TROUBLESHOOTING
FILTER ELEMENT REPLACEMENT.
Cleaning With Water.
Air Cleaner Body.
Duct Work.
WATER COOLING SYSTEM
WARNING SAFETY SUMMARY
TROUBLESHOOTING
TROUBLESHOOTING - Continued
EFFECTS OF COOLING SYSTEM NEGLECT
RUST PREVENTION
PRESSURE FLUSHING
Engine Water Jacket
TEST EQUIPMENT
TRANSMISSION/TORQUE CONVERTER
LIST OF FIGURES AND CHARTS
THEORY OF OPERATION
Transmission - Cross Section
Clutch and Gear Arrangement
Power Flow in Forward 1st, 2nd, and 3rd
Power Flow in Forward 4th, 5th and 6th
Power Flow in Reverse
MAINTENANCE
General Assembly Instructions (sheet 1 of 3)
General Assembly Instructions (sheet 2 of 3)
General Assembly Instructions (sheet 3 of 3)
SPECIFICATIONS AND SERVICE DATA -- POWER SI-4IFT TRANSMISSION AND TORQUE CONVERTER
Torque Specification for Lubricated or Plated Screw Threads
Procedure
External Plumbing and Pressure Check Points (Sheet 1 of 2)
External Plumbing and Pressure Check Points (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION.
TORQUE CONVERTER/TRANSMISSION - Continued
Charging Pump and Valve Assembly (Sheet 1 of 2)
Charging Pump and Valve Assembly (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Converter and Pump Drive (Sheet 1 of 2)
Converter and Pump Drive (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Converter and Transmission Case (Sheet 1 of 2)
Converter and Transmission Case (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Clutch and Gear Assemblies (Sheet 1 of 2)
Clutch and Gear Assemblies (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Oil Seals, Gaskets, Etc.
Housings, Covers. Etc.
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Output Shaft Rolling Torque.
DRIVE PLATE INSTALLATION PROCEDURE
Major Transmission Component.
Clutch Assemblies (Sheet 1 of 2)
Clutch Assemblies (Sheet 2 of 2)
Major Transmission Component. - Continued
Major Transmission Component. - Continued
Major Transmission Component. - Continued
Major Transmission Component. - Continued
Major Transmission Component. - Continued
REVERSE, 3rd AND 4th CLUTCH
REVERSE, 3rd AND 4th CLUTCH - Continued
REVERSE, 3rd AND 4th CLUTCH - Continued
REVERSE, 3rd AND 4th CLUTCH - Continued
3rd AND 4th CLUTCH.
3rd AND 4th CLUTCH. - Continued
3rd AND 4th CLUTCH. - Continued
3rd AND 4th CLUTCH. - Continued
3rd AND 4th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH.
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
IDLER SHAFT.
IDLER SHAFT. - Continued
IMPELLER COVER.
IMPELLER COVER. - Continued
SERVICING THE MACHINE AFTER TRANSMISSION OVERHAUL
TORQUE CONVERTER WITH LOCK- UP
Torque Converter Assembly.
Torque Converter Assembly (Sheet 1 of 2)
Torque Converter Assembly (Sheet 2 of 2)
Drive Plate Group
Torque Converter Hydraulic Flow Path
General Assembly Information
Torque Converter Assembly - Continued
Torque Converter Assembly - Continued
Torque Converter Assembly - Continued
CLEANING AND INSPECTION.
Lock-up Impeller Cover Assembly
Torque Converter Assembly.
Torque Converter Assembly. - Continued
Torque Converter Assembly. - Continued
Torque Converter Assembly. - Continued
Torque Converter Assembly. - Continued
KESSLER AXLE
KESSLER AXLE - Continued
GENERAL INSTRUCTIONS
LOCTITE USE
Special Tools (Sheet 1 of 3)
Special Tools (Sheet 2 of 3)
Special Tools (Sheet 3 of 3)
LOCTITE USAGE CHART
GENERAL LUBRICATION INSTRUCTIONS
ADJUSTMENT VALUES
ROLLING RESISTANCE OF DRIVE PINION BEARING
ROLLING RESISTANCE OF DIFFERENTIAL BEARINGS
Wheel Safety Nut Chart (Sheet 2 of 2)
Bolt Tightening Torques Chart
Wheel Nut Tightening Torques Chart
Wheel End Assembly
Wheel End Assembly (Planetary Gear Axle)
WHEEL END (PLANETARY GEAR AXLE).
WHEEL END (PLANETARY GEAR AXLE). - Continued
WHEEL END (PLANETARY GEAR AXLE). - Continued
AXIAL CLEARANCE ADJUSTMENT.
Assembly.
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING - Continued
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING - Continued
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING - Continued
INSTALLATION OF THE STEERING KNUCKLE TO THE AXLE HOUSING
Drive Pinion Bearing
DIFFERENTIAL AND INSTALLATION
Removal and Disassembly.
SINGLE STAGE CARRIER INSTALLATION
DIFFERENTIAL LOCK.
Assembly
STEERING PUMP
TROUBLESHOOTING
DISASSEMBLY
Steering Pump
MITER GEAR
DESCRIPTION
Miter Gear
ASSEMBLY
RESERVOIRS
DESCRIPTION
LOW PRESSURE INDICATING SWITCH
THEORY OF OPERATION
THROTTLE CONTROL CYLINDER
THEORY OF OPERATION
Throttle Control Cylinder - Cutaway
CLEANING AND INSPECTION.
PRESSURE PROTECTION VALVE
THEORY OF OPERATION
Pressure Protection Valve-Cutaway
R-12 RELAY VALVE
THEORY OF OPERATION
R-12 Relay Valve-Cutaway
ASSEMBLY
STOP LIGHT SWITCH
THEORY OF OPERATION
HYDRAULIC PUMP
THEORY OF OPERATION
Hydraulic Pump - Exploded View
Hydraulic Pump - Cutaway
Seal Removal Tool.
GENERAL PRECAUTIONS.
GENERAL PRECAUTIONS. - Continued
GENERAL PRECAUTIONS. - Continued
ASSEMBLY
ASSEMBLY - Continued
ASSEMBLY - Continued
ASSEMBLY - Continued
ASSEMBLY - Continued
ASSEMBLY - Continued
WEAR LIMITS
LUBRICATION AND OIL RECOMMENDATIONS
INTEGRATED OUTRIGGER VALVE
DESCRIPTION
CLEANING AND INSPECTION
Inegrated Outrigger Valve (Sheet 1 of 4)
Inegrated Outrigger Valve (Sheet 2 of 4)
Integrated Outrigger Valve (Sheet 3 of 4)
Integrated Outrigger Valve (Sheet 4 of 4)
PRESSURE ADJUSTMENT
OUTRIGGER SOLENOID VALVE STACK
THEORY OF OPERATION
Solenoid Valve
HOLDING VALVE
DESCRIPTION
Holding Valve
SWING GEAR BOX AND BRAKE
DESCRIPTION
Swing Gearbox
SWING GEARBOX.
SWING GEARBOX.
CLEANING
Planet Carrier Assembly
LIST OF FIGURES
DANGER NOTE SUMMARY
Theory Of Operation
Model HO-15 Hoist - Cutaway
Troubleshooting
Troubleshooting - Continued
Troubleshooting - Continued
Troubleshooting - Continued
Hydraulic Motor.
Model HO - 15 Hoist Exploded View (Sheet 1 of 2)
Model HO - 15 Hoist Exploded View (Sheet 2 of 2)
CLEANING AND INSPECTION.
Gear Reduction Unit.
Brake Assembly.
Brake Assembly. - Continued
VANE TYPE MOTOR (HO-15C HOIST)
MAINTENANCE
TROUBLESHOOTING
Vane Motor - Exploded View
Vane Motor - Special Tools
DISASSEMBLY
ASSEMBLY
ASSEMBLY - Continued
SWIVEL ASSEMBLY
THEORY OF OPERATION
Typical Swivel Assembly
ASSEMBLY
ELECTRICAL SWIVEL
THEORY OF OPERATION
After Disassembly.
Typical Electrical Swivel
DIESEL HEATER
LIST OF FIGURES
WARNING SAFETY SUMMARY
WARNING SAFETY SUMMARY (continued)
THEORY OF OPERATION
Sectional View of Carburator and Burner Head
MAINTENANCE
Active Electrical Circuits (Sheet 1 of 2)
Active Electrical Circuits (Sheet 2 of 2)
TROUBLESHOOTING
TROUBLESHOOTING - Continued
TROUBLESHOOTING - Continued
TROUBLESHOOTING - Continued
TROUBLESHOOTING - Continued
PREVENTIVE MAINTENANCE
Case and Heat Exhanger
Operating Check and Adjustment
APPENDIX B. RED DOT HEAVY DUTY AIR CONDITIONING AND HEATING SERVICE TRAINING MANUAL
TABLE OF CONTENTS
Inspection and Maintenance without gauges
Visual Inspection System Off
Components Under the Hood
Check Hoses and Fittings
Electrical System Inspection
Inspection & Maintenance
Inspect System Component Cycling and Cab Temperature Levels
Check Clutch Cycling Under Load
Preventive Maintenance Worksheet
PREVENTIVE MAINTENANCE SCHEDULE FOR AIR CONDITIONING SYSTEMS
Troubleshooting & Service Procedures
The Key-Understanding System Function
A Troubleshooting Example
A Troubleshooting Example - Continued
A Troubleshooting Example - Continued
Manifold Gauge Set Installation
Purging Air From Gauge Set Hoses
Purging Air From Gauge Set Hoses - Continued
Stabilizing The AC System
Troubleshooting by Manifold Gauge Set Readings
Extremely Low Refrigerant Charge in the System
Air and/or Moisture in the System
Excessive Air and/or Moisture in the System
Excessive Air and/or Moisture in the System - Continued
Expansion Valve (TXV) Stuck Open
System High Pressure Side Restriction
Compressor Malfunction
Condenser Malfunction or System Overcharge
Thermostatic Switch Malfunction
Review of Frequent Problem Areas
Belts and Compressor Clutch
Other Problems--Leaks, Moisture, and Adding Refrigerant
Conclusion
Refrigerants
Changes in Service Procedures
Draining the Oil from the Previous Recovery Cycle
Performing the Recovery Cycle
Purging Non-Condensable Gases (Air)
Flushing the AC System
Evacuating and Charging the AC System
Charging the AC system
Charging with Refrigerant Gas (on the Low Side)
Charging the System with Liquid Refrigerant
Reclaiming Refrigerant
APPENDIX C. MASTER REPAIR MANUAL AIR COMPRESSORS
Foreword
Table of Contents
NOTES
Section i - Introduction
About the Manual
Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Definition of Terms
Section E - Component Identification
Component Identification
Section F - Familiarization
General Information
Section G - Installation Guidelines
Recommended Installation Guidelines
Oil Change Interval
Cooling System
Water Temperature
Duty Cycle
Application Recommendations
Drive Options
Air Governor
Discharge Air System
Porting Option Flexibility
Air Compressors Installation Diagram with Turbocharger Air Dryer and E-Type
Performance Curves and Specifications
NOTES
Section T - Troubleshooting
Procedures and Techniques
Air Compressor Air Pressure Rises Slowly
Air Compressor Noise Excessive
Air Compressor Pumping Excess Lubricating Oil into Air System
Air Compressor Pumping Excess Lubricating Oil into Air System (Continued)
Air Compressor Will Not Stop Pumping
Air Compressor Cycles Frequently
Air Compressor Will Not Maintain Adequate Air Pressure
Air Compressor Will Not Pump Air
Section 12 - Compressed Air System
Service Tools
Service Tools - Continued
Compressed Air System Specifications
Air Compressor General Information
Gear Driven Compressor
Air Compressor Carbon Buildup
Air Compressor Carbon Buildup - Continued
Air Compressor Carbon Buildup - Continued
Recommended Installation GuidelinesAir Compressor Pin Bore Wear (SS, E-Type, and ST Models) (012-010)
Recommended Installation GuidelinesAir Compressor Pin Bore Wear (SS, E-Type, and ST Models) (012-010) - Continued
Air Compressor Unloader Valve
Holset QE Models
Inspect for Reuse (012-013-007)
Holset QE Models
Air Governor (Air Compressor Will Not Pump) (012-017)
Air Governor (Air Compressor Will Not Pump) (012-017) - Continued
Air Leaks, Compressed Air System
Air Compressor
Air Compressor Cylinder Head (Holset QE Models) (012-104)
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105)
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Compressed Air System Specifications and Torque Values
Compressor Spring Force Specifications
QE296 Specifications
QE296 Specifications - Continued
Support Dimensions
Support Dimensions - Continued
Assembly Torque Specifications
Capscrew Markings and Torque Values - Metric
Capscrew Markings and Torque Values - U.S. Customary
Capscrew Markings and Torque Values
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
Newton-Meter to Foot-Pound Conversion Chart
Pipe Plug Torque Values
Tap-Drill Chart - U.S. Customary & Metric
Weight and Measures - Conversion Factors
NOTES
Section C - Component Manufacturers
Component Manufacturers' Addresses
Component Manufacturers' Addresses - Continued
Component Manufacturers' Addresses - Continued
Section L - Service Literature
Publication Titles
Service Literature Ordering Location
NOTES
Table of Contents
NOTES
NOTES - Continued
APPENDIX D. DELCO REMY 21-SI DELCOTRON GENERATOR SERVICE MANUAL 1G-286
PRODUCT INFORMATION AND SERVICE MANUAL DELCOTRON GENERATOR (21-SI SERIES)
Figure 2. Basic One-Wire System
Figure 4. One-Wire Generator Schematic
Figure 5. Troubleshooting a One-Wire System
RATED OUTPUT CHECK
Figure 6. Rated Output Check
Figure 7. Generator Bench Test
Figure 8. Using Test Hole
Figure 12. Adjusting Belt Tension
Figure 13. Threaded "I" and "R" Terminals
21-SI GENERATOR SPECIFICATIONS
APPENDIX E. DELCO REMY CRANKING MOTORS SERVICE BULLETIN 1M-157 AND DELCO REMY STARTERS SERVICE TEST SPECIFICATIONS 1M-188
Figure 1 Typical 37-MT motor.
Figure 2 Cross-sectional view, typical 37-MT motor
No-Load Test
SERVICE TEST SPECIFICATIONS
SERVICE SPECIFICATIONS STARTER MOTORS
APPENDIX G. DS350 LMI for ATEC (AT422T) TROUBLESHOOTING SECTION
TABLE OF CONTENTS
TABLE OF CONTENTS - continued
GENERAL INFORMATION
BASIC SYSTEM INFORMATION
GENERAL FLOWCHART AND DRAWINGS
LEVER LOCKOUT ACTIVATED
BROKEN LENGTH CABLE
NO DISPLAY
NO DISPLAY - continued
ANTI-TWO BLOCK PROBLEM (SINGLE SWITCH)
ANTI-TWO BLOCK PROBLEM (SINGLE SWITCH) - Continued
ANTI-TWO BLOCK PROBLEM (SINGLE SWITCH) - Continued
ANTI-TWO BLOCK PROBLEM (DOUBLE SWITCH)
ANTI-TWO BLOCK PROBLEM (DOUBLE SWITCH) - Continued
ANTI-TWO BLOCK PROBLEM (DOUBLE SWITCH) - Continued
LENGTH READING PROBLEM
LENGTH READING PROBLEM - continued
LENGTH READING PROBLEM - continued
LOAD READING PROBLEM
LOAD READING PROBLEM - continued
LOAD READING PROBLEM - continued
BAD DATA TRANSFER BETWEEN DISPLAY CONSOLE & CENTRAL UNIT, INTERFERENCE PROBLEM
BAD DATA TRANSFER BETWEEN DISPLAY CONSOLE & CENTRAL UNIT, INTERFERENCE PROBLEM - Continued
ERROR CODE DISPLAY
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
DRAWING 1. ELECTRICAL WIRING CENTRAL UNIT TO CRANE/PRESSURE TRANSDUCERS
DRAWING 2. ELECTRICAL WIRING CENTRAL UNIT TO DISPLAY CONSOLE/CABLE REEL
DRAWING 3A. CENTRAL UNIT DS350/2766
DRAWING 3B. CENTRAL UNIT DS350/2767
DRAWING 4. CABLE REEL
DRAWING 5. 050-350-061-328 DISPLAY CONSOLE
DRAWING 6. IN CENTRAL UNIT, HEATER CONTROL BOARD
DRAWING 7. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 8A. MAIN BOARD W/VOLTMETER ON X1:1 & X1:3
DRAWING 8B. MAIN BOARD W/VOLTMETER ON X1:1 & X1:3
DRAWING 9. IN DISPLAY CONSOLE, HEATER CONTROL BOARD
DRAWING 10. BOOM NOSE JUNCTION BOX
DRAWING 11. SLIP RING W/OHMMETER ON X2:RED & X1:BROWN
DRAWING 12. CABLE REEL W/OHMMETER ON TERMINALS 7 & 8 ON TERMINAL BOARD
DRAWING 13. BOOM BASE JUNCTION BOX W/OHMMETER ON 5 & 6
DRAWING 14. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 15. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 16. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 17. CABLE REEL TERMINAL BOARD W/VOLTMETER
DRAWING 18. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 19. PRESSURE TRANSDUCER CABLE
DRAWING 20. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 21. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 22. SECONDARY ANTI-TWO BLOCK SWITCH
PROCEDURE 1. STRAIN RELIEF INSTALLATION
PROCEDURE 2A. EPROM LOCATION AND INSTALLATION
PROCEDURE 2B. EPROM LOCATION AND INSTALLATION
PROCEDURE 3A. MAIN BOARD 024-350-300-094 REPLACEMENT
PROCEDURE 3B. MAIN BOARD 024-350-300-222 REPLACEMENT
PROCEDURE 4A. PRESSURE TRANSDUCER ZERO ADJUSTMENT
PROCEDURE 4A. PRESSURE TRANSDUCER ZERO ADJUSTMENT - Continued
PROCEDURE 4B. PRESSURE TRANSDUCER ZERO ADJUSTMENT
PROCEDURE 4B. PRESSURE TRANSDUCER ZERO ADJUSTMENT - Continued
PROCEDURE 5 LENGTH POTENTIOMTER AND ANGLE SENSOR ADJUSTMENT
THEORY 1A. MAIN BOARD MEASURING POINTS
THEORY 1B. MAIN BOARD MEASURING POINTS
THEORY 2. OPERATION OF LENGTH POTENTIOMETER
PAT DS350 MAIN BOOM LENGTH SIGNAL VOLTAGES
THEORY 3. OPERATION OF ANGLE SENSOR
PAT DS350 MAIN BOOM ANGLE SIGNAL VOLTAGES
THEORY 4. OPERATION OF PISTON SIDE PRESSURE TRANSDUCER
PAT DS350 PRESSURE TRANSDUCER SIGNAL VOLTAGES
THEORY 5. OPERATION OF ROD SIDE PRESSURE TRANSDUCER
PAT DS350 PRESSURE TRANSDUCER SIGNAL VOLTAGES
APPENDIX G REVISIONS
APPENDIX H. ZF SEMI-INTEGRAL POWER STEERING GEAR, TYPE 7421 INSTRUCTIONS FOR OPERATION, MAINTENANCE, AND INSPECTION
ZF-Semi-Integral Power Steering Gear, Type 7421 (Single Circuit Steering Gear)
Preface
TABLE OF CONTENTS
IMPORTANT INFORMATION FOR DRIVER
CONSTRUCTION AND FUNCTION ZF SINGLE CIRCUIT POWER STEERING GEAR, TYPE 7421
CONSTRUCTION AND FUNCTION ZF SINGLE CIRCUIT POWER STEERING GEAR, TYPE 7421 - Continued
Figure. 1. Diagrammatic view of a ZF Single Circuit Power Steering Gear with an engine-driven or a drive-dependant pump (emergency steering pump)
FUNCTION AND ADJUSTMENT OF HYDRAULIC STEERING LIMIT (STEERING LOCK)
FUNCTION AND ADJUSTMENT OF HYDRAULIC STEERING LIMIT (STEERING LOCK) - Continued
Figure 4.
Steering Systems with Mechanical Steering-Lock Limitation
Steering Systems with Mechanical Steering-Lock Limitation - Continued
MAINTENANCE AND TYPES OF OILS
Filter Change
Checking the Oil Level
ADJUSTMENTS ON STEERING GEAR INSTALLED IN VEHICLE
INSTRUCTIONS FOR REPAIRING EXTERNAL LEAKS
Replacing Shaft Sealing Ring on Pitman Shaft
TOOLS FOR DISASSEMBLY AND ASSEMBLY
TOOLS FOR DISASSEMBLY AND ASSEMBLY - Continued
INSTRUCTIONS CONCERNING INSPECTION
Checking Straight-ahead Position of Steering and Vehicle
Checking for External Leaks
Testing and Adjusting Hydraulic Steering Limit
Steering System Without Power Cylinder
REMOVAL OF STEERING SYSTEM FROM VEHICLE
INSTALLATION OF STEERING SYSTEM INTO VEHICLE
Figure 7. Steering Spindle and Jacket Tube Diameter Chart
Determination of Jacket Tube Length
FAULTS AND REMEDIES
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
ILLUSTRATIONS AND EXPLODED DIAGRAMS
Figure 9. Single-circuit Steering Gear
Figure 10. Longitudinal Section through the Mechanical Steering-lock Limiter Stub Type
Figure 12. ZF Semi-integral Power Steering Gear, Type 7421
Figure 13. ZF Semi-integral Power Steering Gear, Type 7421
Figure 14. ZF Right-angle Gear, Type 7860 (for Flange-mounting to the Steering-lock Limiter Casing of Type 7421 ZF Power Steering Gear)
APPENDIX I. CUMMINS FIELD SERVICE PROCEDURES FOR WABCO AIR COMPRESSOR
INTRODUCTION
TROUBLESHOOTING
Head Assembly Replacement
Figure I-2 Cylinder Head Bolt Tightening Sequence
Installation
Rear Seal and Adapter Replacement
Figure I-4. Compressor Rear Bearing O-ring Seal Installation
Figure I-5. Piston Assembly Replacement
Figure I-6. Correct Piston Ring Orientation
Connecting Rod Assembly Replacement.
Crankshaft Bearing Replacement
Figure I-7. Crankshaft Bearing Replacement
APPENDIX J. WINTERIZING THE ATEC CRANE AT422
SAFETY SUMMARY
INTRODUCTION
Figure J-1. Coolant Heater Operation
THEORY OF OPERATION
Coolant Heater Shutdown
INSTALLATION
Figure J-2. Fuel Tank Modification Dimensions
Figure J-3. Fuel Pickup Tube Installation
Figure J-4. Hydraulic Reservoir Connection Legend
Hydraulic Reservoir Modification
Figure J-5. Hydraulic Reservoir Modification Dimensions Doubler Plate P/N 6705170879
Figure J-6. Hydraulic Reservoir Modification Dimensions Doubler Plate P/N 6705170884
Hydraulic Reservoir Modification Pressure Test
Figure J-7. Hydraulic Reservoir Test Fitting
Figure J-8. Hydraulic Reservoir Heater Element Installation
Figure J-9. Hydraulic Reservoir Bracket Modification (If Necessary)
Figure J-10. Seven Day Timer Installation
Fuel Metering Pump Installation
Figure J-11. Fuel Metering Pump Installation
Figure J-12. Coolant Heater Installation Dimensions
Coolant Heater Installation
Figure J-13. Coolant Heater Installation
Fuel Line Installation
Figure J-14. Coolant Heater Wiring Diagram
Electrical Connections Battery and Fuel Metering Pump
Figure J-15. Battery Box Wiring Installation
Electrical Connections Seven Day Timer
Table J-1. Seven Day Timer Connector Terminal Designations
Figure J-16. Engine Coolant Flow Diagram
Engine Coolant Connections Supply from Engine
Figure J-17. Engine Coolant Supply from Engine Installation
Engine Coolant Connections Return to Engine
Figure J-18. Engine Coolant Return to Engine Installation
Engine Coolant Connections Hydraulic Reservoir
Initial Startup/Testing Procedures
TROUBLESHOOTING
Table J-2. Fault Codes
Table J-2. Fault Codes (Continued)
Table J-2. Fault Codes (Continued)
Table J-2. Fault Codes (Continued)
Fuel Quantity Test
Engine Coolant Heater
Coolant Heater Control Unit
Glow Pin
Figure J-19. Espar Coolant Heater Installation (Sheet 1 of 2)
Figure J-19. Espar Coolant Heater Installation (Sheet 2 of 2)
Figure J-20. Espar Coolant Heater Internal Components (Sheet 1 of 2)
Figure J-20. Espar Coolant Heater Internal Components (Sheet 2 of 2)
Temperature Sensor
Flame Sensor
Burner
Water Pump
Fuel Metering Pump
Heating Elements
Seven Day Timer
APPENDIX K. BERMINGHAMMER PILE DRIVER SYSTEM INSTRUCTIONS FOR MAINTENANCE, TROUBLESHOOTING, AND REPAIR
SAFETY SUMMARY
SAFETY SUMMARY - Continued
SYSTEM DESCRIPTION.
Figure K-1. Crane, Lead Tower, Spotter, and Impact Hammer
Impact Hammer
Figure K-2. Impact Hammer Exterior View
Figure K-3. Impact Hammer Interior View
Impact Hammer - Continued
Figure K-4. Impact Hammer Lower Cylinder and Direct Drive Assembly
Impact Hammer - Continued
Impact Hammer - Continued
Figure K-5. Remote Throttle
Accessory Tools and Components
Accessory Tools and Components - Continued
Table K-1. General Specifications Loaded Shipping/Storage Container
Table K-4. Lubricants Required
Figure K-6. Impact Hammer Stages of Operation
Impact Hammer - Hammer Trip System Operation
Figure K-7. Hammer Trip Assembly Operation
Impact Hammer - Fuel Injection System Operation
Figure K-8. Fuel Injection System Schematic
Impact Hammer - Lubrication System Operation
Impact Hammer - Direct Drive System Operation
Figure K-10. Direct Drive System Operation
Figure K-11. Troubleshooting Flow Chart
Table K-5. Impact Hammer and Spotter Troubleshooting
Table K-5. Impact Hammer Troubleshooting (Continued)
Table K-5. Impact Hammer Troubleshooting (Continued)
Table K-5. Impact Hammer Troubleshooting (Continued)
Table K-5. Impact Hammer Troubleshooting (Continued)
Throttle Valve (Needle Block) Test
Fuel Pump Inlet/Outlet Check Valve Test
MAINTENANCE
Table K-7. Field-level Preventive Maintenance Checks and Services (PMCS)
Repair Instructions
Figure K-13. Blow Count Recorder Disassembly
Lower and Upper Gibs
Figure K-14. Lower and Upper Gib Installation (Upper Gib Shown; Lower Gib Similar)
Direct Drive System Lower Drive Housing
Figure K-15. Lower Drive Housing Installation
Figure K-16. Striker Plate and Striker Plate Cushion Ring Installation
Direct Drive System Direct Drive Assembly from Lower Cylinder
Figure K-17. Direct Drive Assembly Installation
Direct Drive System Cushion Rings, Cushion Compression Ring, and Cushion Shim Ring
Figure K-18. Cushion Rings, Cushion Compression Ring, and Cushion Shim Ring Installation
Figure K-19. Cushion Housing Guide Ring Support and Cushion Housing Guide Ring Installation
Impact Block
Impact Block Compression Rings
Figure K-20. Impact Block and Impact Block Compression Rings Installation
Figure K-21. Catch Ring Cap Installation
Piston
Piston - Continued
Figure K-22. Piston Installation
Fuel System Fuel System Guard
Figure K-23. Fuel System Guard Installation
Fuel System Fuel Pump
Figure K-24. Fuel Pump Installation
Fuel System Throttle Valve (Needle Block).
Figure K-25. Throttle Valve (Needle Block) Installation
Fuel System Fuel Injectors
Figure K-26. Fuel Injector Installation
Fuel System Fuel Pump Feed and Fuel Return Inline Filters
Figure K-27. Fuel Pump Feed and Fuel Return Inline Filter Installation
Fuel System Fuel Filter Element in Fuel Filter Assembly
Figure K-28. Fuel Filter Element Installation
Fuel System Fuel Filter Assembly
Figure K-29. Fuel Filter Assembly Installation
Fuel System Fuel Tank Suction Strainers
Figure K-30. Fuel Tank Suction Strainer Installation
Hammer Trip System Hammer Trip Assembly
Figure K-31. Hammer Trip Assembly Installation
Hammer Trip System Hammer Trip Assembly - Continued
Figure K-32. Hammer Trip Assembly Disassembly
Hammer Trip System Hammer Trip Track Rails
Figure K-33. Hammer Trip Track Rails Installation
Lubricating Oil System Oil Pump
Figure K-34. Oil Pump Installation
Lubricating Oil System Oil Tank Suction Strainers
Figure K-35. Lubricating Oil Tank Suction Strainer Installation
Waste Fuel Drip Tank
Figure K-36. Waste Fuel Drip Tank Installation
Figure K-37. Spotter Slide Manual Release Installation
Spotter
Spotter Inner and Outer Boxes Short and Long Wear Pads
Figure K-38. Spotter Disassembly (Sheet 2 of 2)
Spotter Hydraulic Cylinder
Figure K-39. Pile Gate Disassembly
Pile Gate
FILTER ELEMENT REPLACEMENT.
Cleaning With Water.
Air Cleaner Body.
Duct Work.
WATER COOLING SYSTEM
WARNING SAFETY SUMMARY
TROUBLESHOOTING
TROUBLESHOOTING - Continued
EFFECTS OF COOLING SYSTEM NEGLECT
RUST PREVENTION
PRESSURE FLUSHING
Engine Water Jacket
TEST EQUIPMENT
TRANSMISSION/TORQUE CONVERTER
LIST OF FIGURES AND CHARTS
THEORY OF OPERATION
Transmission - Cross Section
Clutch and Gear Arrangement
Power Flow in Forward 1st, 2nd, and 3rd
Power Flow in Forward 4th, 5th and 6th
Power Flow in Reverse
MAINTENANCE
General Assembly Instructions (sheet 1 of 3)
General Assembly Instructions (sheet 2 of 3)
General Assembly Instructions (sheet 3 of 3)
SPECIFICATIONS AND SERVICE DATA -- POWER SI-4IFT TRANSMISSION AND TORQUE CONVERTER
Torque Specification for Lubricated or Plated Screw Threads
Procedure
External Plumbing and Pressure Check Points (Sheet 1 of 2)
External Plumbing and Pressure Check Points (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION.
TORQUE CONVERTER/TRANSMISSION - Continued
Charging Pump and Valve Assembly (Sheet 1 of 2)
Charging Pump and Valve Assembly (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Converter and Pump Drive (Sheet 1 of 2)
Converter and Pump Drive (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Converter and Transmission Case (Sheet 1 of 2)
Converter and Transmission Case (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Clutch and Gear Assemblies (Sheet 1 of 2)
Clutch and Gear Assemblies (Sheet 2 of 2)
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
TORQUE CONVERTER/TRANSMISSION - Continued
Oil Seals, Gaskets, Etc.
Housings, Covers. Etc.
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Housings, Covers. Etc. - Continued
Output Shaft Rolling Torque.
DRIVE PLATE INSTALLATION PROCEDURE
Major Transmission Component.
Clutch Assemblies (Sheet 1 of 2)
Clutch Assemblies (Sheet 2 of 2)
Major Transmission Component. - Continued
Major Transmission Component. - Continued
Major Transmission Component. - Continued
Major Transmission Component. - Continued
Major Transmission Component. - Continued
REVERSE, 3rd AND 4th CLUTCH
REVERSE, 3rd AND 4th CLUTCH - Continued
REVERSE, 3rd AND 4th CLUTCH - Continued
REVERSE, 3rd AND 4th CLUTCH - Continued
3rd AND 4th CLUTCH.
3rd AND 4th CLUTCH. - Continued
3rd AND 4th CLUTCH. - Continued
3rd AND 4th CLUTCH. - Continued
3rd AND 4th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH.
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
FORWARD HIGH AND 5th AND 6th CLUTCH. - Continued
IDLER SHAFT.
IDLER SHAFT. - Continued
IMPELLER COVER.
IMPELLER COVER. - Continued
SERVICING THE MACHINE AFTER TRANSMISSION OVERHAUL
TORQUE CONVERTER WITH LOCK- UP
Torque Converter Assembly.
Torque Converter Assembly (Sheet 1 of 2)
Torque Converter Assembly (Sheet 2 of 2)
Drive Plate Group
Torque Converter Hydraulic Flow Path
General Assembly Information
Torque Converter Assembly - Continued
Torque Converter Assembly - Continued
Torque Converter Assembly - Continued
CLEANING AND INSPECTION.
Lock-up Impeller Cover Assembly
Torque Converter Assembly.
Torque Converter Assembly. - Continued
Torque Converter Assembly. - Continued
Torque Converter Assembly. - Continued
Torque Converter Assembly. - Continued
KESSLER AXLE
KESSLER AXLE - Continued
GENERAL INSTRUCTIONS
LOCTITE USE
Special Tools (Sheet 1 of 3)
Special Tools (Sheet 2 of 3)
Special Tools (Sheet 3 of 3)
LOCTITE USAGE CHART
GENERAL LUBRICATION INSTRUCTIONS
ADJUSTMENT VALUES
ROLLING RESISTANCE OF DRIVE PINION BEARING
ROLLING RESISTANCE OF DIFFERENTIAL BEARINGS
Wheel Safety Nut Chart (Sheet 2 of 2)
Bolt Tightening Torques Chart
Wheel Nut Tightening Torques Chart
Wheel End Assembly
Wheel End Assembly (Planetary Gear Axle)
WHEEL END (PLANETARY GEAR AXLE).
WHEEL END (PLANETARY GEAR AXLE). - Continued
WHEEL END (PLANETARY GEAR AXLE). - Continued
AXIAL CLEARANCE ADJUSTMENT.
Assembly.
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING - Continued
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING - Continued
STEERING KNUCKLE BEARING AND DOUBLE UNIVERSAL JOINT SHAFT BEARING - Continued
INSTALLATION OF THE STEERING KNUCKLE TO THE AXLE HOUSING
Drive Pinion Bearing
DIFFERENTIAL AND INSTALLATION
Removal and Disassembly.
SINGLE STAGE CARRIER INSTALLATION
DIFFERENTIAL LOCK.
Assembly
STEERING PUMP
TROUBLESHOOTING
DISASSEMBLY
Steering Pump
MITER GEAR
DESCRIPTION
Miter Gear
ASSEMBLY
RESERVOIRS
DESCRIPTION
LOW PRESSURE INDICATING SWITCH
THEORY OF OPERATION
THROTTLE CONTROL CYLINDER
THEORY OF OPERATION
Throttle Control Cylinder - Cutaway
CLEANING AND INSPECTION.
PRESSURE PROTECTION VALVE
THEORY OF OPERATION
Pressure Protection Valve-Cutaway
R-12 RELAY VALVE
THEORY OF OPERATION
R-12 Relay Valve-Cutaway
ASSEMBLY
STOP LIGHT SWITCH
THEORY OF OPERATION
HYDRAULIC PUMP
THEORY OF OPERATION
Hydraulic Pump - Exploded View
Hydraulic Pump - Cutaway
Seal Removal Tool.
GENERAL PRECAUTIONS.
GENERAL PRECAUTIONS. - Continued
GENERAL PRECAUTIONS. - Continued
ASSEMBLY
ASSEMBLY - Continued
ASSEMBLY - Continued
ASSEMBLY - Continued
ASSEMBLY - Continued
ASSEMBLY - Continued
WEAR LIMITS
LUBRICATION AND OIL RECOMMENDATIONS
INTEGRATED OUTRIGGER VALVE
DESCRIPTION
CLEANING AND INSPECTION
Inegrated Outrigger Valve (Sheet 1 of 4)
Inegrated Outrigger Valve (Sheet 2 of 4)
Integrated Outrigger Valve (Sheet 3 of 4)
Integrated Outrigger Valve (Sheet 4 of 4)
PRESSURE ADJUSTMENT
OUTRIGGER SOLENOID VALVE STACK
THEORY OF OPERATION
Solenoid Valve
HOLDING VALVE
DESCRIPTION
Holding Valve
SWING GEAR BOX AND BRAKE
DESCRIPTION
Swing Gearbox
SWING GEARBOX.
SWING GEARBOX.
CLEANING
Planet Carrier Assembly
LIST OF FIGURES
DANGER NOTE SUMMARY
Theory Of Operation
Model HO-15 Hoist - Cutaway
Troubleshooting
Troubleshooting - Continued
Troubleshooting - Continued
Troubleshooting - Continued
Hydraulic Motor.
Model HO - 15 Hoist Exploded View (Sheet 1 of 2)
Model HO - 15 Hoist Exploded View (Sheet 2 of 2)
CLEANING AND INSPECTION.
Gear Reduction Unit.
Brake Assembly.
Brake Assembly. - Continued
VANE TYPE MOTOR (HO-15C HOIST)
MAINTENANCE
TROUBLESHOOTING
Vane Motor - Exploded View
Vane Motor - Special Tools
DISASSEMBLY
ASSEMBLY
ASSEMBLY - Continued
SWIVEL ASSEMBLY
THEORY OF OPERATION
Typical Swivel Assembly
ASSEMBLY
ELECTRICAL SWIVEL
THEORY OF OPERATION
After Disassembly.
Typical Electrical Swivel
DIESEL HEATER
LIST OF FIGURES
WARNING SAFETY SUMMARY
WARNING SAFETY SUMMARY (continued)
THEORY OF OPERATION
Sectional View of Carburator and Burner Head
MAINTENANCE
Active Electrical Circuits (Sheet 1 of 2)
Active Electrical Circuits (Sheet 2 of 2)
TROUBLESHOOTING
TROUBLESHOOTING - Continued
TROUBLESHOOTING - Continued
TROUBLESHOOTING - Continued
TROUBLESHOOTING - Continued
PREVENTIVE MAINTENANCE
Case and Heat Exhanger
Operating Check and Adjustment
APPENDIX B. RED DOT HEAVY DUTY AIR CONDITIONING AND HEATING SERVICE TRAINING MANUAL
TABLE OF CONTENTS
Inspection and Maintenance without gauges
Visual Inspection System Off
Components Under the Hood
Check Hoses and Fittings
Electrical System Inspection
Inspection & Maintenance
Inspect System Component Cycling and Cab Temperature Levels
Check Clutch Cycling Under Load
Preventive Maintenance Worksheet
PREVENTIVE MAINTENANCE SCHEDULE FOR AIR CONDITIONING SYSTEMS
Troubleshooting & Service Procedures
The Key-Understanding System Function
A Troubleshooting Example
A Troubleshooting Example - Continued
A Troubleshooting Example - Continued
Manifold Gauge Set Installation
Purging Air From Gauge Set Hoses
Purging Air From Gauge Set Hoses - Continued
Stabilizing The AC System
Troubleshooting by Manifold Gauge Set Readings
Extremely Low Refrigerant Charge in the System
Air and/or Moisture in the System
Excessive Air and/or Moisture in the System
Excessive Air and/or Moisture in the System - Continued
Expansion Valve (TXV) Stuck Open
System High Pressure Side Restriction
Compressor Malfunction
Condenser Malfunction or System Overcharge
Thermostatic Switch Malfunction
Review of Frequent Problem Areas
Belts and Compressor Clutch
Other Problems--Leaks, Moisture, and Adding Refrigerant
Conclusion
Refrigerants
Changes in Service Procedures
Draining the Oil from the Previous Recovery Cycle
Performing the Recovery Cycle
Purging Non-Condensable Gases (Air)
Flushing the AC System
Evacuating and Charging the AC System
Charging the AC system
Charging with Refrigerant Gas (on the Low Side)
Charging the System with Liquid Refrigerant
Reclaiming Refrigerant
APPENDIX C. MASTER REPAIR MANUAL AIR COMPRESSORS
Foreword
Table of Contents
NOTES
Section i - Introduction
About the Manual
Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Definition of Terms
Section E - Component Identification
Component Identification
Section F - Familiarization
General Information
Section G - Installation Guidelines
Recommended Installation Guidelines
Oil Change Interval
Cooling System
Water Temperature
Duty Cycle
Application Recommendations
Drive Options
Air Governor
Discharge Air System
Porting Option Flexibility
Air Compressors Installation Diagram with Turbocharger Air Dryer and E-Type
Performance Curves and Specifications
NOTES
Section T - Troubleshooting
Procedures and Techniques
Air Compressor Air Pressure Rises Slowly
Air Compressor Noise Excessive
Air Compressor Pumping Excess Lubricating Oil into Air System
Air Compressor Pumping Excess Lubricating Oil into Air System (Continued)
Air Compressor Will Not Stop Pumping
Air Compressor Cycles Frequently
Air Compressor Will Not Maintain Adequate Air Pressure
Air Compressor Will Not Pump Air
Section 12 - Compressed Air System
Service Tools
Service Tools - Continued
Compressed Air System Specifications
Air Compressor General Information
Gear Driven Compressor
Air Compressor Carbon Buildup
Air Compressor Carbon Buildup - Continued
Air Compressor Carbon Buildup - Continued
Recommended Installation GuidelinesAir Compressor Pin Bore Wear (SS, E-Type, and ST Models) (012-010)
Recommended Installation GuidelinesAir Compressor Pin Bore Wear (SS, E-Type, and ST Models) (012-010) - Continued
Air Compressor Unloader Valve
Holset QE Models
Inspect for Reuse (012-013-007)
Holset QE Models
Air Governor (Air Compressor Will Not Pump) (012-017)
Air Governor (Air Compressor Will Not Pump) (012-017) - Continued
Air Leaks, Compressed Air System
Air Compressor
Air Compressor Cylinder Head (Holset QE Models) (012-104)
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor Cylinder Head (Holset QE Models) (012-104) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105)
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Air Compressor (Holset QE230, SS296, SS296E, QE296, SS338E and QE338 Models) (012-105) - Continued
Compressed Air System Specifications and Torque Values
Compressor Spring Force Specifications
QE296 Specifications
QE296 Specifications - Continued
Support Dimensions
Support Dimensions - Continued
Assembly Torque Specifications
Capscrew Markings and Torque Values - Metric
Capscrew Markings and Torque Values - U.S. Customary
Capscrew Markings and Torque Values
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
Newton-Meter to Foot-Pound Conversion Chart
Pipe Plug Torque Values
Tap-Drill Chart - U.S. Customary & Metric
Weight and Measures - Conversion Factors
NOTES
Section C - Component Manufacturers
Component Manufacturers' Addresses
Component Manufacturers' Addresses - Continued
Component Manufacturers' Addresses - Continued
Section L - Service Literature
Publication Titles
Service Literature Ordering Location
NOTES
Table of Contents
NOTES
NOTES - Continued
APPENDIX D. DELCO REMY 21-SI DELCOTRON GENERATOR SERVICE MANUAL 1G-286
PRODUCT INFORMATION AND SERVICE MANUAL DELCOTRON GENERATOR (21-SI SERIES)
Figure 2. Basic One-Wire System
Figure 4. One-Wire Generator Schematic
Figure 5. Troubleshooting a One-Wire System
RATED OUTPUT CHECK
Figure 6. Rated Output Check
Figure 7. Generator Bench Test
Figure 8. Using Test Hole
Figure 12. Adjusting Belt Tension
Figure 13. Threaded "I" and "R" Terminals
21-SI GENERATOR SPECIFICATIONS
APPENDIX E. DELCO REMY CRANKING MOTORS SERVICE BULLETIN 1M-157 AND DELCO REMY STARTERS SERVICE TEST SPECIFICATIONS 1M-188
Figure 1 Typical 37-MT motor.
Figure 2 Cross-sectional view, typical 37-MT motor
No-Load Test
SERVICE TEST SPECIFICATIONS
SERVICE SPECIFICATIONS STARTER MOTORS
APPENDIX G. DS350 LMI for ATEC (AT422T) TROUBLESHOOTING SECTION
TABLE OF CONTENTS
TABLE OF CONTENTS - continued
GENERAL INFORMATION
BASIC SYSTEM INFORMATION
GENERAL FLOWCHART AND DRAWINGS
LEVER LOCKOUT ACTIVATED
BROKEN LENGTH CABLE
NO DISPLAY
NO DISPLAY - continued
ANTI-TWO BLOCK PROBLEM (SINGLE SWITCH)
ANTI-TWO BLOCK PROBLEM (SINGLE SWITCH) - Continued
ANTI-TWO BLOCK PROBLEM (SINGLE SWITCH) - Continued
ANTI-TWO BLOCK PROBLEM (DOUBLE SWITCH)
ANTI-TWO BLOCK PROBLEM (DOUBLE SWITCH) - Continued
ANTI-TWO BLOCK PROBLEM (DOUBLE SWITCH) - Continued
LENGTH READING PROBLEM
LENGTH READING PROBLEM - continued
LENGTH READING PROBLEM - continued
LOAD READING PROBLEM
LOAD READING PROBLEM - continued
LOAD READING PROBLEM - continued
BAD DATA TRANSFER BETWEEN DISPLAY CONSOLE & CENTRAL UNIT, INTERFERENCE PROBLEM
BAD DATA TRANSFER BETWEEN DISPLAY CONSOLE & CENTRAL UNIT, INTERFERENCE PROBLEM - Continued
ERROR CODE DISPLAY
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
ERROR CODE DISPLAY - Continued
DRAWING 1. ELECTRICAL WIRING CENTRAL UNIT TO CRANE/PRESSURE TRANSDUCERS
DRAWING 2. ELECTRICAL WIRING CENTRAL UNIT TO DISPLAY CONSOLE/CABLE REEL
DRAWING 3A. CENTRAL UNIT DS350/2766
DRAWING 3B. CENTRAL UNIT DS350/2767
DRAWING 4. CABLE REEL
DRAWING 5. 050-350-061-328 DISPLAY CONSOLE
DRAWING 6. IN CENTRAL UNIT, HEATER CONTROL BOARD
DRAWING 7. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 8A. MAIN BOARD W/VOLTMETER ON X1:1 & X1:3
DRAWING 8B. MAIN BOARD W/VOLTMETER ON X1:1 & X1:3
DRAWING 9. IN DISPLAY CONSOLE, HEATER CONTROL BOARD
DRAWING 10. BOOM NOSE JUNCTION BOX
DRAWING 11. SLIP RING W/OHMMETER ON X2:RED & X1:BROWN
DRAWING 12. CABLE REEL W/OHMMETER ON TERMINALS 7 & 8 ON TERMINAL BOARD
DRAWING 13. BOOM BASE JUNCTION BOX W/OHMMETER ON 5 & 6
DRAWING 14. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 15. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 16. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 17. CABLE REEL TERMINAL BOARD W/VOLTMETER
DRAWING 18. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 19. PRESSURE TRANSDUCER CABLE
DRAWING 20. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 21. CONNECTION BOARD IN CENTRAL UNIT
DRAWING 22. SECONDARY ANTI-TWO BLOCK SWITCH
PROCEDURE 1. STRAIN RELIEF INSTALLATION
PROCEDURE 2A. EPROM LOCATION AND INSTALLATION
PROCEDURE 2B. EPROM LOCATION AND INSTALLATION
PROCEDURE 3A. MAIN BOARD 024-350-300-094 REPLACEMENT
PROCEDURE 3B. MAIN BOARD 024-350-300-222 REPLACEMENT
PROCEDURE 4A. PRESSURE TRANSDUCER ZERO ADJUSTMENT
PROCEDURE 4A. PRESSURE TRANSDUCER ZERO ADJUSTMENT - Continued
PROCEDURE 4B. PRESSURE TRANSDUCER ZERO ADJUSTMENT
PROCEDURE 4B. PRESSURE TRANSDUCER ZERO ADJUSTMENT - Continued
PROCEDURE 5 LENGTH POTENTIOMTER AND ANGLE SENSOR ADJUSTMENT
THEORY 1A. MAIN BOARD MEASURING POINTS
THEORY 1B. MAIN BOARD MEASURING POINTS
THEORY 2. OPERATION OF LENGTH POTENTIOMETER
PAT DS350 MAIN BOOM LENGTH SIGNAL VOLTAGES
THEORY 3. OPERATION OF ANGLE SENSOR
PAT DS350 MAIN BOOM ANGLE SIGNAL VOLTAGES
THEORY 4. OPERATION OF PISTON SIDE PRESSURE TRANSDUCER
PAT DS350 PRESSURE TRANSDUCER SIGNAL VOLTAGES
THEORY 5. OPERATION OF ROD SIDE PRESSURE TRANSDUCER
PAT DS350 PRESSURE TRANSDUCER SIGNAL VOLTAGES
APPENDIX G REVISIONS
APPENDIX H. ZF SEMI-INTEGRAL POWER STEERING GEAR, TYPE 7421 INSTRUCTIONS FOR OPERATION, MAINTENANCE, AND INSPECTION
ZF-Semi-Integral Power Steering Gear, Type 7421 (Single Circuit Steering Gear)
Preface
TABLE OF CONTENTS
IMPORTANT INFORMATION FOR DRIVER
CONSTRUCTION AND FUNCTION ZF SINGLE CIRCUIT POWER STEERING GEAR, TYPE 7421
CONSTRUCTION AND FUNCTION ZF SINGLE CIRCUIT POWER STEERING GEAR, TYPE 7421 - Continued
Figure. 1. Diagrammatic view of a ZF Single Circuit Power Steering Gear with an engine-driven or a drive-dependant pump (emergency steering pump)
FUNCTION AND ADJUSTMENT OF HYDRAULIC STEERING LIMIT (STEERING LOCK)
FUNCTION AND ADJUSTMENT OF HYDRAULIC STEERING LIMIT (STEERING LOCK) - Continued
Figure 4.
Steering Systems with Mechanical Steering-Lock Limitation
Steering Systems with Mechanical Steering-Lock Limitation - Continued
MAINTENANCE AND TYPES OF OILS
Filter Change
Checking the Oil Level
ADJUSTMENTS ON STEERING GEAR INSTALLED IN VEHICLE
INSTRUCTIONS FOR REPAIRING EXTERNAL LEAKS
Replacing Shaft Sealing Ring on Pitman Shaft
TOOLS FOR DISASSEMBLY AND ASSEMBLY
TOOLS FOR DISASSEMBLY AND ASSEMBLY - Continued
INSTRUCTIONS CONCERNING INSPECTION
Checking Straight-ahead Position of Steering and Vehicle
Checking for External Leaks
Testing and Adjusting Hydraulic Steering Limit
Steering System Without Power Cylinder
REMOVAL OF STEERING SYSTEM FROM VEHICLE
INSTALLATION OF STEERING SYSTEM INTO VEHICLE
Figure 7. Steering Spindle and Jacket Tube Diameter Chart
Determination of Jacket Tube Length
FAULTS AND REMEDIES
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
FAULTS AND REMEDIES - Continued
ILLUSTRATIONS AND EXPLODED DIAGRAMS
Figure 9. Single-circuit Steering Gear
Figure 10. Longitudinal Section through the Mechanical Steering-lock Limiter Stub Type
Figure 12. ZF Semi-integral Power Steering Gear, Type 7421
Figure 13. ZF Semi-integral Power Steering Gear, Type 7421
Figure 14. ZF Right-angle Gear, Type 7860 (for Flange-mounting to the Steering-lock Limiter Casing of Type 7421 ZF Power Steering Gear)
APPENDIX I. CUMMINS FIELD SERVICE PROCEDURES FOR WABCO AIR COMPRESSOR
INTRODUCTION
TROUBLESHOOTING
Head Assembly Replacement
Figure I-2 Cylinder Head Bolt Tightening Sequence
Installation
Rear Seal and Adapter Replacement
Figure I-4. Compressor Rear Bearing O-ring Seal Installation
Figure I-5. Piston Assembly Replacement
Figure I-6. Correct Piston Ring Orientation
Connecting Rod Assembly Replacement.
Crankshaft Bearing Replacement
Figure I-7. Crankshaft Bearing Replacement
APPENDIX J. WINTERIZING THE ATEC CRANE AT422
SAFETY SUMMARY
INTRODUCTION
Figure J-1. Coolant Heater Operation
THEORY OF OPERATION
Coolant Heater Shutdown
INSTALLATION
Figure J-2. Fuel Tank Modification Dimensions
Figure J-3. Fuel Pickup Tube Installation
Figure J-4. Hydraulic Reservoir Connection Legend
Hydraulic Reservoir Modification
Figure J-5. Hydraulic Reservoir Modification Dimensions Doubler Plate P/N 6705170879
Figure J-6. Hydraulic Reservoir Modification Dimensions Doubler Plate P/N 6705170884
Hydraulic Reservoir Modification Pressure Test
Figure J-7. Hydraulic Reservoir Test Fitting
Figure J-8. Hydraulic Reservoir Heater Element Installation
Figure J-9. Hydraulic Reservoir Bracket Modification (If Necessary)
Figure J-10. Seven Day Timer Installation
Fuel Metering Pump Installation
Figure J-11. Fuel Metering Pump Installation
Figure J-12. Coolant Heater Installation Dimensions
Coolant Heater Installation
Figure J-13. Coolant Heater Installation
Fuel Line Installation
Figure J-14. Coolant Heater Wiring Diagram
Electrical Connections Battery and Fuel Metering Pump
Figure J-15. Battery Box Wiring Installation
Electrical Connections Seven Day Timer
Table J-1. Seven Day Timer Connector Terminal Designations
Figure J-16. Engine Coolant Flow Diagram
Engine Coolant Connections Supply from Engine
Figure J-17. Engine Coolant Supply from Engine Installation
Engine Coolant Connections Return to Engine
Figure J-18. Engine Coolant Return to Engine Installation
Engine Coolant Connections Hydraulic Reservoir
Initial Startup/Testing Procedures
TROUBLESHOOTING
Table J-2. Fault Codes
Table J-2. Fault Codes (Continued)
Table J-2. Fault Codes (Continued)
Table J-2. Fault Codes (Continued)
Fuel Quantity Test
Engine Coolant Heater
Coolant Heater Control Unit
Glow Pin
Figure J-19. Espar Coolant Heater Installation (Sheet 1 of 2)
Figure J-19. Espar Coolant Heater Installation (Sheet 2 of 2)
Figure J-20. Espar Coolant Heater Internal Components (Sheet 1 of 2)
Figure J-20. Espar Coolant Heater Internal Components (Sheet 2 of 2)
Temperature Sensor
Flame Sensor
Burner
Water Pump
Fuel Metering Pump
Heating Elements
Seven Day Timer
APPENDIX K. BERMINGHAMMER PILE DRIVER SYSTEM INSTRUCTIONS FOR MAINTENANCE, TROUBLESHOOTING, AND REPAIR
SAFETY SUMMARY
SAFETY SUMMARY - Continued
SYSTEM DESCRIPTION.
Figure K-1. Crane, Lead Tower, Spotter, and Impact Hammer
Impact Hammer
Figure K-2. Impact Hammer Exterior View
Figure K-3. Impact Hammer Interior View
Impact Hammer - Continued
Figure K-4. Impact Hammer Lower Cylinder and Direct Drive Assembly
Impact Hammer - Continued
Impact Hammer - Continued
Figure K-5. Remote Throttle
Accessory Tools and Components
Accessory Tools and Components - Continued
Table K-1. General Specifications Loaded Shipping/Storage Container
Table K-4. Lubricants Required
Figure K-6. Impact Hammer Stages of Operation
Impact Hammer - Hammer Trip System Operation
Figure K-7. Hammer Trip Assembly Operation
Impact Hammer - Fuel Injection System Operation
Figure K-8. Fuel Injection System Schematic
Impact Hammer - Lubrication System Operation
Impact Hammer - Direct Drive System Operation
Figure K-10. Direct Drive System Operation
Figure K-11. Troubleshooting Flow Chart
Table K-5. Impact Hammer and Spotter Troubleshooting
Table K-5. Impact Hammer Troubleshooting (Continued)
Table K-5. Impact Hammer Troubleshooting (Continued)
Table K-5. Impact Hammer Troubleshooting (Continued)
Table K-5. Impact Hammer Troubleshooting (Continued)
Throttle Valve (Needle Block) Test
Fuel Pump Inlet/Outlet Check Valve Test
MAINTENANCE
Table K-7. Field-level Preventive Maintenance Checks and Services (PMCS)
Repair Instructions
Figure K-13. Blow Count Recorder Disassembly
Lower and Upper Gibs
Figure K-14. Lower and Upper Gib Installation (Upper Gib Shown; Lower Gib Similar)
Direct Drive System Lower Drive Housing
Figure K-15. Lower Drive Housing Installation
Figure K-16. Striker Plate and Striker Plate Cushion Ring Installation
Direct Drive System Direct Drive Assembly from Lower Cylinder
Figure K-17. Direct Drive Assembly Installation
Direct Drive System Cushion Rings, Cushion Compression Ring, and Cushion Shim Ring
Figure K-18. Cushion Rings, Cushion Compression Ring, and Cushion Shim Ring Installation
Figure K-19. Cushion Housing Guide Ring Support and Cushion Housing Guide Ring Installation
Impact Block
Impact Block Compression Rings
Figure K-20. Impact Block and Impact Block Compression Rings Installation
Figure K-21. Catch Ring Cap Installation
Piston
Piston - Continued
Figure K-22. Piston Installation
Fuel System Fuel System Guard
Figure K-23. Fuel System Guard Installation
Fuel System Fuel Pump
Figure K-24. Fuel Pump Installation
Fuel System Throttle Valve (Needle Block).
Figure K-25. Throttle Valve (Needle Block) Installation
Fuel System Fuel Injectors
Figure K-26. Fuel Injector Installation
Fuel System Fuel Pump Feed and Fuel Return Inline Filters
Figure K-27. Fuel Pump Feed and Fuel Return Inline Filter Installation
Fuel System Fuel Filter Element in Fuel Filter Assembly
Figure K-28. Fuel Filter Element Installation
Fuel System Fuel Filter Assembly
Figure K-29. Fuel Filter Assembly Installation
Fuel System Fuel Tank Suction Strainers
Figure K-30. Fuel Tank Suction Strainer Installation
Hammer Trip System Hammer Trip Assembly
Figure K-31. Hammer Trip Assembly Installation
Hammer Trip System Hammer Trip Assembly - Continued
Figure K-32. Hammer Trip Assembly Disassembly
Hammer Trip System Hammer Trip Track Rails
Figure K-33. Hammer Trip Track Rails Installation
Lubricating Oil System Oil Pump
Figure K-34. Oil Pump Installation
Lubricating Oil System Oil Tank Suction Strainers
Figure K-35. Lubricating Oil Tank Suction Strainer Installation
Waste Fuel Drip Tank
Figure K-36. Waste Fuel Drip Tank Installation
Figure K-37. Spotter Slide Manual Release Installation
Spotter
Spotter Inner and Outer Boxes Short and Long Wear Pads
Figure K-38. Spotter Disassembly (Sheet 2 of 2)
Spotter Hydraulic Cylinder
Figure K-39. Pile Gate Disassembly
Pile Gate
