TRANSMISSION ASSEMBLY MAINTENANCE... WP 0135 Figure 1. Transmission Sensors Removal... 0135-3 Figure 2. Transmission Hoses Removal... 0135-4 Figure 3. Transmission Oil Fill Tube Removal... 0135-5 Figure 4. Flywheel Housing Access Cover... 0135-5
Figure 5. Flywheel-to-Damper Plate Access Cover Removal... 0135-6 Figure 6. Damper Plates-to-Flywheel Screw Removal... 0135-7 Figure 7. Flywheel Housing Screws Removal... 0135-7 Figure 8. Transmission-to-Mounting Bracket Removal... 0135-8 Figure 9. Electrical Connectors Removal... 0135-9 Figure 10. Transmission Sensors Installation... 0135-10 Figure 11. Transmission-to-Mounting Bracket Screws Installation... 0135-12 Figure 12. Flywheel-to-Damper Plate Screw Installation... 0135-13 Figure 13. Flywheel Housing Screws Installation... 0135-13 Figure 14. Transmission-to-Mounting Bracket Screws Installation... 0135-14 Figure 15. Flywheel Housing Access Cover Installation... 0135-15 Figure 16. Flywheel-to-Damper Plate Access Cover Installation... 0135-15 Figure 17. Transmission Oil Fill Tube Installation... 0135-16 Figure 18. Transmission Hoses Installation... 0135-17 Figure 19. Transmission Electrical Connectors... 0135-18 TRANSMISSION CALIBRATION... WP 0136 Figure 1. Calibration... 0136-2 Figure 2. Calibration... 0136-3 Table 1. Main Transmission Calibration Codes... 0136-4 Table 2. Sub Transmission Calibration Codes... 0136-5 TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT... WP 0137 Figure 1. Transmission Assembly Hose and Pipe Location Diagram... 0137-2 Figure 2. Transmission Hose and Pipe Location... 0137-3 TRANSMISSION OIL DIPSTICK HOSE AND PIPE REPLACEMENT... WP 0138 Figure 1. Transmission Oil Dipstick Hose and Pipe Replacement... 0138-3 TRANSMISSION TORQUE CONVERTER REPLACEMENT... WP 0139 Figure 1. Damper Plates Removal... 0139-1
Figure 2. Torque Converter Removal... 0139-3 TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD MAINTENANCE... WP 0140 Figure 1. Transmission Oil Draining and Filling... 0140-3 Figure 2. Transmission Oil Filters Replacement... 0140-5 Figure 3. Transmission Oil Filter Head Replacement... 0140-6 Figure 4. Transmission Oil Filter Head Replacement... 0140-7 Figure 5. Transmission Internal Coarse Oil Filter Removal... 0140-8 Figure 6. Transmission Internal Coarse Oil Filter Installation... 0140-10 TRANSMISSION OIL COOLER REPLACEMENT... WP 0141 Figure 1. Transmission Oil Coolers Removal... 0141-2 Figure 2. Transmission Oil Coolers Removal... 0141-3 Figure 3. Transmission Oil Coolers Removal... 0141-4 Figure 4. Transmission Oil Coolers Removal... 0141-5 Figure 5. Transmission Oil Coolers Installation... 0141-6 Figure 6. Transmission Oil Coolers Installation... 0141-7 Figure 7. Transmission Oil Coolers Installation... 0141-8 TRANSMISSION OIL FILTER HOSES AND OIL COOLER HOSES AND FITTINGS
REPLACEMENT... WP 0142 Figure 1. Transmission-to-Oil Cooler Hoses Replacement... 0142-3 Figure 2. Transmission-to-Oil Filter Hose Replacement. ... 0142-5 FRONT AND REAR PROPELLER SHAFTS REPLACEMENT... WP 0143 Figure 1. Front Propeller Shaft Removal... 0143-2 Figure 2. Front Propeller Shaft Removal. ... 0143-3 Figure 3. Rear Propeller Shaft Removal... 0143-4 Figure 4. Rear Propeller Shaft Removal... 0143-5 Figure 5. Rear Propeller Shaft Installation. ... 0143-7 UNIVERSAL JOINT REPLACEMENT... WP 0144 Figure 1. Propeller Shaft Universal Joint Replacement... 0144-3
FRONT AXLE ASSEMBLY REPLACEMENT... WP 0145 Figure 1. Front Axle Removal... 0145-2 Figure 2. Front Axle Removal... 0145-3 Figure 3. Front Axle Removal... 0145-4 Figure 4. Front Axle Removal... 0145-5 Figure 5. Front Axle Removal... 0145-6 Figure 6. Front Axle Installation... 0145-7 TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT... WP 0146 Figure 1. Front Axle Vent Hose Removal... 0146-2 Figure 2. Front Axle Vent Hose Replacement... 0146-3 Figure 3. Rear Axle Vent Hose Replacement... 0146-4 Figure 4. Rear Axle Vent Hose Replacement... 0146-5 Figure 5. Transmission Vent Hose Replacement... 0146-7 REAR AXLE ASSEMBLY MAINTENANCE... WP 0147 Figure 1. Rear Axle Rigging... 0147-2 Figure 2. Rear Axle Removal... 0147-3 Figure 3. Rear Axle Installation... 0147-5 CAGING AND UNCAGING PARKING BRAKE... WP 0148 Figure 1. Caging Parking Brake... 0148-2 Figure 2. Caging Parking Brake... 0148-2 Figure 3. Caging Parking Brake... 0148-3 PARKING BRAKE CYLINDER REPLACEMENT... WP 0149 Figure 1. Parking Brake Cylinder Removal... 0149-3 Figure 2. Parking Brake Cylinder Installation... 0149-5 Figure 3. Parking Brake Rotor Removal... 0149-7 Figure 4. Parking Brake Bracket Replacement... 0149-9 PARKING BRAKE PADS MAINTENANCE... WP 0150
Figure 1. Parking Brake Pad Replacement. ... 0150-3 PARKING BRAKE CONTROL VALVE REPLACEMENT... WP 0151 Figure 1. Parking Brake Control Valve Removal... 0151-1 Figure 2. Parking Brake Control Valve Replacement... 0151-3 Figure 3. Parking Brake Control Valve Installation... 0151-4 PARKING BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT... WP 0152 SERVICE BRAKE CONTROL VALVE REPLACEMENT... WP 0153 Figure 1. Service Brake Control Valve Replacement... 0153-2 BRAKE ACCUMULATOR REPLACEMENT... WP 0154 Figure 1. Brake Accumulators and Valve Block Replacement... 0154-2 Figure 2. Brake Accumulators and Valve Block Replacement... 0154-3 Figure 3. Brake Accumulators and Valve Block Replacement... 0154-4 BRAKE AND STEERING ACCUMULATOR SERVICE... WP 0155 Figure 1. Brake Accumulator Testing... 0155-2 Figure 2. Brake Accumulator Testing... 0155-3 Figure 3. Brake Accumulator Testing... 0155-4 Figure 4. Brake Accumulator Testing... 0155-5 Figure 5. Brake Accumulator Testing... 0155-5 Figure 6. Brake Accumulator Charging... 0155-6 Figure 7. Brake Accumulator Charging... 0155-7 Figure 8. Brake Accumulator Charging... 0155-7 Figure 9. Brake Accumulator Charging... 0155-8 Figure 10. Brake Accumulator Charging... 0155-9 Figure 11. Brake Accumulator Charging... 0155-9 Figure 12. Brake Accumulator Charging... 0155-10 Figure 13. Brake Accumulator Charging... 0155-11 Figure 14. Brake Accumulator Testing... 0155-12
Figure 15. Brake Accumulator Charging... 0155-12 Figure 16. Brake Accumulator Charging... 0155-13 Figure 17. Brake Accumulator Charging... 0155-13 Figure 18. Brake Accumulator Charging... 0155-14 Figure 19. Steering Accumulator Pre-charge Pressure Check... 0155-15 BRAKE SYSTEM CHARGING VALVE PRESSURE ADJUSTMENT... WP 0156 Figure 1. Brake System Charging Valve Pressure Adjustment... 0156-3 SERVICE BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT... WP 0157 Figure 1. Service Brake System Hydraulic Hoses and Fittings Replacement... 0157-3 BRAKE COOLING FILTER AND FILTER HEAD REPLACEMENT... WP 0158 Figure 1. Brake Cooling Filter Replacement... 0158-2 Figure 2. Brake Cooling Filter Head Removal... 0158-3 Figure 3. Brake Cooling Filter Head Installation... 0158-4 BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT... WP 0159 Figure 1. Left Lower Panel Removal... 0159-2 Figure 2. Right Lower Panel Removal... 0159-2 Figure 3. Brake Light and Pressure Switch Replacement... 0159-3 STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE... WP 0160 Figure 1. Steering Column Base Removal... 0160-1 Figure 2. Steering Column Base Removal... 0160-2 Figure 3. Steering Column Base Removal... 0160-2 Figure 4. Steering Column Base Disassembly... 0160-3 Figure 5. Steering Column Base Disassembly... 0160-4 Figure 6. Steering Column Base Disassembly... 0160-4 Figure 7. Steering Column Base Assembly... 0160-5 Figure 8. Steering Column Base Installation... 0160-6 Figure 9. Steering Column Base Installation... 0160-6
Figure 10. Steering Column Base Installation... 0160-7 BRAKE INCHING SWITCH REPLACEMENT... WP 0161 Figure 1. Brake Inching Switch Removal... 0161-2 Figure 2. Brake Inching Switch Removal... 0161-3 Figure 3. Brake Inching Switch Installation... 0161-4 WHEEL ASSEMBLY REPLACEMENT... WP 0162 Figure 1. Raise Front Axle... 0162-2 Figure 2. Raise Front Axle... 0162-3 Figure 3. Raise Front Axle... 0162-3 Figure 4. Raise Front Axle... 0162-4 Figure 5. Wheel and Tire Replacement... 0162-5 BOGIE WHEELS AND TIRES MAINTENANCE... WP 0163 Figure 1. Lower Bogie Wheel... 0163-1 Figure 2. Bogie Wheel Replacement... 0163-3 Figure 3. Screw Assembly Removal and Installation... 0163-5 Figure 4. Bogie Wheel Frame Replacement... 0163-7 DOLLY WHEELS AND TIRES MAINTENANCE... WP 0164 Figure 1. Dolly Wheel Disassembly... 0164-2 Figure 2. Dolly Wheel Assembly... 0164-3 STEERING WHEEL REPLACEMENT... WP 0165 Figure 1. Steering Wheel Removal... 0165-1 Figure 2. Steering Wheel Replacement... 0165-2 Figure 3. Steering Wheel Installation... 0165-3 STEERING COLUMN REPLACEMENT... WP 0166 Figure 1. Steering Column Removal... 0166-1 Figure 2. Steering Column Removal... 0166-2 Figure 3. Steering Column Removal... 0166-3
Figure 4. Steering Column Removal... 0166-3 Figure 5. Steering Column Removal... 0166-4 Figure 6. Steering Column Removal and Installation... 0166-5 Figure 7. Steering Column Installation... 0166-6 Figure 8. Steering Column Installation... 0166-7 Figure 9. Steering Column Installation... 0166-8 Figure 10. Steering Column Installation... 0166-9 STEERING COLUMN REPAIR... WP 0167 Figure 1. Steering Column Disassembly and Assembly... 0167-3 STEERING SENSOR REPLACEMENT... WP 0168 Figure 1. Steering Column Sensor Removal... 0168-1 Figure 2. Steering Column Sensor Removal... 0168-2 Figure 3. Steering Column Sensor Removal... 0168-3 Figure 4. Steering Column Sensor Installation... 0168-3 Figure 5. Steering Column Sensor Installation... 0168-4 Figure 6. Steering Column Sensor Installation... 0168-5 EMERGENCY STEERING PUMP REPLACEMENT... WP 0169 Figure 1. Emergency Steering Pump Replacement... 0169-3 STEERING SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT... WP 0170 FRONT AND REAR AXLE STEERING CYLINDERS REPLACEMENT... WP 0171 Figure 1. Front and Rear Steering Cylinder Replacement... 0171-3 STEERING ACCUMULATOR REPLACEMENT... WP 0172 Figure 1. Steering Accumulator Replacement... 0172-3 STEERING CONTROL VALVE REPLACEMENT... WP 0173 Figure 1. Steering Control Valve Removal... 0173-3 Figure 2. Steering Control Valve Removal and Installation... 0173-5 STEERING CALIBRATION... WP 0174
TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT... WP 0175 Figure 1. Skid Plate Replacement... 0175-3 Figure 2. Front Access Cover Replacement... 0175-4 Figure 3. Middle Access Cover and Cab Support Replacement... 0175-5 Figure 4. Rear Access Cover Replacement... 0175-6 BOOM SUPPORT MAINTENANCE... WP 0176 Figure 1. Boom Support Removal... 0176-2 Figure 2. Boom Support Removal... 0176-3 Figure 3. Boom Support Removal... 0176-3 Figure 4. Boom Support Removal... 0176-4 Figure 5. Boom Support Removal... 0176-5 Figure 6. Boom Support Removal... 0176-6 Figure 7. Boom Support Installation... 0176-7 Figure 8. Boom Support Installation... 0176-8 Figure 9. Boom Support Installation... 0176-9 Figure 10. Boom Support Installation... 0176-9 Figure 11. Boom Support Installation... 0176-10 Figure 12. Boom Support Installation... 0176-11 FLEXIBLE CONVEYOR MAINTENANCE... WP 0177 Figure 1. Boom Wiring Harness and Cable Removal... 0177-2 Figure 2. Boom Wiring Harness and Cable Removal... 0177-3 Figure 3. Boom Wiring Harness and Cable Removal... 0177-3 Figure 4. Hydraulic Hoses Removal... 0177-4 Figure 5. Conveyor Removal... 0177-5 Figure 6. Conveyor Installation... 0177-6 Figure 7. Hydraulic Hoses Installation... 0177-7 Figure 8. Wiring Harness and Cable Installation... 0177-7
Figure 9. Wiring Harness and Cable Installation... 0177-8 Figure 10. Connect Cable and Wiring Harness... 0177-9 PINTLE HOOK MAINTENANCE... WP 0178 Figure 1. Tow Pintle Replacement... 0178-2 CAB LIFT FRAME MAINTENANCE... WP 0179 Figure 1. Cab Transport Lift System Inspection... 0179-2 Figure 2. Cab Transport Lift System Inspection... 0179-3 Figure 3. Cab Transport Lift System Inspection... 0179-3 Figure 4. Cab Transport Lift System Inspection... 0179-4 Figure 5. Cab Adjustment: Operational Position... 0179-5 Figure 6. Cab Adjustment: Operational Position... 0179-6 Figure 7. Cab Adjustment: Operational Position... 0179-7 Figure 8. Cab Adjustment: Operational Position... 0179-7 Figure 9. Cab Adjustment: Operational Position... 0179-8 Figure 10. Cab Adjustment: Transport Position... 0179-9 Figure 11. Cab Adjustment: Transport Position... 0179-10 Figure 12. Cab Adjustment: Transport Position... 0179-11 Figure 13. Cab Adjustment: Transport Position... 0179-12 Figure 14. Cab Transport Lift Removal... 0179-13 Figure 15. Cab Transport Lift Removal... 0179-14 Figure 16. Cab Transport Lift Removal... 0179-15 Figure 17. Cab Transport Lift Installation... 0179-16 Figure 18. Cab Transport Lift Installation... 0179-17 Figure 19. Cab Transport Lift Installation... 0179-18 Figure 20. Cab Transport Lift Structure Removal... 0179-19 Figure 21. Cab Transport Lift Structure Removal... 0179-20 Figure 22. Cab Transport Lift Structure Removal... 0179-21
Figure 23. Cab Transport Lift Structure Installation... 0179-22 Figure 24. Cab Transport Lift Structure Installation... 0179-23 Figure 25. Cab Transport Lift Structure Installation... 0179-24 RIGHT-SIDE STEP ASSEMBLY REPLACEMENT... WP 0180 Figure 1. Right-Side Step Assembly Removal... 0180-2 LEFT-SIDE STAIR ASSEMBLY REPLACEMENT... WP 0181 Figure 1. Left-Side Step Assembly Replacement... 0181-1 Figure 2. Left-Side Stair Assembly Removal... 0181-2 Figure 3. Left-Side Stair Assembly Replacement... 0181-3 STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT... WP 0182 Figure 1. Storage Compartment Door Removal... 0182-1 Figure 2. Storage Compartment Door Removal and Installation... 0182-2 Figure 3. Storage Compartment Door Installation... 0182-3 BATTERY AND DOLLY WHEELS STORAGE COMPARTMENT REPLACEMENT... WP 0183 Figure 1. Battery and Dolly Wheels Storage Compartment Replacement... 0183-3 REMOTE HYDRAULIC CONTROL COMPARTMENT REPLACEMENT... WP 0184 Figure 1. Remote Hydraulic Control Compartment Replacement... 0184-2 ENGINE COVER MAINTENANCE... WP 0185 Figure 1. Engine Cover Removal... 0185-1 Figure 2. Engine Cover Disassembly... 0185-2 Figure 3. Engine Cover Disassembly... 0185-2 Figure 4. Engine Cover Disassembly... 0185-3 Figure 5. Engine Cover Assembly... 0185-4 CAB DOOR ASSEMBLY MAINTENANCE... WP 0186 Figure 1. Cab Door Assembly Removal... 0186-1 Figure 2. Cab Door Assembly Removal... 0186-2 Figure 3. Cab Door Disassembly... 0186-3
Figure 4. Cab Door Disassembly and Assembly... 0186-4 Figure 5. Cab Door Installation... 0186-5 Figure 6. Cab Door Installation... 0186-6 Figure 7. Cab Door Installation... 0186-7 CAB DOOR WEATHERSEAL REPLACEMENT... WP 0187 Figure 1. Cab Door Weatherseal Removal... 0187-1 Figure 2. Cab Door Weatherseal Removal... 0187-2 Figure 3. Cab Door Weatherseal Removal... 0187-3 Figure 4. Cab Door Weatherseal Installation... 0187-4 Figure 5. Cab Door Weatherseal Installation... 0187-5 Figure 6. Cab Door Weatherseal Installation... 0187-5 WINDSHIELD AND WINDOW GLASS REPLACEMENT... WP 0188 Figure 1. Window Removal and Installation... 0188-3 Figure 2. Window Removal and Installation... 0188-4 MUDGUARD REPLACEMENT... WP 0189 Figure 1. Mudguard Replacement... 0189-2 FENDER ASSEMBLY REPLACEMENT... WP 0190 Figure 1. Fender and Fender Bracket Removal (RT 240V1)... 0190-2 Figure 2. Fender and Fender Bracket Replacement (RT 240V1)... 0190-3 Figure 3. Front Fender and Fender Bracket Removal (RT 240V1R)... 0190-4 Figure 4. Front Fender and Fender Bracket Replacement (RT 240V1R)... 0190-5 Figure 5. Rear Fender and Fender Bracket Removal (RT 240V2 and RT 240V3)... 0190-6 Figure 6. Rear Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)... 0190-7 Figure 7. Front Fender and Fender Bracket Removal (RT 240V2 and RT 240V3)... 0190-8 Figure 8. Front Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)... 0190-9 Figure 9. Front Bracket Mounting Plate Replacement... 0190-10 SEAT ASSEMBLY MAINTENANCE... WP 0191
Figure 1. Seat Removal... 0191-2 Figure 2. Seat Disassembly... 0191-3 Figure 3. Seat Disassembly and Assembly... 0191-5 Figure 4. Seat Assembly... 0191-7 Figure 5. Seat Installation... 0191-8 SEAT BELT REPLACEMENT... WP 0192 Figure 1. Seatbelt Replacement... 0192-2 REARVIEW MIRRORS REPLACEMENT... WP 0193 Figure 1. Interior Rearview Mirror Replacement... 0193-1 Figure 2. Exterior Rearview Mirror Removal... 0193-2 Figure 3. Exterior Rearview Mirror Removal and Installation... 0193-3 WINDSHIELD WIPER MAINTENANCE... WP 0194 Figure 1. Front Windshield Wiper and Motor Removal... 0194-2 Figure 2. Front Windshield Wiper and Motor Removal... 0194-3 Figure 3. Front Windshield Wiper and Motor Removal... 0194-3 Figure 4. Front Windshield Wiper and Motor Installation... 0194-4 Figure 5. Front Windshield Wiper and Motor Installation... 0194-5 Figure 6. Front Windshield Wiper and Motor Installation... 0194-6 Figure 7. Rear Windshield Wiper and Motor Removal... 0194-7 Figure 8. Rear Windshield Wiper and Motor Removal... 0194-7 Figure 9. Rear Windshield Wiper and Motor Removal and Installation... 0194-9 Figure 10. Rear Windshield Wiper and Motor Installation... 0194-9 Figure 11. Roof Window Windshield Wiper and Motor Removal... 0194-10 Figure 12. Roof Window Windshield Wiper and Motor Removal... 0194-11 Figure 13. Roof Window Windshield Wiper and Motor Removal and Installation... 0194-12 Figure 14. Roof Window Windshield Wiper and Motor Installation... 0194-13 Figure 15. Roof Window Windshield Wiper and Motor Installation... 0194-14
WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT... WP 0195 Figure 1. Windshield Washer Reservoir Replacement... 0195-3 Figure 2. Windshield Washer Pump Removal... 0195-4 Figure 3. Windshield Washer Pump Replacement... 0195-5 Figure 4. Windshield Washer Pump Installation... 0195-6 HEATER HOSES REPLACEMENT... WP 0196 Figure 1. Engine Heater Hoses Removal... 0196-2 Figure 2. Engine Heater Hoses Removal... 0196-3 Figure 3. Engine Heater Hoses Removal... 0196-3 Figure 4. Engine Heater Hoses Removal... 0196-4 Figure 5. Engine Heater Hoses Removal... 0196-5 Figure 6. Engine Heater Hoses Removal... 0196-5 Figure 7. Engine... 0196-6 Figure 8. Engine Heater Hoses Removal... 0196-7 Figure 9. Cab Heater Hoses Removal – RT 240V1 and RT 240V1R... 0196-8 Figure 10. Cab Heater Hoses Removal – RT 240V2 and RT 240V3 Vehicles... 0196-8 Figure 11. Cab Heater Hoses Removal... 0196-9 Figure 12. Cab Heater Hoses Removal... 0196-10 Figure 13. Cab Heater Hoses Removal... 0196-10 Figure 14. Cab Heater Hoses Removal... 0196-11 Figure 15. Cab Heater Hoses Installation... 0196-12 Figure 16. Cab Heater Hoses Installation... 0196-13 Figure 17. Cab Heater Hoses Installation... 0196-13 Figure 18. Cab Heater Hoses Installation – RT 240V1 and RT 240V1R Vehicles... 0196-14 Figure 19. Cab Heater Hoses Installation – RT 240V2 and RT 240V3 Vehicles... 0196-14 CAB HEATER/AIR CONDITIONING UNIT MAINTENANCE... WP 0197 Figure 1. Cab Heater/Air Conditioning Unit Removal... 0197-2
Figure 2. Cab Heater/Air Conditioning Unit Removal... 0197-3 Figure 3. Cab Heater/Air Conditioning Unit Removal... 0197-4 Figure 4. Cab Heater/Air Conditioning Unit Removal... 0197-5 Figure 5. Cab Heater/Air Conditioning Unit Installation... 0197-6 CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT... WP 0198 Figure 1. Front Panel Removal... 0198-1 Figure 2. Cover Removal... 0198-2 Figure 3. Blower Motor and Fan Replacement... 0198-3 Figure 4. Blower Motor and Fan Installation... 0198-4 CAB AIR FILTERS REPLACEMENT... WP 0199 Figure 1. Cab Grille Removal... 0199-2 Figure 2. Cab Side Air Filter Removal... 0199-3 Figure 3. Cab Side Air Filter Installation... 0199-4 Figure 4. Left Lower Panel Removal – RT 240V1 and RT 240V1R Vehicles Only... 0199-5 Figure 5. Cab Interior Air Filter Removal... 0199-5 Figure 6. Cab Interior Air Filter Removal... 0199-6 Figure 7. Left Lower Panel Installation – RT 240V1 and RT 240V1R Vehicles Only... 0199-7 Figure 8. Cab Interior Air Filter Installation... 0199-8 CAB AUXILIARY FAN REPLACEMENT... WP 0200 Figure 1. Access Panel Removal... 0200-1 Figure 2. Auxiliary Fan Replacement... 0200-2 Figure 3. Access Cover Installation... 0200-3 AUTOLUBE SYSTEM MAINTENANCE... WP 0201 Figure 1. Autolube Tube Replacement... 0201-2 Figure 2. Autolube Pump Replacement... 0201-3 Figure 3. Autolube Distribution Valve Replacement... 0201-4 FIRE EXTINGUISHER BRACKET REPLACEMENT... WP 0202
Figure 1. Fire Extinguisher Bracket Replacement... 0202-1 DATA PLATE REPLACEMENT... WP 0203 Figure 1. Data Plate Replacement... 0203-2 RELIEVING HYDRAULIC SYSTEM PRESSURE... WP 0204 Figure 1. Steering Accumulator Evacuation Valve... 0204-2 Figure 2. Steering Accumulator Evacuation Valves... 0204-3 Figure 3. Float Control and Emergency Control Valves... 0204-3 BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT... WP 0205 Figure 1. Pump Replacement... 0205-3 Figure 2. Pump Installation... 0205-5 COOLING FAN HYDRAULIC PUMP REPLACEMENT... WP 0206 Figure 1. Pump Removal... 0206-3 Figure 2. Pump Installation... 0206-5 SERVO CONTROL VALVE REPLACEMENT... WP 0207 Figure 1. Servo Control Valve Replacement... 0207-3 HYDRAULIC SYSTEM COOLING HOSES AND FITTINGS REPLACEMENT... WP 0208 AUXILIARY HYDRAULIC PUMP REPLACEMENT... WP 0209 Figure 1. Cover Removal... 0209-2 Figure 2. Hose and Wire Disconnects... 0209-3 Figure 3. Ground Strap and Power Cable Disconnects... 0209-3 Figure 4. Pump Removal... 0209-4 Figure 5. Pump Installation... 0209-5 Figure 6. Ground Strap and Power Cable Connections... 0209-5 Figure 7. Hose and Wire Connections... 0209-6 Figure 8. Cover Installation... 0209-7 TOPHANDLER HYDRAULIC SLEWING MOTORS MAINTENANCE... WP 0210 Figure 1. Turning Plate Cover Removal... 0210-2
Figure 2. Hydraulic Manifold and Hose Removal... 0210-3 Figure 3. Hydraulic Manifold and Hose Removal... 0210-3 Figure 4. Slewing Motor and Pinion Gear Removal... 0210-5 Figure 5. Slewing Motor and Hydraulic Manifold Installation... 0210-6 Figure 6. Secure Hydraulic Manifold... 0210-7 Figure 7. Hoses and Fittings Installation and Connection... 0210-8 Figure 8. Protective Cover Installation... 0210-9 SLEWING MOTOR BRAKE REPLACEMENT... WP 0211 Figure 1. Spur Gear Removal... 0211-1 Figure 2. Slewing Motor Brake Removal and Replacement... 0211-3 Figure 3. Slewing Motor Gear Replacement... 0211-4 TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT... WP 0212 Figure 1. Pump Removal... 0212-2 Figure 2. Pump Removal... 0212-3 Figure 3. Pump Removal... 0212-3 Figure 4. Pump Removal... 0212-4 Figure 5. Pump Removal... 0212-4 Figure 6. Pump Removal... 0212-5 Figure 7. Pump Removal... 0212-6 Figure 8. Pump Removal... 0212-7 Figure 9. Pump Removal... 0212-7 Figure 10. Pump Removal... 0212-8 Figure 11. Pump Removal... 0212-9 Figure 12. Pump Installation... 0212-10 Figure 13. Pump Installation... 0212-11 Figure 14. Pump Installation... 0212-11 Figure 15. Pump Installation... 0212-12
Figure 16. Pump Installation... 0212-13 Figure 17. Pump Installation... 0212-14 Figure 18. Pump Installation... 0212-14 Figure 19. Pump Installation... 0212-15 Figure 20. Pump Installation... 0212-16 Figure 21. Pump Installation... 0212-17 Figure 22. Pump Installation... 0212-18 TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT... WP 0213 Figure 1. Tophandler Pump Hydraulic Pressure Adjustment... 0213-2 Figure 2. Tophandler Pump Hydraulic Pressure Adjustment... 0213-3 Figure 3. Tophandler Pump Hydraulic Pressure Adjustment... 0213-4 Figure 4. Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment... 0213-5 Figure 5. Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment... 0213-6 Figure 6. Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment... 0213-7 MAIN CONTROL VALVE REPLACEMENT... WP 0214 Figure 1. Main Control Valve Removal... 0214-2 Figure 2. Main Control Valve Removal... 0214-3 Figure 3. Main Control Valve Removal... 0214-5 Figure 4. Main Control Valve Installation... 0214-6 Figure 5. Main Control Valve Installation... 0214-7 BOOM FOLDING CONTROL VALVE REPLACEMENT... WP 0215 Figure 1. Boom Folding Control Valve Replacement... 0215-3 CAB TRANSPORT CONTROL VALVE REPLACEMENT... WP 0216 Figure 1. Cab Transport Control Valve Replacement... 0216-3 CONTROL VALVE SOLENOIDS REPLACEMENT... WP 0217 Figure 1. Control Valve Solenoid Replacement – Type A... 0217-3 Figure 2. Control Valve Solenoid Replacement – Type B... 0217-4
Figure 3. Control Valve Solenoid Replacement – Type C... 0217-5 Figure 4. Control Valve Solenoid Replacement – Type D... 0217-6 BOOM FOLDING CYLINDERS REPLACEMENT... WP 0218 Figure 1. Boom Folding Cylinder Replacement... 0218-3 Figure 2. Boom Folding Cylinder Installation... 0218-4 Figure 3. Boom Folding Cylinder installation... 0218-5 Figure 4. Boom Folding Cylinder Installation... 0218-6 Figure 5. Boom Folding Cylinder Installation... 0218-7 Figure 6. Boom Folding Cylinder Installation... 0218-8 CAB PARKING AND SERVICE BRAKE HYDRAULIC HOSES AND FITTINGS
REPLACEMENT... WP 0219 MAIN HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT... WP 0220 HYDRAULIC SERVO SYSTEM HOSES AND FITTINGS REPLACEMENT... WP 0221 HYDRAULIC SYSTEM TEST POINT HOSES AND FITTINGS REPLACEMENT... WP 0222 CAB TRANSPORT HYDRAULIC HOSES AND FITTINGS REPLACEMENT... WP 0223 BOOM HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT... WP 0224 TOPHANDLER HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT... WP 0225 FORKLIFT KIT HYDRAULIC HOSES AND FITTINGS REPLACEMENT... WP 0226 HYDRAULIC SYSTEM OIL FILTERS REPLACEMENT... WP 0227 Figure 1. Hydraulic Reservoir Return Oil Filter Removal... 0227-2 Figure 2. Reservoir Return Oil Filter Installation... 0227-3 Figure 3. Hydraulic Reservoir Breather Filter Installation... 0227-4 Figure 4. Hydraulic System In-Line Filters and Filter Head Replacement... 0227-5 HYDRAULIC SYSTEM VALVE MAINTENANCE... WP 0228 Figure 1. Pump Shut-Off Valve Removal... 0228-3 Figure 2. Shift Valve Removal... 0228-5 Figure 3. Boom Support/Bogie Supply Valve Removal... 0228-6 Figure 4. Boom Support/Bogie Supply Valve Installation... 0228-7
Figure 5. Servo Pressure Regulator Valve Removal... 0228-9 Figure 6. Bogie/Boom Support Flow Control Valve Removal... 0228-11 Figure 7. Boom Support Locking Pin Check Valve Removal... 0228-12 Figure 8. Boom Support Locking Pin Check Valve Installation... 0228-13 Figure 9. Bogie Pressure Ball Valve Removal... 0228-15 Figure 10. Extension Cylinder Over-Center Valve Replacement... 0228-17 Figure 11. Parking Brake Hold Flow Control Valve Removal... 0228-18 Figure 12. Parking Brake Hold Flow Control Valve Installation... 0228-19 Figure 13. Brake Charging Valve Replacement... 0228-21 Figure 14. Brake Drain Shut-Off Valve Replacement... 0228-23 Figure 15. Brake Circuit Safety Regulating Valve Replacement... 0228-25 Figure 16. Front Brake Cooling Bypass Valve Replacement... 0228-27 Figure 17. Rear Brake Cooling Bypass Valve Replacement... 0228-29 Figure 18. Cooling Fan Control Valve Removal... 0228-30 Figure 19. Emergency Steering Pressure Balancing Valve Removal... 0228-33 Figure 20. Moderation and Tilt Manifold Valve Removal... 0228-34 Figure 21. Tilt Over-Center Valve Removal... 0228-36 Figure 22. Tilt Over-Center Installation... 0228-37 Figure 23. Oscillation Over-Center Valve Installation... 0228-39 Figure 24. Oscillation Float Lock Flow Control Valve Removal... 0228-40 Figure 25. Twistlock Double Pilot Operated Check Valve Removal... 0228-42 LIFT CYLINDER CONTROL VALVE REPLACEMENT... WP 0229 Figure 1. Lift Cylinder Control Valve Replacement... 0229-3 TOPHANDLER CONTROL VALVES REPLACEMENT... WP 0230 Figure 1. Tophandler Control Valve Replacement... 0230-3 BOOM LIFT CYLINDER REPLACEMENT... WP 0231 Figure 1. Boom Lift Cylinder Removal... 0231-2
Figure 2. Boom Lift Cylinder Removal... 0231-3 Figure 3. Boom Lift Cylinder Removal... 0231-4 Figure 4. Boom Lift Cylinder Removal... 0231-5 Figure 5. Boom Lift Cylinder Installation... 0231-6 Figure 6. Boom Lift Cylinder Installation... 0231-7 Figure 7. Boom Lift Cylinder Installation... 0231-7 CAB LIFTING CYLINDER REPLACEMENT... WP 0232 Figure 1. Cab Lifting Cylinder Replacement... 0232-3 CAB SLIDING CYLINDER REPLACEMENT... WP 0233 Figure 1. Cab Sliding Cylinder Replacement... 0233-2 BOGIE WHEEL LIFT CYLINDERS REPLACEMENT... WP 0234 Figure 1. Hydraulic Cylinders Replacement... 0234-3 Figure 2. Hydraulic Cylinders Replacement... 0234-3 Figure 3. Hydraulic Cylinders Replacement... 0234-4 Figure 4. Hydraulic Cylinders Replacement... 0234-5 BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT... WP 0235 Figure 1. Locking Pin Cylinder Removal... 0235-2 Figure 2. Locking Pin Cylinder Removal... 0235-3 Figure 3. Locking Pin Cylinder Removal... 0235-4 Figure 4. Locking Pin Cylinder Installation... 0235-5 Figure 5. Locking Pin Cylinder Installation... 0235-6 Figure 6. Locking Pin Cylinder Installation... 0235-7 LOCKING PIN BUSHING REPLACEMENT... WP 0236 Figure 1. Frame Bushings Removal... 0236-2 Figure 2. Frame Bushings Installation... 0236-3 Figure 3. Boom Support Bushings Removal... 0236-4 Figure 4. Boom Support Bushings Removal... 0236-5
Figure 5. Boom Support Bushings Installation... 0236-6 Figure 6. Boom Support Bushings Installation... 0236-7 Figure 7. Boom Support Bushings Installation... 0236-8 TOPHANDLER TILT CYLINDERS REPLACEMENT... WP 0237 Figure 1. Tophandler Tilt Cylinder Replacement... 0237-3 TOPHANDLER SIDESHIFT CYLINDERS REPLACEMENT... WP 0238 Figure 1. Tophandler Sideshift Cylinder Replacement... 0238-3 TOPHANDLER LEVELING CYLINDERS REPLACEMENT... WP 0239 Figure 1. Tophandler Leveling Cylinder Removal... 0239-3 TOPHANDLER TWISTLOCK CYLINDERS REPLACEMENT... WP 0240 Figure 1. Tophandler Twistlock Cylinder Replacement... 0240-3 TOPHANDLER TWISTLOCK REPLACEMENT... WP 0241 Figure 1. Tophandler Twistlock Removal... 0241-2 Figure 2. Tophandler Twistlock Replacement... 0241-3 DRAINING AND FILLING HYDRAULIC RESERVOIR... WP 0242