Field Maintenance Manual For 924H Wheel Loader -2

FRONT AND REAR TURN SIGNALS DO NOT OPERATE IN EITHER LEFT OR RIGHT POSITIONS, STOPLIGHTS OPERATE NORMALLY
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
Table 1. Front and Rear Turn Signals Do Not Operate in Either Left or Right Positions, Stoplights Operate Normally - Continued.
ONE OR BOTH STOPLIGHTS DO NOT OPERATE, TURN SIGNALS OPERATE NORMALLY
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
Table 1. One or Both Stoplights Do Not Operate, Turn Signals Operate Normally - Continued.
ONE OR BOTH BLACKOUT STOPLIGHTS DO NOT OPERATE
Table 1. One or Both Blackout Stoplights Do Not Operate.
Table 1. One or Both Blackout Stoplights Do Not Operate - Continued.
Table 1. One or Both Blackout Stoplights Do Not Operate - Continued.
Table 1. One or Both Blackout Stoplights Do Not Operate - Continued.
ONE OR BOTH FRONT WORK LIGHTS DO NOT OPERATE
Table 1. One or Both Front Work Lights Do Not Operate.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
Table 1. One or Both Front Work Lights Do Not Operate - Continued.
ONE OR BOTH REAR WORK LIGHTS DO NOT OPERATE
Table 1. One or Both Rear Work Lights Do Not Operate.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
Table 1. One or Both Rear Work Lights Do Not Operate - Continued.
FRONT WINDSHIELD WIPER DOES NOT OPERATE
Table 1. Front Windshield Wiper Does Not Operate.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
Table 1. Front Windshield Wiper Does Not Operate - Continued.
REAR WINDOW WIPER DOES NOT OPERATE
Table 1. Rear Window Wiper Does Not Operate.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
Table 1. Rear Window Wiper Does Not Operate - Continued.
FRONT WINDSHIELD WASHER DOES NOT OPERATE
Table 1. Front Windshield Washer Does Not Operate.
Table 1. Front Windshield Washer Does Not Operate - Continued.
Table 1. Front Windshield Washer Does Not Operate - Continued.
Table 1. Front Windshield Washer Does Not Operate - Continued.
Table 1. Front Windshield Washer Does Not Operate - Continued.
Table 1. Front Windshield Washer Does Not Operate - Continued.
REAR WINDOW WASHER DOES NOT OPERATE
Table 1. Rear Window Washer Does Not Operate.
Table 1. Rear Window Washer Does Not Operate - Continued.
Table 1. Rear Window Washer Does Not Operate - Continued.
Table 1. Rear Window Washer Does Not Operate - Continued.
Table 1. Rear Window Washer Does Not Operate - Continued.
Table 1. Rear Window Washer Does Not Operate - Continued.
WORK AREA VISION SYSTEM (WAVS) DOES NOT OPERATE PROPERLY
Table 1. Work Area Vision System (WAVS) Does Not Operate Properly.
Figure 1. Work Area Vision System (WAVS) Camera.
Table 1. Work Area Vision System (WAVS) Does Not Operate Properly - Continued.
Table 1. Work Area Vision System (WAVS) Does Not Operate Properly - Continued.
Figure 2. Work Area Vision System (WAVS) Camera.
Table 1. Work Area Vision System (WAVS) Does Not Operate Properly - Continued.
Table 1. Work Area Vision System (WAVS) Does Not Operate Properly - Continued.
Table 1. Work Area Vision System (WAVS) Does Not Operate Properly - Continued.
HORN DOES NOT OPERATE
Table 1. Horn Does Not Operate.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
Table 1. Horn Does Not Operate - Continued.
REAR WINDOW DEFROSTER DOES NOT OPERATE
Table 1. Rear Window Defroster Does Not Operate.
Table 1. Rear Window Defroster Does Not Operate - Continued.
Table 1. Rear Window Defroster Does Not Operate - Continued.
Table 1. Rear Window Defroster Does Not Operate - Continued.
Table 1. Rear Window Defroster Does Not Operate - Continued.
EXCESSIVE FORCE NEEDED TO TURN STEERING WHEEL
Table 1. Excessive Force Needed to Turn Steering Wheel.
Table 1. Excessive Force Needed to Turn Steering Wheel - Continued.
Table 1. Excessive Force Needed to Turn Steering Wheel - Continued.
Table 1. Excessive Force Needed to Turn Steering Wheel - Continued.
Table 1. Excessive Force Needed to Turn Steering Wheel - Continued.
MACHINE DOES NOT TURN WHEN STEERING WHEEL IS TURNED
Table 1. Machine Does Not Turn When Steering Wheel Is Turned.
Table 1. Machine Does Not Turn when Steering Wheel Is Turned - Continued.
Table 1. Machine Does Not Turn when Steering Wheel Is Turned - Continued.
Table 1. Machine Does Not Turn when Steering Wheel Is Turned - Continued.
MACHINE TURNS SLOWLY IN ONE OR BOTH DIRECTIONS
Table 1. Machine Turns Slowly in One or Both Directions.
Table 1. Machine Turns Slowly in One or Both Directions - Continued.
Table 1. Machine Turns Slowly in One or Both Directions - Continued.
Table 1. Machine Turns Slowly in One or Both Directions - Continued.
Table 1. Machine Turns Slowly in One or Both Directions - Continued.
MACHINE WILL NOT STAY IN A STRAIGHT LINE
Table 1. Machine Will Not Stay in a Straight Line.
Table 1. Machine Will Not Stay in a Straight Line - Continued.
Table 1. Machine Will Not Stay in a Straight Line - Continued.
ALL IMPLEMENTS WILL NOT OPERATE OR OPERATE SLOWLY
Table 1. All Implements Will Not Operate or Operate Slowly.
Table 1. All Implements Will Not Operate or Operate Slowly Continued.
Table 1. All Implements Will Not Operate or Operate Slowly Continued.
Table 1. All Implements Will Not Operate or Operate Slowly Continued.
Table 1. All Implements Will Not Operate or Operate Slowly Continued.
BOOM WILL NOT LOWER
Table 1. Boom Will Not Lower.
Table 1. Boom Will Not Lower - Continued.
BOOM WILL NOT RAISE OR LOWER
Table 1. Boom Will Not Raise or Lower.
Table 1. Boom Will Not Raise or Lower - Continued.
Table 1. Boom Will Not Raise or Lower - Continued.
Figure 1. Pilot Control Hoses.
Table 1. Boom Will Not Raise or Lower - Continued.
BUCKET WILL NOT TILT
Table 1. Bucket Will Not Tilt.
Table 1. Bucket Will Not Tilt - Continued.
Table 1. Bucket Will Not Tilt - Continued.
Figure 1. Pilot Control Hoses.
Table 1. Bucket Will Not Tilt - Continued.
Table 1. Bucket Will Not Tilt - Continued.
BUCKET CLAMSHELL DOES NOT OPERATE
Table 1. Bucket Clamshell Does Not Operate.
Table 1. Bucket Clamshell Does Not Operate - Continued.
Table 1. Bucket Clamshell Does Not Operate - Continued.
Table 1. Bucket Clamshell Does Not Operate - Continued.
Table 1. Bucket Clamshell Does Not Operate - Continued.
QUICK COUPLER WILL NOT OPERATE
Table 1. Quick Coupler Will Not Operate.
Table 1. Quick Coupler Will Not Operate - Continued.
Table 1. Quick Coupler Will Not Operate - Continued.
Table 1. Quick Coupler Will Not Operate - Continued.
Table 1. Quick Coupler Will Not Operate - Continued.
Table 1. Quick Coupler Will Not Operate - Continued.
Table 1. Quick Coupler Will Not Operate - Continued.
Table 1. Quick Coupler Will Not Operate - Continued.
RIDE CONTROL DOES NOT OPERATE
Table 1. Ride Control Does Not Operate.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
Table 1. Ride Control Does Not Operate - Continued.
IMPLEMENTS DRIFT DOWNWARD
Table 1. Implements Drift Downward.
Table 1. Implements Drift Downward - Continued.
KICKOUT SYSTEM WILL NOT OPERATE OR OPERATES IMPROPERLY
Table 1. Kickout System Will Not Operate or Operates Improperly.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 1. Carry Kickout Position Sensor, Wiring Harness, Magnet, and Mounting Hardware.
Figure 2. Lift Kickout Position Sensor, Wiring Harness, and Mounting Hardware.
Figure 3. Shaft and Fork and Bucket Kickout Position Sensors Mounting Hardware.
Figure 4. Fork and Bucket Kickout Position Sensors, Wiring Harness, and Mounting Hardware.
Figure 5. Shaft, Magnet, and Mounting Hardware.
Figure 6. Green (Power) LEDs on Kickout Position Sensors.
Figure 7. Testing Switch Function of Fork and Bucket Kickout Position Sensors.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 8. Testing Switch Function of Lift and Carry Kickout Position Sensors.
Figure 9. Pilot Valve Cover.
Figure 10. Arm Rest and Operator Console Cover.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 13. Tiedown Straps.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 17. Tiedown Strap.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 20. Operator Console Cover.
Figure 21. Arm Rest and Operator Console Cover.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 24. Bucket Kickout Position Sensor.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 28. Tiedown Straps.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 29. Tiedown Strap.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 30. Tiedown Strap.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Table 1. Kickout System Will Not Operate or Operates Improperly Continued.
Figure 34. Pilot Valve Cover.
Figure 35. Tiedown Straps.
Figure 36. Shaft and Fork and Bucket Kickout Position Sensors Mounting Hardware.
Figure 37. Magnet.
ALL SERVICE BRAKES DO NOT OPERATE
Table 1. All Service Brakes Do Not Operate.
Table 1. All Service Brakes Do Not Operate - Continued.
Table 1. All Service Brakes Do Not Operate - Continued.
Figure 1. MSD Screen.
Table 1. All Service Brakes Do Not Operate - Continued.
Table 1. All Service Brakes Do Not Operate - Continued.
FRONT SERVICE BRAKES DO NOT OPERATE
Table 1. Front Service Brakes Do Not Operate.
Table 1. Front Service Brakes Do Not Operate - Continued.
Table 1. Front Service Brakes Do Not Operate - Continued.
Table 1. Front Service Brakes Do Not Operate - Continued.
REAR SERVICE BRAKES DO NOT OPERATE
Table 1. Rear Service Brakes Do Not Operate.
Table 1. Rear Service Brakes Do Not Operate - Continued.
Table 1. Rear Service Brakes Do Not Operate - Continued.
Table 1. Rear Service Brakes Do Not Operate - Continued.
Table 1. Rear Service Brakes Do Not Operate - Continued.
SERVICE BRAKES DO NOT HOLD
Table 1. Service Brakes Do Not Hold.
Figure 1. Front Axle Inspection Plugs.
Figure 3. Rear Axle Inspection Plugs.
Figure 4. Axle Inspection Port.
Table 1. Service Brakes Do Not Hold - Continued.
PARKING BRAKE DOES NOT HOLD THE MACHINE STATIONARY
Table 1. Parking Brake Does Not Hold the Machine Stationary.
Table 1. Parking Brake Does Not Hold the Machine Stationary - Continued.
PARKING BRAKE DOES NOT ENGAGE WHEN THE PARKING BRAKE CONTROL LEVER IS ACTUATED
Table 1. Parking Brake Does Not Engage When the Parking Brake Control Lever Is Actuated.
Table 1. Parking Brake Does Not Engage When the Parking Brake Control Lever Is Actuated - Continued.
ENGINE OIL PRESSURE TEST
Figure 1. Engine Oil Sample Test Port.
Figure 2. Engine Oil Sample Test Port and Adapter.
Figure 3. Pressure Gauge and Hose.
Figure 4. Pressure Gauge and Hose.
Figure 5. Engine Oil Sample Test Port.
FUEL SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS
Figure 1. Diagnostic Test Menu, and Fuel System Verification Test.
Figure 2. Warning Message.
Figure 3. Set Up Test Conditions.
Figure 4. Test in Progress.
Figure 5. Diagnostic Test Menu, and Injector Solenoid Test.
Figure 6. Injector Solenoid Test Results.
Figure 7. Diagnostic Test Menu, and Cylinder Cutout Test.
Figure 8. Attention Pop-Up Window.
Figure 9. Cylinder Cutout Test Selection.
Figure 10. Cylinder Cutout Test Conditions.
Figure 11. Hydraulic Fan and Engine Speed Warnings.
Figure 12. Cylinder Cutout Test in Progress.
Figure 13. Cylinder Cutout Test Complete.
Figure 14. Secondary Fuel Line.
Figure 15. Fuel Leak-Off Connector, and Fuel Drain Tube.
HIGH LEAK-OFF OF FUEL INJECTORS TEST CONTINUED
Figure 16. Secondary Fuel Line.
HYDRAULIC FAN SPEED TEST AND CALIBRATION
HYDRAULIC FAN SPEED TEST
Figure 1. Fan Grille.
HYDRAULIC FAN SPEED TEST CONTINUED
Figure 2. Hydraulic System Status Parameters.
Figure 3. Service Menu Selection.
Figure 5. Warning Message.
Figure 6. Set Up Test Conditions.
Figure 7. Set Up Test Conditions.
HYDRAULIC FAN SPEED CALIBRATION CONTINUED
Figure 8. Maximum Fan Speed Calibration.
HYDRAULIC FAN SPEED CALIBRATION CONTINUED
Figure 9. Minimum Fan Speed Calibration.
HYDRAULIC FAN SPEED CALIBRATION CONTINUED
Figure 10. Nominal Fan Speed Calibration.
Figure 11. Hydraulic Fan Hoses.
BATTERY AND CHARGING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS
Figure 1. Ammeter.
Figure 2. Ammeter Connection.
Figure 3. Alternator Terminals.
HYDRAULIC SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS
STEERING FORCE CHECK
Figure 1. Steering Wheel.
STEERING PISTON PUMP MARGIN PRESSURE TEST
Figure 2. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 4. 3,600 psi (25,000 kPa) Gauge Assembly.
Figure 5. Steering Pressure Compensator Valve.
Figure 6. 5,800 psi (40,000 kPa) Gauge Assembly.
STEERING PISTON PUMP MARGIN PRESSURE TEST CONTINUED
Figure 8. Steering Pressure Compensator Valve.
Figure 10. Pressure Reducing Valve.
STEERING PISTON PUMP LOW PRESSURE STANDBY TEST
Figure 11. 870 psi (6,000 kPa) Gauge Assembly.
Figure 12. Pressure Reducing Valve.
Figure 13. 3,600 psi (25,000 kPa) Gauge Assembly.
Figure 14. Pressure Reducing Valve.
STEERING HIGH PRESSURE STALL TEST CONTINUED
Figure 16. Steering Pressure Compensator Valve Adjustment.
STEERING WHEEL SLIP CHECK
STEERING WHEEL TIME CHECK
AIR PURGE ON IMPLEMENT HYDRAULIC SYSTEM
Figure 17. Hose Assembly.
Figure 18. Signal Pressure Connector.
Figure 20. Hose Assembly.
Figure 22. Hydraulic Tank Filler Cap.
PUMP CUTOFF PRESSURE TEST
Figure 23. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 25. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 26. Piston Pump Pressure Connection.
Figure 27. Pump Cutoff Pressure Adjustment.
Figure 28. 580 psi (4,000 kPa) Gauge Assembly.
Figure 29. Piston Pump Pressure Connection.
Figure 30. 580 psi (4,000 kPa) Gauge Assembly.
MARGIN PRESSURE TEST
Figure 31. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 32. Signal Pressure Connector.
Figure 33. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 34. Piston Pump Pressure Connection.
Figure 35. Margin Pressure Adjustment.
PILOT SYSTEM PRESSURE TEST
Figure 36. 1,450 psi (10,000 kPa) Gauge Assembly.
Figure 37. Pilot Supply Pressure Connection.
Figure 38. 1,450 psi (10,000 kPa) Gauge Assembly.
Figure 39. Pilot Supply Pressure Connection.
Figure 40. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 41. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 42. Head End of Tilt Cylinder Pressure Port.
RELIEF VALVE PRESSURE FOR ROD END TILT CYLINDER TEST
Figure 43. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 44. Head End of Tilt Cylinder Pressure Port.
Figure 45. 5,800 psi (40,000 kPa) Gauge Assembly.
Figure 46. Rod End of Tilt Cylinder Pressure Port.
Figure 47. Rod End of Tilt Cylinder Pressure Adjustment.
Figure 48. Select Diagnostic Tests.
Figure 49. Select Override Parameters.
Figure 50. Select Ride Control Solenoid Override.
Figure 51. Select Ride Control Solenoid Override On.
Figure 52. Ride Control Solenoid Override Parameter Change.
Figure 53. Ride Control Solenoid Override On.
Figure 54. Select Diagnostic Tests.
Figure 55. Select Override Parameters.
Figure 56. Select Ride Control Solenoid Override.
Figure 57. Select Ride Control Solenoid Override Off.
Figure 58. Ride Control Solenoid Override Parameter Change.
Figure 59. Ride Control Solenoid Override in Override.
Figure 61. 3,600 psi (25,000 kPa) Gauge Assembly.
Figure 62. Brake System Status Screen.
Figure 63. Service Brake Control Valve.
Figure 64. 3,600 psi (25,000 kPa) Gauge Assembly.
POWERTRAIN TESTS, INSPECTIONS, AND ADJUSTMENTS
Figure 1. Transmission - Basic Status Parameter List.
Figure 2. Service Menu Selection.
Figure 3. Transmission Fill Calibration Selection.
Figure 4. Set Up Test Conditions.
Figure 5. Calibration Initializing.
Figure 6. Calibrating Clutch #6.
Figure 8. Calibrating Clutch #2.
Figure 10. Calibrating Clutch #4.
Figure 12. Calibrating Successful.
Figure 13. Calibrating Successful.
CHAPTER 3. PMCS MAINTENANCE INSTRUCTIONS
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES
GENERAL PMCS PROCEDURES CONTINUED
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions
Table 1. Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions - Continued.
GENERAL LUBRICATION INSTRUCTIONS
Table 2. Refill Capacities.
Table 3. Lubricant Type and Temperature.
CHAPTER 4. MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
INSPECTION INSTRUCTIONS
USING JACK STANDS TO SUPPORT MACHINE
Figure 1. Front Support.
REAR MACHINE SUPPORT INSTALLATION
Figure 3. Rear Support.
Figure 4. Front Support.
MECHANICAL GENERAL MAINTENANCE INSTRUCTIONS
RELIEVE HYDRAULIC SYSTEM PRESSURE
GENERAL INFORMATION
CLEANING INSTRUCTIONS
Air Cleaner and Filter Cleaning.
External Engine Cleaning.
CLEANING HOSES, TUBES, AND FITTINGS
INSPECTION INSTRUCTIONS
INSPECTION INSTRUCTIONS CONTINUED
STANDARD TOOL REQUIREMENTS
TAGGING INSTRUCTIONS
HYDRAULIC HOSE GENERAL MAINTENANCE INSTRUCTIONS
RELIEVE HYDRAULIC SYSTEM PRESSURE
CLEANING HOSES, TUBES, AND FITTINGS
HYDRAULIC HOSE REPAIR INSTRUCTIONS
Figure 1. Fittings and Clamps.
FLUID DISPOSAL
Table 1. 924H Hydraulic Hose Index
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
Table 1. 924H Hydraulic Hose Index - Continued.
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS
Figure 1. Single Press Tab Connector.
Figure 2. Double Press Tab Connector (12-Pin).
Figure 3. Connector With Locking Clip.
Figure 4. Double Press Tab Connector (Eight-Pin).
Figure 5. Single Press Tab Connector (Triangular).
Figure 6. Pull Tab Connector.
Figure 7. Threaded Fastener Connector.
Figure 9. Cannon Plug.
WIRING HARNESS AND WIRING HARNESS CONNECTOR INSPECTION
WIRING HARNESS AND WIRING HARNESS CONNECTOR INSPECTION CONTINUED
WIRING HARNESS OPEN CIRCUIT TEST
Figure 10. Splicing Wires.
HEAT-SHRINKABLE TUBING (ELECTRICAL INSULATING SLEEVING)
Figure 12. Military Connector Repair.
Figure 13. Weatherproof Connector - Female.
Figure 14. Female Terminal.
Figure 16. Weatherproof Connector - Male.
Figure 17. Male Terminal.
ELECTRICAL GROUND POINTS
Measuring DC Voltage.
Figure 19. Ammeter.
CIRCUIT BREAKER INSPECTION AND TESTING
PREPARATION FOR TRANSPORT
ROADING MACHINE (SELF-DEPLOYMENT)
HIGHWAY AND RAIL TRANSPORT
HIGHWAY AND RAIL TRANSPORT CONTINUED
Figure 1. Tiedown Locations.
Unloading Machine from Transport
HIGHWAY AND RAIL TRANSPORT CONTINUED
MARINE TRANSPORT
MARINE TRANSPORT CONTINUED
RO/RO Unloading Procedures
AIR TRANSPORT
AIR TRANSPORT CONTINUED
AIR TRANSPORT CONTINUED
Figure 2. Half Counterweight Removal Tool.
Figure 3. Counterweight Removal Tool Adapter.
Figure 4. Counterweight Removal Tool Bracket Link.
Figure 5. Counterweight Removal Tool Pin.
COUNTERWEIGHT REMOVAL
Figure 7. Rear Counterweights.
Side Counterweight Removal
Figure 8. Side Counterweight.
Figure 9. Counterweights.
COUNTERWEIGHT INSTALLATION CONTINUED
Figure 10. Side Counterweight.
Figure 11. Rear Counterweights.
TORQUE LIMITS
Figure 1. Extension Measurement.
Figure 4. Measuring a Bolt.
Table 1. Torque Limits SAE Standard Fasteners.
Table 2. Torque Limits Metric Fasteners.
Table 3. 37-Degree Flare Fitting.
Table 4. Straight Thread With O-ring.
Table 6. O-ring Face Seal End.
Table 8. Pipe Fitting.
POWERPACK REPLACEMENT
Figure 1. Left Hydraulic Tank Support Bracket.
Figure 3. Right Hydraulic Tank Support Bracket.
Figure 4. Right Hydraulic Tank Support Bracket.
Figure 5. Left Hydraulic Tank Support Bracket.
Figure 6. Manifold Assembly.
Figure 7. Hoses.
Figure 8. Steering Manifold.
Figure 9. Implement Pump.
Figure 10. Implement and Steering Pump Assembly.
Figure 11. Implement and Steering Pump Assembly.
Figure 13. Transmission Pump Hose.
Figure 15. Steering Manifold.
Figure 16. Steering Manifold.
Figure 17. Steering Manifold and Solenoid Valve.
Figure 18. Steering Manifold.
Figure 19. Manifold.
Figure 20. Solenoid Valve.
Figure 21. Hoses.
Figure 22. Manifold.
Figure 23. Hose.
Figure 24. Quick Coupler Solenoid Valve.
Figure 25. Transmission Fill Tube.
Figure 26. Transmission Fill Tube.
Figure 27. Implement Control Valve.
Figure 28. Implement Control Valve.
Figure 29. Bracket and Tube Assembly.
Figure 30. Bracket and Tube Assembly.
Figure 31. Bracket.
Figure 33. Transmission Filter Base.
Figure 34. Transmission Filter Base.
Figure 35. Driveshaft.
Figure 37. Brake and Fan Pump.
Figure 38. Fuel Hose.
Figure 39. Engine Wiring Harness.
Figure 40. Fuel Line.
Figure 41. Bracket.
Figure 42. Hose.
Figure 43. Hoses.
Figure 45. A/C Compressor.
Figure 46. Starter.
Figure 49. Starter.
Figure 50. Driveshaft.
Figure 51. Bracket Link.
Figure 52. Line and Fittings.
Figure 53. Chain Hoists.
Figure 54. Left Engine Mount Bracket.
Figure 55. Left Transmission Mount Bracket.
REMOVAL CONTINUED
Figure 56. Left Transmission Mount Bracket.
Figure 57. Powerpack Assembly.
Figure 59. Chain Hoists.
Figure 60. Engine Mounts.
Figure 61. Left Transmission Mount Bracket.
Figure 62. Left Transmission Mount Bracket.
Figure 63. Left Engine Mount Bracket.
Figure 64. Bracket Link.
Figure 65. Line and Fittings.
Figure 66. Driveshaft.
Figure 67. Starter.
Figure 69. Starter.
Figure 71. A/C Compressor.
Figure 72. Drive Belt.
Figure 73. Hoses.
Figure 75. Bracket.
Figure 76. Fuel Line.
Figure 77. Engine Wiring Harness.
Figure 78. Fuel Hose.
Figure 79. Brake and Fan Pump.
Figure 80. Park Brake Bracket.
Figure 81. Driveshaft.
Figure 82. Transmission Filter Base.
Figure 83. Transmission Filter Base.
Figure 84. Implement Control Valve.
Figure 86. Bracket and Tube Assembly.
Figure 87. Bracket and Tube Assembly.
Figure 88. Implement Control Valve.
Figure 89. Implement Control Valve.
Figure 90. Transmission Fill Tube.
Figure 91. Transmission Fill Tube.
Figure 92. Quick Coupler Solenoid Valve.
Figure 93. Hose.
Figure 95. Hoses.
Figure 96. Implement and Steering Pump Assembly.
Figure 97. Implement and Steering Pump Assembly.
Figure 98. Steering Manifold.
Figure 99. Manifold.
Figure 100. Solenoid Valve.
Figure 101. Solenoid Valve.
Figure 102. Steering Manifold.
Figure 103. Steering Manifold.
Figure 104. Steering Manifold.
Figure 105. Steering Manifold.
Figure 106. Steering Manifold.
Figure 107. Implement and Steering Pump Hoses.
Figure 108. Steering Manifold.
Figure 109. Secondary Steering Relief Valve.
Figure 111. Manifold Assembly.
Figure 112. Left Hydraulic Tank Support Bracket.
Figure 113. Right Hydraulic Tank Support Bracket.
Figure 114. Right Hydraulic Tank Support Bracket.
Figure 115. Right Hydraulic Tank Support Bracket.
Figure 116. Left Hydraulic Tank Support Bracket.
ENGINE ASSEMBLY REPLACEMENT
Figure 1. Starter Cables.
Figure 2. Starter.
Figure 4. Alternator.
Figure 6. Engine Wiring Harness.
Figure 7. Exhaust Manifold.
Figure 8. Exhaust Manifold and Turbocharger Assembly.
Figure 9. Wastegate Solenoid.
Figure 10. Engine Stand Adapter.
Figure 11. Engine on Stand.
Figure 12. Coolant Hoses.
Figure 13. Coolant Hoses.
Figure 14. Fuel Filter Assembly.
Figure 15. Oil Sampling Hose.
Figure 16. Engine Wiring Harness.
Figure 17. Engine Wiring Harness.
Figure 18. Engine Wiring Harness.
Figure 19. Engine Wiring Harness.
Figure 21. Brake Pump.
Figure 23. Alternator.
Figure 25. Muffler Bracket.
Figure 27. Left Motor Mount Bracket.
Figure 28. Left Motor Mount Bracket.
Figure 30. Muffler Bracket.
Figure 32. Alternator.
Figure 34. Brake Pump.
Figure 36. Engine Wiring Harness.
Figure 37. Engine Wiring Harness.
Figure 38. Engine Wiring Harness.
Figure 39. Engine Wiring Harness.
Figure 40. Oil Sampling Hose.
Figure 41. Fuel Filter Assembly.
Figure 42. Coolant Hoses.
Figure 44. Engine on Stand.
Figure 45. Engine Stand Adapter.
Figure 46. Wastegate Solenoid.
Figure 47. Exhaust Manifold and Turbocharger Assembly.
Figure 49. Exhaust Manifold.
Figure 50. Engine Wiring Harness.
Figure 51. Alternator.
Figure 53. Starter.
Figure 55. Starter Cables.
ENGINE MOUNT REPLACEMENT
Figure 1. Tube.
Figure 2. A/C Compressor.
Figure 3. Engine Lifting Device and Top Engine Mounts.
Figure 4. Engine Mount Brackets.
Figure 5. Lower Engine Mounts.
Figure 6. Engine Mount Brackets.
Figure 7. Engine Lifting Device and Top Engine Mounts.
Figure 8. A/C Compressor.
Figure 9. Tube.
CYLINDER HEAD REPLACEMENT
Figure 1. Rear of Engine.
Figure 2. Tubes and Fittings.
Figure 3. Glow Plugs.
Figure 4. Heater Hose and Bypass Tube.
Figure 5. Front of Engine.
Figure 6. Cylinder Head Bolt Loosening Sequence.
REMOVAL CONTINUED
Figure 7. Cylinder Head Lifting Device.
Figure 8. Muffler Bracket.
Figure 10. Cylinder Head Flatness Test.
Figure 11. Muffler Bracket.
Figure 13. Cylinder Head Lifting Device.
Figure 14. Cylinder Head Bolt Tightening Sequence.
Figure 15. Front of Engine.
Figure 16. Heater Hose and Bypass Tube.
Figure 17. Glow Plugs.
Figure 18. Tubes and Fittings.
Figure 19. Rear of Engine.
REAR HOUSING CRANKSHAFT SEAL ASSEMBLY REPLACEMENT
Figure 1. Rear Housing Crankshaft Seal Assembly and Retaining Hardware.
INSTALLATION
Figure 3. Rear Housing Crankshaft Seal Assembly and Retaining Hardware.
PULLEY, HUB, AND DAMPER REPLACEMENT
Figure 2. Damper and Crankshaft Pulley.
Figure 3. Damper Bolts.
FRONT CRANKSHAFT OIL SEAL REPLACEMENT
Figure 1. Engine Front Crankshaft Oil Seal Remover.
Figure 2. Front Seal and Protector.
Figure 3. Engine Front Crankshaft Oil Seal.
FLYWHEEL ASSEMBLY REPLACEMENT
Figure 1. Flywheel Bolts.
Figure 2. Flywheel.
Figure 3. Guide Studs.
Figure 4. Guide Studs.
Figure 5. Flywheel.
Figure 6. Torquing Flywheel Retaining Bolts.
FLYWHEEL HOUSING REPLACEMENT
Figure 2. Bracket.
Figure 3. Bolts.
Figure 4. Bolts.
Figure 5. Bolts.
INSTALLATION CONTINUED
Figure 8. P-Clamp.
INSTALLATION CONTINUED
ROCKER ASSEMBLY SERVICE
Figure 1. Rocker Shaft Replacement.
Figure 2. Valve Bridge Replacement.
INSTALLATION
Figure 3. Rocker Shaft Replacement.
Figure 4. Crankshaft Turning Tool.
Figure 5. Inlet/Exhaust Valve Arrangement.
Figure 6. Valve Lash Adjustment.
Figure 7. Crankshaft Turning Tool.
VALVE COVER, GASKET, AND BASE REPLACEMENT
Figure 2. Valve Cover.
Figure 3. Valve Cover Gasket.
Figure 4. Fuel Injector Harness.
Figure 5. Valve Cover Base.
Figure 6. Fuel Injector Harness.
Figure 7. Valve Cover Gasket.
Figure 8. Valve Cover.
VALVE COVER, GASKET, AND BASE REPLACEMENT - Continued
FRONT COVER REPLACEMENT
Figure 2. Front Cover Replacement.
CRANKCASE BREATHER FILTER AND BASE REPLACEMENT
CRANKCASE BREATHER FILTER REMOVAL
Figure 1. Engine Crankcase Breather Filter and Base.
CLEANING AND INSPECTION
Figure 2. Engine Crankcase Breather Filter and Base.
OIL PUMP REPLACEMENT
Figure 2. Oil Pump.
ENGINE OIL SERVICE
Figure 2. Engine Oil Drain Hoses.
Figure 3. Oil Filter Drain Valve.
Figure 4. Engine Oil Filter.
Figure 5. Oil Filter Drain Valve.
Figure 6. Engine Oil Drain Hoses.
Figure 8. Engine Access Plate.
ENGINE OIL FILTER BASE AND OIL COOLER REPLACEMENT
Figure 1. Oil Filter Base Drain.
Figure 2. Oil Filter Base.
Figure 3. Fuel Injection Pump.
Figure 4. Fuel Line.
Figure 5. Engine Control Harness.
Figure 6. Engine Oil Cooler.
Figure 7. Engine Oil Cooler Base.
Figure 8. Engine Oil Cooler.
Figure 9. Engine Control Harness.
Figure 10. Fuel Line.
Figure 11. Fuel Injection Pump.
Figure 12. Oil Filter Base.
Figure 13. Oil Filter Base Drain.
OIL FILLER ASSEMBLY REPLACEMENT
Figure 1. Oil Fill Assembly.
CLEANING AND INSPECTION
ENGINE OIL LEVEL GAUGE REPLACEMENT
REMOVAL
CLEANING AND INSPECTION
OIL PAN REPLACEMENT
Figure 1. Oil Level Gauge Tube.
Figure 2. Oil Pan Drain Valve.
Figure 3. Oil Pan.
Figure 4. Oil Pan Adapter.
Figure 5. Oil Pan Adapter.
Figure 6. Oil Pan.
Figure 7. Oil Pan Drain Valve.
Figure 8. Oil Level Gauge Tube.
INLET MANIFOLD REPLACEMENT
Figure 1. Secondary Fuel Filter Base.
Figure 2. Bracket.
Figure 4. Engine Control Wiring Harness.
Figure 5. Inlet Manifold Bolts and Inlet Manifold.
Figure 6. Inlet Manifold.
Figure 7. Inlet Manifold Bolts and Inlet Manifold.
Figure 9. Engine Control Wiring Harness.
Figure 10. Intake Tube and Fuel Line Bracket.
Figure 12. Secondary Fuel Filter Base.
EXHAUST MANIFOLD REPLACEMENT
Figure 2. Gaskets, Exhaust Manifold, Spacers, and Bolts.
Figure 3. Torque Sequence.
FUEL INJECTOR REPLACEMENT SINGLE INJECTOR
REMOVAL
Figure 1. Valve Link Replacement.
Figure 2. Fuel Injector Fuel Line Replacement.
Figure 3. Fuel Injector Electrical Connection Replacement.
Figure 4. Fuel Injector Removal.
Figure 6. Fuel Injector Code.
Figure 7. Fuel Injector Seals.
Figure 8. Fuel Injector Installation.
Figure 9. Fuel Injector Fuel Line Replacement.
Figure 10. Valve Bridge Replacement.
FUEL INJECTOR REPLACEMENT ALL INJECTORS
REMOVAL
Figure 1. Fuel Injector Fuel Line Replacement.
Figure 2. Fuel Injector Electrical Connection Replacement.
Figure 3. Fuel Injector Removal.
Figure 5. Fuel Injector Code.
Figure 6. Fuel Injector Seals.
Figure 7. Fuel Injector Installation.
Figure 8. Fuel Injector Fuel Line Replacement.
FUEL PRIME PUMP AND BASE ASSEMBLY REPLACEMENT
Figure 2. Fuel Prime Pump Toggle Switch and Bracket.
Figure 3. Fuel Prime Pump Toggle Switch.
FUEL PRIME PUMP AND BASE REMOVAL
Figure 4. Clamps and Hoses.
Figure 5. Elbow Fittings and Adapter at Fuel Prime Pump and Base.
Figure 6. Fuel Prime Pump and Base.
Figure 7. Fuel Prime Pump and Base Isolation Mounts.
Figure 8. Fuel Prime Pump and Base.
Figure 9. Elbow Fittings and Adapter at Fuel Prime Pump and Base.
Figure 10. Clamps and Hoses.
Figure 11. Fuel Prime Pump Toggle Switch.
Figure 12. Fuel Prime Pump Toggle Switch and Bracket.
FOLLOW-ON TASKS
HIGH-PRESSURE FUEL INJECTION TUBE REPLACEMENT
Figure 1. Crankcase Breather Filter.
Figure 3. Fuel Injection Pump.
Figure 4. High-pressure Fuel Injection Inlet Tube.
Figure 5. High-pressure Fuel Injection Inlet Tube Clamps.
HIGH-PRESSURE FUEL INJECTOR TUBES REMOVAL
Figure 6. Fuel Injector Tubes.
Figure 7. Fuel Injector Tubes.
HIGH-PRESSURE FUEL INJECTOR TUBES INSTALLATION
Figure 8. Fuel Injector Tubes.
Figure 9. High-pressure Fuel Injection Inlet Tube Clamps.
Figure 10. High-pressure Fuel Injection Inlet Tube.
Figure 11. Fuel Injection Pump.
Figure 13. Crankcase Breather Filter.
SECONDARY FUEL LINE REPLACEMENT
REMOVAL
Figure 1. Fuel Line Assembly.
Figure 3. Fuel Line Assembly.
Figure 4. Fuel Line Assembly.
Figure 5. Fuel Line.
Figure 7. Fuel Line.
Figure 8. Fuel Line.
Figure 9. Fuel Line.
Figure 11. Fuel Line Assembly.
Figure 12. Fuel Line Assembly.
Figure 13. Crankcase Breather Filter.
Figure 14. Fuel Line Assembly.
FUEL INJECTION PUMP AND GEAR REPLACEMENT
Figure 1. Aftercooler Pipe.
Figure 2. Crankshaft Timing Pin.
Figure 3. Camshaft Timing Pin.
Figure 4. Fuel Injection Pump Lock.
Figure 5. Puller Assembly.
Figure 6. Fuel Injection Pump Gear.
Figure 7. Engine Control Wiring Harness Connectors.
Figure 9. Fuel Tube.
Figure 10. Engine Control Wiring Harness.
Figure 11. Fuel Line.
Figure 12. Secondary Fuel Filter Base.
Figure 13. Fuel Line Clamps.
Figure 14. Fuel Injection Pump Mount.
Figure 15. Fuel Injection Pump Lost Timing.
Figure 16. Fuel Injection Pump Mount.
Figure 17. Secondary Fuel Filter Base.
Figure 18. Fuel Line Clamps.
Figure 20. Engine Control Wiring Harness.
Figure 21. Fuel Tube.
Figure 23. Engine Control Wiring Harness Connectors.
Figure 24. Fuel Injection Pump Gear.
Figure 25. Puller Assembly.
Figure 26. Fuel Injection Pump Lock.
Figure 27. Camshaft Timing Pin.
Figure 28. Crankshaft Timing Pin.
Figure 30. Fuel Injection Pump Gear.
AIR CLEANER HOUSING AND FILTER ELEMENT REPLACEMENT
Figure 1. Air Cleaner Housing Cover.
Figure 2. Primary Air Filter Element.
Figure 3. Secondary Air Filter Element.
Figure 4. Hose Clamps.
Figure 5. Air Cleaner Housing.
Figure 6. Air Cleaner Housing Inlet Hose.
Figure 7. Turbocharger.
Figure 8. Air Cleaner Housing Outlet Assembly.
Figure 9. Air Cleaner Housing Mounting Bracket.
CLEANING AND INSPECTION CONTINUED
Figure 10. Air Cleaner Housing Mounting Bracket.
Figure 11. Air Cleaner Housing Outlet Assembly.
Figure 13. Air Cleaner Housing Inlet Hose.
Figure 14. Air Cleaner Housing.
Figure 15. Hose Clamps.
Figure 16. Secondary Air Filter.
Figure 17. Primary Air Filter.
Figure 19. Turbocharger Hose Clamps.
PRECLEANER REPLACEMENT
Figure 1. Precleaner.
AIR INLET RESTRICTION SWITCH REPLACEMENT
Figure 2. Air Inlet Switch Harness Connector.
Figure 3. Air Inlet Restriction Switch.
Figure 4. Air Inlet Restriction Switch Hose.
AFTERCOOLER AND HOSE REPLACEMENT
Figure 1. Clamps and Hoses.
Figure 2. Bolts, Washers, and Tube.
Figure 3. Bolts, Washers, Hoses, and Tube.
Figure 4. Clamps, Hoses, and Tube.
Figure 5. Aftercooler Bolts, Nuts, and Washers.
Figure 6. Insulator.
Figure 7. Aftercooler Bolts, Nuts, Washers, and Spacer.
Figure 8. Aftercooler.
Figure 9. Aftercooler.
Figure 10. Aftercooler Bolts, Nuts, Washers, and Spacer.
Figure 11. Aftercooler Bolts, Nuts, and Washers.
Figure 12. Insulator.
Figure 13. Clamps, Hoses, and Tube.
Figure 14. Bolts, Washers, Hoses, and Tube.
Figure 15. Bolts, Washers, and Tube.
Figure 16. Clamps and Hoses.
TURBOCHARGER AND OIL LINE REPLACEMENT
REMOVAL
Figure 1. Muffler, Clamp, and Fasteners.
Figure 2. Support Muffler.
Figure 3. Support Tube.
Figure 4. Hoses.
Figure 5. Exhaust Elbow.
Figure 6. Supply Oil Line.
Figure 7. Drain Oil Line.
Figure 8. Wastegate Solenoid Hose.
Figure 9. Turbocharger.
Figure 10. Turbocharger.
Figure 11. Wastegate Solenoid Hose.
Figure 12. Drain Oil Line.
Figure 13. Supply Oil Line.
Figure 14. Exhaust Elbow.
Figure 16. Support Tube.
Figure 17. Support Muffler.
Figure 18. Muffler, Clamp, and Fasteners.
WASTEGATE SOLENOID REPLACEMENT
Figure 1. Wastegate Solenoid Wiring Harness Connector.
Figure 2. Wastegate Solenoid Wiring Harness and Clips.
Figure 3. Wastegate Solenoid.
Figure 4. Fitting and Adapter.
Figure 5. Wastegate Solenoid Tube Assembly (Exhaust Elbow Removed for Clarity).
Figure 7. Wastegate Solenoid Tube Assembly (Exhaust Elbow Removed for Clarity).
Figure 8. Fitting and Adapter.
Figure 9. Wastegate Solenoid.
Figure 11. Wastegate Solenoid Wiring Harness Connector.
PRIMARY FUEL LINE REPLACEMENT
Figure 2. Sending Unit.
Figure 3. Primary Fuel Filter Supply Hose.
Figure 4. Rubber Panel.
Figure 5. Fuel Injection Pump Supply Hose.
Figure 6. Fuel Injection Pump Supply Hose.
Figure 7. Fuel Return Hose to Cooler.
Figure 8. Fuel Return Hose to Cooler.
Figure 10. Fuel Return Hose to Cooler.
Figure 12. Fuel Return Hose to Cooler.
Figure 13. Rubber Panel.
FUEL RETURN HOSE TO FUEL TANK REMOVAL CONTINUED
Figure 14. Fuel Return Hose to Fuel Tank.
Figure 15. Fuel Return Hose to Fuel Tank.
Figure 16. Fuel Return Hose to Fuel Tank.
Figure 17. Fuel Return Hose to Fuel Tank.
Figure 18. Rubber Panel.
Figure 19. Fuel Return Hose to Cooler.
Figure 20. Rubber Panel.
Figure 22. Fuel Return Hose to Cooler.
Figure 24. Fuel Return Hose to Cooler.
Figure 25. Fuel Injection Pump Supply Hose.
Figure 26. Fuel Injection Pump Supply Hose.
Figure 27. Rubber Plate.
Figure 28. Primary Fuel Filter Supply Hose.
Figure 29. Sending Unit.
PRIMARY FUEL LINE REPLACEMENT - Continued
FUEL RAIL REPLACEMENT
REMOVAL
Figure 1. Fuel Line.
Figure 3. Fuel Rail.
Figure 4. Fuel Line.
INJECTOR CYLINDER 5 AND 6 JUMPER HARNESS REPLACEMENT
Figure 1. Injector Cylinder 5 and 6 Jumper Harness.
CLEANING AND INSPECTION
INJECTOR CYLINDER 3 AND 4 JUMPER HARNESS REPLACEMENT
Figure 1. Injector Cylinder 3 and 4 Jumper Harness.
CLEANING AND INSPECTION
INJECTOR CYLINDER 1 AND 2 JUMPER HARNESS REPLACEMENT
Figure 1. Injector Cylinder 1 and 2 Jumper Harness.
CLEANING AND INSPECTION
FUEL PRESSURE RELIEF VALVE REPLACEMENT
Figure 1. Fuel Pressure Relief Valve.
CLEANING AND INSPECTION
DRAIN FUEL TANK
Figure 1. Fuel Tank Bottom Guard.
Figure 2. Fuel Tank Drain Plug.
FUEL TANK REPLACEMENT
Figure 1. Aftercooler Pipe.
Figure 2. Fuel Cooler Hoses.
Figure 3. Battery Cables.
Figure 4. Fuel Tank Strap Access Panel.
Figure 5. Fuel Tank Strap Tension Bolt.
Figure 6. Fuel Tank Strap Access Panel.
Figure 8. Fuel Tank and Straps.
Figure 9. Fuel Sending Unit.
Figure 10. Fuel Sending Unit.
Figure 11. Fuel Tank and Straps.
Figure 12. Fuel Tank Strap Tension Bolt.
Figure 14. Fuel Tank Strap Tension Bolt.
Figure 15. Fuel Tank Strap Access Panel.
Figure 16. Battery Cables.
Figure 17. Fuel Cooler Hoses.
Figure 18. Aftercooler Pipe.
FUEL COOLER REPLACEMENT
REMOVAL
Figure 1. Fuel Cooler Bottom Bracket.
Figure 2. Fuel Cooler Bracket.
Figure 3. Fuel Cooler Bracket.
Figure 4. Fuel Cooler Bottom Bracket.
PRIMARY FUEL FILTER ASSEMBLY REPLACEMENT
REMOVAL
Figure 1. Primary Fuel Filter and Base.
CLEANING AND INSPECTION
Figure 2. Primary Fuel Filter and Base.
SECONDARY FUEL FILTER ASSEMBLY REPLACEMENT
Figure 1. Secondary Fuel Filter and Base.
CLEANING AND INSPECTION
SECONDARY FUEL FILTER BASE REPLACEMENT
Figure 1. Secondary Fuel Filter Base.
Figure 2. Bracket.
Figure 3. Bracket.
Figure 4. Secondary Fuel Filter Base.
FOLLOW-ON TASKS
THIRD FUEL FILTER ASSEMBLY REPLACEMENT
REMOVAL
Figure 1. Third Fuel Filter and Base.
THIRD FUEL FILTER ASSEMBLY REPLACEMENT - Continued
THIRD FUEL FILTER BASE REPLACEMENT
Figure 1. Third Fuel Filter.
Figure 2. Third Fuel Filter Base and Hoses.
Figure 3. Third Fuel Filter Base Elbow Fittings and Adapter.
Figure 4. Third Fuel Filter Base.
Figure 5. Bracket.
Figure 6. Fuel Hose.
Figure 7. ECM.
Figure 8. ECM.
Figure 9. Fuel Hose.
Figure 10. Bracket.
Figure 11. Third Fuel Filter Base.
Figure 12. Third Fuel Filter Base Elbow Adapters and Adapter.
Figure 13. Third Fuel Filter Base and Hoses.
Figure 14. Third Fuel Filter.
ETHER VALVE REPLACEMENT
Figure 1. Ether Bottle.
Figure 2. Ether Line.
ETHER VALVE AND BRACKET REMOVAL
Figure 4. Valve and Bracket.
Figure 5. Valve and Bracket.
Figure 6. Ether Bottle.
Figure 7. Ether Line.
Figure 8. Ether Bottle.
ETHER VALVE REPLACEMENT - Continued
GLOW PLUG REPLACEMENT
Figure 2. Glow Plugs.
Figure 3. Cable Terminals.
PEDAL/GOVERNOR ASSEMBLY REPLACEMENT
Figure 1. Throttle Position Sensor Jumper Harness.
Figure 2. Governor Pedal.
Figure 4. Throttle Position Sensor.
Figure 5. Throttle Position Sensor.
Figure 6. Spacer.
Figure 8. Throttle Position Sensor Jumper Harness.
MUFFLER AND EXHAUST ELBOW REPLACEMENT
Figure 1. Exhaust Pipe.
Figure 2. Support and Plate.
Figure 3. Clamp and Support Bracket.
Figure 4. Elbow.
Figure 5. Elbow Adapter.
Figure 6. Elbow Adapter.
Figure 7. Elbow.
Figure 8. Clamp and Support Bracket.
Figure 9. Support and Plate.
Figure 10. Exhaust Pipe.
ENGINE COOLANT SERVICE
Figure 2. Plate.
Figure 3. Coolant Drain Valve.
Figure 4. Flushing.
Figure 5. Plate.
Figure 6. Cover.
Figure 7. Coolant Tank.
ENGINE COOLANT SERVICE - Continued
RADIATOR REPLACEMENT
Figure 1. Radiator Access Plate.
Figure 2. Lower Radiator Hoses.
Figure 3. Upper Radiator Hose.
Figure 5. Radiator Mounting Plate.
Figure 6. Radiator.
Figure 7. Isolators.
Figure 8. Isolators.
Figure 9. Radiator.
Figure 10. Radiator Mounting Plate.
Figure 11. Drain Hose.
Figure 13. Lower Radiator Hoses.
COOLANT TANK AND HOSE REPLACEMENT
Figure 1. Clamps and Hoses at Coolant Tank.
Figure 2. Coolant Tank.
Figure 3. Bolts and Washers at Coolant Tank.
Figure 4. Overflow Hose.
COOLANT TANK OVERFLOW HOSE REMOVAL CONTINUED
Figure 5. Overflow Hose Clips and Spacer.
Figure 6. Radiator Inlet Hoses Clamps and Tiedown Strap.
Figure 7. Radiator Inlet Hoses Clips and Spacer.
Figure 8. Radiator Inlet Hoses and Tee Fitting.
Figure 9. Radiator Inlet Hose.
RADIATOR OVERFLOW HOSE REMOVAL
Figure 10. Radiator Overflow Hose at Coolant Tank.
Figure 11. Radiator Overflow Hose.
Figure 12. Radiator Overflow Hose.
Figure 13. Radiator Overflow Hose at Coolant Tank.
Figure 14. Radiator Inlet Hose.
Figure 15. Radiator Inlet Hoses and Tee Fitting.
Figure 16. Radiator Inlet Hoses Clips and Spacer.
Figure 17. Radiator Inlet Hoses Clamps and Tiedown Strap.
Figure 18. Overflow Hose Clips and Spacer.
Figure 19. Overflow Hose.
Figure 20. Bolts and Washers at Coolant Tank.
Figure 21. Coolant Tank.
Figure 22. Clamps and Hoses at Coolant Tank.
UPPER AND LOWER RADIATOR HOSE REPLACEMENT
UPPER RADIATOR HOSE REMOVAL
Figure 1. Upper Radiator Hoses.
Figure 2. Cover Plate.
Figure 3. Lower Radiator Hose.
Figure 4. Lower Radiator Hose.
Figure 5. Cover Plate.
Figure 6. Upper Radiator Hoses.
WATER TEMPERATURE REGULATOR REPLACEMENT
Figure 1. Water Temperature Regulator.
Figure 2. Test Port.
Figure 3. Test Port.
Figure 4. Water Temperature Regulator.
WATER PUMP REPLACEMENT
Figure 1. Hub.
Figure 2. Water Pump Inlet Hose.
Figure 3. Water Pump.
Figure 4. Guide Stud.
Figure 5. Water Pump.
Figure 6. Water Pump Guide Studs.
Figure 7. Water Pump Bolt Torque Sequence.
Figure 9. Hub.
WATER PUMP REPLACEMENT - Continued
FAN, GEAR MOTOR, AND FAN SUPPORT REPLACEMENT
Figure 2. Fan.
Figure 3. Camera.
Figure 4. Gear Motor.
Figure 5. Gear Motor Fittings.
Figure 6. Exterior Fan Guard.
Figure 7. Fan Support.
Figure 8. Fan Support.
Figure 9. Exterior Fan Guard.
Figure 10. Gear Motor Fittings.
Figure 11. Gear Motor.
Figure 12. Camera.
Figure 13. Fan.
FAN, GEAR MOTOR, AND FAN SUPPORT REPLACEMENT - Continued
HYDRAULIC COOLING FAN GEAR PUMP REPLACEMENT
Figure 2. Heater Hose Bracket.
Figure 3. Hoses.
Figure 4. Brake Charging Oil Pressure Sensor.
Figure 5. Tube Nut, Hose, and O-ring.
Figure 6. Large Tube Nut, Hose, and O-ring.
Figure 7. Hydraulic Cooling Fan Gear Pump Bolt and Washer.
Figure 9. Hydraulic Cooling Fan Gear Pump Fittings.
Figure 10. Hydraulic Cooling Fan Gear Pump Bolts and Washers.
Figure 11. Hydraulic Cooling Fan Gear Pump Bolt and Washer.
Figure 13. Tube Nut, Hose, and O-ring.
Figure 14. Brake Charging Oil Pressure Sensor.
Figure 15. Hoses.
Figure 16. Heater Hose Bracket.
Figure 17. Engine Access Plate.
SERVICE BRAKE CHARGING OIL PRESSURE SENSOR REPLACEMENT
Figure 1. Service Brake Charging Oil Pressure Sensor.
INSTALLATION

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