Content

Security measures

• Safety devices
• General safety requirements
• Safety instructions
• Warning labels

Work check procedure

• Operation test
• Performance checks - rocker switch on, engine off

Engine

• Theoretical foundations of work
• Engine (OM 501 LA shown)
• Engine troubleshooting
• Adjustments
• Tachometer on OSD (B35D shown)
• Idle adjustment at low and high speeds
• Valve clearance adjustment
• OM 501 LA engine shown
• Adjusting retarders
• Checks
• Cylinder compression test
• Fuel pump pressure test
• Oil pump pressure test

Electrical system

• System information
• Wiring diagram symbols
• CAN bus J1939
• What is a “CAN bus”?
• CANBUS
• Testing the “CAN bus”
• Checking cables
• Check for open circuits, short circuits between wires and short circuits to ground on the CAN wiring harness
• Main harness “CAN”
• “CAN” short circuit to ground
• “CAN” open circuit
• “CAN” short circuit to positive terminal 0 - 24 volts
• Chassis control unit (CCU2 and OEU)
• MDU2 (control display unit)
• MDU2 layout
• MDU2 inputs and outputs
• Relay
• MDU2
• Startup display
• Default screen
• To go to the main menu from the default screen
• Main menu
• Wire marking explanations
• Connectors
• Description of electrical circuits
• SSM
• Pilot lights MDU2
• MDU2 instruments
• CCU2 output characteristics
• OEU output characteristics
• Reference data
• Engine trouble codes (ADM)
• Engine fault codes (PLD-MR)
• DM trouble codes
• Checks
• Checking the key switch
• Relay
• Diode testing
• Tests for pneumatic system solenoids, pressure switches and sensors
• Steering column engagement test

Transmission HD4560

• Theoretical foundations of work
• General descriptions
• Critical speeds
• Planetary gears and power flows
• Basic laws of planetary gear sets
• Heavy duty planetary transmission
• Heavy duty clutch configuration
• Transmission cross section
• Power flow
• Hydraulic system
• Electromagnets
• Hydraulic lines
• Torque converter and lube pressure lines - brief description
• Discharging backfill pressure
• Pressure table and control points
• Retarder
• Application and load capacity
• Inputs and outputs
• Hydraulic retarder control
• Checking the retarder charge pressure
• Heavy duty retarder hydraulics
• Heavy duty retarder hydraulics retarder enabled
• Electronic control system
• Gear selector pushbutton
• RPM sensors (look different on new transmission)
• Wiring harness
• Range/transmit checks
• “Do not shift gear” lamp
• Diagnostic information
• Diagnostic procedure
• Transmission system fault diagnosis
• Checking the transmission fluid level
• Transmission control unit error codes
• Service code diagnostics - how to use transmission code reception
• Error code table
• Electronic control Allison HD 4560R WTEC III
• Settings and tests
• Transmission warm-up procedure
• Transmission oil cooler shrink test

Pneumatic system

• Basics of work
• Operation of the pneumatic system
• Pneumatic system diagram
• Diagnostic information
• Diagnostic procedure
• Pneumatic system troubleshooting
• Settings and tests
• Testing and adjusting the main pressure of the pneumatic system
• Parking brake pressure test
• Setting the parking brake
• Basic seat function test procedures

Hydraulic system

• Theoretical foundations of work
• Symbols in the hydraulic system diagram
• Articulated dump truck hydraulic operation
• Work
• Diagnostic information
• Diagnostic procedure
• Troubleshooting the hydraulic system
• Checks
• Installing the digital thermometer JT05800
• Installing the JT02156A digital-to-analog pressure / temperature analyzer
• Hydraulic oil cleaning procedure with portable filter cassette
• Hydraulic system warm-up procedure
• Testing loop time constants
• Testing and adjusting the residual and compensating valves of the main hydraulic pump
• System relief valve and lift circuit relief valve test
• Priority valve test
• Accumulator pressure reducing valve test and adjustment
• Testing and adjusting the brake accumulator charging valve
• Testing brake accumulators and brake low pressure switches
• Pressure test and charging procedure for front and rear brake accumulators
• Service brake valve test
• Steering system relief valve pressure test and setting
• Steering cylinder leak test
• Testing and adjustment of the residual and compensating valves of the auxiliary steering pump
• Body lowering circuit safety valve test
• Fan drive circuit pressures, B35D and B40D
• Checking and adjusting the fan drive control
• Suspension calibration procedure, B50D only
• Suspension test

Air conditioning and heating

• Theoretical foundations of work
• Air conditioning cycle
• Operation of the heater core
• Diagnostic information
• Troubleshooting the air conditioning system
• Location of air conditioning/heating components
• Checks
• Air conditioning checks
• R134A air conditioning test
• Working pressure troubleshooting tables
• Frost protection control switch test
• Air compressor clutch test
• High/low air pressure switch test
• Air expansion valve test
• Expansion valve bench test
• Refrigerant Leak Test

Maintenance Schedules

Daily or 10-hour checks

Maintenance and checks every 150 hours

• Transmission
• Introduction
• Maintenance instructions
• Lowering and raising the pallet

Maintenance and checks every 500 hours

• Transmission
• Introduction
• Maintenance instructions
• Engine
• Transmission
• Brakes
• Gearbox
• Cleaning, checking and replacing breathers
• General check of driveline and suspension mounts
• Transfer case breather (located under the hydraulic fluid tank)
• Transmission breather and axle breathers
• Cab and electrical
• Checking, cleaning and replacing the air filter in the cab
• Checking batteries, cleaning and tightening terminals
• Checking electrical connectors, harnesses and braids
• Checking working lights, reversing horn and horn
• Recording and deleting fault codes on the menu display
• Testing the driver's controls and instruments
• Lubrication
• Grease lubrication
• Checking the grease level in the automatic lubrication system
• Hydraulics
• Replacing the hydraulic tank breather valve, B35D and B40D
• Wet disc brake coolant oil reservoir (B40D only) (on top of the reservoir)

Maintenance and checks every 1,000 hours

• Transmission
• Introduction
• Maintenance instructions
• Engine
• Replacing the transfer box filter
• Hydraulics and Lubrication
• Replacing the hydraulic tank breather
• Axles, chassis and suspension
• Checking the status of all drive shafts
• Checking the axle oil level (B35D and B40D only)
• Checking the final drive oil level (B35D and B40D only)
• Axle oil change (B35D and B50D with BELL wet brakes)
• Checking the backlash of the shock-absorbing body element

Maintenance and checks every 2,000 hours

• Transmission
• Introduction
• Maintenance instructions
• Engine
• Hydraulics and Lubrication
• Changing the oil in the wet disc brake cooler and filter
• Cab, pneumatic system and electrical part
• Replacing the air dryer filter

Maintenance and checks every 3,000 hours

• Transmission
• Introduction
• Maintenance instructions
• Hydraulics and pneumatics

Maintenance and checks every 4,000 hours

• Transmission
• Replacing the fan belt (B35D and B40D only)
• Hydraulics and pneumatics
• Introduction
• Maintenance instructions

On-demand maintenance

• Engine
• Introduction
• Maintenance instructions
• Cab and lubrication
• Cleaning the air conditioning filters
• Lubrication of hinges with grease
• Checking and cleaning all radiators

Other maintenance and checks

• Transmission
• Introduction
• Maintenance instructions
• Engine
• Wheels
• Electrical
• Using the battery charger
• Headlight adjustment
• Operational test
• Operation test

Troubleshooting

• Symptoms and solutions
• Introduction

Application

• Datasheet OBW - ADT MK IV 001-4002-00
• Technical Data Sheet for hydraulic cooler with fan - ADT MK IV 001-4003-02
• Contents
• Introduction
• Chassis control unit software requirements
• CCU2 headlight and control logic 001-4004-00
• Introduction
• The logic of the headlights and their control
• Wiper control logic CCU2 001-4005-00
• Introduction
• Wiper control logic and timing
• Air conditioning control logic 001-4006-00
• Introduction
• Inputs / outputs
• Body control logic 001-4007-00
• Introduction
• Body control logic
• Parking brake operation
• Introduction