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Hitachi AH350-D AH400-D Articulated Dump Truck Service Manual (KM8TH-E-01)PDF DOWNLOAD
Hitachi AH350-D AH400-D Articulated Dump Truck Service + Technical + Workshop Manual
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Hitachi AH350-D AH400-D Articulated Dump Truck Service + Technical + Workshop Manual
This Manual Includes:
- Hitachi AH350-D AH400-D Articulated Dump Truck Service Manual (KM8TH-E-01)
- Hitachi AH350-D AH400-D Articulated Dump Truck Technical Manual (K8TG-E-02)
- Hitachi AH350-D AH400-D Articulated Dump Truck Workshop Manual (KM-3540DE)
SCREENSHOTS OF THE MANUAL:
DESCRIPTION:
Hitachi AH350-D AH400-D Articulated Dump Truck Service + Technical + Workshop Manual
- 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 HITACHI 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 HITACHI 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 HITACHI 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.
- HITACHI . has a policy of continuous product development, improvement, and design. HITACHI . 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.
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol.
- When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Service manuals are divided in two parts: Technical and Workshop.
- Workshop sections tell how to repair the components. Technical sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction.
- At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Service Manuals are concise guides for specific machines.
- They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
Hitachi AH350-D AH400-D Articulated Dump Truck Service Manual (KM8TH-E-01)
AH350-D/400-D_KM8TH-E-00………………………………………………………….. 1
TO THE SERVICE PERSONNEL………………………………………………………….. 5
SAFETY SYMBOL……………………………………………………………………. 6
IMPORTANT……………………………………………………………………….. 8
ABBREVIATIONS……………………………………………………………………. 9
AMENDMENT……………………………………………………………………….. 11
INTRODUCTION…………………………………………………………………….. 13
TABLE OF CONTENTS………………………………………………………………… 37
SAFETY………………………………………………………………………. 15
SAFETY FEATURES…………………………………………………………… 15
GENERAL SAFETY……………………………………………………………. 16
SAFETY REGULATION…………………………………………………………. 17
SAFETY DECALS………………………………………………………………… 23
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE………………………………………. 47
OPERATIONAL CHECK-OUT……………………………………………………… 47
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF……………………………….. 47
CHAPTER 2. ENGINE…………………………………………………………….. 53
SECTION 1. THEORY OF OPERATION……………………………………………… 53
ENGINE……………………………………………………………….. 53
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS……………………………………… 57
SECTION 3. ADJUSTMENTS…………………………………………………….. 59
DISPLAY MENU TACHOMETER………………………………………………… 59
SLOW AND FAST IDLE ADJUSTMENT…………………………………………… 59
VALVE CLEARANCE ADJUSTMENT……………………………………………… 59
EXHAUST BRAKE ADJUSTMENT……………………………………………….. 60
SECTION 4. TESTS………………………………………………………….. 63
CYLINDER COMPRESSION TEST………………………………………………. 63
FUEL PUMP PRESSURE TEST………………………………………………… 63
OIL PUMP PRESSURE TEST…………………………………………………. 65
CAN BUS J1939…………………………………………………………. 69
WHAT EXACTLY IS A “CAN BUS”…………………………………………….. 69
CANBUS……………………………………………………………….. 71
TESTING THE “CANBUS”…………………………………………………… 73
CHECKING THE CABLES……………………………………………………. 73
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN HARNESS…. 73
MAIN “CAN” HARNESS…………………………………………………….. 74
“CAN” SHORT TO GROUND………………………………………………….. 75
“CAN “OPEN CIRCUIT…………………………………………………….. 76
“CAN” SHORT TO POSITIVE 0 -24 VOLTS……………………………………… 77
CHAPTER 3. ELECTRICAL SYSTEM…………………………………………………… 79
SECTION 1. SYSTEM INFORMATION………………………………………………. 79
ELECTRICAL SCHEMATIC SYMBOLS……………………………………………. 79
CHASSIS CONTROL UNIT (CCU & OEU)………………………………………… 80
MDU2 (MONITOR DISPLAY UNIT)…………………………………………….. 81
MDU2 LAYOUT…………………………………………………………… 82
MDU2 INPUT AND OUTPUTS…………………………………………………. 83
RELAY………………………………………………………………… 85
START-UP DISPLAY………………………………………………………. 86
DEFAULT SCREEN………………………………………………………… 86
DEFAULT SCREEN………………………………………………………… 86
DEFAULT SCREEN………………………………………………………… 86
DEFAULT SCREEN………………………………………………………… 86
DEFAULT SCREEN………………………………………………………… 87
TO GO TO MAIN MENU FROM DEFAULT SCREEN…………………………………… 87
MAIN MENU…………………………………………………………….. 87
EXPLANATION OF WIRE MARKINGS……………………………………………. 92
SECTION 2. DESCRIPTION OF CIRCUITS…………………………………………..125
SSM…………………………………………………………………..137
MDU2 WARNING LIGHTS…………………………………………………….148
MDU2 GAUGES……………………………………………………………152
CCU2 OUTPUT SPECIFICATION……………………………………………….153
OEU OUTPUT SPECIFICATION………………………………………………..157
SECTION 3. REFERENCES………………………………………………………161
ENGINE FAULT CODES (ADM)………………………………………………..161
ENGINE FAULT CODES (PLD-MR)……………………………………………..166
SSM FAULT CODES………………………………………………………..192
PART 2. DM1 FAULT CODES…………………………………………………193
SECTION 4. TESTS…………………………………………………………..211
KEY SWITCH TEST………………………………………………………..211
RELAYS………………………………………………………………..211
Diode Test…………………………………………………………….212
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests……………..213
Steering Column Switch Test……………………………………………..218
CHAPTER 4. TRANSMISSION HD4560………………………………………………….231
SECTION 1. THEORY OF OPERATION………………………………………………231
GENERAL DESCRIPTIONS……………………………………………………231
STALL SPEEDS…………………………………………………………..238
PLANETARY GEARS AND POWER FLOWS………………………………………….240
THE BASIC LAWS OF PLANETARY GEAR SETS…………………………………….241
HD TRANSMISSION PLANETARY CONFIGURATION…………………………………..242
HD TRANSMISSION CLUTCH CONFIGURATION……………………………………..243
TRANSMISSION CROSS SECTIONAL DIAGRAM……………………………………..245
POWER FLOW…………………………………………………………….247
HYDRAULIC SYSTEM……………………………………………………….257
SOLENOIDS……………………………………………………………..261
HYDRAULIC CIRCUITS……………………………………………………..263
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS – OVERVIEW……………………..271
EXHAUST BACKFILL PRESSURE……………………………………………….272
PRESSURE TABLE AND TEST POINTS…………………………………………..277
RETARDER………………………………………………………………278
APPLICATIONS AND CAPACITIES……………………………………………..278
INPUTS AND OUTPUTS……………………………………………………..280
RETARDER CONTROL HYDRAULICS……………………………………………..280
TESTING RETARDER CHARGING PRESSURE……………………………………….281
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF………………………………282
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON……………………………….283
ELECTRONIC CONTROL SYSTEM……………………………………………….284
PUSH BUTTON SHIFT SELECTOR………………………………………………288
SPEED SENSORS………………………………………………………….289
WIRING HARNESSES……………………………………………………….289
RANGE / SHIFT TESTS…………………………………………………….290
DO NOT SHIFT LIGHT……………………………………………………..291
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………293
DIAGNOSTIC PROCEDURE……………………………………………………293
DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS………………………………….294
CHECK THE TRANSMISSION FLUID LEVEL……………………………………….306
TRANSMISSION CONTROL UNIT ERROR CODES…………………………………….309
Service Code Diagnostics – How To Use Listing For Transmission Codes…………310
TABLE OF ERROR CODES……………………………………………………….311
ALLISON HD 4560R ELECTRONIC CONTROL WTEC III………………………………317
SECTION 3. ADJUSTMENTS AND TESTS…………………………………………….319
TRANSMISSION WARM-UP PROCEDURE…………………………………………..319
TRANSMISSION OIL COOLER RESTRICTION TEST………………………………….328
CHAPTER 5. PNEUMATIC SYSTEM…………………………………………………….329
SECTION 1. THEORY OF OPERATION………………………………………………329
PNEUMATIC SYSTEM OPERATION………………………………………………329
PNEUMATIC SYSTEM SCHEMATIC………………………………………………330
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………341
DIAGNOSTIC PROCEDURE……………………………………………………341
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS……………………………………342
SECTION 3. ADJUSTMENTS AND TESTS…………………………………………….344
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT…………………………344
PARK BRAKE PRESSURE TEST………………………………………………..345
PARK BRAKE ADJUSTMENT…………………………………………………..346
GRAMMER SEAT FUNCTIONAL TEST…………………………………………….348
CHAPTER 6. HYDRAULIC SYSTEM…………………………………………………….349
SECTION 1. THEORY OF OPERATION………………………………………………….349
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION……………………………..349
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………….383
DIAGNOSTIC PROCEDURE……………………………………………………….383
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS……………………………………….384
SECTION 3. TESTS………………………………………………………………397
JT05800 DIGITAL THERMOMETER INSTALLATION……………………………………..397
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION…………….397
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY…………………….397
HYDRAULIC SYSTEM WARM-UP PROCEDURE…………………………………………..398
CYCLE TIME TEST……………………………………………………………399
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT………….400
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST…………………….402
PRIORITY VALVE TEST………………………………………………………..403
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT………………………..403
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT…………………………….404
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST…………………………..405
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE…………….406
SERVICE BRAKE VALVE TEST……………………………………………………407
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT…………………………….408
STEERING CYLINDER LEAKAGE TEST………………………………………………408
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT………409
BIN LOWER CIRCUIT RELIEF VALVE TEST………………………………………….410
FAN DRIVE CIRCUIT PRESSURES…………………………………………………411
CHAPTER 7. HEATING AND AIR CONDITIONING………………………………………….413
SECTION 1. THEORY OF OPERATION………………………………………………413
AIR CONDITIONING SYSTEM CYCLE OF OPERATION………………………………..413
HEATER CORE OPERATION…………………………………………………..414
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………415
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS……………………………..415
HEATING/AIR CONDITIONING COMPONENT LOCATION……………………………….417
SECTION 3. TESTS…………………………………………………………..419
AIR CONDITIONING OPERATIONAL CHECKS………………………………………419
R134A AIR CONDITIONING SYSTEM TEST……………………………………….420
OPERATING PRESSURE DIAGNOSTIC CHART………………………………………421
A/C FREEZE CONTROL SWITCH TEST…………………………………………..423
A/C COMPRESSOR CLUTCH TEST………………………………………………423
A/C HIGH/LOW PRESSURE SWITCH TEST………………………………………..423
A/C EXPANSION VALVE TEST………………………………………………..424
EXPANSION VALVE BENCH TEST………………………………………………425
REFRIGERANT LEAK TEST…………………………………………………..426
CHAPTER 8. MAINTENANCE SCHEDULES………………………………………………..429
NOTES:……………………………………………………………………432
CHAPTER 9. DAILY OR 10 HOURLY SERVICE CHECKS……………………………………..433
CHAPTER 10. 150 HOURS SERVICE AND CHECKS…………………………………………435
SECTION 1. DRIVE TRAIN……………………………………………………..435
INTRODUCTION…………………………………………………………..435
SERVICE INSTRUCTIONS……………………………………………………435
LOWER AND RAISE THE BELLY PLATE………………………………………….435
CHAPTER 11. 500 HOURS SERVICE AND CHECKS…………………………………………439
SECTION 1. DRIVE TRAIN……………………………………………………..439
INTRODUCTION…………………………………………………………..439
SERVICE INSTRUCTIONS……………………………………………………439
ENGINE………………………………………………………………..439
TRANSMISSION…………………………………………………………..440
BRAKES………………………………………………………………..443
TRANSFER CASE………………………………………………………….444
SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS…………………………………445
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS……………………………445
TRANSFER CASE BREATHER (LOCATED UNDER THE HYDRAULIC RESERVOIR)………………445
TRANSMISSION BREATHER AND AXLE BREATHERS………………………………….445
SECTION 3. CAB AND ELECTRICAL……………………………………………….447
INSPECT, CLEAN AND REPLACE CAB AIR FILTER…………………………………447
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS………………………………448
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS…………………………..448
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS……………………………….448
RECORD & DELETE FAULT CODES ON THE MDU……………………………………448
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS……………………………….448
SECTION 4. LUBRICATION……………………………………………………..449
GREASE ALL GREASE POINTS………………………………………………..449
HYDRAULICS…………………………………………………………….450
REPLACE HYDRAULIC RESERVOIR BREATHER……………………………………..450
WET DISC BRAKE COOLING OIL RESERVOIR (AH400-D) ONLY (ON TOP OF RESERVOIR)…….451
CHAPTER 12. 1 000 HOURS SERVICE AND CHECKS……………………………………….453
SECTION 1. DRIVE TRAIN……………………………………………………..453
INTRODUCTION…………………………………………………………..453
SERVICE INSTRUCTIONS……………………………………………………453
Engine………………………………………………………………..453
SECTION 2. HYDRAULICS AND LUBRICATION………………………………………..457
REPLACE HYDRAULIC RESERVOIR BREATHER……………………………………..457
SECTION 4. AXLES AND CHASSIS & SUSPENSION…………………………………….459
CHECK AXLE OIL LEVEL……………………………………………………459
CHECK FINAL DRIVE OIL LEVELS…………………………………………….459
CHANGE AXLE OIL (AH350-D With Hitachi Wet Brakes)………………………….459
CHECK BIN SHOCK PAD CLEARANCE……………………………………………460
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 WET DISC BRAKE COOLER OIL AND FILTER………………………………467
SECTION 3. CAB, PNEUMATICS AND ELECTRICAL…………………………………….469
REPLACE PNEUMATIC SYSTEM 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
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
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
SERVICE MANUAL REVISION REQUEST FORM………………………………………………..531
Hitachi AH350-D AH400-D Articulated Dump Truck Technical Manual (K8TG-E-02)
TECHNICALMANUAL……………………………………………………………………………. 1
Introduction…………………………………………………………………………… 3
Contents………………………………………………………………………………. 5
General Information…………………………………………………………………. 7
Safety…………………………………………………………………………. 9
Recognize Safety Information………………………………………………….. 9
Follow Safety Instructions……………………………………………………. 9
Operate Only If Qualified…………………………………………………….. 9
Wear Protective Equipment…………………………………………………….. 10
Avoid Unauthorized Machine Modifications……………………………………….. 10
Inspect Machine……………………………………………………………… 10
Stay Clear Of Moving Parts……………………………………………………. 11
Avoid High-Pressure Fluids……………………………………………………. 11
Beware Of Exhaust Fumes………………………………………………………. 11
Prevent Fires……………………………………………………………….. 12
Prevent Battery Explosions……………………………………………………. 12
Handle Chemical Products Safely……………………………………………….. 13
Dispose of Waste Properly…………………………………………………….. 13
Prepare for Emergencies………………………………………………………. 13
Use Steps And Handholds Correctly……………………………………………… 14
Start Only From Operator’s Seat……………………………………………….. 14
Use And Maintain Seat Belt……………………………………………………. 14
Prevent Unintended Machine Movement……………………………………………. 15
Avoid Work Site Hazards………………………………………………………. 15
Keep Riders Off Machine………………………………………………………. 16
Avoid Backover Accidents……………………………………………………… 16
Avoid Machine Tip Over……………………………………………………….. 17
Operating on Slopes………………………………………………………….. 17
Operating Or Traveling On Public Roads…………………………………………. 18
Inspect and Maintain ROPS…………………………………………………….. 18
Add And Operate Attachments Safely…………………………………………….. 18
Park And Prepare For Service Safely……………………………………………. 19
Service Tires Safely…………………………………………………………. 20
Service Cooling System Safely…………………………………………………. 20
Remove Paint Before Welding or Heating…………………………………………. 21
Make Welding Repairs Safely…………………………………………………… 21
Drive Metal Pins Safely………………………………………………………. 21
Operational Checkout Procedure……………………………………………………….. 23
Operational Checkout Procedure……………………………………………………. 25
Specifications……………………………………………………………………… 33
SPECIFICATIONS………………………………………………………………….. 35
Engine…………………………………………………………………………….. 39
Theory of Operation……………………………………………………………… 41
350D and 400D (OM 501) Engine Sectional View……………………………………. 41
Engine Operation…………………………………………………………….. 43
Electronic Unit Injector Fuel System…………………………………………… 43
Fuel Delivery……………………………………………………………….. 44
Cold Start Operation…………………………………………………………. 48
Diagnose Engine Malfunctions……………………………………………………… 49
Diagnose Engine Malfunctions………………………………………………….. 49
Adjustments…………………………………………………………………….. 53
Display Monitor Tachometer……………………………………………………. 53
Slow and Fast Idle Adjustment…………………………………………………. 53
Valve Clearance Adjustment……………………………………………………. 54
Exhaust Brake Adjustment……………………………………………………… 56
Tests………………………………………………………………………….. 57
Cylinder Compression Test…………………………………………………….. 57
Fuel Pump Pressure Test………………………………………………………. 58
Oil Pump Pressure Test……………………………………………………….. 60
Electrical System…………………………………………………………………… 63
System Information………………………………………………………………. 66
Electrical Diagram Information………………………………………………… 66
CAN BUS J1939…………………………………………………………………… 73
WHAT EXACTLY IS A “CAN BUS”…………………………………………………… 73
TESTING THE “CANBUS”…………………………………………………………. 75
CHECKING THE CABLES………………………………………………………….. 76
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN
HARNESS………. 77
MAIN “CAN” HARNESS…………………………………………………………… 77
“CAN” SHORT TO GROUND………………………………………………………… 78
“CAN” OPEN CIRCUIT…………………………………………………………… 79
“CAN” SHORT TO POSITIVE 0 -24 VOLTS……………………………………………. 80
CCU WITH THE THREE CONNECTORS…………………………………………………. 82
CHASSIS CONTROL UNIT (CCU)……………………………………………………. 81
CCU CONNECTOR X5 (J3)………………………………………………………… 83
CCU CONNECTOR X6A (J1A)………………………………………………………. 84
CCU CONNECTOR X6B (J1L)………………………………………………………. 85
THE FOLLOWING DESCRIBES THE INPUTS AND OUTPUTS OF THE CCU………………………… 86
PLUG X5 (J3)………………………………………………………………… 86
PLUG X6A (J1A)………………………………………………………………. 88
PLUG X6B (J1L)………………………………………………………………. 90
MDU (MONITOR DISPLAY UNIT)……………………………………………………. 93
MDU LAYOUT………………………………………………………………….. 94
MDU INPUT AND OUTPUTS………………………………………………………… 95
THE FOLLOWING DESCRIBES THE INPUTS AND OUTPUTS OF THE MDU………………………… 96
PLUG X37……………………………………………………………………. 96
PLUG X38……………………………………………………………………. 97
MDU MENU STRUCTURE…………………………………………………………… 98
DEFAULT OPTIONS AVAILABLE FOR THE LARGE ADT’S ARE AS FOLLOWS……………………… 99
LARGE ADT, MDU MENU A…………………………………………………………107
LARGE ADT, MDU MENU B…………………………………………………………108
ENGINE VALUES………………………………………………………………..109
TRANSMISSION VALUES…………………………………………………………..110
VEHICLE VALUES……………………………………………………………….111
LARGE ADT, MDU MENU C…………………………………………………………113
CCU INPUTS…………………………………………………………………..115
CCU ANALOG…………………………………………………………………..118
CCU OUTPUTS………………………………………………………………….120
LARGE ADT, MDU MENU D…………………………………………………………123
MENU D CONT………………………………………………………………….125
LARGE ADT, MDU MENU E…………………………………………………………129
ON BOARD WEIGHING…………………………………………………………….134
OBW MODULE…………………………………………………………………..134
X161 CONNECTOR 12 Way Deutch…………………………………………………..134
Calibration of the OBW System………………………………………………….136
MENU C………………………………………………………………………136
MENU D………………………………………………………………………138
Auto Zero……………………………………………………………………139
“Hopper site”………………………………………………………………..139
“OBW Function”……………………………………………………………….139
ELECTRICAL SCHEMATICS…………………………………………………………140
SCHEMATIC SYMBOLS…………………………………………………………….140
EARTH POINTS…………………………………………………………………141
System Diagrams………………………………………………………………….143
Explanation of Wire Markings…………………………………………………..143
Fuse Specifications…………………………………………………………..144
Functional Schematic and Component Location Legend……………………………….146
Functional Schematic………………………………………………………….154
Section Legend……………………………………………………………154
Electrical System Functional Schematic………………………………………….155
Main Power Harness (W6)……………………………………………………….156
Wiring Diagram……………………………………………………………156
Component Location………………………………………………………..158
Front Frame/Engine Harness (W7)………………………………………………..160
Wiring Diagram……………………………………………………………160
Component Location………………………………………………………..162
Engine Main Harness (W8)………………………………………………………164
Wiring Diagram……………………………………………………………164
Component Location………………………………………………………..166
Cab Power Harness (W9)………………………………………………………..167
Wiring Diagram……………………………………………………………167
Component Location………………………………………………………..168
Cab Main Harness (W10)………………………………………………………..170
Wiring Diagram……………………………………………………………170
Component Location………………………………………………………..181
Controller Area Network (CAN) Harness (W11)……………………………………..188
Wiring Diagram……………………………………………………………188
Component Location………………………………………………………..190
Transmission Control Harness (W12)……………………………………………..192
Wiring Diagram……………………………………………………………192
Component Location………………………………………………………..194
Transmission Harness (W13)…………………………………………………….196
Wiring Diagram……………………………………………………………196
Component Location………………………………………………………..198
Hydraulic Harness (W14)……………………………………………………….200
Wiring Diagram……………………………………………………………200
Component Location………………………………………………………..202
Rear Fame Harness (W15)……………………………………………………….204
Wiring Diagram……………………………………………………………204
Component Location………………………………………………………..206
Work Light Harness (W16)………………………………………………………207
Wiring Diagram……………………………………………………………207
Component Location………………………………………………………..208
Air Conditioning Actuator Harness (W18)…………………………………………210
Wiring Diagram……………………………………………………………210
Component Location………………………………………………………..212
Sub-System Diagnostics……………………………………………………………214
Starting and Charging Circuit………………………………………………….214
Theory of Operation……………………………………………………….214
Cold Start Circuit……………………………………………………………218
Theory of Operation……………………………………………………….218
Electronic Unit Injector Controller Circuit……………………………………..220
Theory of Operation……………………………………………………….220
Engine Control Unit Circuit……………………………………………………224
Theory of Operation……………………………………………………….224
Transmission Control Unit Circuit………………………………………………226
Theory of Operation……………………………………………………….226
Chassis Control Unit Circuit…………………………………………………..232
Theory of Operation……………………………………………………….232
Dump Body Control, Fan Drive, and Range Hold Circuit Theory of Operation……………238
Park Brake and Exhaust Brake Circuit……………………………………………242
Theory of Operation……………………………………………………….242
Monitor Display Unit Circuit…………………………………………………..246
Theory of Operation……………………………………………………….246
Turn Signal and 4-Way Flasher Circuit…………………………………………..252
Theory of Operation……………………………………………………….252
Stop Light Circuit……………………………………………………………256
Theory of Operation……………………………………………………….256
Backup Alarm and Backup Light Circuit…………………………………………..258
Theory of Operation……………………………………………………….258
Wiper/Washer Circuit………………………………………………………….260
Theory of Operation……………………………………………………….260
Battery Balancer and 12-Volt Accessory Circuit Theory of Operation…………………264
Air Conditioning Circuit………………………………………………………266
Theory of Operation……………………………………………………….266
Electric Mirror Circuit……………………………………………………….270
Theory of Operation……………………………………………………….270
Unloader Valve Circuit ……………………………………………………….272
Theory of Operation……………………………………………………….272
References………………………………………………………………………273
Service Code Diagnostics………………………………………………………273
After Machine Repair………………………………………………………273
How Codes Are Displayed On Monitor Display Unit………………………………275
How To Use Listing For Transmission Codes……………………………………276
Engine Control Unit……………………………………………………….277
Electronic Unit Injector (EUI) Controller……………………………………285
Chassis Control Unit………………………………………………………302
Transmission Control Unit (TCU)…………………………………………….305
D-Series Articulated Dump Trucks 350D and 400D Service ADVISOR™ Computer Connection….415
Circuit Check Using Monitor Display Unit (MDU) or Service ADVISOR………………….418
Two-Wire Sensor…………………………………………………………..418
Three-Wire Sensor…………………………………………………………419
Key Switch Test………………………………………………………………420
Relay Test…………………………………………………………………..420
Diode Test…………………………………………………………………..421
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests……………………422
Hydraulic Pressure Switches Test……………………………………………….427
Hydraulic Temperature Sensors Test……………………………………………..428
Body Position Sensor Test……………………………………………………..429
Steering Column Switch Test……………………………………………………432
Retarder Voltage Regulator Test………………………………………………..433
Transmission Speed Sensors Test………………………………………………..436
Transmission Solenoids Test……………………………………………………437
Electronic Unit Injector (EUI) Controller……………………………………….438
Remove and Install………………………………………………………..438
Engine Control Unit…………………………………………………………..438
Remove and Install………………………………………………………..438
Cold Start Module…………………………………………………………….440
Remove and Install………………………………………………………..440
Chassis Control Unit………………………………………………………….441
Remove and Install………………………………………………………..441
Transmission Control Unit …………………………………………………….442
Remove and Install………………………………………………………..442
Battery Balancer……………………………………………………………..443
Remove and Install………………………………………………………..443
Monitor Display Unit………………………………………………………….444
Remove and Install………………………………………………………..444
Replace Monitor Display Unit Bulbs……………………………………………..445
Remove, Install, and Calibrate Accelerator Pedal Position Sensor…………………..447
Replace DEUTSCH™ Rectangular or Triangular Connectors…………………………….448
Replace DEUTSCH™ Connectors……………………………………………………449
Install DEUTSCH™ Contact………………………………………………………450
Replace WEATHER PACK™Connector…………………………………………………451
Install WEATHER PACK™Contact…………………………………………………..452
Replace (Pull Type) Metri-Pack™ Connectors………………………………………454
Replace (Push Type) Metri-Pack™ Connectors………………………………………455
Remove Connector Body from Blade Terminals………………………………………455
Power Train…………………………………………………………………………457
Theory of Operation………………………………………………………………459
Transmission External Components……………………………………………….459
Transmission…………………………………………………………………461
Control System……………………………………………………………461
Cross Sectional Diagram……………………………………………………464
TORQUE CONVERTER………………………………………………………….466
Operational Overview………………………………………………………466
TORQUE CONVERTER OPERATION…………………………………………………467
Stator One-way Clutch Operation…………………………………………….468
Vortex Flow………………………………………………………………469
Rotary Flow………………………………………………………………470
LOCK-UP CLUTCH OPERATION…………………………………………………..471
Stall Testing…………………………………………………………….471
Stall Test Procedure………………………………………………………471
AH400-D/AH350-D STALL SPEEDS……………………………………………….473
Analysing Stall Test Results……………………………………………….473
Trouble Shooting A Freewheeling Stator………………………………………473
Troubleshooting A Stuck Stator……………………………………………..473
Stall Torque Ratio………………………………………………………..473
Clutch Engagement…………………………………………………………474
PLANETARY GEARS AND POWER FLOWS…………………………………………….513
THE BASIC LAWS OF PLANETARY GEAR SETS……………………………………….514
CLUTCHES…………………………………………………………………514
HD TRANSMISSION PLANETARY CONFIGURATION……………………………………..515
Transmission Cross
Sectional Diagram……………………………………….518
POWER FLOW……………………………………………………………….520
Neutral Power Flow………………………………………………………..521
1st Range Power Flow………………………………………………………522
2nd Range Power Flow………………………………………………………523
3rd Range Power Flow………………………………………………………524
4th Range Power Flow………………………………………………………525
5th Range Power Flow………………………………………………………526
6th Range Power Flow………………………………………………………527
Reverse Range Power Flow…………………………………………………..528
Retarder Operation………………………………………………………..529
Transmission Thermal Valve Operation……………………………………………533
Differential Lock Operation……………………………………………………534
Inter-Axle Lock Operation……………………………………………………..534
Diagnostic Information……………………………………………………………535
Diagnostic Procedure………………………………………………………….535
Power Train Systems…………………………………………………………..536
Diagnose Malfunctions……………………………………………………..536
Power Train………………………………………………………………….550
Component Location Diagram…………………………………………………550
Tests…………………………………………………………………………..553
Transmission…………………………………………………………………553
Warm Up Procedure…………………………………………………………553
Transmission Pressure Test…………………………………………………….554
Clutch Enable Test with Service ADVISER™………………………………………..562
Transmission Clutch Drag Test………………………………………………….567
Torque Converter Stall Test—350D……………………………………………….569
Torque Converter Stall Test—400D……………………………………………….571
Torque Converter Stator Tests………………………………………………….573
Torque Converter Lockup Test…………………………………………………..575
Transmission Thermal Valve Test………………………………………………..576
Transmission Oil Cooler Restriction Test………………………………………..577
RETARDER…………………………………………………………………….578
Retarder Operation……………………………………………………………578
APPLICATIONS AND CAPACITIES……………………………………………………578
Retarder Control – Overview……………………………………………………579
Apply Controls……………………………………………………………….579
INPUTS AND OUTPUTS……………………………………………………………580
RETARDER CONTROL HYDRAULICS……………………………………………………580
TESTING RETARDER CHARGING PRESSURE……………………………………………..581
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF…………………………………….582
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON……………………………………..583
ELECTRONIC CONTROL SYSTEM……………………………………………………..584
SYSTEM COMPONENTS…………………………………………………………….584
TRANSMISSION CONTROL UNIT (TCU)………………………………………………..584
PULSE WIDTH MODULATION (PWM)…………………………………………………..584
Pulse Width Modulation Waveforms(Solenoid Duty Cycle)…………………………….585
UPSHIFT CLUTCH CONTROL………………………………………………………..585
PUSH BUTTON SELECTORS…………………………………………………………588
Mode………………………………………………………………………..588
Hold Upshift Shift Schedule Or Range Hold……………………………………….588
Pre-select Downshift Shift Schedule…………………………………………….588
Speed Sensor Locations………………………………………………………..589
WIRING HARNESSES……………………………………………………………..589
External Wiring Harness……………………………………………………….589
Internal Wiring Harness……………………………………………………….590
RANGE / SHIFT TESTS…………………………………………………………..590
Range Verification……………………………………………………………590
Off-going Ratio Test………………………………………………………….590
Oncoming Ratio Test…………………………………………………………..591
DO NOT SHIFT LIGHT……………………………………………………………591
Backfill Pressure…………………………………………………………….593
Accumulator Relay Valve……………………………………………………….595
Front Suspension Strut Leakage Check……………………………………………596
Park Brake Test………………………………………………………………596
Park Brake Pad Thickness Check…………………………………………………597
Park Brake Adjustment…………………………………………………………598
Checking Controlled Traction Clutch (Differential Lock) Condition………………….601
Pneumatic System…………………………………………………………………….603
Theory of Operation………………………………………………………………606
Pneumatic System Schematic…………………………………………………….606
Pneumatic System Operation…………………………………………………….607
Air Pressure Supply Circuit Operation…………………………………………..608
Air Dryer and Unloader Valve…………………………………………………..610
Pneumatic Manifold……………………………………………………………612
Pneumatic Circuit…………………………………………………………….618
Diagnostic Information……………………………………………………………623
Diagnostic Procedure………………………………………………………….623
Diagnose Pneumatic System Malfunctions………………………………………….624
Pneumatic System Component Location Diagram……………………………………..628
Tests…………………………………………………………………………..631
Pneumatic System Main Pressure Test and Adjustment……………………………….631
Park Brake Pressure Test………………………………………………………632
Hydraulic System…………………………………………………………………….635
Theory of Operation………………………………………………………………637
Articulated Dump Truck Hydraulic System Operation………………………………..637
Main Hydraulic Pump Operation………………………………………………….640
Main Hydraulic Pump Load Sense Operation………………………………………..642
Service Brake System Operation…………………………………………………646
Steering and Secondary Steering System Operation…………………………………650
Steering Valve Operation………………………………………………………654
Secondary Steering Pump Operation………………………………………………656
Hydraulic System Manifold Operation…………………………………………….658
Fan Drive System Operation…………………………………………………….666
Dump Body Control Valve Operation………………………………………………668
Hydraulic System Circuit Symbols……………………………………………….670
Hydraulic System Schematic—350D………………………………………………..672
Hydraulic System Schematic—400D………………………………………………..674
Diagnostic Information……………………………………………………………677
Diagnostic Procedure………………………………………………………….677
Diagnose Hydraulic System Malfunctions………………………………………….678
Diagnose Service Brake System Malfunctions………………………………………683
Diagnose Steering System Malfunctions…………………………………………..686
Hydraulic System Component Location…………………………………………….690
Tests…………………………………………………………………………..699
JT05800 Digital Thermometer Installation………………………………………..699
JT02156A Digital Pressure/Temperature Analyzer Installation……………………….699
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy……………………….700
Hydraulic System Warm-Up Procedure……………………………………………..701
Cycle Time Test………………………………………………………………702
Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment…………….703
System Relief Valve and Dump Body Raise Circuit Relief Valve Test………………….706
Priority Valve Test…………………………………………………………..707
Accumulator Pressure Reducing Valve Test and Adjustment…………………………..708
Brake Accumulator Charge Valve Test and Adjustment……………………………….710
Brake Low Pressure Switch and Brake Accumulator Test……………………………..712
Front and Rear Brake Accumulators Pressure Test and Charge Procedure……………….714
Service Brake Valve Test………………………………………………………715
Steering Relief Valve Pressure Test and Adjustment……………………………….716
Steering Cylinder Leakage Test…………………………………………………718
Secondary Steering Pump Residual and Compensator Valves Test and Adjustment…………719
Dump Body Lower Circuit Relief Valve Test……………………………………….721
Fan Drive Controller Test and Adjustment………………………………………..722
Wet Disk Brake Thermal Valve Test………………………………………………724
Wet Disk Brake Cooling System Bypass Check Valve Test…………………………….725
Wet Disk Brake Cooler Restriction Test………………………………………….726
Wet Disk Brake Cooling Oil Filter Restriction Test……………………………….728
Heating and Air Conditioning………………………………………………………….731
Theory of Operation………………………………………………………………733
Air Conditioning System Cycle of Operation………………………………………733
Heater Core Operation…………………………………………………………734
Diagnostic Information……………………………………………………………735
Diagnose Air Conditioning System Malfunctions……………………………………735
Diagnose Heater System Malfunctions…………………………………………….737
Heating/Air Conditioning Component Location……………………………………..738
Tests…………………………………………………………………………..741
Air Conditioning Operational Checks…………………………………………….741
R134a Air Conditioning System Test……………………………………………..743
Operating Pressure Diagnostic Chart…………………………………………….745
A/C Freeze Control Switch Test…………………………………………………747
A/C Compressor Clutch Test…………………………………………………….748
A/C High/Low Pressure Switch Test………………………………………………748
A/C Expansion Valve Test………………………………………………………751
Expansion Valve Bench Test…………………………………………………….753
Refrigerant Leak Test…………………………………………………………754
Index………………………………………………………………………………755
REVISION REQUEST FORM………………………………………………………………..761
Hitachi AH350-D AH400-D Articulated Dump Truck Workshop Manual (KM-3540DE)
TECHNICALMANUAL……………………………………………………………………………. 1
Contents………………………………………………………………………………. 3
General Information…………………………………………………………………. 4
Safety…………………………………………………………………………. 6
Recognize Safety Information………………………………………………….. 6
Follow Safety Instructions……………………………………………………. 6
Operate Only If Qualified…………………………………………………….. 6
Wear Protective Equipment…………………………………………………….. 7
Avoid Unauthorized Machine Modifications……………………………………….. 7
Inspect Machine……………………………………………………………… 7
Stay Clear Of Moving Parts……………………………………………………. 8
Avoid High-Pressure Fluids……………………………………………………. 8
Beware Of Exhaust Fumes………………………………………………………. 8
Prevent Fires……………………………………………………………….. 9
Prevent Battery Explosions……………………………………………………. 9
Handle Chemical Products Safely……………………………………………….. 10
Dispose of Waste Properly…………………………………………………….. 10
Prepare for Emergencies………………………………………………………. 10
Use Steps And Handholds Correctly……………………………………………… 11
Start Only From Operator’s Seat……………………………………………….. 11
Use And Maintain Seat Belt……………………………………………………. 11
Prevent Unintended Machine Movement……………………………………………. 12
Avoid Work Site Hazards………………………………………………………. 12
Keep Riders Off Machine………………………………………………………. 13
Avoid Backover Accidents……………………………………………………… 13
Avoid Machine Tip Over……………………………………………………….. 14
Operating on Slopes………………………………………………………….. 14
Operating Or Traveling On Public Roads…………………………………………. 15
Inspect and Maintain ROPS…………………………………………………….. 15
Add And Operate Attachments Safely…………………………………………….. 15
Park And Prepare For Service Safely……………………………………………. 16
Service Tires Safely…………………………………………………………. 17
Service Cooling System Safely…………………………………………………. 17
Remove Paint Before Welding or Heating…………………………………………. 18
Make Welding Repairs Safely…………………………………………………… 18
Drive Metal Pins Safely………………………………………………………. 18
Operational Checkout Procedure……………………………………………………….. 20
Operational Checkout Procedure……………………………………………………. 22
Engine…………………………………………………………………………….. 30
Theory of Operation……………………………………………………………… 32
350D and 400D (OM 501) Engine Sectional View……………………………………. 32
Engine Operation…………………………………………………………….. 34
Electronic Unit Injector Fuel System…………………………………………… 34
Fuel Delivery……………………………………………………………….. 35
Cold Start Operation…………………………………………………………. 39
Diagnose Engine Malfunctions……………………………………………………… 40
Diagnose Engine Malfunctions………………………………………………….. 40
Adjustments…………………………………………………………………….. 44
Display Monitor Tachometer……………………………………………………. 44
Slow and Fast Idle Adjustment…………………………………………………. 44
Valve Clearance Adjustment……………………………………………………. 45
Exhaust Brake Adjustment……………………………………………………… 47
Tests………………………………………………………………………….. 48
Cylinder Compression Test…………………………………………………….. 48
Fuel Pump Pressure Test………………………………………………………. 49
Oil Pump Pressure Test……………………………………………………….. 51
Electrical System…………………………………………………………………… 54
System Information………………………………………………………………. 57
Electrical Diagram Information………………………………………………… 57
System Diagrams…………………………………………………………………. 64
Explanation of Wire Markings………………………………………………….. 64
Fuse Specifications………………………………………………………….. 65
Functional Schematic and Component Location Legend………………………………. 67
Functional Schematic…………………………………………………………. 75
Section Legend…………………………………………………………… 75
Electrical System Functional Schematic…………………………………………. 76
Main Power Harness (W6)………………………………………………………. 77
Wiring Diagram…………………………………………………………… 77
Component Location……………………………………………………….. 79
Front Frame/Engine Harness (W7)……………………………………………….. 81
Wiring Diagram…………………………………………………………… 81
Component Location……………………………………………………….. 83
Engine Main Harness (W8)……………………………………………………… 85
Wiring Diagram…………………………………………………………… 85
Component Location……………………………………………………….. 87
Cab Power Harness (W9)……………………………………………………….. 88
Wiring Diagram…………………………………………………………… 88
Component Location……………………………………………………….. 89
Cab Main Harness (W10)……………………………………………………….. 91
Wiring Diagram…………………………………………………………… 91
Component Location……………………………………………………….. 102
Controller Area Network (CAN) Harness (W11)…………………………………….. 109
Wiring Diagram…………………………………………………………… 109
Component Location……………………………………………………….. 111
Transmission Control Harness (W12)…………………………………………….. 113
Wiring Diagram…………………………………………………………… 113
Component Location……………………………………………………….. 115
Transmission Harness (W13)……………………………………………………. 117
Wiring Diagram…………………………………………………………… 117
Component Location……………………………………………………….. 119
Hydraulic Harness (W14)………………………………………………………. 121
Wiring Diagram…………………………………………………………… 121
Component Location……………………………………………………….. 123
Rear Fame Harness (W15)………………………………………………………. 125
Wiring Diagram…………………………………………………………… 125
Component Location……………………………………………………….. 127
Work Light Harness (W16)……………………………………………………… 128
Wiring Diagram…………………………………………………………… 128
Component Location……………………………………………………….. 129
Air Conditioning Actuator Harness (W18)………………………………………… 131
Wiring Diagram…………………………………………………………… 131
Component Location……………………………………………………….. 133
Sub-System Diagnostics…………………………………………………………… 135
Starting and Charging Circuit…………………………………………………. 135
Theory of Operation………………………………………………………. 135
Cold Start Circuit…………………………………………………………… 139
Theory of Operation………………………………………………………. 139
Electronic Unit Injector Controller Circuit…………………………………….. 141
Theory of Operation………………………………………………………. 141
Engine Control Unit Circuit…………………………………………………… 145
Theory of Operation………………………………………………………. 145
Transmission Control Unit Circuit……………………………………………… 147
Theory of Operation………………………………………………………. 147
Chassis Control Unit Circuit………………………………………………….. 153
Theory of Operation………………………………………………………. 153
Dump Body Control, Fan Drive, and Range Hold Circuit Theory of Operation…………… 159
Park Brake and Exhaust Brake Circuit…………………………………………… 163
Theory of Operation………………………………………………………. 163
Monitor Display Unit Circuit………………………………………………….. 167
Theory of Operation………………………………………………………. 167
Turn Signal and 4-Way Flasher Circuit………………………………………….. 173
Theory of Operation………………………………………………………. 173
Stop Light Circuit…………………………………………………………… 177
Theory of Operation………………………………………………………. 177
Backup Alarm and Backup Light Circuit………………………………………….. 179
Theory of Operation………………………………………………………. 179
Wiper/Washer Circuit…………………………………………………………. 181
Theory of Operation………………………………………………………. 181
Battery Balancer and 12-Volt Accessory Circuit Theory of Operation………………… 185
Air Conditioning Circuit……………………………………………………… 187
Theory of Operation………………………………………………………. 187
Electric Mirror Circuit………………………………………………………. 191
Theory of Operation………………………………………………………. 191
Unloader Valve Circuit ………………………………………………………. 193
Theory of Operation………………………………………………………. 193
References……………………………………………………………………… 194
Service Code Diagnostics……………………………………………………… 194
After Machine Repair……………………………………………………… 194
How Codes Are Displayed On Monitor Display Unit……………………………… 196
How To Use Listing For Transmission Codes…………………………………… 197
Engine Control Unit………………………………………………………. 198
Electronic Unit Injector (EUI) Controller…………………………………… 206
Chassis Control Unit……………………………………………………… 223
Transmission Control Unit (TCU)……………………………………………. 226
D-Series Articulated Dump Trucks 350D and 400D Service ADVISOR™ Computer Connection…. 336
Circuit Check Using Monitor Display Unit (MDU) or Service ADVISOR…………………. 339
Two-Wire Sensor………………………………………………………….. 339
Three-Wire Sensor………………………………………………………… 340
Key Switch Test……………………………………………………………… 341
Relay Test………………………………………………………………….. 341
Diode Test………………………………………………………………….. 342
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests…………………… 343
Hydraulic Pressure Switches Test………………………………………………. 348
Hydraulic Temperature Sensors Test…………………………………………….. 349
Body Position Sensor Test…………………………………………………….. 350
Steering Column Switch Test…………………………………………………… 353
Retarder Voltage Regulator Test……………………………………………….. 354
Transmission Speed Sensors Test……………………………………………….. 357
Transmission Solenoids Test…………………………………………………… 358
Electronic Unit Injector (EUI) Controller………………………………………. 359
Remove and Install……………………………………………………….. 359
Engine Control Unit………………………………………………………….. 359
Remove and Install……………………………………………………….. 359
Cold Start Module……………………………………………………………. 361
Remove and Install……………………………………………………….. 361
Chassis Control Unit…………………………………………………………. 362
Remove and Install……………………………………………………….. 362
Transmission Control Unit ……………………………………………………. 363
Remove and Install……………………………………………………….. 363
Battery Balancer…………………………………………………………….. 364
Remove and Install……………………………………………………….. 364
Monitor Display Unit…………………………………………………………. 365
Remove and Install……………………………………………………….. 365
Replace Monitor Display Unit Bulbs…………………………………………….. 366
Remove, Install, and Calibrate Accelerator Pedal Position Sensor………………….. 368
Replace DEUTSCH™ Rectangular or Triangular Connectors……………………………. 369
Replace DEUTSCH™ Connectors…………………………………………………… 370
Install DEUTSCH™ Contact……………………………………………………… 371
Replace WEATHER PACK™Connector………………………………………………… 372
Install WEATHER PACK™Contact………………………………………………….. 373
Replace (Pull Type) Metri-Pack™ Connectors……………………………………… 375
Replace (Push Type) Metri-Pack™ Connectors……………………………………… 376
Remove Connector Body from Blade Terminals……………………………………… 376
Power Train………………………………………………………………………… 378
Theory of Operation……………………………………………………………… 380
Transmission External Components………………………………………………. 380
Transmission………………………………………………………………… 382
Control System…………………………………………………………… 382
Cross Sectional Diagram…………………………………………………… 385
Torque Converter…………………………………………………………….. 387
Operation……………………………………………………………….. 387
Transmission………………………………………………………………… 389
Clutch Engagement………………………………………………………… 389
Retarder Operation……………………………………………………….. 428
Transmission Thermal Valve Operation…………………………………………… 432
Differential Lock Operation…………………………………………………… 433
Inter-Axle Lock Operation…………………………………………………….. 433
Diagnostic Information…………………………………………………………… 434
Diagnostic Procedure…………………………………………………………. 434
Power Train Systems………………………………………………………….. 435
Diagnose Malfunctions…………………………………………………….. 435
Power Train…………………………………………………………………. 449
Component Location Diagram………………………………………………… 449
Tests………………………………………………………………………….. 452
Transmission………………………………………………………………… 452
Warm Up Procedure………………………………………………………… 452
Transmission Pressure Test……………………………………………………. 453
Clutch Enable Test with Service ADVISER™……………………………………….. 461
Transmission Clutch Drag Test…………………………………………………. 466
Torque Converter Stall Test—350D………………………………………………. 468
Torque Converter Stall Test—400D………………………………………………. 470
Torque Converter Stator Tests…………………………………………………. 472
Torque Converter Lockup Test………………………………………………….. 474
Transmission Thermal Valve Test……………………………………………….. 475
Transmission Oil Cooler Restriction Test……………………………………….. 476
Front Suspension Strut Leakage Check…………………………………………… 477
Park Brake Test……………………………………………………………… 477
Park Brake Pad Thickness Check………………………………………………… 478
Park Brake Adjustment………………………………………………………… 479
Checking Controlled Traction Clutch (Differential Lock) Condition…………………. 482
Pneumatic System……………………………………………………………………. 484
Theory of Operation……………………………………………………………… 487
Pneumatic System Schematic……………………………………………………. 487
Pneumatic System Operation……………………………………………………. 488
Air Pressure Supply Circuit Operation………………………………………….. 489
Air Dryer and Unloader Valve………………………………………………….. 491
Pneumatic Manifold…………………………………………………………… 493
Pneumatic Circuit……………………………………………………………. 499
Diagnostic Information…………………………………………………………… 504
Diagnostic Procedure…………………………………………………………. 504
Diagnose Pneumatic System Malfunctions…………………………………………. 505
Pneumatic System Component Location Diagram…………………………………….. 509
Tests………………………………………………………………………….. 512
Pneumatic System Main Pressure Test and Adjustment………………………………. 512
Park Brake Pressure Test……………………………………………………… 513
Hydraulic System……………………………………………………………………. 516
Theory of Operation……………………………………………………………… 518
Articulated Dump Truck Hydraulic System Operation……………………………….. 518
Main Hydraulic Pump Operation…………………………………………………. 521
Main Hydraulic Pump Load Sense Operation……………………………………….. 523
Service Brake System Operation………………………………………………… 527
Steering and Secondary Steering System Operation………………………………… 531
Steering Valve Operation……………………………………………………… 535
Secondary Steering Pump Operation……………………………………………… 537
Hydraulic System Manifold Operation……………………………………………. 539
Fan Drive System Operation……………………………………………………. 547
Dump Body Control Valve Operation……………………………………………… 549
Hydraulic System Circuit Symbols………………………………………………. 551
Hydraulic System Schematic—350D……………………………………………….. 553
Hydraulic System Schematic—400D……………………………………………….. 555
Diagnostic Information…………………………………………………………… 558
Diagnostic Procedure…………………………………………………………. 558
Diagnose Hydraulic System Malfunctions…………………………………………. 559
Diagnose Service Brake System Malfunctions……………………………………… 564
Diagnose Steering System Malfunctions………………………………………….. 567
Hydraulic System Component Location……………………………………………. 571
Tests………………………………………………………………………….. 580
JT05800 Digital Thermometer Installation……………………………………….. 580
JT02156A Digital Pressure/Temperature Analyzer Installation………………………. 580
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy………………………. 581
Hydraulic System Warm-Up Procedure…………………………………………….. 582
Cycle Time Test……………………………………………………………… 583
Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment……………. 584
System Relief Valve and Dump Body Raise Circuit Relief Valve Test…………………. 587
Priority Valve Test………………………………………………………….. 588
Accumulator Pressure Reducing Valve Test and Adjustment………………………….. 589
Brake Accumulator Charge Valve Test and Adjustment………………………………. 591
Brake Low Pressure Switch and Brake Accumulator Test…………………………….. 593
Front and Rear Brake Accumulators Pressure Test and Charge Procedure………………. 595
Service Brake Valve Test……………………………………………………… 596
Steering Relief Valve Pressure Test and Adjustment………………………………. 597
Steering Cylinder Leakage Test………………………………………………… 599
Secondary Steering Pump Residual and Compensator Valves Test and Adjustment………… 600
Dump Body Lower Circuit Relief Valve Test………………………………………. 602
Fan Drive Controller Test and Adjustment……………………………………….. 603
Wet Disk Brake Thermal Valve Test……………………………………………… 605
Wet Disk Brake Cooling System Bypass Check Valve Test……………………………. 606
Wet Disk Brake Cooler Restriction Test…………………………………………. 607
Wet Disk Brake Cooling Oil Filter Restriction Test………………………………. 609
Heating and Air Conditioning…………………………………………………………. 612
Theory of Operation……………………………………………………………… 614
Air Conditioning System Cycle of Operation……………………………………… 614
Heater Core Operation………………………………………………………… 615
Diagnostic Information…………………………………………………………… 616
Diagnose Air Conditioning System Malfunctions…………………………………… 616
Diagnose Heater System Malfunctions……………………………………………. 618
Heating/Air Conditioning Component Location…………………………………….. 619
Tests………………………………………………………………………….. 622
Air Conditioning Operational Checks……………………………………………. 622
R134a Air Conditioning System Test…………………………………………….. 624
Operating Pressure Diagnostic Chart……………………………………………. 626
A/C Freeze Control Switch Test………………………………………………… 628
A/C Compressor Clutch Test……………………………………………………. 629
A/C High/Low Pressure Switch Test……………………………………………… 629
A/C Expansion Valve Test……………………………………………………… 632
Expansion Valve Bench Test……………………………………………………. 634
Refrigerant Leak Test………………………………………………………… 635
WORKSHOP MANUAL……………………………………………………………………………. 642
Contents………………………………………………………………………………. 644
General Information…………………………………………………………………. 648
Safety…………………………………………………………………………. 650
Recognize Safety Information………………………………………………….. 650
Follow Safety Instructions……………………………………………………. 650
Operate Only If Qualified…………………………………………………….. 650
Wear Protective Equipment…………………………………………………….. 651
Avoid Unauthorized Machine Modifications……………………………………….. 651
Inspect Machine……………………………………………………………… 651
Stay Clear Of Moving Parts……………………………………………………. 652
Avoid High-Pressure Fluids……………………………………………………. 652
Beware Of Exhaust Fumes………………………………………………………. 652
Prevent Fires……………………………………………………………….. 653
Prevent Battery Explosions……………………………………………………. 653
Handle Chemical Products Safely……………………………………………….. 654
Dispose of Waste Properly…………………………………………………….. 654
Prepare for Emergencies………………………………………………………. 654
Use Steps And Handholds Correctly……………………………………………… 655
Start Only From Operator’s Seat……………………………………………….. 655
Use And Maintain Seat Belt……………………………………………………. 655
Prevent Unintended Machine Movement……………………………………………. 656
Avoid Work Site Hazards………………………………………………………. 656
Keep Riders Off Machine………………………………………………………. 657
Avoid Backover Accidents……………………………………………………… 657
Avoid Machine Tip Over……………………………………………………….. 658
Operating on Slopes………………………………………………………….. 658
Operating Or Traveling On Public Roads…………………………………………. 659
Inspect and Maintain ROPS…………………………………………………….. 659
Add And Operate Attachments Safely…………………………………………….. 659
Park And Prepare For Service Safely……………………………………………. 660
Service Tires Safely…………………………………………………………. 661
Service Cooling System Safely…………………………………………………. 661
Remove Paint Before Welding or Heating…………………………………………. 662
Make Welding Repairs Safely…………………………………………………… 662
Drive Metal Pins Safely………………………………………………………. 662
Wheels…………………………………………………………………………….. 664
Removal and Installation…………………………………………………………. 666
Remove and Install Wheel……………………………………………………… 666
Remove and Install Tire………………………………………………………. 668
Axles and Suspension Systems…………………………………………………………. 670
Removal and Installation…………………………………………………………. 672
Axles………………………………………………………………………. 672
Differential or Bevel Drive………………………………………………………. 676
Axle Differential……………………………………………………………. 676
Input Drive Shafts and U-Joints…………………………………………………… 700
Drive Shafts………………………………………………………………… 700
Axle Mounting Parts……………………………………………………………… 708
Axle Links, Stabilizers, and Struts……………………………………………. 708
Front Axle Pivot…………………………………………………………….. 720
Middle and Rear Axle Walking Beams…………………………………………….. 721
Axle Shaft, Bearings, and Reduction Gears………………………………………….. 726
Axle Outboard Planetaries…………………………………………………….. 726
Axle Shafts…………………………………………………………………. 729
Axle Hubs…………………………………………………………………… 729
Transmission……………………………………………………………………….. 738
Removal and Installation…………………………………………………………. 740
Remove and Install Transmission……………………………………………….. 740
Input Drive Shafts and U-Joints…………………………………………………… 742
Remove and Install Transmission-to-Transfer Case Drive Shaft……………………… 742
Gear, Shafts, and Power Shift Clutches…………………………………………….. 744
Disassemble Transmission……………………………………………………… 744
Disassemble and Assemble Torque Converter………………………………………. 751
Disassemble and Assemble Torque Converter Housing……………………………….. 758
Disassemble and Assemble Retarder and P3 Planetary………………………………. 759
Disassemble and Assemble Main Shaft……………………………………………. 769
Disassemble and Assemble P2 Planetary………………………………………….. 770
P1 Planetary………………………………………………………………… 773
Disassemble and Assemble………………………………………………….. 773
Disassemble and Assemble Front Support and Charging Oil Pump……………………… 777
C1/C2 Clutch………………………………………………………………… 783
Disassemble and Assemble………………………………………………….. 783
C3/C4 Clutch and Main Housing…………………………………………………. 793
Disassemble and Assemble………………………………………………….. 793
Disassemble and Assemble Control Valve…………………………………………. 798
Assemble Transmission………………………………………………………… 809
Hydraulic System………………………………………………………………… 820
Remove and Install Transmission Oil Cooler……………………………………… 820
Engine…………………………………………………………………………….. 822
Removal and Installation…………………………………………………………. 824
Engine……………………………………………………………………… 824
Crankshaft, Main Bearings, and Flywheel……………………………………………. 834
Crankshaft and Main Bearing…………………………………………………… 834
Failure Analysis…………………………………………………………. 834
Crankshaft Oil Seals…………………………………………………………. 834
Flywheel……………………………………………………………………. 839
Remove and Install Timing Case Cover…………………………………………… 841
Remove and Install Timing Case………………………………………………… 843
Crankshaft………………………………………………………………….. 846
Bleed Engine Oil Circuit after Major Overhaul…………………………………… 861
Camshaft and Timing Gear Train……………………………………………………. 862
Camshaft……………………………………………………………………. 862
Cylinder Block, Liners, Pistons and Rods…………………………………………… 870
Liner, Piston, and Rod……………………………………………………….. 870
Preliminary Checks……………………………………………………….. 870
Pistons and Connecting Rods…………………………………………………… 871
Cylinder Liners……………………………………………………………… 883
Engine Rotation……………………………………………………………… 892
Check for Excessive Tightness……………………………………………… 892
Lubrication System………………………………………………………………. 894
Remove and Install Oil Filter Housing………………………………………….. 894
Remove, Inspect, and Install Engine Oil Cooler………………………………….. 896
Remove and Install Oil Pan……………………………………………………. 896
Piston Cooling Orifices………………………………………………………. 898
Remove, Inspect and Install……………………………………………….. 898
Engine Oil Pump……………………………………………………………… 899
Remove and Install……………………………………………………….. 899
Oil Pressure Relief Valve…………………………………………………….. 900
Remove and Install……………………………………………………….. 900
Cylinder Head and Valves…………………………………………………………. 902
Cylinder Head and Valves Failure Analysis………………………………………. 902
Remove and Install Valve Cover………………………………………………… 903
Rocker Arms and Shaft………………………………………………………… 903
Clean and Inspect Push Rods…………………………………………………… 906
Cylinder Head……………………………………………………………….. 907
Remove and Install Engine Exhaust Valve Brake…………………………………… 911
Intake and Exhaust Valves…………………………………………………….. 911
Valves……………………………………………………………………… 914
Cylinder Head……………………………………………………………….. 916
Exhaust System………………………………………………………………….. 924
Exhaust Manifold…………………………………………………………….. 924
Remove and Install……………………………………………………….. 924
Fuel Injection System……………………………………………………………. 926
Remove and Install Hand Primer Pump……………………………………………. 926
Remove and Install Fuel Supply Pump……………………………………………. 926
Remove and Install Electronic Unit Injector (EUI)……………………………….. 927
Remove and Install Fuel Delivery Nozzle………………………………………… 928
Air Intake Manifold System……………………………………………………….. 930
Remove and Install Air Intake Manifold…………………………………………. 930
Turbocharger……………………………………………………………………. 932
Turbocharger………………………………………………………………… 932
Remove and Install……………………………………………………….. 932
Turbocharger Seven-Step Inspection…………………………………………….. 935
Cooling System………………………………………………………………….. 942
Water Pump………………………………………………………………….. 942
Thermostats, Housing and Water Piping……………………………………………… 950
Remove and Install Thermostats and Housing……………………………………… 950
Engine Auxiliary System……………………………………………………………… 952
Cooling System………………………………………………………………….. 954
Fan Belt……………………………………………………………………. 954
Remove and Install Radiator…………………………………………………… 954
Intake System…………………………………………………………………… 956
Air Intake System Leakage Check……………………………………………….. 956
Remove and Install Charge Air Aftercooler………………………………………. 956
External Exhaust Systems…………………………………………………………. 960
Remove and Install Muffler and Exhaust Pipes……………………………………. 960
Remove and Install Exhaust Brake Valve Flapper………………………………….. 964
Body Heater Pipes……………………………………………………………. 965
Engine Mounting…………………………………………………………………. 968
Remove and Install Engine and Transmission Rubber Mounts…………………………. 968
External Fuel Supply Systems……………………………………………………… 970
Remove and Install Hand Primer Pump……………………………………………. 970
Remove and Install Primary Fuel Filter (Water Separator)…………………………. 971
Remove and Install Fuel Tank………………………………………………….. 971
Connector Drive (Flexplate)………………………………………………………….. 976
Elements……………………………………………………………………….. 978
Remove and Install Connector Drive (Flexplate)………………………………….. 978
Transfer Drive……………………………………………………………………… 980
Removal and Installation…………………………………………………………. 982
Remove and Install Transfer Case………………………………………………. 982
Gear Shafts and Bearings…………………………………………………………. 992
Transfer Case……………………………………………………………….. 992
Steering System……………………………………………………………………..1018
Secondary Steering……………………………………………………………….1020
Secondary Steering Pump……………………………………………………….1020
Hydraulic System…………………………………………………………………1026
Steering Valve……………………………………………………………….1026
Steering Cylinder…………………………………………………………….1028
Service Brakes………………………………………………………………………1034
Active Elements………………………………………………………………….1036
Service Brakes—350D…………………………………………………………..1036
Service Brakes—400D…………………………………………………………..1043
Hydraulic System…………………………………………………………………1054
Bleed Service Brake Hydraulic System……………………………………………1054
Brake Accumulators……………………………………………………………1055
Brake Valve………………………………………………………………….1056
Wet Disk Brake Thermal Valve…………………………………………………..1059
Wet Disk Brake Cooling Oil Pumps……………………………………………….1061
Wet Disk Brake Cooling Oil Reservoir……………………………………………1062
Wet Disk Brake Cooling Oil Cooler………………………………………………1063
Park Brake………………………………………………………………………….1066
Active Elements………………………………………………………………….1068
Park Brake…………………………………………………………………..1068
Frame and Supporting Structure………………………………………………………..1074
Frame Installation……………………………………………………………….1076
Welding on Machine……………………………………………………………1076
Separate Front and Rear Frames…………………………………………………1076
Articulation Frame……………………………………………………………1081
Oscillation Joint…………………………………………………………….1088
Operator’s Station…………………………………………………………………..1092
Operator Enclosure……………………………………………………………….1094
Remove and Install Cab Mounts………………………………………………….1094
Remove and Install Cab Tilt Pump and Cylinder……………………………………1095
Disassemble and Assemble Cab Tilt Cylinder………………………………………1096
Seat and Seat Belt……………………………………………………………….1098
Operator’s Seat………………………………………………………………1098
Heating and Air Conditioning………………………………………………………1100
Refrigerant Cautions and Proper Handling………………………………………..1100
R134a Refrigerant Oil Information………………………………………………1102
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure…….1104
Recover R134a Refrigerant……………………………………………………..1105
Flush and Purge Air Conditioner System………………………………………….1106
Evacuate R134a System…………………………………………………………1109
Charge R134a System…………………………………………………………..1110
Remove and Install Air Conditioner Compressor……………………………………1110
Disassemble and Assemble Compressor Clutch………………………………………1111
Inspect Compressor Manifold……………………………………………………1114
Remove and Install Condenser…………………………………………………..1114
Remove and Install High/Low Pressure Switch……………………………………..1115
Remove and Install Receiver-Dryer………………………………………………1116
Remove and Install Expansion Valve……………………………………………..1117
Remove and Install Heater Core and Evaporator Core……………………………….1119
Remove and Install Freeze Control Switch………………………………………..1121
Sheet Metal and Styling………………………………………………………………1124
Hood or Engine Enclosure………………………………………………………….1126
Hood………………………………………………………………………..1126
Main Hydraulic System………………………………………………………………..1132
Hydraulic System…………………………………………………………………1134
Main Hydraulic Pump…………………………………………………………..1134
Hydraulic Pump Drive Shaft…………………………………………………….1139
Hydraulic Reservoir…………………………………………………………..1143
Suction Strainer……………………………………………………………..1145
Hydraulic System Manifold Assembly……………………………………………..1145
Hydraulic Fan Motor…………………………………………………………..1154
Fan Drive Controller………………………………………………………….1158
Pneumatic Systems……………………………………………………………………1160
Pumps and Drives…………………………………………………………………1162
Remove and Install Air Compressor………………………………………………1162
Control Valves…………………………………………………………………..1182
Remove and Install Pneumatic Manifold…………………………………………..1182
Remove and Install Park Brake Control Valve……………………………………..1186
Remove and Install Body Tip Control Valve……………………………………….1187
Remove and Install Seat Control Valve…………………………………………..1188
Differential Lock Actuator…………………………………………………….1189
Remove and Install Park Brake Actuator………………………………………….1199
Reservoir, Filter, and Trap……………………………………………………….1202
Air Unloader Valve with Integral Air Dryer………………………………………1202
Remove and Install Regeneration Air Reservoir……………………………………1204
Remove and Install Air Reservoir……………………………………………….1205
Cylinders……………………………………………………………………….1206
Remove and Install Exhaust Brake Air Cylinder……………………………………1206
Haulage Device………………………………………………………………………1208
Frames………………………………………………………………………….1210
Body………………………………………………………………………..1210
Hydraulic System…………………………………………………………………1214
Body Lift Cylinder……………………………………………………………1214
Dealer Fabricated Tools………………………………………………………………1218
Dealer Fabricated Tools…………………………………………………………..1220
DF1002 Rolling Drag Torque Bar…………………………………………………1220
DFT1132 Removal and Installation Tool…………………………………………..1221
DFT1178 Lifting Tool………………………………………………………….1222
DFT1181 Bushing Driver………………………………………………………..1222
DFT1185 Supports……………………………………………………………..1223
DFT1186 Bushing Driver………………………………………………………..1224
DFT1187 Bearing Driver………………………………………………………..1224
DFT1188 Bearing Driver………………………………………………………..1225
DFT1189 Spanner Wrench………………………………………………………..1226
DFT1194 Bearing Puller………………………………………………………..1227
DFT1195 Planetary Alignment Stud……………………………………………….1227
DFT1196 Bushing Driver………………………………………………………..1229
DFT1199 Bushing Pusher………………………………………………………..1230
DFT1200 Bushing Driver………………………………………………………..1231
DFT1222 Wet Disk Brake Piston Seal Installer…………………………………….1232
DFT1223 Transfer Case Mounting Bracket………………………………………….1233
DFT1224 Engine Mounting Adapter………………………………………………..1234
SERVICE MANUAL REVISION REQUEST FORM………………………………………………………….1246
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