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DG744

Shop Manual

DUMP TRUCK

SERIAL NUMBERS A10212 - A10223

®
Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-
sonnel 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.

This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis-
closed except in accordance with written authorization from KAC.
It is the policy of the Company to improve products whenever it is possible and practical to do so. The
Company reserves the right to make changes or add improvements at any time without incurring any obli-
gation to install such changes on products sold previously.
Because of continuous research and development, periodic revisions may be made to this publication.
Customers should contact their local Komatsu distributor for information on the latest revision.

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.
NON-OEM PARTS IN CRITICAL SYSTEMS

For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.

Replacement parts manufactured and supplied by unauthorized sources may not be


designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.

Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.

Use of non-OEM parts places full responsibility for the safe performance of the
Komatsu product on the supplier and user. Komatsu will not in any case accept
responsibility for the failure or performance of non-OEM parts in its products,
including any damages or personal injury resulting from such use.
FOREWORD

This Manual is written for use by the service technician and is designed to help the technician become
fully knowledgeable of the truck and all its systems in order to keep it running and in production. All
maintenance personnel should read and understand the materials in this manual before performing
maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should
be understood and followed when accomplishing repairs on the truck.
The first section covers component descriptions, truck specifications and safe work practices, as
well as other general information. The major portion of the manual pertains to disassembly, service
and reassembly. Each major serviceable area is dealt with individually. For example: The disassem-
bly, service and reassembly of the radiator group is discussed as a unit. The same is true of the
engine and engine accessories, and so on through the entire mechanical detail of the truck.
Disassembly should be carried only as far as necessary to accomplish needed repairs.
The illustrations used in this manual are, at times, typical of the component shown and may not
necessarily depict a specific model.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout and 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 general information section and
individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
All torque specifications have ±10% tolerance unless otherwise specified.

A Product Identification plate is normally located on the truck frame upright in front of the left side
front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial
number), and Maximum G.V.W. (Gross Vehicle Weight) rating.

®
The HAULPAK Model designation consists of three numbers and one letter (i.e. 330M). The three
numbers represent the basic truck model. The letter "M" designates a Mechanical drive and the letter
"E" designates an Electrical propulsion system.

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 Gross Vehicle Weight (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
Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the
fuel & lubricants + the payload.
To determine allowable payload:
Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories,
body liners, tailgates, etc.) and then weigh truck.
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
should be removed as often as practical.

Exceeding the allowable payload will reduce expected life of truck components.

A00019 Introduction A-1


This “ALERT” symbol is used with the signal words,
“CAUTION”, “DANGER”, and “WARNING” in this man-
ual to alert the reader to hazards arising from
improper operating and maintenance practices.

“DANGER” identifies a specific potential hazard


WHICH WILL RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

“WARNING” identifies a specific potential hazard


WHICH MAY RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

“CAUTION” is used for general reminders


of proper safety practices
OR
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.

A-2 Introduction A00019


TABLE OF CONTENTS

SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

ENGINE, FUEL, COOLING AND AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . C

ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . D

TRANSMISSION AND TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . F

DRIVE AXLE, SPINDLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . G

SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H

BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J

AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L

OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q

SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R

A00019 Introduction A-3


KOMATSU 330M HAULPAK TRUCK

A-4 Introduction A00019


SECTION A

GENERAL INFORMATION

INDEX

MAJOR COMPONENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1

GENERAL SAFETY AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1

WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1

STANDARD CHARTS AND TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1

STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-1

A01004 05/04 Index A1-1


NOTES

A1-2 Index 05/04 A01004


MAJOR COMPONENTS AND SPECIFICATIONS

ENGINE POWER STEERING


The 330M Truck is powered by a Komatsu diesel The 330M is equipped with full hydraulic power steer-
engine. ing. The system includes an electric motor driven
pump which automatically provides emergency power
if the steering pump hydraulic flow is reduced below
an established minimum.

TRANSMISSION
The TORQFLOW transmission consists of a 3-ele- BRAKE SYSTEM
ment, single-stage, two-phase torque converter and a
Depressing the brake pedal actuates front and rear
planetary gear, multiple disc clutch transmission which
air-over-hydraulic service brakes. The front service
is hydraulically actuated and force-lubricated for opti-
brakes are caliper disc type. The rear service brakes
mum heat dissipation.
are oil-cooled, multiple-disc brakes (acts also as re-
The TORQFLOW transmission is capable of seven (7)
tarder).
forward speeds and one (1) reverse gear. Automatic
shifting is controlled by electronic shift control with
automatic clutch modulation in all gears. A lockup
system consisting of a wet, double-disc clutch, is acti-
vated in F1–F7 gears for increased fuel savings.

RETARDER
The operator can manually apply the rear oil-cooled,
FINAL DRIVE ASSEMBLY multiple-disc retarder brakes by moving the retarder
contol lever which is mounted on the steering column.
The final drive consists of a plug-in differential with These brakes are automatically activated when the
planetary wheel drive. engine speed exceeds the rated revolutions of the shift
position.

OPERATOR’S CAB
The Operator’s Cab is spacious and comfortable and
includes wide windows all around for excellent visibil- SUSPENSION
ity. All pedals, controls and instruments are arranged
Hydro-pneumatic suspension cylinders are used at
for maximum efficiency and ease of operation. The
each wheel to reduce shock and provide riding comfort
electronic display/monitoring panel keeps the operator
for the operator and machine stability.
informed of the truck’s operating systems. Audible
alarms and lights warn the operator of system malfunc-
tions.

A02039 Major Components and Specifications A2-1


330M MAJOR COMPONENTS

A2-2 Major Components and Specifications A02039


SPECIFICATIONS
ENGINE SERVICE CAPACITIES
Komatsu . . . . . . . . . . . . . . . SA12V140Z-1 . . . . . . . . . . . . . . Liters . U.S. Gallons
Engine . . . . . . . . . . . 147 . . . . . . (39)
Number of Cylinders . . . . . . . . . . . . . . . 12 (Includes Lube Oil Filters)
Operating Cycle . . . . . . . . . . . . . . 4-Stroke Cooling System . . . . . . 256 . . . . . . (66)
Fuel Tank . . . . . . . . . . 1250 . . . . . (330)
Rated 783 kW (1050 SAE Brake HP) @ 2000 RPM Transmission . . . . . . . . 125 . . . . . . (33)
Flywheel . . 753 kW ( 1010 SAE HP) @ 2000 RPM And Torque Converter
Steering & Hoist System . . . 248 . . . . . (65.5)
Maximum torque 4631 N.m (3415 lb-ft) @ 1400 RPM Tank Only . . . . . . . . 145 . . . . . (38.3)
Brake Cooling System . . . 366 . . . . . (96.6)
Tank Only . . . . . . . . . 248 . . . . . (65.5)
TORQFLOW TRANSMISSION Final Drive Case . . . . . . . 250 . . . . . . (66)
Differential & both planetaries
Automatic Electronic Shift Control
. . . with Automatic Clutch Modulation In All Gears. HYDRAULIC SYSTEM
Lockup Clutch . . . . . . . . . Wet, Double-disc, The steering/hoisting and retarder cooling circuits are
. . . . . . . . . . . . . . Activated in F1–F7 gears. independent circuits. Load sensing steering system
controls the flow to the steering circuit in accordance
Torque Converter . . . . 3-Element, Single-stage, with demand.
. . . . . . . . . . . . . . . . . . . . . Two-phase
Hydraulic Pumps . . . . . 2-Separate Gear Pumps
Transmission . Planetary Gear, Multiple Disc Clutch,
Steering/Hoist Functions
. . . . . Hydraulically Actuated, Force-lubricated Flow rated at . . . 636 l/min. (168 U.S. gal/min.)
Speeds . . . . . . . . . . . 7 Forward, 1 Reverse Retarder Cooling
Flow rated at . . 1001 l/min. (264 U.S. gal/min.)
Max Travel Speed . . . . . 61.9 Km/h (38.5 MPH)
Hoist Control Valve . . . . . . . . . . . Spool Type
Positions . . . . . Raise, Hold, Float, and Lower
FINAL DRIVE ASSEMBLY Hydraulic Cylinders
Final Drive . . . . . . . . . . . Plug-in Differential Hoisting . . . . . . . 2-Stage Telescoping Piston
. . . . . . . . . . . . . with Planetary Wheel Drive Steering . . . . . . . . . . . Double Acting Piston
2
Reduction Ratios: Relief Valve Setting . . . . 210 kg/cm (3,000 psi)
Bevel Set . . . . . . . . . . . . . . . . . . 3.47:1 SERVICE BRAKES
Planetary Final Drive . . . . . . . . . . . . 6.50:1
Total Reduction . . . . . . . . . . . . . . 22.54:1 Actuation: . . . . . . . . . . . . Air-Over-Hydraulic
Front . . . . . . . . . . . . . Caliper Disc Brakes
Rear . . . . . . . . . . . Oil-Cooled, Multiple-Disc
ELECTRIC SYSTEM . . . Act as both Service and Retarder Brakes
Batteries . . . . . . . . . . 4 x 12V / 200 Amp Hr. Retarder Brakes:
. . . . . . . . . . . . . 1450 Cold Cranking Amps Normally Applied . . . . Manually By Operator.
Alternator . . . . . . . . 24 Volt, 75 Ampere Output Automatically Actuated . . . . . . . . . . . . .
when engine speed exceeds the rated revolu-
Lighting . . . . . . . . . . . . . . . . . . . 24 Volt tions of the shift position for the transmission.
Parking Brake: . . . Spring-loaded, Caliper Disc
Starter . . . . . . . . . . . . . . . . . One 24-Volt . . . . . . . . . . . . . Actuates On Drive Shaft
Emergency Brakes:
An emergency relay valve actuates the brakes
AIR SYSTEM automatically should air pressure in the air tank
3 drop below a pre-set value.
Compressor . . . . 0.85 m /min . . . . (30 cfm) Manual operation is also possible.

A02039 Major Components and Specifications A2-3


STEERING WEIGHT DISTRIBUTION
3 3
Min Turning Radius . . . . . . . . . . 9.9 m (32’ 6") Based on SAE 2:1 Heaped . . . . 60 m (78 yds )
(w/Komatsu Engine; and 27.00R49 Tires)
Automatic Emergency Steering . . . . . Standard

TIRES EMPTY . . . . . . . . Kilograms . . . Pounds


Front Axle . . . . . . . 33 145 . . . . 73,080
Rock Service (E-3) . . . . . . . . . . . . Tubeless
Rear Axle . . . . . . . 35 905 . . . . 79,170
Standard . . . . . . . . . . . . . 27.00R49XRBT Total . . . . . . . . . . 69 050 . . . 152,250
Rim Size . . . 50 cm X 124.4 cm (19.5 in. X 49 in.)
. . . . . . . . . . . . . . . . Separable Tire Rims LOADED (100 Ton PAYLOAD)
. . . . . . . . . . . . . Kilograms . . . Pounds
DUMP BODY CAPACITY (Standard) Front Axle . . . . . . . 54 080 . . . 119,280
3 3 Rear Axle . . . . . . 112 320 . . . 247,720
Struck . . . . . . . . . . . . . 38.6 m (50.5 yds )
Total * . . . . . . . . 166 400 . . . 367,000
3 3
Heaped @ 2:1 (SAE) . . . . . 60.1 m (78.7 yds )
* Not to Exceed 166 400 kg (367,000 lbs.).
Including Options, Fuel & Payload

OVERALL TRUCK DIMENSIONS


Loading Height . . . . . . . . . . . 4.29 m (14’ 1")
Minimum Clearance Height (Empty) 5.27 m (17’ 3")
Overall Length . . . . . . . . . . 10.47 m (34’ 4")
Maximum Width . . . . . . . . . . . 5.68 m (18’ 7")

OVERALL TRUCK DIMENSIONS


All dimensions shown are with 27.00-49 tires.

A2-4 Major Components and Specifications A02039


GENERAL SAFETY

This safety section also contains precautions for optional equipment and attachments.

Read and follow all safety precautions. Failure to do so may result


in serious injury or death.

SAFETY RULES
• ONLY trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
• When working with another operator or a person on worksite traffic duty, be sure all personnel understand all
hand signals that are to be used.

SAFETY FEATURES
• Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged. (See
Walk-Around Check, Page 3-17 )
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• NEVER remove any safety features. ALWAYS keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.

CLOTHING AND PERSONAL PROTECTIVE ITEMS


• Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause
serious injury or death. Also, do not wear oily clothes because they are
flammable.
• Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine. Always wear safety goggles, hard
hat and heavy gloves if your job involves scattering metal chips or minute
materials--this is so particularly when driving pins with a hammer and
when cleaning the air cleaner element with compressed air. Check also
that there is no one near the machine.

UNAUTHORIZED MODIFICATION
• Any modification made without authorization from Komatsu can create hazards.
• Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury
or damage caused by any unauthorized modification.

A03011 4/98 General Safety and Operating Instructions A3-1


STANDING UP FROM THE SEAT
• To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the
following before standing up from the operator’s seat.
• Place the gear shift lever at neutral and set the parking lever to the PARKING position.
• Lower the dump body, set the dump lever to the HOLD position, then apply the lock.
• Stop the engine. When leaving the machine, always lock everything. Always remember to take the key with you.
If the machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or
death.

MOUNTING AND DISMOUNTING


• NEVER jump on or off the machine. NEVER get on or off a moving machine.
• When getting on or off the machine, face the machine and use the handhold and steps.
• Never hold any control levers when getting on or off the machine.
• Always maintain three-point contact with the handholds and steps to ensure that you support yourself.
• When bringing tools to the operator’s compartment, always pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
• Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
A: For use when getting on or off the machine from the left door.
B: For use when getting on or off the machine from the engine hood or right door.

FIRE PREVENTION FOR FUEL AND OIL


Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
• Keep flame away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil tank caps securely.
• Refueling and oiling should be made in well ventilated areas.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.

A3-2 General Safety and Operating Instructions A03011 4/98


PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
• Immediately after operations, the engine cooling water, engine oil, differential and final drive case oil, and
hydraulic oil are at high temperature and are under pressure. If the cap is removed or the oil or water is drained
or the filters are replaced, there is danger of serious burns. Always wait for the temperature to go down, and carry
out the operation according to the specified procedure.
• To prevent hot water from spurting out:
1) Stop the engine.
2) Wait for the water temperature to go down.
3) Turn the cap slowly to release the pressure before removing the cap.
• To prevent hot oil from spurting out:
1) Stop the engine.
2) Wait for the oil temperature to go down.
3) Turn the cap slowly to release the pressure before removing the cap.

ASBESTOS DUST HAZARD PREVENTION


Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given
below:
• NEVER use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Operate the machine with the wind to your back, whenever possible.
• Use an approved respirator if necessary.

PREVENTION OF INJURY BY WORK EQUIPMENT


• Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead
to serious bodily injury or death.

FIRE EXTINGUISHER AND FIRST AID KIT


• Be sure fire extinguishers have been provided and know how to use them.

• Provide a first aid kit at the storage point.


• Know what to do in the event of a fire.
• Be sure you know the phone numbers of persons you should contact in case of
an emergency.

A03011 4/98 General Safety and Operating Instructions A3-3


PRECAUTIONS WHEN USING ROPS
• If ROPS is installed, the ROPS must never be removed when operating the machine.
• The ROPS is installed to protect the operator if the machine should roll over. If is designed not only to support
the load if the machine should roll over, but also to absorb the impact energy.
• The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without
authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its
function properly. It can only display its performance if it is repaired or modified in the specified way.
• When modifying or repairing the ROPS, always contact your Komatsu distributor.
• Even if the ROPS is installed, it cannot show its full effect if the operator does not fasten the seat belt properly.
Always fasten the seat belt when operating.

PRECAUTIONS FOR ATTACHMENTS


• When installing and using an optional attachment, read the instruction manual for the attachment and the
information related to attachments in this manual.
• Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized
attachments could create a safety problem and adversely affect the proper operation and useful life of the
machine.
• Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the
responsibility of Komatsu.

A3-4 General Safety and Operating Instructions A03011 4/98


PRECAUTIONS DURING OPERATION

BEFORE STARTING ENGINE

SAFETY AT WORKSITE
• Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
• Examine the road surface in the jobsite and determine the best and safest method of operation.
• Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
• If you need to operate on a road, protect pedestrians and cars by designating a person for worksite traffic duty
or by installing fences around the worksite.
• Check the river bed condition, and depth and flow of water before crossing shallow parts of river. NEVER be in
water which is in excess of the permissible water depth.
• The operator must check personally the work position, roads to be used, and existence of obstacles before starting
operations.
• Always determine the travel roads in the worksite and maintain them so that it is always safe for the machines
to travel.

FIRE PREVENTION
• Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine compart-
ment. They could cause a fire.

• Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks
repaired. Wipe up any excess oil, fuel or other flammable fluids.
• Be sure a fire extinguisher is present and working.
• Do not operate the machine near any flame.

IN OPERATOR’S CAB
• Do not leave tools or spare parts lying around in the operator’s compartment. They may damage or break the
control levers or switches. Always put them in the tool box on the right side of the machine.
• Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
• Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use
seat belts when operating your machine.

VENTILATION FOR ENCLOSED AREAS


• If it is necessary to start the engine within an enclosed area, provide adequate ventilation.
Exhaust fumes from the engine can KILL.

A03011 4/98 General Safety and Operating Instructions A3-5


KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN
• Remove any dirt from the surface of the windows or lights to ensure good visibility.
• Adjust the rear view mirror to a position where the operator can see best from the operator’s seat, and keep the
surface of the mirror clean. If any glass should break, replace it with a new part.
• Check that the machine is equipped with the head lamps and working lamps needed for the operating conditions.
Check that all the lamps light up properly.

A3-6 General Safety and Operating Instructions A03011 4/98


OPERATING MACHINE

WHEN STARTING ENGINE


• Walk around your machine again just before mounting it, checking for people and objects that might be in the
way.
• NEVER start the engine if a warning tag has been attached to the control.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.
• Do not allow any person other than the operator in the operator’s compartment or any other place on the machine.
• For machines equipped with a back-up alarm buzzer, check that the alarm buzzer works properly.

CHECK WHEN TRAVELING IN REVERSE


Before operating the machine or work equipment, do as follows:
• Sound the horn to warn people in the area.
• Check that there is no one near the machine. Be particularly careful to check
behind the machine.
• If necessary, designate a person to check the safety. This is particularly
necessary when traveling in reverse.
• When operating in areas that may be hazardous or have poor visibility,
designate a person to direct worksite traffic.
• Do not allow any one to enter the line of travel of the machine. This rule must
be strictly observed even on machines equipped with a back-up alarm or rear view mirror.

TRAVELING
• When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is traveling, the steering wheel will not work, and it will be dangerous
to drive the machine. Apply the brakes immediately and stop the machine.

TRAVELING ON SLOPES
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, go down to level ground before turning.
• Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Take all possible steps to avoid traveling sideways, and always keep the travel
speed low.
• When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly. Do
not use the foot brake except in an emergency.
• If the engine should stop on a slope, apply the brakes fully and apply the parking brake, also, to stop the machine.

A03011 4/98 General Safety and Operating Instructions A3-7


ENSURE GOOD VISIBILITY
• When working in dark places, install working lamps and head lamps, and set up lighting in the work area if
necessary.
• Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a
condition that allows the operation to be carried out safely.

OPERATE CAREFULLY ON SNOW


• When working on snowy or icy roads, there is danger that the machine may slip to the side on even the slightest
slope, so always travel slowly and avoid sudden starting, turning, or stopping.
• Be extremely careful when carrying out snow-clearing operations. The road shoulder and other objects are buried
in the snow and cannot be seen.
• When traveling on snow-covered roads, always install tire chains.

AVOID DAMAGE TO DUMP BODY


• When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits, always drive extremely carefully and lower the dump body completely before driving
the machine.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES


• Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below
between the machine and the electric cable.

Voltage Min. Safety Distance


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:


1) Wear shoes with rubber or leather soles.
2) Use a signalman to give warning if the machine approaches too close to the electric cable.
• If the work equipment should touch the electric cable, the operator should not leave the operator’s compartment.
• When carrying out operations near high voltage cables, do not let anyone come close to the machine.
• Check with the electricity company about the voltage of the cables before starting operations.

A3-8 General Safety and Operating Instructions A03011 4/98


WHEN DUMPING
• Before starting the dumping operation, check that there is no person or object behind the machine.
• Stop the machine in the correct position, and check again that there is no person or object behind the machine.
Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position
a flagman.
• When carrying out dumping operations on slopes, the machine stability will become poor and there is danger
that it may tip over. Always carry out such operations extremely carefully.
• Do not travel with the dump body raised.

WORKING ON LOOSE GROUND


• Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse,
your machine could fall or tip over and result in serious injury or death. Remember that the soil after heavy rain
or blasting is weakened in these areas.
• Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight or vibration of
your machine.
• When operating in places where there is danger of falling rocks or danger of the machine turning over, always
install ROPS and a seat belt.

WHEN LOADING
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
• Do not leave the operator’s seat during the loading operation.

PARKING THE MACHINE


• Choose a horizontal road surface to park the machine. If the machine has to be parked on a slope, always put
blocks under all the wheels to prevent the machine from moving.
• When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn
pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
• Before leaving the machine, lower the dump body fully, set the parking lever to the PARKING position, stop the
engine, then lock everything. Always take the key with you.

A03011 4/98 General Safety and Operating Instructions A3-9


BATTERY

BATTERY HAZARD PREVENTION


• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
• Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or
poison prevention center immediately.
• When working with batteries ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark of
flame.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across
the terminals.
• When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
• Tighten the battery cap securely.
• Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.

STARTING WITH BOOSTER CABLES


• ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
• When starting from another machine, do not allow the two machines to touch.
• Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the ground or negative
(-) cable first when removing them.
• If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. This is dangerous, so
be sure to work carefully.
• Connect the batteries in parallel: positive to positive and negative to negative.
• When connecting the ground cable to the frame of the machine to be started, be sure to connect it as far as
possible from the battery.

A3-10 General Safety and Operating Instructions A03011 4/98


TOWING

WHEN TOWING, FIX WIRE TO HOOK


• Towing in the wrong way may lead to serious personal injury or damage.
• When using another machine to tow this machine, use a wire rope with ample strength for the weight of this
machine.
• Never tow a machine on a slope.
• Do not use any towing rope that has kinks or is twisted.

• Do not stand astride the towing cable or wire rope.


• When connecting a machine that is to be towed, do not let any one come
between the towing machine and the machine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing
portion of the machine, and secure it in position.

(For towing method, see page 3-28.)

A03011 4/98 General Safety and Operating Instructions A3-11


PRECAUTIONS FOR MAINTENANCE

BEFORE CARRYING OUT MAINTENANCE

WARNING TAG
• If others start the engine or operate the controls while you are performing service or lubrication, you could suffer
serious injury or death.
• ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working
on the machine. Attach additional warning tags around the machine, if necessary.
• These tags are available from your Komatsu distributor. (Part No. 09963-03000)

PROPER TOOLS
• Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools
could cause personal injury.

PERIODIC REPLACEMENT OF CRITICAL PARTS


• Periodically replace parts used to insure safety or prevent accident. (See "PERIODIC REPLACEMENT OF
COMPONENT PARTS FOR SAFETY DEVICES", Section 4.)
• Replace these components periodically with new ones, regardless of whether or not they appear to be defective.
These components deteriorate over time.
• Replace or repair any such components if any defect is found, even though they have not reached the time
specified.

STOPPING THE ENGINE BEFORE SERVICE


• When carrying out inspection or maintenance, always stop the machine on firm flat ground, lower the dump body,
then stop the engine.
• If the engine must be run during service, such as when cleaning the radiator, always set the transmission lever
to the neutral position and the parking brake lever to the PARKING position. Always carry out the work with two
people. One person should sit on the operator’s seat so that he can stop the engine if necessary. NEVER move
any controls you do not need to operate.
• When servicing the machine, be careful not to touch any moving part or get your clothes caught.
• Put blocks under the wheels.
• When carrying out service with the dump body raised, always place the dump lever at the HOLD position, apply
the lock, and insert the safety pins securely.

A3-12 General Safety and Operating Instructions A03011 4/98


DURING MAINTENANCE

PERSONNEL
• Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding,
welding, and using a sledge-hammer.

ATTACHMENTS
• Place attachments that have been removed from the machine in a safe place so that they
do not fall. If they fall on you or others, serious injury could result.

WORK UNDER THE MACHINE


• Always lower all movable work equipment to the ground or to their lowest position before
performing service or repairs under the machine.
• Always block the tires of the machine securely.
• Never work under the machine if the machine is poorly supported.

KEEP THE MACHINE CLEAN

• Spilled oil or grease, or scattered tools or broken pieces are dangerous because
they may cause you to slip or trip.
Always keep your machine clean and tidy.
• If water gets into the electrical system, there is danger that the machine may not
move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the
operator’s compartment.

RULES TO FOLLOW WHEN ADDING FUEL OR OIL


• Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
• Always tighten the cap of the fuel and oil fillers securely.
• Never use fuel for washing any parts.
• Always add fuel and oil in a well-ventilated place.

A03011 4/98 General Safety and Operating Instructions A3-13


RADIATOR WATER LEVEL
• If it is necessary to add water to the radiator, stop the engine and allow the engine
and radiator to cool down before adding the water.
• Slowly loosen the caps to relive pressure before removing the caps.

USE OF LIGHTING

When checking fuel, oil, coolant, or battery electrolyte, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is
danger or explosion.

PRECAUTIONS WITH BATTERY


• When repairing the electrical system or when carrying out electrical welding,
remove the negative (-) terminal of the battery to stop the flow of current.

HANDLING HIGH-PRESSURE HOSES


• Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
• Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.

PRECAUTIONS WITH HIGH PRESSURE OIL


• Do not forget that the work equipment circuits are always under pressure.
• Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin
or enters your eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of
wood to check for oil leakage.
• If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.

A3-14 General Safety and Operating Instructions A03011 4/98


PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE
• Immediately after stopping operations, the engine cooling water and oil at all parts
are at high temperature and under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters
are replaced, it may result in burns or other injury. Wait for the temperature to go
down, then carry out the inspection and maintenance in accordance with the
procedures given in this manual.

ROTATING FAN AND BELT


• Keep away from rotating parts and be careful not to let anything get caught in them.
• If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying,
so never touch any rotating parts.

WASTE MATERIALS

• Never dump waste oil in a sewer system, rivers, etc.


• Always put oil drained from your machine in containers. Never drain oil directly
on the ground.
• Obey appropriate laws and regulations when disposing of harmful objects such
as oil, fuel, coolant, solvent, filters, batteries, and others.

A03011 4/98 General Safety and Operating Instructions A3-15


TIRES

HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp stones
on rough road surfaces. This may lead to serious injury or damage.
To maintain safety, always keep to the following conditions:
• Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
• Use the specified tires.

The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual
values may differ depending on the type of tire and the condition under which they are used. For details, please
contact your Komatsu distributor or tire maker.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly dangerous if the tires
become overheated when the tires are under pressure. If the gas generated inside the tire ignites, the internal pressure
will suddenly rise, and the tire will explode, and this may lead to serious personal injury. Explosions differ from
punctures or tire bursts, because the destructive force is extremely large. Therefore, the
following operations are strictly prohibited when the tire is under high internal pressure:
• Welding the rim
• Building fires or carrying out welding near the wheel or tire.

If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and
you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such
maintenance, please consult your Komatsu distributor or tire maker.

STORING TIRES AFTER REMOVAL


• As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored
outside, always erect a fence around the tires and put up "No Entry" and other warning signs that even young
children can understand.
• Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
• If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy,
so trying to hold the tire may lead to serious injury.

A3-16 General Safety and Operating Instructions A03011 4/98


OPERATING INSTRUCTIONS

PREPARING FOR OPERATION


The safest trucks are those which have been properly Local work practices may prevent an operator from
prepared for operation. At the beginning of each shift, performing all tasks suggested here, but to the extent
a careful check of the truck should be made by the permitted, the operator should follow this or similar
operator before attempting to start the engine. routine.
Vehicle breakdowns and UNSCHEDULED downtime
1. Start at left front of truck (see illustration, next
and loss of production can be reduced.
page). While performing the walk around inspec-
tion, visually inspect all lights and safety equip-
SAFETY IS THINKING AHEAD
ment for external damage from rocks or misuse.
Prevention is the best safety program. Prevent a Make sure lenses are clean and unbroken.
potential accident by knowing the employer’s safety
2. Move behind the front of the left front tire, inspect
requirements and all necessary job site regulations, as
the hub and brake assemblies for leaks and any
well as use and care of the safety equipment on the
abnormal conditions. Check that the air system
truck.
cooler is clean and not covered with mud, etc.
Only qualified operators or technicians should attempt
to operate or maintain the truck. Check that all suspension attaching hardware is
secure and inspect for evidence of wear. Check
Safe practices start before the operator gets to that the suspension extension (exposed piston
the equipment! rod) is correct, and that there are no leaks.
• Wear the proper clothing. Loose fitting clothing, 3. Inspect fan and air conditioner belts for correct
unbuttoned sleeves and jackets, jewelry, etc., can tension, obvious wear, and tracking. Inspect fan
catch on a protrusion and cause a potential haz- guard for security and condition.
ard.
4. Look overhead at bottom of cab and check for
•Always use the personal safety equipment pro- leakage of the steering control valve and/or
vided for the operator such as hard hat, safety hoses.
shoes, safety glasses or goggles. There are some
5. Move outboard of the front wheel, and inspect
conditions when protective hearing devices
attaching lugs/wedges to be sure all are tight and
should also be worn for operator safety.
complete. Check tires for cuts, damage or “bub-
• When walking to and from the truck, maintain a bles” and that inflation appears to be correct.
safe distance from all machines even if the opera-
6. Move behind the rear of the front wheel, inspect
tor is visible.
for leaks at hub or brakes or any unusual condi-
tions. Inspect suspension hardware to be sure it
is all in place. Inspect the tie-rod pivots and
At The Truck - Ground Level Walk Around
steering cylinder for proper greasing, and for se-
Inspection
curity of all parts. Inspect for any hydraulic leaks.
At the beginning of each shift, a careful walk around
7. Check pumps on front of transmission for leakage
inspection of the truck should be made before the
and that all parts are secure.
operator attempts engine start-up. A walk around in-
Also check the transmission filter for leaks.
spection is a systematic ground level inspection of the
truck and its components to insure that the truck is safe
8. Inspect sight glass
to operate before entering the operator’s cab.
for transmission oil
Start at the left front corner of the truck (see illustration, level. With engine
next page), and move in a counter-clockwise direction, stopped, hydraulic
front-to-rear, across the rear, and continuing forward fluid should be be-
up the opposite side of the truck to the original starting tween the upper
point. If these steps are taken in sequence, and are two marks.
repeated from the same point and in the same direction (Refer to decal on
before every shift, many potential problems may be transmission oil
avoided. pan.) Notify main-
tenance if oil ap-
If problems or potential problems are found during
pears to be low.
the “walk-around”, be sure to notify maintenance.

A03011 4/98 General Safety and Operating Instructions A3-17


START HERE

330M "WALK-AROUND" INSPECTION

NOTE: Engine Oil and Transmission Oil levels are checked


most accurately when engine is running and all systems are
at normal operating temperatures.
Refer to Section 4, LUBRICATION & SERVICE, 10 Hour (Daily)
Inspection for these procedures.

A3-18 General Safety and Operating Instructions A03011 4/98


9. Move to the 17. Move on around the right dual tires, inspect be-
side of the hy- tween the tires for rocks, and for condition of the
d rau li c ta nk rock ejector, inspect the tires for cuts or damage,
and check the and for correct inflation.
hydraulic fluid
18. Perform same inspection for wheel lugs/wedges,
levels for both
wheel cover latches, and for leaks that was done
the Steering &
on the left hand dual wheels.
Hoist tank (1) and the Brake Cooling Oil tank (2).
Oil should be visible in each sight glass with 19. Move in front of right dual tires, and inspect the
engine stopped and body down. hoist cylinder the same as was done on the left
side.
10. Move on around the hydraulic tank and in front of
the rear dual tires, inspect the hoist cylinder for 20. Move on around the fuel tank, inspect the attach-
any damage and leaks, also that lower guard is ing hardware for the fuel tank at the upper sad-
in place. Inspect both upper and lower hoist cyl- dles, and then at the lower back of the tank for the
inder pins for security, and for proper greasing. security and condition of the mounts.
11. Before leaving this position, look to see that there
is no leakage or any other unusual condition with
transmission or drive shaft.
12. Move on around the dual tires, check to see that
all lugs/wedges are in place and tight. Inspect
wheel for any leakage that may be coming from
inside the wheel housing that would indicate
planetary leakage. Inspect the fuel gauge (2) and note the quantity
Check dual tires for cuts, damage or “bubbles” indicated. Compare this indication later against
and that inflation appears to be correct. Inspect the fuel gauge reading in the instrument panel of
for any rocks that might be lodged between dual the operator cab.
tires, and that rock ejector is in good condition and 21. Move in behind the right front wheel, and inspect
straight so that it can not damage a tire. the tie-rod pivots and steering cylinder for proper
13. Inspect left rear suspension for damage and for greasing, and for security of all parts.
proper inflation, and that there are no leaks. Be sure the suspension protective cover is in
Inspect also for proper greasing, and that covers good condition. Check suspension attaching
over the chromed piston rod are in good condi- hardware and suspension extension, as well as
tion. greasing and attaching hardware for the steering
cylinder.
14. Check final drive housing breather. Replace
breather if obstructed. Check for leakage around 22. Move out and around the right front wheel, inspect
final drive housing and oil disc brake housings that all lugs/wedges are in place and tight.
and the hoses connected to the housings. 23. Move in behind the front of the right front wheel,
15. While standing behind final drive housing, look up check hub and brakes for leaks and any unusual
to see that rear lights are in good condition, along condition. Inspect the engine compartment for
with back up horns. Inspect linkage rods to see any leaks and unusual condition. Inspect the fan
that they are getting proper greasing in all pin guard, and belts also for any rags or debris behind
locations. Also look at both body hinge pins for radiator.
greasing and any abnormal condition. 24. With engine stopped, check engine oil level.
The dipsticks of some engines may be marked on
Drain moisture from both sides;
rear brake air tank by one side marked “With Engine Stopped”, and
pulling chain (1) on other side marked “With Engine Running”.
moisture drain valve. Normal check is with engine running, and at
operating temperature.
Refer to Section 4, Lubrication & Service, 10 Hour
(Daily) Inspection.

16. Perform the same inspection on the right rear Check that the engine oil filters or oil lines to filters
suspension as done on the left. are not leaking.

A03011 4/98 General Safety and Operating Instructions A3-19


25. Move on around to the right front of the truck. 32. Check air cleaner
indicator (1).
26. When moving in front of the radiator, inspect for
If the RED area is
any debris that might be stuck in front of the
showing in the in-
radiator and remove it. Check for any coolant
dicator, the air fil-
leaks. Inspect all headlamps and fog lights.
t er must be
27. Before climbing ladder to first level, be sure cleaned/replac
ground level engine shutdown switch is “ON”. ed before operat-
(If truck is equipped with this feature.) ing truck.
28. Climb ladder to main deck. Always use grab rails 33. Clean cab windows and mirrors; clean out cab
and ladder when mounting or dismounting from floor as necessary. Insure steering wheel, con-
the truck. Clean ladder and hand rails of any trols and pedals are free of any oil, grease or mud.
foreign material, such as ice, snow, oil or mud.
34. Stow personal gear in cab so that it does not
interfere with any operation of the truck. Dirt or
trash buildup, specifically in the operator’s cab,
should be cleared. Do not carry tools or supplies
Always mount and dismount ladders facing the in cab of truck or on the deck.
truck. Never attempt to mount or dismount while 35. Adjust seat and steering wheel so that it is com-
the truck is in motion. fortable for use.
29. When checking coolant 36. Be familiar with all control locations and functions
in radiator, use coolant BEFORE operating truck.
level sight gauge (2). Read this “Operation - Section 3" COMPLETELY
Check that water level and be certain to understand all discussions in the
is between FULL and OPERATOR CONTROLS AND INSTRUMENT
LOW. If water is low, PANEL section.
add water though water
filler (1) to FULL level.

If engine has been running, allow coolant to cool,


before removing the fill cap or draining radiator.
Serious burns may result if coolant is not allowed
to cool.
If it is necessary to remove radiator cap, shut down
engine (if running), and relieve coolant pressure
SLOWLY before removing radiator cap. After add-
ing water tighten cap securely.
30. Inspect battery box
cover for loose-
ness or damage.
Check the brake
c h am be rs fo r
leaks, damage,
etc. Check brake
fluid level (2).

31 . Drain moisture
fro m tank s by
pulling chains (1)
on moisture drain
valves. Check air
tanks and lines
for leaks.

A3-20 General Safety and Operating Instructions A03011 4/98


ENGINE START-UP SAFETY PRACTICES
Safety rules must be observed upon engine start-up. • Check that the Central Warning Lamp and
all monitor lamps and
gauges, light up for
approximately 3 sec-
onds and that the
Insure adequate ventilation before start-up, if the alarm buzzer sounds
truck is in an enclosure. for approximately 2
Exhaust fumes are dangerous! seconds.

1. Insure all personnel are clear of truck before • The speedometer should display “88".
starting engine. • If the air pressure is below normal operating
Always sound the horn as a warning before actu- pressure, the central warning lamp should
ating any operational controls. flash and the buzzer should sound.
2. Check and insure Transmission Range Selector
is in the “Neutral” position before starting. • If the Shift Lever is not at the “N” position,
the central warning
3. In cold weather, if truck is equipped with auxiliary
lamp will flash and
heaters, do not attempt to start engine while
the alarm buzzer
heaters are in operation. Damage to coolant heat-
will sound intermit-
ers will result, due to lack of circulation.
tently. When the
4. The key switch has three positions: Off, On, Start. shift lever is moved
to the “N” position,
When the key switch is rotated one the lamp will go out and the buzzer will stop.
position clockwise, it is in the “On
(run)” position and all electrical cir-
cuits (except “start”) are activated. • When checking the
monitor, check all
Before Starting The Engine caution lamps and
pilot lamps at the
same time.
Press Lamp Check Switch -
During the following safety checks, if the alarm or Check to see that all caution lamps or pilot
red warning lamp does not turn “On” as required, lamps are illuminated.
OR, if the actuation or release of any emergency • Check the Manual Emergency Steering.
control, brake, or steering circuit does not appear With the key switch
normal, shut engine down immediately and notify in the ON position,
maintenance personnel. turn emergency
Do not operate truck until the circuit in question is steering switch ON
fully operational. (red light ON), and
ch eck t hat t he
steering wheel can
Perform the following checks to be certain that the be operated. If the
central warning system, alarm buzzer, and all steering wheel cannot be operated, notify
machine monitors and lamps are functional: maintenance personnel.
Do Not Operate truck.
• Turn the key switch to the “ON” position. • Check the Auto Emergency Steering.
(Do Not Start Engine). With the key switch in
t he O N posi ti on,
NOTE: If the engine has been running, and then move Parking Brake
is stopped, the monitor cannot be checked until lever to the “OFF”
at least 30 seconds have passed. (unlocked) position.
Wait 1.5 seconds and
check that the emer-
gency steering is actuated and the steering can
be operated.

A03011 4/98 General Safety and Operating Instructions A3-21


STARTING THE ENGINE
• Rotate key switch fully clock-
wise to “start” position (with
Transmission Range Selec- Electric starters and engine grid heaters can be a
tor in “Neutral”) and HOLD significant electrical drain on vehicle batteries.
this position until engine The vehicle battery charging system should be
starts (see NOTE below). monitored and maintained at all times, especially
“Start” position is spring during cold weather operation.
loaded to return to “On” when When temperature is below 3oC (38oF), do not
key is released. leave key switch “ON” (engine not operating) for
extended periods of time (i.e. troubleshooting).
NOTE: This truck is equipped with an engine prelube
system. With this feature, a noticeable time delay may
• The truck cannot be push started.
occur (while engine lube oil passages are being filled
Transmission lube and control systems are not
and pressurized) before engine cranking will begin.
operational when engine is not running.
• When getting a battery assist from one truck to
STARTING THE ENGINE IN COLD WEATHER another, use the following procedure to avoid
the possibility of causing sparks near the bat-
The truck is equipped with an Automatic Cold Start Aid tery where explosive gases may be present.
which senses intake manifold temperature and auto-
a. All switches must be “Off” prior to making any
matically turns electric grid heaters in the engine intake
connections.
manifold “On/OFF”.
b. Be certain to maintain correct polarity.
• When the key switch is turned “ON” and the
o o NOTE: 330M trucks are equipped with four 12
manifold temperature is below 3 C (38 F), the
Automatic Cold Start system will energize the volt batteries connected in series and parallel
engine intake manifold grid heaters. to provide 24 volt output. Be certain to maintain
Auto grid heater activation time (t) is: correct voltage and polarity when connecting
booster cables.
o o Damage to electrical components may result if
t1 = 15 sec @ 3 C (38 F) voltage and polarity are not correct.
o o
t2 = 30 sec @ -12 C (10 F)
c. Connect one lead of booster cable to 24V
• The heater pilot lamp positive (+) post of battery needing assist, and
(instrument panel, to right other lead of the booster cable to the 24V
of steering column) will illu- positive (+) post of auxiliary battery (power
minate during heating cy- source).
cle.
d. Connect one lead of second booster cable to
• When the light goes “out”, turn the key switch 24V negative (-) post of auxiliary battery (power
to the “Start” position and hold this position source) and then connect other lead of the
until engine starts. (See prelube NOTE above.) booster cable to a good frame ground on the
disabled truck away from the battery needing
CAUTION: Do not crank engine with an electric
assist.
starter for more than 30 seconds. Severe damage
to starter motor can result from overheating.
Allow two minutes for starter motor cooling before
attempting to start engine again.

• If engine does not start, turn key switch “Off”,


wait for at least two minutes, and repeat the
above procedure.
• Under normal conditions, there is no need to
use the Manual Cold Start Switch.
(Refer to “Instrument Panel and Indicators”,
this Section.)
If it is very cold, and the prelube runs a long
time, the manual switch can be used to main-
tain pre-heating.

A3-22 General Safety and Operating Instructions A03011 4/98


AFTER ENGINE HAS STARTED
• After starting engine, operate engine at ap- 4. Check Parking Brake capacity.
proximately 1000 rpm, until engine lubricating • With the machine on flat ground, check that the
oil temperature and coolant temperature air pressure gauge is indicating “normal”
gauges are indicating “normal” (green) range. (green) range.
• Check also that the air pressure gauge is indi- • Move the Parking Brake Valve Lever to the
cating “normal” (green) range. PARKING (“locked”) position.
• Become thoroughly familiar with steering, Mo ve t he Shift
braking, and emergency controls. Lever to any posi-
tion other than “N”,
and check that the
central warning
During the following safety checks, if actuation or lamp flashes.
release of any steering, brake, or emergency con-
• Set shift lever to
trol circuit does not appear normal, shut engine
the D position, and gradually raise the engine
down immediately and notify maintenance person-
speed to 1770 rpm.
nel.
Check that the machine does not move.
Do not operate truck until circuit in question is fully If machine moves, notify maintenance person-
operational. nel to adjust parking brake.
Do not operate truck until parking brake is
fully operational.
1. Test the truck steering in extreme right and left
directions.
5. Check for normal actuation of the Emergency
Brake.
2. Check for normal actuation of the foot brake.
• With the machine on flat ground, check that the
• With the machine on flat ground,
air pressure gauge is indicating “normal”
depress Foot Brake pedal.
(green) range.
• Move Shift Lever • Move the Emergency Brake Lever to the
to the D position, BRAKE (“unlocked”) position.
and gradually raise
• Set Shift Lever to
the engine speed
the D position, and
to 1680 rpm.
gradually raise the
engine speed to
Check that the machine does not move. full throttle. Check
that the machine
does not move.
3. Check for normal actuation of the retarder. If machine moves, notify maintenance person-
• With the machine on flat ground, pull Retarder nel immediately to repair brakes.
Lever (1) fully. Do not operate truck until emergency brake
is fully operational.
• Set Shift Lever
(2) to the D posi-
tion, and gradu- 6. Check gauges, warning lights and instruments
al l y rai se t he before moving the truck to insure proper system
engine speed to operation and proper instrument functioning.
1240 rpm. Give special attention to braking and steering
circuit warning lights. If warning lights come on,
Check that the machine does not move.
shut down the engine immediately and notify
maintenance personnel to determine the cause.
7. Insure headlights, worklights and taillights are in
proper working order. Good visibility may prevent
an accident. Check operation of windshield wiper
and washer.

A03011 4/98 General Safety and Operating Instructions A3-23


8. When truck body is in dump position, do not allow 5. Observe all regulations pertaining to the job site’s
anyone beneath it, unless body-up retaining de- traffic pattern. Be alert to any unusual traffic pat-
vice is in place. tern. Match the truck speed to haul road condi-
tions and slow the truck in any congested area.
9. Do not use the fire extinguisher for any purpose
Obey the spotter’s signals at shovel and dump.
other than putting out a fire! If extinguisher is
discharged, report the occurrence so the used 6. Do not allow engine to run at “Idle” for extended
unit can be refilled or replaced. periods of time.
10. Do not allow unauthorized personnel to ride in the 7. Check parking brake periodically during working
truck. Do not allow anyone to ride on the ladder shift. Use parking brake for parking and at
or on the deck of the truck. shovel and dump only.
Do not attempt to apply parking brake while truck
8. Do not leave truck unattended while engine is
is moving!
running. Shut down engine before getting out of
cab. 8. Proceed slowly on rough terrain to avoid deep ruts
or large obstacles. Avoid traveling close to soft
edges and the edge of fill area.

MACHINE OPERATION SAFETY 9. Truck operation requires concentrated effort by


the driver. Avoid distractions of any kind while
PRECAUTIONS
operating the truck.
After the truck engine is started and all systems are
functioning properly, the operator must follow all local
safety rules to insure safe machine operation.
LOADING
1. Pull into the loading area with caution. Remain at
a safe distance while truck ahead is being loaded.

If any of the red warning lights come “On” or if any 2. Do not drive over unprotected power cables.
gauge reads in the red area during truck operation, 3. When approaching or leaving a loading area,
a malfunction is indicated. Stop truck as soon as watch out for other vehicles and for personnel
safety permits, shut down engine if problem indi- working in the area.
cates and have problem corrected before resum-
ing truck operation. 4. When pulling in under a loader or shovel, follow
“Spotter” or “Shovel Operator” signals. The truck
operator may speed up loading operations by
1. Always sound the warning horn before moving the observing the location and loading cycle of the
truck. When backing the truck, give back-up sig- truck being loaded ahead, then follow a similiar
nal (three blasts on air horn); when starting for- pattern.
ward, two blasts on air horn. These signals must
be given each time the truck is moved forward or 5. Operator should remain in truck cab with engine
backward. Look to the rear before backing the running while truck is being loaded. Place Trans-
truck. Watch for and obey ground spotter’s hand mission Range Selector in “Neutral” and apply
signals before making any reverse movements. Parking Brake lever.
Spotter should have a clear view of the total area
at the rear of the truck.
2. Operate the truck only while properly seated with
seat belt fastened. Keep hands and feet inside If operator must leave truck cab during loading,
the cab compartment while truck is in operation. engine must be shut down and parking brake ap-
Keep a firm grip on steering wheel at all times. plied. DO NOT use emergency brake for parking.
Remain far enough away from truck to avoid being
3. Check that all mirrors are not damaged, clean,
struck by flying material.
and are properly positioned for optimum view.
4. Check gauges and instruments frequently during
operation for proper readings. 6. When truck is loaded, pull away from shovel as
quickly as possible, but with extreme caution.

A3-24 General Safety and Operating Instructions A03011 4/98


HAULING
1. Always stay alert! If unfamiliar with the road, drive If the Brake Oil Temperature exceeds this limit,
with extreme caution. move the transmission range selector lever to a
lower gear and use the foot-operated service
2. Govern truck speed by the road conditions, brakes to reduce the truck ground speed. This will
weather and visibility. allow the transmission to shift to the next lower
3. Operate truck so it is under control at all times. gear range for more efficient cooling.
4. Use extreme caution when approaching a haul If the Brake Oil Temperature continues to exceed
road intersection. Maintain a safe distance from 248°F (120°C), select a safe area out of the way
oncoming vehicles. of other traffic, stop the truck, move the transmis-
sion range selector lever to the Neutral (N) posi-
5. Obey all road signs. tion, and operate the engine at approximately
6. Always dim headlights when meeting oncoming 1200 RPM until the Brake Oil Temperature gauge
vehicles. registers in the "green" range.
7. Maintain a safe distance when following another For better control under dry road conditions, the
vehicle. Never approach another vehicle from the optional front wheel brakes may be turned on.
rear, in the same lane, closer than 15 m (50 ft).
When operating on a down grade, stay at least 30
m (100 ft) away.
8. During normal operation, the retarder control
lever should be used to control the speed of the
truck and to stop the truck instead of using the
foot-operated service brake pedal. Use of this
lever allows the operator to apply the REAR
oil-cooled brakes only, thus extending the life
of the front caliper disc pads while still maintaining
maximum control of the truck. The foot-operated
brake pedal should be used when maneuvering
in tight places, at the shovel and dump, and when
quick stops or severe braking is required.
Retarder Operation
Before starting down a grade, maintain a speed
that will insure safe driving and provide effective
retarding under all conditions.
Refer to the "Retarding Capacity" decal which is
applied to the upper left-hand corner of the cab
windshield. This decal is designed to help the
operator maintain a safe vehicle speed while
descending a grade with a loaded truck.
For efficient retarder operation, the operator
should: 9. When operating truck in darkness or when visibil-
• Preselect a ground speed and gear range for a ity is poor, do not move truck unless headlights
known grade that will permit continous retarder are on. Do not back truck if back-up horn or lights
operation within the LIMITS OF THE CHART. are inoperative.
• Maintain engine RPM between 1800 — 2400 10. When backing the truck, give back-up signal
RPM, and (three blasts on air horn); when starting forward,
two blasts on air horn. These signals must be
• Observe the Brake Oil Temperature gauge to given each time the truck is moved forward or
make certain the Brake Oil Temperature does not backward.
exceed 248°F (120°C).

A03011 4/98 General Safety and Operating Instructions A3-25


11. Do not stop or park on a haul road unless unavoid- To Raise dump body:
able. If you must stop, move truck to a safe place,
apply parking brake, shut down engine, block
wheels securely and notify maintenance person-
nel for assistance.
12. If the “Emergency Steering” light and/or “Low Air The dumping of very large rocks (10% of payload,
Pressure” warning light come on during opera- or greater) or sticky material (loads that do not flow
tion, steer the truck immediately to a safe stop- freely from the body) may allow the material to
ping area, away from other traffic if possible. move too fast and cause the body to move RAP-
Refer to item 11 above. IDLY and SUDDENLY. This sudden movement may
jolt the truck violently and cause possible injury to
13. Report haul road conditions immediately. Muddy the operator, and/or damage to the hoist cylinders,
or icy roads, pot holes or other obstructions can frame, and/or body hinge pins. If it is necessary to
present hazards. dump this kind of material, refer to the CAUTION
14. Cab doors should remain closed at all times while in the following procedure:
truck is in motion or unattended.
15. Check for flat tires periodically during shift. If truck 4. Pull dump lever up to the
has been run on a “flat”, it must not be parked “RAISE” position and release
in a building until the tire cools. lever.

PASSING
5. Raise engine RPM to accelerate hoist speed.
1. Do not pass another truck on a hill or blind curve! Refer to the CAUTION below. When body is near
2. Before passing, make sure the road ahead is the maximum angle, reduce engine RPM (reduce
clear. If a disabled truck is blocking your lane, foot pressure on the accelerator pedal) to reduce
slow down and pass with extreme caution. shock load to the hydraulic system and hoist
cylinders.
3. Use only the areas designated for passing.

DUMPING
1. Pull into dump area with extreme caution. Make
If dumping very large rocks or sticky material as
sure area is clear of persons and obstructions,
decribed in WARNING above, slowly accelerate
including overhead utility lines. Obey signals di-
engine RPM to raise body.
rected by the spotter, if present.
When the material starts to
Avoid unstable areas. Stay a safe distance from move, move hoist lever to
edge of dump area. “HOLD” position. If material
Position truck on a solid, level surface before does not continue moving and
dumping. clear body, repeat this proce-
dure until material has cleared
body.

6. When the dump body rises to the set position


As body raises, the truck Center of Gravity (CG) (adjusted position of body positioner) dump lever
will move. TRUCK MUST BE ON LEVEL SURFACE returns to the “HOLD” position. If desired to raise
to prevent tipping / rolling! the body further, move dump lever to raise posi-
tion and dump will rise. If dump lever is released,
lever will return to hold position. Dump body will
2. Carefully maneuver truck into dump position. stop in that position.
When backing truck into dump position, use only
the foot-operated brake pedal to stop and hold 7. After material being dumped clears body, lower
truck. body to frame.

3. When in dump position, place transmission range


selector at the “Neutral” position, and apply the
Park Brake lever/switch.

A3-26 General Safety and Operating Instructions A03011 4/98


To Lower Body: SAFE PARKING PROCEDURES
7. After material being dumped The operator must continue the use of safety precau-
clears body, move dump tions when preparing for parking and engine shut-
lever to the “LOWER” posi- down.
tion and dump body will start
to move down. In the event that the equipment is being worked in
consecutive shifts, any questionable truck perform-
8. Release the lever and it will ance the operator may have noticed must be checked
return automatically to the by maintenance personnel before the truck is released
“ FLOAT” position. The to another operator.
body will move down under 1. The truck should be parked on level ground, if at
its own weight. all possible. If parking must be done on a grade,
the truck should be positioned at right angles to
If dumped material builds up at body tailgate and the grade.
body cannot be lowered, shift Transmission
Range Selector to “D” (Drive), release park brake 2. The parking brake must be applied and/or chocks
lever, and drive forward to clear material. Stop, placed fore/aft of wheels so that the truck cannot
shift Transmission Range Selector to “N” (Neu- roll. Each truck should be parked at a reasonable
tral), apply park brake lever and lower body. See distance from another.
NOTE : * below. 3. Haul roads are not safe parking areas. In an
emergency, pick the safest spot most visible to
other machines in the area. If the truck becomes
disabled where traffic is heavy, mark the truck
with warning flags in daylight or with flares at
night.
The truck is not to be moved with
the dump body raised except for
emergency moves only. Failure
to lower body before moving SHUTDOWN PROCEDURE
truck may cause damage to hoist
cylinders, frame and/or body The following sequence of shutdown procedure is
hinge pins. important and should be followed at each shutdown.

NOTE: When traveling, always place the dump lever


at the FLOAT position, regardless of whether or not 1. Stop truck, reduce engine RPM to low idle. Place
the truck is loaded. Transmission Range Selector in “Neutral” and
* If the transmission range selector is moved to any apply parking brake.
position other than “N” (neutral) when the dump lever 2. Allow engine to cool gradually by running at low
is not at the FLOAT position, the central warning lamp idle for 3 to 5 minutes.
will flash and the alarm buzzer will sound intermittently.
3. Turn keyswitch “Off” to stop engine.
9. With body returned to frame, move Transmission 4. Close and lock all windows, remove key from key
Range Selector to “D” (Drive), release park brake switch and lock cab to prevent possible unauthor-
lever, and leave dump area carefully. ized truck operation. Dismount truck properly.

A03011 4/98 General Safety and Operating Instructions A3-27


TOWING
Prior to towing a truck, many factors must be carefully 3. If the engine is NOT operable, never haul the truck
considered. Serious personal injury and/or significant over 800m (2,625 ft).
property damage may result if important safety prac- If the towing distance surpasses that limit, be sure
tices, procedures and preparation for moving heavy to remove the drive shaft between the transmis-
equipment are not observed. sion and the differential case (if final drive sun
gears have not been removed).
The towing speed must not be greater than 8 km/h
(5 mph).
Both right and left planetary sun gears/drive axles
should be removed before any towing. Refer to 4. Inspect tow bar for capacity (it should be strong
Section “G” in the Service Manual for these in- enough to tow 1.5 times the gross vehicle weight
structions. Extensive secondary damage can oc- of truck being towed).
cur to final drive components and/or transmission, 5. Determine that towing vehicle has adequate ca-
if truck is towed without first removing sun pacity to both move and stop the towed truck
gears/drive axles. under all conditions.
6. Protect both operators in the event of tow bar
failure.
7. Release disabled truck brakes and remove all
blocking.

The truck must not be towed except in emergen- Do not tow the truck any faster than 8 kph (5 MPH).
cies.
When towing becomes necessary, use the tow hook 8. Sudden movement may cause tow bar failure.
installed under the front frame and take the following Smooth and gradual truck movement is preferred.
precautions: 9. Minimize tow angle at all times - NEVER EXCEED
o
30 .
1. Block disabled truck to prevent movement while The towed truck must be steered in the direction
attaching tow bar. of the tow bar.
2. If the engine is operable; keep the engine running
while towing the machine, so that the steering and
braking can be used.
If there is a failure in the air circuit, the brakes
cannot be used, so be extremely careful when
towing. When air pressure in air reservoir abnor-
mally drops due to leakage from air circuit, park- BRAKE RELEASE
ing brake and emergency brake are actuated.
When towing truck, both brakes must be re- Releasing Parking Brake And Emergency Brake
leased. Refer to “BRAKE RELEASE” following After Being Actuated In An Emergency
these" TOWING" instructions.
If the pressure inside the air tank drops abnormally due
If the engine is NOT operable, it is possible to to some problem, such as leakage of air from the air
steer using the emergency steering, but do not circuit, the parking brake and emergency brake are
use it for more than 90 seconds, and travel at a automatically actuated.
speed of less than 5 km/h (3 mph).

A3-28 General Safety and Operating Instructions A03011 4/98


RELEASE OF PARKING BRAKE
The parking brake is a dry disc brake mounted on the Refer to Section 4, Lubrication & Service, Parking
rear drive shaft at the differential input with two (2) Brake Inspection and Adjustment, for instructions for
spring-applied, air-released calipers. Each caliper is reconnecting and adjusting park brake.
individually applied/released through separate air
chamber actuators (spring cylinder assemblies). If the
parking brake can not be released after its emergency
application – even if the parking brake valve lever is RELEASE OF EMERGENCY BRAKE
put in RELEASE position – take the following actions When the emergency brake has been applied, do not
to release the parking brake: continue to drive the machine. This will cause seizure
of the brake discs and linings.
If the emergency brake can not be released after its
emergency application – even if the emergency brake
valve lever is put in RELEASE position – release the
emergency brake in the following manner:
Before releasing the air pressure from the emergency
brake reservoir, confirm safety in the surrounding area
and put chocks against the tires.

1. Block disabled truck to prevent movement and


confirm safety in the surrounding area.
2. At the parking brake relay valve, remove both air
hoses (4) connected to the air chambers of the
parking brake spring cylinder assemblies (5).
3. Connect these hoses together using a “tee” fitting
with compatible thread ends.
4. Connect third connector of “tee” to a hose from RELEASING EMERGENCY BRAKE
an air supply of sufficient capacity to release 1. Air Quick Disconnect 2. Drain Valve
calipers. Apply air and release brake. Pull Rings
5. With parking brake released, turn adjustment bolt
(2) counterclockwise, and check for “play” in link-
1. After making preparations to tow the machine, pull
age (3). Remove pin (1). Repeat for other caliper.
rings (2) on the 4 drain valves on the front air tanks
Disconnect air supply.
to release the air pressure.
6. With parking brake disconnected, remove block-
2. After exhausting all air pressure, release rings (2).
ing and immediately move the truck to a safe
place. Refer to INSTRUCTIONS FOR TOWING 3. Drain the rear air tank by pulling and holding the
THE MACHINE. ring on the air drain valve mounted on the frame
in front of the right rear suspension. Keep drain
valve open until all air is exhausted from tank.
This will allow the emergency brake to release.

If the air system is not operating, the service


brakes will not apply; this is very dangerous. Be
sure to tow the truck at low speed, keeping the
engine running (if possible) and always be ready
to steer.

A03011 4/98 General Safety and Operating Instructions A3-29


NOTES

A3-30 General Safety and Operating Instructions A03011 4/98


WARNINGS AND CAUTIONS
The following paragraphs give an explanation of the WARNING, CAUTION, and Service Instruction plates and decals
attached to the truck. The plates and decals listed here are typical of this model, but because of customer options,
individual trucks may have plates and decals that are different from those shown here.
The plates and decals must be kept clean and legible. If any decal or plate becomes worn or unable to be read, it
should be replaced with a new one.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

This caution plate is located inside the cab on the left-hand door panel under the arm rest. It contains (3) CAUTIONS
- Operating Machine Safely, Driving Over A Long Distance, and Hoist Control Lever operation. These decals stress
the importance of reading and understanding the operators manual prior to the operation of equipment.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRE AIR PRESSURE Caution plate is located inside


the cab on left-hand door panel under the arm rest.
Extreme caution should be used when taking a pres-
sure reading. Tire is under high pressure.

A04028 11/98 Warnings and Cautions A4-1


This instruction plate contains (4) WARNINGS -
Inspection and Maintenance With Body In Raised Up
Position, Emergency Steering System Operation, the
Engine Shut Down Procedure, and the Retarder Oil
Temperature Warning Light.
These “ WARNINGS” stress the importance of reading
and understanding the operators manual prior to the
operation of equipment.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caution plates are mounted at the air tank on center


top deck, also at rear frame just below tail light assem-
blies. Caution should be used when opening drain
valves. System under high pressure.
. . . . . . . . . . . . . . . . . . . . . . .
DANGER plates are mounted on each suspension
cylinder. These plates warn that the suspensions are
charged with high pressure nitrogen. No servicing of
any kind should be attempted until the service manual
has been referenced and proper and safe procedures
are followed.

A Brake Cooling Oil decal is located between the filler


cap and sight gauge on the right hand side of the
hydraulic tank.

A4-2 Warnings and Cautions A04028 11/98


This CAUTION plate is located on left hand side of
radiator shroud. Extreme care should be taken when
working around fan and belts. Hands and loose articles
A CAUTION plate is attached to the hydraulic tank, of clothing should be kept away when machine is
alerting the service person that the engine must always operating.
be shut down and cooled before removing fillercap. . . . . . . . . . . . . . . . . . . . . . . .
This plate also alerts the service person of HOT oil
under pressure. Hydraulic oil becomes heated and
pressurized during operation. Care must be taken to
avoid burns when it is necessary to open the hydraulic
system.

Hydraulic fluid escaping under pressure can have


sufficient force to enter a person’s body by pene-
trating the skin and cause serious injury and pos-
sible death if proper medical treatment by a
A plate is mounted on the left hand side of the trans-
physician familiar with this injury is not received
mission oil pan to provide instructions for proper trans-
immediately.
mission oil level check.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering and Hoist Oil decal is located to the left of the A Caution plate is located next to the sight gauge on
left hand filler cap on left hand side of hydraulic tank. the front brake oil tank, mounted on air tank top right
hand deck. The Caution plate alerts service person to
use only SAE-10W oil.
Brake system components are not compatible with
other fluids which can cause component deterioration.

A04028 11/98 Warnings and Cautions A4-3


A service indicator plate is located on the center air
cleaner housing.
A plate is located next to filler cap on fuel cap which Service filter element when red signal reaches service
specifies Diesel Fuel Only. Care should be taken to level in dust indicator.
open cap slowly and bleed off pressure that may be in
tank when removing filler cap.
Operation and Maintenance Manual refered to is from
Engine Manufacturer. When using compressed air, wear safety glasses
. . . . . . . . . . . . . . . . . . . . . . . and all other safety equipment required when
cleaning.
. . . . . . . . . . . . . . . . . . . . . . .

Attached to the interior of battery box lid is a DANGER


plate. This plate stresses the need to keep from mak-
ing any sparks near the battery. When another battery
or 24VDC power source is used for auxiliary power, all
switches must be “Off” prior to making any connec-
tions. When connecting auxiliary power cables, posi-
tively maintain correct polarity; connect the positive (+)
leads together and then connect the negative (-) lead
of the auxiliary power cable to a good frame ground.
Do not connect to the negative post of the truck battery
or near the battery box. This hookup completes the
circuit but minimizes danger of sparks near the batter-
ies.
Sulfuric acid is corrosive and toxic. Use proper safety
gear, goggles, rubber gloves and rubber apron when
handling and servicing batteries. Avoid contact with
skin, eyes or clothing. In event of accident, immedi-
ately flush with plenty of water and call a physician. A caution plate is located on the right hand inside door
KEEP OUT OR REACH OF CHILDREN! panel and also on the lid of the battery box. These
instructions must be followed when welding is done on
the truck to avoid damage to the electronic compo-
nents.

A4-4 Warnings and Cautions A04028 11/98


A Caution plate is located next to the sight gauge on
A Caution plate is located on center deck floor next to the radiator cooling water reserve tank on top of right
radiator fill access cover plate. When actual tempera- hand deck just aft of battery box.
ture differs with the indication, change the ratio of
antifreeze to match ambient conditions. Keep coolant level between “FULL” and “LOW”
when engine is cold.
Service personnel should use caution when serv-
icing radiator. The system is pressurized because . . . . . . . . . . . . . . . . . . . . . . .
of thermal expansion of coolant. “DO NOT” re-
move radiator cap while engine is hot. Severe
burns may result.
. . . . . . . . . . . . . . . . . . . . . .

The Action Code decal is located on the inside of the


Warning plates are mounted on the truck frame in front
cab in the upper left-hand corner of the windshield.
of and to the rear of both front tires to alert all persons
This decal explains what action to take when an action
to stay clear when the truck is being steered.
code is displayed on the monitor panel on the operator
monitor and indicator panel.

A04028 11/98 Warnings and Cautions A4-5


An informational plate for solenoid valve and relays is mounted to the inside lid of the electrical console behind the
operator and passenger seats.

A "Retarding Capacity" decal is applied to the upper left-hand corner of the cab windshield. This decal is designed
to help the operator maintain a safe vehicle speed while descending a grade with a loaded truck.

For efficient retarder operation, the operator should:


• Preselect a ground speed and gear range for a
known grade that will permit continous retarder
operation within the LIMITS OF THE CHART.
• Maintain engine RPM between 1800 — 2400
RPM, and
• Observe the Brake Oil Temperature gauge to
make certain the Brake Oil Temperature does not
exceed 248°F (120°C).
If the Brake Oil Temperature exceeds this limit, move
the transmission range selector lever to a lower gear
and use the foot-operated service brakes to reduce the
truck ground speed. This will allow the transmission to
shift to the next lower gear range for more efficient
cooling.
If the Brake Oil Temperature continues to exceed
248°F (120°C), select a safe area out of the way of
other traffic, stop the truck, move the transmission
range selector lever to the Neutral (N) position, and
operate the engine at approximately 1200 RPM until
the Brake Oil Temperature gauge registers in the
"green" range.

A4-6 Warnings and Cautions A04028 11/98


An informational plate for the fuse table is located to the left of the solenoid valve and relay plate. This is mounted
inside of lid of the electrical console behind the operator and passenger seats.

A product identification plate is located on left hand front fender on the inside top. This lists the vehicle model number,
maximum G.V.W. and Product Identification Number. 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 the proper ordering of many service parts and/or warranty consideration.

A04028 11/98 Warnings and Cautions A4-7


The lubrication chart is located on the left hand front fender behind the ladder. Refer to Section P, "Lubrication and
Service", for more complete lubrication instructions.

A4-8 Warnings and Cautions A04028 11/98


STANDARD CHARTS AND TABLES

This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard
units in parentheses. References throughout the manual to standard torques or other standard values will be to
one of the following Tables.
For values not shown in any of the charts or tables, standard conversion factors for most commonly used measure-
ments are provided in the conversion table below.

INDEX OF TABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
TABLE I STANDARD TIGHTENING TORQUE COMMON CONVERSION MULTIPLIERS
METRIC To ENGLISH
. . . . . . . . . . . . . . . . For Capscrews and Nuts A5-2
Multiply
To Convert From TO By
millimeter (mm) inch – in. 0.0394
TABLE II STANDARD TIGHTENING TORQUE
centimeter (cm) inch – in. 0.3937
. . . . . . . . . . . . . . . . . . .For Split Flange Bolts A5-2
meter (m) foot – ft. 3.2808
meter (m) yard – yd. 1.0936

TABLE III . . . . . .TIGHTENING TORQUE FOR kilometer (km) mile – mi. 0.6210
2) in.2 0.1550
sq. centimeters (cm sq. in. –
. . . . . . . . . . . Flared Tube And Hose Fittings A5-2
sq. centimeters (cm2) sq. ft. – ft.2 0.001

cu. centimeters (cm3) cu. in. – in.3 0.061


TABLE IV . . TEMPERATURE CONVERSIONS A5-3
liters (l) cu. in. – in.3 61.02

cu. meters (m3) cu. ft. – ft.3 35.314


TABLE V . . . . . . . . TORQUE CONVERSIONS liters (l) cu. ft. – ft.3 0.0353
. . . . . . . . . . kilogram meters To foot pounds A5-3 grams (g) ounce – oz. 0.0353
milliliter (ml) fluid ounce – fl. oz. 0.0338
kilogram (kg) pound (mass) 2.2046
TABLE VI . . . . . . . . TORQUE CONVERSIONS
Newton (N) pound (force) – lbs. 0.2248
. . . . . . . . kilogram meters To Newton meters A5-3 Newton.meters (N.m) kilogram.meters (kg.m) 0.102
Newton.meters (N.m) ft. lbs. (force) 0.7376
kilogram.meters (kg.m) ft. lbs. (force) 7.2329
TABLE VII . . . . .PRESSURE CONVERSIONS
kilogram.meters (kg.m) Newton.meters (N.m) 9.807
. . . . . . . . . . . . . . . . . . . . . . . .kg/cm2 To (psi) A5-4 Kilopascals (kPa) psi (pressure) 0.1450
megapascals (MPa) psi (pressure) 145.038
2 2 psi (pressure) 14.2231
kilograms/cm (kg/cm )
TABLE VIII . . . . .PRESSURE CONVERSIONS
2 2 kilopascals (kPa) 98.068
kilograms/cm (kg/cm )
. . . . . . . . . . . . . . . . . . . . . . . . kg/cm2 To kPa A5-4
kilogram (kg) ton (short) 0.0011
metric ton ton (short) 1.1023

TABLE IX . . . . . PRESSURE CONVERSIONS liters (l) quart – qt. 1.0567


liters (l) gallon – gal. 0.2642
. . . . . . . . . . . . . . . . . . . . . . . . . . . psi To kPa A5-4
Watts HP (horsepower) 0.00134
kilowatts (kw) HP (horsepower) 1.3410

A05002 05/04 Standard Charts and Tables A5-1


TABLE I. STANDARD TIGHTENING TORQUE FOR
METRIC HEX HEAD CAPSCREW AND NUT ASSEMBLY

Capscrew Thread Width Kilogram meters Newton meters Foot Pounds


Diameter Across Flat (kg.m) (N.m) (ft.lbs.)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
6 10 1.35 13.2 10
8 13 3.2 31.4 23
10 17 6.7 65.7 48
12 19 11.5 112 83
14 22 18.0 177 130
16 24 28.5 279 206
18 27 39.0 383 282
20 30 56.0 549 405
22 32 76.0 745 550
24 36 94.5 927 684
27 41 135 1320 975
30 46 175 1720 1266
33 50 225 2210 1630
36 55 280 2750 2025
39 60 335 3280 2420
This Table represents standard values only.
Do not use these values to replace torque values which are specified in the Service Manual instructions.

TABLE II. TIGHTENING TORQUE FOR


SPLIT FLANGE BOLTS

Capscrew Thread Width Kilogram meters Newton meters Foot Pounds


Diameter Across Flat (kg.m) (N.m) (ft.lbs.)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
10 14 6.7 65.7 48
12 17 11.5 112 83
16 22 28.5 279 206
This Table represents standard values only.
Do not use these values to replace torque values which are specified in the Service Manual instructions.

TABLE III. TIGHTENING TORQUE FOR


FLARED TUBE AND HOSE FITTINGS

Thread Width Kilogram meters Newton meters Foot Pounds


Diameter of Nut Across Flat (kg.m) (N.m) (ft.lbs.)
(mm) (mm) Tolerances ±10% Tolerances ±10% Tolerances ±10%
14 19 2.5 25 18
18 24 5 50 36
22 27 8 80 58
24 32 14 140 101
30 36 18 175 130
33 41 20 195 145
36 46 25 245 180
42 55 30 295 215

A5-2 Standard Charts and Tables 05/04 A05002


TABLE IV. TEMPERATURE CONVERSIONS
Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F°
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 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.

TABLE V. TORQUE CONVERSIONS


kilogram.meter - kg.m To Foot Pounds - (ft.lbs.)
1 kg.m=7.2339 ft.lbs.
kg.m 0 1 2 3 4 5 6 7 8 9
0 (ft.lbs) 7.23 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.5 303.8 311.0 318.2 325.5 332.7 339.9 347.2 354.4
50 361.6 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

TABLE VI. TORQUE CONVERSIONS


kilogram meter - kg.m To Newton meters (N.m)
1 kg.m=9.807 N.m
kg.m 0 1 2 3 4 5 6 7 8 9
0 (N.m) 9.8 19.6 29.4 39.2 49.0 58.8 68.6 78.5 88.3
10 98.1 107.9 117.7 127.5 137.3 147.1 156.9 166.7 176.5 186.3
20 196.1 205.9 215.8 225.6 235.4 245.2 255.0 264.8 274.6 284.4
30 294.2 304.0 313.8 323.6 333.4 343.2 353.1 362.9 372.7 382.5
40 392.3 402.1 411.9 421.7 431.5 441.3 451.1 460.9 470.7 480.5
50 490.4 500.2 510.0 519.8 529.6 539.4 549.2 559.0 568.8 578.6
60 588.4 598.2 608.0 617.8 627.6 637.5 647.3 657.1 666.9 676.7
70 686.5 696.3 706.1 716.0 725.7 735.5 745.3 755.1 764.9 774.8
80 784.6 794.4 804.2 814.0 823.8 833.6 843.4 853.2 863.0 872.8
90 882.6 892.4 902.2 912.1 921.9 931.7 941.5 951.3 961.1 970.9

A05002 05/04 Standard Charts and Tables A5-3


TABLE VII. PRESSURE CONVERSIONS
2 2
kilograms/cm (kg/cm )To pounds per sq. in. (psi)
1 kg/cm2=14.2231 psi
2 0 1 2 3 4 5 6 7 8 9
kg/cm
0 (psi) 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 185.0 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.2 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.1 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.0 782.3 796.5 810.7 824.9 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 952.9 967.2 981.4
70 995.6 1009.8 1024.1 1038.3 1052.5 1066.7 1081.0 1095.2 1109.4 1123.6
80 1137.8 1152.1 1166.3 1180.5 1194.7 1209.0 1223.2 1237.4 1251.6 1265.9
90 1280.1 1294.3 1308.5 1322.7 1337.0 1351.2 1365.4 1379.6 1393.9 1408.1

TABLE VIII. PRESSURE CONVERSIONS


2 2
kilograms/cm (kg/cm )To kilopascals (kPa)
2
1 kg/cm =98.068 kPa
2 0 1 2 3 4 5 6 7 8 9
kg/cm
0 (kPa) 98 196 294 392 490 588 686 785 883
10 981 1079 1177 1275 1373 1471 1569 1667 1765 1863
20 1961 2059 2157 2256 2354 2452 2550 2648 2746 2844
30 2942 3040 3138 3236 3334 3432 3530 3629 3727 3825
40 3923 4021 4119 4217 4315 4413 4511 4609 4707 4805
50 4903 5001 5100 5198 5296 5394 5492 5590 5688 5786
60 5884 5982 6080 6178 6276 6374 6472 6571 6669 6767
70 6865 6963 7061 7159 7257 7355 7453 7551 7649 7747
80 7845 7944 8042 8140 8238 8336 8434 8532 8630 8728
90 8826 8924 9022 9120 9218 9316 9415 9513 9611 9709

TABLE IX. PRESSURE CONVERSIONS


Pounds/sq. in. [psi] To kilopascals (kPa)
Formula: psi x 6.895 = kPa
psi 0 1 2 3 4 5 6 7 8 9

0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6

NOTE: Tables such as Table V, VI, VII, VIII, and IX may be used as in the following example:
Example: Convert 955 kg.m to foot pounds (ft.lbs.). 4. Go to kg.m row 0, column 5; reads 49.0
5 kg.m = 49 ft.lbs. Add to step 3.
1. Select Table V.
5. 950 + 5 kg.m = 6871 + 49 = 6920 ft.lbs.
2. Go to kg.m row 90, column 5; reads 687.1
955 kg.m = 6920 ft.lbs.
95 kg.m = 687.1 ft.lbs.
3. Multiply by 10:
950 kg.m = 6871 ft.lbs.

A5-4 Standard Charts and Tables 05/04 A05002


Sealants and Adhesives
The recommended coating materials such as adhesives, gasket sealants and greases used for component assem-
bly are listed below. For coating materials not listed below, use the equivalent of products shown in this table.

SEALANTS AND ADHESIVES


Nomenclature Code Part Number Applications
LT-1A TB1521 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast,
LT-1B 790-129-9050
strong seal is needed.
Adhesives
LT-2 VE7533 Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-3
Used as adhesive or sealant for metal, glass and plastic.
(2 part epoxy)
LG-1 Used with gaskets and packings to increase sealing effect.
LG-3 1400266H1 Heat-resistant gasket for precombustion chambers and exhaust piping.
Used by itself on mating surfaces on the final drive and transmission
LG-4 1400265H1
cases. Thickness after tightening: 0.07-0.08 mm (0.0027-0.0032 in)
Liquid Gasket
Used by itself to seal grease fittings, tapered screw fittings and tapered
LG-5 790-129-9080
screw fittings in hydraulic circuits of less than 50 mm (2 in) in diameter.
LG-6 TB1215 Silicone rubber - used to seal oil pan, final drive case mating surfaces.
LG-7 TB1207C Silicone rubber - used to seal oil pan, flywheel housing mating surfaces.
Molybdenum
Applied to bearings and taper shafts to facilitate press-fitting and to pre-
Disulphide LM-P 09940-00040
vent sticking, burning or rusting.
Lubricant
Grease General purpose - applied to bearings, sliding parts and oil seals for lubri-
G2-LI SYG2-400LI-A
cation, rust prevention and facilitation of assembly work.

:
PART NUMBERS
Three Bond Komatsu
TB1374 VE7533
TB1521 TB1521
TB1104 1400265H1
TB1107 1400266H1
TB1110 790-129-9080

A05002 05/04 Standard Charts and Tables A5-5


NOTES

A5-6 Standard Charts and Tables 05/04 A05002


STANDARD VALUE TABLES

ENGINE STANDARD VALUES

MODEL HD785-5LC
ENGINE SA12V140Z-2
ITEM MEASUREMENT CONDITIONS UNIT Standard Value Permissible Value
Power Mode 2350 ± 50 2350 ± 50
High Idle Economy Mode rpm 2300 ± 50 2300 ± 50

Engine Speed HI 1000 ± 50 1000 ± 50


Low Idle Lo rpm 650 ± 25 650 ± 25
Power Mode 2000 ± 50 2000 ± 50
Rated Speed Economy Mode rpm 1900 ± 50 1900 ± 50

A06002 Standard Value Tables A6-1


CHASSIS STANDARD VALUES
ITEM MEASUREMENT CONDITIONS UNIT STANDARD PERMISSIBLE
VALUE VALUE
TRUCK PERFORMANCE
F1 6.6 ± 5% 6.6 ± 5%
F2 9.3 ± 5% 9.3 ± 5%
• Engine water temperature.:
F3 12.4 ± 5% 12.4 ± 5%
Within operating range.
Travel F4 MPH 16.6 ± 5% 16.6 ± 5%
• Transmission oil temperature:
Speed 70°- 90°C
F5 22.0 ± 5% 22.0 ± 5%
• Empty truck
F6 30.0 ± 5% 30.0 ± 5%
• Traveling resistance: 3.3%
F7 40.0 ± 5% 40.0 ± 5%
R 7.1 ± 5% 7.1 ± 5%
ENGINE SPEED
Shift up 2100 ± 50 2100 ± 50
High Power
1450 ± 50 1450 ± 50
Mode
Automatic Shift Control

Shift down
1400 ± 50 1400 ± 50
(F2ŸF1 only) (F2ŸF1 only)
Shift up 2000 ± 50 2000 ± 50
Economy RPM
1350 ± 50 1350 ± 50
Mode
Shift down
1300 ± 50 1300 ± 50
(F2ŸF1 only) (F2ŸF1 only)
• Engine water temp.:
Braking Shift up Within operating range. 2450 ± 50 2450 ± 50
Mode • Transmission oil temp.: 70° - 90°C
Shift down 1550 ± 50 1550 ± 50
• Hydraulic oil temp.: 70° - 90°C
Set F1, F2 1500 1500
Auto Lock-up

• "Braking Mode" refers to when the


F3 - F7 accelerator is OFF or the rear 1250 ± 50 1250 ± 50
brake is ON. RPM
F1, F2 1200 1200
Reset F3 - F7 1100 ± 50 1100 ± 50
Set 2600 ± 10 2600 ± 10
Protection
Overrun

Reset RPM 2350 ± 10 2350 ± 10

Same as shift down Same as shift down


Down-shift Inhibitor RPM for automatic shift for automatic shift
control (see above) control (see above)
TORQUE CONVERTER
• Transmission oil temp.: 70° - 90°C POWER MODE
Engine Speed at Torque Converter • Hydraulic oil temp.: 70° - 90°C RPM 2040 ± 100 2040 ± 100
Stall
• Engine water temp.:
within operating range ECONOMY MODE
RPM 1950 ± 75 1950 ± 75

A06002 Standard Value Table A6-2


CHASSIS STANDARD VALUES (Continued)
ITEM MEASUREMENT CONDITIONS UNIT STANDARD PERMISSIBLE
VALUE VALUE
ACCELERATOR PEDAL
Starting to depress • Operating effort at a point (Electronic governor (Electronic governor
Operating effort 150 mm (5.9 in.) from pedal kg (lbs) specification truck) specification truck)
fulcrum
Fully depressed 1.8 ± 0.5 (4.0 ± 0.7) 1.8 ± 0.5 (4.0 ± 0.7)
+2.0 / - 4.9
42.1 42.1 +2.0 / - 4.9
Travel Starting to depress • Travel at a point 150 mm (5.9 mm +0.07 / -0.19) +0.07 / -0.19)
(1.6 (1.6
in.) from pedal fulcrum (inches)
⇔Fully 44 ± 5(1.7 ± 0.2) 44 ± 5(1.7 ± 0.2)
GEARSHIFT LEVER
Operating effort • At center of lever knob kg 1.6 ± 0.4 Max. 2
(lbs.) (3.5 ± 0.8) (4.4)
R-N
N-D

Travel D-5 mm 18.5 ± 1 18.5 ± 2


5-4 (inches) (0.73 ± 0.04) (0.73 ± 0.08)

4-3
3-L
TORQUE CONVERTER
Oil pressure at Engine @ high idle 8 ± 1 (113 ± 15) 8 ± 1 (113 ± 15)
inlet port
Engine @ low idle 1.3 ± 0.5 (18.5 ± 7) 1.3 ± 0.5 (18.5 ± 7)
Oil pressure at Engine @ high idle • Oil temperature: 4 ± 0.5 (57 ± 14) 4 ± 0.5 (57 ± 14)
70° - 90°C (158° - 194°F)
outlet port
Engine @ low idle • Engine water temperature: kg/cm2 1.0 ± 0.5 (14 ± 7) 1.0 ± 0.5 (14 ± 7)
Lock-up oil Engine @ high idle Within operating temperature (psi) 16.0 ± 0.5 (230 ± 10) 16.0 ± 0.5 (230 ± 10)
pressure Engine @ low idle • Hydraulic oil temperature: 16.0 ± 0.5 (230 ± 10) 16.0 ± 0.5 (230 ± 10)
50° - 80°C (122° - 176°F)
Main relief Engine @ high idle 39.0 ± 2 (555 ± 29) 39.0 ± 2 (555 ± 29)
pressure
Engine @ low idle 34.5 ± 2 (490 ± 29) 34.5 ± 2 (490 ± 29)
TRANSMISSION CONTROL VALVE SET PRESSURE
Engine @ high idle 16.5 ± 1.5 (235 ± 20) 16.5 ± 1.5 (235 ± 20)
L, H, 4th clutch Engine @ low idle 16.5 ± 1.5 (235 ± 20) 16.5 ± 1.5 (235 ± 20)
On actual truck

Engine @ high idle 20.5 ± 1.5 (290 ± 20) 20.5 ± 1.5 (290 ± 20)
3RD clutch
Engine @ low idle 20.5 ± 1.5 (290 ± 20) 20.5 ± 1.5 (290 ± 20)
Engine @ high idle 31.5 ± 1.5 (450 ± 20) 31.5 ± 1.5 (450 ± 20)
1st, 2nd clutch • Oil temperature:
Engine @ low idle 70° - 90°C (158° - 194°F) 31.5 ± 1.5 (450 ± 20) 31.5 ± 1.5 (450 ± 20)
Engine @ high idle • Engine water temperature: kg/cm2 30 ± 1.5 (435 ± 20) 30 ± 1.5 (435 ± 20)
R clutch Within operating temperature (psi)
Engine @ low idle 30 ± 1.5 (435 ± 20) 30 ± 1.5 (435 ± 20)
• Hydraulic oil temperature:
Engine @ high idle 17 ± 2 (242 ± 28) 17 ± 2 (242 ± 28)
modulation Checker

50° - 80°C (122° - 176°F)


L, 4th clutch
Engine @ low idle 17 ± 2 (242 ± 28) 17 ± 2 (242 ± 28)
When using

Engine @ high idle 20 ± 2 (284 ± 28) 20 ± 2 (284 ± 28)


H, 3rd clutch
Engine @ low idle 20 ± 2 (284 ± 28) 20 ± 2 (284 ± 28)
1st, 2nd, R Engine @ high idle 33 ± 2 (469 ± 22) 33 ± 2 (469 ± 22)
clutch Engine @ low idle 33 ± 2 (469 ± 22) 33 ± 2 (469 ± 22)

A06002 Standard Value Tables A6-3


CHASSIS STANDARD VALUES (Continued)
ITEM MEASUREMENT CONDITIONS UNIT STANDARD PERMISSIBLE
VALUE VALUE
TRANSMISSION
• Engine water temperature.: Within
operating range.
Lubricating Oil Pressure • Engine: Full throttle kg/cm2 1.25 ± 0.5 1.25 ± 0.5
• Oil temp.: 60° - 80°C (140° - 176°F) (psi) (18 ± 7) (18 ± 7)
(using EO10-CD) or 70° - 90°C (158° -
194°F) (using EO30-CD)
TIRE INFLATION PRESSURE
27.00 R49 7.0 ± 0.1 7.0 ± 0.1
Standard Tires (front and rear (100 ± 2) (100 ± 2)
wheels) • When empty kg/cm2
27.00-49-48PR (psi) 5.60 5.60
Optional Tires (front and rear (80) (80)
wheels)
STEERING WHEEL
• Oil temp.: 50° - 80°C (122° - 176°F)
Operating Force • Truck stopped and empty. If impossible kg Max. 3.0 Max. 3.6
(Steering wheel turning speed: 30 rpm) when truck is stopped, travel at low (lbs.) (Max 6.6) (Max 8.0)
speed with engine @ low idle.
Play • Length at circumference of steering mm 130 ± 30 130 ± 30
wheel. (in.) (5 ± 1.2) (5 ± 1.2)
• Engine stopped
No. of Turns • Lock ⇒Lock Turns 3.5 ± 0.4 3.5 ± 0.6
Left ⇒Right • Oil temp.: 50° - 80°C (122° - 176°F) Max. 4 Max. 5
Turning Time • Engine speed: Full range sec.
Right ⇒ Left • Lock ⇒Lock Max. 4 Max. 5
STEERING VALVE
Engine @ Hi idle 210 +15 / - 0.0
210 +15 / - 0.0

• Oil temp.: 50° - 80°C (122° - 176°F) kg/cm2 (2986 +215 / - 0.0)
(2986 +215 / - 0.0)
Relief Pressure (psi)
Engine @ Lo idle • Engine: Full throttle
185 +10/ - 0.0 185 +10/ - 0.0
• Demand valve relief valve +140 / - 0.0 ) +140 / - 0.0)
(2630 (2630
BRAKE PEDAL
Operating Force kg Max 30 Max 30
(lbs.) (Max. 66) (Max. 66)
• Tip of pedal
Travel mm (in.) 78 ± 8 78 ± 15
(3 ± 0.3) (3 ± 0.6)
RETARDER CONTROL LEVER
Operating Force kg 1.0 - 4.0 0.5 - 6.0
• At point 10 mm (0.4 in) from tip of lever (lbs.) (2.2 - 8.8) (1.1 - 13.2)
Travel degrees 0 - 90 ± 3 0 - 90 ± 3
PARKING BRAKE LEVER
Operating Force • Tip of lever kg (lbs.) Max. 2.0 (Max. 4.4) 3.0 (6.6)
EMERGENCY BRAKE LEVER
Operating Force • Tip of lever kg 0.01 - 0.02 Max. 0.05
(lbs.) (0.02 - 0.04) (Max. 0.10)
AIR GOVERNOR
• Pressure at which air is stored and
Set pressure circuit is unloaded when air pressure is 8.3 ± 0.3 8.3 ± 0.3
kg/cm2
raised from 0 kg/cm 2 (0 psi) with (120 ± 4.3) (120 ± 4.3)
(psi)
engine at full throttle.

A06002 Standard Value Table A6-4


CHASSIS STANDARD VALUES (Continued)
ITEM MEASUREMENT CONDITIONS UNIT STANDARD PERMISSIBLE
VALUE VALUE
BRAKES
Service brake 91 ton payload Max. 29 (95) Max. 29 (95)
braking distance
Empty • Initial speed: 32 km/h (20 MPH) Max. 22.3 (73) Max. 22.3 (73)
m (ft)
Retarder brake 91 ton payload • Distance from starting speed to stop Max. 29 (95) Max. 38 (125)
braking distance • Max. actuating air pressure:
Empty Max. 22.3 (73) Max. 30 (98)
8.3 kg/cm2 (120 psi)
Front chamber Min. 160 (2275) Min. 160 (2275)
• Max. hydraulic pressure:
Rear chamber kg/cm2 Min. 45 (640) Min. 45 (640)
Brake actuating Rear: 45 kg/cm2 (640 psi)
(service) (psi)
pressure Front: 187 kg/cm 2 (2660 psi)
Rear chamber Min. 45 (640) Min. 45 (640)
• On flat, dry road surface
(retarder)
Stopping distance when emergency • Carrying 91 ton payload
brake is applied • Initial speed: 32 km/h (20 mph) m Max. 60.9 Max. 60.9
• On flat, dry road surface (ft) (200) (200)

PARKING BRAKE
• With 91 ton payload
Braking Capacity (sin θ) • After adjusting clearance between disc % Min. 15 Min. 15
and pad
Starting Test • F2 rpm Min. 2070 Min. 2070
• Torque converter stall
HOIST LEVER
HOLD ⇒ Max. 10 (22) Max. 10 (22)
RAISE
RAISE ⇒ Automatically reset Automatically reset
HOLD

Operating HOLD ⇒ kg 5 - 10 (11 - 22) 5 - 10 (11 - 22)


• Center of control lever knob
Force FLOAT (lbs.)
FLOAT ⇒ 3 - 6 (7- 13) 3 - 6 (7- 13)
HOLD
LOWER ⇒ Automatically reset Automatically reset
FLOAT
FLOAT ⇒ Max. 13 (29) Max. 13 (29)
LOWER
RAISE ⇒ 15 ± 2 15 ± 2
HOLD (A) (0.6 ± 0.07) (0.6 ± 0.07)
Travel HOLD ⇒ (Refer to Figure 6-1 for hoist lever positions mm 11 ± 2 11 ± 2
"A", "B", and "C") (in.)
FLOAT (B) (0.4 ± 0.07) (0.4 ± 0.07)
FLOAT ⇒ 11 ± 2 11 ± 2
LOWER (C) (0.4 ± 0.07) (0.4 ± 0.07)
HOIST VALVE
Engine @ High • Oil temp.: 50° - 80°C (122° - 176°F) 200 +15 / - 0.0
200 +15 / - 0.0
Relief Idle • Engine: Full throttle kg/cm2 +210 / - 0.0) +210 / - 0.0)
(2845 (2845
Pressure (psi)
• Measure at end of stroke when raising +10 / - 0.0 +10 / - 0.0
body 185 185
Engine @ Low Idle +142 / - 0.0) +142 / - 0.0)
(2630 (2630

A06002 Standard Value Tables A6-5


CHASSIS STANDARD VALUES (Continued)
ITEM MEASUREMENT CONDITIONS UNIT STANDARD PERMISSIBLE
VALUE VALUE
BODY
Lifting Speed • Oil temp.: 50° - 80°C (122° - 176°F) 13 ± 1.5 13 ± 1.5
Lowering Speed • Engine: Full throttle sec. 17 ± 1.5 17 ± 1.5
• Use FLOAT when lowering
• Oil temp.: 50° - 80°C (122° - 176°F)
Hydraulic Drift • Set with No. 2 cylinder extended 200 mm Max. 85 170
mm (7.8 in.) (in.) (3.4) (6.7)
• Hydraulic drift after 5 minutes
SUSPENSION CYLINDER
FRONT [A] • On flat road surface 262 ± 10 (10.3 ± 0.4) 262 ± 10 (10.3 ± 0.4)
Installed • When empty mm
FRONT [B] 484 ± 10 (19 ± 0.4) 484 ± 10 (19 ± 0.4)
Length (in.)
REAR [A] 242 ± 10 (9.5 ± 0.4) 242 ± 10 (9.5 ± 0.4)
FRONT (Refer to Figure 6-2 for dimension "A" and 39.5 ± 5 (561 ± 70) 539.5 ± 5 (561 ± 70)
kg/cm2
Pressure "B" locations.)
REAR (psi) 26.0 ± 5 (370 ± 70) 26.0 ± 5 (370 ± 70)
CHECKING BRAKE PERFORMANCE
Service Brake • F2 Min. 1930 Min. 1930
Retarder Brake • Torque converter stall Min. 1540 Min. 1540
• Engine water temperature within
Emergency Brake Min. 1930 Min. 1930
operating range
2 RPM
• Air pressure: 8.3 kg/cm (120 psi)

Parking Brake • Transmission oil temperature: Min. 2070 Min. 2070


70° - 90°C (158° - 194°F)
• Hydraulic oil temperature:
50° - 80°C (122° - 176°F)

FIGURE 6-1. HOIST LEVER POSITIONS FIGURE 6-2. SUSPENSION CYLINDERS

A06002 Standard Value Table A6-6


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
ENGINE CONTROLLER
Verify normal voltages listed below:
1. Turn key switch ON.
Accelerator at Approx.
2. Insert T-adapter.
FULL position Between 3.55 - 3.75 V
Accelerator Sensor AS2 B-C 3. Accelerator LO ⇔ FULL.
Accelerator at Approx.
LOW position 0.35 - 0.55 V
Verify normal resistances listed below:
Water Temp. 25°C Approx.
Engine Water CT1 1. Turn key switch OFF.
(normal) Between 9 K - 10 KΩ
Temperature Sensor 2. Disconnect CT1.
Water temp. 100° C A-B Approx.
0.62 K - 0.65 KΩ
TRANSMISSION CONTROLLER
Engine Oil Pressure EP1 Verify normal voltages listed below: 1. Start engine.
Sensor 2. Insert T-adapter.
Between B - C Approximately 1.1 - 2.1 V

Verify normal voltages listed below:


Voltage Value
When Selected Not Selected
Between (3) - (2) [R] >1.0 V < 15.0 V 1. Turn key switch ON.
2. Insert T-adapter.
Between (4) - (2) [N] >1.0 V < 15.0 V
Shifter Lever SF (male)
Between (5) - (2) [D] >1.0 V < 15.0 V
Between (6) - (2) [5] >1.0 V < 15.0 V
Between (7) - (2) [4] >1.0 V < 15.0 V
Between (8) - (2) [3] >1.0 V < 15.0 V
Between (9) - (2) [L] >1.0 V < 15.0 V
Between (1) - (2) 11.0 - 13.0 V

Verify normal resistances listed below:


HPS (male)
LPS (male) 5 - 25Ω 1. Turn key switch OFF.
2. Insert T-adapter.
Between (1) - (2)
Pressure Control Valve RPS (male Note: resistance should be 13.85Ω ± 5%
Solenoid at 20°C (68 °F)
1PS (male)
2PS (male)
3PS (male)
4PS (male)

Verify normal resistance value listed below: 1. Turn key switch OFF.
Lock-up Solenoid L/CT (male)
Between (1) - (2) 30 - 80Ω 2. Disconnect L/CT

Exhaust Brake Verify normal resistance value listed below: 1. Turn key switch OFF.
Solenoid SL5 (male)
Between (1) - (2) 20 - 60Ω 2. Disconnect SL5.

A06002 Standard Value Tables A6-7


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
TRANSMISSION CONTROLLER (Continued)
Rear Brake (Overrun SL4 (male) Verify normal resistance value listed below: 1. Turn key switch OFF.
Protection) Solenoid 2. Disconnect SL4.
Between (1) - (2) 20 - 60Ω

Verify normal resistances listed below:


Oil Temperature Measure Resistance
Transmission Oil SL5 (male) 1. Turn key switch OFF.
Temperature Sensor Normal temperature: 37 k- 50 kΩ 2. Disconnect SL5.
25°C (77°C) Between (1) - (2)
100°C (212°F) 3.5 k - 4.0 kΩ

Verify normal resistances listed below:


Relay R01 - R29 Between (1) - (2) 100 - 500Ω
(Check as Individual (Except R09, Check as individual part
Part) R11) Between (3) - (4) <0.1 Ω
Between (1) - (2) >1 MΩ

Verify normal resistances listed below:


Between (5) - (6) 100 - 500Ω
Relay R09 - R11 Check as individual part
(Check as Individual Between (3) - (6) <0.1 Ω
Part) Between (3) - (5) >1 MΩ

HSW (male)
LSW (male)

Fill Switch RSW (male) Verify normal resistances listed below: 1. Turn key switch OFF.
2. Disconnect switch
1SW (male) Switch OFF Between (1) and >1 MΩ
chassis connector

2SW (male)
3SW (male)
4SW (male)

Verify normal voltage listed below:


Alternator Engine running @ 1/2 throttle or above: 27.5 - 29.5 V
Alternator Terminal 1. Start engine.
(NOTE: If the battery is old or after starting in cold areas, voltage
R - Chassis
may not rise for some time.)

Verify normal resistances listed below:


Air Pressure: Approx. 160 Ω or
8.3 kg/cm2 (120 psi) less, or approx. 320Ω 1. Turn key switch OFF.
Air Pressure Sensor SR5 (male) 2. Disconnect SR5.
Between (1) - (2)
Air Pressure: Approx. 640 Ω or
5.2 kg/cm 2 (75 psi) approx. 800 Ω

A06002 Standard Value Table A6-8


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
TRANSMISSION CONTROLLER (Continued)
Verify normal resistance value listed below:
Normal temperature: Approx. 9 - 10Ω
Engine Water CT1 1. Turn key switch OFF.
25°C (77°C) Between A - B
Temperature Sensor 2. Disconnect CT1.
100°C (212°F) Approx. 0.62 - 0.65Ω

Verify normal resistances listed below:


Torque Converter Oil TC.SE (male) Normal temperature: 37 k- 50 kΩ
1. Turn key switch OFF.
Temperature Sensor 25°C (77°C) Between (1) - (2)
2. Disconnect TC.SE, and
Retarder Oil 64 (male) 100°C (212°F) 3.5 k - 4.0 kΩ 64.
Temperature Sensor

Verify normal resistances listed below:


1. Turn key switch OFF.
Full Approx 12Ω or less
Fuel Level Sensor 61 (male) (1) - sensor flange 2. Disconnect 61
Empty Approx. 85 - 110Ω

Transmission Shaft Verify normal resistances listed below:


Speed Sensors
Input Shaft N1 (male) Between (1) - (2) 500 - 1000Ω
1. Turn key switch OFF.
Intermediate Shaft N2 (male) Between (1) - (2) 500 - 1000Ω 2. Disconnect N1 - N3.
Output Shaft N3 (male) Between (1) - (2) 500 - 1000Ω

Engine Speed Sensor E12 Verify normal resistance listed below: 1. Turn key switch OFF.
(male) Between (1) - (2) 500 - 1000Ω 2. Disconnect E12

Verify no continuity in circuit as listed below:


Normal
1. Turn key switch OFF.
temperature: No continuity
Steering Oil 21(male) 2. Disconnect 21
Between B and chassis 25°C (77°C)
Temperature Sensor
Oil temperature: No continuity
>123°C (250°C)

Verify normal conditions in circuit as listed below:


Air pressure Min.:
Continuity 1. Turn key switch OFF.
1.4 kg/cm2 2. Disconnect AS3
Retarder Switch AS3 (male) (20 psi)
Between (1) - (2)
Air pressure Max.:
0.6 kg/cm2 No continuity
(8.5 psi)

A06002 Standard Value Tables A6-9


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
TRANSMISSION CONTROLLER (Continued)
Verify normal conditions in circuit as listed below:
Air pressure Min.:

Service Brake Switch AS5 (male) 0.6 kg/cm2 Continuity


1. Turn key switch OFF.
Between (1) - (2) (8.5 psi) 2. Disconnect AS5
Air pressure Max.: No continuity
0.2 kg/cm2
(3 psi)

Verify normal conditions in circuit as listed below:


Air pressure Min.:
4.9 kg/cm2 No continuity
1. Turn key switch OFF.
Emergency Brake AS4 (male) (70 psi) 2. Disconnect AS4
Between (1) - (2)
Switch Air pressure Max.:
3.7 kg/cm2 Continuity
(53 psi)

Verify normal conditions in circuit as listed below:


Air pressure Min.:
5.7 kg/cm2 Continuity
Parking Brake Switch AS2 (male) 1. Turn key switch OFF.
Between (1) - (2) (81 psi) 2. Disconnect AS2
Air pressure Max.:
3.7 kg/cm2 No continuity
(53 psi)

Verify normal conditions in circuit as listed below:


Dump lever @ No continuity
1. Turn key switch OFF.
FLOAT
Body FLOAT Switch RH2 (male) 2. Disconnect RH2
Between (1) - (2) Dump lever at a
position other than Continuity
FLOAT

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Body seated No continuity
Body Seated Switch DB1 (male) Between (1) - (2) 2. Disconnect DB1
Body not seated Continuity

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Tilt 17° or more No continuity
Tilt Sensor SR3 (male) 2. Disconnect SR3
Between (1) - (2) Tilt 13° or less Continuity

Verify normal conditions in circuit as listed below:


Dump lever @ No continuity
RAISE
Body RAISE Switch RH2 (male) 1. Turn key switch OFF.
Between (7) - (8)
Dump lever at a 2. Disconnect RH2
position other than Continuity
RAISE

A06002 Standard Value Table A6-10


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
TRANSMISSION CONTROLLER (Continued)
Verify normal conditions in circuit as listed below:
Transmission Filter 52 (male) 1. Turn key switch OFF.
Filter normal No continuity
Clogging Sensor 2. Disconnect 52
Between (1) - (2) Filter clogged Continuity

Verify normal conditions in circuit as listed below:


Brake Stroke Switch BLSR (male) Stroke normal Continuity 1. Turn key switch OFF.
BLSL (male) 2. Disconnect BLSR, BLSL.
Between (1) - (2)
Large stroke No continuity

Verify normal conditions in circuit as listed below:


Air pressure Min.:
3.7 kg/cm2 Continuity
1. Turn key switch OFF.
Exhaust Brake Switch AS4 (male) (53 psi) 2. Disconnect AS4
Between (1) - (2)
Air pressure Max.:
3.3 kg/cm2 No continuity
(47 psi)

Emergency Steering Relay terminal Engine running: Minimum 20 V 1. Start engine.


Timer Relay 78 - chassis
SUSPENSION CONTROLLER
Verify normal conditions in circuit as listed below:
Radiator water Continuity
level normal 1. Turn key switch OFF.
Radiator Water 03 (male) 2. Disconnect 03.
Between (1) - (2)
Level Switch Radiator water No continuity
level abnormal

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Switch ON Continuity
Power Mode Switch PW (male) Between (2) - (4) 2. Disconnect PW
Switch OFF No continuity

Verify normal resistances listed below: 1. Remove sensor from


FR Suspension 63 (male) suspension cylinder.
2. Insert T-adapter.
Pressure Sensor Between each
3. Verify there is no open or
FL Suspension 62 (male) connector - (3) - chassis 500 - 1000Ω
shorted circuit in wiring
Pressure Sensor harness.
4. Turn key switch ON.

Transmission Output Verify normal resistance in circuit as listed below: 1. Turn key switch OFF.
Shaft Speed Sensor N3 (male) 2. Disconnect N3.
Between (1) - (2) 500 - 1000Ω

A06002 Standard Value Tables A6-11


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
SUSPENSION CONTROLLER (Continued)
Verify normal conditions in circuit as listed below:
Air pressure Min.:
4.9 kg/cm2 No continuity
1. Turn key switch OFF.
Emergency Brake AS4 (male) (70 psi) 2. Disconnect AS4.
Between (1) - (2)
Switch Air pressure Max.:
3.7 kg/cm2 Continuity
(52 psi)

Verify normal conditions in circuit as listed below:


Air pressure Min.:
0.6 kg/cm2 No continuity
1. Turn key switch OFF.
Service Brake Switch AS5 (male) (8.5 psi) 2. Disconnect AS5.
Between (1) - (2)
Air pressure Max.:
0.2 kg/cm2 Continuity
(2.8 psi)

Verify normal conditions in circuit as listed below:


Shift Limit Switch SH (male) 1. Turn key switch OFF.
Switch ON Continuity
Between (2) - (4) 2. Disconnect SH.
Switch OFF No continuity

SL1 (male) Verify normal resistance value listed below: 1. Turn key switch OFF.
Suspension Control 2. Disconnect SL1, SL2,
SL2 (male) Between (1) - (2) 20 - 60Ω
Solenoid Valve SL3.
3. Put black pole of tester in
SL3 (male) contact with (1); put red
pole in contact with (2).

Verify normal conditions in circuit as listed below:


Lever @ FLOAT No continuity
Body FLOAT Switch RH2 (male) 1. Turn key switch OFF.
Lever @ position other Between (7) - (9)
2. Disconnect RH2.
than FLOAT. Continuity
PAYLOAD METER
FR Suspension 39 (male) 1. Remove sensor from
Pressure Sensor suspension cylinder.
2. Insert T-adapter.
FL Suspension 13 (male) Verify voltages are within the range as listed below:
Pressure Sensor 3. Verify there is no open or
shorted circuit in wiring
RR Suspension 63 (male) Between each connec- Approximately 0.45 - 1.50 V harness.
Pressure Sensor tor (3) - chassis 4. Turn key switch ON.
FL Suspension 62 (male)
Pressure Sensor

A06002 Standard Value Table A6-12


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
PAYLOAD METER (Continued)
Verify voltage is within the range as listed below: 1. Park truck on level
ground.
2. Verify there is no open or
Clinometer PM3 Between (1) - (2) Approximately 2.1 - 3.1 V shorted circuit in wiring
harness.
3. Insert T-adapter.
4. Turn key switch ON.
CHASSIS MONITOR
Verify voltage is within the range as listed below: 1. Disconnect terminal.
Engine Oil Pressure 27 (male) 2. Insert T-adapter.
Between B - C Approximately 1.1 - 2.1 V
Sensor 3. Start engine.

Verify voltage is within the range as listed below:


Alternator Alternator
Engine running @ 1/2 throttle or above: 27.5 - 29.5 V
terminal R - 1. Start engine.
chassis (NOTE: If the battery is old or after starting in cold areas, voltage
may not raise for some time.)

Verify (normal) resistances listed below:


Air Pressure: 8.3 kg/ Approx. 160Ω or less,
or approx. 320Ω 1. Turn key switch OFF.
Air Pressure Sensor SR5(male) cm2 (120 psi) 2. Disconnect SR5.
Between (1) - (2)
Air Pressure: 5.2 kg/ Approx. 640Ω or
cm2 (75 psi) approx. 800Ω

Engine Water CT1 (male) Verify (normal) resistance value listed below:
Temperature Sensor
1. Turn key switch OFF.
Torque Converter Oil TC.SE (male) Normal temperature: Approx. 9 - 10Ω
Temperature Sensor 25°C (77°C) Between (1) - (2) 2. Disconnect CT1, TC.SE,
and 64.
Retarder oil 64 (male) 100°C (212°F) Approx. 0.62 - 0.65Ω
Temperature Sensor

Verify (normal) resistances listed below:


Fuel Level Sensor 61 (male) 1. Turn key switch OFF.
Full Approx 12Ω or less
(1) - sensor flange 2. Disconnect 61.
Empty Approx. 85 - 110Ω

Transmission Output Verify (normal) resistance in circuit as listed below: 1. Turn key switch OFF.
Shaft Speed Sensor N3 (male) 2. Disconnect N3.
Between (1) - (2) 500 - 1000Ω

Verify normal conditions in circuit as listed below:


Transmission Filter 1. Start engine.
Filter normal Continuity
Clogging Sensor 52 (male) 2. Disconnect 52.
Filter clogged Between (1) - (2) No continuity

A06002 Standard Value Tables A6-13


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
CHASSIS MONITOR (Continued)
Verify normal conditions in circuit as listed below:
1. Turn key switch OFF.
Switch ON Continuity
Caution Pilot Lamp GK1 (male) 2. Disconnect GK1
Switch OFF Between (1) - (2) No continuity
Bulb Check Switch

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Switch ON Continuity
Exhaust Brake Switch EXH (male) Between (2) - (4) 2. Disconnect EXH.
Switch OFF No continuity

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Switch ON Continuity
AISS Switch A1 (male) 2. Disconnect A1.
Switch OFF Between (2) - (4) No continuity

Between Verify normal conditions in circuit as listed below:


Mode Change Switch 1 Switch Switch ON Between Switch Continuity 1. Turn key switch OFF.
Terminals
Terminals
MS11 - MS12 Switch OFF No continuity
MS11 - MS12

Between Verify normal conditions in circuit as listed below:


Mode Change Switch 2 Switch 1. Turn key switch OFF.
Switch ON Between Switch Continuity
Terminals Terminals
MS21 - MS22 Switch OFF No continuity
MS21 - MS22

Verify normal conditions in circuit as listed below:


Hazard Switch HAZ (male) 1. Turn key switch OFF.
Switch ON Continuity
2. Disconnect HAZ.
Switch OFF Between (2) - (4) No continuity

Verify normal conditions in circuit as listed below:


Fog Lamp Switch FL (male) Switch ON Continuity 1. Turn key switch OFF.
2. Disconnect FL.
Between (2) - (4)
Switch OFF No continuity

Verify normal conditions in circuit as listed below:


Front Brake Cut Switch FB (male) 1. Turn key switch OFF.
Switch ON Continuity
Between (2) - (4) 2. Disconnect FB.
Switch OFF No continuity

A06002 Standard Value Table A6-14


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
CHASSIS MONITOR (Continued)
Verify normal conditions in circuits as listed below:
Lamp switch ON Continuity
Between (5) - (7)
Lamp switch OFF No continuity

Lamp switch ON Between (5) - (6), Continuity


(6) - (7)
Lamp switch OFF No continuity

Turn signal lamp at LEFT Continuity 1. Turn key switch OFF.


Combination Switch CM (male) Between (3) - (8) 2. Disconnect CM.
Turn signal lamp at N No continuity

Turn signal lamp at Continuity


RIGHT Between (3) - (4)
Turn signal lamp at N No continuity

Dimmer switch at high Between (2) - (7) Continuity


beam
Dimmer switch at low Between (1) - (7) No continuity
beam
PMC SYSTEM
Verify normal conditions in circuit as listed below:
Air Cleaner Clogging MM13 (male) 1. Start engine.
Air cleaner normal Between (1) and Continuity
Sensor chassis 2. Disconnect MM13
Air cleaner clogged No continuity

Verify normal conditions in circuit as listed below:


Full-flow Filter clogging MM10 (male) 1. Start engine.
Filter normal Between (1) and Continuity
Sensor
Filter clogged chassis No continuity

Verify normal conditions in circuit as listed below:


Hydraulic Filter 54 (male) Filter normal Continuity 1. Start engine.
Clogging Sensor 2. Disconnect 54.
Between (1) - (2)
Filter clogged No continuity

Verify normal conditions in circuit as listed below:


Hydraulic Retarder 53 (male) 1. Start engine.
Filter normal Continuity
Clogging Sensor Between (1) - (2) 2. Disconnect 53.
Filter clogged No continuity

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Engine Oil level normal Continuity
Engine Oil Level MM9 (male) 2. Disconnect MM9.
Engine Oil level Between (1) - (2) No continuity
Sensor
abnormal

Verify normal conditions in circuit as listed below:


1. Turn key switch OFF.
Hydraulic Oil level Continuity
Hydraulic Oil Level MM14 (male) 2. Disconnect MM14.
normal Between (1) and
Sensor chassis
Hydraulic Oil level No continuity
abnormal

A06002 Standard Value Tables A6-15


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
PMC SYSTEM (Continued)
Verify normal conditions in circuit as listed below:
1. Turn key switch OFF.
Retarder oil level Continuity
Retarder Oil Level MM15 (male) 2. Disconnect MM15.
normal Between (1) and
Sensor chassis
Retarder oil level No continuity
abnormal

Verify normal conditions in circuit as listed below:


Brake Oil Level Sensor MM12 (male) 1. Start engine.
Brake oil level normal Continuity
Between (1) - (2) 2. Disconnect MM12.
Brake oil level abnormal No continuity

Verify normal conditions in circuit as listed below:


Battery electrolyte level
Battery Electrolyte MM11 (male) 1. Start engine.
normal Between (1) - 4 V or above
Level Sensor chassis or (-) 2. Disconnect MM11.
Battery electrolyte level
terminal
abnormal 0V

Verify normal conditions in circuit as listed below: 1. Start engine.


Retarder Wear Sensor MM19 (male) 2. Disconnect MM19 and
No retarder wear Continuity
MM20 (male) Between (1) - (2) MM20.
Retarder wear No continuity 3. Actuate retarder brake.

Verify normal conditions in circuit as listed below:

Air pressure 0.6 kg/cm 2 No continuity


1. Turn key switch OFF.
Service Brake Switch AS5 (male) (8.5 psi) or above 2. Disconnect AS5.
Between (1) - (2)
Air pressure 0.2 kg/cm 2 Continuity
(2.8 psi) or above

Verify normal conditions in circuit as listed below:

Air pressure 4.9 kg/cm 2 No continuity


1. Start engine.
(70 psi) or above
Emergency Brake AS4 (male) Between (1) - (2) 2. Disconnect AS4.
Switch Air pressure 3.7 kg/cm 2 Continuity
(52 psi) or above

Transmission Input N1 (male) Verify normal resistance in circuit as listed below:


Shaft Speed Sensor 1. Turn key switch OFF.
2. Disconnect N1 and N3.
Transmission Output N3 (male) Between (1) - (2) 500 - 1000 Ω
Shaft Speed Sensor

Verify normal resistance in circuit as listed below:


Engine Speed E12 (male) 1. Turn key switch OFF.
Between (1) - (2) 500 - 1000 Ω
Sensor B

A06002 Standard Value Table A6-16


STANDARD VALUES FOR ELECTRICAL PARTS
COMPONENT CONNECTOR COMPONENT TEST TABLE MEASUREMENT
No. CONDITIONS
PMC SYSTEM (Continued)

Verify normal voltage in circuit as listed below: 1. Remove sensor from


FR Suspension 39 (male) suspension cylinder.
Between (3) and Approximately 0.45 - 1.50 V
Pressure Sensor chassis 2. Insert T-adapter.
3. Verify there is no open or
short circuit in wiring
harness.

Verify normal voltage in circuit as listed below: 1. Remove sensor from


FL Suspension 13 (male) Between (3) and Approximately 0.45 - 1.50 V suspension cylinder.
Pressure Sensor 2. Insert T-adapter.
chassis
3. Verify there is no open or
short circuit in wiring
harness.
4. Turn key switch ON.

A06002 Standard Value Tables A6-17


NOTES

A06002 Standard Value Table A6-18


SECTION B

STRUCTURES

INDEX

STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1


GRILLE AND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1
LEFT DECK STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2

RIGHT DECK STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3

CENTER DECK STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2

BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3

BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4

BODY-UP PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4


Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4

ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5


Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
QUICK FUEL OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2

B01014 Index B1-1


NOTES

B1-2 Index B01014


STRUCTURAL COMPONENTS
GRILLE AND HOOD DECKS

Removal The truck left and right decks are mounted to the
frame structure using rubber mounting pads. These
1. Remove grille. pads are placed between the deck and the mount-
2. Attach lifting device to the radiator hood. ing structure to reduce noise and vibration. These
3. Disconnect air horn hoses and headlight wire rubber mounts should be checked periodically and
on the left side of the radiator. worn or defective mounts should be replaced.
4. Remove the three plugs, capscrews, and nuts The center deck section of the truck is rigidly
from across the top of the radiator hood that mounted in the front and rubber mounted in the rear.
secures it to the cross brace below.
5. Remove six (6) mounting capscrews at the
base of the radiator hood.
6. Lift radiator hood off of truck.
7. Check the number of shims under hood mount- The decks of the trucks are also covered with
ing so all shims can be placed back to their anti-slip surfaces. These anti-slip coverings
original location during installation. should be kept clean and replaced as they
become worn. Anti-slip material on the decks
Installation must be inspected and maintained for safety of
personnel.
1. Install deck in reverse order to removal. Tighten
all hardware to standard torque.

FIGURE 2-1. DECK LAYOUT

1. Capscrew 5. Center Deck 9. Ladder Deck


2. Capscrew 6. Engine Lid 10. Cab
3. Cab Mounting Capscrews 7. Capscrew 11. Walkway
4. Right Deck 8. Front Grill

B02011 09/97 Structural Components B2-1


LEFT DECK AND CAB

Removal Installation
1. Disconnect the ground wire between the nega- 1. Lower cab and deck section onto truck and align
tive terminal of the batteries and the frame. capscrew mounting holes. Remove lifting
2. Remove capscrews (2, Figure 2-2) and washers device.
from each corner of the left deck section. 2. Adjust left hand deck rubber mounts;
3. Disconnect all electrical wiring, air lines, and a. Temporarily assemble the mounting parts
hydraulic lines that would interfere with the without shims.
removal of the cab deck.
b. Measure dimension "a" (Figure 2-2) at four
4. Attach lifting device with wood blocks (5,Figure (4) places on each mounting pad as shown.
2-3) and lift deck section up and away from
truck. c. Add shims to the side where dimension "a" is
largest, and adjust so that the difference
5. Mark shims (4) so they will be installed in the
between dimension "a" at the four places is
same location when the cab and deck are
within 0.5 mm (0.02 in.).
installed.
3. Tighten capscrews to 35-43.5 kg.m (254-315
ft.lbs.) torque.

FIGURE 2-2. RUBBER MOUNTING PADS


(LEFT DECK)

1. Cover 5. Rubber Mounting


2. Capscrew 6. Flatwasher FIGURE 2-3. CAB AND DECK
3. Special Washer 7. Nut 1. Cab 4. Door
4. Shims 2. Strap 5. Wood Block
3. Lifting Device

B2-2 Structural Components 09/97 B02011


RIGHT DECK

Removal Installation

1. Disconnect the ground wire between the nega- 1. Lower deck section onto truck and align cap-
tive terminal of the batteries and the frame. screw mounting holes.
2. Disconnect all air hoses and electrical wiring 2. Remove lifting device and
leading from the right deck. Disconnect ground 3. Install capscrews (2, Figure 2-4) and washers.
strap between right deck and frame. Tighten capscrews to standard torque.
3. Attach a lifting device to the deck.
4. Remove the four (4) mounting capscrews (2,
Figure 2-4).
5. Remove deck from truck.

Inspect the rubber mounting pads for cracks, tears or


other damage. Replace with new if damaged.

FIGURE 2-4. RUBBER MOUNTING PADS


(RIGHT DECK)

1. Cover 5. Rubber Mounting


2. Capscrew 6. Bushing
3. Special Washer 7. Nut
4. Washer

B02011 09/97 Structural Components B2-3


CENTER DECK

Removal Installation
1. Disconnect the ground wire between the nega- 1. Install deck on truck and align mounting holes
tive terminal of the batteries and the frame. and the rear rubber mounting studs.
2. Remove the three plugs, capscrews and nuts 2. Tighten all mounting hardware. Install the covers
from the front of the center deck. over the front access holes.
3. Remove the two nuts (2, Figure 2-5) and lock- 3. Connect the ground wire between the negative
washers from the two rear rubber mounts. terminal of the batteries and the frame.
4. Remove deck from truck.

FIGURE 2-5. REAR MOUNTING PADS FOR


CENTER DECK

1. Cover 3. Rubber Mounting


2. Nut 4. Capscrew Pad

B2-4 Structural Components 09/97 B02011


DUMP BODY
Removal

1. Park truck on hard level surface and block all 2. Remove mud flaps from both sides of the truck.
wheels. Using special sling (561-98-61350) con- Pin rock ejectors in the up position.
nect cables and lifting device to the dump body
3. On each side of the dump body, remove the hoist
and take up slack as illustrated in Figure 3-1.
cylinder pin retainer capscrew and washer (4 and
5, Figure 3-2) from the dump body brackets (1).

Before raising or lifting body be sure there is Some means of supporting hoist cylinders will be
adequate clearance between body and overhead necessary prior to removing hoist cylinder pin.
structures or electric power lines.

4. Remove the top hoist cylinder pin (3, Figure 3-2)


from the dump body.

Be sure that lifting device is rated for at least a 35


ton capacity (31780 kg).

FIGURE 3-2. HOIST CYLINDER MOUNTING


FIGURE 3-1. DUMP BODY REMOVAL
1. Lifting Cables 2. Guide Rope 1. Body Brackets 4. Capscrew
2. Hoist Cylinder 5. Washer
3. Pin/Retainer Structure

B03015 Dump Body B3-1


5. Remove the capscrew and washer (2, Figure 3-3) Installation
securing the pivot pin (3). Remove the pivot pin
from each dump body pivot point. Pivot pin spac-
ers (4), will come out after pin is removed. Store 1. Attach lifting device to dump body and lower over
spacers in a manner so they will be installed in the truck frame. Align the dump body pivot with
the same location they were removed. frame mounting bracket.
6. Lift dump body clear of truck and move to storage 2. Install the spacers (4, Figure 3-3) as removed and
or work area. Place on blocks. body pivot pins (3) on each side of truck. If nec-
essary, adjust body to center it between the frame
7. Inspect bushings (6) in the body pivots for wear
rails. Refer to Figure 3-3.
or damage. Replace, if necessary.

NOTE: After installation, check to insure that the side


of the canopy and the side of the operators cab are in
alignment within 30mm (1.2 in). If necessary, adjust
body with shims at body pivot.

3. Secure pivot pin in place with capscrew and


washer (3, Figure 3-3). Tighten capscrews to
25-31.5 kg.m (181-228 ft.lbs.) torque.
4. If equipped, check engine exhaust tube in heated
body. Tube should be centered in body opening.
5. Align top eye of hoist cylinder and install hoist
cylinder pins. Secure pins with capscrews and
washers (4 and 5, Figure 3-2). Tighten capscrews
to 16-20 kg.m (116-145 ft.lbs.) torque.
6. Install mud flaps and release rock ejectors on
dump body.

FIGURE 3-3. BODY PIVOT PIN CROSS SECTION

1. Dump Body 4. Spacer


2. Capscrew & Washer 5. Frame Pivot Structure
3. Pivot Pin 6. Seal
7. Bushing

B3-2 Dump Body B03015


BODY PAD BODY PAD ADJUSTMENT (SIDE)

Removal With pads in place.


NOTE: It is not necessary to remove the dump body 1. Completely lower empty dump body until in con-
for replacing the body pads. Replace pads if worn tact with frame rail. Check all eight (8) pads to
excessively. insure full contact with frame. If not, adjust with
shims.
1. Raise dump body to sufficient height for removal
of body pads.

With pads removed.


1. Install a 55mm (2.16 in) spacer (1, Figure 3-5)
between the front of dump body and the frame.
Measure and record the distance between the
Place blocks between dump body and frame. Se- dump body and frame at four (4) locations on
cure blocks in place. each frame rail. Refer to Figure 3-5.
2. Subtract 35mm (1.38 in) from each dimension
2. Remove capscrews, lockwashers and rubber recorded above.
body pads with shims from body pad mounting 3. Raise body high enough to install pads and block
surface. Refer to Figure 3-4. in position to prevent body from lowering. Assem-
ble a shim pack for each pad as determined in
Installation Step 2 and install with capscrews, flatwashers,
1. Install new rubber body pads and shims. Install and nuts.
capscrews and lockwashers. 4. Remove blocking and spacer and lower body
completely.
5. Check all eight (8) pads to insure full contact with
frame. Adjust with shims if necessary.

FIGURE 3-4. BODY PAD AND GUIDE


FIGURE 3-5. BODY PAD ADJUSTMENT
1. Capscrew & Nut 5. Frame
2. Mounting Surface 6. Guide 1. 55mm (2.16 in) spacer 2. Body Pads
3. Shims a. Gap 1-2 mm
(4 locations)
4. Body Pad (0.040-0.080 in)

B03015 Dump Body B3-3


BODY PAD ADJUSTMENT (FRONT) BODY GUIDE
At time of body pad replacement, wear plates, which
NOTE: Adjust after lower body pads have been ad- the body guides contact, should be inspected for serv-
justed. iceability. Prior to checking the gap between the body
guides and wear plates, insure the body is centered on
the frame. The gap between the guides and wear
1. Total thickness of rubber pad (1, Figure 3-6) plates should be 1-2 mm (0.040-0.080 in.). Refer to
should be 50mm (2.0 in). Figure 3-4.

2. If not, adjust with shims (2). NOTE: Size of weld for body guide and wear plate is
0.31 inch (7.87 mm) unless otherwise specified. Use
AWS E 70 Series, Low Hydrogen Type Welding Rods,
such as E7016 or E7018.

BODY PIN

The body pin is located under the dump body at the


rear of the truck. This pin is intended to be used as a
safety to hold the body in the up position while the
technicians work under it.

Always store pin in body storage hole. Placement


of the pin in mainframe or matching body-up holes
located on the body can cause damage to frame or
body during dumping cycle.
Never work under a raised body unless body
FIGURE 3-6. FRONT BODY PAD safety pin is in the proper position to hold body up.

1. Pad 3. 50mm (2.0 in)


2. Shims 4. Capscrew

B3-4 Dump Body B03015


ROCK EJECTORS
Rock ejectors are placed between the rear dual wheels
to keep rocks or other material from lodging between
the dual tires. Failure to keep ejectors in working order
could allow debris to build up between the dual wheels
and cause damage to the tires. The rock ejectors can
be pinned up out of the way if desired.

Inspection

1. The ejectors must be positioned on the center line


between the rear tires within 0.25 in. (6.35 mm).
2. With the truck parked on a level surfact, the arm
structure should be approximately 4.88 in. (124
mm) away from the wheel spacer ring.
FIGURE 3-7 ROCK EJECTOR
NOTE: With Rock Ejector Arm (2, Figure 3-7) hang-
ing vertical, there must be NO GAP at stop on 1. Pin Structure 3. Cotter Pin
bracket (4). 2. Rock Ejector Arm 4. Rock Ejector Bracket

3. If the arm (2) becomes bent, it must be removed


and straightened.
4. The wear plates must be replaced if severely
worn.
5. Inspect the mounting brackets, pins (1) and stops
at each shift change for wear and/or damage, and
repair as necesary.

B03015 Dump Body B3-5


NOTES

B3-6 Dump Body B03015


FUEL TANK
The truck is equipped with a fuel tank mounted in front 2. Remove wire from tank sender if equipped with
of the rear tires on the right side. The tank is equipped fuel level indicator in instrument panel.
with an external fuel gauge and optional electric
3. Disconnect the fuel supply and return lines. Cap
sender for the instrument panel gauge.
all hoses and tank openings to prevent contami-
nation.
Removal
4. Connect a suitable lifting device to the tank and
1. Drain all fuel from tank to reduce weight to be
take up slack.
handled.

FIGURE 4-1. FUEL TANK INSTALLATION


1. Fuel Tank 9. Drain Cock 17. Nut 25. Straight Fitting
2. Fuel Gauge 10. Gasket 18. Washer 26. Return Hose
3. Gasket 11. Cover 19. Pipe Plug 27. Tapping Screw
4. Capscrew 12. Lockwasher 20. Breather Cap 28. Lockwasher
5. Lockwasher 13. Capscrew 21. Elbow Fitting 29. Collar
6. Filler Cap 14. Mounting Plate 22. Shutoff Valve 30. Bolt
7. Strainer 15. Mounting Plate 23. Nipple
8. Bushing 16. Bolt 24. Supply Hose

B04014 Fuel Tank B4-1


5. Loosen the bottom and top mount capscrews (16, If a tank has been damaged and requires structural
Figure 4-1) and take up slack on lifting device. repair, carry out such repairs before final cleaning. A
Remove capscrews and move tank to safe work- small amount of light oil should be sprayed into the tank
ing area. to prevent rust if the tank is to remain out of service.
All openings should be sealed for rust prevention.
6. Remove sending unit (2) and cover (11) on tank,
and other fittings as required to carry out interior
cleaning.
VENT
The fuel tank is vented through a small breather cap
Installation (20, Figure 4-1) installed in a port on the top of the tank.
1. Thoroughly clean the mounting areas on the This vent should be cleaned periodically and can be
frame and the tank. blown out with solvent. The vent must be free of caked
mud and debris that would cover the vent and prevent
2. Lift the fuel tank into position near the frame and proper fuel suction and return.
lower into position. Install capscrews (16), lock-
washers and nuts. Refer to Section “M” for information on various quick
fill systems, if equipped.
3. Tighten capscrews (16) evenly to 50-62 kg.m
(362-450 ft. lbs.) torque.
4. Connect fuel lines and fuel sender wire.
QUICK FUEL INSTALLATION (OPTION)
5. Close the tank drain cock, fill with fuel and check
for leaks. An optional quick fuelling system may be installed in
place of cover (11, Figure 4-1).

If a tank is to be weld repaired, special precautions


are necessary to prevent fire or explosion. Consult
local authorities if necessary, on safety regula-
tions before proceeding.

Cleaning
The fuel tank is provided with a drain and a cleaning
port in the side that allows steam or solvent to be
utilized in cleaning tanks that have accumulated for-
eign material.
It is not necessary to remove the tank from the truck
for cleaning of sediment, however rust and scale on
the walls and baffles may require complete tank re-
moval. This allows cleaning solutions to be in contact
with all interior surfaces by rotating the tank in various
positions, etc.
Prior to a cleaning procedure of this type, all vents, fuel
gauges, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material have been removed, the temporary plugs can
be removed.

B4-2 Fuel Tank B04014


SECTION C
ENGINE, RADIATOR & AIR CLEANER
INDEX

COOLING SYSTEM
RADIATOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3
BRAKE OIL COOLER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
FAN
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
FAN BELT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-5

ENGINE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-4
DRIVE LINE ADAPTER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-7

AIR FILTRATION SYSTEM


AIR CLEANER
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1
MAIN FILTER ELEMENT
Main Filter Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3
Air Intake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-4

C01016 Index C1-1


NOTES

C1-2 Index C01016


COOLING SYSTEM
RADIATOR 3. Remove grille and steering oil cooler (2, Figure
3-1).
Engine cooling is accomplished by circulating the cool-
ant through the engine water jacket and the radiator. 4. Remove hood according to “Removal” instruc-
Air is pulled through the radiator core by an engine tions in Section “B”.
driven fan to remove heat from the circulating coolant. 5. If equipped with air conditioning, remove the
capscrews retaining the condenser core to the
Removal radiator and rotate the condenser core towards
1. Disconnect the negative and then the positive the left fender. Secure refrigerant lines and con-
battery cable. denser core away from radiator to prevent possi-
ble damage during radiator removal. If it is
necessary to remove the condenser from the
truck, refer to Section “M” and discharge the
refrigerant from the system, then remove the
condenser.

Before removing any cooling system components,


release cooling system pressure by turning radia-
tor cap counterclockwise to the first notch. Failure
to release pressure may result in hot coolant being
expelled causing serious injury.
Wear a face shield and protective gloves while
venting refrigerant from the air conditioning sys-
2. Position a container (completely clean if the cool- tem. Contact with the refrigerant will cause skin
ant is to be reused) under the drain cocks on the and tissue freezing (frostbite).
radiator and brake oil cooler. Be prepared to catch
as much as 256 l (67.6 gal.) of coolant. Open drain
cocks and allow coolant to drain completely. 6. Disconnect headlight wire (1, Figure 3-2) and air
horn hoses (2) on the left side of the radiator.

FIGURE 3-1. OIL COOLER FIGURE 3-2. WIRING AND HORN


1. Radiator 2. Steering Oil 1. Headlight Wiring 2. Air Horn Hoses
Cooler

C03018 Cooling System C3-1


10. Remove thermostat outlet hoses (2 & 3).
11. Disconnect de-aeration hose (4) and bypass hose
(5).
12. Remove radiator outlet hose (1, Figure 3-5) and
radiator bypass hose (2).
13. Remove torque converter oil cooler hoses (3 & 4).

FIGURE 3-3. RADIATOR HOOD


1. Radiator Hood 3. Radiator Support
2. Damper 4. Capscrews

7. Remove the three plugs, capscrews, and nuts


from across the top of the radiator hood that
secures it to the cross brace below.
8. Remove six (6) mounting capscrews (4, Figure
3-3) at the base of the radiator hood and remove.
Tag the shims for proper placement during as-
sembly.
9. Remove fan guard (1, Figure 3-4).

FIGURE 3-5. COOLANT AND OIL LINES


1. Outlet Hose 3. Torque Converter
2. Bypass Hose Hose
4. Torque Converter

FIGURE 3-4. RADIATOR COMPONENTS


1. Fan Guard 4. De-Aeration Hose
2. Thermostat Outlet Hose 5. Bypass Hose
3. Thermostat Outlet Hose

C3-2 Cooling System C03018


Service
Radiator service is a specialized function usually not
accomplished by most maintenance shops. The large
size and weight of the off-road truck radiators dictates
Radiator assembly weighs approximately 410 kg that a specialized radiator shop be used for service and
(904 lbs.) Use adequate lifting device. repair on the radiators.
14. Attach a sling or hoist to the radiator and take up
the slack. Remove radiator top mounting rod by
removing nuts (1, Figure 3-6).
Installation
15. Remove radiator bottom mount capscrews (4) and
remove radiator and torque converter oil cooler
assembly. Move radiator to a clean work area for 1. Inspect dampers (5, Figure 3-6) for cracks or
service. excessive stress. Replace as required.
2. Install radiator with torque converter oil cooler
assembly with radiator bottom mount capscrews
(4) .
3. Install radiator top mounting rod with nuts (1).
Tighten nuts on each end of tie rod and center the
rods between the brackets to position the radiator
so that the fan blades are centered in the shroud.
4. Install torque converter oil cooler hoses (3&4,
Figure 3-5).
5. Install radiator outlet hose (1) and radiator bypass
hose (2).
6. Connect de-aeration hose (4, Figure 3-4) and
bypass hose (5).
7. Install thermostat outlet hoses (2&3).
8. Install fan guard (1).
9. Install six mounting capscrews (4, Figure 3-3) at
the base of the radiator hood and remove.
10. Install the three plugs, capscrews, and nuts from
across the top of the radiator hood that secures it
to the cross brace below.
11. Connect headlight wire (1, Figure 3-2) and air horn
hoses (2) on the left side of the radiator.
12. If equipped with air conditioning, install the con-
denser core to the radiator. Refer to Section “M”
to evacuate and recharge the system.
13. Install hood according to “Installation” instructions
in Section “B”.

FIGURE 3-6. RADIATOR MOUNTING 14. Install oil cooler (2, Figure 3-1) and radiator grille.
1. Nut 5. Damper 15. Make sure all coolant drains are closed and all
2. Washer 6. Washers hoses installed. Service cooling system with the
3. Rubber Mount 7. Radiator Support proper mixture of antifreeze as recommended in
4. Capscrews & 8. Capscrews the Lubrication and Service Section. Check for
Lockwashers static leakage and correct any leaks.

C03018 Cooling System C3-3


16. Install the battery cables as follows: 4. Attach a suitable lifting device to the brake oil
a. Install the battery positive cable first. cooler and remove mounting bolts from brackets
at right and left sides of the cooler. Lower cooler
b. Install the negative cable next.
from truck.
17. Start engine and run until cooling system reaches
operating temperature, recheck the cooling sys- Installation
tem for leakage during engine operation.
1. Lift cooler up in place and secure with mounting
capscrews.
2. Connect brake cooling oil lines and water coolant
lines to cooler.

If air is not completely bled from cooling system 3. Fill radiator and brake cooling oil tank to proper
during refill, additional coolant may be required levels with proper fluids as specified in Section
due to air entrapped which will gradually dissipate "P", "Lubrication and Service".
as the engine comes up to temperature. Refill
radiator as required before putting machine to FAN
work.
Removal
BRAKE OIL COOLER 1. Remove radiator, hood, grill, and water piping as
specified in Section “B” or earlier in this section.
Removal
2. The fan guard may be separated and removed or
1. Drain engine coolant and the brake cooling oil. can be moved back toward the engine clear of the
2. Disconnect the two cooling water hoses (1, 2, fan hub.
Figure 3-7) from the right side of the brake cooler. 3. Remove capscrews and lockwashers and lift fan
3. Disconnect the brake oil cooling lines (3, 5) from and spacer from pulley hub.
the brake oil cooler.

Bent or cracked fan blades cannot be repaired. The


fan must be replaced. Do not attempt to repair
The brake oil cooler weighs 247 kgs (545 lbs). Use damaged blades.
a suitable lifting device that can safely handle 247
kgs (545 lbs). Installation
1. Inspect fan carefully before installation. If blades
are bent or cracks are evident, install a new fan.
2. Clean mounting surfaces thoroughly and install
spacer on fan hub.
3. Lift fan into position and install over pilot diameter
of hub.
4. Install the capscrews and lockwashers and torque
to standard torque. Use alternating pattern and
increasing levels of torque until all capscrews are
evenly torqued.
5. Install fan guard around fan if separated during
removal.

FIGURE 3-7. BRAKE OIL COOLER 6. Install radiator, hood, grille and water piping as
1. Water Outlet Hose 4. Brake Oil Cooler specified in Section “B” or earlier in this section.
2. Water Inlet Hose 5. Oil Outlet Tube 7. Refill with coolant.
3. Oil Inlet Tube

C3-4 Cooling System C03018


FAN BELT Installation
The Poly-Vee type belt can be changed by removing 1. Work the belt around fan blades and into the area
the fan guard without dismantling or removing the fan of the pulleys.
from the engine. Care must be exercised in doing this 2. With a long one inch drive wrench, have one
however as the belt will be a tight fit around edge of person rotate the belt tensioner clockwise until
blades and sheet metal of shroud. the belt can be installed over the grooves of both
pulleys. Make sure the belt is on the correspond-
Removal ing grooves of both pulleys and slowly release the
The belt tension is automatically maintained by spring belt tensioner pulley against the belt.
pressure to the idler pulley. Manual adjustment is not
necessary.
1. Poly-Vee belt removal will require 2 people. With
a long handled one inch drive wrench, turn the
tension hub clockwise against spring pressure to
release tension on the fan belt. This will take
considerable effort against the spring pressure.
Refer to Figure 3-8.
2. Remove belt from pulleys and work around fan to
remove from truck. Note that considerable spring
tension is involved and it must be released care-
fully until the tensioner pulley is fully released
counter clockwise.

FIGURE 3-8. FAN BELT REMOVAL

C03018 Cooling System C3-5


NOTES

C3-6 Cooling System C03018


ENGINE
ENGINE
The Model 330M truck is equipped with a Komatsu
SA12V140Z-1 turbocharged diesel engine. Engine
power is transmitted to the TORQFLOW transmission
by a drive line adapter with damper assembly, and a
drive shaft with two universal joints.

Removal
1. Position the truck in work area with adequate
overhead clearance to permit raising the dump
body.
2. Apply parking brake and block wheels to prevent
truck movement. Raise body and install safety
pin.

FIGURE 4-2. PIPES AND WIRING


Do not work under raised body without first mak- 1. Water Pipes 3. Hose
ing sure the safety pin is securely installed. 2. Ground Terminal 4. Alternator Wire

3. Close the fuel supply valve. NOTE: Prior to disassembly or removal, tag or mark
all air lines, oil lines, fuel lines and electrical connec-
4. Remove grille according to procedure in Section
tions to assure correct assembly at time of engine
“B”. Remove radiator according to “Radiator Re-
installation. Plug all ports and cover all hose fittings or
moval” procedure in this section.
connections when disconnected to prevent dirt or for-
5. Disconnect the negative, then the positive battery eign material from entering.
cables. Disconnect the electrical lead from the
7. Disconnect water pump pipes (1, Figure 4-2) and
battery charging alternator.
hose (3).
6. Disconnect by-pass filter hoses (3, Figure 4-1)
8. Disconnect ground terminal (2) and alternator wire
and fuel filter hoses (4).
(4).
9. Disconnect starter motor wiring (1, Figure 4-3) and
ground terminals (2).

FIGURE 4-1. OIL LINES


FIGURE 4-3. STARTING MOTOR
1. By-pass Filter 3. By-pass Filter Hose
2. Fuel Filter 4. Fuel Filter Hose 1. Starter Motor 2. Ground Terminals
Wiring

C04019 3/00 Engine C4-1


FIGURE 4-4. ENGINE HOSES AND WIRING FIGURE 4-6. INTAKE AND EXHAUST PIPING

1. Priming Hose 1. Intake Pipes 2. Exhaust Pipes


4. Shut-off Valve
2. Return Hose Wiring
3. Engine Control Cable 5. Air Hose

10. Disconnect priming hose (1, Figure 4-4), return


13. Remove intake pipes (1, Figure 4-6), and exhaust
hose (2), engine control cable (3), and shut-off
pipes (2).
valve wiring (4).
14. Remove cover (1, Figure 4-7).
11. Disconnect air hose (5), and temperature sensor
wire (6).
12. Disconnect water temperature sensor connector
(1, Figure 4-5), heater hose (2), and hoses (3).

FIGURE 4-7. COVER


1. Cover
FIGURE 4-5. ENGINE HOSES AND WIRING
1. Sensor Connector 3. Hoses
2. Heater Hose

C4-2 Engine C04019 3/00


FIGURE 4-8. ENGINE WIRING AND LINES FIGURE 4-10. OIL LINES
1. Air Compressor Tube 3. RPM Sensor 1. Brake Cooling Hose 2. Tubes
2. Switch Wire Wiring

17. Remove brake cooling hose (1, Figure 4-10), and


tubes (2).
15. Disconnect air compressor tube (1, Figure 4-8), 18. Remove drive shaft guard (1, Figure 4-11), and
engine oil temperature switch wire (2), and RPM drive shaft (2).
sensor wiring (3).
16. Disconnect engine ground terminals (1, Figure
4-9).
The complete engine module weighs approxi-
mately 3,200 kgs (7,050 lbs.). Make sure sling,
hoist, and spreader bar is of adequate capacity.
During engine removal, insure that engine removal
path is clear of personnel and equipment.

19. Attach lifting device to engine and remove from


frame. Move engine to a clean work area and
mount on work stands or cribbing.

FIGURE 4-9. GROUND CONNECTIONS

1. Engine Ground Terminal

FIGURE 4-11. DRIVE SHAFT


1. Drive Shaft Guard 2. Drive Shaft

C04019 3/00 Engine C4-3


Installation
10. Connect priming hose (1, Figure 4-4), return hose
(2), engine control cable (3), and shut-off valve
wiring (4).

The complete engine module weighs approxi- 11. Connect starter motor wiring (1, Figure 4-3) and
mately 3,200 kgs (7,050 lbs.). Make sure sling, ground terminals (2).
hoist, and spreader bar is of adequate capacity. 12. Connect ground terminal (2) and alternator wire
During engine removal, insure that engine removal (4).
path is clear of personnel and equipment.
13. Connect water pump pipes (1, Figure 4-2) and
hose (3).
1. Attach lifting device to engine and install in frame.
Tighten engine mounting capscrews to 56 ±6 14. Connect by-pass filter hoses (1, Figure 4-1).
kg.m (405±43 ft.lbs.) 15. Connect the negative, then the positive battery
NOTE: Refer to the procedure for centering the engine cables. Connect the electrical lead from the bat-
assembly and transmission assembly in Section tery charging alternator.
“F”,"Transmission Installation". 16. Refer to “Radiator Installation” procedure, this
section and install the radiator. Install grille ac-
2. Install drive shaft guard (1, Figure 4-11), and drive cording to procedure in Section “B”.
shaft (2). Apply a thread tightener (Three Bond 17. Open the fuel supply valve.
#1374) to capscrews. Tighten capscrews to 18 ±2
18. Adjust throttle cables per instructions in “Engine
kg.m (130 ±14 ft.lbs.) torque.
Components”, this Section.
3. Install brake cooling hose (1, Figure 4-10), and
19. Recheck engine to be assured all air, oil, electric,
tubes (2).
and fuel lines have been reconnected to the
4. Connect engine ground terminals (1, Figure 4-9). proper locations and that all connections are se-
cure.
5. Connect air compressor tube (1, Figure 4-8),
engine oil temperature switch wire (2), and RPM NOTE: Refer to Section “P”, Lubrication and Service
sensor wiring (3). for the proper fluids.
6. Install cover (1, Figure 4-7).
20. Fill engine oil to the specified level. Refill radiator
7. Install intake pipes (1, Figure 4-6), and exhaust
with coolant to the specified level and run the
pipes (2).
engine to circulate the oil and coolant through the
8. Connect water temperature sensor connector (1, system until temperatures are stabilized. Then
Figure 4-5), heater hose (2), and hoses (3). check fluid levels again. Check for oil, fuel or
coolant leakage.
9. Connect air hose (5), and temperature sensor wire
(6).

C4-4 Engine C04019 3/00


Drive Line Adapter
If a new, or replacement engine, is to be installed, it 7. Remove bearing (1, Figure 4-15) for cleaning,
may be necessary to remove and install the drive line inspection, and fresh lubrication, or replacement,
adapter. if necessary.

Drive Line Adapter Removal


1. Position the truck in work area with adequate
overhead clearance to permit raising the dump
body.

Do not work under raised body without first mak-


ing sure the safety pin is securely installed.
2. Apply parking brake and block wheels to prevent
truck movement. Raise body and install safety
pin. FIGURE 4-13. OUT PUT SHAFT
3. Remove drive shaft guard (1, Figure 4-11). Re- 1. Snap Ring 2. Damper Cover
move capscrews (5, Figure 4-12) from cross and 3. Capscrew
bearing assembly (2) at both ends of drive shaft,
and then remove drive shaft assembly (1).
4. Remove output drive flange (6). Remove cap-
screws (7) and bearing cover (3).
5. Remove snap ring (1, Figure 4-13). Remove re-
taining capscrews (3) around damper cover (2),
and then with sling, eye bolts, and guide bolts,
remove damper cover (2).
6. Remove capscrews holding damper assembly to
flywheel (12, Figure 4-16). Attach a sling and
lifting device and remove output shaft damper
assembly (1, Figure 4-14).
FIGURE 4-14. OUTPUT SHAFT DAMPER ASSEMBLY
1. Output Shaft Damper Assembly 2. Housing

FIGURE 4-12. DRIVE SHAFT


1. Drive Shaft 4. Damper Cover
2. Cross & Bearing Assy. 5. Capscrews FIGURE 4-15. PILOT BEARING
3. Bearing Cover 6. Output Drive Flange 1. Bearing 2. Flywheel
7. Capscrews

C04019 3/00 Engine C4-5


Drive Line Adapter Installation
1. Position the truck in work area with adequate
overhead clearance to raise the dump body.

Do not work under raised body without first mak-


ing sure the safety pin is securely installed.
2. Apply parking brake and block wheels to prevent
truck movement. Raise body and install safety
pin.
3. Refer to “Drive Line Adapter Damper Assembly”
for assembly of the adapter, if this was disassem-
bled.
4. If removed, use a push tool, and press fit bearing
(1, Figure 4-15 / 9, Figure 4-16) into flywheel.
Bearing must be packed and roller surface lubri-
cated with Komatsu lubricant, 427-12-11871, for
long life. Refer to “Recommended Lubricants”
later in this section.
5. Apply thread tightener (Three Bond #1374) to
FIGURE 4-16. ADAPTER CROSS SECTION
capscrews (12, Figure 4-16) and install output
1. Oil Seal 7. Rubber
shaft damper assembly (1, Figure 4-14) to fly-
2. Bearing 8. Outer Body
wheel. Tighten capscrews (12, Figure 4-16) to
3. Output Shaft 9. Pilot Bearing
11.5 ± 1 kg.m (83 ± 7 ft lbs) torque. 4. (not shown) Damper Assembly 10.Capscrew
6. Use eye bolts and guide bolts to install damper (includes 3*, 5*, 6*, 7*, & 8*) 11. Capscrew
cover (2, Figure 4-13). Apply thread tightener to 5. Flange 12. Capscrew
capscrews and tighten capscrews (3, Figure 4-13 6. Inner Body 13. Capscrew
/13, Figure 4-16) to 3.2 kg.m (23 ft lbs) torque.
NOTE: Do not over pack fill points. Forcing too
7. Bearing (2, Figure 4-16 / 13, Figure 4-18) must be much grease into cavities could displace seals.
packed with Komatsu lubricant, 427-12-11871.
(Refer to “Recommended Lubricants” and Figure
4-17 for packing bearing and cavity with grease.)
If removed, press fit bearing (13, Figure 4-18) in
cover (11). Install retaining ring (14).
8. Apply thread tightener to capscrews (18) and
install bearing cover (15). Tighten capscrews to
11.5 ± 1 kg.m (83 ± 7 ft lbs) torque.
9. Install oil seal (19) into bearing cover (15). Push
drive flange onto output shaft (3, Figure 4-16).
10. Attach a sling and lifting device and move drive
shaft assembly (1, Figure 4-12) into position.
11. Install cross and bearing assembly (2) between
drive shaft and flange at both ends of drive shaft
with capscrews (5). Tighten cross and bearing to
flange capscrews (5) to 18 ±2 kg.m (130 ±14 ft.
lbs.) torque.
12. Install drive shaft guard (1, Figure 4-11). FIGURE 4-17. PACKING BEARING AND CAVITY

C4-6 Engine C04019 3/00


Drive Line Adapter Damper Disassembly
1. Remove oil seal (19, Figure 4-18) from bearing 4. Disassemble output shaft damper assembly as
cover (15), if not previously removed. follows.
2. Remove bearing (13) from damper cover (11), if a. Match mark positions of flanges (6A/B), inner
not previously removed. body/shaft (10), and outer body (8), before
disassembling.
3. Do not remove output shaft from damper assem-
b. Remove flanges (6A/B), inner body/shaft (10),
bly (4). The inner body/output shaft assembly (10)
and rubber dampers (9) from outer body (8).
is provided as a one-piece part. No effort should
be made to separate the pieces. If shaft appears 5. If not previously removed, remove bearing (2)
loose in inner body, replace this assembly. from flywheel for cleaning, inspection, and fresh
lubrication, or replacement, if necessary.
NOTE: To keep the balance when reassembling, mark
the set positions of flanges (6A/6B), outer body (8), and
inner body/shaft (10) before disassembling.

FIGURE 4-18. DRIVE LINE ADAPTER


1. Flywheel Housing 8. Outer Body 15. Bearing Cover
2. Pilot Bearing 9. Rubber Damper (large) 16. Breather
3. Capscrew & Washer 9A. Rubber Damper (small) 17. Plug
4. Damper Assembly 10. Inner Body/Output Shaft 18. Capscrew & Washer
5. Capscrew & Washer 11. Cover 19. Oil Seal
6A. Flange 12. Capscrew & Washer 20. Output Drive Flange
6B. Flange 13. Bearing 21. Cap Plate
7. Dowel Pin 14. Retaining Ring 22. Retaining Ring

C04019 3/00 Engine C4-7


Drive Line Adapter Damper Assembly 6. Apply adhesive (Three Bond #1104) on flange
(6B, Figure 4-18) and install according to balance
1. Replace any worn or damaged parts.
lines that were made during disassembly.
2. Coat mating surface of outer body (8, Figure 4-18)
7. Align the balance lines of the outer body, inner
and mating surface side of flange (6A) with adhe-
body, and flange, then assemble.
sive (Three Bond #1104), then assemble accord-
ing to balance lines that were made during 8. Apply a thread tightener (Three Bond #1374) on
disassembly. Apply a thread tightener (Three flange mounting bolts (5) and tighten to 18 ±2
Bond #1374) on flange mounting bolts (5) and kg.m (130 ±14 ft.lbs.) torque.
tighten to 18 ±2 kg.m (130 ±14 ft.lbs.) torque.
9. Refer to “Drive Line Adapter Installation, steps 4
3. Install inner body/output shaft (10) according to through 12", for remaining installation of all other
balance lines that were made during disassem- related parts, and driveline.
bly.
4. Coat outer body (8), inner body/shaft (10), and RECOMMENDED LUBRICANTS
rubber dampers (9) with LW008-27 grease. Refer The instructions listed in these pages contain refer-
to “Recommended Lubricants”. ences to lubricants that are used in Haulpak manufac-
5. After assembling rubber dampers (2 & 5, Figure turing and assembly processes. These lubricants may
4-19), fill the space (3, shaded portion) uniformly be identified and obtained as follows:
with LW008-27 grease. Refer to “Recommended NOTE: “Approved source” indicates the material prop-
Lubricants”. erties have been approved for Haulpak manufacturing.
This is not a commercial endorsement for the product.
The rubber damper area requires LW008-27,
Multi-Purpose NLGI #2 grease. This is a multi-
NOTE: Do not over pack fill space. Forcing too purpose extreme pressure lubricating grease,
much grease into cavities could displace rubber consisting of a lithium complex soap base and
dampers. mineral oil.
Approved source:
Mobilgrease HP, from Mobil Oil Corp.
The bearings are to be packed with LW030-27.
The present source for this lube, is Komatsu
Parts Distribution, part number 427-12-11871,
which is a one gallon container.
This amount is enough for two installations.

Recommended Lubricants & Sealants


A Komatsu Lubricant 1 gallon Can -
(427-12-11871) Order from Haulpak
B LW008-27 grease. Mobil Grease HP
3 Tubes*
C Thread Tightener Three Bond #1374*
D Liquid Gasket Three Bond USA-
LW067-78 grade #1104*

FIGURE 4-19. * - Obtain locally


1. Outer Body Member 4. Inner Body Member
2. Large Rubber Damper 5. Small Rubber NOTE: Refer to Section “P”, Lubrication and Service,
3. Grease Area Damper for periodic inspections of this drive area.

C4-8 Engine C04019 3/00


AIR FILTRATION SYSTEM
AIR CLEANER Filter Element Replacement
Air used by the diesel engine passes through the air
cleaner assembly mounted on the right side deck of
the truck. This dry type air cleaner filters particles as
air passes through the filter elements.
The truck engine MUST NEVER be operated with
Service Checks elements removed. Engine operation with filter
elements removed can cause serious engine
damage. Run the engine ONLY with the air
cleaner assembly completely assembled and
closed.
The truck engine must be shut down before ser- Main filter element restriction is registered by a ser-
vicing the air cleaner assembly or opening the vice indicator located above the air filter assembly.
engine air intake system. As filter becomes clogged with dirt, a vacuum differ-
1. Inspect and empty air cleaner dust collector at ential is created by engine demand for air causing
regular intervals. Daily inspections are recom- indicator float to expose red area. Filter service is
mended. needed when red area is exposed.
2. Before operation or after the engine has been 1. Shut engine down. Clean area around filter ele-
shut down, observe the air cleaner service vac- ment cover and remove outer wing nut (3, Fig-
uum indicator which is located above the air fil- ure 5-1) and cover
ter assembly. Filter service is required when the 2. Loosen inner wing nut (3) on air cleaner to free
indicator shows maximum restriction (RED). main element assembly. Pull main element
3. Make certain that the air inlet on the air cleaner clear of assembly.
is free of obstruction. Inlet must not be clogged 3. Inspect filter element carefully for possible dam-
or damaged. age, holes, breaks, etc., which might affect
4. Check engine air intake tube, hoses and reuse of element. If element appears service-
clamps. All connections and joints must be air able other than being dirty, proceed with the
tight to prevent entrance of dirty air. cleaning procedure. If defects are found, dis-
card element.
5. Air cleaner housing fasteners and mountings
must be tight.
6. After filter service has been accomplished, reset
air cleaner service vacuum indicator by pushing
the reset button on top of indicator.

Have a new safety (secondary) filter element at


hand before removing old one. Do not keep
intake system open to atmosphere any longer
than absolutely necessary.

C05010 12/91 Air Filtration System C5-1


FIGURE 5-1. AIR CLEANER ASSEMBLY

1. Air Intake Cover 4. Primary Filter Element


2. Safety Filter Element Nut 5. Safety Filter Element
3. Outer and Inner Wing Nuts

C5-2 Air Filtration System 12/91 C05010


4. Install new safety element and secure with wing b. Rinse element with a stream of fresh water in
nut. Tighten wing nut to 10 ft. lbs. (13 N.m) the opposite direction of normal air flow until
torque. rinse water runs clear. Maximum permissible
5. Install clean or new main filter element into air water pressure is 40 psi (276 kPa). A com-
cleaner and secure with wingnut. Tighten wing plete, thorough rinse is essential.
nut hand tight, do not use a wrench or pliers. If c. Dry the element thoroughly. If drying is done
filter element is being reused, make sure seal- with heated air, the maximum temperature
ing gasket is not damaged, the gasket must must not exceed 140°F (60°C) and must be
seal completely. circulated continually. Do not use a light bulb
6. Install cover and tighten outer wing nut. for drying elements.
7. Close and latch the dust collector on the bottom d. When the element is thoroughly clean,
of air cleaner assembly. inspect carefully for even the slightest rup-
tures or punctures and for damaged gaskets.
A good method to detect ruptures in the
paper filter material is to hold a light inside fil-
ter element as shown in Figure 5-2 and
inspect outer surface of element, any holes
or ruptures will be easily spotted. If holes or
ruptures are found, do not reuse the ele-
ment, discard and install a new unit.
2. Clean dust loaded elements with dry, filtered,
compressed air:
a. Maximum nozzle pressure must not exceed
30 psi (207 kPa). Nozzle distance from filter
element surface must be at least one inch
(25 mm) to prevent damage to the filter
FIGURE 5-2. INSPECTING FILTER ELEMENT material.
b. As shown in Figure 5-3, direct stream of air
from nozzle against inside of filter element.
This is the clean air side of the element and
Main Filter Element Cleaning air flow should be opposite of normal air flow.
NOTE: Remember that only the main (primary) filter
element may be cleaned, and then only if it is
structurally intact. Do not reuse any element which is
damaged. DO NOT clean and reuse the safety
(secondary) filter element. Replace this item when
clogged or damaged.
After inspection, determine if the element should be
cleaned by using either washing or compressed air
methods. If element is clogged with dust, com-
pressed air will clean element. If element is clogged
with carbon, soot, oil and/or dust, the complete wash-
ing procedure will produce the best results.
1. Wash elements with water and detergent as fol-
lows:
a. Soak the element in a solution of detergent
and water for at least 15 minutes. Rotate ele-
ment back and forth in the solution to loosen FIGURE 5-3. CLEANING FILTER ELEMENT WITH
dirt deposits. DO NOT soak elements for COMPRESSED AIR
more than 24 hours.

C05010 12/91 Air Filtration System C5-3


c. Move air flow up and down vertically with
pleats in filter material while slowly rotating
filter element.
d. When cleaning is complete, inspect filter ele-
ment as shown in Figure 5-2 and if holes or
ruptures are noted, replace the element with
a new item.

Air Intake Troubleshooting


To insure maximum engine protection, be sure that
all connections between air cleaner and engine
intake are tight and positively sealed. If air leaks are
suspected, check the following:
1. All intake lines, tubes and hump hoses for
breaks, cracks, holes, etc., which could allow an
intake air leak.
2. Check all air cleaner gaskets for positive seal-
ing.
3. Check air cleaner elements, main and safety, for
ruptures, holes or cracks.
4. Check air cleaner assembly for structural dam-
age, cracks, breaks or other defects which
could allow air leakage. Check all mounting
hardware for tightness.

C5-4 Air Filtration System 12/91 C05010


SECTION D
ELECTRICAL SYSTEM
INDEX
24VDC ELECTRICAL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . D2-2
Spillage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
BATTERY CHARGING ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . D2-3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-4
ENGINE PRELUB SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7

24VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . D3-1


VEHICLE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1
Vehicle Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4
Sensors, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4
MONITOR PANEL DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6
INSTRUMENT PANEL INDICATORS, TEST SWITCH . . . . . . . . . . . . . . . . . D3-10
ELECTRONIC ACCELERATOR PEDAL SYSTEM . . . . . . . . . . . . . . . . . . . D3-12
AISS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-13
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-14

POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . D4-1


POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . D4-2
Points to remember when handling electric equipment . . . . . . . . . . . . . . . . . . D4-2
Handling of controller boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-7
Precautions when performing arc welding on the truck . . . . . . . . . . . . . . . . . . D4-7
Points to remember when troubleshooting electric circuits . . . . . . . . . . . . . . . . D4-7
Points to remember when handling hydraulic equipment
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . D4-10
TYPE OF CONNECTOR AND POSITION OF INSTALLATION . . . . . . . . . . . . . . D4-12
FOR ARSC (AUTOMATIC RETARDER SPEED CONTROL) . . . . . . . . . . . . . . . D4-17
CONNECTOR PIN ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . D4-18
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . D4-23
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM D4-33
Explanation of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-33
Explanation of self-diagnostic display functions . . . . . . . . . . . . . . . . . . . . D4-33
Checking operation of electrical system . . . . . . . . . . . . . . . . . . . . . . . . D4-35

D01021 8/99 Index D1-1


MONITOR PANEL ACTION CODES AND SERVICE MODE . . . . . . . . . . . . . . . . D4-39
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-39
Action code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-39
Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-40
Method of deleting trouble data from memory . . . . . . . . . . . . . . . . . . . . . . D4-48
Precautions when operating service mode . . . . . . . . . . . . . . . . . . . . . . . D4-48
Table 1 bit numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-51
Brake air pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-52
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS . D4-53
Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-53
Transmission controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-53
Self -diagnostic display code table . . . . . . . . . . . . . . . . . . . . . . . . . D4-53
Warning display table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-54
Method of re-enacting fault displayed . . . . . . . . . . . . . . . . . . . . . . . . D4-55
Operation of controller when fault is detected . . . . . . . . . . . . . . . . . . . . D4-55
Transmission mode display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-56
Saving self-diagnostic display to memory . . . . . . . . . . . . . . . . . . . . . . . . D4-56
Saving service code to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-57
TABLE OF SERVICE CODES AND ACTION CODES
Table of service codes and action codes related to monitor panel . . . . . . . . . . . D4-58
Table of service codes and action codes related to transmission controller . . . . . . . D4-59
Table of service codes and action codes related to suspension controller . . . . . . . D4-62
Table of service codes and action codes related to PMC . . . . . . . . . . . . . . . . D4-63
METHOD OF USING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-64
METHOD OF USING TOUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . D4-65
Method of using troubleshooting chart for each troubleshooting fault . . . . . . . . . . D4-65
ADJUSTING ELECTRONIC MONITOR (Speedometer, module) . . . . . . . . . . . . . . D4-67
SETTING ROTARY SWITCH (Model and network data) when replacing trans. controller . D4-68
METHOD OF DELETING DATA FROM TRANS. CONTROLLER MEMORY . . . . . . . . D4-69

TRANSMISSION SHIFT CONTROLLER SYSTEM TROUBLESHOOTING . . . . . . . . . . D5-1


TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-1
Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-1

MONITOR PANEL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . D6-1


TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-1
Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-1

ENGINE ELECTRONIC DIAGNOSTIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . D7-1


Fault Code Information (T01-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . D7-4
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7-6

HYDRAULIC & MECHANICAL SYSTEMS TROUBLESHOOTING . . . . . . . . . . . . . . D8-1


Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8-1
SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . D9-1

D1-2 Index D01021 8/99


24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION Service

Four (4) 12 volt storage batteries are located on the All batteries must be maintained periodically, espe-
right hand deck and are wired in a series and parrallel cially machines equipped with electric starters.
combination to provide 24VDC for the Truck electrical The electrolyte level of each cell should be checked at
system and components. the interval specified in the Lubrication and Service
When the engine is shut down and keyswitch is “Off”, Section “P”, and water added if necessary. The proper
24 volts is supplied to the circuits for the alternator, level to maintain is 3⁄8– 1⁄2 in. (10-13 mm) above the
keyswitch, and the hazard flasher. plates. To insure maximum battery life, use only dis-
tilled water or water recommended by the battery
With engine running and keyswitch “On”, all circuits
manufacturer. After adding water in freezing weather,
are capable of operating under the necessary condi-
operate the engine for at least 30 minutes to thoroughly
tions for the circuit. Whether a particular circuit is
mix the electrolyte.
activated depends on components in the circuit and
purpose.
The electric system is made up of many circuits that
warn, illuminate, start, control, and monitor the truck
electric components during operation. DO NOT SMOKE or allow flame around a dead
Refer to the Electrical Schematic, Section “R”, for battery or during the recharging operation. The
specific circuit details. expelled gas from a dead cell is extremely explo-
sive.

Excessive consumption of water indicates leakage or


overcharging. Normal water usage for a unit operating
Before welding on truck, be certain that each of eight hours per day is about one to two ounces per cell
these components are completely disconnected: per month. For heavy duty operation (24 hour) normal
consumption should run about one to two ounces per
• Transmission Controller cell per week. Any appreciable increase over these
• Batteries figures should be considered a danger signal.
• Battery Charging Alternator
Storage
BATTERY Idle batteries should not be allowed to stand unat-
The four (4) 12 volt storage batteries are of the lead- tended. If equipment is to stand unused for more than
acid type, each containing six 2-volt cells. During two weeks, the batteries should be removed and
operation, the storage batteries function as an electro- placed in a cool, dry place where they may be checked
chemical device for converting chemical energy into periodically and charged when necessary.
the electrical energy required for operating the acces-
All batteries will self discharge over a period of time if
sories when the engine is shut down.
not used and charged. A fully charged battery will lose
25% of its power in as little as 30 days in warm
weather. A 50% power loss will occur in 60 days. This
self discharge takes place even though the battery is
not connected in a circuit and is more pronounced in
Lead-acid storage batteries contain sulphuric warm weather than in cold.
acid, which if handled improperly may cause seri- The rate of self-discharge of a battery kept at 100°F
ous burns on skin or other serious injuries to (38°C) is about six times that of a battery kept at 50°F
personnel. Wear protective gloves, aprons and eye (19°C) and self-discharge of a battery kept at 80°F
protection when handling and servicing lead–acid (27°C) is about four times that one at 50°F (10°C).
storage batteries.
See the precautions in Section “A” of this manual Over a thirty day period, the average self-discharge
to insure proper handling of batteries and treat- runs about 0.002 specific gravity per day at 80°F
ment for accidents involving sulphuric acid. (27°C).

D02020 04/00 24VDC Electric Supply System D2-1


Some possible causes for an undercharged battery
Specific Gravity Freezing Temperature are:
Corrected to 80°F (27°C) Degrees
Sulfated battery plates
1.280 -90°F (-70°C)
Loose battery connections
1.250 -60°F (-54°C)
Defective wire in electrical system
1.200 -16°F (-27°C)
Loose alternator drive belt
1.150 +5°F (-15°C)
A defective alternator
1.100 +19°F (-7°C)
Overcharging, which causes overheating, is first indi-
cated by excessive use of water. If allowed to continue,
To offset the results of self-discharge, idle batteries cell covers will push up at the positive ends and in
should receive a booster charge (not a quick charge) extreme cases the battery container will become dis-
at least once every thirty days. Batteries allowed to torted and cracked.
stand for long periods in a discharged condition are
attacked by a crystallization of the lead sulfate on the A battery can discharge if it is not clean and dry. A fully
plates. Such batteries are called sulfated and are, in charged battery can become discharged to a level low
the majority of cases, irreparably damaged. In less enough to prevent it from starting an engine in as little
severe cases, the sulfated battery may be restored to time as one week. The problem may be acid film and
limited service by prolonged charging at a low rate dirt lying on top of the battery. This creates a path for
(approximately 1⁄2 normal rate). electricity to travel between the terminals, thus dis-
charging the battery.
An undercharged battery is extremely susceptible to
freezing when allowed to stand in cold weather. Use either an analog or digital voltmeter to determine
if there is a path between the terminals.
The electrolyte of a battery in various stages of charge
will start to freeze at temperatures indicated in the a. Set the voltmeter at a range to indicate battery
tableabove. voltage.

The temperatures in the table indicate the points at b. Place the positive lead of the voltmeter on the
which the first ice crystals appear. Lower temperatures positive battery post.
must be reached for a solid freeze. Solid freezing of c. Place the negative lead so that it touches the
the electrolyte may crack the battery case and damage battery case approximately one inch away from
the positive plates. As will be noted, a 3⁄4 charged the positive post.
battery is in no danger of freezing, therefore, a 3⁄4
d. The voltmeter should indicate 0.0 volts. If any
charge or better is desirable, especially during winter
voltage is indicated, there is a path that will dis-
weather.
charge the battery. The higher the voltage, the
quicker the discharge rate.
e. Move the negative probe to several locations
(near the positive post) to verify the test results.
Do not attempt to charge a frozen battery. Serious If voltage was detected in the previous test, the battery
injuries to service personnel can result! should be cleaned. The top of the battery may be wiped
off with a damp cloth or washed with a baking soda or
ammonia solution. If the battery is washed, be sure
Maintenance and Troubleshooting none of the cleaning solution is allowed into the battery
cells. Be sure terminals are clean and tight. Clean
Two most common troubles that occur in the charging terminals are very important in a voltage regulated
system are undercharging and overcharging of the system. Be sure to clean the entire battery compart-
truck’s batteries. ment thoroughly as it may contain acid residue. Be
An undercharged battery is incapable of providing careful not to splash any overspray onto surrounding
sufficient power to the truck’s electrical system. components. Rinse the area completely to remove all
traces of battery acid from machine.

D2-2 24VDC Electric Supply System D02020 04/00


Leakage can be detected by continual wetness of the BATTERY DISCONNECT SWITCH (Optional)
battery or excessive corrosion of the terminals, battery
An optional battery disconnect switch (2, Figure 2-1)
carrier and surrounding area. (A slight amount of cor-
is available. This switch provides a quick and conven-
rosion is normal in lead–acid batteries). Inspect the
ient method of opening the battery positive (+) power
case, covers and sealing compound for holes, cracks
circuit without the need to remove cables from the
or other signs of leakage. Check battery hold down
battery terminals.
connections to make sure the tension is not great
enough to crack the battery, or loose enough to allow The battery disconnect switch is located on the front
vibration to open the seams. A leaking battery should side of the battery box (3) on the right deck (1). When
be replaced. the switch lever is moved to the right (away from the
cab) the switch is in the OFF position and the battery
To remove corrosion, clean the battery with a solution
circuit is open. Move the switch lever toward the cab
of ordinary baking soda and a stiff, non-wire brush and
to restore battery power.
flush with clean water. Corrosion creates resistance in
the charging circuit which causes undercharging and
gradual starvation of the battery.
NOTE: When washing batteries, make sure cell caps
are tight to prevent cleaning solution from entering the
cells.

Maintaining clean batteries will provide longer service


life and a higher rate of performance.

Spillage
Addition of acid will be necessary if considerable elec-
trolyte has been lost through spillage. Before adding
acid, make sure battery is fully charged. This is accom-
plished by putting the battery on charge 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 charged. Additional acid may
now be added. Continue charging for another hour and
again check specific gravity. Repeat the above proce-
dure until all cells indicate a specific gravity of 1.260-
1.265 corrected to 80°F (27°C).
NOTE: Use 1.400 strength sulphuric acid when mak-
ing specific gravity adjustments. Acid of higher
strength will attack the plates and separators before it
has a chance to diffuse into the solution.

FIGURE 2-1. BATTERY DISCONNECT SWITCH


If the temperature of the electrolyte is not reasonably HOOKUP
close to 80°F (27°C) when the specific gravity is taken,
temperature should be corrected to 80°F (27°C): 1. R.H. Deck Structure 3. Battery Box
• For every 10°F (5°C) below 80°F (27°C), 0.004 2. Battery Disconnect 4. Battery Relay Switches
should be SUBTRACTED from the specific gravity Switch
reading.
• For every 10°F (5°C) above 80°F (27°C), 0.004
should be ADDED to the reading.

D02020 04/00 24VDC Electric Supply System D2-3


BATTERY CHARGING CIRCUIT BATTERY CHARGING ALTERNATOR
COMPONENTS A 24 volt alternator is used to supply electric current
Batteries - Four (4) 12 volt lead-acid type storage for the 24VDC circuits when the engine is running. The
batteries are located on the right hand deck and are alternator is equipped with an internal regulator system
wired in a series and parrallel combination to provide used to keep the batteries at full charge. Internal
24VDC for the Truck electrical system. diodes convert the alternator’s AC output to DC.
The only movable part in the assembly is the rotor,
which is mounted on a ball bearing at the drive end and
a roller bearing at the rectifier end. All current carrying
conductors are stationary. These conductors are the
field winding, the stator windings, the six rectifying
diodes and the regulator circuit components. The regu-
lator and diodes are enclosed in a sealed compart-
ment.
A fan located on the drive end provides air flow for
cooling. Grease reservoirs contain an adequate supply
of lubricant so that no periodic maintenance is re-
quired. For repair or maintenance contact your local
Alternator - Is located on the upper right front corner
Delco-Remy Distributor.
of the engine. The alternator produces 27.5 – 29.5 volt
output and is capable of up to 75 amperes. NOTE: The hex head bolt on the output terminal is
electrically insulated; no voltage reading can be ob-
Charge Warning Light - Is located on the left side of
tained by connecting to the hex head.
the instrument panel and, when illuminated while the
engine is running, indicates an abnormality in the
charging system. Normal indicated voltage at high idle
is 27.5 – 29.5 volts.

Before welding on truck, be certain that each of


these components are completely disconnected:
• Transmission Controller
• Batteries
• Battery Charging Alternator

D2-4 24VDC Electric Supply System D02020 04/00


Operation Capacitor C1 protects the generator diodes from high
transient voltages and suppresses radio interference.
The basic operating principles are explained as follows
Resistor R5 prevents current leakage through TR3 at
(Refer to Figure 2-2):
high temperatures. Diode D5 prevents high transient
As the rotor begins to turn, the permanent magnetism voltages in the field coil when the field current is
therein induces voltages in the stator windings. The decreasing. Resistor R7, capacitor C3, and resistor
voltages across the six diodes cause current to flow to R4, all act to cause transistors, TR2 and TR1, to turn
charge the battery. on and off more quickly.
Current from the stator flows through the three diodes
Magnetizing The Rotor
to resistor R6 and the base-emitter of TR2 and TR1 to
turn these transistors on. Current also flows from the The rotor normally retains magnetism to provide volt-
stator through the diode trio D1, D2 and D3, the field age build-up when the engine is started. After disas-
coil and transistor TR1, returning to the stator through sembly or servicing, however, it may be necessary to
the other three diodes. All stator current, except reestablish the magnetism. To magnetize the rotor
through the diode trio D1, D2 and D3, flows through connect the alternator to the battery in a normal man-
the six diodes connected to the stator. ner, then momentarily connect a jumper lead from the
battery positive post to the relay “R” terminal.
Current flow through R1, R2 and R3 causes a voltage
to appear at zener diode D4. When the voltage be-
comes high enough due to increasing generator
speed, D4 and the base-emitter of TR3 conduct cur-
rent and TR3 turns on. TR2 and TR1 then turn off,
decreasing the field current and the system voltage
decreases. The voltage at D4 decreases, D4 and TR3
turn off, TR2 and TR1 turn back on and the system
voltage increases. This cycle then repeats many times
per second to limit the system voltage as determined
by the setting of the potentiometer R2.

FIGURE 2-2. ALTERNATOR & REGULATOR SCHEMATIC

D02020 04/00 24VDC Electric Supply System D2-5


NOTES

D2-6 24VDC Electric Supply System D02020 04/00


ENGINE PRELUB SYSTEM
The Prelub system automatically, safely, and When the pressure switch opens at 0.18 kg/cm2 (2.5
quickly fills fills filters and all oil passages prior to psi), the circuit to the timer solenoid is opened. After a
cranking at each engine startup. In addition, the sys- 3 second delay, the Prelub starter will stop com-
tem prevents startup if there is no oil present in the pletely and the timer solenoid will provide current to
engine. the standard starter solenoid. The starter and pinion
gear will engage the flywheel ring gear and normal
The prelub system consists of the following compo-
cranking will occur.
nents:
• Pump
• Timer Solenoid
Pressure Switch
• Oil pressure switch
The pressure switch (7, Figure 2-3) is a 0.18 kg/cm2
• Oil suction line
(2.5 psi), normally closed (N.C.) switch, located so that
• Oil outlet line it can sense oil pressure after the engine oil has
• Check valve passed through the filters.
• Electrical harness

Check Valve
The Prelub starter is an electric starter motor which
has an extended armature shaft to drive an attached The oil pressure supply hose has a check valve in-
oil pump (1, Figure 2-4) at the brush end of the starter. stalled between the Prelub unit and the engine. The
check valve prevents the passage of oil from the
engine back to the pan after the engine is started. The
The Prelub Starter mounting is the same as that used oil flow through the valve is toward the engine as
for the standard starter. Engine oil is drawn through a indicated by an arrow on the valve.
suction hose attached to the oil pan, and then returned
to the engine through an outlet line attached to the Timer Solenoid
engine oil supply ahead of the filters.
The timer solenoid (6) controls the prelubrication cycle.
NOTE: Before starting engine in cold weather, refer to Current is supplied to the timer through the keyswitch.
the Operation & Maintenance Manual, Section 3 for The ground path is completed by the normally closed
proper starting procedure. pressure switch which is preset to open at 0.18 kg/cm2
(2.5 psi).
When the switch opens, current is redirected to the
standard starter solenoid for engine cranking, follow-
ing a 3 second delay.
OPERATION
The Prelub starter is activated when the operator
turns the key switch and holds it in the “start” position.
The normal starter solenoid is bypassed and the cur-
rent flows to the Prelub Starter Solenoid Timer.
When this Solenoid Timer is activated, current flows to
the Prelub Starter motor, but does not engage the
starter pinion gear. The motor drives the Prelub
pump assembly which will deliver approximately 57
liters (15 gallons) of oil per minute to the engine. DO NOT attempt to jump start the truck using the
terminals on the timer solenoid. INTERNAL DAM-
AGE TP THE TIMER WILL RESULT.

D02020 04/00 24 VDC Electric Supply System D2-7


with Prelub Starter
WIRE COLOR LEGEND

WH = White
OR = Orange
PK = Pink
RED = Red
PUR = Purple
BK = Black
YL = Yellow
GN = Green
WH/BK = White with black stripe

FIGURE 2-3. PRELUB SYSTEM ELECTRICAL DIAGRAM


1. Key Switch 4. Starter Safety Relay # 1 7. Prelub Oil Pressure Switch
2. 24VDC Battery (+) 5. Starter Safety Relay # 2 8. Prelub Starter
3. Alternator Supply 6. Timer Solenoid

D2-8 24 VDC Electric Supply System D02020 04/00


with Prelub Starter
MAINTENANCE
Prelub system maintenance should be performed
annually or at 5000 hour intervals as described below.

Prelub System Operation Brush dust will be present in all motors. Do not
Verify system operates according to the two phases of confuse brush dust with oil. Brush dust will appear
operation as listed in “Troubleshooting Prelub Starter as a black/brown, dry coating within the motor.
Circuit” on the following page. If a problem exists, refer
to the list of problems and possible causes for trou-
bleshooting system components. 4. If oil is present in the motor, install a 14 kg/cm2
(200 psi) gauge in the pump pressure test port (3)
If system is operating properly, continue with the in- located near the pump outlet hose.
spection of component parts below:
5. Close the battery disconnect switch or reconnect
Starter/Prelub Pump batteries and observe the pressure gauge while
the engine is started.
The starter motor (with the Prelub pump) should be
inspected as follows for possible oil leakage from the a. If there is any indication of pressure, remove
pump to the starter housing. and repair the the Prelub starting motor and
the check valve located between the pump
1. Disconnect batteries or open the battery discon- outlet and the engine/filters.
nect switch to prevent engine startup. b. If there is no indication of pressure, remove and
2. Remove the inspection plug (2, Figure 2-4). repair the Prelub starter motor only.
3. Using a flashlight (and mirror if necessary), in- 6. If no oil is present, carefully reinstall inspection
spect interior of starter motor housing for the plug (2).
presence of engine oil. Oil may be present in large
amounts or as a light mist. Oil in any quantity in
the housing indicates a failed motor and re-
pair or replacement is necessary. Perform
additional tests below to determine what compo- Check Valve
nents require repair. Verify no internal leakage exists in the check valve
when the engine is running. Check valve leakage back
to the Prelub pump will cause extensive damage to
the pump and starter motor.
If check valve replacement is required, be certain the
valve is installed with the arrow pointed toward the
engine, NOT toward the pump.

Timer Solenoid
Inspect Timer Solenoid for physical damage and to
verify wiring is in good condition.

FIGURE 2-4. PRELUB PUMP AND STARTER


1. Prelub Pump 2. Inspection Plug
3. Pressure Test Port

D02020 04/00 24 VDC Electric Supply System D2-9


with Prelub Starter
Troubleshooting Prelub Starter Circuit
Two distinct phases are involved in a complete prelu-
brication cycle. The two phases are:

1. Prelubrication Phase- Begins when the key 2. Delay and Crank Phase- Begins when the pres-
switch is held in the start position. A circuit is sure switch opens. A 3 second delay precedes
provided to ground through the normally closed the crank mode.
pressure switch. The circuit is interrupted upon
opening of the pressure switch when the Prelub
pressure reaches 0.18 kg/cm2 (2.5 psi).

Problem Probable Cause


1. Starter prelubricates only. Does not delay or 1. Indicates oil pressure is not sufficient to open the
crank. pressure switch.
a. No oil or low oil in engine. The pump can not
build sufficient pressure to open switch.
b. Gear pump failure.
c. Pressure switch has failed close and is holding
ground.
d. Oil pressure switch wire chafed and shorting to
block.
2. Starter prelubricates continuously regardless of 2. Indicates Prelub Timer Solenoid contacts have
key switch position. welded.
a. Low voltage can cause relay failure.
b. Jump starting of the vehicle with a voltage that
is higher than was designed for the system, can
cause solenoid contacts to weld.
3. Starter delays and cranks. No prelubrication 3. If an operator indicates the ignition is totally dead,
mode. make certain the key is being held in the crank
position for 3 to 4 seconds. If the engine cranks
after a short delay, this indicates that a ground
connection to the pressure switch has been bro-
ken. Without a ground path, the prelubrication unit
will proceed to delay and crank.
a. Check the wire to the pressure switch. If the
wire is removed or cut, replace it.
b. Check the ground strap to engine block. If the
ground strap is missing the block is not
grounded.
c. Check the pressure switch for an open circuit.
Remove the wire, then check for an open circuit
between the switch terminal and the switch
base. If open, replace the pressure switch.

D2-10 24 VDC Electric Supply System D02020 04/00


with Prelub Starter
Problem Probable Cause
4. Starting circuit is irregular when in crank mode. 4. a. Check for low or dead batteries.
b. Check alternator output.
c. Check for bad ground strap or NO GROUND
wire from the starter battery ground post to “G”
terminal of starter bendix solenoid.
d. Check for bad starter safety relays.
e. If everything checks OK, replace batteries.
NOTE: Maximum allowable voltage drop is - 2
volts for starter control circuit.
5. Starter has very long prelubrication cycle. 5. Except for severe cold weather starts, the Prelub
cycle should not exceed 45 seconds.
a. Low oil pressure.
b. Make sure oil of the proper viscosity is being
used in respect to outside temperature. (Refer
to engine manufacturer’s specifications).
c. Check for suction side air leaks, loose connec-
tions, cracked fittings, pump casting, or hose
kinks and blockage.
d. Make sure the suction hose is a -20. Reducing
hose diameter will reduce pump output dra-
matically.
e. Check the oil pressure switch for the correct
location. Be certain that it has not been moved
into a metered oil flow, as in a bypass filter or
governor assembly.
6. Starter has no prelubrication, no delay and no 6. If the starter is totally inoperative and no prelubri-
crank. cation, no delay and crank, this indicates a possi-
ble failure of the prelubrication timer solenoid.
Remove the wire from the pressure switch (ground
wire) and activate machine starter switch for several
seconds.
a. If the starter delays- then cranks, the Prelub
Timer Solenoid is bad. Replace the timer sole-
noid assembly.
b. If the starter is still inoperative, check the vehi-
cle starter switch. Make sure proper voltage is
available to the Prelub Timer Solenoid when
the key is activated.
7. Starter prelubricates, delays, then does not crank. 7. Indication is either a timer failure, or a starter
problem.
a. Pace a jumper wire to the starter solenoid “S”
post. If the engine starts to crank, replace the
Prelub Timer Solenoid.
b. If the engine fails to crank when the “S” post is
energized with voltage, check out starter
bendix solenoid and starter pinion drive.

D02020 04/00 24 VDC Electric Supply System D2-11


with Prelub Starter
NOTES

D2-12 24 VDC Electric Supply System D02020 04/00


with Prelub Starter
24VDC ELECTRICAL SYSTEM COMPONENTS

VEHICLE MONITOR SYSTEM

General Description Service Mode


The vehicle monitor system observes the condition of The service mode provides diagnostic information to
the truck systems through sensors installed at various service personnel.
locations. It processes that information and displays it
1. Machine data monitoring mode:
on the monitor panel to inform the operator of the
condition of the machine. The input and output values supplied to the net-
work controller are displayed in real time.
The vehicle monitor system consists of the monitor
panel, various sensors, switches, and relays, alarm 2. Service code, travel data display mode:
buzzer, warning lamps and power source.
Displays the fault codes stored in the network
controllers.
The items displayed can be broadly divided into:
Network Signals
• “Caution” items: Used to display warnings if any
abnormality should occur in the truck. 1. Speed display

• “Gauge” section: constantly displays the condi- 2. Engine speed display


tions, such as gauges, speedometer, tachometer, 3. Shift light display
service meter, odometer, and pilot lamps.
4. Shift position display
5. Speed range display
The monitor panel has a normal mode and a service
mode. 6. Lockup display
7. Automatic gear shift (mechatronics) fault display
Normal Mode
8. Mode selection display
The normal mode primarily displays useful information
to the operator. 9. Air pressure display

1. Items always displayed include: 10. Coolant temperature display

Meters (speedometer, tachometer, service me- 11. Torque converter oil temperature display
ter, odometer). 12. Retarder oil temperature display
Gauges (air pressure, engine coolant tempera- 13. Fuel level display
ture, torque converter oil temperature, retarder oil
temperature, fuel level). 14. Caution/pilot lamp output

2. Items displayed when abnormal conditions occur:


Cautions, Action code display.

D03018 8/99 24VDC Electrical Components D3-1


FIGURE 3-1. MONITOR PANEL

D3-2 24VDC Electrical Components 8/99 D03018


VEHICLE MONITOR PANEL

FIGURE 3-2. ELECTRONIC MONITOR PANEL


1. Air pressure monitor 13. Tachometer 25. Suspension: Soft
2. Air pressure gauge 14. Shift limiter pilot lamp 26. Service Meter
3. Coolant temperature monitor 15. Lockup pilot lamp 27. Service Meter Indicator
4. Coolant temperature gauge 16. Transmission shift position pilot lamp 28. Odometer (total distance
5. Torque converter oil 17. Shift indicator traveled)
temperature monitor 18. Engine controller monitor 29. Power mode indicator (high)
6. Torque converter oil 19. Automatic transmission control 30. Power mode indicator
temperature gauge monitor (economy)
7. Retarder oil temperature 20. Faults in other control systems 31. Right hand module
monitor 32. Center module
21. Fuel level monitor
8. Retarder oil temperature gauge 33. Left hand module
22. Fuel level gauge
9. High beam pilot lamp 34 Speedometer compensation
23. Suspension: Hard
10. Turn signal pilot lamp (left) switch
24. Suspension: Medium
11. Turn signal pilot lamp (right)
12. Speedometer

D03018 8/99 24VDC Electrical Components D3-3


VEHICLE MONITOR PANEL
The monitor panel consists of the L.H. module, center Specifications: Measuring between pins 1 & 2.
module, R.H. module, service meter, odometer, plate,
25°C (77°F) 37-50 Ω
and other structural parts.
100°C (212°F 3.5-4.5 Ω
The center module has one microcomputer mounted,
and it processes and displays the network and other
signals. • Engine coolant above 102° C (216° F)
A liquid crystal display is used. • Retarder oil above 120° C (248° F)
The monitors and gauges inside the R.H. module and • Torque Converter oil above 120° C (248° F)
L.H. module are actuated by signals from the center
module and the odometer is also actuated by signals
from the center module. AIR PRESSURE SENSOR
The service meter is actuated by a signal from the The air pressure sensor is installed to the air piping
alternator terminal R. behind the operator’s seat. It converts any changes in
the air pressure inside the wet tank to a change in the
SENSORS, SWITCHES resistance, and sends a signal to the shift controller.

ENGINE WATER TEMPERATURE SENSOR The signal is sent from the transmission shift controller
through the network to the machine monitor panel, and
RETARDER OIL TEMPERATURE SENSOR the air pressure is displayed. If the air pressure goes
below the specified pressure (5.3 kg/cm2, 75 psi), the
TORQUE CONVERTER OIL TEMPERATURE monitor panel lamp flashes and the alarm buzzer
SENSOR sounds to warn the operator of the abnormality.

The above sensors (refer to Figure 3-3) are installed


in the retarder oil piping, engine block, and transmis-
sion case.
Any change in the temperature is taken as a change
in the resistance of the thermistor, and a signal is sent
to the shift controller. The signal is then sent from the
shift controller through the network to the machine
monitor panel to display the temperature. When the
monitor panel display reaches a pre-determined value,
a corresponding lamp flashes and the buzzer sounds
to warn the operator of excessive temperature in the
affected system.
FIGURE 3-4. AIR PRESSURE SENSOR
1. Electrical 2. Pressure Tube
Connector

FIGURE 3-3. TEMPERATURE SENSOR


1. Connector 3. Thermistor
2. Plug

D3-4 24VDC Electrical Components 8/99 D03018


FUEL LEVEL SENSOR
The fuel level sensor (Figure 3-5) is installed to the side
face of the fuel tank and a float (4) moves up and down
in accordance with the fuel level. The movement of the
float is passed through an arm (3) to actuate a variable
resistor, sending a signal to the transmission shift
controller. The signal is sent from the shift controller
through the network to the dash monitor system to
display the fuel level. When the display on the monitor
panel reaches a certain position, the warning lamp
flashes.

FIGURE 3-6. ENGINE SPEED SENSOR

1. Magnet 4. Boot
2. Terminal 5. Connector
3. Case

3. Screw in sensor by hand until the tip of sensor


contacts gear tooth - do not force. Do not use a
wrench or other tool to tighten.
4. Turn counter-clockwise 1/4 - 1/2 turn from the
point where sensor contacts gear to obtain clear-
ance “a” (0.4 mm (0.016in.)).
Tighten locknut (2) to 6 ±1 kg.m (43 ±7 ft. lbs.).
FIGURE 3-5. FUEL LEVEL SENSOR 5. Reinstall harness connector. Be certain harness
is properly clamped and supported to prevent
1. Connector 3. Arm strain on connector and wiring.
2. Variable Resistor 4. Float

ENGINE SPEED SENSOR


The engine speed sensor (Figure 3-6) is installed in
the flywheel housing and generates a pulsed voltage
signal which varies in frequency with the speed of the
flywheel ring gear. The voltage signal is then sent to
the transmission shift controller and the monitor panel
to operate the tachometer display.

Adjusting Engine Speed Sensor


1. Disconnect sensor (1, Figure 3-7) electrical con-
nector, loosen locknut (2), and remove sensor.
FIGURE 3-7. ENGINE SPEED SENSOR
NOTE: Inspect sensor tip for iron particles or other ADJUSTMENT
contaminants. Inspect for damage.
2. Verify a gear tooth tip is aligned with the sensor 1. Sensor 3. Flywheel Teeth
mounting hole as shown. (If necessary, rotate 2. Locknut a. 0.4 mm (0.016 in)
flywheel to achieve alignment.)

D03018 8/99 24VDC Electrical Components D3-5


MONITOR PANEL DISPLAYS
Figures 3-8 through 3-11 list the various monitor panel In addition, each function lists the conditions under
gauges, pilot lamps, caution lamps etc.. Each function which the display is ON or OFF and any additional
is listed in its display category and shows the symbol warnings such as the central warning lamp or buzzer.
(when applicable) that appears on the display area.

FIGURE 3-8. MONITOR PANEL DISPLAYS, FUNCTIONS

D3-6 24VDC Electrical Components 8/99 D03018


FIGURE 3-9. MONITOR PANEL DISPLAYS, FUNCTIONS

D03018 8/99 24VDC Electrical Components D3-7


FIGURE 3-10. MONITOR PANEL DISPLAYS, FUNCTIONS

D3-8 24VDC Electrical Components 8/99 D03018


FIGURE 3-11. MONITOR PANEL DISPLAYS, FUNCTIONS

D03018 8/99 24VDC Electrical Components D3-9


INSTRUMENT PANEL INDICATORS,
TEST SWITCH
Figures 3-12 and 3-13 lists the warning and caution The conditions under which the central warning lamp
devices located on the instrument panel, below the will illuminate and the buzzer will sound are listed
Monitor Panel. The central warning lamp, located to
the left of the indicators listed below, can be identified
by its Red convex lens.

FIGURE 3-12. INSTRUMENT PANEL INDICATORS, TEST SWITCH

D3-10 24VDC Electrical Components 8/99 D03018


FIGURE 3-13. INSTRUMENT PANEL INDICATORS, TEST SWITCH

D03018 8/99 24VDC Electrical Components D3-11


ELECTRONIC ACCELERATOR PEDAL • (AS1) Idle Validation Switch signals
The accelerator pedal provides two digital signals
Operation to indicate whether the accelerator pedal is de-
pressed or released. These signals are used by the
The throttle/accelerator pedal is a foot-operated pedal transmission controller to allow upshift or down
containing a spring-loaded roller arm and inclinded shifts.
ramp, two electrical rheostats and a switch with elec-
trical connectos. • (AS2) pedal (throttle) signal:
This throttle signal is varied as the accelerator
The spring-loaded roller arm is connected to the switch pedal is depressed. As the pedal is depressed, the
and rheostats. As the roller arm travels along the output voltage signal increases and engine rpm
inclined ramp (when the operator depresses the increases. The signal goes to the engine controller.
pedal), electric signals are generated and sent to
various controllers to control fuel (engine rpm), throttle • (AS3) Transmission Controller Throttle signal.
position (pedal depressed/released), and transmis- This throttle signal is varied as the accelerator
sion shift controls. pedal is depressed. The transmission controller
uses this signal, as well as others to determine the
proper timing of up shifts and down shifts for maxi-
mum truck performance.

FIGURE 3-14. ELECTRONIC ACCELERATOR PEDAL


1. Pedal

D3-12 24VDC Electrical Components 8/99 D03018


AISS
(Automatic Idling Setting System)

This switch is used by the operator to control the idle When the switch is “out”, normal position, the light in
speed of the engine. The switch when pushed “in” the the switch “OFF”, this is the automatic position. In this
light in the switch will be “ON”, is in the manual position the engine is controlled automatically depend-
position. This provides for “LOW” engine idle speed. ing on operating status of the truck. The following chart
In this position the operator has greater control for outlines the conditions for the engine idle speed.
movement in confined spaces, such as parking or
driving in or out of service areas.

AISS OPERATIONAL CHART


ENGINE WATER
AISS SWITCH OPERATION OPERATING CONDITION IDLE SPEED
TEMPERATURE
ON Manual - - Low
30°C (90°F) - 50°C (120° F)
Retarder lever operated or parking
OFF automatic (when water temperature is Low
brake applied
above 50°C and goes down)
Retarder lever operated or parking
OFF automatic Above 50°C (120°F) Low
brake applied
30°C (90°F) - 50°C (120°F)
Retarder lever operated or parking
OFF automatic (when water temperature is High
brake applied
below 30°C and goes up)
Retarder lever operated or parking
OFF automatic Below 30°C (90°F) High
brake applied
Retarder lever not operated or
OFF automatic - High
parking brake released

D03018 8/99 24VDC Electrical Components D3-13


TRANSMISSION CONTROLLER
4. Speed sensors are located at three points (trans-
OUTLINE
mission input shaft, intermediated shaft, and out-
This transmission controller is designed to control the put shaft) to make it possible to detect any
system, so it has a built-in computer. It has the follow- slipping of the transmission clutches. It also acts
ing features and functions. to protect the transmission when there is any
abnormality in the hydraulic system.
1. It has a high-power mode and economy mode and
it changes the shift pattern. 5. It is connected to the network and makes various
data common with other controllers.
2. The braking mode is when the brake is being
used. The shifting point is raised and the brake 6. It receives the input of model selection data (what
cooling pump speed increased to improve the machine the controller is mounted on ) and net-
cooling effect for the retarder. At the same time it work data (what controller is connected to the
enables the braking force of the engine to be used network), and contacts the other controllers
effectively. through the network.
3. It drives and controls the torque converter lock-up 7. It has a divided self-diagnostic function for both
solenoid valve, overrun prevention solenoid the input and output system.
valve, exhaust brake solenoid valve, and BCV
8. The content of the self-diagnostic display is shown
solenoid valve.
with 2-digit numbers.
9. When any failure is detected , it sends details to
the network, and displays it on the other display
panels.

FIGURE 3-15. TRANSMISSION CONTROLLER

1. Self Diagnostic Display Window 5. Model Selection Switch (Sw 1) 9. ATC5B


2. Connector 6. Network switch (Sw 2) 10. ATC5A
3. Case 7. ATC2 11. ATC4
4. Printboard 8. ATC1 12. ATC3B
13. ATC3A

D3-14 24VDC Electrical Components 8/99 D03018


10. The content of the self-diagnosis is recorded in OPERATION:
memory, so when the main switch is turned off it
is possible to check details of failures. The automatic shift control system receives the shift
lever position signal, accelerator pedal signal, trans-
11. It sends the trouble data to the network, and mission speed signal, and signals from other switches
displays this on the other display panels. and sensors, and based on the information received
12. The location of any existing failure is displayed on the transmission shift controller acts to automatically
the monitor panel. control the shift of the transmission to the optimum
speed range. The transmission shift controller also
13. It has an emergency travel function for use if there drives and controls the torque converter lockup sole-
is any failure in the electrical system. noid and overrun prevention solenoid valve. Each
14. It is located separately from the gearshift lever. clutch in the transmission is equipped with an elec-
tronically controlled modulation valve and is inde-
pendently controlled.
In addition, based on the information received by the
transmission controller, it drives the monitor panel
display, caution lamps, and pilot lamps and transmits
data to the network.

D03018 8/99 24VDC Electrical Components D3-15


NOTES

D3-16 24VDC Electrical Components 8/99 D03018


POINTS TO REMEMBER WHEN TROUBLESHOOTING
For these reasons, it is necessary to carry out a
thorough prior investigation and to follow proper trou-
bleshooting procedures.
• Stop the truck on a level surface, and verify the
2. Questions to ask the operator:
body safety pin and wheel chocks are in place,
and the parking brake is applied. a. Have any other problems occurred apart from
the problem that has been reported?
• Be extremely careful of hot components or ro-
b. Was there anything strange about the machine
tating parts. Allow engine to cool thoroughly
before the failure occurred?
before removing the radiator cap.
c. Did the failure occur suddenly, or has the
• When troubleshooting with two or more work- problem occurred on previous occasions?
ers, keep strictly to the agreed signals, and do
d. Under what conditions did the failure occur?
not allow any unauthorized personnel in the
area. e. Had any repairs been performed before the
failure?
• If necessary to open any air, water, or hydraulic
oil piping, be certain all pressure has been re- 3. Checks before troubleshooting:
lieved before opening. a. Check for a history of operator reports of prob-
lems with the truck.
• When disconnecting wiring, always disconnect
the negative (-) terminal of the battery first. b. Refer to “Checks Before Troubleshooting” for
a list of items that must be checked and cor-
• When installing test equipment, be sure to con- rected if necessary before troubleshooting a
nect it properly. specific problem.
The aim of troubleshooting is to pinpoint the basic 4. Confirming the failure:
cause of the failure, to carry out repairs swiftly, and to
a. Verify an actual problem exists. Have the Op-
prevent reoccurrence of the failure.
erator try to repeat the problem; be certain the
When troubleshooting, an important point is of course problem is not actually a result of improper
understanding the function of all the truck’s operational operation procedures.
systems. However, a short cut to effective trou- b. When operating the truck to re-enact the symp-
bleshooting is to ask the operator various questions to toms, do not perform any operations that may
form some idea of possible causes of the failure that make the problem worse or increase damage
would produce the reported symptoms. to a component.
1. When troubleshooting, do not hurry to disassem- 5. Troubleshooting:
ble components. Use the results of the investigation and inspection
If components are disassembled immediately af- in Items 2 - 4 to narrow down the causes of failure,
ter any failure occurs: then refer to the appropriate section of this man-
• Components unrelated to the failure may be ual to for the specific component(s) that may
unnecessarily removed. cause the problem.
• It may become impossible to find the actual • Start with the most likely cause.
cause of the failure. • Try the simplest solution first.
This can also lead to a waste of man-hours, • Investigate other related parts or information.
replacement of properly functioning parts, or in-
6. Measures to remove primary cause of failure:
ternal contamination of parts from dirt grease, oil
Even if the failure is repaired, if the primary cause
etc.
of the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the prob-
lem occurred, then remove the cause.

D04009 02/00 Introduction to Electrical Troubleshooting D4-1


POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE
To maintain the performance of the truck over a long
period, and to prevent failures or other problems be-
fore they occur, correct operation, maintenance and
inspection, troubleshooting, and repairs must be car-
ried out. This section deals particularly with correct
repair procedures for mechatronics and is aimed at
improving the quality of repairs.

POINTS TO REMEMBER WHEN HANDLING


ELECTRIC EQUIPMENT

Handling wiring harnesses and connectors


Wiring harnesses consist of a connector used to con-
nect one component to another component. Connec-
tors used for connecting and disconnecting one wire
from another wire, and protectors or covers used for
protecting the wiring.
Unlike other electrical components fitted in boxes or
cases, these wiring harnesses (Figure 4-1) are more FIGURE 4-1. AFFECTS OF WEATHER
likely to be affected by rain, water, heat, or vibration.
Furthermore, during inspection or repair operations,
they are frequently removed and reinstalled, so they
are likely to suffer deformation or damage. For this
reason, it is necessary to be extremely careful when
handling wiring harnesses.

Failures that occur in wiring harness


1. Inadequate connection (Figure 4-2) caused by
faulty connector housings or connector pins.
Problems with defective connectors are likely to FIGURE 4-2. IMPROPER INSERTION
occur because the male connector is not properly
inserted into the female connector, or one or both
of the connectors are deformed. Also because
there is corrosion or oxidization of the pin sur-
faces.
Improper Crimp
2. Defective crimping or soldering of pins (Figure
4-3). The pins of the male and female connectors
are in contact with this wire at the crimped termi-
nal or soldered joint.
However, if the crimp or solder joint is improperly
completed, oxidization can occur causing a break
in the electrical connection.

FIGURE 4-3. IMPROPER CRIMP

D4-2 Introduction to Electrical Troubleshooting D04009 02/00


3. Damage to wiring during disconnecting
connectors
If the connectors are pulled apart by pulling on
the wires or components are removed with the
wires still connected, damage to the pin termi-
nals, solder joints, connector or the wires can
occur.

4. High-pressure water entering connector


The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on the
connector, water may enter the connector, de-
FIGURE 4-4. IMPROPER HANDLING
pending on the direction of the water jet.

As stated above, the connector is designed to


prevent water from entering, but at the same
time, if water does enter, it is difficult for it to
drain. Therefore, if water should get into the
connector, the pins will be short-circuited.
If water gets in, immediately dry the connector
or take other appropriate action before allowing
current to flow through it.

5. Oil or dirt in the connector


If oil or grease have entered the connector, an
oil film can form on the mating surface between FIGURE 4-5. WATER COROSION
the male and female pins. This oil film will not
let current flow, resulting in an open circuit.
If there is oil or grease on the connector, wipe
it off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact cleaner.

• When wiping the mating portion of the connec-


tor, be careful not to use excessive force or
deform the pins.
• If there is oil or water in the compressed air, the
contacts will become even dirtier. Completely
remove all oil and water from the compressed
air supply before cleaning the connections.

FIGURE 4-6. CLEANING THE CONNECTOR

D04009 02/00 Introduction to Electrical Troubleshooting D4-3


Removing, installing, and drying connectors and
wiring harnesses.

1. Disconnecting connectors
When disconnecting the connectors, hold the con-
nectors and not the wires (Figure 4-7). For con-
nectors held by a screw, loosen the screw fully,
then hold the male and female connectors in each
hand and pull apart. For connectors which have
FIGURE 4-7. DISCONNECTING CONNECTORS
a lock tab, press down the tab with your thumb
and pull the connectors apart.
NOTE: Never pull with one hand.

2. When removing from clips


When removing a connector from a clip (Figure
4-8), pull the connector in a parallel direction from
the clip until the catches disengage (Figure 4-9).
NOTE: If the connector is twisted up and down or to FIGURE 4-8. CONNECTOR CLIPS
the left or right, the housing may break.

3. After removing connectors


After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from
getting in the connector (Figure 4-10).
NOTE: If the wiring harness is left disassembled for a
long period of time, it is likely the contacts will become
contaminated by dirt, oil etc. A cover will prevent this FIGURE 4-9. CATCHES
from occurring.

FIGURE 4-10. COVERING CONNECTOR

D4-4 Introduction to Electrical Troubleshooting D04009 02/00


4. Connecting Connectors
A.. Check the connector visually.
1.) Verify there is no oil, dirt, or water in the
connector pins (mating portion).
2.) Verify the connector is not deformed, cor-
roded, and the connector pins are not dam-
aged.
c.) Verify there is no damage or cracks in the
connector housing.
NOTE: If there is any oil, water, or dirt in the connector,
wipe it off with dry cloth.
If there has been water inside the connector, warm the
inside Using a dryer. Do Not use excessive heat.
If there is any damage or breakage, replace the con-
nector. FIGURE 4-11. CONNECTING CONNECTORS

B. Install the connector properly


1.) Align the connector properly, then insert it
securely.
2.) For connectors with locking tabs, push in the
connector until the tab clicks into position.
C. For connectors fitted with boots, visually in-
spect the boot for damage, cracks, etc. Re-
place the boot if necessary.
D. If the wiring harness is misaligned, or the clamp
is out of position, reposition as necessary.
NOTE: If the connector cannot be connected easily,
remove the clamp and adjust the position.
NOTE: If the wiring harness or connector has been
removed from a clamp (Figure 4-13), be sure to rein-
stall it to its original position. Verify all clamps are
properly tightened.
FIGURE 4-12. INSTALLING CONNECTOR

FIGURE 4-13. HARNESS CLAMPS

D04009 02/00 Introduction to Electrical Troubleshooting D4-5


E. Drying wiring harness
1.) If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth (Figure 4-14).
2.) Avoid washing it in water or using steam. If
the connector must be washed in water, do
not use high-pressure water or steam di-
rectly on the wiring harness.

If water gets directly on the connector, per-


form the following:
3.) Disconnect the connector and wipe off the
water with a dry cloth.
FIGURE 4-14. CLEANING THE CONNECTOR
4.) If the connector is blown dry with com-
pressed air, use only a clean, dry air source.
A contaminated air source can prevent
proper pin/socket contact.

F. Drying the inside of the connector with a dryer.


1.) If water gets inside the connector, use a
dryer to dry the connector (Figure 4-15).

DO NOT use excessive heat. Excessive heat can


distort the connector housing !

FIGURE 4-15. DRYING THE CONNECTOR

5. Connector continuity test


After drying, leave the wiring harness disconnected
and perform a continuity test to check for any short
circuits between pins caused by water (Figure 4-16).
After completely drying the connector, spray it with a
contact cleaner and reassemble.

Be certain contact cleaner is compatible with con-


nector housing material before spraying.

FIGURE 4-16. TESTING THE CONNECTOR

D4-6 Introduction to Electrical Troubleshooting D04009 02/00


HANDLING CONTROLLER BOXES
The controller boxes contain a microcomputer and
electronic circuits. These control all of the electronic
circuits on the truck so be extremely careful when
handling the box.
• Do not open the cover of the controller box
unless necessary.
• Do not place objects on top of the controller box.
• Cover the connectors with tape or a vinyl bag.
• Never touch the connector contacts with your
hand.
• During rainy weather, do not leave the controller
box in a place where it is exposed to the
weather.
• Do not place the control box on oil, water, or dirt,
or in any hot place, even for a short time. Place
it on a suitable dry stand.
FIGURE 4-17. CONTROLLER BOX
Precautions when performing arc welding on the
truck.
• Disconnect all wiring harness connectors con-
nected to the controller box. Attach the arc
welding ground close to the welding point.

Points to remember when troubleshooting


electric circuits
• Always turn the power OFF before disconnect-
ing or connecting connectors.
• Before troubleshooting, check that all the re-
lated connectors are properly connected.
• Disconnect and connect the related connectors
several times to check.
• Always connect any disconnected connectors
before going on to the next step.
• If the power is turned ON with the connectors
still disconnected, unrelated fault codes may be
displayed.
• When troubleshooting electrical circuits (meas-
uring the voltage, resistance, continuity, or cur- FIGURE 4-18. THINGS NOT TO DO
rent), move the related wiring and connectors
several times and check that there is no change
in the reading of the tester. If there is any
change, there is probably a defective connec-
tion in that circuit.

D04009 02/00 Introduction to Electrical Troubleshooting D4-7


POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT

The most common cause of failure in a hydraulic


system is dirt (foreign material). When adding hydrau-
lic oil, or when disassembling or assembling hydraulic
equipment, procedures must be followed to prevent
system contamination.

Be careful of the operating environment.


• Avoid adding hydraulic oil, replacing filters, or
repairing the truck in rain, or high winds, or
areas where there is a lot of dust.

Disassembly and maintenance work in the field


• If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perform- FIGURE 4-19. IMPROPER OIL HANDLING
ance should be confirmed with the appropriate
test equipment before reinstallation on the
truck.

Sealing openings
• After any piping or component is removed, the
openings should be sealed with caps, plugs,
tapes, or vinyl bags to prevent any dirt or dust
form entering. If the opening is left open or is
blocked with a rag, there is danger of dirt enter-
ing or of the surrounding area becoming dirty
from the leaking oil.
• Do not simply drain oil out on to the ground, FIGURE 4-20. OIL PUMP WITH FILTER
collect it and dispose of it properly.

Do not let any dirt or dust get in during refilling


operations.
• Be careful not to let any dirt or dust get in when
re-filling with hydraulic oil. Always keep the oil
filler and the area around it clean. Also use clean
pumps or oil containers.
• An oil filtering device is highly recommended.
If an oil filtering device is used, it is possible to
remove dirt that has collected during storage.

D4-8 Introduction to Electrical Troubleshooting D04009 02/00


Change oil when the oil temperature is warm.
• When oil is warm, it flows easily. In addition, the
sludge can also be drained out easily from the
system together with the oil.
• When changing the oil, as much as possible of
the old oil should be drained out. (Drain the oil
from the tank; also drain the oil from the filter
and from the drain plug in the system).
• If any old oil is left, the contaminants and sludge
in it will mix with the new oil and will shorten the
life of the oil.

Flushing operations
• After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the system.
• Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and FIGURE 4-21. OIL FLUSHING
secondary flushing is carried out with the speci-
fied oil.

Cleaning operations
• After repairing the equipment (pump, control
valve, etc.) or when running the truck, carry out
oil cleaning to remove the sludge or contami-
nants in the oil circuit.
• The oil cleaning equipment is used to remove
the ultra fine (about 3µ) particles that the filters
installed on the truck are unable to remove.

FIGURE 4-22. OIL PUMP WITH FILTER

D04009 02/00 Introduction to Electrical Troubleshooting D4-9


CHECKS BEFORE TROUBLESHOOTING

Item Standard value Action


1. Check fuel level Fuel gauge Add fuel
2. Check for dirt or water in fuel - Clean, drain
3. Check for water in air tank - Drain
Air Circuit,
4. Check transmission oil level Oil level gauge Add oil
hydraulic oil,
5. Check hydraulic oil level Sight gauge Add oil
lubricating oil,
6. Check engine oil level (Level of oil in oil pan) Oil level gauge Add oil
cooling water,
7. Check cooling water level - Add water
8. Check condition of dust indicator Dust indicator Clean
9. Check front brake oil level (Level of oil in tank) Oil level gauge Add oil
10. Check for water in emergency brake air tank - Drain
11. Check play of steering wheel 100-140 mm -
12. Check operation of emergency steering Operation: 20 sec. Repair
13. Check length of suspension for proper charge Label Adjust
14. Check tire inflation pressure and damage - Charge air
1. 15. Check wheel mounting nuts - Tighten
Air,
16. Check operation of service brake - Adjust
Checks hydraulic,
17. Check operation of parking brake - Adjust or repair
before mechanical
18. Check operation of emergency brake - Adjust or repair
starting components
19. Check operation of steering - Adjust or repair
20. Check the right and left view mirror - Adjust
21. Check exhaust color and engine for abnormal noise - Adjust or repair
22. Check operation of retarder - Adjust or repair
23. Check wear of body pads - Adjust or repair
- Repair
24. Check air horn
- Repair or replace
25. Check function of lights
- Adjust or repair
26. Check function of gauges
- Adjust or replace
27. Check monitor panel
Electrical - Repair or replace
28. Check truck monitor system
equipment - Repair or replace
29. Check central warning light
- Re-tighten or clean
30. Check for loose or corroded battery terminals
- Re-tighten or clean
31. Check for loose or corroded alternator terminals
- Re-tighten or clean
32. Check for loose or corroded starting motor terminals

Hydraulic, 33. Check abnormal noise or smell - Repair


Mechanical 34. Check for oil leakage - Repair
components 35. Bleed air from all systems - Bleed air
36. Check battery voltage (engine stopped) Replace
37. Check level of battery electrolyte Add or replace
2. 20-30 V
38. Check for discolored, burnt, or bare wiring Replace
-
39. Check for missing wiring clamps, hanging wire Repair
Other check -
40. Checks for water leaking onto wiring Disconnect
Items Electrical -
(check carefully water leakage at connectors and terminals) connector and dry
components -
41. Check for broken or corroded fuses connection
-
42. Check alternator voltage Replace
27.5-29.5V
(engine running at over half throttle) Replace
-
43. Noise when battery relay is operated. Replace
(Switch starting switch from ON to OFF)

D4-10 Introduction to Electrical Troubleshooting D04009 02/00


CONNECTOR TYPE AND LOCATION

The following tables identify the electrical harness connectors used


on the truck. It also lists the type connector, and the number of pins
used.

• The location (Loc.) column in the following tables shows the


X/Y position of individual electrical connectors on the truck in
Figures 4-23, 4-24, 4-25, 4-26 and 4-27.
• The connector number listed in these illustrations may be
preceded with a “CN-” on the electrical schematic.

D04009 02/00 Introduction to Electrical Troubleshooting D4-11


Connec Con No. Con Con No.
tor nector of MOUNTING LOCATION Loc. nector nector of MOUNTING LOCATION Loc.
No. Type pins No. Type pins
01 SWP 14 Intermediate connector D7 1-pin
34 1 Clearance lamp A5
02 SWP 8 Intermediate connector conn.

03 X 2 Radiator water level sensor A6 1-pin


35 1 Clearance lamp A6
conn.
04 X 2 Air conditioner pressure switch B2
1-pin
06L - 3 Head lamp (Lo) D1 36 1 Turn signal lamp A5
conn.
07H - 3 Head lamp (Hi) C1 1-pin
37 1 Fog lamp A5
1-pin conn.
08 1 Clearance lamp D1
conn. 39 X 3 Suspension pressure sensor C7
1-pin 40 SWP 6 Payload meter display lamp (right) C7
09 1 Clearance lamp E1
conn.
41 M 1 Right side lamp B7
1.PS x 2 Transmission solenoid valve U9
51 X 2 Flow switch G1
1.SW x 1 Fill switch U9
52 X 2 Transmission oil filter sensor J3
2.PS x 2 Transmission solenoid valve V9
53 X 2 Retarder filter sensor
2.SW x 1 Fill switch U9
54 X 2 Hydraulic oil filter sensor
3.PS x 2 Transmission solenoid valve V9
55 X 2 BCV solenoid
3.SW x 1 Fill switch V9
59 SWP 6 Tail lamp J9
4.PS x 2 Transmission solenoid valve W9
60 SWP 6 Tail lamp K9
4.SW x 1 Fill switch V9
61 X 1 Fuel gauge sensor F9
1pin-
10 1 Turn signal lamp E1 62 X 3 Suspension pressure sensor K9
conn.
1pin 63 X 3 Suspension pressure sensor J9
11 1 Fog lamp D1
conn. 64 X 2 Retarder oil temperature sensor A3
12 - 2 Washer motor C7 1-pin
76 1 Auto drain valve heater
13 x 3 Suspension pressure sensor F1 conn.

Payload meter external display Emergency stop solenoid


14 SWP 6 G1 84 - 2 (mechanical governor
lamp (left)
specification)
15 M 1 Left side lamp C7
AISS motor (mechanical governor
17 - 1 Air conditioner compressor 86 - 8 -
specification)
18 - 2 Diode A3 Engine stop motor (mechanical
87 - 8 -
20 SWP 14 Intermediate connector governor specification)
21 X 1 Steering oil temperature sensor K3 90 - 2 Diode
24 X 2 Starting motor 99 - 2 Intermediate connector -
CTI X 2 Water temperature A1 KES1 1 Emergency escape switch Z3
EPI - 1 Engine oil pressure sensor A2 KES 1 Emergency escape switch Z3
Emergency stop solenoid AC1 M 4 Intermediate connector N7
28 - 2 (mechanical governor Al - 7 AISS switch O6
specification)
AS1 X 2 Exhaust brake switch T5
30 SWP 14 Intermediate connector B7
AS2 X 2 Parking brake switch T5
31 SWP 8 Intermediate connector
AS3 X 2 Retarder brake switch T5
32H - 3 Head lamp (Hi) A4
AS4 X 2 Emergency brake switch T5
33L - 3 Head lamp (Lo) A5
AS5 X 2 Service brake switch T5
ATC1 MIC 17 Transmission controller X1

D4-12 Introduction to Electrical Troubleshooting D04009 02/00


Con Con Con Con
No. of No. of
nector nector MOUNTING LOCATION Loc. nector nector MOUNTING LOCATION Loc.
pins pins
No. Type No. Type
ATC2 MIC 21 Transmission controller X2 DB1 X 4 Body seated switch J9
ATC3A AMP040 20 Transmission controller X2 DB4 - 2 Diode -
ATC3B AMP040 16 Transmission controller X1 DLB X 2 Differential lock switch S4
ATC4 AMP040 12 Transmission controller X1 DP01 MIC 5 Monitor panel P9
ATC5A AMP040 20 Transmission controller X1 DP02 AMP040 8 Monitor panel P9
ATC5B AMP040 16 Transmission controller X1 DP03 Socket 2 Monitor panel O6
ATC6 X 4 Transmission controller DP04 AMP040 8 Monitor panel P9
BLSL X 2 Brake stroke sensor F8 DP05 AMP040 12 Monitor panel O6
BLSR X 2 Brake stroke sensor E8 DP06 Socket 2 Monitor panel P6
BT1 - - Fuse box T1 DP07 Socket 2 Monitor panel P9
BT2 - - Fuse box T2 DP08 AMP040 16 Monitor panel Q9
BT3 - - Fuse box S2 DP09 Socket 2 Monitor panel Q8
BZ M 2 Alarm buzzer O3 DP10 AMP040 8 Monitor panel R8
C1 - 1 Intermediate connector DP11 AMP040 16 Monitor panel R8
C2 - 1 Intermediate connector DP12 M 4 Monitor panel R5
1-pin DP13 Socket 2 Moniro panel R5
CA+ 1 AM/FM cassette
conn. EXH Socket 7 Exhaust brake switch O5
1-pin
CA- 1 AM/FM cassette
conn.
1-pin
CAB 1 AM/FM cassette
conn.
1-pin
CG1 1 Cigar lighter M6
conn.
1-pin
CG2 1 Cigar lighter M5
conn.
CK1 KES1 2 Bulb check switch N7
CM S 8 Combination switch Q8
CNS S 12 Intermediate connector O2
Transmission oil
C/V.T X 2 W6
temperature sensor
D04 - 2 Diode S2
D05 - 2 Diode X2
D06 - 2 Diode X2
D08 - 2 Diode O3
D1 - 2 Diode B2
D1 - 10 Message display
1-pin
D5-1 1 Horn valve
conn.
1-pin
D5-2 1 Horn valve
conn.
D12 - 2 Diode M4
D14 - 2 Diode S3

D04009 02/00 Introduction to Electrical Troubleshooting D4-13


Con Con Con Con
No. of No. of
nector nector MOUNTING LOCATION Loc. nector nector MOUNTING LOCATION Loc.
pins pins
No. Type No. Type
FB PA 7 Front brake cut switch P5 MS11 M 1 Model selection switch
FCM - 7 Intermediate connector MS12 M 1 Model selection switch
FCS - 7 Intermediate connector Q5 N1 X 2 Input shaft speed sensor W6
FL PA 7 Fog lamp switch O6 N2 X 2 Intermediate shaft speed sensor W8
FU - 2 Fuse unit N3 X 2 Output shaft speed sensor W8
HAZ socket 7 Hazard switch O5 P15 M 2 MPH selection connector P6
HEAT M 1 Heater PL1 S 10 Monitor lamp N6
1-pin Suspension pressure sensor
HN 1 Horn Q8 PL1 - 2 N6
conn. GND selection connector
H.PS X 2 Transmission solenoid valve T8 PL2 S 10 Monitor lamp O6
H.SW X 1 Fill switch T8 Suspension pressure sensor
PL2 - 2 06
HT PA 7 Preheat switch N6 GND selection connector

Intermediate connector PLS M 4 Monitor lamp M3


J01 S 16 S4
inside, outside cab PM1 MIC 21 Payload meter M8
Intermediate connector PM2 M 4 Payload meter G1
J02 S 16 S4
inside, outside cab PM3 X 3 Clinometer I2
Intermediate connector PM4 M 6 Intermediate connector M9
J03 S 16 S4
inside, outside cab
PM5 MIC 13 Payload meter (card type) N9
Intermediate connector
J04 S 12 T5 AMP04
inside, outside cab PM6 12 Payload meter (card type) O9
0
Intermediate connector
J06 terminal 1 S3 Suspension pressure sensor FR
inside, outside cab PM6 KES1 2 V1
selection connector
Intermediate connector
J07 terminal 1 S3 PM7 MIC 9 Payload meter (card type) O9
inside, outside cab
J09 S 12 Intermediate connector - PM7B MIC 9 Payload meter (card type)
J10 S 16 Intermediate connector - PM8 MIC 5 PC connector N7
J11 S 12 Intermediate connector -
Torque converter lock-up
L/C.T X 2 T8
solenoid
LPS X 2 Transmission solenoid valve U8
LS M 3 Rheostat R7
LSW X 1 Fill switch sensor T8

D4-14 Introduction to Electrical Troubleshooting D04009 02/00


Con Con No. Con Con No.
nector nector of MOUNTING LOCATION Loc. nector nector of MOUNTING LOCATION Loc.
No. Type pins No. Type pins
PMCD X 2 For off-board PMC power source U1 R29 socket 6 Hazard lamp relay W4
PMR1 S 16 Intermediate connector RAD - 9 AM radio O6
PMR2 S 12 Intermediate connector RE1 socket 1 Resistor R6
PMR3 S 16 Intermediate connector RE2 socket 1 Resistor R6
PMR4 S 16 Intermediate connector RH1 S 10 Intermediate connector X3
PMRA S 12 Intermediate connector RH2 S 12 Intermediate connector W1
PMRB S 12 Intermediate connector RH4 S 8 Intermediate connector X3
PMRC S 16 Intermediate connector 1-pin
RL 1 Room lamp F9
PMS S 12 Intermediate connector conn.

PW PA 7 Power mode switch Q1 RPS X X Transmission solenoid valve U9

Suspension pressure sensor FR RSW X X Fill switch sensor U9


PWR KES1 2 W1
selection connector RT1 terminal 1 Timer for emergency steering
R01 socket 5 Engine starting relay U1 RT2 terminal 1 Timer for emergency steering
R02 socket 5 Transmission neutral relay T2 RT3 terminal 1 Timer for emergency steering
R03 socket 5 Service brake relay T2 RT4 terminal 1 Timer for emergency steering
R04 socket 5 BCV relay RT5 terminal 1 Timer for emergency steering
R05 socket 5 Backup alarm relay S3 RT6 terminal 1 Timer for emergency steering
R06 socket 5 Head lamp relay (Hi) RT7 terminal 1 Timer for emergency steering
R07 socket 5 Marker lamp relay U1 RT8 terminal 1 Timer for emergency steering
R08 socket 5 Head lamp relay (Lo) T2 Selection connector for each
R09 socket 6 Rear brake pilot relay S3 SCF KES1 2 suspension pressure sensor X3
specification
R11 socket 6 Payload meter relay S4
Selection connector for each
Payload meter external display SCFR KES1 2 suspension pressure sensor X3
R16 socket 5 X3
lamp relay specification
Payload meter external display SF S 12 Gearshift lever O1
R17 socket 5 W4
lamp relay
SH socket 7 Shift limit switch O2
Payload meter external display
R18 socket 5 V5 SL1 X 2 Suspension control solenoid W4
lamp relay
Payload meter external display SL2 X 2 Suspension control solenoid V4
R19 socket 5 V5
lamp relay SL3 X 2 Suspension control solenoid U5
Payload meter external display SL4 X 2 Over-run prevention solenoid W4
R20 socket 5 S4
lamp relay SL5 X 2 Exhaust brake solenoid V4
R21 socket 5 Parking brake relay X3 SL6 X 2 Front brake cut-off solenoid U5
Governor cut relay (electronic SL7 X 2 Front brake cut-off solenoid U5
R22E socket 5
governor specification)
SNUB X 2 AISS relay resistor W8
Governor cut relay (electronic
R23E socket 5 1-pin
governor specification) SP1 1 AM/FM cassette
conn.
R25 socket 5 Transmission cut relay V5
1-pin
R27 socket 5 Hazard relay U5 SP2 1 AM/FM cassette Z7
conn.
R28 socket 6 Hazard lamp relay X3 1-pin
SP3 1 AM/FM cassette
conn.
1-pin
SP4 1 AM c8
conn.

D04009 02/00 Introduction to Electrical Troubleshooting D4-15


Con Con
No. of
nector nector MOUNTING LOCATION Loc.
pins
No. Type
1-pin
SP5 1 Speaker (right) c7
conn.
1-pin
SP6 1 Speaker (right) V9
conn.
1-pin
SP7 1 Speaker (left) H2
conn.0
1-pin
SP8 1 Speaker (left) I2
conn.
SR2 X 3 Steering sensor
SR3 X 2 Tilt sensor U1
SR4 M 3 Bimetal timer S2
SR5 X 2 Air pressure sensor T4
SSP1 MIC 21 Suspension controller X3
SSP2A AMP040 20 Suspension controller X3
SSP2B AMP040 16 Suspension controller X2
SU3 S 16 Intermediate connector X1
Selection connector for each
SU6 KES1 2 suspension pressure sensor V1
specification
Torque converter oil
TC.SE X 2 V5
temperature sensor
Torque converter oil
TC.SW X 2 N2
temperature switch
TM2 SWP. 14 Intermediate connector L4
TM3 SWP 14 Intermediate connector L4
TM4 SWP 14 Intermediate connector L4
TMA S 16 Intermediate connector V1
TMB S 16 Intermediate connector V1
TMC S 12 Intermediate connector W1
TMD S 16 Intermediate connector X2
WAS1 S 6 Acceleration sensor C2
Acceleration sensor
WAS2 X 3 (electronic governor C2
specification)
WL M 2 Caution lamp O4
WP1 S 8 Wiper switch N4
WP2 KES1 6 Wiper motor relay F1
WP3 KES0 6 Intermittent wiper relay R7

D4-16 Introduction to Electrical Troubleshooting D04009 02/00


ARSC ( AUTOMATIC RETARDER SPEED CONTROL)

Con Con Con Con


No. of No. of
nector nector MOUNTING LOCATION Loc. nector nector MOUNTING LOCATION Loc.
pins pins
No. Type No. Type
1-8 X 1 Selection connector d4 R4 Terminal 1 Travel speed display -
1-pin R5 Terminal 1 Travel speed display -
78/98 1 Model selection connector -
conn. R6 Terminal 1 Travel speed display -
8S X 1 Selection connector d4 RB Relay 5 RB relay Z6
250 - 2 Resistor a3 RW Relay 6 RW relay Y6
1020 - 2 Resistor Z3 RZ Relay 5 RZ relay Y6
1-pin SHIFT X 1 Selection connector c4
A1 1 ARSC caution lamp Z3
conn.
SHUT - 2 Air shut-off valve D8
1-pin
A2 1 ARSC caution lamp Z3 SOSW X 2 Air switch (air shut-off valve) D8
conn.
1-pin Suspension pressure
A6 1 ARSC stand-by lamp Y4 SP2 M 2 Z7
conn. selection connector
ARC1 MIC 21 ARSC controller Y6 Power source for
SP4 M 2 suspension pressure sensor c7
ARC2 AMP040 20 ARSC controller Y6 /sensor GND connection
ARC3 AMP040 16 ARSC controller a7 Power source for
BRJ M 8 Intermediate connector b7 suspension pressure
SP5 M 2 c7
BRR X 2 Air switch (brake solenoid) D8 sensor/sensor GND
connection
BSOR - 2 Brake solenoid valve (right) E8
Suspension pressure
BT3 - - Fuse box d4 SPR M 2 a7
selection connector
BZ-EL1 M 2 Buzzer b3 SPSW M 3 ARSC set switch b3
BZ-EL2 M 2 Buzzer b3 SW - 7 ARSC system switch c3
CR1 M 1 For clearing error code b8 Tire large diameter/small
TIRE1 X 1 c4
CR2 M 1 For clearing error code b8 diameter selection
D01 - 2 Diode d6 Tire large diameter/small
TIRE2 X 1 c4
diameter selection
D02 - 2 Diode d5
TMA1 X 16 Intermediate connector d7
D03 - 2 Diode d6
TMA2 X 16 Intermediate connector d5
1pin
FS1 1 Spare terminal d5 TMB1 X 16 Intermediate connector d7
conn.
J02-EL1 S 16 Intermediate connector b8 TMB2 X 16 Intermediate connector d5
J02-EL2 S 16 Intermediate connector c8 TMC1 X 12 Intermediate connector d7
J04-EL1 S 12 Intermediate connector c8 TMC2 X 12 Intermediate conector d5
J04-EL2 S 12 Intermediate connector c7 TMD1 X 16 Intermediate connector d7
1-pin TMD2 X 16 Intermediate connector d6
KO 1 ARSC stand-by lamp Y4
conn. WL-
M 2 Warning lamp c3
PH1- EL1
S 10 Intermediate connector -
EL1 WL-
M 2 Warning lamp b3
PH1- EL2
S 10 Intermediate connector -
EL2
PM4-1 M 6 Payload meter Y5
PM4-2 M 6 Payload meter Y5
R2 Terminal 1 Travel speed display -
R3 Terminal 1 Travel speed display -

D04009 02/00 Introduction to Electrical Troubleshooting D4-17


CONNECTOR LOCATION (Chassis)

FIGURE 4-23. CONNECTOR LOCATIONS

D4-18 Introduction to Electrical Troubleshooting D04009 02/00


FIGURE 4-24. CONNECTOR LOCATIONS

D04009 02/00 Introduction to Electrical Troubleshooting D4-19


CONNECTOR LOCATION, CONT. (Instrument Panel, Console)

FIGURE 4-25. CONNECTOR LOCATIONS

D4-20 Introduction to Electrical Troubleshooting D04009 02/00


CONNECTOR LOCATION, CONT. (Transmission, Rear Cab Area))

FIGURE 4-26. CONNECTOR LOCATIONS

D04009 02/00 Introduction to Electrical Troubleshooting D4-21


CONNECTOR LOCATION, CONT. (General Cab Area)

FIGURE 4-27. CONNECTOR LOCATION

D4-22 Introduction to Electrical Troubleshooting D04009 02/00


CONNECTOR TYPE IDENTIFICATION CHARTS
The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating
portion of the housing.

D04009 02/00 Introduction to Electrical Troubleshooting D4-23


D4-24 Introduction to Electrical Troubleshooting D04009 02/00
D04009 02/00 Introduction to Electrical Troubleshooting D4-25
D4-26 Introduction to Electrical Troubleshooting D04009 02/00
D04009 02/00 Introduction to Electrical Troubleshooting D4-27
D4-28 Introduction to Electrical Troubleshooting D04009 02/00
D04009 02/00 Introduction to Electrical Troubleshooting D4-29
D4-30 Introduction to Electrical Troubleshooting D04009 02/00
D04009 02/00 Introduction to Electrical Troubleshooting D4-31
D4-32 Introduction to Electrical Troubleshooting D04009 02/00
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF
ELECTRICAL SYSTEM
This section provides information for troubleshooting When the self-diagnostic display function is actuated,
the electrical system, and explains the functions and the fault occurrence data is transmitted from each
nature of checks for the transmission controller, moni- controller to the net-work and the monitor panel dis-
tor panel and if equipped, the suspension controller. plays the action code. The service code (fault) is
displayed and the warning lamp, and buzzer may also
be actuated.
SYSTEM FUNCTION The service codes which display the causes of these
problems can be viewed by pushing the bulb check
The electrical system control mechanism consists of
switch. In addition, the controllers share some of the
the transmission controller, monitor panel and the
sensor signals, such as the transmission out-put shaft
suspension controller (if equipped). They provide vari-
speed signal. If any problem occurs in these sensor
ous controls such as modifying engine output (power
signals, the same type of failure may be displayed for
mode), providing the most suitable transmission clutch
another controller.
oil pressure (full electronic modulation), and changing
the front suspension damping rates if equipped with Signal inputs from the switches and the relay listed
the automatic suspension option. below, do not have a specific service code. If a truck
operation problem occurs, refer to “checking Opera-
The monitor panel informs the operator of a problem if
tion of Electrical System” in this Section.
there is a component failure in each system. At the
same time, it uses the service mode to monitor the
input and output, such as the input voltage from the
Switches:
switch sensors of each controller and the output cur-
rent to the solenoids, and a monitor function for the • Shift Limiter
failure data stored in each controller’s memory. • Power Mode
• Key Switch
• Body Seated
• Body Float
SELF-DIAGNOSTIC DISPLAY FUNCTIONS • Rear Brake
• Service Brake
Each controller is equipped with a self-diagnostic trou-
bleshooting display. A service code will be displayed • Emergency Brake
if any electrical problem (disconnection, short circuit, • Tilt
internal short, or short circuit between wires, etc.) Relay:
occurs in output or input signals, or there is an input or
output that does not match the operation of the truck. • Engine Heater (Hot Start)

D04009 02/00 Introduction to Electrical Troubleshooting D4-33


DATA DISPLAYED
• Troubleshooting information
• Action code
• Caution signal
• Transmission failure codes
• Alarm buzzer
• Suspension failure codes
(optional)
• Engine speed
• Truck speed (transmission,
Network Data output may p/u)
• Power mode
• Shift lever position
• Shift indicator
• Lock-up ON/OFF
• Shift limit
• Air pressure
• Retarder oil temp.
• Engine coolant temp.
• Transmission torque converter
temperature
• Retarder oil temp.
• Engine oil pressure
• Transmission oil filter
• Fuel level
• Parking brake ON/OFF
• Rear brake ON/OFF
• Body float
• Exhaust brake (optional)
• Lateral inclination
• Emergency steering
• Body seat switch
• Alternator. “R”
• Key Sw. “C” terminal
• Brake stroke Switch

FIGURE 4-28. MONITOR PANEL

D4-34 Introduction to Electrical Troubleshooting D04009 02/00


CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)
When a sequence of operations is carried out using the procedure below, and if the monitor panel, transmission
controller, suspension controller, and payload meter controller perform as shown below, it means the input and output
signals, the monitor panel and the controllers are operating normally.
Perform the actuation check with the truck unloaded. (The actuation of the suspension controller (if equipped) differs
when the truck is loaded or unloaded, but it is possible to check all of the mode selections with the truck unloaded.)

Sequence of operations and CHECK ITEMS (Systems Normal)


truck conditions Monitor panel Engine controller Transmission controller Suspension controller (optional)
(1) Key switch OFF All OFF All OFF All OFF All OFF
Monitor panel liquid
Turn key switch to ACC 8.8 is displayed for 3
crystal display lights
seconds
Suspension mode Self-diagnostic display
* Parked: only with parking
soft portion lights lights up for 4.2
brake
(optional) seconds, then goes
Caution, pilot lamps out, and details of past
* Bulb check switch ON failures are displayed
all light up
for 3 seconds each.
(2) * Power mode selection switch- * Power mode After that, if the
"OFF" display condition is normal, 0.0
* Power mode switch-"ON" Economy/high or 0.c (in cold weather)
switch light “ON” power lights up is displayed.
Shift limiter liquid
* Shift limiter switch ON/OFF crystal display lights
up/goes out
Shift indicator N
* Shift lever set to N * Shift position 2-digit LED displays 0.0 (normal)
display: N
* Engine speed is
Start engine
displayed When transmission oil
* If water temperature is below
* On cooling water Engine speed temperature is below
40°C (105°F) automatic
temperature 1000 rpm 10°, 0.0 is displayed
warming-up operation is
(3) display, only lowest
actuated
segment lights up
* IF water temp is above 70°C When water temp When oil temperature
Engine speed:
(160°F) after completion of display is in green is below 10°, 0.0 is
650 rpm
warming-up operation range displayed
Engine speed rises
Parking lamp goes
out
Release parking brake and Rear brake lamp Engine speed:
apply the service brake only lights up 1000 rpm
Suspension mode
(4) display (if equipped)
Soft-medium
* Rear brake lamps
light up
Release service brake and pull Engine speed: Suspension mode switched
* Suspension mode
retarder lever 1000 rpm Soft-medium
soft portion lights up
(if equipped)
Apply parking brake and raise Suspension mode Suspension mode selection
(5)
body display Soft->hard Soft-hard
2-digit LED Body FLOAT
Shift indicator N displays 0.0 REVERSE safety
In condition (5), set shift lever * Shift position (normal) actuated
(6)
to R display R * When body is at
* Body FLOAT, truck travels in
reverse

D04009 02/00 Introduction to Electrical Troubleshooting D4-35


CHECK ITEMS (Systems Normal)
Sequence of operations and
truck conditions Transmission Suspension
Monitor Panel Engine Controller
Controller Controller (Optional)
(7) Lower body, release parking
brake, then set shift lever to L
and travel forward Shift indicator 1 Travel speed range
Release brake Shift position display L F1-F2 Suspension mode
After truck moves off, press selection
accelerator pedal Hard -> soft
Shift limiter switch ON Shift limiter function
Switch light ON Shift indicator display 1/1-2 actuated F1
Shift limiter switch OFF fixed/shifts up to F2
(8) Shift indicator 3
Set shift lever to D and shift up Travel speed range
Shift position display D
to F3 or above F2-F7
Lock-up liquid crystal display
Exhaust brake is
Turn exhaust brake switch
actuated even Suspension mode
(EXH. BRAKE) ON and release
when retarder lever selection
accelerator pedal
is not actuated Hard -> Soft
Turn exhaust brake switch
(EXH. BRAKE) OFF and release Change in exhaust
accelerator pedal/Release brake logic
accelerator peedal and operate Not actuated
retarder lever

LOCK-UP FUNCTION CHECK


(Systems Normal)

(9) Check Lock-up function Monitor Panel Transmission Controller


Lock-up is not actuated when
Set shift lever to R Lock-up display does not light up
traveling in reverse
Set shift lever to D or 5 - L Lock-up range is F1 - F7
Set to F1 or F2, release accelerator pedal, and
(1) Lock-up display does not light up Lock-up is actuated
move truck without operating brake
(2) Engine speed 1500 rpm
Lock-up display lights up Lock-up is actuated
or more
Depress accelerator Engine speed 1200 rpm
Lock-up display does not light up Lock-up is not actuated
pedal or operate brake or less
After Switching shift indicator
Shift gear display, lock-up display goes out Lock-up is canceled when shifing gear
temporarily
(3) Lock-up display stays lit until shift Shifts down F7 - F6, F4-F3 with the
Release accelerator
indicator display is 4 lock-up still engaged.
pedal and do not Shift down
Lock-up display remains off after For F3 and down, transmission shifts
operate brake
shift indicator display becomes 3 down without engaging lock-up.

D4-36 Introduction to Electrical Troubleshooting D04009 02/00


OPTIONAL CONTROLLERS
(If Installed)

Note: The following should be observed while performing steps 1 through 5, page 35.

Check items (when normal)


PMC controller (If equipped) Payload meter controller (If equipped)
(1) All OFF All OFF
0.x (x:a-d) is display for 1 second
(2) 8.8,8.8 display, external display lamps all light up
After that, if the condition is normal, the display changes to 0.0
Buzzer sounds for 3 seconds
* Engine speed: 1,000 rpm
(3) 9 items, such as payload meter switch settings, are displayed for
* Engine speed: 650 rpm 3 seconds each.
* Engine speed: 1,000 rpm After that, payload display is given
(4)
* Engine speed: 1000 rpm
(5) If condition is normal, 0.0 is displayed b-FL display, buzzer sounds

D04009 02/00 Introduction to Electrical Troubleshooting D4-37


NOTES

D4-38 Introduction to Electrical Troubleshooting D04009 02/00


MONITOR PANEL ACTION CODES AND SERVICE MODE
OUTLINE
If a failure is detected when the monitor panel is in the The displays (Figure 4-29 & 4-30) are repeated in turn
normal mode, the lamp or caution display for the for 1 second each.
applicable location lights up and an action code is
However, if a new fault occurs, data is sent while the
displayed according to the failure to aid the operator in
action code is being displayed and the action code for
taking suitable action. When an action code is dis-
the new fault has priority over the existing action code
played, the operator should follow the recommended
being displayed. The display will change to the new
action, and should also follow the Operation and Main-
action code. If the new code has a low priority, the
tenance Manual to display the service codes on the
display stays unchanged. In other words, the action
monitor panel to check the cause of the action code.
code with the highest priority is always displayed.
In addition, to make troubleshooting easier, there is a
There are seven types of action code from 01 to 07.
service mode on the monitor panel. This can display
(A decal is stuck to the top left of the window glass at
trouble data saved in the memory of the controllers on
the front of the cab to tell the operator what action to
the network and display the recognized values for the
be taken when a fault occurs). If an action code is
input and output signals from each controller.
displayed, have the operator check the service code
for the fault and then have him inform the service
ACTION CODE DISPLAY
department.
If any controller on the network detects a fault, the While the action code is being displayed, if lamp check
controller LED display panel will show the fault. The switch (1) is pressed for at least 2.5 seconds and then
monitor panel displays an action code according to the released, the applicable service code is displayed. If
fault transmitted to the network, and continues to dis- more than one fault has occurred, each fault is dis-
play it until the condition is corrected. played in turn for 3 seconds, and when all of the service
codes have been displayed, the system returns auto-
matically to the action code display.

FIGURE 4-29. DISPLAYING OCCURRENCE OF


AN ERROR (E-) FIGURE 4-30. DISPLAYING ACTION CODE (03)

FIGURE 4-31. SERVICE CODE FOR EXISTING FAILURE IS (A111)

D04009 02/00 Introduction of Electrical Troubleshooting D4-39


SERVICE MODE For Service Mode Switch operation and use, refer to
“Service Mode Operation” (page D4-44). This is the
The service mode is used when it is desired to know
mode to display the input values of the sensors and
the service codes for existing failures or failures that
switches recognized by the controllers, and the output
have occurred in the past. Also to monitor the values
values of the controllers. Each controller can monitor
recognized for the signals from the controllers.
up to several switch and sensor input values and
electric current or other output values.
The service mode contains the following:
• Service codes, (this mode displays the fault The illustration below (Figure 4-32) shows the monitor
occurrence data as well as faults saved in the display when engine speed is being monitored by the
memory of the controllers on the network) transmission controller.
• Truck data monitoring mode: (this mode dis-
plays the values for the inputs and outputs
recognized by the controller on the network)

The modes are switched by using the mode change


switches. IF the key switch is turned “OFF” when there
is a service code displayed, it is possible to start again
from the normal mode after the key switch is turned
“ON”. If the monitor panel or other controllers detect a
fault while in the service mode, the system automat-
ically returns to the normal mode and displays the
action code.

Truck data value monitoring mode FIGURE 4-32. MONITOR DISPLAYS


• Refer to chart - “Monitoring Items In Truck Data 1. This is a “b” which is the service code for the
Value Monitoring Mode” (page D4-49) for a list transmission.
of items that can be monitored by the control- 2. This is the monitoring code which is the engine
lers. speed. “05"
• The sequence in which the controllers appear 3. The display is in units of 10 rpm, so the display
on the display depends on the order of the means 2,050 rpm.
controller code listed below
Controller Display Sequence
Controllers will appear in the sequence shown in the
Figure 4-33 shows switch input conditions as recog-
chart below:
nized by the transmission controller:
Sequence
Code Description
No.
1 A Monitor panel
2 b Transmission controller
3 d Suspension controller (optional)
4 e PMC (optional)
5 f Payload Meter II (PLMII) (optional)

Note: To make it possible to display the controller


codes with the 7-segment LED, uppercase and lower
case letters are used.
Note: Controllers that are options and not installed on
the truck are automatically omitted and are not dis-
played.

D4-40 Introduction of Electrical Troubleshooting D04009 02/00


In the same way as with the truck data value monitoring
code, the controller display sequence order depends
on the order of the controller code, but controllers that
are options and are not installed are automatically
omitted.
Display of elapsed time since the code was de-
leted.
The display (Figure 4-35) shows the time elapsed
(service meter reading) since the latest trouble data
item was deleted form memory.

FIGURE 4-33. MONITOR DISPLAYS


1. This is a “b” which is the service code for the
transmission.
2. This is the monitoring code which is for
“switch check”
3. Bit 1 and bit 13 in item 3 are ON. This means
that the body seated switch is ON (seated)
and model selection signal 4 is ON (GND).
NOTE: Refer to Figure 4-45 for bit number assign- FIGURE 4-35. MONITOR DISPLAYS
ments. (Time since deletion)

Note: The elapsed time (101h) since the last


• The controller code and monitor code are dis- deletion is shown on the display for 2 seconds.
played for one second each. When the deletion operation is carried out, the
• Refer to Table 1. for details regarding mode elapsed time is reset and starts again from 0.
switch operation and the data displayed during If necessary, note down the elapsed time be-
various switch operation sequences. fore deleting any item.

Service code and trouble data display mode


For service mode switch operation, refer to “Service
Mode Operation” (page D4-44). Note: Refer to “Deleting Trouble Data From Memory”,
This mode displays (Figure 4-34) the time elapsed (Page D4-48) for data deletion instructions.
since the deletion operation, and gives the service
code and trouble data display. The service code is
displayed for each controller for faults that currently Display timing:
exist and faults that occurred in the past which have The system immediately enters the service code and
been repaired. trouble data display mode. The display is given once
only and it then goes automatically to the next service
code and trouble data display.

FIGURE 4-34. MONITOR DISPLAYS


(DELETE Display - 2 seconds)

D04009 02/00 Introduction of Electrical Troubleshooting D4-41


Service code and trouble data display
Refer to Figures 4-36, 4-37, 4-38 and 4-39 for an E. Order of display
example of the following. (1) The four items under “A” above are displayed
Display Details in order for each controller.
(2) Data for currently existing fault (service mode,
A . The following trouble data (1) - (4) are displayed
elapsed time (1), elapsed time (2), number of
for each controller and each service code.
occurrences) inside the same controller are
(1) Service code (the controller code explained displayed first, then data for faults that have
above (A,b,c,.....) + 3 digit number (fault) already been repaired are displayed.
(2) Elapsed time 1 (elapsed time (service meter (3) For faults that are currently existing and faults
reading) since that failure first occurred) that have already been corrected, the data is
(3) Elapsed time 2 (elapsed time (service meter displayed in turn, starting for each type from the
reading) since that failure last occurred) failure that occurred most recently (the small-
(4) Number of occurrences (the number of times est value for elapsed time (2)).
that the fault has occurred)
B. The high beam pilot light will illuminate for a Example of display sequence:
currently existing fault.
When the trouble data in the memory of one of the
C. Unless the display is changed by operating the controllers is as follows:
mode switch, the above four items will continue
to be displayed. Service code A111 A121 A131 A141
Elapsed time 5 2 6 12
D. If there is no trouble data, or it has all been
deleted, — is displayed. Existing
/corrected Existing corrected existing corrected
1. Only for the trouble data display for the suspen-
sion controller (controller code: d), the above (The information is shown in the order above for each
elapsed time is displayed as — . controller.)

D4-42 Introduction of Electrical Troubleshooting D04009 02/00


If the high beam pilot lamp (see Figure 4-36) lights up, The displays (shown in figures 4-36 thru 4-39) are
this indicates the trouble data is for a currently existing displayed repeatedly in turn for 2 seconds each.
fault.
NOTE: After displaying Figure 4-39, the display returns
If the high beam pilot lamp is off, this indicates the to Figure 4-36
trouble data is for a fault that has been corrected.
For details of the service code, see TABLE OF SERV-
ICE CODES AND ACTION CODES

FIGURE 4-36. SERVICE CODE (A111) FIGURE 4-39. FAULT OCCURRENCES


• Shows that A111 currently exists. • Shows that within a period of 1151hours,
this fault occurred 3 times.

FIGURE 4-37. FIRST FAULT OCCURED FIGURE 4-38. LAST FAULT OCCURED
• This shows that the fault first occured • Shows that the fault last occurred 1hour
1151hours ago. ago.

D04009 02/00 Introduction of Electrical Troubleshooting D4-43


SERVICE MODE OPERATION Operation A: Selecting Service Mode
Note: Refer to Table 1 “ Methods of Operating Note: Refer to Figure 4-41 and Table 1 for switch
Switches” for switch operation & function. operation and function.
The service mode is operated by using the mode 1. Operate both mode change switches (1) and (2)
change switches (2 & 3, Figure 4-40) at the left side to the ON position at the same time for at least
the dashboard, next to steering column. 0.2 seconds (but not more than 2.5 seconds).
2. Release both switches to the “OFF” position. (This
will switch to the truck data monitoring mode.)
3. To switch the mode, actuate the switches again.
(This displays elapsed time, service mode and
trouble data mode.)
4. Operate the switches again, the display will return
to normal mode.

Note: In the normal mode, if a fault currently exists, and


the action code for that fault is displayed, and Opera-
tion A is carried out, the action code will go out.
IF a fault with an action code of a lower priority than
FIGURE 4-40. MODE SWITCHES the action code being displayed, even when the Op-
eration A is carried out, the action code will not go out,
1. Bulb Check Switch 2. Mode Switch “1” (Red)
but the display will change to the code with the lower
3. Mode Switch “2” (Black)
priority.
In addition, even if a fault with the same action code
There are two mode change switches, (1) and (2) : has occurred several times, Operation A must be
• Switch (1): toward front of truck (“red color”) carried out the same number of times as the number
• Switch (2): toward rear of truck (“black color”). of occurrences for the action code display go out.
If Operation A is carried out, it is possible to enter the
NOTE: The switches are labeled on the switch box. truck data monitoring mode.

To operate the mode change switches, move the


switch to the right for the “ON” position; when the
switch is released, it will automatically return (spring
return) to the OFF position.

FIGURE 4-41. CHANGE IN SERVICE MODE

D4-44 Introduction of Electrical Troubleshooting D04009 02/00


Operation B: Changing display in truck data moni- Operation C: Changing display items in service
toring mode code and trouble data display mode
1. When the system enters the truck data monitoring 1. When the system enters the service code and
mode, it automatically displays first standard trouble data display mode, it first displays the
service meter on the monitor panel (controller elapsed time since the latest deletion. Then it
code: A). automatically displays the first trouble data item
on the monitor panel (controller code: A).
2. To go on to the next display, press switch (1) to
the “ON” position for 0.2 - 2.5 seconds, then 2. If there is no trouble data in the monitor panel
“OFF”. (Operation B) memory, — is displayed.
3. To go back to the previous item, press switch (2) 3. To go on to the next item, press switch (1) to the
to the ON position for 0.2 - 2.5 seconds, then “ON” position for 0.2 - 2.5 seconds, then OFF.
“OFF”. (Operation D) (Operation B)
4. After pressing mode change switch (1) to the “ON” 4. To go back to the previous item, press switch (2)
position for at least 2.5 seconds, turn it OFF. to the ON position for 0.2 - 2.5 seconds, then
(Operation C) The system will then move to the OFF. (Operation D)
next controller and display the first item.
5. After pressing switch (1) to the ON position for at
5. After holding switch (2) pressed to the ON position least 2.5 seconds, then OFF. (Operation C) The
for at least 2.5 seconds, then OFF, (Operation E) system will then move to the previous controller
the system will then move to the previous control- and display the first item of data.
ler and display the first item.

TABLE 1. METHODS OF OPERATING SWITCHES

D04009 02/00 Introduction of Electrical Troubleshooting D4-45


FIGURE 4-42. METHODS OF OPERATING SWITCHES

D4-46 Introduction of Electrical Troubleshooting D04009 02/00


Operation of machine Operation of mode change switch Monitor panel display
Normal mode is displayed after 3 seconds
Turn starting switch ON
Normal mode remains displayed
Start engine
Operation A Monitor panel item code 1 (standard service meter) of truck
(Switch mode and enter service mode) data monitoring mode is displayed

Operation C Transmission controller item code 1 (model recognition) of


(Go to next controller) machine data monitoring mode is displayed

Operation B Transmission controller item code 2 (service meter) of truck


(Go to next item code) data monitoring mode is displayed

Operation B Transmission controller item code 3 (switch check) of truck


(Go to next item code) data monitoring mode is displayed

Operation B Transmission controller item code 4 (fill signal check) of truck


(Go to next item code) data monitoring mode is displayed

Shift to F2. L clutch (bit No. 1, Figure 4-43) and 2nd clutch (bit
Check that parking brake and
No. 5) are engaged and applicable portion lights up
retarder brake are applied, then
operate shift lever to D position

L clutch (bit No. 1 ) and 2nd clutch (bit No. 5) are disengaged
Return shift lever to N position
and applicable portion goes out

Operation A After elapsed time since deletion operation is displayed (2


(Switch mode and enter service code, seconds), displays item 1 of transmission controller trouble
trouble data display mode) data in service code, trouble data display mode

Operation A Displays normal mode


(Switch mode and return to normal
mode)

6. Press the mode change switch (2) to the ON


position for at least 2.5 seconds, then OFF. (Op-
eration E) The system will then move to the
previous controller and display the first item of
data.

Checking that fill signal for 2nd clutch is


correctly recognized by transmission controller
• At any stage in the above process, if the key
switch is turned OFF, and then ON again, the
monitor panel will return to the normal display.
• While the system is in the service mode, if the
monitor panel or other controller detects a fault, FIGURE 4-43. DISPLAY MESSAGE
the system will automatically return to the nor-
mal mode and display the action code.

D04009 02/00 Introduction of Electrical Troubleshooting D4-47


Method of deleting trouble data from memory Precautions when operating service mode
In the service code and trouble data display mode, it 1. When deleting the trouble data from memory, if
is possible to delete the displayed trouble data from mode change switches (1) and (2) are not kept
memory. However, the data for currently existing prob- pressed to the “ON” position at the same time for
lems cannot be deleted. at least 5 seconds, the monitor panel will judge
that it is Operation A and the system will return to
Method Of Deletion
the normal mode without deleting the data form
1. Enter the service code and trouble data display memory.
mode, and display the trouble data that is to be
If the data is deleted correctly, the system will
deleted.
automatically switch to the next trouble data dis-
2. Press mode change switches (1) and (2) to the play, so the deletion operation can be checked. If
ON position at the same time for at least 5 sec- all the trouble data inside the controller is deleted,
onds, then off (Operation F). “ — ” is displayed, so the completion of the dele-
tion operation can be checked.
3. The display trouble data will be deleted from
memory and the display will automatically switch 2. If you enter the service mode or operate mode
to the next trouble data. change switch (1) or (2) in order to switch some-
thing in the service mode, if it overlaps the timing
NOTE: When the deletion operation is carried out, the
of detection of occurrence or restoration of fault
elapsed time is reset and starts again from 0, so it may
on the monitor panel or controllers, it may take
be necessary to note the elapsed time before deleting
time for the service mode display to switch. In
any item.
such cases, return to the normal mode and try
again.

FIGURE 4-44. MODE SWITCHES

D4-48 Introduction of Electrical Troubleshooting D04009 02/00


3.5 Monitoring items in truck data monitoring mode
* For details of the method for going on to the next monitor item (or going back to the previous monitor item) in the
truck data monitoring mode, see Method of operating service mode.
Contro Monitor
Item Display unit Remarks
ller code item code
Monitor Panel
After 10000h, shows units of 100h, and left turn signal
1 Standard service meter 10h
lamp lights up
The 1), 2), etc. in the item corresponds to the bit number.
Switch check
When ON, applicable bit number lights up, See Table 1
1) KPH/MPH selector signal ON/OFF ON: mph displayed
A 2 2) Exhaust brake switch (optional) ON/OFF Only when exhaust brake is installed
3) AISS switch ON/OFF
4) Mode selector switch 1 ON/OFF
5) Mode selector switch 2 ON/OFF
0 - 9 stay as they are, A - F are replaced with 10 - 15,
3 Rotary switch setting 0 - F level
applicable number in Table 1 lights up
Transmission Controller
1 Model recognition See Table 2 (*2)
For details, see item 3) Service meter for each controller
2 Service meter 10h After 1000h, shows units of 100h, and left turn signal lamp
lights up
The 1), 2), etc. in the item corresponds to the bit number.
Switch check
When ON applicable bit number lights up. See Table 1
1) Body seated switch ON/OFF ON: When seated
2) Not used
3) Not used
4) Not used
5) Not used
6) Not used
3 7) Not used ON/OFF
8) Not used
9) BCV solenoid ON/OFF
10) Model selection signal 1 ON/OFF ON : GND.
B
11) Model selection signal 2 ON/OFF ON : GND.
12) Model selection signal 3 ON/OFF ON : GND.
13) Model selection signal 4 ON/OFF ON : GND.
14) Connector check 1 ON/OFF ON : GND.
15) Connector check 2 ON/OFF ON : GND.
16) Emergency escape switch ON/OFF
17) Starting switch ON/OFF
The 1), 2), etc. in the item corresponds to the bit number.
Fill signal switch
When ON applicable bit number lights up. See Table 1
1) L clutch ON/OFF
2) Not used ON/OFF
4 3) H clutch ON/OFF
4) 1st clutch ON/OFF
5) 2nd clutch ON/OFF
6) 3rd clutch ON/OFF
7) 4th clutch ON/OFF
8) R clutch ON/OFF
5 Engine speed 10 rpm
6 Transmission input shaft speed 10 rpm
7 Transmission intermediate shaft speed 10 rpm

D04009 02/00 Introduction of Electrical Troubleshooting D4-49


Contro Monitor
Item Display unit Remarks
ller code item code
Transmission Controller
8 Transmission output shaft speed 10 rpm
9 Accelerator sensor 0.02V
10 Brake air pressure See Table 3
11 Not used
12 Rear brake cooling oil temperature 1°C Lo display when less than 60° C, see Table 4
13 Not used
14 Not used
15 Torque converter outlet port oil temp 1° C Lo display when less than 60° C, see Table 4
16 Fuel Level 1Ω
17 Not used
18 ECMV oil temperature 1° C Lo display when less than 60° C, see Table 4
19 Not used
B
20 Not used
21 Not used
22 Not used
23 Max. Speed range 4-7 4 - 7: F4 - F7 (no limit)
1 - 3: F1 - F3, 0: default (F2 only when lever is at D, F1 only when
24 Max. Speed range (when body is raised) 0-3
lever is at position other than D)
25 Caution setting (when body is raised) 1 or 2 1: OFF, 2: ON
26 Spare
27 Solenoid H output 4 mmA
28 Solenoid L output 4 mmA
29 Solenoid 1 output 4 mmA
30 Solenoid 2 output 4 mmA
31 Solenoid 3 output 4 mmA
32 Solenoid 4 output 4 mmA
33 Spare
34 Spare
Suspension Controller (Optional)
For details, see item 3) Service meter for each controller (5) After
1 Service meter 10h
10000h, shows units of 100h, and left turn signal lamp lights up
The 1), 2), etc. in the item corresponds to the bit number.
Switch check
When ON, applicable bit number lights up, See Table 1
1) Auto suspension solenoid 1 output ON/OFF
2 2) Auto suspension solenoid 2 output ON/OFF
3) Auto suspension solenoid 3 output ON/OFF Transmission output shaft speed
4) Rear brake ON/OFF
C 5) Body FLOAT switch ON/OFF ON: GND (when not at FLOAT position)
6) Body selection awitch ON/OFF ON: GND (HD465) OFF: OPEN (HD605)
3 Suspension pressure (left) {1kg/cm}
4 Suspension pressure (right) {1kg/cm}
5 Steering angle speed
6 Spare
7 Spare
8 Spare
9 Spare
10 Spare
11 Transmission output shaft speed 10 rpm

D4-50 Introduction of Electrical Troubleshooting D04009 02/00


Table 1 Bit numbers (Refer to Figure 4-45) TABLE 2 - CONTROLLER MODEL RECOGNITION
When it is difficult to judge which bit number is lighted Machine data monitoring mode
Machine specification
up (in particular, numbers 3 and 8 or 5 and 14), it is model display value
possible to press the lamp check switch (1, Figure 330 330 M Electric governor
4-46) to light up all the segments and check the bit 33A
330 M Electric governor, ABS
position. installed (ABS is an option)

FIGURE 4-45. BIT NUMBER LOCATIONS

FIGURE 4-46. DISPLAY PANEL


1. Lamp Check Switch

D04009 02/00 Introduction of Electrical Troubleshooting D4-51


BRAKE AIR PRESSURE SENSOR
Pressure display of brake air pressure sensor.
The brake air pressure sensor is not an analog output
but a level output, so the value for the pressure display
corresponds to the air pressure in table 3 below.

TABLE 3 - BRAKE AIR PRESSURE SENSOR


Pressure display value in truck data monitoring mode MPa {kg/cm}
Caution level Gauge level
When pressure is rising and at present level When pressure is rising and at present level
Red 7 0.932 {9.5}
Green 6 0.814 {8.3} 0.912 {9.3}
Green 5 0.716 {7.3} 0.794 {8.1}
Green 4 0.618 {6.3} 0.696 {7.1}
Green 3 0.510 {5.2} 0.598 {6.1}
Red 2 0.245 {2.5} 0.510 {5.2}

Example of display (torque converter outlet port oil


temperature) Figure 4-47.
This shows that item code 15 (torque converter outlet
port oil temperature) on the transmission controller
(controller code b) is below 60°C.
Note: Service meter for each controller. The service
meter holds individual values for each controller and
those values are displayed. However, basically, the
values are the same for all controllers. However, if the
controller is replaced with a new controller, the service
meter for that controller will have lower values than the
other controllers.
In such cases, the service meter used for the time of
occurrence of a trouble data display is standardized as
the standard time for the network system (service
meter on the monitor panel). Therefore, even if a
controller is replaced with a new part, when the failure
FIGURE 4-47. MONITOR DISPLAY
detected by the controller is displayed, the service
meter display is the standard time for the network
system, so there is no difference from the other con-
trollers.

D4-52 Introduction of Electrical Troubleshooting D04009 02/00


SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND
CONTROLLERS
For details of the display on the monitor panel, see Monitor panel action code and service mode function.

MONITOR PANEL
After the starting switch is turned ON, the monitor itself carries out self-diagnosis. After that, it goes to the normal
display.
Check the bulbs of the pilot and caution lamps by pressing the lamp check switch at the right edge of the panel.
For details of the service codes, see SERVICE CODE TABLE.

TRANSMISSION CONTROLLER
1. Self-diagnostic display, warning display
The content of the self-diagnosis and warning is displayed by a 2-digit LED code.
If any abnormality is detected during self-diagnosis, the fault occurrence data is sent to the network and the action
code is displayed on the monitor panel. The electronic controller display on the monitor panel may also light up. The
warning lamp and buzzer may also be actuated.
The warning display is the detection of a fault in the pilot lamp display sensor systems and warnings and warning
actuations. If problems are detected, the warning lamp and buzzer may also be actuated.

Self-diagnostic Display Code Table


Abnormal system Display code Action of controller Action to be taken
0.1, d.A
Defective controller power source system A 1
0.2, d.b
Neutral safety 0.3 A 1
0.4
Defective controller system A 1
0.5
Defective transmission cut relay system 0.6 A 1
Defective rear brake solenoid system 0.8 B
Defective exhaust brake solenoid system 0.9 B 2
Defective BCV rear solenoid system C.4, C.6, C.8 B 1
Defective engine speed sensor system 1.0, 6.0 C 3
Defective transmission input shaft speed sensor system 1.1, 6.1 C 1
Defective transmission intermediate shaft speed sensor
1.2, 6.2 C 4
system
Defective transmission output shaft speed sensor system 1.3, 6.3 C 1
Clutch slipping or defective speed sensor system 2. ←2-8 D 4
Defective model selection signal system 1.4, A.1S E 1
0.7
Defective shift lever system 1.5 B 5
1.6
Defective accelerator sensor system 1.7 B 1
Defective transmission valve oil temperature sensor system 1.9 B 1
3. ←2-8
Defective pressure control valve system D 4
4. ←2-8
Defective oil flow control valve system 5. ←2-8 C 4
7. ←1-8 E
Defective pressure control solenoid system 4
9. ←1-8 B
A.2, A.3
Defective monitor panel display sensor system [b2,b7 are
b.3, b.4 B 1
for mechanical governor specification machine only]
b.2, b.7
Mistaken connector connection C.1 E 1

D04009 02/00 Introduction of Electrical Troubleshooting D4-53


Warning Display Table
Action of Action to be
Abnormal system Display code
controller taken
Pilot lamp warning
Transmission filter clogging d.1 F 6
Tilt warning d.5 F 6
Drop in radiator water level d.6 F 6
Battery charge d.7 F 6
Steering oil level (overheating) E.5 F 6
Drop in rear brake oil pressure F.6 F 6
Actuation warning
Engine overrun actuated d.8 F -
Engine overrun short circuit actuated d.9 F -
Overheat warning
Torque converter oil temperature d.2 F -
Retarder oil temperature d.3 F -
Pressure drop warning
Drop in air pressure d.9 F -

Explanation of symbols: [ ] 1 - 8: indicates that there are display patterns from 1 to 8 that appear in the [ ] portion.
1. : Lock - up clutch related parts
2. : H clutch related parts
3. : L clutch related parts
4. : 1st clutch related parts
5. : 2nd clutch related parts
6. : 3rd clutch related parts
7. : 4th clutch related
8. : R clutch related parts
|_| : Blank (no display)

NOTE: See the next page for explanation of the symbols used in the action of controller column.

D4-54 Introduction of Electrical Troubleshooting D04009 02/00


Method of re-enacting fault displayed (Action to be taken).
Using the following procedure, it is possible to re-enact the fault and carry out inspection.
1 Turn the key switch OFF - ON.
5 Turn the key switch OFF - ON, and operate the lever slowly in turn to N, R, N, D, 5, 4, 3, L.
(Stop for at least 3 seconds at each position, then go to the next position).
3 Set the lever to N and start the engine.
4 Use the clutch specified in the fault display (set to the speed range using that clutch) and carry out
a trouble test.

Display Applicable clutch Speed range


Either 7 or 9
(inside ) 1. Lock - up clutch L/U
2. H clutch F3, F5, F7
3. L clutch F1, F2, F4, F6
4. 1st clutch F1
One of 2, 3, 4, 5, 7, 9 5. 2nd clutch F2, F3
(inside ) 6. 3rd clutch F4, F3
7. 4th clutch F6, F7
8. R clutch R

- (intermediate shaft
1.2 F2
sensor)

2 Apply exhaust brake during travel test. (When traveling in lock - up, operate the exhaust brake switch
then the accelerator released)
6 If there is a fault in the sensor system, turn the key switch OFF - ON.

Operation of controller when fault is detected (Action of Controller)


If an fault is detected, the transmission controller displays the fault and carries out the following action.
A Transmission neutral . . . . . . . . . . there is a fault in the power source or controller, so the transmission is
set to neutral.
E Transmission neutral . . . . . . . . . . the electrical system for the truck and the controller may have failed,
so the controller automatically turns the output OFF.
D Transmission neutral . . . . . . . . . . there is probably a fault in the hydraulic or mechanical part of the
transmission, so to avoid fatal damage to the transmission,
the controller automatically turns the output OFF.
C Speed range held, .......... because of a fault condition, the controller judges it is impossible to shift
but when lever is gear, so it holds the gear range.
moved to N, N is held
B Travel possible, ........... the controller automatically stops the functions in the faulty system.
but some functions
are inoperative -
F Travel possible . . . . . . . . . . . . . . the controller works normally

D04009 02/00 Introduction of Electrical Troubleshooting D4-55


2. Transmission mode display
The transmission controller always displays if the transmission is being controlled in the normal temperature mode
or in the low temperature mode.

Transmission mode display


When normal When abnormality is detected
Normal temperature mode 0.0 After E. |_| is displayed, code is displayed to show a fault
Low temperature mode 0.C After E.C is displayed, code is displayed to show a fault

3. Saving self-diagnostic display to memory


Once an fault is detected, even if the fault is removed, self-diagnostic display remains displayed for 5 minutes.
NOTE: The action code display on the monitor panel, the electronic controller display, warning lamp, and buzzer stop
when the fault is removed.
NOTE: Even when two or more faults occur at the same time, all the fault occurrence data are transmitted to the
network and the self-diagnostic display is given.

Display method: The code display starts with the faults that have occurred in order, and after completing the display
of the content of all the faults, the display returns to the first code display. It continues to repeat this order. If the fault
is repaired, it returns to the normal display 5 minutes after the repair.

D4-56 Introduction of Electrical Troubleshooting D04009 02/00


4. Saving service code to memory
The transmission controller has a function to save the service code, time of occurrence (service data) and number
of occurrences to memory, and keep them in memory even after the starting switch is turned OFF.
When the key switch is turned ON, it is possible to check the details of the faults that have occurred up to that point
with the trouble data display mode of the monitor panel service function and the controller LED’s.
Method of saving and displaying service code (transmission controller LED display)

FIGURE 4-48. TRANSMISSION CONTROLLER DISPLAY

To make full use of the memory function to clearly display when the failure occurred and what failures have already
been corrected, keep strictly to the procedure given below.
Deleting service code from memory
For details of the method of deletion, see Method of deleting trouble data from memory (page D4-48)
Carry out troubleshooting, and when the fault has been repaired, the self-diagnostic display returned to normal, to
delete the transmission controller service codes from memory, turn the starting switch OFF, then turn it ON again,
and check the past faults in memory have been deleted
For details, see MONITOR PANEL ACTION CODES AND SERVICE MODE FUNCTION, Method of deleting trouble
data from memory.
(if the data have been deleted, 8.8 is displayed for 3 seconds, then the display shows the part number, and after 3.5
seconds, the display returns to the normal display of 0.0 or 0.C)

D04009 02/00 Introduction of Electrical Troubleshooting D4-57


TABLE OF SERVICE CODES AND ACTION CODES
1. TABLE OF SERVICE CODES AND ACTION CODES RELATED TO MONITOR PANEL

TABLE OF SERVICE CODES AND ACTION CODES RELATED TO MONITOR PANEL


Monitor panel display
Service code
When only lamp Central
Display in caution
No. Details of failure check switch is kept Action warning
service code, lamp
pressed for at least lamp
trouble data
2.5 sec and then
display mode
released
(Existing) (Existing) (Existing) (Existing) (Existing)
1 Short circuit in lamp output system A001 A000 02 ON OFF
2 Short circuit in central warning lamp output system A002 A000 02 ON OFF
3 Short circuit in alarm buzzer output system A003 A000 02 ON OFF
Connection data for network system does not
4 A012 A011 02 ON ON
match
5 Fault in network system (transmission controller) A013 A011 02 ON OFF
6 Fault in network system (PMC) (optional) A014 A011 02 ON ON
7 Fault in network system (engine controller) A015 A011 02 ON ON
8 Fault in network system (suspension controller) A016 A011 02 ON ON
9 Fault in model selection data A018 A011 04 ON ON
10 Fault in option data A019 A011 04 ON ON

Note 1: “Existing” means that the problem is still occurring; “history” means that the problem occurred in the past.
Note 2: If the problem is still existing, the alarm buzzer will also sound. (When the central warning lamp is ON).

D4-58 Introduction of Electrical Troubleshooting D04009 02/00


2. TABLE OF SERVICE CODES AND ACTION CODES RELATED TO TRANSMISSION CONTROLLER

Table Of Service Codes And Action Codes Related To Transmission Controller


Monitor panel display
Automatic Transmission oil
gear Central temperature
Service Action
No. Details of failure shifting warning 15° C Below
code code
caution lamp (60 ° F) 15° C
lamp or above (60 ° F)
(Existing,
(Existing) (Existing) (Existing) (Existing) (Existing (History)
reset)
1 Fault in battery power source voltage system b001 04 ON ON E. ↔ 01 EC ↔ 01 01
2 Fault in solenoid power source system b002 04 ON ON E. ↔ 02 EC ↔ 02 02
3 Fault in neutral safety system b003 - ON ON E. ↔ 03 EC ↔ 03 03
4 Double engagement of clutches b005 04 ON ON E. ↔ 05 EC ↔ 05 05
5 Fault in transmission cut relay b006 04 ON ON E. ↔ 06 EC ↔ 06 06
6 Fault in shift lever assembly power source (12V) b007 04 ON ON E. ↔ 07 EC ↔ 07 07
7 Fault in engine overrun solenoid system b008 02 ON ON E. ↔ 08 EC ↔ 08 08
8 Fault in exhaust brake solenoid system b009 02 ON ON E. ↔ 09 EC ↔ 09 09
9 Disconnection in engine speed sensor system b010 02 ON ON E. ↔ 10 EC ↔ 10 10
Disconnection in transmission input shaft speed
10 b011 02 ON ON E. ↔ 11 EC ↔ 11 11
sensor
Disconnection in transmission intermediate shaft
11 b012 02 ON ON E. ↔ 12 EC ↔ 12 12
speed sensor system
Disconnection in transmission output shaft speed
12 b013 02 ON ON E. ↔ 13 EC ↔ 13 13
sensor system
13 Fault in model selection signal system b014 04 ON ON E. ↔ 14 EC ↔ 14 14
14 Multiple input of shift lever signal b015 02 ON ON E. ↔ 15 EC ↔ 15 15
15 Disconnection in shift lever signal b016 02 ON ON E. ↔ 16 EC ↔ 16 16
16 Fault in accelerator signal b017 02 ON ON E. ↔ 17 EC ↔ 17 17
Fault in transmission valve oil temperature sensor
17 b019 02 ON ON E. ↔ 19 EC ↔ 19 19
system
18 Fault in H clutch system b022 02 ON ON E. ↔ 22 EC ↔ 22 22
19 Fault in L clutch system b023 02 ON ON E. ↔ 23 EC ↔ 23 23
20 Fault in 1st clutch system b024 02 ON ON E. ↔ 24 EC ↔ 24 24
21 Fault in 2nd clutch system b025 02 ON ON E. ↔ 25 EC ↔ 25 25
22 Fault in 3rd clutch system b026 02 ON ON E. ↔ 26 EC ↔ 26 26
23 Fault in 4th clutch system b027 02 ON ON E. ↔ 27 EC ↔ 27 27
24 Fault in R clutch system b028 02 ON ON E. ↔ 28 EC ↔ 28 28
25 Fault 1 in pressure control valve system for H clutch b032 02 ON ON E. ↔ 32 EC ↔ 32 32
26 Fault 1 in pressure control valve system for L clutch bo33 02 ON ON E. ↔ 33 EC ↔ 33 33

D04009 02/00 Introduction of Electrical Troubleshooting D4-59


Table Of Service Codes And Action Codes Related To Transmission Controller (Continued)
Monitor panel display Controller LED display
Automatic Transmission oil
gearshiftin Central temperature
Service Action
No. Details of faulure g warning 15° Below
code code
caution lamp (60 ° F) 15°
lamp or above (60 ° F)
(Existing,
(Existing) (Existing) (Existing) (Existing) (Existing) (History)
reset)
27 Fault 1 in pressure control valve system for 1st clutch b034 02 ON ON E. ↔ 34 EC ↔ 34 34
28 Fault 1 in pressure control valve system for 2nd clutch b035 02 ON ON E. ↔ 35 EC ↔ 35 35
29 Fault 1 in pressure control valve system for 3rd clutch b036 02 ON ON E. ↔ 36 EC ↔ 36 36
30 Fault 1 in pressure control valve system for 4th clutch b037 02 ON ON E. ↔ 37 EC ↔ 37 37
31 Fault 2 in pressure control valve system for R clutch b038 02 ON ON E. ↔ 38 EC ↔ 38 38
32 Fault 2 in pressure control valve system for H clutch b042 02 ON ON E. ↔ 42 EC ↔ 42 42
33 Fault 2 in pressure control valve system for L clutch b043 02 ON ON E. ↔ 43 EC ↔ 43 43
34 Fault 2 in pressure control valve system for 1st clutch b044 02 ON ON E. ↔ 44 EC ↔ 44 44
35 Fault 2 in pressure control valve system for 2nd clutch b045 02 ON ON E. ↔ 45 EC ↔ 45 45
36 Fault 2 in pressure control valve system for 3rd clutch b046 02 ON ON E. ↔ 46 EC ↔ 46 46
37 Fault 2 in pressure control valve system for 4th clutch b047 02 ON ON E. ↔ 47 EC ↔ 47 47
38 Fault 2 in pressure control valve system for R clutch b048 02 ON ON E. ↔ 48 EC ↔ 48 48
39 Fault in oil flow detection valve system for H clutch b052 02 ON ON E. ↔ 52 EC ↔ 52 52
40 Fault in oil flow detection valve system for L clutch b053 02 ON ON E. ↔ 53 EC ↔ 53 53
41 Fault in oil flow detection valve system for 1st clutch b054 02 ON ON E. ↔ 54 EC ↔ 54 54
42 Fault in oil flow detection valve system for 2nd clutch b055 02 ON ON E. ↔ 55 EC ↔ 55 55
43 Fault in oil flow detection valve system for 3rd clutch b056 02 ON ON E. ↔ 56 EC ↔ 56 56
44 Fault in oil flow detection valve system for 4th clutch b057 02 ON ON E. ↔ 57 EC ↔ 57 57
45 Fault in oil flow detection valve system for R clutch b058 02 ON ON E. ↔ 58 EC ↔ 58 58
46 Fault in engine speed sensor system b060 02 ON ON E. ↔ 60 EC ↔ 60 60
47 Fault in transmission input shaft speed sensor system b061 02 ON ON E. ↔ 61 EC ↔ 61 61
Fault in transmission intermediate shaft speed sensor
48 b062 02 ON ON E. ↔ 62 EC ↔ 62 62
system
Fault in transmission output shaft speed sensor
49 b063 02 ON ON E. ↔ 63 EC ↔ 63 63
system
50 Short circuit in lock-up clutch solenoid system b071 02 ON ON E. ↔ 71 EC ↔ 71 71
51 Short circuit in H clutch solenoid b072 02 ON ON E. ↔ 72 EC ↔ 72 72
52 Short circuit in L clutch solenoid b073 02 ON ON E. ↔ 73 EC ↔ 73 73
53 Short circuit in 1st clutch solenoid b074 02 ON ON E. ↔ 74 EC ↔ 74 74
54 Short circuit in 2nd clutch solenoid b075 02 ON ON E. ↔ 75 EC. ↔ 75 75
55 Short circuit in 3rd clutch solenoid b076 02 ON ON E. ↔ 76 EC. ↔ 76 76
56 Short circuit in 4th clutch solenoid b077 02 ON ON E. ↔ 77 EC. ↔ 77 77
57 Short circuit in R clutch solenoid b078 02 ON ON E. ↔ 78 EC. ↔ 78 78
58 Disconnection in lock-up clutch solenoid system b091 02 ON ON E. ↔ 91 EC ↔ 91 91
59 Disconnection in H clutch solenoid b092 02 ON ON E. ↔ 92 EC ↔ 92 92
60 Disconnection in L clutch solenoid b093 02 ON ON E. ↔ 93 EC ↔ 93 93
61 Disconnection in 1st clutch solenoid b094 02 ON ON E. ↔ 94 EC ↔ 94 94

D4-60 Introduction of Electrical Troubleshooting D04009 02/00


Table Of Service Codes And Action Codes Related To Transmission Controller (Continued)
Monitor panel display Controller LED display
Automatic Transmission oil
gear Central temperature
Service Action
No. Details of failure shifting warning 15° Below
code code
caution lamp (60 ° F) 15°
lamp or above (60 ° F)
(Existing,
(Existing) (Existing) (Existing) (Existing) (Existing) (History)
reset)
62 Disconnection in 2nd clutch solenoid b095 02 ON ON E. ↔ 95 EC ↔ 95 95
63 Disconnection in 3rd clutch solenoid b096 02 ON ON E. ↔ 96 EC ↔ 96 96
64 Disconnection in 4th clutch solenoid b097 02 ON ON E. ↔ 97 EC ↔ 97 97
65 Disconnection in R clutch solenoid b098 02 ON ON E. ↔ 98 EC ↔ 98 98
66 Fault in model selection system rotary switch b0A1 04 ON ON E. ↔ A1 EC ↔ A1 A1
Fault in torque converter oil temperature sensor
67 b0A2 02 ON ON E. ↔ A2 EC ↔ A2 A2
system
69 Fault in air pressure sensor system b0b3 02 ON ON E. ↔ b3 EC ↔ b3 b3
Fault in retarder brake oil level sensor (right)
70 b0b4 02 ON ON E. ↔ b4 EC ↔ b4 b4
system
72 Fault in connector connection b0c1 04 ON ON E. ↔ C1 EC ↔ C1 C1
73 Short circuit with ground in BCV solenoid system b0c4 c4 ON ON E. ↔ C4 EC ↔ C4 C4
74 Disconnection in BCV solenoid system b0c6 c4 ON ON E. ↔ C6 EC ↔ C6 C6
75 Short circuit in BCV solenoid system b0c8 c4 ON ON E. ↔ C8 EC ↔ C8 C8
76 Transmission filter clogging warning b0d1 01 OFF ON E. ↔ d1 EC ↔ d1 d1
Torque converter oil temperature overheat
77 b0d2 05 OFF ON E. ↔ d2 EC ↔ d2 d2
warning
78 Engine water temperature overheat warning b0d3 05 OFF ON E. ↔ d3 EC ↔ d3 d3
79 Tilt warning b0d5 07 OFF OFF E. ↔ d5 EC ↔ d5 d5
80 Radiator water level drop warning b0d6 01 OFF OFF E. ↔ d6 EC ↔ d6 d6
81 Fault in charging circuit system b0d7 01 OFF ON E. ↔ d7 EC ↔ d7 d7
82 Engine overrun actuated b0d8 03 OFF OFF E. ↔ d8 EC ↔ d8 d8
83 Engine overshoot b0d9 02 ON ON E. ↔ d9 EC ↔ d9 d9
84 Drop in battery direct power source voltage b0dA 04 ON ON E. ↔ dA EC ↔ dA dA
85 Drop in main power source voltage b0db 04 ON ON E. ↔ db EC ↔ db db
86 Steering oil temperature overheat warning b0E5 05 OFF OFF E. ↔ E5 EC ↔ E5 E5
87 Drop in air pressure b0E9 05 OFF OFF E. ↔ E9 EC ↔ E9 E9
Transmission lubricating oil temperature
88 b0F4 02 OFF OFF E. ↔ F4 EC ↔ F4 F4
overheat warning
89 Drop in engine oil pressure b0F5 04 OFF OFF E. ↔ F5 EC ↔ F5 F5
90 Fault in brake circuit system b0F6 c4 OFF OFF E. ↔ F6 EC ↔ F6 F6

* Applicable only for mechanical governor specification truck


Note 1: “Existing” means that the problem is still occurring; “History” means that the problem occurred in the past.
Note 2: If the problem is still existing, the alarm buzzer will also sound. (When the central warning lamp is ON).
Note 3: Reset fault are kept as existing fault for 5 minutes by the transmission controller only; after that, they
are saved as a service code for past fault.
Note 4: For details of the method of display of the service code for reset fault on the monitor panel, see
MONITOR PANEL ACTION CODE AND SERVICE MODE FUNCTION, SERVICE CODE
AND TROUBLE DATA DISPLAY MODE in the Foreword to the Troubleshooting Section. For the method
of displaying the transmission controller LED SERVICE CODE TO MEMORY in the Foreword to
the Troubleshooting Section.

D04009 02/00 Introduction of Electrical Troubleshooting D4-61


3. TABLE OF SERVICE CODES AND ACTION CODES RELATED TO SUSPENSION CONTROLLER

Table Of Service Codes And Action Codes Related To Suspension Controller


Monitor panel display
Other Controller
Central LED display
No. Details of failure Service code Action code gearshifting
warning lamp
caution lamp
(Existing,
(Existing) (Existing) (Existing) (Existing)
reset)
1 Fault in power source system d001 - OFF OFF E. ↔ 01
2 Fault in controller d002 - OFF OFF E. ↔ 02
3 Fault in pressure sensor (right) system d011 02 ON ON E. ↔ 11
4 Fault in pressure sensor (left) system d012 02 ON ON E. ↔ 12
5 Fault in travel speed sensor system d015 02 ON ON E. ↔ 12
6 Fault in steering sensor system d016 02 ON ON E. ↔ 16
7 Fault in solenoid 1 system d021 02 ON ON E. ↔ 21
8 Fault in solenoid 2 system d022 02 ON ON E. ↔ 22
9 Fault in solenoid 3 system d023 02 ON ON E. ↔ 23
10 Fault in network system d0C1 - OFF OFF E. ↔ C1
11 Defective model selection data d0C2 - OFF OFF E. ↔ C2
12 Defective travel speed compensation d0C3 - OFF OFF E. ↔ C3

Note 1: “Existing” means that the problem is still occurring;


Note 2: For the items where the central warning lamp lights up, the alarm buzzer also sounds.
Note 3: For details of the method of display of the service code for reset failures on the monitor panel, see
MONITOR PANEL ACTION CODE AND SERVICE MODE FUNCTION, SERVICE CODE AND TROUBLE
DATA DISPLAY MODE in the Foreword to the Troubleshooting Section.
Note 4: Reset faults are not displayed on the suspension controller LED display.

D4-62 Introduction of Electrical Troubleshooting D04009 02/00


4. Table of service codes and action codes related to PMC (Power Train Management Controller)

Monitor panel display


Controller
Other Central LED
No. Details of failure Service code Action caution warning display
lamp lamp
(Existing) (Existing) (Existing) (Existing) (Existing)
1 NV RAM data fault E001 02 ON ON 01 (flashes)
2 Drop in voltage of batter y direct power source E002 02 ON ON 02 (flashes)
3 Faulty connection of connector E003 04 ON ON 03 (flashes)
4 Fault in GSP communications E011 02 ON ON 11 (flashes)
5 Fault in GSP communications E012 02 ON ON 12 (flashes)
6 Disconnection MOM communications E013 02 ON ON 13 (flashes)
7 Fault in MOM communications E014 02 ON ON 14 (flashes)
8 Disconnection in TMS communications E015 15 ON ON 15 (flashes)
9 Fault in TMS communications E016 16 ON ON 16 (flashes)
10 Disconnection in CENSE communications E017 02 ON ON 17 (flashes)
11 Fault in CENSE communications E018 02 ON ON 18 (flashes)
12 PLM communication faulty 1 E026 02 ON ON 26 (flashes)
13 PLM communication faulty 2 E027 02 ON ON 27 (flashes)
14 PLM communication faulty 3 E028 02 ON ON 28 (flashes)
15 PLM communication faulty 4 E029 02 ON ON 29 (flashes)
16 PLM communication faulty 5 E02A 02 ON ON 2A (flashes)
17 Idling validation fault E035 02 ON ON 35 (flashes)
18 Disconnection, short circuit with ground in suspicion pressure sensor (right) system E041 02 ON ON 41 (flashes)
19 Disconnection, short circuit with ground in suspension pressure sensor (left) system E042 02 ON ON 42 (flashes)
20 Short circuit in suspension pressure sensor (right) system E043 02 ON ON 43 (flashes)
21 Short circuit in suspension pressure sensor (left) system E044 02 ON ON 44 (flashes)
22 Disconnection in accelerator E054 02 ON ON 54(flashes)
23 Short circuit in accelerator signal system E055 02 ON ON 55 (flashes)
24 Fault in engine speed sensor system E056 02 ON ON 56 (flashes)
25 Fault in transmission input shaft speed sensor system E057 01 ON ON 57(flashes)
26 Fault in travel speed sensor (transmission output shaft speed sensor) system E058 01 ON ON 58 (flashes)
27 Drop in brake oil level E0A1 01 OFF OFF A1 (flashes)
28 Drop in retarder oil level E0A2 01 OFF OFF A2 (flashes)
29 Drop in hydraulic oil level E0A3 01 OFF OFF A3 (flashes)
30 Retarder filter clogged E0A5 01 OFF OFF A5 (flashes)
31 Full-flow filter clogged E0A7 01 OFF OFF A7 (flashes)
32 Hydraulic filter clogged E0A8 01 OFF OFF A8 (flashes)
33 Wear of retarder brake disc right E0b2 01 OFF OFF b2 (flashes)
34 Wear of retarder brake disc left E0b3 01 OFF OFF b3 (flashes)
35 Drop in battery electrolyte level E0b4 01 OFF OFF b4 (flashes)
36 Drop in engine oil level E0b5 01 OFF OFF b5 (flashes)
37 Air cleaner clogged E0b6 01 OFF OFF b6 (flashes)
38 Fault in network system E0C1 02 OFF OFF C1 (flashes)
39 Fault in model selection data E0C2 04 OFF OFF C2 (flashes)
40 Fault in travel speed compensation data E0C3 04 OFF OFF C3 (flashes)

Note 1: “Existing” means that the problem is still occurring.


Note 2: History faults are not saved as memory data.
Note 3: For the items where the central warning lamp lights up, the alarm buzzer also sounds.

D04009 02/00 Introduction of Electrical Troubleshooting D4-63


METHOD OF USING TABLE
This table is a tool to determine if the problem with the truck is caused by a fault in the electrical system or by a
problem in the hydraulic or mechanical system.
The systems are then used to decide which troubleshooting chart (A-OO, H-OO, etc.) matches the systems
* For problems with the monitor panel system, go directly to troubleshooting of the monitor panel system chart (P-OO).
(See the contents for troubleshooting of the monitor panel).
[Method of using judgment table]
A • mark is put at the places where the fault mode and self-diagnostic display match, so check if
an error display is given on the monitor panel, and
* If an error display is given, go to the troubleshooting chart reference at the bottom ( )
of the judgment table.................................................................................................................................(A-OO).
* If a problem has appeared but no error display is given, go to the troubleshooting chart reference
on the right side ( ) ...................................................................................................................................(H-OO).
If no input signal is displayed, go to the troubleshooting code at the bottom of the judgement table...... (P-OO).
* If there is no• mark, go directly to the troubleshooting code on the right side ( ).
<Example> Failure mode “Excessive shock when starting”.
Procedure Check if an error code is given on the dispaly of the monitor panel or on the controller dispaly.

FIGURE 4-49. JUDGEMENT TABLE

NOTE: See actual chart on Page D5-26.


Judgments
* If error code [ 1• 7] is given on the dispaly..........go to troubleshooting A-12 for the transmission controller system.
* If no error code is given on the display, and there is excessive shock when moving the machine.........Go to
troubleshooting H-4 of the hydraulic system.

D4-64 Introduction of Electrical Troubleshooting D04009 02/00


METHOD OF USING TROUBLESHOOTING CHARTS
1. Category of troubleshooting chart number

Troubleshooting chart Component


A-OO Troubleshooting of transmission controller system
SP-OO Troubleshooting of suspension controller input signal system
LC-OO Troubleshooting of payload meter (card type) system
H-OO Troubleshooting of hydraulic, mechanical system
P-OO Troubleshooting of machine monitor panel system

2. Method of using troubleshooting chart for each troubleshooting fault.


Troubleshooting chart number and problem. (See the examples on the next page.)
(1) The title at the top of the troubleshooting chart gives the fault problem with the truck.
(2) Distinguishing conditions
Even with the same fault (problem), the method of troubleshooting may differ according to the model, component,
or problem. In such cases, the fault (problem is further divided into sections marked with small letters (for
example, a) ), so go to appropriate section to carry out troubleshooting.
If the troubleshooting chart is not divided into sections, start troubleshooting from the first check item in the fault.
(3) General precautions
When carrying out troubleshooting for the fault (problem), precautions that apply to all items are given at the top
of the page and marked with*.
The precautions marked * must always be followed first before carrying out the check inside the (box).
(4) Method of following diagnostic flow chart
• Check or measure the item inside (box), and according to the answer follow either the YES line or the NO line
to go to the next (box). (Note: The number written at the top right corner of the (box) is an index number;
it does not indicate the order to follow).
• Following the YES or NO lines according to the results of the check or measurement will lead finally to the
Cause column. Check the cause and take the action given in the Remedy column on the right.
• Below the (box) there is the method for performing an inspection or measurement. Approximate values are
given for the measurements. If the findings below the (box) are correct or the answer to the question inside
the (box) is YES, follow the YES line; if the findings are not correct, or the answer to the question is NO, follow
the NO line.
(5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS
FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
A diagram or chart is given for the connector type, installation position, and connector pin number. When carrying
out troubleshooting, see this chart for details of the location for inspection and measurement of the wiring
connector and the pin number appearing in the troubleshooting flow chart for each fault.

D04009 02/00 Introduction of Electrical Troubleshooting D4-65


(1) A-1 Abnormality in power source system

(2) a) [OFF] Controller self-diagnostic display LED does not light up


• When fuse BT1 (No. 10) is normal. If it is blown, check for a short circuit with the ground between the fuse and
controller.
• When the battery is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

FIGURE 4-50.

A-1 a) Related electrical circuit diagram

FIGURE 4-51.

D4-66 Introduction of Electrical Troubleshooting D04009 02/00


ADJUSTING ELECTRONIC MONITOR
(Speedometer Module)
The speedometer on the electronic monitor are com-
mon for all models, but the input signal corresponding
to the travel speed may differ according to tire size. So
it is necessary to adjust to match the tire size.

Adjustment procedure
NOTE: Turn off the power, then remove the electronic
monitor and carry out adjustments at the rear of the
speedometer.
1. Remove the rubber cap from # 2 port at the rear FIGURE 4-52. ADJUSTING SPEEDOMETER
of the speedometer.
2. When the rubber cap is removed, a rotary switch
can be seen (See Figure 4-53).
3. Using a flat-headed screwdriver, turn this switch
and adjust to the values in the table below.

Tire size Switch 2


27.00 R49 7 or 8

4. After adjusting, fit the rubber cap securely and


install the electronic monitor.
NOTE: It may be necessary to adjust switch (2) to
obtain a correct speedometer reading. Use the table
below to compensate for incorrect speedometer read-
ing.

Switch position 0 1 2 3 4 5 6 7
Compensation (%) +7 +6 +5 +4 +3 +2 +1 0

Switch position 8 9 A B C D E F
Compensation (%) 0 -1 -2 -3 -4 -5 -6 -7

FIGURE 4-53. SWITCH LOCATION

D04009 02/00 Introduction of Electrical Troubleshooting D4-67


SETTING ROTARY SWITCH
(Model Data, Network Data)
WHEN REPLACING TRANSMISSION
CONTROLLER
NOTE: If the transmission controller is replaced with a
new controller or the controller is used on another
truck, set the model data and network connection data
to match the model and specification of the truck

1. Remove left and right grommets (1) on the top


face of the old controller (controller being re-
placed) and check the settings of built-in rotary FIGURE 4-54. SETTING ROTARY SWITCH
switch (2). 1. Grommets 2. Rotary Switch
2. Remove left and right grommets (1) on the top
face of the new (replacement) controller and use
a screwdriver to turn built-in rotary switch (2) to
set the controller settings to the settings of the old
controller (settings before replacement).
3. Put left and right rubber grommets (1) back in their
original positions on the top face.
Reference
The model data are set with the right rotary switch
(switch 1) and the network connection data are
set with the left rotary switch (switch 2).
The relationship of the settings and the model
data and network connection data is as shown in
the table below.

Rotary switch combination table


Rotary switch (switch 1, 2) combinations
C0 C1 C2 C3 E0 E1 E2 E3
(Switch 1 setting) - (Switch 2 setting)
ABS system NO NO NO NO YES YES YES YES
PMC controller YES NO YES NO YES NO YES NO
Suspension controller (SOS) YES YES NO NO YES YES NO NO

D4-68 Introduction of Electrical Troubleshooting D04009 02/00


METHOD OF DELETING DATA FROM
TRANSMISSION CONTROLLER
MEMORY
(CONTROL FROM MONITOR PANEL)
NOTE: For details, see MONITOR PANEL ACTION
CODE AND SERVICE MODE FUNCTION in the Fore-
word of the Troubleshooting Section.

A. Outline
NOTE: If the transmission controller is going to be used
on another truck, delete the trouble data and other data
related to the current truck from the memory of the
transmission controller and PMC as follows. FIGURE 4-55. MODE SWITCHES
1. Bulb Check Switch 3. Mode Switch (Black)
1. This function is used to delete data from the 2. Mode Switch (Red)
memory of the transmission controller and PMC.
2. This function is effected by operating bulb check
switch (1, Figure 4-55) and mode change
switches (2) (the red switch at the front of the truck
and (3) (the black switch at the rear of the ma-
chine) and using the S-NET to send the command
from the monitor panel to each controller to delete
the data from memory.
3. The monitor panel accepts the operation for their
function only when the key switch is ON and the
engine is stopped.
In addition, each controller also accepts the op-
eration for this function only when the key switch
in ON and the engine is stopped.
4. To prevent the data from being deleted from the
memory of the wrong controller, an instrument
panel caution display (5, Figure 4-56) lights up to
make it possible to confirm the controller from FIGURE 4-56. CONFIRMING DATA DELETION
which the data is being deleted. 5. Caution Light

D04009 02/00 Introduction of Electrical Troubleshooting D4-69


B. Deletion Method Flow Chart
Change in condition of monitor panel.
Items (1-5, Figure 4-57) shows the change in different
conditions.

FIGURE 4-57. DIFFERENT MONITOR CONDITIONS

C. Method of operation
1. (Shown at location A in figure 4-57)
Operate bulb check switch (1, Figure 4-58) and
both mode change switches (2) & (3). Keep the
switches pressed to the ON position at the same
time for at least 2.5 seconds, then release them.
(When the switches are released, they will return
automatically to the OFF position).
2. (Shown at location B in Figure 4-57)
No particular operation is needed; after Step 1
and display (3) is shown, the display automat-
ically changes to display (4).
3. (Shown at location D in Figure 4-57)
Operate bulb check switch (1, Figure 4-58) and
FIGURE 4-58. MODE SWITCHES
both mode change switches (2) & (3). Keep the
switches pressed to the ON position at the same 1. Bulb Check Switch 3. Mode Switch (Black)
time for at least 5 seconds, then release them. 2. Mode Switch (Red)
(When the switches are released, they will return
automatically to the OFF position).

D4-70 Introduction of Electrical Troubleshooting D04009 02/00


D. Monitor panel functions for each condition
NOTE: For items 1 - 5 below, refer to corresponding
items 1 - 5 in Figure 4-57.
1. Normal mode: None in particular
2. Memory data deletion mode: The total for this
function
(For details, see item “ C. Method of Operation”).
NOTE: When entering the deletion mode, if the con-
troller detects an error, it will display a service code,
but this is not a fault for this function.

3. Deletion mode entry display:


Two items will light up at the same time for 3 FIGURE 4-59.
seconds:
• Automatic gear shifting mechatronics caution
display (5).
• Other mechatronics caution display (6).
4. Transmission controller deletion setting display:
Automatic gearshifting mechatronics caution dis-
play (5) lights up.
5. Transmission controller data deletion command
issued.

E. Remarks
The memory data deletion mode is also in the normal
mode except for the other mechatronics caution dis-
play (6).

D04009 02/00 Introduction of Electrical Troubleshooting D4-71


NOTES:

D4-72 Introduction of Electrical Troubleshooting D04009 02/00


TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM
(A-DIAGNOSIC FLOW CHART)

Points to remember when carrying out troubleshooting of transmission controller system D5-4
Action taken by self-diagnostic device and problems on the truck D5-6
Table for transmission controller, transmission related parts D5-26

A-1 Faults in power source system


A-1 ( u.u ) a) (OFF) Controller self-diagnostic display LED does not light up D5-28
b001 (E.↔ 0.1) b) Drop in voltage of controller power source is displayed D5-29
b0dA (E.↔ d.A) c) Drop in voltage of battery direct power source is displayed D5-30
b0db (E.↔ d.b) d) Drop in voltage of main power source is displayed D5-31
b002 (E.↔ 0.2) e) Fault in transmission cut relay power source is displayed D5-32
A-2 b003 (E.↔ 0.3) Fault in neutral safety circuit is displayed D5-33
A-3 b005 (E.↔ 0.5) Double engagement for clutch is displayed D5-34
A-4 b006 (E.↔ 0.6) Fault in transmission (cut relay) is displayed D5-35
A-5 b008 (E.↔ 0.8) Fault in rear brake solenoid is displayed D5-36
A-6 b009 (E.↔ 0.9) Fault in exhaust brake solenoid is displayed D5-37
A-7 b0C4 (E.↔ C.4) a) Short circuit with ground in BCV rear solenoid is displayed D5-38
b0C6 (E.↔ C.6) b) Short circuit in BCV rear solenoid is displayed D5-38
b0C8 (E.↔ C.8) c) Disconnection in BCV rear solenoid is displayed D5-40

A-8 Fault in speed sensor


A-8 b010 (E.↔1.0) or b060 (E. ↔ 6.0)
a) Disconnection in engine speed sensor is displayed on truck or fault of
engine speed sensor is displayed (electronic governor specification on truck) D5-41
b011 (E.↔1.1) or b061 (E. ↔ 6.1)
b) Disconnection in input shaft speed sensor is displayed or fault of input
shaft speed sensor is displayed D5-42
b012 (E.↔1.2) or (E. ↔ 6.2)
c) Disconnection in intermediate shaft speed sensor is displayed or fault
of intermediate shaft speed sensor is displayed D5-43
b013 (E.↔1.3) or (E. ↔ 6.3)
d) Disconnection in transmission output shaft speed sensor is displayed or
fault of output shaft speed sensor is displayed D5-44

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-1


Speed sensor, clutch slipping
A-9 b022 (E.↔ 2.2) or b023 (E. ↔ 2.3)
a) Input shaft speed sensor or H, L clutch is displayed D5-45
b024 (E.↔ 2.4) - b028 (E. ↔ 2.8)
b) Transmission output shaft or speed clutch (1,2,3,4,R) system is displayed D5-46
Fault in model selection
A-10 b014 (E.↔ 1.4) a) Fault in model selection (wiring harness) is displayed D5-47
b0A1 (E.↔ A.1) b) Fault in model selection (rotary switch) is displayed D5-48
Fault in shift lever
A-11 b007 (E.↔ 0.7) a) Short circuit in shift lever assembly power source is displayed D5-49
b015 (E.↔ 1.5) b) Shift lever position signal input for 2 or more circuit is displayed D5-50
b016 (E.↔ 1.6) c) Shift lever position signal is not inputted D5-52
A-12 b017 (E.↔ 1.7) Fault in accelerator signal is displayed D5-54
A-13 b019 (E.↔ 1.9) Fault in transmission oil temperature sensor is displayed D5-55
Fault in pressure control valve
A-14 b032 (E.↔ 3.2) - b038 (E. ↔ 3.8)
a) Fill switch (clutch ON) is displayed regardless of command D5-56
b042 (E.↔ 4.2) - b048 (E. ↔ 4.8)
b) Fill signal is not inputted and clutch slipping is displayed D5-58
b-1) Inspecting fill switch signal D5-58
b042 (E.↔ 4.2) - b043 (E. ↔ 4.3)
b-2)Checking transmission input shaft speed signal H,L clutch
(check clutch slip) D5-59
b044 (E.↔ 4.4) - b048 (E. ↔ 4.8)
b-3) Checking transmission output shaft speed signal 1-4, R clutch
(inspecting clutch slip) D5-59
A-15 b052 (E.↔ 5.2) - b058 (E. ↔ 5.8)
When fill signal is not input (flow detector valve) D5-60
A-16 b071 (E.↔ 7.1) - b078 (E. ↔ 7.8)
short circuit in pressure control valve solenoid is displayed D5-61
b091 (E.↔ 9.1) - b098 (E. ↔ 9.8)
Disconnection in pressure control valve solenoid is displayed D5-61
Fault in sensor
A-17 b0A2 (E.↔ A.2) a) Fault in torque converter oil temperature sensor is displayed D5-63
b0A3 (E.↔ A.3) b) Fault in fuel level sensor is displayed D5-64
b0b2 (E.↔ b.2) c) Fault in cooling water temperature sensor is displayed D5-65
b0b3 (E.↔ b.3) d) Fault in air pressure sensor is displayed D5-66
b0b4 (E.↔ b.4) e) Fault in retarder brake oil temperature sensor is displayed D5-67

D5-2 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Warning display
A-18 b0d1 (E.↔ d.1) a) Transmission filter clogged warning is displayed D5-68
b0d5 (E.↔ d.5) b) Tilt warning is displayed D5-69
b0d6 (E.↔ d.6) c) Drop in radiator water level warning is displayed D5-70
b0d7 (E.↔ d.7) d) Battery charge level warning is displayed D5-71
b0E5 (E.↔ E.5) e) Steering oil temperature overheat warning is displayed D5-72
b0F5 (E.↔ F.5) f) Drop in engine oil pressure warning is displayed D5-73
b0F6 (E.↔ F.6) g) Rear brake oil pressure warning is displayed D5-74
A-19 b0B7 (E.↔ B.7) Fault in engine oil pressure sensor is displayed D5-75
A-20 b0C1 (E.↔ C.1) Fault in connector connection is displayed D5-76
A-21 b0d2 (E.↔ d.2) a) Torque converter oil temperature overheat warning is displayed D5-77
b0d3 (E.↔ d.3) b) Engine water temperature overheat warning is displayed D5-77
b0E9 (E.↔ E.9) c) Air pressure drop warning is displayed D5-77
b0F3 (E.↔ F.3) d) Retarder brake oil temperature overheat warning is displayed D5-77
b0d8 (E.↔ d.8) e) Engine overrun actuated is displayed D5-78
b0d9 (E.↔ d.9) f) Engine overshoot actuated is displayed D5-78

Re-enacting failures in electrical system


With problems in the electrical circuits, there are cases where poor connections in the wiring harnesses and con-
nectors occur only under special conditions. (For example, when the engine is running at high speed or the truck is
traveling at high speed on rough road surfaces)
Therefore, investigate the values for the resistance and voltage at the locations indicated by the flow chart. Even if
no fault is found, it is necessary to investigate the conditions under which the fault occurred, and to try to re-enact
the fault condition to carry out troubleshooting.

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-3


POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF
TRANSMISSION CONTROLLER
1. Troubleshooting of electrical circuit and 2. Saving service code
mechanical system
The transmission controller records faults that have
If the fault display shows 2. ‰, 3. ‰, 4. ‰, 5. ‰, occurred in the past, and can display the ones
there are some cases where there is a problem in saved in memory in the monitor panel service mode,
the electrical circuit (sensors, wiring harnesses), (For details of the operation, see Method of operat-
and other cases where the problem is in the ing monitor panel service mode). When the key
mechanical or hydraulic system (ECMV) or clutch). switch is turned OFF-ON, the transmission control-
ler displays the codes as shown in Figure 1.
Therefore, if troubleshooting is carried out on the
electrical circuit and no problem is found, go to trou- Therefore, by seeing these service codes, it is pos-
bleshooting of the mechanical and hydraulic sys- sible to obtain information about problems that have
tem. On the other hand, if no problem is found occurred in the past.
during troubleshooting of the mechanical and
hydraulic system, go to troubleshooting of the elec-
trical circuit.

FIGURE 5-1. TRANSMISSION CONTROLLER LED DISPLAY

D5-4 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Note: When investigating faults, if the key switch is turned ON/OFF with a connector disconnected, the controller
may determine there is an fault, and a fault code may be recorded.
Therefore, after carrying out troubleshooting, always delete the recorded data and check to see the fault has been
deleted.
(For details of the method of deleting the data, see MONITOR PANEL DISPLAY AND SERVICE CODES).
When disconnecting and connecting the connectors of any other controller or monitor system, check to be sure the
transmission controller has not taken it as a fault

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-5


TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND
PROBLEMS ON TRUCK

Display code Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

1. Between (+) battery - (+) circuit breaker


Defective controller per source 2. Between (+) circuit breaker - J07
♦ Input voltage: Max. 37V Min. 9V 3. Between (+) J07 - BT1 fuse No. 10 - TMB (11)
4. Between (+) TMB (11) - ATC1 (9), (17)
♦ Power source voltage inside controller 5. Between (-) ATC (8) - TMC (1) - J06 - battery relay terminal E
6. Defective alternator regulator
7. Defective power circuit inside controller

Controller system Defective controller


♦ Watch dog timer actuated
When controller input voltage has become weak
b001 Drop in controller voltage 1. Alternator output faulty
(E. ↔ 0.1) ♦ Input voltage, when engine speed is 500 2. Battery tends to become discharged
(E.C ↔ 0.1) rpm or more: Max. 19V and direct input 3. Defective charging circuit
voltage max. 19V 1) Between alternator terminal B - emergency steering relay terminal B -
battery 4 (+)
2) Between alternator terminal E - chassis
When controller input voltage has become weak
b0dA Drop in battery direct voltage 1. Alternator output faulty
(E. ↔ d.A) ♦ Difference in electric potential between 2. Battery tends to become discharged
(E.C ↔ d.A) main supply voltage and battery voltage: 3. Defective charging circuit
Min. 5V 1) Between alternator terminal B - emergency steering relay terminal
B-battery 4 (+)
2) Between alternator terminal E - chassis
When controller input voltage has become weak
b0db Drop in main supply power voltage 1. Alternator output faulty
(E. ↔ d.b) ♦ Difference in electric potential between 2. Battery tends to become discharged
(E.C ↔ d.b) battery direct voltage and main supply 3. Defective charging circuit
voltage: Min. 5V 1) Between alternator terminal B - emergency steering relay terminal
B - battery 4 (+)
2) Between alternator terminal E - chassis
b002 Drop in solenoid supply voltage Defective solenoid circuit
(E. ↔ 0.2) ♦ Solenoid input voltage when engine 1. Defective transmission cut relay
(E.C ↔ 0.2) speed is 500 rpm or more and input volt- 2. Between ATC (1), (12) - TMC (2) - R25 (5), (3)
age is 20V or more: 18V (transmission cut relay) - BT1 fuse No. 10

N safety 1. Defective handling of machine


b003 ♦ With key switch "ON" Shift lever at posi- 2. Defective controller system
(E. ↔ 0.3) tion other than N 1) Looseness of J07, circuit breaker, battery (+)
(E.C ↔ 0.3) There may also be sudden cut in power 2) Defective insertion of fuse BT1 fuse (No. 10)
(when there is defective contact of control 3) Defective contact of connectors ATC (9), (17), TMB (11)
power and power is momentarily cut and 4) Looseness of terminal J06, battery relay E
comes on again) 5) Defective contact of connectors ATC1 (8), (16), TMC (1)

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-6 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND
PROBLEMS ON TRUCK
(Continued)
Symptoms that appear in truck
Condition when normal: Check with tester Action of controller when a when there is fault
Voltage (V), current (A), resistance value Ω fault is detected Mechatronics display given,
warning actuated

1. Between ATC1 (9), (17) - (8) (V): 20 - 30 V Cannot carry out control Transmission suddenly shifts to
2. Between TMB (11) - TMC (1) (V): 20 - 30 V (Transmission is placed in Neutral) Neutral during propel or truck can-
3. Between J07 - J06 (V): 20 - 30 V not move again
4. BT1 fuse No. 10 is not blown

Cannot carry out control Transmission suddenly shift to


Normal controller display: Shows 0.0 or 0.C (Transmission is placed in Neutral) Neutral during propel or truck can-
not move again
1. Between ATC (9), (17) - (8) (V): 20 - 30 V
2. ATC (7) - (8) (V): 20 - 30 V
3. Between TMB (11) - TMC (1) (V): 20 - 30 V Transmission suddenly shifts to
4. Between TMC (6) - (11) (V): 20 - 30 V Shift Neutral Neutral during propel or truck can-
5. Between J07 - J06 (V): 20 - 30 V not move again
6. Between J07 (13) - J06 (V): 20 - 30 V
7. No looseness of terminals: alternator B, battery relay B, battery (+)

1. Between ATC (7) - (8) (V): 20 - 30 V


2. Between TMB (11) - TMC (6) (V): 20 - 30 V Only gives self-diagnostic display; There is no problem with automatic
3. Between J03 (13) - J06 (V): 20 - 30 V does not take any action gearshifting function
4. No looseness of terminals: alternator B, battery relay B, battery (+)

1. Between ATC (9), (17) - (18) (V): 20 - 30 V


2. Between TMB (11) - TMC (1) (V): 20 - 30 V Only gives self-diagnostic display; There is no problem with automatic
3. Between J07 - J06 (V): 20 - 30 V does not take any action gearshifting function
4. No looseness of terminals: alternator B, battery relay B, battery (+)

1. Between ATC (1), (12) - chassis (V): 20 - 30 V


2. Between TMC (2) - chassis (V): 20 - 30 V Actuates transmission cut relay Transmission suddenly shifts to
3. Between R25 (5) - chassis (V): 20 - 30 V and to shifts to Neutral Neutral during propel or truck can-
4. Between R25 (3) - chassis (V): 20 - 30 V not move again

1. When key switch is turned "ON"


and operation to move truck is car-
1. Key switch "ON" and shift lever "N" If there is fault when switch is "ON" ried out, and it does not move. But
2. No looseness of terminals: battery, circuit breaker, J07, J06, battery transmission is held at neutral if shift lever is returned to N,
relay E machine can start again
3. Connectors TMB, TMC, ATC1 securely inserted 2. There is no mechantronics fault
display.
3. Applicable position on monitor
panel shift position display flashes.

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-7


Display code Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

1. Defective controller
b005 Double engagement of clutch 2. Defective fill switch
(E. ↔ 0.5) ♦ With double engagement of clutch, input 3. Between H SW - TM3 (3) - ATC5A (12)
(E.C ↔ 0.5) of fill sensor signal was detected Between L SW - TM3 (6) - ATC5A (10)
Double engagement: Actuated for 2.1 - Between R SW - TM3 (9) - ATC5A (13)
4.7 sec Between 1 SW - TM4 (3) - ATC5A (14)
Between 2 SW - TM4 (6) - ATC5A (15)
Between 3 SW - TM4 (9) - ATC5A (11)
Between 4 SW - TM4 (12) - ATC5A (16)

Disconnection, short circuit, short circuit


b006 with ground in transmission cut relay 1. Defective transmission cut relay
(E. ↔ 0.6) ♦Transmission cut relay output terminal 2. Between ATC1 (15) - TMC (3) - R25 (2), (1) (transmission cut relay) BT1
(E.C ↔ 0.6) voltage fuse No. 10
• When actuated: > 11V
• When not actuated: < 11V
b007 Short circuit with ground in 12V output cir-
(E. ↔ 0.7) cuit (Shift lever power supply) 1. Between (+) ATC2 (14) - TMB (1) - SF (1)
(E.C ↔ 0.7) ♦12V output terminal voltage, < 6V 2. Defective voltage circuit inside controller

Disconnection, short circuit, short circuit


b008 with ground in rear brake prevention sole- 1. Between (+) ASTC1 (13) - TMB (16) - RH4 (6) - SL4 (1)
(E. ↔ 0.8) noid 2. Between (-) SL4 (2) - RH4 (5) - GND ER
(E.C ↔ 0.8) ♦ Rear brake 3. Between (+) ATC1 (5) - TMC (10) - BT1 fuse No. 10
• When actuated: > 11V 4. Defective rear brake solenoid
• When not actuated < 11V
b009 Disconnection, short circuit, short circuit 1. Between (+) ATC1 (14) - TMB (15) - RH4 (5) - GND ER
(E. ↔ 1.0) with ground in exhaust brake solenoid 2. Between (-) SL5 (2) - RH4 (5) - GND ER
(E.C ↔ 1.0) ♦ Exhaust brake 3. Between (+) SL5 (1) RH4 (5) - BT1 fuse No. 10
• When actuated: > 11V 4. Defective exhaust brake solenoid
• When not actuated: < 11V

b010 Defective engine speed sensor output 1. Engine speed sensor


(E. ↔ 1.0) ♦ Engine speed less than 350 rpm and 1) Between E12 (1) - J09M (9) - TMD (13) - ATC3A (13)
(E.C ↔ 1.0) transmission speed more than 500 rpm 2) Between E12 (2) - J09M (10) - TMD (14) - ATC3A (14)
continues for 10 sec. 2. Defective engine speed sensor

b011 Disconnection in transmission input shaft 1. Input shaft speed sensor


(E. ↔ 1.1) speed sensor 1) Between N1 (1) - TM2 (1) - ATC3A (2)
(E.C ↔ 1.1) ♦ If disconnection detection is actuated 2) Between N2 (2) - TM2 (2) - ATC3A (14)
but there is no sensor signal 2. Defective input shaft speed sensor

b012 Defective transmission intermediate shaft 1. Intermediate shaft speed sensor


(E. ↔ 1.2) speed sensor output 1) Between N2 (1) - TM2 (3) - ATC3A (12)
(E.C ↔ 1.2) ♦ If disconnection detection is actuated 2) Between N2 (2) - TM2 (4) - ATC3A (14)
but there is no sensor signal

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-8 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in
Condition when normal: Check with tester Action of controller truck when there is fault
Voltage (V), current (A), resistance value Ω when a Mechatronics display
fault is detected given, warning actuated

Display is as shown in the table below when shift lever is at Neutral

H SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (12) - chassis Actuates Transmission suddenly
L SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (10) - chassis
transmission cut relay shifts to Neutral during
and shifts to Neutral propel or truck cannot
R SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (13) - chassis
> 1M Ω or > 1 M Ω move again
1 SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (14) - chassis between terminals

2 SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (15) - chassis

3 SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (11) - chassis

4 SW (male) - chassis TM3 (male) (12) - chassis ATC5A (female) (16) - chassis

AT1 TMC R25 (V) Ω Actuates Transmission suddenly


(15) - chassis (1) - chassis (1) - chassis 20 - 30 V - transmission cut relay shifts to Neutral during
- - Between relay - 100 - 500 Ω and shifts to Neutral propel or truck cannot
(1) - (2) move again

1. Between ATC2 (14) - chassis (V): 12V 12V output circuit OFF Transmission suddenly
2. Between TMB (1) - chassis (V): 12V (does not give +12V) shifts to Neutral during
3. Between SF (1) - (2) (V): 12V Shifts to Neutral propel or truck cannot
4. Each terminal of ATC2 (14), TMB (1), DF (1) - chassis: > 1MΩ move again
Even when engine speed
1. Between ATC2 (13) - chassis: 20 - 60 Ω Only gives self-diag- exceeds 2,600 rpm and
2. Between SL4 (male) (1) - (2): 20 - 60 Ω nostic display; does not engine overruns, brake to
3. Between ATC1 (13) - ATC1 (4) (V): 20 30 V take any action prevent overrun is not
actuated

Even when accelerator


1. Between ATC1 (14) - chassis: 20 - 60 Ω Operation of exhaust pedal is released and
2. Between SL4 (male) (1) - (2): L 20 - 60 Ω brake function stopped retarder lever is operated,
3. Between ATC (5) - (14) (V): 20 - 30 V exhaust brake is not actu-
ated.
1. gearshifting becomes
1. Engine speed display on monitor panel is normal. Speed range used dur- impossible.
2. Between ATC3A (13) - (14): 500 - 1,000 Ω, AC: > 0.5V ing propel is maintained 2. If shift lever is set to
3. Between each terminal ATC3A (13), (14) - chassis: > 1MΩ If shift lever is at Neu- Neutral, it becomes
4. Between E12 (male) (1) - (2): 500 - 1,000Ω tral, transmission is impossible to move
held in Neutral truck again unless it is
stopped.
Speed range used dur- 1. Gearshifting becomes
ATC3A (female) TM2 (male) N1 (male) Ω ing propel is maintained impossible.
Between (2) - (14) Between (1) - (2) Between (1) - (2) 500 - 1,000 Ω
If shift lever is at Neu- 2. If shift lever is set to
tral, transmission is Neutral, it becomes
Each terminal - chassis > 1ΜΩ.
held in Neutral impossible to move
truck again unless it is
stopped.
Speed range used dur- 1. Gearshifting becomes
ATC3A (female) TM2 (male) N2 (male) Ω
ing propel is maintained impossible.
If shift lever is at Neu- 2. If shift lever is set to
Between (14) - (12) Between (3) - (4) Between (1) - (2) 500 - 1,000 Ω
tral, transmission is Neutral, it becomes
Each terminal - chassis > 1ΜΩ. held in Neutral impossible to move
truck again unless it is
stopped.

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-9


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

b013 Disconnection in transmission output shaft 1. Output shaft speed sensor


(E. ↔ 1.3) speed sensor 1) Between N3 (1) - TM2 (5) - ATC3A (3)
(E.C ↔ 1.3) ♦ If disconnection detection is actuated but 2) Between N3 (2) - TM2 (6) - ATC3A (14)
there is no sensor signal 2. Defective output shaft speed sensor

b014 Defective model selection signal


(E. ↔ 1.4) ♦ After the key switch is turned "ON", depend- 1. Between ATC5B (13) - ATC1 (8)
(E.C ↔ 1.4) ing on the wiring harness, the model selec- 2. Defective contact of ATC5B, ATC1 connector
tion signal does not match
b015 Short circuit, short circuit with ground in lever
(E. ↔ 1.5) signal circuit
(E.C ↔ 1.5) ♦ When two or more lever signals are gener- 1. R Between ATC5B (2) - TMB (2) - SF (3)
ated, and this continues for 3 seconds N Between ATC5B (3) - TMB (3) - SF (4)
D Between ATC5B (4) - TMB (4) - SF (5)
5 Between ATC5B (5) - TMB (5) - SF (6)
4 Between ATC5B (6) - TMB (6) - SF (7)
3 Between ATC5B (7) - TMB (7) - SF (8)
b016 Disconnection in lever signal circuit L Between ATC5B (8) - TMB (8) - SF (9)
(E. ↔ 1.6) ♦ When there is no lever signal for 3 seconds GND Between ATC5A (16) - TMB (9) - SF (2)
2. Defective shift lever
(E.C ↔ 1.6)

b017 Accelerator signal circuit Disconnection, defec- 1. Between ATC3B (11) - TMA (13) - C/V.T (1)
(E. ↔ 1.7) tive adjustment of mount, link out of position 2. Defective adjustment of clearance of sensor mount
(E.C ↔ 1.7) ♦ Voltage between ATC3B (11) sand chassis 3. Damaged accelerator pedal link
• > 4.7 ± 0.1V 4. Defective acceleration sensor
• < 0.6± 0.1V 5. Defective engine controller acceleration sensor power source circuit

b019 Short circuit with ground in transmission valve 1. Between (+) ATC3B (9) - TM4 (13) - C/V.T (1)
(E. ↔ 1.9) oil temperature circuit Between (-) ATC3A (16) - TM4 (14) - C/V.T (2)
(E.C ↔ 1.9) ♦ When transmission oil temperature sensor 2. Defective transmission valve lil temperature sensor
signal is more than 150°C

b022 Clutch slipping or defective transmission 1. Input shaft 1) Between N1 (1) - TM2 (1) - ATC3A (2)
| speed sensor. Speed sensor 2) Between N1 (2) - TM2 (2) - ATC3A (14)
b028 ♦ When the input shaft speed, intermediate 2. Output shaft 1) Between N3 (1) - TM2 (1) - ATC3A (5)
(E. ↔ 2.2) shaft speed, output shaft speed are con- Speed sensor 2) Between N3 (2) - TM2 (6) - ATC3A (14)
(E.C ↔ 2.2) verted and it is found that there is an fault 3. One of following clutches worn or damaged: H, L, 1st, 2nd, 3rd, 4th, R
| with either the HL clutch or speed clutch.
(E. ↔ 2.8)
(E.C ↔ 2.8)

b022 Defective H clutch or input shaft speed sensor See items for display codes b022 - b028
(E. ↔ 2.2) (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.2)

b023 Defective L clutch or input shaft speed sensor See items for display codes b022 - b028
(E. ↔ 2.3) system (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8
(E.C ↔ 2.3)

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-10 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in
Condition when normal: Check with tester Action of controller when truck when there is fault
Voltage (V), current (A), resistance value Ω a fault is detected Mechatronics display
given, warning actuated
1. Speedometer shows 0
Speed range used during km/h when moving, and
ATC3A (female) TM2 (male) N3 (male) Ω propel is maintained If gearshifting cannot be
Between (3) - (14) Between (5) - (6) Between (1) - (2) 500 - 1,000 Ω
shift lever is at Neutral, carried out.
transmission is held in 2. If shift lever is shifted to
N3 (1) - TM2 (5) - ATC3A (3) - chassis > 1 MΩ
Neutral Neutral, it becomes
impossible to move
truck again unless it is
stopped.
If there is fault when key When key switch is turned
1. Between ATC5B (female) (13) - ATC1 (female) (8): 0 Ω switch is turned "ON", "ON", truck cannot move
2. ATC5B, ATC1 connectors are securely inserted. transmission is held in off even when shift lever is
Neutral. operated.
Set in order of priority, 1. Shifts to same speed
Shift lever position ATC5B TMB SF (V) N>D>5>4>3>L range or higher than
R (2) - chassis Between (2) - (9) Between (3) - (2) If it is together with R, it is range set by shift lever.
taken as N 2. Stays in Neutral and
N (3) - chassis Between (3) - (9 Between (4) - (2)
cannot move.
D (4) - chassis Between (4) - (9) Between (5) - (2)
< 1.5 V (1.0 V)
1. Shifts to speed range
5 (5) - chassis Between (5) - (9) Between (6) - (2)
higher than range set
4 (6) - chassis Between (6) - (9) Between (7) - (2)
by shift lever.
3 (7) - chassis Between (7) - (9) Between (8) - (2) Holds at position before 2. Stays in Neutral and
L (8) - chassis Between (8) - (9) Between (9) - (2) signal stopped cannot move.
When lever is not in the above position / Between above terminals > 15V (24V) 3. Impossible to shift
between FORWARD
and REVERSE
1. Automatic gear-shifting
ATC3B TMA WAS2 Ω is carried out with nor- 1. Transmission shift
(11) - chassis Between (13) - chassis Between (2) - (3) 0.6 − 4.5ς
mal mode shock becomes greater
2. Control of clutch oil 2. Immediately shifts up
pressure is carried out when going downhill
as for when accelera-
tor is fully depressed

ATC3B,3A (female) TM4 (female) C/V.T (male) Ω


Clutch oil pressure control Transmission shift shock
Between (9) -(16) Between (13) - (140) Between (1) - (2) 1 ΚΩ. − 100 ΚΩ
is carried out in mode becomes greater
(9) - chassis (13) - chassis (1) - chassis used before fault occurred

1.
ATC3A (female) Ω 1. Transmission suddenly
Between (2) - (14)
shifts to Neutral during
Shift to Neutral propel or truck cannot
Between (12 - (14) 500 - 1,000 Ω. move again
Between (3) - (14) 2. Power is lost when in
Each terminal - chassis > 1 MΩ propel, and trans-mis-
2. See TESTING AND ADJUSTING OF TRANSMISSION sion repeatedly shifts
when going uphill
3. Transmission oil is not black enough to indicate problem
See items for display
1. Between ATC3A (female) (2) - (14): 500 - 1,000 Ω. Shift to Neutral codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, H clutch portion. (E.↔2.2, E.C↔2.2,
E.↔2.8, E.C↔2.8)
See items for display
1. Between ATC3A (female) (2) - (14): 500 - 1,000 Ω. Shift to Neutral codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, L clutch portion. (E.↔2.2, E.C↔2.2,
E.↔2.8, E.C↔2.8)

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-11


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

b024 Defective 1st clutch or output shaft See items for display codes b022 - b028
(E. ↔ 2.4) speed sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8
(E.C ↔ 2.4)
b025 Defective 2nd clutch or output shaft See items for display codes b022 - b028
(E. ↔ 2.5) speed sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8)
(E.C ↔ 2.5)
b026 See items for display codes b022 - b028
(E. ↔ 2.6) Defective 3rd clutch or output speed sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8
(E.C ↔ 2.6)
b027 Defective 4th clutch or output shaft See items for display codes b022 - b028
(E. ↔ 2.7) speed sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8
(E.C ↔ 2.7)
b028 Defective R clutch or output shaft See items for display codes b022 - b028
(E. ↔ 2.8) speed sensor (E. ↔ 2.2, E.C ↔ 2.2, E. ↔ 2.8, E.C ↔ 2.8
(E.C ↔ 2.8)

b032 1. Dirt caught in pressure control spool


| 2. Short circuit, short circuit with ground in fill detection switch
b038 1) Between H SW - TM3 (3) - ATC5A (12)
(E. ↔ 3.2) 2) Between L SW - TM3 (6) - ATC5A (10)
(E.C ↔ 3.2) Defective pressure control valve 3) Between R SW - TM3 (9) - ATC5A (16)
| ♦ When the controller is issuing the command 4) Between 1 SW - TM4 (3) - ATC5A (13)
(E. ↔ 3.8) to disengage the clutch, but the fill signal is 5) Between 2 SW - TM4 (6) - ATC5A (14)
(E.C ↔ 3.8) still being sent (clutch is engaged) 6) Between 3 SW - TM4 (9) - ATC5A (15)
7) Between 4 SW - TM4 (12) - ATC5A (11)

b032 Defective H clutch pressure control valve 1. Dirt caught in H clutch pressure control spool
(E. ↔ 3.2) 2. Between HSW - TM3 (3) - ATC5A (12)
(E.C ↔ 3.2)
b033 Defective L clutch pressure control valve 1. Dirt caught in L clutch pressure control spool
(E. ↔ 3.3) 2. Between LSW - TM3 (6) - ATC5A (10)
(E.C ↔ 3.3)
b034 Defective 1st clutch pressure control valve 1. Dirt caught in 1 clutch pressure control spool
(E. ↔ 3.4) 2. Between 1SW - TM4 (3) - ATC5A (13)
(E.C ↔ 3.4)
b035 Defective 2nd clutch pressure control valve 1. Dirt caught in 2 clutch pressure control spool
(E. ↔ 3.5) 2. Between 2SW - TM4 (6) - ATC5A (14)
(E.C ↔ 3.5)
b036 Defective 3rd clutch pressure control valve 1. Dirt caught in 3 clutch pressure control spool
(E. ↔ 3.6) 2. Between 3SW - Tm4 (9) - ATC5A (15)
(E.C ↔ 3.6)
b037 Defective 4th clutch pressure control valve 1. Dirt caught in 4 clutch pressure control spool
(E. ↔ 3.7) 2. Between 4SW - TM4 (12) - ATC5A (11)
(E.C ↔ 3.7)
b038 Defective R clutch pressure control valve 1. Dirt caught in R clutch pressure control spool
(E. ↔ 3.8) 2. Between RSW - TM3 (9) - ATC5A (16)
(E.C ↔ 3.8)

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-12 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Action of Symptoms that appear in truck when
Condition when normal: Check with tester controller there is fault
Voltage (V), current (A), resistance value Ω when a Mechatronics display given, warning
fault is actuated
detected

1. Between ATC3A (female) (3) - (14): 500 - 1,000 Ω Shift to See items for display codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, 1st clutch portion. Neutral (E. ↔2.2, E.C↔2.2, E. ↔2.8, E.C↔2.8)

1. Between ATC3A (female) (3) - (14): 500 - 1,000 Ω Shift to See items for display codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, 2nd clutch portion. Neutral (E. ↔2.2, E.C↔2.2, E. ↔2.8, E.C↔2.8)

1. Between ATC3A (female) (3) - (14): 500 - 1,000 Ω Shift to See items for display codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, 3rd clutch portion. Neutral (E. ↔2.2, E.C↔2.2, E. ↔2.8, E.C↔2.8)

1. Between ATC3A (female) (3) - (14): 500 - 1,000 Ω Shift to See items for display codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, 4th clutch portion. Neutral (E. ↔2.2, E.C↔2.2, E. ↔2.8, E.C↔2.8)

1. Between ATC3A (female) (3) - (14): 500 - 1,000 Ω Shift to See items for display codes b022 - b028
2. See TESTING AND ADJUSTING OF TRANSMISSION, R clutch portion. Neutral (E. ↔2.2, E.C↔2.2, E. ↔2.8, E.C↔2.8)

When transmission shift is at N, conditions are as in table below Ω

H SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (12) - chassis

H SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (10) - chassis > 1M Ω or > 1 M Ω
between terminals Shift to Transmission suddenly shifts to Neutral
H SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (16) - chassis
Neutral during propel or truck cannot move again
H SW (male) - chassis TM3 (male) (3) - chassis ATC5A (female) (13) - chassis

H SW (male) - chassis TM3 (male) (6) - chassis ATC5A (female) (14) - chassis

H SW (male) - chassis TM3 (male) (9) - chassis ATC5A (female) (15) - chassis

H SW (male) - chassis TM3 (male) (12) - chassis ATC5A (female) (11) - chassis

H SW (male) - chassis TM3 (female) ATC5A (female) > 1 M Ω or > 1 M Ω


Shift to Transmission suddenly shifts to neutral
(3) - chassis (12) - chassis between terminals Neutral during propel or truck cannot move again

L SW (male) TM3 (female) ATC5A (female) > 1 M Ω or > 1 M Ω


Shift to Transmission suddenly shifts to neutral
(6) - chassis (10) - chassis between terminals Neutral during propel or truck cannot move again

1 SW (male) - chassis TM4 (female) ATC5A (female) > 1 M Ω or > 1 M Ω Shift to Transmission suddenly shifts to neutral
(3) - chassis (13) - chassis between terminals Neutral during propel or truck cannot move again

2 SW (male) - chassis TM4 (female) ATC5A (female) > 1 M Ω or > 1 M Ω


Shift to Transmission suddenly shifts to neutral
(6) - chassis (14) - chassis between terminals Neutral during propel or truck cannot move again

3 SW (male) - chassis TM4 (female) ATC5A (female) > 1 M Ω or > 1 M Ω


Shift to Transmission suddenly shifts to neutral
(9) - chassis (15) - chassis between terminals Neutral during propel or truck cannot move again

4 SW (male) - chassis TM4 (female) ATC5A (female) > 1 M Ω or > 1 M Ω


Shift to Transmission suddenly shifts to neutral
(12) - chassis (11) - chassis between terminals Neutral during propel or truck cannot move again

R SW (male) - chassis TM3 (female) ATC5A (female) > 1 M Ω or > 1 M Ω


Shift to Transmission suddenly shifts to neutral
(9) - chassis (16) - chassis between terminals Neutral during propel or truck cannot move again

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-13


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative
b042
|
b048 Defective pressure control valve
(E. ↔ 4.2) ♦ When it is tried to engage the clutch, the Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.2) controller issues the command, but the fill
| sensor signal is not given, and the clutch is
(E. ↔ 4.8) not engaged
(E.C ↔ 4.8)
b042
(E. ↔ 4.2) Defective H clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.2)
b043
(E. ↔ 4.3) Defective L clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.3)
b044
(E. ↔ 4.4) Defective 1st clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.4)
b045
(E. ↔ 4.5) Defective 2nd clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.5)
b046
(E. ↔ 4.6) Defective 3rd clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.6)
b047
(E. ↔ 4.7) Defective 4th clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.7)
b048
(E. ↔ 4.8) Defective R clutch pressure control valve Pressure control spool is stuck at clutch disengage position
(E.C ↔ 4.8)

b052 1. Disconnection in fill switch circuit


| 1) Between H SW - TM3 (3) - ATC5A (12)
b058 Disconnection in fill detection switch 2) Between L SW - TM3 (6) - ATC5A (10)
(E. ↔ 5.2) ♦ When it is tried to engage the clutch, the 3) Between R SW - TM3 (9) - ATC5A (16)
(E.C ↔ 5.2) controller issues the command, but the fill 4) Between 1 SW - TM4 (3) - ATC5A (13)
| sensor signal is not given. However, the 5) Between 2 SW - TM4 (6) - ATC5A (14)
(E. ↔ 5.8) clutch is engaged. 6) Between 2 SW - TM4 (9) - ATC5A (15)
(E.C ↔ 5.8) 7) Between 4 SW - TM4 (12) - ATC5A (11)
2. Defective fill switch

b052 Defective H clutch flow control valve 1. Between HSW - TM3 (3) - ATC5A (12)
(E. ↔ 5.2) 2. Defective H clutch fill switch
(E.C ↔ 5.2)

b053 Defective L clutch flow control valve 1. Between LSW - TM3 (6) - ATC5A (10)
(E. ↔ 5.3) 2. Defective L clutch fill switch
(E.C ↔ 5.3)

b054 Defective 1st clutch flow control valve 1. Between 1SW - TM4 (3) - ATC5A (13)
(E. ↔ 5.4) 2. Defective 1st clutch fill switch
(E.C ↔ 5.4)

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-14 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Action of controller Symptoms that appear in truck when there is a fault
Condition when normal: Check with tester when a fault is
Voltage (V), current (A), resistance value Ω detected Mechatronics display given, warning actuated

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again

Normal controller display: Shows 0.0 or 0.C Shift to Neutral Transmission suddenly shift to Neutral during propel
or truck cannot move again
When each gear range is engaged using the shift checker, the fill
switch signal is given with the combinations shown in Table 1

Table 1 Relationship between gear range and fill switch signal Gear range used
during propel is 1. Gearshifting during propel becomes impossible.
H L 1 2 3 4 R maintained 2. If shift lever is in Neutral, it becomes impossible to
R O O If shift lever is in move truck
F1 O O Neutral, transmission
is held in Neutral
F2 O O

F3 O O

F4 O O

F5 O O

F6 O O

F7 O O

When each gear range is engaged with the shift checker, the fill switch See items for display 1. Gearshifting during propel becomes impossible.
signal is issued for the combinations in Table 1 of the items for display codes b052 - b058 2. If shift lever is in Neutral, it becomes impossible to
codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, move truck
(E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8 E. ↔ 5.8, E.C ↔ 5.8)
When each gear range is engaged with the shift checker, the fill switch See items for display 1. Gearshifting during propel becomes impossible.
signal is issued for the combinations in Table 1 of the items for display codes b052 - b058 2. If shift lever is in Neutral, it becomes impossible to
codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, move truck
(E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8) E. ↔ 5.8, E.C ↔ 5.8)

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-15


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

b055 Defective 2nd clutch flow control valve 1. Between 2SW - TM4 (6) - ATC5A (14)
(E. ↔ 5.5) 2. Defective 2nd clutch fill switch
(E.C ↔ 5.5)

b056 Defective 3rd clutch flow control valve 1. Between 3SW - TM4 (9) - ATC5A (15)
(E. ↔ 5.6) 2. Defective 3rd clutch fill switch
(E.C ↔ 5.6)

b057 Defective 4th clutch flow control valve 1. Between 4SW - TM4 (12) - ASTC5A (11)
(E. ↔ 4.4) 2. Defective 4th clutch fill switch
(E.C ↔ 4.4)

b058 Defective R clutch flow control valve 1. Between RSW - TM3 (9) - ATC5A (16)
(E. ↔ 5.8) 2. Defective R clutch fill switch
(E.C ↔ 5.8)

1. 1) Lock-up Between (+) L/U.t (1) - ATC1 (1)


Between (-) L/U.T (2) - ATC1 (8), (16)
2) H clutch Between (+) H.PS (2) - ATC2 (9)
b071 Short circuit in pressure control solenoid Between (-) H.PS (2) - ATC2 (19)
| ♦ When it is tried to disengage the clutch, 3) L clutch Between (+) L.PS (1) - ATC2 (7)
b078 Between (-) L.PS (2) - ATC2 (17)
(E. ↔ 7.1) • The pressure control solenoid output is 4) 1st clutch Between (+) 1.PS (1) - ATC2 (2)
(E.C ↔ 7.1) turned OFF, but the solenoid current still Between (-) 1.PS (2) - ATC2 (13)
| flows 5) 2nd clutch Between (+) 2.PS (1) - ATC2 (4)
(E. ↔ 7.8) or Between (-) 2.PS (2) - ATC2 (15)
(E.C ↔ 7.8) • Excessive solenoid current flows 6) 3rd clutch Between (+) 3.PS (1) - ATC2 (3)
Between (-) 3.PS (2) - ATC2 (13)
7) 4th clutch Between (+) 4.PS (1) - ATC2 (8)
Between (-) 4.PS (2) - ATC2 (18)
8) R clutch Between (+) R.PS (1) - ATC2 (5)
Between (-) R.PS (2) - ATC2 (15)
2. Defective pressure control solenoid
b071 Short circuit in lock-up pressure control See items for display codes b071 - b078
(E. ↔ 7.1) solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.1)
b072 Short circuit in H clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.2) solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.2)
b073 Short circuit in L clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.3) solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.3)
b074 Short circuit in 1st clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.4) solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.4)
b075 Short circuit in 2nd clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.5) solenoid (E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 5.5)

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-16 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in
Condition when normal: Check with tester Action of controller when a fault is detected truck when there is a fault
Voltage (V), current (A), resistance value Ω
Mechatronics display given,
warning actuated
When each gear range is engaged with the shift checker, the fill 1. Gearshifting during propel
switch signal is issued for the combinations in Table 1 of the items See items for display codes b052 - b058 becomes impossible.
for display codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8) 2. If shift lever is in Neutral, it
(E. ↔ 5.2, E.C ↔ 5.2 - E. ↔ 5.8, E.C ↔ 5.8) becomes impossible to
move the truck
When each gear range is engaged with the shift checker, the fill 1. Gearshifting during propel
switch signal is issued for the combinations in Table 1 of the items See items for display codes b052 - b058 becomes impossible.
for display codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8) 2. If shift lever is in Neutral, it
(E. ↔ 5.2, E.C ↔ 5.2 - E. ↔ 5.8, E.C ↔ 5.8) becomes impossible to
move the truck
When each gear range is engaged with the shift checker, the fill 1. Gearshifting during propel
switch signal is issued for the combinations in Table 1 of the items See items for display codes b052 - b058 becomes impossible.
for display codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8) 2. If shift lever is in Neutral, it
(E. ↔ 5.2, E.C ↔ 5.2 - E. ↔ 5.8, E.C ↔ 5.8) becomes impossible to
move the truck
When each gear range is engaged with the shift checker, the fill 1. Gearshifting during propel
switch signal is issued for the combinations in Table 1 of the items See items for display codes b052 - b058 becomes impossible.
for display codes b052 - b058 (E. ↔ 5.2, E.C ↔ 5.2, E. ↔ 5.8, E.C ↔ 5.8) 2. If shift lever is in Neutral, it
(E. ↔ 5.2, E.C ↔ 5.2 - E. ↔ 5.8, E.C ↔ 5.8) becomes impossible to
move the truck

ATC1 (female) ATC2 (female) Ω

Between (1) - (8), (16) — 30 - 80 Ω

Between (9) - (19)

Between (7) - (17)

Between (2) - (13)


5 - 25 Ω Actuates transmission cut relay and shifts to Transmission suddenly shifts
— Between (4) - (15) Neutral to Neutral during propel or
Between (3) - (13) truck cannot move again
Between (8) - (18)

Between (5) - (15)

Resistance value between each terminal > 1 MΩ

Between each terminal - chassis > 1 MΩ

Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
Check with table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1, E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-17


Fault Conditions Details of fault Check the wiring harnesses and equipment given below: Disconnec-
Display code ♦ Possible causes: tion, short circuit in wiring harness (+): Positive, (-): Negative

b076 Short circuit in 3rd clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.6) solenoid (E. ↔ 7.1, E.C ↔ 7.1- E. ↔ 7.8, E.C ↔ 7.8
(E.C ↔ 7.6)
b0077 Short circuit in 4th clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.7) solenoid (E. ↔ 7.1, E.C ↔ 7.1- E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.7)
b0078 Short circuit in R clutch pressure control See items for display codes b071 - b078
(E. ↔ 7.7) solenoid (E. ↔ 7.1, E.C ↔ 7.1- E. ↔ 7.8, E.C ↔ 7.8)
(E.C ↔ 7.7)

b091 1. 1) Lock - up Between (+) L/U.T (1) - ATC1 (1), Between (-) L/U.T (2) - ATC1 (8), (16)
| 2) H clutch Between (+) H.PS (1) - ATC2 (9), Between (-) H.PS (2) - ATC2 (19)
b098 Disconnection in pressure control solenoid 3) L clutch Between (+) L.PS (1) - ATC2 (7), Between (-) L.PS (2) - ATC2 (17)
(E. ↔ 9.1) ♦When it is tried to disengage the clutch, 4) 1st clutch Between (+) 1.PS (1) - ATC2 (2), Between (-) 1.PS (2) - ATC2 (13)
(E.C ↔ 9.1) the pressure control solenoid output is 5) 2nd clutch Between (+) 2.PS (1) - ATC2 (4), Between (-) 2.PS (2) - ATC2 (15)
| turned ON, but the solenoid current does 6) 3rd clutch Between (+) 3.PS (1) - ATC2 (3), Between (-) 3.PS (2) - ATC2 (13)
(E. ↔ 9.8) not flow 7) 4th clutch Between (+) 4.PS (1) - ATC2 (8), Between (-) 4.PS (2) - ATC2 (18)
(E.C ↔ 9.8) 8) R clutch Between (+) R.PS (1) - ASTC2 (5), Between (-) R.PS (2) - ATC2 (15)

2. Defective pressure control solenoid

b091
(E. ↔ 9.1) Disconnection in lock-up pressure control See items for display codes b091 - b098
(E.C ↔ 9.1) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8

b092 Disconnection in H clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.2) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.2)
b093 Disconnection in L clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.3) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8
(E.C ↔ 9.3)
b094 Disconnection in 1st clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.4) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8
(E.C ↔ 9.4)
b095 Disconnection in 2nd clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.7) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8
(E.C ↔ 9.7)
b096 Disconnection in 3rd clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.6) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.6)
b097 Disconnection in 4th clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.7) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8)
(E.C ↔ 9.7)
b098 Disconnection in R clutch pressure control See items for display codes b091 - b098
(E. ↔ 9.8) solenoid (E. ↔ 9.1, E.C ↔ 9.1, E. ↔ 9.8, E.C ↔ 9.8
(E.C ↔ 9.8)

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-18 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in
Condition when normal: Check with tester Action of controller when a fault is detected truck when there is a fault
Voltage (V), current (A), resistance value Ω
Mechatronics display given,
warning actuated
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1 - E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1 - E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
Check with Table 2 for the items for display codes b071 - b078 Actuates transmission cut relay and shifts to Transmission suddenly shifts
(E. ↔ 7.1, E.C ↔ 7.1 - E. ↔ 7.8, E.C ↔ 7.8) Neutral to Neutral during propel or
truck cannot move again
When each gear range is engaged using the shift checker, the fill
switch signal is given with the combinations shown in Table1.

Table 2 Solenoid valve check


ATC1 (female) ATC2 (female) Ω
Even when a disconnection is detected, it 1. Power is lost when propel-
Between (1) - (8), (16) — 30 - 80 Ω
tries to send current to the solenoid ling, and when shifting up,
Between (9) - (19) transmission immediately
Between (7) - (17) • This is because there is no danger of dam- shifts down again
Between (2) - (13) age to the controller even if there is a dis- • This frequently happens
5 - 25 Ω

connection when going uphill loaded
Between (4) - (15)

Between (3) - (13)


2. Shift indicator display
Between (8) - (18) shows "E"
Between (5) - (15)

Resistance value between each terminal > 1 MΩ

Between each terminal - chassis > 1 MΩ

See items for display codes


Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 b091 - b098
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔
9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)
Check with Table 2 for the items for display codes b091 - b098 See items for display codes b091 - b098 See items for display codes
(E. ↔ 9.1, E.C ↔ 9.1 - E. ↔ 9.8, E.C ↔ 9.8) (E. ↔ 9.1, E.C ↔ 9.1- E ↔ 9.8, E.C ↔ 9.8) b091 - b098 (E. ↔ 9.1, E.C
↔ 9.1- E ↔ 9.8, E.C ↔ 9.8)

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-19


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

b060 Defective engine speed sensor output 1. Engine speed sensor B


(E. ↔ 6.0) ♦Engine speed less than 350 rpm and 1) Between E12 (1) - J09M (9) - TMD (13) - ATC3A (13)
(E.C ↔ 6.0) transmission speed more than 500 rpm 2) Between E12 (2) - J09M (10) - TMD (14) - ATC3A (14)
continues for 10 sec 2. Defective engine speed sensor
b061 Defective output of transmission input shaft 1. Input shaft speed sensor
(E. ↔ 6.1) speed sensor 1) Between N1 (1) - TM2 (1) - ATC3A (2)
(E.C ↔ 6.1) ♦When the engine speed, input shaft 2) Between N2 (2) - TM2 (2) - ATC3A (14)
speed, and intermediate shaft speed are 2. Defective input shaft speed sensor
converted and it is found that there is a
problem in lock-up clutch and HL clutch
b062 Defective output of transmission intermedi- 1. Intermediate shaft speed sensor
(E. ↔ 6.2) ated shaft speed sensor 1) Between N2 (1) - TM2 (3) - ATC3A (12)
(E.C ↔ 6.2) ♦When the input shaft speed, intermediate 2) Between N2 (2) - TM2 (4) - ATC3A (14)
shaft speed, and output shaft speed are 2. Defective intermediate shaft speed sensor
converted and it is found that there is a
problem in HL clutch and speed clutch
(When disconnection detection is actuated
and there is no sensor signal)
Defective output of transmission output
b063 shaft speed sensor 1. Output shaft speed sensor
(E. ↔ 6.3) ♦When the engine speed, input shaft 1) Between N3 (1) - TM2 (5) - ATC3A (3)
(E.C ↔ 6.3) speed, intermediate shaft speed, and out- 2) Between N3 (2) - TM2 (6) - ATC3A (14)
put shaft speed are converted and it is 2. Defective output shaft speed sensor
found that there is a problem in relation-
ship

b0A1 Fault in model selection 1. Defective controller


(E. ↔ A.1) ♦The setting of rotary switch is different 2. Defective setting of rotary switch
(E.C ↔ A.1) from the model in the software.

b0A2 Short circuit with ground in torque converter 1. Between (+) ATC3B (7) - TM2 (7) - TC.SE (1)
(E. ↔ A.2) oil temperature Between (-) ATC3A (16) - TMB (9) - TMC (5) - TM2 (8) - TC.SE (2)
(E.C ↔ A.2) ♦When torque converter oil temperature 2. Defective torque converter oil temperature sensor
sensor signal is more than 150°C
b0A3 Disconnection in fuel level sensor 1. Between (+) ATC5B (5) - TMA (15) - J09M (12), (15) - J02 (1) - 26 (1)
(E. ↔ A.3) ♦Input voltage: > 4 V 2. Defective fuel sensor
(E.C ↔ A.3)

b0b2 Short circuit with ground in cooling water 1. Between (+) ATC5B (5) - TMA (7) -J09M (12), (15) - J02 (1) - 26 (1)
(E. ↔ b.2) temperature sensor Between (-) ATC5A (16) - TMB (9) - J09M (13), (16) - J02 (3) - 26 (2)
(E.C ↔ b.2) ♦When input resistance of cooling water 2. Defective coolant water temperature sensor
temperature sensor signal is more than
170 Ω

b0b3 Disconnection in brake air pressure sensor 1. Between (+) ATC3B (2) - TMA (7) - RH4 (1) - SR5 (1)
(E. ↔ b.3) ♦ When input resistance of brake air pres- Between (-) ATC5A (16) - TMB (9) - RH4 (10) - SR5 (2)
(E.C ↔ b.3) sure sensor signal is more than 3,000 Ω 2. Defective brake air pressure sensor

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-20 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in truck when
Condition when normal: Check with tester Action of controller when there is fault
Voltage (V), current (A), resistance value Ω a fault is detected Mechatronics display given, warning
actuated
1. Engine speed display on monitor panel is normal Gear range used during 1. Gearshifting becomes impossible.
2. Between ASTC3A (13) - (14): 500 - 1,000 AC sym: > 0.5V propel maintained 2. If shift lever is in Neutral, it
3. Between each terminal of ATC3A (13), (14) - chassis: > 1 MΩ If shift lever is in Neutral, becomes impossible to move the
4. Between E12 (male) (1) - (2): 500 - 1,000 Ω transmission is held in truck again unless it is stopped.
Neutral

ATC3A (female) TM2 (male) N1 (male) Ω Gear range used during 1. Gearshifting becomes impossible.
Between (2) - (14) Between (1) - (2) Between (1) - (2) 500 - 1,000 Ω
propel is maintained 2. If shift lever is in Neutral, it
If shift lever is in Neutral, becomes impossible to move the
Each terminal - chassis >1MΩ
transmission is held in truck again unless it is stopped.
Neutral

Gear range used during 1. Gearshifting becomes impossible.


ATC3A (female) TM2 (male) N2 (male) Ω
propel is maintained 2. If shift lever is in Neutral, it
Between (14) - (12) Between (3) - (4) Between (1) - (2) 500 - 1,000 Ω If shift lever is in Neutral, becomes impossible to move the
Each terminal - chassis >1MΩ transmission is held in truck again unless it is stopped.
Neutral

Gear range used during 1. Speedometer displays 0 km/h


ATC3A (female) TM2 (male) N3 (male) Ω propel is maintained during propel and gear-shifting
Between (3) - (14) Between (5) - (6) Between (1) - (2) 500 - 1,000 Ω
If shift lever is in Neutral, becomes impossible.
transmission is held in 2. If shift lever is in Neutral, it
Between N3 (1) - TM2 (5) - ATC3A (3) - chassis >1MΩ
Neutral becomes impossible to move the
truck again unless it is stopped.

When effort to move the truck is car-


Set value of rotary switch 1 2, 3, 4 or 5 Holds at neutral ried out, it does not move.

ATC3B,3A (female) TM2 (female) TC.SE (male) Ω Only gives self-diagnos- No display at all is given on torque
Between (7) - (16) Between (7) - (8) Between (10 - (2) tic display; does not take converter oil temperature gauge dis-
1 KΩ - 100 KΩ any action play on monitor panel.
(7) - chassis (7) - chassis (1) - chassis

Only gives self-diagnos- No display at all is given on fuel level


ATC3B TMD J02 61 (V)
tic display; does not take gauge display on monitor panel.
(4) - chassis (7) - chassis (15) - chassis (1) - chassis 0.2 − 0.4 V
any action

When engine water temperature is between 25°C (normal temperature) and 100°C, condition is as shown in
table below. Only gives self-diagnos- No display at all is given on engine
ATC3B,3A (male) TMA, TMB (male) J09M J02 61 (W)
tic display; does not take water temperature gauge display on
any action monitor panel.
Between Between Between (12), (15) Between (1) - (3) Between (1) - (2)
(5) - (16) (15) - (9) - (13), (16) 37 Ω
|
(5) - chassis (15) - chassis (12), (15) - chassis (1) - chassis (1) - chassis 4Ω

ATC3B,3A (male) TMA, TMB (male) RH4, RH1 SR5 Ω Only gives self-diagnos- No display at all is given on air pres-
Between (2) - (16) Between (7) - (9) Between (1) - (10) Between (1) - (2) tic display; does not take sure gauge display on monitor
3 - 1,000 Ω any action panel.
(2) - chassis (7) - chassis (1) - chassis (10) - chassis

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-21


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

b0b4 Short circuit with ground in retarder brake oil 1. Between (+) ATC3b (8) - tmd (5) - J02 (10) - 64 (1)
(E. ↔ b.4) temperature sensor Between (-) ATC3A (16) - TMB (9) - J02 (9) - 64 (2)
(E.C ↔ b.4) ♦ When retarder brake oil temperature sen- 2. Defective retarder brake oil temperature sensor
sor signal is more than 150°C

b0b7 Disconnection, short circuit with ground in 1. Between ATC3B (12) - TMD (15) - J02 (2) - 27 (3)
(E. ↔ b.7) engine oil pressure sensor Between (+) ATC3A (6) - TMA (16) - J09M (11) - (14) - J01 (11) - 27 (2)
(E.C ↔ b.7) ♦ Voltage between ATC3B (12) - chassis 2. Defective voltage circuit inside controller
• 4.6 ± 0.1 V 3. Defective engine oil pressure sensor
• 0.4 ± 0.1 V
Improper connection of connector
b0C1 ♦ After the key switch is turned "ON", de- 1. Between ATC5A (1) - ATC1 (16).
(E. ↔ C1) pending on the wiring harness, the model 2. Defective contact of ATC5A connector
(E.C ↔ C1) selection signal does not match

b0C4 Short circuit with ground in BCV rear solenoid 1. Defective BCV relay R04
(E. ↔ C.4) ♦ BCV output terminal voltage 2. Between ATC (11) - TMB (13) - R04 (1)
(E.C ↔ C.4) • When actuated: > 11V or above
• When not actuated: < 11V or below

b0C6 Disconnection in BCV rear solenoid 1. Defective BCV relay R04


(E. ↔ C.6) ♦ BCV output terminal voltage 2. Between ATC (11) - TMB (13) - R04 (1), from R04 (2) - GND, ER
(E.C ↔ C.6) • When actuated: > 11V or above
• When not actuated: < 11V or below

b0C8 Short circuit in BCV rear solenoid 1. Defective BCV relay R04
(E. ↔ C.8) ♦ BCV output terminal voltage 2. Between ATC (11) - TMB (13) - R04 (2)
(E.C ↔ C.8) • When actuated: > 11V or above
• When not actuated: < 11V or below

b0d1 Transmission filter clogging warning 1. Between (+) ATC5A (6) - TMD (6) - J02 (13) - 52 (10
(E. ↔ d.1) ♦ When the transmission oil filter switch is Between (-) J03 (8) - 52 (2)
(E.C ↔ d.1) OFF with the torque converter outlet port 2. Defective transmission filter sensor
oil temperature 50°C or above.

b0d5 Tilt warning display 1. Between (+) ATC5A (5) - TMD (2) - SR3 (1)
(E. ↔ d.5) ♦ When the machine tilt angle switch is OFF. Between (-) SR3 (2) - GND.ER
(E.C ↔ d.5) 2. Defective tilt sensor

b0d6 Drop in radiator water level warning display 1. Between (+) ATC5B (15) - TMD (4) - J02 (7) - 01 (9) - 03 (1)
(E. ↔ d.6) ♦ When the engine cooling water level switch Between (-) 03 (2) - GND.16
(E.C ↔ d.6) is OFF. 2. Defective radiator water level sensor

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-22 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in truck
Condition when normal: Check with tester Action of controller when when there is fault
Voltage (V), current (A), resistance value Ω a fault is detected Mechatronics display given,
warning actuated

ATC3B,3A (male) TMD, TMB (male) J02 64 Ω Only gives self-diagnos- No display at all is given on
Between (8) - (16) Between (5) - (9) Between (10) - (9) Between (1) − (2)
tic display; does not take retarder oil temperature gauge
2k Ω - 20k Ω
(25°C - 120°C)
any action display on monitor panel.
(8) - chassis (5) - chassis (10) - chassis (1) − chassis

ATC3B TMD J02 27 (V) Only gives self-diagnos- Drop in engine oil pressure
(12) - chassis (15) - chassis (2) - chassis (3) − chassis
tic display; does not take cannot be detected.
0.4 - 4.6 V any action
Between (2) - (3)

If there is a fault when


1. Between ATC5A (1) - ATC1 (16): 0 Ω key switch is turned When key switch is turned
2. ATC5A, ATC1 connectors are securely inserted. "ON", transmission is "ON", truck cannot move even
held at Neutral. when shift lever is operated.

ATC1 TMB R04 (V) Ω


Only gives self-diagnos- BCV is not actuated
(11) - chassis (13) - chassis (1) - chassis 20 − 30 V tic display; does not take
Between relay (1) 100 - 500 Ω any action
and (2)

ATC1 TMB R04 (V) Ω Only gives self-diagnos- BCV is not actuated
(11) - chassis (13) - chassis (1) - chassis 20 − 30 V tic display; does not take
Between relay (1) 100 - 500 Ω any action
and (2)

ATC1 TMB R04 (V) Ω Only gives self-diagnos- BCV in mistakenly actuated
(11) - chassis (13) - chassis (1) - chassis 20 − 30 V tic display; does not take
Between relay (1) 100 - 500 Ω
any action
and (2)

1. If operations are continued,


When transmission filter is normal, condition is as shown in table below.
Only gives self-diagnos- dirt will circulate in transmis-
ATC5A TMD J02 52 tic display; does not take sion circuit.
(6) - chassis (2) - chassis (13) - chassis (1) − chassis any action 2. Mechatronics display is not
No continuity given.
Between (1) - (2)
3. Buzzer does not sound.
1. If operations are continued,
When machine tilt angle is ± 15°, condition is as shown in table below.
Only gives self-diagnos- truck may roll over.
ATC5A TMD SR3 tic display; does not take 2. Mechatronics display is not
(5) - chassis (2) - chassis (1) - chassis, (1) - (2) Continuity any action given.

When radiator water level is normal, condition is as shown in table below.


Only gives self-diagnos- 1. If operations are continued,
ATC5B TMD J02 01 03 tic display; does not take there will be overheating.
(15) - chassis (4) - chassis (7) - chassis (8) - chassis (1) - chassis, Continuity any action 2. Mechatronics display is not
(1) - (2) given.

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-23


Fault Conditions Details of fault Check the wiring harnesses and equipment given below:
Display code ♦ Possible causes: Disconnection, short circuit in wiring harness (+): Positive, (-): Negative

b0d7 Battery charge warning display 1. Between ATC3B (1) - TMD (1) - J01 (1) - alternator terminal R
(E. ↔ d.7) ♦ When battery charge switch is OFF with 2. Defective charging circuit
(E.C ↔ d.7) engine speed at 500 rpm or above.

b0F5 Engine oil pressure drop warning 1. Between ATC3B (12) - TMD (15) - J02 (2) - 27 (3)
(E. ↔ F.5) ♦ When fault is recognized in the engine 2. Defective engine lubricating oil circuit
(E.C ↔ F.5) speed at 700 rpm or above. 3. Defective engine oil pressure sensor

b0E5 Steering oil temperature overheat warning 1. Between ATC3A (11) - TMA (8) - J01 (6) - 21 (1)
(E. ↔ E.5) ♦ When steering oil temperature switch in 2. Defective steering oil temperature sensor
(E.C ↔ E.5) ON.

b0F6 Rear brake oil pressure warning display 1. Between (+) ATC5A (8) - TMC (12) - J)3 (2) - BLSL (1)
(E. ↔ F.6) ♦ When brake stroke switch is ON for 2 sec- Between BLSL (2) - BLSR (1)
(E.C ↔ F.6) onds. Between (-) BLSR (2) - GND.67
2. Defective brake stroke sensor

b0d3 Engine water temperature overheat warning Abnormal rise in engine water temperature.
(E. ↔ d.3) ♦ When engine water temperature sensor
(E.C ↔ d.3) signal is above 102°C

Torque converter oil temperature overheat


b0d2 warning Abnormal rise in torque converter oil temperature
(E. ↔ d.2) ♦ According to network data from monitor
(E.C ↔ d.2) system.
b0E9 Air pressure drop warning
(E. ↔ E.9) ♦ According to network data from monitor Abnormal drop in air pressure inside air tank
(E.C ↔ E.9) system.

b0F3 Retarder oil temperature overheat warning


(E. ↔ F.3) ♦ According to network data from monitor Abnormal rise in retarder oil temperature
(E.C ↔ F.3) system.

b0d8 Engine overrun actuated display


(E. ↔ d.8) ♦ Overrun actuated with transmission input Engine overrun actuated display
(E.C ↔ d.8) shaft speed more than 2,600 rpm.

b0d9 Engine overshoot display


(E. ↔ d.9) ♦ When d.8 does not detect engine over- Engine overshoot display (sudden spurt)
(E.C ↔ d.9) shoot display with engine speed at 2,600
rpm or above

The top code in the Display code column shows the monitor panel display and the bottom code (in [ ] ) shows the
transmission controller LED display. (< less than - > greater than)

D5-24 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Symptoms that appear in truck
Condition when normal: Check with tester Action of controller when there is fault
Voltage (V), current (A), resistance value Ω when a fault is Mechatronics display given,
detected warning actuated
1. Propel is possible until control
power source voltage drops. If
When engine is running (1/2 throttle or above), condition is as shown in table below.
Only gives self-diag- operations are continued, bat-
ATC3B TMD J01 (V) nostic display; does not tery life will be reduced.
(1) - chassis (1) - chassis (1) - chassis 27.5 - 29.5 V take any action 2. Mechatronics display is not
given
3. Buzzer does not sound
1. Loses power during opera-
ATC3A TMD J02 27 Only gives self-diag- tions.
1,000 (12) - chassis (15) - chassis (2) − chassis Between 1.3 - 5.0 V nostic display; does not 2. Engine acceleration becomes
Engine rpm (1) - (3) take any action poor.
Speed
1,800 (12) - chassis (15) - chassis (2) - chassis Between 2.1 - 5.0 V 3. Mechatronics display is not
rpm (1) - (3) given

When steering oil temperature is 25°C (normal temperature), condition is as shown in table below. If there is a fault when 1. If operations are continued, oil
ATC3A TMA J01 21 — key switch is turned may leak.
(11) - chassis (8) - chassis (6) - chassis (1) - chassis No continuity "ON", transmission is 2. Mechatronics display is not
held at Neutral. given.

When brake stroke is normal, condition is as shown in table below. Only gives self-diag- 1. If operations are continued, oil
ATC5A TMD J03 BLSL nostic display; does not may leak.
(8) - chassis (12) - chassis (2) - chassis (1) - chassis take any action 2. Mechatronics display is not
— — — (1) - (2), (2) - chassis
Continuity given.

1. Low power during operation.


Only gives self-diag- 2. Engine acceleration becomes
nostic display; does not poor.
take any action 3. Mechatronics display is not
given
1. If operations are continued,
Only gives self-diag- engine may be damaged.
nostic display; does not 2. Mechatronics display is not
take any action given
1. If operations are continued,
Only gives self-diag- engine may be damaged.
nostic display; does not 2. Mechatronics display is not
take any action given
1. If operations are continued,
Only gives self-diag- engine may be damaged.
nostic display; does not 2. Mechatronics display is not
take any action given
1. If operations are continued,
Only gives self-diag- engine may be damaged.
nostic display; does not 2. Mechatronics display is not
take any action given
1. If operations are continued,
Only gives self-diag- engine may be damaged.
nostic display; does not 2. Mechatronics display is not
take any action given

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-25


TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS

D5-26 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-27
A-1 FAULTS IN POWER SOURCE SYSTEM

a) (OFF) Controller self-diagnostic display LED does not light up

• When fuse BT1 (No. 10) is normal.If it is blown, check for a short circuit with the ground in the wiring harness
between the fuse and controller.
• When the battery is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-1 a) Related electrical circuit diagram

D5-28 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


b) Drop in voltage of controller power source is displayed

• When fuses BT1 (10) (19 - 20) and BT2 (8) (15 - 16) are normal.If it is blown, check for a short circuit with the
ground inside the controller and in the wiring harness between the fuse and controller.
• When the battery is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-1 b) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-29


c) Drop in voltage of battery direct power source is displayed

• When fuse BT2 (8) (15 - 16) is normal.If it is blown, check for a short circuit with the ground inside the controller
and in the wiring harness between the fuse and controller.
• When the battery is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on the next step.

A-1 c) Related electrical circuit diagram

D5-30 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


d) Drop in voltage of main power source is displayed

• When fuse BT1 (10) (19 - 20) is normal.If it is blown, check for a short circuit with ground inside the controller
and in the wiring harness between the fuse and controller.
• When the battery is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A - 1 d) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-31


e) Faults in transmission cut relay power source is displayed

• When battery and charging voltage are normal


• When fuse FB1 (No. 10) is normal
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-1 e) Related electrical circuit diagram

D5-32 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-2 Faults in neutral safety system is displayed

• When the key switch is turned to ON with the shift lever at a position other than N, or when the power source is
momentarily cut when moving.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-2 Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-33


A-3 Double engagement for clutch is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

D5-34 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-4 Faults in transmission [cut relay] system displayed

• Displays disconnection, short circuit, or short circuit with chassis ground in transmission cut relay system.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-4 Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-35


A-5 Faults in rear brake solenoid circuit is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-5 related electrical circuit diagram

D5-36 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-6 Faults in exhaust brake solenoid circuit is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-6 Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-37


A-7

a) Short circuit with ground in BCV rear solenoid is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-7 a) Related electrical circuit diagram

D5-38 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


b) Short circuit in BCV rear solenoid is displayed

• Check that the mounting bolts of the input shaft speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.

A-7 b) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-39


c) Disconnection in BCV rear solenoid is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-7 c) Related electrical circuit diagram

D5-40 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-8 Fault in speed sensor

a) -2 Disconnection in engine speed sensor [B] is displayed on truck


or

Failure of engine speed sensor is displayed on truck

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-8 a) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-41


b) Disconnection in input shaft speed sensor is displayed

or

Failure of input shaft speed sensor is displayed

• Check that the mounting bolts of the input shaft speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

TABLE 1.
ATC3A (female) N1 (male) Resistance
Between (2) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (2) & chassis Between (1) & chassis > 1M Ω

A-8 b) Related electrical circuit diagram

D5-42 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


c) Disconnection in intermediate shaft speed sensor is displayed

or

Failure of intermediate shaft speed sensor is displayed

• Check that the mounting bolts of the input shaft speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

TABLE 1.
ATC3A (female) N2 (male) Resistance
Between (2) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (12) & chassis Between (1) & chassis > 1M Ω

A-8 c) Related electrical diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-43


d) Disconnection in speed sensor (transmission output shaft speed
sensor) us displayed

or

Failure of output shaft speed sensor is displayed

• Check that the mounting bolts of the speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Table 1.
ATC3A (female) N2 (male) Resistance
Between (3) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (3) & chassis Between (1) & chassis > 1M Ω

A-8 d) Related electrical circuit diagram

D5-44 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-9 Speed sensor, clutch slipping

a) Input shaft speed sensor

or

H,L clutch is displayed

• Check that the mounting bolts of the speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step

Table 1.
ATC3A N2 Resistance
Between (2) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (2) & chassis Between (1) & chassis > 1M Ω

A-9 a) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-45


b) Output shaft speed sensor or speed
clutch (1,2,3,4,R) system is displayed
~
• Check that the mounting bolts of the speed sensor are not loose.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

TABLE 1.
ATC3A N2 Resistance
Between (3) - (14) Between (1) - (2) 500 Ω - 1000 Ω
Between (3) & chassis Between (1) & chassis > 1M Ω

A-9 b) Related electrical circuit diagram

D5-46 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-10 Fault in model selection (wiring harness) is displayed

a) Fault in model selection (wiring harness) is displayed

• When the controller power source is normal.


• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Table 1.
ATC5B ATC1 Voltage
(10) - (8) > 15 V
(11) - (8) >1V
(12) - (8) >1V
(13) - (8) <1V

A-10 a) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-47


b) Fault in model selection (rotary switch) is displayed

• When the controller power source is normal.


• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

D5-48 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-11 Fault in shift lever circuit

a) Short circuit in shift lever assembly power source is displayed

• When the controller power source is normal.


• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-11 a) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-49


b) Shift lever position signal input for 2 or more circuits is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

D5-50 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


Table 1.
Abnormal system System with failed wiring harness
N SF (4) - ATC5B (3) - transmission neutral relay R02
(2) - payload meter relay R11 (6)
R SF (3) - ATC5B (2) - backup alarm relay R06 (2)
D SF (5) - ATC5B (4)
5 SF (6) - ATC5B (5)
4 SF (7) - ATC5B (6)
3 SF (8) - ATC5B (7)
2 SF (9) - ATC5B (8)

A-11 b) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-51


c) Shift lever position signal is not inputted

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Table 1
Lever position Terminal of TORQFLOW Voltage when position Voltage when position Shift lever
transmission controller is selected is not selected SF terminal
N ATC5B (3) < 1.0 V > 15.0 V SF (4)
R ATC5B (2) < 1.0 V > 15.0 V SF (3)
D ATC5B (4) < 1.0 V > 15.0 V SF (5)
5 ATC5B (5) < 1.0 V > 15.0 V SF (6)
4 ATC5B (6) < 1.0 V > 15.0 V SF (7)
3 ATC5B (7) < 1.0 V > 15.0 V SF (8)
L ATC5B (8) < 1.0 V > 15.0 V SF (9)

D5-52 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-11 c) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-53


A-12 Fault in accelerator signal is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-12 Related electrical circuit diagram

D5-54 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-13 Fault in transmission oil temperature sensor is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-13 Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-55


A-14 Fault in pressure control valve

a) Fill switch (clutch ON) is displayed


regardless of command
~
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Table 1
Connection of connector and fill switch Fill switch
Transmission controller When connected When Open
Service code display Corresponding connector and pin Fill switch Voltage Resistance Voltage Resistance
clutch number
b042 H clutch ATC5A (12) - H. SW <1V <1Ω 15 -25 V > 1 MΩ
[E.↔ 4.2,E.C↔4.2]
b043 L clutch ATC5A (10) - L. SW <1V <1Ω 15 -25 V > 1 MΩ
[E.↔ 4.3,E.C↔ 4.3]
b044 1 clutch ATC5A (13) - 1. SW <1V <1Ω 15 -25 V > 1 MΩ
[E.↔ 4.4,E.C↔ 4.4]
b045 2 clutch ATC5A (14) - 2. SW <1V <1Ω 15 -25 V > 1 MΩ
[E.↔ 4.5,E.C↔ 4.5]
b046 3 clutch ATC5A (15) - 3. SW <1V <1Ω 15 -25 V > 1 MΩ
[E↔ 4.6,E.C↔ 4.6]
b047 4 clutch ATC5A (11) - 4. SW <1V <1Ω 15 -25 V > 1 MΩ
[E.↔ 4.7,E.C↔ 4.7]
b048 R clutch ATC5A (16) - R. SW <1V <1Ω 15 -25 V > 1 MΩ
[E.↔ 4.8,E.C ↔4.8]

D5-56 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-14 a) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-57


b) Fill switch signal is not input and clutch
slipping is displayed
~
• Measure the clutch oil pressure of the circuit where the fault is displayed. If the oil pressure is normal, carry out
the troubleshooting below.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

b-1) Inspecting fill switch signal

Table 1
Connection of connector and fill switch Fill switch
Transmission controller When connected When Open
Service code Corresponding connector and pin Fill switch Voltage Resistance Voltage Resistance
display clutch number
b042
[E.↔ 4.2,E.C↔4.2] H clutch ATC5A (12) - H. SW <1V <1Ω 15 -25 V > 1 MΩ
b043
[E.↔ 4.3,E.C↔ 4.3] L clutch ATC5A (10) - L. SW <1V <1Ω 15 -25 V > 1 MΩ
b044
[E.↔ 4.4,E.C↔ 4.4] 1 clutch ATC5A (13) - 1. SW <1V <1Ω 15 -25 V > 1 MΩ
b045
[E.↔ 4.5,E.C↔ 4.5] 2 clutch ATC5A (14) - 2. SW <1V <1Ω 15 -25 V > 1 MΩ
b046
[E↔ 4.6,E.C↔ 4.6] 3 clutch ATC5A (15) - 3. SW <1V <1Ω 15 -25 V > 1 MΩ
b047
[E.↔ 4.7,E.C↔ 4.7] 4 clutch ATC5A (11) - 4. SW <1V <1Ω 15 -25 V > 1 MΩ

D5-58 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


b-2) Inspecting transmission input shaft speed signal system, H, L clutch (check clutch slip)

When
. is displayed.

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Go to Troubleshooting A-7b.

b-3) Inspecting transmission output shaft speed signal system, 1-4, R clutch (check clutch slip)

When
~ is displayed.

Go to troubleshooting of A-7a.

A-14 b) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-59


A-15 When fill switch signal is not input
(flow detector valve)
~

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Carry out troubleshooting of A-13 b-1) Fill switch signal.
Respond to the display as follows: 5.2 ↔ 4.2
5.3 ↔ 4.3
5.4 ↔ 4.4
5.5 ↔ 4.5
5.6 ↔ 4.6
5.7 ↔ 4.7
5.8 ↔ 4.8

A-15 Related electrical circuit diagram

D5-60 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-16 Short circuit in pressure control
valve solenoid is displayed

Disconnection in pressure control valve


solenoid is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Table 1
Display Measurement location
7.2 Trouble-shooting 1 Toubleshooting 2 Measurement item Normal value
9.2
7.3 Between ATC1 (9) - (19) Between HPS (1) - (2) Resistance 5 - 25 Ω
9.3 between (1) - (2)
7.4 Between ATC2 (7) - (17) Between 1 PS (1) - (2)
9.4
7.5 Between ATC2 (4) - (15) Between 2 PS (1) - (2) Resistance between >1MΩ
9.5 (2) - chassis ground
7.6 Between ATC2 (3) - (13) Between 3 PS (1) - (2)
9.6
7.7 Between ATC2 (8) - (18) Between 4 PS (1) - (2)
9.7
7.8 Between ATC2 (5) - (15) Between RPS (1) - (2)
9.8

Table 2
Display Measurement location Measurement item Normal value
Troubleshooting 1 Troubleshooting 2 Resistance between (1) - (2) 30 - 80 Ω
7.1 Between ATC1(1) - Between LCT(1) - Resistance between (2) - chassis ground >1MΩ
9.1 (8) (16) (2)

* b0 [E., E.C] is omitted from the Display column.

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-61


A-16 Related electrical circuit diagram

D5-62 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-17 Fault in sensor circuits

a) Fault in torque converter oil temperature sensor is displayed

• When the controller power source is normal.


• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-17 a) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-63


b) Fault in fuel level sensor is displayed

(It takes 30 seconds for the fuel gauge to change 1 level. Take this into account when carrying out troubleshooting).
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-17 b) Related electrical circuit diagram

D5-64 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


c) Fault in cooling water temperature sensor is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-17 c) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-65


d) Fault in air pressure sensor is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-17 d) Related electrical circuit diagram

D5-66 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


e) Fault in retarder brake oil temperature sensor is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-17 e) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-67


A-18 Warning display

a) Transmission filter clogged warning is displayed

• Before carrying out troubleshooting, check that the transmission oil filter is not clogged.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 a) Related electrical circuit diagram

D5-68 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


b) Tilt warning is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 b) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-69


c) Drop in radiator water level warning is displayed

• Before carrying out troubleshooting, check that the cooling water level is not low.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 c) Related electrical circuit diagram

D5-70 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


d) Battery charge warning is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 d) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-71


e) Steering oil temperature overheat warning is displayed

• Before carrying out troubleshooting, check if the steering oil temperature is high.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 e) Related electrical circuit diagram

D5-72 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


f) Drop in engine oil pressure warning is displayed

• Before carrying out troubleshooting, check if the engine oil pressure is low.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 f) Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-73


g) Rear brake oil pressure warning is displayed

• Before carrying out troubleshooting, check if the rear brake chamber has reached the end of its stroke.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-18 g) Related electrical circuit diagram

D5-74 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-19 Fault in engine oil pressure sensor is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-19 Related electrical circuit diagram

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-75


A-20 Fault in connector connection is displayed

• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

A-20 Related electrical circuit diagram

D5-76 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


A-21

a) Torque converter oil temperature overheat warning is displayed

• This shows that there had been an abnormal rise in the torque converter oil temperature.
• If the rise in the torque converter oil

b) Engine water temperature overheat warning is displayed

• This shows that there has been an abnormal rise in the engine water temperature.
• If the rise in the engine water temperature is abnormal, see the engine Shop Manual.

c) Air pressure drop warning is displayed

• This shows that there has been an abnormal drop in the air pressure.
• If the drop in the air pressure is abnormal, carry out troubleshooting H-18.

d) Retarder brake oil temperature overheat warning is displayed

• This shows that there had been an abnormal rise in the retarder brake oil temperature.
• If the rise in the retarder brake oil temperature is abnormal, see the Operation and Maintenance Manual.

D05007 06/07 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM D5-77


e) Engine overrun actuated is displayed

• This shows that the engine overrun prevention had been actuated to protect the transmission.

f) Engine overshoot actuated is displayed

• This shows that there has been engine overshoot (sudden spurt).

D5-78 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 06/07 D05007


MONITOR PANEL TROUBLESHOOTING
(P - Diagnostic Flow Charts)

Monitor panel and controller self-diagnostic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-3


Action taken by self-diagnostic device and problems on truck (monitor panel system) . . . . . . . . . . . . D6-4
P-1 Check pattern for wiring harnesses between modules . . . . . . . . . . . . . . . . . . . . . . . . . D6-8
P-2 Nothing on monitor panel works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-11
P-3 LH, RH module and fuel gauge do not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-12
P-4 LH, RH module and fuel gauge do not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-13
P-5 RH module does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-14
P-6 LH module does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D6-15
. .
P-7 Odometer does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-16
P-8 Service meter display does not operate correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-17
P-9 Central warning lamp does not operate, or monitor panel detects fault code [A002] . . . . . . . . . D6-18
P-10 Central warning lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-19
P-11 Alarm buzzer does not operate , or monitor panel detects failure code [A003] . . . . . . . . . . . . D6-20
P-12 Alarm buzzer continues to sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-21
P-13 All data from shift controller (speedometer, tachometer, shift indicator, etc.) are abnormal
(nothing is displayed, or display does not change), or monitor panel detects service code [A018] . D6-22
P-14 Suspension mode power/economy mode displays are abnormal (nothing is displayed or
display does not change), or monitor panel detects service code [A016] . . . . . . . . . . . . . . . D6-23
P-15 Gauge displays are abnormal (nothing is displayed, or display does not change) . . . . . . . . . . . D6-24
P-16 Cooling water level drop caution lamp does not operate,
or monitor panel detects service code [A001] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-25
P-17 Cooling water level drop caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-26
P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code [A001] . . . D6-27
P-19 Emergency steering pilot lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-28
P-20 Engine oil pressure drop caution lamp does not operate, or
monitor panel detects service code [A001] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-29
P-21 Engine oil pressure drop caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-30
P-22 Exhaust brake pilot lamp does not operate, or monitor panel detects service code [A001] . . . . . . D6-31
P-23 Exhaust brake pilot lamp (optional) stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-32
P-24 Charging circuit fault caution lamp does not operate, or monitor panel detects service code [A001] . D6-33
P-25 Charging circuit fault caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-34
P-26 Transmission filter clogging caution lamp does not operate, or monitor panel detects
service code [A001] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-35
P-27 Transmission filter clogging caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . D6-36
P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code [A001] . . . . . D6-37

D06003 10/00 Monitor Panel Troubleshooting D6-1


P-29 Brake stroke caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-38
P-30 Preheating switch pilot lamp does not operate, or monitor panel detects service code [A001] . . . . D6-39
P-31 Preheating switch pilot lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-40
P-32 Tilt warning lamp does not operate, or monitor panel detects service code [A001] . . . . . . . . . D6-41
P-33 Tilt warning lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-42
P-34 Body FLOAT (except FLOAT) pilot lamp does not operate,
or monitor panel detects service code [A001] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-43
P-35 Body FLOAT (except FLOAT) pilot lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . D6-44
P-36 Rear brake pilot lamp does not operate, or monitor panel detects service code [A001] . . . . . . . D6-45
P-37 Rear brake pilot lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-46
P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code [A001] . . . . . . D6-47
P-39 Parking brake pilot lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-48
P-40 Maintenance caution lamp does not operate, or monitor panel detects service code [A001] . . . . D6-49
P-41 Maintenance caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-50
P-42 Steering oil temperature caution lamp does not operate,
or monitor panel detects service code [A001] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-51
P-43 Steering oil temperature caution lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-52
P-46 High beam display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-53
P-47 Turn signal lamp (right) does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-55
P-48 Turn signal lamp (left) does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-56
P-49 Lamp check switch does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-57
P-50 AISS switch does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-58
P-51 Exhaust brake switch (optional) does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . D6-59
P-52 Mode change switch (1) does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-60
P-53 Mode change switch (2) does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-61
P-54 KPH/MPH speedometer unit selector does not operate . . . . . . . . . . . . . . . . . . . . . . . D6-62
P-55 Improper operation of all switch inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-63
P-56 Monitor panel detects service codes [A014] or [A019] . . . . . . . . . . . . . . . . . . . . . . . . D6-64
P-58 Monitor panel detects service code [A011] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-65
P-59 Monitor panel detects service code [A012] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-65
P-60 Monitor panel detects service code [A000] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-65

D6-2 Monitor Panel Troubleshooting D06003 10/00


MONITOR PANEL AND CONTROLLER
SELF-DIAGNOSTIC DISPLAY
1. After the key switch is turned ON, all lamps light 3. Press the caution and pilot lamp bulb check switch
for 3 seconds during the monitor self-diagnostic at the right side of the dash to verify bulb operation
test.
2. Refer to Monitor Panel Action Codes and Service
Mode Function for the displays indicating a fault
has occurred in any controller or the monitor
panel itself.

SERVICE
No. CODE FAILURE DESCRIPTION DISPLAY CONDITIONS
Display conditions, display in service code,
1 A000 Short circuit in output
trouble data display mode.
2 A001 Short circuit in lamp output
Display when lamp check switch is pressed
3 A002 Short circuit in central warning lamp output for at least 2.5 seconds and then released.
4 A003 Short circuit in alarm buzzer output
Display in service code, trouble data display
5 A011 Fault in network
mode
Network system connection data does not
6 A012
match
7 A013 Fault in network — transmission controller
8 A014 Fault in network — PMC Display when lamp check switch is pressed
for at least 2.5 seconds and then released.
9 A015 Fault in network — engine controller
10 A016 Fault in network — suspension controller
11 A018 Fault in model selection data
12 A019 Fault in option data
13 A021 Abnormal drop in air pressure
Engine cooling temperature overheat
14 A022
warning
Torque converter oil temperature overheat
15 A023
warning
16 A024 Brake oil temperature overheat warning

SELF-DIAGNOSTIC SERVICE CODE TABLE

D06003 10/00 Monitor Panel Troubleshooting D6-3


ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON TRUCK
MONITOR PANEL SYSTEM

FAULT TROUBLESHOOTING
CODE FAULT CONDITION POSSIBLE CAUSE NOTE: Check wiring harness circuits and components listed below for
short circuit, open circuit, etc.
1. Fault between lamp (+) and monitor panel. (Refer to P-16, 18, 20, 22,
A001 Short circuit in lamp output Short circuit in output 24, 26, 28, 30, 32, 34, 36, 38, 40, 42 for troubleshooting details.)
2. Defective lamp
1. Between (+) DP08 pin 2 and WL pin 2.
Short circuit in Central
A002 Warning Lamp output Short circuit in output 2. Defective central warning lamp

1. Between (+) DP08 pin 2 and BZ pin 2.


Short circuit in alarm buzzer
A003 output Short circuit in output 2. Defective alarm buzzer

1. Incorrect shift controller model selection setting


Network system fault Connection data does
A012 not match

1. Between (+) DP05 pin 3, TMD pin 10, and ATC4 pin 6.
2. Between (+) DP05 pin 4, TMD pin 12, and ATC4 pin 12.
3. Between (-) DP05 pin 5, TMD pin 9, and ATC4 pin 10.
Transmission 4. Between (-) DP05 pin 5, TMD pin 11, and ATC4 pin 10.
A013 Network system fault Controller system 5. Defective shift controller

1. Between (+) DP05 pin 3 and PMC pin 1.


2. Between (+) DP05 pin 4 and PMC pin 2.
A014 Network system fault PMC system 3. Between (-) DP05 pin 5 and PMC pin 3.
4. Defective PMC

1. Between (+) DP05 pin 3, SU3 pin 9, and SSP1 pin 1.


2. Between (+) DP05 pin 4, SU3 pin 13, and SSP1 pin 12.
Suspension 3. Between (-) DP05 pin 5, SU3 pin 12, and SSP2 pin 9.
A016 Network system fault Controller 4. Between (-) DP05 pin 5, SU3 pin 14, and SSP2 pin 9.
5. Defective Suspension Controller

1. Incorrect Shift Controller model selection setting.


2. Between (+) DP05 pin 3, TND pin 10, and ATC4 pin 6.
3. Between (+) DP05 pin 4, TND pin 12, and ATC4 pin 12.
4. Between (-) DP05 pin 5, TND pin 9, and ATC4 pin 10.
A018 Network system fault Model selection data 5. Between (-) DP05 pin 5, TND pin 11, and ATC4 pin 20.
6. Defective Shift Controller.

1. Between (+) DP05 pin 3 and PMC pin 1.


2. Between (+) DP05 pin 4 and PMC pin 2.
A019 Network system fault Option data 3. Between (+) DP05 pin 5 and PMC pin 3.
4. Defective PMC.

D6-4 Monitor Panel Troubleshooting D06003 10/00


CONDITION WHEN NORMAL CONTROLLER ACTION TRUCK SYMPTOMS
NOTE: Use a DMM to verify voltage or
WHEN FAULT IS DETECTED WHEN FAULT IS PRESENT
resistance values listed below.
1. Other mechatronics caution lamp flashes.
Lamp ON: Voltage between monitor panel
2. Displays action code. Applicable lamp always OFF.
connector and chassis ground: <0.1 volts
3. Applicable lamp forcibly turned OFF.
Central Warning Lamp ON: Voltage 1. Other mechatronics caution lamp flashes.
between DP08 pin 1 and WL pin 2 <0.1 2. Displays action code. Central Warning Lamp always OFF.
volts. 3. Central Warn. Lamp forcibly turned OFF.
1. Other mechatronics caution lamp flashes.
Buzzer ON: Voltage between DP08 pin 2
2. Displays action code. Buzzer does not sound.
and BZ pin 2 <0.1 volts.
3. Alarm buzzer forcibly stopped.
1. Other mechatronics caution lamp flashes. If the setting is for a truck with the electronic
Shift Controller model selection setting
governor specification, engine output will
and actual mounting condition of
2. Displays action code. decrease and engine speed may not
Controller in network match.
increase.
1. Resistance between (+) DP05 pin 3, 1. Other mechatronics caution lamp flashes.
TMD pin 10, ATC4, pin 6 is 0 ohms.
2. Resistance between (+) DP05 pin 4, 2. Displays action code. For trucks with electronic governor
TMD pin 12, ATC4, pin 12 is 0 ohms. specification, the engine mode switching,
3. Display is fixed for all data from Transmission the engine mode selection, or AISS may
3. Resistance between (-) DP05 pin 5,
Controller (speedometer, tachometer, gauges, not work. Engine output may be reduced or
TMD pin 9, ATC4, pin 10 is 0 ohms. speed may not increase.
etc.)
4. Resistance between (-) DP05 pin 5,
TMD pin 11, ATC4, pin 10 is 0 ohms.
1. Resistance between (+) DP05 pin 3 1. Other mechatronics caution lamp flashes.
and PMC pin 1 is 0 ohms. MOM may not function properly at times.
2. Resistance between (+) DP05 pin 4 2. Displays action code. For trucks with electronic governor
and PMC pin 2 is 0 ohms. specification, the engine output may be
3. Resistance between (-) DP05 pin 5 and reduced or the speed may not increase.
PMC pin 3 is 0 ohms.
1. Resistance between (+) DP05 pin 3, 1. Other mechatronics caution lamp flashes.
SU3 pin 9, SSP1 pin 2 is 0 ohms.
2. Resistance between (+) DP05 pin 4, 2. Displays action code.
SU3 pin 13, SSP1 pin 12 is 0 ohms. In some cases, suspension control is
3. Resistance between (-) DP05 pin 5, 3. Suspension mode display does not change or inoperable.
SU3 pin 12, SSP2 pin 9 is 0 ohms. all lamps go out.
4. Resistance between (-) DP05 pin 5,
SU3 pin 14, SSP2 pin 9 is 0 ohms.
1. Shift Controller model selection setting 1. Other mechatronics caution lamp flashes.
is correct.
2. Resistance between (+) DP05 pin 3, 2. Displays action code.
TND pin 10, ATC4 pin 6 is 0 ohms. In some cases, the transmission may
3. Resistance between (+) DP05 pin 4, remain in neutral or the engine may remain
3. In addition to 1 & 2, only the speed unit, turn
TND pin 12, ATC4 pin 12 is 0 ohms. at low idle.
signal lamp, and high beam pilot lamp are
4. Resistance between (-) DP05 pin 5, displayed.
TND pin 9, ATC4 pin 10 is 0 ohms.
5. Resistance between (-) DP05 pin 5,
TND pin 11, ATC4 pin 10 is 0 ohms.
1. Resistance between (+) DP05 pin 3
1. Other mechatronics caution lamp flashes.
and PMC pin 1 is 0 ohms. MOM may not function properly. For trucks
2. Resistance between (+) DP05 pin 4 with electronic governor specification, the
2. Displays action code. engine output may be reduced or speed
and PMC pin 2 is 0 ohms.
3. Resistance between (+) DP05 pin 5 may not increase.
and PMC pin 3 is 0 ohms.

D06003 10/00 Monitor Panel Troubleshooting D6-5


FAULT
CODE FAULT CONDITION POSSIBLE CAUSE
TROUBLESHOOTING

A004 Fault in engine control Refer to “Electrical Troubleshooting”.

A005 Fault in engine control Refer to “Electrical Troubleshooting”.

A006 Fault in engine control Refer to “Electrical Troubleshooting”.

D6-6 Monitor Panel Troubleshooting D06003 10/00


CONTROLLER ACTION TRUCK SYMPTOMS
CONDITION WHEN NORMAL
WHEN FAULT IS DETECTED WHEN FAULT IS PRESENT
1. Engine mechatronics caution lamp flashes. In some cases, the engine may not start.
2. Displays action code. Engine output may be reduced or the speed
3. Engine Stop Lamp (red) flashes. may not increase.
1. Engine mechatronics caution lamp flashes. In some cases, the engine may not start.
2. Displays action code. Engine output may be reduced or the speed
3. Engine Protection Lamp (blue) flashes. may not increase.
1. Engine mechatronics caution lamp flashes. In some cases, the engine may not start.
2. Displays action code. Engine output may be reduced or the speed
3. Engine Check Lamp (yellow) flashes. may not increase.

D06003 10/00 Monitor Panel Troubleshooting D6-7


TROUBLESHOOTING

P-1 Check pattern for wiring harnesses between modules

NOTE: When troubleshooting the monitor panel, if the The following instructions must be followed when trou-
item in the troubleshooting flow chart or the item in the bleshooting the monitor panel and associated compo-
“remedy” column indicates “carry out check of wiring nents and wire harnesses:
harnesses between modules”, refer to the number
• Be certain all harnesses are properly inserted in
displayed in the following tables and check the female
the mating connectors.
connector of the wiring harnesses between modules.
• Before removing any harness connector, be cer-
tain the key switch is in the OFF position.
• The key switch must remain in the OFF position
when performing the following checks on the wir-
ing harnesses.
Be certain truck wheels are blocked to prevent • Visually inspect harnesses and connectors for
movement during troubleshooting procedures. physical damage, insulation cracks, pin damage
etc.

X Y
No. SIGNAL NAME
CONNECTOR PIN No. CONNECTOR PIN No.
DP11 1
A-1 1 VB (20V)
DP04 1
A-2 2 LCD TX OUT DP10 3
A-3 3 LCD TX IN DP04 4
DP10 4
A-4 4 SCK
DP04 5
DP10 5
A-5 5 LCD LOAD
DP02 DP04 6
DP10 6
A-6 6 LCD COM
DP04 7
DP10 7
A-7 7 RESET DP04 8
DP12 4
DP10 8
DP11 2
A-8 8 GND DP08 16
DP05 12
DP12 2
A-9 1 P/S DATE DP04 3
DP10
A-10 2 SHIFT/LOAD DP04 2

TABLE a. WIRING HARNESS CONTINUITY CHECK


NOTE: Circuit between “X” and “Y” connector must have continuity.

D6-8 Monitor Panel Troubleshooting D06003 10/00


No. CONNECTOR PIN No. SIGNAL NAME
B-1 1 VB (20V)
B-2 2 LCD TX OUT
B-3 3 LCD TX IN
DP02
B-4 4 SCK
B-5 5 LCD LOAD
B-6 6 LCD COM
B-7 7 RESET
B-8 1 P/S DATE
DP10
B-9 2 SHIFT/LOAD

TABLE b. WIRING HARNESS GROUND CHECK


NOTE: Above circuits must be isolated from chassis ground.

D06003 10/00 Monitor Panel Troubleshooting D6-9


X Y
No. SIGNAL NAME
CONNECTOR PIN No. CONNECTOR PIN No.
C-1 DP05 12
C-2 1
C-3 2
C-4 POWER 3
C-5 DP05 6 SUPPLY DP02 4
C-6 (+24V) 5
C-7 6
C-8 7
C-9 8
C-10 1
DP10
C-11 2
C-12 2
C-13 3
C-14 DP02 4
C-15 DP02 1 VB(20V) 5
C-16 6
C-17 7
C-18 1
DP10
C-19 2
C-20 3
C-21 4
C-22 DP02 5
DP02 2 LCD TX OUT
C-23 6
C-24 7
C-25 1
DP10
C-26 2
C-27 4
C-28 DP02 5
C-29 DP02 3 LCD TX IN 6
C-30 7
C-31 1
DP10
C-32 2
C-33 5
C-34 DP02 6
C-35 DP02 4 SCK 7
C-36 1
DP10
C-37 2
C-38 6
DP02
C-39 DP02 5 LCD LOAD 7
C-40 1
DP10
C-41 2
C-42 DP02 7
C-43 DP02 6 LCD COM 1
DP10
C-44 2
C-45 1
DP02 7 RESET DP10
C-46 2
C-47 DP10 1 P/S DATE DP10 2
TABLE c. HARNESS SHORT CIRCUIT CHECK
NOTE: No continuity should exist between “X” and “Y”

D6-10 Monitor Panel Troubleshooting D06003 10/00


P-2 Nothing on Monitor Panel Operates

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.
• Refer to P-1 for Table b.

D06003 10/00 Monitor Panel Troubleshooting D6-11


P-3 LH, RH Module and fuel gauge do not operate

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.
• Refer to P-1 for Table b.

D6-12 Monitor Panel Troubleshooting D06003 10/00


P-4 LH, RH Module and fuel gauge do not operate

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.
• Refer to P-1 for Table a or b.

D06003 10/00 Monitor Panel Troubleshooting D6-13


P-5 RH Module does not operate

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.
• Refer to P-1 for Table a.

D6-14 Monitor Panel Troubleshooting D06003 10/00


P-6 LH module does not operate
• Before troubleshooting, verify all connectors related to the wiring har-
nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.
• Refer to P-1 for Table a and b.

D06003 10/00 Monitor Panel Troubleshooting D6-15


P-7 Odometer does not operate

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-16 Monitor Panel Troubleshooting D06003 10/00


P-8 Service meter does not operate correctly

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D06003 10/00 Monitor Panel Troubleshooting D6-17


P-9 Central Warning Lamp does not operate, or monitor panel detects
fault code (monitor panel display) [A002]

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-18 Monitor Panel Troubleshooting D06003 10/00


P-10 Central warning lamp stays ON

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D06003 10/00 Monitor Panel Troubleshooting D6-19


P-11 Alarm buzzer does not operate. or Monitor Panel detects
fault code A003:

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-20 Monitor Panel Troubleshooting D06003 10/00


P-12 Alarm buzzer continues to sound

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D06003 10/00 Monitor Panel Troubleshooting D6-21


P-13 All data from Shift Controller (speedometer, tachometer, shift
indicator, etc.) is faulty (nothing is displayed, or display does not
change), or
Monitor Panel
detects service code
A013: or service
code A0018:
• Before troubleshooting, verify all connectors re-
lated to the wiring harnesses between the mod-
ules are properly inserted.
• Always connect any disconnected connectors be-
fore going on to the next step.

D6-22 Monitor Panel Troubleshooting D06003 10/00


P-14 Suspension mode, power/economy mode displays are
faulty(nothing is displayed, or display does not change), or
Monitor Panel detects
service code A016:
• Before troubleshooting, verify all
connectors related to the wiring har-
nesses between the modules are
properly inserted.
• Always connect any disconnected
connectors before going on to the
next step.

D06003 10/00 Monitor Panel Troubleshooting D6-23


P-15 Gauge displays are faulty (nothing is displayed or display does not
change)
• Before troubleshooting, verify all connectors related to the wiring har-
nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.
• Refer to P-1 for Tables a and b.

D6-24 Monitor Panel Troubleshooting D06003 10/00


P-16 Cooling water level drop caution lamp does not operate, or Monitor
Panel detects service code A001:

• Before troubleshooting, verify all


connectors related to the wiring har-
nesses between the modules are
properly inserted.
• Always connect any disconnected
connectors before going on to the
next step.

D06003 10/00 Monitor Panel Troubleshooting D6-25


P-17 Cooling water level drop caution lamp stays ON

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-26 Monitor Panel Troubleshooting D06003 10/00


P-18 Emergency steering pilot lamp does not operate, or monitor panel
detects service code A001:

• Before troubleshooting, verify all


connectors related to the wiring har-
nesses between the modules are
properly inserted.
• Always connect any disconnected
connectors before going on to the
next step.

D06003 10/00 Monitor Panel Troubleshooting D6-27


P-19 Emergency steering pilot lamp stays ON

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-28 Monitor Panel Troubleshooting D06003 10/00


P-20 Engine oil pressure drop caution lamp does not operate, or monitor
panel detects service code
A001:
• Before troubleshooting, verify all
connectors related to the wiring har-
nesses between the modules are
properly inserted.
• Always connect any disconnected
connectors before going on to the
next step.

D06003 10/00 Monitor Panel Troubleshooting D6-29


P-21 Engine oil pressure drop caution lamp stays on.

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-30 Monitor Panel Troubleshooting D06003 10/00


P-22 Exhaust brake (Optional) pilot lamp does not operate, or monitor
panel detects service code A001:

• Before troubleshooting, verify all connec-


tors related to the wiring harnesses be-
tween the modules are properly inserted.
• Always connect any disconnected connec-
tors before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-31


P-23 Exhaust brake pilot lamp stays on (Optional)

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-32 Monitor Panel Troubleshooting D06003 10/00


P-24 Charging circuit fault caution lamp does not operate. or monitor
panel detects service code A001:

• Before troubleshooting, verify all connectors


related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connectors
before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-33


P-25 Charging circuit fault caution lamp stays ON

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-34 Monitor Panel Troubleshooting D06003 10/00


P-26 Transmission filter clogging caution lamp does not operate, or
monitor panel detects
service code A001:

• Before troubleshooting, verify all connec-


tors related to the wiring harnesses be-
tween the modules are properly inserted.
• Always connect any disconnected con-
nectors before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-35


P-27 Transmission filter clogging caution lamp stays ON

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-36 Monitor Panel Troubleshooting D06003 10/00


P-28 Brake stroke caution lamp does not operate, or
monitor panel detects
service code A001:
• Before troubleshooting, verify all
connectors related to the wiring har-
nesses between the modules are
properly inserted.
• Always connect any disconnected
connectors before going on to the
next step.

D06003 10/00 Monitor Panel Troubleshooting D6-37


P-29 Brake stroke caution lamp stays on

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-38 Monitor Panel Troubleshooting D06003 10/00


P-30 Preheating switch pilot lamp does not work, or monitor panel
detects service code A001:
• Before troubleshooting, verify all connec-
tors related to the wiring harnesses be-
tween the modules are properly inserted.
• Always connect any disconnected con-
nectors before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-39


P-31 Preheating switch pilot lamp stays on.

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-40 Monitor Panel Troubleshooting D06003 10/00


P-32 Tilt warning lamp does not operate, or monitor panel detects
service code A001:

• Before troubleshooting,
verify all connectors related
to the wiring harnesses be-
tween the modules are
properly inserted.
• Always connect any discon-
nected connectors before
going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-41


P-33 Tilt warning lamp stays on.

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-42 Monitor Panel Troubleshooting D06003 10/00


P-34 Body FLOAT (except FLOAT) pilot lamp does not operate, or
monitor panel detects service code A001:

• Before troubleshooting, verify all connectors


related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connec-
tors before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-43


P-35 Body FLOAT (except FLOAT) pilot lamp stays on.

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-44 Monitor Panel Troubleshooting D06003 10/00


P-36 Rear brake pilot lamp does not work, or monitor panel detects
service code A001:
• Before troubleshooting, verify all con-
nectors related to the wiring harnesses
between the modules are properly in-
serted.
• Always connect any disconnected con-
nectors before going on to the next
step.

D06003 10/00 Monitor Panel Troubleshooting D6-45


P-37 Rear brake pilot lamp stays on

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-46 Monitor Panel Troubleshooting D06003 10/00


P-38 Parking brake pilot lamp does not operate, or monitor panel detects
service code A001:
• Before troubleshooting, verify all connec-
tors related to the wiring harnesses be-
tween the modules are properly inserted.
• Always connect any disconnected con-
nectors before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-47


P-39 Parking brake pilot lamp stays on

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-48 Monitor Panel Troubleshooting D06003 10/00


P-40 Maintenance caution lamp does not operate, or monitor panel
detects service code A001:

• Before troubleshooting, verify all connectors


related to the wiring harnesses between the
modules are properly inserted.
• Always connect any disconnected connec-
tors before going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-49


P-41 Maintenance caution lamp stays on

• Before troubleshooting, verify all connectors related to the wiring har-


nesses between the modules are properly inserted.
• Always connect any disconnected connectors before going on to the next
step.

D6-50 Monitor Panel Troubleshooting D06003 10/00


P-42 Steering oil temperature caution lamp does not operate, or monitor
panel detects service code A001:

• Before troubleshooting, verify all connectors re-


lated to the wiring harnesses between the mod-
ules are properly inserted.
• Always connect any disconnected connectors be-
fore going on to the next step.

D06003 10/00 Monitor Panel Troubleshooting D6-51


P-43 Steering oil temperature caution lamp stays on
• Before troubleshooting, verify all connectors related to the wiring har-
nesses between the modules are properl