assemble
one new ring and one used ring; or two used rings that
have not previously run together.
ALWAYS USE NEW TORIC RINGS!!
1. Inspect seal surfaces and mounting cavities for
rough tool marks or nicks that may damage rub-
ber seal rings. Hone smooth and clean, if required.
Remove any oil, dust, protective coating or other
foreign matter from the metal seal rings, the toric
rings, and both the housing and seal ring ramps.
Use tri-chloroethane # 111 which is a non-petro-
leum base, rapid drying solvent leaving no film.
Allow surfaces to dry completely. Use clean, lint-
free material such as "Micro-Wipes # 05310" for
cleaning and wiping.
When using tri-chloroethane or any solvent, avoid
prolonged skin contact. Use solvents only in well
vetilated areas and use approved respirators to
avoid breathing fumes. Do not use near open flame
or welding operations or other heated surfaces
exceeding 900F (482C). Do not smoke around
solvents.
Both ramps must be dry. Use clean, lint-free
cloths or lint-free paper towels for wiping.
NOTE: Oil from adjacent bearing installations or seal
ring face lubrication MUST NOT get on the ramp or
toric until after both seal rings are together in their
final assembled postion.
2. Install the rubber toric on the seal ring.
FIGURE 6- 8. FLOATING RING SEAL TERMINOLOGY
1. Seal Ring 6. Seal Ring Face
2. Rubber Toric 7. Seal Ring Ramp
3. Housing Retainer Lip 8. Seal Ring Retainer Lip
4. Housing Ramp 9. Installation Tool
5. Seal Ring Housing
J06008 9/90 Rear Wet Disc Brake Assembly J6-7
Make sure it is STRAIGHT! Make sure the toric
ring is not twisted and that it is seated against
the retaining lip of the seal ring ramp. Use the flash
line as a reference guide to eliminate twist.The
flash line should be straight and uniform around
the toric.
NOTE: Handle seal carefully; nicks and scratches
on the seal ring face cause leaks.
3. Place installation tool onto seal ring with toric.
Refer to Special Tools, Section "M" for installation
tool. Lower the rings into a container of tri-chlo-
roethane until all surfaces of toric ring are wet.
ALTERNATE PROCEDURE:
After positioning the seal squarely over the retain-
ing lip, thoroughly lubricate the ring by spraying
with tri-chloroethane # 111.
DO NOT USE Stanosol or any other liquid that
leaves an oily film or does not evaporate quickly.
4. With all surfaces of toric ring wet, use installation
tool to position seal ring and toric ring squarely
against the seal housing.
APPLY SUDDEN AND EVEN PRESSURE to pop
(push) toric under housing retaining lip.
5. CHECK WITH SIGHT GAGE. Check variation in
seal ring "assembled height" in four places, 90
apart. Height variation around the assembled ring
should not exceed 0.51 0.05 in. (1.30 0.01
mm) for brake assembly floating seal or 0.45
0.04 in. (1.14 0.01 mm) for the wheel hub seal.
6. If small adjustments are necessary, DO NOT
PUSH DIRECTLY ON THE SEAL RING. Make
any required adjustments with installation tool.
7. Toric can twist if it is dry on one spot or if there are
burrs or fins on the housing retaining lip.
A bulging toric or cocked seal can contribute to
eventual failure.
NOTE: Toric ring must not slip on ramps of either seal
ring or housing. To prevent slippage, -- WAIT -- at least
two minutes. Let all tri-chloroethane evaporate before
further assembly. Once correctly in place, the toric ring
must roll on the ramps only. If correct installation is
not obvious, repeat steps 3 through 6.
CORRECT ASSEMBLY
J6-8 Rear Wet Disc Brake Assembly J06008 9/90
8. Wipe the polished metal seal surfaces with clean
tri-chloroethane to remove any foreign material or
fingerprints. No foreign particles of any kind
should be on the seal ring faces.
Something as small as a paper towel raveling will
hold the seal faces apart and cause leakage.
9. Apply a thin film of clean oil on the seal faces. Use
an lint-free applicator or a clean finger to distribute
the oil evenly. Make sure no oil comes in contact
with the rubber toric rings or their mating surfaces.
Before assembling both seals & housing together
-- WAIT -- at least two minutes. Let all tri-chlo-
roethane evaporate. (Some may still be trapped
between toric and housing ramp.)
10. Be certain both housings are in correct alignment
and are square and concentric. Move the parts
slowly and carefully toward each other.
NOTE: Do not slam, bump or drop seals together. High
impact can damage the seal face and cause leakage.
MAKE SURE
SEALS ARE SQUARE
and CONCENTRIC.
INCORRECT ASSEMBLIES
J06008 9/90 Rear Wet Disc Brake Assembly J6-9
A wet spot between housing
and ramp can cause sliding
and cock the seal.
Cocked seals cause uneven
presure on the seal face and
may cause seal to wobble.
Uneven pressure causes
leakage or scoring.
Wobbling seals can cause dirt
entry problems in the field.
Wet Spot Slippage
RESULTS OF INCORRECT ASSEMBLY
Points "A" & "B" Remain Stationary
ORIGINAL POSITION "AS ASSEMBLED"
Points "X" & "Y" Rotate 180
This causes high
pressure at "A""Y" and
possible galling.
Whereas at "B""X" there is
low pressure and
possible leakage.
ROTATED 180 FROM "ORIGINAL POSITION"
J6-10 Rear Wet Disc Brake Assembly J06008 9/90
Wet Disc Brake Assembly
1. Position hub (2, Figure 6-9) and brake housing (5)
each with seal cavity (3 & 4) facing up. Clean seal
cavities and inspect for any damage.
2. If no damage is found in seal cavity refer to
"Floating Ring Seal Installation" procedure and
install new seal halves (3 & 4).
3. After seals have been properly installed, attach
lifting device to hub (2) and position over housing
(5). Very carefully lower hub into housing. Do not
damage the seal or surfaces. Align the drilled
holes in the hub with the three raised bracket pads
on housing.
4. Secure retaining brackets (6) to hub (2) and hous-
ing (5) with capscrews (7). Tighten capscrews to
standard torque.
The three brackets are for TEMPORARY USE ONLY
while assembling and installing the Wet Disc Brake
Assembly. They must be removed before final
wheel bearing adjustment takes place.
5. Invert the housing and hub assembly with the hub
side facing down (4, Figure 6-10). Position the hub
mounting surface on wood blocks.
FIGURE 6-9. HUB AND BRAKE HOUSING ASSEMBLY
1. O-Ring Bore 4. Floating Ring Seal 6. Retaining Bracket
2. Rotating Hub 5. Brake Housing 7. Capscrews
3. Floating Ring Seal
FIGURE 6-10. DISC PACK REMOVAL/INSTALLATION
1. Disc Pack 4. Rotating Hub
2. Spacer 5. Retaining Brackets
3. Housing and Capscrews
J06008 9/90 Rear Wet Disc Brake Assembly J6-11
6. Prior to assembling disc pack, wipe each plate with
a lint-free cloth. Inspect and measure all dampers,
separator plates, friction discs and spacer for
wear or damage. If any damage is found or if a
part does not meet specifications, replace part.
Plate Measurements are:
Quantity Description New Plate Thickness
2 Dampers 0.272 0.020 in.
(6.9 0.5 mm)
10 Separator
Plates
0.094 0.004 in.
(2.4 0.1 mm)
11 Friction
Discs
0.200 0.005 in.
(5.08 0.13 mm)
1 Spacer 0.438 0.005 in.
(11.13 0.13 mm)
7. Place spacer (2) into the brake housing (3). It is
not included in the disc pack measurement.
8. Assemble disc pack in a clean, dry area away from
brake housing. Using two wooden blocks of equal
thickness and of suitable length to support the
disc pack during measurement, assemble the
plates as follows:
1 -- Damper - Cork material facing down.
(Unfaced steel side always faces friction disc.)
1 -- Friction disc (internal splines)
1 -- Separator plate (external splines)
Continue to alternate friction discs and separator
plates until all eleven friction discs and ten sepa-
rator plates are used; finish with:
1 -- Damper - Cork material facing up.
(Unfaced steel side always faces friction disc.)
9. Disc pack must be compressed using a minimum
of 50 lbs. (22.7 kg) of weight distributed evenly
over disc pack. Keep weight applied during meas-
urement of disc pack thickness (step 10).
10. Using a 3" - 4" micrometer, take three measure-
ments on the outside edge of disc stack, in equally
spaced locations. Record each measurement and
average the three readings. The total disc pack
average thickness must be between 3.720 in.
(94.50 mm) minimum and 3.819 in. (97.00 mm)
maximum.
If average thickness is less than 3.720 in. (94.50
mm.), an additional separator plate will be re-
quired during assembly (see NOTE below).
If average thickness is greater than 3.819 in.
(97.00 mm), check individual plates for correct
quantity and thickness (step 6).
NOTE: If an extra separator plate is required, place
extra separator plate in the brake housing between the
spacer and first damper.
11. When disc pack stacked dimension has been
determined, place discs into brake housing in the
same order as stated in step 8 (spacer should
have been placed in housing previously). Be cer-
tain that first damper has cork side facing
spacer and last damper has cork side facing
piston; unfaced steel side always faces friction
disc.
J6-12 Rear Wet Disc Brake Assembly J06008 9/90
12. Attach lifting device to the assembled piston as-
sembly (2, Figure 6-11) making sure new O-ring
(8) is in place and lubricated with clean C-3 hy-
draulic oil. Position piston assembly over housing
(3) and align match marks. Lower piston assem-
bly into housing.
13. Install capscrews (9) securing piston assembly to
housing. Tighten capscrews to standard torque.
Refer to "Installation" procedure to install assem-
bly on final drive.
REAR WET DISC BRAKE
BLEEDING PROCEDURE
If hydraulic lines were removed from brake hous-
ing, be certain suction plug on hydraulic tank has
been tightened. If plug is left loose and engine is
started, hydraulic oil will leak from the plug.
1. Block wheels of truck.
2. A male quick-disconnect fitting is installed on the
back of each wet disc brake housing adjacent to
the rear brake shuttle valve. Locate both fittings
and clean thoroughly.
3. Assemble an open-close valve with a drain hose
and a female quick-disconnect fitting on one end.
4. Attach hose/valve and quick-disconnect assembly
onto brake housing quick-disconnect fitting.
5. Start engine and allow accumulators to charge.
Operate engine at 1000 rpm and apply brake lock
valve. Slowly open valve attached to rear brake
and drain oil into a clean container (5 gal. mini-
mum) for one minute or until a clear, steady flow
of oil is obtained.
6. Shut off engine and remove hose/valve and quick-
disconnect assembly from brake assembly.
7. Repeat Steps 4 and 5 with other rear brake.
8. After bleeding procedure is completed, fill hydrau-
lic tank if needed.
FIGURE 6-11. PISTON REMOVAL/INSTALLATION
1. Eyebolt 4. Retaining Bracket & Capscrews 7. Disc Pack
2. Piston Assembly 5. O-Ring Seal Bore 8. O-Ring
3. Brake Housing 6. Rotating Hub 9. Capscrews
J06008 9/90 Rear Wet Disc Brake Assembly J6-13
REAR BRAKE DISC WEAR INDICATOR
Rear brake disc wear should be checked every 1000
hrs. using the wear indicator tool (Figure 6-12)
mounted in one of the rear brake housings. On a new
truck, the wear indicator tool is located in the lower left
brake housing near the cooling oil line.
1. Park truck on a level surface and apply park brake.
Shut engine down and block rear wheels.
2. Thoroughly clean both rear brake assemblies,
especially the area surrounding the lower cooling
oil lines.
3. Place the transmission in neutral and start engine.
Apply brake lock and keep parking brake applied.
4. Remove wear indicator cover (1, Figure 6-12).
5. Operate engine at 1000 RPM.
6. Push rod (2) in until it stops against brake piston.
7. Measure the distance from rod shoulder (2) to
housing face (3).
If rod shoulder (2) is even with the housing face
(3) or below, disc pack is worn to maximum safe
wear limits. Brakes should be scheduled for re-
build.
If rod shoulder (2) does not go to housing face
(3), brake disc wear is still within allowable limits.
8. Pull rod (8) out until it stops against tool housing
(6) and install protective cover (1).
9. Release brake lock. Shut engine down.
NOTE: Checking disc wear in both brake assemblies
is recommended. Disc wear in one brake assembly
may be different from the other due to dissimilar op-
eration of parts and/or haul profiles which require
repeated braking/retarding while steering in one di-
rection only.
Removal/Installation
From One Brake To Another
The brake disc wear indicator tool is inserted in a port
which is open to cooling oil. Removal of the brake disc
wear indicator will cause the loss of some of this oil.
Advance planning will help to minimize oil loss.
1. Consider scheduling brake disc wear inspections
along with the recommended 1000 hr. change of
hydraulic oil and filters. Also consider obtaining
an additional brake disc wear indicator tool for
permanent installation on truck. If both brake as-
semblies are equipped with disc wear indicators,
future checks will not require removal.
2. Perform steps 1 and 2, "REAR BRAKE DISC WEAR
INDICATOR".
3. To prevent hydraulic oil from siphoning from tank,
loosen the plug above the return tube in the top
cover of the hydraulic tank. Refer to Hydraulic
Tank, Section "L".
4. Obtain a VM0315 (0.750 - 16 UNF-2B) O-ring plug
and be prepared to insert in hole as indicator tool
is removed. Position container to catch oil.
5. Remove the brake disc wear indicator tool, install
O-ring plug in place of tool. Inspect brake disc
wear indicator and replace O-rings (4, 5 & 7,
Figure 6-12).
6. Move to other brake assembly. Locate O-ring plug
in the lower part of brake housing near the cooling
oil line. Be prepared to insert indicator tool in hole
as O-ring plug is removed. Position container to
catch oil.
7. Remove the O-ring plug, install brake disc wear
indicator tool in place of plug.
8. Refill hydraulic tank as required. Tighten the plug
above the return tube in the top cover of the
hydraulic tank. Refer to Hydraulic Tank, Section
"L".
9. Perform steps 3 through 9, "REAR BRAKE DISC
WEAR INDICATOR".
10. If brake rebuild is necessary, refer to Removal,
Disassembly, Assembly, Installation this section.
NOTE: If any leakage is observed around the brake
disc wear indicator tool, replace O-rings (4, 5 and 7
Figure 6-12).
FIGURE 6-12. WEAR INDICATOR TOOL
1. Protective Cover 5. O-ring
2. Indicator Rod Shoulder 6. Tool Housing
3. Housing Face (Ref.) 7. O-ring
4. O-ring 8. Indicator Rod
J6-14 Rear Wet Disc Brake Assembly J06008 9/90
PARKING BRAKE
The Parking Brake Assembly is mounted to the rear of
the Allison transmission. It is controlled by an actuator
which is spring applied and hydraulically released.
Removal/Installation
If park brake assembly requires repair, refer to Allison
Transmission Service Manual for procedure.
Park Brake Lining Adjustment
1. With park brake released, move truck as required
to position access hole in park brake drum for
access to the adjusting star wheel (1, Figure 7-1).
2. Shut down engine. Securely block all wheels.
3. Remove hose at actuator.
4. Install a hand operated hydraulic pump with a
0-5000 psi (0-35 000 kPa) gauge to the fitting on
the park brake actuator (2, Figure 7-2).
5. Apply 1750 psi (12 066 kPa) to the park brake
actuator to release the brake.
6. Turn star wheel until linings are tight against brake
drum.
7. Back off star wheel three turns.
8. Relieve hand operated hydraulic pump pressure
and remove pump. Install hydraulic line on fitting
(2, Figure 7-2).
Park Brake Linkage Adjustment
NOTE: If transmission is exchanged or brake lever
and/or cam is changed, it will be necessary to make a
preliminary adjustment for lever to actuator linkage.
1. Refer to Steps 1 through 5 of park brake lining
adjustment to position actuator in released posi-
tion.
2. Turn star wheel adjuster until linings are tight
against brake drum.
3. Install link (3, Figure 7-2) to actuator (1).
4. Observe the relationship of park brake actuator
link (3) to the eye of park brake lever (4).
5. If the relationship is not close enough to allow the
lever to slide on the link pin, the park brake lever
will have to be removed from the serrated shaft
and moved to a position that will allow the lever to
slide on the link pin.
6. Install link pin, washer and key.
7. Proceed with the lining adjustment.
FIGURE 7-1. PARKING BRAKE ADJUSTMENT
1. Star Wheel Adjuster
FIGURE 7-2. PARK BRAKE LINKAGE ADJUSTMENT
1. Actuator 3. Link
2. Hydraulic Hose Fitting 4. Park Brake Lever
J07007 4/92 Parking Brake J7-1
PARK BRAKE ACTUATOR ASSEMBLY
The decal shown above is on the top of the park
brake actuator assembly. Do not remove nuts from
spring retainer plate end of assembly until spring
force is removed. Failure to follow instructions
could result in serious personal injury.
Removal
1. Block wheels of truck securely before disconnect-
ing park brake.
2. With key switch "On" and engine running, move
parking brake switch to "Off" position.
3. Remove cotter pin (1, Figure 7-3) and pin (2).
4. Move parking brake switch to "On" position, turn
key switch "Off" and shut engine down.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
Before removing any hydraulic lines or compo-
nents, be sure steering accumulator is bled down.
Turn key switch "Off", shut down engine and wait
at least 90 seconds. Rotate steering wheel back
and forth; no front wheel movement should occur.
5. After steering accumulator is completely bled
down, remove hydraulic line at actuator. Cap/plug
hydraulic line to prevent dirt entry.
6. Remove park brake actuator from rear cover of
transmission.
Installation
1. Mount park brake actuator on rear cover of trans-
mission. Tighten capscrews to standard torque.
2. Connect hose to fitting of park brake actuator.
NOTE: It is not necessary to bleed park brake actuator.
3. Start engine and allow hydraulic system to com-
pletely charge.
4. With key switch "On" move park brake switch to
"Off" position.
5. Connect park brake actuator to lever of park brake.
With park brake in "Off" position, linings should not
be in contact with drum. If adjustment is needed
refer to "Park Brake Adjustment" Procedure.
6. Move parking brake switch to "On" position, turn
key switch "Off" and shut engine down. Remove
blocks from wheels.
FIGURE 7-3. PARK BRAKE ACTUATOR ATTACHMENT
1. Cotter Pin 2. Pin w/Washers
J7-2 Parking Brake J07007 4/92
Disassembly
1. Remove nuts (2, Figure 7-4) on actuator end of
assembly from the three retainer rods (7).
Do not allow retainer rods to turn with nuts.
2. Remove actuator assembly (3) from spring pod
assembly (6).
NOTE: Normal service of the parking brake actuator
assembly will NOT require disassembly of the actuator
spring pod assembly. If service is required, refer to
"Actuator Spring Pod Disassembly/Assembly".
3. Remove plunger (1), wiper (4) and seal (5) from
the actuator assembly housing.
Assembly
1. Clean and inspect all parts thoroughly.
2. Install new seal (5, Figure 7-4) and wiper (4). Install
tip of seal toward eye end of actuator, tip of wiper
points away from eye end.
3. Place plunger (1) in housing of actuator (3). Install
actuator assembly onto three retainer rods of
spring pod assembly (6).
4. Install nuts (2). Tighten nuts to standard torque.
Actuator Spring Pod Disassembly
1. Remove clamp (6, Figure 7-5) and boot (8).
2. Weld a nut to one end of 0.375 in. (9 mm) threaded
rod 12 in. (304 mm) long, this will be the spring
compression rod (1).
3. Install compression rod with welded nut (1) in
recess of actuator base.
FIGURE 7-5. ACTUATOR SPRING POD
1. Compression Rod 6. Clamp
2. Retainer Plate 7. Retainer Rods
3. Washer 8. Boot
4. Nut 9. Spring
5. Self Locking Nut 10. Spring Pod Base
FIGURE 7-4. PARK BRAKE ACTUATOR ASSEMBLY
1. Plunger 4. Wiper
2. Nuts 5. Seal
3. Actuator Assembly 6. Spring Pod Assembly
7. Retainer Rods
J07007 4/92 Parking Brake J7-3
4. Install washer (3), nut (4) to spring retainer end of
compression rod.
5. Tighten nut (4) enough to relieve force on retainer
rod nuts (5).
Position spring assembly so the retainer plate is
not pointed at anyone.
6. Remove retainer rod nuts (5).
7. Hold nut (4) of compression rod (1) and unscrew
rod by the welded nut on compression rod.
8. Free length of spring is approximately 14.8 in. (375
mm).
9. After all spring pressure is released, remove spring
compression rod.
10. Separate retainer plate (2), spring (9) and actuator
base (10).
Actuator Spring Pod Assembly
1. Install spring compression rod (1, Figure 7-5) with
welded nut in recess of actuator base (10).
2. Install spring (9) and retainer rods (7) to actuator
base.
3. Place spring retainer plate (2) on end of spring with
compression rod through center hole. Install
washer (3) and nut (4) to compression rod.
4. Hold nut (4) on retainer plate end of spring.
5. Align retainer rods with holes of retainer plate.
Tighten welded nut to compress spring.
6. Compress spring until retainer rod nuts (5) can be
installed.
7. The assembled length of spring pod (Dimension
"A", Figure 7-6) should be 8.312 in. (211 mm).
8. Remove spring compression rod.
9. Install boot (8, Figure 7-5) and clamp (6).
PARK BRAKE BURNISHING
NOTE: New brake drum and brake shoe linings need
to be burnished before truck is placed in production.
1. When burnishing brake, operate truck in a level
area free of obstacles and other equipment.
2. Place range selector in "Drive" position and accel-
erate truck to a maximum speed of 10 MPH (16
km/ph). With truck in motion, release throttle and
move range selector to "Neutral" position and
move park brake switch to "On" position.
3. Repeat Step 2 five times at one minute intervals.
4. After burnishing, check that lining to drum clear-
ance is correct. Adjust as required. Refer to "Park
Brake Lining Adjustment".
FIGURE 7-6. ASSEMBLED SPRING LENGTH
J7-4 Parking Brake J07007 4/92
SECTION L
HYDRAULIC SYSTEM
INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L2-1
HYDRAULIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . L2-1
HYDRAULIC SYSTEM COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . L3-1
TANDEM HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-1
Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-2
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-4
Cartridge Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-5
Cartridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-7
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-9
Filling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-10
HYDRAULIC TANK BREATHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-10
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-11
DIFFERENTIAL PRESSURE SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . L3-12
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3-13
STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-1
STEERING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L4-1
STEERING CIRCUIT COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . L4-1
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-2
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-5
Alternate Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L5-5
STEERING CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-1
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-2
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-3
LOW PRESSURE ACCUMULATOR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . L6-3
ACCUMULATOR CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . L6-4
INLINE FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-5
STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-6
L01009 5/92 Index L1-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-6
BRAKE/STEERING PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-13
PUMP SPECIFICATIONS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6-21
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION . . . . . . . . . . . . . . L7-1
CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-1
Hoist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-1
Auxiliary Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-2
Counter Balance (overcenter) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-2
Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-2
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L7-2
HOIST CIRCUIT COMPONENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-1
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-3
HOIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L8-6
Hoist Cylinder Mounting Bearing Replacement . . . . . . . . . . . . . . . . . . . L8-6
HYDRAULIC CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-1
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE . . . . . . . . . . . . L10-1
INITIAL SYSTEM SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-1
Accumulator And Piston Pump Checks . . . . . . . . . . . . . . . . . . . . . . . . L10-1
Steering Valve Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-3
Steering Cylinder Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-3
TROUBLESHOOTING CHART (STEERING SYSTEM) . . . . . . . . . . . . . . . . . . . L10-4
HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . L10-6
AUXILIARY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-6
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-6
Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-6
Checking And Adjusting Hoist System Pressure Relief Valve . . . . . . . . . . . . L10-7
Checking And Adjusting "Power Down" Pressure . . . . . . . . . . . . . . . . . . . L10-7
TROUBLESHOOTING CHART (HOIST SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . L10-8
STEERING SYSTEM DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-11
HOIST SYSTEM DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L10-12
HYDRAULIC SYSTEM FLUSHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . L10-13
L1-2 Index L01009 5/92
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DESCRIPTION
The hydraulic system consists of the hoist, steering,
brake apply and brake cooling circuits. The following
information discusses basic operation and oil flow
through the entire system when the engine is running
and all controls are in the neutral position. Additional
and more detailed information regarding the brake
system can be found in Section J. Additional infor-
mation regarding the operation of individual hoist and
steering circuit components can be found in this Sec-
tion. Refer to Figure 2-3 for the location of individual
components on the truck and to the hydraulic system
schematic in Section R.
The hydraulic tank (Figure 2-1), located on the left side
of the frame provides the oil supply for the entire
system. The tandem pump oil supply tube (1, Figure
2-1) is positioned above the oil level in the tank and
receives oil by siphoning oil from inside tube (2). This
arrangement allows pickup of clean oil while contami-
nants not trapped by the system filters and screens
return to the tank and settle to the bottom.
The shaft end of the tandem pump (2, Figure 2-2),
mounted on the rear of the transmission PTO drive (3)
provides oil to the open center hoist valve. Oil leaving
the hoist valve is routed to the rear, dual filter located
behind the left front wheel. The outlet of the cover end
cartridge of the tandem pump is routed to the front
filter. The two supplies are combined after the oil is
filtered and routed to the heat exchanger located under
the radiator. A Tee ahead of the heat exchanger
routes oil back to the hydraulic tank through a relief
valve (3, Figure 2-1) if pressure exceeds 85 psi (586
kPa).
After the oil is cooled in the heat exchanger the oil is
routed to the rear brake system and used to cool the
disc brakes during truck operation and then is returned
to the hydraulic tank. A portion of the oil leaving the
heat exchanger is routed through a filter screen to the
inlet of the steering/brake supply pump mounted on
the front of the transmission PTO drive.
The brake/steering pump (4, Figure 2-2) is a piston type
pump. It contains an internal pressure compensator to
provide "standby" oil pressurized to 2750 psi (18.9
MPa) at all times to the steering and brake circuits.
There is no oil flow from the pump unless there is a
demand for oil from one of the circuits.
FIGURE 2-1. HYDRAULIC TANK ASSEMBLY
1. Tandem Pump
Oil Supply Tube
2. Tube
3. Relief Valve
4. By-Pass Return
5. Cooling Circuit Return
FIGURE 2-2. HYDRAULIC PUMPS
1. Fuel Tank
2. Tandem Pump
3. PTO
4. Brake/Steering Pump
L02007 8/90 Hydraulic System L2-1
FIGURE 2-3. HYDRAULIC SYSTEM COMPONENT LOCATION
L2-2 Hydraulic System L02007 8/90
Pressure oil from the brake/steering pump is routed to
the auxiliary valve, steering system components and
brake system components.
A pressure reducing valve in the Auxiliary manifold
reduces the 2750 psi (18.9 MPa) pressure to provide
125 psi (862 kPa) oil pressure to the hoist pilot control
valve to control the hoist valve mounted on the fuel
tank. When the hoist valve is actuated, oil flows from
the hoist valve to extend the hoist cylinders. An Over-
center valve provides a hydraulic cushion to prevent
damage to the cylinders when reaching the end of the
fully extended stage. A pressure switch mounted on
the Auxiliary Manifold activates a Low Steering Pres-
sure warning light and horn if steering circuit pressure
decreases to 1800 psi (12.4 MPa).
This oil supply is used for releasing the parking brake
actuator, operation of the hoist valve and steering
circuit pressure detection.
The remainder of the volume of oil from the brake/steer-
ing pump is routed to a manifold and through check
valves to the three accumulators as shown in Figure
2-3. The check valves maintain oil pressure in the
accumulators in the event of a loss of oil supply from
the brake/steering pump. This supply of pressurized oil
is available to steer the truck and bring it to a safe stop.
The smaller, outboard accumulator and the center
accumulator provide oil to the Low Brake Pressure
Detection Module located under the accumulators.
This module senses brake pressure to provide a warn-
ing if the brake system pressure falls below 2000 psi
(13.8 MPa) and automatically applies the brakes if
pressure falls below 1650 psi (11.4 MPa). This module
also contains valves used to manualy bleed the hydrau-
lic pressure from the brake system accumulators for
system maintenance and repair.
Oil is routed from the Low Brake Pressure Detection
Module to the Brake Manifold to provide an oil supply
for the retarder, front and rear brake treadle valves and
the brake lock circuit.
The inboard accumulator supplies oil to the steering
circuit. A portion of the oil is routed from the accumu-
lator to the Brake Manifold containing the accumulator
bleeddown solenoid. When the engine is shut down
and the key switch turned Off, oil pressure stored in
the steering accumulator is drained back to the tank.
Oil flow is also routed through a filter screen to the
closed center Steering Control Valve. If the operator
turns the steering wheel, the oil supply is directed to
the steering cylinders to extend one cylinder and to
retract the opposite cylinder.
FIGURE 2-4. ACCUMULATOR INSTALLATION
1. Steering Accumulator
2. Rear Brake Accumulator
3. Front Brake Accumulator
4. Brake Accumulator Bleedown Valves
5. Low Brake Pressure Detection Module
6. Pressure Test Port
7. Brake System Warning Pressure Switch
8. Oil Supply to Accumulators
9. Manifold
10. Accumulator Check Valves
L02007 8/90 Hydraulic System L2-3
Block Wheels of Truck!
Turn key switch Off and shut down engine. Wait at least 90 seconds to bleed down the
steering accumulator. Rotate the steering wheel back and forth; no movement should
occur.
Bleed down the brake accumulators by turning the Bleeder Valve handles counterclock-
wise to open and wait at least 90 seconds. When accumulators are completely bled
down, close bleeder valves by turning Bleeder Valve handles clockwise. Do not leave
open.
The following procedure should be observed prior to any
repairs and maintenance to hydraulic system components:
This hydraulic system contains stored energy. Always relieve pressure
before disconnecting any hydraulic line. Tighten all connections securely
before starting the engine.
Hydraulic fluid escaping under pressure can have sufficient force to enter
a persons body by penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a physician familiar with
this type of injury is not received immediately.
Always maintain complete cleanliness when opening any hydraulic con-
nection. Insure that all system lines and components are capped to prevent
contamination.
L2-4 Hydraulic System L02007 8/90
HYDRAULIC SYSTEM COMPONENT REPAIR
TANDEM HYDRAULIC PUMP
Removal
1. Block the wheels of the truck.Turn the key switch
Off and allow at least 90 seconds for the steering
accumulator to bleed down. Open the valves lo-
cated in the Low Brake Pressure Detection Mod-
ule to manually bleed the pressure from the brake
accumulators.
Relieve pressure before disconnecting hydraulic
lines. Tighten all connections securely before ap-
plying pressure.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
2. Loosen the center plug (4, Figure 3-2) on the top
cover (2) of the hydraulic tank.
3. Place a container under the pump (2, Figure 3-1).
Be prepared to catch approximately 10 gal (38 l)
of oil.
4. Remove the pump inlet and outlet hose flanges
and remove hoses. Cap hoses to prevent con-
tamination.
5. Remove capscrews and remove the pump from
the PTO.
6. Remove the oil filter elements and inspect for
contamination. If excessive amounts of contami-
nation are found, the hydraulic tank should be
completely drained and thoroughly cleaned.
7. Move pump to a clean work area for disassembly.
Installation
1. Install a new O-ring on pump mounting flange.
Align splines on pump with splines in PTO. Secure
pump to PTO housing with capscrews and lock-
washers. Tighten to standard torque.
FIGURE 3-1. HYDRAULIC PUMP INSTALLATION
1. Fuel Tank
2. Tandem Hydraulic Pump
3. Transmission PTO
4. Steering/Brake Pump
FIGURE 3-2. HYDRAULIC TANK
1. Cover Gasket
2. Cover
3. Capscrews
4. Vent Plug
5. Filler Tube
L03006 7/93 Hydraulic System Component Repair L3-1
2. Uncap outlet lines and attach to the proper con-
nections using new O-rings.
3. Install new O-ring and install inlet hose on pump
and secure with capscrews.
4. Remove the cover (2, Figure 3-2) from the hydrau-
lic tank and fill the suction tube for the tandem
pump with clean Type C-3 hydraulic oil. Loosen
the capscrews on the pump inlet to remove
trapped air in line. After air is bled from line, tighten
capscrews to standard torque.
5. Refill tank to top of the filler tube (5). Tighten the
plug (4) in the tank cover.
6. Install new oil filter elements.
Pump Disassembly
1. Support the pump on blocks or clamp the body in
a vise as shown in Figure 3- 3. If a vise is used, use
protective jaws to avoid damage to outlet body
and its machined surfaces.
2. Mark the pump inlet, outlet and cover for correct
reassembly (Figure 3-3).
3. Remove the cover screws (1, Figure 3-6) and lift
end cover (2) from the pump. This will expose the
cover end cartridge. Discard square cut seal (5)
and O-ring (6).
4. Pull cover end cartridge from the inlet housing
(Figure 3-4).
5. Set cover end cartridge aside for disassembly.
6. Separate inlet housing and outlet body as shown
in Figure 3-5. This will expose shaft end cartridge.
Discard square cut seal and O-ring (5 & 6, Figure
3-6).
7. Rotate shaft to loosen shaft end cartridge then
remove the cartridge from outlet body (25). Set
aside for disassembly during Step 11.
8. Remove spirolox ring (19). Slide shaft (22) and
bearing (21) from outlet body (25).
FIGURE 3-3. REMOVAL OF COVER SCREWS
FIGURE 3-4. REMOVAL OF COVER END
FIGURE 3-5. INLET HOUSING REMOVAL
L3-2 Hydraulic System Component Repair L03006 7/93
9. If bearing (21) is worn, remove retaining ring (20)
and press bearing from the shaft with an arbor
press.
10. Remove spacer (23) and shaft seal (24) from the
outlet body (25). Be careful not to damage the bore
areas where the seals are located.
NOTE: Preassembled and tested pump cartridges are
available as service items, if needed.
FIGURE 3-6. HYDRAULIC PUMP
1. Screw
2. End Cover
3. Backup Ring
4. O-Ring
5. Square Cut Seal
6. O-Ring
7. Outlet Support Plate
8. Seal Pack Sub-Assemblies
9. Flex Side Plate
10. Rotor
11. Vanes & Inserts
12. Ring
13. Flex Side Plate
14. Seal Pack Sub-Assemblies
15. Inlet Support Plate
16. Locating Pins
17. Screw
18. Inlet Housing
19. Spirolox Retaining Ring
20. Retaining Ring
21. Bearing
22. Shaft
23. Washer (Spacer)
24. Primary Shaft Seal
25. Outlet Body
26. Seal
L03006 7/93 Hydraulic System Component Repair L3-3
Pump Assembly
1. Clamp outlet body (25, Figure 3-6) in a vise or
place on 2 x 4 wood blocks to facilitate assembly.
2. Lubricate primary shaft seal (24) with petroleum
jelly and place in position within outlet body (25),
garter spring up. See Figure 3-7 for seal arrange-
ment.
3. Use seal installation tool shown in Figure 3-8 to
prevent damage to the seal. Press seal (24, Figure
3-6) into the body until it bottoms out against the
shoulder.
4. Press shaft (9) into the new bearing with an arbor
press while supporting the bearing inner race.
Refer to Figure 3-7 for correct location of bearing
on the shaft. Install a small retaining ring (20,
Figure 3-6) behind the bearing on the shaft.
5. Place the bearing spacer washer (23) over the
shaft, against the front of the bearing. Use plastic
tape over the shaft end to prevent damage to the
seal. Lubricate with petroleum jelly and carefully
push the shaft through the seal until the bearing
and spacer are in location within the body.
6. Install the large spirolox ring (19) into the outlet
body retaining ring groove located just behind the
bearing.
7. Install square cut seal (5) into outlet body (25).
8. Install O-ring (4) and backup ring (3) on the car-
tridge outlet support plate hub.
9. Carefully install shaft end cartridge over shaft (22)
and into outlet body (25) with one of the chamfers
on the ring in alignment with the outlet port.
10. Lubricate and install O-ring (6) between the large
inlet housing (18) and outlet body (25). Locate
O-ring in O-ring groove of the outlet body.
11. Install inlet housing (18) in position; move back and
forth until the cartridge pins drop into the align-
ment holes located within the housing.
12. Turn the inlet housing slightly until the alignment
marks are in line and the large screw holes are
aligned.
13. Turn pump shaft by hand to check for free rotation
of the cartridges.
14. Install a square seal (5) into the outlet cover (2).
15. Install O-ring (4) and backup ring (3) on the cover
end cartridge outlet support plate hub.
16. Carefully install cover end cartridge over shaft (22)
and into the inlet housing.
17. Turn cartridge slightly to bring into alignment the
pin holes and cartridge alignment pins.
18. Install outlet cover to inlet housing O-ring seal (6)
over the cartridge and up against the inlet housing.
19. Make sure square cut seal is in place within the
cover. Align the cover to agree with the alignment
marks and gently slide the cover over the outlet
cartridge.
FIGURE 3-7. SHAFT SEAL ARRANGEMENT
1. Primary Seal
2. Standard Shaft
3. Steel Ball
FIGURE 3-8. PRIMARY SHAFT SEAL DRIVER
L3-4 Hydraulic System Component Repair L03006 7/93
Be careful not to cut square cut seal (5) or pinch
O-ring (6) during cover installation.
20. Oil and install capscrews (1). Tighten capscrews to
255-275ft.lbs. (346-373 N.m) torque.
21. Turn the pump shaft to check for free rotation of
the cartridges.
Cartridge Disassembly
Disassemble the two cartridge kits, one at a time,
according to the following instructions. Keep parts
separated from each other during inspection, repair,
and assembly.
1. Remove O-ring (4, Figure 3-6), backup ring (3) and
square cut seal (5) from the outlet support plate.
2. Scribe a line across the outer surface of the car-
tridge kit. (Refer to Figure 3-9). The scribe marking
will provide a reference for parts alignment during
assembly.
3. Place the cartridge on a flat surface (outlet support
plate down) and remove the two sockethead
screws (17, Figure 3-6).
Do not slide flex plates across the ring and rotor.
Burrs on the ring or rotor can cause deep
scratches in the soft bronze surface.
4. Slide inlet support plate (15) and seal pack sub-
assemblies (14) off the cartridge. DO NOT allow
the flex side plate (13) to slide with the support
plate.
5. Move flex side plate (13) off center just enough to
lift up and away without sliding. Refer to Figure
3-10.
6. Place a small clean piece of wood over the ex-
posed ring and rotor. Turn cartridge and wood
upside down as shown in Figure 3-11.
7. Slide outlet support plate (7, Figure 3-6) and seal
pack sub-assemblies (8) off flex side plate (9). DO
NOT permit flex side plate (9) to move across the
ring and rotor.
8. Move flex side plate (9, Figure 3-6) off center just
enough to lift up and away without sliding. Refer
to Figure 3-10.
9. Lift ring (12, Figure 3-6) away from rotor (10) and
vanes (11). Locate the arrow stamped into the
rotor periphery.
10. Remove the vanes and inserts in order, starting at
the arrow. Keep them in order for inspection.
NOTE: Do not remove cartridge locating pins (16,
Figure 3-6) from the inlet support plate unless they are
damaged. The pins are of a drive-loc type and can be
difficult to remove.
Inspection
1. All parts must be thoroughly cleaned and kept
clean during inspection and assembly. The close
tolerance of the parts makes this requirement very
important.
2. Clean all removed parts, using a cleaning solvent
that is compatible with the system oil.
FIGURE 3-9. SCRIBING THE CARTRIDGE
L03006 7/93 Hydraulic System Component Repair L3-5
When using cleaning solvents follow solvent manu-
facturers instructions.
NOTE: Compressed air may be used in cleaning, but
it must be filtered to remove water and contamination.
3. Discard the square cut seals, O-rings, backup ring
and seal sub-assemblies. Use new seal kits for
assembly.
4. Check the cartridge wear surfaces for pickup,
scoring and excessive wear. Slight heat discolora-
tion of the flex side plate bronze surface is normal.
Score marks deeper than 0.001 in. (0.025 mm)
and scratches deeper than 0.002 in. (0.050 mm)
indicate a new part is needed. Slight scoring
and/or scratches can be removed with an oiled
honing stone.
DO NOT use a dry stone on bronze surface or
scratches will result.
5. Inspect both sides of each vane (11, Figure 3-6)
and insert in order. If pickup, heavy wear or scor-
ing is found, inspect the appropriate rotor (10)
slot. Replace scored parts.
NOTE: Inspect each vane tip for excessive wear. Ex-
cessive vane tip wear will reduce pump efficiency.
6. Inspect ring (12) for vane chatter marks, wear
and/or scratches. Replace if scoring is evident.
FIGURE 3-10. INLET FLEX SIDE PLATE REMOVAL
L3-6 Hydraulic System Component Repair L03006 7/93
Replacement ring width must be identified to the
ring being replaced or reduced life of output flow
will result. The minimum ring to rotor clearance
limit is 0.0016 in. (0.0406 mm).
NOTE: All cartridge kit parts must be free of burrs.
Stone the mating surfaces of each part with an oiled
honing stone prior to assembly. Clean parts after ston-
ing.
7. Vane to rotor wear can be checked by inserting
the vane in the rotor slot and checking for exces-
sive play. Replace rotor (10, Figure 3-6) and vanes
(11) if wear is evident.
8. Rotate bearing (21) while applying pressure to
check for wear, looseness and pitted or cracked
races.
9. Inspect the seal and bushing mating surfaces on
shaft (22) for scoring or wear. Replace the shaft if
wear exceeds 0.005 in. (0.127 mm) diametrical
change, or if marks cannot be removed by light
polishing. If wear is found in the bushing area, a
new bushing will be required.
Cartridge Assembly
NOTE: Coat all parts except seals and backup rings
with clean Type C-3 hydraulic oil to facilitate assembly
and provide initial lubrication. Use small amounts of
petroleum jelly to hold the O-rings in place during
assembly.
1. The direction of rotation is viewed from the shaft
end. Right hand rotation is clockwise; left hand
rotation is counterclockwise. Be certain pump
assembly provides same rotation as found during
disassembly.
NOTE: Assemble shaft end cartridge in the direction
of rotation noted at disassembly. Assemble cover end
cartridge in reverse of the shaft end cartridge.
NOTE: If locating pins (16, Figure 3-6) were removed
from inlet support plate (15), install new pins with
locking flutes located within the inlet support plate.
Drive the new pins into the support plate with a soft
tipped hammer.
2. Place the inlet and outlet support plates on a flat
surface. Install seal pack sub-assemblies (8 & 14)
into cavities with seal retainer surface up (O- rings
facing downward into the cavities).
FIGURE 3-11. CARTRIDE DISASSEMBLY
L03006 7/93 Hydraulic System Component Repair L3-7
3. Place flex side plates (9 & 13) over each of the
support plates with bronze wear surface facing
up. Align scribe marks to make sure the correct
flex side plate is used with the correct support
plate (bronze wear surfaces must face rotor when
assembled).
NOTE: Flex side plates develop a wear pattern with the
rotor and vanes and should not be interchanged.
4. For right hand rotation units, set the rotor on a flat
wooden board with the arrow pointing right (for
left hand rotation, the arrow should point left).
5. Assemble the vanes and inserts into the rotor in
reverse order of disassembly. Make sure the
sharp chamfer edge of each vane leads in the
direction of rotation. All vanes must move freely in
the rotor slots with no evidence of bind.
6. Assemble the ring (12, Figure 3-6) over rotor (10)
and vanes (11) with arrow pointing in the same
direction as the rotor. Lubricate the top surface of
the rotor and vanes liberally with Type C-3 hydrau-
lic oil.
7. Locate the scribe mark on ring (12), outlet support
plate (7) and flex side plate (9). Hold the outlet
support plate and flex plate together and assem-
ble over the ring and rotor with the scribe marks
in line.
8. Hold the cartridge together to prevent movement
and turn the assembly over so the outlet support
plate rests on a flat surface.
9. Lubricate the exposed surface of the rotor and
vanes with system oil. Locate the scribe mark on
inlet support plate (15) and flex side plate (13).
10. Hold the inlet support plate and flex side plate
together and assemble over the exposed ring,
rotor and vanes. Make sure the scribe marks are
in line.
NOTE: The O.D. of all component parts of the cartridge
kit must be in line with each other or the cartridge will
bind during assembly. Align the cartridge as follows:
a. Build a V block from hardwood (Reference
Figure 3-12) or use a metal V block if it is
available.
b. Place the cartridge into the V block on its side.
c. Loosen socket head screws (17, Figure 3-6)
enough to allow each section of the cartridge
to come into alignment within the V block.
d. Tighten the socket head screws (17) to 100
in.lbs. (11.29 N.m) torque.
e. Check alignment again after tightening.
11. Check rotor (10) for bind by inserting the index
finger through the shaft opening of inlet support
plate (15). Hold the cartridge kit in a horizontal
shaft position and lift the rotor with the finger. The
rotor should move freely back and forth within the
cartridge. If the rotor binds, open the kit, clean and
stone all possible areas of bind, then reassemble
using the aforementioned procedure. The rotor
MUST move freely within the cartridge when as-
sembled.
12. Repeat Steps 1 thru 11 for assembly of other
cartridge kit.
FIGURE 3-12.
CARTRIDGE
ALIGNMENT
BLOCK
L3-8 Hydraulic System Component Repair L03006 7/93
HYDRAULIC TANK
Filling Instructions
NOTE: If filling is required, use clean Type C-3 hydrau-
lic oil only.
Prior to opening the hydraulic tank, allow at least
90 seconds for the accumulators to bleed down
after engine shutdown with the key switch Off.
1. With the body down, shut down engine and turn
key switch Off. Wait at least 90 seconds.
2. Remove cap from fill tube (7, Figure 3-13) and add
clean, filtered Type C-3 hydraulic oil until oil is at
the top of fill tube.
NOTE: The final filter in the filling apparatus must be 3
micron.
3. Replace fill cap.
4. Start the engine, raise and lower the dump body
three times.
5. Continue to repeat Steps 1 through 4 until oil level
is maintained at the fill tube.
NOTE: When engine is shut down, oil should be visible
in sight glass.
If a component in the hydraulic system should fail, and
foreign particles are evident, the system must be
flushed. Refer to Hydraulic System Flushing instruc-
tions.
Removal
1. Block the wheels of the truck. Turn keyswitch Off
and allow at least 90 seconds for the steering
accumulator to bleed down. Open the manual
bleedown valves on the Low Brake Pressure De-
tection Module to relieve the oil pressure in the
brake system accumulators. Close valves when
brake accumulators are bled down.
2. Loosen the vent plugs (1, Figure 3-13). Drain the
hydraulic tank by use of the drain (9) located in
the bottom of the tank. Be prepared to catch
approximately 95 gal (360 l) of oil.
3. Thoroughly clean the outside of the hydraulic tank.
4. Disconnect hydraulic lines. Plug lines to prevent
spillage and possible contamination to the sys-
tem. Tag each line as removed for proper identifi-
cation during installation. Disconnect wires on
inboard side of tank. Remove the transmisssion
filler pipe (6) and position to allow tank removal.
Take care to avoid contact with hot oil if truck has
been operating. Avoid spillage and contamination.
5. Attach a lifting device to the hydraulic tank.
6. Remove the nuts, washers,capscrews, lockwash-
ers and U-bolts securing the hydraulic tank to the
frame.
7. Move hydraulic tank to a clean work area for
disassembly or repair.
FIGURE 3-13. HYDRAULIC TANK
1. Vent Plugs
2. Breather Elements
3. Capscrew
4. Cover
5. Gasket
6. Transmission Fill Pipe
7. Tank Filler Tube
8. Sight Gauge
9. Drain Plug
10. Lower Mount
L03006 7/93 Hydraulic System Component Repair L3-9
Installation
1. Install hydraulic tank and secure with u-bolts,
washers and nuts at upper mounts. Install cap-
screw, washers, rubber mount and nut in lower
mount. Tighten to standard torque.
2. Remove caps from hydraulic lines and attach to
the proper connections using new O-rings and
gasket where applicable.
3. Attach transmission filler pipe assembly to the
tank. Reconnect wiring to temperature sending
unit and thermostat switch on inboard side of
tank.
3. With the cover (4, Figure 3-13) removed, fill the
hydraulic tank with C-3 hydraulic oil. Be certain to
fill the center, internal tube supplying oil to the
tandem pump. Bleed all air from hydraulic lines.
4. Install the tank cover using a new gasket. Tighten
the vent plugs (1) to assure a positive seal.
5. Refer to Filling Instructions and fill tank to obtain
proper oil level.
HYDRAULIC TANK BREATHERS
The hydraulic tank breathers (2, Figure 3-13) maintain
atmospheric pressure inside the hydraulic tank as oil
is pumped from and returned to the tank.
Hydraulic system malfunctions such as overheating,
erratic operation, and pump failure can result if truck is
operated with plugged or restricted breathers. Be sure
that breathers are kept clean and are not covered with
mud or debris.
The breathers are replaceable assemblies that should
be changed at 1000 hour intervals under normal oper-
ating conditions.
DUAL HYDRAULIC FILTERS
Two oil filters are located behind the left front tire as
shown in Figure 3-14. Oil is filtered through 12 micron
filters to remove contamination from the system and
reduce the possibilities of large particles damaging
system components.
Included in the front filter assembly is a differential
pressure (P) switch to indicate when oil passing
through the filter element is restricted. The differential
pressure switch is factory preset to actuate at 35 5
psi (241 35 kPa) and is designed to give the operator
an alert before the filter begins to by-pass. Actual filter
by-pass will occur at 50 psi (345 kPa).
NOTE: Upon start-up with cold oil, the restriction
caused by cold oil may cause the warning indicator
light to turn on. Hyraulic oil should be warmed up to
normal operating temperature before using the
warning light as an indicator to change elements.
The filter elements should be changed every 250 hours
or when the warning light comes on.
Premature filter restriction may indicate a system com-
ponent failure and signal a service requirement before
extensive secondary damage can occur.
FIGURE 3-14. FILTER INSTALLATION
1. LH Frame Rail
2. Filter Assemblies
3. Front Suspension
L3-10 Hydraulic System Component Repair L03006 7/93
Removal
Relieve pressure before disconnecting hydraulic
and other lines. Tighten all connections before
applying pressure.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury and pos-
sibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
The following instructions are applicable to either filter
assembly. Only the front filter is equipped with a differ-
ential pressure switch.
1. With engine shut down and key switch Off, allow
at least 90 seconds for the accumulator to bleed
down.
Take care to avoid contact with hot oil if truck has
been operating. Avoid spillage and contamination!
2. Remove rotolock and bowl (8, Figure 3-15) and
element (7) and drain the oil from the filter housing
into a suitable container. Remove filter element (7)
from bowl.
3. Before discarding element (7), inspect closely.
Evidence of debris may signal a component prob-
lem within the system.
4. Remove O-ring (5) in filter head and discard.
Installation
1. Install new O-ring (5) in filter head (4) and check
for new O-ring (6) on new filter element (7).
2. Install new filter element (7) in rotolock and bowl
(8). Install complete assembly onto filter head (4)
and tighten securely.
NOTE: The differential pressure switch (1, Figure 3-15)
and the warning light circuit it activates should be
tested periodically for proper operation. Refer to the
following instructions and equipment necessary to
test differential pressure switch.
FIGURE 3-15. FILTER ASSEMBLY
1. Differential Pressure
Switch
2. O-Ring
3. O-Ring
4. Filter Head Assembly
5. O-Ring (Head)
6. O-Ring (Element)
7. Filter Element
8. Rotolock and Bowl
L03006 7/93 Hydraulic System Component Repair L3-11
DIFFERENTIAL PRESSURE SWITCH
TESTING
The differential pressure switch and warning light cir-
cuit should be routinely tested as a part of the regular
vehicle preventative maintenance. Figure 3-16 shows
a pressure switch tester and Figure 3-17 shows a test
block to accept the switch during testing. The test
block may be fabricated as shown.
Test Procedure:
1. Remove differential pressure switch from filter
head and install in test block or pressure switch
tester.
2. Reconnect wiring harness to switch.
3. Pump up pressure to test block and watch for
warning light indication.
4. Differential Pressure switch should turn on warning
light at 35 5 psi (241 35 kPa).
If the differential pressure switch does not operate
within the specified range, replace the complete com-
ponent. Switch adjustment is not recommended.
FIGURE 3-16. PRESSURE SWITCH TESTER
Kent-Moore Part Number--J-33884-4
FIGURE 3-17. DIFFERENTIAL PRESSURE SWITCH TEST BLOCK
L3-12 Hydraulic System Component Repair L03006 7/93
FIGURE 3-18. INDICATOR LIGHT TEST WIRING HARNESS
Male Electrical Connector (on switch):
MS3102R-10SL-3P (revised)
Female Mating Electrical Connector:
MS3106-A10SL-3S (straight plug)
or
MS3108-A10SL-3S (90 angle plug)
The following information is provided to assist in making (if desired)
a temporary wiring harness for testing purposes.
L03006 7/93 Hydraulic System Component Repair L3-13
NOTES
L3-14 Hydraulic System Component Repair L03006 7/93
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
Oil from the outlet port of the steering/brake pump is
directed to both the accumulator oil supply manifold
and the auxiliary manifold. Oil going to the auxiliary
manifold is used for control functions. Oil going to the
accumulator supply manifold passes through the
manifold and through the three check valves to fill the
steering accumulator and the two brake accumulators.
Oil from the steering accumulator is directed to the
steering valve inlet port and steering bleeddown sole-
noid valve located on the brake manifold. With the
engine running and no movement of the steering
wheel, oil flow is blocked. When the engine is first
started, the Emergency Steering warning light and
alarm will be on until steering circuit pressure reaches
1800 psi (12.5 MPa). Steering circuit pressure will con-
tinue to increase until 2750 50 psi (19.25 0.35 MPa)
maximum circuit pressure is reached.
When the steering wheel is turned, the attached steer-
ing control valve directs oil from the steering accumu-
lator to the steering cylinders. As circuit pressure
drops, pump flow increases, supplying oil to the accu-
mulator to be directed to the rod end of one steering
cylinder and head end of the other cylinder. The other
port of each cylinder is connected through the steering
valve to the tank. When oil flow to the steering cylinders
is stopped by the steering control valve, circuit pres-
sure increases again to maximum.
If the pump supply is removed while the truck is oper-
ating, the accumulator will supply oil for steering until
the truck can be stopped. As steering circuit pressure
decreases, the steering system pressure switch closes
at 1800 psi (12.6 MPa), turning on the warning light and
alarm on the instrument panel, warning the operator.
When shutting down the engine, turning off the key
switch activates a timer that energizes the solenoid of
the normally closed bleeddown valve. The valve is
open for 90 seconds allowing nitrogen to force oil out
of accumulator back to tank. Refer to the Hydraulic
Schematic in Section "R".
STEERING CIRCUIT COMPONENT
DESCRIPTION
STEERING CONTROL VALVE
The steering control valve (Figure 4-1) is mounted
below the floor of the cab. Rubber mounting bushings
are utilized to minimize noise and vibration. The steer-
ing column is connected to the valve through a vibra-
tion isolation coupling.
The unit consists of a rotary directional valve and
gerotor. The directional valve is closed center, blocking
the cylinder ports and inlet port from tank. The spool
of the directional valve is connected to the steering
wheel through the steering column. The control sleeve
of the unit is linked to a gerotor. Leaf springs are located
between the spool and sleeve to center the two when
steering wheel rotation stops.
Turning the steering wheel in either direction rotates
the spool in relation to the sleeve allowing supply oil to
the gerotor. Supply oil drives the gerotor which delivers
oil back through the sleeve and out to the steering
cylinders. Return oil from non-pressurized cylinder
ports return through the sleeve and back to tank. As
long as the steering wheel is rotated, the gerotor and
sleeve are trying to catch up to the spool. When steer-
ing wheel rotation stops, the spool and sleeve return to
center shutting off oil to the gerotor and stopping flow
to the steering cylinders.
FIGURE 4-1. STEERING CONTROL VALVE
L04015 6/90 Steering Circuit L4-1
STEERING PUMP
The steering pump is a variable displacement, radial
piston pump. Inlet oil enters through the inlet port (11,
Figure 4-2) in the pump housing (6). A common inlet
gallery (4) in the pump housing provides oil to eight
inlet valves (5). Pistons (10) radially surround an eccen-
tric cam. The cam uses a bearing race (3) upon which
the pistons ride. Behind each piston is a spring which
pushes in and holds pistons against the bearing race.
As the pump shaft (2) rotates, a low pressure cavity
develops in the piston spring area during the down-
ward stroke of the piston. This low pressure allows the
inlet valve to open, filling the piston cavity with oil. The
inlet valves close at the end of inlet stroke of pistons.
High pressure oil is developed as the race pushes the
pistons outward. As pressure increases, the outlet
valve (9) opens, allowing circuit pressure oil to pass
into the outlet gallery. At the end of the stroke, circuit
pressure oil in the outlet gallery closes the outlet valve.
All outlet valves share a common outlet gallery in the
pump housing. An orifice (1) is located between the
crankcase and the inlet gallery. Any oil leakage past the
pistons is routed through this orifice to the inlet gallery.
This flow allows for cooling and lubrication. The pump
is designed to provide On Demand circuit pressure
oil regardless of flow requirements. As demand for oil
decreases, circuit pressure increases. This increased
pressure closes the crankcase outlet valve (7) and then
opens the stroke control valve (8) allowing high pres-
sure oil to dump into the crankcase as maximum circuit
pressure is reached. Increased pressure in the crank-
case overcomes piston spring pressure and holds the
pistons away from the race, thereby destroking the
pump.
FIGURE 4-2. BRAKE/STEERING PUMP ASSEMBLY
1. Orifice
2. Shaft
3. Bearing Race
4. Inlet Oil Gallery
5. Inlet Valve
6. Pump Housing
7. Crankcase Outlet Valve
8. Pressure Compensator Valve
9. Discharge Valve
10. Piston
11. Oil Inlet Port
L4-2 Steering Circuit L04015 6/90
Pressure Compensator
The pump contains a stroke control valve (pressure
compensator) housing (1, Figure 4-3). The stroke con-
trol valve housing is connected to the pump inlet gallery
(2), outlet gallery (3), and pump crankcase (4 and 5).
The stroke control valve (6), working with the crank-
case outlet valve (7), maintains circuit pressure under
varying flow demands. Circuit pressure oil enters at
point (3) and flows to the center section of the stroke
control valve. At full pump stroke, crankcase pressure
is at inlet pressure. As demand for circuit oil decreases,
circuit pressure will begin to increase, causing crank-
case the outlet valve (7) to close (move downward).
This blocks the pump crankcase oil (4) from the inlet
gallery (2) except for any oil which passes through the
crankcase orifice. As maximum circuit pressure is ap-
proached, the stroke control valve (6) opens (moves
downward) and allows circuit pressure oil into the
crankcase.
As circuit pressure rises further, more oil enters the
crankcase than can flow through the orifice. Crankcase
pressure increases to slightly higher than inlet pressure
overcoming the combined spring force on the pump
pistons. The pistons are then held away from the pump
shaft bearing race destroking the pump. The pump
shaft continues to rotate, but the pistons travel only
enough to supply flow through the crankcase.
As demand for circuit oil increases, circuit pressure will
decrease closing the stroke control valve. Oil will no
longer be routed to the crankcase. Crankcase pressure
begins to decrease as oil flows through the crankcase
orifice. When circuit pressure decreases sufficiently,
the crankcase outlet valve (7) opens (moves upward)
rapidly dumping the pump crankcase. The pump pis-
ton springs overcome the decreased crankcase pres-
sure and the pistons again come in contact with the
shaft bearing race putting the pump into stroke.
STEERING ACCUMULATOR
The steering accumulator is a floating piston type with
nitrogen on top of the piston. Oil from the steer-
ing/brake pump enters the accumulator through a
check valve and fills the bottom of the accumulator until
pressure on the nitrogen side of the piston equals
maximum circuit pressure established by the compen-
sator of the steering/brake pump. The outlet port is
connected to the steering control valve. The top of the
accumulator contains a nitrogen charge pressure
switch and a nitrogen charging valve.
STEERING BLEEDDOWN SOLENOID VALVE
The bleeddown solenoid valve is a normally closed
valve mounted on the brake manifold. The solenoid is
energized by a timer that is turned on when the key
switch is turned Off and engine shut down. The timer
energizes the solenoid for 90 seconds, allowing oil in
the bottom of the accumulator to return to tank when
the truck is shut down.
STEERING PRESSURE SWITCH
The steering pressure switch turns on a warning light
and alarm on the instrument panel when steering cir-
cuit pressure is below 1800 psi (12.5 MPa).
STEERING CYLINDERS
Double acting cylinders are connected between the
frame rails and each front spindle.
FIGURE 4-3. STROKE CONTROL VALVE
1. Housing 5. Pump Crankcase
2. Pump Inlet Gallery 6. Stroke Control Valve
3. Outlet Gallery 7. Crankcase Outlet Valve
4. Pump Crankcase
L04015 6/90 Steering Circuit L4-3
NOTES
L4-4 Steering Circuit L04015 6/90
STEERING CONTROL VALVE
Removal
1. Shut down engine and bleed down steering circuit.
Allow at least 90 seconds for system to bleed.
Open the manual bleeddown valves to release
the pressure from the brake accumulators.
NOTE: To insure the hydraulic oil has completely
drained from the accumulator, turn the steering wheel.
If the wheels do not turn, all the hydraulic pressure has
been drained from accumulator.
2. Clean exterior of steering control valve thor-
oughly.
3. Tag and disconnect hydraulic lines. Plug lines and
ports securely to prevent spillage and possible
contamination to the system.
4. Remove capscrews at flange (3, Figure 5-1).
Remove nuts (6), washers (7 & 8) and capscrew
at each rubber bushing. Lower and remove valve.
Installation
1. Assemble steering control valve (10, Figure 5-1)
to mounting plate (11). Insert assembly through
bottom of cab floor and align splines on valve
column (4) with the flange assembly (3). Install
capscrews (9), from bottom side of mounting
plate, through the rubber bushings (12). Install
flatwashers, lockwashers and nuts. Tighten to
standard torque.
2. Install capscrews in flange (3) and tighten to
standard torque.
3. Remove caps from hydraulic lines. Be certain that
previously tagged lines are connected to their
respective ports according to the markings on the
steering control valve assembly.
Ports on steering control valve are marked:
T - Tank (Return to tank) - Upper Left Port
L - Left Steering Cylinder - Upper Right Port
P - Pressure (In from Pump) - Lower Port *
FIGURE 5-1. STEERING CONTROL VALVE
1. Universal Joint
2. Stub Shaft
3. Flange & Isolator
4. Steering Valve Column
5. Mounting Plate
6. Nut
7. Lockwasher
8. Flatwasher
9. Capscrew
10. Steering Control Valve
11. Valve Mount Plate
12. Rubber Bushing
FIGURE 5-2. INLINE FILTER INSTALLATION
1. Steering Control Valve 2. Filter
L05009 5/98 Steering Control Valve L5-1
R - Right Steering Cylinder - Lower Port *
* See NOTE on next page.
NOTE: HAULPAK
Distributor.
Assembly
1. Install bearing (14, Figure 8-6), buffer seal (13), rod
seal (12) and wiper (11) in bearing retainer (3). Lip
of buffer seal and rod seal point toward bearing.
Lip of wiper points away from bearing.
2. Install O-ring (16) and backup ring (15) on retainer
with backup ring toward bolt flange.
3. Install bearing (7), buffer seal (8), rod seal (9) and
wiper (10) in tube (5). Lip of buffer seal and rod
seal point toward bearing. Lip of wiper points
away from bearing.
4. Lightly coat all seals and bearings with hydraulic
oil.
5. Position bearing retainer (3) on tube (5). Slide tube
onto rod eye tube (6).
6. Install bearings (19) and seal (20) on bearing
retainer (22).
7. Install bearing retainer (22) into tube (5) and over
end of rod (6).
8. Install capscrews (17) and flat washers (18).
Tighten to standard torque.
9. Install bearings (21) on tube (5). Slide housing over
tube. Install gland (3), capscrews (1)and washers
(2) to housing (3). Tighten to standard torque.
10. If test equipment is available for testing after as-
sembly, the following values should be present:
Extended at 2500 psi (17 238 kPa), leakage at
RET port should not exceed 20 cu. in. (32 l) per
minute.
Retracted at 2500 psi (17 238 kPa), leakage at
EXT port should not exceed 40 cu. in. (0.64 l)
per minute.
11. Plug ports at rod eye to prevent contamination
during handling of cylinder.
Hoist Cylinder Mounting Bearing Replacement
The following procedure is applicable to either end of
cylinder:
1. Remove one snap ring (4, Figure 8-5) retaining
bearing (5).
2. Remove bearing.
3. Repeat Steps 1 and 2 for other bearing.
4. Inspect bearing bores, pin and lower frame mount
for damage.
5. Press spherical bearing (5) into bore of cylinder
eye.
6. Install snap ring (4).
7. Repeat Steps 5 and 6 for other end.
L8-6 Hoist Circuit Component Repair L08006 4/92
HYDRAULIC CHECK-OUT PROCEDURE
GENERAL INFORMATION
The hydraulic check-out procedure is intended to help
the technician to check, adjust, and diagnose prob-
lems in the steering and hoist circuits. The technician
should read the entire check-out procedure prior to
performing any steps to become familiar with the pro-
cedures and all the warnings and cautions.
The check-out procedure begins by checking the basic
system before checking individual components.
Included on the last page is a data sheet to record the
information observed during the hydraulic system
check-out procedure. The data sheet is designed to be
removed, copied, and used during the check-out pro-
cedure.
* Steps indicated in this manner should be re-
corded on the data sheet for reference.
STEERING CIRCUIT CHECK-OUT &
ADJUSTMENT PROCEDURE
The steering circuit hydraulic pressure is supplied from
the piston pump and steering accumulator. Some
steering system problems, such as spongy or slow
steering or abnormal operation of the "Low Steering
Pressure" warning light can sometimes be traced to
internal leakage of steering components. If internal
leakage is suspected, refer to "Steering Circuit Compo-
nent Leakage Test."
NOTE: Excessive internal leakage within the brake
circuit may contribute to problems within the steering
circuit. Be certain that brake circuit leakage is not
excessive before troubleshooting steering circuit. For
Brake Circuit Test Procedure, refer to Section "J",
Brake System.
The steering circuit can be isolated from the brake
circuit by removing the brake supply line from the
distribution manifold to the brake accumulators
(see WARNING). Plug the brake supply lines and
cap the ports in the distribution manifold to prevent
high pressure leakage.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by pene-
trating the skin and cause serious injury, and pos-
sibly death, if proper medical treatment by a
physician familiar with this type of injury is not
received immediately.
Before disconnecting pressure lines, replacing
components in the hydraulic circuits, or installing
test gauges, ALWAYS bleed down hydraulic steer-
ing accumulator.
The steering accumulator can be bled down with en-
gine shut down, turning key switch "Off", and waiting
90 seconds. Confirm the steering pressure is released
by turning the steering wheel - No front wheel move-
ment should occur.
INITIAL SYSTEM SET-UP
Accumulator And Piston Pump Checks
The following equipment will be necessary to properly
check-out the hydraulic steering circuit
a. Hydraulic schematic, refer to Section "R".
b. Two 0-5000 psi (0-35 000 kPa) range calibrated
pressure gauges and hoses.
c. Accumulator charging kit with gauges and dry
nitrogen
d. One oz / ml graduated container.
NOTE: The following procedures may be easier if the
gauges are connected such that they can be read in
the cab or where the technician can communicate with
person operating the controls.
Prior to checking the steering system, the hydraulic
steering and brake systems must have the correct
accumulator precharge and be up to normal operating
temperatures. Also prior to checking the system make
sure the parking brake is properly adjusted. Refer to
Parking Brake Adjustment, Section "J". With the brake
system functioning properly and the parking brake on,
proceed as follows:
L10001 4/92 Hydraulic Check-out Procedure L10-1
NOTE: Always allow nitrogen gas temperature to ap-
proach ambient temperatures before completing pre-
charge procedure. For best resul t s, charge
accumulator in the ambient temperature conditions in
which the truck will be operating
1. Shut down engine and turn key switch off. Wait 90
seconds for the steering accumulator to com-
pletely bleed down before opening circuits to take
measurements, to make repairs, or to install or
remove a gauge.
Be sure steering accumulator oil pressure has
been bled down. Turn the steering wheel; the
wheels should not move if all oil pressure has been
relieved.
2. Check hydraulic oil level in tank, add if required.
3. Check nitrogen charge pressure in steering accu-
mulator before proceding. (Follow the accumula-
tor nitrogen service procedure in this Section.)
* Record pressure reading on data sheet.
4. Install a reliable 5000 psi (35 000 kPa) minimum
pressure gauge at the pressure tap (2, Figure
10-1) on the brake manifold.
5. Install a reliable 5000 psi (35 000 kPa) minimum
pressure gauge at the pressure tap (1, Figure
10-2) on the piston pump.
6. Start engine and cycle the oil through the circuits
to bring the the oil temperature up to normal
operating temperature. Steer slowly both left and
right several times to stabilize the steering circuit
temperatures (both nitrogen and oil).
7. The pressure gauge on the piston pump should
indicate 2750 50 psi (18 961 345 kPa) at 1500
rpm.
* Record pressure reading on data sheet.
8. If pressure is not correct, adjust as follows:
a. Shut down engine and turn key switch off. Wait
90 seconds for the steering accumulator to
completely bleed down before opening circuits
to take measurements, to make repairs, or to
install or remove a gauge
b. Loosen jam nut, turn adjusting screw (3) clock-
wise to increase pressure or counterclockwise
to decrease pressure. Tighten jam nut.
c. Continue checking and adjusting until correct
pressure is obtained.
NOTE: If the piston pump pressure or volume is low,
check charge pressure at port (2). Pressure should be
greater than 10 psi (69 kPa) at high idle.
9. Shut down engine and turn key switch off. Wait 90
seconds, then observe the brake manifold pres-
sure gauge. It should indicate zero pressure.
10. Start the engine. Immediately after starting, check
brake manifold pressure gauge. It will quickly
build to nitrogen pressure of approximately 1050
psi (7240 kPa), pause momentarily, and then in-
crease to the adjusted steering pressure of 2750
50 psi ( 18 961 345 kPa).
* Record pressure reading on data sheet.
FIGURE 10-1 BRAKE MANIFOLD
1. Brake Manifold 2. Pressure tap
FIGURE 10-2 PISTON PUMP
1. High Pressure Tap 3. Adjusting Screw
2. Charge Pressure 4. Allen Wrench
L10-2 Hydraulic Check-out Procedure L10001 4/92
11. Shut down engine and turn key switch off. Wait 90
seconds for steering accumulator to bleed down.
12. Remove pressure gauge from piston pump.
Steering Valve Leakage Check
Never shut off keyswitch to activate accumulator
bleeddown or turn the steering wheel when steer-
ing return lines or ports are open. Return port will
see accumulator oil flow during the bleed down
cycle or turning of the steering wheel.
13. Disconnect steering valve return hose at steering
valve and cap hose.
14. Install a hose into return port of steering valve and
place other end into a suitable measuring con-
tainer.
15. Start engine and allow steering pressure to stabi-
lize.
Never shut off keyswitch to activate accumulator
bleeddown or turn the steering wheel when steer-
ing return lines or ports are open. Return port will
see accumulator oil flow during the bleed down
cycle or turning of the steering wheel.
16. Shut down engine, leave key switch in the run
position.
17. Record the system volume loss from the steering
valve. Maximum leakage should not exceed
111oz / 10 min (3.3 l / 10 min).
* Record on data sheet.
18. If leakage is within specifications, go to step 20.
If leakage is excessive, go to step 19.
19. If excessive leakage from the control valve is
found:
a. Connect return hose back to the steering valve.
b. Turn key switch off and wait 90 seconds for
steering accumulator to bleed down.
c. Inspect steering linkage for binding. This may
cause the steering control valve to be held in
an open position. If this occurs, the allowable
leakage will be greatly affected.
d. Start engine and turn steering wheel to allow
valve to recenter itself again.
e. Shut down engine and turn key switch off, wait
90 seconds for steering accumulator to bleed
down.
f. Check leakage rate again, starting at Step 13. If
leakage is still excessive, rebuild unit according
to the instructions in this Section.
20. Connect return hose to steering control valve.
21. Turn key switch off to bleed down accumulator.
Steering Cylinder Leakage Check
22. Start engine and turn steering wheel to full left lock.
23. Shut down engine and turn key switch off, wait 90
seconds for steering accumulator to bleed down.
24. Remove hose on left steering cylinder on the end
near the frame attachment point. Plug hose end
to prevent high pressure leakage.
25. Start engine and hold pressure on steering wheel
against left lock to pressurize the end of the steer-
ing cylinder still connected to the truck.
26. Measure cylinder leakage at the open steering
cylinder port while holding steering wheel against
left lock.
27. Maximum cylinder leakage must not exceed 0.6
oz / min (17.7 ml / min).
* Record leakage on data sheet.
28. Shut down engine and turn key switch off, wait 90
seconds for steering accumulator to bleed down.
Reconnect hose to steering cylinder.
29. Repeat procedure for the right steering cylinder
while holding pressure on the steering wheel
against the right lock.
* Record leakage on data sheet.
30. If the steering cylinders have excessive leakage,
they must be repaired or replaced.
31. Check hydraulic oil level in tank, add if required.
L10001 4/92 Hydraulic Check-out Procedure L10-3
TROUBLESHOOTING CHART
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Slow Steering, Hard Steering or Loss of Power Assist
Overloaded Steering Axle.
Piston pump pressure lower than specified.
Worn or malfunctioning pump.
Restricted inlet screens in piston pump or steering
valve.
Reduce Axle Loading.
Adjust pump pressure. See "Steering Circuit Check-
Out Procedure".
Replace pump.
Clean or replace screens.
TROUBLE: Drift - Truck Veers Slowly In One Direction.
Rod end of cylinder slowly extends without turning the
steering wheel.
Worn or damaged steering linkage.
A small rate of extension may be normal on a closed
center system.
Replace linkage and check alignment or toe-in of the
front wheels.
TROUBLE: Wander - Truck Will Not Stay In Straight Line.
Air in system due to low oil level, pump cavitation,
leaking fittings, pinched hoses, etc.
Loose cylinder piston.
Broken centering springs (Steering Valve).
Worn mechanical linkage.
Bent linkage or cylinder rod.
Severe wear in steering control valve.
Correct oil supply problem and/or oil leakage.
Repair or replace defective components.
Replace centering springs.
Repair or replace.
Repair or replace defective components.
Repair steering control valve
TROUBLE: Slip - A Slow Movement of Steering Wheel Fails To Cause Any Movement of the Steered Wheels
Leakage of cylinder piston seals.
Worn steering control valve.
Replace seals.
Repair or replace steering control valve.
TROUBLE: Spongy or Soft Steering
Low oil level.
Air in hydraulic system. Most likely air trapped in cylin-
ders or lines.
Service hydraulic tank and check for leakage.
Bleed air from system. Placing ports on top of cylinder
will help avoid trapping air.
TROUBLE: Erratic Steering
Air in system due to low oil level, cavitating pump, leaky
fittings, pinched hose, etc.
Loose piston in steering cylinder.
Correct condition and add oil as necessary.
Repair or replace cylinder.
L10-4 Hydraulic Check-out Procedure L10001 4/92
TROUBLESHOOTING CHART (Continued)
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Free Wheeling - Steering Wheel Turns Freely with No Back Pressure or No Action of the Front
Wheels
Lower splines of column may be disengaged or dam-
aged.
No flow to steering control valve can be caused by:
1. Low oil level.
2. Ruptured hose.
3. Broken gerotor drive pin.
Repair or replace steering column.
1. Add oil and check for leakage.
2. Replace hose.
3. Replace drive pin.
TROUBLE: Excessive Free Play at Steered Wheels
Broken or worn linkage between cylinder and steered
wheels.
Leaky cylinder seals.
Check for loose fitting bearings at anchor points in
steering linkage between cylinder and steered wheels.
Remove and replace cylinder seals.
TROUBLE: Binding or Poor Centering of Steered Wheels
Binding or misalignment in steering column or splined
column or splined input connection.
High back pressure in tank can cause slow return to
center. Should not exceed 300 psi (2068 kPa).
Large particles can cause binding between the spool
and sleeve in the steering control valve.
Align column pilot and spline to steering control unit.
Reduce restriction in the lines or circuit by removing
obstruction or pinched lines, etc.
Clean the steering control valve and filter the oil. If
another component has malfunctioned generating
contaminating materials, flush the entire hydraulic sys-
tem.
TROUBLE: Steering Control Valve Locks Up
Large particles in meter section.
Insufficient hydraulic power (units over 15 inch).
Severe wear and/or broken pin.
Clean the steering control valve.
Check hydraulic power supply.
Replace the steering control valve.
TROUBLE: Steering Wheel Oscillates or Turns By Itself
Lines connected to wrong ports.
Parts assembled wrong. Steering control valve improp-
erly timed.
Check line routing and connections.
Reassemble correctly and retime control valve.
TROUBLE: Steered Wheels Turn in Opposite Direction When Operator Turns Steering Wheel
Lines connected to wrong cylinder ports. Check proper line connections.
L10001 4/92 Hydraulic Check-out Procedure L10-5
HOIST CIRCUIT CHECKOUT &
ADJUSTMENT PROCEDURE
The following equipment will be necessary to properly
check the hydraulic hoist circuit.
a. Hydraulic schematic, refer to Section "R".
b. One 0-500 psi (0-3448 kPa) range calibrated
pressure gauge and hose.
c. One 0-5000 psi (0-35 000 kPa) range calibrated
pressure gauge and hose.
d. One oz / ml graduated container.
NOTE: The following procedures may be easier if the
gauges are connected such that they can be read in
the cab or where the technician can communicate with
person operating the controls.
Auxiliary Valve
Pressure Check
1. Install 0-500 psi (0- 3448 kPa) pressure gauge to
pressure tap on auxiliary valve (Figure 10-3).
2. Start engine and operate at low idle.
3. Check hoist valve pilot pressure in " float, power
down, power up and hold" positions. Pressure
should be 125 psi (862 kPa).
* Record pressure reading on data sheet.
4. To adjust pilot pressure reducing valve, loosen jam
nut on pressure regulator screw and turn adjust-
ing screw clockwise to increase pressure or coun-
terclockwise to decrease pressure. Tighten jam
nut.
5. Shut down engine and turn key switch off, wait 90
seconds for steering accumulator to bleed down.
6. Remove pressure gauge.
Leakage Check
Excessive leakage in the auxiliary manifold can affect
the operation of the hoist circuit, park brake circuit, and
other circuits connected to the manifold.
1. Disconnect piston pump vent hose at auxiliary
manifold port and cap port at valve to prevent
leakage.
NOTE: Before disconnecting any lines from the suc-
tion line, remove center plug on top of hydraulic tank
to prevent siphoning of the hydraulic oil from the
hydraulic tank. Any time the siphon is broken and oil
is drained from the suction line, the hydraulic tank top
cover must be removed and the suction line filled with
clean oil. Also loosen the capscrews at the pump inlet
line to remove trapped air in the line. This prevents
aeration and possible pump damage during start up.
2. Disconnect auxiliary manifold drain line at hoist
pump suction line and place end in a container
suitable for measuring oil volume.
3. Connect the piston pump vent hose to the hoist
pump suction line in place of the auxiliary manifold
drain line.
4. Start engine and operate at low idle.
5. Measure leakage from open auxiliary manifold
drain line. Maximum leakage is 3.2 oz / min (95
ml/min).
* Record leakage on data sheet.
6. Shut down engine and turn key switch off, wait 90
seconds for steering accumulator to bleed down.
7. If leakage is within specifications, go to step 11.
If leakage is excessive, go to step 8.
8. Excessive leakage can be caused by the following:
a. Defective park brake solenoid valve.
b. Defective raise/lower solenoid valve.
c. Defective pressure reducing valve.
d. Defective O-rings.
e. Defective auxiliary valve housing.
9. Remove each component and inspect for dam-
age, imperfections or defective O-rings. Repair or
replace as necessary.
10. Check for excessive leakage again by starting at
step 5.
11. Connect hoses to original locations.
FIGURE 10-3 AUXILIARY MANIFOLD
L10-6 Hydraulic Check-out Procedure L10001 4/92
Checking and Adjusting Hoist System
Pressure Relief Valve
1. Install 0-5000 psi (0-35 000 kPa) pressure gauge
to pressure tap (5, Figure 10-4) on hoist valve.
FIGURE 10-4 HOIST VALVE
1. Capscrew & Washer 4. Hoist Circuit Pressure
2. Capscrew & Washer Relief Valve Adjustment
3. Power Down Pressure 5. Hoist Pressure Test Port
Adjustment
NOTE : If hoist valve assembly or relief valve cartridge
has been replaced or rebuilt, remove relief valve acorn
nut, loosen jam nut and back out adjustment screw.
Before raising body to full up position be sure there is
adequate clearance between body and any overhead
structures or electric power lines.
2. Start engine and allow accumulators to charge.
Raise dump body to full up position. Hold hoist
control valve lever in power "UP" position and
adjust engine speed to 1500 RPM.
NOTE: Do not hold in power up position any longer
than necessary to obtain an accurate reading. Over
heating of hydraulic oil may result.
3. Pressure gauge should indicate 2750 50 psi (18
961 345 kPa).
* Record pressure reading on data sheet.
4. If pressure is within specifications, go to step 7.
If pressure is not within specifications, go to step
5.
5. Remove acorn nut (4) and loosen jam nut. Turn
relief valve adjusting screw clockwise to increase
pressure or counterclockwise to decrease pres-
sure.
NOTE: Turning adjusting screw 1/16 of a turn will
change pressure approximately 100 psi (690 kPa).
6. Hold adjusting screw and tighten jam nut. Check
pressure again. Install acorn nut after correct
pressure is obtained.
7. Lower dump body completely.
8. Shut down engine and turn key switch off, wait 90
seconds for steering accumulator to bleed down.
9. Remove pressure gauge from hoist valve.
Checking and Adjusting "Power Down"
Pressure
After completing hoist relief valve setting, it is neces-
sary to adjust power "Down" pressure. This adjustment
is required to provide proper hoist circuit operation.
1. Install 0-5000 psi (0-35 000 kPa) pressure gauge
to test port (5, Figure 10-4) on hoist valve.
2. Start engine and charge accumulator. Move hoist
control lever to power "Down" position and hold
lever in this position. Increase engine RPM to high
idle.
NOTE: Do not hold in power down position any longer
than necessary to obtain an accurate reading. Over
heating of hydraulic oil may result.
3. Pressure gauge should indicate 1000 50 psi
( 690 345 kPa).
* Record pressure reading on data sheet.
4. Return engine to low idle and release hoist control
valve lever.
5. Shut down engine and turn key switch off, wait 90
seconds for steering accumulator to bleed down.
6. If pressure is within specifications, remove pres-
sure gauge and stop here. If pressure is not within
specifications, go to step 7.
7. Remove acorn nut (3) and loosen jam nut. Turn
adjusting screw in to increase pressure or out to
decrease pressure. Tighten jam nut.
8. Repeat steps 2 thru 6 until correct pressure is
obtained. Install acorn nut (3).
L10001 4/92 Hydraulic Check-out Procedure L10-7
TROUBLESHOOTING CHART FOR HOIST CIRCUIT
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Pump Not Delivering Oil
Low oil level.
Siphon plugs on hydraulic tank leaking or missing.
Tank vent breathers restricted.
Pump not priming. Air leak in suction line.
PTO drive inoperable.
Pump shaft broken.
Vane(s) stuck in the rotor slot(s).
Driven in the wrong direction of rotation.
Fill to proper level.
Tighten or install plugs.
Replace filters.
Tighten clamp connections.
Check minimum engine low idle speed.
Adjust idle speed, if necessary.
Inspect PTO drive assembly. Refer to Section F.
Remove pump and inspect.
Check pump for free rotation.
Disassemble the pump. Check for dirt or metal chips.
Clean the parts thoroughly and replace any damaged
pieces. If necessary, flush the system and refill it with
clean hydraulic oil. Repair as required.
Pump cartridge installed incorrectly. Disassemble
pump and check cartridge for proper installation ac-
cording to drive shaft rotation.
TROUBLE: Slow Hydraulic Functions
Low oil level.
Cold oil.
Air leak in suction line. (Foamy oil in tank.)
Incorrect oil viscosity.
Slow engine speed.
Low pilot oil pressure.
Fill to proper level.
Warm oil to normal operating temperature.
Tighten clamp connections. Check pump shaft seal for
air leak. Replace seal if necessary.
Completely drain hydraulic system. Refill with filtered
oil of proper viscosity.
Increase engine speed. Check high Idle speed, adjust
if necessary.
Check or adjust pilot pressure. (See auxiliary valve
adjustment).
L10-8 Hydraulic Check-out Procedure L10001 4/92
TROUBLESHOOTING CHART (Continued)
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Slow Hydraulic Functions (Continued)
Check valves in pilot lines and/or hoist-up/return lines
sticking or not installed with correct direction of free
flow.
Hoist valve spool binding.
Defective hoist relief valve.
Excess leakage past cylinder seals.
Low pump output.
Remove check valves and clean. Be certain valves are
installed with correct direction of free flow.
Inspect spool for free movement.
Refer to Checking and Adjusting Hoist System Pres-
sure Relief Valve, this section.
Remove and inspect relief valve. Repair or replace.
Repair cylinder.
Refer to Checking and Adjusting Hoist System Pres-
sure Relief Valve, this section. If pressure does not
reach 2,750 PSI and oil is not being bypassed at the
relief valve, remove and repair pump.
TROUBLE: Low Lifting Capacity Of Hoist Circuit
Low oil level.
Excessive load .
Low pilot oil pressure.
Defective hoist relief valve.
Low pump output.
Excessive leakage around hoist spool valve.
Hoist-up/return check valve stuck, orifice restricted or
installed backwards.
Pilot line check valves stuck, orifice restricted or in-
stalled backwards.
Fill to proper level.
Remove excessive load.
Refer to Hoist Circuit Checkout And Adjustment Pro-
cedure.
Refer to Checking and Adjusting Hoist System Pres-
sure Relief Valve, this section. Remove and inspect
relief valve. Repair or replace.
Refer to Checking and Adjusting Hoist System Pres-
sure Relief Valve, this section. If pressure does not
reach 2,500 PSI and oil is not being bypassed at the
relief valve, remove and repair pump.
Inspect hoist valve. Repair or replace.
Remove check valve and clean. Inspect for 0.375 in.
(9.53 mm) orifice. Replace if necessary. Install check
valve with correct direction of free oil flow.
Remove check valves and clean. Inspect for 0.040 in.
(1.016 mm) orifice. Replace if necessary. Install check
valves with correct direction of free oil flow.
L10001 4/92 Hydraulic Check-out Procedure L10-9
TROUBLESHOOTING CHART (Continued)
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Pump Making Noise
Low oil level.
Wrong viscosity oil.
Suction line restricted.
Suction line air leak.
Pump drive speed too slow or too fast.
Broken vanes or vane ring.
Fill to proper level.
Fill with proper oil.
Check all strainers and filters for dirt and sludge. Clean
if necessary.
Inspect inlet hose and fittings.
Check and adjust engine RPM.
Remove and rebuild/replace pump.
TROUBLE: Hot Oil
Low oil level.
High pressure leak in steering circuit.
Partial restriction in hoist valve.
Restricted heat exchanger.
Improper gear range during retarding.
Worn pump.
Hoist-up/return check valve orifice restricted.
Pilot line check valves installed incorrectly for free flow
or orifice restricted preventing free flow of hydraulic oil
back to tank
Fill to proper level.
Refer to Steering Circuit Test Procedure.
Check pilot pressure.
Defective relief valve or O-rings in relief valve.
Remove and clean.
Select proper gear range.
Remove pump and repair.
Remove check valve and clean. Inspect for 0.375 in.
(9.53 mm) orifice. Replace if necessary.
Remove check valves and clean. Inspect for 0.040 in.
(1.016 mm) orifice. Replace if necessary. Install check
valves with correct direction of free oil flow.
L10-10 Hydraulic Check-out Procedure L10001 4/92
HAULPAK
CHECK-OUT PROCEDURE
STEERING SYSTEM DATA SHEET
MACHINE MODEL UNIT NUMBER SERIAL NUMBER
STEERING SYSTEM
Operate Hydraulic Steering System to obtain proper operating temperature. Refer to
Check-out Procedures.
STEP 3 Steering Accumulator charged to 1050 psi (7240 kPa).
STEP 7 Steering Pressure At Piston Pump.
STEP 10 Steering Pressure At Brake Manifold.
STEP 17 Steering Valve Leakage.
STEP 17 Steering Valve Leakage (Second Test If Needed).
STEP 27 Steering Cylinder Leakage (Left Cylinder).
STEP 28 Steering Cylinder Leakage (Right Cylinder).
Name of Technician or Inspector Performing Check-Out
DATE
L10001 4/92 Hydraulic Check-out Procedure L10-11
HAULPAK
CHECK-OUT PROCEDURE
HOIST SYSTEM DATA SHEET
MACHINE MODEL UNIT NUMBER SERIAL NUMBER
HOIST SYSTEM
Operate Hydraulic Steering System to obtain proper operating temperature. Refer to
Check-out Procedures.
Auxiliary Valve
STEP 3 Auxiliary Valve Pilot Pressure.
STEP 5 Auxiliary Valve Leakage.
Hoist Valve
STEP 3 High Pressure Relief Valve.
Power Down Pressure.
STEP 3 Power Down Pressure.
Name of Technician or Inspector Performing Check-Out
DATE
L10-12 Hydraulic Check-out Procedure L10001 4/92
HYDRAULIC SYSTEM FLUSHING PROCEDURE
The following instructions outline the procedure for
flushing the hydraulic system.
1. Shut down engine and turn key switch "Off". Allow
at least 90 seconds for the steering accumulator
to bleed down. Open the brake accumulator bleed
down valves on the low brake pressure detection
manifold. This will return all contaminants in the
brake accumulators to the hydraulic tank.
2. Thoroughly clean the exterior of the tank. Drain the
hydraulic tank and remove top cover. Flush the
interior of hydraulic tank with a cleaning solvent.
Inspect all hydraulic hoses for deterioration or
damage.
NOTE: If a system component fails, all flexible hoses
should be removed and back flushed with a cleaning
solvent. Inspect for small particles which may be
trapped inside the hose.
3. Change high pressure filter elements.
4. Clean or replace the inline hydraulic screens at the
inlet to the brake/steering pump and steering
valve.
NOTE: The final filter in the filling apparatus must be 3
micron.
NOTE: Refer to the lubrication chart in Section "P",
Lubrication And Service, for proper oil selection.
5. Fill the hydraulic tank with clean filtered hydraulic
oil.
6. Fill the center tube in the hydraulic tank with oil to
prevent aeration of hydraulic oil during start up.
Replace top cover.
7. Set all controls in the "Neutral" position. Do not
steer the truck or operate controls until the next
step is completed.
8. Start the engine and run at 1000 RPM for four
minutes. This will circulate oil with all valves in the
neutral position.
9. To increase flow and turbulence in the system,
increase engine speed to full throttle and maintain
for four minutes. This will carry contaminates to
the hydraulic tank.
10. Shut down engine and turn key switch "Off". Allow
at least 90 seconds for the accumulator to bleed
down. Open the brake accumulator bleed down
valves on the low brake pressure detection mani-
fold. This will return all contaminants in the brake
accumulators to the hydraulic tank.
11. Close brake accumulator bleedown valves.
NOTE: Hydraulic tank oil temperature should be 110
o
-
130
o
F (43
o
-54
o
C) after accomplishing Step 12. If not,
repeat Step 10 to increase oil temperature to the
proper operating range.
12. Start engine and run at 1000 RPM while performing
the following:
a. Steer truck full left then full right - repeat four
times.
b. Steer full left (keeping pressure against the
steering wheel) and hold for 10 seconds.
c. Steer full right (keeping pressure against the
steering wheel) and hold for 10 seconds.
13. Increase engine speed to full throttle and steer full
left and full right.
14. Return all controls to "Neutral".
15. Reduce engine speed to 1000 RPM and perform
the following:
a. Extend hoist cylinders fully and "FLOAT" down
- repeat four times.
NOTE: As second stage starts out of hoist cylinder in
the Power Up mode, slowly decrease engine speed to
prevent sudden bottoming of the second stage.
b. Extend hoist cylinders and hold at full extension
for 10 seconds. Hoist control lever must be held
in the "Up" position.
c. Lower hoist cylinders and hold lever in "Down"
position for 10 seconds after cylinders are fully
retracted.
L10001 4/92 Hydraulic Check-out Procedure L10-13
16. Increase engine speed to full throttle and perform
the following:
a. Hoist up to full extension (see NOTE above),
then allow cylinders to float down.
b. Return hoist control to "Neutral".
17. Shut down engine and turn key switch "Off". Allow
at least 90 seconds for the accumulator to bleed
down.
18. Remove hydraulic filters, clean housings and in-
stall new filters.
19. With hydraulic system charged, inspect all con-
nections and fittings for leaks. Tighten or repair
any leaking connections.
L10-14 Hydraulic Check-out Procedure L10001 4/92
SECTION M
OPTIONS AND SPECIAL TOOLS
INDEX
LINCOLN AUTOMATIC LUBRICATION SYSTEM (M03001) . . . . . . . . . . . . . . . . . M3-1
QUICK FUEL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M5
WIGGINS QUICK FUEL SYSTEM (M05002) . . . . . . . . . . . . . . . . . . . . . . M5-1
BUCKEYE QUICK FUEL SYSTEM (M05003) . . . . . . . . . . . . . . . . . . . . . . M5-1
KIM HOTSTART SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M7-1
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8-1
AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-1
PRINCIPLES OF REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-2
AIR CONDITIONER SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . M9-3
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-5
SYSTEM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-6
Installing Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-9
System Stabilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-10
Adding R-12 (Prior to performance test) . . . . . . . . . . . . . . . . . . . . . . M9-11
System Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-12
Discharging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-13
Flushing Air Conditioner Components . . . . . . . . . . . . . . . . . . . . . . . M9-14
SYSTEM REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-15
Hoses, Fittings, and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-15
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-15
Receiver Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-15
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-15
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-16
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-16
CHECKING COMPRESSOR OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . M9-16
EVACUATING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-19
CHARGING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-22
Preparing For Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-22
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M9-23
AUTOMATIC POSITIVE LOCKING DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . M12-1
RADIATOR SHUTTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M19-1
M01009 7/91 Index M1-1
NOTES
M1-2 Index M01009 7/91
LINCOLN AUTOMATIC LUBRICATION SYSTEM
Operation
The automatic lubrication system (Figure 3-1) is con-
trolled by an electric timer and an electrically operated
solenoid valve. During truck operation, the timer peri-
odically operates a switch which energizes the sole-
noid air valve. As the solenoid air valve opens,
regulated air enters the pump air motor, and the pump
begins to operate, delivering lubricant through the
supply lines to each injector. At the same time, as
regulated air is applied to the air motor, regulated air is
applied to the vent valve which keeps the vent valve
closed until the 3-way solenoid air valve is denergized.
After the injectors have cycled, lubricant pressure rises
quickly to 2500 psi (17.5 MPa), and the pump stalls
against this pressure. The pump will remain stalled for
a few seconds until the timer switch contact is broken
and the solenoid air valve is de-energized, shutting off
the air supply. Trapped air exhausts, the vent valve
opens, and lubricant pressure in the supply line is
vented back to the reservoir. The injectors reload and
the system is reset and ready for the next lube cycle.
Figure 3-1 shows input air supply to the pump going
through the solenoid air valve, then through an air
regulator to the air powered pump. A branch line of
regulated air is routed directly to the vent valve.
Components
The system is comprised of seven basic elements plus
the necessary hoses and lube lines:
1. Air Pressure
2. Air Regulator and Gauge
3. 24 VDC Solid State Timer
4. 3-way Solenoid Air Valve
5. Lube Injectors
6. Grease Reservoir
7. Air Pump Motor
Description of Components
1. Air Powered Reciprocating Pump
a. 50:1 Pressure Ratio.
b. Reservoir Grease Capacity of 60 lbs. (27.2 kg).
2. Air Regulator and Gauge
a. Normal Operation - regulator output should be
set at 60-65 psi (414-448 kPa).
b. Extreme Winter Conditions - regulator output
may be reset to 90 psi (621 kPa).
3. 24 VDC Solid State Timer:
Operating Temperature Range -20F to 131F
(-29C to 55C). The timer is mounted in the cab
to help insure temperature stability.
FIGURE 3-1. TYPICAL AUTOMATIC LUBRICATION SYSTEM
1. Air Supply 5. Vent Valve 9. To Next Injector Grp. 13. Pipe Plug
2. D.C. Timer 6. Unloader 10. Injectors 14. Pipe Plug or
3. Solenoid Air Valve 7. Pump 11. Lubricant Reservoir Grease Coupler
4. Air Regulator & Guage 8. To Lube Point 12. Lubricant Supply Line
M03001 12/98 Lincoln Automatic Lube System M3-1
4. Solenoid Air Valve - Three-way
a. Routes system air to the appropriate locations
in the lube system.
b. Power requirement for solenoid air valve and
timer is 15 watts.
5. Injectors (SL-1)
a. Each lube injector services only one grease
point.
b. Injectors are available in banks of two, three,
four and five as well as single replacement
units.
c. Injector output is adjustable:
Maximum output = 0.08 in
3
(1.31 cc).
Minimum output = 0.008 in
3
(0.13 cc).
d. In case of air pump malfunction, each injector
is equipped with a covered grease fitting to
allow the use of external lubricating equipment.
GENERAL INSTRUCTIONS
Lubricant Required for System
Refer to Lubrication Chart, Lube Key E, for correct
lubricant specification and for specific lube points for
a specific truck model.
1. Above 90F (32C) - Use NLGI No.2 multipurpose
grease (MPG).
2. -25 to 90F (-32 to 32C) - Use NGLI No. 1 MPG.
3. Below -25F (-32C) - Refer to local supplier for
extreme cold weather lubricant requirements.
Initial Reservoir Fill
1. Remove 0.50 in. (1.27 cm) pipe plug (13, Figure
3-1) from upper portion of lubricant reservoir. This
will prevent damage to reservoir by allowing air to
escape as reservoir is being filled.
NOTE: The 830E is factory equipped with a fill line
attached to a plate, mounted on the right side of the
front bumper and connected to grease coupler (14) on
lower portion of reservoir.
2. Clean grease coupler (14) on lower portion of
reservoir.
3. Attach supply hose from external fill source to
coupler (14).
4. Fill reservoir with approximately 60 lbs. (27.24 kg)
of grease. When reservoir is filled, grease will
appear at upper pipe plug hole (13).
5. Remove supply hose from grease coupler (14).
Remove excess grease from coupler. Install pipe
plug (13) and tighten to standard torque.
System Priming
The system must be full of grease and free of air
pockets to function properly. After maintenance, if the
primary or secondary lubrication lines were replaced,
it will be necessary to reprime the system to eject all
entrapped air. To run the air pump when priming the
lube system, connect a jumper wire between the igni-
tion and solenoid posts on the solid state timer.
FIGURE 3-2. REAR LUBE INJECTOR INSTALLATION (TYPICAL)
1. Suspension, Lower LH 5. Body Pivot, L.H. 9. Suspension, Lower RH 13. Anti-Sway Bar, L.H.
2. Hoist Cyl., Top, L.H. 6. Body Pivot, R.H. 10. Hoist Cyl., Top, R.H. 14. Anti-Sway Bar, R.H.
3. Hoist Cyl., Lower, L.H. 7. Suspension, Top, R.H. 11. Hoist Cyl., Lower, R.H.
4. Suspension, Top, L.H. 8. Grease Supply Line 12. Axle Pivot Pin
M3-2 Lincoln Automatic Lube System M03001 12/98
1. Fill lube reservoir with lubricant, if necessary.
2. Remove plugs from all injector manifold dead ends
and supply lines.
3. Turn air pump vent plug counterclockwise one full
turn. To expel trapped air between air pump and
supply line connection, run air motor until grease
flows freely from the vent plug. Close vent plug
clockwise.
4. Continue to run air pump until grease flows from
any one plug opening in the system. Replace plug
in this opening.
5. Repeat step 4 until all lines are full and all plugs
replaced.
NOTE: Fill each feed line with grease before connect-
ing lines to the injector outlets and bearings. This will
prevent having to cycle the individual injectors once
for each 1.0 in. (25 mm) length of feed line between
the injector and bearing fitting.
System Checkout
To check system operation (not including timer), pro-
ceed as follows:
1. Lift the passenger seat and connect a jumper wire
between SOL terminal and LUBE SW terminal
on the 24 VDC solid state lube timer.
Turn keyswitch "ON". Pump should operate.
NOTE: If terminal post identification on the solid state
timer is not legible, refer to Figure 3-5 for terminal
positions.
2. Keep jumper wire connected until the pump stalls.
3. Disconnect jumper wire. System should vent.
Turn keyswitch "OFF".
24 VDC Solid State Timer Check
To check the solid state timer operation without waiting
for the normal timer setting, proceed as follows:
1. Remove timer dust cover.
NOTE: The timer incorporates a liquid and dust
tight cover which must be in place and secured
at all times during truck operation.
2. Adjust timer to 5 minute interval setting.
3. The timer should cycle in five minutes if the truck
is operating.
NOTE: If the timer check is being made on a cold start,
the first cycle will be approximately double the nominal
setting. All subsequent cycles should be within the
selected time tolerance.
4. Voltage checks at the timer should be accom-
plished if the above checks do not identify the
problem.
a. Insure timer ground connection is clean and
tight.
b. Using a Volt-Ohm meter, read the voltage be-
tween positive and negative posts on the solid
state timer with the truck keyswitch "ON".
Normal reading should be 18-26 VDC, depend-
ing upon whether or not the engine is running.
24 VDC Solid State Timer Adjustment
The timer is factory set for a nominal 2.5 minute (off
time) interval. Dwell time is approximately 1 minute, 15
seconds. A longer interval (off time) is obtained by
turning the Selector knob (3, Figure 3-3) to the desired
position .
NOTE: Set timer by turning the Selector knob (3) to the
2.5 minute setting point. Then, turn the Selector clock-
wise, one detent at a time, to the desired setting, or
until the maximum limit of eighty minutes is reached.
The solid state timer is a sealed unit, do not attempt
disassembly.
FIGURE 3-3. TIMER (TOP COVER REMOVED)
1. Timer 3. Timer Selector
2. Red LED (Light Emitting Diode)
indicates pump solenoid is "ON".
M03001 12/98 Lincoln Automatic Lube System M3-3
Injectors (SL-1 Series " H")
Injector Specifications
a. Each lube injector services only one grease
point. In case of pump malfunction, each injec-
tor is equipped with a covered grease fitting to
allow the use of external lubricating equipment.
b. Injectors are available in banks of two, three,
four and five as well as single replacement
units.
c. Injector output is adjustable:
Maximum output = 0.08 in
3
(1.31 cc).
Minimum output = 0.008 in
3
(0.13 cc).
d. Operating Pressure:
Minimum - 1850 psi (12 755 kPa)
Maximum - 3500 psi (24 133 kPa)
Recommended - 2500 psi (17 238 kPa)
Maximum Vent Pressure - (Recharge)
600 psi (4 137 kPa)
Injector Adjustment
The injectors may be adjusted to supply from 0.008 in
3
to 0.08 in
3
(0.13 cc to 1.31 cc) of lubricant per injection
cycle. The injector piston travel distance determines
the amount of lubricant supplied. This travel is in turn
controlled by an adjusting screw in the top of the
injector housing.
Turn the adjusting screw (1, Figure 3-4) counterclock-
wise to increase lubricant amount delivered and clock-
wise to decrease the lubricant amount.
When the injector is not pressurized, maximum injector
delivery volume is attained by turning the adjusting
screw (1) fully counterclockwise until the indicating pin
(8) just touches the adjusting screw. At the maximum
delivery point, about 0.38 inch (9.7 mm) adjusting
screw threads should be showing. Decrease the deliv-
ered lubricant amount by turning the adjusting screw
clockwise to limit injector piston travel. If only half the
lubricant is needed, turn the adjusting screw to the
point where about 0.19 inch (4.8 mm) threads are
showing. The injector will be set at minimum delivery
point with about 0.009 inch (0.22 mm) thread showing.
NOTE: The above information concerns adjustment of
injector delivery volume. The timer adjustment should
also be changed, if overall lubricant delivery is too little
or too much. Injector output should NOT be adjusted
to less than one-fourth capacity.
FIGURE 3-4. TYPE SL-1 INJECTOR (SINGLE)
1. Adjusting Screw 11. Spring Seat
2. Locknut 12. Plunger
3. Piston Stop Plug 13. Viton Packing
4. Gasket 14. Inlet Disc
5. Washer 15. Viton Packing
6. Viton O-Ring 16. Washer
7. Injector Body Assy. 17. Gasket
8. Piston Assembly 18. Adapter Bolt
9. Fitting Assembly 19. Adapter
10. Plunger Spring 20. Viton Packing
NOTE: The Piston Assembly (8) has a visible indicator
pin at the top of the assembly to verify the injector
operation.
FIGURE 3-4A. INJECTOR (MANIFOLD TYPE)
M3-4 Lincoln Automatic Lube System M03001 12/98
INJECTOR OPERATION
STAGE 1.
The injector piston (2) is in its normal or
"rest" position. The discharge chamber (3)
is filled with lubricant from the previous cy-
cle. Under the pressure of incoming lubri-
cant (6), the slide valve (5) is about to open
the passage (4) leading to the measuring
chamber (1) above the injector piston (2).
STAGE 2.
When the slide valve (5) uncovers the pas-
sage (4), lubricant (6) is admitted to the
measuring chamber (1) above the injector
piston (2) which forces lubricant from the
discharge chamber (3) through the outlet
port (7) to the bearing.
STAGE 3.
As the injector piston (2) completes its
stroke, it pushes the slide valve (5) past the
passage (4), cutting off further admission of
lubricant (6) to the passage (4) and meas-
uring chamber (1). The injector piston (2)
and slide valve (5) remain in this position
until lubricant pressure in the supply line (6)
is vented (relieved at the pump).
STAGE 4.
After venting, the injector spring expands,
causing the slide valve (5) to move, so that
the passage (4) and discharge chamber (3)
are connected by a valve port (8). Further
expansion of the spring causes the piston
to move upward, forcing the lubricant in the
measuring chamber (1) through the pas-
sage (4) and valve port (8) to refill the dis-
charge chamber (3).
Injector is now ready for the next cycle.
M03001 12/98 Lincoln Automatic Lube System M3-5
TROUBLESHOOTING CHART
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Pump Does Not Operate.
Low air pressure.
Lube system not grounded.
Electrical power loss.
Timer malfunction.
Solenoid valve malfunctioning.
Pump malfunction.
Adjust air pressure to 60 -- 65 psi (414 -- 448 kPa), if
necessary [90 psi (621 kPa) during cold weather].
Correct grounding connections to pump assembly and
truck chassis.
Locate cause of power loss and repair. 24 VDC power
required; be sure keyswitch is "ON".
Replace timer assembly
Replace the solenoid valve assembly
Replace pump assembly
NOTE: On intial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing
cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as specified.
TROUBLE: Pump Will Not Prime
Low lubricant supply.
Dirt in reservoir, pump inlet clogged.
Air trapped in pump.
Check lubricant level in reservoir and service reservoir
with specified grease until grease weeps from vent
plug.
Clean reservoir completely, remove and clean pump
assembly thoroughly.
Open vent plug counterclockwise with pump running.
When grease flows freely from vent, close vent plug
clockwise.
NOTE: System air applied to the lube system air pump is also applied to the vent valve. When the pump is operating,
air pressure keeps the vent valve closed and grease is directed from the pump outlet and to the injectors. When air
supply to the air motor is interrupted, the vent valve opens and supply pressure vents back to the reservoir.
Safety unloader valve faulty. Replace safety unloader valve.
NOTE: The safety unloader valve prevents buildup of excessively high pressure in the lube system which could
damage components. This valve is factory preset to open between 3750 - 4250 psi (25.9 - 29.3 MPa). The valve is not
serviceable, nor is it adjustable.
Outlet check valve clogged. Remove check valve from pump outlet, clean thor-
oughly or replace.
M3-6 Lincoln Automatic Lube System M03001 12/98
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Pump Will Not Build Pressure
Pump not primed.
Air trapped in lubricant supply line.
Lubricant supply line leaking.
Vent valve leaking.
Pump cylinder scored, by-passing air.
See items in Pump Will Not Prime.
Prime system to remove trapped air.
Check lines and connections to repair leakage.
Clean or replace vent valve.
Repair or replace pump cylinder or pump assembly.
TROUBLE: Injector Indicator Stem Does Not Operate
NOTE: Normally, during operation, the injector indicator stem (Figure 3-4) will move into the body of the injector when
pressure builds properly. When the system vents (pressure release) the indicator stem will again move out into the
adjusting yoke.
Malfunctioning injector - usually indicated by the air
pump building pressure and then venting.
All injectors inoperative - pump build up not sufficient
to cycle injectors.
Replace individual injector assembly.
Service and/or replace pump assembly.
FIGURE 3-5. TYPICAL ELECTRICAL HOOKUP FOR AUTOMATIC LUBE
1. Solenoid Air Valve 5. Fuse Holder 9. Solenoid 13. Battery
2. Main Air Supply 6. Keyswitch 10. Relay 14. Keyswitch
3. To Air Pump Motor 7. To Battery (+ ) 11. Timer (solid State) 15. 7.5 Amp Fuse
4. Timer * 8. To Ground (-) 12. Timer (Housing)
* Keyswitch (6) must be closed ("ON") to energize Timer (4).
M03001 12/98 Lincoln Automatic Lube System M3-7
NOTES
M3-8 Lincoln Automatic Lube System M03001 12/98
WIGGINS QUICK FILL FUEL SYSTEM
FUEL RECEIVER
The fuel receiver (3, Figure 5-1) is normally mounted
on the fuel tank (1). Optional locations are the left hand
frame rail (Figure 5-3) or at the Service Center in front.
Keep the cap on the receiver to prevent dirt build up in
valve area and nozzle grooves. If fuel spills from tank
breather valve, or tank does not completely fill, check
breather valve to see that float balls are in place and
outlet screen is clean. If valve is operating properly, the
problem will be with the fuel supply system.
FIGURE 5-1. FUEL TANK BREATHER & RECEIVER INSTALLATION
1. Fuel Tank
2. Breather Valve
3. Fuel Receiver
4. Fuel Level Gauge
NOTE: This Illustration Represents a Typical Installation.
Fuel tank may vary in size, shape and location depending on truck model.
M05002 10/96 Wiggins Quick Fill Fuel System M5-1
TANK BREATHER VALVE
Removal
Unscrew breather valve (2, Figure 5-1) from tank (1).
Installation
Screw breather valve into tank.
Disassembly
1. Remove spring clamp (4, Figure 5-2) from outlet.
2. Pull off rubber cover and screen (3).
3. Unscrew nut (5) from top of breather valve. Re-
move cover (6), spring (7), and steel ball (8).
4. Slide valve assembly (9) from housing.
5. Disengage tapered spring (1) containing three
balls (2) from valve stem.
Assembly
1. Clean and inspect all parts. If valve, body, or
springs are damaged, replace complete breather
valve.
2. Install in order; tapered spring, one steel ball, one
cork ball and one hollow aluminum ball.
3. Engage three coils of spring on small end of valve
stem with hollow aluminum ball.
4. Install valve into housing.
5. Place steel ball (8) on top of valve. Install spring
(7).
6. Place cover (6) over spring. Screw on large nut (5).
7. Install screen and rubber cover (3) over outlet.
8. Install spring clamp (4).
FIGURE 5-2. BREATHER VALVE
1. Tapered Spring
2. Float Balls
3. Cover and Screen
4. Spring Clamp
5. Nut
6. Cover
7. Spring
8. Steel Ball
9. Valve Assembly
M5-2 Wiggins Quick Fill Fuel System M05002 10/96
LEFT SIDE FILL
This location permits fueling the truck from the left side.
Keep the cap on the receiver to prevent dirt build up in
valve area and nozzle grooves. If fuel spills from tank
breather valve, or tank does not completely fill, check
breather valve to see that float balls are in place and
outlet screen is clean. If valve is operating properly, the
problem will be with the fuel supply system.
FIGURE 5-3. LEFT SIDE FILL
1. Hydraulic Tank 3. Frame Rails 5. Filler Cap 7. Refueling Box
2. Filler Hose 4. Fuel Tank 6. Receiver Assembly 8. Capscrew
9. Tapped Bar
NOTE: This Illustration Represents a Typical Installation. Installation may vary depending on truck model.
M05002 10/96 Wiggins Quick Fill Fuel System M5-3
NOTES
M5-4 Wiggins Quick Fill Fuel System M05002 10/96
BUCKEYE QUICK FUEL SYSTEM
FUEL TANK BREATHER VALVE
Maintenance
Normal maintenance involves cleaning or replacement
of the breather valve filter during 1000 hour servicing.
Operation in extremely dusty conditions may require
more frequent cleaning or replacement intervals.
Filter Service
1. Remove three capscrews (7, Figure 5-1) on vent
housing.
2. Remove housing (1) and filter (3).
3. Clean the filter in solvent and blow dry with com-
pressed air.
4. Inspect filter for damage and replace if necessary.
5. Install filter on seat (6).
6. Inspect the housing O-ring seal (8) and replace if
necessary.
7. Install the housing and secure in place with cap-
screws (7).
Disassembly
1. Remove breather valve assembly from the fuel
tank. (Refer to Figure 5-2.)
2. Loosen three capscrews (7, Figure 5-1) and re-
move vent housing (1).
3. Remove filter (3).
4. Compress the spring (12, Figure 5-1) and remove
the cotter pin (17).
5. Remove the retaining washer (16), spring and balls
(13, 14, and 15).
Inspection
1. Inspect filter and clean or replace as required.
2. Clean all parts thoroughly and inspect for damage.
Assembly
1. Assemble using new O-ring seals.
2. Install filter (3) and housing (1).
3. Insert balls in order as shown in Figure 5-1.
a. Install aluminum ball.
b. Install plastic ball.
c. Install steel ball.
4. Insert spring (12) and retaining washer (16). Com-
press spring to insert cotter pin (17).
5. Install assembly in fuel tank.
91492
FIGURE 5-1. FUEL TANK BREATHER VALVE
1. Vent Housing
2. Inner Tube
3. Filter
4. Cotter Pin
5. O-ring
6. Seat
7. Capscrew
8. O-ring
9. Vent Base
10. Nipple
11. Outer Tube
12. Spring
13. Aluminum Ball
14. Plastic Ball
15. Steel Ball
16. Retaining Washer
17. Cotter Pin
M05003 5/90 Buckeye Quick Fill Fuel System M5-1
FUEL RECEIVER
The fuel receiver (3, Figure 5-2) is mounted on the fuel
tank (2). Keep the cap on the receiver to prevent dirt
build-up during truck operation. If fuel spills from
breather valve or tank does not fill completely, check
breather to see that the balls are in place and the filter
is clean.
91493
FIGURE 5-2. FUEL TANK BREATHER AND
RECEIVER INSTALLATION
1. Breather Valve
2. Fuel Tank
3. Fuel Receiver
4. Fuel Level Gauge
NOTE:
This Illustration Represents a Typical Installation.
Fuel tank may vary in size, shape and location
depending on truck model.
M5-2 Buckeye Quick Fill Fuel System M05003 5/90
ENGINE COOLANT AND OIL HEATERS
ENGINE COOLANT HEATER
To aid in cold weather starting, the truck can be
equipped with a cooling system heater. One high ca-
pacity coolant heating unit is mounted on the right side
of the engine block. The system includes:
Heaters
Thermostat
Hoses
220 volt Receptacle
Power Cables, Thermostat Wiring, and Junc-
tion Box
Heater operation is controlled by a thermostat
mounted on the intake end of the heating unit. The
thermostat turns the heater On at 120F (48C) and
Off at 140F (60C).
Do not operate engine while the cooling system
heater is operating as it will cause a lack of circu-
lation in the heater and burn out the heating ele-
ments.
Maintenance
To check for operation of the heating unit, the outlet
water hose should feel warm to the touch.
1. Check all electrical connections to insure proper
connections are made.
2. Check for a burned out heating element (4, Figure
7-1)(Do not remove heating unit from the truck).
a. Remove the two Phillips head screws and slide
end cover (5) out of the way.
b. Connect a voltmeter at the two electrical termi-
nals (6) and check for operating voltage (220 to
230 volts) while coolant temperature is below
120F (48C). If correct voltage is present, the
heating element is defective and should be
replaced.
3. If correct voltage (measured above) is not read at
heating element terminals, the thermostat is de-
fective and should be replaced.
HEATING ELEMENT
Removal
1. Disconnect the external power source at the plug-
in receptacle.
2. Open petcock valve on lower radiator coolant tube
and drain coolant. Cooling system holds approxi-
mately 48 gallons (182 L.) of coolant.
3. Remove heating element.
a. Remove the two Phillips head screws from
cover (5) at power cable entry. Slide cover out
of the way.
b. Disconnect the two electrical leads (6) and
remove heating element (4) from the cartridge.
Installation
1. Install new heating element.
91464
FIGURE 7-1. COOLANT HEATER
1. Thermostat
2. Heater Assembly
3. Water Outlet Port
4. Heating Element
5. Cover
6. Terminals
M07006 9/90 Engine Coolant Heater M7-1
a. Cover the new heating element threads with an
anti-seize thread compound.
b. Screw heating element into cartridge and
tighten securely to insure against leaks.
2. Connect the electrical leads.
3. Slide element cover into position and secure with
screws.
4. Close drain petcock and refill system with coolant.
Refer to section "P", Lubrication And Service for
proper coolant and mixtures.
5. Start engine, allow coolant to circulate 10-15 min-
utes to eliminate trapped air in cooling system.
Shut down engine.
6. Check for leaks and proper coolant level.
7. Plug in the external power source. After allowing
time for the element to warm up, outlet hose
should feel warm to the touch.
THERMOSTAT
Removal
1. Disconnect the external power source at the plug
in receptacle.
NOTE: It is not necessary to remove the thermostat
assembly from the heater.
2. Remove the two screws and slide cover (1,Figure
7-2) out of the way.
3. Disconnect the two electrical leads.
4. Loosen the two setscrews (4) and remove the
temperature sensing unit (2).
Installation
1. Install a new temperature sensing unit and secure
in place with two setscrews (4).
2. Connect the electrical leads.
3. Move cover (1) into position and secure in place
with screws.
4. Plug in the external power source.
After allowing time for the element to warm up, outlet
hose should feel warm to the touch.
91465
FIGURE 7-2. THERMOSTAT ASSEMBLY
1. Cover
2. Temperature Sensing
Unit
3. Housing
4. Setscrew
M7-2 Engine Coolant Heater M07006 9/90
TRANSMISSION AND ENGINE OIL
HEATERS
One 230 volt, 600 watt engine oil heater is located in
the engine and transmission oil pans. Operation of the
oil heaters is controlled by the coolant system heater
thermostat.
Troubleshooting
Operation of the heaters can be checked by touching
each mounting boss (3, Figure 7-3) on the oil pan after
allowing time for the heaters to warm up:
1. If the boss (3, Figure 7-3) feels warm to the touch,
the heater is functioning.
2. If no heat is detected, verify proper operating
voltage (220 to 230 volts) at the heating element
leads.
3. If voltage is not present, check the thermostat
circuit at the engine coolant heater. (Refer to
Engine Coolant Heater.) Also check circuits be-
tween heaters and the plug-in receptacle.
4. If no heat is detected, but voltage is correct, the
heating element must be replaced.
HEATING ELEMENT
Removal
1. Disconnect the external power source at the plug-
in receptacle.
NOTE: Heater element replacement can be accom-
plished without draining the crankcase or transmis-
sion oil by disassembling all parts from the element
cover. Figures 7-4 and 7-5 show the complete heater
assembly removed from the pan.
2. Remove cap (7, Figure 7-4), remove connectors
(9) and disconnect wires (8).
3. Remove cord grip cap (2) and remove power cord
from the housing.
4. Remove the heater housing (5) from the element
cover (6).
5. Loosen the setscrew (3, Figure 7-5) and remove
the heater element (2) from the cover (1).
81265
FIGURE 7-3. ENGINE OIL HEATER
1. Heater Assembly
2. Power Cord
3. Oil Pan Mounting
Boss
81266
FIGURE 7-4. HEATER ASSEMBLY
1. Power Cord
2. Cord Grip Cap
3. Washer
4. Rubber Bushing
5. Housing
6. Element Cover
7. Housing Cap
8. Electrical Leads
9. Wire Connectors
M07006 9/90 Engine Coolant Heater M7-3
Installation
1. Install a new heater element and secure in place
with the setscrew (3, Figure 7-5).
2. Coat the threads of the element cover (6, Figure
7-4) with an anti-seize compound and install into
housing (5).
3. Insert the power cord (1), cord grip bushing (4),
washer (3) and cap (2) into the housing.
4. Twist the wires together and place a screw-on
connecter on each pair.
5. Adjust the power cord and tighten the cord grip
cover.
6. Replace the housing cap.
7. If any oil was drained, refill with proper oil. Refer to
section "P", Lubrication And Service for proper oil.
FIGURE 7-5. HEATING ELEMENT REMOVAL
1. Element Cover
2. Heating Element
3. Element Retaining
Setscrew
81268
1. Junction Box
2. Terminal Strip
FIGURE 7-6 WIRING DIAGRAM
M7-4 Engine Coolant Heater M07006 9/90
SPECIAL TOOLS
SECTION C
Special tools have been referenced throughout this
manual. The tools shown here will be listed under the
section where they were used. Dimensioned tools
maybe manufactured locally and non-dimensioned
tools may be purchased under the indicated part num-
ber.
Unless noted for a specific application, these tools may
be used for both the 140M and 210M HAULPAK
Trucks.
FIGURE 8-1. CUMMINS ENGINE LIFTING TOOL
M08003 9/90 Special Tools M8-1
SECTION G
FIGURE 8-2.
M8-2 Special Tools M08003 9/90
SECTION G
FIGURE 8-3.
M08003 9/90 Special Tools M8-3
SECTION G
FIGURE 8-4.
M8-4 Special Tools M08003 9/90
SECTION G
FIGURE 8-5.
M08003 9/90 Special Tools M8-5
SECTION G
FIGURE 8-6.
M8-6 Special Tools M08003 9/90
FIGURE 8-7.
( USED WITH TORQUING BASE SS 1122)
SECTION G
M08003 9/90 Special Tools M8-7
SECTION G
FIGURE 8-8.
M8-8 Special Tools M08003 9/90
SECTION G
FIGURE 8-9.
( USED WITH TORQUING BASE SS 1121)
M08003 9/90 Special Tools M8-9
SECTION G
FIGURE 8-10.
M8-10 Special Tools M08003 9/90
SECTION G
FIGURE 8-11. SS1128 DIFFERENTIAL LIFTING BRACKET
FIGURE 8-12.
M08003 9/90 Special Tools M8-11
SECTION G
FIGURE 8-13.
FIGURE 8-14.
FIGURE 8-15.
FIGURE 8-16.
M8-12 Special Tools M08003 9/90
SECTION H
SECTION J
SECTION J
SECTION J
BRAKE HUB RETAINING BRACKET
(140M and 210M)
FIGURE 8-17. VD4665 NITROGEN CHARGING KIT
FIGURE 8-18.
FIGURE 8-19.
FIGURE 8-20. EB1722 WEAR INDICATOR
FOR OIL DISC BRAKES
M08003 9/90 Special Tools M8-13
SECTION J
FIGURE 8-21.
M8-14 Special Tools M08003 9/90
SECTION L
PRESSURE SWITCH TESTER
KENT-MOORE PART NUMBER J-33884-4
Tester may be purchased from:
Kent-Moore Heavy Duty Div.
Sealed Power Corp.
29784 Little Mack
Roseville, MI 48066-9984
Telephone No. (313) 774-9500
Telex: 23-5377
Telex outside North America: 023-5377
FIGURE 8-22.
FIGURE 8-23.
M08003 9/90 Special Tools M8-15
SECTION L
FIGURE 8-24.
M8-16 Special Tools M08003 9/90
SECTION L
FIGURE 8-25.
FIGURE 8-26.
FIGURE 8-27.
FIGURE 8-28.
M08003 9/90 Special Tools M8-17
NOTES
M8-18 Special Tools M08003 9/90
AIR CONDITIONING SYSTEM
Environmental Impact
Environmental studies have indicated a weakening of
the earths protective Ozone (O3) layer in the outer
stratosphere. Chloro-flouro-carbon compounds
(CFCs), such as R-12 refrigerant (Freon
), commonly
used in mobile equipment air conditioning systems,
has been identified as a possible contributing factor to
the Ozone depletion.
Consequently, legislative bodies in more than 130
countries have mandated that the production and dis-
tribution of R-12 refrigerant be discontinued after 1995.
In addition, the practice of releasing refrigerant to the
atmosphere during the charging/recharging proce-
dure is now prohibited.
FIGURE 9-1. BASIC AIR CONDITIONING SYSTEM (TYPICAL)
1. Blower Switch
2. Thermostatic Switch
3. Battery Supply
4. Circuit breaker
5. Blower
6. Temperature Sensor
7. Evaporator
8. Expansion Valve
9. Suction Line
10. Test gauges & Manifold
11. Compressor
12. Refrigerant Container
13. Magnetic Clutch
14. Compressor Drive Pulley
15. Receiver/Drier
16. Discharge Line
17. Condenser
M09003 11/95 Air Conditioning System M9-1
for R-12 Refrigerant
These new restrictions require the use of new equip-
ment and new procedures which are significantly dif-
ferent from those traditionally used in air conditioning
service techniques. The use of new equipment and
techniques permits the complete recovery of refriger-
ant, which will not only help to protect the environment,
but through the re-cycling of the refrigerant, will pre-
serve the physical supply as well as help to reduce the
cost of the refrigerant.
OPERATOR CAB AIR CONDITIONING
Mining and construction vehicles have unique charac-
teristics of vibration, shock-loading, operator changes,
and climate conditions that present different design
and installation problems for Air Conditioning systems.
Off-highway equipment, in general, is unique enough
that normal automotive or highway truck engineering
is not sufficient to provide the reliability to endure the
various work cycles encountered.
Air conditioning is a form of environmental control. As
applied to the cab, it refers to the control of tempera-
ture, humidity, cleanliness, and circulation of air. In the
broad sense, a heating unit is as much an air condi-
tioner as is a cooling unit. The term Air Conditioner
is commonly used to identify an air cooling unit. To be
consistent with common usage, the term Air Condi-
tioner will refer to the cooling unit utilizing the princi-
ples of refrigeration; sometimes referred to as the
evaporator unit.
The cab tightness, insulation, and isolation from heat
sources is very important to the efficiency of the sys-
tem. It is advisable to close all vents, even the intakes
of pressurization systems, when there are high humid-
ity conditions.
The general cleanliness of the system and components
is important. Dust or dirt collected in the condenser,
evaporator, or air filters decreases the systems cooling
capacity.
The refrigerant pump (compressor), condenser,
evaporator units, hoses and fittings must be installed
clean and tight and be capable of withstanding the
strain and abuse they are subjected to from off-high-
way vehicles.
Equipment downtime costs are high enough to encour-
age service areas to perform preventive maintenance
at regular intervals on vehicle air-conditioning systems.
(Cleaning, checking belt tightness, and operation of
electrical components).
PRINCIPLES OF REFRIGERATION
A review of the principles of air conditioning will relate
the function of the components, the technique of
trouble shooting and the corrective action necessary
to keep the A/C unit into top operating efficiency.
Too frequently, the operator and the serviceman over-
look the primary fact that no A/C system will function
properly unless it is operated within a completely con-
trolled cab environment. The circulation of air must be
a directed flow. The cab must be sealed against seep-
age of ambient air. The cab interior must be maintained
for cleanliness, dust, and dirt which, if picked up in the
air system, will clog the intake side of the evaporator
coil.
REFRIGERATION - THE ACT OF COOLING
differential.
Installation Of Locking Differential To Replace
The Standard HAULPAK
Differential
1. Refer to Section "G" for Differential Carrier Assem-
bly Removal, Differential Cage Removal, and Dif-
ferential Cage Disassembly.
2. Remove all roll pins from differential cage.
3. None of the internal parts of the HAULPAK
Suspension
Charging . . . . . . . . . . . . . . . . . . . H4-1
Front . . . . . . . . . . . . . . . . . . . . . H2-1
Rear . . . . . . . . . . . . . . . . . . . . . H3-1
Spherical Bearing (Rear) . . . . . . . . . . H3-4
Hydraulic
Circuit Description . . . . . . . . . . . . . . L2-1
Diagram . . . . . . . . . . Schematics, Section R
Filter Pressure Switch . . . . . . . . . . . . L3-12
Hydraulic Filter(s) . . . . . . . . . . . . . . L3-10
Pump Specifications . . . . . . . . . . . . L6-21
Steering Brake Pump Repair . . . . . . . . L6-7
Steering Circuit . . . . . . . . . . . . . . . L4-1
System . . . . . . . . . . . . . . . . . . . L2-1
Tank . . . . . . . . . . . . . . . . . . . . . L3-9
Breathers . . . . . . . . . . . . . . . . . L3-10
I
Indicator Light Circuit . . . . . . . . . . . . . D3-3
Instrument Panel . . . . . . . . . . . . . . . N5-1
K
Keyswitch . . . . . . . . . . . . . . . . . . . D4-6
L
Light Circuit . . . . . . . . . . . . . . . . . . D3-6
Low Brake Pressure Detection Module . . . . J3-1
Low Pressure Sensing Valve . . . . . . . . . J2-2
Lubrication . . . . . . . . . . . . . . . . . . . P2-1
M
Manifold, Brake . . . . . . . . . . . . . . . . J3-1
Manifold, Stop Light and Tee . . . . . . . . . J2-5
Manual/Auto Maintenance Switch . . . . . . . D4-5
Metric Conversion Chart . . . . . . . . . . . . A5-1
N
Nitrogen Charging, Accumulators, . . . . . . . L6-1
Nitrogen Charging, Suspensions . . . . . . . H4-3
Q1-2 Alphabetical Index Q01014 9/90
O
Oil Cooled Disc Brakes (Rear) . . . . . . . . . J6-1
Bleeding Procedure (Rear) . . . . . . . . . J6-13
Brake Disc Wear Indicator . . . . . . . . . J6-14
Brake Circuit . . . . . . . . . . . . . . . . . J2-1
Circuit Check-Out Procedure . . . . . . . . . J4-1
Circuit Component Service . . . . . . . . . . J3-1
Diagram (Hydraulic) . . . Schematics, Section R
Disc Pack Specifications . . . . . . . . . . J6-12
Heat Exchanger . . . . . . . . . . . . . . . C3-4
Oil Temperature Warning Switch . . . . . . . D3-5
Piston . . . . . . . . . . . . . . . . . . . . . J6-6
Return Spring Specifications . . . . . . . . . J6-6
Oil Cooled Disc Brakes (contd)
Seal Assembly/Installation . . . . . . . . . . J6-7
Oil Pressure Gauge, (Engine) . . . . . . . . . D3-3
Oil Pressure Sensor . . . . . . . . . . . . . . D3-3
Oil Pressure Switch . . . . . . . . . . . . . . D3-3
Operators Cab . . . . . . . . . . . . . . . . . N2-1
Seat . . . . . . . . . . . . . . . . . . . . . N4-1
Operator Controls . . . . . . . . . . . . . . . N5-1
Retarder Operation . . . . . . . . . . . . . . N5-8
Throttle Pedal . . . . . . . . . . . . . . . N5-13
P
Panel, Instrument . . . . . . . . . . . . . . . N5-4
Panhard Rod Bearing . . . . . . . . . . . . G4-3
Park Brake . . . . . . . . . . . . . . . . . . . J7-1
Park Brake Actuator . . . . . . . . . . . . . . J7-2
Park Brake Circuit . . . . . . . . . . . . . . . D3-2
Parking Brake-Hoist Valve Circuit . . . . . . . L7-2
Power Down Pressure . . . . . . . . . . . . L10-7
Power Take-Off . . . . . . . . . . . . . . . . F4-1
Pressure Relief Valve, Adjusting . . . . . . . L10-7
Pump, Hoist . . . . . . . . . . . . . . . . . . L3-1
Pump, Steering . . . . . . . . . . . . . . . . . L4-1
Q
Quick Fuel Systems . . . . . . . . . . . . . M5-1
R
Radiator . . . . . . . . . . . . . . . . . . . . C3-1
Radiator Shutters . . . . . . . . . . . . . . M19-1
Relay Box . . . . . . . . . . . . . . . . . . . D4-6
Rear Brake Shuttle Valves . . . . . . . . . . . J2-5
Rear Wet Disc Brakes . . . . . . . . . . . . J6-1
Retarder Operation . . . . . . . . . . . . . . N5-8
Retarder Treadle Valve . . . . . . . . . . . . J3-10
Return Hydraulic Filter(s) . . . . . . . . . . . L3-10
S
Safety Rules . . . . . . . . . . . . . . . . . A3-1
Seat, Operators . . . . . . . . . . . . . . . . N4-1
Service Brake, Treadle Valve . . . . . . . . . J3-2
Shutters, Radiator . . . . . . . . . . . . . . M19-1
Shuttle Valves, Rear Brake . . . . . . . . . J2-5
Solenoid, Start . . . . . . . . . . . . . . . . D4-6
Special Tools . . . . . . . . . . . . . . . . . M8-1
Specifications . . . . . . . . . . . . . . . . . A2-1
Speedometer . . . . . . . . . . . . . . . . . D3-3
Spider Gear . . . . . . . . . . . . . . . . . . G5-8
Spindle . . . . . . . . . . . . . . . . . . . . G3-1
Start Solenoid . . . . . . . . . . . . . . . . . D4-6
Starter, 24V . . . . . . . . . . . . . . . . . . D3-8
Steering Bleeddown Circuit . . . . . . . . . . D3-5
Steering Circuit . . . . . . . . . . . . . . . . L4-1
Steering Control Valve . . . . . . . . . . . . L5-1
Steering Cylinders . . . . . . . . . . . . . . L4-3
Steering Pressure Switch . . . . . . . . . . . L4-3
Structures
Body Pads . . . . . . . . . . . . . . . . . . B2-1
Body Pivot Pins . . . . . . . . . . . . . . . B2-1
Body Position Indicatior . . . . . . . . . . . B3-4
Body-Up Pin . . . . . . . . . . . . . . . . . B3-3
Cowl and Hood . . . . . . . . . . . . . . . B2-1
Decks . . . . . . . . . . . . . . . . . . . . B2-1
Dump Body . . . . . . . . . . . . . . . . . B3-1
Fuel Tank . . . . . . . . . . . . . . . . . . B4-1
Liner Plates/Body Repair . . . . . . . . . . B3-4
Rock Ejectors . . . . . . . . . . . . . . . . B3-4
Switch, Body-Up Limit . . . . . . . . . B3-4, D3-5
Switch, Brake Pressure Warning . . . . . . . J2-5
System, Electrical . . . . . . . . . . . . . . . D2-1
Q01014 9/90 Alphabetical Index Q1-3
T
Tachometer Circuit . . . . . . . . . . . . . . D3-3
Tank, Hydraulic . . . . . . . . . . . . . . . . L3-9
Tank, Fuel . . . . . . . . . . . . . . . . . . B4-1
Throttle Control Pedal . . . . . . . . . . . . N5-13
Tires and Rims . . . . . . . . . . . . . . . . G2-1
Front . . . . . . . . . . . . . . . . . . . . G2-3
Rear . . . . . . . . . . . . . . . . . . . . . G2-4
Removal . . . . . . . . . . . . . . . . . . . G2-2
Tire Matching . . . . . . . . . . . . . . . . G2-5
Toe-In Adjustment . . . . . . . . . . . . . . G3-6
Torque Chart, Standard . . . . . . . . . . . . A5-1
Transmission . . . . . . . . . . . . . . . . . . F2-1
Transmission Circuit Components . . . . . . D4-6
Check Light . . . . . . . . . . . . . . . . . D4-1
"Do Not Shift" Light . . . . . . . . . . . . . D4-1
Transmission Control Circuits . . . . . . . . D4-3
Transmission Drive Line . . . . . . . . . . . F5-1
Transmission Filter . . . . . . . . . . . . . . F2-4
Transmission Heat Exchanger . . . . . . . . F3-1
Troubleshooting
Air Conditioning . . . . . . . . . . . . . . M9-22
Brake System . . . . . . . . . . . . . . . . J2-5
Hydraulic System . . . . . . . . . . . . . . L10-8
V
Valves
Accumulator Charging Valve . . . . . . . . L6-4
Accumulator Discharging Valve . . . . . . . J2-2
Accumulator Shuttle Valve . . . . . . . . . . J2-2
Auxiliary Valve Adjustment . . . . . . . . L10-6
Brake Lock Shuttle Valve . . . . . . . . . . J2-3
Brake Lock Solenoid Valve . . . . . . . . . J2-3
Brake Manifold Shuttle Valve . . . . . . . . J2-3
Check Valves, Hoist Circuit . L7-2, L10-9, L10-10
Emergency Apply Valve . . . . . . . . . . . J2-3
Hoist Valve . . . . . . . . . . . . . . . . . . L8-1
Low-Pressure Sensing Shuttle . . . . . . . . J2-2
Overcenter Valve . . . . . . . . . . . . . . L7-2
Pressure Reducing Valve . . . . . . . . . . L7-2
Retarder Treadle Valve . . . . . . . . . . J3-10
Service Brake Treadle Valve . . . . . . . . J3-2
Shuttle Valves
Accumulator Shuttle Valve . . . . . . . . . J2-2
Brake Lock Shuttle Valve . . . . . . . . . J2-3
Rear Brake Shuttle Valves . . . . . . . . J2-5
Service Brake/Retarder Shuttle Valve . . . J2-4
Steering Bleeddown Solenoid Valve . . . . . D3-5
Steering Control Valve . . . . . . . . . . . . L5-1
W
Warning Lights . . . . . . . . . . . . . . D4-5, N5-9
Warnings and Cautions . . . . . . . . . . . . A4-1
Warning Light Circuit . . . . . . . . . . . . . D3-3
Wet Disc Brakes, Rear . . . . . . . . . . . . J6-1
Wheel Hub Removal, Rear . . . . . . . . . . G6-1
Wheel Speed Disc Brake . . . . . . . . . . . J5-1
Windshield Washer . . . . . . . . . . . . . . D3-1
Windshield Wiper Circuit . . . . . . . . . . . D3-1
Q1-4 Alphabetical Index Q01014 9/90
SECTION R
SYSTEM SCHEMATICS
INDEX
ELECTRIC SCHEMATIC (3 Fold-Out Pages) . . . . . . . . . . . . . . . . . . . . . . . . . HE 403
HYDRAULIC SYSTEM SCHEMATIC (1 Fold-Out Page) . . . . . . . . . . . . . . . . . . . . HH 311
(With Rexroth Steering/Brake Pump and Rear Oil-Cooled Disc Brakes)
ALLISON TRANSMISSION (CLT 5963/6063) HYDRAULIC SCHEMATIC . . . . . . . . AT 5/6-HO12
R01005 8/95 Schematics R1-1
NOTES
R1-2 Schematics R01005 8/95