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B50D Mk III 6X6 ARTICULATED DUMP TRUCK SERVICE MANUAL Document Part Number 872152


TO THE SERVICE PERSONNEL ‹ WARNING Do not operate the machine unless you have read the Operator’s Manual and fully understand how to operate the machine properly. This manual is written for an experienced technician and are on-the-job guides containing only the vital information needed for diagnosis, analyses, testing and repair. Essential tools required in performing certain service works are identified and in this manual and are recommended for use. The safe operation of your BELL EQUIPMENT machines very important to prevent any personal injury and/ or damage. This manual must be read and fully understood before carrying out any tests on your BELL EQUIPMENT machine. Right and left hand sides are determined by facing in the direction of forward travel. This manual is divided into chapters. The information contained in the manual is in logical sequence, with the instructions written in step by step format. Effective maintenance on your BELL EQUIPMENT machine is achieved when personnel fully understand the information contained in this manual. Every effort has been made to ensure that the information contained in this manual was correct at the time of publication. BELL EQUIPMENT Co. has a policy of continuous product development, improvement, and design. BELL EQUIPMENT Co. reserves the right to change, amend and update the design of its product at any time without prior notice. With this policy, changes may have occurred that are not included in this manual.


SAFETY SYMBOL The following safety symbol is used for all safety messages. When you see the safety symbol, follow the safety message to avoid personal injury or death. WARNINGS and CAUTIONS must be read, fully understood and followed, before carrying out the action or maintenance procedure concerned. WARNINGS and CAUTIONS are always placed before any action or maintenance procedure where personal injury and/or damage to the machine could occur if that action, test or maintenance procedure is not carried out correctly. WARNINGS and CAUTIONS are always placed before any action or maintenance procedure where personal injury and/or damage to the machine could occur if that action or maintenance procedure is not carried out correctly.

‹

WARNING AND CAUTION SYMBOL Throughout this manual the word WARNING is used to alert the operator and others of the risk of personal injury during the operation of the equipment. CAUTION indicates the possible damage to the machine. NOTE highlights information of special interest.

‹ 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.


B50D Mk III 6X6 ARTICULATED DUMP TRUCK SERVICE MANUAL

Document Part Number 872152

Revision:0 Technical Documentation BELL EQUIPMENT COMPANY Richards Bay


IMPORTANT Due to BELL EQUIPMENT’S policy of continuous product improvement, the information contained in this manual was correct up to the time of printing (Revised date of manual). Any changes after this date will only be included in the next update of this manual. The illustrations in this manual are pictorial and not necessarily true representations of components. Photographs and illustrations may show optional equipment.


B50D Mk III 6X6 ADT

ABBREVIATIONS

872152

ABBREVIATION LIST The table below lists the abbreviations used in this manual:

Abbreviation

Meaning

Abbreviation

Meaning

ºC

degrees Celsius

Nm

Newton metre

ºF

degrees Fahrenheit

psi

pounds per square inch

A

ampere

PTO

Power Take-Off

ADT

Articulated Dump Truck

R

Reverse

Ah

ampere hours

r.p.m.

revolutions per minute

CB

circuit breaker

ROPS

d

diagnostic

Roll Over Protective Structure

D

drive

SMR

Service Meter Reading

DNS

Do Not Shift

SS

Single Speed

ECU

Electronic Control Unit

SSM

Sealed Switch Module

FOPS

Falling Objects Protective Structure

USGAL

United States Gallon

V

Volt

ft

foot (feet)

yd³

cubic yard

ft lb

foot pound

OBW

On Board Weighing

HP

Horsepower

ISO

International Standards Organisation

kg

kilogram

km

kilometre

km/hr

kilometres per hour

kPa

kilo pascal

kW

kilowatt

lb

pound

LCD

Liquid Crystal Display

LED

Light Emitting Diode

cubic metre

N

Neutral

m.p.h.

miles per hour

MSDS

Material Safety Data Sheet

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ABBREVIATIONS

B50D Mk III 6X6 ADT

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B50D Mk III 6X6 ADT

AMENDMENT

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The table below is a record of amendments made to this manual after the publication date.

Amendment Record Sheet Amendment

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Page No’s. Replaced

Date

Page amended/ Pages Inserted By

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AMENDMENT

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B50D Mk III 6X6 ADT

INTRODUCTION

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INTRODUCTION ‹ WARNING All specifications in this manual apply to a standard machine as supplied by the factory and any modifications done to the machine such as greedy boards, etc. will result in different specifications and we as OEM cannot take responsibility for this. Read this manual carefully for it has been produced to assist you in the correct operation, maintenance and care of your BELL EQUIPMENT machine. Failure to do so could result in personnel injury or equipment damage. Right and left hand sides are determined by facing in the direction of forward travel. Warranty is provided as part of BELL EQUIPMENT’S support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. This manual is divided into chapters. The information contained in the manual is in logical sequence, with the instructions written in step by step format. Effective maintenance on your BELL EQUIPMENT machine is achieved when personnel fully understand the information contained in this manual. Every effort has been made to ensure that the information contained in this manual was correct at the time of publication. BELL EQUIPMENT Co. has a policy of continuous product development, improvement, and design. BELL EQUIPMENT Co. reserves the right to change, amend and update the design of its product at any time without prior notice. With this policy, changes may have occurred that are not included in this manual. Whilst every endeavour has been made to provide accurate and reliable information, BELL EQUIPMENT Co. specifically disclaims any actual or implied warranty and under no circumstances shall be liable for any loss, damage or injury to person or property suffered, whether direct, indirect or consequential, arising from the use of this manual. In particular and without detracting from above, the disclaimer also applies in the event of any specification, warning, or representation contained in this manual being inadequate, inaccurate, or unintentionally misleading. The user is urged to strictly comply with the instructions and warnings that are given in the interests of general safety. Please do not hesitate to contact your BELL EQUIPMENT Product Support Representative whenever you have a query on your BELL EQUIPMENT product or this manual.

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INTRODUCTION

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SAFETY

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SAFETY SPECIFICATION This machine complies to the CE Specification.

SAFETY FEATURES 2

3

1

14

16

15

12

11

4 5 6

7

8

13

9

10 50D0004CV

1.

2.

ROPS/FOPS Cab Protection. The Roll Over Protective Structure has been certified to meet specified test requirements according to SAE J1040 and ISO 3471. The Falling Objects Structure has been certified to meet specified test requirements according to SAE J/ISO 3449 and ISO 3449. Cab with Heater/Defroster. Positive pressure ventilation system circulates both outside and inside air through filters for a clean working environment. Built in defroster vents direct air flow for effective window de-fogging/de-icing.

3.

Dump Body Service Lock.

4.

Stop/Back lights. Highly visible lights.

5.

Backup Alarm.

6.

Independent Parking Brake.

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7.

Articulation locking Bar.

8.

Secondary Steering. Ground driven, continuously in operation. Secondary steering indicator light will light when activated.

9.

Horn.

10. Halogen Lights and Turn Signals. 11. Engine Fan Guard. 12. By-pass Start Protection. 13. Exhaust Brake and Transmission Retarder (If Equipped). 14. Safety Belt Retractors. 15. Mirrors. 16. Large Windshield Wiper With Washer.

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SAFETY

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MATERIAL SAFETY DATA SHEETS (MSDS) The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 CFR 1910.1200 and in some cases, State and Local Right-to-Know laws, may require that specific MSDS be available to the employees prior to operating this equipment. This may include information on substances contained in this equipment such as antifreeze, engine oil, battery acid, hydraulic fluid and freon (if equipped with an air conditioner). To ensure a prompt response, please be sure to include your return address and ZIP (postal) code, along with the model, serial number and/or VIN number of your machine.

UNAUTHORISED MODIFICATIONS OF THE ROLL OVER PROTECTIVE STRUCTURE (ROPS) AND THE FALLING OBJECTS PROTECTIVE STRUCTURE (FOPS) Do not make unauthorised modifications or alterations to the ROPS and FOPS such as: welding on extinguisher brackets, CB aerial brackets, fire suppression systems etc. Unauthorised modifications will affect the structural limits of the ROPS and FOPS and will void the certification (and increase the risk of an adverse safety incident.) The Roll Over Protective Structure has been certified to meet specified test requirements according to SAE J1040 and ISO 3471. The Falling Objects Protective Structure has been certified to meet specified test requirements according to SAE J/ISO 3449 and ISO 3449, Level II. Any planned modification or change must be reviewed in advance by the BELL EQUIPMENT Engineering Department to determine if the modification or change can be made within the limits of the certifying tests. It is important that each person in your organisation, including management, be made fully aware of these rules involving ROPS and FOPS. Whenever anyone sees unauthorised modifications or changes to a machine’s ROPS or FOPS both the customer and manufacturer must be notified in writing. The protection offered by ROPS or FOPS will be impaired if they are subjected to structural damage, is involved in an overturn incident, or is altered in any way and as such ROPS or FOPS must be replaced, not reused.

LOOSENING OR REMOVAL OF THE ROLL OVER PROTECTIVE STRUCTURE (ROPS) AND THE FALLING OBJECTS PROTECTIVE STRUCTURE (FOPS) Make sure that all parts are installed correctly if the ROPS or FOPS is loosened or removed for any reason. Once the mounting bolt and nut assembly has been removed or loosened it must be replaced with new parts as specified in the parts manual. Tighten the mounting bolts to the correct torque specification as specified in the parts manual. Failure to comply could compromise product safety and increase the risk to safety. A damaged ROPS or FOPS must be replaced, not reused.

NOISE EMISSION LEVELS The sound pressure was tested according to ISO 6394 (SAE J/ISO 6394) and the sound power was tested according to ISO 6393 (SAE J 2102).\plain \par

GENERAL SAFETY Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety decals immediately if missing or damaged.

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Operate Only On Solid Footing

SAFETY REGULATION Every country (State) has its own safety regulations. It is the obligation of the operator to know and follow these. This also applies to local regulations covering different types of work. Should the recommendations in this manual deviate from those of your country, your local safety regulations should be followed.

Mounting And Dismounting The Machine

Operate only on solid footing with strength sufficient to support machine. Be alert working near embankments, excavations and with bin raised. Avoid working on surfaces that could collapse under machine. Use caution when backing up to berms before dumping load. Keep Riders Off the Machine

Always use the handrails and steps provided to get on and off the machine. Use both hands and face the machine. Never get on or off a moving machine. Never jump off the machine. Use a hand line to pull equipment up onto the platform, do not climb on or off the machine carrying tools or supplies. GD0015CFM

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease, oil and foreign objects.

Do not allow unauthorised personnel on the machine.

Avoid Work Site Hazards

Prepare for Emergencies

GD0017CFM

Keep a first aid kit and fire extinguishers handy and know how to use them. Inspect and have your extinguisher serviced as recommended on its instruction plate. Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.

GD0014CFM

Avoid Overhead Power Lines Never move any part of the machine within 4 m (13 ft) plus twice the line insulator length, as serious injury or death may result.

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B50D Mk III 6X6 ADT

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS).

Avoid Backing Over Accidents

GD0016CFM

Make sure all persons are clear of machine path before moving the machine. Where conditions permit, raise bin for better visibility to the rear. Use mirrors to assist in checking all round machine. Keep windows, mirrors and backup alarm clean and in good condition. Use a signal person when backing if view is obstructed and/or in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Handle Chemical Products And Flammable Fluids Safety GD0018CFM

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

Handle fuel with care, as it is highly flammable. Do not smoke or go near an open flame or sparks while refuelling. Always stop the engine before refuelling the machine and fill the fuel tank outdoors. Keep all fuels and lubricants in properly marked containers and away from all unauthorised persons. Do not smoke in the storage areas. Store oily rags and other flammable material in a protective container, in a safe place. Do not weld or flame cut pipes or tubes that have contained flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting them. Starting fluid is highly flammable. Keep all sparks and flames away when using it. To prevent accidental discharge when storing the pressurised can, keep the cap on the can and store it in a cool protected place. Do not burn or puncture a starting fluid container.

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Clean the Machine Regularly

If you spill acid on yourself:

Wait until the engine has cooled before removing trash from areas such as the engine, radiator, batteries, hydraulic lines, fuel tank and operators cab. Remove any grease, oil or debris build-up. Keep the machine, especially the walkways and steps, free of foreign material, such as debris, oil, tools and other items which are not part of the machine.

• Flush your skin with water. • Apply baking soda or lime to help neutralise

Prevent Battery Explosions and Acid Burns

the acid. • Flush your eyes with water for 10 - 15 minutes and get medical attention immediately. If acid is swallowed:

• Drink large amounts of water or milk. • Then drink milk of magnesia, beaten eggs, or vegetable oil. • Get medical attention immediately. Wear Protective Equipment

GD0019CFM

The standard battery supplied with the machine is a sealed type that does not need maintenance. Keep sparks and flames away from the batteries. If a non-sealed battery is subsequently installed, keep sparks and flames away from the batteries. Use a flashlight to check the battery electrolyte level. Use a voltmeter or hydrometer to check battery charge. Never place a metal object across the posts. Always remove the grounded (Negative -) battery clamp first and replace it last. Do not smoke in areas where batteries are being charged.

GD0013CFM

Wear a hard hat, protective glasses and other protective equipment as required by the job conditions. Do not wear loose clothing or jewellery that can catch on controls or other parts of the machine. When you drive connecting pins in or out, guard against injury from flying pieces of debris by wearing goggles or protective glasses. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs. Wear gloves when handling wire rope cable.

Sulphuric acid in battery electrolyte is poisonous and is strong enough to burn skin, eat holes in clothing and cause blindness if splashed into the eyes.

Use the Seat Belt

Avoid the hazard by:

The seat belt must not be altered or modified in any way. Such changes can render the belt ineffective and unsafe.

• Filling the batteries in a well ventilated area. • Wearing eye protection and rubber gloves. • Avoid breathing fumes when electrolyte is added.

• Avoid spilling or dripping electrolyte.

REVISION 0

Use a seat belt at all times to minimise the chance of injury in an accident.

The seat belt is designed and intended for the seat’s occupant to be of adult build and for one occupant of the seat only.

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SAFETY

Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve the pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor who is familiar with this type of injury or gangrene may result. Stay Clear Of Moving Parts Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting or maintaining any part of the machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete. Beware of Toxic Fumes

B50D Mk III 6X6 ADT

If a solvent or paint stripper is used, wash surface with soap and water. Remove solvent or paint containers before welding and allow at least 15 minutes before welding or heating. Dispose of Waste Properly Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service centre to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental centre or your dealer for more information. Start Only From Operator’s Seat

‹ WARNING Never turn the ignition switch On and immediately OFF again. This will reset the cranking time and damage to the starter motor can occur.

GD0020CFM

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. Operate only in well ventilated indoor areas. Avoid hazardous fumes by first removing paint on painted surfaces before welding. Wear an approved respirator when sanding or grinding painted surfaces.

18

GD0022CFM

Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine.

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SAFETY

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals. Lower bin during work interruptions, apply park brake and be careful not to accidentally actuate controls when co-workers are present.

872152

Welding Repairs NOTE: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine, alternator and machine microprocessors.

Operating The Machine Avoid Tip Over Use safety belt at all times. Do not jump from machine if it tips. Use extra care when bin is raised. Machine stability is greatly reduced when bin is raised. Drive slowly, avoid sharp turns and uneven ground. Do not over load the machine.

GD0021CFM

Before operating machine after it has tipped, carefully inspect all hydraulic and electrical lines.

Avoid welding near fluid lines. Do not let heat go beyond work area near fluid lines.

Operating on Slopes

Remove paint properly. Wear eye protection and protective equipment when welding. Do not inhale dust or fumes.

GD0023CFM

Avoid side slope travel whenever possible. Check service brakes frequently when operating on slopes. The maximum slope will be limited by the ground conditions.

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Tyre Information Welding or heating of the rim components, external fire or excessive use of brakes can cause overheating of the tyres, which could cause a tyre explosion. This explosion can propel the tyre, rim and final drive components approximately 500 metres (1 640ft) from the machine, which may cause personal injury or death and/or property damage. If the tyre is overheating and could explode, do not approach it within the area represented by the shaded area in the drawing, until it has cooled. Stand behind the tread and use a self attaching chuck with extension hose to inflate the tyres. Use a safety cage if available. Do not stand over the tyre.

15 m (49'3")

Use a safety cage if available

500 m (1 640 ft)

Do not stand over the tyre, use a clip-on chuck and extension hose GC0002FM

NOTE: It is recommended that only trained personnel service and change tyres and rims.

Inspect and Maintain ROPS A damages roll-over protective structure (ROPS) should be replaced, not reused. If the ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. To Maintain the ROPS: • • • •

Replace missing hardware using correct grade hardware. Check hardware torque. Check isolation mounts for damage, looseness or wear; Replace if necessary. Check ROPS for cracks or physical damaged.

Drive Metal Pins

Always wear protective goggles or safety glasses and other safety equipment. Use soft hammer or a brass bar between hammer and object to prevent chipping.

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SAFETY DECALS There are several safety decals on your BELL EQUIPMENT machine. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarise yourself with these safety decals. Keep the decals clean by using a soft cloth, water, and soap. Do not use solvent, gasoline, etc. You must replace a decal if it is damaged, missing or cannot be read. If a decal is on a part that is replaced, ensure a new decal is installed on the replacement part. Contact your BELL EQUIPMENT Representative for new decals.

CAUTION

CAUTION BEFORE WELDING ON THIS UNIT: To avoid control circuit damage: 1. Turn the electrical disconnect switch to “OFF”. 2. Make sure the vehicle ground straps are properly installed. 3. The welding ground clamp must have a good connection to the machine structure and close to the point of weld. 4. Attach welding ground clamp directly to structure before welding.

This instructional seat has been provided only for training operators or to diagnose machine problems. Keep all other riders off this machine. Always wear your seat belt. 207339-aFM

Located inside the cab on the rear panel

Located on the silencer heat shield

CAUTION

WARNING

AVOID DEATH OR SERIOUS INJURY *READ AND UNDERSTAND OPERATOR’S MANUAL BEFORE OPERATING *THIS MACHINE. *OPERATE ONLY FROM THE OPERATOR’S SEAT. *BEFORE LEAVING SEAT: LOWER BODY TO FRAME REST. PLACE TRANSMISSION IN NEUTRAL. APPLY PARK BRAKE. STOP ENGINE (TURN KEY SWITCH TO OFF). *DO NOT PERMIT RIDERS. *AVOID CONTACT WITH OVERHEAD OBSTACLES WHEN OPERATING OR *HAULING THE TRUCK. *USE EXTRA CARE TO AVOID TIP-OVER WHEN DUMPER BODY IS RAISED.

Torque all wheel nuts to 650 N.m [480 LB.FT.] after the first 5 hours and then again after 50 hours. Repeat this procedure if wheels are changed.

207307FM

207295FM

Located inside the cab on the roof panel

Located on the silencer heat shield

WARNING CRUSHING INJURY * Do not disconnect / loosen any of the suspension hoses until the pressure in the system has been released. * Front chassis could ‘sag’ slowly after the engine has been switched off. * Refer to Operator’s Manual for the correct removal, installation and maintenance procedure of the suspension hoses in this area.

WARNING

217486V

Located on both sides of the front chassis WARNING

CRUSHING INJURY Do not touch or move the Height Sensor when the ignition is on. Refer to Operator’s Manual.

AVOID SERIOUS INJURY Block wheels to prevent machine movement before deactivating park brake for towing.

Located on both sides of the front chassis

207338FM

WARNING SPRING UNDER PRESSURE

Located inside the cab next to the park brake

Read the manual before carrying out maintenance in this 207350FM area

217487V

WARNING

Located on the inside of the rear chassis

COMPRESSED AIR RESERVOIR Avoid injury, drain completely before carrying out maintenance. Typical working pressure: 800 kPa (116 PSI).

WARNING Ensure that the cab support is properly engaged before carrying out any maintenance in this area. 207383FM

207349-AFM

Located on the air reservoir

WARNING HIGH PRESSURE HYDRAULICS See manual for correct maintenance procedure. Typical working pressure: 8000 kPa 207329FM (1160 PSI).

WARNING

Located on the chassis underneeth the cab

AVOID INJURY Ensure propshaft guards are in place at all times 207330FM

Located on the side of the machine and suspension struts Located on the inside of the front chassis

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Located inside the cab on the rear pillar

WARNING Any alteration, modification, repair, structural damage or an overturn reduces this structure’s protective capabilities and invalidates this certification. Consult the manufacturer to determine this structure’s limitations.

IMPORTANT

WARNING

Avoid crushing Do not jump if machine tips

EMERGENCY EXIT Use tool to break window

B50D Mk III 6X6 ADT

DANGER Located inside Serious injury or death can result from contact with electric lines. Never move any part of unit or load closer than: 3m[10FT] plus twice the line insulator length to an electric line.

STAY CLEAR

USE SEAT BELT

ROLLOVER (ROPS) AND FALLING OBJECT (FOPS) PROTECTIVE STRUCTURE CERTIFICATION

OPERATOR MAY REVERSE MACHINE.

207192FM

Performance certified at date of manufacture to:

WARNING

the cab on the rear pillar

207337FM

207411FM 207191FM

ROPS: SAE J 1040: 1994 ISO 3471: 2000

Located on the rear of the machine & on the sides of the machine

Located inside the cab on the right hand side window

FOPS: SAE J/ISO 3449: 1998 ISO 3449: 1992 PROTECTIVE STRUCTURE PART NUMBERS: 262796 CERTIFIED PRIME MOVER MASS: 15750 Kg (34722 Lbs.)

DANGER To avoid injury or death, install bin support pole before carrying out any maintenance in this area 207351FM

CERTIFIED ARTICULATED DUMP TRUCK MODELS: B50D

BELL EQUIPMENT C0. S.A. (PTY) LTD RICHARDS BAY SOUTH AFRICA

Located on both sides of the rear chassis

208645

Located inside the cab

WARNING Crushing injury may result in hinge area if machine is turned. Make sure people are clear of machine before starting engine or moving steering wheel. Attach locking bar before performing service near center of machine or transporting on a truck. 207336FM

Located on both sides of the articulation joint

WARNING

IMPORTANT

AVOID INJURY Keep clear of rotating fan blades

Neutral to forward or reverse shifts are automatically prevented at high engine speeds. Reduce engine speed to below 900 rpm to allow neutral to forward or reverse shift.

207331FM

Located in the engine compartment on the fan cowling

Located inside the cab next to the gear shift control

207385-AFM

DANGER

WARNING HIGH PRESSURE HYDRAULICS See manual for correct maintenance procedure. Typical working pressure: 8000 kPa (1160 PSI). 207329

Located on the suspension cylinders

Start only from seat in park or neutral. Starting in gear kills. 207408FM

Located on the starter

IMPORTANT CAB TILT PROCEDURE Raising: 1.Park truck on level ground with body lowered. Engage park brake. 2.Turn ignition switch off. Turn battery disconnect switch off. 3.Remove 2 retaining bolts per left hand side rubber cab mounting. 4.Close cab and right hand side external compartment doors. Mirrors to be in normal operating position. 5.Insert tilt pump lever into the pump. 6.Put directional valve lever in “Cab Raise” position. 7.Pump until cab is tilted to the up position. 8.Slowly rotate directional valve clockwise towards “Cab Lower” position while pressing the strut handle towards the engine compartment. 9.Ensure the cab support sliding bolt is properly locked into the slot notch profile. 10.Place tilt pump lever in “Cab Raise” position. Lowering: 1.Ensure the cab area is free of obstacles. 2.Directional valve lever to be in “Cab Raise” position. 3.Ensure conditions apply as per 4 above. 4.Pump cab upward until peg has disengaged from support strut slot. 5.Slowly rotate directional valve lever clockwise, while pulling strut handle away from engine compartment, lowering cab until properly seated. 6.Install and torque new locking bolts. Refer to operator manual and parts manual for correct fastener and torque specifications. 7.Ensure directional valve lever is in “Cab Lower” position. 207382-BFM

Located in the engine compartment on the cab tilt pump

50D0014CFM

Refer to Operator's or Parts Manuals for details of decals.

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BULLETINS

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BULLETINS Record the relevant information from the Technical Documentation Bulletins, Service Bulletins and Parts Bulletins into this manual as follows: Ensure the manual number (87————) reflected in the bulletin is the same as the 87——— number at the top of the main content pages. Carry out the instructions as detailed in the bulletin. Record the required information below. File the bulletins in numerical order in a suitable 3 or 4 ring binder.

TECHNICAL DOCUMENTATION BULLETIN RECORD BULLETIN No.

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SUBJECT

INSERTED BY NAME

SIGNATURE

DATE

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TECHNICAL DOCUMENTATION BULLETIN RECORD BULLETIN No.

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SUBJECT

INSERTED BY NAME

SIGNATURE

DATE

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FEEDBACK

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USER’S INFORMATION FEEDBACK FORM Should you, as user of this manual, have any suggestion for improving the manual, or you find any errors or omissions, then we would like to know. Please complete a facsimile of this form and hand it in to your nearest BELL EQUIPMENT Product Support Representative or post it directly to your nearest BELL EQUIPMENT Branch. Addresses are given at the beginning of this manual. Ideas, Comments (Please State Page Number): _____________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ Machine Model: _______________________________________________________________________ Serial Number:________________________________________________________________________ VIN: ________________________________________________________________________________ Page Number: ________________________________________________________________________ OVERALL, how would you rate the quality of this manual? (Check one) Poor 1

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3

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5

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7

8

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10

Company Name: ______________________________________________________________________ Technician Name: _____________________________________________________________________ Address: ____________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ Phone Number: _______________________________________________________________________ Fax Number: _________________________________________________________________________ Thank you for your co-operation.

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TABLE OF CONTENTS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 SAFETY REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . 39 OPERATIONAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 OPERATIONAL CHECKS - KEY SWITCH ON, ENGINE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

CHAPTER 2. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 SECTION 3. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 DISPLAY MENU TACHOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 SLOW AND FAST IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 EXHAUST BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

SECTION 4. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 CYLINDER COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 OIL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 CAN BUS J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 WHAT EXACTLY IS A “CAN BUS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 CANBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 TESTING THE “CANBUS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 CHECKING THE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 MAIN “CAN” HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 “CAN” SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 “CAN “OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 “CAN” SHORT TO POSITIVE 0 -24 VOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 REVISION 0

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CHAPTER 3. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 SECTION 1. SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ELECTRICAL SCHEMATIC SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 CHASSIS CONTROL UNIT (CCU & OEU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 MDU2 (MONITOR DISPLAY UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 MDU2 LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 MDU2 INPUT AND OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 START-UP DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 TO GO TO MAIN MENU FROM DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 EXPLANATION OF WIRE MARKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

SECTION 2. DESCRIPTION OF CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 MDU2 WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 MDU2 GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 CCU2 OUTPUT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 OEU OUTPUT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

SECTION 3. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 ENGINE FAULT CODES (ADM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 ENGINE FAULT CODES (PLD-MR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 SSM FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 PART 2. DM1 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

SECTION 4. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 Pneumatic System Solenoids, Pressure Switches, and Sensor Tests . . . . . . . . . . . . . . . . . . . . . . 201 Steering Column Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206

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CHAPTER 4. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 GENERAL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219 STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 PLANETARY GEARS AND POWER FLOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228 THE BASIC LAWS OF PLANETARY GEAR SETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 HD TRANSMISSION PLANETARY CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 HD TRANSMISSION CLUTCH CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231 POWER FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 SOLENOIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 3000 and 4000 4th Generation Control Valve Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246 HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248 TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS - OVERVIEW . . . . . . . . . . . . . . . . . 256 EXHAUST BACKFILL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 PRESSURE TABLE AND TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 APPLICATIONS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 INPUTS AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 RETARDER CONTROL HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 TESTING RETARDER CHARGING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269 PUSH BUTTON SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273 SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274 WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274 RANGE / SHIFT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 DO NOT SHIFT LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276

SECTION 2. DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 CHECK THE TRANSMISSION FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 TRANSMISSION CONTROL UNIT ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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TABLE OF ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 ALLISON HD 4560R ELECTRONIC CONTROL WTEC III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

SECTION 3. ADJUSTMENTS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 TRANSMISSION WARM-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 TRANSMISSION OIL COOLER RESTRICTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

CHAPTER 5. PNEUMATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 PNEUMATIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 PNEUMATIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312

SECTION 2. DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321 DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

SECTION 3. ADJUSTMENTS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 324 PARK BRAKE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326 GRAMMER SEAT FUNCTIONAL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328

CHAPTER 6. HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . 329

SECTION 2. DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359 DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

SECTION 3. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 JT05800 DIGITAL THERMOMETER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION. . . 371 HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY . . . . . . . . . . . . 371 HYDRAULIC SYSTEM WARM-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 CYCLE TIME TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373 MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374 SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST. . . . . . . . . . . . . . . . . 376 PRIORITY VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377 ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT . . . . . . . . . . . . . . 377 BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 378 BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST. . . . . . . . . . . . . . . . . . 379 30

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TABLE OF CONTENTS FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380 SERVICE BRAKE VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .382 STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 383 STEERING CYLINDER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383 SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 BIN LOWER CIRCUIT RELIEF VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385 SUSPENSION CALIBRATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386 SUSPENSION SERVICE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387 Hydraulic Pressure Setting and Fault Finding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

CHAPTER 7. HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . 403 SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 AIR CONDITIONING SYSTEM CYCLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 HEATER CORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404

SECTION 2. DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 HEATING/AIR CONDITIONING COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

SECTION 3. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 AIR CONDITIONING OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409 R134A AIR CONDITIONING SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410 OPERATING PRESSURE DIAGNOSTIC CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411 A/C FREEZE CONTROL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413 A/C COMPRESSOR CLUTCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413 A/C HIGH/LOW PRESSURE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413 A/C EXPANSION VALVE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414 EXPANSION VALVE BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415 REFRIGERANT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416

CHAPTER 8. MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 NOTES:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421

CHAPTER 9. DAILY OR 10 HOURLY SERVICE CHECKS. . . . . . . . . . . . . . . . . . . . 423 CHAPTER 10. 500 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . 425 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .428 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431 REVISION 0

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TABLE OF CONTENTS AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .432

SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS . . . . . . . . . . . . . . . . . . . . . . 433 GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . 433 TRANSMISSION BREATHER (LOCATED UNDER CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 REPLACE FUEL TANK BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433 TRANSFER CASE BREATHER (LOCATED BEHIND CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 AXLE BREATHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434

SECTION 3. CAB AND ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 INSPECT, CLEAN AND REPLACE CAB AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS . . . . . . . . . . . . . . . . . . . . . . 436 CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 RECORD & DELETE FAULT CODES ON THE MDU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 CHECK THE OPERATOR CONTROLS AND INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

SECTION 4. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 CHECK GREASE LEVEL OF AUTO GREASING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 REPLACE AUTO GREASING SYSTEM FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437 HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438

CHAPTER 11. 500 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . 441 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445

SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS . . . . . . . . . . . . . . . . . . . . . . 447 GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . 447 TRANSFER CASE BREATHER (LOCATED UNDER THE CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . 447 AXLE BREATHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447

SECTION 3. CAB AND ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449 INSPECT, CLEAN AND REPLACE CAB AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449 CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS . . . . . . . . . . . . . . . . . . . . . . 450 CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 RECORD & DELETE FAULT CODES ON THE MDU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 CHECK THE OPERATOR CONTROLS AND INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

SECTION 4. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 CHECK GREASE LEVEL OF AUTO GREASING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 REPLACE AUTO GREASING SYSTEM FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451 HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452 32

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CHAPTER 12. 1 000 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 455 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455

SECTION 2. HYDRAULICS AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 REPLACE HYDRAULIC RESERVOIR BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459

SECTION 4. AXLES AND CHASSIS & SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 CHECK AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461 CHECK FINAL DRIVE OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461 CHECK BIN SHOCK PAD CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461

CHAPTER 13. 2 000 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 463 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463

SECTION 2. HYDRAULICS AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 REPLACE HYDRAULIC OIL RETURN FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467

SECTION 3. CAB, PNEUMATICS AND ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 469 REPLACE PNEUMATIC SYSTEM DRYER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469 DRYER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469

CHAPTER 14. 3 000 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 471 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471

SECTION 2. HYDRAULICS AND PNEUMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473

CHAPTER 15. 4 000 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 475 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 REPLACE FAN BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475

SECTION 2. HYDRAULICS AND PNEUMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477

CHAPTER 16. AS REQUIRED SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479 SECTION 1. ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479 REVISION 0

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TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479

SECTION 2. CAB AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483 CLEAN AIR CONDITIONING FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483 GREASE HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483

CHAPTER 17. MISCELLANEOUS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . 485 SECTION 1. DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485

SECTION 2. ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487 USING BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487 ADJUST HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489

SECTION 3. OPERATIONAL CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493 OPERATIONAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493

CHAPTER 18. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 SECTION 1. SYMPTOMS AND REMEDIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

CHAPTER 19. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 OBW Functional Description – ADT Mk IV 001-4002-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 HYDRAULIC FAN COOLER FUNCTIONAL DESCRIPTION – ADT MK IV 001-4003-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516 2. CHASSIS CONTROL UNIT SOFTWARE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 516

CCU2 HEADLIGHT LOGIC AND CONTROL 001-4004-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519 2. HEADLIGHT LOGIC AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519

CCU2 WIPER CONTROL LOGIC 001-4005-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521 34

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872152

2. WIPER CONTROL LOGIC AND TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521

AIR-CONDITIONING CONTROL LOGIC 001-4006-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523 2. INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523

BIN CONTROL LOGIC 001-4007-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525 2. BIN CONTROL LOGIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525

PR001_PARK BRAKE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .529

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35


PART 1 OPERATION AND TEST


B50D Mk III 6X6 ADT

CHAPTER 1

872152

CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE OPERATIONAL CHECK-OUT Use this procedure to check operation of the machine. This procedure is designed so you can make a quick check of the machine operation while performing specific checks from the operator’s seat. Should you experience a problem with the machine, you will find helpful diagnostic information in this check-out that will help pinpoint the cause. A location will be required which is level and has adequate space to perform the check-out procedure. No tools or equipment are required to perform the check-out procedure. Compete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkages, wiring, etc.) prior to doing the operational check-out. The machine must be at operating temperature for many of the checks. Start at the top of the left column and read completely down column before performing check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred to either a chapter in this manual for specific test or the repair manual for repair procedure.

OPERATIONAL CHECKS - KEY SWITCH ON, ENGINE OFF Turn battery disconnect switch ON. Turn key switch to ON position. CHECKS Gauges and Indicator Lights

QUESTIONS/TASKS Do all indicator lights come ON or flash? Do all gauges and speedometer move to centre position? Do all sections of monitor liquid crystal display’s appear? Does audible alarm come ON?

RESULTS YES: Go to next check. NO: Check circuit breakers and fuses. Reset circuit breakers and/or replace fuses as necessary.

NOTE: 1. Cold start indicator light will remain ON for a maximum of 20 seconds in low ambient temperature conditions. 2. Air pressure indicator (1) on the numerical display Check indicator screen may remain ON, depending on system air pressure. light bulbs. Replace if Do all gauges and displays return to normal operation mode necessary. and audible alarm go OFF after 3 seconds? Go to (“Menu Do all indicator lights, except for secondary steering (marked Display Unit”. emergency steering), battery charge and park brake to go OFF and low brake accumulator brake pressure, depending on the pressure in the accumulator?

REVISION 0

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872152

CHAPTER 1

CHECKS Transmission Shift Control

QUESTIONS/TASKS Does shift control operate correctly?

B50D Mk III 6X6 ADT RESULTS YES: Go to next check. NO: Replace transmission shift control.

Gauges and Indicator Lights

Start engine. NOTE: 1. Low air pressure alarm will be ON until air pressure reaches normal operating pressure. 2. Transmission oil temperature gauge will not begin to indicate temperature until transmission oil is close to operating temperature.

YES: Go to next check. NO: Go to (“Menu Display Unit”.

Do all indicator lights, except park brake indicator light, go OFF after the engine starts? Does the Menu Display Unit display engine speed? Does engine oil pressure gauge display engine oil pressure? Does the needle of the gauge indicates pressure is increasing to green (Normal)? Check the air pressure gauge immediately after the engine has started. Does the needle of the gauge indicates pressure is increasing to green (Normal)? Service Brake Accumulator

Apply brakes repeatedly until main hydraulic pump strokes to charge accumulators. When accumulators are fully charged, pump will de-stroke. Turn engine “OFF”. Turn key switch “ON” again and wait for indicator lights to go “OFF” Apply the service brakes, counting the number of applications until the accumulator low pressure light illuminates.

Service Brake

YES: Go to next check. NO: Go to (“Font And Rear Brake Accumulators Pressure Test And Charge Procedure”.

NOTE: Perform this check in an open area where machine YES: Go to next check. can travel at full speed. NO: Go to Drive machine slowly. (“Service Brake System Apply brake pedal to stop machine. Malfunction”. Release the brake pedal. Does brake pedal push easily without binding? Does brake pedal return to the released position so brakes are not dragging? Do brakes stop machine in a reasonable distance without pulling to one side or making noise? Drive machine at full speed. Release accelerator and apply brake pedal to stop machine. Do brakes stop machine in a reasonable distance without pulling to one side or making noise?

40

REVISION 0


B50D Mk III 6X6 ADT CHECKS

CHAPTER 1 QUESTIONS/TASKS

Park Brake

‹ CAUTION Machine will stop abruptly during this check. Fasten seat belt. Perform check in open area. From an initial start up, if the air pressure was below 6 bar, the park brake needs to be released, applied and released again.

872152 RESULTS YES: Continue check. NO: Go to (“Diagnose Power Train System Malfunction”.

Start engine. Switch park brake switch "OFF" Drive machine at slow idle in 1 st gear at ~ 4 km/h (2.5 m.p.h.). Switch park brake "ON". Does park brake indicator light illuminates? Does the park engages and machine stops With engine “ON”, transmission in “N” (Neutral) and park brake “ON” switch park brake switch "OFF".

YES: Continue check.

Shift transmission to “D” (Drive).

NO: Go to (“Diagnose Power Train System Malfunction”.

Slowly increase engine speed. Does machine move when engine speed is just above slow idle? Return engine to slow idle. Shift transmission to “N” (Neutral). Steering

Park machine in an open area, on a hard level surface. Turn inter-axle switch to the “OFF” position. Ensure that the inter-axle lock switch is in the “OFF” position and the IDL light on the MDU is “OFF”. Release park brake. Release service brakes.

YES: Continue check. NO: Go to (“Steering System Malfunction”.

Run engine at slow idle. Turn steering wheel fully left and then fully right. Does machine turn smoothly in both directions. Run engine at fast idle. Turn steering wheel fully left then right. Does machine turn smoothly in both directions.

REVISION 0

YES: Continue check. NO: Go to (“Steering System Malfunction”.

41


872152

CHAPTER 1

CHECKS

QUESTIONS/TASKS

Bin

‹ CAUTION Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Area must have enough overhead clearance to raise bin to full height of 6207 mm (20 ft. 4 in.). Do not perform this test within 4 m (13ft.) of high voltage power lines.

B50D Mk III 6X6 ADT RESULTS YES: Continue check. NO: Go to (“Hydraulic System Malfunctions”.

Perform this check in an open area, clear of bystanders. Position the machine frames straight. Operate the engine at 1500 r.p.m. Pull bin control lever rearward to raise bin. When bin is almost complete up, reduce engine speed to slow idle. Does bin raise to full height smoothly? Release bin control lever. Does bin control lever return to neutral position?

YES: Continue check.

Push bin control lever to full forward detent bin float position and release lever.

YES: Go to next check.

Does the control lever stay in the float position until the last 5% (3.5°) of body travel, at which time the lever returns to neutral position?

NO: Go to (“Bin Control Circuit”.

NO: Go to bin Control Valve Operation. (See Chapter 21, SECTION 1, Repair Manual)

Dos bin lower to full down position smoothly? Viscous Fan Drive

NOTE: Engine must be cool or fan may not turn freely by hand.

YES: Do to next check.

Allow engine to cool.

NO: Replace viscous fan drive.

Turn fan by hand, feel for rough bearing or fan not turning freely. Does fan turn freely and smoothly? Start engine and run 2 -3 minutes. Check that fan turns at near engine speed, then slows down. As engine warms to normal operating temperature, fan will speed up to near engine speed. Does fan speed increase as engine warms? Turn engine “OFF”

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B5D Mk III 6X6 ADT CHECKS Exhaust Smoke

CHAPTER 1 QUESTIONS/TASKS

872152 RESULTS

Start engine and allow to warm to normal working temperature.

YES: Continue to next check.

Operate machine under full load at fast engine speed.

NO: Go to (“Diagnose Engine Malfunctions”.

Observe exhaust colour. No smoke is normal. Blue smoke indicates faulty or stuck piston rings. White or grey smoke indicates stuck piston rings, fuel cetane too low or engine running too cold. Heavy black smoke indicates injection nozzles faulty, engine injection system incorrect, fuel cetane to low or air filter element clogged. Is engine exhaust smoke normal colour? Engine Speed

Start engine and warm to normal operating temperature. Run engine at low idle; Record r.p.m. Is engine speed 600 ± 20 r.p.m? Increase engine speed to high idle. Record r.p.m. Is engine speed 2600 ± 20 r.p.m.

REVISION 0

YES: Check complete. NO: Do slow and Fast idle Adjustment. (See “Slow And Fast Idle Adjustment".

43


872152

44

CHAPTER 1

B50D Mk III 6X6 ADT

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872152

CHAPTER 2. ENGINE SECTION 1. THEORY OF OPERATION ENGINE

1.

Final Fuel Filter.

9.

2.

Oil Filter.

10. Camshaft

3.

Engine Exhaust Valve Rocker Arm.

11. Starter Motor.

4.

Engine Intake Valve Rocker Arm.

12. Crankshaft.

5.

Engine Exhaust Valve Brake.

13. Alternator.

6.

Fuel Delivery Nozzle.

14. Fuel Pump.

7.

Electronic Unit Injector (EUI).

15. Flywheel.

8.

Intake Manifold.

16. Oil Pump.

Turbo Charger

The engine is a V - 8 cylinder lliquid cooled cast iron block and cast iron cylinderhead engine. It has overhead valves, 3 per cylinder, two intake valves and one exhaust valve. Roller cam followers ride on the camshaft which move the push rods that open and close the valves. The EUI’s (Electronic Unit Injectors) also ride on the camshaft which send pressurized fuel through a fuel pipe to the fuel delivery nozzles, which are located directly over the top of the piston. The EUI’s are electronically controlled by the EUI controller, a crankshaft position sensor, camshaft position sensor and a solenoid.

REVISION 0

45


872152

CHAPTER 2

Electronic Unit Injector Fuel System

B50D Mk III 6X6 ADT

Fuel Delivery Suction Stage 1

2

4

3 5

12

The EUI system is designed to precisely control:

• The start of injection. • An accurate delivery of a calculated amount of

6

11

fuel. • A sharp end of injection.

7

10 8

The fuel system consists of four sub-systems;

• • • •

Low Pressure Supply System, High Pressure System - Unit Injectors, Fuel Delivery Nozzles, Control System.

The electronic unit injector fuel system has these notable features:

• • • • • • • • •

Precision control of timing and fuel delivery, Field proven reliability, Electronic control of each cylinder, One unit injector per cylinder, High injection pressures, Low emissions, Compact design, Eliminates injection pump, No injection timing adjustment required.

9

13 RETURN FUEL 14 LOW PRESSURE 40D3001CV

1.

Fuel Delivery Nozzle.

2.

Connector Pipe.

3.

EUI (Electronic Unit Injector).

4.

Valve.

5.

Solenoid.

6.

Supply Gallery in Crankcase.

7.

High Pressure Chamber.

8.

Pump Plunger.

9.

Engine Camshaft.

10. Pressure Relief Chamber. 11. Return Flow Gallery in Crankcase. 12. Bleed-Off Chamber. 13. Return Fuel. 14. Low Pressure. The EUI’s (3) ride on individual lobes on the engine camshaft (9). There is one EUI per cylinder. The EUI’s are mounted in the block of the engine under the intake manifold.

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872152

There are passages in the block that route fuel to and from the EUI’s. The fuel delivery nozzles (1) are located in the cylinder head and are positioned directly above the pistons.

12. Bleed-Off Chamber.

A connector pipe (2) is used to direct fuel from the EUI’s to the nozzles. Internal passages in the cylinder heads allow excess fuel from the nozzles to be bled off.

During the pre-delivery stage, the pump plunger (8) moves up. As the valve (4) is not yet closed, the fuel is first forced into the pressure relief chamber (10), then into the return gallery(11).

A solenoid (5) controls the fuel metering valve (4). For complete electrical theory of the MR/PLD SEE “Engine Control Unit MR/PLD”.

Delivery Stage

13. Return Fuel. 14. Low Pressure.

1

2

4

3

During the suction stage, the pump plunger (8) moves down. As a result of the constant fuel excess pressure of approximately 600kPa (6 bar) (87 psi) in the fuel low pressure circuit, the high pressure chamber (7) of the unit pump is fitted with fuel through the supply gallery (6).

5

Pre-Delivery Stage

12 6

11 8

10

7

13 RETURN FUEL 14 LOW PRESSURE

9

1.

Fuel Delivery Nozzle.

2.

Connector Pipe.

3.

EUI (Electronic Unit Injector).

4.

Valve.

5.

Solenoid.

6.

Supply Gallery in Crankcase.

7.

High Pressure Chamber.

8.

Pump Plunger.

9.

Engine Camshaft.

15 HIGH PRESSURE

1.

Fuel Delivery Nozzle.

2.

Connector Pipe.

3.

EUI (Electronic Unit Injector).

4.

Valve.

5.

Solenoid.

6.

Supply Gallery in Crankcase.

7.

High Pressure Chamber.

8.

Pump Plunger.

9.

Engine Camshaft.

40D3003CV

10. Pressure Relief Chamber. 11. Return Flow Gallery in Crankcase. 12. Bleed-Off Chamber. 13. Return Fuel. 14. Low Pressure. 15. High Pressure.

10. Pressure Relief Chamber. 11. Return Flow Gallery in Crankcase. REVISION 0

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872152

CHAPTER 2

B50D Mk III 6X6 ADT

As soon as the valve (4) is closed while the pump plunger (8) is moving towards its top dead centre, the unit pump is in the delivery stroke. Fuel injection into the combustion chamber takes place in the delivery stage. During this stage the fuel pressure in the high pressure chamber (7) rises to a pressure approximately 160 000 kPa (1600 bar) (23 206 psi).

After the valve (4) has opened (end of delivery), The fuel pressure in the high pressure chamber (7) is collapsing.

Residual Stage

The pressure relief chamber serves as an expansion chamber for the pressure peaks of the unit pump in the residual stage. This prevents the pressure ratio of the adjacent unit pumps being affected through the return flow gallery.

1

2

4

3 5

The remaining fuel delivery by the pump plunger (8) up to the apex of the camshaft (9), is again forced into the pressure relief chamber (10) and the return flow gallery (11).

Cold Start Operation

12 6

11 7

8

10

13 RETURN FUEL 14 LOW PRESSURE

9

40D3004CV

1.

Glow Plug.

2.

Solenoid.

EUI (Electronic Unit Injector).

3.

Cold Start Jet.

4.

Valve.

5.

Solenoid.

6.

Supply Gallery in Crankcase.

The cold start system operates only when the engine coolant temperature is below 15° C (59° F).

7.

High Pressure Chamber.

8.

Pump Plunger.

9.

Engine Camshaft.

1.

Fuel Delivery Nozzle.

2.

Connector Pipe.

3.

10. Pressure Relief Chamber. 11. Return Flow Gallery in Crankcase. 12. Bleed-Off Chamber. 13. Return Fuel. 14. Low Pressure.

48

When the key switch is tuned to the “ON” the position, the glow plug (1) begins to heat up and the indicator light on the dash will light up. Light will stay on and the glow plug will continue to heat up for approximately twenty seconds. When the key switch is turned to the START position, the solenoid (2) is energized, allowing fuel to flow to the cold start jet (3). The fuel from the jet is sprayed on the glow plug causing the fuel to atomize. The atomized air/fuel mixture is directed to the cylinders by the incoming air through the intake manifold. machine. Replace the seat belt at least every three years, regardless of the condition.

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872152

CHAPTER 2. ENGINE SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS Symptom Starter motor turns engine too slowly

Hard starting when cold

Engine turns but does not start

Engine stops soon after starting

Problem Batteries under charged

Recharge or replace batteries.

Poor engine ground connection.

Repair, clean or secure connections.

Loose or dirty battery terminals.

Clean and tighten battery terminals.

Worn starter motor.

Perform starter load test.

Hydraulic Cut Off Solenoid Valve.

Go to “Hydraulic System Manifold Operation (Top View)”.

Defective cold start aid.

See “Cold Start Operation”

Incorrect valve clearance.

Adjust valve clearance (See “Valve Clearance Adjustment”)

Compression too low.

Test compression (See “Cylinder Compression Test”)

Insufficient fuel in fuel tank.

Fill tank and bleed system.

Compression too low.

Test compression (See “Cylinder Compression Test”)

Low fuel pump pressure.

Test fuel pump pressure (See “Fuel Pump Pressure Test”)

Insufficient fuel in fuel tank.

Fill tank and bleed system.

Air in fuel system.

Bleed system, check and repair air entry.

Blocked fuel filters.

Replace fuel filters.

Low fuel pump pressure.

Test fuel pump pressure (See “Fuel Pump Pressure Test”)

Electronic Unit Injector. Engine misfires

Check fault codes.

Incorrect valve clearance.

Adjust valve clearance (See “Valve Clearance Adjustment”)

Compression too low.

Test compression (See “Cylinder Compression Test”)

Low fuel pump pressure.

REVISION 0

Solution

Test fuel pump pressure (See “Fuel Pump Pressure Test”)

49


872152

CHAPTER 2

Symptom Low engine oil pressure

Problem

Test or replace.

Incorrect grade of oil.

Change oil.

Low pump output.

Test oil pump pressure. Do Oil Pump Pressure Test (See “Oil Pump Pressure test”)

Engine bearings worn.

Excessive vibration at any speed. Black smoke from exhaust.

White smoke from exhaust.

Install new pressure relief valve (See Remove and Install Oil Pressure relief valve in CHAPTER 4, SECTION 5 of Repair Manual.) Remove, inspect and repair.

Crankcase breather or line blocked.

Inspect and repair.

Valve stem seals worn.

Replace valve stem seals.

Valve guides worn.

Replace valve guides.

Piston rings worn; cylinders scored.

Test compression (See “Cylinder Compression Test”)

Worn or broken engine mountings.

Inspect, repair or replace.

Drive shaft out off balance.

Balance or replace.

Inlet system restricted.

Service and repair inlet system.

Incorrect grade of fuel.

Reset valve clearance.

Worn fuel delivery nozzles.

Replace fuel delivery nozzles (See Remove and Install Fuel Delivery Nozzles in CHAPTER 4, SECTION 8 in repair manual).

Engine running too cold.

Check that thermostats are not stuck open.

Worn fuel delivery nozzles.

Replace fuel delivery nozzles (See Remove and Install Fuel Delivery Nozzles in CHAPTER 4, SECTION 8 in repair manual).

Pistons, rings or liners scored.

Test compression (See “Cylinder Compression Test”)

Coolant entering cylinder bores.

Cold start solenoid defective.

50

Solution

Failed pressure gauge/sensor.

Pressure relief valve stuck.

Abnormal oil consumption

B50D Mk III 6X6 ADT

Check cylinder head gasket. Replace cylinder head gasket. (See Cylinder Head in CHAPTER 4, SECTION 6 in repair manual). Test solenoid. (See “Cold Start Circuit”)

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872152

CHAPTER 2. ENGINE SECTION 3. ADJUSTMENTS DISPLAY MENU TACHOMETER

VALVE CLEARANCE ADJUSTMENT ‹ CAUTION To prevent accidental starting of the engine while performing valve adjustments, always turn battery disconnect switch to “OFF” NOTE: Check and adjust valve clearance only when engine is COLD.

The tachometer on the Menu Display Unit is accurate enough for test work. (See Operators Manual CHAPTER 2 for more information and CHAPTER 8 for detail operating the Menu Display Unit).

Remove rocker arm cover. Install cranking device DC280088.

SLOW AND FAST IDLE ADJUSTMENT There is no slow or fast idle adjustment. If slow or fast idle is not within specification, check for an engine mechanical problem or an electrical failure. Slow Idle Speed RPM’s . . . . . . . . . 600 ± 20 Fast Idle Speed RPM’s . . . . . . . . 2240 ± 20 If no mechanical failure is found and the controller is suspected, See Engine Control Unit (ADM)” and “Engine Control Unit (MR/PLD)”

There are 37 slots (1) machined in the flywheel. One slot has a dimple in it. This is the TDC timing mark. Turn engine in the direction of rotation until TDC timing mark (2) on flywheel lines up in centre of the window in timing case. NOTE: All valves can be adjusted in two crankshaft positions. Rocker arms and push rods for number one cylinder should be loose. If not, rotate engine 360°. Engine must be at TDC on the compression stroke for number one cylinder. NOTE: When adjusting valve clearance, the bolt on the valve bridge should on no account be loosened.

REVISION 0

51


872152

CHAPTER 2

Measure the valve clearance between the rocker arm and the valve bridge with a feeler gauge.

B50D Mk III 6X6 ADT

Crank engine until cylinder six is on TDC (cylinder six valve overlap): Check valve clearance on cylinder one - intake and outlet, cylinder two - exhaust, cylinder three intake, cylinder four - intake, cylinder five exhaust, cylinder seven - exhaust and cylinder eight - intake. With number one cylinder on TDC (cylinder one valve overlap): Check the valve clearance on cylinder two intake, cylinder three - exhaust, cylinder four exhaust, cylinder five - intake, cylinder six - intake and exhaust, cylinder seven - intake and cylinder eight - exhaust. Crank engine until cylinder six is on TDC (cylinder six valve overlap): Check valve clearance on cylinder one - intake and outlet, cylinder two - exhaust, cylinder three intake, cylinder four - intake, cylinder five exhaust, cylinder seven - exhaust and cylinder eight - intake. Intake Valve Clearance . . . 0.40 mm (0.016in.) Exhaust Valve Clearance . . 0.60 mm (0.024in.) Locknut tightening torque . . . . 50Nm (37 lb-ft) To adjust clearance: Loosen locknut (1) and turn adjusting screw (2) in or out depending on gap to big or small.

Check the valve clearance on cylinder two intake, cylinder three - exhaust, cylinder four exhaust, cylinder five - intake, cylinder six - intake and exhaust, cylinder seven - intake and cylinder eight - exhaust.

52

Tighten locknut to specification while holding adjusting screw in position. Adjust valves in same order used for checking. Check clearance again after tightening locknut.

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872152

EXHAUST BRAKE ADJUSTMENT

Check control arm (1) to stop (2) clearance. The control arm must not rest on the stop. There must be slight clearance between the control arm and stop to ensure that exhaust brake is fully closed. If adjustment is needed, loosen locknut (3), remove clip (4) and disconnect cylinder from control arm. Turn rod end (5) for adjustment. With engine off, check the clearance between the control arm (1) and the stop (2). In the brake valve “OFF� position, the control arm should be resting on the stop. Disconnect the air line (3) from the cylinder. Connect a regulated air supply line to the cylinder. Regulate air pressure so pressure is approximately 740 - 810 kPa (7.4 - 8.1 bar) (107 117 psi).

REVISION 0

53


872152

54

CHAPTER 2

B50D Mk III 6X6 ADT

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872152

CHAPTER 2. ENGINE SECTION 4. TESTS CYLINDER COMPRESSION TEST The test is normally performed with the MiniDiag Special Tool. NOTE: Compression pressures are affected by the cranking speed of the engine. Before beginning the test, ensure that the batteries are fully charged and the starter motor is in a good working condition. Remove fuel delivery nozzle from cylinder being tested. See CHAPTER 4, SECTION 8 of repair Manual Remove and Install Fuel Delivery Nozzle.

‹ CAUTION Engine must not be started with fuel line from EUI disconnected. Remove Fuse 17 (ECU/EUI Power Fuse). Crank engine approximately ten seconds. Record readings and compare to specification. Engine Compression Pressure . . . . . . . . . . . 2800 kPa (28 bar) (406 psi). Permissible Difference Between Cylinders . . . . . . . . . . . . . 400 kPa (4 bar) (58psi).

FUEL PUMP PRESSURE TEST Specification Pressure At Slow Idle . . . . . . . 210 -300 kPa . . . . . . . . . . . . . (2.1 - 3 bar) (30 - 44psi). Pressure At Fast Idle. . . . . . . . 500 - 600kPa . . . . . . . . . . . . . . (5 - 6 bar) (73 - 87psi).

Essential Tools Parker No. 34982-16-6: Banjo Union. Parker No. 0502-12-12: 1 1/16 - 12M x 3/4 14NPT F Adapter. Parker No. 3/4 x 1/2 PTR: 3/4 - 14 PT M x 1/2 - 14 NPT F Pipe Thread Reducer. Install JDG1599 compression tester adapter (1) into cylinder head. Install holddown clamp (2) using an M10 x 1.5 x 70 mm long cap screw (3). Install compression tester to adapter.

Parker No. 1/2 x 3/8 PTR: 1/2 - 14 NPT M x 3/8 - 18 NPT F Pipe Thread Reducer. Parker No. 30182-6-6: 3/8 - 18 NPT M x 3/8 Barb Fitting.

Service Equipment And Tools JT07148 Digital Hydraulic Tester. JT07156 0.5 to 15 GPM Lt. Flow Meter.

REVISION 0

55


872152

CHAPTER 2

B50D Mk III 6X6 ADT

4

5

3 2

1

1 1

1 50D3001CV

NOTE: Above illustration is of a LA 501 engine with photos of the LA 502 engine inserted. Connect banjo union fittings (1) to fuel pump outlet port and fuel filter inlet. Connect fittings (2 - 5) to flow meter and flow meter to hydraulic tester. Run engine at slow idle and measure fuel pump pressure. Compare to specification. Run engine at fast idle and compare to specification.

56

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872120

OIL PUMP PRESSURE TEST Specification Engine Oil Pressure at Slow Idle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 50kPa (0.5 bar) (7.3psi). Engine Oil Pressure at Fast Idle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 250 kPa (2.5 bar) (36.3psi).

Essential Tools Parker No. 8M16F80MX: M 16 x 1.5 M x 3/4 - 16 M 37° Adapter. JT03132: 3/4 - 16 M 37° x 3/4 - 16 F 37° Sw 90° Elbow. JT03003: 7/16 - 20 M 37° x 3/4 - 16 F 37° Reducer.

Service Equipment And Tools • 413 kPa (4.1 bar) (60psi) Gauge.

1

1000 500

1500 2000

0

2

3

40D3006CV

Remove engine oil pressure sensor. (See “Engine Main Harness” ).

REVISION 0

57


872152

CHAPTER 2

B50D Mk III 6X6 ADT

Install adapter (1), elbow (2) and reducer (3) to engine and connect gauges to fittings. NOTE: To achieve an accurate oil pressure reading, warm engine to 105° C (220° F). Run engine at slow idle. Compare reading to specification. Run engine at fast idle. Compare reading to specification.

58

REVISION 0


5

6

7

8

Y11

Y12

Y13

4

3

2

1

V8

B10

Y9

Y8

Y7

Y6

2

1

1

GY/PL 1.5

PL 0.35

B10 B11 B12 B14 B15 B16 B65 B90

N3-24

N3-55

N3-52

N3-51

START-K150 1

2

8

1

96 Ay

R7-87

8

8

E1

85

30

86

87

87a

X10

15-15

R5-86

RD/YL 1.5

RD 1.5

RD 1.5

14 2

91 8

95 8

86 8

BELL TRAINING CENTER TR001233 B50D REVISION 0.1

2260........2701 Ohm 0,6...1,1 Volt 15........22 Ohm 1000........1385 Ohm 1000........1385 Ohm 2260........2701 Ohm 1,0...1,4 Volt 2205........2653 Ohm NORMALLY OPEN NORMALLY OPEN 0,07........0.37 Ohm 0,07........0.37 Ohm 0,07........0.37 Ohm 0,07........0.37 Ohm 0,07........0.37 Ohm 0,07........0.37 Ohm 0,07........0.37 Ohm 0,07........0.37 Ohm

VALUE @ 20 C

RELAY 12 ADM / MR SUPPLY

FUSE6-1

R7-86

E1

DIAG-F BK/WH 1.5

BK 1.5

15 2

ADM MERCEDES ENGINE CONTROL UNIT

FUSE8-1

OR 1.5

12-2

12-1

18-9

18-2

15-6

15-14 BL 1.0 BN 1.0

X8

15-13 BK 1.0

15-5

YL/GN 1.0

21-2

BL/RD 1.5

RD 1.5

21-12 21-3

BK 1.5

21-13

21-14

21-20

21-21

21-19

21-1

GN 1.5

BL/YL 1.5

BL/GN 1.5

X9

SHIELD

GN 1.0

YL 1.0

BK/YL 1.5

BK 1.5

BK 1.5

RD 1.5

RD 1.5

E1

E1

X19 - C

X19 - B

X19 - A

X7

FUEL PRESSURE SENSOR OIL TEMPERATURE SENSOR (COMBINATION SENSOR) OIL PRESSURE SENSOR (COMBINATION SENSOR) OIL LEVEL SENSOR CAM SHAFT SENSOR CRANK SHAFT SENSOR COOLANT TEMPERATURE SENSOR CHARGE AIR PRESSURE SENSOR (COMBINATION) CHARGE AIR TEMPERATURE SENSOR START BUTTON STOP BUTTON UNIT PUMP SOLENOID CYLINDER 1 UNIT PUMP SOLENOID CYLINDER 2 UNIT PUMP SOLENOID CYLINDER 3 UNIT PUMP SOLENOID CYLINDER 4 UNIT PUMP SOLENOID CYLINDER 5 UNIT PUMP SOLENOID CYLINDER 6 UNIT PUMP SOLENOID CYLINDER 7 UNIT PUMP SOLENOID CYLINDER 8

DESCRIPTION

8

87

8

90 89 88

CHAPTER 2

N3-50

N3-14

N3-43

N3-42

N3-41

N3-40

N3-13

N3-36

N3-4

N3-28

N3-27

S10 S11 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13

UNIT

N3-31

PL 1.5

MR-13

LEGEND

BK/WH 1.5

MR-12 X3 - 28

BK/WH 1.5

MR-8

N3-18

N3-26

RD 1.5

GN 2.5

E2

GN 2.5 X3 - 6

X3 - 5

BK 2.5

MR-6

MR-5

MR-15

MR-11

MR-9

X3 - 25

X3 - 24

MR-4 MR-2

X3 - 13

X25 - 1

X25 - 2

X25 - 5

X25 - 3

X25 - 4

X25 - 6

MR-3

BN 0.35

YL 0.35

RD 0.35

WH 0.35

GN 0.35

X3 - 14

X106

1

2

5

3

4

6

PWM ACCELERATOR PEDAL

MR-1

PLD ENGINE CONTROL UNIT

_

N3-21

N3-17

N3-16

N3-47

N3-9

OR/BL 1.5

GY/GN 1.5

N3-37

GY/WH1.5

N3-45

N3-38

GY/YL 1.5

N3-46

WH/RD 1.5

OR/GN 1.5

N3-53

N3-44

GY/BL 1.5

WH/BL 1.5

N3-54

GY/BK 1.5

N3-12

N3-11

N3-35

RD/WH 0.5

2

N3-25

RD/BK 0.5

1

STOP S11

N3-30

BL/WH 0.5

2

N3-49 N3-33

YL 0.5 WH 0.5

START S10

N3-10 N3-6

BR/GY 0.5

2 3 N3-8

N3-32

N3-48

GN/BL 0.5

BR/BK 0.5

2

N3-29

N3-22

GR/YL 0.5

VL 0.5

4 1

BL 0.5

1

N3-7

N3-5

N3-23

N3-39

N3-15

N3-34

2

B12

TEMP

GN 0.5

3

GY/BR 0.5

1

RD/YL 0.5 BR/WH 0.5

1

2

N3-3

N3-2

N3-19

N3-20

N3-1

1

Y10

B14

B90

B11

WH/YL 0.5

BK/VL 0.5

1 2

BR/VL 0.5

2

BR/YL 0.5

(4) (2)

BK/YL 0.5

PWM

PWM

1

MCB1-2

2

(1)

B65

B15

B16

(6) (5)

(3)

+

MERCDES BENZ ADM AND PLD SCHEMATIC FOR OM502 LA B50D ADT +

REVISION 0 _

DIAG-G

B50D Mk III 6X6 ADT 872152

Engine Schematic

59


872152

CHAPTER 2

B50D Mk III 6X6 ADT

CAN BUS J1939

There are numerous advantages of using a “CAN” system:

WHAT EXACTLY IS A “CAN BUS”

Reliable.

The Controller Area Network (CAN) is a serial communications protocol that efficiently distributes real time control (Data) with great Data integrity. In other words it is a system that sends data (In a binary code or math between electronic control units.)

Cost effective.

The “CAN” is a means of transferring data between components and in the case of the "D" Series ADT’s there is a “CAN” between numerous components, namely:

Fast.

High flexibility. The following illustrations describe the Bell “CAN” and the tests that can be carried out to test the wiring.

SSM · Sealed Switch Module MDU · Monitor Display Unit TCU · Transmission Control Unit CCU · Chassis Control Unit ECU · Commonly known as the ADM is the · · · · Engine control unit (Cab Mounted). MR · · Engine mounted control unit (PLD). OBW · On Board Weighing FDC · Fan Drive Controller SCU · Suspension control unit MM· · Memory module OEU · Output Expansion Unit.

60

REVISION 0


REVISION 0

X94 - C

X94 - B

X94 - A

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

MR

Diag

MDU

SHIELD

7.2 V

GN 1.0

YL 1.0

Wake up Module

SHIELD

SHIELD

SHIELD GN 1.0 YL 1.0

GN 1.0 YL 1.0

SHIELD

SHIELD GN 1.0 YL 1.0

FDC

SAT. Modem

OBW

SHIELD

MM & GPS

CCU

YL 1.0

SCU

TCU

GN 1.0

ADM

CTI

SAE J1939 CAN BUS

X93 - C

X93 - B

X93 - A

BELL TRAINING CENTER TR001634 B50D REVISION 01

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

B50D Mk III 6X6 ADT CHAPTER 2 872152

CANBUS

YL 1.0

GN 1.0

GN 1.0 YL 1.0

SHIELD GN 1.0 YL 1.0

GN 1.0 YL 1.0

SHIELD

SHIELD

GN 1.0

YL 1.0

61


872152

CHAPTER 2

B50D Mk III 6X6 ADT

TESTING THE “CANBUS”

CHECKING THE CABLES

The construction of the “CAN” line is of a high quality cable consisting of a CAN_H and a CAN_L cable. These two cables carry the information in Series to and from the Control units in the system. CAN_H and CAN_L Both send the same messages and basically check on each other.

When testing the “CANBUS” the most important factor will be the 60 Ohm reading across the CAN_H and CAN_L.

The O’s and 1’s are created by voltages that are produced inside the control units.The two cables are protected by a shield around the outside to prevent in EMI (Electro Magnetic Interferences).This EMI can cause false or incorrect signals in the system. The “CANBUS” has two resistors connected to the end of the “CAN line.” These Resistors are fitted to Terminate the signals in the “BUS”. If these Resistors where not fitted the signals would reflect in the “CAN” line and the System would not work.The Resistors also play an important Role in the system for the technician,The resistors are connected across the CAN_H and CAN_L lines.If You measure the Resistance across any of the two lines at any of the control units you will measure 60 Ohms. A short circuit or open circuit will cause the resistances to change. There are numerous errors that can occur within the system. 1. CAN_H Short to ground. 2. CAN_L Short to ground.

NOTE: A digital Multi meter Must be used to check any readings on the D Series Machines. Before beginning the troubleshooting process, read and understand the following: Wire identification presents the Connector, the terminal on the connector and the colour. Shut off the engine and ignition before any harness connectors are disconnected or connected. When disconnecting a harness connector, be sure that pulling force is applied to the connector itself and not the wires extending from the connector. Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to maintain firm contact. Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-residue, non-lubricating solvent. When checking the CAN harness at the connectors, it is important to remember to check the CAN from each of the pins on the different plugs that are used in the CAN circuit.

3. CAN_H Short to CAN_L. 4. CAN_H Open circuit. 5. CAN_L Open circuit 6. CAN_H and CAN_L Open circuit. 7. CAN _H or CAN_L shorted to a Arbitrary Potential (Voltages) Any of these errors will cause a Error code to come up on the MDU Display. The Display will show For example “CCU CAN ERROR” on the display.

62

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN HARNESS NOTE: Always make sure that all the connectors are removed from all the control units before testing. Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of the problems, reconnect the clean connectors and operate the vehicle normally.

872152

MAIN “CAN” HARNESS The Main “CAN” Harness is measured in Ohms and One should measure 60 Ohms as per the calculation shown previously. The reading obtained in Ohms is very important as previously discussed as this will determine if there is a problem with the “CAN” Line. Once all the connectors have been removed each connector can be measured for 60 Ohms. There are Numerous faults that can occur to prevent the 60 Ohms reading from being obtained.

If all connectors are clean and connected correctly, determine which Control unit is causing the error on the display. Remove all the connectors on the control units and measure the resistance of the “CAN BUS” as shown below for each fault. Each control unit has their own connector as they are manufactured by different OEM’S.

REVISION 0

63


872152

CHAPTER 2

B50D Mk III 6X6 ADT

“CAN” SHORT TO GROUND A short to ground on one or both “CAN” lines will result in continuity being read to ground. Check the continuity on any connector as shown below. Make sure that the ground you are using is a good clean ground.

0

Ð

VOLT/OHMMETER (VOM)

CAN_H or CAN_L Shorted to ground

0

Ð + +

X19 - A

X19 - B

E X19 - C

ECU CAN

X18 - A

X18 - B

X18 - C

CCU CAN

E

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

CANT1-A

YL 1.0

CANTERM - A

CANT1-B

GN 1.0

CANTERM - B

CANT1-C

SHIELD

CANTERM - C

CAN Short To Ground CV

64

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 2

872152

“CAN “OPEN CIRCUIT A Open circuit on one or both “CAN” lines will result in only one resistor being read which will show 120 Ohms on the multimeter. Check the resistance on all the connectors as shown below. Also Check the Resistance of the individual Resistors (120 Ohms).

CAN_H or CAN_L Open circuit or both Open Circuit

0

0

X19 - A

X19 - B

X19 - C

ECU CAN

X18 - A

X18 - B

X18 - C

CCU CAN

VOLT/OHMMETER (VOM)

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

CANT1-A

YL 1.0

CANTERM - A

CANT1-B

GN 1.0

CANTERM - B

CANT1-C

SHIELD

CANTERM - C

CAN Open Circuit CV

REVISION 0

65


872152

CHAPTER 2

B50D Mk III 6X6 ADT

“CAN” SHORT TO POSITIVE 0 -24 VOLTS CAN_H or CAN_L must also be measured for a voltage at the connectors in case the lines have shorted to a positive. Check from any connector to ground for a Voltage, make sure that the ground you are using is a good clean ground.

CAN_H or CAN_L 0

VOLT/OHMMETER (VOM)

Shorted to a Voltage

0

A voltage from 0-24V

X19 - A

X19 - B

E X19 - C

ECU CAN

X18 - A

X18 - B

X18 - C

CCU CAN

E

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

120 OHM 3 WAY DEUTSCH CAN TERMINATOR

CANT1-A

YL 1.0

CANTERM - A

CANT1-B

GN 1.0

CANTERM - B

CANT1-C

SHIELD

CANTERM - C

CAN Short To + 0 -24Volts CV

66

REVISION 0


B50D Mk III 6X6 ADT

CHAPTER 3

872152

CHAPTER 3. ELECTRICAL SYSTEM SECTION 1. SYSTEM INFORMATION

1

DFM L

B+

M

15

S

Circuit Breaker

W

A

0

ACC 0 IGN ST

2

Kl30

Kl50

ELECTRICAL SCHEMATIC SYMBOLS

1

BGND

BAT

Isolator Switch

Starter

Fuse

Alternator

12 V Cigarette Lighter / Accessory Socket

5

Battery

H

2

8

Ignition Switch

Horn

2

G

6

G

2

3 30

86

4

Continue 85

T

Radio / Cassette Player

P

W

W

6 87

2

Diode

Ignition Solenoid

3

P

1

1

Temperature Sender

Battery Balancer Pressure Switch

P

2

2

1

1

Pressure Sender

Head Light Switch

87a 87

1

30 85

3

Engine Speed Sensor

86

Pressure Switch

“-"

2

1

Latch Switch

Relay

“+"

CW

12 V Two Way Radio

Speaker

1

2

Light Pot

Solenoid 2

1

2

B

1

A

Compressor Clutch Solenoid

Monitor

H Sol

0 1 V7

Retarder Accum. Resistor

Headlight

Retarder Solenoid

Retarder Temp Sensor

1

3

Thermal Protection

C

A

B

1

1

(6)

6 (4) PWM

R

(1)

L

HORN WASHER

INDICATORS

WIPERS

DIP/BRIGHTS

J

MIRROR SERVO 3 M

2 1

_

BRIGHTS

1 0

4

5

+

(2)

(5)

_

(3)

Wiper motor

2

M

+

3

Pump & Motor

2

Switch

PWM

4

2

Ignition

M

Park

1

Earth

Position Sensor 2

M

DIPS

4

C

M

Fan / Blower

Switch

B

Motor Speed Switch

Demister

5

Diode Bank

0 (OFF) 1 (L) 2 (M) 3 (H)

V6

Diode Light

PWM Accelerator Pedal

MIRROR SERVO

Steering Column Switch Symbols Elec

REVISION 0

67


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Hitachi b50d mk ⅲ 6×6 articulated dump truck service repair manual  
Hitachi b50d mk ⅲ 6×6 articulated dump truck service repair manual  
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