Ce BM 021004
Ce BM 021004
Ce BM 021004
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS
A30049-A30055, A30058-A30064,
A30067-A30070, A30073-A30075,
A30078-A30080, A30085-A30090,
A30095-A30108
With SDA12V160 Engine
Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel
must read and understand this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known
to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands
after handling.
CALIFORNIA
Proposition 65 Warning
Mercury and mercury compounds are known to the State of California to cause developmental problems. This machine may be equipped with optional HID lamps which contain mercury. There is no risk
of exposure unless the lamps are broken. However, the lamps must be reused, recycled or properly
disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.
FOREWORD
This manual is written for use by the operator and/or the service technician and is designed to help these persons
to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before
repairing the truck.
This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front,
or rear are made with respect to the operator's normal seated position, unless specifically stated otherwise.
Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 Nm (100 ft lb). All torque specifications have 10% tolerance
unless otherwise specified.
The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of
what is found on the truck.
A product identification plate is located on the frame in front of the right side front wheel and designates the truck
model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW)
rating.
The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.
The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design
and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight. This is equal to
the empty vehicle weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty
truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating.
The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations must be removed as often as
practical.
Exceeding the allowable payload will reduce expected life of truck components.
A00036
Introduction
A-1
A-2
Introduction
A00036
TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SUSPENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R
A00036
Introduction
A-3
A-4
Introduction
A00036
SECTION A
GENERAL INFORMATION
INDEX
A01001 8/10
Index
A1-1
NOTES
A1-2
Index
8/10 A01001
Power Steering
Transmission
The Torqflow transmission is a planetary gear, multiple disc clutch transmission. The transmission is
hydraulically actuated and force-lubricated for optimum heat dissipation. A three-element, single-stage,
two-phase torque converter is mounted to the front of
the transmission.
The Torqflow transmission is capable of seven forward speeds and one reverse speed. Automatic
shifting is controlled by an electronic shift control system with automatic clutch modulation in all gears. A
lockup system consisting of a wet, double-disc
clutch, is activated in F1-F7 gears for increased fuel
savings.
Retarder
Final Drive
The final drive consists of a plug-in differential with
planetary wheel drive.
Operators Cab
The HD1500-7 operator's cab has been engineered
for maximum operator comfort and to allow for efficient and safe operation of the truck.
The cab provides for wide visibility, with an integral
four-post ROPS/FOPS. It includes the following:
tinted safety-glass windshield, power-operated side
windows, deluxe interior with a fully adjustable seat
with lumbar support, fully adjustable tilt steering
wheel, controls mounted within easy reach of the
operator, and an electronic display/monitoring panel
to keep the operator informed of the truck's operating
circuits. Audible alarms and indicator lights warn the
operator of system malfunctions.
A02077
Brake System
Suspension
Hydro-pneumatic suspension cylinders are mounted
at each wheel to reduce shock. The suspensions
provide riding comfort for the operator and machine
stability for safe travel.
A2-1
A2-2
7. Pump Drive
8. Transmission
9. Hoist Cylinders
10. Final Drive
11. Rear Wet Disc Brakes
12. Differential
A02077
SPECIFICATIONS
Engine
Service Capacities
Komatsu . . . . . . . . . . . . . . . . . . . . . . . SDA12V160*
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 12
Operating Cycle (diesel) . . . . . . . . . . . . . . . 4-Stroke
* Tier 1 Compliant
Transmission
1 . . . . . . . . . . . . . . . . . . . . . . 11.0 . . . . . . . . . 6.8
2 . . . . . . . . . . . . . . . . . . . . . . 14.6 . . . . . . . . . 9.1
3 . . . . . . . . . . . . . . . . . . . . . . 19.5 . . . . . . . . 12.1
5 . . . . . . . . . . . . . . . . . . . . . . 32.6 . . . . . . . . 20.3
Hydraulic Cylinders
Hoist . . . . . . . . . . . . . 3-Stage Telescoping Piston
Steering . . . . . . . . . . . Twin - Double Acting Piston
6 . . . . . . . . . . . . . . . . . . . . . . 44.2 . . . . . . . . 27.5
7 . . . . . . . . . . . . . . . . . . . . . . 58.0 . . . . . . . . 36.0
4 . . . . . . . . . . . . . . . . . . . . . . 24.5 . . . . . . . . 15.2
Final Drive
Electrical System
Batteries (series-parallel). . 4 x 12V / 140 Amp-Hour
Alternator . . . . . . . . . . . . . . 24 Volt, 140 Amp Output
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
Cranking Motors . . . . . . . . . . . Two - 24 Volt Electric
Service Brakes
Actuation: . . . . . . . . . . . . . . . . . . . . . . . All-Hydraulic
Front . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
Rear . . . . . . . . . . . . . . . Oil-Cooled, Multiple-Disc
. . . . . . . . . . Both act as service and retarder brakes
Retarder Brakes:
Normally Applied . . . . . . . . Manually By Operator.
. . . . . . . . . . . . . . . . . . . . . . . . . . (w/ ARSC control)
Automatically Actuated . . . . . . . . . . . . . . . . . . . . . .
when engine speed exceeds the rated revolutions
of the shift position for the transmission.
Parking Brake: . . . . . . Spring-Applied, Oil Released
. . . . Dry Caliper Disc Actuates On Rear Drive Shaft
Emergency Brakes: Manual or automatic operation.
A02077
A2-3
Steering
Turning Circle Diameter (SAE) . . . . . . . 24.4 m (80 ft)
Automatic Emergency Steering . . . . 2 Accumulators
Tires
Rock Service (E-3) . . . . . . . . . . . . . . . . . . . Tubeless
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 33.00 R51
Separable Tire Rims:
Rim Size . . . . . 61x 12.95 x 12.7 cm (24 x 51 x 5 in.)
A2-4
A02077
SECTION A3
GENERAL SAFETY AND OPERATION
INDEX
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Leaving The Operators Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Precautions With High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Prevention Of Injury By Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
HAUL ROADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Ventilation In Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
In Operators Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Precautions For Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Ensure Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
Operate Carefully On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Avoid Damage To Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Loading The Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
Battery Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3-11
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
A03036 03/11
A3-1
A3-2
03/11 A03036
Unauthorized Modification
Safety Features
A03036 03/11
A3-3
If there is any oil, grease, or mud on the handholds or steps, wipe them clean immediately.
Always keep these areas clean. Repair any
damage and tighten any loose bolts.
3. Depress
the
pressure
release button on the cap to vent cooling system pressure.
4. Turn the radiator cap slowly to release the pressure before removing.
To prevent hot engine oil spray:
1. Stop the engine.
2. Wait for the oil temperature to cool down.
A3-4
03/11 A03036
A03036 03/11
A3-5
HAUL ROADS
Determining the travel road at the work site is an
important for safety, maintenance and speed.
When possible restrict travel to one direction. If it
is necessary to provide for traffic in both
directions, ensure the road is wide enough.
When creating haul roads, orient the road so the
loaded truck passes on the side closest to the hill
face. Keep the road as straight as possible. If
curves are necessary, make the curve radius and
road width as large as possible. Ramp the
outside of curves so they are higher than the
inside.
Limit intersections if possible. Design any
necessary intersections to provide safe
crossings.
A3-6
03/11 A03036
Fire Prevention
A03036 03/11
A3-7
the
The tire and rim assembly may explode if subjected to excessive heat. Move personnel to a
remote or protected location if there is evidence
of excessive heat in the wheel, brake and tire
area.
If the truck must be approached to extinguish a
fire, those personnel should do so only while facing the tread area of the tire (front or back),
unless protected by use of large heavy equipment as a shield. Stay at least 15 m (50 ft) from
the tread of the tire.
A3-8
03/11 A03036
Traveling
Traveling On Slopes
Traveling In Reverse
Before operating the machine or work equipment,
observe the following:
A03036 03/11
A3-9
When Dumping
6.6 kv
3m
10 ft
33.0 kv
4m
14 ft
66.0 kv
5m
17 ft
154.0 kv
8m
27 ft
275.0 kv
10 m
33 ft
The following actions are effective in preventing accidents while working near high voltages:
Check
with
the
electrical
maintenance
department about the voltage of nearby cables
before operating.
A3-10
03/11 A03036
TOWING
Operating
Always
wear
safety glasses or
goggles
when
starting
the
machine
with
booster cables.
When
using
booster cables,
DO NOT allow the two machines to touch.
A03036 03/11
A3-11
MAINTENANCE PRECAUTIONS
Warning Tag
Proper Tools
Any time personnel are required to perform maintenance on the vehicle with the dump body in the
raised position, the body-up retention cable must
be installed.
The Komatsu body-up retention cable can only
be used with a Komatsu body. Non-OEM dump
bodies may not accommodate the Komatsu
body-up retention cable. The end user must
ensure that a proper cable/sling is used.
1. To hold the dump body in the raised position,
raise the body to it's maximum height. Refer to
Figure 3-1.
2. Remove cable (2) from its stored position on the
body and install between dump body (1) and
the axle housing ear.
A3-12
03/11 A03036
A03036 03/11
A3-13
DURING MAINTENANCE
Personnel
Attachments
Place attachments
been
removed
machine in a safe
manner to prevent
falling.
that have
from
the
place and
them from
If it is necessary to add
coolant to the radiator, stop
the engine, and allow the
engine and radiator to cool.
Depress
the
pressure
release button on the cap to
vent cooling system pressure.
A3-14
Use Of Lighting
When checking fuel, oil, coolant, etc., always use
lighting with anti-explosion specifications. If such
lighting equipment is not used, there is danger of
explosion.
03/11 A03036
When
repairing
the
electrical system or when
performing
electrical
welding,
remove
the
negative (-) terminal of
the battery to stop the
flow of current.
A03036 03/11
Waste Materials
A3-15
TIRES
Handling Tires
If the proper tires are not used for the mine conditions, the tires may overheat and burst. Improper tire
usage can also lead to cuts from sharp stones resulting in bursting tires. This may lead to serious injury or
damage.
To maintain tire safety, always adhere to the following conditions:
or
creating
open
A3-16
03/11 A03036
A03036 03/11
Any operating fluid, such as hydraulic oil escaping under pressure, can have sufficient force to
enter a person's body by penetrating the skin.
Serious injury and possibly death may result if
proper medical treatment by a physician familiar
with this injury is not received immediately.
12. After adjustments or repairs, replace all shields,
screens and clamps.
13. Use extreme caution when working near tires
and rims.:
A3-17
Use this space to add any additional job site rules not covered in any of the previous discussions.
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A3-18
03/11 A03036
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
The safest trucks are those which have been properly prepared for operation. At the beginning of each
shift, the operator must perform a careful check of
the truck before starting the engine.
Safety Is Thinking Ahead
Prevention is the best safety program. Prevent a
potential accident by knowing the employer's safety
requirements and all necessary job site regulations.
Be familiar with use and care of the safety equipment
on the truck. Only qualified operators or technicians
may operate or maintain the truck.
A safe work environment begins before the operator
boards the truck.
Wear the proper clothing. Loose fitting clothing,
unbuttoned sleeves and jackets, jewelry, etc., are
a potential hazard.
Use personal safety equipment provided for the
operator such as a hard hat, safety shoes, and
safety glass. There are some conditions when
protective hearing devices must also be worn for
operator safety.
When walking to and from the truck, maintain a
safe distance from all machines even if the
operator is visible.
A03036 03/11
A3-19
A3-20
7. Pump Drive
8. Transmission
9. Hoist Cylinders
10. Final Drive
11. Rear Wet Disc Brakes
12. Differential
03/11 A03036
4. Inspect the fan and air conditioner belts for correct tension, wear, and tracking. Inspect the fan
guard condition and secureness.
5. Move outboard of the front wheel. Inspect
attaching lugs and clamps to ensure all are tight
and intact. Check the tire for damage. Ensure
the tire is properly inflated.
6. Move behind the rear of the front wheel. Check
for leaks or any unusual conditions at the hub
and brakes. Inspect the suspension hardware.
Ensure the tie rod and steering cylinder pivots
are properly greased. Check the secureness of
all parts. Check for hydraulic leaks.
7. Check the transmission oil level. Check the
pumps at the front of the transmission. Check
for proper component mounting and ensure no
leaks exist.
8. Move to the side of the hydraulic tank. Check
the hydraulic fluid level for both the hydraulic
tank and brake cooling oil. Oil must be visible in
the sight glass with the engine stopped and the
body down.
9. Move around the hydraulic tank and in front of
the rear dual tires. Inspect the hoist cylinder for
damage or leaks. Inspect the upper and lower
hoist cylinder pins for secureness. Ensure the
pins are properly greased.
10. Before leaving this position, verify there is no
leakage or any other unusual condition with the
transmission or rear drive shaft.
11. Move around the dual tires. Verify all lugs
clamps are intact and tight. Check the wheel for
leakage from inside of the wheel housing Fluid
may indicate planetary leakage. Check the dual
tires damage and proper inflation. Check for
rocks that might be lodged between the dual
tires. Verify the rock ejector is in good condition
and straight.
12. Check the left rear suspension for damage,
proper extension, and leaks. Ensure the suspension pins are properly greased. Ensure the
covers over the chrome piston rod are in good
condition.
A03036 03/11
A3-21
2. Power Receptacle
Do not operate the engine while the heater system is operating. Lack of coolant circulation in
the heaters will burn out the heating elements.
A3-22
03/11 A03036
Ensure there is adequate ventilation before startup if the truck is in an enclosure. Exhaust fumes
are dangerous!
A03036 03/11
A3-23
Jump Starting
Become thoroughly familiar with the steering, braking, and emergency controls. Perform the following
checks to ensure safe truck operation before each
shift.
Steering
1. Test the truck steering in extreme right and left
directions. If the steering system is not operating properly, shut the engine off, immediately.
Determine the problem, and repair before
resuming operation.
NOTE: The steering and brake systems each have
two accumulators that store energy and provide
capability to steer and stop the truck in the event of
an unexpected engine or pump failure.
NOTE: As part of the routine maintenance of the
vehicle, one requirement to ensure proper operation
of each system is to maintain proper accumulator
nitrogen pre-charge. Refer to Section L for proper
procedures when charging the accumulators.
Service Brake
2. With the truck on flat ground, check for normal
operation of the service brake:
a. Depress brake pedal (5, Figure 3-4).
A3-24
03/11 A03036
Auxiliary Brake
b. Move transmission shift lever (2, Figure 3-5)
to the D position and gradually increase
engine speed to 1700 rpm. The truck must
remain stationary. Placing the shift lever in D
ensures that the transmission will start in F2.
c. Reduce engine speed to low idle and release
the service brake. Place the shift lever in N.
Retarder
3. With the truck on flat ground, check retarder
operation:
a. Move retarder lever (2, Figure 3-4) to the
maximum retard position -lever down. Verify
the retarder pilot lamp in the electronic display panel illuminates.
b. Move the transmission shift lever to the D
position and gradually increase engine
speed to 1700 rpm. The truck must remain
stationary. Placing the shift lever in D
ensures the transmission will start in F2.
c. Reduce engine speed to low idle. Move the
retarder lever to OFF -lever up. The retarder
pilot lamp should turn off. Place the shift
lever in NEUTRAL.
Brake Lock
6. Check the operation of the brake lock:
Parking Brake
4. Check operation of the parking brake:
a. Apply parking brake switch (3, Figure 3-4).
Verify the red parking brake lamp in the electronic display panel illuminates.
b. Move transmission shift lever (2, Figure 3-5)
to any position other than N. Verify the central warning lamp on the electronic display
panel flashes.
c. Move the transmission shift lever to the D
position. Gradually increase engine speed to
1550 rpm. Placing the shift lever in D
ensures that the transmission will start in F2.
The truck must remain stationary. If the truck
moves, notify maintenance personnel to
adjust the parking brake. DO NOT operate
the truck until the parking brake is fully operational.
d. Reduce engine speed to low idle. Place the
selector lever in NEUTRAL.
A03036 03/11
A3-25
7. Check the gauges, warning lights and instruments before truck use to ensure proper system
operation. If any warning lights are illuminated,
shut off the engine immediately and determine
the cause.
8. Ensure headlights, work lights and taillights are
working properly. Good visibility may prevent an
accident. Check the operation of the windshield
wiper and washer.
A3-26
03/11 A03036
A03036 03/11
A3-27
LOADING
HAULING
3. When near loading areas, watch for other vehicles and for personnel working in the area.
A3-28
03/11 A03036
RETARDER OPERATION
Two lists are provided on the retarding capacity
decal. One list is for a continuous rating. The second
list is for a short-length rating. Both lists are matched
to the truck at maximum Gross Vehicle Weight
(GVW).
The continuous numbers on the chart indicate the
combination of speeds and grades the vehicle can
safely negotiate for an unlimited time or distance.
The short-length numbers listed on the chart indicate
the combination of speeds and grades the vehicle
can safely negotiate for three minutes. These speeds
are faster than the continuous values, reflecting the
thermal capacity of various system components.
System components can accept heating at a higherthan-continuous rate for a short period of time.
Beyond this period, the system would become overheated.
The short-length rating, sometimes called the "threeminute" limit, will successfully accommodate most
downhill hauls. It is necessary to divide the haul road
grade segment length by allowable speed to determine actual time on the grade. If actual time on the
grade exceeds the allowable amount, travel speed
must be at continuous speed. Ambient temperature,
as well as the temperature of the brake cooling oil
can affect this number. (The brake cooling oil could
already be above the normal range from recent operating conditions).
PASSING
1. DO NOT pass another truck on a hill or at a
blind curve!
A03036 03/11
A3-29
DUMPING
When dumping very large rocks or sticky material, the material may exit the body too fast. This
may cause a violent jolt to the dump body and
cause possible injury to the operator. Damage to
the hoist cylinders, frame, and the dump body
hinge pins may also result. If it is necessary to
dump this kind of material, refer to the caution in
the following procedure.
4. Move hoist control lever (1, Figure 3-6) to
POWER UP position (4) and release the lever.
Releasing the hoist lever anywhere in the lever
stroke when raising will place the dump body in
HOLD at that position.
5. Raise engine rpm to accelerate the hoist speed.
Refer to the following caution note.
When the body is near the maximum angle,
reduce engine rpm in order to reduce the shock
load to the hydraulic system and hoist cylinders.
A3-30
3. POWER DOWN
Position
4. POWER UP Position
5. Center Console
03/11 A03036
A03036 03/11
The operator must continue to use safety precautions when parking and turning the engine off.
Any questionable truck performance must be
checked by maintenance before the truck is used for
another shift.
1. Park the truck on level ground when possible,
and away from other vehicles. If parking on a
grade, position the truck perpendicular to the
grade.
Haul roads are not safe parking areas. In an
emergency, choose the safest spot most visible
to other machines in the area.
2. Apply the parking brake. Verify that the parking
brake is operating properly and is capable of
holding the truck stationary.
A3-31
If the engine suddenly stops, stored hydraulic pressure in the brake and steering accumulators enables
temporary usage of steering and brake functions.
Because accumulator oil supply is limited, it is important to stop the truck as quickly and safely as possible after the loss of engine power. When pressures
drop to a pre-determined level, the low brake pressure and low steering pressure indicators will illuminate and a buzzer will sound. If the brake pressure
continues to decrease, the auto-apply feature will
activate and the service brakes will automatically
apply to stop the truck.
A3-32
03/11 A03036
Hookup
2. Purge the pressure from the brake accumulators, steering accumulators, and hydraulic tanks
on each truck.
3. Attach a hose from the power up quick disconnect on the good truck to the power down circuit
on the disabled truck. Hoses must be rated to
withstand 19 305 kPa (2800 psi) or greater
pressure.
NOTE: The power down circuit uses a smaller
diameter hose (tube) than the power up circuit.
4. Connect another hose from the power down
quick disconnect on the good truck to the power
up circuit on the disabled truck.
A03036 03/11
2. Power Up Circuit
A3-33
A3-34
03/11 A03036
2. Purge any pressure from the steering accumulators on each truck. Verify no pressure exists
by attempting to steer each machine.
3. Connect the supply and return hoses to the
quick disconnects on each bleed-down manifold. Route and secure the hoses in a safe manner that will prevent hose damage during
machine movement.
4. Install pressure gauges in the brake supply circuit on both trucks for verification of proper
brake system pressures after machine start up.
5. Position the retarder lever on the bad truck in
the OFF position. DO NOT use the retarder
lever during machine towing.
6. Turn the disabled truck key switch to the ON
position. This prevents oil transfer between
trucks from the retarder command circuit.
7. Start the good truck, and allow the engine to
idle for a minimum of three minutes.
8. Verify proper brake system pressures on both
trucks. HD1500: 18 960 kPa (2750 psi).
9. Slowly operate the steering wheel on each truck
to check steering function. Slow movement will
allow any trapped air to bleed out of the system.
10. Check all hydraulic connections for leakage
before machine travel.
FIGURE 3-9. STEERING QUICK DISCONNECTS
1. Bleed-down
Manifold
A03036 03/11
2. Supply Port
3. Return Port
A3-35
A3-36
03/11 A03036
FIGURE 3-10. GOOD TRUCK / DISABLED TRUCK STEERING AND BRAKING HOOKUP
TOWING
3. Determine the primary reason that the truck is
disabled.
A03036 03/11
A3-37
5. If the engine on the disabled truck is operational, start the engine before towing to release
the parking brake, and to enable steering and
braking.
6. If the engine is inoperable, hydraulic power for
steering, braking and transmission lubrication
will not be available.
Install the necessary hydraulic connections
between the tow vehicle and the disabled truck
to provide hydraulic power. Refer to Disabled
Truck Steering and Braking.
7. If the body of the disabled truck contains a load,
dump the load before towing. If the engine is not
operational, refer to Disabled Truck Dumping.
A3-38
03/11 A03036
FC - Character positions 10 and 11 identify the Factory Code (FC). The FC identifies the Komatsu factory in charge of claims for the product. The FC for
electric drive trucks is 61.
A04055 10/11
A4-1
A4-2
10/11 A04055
A04055 10/11
A plate is mounted on the left hand side of the transmission oil pan. The decal provides instructions for
properly checking the transmission oil level. Refer to
Section P2, Lubrication And Service, for more information on filling the transmission.
A4-3
A4-4
10/11 A04055
These decals are placed above the battery disconnect switches on the right side of the front bumper to
indicate OFF and ON positions of the switches.
A04055 10/11
A4-5
A4-6
10/11 A04055
INDEX OF TABLES
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
TABLE 1
Standard Tightening Torque For Metric Cap screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . A5-2
TABLE 2
Standard Tightening Torque For SAE Grade 5 & 8 Cap Screws and Nuts . . . . . . . . . . . . . . . . A5-3
TABLE 3
TABLE 4
TABLE 5
TABLE 6
TABLE 7
TABLE 8
TABLE 9
TABLE 10
TABLE 11
TABLE 12
TABLE 13
TABLE 14
A05005 09/11
A5-1
A5-2
TABLE 1.
Standard Tightening Torque
for Metric Class 10.9 Cap screws & Class 10 Nuts
Cap Screw
Size
Torque
Nm
Torque
ft lb
Torque
kgm
M6
13
10
1.35
M8
31
23
3.2
M10
66
48
6.7
M12
112
83
11.5
M14
177
130
18.0
M16
279
206
28.5
M18
383
282
39.0
M20
549
405
56.0
M22
745
550
76.0
M24
927
684
94.5
M27
1320
975
135
M30
1720
1266
175
M33
2210
1630
225
M36
2750
2025
280
M39
3280
2420
335
09/11 A05005
Example: 7/16 - 20
7/16 = shank diameter (7/16 inch (0.438 inch))
20 = threads per inch
TABLE 2.
Standard Tightening Torque
for SAE Hex Head Cap Screw And Nut Assembly
Torque Grade 5
Torque Grade 8
Cap
Screw
Size
Nm
ft lb
kgm
Nm
ft lb
1/4-20
9.5
0.97
13.6
10
1/4-28
10.8
1.11
14.9
11
5/16-18
20.3
15
2.07
28
21
Torque Grade 5
Torque Grade 8
kgm
Cap
Screw
Size
Nm
ft lb
kgm
Nm
ft lb
kgm
1.38
3/4-16
319
235
32.5
454
335
46.3
1.52
7/8-9
475
350
48.4
678
500
69.2
2.90
7/8-14
508
375
51.9
719
530
73.3
5/16-24
22
16
2.21
30
22
3.04
1.0-8
712
525
72.6
1017
750
103.7
3/8-16
34
25
3.46
47
35
4.84
1.0-12
759
560
77.4
1071
790
109.3
3/8-24
41
30
4.15
54
40
5.5
1.0-14
773
570
78.8
1085
800
110.6
7/16-14
54
40
5.5
79
58
8.0
1 1/8-7
881
650
89.9
1424
1050
145
7/16-20
61
45
6.2
84
62
8.57
1 1/8-12
949
700
96.8
1546
1140
158
1/2-13
88
65
122
90
12.4
1 1/4-7
1234
910
125.9
2007
1480
205
1/2-20
95
70
9.7
129
95
13.1
1 1/4-12
1322
975
134.8
2142
1580
219
9/16-12
122
90
12.4
169
125
17.3
1 3/8-6
1627
1200
166
2630
1940
268
9/16-18
129
95
13.1
183
135
18.7
1 3/8-12
1776
1310
181
2874
2120
293
5/8-11
169
125
17.3
237
175
24.2
1 1/2-6
2142
1580
219
3471
2560
354
5/8-18
183
135
18.7
258
190
26.2
1 1/2-12
2305
1700
235
3756
2770
383
3/4-10
298
220
30.4
420
310
42.8
A05005 09/11
A5-3
TABLE 3.
Standard Tightening Torque
for 12-Point, Grade 9 Cap Screws
Cap Screw Size*
Torque
Nm
Torque
ft lb
Torque
kgm
0.250 - 20
16
12
1.7
0.312 - 18
33
24
3.3
0.375 - 16
57
42
5.8
0.438 -14
95
70
9.7
0.500 -13
142
105
14.5
0.562 - 12
203
150
20.7
0.625 - 11
278
205
28.3
0.750 - 10
488
360
49.7
0.875 - 9
780
575
79.4
1.000 - 8
1166
860
119
1.000 - 12
1240
915
126
1.125 - 7
1670
1230
170
1.125 - 12
1800
1330
184
1.250 - 7
2325
1715
237
1.250 - 12
2495
1840
254
1.375 - 6
3080
2270
313
1.375 - 12
3355
2475
342
1.500 - 6
4040
2980
411
1.500 - 12
4375
3225
445
A5-4
09/11 A05005
TABLE 4.
Tightening Torque For
T-Bolt Type Hose Clamp (SAE J1508 Type TB)
Thread Size
Band Width
Newton meters
(Nm)
Inch Pounds
(in. lb)
0.25-28 UNF
8.5 0.6 Nm
75 5 in lb
Thread
Diameter of Nut
(mm)
14
18
22
24
30
33
36
42
A05005 09/11
Width
Across Flat
(mm)
14
17
22
TABLE 5.
Tightening Torque For
Split Flange Clamp Bolts
Newton meters
(Nm)
Tolerances 10%
66
112
279
Foot Pounds
(ft lb)
Tolerances 10%
48
83
206
Kilogram meters
(kgm)
Tolerances 10%
6.7
11.5
28.5
Width
Across Flat
(mm)
19
24
27
32
36
41
46
55
TABLE 6.
Tightening Torque For
Flared Tube And Hose Fittings
Newton meters
(Nm)
Tolerances 10%
25
50
80
140
175
195
245
295
Foot Pounds
(ft lb)
Tolerances 10%
18
36
58
101
130
145
180
215
Kilogram meters
(kgm)
Tolerances 10%
2.5
5
8
14
18
20
25
30
A5-5
TABLE 7.
Torque Chart For JIC 37 Swivel NutS
With Or Without O-ring Seals
Size
Code
Tube Size
(OD)
Threads UNF-2B
Newton meters
(Nm)
Foot Pounds
(ft lb)
0.125
0.312 24
51
41
0.188
0.375 24
11 4
83
0.250
0.438 20
16 4
12 3
0.312
0.500 20
20 4
15 3
0.375
0.562 18
24 7
18 5
0.500
0.750 16
40 7
30 5
10
0.625
0.875 14
54 7
40 5
12
0.750
1.062 12
75 7
55 5
14
0.875
1.188 12
88 7
65 5
16
1.000
1.312 12
108 7
80 5
20
1.250
1.625 12
136 14
100 10
24
1.500
1.875 12
163 14
120 10
32
2.000
2.500 12
312 27
230 20
TABLE 8.
Torque Chart For
Pipe Thread Fittings
A5-6
Size
Code
Pipe Thread
Size
With Sealant
Nm
With Sealant
ft lb
Without Sealant
Nm
Without Sealant
ft lb
0.125 27
20 4
15 3
27 7
20 5
0.250 18
27 7
20 5
34 7
25 5
0.375 18
34 7
25 5
48 7
35 5
0.500 14
48 7
35 5
61 7
45 5
12
0.750 14
61 7
45 5
75 7
55 5
16
1.000 11.50
75 7
55 5
88 7
65 5
20
1.250 11.50
95 7
70 5
108 7
80 5
24
1.500 11.50
108 7
80 5
129 14
95 10
32
2.000 11.50
129 14
95 10
163 14
120 10
09/11 A05005
TABLE 9.
Torque Chart For
O-ring Boss Fittings
Size
Code
Tube Size
(OD)
Threads UNF-2B
Newton meters
(Nm)
Foot Pounds
(ft lb)
0.125
0.312 24
43
42
0.188
0.375 24
73
52
0.250
0.438 20
11 4
83
0.312
0.500 20
14 4
10 3
0.375
0.562 18
18 4
13 3
0.500
0.750 16
33 7
24 5
10
0.625
0.875 14
43 7
32 5
12
0.750
1.062 12
65 7
48 5
14
0.875
1.188 12
73 7
54 5
16
1.000
1.312 12
98 7
72 5
20
1.250
1.625 12
109 7
80 5
24
1.500
1.875 12
109 7
80 5
32
2.000
2.500 12
130 14
96 10
TABLE 10.
Torque Chart For
O-ring Face Seal Fittings
A05005 09/11
Size
CodeE
Tube Size
(O.D.)
Threads UNF-2B
Newton meters
(Nm)
Foot Pounds
(ft lb)
0.250
0.438 20
15 1
11 1
0.375
0.562 18
24 3
18 2
0.500
0.750 16
48 5
35 4
10
0.625
0.875 14
69 7
51 5
12
0.750
1.062 12
96 10
71 7
16
1.000
1.312 12
133 8
98 6
20
1.250
1.625 12
179 10
132 7
24
1.500
1.875 12
224 20
165 15
A5-7
TABLE11.
Common Conversion Multipliers
Metric To English
To Convert From
To
Multiply
By
millimeter (mm)
inch (in.)
0.0394
centimeter (cm)
inch (in.)
0.3937
meter (m)
foot (ft)
3.2808
meter (m)
yard (yd)
1.0936
kilometer (km)
mile (mi)
0.6210
(cm3
liters (l)
cubic meters (m
liters (l)
A5-8
0.001
0.061
3)
61.02
0.1550
(ft3)
35.314
3)
0.0353
cubic feet
grams (g)
ounce (oz)
0.0353
milliliter (ml)
0.0338
kilogram (kg)
pound (mass)
2.2046
Newton (N)
pounds (lb)
0.2248
0.102
0.7376
7.2329
9.807
kilopascals (kPa)
0.1450
megapascals (MPa)
145.038
kilograms/cm2 (kg/cm2)
14.2231
kilograms/cm2 (kg/cm2)
kilopascals (kPa)
98.068
kilogram (kg)
0.0011
metric ton
1.1023
liters (l)
quart (qt)
1.0567
liters (l)
gallon (gal)
0.2642
Watts (W)
horsepower (hp)
0.00134
kilowatts (kW)
horsepower (hp)
1.3410
09/11 A05005
TABLE 12.
Common Conversion Multipliers
English to Metric
To Convert
From
To
Multiply
By
inch (in.)
millimeter (mm)
25.40
inch (in.)
centimeter (cm)
2.54
foot (ft)
meter (m)
0.3048
yard (yd)
meter (m)
0.914
mile (mi)
kilometer (km)
1.61
6.45
929
16.39
liters (l)
0.016
0.028
liters (l)
28.3
square inch
(in.2
ounce (oz)
kilogram (kg)
0.028
milliliter (ml)
29.573
pound (lb)
kilogram (kg)
0.454
pound (lb)
Newton (N)
4.448
0.113
1.356
0.138
9.807
kilopascals (kPa)
6.895
megapascals (MPa)
0.007
kilograms/square centimeter
0.0704
(kg/cm2)
A05005 09/11
kilogram (kg)
907.2
0.0907
quart (qt)
liters (l)
0.946
gallon (gal)
liters (l)
3.785
horsepower (hp)
Watts (w)
745.7
horsepower (hp)
kilowatts (kw)
0.745
A5-9
Celsius
C
121
118
116
113
110
107
104
102
99
96
93
91
88
85
82
79
77
74
71
68
66
250
245
240
235
230
225
220
215
210
205
200
195
190
185
180
175
170
165
160
155
150
TABLE 13.
Temperature Conversions
Formula: F - 32 1.8 = C or C x 1.8 + 32 = F
Fahrenheit
Celsius
Fahrenheit
Celsius
F
C
F
C
482
63
145
293
4
473
60
140
284
2
464
57
135
275
1
455
54
130
266
4
446
52
125
257
7
437
49
120
248
9
428
46
115
239
12
419
43
110
230
15
410
41
105
221
18
401
38
100
212
21
392
35
95
293
23
383
32
90
194
26
374
29
85
185
29
365
27
80
176
32
356
24
75
167
34
347
21
70
158
37
338
18
65
149
40
329
15
60
140
43
320
13
55
131
46
311
10
50
122
48
302
7
45
113
51
40
35
30
25
20
15
10
5
0
5
10
15
20
25
30
35
40
45
50
55
60
Fahrenheit
F
104
95
86
77
68
59
50
41
32
23
14
5
4
13
22
31
40
49
58
67
76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C) or Fahrenheit (F). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C) or read to the right to convert to degrees Fahrenheit (F). If
starting with a known temperature (either C or F), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
A5-10
09/11 A05005
TABLE 14.
Sealants And Adhesives
Nomenclature
Adhesives
Code
Three Bond *
Applications
LT-1A
TB1521
LT-1B
1000B - 1000W
LT-2
TB1374
Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-2A
TB2411
Preventing bolts, nuts and plugs from loosening and leaking oil. (1)
LT-2B
TB2403
Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
LT-2C
TB2430 or
TB2440
Preventing bolts, nuts and plugs from loosening and leaking oil. (2)
TB2001
TB2105
LG-1
TB1108B
LG-3
TB1107
LG-4
TB1104
Used by itself on mounting surfaces on the final drive and transmission cases.
Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)
LG-5
TB1110B
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm (2 in) in diameter.
Anti-friction
compound
LM-P
Applied to bearings and taper shafts to facilitate press-fitting and to prevent sticking, burning or rusting.
Grease
G2-LI
Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Vaseline
Liquid Gasket
* NOTE: The part numbers in this column are not Komatsu numbers. These are vendor designations.
(1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable, and a pressure of
1965 kPa (285 psi) or less.
(2) Used for threaded areas (for example, stud, etc.) which are not removable, and a pressure of 1965 kPa
(285 psi) or less.
Part Numbers
Three Bond
Komatsu
TB1374
09940-00030
TB1521
790-129-9030
TB1104
790-129-9020
TB1108B
790-129-9010
TB1110B
790-129-9080
A05005 09/11
A5-11
A5-12
09/11 A05005
SECTION A7
STORAGE PROCEDURES
INDEX
A07005
Storage Procedures
A7-1
NOTES
A7-2
Storage Procedures
A07005
Much of this material is of a general nature. The storage environment will play a big part in its overall condition. Hot, humid climate will affect vehicle
components much differently than the dry desert
atmosphere or a cold arctic environment. Storage
procedures must match the environmental conditions.
These instructions only provide the minimum guidelines. The final goal must be to provide the operator
with a safe, fully productive vehicle, that he can rely
on.
A07005
Storage Procedures
A7-3
10. Disconnect the batteries, if possible. Store batteries in a battery shop or a cool dry location.
Clean the battery compartment. Remove all
corrosion and paint the battery compartment
with acid-proof paint.
A7-4
Storage Procedures
A07005
8. Open the drain on the fuel tank to remove moisture or sediment that may have accumulated
while in storage. Close the drain and fill the fuel
tank with approved diesel fuel.
11. Install fully charged batteries. The battery compartment must be free of corrosion. Clean the
connections, then connect the battery cables.
Secure the batteries with the hold downs.
12. Check all electrical cables for weathering,
cracks and/or damage. Replace any defective
cables.
13. Check the tires for damage. Repair as necessary.
14. Inflate the tires to the proper pressure.
15. If disconnected, reconnect the parking brake
linkage.
16. Completely service the vehicle as recommended in Section P, Lubrication and Service,
10 and 100 hour inspections.
A07005
Storage Procedures
A7-5
1. Remove all trash and thoroughly clean the vehicle before inspection and maintenance.
2. Remove the vehicle batteries. Move the batteries to a battery shop for service and charging.
A7-6
Storage Procedures
A07005
To prevent injuries, always release spring tension before replacing the fan belt.
g. Check and tighten the engine mounts.
6. Inspect and service the transmission. Refer to
Section P, Lubrication and Service, for information on oil and filter service.
a. Check all transmission electrical connections
for corrosion, cleanliness and tightness.
Check electrical cables for damage and
proper clamping.
b. Check drive lines for worn U-joints and
proper hardware torque.
c. Check the condition of the transmission
mounts.
7. If fuel was left in the fuel tank, it must be
removed. DO NOT attempt to use old diesel
fuel.
a. With the tank empty, remove the inspection
plates and thoroughly check the interior of
the tank. Clean if necessary to remove sediment and contamination. If the fuel was contaminated, remove the lines and flush with
air.
b. Check all fuel lines for deterioration or damage. Replace lines as necessary.
c. Replace inspection covers, and install new
gaskets.
d. Fill the tank with specified diesel fuel.
e. Replace the fuel filters.
A07005
Storage Procedures
A7-7
8. Drain the hydraulic tank. If oil is not contaminated and is stored in clean containers, it may
be reused. Before reuse, the oil must be filtered
through filter elements with a 3-micron rating.
Do not attempt to use contaminated hydraulic
oil, especially if water is present in the oil.
Refer to Section P, Lubrication and Service, for
proper oil specifications.
a. Replace hydraulic filter elements and clean
suction strainer elements. While suction
strainers are removed, inspect and clean the
interior of the tank thoroughly to remove all
sediment and foreign material.
b. Inspect all hydraulic lines for deterioration or
damage. Replace any suspect lines.
c. Check all hydraulic pumps, valves and cylinders for damage and corrosion. Secure all
mountings and connections. Control valves
in the cab must move freely without binding.
d. Check exposed portions of all hydraulic cylinders for rust, pitting and corrosion. If plating is deteriorated, the cylinder must be
removed and overhauled or replaced. Pitted
or scored plating will cause leakage at the
cylinder seals.
9. Check the front wheel hub, final drive and rear
axle lubricants. If contamination is suspected,
drain the oil and service the component with the
proper lubricant. If major contamination is present, disassembly and overhaul is necessary.
11. Lubricate all grease fittings, not part of the automatic lubrication system, with the specified
lubricants. All pivot points must be free of any
binding.
12. Check the alternator for corrosion or deterioration. The alternator rotor must be free, with no
binding or roughness. Inspect, install and properly tension the alternator drive belt.
13. Check the secureness of the steering cylinder
ball joints, link, and hydraulic connections.
14. Examine the suspensions for signs of damage.
a. Discharge the nitrogen from the suspensions
as outlined in Section H, Oiling and Charging. Check the condition of the suspension
oil and the cylinder wiper seals. If the wipers
are cracked or hardened, the suspension
must be rebuilt. Recharge the suspension
with new oil if the old oil is deteriorated.
b. Check the exposed chrome portions of the
cylinder for rust, pitting and corrosion. If the
plating is deteriorated, the suspension must
be removed and overhauled or replaced. Pitted or scored plating will rapidly cause leakage at the seals.
c. Recharge the suspensions as outlined in
Section H, Oiling and Charging.
15. If not previously done, install fully charged batteries into the battery box.
A7-8
Storage Procedures
A07005
ENGINE OPERATION
A07005
Storage Procedures
A7-9
A7-10
Storage Procedures
A07005
12. Turn the fuel pump manual shutoff valve counterclockwise until it stops.
13. Crank the engine slowly. Spray lubricating oil
into the intake manifold and the inlet of the air
compressor.
14. Cover all of the openings with tape to prevent
dirt and moisture from entering the engine.
15. Drain the coolant.
NOTE: It is not necessary to drain the coolant if it is a
permanent type antifreeze with a rust inhibitor.
16. Store the engine in an area that is dry and has a
constant, even temperature.
17. Use a bar to turn the crankshaft two or three
revolutions every three to four weeks.
A07005
Storage Procedures
A7-11
3. Fill the oil pan sump, oil filters, and fuel filters.
4. Drain the rust preventative compound from the
cooling system. Fill the cooling system with
coolant. Refer to Section P, Lubrication and
Service.
5. Prime the lubricating system. Refer to Cummins
Engine Shop Manual, Section 14-01, Engine
Run-in-Period.
6. Adjust the injector and the valve clearance.
Refer to Cummins Engine Shop Manual, Section 00-02, Engine Assembly.
7. Tighten the intake manifold mounting cap
screws.
A7-12
Storage Procedures
A07005
A07005
Storage Procedures
A7-13
NOTES
A7-14
Storage Procedures
A07005
SECTION B
STRUCTURES
INDEX
B01019
Index
B1-1
NOTES
B1-2
Index
B01019
SECTION B2
STRUCTURAL COMPONENTS
INDEX
B02030 10/11
Structural Components
B2-1
NOTES
B2-2
Structural Components
10/11 B02030
STRUCTURAL COMPONENTS
The deck structures and components are removable
in sections, as shown in Figure 2-1.
Refer to Preparation for tasks to perform before the
ladders, decks, and hood can be removed. Additional
steps may be required depending on optional equipment installed on the truck.
Prior to component removal or repair, it may be necessary to remove the body to provide clearance for
lifting equipment to be used. If body removal is not
required, raise the body and install the safety cable.
PREPARATION
1. If installed, raise the body and install the body
safety cable. Place the hoist lever in FLOAT.
Slowly lower the body until supported by the
safety cable.
2. Reduce the engine speed to idle. Place the
range selector in NEUTRAL and apply the parking brake.
3. Shut off the engine. Allow the steering accumulators to bleed completely. Verify the steering
accumulators have bled down by attempting to
steer the machine.
4. Bleed the brake accumulators using the manual
bleed valves on the brake manifold.
5. Open the battery disconnect switch located on
battery box (11, Figure 2-1).
B02030 10/11
6. Center Deck
7. Right Deck
8. Right Deck Mounts
9. Center Deck Mounts
Structural Components
B2-3
Ladders
B2-4
Structural Components
10/11 B02030
DECKS
Removal
1. Follow the instructions outlined in Preparation
at the beginning of this chapter.
To prevent damage to the battery equalizer circuit when disconnecting the battery cables, disconnect the negative (-) lead first, then the
positive (+) cable. When reinstalling battery
cables, attach the positive (+) lead first, then the
negative lead.
CENTER DECK
Removal
Installation
1. Clean all mounting pad surfaces before installation.
2. Clean contact surfaces before installing ground
cables.
3. Attach lifting apparatus to each corner of the
center deck. The weight of the deck is approximately 239 kg (527 lb).
4. Using a hoist, carefully raise the deck into position on the truck.
5. Install the deck mounting hardware. Tighten all
hardware to the standard torque specifications
listed in Section A.
6. Reattach any hoses, cables, pipe supports, etc.
that were removed during deck removal.
Ensure all electrical connections and harness
clamps are installed and secure.
B02030 10/11
Installation
1. Clean all mounting pad surfaces before installation.
2. Clean contact surfaces before installing ground
cables.
Structural Components
B2-5
Installation
B2-6
Structural Components
10/11 B02030
SECTION B3
DUMP BODY
INDEX
B03019 10/11
Dump Body
B3-1
NOTES
B3-2
Dump Body
10/11
B03019
DUMP BODY
Removal
1. Park the truck on a hard, level surface and
chock the wheels. Attach appropriate lifting
cables and a hoist of sufficient capacity to the
dump body. Ensure the lifting cables are taut. A
typical body, as shown in Figure 3-1, weighs
approximately 20 000 kg (44,082 lb).
4. Retainer Ring
5. Bearing
6. Hoist Cylinder
B03019 10/11
2. Guide Rope
Dump Body
B3-3
4. Pivot Bushing
5. Cap screw
6. Lock Nut
B3-4
Dump Body
10/11
B03019
Installation
3. Lift the pivot pin into position and align the pin
retainer cap screw hole. The weight of the pivot
pin is approximately 49 kg (108 lb). Push pivot
pin (1) through the shim(s) and into the pivot
bushings in each side of the frame.
6. Install pin retainer (1) and cap screws (2). Position the retainer to obtain 0.5 mm (0.020 in)
clearance between the retainer and the bottom
of the slot in body pin (3). Tighten the cap
screws to standard torque. Repeat for the
remaining hoist cylinder.
BODY PADS
Inspect the body pads during scheduled maintenance inspections. Replace if damaged or worn,
excessively.
Removal
1. Raise the body to a height that is sufficient to
allow access to all of the pads.
B03019 10/11
Dump Body
B3-5
TW8650
XC3756
6. Mounting Pad
7. Shims (as required)
8. Body Pad
9. Main Frame
Installation
1. Install the new pads and use the same number
of shims as removed.
2. Install the mounting hardware and tighten to 34
Nm (25 ft lb).
B3-6
Dump Body
10/11
B03019
4. Shim
5. Body Pad
TABLE 2: SPECIFICATIONS
B03019 10/11
Shim Thickness
Dump Body
B3-7
BODY GUIDE
Inspect body guide wear points (2, Figure 3-8) each
time a body pad inspection is performed. If the gap
becomes excessive, replacement parts must be
installed.
3. Body Rail
4. Main Frame
B3-8
Dump Body
10/11
B03019
ROCK EJECTORS
Any time personnel are required to perform maintenance on the vehicle with the dump body in the
raised position, the body-up retention cable must
be installed.
B03019 10/11
Dump Body
4. Flat Washer
5. Cotter Pin
B3-9
NOTES
B3-10
Dump Body
10/11
B03019
SECTION B4
FUEL TANK
INDEX
B04027 10/11
Fuel Tank
B4-1
NOTES
B4-2
Fuel Tank
10/11 B04027
FUEL TANK
Removal
1. Park the truck on a hard, level surface and
apply the parking brake.
2. Raise the truck body and secure in position
with the safety cable. Shut the engine off.
3. Open drain cock (1, Figure 4-1) and drain the
fuel from the tank into clean containers. The
fuel tank has a capacity of 2120 l (560 gal).
4. Close shut off valve (2, Figure 4-1).
5. Disconnect fuel supply hose (2, Figure 4-2)
and return hose (3) from the tank. Cap the
hoses and tank fittings to prevent contamination.
6. Disconnect all electrical connections to the
tank.
7. Remove filter bracket bolts (3, Figure 4-1) and
tie the filters and hoses away from the fuel
tank.
8. Attach an appropriate lifting device to the fuel
tank lift brackets (1, Figure 4-2). The weight of
the empty fuel tank is approximately 932 kg
(2055 lb).
9. Remove nut (4, Figure 4-1), flat washer (8),
cap screw (5), and flat washer (6) and flat
washer (9) from the lower mounts.
6. Flat Washer
7. Rubber Dampener
8. Flat Washer
9. Flat Washer
B04027 10/11
Fuel Tank
B4-3
Cleaning
Repair
Clean the fuel tank before and after repairs are performed.
Installation
B4-4
Fuel Tank
10/11 B04027
FUEL RECEIVER
Removal
1. Partially drain the fuel until the fuel level is
below the on-tank fuel gauge.
2. Disconnect the wiring from the assembly.
3. Remove the two screws that secure the fuel
gauge to the sending unit. Remove the gauge
from the sending unit.
4. Remove the four cap screws that secure the
sending unit to the fuel tank. Remove the gasket.
5. Cover the opening in the fuel tank.
Installation
1. Clean the mating surface on the fuel tank. Use
extreme care not to allow debris to enter the
fuel tank.
1. Install a new gasket.
2. Position the sending unit in the fuel tank.
Ensure the float is properly oriented and
moves freely in a vertical plane.
3. Install the four mounting cap screws and
tighten to standard torque.
4. Install the fuel gauge onto the sending unit.
Install the two screws.
5. Reconnect the wiring.
6. Refill the fuel tank. Verify proper operation of
the fuel gauges and check for fuel leaks.
B04027 10/11
Fuel Tank
B4-5
1. Screen
2. Cover
3. Clamp
4. Body
5. Valve Spring
6. O-Ring
7. End Fitting
8. Stem
9. O-Ring
10. Ball Cage
11. Solid Ball
12. Float Ball
B4-6
Fuel Tank
10/11 B04027
83686
B04027 10/11
3. Receiver Assembly
4. Refueling Box
Fuel Tank
B4-7
NOTES
B4-8
Fuel Tank
10/11 B04027
SECTION C
ENGINE
INDEX
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
C01022
Index
C1-1
NOTES
C1-2
Index
C01022
SECTION C3
COOLING SYSTEM
INDEX
C03031 10/11
Cooling System
C3-1
NOTES
C3-2
Cooling System
10/11 C03031
COOLING SYSTEM
DESCRIPTION
The cooling system dissipates heat generated in the
engine, transmission and brake systems. Radiator
(1, Figure 3-1) is filled with a water/ethylene-glycol
coolant mixture. The coolant circulates through the
engine, transmission cooler (4), and brake cooler (5).
Engine water pump (6) circulates the coolant
throughout the system. Coolant temperature is controlled by a thermostat located on the engine. A thermostatically controlled, engine mounted fan draws air
through the grille and across the finned radiator
tubes, reducing coolant temperature. If coolant temperature is low, fan clutch (7), mounted in the fan
hub, allows the fan to free-wheel. When coolant temperature rises to a preset temperature, the fan clutch
engages the fan. A ribbed belt drives the fan clutch
assembly from a pulley on the front of the crankshaft.
Refer to Section C for additional information regarding the fan clutch.
NOTE: The fan clutch will engage the fan when the
air conditioner is being used.
The radiator is mounted above the front bumper. The
radiator is attached to the truck frame near the bottom tank. Support rods near the top tank attached the
radiator to the left and right uprights. Correct radiator
positioning is adjusted using shims at the lower
mounts and the upper mounts. Adjustable support
rods, near the top of the radiator, also allow radiator
adjustment.
FIGURE 3-1. COOLING SYSTEM
1. Radiator
2. Fuel Cooler
3. A/C Condenser
4. Transmission Cooler
C03031 10/11
Cooling System
5. Brake Cooler
6. Engine Water Pump
7. Fan Clutch
C3-3
If a leak occurs in one of the coolers, antifreeze/coolant may contaminate the transmission oil or brake oil
supply. Conversely, transmission oil or brake system
oil may contaminate the engine cooling system.
If the engine coolant is found to be contaminated with
oil, the system must be examined for leaks and
repaired as necessary. The system must be flushed
to remove oil contamination and then refilled with a
clean coolant mixture.
If a leak has been found or is suspected in the transmission cooler, the transmission oil must be examined immediately. Ethylene glycol, even in small
amounts, will damage friction faced clutch plates.
C3-4
Cooling System
10/11 C03031
RADIATOR REMOVAL
1
5
4
C03031 10/11
83690
Cooling System
C3-5
1
7
6
5
4
8
3
2
9
1
83691
10
5. Hose
6. Fan Guard
7. Upper Support Rod
C3-6
83688
6. Hose
7. Hose
8. Hump Hose
9. Mounting Hardware
10. Hump Hose
Cooling System
10/11 C03031
RADIATOR REPAIR
Internal Inspection
If desired, an internal inspection can be performed on
the radiator before complete disassembly. The
inspection entails removing tubes in the radiator core
and cutting them open. This type of inspection can
indicate overall radiator condition, as well as coolant
and additive breakdown.
C03031 10/11
To perform this inspection, remove about four random tubes from the air inlet side of the radiator.
Remove tubes from both the top and bottom cores,
and near each end of the radiator. Refer to Disassembly and Assembly in this section for proper
instructions for tube removal and installation. Analyze any contaminant residue inside the tube to
determine the cause. Flush the system before returning the radiator to service. Contact your nearest L&M
Radiator facility for further instruction or visit the L&M
website for further information at www.mesabi.com.
External Cleaning
Many radiator shops use a hot alkaline soap, caustic
soda, or chemical additives in their boil-out tanks
which can attack solders. These tanks are generally
not recommended.
Cooling System
C3-7
Disassembly
C3-8
Cooling System
10/11 C03031
Assembly
4. Remove all the tubes at the top, before removing the bottom tubes.
5. After all of the tubes are removed, use pliers to
remove the seals from the tanks. Discard all
seals. New seals must be used for assembly.
2. Use a 13 mm (0.5 in.) diameter brush to lubricate the seals with lube/release agent
(XA2308).
3. Use a spray bottle to lubricate the tube ends
with the lube/release agent.
C03031 10/11
Cooling System
C3-9
Inspect seals for damage before trying to reinstall tube. Replace as necessary.
4. Move to the front of the radiator (opposite of fan
side). Install the bottom row of tubes starting
with the fan side row.
When installing the tubes, center the top of the
tube in the top seal while angling the tube only
as much as necessary. Twist the tube while
applying upward force. Push the tube into the
seal until enough clearance is available to
install the bottom end of the tube into the bottom seal.
5. Center the bottom end of the tube in the bottom
seal. Push the tube downward until the formed
bead on the tube is seated inside of the lock
ring groove in the seal. If necessary, use the
installation tool (VJ6567) to pull the tube downward into the seal. The tool has a hooking
device on the end of one of the handles for aiding in installation. Refer to Figure 3-9.
Pressure Testing
Pressure test radiators at 103 kPa (15 psi) for 30
minutes. Various methods of pressure testing include
the following:
Pressurize the radiator and submerge into a test
tank. Watch for leaks.
Lay the front side of the radiator on the floor. Cap
off ports, and fill the radiator with hot water.
Pressurize the radiator and check for leaks.
Cap off radiator ports. Install an air pressure
gauge and pressurize to 103 kPa (15 psi).
Remove the air source and monitor the pressure
gauge.
Pressurize the radiator with air, and spray sealed
joints with soapy water.
C3-10
Cooling System
10/11 C03031
RADIATOR INSTALLATION
1. If hoses (4 & 5, Figure 3-3) and hose (7,
Figure 3-4) were removed from the radiator,
install the hoses and clamping onto the radiator.
2. Attach an appropriate lifting device to the radiator assembly. The weight of the radiator is 1191
kg (2626 lb).
3. Lift the radiator into position over the lower
mounts and the fan blades.
4. Place the shims that were removed between
the frame mount block and the radiator mounting pad. Lower the radiator onto the mounts and
install mounting hardware (9).
NOTE: If necessary, add or remove the long shims
(two holes) to align the radiator outlet tube vertically
with the transmission cooler inlet. Use the short
shims (one hole) to tilt the radiator until plumb.
5. Tighten the lower mounting cap screws evenly.
Tighten the lower mounting cap screws to 549
Nm (405 ft lb).
6. Install support rods (7, Figure 3-3) onto the top
of the radiator.
C03031 10/11
Cooling System
C3-11
19. Install the hoses onto the fuel cooler and fuel
tubes.
20. Install the hood and the two grilles. Refer to
Section B, Structural Components.
21. Fill the radiator with the proper coolant mixture
as specified in Section P, Lubrication And Service.
22. Start the engine, and check for leaks. Repair as
necessary.
1. Transmission Cooler
2. Brake Cooler
3. Coolant Inlet
4. Coolant Outlet
5. Orifice Check Valve
6. Brake Oil Inlet Hoses
C3-12
Cooling System
7. Transmission Oil
Outlet Hose
8. Transmission Oil Inlet
Hose
9. Brake Oil Outlet
Hoses
10/11 C03031
Removal
1. Apply the parking brake, and shut the engine
off. Allow steering accumulator pressure to dissipate. Turn the steering wheel to ensure all
pressure has been released. Open the bleed
valves in the hydraulic cabinet, and bleed the
pressure from the brake accumulators. Close
the valves after all pressure has been released.
2. Drain the oil from the hydraulic tank. The capacity of the hydraulic tank is 900 l (238 g).
3. Drain the oil from transmission sump. The
capacity of the transmission is 153 l (41 g).
4. Drain the coolant system as described previously in Radiator Removal.
5. Remove the clamps and hoses connecting
coolant inlet (3, Figure 3-11) and outlet (4) to
the coolers.
6. Remove brake oil inlet hoses (6) and outlet
hoses (9). Remove orifice check valve (5).
Disassembly
1. Remove the hardware securing the cooler end
caps, or tanks, to the main housing. Remove
each end. Ensure each end is properly identified for installation purposes. Clean the gasket
material from the end caps and from the housing.
Most coolers are stamped with an S for short
end, and an L for long end. The short end is
the end that contains the shorter, smooth section of the tubes. The long end contains the longer, smooth section of the tubes. Refer to
Figure 3-12.
C03031 10/11
Cooling System
C3-13
Assembly
1. Use cleaning solvent to wipe out the header
holes on the long end of the cooler before seal
installation. Verify that no damage exists.
2. Install new seals into the long end header plate.
DO NOT use any lubricant during installation.
Push the outer lip of each seal flush against the
header plate.
3. Use SAE 10 mineral oil to lubricate tube ends
and the inner portion of the long end seals.
4. Insert the long end of a tube into the short end
side of the cooler. Slowly push the tube by hand
until it contacts the long end seal. Repeat this
step for the remaining tubes.
C3-14
Cooling System
10/11 C03031
Inspection
1. Inspect each tube end for any seal fragments. If
there is evidence of any seal damage, remove
the corresponding tube. Install new seals, and
install the tube.
2. Inspect all seals. The seals must be seated
flush against the header plates. If a gap of more
than 0.79 mm (0.031 in.) exists, the seal must
be removed, inspected and reinstalled.
C03031 10/11
Cooling System
C3-15
Installation
1. Move the cooler assembly under the truck.
Using an appropriate lifting device, raise the
assembly into position against the mounting
brackets on the frame. The weight of the
assembly is approximately 397kg (875 lb).
2. Install the mounting cap screws and lock washers. Tighten the cap screws to standard torque.
C3-16
Cooling System
10/11 C03031
SECTION C4
ENGINE
INDEX
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-7
DRIVE LINE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-10
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-18
Bearing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-19
C04031 03/09
Engine
C4-1
NOTES
C4-2
Engine
03/09 C04031
ENGINE
The HD1500 truck is equipped with a turbocharged
diesel engine. Engine power is transmitted to the
Torqflow transmission by a drive line adapter,
damper assembly and drive shaft.
Removal
7. Disconnect the tubing for the air cleaner restriction indicators at ports (7, Figure 4-1).
DO NOT work under a raised body unless the
safety cable is securely installed.
C04031 03/09
Air Cleaner
Clamp
Hump Hose
LH Intake Pipe
RH Intake Pipe
Support Rod Clamp
7.
8.
9.
10.
11.
Engine
C4-3
Alternator
Cooler Assembly
Water Pump Inlet Pipe
Coolant Temperature
Sensor
4. Suction Hose
5. Clutch Connector
6. Harness Clamps
5. Fan Clutch
6. Heater Shutoff Valves
C4-4
Engine
2. Coolant Temperature
Sensor
03/09 C04031
3. Harness Clamps
4. Oil Pressure Switch
4. Starter Cables
5. Starter Motors
6. Exhaust Pipe
C04031 03/09
Engine
2. Drive Shaft
C4-5
Inspection
The complete engine (dry) weighs approximately
5,813 kg (12,815 lb). Ensure all lifting apparatus,
hoists, and spreader bars are of adequate capacity. During engine removal, ensure that the
engine removal path is clear of personnel and
equipment.
C4-6
Engine
03/09 C04031
Installation
12. Connect all engine ground cables.
13. Install coolant pipe (3, Figure 4-2) between the
water pump inlet and cooler assembly (2).
The complete engine (dry) weighs approximately
5,813 kg (12,815 lb). Ensure all lifting apparatus,
hoists, and spreader bars are of adequate capacity. During engine removal, ensure that the
engine removal path is clear of personnel and
equipment.
24. Fill the engine oil to the specified level. Refill the
radiator with coolant to the specified level.
NOTE: Refer to Section P, Lubrication and Service
for the proper fluids and capacities.
25. Charge the air conditioning system with refrigerant. Refer to Section N, Operator Comfort for
instructions.
10. On the left side of the engine, install the air conditioner compressor suction and discharge
hoses.
11. Install clutch connector (5, Figure 4-3). Route
the remaining wires to the receiver-drier. Install
harness clamps (6).
C04031 03/09
Engine
C4-7
C4-8
Engine
23. Plug
24. Cap Screws
25. Cap
26. Retainer Ring
27. Coupling Assembly
28. Cap Screw & Washer
29. Oil Seal
30. Output Shaft
31. Cover Assembly
03/09 C04031
Removal
1. Park the truck in a work area with adequate
overhead clearance to permit raising the body.
3. Coupling
2. Housing
C04031 03/09
Engine
C4-9
Disassembly
2. Shaft
3. Snap Ring
4. Oil Seal
2. Damper Cover
C4-10
Engine
03/09 C04031
2. Bearing Tool A
5. Use a press and bearing tool A to press bearings (2, Figure 4-18) and spacer (3) from the
cover. Do not use excessive force when removing the bearings.
8. Rubber - Small*
9. Outer Body*
10. Cap Screw - Cover
11. Cap Screw - Flange*
12. Plug(s)**
13. Output Shaft**
14. Cap Screw - Outer body
C04031 03/09
2. Snap Ring
Engine
C4-11
2. Flange
2. Cap Screw
4. Inner Body
5. Spacer
C4-12
Engine
03/09 C04031
No.
Check Item
Tolerance
Remedy
Shaft
Hole
Standard
Clearance
Clearance
Limit
120
+0.018
+0.003
0.000
-0.020
-0.038~
-0.003
Nominal Size
Replace
215
0
-0.03
-0.008
-0.037
-0.037~
0.0
0.025
120
+0.018
+0.003
+0.077
+0.047
-0.029~
0.074
0.1
Standard Backlash
Backlash Limit
0.080 ~ 0.243
0.4
Backlash of spline
between coupling
and shaft
Standard Backlash
Backlash Limit
0.080 ~ 0.246
0.4
Size
Deformation of
rubber cushion
Large
Nominal Size
Tolerance
Repair Limit
170
0 - 0.100
-0.160
180
0 - 0.100
-0.160
Smallest Dimension: L
Original Dimension: L0
L0
110
99
90
81
Replace
Replace
Replace
Small
External
C04031 03/09
Repair by
Rechroming or
Replace
No Cracks
Engine
C4-13
Assembly
NOTE: Bearing removal and installation tools allow
for easier disassembly and assembly of the driveline
adapter. The tools can be fabricated locally.
Manufacturing details are shown in Bearing Tools
located later in this chapter.
2. Dowel Pin
C4-14
Engine
03/09 C04031
3. Bearing Tool B
4. Bearing
1. Oil Seal
2. Grease Area
3. Bearing
4. Cover
20. Fill grease area (2), between oil seal (1) and
bearing (3), with 260 cc (9 oz) of Komatsu
grease (p/n 427-12-11871). Apply a small
amount of the grease to the lip of the oil seal.
13. Apply Loctite 648 to the outside circumference of bearing (4). Press the bearing into
damper cover (2) using bearing tool A (1).
Press the bearing until it is seated against the
bottom shoulder of the cover.
14. Fill the bearing (4) with 65 cc (2.2 oz.) of Komatsu grease (p/n 427-12-11871)
16. Apply Loctite 648 to the outside circumference of bearing (16). Press the bearing into the
cover against spacer (17).
17. Fill the bearing (16) with 65 cc (2.2 oz.) of Komatsu grease (p/n 427-12-11871)
C04031 03/09
Engine
C4-15
26. Install snap ring (2, Figure 4-13) and snap ring
(3).
27. Apply Loctite 648 to the outer surface of oil
seal (4).
28. Install the oil seal into the cover using a press
and bearing tool D.
29. Fill the area between the oil seal and the
inboard bearing with 160 cc (5.5 oz) of Komatsu
grease (p/n 427-12-11871).
2. Bearing Tool A
C4-16
Engine
03/09 C04031
C04031 03/09
Engine
C4-17
Installation
NOTE: Refer to Figure 4-9 during assembly of the
drive line adapter.
1. Attach a sling and lifting device to damper
assembly (1, Figure 4-12). The weight of the
assembly is approximately 151 kg (333 lb). Lift
the damper onto the flywheel.
2. Apply Komatsu sealant (p/n 09940-00030) to
cap screws (24, Figure 4-9). Install and tighten
to 260 25 Nm (192 15 lb ft).
3. Apply a thin layer of Komatsu sealant to mating
surfaces of cover (19, Figure 4-9).
4. Install lifting device to damper cover. The
weight of the cover is approximately 140 kg
(308 lb). Install guide bolts to aid in cover installation. Lift the cover onto the assembly. Position
the cover so that breather (2, Figure 4-9) is in
the 12 oclock position. Install cap screws (28).
Remove the guide bolts. Tighten the cap
screws in a criss-cross pattern to 111 10 Nm
(81 7 lb ft).
3. Coupling
C4-18
Engine
03/09 C04031
Bearing Tools
C04031 03/09
Engine
C4-19
C4-20
Engine
03/09 C04031
SECTION C5
AIR FILTRATION SYSTEM
INDEX
C05014 07/10
C5-1
NOTES
C5-2
07/10 C05014
General Maintenance
Operation
The air cleaners are mounted on the uprights on
each side of the radiator. Intake air, required by the
engine, enters through the air cleaners. The air
cleaners discharge heavy particles of dust and dirt
using centrifugal action. Finer particles are removed
by passing air through filter cartridges.
The engines demand for air creates a vacuum in the
air cleaners. This causes outside air to be drawn in
through the air inlets on the air cleaners. Dirty air
entering the cleaners is drawn through a series of
tubes that are designed to produce a cyclonic action.
As the air passes through the outer portion of the
tubes, the circular motion causes dust and dirt particles to be thrown from the air stream into the dust
collector cups. At the same time, the air stream turns
and is directed up through the center of the tubes into
another chamber. Here the air passes through the
main filter element and safety filter element. The air
then flows out of the clean air outlet to the engine air
intake system.
C05014 07/10
C5-3
C5-4
07/10 C05014
Removal
C05014 07/10
C5-5
a. Soak the element in a solution of liquid detergent and water for 15 to 30 minutes. Rotate
the element back and forth in the solution to
free the dirt deposits. DO NOT soak elements for more than 24 hours.
b. Rinse the element with a stream of fresh
water from the inside to the outside. Rinse
until the exit water appears clear. Maximum
permissible water pressure is 276 kPa (40
psi). A complete, thorough rinse is essential.
c. Dry the element thoroughly. If heated air is
used, the maximum temperature must not
exceed 60C (140F) and the air must be circulated, continually. DO NOT use a light bulb
for drying filter elements.
d. After cleaning the element, inspect thoroughly for ruptures and gasket damage. A
good method to detect paper ruptures is to
place a light inside the filter element as
shown in Figure 5-3. Inspect the outer surface of the filter element.
C5-6
07/10 C05014
PRECLEANER CLEANING
Clean the Donaclone tubes in the precleaner section
of the air cleaner at least once annually. More frequent cleaning may be necessary depending upon
operating conditions and local environment. The
tubes must also be cleaned at each engine overhaul.
To inspect the tubes in the precleaner section,
remove the main filter element. DO NOT remove the
safety element. Loosen the clamps and remove the
dust collector cup. Use a light to inspect the tubes. All
tubes must be clear and the light visible.
Clean the Donaclone tubes as follows if clogging is
evident.
C05014 07/10
C5-7
When installing air intake hoses and tubes, it is crucial to properly align and clamp the intake hoses to
achieve proper sealing.
Installation
1. Loosely install the hangers for the air intake
tubes.
2. Position the air cleaner flex hose and clamps as
shown in Figure 5-7. Position the engine flex
hose and clamps as shown in Figure 5-8. The
engine side of flex hose (4) is secured with one
clamp. The air cleaner side is secured with two
clamps.
3. Check the tubes being joined. Align the tubes to
prevent stretching of the hoses.
4. Tighten the hangers as necessary to support
the intake tubes in proper alignment. Ensure the
hoses are still properly installed.
5. Position the clamping bolts on adjacent clamps
180 apart, as shown in Figure 5-9.
6. Tighten each clamp to 8.5 0.6 Nm (70 5
in.lb). Verify the clamps are perpendicular to
the tube as shown in Figure 5-10. If the clamps
are not perpendicular to the tube, the hose may
not seal properly and allow dirt intrusion.
C5-8
4. Hump Hose
5. Intake Tube
07/10 C05014
2. Engine Intake
C05014 07/10
C5-9
NOTES
C5-10
07/10 C05014
SECTION C7
FAN CLUTCH
INDEX
C07002
Fan Clutch
C7-1
NOTES
C7-2
Fan Clutch
C07002
FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
C07002
Fan Clutch
C7-3
C7-4
Fan Clutch
C07002
C07002
Fan Clutch
C7-5
C7-6
Fan Clutch
C07002
3. Pitot Tube
4.Wear Sleeve
5. Retainer/Seal Assembly
6. Shaft Assembly
8. Washer
9. Bolt
10. Oil Seal
11. Bearing Retainer
13. O-Ring Seal
14. Main Bearing
C07002
Fan Clutch
38. Bolt
39. Wear Sleeve
40. Retainer/Seal Assembly
41. Sleeve Bearing
(rear, short)
42. Fan Mounting Hub
Assembly
44. Sleeve Bearing
(front, long)
45. End Cap
C7-7
FIGURE 7-4.
FIGURE 7-2.
1. Support the fan clutch on a bench with fan
mounting hub (42) facing upward. Support the
assembly beneath the pulley. Remove bolts
(38) and washers (37).
FIGURE 7-5.
FIGURE 7-3.
2. Install lifting eyes, and attach a hoist and chains
to front bearing retainer (35). Use a small
screwdriver to separate the front bearing
retainer from pulley adapter (21), and set it
aside on a bench.
C7-8
Fan Clutch
C07002
FIGURE 7-8.
FIGURE 7-6.
FIGURE 7-9.
FIGURE 7-7.
8. Remove internal snap ring (32).
6. Position the sub-assembly beneath the ram of a
press. Support the assembly beneath the bearing retainer as close as possible to fan mounting hub (42). Press the fan mounting hub out of
the front bearing using tooling (B).
C07002
Fan Clutch
C7-9
FIGURE 7-10.
FIGURE 7-12.
FIGURE 7-13.
FIGURE 7-11.
10. Support beneath the fan mounting hub with end
cap (45) down, but approximately 2 in. (50 mm)
above the press bed. Using a solid steel bar or
equivalent, press the end cap from the fan
mounting hub.
C7-10
Fan Clutch
C07002
FIGURE 7-14.
12. Inspect sleeve bearing (44) and sleeve bearing
(41). Compare the color of each bearing to the
chart below. The lighter the appearance of the
bearing, the more worn it is. If either bearing
needs replacing, proceed to the next step. If the
bearings are in good condition, skip the next
step.
FIGURE 7-16.
14. Remove the stack of facing plates (30) and
steel clutch plates (31) from inside the pulley.
FIGURE 7-17.
FIGURE 7-15.
13. Position tooling (C) against sleeve bearing (41).
Press the front sleeve bearing downward to
press it out of the fan mounting hub. Rear
sleeve bearing (44) will be pressed out simultaneously.
C07002
Fan Clutch
C7-11
FIGURE 7-20.
FIGURE 7-18.
16. Attach wire lifting hooks to piston (23). Use the
lifting hooks to pull the piston from pulley
adapter (21).
FIGURE 7-19.
FIGURE 7-21.
17. Remove seal rings (22 & 24) from the piston.
19. Install lifting eyebolts to the shaft and bearing
retainer assembly. Use a suitable lifting device
to lift the assembly from the pulley. Remove Oring seal (13).
NOTE: It may be necessary to use a soft rubber
mallet to separate the shaft and bearing retainer from
the pulley.
C7-12
Fan Clutch
C07002
FIGURE 7-22.
20. Position the shaft as shown. Insert a phillipshead screwdriver into pitot tubes (3) to loosen
and remove them from the shaft. Rotate the
pitot tube until the sealant holding it tight is broken loose. Then, grip the pitot tube with a pair of
pliers, and gently tap on the pliers to remove the
pitot tubes from the hole in the shaft.
FIGURE 7-24.
FIGURE 7-23.
C07002
FIGURE 7-25.
Fan Clutch
C7-13
FIGURE 7-28.
FIGURE 7-26.
24. Support the bearing retainer as close as possible to the bearing bore. Use care not to damage
the retainer/seal assembly. Press the shaft out
of bearing (14) using tooling (E).
FIGURE 7-29.
FIGURE 7-27.
C7-14
Fan Clutch
C07002
FIGURE 7-30.
C07002
Fan Clutch
C7-15
1. Check the shaft assembly for wear or damage. Refer to Figure 7-31 for dimensions.
NOTE: Some shafts were manufactured as two-piece assemblies. Do Not attempt to separate the shaft assembly.
2. Inspect and clean pitot tube holes in the shaft. Use a standard reamer, straight flute 0.3770 in. diameter.
Remove pipe plugs in the shaft for cleaning and reinstall using Loctite Primer N and #242.
C7-16
Fan Clutch
C07002
FIGURE 7-32.
FIGURE 7-34.
FIGURE 7-33.
C07002
Fan Clutch
C7-17
FIGURE 7-36.
C7-18
Fan Clutch
C07002
FIGURE 7-37.
C07002
Fan Clutch
C7-19
FIGURE 7-39.
FIGURE 7-38.
C7-20
Fan Clutch
C07002
FIGURE 7-40.
FIGURE 7-42.
4. Turn the hub over on the bed of the press.
Again using tooling (B), press rear sleeve bearing (41) into the fan mounting hub until the tool
contacts the shoulder of the hub.
FIGURE 7-41.
C07002
Fan Clutch
C7-21
FIGURE 7-44.
FIGURE 7-43.
5. Press front retainer/seal assembly (40) onto the
fan mounting hub (42) using tooling (D). The
inner race of the retainer should be recessed
0.040 in. (1.0 mm) below the shoulder.
Check carefully to insure the retainer/seal
assembly is installed straight, and not bent or
damaged in any way which will cause interference between it and the bearing retainer after
assembly.
Front
wear
sleeve
(39)
is
NOT
interchangeable with rear (notched) wear
sleeve (4). The ID of the front wear sleeve is
color coded red.
Note the direction of the lead pattern on the
sleeve. The wear sleeve must be installed
with the pattern leading in the correct
direction in order to prevent leakage from
occurring.
Use extreme care when handling the wear
sleeve. The slightest nicks or scratches may
cause leakage.
FIGURE 7-45.
C7-22
Fan Clutch
C07002
FIGURE 7-46.
FIGURE 7-48.
FIGURE 7-47.
FIGURE 7-49.
8. Apply Loctite Primer N and #609 to the mating
surfaces of front bearing (33) and front bearing
retainer (35). Place the bearing into position on
the retainer with the notch for the bearing pin
facing downward.
Press the front bearing into the bearing retainer
using tooling (E) or equivalent. Press ONLY on
the outer race of the bearing until it seats at the
bottom of the bore.
C07002
Fan Clutch
C7-23
FIGURE 7-50.
11. Coat the bearing I.D.and the fan mounting hub
bearing journal with Loctite Primer N and #609
(or equivalent). Place the front bearing retainer
sub-assembly into position on the fan mounting
hub. (Ensure the notch in the bearing is aligned
with the bearing dowel pin.) Do not allow the
seal lip to come in contact with the Loctite.
Press the bearing onto the hub using tooling (D)
until it contacts the wear sleeve.
FIGURE 7-51.
FIGURE 7-52.
13. Install external snap ring (28) to hold the clutch
hub in place.
C7-24
Fan Clutch
C07002
FIGURE 7-53.
FIGURE 7-55.
FIGURE 7-54.
C07002
Fan Clutch
C7-25
FIGURE 7-57.
FIGURE 7-56.
C7-26
FIGURE 7-58.
Fan Clutch
C07002
FIGURE 7-59.
19. Some fan clutches were assembled with an external snapring that is used as a spacer between the bearing
and the oil seal. Newer models were assembled using a notched spacer. If an external snapring was used,
place the snapring (12) on top of the bearing (oil seal side). If a notched spacer was used, the spacer will be
installed in a later step. Proceed to the following step.
FIGURE 7-60.
FIGURE 7-61.
20. Coat the O.D. of rear oil seal (10) with Loctite
Primer N and #242 (or equivalent). Use tooling
(E) or the equivalent to install the oil seal in the
rear bearing retainer, flush with the rear face.
Do not lubricate the seal. The seal is made of
teflon and must be installed dry.
C07002
Fan Clutch
C7-27
FIGURE 7-62.
FIGURE 7-63.
23. Install external snap ring (16). Ensure the snapring is fully seated in the groove. It may be necessary to tap on the snapring with a screwdriver
to fully seat the snapring.
Carefully, lower the rear bearing retainer subassembly in place on the shaft. Do not allow the
seal lip to come in contact with the Loctite.
Ensure the notch in the bearing and the dowel
pin are aligned. If external snapring (16) was
installed in the bearing retainer, ensure the
opening is aligned with the dowel pin.
Press the bearing onto the shaft until it reaches
the shoulder of the wear sleeve. Wipe any
excess Loctite from the assembly.
Ensure the seal lip is dry. The seal must
remain dry for proper sealing.
Spin the bearing retainer approximately 25
times to burnish the teflon seal on the wear
sleeve. Check for abnormal sounds or other
indications of contact between the retainer/seal
assembly and the bearing retainer. If interference is found, remove the bearing retainer and
eliminate the point of interference.
FIGURE 7-64.
24. Be sure the pitot tube holes in the shaft are
clean and free of burrs and staking material, to
allow the pitot tubes to fit into the holes and seat
completely to the bottom. Apply a thin coating of
Loctite Primer N and #609 (or equivalent) on
the straight end of one pitot tube (3). Coat the
C7-28
Fan Clutch
C07002
FIGURE 7-66.
FIGURE 7-65.
FIGURE 7-67.
C07002
Fan Clutch
C7-29
FIGURE 7-69.
30. Install spring washer (25), shim (26), and spirolock ring (27). It will be necessary to press
downward to compress the spring washer, while
forcing the spirolock to properly seat in the
groove. The shim must then be centered on the
spring washer to prevent it from interfering with
the movement of the piston.
FIGURE 7-68.
FIGURE 7-70.
31. Place the front bearing retainer sub-assembly
on the bench with the clutch hub up.
Install one steel clutch plate (31) in place in the
bearing retainer. Now dip a facing plate (30) in
new engine oil, allow the excess to drain off,
and place the plate on top of the steel plate.
Repeat this step until all 16 plates have been
installed.
C7-30
Fan Clutch
C07002
FIGURE 7-71.
FIGURE 7-73.
33. Install at least four bolts (38) with lockwashers
(37) and snug. Insert the bolts 90 apart.
FIGURE 7-72.
C07002
Fan Clutch
C7-31
FIGURE 7-76.
FIGURE 7-74.
FIGURE 7-77.
FIGURE 7-75.
35. Lubricate the hook type sealrings (17) on the
shaft assembly. Carefully lower the shaft subassembly into the pulley bore and onto the pulley until the retainer rests on the pulley. Use
caution when lowering. Damage to the sleeve
bearings may result if the shaft is cocked during
installation.
C7-32
Fan Clutch
C07002
FIGURE 7-78.
38. Turn the assembly over on the bench. Install the remaining bolts (38) and lockwashers (37), and torque all to
49-58 Nm (36-43 lb ft).
C07002
Fan Clutch
C7-33
TEST PROCEDURE
1. The fan clutch should be fully locked up with 40 psi oil pressure supplied at the control pressure port.
2. Operate the fan clutch with 180 F (82 C) oil supplied to the oil in port for 2 hours. Manually engage and disengage the clutch during the test to operate seals in both modes. Restrict the fan mounting hub rotation while
the clutch is disengaged, but ensure the fan mounting hub is allowed to rotate freely while the clutch is
engaged.
The fan clutch rotation causes the pitot tubes to pump lubrication oil from inside the fan clutch,
maintaining low internal oil pressure. If lubricating oil is supplied to the fan clutch before it is rotating in
the proper direction, internal pressures will become excessive, causing the oil seals to leak.
C7-34
Fan Clutch
C07002
SECTION D
ELECTRICAL SYSTEM
INDEX
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D21-1
VHMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D31-1
D01043 05/11
Index
D1-1
NOTES
D1-2
Index
05/11 D01043
SECTION D2
BATTERIES AND STARTING SYSTEM
INDEX
D02036
D2-1
D2-2
D02036
Electrolyte Levels
Cleaning
To remove corrosion, clean the battery with water,
baking soda and a stiff, non-wire brush. Flush with
clean water. Do not allow the baking soda solution
into the battery cells.
DO NOT smoke or allow flame around a dead battery or during the recharging operation. The
expelled gas from a dead cell is extremely explosive.
D02036
D2-3
Other Maintenance
Adding acid will be necessary if considerable electrolyte has been lost through spillage. Before adding
acid, ensure the battery is fully charged. This is
accomplished by putting the battery on a charger and
taking hourly specific gravity readings on each cell.
When all the cells are gassing freely and three successive hourly readings show no rise in specific gravity, the battery is considered fully charged. Additional
acid may now be added. Continue charging for
another hour and again check specific gravity.
Repeat the above procedure until all cells indicate a
specific gravity of 1.260-1.265 corrected to 27C
(80F).
If the temperature of the electrolyte is not reasonably
close to 27C (80F) when the specific gravity is
taken, the temperature must be adjusted to 27C
(80F):
For every 5C (10F) below 27C (80F), subtract
0.004 from the specific gravity reading.
For every 5C (10F) above 27C (80F), add
0.004 to the specific gravity reading.
Use 1.400 strength sulfuric acid when making specific gravity adjustments. Acid of higher strength will
attack the plates and separators before it has a
chance to diffuse into the solution.
Do not allow idle batteries to go unattended. If equipment is to go unused for more than two weeks,
remove the batteries and place in a cool, dry place.
Periodically check the batteries and charge as
needed. Remember, all lead-acid batteries discharge
when not in use. Self discharge takes place even
when the battery is not connected in a circuit. This
phenomenon is more pronounced in warm weather
than in cold.
D2-4
TABLE 1.
Specific Gravity
Corrected to
80F (27C)
Freezing Temperature
Degrees
1.280
-70C (-90F)
1.250
-54C (-60F)
1.200
-27C (-16F)
1.150
-15C (+5F)
1.100
-7C (+19F)
D02036
D02036
D2-5
OPERATION
Refer to the electrical schematic diagram in Figure 23.
The Prelub system is activated when the operator
turns the key switch and holds it in the START position. This allows current to flow to the timer solenoid.
Engine oil pressure switch (2, Figure 2-1) provides
the ground for the circuit. The switch contains normally closed contacts that open when oil pressure
reaches 17 kPa (2.5 psi). While the contacts are
closed, the timer solenoid closes the contacts that
supply power from the alternator to the prelube
motor/pump. The pump, which has a dedicated
frame ground, begins pumping oil into the engine.
During this time, the timer solenoid prevents the
cranking motors from operating.
D2-6
3. Outlet Line
4. Check Valve
D02036
3. Frame Ground
D02036
5. Diode
6. Prelub Timer Solenoid
7. Alternator
8. 400 Amp Fusible Link
D2-7
MAINTENANCE
Prelub System Operation
FIGURE 2-4. ENGINE OIL PRESSURE SWITCH
1. Oil Pressure Switch
2. Engine Damper
Check Valve
Check valve (4, Figure 2-1) is installed between the
prelub pump pressure hose and the engine. The oil
flow through the valve (arrow on valve) must be
toward the engine. The check valve prevents backflow from the engine back to the prelub pump after
the engine is started. Failure to prevent backflow to
the pump will result in pump failure.
Timer Solenoid
Timer solenoid (1, Figure 2-2) controls the prelubrication cycle by completing the power supply circuit to
operate the prelub pump. Current is supplied to the
timer solenoid through the key switch. The ground
path is completed by the normally closed pressure
switch (1, Figure 2-4) which is preset to open at 17
kPa (2.5 psi).
D2-8
D02036
Check Valve
Verify no internal leakage exists in the check valve
when the engine is on. Check valve leakage back to
the pump will cause extensive damage to the pump.
If check valve replacement is required, install the
valve with the arrow pointed toward the engine, not
toward the pump.
Timer Solenoid
Inspect the timer solenoid for physical damage. Verify the wiring and connectors are in good condition.
Use extreme caution when performing the following step. Hot oil can cause severe burns.
5. Start the engine, and observe the output line
while the engine is operating to verify that check
valve (4) is functioning properly.
a. If there is no oil flow from the hose, only the
pump must be replaced.
b. If there oil flow from the hose, the check
valve is faulty. The pump and check valve
must be replaced.
D02036
D2-9
PROBLEM
POSSIBLE CAUSES
D2-10
D02036
PROBLEM
POSSIBLE CAUSES
D02036
D2-11
STARTING SYSTEM
CRANKING MOTORS
Removal
When the key switch is moved to the START position, the prelub system is activated. Refer to Prelub
System. The prelub system lubricates internal engine
components with oil to prevent excessive wear due
to dry starts. When oil pressure reaches 17 kPa (2.5
psi), current flow is diverted to the cranking system
by the prelub timer solenoid. The magnetic switches
close, connecting the motor solenoid "S" terminals to
the batteries. When the solenoid windings are energized, plunger (56, Figure 2-7) is pulled in. Starter
drive (71) moves forward in the nose housing to
engage the engine flywheel ring gear. When the solenoid plunger is pulled in, the main solenoid contacts
close to provide current to the cranking motor armature and cranking occurs. After the engine starts, an
overrunning clutch in the drive assembly protects the
armature from excessive speed until the key switch is
released. When the key switch is released, a return
spring causes the drive pinion to disengage.
After the engine has started, a normally closed pressure switch senses engine oil pressure and opens
the electrical circuit. This prevents actuation of the
cranking motors with the engine on.
D2-12
3. Solenoid
D02036
Disassembly
Armature Servicing
Only disassemble the cranking motor as far as necessary to repair or replace defective parts.
D02036
D2-13
D2-14
1. CE Frame
2. Washers
3. O-Ring
4. Insulator
5. Support Plate
6. Brush Plate Insulator
7. Washers
8. Plate & Stud
9. Plate
10. Brush Holder
11. Lock Washer
12. Screw
13. Brush (12 req'd)
14. Lock Washer
15. Screw
16. Brush Spring
17. Screw
18. Screw
19. Screw
20. Lock Washers
21. Plate
22. Brush Holder Insulator
23. Screw
24. Lock Washer
25. Washer
26. O-Ring
27. Bushing
28. Insulator
29. Washer
30. Lock Washer
31. Nut
32. Nut
33. Lock Washer
34. Screw
35. Field Frame
36. Stud Terminal
37. Bushing
38. Gasket
39. Washers
40. Washer
41. Nut
42. Connector
43. Lock Washer
44. Nut
45. Armature
46. Field Coil (6 Coils)
47. Shoe
48. Insulator
49. Screw
50. Washer
51. O-Ring
52. Inspection Plug
53. Solenoid Housing
54. Lock Washer
55. Screw
56. Plunger
57. Washer
58. Boot
59. Washer
60. Spring
61. Retainer
62. Snap Ring
63. Shift Lever
64. Nut
65. O-Ring
66. O-Ring
67. Snap Ring
68. Lever Shaft
69. Drive Housing
70. Screw
71. Drive Assembly
72. Gasket
73. Plug
74. Gasket
75. Brake Washer
76. Screw
77. Lock Washer
78. Lever Housing
79. Washer
80. O-Ring
D02036
D02036
D2-15
Solenoid Checks
A basic solenoid circuit is shown in Figure 2-8. Solenoids can be checked electrically using the following
procedure.
Test
1. Disconnect all leads from the solenoid. Make
test connections as shown to the solenoid, the
switch terminal and the second switch terminal
"G", to check the hold-in winding (Figure 2-9).
2. Use the carbon pile to decrease battery voltage
to 20 volts. Close the switch and read current.
a. The ammeter should read 6.8 amps max.
3. To check the pull-in winding, connect from the
solenoid switch terminal "S" to the solenoid
motor "M" or "MTR" terminal (Figure 2-10).
D2-16
D02036
3. Do not cross-drill bearings. Because the bearings are highly porous, oil from the wick touching the outside bearing surface will bleed
through and provide adequate lubrication.
4. The middle bearing is a support bearing used to
prevent armature deflection during cranking.
The clearance between this bearing and the
armature shaft is large compared to the end
frame bearings.
Motor Assembly
1. Install the end frame (with brushes) onto the
field frame as follows:
a. Insert armature (45, Figure 2-7) into field
frame (35). Pull the armature out of the field
frame just far enough to permit the brushes
to be placed over the commutator.
b. Place end frame (1) on the armature shaft.
Slide the end frame and armature into place
against the field frame.
c. Insert screws (34) and washers (33). Tighten
securely.
FIGURE 2-10. SOLENOID PULL-IN
WINDING TEST
Assembly
Lubricate all bearings, wicks and oil reservoirs with
SAE No. 20 oil during assembly.
Bearing Replacement
1. If any of the bronze bearings are to be replaced,
dip each bearing in SAE No. 20 oil before
pressing into place.
Install the lubricated wick prior to installing the
bearings.
2. Do not attempt to drill or ream sintered bearings. These bearings are supplied to size. If
drilled or reamed, the I.D. will be too large and
the bearing pores will seal over.
D02036
D2-17
3. Push the pinion or drive back towards the commutator end to eliminate endplay.
Pinion Clearance
To adjust the pinion clearance, follow the steps listed
below.
1. Make connections as shown in Figure 2-11.
D2-18
D02036
Installation
No-Load Test
batteries
in
the
following
TROUBLESHOOTING
If the cranking system is not functioning properly,
check the following to determine which part of the
system is at fault:
Batteries- Verify the condition of the batteries,
cables, connections and charging circuit.
Wiring- Inspect all wiring for damage or loose
connections at the key switch, magnetic
switches, solenoids and cranking motors. Clean,
repair or tighten as required.
If the above inspection indicates the cranking motor
to be the cause of the problem, remove the motor
from the truck. Perform the following tests prior to
disassembly to determine the condition of the motor
and solenoid.
Preliminary Inspection
1. Check the cranking motor to ensure the armature turns freely. Insert a flat blade screwdriver
through the opening in the nose housing.
2. Pry the pinion gear to rotate the armature.
D02036
D2-19
D2-20
D02036
MAGNETIC SWITCH
Coil Test
1. Using an ohmmeter, measure the coil resistance across the coil terminals.
The coil should read approximately 28ohms at
22 C (72F).
Removal
1. Remove battery power as described in Cranking Motors - Removal.
2. Disconnect the cables from the switch terminals. Disconnect the wires from the coil terminals (Figure 2-14).
NOTE: If the magnetic switch being removed has a
diode across the coil terminals, mark the leads prior
to removal. This is done to ensure correct polarity
during installation.
3. Remove the mounting cap screws and washers. Remove the switch from the mounting
bracket.
4. The switch coil circuit can be tested as
described in Coil Test.
Installation
1. Attach the magnetic switch to the mounting
bracket using the cap screws and lock washers
previously removed.
D02036
D2-21
NOTES
D2-22
D02036
SECTION D3
ELECTRICAL SYSTEM COMPONENTS
INDEX
D03032 08/07
D3-1
NOTES
D3-2
08/07 D03032
D03032 08/07
D3-3
D3-4
7. Relay Centers
8. Turn Signal Flasher
9. Steering Bleeddown Timer
10.Windshield Wiper Delay Timer
11.External Harness Interface Connection Panel
12.ORBCOMM Modem
08/07 D03032
CIRCUIT BREAKERS
Table 1 lists the truck circuit breakers located at the
battery box and on the AC/heater unit.
AMPS
VOLTS
CIRCUIT NUMBER
IN
CONTROL DESCRIPTION
OUT
LOCATION: BATTERY BOX
CB24V
50
+24
12
CB12V
50
+12
12V
20
+24
12AC
D03032 08/07
D3-5
RELAY CENTER
The relay centers shown in Figure 3-3 contain a maximum of 33 relays in its three convenience centers.
Circuit breakers are not used on this board.
D3-6
08/07 D03032
COIL CIRCUITS
+
CONTACT CIRCUITS
COM.
NO
FUNCTION
NC
Relay Center 1
L
39J
39A
39J
RLNO
39AA
39J
39B
39J
RMNO
39BA
39J
39C
39J
RNNO
39CA
41H
11HA
41HA
RPNC
41H
11HB
41HB
RRNC
41
11LA
41LA
RSNC
48FS
48FP
48F
RTNC
U
V
51R
51T
RVNO
51S
W
X
Fog Lights
Not Used
Steering Bleed Down
Not Used
25N
RXNO
25N1
Relay Center 2
L
41
11LB
41LB
RLNC
45L
11CLL
45LL
45LL2
45R
11CLR
45RL
45RLZ
41TS
11T
41C
RPNC
Clearance Lights
44A1
44R1
44A1
44R
RRNC
44B1
44B4
44B1
44D
RSNC
52C1
52R1
52P
52C3
RTNC
52C2
5ZRZ
52P
52C4
RVNC
U
V
Not Used
43
11H
43
64
RWNC
Front Horn
43
11H
43
64
RXNC
Front Horn
Relay Center 3
L
44A1
44R4
44A1
44L
RLNC
45RR
46H
46
46A1
Hazard Light
25R
47A
47
RRNC
Backup Light
28A1
68B
68C
RSNC
Ether Start
63L1
63
63L
RTNC
63H1
63
63H
RVNC
M
N
Not Used
Not Used
U
V
Not Used
W
X
D03032 08/07
25N
21S
21PT
RXNC
Engine Start
D3-7
D3-8
08/07 D03032
D03032 08/07
D3-9
D3-10
08/07 D03032
FUSE PANEL
The fuse panel is located in the rear electrical compartment behind the drivers seat (Figure 3-7). The
panel consists of three fuse blocks.
Refer to the following tables and diagrams for circuit
identification.
D03032 08/07
D3-11
11
Fuse
Function
Amperage
5A
PLM LIghts
10A
SBDT
5A
Lincoln Lube
10A
Hoist Limit SW
5A
Brake Light
10A
Brake Controls
10A
Rear Retard Lt
10A
10A
10
---
11
---
---
12
---
---
13
14
VHMS/ORBCOMM
5A
15
10A
16
5A
17
15A
---
10A
18
15A
19
15A
20
Service LTS
10A
21
Fog Lights
10A
22
SBDT
5A
23
---
---
24
---
---
D3-12
08/07 D03032
21
Fuse
Function
Amperage
15a
15A
Head LT Controls
5A
LO BM HD LT Inside Position
15A
Clearance Lights
15A
ATC
10A
EDP
5A
15A
Hazard Lights
10A
10
RCM
10A
11
---
---
12
---
---
13
Start Signal
5A
14
---
---
15
---
---
16
---
---
17
---
---
18
---
---
19
---
---
20
---
21
10A
22
10A
23
10A
24
10A
---
D03032 08/07
D3-13
12V
FUSE
FUNCTION
Amperage
20A
ATC
10A
Shifter
5A
EDP Signals
5A
---
---
Turn Signals
5A
15A
10A
Windshield Wiper
15A
10
Drivers Seat
5A
11
Ether Start
5A
12
---
---
13
Key SW Signal
5A
14
5A
15
EDP
5A
16
Switch Lights
5A
17
AM/FM Radio
5A
18
Cigar Lighter
10A
19
10A
20
10a
21
20A
22
RT Window Motor
20A
23
---
---
24
---
---
D3-14
08/07 D03032
EXTERIOR COMPONENTS
BATTERY BOX
BATTERY EQUALIZER
Test
If the batteries are not being charged equally or other
problems are apparent, perform the following tests:
1. Check the circuit breaker on the end of the
enclosure to see if it has opened. If so, press
the button to reset.
2. Measure the voltage of each individual battery.
Each should measure approximately 12 volts. If
not, check voltages below:
a. Measure the voltage between the 24 volt terminal and ground terminal on the battery
equalizer and record.
b. Measure the voltage between the 12 volt terminal and ground terminal on the battery
equalizer and record.
3. If the difference between the two voltage readings in the previous step exceeds 0.75 volts, the
battery equalizer must be replaced.
CIRCUIT BREAKERS
Two, fifty amp circuit breakers protect the power circuits between the batteries and the power bus bars
located in the truck cab. Circuit breaker (4) is used in
the 24 volt circuit and circuit breaker (5) is used in the
12 volt circuit.
D03032 08/07
D3-15
D3-16
08/07 D03032
D03032 08/07
D3-17
D3-18
08/07 D03032
D03032 08/07
D3-19
SPEED SENSORS
A speed sensor (Figure 3-15), located in the brake
assembly in each rear wheel provides individual
wheel speed signals to the RCM. The speed signals
are used to determine truck speed and to monitor
wheel slip.
The sensors are mounted in the brake hub and
adjusted to provide a slight gap between the tip of the
sensor and the gear teeth on the periphery of the
seal carrier.
Each sensor is supplied with +18 volts through pin A.
Pin B is common (-) and grounded to the sensor
shell. Pin C provides the signal out.
No maintenance is required, normally. However, it is
necessary to adjust the sensor after brake rebuild.
D3-20
3. Connector End
08/07 D03032
Sensor Adjustment
GENERAL TROUBLESHOOTING
To prevent possible damage to the battery equalizer system, the following procedure must be followed when the battery cables are removed or
installed.
When removing cables, disconnect
remove the positive (+) cables first.
and
install
the
D03032 08/07
3. Brake Assembly
D3-21
D3-22
08/07 D03032
SECTION D10
CHARGING SYSTEM
INDEX
D10004 04/08
Charging System
D10-1
NOTES
D10-2
Charging System
04/08 D10004
CHARGING SYSTEM
The charging system is an important part of the electrical system. It provides electrical current for the
lights, the radio, the engine electrical systems, and
all other electrical accessories. It also maintains the
batteries in a charged state, recharging them as necessary.
The charging system has three main components:
the alternator, the voltage regulator, and the batteries. To properly service the charging system, a good
understanding of how each component works is necessary.
The alternator generates electrical power to operate
accessories and to recharge the batteries. The alternator is driven by a belt located off of an accessory
pulley. Mechanical energy from the drive pulley is
converted by the alternator into electrical energy for
the batteries and the electrical system.
The alternator is a brushless alternator designed to
generate high output at low speeds. The alternator is
also designed to withstand high heat exposure and
vibration. The 24 volt alternator is capable of generating 140 amps of electrical power.
The voltage regulator controls alternator output and
senses when the batteries need recharging, and
increases in electrical demand. The voltage regulator
adjusts alternator output, accordingly.
The batteries are a reservoir of chemical electrical
power. Their primary purpose is to provide electrical
energy for engine cranking. The batteries also supply
power to vehicle accessories when the electrical load
is too great for the alternator, alone.
D10004 04/08
Charging System
D10-3
TROUBLESHOOTING
PREVENTIVE MAINTENANCE
PROCEDURES
The object of preventive maintenance is to identify
and correct potential problems before they occur.
There are three preventive maintenance procedures
that can greatly enhance the efficiency of charging
system functions. These three procedures also represent the initial steps to follow when fully diagnosing
a problem in the charging system. Preventive maintenance procedures are as follows:
Alternator Cleanliness
Ensure that all alternator surfaces are clean. A
buildup of dirt, grease or dust may result in poor performance and/or damage to the alternator. Air flow
passages must be clear of debris so that air can easily pass through the unit. All electrical connection
points must be clean and free from corrosion.
Timely preventive maintenance of the charging system will help keep it operating smoothly. However,
when a problem does occur, effective diagnostic procedures will help you locate and correct the problem.
Before analyzing the charging system, ensure the
batteries have been properly tested and are at least
75% charged. Otherwise, any electrical tests conducted on the charging system will be inaccurate.
If the troubleshooting diagnosis points to a faulty
alternator, a new alternator must be installed. If the
vehicle has had a history of charging problems and
system failure has been eliminated, it may be necessary to reevaluate the capacity of the alternator. The
addition of add-on electrical devices also make it
necessary to reevaluate the capacity of the alternator. Consult your area support manager for questions
regarding this issue.
Alternator Mounting
Charging system components must be securely
mounted to their brackets. Mounting brackets must
be bolted securely to the engine. If charging system
components are poorly mounted, damaging vibration
and diminished belt drive performance will result.
Ensure all components are securely mounted to the
truck. Verify that all mounting components are in
good condition and that the belt drive system is in
proper alignment.
D10-4
Charging System
04/08 D10004
D10004 04/08
Charging System
D10-5
VOLTAGE REGULATOR
ADJUSTMENT
The voltage regulator is factory set to operate at 28.2
volts. If adjustment is necessary after performing the
alternator performance test, follow the steps below.
1. Access the voltage regulator adjustment screw.
Refer to Figure 10-7 for the location of the
adjustment screw.
2. Install a voltmeter across the positive and negative output terminals of the alternator. Install an
ammeter at least 15 cm (6 in.) away on the positive output cable. Refer to Figure 10-1.
3. Start the engine and operate at approximately
850 rpm (alternator @ 3000 rpm).
4. Create an electrical load of 10-15 amps by turning on lights or other accessories.
5. Check the voltage on the voltmeter. Acceptable
voltage ranges from 27.8 - 28.4 volts with the
desired voltage being 28.2 volts.
If it is necessary to adjust the voltage, turn the
adjustment screw clockwise to raise the voltage. Turn the screw counterclockwise to lower
the voltage.
If the voltage cannot be adjusted to within the
specifications, the alternator is defective and
must be replaced.
D10-6
Charging System
04/08 D10004
ALTERNATOR
Removal
1. Park the truck and shut off the engine. Disconnect the batteries with the battery disconnect
switch located on the battery box.
2. Tag all cable and wire connections at the rear of
the alternator and disconnect.
3. Remove the cap screws that secure belt guard
(2, Figure 10-5). Remove the belt guard assembly from the engine.
2. Pulley
2. Belt Guard
D10004 04/08
Charging System
D10-7
Installation
1. Ensure the battery disconnect switch on the
battery box is open in order to isolate battery
power from the truck.
2. Place the alternator into position on the mounting bracket. Install mounting cap screws (2, Figure 10-7)
3. If removed, install pulley (2, Figure 10-2), and
secure with nut (1) and the washer. Tighten to
102 7 Nm (75 5 lb ft).
4. Attach the cable and wire connections at the
rear of the alternator.
5. Use a breaker bar to rotate the belt tensioner to
allow installation of the drive belt. Install the belt
and ensure the belt is aligned and positioned
properly in the grooves.
6. Place belt guard (2, Figure 10-1) into position
over the alternator. Install the cap screws that
secure the guard to the engine.
7. Connect battery power to the truck by closing
the battery disconnect switch on the battery
box.
8. Verify the alternator is charging properly. Refer
to Alternator Performance Test.
D10-8
Charging System
04/08 D10004
D10004 04/08
Charging System
D10-9
D10-10
Charging System
04/08 D10004
SECTION D11
AUTOMATIC TRANSMISSION CONTROLLER
INDEX
D11012 08/11
D11-1
NOTES
D11-2
08/11 D11012
D11012 08/11
D11-3
Note that when the operator selects D, the recommended range for normal operation, the transmission
controller will engage 2nd gear and automatically
shift through the 3rd through 7th gear ranges as
required. This will result in the most economical operation. If the operator selects 3, 4, or 5, the transmission will initially select 1st gear and then upshift only
as far as the gear selected. These positions provide
more effective retarding on grades.
If the F1 start switch is activated, the transmission
will always start in F1 even though the shift lever is in
the DRIVE position. This switch is used for the inhibition of driving under the torque converter range. For
example, torque converter lock-up clutch off if in F2
and available for prevention of torque converter overheat.
D11-4
08/11 D11012
NETWORK DATA
OPERATING MODES
MODE
CONDITIONS
Braking
Mode
Normal
Mode
Engine Speed
D11012 08/11
Item
Number
Item
Gear speed
Lock-up status
F1 start switch
Overrun alarm
10
11
12
Alternator R terminal
13
14
15
16
Fuel level
17
18
Body seating
19
Float caution
20
21
22
23
24
25
26
D11-5
Item
Item
27
28
29
30
31
32
Item
Item
Service meter
10
11
12
13
14
15
16
D11-6
08/11 D11012
SHIFT LOGIC
NOTE: Safety functionality of the ATC may cause the
transmission to operate in a manner different than
described below. Refer to Safety Functionality in this
chapter for more information.
When the shift lever is set in position D, the transmission is set to the F2 torque converter range. When
the accelerator pedal is depressed, the engine speed
increases. When the transmission input shaft speed
reaches 1250-1300 rpm, the lock-up clutch is
engaged, so the torque converter is directly engaged
and the transmission is set to direct travel.
D11012 08/11
D11-7
SAFETY FUNCTIONALITY
Down-Shift Inhibitor Function
Self-diagnostic function
The controller performs self-diagnosis of the system
and displays any abnormalities. The details of the
self-diagnosis are displayed on a monitor. If any
abnormality is detected during self-diagnosis, the
abnormality data is transmitted to the network and is
displayed as an action code on the machine monitor.
The transmission system caution, warning lamp, or
alarm buzzer may also be actuated.
D11-8
08/11 D11012
D11012 08/11
D11-9
Condition When
Problem Occurred
Limp Home
Procedure
1500L0
Condition 2
Procedure 2
15G0MW
Condition 2
Procedure 3
D L: F2
15H0MW
Condition 7
Procedure 1
D L: F2, R: R
15J0MW
Condition 7
Procedure 1
D L: F2, R: R* (RM)
15K0MW
Condition 7
Procedure 3
D L: F1, R: R
15L0MW
Condition 7
Procedure 3
D L: F2, R: R
15M0MW
Condition 7
Procedure 3
D L: F2, R: R
15X0MW
Condition 7
Procedure 1
D L: F1, R: R
15SBL1
Condition 7
Procedure 1
15SBMA
Condition 3
Procedure 1
D L: F2
R: R
15SCL1
Condition 7
Procedure 1
D L: F3
15SCMA
Condition 7
Procedure 1
D L: F2, R: R
15SDL1
Condition 7
Procedure 1
D L: F1, R: R
15SDMA
Condition 7
Procedure 1
D L: F2, R: R* (M,R)
15SEL1
Condition 7
Procedure 1
D L: F2
15SEMA
Condition 7
Procedure 1
D L: F1, R: R
15SFL1
Condition 7
Procedure 1
D L: F1
15SFMA
Condition 7
Procedure 1
D L: F2, R: R
15SGL1
Condition 7
Procedure 1
D L: F3* (L,3rd)
15SGMA
Condition 7
Procedure 1
D L: F2, R: R
15SSL1
Condition 7
Procedure 1
D L: F2, R: R* (M,R)
15SSMA
Condition 3
Procedure 1
D L: F1, R: R
15SJMA
Condition 1
Procedure 1
D L: F2, R: R
DAQ0KK
Condition 1
Procedure 5
DAQ2KK
Condition 1
Procedure 4
DAQ9KQ
Condition 4
Procedure 6
DAQRKR
Condition 2
Procedure 5
DAQRMA
Condition 4
Procedure 1
D L: F2, R: R
DDTHKA
Condition 1
Procedure 1
D L: F3
DDTJKA
Condition 1
Procedure 1
D L: F1, R: R
DDTKKA
Condition 1
Procedure 1
D L: F2
DDTLKA
Condition 1
Procedure 1
D L: F1
DDTMKA
Condition 1
Procedure 1
D L: F3* (L,3rd)
DDTNKA
Condition 1
Procedure 1
R: R
DDTRKA
Condition 1
Procedure 1
D L: F2, R: R* (M,R)
DF10KA
Condition 5
Procedure 7
D11-10
Remarks
Condition 1
Gear speed is kept fixed even
after restart.
If lever is set to N position, gear is
set in neutral.
Condition 2
Transmission shifts to neutral
suddenly during travel. Once the
truck stops, the transmission
remains in neutral, but the truck
will not start when lever is operated.
Condition 3
Transmission shifts to neutral
suddenly during travel.
Condition 4
After engine is started, gear is
kept in neutral and machine does
not start when lever is operated.
Condition 5
Lever responds abnormally and
does not work. If lever is operated, gear is set in neutral.
Condition 6
Gear speed is kept fixed and gear
is not shifted from fixed gear after
machine restarts.
If lever is set to N position, gear is
set in neutral but cannot be
shifted any more.
Condition 7
Proper clutch for travel is used
and gear speed is fixed. If there is
not proper clutch, gear is set in
neutral.
If lever is in N position, gear is set
in neutral.
Note 1
Even if problem disappears, gear
is kept in neutral until the lever is
moved
08/11 D11012
Condition When
Problem Occurred
Limp Home
Procedure
DF10KB
Condition 5
Procedure 7
DLE2KA
Condition 1
Procedure 1
D L: F1, R: R
DLE2LC
Condition 1
Procedure 1
D L: F1, R: R
DLF1KA
Condition 1
Procedure 1
D L: F2, R: R
DLF1LC
Condition 1
Procedure 1
D L: F2, R: R
DLF2KA
Condition 1
Procedure 1
D L: F2, R: R
DLF2LC
Condition 1
Procedure 1
D L: F2, R: R
DLT3KA
Condition 6
Procedure 3
D L: F2, R: R
DLT3LC
Condition 6
Procedure 3
D L: F2, R: R
DXH1KA
Condition 1
Procedure 1
D L: F2, R: R
DXH1KB
Condition 1
Procedure 1
D L: F2, R: R
DXH1KY
Condition 1
Procedure 1
D L: F2, R: R
DXH2KA
Condition 7
Procedure 1
D L: F2, R: R
DXH2KB
Condition 7
Procedure 1
D L: F2, R: R
DXH2KY
Condition 7
Procedure 1
D L: F3
DXH3KA
Condition 7
Procedure 1
D L: F2, R: R* (M,R)
DXH3KB
Condition 7
Procedure 1
D L: F2, R: R* (M,R)
DXH3KY
Condition 7
Procedure 1
D L: F1, R: R
DXH4KA
Condition 7
Procedure 1
D L: F1, R: R
DXH4KB
Condition 7
Procedure 1
D L: F1, R: R
DXH4KY
Condition 7
Procedure 1
D L: F2
DXH5KA
Condition 7
Procedure 1
D L: F2, R: R
DXH5KB
Condition 7
Procedure 1
D L: F2, R: R
DXH5KY
Condition 7
Procedure 1
D L: F1
DXH6KA
Condition 7
Procedure 1
D L: F2, R: R
DXH6KB
Condition 7
Procedure 1
D L: F2, R: R
DXH6KY
Condition 7
Procedure 1
D L: F3* (L,3rd)
DXH7KA
Condition 3
Procedure 1
D L: F2
DXH7KB
Condition 3
Procedure 1
D L: F2
DXH7KY
Condition 7
Procedure 1
DXJ7KA
Condition 3
Procedure 1
D L: F1, R: R
DXJ7KB
Condition 3
Procedure 1
D L: F1, R: R
DXJ7KY
Condition 7
Procedure 1
D L: F2, R: R* (M,R)
D11012 08/11
R: R
Remarks
Condition 1
Gear speed is kept fixed even
after restart.
If lever is set to N position, gear is
set in neutral.
Condition 2
Transmission shifts to neutral
suddenly during travel. Once the
truck stops, the transmission
remains in neutral, but the truck
will not start when lever is operated.
Condition 3
Transmission shifts to neutral
suddenly during travel.
Condition 4
After engine is started, gear is
kept in neutral and machine does
not start when lever is operated.
Condition 5
Lever responds abnormally and
does not work. If lever is operated, gear is set in neutral.
Condition 6
Gear speed is kept fixed and gear
is not shifted from fixed gear after
machine restarts.
If lever is set to N position, gear is
set in neutral but cannot be
shifted any more.
Condition 7
Proper clutch for travel is used
and gear speed is fixed. If there is
not proper clutch, gear is set in
neutral.
If lever is in N position, gear is set
in neutral.
D11-11
D11-12
08/11 D11012
SECTION D15
MACHINE MONITOR
INDEX
D15002
Machine Monitor
D15-1
NOTES
D15-2
Machine Monitor
D15002
MACHINE MONITOR
CHARACTER DISPLAY
2. Character Display
D15002
Operator mode
1
Operation Information
Machine Monitor
D15-3
Odometer
Select, Run
Service Meter
If the key switch is in the OFF position, the () portion of mode select switch 1 can be pressed to display the odometer.
Operation Information
Operation information allows the operator to view the
total payload and dump counter.
To display operation information, the character display must be at the service meter/odometer display
(or an action code, if present). If another display is
showing, turn the key switch to OFF, then back to
ON. After the initial check and the service meter/
odometer is displayed, press the () portion of mode
select switch 1. The display should switch to operator
information.
D15-4
Machine Monitor
D15002
D15002
Machine Monitor
D15-5
Display Items
Item
Interval
In Hours
Character
Display
ID
Number
Fuel filter
250
FUEL FILT
03
250
ENG FILT
02
Engine oil
250
ENG OIL
01
Transmission
oil filter
500
TM FILT
13
Corrosion
resistor
250
CORR RES
06
Torque converter,
transmission
and brake cooling
oil
1000
TC/TM/BKOIL
24
Brake cooling
oil filter
1000
BK C FILT
16
Hydraulic
oil filter
1000
HYD FILT
04
Differential
case oil
2000
DIFF OIL
11
2000
FNL OIL
08
Hydraulic oil
4000
HYD OIL
10
3. Press (>) or (<) on mode select switch 2 to display the item to be reset.
D15-6
Machine Monitor
D15002
Selecting A Language
This function can be used to change the default language for the character display.
1. Beginning at the service meter display, press
the () on mode select switch 1 to display the
operation information.
2. Press (>) or (<) on mode select switch 2 to
scroll to the LANGUAGE display.
D15002
Machine Monitor
D15-7
If there is a machine failure or if maintenance is necessary, an action code is displayed on the character
display to recommend a suitable response.
If more than one failure is present, the most important action code is displayed. The order of importance, starting from the highest, is E03, E02, and
E01. If failures of equal importance occur at the
same time, the latest one is displayed.
When action codes E02 or E03 occur, the alarm
buzzer sounds intermittently and the central warning
lamp illuminates.
E03 Codes
4. Press (>) or (<) on mode select switch 2 to
select a different language. The available languages are: English, Japanese, German,
French, Italian, Spanish, and Swedish.
When E03 is displayed, stop the machine immediately. Check the failure code, and contact your Komatsu distributor for repairs. Refer to Checking Failure
Codes later in this chapter.
5. Press the () on mode select switch 1 to activate the new language change. The display will
then return to the previous screen.
If the desired language has been set, press ()
on mode selector switch 2 twice or turn the key
switch to OFF to exit.
D15-8
Machine Monitor
D15002
E01 Codes
When an E03 code is present, the top line displays
E03. The bottom line alternates between CHECK
RIGHT NOW and CALL. The display will alternate in
3 second intervals. The telephone number is displayed to the right of CALL. If the telephone number
has not been set, the spaces will be blank. Refer to
Character Display - Inputting Telephone Numbers.
E02 Codes
When an E02 code is present, the top line of the
character display will indicate E02. The bottom line
indicates whether the condition of the machine is
related to overspeed or overheat.
When an E02 code is displayed, it is important to act
accordingly.
If an overspeed related fault is displayed, reduce
the engine speed and the speed of the machine.
If an overheat related fault is displayed, safely
stop the machine and operate the engine under
no load at a mid-range speed.
D15002
Machine Monitor
D15-9
Monitor Panel
Transmission
Transmission controller
Brake
RCM controller
VHMS
VHMS controller
2 Items
6. Press (>) or (<) to scroll through the list of monitoring menus listed in Table 1.
Press () to advance to the individual monitoring items listed in Table 2. Press (>) or (<) to
scroll through the list of monitored items for that
system. Hold the (>) or (<) to scroll at high
speed.
D15-10
Machine Monitor
D15002
Example:
3. Determine which two items to view on the monitor. The item list and their five-digit codes are
listed in Table 2.
D15002
Machine Monitor
D15-11
Code
Output
Unit
Controller Description
RCM
20214
Part number
--
RCM
Application version
20231
Application
--
RCM
Data Version
20232
Version data
--
0.00~5.00
RCM
37701
RCM
39800
ON [1]
OFF [0]
--
RCM
39801
ON [1]
OFF [0]
--
RCM
39900
ON [1]
OFF [0]
--
RCM
33700
0~1000
mA
RCM
33802
0~1000
mA
10
RCM
33804
0~1000
mA
11
RCM
33701
0~1000
mA
12
RCM
33803
0~1000
mA
13
RCM
33805
0~1000
mA
14
RCM
35100
ON [1]
OFF [0]
--
15
RCM
35102
ON [1]
OFF [0]
--
16
RCM
30201
0~160
17
RCM
30204
0.00~5.00
18
RCM
30207
0~160
19
RCM
30209
0.00~5.00
20
RCM
30208
0~160
21
RCM
30210
0.00~5.00
22
RCM
44700
ON [1]
OFF [0]
--
23
RCM
35701
ON [1]
OFF [0]
--
24
RCM
35702
ON [1]
OFF [0]
--
25
RCM
35703
ON [1]
OFF [0]
--
26
RCM
32101
ON [1]
OFF [0]
--
27
RCM
32102
ON [1]
OFF [0]
--
28
RCM
Empty or loaded
39400
29
RCM
Hydraulic filter
35700
ON [1]
OFF [0]
--
30
RCM
34105
ON [1]
OFF [0]
--
31
RCM
34106
ON [1]
OFF [0]
--
32
RCM
34102
--
33
RCM
34103
--
34
RCM
34104
--
35
RCM
Retard lever
33900
0.00~5.00
36
RCM
33901
0.00~5.00
37
RCM
33902
0.00~5.00
38
RCM
44800
D15-12
Machine Monitor
Loaded [1]
ON [1]
Empty [0]
OFF [0]
--
--
D15002
Controller Description
Code
Output
ON [1]
OFF [0]
Unit
39
RCM
44801
--
40
RCM
35402
-90.0~90.0
41
RCM
35400
0.00~5.00
42
RCM
32803
0.00~20.10
MPa
43
RCM
32809
0.00~5.00
44
RCM
32802
0.00~20.10
MPa
45
RCM
32808
0.00~5.00
46
RCM
31400
0~32767
rpm
47
RCM
39705
0~32767
rpm
48
RCM
39704
0~32767
rpm
49
T/M
20201
Part number
--
50
T/M
Application version
20223
Application
--
51
T/M
Data Version
20224
Version data
--
52
T/M
Acceleration
38500
Quick [1]
Normal [0]
--
53
T/M
Alternator R
4301
ON [1]
OFF [0]
--
54
T/M
Body seated
34600
ON [1]
OFF [0]
--
55
T/M
44900
0~100
56
T/M
44901
0~100
57
T/M
Coolant temperature
04104
-40~210
58
T/M
31602
0~1000
mA
59
T/M
1st (ECMV 1)
31612
0~4000
mA
60
T/M
31603
0~1000
mA
61
T/M
2nd (ECMV 2)
31613
0~4000
mA
62
T/M
31604
0~1000
mA
63
T/M
3rd (ECMV 3)
31614
0~4000
mA
64
T/M
H (ECMV H dir)
31600
0~1000
mA
65
T/M
H (ECMV H)
31610
0~4000
mA
66
T/M
ECMV L dir
31601
0~1000
mA
67
T/M
ECMV L
31611
0~4000
mA
68
T/M
ECMV LU dir
31609
0~1000
mA
69
T/M
ECMV LU
31619
0~4000
mA
70
T/M
ECMV M dir
31640
0~1000
mA
71
T/M
ECMV M
31641
0~4000
mA
72
T/M
ECMV R dir
31606
0~1000
mA
73
T/M
ECMV R
31616
0~4000
mA
74
T/M
Emergency travel
32400
75
T/M
Engine speed
01002
76
T/M
F1 switch
35200
ON [1]
OFF [0]
--
77
T/M
Fill switch
31520
ON [1]
OFF [0]
--
78
T/M
Fill time 1
41802
0~2550
mSec
79
T/M
Fill time 2
41803
0~2550
mSec
80
T/M
Fill time 3
41804
0~2550
mSec
D15002
Machine Monitor
ON [1]
OFF [0]
0~32767
-rpm
D15-13
Controller Description
Code
Output
Unit
81
T/M
Fill time H
41801
0~2550
mSec
82
T/M
Fill time L
41800
0~2550
mSec
83
T/M
Fill time M
41809
0~2550
mSec
84
T/M
Fill time R
41806
0~2550
mSec
85
T/M
Fuel sensor
04201
0~250
86
T/M
Fuel sensor
4200
0.00~5.00
87
T/M
Key switch
32300
88
T/M
32601
0.00~5.00
MPa
89
T/M
32602
0.00~5.00
90
T/M
30100
0~160
91
T/M
30101
0.00~5.00
92
T/M
32603
0.00~5.00
MPa
93
T/M
32604
0.00~5.00
94
T/M
Transmission filter
33300
95
T/M
32500
0~160
96
T/M
32501
0.00~5.00
97
T/M
Transmission speed: in
31200
0~32767
rpm
98
T/M
31300
0~32767
rpm
ON [1]
Clogged [1]
OFF [0]
Normal [0]
--
--
99
T/M
31400
0~32767
rpm
100
T/M
Throttle mod
36000
-100~100
101
T/M
Throttle position
31700
0.00~5.00
102
T/M
38700
0~17
--
103
T/M
38600
Keep [1]
Normal [0]
--
104
Monitor
20200
Part number
--
105
Monitor
Application version
20221
Application
--
106
Monitor
Data Version
20222
Version data
--
107
Monitor
AISS switch
30400
108
Monitor
Conn chk 1, 2
30700
ON or OFF [1 of 0],
ON or OFF [1 of 0]
--
109
Monitor
Rheostat
30300
0.0~51.0
--
110
Monitor
30800
--
111
Monitor
Sw5-1, Sw5-2
30900
ON or OFF [1 of 0],
ON or OFF [1 of 0]
--
112
Monitor
Sw5-3, Sw5-4
30901
ON or OFF [1 of 0],
ON or OFF [1 of 0]
--
113
Monitor
Sw6-1, Sw6-2
30902
ON or OFF [1 of 0],
ON or OFF [1 of 0]
--
114
Monitor
Sw6-3, Sw6-4
30903
ON or OFF [1 of 0],
ON or OFF [1 of 0]
---
37800
ON [CN2B-2:close, CN2B-2:open]
OFF [CN2B-2:open, CN2B-2:close]
+++ [CN2B-2:close, CN2B-2:open]
--- [CN2B-2:open, CN2B-2:close]
115
D15-14
Monitor
ABS
Machine Monitor
ON [Close]
OFF [Open]
--
D15002
Controller Description
116
Monitor
ARSC
Code
Output
Unit
--
37700
ON [CN2B-1:close, CN2B-1:open]
OFF [CN2B-1:open, CN2B-1:close]
+++ [CN2B-1:close, CN2B-1:open]
--- [CN2B-1:open, CN2B-1:close]
ON [CN2B-3:close, CN2B-3:open]
OFF [CN2B-3:open, CN2B-3:close]
+++ [CN2B-3:close, CN2B-3:open]
--- [CN2B-3:open, CN2B-3:close]
--
117
Monitor
ASR
37900
118
VHMS
Body seated
34601
ON [1]
OFF [0]
--
119
VHMS
Inclinometer
32901
-15.0~+15.0
120
VHMS
Inclinometer
32902
0.00~5.10
121
VHMS
Payload
42200
0.0~655.4
122
VHMS
Rate weight
42201
0.0~655.4
123
VHMS
Shift lever N
42500
ON [1]
OFF [0]
--
124
VHMS
45000
ON [1]
OFF [0]
--
125
VHMS
32805
0.00~20.10
MPa
126
VHMS
32811
0.00~5.00
127
VHMS
32804
0.00~20.10
MPa
128
VHMS
32810
0.00~5.00
129
VHMS
32807
0.00~20.10
MPa
130
VHMS
32813
0.00~5.00
131
VHMS
32806
0.00~20.10
MPa
132
VHMS
32812
0.00~5.00
133
VHMS
Truck status
42400
0~8
--
D15002
Machine Monitor
D15-15
D15-16
Machine Monitor
D15002
D15002
Machine Monitor
D15-17
D15-18
Machine Monitor
D15002
D15002
Machine Monitor
D15-19
NOTES
D15-20
Machine Monitor
D15002
SECTION D20
FAILURE CODES
INDEX
D20001 03/09
Fault Codes
D20-1
NOTES
D20-2
Fault Codes
03/09 D20001
FAILURE CODES
ACTION CODE DISPLAYS
If there is a machine failure or if maintenance is necessary, an action code is displayed on the character
display to recommend a suitable response.
If more than one failure is present, the most important action code is displayed. The order of importance, starting from the highest, is E03, E02, and
E01. If failures of equal importance occur at the
same time, the latest one is displayed.
When action codes E02 or E03 occur, the alarm
buzzer sounds intermittently and the central warning
lamp illuminates.
E02 Codes
When an E02 code is present, the top line of the
character display will indicate E02. The bottom line
indicates whether the condition of the machine is
related to overspeed or overheat.
When an E02 code is displayed, it is important to act
accordingly.
If an overspeed related fault is displayed, reduce
the engine speed and the speed of the machine.
If an overheat related fault is displayed, safely
stop the machine and operate the engine under
no load at a mid-range speed.
E03 Codes
When E03 is displayed, stop the machine immediately. Check the failure code, and contact your Komatsu distributor for repairs. Refer to Checking Failure
Codes later in this chapter.
E01 Codes
When an E01 code is present, the top line of the
character display will display E01. The bottom line
will either display MAINTENANCE or another
description that indicates the affected system. E01
codes do not require immediate attention. If desired,
the truck can operate until the end of the shift before
returning for service.
D20001 03/09
Fault Codes
D20-3
The following failure code table is sorted in alphabetical and numerical order.
The Applicable Controller column in the fault code
table indicates the controller that logged the failure.
Below are the controllers:
MON: Machine monitor system
ENG: Engine controller
If MAINTENANCE is displayed, check the failure
code and contact your Komatsu distributor for
repairs.
D20-4
Fault Codes
03/09 D20001
D20001 03/09
Fault Codes
D20-5
Failure
codes
Description
Applicable Action
History
controller code classification
1500L0
TM
E03
Mechanical
system
15B0NX
TM
E01
Mechanical
system
15F0KM
TM
Mechanical
system
15F0MB
TM
Mechanical
system
15F7KM
TM
Mechanical
system
15G0MW
TM
E03
Electrical
system
15G7KM
TM
Mechanical
system
15H0MW
TM
E03
Electrical
system
15J0MW
TM
E03
Electrical
system
15K0MW
TM
E03
Electrical
system
15L0MW
TM
E03
Electrical
system
15M0MW
TM
E03
Electrical
system
15SBL1
TM
E03
Electrical
system
15SBMA
TM
E03
Electrical
system
15SCL1
TM
E03
Electrical
system
15SCMA
TM
E03
Electrical
system
15SDL1
TM
E03
Electrical
system
15SDMA
TM
E03
Electrical
system
15SEL1
TM
E03
Electrical
system
15SEMA
TM
E03
Electrical
system
15SFL1
TM
E03
Electrical
system
15SFMA
TM
E03
Electrical
system
15SGL1
TM
E03
Electrical
system
D20-6
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
15SGMA
TM
E03
Electrical
system
15SJMA
TM
E03
Electrical
system
15SSL1
TM
E03
Electrical
system
15SSMA
TM
E03
Electrical
system
15X0MW
TM
E03
Electrical
system
2G39MA
BK
E03
Electrical
system
2G3AMA
BK
E03
Electrical
system
2G41ZG
BK
E03
Mechanical
system
2J00MA
BK
E03
Electrical
system
4A00ZG
BK
E03
Mechanical
system
4A5WZH
BK
E01
Mechanical
system
4A5XZH
BK
E01
Mechanical
system
6014NX
BK
E01
Mechanical
system
989A00
TM
E02
Mechanical
system
Alternator: Malfunction
TM
E03
Electrical
system
MON
E03
Mechanical
system
MON
E02
Mechanical
system
MON
Mechanical
system
MON
E02
Mechanical
system
MON
E02
Mechanical
system
MON
E02
Mechanical
system
MON
E02
Mechanical
system
BK
E01
Mechanical
system
BK
E01
Mechanical
system
BK
E01
Mechanical
system
AB00MA
D20001 03/09
Fault Codes
D20-7
Failure
codes
Description
Applicable Action
History
controller code classification
C115
ENG
E03
C124
ENG
E02
C135
ENG
E02
C141
ENG
E02
C143
ENG
E02
C144
ENG
E02
C145
ENG
E02
C146
ENG
E02
C151
ENG
E03
C153
ENG
E02
C154
ENG
E02
C155
ENG
E03
C156
ENG
E02
C157
ENG
E02
C158
ENG
E03
C159
ENG
E02
C161
ENG
E02
C162
ENG
E03
C163
ENG
E02
C164
ENG
E02
C165
ENG
E03
C187
ENG
E02
C195
ENG
E02
C196
ENG
E02
C197
ENG
E02
D20-8
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
C212
ENG
E02
C213
ENG
E02
C221
ENG
E02
C222
ENG
E02
C223
ENG
E02
C224
ENG
E02
C227
ENG
E02
C228
ENG
E03
C231
ENG
E02
C232
ENG
E02
C234
Eng Overspeed
ENG
E03
C235
ENG
E03
C237
ENG
E02
C238
ENG
E02
C245
ENG
E02
C261
ENG
E02
C263
ENG
E02
C265
ENG
E02
C271
ENG
E02
C272
ENG
E02
C285
ENG
E02
C286
ENG
E02
C319
ENG
E01
C322
ENG
E02
C323
ENG
E02
D20001 03/09
Fault Codes
D20-9
Failure
codes
Description
Applicable Action
History
controller code classification
C324
ENG
E02
C325
ENG
E02
C331
ENG
E02
C332
ENG
E02
C342
ENG
E03
C343
ENG
E02
C349
ENG
E02
C351
ENG
E02
C352
ENG
E02
C386
ENG
E02
C415
ENG
E03
C418
ENG
E01
C421
ENG
E02
C431
ENG
E02
C432
ENG
E03
C441
ENG
E02
C442
ENG
E02
C449
ENG
E03
C451
ENG
E02
C452
ENG
E02
C487
ENG
E02
C488
ENG
E02
C489
ENG
E02
C497
ENG
E02
C527
ENG
E02
D20-10
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
C529
ENG
E02
C546
ENG
E02
C547
ENG
E02
C556
ENG
E03
C559
ENG
E02
C599
ENG
E03
C611
ENG
C621
ENG
E01
C622
ENG
E01
C623
ENG
E01
C624
ENG
E01
C625
ENG
E01
C626
ENG
E01
C627
ENG
E01
C628
ENG
E01
C631
ENG
E01
C632
ENG
E01
C633
ENG
E01
C634
ENG
E01
C635
ENG
E01
C636
ENG
E01
C637
ENG
E01
C638
ENG
E01
C671
ENG
E01
C672
ENG
E01
D20001 03/09
Fault Codes
D20-11
Failure
codes
Description
Applicable Action
History
controller code classification
C673
ENG
E01
C674
ENG
E01
C675
ENG
E01
C676
ENG
E01
C677
ENG
E01
C678
ENG
E01
C689
ENG
E02
C697
ENG
E02
C698
ENG
E02
C721
ENG
E01
C722
ENG
E01
C723
ENG
E01
C724
ENG
E01
C725
ENG
E01
C726
ENG
E01
C727
ENG
E01
C728
ENG
E01
C731
ENG
E02
C781
ENG
E02
C783
ENG
E03
C1117
ENG
C1135
ENG
E03
C1256
ENG
E02
C1257
ENG
E03
C1357
ENG
E02
D20-12
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
C1358
ENG
E02
C1359
ENG
E02
C1361
ENG
E02
C1362
ENG
E02
C1363
ENG
E01
C1367
ENG
E01
C1368
ENG
E01
C1369
ENG
E01
C1371
ENG
E01
C1372
ENG
E01
C1373
ENG
E01
C1376
ENG
E01
C1377
ENG
E01
C1378
ENG
E01
C1381
ENG
E01
C1383
ENG
E01
C1384
ENG
E01
C1385
ENG
E01
C1386
ENG
E01
C1387
ENG
C1514
ENG
E02
C1516
ENG
E01
C1517
ENG
E03
C1518
ENG
E02
C1519
ENG
E01
D20001 03/09
Fault Codes
D20-13
Failure
codes
Description
Applicable Action
History
controller code classification
C1521
ENG
E01
C1522
ENG
E01
C1523
ENG
E01
C1524
ENG
E01
C1525
ENG
E01
C1526
ENG
E01
C1527
ENG
E01
C1528
ENG
E01
C1529
ENG
E01
C1531
ENG
E01
C1532
ENG
E01
C1533
ENG
E01
C1534
ENG
E01
C1535
ENG
E01
C1536
ENG
E01
C1537
ENG
E01
C1544
ENG
E01
C1548
ENG
E02
C1549
ENG
E02
C1551
ENG
E02
C1552
ENG
E02
C1553
ENG
E02
C1554
ENG
E02
C1555
ENG
E02
C1556
ENG
E02
D20-14
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
C1557
ENG
E02
C1558
ENG
E02
C1559
ENG
E02
C1595
ENG
E02
C1596
ENG
E01
C1597
ENG
E01
C1618
ENG
E01
C1619
ENG
E01
C1622
ENG
E02
C1634
ENG
E02
C1638
ENG
E01
C1843
ENG
E02
C1844
ENG
E02
C1845
ENG
E01
C1846
ENG
E01
C1847
ENG
E03
C1852
ENG
E02
C1888
ENG
E01
C1889
ENG
E01
C1891
ENG
E02
C1911
ENG
E02
C1984
ENG
E02
C1985
ENG
E02
C1986
ENG
E02
C1987
ENG
E02
D20001 03/09
Fault Codes
D20-15
Failure
codes
Description
Applicable Action
History
controller code classification
C1988
ENG
E02
C2121
ENG
E02
C2122
ENG
E02
C2123
ENG
E02
C2124
ENG
E02
C2125
ENG
E02
C2126
ENG
E02
C2127
ENG
E02
C2128
ENG
E02
C2129
ENG
E02
C2131
ENG
E02
C2132
ENG
E02
C2133
ENG
E02
C2134
ENG
E02
C2135
ENG
E02
C2136
ENG
E02
C2137
ENG
E02
C2138
ENG
E02
C2139
ENG
E02
C2146
ENG
E01
C2147
ENG
E01
C2151
ENG
E01
C2152
ENG
E01
C2157
ENG
E03
C2158
ENG
E03
D20-16
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
C2159
ENG
E03
C2185
ENG
E02
C2186
ENG
E02
C2215
ENG
E02
C2241
ENG
E03
C2242
ENG
E02
C2243
ENG
E02
C2244
ENG
E03
C2245
ENG
E03
C2246
ENG
E02
C2247
ENG
E02
C2248
ENG
E03
C2261
ENG
E01
C2262
ENG
E01
C2265
ENG
E02
C2266
ENG
E02
C2311
ENG
E02
C2321
ENG
C2322
ENG
C2377
ENG
E02
C2474
ENG
E02
C2557
ENG
E02
C2558
ENG
E02
C2963
ENG
C2964
ENG
D20001 03/09
Fault Codes
D20-17
Failure
codes
Description
Applicable Action
History
controller code classification
MON
E03
Electrical
system
TM
E03
Electrical
system
DAQ0KK
TM
E03
Electrical
system
DAQ2KK
TM
E03
Electrical
system
DAQ9KQ
MON
E03
MON
E03
MON
E03
MON
E03
Electrical
system
MON
E01
Electrical
system
DASRKR
MON
E03
Electrical
system
DB10KT
BK
E01
Electrical
system
DB12KK
BK
E03
Electrical
system
DB13KK
BK
E03
Electrical
system
DB19KQ
MON
E03
DB1RKR
TM
E03
DB1RMA
MON
E03
dBBRKR
MON
E01
Electrical
system
DDB4MA
BK
E01
Electrical
system
DDD7KX
BK
E03
Electrical
system
DDD8KA
BK
E03
Electrical
system
DDD8KB
BK
E03
Electrical
system
BK
E01
Electrical
system
BK
E01
Electrical
system
DDP6MA
BK
E01
Electrical
system
DDTHKA
TM
E03
Electrical
system
DAF9KM
DAFRKR
D20-18
Fault Codes
Electrical
system
Electrical
system
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
DDTJKA
TM
E03
Electrical
system
DDTKKA
TM
E03
Electrical
system
DDTLKA
TM
E03
Electrical
system
TM
E03
Electrical
system
DDTNKA
TM
E03
Electrical
system
DDTRKA
TM
E03
Electrical
system
DF10KA
TM
E03
Electrical
system
DF10KB
TM
E03
Electrical
system
DGF1KX
TM
E03
Electrical
system
DGR2KB
BK
E01
Electrical
system
DGR2KZ
BK
E01
Electrical
system
DGR3KB
BK
E01
Electrical
system
DGR3KZ
BK
E01
Electrical
system
DGR4KB
BK
E01
Electrical
system
DGR4KZ
BK
E01
Electrical
system
DGT1KX
TM
E01
Electrical
system
dHP4KX
BK
E03
Electrical
system
DhP4KX
VHMS
E03
Electrical
system
dHP5KX
BK
E03
Electrical
system
DhP5KX
VHMS
E03
Electrical
system
DHP6KX
VHMS
E03
Electrical
system
DHP7KX
VHMS
E03
Electrical
system
DHT5KX
TM
E01
Electrical
system
DHT5L6
TM
E01
Electrical
system
DHT7KX
TM
E01
Electrical
system
D20001 03/09
Fault Codes
D20-19
Failure
codes
Description
Applicable Action
History
controller code classification
DHT7L6
TM
E01
Electrical
system
DJF1KA
TM
E01
Electrical
system
DK11KX
TM
E03
Electrical
system
DK30KX
BK
E01
Electrical
system
DK51KX
BK
E03
Electrical
system
DKH1KX
VHMS
E01
Electrical
system
DL10LC
BK
E01
Electrical
system
DLE2KA
TM
E03
Electrical
system
DLE2LC
TM
E03
Electrical
system
DLF1KA
TM
E03
Electrical
system
DLF1LC
TM
E03
Electrical
system
DLF2KA
TM
E03
Electrical
system
DLF2LC
TM
E03
Electrical
system
DLF8LC
BK
E01
Electrical
system
DLF9LC
BK
E01
Electrical
system
dLt3KA
BK
E03
Electrical
system
dLT3KA
BK
E01
Electrical
system
DLT3KA
TM
E03
Electrical
system
dLt3LC
BK
E03
Electrical
system
dLT3LC
BK
E01
Electrical
system
DLT3LC
TM
E03
Electrical
system
BK
E01
Electrical
system
MON
E01
Electrical
system
DW78KZ
BK
E01
Electrical
system
DW79KZ
BK
E01
Electrical
system
D20-20
Fault Codes
03/09 D20001
Failure
codes
Description
Applicable Action
History
controller code classification
BK
E03
Electrical
system
BK
E03
Electrical
system
DWA1K4
BK
E03
Electrical
system
BK
E03
Electrical
system
BK
E03
Electrical
system
DWA1KY
BK
E03
Electrical
system
BK
E03
Electrical
system
BK
E03
Electrical
system
DX12KA
BK
E03
Electrical
system
DX12KB
BK
E03
Electrical
system
DX12KY
BK
E03
Electrical
system
DX12MA
Front brake PPC solenoid valve: Malfunction (Valve does not operate)
BK
E03
Electrical
system
DX27K4
BK
E03
Electrical
system
DX27KA
BK
E03
Electrical
system
DX27KB
BK
E03
Electrical
system
DX27KY
BK
E03
Electrical
system
DX27MA
RIght rear PPC solenoid valve: Malfunction (valve does not operate)
BK
E03
Electrical
system
DX28K4
BK
E03
Electrical
system
DX28KA
BK
E03
Electrical
system
DX28KB
BK
E03
Electrical
system
DX28KY
BK
E03
Electrical
system
DX28MA
BK
E03
Electrical
system
DXH1KA
TM
E03
Electrical
system
DXH1KB
TM
E03
Electrical
system
DXH1KY
TM
E03
Electrical
system
D20001 03/09
Fault Codes
D20-21
Failure
codes
Description
Applicable Action
History
controller code classification
DXH2KA
TM
E03
Electrical
system
DXH2KB
TM
E03
Electrical
system
DXH2KY
TM
E03
Electrical
system
DXH3KA
TM
E03
Electrical
system
DXH3KB
TM
E03
Electrical
system
DXH3KY
TM
E03
Electrical
system
DXH4KA
TM
E03
Electrical
system
DXH4KB
TM
E03
Electrical
system
DXH4KY
TM
E03
Electrical
system
DXH5KA
TM
E03
Electrical
system
DXH5KB
TM
E03
Electrical
system
DXH5KY
TM
E03
Electrical
system
DXH6KA
TM
E03
Electrical
system
DXH6KB
TM
E03
Electrical
system
DXH6KY
TM
E03
Electrical
system
DXH7KA
TM
E03
Electrical
system
DXH7KB
TM
E03
Electrical
system
DXH7KY
TM
E03
Electrical
system
DXJ7KA
TM
E03
Electrical
system
DXJ7KB
TM
E03
Electrical
system
DXJ7KY
TM
E03
Electrical
system
D20-22
Fault Codes
03/09 D20001
TROUBLESHOOTING
If a failure code has been detected, use the following
failure code troubleshooting charts to determine the
problem. The tables are sorted numerically and
alphabetically in ascending order.
Failure code
E03
1500L0
Contents of
trouble
Fill switch signals have been inputted from 2 clutches that do not form a normal combination.
Controller
response
Suddenly shifts to Neutral while traveling, and cannot move off again.
Even after the repair, does not resume to normal unless starting switch is once turned OFF.
Problem that
appears on
machine
Related
information
Other problem (clutch pressure control valve system failure code [15S*L1]) occurs at same time.
Description
Cause
1
Possible causes
and standard
value in normal
2
state
3
D21003 02/09
Troubleshooting
D21-1
Failure code
E01
15B0NX
Contents of
trouble
When the transmission oil filter becomes restricted, the signal circuit of the transmission restriction sensor
is opened (disconnected from GND).
Controller
response
None in particular.
Problem that
appears on
machine
If the machine is used without repairing, dust may enter the transmission circuit.
Description
Cause
1
Restriction of transmission
filter
Filter is normal
Resistance
Max. 1
Filter is clogged
Resistance
Min. 1 M
Filter is normal
Resistance
Max. 1
Filter is clogged
Resistance
Min. 1 M
Disconnection in wiring
harness
(Disconnection or defective
contact)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
D21-2
Between ATC1
(female) (17)
ground
Filter is normal
Voltage
Max. 1V
Filter is clogged
Voltage
20 30 V
Between ATC1
(female) (17)
ground
Filter is normal
Voltage
Max. 1V
Filter is clogged
Voltage
20 30 V
Troubleshooting
02/09 D21003
D21003 02/09
Troubleshooting
D21-3
Failure code
15F0KM
Contents of
trouble
When output shaft speed is 200 300 rpm (about 5 8 km/h), gear shifting from reverse to forward has
been detected.
Controller
response
Non in particular.
Problem that
appears on
machine
Related
information
Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
Description
Failure code
15F0MB
Contents of
trouble
When output shaft speed is above 300 rpm (about 8 km/h), gear shifting from reverse to forward has been
detected.
Controller
response
Non in particular.
Problem that
appears on
machine
Related
information
Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
D21-4
Description
Troubleshooting
02/09 D21003
Failure code
15F7KM
Contents of
trouble
When the engine speed is above 1,800 rpm, gear shifting from neutral or reverse to forward has been
detected.
Controller
response
Non in particular.
Problem that
appears on
machine
Description
Related
information
Possible causes Cause
and standard
value in normal 1
Abuse
state
D21003 02/09
Troubleshooting
D21-5
Failure code
E03
15G0MW
Contents of
trouble
When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission
input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Controller
response
Problem that
appears on
machine
Related
information
Electric current of out put to ECMV can be checked with monitoring function (Code: 31606 (mA)).
If electrical system is normal, check reverse clutch and mechanical/hydraulic system of pressure control
valve for defect.
Description
Cause
R clutch: Slipping
(R command is holding pressure, R clutch, fill switch is ON, and slipping
detected)
(Transmission controller system)
Possible causes
and standard
value in normal 2
state
D21-6
Disconnection in wiring
harness
(Disconnection or defective
contact)
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
D21003 02/09
Troubleshooting
D21-7
Failure code
15G7KM
Contents of
trouble
When the engine speed is above 1,800 rpm, gear shifting from neutral or forward to reverse has been
detected.
Controller
response
None in particular.
Problem that
appears on
machine
Description
Related
information
Possible causes Cause
and standard
value in normal 1
Abuse
state
D21-8
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-9
Failure code
E03
15H0MW
Contents of
trouble
When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the transmission
input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Controller
response
Shifts up and keeps gear according to gear speed before trouble and Table 1.
Turns lockup system OFF.
Problem that
appears on
machine
Related
information
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-10
Disconnection in wiring
harness
(Disconnection or defective
contact)
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
F7
3rd
High
F6
3rd
Mid
F5
2nd
High
F4
2nd
Mid
F3
1st
High
F2
1st
Mid
F1
2nd
Low
Reverse
Low
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
2nd
3M
F6
OFF
High
3M
F6
OFF
2nd
3M
F6
OFF
Mid
2H
F5
OFF
1st
2M
F4
OFF
High
2M
F4
OFF
1st
2M
F4
OFF
Mid
1H
F3
OFF
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-11
Failure code
E03
15J0MW
Contents of
trouble
When a signal is output to the low clutch ECMV, the value calculated from the signals of the transmission
input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Controller
response
Shifts up and keeps gear according to gear speed before trouble and Table 1.
Turns lockup system OFF.
Problem that
appears on
machine
Related
information
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-12
Disconnection in wiring
harness
(Disconnection or defective
contact)
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-13
Failure code
E03
15K0MW
Contents of
trouble
During an output to the 1st clutch ECMV, an abnormality exists in the value calculated from the
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in Table 1.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-14
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
D21003 02/09
Troubleshooting
D21-15
Failure code
E03
15L0MW
Contents of
trouble
During an output to the 2nd clutch ECMV, an abnormality exists in the value calculated from the
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in Table 1.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31603 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-16
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
3rd
High
F7
F6
3rd
Mid
F5
2nd
High
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
2nd
3M
F6
OFF
High
3M
F6
OFF
3M
F6
OFF
F4
2nd
Mid
2nd
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
1st
2M
F4
OFF
Mid
1H
F3
OFF
2nd
1M
F2
OFF
F2
1st
Mid
F1
2nd
Low
Reverse
Low
Low
1M
F2
OFF
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-17
Failure code
E03
15M0MW
Contents of
trouble
During an output to the 3rd clutch ECMV, an abnormality exists in the value calculated from the
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
and transmission output shaft speed sensor.
Controller
response
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31604 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-18
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-19
FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code
Failure code
E03
15SBL1
Contents of
trouble
Even when output to the R clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and the
clutch is not released.
Controller
response
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31606 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1: ON).
If electrical system is normal, check hydraulic and mechanical systems of R clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When R
is disenBetween CN6 (R,SW) (male) (1) gaged
ground
When R
is
engaged
Resistance
Min. 1 M
Resistance
Max. 1
Min. 1 M
D21-20
Defective transmission
controller
Troubleshooting
When R
is disengaged
Resistance
Min. 1 M
When R
is
engaged
Resistance
Max. 1
02/09 D21003
D21003 02/09
Troubleshooting
D21-21
Failure code
Description
E03
15SBMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the R clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31606 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for R clutch or
pressure control valve.
Cause
Possible causes
and standard
value in normal 2
state
D21-22
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
D21003 02/09
Troubleshooting
D21-23
FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT
OFF
Action code
Failure code
E03
15SCL1
Contents of
trouble
Even when output to the Hi clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and the
clutch is not released.
Controller
response
Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in Table 2.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1: ON).
If electrical system is normal, check hydraulic and mechanical systems of high clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When Hi
is disengaged
Resistance
Min. 1 M
When Hi
is
engaged
Resistance
Max. 1
Min. 1 M
D21-24
Defective transmission
controller
Troubleshooting
When Hi
is disengaged
Resistance
Min. 1 M
When Hi
is
engaged
Resistance
Max. 1
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-25
TABLE 2
Speed when trouble was
detected
D21-26
Mid
Failed clutch
(Fill switch ON)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-27
Failure code
E03
15SCMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the Hi clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in Table 1.
Turns lock up system off.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Hi clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-28
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
3rd
High
F7
F6
3rd
Mid
F5
2nd
High
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
2nd
3M
F6
OFF
High
3M
F6
OFF
3M
F6
OFF
F4
2nd
Mid
2nd
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
1st
2M
F4
OFF
Mid
1H
F3
OFF
2nd
1M
F2
OFF
F2
1st
Mid
F1
2nd
Low
Reverse
Low
Low
1M
F2
OFF
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-29
FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code
Failure code
E03
15SDL1
Contents of
trouble
Even when output to the Low clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
the clutch is not released.
Controller
response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31601 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1: ON).
If electrical system is normal, check hydraulic and mechanical systems of low clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When
Low is
released
Resistance
Min. 1 M
When
Low is
engaged
Resistance
Max. 1
Min. 1 M
D21-30
Defective transmission
controller
Troubleshooting
When
Low is
released
Resistance
Min. 1 M
When
Low is
engaged
Resistance
Max. 1
02/09 D21003
TABLE 2
Speed when trouble was
detected
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
Failed clutch
(Fill switch ON)
ON/OFF state of
lockup clutch
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-31
TABLE 2
Speed when trouble was
detected
D21-32
Mid
Failed clutch
(Fill switch ON)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-33
Failure code
E03
15SDMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the Low clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31601 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Low clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-34
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-35
FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code
Failure code
E03
15SEL1
Contents of
trouble
Even when output to the 1st clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
the clutch is not released.
Controller
response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1: ON).
If electrical system is normal, check hydraulic and mechanical systems of 1st clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When 1st is
Between CN8 (1,SW) (male) (1) released
ground
When 1st is
engaged
Resistance
Min. 1 M
Resistance
Max. 1
Min. 1 M
D21-36
Defective transmission
controller
Troubleshooting
When 1st is
released
Resistance
Min. 1 M
When 1st is
engaged
Resistance
Max. 1
02/09 D21003
TABLE 2
Speed when trouble was
detected
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
Failed clutch
(Fill switch ON)
ON/OFF state of
lockup clutch
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-37
TABLE 2
Speed when trouble was
detected
D21-38
Mid
Failed clutch
(Fill switch ON)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-39
Failure code
E03
15SEMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the 1st clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-40
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-41
FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code
Failure code
E03
15SFL1
Contents of
trouble
Even when output to the 2nd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
the clutch is not released.
Controller
response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31603 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1:ON).
If electrical system is normal, check hydraulic and mechanical systems of 2nd clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When 2nd
is
released
Resistance
When 2nd
is
engaged
Resistance
Max. 1
Min. 1 M
D21-42
Defective transmission
controller
Troubleshooting
When 2nd
is
released
Resistance
Min. 1 M
When 2nd
is
engaged
Resistance
Max. 1
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
ON/OFF state of
lockup clutch
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-43
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
D21-44
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-45
Failure code
E03
15SFMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the 2nd clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31603 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-46
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-47
FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code
Failure code
E03
15SGL1
Contents of
trouble
Even when output to the 3rd clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
the clutch is not released.
Controller
response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31604 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1:ON).
If electrical system is normal, check hydraulic and mechanical systems of 3rd clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When 3rd
is
Between CN4 (3,SW) (male) (1) released
ground
When 3rd
is
engaged
Resistance
Min. 1 M
Resistance
Max. 1
Min. 1 M
D21-48
Defective transmission
controller
Troubleshooting
When 3rd
is
released
Resistance
Min. 1 M
When 3rd
is
engaged
Resistance
Max. 1
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
OFF
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-49
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
3rd
N
Mid
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
D21-50
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-51
Failure code
E03
15SGMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the 3rd clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31604 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-52
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-53
Failure code
Description
E03
15SJMA
Contents of
trouble
During an output to the lockup clutch ECMV, an abnormality exists in the value calculated from the signals
of engine speed sensor, transmission intermediated shaft speed sensor, and transmission output shaft
speed sensor.
Controller
response
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31609 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for lockup
clutch or pressure control valve.
Cause
Possible causes
and standard
value in normal 2
state
D21-54
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
Action code
Failure code
E03
15SSL1
Contents of
trouble
Even when output to the Mid clutch ECMV is turned "OFF", the signal from the fill switch stays "ON" and
the clutch is not released.
Controller
response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31640 (mA))
Fill switch input signal can be checked with code: 31520 (0: OFF, 1: ON).
If electrical system is normal, check hydraulic and mechanical systems of high clutch or pressure control
valve for defect.
Description
Cause
Possible causes
and standard
value in normal 2
state
When 3rd
Resistance
Between CN4 (3,SW) (male) (1) is released
ground
When 3rd
Resistance
is engaged
Min. 1 M
Max. 1
Resistance
Min. 1 M
D21003 02/09
Defective transmission
controller
Troubleshooting
When 3rd
Resistance
is released
Min. 1 M
When 3rd
Resistance
is engaged
Max. 1
D21-55
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
F7
F6
F5
F4
F3
F2
F1
D21-56
3rd
High
3rd
Mid
2nd
High
2nd
Mid
1st
High
1st
Mid
2nd
Low
Reverse
Low
OFF
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
3rd
N
Mid
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
D21003 02/09
Troubleshooting
D21-57
Failure code
E03
15SSMA
Contents of
trouble
The signal from the fill switch stays "OFF" during an output to the Mid clutch ECMV and an abnormality
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Controller
response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Related
information
Electric current of output to ECMV can be checked by monitoring function (code: 31640 (mA))
If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Mid clutch or
pressure control valve.
Description
Cause
Possible causes
and standard
2
value in normal
state
D21-58
Disconnection in wiring
harness
(Disconnection or defective
contact)
Defective transmission
controller
5 15
Resistance
Resistance Min. 1 M
Resistance Max. 1
Resistance Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-59
Failure code
E03
15X0MW
Contents of
trouble
When a signal is output to the Mid clutch ECMV, the value calculated from the signals of the transmission
input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Controller
response
Shifts up and keeps gear according to gear speed before trouble and Table 1.
Turns lockup system OFF.
Problem that
appears on
machine
Related
information
Description
Cause
Possible causes
and standard
value in normal 2
state
D21-60
Disconnection in wiring
harness
(Disconnection or defective
contact)
5 15
Resistance
Resistance Min. 1 M
Max. 1
Max. 1
Troubleshooting
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-61
Failure code
E03
2G39MA
Contents of
trouble
Brake does not operate even though the driver works the foot brake.
Controller
response
None in particular
Problem that
appears on
machine
Related
information
Description
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting. Check front brake pressure. Disconnect CN027.
3
Possible causes
and standard
value in normal
state
Voltage
24 V
Voltage
0V
Brake apply and brake pedal RCM2 (17) - RCM2 (39) Brake not applied
proximity switches
RCM1 (12) - RCM1 (21) Brake applied
Voltage
about 8V
Voltage
0V
Voltage
about 8V
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
5
D21-62
Voltage
Max. 1 V
Voltage
Max. 1 V
If there were no faults found in the wiring, the controller may be defective.
Troubleshooting
02/09 D21003
Failure code
E03
2G3AMA
Contents of
trouble
Brake (rear) does not operate even though the driver works the foot brake.
Controller
response
None in particular
Problem that
appears on
machine
Related
information
Input state can be checked with monitoring function (Code: 34103, 34104).
Description
Check oil pressure output at the relay valve. Correct pressure with brake
depressed is 14 479 kPa (2100 psi).
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
(Right retard apply switch
and left retard apply switch
failure)
Possible causes
and standard
value in normal
state
3
D21003 02/09
Resistance
Max. 1
Resistance
Max. 1
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Resistance
Min. 1 M
Voltage
Max. 1 V
Voltage
Max. 1 V
Defective Retarder controller If no other problems were found, the controller may be defective.
Troubleshooting
D21-63
Failure code
E03
2G41ZG
Contents of
trouble
Oil pressure reduction (Max. 12.76 MPa {130 kg/cm2}) was detected by signal from accumulator oil pressure sensor (front).
Controller
response
Problem that
appears on
machine
Related
information
Description
Hydraulic system (pump, relief valve or piping) may have trouble. If pressure is reduced, remove cause of trouble.
Open in harness
Possible causes
and standard
2
value in normal
state
3
D21-64
Resistance
Max.1
Defective accumulator (front) If no other problems are found, the oil pressure switch may be defecoil pressure switch
tive.
Troubleshooting
02/09 D21003
Failure code
E03
2J00MA
Contents of
trouble
Emergency brake operates although the driver does not work the emergency brake.
Controller
response
None in particular
Problem that
appears on
machine
Brake drags
Related
information
Description
Check the emergency brake valve. If the valve is inoperable, replace with
a new valve.
Prepare with starting switch OFF, then perform troubleshooting without
turning starting switch ON.
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
Emergency auto apply sw
failure)
Emergency brake sw failure
Grounding fault in wiring
harness
(Contact with ground circuit)
(Emergency brake sw failure)
Prepare with starting switch OFF and the emergency brake switch OFF.
Possible causes
and standard
value in normal
3
state
D21003 02/09
Resistance
Resistance
Max. 1
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Wiring harness between CN169 (female) (1)
RCM2 (25)
Voltage
Max. 1 V
Voltage
Max. 1 V
Troubleshooting
D21-65
Failure code
E03
4A00ZG
Contents of
trouble
Low oil pressure (less than 12.76 MPa {130 kg/cm2}) was detected by signal from low steering pressure
sensor.
Controller
response
Problem that
appears on
machine
Description
Related
information
Refer to page 7 in the electrical schematic for reference.
Cause
Possible causes 1
and standard
value in normal 2
state
3
D21-66
Hydraulic system (pump, relief valve or piping) may have trouble. If pressure is reduced, remove cause of trouble.
If no other problems are found, the steering oil pressure sensor may be
defective.
Troubleshooting
Resistance
Max. 1
02/09 D21003
Failure code
E03
4A5WZH
Contents of
trouble
Oil pressure reduction (Max. 12.75 MPa {130 kg/cm2}) was detected by signal from accumulator1 oil pressure sensor (steering).
Controller
response
Problem that
appears on
machine
Related
information
Input signal from oil pressure sensor can be checked with monitoring function (Code: 44800).
Description
D21003 02/09
Hydraulic system (pump, relief valve or piping) may have trouble. If pressure is reduced, remove cause of trouble.
Resistance
Max.1
Defective accumulator1
If cause 1 is not detected, accumulator (front) oil pressure sensor sys(steering) oil pressure sensor
tem may be defective.
system
Troubleshooting
D21-67
Failure code
E03
4A5XZH
Contents of
trouble
Oil pressure reduction (Max. 12.75 (MPa) {130 (kg/cm2)}) was detected by signal from accumulator2 oil
pressure sensor (steering).
Controller
response
Problem that
appears on
machine
Related
information
Input signal from oil pressure sensor can be checked with monitoring function (Code: 44801).
Description
D21-68
Hydraulic system (pump, relief valve or piping) may have trouble. If pressure is reduced, remove cause of trouble.
Resistance
Max.1
Defective accumulator2
(steering) oil pressure sensor If no other problems are found, the pressure sensor may be defective.
system
Troubleshooting
02/09 D21003
Failure code
E01
6014NX
Contents of
trouble
When the hydraulic filter becomes restricted, the signal circuit of the hydraulic restriction sensor is opened
(disconnected from GND).
Controller
response
None in particular.
Problem that
appears on
machine
If the machine is used without repairing, dust may enter the hydraulic circuit.
Related
information
This failure can be checked in the monitoring function (Code: 35700). (normal: 1, restricted: 0)
Description
Possible causes
and standard
value in normal 3
state
Restriction of hydraulic
filter
Resistance
Max. 1
Filter is clogged
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Filter is normal
Voltage
Max. 1V
Filter is clogged
Voltage
about 8 V
Between CN158
(male) (A) (B)
D21003 02/09
Troubleshooting
D21-69
Failure code
E02
989A00
Contents of
trouble
When gear speed is set at the position other than neutral, transmission input shaft speed signal exceeds
the input shaft speed which is set for each gear speed to prevent over run.
Controller
response
Problem that
appears on
machine
Related
information
Input shaft speed can be checked in monitoring function (code: 31200 (rpm)).
Information on operation of engine overrun prevention command is obtained from transmission controller
through network.
Description
Cause
Possible causes
1
and standard
value in normal
state
2
D21-70
Defective transmission
controller
Troubleshooting
02/09 D21003
Failure code
Description
Alternator: Malfunction
(Failure in battery charging circuit)
(Transmission controller system)
E03
AB00MA
Contents of
trouble
A generation signal is not input from the alternator while the engine is running.
Controller
response
None in particular.
Problem that
appears on
machine
If the machine is used without repairing, the source voltage may lower so much that the machine cannot
travel.
Related
information
This failure can be checked in the monitoring function (Code: 04301 (0: OFF, 1:ON)).
Defective alternator
Voltage
27.5 29.5 V
If the battery is deteriorated or used in a cold district, the voltage may not
rise for a while after the engine is started.
Possible causes
and standard
value in normal 2
state
Disconnection in wiring
harness
(Disconnection or defective
contact)
Voltage
27.5 29.5 V
If the battery is deteriorated or used in a cold district, the voltage may not
rise for a while after the engine is started.
Voltage
20 30 V
If the battery is deteriorated or used in a cold district, the voltage may not
rise for a while after the engine is started.
D21003 02/09
Troubleshooting
D21-71
Failure code
E03
B@BAZG
Description
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related information
D21-72
Troubleshooting
02/09 D21003
Failure code
E02
B@BCNS
Description
Engine: overheat
(Engine controller system)
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related information
D21003 02/09
Troubleshooting
D21-73
Failure code
B@BFZK
Contents of
trouble
Fuel level sensor signal indicates lowering of fuel level (Resistance of 70 or higher is detected).
Controller
response
Problem that
appears on
machine
None in particular.
Related
information
When fuel level is below LOW and fuel is added, if failure code disappears, fuel was insufficient.
Signal from fuel level sensor can be checked with monitoring function.
(Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200 (V) / 04201 ())
Method of reproducing failure code: Turn starting switch ON.
Description
Cause
Standard value in normal state/Remarks on troubleshooting
Possible causes
Lack of fuel (When system is
and standard
1
Fuel may be insufficient. Check and add fuel, if necessary.
normal)
value in normal
When not recover by above 1,then perform troubleshooting for failure
state
2 Defective fuel level sensor
code [DJF1KA].
D21-74
Troubleshooting
02/09 D21003
Failure code
E02
B@C6NS
Contents of
trouble
While engine was running, oil overheat was detected by signal from front brake (retarder) oil temperature
sensor.
Controller
response
Problem that
appears on
machine
Related
information
Input signal from oil temperature sensor can be checked with monitoring function (Code: 30201 (?),
30204 (V)).
For troubleshooting for brake (retarder) (front) oil temperature sensor, see failure code [DGR4KZ].
If CNR02-T (BCV relay) primary side has trouble, error code [DW79KB] is displayed.
Description
Turn starting switch OFF and disconnect CN157, then perform troubleshooting without turning starting switch ON (Measure in diode check
mode).
2
Defective diode
Between CN157
(male) (1) (2)
Possible causes
and standard
value in normal
state
3
Forward direction:
There is continuity
Continuity
Backward direction:
There is not continuity
Turn starting switch OFF and disconnect CNR02-T (BCV relay) and
CN156, then perform troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Between CNR02-T (female) (43) CN156
or defective contact in con- (female) (1)
nector)
Between (ground) CN156 (female) (2)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Grounding fault in wiring har- Turn starting switch OFF and disconnect CNR02-T, then perform troubleshooting without turning starting switch ON.
ness (Contact with ground
circuit)
Between CNR02-T (female) (1) ground
Resistance
Min. 1 M
Cause
Possible causes
Trouble in hydraulic system
and standard
6
(when electrical system is
value in normal
normal)
state
7
D21003 02/09
Troubleshooting
D21-75
Failure code
E02
B@C7NS
Contents of
trouble
While engine was running, oil overheat was detected by signal from rear brake (retarder) oil temperature
sensor.
Controller
response
Problem that
appears on
machine
Related
information
Input signal from oil temperature sensor can be checked with monitoring function (Code: 30208 (?),
30210 (V)).
For troubleshooting for brake (retarder) (right rear) oil temperature sensor, see failure code [DGR2KZ].
If CNR02-V (BCV relay) primary side has trouble, error code [DW78KZ] is displayed.
Description
Defective diode
Turn starting switch OFF and disconnect CN154, then perform troubleshooting without turning starting switch ON (Measure in diode check
mode).
Between CN154
(male) (1) (2)
Possible causes 3
and standard
value in normal
state
D21-76
Turn starting switch OFF and disconnect CNR02-V (BCV relay) and
CN153, then perform troubleshooting without turning starting switch ON.
Between CNR02-V (female) (45) CN153
(female) (1)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Grounding fault in wiring har- Turn starting switch OFF and disconnect CN153, then perform troubleshooting without turning starting switch ON.
ness (Contact with ground
circuit)
Between CNR02-V (female) (59) ground
Resistance
Min. 1 M
Troubleshooting
02/09 D21003
Failure code
E02
B@C7NS
Contents of
trouble
While engine was running, oil overheat was detected by signal from rear brake (retarder) oil temperature
sensor.
Controller
response
Problem that
appears on
machine
Related
information
Input signal from oil temperature sensor can be checked with monitoring function (Code: 30207 (?),
30209 (V)).
For troubleshooting for brake (retarder) (left rear) oil temperature sensor, see failure code [DGR3KZ].
If CNR02-V (BCV relay) primary side has trouble, error code [DW78KZ] is displayed.
Description
Defective diode
Turn starting switch OFF and disconnect CN154, then perform troubleshooting without turning starting switch ON (Measure in diode check
mode).
Between CN154
(male) (1) (2)
Possible causes 3
and standard
value in normal
state
D21003 02/09
Turn starting switch OFF and disconnect CNR02-V (BCV relay) and
CN153, then perform troubleshooting without turning starting switch ON.
Between CNR02-V (female) (45) CN153
(female) (1)
Resistance
Max. 1
Resistance
Max. 1
Max. 1
Grounding fault in wiring har- Turn starting switch OFF and disconnect CN153, then perform troubleshooting without turning starting switch ON.
ness (Contact with ground
circuit)
Between CNR02-V (female) (59) ground Resistance Min. 1 M
Troubleshooting
D21-77
Failure code
E02
B@CENS
Contents of
trouble
Controller
response
Turns torque converter oil temperature caution lamp ON and sounds alarm buzzer.
Problem that
appears on
machine
Related
information
Signal of torque converter oil temperature sensor is input to transmission controller and then its information is transmitted to machine monitor through communication system.
Power train oil temperature can be checked with monitoring function.
(Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100 (?) / 30101 (V))
Description
Cause
Possible causes
1
and standard
value in normal
state
2
D21-78
Defective torque converter oil If cause 1 is not detected, torque converter oil temperature sensor system
temperature sensor system
may be defective. Perform troubleshooting for failure code [DGT1KX].
Troubleshooting
02/09 D21003
Failure code
E01
B@M6NX
Contents of
trouble
When the brake cooling oil filter becomes restricted, the signal circuit of the front brake cooling restriction
sensor is opened (disconnected from GND).
Controller
response
None in particular.
Problem that
appears on
machine
If the machine is used without repairing, dust may enter the brake cooling circuit.
Related
information
This failure can be checked in the monitoring function (Code: 35701). (normal: 0, restricted: 1)
Description
Possible causes
and standard
value in normal 3
state
Disconnection in wiring
harness
(Disconnection or defective
contact)
Clean or replace.
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Voltage
Max. 1V
Voltage
about 8 V
D21003 02/09
Troubleshooting
D21-79
FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION
Action code
Failure code
E01
B@M7NX
Contents of
trouble
When the #2 rear brake cooling oil filter becomes restricted, the signal circuit of the rear brake cooling
restriction sensor is opened (disconnected from GND).
Controller
response
None in particular.
Problem that
appears on
machine
If the machine is used without repairing, dust may enter the brake cooling circuit.
Related
information
This failure can be checked in the monitoring function (Code: 35703). (normal: 1, restricted: 0)
Description
Possible causes
and standard
value in normal 3
state
Disconnection in wiring
harness
(Disconnection or defective
contact)
Resistance
Max. 1
Filter is clogged
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Filter is normal
Voltage
Max. 1V
Filter is clogged
Voltage
approx. 8 V
Between CN150
(male) (A) (B)
D21-80
Troubleshooting
02/09 D21003
FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION
Action code
Failure code
E01
B@M8NX
Contents of
trouble
When the #1 rear brake cooling oil filter becomes restricted, the signal circuit of the rear brake cooling
restriction sensor is opened (disconnected from GND).
Controller
response
None in particular.
Problem that
appears on
machine
If the machine is used without repairing, dust may enter the brake cooling circuit.
Related
information
This failure can be checked in the monitoring function (Code: 35702). (normal: 1, restricted: 0)
Description
Possible causes
and standard
value in normal 3
state
Disconnection in wiring
harness
(Disconnection or defective
contact)
Resistance
Max. 1
Filter is clogged
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Voltage
Max. 1V
Voltage
20 30 V
Between CN149
(male) (A) (B)
D21003 02/09
Troubleshooting
D21-81
Failure code
E03
DAF9KM
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related
information
Description
Possible causes
and standard
value in normal
state
Wrong connection of connec- Connector CN2A (female) may be connected to CN3A (male) by mistake.
tor
Check and connect it correctly, if connected wrongly.
Voltage
20 30 V
D21-82
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-83
Failure code
E03
DAFRKR
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related
information
Description
Resistance
Approx. 120 12
Possible causes
and standard
value in normal
state
D21-84
SDA12V160 only:
Wiring harness between ATC2 -32 - CAN043 (A), CAN04-2 (A), CAN04-1 (A);
Wiring harness between RCM2 (32)
CAN03-3 (A), CAN03-2 (A), CAN03-1 (A);
Wiring harness between HM4A (04)
CAN02-3 (A), CAN02-2 (A), CAN02-1 (A);
Wiring harness between CN062 (3)
CAN08-3 (A), CAN08-2 (A), CAN08-1 (A);
Wiring harness between CN4 (3) CAN013 (A), CAN01-2 (A), CAN01-1 (A)
Disconnection in wiring
harness
(Disconnection in wiring or
2
defective contact in connector)
SDA12V160 only:
Wiring harness between ATC2 -22 - CAN043 (B), CAN04-2 (B), CAN04-1 (B);
Wiring harness between RCM2 (22)
CAN03-3 (B), CAN03-2 (B), CAN03-1 (B);
Wiring harness between HM4A (12)
CAN02-3 (B), CAN02-2 (B), CAN02-1 (B);
Wiring harness between CN062 (10)
CAN08-3 (B), CAN08-2 (B), CAN08-1 (B);
Wiring harness between CN4 (8) CAN013 (B), CAN01-2 (B), CAN01-1 (B)
Troubleshooting
Resistance
Max. 1
Resistance
Max. 1
02/09 D21003
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connec- SSA16V159 only:
tor)
Wiring harness between CAN06 (B)
CAN05-3 (B), CAN05-2 (B), CAN05-1 (B);
Wiring harness between CAN07 (D)
CAN04-3 (B), CAN04-2 (B), CAN04-1 (B);
Wiring harness between ATC2 (22)
CAN03-3 (B), CAN03-2 (B), CAN03-1 (B);
Wiring harness between RCM2 (22)
CAN02-3 (B), CAN02-2 (B), CAN02-1 (B);
Wiring harness between HM4A (12)
CAN08-3 (B), CAN08-2 (B), CAN08-1 (B);
Wiring harness between CN062 (10)
CAN01-3 (B), CAN01-2 (B), CAN01-1 (B),
CN4 (8)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
SSA16V159 only:
Between ground and CAN06 (A), CAN07
(E), ATC2 (32), RCM2 (32), HM4A (04),
CN062 (B), CN4 (3)
Resistance
Min. 1 M
SSA16V159 only:
Between ground and CAN06 (B), CAN07
(D), ATC2 (22), RCM2 (22), HM4A (12),
CN062 (10), CN4 (8)
Resistance
Min. 1 M
SDA12V160 only:
Grounding fault in wiring
Between ground and CAN05 (B), ATC2
harness
(22), RCM2 (22), HM4A (12), CN062 (10),
3
(Contact with ground circuit) CN4 (8)
D21003 02/09
Troubleshooting
D21-85
Cause
Possible causes
and standard
value in normal
state
D21-86
SDA12V160 only:
Between ground and CAN05 (A), ATC2
(32), RCM2 (32), HM4A (04), CN062 (3),
CN4 (3)
Voltage
Max. 1V
SDA12V160 only:
Between ground and CAN05 (B), ATC2
(22), RCM2 (22), HM4A (12), CN062 (10),
CN4 (8)
Voltage
Max. 1V
SSA16V159 only:
Between ground and CAN06 (A), CAN07
(E), ATC2 (32), RCM2 (32), HM4A (04),
CN062 (B), CN4 (3)
Voltage
Max. 1V
SSA16V159 only:
Between ground and CAN06 (B), CAN07
(D), ATC2 (22), RCM2 (22), HM4A (12),
CN062 (10), CN4 (8)
Voltage
Max. 1V
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-87
Failure code
E03
DAQ0KK
Contents of
trouble
Controller
response
Description
While engine was running, controller direct power supply circuit voltage lowered below 18 V.
Keeps current gear speed.
If gearshift lever is set in N, transmission is set in neutral.
Problem that
appears on
machine
If there is not power supply voltage (there is disconnection), transmission is set in neutral suddenly during
travel and machine cannot restart until voltage becomes normal.
The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage rises
to the normal level.
If power supply voltage is low, machine can move but transmission may slip because of load.
Related
information
If failure code "AB00MA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
If the fuse is broken, check the line between the fuse and ATC3 (female) (1) and (11) for grounding fault.
1 Defective battery
Test the battery voltage and specific gravity of the battery fluid.
Battery voltage
Specific gravity of battery fluid
Voltage
Min. 24 V
Specific gravity
Min. 1.26
Possible causes
and standard
value in normal
state
Voltage
20 30 V
Voltage
20 30 V
If there is voltage between battery relay terminal B and ground and there
is not voltage between ATC3 (1) and (11), wiring harness between them
has disconnection.
1) Turn starting switch OFF.
2) Disconnect negative () terminal of battery and connect T-adapter to
ATC3 (female)
Wiring harness between ATC3 (female)
(21), (31), (32), (33) ground
Resistance
Max. 1
If there is voltage between battery relay terminal B and ground but not
between ATC3 (1), (11), (14), (24) and ground, wiring harness or fuse is
broken.
D21-88
Troubleshooting
Voltage
20 30 V
02/09 D21003
Failure code
E03
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related
information
DAQ2KK
Description
Battery direct power source voltage of transmission controller has dropped to above 20 V, and
ECMV power source voltage has dropped to below 18 V.
Holds the gear speed.
Keeps neutral with shift lever neutral.
Suddenly shifts to neutral while traveling, and the machine cannot move off again.
When the fuse is blown, check for ground fault of line from fuse ATC3 (female) (2), (12), (22).
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
1
(Disconnection or defective
contact)
Voltage
20 30 V
Voltage
20 30 V
Defective transmission
controller
D21003 02/09
Troubleshooting
Voltage
20 30 V
D21-89
Failure code
E03
DAQ9KQ
Contents of
trouble
Description
Machine model information from machine monitor is different from machine model information saved in
transmission controller.
Monitor
response
Problem that
appears on
machine
Related
information
Refer to page 6 in the electrical schematic for reference.
Cause
1
Possible causes
and standard
value in normal
state
Resistance
Max. 1
SSA16V159 only:
Between ATC2 (28) - GB10 ground
Resistance
Max. 1
Resistance
Min. 1M
Resistance
Min. 1M
SDA12V160 only:
Short to ground in wiring har- Between ATC2 (28) - CNJ04 (23)
3
ness.
SSA16V159 only:
Between ATC2 (38) - CNJ04 (23)
4
D21-90
Troubleshooting
02/09 D21003
Failure code
E03
DAQRKR
Contents of
trouble
Description
Machine monitor cannot obtain information from transmission controller through CAN communication circuit.
Controller
response
Problem that
appears on
machine
Related
information
Possible causes
Cause
Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Perform troubleshooting for failure code [DAFRKR]
state
D21003 02/09
Troubleshooting
D21-91
Failure code
E03
Contents of
trouble
Monitor
response
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D21-92
DAQRMA
Description
Option setting signals inputted from machine monitor with the starting switch ON are different from the
option settings that controller memorizes.
Holds the gear speed in neutral.
Controls with the option setting that the controller memorizes.
It does not return normal unless the starting switch is turned OFF.
The gear speed becomes neutral and the machine cannot move off again.
Perform initial setting and initial adjustment as when transmission controller is replaced.
Cause
1
Troubleshooting
02/09 D21003
Failure code
E03
DASOMA
Contents of
trouble
Problem that
appears on
machine
D21003 02/09
Engine controller detects an engine error code. The status of the code triggers the red stop light.
Monitor
response
Related
information
Description
Troubleshooting
D21-93
Failure code
E03
DASOMC
Contents of
trouble
Problem that
appears on
machine
D21-94
Engine controller detects an engine error code. The status of the code triggers the amber caution light.
Monitor
response
Related
information
Description
Troubleshooting
02/09 D21003
Failure code
E03
DASRKR
Contents of
trouble
Monitor
response
Problem that
appears on
machine
Related
information
Description
Monitor does not receive engine coolant temperature information properly through the communication network.
Turns on warning lamp and activates the warning alarm buzzer.
The monitor does not receive correct engine information related to coolant temperature and lamp status.
Possible causes
Cause
Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Perform troubleshooting for DAFRKR. If the failure code persists, contact the engine manufacturer.
state
D21003 02/09
Troubleshooting
D21-95
Failure code
E01
DB10KT
Contents of
trouble
Controller
response
Problem that
appears on
machine
Description
Related
information
Possible causes
and standard
value in normal
state
D21-96
Cause
1
Troubleshooting
02/09 D21003
Failure code
E03
DB12KK
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related
information
Description
While controller direct power source voltage is normal, solenoid power source voltage has become below
18 V.
Turn OFF all of output circuits.
Turn OFF sensor 24 V power source.
All systems of retarder controller do not operate. (retarder, ARSC and ASR)
If the fuse is blown, check for ground fault of line from fuse RCM3 (female) (2), (12), (22).
If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power source) is displayed, perform troubleshooting for it first.
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
1
(Disconnection or defective
contact)
Voltage
20 30 V
Voltage
20 30 V
If voltage at fuse FU1 (7) is normal and voltage at RCM3 (2), (12), (22)
is abnormal, wiring harness between fuse FU1 (7) RCM3 (female)
(2), (12), (22) has disconnection.
1)Turn starting switch OFF.
2)Disconnect negative () terminal of battery and connect T-adapter to
RCM3 (female).
3)Connect negative () terminal of battery.
4)Turn starting switch ON.
Wiring harness between RCM3 (female)
(21), (31), (32), (33) ground
Max. 1
D21003 02/09
Resistance
Troubleshooting
Voltage
20 30 V
D21-97
Failure code
E03
DB13KK
Contents of
trouble
Controller
response
Problem that
appears on
machine
Related
information
Description
1 Defective battery
Battery voltage
Voltage
Min. 24 V
Specific
gravity
Min. 1.26
Resistance
Max. 1
Voltage
20 30 V
Voltage
20 30 V
D21-98
Troubleshooting
Voltage
20 30 V
02/09 D21003
Failure code
E03
DB19KQ
Contents of
trouble
Monitor
response
Problem that
appears on
machine
Related
information
Description
Information of model selection input from machine monitor when starting switch is turned ON is different
from model selection saved in retarder controller.
Turns all outputs OFF.
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
When operator performs starting operation, machine does not start.
Perform initial setting and adjustment of retarder controller to be performed after replacement.
Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
D21003 02/09
Wrong retarder controller may be installed. Check its part No. and
install correct retarder controller.
Troubleshooting
D21-99
Failure code
DB1RKR
Description
Related
information
Refer to pages 10 of the electrical schematic.
Cause
Defective CAN terminal
1
resistor (Internal defect)
Resistance
Approx. 120 12
Possible causes
and standard
value in normal
state
D21-100
Disconnection in wiring
harness
2 (Disconnection in wiring or
defective contact in connecWiring harness between CAN06 (B)
tor)
CAN05-3 (B), CAN05-2 (B), CAN05-1 (B);
Wiring harness between CAN07 (D)
CAN04-3 (B), CAN04-2 (B), CAN04-1 (B);
Wiring harness between ATC2 (22)
CAN03-3 (B), CAN03-2 (B), CAN03-1 (B);
Wiring harness between RCM2 (22)
CAN02-3 (B), CAN02-2 (B), CAN02-1 (B);
Wiring harness between HM4A (12)
CAN08-3 (B), CAN08-2 (B), CAN08-1 (B);
Wiring harness between CN062 (10)
CAN01-3 (B), CAN01-2 (B), CAN01-1 (B),
CN4 (8)
Troubleshooting
Resistance
Max. 1
Resistance
Max. 1
02/09 D21003
Cause
Possible causes
and standard
value in normal
state
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Defective hot short in wiring
4 harness
(a contact with 24 V circuit)
D21003 02/09
Voltage
Max. 1V
Voltage
Max. 1V
Troubleshooting
D21-101
Failure code
E03
DB1RMA
Contents of
trouble
Monitor
response
Problem that
appears on
machine
Related
information
Description
Information of option setting sent from machine monitor when starting switch is turned ON is different from
option setting saved in retarder controller.
Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Controls with option setting saved in controller.
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
None in particular.
Perform initial setting and adjustment of retarder controller to be performed after replacement.
Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
D21-102
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Troubleshooting
02/09 D21003
Failure code
E03
dBBRKR
Description
Contents of
trouble
Machine monitor cannot obtain information from the VHMS controller through the communication network.
Controller
Response
Problem that
appears on
machine
Related
information
Possible causes
Cause
and standard
value in normal Perform troubleshooting for DAFRKR.
state
D21003 02/09
Troubleshooting
D21-103
Failure code
E01
DDB4MA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Suspension pressure sensor system: Brake pedal sw, front brake apply
sw, brake apply sw (Retarder controller system)
Brake operates even though the driver does not work the foot brake.
None in particular
Brake drags
Input state can be checked with monitoring function (Code: 44700 (Brake pedal), 35102 (Front brake
apply), 35700 (Brake apply)).
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Max. 1
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
2
defective contact in connector)
Brake pedal sw failure
Grounding fault in wiring
harness
3 (Contact with ground circuit)
Front brake apply sw or
Brake apply sw failure
Defective hot short in wiring
harness
(a contact with 24 V circuit)
4
Front brake apply switch or
brake apply switch failure
D21-104
Defective Retarder
controller
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Wiring harness between CN231 (female)
(B) RCM3 (39)
Voltage
Max. 1 V
Voltage
Max. 1 V
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-105
Failure code
DDD7KX
Description
The input signal circuit voltage of the travel speed set switch is below 0.3 V.
Controller
When ARSC operates, the controller releases the brake gradually.
Response
Problem that
appears on
This failure does not have a serious effect on the machine.
machine
Related
None in particular.
information
Refer to pages 7 of the electrical schematic.
Cause
Standard value in normal state/Remarks on troubleshooting
1) Turn the starting switch OFF.
2) Replace the travel speed set switch (ARSC SET switch).
Defective travel speed set
1
Failure is not
Replace the travel
switch (ARSC SET switch)
Switch is normal
repaired.
speed set switch
(ARSC SET switch). Failure is repaired.
Switch is defective
1) Turn the starting switch OFF.
2) Disconnect connector CN034.
2 Defective register (250 )
3) Connect T-adapter.
Between CN034 (female) (1) (2)
Resistance
250 25
1) Turn the starting switch OFF.
Possible causes
2) Disconnect connector CN035.
3 Defective resistor (1,020 ) 3) Connect T-adapter.
and standard
value in normal
Between CN035 (female) (1) (2)
Resistance 1,020 102
state
1) Turn the starting switch OFF.
2) Disconnect connectors RCM1, RCM3, CN092, and CN035, CN034.
3) Connect T-adapter.
Wiring harness between RCM3 (female)
Resistance
Max. 1
Disconnection in wiring har- (34) CN034 (male) (2)
ness
Wiring harness between RCM1 (female)
4
(Disconnection or defective (13) CN034 (male) (1) CN092 (female)
Resistance
Max. 1
contact)
(1)
Wiring harness between CN035 (male) (1)
Resistance
Max. 1
CN092 (female) (3)
Wiring harness between CN035 (male) (2)
Resistance
Max. 1
CN092 (female) (2)
D21-106
Troubleshooting
02/09 D21003
Cause
Possible causes
and standard
value in normal
state
D21003 02/09
Troubleshooting
D21-107
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDD8KA
Description
The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
When ARSC operates, the controller releases the brake gradually.
Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
Possible causes
and standard
value in normal
state
Resistance
Max. 1
No
Yes
D21-108
Troubleshooting
Voltage
20 30 V
Voltage
Max. 1 V
02/09 D21003
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDD8KB
Description
The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
When ARSC operates, the controller releases the brake gradually.
Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
Possible causes
and standard
value in normal
state
Voltage
Max. 1 V
Voltage
Max. 1 V
No
Yes
D21003 02/09
Troubleshooting
Voltage
20 30 V
Voltage
Max. 1 V
D21-109
Failure code
E01
DDDAKA
Description
Contents of
trouble
The ON input of the ASR system switch is OFF and the OFF input of the system switch is OFF.
Controller
Response
Problem that
appears on
machine
Related
information
Refer to pages 3 of the electrical schematic.
Cause
Max. 1
Resistance
Max. 1
Possible causes
and standard
value in normal
state
Resistance
No
Yes
D21-110
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
20 30 V
Troubleshooting
02/09 D21003
Failure code
E01
DDDAKB
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
ASR cut switch ON input is turned ON and system switch OFF input is turned ON.
Resets ASR control.
Machine is not affected particularly.
ASR control cannot be continued.
Related
information
Refer to pages 3 of the electrical schematic.
Cause
Possible causes
and standard
value in normal
state
Voltage
Max. 1 V
Voltage
Max. 1 V
No
Yes
D21003 02/09
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
20 30 V
Troubleshooting
D21-111
Failure code
E01
DDP6MA
Description
Contents of
trouble
Brake does not operate even though the driver works the emergency brake.
Controller
Response
None in particular
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
2 defective contact in connector)
Front brake apply sw or
Brake apply sw failure
Defective hot short in wiring
harness
3 (a contact with 24 V circuit)
Front brake apply sw or
Brake apply sw failure
4 Defective retarder controller
D21-112
Resistance
Resistance
Brake ON
Max. 1
Brake OFF
Min. 1 M
Brake ON
Max. 1
Brake OFF
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Wiring harness between CN231 (female)
(B) RCM3 (39)
Voltage
Max. 1 V
Voltage
Max. 1 V
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-113
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDTHKA
Description
When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
The controller keeps the current gear speed.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
The gear cannot be shifted.
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31520).
Cause
When disResistance
engaged
Min. 1 M
When
engaged
Max. 1
Resistance
Resistance
Max. 1
When disResistance
engaged
Min. 1 M
When
engaged
Max. 1
D21-114
Troubleshooting
Resistance
02/09 D21003
D21003 02/09
Troubleshooting
D21-115
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDTJKA
Description
When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
The controller keeps the current gear speed.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
The gear cannot be shifted.
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31520).
Cause
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
Resistance
Max. 1
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
D21-116
Troubleshooting
02/09 D21003
D21003 02/09
Troubleshooting
D21-117
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDTKKA
Description
When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
The controller keeps the current gear speed.
If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
The gear cannot be shifted.
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31520).
Cause
Possible causes
and standard
value in normal
state
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
D21-118
Troubleshooting
02/09 D21003
D21003 02/09
Troubleshooting
D21-119
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDTLKA
Description
When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
The controller keeps the current gear speed.
If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
The gear cannot be shifted.
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31520).
Cause
Possible causes
and standard
value in normal
state
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
Resistance
Max. 1
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
D21-120
Troubleshooting
02/09 D21003
D21003 02/09
Troubleshooting
D21-121
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DDTMKA
Description
When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
The controller keeps the current gear speed.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
The gear cannot be shifted.
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31520).
Cause
Possible causes
and standard
value in normal
state
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
D21-122
Troubleshooting
02/09 D21003
D21003 02/09
Troubleshooting
D21-123
Failure code
E03
DDTNKA
Description
Contents of
trouble
When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
Controller
Response
Problem that
appears on
machine
Related
information
Cause
Possible causes
and standard
value in normal
state
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
When disengaged
Resistance
Min. 1 M
When
engaged
Resistance
Max. 1
D21-124
Troubleshooting
02/09 D21003
D21003 02/09
Troubleshooting
D21-125
Failure code
E03
DDTRKA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
When the output to the Mid clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
switch is not turned ON.
The controller keeps the current gear speed.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
The gear cannot be shifted.
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31520).
Cause
Possible causes
and standard
value in normal
state
Resistance Max. 1
D21-126
Troubleshooting
Resistance Max. 1
02/09 D21003
D21003 02/09
Troubleshooting
D21-127
Failure code
DF10KA
Problem that
appears on
machine
Description
Controls according to previous gear shift lever information before abnormality occurs.
Disconnection in wiring
harness
2
(Disconnection or defective
contact of connectors)
Possible causes
and standard
value in normal
state
D21-128
Gear shift lever has been stopped at the midway point between each of
the gear positions.
1)Turn starting switch OFF.
2)Connect T-adapter to connector CN033A (male).
Harness between FU3 (3) CN033A (male)
Resistance
Max. 1
(1)
Wiring harness between ATC2 (female) (35)
Resistance
Max. 1
CN033A (male) (3)
Wiring harness between ATC2 (female) (25)
Resistance
Max. 1
CN033A (male) (5)
Wiring harness between ATC1 (female) (6)
Resistance
Max. 1
CN033A (male) (4)
Wiring harness between ATC2 (female) (15)
Resistance
Max. 1
CN033A (male) (6)
Wiring harness between ATC2 (female) (5)
Resistance
Max. 1
CN033A (male) (7)
Wiring harness between ATC2 (female) (36)
Resistance
Max. 1
CN033A (male) (8)
Wiring harness between ATC2 (female) (26)
Resistance
Max. 1
CN033A (male) (9)
Wiring harness between ATC2 (female) (16)
Resistance
Max. 1
CN033A (male) (10)
Wiring harness between ATC2 (female) (6)
Resistance
Max. 1
CN033A (male) (11)
Wiring harness between ATC3 (female) (21)
Resistance
Max. 1
(31), (32), (33) CN033A (male) (2)
1)Turn starting switch OFF.
2)Connect T-adapter to connectors ATC1 (female), ATC2 (female), and
CN033A (male).
3)Turn starting switch ON.
Between ground and wiring harness
between ATC2 (female) (35) CN033A
(male) (3)
Between ground and wiring harness
between ATC2 (female) (25) CN033A
(male) (5)
Troubleshooting
Resistance
Min. 1 M
Resistance
Min. 1 M
02/09 D21003
Cause
Possible causes
and standard
value in normal
state
D21003 02/09
Troubleshooting
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
Voltage
20 30 V
Voltage
Max. 1 V
D21-129
Cause
Possible causes
and standard
value in normal
state
D21-130
Defective transmission
controller
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-131
Failure code
DF10KB
Description
Contents of
trouble
Gear shift lever signals have been inputted at the same time from 2 or more systems.
Controller
Response
Problem that
appears on
machine
There are cases where the gear speed is shifted to a higher gear speed than that which has been set by
the gear shift lever.
Gear speed is still in neutral and cannot start vehicle.
Gear shift lever position lamp does not indicate actual gear shift lever position.
Related
None in particular.
information
Refer to pages 2, 5 & 6 of the electrical schematic for reference.
Cause
Standard value in normal state/Remarks on troubleshooting
1)Turn starting switch OFF.
2) Connect T-adapter to connectors ATC1 (female), ATC2 (female), and
CN033A (male).
3) Turn starting switch ON.
Between ground and wiring harness
When not at
between ATC2 (female) (35) CN033A
Voltage
R,
(male) (3)
Max. 1 V
Between ground and wiring harness
When not at
between ATC2 (female) (25) CN033A
Voltage
D,
(male) (5)
Max. 1 V
Between ground and wiring harness
When not at
between ATC1 (female) (6) CN033A
Voltage
N,
(male) (4)
Max. 1 V
Between ground and wiring harness
When not at
Possible causes
Voltage
6,
and standard
Defective hot short in wiring between ATC2 (female) (15) CN033A
(male) (6)
Max. 1 V
value in normal 1 harness
state
(a contact with 24 V circuit) Between ground and wiring harness
When not at
between ATC2 (female) (5) CN033A
Voltage
5,
(male) (7)
Max. 1 V
Between ground and wiring harness
When not at
between ATC2 (female) (36) CN033A
Voltage
4,
(male) (8)
Max. 1 V
Between ground and wiring harness
When not at
between ATC2 (female) (26) CN033A
Voltage
3,
(male) (9)
Max. 1 V
Between ground and wiring harness
When not at
between ATC2 (female) (16) CN033A
Voltage
2,
(male) (10)
Max. 1 V
Between ground and wiring harness
When not at
between ATC2 (female) (6) CN033A
Voltage
L,
(male) (11)
Max. 1 V
D21-132
Troubleshooting
02/09 D21003
Cause
Possible causes
and standard
value in normal
state
D21003 02/09
Defective transmission
controller
Troubleshooting
D21-133
Cause
Possible causes
and standard
value in normal
3
state
D21-134
Defective transmission
controller
Troubleshooting
02/09 D21003
Failure code
E03
DGF1KX
Description
Contents of
trouble
The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V (above 150?)
or only transmission oil temperature is low (transmission oil temperature sensor signal circuit voltage is
above 4.56 V (below 15 ?) and torque converter and brake oil temperature sensor voltage is below 3.7 V
(above 55 ?).
Controller
Response
The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 32500 (?), 32501 (V)).
Possible causes
and standard
value in normal
state
Between
LUB,T
(male) (1)
(2)
Oil temperature: 25
?
Resistance
37 50 k
Resistance
3.5 4.0 k
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Voltage
Max. 5 V
D21003 02/09
Oil temperature: 25
?
Resistance
37 50 k
Resistance
3.5 4.0 k
Troubleshooting
D21-135
FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT
TO GROUND
Action code
Failure code
E01
DGR2KB
Description
Contents of
trouble
Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
Controller
Response
None in particular.
Problem that
appears on
machine
Related
information
Oil temperature gauge does not work because of failure mode of sensor.
Input signal from oil temperature sensor can be checked with monitoring function (codes: 30208 (?) and
30210 (V)).
Possible causes
and standard
value in normal
state
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Short circuit of harness
(Contact with ground circuit
2
or contact between harnesses)
RCM1 (female)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with the starting switch OFF. Turn the switch ON and perform the
troubleshooting.
3
D21-136
Troubleshooting
Oil temperature
02/09 D21003
FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN
OR SHORT CIRCUIT
Action code
Failure code
E01
DGR2KZ
Description
Contents of
trouble
Controller
Response
None in particular.
Problem that
appears on
machine
Related
information
Oil temperature gauge does not work because of failure mode of sensor.
Input signal from oil temperature sensor can be checked with monitoring function (codes: 30208 (?) and
30210 (V)).
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
RCM1 (female)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Short circuit of harness
(Contact with ground circuit
3
or contact between harnesses)
RCM1 (female)
D21003 02/09
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF and troubleshooting with starting switch
still ON.
Check with monitoring
function code: 30208.
Troubleshooting
Oil
Actual oil temperature and distemperature played temperature are same.
D21-137
FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT
TO GROUND
Action code
Failure code
E01
DGR3KB
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
None in particular.
Oil temperature gauge does not work because of failure mode of sensor.
Input signal from oil temperature sensor can be checked with monitoring function (codes: 30207 (?) and
30209 (V))
Possible causes
and standard
value in normal
state
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Short circuit of harness
(Contact with ground cir2
cuit or contact between harnesses)
RCM1 (female)
D21-138
Retarder oil
temperature (?)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF and troubleshooting with starting switch
still ON.
Check with monitoring
function code: 30207
Troubleshooting
Oil temperature
02/09 D21003
FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN
OR SHORT CIRCUIT
Action code
Failure code
E01
DGR3KZ
Description
Contents of
trouble
Signal circuit voltage of retarder oil temperature sensor has become above 4.721 V.
Controller
Response
None in particular.
Problem that
appears on
machine
Related
information
Oil temperature gauge does not work because of failure mode of sensor.
Input signal from oil temperature sensor can be checked with monitoring function (codes: 30207 (?) and
30209 (V)).
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
RCM1 (female)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Short circuit of harness
(Contact with ground circuit
3
or contact between harnesses)
RCM1 (female)
D21003 02/09
Retarder oil
temperature (?)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF and troubleshooting with starting switch
still ON.
Check with monitoring
function code: 30207
Troubleshooting
Oil
Actual oil temperature and distemperature played temperature are same.
D21-139
Failure code
E01
DGR4KB
Description
Contents of
trouble
Signal circuit voltage of retarder oil temperature sensor has become above 4.721 V.
Controller
Response
None in particular.
Problem that
appears on
machine
Related
information
Oil temperature gauge does not work because of failure mode of sensor.
Input signal from oil temperature sensor can be checked with monitoring function (codes: 30201 (?) and
30204 (V)).
Retarder oil
temperature (?)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
RCM1 (female)
Retarder oil
temperature (?)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Short circuit of harness
(Contact with ground circuit
3
or contact between harnesses)
RCM1 (female)
D21-140
Retarder oil
temperature (?)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF and troubleshooting with starting switch
still ON.
Check with monitoring
function code: 30201
Troubleshooting
Oil temperature
02/09 D21003
Failure code
E01
DGR4KZ
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
None in particular.
Oil temperature gauge does not work because of failure mode of sensor.
Input signal from oil temperature sensor can be checked with monitoring function (codes: 30201 (?) and
30204 (V)).
Possible causes
and standard
value in normal
state
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF, disconnect connector RCM1 and troubleshooting with starting switch still OFF.
Short circuit of harness
(Contact with ground circuit
2
or contact between harnesses)
RCM1 (female)
D21003 02/09
Retarder oil
temperature (?)
Retarder oil
temperature (?)
Resistance (k)
25
42.7
30
35.13
80
6.556
90
4.925
100
3.75
Prepare with starting switch OFF and troubleshooting with starting switch
still ON.
Check with monitoring
function code: 30201
Troubleshooting
Oil
temperature
D21-141
Failure code
E01
DGT1KX
Description
Contents of
trouble
The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above 150
?) or when transmission valve oil temperature signal voltage is below 0.37 V (above 5C) and there is no
abnormality, torque converter oil temperature sensor signal circuit voltage is above 4.56 V (below 15?).
Controller
Response
None in particular.
Problem that
appears on
machine
Related
information
The torque converter oil temperature gauge does not indicate normally.
This failure can be checked in the monitoring function (Code: 30100 (?), 30101 (V)).
Possible causes
and standard
value in normal
state
Between
CN152
(male) (1)
(2)
Oil temperature: 25
?
Resistance
37 50 k
Resistance
3.5 4.0 k
Resistance
Max. 1
Resistance
Max. 1
D21-142
Resistance Min. 1 M
Voltage
Max. 1 V
Oil temperature: 25
?
Resistance
37 50 k
Resistance
3.5 4.0 k
Troubleshooting
02/09 D21003
Failure code
Description
E03
dHP4KX
Contents of
trouble
The voltage of the signal circuit of the suspension pressure sensor (right front) is below1.0 V or above 4.7
V.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from suspension pressure sensor (right front) can be checked with monitoring function (Code:
32802 (MPa), 32808 (V)).
Defective suspension
pressure sensor
Voltage
20 -30 V
Voltage
1.0 - 4.6 V
Possible causes 2
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Possible causes 4
and standard
value in normal
state
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Between HM2B (1) (9)
D21003 02/09
Troubleshooting
Voltage
1.0 4.6 V
D21-143
Failure code
Description
E03
DhP4KX
Contents of
trouble
Signal circuit voltage for the right front suspension pressure sensor is below1.0 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from suspension pressure sensor (right front) can be checked with monitoring function (Code:
32802 (MPa), 32808 (V)).
Defective suspension
pressure sensor
Voltage
20 -30 V
Voltage
1.0 - 4.6 V
Possible causes 2
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Possible causes 4
and standard
value in normal
state
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Between HM2B (1) (9)
D21-144
Troubleshooting
Voltage
1.0 4.6 V
02/09 D21003
Failure code
E03
dHP5KX
Contents of
trouble
The voltage of the signal circuit of the suspension pressure sensor (left front) is below1.0 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from suspension pressure sensor (left front) can be checked with monitoring function (Code:
32803 (MPa), 32809 (V)).
Description
Defective suspension
pressure sensor
Voltage
20 -30 V
Voltage
1.0 - 4.6 V
Possible causes 2
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Possible causes 4
and standard
value in normal
state
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Between RCM1 (7) HM2B (9)
D21003 02/09
Troubleshooting
Voltage
1.0 4.6 V
D21-145
Failure code
Description
E03
DhP5KX
Contents of
trouble
The voltage of the signal circuit of the suspension pressure sensor (left front) is below1.0 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from suspension pressure sensor (left front) can be checked with monitoring function (Code:
32805 (MPa), 32811 (V)).
Defective suspension
pressure sensor
Voltage
20 -30 V
Voltage
1.0 - 4.6 V
Possible causes 2
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
defective contact in connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Possible causes 4
and standard
value in normal
state
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Between HM2B (2) (9)
D21-146
Troubleshooting
Voltage
1.0 4.6 V
02/09 D21003
Failure code
E03
DHP6KX
Contents of
trouble
The voltage of the signal circuit of the suspension pressure sensor: is below 1.0 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from suspension pressure sensor: can be checked with monitoring function (Code: 32806
(MPa), 32812 (V)).
Description
Voltage
20 -30 V
Voltage
1.0 - 4.6 V
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
Possible causes
and standard
value in normal
state
Resistance
Max
Resistance
Max
Resistance
Max
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
3
Resistance
MinM
Resistance
MinM
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
4
D21003 02/09
Voltage
MaxV
Voltage
MaxV
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
Between HM2B (7) - (9)
Troubleshooting
Voltage
1.4 - 4.6 V
D21-147
FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE
Action code
Failure code
E03
DHP7KX
Contents of
trouble
The voltage of the signal circuit of the suspension pressure sensor: is below 1.0 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from suspension pressure sensor: can be checked with monitoring function (Code: 32807
(MPa), 32813 (V)).
Description
Voltage
20 -30 V
Voltage
1.0 - 4.6 V
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
Possible causes
and standard
value in normal
state
Resistance
Max
Resistance
Max
Resistance
Max
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
3
Resistance
MinM
Resistance
MinM
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
4
D21-148
Voltage
MaxV
Voltage
MaxV
Prepare with the starting switch OFF, then turn starting switch ON and
perform troubleshooting.
Between HM2B (8) - (9)
Troubleshooting
Voltage
1.0 - 4.6 V
02/09 D21003
FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF
RANGE
Action code
Failure code
E01
DHT5KX
Contents of
trouble
The voltage of the signal circuit of the torque converter inlet oil pressure sensor is below 0.5 V or above
4.5 V.
Controller
Response
The controller controls the machine, fixing the torque converter inlet oil pressure to the set pressure in
itself.
Description
Torque converter inlet oil pressure sensor: Out of input signal range
(Transmission controller system)
Problem that
appears on
machine
Related
information
Input state from torque converter inlet oil pressure sensor can be checked with monitoring function (Code:
32601 (MPa), 32602 (V)).
3. Connect T-adapter.
Disconnection in wiring
harness
Wiring harness between ATC1 (female) (7)
(Disconnection in wiring or
TC IN (female) (3)
defective contact in connecWiring harness between ATC1 (female) (16)
tor)
TC IN (female) (2)
Wiring harness between ATC1 (female) (21)
TC IN (female) (1)
Resistance
Max. 1
Resistance
Max
Resistance
Max
3. Connect T-adapter.
Grounding fault in wiring
harness
Wiring harness between ATC1 (female) (7)
(Contact with ground circuit) TC IN (female) (3)
Possible causes
and standard
value in normal
state
Resistance
Min
Resistance
Min
Resistance
Max
3. Connect T-adapter.
Between TC IN (1) - (2)
Voltage
20 - 30 V
Voltage
0.8 - 2.0 V
D21003 02/09
3. Connect T-adapter.
Between ATC1 (7) - (21)
Voltage
0.8 - 2.0 V
Voltage
20 - 30 V
Troubleshooting
D21-149
Failure code
E01
DHT5L6
Contents of
trouble
Controller
Response
The controller controls the machine, fixing the torque converter inlet oil pressure to the set pressure initself.
Problem that
appears on
machine
Related
information
Input state from torque converter inlet oil pressure sensor can be checked with monitoring function (Code:
32601 (MPa), 32602 (V)).
Description
While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter inlet
oil pressure sensor.
3. Connect T-adapter.
4. Turn the key switch to ON.
Wiring harness between ATC1 (female) (7) - TC
IN (female) (3)
Voltage
Max. 1.2 V
3. Connect T-adapter.
4. Turn the key switch to ON.
Between TC IN (1) - (2)
Voltage
20 - 30 V
Voltage
0.8 - 2.0 V
Voltage
20 - 30 V
Voltage
0.8 - 2.0 V
D21-150
3. Connect T-adapter.
4. Turn the key switch to ON.
Troubleshooting
02/09 D21003
FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT
OF RANGE
Action code
Failure code
E01
DHT7KX
Contents of
trouble
The voltage of the signal circuit of the torque converter outlet oil pressure sensor is below 0.5 V or above
4.5 V.
Controller
Response
The controller controls the machine, fixing the torque converter outlet oil pressure to the set pressure in
itself.
Problem that
appears on
machine
Related
information
Input state from torque converter outlet oil pressure sensor can be checked with monitoring function
(Code: 32603 (MPa), 32604 (V)).
Description
Torque converter outlet oil pressure sensor: Out of input signal range
(Transmission controller system)
3. Connect T-adapter.
Disconnection in wiring
Wiring harness between ATC1 (female) (1)
harness
TC OUT (female) (3)
(Disconnection in wiring or
defective contact in connector) Wiring harness between ATC1 (female) (16)
TC OUT (female) (2)
Wiring harness between ATC1 (female) (21)
TC OUT (female) (1)
Resistance
Max. 1
Resistance
Max
Resistance
Max
Possible causes
and standard
value in normal
state
3. Connect T-adapter.
Wiring harness between ATC1 (female) (1)
TC OUT (female) (3)
Resistance
Min
Resistance
Min
Resistance
Max
3. Connect T-adapter.
Between TC OUT (1) - (2)
Voltage
20 - 30 V
Voltage
0.8 - 2.0 V
Voltage
0.8 - 2.0 V
Voltage
20 - 30 V
D21003 02/09
3. Connect T-adapter.
Troubleshooting
D21-151
Failure code
E01
DHT7L6
Contents of
trouble
While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter outlet oil pressure sensor.
Controller
Response
The controller controls the machine, fixing the torque converter outlet oil pressure to the set pressure initself.
Problem that
appears on
machine
Related
information
Input state from torque converter outlet oil pressure sensor can be checked with monitoring function
(Code: 32603 (MPa), 32604 (V)).
Description
3. Connect T-adapter.
4. Turn the key switch to ON.
Wiring harness between ATC1 (female) (1) - TC
OUT (female) (3)
Voltage
Max. 1.2 V
3. Connect T-adapter.
4. Turn the key switch to ON.
Between TC OUT (1) - (2)
Voltage
20 - 30 V
Voltage
0.8 - 2.0 V
Voltage
20 - 30 V
Voltage
0.8 - 2.0 V
D21-152
3. Connect T-adapter.
4. Turn the key switch to ON.
Troubleshooting
02/09 D21003
Failure code
E01
DJF1KA
Contents of
trouble
The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Controller
Response
None in particular.
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 04200 (V)).
Description
Fuel level:
When full
Resistance
Max. 12
Fuel level:
When empty
Resistance
82 88
Resistance
Max. 1
Resistance
Max. 1
Voltage
Max. 1 V
Fuel level:
When FULL
Resistance
Max. 12
Fuel level:
When EMPTY
Resistance
82 88
2
Possible causes
and standard
value in normal
state
3
Disconnection in wiring
harness
(Disconnection in wiring or
Wiring harness between ATC1 (female) (8)
defective contact in connec- FLVL (female) (1)
tor)
Wiring harness between ATC1 (female) (21)
FLVL (female) (2)
D21003 02/09
Troubleshooting
D21-153
Failure code
E03
DK11KX
Contents of
trouble
The voltage of the signal circuit of the accelerator sensor is below 0.6 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 31700 (V)).
Description
Possible causes
and standard
value in normal
state
Pedal not
actuated
3.8 0.2 V
Pedal fully
actuated
1.2 0.2 V
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Voltage
5V
Min. 1 M
Resistance
Min. 1 M
Voltage
5V
Pedal not
actuated
3.8 0.2 V
Pedal fully
actuated
1.2 0.2 V
D21-154
Troubleshooting
02/09 D21003
Failure code
E01
DK30KX
Contents of
trouble
Controller
Response
None in particular.
Problem that
appears on
machine
Since steering angle signal is not input to retarder controller, ASR may not operate normally and tires may
slip consequently.
Related
information
Input state from steering angle sensor can be checked with monitoring function (Code: 35400 (V), 35402
()).
Description
Defective sensor
Resistance
5 k 20%
0 5 k *1
0 5 k *1
D21003 02/09
Turn starting switch OFF and disconnect CN228, then perform troubleshooting without turning starting switch ON.
Resistance
Max. 1
Voltage
5V
Grounding fault in wiring har- Turn starting switch OFF and disconnect CN228, then perform troubleshooting without turning starting switch ON.
ness
(Contact with ground circuit) Between CN228 (female) (B) ground
Resistance Min. 1 M
Troubleshooting
D21-155
Failure code
E03
DK51KX
Description
Contents of
trouble
The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V.
Controller
Response
Problem that
appears on
machine
Related
information
Disconnection in wiring
harness
1 (Disconnection in wiring or
defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Voltage
Max. 1 V
D21-156
Troubleshooting
02/09 D21003
D21003 02/09
Voltage
5V
Voltage
0.25 4.75 V
Voltage
5V
Voltage
0.25 4.75 V
Troubleshooting
D21-157
Failure code
E01
DKH1KX
Contents of
trouble
Controller
Response
None in particular.
Cannot detect tipping over.
Problem that
appears on
machine
Related
information
Input state from torque converter inlet oil pressure sensor can be checked with monitoring function (Code:
32901 (), 32902 (V))
Description
Voltage
20 - 30 V.
Voltage
0.5 - 4.5 V.
Resistance
Max
Resistance
Max
Resistance
Max
Resistance
Min
Resistance
Min
Possible causes
and standard
value in normal
state
Voltage
Max. 4.6 V
D21-158
3. Connect T-adapter.
Between HM1 (2) - HM2B (9)
Voltage
20 - 30 V
Voltage
0.5 - 4.5 V
Troubleshooting
02/09 D21003
Failure code
E01
DL10LC
Contents of
trouble
Both wheel speed signal (pulse) inputs to the retarder controller are abnormal.
Controller
Response
Problem that
appears on
machine
Related
information
Input state from the wheel speed sensors can be checked with monitoring function (Codes: 39704, 39705
(rpm)).
Description
Voltage
0.4 - 5V
Turn starting switch OFF and disconnect CN134, RCM1 and RCM2. Perform troubleshooting without turning starting switch ON.
Possible causes
and standard
2
value in normal
state
D21003 02/09
Disconnection in wiring
harness
(Disconnection in wiring
or defective contact in
connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Turn starting switch OFF and disconnect CN137, RCM1 and RCM2. Perform troubleshooting without turning starting switch ON.
Between CN137 (female) (1) RCM1
(female) (22)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Turn starting switch OFF and disconnect CN134 and CN137, then perform troubleshooting without turning starting switch ON.
Between CN134 (female) (3) ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
D21-159
Failure code
E03
DLE2KA
Contents of
trouble
The signal circuit of the Engine speed sensor is disconnected and signals are not input.
Controller
Response
The controller keeps the current gear speed and turns the lockup operation OFF.
If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 01002 (rpm)).
Description
Possible causes
and standard
value in normal
state
Wrong adjustment of
transmission output shaft
speed sensor
Defective transmission
output shaft speed sensor
Resistance
500
1,000
Resistance
Min. 1 M
Disconnection in wiring
harness
Wiring harness between ATC2 (female) (10)
(Disconnection in wiring or
CN178 (female) (1)
defective contact in connector)
Wiring harness between ATC2 (female) (39)
CN178 (female) (2)
Defective retarder
controller
Max. 1
Resistance
Max. 1
Resistance
500
1,000
D21-160
Resistance
Troubleshooting
02/09 D21003
Failure code
E03
DLE2LC
Contents of
trouble
The speed calculated from the transmission input shaft speed sensor signal, transmission intermediate
shaft speed sensor signal, and transmission output shaft speed sensor signal is different from the signal
speed of the engine speed sensor.
Controller
Response
The controller keeps the current gear speed and turns the lockup operation OFF.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 01002 (rpm)).
Description
Defective transmission
output shaft speed sensor
Resistance
500
1,000
Possible causes
and standard
value in normal
state
Defective retarder
controller
Voltage
Max. 1 V
Resistance
500
1,000
D21003 02/09
Resistance Min. 1 M
Troubleshooting
D21-161
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
Action code
Failure code
E03
DLF1KA
Contents of
trouble
The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not input.
Controller
Response
The controller keeps the current gear speed and turns the lockup operation OFF.
If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 31200 (rpm)).
Description
Wrong adjustment of
transmission input shaft
speed sensor
Possible causes
and standard
value in normal
state
500 1,000
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Resistance
500 1,000
Disconnection in wiring
harness
(Disconnection in wiring or
Wiring harness between ATC2 (female)
defective contact in connec- (40) N1 (female) (1)
tor)
Wiring harness between ATC2 (female)
(29) N1 (female) (2)
Defective transmission controller
D21-162
Resistance
Resistance
Troubleshooting
02/09 D21003
Failure code
Description
E03
DLF1LC
Contents of
trouble
The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sensor
signal, and transmission output shaft speed sensor signal is different from the signal speed of the transmission input shaft speed sensor.
Controller
Response
The controller keeps the current gear speed and turns the lockup operation OFF.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 31200 (rpm)).
2
Possible causes
and standard
value in normal
state
500 1,000
Resistance
Min. 1 M
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
500 1,000
D21003 02/09
Resistance
Troubleshooting
D21-163
Failure code
E03
DLF2KA
Contents of
trouble
The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are not
input.
Controller
Response
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 31300 (rpm)).
Description
Wrong adjustment of
transmission intermediate
shaft speed sensor
Possible causes
and standard
value in normal
state
500 1,000
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Resistance
500 1,000
Disconnection in wiring
harness
(Disconnection in wiring or
Wiring harness between ATC2 (female)
defective contact in connec- (20) N2 (female) (1)
tor)
Wiring harness between ATC2 (female)
(39) N2 (female) (2)
Defective transmission controller
D21-164
Resistance
Troubleshooting
02/09 D21003
Failure code
Description
E03
DLF2LC
Contents of
trouble
The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor signal,
and transmission output shaft speed sensor signal is different from the signal speed of the transmission
intermediate shaft speed sensor.
Controller
Response
Problem that
appears on
machine
Related
information
This failure can be checked in the monitoring function (Code: 31300 (rpm)).
2
Possible causes
and standard
value in normal
state
Transmission intermediate
shaft speed sensor defective
Resistance
500 1,000
Resistance
Min. 1 M
Resistance
Min. 1 M
Voltage
Max. 1 V
D21003 02/09
Troubleshooting
Resistance
500 1,000
D21-165
Failure code
E01
DLF8LC
Description
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Turn starting switch OFF and disconnect CN134. Perform troubleshooting without turning starting switch ON.
Between CN134 (female) (3) Ground
Resistance
Min. 1 M
Turn starting switch OFF and remove the sensor from the brake housing.
Install a T-adapter to CN134 and turn the key to ON.
3 Defective wheel speed sensor Pass a piece of metal in front of the sensor
face while measuring the voltage between
CN134 (3) - CN134 (2).
4 Defective retarder controller
D21-166
Voltage
0.4 - 5V
Troubleshooting
02/09 D21003
Failure code
E01
DLF9LC
Description
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Turn starting switch OFF and disconnect CN134. Perform troubleshooting without turning starting switch ON.
Between CN137 (female) (3) Ground
Resistance
Min. 1 M
Turn starting switch OFF and remove the sensor from the brake housing.
Install a T-adapter to CN137 and turn the key to ON.
3 Defective wheel speed sensor Pass a piece of metal in front of the sensor
face while measuring the voltage between
CN137 (3) - CN137 (2).
4 Defective retarder controller
D21003 02/09
Voltage
0.4 - 5V
Troubleshooting
D21-167
FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
Action code
Failure code
E03
dLt3KA
Description
Contents of
trouble
The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input.
Controller
Response
Problem that
appears on
machine
Related
information
2
Possible causes
and standard
value in normal
state
Defective transmission
output shaft speed sensor
Disconnection in wiring
harness
3 (Disconnection in wiring or
defective contact in connector)
Defective retarder
4
controller
Resistance
Resistance
Max. 1
Resistance
Max. 1
D21-168
Min. 1 M
Troubleshooting
02/09 D21003
FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
Action code
Failure code
E01
dLT3KA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input.
When ARSC operates, the controller releases the brake gradually.
Stops controlled ASR
ASR is not controlled normally
ARSC is not controlled normally
This failure can be checked in the monitoring function (Code: 31400 (rpm)).
2
Possible causes
and standard
value in normal
state
Defective transmission
output shaft speed sensor
Disconnection in wiring
harness
3 (Disconnection in wiring or
defective contact in connector)
Defective retarder
4
controller
Resistance
500 1,000
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
D21003 02/09
Troubleshooting
Resistance
500 1,000
D21-169
Failure code
E03
DLT3KA
Contents of
trouble
The signal circuit of the transmission output shaft speed sensor is open and signals are not received by the
controller.
Controller
Response
Problem that
appears on
machine
Operator can move the machine by following the limp home procedure.
1) Stop travel and set gearshift lever in N position.
2) Momentarily disconnect the limp home jumper from connector CN041 to set the machine in limp home
mode. Plug the jumper back into the connector.
3) Operate gearshift lever and start machine again.
a. When operating gearshift lever, release accelerator pedal.
b. Operate gearshift lever from N to D L or from N to R.
c. Machine is kept in limp home mode until starting switch is turned OFF.
Related
information
This failure can be checked with monitor function code: 31400 (rpm).
Description
2
Possible causes
and standard
value in normal
state
Defective transmission
output shaft speed sensor
Resistance
500 1,000
Resistance
Min. 1 M
Disconnection in wiring
harness
3 (Disconnection in wiring or
Wiring harness between ATC2 (female)
defective contact in connec- (30) N3 (female) (1)
tor)
Wiring harness between ATC2 (female)
(29) N3 (female) (2)
Defective retarder
4
controller
Max. 1
Resistance
Max. 1
Resistance
500 1,000
D21-170
Resistance
Troubleshooting
02/09 D21003
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
dLt3LC
Description
Left and right wheel speed sensor signals are different from the signal speed of the transmission output
shaft speed sensor.
When ARSC operates, the controller releases the brake normally.
Stops controlled ASR
ASR is not controlled normally.
ARSC is not controlled normally.
This failure can be checked in the monitoring function (Code: 31400 (rpm)).
Defective transmission
output shaft speed sensor
Resistance
500 1,000
Resistance
Min. 1 M
Possible causes
and standard
value in normal
state
Defective retarder
4
controller
Min. 1 M
Voltage
Max. 1 V
Resistance
500 1,000
D21003 02/09
Resistance
Troubleshooting
D21-171
Failure code
E01
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
dLT3LC
Description
Left and right wheel speed sensor signals are different from the signal speed of the transmission output
shaft speed sensor.
When ARSC operates, the controller releases the brake normally.
Stops controlled ASR
ASR is not controlled normally.
ARSC is not controlled normally.
This failure can be checked in the monitoring function (Code: 31400 (rpm)).
Defective transmission
output shaft speed sensor
Resistance
500 1,000
Resistance
Min. 1 M
Possible causes
and standard
value in normal
state
Defective retarder
4
controller
Min. 1 M
Voltage
Max. 1 V
Resistance
500 1,000
D21-172
Resistance
Troubleshooting
02/09 D21003
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL
Action code
Failure code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
DLT3LC
Description
The engine speed sensor, transmission input shaft speed sensor, and transmission intermediate speed
sensor does not match transmission output shaft speed.
The controller keeps the current gear speed and turns the lockup operation OFF.
If the shift lever is set in the N position, the controller keeps the gear in NEUTRAL.
The operator can move the truck by following the limp home procedure outlined earlier in this section.
This failure can be checked in the monitoring function (Code: 31400 (rpm)).
Possible causes
and standard
value in normal
state
Defective transmission
output shaft speed sensor
Resistance
500 1,000
Resistance
Min. 1 M
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
500 1,000
Defective retarder
4
controller
D21003 02/09
Troubleshooting
D21-173
Failure code
E01
DNCCMA
Description
Contents of
trouble
Brake does not work even though the driver works the foot brake.
Controller
Response
None in particular
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Voltage
0V
Voltage
about 8 V
Resistance
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
3
D21-174
Defective retarder
controller
ON
OFF
Troubleshooting
02/09 D21003
Failure code
E01
DV00KB
Description
Contents of
trouble
Monitor
Response
Problem that
appears on
machine
Related
information
1 Defective buzzer
Possible causes
and standard
value in normal
state
1)Turn starting switch OFF, disconnect the buzzer connector, and remove
buzzer.
2)Connect +24 V to buzzer (+) and connect GND to buzzer (-).
If buzzer does not sound, buzzer is defective. Replace.
Turn starting switch OFF and disconnect the buzzer connector, then perGrounding fault in wiring
form troubleshooting without turning starting switch ON.
harness
2
(Contact with ground circuit)
Between CN1 (male) (13) ground
Resistance
Min. 1 M
(Reference)
Hot short
3 (Contact with 24V circuit) in
wiring harness
Disconnection in wiring
harness
4 (Disconnection in wiring or
defective contact in
connector) (Reference)
5 Defective machine monitor
D21003 02/09
1)Turn starting switch OFF, disconnect CN1 and the buzzer connector,
and insert T-adapter in CN1 (female).
2)Turn starting switch ON and perform troubleshooting.
Between CN1 (male) (13) ground
Voltage
Max. 1 V
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
D21-175
FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT
Action code
Failure code
E01
DW78KZ
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned ON/
OFF. Accordingly, BCV solenoid cannot be driven.
Stops supplying current when BCV circuit is disconnected.
Turns output to BCV relay (CNR02-V) primary side OFF.
Since retarder is not cooled, it may overheat.
For troubleshooting for BCV relay (CNR02-V) secondary side, see [B@C7NS] or [B@C8NS]..
Possible causes
and standard
value in normal
state
D21-176
CNR02-V
(female: Wiring harness side)
Resistance
100 500
Turn starting switch OFF and disconnect CNR02-V (BCV relay), then perform troubleshooting without turning starting switch ON.
Resistance
Min. 1 M
Turn starting switch OFF and disconnect CNR02-V (BCV relay) and
RCM3, then perform troubleshooting without turning starting switch ON.
Disconnection in wiring
harness
3 (Disconnection in wiring
or defective contact in
connector)
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
02/09 D21003
FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT
Action code
Failure code
E01
DW79KZ
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned ON/
OFF. Accordingly, BCV solenoid cannot be driven.
Stops supplying current when BCV circuit is disconnected.
Turns output to BCV relay (CNR02-T) primary side OFF.
Since retarder is not cooled, it may overheat.
For troubleshooting for BCV relay (CNR02-T) secondary side, see [B@C6NS].
Possible causes
and standard
value in normal
state
Defective CNR02-T(BCV
relay)
Resistance
100 500
Turn starting switch OFF and disconnect R14 (BCV relay), then perform
troubleshooting without turning starting switch ON.
D21003 02/09
CNR02
(female: Wiring harness side)
Resistance
Min. 1 M
Turn starting switch OFF and disconnect CNR02-T (BCV relay) and
RCM3, then perform troubleshooting without turning starting switch ON.
Between RCM3 (female) (8) CNR02
(female) (57)
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
D21-177
Failure code
E03
DW7FMA
Description
Contents of
trouble
Emergency brake does not operate even though the driver works the manual emergency brake.
Controller
Response
None in particular
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Resistance
Min. 1 M
Voltage
Max. 1 V
D21-178
Defective retarder
controller
ON
OFF
Troubleshooting
02/09 D21003
FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT
CIRCUIT
Action code
Failure code
E03
DW7GMA
Description
Contents of
trouble
Brake (rear) does not operate even though the driver works the foot brake or brake lock sw.
Controller
Response
None in particular
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
(Disconnection in wiring or
2 defective contact in connector)
(Brake lock sw or brake
apply sw failure)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
Wiring harness between CN068 (female) (3)
RCM2 (35)
Voltage
Max. 1 V
Prepare with starting switch OFF, then turn starting switch ON and perform troubleshooting.
4 Defective retarder controller
D21003 02/09
ON
OFF
Troubleshooting
D21-179
FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)
Action code
Failure code
E03
DWA1K4
Description
Contents of
trouble
PPC cut valve pressure sensor does not respond to PPC cut valve ON command of retarder controller.
Controller
Response
None in particular
Problem that
appears on
machine
Related
information
When rear retarder brake should be cut as treatment of DX27K4 and DX28K4, rear retarder brake is not
cut.
If PPC cut valve has electrical trouble, code [DWA1KA], [DWA1KB] or [DWA1KY] is output.
Possible causes
and standard
value in normal
state
Resistance
Key ON
Min. 1 M
Engine ON
Max. 1
Turn starting switch OFF and disconnect CN238, RCM1, RCM3 and
CN239, then perform troubleshooting without turning starting switch ON.
Disconnection in wiring
harness
3 (Disconnection in wiring or
defective contact in connector)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Turn starting switch OFF and disconnect ASR7, then perform troubleGrounding fault in wiring
shooting without turning starting switch ON.
4 harness
(Contact with ground circuit) Between CN238 (female) (C) ground
Resistance
Min. 1 M
5 Defective retarder controller
D21-180
Troubleshooting
02/09 D21003
Failure code
E03
DWA1KA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
When signal is output to PPC cut valve solenoid circuit, no current flows.
None in particular
Signal is not output to PPC cut valve solenoid circuit until starting switch is turned OFF once.
Possible causes
and standard
value in normal
state
D21003 02/09
Resistance
5 28
Resistance
5 28
Resistance
5 28
Troubleshooting
D21-181
Failure code
E03
DWA1KB
Description
Contents of
trouble
When signal is output to PPC cut valve solenoid circuit, abnormal current flows.
Controller
Response
Problem that
appears on
machine
Related
information
Signal is not output to PPC cut valve solenoid circuit until starting switch is turned OFF once.
Resistance
5 28
Turn starting switch OFF and disconnect RCM3, then perform troubleGrounding fault in wiring
shooting without turning starting switch ON.
2 harness
(Contact with ground circuit) Between RCM3 (female) (27) ground
Resistance
Min. 1 M
Turn starting switch OFF and disconnect RCM3 and CN239, then perform
Short circuit in wiring
troubleshooting without turning starting switch ON.
3 harness
(with another wiring harness) Wiring harness between RCM3 (female)
Resistance
Min. 1 M
(27) RCM (female) (pin other than (15))
5 Defective retarder controller
D21-182
Troubleshooting
02/09 D21003
Failure code
E03
DWA1KY
Description
Contents of
trouble
When signal is output to PPC cut valve solenoid circuit, abnormal current flows.
Controller
Response
None in particular
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Turn starting switch OFF and disconnect CN237, then perform troubleshooting without turning starting switch ON.
CN237 (male)
Resistance
5 28
Turn starting switch OFF and insert T-adapter in RCM3, then turn starting
Hot short (Contact with 24 V switch ON and perform troubleshooting.
circuit) in wiring harness
Between RCM3 (female) (27) ground
Voltage
Max. 1 V
D21003 02/09
Troubleshooting
D21-183
FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)
Action code
Failure code
E03
DWA1MA
Description
Contents of
trouble
Sensor does not respond to PPC cut valve OFF command of retarder controller.
Controller
Response
Problem that
appears on
machine
Related
information
Possible causes
Cause
Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Perform troubleshooting for failure code [DWA1K4].
state
D21-184
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-185
FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE
STUCK ON)
Action code
Failure code
E03
DX12K4
Description
Contents of
trouble
Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not return
or their condition cannot be judged normally because of defect in sensor switch after they return.
Controller
Response
Continues control.
Problem that
appears on
machine
Related
information
Resistance
Max. 1
Oil
pressure is
OFF.
Resistance
Min. 1 M
Possible causes
and standard
value in normal
state
CN236
Between (B) (C)
Defective retarder pressure
switch
Front retard apply sw
3 Brake pedal signal
Emergency auto apply sw
Brake apply sw
Front brake apply sw
CN240
Between (B) (C)
CN027
Between (B) (C)
CN222
Between (1) (2)
CN231
Between (B) (C)
D21-186
Oil
pressure is
ON.
Troubleshooting
Retarder
Voltage
81V
When operated
Max. 1 V
Brake
Voltage
applied
0V
not applied
81V
Brake
Voltage
applied
0V
not applied
81V
Retarder
Voltage
When operated
81V
0V
Brake
Voltage
applied
0V
not applied
81V
02/09 D21003
D21003 02/09
Troubleshooting
Oil
pressure is
ON.
Voltage
Max. 1 V
Oil
pressure is
OFF.
Voltage
81V
D21-187
FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT
Action code
Failure code
E03
DX12KA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
When output to front brake proportional pressure reducing valve solenoid circuit is ON, current does not
flow.
Turn output to front brake proportional pressure reducing valve solenoid OFF.
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective front brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
Resistance
8.5 9.1
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
D21-188
Troubleshooting
Resistance
8.5 9.1
02/09 D21003
FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT
Action code
Failure code
E03
DX12KB
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
When output to solenoid circuit of front brake proportional pressure reducing valve is turned ON, much
current flows.
Turns output to solenoid circuit of front brake proportional pressure reducing valve OFF.
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective front brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Resistance
8.5 9.1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
8.5 9.1
D21003 02/09
Troubleshooting
D21-189
FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER
Action code
Failure code
E03
DX12KY
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
When output to front brake proportional pressure reducing valve solenoid circuit is OFF, electric current
flows.
Turn output to front brake proportional pressure reducing valve solenoid OFF.
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective front brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Resistance
8.5 9.1
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
8.5 9.1
D21-190
Troubleshooting
02/09 D21003
FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE
DOES NOT OPERATE)
Action code
Failure code
E03
DX12MA
Description
Front brake PPC solenoid valve: Malfunction (valve does not operate)
(Retarder controller system)
Contents of
trouble
Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not return
or their condition cannot be judged normally because of defect in sensor switch after they return.
Controller
Response
Continues control.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Resistance
Max. 1
Oil
pressure
is OFF.
Resistance
Min. 1 M
Oil
pressure
is ON.
Retarder
Voltage
81V
When operated
Max. 1 V
Resistance
Min. 1 M
Oil
pressure
is ON.
Voltage
Max. 1 V
Oil
pressure
is OFF.
Voltage
81V
D21003 02/09
Troubleshooting
D21-191
FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE
STUCK ON)
Action code
Failure code
E03
DX27K4
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Rear right brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
return or their condition cannot be judged normally because of defect in sensor switch after they return.
Stops controlling ASR.
PPC cut valve ON
If solenoid is defective, rear right brake drags.
ASR is not controlled normally
Rear right retarder oil pressure switch state can be checked with monitoring function (Code: 34104).
Oil
pressure is Resistance Min. 1 M
OFF.
Possible causes
and standard
value in normal
state
81V
Max. 1 V
81V
Brake applied
Max. 1 V
not applied
Max. 1 V
applied
81V
81V
Max. 1 V
81V
Brake applied
Max. 1 V
Brake applied
81V
Min. 1 V
Brake lock ON
Pilot lamp on
Brake lock
Check with monitor function code: 39900
D21-192
Oil
pressure is Resistance Max. 1
ON.
Troubleshooting
02/09 D21003
D21003 02/09
Resistance Min. 1 M
Troubleshooting
Voltage
Max. 1 V
Oil pressure is
OFF.
Voltage
81V
D21-193
FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT
Action code
Failure code
E03
DX27KA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
When output to rear right brake proportional pressure reducing valve solenoid circuit is ON, current does
not flow.
Turn output to rear brake proportional pressure reducing valve solenoid OFF.
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective rear right brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
Resistance
8.5 9.1
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
D21-194
Troubleshooting
Resistance
8.5 9.1
02/09 D21003
FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT
Action code
Failure code
E03
DX27KB
Description
Contents of
trouble
When output to solenoid circuit of rear right brake proportional pressure reducing valve is turned ON, much
current flows.
Controller
Response
Turns output to solenoid circuit of rear right brake proportional pressure reducing valve OFF.
Problem that
appears on
machine
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective rear right brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Resistance
8.5 9.1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
8.5 9.1
D21003 02/09
Troubleshooting
D21-195
FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER
Action code
Failure code
E03
DX27KY
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
When output to rear right brake proportional pressure reducing valve solenoid circuit is OFF, electric current flows.
Turn output to rear brake proportional pressure reducing valve solenoid OFF.
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective rear right brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Resistance
10 30
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
10 30
D21-196
Troubleshooting
02/09 D21003
Failure code
E03
DX27MA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Right rear PPC solenoid valve: Malfunction (valve does not operate)
(Retarder controller system)
Rear right brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
return or their condition cannot be judged normally because of defect in sensor switch after they return.
Continues control.
If solenoid is defective, rear right brake drags.
If switch is defective or switch input circuit has disconnection, condition does not change.
Condition of rear right retarder oil pressure switch can be checked with monitoring function (Code: 34104)
Possible causes
and standard
value in normal
state
Resistance
Max. 1
Oil
pressure
is OFF.
Resistance
Min. 1 M
Oil
pressure
is ON.
Retarder
Voltage
81V
When operated
Max. 1 V
Resistance
Min. 1 M
Oil
pressure
is ON.
Voltage
Max. 1 V
Oil
pressure
is OFF.
Voltage
81V
D21003 02/09
Troubleshooting
D21-197
FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION
Action code
Failure code
E03
DX28K4
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Rear left brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
return or their condition cannot be judged normally because of defect in sensor switch after they return.
Stops controlling ASR.
PPC cut valve ON.
If solenoid is defective, rear left brake drags.
Rear left retarder oil pressure switch state can be checked with monitoring function (Code: 34103).
Resistance
Oil
pressure
is OFF.
Resistance Min. 1 M
Max. 1
Possible causes
and standard
value in normal
state
81V
Max. 1 V
81V
Brake applied
Max. 1 V
not applied
Max. 1 V
applied
81V
81V
Retarder operated
Max. 1 V
81V
Brake applied
Max. 1 V
Brake applied
81V
Min. 1 V
Brake lock ON
Pilot lamp on
Brake lock
Check with monitor function code: 39900
D21-198
Oil
pressure
is ON.
Troubleshooting
02/09 D21003
D21003 02/09
Resistance Min. 1 M
Troubleshooting
Oil
pressure
is ON.
Voltage
Max. 1 V
Oil
pressure
is OFF.
Voltage
81V
D21-199
FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT
Action code
E03
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Failure code
DX28KA
Description
Rear left brake proportional pressure reducing solenoid valve output circuit: Disconnection
(Retarder controller system)
When output to rear left brake proportional pressure reducing valve solenoid circuit is ON, current does not
flow.
Turn output to rear left brake proportional pressure reducing valve solenoid OFF.
Related
information
Refer to page 8 in the electrical schematic for reference.
Cause
Defective rear left brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
Resistance
8.5 9.1
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
D21-200
Troubleshooting
Resistance
8.5 9.1
02/09 D21003
FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT
Action code
Failure code
E03
DX28KB
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Description
When output to solenoid circuit of rear left brake proportional pressure reducing valve is turned ON, much
current flows.
Turns output to solenoid circuit of rear left brake proportional pressure reducing valve OFF.
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective rear left brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Resistance
8.5 9.1
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
8.5 9.1
D21003 02/09
Troubleshooting
D21-201
FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER
Action code
Failure code
E03
DX28KY
Description
Contents of
trouble
When output to rear left brake proportional pressure reducing valve solenoid circuit is OFF, electric current
flows.
Controller
Response
Turn output to rear left brake proportional pressure reducing valve solenoid OFF.
Problem that
appears on
machine
Related
information
Refer to page 8 of the electrical schematic for reference.
Cause
Defective rear left brake
1 proportional pressure
reducing solenoid valve
Possible causes
and standard
value in normal
state
Resistance
8.5 9.1
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
8.5 9.1
D21-202
Troubleshooting
02/09 D21003
FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE
DOES NOT OPERATE)
Action code
Failure code
E03
DX28MA
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related
information
Description
Left rear PPC solenoid valve: Malfunction (Valve does not operate)
(Retarder controller system)
Rear left brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
return or their condition cannot be judged normally because of defect in sensor switch after they return.
Continues control.
If solenoid is defective, rear left brake drags.
If switch is defective or switch input circuit has disconnection, condition does not change.
Condition of rear left retarder oil pressure switch can be checked with monitoring function (Code: 34103)
(bit [3], 0:OFF, 1:ON).
Possible causes
and standard
value in normal
state
Resistance
Max. 1
Oil
pressure
is OFF.
Resistance
Min. 1 M
Oil
pressure
is ON.
Retarder
Voltage
81V
When operated
Max. 1 V
Resistance
Min. 1 M
Oil
pressure
is ON.
Voltage
Max. 1 V
Oil
pressure
is OFF.
Voltage
81V
D21003 02/09
Troubleshooting
D21-203
FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXH1KA
Description
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Output current to lockup ECMV can be checked with monitoring function (Code: 31609 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or improper
contact)
Defective transmission
3
controller
D21-204
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXH1KB
Description
Contents of
trouble
Abnormally excessive current flows while output to lockup clutch ECMV is ON.
Controller
Response
Keeps gear speed used for travel and turns lockup operation OFF.
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on
machine
Related information
Output current to lockup ECMV can be checked with monitoring function (Code: 31609 (mA)).
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21003 02/09
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
Resistance
5 15
D21-205
FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXH1KY
Contents of
trouble
Controller
Response
Description
Problem that
appears on
machine
Related information
Output current to lockup ECMV can be checked with monitoring function (Code: 31609 (mA))
Possible causes
and standard
value in normal
state
D21-206
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1 V
Troubleshooting
Resistance
5 15
02/09 D21003
D21003 02/09
Troubleshooting
D21-207
FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXH2KA
Description
Contents of
trouble
Controller
Response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31600 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or
defective contact)
D21-208
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-209
FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXH2KB
Contents of
trouble
Controller
Response
Description
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21-210
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
F7
3rd
High
F6
3rd
Mid
F5
2nd
High
F4
2nd
Mid
F3
1st
High
F2
1st
Mid
F1
2nd
Low
Reverse
Low
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
2nd
3M
F6
OFF
High
3M
F6
OFF
2nd
3M
F6
OFF
Mid
2H
F5
OFF
1st
2M
F4
OFF
High
2M
F4
OFF
1st
2M
F4
OFF
Mid
1H
F3
OFF
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-211
FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXH2KY
Description
Contents of
trouble
Controller
Response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31600 (mA)).
Cause
Possible causes
and standard
value in normal
state
D21-212
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1V
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-213
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
D21-214
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-215
FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXH3KA
Description
Contents of
trouble
Current does not flow when output to low clutch ECMV is ON.
Controller
Response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31601 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
D21-216
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-217
FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXH3KB
Contents of
trouble
Controller
Response
Description
Abnormally excessive current flows while output to low clutch ECMV is ON.
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31601 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21-218
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-219
FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXH3KY
Contents of
trouble
Controller
Response
Description
When output to low clutch ECMV is turned OFF, current flows to circuit.
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31601 (mA)).
Cause
Possible causes
and standard
value in normal
state
2
D21-220
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
5 15
Troubleshooting
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-221
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
D21-222
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-223
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXH4KA
Description
Contents of
trouble
Current does not flow when output to 1st clutch ECMV is ON.
Controller
Response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31602 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or improper
contact)
D21-224
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Resistance
5 15
Troubleshooting
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-225
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXH4KB
Description
Contents of
trouble
Abnormally excessive current flows when output to 1st clutch ECMV is ON.
Controller
Response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21-226
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
5 15
Troubleshooting
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-227
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXH4KY
Description
Contents of
trouble
Controller
Response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31602 (mA)).
Cause
Possible causes
and standard
value in normal
state
D21-228
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1 V
Resistance
5 15
Troubleshooting
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-229
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
D21-230
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-231
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXH5KA
Description
Contents of
trouble
Current does not flow when output to 2nd clutch ECMV is ON.
Controller
Response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31603 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
Defective transmission
3
controller
D21-232
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Resistance
5 15
Troubleshooting
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-233
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXH5KB
Contents of
trouble
Controller
Response
Description
Abnormally excessive current flows while output to 2nd clutch ECMV is ON.
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31603 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21-234
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-235
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXH5KY
Description
Contents of
trouble
Controller
Response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31603 (mA)).
Cause
Possible causes
and standard
value in normal
state
D21-236
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1 V
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-237
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
D21-238
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-239
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXH6KA
Description
Contents of
trouble
Current does not flow when output to 3rd clutch ECMV is ON.
Controller
Response
Problem that
appears on
machine
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31604 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
Defective transmission
3
controller
D21-240
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-241
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXH6KB
Contents of
trouble
Controller
Response
Description
Abnormally excessive current flows while output to 3rd clutch ECMV is ON.
The controller sets the gear in neutral.
The controller disengages the lockup circuit.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31604 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21-242
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-243
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXH6KY
Description
Contents of
trouble
Controller
Response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31604 (mA)).
Cause
Possible causes
and standard
value in normal
state
D21-244
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1 V
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-245
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
D21-246
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-247
Failure code
E03
DXH7KA
Description
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31606 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or defective
contact)
Defective transmission
3
controller
D21-248
Resistance
5 15
Resistance
Min. 1 M
Resistance
Max. 1
Resistance
Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-249
Failure code
E03
DXH7KB
Contents of
trouble
Controller
Response
Description
Problem that
appears on
machine
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31606 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
5 15
Resistance
Min. 1 M
Defective transmission
3
controller
D21-250
Resistance
Min. 1 M
Resistance
Min. 1 M
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 1
Speed when trouble was
detected
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
F7
3rd
High
3rd
OFF
NEUTRAL
OFF
High
OFF
NEUTRAL
OFF
F6
3rd
Mid
3rd
OFF
NEUTRAL
OFF
Mid
3H
F7
OFF
F5
2nd
High
2nd
3M
F6
OFF
High
3M
F6
OFF
F4
2nd
Mid
2nd
3M
F6
OFF
Mid
2H
F5
OFF
F3
1st
High
1st
2M
F4
OFF
High
2M
F4
OFF
F2
1st
Mid
1st
2M
F4
OFF
Mid
1H
F3
OFF
F1
2nd
Low
2nd
1M
F2
OFF
Low
1M
F2
OFF
Reverse
Low
Reverse
OFF
NEUTRAL
OFF
Low
RM
R*
OFF
D21003 02/09
Troubleshooting
D21-251
Failure code
E03
DXH7KY
Description
Contents of
trouble
Controller
Response
Problem that
appears on
machine
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31606 (mA)).
Cause
Possible causes
and standard
value in normal
state
D21-252
Defective transmission
controller
Resistance
5 15
Resistance
Min. 1 M
Voltage
Max. 1 V
Troubleshooting
Resistance
5 15
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-253
TABLE 2
Speed when trouble was
detected
Mid
Failed clutch
(Fill switch ON)
Action of controller
(Selected clutch, gear speed)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
D21-254
Troubleshooting
02/09 D21003
NOTES
D21003 02/09
Troubleshooting
D21-255
FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
Action code
Failure code
E03
DXJ7KA
Description
Contents of
trouble
Current does not flow when output to Mid clutch ECMV is ON.
Controller
Response
Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure
Turns lock up to OFF.
Problem that
appears on
machine
Related information
As ECMV detects disconnection while output is ON, be sure to turn output ON to check operation after
repair.
Electric current of output to ECMV can be checked with monitoring function (code: 31640 (mA)).
Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned ON,
wait for 5 seconds without starting the engine.
If trouble has not been repaired, error is detected again.
Once the gear shift lever is set to neutral, the machine cannot move off in any gear speeds.
Cause
Possible causes
and standard
value in normal
state
Disconnection in wiring
harness
2
(Disconnection or
defective contact)
D21-256
5 15
Resistance
Resistance Min. 1 M
Resistance Max. 1
Resistance Max. 1
Troubleshooting
Resistance
5 15
02/09 D21003
D21003 02/09
Troubleshooting
D21-257
FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
Action code
Failure code
E03
DXJ7KB
Contents of
trouble
Controller
Response
Description
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine cannot move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31640 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
Resistance Min. 1 M
D21-258
5 15
Defective transmission
controller
Troubleshooting
Resistance
5 15
02/09 D21003
D21003 02/09
Troubleshooting
D21-259
FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
Action code
Failure code
E03
DXJ7KY
Description
Mid clutch ECMV output circuit: Short circuit to power source line
(Transmission controller system)
Contents of
trouble
When output to Mid clutch ECMV is turned "OFF", current flows to circuit.
Controller
Response
Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Turns lock up to OFF.
Problem that
appears on
machine
Once the gear shift lever is set to neutral, the machine cannot move off in any gear speeds.
Related information
Electric current of output to ECMV can be checked by monitoring function (code: 31640 (mA)).
Cause
Possible causes
and standard
value in normal
state
Resistance
Resistance Min. 1 M
D21-260
Defective transmission
controller
5 15
Voltage
Max. 1V
Resistance
5 15
Troubleshooting
02/09 D21003
TABLE 2
Speed when trouble was
detected
Failed clutch
(Fill switch ON)
2nd
3rd
High
F7
3rd
Mid
F6
2nd
High
F5
2nd
Mid
F4
1st
High
F3
1st
Mid
F2
2nd
Low
F1
Reverse
Low
D21003 02/09
NEUTRAL*
ON/OFF state of
lockup clutch
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
3H
F7
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
3M
F6
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
OFF
NEUTRAL*
OFF
Reverse
OFF
NEUTRAL*
OFF
High
2H
F5
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
Mid
2M
F4
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
2nd
2M
F4
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Low
OFF
NEUTRAL*
OFF
3rd
3M
F6
OFF
1st
1M
F2
OFF
Reverse
OFF
NEUTRAL*
OFF
High
1H
F3
OFF
Mid
1M
F2
OFF
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
High
RH
R*
OFF
Mid
RM
R*
OFF
Troubleshooting
D21-261
TABLE 2
Speed when trouble was
detected
D21-262
Mid
Failed clutch
(Fill switch ON)
ON/OFF state of
lockup clutch
3rd
OFF
NEUTRAL*
OFF
2nd
OFF
NEUTRAL*
OFF
1st
OFF
NEUTRAL*
OFF
HIgh
OFF
NEUTRAL*
OFF
Low
OFF
NEUTRAL*
OFF
Troubleshooting
02/09 D21003
SECTION D30
VHMS INITIALIZATION
INDEX
D30003
VHMS
D30-1
NOTES
D30-2
VHMS
D30003
Tools
Part Number
Description
799-608-3211
Software Disc
799-608-3220
Download Cable
Commercially
available
Machine Information
Model name
Machine serial number
Current service meter hour
Engine serial number
Transmission serial number
2. Turn the key switch to the OFF position. Connect the download harness to the PCs RS232C
terminal and the other end to download connector HM6VA. Download connector HM6VA is
located behind the passenger seat or at the
ground level download box. Refer to Figures
30-1 and 30-2.
D30003
VHMS
D30-3
c. Verify that the ORBCOMM controller is capturing the communication satellite from the
VHMS controller. This check must be done
within 3 minutes after the VHMS is powered.
Observe the LEDs situated in the right side
of VHMS controller. Refer to the decimal
point on the right hand digit to verify that the
ORBCOMM controller has captured the
communication satellite. If the decimal point
blinks slowly, the ORBCOMM controller is
operating normally. Communication between
the terminals is normal. The terminals have
transmission data and have captured the
satellite.
D30-4
VHMS
D30003
4. Turn on the PC. Start up the VHMS initial setting tool by clicking on the VHMS icon.
Appearance of the setup screen of the VHMS setting tool depends its version.
When using a version older than 3.5.2.1 (CDROM), the setting procedures must conform to
those described in steps 8 thru 21.
When using Version 3.5.2.1 or newer, the procedures in steps 22 thru 31 must be used.
It is recommended to download the latest VHMS
version from WebCARE to update the currently
used version.
5. Enter the 10-digit service ID to [Service ID].
Service ID: 7826133000
6. Select [Data clear and Set up] from the [Select
Function] box.
D30003
VHMS
D30-5
Engine Model
Installed
SDA12V160
Installed
SSA16V159
D30-6
Model
Type
HD1500
-7
VHMS
Variation Code
T1
T2
Date/Time
Time Difference
(GMT)
Summertime
Set Properly
D30003
D30003
VHMS
D30-7
Code
Applicable Region
120
Italy
121
Malaysia
122
Korea
130
Japan
D30-8
VHMS
D30003
23. Select [Set up & All clear] and press the [Next]
button.
21. Fill in the necessary information on the ORBCOMM activation form later in this chapter.
Send by fax or by mail to Customer Support Gr.
Solution Division, Komatsu Ltd.
D30003
VHMS
D30-9
D30-10
VHMS
D30003
26. Set the GCC code to the target region of application and, as setting is completed, press the
[Next] button.
Applicable Region
120
Italy
121
Malaysia
122
Korea
130
Japan
D30003
VHMS
D30-11
29. After the setting is complete, press the [OK] button to end the program.
31. Fill in the necessary information on the ORBCOMM activation form on the following page.
Send by fax or by mail to Customer Support Gr.
Solution Division, Komatsu Ltd.
NOTE: The ORBCOMM modem installed from the
factory on all new trucks may not be approved for
use in certain countries of the world. Local regulation
may prohibit the use of the ORBCOMM modem/
satellite communicator. Depending on local
regulation, you may need to either remove the
modem or disconnect it and remove the antenna.
Check with KAC service for assistance and preferred
action in your area.
The following is a list of "at risk" countries: China,
Russia, Serbia, Tanzania, Senegal, Zambia,
Botswana and Namibia.
D30-12
VHMS
D30003
D30003
VHMS
D30-13
Executing Quick PM
The [] in the leftmost position of the lower column is replaced with [*] for every 30 seconds.
When two or more [*] signs are displayed, the
rightmost one flashes.
5. Press mode switch []. [READY] will be displayed on the screen and the monitor will switch
to standby mode. The lower column displays 15
[] symbols.
D30-14
VHMS
D30003
Finish
0:00
2:00
2:00
3
4
5
Time
Engine Speed
AISS
switch
Shift
lever
Parking
brake
Retarder
Hoist
lever
Auto
ON
ON
HOLD
3:00
60 sec
Auto
OFF
OFF
HOLD
3:00
4:00
60 sec
Auto
ON
ON
FLOAT
4:00
5:00
60 sec
Auto
ON
ON
HOLD
5:00
5:30
30 sec
High idle
Auto
ON
ON
HOLD
5:30
6:00
30 sec
Auto
OFF
ON
HOLD
6:00
6:30
30 sec
High idle
&
20 pumps of foot brake
Auto
ON
ON
HOLD
Remarks
(*1)
(*2, *3)
D30003
VHMS
D30-15
D30-16
VHMS
D30003
D30003
VHMS
D30-17
D30-18
VHMS
D30003
3. When using the ground level download connector, move switch (2, FIGURE 30-4) to the ON
position. The green LED (3) will illuminate.
D30003
VHMS
D30-19
Disconnecting the PC
Reporting to Komatsu
D30-20
VHMS
D30003
D30003
VHMS
D30-21
D30-22
VHMS
D30003
D30003
VHMS
D30-23
[For storage]
VHMS Initial Setting Work Check Sheet
Date of setting:
DB/branch
office name
Data entered by:
Setup step
Check item
Result
Model name
Serial No.
Confirmation of machine body and
1
component nameplates
yes
no
Is it operating normally?
(Displays counting in ascending-order succeeding to
rotation)
yes
no
Is "Data Clear and Set up" selected for the setting tool
mode?
yes
no
yes
no
yes
no
yes
no
yes
no
yes
no
yes
no
6 Saving of settings
yes
no
yes
no
8 Execution of Quick PM
yes
no
yes
no
10 Download
yes
no
yes
no
Hour, minute:
D30-24
[Confirmation of data]
Is [MFA0] error present in Fault History?
yes
no
yes
no
yes
no
yes
no
VHMS
D30003
[For storage]
ORBCOMM Station Opening Work
Check Sheet
Date of setting:
DB/branch
office name
Data entered by:
Setup step
Check item
Result
Model name
Serial No.
1
yes
no
Is it operating normally?
(Displays counting in ascending-order succeeding to
rotation)
yes
no
yes
no
On
Off
On
Off
On
Off
Presence/absence of communication
Number of cases (Default is 8 cases)
Entry of setting of S.Trend Analysis setting
Presence/absence of communication
Interval (Default is 20H)
D30003
day
yes
no
yes
no
yes
no
VHMS
D30-25
D30-26
VHMS
D30003
D30003
VHMS
D30-27
10. The setup result is displayed. Confirm the contents and press the [Close] button.
D30-28
VHMS
D30003
D30003
VHMS
D30-29
7. The above completes modification of the setting. Press the [OK] button to end the VHMS initial setting tool.
D30-30
VHMS
D30003
D30003
VHMS
D30-31
D30-32
VHMS
D30003
[] : Return to the highest numerical placeholder to enter the value again. If this button is
pressed again, the editing data process data is
stopped and the previous screen appears.
Input range
HD1500-7:
D30003
VHMS
D30-33
D30-34
VHMS
D30003
D30003
VHMS
D30-35
[] : Return to the largest position of the number to input the value again. If this button is
pressed again, editing of the weight is stopped
and the previous screen appears.
Input range
HD1500-7:
A1 (A1 0.25) (metric ton)
However,
A1 = {105.3 [t] (Empty weight)
+ 144.1 [t] (Load capacity)}
HD1500-7:
A2 (A2 0.25) (metric ton)
However,
A2 = {105.3 [t] (Empty weight)
D30-36
VHMS
D30003
D30003
VHMS
D30-37
D30-38
VHMS
D30003
Enter the indication range of the outside indicator lamps by pressing the following buttons.
(Default: 15%)
This function does not ensure the operation
because of the contrary phenomena shown
below.
If the load weight value is not entered correctly,
the start of loading data will be inaccurate.
If the value is increased and a loader having a
small-capacity bucket is used, the forecast
function of the outside indicator lamps and the
MMS communication may not operate normally.
D30003
VHMS
D30-39
D30-40
VHMS
D30003
SECTION D31
VEHICLE HEALTH MONITORING SYSTEM (VHMS)
INDEX
D31003 10/11
VHMS
D31-1
NOTES
D31-2
VHMS
10/11 D31003
D31003 10/11
VHMS
D31-3
VHMS DOWNLOADING
Downloading from inside the cab:
1. Turn the key switch to the ON position.
2. Connect the PLM download cable to PLM connector (1). Connect the other end of the cable to
the RS232C port of the personal computer. If
necessary, use a USB adapter to connect.
Refer to Other Settings later in this chapter.
3. Download the data.
D31-4
VHMS
10/11 D31003
PAYLOAD METER
The payload meter interprets machine data to calculate payload. The system uses the following inputs:
suspension pressure sensors, inclinometer, body up
switch, transmission shift lever, and speed sensors.
The microcomputer built into the controller uses the
inputs to calculate the payload. The calculated payload is displayed on the character display on the
Electronic Display Panel (EDP). The external display
lamps also display the payload conditions.
Payload display
D31003 10/11
VHMS
D31-5
---
Stopped (*1)
OFF
Traveling
Standard display
OFF
When empty
During loading
When loaded
When dumping
Stopped
Payload display
Traveling
Standard display
OFF
Stopped
Payload display
Payload display
Traveling
Standard display
OFF
Stopped
Traveling
Standard display
OFF
(*1) Stopped = shift lever is in the N position and the travel speed signal is 0.
(*2) For details of the standard display on the machine monitor, refer to Section D15, Machine Monitor.
(*3) The machine starts off empty and is being loaded. It is necessary to wait for the load to go above approximately 15% of the
rated payload and for the change in the load to stabilize when the machine is stopped.
D31-6
VHMS
10/11 D31003
Green
68 & up
Yellow
122 & up
Red
143 & up
1st
Bucket
2nd
Bucket
3rd
Bucket
If the red lamp illuminates, the machine is overloaded. DO NOT haul a load with the red lamp on.
Use the predicted load display to prevent overloading. Refer to Predicted Load Display.
4th
Bucket
Explanation
The actual load
is 37 tons, so
none of the
lamps illuminate.
The predicted
load is 74 tons,
so none of the
lamps flash.
The predicted load display and actual payload display are shown at the same time.
Example:
Indicator Lights
D31003 10/11
VHMS
D31-7
CALIBRATING PLM
Perform calibrations when:
the machine is received
3. With the service meter/odometer value displayed on character display (3), press the ()
portion of mode select switch (1) to switch to the
operation information display.
D31-8
VHMS
10/11 D31003
Time of dump
Machine ID
Speed limit
Open ID
Payload
D31003 10/11
VHMS
D31-9
PLM DOWNLOADING
Download the recorded data to a laptop computer
that has the download software installed.
Downloading From Ground Level Box
Downloading From Inside Of The Cab
1. Connect the PLM download cable to PLM connector (1). Connect the other end of the cable to
the RS232C port of the personal computer. If
necessary, use a USB adapter to connect.
Refer to Other Settings later in this chapter.
2. Turn the key switch to the ON position.
3. Turn on the computer and use the software to
download the data.
D31-10
VHMS
10/11 D31003
D31003 10/11
VHMS
D31-11
The following two methods can be used for confirming the haul payload.
Other Settings
The method for processing and confirming the payload in method (2) is useful if the dumping point is at
an angle.
ADDITIONAL FUNCTIONS
Additional functions are available, but for normal use,
there is no need to make any changes. If it is necessary to change these settings, please consult your
Komatsu distributor.
Travel distance:
Travel distance is used to recognize completion of
loading. The payload meter determines that the cycle
is complete when the machine has traveled 160 m
(525 ft) continuously from the loading point. If the
dumping point is within 160 m (525 ft) from the loading point, the system will not recognize that a dump
has occurred. Therefore, the cycle data will be
incomplete. In instances where the loading point and
the dumping point are extremely close, use this function to change the setting needed to recognize the
completion of a cycle.
D31-12
VHMS
10/11 D31003
SECTION F
TRANSMISSION / TORQUE CONVERTER
INDEX
F01015
Index
F1-1
NOTES
F1-2
Index
F01015
SECTION F2
TORQUE CONVERTER AND TRANSMISSION
INDEX
F02021 10/11
F2-1
ECMV Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRANSMISSION FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TRANSMISSION SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRANSMISSION OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRANSMISSION OIL PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 32
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F2-2
10/11 F02021
The transmission oil supply is filtered through washable strainers located in the transmission sump.
Remove and clean the strainers every 1000 hours of
operation.
External, replaceable transmission filter elements are
located at the front of the fuel tank. Replace the two
transmission filter elements at 500 hour intervals. If
the maintenance monitor indicates high restriction
regardless of interval, the filters must be replaced.
A control valve filter is located on top of the left side
of the transmission, next to the Electronic Control
Modulation Valves (ECMV). Replace this filter during
transmission rebuild.
Transmission maintenance intervals are outlined in
section P, Lubrication and Service.
F02021 10/11
F2-3
TORQUE CONVERTER
The torque converter is a three element, singlestage, two phase torque converter with lock-up
clutch.
Specifications are listed for the transmission and
torque converter components on the following
pages. It is assumed the specified oil type and
viscosity is being used, the oil level is correct,
and oil is at the normal operating temperature.
F2-4
10/11 F02021
F02021 10/11
6. Stator
7. Coupling
8. Input Shaft
9. Turbine
10. Piston
F2-5
Actuating Pressure
Engine @ 2100 rpm
Oil Temperature @ 70 - 90 C (158 - 194 F)
. . . . . . . . . . . . . . . . . . .990 100 kPa (144 15 psi)
F2-6
10/11 F02021
FIGURE 2-7. MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
1. Spring (Small)
2. Spring (Large)
3. Valve Body
4. Main Relief Valve
5. Main Relief Valve Piston
6. Piston Spring
F02021 10/11
F2-7
Actuating Pressure
Engine @ 2100 rpm
Oil Temperature @ 70 - 90 C (158 - 194 F)
. . . . . . . . . . . . . . . . . . . .550 100 kPa (80 15 psi)
F2-8
4. Pressure Tap
5. Inlet From Torque
Converter
10/11 F02021
LOCK-UP CLUTCH
The lock-up clutch is located in the torque converter.
Refer to Figure 2-4. The clutch is used to create a
direct mechanical connection from the engine to the
transmission. This direct drive connection helps minimize energy loss that occurs while the engine is
hydraulically connected to the transmission via the
torque converter.
The operation of the lock-up clutch utilizes an ECMV
identical to those used to actuate the transmission
range clutches. At the correct rpm, the transmission
controller will provide the signal for lock-up clutch
engagement. Through the use of this valve and two
pressure sensors, the pressure in the apply piston
chamber is maintained at the same pressure as the
internal torque converter pressure instead of dropping to zero pressure. This keeps the lock-up clutch
cavity filled with oil while waiting for the next lock-up
application. This method of lock-up clutch application
greatly reduces the shift shock felt when the lock-up
clutch is applied.
The pressure sensors monitor the inlet and outlet
pressures in the torque converter to actuate the
ECMV to control the pressure in the lock-up clutch
cavity. In addition, the input and output shaft speeds
are also monitored.
2. Lock-up Clutch
Accumulator
F02021 10/11
F2-9
HYDRAULIC PUMP
Torque converter and transmission
Volume: . . . . . . . . 471 l/min (125 gpm) @ 2100 rpm
Pump Rotation . . . . . . . . . . . LH (Counterclockwise)
F2-10
7. Plug
8. Flange
9. Body
10. Dowel Pin
11. O-Ring
12. O-Ring
10/11 F02021
Low rpm:
Transmission oil viscosity high due to low
temperature, wrong oil or bad oil
Engine power is not within specs
High rpm:
3. Apply and hold the service brakes fully to prevent movement of the machine.
F02021 10/11
F2-11
TRANSMISSION
F2-12
10/11 F02021
F02021 10/11
F2-13
Operating Pressure
Engine @ 2100 rpm
Oil Temperature @ 70 - 90 C (158 - 194 F)
. . . . . . . . . . . . . . . . . . . 304 100 kPa (44 15 psi)
Cracking Pressure: . . . . . . . . . . . . . 343 kPa (50 psi)
F2-14
7. Spring Guide
8. Spring
9. Plate
10. Spool
11. Gasket
10/11 F02021
F02021 10/11
SPEED
RANGE
ECMV
R
RATIO
L
5.600
F1
F2
F3
5.434
4.063
F4
F5
F7
2.415
F6
3.048
1.811
1.333
1.000
F2-15
Torque Converter
*Torque Converter Relief Valve: 990 100 kPa (144 15 psi)
*Main Relief Valve: 4320 200 kPa (627 29 psi)
*Torque Converter Regulator Valve: 550 100 kPa (80 15 psi)
Oil Cooler
*Lubrication Relief Valve: 304 100 kPa (44 15 psi)
Filter Assemblies
Hydraulic Pump
Strainer
Transmission Oil Pan
Fill Switch
Proportional Solenoid: 1862 97 kPa (270 14 psi)
Lock-up Clutch
ECMV (Medium Clutch): 1863 97 kPa (270 14 psi)
Medium Clutch
F2-16
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
10/11 F02021
F02021 10/11
6. Proportional Solenoid
7. Pressure Control Valve Spool
8. Load Piston
9. Spring
A: To clutch
B: Drain
C: From Pump
a: Clutch Pressure
Measurement Port
F2-17
F2-18
10/11 F02021
ECMV Operation
The ECMV is controlled by the command current
from the transmission controller to the proportional
solenoid, and the output signal of the fill switch. The
relationship between the ECMV proportional solenoid command current and clutch input pressure and
the output signal of the fill switch is shown in the diagram in Figure 2-19.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
FIGURE 2-20.
FIGURE 2-21.
F02021 10/11
F2-19
Starting to fill - trigger command input to pressure control valve - B range, Figure 2-19
1. Refer to Figure 2-22: When there is no oil inside
the clutch and the trigger current is sent (maximum current is applied) to proportional solenoid
(6), the proportional solenoid moves the full
stroke. Pressure control valve spool (7) moves
to the left. As a result of this, pump port (A) and
pressure control valve output port (B) are
opened. Oil passes through orifice (a) and
starts to fill the clutch.
FIGURE 2-22.
FIGURE 2-23.
Filling completed - pressure control set to initial
pressure - C range, Figure 2-19
1. Refer to Figure 2-24: When pump port (D)
opens, a difference in pressure is created
between the upstream and downstream sides
of orifice (a). This continues to push flow sensor
valve spool (3) to the left. When this occurs, and
the current of proportional solenoid (6) is lowered momentarily to the initial pressure level,
almost the complete pump pressure acts on
load piston (8). As a result, pressure control
valve spool (7) is pushed to the right. A small
amount of oil flows from pressure control valve
outlet port (B) to drain port (E). Since most of
the oil from the pump flows to the clutch, flow
sensor valve spool (3) continues to be pushed
to the left.
F2-20
FIGURE 2-24.
10/11 F02021
FIGURE 2-26.
F02021 10/11
F2-21
ECMV REPAIR
Preparation
1. Thoroughly wash and flush debris and dirt from
the transmission control valve mounted on top
of the transmission.
2. Thoroughly wash and flush the area surrounding filter assembly (4, Figure 2-27) to prevent
the intrusion of dirt and debris.
3. Remove nuts (2) and cover (1). Flush the area
under the cover. Do not allow dirt and debris to
enter the ECMV, valve seats, etc.
Filter Replacement Procedure
1. Remove cover (8, Figure 2-27). Prior to removal
of filter assembly (4), loosen filter case (8) from
filter head (5). Rotating the case counterclockwise, using the hex nut at the case tip.
2. Remove the complete filter assembly.
7. Filter Case
8. Cover
9. ECMV Assembly
10. Bolt
11. Valve Plate
F2-22
4. O-Ring
5. O-Ring
10/11 F02021
ECMV Identification
Disassembly
Fill Switch
R, 1st, 2nd, L, M
hex head
with
3rd, H
with
Lock-up
without
ECMV Removal
1. Remove the paint along the boundary between
fill switch assembly (16, Figure 2-29) and valve
body (1) at each ECMV to be removed.
2. Disconnect the electrical connectors for fill
switch assembly (16) and solenoid valve (9).
3. Remove the switch and solenoid connectors
from bracket (18).
4. Remove bolts (8, Figure 2-30) from ECMV
assembly (9, Figure 2-27). Separate the ECMV
assembly from valve plate (12, Figure 2-27).
NOTE: Protect valve plate (11, Figure 2-27) and the
valve mating surfaces by applying masking tape, etc.
Prevent dirt from entering the transmission by
covering all openings. Place all removed parts in
storage. Do not scratch parts when handling.
F02021 10/11
F2-23
F2-24
10. Bolt
11. Flow Sensor Valve
12. Spring
13. Plug
14. Pressure Test Port
15. Spring
16. Fill Switch
17. Bolt
18. Cover Plate
10/11 F02021
Assembly
Inspect each part thoroughly and confirm that the
part is free from dirt, scratches, etc. Wash all parts
with solvent. Lubricate spools and plungers with a
small amount of transmission oil during assembly.
Spools and plungers must be reassembled into their
original valve body bores.
6. Set spring (15, Figure 2-29) in place. Install Oring (17) and position fill switch (16) and bracket
(18) on the valve body. Install two bolts (19) and
tighten to 27 - 34 Nm (20 - 25 lb ft).
8. Install cover plate (21) with bolts (23) and washers (20). Tighten the bolts to standard torque.
Assemble the components in a clean room or at a
workstation free from dirt, dust, and other contaminents.
1. Insert pressure control valve spool (4, Figure 230) into valve body (1). Ensure the valve movement is smooth by pushing the valve at both
ends.
2. Install solenoid valve (9) together with O-ring (8,
Figure 2-29). Install four bolts (10). Tighten the
bolts to 12 - 15 Nm (9 - 11 lb ft).
3. Place piston (5) inside spool (4). Ensure piston
movement is smooth.
4. Install shims (7) and spring (6) in the pressure
control valve. Install O-ring (22) in the valve
body.
9. Install connectors (2, Figure 2-30) and connectors (3) onto the bracket.
Installation
1. Ensure the ECMV mounting surfaces are free
from dirt/dust, scratches, etc.
2. Install O-rings at the three ports on the valve
seat.
3. Ensure the orifice is in place in pump port (4,
Figure 2-31). Not all ECMVs require an orifice.
Refer to Table 1 for orifice locations and sizes.
F02021 10/11
83673
3. Clutch Port
4. Pump Port
F2-25
Orifice Size
Letter Stamp
Lockup Clutch
No orifice
Medium Clutch
4.5 mm
High Clutch
6 mm
Low Clutch
No orifice
3rd Clutch
6 mm
2nd Clutch
5 mm
1st Clutch
5.5 mm
Reverse Clutch
No orifice
F2-26
10/11 F02021
TRANSMISSION FILTERS
The transmission filter elements must be replaced
every 500 hours of operation or sooner if the maintenance monitor indicates high restriction. This maintenance interval may be increased or reduced,
depending on operating conditions. The maintenance monitor will alert the operator of a filter restriction.
The two transmission filters are located on the outside of the right frame rail, ahead of the fuel tank. An
additional filter is located in the control valve assembly. Refer to ECMV Repair - Filter Replacement Procedure.
Installation
1. Install new element (5, Figure 2-32). Install bowl
(4) and tighten.
2. Replace plug (6), and O-ring (7).
F02021 10/11
6. Plug
7. O-Ring
8. Core Assembly
9. Bypass Valve
10. Anti-Backflow Valve
F2-27
Adjustment Procedure
1. Disconnect electrical connector (1, Figure 235), loosen locknut (4), and remove the two cap
screws that secure the sensor. Observe the
location of the gear teeth through the sensor
mounting hole. For proper adjustment, the tip of
a gear tooth must be aligned with the sensor
hole as shown in Figure 2-36. If necessary,
reposition the gear.
2. Inspect the sensor for iron particles or other foreign material and clean, if necessary.
3. Reinstall the sensor. Turn the sensor clockwise
by hand until the tip just contacts the gear tooth.
83676
83674
1. Connector
2. Flange
3. Sensor
4. Locknut
83677
2. Output Case
0.9 0.2 mm
(0.035 0.008 in.)
83675
F2-28
10/11 F02021
1. Engine Off:
The oil level must be visible in the upper part of
the sight gauge (STOP) between H and L. This
level guarantees there is sufficient oil to safely
operate the transmission when the engine is off,
or when the transmission oil is cold.
Check the oil level again, as described below,
when the transmission oil reaches operating
temperature.
2. Engine On:
The oil level must be visible in the lower part of
the sight gauge (turtle) between H and L.
Check the transmission oil level with:
the truck parked on a level surface,
the engine at low idle,
the transmission in NEUTRAL
the transmission oil at normal operating
temperature
Add clean oil as required through the transmission oil filler tube at the left rear of the transmission.
F02021 10/11
F2-29
Oil Temperature
Engine rpm
Pressure Range
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
Lubrication Oil
Pressure
Torque Converter
Inlet Oil Pressure
Torque Coverter
Outlet Oil Pressure
F2-30
10/11 F02021
DETAIL A
83672
F02021 10/11
F2-31
Preliminary Checks
Prior to detailed troubleshooting, check for obvious
problems such as:
F2-32
10/11 F02021
PROBLEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE
ACTION
Pump cavitating
Defective pump
Defective ECMV
Replace ECMV
Defective ECMV
Replace ECMV
Defective pump
Restricted strainers
Pump cavitating
Defective pump
Defective ECMV
Replace ECMV
Restricted strainer
Pump cavitating
Defective ECMV
Replace ECMV
F02021 10/11
F2-33
PROBLEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE
ACTION
Replace ECMV
Restricted strainer
Pump cavitating
Defective pump
Restricted strainer
Pump cavitating
Defective pump
Restricted strainer
Pump cavitating
F2-34
10/11 F02021
PROBLEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE
ACTION
TRUCK LACKS POWER OR SPEED WHEN TRAVELLING, ALL SPEED RANGES (Continued):
Torque converter inlet pressure
low (transmission set pressure
normal)
Defective pump
Restricted strainer
Pump cavitating
Pump defective
Pump cavitating
Pump defective
F02021 10/11
F2-35
TRANSMISSION REMOVAL
1. Thoroughly clean all components in the area of
the transmission, pumps and drivelines.
2. Park the truck on a hard, level surface. Chock
the wheels and apply the parking brake. Raise
the dump body and install the body retention
cable. Move the hoist lever to the FLOAT position to put the weight of the dump body on the
cable. Place the lever in HOLD.
F2-36
2. Hydraulic Hoses
10/11 F02021
TRANSMISSION INSTALLATION
NOTE: Check the vibration dampener for wear,
damage or deterioration before transmission
installation. Replace any rubber cushions or
dampeners in doubtful condition. Refer to Section C,
Engine for information on the driveline adapter and
dampener.
F02021 10/11
F2-37
3. 4 mm Chamfer
4. 2 mm Chamfer
F2-38
10/11 F02021
F02021 10/11
F2-39
NOTES
F2-40
10/11 F02021
SECTION F2
TORQUE CONVERTER AND TRANSMISSION (-40C)
INDEX
F02022 10/11
F2-1
F2-2
10/11 F02022
The transmission oil supply is filtered through washable strainers located in the transmission sump.
Remove and clean the strainers every 1000 hours of
operation.
External, replaceable transmission filter elements are
located at the front of the fuel tank. Replace the two
transmission filter elements at 500 hour intervals. If
the maintenance monitor indicates high restriction
regardless of interval, the filters must be replaced.
A control valve filter is located on top of the left side
of the transmission, next to the Electronic Control
Modulation Valves (ECMV). Replace this filter during
transmission rebuild.
Transmission maintenance intervals are outlined in
section P, Lubrication and Service.
F02022 10/11
F2-3
TORQUE CONVERTER
The torque converter is a three element, singlestage, two phase torque converter with lock-up
clutch.
Specifications are listed for the transmission and
torque converter components on the following
pages. It is assumed the specified oil type and
viscosity is being used, the oil level is correct,
and oil is at the normal operating temperature.
F2-4
10/11 F02022
F02022 10/11
6. Stator
7. Coupling
8. Input Shaft
9. Turbine
10. Piston
F2-5
Actuating Pressure
Engine @ 2100 rpm
Oil Temperature @ 70 - 90 C (158 - 194 F)
. . . . . . . . . . . . . . . . . . .990 100 kPa (144 15 psi)
F2-6
10/11 F02022
FIGURE 2-7. MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
1. Spring (Small)
2. Spring (Large)
3. Valve Body
4. Main Relief Valve
5. Main Relief Valve Piston
6. Piston Spring
F02022 10/11
F2-7
Actuating Pressure
Engine @ 2100 rpm
Oil Temperature @ 70 - 90 C (158 - 194 F)
. . . . . . . . . . . . . . . . . . . .550 100 kPa (80 15 psi)
F2-8
4. Pressure Tap
5. Inlet From Torque
Converter
10/11 F02022
1. Spring
2. Spool
3. Piston
LOCK-UP CLUTCH
The lock-up clutch is located in the torque converter.
Refer to Figure 2-4. The clutch is used to create a
direct mechanical connection from the engine to the
transmission. This direct drive connection helps minimize energy loss that occurs while the engine is
hydraulically connected to the transmission via the
torque converter.
F02022 10/11
F2-9
F2-10
2. Lock-up Clutch
Accumulator
10/11 F02022
HYDRAULIC PUMP
Torque converter and transmission
Volume: . . . . . . . . .471 l/min (125 gpm) @ 2100 rpm
Pump Rotation. . . . . . . . . . . . LH (Counterclockwise)
F02022 10/11
7. Plug
8. Flange
9. Body
10. Dowel Pin
11. O-Ring
12. O-Ring
F2-11
Prior to performing a stall test, ensure that all systems such as exhaust piping, air intake piping, fuel
controls, and engine warning systems are all working
properly, and within specifications. Insufficient fuel or
restricted piping can also effect stall speed.
Low rpm:
Transmission oil viscosity high due to low
temperature, wrong oil or bad oil
Engine power is not within specs
High rpm:
Transmission oil viscosity is low due to high
temperature, wrong oil, bad oil, or lack of oil flow
Engine power is not within specs
Faulty torque converter assembly or components
F2-12
10/11 F02022
TRANSMISSION
F02022 10/11
F2-13
F2-14
10/11 F02022
Operating Pressure
Engine @ 2100 rpm
Oil Temperature @ 70 - 90 C (158 - 194 F)
. . . . . . . . . . . . . . . . . . . 304 100 kPa (44 15 psi)
Cracking Pressure:. . . . . . . . . . . . . 343 kPa (50 psi)
F02022 10/11
7. Spring Guide
8. Spring
9. Plate
10. Spool
11. Gasket
F2-15
F2-16
SPEED
RANGE
ECMV
R
RATIO
L
5.600
F1
F2
F3
5.434
4.063
F4
F5
F7
2.415
F6
3.048
1.811
1.333
1.000
10/11 F02022
Torque Converter
*Torque Converter Relief Valve: 990 100 kPa (144 15 psi)
*Main Relief Valve: 4320 200 kPa (627 29 psi)
*Torque Converter Regulator Valve: 550 100 kPa (80 15 psi)
Oil Cooler
*Lubrication Relief Valve: 304 100 kPa (44 15 psi)
Filter Assemblies
Hydraulic Pump
Strainer
Transmission Oil Pan
Fill Switch
Proportional Solenoid: 1862 97 kPa (270 14 psi)
Lock-up Clutch
ECMV (Medium Clutch): 1863 97 kPa (270 14 psi)
Medium Clutch
ECMV (High Clutch): 1961 97 kPa (284 14 psi)
F02022 10/11
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
High Clutch
ECMV (Low Clutch): 3434 145 kPa (498 21 psi)
Low Clutch
ECMV (2nd Clutch): 3434 145 kPa (498 21 psi)
2nd Clutch
ECMV (1st Clutch): 3434 145 kPa (498 21 psi)
1st Clutch
ECMV (Reverse Clutch): 3434 145 kPa (498 21 psi)
Reverse Clutch
ECMV (3rd Clutch): 1863 97 kPa (270 14 psi)
3rd Clutch
ECMV Oil Filter
Lock-up Clutch Accumulator
*Cold Relief Valve: 1270 50 kPa (185 7 psi)
*Filter Relief Valve: 5585 kPa (810 psi)
F2-17
F2-18
6. Proportional Solenoid
7. Pressure Control Valve Spool
8. Load Piston
9. Spring
A: To clutch
B: Drain
C: From Pump
a: Clutch Pressure
Measurement Port
10/11 F02022
F02022 10/11
F2-19
ECMV Operation
The ECMV is controlled by the command current
from the transmission controller to the proportional
solenoid, and the output signal of the fill switch. The
relationship between the ECMV proportional solenoid command current and clutch input pressure and
the output signal of the fill switch is shown in the diagram in Figure 2-21.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
FIGURE 2-22.
FIGURE 2-23.
F2-20
10/11 F02022
Starting to fill - trigger command input to pressure control valve - B range, Figure 2-21
1. Refer to Figure 2-24: When there is no oil inside
the clutch and the trigger current is sent (maximum current is applied) to proportional solenoid
(6), the proportional solenoid moves the full
stroke. Pressure control valve spool (7) moves
to the left. As a result of this, pump port (A) and
pressure control valve output port (B) are
opened. Oil passes through orifice (a) and
starts to fill the clutch.
FIGURE 2-24.
FIGURE 2-25.
Filling completed - pressure control set to initial
pressure - C range, Figure 2-21
1. Refer to Figure 2-26: When pump port (D)
opens, a difference in pressure is created
between the upstream and downstream sides
of orifice (a). This continues to push flow sensor
valve spool (3) to the left. When this occurs, and
the current of proportional solenoid (6) is lowered momentarily to the initial pressure level,
almost the complete pump pressure acts on
load piston (8). As a result, pressure control
valve spool (7) is pushed to the right. A small
amount of oil flows from pressure control valve
outlet port (B) to drain port (E). Since most of
the oil from the pump flows to the clutch, flow
sensor valve spool (3) continues to be pushed
to the left.
F02022 10/11
FIGURE 2-26.
F2-21
FIGURE 2-28.
F2-22
10/11 F02022
ECMV REPAIR
Preparation
1. Thoroughly wash and flush debris and dirt from
the transmission control valve mounted on top
of the transmission.
2. Thoroughly wash and flush the area surrounding filter assembly (4, Figure 2-29) to prevent
the intrusion of dirt and debris.
3. Remove nuts (2) and cover (1). Flush the area
under the cover. Do not allow dirt and debris to
enter the ECMV, valve seats, etc.
Filter Replacement Procedure
1. Remove cover (8, Figure 2-29). Prior to removal
of filter assembly (4), loosen filter case (8) from
filter head (5). Rotating the case counterclockwise, using the hex nut at the case tip.
2. Remove the complete filter assembly.
7. Filter Case
8. Cover
9. ECMV Assembly
10. Bolt
11. Valve Plate
F02022 10/11
4. O-Ring
5. O-Ring
F2-23
ECMV Identification
Disassembly
Fill Switch
R, 1st, 2nd, L, M
hex head
with
3rd, H
with
Lock-up
without
ECMV Removal
1. Remove the paint along the boundary between
fill switch assembly (16, Figure 2-31) and valve
body (1) at each ECMV to be removed.
2. Disconnect the electrical connectors for fill
switch assembly (16) and solenoid valve (9).
3. Remove the switch and solenoid connectors
from bracket (18).
4. Remove bolts (8, Figure 2-32) from ECMV
assembly (9, Figure 2-29). Separate the ECMV
assembly from valve plate (12, Figure 2-29).
NOTE: Protect valve plate (11, Figure 2-29) and the
valve mating surfaces by applying masking tape, etc.
Prevent dirt from entering the transmission by
covering all openings. Place all removed parts in
storage. Do not scratch parts when handling.
F2-24
10/11 F02022
F02022 10/11
10. Bolt
11. Flow Sensor Valve
12. Spring
13. Plug
14. Pressure Test Port
15. Spring
16. Fill Switch
17. Bolt
18. Cover Plate
F2-25
Assembly
Inspect each part thoroughly and confirm that the
part is free from dirt, scratches, etc. Wash all parts
with solvent. Lubricate spools and plungers with a
small amount of transmission oil during assembly.
Spools and plungers must be reassembled into their
original valve body bores.
6. Set spring (15, Figure 2-31) in place. Install Oring (17) and position fill switch (16) and bracket
(18) on the valve body. Install two bolts (19) and
tighten to 27 - 34 Nm (20 - 25 lb ft).
8. Install cover plate (21) with bolts (23) and washers (20). Tighten the bolts to standard torque.
Assemble the components in a clean room or at a
workstation free from dirt, dust, and other contaminants.
1. Insert pressure control valve spool (4, Figure 232) into valve body (1). Ensure the valve movement is smooth by pushing the valve at both
ends.
2. Install solenoid valve (9) together with O-ring (8,
Figure 2-31). Install four bolts (10). Tighten the
bolts to 12 - 15 Nm (9 - 11 lb ft).
3. Place piston (5) inside spool (4). Ensure piston
movement is smooth.
4. Install shims (7) and spring (6) in the pressure
control valve. Install O-ring (22) in the valve
body.
9. Install connectors (2, Figure 2-32) and connectors (3) onto the bracket.
Installation
1. Ensure the ECMV mounting surfaces are free
from dirt/dust, scratches, etc.
2. Install O-rings at the three ports on the valve
seat.
3. Ensure the orifice is in place in pump port (4,
Figure 2-33). Not all ECMVs require an orifice.
Refer to Table 1 for orifice locations and sizes.
F2-26
83673
3. Clutch Port
4. Pump Port
10/11 F02022
Orifice Size
Letter Stamp
Lockup Clutch
No orifice
Medium Clutch
4.5 mm
High Clutch
6 mm
Low Clutch
No orifice
3rd Clutch
6 mm
2nd Clutch
5 mm
1st Clutch
5.5 mm
Reverse Clutch
No orifice
F02022 10/11
F2-27
TRANSMISSION FILTERS
The transmission filter elements must be replaced
every 500 hours of operation or sooner if the maintenance monitor indicates high restriction. This maintenance interval may be increased or reduced,
depending on operating conditions. The maintenance monitor will alert the operator of a filter restriction.
The two transmission filters are located on the outside of the right frame rail, ahead of the fuel tank. An
additional filter is located in the control valve assembly. Refer to ECMV Repair Procedure - Filter Cleaning Procedure.
Installation
1. Install new element (5, Figure 2-34). Install bowl
(4) and tighten.
2. Replace plug (6), and O-ring (7).
1. Head Assembly
2. Indicator Switch
3. Seal
4. Bowl
5. Filter Element
6. Plug
7. O-Ring
8. Core Assembly
9. Bypass Valve
10. Anti-Backflow Valve
F2-28
10/11 F02022
Trucks that meet the -50C cold weather specification are equipped with an extra valve in the transmission filter circuit. The purpose of the valve is to
relieve high pressure oil when restriction in the filter
circuit exceeds 5585 kPa (810 psi). Refer to
Figure 2-35 for the location of the valve.
As the cold oil passes through the relief valve, the oil
warms. As the oil warms, there is less restriction in
the filter circuit and more oil flows through the filters
to the rest of the circuit.
Refer to the cold weather hydraulic schematic in Section R for a diagram of the filter circuit.
83676
2. Transmission
83677
2. Output Case
F02022 10/11
F2-29
Adjustment Procedure
1. Disconnect electrical connector (1, Figure 238), loosen locknut (4), and remove the two cap
screws that secure the sensor. Observe the
location of the gear teeth through the sensor
mounting hole. For proper adjustment, the tip of
a gear tooth must be aligned with the sensor
hole as shown in Figure 2-39. If necessary,
reposition the gear.
2. Inspect the sensor for iron particles or other foreign material and clean, if necessary.
3. Reinstall the sensor. Turn the sensor clockwise
by hand until the tip just contacts the gear tooth.
4. Then, turn counterclockwise 2/3 of a revolution
to obtain the proper clearance of 0.9 0.2 mm
(0.035 0.008 in.). Tighten the locknut.
5. Reinstall the wire connector.
1. Engine Off:
The oil level must be visible in the upper part of
the sight gauge (STOP) between H and L. This
level guarantees there is sufficient oil to safely
operate the transmission when the engine is off,
or when the transmission oil is cold.
Check the oil level again, as described below,
when the transmission oil reaches operating
temperature.
2. Engine On:
The oil level must be visible in the lower part of
the sight gauge (turtle) between H and L.
Check the transmission oil level with:
83674
0.9 0.2 mm
(0.035 0.008 in.)
3. Sensor
4. Locknut
83675
F2-30
10/11 F02022
Torque Converter
Inlet Oil Pressure
Torque Converter
Outlet Oil Pressure
Oil Temperature
Engine rpm
Pressure Range
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
650
1500
1900
2100
Transmission Oil:
70-90 C (158-194 F)
F02022 10/11
F2-31
DETAIL A
83672
F2-32
10/11 F02022
Preliminary Checks
Prior to detailed troubleshooting, check for obvious
problems such as:
F02022 10/11
F2-33
PROBLEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE
ACTION
Pump cavitating
Defective pump
Defective ECMV
Replace ECMV
Defective ECMV
Replace ECMV
Defective pump
Restricted strainers
Pump cavitating
Defective pump
Defective ECMV
Replace ECMV
Restricted strainer
Pump cavitating
Defective ECMV
Replace ECMV
F2-34
10/11 F02022
PROBLEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE
ACTION
Replace ECMV
Restricted strainer
Pump cavitating
Defective pump
Restricted strainer
Pump cavitating
Defective pump
Restricted strainer
Pump cavitating
F02022 10/11
F2-35
PROBLEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE
ACTION
TRUCK LACKS POWER OR SPEED WHEN TRAVELLING, ALL SPEED RANGES (Continued):
Torque converter inlet pressure
low (transmission set pressure
normal)
Defective pump
Restricted strainer
Pump cavitating
Pump defective
Pump cavitating
Pump defective
F2-36
10/11 F02022
TRANSMISSION REMOVAL
1. Thoroughly clean all components in the area of
the transmission, pumps and drivelines.
2. Park the truck on a hard, level surface. Chock
the wheels and apply the parking brake. Raise
the dump body and install the body retention
cable. Move the hoist lever to the FLOAT position to put the weight of the dump body on the
cable. Place the lever in HOLD.
F02022 10/11
2. Hydraulic Hoses
F2-37
TRANSMISSION INSTALLATION
NOTE: Check the vibration dampener for wear,
damage or deterioration before transmission
installation. Replace any rubber cushions or
dampeners in doubtful condition. Refer to Section C,
Engine for information on the driveline adapter and
dampener.
F2-38
10/11 F02022
3. 4 mm Chamfer
4. 2 mm Chamfer
F02022 10/11
F2-39
F2-40
10/11 F02022
SECTION F3
TRANSMISSION OIL COOLER & STRAINERS
INDEX
F03009
F3-1
NOTES
F3-2
F03009
Transmission oil cooler (1, Figure 3-1) and brake circuit oil cooler are contained in a combined unit. The
unit is located at the rear of the radiator.
Repair
Repairs to Section C, Cooling System for information
on oil cooler repair.
4. Washer
5. Cap Screw
F03009
F3-3
Removal
1. Drain the transmission oil. The capacity of the
transmission is approximately 153 liters (41
gal).
2. Remove cap screws (5, Figure 3-2) and cover
(3).
3. Remove magnetic strainer (1) and inspect.
1. Screen Element
2. Black Foreign Matter
(non-metallic)
3. Magnets
4. Iron Particles
Installation
F3-4
F03009
SECTION F5
DRIVE SHAFTS
INDEX
F05012
08/10
Drive Shafts
F5-1
NOTES
F5-2
Drive Shafts
08/10
F05012
DRIVE SHAFTS
The front drive shaft is located between the engine
and the transmission. The rear drive shaft is located
between the transmission and the rear axle. The two
drive shafts differ in length and design. The front
drive shaft is a fixed length. The rear drive shaft has
a slip-joint to permit oscillation of the rear axle.
Removal and installation procedures for each drive
shaft are similar.
Disassembly
1. Remove cap screws (4, Figure 5-1) securing
the U-joints at each end of the drive shaft.
2. Remove the U-joints. Inspect the assemblies for
seized and damaged bearings.
NOTE: Do not disassemble the U-joints. If the
bearings require replacement, replace the entire
assembly as a unit.
Removal
5. Clean all parts (except the U-joint) in clean solvent and blow dry with compressed air.
Assembly
F05012
08/10
4. Cap Screws
5. Transmission Input
Drive Shafts
F5-3
Installation
F5-4
Drive Shafts
08/10
F05012
2. Torque Converter
F05012
08/10
Drive Shafts
F5-5
2. Coupling
F5-6
Drive Shafts
08/10
F05012
Example Measurements: A = 3 mm B = 7 mm
C = 20 mm D = 6 mm
F05012
08/10
Drive Shafts
F5-7
2. Shims
F5-8
Drive Shafts
4. Transmission Output
5. Final Drive Input
08/10
F05012
Disassembly
Installation
2. Match mark the drive shaft halves for proper orientation during assembly. This is done to maintain the balance on the shaft.
3. Inspect all parts for wear and damage. If either
the tube or the yoke must be replaced, replace
with a new, balanced drive shaft.
4. Remove the grease fittings. Ensure all grease
passages are clear.
5. Clean all parts (except the U-joints) in clean solvent and blow dry with compressed air.
Assembly
1. Lubricate the splines of the drive shaft with
multi-purpose grease. Carefully slide both
shafts together using the alignment marks from
disassembly.
2. Install the U-joint at each end of the drive shaft.
Tighten cap screws (3, Figure 5-9) to 397 20
Nm (293 15 lb ft).
NOTE: Due to limited space, these cap screws must
be properly tightened before the drive shaft is
installed.
3. Install the grease fittings. Lubricate the bearings
with multi-purpose grease. Refer to Section P,
Lubrication and Service, for complete grease
specifications.
F05012
08/10
Drive Shafts
3. Male Slip-Joint
4. Differential Coupling
F5-9
NOTES
F5-10
Drive Shafts
08/10
F05012
SECTION F8
TORQUE CONVERTER REBUILD
INDEX
F08003 4/09
F8-1
NOTES
F8-2
4/09 F08003
REMOVAL
1. Remove the transmission and torque converter
from the truck. Refer to Transmission Removal
in Section F2 for instructions.
2. Thoroughly clean the transmission and torque
converter to remove any dirt accumulation.
3. Remove hydraulic pumps (2, 3, 4, & 5, Figure 81). Remove trunnion (6).
FIGURE 8-2. SENSOR WIRING
1. Torque Converter
2. Inlet Pressure Sensor
3. Outlet Pressure Sensor
4. ECMV Cover
5. Output Flange
F08003 4/09
4. Transmission Pump
5. Brake Cooling Pump
6. Trunnion
F8-3
F8-4
4/09 F08003
INSTALLATION
1. Vertically position the transmission with the
input shaft upward, as shown in Figure 8-6. The
weight of the transmission is approximately
2270 kg (5000 lb).
6. Bolt
7. Lift Eye
8. Lift Plate
F08003 4/09
F8-5
3. O-rings
4. O-rings
2. O-Rings
5. Raise torque converter (3, Figure 8-6) and position over transmission input shaft (2). Carefully
lower the assembly while aligning the splines in
the converter stator with the splines on the
transmission shaft.
F8-6
4/09 F08003
DISASSEMBLY
1. Place a container under the torque converter to
capture oil when the converter is drained.
Approximate capacity is 45 - 55 l (12 - 15 gal).
2. Remove two cap screws (2, Figure 8-9) and
drain oil from pump (1) and the stator.
2. Cap Screws
FIGURE 8-11. RETAINER REMOVAL
1. Snap Ring
2. Tapped Hole
F08003 4/09
3. Retainer
4. Input Shaft
F8-7
3. Cover
4. Round Nut
4. Lift Eye
5. Cap Screw and
Washer
F8-8
2. Front Housing
4/09 F08003
2. Cap Screws
2. Rear Housing
22. Remove snap ring (2, Figure 8-18).
2. Snap Ring
F08003 4/09
2. Clutch Housing
F8-9
2. Cap Screws
2. Clutch Plate
2. Housing
FIGURE 8-22. NUT REMOVAL TOOL
27. Remove three lockup clutch discs (1, Figure 821) and two plates (2).
F8-10
1. Bearing Retainer
Nuts
2. Special Tool
4/09 F08003
33. Install pusher bolts in tapped holes (1, Figure 825). Tighten the bolts and remove retainer (2).
Remove the bearing outer race from the
retainer.
2. Rear Housing
FIGURE 8-25. RETAINER REMOVAL
1. Tapped Hole
2. Retainer
F08003 4/09
1. Driver Tool
2. Free-Wheel
F8-11
3. Plate
1. Special Tool
2. Nut
2. Retainer Nut
37. Use special tool (1, Figure 8-29) (p/n 792-3351400) to remove bearing retainer nut (2).
2. Shaft
F8-12
4/09 F08003
2. Cap Screws
4. Snap Ring
5. Plate
6. Bearing
7. Gear
F08003 4/09
F8-13
1. Bearing
2. Holder
2. Front Housing
F8-14
4. Plate
5. Bearing
4/09 F08003
3. Snap Ring
3. Cover
2. Snap Ring
F08003 4/09
F8-15
Refer to Figure 8-41 for location of areas to be measured. The standard dimension of the item, and the
maximum permissible wear is listed in Table I.
Install new O-rings during assembly. Inspect all cap
screws for cracks or thread damage. Replace any
damaged parts.
F8-16
4. Input Shaft
5. Lockup Clutch Piston
6. One-Way Clutch Assembly
4/09 F08003
DESCRIPTION
Standard Size
mm
Inches
mm
Inches
Remedy
125
4.921
124.8
4.913
Repair or replace
input flange.
35.0
1.378
35.1
1.382
Repair or replace
input shaft.
153.17
6.030
153.2
6.031
134.17
5.282
134.14
5.281
185
7.283
185.5
7.303
Repair or replace
bearing retainer.
5.4
.213
4.8
0.189
Replace clutch
disk.
4.45
wide
0.175
wide
4.0
wide
0.157
wide
6.5
thick
0.256
thick
5.9
thick
0.232
thick
Replace one-way
clutch
No Crack
Replace Bolt
F08003 4/09
Backlash
0.193~0.504
0.193~0.504
0.204~0.538
0.204~0.538
F8-17
ASSEMBLY
1. Place shaft (1, Figure 8-42) in dry ice to cool.
After thoroughly chilled, place the shaft into
position on the housing. Align the cap screw
holes in the shaft with the holes in the housing.
2. Apply thread lock (p/n 09940-00030) to 13 cap
screws (2). Install the cap screws and washers.
Tighten to 110 12 Nm (81 9 lb ft).
3. Retainer
4. Bearing Outer Race
5. Pump
F8-18
5. Bearing
6. Pump
7. Seal Ring
8. Retainer
4/09 F08003
2. Bearing Retainer
Nut
3. Plate
16. Turn the race over with the tapped holes positioned at the top.
17. Position the free-wheel in the bore of the race
with the arrow pointing clockwise. Refer to
Figure 8-47.
F08003 4/09
2. Sprag
F8-19
18. Use a mallet and installation tool (1, Figure 848) to tap the free-wheel into the bore of the
race. Use caution when installing. Damage to
sprags or drag springs may result with too much
force.
2. Free-Wheel
F8-20
6. Nut
7. Lock Plate
8. Nut
9. Spacer
10. Race
4/09 F08003
2. Rear Housing
F08003 4/09
F8-21
27. Install nut (8). Use special tool (p/n 792-3351300) and tighten to 367 24 Nm (271 18 lb
ft).
Example:
Initial 3 measurements:
3 kg, 2.8 kg, 3.2 kg = 3 kg Average (Step 25)
Secondary 3 measurements:
F8-22
4/09 F08003
2. Turbine
4. Pin
5. Piston Seal Ring
F08003 4/09
2. Clutch Plate
F8-23
43. Press dowel pins (3, Figure 8-59) into the four
holes in bottom of input shaft (1).
44. Press bearing inner race (2) onto the shaft until
seated against the shoulder.
45. Align the dowel pins in the shaft with the holes
in piston housing (4). Tap the shaft until seated
on the housing.
2. Cap Screws
4. Piston Housing
5. Cap Screw
6. Washer
F8-24
4. Snap Ring
5. Snap Ring
4/09 F08003
2. Clutch SubAssembly
59. Insert gear (4) into the front housing bore. Press
the remaining inner race (8) onto the shaft.
Install plate (5) and snap ring (6).
60. Apply thread lock (p/n 09940-00030) and install
nut (7). Use tool p/n 790-102-1891 to tighten to
353 39 Nm (260 29 lb ft).
5. Plate
6. Snap Ring
7. Nut
8. Inner Race
F08003 4/09
F8-25
FIGURE 8-61. PTO UPPER PUMP DRIVE & IDLER GEAR ASSEMBLY
1. Snap Ring
2. Outer Race
3. Snap Ring
4. Outer Race
5. Inner Race
6. Inner Race
7. Cover
8. Cap Screw
9. Holder
10. Upper Idler Gear
11. O-ring
F8-26
3. Cap Screws
4/09 F08003
6. Nut
7. Snap Ring
8. Transmission Pump
Drive Gear
9. Lower Idler Gear
2. Rear Housing
F08003 4/09
2. Washer
F8-27
1. Cover
2. Bearing & Boss
2. Housing
3. Snap Ring
2. Snap Ring
74. Press fit bearing and boss (2, Figure 8-69) into
cover (1). Install snap ring (3).
F8-28
8. Snap Ring
9. Bearing
10. Snap Ring
11. Boss
12. Cover
13. Cap Screw
14. O-Ring
4/09 F08003
3. Cover
7. Holder
8. Cap Screw
9. O-ring
10. Collar
11. Front Housing
F08003 4/09
F8-29
SPECIAL TOOLS
Special tools are available from Komatsu that have
been designed to aid in torque converter rebuild.
Information is also provided to allow fabrication of lifting plates (see below) for lifting the torque converter
assembly off the transmission.
2. Cap Screw
F8-30
2. Shaft
4/09 F08003
F08003 4/09
F8-31
NOTES
F8-32
4/09 F08003
SECTION F8
TORQUE CONVERTER REBUILD (-40C)
INDEX
F08004 07/11
F8-1
NOTES
F8-2
07/11 F08004
3. Remove hydraulic pumps (2, 3, 4, & 5, Figure 81). Remove trunnion (6).
4. If the transmission is to be disassembled,
remove the cap screw on the output shaft and
remove drive shaft flange (5, Figure 8-2).
5. Remove cover (4) from the ECMV valve assembly.
6. Disconnect inlet pressure sensor (2) and outlet
pressure sensor (3).
REMOVAL
1. Remove the transmission and torque converter
from the truck. Refer to Transmission Removal
in section F2 for instructions.
2. Thoroughly clean the transmission and torque
converter to remove any dirt accumulation.
4. ECMV Cover
5. Output Flange
(2,
Figure 8-5).
F08004 07/11
4. Transmission Pump
5. Brake Cooling Pump
6. Trunnion
F8-3
2. Cap Screw
4. Regulator Valve
5. Lockup Clutch Accumulator
F8-4
4. Tube
5. O-Ring
07/11 F08004
F08004 07/11
F8-5
INSTALLATION
1. Vertically position the transmission with the
input shaft upward, as shown in Figure 8-9. The
weight of the transmission is approximately
2294 kg (5057 lbs).
6. Bolt
7. Lift Eye
8. Lift Plate
F8-6
07/11 F08004
3. O-rings
4. O-rings
2. O-Rings
10. Install main relief valve (3, Figure 8-3) over the
oil passages on the top surface of the torque
converter housing. Ensure the O-rings remain
in place.
5. Raise torque converter (3, Figure 8-9) and position over transmission input shaft (2). Carefully
lower the assembly while aligning the splines in
the converter stator with the splines on the
transmission shaft.
F08004 07/11
F8-7
12. Install valve seat (5, Figure 8-6) and O-ring (6)
onto the torque converter housing. Apply petroleum jelly to the O-rings. Install cap screws (4)
and tighten to 110 12 Nm (81 9 lb ft).
13. Install O-rings (3) between the valve seat and
the valve body. Apply petroleum jelly to the Orings. Place regulator valve (1) into position.
Install cap screws and washers (2). Tighten the
cap screws to 49 5 Nm (36 4 lb ft).
DISASSEMBLY
1. Place a container under the torque converter to
capture oil when the converter is drained.
Approximate capacity is 45 - 55 l (12 - 15 gal).
2. Remove two cap screws (2, Figure 8-12) and
drain oil from pump (1) and the stator.
2. Cap Screws
F8-8
07/11 F08004
3. Retainer
4. Input Shaft
1. Cover
2. Cap Screw
3. Lift Plate
4. Lift Eye
5. Cap Screw and
Washer
F08004 07/11
3. Cover
4. Round Nut
F8-9
2. Front Housing
2. Clutch Housing
2. Cap Screws
2. Rear Housing
F8-10
07/11 F08004
1. Piston
1. Turbine Shaft
2. Housing
2. Snap Ring
27. Remove three lockup clutch discs (1, Figure 824) and two plates (2).
25. Install lift eyes, lifting chains and a hoist to housing (1). Lift the housing from the case.
2. Cap Screws
2. Clutch Plate
F08004 07/11
F8-11
2. Special Tool
33. Install pusher bolts in tapped holes (1, Figure 828). Tighten the bolts and remove retainer (2).
Remove the bearing outer race from the
retainer.
2. Rear Housing
1. Tapped Hole
2. Retainer
F8-12
07/11 F08004
2. Retainer Nut
37. Use special tool (1, Figure 8-32) (p/n 792-3351400) to remove bearing retainer nut (2).
2. Free-Wheel
1. Special Tool
3. Plate
F08004 07/11
2. Nut
F8-13
2. Shaft
2. Cap Screws
F8-14
4. Snap Ring
5. Plate
6. Bearing
7. Gear
07/11 F08004
2. Front Housing
2. Holder
F08004 07/11
4. Plate
5. Bearing
F8-15
3. Snap Ring
3. Cover
2. Snap Ring
F8-16
07/11 F08004
Refer to Figure 8-44 for location of areas to be measured. The standard dimension of the item, and the
maximum permissible wear is listed in Table I.
Install new O-rings during assembly. Inspect all cap
screws for cracks or thread damage. Replace any
damaged parts.
F08004 07/11
4. Input Shaft
5. Lockup Clutch Piston
6. One-Way Clutch Assembly
F8-17
DESCRIPTION
Standard Size
mm
Inches
mm
Inches
Remedy
125
4.921
124.8
4.913
Repair or replace
input flange.
35.0
1.378
35.1
1.382
Repair or replace
input shaft.
153.17
6.030
153.2
6.031
134.17
5.282
134.14
5.281
185
7.283
185.5
7.303
Repair or replace
bearing retainer.
5.4
.213
4.8
0.189
Replace clutch
disk.
4.45
wide
0.175
wide
4.0
wide
0.157
wide
6.5
thick
0.256
thick
5.9
thick
0.232
thick
Replace one-way
clutch
No Crack
Replace Bolt
F8-18
Backlash
0.193~0.504
0.193~0.504
0.204~0.538
0.204~0.538
07/11 F08004
ASSEMBLY
1. Place shaft (1, Figure 8-45) in dry ice to cool.
After thoroughly chilled, place the shaft into
position on the housing. Align the cap screw
holes in the shaft with the holes in the housing.
3. Retainer
4. Bearing Outer Race
5. Pump
F08004 07/11
5. Bearing
6. Pump
7. Seal Ring
8. Retainer
F8-19
2. Bearing Retainer
Nut
3. Plate
16. Turn the race over with the tapped holes positioned at the top.
17. Position the free-wheel in the bore of the race
with the arrow pointing clockwise. Refer to
Figure 8-50.
F8-20
2. Sprag
07/11 F08004
18. Use a mallet and installation tool (1, Figure 851) to tap the free-wheel into the bore of the
race. Use caution when installing. Damage to
sprags or drag springs may result with too much
force.
2. Free-Wheel
F08004 07/11
6. Nut
7. Lock Plate
8. Nut
9. Spacer
10. Race
F8-21
2. Rear Housing
F8-22
07/11 F08004
27. Install nut (8). Use special tool (p/n 792-3351300) and tighten to 367 24 Nm (271 18 lb
ft).
Example:
Initial 3 measurements:
3 kg, 2.8 kg, 3.2 kg = 3 kg Average (Step 25)
Secondary 3 measurements:
F08004 07/11
F8-23
2. Turbine
4. Pin
5. Piston Seal Ring
2. Clutch Plate
2. Cap Screws
F8-24
07/11 F08004
4. Snap Ring
5. Snap Ring
4. Piston Housing
5. Cap Screw
6. Washer
43. Press dowel pins (3, Figure 8-62) into the four
holes in bottom of input shaft (1).
44. Press bearing inner race (2) onto the shaft until
seated against the shoulder.
45. Align the dowel pins in the shaft with the holes
in piston housing (4). Tap the shaft until seated
on the housing.
F08004 07/11
F8-25
2. Clutch SubAssembly
59. Insert gear (4) into the front housing bore. Press
the remaining inner race (8) onto the shaft.
Install plate (5) and snap ring (6).
60. Apply thread lock (p/n 09940-00030) and install
nut (7). Use tool p/n 790-102-1891 to tighten to
353 39 Nm (260 29 lb ft).
5. Plate
6. Snap Ring
7. Nut
8. Inner Race
F8-26
07/11 F08004
FIGURE 8-64. PTO UPPER PUMP DRIVE & IDLER GEAR ASSEMBLY
1. Snap Ring
2. Outer Race
3. Snap Ring
4. Outer Race
5. Inner Race
6. Inner Race
F08004 07/11
7. Cover
8. Cap Screw
9. Holder
10. Upper Idler Gear
11. O-ring
F8-27
3. Cap Screws
1. Front Housing
2. Outer Race
3. Inner Race
4. Plate
5. Inner Race
6. Nut
7. Snap Ring
8. Transmission Pump
Drive Gear
9. Lower Idler Gear
2. Rear Housing
F8-28
07/11 F08004
2. Washer
2. Snap Ring
75. Press fit bearing and boss (2, Figure 8-72) into
cover (1). Install snap ring (3).
2. Housing
1. Cover
2. Bearing & Boss
3. Snap Ring
F08004 07/11
F8-29
8. Snap Ring
9. Bearing
10. Snap Ring
11. Boss
12. Cover
13. Cap Screw
14. O-Ring
F8-30
3. Cover
07/11 F08004
2. Cap Screw
7. Holder
8. Cap Screw
9. O-ring
10. Collar
11. Front Housing
2. Shaft
F08004 07/11
F8-31
SPECIAL TOOLS
Special tools are available from Komatsu that have
been designed to aid in torque converter rebuild.
Information is also provided to allow fabrication of lifting plates (see below) for lifting the torque converter
assembly off the transmission.
F8-32
07/11 F08004
SECTION F9
TRANSMISSION REBUILD
INDEX
F09003 10/11
Transmission Rebuild
F9-1
F9-2
Transmission Rebuild
10/11 F09003
TRANSMISSION REBUILD
Refer to Section F2 for the proper procedures for
removing and installing the transmission/torque converter from the truck. Refer to Section F8 for the
proper procedures for removing and installing the
torque converter.
The transmission assembly weighs approximately 2294 kg (5057 lb). Use appropriate lifting
apparatus capable of lifting that weight.
TRANSMISSION DISASSEMBLY
2. Sleeves
F09003 10/11
5. Wire Harness
6. Intermediate Shaft
Speed Sensor
7. Input Shaft Speed
Sensor
Transmission Rebuild
F9-3
2. Cap Screws
3. Rear Case
F9-4
Transmission Rebuild
10/11 F09003
F09003 10/11
Transmission Rebuild
2. Rear Case
F9-5
4. Return Spring
5. Guide Pin
17. Press hub (1, Figure 9-10) from the clutch housing bearing bore.
18. Remove snap ring (3). Turn the housing over
and press bearing (2) from clutch housing (4).
Use a bearing removal tool to press on the
outer race of the bearing during removal.
F9-6
6. Snap Ring
7. Cover
8. Spacer
9. Cap Screw
10. Clutch Housing
Transmission Rebuild
10/11 F09003
4. Clutch Housing
5. Support Blocks
FIGURE 9-11. HOUSING REMOVAL
1. Number One Clutch
Housing
2. Snap Ring
3. Cap Screw
F09003 10/11
Transmission Rebuild
3. Bearing
4. Bushing
5. Pin
F9-7
F9-8
Transmission Rebuild
10/11 F09003
13. Spacer
14. Number Three Sun
Gear
15. Bearing Inner Race
16. Planetary Gear
17. Gear Shaft
18. Ball
19. Thrust Washer
20. Bearing
21. Spring
22. Number Three
Carrier
F09003 10/11
Transmission Rebuild
3. Guide Pin
4. Springs
5. Discs & Plates
F9-9
6. Cover
7. Bearing
8. Snap Ring
9. Seal Ring
F9-10
Transmission Rebuild
10/11 F09003
6. Planet Gear
7. Thrust Washer
8. Shaft
9. Ball
10. Bearing
F09003 10/11
Transmission Rebuild
F9-11
5. Cover
6. Bearing
7. Oil Seal
F9-12
Transmission Rebuild
10/11 F09003
4. Collar
5. Pin
F09003 10/11
4. Number Seven
Clutch Housing
Transmission Rebuild
F9-13
F9-14
Transmission Rebuild
10/11 F09003
NOTE: The column labelled No. in the following Tables refers to numbered components shown in Figure 9-29.
Standard - New
Description
Minimum - Used
Free
Length
Installed
Length
Installed
Load
Free
Length
Installed
Load
91.0 mm
(3.58 in.)
87.0 mm
(3.43 in.)
3.6 kg
(7.94 lb)
85.5 mm
(3.37 in.)
3.1 kg
(6.83 lb)
91 mm
(3.58 in.)
69 mm
(2.72 in.)
19.8 kg
(43.7 lb)
85.5 mm
(3.37 in.)
16.8 kg
(37.0 lb)
91.0 mm
(3.58 in.)
75 mm
(2.96 in.)
14.4 kg
(31.7 lb)
85.5 mm
(3.37 in.)
12.2 kg
(26.90 lb)
91 mm
(3.58 in.)
74.8 mm
(2.94 in.)
14.6 kg
(32.2 lb)
85.5 mm
(3.37 in.)
12.4 kg
(27.3 lb)
91 mm
(3.58 in.)
71 mm
(2.80 in.)
18.0 kg
(39.7 lb)
85.5 mm
(3.37 in.)
15.3 kg
(33.7 lb)
Remedy
Replace
NOTE: Discard all clutch spacer springs and replace with new parts during assembly.
F09003 10/11
Transmission Rebuild
F9-15
Description
Standard New
Tolerance
Minimum Used
No. 1 clutch
Total thickness: 8 discs + 7 plates
70.1 mm
(2.760 in.)
0.387 mm
(0.015 in.)
67.7 mm
(2.665 in.)
No. 2 clutch
Total thickness: 4 discs + 3 plates
37.2 mm
(1.465 in.)
0.346 mm
(0.014 in.)
34.8 mm
(1.370 in.)
No. 3 clutch
Total thickness: 4 discs + 3 plates
42.6 mm
(1.677 in.)
0.346 mm
(0.014 in.)
40.2 mm
(1.583 in.)
No. 4 clutch
Total thickness: 5 discs + 5 plates
55.0 mm
(2.165 in.)
0.316 mm
(0.012 in.)
52.0 mm
(2.047 in.)
10
No. 5 clutch
Total thickness: 5 discs + 5 plates
55.0 mm
(2.165 in.)
0.316 mm
(0.012 in.)
52.0 mm
(2.047 in.)
11
No. 6 clutch
Total thickness: 6 discs + 5 plates
60.2 mm
(2.370 in.)
0.33 mm
(0.113 in.)
56.6 mm
(2.228 in.)
12
No. 7 clutch
Total thickness: 4 discs + 3 plates
37.2 mm
(1.465 in.)
0.346 mm
(0.114 in.)
34.8 mm
(1.370 in.)
13
No. 1 clutch
Single disc thickness
5.0 mm
(0.197 in.)
0.1 mm
(0.004 in.)
4.4 mm
(0.173 in.)
14
No. 2, 3 clutch
Single disc thickness:
5.4 mm
(0.213 in.)
0.15 mm
(0.006 in.)
4.8 mm
(0.189 in.)
15
5.2 mm
(0.205 in.)
0.1 mm
(0.004 in.)
4.6 mm
(0.181 in.)
16
No. 7 clutch
Single disc thickness:
5.4 mm
(0.213 in.)
0.15 mm
(0.006 in.)
4.8 mm
(0.189 in.)
17
No. 1 clutch
Single plate thickness:
4.3 mm
(0.169 in.)
0.1 mm
(0.004 in.)
4.1 mm
(0.161 in.)
18
No. 2 clutch
Single plate thickness:
5.2 mm
(0.205 in.)
0.1 mm
(0.004 in.)
5.0 mm
(0.197 in.)
19
No. 3 clutch
Single plate thickness:
7.0 mm
(0.276 in.)
0.1 mm
(0.004 in.)
6.8 mm
(0.268 in.)
20
5.8 mm
(0.228 in.)
0.1 mm
(0.004 in.)
5.6 mm
(0.220 in.)
21
No. 7 clutch
Single plate thickness:
5.2 mm
(0.205 in.)
0.1 mm
(0.004 in.)
5.0 mm
(0.197 in.)
F9-16
Transmission Rebuild
Remedy
Replace
10/11 F09003
22
23
24
25
26
27
28
29
Description
Standard New
Tolerance
Minimum Used
Transmission input
shaft seal ring
(34.5 mm dia. seal
ring)
Width
2.56 mm
(0.101 in.)
-0.01 to -0.03 mm
(-0.0004 to -0.0012 in.)
2.30 mm
(0.091 in.)
Thickness
1.70 mm
(0.067 in.)
0.1 mm
(0.004 in.)
1.55 mm
(0.061 in.)
Transmission input
shaft seal ring (89
mm dia. seal ring)
Width
3.00 mm
(0.118 in.)
-0.01 to -0.03 mm
(-0.0004 to -0.0012 in.)
2.70 mm
(0.106 in.)
Thickness
3.70 mm
(0.146 in.)
0.12 mm
(0.0047 in.)
3.55 mm
(0.140 in.)
Width
4.00 mm
(0.157 in.)
-0.01 to -0.03 mm
(-0.0004 to -0.0012 in.)
3.60 mm
(0.118 in.)
Thickness
4.50 mm
(0.177 in.)
0.12 mm
(0.0047 in.)
4.35 mm
(0.171 in.)
Width
4.00 mm
(0.157 in.)
-0.01 to -0.04 mm
(-0.0004 to -0.0016 in.)
3.60 mm
(0.118 in.)
Thickness
5.00 mm
(0.248 in.)
0.15 mm
(0.0059 in.)
4.85 mm
(0.191 in.)
Width
4.00 mm
(0.157 in.)
-0.01 to -0.04 mm
(-0.0004 to -0.0016 in.)
3.60 mm
(0.118 in.)
Thickness
4.00 mm
(0.157 in.)
0.15 mm
(0.0059 in.)
3.85 mm
(0.152 in.)
Width
4.50 mm
(0.177 in.)
-0.01 to -0.03 mm
(-0.0004 to -0.0012 in.
4.05 mm
(0.159 in.)
Thickness
5.20 mm
(0.157 in.)
0.12 mm
(0.0047 in.)
5.05 mm
(0.199 in.)
Width
3.00 mm
(0.118 in.)
-0.01 to -0.03 mm
(-0.0004 to -0.0012 in.)
2.70 mm
(0.106 in.)
Thickness
1.70 mm
(0.067 in.)
0.1 mm
(0.004 in.)
1.55 mm
(0.061 in.)
Width
4.50 mm
(0.177 in.)
-0.01 to -0.03 mm
(-0.0004 to -0.0012 in.)
4.05 mm
(0.159 in.)
Thickness
5.50 mm
(0.217 in.)
0.15 mm
(0.0059 in.)
5.35 mm
(0.211 in.)
F09003 10/11
Transmission Rebuild
Remedy
Replace
F9-17
Description
Remedy
Minimum
Maximum
30
0.15 mm
(0.006 in.)
0.40 mm
(0.016 in.)
31
0.17 mm
(0.007 in.)
0.44 mm
(0.017 in.)
32
0.14 mm
(0.006 in.)
0.37mm
(0.015 in.)
33
0.17 mm
(0.007 in.)
0.43 mm
(0.017 in.)
34
0.15 mm
(0.006 in.)
0.40 mm
(0.016 in.)
35
0.17 mm
(0.007 in.)
0.43 mm
(0.017 in.)
36
0.14 mm
(0.006 in.)
0.37 mm
(0.015 in.)
37
0.16 mm
(0.006 in.)
0.40 mm
(0.016 in.)
38
0.14 mm
(0.006 in.)
0.37 mm
(0.015 in.)
39
0.11 mm
(0.004 in.)
0.38 mm
(0.015 in.)
40
0.16 mm
(0.006 in.)
0.40 mm
(0.016 in.)
41
0.3 mm
(0.012 in.)
F9-18
Transmission Rebuild
Replace
10/11 F09003
Description
Specification
Remedy
Standard - New
Tolerance
Minimum Used
41
3 mm
(0.118 in.)
0.1 mm
(0.004 in.)
2.5 mm
(0.098 in.)
42
2 mm
(0.079 in.)
0.1 mm
(0.002 in.)
1.5 mm
(0.059 in.)
Replace
thrust
washer
Standard - New
Maximum Used
0.25 to 0.90 mm
(0.010 to 0.035 in.)
1.5 mm
(0.059 in.)
Maximum Used
Coupling Capscrew:
46
F09003 10/11
Replace
thrust
washer or
replace
carrier
0.05 mm
(0.002 in.)
Minimum
Diameter
145 mm
(5.709 in.)
144.8 mm
(5.701 in.)
Replace
Replace
No Cracks Found
Cracks Found
Reuse
Replace
Transmission Rebuild
F9-19
F9-20
Transmission Rebuild
10/11 F09003
TRANSMISSION ASSEMBLY
GENERAL INSTRUCTIONS
Install new O-rings, seals, and gaskets when
components are assembled.
During assembly, coat seal rings and grooves
with petroleum jelly.
Apply clean power line oil to all rotating and
sliding components before assembly.
Freeze planetary gear shafts in dry ice before
installing in carriers.
Use standard fastener torque values during
assembly unless otherwise specified.
F09003 10/11
Transmission Rebuild
F9-21
11. Press bearing (4) into the output shaft until fully
seated against the shoulder of the bore.
F9-22
Transmission Rebuild
1. Piston
2. Output Shaft
3. Seal
10/11 F09003
17. Install a clutch disc (9) over the hub teeth until
seated in the carrier. Alternately install clutch
plates (8) and the remaining discs. Install wave
springs (7) around the discs. There are three
plates, four discs, and four springs.
F09003 10/11
Transmission Rebuild
F9-23
3. Bearing
4. Collar
5. Cover
6. Bearing
7. Oil Seal
F9-24
Transmission Rebuild
10/11 F09003
7. O-Ring
8. Rear Case
9. Seal Ring
10. Intermediate Shaft
11. Spacer
12. Bearing
2. Dry Ice
36. Install seal ring (9, Figure 9-37) onto the intermediate shaft. Coat the seal with petroleum jelly
to aid in assembly.
37. Place intermediate shaft (1, Figure 9-38) in a
container of dry ice (2) to freeze the bearing
mounting area. Refer to Figure 9-38. Freeze for
20 minutes or more before installing.
F09003 10/11
Transmission Rebuild
F9-25
6. Clutch Disc
7. Clutch Plate
8. Number Six Ring
Gear
9. Piston Seal
48. Install number five clutch housing (4, Figure 942) over the dowel pins and firmly seat against
the number six clutch housing. Verify the
sleeves are installed in all 22 tie bolt holes.
F9-26
4. ClutchDiscs,Plates,
& Springs
Transmission Rebuild
10/11 F09003
8. Spring
9. Number Four
Carrier
10. Cap Screw
11. Bearing Cage
Assembly
12. Snap Ring
13. Number Four Sun
Gear
49. Coat new piston seal rings (3 and 5, Figure 942) with petroleum jelly. Install seal (5) in the
clutch housing groove. Install seal (3) in number
five clutch piston (2). Position the seal with the
cup opening toward the clutch oil pressure cavity as shown in Figure 9-43.
50. Install the piston in the clutch housing.
F09003 10/11
Transmission Rebuild
5. Ball
6. Planetary Gear
7. Thrust Washer
8. Shaft
9. Ball
10. Bearing
F9-27
6. Cover
7. Bearing
8. Snap Ring
9. Seal Ring
F9-28
Transmission Rebuild
10/11 F09003
F09003 10/11
7. NumberFourClutch
Assembly
8. Housing
9. Number Four Ring
Gear
10. Washer
11. Tie Bolt
b. Install a clutch disc, then install a plate. Continue to alternately install a total of four discs
and three plates. Lubricate the discs with
TO-30 or TO-10 power line oil as they are
installed.
NOTE: The ear of the clutch plates for the number
three clutch are stamped with the letter L.
c. Install a separator spring over the guide pins
between the discs as they are installed.
d. Install piston return springs (8).
Transmission Rebuild
F9-29
71. Install plate (7) over the dowel pins in the number three clutch housing. Install 17 cap screws
and washers (12). Tighten to 385 42 Nm (284
31 lb ft).
Clutch Test
72. Use 586 kPa (85 psi) of pressurized air and oil
leak tester (p/n 799-301-1600). Pressurize each
clutch through the hydraulic oil port to 483 kPa
(70 psi) or more to check for normal operation.
3. Snap Ring
F9-30
8. Spring
9. Number Three Ring
Gear
10. Cap Screw
11. Bearing Cage
12. Cap Screw &
Washer
Transmission Rebuild
10/11 F09003
F09003 10/11
Transmission Rebuild
F9-31
89. Coat the piston seals (Figure 9-52) with petroleum jelly. Install the piston seals as shown in
Figure 9-52.
6. Planetary Pinion
Gear
7. Cover
8. Cap Screws
87. Using a tool as shown in Figure 9-51, align collar (2) with pin (1) and press onto carrier (5).
88. Coat seal rings (4) and the collar grooves with
petroleum jelly. Install the seal rings.
4. Seal Rings
5. Number One
Carrier
1. Separator Plate
2. Piston
3. Carrier Seal
4. Number One
Carrier
91. Align the guide hole in piston (2) with the lock
pin in carrier (4). Install the piston. Install separator plate (1).
F9-32
Transmission Rebuild
10/11 F09003
F09003 10/11
4. Bushing
5. Pin
5. Spacer
6. Number Three
Carrier
7. Hub
Transmission Rebuild
F9-33
3. Tool
4. Snap Ring
5. Bearing
F9-34
2. Bearing
3. Snap Ring
Transmission Rebuild
10/11 F09003
4. Hub
5. Piston
6. Piston Seal
7. Spring
6. Snap Ring
7. Spacer
8. Cover
9. Cap Screw
10. Bearing Inner Race
11. Carrier Seal Ring
F09003 10/11
Transmission Rebuild
F9-35
2. Number Three
Clutch Housing
Plate
2. Rear Housing
Final Assembly
112. Install new O-rings in the hydraulic oil ports on
the face of the rear transmission case.
F9-36
113. Attach lifting apparatus and a hoist to the transmission case. Coat a new O-ring (4, Figure 962) with petroleum jelly. Install the O-ring in the
groove at the rear of the case. Carefully lower
the case over the power train.
114. Install 21 cap screws (2) and the washers that
secure the main case to the rear case. Install
the six nuts and washers. Tighten the cap
screws and nuts to standard torque.
Transmission Rebuild
10/11 F09003
3. Rear Case
4. O-ring
F09003 10/11
4. Cover
5. Clutch Housing
6. Cap Screw (14 mm)
Transmission Rebuild
F9-37
F9-38
3. Hub
4. Spacer
5. Bearing
Transmission Rebuild
10/11 F09003
External Components
125. Install oil pan (1, Figure 9-68) and a new gasket
onto the transmission case. Install the magnet
assemblies and new O-rings.
2. Cap Screws
F09003 10/11
Transmission Rebuild
2. Sleeves
F9-39
F9-40
5. Wire Harness
6. Intermediate Shaft
Speed Sensor
7. Input Shaft Speed
Sensor
Transmission Rebuild
10/11 F09003
SECTION G
DRIVE AXLE, SPINDLES AND WHEELS
INDEX
G01018
Index
G1-1
NOTES
G1-2
Index
G01018
SECTION G2
TIRES AND RIMS
INDEX
G02023 10/11
G2-1
NOTES
G2-2
10/11
G02023
G02023 10/11
G2-3
Removal
2. A-Arm
G2-4
4. Capscrew
5. Wheel Rim
6. Wheel Hub
10/11
G02023
Installation
1. Remove all dirt, debris and rust from mating
parts before installing the wheel.
2. Grasp the wheel with the tire handler and position the wheel on the wheel hub. Align the notch
in the wheel hub with the rim stopper.
3. Install wheel clamps (1, Figure 2-3) and nuts
(2). Moderately tighten the nuts in the sequence
specified in Figure 2-4. Rotate the wheel, then
check that the lateral runout of the rim is within
5 mm (0.20 in.). Adjust the wheel as necessary.
4. Continue tightening the nuts following the
proper sequence. Tighten to the following
torques:
Threads coated with LM-P anti friction
compound: 1715 197 Nm (1265 145 lb ft)
Dry threads: 2210 245 Nm (1630 181 lb ft)
5. Adjust the tire inflation to the tire manufacturer's
recommended pressure.
Removal
1. Stop the machine on level ground. Apply the
parking brake, and chock the front wheels.
2. Raise the final drive enough for the tires to clear
the ground surface for removal. Block the final
drive case, securely.
3. Remove air valve lock plate (2, Figure 2-5)
4. Remove clamp nuts (4) and clamps (3).
5. Remove wedge ring (7, Figure 2-7). A special
tool is available to aid in wedge ring removal.
Refer to Section M, Special Tools.
6. Move the tire handler into position on the outside wheel.
7. Remove spacer (2, Figure 2-6). Use the tire
handler or other lifting device to remove the
spacer. The weight of the spacer is approximately 93 kg (205 lb).
8. Remove nuts (12, Figure 2-7) and clamps (13).
3. Clamp
4. Nut
G02023 10/11
G2-5
10. Move the tires to a storage area and safely position the tire so it cannot fall.
G2-6
5. Lock Ring
6. Spacer
7. Wedge Ring
8. Valve Extension
9. Nut
10. Clamp
11. Hub
12. Nut
13. Clamp
14. Inflation Valve
Extension
10/11
G02023
Installation
1. Clean all tire mounting surfaces. Ensure all contact surfaces are free of damage and debris.
G02023 10/11
G2-7
TIRE MATCHING
The matching of tires on the drive axle and dual
wheel installations is very important. Tire matching is
necessary to achieve satisfactory life of the tires and
the final drive.
To check the match between the mounted dual
wheels, use a large square. If one tire is too small, it
becomes obvious as the square is laid across the
dual tires. The square can be made from two 25 x 50
mm (1 x 2 in.) wood strips. One piece must be long
enough to span the dual tires. The two wood strips
must be squared with a carpenter's square and rigidly fastened to maintain a true 90 angle.
Matching of tire diameters from one side of an axle to
the opposite side is important to prevent:
RIM
Tire Removal From Rim
3. Force bead seat band (3), side ring (1) and the
tire away from lock ring (5). Remove the lock
ring.
4. Remove O-ring (4) from the rim.
5. Remove the bead seat band and the side ring.
6. Loosen the tire bead from the back flange side
of the rim.
7. Remove the tire from rim (2).
G2-8
10/11
G02023
4. Position the tire over the rim and work the tire
on as far as possible without prying against the
beads. Any damage to the tire bead will destroy
the air seal and cause air leakage at these locations.
5. Install the outer side ring in position and install
bead seat band (3). Push in on the bead seat
band to expose the O-ring groove in the rim.
6. Lubricate the new O-ring with soap solution and
install into the groove.
7. Install lock ring (5) and tap into place with a lead
hammer. The lock ring lug must fit into the slot
on the rim.
G02023 10/11
G2-9
2. Wheel Stud
G2-10
2. Nut
10/11
G02023
G02023 10/11
G2-11
NOTES
G2-12
10/11
G02023
SECTION G3
FRONT WHEEL HUB AND SPINDLE
INDEX
G03024
03/09
G3-1
NOTES
G3-2
03/09 G03024
If any of the following conditions appear, an inspection or adjustment of the front wheel bearings is
required:
The amount of metal found on the magnetic plug
is high. The magnetic plug will attract metal from
the oil. A failure is indicated by an increased
amount of metal on the magnetic plug.
External oil leaks around the front hub and
spindle area.
G03024
03/09
G3-3
Removal
NOTE: The brake must be removed with the hub as a
single assembly and disassembled after removal.
1. Park the truck on a hard, level surface and
apply the parking brake. Chock the rear wheels.
2. Drain the hydraulic tank. Refer to Section L,
Hydraulic System.
13. Lift the wheel hub and brake from the spindle.
Disassembly
1. Remove the outer races for bearing (15,
Figure 3-1) and bearing (21).
2. Remove bearing spacer (47).
Inspection
1. Clean all metal parts in cleaning solvent.
2. Inspect all seals and bearings and replace as
required.
3. Check the seal ring mounting area on the wheel
hub and spindle for damage. Inspect the splined
areas for excessive wear.
4. Inspect the spindle bearing surfaces and the
radius under the spacer for distress or cracks.
Use a non-destructive method for crack detection such as dye penetrant or magnaflux.
G3-4
03/09 G03024
Assembly
1. Clean all metal parts in cleaning solvent and
lubricate all splines and bearing surfaces with
clean type C-4 hydraulic oil.
2. If removed, install bearing spacer (6).
3. Use a push tool and a press to install the outer
races for bearing (15, Figure 3-1) and bearing
(21).
4. Position the assembly with the brake assembly
flat on the floor.
5. Install a new O-ring (25). Lightly lubricate the
inner circumference of the O-ring with clean
hydraulic oil.
6. Lubricate the inner circumference of seal rings
(23) with clean engine oil (SAE 30-40).
7. Check the position of the floating seals. Measure dimension (C, Figure 3-2) in four places.
The distance must be 90 1 mm (3.54 0.039
in.). Adjust as necessary.
8. Check the alignment of the brake discs. Align
the discs as necessary to allow insertion of the
wheel hub.
9. Attach appropriate lifting apparatus to the wheel
hub and slowly lift the hub straight onto the
assembly. The weight of the wheel hub is
approximately 781 kg (1722 lb).
When lowering the wheel hub, align the dowel
pins in retainer (27) with the mating holes in the
wheel hub.
Slowly lower the hub in through the floating
seals. DO NOT disturb the seals during installion.
When the gear portion of the hub reaches the
brake discs, it may be necessary to slightly
rotate the hub to align the splines.
10. Inspect the assembly to ensure that the hub is
evenly seated. If the assembly is properly
mated, install the three bracket tools (EM5308)
to secure the wheel hub to the brake. Use the
tapped holes (5) in the wheel hub to mount the
tools. Attach the other side of the tool to the
brake.
G03024
03/09
G3-5
G3-6
03/09 G03024
2. Seal Retainer
Front Wheel Hub Bearing Adjustment
Installation
1. Install pin (2, Figure 3-1) and inner bearing (21)
onto the spindle.
NOTE: Lubricate the bearings with clean hydraulic oil
during assembly. Bearing adjustment will require
rotation of the hub prior to filling the hub with oil.
2. if not already installed, install the three bracket
tools (EM5308) to secure the wheel hub to the
brake. Use the tapped holes (5) in the wheel
hub to mount the tools. Attach the other side of
the tool to the brake.
G03024
03/09
2. Depth Micrometer
G3-7
FRONT SPINDLE
The spindles are part of the front suspension cylinder
housings. To remove or install a spindle, refer to
Section H, Suspensions.
When removing the retainer, use caution to prevent bearing (15, Figure 3-1) from being
removed.
NOTE: Select the combination of shims (12, 13, &
14, Figure 3-1) that gives the minimum number of
shims.
4. Apply thread tightener, Three Bond #1374, to
cap screws (9). Install the shim pack and
retainer (11). Tighten the capscrews evenly, in
an alternating pattern, to 929 98 Nm (685
72 lb ft).
5. Rotate the hub 20-30 times. Check the torque
on the cap screws. If necessary, tighten the cap
screws again to the specified torque. Repeat
this step until the proper torque is maintained.
6. install O-ring (17) into hub cover (10). Place the
hub cover into position and secure with cap
screws & washers (18).
7. Rotate plug (16) to the 12 o-clock position.
Remove the plug and fill the hub with clean
hydraulic oil. Install a new O-ring onto the plug
and install the plug.
8. Connect the brake apply lines and brake cooling lines to brake assembly.
9. Install the front tire and rim. Refer to Front Tire
and Rim Installation in this Section.
A-ARM
Removal
1. Refer to Section G, Front Tire and Rim
Removal and remove front tires.
2. Refer to Section H, Front Suspension Removal
and remove the front suspension.
3. Use a suitable lifting device and support the Aarm. Remove the retaining capscrew and pin (7,
Figure 3-4) and spacers (3).
4. Remove the A-arm from the frame.
Inspection
1. Inspect bushings (1, Figure 3-4). If damaged,
remove old bushings and install new parts.
NOTE: Bushings (1) are a tight fit in frame ears (2).
When installing new bushings, apply a small amount
of heat to the frame ears and freeze the bushings
before attempting to press the new bushings into the
bores.
2. Inspect pin (7) and bearing (6). Replace if parts
are damaged or wear is excessive.
3. Inspect snap ring/seal (4). Replace if damaged
or if new bearing is installed.
Installation
1. Install new O-Rings (5, Figure 3-4) in bearing
(6).
2. Position the A-arm onto the frame and install
spacers (3) and pins (7). Install the retaining
capscrews, and tighten to standard torque.
3. Refer to Section H, Front Suspension Installation and install the front suspension.
4. Refer to Section G, Front Tire and Rim Installation and install the front tires.
G3-8
03/09 G03024
Inspection
1. Inspect all bushings (4, 6, and 11, Figure 3-5)
for wear.
2. Inspect all seals (12) and O-Rings (5, and 15).
3. Replace any worn or damaged parts.
Installation
FIGURE 3-4. A-ARM PIN
1. Bushing
2. Frame
3. Spacer
4. Snap Ring\Seal
5. O-Ring
6. Bearing
7. Pin
G03024
03/09
G3-9
5. O-Ring
6. Bushing
7. Pivot Link
8. Spacer
TOE IN ADJUSTMENT
The correct toe-in specification for these model trucks is zero (0) with the truck at the empty vehicle weight. As the
truck is loaded, the geometry of the suspension and steering will result in minor toe-in angles.
Adjustment Procedure
1. Park the truck on a hard, level surface and
chock the rear wheels.
2. Ensure the front and rear suspensions are oiled
and charged according to shop manual specifications. Refer to Section H4, Oiling and Charging Procedures. The suspensions must be
properly charged and oiled to ensure accurate
toe adjustment.
G3-10
03/09 G03024
G03024
03/09
G3-11
G3-12
03/09 G03024
G03024
03/09
G3-13
NOTES
G3-14
03/09 G03024
SECTION G4
REAR AXLE ATTACHMENTS
INDEX
G04017
G4-1
NOTES
G4-2
G04017
If only one end of a link is to be disconnected, support the free end of the link so it cannot fall and
become a hazard to personnel.
If more than one link is to be removed, extra supports must be in place to prevent the frame and
axle from moving out of position. Use adequate
supports and lifting devices.
G04017
G4-3
Inspection
1. Clean all parts.
2. Inspect bushings (2, Figure 4-2) and pin (1) for
wear, galling and cracks.
3. Inspect bearing (6) for wear and excessive
movement.
4. Inspect dirt seal (4) for cracks or damage.
Replace if necessary.
5. Replace any damaged or worn components
found during inspection.
Installation
5. Link
6. Spherical Bearing
7. Retainer Plate
8. Cap Screw & Washer
1. Install one snap ring (4, Figure 4-2) into the link.
Press bearing (6) into the link until it contacts
the snap ring. Install the second snap ring on
the other side of the link.
NOTE: Orient the snap rings as shown in Figure 4-3.
G4-4
G04017
Removal
1. Park the truck on a level surface and chock the
wheels.
2. Remove the rear drive shaft. Refer to Section F,
Drive Shafts, for the proper procedure.
3. Support the frame on each side under the lower
hoist cylinder mounts. Raise the frame until the
weight is removed from the rear axle.
4. Attach an appropriate lifting device to panhard
rod (1, Figure 4-4). The weight of the rod is
approximately 95 kg (210 lb).
5. Remove two cap screws and washers (8, Figure 4-2). Remove retainer plate (7) and link pin
(1).
2. Snap Ring
4. Panhard Rod
(Diagonal Link)
G04017
G4-5
Installation
6. Remove two spacers.
7. If the rod is to be removed from the truck,
repeat the previous steps for the other end of
the rod. Lift the rod from the truck.
8. If the spherical bearings are to be replaced,
remove snap rings (4) and bearings (6). Refer
to Spherical Bearing Replacement.
1. Install one snap ring (4) into the bore of the rod.
Press bearing (6) into the link until it contacts
the snap ring. Install the second snap ring on
the other side of the link.
NOTE: Orient the snap rings as shown in Figure 4-3.
2. Repeat the previous step for the opposite end
of the link.
Inspection
1. Clean all parts.
2. Inspect bushings (2, Figure 4-2) and pin (1) for
wear, galling and cracks. Replace parts as necessary.
3. Inspect bearing (6) for wear and excessive
movement.
4. Inspect dirt seal (4) for cracks or damage.
Replace the seal if necessary.
5. Replace any damaged or worn components
found during inspection.
G4-6
G04017
SECTION G5
REAR AXLE AND FINAL DRIVE ASSEMBLY
INDEX
G05026 03/09
G5-1
NOTES
G5-2
03/09 G05026
DIFFERENTIAL OPERATION
Straight-away-travel
Power from the transmission to the input pinion
passes through the differential bevel gears to turn the
differential case. The differential pinions transfer this
rotation to the differential side gears where it turns
the drive shafts splined to the gears. During straightaway travel, the resistance on the tires is equal,
same resistance on both left and right drive shafts,
so the differential pinions do not turn. Instead, the
rotation of the case is transferred directly to the side
gears. In this case, bevel and side gears rotate at the
same speeds, so the case and the shaft turn as a
single unit.
Turning
During a turn, the resistance on the inside tire is
greater than on the outside one so the resistances on
the drive shaft are not balanced. Consequently, the
side gears then rotate at different speeds. The differential pinions; therefore, rotate as they transmit the
rotation of the case to the side gears. This rotation
forces the two side gears to rotate in opposite directions. The net effect is that the outside wheel turns at
a rate equal to the sum of the bevel gear speed and
the differential pinion speed, while the inside one
turns at a rate equal to the difference.
Specifications:
Reduction Ratio:
Differential: 2.647
Final Drive: 7.235
Total: 19.15
Tire size: 33.00 - 51, 50 PR
Rim size: 24.00 - 51
G05026 03/09
G5-3
Installation
G5-4
03/09 G05026
3. Install the axle links. Refer to Final Drive Attachment in this section for link installation procedures.
4. Raise the diagonal link to connect to the frame.
Refer to Final Drive Attachment in this Section,
for diagonal link installation.
5. Install the rear suspensions. Refer to Section H,
Rear Suspension - Installation.
6. Install the driveshaft with the slip joint end nearest the transmission. Tighten the companion
flange capscrews to 392 20 Nm (289 14 lb
ft).
7. Install all hydraulic lines to the parking brake
assembly and both rear brake assemblies.
8. Before releasing the truck for operation, the
brakes must be bled. Refer to Section J for the
proper brake bleeding procedures.
9. Install all electrical wiring and lube lines that
were previously removed with the final drive
assembly. Install the rock ejectors on both sides
of the body.
G05026 03/09
4. Pin
5. Drain Plug
6. Axle Housing Breather
G5-5
DIFFERENTIAL ASSEMBLY
The differential assembly is designed to transmit the
rotary power from the drive shaft to the left and right
wheels. It consists of a reduction unit and a differential unit which provides a difference in rotational
speed to the left and right wheels when turning.
Because of the design of the differential assembly,
the differential input pinion bearing is subject to both
thrust and radial forces. For this reason, a taper roller
bearing is used. In order to adjust the bearings and
gear backlash, shims are used at the pinion end, and
adjusting nuts are used at the bevel gear end.
Specifications:
6. Install a lifting shackle to the differential mounting surface, then fit a lever block to the pinion
end to adjust the height when removing.
Splash-Type Lubrication
Ratio: 2.647
Removal
1. Place a container(s) into position and prepare
to recover 300 l (79.0 gal) of oil from the differential gear case and 120 liters (31.7 gal) of oil
from each planetary final drive gear case.
Remove drain plug (5, Figure 5-2) and drain the
oil from the differential gear case.
G5-6
1. Lift Chain
2. Differential Assembly
03/09 G05026
Installation
Disassembly
3. Connecting Pin
4. Lever
G05026 03/09
G5-7
2. Carrier Assembly
G5-8
03/09 G05026
G05026 03/09
19. Cage
20. Cross Shaft
21. Differential Case
22. Retainer
23. Capscrew & Washer
24. Bearing
25. Dowel Pin
26. Ring
27. Bearing Carrier Cage
G5-9
4. Inner Bearing
5. Spacer
FIGURE 5-10. DIFFERENTIAL
1. Locks
2. Wrench (790-425-1660)
3. Adjustment Nut
G5-10
4. Holder
5. Inner Race
6. Pinion Gear
03/09 G05026
2. Bearing
FIGURE 5-14. THRUST WASHER
1. Thrust Washer
2. Case
2. Capscrews
G05026 03/09
2. Gear
G5-11
2. Cross Shaft
3. Collar
4. Shaft
9. Remove bearing outer races (1 & 2, Figure 519) from pinion gear.
NOTE: The bearing is an adjustment-free bearing.
Check the matching numbers of the bearing, collar,
and outer race, and keep together as a set in a safe
place.
G5-12
3. Pinion Gear
03/09 G05026
1. Thrust Washer
2. Bevel Gear
2. Outer Race
FIGURE 5-20.
1. Side Gear
2. Bevel Gear
G05026 03/09
3. Bevel Gear
4. Capscrews, Washers
G5-13
Assembly
Differential Bearing
1. Set the differential case in tool repair stand (2,
Figure 5-4).
2. Using a push tool, press fit bearing (1, Figure 523) in differential case (3). Install snap ring (2).
3. Differential Case
2. Install side bearing (1). Fit the bearing by heating to 100 C (212 F).
NOTE: Use heat lamps, an oil bath, or induction
heaters to heat the bearings. DO NOT use a torch or
heat greater than 176 C (350 F). After the bearing
cools, check that there is no clearance between the
end face of the case and the bearing.
3. Turn the case over. Align with dowel pins, and
install thrust washer (1, Figure 5-21).
a. Ensure the head of the dowel pin is 0.5
[+0.2/-0.0] mm (0.020 [+0.008/-0.00] in.)
lower than the surface of the washer.
G5-14
03/09 G05026
6. Assemble pinion gear assembly (1, Figure 516) to cross shaft (2), then raise and install in
the case.
NOTE: Align the notched portion of the pinion gear
shaft with the case dowel pin and install. Move the
pinion gear, and verify gear assembly rotates easily.
2. Case
G05026 03/09
2. Shaft
G5-15
2. Capscrews
1. Micrometer
(792-525-3000)
2. Adapter
G5-16
03/09 G05026
G05026 03/09
10. O-Ring
11. Capscrew & Washer
12. Holder
13. Bearing Race
14. Pinion Gear (15 T)
15. Bearing Carrier
16. Shim Assembly
17. Capscrew & Washer
18. Bearing Assembly
G5-17
FIGURE 5-31.
1. Outer Race
3. Carrier
2. Outer Race
FIGURE 5-32.
1. Holder
2. Bearing Inner Race
3. Pinion Gear
1. Spacer
G5-18
03/09 G05026
FIGURE 5-34.
FIGURE 5-36.
1. Bearing
2. Carrier
3. Pinion Gear
3. Oil Seal
FIGURE 5-35.
1. Cage Assembly
G05026 03/09
FIGURE 5-37.
1. Park Brake Support
2. O-Ring and Holder
3. Bolt
4. Coupling
G5-19
Method #2:
b. Measure the axial bearing end play for: 0.0 0.118 mm (0.0 - 0.0046 in.)
Measuring method:
1.) After 20 to 30 bearing revolutions, set a
dial gauge, as shown in Figure 5-39, to
align with point zero.
FIGURE 5-39.
FIGURE 5-40.
G5-20
03/09 G05026
2. Dial Indicator
2. Adjustment Nut
G05026 03/09
G5-21
4. Holder
5. Support
6. Capscrews
G5-22
3. Caliper
03/09 G05026
G05026 03/09
G5-23
NOTES
G5-24
03/09 G05026
SECTION G6
FINAL DRIVE PLANETARIES AND WHEEL HUBS
INDEX
G06012 7/10
G6-1
NOTES
G6-2
7/10 G06012
6. Cover
7. Ring Gear (106 Teeth)
8. Spacer
9. Retainer
10. Inner Hub
SPECIFICATIONS:
Splash-type Lubrication
Ratio: 7.235
Oil: 120 L (32 gal) - each side
G06012 7/10
G6-3
3. Drain Plug
2. Button
G6-4
4. Snap Ring
5. Sun Gear
7/10 G06012
7. Add oil to the final drive case. Fill to the specified level and check the oil level again. Refer to
Section P, Lubrication and Service, for the
proper oil.
Disassembly
1. Remove nine cap screws (6, Figure 6-6) and six
cap screws (7). Remove plate (3).
2. Use a press to remove shaft (4).
2. Rim
Installation
1. Attach appropriate lifting apparatus to carrier
assembly (1, Figure 6-5). The weight of the carrier assembly is approximately 630 kg (1,390
lb). Lift the carrier assembly into position on the
truck.
2. Attach a lifting device to the drive shaft. The
weight of the assembly is approximately 176 kg
(388 lb). Lift the shaft into position. Install an
eyebolt at the end of drive shaft (3). Insert a bar
through the eyebolt and use the bar to push the
drive shaft into the carrier.
5. Gear Assembly
6. Cap Screws
7. Cap Screws
8. Spacer
G06012 7/10
G6-5
Assembly
1. Install spacer (8, Figure 6-6) in the carrier.
2. Install snap ring (3, Figure 6-8).
3. Position spacer (2), and press fit outer race (1).
4. Set spacer (2, Figure 6-6) and bearing (1) into
position. Raise the planetary gear and assemble. Install bearing (1) from the top.
5. Push planetary gear assembly (5) into the carrier.
6. Temporarily install plate (3) with cap screw (7).
Install two guide cap screws to shaft (4), and
press fit.
FIGURE 6-7. BEARINGS
1. Bearings
2. Spacer
3. Remove gear assembly (5). Remove two bearings (1) and spacer (2). Refer to Figure 6-6 and
Figure 6-7.
4. Remove outer race (1, Figure 6-8) and spacer
(2).
NOTE: The bearing is an adjustment-free bearing.
Keep the bearing together as a set, in a safe place.
5. Remove snap ring (3).
6. Remove spacer (8, Figure 6-6) from the carrier.
G6-6
1. Carrier
2. Retainer Plate
3. Snap Ring
7/10 G06012
b. Remove mounting cap screws (2, Figure 611). Remove retainer (1) and the shims.
NOTE: Note the number and thickness of the shims.
Keep the shim pack together in a safe place.
2. Cap Screws
G06012 7/10
4. Inner Gear
5. Temporary Cap Screw
6. Wheel Hub
2. Hub
G6-7
3. Inner Hub
4. Ring Gear
4. Outer Gear
5. Wheel Hub
b. Remove wheel hub assembly (2, Figure 616) slowly until the outer bearing is
unseated. Remove outer bearing (1) and
bearing inner race pin. The weight of the
bearing is approximately 76 kg (168 lb).
NOTE: DO NOT allow the bearing to fall. The bearing
is easily dislodged.
G6-8
2. Housing
7/10 G06012
2. Hub Assembly
1. Bearing
2. Axle
3. Pin
Assembly
NOTE: Refer to Section J, Rear Wet Disc Brakes Floating Ring Seal Assembly/Installation for detailed
seal installation instructions.
1. Install floating seal assembly (13, Figure 6-1) to
the wheel hub seal carrier. Install a new O-ring
on the seal carrier.
2. Install inner bearing (1, Figure 6-18) and pin (3).
3. Assemble the wheel hub.
7. Remove inner bearing (1, Figure 6-18 and bearing inner race pin (3). The weight of the bearing
is approximately 75 kg (165 lb).
8. Remove floating seal carrier (13, Figure 6-1)
from the axle.
G06012 7/10
G6-9
3. Capscrew
4. Axle Housing
G6-10
7/10 G06012
SECTION H
SUSPENSIONS
INDEX
H01017
Index
H1-1
NOTES
H1-2
Index
H01017
SECTION H2
FRONT SUSPENSION
INDEX
H02022 08/08
Front Suspensions
H2-1
NOTES
H2-2
Front Suspensions
08/08 H02022
FRONT SUSPENSION
The suspensions are hydro-pneumatic components
containing oil and nitrogen gas. The oil and gas in the
four suspension cylinders carry the gross truck
weight less the axles and wheels.
The suspension system supports the weight of the
chassis and absorbs the shock from uneven road
surfaces to provide a comfortable ride for the operator. At the same time, it maintains the stability of the
machine by ensuring that all four wheels are always
in contact with the ground surface.
H02022 08/08
Front Suspensions
H2-3
H2-4
Front Suspensions
9. Tube
10. Valve Assembly
11. Leaf Springs
12. Orifice Plate
A. Gas Chamber
B. Oil Chamber
C. Oil Chamber
08/08 H02022
Removal
1. Park the truck on a hard level surface. Apply the
parking brake and turn the key switch to OFF.
Chock the rear wheels.
2. Place a jack of sufficient capacity below the
base of the suspension cylinder to be removed
(on the A-arm). Place another jack below the
front of the frame on the side being serviced.
Raise both jacks to allow for tire removal.
3. Remove the front tire on the side being serviced. Refer to Section G, Tires And Rims.
4. Pin
5. Grease Lines
H02022 08/08
4. Suspension
5. Pressure Sensor
Harness
Front Suspensions
H2-5
Installation
1. Clean all paint and debris from the mounting
surface of the suspension. Ensure the mounting
surfaces of the suspension and the A-arm are
smooth and free of any oil.
2. Attach a suitable lifting device to the suspension housing. The weight of the suspension is
approximately 1850 kg (4080 lb). Refer to
Figure 2-6.
3. Raise the suspension into position at the top
cylinder mount. Install cylinder pin (2, Figure 26). Install the pin retainer.
4. Raise the A-arm into position at the lower cylinder mount. Install capscrews (2, Figure 2-5) and
lock washers (3).
1. Suspension Cylinder
2. Cylinder Pin
3. Lockwashers
5. Move steering cylinder (1, Figure 2-4) and tie
rod (2) into position on the steering knuckle.
6. Install pin (3) and pin (4).
7. Install elbow fitting on pin (3) and pin (4). Connect grease lines (5) to the fittings.
8. Install the grease injector manifold on the suspension cylinder.
H2-6
Front Suspensions
08/08 H02022
Disassembly
The suspension cylinders require only normal care
when handling as a unit. However, after being disassembled these parts must be handled carefully to
prevent damage to the machined surfaces. Surfaces
are machined to extremely close tolerances and are
precisely fitted. All parts must be completely clean
during assembly.
If available, mount the suspension in a roll-over stand
to retain the assembly and allow repositioning during
disassembly. Use extreme care when handling
machined surfaces and critical components.
1. Remove the top suspension cover if installed.
2. Remove charging valve (8, Figure 2-7) and
pressure sensor/valve (9) from the top of the
cylinder.
3. Remove flange capscrews (7) and air bleed
valve (15).
4. Lift the cylinder rod assembly out of the housing
with plate (20), retainer (6), and flange (5)
installed. If necessary, install pusher bolts into
the flange to separate the flange from the cylinder housing.
After the rod assembly has been removed from
the housing, remove the plate, retainer, and
flange from the rod.
5. Remove wear ring (1) and stopper (3) from cylinder rod (2).
6. Remove dust seal (13) and bushing (12) from
the retainer.
7. Remove seal (11), bushing (10) and buffer seal
(14) from the flange.
8. Remove O-ring (16) and backup ring (17) from
the flange.
9. Remove tube (18) and valve body (19) from the
cylinder. Remove the O-rings from the tube and
the valve body.
If further disassembly of the damping valve is
necessary, refer to Damping Valve Repair later
in this chapter.
H02022 08/08
Front Suspensions
H2-7
H2-8
8. Charging Valve
9. Pressure Sensor/Valve
10. Bushing
11. Seal
12. Bushing
13. Dust Seal
14. Buffer Seal
Front Suspensions
08/08 H02022
2. Backup Ring
Assembly
All components must be clean before assembling.
Lightly lubricate all O-rings with petroleum jelly or
clean suspension oil.
1. If removed, install the spherical bushing in the
cylinder rod eye. Use a press and a step plate
to install the bushing. Install the two snap rings
that secure the bushing.
2. Install new O-rings and backup rings on tube
(21, Figure 2-7). Orient the O-rings as shown in
Figure 2-8.
3. Place valve body (19, Figure 2-7) into position
on cylinder housing (4). Apply LT-2 to the capscrews that secure the valve body. Tighten the
capscrews to 277 32 Nm (204 24 lb ft).
4. Install the O-rings onto tube (18). Place the tube
into position and install the mounting capscrews. Tighten the capscrews to 111 12 Nm
(82 9 lb ft).
H02022 08/08
Front Suspensions
H2-9
Pressure Tests
Allow all sealants to properly cure before pressure
testing the suspension.
Perform a nitrogen leak test and a hydraulic oil leak
test as follows:
1. Position the cylinder upright and secure.
2. Remove pressure sensor (1, Figure 2-10) and
install a fitting to attach a nitrogen supply.
Charging valve (2) must be installed and remain
closed during the tests.
3. Apply 490 kPa (71 psi) pressure for 2 minutes.
Spray a soapy water solution at all joints and at
the rod seal area to check for leakage. No leaks
are permitted.
4. Turn off the pressure supply. Loosen air bleed
valve (3) one revolution and discharge the nitrogen from the suspension.
5. Remove charging valve (2) and attach an oil fitting to pump pressurized oil into the suspension.
6. Pressure test the suspension by applying
10,308 kPa (1495 psi) of oil pressure for 10
minutes. No leakage is permitted. If leakage is
present, the source of the leak must be
repaired.
7. Turn off the hydraulic pump, relieve pressure,
and remove the test equipment.
8. Drain the oil.
Oil Adjustment
9. The suspension must be filled to the correct oiling dimension (A, Figure 2-10). Refer to Section
H, Oiling and Charging for oil specifications.
FIGURE 2-9. LIQUID GASKET SEAL AREA
1. Retainer
2. Flange
A - Sealant Area
B - No Sealer in this area
H2-10
Front Suspensions
08/08 H02022
H02022 08/08
Front Suspensions
H2-11
Assembly
1. Install pin (10, Figure 2-11) to orifice plate (9).
NOTE: In the following step, assemble each oblong
leaf spring (7) and circular leaf spring (8) with the
chamfered side facing orifice plate (2). Refer to
Figure 2-8.
2. Assemble circular leaf springs (8), oblong leaf
springs (7) with plates (9), (6), and (5). Secure
the assembly with capscrew (4), and tighten to
66 Nm (49 lb ft).
3. Install orifice plate assembly (3) to valve body
(2). Tighten the capscrews to 66 Nm (49 lb ft).
4. Position the O-ring and valve body (2) into position on the suspension. Coat the capscrew
threads with Three Bond TB1374. Install the
capscrew and tighten to 279 Nm (206 lb ft).
5. With new O-rings installed, place tube (1) into
position. Install the capscrews and tighten to
110 Nm (81 lb ft).
6. If damping valve repairs have been performed
while the suspension is still mounted on the
truck, fill the suspension assembly with oil and
recharge with nitrogen. Refer to Section H, Suspension Oiling and Charging.
H2-12
6. Plate
7. Oblong Leaf Spring
8. Circular Leaf Spring
9. Orifice Plate
10. Pin
Front Suspensions
08/08 H02022
SECTION H3
REAR SUSPENSION
INDEX
H03025 09/08
Rear Suspensions
H3-1
NOTES
H3-2
Rear Suspensions
09/08 H03025
REAR SUSPENSION
Suspensions are hydro-pneumatic cylinders containing oil and nitrogen gas. The oil and gas in the four
suspensions carry the gross weight of the truck
minus the wheels, spindles and rear axle. The rear
suspension cylinders consist of two basic components, a suspension housing attached to the truck
frame and a suspension rod attached to the axle
housing.
Each rear suspension cylinder contains a charging
valve (1, Figure 3-1). The charging valve is used to
charge the suspension with pressurized nitrogen.
The suspension must be properly maintained with oil
and nitrogen for optimum performance. Refer to Section H, Oiling and Charging Procedures, for proper
charging instructions.
The suspension is also equipped with a pressure
sensor. The sensor senses internal gas pressure and
sends that information to the VHMS controller. The
information is used to calculate payload data by the
payload meter.
The suspension cylinder requires only normal care
when handling as a unit. However, after being disassembled these parts must be handled very carefully
to prevent damage to the machined surfaces. Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
H03025 09/08
Rear Suspensions
2. Pressure Sensor
H3-3
Operation
The suspension cylinder functions both as a shock
absorber (retracting) and a spring (extending).
H3-4
Rear Suspensions
5. Oil Cavity
6. Oil Cavity
7. Piston Rod
09/08 H03025
Removal
1. Park the unloaded truck on hard, level surface.
Apply the parking brake and chock the wheels.
2. Raise and support the rear of the truck frame.
3. Wear a face mask or goggles, and discharge
the nitrogen pressure from the suspension.
Refer to Section H, Oiling and Charging Procedures, for the proper procedure for discharging
nitrogen.
4. Remove pressure sensor (5, Figure 3-3) and
remove the clamps securing the sensor harness to the suspension.
5. Remove the upper pin retainer and remove
upper pin (1).
6. Attach an appropriate lifting device to the suspension. The suspension weighs approximately
500 kg (1100 lb).
7. Remove the lower pin retainer and remove
lower pin (2). Lift the suspension from the truck.
8. Move the suspension to a clean work area.
Installation
1. Attach an appropriate lifting device to the suspension. The suspension weighs approximately
500 kg (1100 lb).
2. Lift the suspension into position on the truck.
Lubricate lower pin (2, Figure 3-3 with multi-purpose grease and install the pin. Install the pin
retainer and cap screws.
3. Lubricate upper pin (1) with multi-purpose
grease and install the pin. Install the pin retainer
and cap screws.
4. If not done already, fill the suspension with oil,
and charge with nitrogen gas. Refer to Section
H, Suspension Oiling and Charging Procedures, for more information.
5. Install the clamps that secure the sensor harness to the suspension.
H03025 09/08
1. Upper Pin
2. Lower Pin
3. Cover
4. Clamp
5. Pressure Sensor
6. Charging Valve
Disassembly
1. If available, mount the suspension assembly in
a roll-over stand. Position the assembly upright
as installed on the truck.
2. Remove clamp (4, Figure 3-3) and cover (3).
3. Remove charging valve (6) and the pressure
sensor schrader valve from the suspension.
Drain the oil from the cylinder.
4. Rotate the assembly to position the flange on
top. Remove cap screws (1, Figure 3-4) and the
washers.
Rear Suspensions
H3-5
FIGURE 3-4.
1. Cap Screw
2. Plate
FIGURE 3-6.
1. Rod
2. Cylinder Housing
FIGURE 3-7.
FIGURE 3-5.
1. Rod
1. Plate
2. Flange
H3-6
2. Wear Ring
3. Cylinder Housing
4. Retainer
Rear Suspensions
09/08 H03025
FIGURE 3-8.
FIGURE 3-9.
1. Seal
2. Bushing
3. Retainer
1. Packing
2. Flange
3. Bushing
4. O-Ring
5. Backup Ring
H03025 09/08
Rear Suspensions
H3-7
H3-8
7. Charging Valve
8. Cover
9. Cap Screw
10. Wear Ring
11. Cylinder Housing
12. Bushing
Rear Suspensions
19. Plate
20. Retainer
21. Flange
22. O-ring
23. Backup Ring
09/08 H03025
If scratches or scores are found in housing or on suspension tube, contact the nearest Komatsu distributor for additional information regarding repair
services or factory recommended repair procedures.
Suspensions must be assembled in a clean, dust
free area. Clean metal suspension parts with Trichlorethane 1,1,1, acetone, or lacquer thinner prior to
final assembly. Clean the seals, wipers, O-rings and
backup rings with solvent and a clean cloth. Wipe
each part prior to lubrication and installation.
Assembly
1. All components must be clean before assembling. Lightly lubricate all O-rings with petroleum
jelly or clean suspension oil.
2. Install wear ring (2, Figure 3-7) on rod (1).
A - Sealant Area
B - Seal Area
11. Secure the flange, retainer, and plate to the cylinder with cap screws (1, Figure 3-4) and the
washers. Tighten the cap screws to 382 45
Nm (282 33 lb ft).
12. Install a new seal onto charging valve (7,
Figure 3-10) and schrader valve (5). Install the
valves in the cylinder housing. Tighten the
valves to 44 5 Nm (33 4 lb ft).
NOTE: The charging valves must be installed in the
outboard ports (as viewed while the suspension is
mounted on the truck).
13. If removed, install cover (8).
14. Install the spherical bearings, if necessary.
Refer to Spherical Bearings - Installation.
15. Leak test the suspension. Refer to Leak Testing
later in this chapter for instructions.
H03025 09/08
Rear Suspensions
H3-9
LEAK TESTING
It is necessary to leak test the cylinder after rebuild
and assembly to verify proper operation of the cylinder. Use the pressure sensor port to charge the cylinder during the leak test.
Air Leak Test
1. Secure the cylinder in the retracted position for
the duration of the test.
2. Remove the valve from the pressure sensor
port and connect an air or nitrogen source. Verify the suspension cylinder charging valve is
closed before proceeding with the test.
3. Submerge the cylinder in a water tank if available. If a tank is not available, acquire a large
spray bottle of soapy water.
4. Pressurize the cylinder to 689 138 kPa (100
20 psi).
Inspection
1. Inspect the bearing bores for damage. Inspect
the retainer ring grooves. Repair or replace as
necessary.
2. Inspect the mounting pin, snap rings, and
spherical bearing. Replace if damaged.
Installation
1. Install one snap ring (1, Figure 3-12) into one of
the snap ring grooves.
2. Use a press and a pusher plate to install the
spherical bearing in the bore.
3. Install the remaining snap ring.
SPHERICAL BEARINGS
NOTE: If either the top or bottom spherical bearings
are to be replaced with the suspension mounted on
the truck, ensure the truck frame is securely
supported. Refer to Suspension Removal and
Installation for more information on suspension
removal. Securely support the suspension as the
bearing is being removed and installed.
1. Snap Ring
2. Spherical Bearing
Removal
1. Remove two snap rings (1, Figure 3-12) from
the mounting eye.
2. Use a press and a pusher plate to remove bearing (2).
H3-10
Rear Suspensions
09/08 H03025
SECTION H4
SUSPENSION OILING AND CHARGING
INDEX
H04020 03/11
H4-1
NOTES
H4-2
03/11 H04020
Equipment List
1. Service Kits:
H04020 03/11
H4-3
Part Number
AK4063
AK4064
19 l (5 gal) container
See Vendor
See Vendor
See Vendor
Shell Tellus 46
See Vendor
AK4065
AK4066
-48.5C & above
(-55F & above)
Description
19 l (5 gal) container
208 l (55 gal) container
See Vendor
Mobil EJ44/13AAC
See Vendor
See Vendor
NOTE: DO NOT mix arctic oils with higher temperature oils. Oils with varying temperature ranges are not
compatible in the same suspension.
DO NOT add friction modifier to suspension oils. Komatsu branded oils are the only oils that are to be used with
friction modifier. Komatsu oils contain the correct concentration of friction modifier and do not require further mixing.
Nitrogen gas must meet or exceed CGA specification G-10.1 for Type 1, Grade F Nitrogen Gas
H4-4
Property
Value
Nitrogen
99.9% Minimum
Water
32 ppm Maximum
Dew Point
Oxygen
0.1% Maximum
03/11 H04020
FRONT SUSPENSION
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and chock the
wheels.
2. Verify that the bottom of each cylinder cover is
within the range designated by the arrows
(Figure 4-1) signifying correct nitrogen charge.
3. If each suspension is within the area indicated
by the arrows, no service is necessary for the
front suspensions. See the note below for
guidelines. If a suspension is not within the area
indicated by the arrows, the front suspensions
must be serviced.
the
suspension
is
H04020 03/11
H4-5
1. Park the unloaded truck on a hard, level surface. Apply the parking brake, and block the
wheels.
2. Remove the outside suspension covers and
thoroughly clean the area around charging
valves (3, Figure 4-2).
3. Place a hydraulic jack (1, Figure 4-3) under the
main frame, and raise the jack until it contacts
the frame. The jack must be rated for a minimum of 50 tons.
4. While wearing a face mask or goggles, discharge the nitrogen pressure from the suspension by loosening pressure sensor valve
assembly (2, Figure 4-4) one revolution. DO
NOT exceed one revolution. Nitrogen pressure
cannot be released by loosening the pressure
sensor, itself. The schrader valve in the valve
assembly (2) will prevent nitrogen from being
released.
3. Charging Valve
H4-6
A: 97 3 mm
(3.8 0.12 in.)
03/11 H04020
3. Sensor
FIGURE 4-5. OIL CHARGING KIT (EC6027)
1. Hose
2. Connector
3. Adapter
4. Fitting
5. Charging Valve
6. Pressure Sensor
7. Air Bleed Valve
8. Air Bleed Hole
9. Oil Pump Lever
10. Oil Pump
Use caution when tightening the valves and fittings on the suspensions. DO NOT overtighten.
Overtightening can damage the fittings or the
suspension housing resulting in gas and oil
leaks. Tighten to the specified torque.
10. When no more air bubbles or foamy oil is discharged, tighten air bleed valve (7) to 44 5
Nm (33 3 lb ft).
11. Remove pressure sensor valve assembly (6),
then operate the oil pump until no air bubbles or
foamy oil is discharged from the plug hole.
12. After all air and/or foamy oil is discharged,
install and tighten the pressure sensor valve
assembly to 44 5 Nm (33 3 lb ft).
13. After filling with oil, remove the oil pump and fittings, then install charging valve (5) and tighten
the valve to 44 5 Nm (33 3 lb ft).
H04020 03/11
H4-7
H4-8
03/11 H04020
7. Turn handle (6) on valve adapter (5) fully counterclockwise to close the charging valve. Then,
remove the charging equipment, the hydraulic
jack, and install the suspension covers.
8. Use soapy water to check the charging valve,
the air bleed valve and the pressure sensor fittings for leaks. Repair as necessary.
9. Install the caps and O-rings onto charging
valves (3, Figure 4-2).
DIMENSION
CHARGING
HEIGHT
CHARGING
PRESSURE
FRONT "A"
287 10 mm (11.3
0.4 in.)
2903 kPa
(421 psi)
H04020 03/11
H4-9
REAR SUSPENSION
GENERAL INFORMATION
If the rear suspension is being filled with oil while
installed on the truck, the angle in which the rear suspension is positioned coupled with the location of the
charging valve port results in a significantly large volume of air being trapped inside the suspension. This
has the effect of lowering the oiling height since the
rear suspension can not be filled with the correct
amount of oil. To compensate for this, all rear suspensions being filled with oil while installed on the
truck must use the "Installed On Truck" oiling heights
listed in Table 3.
When the suspension is in a vertical position while off
the truck, the oiling height will be different. All rear
suspensions being filled with oil while off the truck
should use the "On Bench" oiling heights listed in
Table 4.
NOTE: Refer to Table 3 for the approximate block
height. The oiling height of the cylinder must always
be determined by using Dimensions A or C, only.
The final charging height in Table 3 is for suspensions at normal operating temperature and must not
be exceeded. After charging a cold suspension,
operate the truck for several hours and check/adjust
the charging height at normal operating temperature.
If the suspensions are not checked/adjusted at normal operating temperature, the suspension height
may be incorrect, possibly causing excessive driveline angles that could result in damage to powertrain
components.
H4-10
03/11 H04020
5. Charging Valve
6. Pressure Sensor
7. Oil Pump
H04020 03/11
1. Schrader Valve
2. Valve Assembly
3. Pressure Sensor
2. Cylinder
H4-11
2. Retainer
On Bench
Installed On Truck
On Bench
Dimension A
Dimension C
H4-12
95 mm (3.7 in.)
03/11 H04020
4. Disconnect the pressure sensor harness connectors and remove the clamps securing the
harnesses.
Use caution when tightening the valves and fittings on the suspensions. DO NOT overtighten.
Overtightening can damage the fittings or the
suspension housing resulting in gas and oil
leaks. Tighten to the specified torque.
H04020 03/11
H4-13
H4-14
03/11 H04020
H04020 03/11
H4-15
NOTES
H4-16
03/11 H04020
SECTION J
BRAKE SYSTEM
INDEX
J01040
Index
J1-1
NOTES
J1-2
Index
J01040
SECTION J2
BRAKE SYSTEM OPERATION
INDEX
J02040
Brake System
J2-1
NOTES
J2-2
Brake System
J02040
Brake lock
3. Steering Pump
4. PTO
Auxiliary brake
Parking Brake
The brake system consists of several major components: the foot-operated, brake treadle valve, hydraulically operated relay valves, a brake manifold and a
Retard and Control Monitor (RCM) with retard lever.
The brake treadle valve, RCM and retard lever are all
located in the cab. The remainder of the control system, including the relay valves, brake manifold and
accumulators is located in the weatherproof hydraulic
cabinet. The cabinet is located next to the cab on the
center deck, and is easily accessible for brake system diagnosis and service.
J02040
Brake System
J2-3
J2-4
Brake System
J02040
NOTE: Hoist pilot manifold (10) and hoist pilot valve (11) are part of the hoist circuit and are not
discussed in this section. Refer to Section L for information on these components.
J02040
Brake System
J2-5
J2-6
Brake System
J02040
Distribution Manifold
Distribution manifold (8) provides a central location
for high pressure oil to be distributed to the brakes.
The manifold also provides a convenient location for
installation of the various brake apply pressure
switches and test ports for testing apply pressure.
Refer to Figure 2-3 for identification of the switches
and diagnostic ports.
Each switch in the manifold is a normally open
switch. When pressure in the circuit rises to 517 48
kPa (75 7 psi), the contacts close creating a path
from the RCM to ground. The switches are used by
the RCM to illuminate the brake and retarder lights
and are also used to detect malfunctions in the brake
circuit.
J02040
Brake Manifold
Brake manifold (12) is the heart of the brake system.
The manifold is connected to supply oil provided by
the steering pump, and also provides a drain source
back to the hydraulic tank. The cartridges and solenoids that screw into the manifold provide a means of
directing oil flow for various braking demands and
scenarios. The brake accumulators are mounted
directly to the brake manifold, as well.
Brake System
J2-7
Front accumulator check valve (24, Figure 2-4) isolates the front brake accumulator circuit and retarder
circuits and prevents backflow to the steering pump.
J2-8
Low brake accumulator pressure switch (3) is a normally open switch. When accumulator pressure rises
above 12 755 359 kPa (1850 52 psi) the switch
contacts will close. If brake system pressure falls
below the preset value, the switch contacts will open
and the brake oil pressure indicator on the EDP
alerts the operator that a problem exists. Normal
operating pressure in the brake system is 18 961 kPa
(2750 psi).
Brake System
J02040
J02040
Brake System
J2-9
Brake lock pressure reducing valve (8) reduces pressure going to the brake lock circuit to 14 479 kPa
(2100 psi).
J2-10
Brake System
J02040
NOTES
J02040
Brake System
J2-11
J2-12
Brake System
J02040
J02040
5. Steering Pump
6. Rear Brake Relay Valve
7. Front Brake Relay Valve
8. Distribution Manifold
Brake System
J2-13
RETARDING CIRCUIT
The retarding circuit works in a manner similar to the
service brake actuation. However, the retarding signal is generated by the position of the potentiometer
in the retard lever. The further the retard lever is
rotated downward, the higher the voltage that will be
supplied to the RCM, resulting in higher braking
force.
When retard lever (1, Figure 2-6) is applied, it sends
a variable voltage to the RCM that is based on the
position of the lever. The RCM will de-energize PPC
supply cut valve (8) to allow the supply of pressurized oil to flow to the PPC valves. De-energizing the
supply cut solenoid allows the spring inside the valve
to shift the valve spool creating a path to supply pressurized oil from the front accumulator to each PPC
valve.
The RCM then determines the strength of the electrical signal that is to be sent to front PPC valve (9),
right rear PPC valve (15), and left rear PPC valve
(16). The strength of that electrical signal is based on
the position of the retarder lever.
The electrical signal sent to the front PPC valve
causes the valve's solenoid to shift the spool an
amount that is proportional to the signal sent. This
allows a certain pressure, as calculated by the RCM,
to exit Port B and enter front brake relay valve (7) at
port TC1.
Pressurized oil from the front brake accumulator
enters the front brake relay valve at port P. When the
oil signal is received from the front PPC valve, the
front relay valve spool shifts and creates a path for
apply oil to pass through the relay valve and exit at
port B. The pressure of the oil exiting the front relay
valve is proportional to the signal oil that was
received from the front PPC valve. After exiting the
front relay, the oil passes through distribution manifold (8) and then on to the front brake assemblies.
J2-14
Brake System
J02040
J02040
Brake System
J2-15
J2-16
Brake System
J02040
J02040
Brake System
J2-17
AUTO APPLY
The auto apply feature causes the brakes to apply
(either front or rear) when pressure in the system
falls below 11 376 kPa (1650 psi). When the pressure in either brake circuit falls below 11 376 kPa
(1650 psi), the spool inside auto apply valve (12,
Figure 2-8) shifts due to spring pressure. When the
spool shifts, a path is created connecting the brake
accumulator with the higher pressure to the auto
apply circuit. This pressure is supplied to brake treadle valve (1) at port PX.
J2-18
Brake System
J02040
J02040
5. Steering Pump
6. Rear Brake Relay Valve
7. Front Brake Relay Valve
8. Distribution Manifold
Brake System
J2-19
J2-20
Brake System
J02040
J02040
Brake System
J2-21
J2-22
Brake System
J02040
J02040
5. Steering Pump
6. Brake Lock Solenoid Valve
7. Rear Brake Relay Valve
8. Distribution Manifold
Brake System
J2-23
J2-24
Brake System
J02040
J02040
Brake System
J2-25
J2-26
1. Heat Exchanger
Brake System
2. Check Valve
J02040
2. Rear Axle
J02040
Brake System
2. Front BCV
J2-27
When the truck is braking or retarding, the RCM deenergizes BCV solenoid valve (3, Figure 2-15). The
spool in the solenoid valve is shifted into position by
the valve spring and blocks a passage to tank. This
allows a pilot signal from BCV inlet (E, Figure 2-16)
to be supplied to the spring side of main valve spool
(4). The pilot pressure and main valve spring (6)
push the main valve spool against valve body (2) and
block the flow of oil to tank at port (C). This forces all
of the brake cooling oil to be delivered to the front or
rear brakes.
A relief valve is incorporated into each BCV to limit
the maximum pressure of the brake cooling oil that is
supplied to the brakes. Relief valve (1) is mounted
between solenoid valve (3) and valve body (2). The
relief valve limits the pilot pressure that can be supplied to the inlet side of main valve spool (4) to 883
kPa (128 psi).
NOTE: One full turn of the adjusting screw will
change the pressure 234 kPa (34 psi).
When the pilot pressure exceeds the relief valve setting, the valve spool will shift and divert the excess
pressure to tank. Since the pressure being supplied
to BCV inlet (E) will exceed the relief valve setting,
the main valve spool will move slightly and start to
allow some of the pump supply oil to pass through
the valve to tank at port (C). The main valve spool
will seat when the pilot pressure drops below 789
kPa (114 psi).
When braking or retarding is not required, the RCM
will energize solenoid valve (3). The solenoid shifts
the valve spool blocking the pilot signal supplied from
BCV inlet (E). It also opens a passage to tank to
relieve the pilot pressure from the spring side of main
spool (4). Oil from the brake cooling pump enters
valve body (2) through passage (E), and pushes
against main valve spool (4). When the pressure at
the BCV inlet exceeds the pressure created by main
valve spool spring (6) 196 kPa (28 psi), main valve
spool (4) will move and allow the oil to return to tank.
Restriction plate (5) is incorporated on the inlet of the
BCV to limit the flow to tank
J2-28
Brake System
A: Pilot Port
B: Pilot Port
C: Main Return to Tank
D: Pilot Port
E: From Pump
F: To Tank
J02040
Specifications:
SAE 10W oil . . . . . . . . . . . . . . . . . . . @ 50C 10C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (122 F 50 F)
Solenoid Valve Off:
Cracking Pressure: . . . . . 883 48 kPa @ 1 - 2 l/min
. . . . . . . . . . . . . . . . . (128 7.1 psi @ 0.3 - 0.5 gpm)
..........................................
Seat Pressure (Min.) . . . . . . . . 786 kPa @ 1 - 2 l/min
. . . . . . . . . . . . . . . . . . . . . . (114 psi @ 0.3 - 0.5 gpm)
Oil Leakage (Max.) . . . . . . . 800 cc/min @ 586 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . 27 oz/min @ (85 psi)
J02040
A: Pilot Port
B: Pilot Port
C: Main Return to Tank
D: Pilot Port
E: From Pump
F: To Tank
Brake System
J2-29
J2-30
Brake System
J02040
SECTION J3
BRAKE CIRCUIT COMPONENT SERVICE
INDEX
J03039 02/09
J3-1
J3-2
02/09 J03039
Depressurize system accumulators before opening hydraulic circuits or installing test gauges.
For the steering circuit, turn the key switch to
OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the steering wheel to verify that pressure has been purged
from the circuit. If the wheels do not move, the
steering circuit is safe to service.
For the brake circuit, first, chock the wheels.
Then, open the shut-off valves on the brake manifold. Opening the valves allows accumulator
pressure to be released to the hydraulic tank.
J03039 02/09
J3-3
BRAKE VALVE
Removal
Rebuild Criteria
If any one of the following conditions exist, the brake
valve should be removed and repaired:
Excessive cam rock in pedal actuator.
Any sign of external leakage.
Internal leakage at the tank port must be less
than 100 CD/minute with the valve in the
released position and system pressure supplied
to the "P1" and "P2" inlet ports.
Tank port leakage must be less than 250 cc/
minute with valve pilot or manual applied at
18 960 kPa (2750 psi) system pressure.
5. In the cab at the brake valve, remove capscrews and lockwashers securing the brake
valve assembly to the mount.
Varying output
depressed.
J3-4
pressure
with
pedal
fully
02/09 J03039
Installation
1. Place the brake valve assembly into position
and secure in place with capscrews and lockwashers. Tighten capscrews to standard
torque.
2. Remove plugs from brake valve assembly and
hydraulic lines. Install fittings and connect lines
to brake valve assembly and tighten. Connect
the proximity switch to the harness.
NOTE: Prior to checking the brake valve operation,
the steering system must have the proper nitrogen
precharge in the steering accumulators (refer to
Section L, Hydraulic System, for steering
accumulator precharge procedure). In addition, the
brake system lines must be bled of air and the brake
accumulators must also be precharged with nitrogen
(refer to brake accumulator precharge procedures,
this section).
3. With the engine shut down and key switch OFF,
open both brake accumulator bleed down
valves (3 & 4, Figure 3-1). Precharge both
accumulators (1 & 2) mounted on brake manifold to 9600 kPa (1400 psi).
NOTE: For best performance, charge the
accumulators in the temperature conditions the
vehicle is expected to operate in. During the
precharge, allow temperature of the nitrogen gas to
come into equilibrium with the ambient temperature.
4. Close both accumulator bleed down valves
after accumulators have been properly charged.
5. Bleed air from brake apply circuit. Refer to Wet
Disc Brake Bleeding Procedure, in this section
of the manual.
6. Check for fluid leaks at the brake valve.
J03039 02/09
8. Bolt
9. Lock Nut
10. Foot Pad
11. Pedal Actuator
12. Pivot Stop
13. Spring
14. Pivot Stop
J3-5
Disassembly
NOTE: During disassembly, precision machined
parts should be ink marked or tagged to ensure
proper reassembly and minimize adjustment time. All
internal parts must be placed back into the bores
from which they were removed.
5. Capscrew
6. Actuator Base
7. Threaded Insert
J3-6
02/09 J03039
J03039 02/09
J3-7
J3-8
9. Regulator Spring
10. Plunger Return Spring
11. Spring Seat
12. Regulator Spool
13. Back-up Ring
14. O-Ring
15. Back-up Ring
16. O-Ring
02/09 J03039
Assembly
J03039 02/09
J3-9
4. Back-Up Ring
5. Wiper Seal
6. Actuator Base
J3-10
02/09 J03039
Assembly of Valve
NOTE: Start with either side (circuit) of the valve and
build that side complete through Step 4 before
starting on the other side (circuit). Be careful to
assemble components into the circuit from which
they were removed.
1. If removed, install stud (4, Figure 3-4) in plunger
(3). Tighten nut (2).
2. Install new packing (5) on staging seat (6) and
insert in plunger bore.
3. Lightly lubricate the actuation plunger Glyde
ring (7).
3. Glyde Ring
4. Sharp Edges
J03039 02/09
J3-11
J3-12
3. Nut
4. Actuator Plunger
3. Attach the main supply input pressure to the Oring ports on the rear of the valve labeled "P1"
and "P2".
4. Attach the tank return line to the O-ring port
labeled "T" on the rear of the valve.
02/09 J03039
5. Needle Valve
6. Brake Valve
7. Front Brake Pressure Gauge
8. Shut Off Valves
NOTE: Shut off valves (8) are for tests not requiring simulated brake loads, such as circuit tracking.
NOTE: B1, B2 cylinders must be capable of a 10 cubic inch maximum displacement.
J03039 02/09
J3-13
J3-14
02/09 J03039
18. Continue turning the adjustment bolt until pressure begins to rise on one of the brake apply
pressure gauges.
19. Back-off the adjustment bolt 1/8 turn.
20. Tighten the jam nut (2) and remove the shim
stock inserted earlier in this procedure.
21. Fully stroke the brake pedal actuator to check
that output pressure at port "B1" and "B2" are
within specifications.
NOTE: If pedal is adjusted properly, the spring and
spring pivots will not interfere with pedal travel.
J03039 02/09
J3-15
J3-16
3. Proximity Switch
4. Jam Nuts
02/09 J03039
5. Assemble spring assembly (13) and install complete assembly to brake pedal actuator as
shown.
26. Lock switch in position with the two jam nuts (4).
27. Connect an ohmmeter to the switch harness to
check continuity.
28. Slowly apply the brake pedal and note the pressure on the gauge at which the ohmmeter indicates continuity in the switch.
29. Readjust the switch if necessary to trip when
the pressure reaches 517 kPa (75 psi).
J03039 02/09
J3-17
BRAKE ACCUMULATORS
There are two identical hydraulic brake accumulators
located on the brake manifold in the brake control
cabinet behind the operator's cab. The left accumulator supplies the pressure necessary for actuation of
the rear service brakes. The right accumulator supplies pressure to activate the front service brakes.
NOTE: If both accumulators are low on nitrogen,
charge both accumulators at the same time.
Depressurize system accumulators before opening hydraulic circuits or installing test gauges.
For the steering circuit, turn the key switch to
OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the steering wheel to verify that pressure has been purged
from the circuit. If the wheels do not move, the
steering circuit is safe to service.
For the brake circuit, first, chock the wheels.
Then, open the shut-off valves on the brake manifold. Opening the valves allows accumulator
pressure to be released to the hydraulic tank.
J3-18
8. Anti-Extrusion Ring
9. Bladder Assembly
10. Shell
11. Charging Valve
12. O-Ring
13. Lock Nut
14. Protective Cap
15. Port Protector
02/09 J03039
Removal
Installation
Disassembly
1. Clean the exterior of the accumulator before
starting disassembly.
2. Securely clamp the accumulator body in a vise,
preferably a chain vise. Ensure the accumulator
shell is protected by strips of padding or soft
metal on the vise jaws.
3. With pressure relieved from the accumulator,
remove the valve core from the charging valve.
Refer to Figure 3-12.
FIGURE 3-12.
J03039 02/09
J3-19
4. Remove bleed plug (2, Figure 3-11) from poppet assembly (1).
5. Remove locking ring (3) from the port assembly
using two wrenches. Refer to Figure 3-13.
J3-20
02/09 J03039
Assembly
1. Assemble the accumulator in a dust and lintfree area. Maintain complete cleanliness during
assembly to prevent possible contamination.
2. If removed earlier, clamp the accumulator in a
vise, preferably a chain vise. Ensure the accumulator shell is protected by strips of padding or
soft metal on the vise jaws.
3. Thoroughly lubricate the inside of the accumulator with clean C-4 hydraulic oil to cushion the
bladder. Spray the entire inside surface of the
accumulator with 1 liter (32 oz).
J03039 02/09
J3-21
J3-22
02/09 J03039
Leak Testing
To perform leak testing, a source of nitrogen pressure of 9653 kPa (1400 psi) and hydraulic pressure
of 24 132 kPa (3500 psi) will be required. A water
tank large enough to hold the accumulator and a
method of safely securing the accumulator in a holding fixture will be necessary.
1. Attach appropriate lifting apparatus to the accumulator. The weight of the accumulator is
approximately 58 kg (127 lb). Lift the accumulator into the holding fixture and secure. Attach
the lifting apparatus to the holding fixture and lift
it into the test tank.
J03039 02/09
J3-23
ACCUMULATOR CHARGING
Depressurize system accumulators before opening hydraulic circuits or installing test gauges.
For the steering circuit, turn the key switch to
OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the steering wheel to verify that pressure has been purged
from the circuit. If the wheels do not move, the
steering circuit is safe to service.
1. With the key switch OFF, allow at least 90 seconds for the steering accumulators to depressurize. Turn the steering wheel to ensure no oil
pressure remains in the accumulator. Open the
shut-off valves on the brake manifold.
J3-24
02/09 J03039
8. Turn the T handle clockwise to open the accumulator gas valve. Do not turn the T handle all
the way down, as it will damage the valve core.
9. Set the regulator for 172 kPa (25 psi), then
slightly open the nitrogen bottle and slowly fill
the accumulator. The proper fill rate for these
accumulators is 2 minutes.
4. Pressure Gauge
5. Manifold
6. Charging Valve
Adaptor
If the accumulators are being charged for storage, only charge to 690 - 827 kPa (100 - 120 psi).
Refer to Accumulator Storage later in this chapter for more information.
J03039 02/09
J3-25
brake
accumulator
bleed-down
Charging Pressure
70 kPa (10 psi)
-17C (0F)
-12C (10F)
-7C (20F)
-1C (30F)
4C (40F)
10C (50F)
16C (60F)
21C (70F)
27C (80F)
32C (90F)
38C (100F)
43C (110F)
49C (120F)
J3-26
02/09 J03039
ACCUMULATOR STORAGE
Installation
The shelf life of bladders, under normal storage conditions, is one year. Normal storage conditions consist of the bladder being heat sealed in a black plastic
bag and placed in a cool, dry place away from the
sun, ultraviolet, and fluorescent lights, as well as
electrical equipment. Direct sunlight or fluorescent
light can cause the bladder to weather check and dry
rot, which appear on the bladder surface as cracks.
Follow this procedure when installing an accumulator that was in storage. This procedure also
applies to newly purchased accumulators.
1. Install the pressure gauges on the accumulator
and check the pressure. Refer to Accumulator
Charging in this chapter.
J03039 02/09
J3-27
A: Pilot Port
B: Pilot Port
C: Main Return to Tank
D: Pilot Port
E: From Pump
F: To Tank
FIGURE 3-25. BRAKE COOLING VALVE (BCV)
1. Pilot Relief Valve
2. Valve Body
3. Solenoid Valve
4. Main Valve Spool
5. Restrictor Plate
J3-28
A: Pilot Port
B: Pilot Port
C: Main Return to Tank
D: Pilot Port
E: From Pump
F: To Tank
02/09 J03039
Removal
Adjustment of the retarder control lever or replacement of the potentiometer requires removal of the
assembly from the steering column.
1. Tilt the steering wheel downward, and telescope the wheel towards the operator seat.
Remove the top cover from the steering column.
a. Lever Disassembly
If the retarder control lever is to be completely disassembled, loosen and remove
locknut (10). Remove tang washer (11),
spring (12), and washer (13).
1. Remove capscrews (1, Figure 3-26) and lockwashers (2) from steering column (4).
Remove the lever and shaft assembly. If necessary, unscrew lever (17) from shaft (16)
and handle (18).
Installation
1. Connect the wiring harness to harness connector (6, Figure 3-26) on retarder control lever (5).
2. Place the retarder control lever into position on
steering column (4).
3. Install capscrews (1) and lockwashers (2).
Tighten the capscrews to 4 Nm (36 lb in.).
4. Place the cover on the top of the steering column and return the steering wheel to its original
position.
5. Recalibrate the RCM.
b. Lever Adjustments
Rotational Friction Adjustment: The lever
must be adjusted so that frictional force will
hold the lever firmly in the position selected
by the operator. At the same time, the adjustment should not be so tight as to cause the
operator to use undue force to move the
lever. Loosen or tighten locknut (10) to attain
the proper frictional force 226 - 339 mNm (2
- 3 lb in.) at the handle.
The position of the lever should remain stationary without moving from its own weight or
due to machine vibrations during truck operation.
When the desired adjustment is obtained,
bend the tang on washer (11) into the slots
on locknut (10).
Detent Adjustment: The detent that holds the
lever in the OFF position can be adjusted, as
well. Loosen or tighten set screw (14) to
adjust the detent. The breakout force of the
detent must be between 1921 - 2260 mNm
(17 - 20 lb in.).
J03039 02/09
J3-29
J3-30
7. Capscrew
8. Lockwasher
9. Potentiometer
10. Locknut
11. Tanged Washer
12. Disc Spring
02/09 J03039
Potentiometer Check
Assembly
signal voltage
input voltage
) x 100
J03039 02/09
J3-31
J3-32
02/09 J03039
SECTION J4
BRAKE CIRCUIT CHECKOUT
INDEX
J04039 03/10
J4-1
NOTES
J4-2
03/10 J04039
REQUIRED EQUIPMENT
The following equipment will be necessary to properly check the hydraulic brake circuit:
Hydraulic brake schematic. Refer to Section R.
Calibrated pressure gauges:
Four, 0 - 21 000 kPa (0 - 3000 psi) range.
Hoses long enough to reach from the brake
cabinet to the inside of the operator's cab for
each pressure gauge.
PREPARATION
The following items must be performed before proceeding with brake system checks.
Depressurize system accumulators before opening hydraulic circuits or installing test gauges.
For the steering circuit, turn the key switch to
OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the steering wheel to verify that pressure has been purged
from the circuit. If the wheels do not move, the
steering circuit is safe to service.
For the brake circuit, first, chock the wheels.
Then, open the shut-off valves on the brake manifold. Opening the valves allows accumulator
pressure to be released to the hydraulic tank.
J04039 03/10
J4-3
J4-4
2. Manifold
03/10 J04039
2. Brake Manifold
Parking Brake
NOTE: Move the pressure gauge from the LAP1 test
port to the parking brake or PK2 port on the brake
manifold.
J04039 03/10
J4-5
Brake Lock
12. * Apply the brake lock. Proper rear brake pressure is 14 479 690 kPa (2100 100 psi).
Front brake pressure must be zero. Record the
brake pressures.
13. Cycle the brake lock several times to ensure
crisp application and release of brake pressure.
J4-6
03/10 J04039
Validation
22. Start the engine to recharge the hydraulic system. Allow the engine to operate until the low
brake accumulator pressure stabilizes at or
above 18 616 kPa (2700 psi).
23. * Shut the engine off, but leave the key switch in
the ON position. Slowly depress the brake
pedal every 15 seconds until the low brake
accumulator pressure warning illuminates.
Record the number of brake applications before
the activation of the low brake accumulator
pressure warning. The warning should not illuminate before the sixth brake application.
Retarding
24. Install pressure gauges at:
a. Front brake test port (FB, Figure 4- 1)
b. Rear brake test ports (RBL, RBR, Figure 41)
c. Low accumulator pressure test port (LAP1,
Figure 4- 2)
25. Start the engine to recharge the hydraulic system. Allow the engine to operate until the low
brake accumulator pressure stabilizes at or
above 18 616 kPa (2700 psi).
26. * Move the retarder lever to full retard. Verify
that the front and rear brake pressures are at
14 479 869 kPa (2100 126 psi) within 1 second. Record the front and rear brake pressures.
With the lever still at full retard, the brake pressures should remain above their minimum values for a minimum of 20 seconds.
27. * Quickly return the retarder lever to OFF. The
front and rear brake pressures should return to
zero within 2 seconds. No residual pressure
trapped in the brakes is allowed. Record the
pressures.
J04039 03/10
J4-7
Step 4
_______________
Front brake pressure when auto apply releases: 11 376 690 kPa
(1650 100 psi)
_______________
Left rear brake pressure when auto apply releases: 11 376 690 kPa
(1650 100 psi)
_______________
Right rear brake pressure when auto apply releases: 11 376 690
kPa (1650 100 psi)
Step 7
_______________
Step 9
_______________
_______________
_______________
Left rear brake pressure with emergency brake applied: 0 kPa (0 psi)
_______________
Step 10
_______________
_______________
_______________
Step 11
J4-8
_______________
_______________
_______________
03/10 J04039
BRAKE LOCK
Step 12
_______________
_______________
Left rear brake pressure (brake lock applied): 14 479 690 kPa
(2100 100 psi)
_______________
Right rear brake pressure (brake lock applied): 14 479 690 kPa
(2100 100 psi)
Step 15
_______________
Step 16
_______________
LAP pressure when auto apply occurs: 9653 586 kPa (1400 85
psi)
_______________
Front brake pressure after auto apply: 9653 586 kPa (1400 85 psi)
_______________
Right rear brake pressure after auto apply: 14 479 690 kPa (2100
100 psi)
_______________
Left rear brake pressure after auto apply: 14 479 690 kPa (2100
100 psi)
Step 17
_______________
LAP pressure when brake and retard lights illuminate: 6722 172
kPa (975 25 psi)
Step 18
_______________
LAP pressure when warning lamp and buzzer turn off: 12 755 517
kPa (1850 75 psi)
Step 19
_______________
LAP pressure when warning lamp turns on: within 690 kPa (100 psi)
of the pressure recorded in Step 15
Step 20
_______________
LAP pressure when auto apply occurs: within 690 kPa (100 psi)
of the pressure recorded in Step 16
_______________
Front brake pressure after auto apply: 14 479 690 kPa (2100 100
psi)
_______________
Right rear brake pressure after auto apply: 9653 586 kPa (1400 85
psi)
_______________
Left rear brake pressure after auto apply: 9653 586 kPa (1400 85
psi)
J04039 03/10
J4-9
VALIDATION
Step 23
_______________
_______________
Front brake pressure (retarder applied): 14 479 869 kPa (2100 126
RETARDING
Step 26
psi)
_______________
Left rear brake pressure (retarder applied): 14 479 869 kPa (2100
126 psi)
_______________
Step 27
_______________
_______________
_______________
Machine __________________
S/N ______________
J4-10
03/10 J04039
Replace coil.
Remove restriction.
Remove obstruction.
Replace piston.
PROBLEM: A Low Brake Pressure Warning Occurs When the Brakes are Not Applied
Short in electrical system.
Check wiring.
J04039 03/10
J4-11
POSSIBLE CAUSES
PROBLEM: A Low Brake Pressure Warning Occurs When Brakes are Applied
Leak or other malfunction in one brake circuit.
PROBLEM: Differential Pressure Warning Circuit activates Briefly When Brakes are Applied or Released
Brake valve out of balance (not tracking).
Accumulator precharge/leak.
Bleed brakes.
Replace bulb.
Electrical problem.
Replace RCM.
J4-12
03/10 J04039
POSSIBLE CAUSES
PROBLEM: Trucks veers to Left (or Right) when brakes are applied.
Hoses between proportional pressure control valve
(PPC) and rear relay valve are crossed.
PROBLEM: The Pump Cycles Too Often Or Low Pressure Warning Comes On At Low Engine RPM
Excessive internal leakage in a component.
Correct plumbing.
J04039 03/10
J4-13
POSSIBLE CAUSES
Check wiring.
PROBLEM: A Brake Accumulator Bleeds Off Quickly When Supply Pressure is Cut Off
Accumulator bleeddown valve is open.
Recharge accumulator
Check plumbing.
Normal
PROBLEM: The Output Pressure At Controller is Correct but Brakes are Not Applying
Brake lines are blocked or improperly connected.
Check plumbing.
PROBLEM: The Brake Pressures Drift Excessively While Pedal is Held Steady
Contamination in brake valve assembly.
J4-14
03/10 J04039
SECTION J5
FRONT WET DISC BRAKES
INDEX
J05022
J5-1
NOTES
J5-2
J05022
Ring gear (7) is internally splined to retain the dampers (2) and separator plates (3). The separator plates
are alternately placed between the friction discs (4).
The friction discs are splined to wheel hub (5).
The inboard side of the assembly contains piston (1)
which is activated by hydraulic pressure supplied by
the brake valve through the front relay valve. As
hydraulic pressure is applied, the piston moves to
compress the rotating friction faced discs against the
stationary steel discs. The friction forces that are
generated resist the rotation of the wheel hub/wheel.
As hydraulic pressure increases, friction forces are
increased and wheel rotation is slowed until maximum force is reached and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The low pressure cooling circuit is completely isolated from the high pressure, piston apply circuit.
Cooling oil flows from the hydraulic tank to the tandem front and rear brake cooling pump. Cooling oil
flows from one section of the pump to the front wet
disc brake cooling circuit.
J05022
J5-3
BRAKE MAINTENANCE
A Brake Cooling Valve (BCV) is located in the circuit.
If activated (no brake apply signal) 50% of the cooling oil will be routed directly back to tank. If the BCV
is not activated (due to the presence of a brake signal) then 100% of the oil is routed through the front
brake cooling oil circuit.
After the cooling oil has passed through the brake,
the oil is routed through a one way orifice check
valve. This valve provides a back pressure of 448
kPa (65 psi) in the front brake cooling circuit. Cooling
oil pressure returns the piston when the brakes are
not applied.
NOTE: If cooling oil pressure falls below 448 kPa (65
psi), the piston may not fully release the brake discs
causing premature wear.
After passing through the check valve, cooling oil
flows through the heat exchanger and then back to
tank.
J5-4
J05022
3. Bleeder Plugs
4. Wear Gauge Plug
J05022
J5-5
Installation
1. The wheel hub and brake must be installed as
an assembly. Install the assembly onto the spindle. Refer to Section G, Front Wheel Hub and
Spindle for instructions.
Disassembly
NOTE: Etch orientation marks onto the profile of
major exterior components before disassembly to
ensure correct assembly.
1. Position the brake assembly on a clean work
surface as shown in Figure 5-4.
2. Attach lifting apparatus to seal retainer (2). The
weight of the retainer is approximately 23 kg (51
lb). Lift the retainer off of the brake.
3. Remove lip seal (3), O-ring (15) and floating
seal (4) from the retainer.
4. Remove capscrews and flatwashers (5) from
brake hub (6).
5. Attach lifting apparatus to brake hub (6). The
weight of the hub is approximately 62 kg (137
lb). Lift the hub off of the brake.
6. Remove O-ring (1) and floating seal (4) from the
brake hub.
10. Damper
11. Capscrew & Washer
12. Piston
13. O-Ring
14. Cylinder
15. O-Ring
16. Piston Seals
17. O-Ring
J5-6
J05022
3. O-Ring
4. Gear
J05022
J5-7
Assembly
TABLE 1. FRONT BRAKE INSPECTION
ITEM
NEW
WEAR LIMIT
Separator Plate
2.4 mm
(0.095 in)
2.15 mm
(0.085 in)
Disc
5.1 mm
(0.201 in)
4.6 mm
(0.181 in)
Damper
6.9 mm
(0.272 in)
5.1 mm
(0.201 in)
Disc
Warping
0.45 mm
(0.018 in)
0.7 mm
(0.028 in)
Separator Plate
Warping
0.50 mm
(0.012 in)
0.7 mm
(0.028 in)
Assembled
Thickness of Discs
And Plates
101.4 mm
(3.992 in)
93.4 mm
(3.667 in)
J5-8
J05022
4. Wheel Hub
5. Floating Seals
6. Cap Screw & Washer
2. Apply Loctite # 648 to the outside circumference of lip seal (3, Figure 5-4). Use a press and
pusher tool to install the lip seal in brake hub
(6). Lubricate the lip area with clean hydraulic
oil.
3. Lubricate O-ring (1) with clean hydraulic oil and
install onto brake hub (6).
4. Lubricate O-ring (15) with clean hydraulic oil
and install into seal retainer (2).
5. Position wheel hub (4, Figure 5-8) on the floor
as shown.
6. Lubricate the sliding surfaces of the floating
seals with clean engine oil (SAE 30-40).
J05022
J5-9
2. Seal Retainer
J5-10
J05022
J05022
J5-11
ASSEMBLED HEIGHT
J5-12
CORRECT INSTALLATION
J05022
INCORRECT INSTALLATION
J05022
J5-13
BRAKE BLEEDING
1. Chock the wheels.
2. Verify that the brake hydraulic circuit is functioning properly. Refer to Section J, Brake Circuit
Checkout.
3. Verify that the bleed-down valves on the brake
manifold are closed.
4. Check the hydraulic tank oil level and fill, if necessary.
5. Start the engine and allow the accumulators to
fill.
6. Install a clear hose onto a bleed valve on the
back of the brake housing. Route the hose to a
container.
7. With the brake pedal partially depressed, slowly
open the bleed valve. Bleed valve (2, Figure 511) vents the cooling oil. Bleed valve (1) vents
the piston. Close the bleeder valve when clear
oil (free of air/bubbles) exits the bleeder. Repeat
at the remaining valve.
J5-14
J05022
SECTION J6
REAR WET DISC BRAKES
INDEX
J06023
J6-1
NOTES
J6-2
J06023
OPERATION
Housing (4, Figure 6-1) is internally splined to retain
steel damper (16) and separator discs (12). The separator discs are alternately placed between the friction faced discs (13) which are splined to rotating
inner gear (9). The inboard side of the assembly contains piston assembly (3) which is actuated by
hydraulic pressure from either the service brake treadle valve or the retarder. As hydraulic pressure is
applied, the piston moves and compresses the rotating friction faced discs against the stationary steel
discs. The friction forces that are generated resist the
rotation of the wheels. As hydraulic pressure
increases, friction forces are increased and wheel
rotation is slowed until maximum force is reached
and the wheel is stopped.
The complete brake disc pack is cooled by hydraulic
oil. The cooling oil circuit is a low-pressure circuit
which is completely isolated from the high-pressure
piston apply circuit. Cooling oil flows from the tank to
the brake cooling pump. Pump oil then flows to the
brake assembly housing (from the outside of the
housing inward to the rotating hub for maximum cooling). The oil then flows through a heat exchanger and
two filters, back to the hydraulic tank. Additional cooling circuit oil is supplied by the hoist valve when the
body is not being raised.
J06023
9. Inner Gear
10. Seal Retainer
11. Hub
12. Separator Plate
13. Friction Disc
14. Housing Drain Plug
15. Piston Cavity Plug
16. Damper
17. Capscrews
18. O-Ring
J6-3
MAINTENANCE
Brake disc wear must be checked every 1000 hours
using the brake disc wear tool (refer to Section M,
Special Tools). The brake disc wear tool is inserted
in the wear gauge port on the brake assembly cylinder. Figure 6-3 shows the rear brake wear tool port
location. Refer to Front Wet Disc Brakes, earlier in
this section, for the port location on front wheel
brakes.
J6-4
3. Bleeder Ports
4. Wear Tool Port/Plug
J06023
REMOVAL
1. Remove the rear rims and tires, the planetary
drive, and the wheel hubs. Refer to Section G,
Drive Axle, Spindles and Wheels for instructions.
Check disc wear in all four brake assemblies during inspections. Disc wear in one brake assembly
may be different from the other due to dissimilar
operation of parts and/or haul profiles. Therefore,
one side may exceed maximum wear limits while
the other side may be within limits.
J06023
J6-5
INSTALLATION
1. Attach a suitable lifting device to the brake
assembly. The brake assembly weighs approximately 1100 kg (2425 lb). The brake housing
must be properly oriented to align with the
hydraulic connections and mounting holes on
the inner side.
Place O-ring (18, Figure 6-5) into position and
ensure the O-ring remains in place during
installation.
2. Move the brake assembly into position against
the flange on the axle. Coat mounting capscrew
threads (17, Figure 6-5) with Three Bond (p/n
TB1374 or 09940-00030). Install the capscrews
and washers, and tighten to 1715 195 Nm
(1258 144 lb ft).
FIGURE 6-4. BRAKE ASSEMBLY REMOVAL
1. Brake Assembly
2. Lifting Device
3. Floating Seal
Retaining Tool
6. Remove capscrews and washers (17, Figure 65). Carefully lift the brake assembly outward
until it is clear of the rear axle.
7. Move the brake assembly to a clean work area
for disassembly.
J6-6
J06023
3. Inner Gear
J06023
9. Inner Gear
10. Seal Retainer
11. Hub
12. Separator Plate
13. Friction Disc
14. Housing Drain Plug
15. Piston Cavity Plug
16. Damper
17. Capscrews
18. O-Ring
J6-7
BRAKE REBUILD
Disassembly
NOTE: Match mark brake assembly components to
ensure correct orientation of parts during
reassembly.
1. Position the brake assembly on a work surface,
as shown in Figure 6-7.
2. Install a suitable lifting device on inner gear (1,
Figure 6-7) or on the wheel hub. Remove seal
retainer tools (3, Figure 6-4).
3. Carefully, lift the inner gear from the assembly.
10. Damper
11. Capscrew & Washer
12. Piston
13. O-Ring
14. Cylinder
15. O-Ring
16. Piston Seals
17. O-Ring
J6-8
J06023
NEW
WEAR LIMIT
Damper
7.6 mm
(0.299 in.)
5.8 mm
(0.228 in.)
Separator Plate
3.1 mm
(0.122 in.)
2.85 mm
(0.112 in.)
Separator Plate
Warping
0.50 mm
(0.020 in.)
0.7 mm
(0.028 in.)
Friction Disc
6.7 mm
(0.264 in.)
6.2 mm
(0.244 in.)
Friction Disc
Warping
0.70 mm
(0.028 in.)
0.9 mm
(0.004 in.)
Assembled
Thickness of
Plates and Discs
80.70 mm
(3.177 in.)
75.2 mm
(32.961 in.)
Assembly
Clean all parts, and check for dirt or damage. Coat
the sliding surfaces of all parts with hydraulic oil
before installing.
1. Refer to Floating Ring Seal Assembly/Installation in this chapter for proper seal installation
procedures.
a. Install floating seal assembly (4, Figure 6-7)
to seal carrier (2) and hub (6).
J06023
J6-9
10. Attach a lifting device to inner gear (1) and carefully lower the gear over the assembly. Align the
gear teeth with the disc teeth.
11. Install seal assembly retainer tools (3, Figure 64) on the hub and inner gear. Position the tools
at three equally spaced holes to secure the
floating seal until the brake assembly is
installed.
J6-10
J06023
J06023
J6-11
CORRECT INSTALLATION
ASSEMBLED HEIGHT
J6-12
J06023
INCORRECT INSTALLATION
J06023
J6-13
J6-14
J06023
SECTION J7
PARKING BRAKE
INDEX
J07012 01/04
Parking Brake
J7-1
NOTES
J7-2
Parking Brake
01/04 J07012
PARKING BRAKE
Description
The following specifications should be used to determine the state of parking pads and the disc. Replace
if any of the limits have been exceeded.
Item
New
Limit
0.4 mm
(0.016 in.)
0.8 mm
(0.032 in.)
Disc Thickness
25 mm
(0.99 in.)
20 mm
(0.79 in.)
Pads
(Includes plate thickness)
20.0 mm
(0.787 in.)
12.2 mm
(0.48 in.)
J07012 01/04
Parking Brake
J7-3
Removal
Installation
11. Install the hose clamps (8) onto the case with
capscrews (6) and lock washers (7). Tighten to
standard torque.
J7-4
Parking Brake
01/04 J07012
J07012 01/04
8. Clamp
9. Washer
10. Capscrew
11. Spring
12. Spring
13. Brake Assembly
14. Hose
15. Bracket
16. Capscrew
17. Washer
18. Nut
19. Plate
20. Disc
21. Capscrew
Parking Brake
22. Washer
23. Dowel Pin
24. Bracket
25. Capscrew
26. Fitting
J7-5
Installation
6. Turn adjuster nut (14) clockwise until no clearance exists between brake pads and disc.
J7-6
Parking Brake
01/04 J07012
J07012 01/04
Parking Brake
J7-7
J7-8
6. Locking Nut
7. Nut
8. Flat Washer
9. Spring Can
10. Brake Head
Parking Brake
01/04 J07012
SECTION L
HYDRAULIC SYSTEM
INDEX
L01033
Index
L1-1
NOTES
L1-2
Index
L01033
SECTION L2
HYDRAULIC SYSTEM OVERVIEW
INDEX
L02040
Hydraulic System
L2-1
NOTES
L2-2
Hydraulic System
L02040
SYSTEM COMPONENTS
HYDRAULIC TANK
The hydraulic tank (Figure 2-1) is divided into two
sections. Front section (1) provides the oil supply for
the steering and brake circuits. Rear section (2) provides the oil supply for the hoist and wet disc brake
cooling oil. The total hydraulic system requires
approximately 710 liters (187.6 gal). Refer to Section
P, Lubrication and Service for the recommended oil
specification for use under various ambient temperatures and tank refill capacity. The oil level should be
checked periodically with the body down, engine
stopped, and the truck parked on level ground.
4. Transmission Cooling
Pump
5. Brake Cooling Pump
L02040
5. Breather Valve
6. Pressure Release
7. Filter
Hydraulic System
L2-3
L2-4
3. Accumulators
4. Flow Amplifier Valve
Hydraulic System
5. Manifold
6. Steering Cylinders
L02040
BLEED-DOWN MANIFOLD
Steering and brake pump (3, Figure 2-2) supplies oil
to high pressure filter (1, Figure 2-3). Filtered oil
passes through a one-way check valve, and into
bleed-down manifold (2), located on the inside left
frame rail just forward of the filter.
Oil within the bleed-down manifold is directed to
accumulators (3), flow amplifier (4), the steering control valve and steering cylinders (6), via flow amplifier
(4). Oil is also supplied from the bleed-down manifold
to the wet disc brake system for service brake application.
The steering and brake pump has a compensator set
at 18 961 kPa (2750 psi) to regulate the steering and
brake pressure. Oil returning from the steering and
brake circuits flows back to tank (1, Figure 2-4)
through diffuser (5) mounted in the bottom of the
tank.
HOIST VALVE
Hoist valve (2, Figure 2-4) is located on the rear of
the hydraulic tank, between the tank and the left
frame rail. The hoist valve is controlled by a hoist
pilot control valve that is located in the hydraulic cabinet on the center deck. The hoist valve controls oil
flow to the hoist cylinders to raise the dump body
when requested by the operator.
1. Hydraulic Tank
2. Hoist Valve
3. Hoist Pilot Valve
Supply
HOIST PUMP
Oil from tandem gear pump (2, Figure 2-2), mounted
on the left side of the transmission PTO, is directed
to the split spool hoist valve. Whenever the truck
body is not being raised, the oil is directed through
the rear brake cooling circuit before returning to tank.
On its path it will pass through a pair of filters and a
heat exchanger. This circuit also utilizes a Brake
Control Valve (BCV). If the rear brakes are not
applied, 50% of the oil returning from the hoist valve
will be bypassed around the rear brake cooling circuit
and flow directly to tank.
An internal, adjustable relief valve protects the hoist
circuit from pressures in excess of 18 961 kPa (2750
psi).
Refer to Section J2 for more information on the brake
cooling valves.
L02040
Hydraulic System
L2-5
The truck is also equipped with three low pressure filters, for the hoist and brake cooling circuits. All three
filters have a built in bypass system which also activates a display message on the EDP when the differential pressure indicates by-pass for any of the filters.
The filter elements must be changed as soon as possible after the indicator alert, before actual by-pass
occurs. For the regular filter service interval, refer to
Lubrication and Service, Section P, or replace when
the indicator light turns on.
L2-6
Hydraulic System
L02040
SECTION L3
HYDRAULIC SYSTEM COMPONENT REPAIR
INDEX
L03036
L3-1
NOTES
L3-2
L03036
MAINTENANCE
L03036
L3-3
Removal
L3-4
L03036
L03036
4. Cap Screw
5. Hydraulic Tank
6. Cap Screw
7. Spacer
8. Cap Screw
9. Shim
L3-5
Installation
L3-6
L03036
9. Strainers
10. Wire Mesh Strainer
11. Strainer
12. Cover
13. Cap Screws
14. Oil Drain
15. Diffuser
L03036
L3-7
2. Cover
3. Diffuser
Installation
1. Install strainers (9 & 11, Figure 3-5) and diffusers (6).
2. Install covers (7 & 12) and new gaskets. Install
cap screws (8 & 13). Tighten to standard
torque.
3. Install diffuser (3, Figure 3-6) into the hydraulic
tank.
4. Install strainer (10, Figure 3-5).
5. Place cover (2) and a new gasket into position
on the hydraulic tank. Install cap screws and
washers (1). Tighten the cap screws to standard torque.
6. Connect the inlet and outlet lines to the proper
ports on the tank.
L3-8
3. Element
L03036
Service
1. Shut off the engine. Relieve internal pressure
using the relief valve on top of the hydraulic
tank.
2. Clean dirt accumulations from the area around
the breather.
3. Remove the breather from the tank.
4. Remove snap ring (1 Figure 3-7), cover (2), and
filter element (3).
5. Clean the breather in solvent and thoroughly
dry.
6. Install a new filter element. Lubricate the Orings with clean hydraulic oil during assembly.
7. Install the breather onto the hydraulic tank.
L03036
L3-9
HYDRAULIC PUMPS
Hoist pump (2, Figure 3-8) and brake cooling pump
(7) are similar in design. The following removal,
installation and rebuild procedures are applicable to
both pumps. Pump rebuild instructions are also applicable to both pumps.
Removal
1. Turn key switch OFF and allow at least 90 seconds for the accumulators to bleed down.
L3-10
L03036
Installation
6. Remove cap screws and lock washers securing
the pump to the torque converter. Remove the
pump.
7. Move the pump to a clean work area for disassembly.
L03036
5. Hoist Valve
6. PTO
7. Brake Cooling Pump
L3-11
7. O-Ring
8. Bearing Plate
9. Splined Coupling
10. Rear Drive Gear
11. Body (Rear)
12. Cover Plate
PUMP REBUILD
13. Stud
14. Nut
15. Flat washer
16. Rear Idler Gear
17. O-Ring
18. Dowel Pin
19. O-Ring
20. O-Ring
21. Steel Ball
22. Front Idler Gear
Disassembly
L3-12
L03036
3. Backup Ring
4. Ring Retainer
2. Pressure Plate
L03036
L3-13
2. Gear Track-in
Grooves
L3-14
2. Pressure Plate
L03036
Inspection Of Parts
1. Inspect the gear bores in the pump bodies. During initial break-in at the factory, the gears cut
into the housing. The nominal depth of this cut
is 0.20 mm (.008 in.) and should not exceed
0.38 mm (.015 in). Due to the hydraulic loading
of the gears, the cut will start on the suction side
of the body and will continue about one third of
the way around each gear bore. The cut should
be smooth with no deep grooves or deep
scratches. Reject the body if the depth of the
groove is greater than 0.38 mm (.015 in.), or if
the gear bores look like they have been sand
blasted. Reject the body if it is cracked or otherwise damaged.
2. Examine the pressure plates The plates should
not have excessive wear on the bronze side. If
deep curved wear marks are visible, the plates
must be replaced.
3. Examine the gears. If excessive wear is visible
on any part of the gear, replace with new parts.
Assembly
1. Install the flange plate seal. Refer to Seal
Replacement for instructions.
2. Position rear pump body (11, Figure 3-9) so that
the orientation mark is visible. If a new body
must be used, ensure the same side is visible.
NOTE: Observe that the body has a wide and a
narrow boss. The side having the wide boss is
always the suction side of the body.
3. Coat the inside of pump body (11) with clean
hydraulic oil.
4. Examine the two isolation plates from the rear
section. The plates are slightly different.
Choose the plate with the rounded edge indicated by the arrow in Figure 3-14. With the
rounded edge down, install the plate on the suction side in the bottom of the body.
5. Install back-up ring (7, Figure 3-15), O-ring (6),
and ring retainer (2).
L03036
5. Isolation Plate
6. O-Ring
7. Back-up Ring
8. Drive Gear
L3-15
L3-16
3. Trap Slots
4. Inlet Side(Body)
L03036
2. Tooth Valley
19. With the gear bores facing up and the orientation marks aligned, slide front pump body (6)
onto the studs. Position the body firmly onto the
O-ring in the bearing plate.
20. Install dowels (16) in body (3).
21. Repeat the applicable steps to assemble the
front section. Proceed to the next step for gear
timing.
L03036
L3-17
23. Install idler gear (22, Figure 3-9) and the pressure plate. Position the bronze side of the plate
downward and the traps facing the discharge
side of this body.
24. Install the isolation plate, back ring, O-ring, and
ring retainer over the pressure plate.
Bearing Replacement
If the bearings are worn down to the bronze material,
the complete flange or body housing must be
replaced. Installing a new bearing in an old flange or
body is not recommended.
25. Install O-ring (20) in flange plate (5). Use petroleum jelly to hold the O-ring in the groove.
Seal Replacement
27. With the O-ring in flange plate (5) facing downward, slide the flange plate over the studs and
shafts. Slide the plate until it contacts the dowels in the pump body. Use a plastic hammer to
gently tap the flange plate into position.
28. Lubricate the threads on the two opposite studs.
Install washers (15) and nuts (14). Tighten the
nuts to 217 - 237 Nm (160 - 175 lb ft).
29. Use an adjustable wrench to turn the drive
shaft. The shaft should turn at a maximum of 7 14 Nm (5 - 10 lb ft).
30. If the shaft does not turn properly, disassemble
the pump and examine the parts. Check for
burrs or foreign material causing build-up or
interference between the parts. Remove the
cause of the interference and reassemble the
pump.
31. After verifying proper shaft rotation, lubricate
the threads on the studs. Install the remaining
nuts and washers. Tighten the nuts to 217 - 237
Nm (160 - 175 lb ft) in an alternating, progressive pattern.
L3-18
L03036
3. Wooden Blocks
FIGURE 3-20. SHAFT SEAL REMOVAL
1. Flange
2. Punch
3. Bearings
L03036
L3-19
L3-20
3. Bearing Projection
L03036
TROUBLESHOOTING GUIDE
Hoist Pump
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
3. Lube groove enlarged and edges Abrasive wear caused by fine partirounded
cles - dirt (fine contaminants, not
4. Dull area on shaft at root of tooth visible to the eye).
2. Scored shafts
3. Scored gear bore
Aeration-cavitation
a. Restricted oil flow to pump
b. Aerated oil
1. Broken shaft
Overpressure
L03036
L3-21
NOTES
L3-22
L03036
SECTION L4
STEERING CIRCUIT
INDEX
L04050
Steering Circuit
L4-1
NOTES
L4-2
Steering Circuit
L04050
STEERING CIRCUIT
OPERATION
COMPONENT DESCRIPTION
The steering and brake pump supplies oil to bleeddown manifold (2, Figure 4-1). The bleed-down manifold supplies oil to steering accumulators (3) and the
steering control valve via flow amplifier (4). Oil entering the accumulators pushes the floating pistons
within the accumulators upward, compressing the
nitrogen on the opposite side of the pistons. The
nitrogen pressure increases directly with steering circuit pressure. The top side of the pistons are precharged to 9653 kPa (1400 psi) with pure dry nitrogen. When the steering circuit pressure reaches
18 961 kPa (2750 psi), each accumulator will contain
approximately 23 l (4 gal.) of hydraulic oil. The accumulators supply hydraulic oil to the steering circuit in
an emergency situation when steering pump pressure is lost.
Bleed-down Manifold
The steering circuit pressure is normally maintained
at 18 961 kPa (2750 psi) by the compensator located
in the steering/brake pump. Should a malfunction
occur and system pressure exceed this setting, the
bleed-down manifold relief valve will relieve the pressure at 22 408 kPa (3250 psi).
L04050
The bleed-down solenoid will relieve pressure contained in the steering accumulators each time the key
switch is turned to the OFF position.
The check valve in the supply port allows flow to
enter the bleed-down manifold, but blocks reverse
flow back to the pump in the event of pump failure.
All check valves, relief valves and the bleed-down
solenoid are replaceable. Valves and solenoids are
replaced as a unit and are not repairable.
Steering Circuit
L4-3
3. Accumulators
4. Flow Amplifier Valve
5. Manifold
6. Steering Cylinder
Bleed-down Solenoid
Each time the key switch is turned OFF, it activates a
timer that energizes the bleed-down solenoid. When
the bleed-down solenoid is energized, all hydraulic
steering pressure, including the accumulators, is
purged back to the hydraulic tank.
L4-4
After approximately 90 seconds, the timer will deenergize to close the return port to tank. By this time
all the oil in the accumulators should have returned
to tank.
Steering Circuit
L04050
Accumulators
The high pressure filter is a secondary filtering system, filtering oil for the steering and brake apply circuits. Oil is filtered through a Beta 12=200 filter to
reduce the possibility of contamination and subsequent damage to the hydraulic system.
Flow Amplifier
The flow amplifier (Figure 4-2) is located on the left
frame rail forward of the front suspension. The flow
amplifier is necessary in the steering circuit due to
the large volume of oil required for steering. The flow
amplifier uses the amount of flow from the steering
control valve to determine the amount of amplified
flow to send from the bleed-down manifold to the
steering cylinders.
L04050
Warning Devices
Several methods are used to warn the operator of
impending problems in the hydraulic system.
Warning lamps on the EDP will illuminate if a problem occurs with low steering pressure or low accumulator nitrogen precharge. If either or both of these
lights illuminate, the central warning lamp will illuminate. The EDP will display a fault code indicating the
exact problem, including the accumulator with the
low precharge or open switch circuit.
Steering Circuit
L4-5
L4-6
Steering Circuit
L04050
L04050
Steering Circuit
L4-7
L4-8
Steering Circuit
L04050
Steering Left
(Refer to Figure 4-4):
When the operator turns the steering wheel to the
left, the steering control unit valve is opened. This
allows oil entering through port P to pass to the gerotor section of the control unit to turn the rotor. Oil in
the other side of the gerotor flows through other passages in the control unit valve and out steering control unit port L. This oil enters port L in the flow
amplifier and flows to closed area B in the directional
valve.
As pressure in this area increases, oil also flows into
the spool through orifice C to the spring area on the
end of the directional valve. The pressure then forces
the spool to compress the springs on the opposite
end. This movement allows the oil entering area B to
pass through the directional valve to area D of the
amplifier valve through sleeve E holes to a passage
between sleeve E and valve F, through hole G in
sleeve E where it initially is blocked by the valve
body.
As pressure increases in this area, oil also flows from
area D around the outside of sleeve E around pin H
through orifice J to build pressure on the end of the
amplifier valve and opens hole G only enough to
allow the flow of oil coming from the steering control
unit to pass to the control area of the directional
valve.
At the same time, the movement of sleeve E opened
the holes near the spring end to allow the oil from the
priority valve to flow into the center of sleeve E.
L04050
Steering Circuit
L4-9
L4-10
Steering Circuit
L04050
Steering Right
(Refer to Figure 4-5):
Only a few differences occur between steer left and
steer right. When the operator turns the steering
wheel right, oil is supplied out ports R and LS of the
steering control unit.
The oil enters the flow amplifier assembly at port R
and shifts the directional valve the opposite direction.
The oil flows through the amplifier valve exactly the
same. The combined oil from the amplifier valve
passes through the center area Q of the directional
valve to port CR where it goes to the opposite ends
of the steering cylinders to turn the wheels right.
The returning oil flows through port CL back to the
tank. The LS oil operates exactly the same as steering left.
L04050
Steering Circuit
L4-11
L4-12
Steering Circuit
L04050
L04050
Steering Circuit
L4-13
L4-14
Steering Circuit
L04050
STEERING/BRAKE PUMP
COMPONENTS
Drive shaft (1, Figure 4-7) is located through the center line of pump housing (5) and valve plate (31).
Pump cylinder barrel (30) is splined to the drive shaft.
L04050
Steering Circuit
L4-15
L4-16
Steering Circuit
L04050
OPERATION
Full Pump Volume (Figure 4-8):
Rotating the drive shaft turns the splined cylinder,
which contains the pistons. When the cylinder is
rotated, the pistons move in and out of their bores as
the shoes ride against the angled swashblock.
As the cylinder rotates, the individual piston bores
are connected, alternately, to Port A (upper) and Port
B (lower). While connected to the upper side (suction) Port A, each piston moves outward, drawing
fluid from Port A into the piston bore until it's outermost stroke is reached. At that point, the piston bore
passes from the upper crescent port to the lower
crescent port.
L04050
Steering Circuit
L4-17
NOTES
L4-18
Steering Circuit
L04050
SECTION L5
STEERING CONTROL UNIT
INDEX
L05032
L5-1
NOTES
L5-2
L05032
Installation
1. Lubricate the male splines on the end of the
steering column shaft.
2. Place steering control unit (7) into position.
Install cap screws (10). Tighten the cap screws
to standard torque.
L05032
L5-3
REBUILD PROCEDURE
Tools required for disassembly and assembly:
2 screwdrivers (4-6 in. long, 1/8 in. flat blade)
1/2 inch socket (12 point)
1/2 inch breaker bar
Torque wrench, 120 Nm (90 lb ft) capacity.
Plastic hammer or rubber hammer
Retaining ring pliers
Fabricated spring installation tool (Figure 5-4).
The steering control unit is a precision unit manufactured to very close tolerances. Complete cleanliness
is necessary when rebuilding the unit. Work in a
clean area and use lint free wiping materials or dry
compressed air. Use a wire brush to remove foreign
material and debris from around the exterior joints of
the unit before disassembly. Use clean solvent for
cleaning and clean hydraulic oil for initial lubrication.
L5-4
L05032
Disassembly
1. Clamp the housing in a vise with the metering
end up. Clamp lightly on the edges of the
mounting area, as shown in Figure 5-5.
3. Remove the end cover cap screws and washers. Remove cap screw with rolled pin (3, Figure 5-6). Mark the location of the cap screw for
reassembly.
4. Remove end cover (1, Figure 5-7) and O-ring
(2). Remove gear wheel set (3).
5. Remove cardan shaft (11, Figure 5-10) distribution plate (15) and O-ring (14).
FIGURE 5-5. CLAMPING STEERING UNIT
L05032
6. Remove threaded bushing (4) and ball (3). Separate the spools from the housing. Remove Oring (5), kin ring (6) and bearing assembly (7).
7. Remove ring (8) and pin (9). Carefully push the
inner spool out of the outer sleeve.
8. Press neutral position springs (10) out of their
slot in the inner spool. Note the orientation of
the centering springs.
9. Remove dust seal (2, Figure 5-8) using a
screwdriver. DO NOT scratch the seal bore.
L5-5
3. Spool
4. Sleeve
L5-6
3. Housing
L05032
L05032
9. Pin
10. Neutral Position Springs
11. Cardan Shaft
12. Spacer
13. Tube
14. O-ring
15. Distribution Plate
16. Gear Wheel Set
17. O-ring
18. O-ring
19. End Cover
20. Washers
21. Rolled Pin
22. Cap Screw With Bore
23. Cap Screws
L5-7
Assembly
NOTE: When assembling the spool and sleeve, only
one of the two possible matching positions of the
spring slots can be used. The reason is that in the
other end of the sleeve and spool (opposite end of
the spring slots) there are three slots in the spool and
three holes in the sleeve. These must be opposite
each other during assembly so that the holes are
partly visible through the slots in the spool. Refer to
Figure 5-10.
2. Centering Springs
1. Spring Installation
Tool
Alternate
Springs
Method
For
Installing
Centering
d. Slide the inner spool in the sleeve. Compress the ends of the neutral position springs
and push the springs into place in the sleeve.
Install the cross pin.
6. Insert one end of the spring set into the installation tool (Figure 5-11).
7. Compress the end of the centering spring set
and push into the spool and sleeve assembly.
Keep pressure on the spring ends when withdrawing the installation tool, pushing forward on
spring set.
L5-8
L05032
L05032
L5-9
13. Install distribution plate (15, Figure 5-9), aligning the channel holes to match the corresponding holes in the housing. Guide cardan shaft
(11) into the bore. The slot in the cardan shaft
must be parallel to the cross pin.
NOTE: Position the cardan shaft so that it is held up
and in position by a mounting fork. Refer to Figure 516. The mounting fork can be fabricated from a small
piece of thin gauge metal.
L5-10
L05032
3. Rotor
4. Cardan Shaft
L05032
L5-11
NOTES
L5-12
L05032
SECTION L6
STEERING CIRCUIT COMPONENT REPAIR
INDEX
L06040 03/11
L6-1
L6-2
03/11 L06040
Removal
NOTE: It may not be necessary to remove the bleeddown manifold from the truck to replace components.
If a problem area has been isolated, simply remove
the inoperative component and replace with a new
part.
FIGURE 6-1. BLEEDDOWN MANIFOLD
Adjusting Relief Valve
1. Depressurize the system and install a 34 474
kPa (5000 psi) pressure gauge in the pressure
test port (6, Figure 6-1) of the bleed-down manifold.
2. Start the engine and operate at low idle.
3. Loosen the locknut on the compensator valve
on the steering pump.
8. To Flow Amplifier
9. From Flow Amplifier
10. Accumulator BleedDown Solenoid
11. Low Steering
Pressure Switch
12. Auto-Lube Supply
L06040 03/11
L6-3
DO NOT turn the key switch to OFF to depressurize the accumulators while the steering return
lines are open. The return lines will contain accumulator oil flow during the depressurization
cycle.
5. If leakage is excessive, reconnect the return
line.
6. Turn the key switch to OFF and allow at least
90 seconds for the accumulators to depressurize.
7. Remove bleed-down solenoid valve (10) and
relief valve (4). Replace the O-rings on both
valves and reinstall.
8. Repeat the test procedure.
9. If leakage is still excessive, replace both the
bleed-down solenoid valve and the relief valve.
L6-4
03/11 L06040
FLOW AMPLIFIER
Disassembly
Removal
The flow amplifier valve is a precision unit manufactured to close tolerances. Therefore, complete cleanliness is a must when handling the flow amplifier
valve. Work in a clean area and use lint free wiping
materials or dry compressed air. Use a wire brush to
remove foreign material and debris from around the
exterior of the valve before disassembly. Use clean
solvent to ensure cleanliness and clean hydraulic oil
for initial lubrication.
Installation
1. Lift the flow amplifier into position. The weight of
the flow amplifier is approximately 29 kg (69 lb).
2. Install the mounting cap screws and tighten to
standard torque.
3. Identify hydraulic line location. Remove the
plugs from the hoses. Install new O-rings on the
flange fittings and connect the lines to the
proper locations. Tighten the fittings securely.
L06040 03/11
L6-5
L6-6
03/11 L06040
Cap Screw
Lock Washer
Cap Screws
Lock Washer
Cover
O-ring
O-ring
O-ring
Seal Plate
O-ring
O-ring
Shock/Suction Valve (Complete)
Orifice Screw
Valve Housing
Counterpressure Valve (Complete)
O-ring
Plug
Plug
Seal
Relief Valve (Complete)
Steel Seal
Stop
Spring
Spring
Spring Control
Orifice Screw
O-ring
Shock/Suction Valve (Complete)
Main Spool
O-ring
Spring Control
Spring
Spring
Spring Stop
Orifice Screw
Cap Screws
Cap Screw
Lock Washer
Lock Washer
O-rings
Stop
Spring
Spool
Name Plate
Orifice Screw
Spring
Cover
Pins
O-rings
Seal Plate
Amplifier Spool Assembly (Complete)
O-ring
Orifice Screw
Check Valve
Spring
L06040 03/11
3. O-Ring
L6-7
7. Retaining Ring
8. Inner Spool
9. Spring
10. Plug
11. Orifice Screw
Assembly
1. Thoroughly clean all parts. Lubricate each part
prior to installation with clean hydraulic oil.
2. Reassemble the amplifier spool assembly.
Install O-ring (2, Figure 6-5). Install check valve
(1). Install orifice screw (11) in plug (10). Install
pin (5) and retaining ring (7). Install spring (9)
and plug (10). Install pin (4) and retaining ring
(6). Install inner spool (8).
L6-8
03/11 L06040
ACCUMULATORS
1. Remove charging valve guard (5, Figure 6-6).
Removal
2. Loosen swivel nut (4, Figure 6-9) three complete revolutions while holding the valve body
stationary.
3. Remove valve cap (1). Install the charging manifold assembly and release all the nitrogen pressure.
6. Valve Cap
7. Flat Gasket
8. Valve Assembly
9. Pressure Switch
L06040 03/11
L6-9
Installation
1. Attach a lifting device to the top of the accumulator. The weight of the accumulator is 140 kg
(309 lb). Lift the accumulator into position onto
mounting bracket (4, Figure 6-7).
2. Install the clamps (2) and hardware to secure
the accumulator to the mounting bracket. Do
not overtighten as this could distort the accumulator.
3. If necessary, install the pressure switches. Connect the wiring harness to the pressure
switches.
L6-10
7. O-Ring
8. O-Ring Back-Up
9. Spacer
10. Lock Ring
11. Valve Assembly
12. Bleed plug
03/11 L06040
Disassembly
1. Secure the accumulator body in a vise (preferably a chain vise).
NOTE: If a standard jaw vise is used, copper inserts
must be used to protect the hydraulic port from
damage. Clamp against the wrench flats only when
using a jaw vise to prevent the accumulator from
turning.
2. Remove bleed plug (12, Figure 6-8).
3. Using a spanner wrench, remove lock ring (10).
Use an adjustable wrench on the flats of
hydraulic port assembly (2) to prevent it from
rotating.
DO NOT attempt to repair the accumulator housing. Repairs may weaken the housing and result
in serious injury to personnel when pressurized.
Replace the accumulator housing if damaged.
Assembly
Assemble the accumulator in a dust and lint-free
area. Maintain complete cleanliness during assembly
to prevent possible contamination of the hydraulic
system.
1. Place accumulator shell (4, Figure 6-8) in a vise
or on a table.
L06040 03/11
L6-11
To perform leak testing, a source of nitrogen pressure of 9653 kPa (1400 psi) and hydraulic pressure
of 24 132 kPa (3500 psi) will be required. A water
tank large enough to hold the accumulator and a
method of safely securing the accumulator in a holding fixture will be necessary.
L6-12
03/11 L06040
L06040 03/11
L6-13
Depressurize system accumulators before opening hydraulic circuits or installing test gauges.
For the steering circuit, turn the key switch to
OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the steering wheel to verify that pressure has been purged
from the circuit. If the wheels do not move, the
steering circuit is safe to service.
For the brake circuit, first, chock the wheels.
Then, open the shut-off valves on the brake manifold. Opening the valves allows accumulator
pressure to be released to the hydraulic tank.
Pure dry nitrogen is the only gas approved for
use in the steering accumulator. The accidental
charging of oxygen, or any other gas in this component, may cause an explosion.
When charging or discharging nitrogen gas in
the accumulator, ensure the warning labels are
observed, and the instructions regarding the
charging valve are carefully read and understood.
1. With the key switch OFF, allow at least 90 seconds for the accumulator to depressurize. Turn
the steering wheel to ensure no oil pressure
remains in the accumulator.
FIGURE 6-9. CHARGING VALVE
1. Valve Cap
6. Valve Body
2. Seal
(Large Hex Nut)
3. Valve Core
7. O-Ring
4. Swivel Nut
8. Valve Stem
(Small Hex Nut)
9. O-Ring
5. Rubber Washer
L6-14
03/11 L06040
4. Swivel Connector
5. Pressure Gauge (Regulated)
6. Regulator
7. Adapter
8. Valve
9. Pressure Gauge
Nitrogen pressure may be present in the accumulator. Turning the complete valve assembly may
result in the valve assembly being forced out of
the accumulator by the nitrogen pressure inside.
Ensure only swivel nut (4) is loosened.
8. Hold the charging valve stationary using valve
body (6, Figure 6-9) with one wrench and
loosen swivel nut (4) with a second wrench.
This will open the poppet inside the charging
valve.
L06040 03/11
L6-15
16. Install and tighten the valve cap to 1-2 Nm (1015 lb in.). The valve cap serves as a secondary
seal. Install valve guard (5, Figure 6-6). Close
the valve on the nitrogen supply tank.
L6-16
03/11 L06040
ACCUMULATOR STORAGE
Temperature variation can affect the precharge pressure of an accumulator. As the temperature
increases, the pressure increases. Conversely,
decreasing temperature will decrease the pressure.
To ensure accuracy, it is necessary to adjust the
charging pressure to offset temperature variations.
The temperature variation is determined by the ambient temperature at the time of charging. If the accumulator is mounted on the truck, wait one hour after
shutting the engine off. After an hour, measure the
ambient temperature to determine the proper charging pressure. Refer to Table 1.
The shelf life of bladders, under normal storage conditions, is one year. Normal storage conditions consist of the bladder being heat sealed in a black plastic
bag and placed in a cool, dry place away from the
sun, ultraviolet, and fluorescent lights, as well as
electrical equipment. Direct sunlight or fluorescent
light can cause the bladder to weather check and dry
rot, which appear on the bladder surface as cracks.
Charging Pressure
70 kPa (10 psi)
-17C (0F)
-12C (10F)
-7C (20F)
-1C (30F)
4C (40F)
10C (50F)
16C (60F)
21C (70F)
27C (80F)
32C (90F)
38C (100F)
43C (110F)
49C (120F)
L06040 03/11
L6-17
Installation
Follow this procedure when installing an accumulator that was in storage. This procedure also
applies to newly purchased accumulators.
1. Install the pressure gauges on the accumulator
and check the pressure. Refer to Steering
Accumulator Charging in this chapter.
a. If the pressure is 165 kPa (24 psi) or less,
slowly drain off any nitrogen and proceed to
Step 2.
L6-18
03/11 L06040
STEERING CYLINDER
Removal
Installation
1. Lift steering cylinder (5, Figure 6-11) into position. The weight of the steering cylinder is
approximately 131 kg (289 lb).
2. Position rubber boot (1, Figure 6-12) and install
pin (4, Figure 6-11). Install the pin retaining cap
screw and washer and tighten to standard
torque.
3. Move the piston rod eye into position. Install
rubber boot (1) and the pin. Install the pin
retaining cap screw and washer and tighten to
standard torque.
4. Connect the lubrication lines.
5. Install a new O-ring onto hose (3, Figure 6-11).
Connect the hose to the cylinder.
2. Pin
L06040 03/11
4. Pin
5. Steering Cylinder
L6-19
L6-20
5. Seal Assembly
6. O-Ring
7. Backup Ring
8. Gland
9. Cap Screw
10. Rod
11. Wiper
12. Seal
13. Bearing
14. Retaining Ring
15. O-Ring
16. Bushing
03/11 L06040
Assembly
STEERING/BRAKE PUMP
Removal
1. Install new piston seal (5, Figure 6-13) onto piston (3) as follows:
a. Heat piston seal assembly (5) in boiling
water for 3 to 4 minutes.
b. Remove the piston seal from the water and
assemble onto the piston. Install within 5
seconds before the seal hardens. Use piston
bearing (4) to position the seal assembly in
the groove. Apply pressure evenly to prevent
cocking the seal.
c. If the seal is loose on the piston, a belt type
wrench or similar tool can be used to compress the OD of the seal until it fits tightly on
the piston.
2. Install bearing (4) in the piston groove.
Cylinder Assembly:
1. Install a new bearing (13), rod seal (12), rod
wiper (11), backup ring (7) and O-ring (6) in
gland (8).
2. Push rod (10) through the top of the gland.
Slowly advance the rod over the seal and the
rod wiper.
3. Install piston assembly (3) onto the rod. Install
locknut (2) and tighten to 2712 Nm (2000 lb ft).
4. Carefully install the rod and the gland assembly
into cylinder housing (1). Ensure the O-ring and
the backup ring are not damaged during installation of the gland.
5. Install cap screws (9). Tighten to 420 Nm (310
lb ft).
Testing
After the cylinder is assembled, perform the following
tests to verify that performance is within acceptable
limits.
Piston leakage must not exceed 16.4 cm3/min.
(1.0 in3/min.) at 17 250 kPa (2,500 psi), port to
port.
Rod seal leakage must not exceed one drop of oil
in eight cycles of operation.
Piston break-away force must not exceed 690
kPa (100 psi).
L06040 03/11
L6-21
Installation
1. Install a new O-ring onto the pump mounting
flange.
2. Inspect the splined coupler to verify the internal
snap ring is properly seated. Install the coupler
onto the transmission pump drive shaft.
3. Attach an appropriate lifting device to the steering pump. The pump weighs approximately 50
kg (110 lb). Lift the steering pump into position.
Engage the steering pump shaft with the transmission pump splined coupler.
4. Align the cap screw holes and install the steering pump mounting cap screws. Tighten the
mounting cap screws to standard torque.
5. Remove the plugs from suction hose (3, Figure
6-14) and outlet hose and install new O-rings.
Connect the hoses to the steering pump.
Tighten the cap screws, securely.
6. Remove fitting (4) and add clean oil to the pump
until the housing is full. This may require 2 to 3
liters (2 to 3 qts) of oil.
7. Remove the cap from case drain line (2) and
connect to fitting (4).
8. Replace the hydraulic filter elements. Refer to
Hydraulic Filters, earlier in this section.
FIGURE 6-14. STEERING/BRAKE PUMP
1. Transmission Pump
2. Case Drain Line
3. Suction Hose
5. Attach an appropriate lifting device to the steering pump. The pump weighs approximately 50
kg (110 lb). Remove the two pump mounting
cap screws.
10. With the body down and the engine off, fill the
hydraulic tank with clean hydraulic oil. Fill until
oil is visible in the top sight glass. The capacity
of the hydraulic is 576 liters (152 gal.).
L6-22
03/11 L06040
PUMP REBUILD
When disassembling or assembling unit:
Choose a work area free of dust, sand or other
abrasive particles.
Place all parts on a clean surface.
Use clean solvents to clean parts.
All tools and gauges must be clean. Use new,
clean and threadless rags to handle and dry
parts.
Disassembly
1. Drain the hydraulic oil from the pump inlet, discharge and case drain ports.
Do not allow the engine to operate with the needle valves in the open position for longer than
this recommendation. Excessive hydraulic system heating will occur.
Do not operate the hydraulic pumps for the first
time after an oil change, or pump replacement,
with the truck dump body raised. The oil level in
the hydraulic tank may be below the level of the
pump(s), causing premature pump wear during
initial start-up.
L06040 03/11
L6-23
Control Group
NOTE: Prior to removing the control group from the
pump housing, loosen all external plugs for easier
removal.
L6-24
9. O-Ring
10. Control Piston Pin
11. Plug
12. Plug
13. O-Ring
14. Relief Valve Bonnet
15. Spring
16. Shim
25. Orifice
26. Orifice
27. Spring
28. End Plug
29. O-Ring
30. Orifice
31. Gasket
03/11 L06040
Rotating Group
L06040 03/11
7. Screw
8. Guide Plate
9. Roll Pin
10. O-Ring
11. Roll Pin
12. Roll Pin
19. Plug
20. O-Ring
21. Plug
22. O-Ring
L6-25
Swashblock Group
24. Remove the flat head screws (7, Figure 6-16)
and guide plate (8).
FIGURE 6-17. PISTON/SHOE REMOVAL
1. Cylinder Barrel
2. Spring
3. Fulcrum Ball
4. Piston/Shoe Assembly
5. Shoe Retainer
L6-26
25. Reach inside the case and remove the swashblock (14) and the saddle bearings (13).
Inspection
Control Group
4. Carefully check control piston pin (10, Figure 615) for cracks and/or signs of fatigue. Check the
fit of the pin in the swashblock. The pin should
be a slip fit without any radial free-play.
5. Verify all orifices and passages are free of
obstructions.
6. Check main control piston (5), bias control piston (7), and housing (1) for excessive wear or
scoring.
03/11 L06040
4. Shoe Retainer
5. Piston & Shoe Assembly
6. Retainer Ring
Rotating Group
9. Inspect cylinder barrel (1, Figure 6-18). Check
the piston bores and the face that mates with
the valve plate for wear and scoring.
10. Remove minor defects on the face by lightly
stoning or lapping the surface. If defects can not
be removed by this method, replace the cylinder
barrel.
7. Cylinder Bearing
8. Roll Pin
L06040 03/11
L6-27
Assembly
FIGURE 6-19. PISTON/SHOE INSPECTION
1. Piston
2. Shoe
Swashblock Group
19. Inspect swashblock (14, Figure 6-16) for wear
and scoring. If defects are minor, stone the
swashblock, lightly. If damage is extensive,
replace the swashblock.
20. Check the small holes in the face of the swashblock. These passageways are ports for the
hydrostatic balance fluid of the piston/shoe
assembly. The fluid is channelled through the
swashblock to the face of the saddle bearing
providing lubrication.
21. Inspect saddle bearing (13). Compare the thickness in a wear area to the thickness in a nonwear area. Replace the saddle bearing if the difference is greater than 0.40 mm (0.015 in.).
Swashblock Group
L6-28
03/11 L06040
Rotating Group
9. Once in place, verify that the swashblock swivels in the saddle bearings. With new bearings,
swivelling may be stiff and not always smooth.
10. Verify roll pins (8, Figure 6-20) are inserted into
cylinder bearing (7).
11. Position the cylinder bearing with the pins
located nearest the control facing the outboard
end of the drive shaft. Position the bearing with
the "scarf" cuts positioned top and bottom with
pins (8) located on top of internal cast boss. The
bearing should fit into place with little difficulty
and be square to the axis of the pump.
12. Tap the bearing into place, if necessary. Use
extreme care. DO NOT damage the bearing.
13. Install retaining ring (6).
The assembled rotating group weighs approximately 7 kg (15 lb). Assistance from others and
proper use of proper lifting techniques is
strongly recommended to prevent personal
injury and damage to the pump.
L06040 03/11
L6-29
28. Install rear valve plate (17). Verify the end of the
drive shaft engages the bushing in the rear
valve plate while positioning the valve plate on
pins (11) and on the housing.
29. Install one cap screw (18) closest to O-ring (10)
first. Do not tighten the cap screw. Then, install
and alternately tighten the other cap screws.
L6-30
4. Shoe Retainer
5. Piston & Shoe Assembly
6. Retainer Ring
7. Cylinder Bearing
8. Roll Pin
03/11 L06040
9. O-Ring
10. Control Piston Pin
11. Plug
12. Plug
13. O-Ring
14. Relief Valve Bonnet
15. Spring
16. Shim
Control Group
30. Insert orifice (20, Figure 6-21). Install a new Oring (19) onto relief valve seat (18). Install and
tighten the seat, securely.
31. Install relief poppet (17), shim (16) and spring
(15).
25. Orifice
26. Orifice
27. Spring
28. End Plug
29. O-Ring
30. Orifice
31. Gasket
L06040 03/11
L6-31
Installation
1. Install a new O-ring (4) and backup ring (5) in
the filter head.
2. Install a new element (7). Install housing (8) and
tighten.
3. Replace drain plug (10), and O-ring (9).
NOTE: The indicator switch (2, Figure 6-22) is preset
to actuate at 241 kPa (35 psi). The switch is not
repairable or adjustable. If the indicator switch is
inoperative, replace the complete switch.
L6-32
6. Bypass Valve
7. Filter Element
8. Housing
9. O-Ring
10. Plug
03/11 L06040
TROUBLESHOOTING CHART
POSSIBLE CAUSES
Replace pump
Repair or replace
SYMPTOM: Slip - A Slow Movement of Steering Wheel Fails To Cause Any Movement of the Steered
Wheels
Cylinder piston seal leakage
Replace seals
Replace cylinder
L06040 03/11
L6-33
TROUBLESHOOTING CHART
POSSIBLE CAUSES
SYMPTOM: Free Wheeling - Steering Wheel Turns Freely with No Back Pressure or No Action of the
Front Wheels
Lower splines of steering column may be disengaged
or damaged
SYMPTOM: Steered Wheels Turn in Opposite Direction When Operator Turns Steering Wheel
Lines connected to wrong cylinder ports
L6-34
03/11 L06040
SECTION L7
HOIST CIRCUIT
INDEX
L07036 05/11
Hoist Circuit
L7-1
NOTES
L7-2
Hoist Circuit
05/11 L07036
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
The following information describes the basic hoist
circuit. Further circuit description is outlined under
the individual component descriptions.
L07036 05/11
6. Manifold
7. Brake Control Valve (BCV)
8. Hoist Pilot Valve
9. Power Down Hoist Limit Solenoid
10. Power Up Hoist Limit Solenoid
Hoist Circuit
L7-3
COMPONENT DESCRIPTION
Hydraulic Tank
Hoist Valve
Hoist Pump
The hoist pump is a tandem gear type pump driven
by the transmission PTO gear case. The pump has a
total output of 845 l/min (224 gpm) at 2100 rpm. Maximum hoist pump output pressure is 18 961 kPa
(2750 psi). Pump output pressure is limited by relief
valves located within the hoist control valve.
If the operator is not raising the truck body, hoist circuit oil is routed to the rear disc brake cooling circuit
and the rear brake control valve. If the brakes are not
applied, 50% of the oil will be routed directly back to
the hydraulic tank by the brake control valve and the
remaining 50% is routed to the disc brake housings.
Oil leaving the brake housings is routed through low
pressure filters and a heat exchanger before returning to the hydraulic tank.
L7-4
Hoist Circuit
05/11 L07036
3. Inlet Section
4. Spool Section
L07036 05/11
Hoist Circuit
L7-5
4. Manifold
5. Control Cable
6. Power Down Solenoid
7. Piloted Check Valve
Power Up Solenoid
Power up solenoid (3, Figure 7-3) is used in the
hydraulic circuit to prevent maximum hoist cylinder
extension.
The solenoid valve is "normally closed" and is controlled by a proximity switch (hoist limit switch). The
switch is located inside the rear frame rail near the
body pivot pin. When the solenoid is signalled to
open by the hoist limit switch, the raise pilot line is
opened to tank. This allows the hoist control spools
to shift to center stopping oil flow to the cylinders.
This locks the circuit in the HOLD position.
L7-6
Hoist Circuit
05/11 L07036
L07036 05/11
Hoist Circuit
L7-7
L7-8
Hoist Circuit
05/11 L07036
POWER UP
Refer to Figure 7-5 for the following description.
The hoist pilot valve spool is moved to the POWER
UP position when the operator moves the lever in the
cab. The pilot supply oil coming in port (12) is prevented from returning to the tank and, instead, is
directed out port (14) and into port (14) of the hoist
valve. There it goes to the top of head end spool (8),
builds pressure on the end of the spool, causes the
spool to move down compressing the bottom spring,
and connects the high pressure passage (19) to
head end port (9). Working oil flow in the high pressure passage is now allowed to flow through the
spool and out port (9) to extend the hoist cylinders.
Even though a small amount of oil flows through the
check poppet in the top of spool (8), raise pilot pressure at ports (14) increases to slightly higher pressure than the required hoist cylinder pressure. As a
result, the pilot supply pressure in port (12) also
increases causing back pressure to occur in the
spring area of flow control valve (2). This overcomes
the pilot pressure on the other end of the flow control
valve causing it to close and direct the incoming
pump oil through head end spool (8) to the hoist cylinders to extend them.
L07036 05/11
Hoist Circuit
L7-9
L7-10
Hoist Circuit
05/11 L07036
HOLD
Refer to Figure 7-6 for the following description.
When the operator releases the lever as the body
travels upward, the hoist pilot valve spool returns to
the HOLD position. The pilot valve spool is positioned to allow the pilot supply oil entering port (12) to
return to the tank through port (10). Pilot supply pressure in ports (12) then decreases to zero pressure
allowing flow control valve (2) to open and return the
incoming pump oil to the tank through port (10). Both
pilot ports (14 & 15) in the pilot valve are closed by
the pilot valve spool. In this condition pressure is
equalized on each end of each main spool allowing
the springs to center the spools and close all ports to
trap the oil in the cylinders and hold the body in its
current position.
L07036 05/11
Hoist Circuit
L7-11
L7-12
Hoist Circuit
05/11 L07036
POWER DOWN
Refer to Figure 7-7 for the following description.
When the operator moves the lever to lower the
body, the hoist pilot valve is positioned to direct the
pilot supply oil in ports (12) through ports (15) to the
top of rod end spool (7). Pilot pressure increases to
move the spool down compressing the bottom
spring. Movement of the spool connects high pressure passage (19) to the rod end (annulus area) of
the hoist cylinders. At the same time, flow control
valve (2) is forced to close as pilot pressure
increases thus directing the incoming pump oil to the
hoist cylinders through spool (7) and snubber valve
(4) rather than back to the tank.
The pilot pressure in port (14) is open to tank through
the pilot valve spool. As oil attempts to return from
the head end of the hoist cylinders, it initially encounters the closed head end spool (8). Pressure
increases on the bottom end of the spool causing it to
move upward. This allows the returning oil to go into
low pressure passage (20), build up 517 kPa (75 psi)
to open low pressure relief (3), and exit the hoist
valve through port (10) to the tank.
L07036 05/11
Hoist Circuit
L7-13
L7-14
Hoist Circuit
05/11 L07036
FLOAT
Refer to Figure 7-8 for the following description.
When the operator releases the lever as the body
travels downward, the hoist pilot valve spool returns
to the FLOAT position. In this position all ports (10,
12, 14, & 15) are common with each other. Therefore, the pilot supply oil is returning to tank with no
pressure build-up thus allowing flow control valve (2)
to remain open to allow the pump oil to return to the
tank through hoist valve port (21). With no blockage
of either raise or down pilot ports (14 & 15) in the pilot
valve, there is no pressure on the top of either main
spool. The oil returning from the head end of the
hoist cylinders builds pressure on the bottom of the
head end spool (8) exactly like in power down allowing the returning oil to transfer to the low pressure
passage (20). The back pressure in the low pressure
passage created by low pressure relief valve (3)
causes pressure under rod end spool (7) to move the
spool upward. This connects the low pressure passage to the rod end of the hoist cylinders. The 517
kPa (75 psi) in the low pressure passage causes oil
to flow to the rod end of the cylinders to keep them
full of oil as they retract. When the body reaches the
frame and there is no more oil flow from the cylinders, the main spools center themselves and close
the cylinder ports and the high and low pressure Passages.
L07036 05/11
Hoist Circuit
L7-15
L7-16
Hoist Circuit
05/11 L07036
SECTION L8
HOIST CIRCUIT COMPONENT REPAIR
INDEX
L08040 07/10
L8-1
NOTES
L8-2
07/10 L08040
Removal
1. Shut off the engine and turn the key switch to
OFF. Allow at least 90 seconds for the accumulators to bleed down. Turn the steering wheel to
ensure hydraulic pressure has been relieved
before removing any hydraulic lines.
Installation
1. Attach a suitable lifting device to the hoist valve
and remove from truck. The hoist valve weighs
approximately 55 kg (121 lb).
2. Lift the hoist valve into position and secure in
place with cap screws, nuts and washers (3,
Figure 8-1). Tighten the capscrews to standard
torque.
3. Install new O-rings at the flange fittings, and
connect the hydraulic lines. Tighten the flange
cap screws to standard torque. Refer to Figure
8-1 for hydraulic line location.
4. Connect the pilot supply lines and tighten the fittings, securely.
5. Start the engine. Raise and lower the body to
check for proper operation. Observe for leaks.
6. Service the hydraulic tank if necessary.
FIGURE 8-1. HOIST VALVE REMOVAL
1. Supply From Pump
2. Return To Manifold/
BCV
3. Capscrews, Washers &
Nuts
L08040 07/10
4. To Hydraulic Cabinet
5. To Hoist Cylinders
6. Return To Tank
7. To Hoist Cylinders
8. Snubber Valve
L8-3
O-Ring Replacement
NOTE: It is not necessary to remove the individual
valve sections for repair unless emergency field
repair is required to replace leaking O-rings between
sections. Loosening and tightening of the main valve
tie rod nut could cause distortion resulting in binding
or severely sticking plungers, poppet and spools.
The following procedure is for replacing the O-rings
between the valve sections.
1. Remove four tie rod nuts (10, Figure 8-2) from
one end of the valve. Slide tie rods (9) from the
valve and separate the sections.
2. Inspect the machined sealing surfaces for
scratches or nicks. If scratches or nicks are
found, remove by lapping on a smooth flat steel
surface with fine lapping compound.
L8-4
07/10 L08040
5. Spring
6. Sleeve
7. Low Pressure Relief
8. O-Rings
13. Cover
14. Capscrews
INLET SECTION
Disassembly
1. Match mark or identify each part when removed
in respect to its location or mating bore to aid
reassembly.
2. Disconnect the external tube at the cover end
and remove. Remove capscrews (14, Figure 85), remove cover (13). Remove springs (12),
poppets (11) and O-rings (10).
NOTE: Figure 8-5 shows the inlet section removed
from the main valve body for clarity.
3. Remove capscrews (1) and cover (2). Remove
springs (3 & 5) and main relief valve (4).
Remove sleeve (6), low pressure relief (7) and
O-rings (8). DO NOT attempt to disassemble or
change the adjustment of main relief valve (4).
The main relief is factory preset at 18 961 kPa
(2750 psi). Replace as a complete assembly
only.
4. Remove sleeve (9), backup ring (8), O-ring (7),
and backup ring (6). Remove backup ring (5),
O-ring (4), backup ring (3) and restrictor poppet
(2).
5. Repeat the previous steps for the opposite inlet
section, if required.
L08040 07/10
6. Backup Ring
7. O-ring
8. Backup Ring
9. Sleeve
L8-5
SPOOL SECTION
Disassembly
Assembly
1. Coat all parts including housing bores with
clean hydraulic oil. Lubricate O-rings lightly with
a multipurpose grease.
2. If restrictor poppet (2, Figure 8-6) was removed,
reassemble in the order shown.
3. Install poppets (11, Figure 8-5) in their respective bores. Install springs (12).
4. Install O-rings (10), and cover (13). Install capscrews (14). Tighten capscrews to 81 Nm (60
lb ft).
5. Install low pressure relief (7) in sleeve (6) and
install assembly in housing (9). Install main
relief valve (4). Install springs (3 & 5). Install
cover (2). Install capscrews (1). Tighten the
capscrews to 81 Nm (60 lb ft).
L8-6
3. O-Ring
07/10 L08040
3. Spool
4. Seal Ring
5. O-Ring
L08040 07/10
L8-7
L8-8
9. Restrictor Poppet
10. O-Ring
11. Spring
12. Restrictor Poppet (Green)
13. Spool Housing
14. Spool Assembly
15. Spool End
16. Spring (Blue)
17. O-Ring
18. Poppet
19. Spool Cover
20. Spool Assembly
21. Restrictor Poppet (Red)
22. Restrictor Poppet (White)
07/10 L08040
Assembly
1. Lubricate O-rings (4, 5 & 10, Figure 8-10) with
clean hydraulic oil. Install the O-rings in the
spool housing. Install poppet (18) and install
cover (19). Install the capscrews that secure the
cover. Tighten the capscrews to 81 Nm (60 lb
ft).
2. Install spring (11) in spool (20). Install spring
seat (2). Apply Loctite to the threads of spool
end (15). Install the spool end and tighten to 34
Nm (25 lb ft). Install red poppet (21). Apply Driloc #204 to the threads of plug (3). Install the
plug and tighten to 20 Nm (15 lb ft).
NOTE: Poppets 12, 21 and 22 may be color coded
and must be installed in their original location.
3. Repeat the previous step for the opposite end
of spool (20). Ensure poppet (22) is white and
spring (16) is blue in color.
4. Lubricate the spool assembly and carefully
install in spool housing (13). Make sure the V
groove in the spool is in the up position, or
toward cover (1).
5. Install spring (11) in remaining spool (14). Install
spring seat (2). Apply Loctite to the threads of
spool end (15). Install the spool end and tighten
to 34 Nm (25 lb ft). Install green poppet (12).
Apply Dri-loc #204 to the threads of plug (3).
Install the plug and tighten to 20 Nm (15 lb ft).
L08040 07/10
Spools (14) and (20) are physically interchangeable. Ensure spool (14) is installed toward the
base port of the spool housing.
8. If used, install a new O-ring and backup ring on
restrictor poppet (1, Figure 8-8). Install the
restrictor poppet in the housing.
9. Install new O-rings (4, 5 & 10, Figure 8-10).
10. Install a new O-ring on poppet (6). Ensure the
small steel ball is installed in the poppet. Install
the poppet in cover (1).
11. Install the cover on housing (13). Secure the
cover in place with the cover capscrews.
Tighten the capscrews to 81 Nm (60 lb ft).
L8-9
Removal
1. Shut off the engine and turn the key switch to
OFF. Allow at least 90 seconds for the accumulators to bleed down. Turn the steering wheel to
ensure hydraulic pressure has been relieved
before removing any hydraulic lines.
2. Place the hoist control lever in the POWER
DOWN position. Ensure the body is at rest on
the frame. Release the hoist control lever to
return the hoist valve spool to the FLOAT position.
3. Disconnect the hydraulic hoses from hoist pilot
valve (1, Figure 8-11).
4. Remove capscrews (6, Figure 8-12).
5. Loosen and unscrew jam nut (3). Unscrew
sleeve (2) until cotter pin (7) and pin (1) are
exposed.
1. Place hoist pilot valve (1, Figure 8-11) into position on the mounting bracket. Secure the valve
in place with the mounting capscrews.
2. Connect the hydraulic hoses to the corresponding ports. Tighten the hydraulic line connections, securely.
NOTE: Seal plate (16, Figure 8-13) must be in place
when installing the hoist cable. Leakage will result if
the plate is not properly installed during cable
installation.
3. Place the hoist control lever in the FLOAT position. Adjust the pilot valve spool until the centerline of the cable attachment hole extends 29.5
mm (1.16 in.) from the face of the valve body.
Refer to Figure 8-12.
L8-10
5. Flange
6. Capscrew
7. Cotter Pin
07/10 L08040
Disassembly
1. Thoroughly clean the exterior of the valve.
Place the valve in a clean work area for disassembly.
2. Remove machine screw (15, Figure 8-13) seal
plate (16), wiper (13) and O-ring (12).
3. Remove snap ring (1), capscrews (6), cap (24),
spacer (23), and detent sleeve (22). Separate
cap (24), spacer (23) and detent sleeve (22).
Detent balls (2) and (21) will fall free when the
cap and detent sleeve are removed.
4. Carefully slide spool (14) out of spool housing
(17). Remove seal retainer (25), wiper (26) and
O-ring (27) from spool (14).
5. Insert a rod in the cross holes of detent pin (3)
and unscrew from spool (14). Slight pressure
should be exerted against the detent pin as it
disengages and spring tension is released.
6. Remove spring seats (19), spring (4) and
spacer (5).
7. Remove relief valve (5, Figure 8-11) from the
valve housing.
8. Scribe identifying marks on the inlet and outlet
housings in relationship to the spool housing to
ensure correct assembly.
9. Remove nuts (8 Figure 8-13) and nuts (10).
Remove tie rods (9). Separate the valve housings. Remove O-ring (11). Remove check poppet (2, Figure 8-14) and spring (3) from housing
(1).
L08040 07/10
L8-11
Assembly
1. Thoroughly coat all parts, including the housing
bores, with clean hydraulic oil.
2. Install check poppet (2, Figure 8-14) and spring
(3) in spool housing (1).
4. O-ring
5. Outlet Housing
L8-12
4. Tie Rod
5. Outlet Housing
07/10 L08040
HOIST CYLINDERS
Removal
L08040 07/10
4. Retainer Ring
5. Bearing
6. Hoist Cylinder
L8-13
L8-14
4. Lock Plate
5. Retainer Ring
6. Bearing
07/10 L08040
Installation
1. Install a retaining strap or chain to prevent the
cylinder from extending during handling. The
hoist cylinder weighs approximately 330 kg
(730 lb). Attach a suitable lifting device that can
handle the load safely.
2. Raise the cylinder into position over the pivot
point on the frame. The air bleed vent at the top
of the cylinder must be toward the front of the
truck. Align the bearing eye with the pivot pin
and push the cylinder into place.
3. Install retainer (2, Figure 8-17), lock plate (4),
and the capscrews. Tighten the capscrews to
standard torque, and bend the lock plate tabs
over the capscrew flats.
As internal parts are exposed during disassembly, protect machined surfaces from scratches or
nicks.
8. Start the engine, raise and lower the body several times to bleed air from the cylinders. Check
for proper operation and inspect for leaks.
Disassembly
1. If removal of the hoist cylinder eye bearings is
necessary, remove retainer ring (5, Figure 8-17)
and press out bearing (6).
2. Mount the hoist cylinder in a fixture which will
allow it to be rotated 180.
3. Position cylinder head (10, Figure 8-18) at the
top. Remove capscrews (11) and the lockwashers.
L08040 07/10
L8-15
1. Rod
2. Second Stage Cylinder
3. First Stage Cylinder
4. Housing
5. Flatwasher
6. Bearing Retainer
7. Capscrew
8. Seal
9. Snap Ring
10. Cylinder Head
11. Capscrews & Lockwashers
12. O-Ring
13. Bearing
14. Seal
15. Bearing
16. Seal
17. Bearing
18. Buffer Seal
19. Bearing
20. Rod Seal
21. Rod Wiper
22. Quill Assembly
23. Backup Ring
24. Snap Ring
L8-16
07/10 L08040
2. Quill Assembly
L08040 07/10
L8-17
Quill Installation
1. Check plugs (3, Figure 8-20) and check balls
(4) in the quill during any cylinder repair to
ensure the plugs are tight and the ball seats are
not damaged. Refer to Installation of Check
Balls and Plugs in Quill.
2. Secure cap assembly (1) in a sturdy fixture.
Ensure the threads in the cap and the threads
on the quill are clean and dry (free of oil and solvent).
3. Using Loctite LOCQUIC Primer "T" (part number TL8753) or the equivalent, spray the mating
threads of both cap assembly (1) and quill
assembly (2). Allow the primer to dry three to
five minutes.
4. Apply Loctite Sealant #277 (part number
VJ6863) or the equivalent to the mating threads
of both the cap assembly and the quill assembly.
5. Install the quill and use tool SS1143 to tighten
the quill to 1356 Nm (1000 lb ft). Allow the
parts to cure for two hours before exposing the
threaded areas to oil.
NOTE: If LOCQUIC primer "T" (TL8753) was not
used, the cure time will require 24 hours instead of 2
hours.
6. Tack weld the quill in two places as shown in
Figure 8-20.
7. Remove all slag and foreign material from the
tack weld area before assembly of the cylinder.
During future cylinder rebuilds, removal of the quill
will not be necessary unless it has loosened or is
damaged. Removal, if necessary, will require a
break-loose force of at least 2712 Nm (2000 lb ft)
after the tack welds are ground off.
L8-18
3. Plug
4. Check Ball
07/10 L08040
L08040 07/10
L8-19
Assembly of Cylinder
NOTE: Installation tools are available to assist in
assembly of the hoist cylinder. The tools fit into the
snap ring grooves on the first and second stage
tubes to prevent components from catching on the
grooves during installation. The tool part numbers
are listed in the table below.
Part Number
1st Stage
PC2713
2nd Stage
PC2712
Installation Tools
Component
L8-20
07/10 L08040
Pressure Testing
After the cylinder is assembled, perform the following
tests to verify that performance is within acceptable
limits.
1. With the rod fully extended, piston leakage
must not exceed 164 cm3/min. (10.0 in3/min.) at
17 250 kPa (2,500 psi), port to port.
2. With the rod fully retracted, piston leakage must
not exceed 328 cm3/min. (20.0 in3/min.) at
17 250 kPa (2,500 psi), port to port.
3. External rod seal leakage must not exceed one
drop of oil in eight cycles of operation.
L08040 07/10
L8-21
NOTES
L8-22
07/10 L08040
SECTION L9
HYDRAULIC SYSTEM FILTERS
INDEX
L09010 10/11
L9-1
NOTES
L9-2
10/11
L09010
Removal
L09010 10/11
6. Filter Element
7. Bowl
8. O-Ring
9. Drain Plug
L9-3
Installation
1. Install new element (6). Install bowl (7) and
tighten.
2. Replace drain plug (9), and O-ring (8).
NOTE: Indicator switch (1, Figure 9-1) is not
repairable. If the indicator switch is inoperative,
replace as a unit. Switch adjustment is not necessary
or recommended.
TRANSMISSION FILTER
Oil from the transmission pump flows through two filters prior to entering the transmission. The filters are
located on the right frame rail, forward of the fuel
tank.
L9-4
10/11
L09010
Removal
Installation
1. Install new element (5, Figure 9-2). Install bowl
(4) and tighten.
2. Replace drain plug (6), and O-ring (7).
L09010 10/11
6. Plug
7. O-Ring
8. Core Assembly
9. Bypass Valve
10. Anti-Backflow Valve
L9-5
NOTE
L9-6
10/11
L09010
SECTION L10
HYDRAULIC CHECK-OUT PROCEDURE
INDEX
L10030 05/08
L10-1
NOTES
L10-2
05/08 L10030
L10030 05/08
L10-3
Equipment Requirements
The following equipment is necessary to properly
check the steering circuit
Hydraulic schematic, refer to Section R.
Three 0-34 474 kPa (0-5000 psi) calibrated
pressure gauges and hoses.
Two 0-25 579 kPa (0-4000 psi) calibrated
pressure gauges and hoses.
NOTE: A data sheet for recording test pressures is
located at the rear of the chapter. Record all pressure
checks on this sheet.
Installation Of Gauges
1. Install a 0-34 474 kPa (0-5000 psi) pressure
gauge at test port (6, Figure 10-1) on the bleeddown manifold.
2. Install two 0-34 474 kPa (0-5000 psi) pressure
gauges onto the pressure ports on the steering
cylinder manifold (2, Figure 10-5) below the
horsecollar.
3. Install a 0-25 579 kPa (0-4000 psi) pressure
gauge onto the hoist pump outlet pressure port.
Install another 0-25 579 kPa (0-4000 psi) pressure gauge at the brake cooling outlet pressure
port.
L10-4
8. To Flow Amplifier
9. From Flow Amplifier
10. Accumulator BleedDown Solenoid
11. Low Steering
Pressure Switch
12. Auto-Lube Supply
05/08 L10030
17. Stop the engine. Check the level of the hydraulic tank and add oil if necessary.
L10030 05/08
L10-5
2. Plug
FIGURE 10-4. STEERING DISTRIBUTION
MANIFOLD
L10-6
1. Steering Distribution
Manifold
2. Steering Cylinder
05/08 L10030
2. Hoist Distribution
Manifold
34. Disconnect the hoist cylinder lines at the distribution manifold and cap the power up and
power down ports (four locations).
35. Start the engine and operate at high idle.
L10030 05/08
L10-7
36. Place the hoist lever in the POWER UP position. The pressure at the manifold must be
18 961 1034 kPa (2750 150 psi).
37. If the power up relief pressure is incorrect,
adjust the pressures as follows:
a. Return hoist lever to the FLOAT position.
b. Relieve all hydraulic pressure from the hoist
system.
6. Sleeve
7. Secondary Low
Pressure Valve
8. O-Rings
9. Inlet Valve body
L10-8
05/08 L10030
1. Check combined leakage from the steering control unit and flow amplifier.
13. If the leakage is excessive, the bleeddown solenoid valve or the bleeddown manifold relief
valve must be replaced.
2. Start the engine and allow the system to stabilize at 18 961 1034 kPa (2750 150 psi).
3. Measure the leakage obtained in the graduated
container:
Maximum allowable leakage is 984 ml (60
in3) per minute.
4. Shut off the engine.
5. If leakage exceeds the maximum, measure the
leakage from the steering control valve as follows:
a. Remove the steering control valve tank
return line at the flow amplifier.
b. Plug the flow amplifier port.
c. Place the end of the disconnected hose in a
graduated container.
6. Start the engine and allow the system to stabilize at 18 961 1034 kPa (2750 150 psi).
7. Check the leakage obtained in the graduated
container:
Maximum allowable leakage is 164 ml (10
in3) per minute.
8. If the leakage exceeds the maximum allowed,
repair or replace the steering control unit. If the
leakage rate is acceptable, perform the next
step to check flow amplifier leakage.
L10030 05/08
L10-9
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
32. Pressure at which low steering pressure indicator light illuminates and warning
buzzer sounds
___________________
___________________
___________________
___________________
L10-10
05/08 L10030
SECTION M
OPTIONS AND SPECIAL TOOLS
INDEX
M01058
Index
M1-1
NOTES
M1-2
Index
M01058
SECTION M7
HOT START SYSTEM
INDEX
M07013
M7-1
NOTES
M7-2
M07013
SYSTEM OPERATION
The hot start system is a 240V system and is
equipped with heating elements in the following components:
Engine oil pan
Cooling system
Rear axle
Hydraulic tank
Transmission oil pan
Battery box
1. Junction Box
2. Power Receptacle
M07013
The heaters in each location are controlled by thermostats. The thermostats turn on the heaters when
temperature falls below a preset value. After the
heating element raises the oil or coolant temperature
above the preset value, the thermostats remove
power to the heating elements.
Do not operate the engine while the cooling system heater is plugged in. The flow check valve
eliminates coolant flow through the heater while
the engine is on. This will cause a lack of circulation in the heater and burn out the heating elements.
2. Terminal Boards
Close the shut off valves before replacing a coolant heater. Failure to close the valve will result in
a loss of coolant from the cooling system.
M7-3
HEATER INFORMATION
Hydraulic Tank
Coolant Heaters
Heater Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Heater Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500W
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500W
2. Heater
FIGURE 7-5. COOLING SYSTEM HEATERS
1. Shut-Off Valve
2. Coolant Heater
Transmission
3. Thermostat
Heater Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Operating Range: . . . . . . . . 16 - 27 C (60 - 80 F)
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500W
Engine
Heater Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operating Range: . . . . . . . . 16 - 27 C (60 - 80 F)
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500W
M7-4
3. Thermostat
3. Thermostat
M07013
Rear Axle
Heater Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Range: . . . . . . . 27 - 38 C (80 - 100 F)
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500W
3. Thermostat
Battery Box
Heating Pad Quantity . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Range: . . . . . . . . 16 - 27 C (60 - 80 F)
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75W
M07013
3. Battery Box
M7-5
TROUBLESHOOTING GUIDELINES
Refer to the electrical schematic located in Section M
for a diagram of the circuits.
SYMPTOM
RECOMMENDED CHECKS
Check for power going into the main power receptacle.
M7-6
M07013
SPECIAL TOOLS
PART NO.
DESCRIPTION
PART NO.
EC3331
DESCRIPTION
NItrogen
Charging Kit
USE
Brake Disc Wear
Tool
USE
Suspension &
accumulator
nitrogen charging
PART NO.
PC2061
PART NO.
DESCRIPTION
569-86-87361 Download
Harness
M08022 6/10
DESCRIPTION
Belt Tension
Tester
USE
A/C Belt Tension
USE
PLM Download
Data
Special Tools
M8-1
PART NO.
EL8868
DESCRIPTION
V-Belt Alignment Tool
USE
Aligning A/C
pulleys
PART NO.
PART NO.
SE21188
M8-2
DESCRIPTION
Drive Shaft
Alignment Tool
DESCRIPTION
PB8528
Wheel Chock
PB8529
Mounting
Bracket
USE
Prevents truck
rollaway
USE
Aligning driveline
components
PART NO.
DESCRIPTION
EH4902
Removal Tool
EG7806
Threaded Rod
Special Tools
USE
Wheel Rim
Retainer
Removal
6/10 M08022
PART NO.
DESCRIPTION
XB5789
Face Seal
Installation Tools
XB5790
PART NO.
XB0887
M08022 6/10
DESCRIPTION
Hydraulic Tank
Vacuum Kit
USE
548 mm
diameter seals
(front brake, rear
brake small)
821 mm
diameter seals
(rear brake large)
USE
To prevent oil
flow from the
hydraulic tank
when opening
the hydraulic system.
Special Tools
M8-3
NOTES
M8-4
Special Tools
6/10 M08022
SECTION N
OPERATOR CAB
INDEX
N01027
Index
N1-1
NOTES
N1-2
Index
N01027
SECTION N2
OPERATOR CAB
INDEX
N02022 10/11
Operator Cab
N2-1
NOTES
N2-2
Operator Cab
10/11 N02022
OPERATOR CAB
The operator cab is fully insulated for maximum operator comfort. The cab contains an integral Roll Over
Protection Structure (ROPS) for maximum operator
safety. All gauges, switches, and controls have been
designed to simplify operation and are within easy
reach of the operator. Servicing of the cab and associated electrical systems is simplified by use of
heavy-duty connectors on the various wiring harnesses.
Hydraulic components and some electrical connections are located outside of the interior and are
accessed through the large access cover on the front
of the cab. Refer to Figure 2-1.
N02022 10/11
Operator Cab
N2-3
Removal
Prior to cab removal or repairs, it may be necessary
to remove the body to provide clearance for lifting
equipment to be used. If body removal is not
required, raise the body and install the body retention
cable.
3. Ground Cable
Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere.
An approved recovery/recycle station must be
used to remove the refrigerant from the air conditioning system.
5. Evacuate the air conditioning system. Attach a
recovery station to the air conditioning service
valves. Refer to Air Conditioning System in this
section for detailed instructions.
2. Water Pump
N2-4
Operator Cab
10/11 N02022
4. Clamp
5. A/C Hoses
1. Radio Antenna
N02022 10/11
Operator Cab
2. Harness
N2-5
18. Lift the cab from the truck and move to an area
for further service.
12. Check for any other remaining hoses and electrical connections. Install as necessary.
Installation
1. Attach appropriate lifting apparatus and a hoist
to the lifting eyes on top of the cab. The cab
weighs approximately 2270 kg (5000 lb).
2. Lift the cab into position on the truck and align
the mounting pad holes with the tapped pads.
Partially install at least one cap screw (1, Figure
2-7) and washer at each of the four mounting
pads prior to completely lowering the cab onto
the deck. This will aid in alignment.
3. After the cab is properly positioned, insert the
remaining cap screws and washers. Tighten the
cap screws to 950 Nm (700 lb ft).
4. Connect harness (2).
5. Connect two vacuum hoses (1, Figure 2-5) to
the fittings at the front of the cab. Connect radio
antenna (1, Figure 2-6) at the front of the cab.
Install the outer access covers onto the front of
the cab.
accumulator
bleed-down
CAB DOORS
For repairs on the door latches or window controls it
is usually better, but not necessary, to remove the
door from the cab and lower it to the floor for service.
Instructions in this section are the same for both the
LH and RH door.
Removal
6. Connect two air conditioning hoses (5, Figure 24) to the fittings below the cab. The receiver
drier and the accumulator must be replaced and
oil added to the system. Refer to Air Conditioning System in Section N for detailed instructions.
7. Install two heater hoses (2). Install clamp (4)
that secures the hoses to the cab. Open heater
shutoff valves (1, Figure 2-3).
N2-6
brake
Operator Cab
10/11 N02022
Installation
1. Attach a lifting sling and a hoist to the door. The
weight of each door is approximately 68 kg (150
lb). Lift the door into position on the cab.
2. Align the door hinges with the cab and install
the hinge cap screws.
3. Attach the travel limiting strap with bolt (2, Figure 2-11) and secure with retainer clip (1).
4. Connect window motor harness (4) to the connector in the cab floor.
5. Verify proper operation of the power window
and the door latch adjustment.
N02022 10/11
3. Frame
4. Seal
Operator Cab
N2-7
2. Remove the door panel. Refer to Door Panel Removal in this chapter.
3. Carefully lower the door panel a few centimeters. Hold the glass at the top to prevent it from
dropping. Slide the door panel toward the cab to
disengage the window regulator roller (Figure 212) from the track on the bottom of the glass.
Slide the panel away from the cab to disengage
the other top roller and lower roller from its
tracks. Place the panel out of the way after
removal.
4. Door
5. Lower Latch
N2-8
Operator Cab
10/11 N02022
DOOR PANEL
Removal
1. Remove hair pin clip (1, Figure 2-11) and bolt
(2) from the door check strap.
2. Remove the two cap screws that secure door
strap bracket (3) to the door.
3. Disconnect window motor harness (4).
4. Open the door as far as possible for removal of
the internal door panel.
5. Lower the window about half way. This will position the rollers for easier removal of the panel.
N02022 10/11
Operator Cab
N2-9
DOOR WINDOW
Removal
1. Remove the door panel. Refer to Door Panel Removal for instructions.
2. Remove two screws (Figure 2-13) while holding
the bottom of the roller track.
FIGURE 2-11.
1. Pin Clip
2. Door Strap Bolt
3. Strap Bracket
4. Wiring Harness
5. Panel Screws
6. Window Regulator
Mounting Screw
FIGURE 2-13.
3. Support the glass in the door frame as shown in
Figure 2-14. Remove two screws (2) that hold
the adapter for the window regulator track.
Remove the adapter, the gaskets, the plate, and
the bushings.
FIGURE 2-14.
1. Support Blocks
2. Screws
FIGURE 2-12.
N2-10
Operator Cab
10/11 N02022
FIGURE 2-15.
1. Screws
4. Remove the screw at the lower end of the window channels. It is necessary to pull rubber felt
insert (2, Figure 2-15) out of the channel in
order to be able to remove the screws.
5. Remove trim screws (1, Figure 2-16) that hold
the window frame to the door.
NOTE: Screws along the bottom of window frame
may be shorter than along the top and sides.
FIGURE 2-17.
1. Window Frame
FIGURE 2-16.
1. Screws
N02022 10/11
Operator Cab
N2-11
Installation
11. Before installing a new window, first inspect the
window frame. In each corner there is an L
shaped bracket (1, Figure 2-18) with two screws
in it to hold the corners of the frame together.
Verify the screws are tight to properly align the
angled joints. (The joints are welded on newer
frames.) Verify the rubber insert in the window
channels is in good condition. Replace, if necessary.
12. Slide the new window glass into the window
frame channels. Move the glass to the top of the
frame.
13. Lift the window frame, holding the glass at the
top of the frame, and lower the assembly into
the door.
Verify that the channel of window frame (5, Figure 2-19) is properly positioned to the inside of
latch assembly (4).
16. Install the trim over the top of the screws that
secure the window frame to the door. Use a flat
blade screwdriver to assist with the installation
of the trim. Refer to Figure 2-20. DO NOT cut
the retainer lip on the trim.
17. Install two screws (1, Figure 2-15). Push rubber
insert (2) into position in the channel after installation of the screws.
18. Assemble the adapter bracket, gaskets, bushings and the plate on the window, as shown in
Figure 2-19.
FIGURE 2-18.
1. L Shaped Brackets
N2-12
Operator Cab
10/11 N02022
19. Lift the window into the frame. Install the window regulator roller track to the adapter bracket
installed in the previous step. Refer to Figure 213.
FIGURE 2-20.
FIGURE 2-19.
1. Adapter Bracket
2. Bushing
3. Rubber Gasket
4. Regulator Track
5. Screw
6. Plate
7. Window
8. Rubber Gasket
4. Latch Assembly
5. Window Frame
20. Holding the window glass as shown in Figure 212 (a few centimeters from the top) install the
lower and upper regulator rollers in their tracks.
Start by moving the door panel (with window
regulator) away from the cab just far enough to
allow the rollers to enter their tracks. Then, with
the rollers in the tracks, slide the panel toward
the cab. Move the panel just far enough to allow
the upper regulator roller to go into the track on
the bottom of the glass.
21. Install the door panel. Refer to Door Panel Installation.
N02022 10/11
Operator Cab
N2-13
Installation
1. Move the window regulator to the up position.
Place the window regulator into position on the
door panel. Verify that the regulator gear and
the window motor gear are properly meshed.
2. Install four mounting screws (6, Figure 2-11).
Tighten the screws securely.
3. Install the door panel as outlined in Door Panel
- Installation.
FIGURE 2-21.
WINDOW REGULATOR
Removal
1. Remove the door panel from the door as outlined in Door Panel - Removal.
2. Move the door panel to a work area to enable
replacement of the window regulator. Remove
four mounting screws (6, Figure 2-11) and
remove the regulator from the door panel.
Installation
1. Place the outside door handle into position, if
removed. Install three screws (3, Figure 2-20)
that secure the door handle.
1. Place the latch into position and align the
mounting holes. Install four mounting screws
(2).
2. Align the inside door handle and install cap
screw and nut (3).
3. Install the door panel. Refer to Door Panel Installation.
N2-14
Operator Cab
10/11 N02022
DOOR SEALS
Removal
1. The three-sided door seal seals the two sides
and the top of the door. The seal is glued onto
the door and can be replaced by peeling the
seal away from the door frame. Use a suitable
cleaner to remove the remaining seal and glue
material.
Installation
1. Clean the mounting surface for the door seal.
The surface must be free of dirt and oil. Apply
weatherstrip adhesive onto the area where the
seal is to installed.
2. Install seal (3, Figure 22) so that the corners of
the seal fit up into the corners of the door frame.
NOTE: Repeat the previous steps for replacement of
door hinge seal (2, Figure 23).
FIGURE 2-22.
1. Door Opening Seal
Removal
1. Starting at the lower center of the door opening,
pull up on one end of the seal. Remove the seal
from the opening.
Installation
1. Inspect the cab opening lip for damage, dirt, or
oil. Clean and repair the cab opening as necessary. Remove any dirt and adhesive. Verify the
opening is clean and free of burrs.
2. Install the seal around the door opening in the
cab. Start at the bottom center of the cab opening and work the seal lip over the edge of the
opening. Verify the seal fits tightly in the corners. A soft face tool may be used to work the
seal up into the corners.
3. Continue working all the around the opening.
When the ends of the seal meet at the starting
bottom center of the cab opening, it may be
necessary to trim off some of the seal.
NOTE: The ends of the seal must be square-cut to
ensure a proper fit.
FIGURE 2-23.
1. Door Opening Seal
N02022 10/11
Operator Cab
N2-15
GLASS REPLACEMENT
Replacement
Recommended Tools
Pneumatic knife
Heavy protective gloves
The first concern with all glass replacement is
safety! Wear heavy protective gloves and safety
goggles when working with glass.
Safety goggles
Glazing adhesive & application gun
SM2897 glass installation spacers
(quantity varies per window)
Window glass (Refer to Parts Catalog)
Recommended adhesives:
SikaTack Ultrafast or Ultrafast II (both heated).
The vehicle can be put into service after four
hours in optimum conditions. Heated adhesives
require a Sika approved oven to heat adhesive to
80 C (176 F).
Sikaflex 255FC or Drive (unheated). The vehicle
can be put into service after eight hours in
optimum conditions.
Sika Corporation
30800 Stephenson Hwy.
Madison Heights, MI 48071
Toll Free Number: 1-800-688-7452
Fax number: 248-616-7452
http://www.sika.com or
http://www.sikasolutions.com
N2-16
Operator Cab
10/11 N02022
N02022 10/11
Operator Cab
3. Weatherstrip
4. Sheet Metal
N2-17
Installation
1. If the weatherstrip that was previously removed
is broken, weathered, or damaged in any way,
install a new rubber weatherstrip.
N2-18
Operator Cab
3. Weatherstrip
4. Sheet Metal
10/11 N02022
SECTION N3
CAB COMPONENTS
INDEX
N03028 2/09
Cab Components
N3-1
NOTES
N3-2
Cab Components
2/09 N03028
CAB COMPONENTS
WIPER MOTOR
The windshield wipers are operated by a 24 volt
electric motor. The wipers can be adjusted for a
variable intermittent delay or a constant low or high
speed by the switch mounted on the turn signal lever.
Removal
Installation
1. Place wiper motor (1, Figure 3-1) into position
on plate (5).
2. Install three capscrews (6) with flat washers (7)
and lockwashers (8). Tighten the capscrews to
8 - 9 Nm (71 - 79 lb in.).
3. Align the motor output shaft with linkage (9).
Install nut (10) while holding the linkage
stationary. Tighten the nut to 22 - 24 Nm (16 18 ft. lbs.).
4. Reconnect the wiper motor harness connector.
5. Verify that the wipers operate properly and park
in the proper position. Refer to Figure 3-3.
N03028 2/09
6. Capscrew
7. Flat Washer
8. Lockwasher
9. Linkage
10. Nut
Cab Components
N3-3
WIPER ARM
Removal
1. Note the parked position of wiper arm (1, Figure
3-2).
2. Lift the wiper arm cover and remove nut (2) and
spring washer (3).
3. Disconnect washer hose (9, Figure 3-3), and
remove the wiper arm.
5. Flat Washer
6. Wiper Arm
7. Nozzle
8. Retainer
9. Hose
Installation
1. Place wiper arm (1, Figure 3-2) into the parked
position that was noted during removal. Install
spring washer (3) and nut (2). Tighten the nut to
16 - 20 Nm (142 - 177 lb in.). Close the cover.
2. Connect washer hose (9, Figure 3-3) to wiper
arm (6).
3. Verify that the wiper arms operate properly and
park in the proper position after installation is
complete. Refer to Figure 3-3.
N3-4
Cab Components
2/09 N03028
WIPER LINKAGE
WINDSHIELD WASHER
Removal
Operation
with
Installation
1. Place the wiper assembly into position in the
wiper compartment.
N03028 2/09
Cab Components
3. Outlet Hose
4. Filler Cap
N3-5
OPERATOR SEAT
N3-6
Cab Components
2/09 N03028
Seat Removal
1. Remove mounting hardware (10, Figure 3-5)
that secures the seat base to the riser. Remove
mounting hardware (11) that secures the tether
to the floor.
2. Remove the seat assembly from cab.
Seat Installation
1. Mount the seat assembly to the riser. Install
mounting hardware (10, Figure 3-5). Tighten
the capscrews to standard torque.
2. Fasten the tether straps to the floor with
mounting hardware (11). Tighten the capscrews
to the standard torque.
N03028 2/09
Cab Components
N3-7
NOTES
N3-8
Cab Components
2/09 N03028
SECTION N4
HEATING AND AIR CONDITIONING
INDEX
HEATER/AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
HEATER/AIR CONDITIONER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3
Fan Speed Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Flow Directional Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N4-3
N4-3
N4-3
N4-4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Motor And Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N4-4
N4-4
N4-4
N4-5
N4-5
N4-5
N4-10
N4-10
N4-10
N4-10
N4-11
N4-11
N4-11
N04038 10/11
N4-15
N4-15
N4-16
N4-16
N4-17
N4-18
N4-18
N4-1
N4-2
10/11
N04038
4. Red Zone
5. Air Flow Directional
Knob
6. Vents
N04038 10/11
N4-3
COMPONENTS
Figure 4-2 and Figure 4-4 illustrate both the heater
system and air conditioning system parts contained
in the cab mounted enclosure. Refer to the air conditioning system topics later in this section for additional information regarding air conditioning system
components, maintenance and repair.
Relays
Three relays (8, Figure 4-2) control the damper
doors, A/C compressor clutch, temperature control
switch, water (heater) valve and the actuator motors.
Heater Core
Heater core (2, Figure 4-4) receives engine coolant
through water valve (33) when heat is selected. If
temperature control knob (2, Figure 4-1) is placed in
between the red and blue area, or turned counterclockwise to the blue area, coolant flow will be
blocked.
If temperature control knob (2) and water valve (33,
Figure 4-4) appear to be working properly, yet no
heat is apparent in heater core (2), the core may be
restricted. Remove and clean or replace the core.
Fuse
Before attempting to troubleshoot the electrical circuit
in the heater enclosure, turn the key switch ON and
verify that the fuse is good. The fuse is designated as
fuse 1 and is located in fuse panel 3 in the rear electrical compartment. Refer to the electrical schematic
for more detailed information.
N4-4
10/11
N04038
Recirculation air filter (5, Figure 4-4) and fresh air filter (2, Figure 4-3) in the front access panel of the cab
need periodic cleaning to prevent restrictions in air
circulation. Restricted filters will decrease the performance of the heater and air conditioner. The recommended interval for cleaning and inspection is 250
hours, but in extremely dusty conditions the filters
may need daily service and inspection, especially the
outer panel filter on the cab shell. The filter elements
should be cleaned with water and dried in a dust free
environment before reinstallation. Replace the filter
element every 2000 hours, or sooner if inspection
indicates a clogged or damaged filter.
Actuators
Two rotary actuator motors (9, Figure 4-4) are
installed inside the heater housing and are used to
actuate the damper doors for the following:
Defroster outlet
N04038 10/11
2. Cab Filter
N4-5
N4-6
10. Louver
11. Thermostat
12. LH Seal
13. Front Seal
14. Top Seal
15. Screw
16. Screw
17. Cover
18. Knob
19. Seal
20. Foam
21. Foam
22. Bracket
23. Case
24. Bracket
25. Control Panel Harness
26. Main Unit Harness
27. Seal
28. Screw
29. Screw
30. Bulb
31. Pivot Bushing
10/11
N04038
N04038 10/11
7. Evaporator
8. Expansion Valve
9. Suction Line
10. Test Gauges & Manifold
11. Compressor
12. Refrigerant Container
N4-7
The general cleanliness of the system and components is important. Dust or dirt collected in the condenser, evaporator, or air filters decreases the
system's cooling capacity.
The compressor, condenser, evaporator units, hoses
and fittings must be installed clean and tight and be
capable of withstanding the strain and abuse they
are subjected to on off-highway vehicles.
Equipment downtime costs are high enough to
encourage service areas to perform preventative
maintenance at regular intervals on vehicle Air Conditioning (A/C) systems. (Cleaning, checking belt
tightness, and operation of electrical components).
PRINCIPLES OF REFRIGERATION
A brief review of the principles of air conditioning is
necessary to relate the function of the components,
the technique of troubleshooting and the corrective
action necessary to put the A/C unit into top operating efficiency.
Too frequently, the operator and the serviceman
overlook the primary fact that no A/C system will
function properly unless it is operated within a completely controlled cab environment. The circulation of
air must be a directed flow. The cab must be sealed
against seepage of ambient air. The cab interior must
be kept free of dust and dirt which, if picked up in the
air system, will clog the intake side of the evaporator
coil.
N4-8
Air Conditioning
Air conditioning is a form of environmental control. As
applied to the cab, it refers to the control of temperature, humidity, cleanliness, and circulation of air. In
the broad sense, a heating unit is as much an air
conditioner as is a cooling unit. The term air conditioner is commonly used to identify an air cooling
unit. To be consistent with common usage, the term
air conditioner will refer to the cooling unit utilizing
the principles of refrigeration; sometimes referred to
as the evaporator unit.
10/11
N04038
This simplified explanation of the principles of refrigeration does not call attention to the fine points of
refrigeration technology. Some of these will be covered in the following discussions of the components,
controls, and techniques involved in preparing the
unit for efficient operation.
The compressor (refrigerant pump) takes in low pressure heat laden refrigerant gas through the suction
valve (low side), and as its name indicates, pressurizes the heat laden refrigerant and forces it through
the discharge valve (high side) on to the condenser.
N04038 10/11
N4-9
Service Valves
Quick-connect hose end fittings with integral service
valves attach to system service ports for servicing
the unit. A manifold gauge set is connected into the
system at the service valve ports and all procedures,
such as discharging, evacuating and charging the
system, are performed through the service valves.
Condenser
The condenser receives the high pressure, high-temperature refrigerant vapor from the compressor and
condenses it to high pressure, hot liquid.
It is designed to allow heat movement from the hot
refrigerant vapor to the cooler outside air. The cooling of the refrigerant changes the vapor to liquid.
Heat exchange is accomplished using cooler air flowing through the condenser. Condenser cooling is
achieved by air flowing from the radiator fan along
with ram air provided by vehicle movement. The radiator fan moves more than 50% of condenser air flow
unless travel speed is at least 25 mph.
N4-10
Ram air condensers depend upon the vehicle movement to force a large volume of air past the fins and
tubes of the condenser. The condenser is usually
located in front of the radiator or on the roof of the
truck.
Condensing of the refrigerant is the change of state
of the refrigerant from a vapor to a liquid. The action
is affected by the pressure of the refrigerant in the
coil and air flow through the condenser. Condensing
pressure in an A/C system is the controlled pressure
of the refrigerant which affects the temperature at
which it condenses to liquid, giving off large quantities of heat in the process. The condensing point is
sufficiently high to create a wide temperature differential between the hot refrigerant vapor and the air
passing over the condenser fins and tubes. This difference permits rapid heat transfer from the refrigerant to ambient air.
Receiver-Drier
The receiver-drier is an important part of the air conditioning system. The drier receives the liquid refrigerant from the condenser and removes any moisture
and foreign matter present which may have entered
the system. The receiver section of the tank is
designed to store extra refrigerant until it is needed
by the evaporator. The storage of this refrigerant is
temporary and is dependent on the demand of the
expansion valve.
A desiccant is a solid substance capable of removing
moisture from gas, liquid or solid. It is held in place
within the receiver between two screens, which also
act as strainers.
The receiver-drier is also equipped with a sight glass
and a moisture indicator. The sight glass can give a
good indication of the charge of the system. If the
sight glass is not clear, the system is low on refrigerant.
The moisture indicator is a device to notify service
personnel that the drier is full of moisture and must
be replaced. The indicator is blue when the component is free from moisture. When the indicator turns
beige or tan, the drier must be replaced.
10/11
N04038
Accumulator
As the accumulator receives vaporized refrigerant
from the evaporator, moisture and/or any residual liquid refrigerant is collected at the bottom of the component. The moisture is absorbed by the desiccant
where it is safely isolated from the rest of the system.
N04038 10/11
Evaporator
The evaporator cools and dehumidifies the air before
it enters the cab. Cooling a large area requires that
large volumes of air be passed through the evaporator coil for heat exchange. Therefore, a blower
becomes a vital part of the evaporator assembly. It
not only draws heat laden air into the evaporator, but
also forces this air over the evaporator fins and coils
where the heat is surrendered to the refrigerant. The
blower forces the cooled air out of the evaporator into
the cab.
Heat exchange, as explained under condenser operation, depends upon a temperature differential of the
air and the refrigerant. The greater the temperature
differential, the greater will be the amount of heat
exchanged between the air and the refrigerant. A
high heat load condition, as is generally encountered
when the air conditioning system is turned on, will
allow rapid heat transfer between the air and the
cooler refrigerant.
The change of state of the refrigerant in and going
through the evaporator coil is as important as that of
the air flow over the coil.
All or most of the liquid that did not change to vapor
in the expansion valve or connecting tubes boils
(expands) and vaporizes immediately in the evaporator, becoming very cold. As the process of heat loss
from the air to the evaporator coil surface is taking
place, any moisture (humidity) in the air condenses
on the cool outside surface of the evaporator coil and
is drained off as water.
At atmospheric pressure, refrigerant boils at a point
lower than water freezes. Therefore, the temperature
in the evaporator must be controlled so that the water
collecting on the coil surface does not freeze on and
between the fins and restrict air flow. The evaporator
temperature is controlled through pressure inside the
evaporator, and temperature and pressure at the outlet of the evaporator.
N4-11
ELECTRICAL CIRCUIT
Compressor Clutch
Thermostat
An electromagnetic clutch is used on the compressor
to provide a means of constant temperature control
of the cab. The clutch is controlled by a thermostat in
the evaporator which is set initially by the driver to a
predetermined point. Evaporator temperature is then
maintained by the cycling action of the clutch.
The thermostat is simply a thermal device which controls an electrical switch. When warm, the switch is
closed; when cold, it is open. Most thermostats have
a positive OFF position as a means to turn the clutch
off regardless of temperature.
The bellows type thermostat has a capillary tube connected to it which is filled with refrigerant. The capillary tube is attached to the bellows inside of the
thermostat. Expansion of the gases inside the capillary tube exerts pressure on the bellows, which in
turn closes the contacts at a predetermined temperature.
N4-12
10/11
N04038
Trinary Switch
This switch is mounted on the receiver-drier and has
three functions, as implied by the name:
1. Disengage the compressor clutch when system
pressure is too high.
2. Disengage the compressor clutch when system
pressure is too low.
3. Engage and disengage the radiator fan drive
clutch during normal variation of system pressure.
The Trinary switch performs three distinct functions to monitor and control refrigerant pressure in
the system. This switch is installed on the receiverdrier. The switch functions are:
Terminals 1 & 2 are connected internally through
two, normally closed pressure switches in series, the
low pressure switch and the high pressure switch.
CLOSES
Low
Pressure
103-207 kPa
(15-30 psi)
descending
pressure
276 kPa
(40 psi)
rising pressure
High
Pressure
2068-2413 kPa
(300-350 psi)
1448-1724 kPa
(210-250 psi)
241-414 kPa
(35-60 psi)
below closing
pressure
1379-1586 kPa
(200-230 psi)
rising pressure
Fan Clutch
The pressures listed above are typical of pressures at the receiver-drier. Due to normal system
flow losses and the distance between the service
port and the receiver-drier, it is expected that
actual system pressure displayed on the gauge
will normally be approximately 20 psi higher. This
factor should be observed when checking for
proper operation of the switch.
Terminals 3 & 4 are connected internally through a
normally open switch that is used to control the
clutch that drives the radiator fan. This switch closes
and causes the cooling fan clutch to engage when
system pressure rises to 1379-1586 kPa (200-230
psi). When pressure falls to 965-1344 kPa (140-195
psi), the switch contacts open, and the cooling fan
clutch disengages.
Low Pressure - This switch opens and
disengages the compressor clutch if system
pressure drops into the 103-207 kPa (15-30 psi)
range. When pressure rises above 276 kPa (40
psi), the switch contacts close, and the clutch
engages the compressor. Since temperature has
a direct effect on pressure, if the ambient
temperature is too cold, system pressure will
drop below the low range, and the pressure
switch will disengage the clutch.
N04038 10/11
N4-13
SYSTEM SERVICING
Servicing an air conditioning system really means
closely monitoring refrigerant flow. For this reason,
the following procedures deal extensively with the
proper use, handling, care and safety factors
involved in the R-134a refrigerant quality and quantity in an air conditioning system.
Because the refrigerant in an air conditioning system
must remain pressurized and sealed within the unit to
function properly, safety is a major consideration
when anything causes this pressurized, sealed condition to change. The following warnings are provided here to alert service personnel to their
importance before learning the correct procedures.
Read, remember, and observe each warning before
beginning actual system servicing.
NOTE: If the mine operates a fleet with some trucks
using R-12 and others using R-134a refrigerant, it is
essential that servicing tools that come into contact
with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one
type refrigerant only, to prevent cross contamination.
Ensure sufficient ventilation whenever refrigerant is being discharged from a system, keeping
in mind refrigerant is heavier than air and will fall
to low-lying areas.
When exposed to flames or sparks, the components of refrigerant change and become deadly
phosgene gas. This poison gas will damage the
respiratory system if inhaled. NEVER smoke in
an area where refrigerant is used or stored.
Never direct a steam cleaning hose or torch in
direct contact with components in the air conditioning system. Localized heat can raise the
pressure to a dangerous level.
Do not heat or store refrigerant containers above
49 C (120 F).
Do not flush or pressure test the system using
shop air or another compressed air source. Certain mixtures of air and R-134a refrigerant are
combustible when slightly pressurized. Shop air
supplies also contain moisture and other contaminants that could damage system components.
N4-14
10/11
N04038
To accomplish this, the recovery/recycle station separates the oil from the refrigerant and filters the
refrigerant multiple times to reduce moisture, acidity,
and particulate matter found in a used refrigerant.
Leak Detector
The electronic detector (Figure 4-7) is very accurate
and safe. It is a small hand-held device with a flexible
probe used to seek refrigerant leaks. A buzzer, alarm
or light will announce the presence of even the smallest leak.
Some leak detectors are only applicable to one type
of refrigerant. Ensure the leak detector being used
applies to the refrigerant in the system.
N04038 10/11
N4-15
3. Service Hose
nection
Co
Vacuum Pump
Service Valves
Because an air conditioning system is a sealed system, two service valves are provided on the compressor to enable diagnostic tests, system charging
or evacuation. Connecting the applicable hoses from
the manifold gauge set to the compressor service
valves enables each of these to be readily performed.
N4-16
10/11
N04038
N04038 10/11
N4-17
Shut off engine. DO NOT attempt to connect service equipment when the engine is running.
4. Connect the two service hoses from the manifold to the correct service valves on the compressor and accumulator, as shown in Figure 411. (High side to compressor discharge valve
and low side to accumulator.) Do not open the
service valves at this time.
N4-18
10/11
N04038
10. Check the cab vents for cool air. Outlet air temperature should be approximately 16 - 22 C
(30 - 40 F) below ambient air temperature.
11. If pressures and temperatures are not within the
specified ranges, the system is not operating
properly. Refer to Preliminary Checks near the
end of this chapter for tips on diagnosing poor
system performance.
21 C (70 F)
27 C (80 F)
32 C (90 F)
38 C (100 F)
43 C (110 F)
NOTE: All pressures in this chart are for reference, only. Weight is the only absolute means of
determining proper refrigerant charge.
N04038 10/11
N4-19
SYSTEM OIL
Oil Quantity
It is critical to keep the correct amount of lubricant in
the air conditioning system at all times. Failure to do
so could result in damage to the compressor.
Damage to the compressor can be a result from not
only a lack of oil, but from too much oil, also. A lack
of oil will cause excess friction and wear on moving
parts. Excessive oil can result in slugging the compressor. This condition occurs when the compressor
attempts to compress liquid oil as opposed to vaporized refrigerant. Since liquid cannot be compressed,
damage to internal parts results.
Under no circumstances should the A/C compressor be stood upright onto the clutch assembly. Damage to the compressor clutch will result,
leading to premature compressor failures.
2. Inspect the oil for any foreign particles. If particles are found, further investigation and service
are necessary to determine the source. After
repair, the system will need to be flushed. Refer
to System Flushing. If no particles are found,
proceed to the next step.
3. Add 207 ml (7oz.) of PAG oil to the compressor
sump. Add the oil through the drain port, and
install the drain plug. It is important to only add
the specified amount to ensure optimal system
performance. Too much oil will result in a reduction in cooling. Too little oil will result in compressor failure.
4. Determine the correct amount of additional oil
to add to the system by using the Replacing Oil
listed in Table 2. Add this extra oil to the inlet
side of the receiver drier or accumulator.
NOTE: If truck is being assembled for the first time,
add 207 ml (7oz.) of PAG oil to the inlet side of the
receiver-drier or to the accumulator.
EXAMPLE - If only the accumulator and receiver
drier were replaced, then add 120 ml (4 oz.) of PAG
oil to the inlet side of the receiver-drier or to the accumulator. If the evaporator was also replaced at this
time, then add 150 ml (5 oz.) of PAG oil to the inlet
side of the receiver-drier or to the accumulator.
NOTE: The proper quantity of oil may be injected into
the system during charging as an alternate method of
adding oil.
N4-20
10/11
N04038
REFRIGERANT
Recycled Refrigerant
When installing a new compressor, the compressor must be completely drained of its oil before
installation. Add 207 ml (7 oz.) of new PAG oil to
the compressor to ensure proper system oil
level. Failure to adjust the amount of oil in the
compressor will lead to excessive system oil and
poor A/C performance. Additionally, a new
receiver-drier and accumulator must be installed
and oil added to both of these components.
Component
Oil to add
Condenser
Evaporator
30 ml (1 ounce)
Receiver-Drier
60 ml (2 ounces)
Accumulator
60 ml (2 ounces)
Compressor
207 ml (7 ounces)
Block Valve
(Expansion)
Hoses
5. Connect all hoses and components in the system. Lubricate O-Rings with clean mineral oil
before assembly.
NOTE: Do not use PAG oil to lubricate O-Rings or
fittings. PAG oil will attract moisture and will corrode
fittings when used externally. Use only clean mineral
oil to lubricate fittings and O-Rings during assembly.
6. Evacuate the system. Refer to Evacuating The
System.
N04038 10/11
Always use new, recycled, or reclaimed refrigerant when charging a system. Failure to adhere to
this recommendation may result in premature
wear or damage to air conditioning system components and poor cooling performance.
Refrigerant Quantity
If not enough refrigerant is charged into the system,
cooling ability will be diminished. If too much refrigerant is charged into the system, the system will operate at higher pressures, and in some cases, may
damage system components. Exceeding the specified refrigerant charge will not provide better cooling.
N4-21
N4-22
2. 28 kg (60 lb)
Cylinder
10/11
N04038
Tracer Dyes
Tracer dyes are available that can be added to the
system as refrigerant is added. The system is then
operated to thoroughly circulate the dye. As refrigerant escapes, it leaves a trace of the dye at the point
of leakage, which is then detected using an ultraviolet light (black light), revealing a bright fluorescent
glow.
N04038 10/11
N4-23
System Flushing
If any contaminants are found in system hoses, components or oil, the entire system must be flushed.
Major components such as the compressor are
extremely susceptible to foreign particles and must
be replaced. If contaminated, the evaporator and
condenser must also be replaced. The evaporator
and condenser are multi-pass units, and they can not
be properly cleaned by flushing.
SYSTEM REPAIR
The following service and repair procedures are not
any different than typical vehicle service work. However, A/C system components are made of soft metals (copper, aluminum, brass, etc.). Comments and
tips that follow will make the job easier and reduce
unnecessary component replacement.
N4-24
10/11
N04038
N04038 10/11
N4-25
2. Drive Pulley
3. Alignment Tool
N4-26
10/11
N04038
COMPONENT REPLACEMENT
Hoses and Fittings
Receiver-Drier
Lines
Always use two wrenches when disconnecting or
connecting A/C fittings attached to metal lines. Copper and aluminum tubing can kink or break very easily. When grommets or clamps are used to prevent
line vibration, be certain these are in place and
secure.
NOTE: Do not use PAG oil to lubricate O-Rings or fittings. PAG oil will attract moisture and will corrode fittings when used externally. Use only clean mineral
oil to lubricate fittings and O-Rings during assembly.
Thermostat
Fitting Size
Foot Pounds
Newton Meters
10 - 15 ft.lb
14 - 20 Nm
24 - 29 ft.lb
33 - 39 Nm
10
26 - 31 ft.lb
36 - 42 Nm
12
30 - 35 ft.lb
41 - 47 Nm
Expansion Valve
When removing the expansion valve from the system, remove the insulation, clean the area and disconnect the line from the receiver-drier. Detach the
capillary (bulb) and external equalizer tube (if present) from their mounting locations. Remove the
expansion valve from the evaporator inlet. Expansion
valve service is limited to cleaning or replacing the filter screen. If this is not the problem, replace the
valve. Secure the capillary and equalizer, if used, to
clean surfaces and replace or attach any insulating
material.
N04038 10/11
A thermostat can be stuck open or closed due to contact point wear or fusion. The thermostat temperature
sensing element (capillary tube) may be broken or
kinked closed and therefore unable to sense evaporator temperature.
When thermostat contact points are stuck open or
the sensing element can not sense temperature in
the evaporator, the clutch will not engage (no A/C
system operation). Causes are a loss of charge in
the capillary tube or a kink, burned thermostat contact or just no contact. When troubleshooting, bypass
the thermostat by hot wiring the clutch coil with a
fused lead. If the clutch engages, replace the thermostat.
Thermostat contact points may be fused (burned)
closed and the clutch will not disengage. Causes are
a faulty switch that could be due to fatigue. The thermostat must be replaced. When the clutch will not
disengage you may also note that condensate has
frozen on the evaporator fins and blocked air flow.
There will also be below normal pressure on the low
side of the system. Side effects can be compressor
damage caused by oil accumulation (refrigeration oil
tends to accumulate at the coldest spot inside the
system) and lower than normal suction pressure that
can starve the compressor of oil.
N4-27
Compressor
The compressor can fail due to shaft seal leaks (no
refrigerant in the system), defective valve plates,
bearings, or other internal parts or problems associated with high or low pressure, heat, or lack of lubrication. Be sure the compressor is securely mounted
and the clutch pulley is properly aligned with the
drive pulley.
Use a mechanic's stethoscope to listen for noises
inside the compressor.
When installing a new compressor, the compressor must be completely drained of its oil before
installation. Add 207 ml (7 oz.) of new PAG oil to
the compressor to ensure proper system oil
level. Failure to adjust the amount of oil in the
compressor will lead to excessive system oil and
poor A/C performance.
Under no circumstances should the A/C compressor be stood upright onto the clutch assembly. Damage to the compressor clutch will result,
leading to premature compressor failures.
Accumulator
The accumulator can not be serviced or repaired. It
must be replaced whenever the system is opened for
any service.
Clutch
Clutch problems include electrical failure in the clutch
coil or lead wire, clutch pulley bearing failure, worn or
warped clutch plate or loss of clutch plate spring temper. Defective clutch assembly parts may be
replaced or the whole assembly replaced. If the
clutch shows obvious signs of excessive heat damage, replace the whole assembly.
The fast way to check electrical failure in the lead
wire or clutch coil is to hot wire the coil with a fused
lead. This procedure enables you to bypass clutch
circuit control devices.
N4-28
10/11
N04038
**J-9403
Spanner Wrench
**J-25030
J-9401
J-8433
Pulley Puller
J-9395
Puller Pilot
***J-24092
Puller Legs
J-8092
Universal Handle
J-9481
J-9480-01
J-9480-02
FIGURE 4-17.
1. Belt Pulley
2. Clutch Hub/Drive Plate
3. Shaft
4. Locknut
N04038 10/11
N4-29
FIGURE 4-19.
1. Clutch Assembly
FIGURE 4-18.
1. Thin Wall Socket
2. Clutch Hub Holding Tool
3. Clutch Hub
FIGURE 4-20.
1. Square Key
N4-30
2. Keyway in Shaft
10/11
N04038
Pulley Removal
8. Use retaining ring pliers (3, Figure 4-22) to
remove pulley retainer ring (2) from pulley (1).
FIGURE 4-21.
1. Clutch Hub
2. Pulley
1. Pulley Puller
2. Pulley Assembly
N04038 10/11
FIGURE 4-23.
3. Puller Pilot
N4-31
Pulley Installation
FIGURE 4-24.
1. Bearing Installer
2. Universal Handle
FIGURE 4-25.
1. Drive Plate Installer
N4-32
2. Spacer
10/11
N04038
N04038 10/11
N4-33
Using a pump to create a vacuum in the air conditioning system effectively vaporizes any moisture, allowing the water vapor to be easily drawn out by the
pump. The pump does this by reducing the point at
which water boils (100C, 212F at sea level with
14.7 psi). In a vacuum, water will boil at a lower temperature depending upon how much of a vacuum is
created.
As an example, if the ambient air outside the truck is
24C (75F) at sea level, by creating a vacuum in the
system so that the pressure is below that of the outside air (in this case, at least 749.3 mm (29.5 in.) of
vacuum is needed), the boiling point of water will be
lowered to 22C (72F). Thus any moisture in the
system will vaporize and be drawn out by the pump if
the pump is run for approximately an hour. The following steps indicate the proper procedure for evacuating all moisture from the heavy duty air conditioning
systems.
N4-34
10/11
N04038
Optimal Vacuum
76.0 (29.92)
305 (1000)
73.5 (28.92)
610 (2000)
70.7 (27.82)
914 (3000)
68.1 (26.82)
1219 (4000)
65.6 (25.82)
1524 (5000)
63.3 (24.92)
1829 (6000)
60.8 (23.92)
2134 (7000)
58.5 (23.02)
2438 (8000)
56.4 (22.22)
2743 (9000)
54.2 (21.32)
NOTE: The chart indicates the expected gauge readings at altitude to obtain the optimal
vacuum.
N04038 10/11
N4-35
1. Charge the A/C system with 3.4 kg (7.4 lb) of R134a refrigerant.
NOTE: Charging is to be performed with the engine
and compressor operating. Charge the A/C system
through the low side service port. Trucks equipped
with accumulators may charge the refrigerant as a
liquid or as a vapor.
2. Check the system for leaks. Refer to System
Leak Testing.
3. If no leaks are found, verify the systems cooling
capacity meets requirements. Refer to System
Performance Testing.
N4-36
10/11
N04038
TROUBLESHOOTING
Preliminary Checks
If the system indicates insufficient cooling, or no cooling, the following points should be checked before
proceeding with the system diagnosis procedures.
NOTE: If the truck being serviced is a model 830EAC or a 930E, be certain the rest switch in the cab is
ON. Place the GF cutout switch in the CUTOUT
position.
Some simple, but effective checks can be performed
to help determine the cause of poor system performance. Check the following to ensure proper system
operation.
Compressor belt - Must be tight, and aligned.
Compressor clutch - The clutch must engage. If it
does not, check fuses, wiring, and switches.
Oil leaks - Inspect all connection or components
for refrigeration oil leaks (especially in the area of
the compressor shaft). A leak indicates a
refrigerant leak.
Electrical check - Check all wires and
connections for possible open circuits or shorts.
Check all system fuses.
Cooling system - Check for correct cooling
system operation. Inspect the radiator hoses,
heater hoses, clamps, belts, water pump,
thermostat and radiator for condition or proper
operation.
Radiator shutters - Inspect for correct operation
and controls, if equipped.
Fan and shroud - Check for proper operation of
fan clutch. Check installation of fan and shroud.
N04038 10/11
N4-37
N4-38
10/11
N04038
Possible Causes
- Extremely low or no refrigerant in the system.
Possible leak in the system.
N04038 10/11
N4-39
- Leaks in system.
N4-40
10/11
N04038
Possible Causes
Kink in a line, collapsed hose liners, plugged
receiver-drier or condenser, etc.
N04038 10/11
N4-41
Possible Causes
N4-42
10/11
N04038
Possible Causes
N04038 10/11
N4-43
Date:____________Hour Meter:________________
Maintenance Interval
COMPONENT
(months)
3
12
Maintenance Interval
Done
COMPONENT
1. Compressor
Check noise level
Check clutch pulley
Check oil level
Run system 5 minutes
Check belt tension
(80-100) lb; V-belt
3
5. Expansion Valve
2. Condenser
Clean dirt, bugs, leaves, etc.
from coils (w/compressed air)
Verify engine fan clutch is
engaging (if installed)
Check inlet/outlet for
obstructions or damage
3. Receiver-Drier
12
Done
6. Evaporator
Clean dirt, bugs, leaves, etc.
from fins (w/ compressed air)
(months)
7. Other Components
Check discharge lines
(hot to touch)
Check suction lines
(cold to touch)
Inspect fittings/clamps/hoses
Check thermostatic switch for
proper operation
Outlets in cab: 40F to 50 F
Inspect all wiring connections
Operate all manual controls
through full functions
N4-44
10/11
N04038
SECTION N5
OPERATOR CAB AND CONTROLS
INDEX
N05077 06/10
N5-1
N5-2
06/10 N05077
N05077 06/10
N5-3
5. Multi-Function Turn
Signal Lever
6. Retarder Control
Lever
Multi-function turn signal switch (5) is used to activate the turn signal lights, the windshield wipers, and
to select either high or low beam headlights.
Turn Signal Operation
Move the lever upward to signal a right turn.
An indicator in the top, center
of the instrument panel will illuminate to indicate turn direction
selected. Refer to Instrument
Panel and Indicator Lights in
this section.
N5-4
06/10 N05077
b. When the lever is rotated "downward" (clockwise), it is in the ON/RETARD position. The
ON position encompasses a full range of
motion that allows a variable retarding effort
depending on the position of the lever. As the
lever is rotated further clockwise, more
retarding effort will be applied.
c. For long downhill hauls, the lever may be
positioned anywhere to provide the desired
retarding effort. The lever will remain where it
is positioned until moved. Refer to Retarder
Operation in the previous section for cautions when using the retarder on a downhill
grade.
N05077 06/10
N5-5
STEERING WHEEL
2. Install nut (2). Tighten the nut to 81 7 Nm (60
5 ft lb).
Removal
1. Turn off the battery disconnect switch to remove
battery power from the horn circuit.
2. Use a pocket screwdriver to pry horn button (4,
Figure 5-3) from steering wheel (1).
3. Disconnect horn wire (3) and set the horn button aside.
4. Remove nut (2).
Service brake pedal (3, Figure 5-1) is a single function, foot-operated pedal which controls and modulates service brake pressure directly through a
hydraulic valve.
ACCELERATOR PEDAL
Accelerator pedal (4, Figure 5-1) is a foot-operated
pedal which allows the operator to control engine
rpm, depending on pedal depression.
3. Horn Wire
4. Horn Button
The foot-operated treadle pedal contains an electronic sensor which sends signals to the Quantum
fuel control system. The movement of the fuel governor control arm corresponds directly to the travel of
the treadle pedal as it is applied by the operator.
When the pedal is released, springs return the control arm and the pedal to their rest positions and the
engine speed returns to low idle.
Installation
1. Place steering wheel (1, Figure 5-3) into position on the steering column shaft while guiding
horn wire (3) through the access hole in the
steering wheel. Align the marks on the steering
wheel and the shaft that were made during disassembly. Align the serrations and push the
steering wheel onto the shaft.
N5-6
INSTRUMENT PANEL
Instrument panel (5, Figure 5-1) includes a center
electronic display panel, and LH & RH switch panels
that contain a variety of switches.
Refer to Instrument Panel And Indicators later in this
section for a detailed description of the function and
location of each of these components.
06/10 N05077
RADIO SPEAKERS
Radio speakers (9, Figure 5-1) for the AM/FM stereo
radio are located at the far left and right of the overhead panel.
N05077 06/10
N5-7
CENTER CONSOLE
Center console (1, Figure 5-4) located to the right of
the operator seat, is a housing which provides a
mounting surface for certain operator controls. The
passenger seat is located directly to the right of the
console.
N5-8
06/10 N05077
N05077 06/10
N5-9
N5-10
06/10 N05077
N05077 06/10
N5-11
3. Hazard Flasher
Switch
F1 Start Switch
F1 start switch (2, Figure 5-6) is
used to ensure that the transmission starts in F1 when the transmission shift lever is in D. When
this switch is ON and the transmission shift lever is in the D position,
the transmission will shift to F1 to
start. When this switch is OFF and the shift lever is in
D, the transmission will start in second gear. Refer to
Transmission Shift Lever, D - DRIVE. All other forward gear ranges (L, F2, F3, F4, F5, F6) start out in
F1 regardless of the F1 start switch position.
Depressing the bottom of the switch moves the
switch to the ON position. Depressing the top moves
the switch to the OFF position.
N5-12
06/10 N05077
Key Switch
Key switch (1, Figure 5-7) is a four position (ACC,
OFF, RUN, START) switch.
OFF - Key insertion/withdrawal
position
When the key slot is in the vertical position, the electrical system is off and no electrical
devices are energized.
Use this key position to stop the
engine when it is operating.
ACC- When the key is rotated counterclockwise
from the OFF position, it is in the accessory
(ACC) position. This position is used to power
certain accessories such as the radio when
there is no intention of starting the engine.
N05077 06/10
4. ARSC Switch
5. AISS Switch
6. Auxiliary Brake Switch
N5-13
ARSC Switch
Ether Starting Aid Switch
Ether starting aid switch (2,
Figure 5-7) is an ON/OFF type
rocker switch that is spring-loaded
to the OFF position. This switch is
optional equipment.
When the outside temperature is
below
-5C (23F), depress
the top of this switch and hold for 2-3 seconds before
starting the engine. The cold starting aid atomizes
ether into the engine intake manifold.
Refer to Key Switch - START for further details
regarding the use of this switch.
N5-14
06/10 N05077
N05077 06/10
N5-15
N5-16
06/10 N05077
N05077 06/10
N5-17
Select, Run
N5-18
06/10 N05077
N05077 06/10
N5-19
N5-20
06/10 N05077
The shift lever pilot lamp displays the position of the shift lever.
The letter or number for the selected speed
range will be illuminated.
N05077 06/10
N5-21
METER DISPLAYS
Speedometer
4. Speedometer
5. Retarder Oil Temperature Gauge
6. Fuel Gauge
Engine Tachometer
N5-22
06/10 N05077
Fuel Gauge
The white range indicates normal operating temperature. If the temperature rises to the red range during
operation, the alarm buzzer will sound and the central warning lamp will illuminate. E02 TC OVERHEAT
will simultaneously be displayed on the character display. Stop the truck and operate the engine under no
load at a mid-range speed until the meter enters the
white range.
N05077 06/10
N5-23
CAUTION ITEMS
N5-24
06/10 N05077
N05077 06/10
N5-25
N5-26
06/10 N05077
N05077 06/10
N5-27
When the lamp is lit, E02 TC OVERHEAT will simultaneously be displayed on the character display. Stop
the truck in a safe place, and move the shift lever to
the N. Operate the engine under no load at a midrange speed until the lamp turns off.
N5-28
06/10 N05077
CHARACTER DISPLAY
2. Character Display
N05077 06/10
Operator mode
1
Operation Information
Refer to Section D, Machine Monitor, for more information on using the character display.
N5-29
CIRCUIT NUMBER
No.
AMPS
VOLTS
IN
CB24V
50
+24
CB12V
50
+12
CONTROL DESCRIPTION
OUT
LOCATION: BATTERY BOX
12
12V
N5-30
20
+24
12AC
06/10 N05077
N05077 06/10
N5-31
N5-32
06/10 N05077
When the ARSC is actuated on slippery road surfaces, the wheels may lock. If this occurs, turn
the ARSC system off and use the manual retard
lever or brakes to safely control the truck.
The ARSC system will only apply retarding effort
when the ARSC switch is on. If the switch is turned
off during retarding, the set speed indicator and
ARSC pilot lamp will turn off and the brakes will
release.
The ARSC will only apply retarding effort when the
accelerator pedal is not being depressed. If the
accelerator is pressed while the ARSC system is on,
the RCM will cancel the ARSC. The service brakes
and the retarder lever will both continue to function
while the ARSC system is on.
The retard lever is more responsive when the ARSC
system is on. Use small increments when moving the
lever to avoid locking the brakes.
N05077 06/10
N5-33
N5-34
06/10 N05077
N05077 06/10
N5-35
N5-36
4. Accelerator Pedal
5. Brake Pedal
6. Character Display
06/10 N05077
Depressing the top of the switch turns the ASR system off. An amber light will illuminate the switch notifying the operator that traction control is inactive.
N05077 06/10
N5-37
NOTES
N5-38
06/10 N05077
SECTION P
LUBRICATION AND SERVICE
INDEX
P01016
Index
P1-1
NOTES
P1-2
Index
P01016
SECTION P2
LUBRICATION AND SERVICE
INDEX
P02056 10/11
P2-1
NOTES
P2-2
10/11 P02056
Unacceptable Practices
Use of high-silicate anti-freeze.
Under concentration or over concentration of
Extended Service Additive (SCA).
Use of anti-freezes/coolants that are not fully
formulated for extended service intervals.
Use of sealing additives (stop-leak) in the cooling
system.
SERVICE CAPACITIES
Liters
US
Gallons
193
51
Cooling System
532
141
Hydraulic System
Refer to Hydraulic Tank Service in
this chapter
900
238
Differential Case
297
78
120
32
2120
560
Transmission Case
including torque converter
153
41
Engine Crankcase
(including lube oil filters)
COOLANT SPECIFICATIONS
For ambient temperatures of -25 F (-32 C) and
above, use a standard 50/50 anti-freeze-to-water
mixture.
For arctic climates with ambient temperatures
between -25 F (-32 C) and -65 F (-54 C), use
a 60/40 anti-freeze-to-water mixture.
NOTE: Do not use propylene glycol coolant in arctic
climates. Only use ethylene glycol coolants.
P02056 10/11
P2-3
Filling Instructions
1. Lower the dump body and turn the key switch
OFF.
P2-4
10/11 P02056
8. Accumulators
Refer to the following table for the maximum recomended fill pressures for the service center.
kPa
psi
Engine Crankcase
345
50
Hydraulic Tank
345
50
Coolant
345
50
Grease
10 342
1,500
P02056 10/11
P2-5
P2-6
10/11 P02056
COMMENTS
CHECKED INITIALS
P02056 10/11
P2-7
COMMENTS
CHECKED INITIALS
2. Air Cleaners
Check air cleaner vacuum gauges. Clean or replace
filter elements if restriction vacuum reaches 6.2 kPa
(25 in. H2O). Push the reset button on the face of the
gauge to return to zero.
3. Drive Belts
a. Check the condition of the alternator and fan
belts. Check for proper tension.
b. Inspect belt alignment.
5. Tires
a. Check for proper inflation and wear.
b. Inspect for embedded debris, cuts or other
damage.
P2-8
10/11 P02056
COMMENTS
CHECKED INITIALS
P02056 10/11
P2-9
COMMENTS
Air Conditioner Compressor Belt- Check the compressor belt for cracks, cuts or glazing. Check for
proper tension. Repair or adjust as necessary.
Fan Belt - Check the fan belt for cracks, cuts or glazing. Check for proper tension. Repair or adjust as
necessary.
Hydraulic Tank Breather - Remove breather, and disassemble. Remove the filter element and replace.
Reassemble and reinstall.
CHECKED INITIALS
P2-10
10/11 P02056
COMMENTS
CHECKED INITIALS
FIGURE 40-4.
1. Filter Cover
2. Cab Filter
P02056 10/11
P2-11
COMMENTS
P2-12
CHECKED INITIALS
10/11 P02056
COMMENTS
CHECKED INITIALS
Parking brake
-Manually lubricate the parking brake linkage at 6
points - Lube key D.
Steering, Brake, Hoist, & Rear Brake Cooling Oil Filters - Replace the filters.
P02056 10/11
P2-13
COMMENTS
CHECKED INITIALS
Hydraulic Tank Oil a. Drain the oil from the tank and refill. Capacity
of the hydraulic tank is 576 l (152 gal). Refer
to the lubrication chart for type of oil to use.
Lube key C.
b. Remove and clean hydraulic tank strainers.
Refer to Hydraulic Tank Service in this chapter for
proper filling instructions. Instructions
P2-14
10/11 P02056
COMMENTS
CHECKED INITIALS
P02056 10/11
P2-15
NOTES
P2-16
10/11 P02056
SECTION P3
AUTOMATIC LUBRICATION SYSTEM
INDEX
P03028 07/10
P3-1
NOTES
P3-2
07/10 P03028
7. Vent Valve
8. Pressure Gauge*
9. Pump Assembly
10. Flow Control Valve
11. Pressure Switch
12. Grease Reservoir
13. Vent Hose
P03028 07/10
P3-3
P3-4
07/10 P03028
P03028 07/10
P3-5
P3-6
Lube Group
Number of Injectors
07/10 P03028
SYSTEM COMPONENTS
Filter
Solenoid Valve
A filter assembly mounted on the grease reservoir filters the grease from the shop supply. A bypass indicator alerts service personnel when the filter requires
replacement.
Vent Valve
Vent valve (7, Figure 3-1) opens and closes to control the pressure in the system. With the valve
closed, the pump continues to operate until maximum grease pressure is achieved. As this occurs,
the vent valve opens and allows the grease pressure
to drop to 0, so the injectors can recharge for their
next output cycle.
Injectors
Each injector (Figure 3-2) delivers a controlled
amount of pressurized lubricant to a designated lube
point.
Grease Reservoir
Grease reservoir (12) has an approximate capacity
of 41 kg (90 lb) of grease. When the grease supply is
replenished, grease entering the system passes
through the filter to remove contaminants before settling into the reservoir.
P03028 07/10
Lubrication Timer
Lubrication timer (1, Figure 3-3) is a solid state controller providing a 24 VDC timed-interval signal to
energize solenoid valve (5, Figure 3-1). Operation of
the solenoid valve controls the oil flow to operate the
hydraulic motor. This controller is mounted in the
electrical compartment in the rear of the cab.
Pressure Gauge
Pressure gauge (8, Figure 3-1) monitors hydraulic oil
pressure to the inlet of the hydraulic motor.
NOTE: Newer models do not come equipped with a
pressure gauge. However, a gauge may be installed
in the port if desired.
P3-7
2. Indicator Light
P3-8
07/10 P03028
SYSTEM OPERATION
1. During truck operation, the lubrication controller
will energize the system at a preset time interval.
6. When the timing period is complete, the controller will remove the power from the pump solenoid valve.
P03028 07/10
P3-9
INJECTOR OPERATION
STAGE 1.
Injector piston (2) is in its normal or rest
position. Discharge chamber (3) is filled with
lubricant from the previous cycle. With pressure applied from incoming lubricant (6),
slide valve (5) is about to open passage (4)
leading to measuring chamber (1).
STAGE 2.
When slide valve (5) opens to passage (4),
lubricant (6) is admitted to measuring chamber (1). This forces lubricant from discharge
chamber (3) through outlet port (7) to the
lubrication destination.
STAGE 3.
As injector piston (2) completes its stroke, it
pushes slide valve (5) past passage (4). This
stops further admission of lubricant (6) to
passage (4) and measuring chamber (1).
Injector piston (2) and slide valve (5) remain
in this position until lubricant pressure in supply line (6) is vented.
STAGE 4.
After venting, the injector spring expands,
causing slide valve (5) to move. As the valve
moves, passage (4) and discharge chamber
(3) connect through valve port (8). Further
expansion of the spring causes the piston to
move upward. This forces the grease into
measuring chamber (1) through passage (4)
and valve port (8). Discharge chamber (3)
refills.
The injector is now ready for the next cycle.
P3-10
07/10 P03028
LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Check the oil level at
1000 hour intervals. To add oil, remove plug (4, Figure 3-6) and fill the housing to the bottom of the plug
hole. Newer models are equipped with a dipstick (3).
Remove the dipstick and add oil to the proper level.
Pump Pressure Control
High pressure hydraulic fluid from the truck steering
system is reduced to 2240 to 2413 kPa (325 to 350
psi) by pressure reducing valve (1). The reducing
valve is located on the manifold on top of the pump
motor. Operating pressure can be read on the gauge
installed on the manifold. Occasionally check the
gauge to verify pressure is within the specified range.
The pressure reducing valve is not adjustable. If
operating pressure is not within limits, the pressure
reducing valve must be replaced.
P03028 07/10
P3-11
Injector Adjustment
The injectors may be adjusted to supply from 0.13 cc
to 1.31 cc (0.008 in3 to 0.08 in3) of lubricant per injection cycle. The injector piston travel distance determines the amount of lubricant supplied. Piston travel
is controlled by an adjusting screw in the top of the
injector housing.
Turn adjusting screw (1, Figure 3-7) counterclockwise to increase injector output and clockwise to
decrease injector output.
When the injector is not pressurized, maximum injector delivery volume is attained by turning the adjusting screw (1) fully counterclockwise. Turn until the
indicating pin (8) just touches the adjusting screw. At
the maximum delivery point, about 9.7 mm (0.38 in.)
of adjusting screw threads will be exposed. Decrease
the delivered lubricant amount by turning the adjusting screw clockwise to limit injector piston travel. If
only half the lubricant is needed, turn the adjusting
screw to the point where about 4.8 mm (0.19 in.)
threads are exposed. The injector will be set at the
minimum delivery point with about 0.22 mm (0.009
in.) thread exposed.
P3-12
07/10 P03028
SYSTEM PRIMING
The system must be full of grease and free of air
pockets to function properly. After maintenance, if the
primary or secondary lubrication lines were replaced,
it will be necessary to prime the system to purge
entrapped air.
1. Fill the reservoir with lubricant, if necessary.
2. To purge air from the main supply line, remove
the main supply line at the reservoir and connect an external grease supply to the line.
3. Remove plugs from each injector group in
sequence (right front, left front, and rear axle).
4. Using the external grease source, pump grease
until it reaches the injector group. Install the
pipe plug and repeat for the remaining injector
groups.
5. Remove the caps from each injector. Connect
an external grease supply to the zerk on the
injector. Pump until grease reaches the far end
of the individual grease hose or the joint being
greased.
Filter Assembly
Replace element (5, Figure 3-8) if bypass indicator
(2) indicates excessive element restriction.
P03028 07/10
6. Spring
7. Bowl
8. O-Ring
9. Plug
P3-13
SYSTEM CHECK
To check system operation (not including timer), proceed as follows:
1. Start the engine.
2. Actuate the lube system test switch at the reservoir/pump assembly.
P3-14
07/10 P03028
P03028 07/10
3. Cover
P3-15
Symptom
Possible Causes
Corrective Action
Controller malfunction.
NOTE: Normally during operation, the injector indicator stem will move into the
body of the injector when pressure builds. When the system vents and releases
pressure, the indicator stem will again move out into the adjusting yoke.
Injector Indicator Stem
Does Not Operate
P3-16
07/10 P03028
Symptom
Pump Pressure Builds Very
Slowly Or Not At All
Possible Causes
Corrective Action
No signal at solenoid.
Check timer.
Bearing Points
Excessively Lubricated
P03028 07/10
P3-17
PREVENTATIVE MAINTENANCE
Use the following maintenance procedures to ensure
proper system operation.
Daily Lubrication System Inspection
1. Check grease reservoir level.
Inspect grease level height after each shift of
operation. Grease usage should be consistent
from day-to-day operations.
Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate a broken supply line.
2. Check filter bypass indicator when filling reservoir. Replace element if bypassing.
5. System Checkout
P3-18
07/10 P03028
P03028 07/10
P3-19
PUMP REBUILD
10. Remove the crankrod assembly (items 1
through 8) from the pump by unscrewing button
head screws (11) and pulling out wrist pin
bushings (12).
Be certain to bleed steering accumulators to
relieve hydraulic pressure and to relieve pump
outlet grease pressure before removing any
hoses or fittings.
Disassembly
1. Remove four socket head screws (32, Figure 310). Separate manifold (37) from hydraulic
motor (42).
2. Remove pipe plug (45) and drain the crankcase
oil from pump housing (46).
3. Remove six screws (28). Remove housing
cover (29) and cover gasket (30).
4. Remove inlet screen (60), retaining ring (57)
and pull shovel plug (56) from housing tube
(55).
5. Remove two socket head screws (44).
Separate hydraulic motor (42) from pump
housing (46).
6. Remove two outlet pin nuts (50) from the pump
housing.
7. Remove the pump subassembly (items 1
through 27) from the pump housing. Pushing
the subassembly up with a 19 mm (0.75 in.)
diameter wooden or plastic rod against check
seat housing (27) is helpful.
P3-20
07/10 P03028
P03028 07/10
49. O-Ring
50. Outlet Pin Nut
51. Bronze Bearing
52. O-Ring
53. Backup Washer
54. O-Ring
55. Housing Tube
56. Shovel Plug
57. Retaining Ring
58. Orifice Fitting
59. Gasket
60. Inlet Strainer
P3-21
P3-22
07/10 P03028
Crankrod (4)
Assembly
Note: Use Loctite 242 (or equivalent) thread locker
on all torqued, threaded connections. Use extreme
care to prevent thread locker from flowing into
adjacent areas such as clearance fits and ball check.
Allow a minimum of 30 minutes cure time before
operating pump.
1. Support ball bearing (7, Figure 3-10) inner race
and press crank eccentric (6) into the bore.
Install small retaining rings (5).
2. Assemble the ball bearing assembly, large
retaining rings (3), and counterweights (2) in
crankrod (4), and install flat head screws (1).
Tighten to 11 - 12 Nm (100 - 110 lb in.).
3. Using new O-ring (9), install plunger tube (10)
on outlet pin (8). Tighten to 11 - 12 Nm (100 110 lb in.).
P03028 07/10
P3-23
16. Install gasket (30), cover (29) and six selftapping screws (28) on the pump housing.
17. Using new O-rings (40), install manifold (37) on
motor (42). Install socket head screws (33).
Tighten to 27 - 34 Nm (20 - 25 lb ft).
18. If removed, install pressure reducing valve (38)
into manifold (37). Tighten to 27 - 34 Nm (20 25 lb ft).
19. If removed, install flow control valve (39) into
manifold (37). Tighten to 27 - 34 Nm (20 - 25 lb
ft).
20. If removed, install solenoid valve (34) into
manifold (37). Tighten to 20 - 27 Nm (15 - 20 lb
ft).
21. With the pump assembly in its normal operating
position, add SAE 10W-30 motor oil to the
pump housing until the oil is level with the
bottom of pipe plug (45) hole. Install the pipe
plug.
P3-24
07/10 P03028
SECTION R
SYSTEM SCHEMATICS
INDEX
R01095
Index
R1-1
NOTES
R1-2
Index
R01095
EM3670-1 FEB 08
HYDRAULIC SCHEMATIC
HD1500-7
A30001 & UP
EM7477-1 FEB 08
HYDRAULIC SCHEMATIC
COLD WEATHER (-40 C)
HD1500-7
A30035 & UP
EL5433-1 NOV 07
BRAKE SCHEMATIC
HD1500-7
A30001 & UP
XS4490-3 APRIL 09
HOOKUP SCHEMATIC
SHEET 1 - PAGE 1
HD1500-7 w/ SDA12V160 ENGINE
A30001 and UP
XS4490-3 APRIL 09
SHEET 1 - PAGE 2
XS4490-3 APRIL 09
SHEET 1 - PAGE 3
XS4490-3 APRIL 09
SHEET 1 - PAGE 4
Units 1 - 108
Units 1 - 108
XS4490-3 APRIL 09
HOOKUP SCHEMATIC
SHEET 2 - PAGE 1
HD1500-7 w/ SDA12V160 ENGINE
A30001 and UP
XS4490-3 APRIL 09
SHEET 2 - PAGE 2
XS4490-3 APRIL 09
SHEET 2 - PAGE 3
XS4490-3 APRIL 09
SHEET 2 - PAGE 4
XS4401-1 AUGUST 08
ELECTRICAL SCHEMATIC
INDEX AND SYMBOLS
XS4402-1 AUGUST 08
ELECTRICAL SCHEMATIC
MAIN POWER & STARTING CIRCUITS
XS4403-1 AUGUST 08
ELECTRICAL SCHEMATIC
ELECTRONIC DISPLAY PANEL I/O'S
XS4404-1 AUGUST 08
ELECTRICAL SCHEMATIC
ENGINE CONTROLS
XS4405-1 AUGUST 08
ELECTRICAL SCHEMATIC
TRANSMISSION INPUTS
XS4406-1 AUGUST 08
ELECTRICAL SCHEMATIC
TRANSMISSION CONTROLS
XS4407-2 AUGUST 08
ELECTRICAL SCHEMATIC
RCM CONTROLLER INPUTS
XS4408-1 AUGUST 08
ELECTRICAL SCHEMATIC
BRAKE SOLENOID CONTROLS
XS4409-1 AUGUST 08
ELECTRICAL SCHEMATIC
VHMS CONTROLLER
XS4410-1 AUGUST 08
ELECTRICAL SCHEMATIC
CONTROLLER COMMUNICATIONS
XS4411-1 AUGUST 08
ELECTRICAL SCHEMATIC
MISCELLANEOUS CONTROL CIRCUITS
XS4412-2 AUGUST 08
ELECTRICAL SCHEMATIC
TURN SIGNAL AND BRAKE LIGHTS
XS4413-1 AUGUST 08
ELECTRICAL SCHEMATIC
FOG LIGHTS AND HEADLIGHTS
XS4414-1 AUGUST 08
ELECTRICAL SCHEMATIC
WORK LAMPS & MISC. CIRCUITS
XS4415-1 AUGUST 08
ELECTRICAL SCHEMATIC
AIR CONDITIONER / HEATER CIRCUITS
XS4416-1 AUGUST 08
ELECTRICAL SCHEMATIC
24V/12V POWER CIRCUIT SUMMARY
XS4417-1 AUGUST 08
ELECTRICAL SCHEMATIC
24V POWER CIRCUIT SUMMARY
XS4418-3 APRIL 09
ELECTRICAL SCHEMATIC
FRAME & BATTERY GROUND CIRCUITS
XS4419-1 AUGUST 08
ELECTRICAL SCHEMATIC
FRAME & ISOLATED GROUND CIRCUITS
XS4420-2 AUGUST 08
ELECTRICAL SCHEMATIC
COMPONENT LOCATOR
XS4421-1 AUGUST 08
ELECTRICAL SCHEMATIC
CIRCUIT NUMBER IDENTIFIER LOCATOR
XS4422-1 MARCH 09
ELECTRICAL SCHEMATIC
HOT START SYSTEM (STANDARD SPEC)
XS4423-1 MARCH 09
ELECTRICAL SCHEMATIC
HOT START SYSTEM (-50C SPEC)
HD1500-7
730E
830E
830E-AC
930E-4
A30049 and UP
A30552 and UP
A30891 and UP
A30174 and UP
A30693 and UP
HE484
FEB 07
ELECTRICAL SCHEMATIC
HEATER / AIR CONDITIONER CONTROLS
Sheet 1 of 1
XC2627-0 MARCH 11
CONNECTOR LOCATOR
HD1500-7 w/ SDA12V160 ENGINE
A30109 & UP
SHEET 1 OF 4
XC2627-0 MARCH 11
CONNECTOR LOCATOR
HD1500-7 w/ SDA12V160 ENGINE
A30109 & UP
SHEET 2 OF 4
XC2627-0 MARCH 11
CONNECTOR LOCATOR
HD1500-7 w/ SDA12V160 ENGINE
A30109 & UP
SHEET 3 OF 4
XC2627-0 MARCH 11
CONNECTOR LOCATOR
HD1500-7 w/ SDA12V160 ENGINE
A30109 & UP
SHEET 4 OF 4
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