| Content
Security measures
Safety devices
General safety requirements
Safety instructions
Warning labels
Work check procedure
Operation test
Performance checks - rocker switch on, engine off
Engine
Theoretical foundations of work
Engine (OM 501 LA shown)
Engine troubleshooting
Adjustments
Tachometer on OSD (B35D shown)
Idle adjustment at low and high speeds
Valve clearance adjustment
OM 501 LA engine shown
Adjusting retarders
Checks
Cylinder compression test
Fuel pump pressure test
Oil pump pressure test
Electrical system
System information
Wiring diagram symbols
CAN bus J1939
What is a “CAN bus”?
CANBUS
Testing the “CAN bus”
Checking cables
Check for open circuits, short circuits between wires and short circuits to ground on the CAN wiring harness
Main harness “CAN”
“CAN” short circuit to ground
“CAN” open circuit
“CAN” short circuit to positive terminal 0 - 24 volts
Chassis control unit (CCU2 and OEU)
MDU2 (control display unit)
MDU2 layout
MDU2 inputs and outputs
Relay
MDU2
Startup display
Default screen
To go to the main menu from the default screen
Main menu
Wire marking explanations
Connectors
Description of electrical circuits
SSM
Pilot lights MDU2
MDU2 instruments
CCU2 output characteristics
OEU output characteristics
Reference data
Engine trouble codes (ADM)
Engine fault codes (PLD-MR)
DM trouble codes
Checks
Checking the key switch
Relay
Diode testing
Tests for pneumatic system solenoids, pressure switches and sensors
Steering column engagement test
Transmission HD4560
Theoretical foundations of work
General descriptions
Critical speeds
Planetary gears and power flows
Basic laws of planetary gear sets
Heavy duty planetary transmission
Heavy duty clutch configuration
Transmission cross section
Power flow
Hydraulic system
Electromagnets
Hydraulic lines
Torque converter and lube pressure lines - brief description
Discharging backfill pressure
Pressure table and control points
Retarder
Application and load capacity
Inputs and outputs
Hydraulic retarder control
Checking the retarder charge pressure
Heavy duty retarder hydraulics
Heavy duty retarder hydraulics retarder enabled
Electronic control system
Gear selector pushbutton
RPM sensors (look different on new transmission)
Wiring harness
Range/transmit checks
“Do not shift gear” lamp
Diagnostic information
Diagnostic procedure
Transmission system fault diagnosis
Checking the transmission fluid level
Transmission control unit error codes
Service code diagnostics - how to use transmission code reception
Error code table
Electronic control Allison HD 4560R WTEC III
Settings and tests
Transmission warm-up procedure
Transmission oil cooler shrink test
Pneumatic system
Basics of work
Operation of the pneumatic system
Pneumatic system diagram
Diagnostic information
Diagnostic procedure
Pneumatic system troubleshooting
Settings and tests
Testing and adjusting the main pressure of the pneumatic system
Parking brake pressure test
Setting the parking brake
Basic seat function test procedures
Hydraulic system
Theoretical foundations of work
Symbols in the hydraulic system diagram
Articulated dump truck hydraulic operation
Work
Diagnostic information
Diagnostic procedure
Troubleshooting the hydraulic system
Checks
Installing the digital thermometer JT05800
Installing the JT02156A digital-to-analog pressure / temperature analyzer
Hydraulic oil cleaning procedure with portable filter cassette
Hydraulic system warm-up procedure
Testing loop time constants
Testing and adjusting the residual and compensating valves of the main hydraulic pump
System relief valve and lift circuit relief valve test
Priority valve test
Accumulator pressure reducing valve test and adjustment
Testing and adjusting the brake accumulator charging valve
Testing brake accumulators and brake low pressure switches
Pressure test and charging procedure for front and rear brake accumulators
Service brake valve test
Steering system relief valve pressure test and setting
Steering cylinder leak test
Testing and adjustment of the residual and compensating valves of the auxiliary steering pump
Body lowering circuit safety valve test
Fan drive circuit pressures, B35D and B40D
Checking and adjusting the fan drive control
Suspension calibration procedure, B50D only
Suspension test
Air conditioning and heating
Theoretical foundations of work
Air conditioning cycle
Operation of the heater core
Diagnostic information
Troubleshooting the air conditioning system
Location of air conditioning/heating components
Checks
Air conditioning checks
R134A air conditioning test
Working pressure troubleshooting tables
Frost protection control switch test
Air compressor clutch test
High/low air pressure switch test
Air expansion valve test
Expansion valve bench test
Refrigerant Leak Test
Maintenance Schedules
Daily or 10-hour checks
Maintenance and checks every 150 hours
Transmission
Introduction
Maintenance instructions
Lowering and raising the pallet
Maintenance and checks every 500 hours
Transmission
Introduction
Maintenance instructions
Engine
Transmission
Brakes
Gearbox
Cleaning, checking and replacing breathers
General check of driveline and suspension mounts
Transfer case breather (located under the hydraulic fluid tank)
Transmission breather and axle breathers
Cab and electrical
Checking, cleaning and replacing the air filter in the cab
Checking batteries, cleaning and tightening terminals
Checking electrical connectors, harnesses and braids
Checking working lights, reversing horn and horn
Recording and deleting fault codes on the menu display
Testing the driver's controls and instruments
Lubrication
Grease lubrication
Checking the grease level in the automatic lubrication system
Hydraulics
Replacing the hydraulic tank breather valve, B35D and B40D
Wet disc brake coolant oil reservoir (B40D only) (on top of the reservoir)
Maintenance and checks every 1,000 hours
Transmission
Introduction
Maintenance instructions
Engine
Replacing the transfer box filter
Hydraulics and Lubrication
Replacing the hydraulic tank breather
Axles, chassis and suspension
Checking the status of all drive shafts
Checking the axle oil level (B35D and B40D only)
Checking the final drive oil level (B35D and B40D only)
Axle oil change (B35D and B50D with BELL wet brakes)
Checking the backlash of the shock-absorbing body element
Maintenance and checks every 2,000 hours
Transmission
Introduction
Maintenance instructions
Engine
Hydraulics and Lubrication
Changing the oil in the wet disc brake cooler and filter
Cab, pneumatic system and electrical part
Replacing the air dryer filter
Maintenance and checks every 3,000 hours
Transmission
Introduction
Maintenance instructions
Hydraulics and pneumatics
Maintenance and checks every 4,000 hours
Transmission
Replacing the fan belt (B35D and B40D only)
Hydraulics and pneumatics
Introduction
Maintenance instructions
On-demand maintenance
Engine
Introduction
Maintenance instructions
Cab and lubrication
Cleaning the air conditioning filters
Lubrication of hinges with grease
Checking and cleaning all radiators
Other maintenance and checks
Transmission
Introduction
Maintenance instructions
Engine
Wheels
Electrical
Using the battery charger
Headlight adjustment
Operational test
Operation test
Troubleshooting
Symptoms and solutions
Introduction
Application
Datasheet OBW - ADT MK IV 001-4002-00
Technical Data Sheet for hydraulic cooler with fan - ADT MK IV 001-4003-02
Contents
Introduction
Chassis control unit software requirements
CCU2 headlight and control logic 001-4004-00
Introduction
The logic of the headlights and their control
Wiper control logic CCU2 001-4005-00
Introduction
Wiper control logic and timing
Air conditioning control logic 001-4006-00
Introduction
Inputs / outputs
Body control logic 001-4007-00
Introduction
Body control logic
Parking brake operation
Introduction |
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