Service Maunal 2306D 2806D MK 5 SM

ARTICULATED HAULER
Mk V
SERVICE MANUAL
Document Part Number 872272
THIS MANUAL IS APPLICABLE TO :
2806D HAULER
2306D HAULER
Revision 0: November 2009
IMPORTANT: Due to BELL EQUIPMENT’S policy of

continuous product improvement, the information contained in
this manual was correct up to the time of printing (Revised date
of manual). Any changes after this date will only be included in
the next update of this manual. The illustrations in this manual
are pictorial and not necessarily true representations of
components. Photographs and illustrations may show optional
Technical Services: Documentation Unit

Bell Equipment Company (Pty) Ltd
Richards Bay
SERVICE MANUAL MK V 2806D-2306D
2 Doc. No. 872272 : Rev 0

2806D-2306D SERVICE MANUAL MK V
TO THE SERVICE PERSONNEL

‹ WARNING
Do not operate the machine unless you have read the Operator’s Manual and fully understand
how to operate the machine properly.
This manual is written for an experienced technician and are on-the-job guides containing only the vital
information needed for diagnosis, analyses, testing and repair. Essential tools required in performing
certain service works are identified and in this manual and are recommended for use.
The safe operation of your BELL EQUIPMENT machines very important to prevent any personal injury
and/ or damage. This manual must be read and fully understood before carrying out any tests on your
BELL EQUIPMENT machine.
Right and left hand sides are determined by facing in the direction of forward travel.
This manual is divided into chapters. The information contained in the manual is in logical sequence, with
the instructions written in step by step format.
Effective maintenance on your BELL EQUIPMENT machine is achieved when personnel fully understand
the information contained in this manual.
Every effort has been made to ensure that the information contained in this manual was correct at the
time of publication. BELL EQUIPMENT Co. has a policy of continuous product development,
improvement, and design. BELL EQUIPMENT Co. reserves the right to change, amend and update the
design of its product at any time without prior notice. With this policy, changes may have occurred that
are not included in this manual.
Doc. No. 872272 : Rev 0 3

SAFETY SYMBOL
The following safety symbol is used for all safety messages. When you see the safety symbol, follow the
safety message to avoid personal injury or death.
WARNINGS and CAUTIONS must be read, fully understood and followed, before carrying out the action
or maintenance procedure concerned.
WARNINGS and CAUTIONS are always placed before any action or maintenance procedure where
personal injury and/or damage to the machine could occur if that action, test or maintenance procedure is
not carried out correctly.
WARNING AND CAUTION SYMBOL
Throughout this manual the word WARNING is used to alert the operator and others of the risk of
personal injury during the operation of the equipment. CAUTION indicates the possible damage to the
machine. NOTE highlights information of special interest.
‹ WARNING
Diesel engine exhaust and some of its constituents are known to the state of California to cause
Cancer, birth Defects and other Reproductive Harm.
4 Doc. No. 872272 : Rev 0

ABBREVIATION LIST
The table below lists the abbreviations used in this manual:
Abbreviation Meaning Abbreviation Meaning

ºC degrees Celsius Nm Newton metre
ºF degrees Fahrenheit psi pounds per square inch
A ampere PTO Power Take-Off
ADT Articulated Dump Truck R Reverse
Ah ampere hours r.p.m. revolutions per minute
CB circuit breaker ROPS Roll Over Protective

Structure
d diagnostic
SMR Service Meter Reading
D drive
SS Single Speed
DNS Do Not Shift
SSM Sealed Switch Module
ECU Electronic Control Unit
USGAL United States Gallon
FOPS Falling Objects Protective
Structure V Volt
ft foot (feet) yd³ cubic yard
ft lb foot pound OBW On Board Weighing
HP Horsepower
ISO International Standards

Organisation
kg kilogram
km kilometre
km/hr kilometres per hour
kPa kilo pascal
kW kilowatt
lb pound
LCD Liquid Crystal Display
LED Light Emitting Diode
m³ cubic metre
N Neutral
m.p.h. miles per hour
MSDS Material Safety Data

Sheet
Doc. No. 872272 : Rev 0 5

The table below is a record of amendments made to this manual after the publication date.
Amendment Record Sheet

Page No’s. Page amended/
Amendment Date
Replaced Pages Inserted By
6 Doc. No. 872272 : Rev 0

INTRODUCTION
‹ WARNING
All specifications in this manual apply to a standard machine as supplied by the factory and any
modifications done to the machine such as greedy boards, etc. will result in different
specifications and we as OEM cannot take responsibility for this.
Read this manual carefully for it has been produced to assist you in the correct operation, maintenance
and care of your BELL EQUIPMENT machine. Failure to do so could result in personnel injury or
equipment damage.
Right and left hand sides are determined by facing in the direction of forward travel.
Warranty is provided as part of BELL EQUIPMENT’S support program for customers who operate and
maintain their equipment as described in this manual. The warranty is explained on the warranty
certificate which you should have received from your dealer.
Should the equipment be abused, or modified to change its performance beyond the original factory
specifications, the warranty will become void and field improvements may be denied.
This manual is divided into chapters. The information contained in the manual is in logical sequence, with
the instructions written in step by step format.
Effective maintenance on your BELL EQUIPMENT machine is achieved when personnel fully understand
the information contained in this manual.
Every effort has been made to ensure that the information contained in this manual was correct at the
time of publication. BELL EQUIPMENT Co. has a policy of continuous product development,
improvement, and design. BELL EQUIPMENT Co. reserves the right to change, amend and update the
design of its product at any time without prior notice. With this policy, changes may have occurred that
are not included in this manual.
Whilst every endeavour has been made to provide accurate and reliable information, BELL EQUIPMENT
Co. specifically disclaims any actual or implied warranty and under no circumstances shall be liable for
any loss, damage or injury to person or property suffered, whether direct, indirect or consequential,
arising from the use of this manual. In particular and without detracting from above, the disclaimer also
applies in the event of any specification, warning, or representation contained in this manual being
inadequate, inaccurate, or unintentionally misleading.
The user is urged to strictly comply with the instructions and warnings that are given in the interests of
general safety. Please do not hesitate to contact your BELL EQUIPMENT Product Support
Representative whenever you have a query on your BELL EQUIPMENT product or this manual.
See OM for address list.
Doc. No. 872272 : Rev 0 7

8 Doc. No. 872272 : Rev 0

SAFETY
SPECIFICATION
This machine complies to the CE Specification.
SAFETY FEATURES
TD0006775
1. ROPS/FOPS Cab Protection. 7. Articulation locking Bar (on left side of

The Roll Over Protective Structure has been machine).
certified to meet specified test requirements 8. Horn.
according to SAE J1040 and ISO 3471. The
Falling Objects Structure has been certified to 9. Halogen Lights and Turn Signals.
meet specified test requirements according to SAE 10. Secondary steering.
J/ISO 3449 and ISO 3449.
Ground driven, continuously in operation.
2. Cab with Heater/Defroster. Secondary steering indicator light will light when
Positive pressure ventilation system circulates activated.
both outside and inside air through filters for a 11. Engine Fan Guard.
clean working environment. Built in defroster vents
direct air flow for effective window de-fogging/ 12. Bypass Start Protection.
de-icing. 13. Exhaust Brake and Transmission
3. Stop/Back lights. Highly visible lights. Retarder (If Equipped).
4. Body service lock. 14. Safety Belt Retractors.
5. Backup Alarm. 15. Mirrors.
6. Independent Parking Brake. 16. Large Windshield Wiper With Washer.
Doc. No. 872272 : Rev 0 9

MATERIAL SAFETY DATA SHEETS (MSDS)

The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 CFR 1910.1200 and in
some cases, State and Local Right-to-Know laws, may require that specific MSDS be available to the
employees prior to operating this equipment. This may include information on substances contained in
this equipment such as antifreeze, engine oil, battery acid, hydraulic fluid and freon (if equipped with an
air conditioner).
To ensure a prompt response, please be sure to include your return address and ZIP (postal) code, along
with the model, serial number and/or VIN number of your machine.
UNAUTHORISED MODIFICATIONS OF THE ROLL OVER PROTECTIVE

STRUCTURE (ROPS) AND THE FALLING OBJECTS PROTECTIVE
STRUCTURE (FOPS)
Do not make unauthorised modifications or alterations to the ROPS and FOPS such as: welding on
extinguisher brackets, CB aerial brackets, fire suppression systems etc. Unauthorised modifications will
affect the structural limits of the ROPS and FOPS and will void the certification (and increase the risk of
an adverse safety incident.)
The Roll Over Protective Structure has been certified to meet specified test requirements according to
SAE J1040 and ISO 3471. The Falling Objects Protective Structure has been certified to meet specified
test requirements according to SAE J/ISO 3449 and ISO 3449, Level II.
Any planned modification or change must be reviewed in advance by the BELL EQUIPMENT
Engineering Department to determine if the modification or change can be made within the limits of the
certifying tests. It is important that each person in your organisation, including management, be made
fully aware of these rules involving ROPS and FOPS. Whenever anyone sees unauthorised modifications
or changes to a machine’s ROPS or FOPS both the customer and manufacturer must be notified in
writing. The protection offered by ROPS or FOPS will be impaired if they are subjected to structural
damage, is involved in an overturn incident, or is altered in any way and as such ROPS or FOPS must be
replaced, not reused.
LOOSENING OR REMOVAL OF THE ROLL OVER PROTECTIVE

STRUCTURE (ROPS) AND THE FALLING OBJECTS PROTECTIVE
STRUCTURE (FOPS)
Make sure that all parts are installed correctly if the ROPS or FOPS is loosened or removed for any
reason. Once the mounting bolt and nut assembly has been removed or loosened it must be replaced
with new parts as specified in the parts manual. Tighten the mounting bolts to the correct torque
specification as specified in the parts manual. Failure to comply could compromise product safety and
increase the risk to safety. A damaged ROPS or FOPS must be replaced, not reused.
NOISE EMISSION LEVELS

The sound pressure was tested according to ISO 6394 (SAE J/ISO 6394) and the sound power was
tested according to ISO 6393 (SAE J 2102).\plain \par
GENERAL SAFETY
Be sure all operators of this machine understand every safety message. Replace operator’s manual and
safety decals immediately if missing or damaged.
10 Doc. No. 872272 : Rev 0

SAFETY REGULATION Operate Only On Solid Footing
Operate only on solid footing with strength

Every country (State) has its own safety sufficient to support machine. Be alert working
regulations. It is the obligation of the operator to near embankments and excavations. Avoid
know and follow these. This also applies to local working on surfaces that could collapse under
regulations covering different types of work. machine.
Should the recommendations in this manual
deviate from those of your country, your local Use caution when backing up to berms before
safety regulations should be followed. dumping load.
Mounting And Dismounting The Keep Riders Off the Machine

Machine
Always use the handrails and steps provided to

get on and off the machine. Use both hands and
face the machine. Never get on or off a moving
machine. Never jump off the machine. Use a
hand line to pull equipment up onto the platform,
do not climb on or off the machine carrying tools HD0009CFM
or supplies.
Use extra care when mud, snow, or moisture

Do not allow unauthorised personnel on the
present slippery conditions. Keep steps clean
machine.
and free of grease, oil and foreign objects.
Prepare for Emergencies
Avoid Work Site Hazards
GD0017CFM
Keep a first aid kit and fire extinguishers handy

and know how to use them. Inspect and have
your extinguisher serviced as recommended on
its instruction plate. Keep emergency numbers
for doctors, ambulance service, hospital and fire
department near your telephone.
HD0008CFM
Avoid Overhead Power Lines
Never move any part of the machine within 3 m

(10 ft) plus twice the line insulator length, as
serious injury or death may result.
Doc. No. 872272 : Rev 0 11

Avoid Reversing Accidents sparks while refuelling. Always stop the engine
before refuelling the machine and fill the fuel tank
outdoors.
Keep all fuels and lubricants in properly marked

containers and away from all unauthorised
persons. Do not smoke in the storage areas.
Store oily rags and other flammable material in a

protective container, in a safe place.
HD0007CFM Do not weld or flame cut pipes or tubes that have

contained flammable fluids. Clean them
thoroughly with nonflammable solvent before
Make sure all persons are clear of machine path welding or flame cutting them.
before moving the machine. Use mirrors to assist
in checking all round machine. Starting fluid is highly flammable. Keep all sparks
and flames away when using it. To prevent
Keep windows, mirrors and backup alarm clean accidental discharge when storing the
and in good condition. pressurised can, keep the cap on the can and
store it in a cool protected place. Do not burn or
Use a signal person when backing if view is puncture a starting fluid container.
obstructed and/or in close quarters. Keep signal
person in view at all times.
Use prearranged hand signals to communicate.
Handle Chemical Products And Flammable

Fluids Safety
Exposure to hazardous chemicals can cause

serious injury. Under certain conditions,
lubricants, coolants, paints and adhesives used
with this machine may be hazardous.
If uncertain about safe handling or use of these

chemical products, contact your authorized
dealer for a Material Safety Data Sheet (MSDS).
GD0018CFM
Handle fuel with care, as it is highly flammable.

Do not smoke or go near an open flame or
12 Doc. No. 872272 : Rev 0

Clean the Machine Regularly If you spill acid on yourself:
Wait until the engine has cooled before removing • Flush your skin with water.
trash from areas such as the engine, radiator, • Apply baking soda or lime to help neutralise
batteries, hydraulic lines, fuel tank and operators the acid.
cab. Remove any grease, oil or debris build-up.
Keep the machine, especially the walkways and • Flush your eyes with water for 10 - 15 minutes
steps, free of foreign material, such as debris, oil, and get medical attention immediately.
tools and other items which are not part of the
machine. If acid is swallowed:
Prevent Battery Explosions and Acid Burns • Drink large amounts of water or milk.
• Then drink milk of magnesia, beaten eggs, or
vegetable oil.
• Get medical attention immediately.
Wear Protective Equipment
GD0019CFM
The standard battery supplied with the machine

GD0013CFM
is a sealed type that does not need maintenance.
Wear a hard hat, protective glasses and other
Keep sparks and flames away from the batteries.
protective equipment as required by the job
If a non-sealed battery is subsequently installed, conditions. Do not wear loose clothing or
keep sparks and flames away from the batteries. jewellery that can catch on controls or other parts
Use a flashlight to check the battery electrolyte of the machine.
level. Use a voltmeter or hydrometer to check
When you drive connecting pins in or out, guard
battery charge. Never place a metal object
against injury from flying pieces of debris by
across the posts. Always remove the grounded
wearing goggles or protective glasses. Prolonged
(Negative -) battery clamp first and replace it last.
exposure to loud noise can cause impairment or
Do not smoke in areas where batteries are being loss of hearing. Wear a suitable hearing
charged. protective device such as earmuffs or earplugs.
Wear gloves when handling wire rope cable.
Sulphuric acid in battery electrolyte is poisonous
and is strong enough to burn skin, eat holes in Use the Seat Belt
clothing and cause blindness if splashed into the
eyes. Use a seat belt at all times to minimise the
chance of injury in an accident.
Avoid the hazard by:
The seat belt must not be altered or modified in
any way. Such changes can render the belt
• Filling the batteries in a well ventilated area. ineffective and unsafe.
• Wearing eye protection and rubber gloves.
• Avoid breathing fumes when electrolyte is The seat belt is designed and intended for the
added. seat’s occupant to be of adult build and for one
• Avoid spilling or dripping electrolyte. occupant of the seat only.
Doc. No. 872272 : Rev 0 13

Avoid High Pressure Fluids If a solvent or paint stripper is used, wash surface
with soap and water. Remove solvent or paint
Escaping fluid under pressure can penetrate the containers before welding and allow at least 15
skin causing serious injury. Relieve the pressure minutes before welding or heating.
before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure. Dispose of Waste Properly
Keep hands and body away from pinholes and
nozzles which eject fluids under high pressure. Improper disposal of waste can threaten the
Use a piece of cardboard or paper to search for environment. Fuel, oils, coolants, filters and
leaks. batteries used with this machine may be harmful
if not disposed of properly.
If any fluid is injected into the skin it must be
surgically removed within a few hours by a doctor Never pour waste onto the ground, down a drain
who is familiar with this type of injury or gangrene or into any water source.
may result.
Air conditioning refrigerants can damage the
Stay Clear Of Moving Parts atmosphere. Government regulations may
require using a certified service centre to recover
Entanglements in moving parts can cause and recycle used refrigerants.
serious injury.
If uncertain about the safe disposal of waste,
Stop engine before examining, adjusting or contact your local environmental centre or your
maintaining any part of the machine with moving dealer for more information.
parts.
Start Only From Operator’s Seat
Keep guards and shields in place. Replace any
guard or shield that has been removed for
access as soon as service or repair is complete.
‹ WARNING
Never turn the ignition switch On and
Beware of Toxic Fumes immediately OFF again. This will reset the
cranking time and damage to the starter
motor can occur.
GD0020CFM
Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
Operate only in well ventilated indoor areas.

Avoid hazardous fumes by first removing paint on
painted surfaces before welding.
GD0022CFM
Wear an approved respirator when sanding or
grinding painted surfaces.
Avoid unexpected machine movement. Start
engine only while sitting in operator’s seat.
Ensure all controls and working tools are in
proper position for a parked machine.
14 Doc. No. 872272 : Rev 0

Never attempt to start engine from the ground. Servicing

Do not attempt to start engine by shorting across
the starter solenoid terminals.
‹ Warning
Operating The Machine 1. Always install the cab prop when the cab is
raised and ensure that the cab prop is in
secure in one of the stop positions when
Apply park brake during work interruptions and
work or service is to be done under the cab.
be careful not to accidentally actuate controls
Welding Repairs
when co-workers are present.
Avoid Tip Over NOTE: Disable electrical power before

welding. Turn off main battery switch or
Use safety belt at all times. Do not jump from disconnect positive battery cable. Separate
machine if it falls over. Drive slowly, avoid sharp harness connectors to engine, alternator and
turns and uneven ground. vehicle microprocessors.
Do not over load the machine.
Before operating machine after it has fallen over,

carefully inspect all hydraulic and electrical lines.
Operating on Slopes
GD0021CFM
Avoid welding near fluid lines. Do not let heat go

beyond work area near fluid lines.
HD0010CFM Remove paint properly. Wear eye protection and

protective equipment when welding.
Avoid side slope travel whenever possible. Do not inhale dust or fumes.
Check service brakes frequently when operating

on slopes.
The maximum slope will be limited by the ground

conditions.
Doc. No. 872272 : Rev 0 15

Tyre Information
Welding or heating of the rim components, external fire or excessive use of brakes can cause overheating
of the tyres, which could cause a tyre explosion.
This explosion can propel the tyre, rim and final drive components approximately 500 metres (1 640ft)
from the machine, which may cause personal injury or death and/or property damage.
If the tyre is overheating and could explode, do not approach it within the area represented by the shaded
area in the drawing, until it has cooled.
Stand behind the tread and use a self attaching chuck with extension hose to inflate the tyres. Use a
safety cage if available. Do not stand over the tyre.
NOTE: It is recommended that only trained personnel service and change tyres and rims.
Inspect and Maintain ROPS
A damages roll-over protective structure (ROPS) should be replaced, not reused.
If the ROPS was loosened or removed for any reason, inspect it carefully before operating the machine
again.
To Maintain the ROPS:
• Replace missing hardware using correct grade hardware.

• Check hardware torque.
• Check isolation mounts for damage, looseness or wear; Replace if necessary.
• Check ROPS for cracks or physical damaged.
•
Drive Metal Pins
Always wear protective goggles or safety glasses and other safety equipment.
Use soft hammer or a brass bar between hammer and object to prevent chipping.
SAFETY DECALS
There are several safety decals on your BELL EQUIPMENT machine. Their exact location and
description of the hazard are reviewed in the Operator's Manual. Please take the time to familiarise
yourself with these safety decals.
Keep the decals clean by using a soft cloth, water, and soap. Do not use solvent, gasoline, etc. You must
replace a decal if it is damaged, missing or cannot be read. If a decal is on a part that is replaced, ensure
a new decal is installed on the replacement part. Contact your BELL EQUIPMENT Representative for
new decals.
16 Doc. No. 872272 : Rev 0

BULLETINS
Record the relevant information from the Technical Documentation Bulletins, Service Bulletins and Parts
Bulletins into this manual as follows:
Ensure the manual number (87————) reflected in the bulletin is the same as the 87——— number at
the top of the main content pages.
Carry out the instructions as detailed in the bulletin.
Record the required information below.
File the bulletins in numerical order in a suitable 3 or 4 ring binder.
TECHNICAL DOCUMENTATION BULLETIN RECORD

INSERTED BY
BULLETIN No. SUBJECT
NAME SIGNATURE DATE
Doc. No. 872272 : Rev 0 17

TECHNICAL DOCUMENTATION BULLETIN RECORD

INSERTED BY
BULLETIN No. SUBJECT
NAME SIGNATURE DATE
18 Doc. No. 872272 : Rev 0

USER’S INFORMATION FEEDBACK FORM

Should you, as user of this manual, have any suggestion for improving the manual, or you find any errors
or omissions, then we would like to know.
Please complete a facsimile of this form and hand it in to your nearest BELL EQUIPMENT Product
Support Representative or post it directly to your nearest BELL EQUIPMENT Branch. Addresses are
given at the beginning of this manual.
Ideas, Comments (Please State Page Number): _____________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Machine Model: _______________________________________________________________________
Serial Number:________________________________________________________________________
VIN: ________________________________________________________________________________
Page Number: ________________________________________________________________________
OVERALL, how would you rate the quality of this manual question (Check one)
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Company Name: ______________________________________________________________________
Technician Name: _____________________________________________________________________
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Phone Number: _______________________________________________________________________
Fax Number: _________________________________________________________________________
Thank you for your co-operation.
Doc. No. 872272 : Rev 0 19

20 Doc. No. 872272 : Rev 0

TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAFETY REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . 31

OPERATIONAL CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATIONAL CHECKS - KEY SWITCH ON, ENGINE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHAPTER 2. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE (OM 906 LA SHOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 3. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DISPLAY MENU TACHOMETER (B20D SHOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SLOW AND FAST IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
EXHAUST BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 4. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CYLINDER COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FUEL INTAKE PRESSURE UPSTREAM OF FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 46
FUEL SYSTEM LOW PRESSURE FUEL CIRCUIT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OIL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHAPTER 3. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 1. SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ELECTRICAL SCHEMATIC SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CAN BUS J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
WHAT EXACTLY IS A “CAN BUS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

CANBUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TESTING THE “CANBUS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Doc. No. 872272 : Rev 0 21

CHECKING THE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
MAIN “CAN” HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

“CAN” SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
“CAN “OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
“CAN” SHORT TO POSITIVE 0 -24 VOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CHASSIS CONTROL UNIT (CCU2 & OEU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
MDU2 (MONITOR DISPLAY UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
MDU2 LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MDU2 INPUT AND OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
MDU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
START-UP DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DEFAULT SCREEN (B20D SHOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
TO GO TO MAIN MENU FROM DEFAULT SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
IQAN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INPUTS AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
PLUG X237 -2 (42 WAY AMP CONNECTOR) XP CAN 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
IQAN UNIT OPERATION AND SETTING OF PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DESCRIPTION OF THE MENU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 MODE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4 SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5 DISPLAY SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6 MEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CHANNEL PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CIRCUIT SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SECTION 2. CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
22 Doc. No. 872272 : Rev 0

SECTION 3. GENERAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

SECTION 4. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
ENGINE FAULT CODES (ADM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
ENGINE FAULT CODES (PLD-MR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
DM1 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
SECTION 6. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
PNEUMATIC SYSTEM SOLENOIDS, PRESSURE SWITCHES AND SENSOR TESTS. . . . . . . . 219
STEERING COLUMN SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
CHAPTER 4. TRANSMISSION ZF 6 HP 592 C PLUS . . . . . . . . . . . . . . . . . . . . . . . . 227

SECTION 1. THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
GENERAL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
PLANETARY GEARS AND POWER FLOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
THE BASIC LAWS OF PLANETARY GEAR SETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

ECOMAT TRANSMISSION PLANETARY CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
TRANSMISSION CLUTCH CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
CLUTCH CONFIGURATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
TRANSMISSION CROSS SECTIONAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

POWER FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
THE VARIOUS SHIFT ELEMENTS. VALVE SCHEMATIC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
VALVE SCHEMATIC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

HYDRAULIC PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
PRESSURE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
RETARDER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
ZF GEAR SHIFT CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
INTERNAL SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
REMOVE VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

SOLENOID TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
RENEWING SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
EXTERNAL SOLENOIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Doc. No. 872272 : Rev 0 23

WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

SECTION 2. DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
CHECK THE TRANSMISSION FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
TRANSMISSION CONTROL UNIT ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
TABLE OF ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

SECTION 3. ADJUSTMENTS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
TRANSMISSION WARM-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
CHAPTER 5. PNEUMATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

PNEUMATIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
PNEUMATIC SYSTEM SCHEMATIC WITH TRAILER BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

SECTION 3. ADJUSTMENTS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 303
PARK BRAKE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
CHAPTER 6. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

HYDRAULIC SYSTEM CIRCUIT SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
HYDRAULIC SCHEMATIC 2306D AND 2806D WITHOUT POWER BEYOND . . . . . . . . . . . . . . . 310
HYDRAULIC SCHEMATIC 2806D WITH POWER BEYOND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
HYDRAULIC SCHEMATIC 2806D WITH POWER BEYOND (CONT) . . . . . . . . . . . . . . . . . . . . . . 312
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . 313
MAIN HYDRAULIC PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
MAIN HYDRAULIC PUMP LOAD SENSE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
STEERING VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
SECONDARY STEERING PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
HYDRAULIC SYSTEM MANIFOLD WITH AUXILIARY SPOOL (FONT VIEW) . . . . . . . . . . . . . . . 324
HYDRAULIC SYSTEM MANIFOLD WITHOUT AUXILIARY SPOOL (FONT VIEW) . . . . . . . . . . . 325
24 Doc. No. 872272 : Rev 0

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
HYDRAULIC SYSTEM MANIFOLD WITH AUXILIARY SPOOL (REAR VIEW) . . . . . . . . . . . . . . . 326
HYDRAULIC SYSTEM MANIFOLD WITHOUT AUXILIARY SPOOL (REAR VIEW) . . . . . . . . . . . 327
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
HYDRAULIC SYSTEM MANIFOLD WITH AUXILIARY SPOOL (RIGHT VIEW). . . . . . . . . . . . . . . 328
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
HYDRAULIC SYSTEM MANIFOLD WITHOUT AUXILIARY SPOOL (RIGHT VIEW) . . . . . . . . . . . 329
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
MANIFOLD SCHEMATIC WITH AUXILIARY SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
MANIFOLD SCHEMATIC WITHOUT AUXILIARY SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
L90LS AUXILIARY HYDRAULIC MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Auxiliary Spool Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
L90LS DIRECTIONAL CONTROL VALVE ASSEMBLY OPERATION.. . . . . . . . . . . . . . . . . . . . . . 336
STACKABLE MULTI SPOOL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
END SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
SERVICE BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
STEERING AND SECONDARY STEERING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . 338
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

SECTION 3. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
DIGITAL THERMOMETER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION . . . . . . . . . . . 347
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY . . . . . . . . . . . . 347
HYDRAULIC SYSTEM WARM-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
SETTING HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
SET THE EMERGENCY STEERING PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
SET THE EMERGENCY STEERING PUMP RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . 350
SET THE EMERGENCY STEERING PUMP COMPENSATING PRESSURE . . . . . . . . . . . . . . . . 351
Doc. No. 872272 : Rev 0 25

SET THE MAIN PUMP RESIDUAL PRESSURE 2306D/2806D . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
SET THE MAIN PUMP COMPENSATING PRESSURE 2306D/2806D . . . . . . . . . . . . . . . . . . . . . 352
SET THE BRAKE CIRCUIT PRESSURE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
CYCLE TIME TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
CHAPTER 7. HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . 357

AIR CONDITIONING SYSTEM CYCLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
HEATER CORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
HEATING/AIR CONDITIONING COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
SECTION 3. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
AIR CONDITIONING OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
R134A AIR CONDITIONING SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
OPERATING PRESSURE DIAGNOSTIC CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Air FREEZE CONTROL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Air COMPRESSOR CLUTCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Air HIGH/LOW PRESSURE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Air EXPANSION VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
EXPANSION VALVE BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
REFRIGERANT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
CHAPTER 8. MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

DAILY OR 10 HOURLY SERVICE CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
CHAPTER 9. 150 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . 379

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
LOWER AND RAISE THE BELLY PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
CHAPTER 10. 500 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . 383

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
26 Doc. No. 872272 : Rev 0

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . 388
TRANSFER CASE BREATHER (LOCATED UNDER THE HYDRAULIC RESERVOIR) . . . . . . . . 388
TRANSMISSION BREATHER AND AXLE BREATHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
INSPECT, CLEAN AND REPLACE CAB AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS . . . . . . . . . . . . . . . . . . . . . . 391
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
RECORD & DELETE FAULT CODES ON THE MDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
GREASE ALL GREASE POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
OSCILLATION TUBE AND OSCILLATION TUBE THROUGH DRIVE SHAFT BEARING REAR. . 392
HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
REPLACE HYDRAULIC RESERVOIR BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
CHAPTER 11. 1 000 HOURS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 395

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
REPLACE HYDRAULIC RESERVOIR BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
CHECK AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
CHECK FINAL DRIVE OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
REPLACE PNEUMATIC SYSTEM DRYER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Doc. No. 872272 : Rev 0 27


INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
REPLACE FAN BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
CHAPTER 15. AS REQUIRED SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
CLEAN AIR CONDITIONING FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
GREASE HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
CHECK AND CLEAN COOLERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS . . . . . . . . . . . . . . . . . . 415

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
USING BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
ADJUST HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
CHAPTER 17. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

SECTION 1. SYMPTOMS AND REMEDIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
28 Doc. No. 872272 : Rev 0

PART 1
OPERATION AND TEST
Doc. No. 872272 : Rev 0 29

30 Doc. No. 872272 : Rev 0

CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE
OPERATIONAL CHECK-OUT
Use this procedure to check operation of the machine. This procedure is designed so you can make a
quick check of the machine operation while performing specific checks from the operator’s seat.
Should you experience a problem with the machine, you will find helpful diagnostic information in this
check-out that will help pinpoint the cause.
A location will be required which is level and has adequate space to perform the check-out procedure. No
tools or equipment are required to perform the check-out procedure.
Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkages,
wiring, etc.) prior to doing the operational check-out. The machine must be at operating temperature for
many of the checks.
Start at the top of the left column and read completely down column before performing check. Follow this
sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to
next check. If a problem is indicated, you will be referred to either a chapter in this manual for specific test
or the repair manual for repair procedure.
OPERATIONAL CHECKS - KEY SWITCH ON, ENGINE OFF

Turn battery disconnect switch ON. Turn key switch to ON position.
CHECKS QUESTIONS/TASKS RESULTS
Gauges and Do all indicator lights come ON or flashquestion YES: Go to next

Indicator Lights Do all gauges and speedometer move to centre check.
positionquestion NO: Check circuit
Do all sections of monitor liquid crystal display’s breakers and
appearquestion fuses. Reset circuit
breakers and/or
Does audible alarm come ONquestion replace fuses as
NOTE:1. Cold start indicator light will remain ON for a necessary.
maximum of 20 seconds in low ambient temperature Check indicator
conditions. light bulbs.
2. Air pressure indicator (1) on the numerical display Replace if
screen may remain ON, depending on system air pressure. necessary.
Do all gauges and displays return to normal operation mode Go to “Menu
and audible alarm go OFF after 3 secondsquestion Display Unit”
Do all indicator lights, except for secondary steering (marked

emergency steering), battery charge and park brake to go
OFF and low brake accumulator brake pressure, depending
on the pressure in the accumulatorquestion
Doc. No. 872272 : Rev 0 31

Transmission Does shift control operate correctlyquestion YES: Go to next

Shift Control check.
NO: Replace
transmission shift
control.
Gauges and Start engine. YES: Go to next

Indicator Lights NOTE:1. Low air pressure alarm will be ON until air check.
pressure reaches normal operating pressure. NO: Go to “Menu
2. Transmission oil temperature gauge will not begin to Display Unit”.
indicate temperature until transmission oil is close to
operating temperature.
Do all indicator lights, except park brake indicator light, go

OFF after the engine startsquestion
Does the Menu Display Unit display engine speedquestion
Does engine oil pressure gauge display engine oil
pressurequestion
Does the needle of the gauge indicates pressure is
increasing to green (Normal)?
Check the air pressure gauge immediately after the engine
has started.
Does the needle of the gauge indicates pressure is
increasing to green (Normal)?
Service Brake Apply brakes repeatedly until main hydraulic pump strokes to YES: Go to next
Accumulator charge accumulators. When accumulators are fully charged, check.
pump will de-stroke. Turn engine “OFF”. NO: Go to “Font
Turn key switch “ON” again and wait for indicator lights to go And Rear Brake
“OFF” Accumulators
Apply the service brakes, counting the number of applications Pressure Test And
until the accumulator low pressure light illuminates. Charge
Procedure”.
Service Brake NOTE: Perform this check in an open area where machine YES: Go to next
can travel at full speed. check.
NO: Go to “Service
Drive machine slowly. Brake System
Apply brake pedal to stop machine. Malfunction".
Release the brake pedal.
Does brake pedal push easily without bindingquestion
Does brake pedal return to the released position so brakes
are not draggingquestion
Do brakes stop machine in a reasonable distance without
pulling to one side or making noisequestion
Drive machine at full speed.
Release accelerator and apply brake pedal to stop machine.
Do brakes stop machine in a reasonable distance without
pulling to one side or making noisequestion
32 Doc. No. 872272 : Rev 0

Park Brake YES: Continue

‹ CAUTION check.
Machine will stop abruptly during this check. Fasten seat NO: Go to
belt. Perform check in open area. “Diagnose Power
Train System
From an initial start up, if the air pressure was below 6 bar, Malfunction”.
the park brake needs to be released, applied and released
again.
Start engine.
Switch park brake switch "OFF"
Drive machine at slow idle in 1 st gear at ~ 4 km/h (2.5
m.p.h.). Switch park brake "ON".
Does park brake indicator light illuminatesquestion
Does the park engage and machine stop
With engine “ON”, transmission in “N” (Neutral) and park YES: Continue
brake “ON” switch park brake switch "OFF". check.
Shift transmission to “D” (Drive). NO: Go to
Slowly increase engine speed. “Diagnose Power
Train System
Does machine move when engine speed is just above slow Malfunction”.
idlequestion
Return engine to slow idle.
Shift transmission to “N” (Neutral).
Steering Park machine in an open area, on a hard level surface. YES: Continue
Turn inter-axle switch to the “OFF” position. Ensure that the check.
inter-axle lock switch is in the “OFF” position and the IDL NO: Go to
light on the MDU is “OFF”. “Steering System
Release park brake. Malfunction”.
Release service brakes.
Run engine at slow idle.
Turn steering wheel fully left and then fully right.
Does machine turn smoothly in both directions.
Run engine at fast idle. YES: Continue

Turn steering wheel fully left then right. check.
Does machine turn smoothly in both directions. NO: Go to
“Steering System
Malfunction”.
Doc. No. 872272 : Rev 0 33

Viscous Fan NOTE: Engine must be cool or fan may not turn freely by YES: Do to next
Drive hand. check.
NO: Replace
Allow engine to cool. viscous fan drive.
Turn fan by hand, feel for rough bearing or fan not turning
freely.
Does fan turn freely and smoothlyquestion
Start engine and run 2 -3 minutes.
Check that fan turns at near engine speed, then slows down.
As engine warms to normal operating temperature, fan will
speed up to near engine speed.
Does fan speed increase as engine warmsquestion
Turn engine “OFF”
Exhaust Smoke Start engine and allow to warm to normal working YES: Continue to
temperature. next check.
Operate machine under full load at fast engine speed. NO: Go to
Observe exhaust colour. “Diagnose Engine
Malfunctions”.
No smoke is normal.
Blue smoke indicates faulty or stuck piston rings.
White or grey smoke indicates stuck piston rings, fuel cetane
too low or engine running too cold.
Heavy black smoke indicates injection nozzles faulty, engine
injection system incorrect, fuel cetane to low or air filter
element clogged.
Is engine exhaust smoke normal colourquestion
Engine Speed Start engine and warm to normal operating temperature. YES: Check
Run engine at low idle; Record r.p.m. complete.
Is engine speed 680 ± 20 r.p.m NO: Do slow and
Fast idle
Increase engine speed to high idle. Record r.p.m. Adjustment.
Is engine speed 2240 ± 20 r.p.m.
34 Doc. No. 872272 : Rev 0

CHAPTER 2. ENGINE
SECTION 1. THEORY OF OPERATION
ENGINE (OM 906 LA SHOWN)
1. Final Fuel Filter. 9. Turbo Charger.

2. Oil Filter. 10. Camshaft.
3. Engine Exhaust Valve Rocker Arm. 11. Starter Motor.
4. Engine Intake Valve Rocker Arm. 12. Crankshaft.
5. Engine Exhaust Valve Brake. 13. Alternator.
6. Fuel Delivery Nozzle. 14. Flywheel.
7. Electronic Unit Injector (EUI). 15. Oil Pump.
8. Intake Manifold.
The OM 906 LA engine is a 6 cylinder liquid cooled cast iron block and cast iron cylinder head engine. It
has overhead valves, three per cylinder, two intake valves and one exhaust valve. Roller cam followers
ride on the camshaft which move the push rods that open and close the valves. The EUI’s (Electronic Unit
Injectors) also ride on the camshaft which send pressurized fuel through a fuel pipe to the fuel delivery
nozzles, which are located directly over the top of the piston. The EUI’s are electronically controlled by
the EUI controller, a crankshaft position sensor, camshaft position sensor and a solenoid.
Doc. No. 872272 : Rev 0 35

Electronic Unit Injector Fuel System Fuel Delivery
Suction Stage
1
2
4 3
5
12
The EUI system is designed to precisely control:
• The start of injection. 11 6
• An accurate delivery of a calculated amount of 7

fuel.
10
• A sharp end of injection. 8
The fuel system consists of four sub-systems;
• Low Pressure Supply System, 13 RETURN FUEL
• High Pressure System - Unit Injectors, 9 14 LOW PRESSURE
• Fuel Delivery Nozzles, 40D3001CV
• Control System.
1. Fuel Delivery Nozzle.
The electronic unit injector fuel system has these
notable features: 2. Connector Pipe.
3. EUI (Electronic Unit Injector).
• Precision control of timing and fuel delivery,
4. Valve.
• Field proven reliability,
• Electronic control of each cylinder, 5. Solenoid.
• One unit injector per cylinder, 6. Supply Gallery in Crankcase.
• High injection pressures, 7. High Pressure Chamber.
• Low emissions,
8. Pump Plunger.
• Compact design,
• Eliminates injection pump, 9. Engine Camshaft.
• No injection timing adjustment required. 10. Pressure Relief Chamber.
11. Return Flow Gallery in Crankcase.
12. Bleed-Off Chamber.
13. Return Fuel.
14. Low Pressure.
The EUI’s (3) ride on individual lobes on the

engine camshaft (9). There is one EUI per
cylinder. The EUI’s are mounted in the block of
the engine under the intake manifold.
36 Doc. No. 872272 : Rev 0

There are passages in the block that route fuel to 13. Return Fuel.
and from the EUI’s. The fuel delivery nozzles (1) 14. Low Pressure.
are located in the cylinder head and are
positioned directly above the pistons. During the pre-delivery stage, the pump plunger
(8) moves up. As the valve (4) is not yet closed,
A connector pipe (2) is used to direct fuel from the fuel is first forced into the pressure relief
the EUI’s to the nozzles. Internal passages in the chamber (10), then into the return gallery(11).
cylinder heads allow excess fuel from the nozzles
to be bled off. Delivery Stage
A solenoid (5) controls the fuel metering valve
(4). 1 2
4 3
During the suction stage, the pump plunger (8) 5
moves down. As a result of the constant fuel

excess pressure of approximately 600kPa (6 bar)
(87 psi) in the fuel low pressure circuit, the high
pressure chamber (7) of the unit pump is fitted
with fuel through the supply gallery (6).
Pre-Delivery Stage
12
1 2 11 6
7
4 3 5
10
8
13 RETURN FUEL
14 LOW PRESSURE
15 HIGH PRESSURE
9 40D3003CV
12

11 6 2. Connector Pipe.
7
10
8 4. Valve.
5. Solenoid.
13 RETURN FUEL
6. Supply Gallery in Crankcase.
14 LOW PRESSURE
9
40D3002CV
7. High Pressure Chamber.
8. Pump Plunger.
9. Engine Camshaft.
2. Connector Pipe.
10. Pressure Relief Chamber.
4. Valve.
5. Solenoid.
13. Return Fuel.
14. Low Pressure.
7. High Pressure Chamber.
15. High Pressure.
8. Pump Plunger.
9. Engine Camshaft.
Doc. No. 872272 : Rev 0 37

As soon as the valve (4) is closed while the pump The remaining fuel delivery by the pump plunger
plunger (8) is moving towards its top dead centre, (8) up to the apex of the camshaft (9), is again
the unit pump is in the delivery stroke. Fuel forced into the pressure relief chamber (10) and
injection into the combustion chamber takes the return flow gallery (11).
place in the delivery stage. During this stage the
fuel pressure in the high pressure chamber (7) The pressure relief chamber serves as an
rises to a pressure approximately 160 000 kPa expansion chamber for the pressure peaks of the
(1600 bar) (23 206 psi). unit pump in the residual stage. This prevents the
pressure ratio of the adjacent unit pumps being
Residual Stage affected through the return flow gallery.
1
Cold Start Operation
2
4 3 5
12
11 6
7
10
8
13 RETURN FUEL
14 LOW PRESSURE
40D3004CV
1. Glow Plug.
2. Solenoid.
2. Connector Pipe.
3. Cold Start Jet.
4. Valve. The cold start system operates only when the
engine coolant temperature is below 15° C
5. Solenoid. (59°F).
When the key switch is tuned to the “ON” the
7. High Pressure Chamber. position, the glow plug (1) begins to heat up and
8. Pump Plunger. the indicator light on the dash will light up. Light
will stay on and the glow plug will continue to
9. Engine Camshaft. heat up for approximately twenty seconds.
When the key switch is turned to the START
11. Return Flow Gallery in Crankcase. position, the solenoid (2) is energized, allowing
12. Bleed-Off Chamber. fuel to flow to the cold start jet (3). The fuel from
the jet is sprayed on the glow plug causing the
13. Return Fuel. fuel to atomize. The atomized air/fuel mixture is
14. Low Pressure. directed to the cylinders by the incoming air
through the intake manifold.
After the valve (4) has opened (end of delivery),
The fuel pressure in the high pressure chamber
(7) is collapsing.
38 Doc. No. 872272 : Rev 0

CHAPTER 2. ENGINE
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS
Symptom Problem Solution

Starter motor turns engine too Batteries under charged Recharge or replace batteries.
slowly Poor engine ground connection. Repair, clean or secure
connections.
Loose or dirty battery terminals. Clean and tighten battery
terminals.
Worn starter motor. Perform starter load test.
Hydraulic Cut Off Solenoid Go to “Hydraulic System
Valve. Manifold Operation (Top
View)”.
Hard starting when cold Defective cold start aid. See “Cold Start Operation”.
Incorrect valve clearance. Adjust valve clearance.
Compression too low. Test compression.
Engine turns but does not start Insufficient fuel in fuel tank. Fill tank and bleed system.
Low fuel pump pressure. Test fuel pump pressure.
Engine stops soon after starting Insufficient fuel in fuel tank. Fill tank and bleed system.
Air in fuel system. Bleed system, check and repair
air entry.
Blocked fuel filters. Replace fuel filters.
Electronic Unit Injector. Check fault codes.
Engine misfires Incorrect valve clearance. Adjust valve clearance.

Low engine oil pressure Failed pressure gauge/sensor. Test or replace.
Incorrect grade of oil. Change oil.

Low pump output. Test oil pump pressure. Do Oil
Pump Pressure Test..
Pressure relief valve stuck. Install new pressure relief valve.
Engine bearings worn. Remove, inspect and repair.
Abnormal oil consumption Crankcase breather or line Inspect and repair.

blocked.
Valve stem seals worn. Replace valve stem seals.
Valve guides worn. Replace valve guides.
Piston rings worn; cylinders Test compression.
scored.
Doc. No. 872272 : Rev 0 39


Excessive vibration at any Worn or broken engine Inspect, repair or replace.
speed. mountings.
Drive shaft out off balance. Balance or replace.
Black smoke from exhaust. Inlet system restricted. Service and repair inlet system.
Incorrect grade of fuel. Reset valve clearance.
Worn fuel delivery nozzles. Replace fuel delivery nozzles.
White smoke from exhaust. Engine running too cold. Check that thermostats are not
stuck open.
Worn fuel delivery nozzles. Replace fuel delivery nozzles.
Pistons, rings or liners scored. Test compression.
Coolant entering cylinder bores. Check cylinder head gasket.
Replace cylinder head gasket.
Cold start solenoid defective. Test solenoid. See “Cold Start
Circuit”.
40 Doc. No. 872272 : Rev 0

CHAPTER 2. ENGINE
SECTION 3. ADJUSTMENTS
DISPLAY MENU TACHOMETER VALVE CLEARANCE

(B20D SHOWN) ADJUSTMENT
‹ CAUTION
To prevent accidental starting of the engine
while performing valve adjustments, always
turn battery disconnect switch to “OFF”
NOTE: Check and adjust valve clearance only

when engine is COLD.
The tachometer on the Menu Display Unit is

accurate enough for test work.
SLOW AND FAST IDLE

ADJUSTMENT
There is no slow or fast idle adjustment. If slow or
fast idle is not within specification, check for an
engine mechanical problem or an electrical Remove rocker arm cover.
failure.
Install cranking device DC280088.
Slow Idle Speed RPM’s . . . . . . . . . 680 ± 20
There are 37 slots (1) machined in the flywheel.
Fast Idle Speed RPM’s . . . . . . . . 2240 ± 20 One slot has a dimple in it. This is the TAC timing
mark. Turn engine in the direction of rotation until
If no mechanical failure is found and the TAC timing mark (2) on flywheel lines up in
controller is suspected. centre of the window in timing case.
NOTE: All valves can be adjusted in two

crankshaft positions.
Rocker arms and push rods for number one

cylinder should be loose. If not, rotate engine
360°. Engine must be at TAC on the compression
stroke for number one cylinder.
NOTE: When adjusting valve clearance, the

bolt on the valve bridge should on no account
be loosened.
Measure the valve clearance between the rocker

arm and the valve bridge with a feeler gauge.
Rocker arms and push rods for number one

cylinder should be loose. If not, rotate engine
Doc. No. 872272 : Rev 0 41

360°. Engine must be at TAC on the compression EXHAUST BRAKE

stroke for number one cylinder.
ADJUSTMENT
NOTE: When adjusting valve clearance, the
bolt on the valve bridge should on no account
be loosened.
Measure the valve clearance between the rocker

arm and the valve bridge with a feeler gauge.
With engine off, check the clearance between the

control arm (1) and the stop (2). In the brake
valve “OFF” position, the control arm should be
resting on the stop.
Disconnect the air line (3) from the cylinder.

Connect a regulated air supply line to the
cylinder. Regulate air pressure so pressure is
approximately 740 - 810 kPa (7.4 - 8.1 bar) (107 -
117 psi).
With number one cylinder on TAC, Check the

valve clearance on cylinder one - intake and
exhaust, cylinder two - intake, cylinder three -
exhaust, cylinder four - intake and cylinder five -
exhaust.
Crank engine until cylinder six is on TAC

(cylinder one valve overlap):
Check valve clearance on cylinder two - exhaust,

cylinder three - intake, cylinder four - exhaust,
cylinder five - intake and cylinder six - intake and
exhaust. Check control arm (1) to stop (2) clearance. The
control arm must not rest on the stop. There must
Intake Valve Clearance . . . 0.40 mm (0.016in.) be slight clearance between the control arm and
Exhaust Valve Clearance . . 0.60 mm (0.024in.) stop to ensure that exhaust brake is fully closed.
Locknut tightening torque . . . . 50Nm (37 lb-ft)
If adjustment is needed, loosen locknut (3),
To adjust clearance: Loosen locknut (2) and turn remove clip (4) and disconnect cylinder from
adjusting screw (1) in or out depending on gap to control arm. Turn rod end (5) for adjustment.
big or small.
Tighten locknut to specification while holding

adjusting screw in position.
Adjust valves in same order used for checking.
Check clearance again after tightening locknut.
42 Doc. No. 872272 : Rev 0

CHAPTER 2. ENGINE
SECTION 4. TESTS
CYLINDER COMPRESSION TEST

NOTE:1. Compression pressures are affected by the cranking speed of the engine. Before beginning the
test, ensure that the batteries are fully charged and the starter motor is in a good working condition.
2. Repeat procedure for all cylinders.
Disconnect fuel delivery line and blank line off.
Install compression tester adapter (1) into cylinder head.
Install hold down clamp (2) using an M10 x 1.5 x 70 mm long cap screw (3).
Install compression tester to adapter.
‹ Caution
Engine must not be started with fuel line from EUI disconnected.
Crank engine approximately ten seconds. Record readings and compare to specification.
Engine Compression Pressure

· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2800 kPa (28 bar) (406 psi).
Permissible Difference Between Cylinders
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 400 kPa (4 bar) (58psi).
Doc. No. 872272 : Rev 0 43

FUEL PUMP PRESSURE TEST
Specification
Pressure At Slow Idle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · >430 kPa
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · (4.3 bar) (62 psi).
Pressure At Fast Idle· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 400 - 650kPa
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · (4 - 6.5 bar) (58 -94 psi).
Essential Tools
Parker No. 34982-16-6: Banjo Union.
Parker No. 0502-12-12: 1 1/16 - 12M x ¾ - 14NPT F Adapter.
Parker No. ¾ x ½ PTR: ¾ - 14 NPT M x ½ - 14 NPT F Pipe Thread Reducer.
Parker No. ½ x 3/8 PTR: ½ - 14 NPT M x 3/8 - 18 NPT F Pipe Thread Reducer.
Parker No. 30182-6-6: 3/8 - 18 NPT M x 3/8 Barb Fitting.
Service Equipment And Tools

Digital Hydraulic Tester.
0.5 to 15 GPM Lt. Flow Meter.
NOTE: 904 engine shown.

Remove cover (1). Install ring piece (5), pressure gauge (6) and
measuring hose (7) on adapter piece (4).
Unplug wiring harness connecter (2) from
temperature sensor (3). Connect wiring harness connecter plug to
temperature sensor and attach on engine.
Remove temperature sensor (3).
Start engine and compare to specification.
Install adapter piece (4) with seal ring on
crankcase. If out of specifcation, repair
44 Doc. No. 872272 : Rev 0

FUEL RETURN FLOW QUANTITY AT ENGINE TEST
Specification
Measuring Point - Bypass Valve

Fuel return flow at fuel filter housing at idle 600 - 650 r.p.m. for more than 1 minute · · · · · · · · · · · ·
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · <0.3l/min (0.07 Gal/min)
Fuel return flow at fuel filter housing at 2500 r.p.m. for more than 30 seconds · < 0.3 l/min (0.07 Gal/min)
Fuel return flow at bypass valve at idle 600 - 650 r.p.m. for more than 1 minute · · · · · · · · · · · · · · · · · · · · ·
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · <0.9 - 1.7l/min (0.2 - 3.7 Gal/min)
Fuel return flow at bypass valve at 2500 r.p.m. for more than 30 seconds · · · · · · · · · · · · · · · · ·
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · < 2.7 - 7.5 l/min (0.6 - 1.65 Gal/min)
Special Tools
NOTE: 904 engine shown.

Remove cover (1). Disconnect fuel return line (14) on fuel filter
housing (12), connection “RL” and install
Disconnect fuel return line (4) on bypass valve transparent fuel line (13).
(6). Steady bypass valve (6) when loosening the
fuel return line (3). The support (11) with opening clamp (arrow)
must press the non-return valve into the
Seal fuel return line (3) with banjo bolt (2) and connection.
lock nut (7).
Guide fuel return line (13) into a clean container
Detach ring piece (5) from bypass valve (6). (10).
Steady bypass valve (6) when tightening bolts.
Start engine and compare to specification.
Install transparent fuel line (9) on ring piece (5)
and guide into a clean container (8).
Doc. No. 872272 : Rev 0 45

FUEL INTAKE PRESSURE UPSTREAM OF FUEL PUMP TEST
Specification

Fuel pressure upstream of fuel pump at 600 - 650 r.p.m. · · · · · · · · · · · · · · · · · - · · · · · · 90 to-120 kPa
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · -0.09 to -0.12 bar (-13 to -17 psi)
Fuel pressure upstream of fuel pump at 2500 r.p.m.· · · · · · · · · · · · · · · · · · · · · · · · · · -400 to -500 kPa
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · (-0.4 to -0.5 bar)(-58 to -73 psi)
Special Tools
Gauge vacuum
Install tester (1) with test cables (2) and Bleed fuel system.
connectors (3) between fuel supply line (4) and
pre-filter housing (5). Attach tester (1) to frame.
The support (6) with opening clamp (arrow) must Start engine.
press the non-return valve into the connection
(7). Compare to specification.
Check sealing ring on support (6) for damage

and replace if necessary.
46 Doc. No. 872272 : Rev 0

FUEL SYSTEM LOW PRESSURE FUEL CIRCUIT LEAK TEST
Specification

Test pressure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · - 1000 kPa (10 bar) (145 psi)
Test time · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·5Minutes
Pressure drop · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · <250 kPa (0.25 bar) (36 psi)
Special Tools
Pressure gauge 1500kPA (15 bar) (218 psi).
Remove cover (1).

Detach fuel return line (9) on fuel filter housing
Remove fuel temperature sensor harness (2) and (12), connection “RL” and seal with cap (8).
fuel temperature sensor (3).
Detach fuel supply line (14) on fuel pre-filter
Install adapter piece (4) with seal ring on housing, connection “VL” and install connection
crankcase. line (10) with shut-off cock (11).
Install ring piece (5), measuring hose (6) and

pressure gauge (13) on adapter piece (4).
Doc. No. 872272 : Rev 0 47

OIL PUMP PRESSURE TEST
Specification
Engine Oil Pressure at Slow Idle . . . . . . . . .
. . . . . . . . . . . . . 50kPa (0.5 bar) (7.3psi).
Engine Oil Pressure at Fast Idle . . . . . . . . . . . . .
. . . . . . . . . . . 250 kPa(2.5 bar) (36.3psi).
Essential Tools
Parker No. 8M16F80MX: M 16 x 1.5 M x ¾ - 16

M 37° Adapter.
¾ - 16 M 37° x ¾ - 16 F 37° Sw 90° Elbow.

Install adapter (1) and connect gauges (2) to
7/16 - 20 M 37° x ¾ - 16 F 37° Reducer. fittings.
Service Equipment And Tools To achieve an accurate oil pressure reading,

warm engine to 105° C (220° F).
• 413 kPa (4.1 bar) (60psi) Gauge. Run engine at slow idle. Compare reading to
specification.
Run engine at fast idle. Compare reading to

specification.
When installing plug ensure that there is no oil

leaks and that the plug is screwed in tight.
Remove plug on main oil supply channel (1).
48 Doc. No. 872272 : Rev 0

B16
2 BK/YL 0.5 N3-1
MERCDES BENZ ADM AND PLD
1 BR/YL 0.5 N3-20
B15
2806D-2306D
SCHEMATIC FOR OM906LA 2 BR/VL 0.5 N3-19

1 BK/VL 0.5 N3-2
ALL SMALL ADT’S 2 WH/YL 0.5 N3-3
B65
1 RD/YL 0.5 N3-34
2 BR/WH 0.5 N3-15
B11
1 GY/BR 0.5 N3-39
Engine Schematic
N3-4
N3-5
Doc. No. 872272 : Rev 0

B90 3 GN 0.5 N3-7
1 BL 0.5 N3-22
4 VL 0.5 N3-29 15 15 15
TEMP GN 0.75 FUSE2-2 9 1
+
2 BR/BK 0.5 N3-48 164 163 162
(6)
6 120 OHM 3 WAY
PL 0.35 ACCP-6 DEUTSCH CAN
GN/BL 0.5
(4)
B12 1 N3-32 CANT1-C
CABT1-B
CANT1-A
4 TERMINATOR
GR/YL 0.5
GN 0.35 ACCP-4 21-1
PWM
2 N3-10
3
_
(3)
BR/GY 0.5 N3-6 WH 0.35 ACCP-3 OEUJ2-A1 YL 0.75 21-19
3
+ 5
N3-8 RD 0.35 ACCP-5 OEUJ2-B1 GN 0.75 21-21
(5)
YL 0.5
2
(2)
2 N3-49 YL 0.35 ACCP-2 OEUJ2 BK 0.75 21-20
PWM
B14 1
1 WH 0.5 N3-33 BN 0.35 ACCP-1 BK/YL 0.75 21-14
_
(1)
6 5 4 3 2 1 2 BL/WH 0.5 N3-30
BL/GN 0.75 21-13
START
1 RD/BK 0.5 N3-25
S10 ACCELERATOR BL/YL 0.75 21-12
RD/WH 0.5 N3-35 PEDAL
2 BK 0.75 21-3
Y9
Y8
Y7
Y6
N3-11 E3
Y11
Y10
STOP
S11 1 RD 0.75 21-2
N3-12
GY/BK 1.5 N3-54
GY/WH 1.5 N3-53 BL/RD 0.75 15-5
WH/RD 1.5 N3-47 MR-1 D3 - 14 YL/GN 0.75 15-13
RD/GN 1.5 N3-16 MR-3 D3 - 13 BK 0.75 BK 0.75 15-14
GY/BL1.5 N3-44 MR-4 D3 - 24 BK 0.75
RD/BL 1.5 N3-9
MR-2 D3 - 25 BN 0.75 15-15
WH/BL 1.5 N3-38
MR-9 BK 2.5 RD/YL 0.75 15-6
GY/YL 1.5 N3-45
EE
MR-11
N3-13
MR-15 D3 - 5 18-9
N3-14 E3
N3-17 MR-5 BK 0.75 18-11
N3-18 MR-6 18-16

N3-21 MR-12
LEGEND N3-23 MR-13 PL 1.5 D3 - 28 12-2
N3-24
UNIT DESCRIPTION
N3-26 ADM - MERCEDES ECU
B11 OIL TEMPERATURE SENSOR OR 0.75 DIAG-H 169 25
GN 2.5
GN 2.5
RD 1.5
RD 1.5
PL 0.75
N3-27
BK/WH 1.5
B12 OIL PRESSURE SENSOR RD/PK 0.75 R4-87 141 12

N3-28 MR -
B14 OIL LEVEL SENSOR
N3-31 ENGINE ECU
B15 CAM SHAFT SENSOR
B16 CRANK SHAFT SENSOR N3-36 EVBSOL-1 EVBSOL-2
STAR-50
DIAG-J
MCB-1
MCB-1
FUSE 17-2
FUSE 17-2
2
N3-37 BK 0.75
B65 COOLANT TEMPERATURE SENSOR 1 E5
B90 CHARGE AIR PRESSURE AND TEMPERATURE SENSOR N3-40
170 3 6 5 33 32 EXHAUST BRAKE SOLENOID
S10 START BUTTON N3-41
S11 STOP BUTTON 25 1 1 1 2 2
N3-42
Y6 UNIT PUMP SOLENOID CYLINDER 1 N3-43
Y10 UNIT PUMP SOLENOID CYLINDER 5
N3-52
Y11 UNIT PUMP SOLENOID CYLINDER 6
N3-55
TD0005986
49
SERVICE MANUAL MK V
50 Doc. No. 872272 : Rev 0

CHAPTER 3. ELECTRICAL SYSTEM
SECTION 1. SYSTEM INFORMATION
ELECTRICAL SCHEMATIC SYMBOLS
Doc. No. 872272 : Rev 0 51

CAN BUS J1939
WHAT EXACTLY IS A “CAN BUS”

The Controller Area Network (CAN) is a serial communications protocol that efficiently distributes real
time control (Data) with great Data integrity. In other words it is a system that sends data (In a binary
code or math between electronic control units.)
The “CAN” is a means of transferring data between components and in the case of the "D" Series
Hauler there is a “CAN” between numerous components, namely:
SSM Sealed Switch Module
MDU Monitor Display Unit
TCU Transmission Control Unit
CCU2 Chassis Control Unit
ECU Commonly known as the ADM is the Engine control unit (Cab Mounted).
MR Engine mounted control unit (PLD).
OEU Output Expansion Unit.
There are numerous advantages of using a “CAN” system:
• Reliable.
• Fast.
• Cost effective.
• High flexibility.
52 Doc. No. 872272 : Rev 0

CANBUS
The following illustrations describe the Bell “CAN” and the tests that can be carried out to test the wiring.
DEUTSCHCAN
120OHM3WAY
TERMINATOR
SAEJ1939CANBUS
CANTERM- B
CANTERM-C
CANTERM-A
SSM
YL1.0
GN 1.0
SHIELD
SAEJ1939 CANBUS
CCU2
YL 1.0
GN 1.0
SHIELD
OEU
YL 1.0
GN1.0
SHIELD
MDU2
YL1. 0
GN1.0
OPTIONAL
MM&
SHIELD GPS
YL 1.0
GN 1.0
SHIELD
TCU
YL 1.0
GN 1.0
SHIELD
ADM
YL 1.0
GN1.0
SHIELD
Diag
YL 1.0
GN 1.0
SHIELD
MR
CANT1-C
CANT1-A
CANT1-B
DEUTSCHCAN
120OHM3WAY
TERMINATOR
TD0006844
Doc. No. 872272: Rev 0 53

TESTING THE “CANBUS” CHECKING THE CABLES

The construction of the “CAN” line is of a high When testing the “CANBUS” the most important
quality cable consisting of a CAN_H and a factor will be the 60 Ohm reading across the
CAN_L cable. These two cables carry the CAN_H and CAN_L.
information in Series to and from the Control
units in the system. CAN_H and CAN_L Both NOTE:A digital Multi meter Must be used to
send the same messages and basically check on check any readings on the D Series Machines.
each other.
Before beginning the troubleshooting process,
The O’s and 1’s are created by voltages that are read and understand the following:
produced inside the control units. The two cables
are protected by a shield around the outside to Wire identification presents the Connector, the
prevent in EMI (Electro Magnetic terminal on the connector and the colour.
Interferences).This EMI can cause false or
incorrect signals in the system. Shut off the engine and ignition before any
harness connectors are disconnected or
The “CANBUS” has two resistors connected to connected.
the end of the “CAN line.” These Resistors are
fitted to Terminate the signals in the “BUS”. If When disconnecting a harness connector, be
these Resistors where not fitted the signals would sure that pulling force is applied to the connector
reflect in the “CAN” line and the System would itself and not the wires extending from the
not work. The Resistors also play an important connector.
Role in the system for the technician. The
resistors are connected across the CAN_H and Inspect all connector terminals for damage.
CAN_L lines. If You measure the Resistance Terminals may have bent or lost the necessary
across any of the two lines at any of the control tension to maintain firm contact.
units you will measure 60 Ohms. A short circuit or
Clean dirty terminals or connectors with isopropyl
open circuit will cause the resistance to change.
alcohol and a cotton swab, or a good quality,
There are numerous errors that can occur within non-residue, non-lubricating solvent.
the system.
When checking the CAN harness at the
1. CAN_H Short to ground. connectors, it is important to remember to check
the CAN from each of the pins on the different
2. CAN_L Short to ground. plugs that are used in the CAN circuit.
3. CAN_H Short to CAN_L.

CHECKING OPENS, SHORTS
4. CAN_H Open circuit. BETWEEN WIRES AND SHORTS
5. CAN_L Open circuit
TO GROUND ON THE CAN
HARNESS
6. CAN_H and CAN_L Open circuit.
NOTE:Always make sure that all the
7. CAN _H or CAN_L shorted to a Arbitrary
connectors are removed from all the control
Potential (Voltages)
units before testing.
Any of these errors will cause a Error code to
come up on the MDU Display. Thoroughly clean corroded or dirty terminals. If
dirty or corroded terminals are the probable
The Display will show For example “CCU CAN cause of the problems, reconnect the clean
ERROR” on the display. connectors and operate the vehicle normally.
If all connectors are clean and connected

correctly, determine which Control unit is causing
the error on the display.
54 Doc. No. 872272 : Rev 0

Remove all the connectors on the control units and measure the resistance of the “CAN BUS” as shown
below for each fault.
Each control unit has their own connector as they are manufactured by different OEM’S.
MAIN “CAN” HARNESS

The Main “CAN” Harness is measured in Ohms and One should measure 60 Ohms as per the
calculation shown previously. The reading obtained in Ohms is very important as previously discussed as
this will determine if there is a problem with the “CAN” Line.
Once all the connectors have been removed each connector can be measured for 60 Ohms.
There are Numerous faults that can occur to prevent the 60 Ohms reading from being obtained.
“CAN” SHORT TO GROUND

A short to ground on one or both “CAN” lines will result in continuity being read to ground.
Check the continuity on any connector as shown below.
Make sure that the ground you are using is a good clean ground.
CAN_H or CAN_L
0
VOLT/OHM- Shorted to ground

METER
Ð
(VOM)
Ð
Fig 1
E E
CCU CAN
ECU CAN
X18 - C
X19 - C
X18 - B
X18 - A
X19 - B
X19 - A
120 OHM 3 WAY 120 OHM 3 WAY

DEUTSCH CAN DEUTSCH CAN
TERMINATOR TERMINATOR
CANT1-A YL 1.0 CANTERM - A
CANT1-B GN 1.0 CANTERM - B
CANT1-C SHIELD CANTERM - C
CAN Short To Ground CV
Doc. No. 872272: Rev 0 55

“CAN “OPEN CIRCUIT

A Open circuit on one or both “CAN” lines will result in only one resistor being read which will show 120
Ohms on the multimeter.
Check the resistance on all the connectors as shown above.
Also Check the Resistance of the individual Resistors (120 Ohms).
CAN_H or CAN_L
0 0
Open circuit or both

Open Circuit
VOLT/OHM-
METER
Ð
(VOM) Ð
+ +
CCU CAN
ECU CAN
X18 - C
X19 - C
X18 - B
X18 - A
X19 - B
X19 - A

CAN Open Circuit CV
56 Doc. No. 872272 : Rev 0

“CAN” SHORT TO POSITIVE 0 -24 VOLTS

CAN_H or CAN_L must also be measured for a voltage at the connectors in case the lines have shorted
to a positive.
CAN_H or CAN_L
Shorted
VOLT/OHM-
0
to a Voltage
METER
Ð
(VOM)
Ð
A voltage from 0-24V
E E
CCU CAN
ECU CAN
X18 - C
X19 - C
X18 - B
X18 - A
X19 - B
X19 - A

CAN Short To + 0 -24Volts CV
Check from any connector to ground for a Voltage, make sure that the ground you are using is a good
clean ground.
Doc. No. 872272: Rev 0 57

CHASSIS CONTROL UNIT (CCU2 MDU2 (MONITOR DISPLAY

& OEU) UNIT)
1 2 3
30 40
20 50
10 60
4
20
0 10 30 70
40
COOLANT Km/h RPM

TEMP M/h n/min
TRANS
TEMP FUEL
7
COLD COOLANT ENGINE EMERGENCY PARK BRAKE BRAKE HYDRAULIC
6 START LEVEL FAULT STEERING BRAKE PRESSURE TEMP
n/min
TYRE TRANS RETARDER ENGINE BATTERY BIN INTER-AXLE DIFF HIGH

PRESSURE FAULT AIR FILTER CHARGE UP DIFF LOCK LOCK RANGE
GD1037CV
The Chassis Control Unit, commonly known as The Monitor Display Unit, commonly known as
the “CCU”, is a processor that has been the “MDU” is a multi-functional display unit.
designed to control certain functions used on the
machine. This unit is capable of displaying vehicle speed in
kilometres per hour and miles per hour.
This processor reads inputs, sends outputs and
sends and receives Can-bus signals. A fuel gauge, engine oil pressure gauge, coolant
temperature gauge, transmission temperature
Inputs:Digital signals ( Ground eg: Indicator gauge and air pressure gauge have been
left turn signal from indicator switch). incorporated for easy and clear viewing for the
Analog signals (Variable resistance operator. There are two alpha numeric displays
eg: Air pressure sender unit). CAN-bus which can show numerous values selected by
(J 1939) signals (eg: Engine the operator, there are seven main menus, each
temperature). menu having sub-menu’s (Each menu will be
discussed later in this section). These are
Outputs:Digital signals (+24V dc eg: Energise selected by using the four push buttons on the
left turn indicator). right-hand side of the unit.
Proportional Outputs. e.g (Aux
Solenoids). The unit also consists of warning indicators, for
example: general warning, change in direction
CAN-bus (J 1939) signals and transmission faults.
(eg: To bring on the MDU left turn
signal). The MDU receives all of its information from
digital inputs or CAN -BUS signals from the other
Example: When the indicator switch is moved to vehicle control units such as Chassis Control Unit
left turn it supplies a ground signal to (CCU), Transmission Control Unit (TCU) or
the MDU2. At the same time a CAN Engine Management System (ADM).
message is send to the CCU2. CCU
receives this digital ground signal
processes it and sends
out and intermittent digital +24V signal
to the Left turn indicator light
controlling the flashing. At the same
time it will send out a “CAN-BUS”
(J1939) signal to the MDU to bring on
the left turn indicator signal light.
58 Doc. No. 872272 : Rev 0

MDU2 LAYOUT
1 2 3
30 40
20 50
10 60
4
20
0 10 30 70
40
COOLANT Km/h RPM

TEMP M/h n/min
28
TRANS
TEMP FUEL
27

6 START LEVEL FAULT STEERING BRAKE PRESSURE TEMP
n/min
7 TYRE TRANS RETARDER ENGINE BATTERY BIN INTER-AXLE DIFF HIGH 26

8
25
GD0036CV
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1 Coolant Temperature gauge. 15 Main Warning Light.

2 Speedometer. 16 Engine Air Filter Indicator Light.
3 Menu Display Screen. 17 Battery Charge Warning Light.
4 Revolution Counter. 18 High Beam Indicator Light.
5 Fuel Gauge. 19 Bin Raised Warning Light.
6 Transmission Temperature Gauge. 20 Engine Over Speed Warning Light.
7 Cold Start Warning Light. 21 Inter Axle Differential Lock Light.
8 Left Indicator. 22 Controlled Traction Differential Lock Light.
9 Coolant Level Warning Light. 23 Brake Pressure Warning Light.
10 Tyre Pressure Indicator Light. 24 High Speed Indicator Light.
11 Engine Fault Warning Light. 25 Right Turn Indicator Light.
12 Transmission Fault Warning Light. 26 High Hydraulic Fluid Temperature
Warning Light.
13 Emergency Steering Warning Light.
27 Brake Temperature Warning Light.
14 Retarder Light.
28 Park Brake Warning Light.
Doc. No. 872272 : Rev 0 59

MDU2 INPUT AND OUTPUTS
MDU2J1
MDU2J2
A
B B
30 40 50
20 60
K 10 70 E
0 20 30 80
km/h 10 40
P mph 0 50 F
COOLANT RPM
F TEMP G
G H
H J
J C
L TRANS K
TEMP FUEL
M L
N R
A S
C P
E M
D D
MDU2_PLUGS_CV
MDU2J1 MDU2J2
A: Battery Positive, Input, Fuse 8, 10A A: Ground via Hyd. Filter Pressure Switch
B: Not used B: Not Used
C: J1939 CAN C: Output to Low ACC Brake Pressure Switch
D: Buzzer D: Output to CTD Pressure Switch
E: Not used E: Output to Emergency Steering Switch
F: Not used F: Battery Positive Input via Steering Column
Switch
G: Not used G: Battery Positive Input via Steering Column
Switch
H: Not used H: Output Signal to Low Coolant Level Switch
J: Not used J: Output to Cold Start Module
K: J1939 CAN K: Not Used
L: Battery Positive, Input, Fuse 33, 10A L: Not Used
M: Buzzer M: J1939 CAN From SSM
N: Output to Ground via Fuel Sender N: To Engine Air Intake Pressure Switch
P: Ground P: Not Used
R: Output to Ground via Steering Column Switch
Left
S: Output to Ground via Steering Column Switch
Right
60 Doc. No. 872272 : Rev 0

The “MDU” displays the selected menu and it’s • ENG RET TORQ
different values. • FUEL
NOTE:In the Default Menus some of the value on • AIR PRESSURE
the “MDU” can be altered by the operator to • HYD TEMP
display the information that the operator would • BRAKE TEMP
prefer. • PAYLOAD
• TIME
MDU2 • DATE
NOTE:1. To scroll from one option in this
The “MDU” displays the selected menu and it’s menu to the next option, just press “Next”. To
different values. scroll backwards, press "BACK" button.
NOTE:There are five Default Menus. In some Press the "Select" button on the MDU to scroll
of the menus, the operator can choose what between "DEFAULT SCREENS".
to display. To go to the MAIN MENU from any
default screen: Press the MENU In this screen the information displayed at the
BUTTON.display. To go to the MAIN MENU bottom can be changed by the operator.
from any default screen: Press the MENU
BUTTON. To change to DEFAULT SCREEN 2: Press the
"Select" button on the MDU.
START-UP DISPLAY
DEFAULT SCREEN
When the machine is switched on the MDU
will come up with "BELL LOGO".
It will then automatically scroll to the default

menu that was last active.
NOTE:To scroll backwards through the

options, press the "BACK" button.
DEFAULT SCREEN
In this screen the information displayed in the To change to DEFAULT SCREEN 3: Press the
middle right hand side of the screen can be "Select" button on the MDU.
changed to display one of the following options in
sequence; DEFAULT SCREEN
• MACHINE TYPE
• BIN TIP COUNT
• TRIP ODO
• TRIP TIME
• TRIP FUEL
• TRIP LOAD
• LCKUP CTH
• CURRENT GEAR
• SUMP OIL
• RET OIL TEMP
To change to the next DEFAULT SCREEN:
• ENG COOLANT
Press the "Select" button on the MDU.
• ENG OIL
• BOOST PRESS
• FUEL ECONOMY
• ENGINE TORQ
Doc. No. 872272 : Rev 0 61

DEFAULT SCREEN (B20D MAIN MENU
SHOWN) The following sub-menus are available in the

main menu:
Main Menu 1/7

1-Counters
2-Actual Values
3-Diagnostics
4-Machine Config
To change to the next DEFAULT SCREEN: 5-Machine ID
Press the "Select" button on the MDU.
6-Service Mode
DEFAULT SCREEN 7-Factory Mode
When a menu is selected, the first option will be

high lighted.
To scroll between the options in sub-menus

press “NEXT” button. To go back to the previous
menu, press “BACK” button.
NOTE: To choose an option in a menu, press

the "SELECT" Button.
1. Counters
To change the info displayed at the right hand
bottom of the screen when in this screen:
Counters 1/7
Press the "NEXT" button to scroll between ODM
(Km/m.p.h); HOURS (total hours) and SPEED 1- Trip Info
(Km/h or m.p.h) 2 - Bintip Count
To change to DEFAULT SCREEN 3: Press the 3 - Service
"Select" button on the MDU.
4 - Bonnet Fan
TO GO TO MAIN MENU FROM 5 - Hydraulic Fan
DEFAULT SCREEN
Press the "NEXT" button to scroll between the
Press the “MENU” button to go to "MAIN options.
MENU" from default screen.
62 Doc. No. 872272 : Rev 0

1.1 Trip Info 1.2 Bin tip Count
Press "NEXT" Button when in the "Trip Info" Bintip Count

menu to scroll between the following "Trip Info"
sub-menus: Total : 0000000
Trip Distance ¼ Trip : 0000000
Press SELECT to Reset
Trip Distance 1/4
Total : 000000.0 km To reset a value in this sub-menu: Press
“SELECT” button and hold for three beeps, the
Trip : 000000.0 km system will reset that value in the sub-menu.
1.3 Service
Trip Time 2/4
.
Service
Trip Time 2/4
Last: 0000000 hrs
Total : 000000.0 hrs
Next: 0000000 hrs
Trip : 000000.0 hrs Press SELECT to Reset
NOTE:In the "Service" sub-menu, the reset
Trip Fuel ¾ can only be done by a service technician once
in service mode.
Trip Fuel 3/4
Total : 000.0 l/h 1.4 Bonnet Fan
Trip : 000.0 l/h Bonnet Fan

Press SELECT to Reset Total : 00000.0 min
Trip Load 4/4 Trip : 00000.0 min
Trip Load 4/4
Total : 0000000 T The bonnet fan will only be displayed in "Service
Mode" and is not applicable for this trucks.
Trip: 000000.0 T
Press SELECT to Reset 1.5 Hydraulic Fan
NOTE:When in a sub-menu and the “BACK” Hydraulic Fan

press button is pressed, the system will go back
Total : 00000.0 min
NOTE: Bold = Service Mode Trip : 00000.0 min
Bold & Italic = Factory Mode Press SELECT to Reset
to the "COUNTERS" Menu.
To reset a value in this sub-menu: Press

“SELECT” button and hold for three beeps, the
system will reset that value in the sub-menu.
Doc. No. 872272 : Rev 0 63

Engine Values 4/5

2. Actual Values
In "Main Menu" press "NEXT" to scroll to this

Engine Values 4/5
option, press "SELECT" button to select this
option.
Eng Oil Press 00. 0 bar
Boost Press 000 kPa
The actual values menu has three sub-menus:
Engine Oil Level 000 %
Actual Values 1/3 Fuel Consump 000.0 l/h
1-Engine Values
Engine Values 5/5 E
2-Trans Values
3-Vehicle Values Engine Values 5/5
Throttle Position 000 %
2.1 Engine Values Kick Down
Ref Ret Torq 0000 Nm
This menu has five sub-menus. Use the "NEXT"
button to scroll between this menus and "BACK" Ref Engine Torq 0000 Nm
to go to Actual Value menu.
Engine Values 1/5 2.2 Trans Values
Engine Values 1/5 This menu has three sub-menus. Use the
Engine Torq 000 % "NEXT" button to scroll between this menus and
"BACK" to go to Actual Value menu.
Req Eng Torq 000 %
Trans Values 1/3
Req RPM 0000 RPM
Trans Values 1/3
Actual Torq 0000 Nm
Ret Torque 000 %
Engine Values 2/5
. .
Ret Control Mode Speed

Engine Values 2/5 Req Ret Torq 000 %
Engine Ret Torq 000 % Output Speed 0000 RPM
Ret Control Mode Torq Trans Values 2/3
Req Ret Torq 000 %
Trans Values 2/3
Engine Values 3/5 Select Gear 00
Engine Values 3/5 Current Gear 00
Engine Oil Temp 000 °C Lock Up Clutch
Eng Coolant Temp 000 °C Shift Program prim
Intake Manifold 000 °C
Fuel Temp 000 °C
64 Doc. No. 872272 : Rev 0

Trans Values 3/3 Vehicle Values 4/4
Trans Values 3/3 Vehicle Values 4/4

Gear Hold Req Wet Brake Temp 000 °C
Sump Oil Temp 000 °C Hyd Temp 000 °C
Ret Oil Temp 000 °C Fuel Level 000 %
Ref Ret Torq 0000 Nm Fuel 000 l
2.3 Vehicle Values

. 3 Diagnostics
This menu has four sub-menus. Use the "NEXT" In "Main Menu" press "NEXT" to scroll to this
button to scroll between this menus and "BACK" option, press "SELECT" button to select this
to go to Actual Value menu. option.
Vehicle Values ¼ The diagnostics menu has ten sub-menus:
Vehicle Values 1/4 Diagnostics 1/10

Aircon Air Temp 000 °C 1-Actual Faults
Cab Temp 000 °C 2-Stored Faults
Req Cab Temp 000 °C 3-CCU Diagnostics
Vehicle Values 2/4

4-OEU Diagnostics
5-MDU Diagnostics
Vehicle Values 2/4
6-OBW Diagnostic
Battery 24V 00.0 mV
7-MM Diagnostic
Battery 12V 00.0 mV
8-CAN Diagnostic
Bin Position 000 %
9-TPM Diagnostic
Bin Lever Position 000 %
10-Task Times
Vehicle Values ¾
3.1 Actual Faults
Vehicle Values 3/4
There can be up-to twenty sub-menus and each
Left Height 000 mm sub-menu will display an active fault code.
Right Height 000 mm
Artic Angle 000 ° Active Codes 1/20
Air Pressure 00.0 bar ECU 000000.00
Occur Count : 000000
Mach hrs Last: 000000.0
SELECT for Detail
Press "SELECT" button in the sub-menu for an

detailed description of the fault code.
Doc. No. 872272 : Rev 0 65

CCU Inputs 2/8

3.2 Stored Faults
CCU Inputs 2/8
There can be up-to twenty sub-menus and each
sub-menu will display a stored fault code. F Wiper Park Sig
R Wiper Park Sig
Stored Faults 1/20
Scraper Dash Sw
ECU 000000.00
IDL Pressure Sw
Occur Count : 000000
Mach hrs Last: 000000.0 CCU Inputs 3/8
SELECT for Detail CCU Inputs 3/8

Press "SELECT" button in the sub-menu for a Two Speed Press
detailed description of the fault code.
F Two Speed Sw
NOTE: The stored faults can only be cleared Mid Two Speed Sw
in service mode. R Two Speed Sw
3.3 CCU Diagnostics CCU Inputs 4/8
In "Diagnostics Menu" scroll to CCU Diagnostics. CCU Inputs 4/8

The CCU Diagnostics Menu has three Horn Sw
sub-menus:
Aircon Thermo Sw
CCU Diagnostics 1/3
Bonnet Fan Temp Sw
CCU Diagnostics 1/3
1-CCU Inputs CCU Inputs 5/8
2-CCU Analog
CCU Inputs 5/8
3-CCU Outputs
Hardware Detect 1
3.3.1 CCU Inputs Hardware Detect 2

Hardware Detect 3
CCU Inputs Menu has eight sub-menus.
CCU Inputs 1/8
CCU Inputs 6/8
CCU Inputs 1/8
CCU Inputs 6/8
Start Signal
Brake Light Sw Valve Power 1
Hazard Dash Sw Valve Power 2
Valve Power 3
Park Brake Dash Sw
66 Doc. No. 872272 : Rev 0

CCU Inputs 7/8 CCU Analog 3/6
CCU Inputs 7/8 CCU Analog 3/6

Valve Power 4 Battery 24V 00000 mV
Valve Power 5 Battery 12V 00000 mV
Valve Power 6 5V Supply 1 00000 mV
5V Supply 2 00000 mV
SSM 8/8 CCU Analog 4/6
SSM 8/8 CCU Analog 4/6

Press Aircon Air Temp 000.0 °C
any Aircon Air Temp 0000 mV
button Cab Temp 000.0 °C
Cab Temp 0000 mV
CCU Analog 5/6

3.3.2 CCU Analog
CCU Analog 5/6
CCU Analog has six sub-menus.
Wet Brake Temp 000.0 °C
CCU Analog 1/6
Wet Brake Temp 0000 mV
CCU Analog 1/6 Artic Angle 000.0 °
Bin Position 000.0 % Artic Angle 00000 mV
Bin Position 0000 mV
CCU Analog 6/6
Bin Lever Pos 000 %
Bin Lever Pos 0000 mV CCU Analog 6/6
Left Height 000.0 mm
CCU Analog 2/6
Left Height 00000 mV
CCU Analog 2/6
Right Height 000.0 mm
Air Pressure 00.0 bar Right Height 00000 mV
Air Pressure 0000 mV
Hydraulic Temp 000.0 °C 3.3.3 CCU Outputs
Hydraulic Temp 0000 mV
Test Outputs
Test all Outputs
(Ignition on and engine not running)
Press SELECT to Test

NOTE:
Output values can only be viewed
while engine is running and not tested.
Doc. No. 872272 : Rev 0 67

The CCU Outputs Menu has eight sub-menus CCU Ouputs 6/8
and can only be accessed in the service mode.
CCU Outputs 6/8
CCU Ouputs 1/8
Horn / Hooter
CCU Outputs 1/8
Park Brake Sol
Artic Reverse Light
Overspeed Control
Brake Light
IDL Solenoid
Left Ind Light
CCU Ouputs 7/8
Right Ind Light
CCU Outputs 7/8
CCU Ouputs 2/8
CTD Solenoid
CCU Inputs 2/8
Pneumatic Blow Off
F Wiper Park Sig Mirror Heating
R Wiper Park Sig Hyd Cut Sol
Scraper Dash Sw
CCU Ouputs 8/8
IDL Pressure Sw
CCU Outputs 8/8
CCU Ouputs 3/8
D plus
CCU Inputs 3/8
A/C Clutch Sol
Two Speed Press
Recirc Flap 000.0 %
F Two Speed Sw
Mid Two Speed Sw
R Two Speed Sw 3.4 OEU Diagnostics
CCU Ouputs 4/8 The OEU Diagnostics Menu has two sub-menus:
CCU Inputs 4/8 OEU Diagnostics 1/2

Horn Sw 1-OEU Inputs
Aircon Thermo Sw 2-OEU Outputs
Bonnet Fan Temp Sw
There are three sub-menus in the OEU Inputs

Menu.
CCU Ouputs 5/8
CCU Outputs 5/8

Bin Up Solenoid 00000
Bin Down Solenoid 00000
Bin Press Reduc
Bin Lever Latch
68 Doc. No. 872272 : Rev 0

OEU Inputs 1/3 OEU Outputs 2/7

Hardware Detect 1 Left Strut Up 00.0 %
Hardware Detect 2 Left Strut Down 00.0 %
Hardware Detect 3 Right Strut Up 00.0 %
Right Strut Down 00.0 %
Valve Power 1 Two Speed Solenoid

Valve Power 2 Automatic Neutral
Valve Power 3 Pre-Sel Sec Gear
Unladen

Valve Power 4 Blower Speed 1 00000
JD Starter 00000
OEU Outputs 5/7

There are seven sub-menus in the OEU Outputs
Menu and is can only be accessed in Service
Mode.
OEU Outputs 5/7
OEU Outputs 1/7 Feet Actuator 000.0 %
OEU Outputs 1/7 Mid/Demist Act 000.0 %
Heater Valve Act 000.0 %
Fan Cut Solenoid
Fan Low Solenoid
Fan Medium Solenoid OEU Outputs 6/7
Gear Hold Control OEU Outputs 6/7

Load Light Yellow
Load Light Green
Load Light Red
Doc. No. 872272 : Rev 0 69

OEU Outputs 7/7

3.6 OBW Diagnostics
OEU Outputs 7/7 There are three sub-menus under the OBW
Bonnet Fan 1 00000 Diagnostics menu. (Can only be switched on in
Factory mode).
Bonnet Fan 1 00000
OBW Diagnostic 1/3
OBW Diagnostic 1/3

Payload 000.0 T
3.5 MDU Diagnostics Gain 000.0 kg/cnt
Mode XXXXXXXX
There are four sub-menus under the MDU
Diagnostics menu. Offset 00000000
MDU Diagnostic ¼
OBW Diagnostic 2/3
MDU Diagnostic 1/4 OBW Diagnostic 2/3

Fuel Level 000.0 % Raw Counts 00000000000
Fuel Level 000.0 mV MDU Gain 000.0 kg/cnt
Hyd Filter Sw
Test Wgt 000.0 T
Hyd Level Sw
Test Off 00000000
MDU Diagnostic 2/4
OBW Diagnostic 3/3
MDU Diagnostic 2/4 OBW Diagnostic 3/3
CTD Sw
Tau 00
E/Steering Sw
H/Light Bright Sw
H/Light Dip Sw
MDU Diagnostic ¾
MDU Diagnostic 3.7 MM Diagnostics

3/4
Eng Cool Lvl Sw There are three sub-menus under the MM
Diagnostics menu.
Cold Start Sw
MM Diagnostics 1/3
Eng Filter Sw
Trans Filter Sw MM Diagnostic 1/3
Total Msg TX 000000
MDU Diagnostic 4/4
Total Msg RX 000000
MDU Diagnostic 4/4 Critical Rec 000000
Low Brake Press Sw Event Credits 000000
Park Brake Press
70 Doc. No. 872272 : Rev 0

MM Diagnostics 2/3 Can Stats 2/4
MM Diagnostic 2/3 CAN Stats 1/4

MT2000 Status Bus Load 000.0
Program Mode TX Count 00000000
Package XXXXXXXX RX Count 00000000
Frequency XXXXXXXX Errors/sec 000.0
Can Stats ¾
MM Diagnostics 3/3
CAN Stats 3/4
MM Diagnostic 3/3
ACK Errors 00000000
Altitude 00000.00 m
Bit 1 Errors 00000000
Latitude 00000.0000
Bit 0 Errors 00000000
Longitude 00000.0000
CRC Errors 00000000
GPS Speed 00.0 KM/H
Can Stats 4/4
3.8 CAN Diagnostics
CAN Stats 4/4
There are two sub-menus under the CAN
Diagnostics menu. SELECT to Reset Errors
Can Diagnostics ½
CAN Diagnostics 1/2

1-CAN Stats
2-RX CAN Mess 3.8.2 RX CAN Mess
RX CAN Mess will display all active controllers.
RX CAN Mess 1/x

3.8.1 CAN Stats
ECU 00000000 000.0
CAN Stats has four sub-menus.
ECU 00000000 000.0
Can Stats ¼
ECU 00000000 000.0
CAN Stats 1/4 ECU 00000000 000.0
Bus Load 000.0
TX Count 00000000
RX Count 00000000
Errors/sec 000.0
Doc. No. 872272 : Rev 0 71

3.9 TPM Diagnostics Left Rear 5/6
TPM Diagnostics has six sub-menus. Left Rear 5/6

Left Front 1/6 Tire Temperature 000.0 °C
Left Front 1/6 Gauge Pressure 000 kPa
Comp Set Press 000 kPa
Tire Temperature 000.0 °C
Tire ID 00000000000000
Gauge Pressure 000 kPa
Comp Set Press 000 kPa Right Rear 6/6
Tire ID 00000000000000
Right Rear 6/6
Right Front 2/6
Tire Temperature 000.0 °C
Right Front 2/6 Gauge Pressure 000 kPa
Tire Temperature 000.0 °C Comp Set Press 000 kPa
Gauge Pressure 000 kPa Tire ID 00000000000000
Comp Set Press 000 kPa
Tire ID 00000000000000 3.10 Task Times
Task Times has three sub-menus and can only

be accessed in Factory Mode.
Left Middle 3/6 Task TImes 1/3
Left Middle 3/6 Task Times 1/3

Tire Temperature 000.0 °C Task 750 us 00.000
Gauge Pressure 000 kPa Task 1 ms 00.000
Comp Set Press 000 kPa Task 3 ms 00.000
Tire ID 00000000000000 Task 5 ms 00.000
Right Middle 4/6 Task Times 2/3
Right Middle 4/6 Task Times 2/3

Tire Temperature 000.0 °C Task 10 ms 00.000
Gauge Pressure 000 kPa Task 20 ms 00.000
Comp Set Press 000 kPa Task 50 ms 00.000
Tire ID 00000000000000 Task 100 ms 00.000
72 Doc. No. 872272 : Rev 0

Task Times 3/3 4.1 Monitor Settings

Task Times 3/3 There are six sub-menus in menu "Monitor
Settings".
Task 250 ms 00.000
Monitor Settings
Task 1 s 00.000
Task 10 s 00.000 Monitor Settings 1/6
1-Language
2-Units
4 Machine Config 3-Backlighting
In the Main Menu, scroll to "Machine Config" 4-Time Offset
menu and press "SELECT" button.
5-LCD Contrast
There are fourteen sub-menus in menu "Machine
Config". 6-LCD Offset
Machine Config 1/14
4.1.1 Language Menu
Machine Config 1/14 Language
1-Monitor Settings
v English
2-Wiper Timing
German
3-Scraper Function
French
4-Prod Options
Spanish
5-Bin Settings
6-Tire Size There are four options to choose from:
7-Position Sensors 4.1.2 Units Menu
8-OBW Config
Units
9-MM Config
10-TPM Config v Metric
11-Hyd Press Setup Imperial
12-Sus Setup
13-Enable Options
14-Factory Functions
There are two options to choose from:
Doc. No. 872272 : Rev 0 73

4.1.3 Backlighting Menu 4.2 Wiper Timing

Backlighting Wiper Timing
MENU to Exit MENU to Exit
BACK to Decrease BACK to Decrease
NEXT to Increase NEXT to Increase
SELECT to Store SELECT to Store
50 5 sec
4.1.4 Time Offset Menu 4.3 Scraper Function (Not Used)

Time Offset
The Scrape Menu has two sub-menus:
MENU to Exit Scraper Function 1/2
BACK to Decrease
1-Scrape Gear
NEXT to Increase
2-Hold Out Gear
SELECT to Store
2
4.1.5 LCD Contrast Menu
LCD Contrast 4.3.1 Scrape Gear Menu

MENU to Exit Scrape Gear
BACK to Decrease
MENU to Exit
NEXT to Increase
BACK to Decrease
SELECT to Store
NEXT to Increase
5
SELECT to Store
1
4.1.6 LCD Offset Menu (Accessible in Service
Mode only)
LCD Offset 4.3.2 Hold Out Gear Menu
LCD Offset Hold Out Gear

45 2
74 Doc. No. 872272 : Rev 0

Speed Limit 1
4.4 Prod Options
Speed Limit 1
Prod Options Menu has three options:
MENU to Exit
Prod Options 1/3
BACK to Decrease
1-e-Bin NEXT to Increase
2-Engine Limit
SELECT to Store
3-Speed Limit
99 KM/H
Speed Limit 2
Prod Options 1/3
Speed Limit 2
Prod Options 1/3
MENU to Exit
v Bin Restriction
BACK to Decrease
Load Selection
NEXT to Increase
Load Spreading
SELECT to Store
99 KM/H
Engine Limit
Site Limit
Engine Limit Site Limit

2240 99 KM/H
Speed Limit has four sub-menus: Factory Limit
Speed Limit ¼ Factory Limit

Speed Limit 1/4 MENU to Exit
1-Speed Limit 1 BACK to Decrease
2-Speed Limit 2 NEXT to Increase
3-Site Limit SELECT to Store
4-Factory Limit 99 KM/H
Doc. No. 872272 : Rev 0 75

4.5 Bin Settings 4.7 Position Sensors (Only Accessible

in Service Mode)
There are two sub-menus in menu "Bin Settings".
4.7.1 Bin Position (Only Accessible in Service
Bin Settings Mode)
Bin Settings 1/2 The bin position menu has seven sub-menus:
1-Production Limit Bin Position 1/7
2-Safety Limit Bin Position 1/7

SELECT to Set Zero
Production Limit 000 %

0000 mV 0000 mV
Production Limit
Bin Position 2/7
MENU to Exit
BACK to Decrease Bin Position 2/7
NEXT to Increase SELECT to Set Full Tip
SELECT to Store
100 % 000 %
0000 mV 0000 mV
Safety Limit (Accessible in service mode only)
Bin Position 3/7
Safety Limit
Bin Position 3/7
MENU to Exit
BACK to Decrease SELECT to Set Bin Pole
NEXT to Increase
000 %
SELECT to Store
0000 mV 0000 mV
100 %
Arctic Position 4/7
4.6 Tire Size (Only Accessible in Artic Position 4/7

Service Mode)
SELECT to Set Left
Tire Size Menu
Tire Size
000 %
MENU to Exit 0000 mV 0000 mV 0000 mV
BACK to Decrease
NEXT to Increase
SELECT to Store
Goodyear 23.5 R25
76 Doc. No. 872272 : Rev 0

Arctic Position 5/7 OBW Gain
Artic Position 5/7 OBW Gain

SELECT to Set Middle MENU to Exit
BACK to Move
000 % NEXT to Increase
0000 mV 0000 mV 0000 mV SELECT to Store
10.50 kg/cnt
Arctic Position 6/7
Artic Position 6/7 Weight Offset
SELECT to Set Right Weight Offset

SELECT to Set Offset
000 %
0000 mV 0000 mV 0000 mV
Stored 0000000000
Arctic Position 7/7 Stored 0000000000
Height Sensor 7/7
Bin Capacity
SELECT to Set Top
Bin Capacity
00.0 mm 00.0 mm SELECT to Set Offset

0000 mV 0000 mV MENU to Exit
NEXT to Increase
4.8 OBW Configure (Only Accessible SELECT to Store
in Service Mode)
10.50 T
On board weighing has three sub-menus:
4.9 MM Config (Only Accessible in
OBW Config 1/3 Service Mode)
1-OBW Gain
MM Config has four sub-menus:
2-Weight Offset
MM Config 1/2
3-Bin Capacity
1-Test Message
2-Frequency Setup
3-Geofence
3-Package
Doc. No. 872272 : Rev 0 77

Test Message Longitude
Test Message Longitude

SELECT to Send Test MENU to Exit
BACK to Move
NEXT to Increase
SELECT to Store
+000.0000
Frequency Setup
Frequency Setup 1/6 Radius
v Africa Radius
Australia MENU to Exit
Europe BACK to Move
Saudi NEXT to Increase
N America SELECT to Store
Auto Detect 00.0 km
Geofence has three sub-menu Package
Geofence Package 1/5
Geofence 1/3 v None

1-Latitude Lite
Standard
2-Longitude
3-Radius Max
Custom
4.10 TPM Config

Latitude
TPM Config has three sub-menus:

Latitude
TPM Config 1/3
MENU to Exit
BACK to Move 1-CIP Setup
NEXT to Increase 2-Manual Mapping
SELECT to Store 3-Auto Mapping
+000.0000
78 Doc. No. 872272 : Rev 0

CIP Setup Left Front
CIP Setup has three sub menus: Left Front

Front Axle CIP MENU to Exit
Front Axle CIP BACK to Move
NEXT to Increase
MENU to Exit
SELECT to Store
BACK to Move
NEXT to Increase 0000000000
SELECT to Store Right Front
100 kPa Right Front

Middle Axle CIP MENU to Exit
Middle Axle CIP BACK to Move
NEXT to Increase
MENU to Exit
BACK to Move SELECT to Store
SELECT to Store
Left Middle
100 kPa
Left Middle
Rear Axle CIP MENU to Exit
Rear Axle CIP BACK to Move
NEXT to Increase
MENU to Exit
SELECT to Store
BACK to Move
SELECT to Store Right Middle
100 kPa Right Middle
Manual Mapping MENU to Exit

BACK to Move
Manual Mapping has six sub-menus:
NEXT to Increase
Auto Mapping 1/6 SELECT to Store
1-Left Front 0000000000
2-Right Front
3-Left Middle
4-Right Middle
5-Left Rear
6-Right Rear
Doc. No. 872272 : Rev 0 79

Left Rear Right Front
Left Rear Right Front

BACK to Move BACK to Move
0000000000 0000000000
Right Rear Left Middle
Right Rear Left Middle

BACK to Move BACK to Move
0000000000 0000000000
Right Middle
Auto Mappint Right Middle

Auto Mapping has six sub-menus: MENU to Exit
Auto Mapping 1/6 BACK to Move
NEXT to Increase
1-Left Front
SELECT to Store
2-Right Front
3-Left Middle 0000000000
4-Right Middle Left Rear
5-Left Rear Left Rear

6-Right Rear
MENU to Exit
Left Front BACK to Move
Left Front NEXT to Increase
MENU to Exit SELECT to Store

BACK to Move 0000000000
NEXT to Increase
SELECT to Store
0000000000
80 Doc. No. 872272 : Rev 0

Right Rear
4.13 Enable Options (Accessible in
Right Rear Service Mode Only)
MENU to Exit Enable Options has twelve sub-menus:

BACK to Move Enable Options 1/12
NEXT to Increase
v OBW
SELECT to Store
MMU
0000000000
TPM
4.11 Hyd Pressure Setup (Accessible Flashing Beacon

in Service Mode Only) Mirror Heating
Hyd Pressure Setup has seven sub-menus: Work Lights
Rear Wiper
Hyd Press Setup 1/5
Load Lights
v Normal
Artic Rev Light
Hyd Pump
Wet Disk Brake
Bin Up Reduc Disable Bin
Bin Float Eng Cool Fan
Fan Low Speed
Fan Med Speed 4.14 Factory Function (Accessible in
Fan High Speed Factory Mode Only)
Factory Function has seven sub-menus:

4.12 Sus Setup (Accessible in Service
Mode Only) Factory Function 1/4
Suspension Setup has five sub-menus: 1-Erase CCU

2-Erase MDU
Suspension Setup 1/5
3-Erase Both
v Normal
4-Change VIN
Left Up
5-Calc CRC
Left Down
6-Machine Hours
Right Up 7-Odometer
Right Down
Doc. No. 872272 : Rev 0 81

Erase CCU Machine Hours
Erase CCU Machine Hours

SELECT to Erase MENU to Exit
BACK to Move
NEXT to Increase
SELECT to Store
0000000000
Erase MDU
Erase MDU Odometer
SELECT to Erase Odometer

MENU to Exit
BACK to Move
NEXT to Increase
SELECT to Store
Erase Both
0000000000
Erase Both
SELECT to Erase 5 Machine ID
There are nine sub-menus in menu "Machine ID".
Machine ID 1/9
1-ECU
Change VIN 2-TCU
Change VIN 3-MDU
MENU to Exit 4-CCU

BACK to Move 5-OEU
NEXT to Increase 6-SSM
SELECT to Store 7-MMU
AEB0000000R000001 8-OBW
9-TPM
Calc CRC
Calc CRC Each of the menus above has only one

sub-menu.
SELECT to Proceed
82 Doc. No. 872272 : Rev 0

ECU SSM
ECU 1/1 SSM 1/1

HW Ver: 0000.0 HW Ver: 0000.0
SW Ver: 0000.0 SW Ver: 0000.0
ECU Hours: 000000.0
TCU MMU
TCU 1/1 MMU 1/1

SW Ver: 0000.0 HW Ver: 0000.0
Cal Ver: 0000.0 SW Ver: 0000.0
Cal Type: 000000.0 MT2000 xxxxxxxxxxx
MDU OBW
MDU 1/1 OBW 1/1

HW Ver: 0000.0 HW Ver: 0000.0
SW Ver: 0000.0 SW Ver: 0000.0
VIN: xxxxxxxxxxx
CCU TPM
CCU 1/1 TPM 1/1

HW Ver: 0000.0 HW Ver: 0000.0
SW Ver: 0000.0 SW Ver: 0000.0
VIN: xxxxxxxxxxx
OEU 6 Service Mode (Accessible in Service

OEU Mode Only)
1/1
HW Ver: 0000.0 Service Mode
SW Ver: 0000.0 Service Mode

MENU to Exit
BACK to Move
NEXT to Increase
SELECT to Store
0000 0000
Doc. No. 872272 : Rev 0 83

7 Factory Mode (Accessible in Factory The On Board Weighing Module (OBW)

measures the strain as seen by the truck’s
Mode Only)
walking beams.
Factory Mode
This data is sent to the Chassis Computer Unit
(CCU) via the Controller Area Network (CAN),
Factory Mode where the strain is used to calculate the payload
of the truck.
MENU to Exit
BACK to Move The calculated payload is transmitted on the CAN
bus in the vehicle weight message, cargo weight.
NEXT to Increase (See specification SAE J1939 – 71, message
Vehicle weight for more detail.) The OBW Module
SELECT to Store uses this data to determine which load light
should be on.
0000 0000
The Chassis Control Unit (CCU) determines the
truck’s rated capacity (in short tons) from the VIN
number. The CCU module converts this value to
Trip Load
metric tones and drive the load lights in the
following manner:
NOTE:This value is only displayed when an
On Board Weighing System is installed on the • If the vehicle speed is lower than 5 km/h and
machine, otherwise “- - - - ” is displayed. the payload is less than 75% of the truck’s
rated capacity, the yellow light is blinking at a
This option on the default menu gives the
rate of 1 blink per second.
accumulated weight in metric tons since the last
reset of the “Trip Load”. (Example: If the trip • Irrespective of the vehicle speed, if the
load was reset in the morning and has done 10 payload is equal or larger than 75% but less
trips for the day; it will display the total amount of than 95% of the truck’s rated capacity, the
tons moved for the ten trips). yellow light is permanently on.
• Irrespective of the vehicle speed, if the
payload is equal to 95% and less than 110%
Pay Load
of the truck’s rated capacity, the green light is
permanently on.
NOTE:This value is only displayed when an
On Board Weighing System is installed on the • Irrespective of the vehicle speed, if the
machine, otherwise “- - - -” is displayed. payload is larger than 110% of the truck’s
rated capacity, the red light will be on.
This value is displayed in screen one and five. It
is the actual load on the bin. If the bin is empty, During power-on, the CCU Module tests the load
the value displayed will be “0”. If OBW is not lights. First it switches only the yellow light on for
installed, “- - - -” will be displayed. a period of 100 ms, then only the green light for
100 ms then only the red light for 100 ms. At the
The “Pay Load” is measured automatically by end it switches all the lights off for 200ms.
the “On Board Weighing System”.
The above sequence repeats 10 times after
On Board Weighing System (OBW) (Optional) which the CCU Module commences with its
normal operation. This power-up sequence can
The OBW weighs the load as it is loaded onto the be used during the installation phase to confirm
bin. It automatically add up the weight as it is the wiring and light colours.
loaded.
If the OBW function is switched off at the MDU,
Functional description of the OBW with the OBW module will complete the power-on test
upgraded software (See Service Bulletin sequence but will not drive any lights during
2005/1013). normal operation.
84 Doc. No. 872272 : Rev 0

Iqan Unit
X237
X238
TD0006810
INPUTS AND OUTPUTS
PLUG X238 42 WAY AMP CONNECTOR
PIN INPUT/OUTPUT RANGE
1 Ground Ouput Negative output for paddle switches (Common

to all 6 paddles switches)
2 Ground Ouput Paddle switch 1 analog return 0-5V
3 Analog Input Paddle switch 2 analog return 0-5V
8 Ground Output Common ground for hydraulic valves 1 and 2
Doc. No. 872272 : Rev 0 85

PIN INPUT/OUTPUT RANGE
14 Ground Chassis ground
15 Positive Output 5V Common output for all 6 paddle switches
22 Positive Output Variable current output to hydraulic valve 1
28 Positive Input Ignition positive from fuse 13 24 Volt
29 Positive Input Ignition positive from fuse 13 24 Volt
42 Positive Input Ignition Positive From Fuse 13 24 Volt
86 Doc. No. 872272 : Rev 0

PLUG X237 -2 (42 WAY AMP PADDLE CONTROLS AND

CONNECTOR) XP CAN 2 PROPORTIONAL VALVES
The paddle controls are used to activate and

PIN INPUT/OUTP RANGE control the proportional valves on the rear chassis
UT which in turn will control the hydraulic flow to and
from the scraper, which is connected to the valve
2 Data Line Digital data bank. The valves are proportional, there for the
line CAN - hydraulic flow rate through these valves can be
BUS controlled by the operator by moving the
(Terminator) appropriate paddle to the desired position. These
paddles have a built-in return to zero feature,
6 Data Line Digital data meaning that, should the operator let go of the
line CAN - paddle it will immediately return to the rest (zero)
BUS position.
(Terminator)
The MDM is mounted in the cab roof on the right
hand side. This module allows the operator to:
IQAN UNIT OPERATION AND
• View system information.
SETTING OF PARAMETERS • View system settings (clock, sounds etc.)
• Use the display as a tool to view input/output
currents and voltages.
1
Using a factory access code, personnel are able to:
• Change function modes.

• Adjust operating properties.
3
2
Description of the menu system
4 Overview
ESC
11:48 30 Nov 2000 M Mode
Reach Stacker 02.01
+
Properties Information
Own menu figures -
TD0006813
24,00 V
Measure SETTINGS
Settings
IQAN CONTROLS
1. Master display module (MDM).

2. Iqan scraper function switch.
3. Iqan cut switch.
4. Paddle controls. The operational position and the menu system.
The character window, general

information
This chapter describes how to utilize the display by

using the menu system. In the display’s menu
Doc. No. 872272 : Rev 0 87

system, you get access to information and The menu system

settings concerning the IQAN system.
Bell 2806D 02.02

When you read about the different menus, it is
When you turn on the display, the date and time also recommended to look at the menu overview.
are shown in the character window together with
application description and version. We call this The system consists of five menus and their
the operational position. This information is submenus:
normally shown when the machine is in
operation. In the menu system you can change • Mode
driver mode, display settings, channel properties, • Information
read the system information and measure on • Settings
channels. • Measure
The top level in the menu system. • Properties
The information menu.
On the display there are three function

buttons[F1], [F2] and [F3]. These are used to
select different functions in the system’s
submenus. Above every function button, there is
an informative tab for the current function.
The five menus are characterised by their own
icon which is shown before the menu name. The UP/DN button in the submenus
Browsing in the menu system. When you are in In the submenus, the UP/DN button is used for
operational position, use the ESC-button to go to the following:
the menu system and also when you want to
return to the operational position. (To return to Indication Description
operational position, you must be on the first Browse in list
menu level.)
Increase/decrease value
To browse between the different menus, use the

UP/DN-button to the right of the character
window. The indication is shown in the upper right corner
of the character window.
Every menu contains one or several submenues.
In this submenues, use the ESC-button to return The symbol of browse in
list.
to the previous menu level.
Operational position
Browse in list.
In the operational position, date and time are
shown. This is the mode that is shown during The symbol of increase/
normal operation. decrease value.
Increase/decrease value.
Bell 2806D 02.02

3 Mode setting
The operational position.
NOTE
88 Doc. No. 872272 : Rev 0

The changing or copying of modes is only Press APPLIC [F1] to show application
intended for factory use and is password description and version.
protected System information, application.
In this menu, you can switch between up to four • Press MORE.. [F1] to show information about
different driver modes and copy the values from the latest change.
one mode to the active mode. • To return to the previous menu, press ESC
The current mode is always shown in the Show application comments
character window’s upper right corner.
Press COMMENT[F2] to show application
Select mode comments.
Active mode.
Bell 2806D 02.02
Bell 2806D Scraper control software.

Detents in both directions
March 2006
Select mode. Comments about the application.
• Press SELECT [F1] to select the function The COMMENT tab appears if there are any
SELECT MODE. comments in the application. The display can
• Browse to desired mode using UP/DNand show four rows of comments at the same time.
press OK [F1] to save. The display will
thereafter automatically return to show the • Press UP/DN to show more comments.
operational position.
• If you press CANCEL [F2] or ESC, the display Show module information
returns to the previous menu without changing
Under the module tab you find information about
mode setting.
the including modules. Example, information
about software, hardware and status.
4 System information
This menu contains functions for showing
information about the application, and the
including modules.
Show application information
System information, modules.
• Browse between the different modules using

UP/DN.
Bell 2806D 02.02 Application description and version.
Show module status information•
080815 14:25:48 Latest change (date and time).
0000001CDAE0 Latest change (key id).
KOBUS JACOBS Key label.
Doc. No. 872272 : Rev 0 89

PressSTATUS[F1] to show status for the 5 Display settings

selected module.
Module type.
Hardware version and Production date.
Serie number hardware and Operating time
.
Status for the selected module.
Disable modules
• Press ENABLE/DISABLE [F1] to disable a This menu contains functions to change the
specific module if it´s not to be used in the display’s contrast and light, change language on
application. the menu texts, set the volume for the buzzer,
change button sound and set the date and time.
• Press ESC to return to previous menu.
Show internal value information
Under the tab INTERNAL you find internal values

for every module, for example power supply,
reference voltage and temperature.
Display settings.
There is not enough space in this menu for all

function tabs in the character window. Using
MORE [F3], will switch between the different
Module type.
tabs.
Power supply.
Temperature and Utilization.
Change contrast
• Press LCDF1LCD SETTINGS.
The internal values for the IQAN-MDM.
Show software information
There are some information about the software

for respective module. For example software
version and EAN-number.
LCD settings, contrast.
Module type. • Press CONTRAST [F1] to select the function

Software version and Software EAN.
Software check sum and IDP version.
LCD CONTRAST.
• Change to desired contrast using UP/DNand
press OK [F1] to save the setting and return to
the previous menu.
• CANCEL [F2] or ESC returns the character
Information about the software in the IQAN-MDM. window to the previous menu without saving
any new setting.
Show hardware information
Reset contrast
There are information about the hardware for
every module. For example the module´s serial RESET [F3] resets the character window’s
number, production date and operating time. contrast to the pre-set factory value which
Information about the IQAN-MDM´s hardware. corresponds to 30.
90 Doc. No. 872272 : Rev 0

Change light • PressALARM[F1] to select the function for

setting the volume for the alarm signal.
Press LCD [F1] to select the function LCD
SETTINGS.
• Change to the desired volume using
• UPDN. There are ten volume levels. 0 implies
• LCD settings, light. that the sound is turned off. 100 is the loudest.
Thereafter, press OK[F1] to save the value
and return to the previous menu.
• CANCEL[F2] or ESC returns the character
window to the previous menu without saving
any new setting.
Reset the volume
RESET[F3] resets the alarm volume to the

pre-set factory value which corresponds to 50.
Press LIGHT [F2] to select the function LCD
LIGHT. Change button sound
• Change to desired light value using UP/DNand Press SOUNDF1SOUNDSETTINGS
press OK [F1] to save the setting and return to
the previous menu.
• CANCEL[F2] or ESC returns the character
window to the previous menu without saving
any new setting.
Reset light
RESET [F3] resets the character window’s light

to the pre-set factory value which corresponds to
100.
Sound settings, button.
Sound settings
• Press BUTTON[F2 to select the function to
In this menu, you can set the volume of the alarm change the button sound.
signal and the level of the button sound.
• Change to the desired button sound using
UP/DN. There are 10 different button beep
levels. 0 implies that the button beep is turned
off.100 is the loudest beep sound. Thereafter,
press OK[F1] to save the value and return to
the settings menu.
Display settings, buzzer. • CANCEL[F2] or ESC returns the character
window to the settings menu without saving
• To shift to the tab SOUND, press MORE [F3]. any changed setting.
Set the alarm volume Reset the volume
PressSOUND[F1] to select the function SOUND RESET [F3] resets the button sound to the
SETTINGS pre-set factory value which corresponds to 50.
Set date and time
In this menu, you can set the date and time.
To shift to the tab SET CLOCK press MORE [F3].
Buzzer settings, alarm.
Doc. No. 872272 : Rev 0 91

Inputs Outputs Other

Voltage in Current out Event counter
Digital in Digital out Hour counter
Frequency in PWM out
Direction (Lever X,Y, Z)
• browse in the list for the different types of

inputs, outputs respective function parameters
using UP/DN
• Press SELECT [F1] to choose channel type.
Measure on an analog input
Below follows the instruction on how to measure

Display settings, set clock.
a voltage input. The measure procedure is
applicable on the channel types Frequency in
• Using SET CLOCK [F2], you select the and Direction too.
function for setting date and time.
Select VOLTAGE IN and thereafter press
Browse using UP/DNand thereafter press SELECT [F1].
SELECT [F1] to select desired alternative from
the list.
Year
Month
Day Channel type and PIN-number.
Hour
Measured value.
Minute Joystick 1
Channel name.
• Change to desired value using UP/DN and

press OK [F1] to save and return to the Measure inputs, voltage.
previous menu.
• CANCEL [F2] or ESC returns the character • Browse in the list for the different voltage
window to the previous menu without saving inputs using UP/DN.
any changed setting. • Use ESC to return to previous menu.
Show the voltage value or the scaled value
6 Measure
• on the tab MV/ SCALED [F1], you can
This menu contains functions for measuring on choose between showing the voltage value or
the different channels. the scaled value for the input.
For the channel type Frequency it shows the

unscaled value in [Hz].
Scope
Measuring channels. Using SCOPE [F3], you can get the channel’s
value presented in the form of a graph to be able
• Press INPUTS [F1], OUTPUTS [F2] respective to read an historic trend.
OTHER [F3] to select if you want to measure
the value of an input, output or function
parameter.
Voltage in, scope.
92 Doc. No. 872272 : Rev 0

Measure on an analog output Channel properties

Below follows information how to measure on a
current output channel. The measure procedure This menu contains functions for calibrating
is also applicable on the channel type PWM out. inputs, adjusting outputs and changing the values
of function parameters.
• Press OUTPUTS [F2] to measure on an
NOTE
output.
• Select CURRENT OUT and press SELECT These options are only intended for factory use
[F1]. andis password protected
Properties for the channels.•
Channel type and pin number.
Measured value.
Output 1
Channel name.
Measure outputs, current.
• Browse in the list for the different current

outputs using UP/DN.The +/- characters show
if the output is working in a positive or negative
direction.
Scope
Using SCOPE [F3], you can get the channel’s

value presented in the form of a graph to be able
to read an historic trend
Current out, scope.
To the left in the graph, the channel’s minimum

and maximum values are shown. The graph is
drawn from left to right. After 30 seconds, the
curve is drawn from the left again.
• To return to the previous menu, press ESC.
Doc. No. 872272 : Rev 0 93

Multiple Wire Colours WIRE COLOUR

Wires with more than one colour abbreviation will The wire colour (Two character code) is simply
have a stripe running parallel to the wire. an abbreviation of the wire colour.
The first colour abbreviation will be the main

WIRE COLOUR SCHEMATIC
colour, the second abbreviation will be the colour
ABBREVIATION
of the stripe.
Black BK
Example: WH/BK represents a white wire with a
black stripe. Blue BL
Wires with three colour abbreviations will have Brown BN
two stripes running parallel to the wire. The
second and third colour abbreviations will be the Green GN
colour of the stripes.
Grey GY
Example: BK/WH/GN represents a black wire
with a white and green stripe. Orange OR
Pink PK
Purple PL
Red RD
White WH
Yellow YL
94 Doc. No. 872272 : Rev 0

Diodes/Resistors, Fuses and Relays/Voltage Regulator
FUSE AND RELAY LAYOUT
R1 - 12V SUPPLY R2 - GEAR HOLD TCU S1 - STUD 1

ECU (20A on JD ECU)
30 30 OEU BATTERY POWER
CCU2
87a 87a MM
BATTERY BALANCER
85 86 85 86
87 87 DIAGNOSTIC
CONNECTOR
BATTERY
FUSE 1
FUSE 2
FUSE 3
FUSE 4
FUSE 5
FUSE 6
FUSE 7
10A
10A
20A
20A
10A
10A
10A
MDU2
R3 - AUTO NEUTRAL R4 - OVERSPEED
IQAN FUSE 43 12V RADIO IGNITION
30 30 INTERIOR LIGHT, BRAKE SWITCH
& HAZARD SWITCH 10A
87a 87a FUSE 44 12V 2WAY RADIO &
REVERSE MONITOR
85 86 85 86 10A
87 87 BATTERY
SPARE 2
SPARE 3
SPARE 4
SPARE 1
FUSE 10
FUSE 8
FUSE 9
FUSE 45 12V POWER SOCKET &
10A
10A
10A
10A
10A
10A
10A
12V CIGARETTE LIGHTER
10A
FUSE 46 MM 12V INPUT &
CCU 12V INPUT
10A
FUSE 47 12V BATTERY POWER -
RADIO SUPPLY
10A
IGNITION IGNITION IGNITION IGNITION
SPARE 5
FUSE 15 TCU FUSE 22 OEU FUSE 29 CCU2 FUSE 36 HARDWARE DETECTION, MM IGN. STATUS, PARK
IGNITION STATUS IGNITION STATUS BRAKE DASH & PRES.SWITCH, HIGH RANGE DIODE 1 ALTERNATOR D+
10A 10A 10A 10A PRES. SWITCH
FUSE 16 COLDSTART FUSE 23 OEU OUTPUT FUSE 30 CCU2 OUTPUT FUSE 37 12V RELAY, FR WIPER PARK SIGNAL, HDLIGHT
DRIVER SUPPLY 2 DRIVER SUPPLY 2 SWITCH, DRIVER ID, AUTO GREASER
40A 25A 25A 10A INDICATOR, REAR WIPER MOTOR PARK SIGNAL
FUSE 17 ECU FUSE 24 OEU OUTPUT FUSE 31 CCU2 OUTPUT FUSE 38 LOW ACC BRAKE PRES., EMERGENCY
DRIVER SUPPLY 1 DRIVER SUPPLY 1 STEERING, TPM ON 4206D
10A 15A 15A 10A
FUSE 18 OEU OUTPUT FUSE 25 CCU2 OUTPUT FUSE 32 DIAGNOSTIC FUSE 39 AUTO GREASER IGN. SUPPLY
DRIVER SUPPLY 3 DRIVER SUPPLY 3 CONNECTOR
20A 20A 10A 10A
FUSE 19 OEU OUTPUT FUSE 26 CCU2 OUTPUT FUSE 33 MDU2 FUSE 40 ELECTRICAL SEAT
S2 - STUD 2
DRIVER SUPPLY 6 DRIVER SUPPLY 6 IGNITION STATUS
30A 30A 10A 10A
IGNITION POWER
FUSE 20 OEU OUTPUT FUSE 27 CCU2 OUTPUT FUSE 34 IQAN FUSE 41 OBW, TPM
DRIVER SUPPLY 4 DRIVER SUPPLY 4 IGNITION SYPPLY
20A 20A 10A 10A
FUSE 21 OEU OUTPUT FUSE 28 CCU2 OUTPUT FUSE 35 MIRROR ELECTRICAL ZF EOL ZF EOL PROG. PIN
DRIVER SUPPLY 5 DRIVER SUPPLY 5
20A 20A 10A
217845
700437-00ii_B
RELAY
At Bell we use a five pin relay, commonly known as a change over relay. This type of relay can be wired
normally open or normally closed. A relay has two sections, the trigger section and the load section.
The pin numbers are numbered as follows:
87a
87
30
85 86
TR000237a
85 Trigger
86 Trigger
30 Supply
87 Normally open (Load)
87a Normally closed (Load)
Doc. No. 872272 : Rev 0 95

96
WH 2.5 D6-T WH 2.5 D1-T WH 2.5 R1-30 1 4
CB1 20A OUT IN
YL/RD 1.5 D3-3 YL/RD 0.75 RD 0.75 FUSE 35-2 2 3
CB1-1 CB1-2
WH 2.5 DIODE1 3A
(Not on B50D & JD 250/300D) BK/WH 1.5 MR-12 3 18
ALT YL/RD 1.5 (JD 250/300D Only)
EE D3-6 BK/WH 1.5 OEUJ1-H1&H2 4 14
RD 70.0 BK 70.0
D6-W GN 2.5 MR-5 5 18
(JD 250/300D Only)
GN 2.5 FUELTP-5 7 19
SERVICE MANUAL MK V
ALT-D+ D6-X GN 2.5 MR-6 6 18

Circuit Schematics
D+ M STUD 1 FUSE 1 10A

GN 10.0 GN 1.5 TCU-2 8 23 Transmission Interface
+ 1 2
ALT-B+ B+ A ALT-E
FUSE 2 10A
KL30
BK/WH 1.5
BK/WH 1.5
GN 0.75 ADM21-1 9 18 JD ECU - 2 (Int) - 20A
D1-U
1 2
KL50
BK 16.0
D6-R
FUSE 3 20A
ALTERNATOR STAR-50 GN 1.5 OEUJ2-L1
1 2
10 15 Output Expansion Unit
STARTER
RD 70.0
EE
BATTERY 12V
DIODE 3A-(JD 250/300D Only) FUSE 4 20A
GN 10.0
GN 1.5 CCU2J2-L1 11 10 Chassis Control Unit
BK/WH 1.5 BK 1.5 1 2
EE
GN 16.0
GN 0.75 MM21C-16 12 25 Memory Module
- FUSE 5 10A
GN 0.75 MM21B-1 13 25 Memory Module
MCB1 60A GN 4.0 1 2
+ +
GN 16.0 GN 10.0 D6-U FUSE 6 10A
ISW1-IN IN OUT ISW1-OUT MCB-1 GN 1.5 BB-2 14 4 Battery Balancer
MCB-2 1 2
GN 10.0
ISW2-IN ISW2-OUT
RD 70.0
- -
FUSE 7 10A
IN OUT GN GN 0.75 DIAG-B 15 25 Diagnostic Connector
1 2
IGNS-1 2.5 IGNS-30
ISOLATOR
86 30
BK 70.0
SWITCH FUSE 8 10A
GN 0.75 MDU2J1-A 16 5 Monitor Display Unit
+ IGNITION 1 2
EE CONT
SOLENOID
FUSE 9 10A
85 87 GN 1.5 IQAN-3 17 29 Iqan Interface
1 2
IGNS-2 IGNS-87
GN 0.75 ILHT-A 18 26 Interior Light
FUSE 10 10A
GN 0.75 BLS-1 19 9 Brake Lights Switch
1 2
GN 0.75 HZDSW-2 20 11 Hazard Switch
BATTERY 12V
IGN-3 IGN-2 RD 10.0 D6-S D1-S RD 10.0 FUSE 15-1 21 2 Interface Connector
Figure 1 : Starting & Charging Circuit
(All Small Trucks)

RD 2.5 AH-1 22 6 Air Heater (Small)
- CB2 20A
ST
ACC
0
IGN
(All Large Trucks) RD 2.5 AH-1 23 6 Air Heater (Large)
RD 4.0 D6-Y RD 2.5 FF-1 24 6 Fuel Filter

CB2-1 CB2-2
(JD 250/300D RD 1.5 COL-1 25 6 Coolant Level
BK 70.0 BAT GND Only)
RD/BK 2.5 D6-V RD/BK 2.5 D1-V RD1.5 ETH-B 203 20 Ether Start Solenoid
IGN-1 E3 BB-6
RD/BK2.5 RD/BK 1.5 26 4
BK 1.5
BK/GN 0.75 CCU2J1-C2 27 7 1
IGNITION SWITCH
700437_001_A_MK V
2806D-2306D
Doc. No. 872272 : Rev 0

2806D-2306D
3 28 FUSE 29-1 RD 6.0

STUD 2
Ignition Solenoid 1 21 IGNS-87 RD 10.0 RD 6.0
Doc. No. 872272 : Rev 0

FUSE15 10A FUSE22 10A
Interface Connector 23 29 TCU-3 RD 1.5 RD 1.5 OEUJ2-M1 42 15 Ignition Status
2 1 1 2

Cold Start Ignition Supply 18 30 CS8-1 RD 2.5 RD 2.5 RD 2.5 RD 1.5 OEUJ3-G1 43 16 Output Driver Supply 2
2 1 1 2
Cold Start Ignition Supply 18 31 CS4-4 RD 2.5 RD 1.5 OEUJ3-G2 44 16 Output Driver Supply 2

ADM, JD ECU 18 32 ADM21-2 RD 0.75 RD 1.5 RD 2.5 RD 1.5 OEUJ3-H3 45 16 Output Driver Supply 1
2 1 1 2
MR 18 33 MR-15 RD 1.5 RD 1.5 OEUJ3-H4 46 16 Output Driver Supply 1

Output Driver Supply 3 14 34 OEUJ1-G3 RD 1.5 RD 2.5 RD 2.5 RD 1.5 CCU2J1-G3 47 7 Output Driver Supply 3
2 1 1 2
Output Driver Supply 3 14 35 OEUJ1-G4 RD 1.5 RD 1.5 CCU2J1-G4 48 7 Output Driver Supply 3

Output Driver Supply 6 14 36 OEUJ1-H3 RD 1.5 RD 2.5 RD 2.5 RD 1.5 CCU2J1-H3 49 7 Output Driver Supply 6
2 1 1 2
Output Driver Supply 6 14 37 OEUJ1-H4 RD 1.5 RD 1.5 CCU2J1-H4 50 7 Output Driver Supply 6

Output Driver Supply 4 15 38 OEUJ2-L3 RD 1.5 RD 2.5 RD 2.5 RD 1.5 CCU2J2-L3 51 10 Output Driver Supply 4
2 1 1 2
Figure 2 : Ignition Power Fuses
Output Driver Supply 4 15 39 OEUJ2-M3 RD 1.5 RD 1.5 CCU2J2-M3 52 10 Output Driver Supply 4

Output Driver Supply 5 15 40 OEUJ2-L4 RD 1.5 RD 2.5 RD 2.5 RD 1.5 CCU2J2-L4 53 10 Output Driver Supply 5
2 1 1 2
Output Driver Supply 5 15 41 OEUJ2-M4 RD 1.5 RD 1.5 CCU2J2-M4 54 10 Output Driver Supply 5
2
700437-02_MK5
97
SERVICE MANUAL MK V
98
Stud 2 Connection 2 28 FUSE 15-1 RD 6.0
Signal Ignition Supply 1 -
RD 0.75 CCU2J3-F4 67 12 Hardware Detection
Ignition Status 10 55 CCU2J2-M1 RD 1.5 RD 6.0 RD 1.5 RD 0.75 PBDSW-2 66 11 Park Brake Dash Switch
2 1 1 2
RD 0.75 MM21C-5 68 25 Memory Module Ignition Status

RD 0.75 PBPS-2 69 6 Park Brake Pressure Switch
FUSE30 25A
SERVICE MANUAL MK V
Output Driver Supply 2 12 56 CCU2J3-G1 RD 1.5 RD 2.5 RD 0.75 2SPS-3 70 7 2 Speed Pressure Switch
2 1
Output Driver Supply 2 12 57 CCU2J3-G2 RD 1.5
FUSE31 15A
Output Driver Supply 1 12 58 CCU2J3-H3 RD 1.5 RD 2.5 FWMD-3 71 8 Front Wiper Park Signal
2 1
Output Driver Supply 1 12 59 CCU2J3-H4 RD 1.5 SCS12-1 72 6 Headlight Switch (Flash)
FUSE37 10A SCS12-4 73 6 Headlight Switch (Dip & Bright)

Diagnostic Tool Ignition Supply
FUSE32 10A RD 0.75
1 2
(DIAG-B) 25 60 DIAG-E RD 0.75 DID-1 74 25 Driver ID Ignition Supply
2 1
AGI-A 75 26 Automatic Greaser Indicator

RWMI-3 76 8 Rear Wiper Motor Park Signal
FUSE33 10A
Ignition Supply 6 61 SSM-1 RD 0.75 RD 0.75 R1-86 77 4 12V Relay Ignition
2 1
Ignition Status 5 62 MDU2J1-L RD 1.5
Ignition Supply
(Via Interface Connector) 29 63 IQAN-1 RD 1.5 RD 1.5 D2-N
2 1 1 2
FUSE35 10A FUSE39 10A Automatic Greaser

Ignition Supply via Diode 1 1 2 DIODE 1-IN RD 0.75 D2-R RD 1.5 AG-1 80 26 Ignition Supply
2 1 1 2
Ignition Supply 27 64 MSW-2 RD 0.75
Aircon Ignition Supply 17 65 ACU-8

FUSE40 10A
RD 1.5 ESEAT-1 81 26 Electrical seat
1 2
FUSE41 10A
D5-X RD 1.5 AHP-P RHP-P OBW-4 82 28 Ignition Supply On Board Weighing
1 2
TPM-3 83 28 Ignition Supply Tyre Pressure Monitor

Figure 3 : Ignition Power, Fuses 29 to 41 & ZF EOL
ZF EOL 00A EOL Programming Pin

PK/GY 0.75 TCU-10 84 23 (TCU Interface)
1 2
3
700437-03_C_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

1
CUSTOMER SUPPLIED
2806D-2306D
1 IN-LINE FUSE 2A
12V TWO WAY RADIO BK REVERSE
CAMERA "-" LFS-1
BK
"+" LFS-2
CB1-2
BL
LEFT SPEAKER
2WR-2
2WR-1
Doc. No. 872272 : Rev 0

E2
REVERSE "-" RFS-1
BK 1.5
RM - 2
RM - 1
MONITOR "+" RFS-2
E6
WH 2.5
BK 1.5
RIGHT SPEAKER
FUSE47 10A E2
WH 1.5 WH 1.5
1 2 12V Battery Power - Radio Supply
BK 1.5
87a FUSE43 10A

WH/RD 2.5 WH/RD 1.5 WH/RD 1.5
1 2 12V Radio Ignition
30 87
85 86 FUSE44 10A
BK 1.5 WH/RD 1.5 WH/RD 1.5
1 2 12V 2Way Radio
RADI-A
RADI-B
RADI-C
E3 FUSE45 10A
RELAY 1 WH/RD 1.5 WH/RD 1.5
12V SUPPLY 1 2 12V Power Socket, 12V Cigarette Lighter
BK 1.5
BK 1.5
BK 1.5
WH 1.5
BK/BL 1.5
BK/GN 1.5
WH/RD 1.5
FUSE46 10A
RD 0.75
WH/RD 1.5
WH/RD 1.5 WH/RD 1.5
1 2
3 77 FUSE 37-2
WH/RD 1.5
WH/RD 1.5
A7 A4 A8 B3 B4 B5 B6
Figure 4 : 12V Circuit
WH/RD 0.75
WH/RD 0.75
CL-1 12V-A
4
12V ANTENNA
12V RADIO
12V
2 GN 1.5
CL-2 12V-B
6 RD/BK 1.5 BK 1.5 BK 1.5
E6 E2
CCU2J1-F1
MM21C-1
5 CIGARETTE 12V POWER
LIGHTER SUPPLY
3
85 86
1 BK 1.5
7 25
IGN-3
FUSE 6-2
BATTERY BALANCER E2
26 14
1 1
4
CCU 12V Input
MM 12V Input
700437-04_C_MK5
99
SERVICE MANUAL MK V
100
MDU2J1
A GN 0.75 FUSE 8-2 16 1

MDU2J2
B B
30 40 50
20 60
K 10 70 E DIAG-D 93 25
0 20 30 80
km/h 10 40
P 50 F DIAG-C 94 25
mph 0
COOLANT RPM
6 87 SCS 12-3 WH/GY 0.75 F TEMP G DIAG 95 25
SERVICE MANUAL MK V
6 88 SCS 12-5 GY/WH 0.75 G H
6 89 COL-3 WH/BL 0.75 H J BK 0.75 SSM 96 6
18 90 CS8-8 OR/GN 0.75 J C YL 0.75 SSM-3 97 6

(Used on 4206D Only)
29 91 HLS-1 YL/BL 0.75 L TRANS K GN 0.75 SSM-4 98 6
TEMP FUEL
6 92 PBPS-1 BL/YL 0.75 M L RD 1.5 FUSE 33-2 62 3

Engine Air Intake
Filter Pressure Switch D3-30 PL/GN 0.75 N R BN/RD 0.75 SCS 12-10 99 6
BL/WH 0.75 A S YL/RD 0.75 SCS 12-9 100 6

RD/GY 0.75 C P BK 1.5
E3
OR/BK 0.75 E M BK/RD 0.75 BUZ-1
D D OR/WH 0.75
B
N BL/WH 0.75
BUZ-2
MONITOR DISPLAY UNIT BUZZER
D2-Q
D2-A
D2-B
OR/BK 0.75
D3 - 27
RD/GY 0.75
G
FUEL-1 FUEL-2
HFP-1
Q
BK 1.5
Figure 5 : Monitor Display Unit
AFP-1
FUEL SENDER EE
BL/WH 1.5
P P P E1
BL/WH 1.5
AE AE AE CTDPS-1 1 2
2 1 ES-2 2 1 ES-1 ES-2 2 1 ES-1 BK 1.5 G
HFP-2 BK 1.5 BK 1.5 BK 1.5 FUEL-1 FS-1 FS-2 FUEL-2
3
CTDPS-3 Q
BK 1.5
LOW ACC BRAKE EMERGENCY AFP-2

HYD FILTER PRESSURE 2 STEERING 2 CTD PRESSURE FUEL SENDER EE
PRESSURE (S4) (SP1) SWITCH
5
700437-05_C_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

3 5 5 5 3 5 1 1
2806D-2306D
61 97 98 96 69 92 22 24
1 2 3
MDU2J2-M
FUSE 33-2
MDU2J1-C
MDU2J1-K
MDU2J1
FUSE 36-2
CB2-2
CB2-2
Doc. No. 872272 : Rev 0

SSM-1
RD 0.75
SSM-2 AH-2 t AH-1 FF-1 t<7.2°C FF-2
4 5 6 BK 1.5 RD 2.5 RD 2.5
E5
RD 0.75
SSM-3
BL/YL 0.75
YL 0.75 P
AIR HEATER FUEL FILTER
BK 2.5
BK 2.5
SSM-4 PBPS-2 2 1 PBPS-1

GN 0.75
9
EE E3
7 8 BK 0.75 3
A
PARK BRAKE RD 0.75 FUSE 37-2 73 3
. 0 PRESSURE SWITCH
RD 0.75 FUSE 37-2 72 3
BN/RD 0.75 MDU2J1-R 99 5

SEALED SWITCH MODULE YL/RD 0.75 MDU2J1-S 100 5
24 197 SSCAN-A YL 0.75 GN/BK 0.75 CCU2J1-F2 101 7
24 198 SSCAN-B GN 0.75
SSCAN-C BK 0.75
SCS12-4
SCS12-1
SCS12-9
SCS12-10
SCS12-2
24 199
56 30 Sx Dx 49
L R
COL-2
EE BK 1.5 2 _
HORN
COL-1
INDICATORS
D3 - 2 DIPS BRIGHTS
HEADLIGHTS
5 89 MDU2J2-H WH/BL 1.5 1 SIG
& Coolant Level Circuit

56b 56a L 31
LOW COOLANT
STEERING
LEVEL SWITCH
COLUMN
SCS12-5
SCS12-3
SCS12-11
SCS12-12
SWITCH
BK 0.75
BK 0.75
COL-2
WH/GY 0.75
GY/WH 0.75
EE BK 1.5 2 _ BK 1.5
COL-3
5 89 MDU2J2-H D3 - 2 WH/BL 1.5 3 SIG
COL-1
E3
1 25 CB2-2 RD 1.5 1 +
COL-4
MDU2J2-G
MDU2J2-F
LOW COOLANT 88 87
LEVEL SWITCH 6
5 5
700437-06_A_MK5
Figure 6 : Sealed Switch Module, Steering Column Switch, Air Heater, Fuel Filter
101
SERVICE MANUAL MK V
102
AHP-K RREV-2 RHP-K BK 1.5 RREV-2 RREV-1 RREV-1 YL/GN 1.5 BK 1.5 RHP-K AHP-K
4206D Only 4206D Only R2SSW-1 1 2 R2SSW-2
BUA-B
R2SP1-2 RHP-U AHP-U BK 1.5
AE AE AE
RIGHT REVERSE LIGHT BACK UP REAR 2 SPEED SWITCH
B (NORMALLY CLOSED)
ALARM SPRING APPLIED
AIR RELEASED (B50D ONLY)
LN H
BUA-A
AHP-K LREV-2 RHP-K BK 1.5 LREV-2 LREV-1 LREV-1 YL/GN 1.5

4206D Only 4206D Only
SERVICE MANUAL MK V
AE M2SSW-1 1 2 M2SSW-2
LEFT REVERSE LIGHT R2SP1-2 MAP-2 RHP-U AHP-U BK 1.5
AE
SREV-1 YL/GN 1.5 MID 2 SPEED SWITCH
SPARE REVERSE (NORMALLY CLOSED)
SPRING APPLIED
2306D Only AIR RELEASED (B50D ONLY)
SREV-2 BK 1.5 LN H
E4
REAR EARTH BK 2.5 YL/GY 0.75 RWMI-4 103 8
2306D Only
1 27 IGN-2 BK/GN 0.75 GN/WH 0.75 IQAN-4 104 29
MAP-1
R2SP1-1
G P 2 SPEED
2SPS-1 1 2
PSEN-A
PRESSURE SWITCH
(B50D ONLY)
P 3 2SPS-3
RD 0.75 FUSE 36-2 70 3
RHP-D
RHP-B
W
10 102 CCU2J2-K2 BK/YL 0.75
AIR PRESSURE
SENDER 0-10bar RD/OR 0.75 FWMD-4 105 8
PSEN-B
WH/RD 0.75 FUSE 46-2 85 4
AHP-D
RHP-A
AHP-B
GN/BK 0.75 SCS-2 101 6
LHL-2 LHL-3 BL 0.75 TCU-6 106 23
LHL-1 PBDSW-8 107 11
AHP-A
BL/YL 1.5
WH/OR 1.5
D3-26 108 8
LEFT HEADLIGHT
GY/WH 1.5
BK 1.5
D2-P 109 13
WH/GY 1.5
RHL-1 RD 1.5 FUSE 25-2 47 2
D5-R
D5-P
D2-C
RHL-2 RHL-3 RD 1.5 FUSE 25-2 48 2
EE
RD/WH 1.5 WLHT-A
Figure 7 :CCU2 J1 Circuit (Page 1)
110 8
D3-10
D3-11
RIGHT HEADLIGHT RD/WH 1.5 WLHT-B 111 8
BL 0.75
BL 0.75
YL/GN 1.5
BL/YL 0.75
YL/GY 0.75
GN/BK 0.75
PL/WH 0.75
RD/OR 0.75
WH/RD 0.75
WH/OR 0.75
GN/WH 0.75
RD 1.5 FUSE 26-2 49 2
RD 1.5 FUSE 26-2 50 2
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4
CCU2 J1
7
700437-07_C_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

12 7 9 3 3 9 8 10
2806D-2306D
112 105 113 71 76 114 103 115
CCU2J3-C1
CCU2J1-E3&E4
CCU2J2-E2
FUSE 37-2
FUSE 37-2
CCU2J2-E1
CCU2J1-D3&D4
CCU2J2-G4
Doc. No. 872272 : Rev 0

Thermal 2 2 Thermal
Protection BL 1.5 FWMD-2 OR 0.75 RWMI-2 OR/BL 0.75 RWMD-2 BL 1.5 Protection
2 2
M RD 1.5 FWMD-4 RD/OR 0.75 RWMI-4 YL/GY 0.75 RWMD-4 RD 1.5 M

4 4
1 1
Park Park
GN 1.5 FWMD-1 PK 0.75 RWMI-1 PK/BL 0.75 RWMD-1 GN 1.5
1 1
Earth Earth
BK 1.5 FWMD-6 BK 1.5 RWMI-6 BK 1.5 RWMD-6 BK 1.5
6 E3 E5 6
Ignition Ignition
YL 1.5 FWMD-3 RD 0.75 RWMI-3 RD 0.75 RWMD-3 YL 1.5
3 3
FRONT WIPER MOTOR DOGA REAR WIPER MOTOR DOGA
EE
7 108 CCU2J1-F3&F4 D3-26 BL 1.5 LPLHT-1 LPLHT-2 BK 1.5
FRONT LEFT PARKLIGHT
EE
BL 1.5 RPLHT-1 RPLHT-2 BK 1.5
FRONT RIGHT PARKLIGHT

Figure 8 :CCU2 J1 Circuit (Page 2)
7 110 CCU2J1-H1 RD/WH 1.5 WLHT-A RD 1.5 LWL-1 LWL-2 WLHT-C BK 1.5
E6
LEFT WORKLIGHT
BK 1.5
7 111 CCU2J1-H2 RD/WH 1.5 WLHT-B RD 1.5 RWL-2 RWL-2
RIGHT WORKLIGHT 8
700437-08_0_MK5
103
SERVICE MANUAL MK V
104
SCHOTTKY DIODE
1A/100V
GN/BK 0.75 IQAN-5 116 29

GN/BK 0.75 HZDSW-3 117 11
PL/YL 1.5 HSR-4 118 10
2
BK 1.5 GN/PL 1.5 PL/RD 0.75 BL-6 119 10
AE BPR-2 1 BPR-1
PK/BK 0.75 RWMI-1 114 8
SERVICE MANUAL MK V
BIN PRESSURE PK 0.75 FWMD-1 113 8

REDUCTION SOLENOID
Not on 4206D PL/RD 1.5 AS-B 120 10
Not on Small Trucks
10 129 HSL-4 PL/BL 1.5 SCHOTTKY DIODE
1A/100V
t
EE
BFI-4 FTS-2 BK 1.5 YL/PL 1.5 FTS-1
2 1 1
YL/GN 2.5 BK 2.5
BONNET PBOS-2 2 PBOS-1
SCHOTTKY DIODE FAN TEMP
1A/100V EE
SWITCH
PNEUMATIC BLOW
OFF SOLENOID
AHP-L RHP-L PL/GN 1.5 BPS-B 121 10

1
BK 0.75 GN/BL 0.75
IDLSOL-2 2 IDLSOL-1
P
E5 IDLPS-1 1 2
INTER AXLE
BFI-1
D6-Z
SUS-8
DIFF LOCK SOLENOID 3 (B50D SS Only)
Small Trucks Only GN/GY 0.75 D5-M GN/GY 1.5 FDL-1 122 28
IDLPS-3
1 2
1 19 FUSE 10-2 GN 0.75 BLS-1 BLS-2 IDL PRESSURE
SWITCH
D3-4
D5-T
D2-T
AE
D5-W
BRAKE LIGHTS
D3-31
SWITCH
Figure 9 :CCU2 J1 (A-F) Circuit)
GN 0.75 SCHOTTKY DIODE

1A/100V
YL 0.75
PK 0.75
YL/PL 0.75
PL/YL 0.75
PL/BL 0.75
PL/RD 0.75
PK/BK 0.75
PL/RD 0.75
GN/PL 0.75
GN/BL 0.75
YL/GN 0.75
PL/GN 0.75
GN/BK 0.75
GN/GY 0.75
GY/GN 0.75
BK 0.75
OEUJ2-B1 GN 0.75
E5
OEUJ2-A1 YL 0.75 OR/BN 0.75 2 BK 1.5
1
TCUCAN-B
TCUCAN-A
TCUCAN-C
CTDSOL-1 CTDSOL-2
OEUJ2 BK 0.75
CTD
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4 See pg10 for SOLENOID
128 127 126 125 124 123 CCU2 J2 Pins G-M
23 23 23 15 15 15 CCU2-J2 (A-F) 9
700437-09_A_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

9 HEIGHT 9 HEIGHT 9 ARTIC 12 11 17 7 9 BIN 9
X° SENSOR X° SENSOR SENSOR POSITION
129 SIG - + LEFT 118 SIG - + RIGHT 120 (B50D & 4206D 130 131 132 102 121 SENSOR 119
C B A A B C
2806D-2306D
Only)
(B50D Only) (B50D Only) (Not on 4206D,
4 1 5 4 1 5 2306D & T17D F/D)
BIN
LEVER
CCU2J2-C3
CCU2J2-D3
CCU2J2-E3
HTS-B
WBT-2
ACU-9
PSEN-B
CCU2J2-F1
CCU2J2-D4
PL/BL 1.5
PL/YL 1.5
BK/YL 1.5
BK/YL 1.5
BK/YL 1.5
BK/YL 1.5
RD/YL 1.5
RD/YL 1.5
RD/YL 1.5
PL/RD 1.5
PL/GN 1.5
RD/OR 1.5
BL/GN 1.5
Doc. No. 872272 : Rev 0

HORN-1
D2-M
H
BK/YL 0.75
BK/YL 0.75
PL/RD 0.75
EE
D3 - 15
RHP-N
RHP-M
HORN-2
SUS-7
SUS-7
BK 1.5
(B40/35D Only)
(B40/35D Only)
ELECTRIC
SUS-1
SUS-11
HORN
(B40/35D Only)
(B40/35D Only)
AHP-N
AHP-M
BL/GN 0.75
BL-2
BL-3
BL-1
BL-6
BL-5
HSOL-1 2
BK 1.5
D2-O
D2-L
D2-V
D2-U
HSOL-2
E5
1
BK 0.75
HORN SUS-12 D5-V

SOLENOID
D5-S
BL/GN 0.75 SCHOTTKY DIODE

1A/100V
E5
GN 1.5 FUSE 4-2 11 1
RD 1.5 FUSE 27-2 51 2
RD 1.5 FUSE 28-2 2

Figure 10 : CCU2 J2 (G-M) Circuit
53
RD 1.5 FUSE 29-2 55 3
BK 1.5 E2
RD 1.5 FUSE 27-2 52 2
BK/YL 0.75
BK/YL 0.75
RD/YL 0.75
BL/GY 0.75
BL/GN 0.75
RD/BK 0.75
OR/BK 0.75
WH/BL 0.75
PL/WH 0.75
GY/RD 0.75
RD/OR 0.75
OR/GN 0.75
OR/WH 0.75
RD 1.5 FUSE 28-2 54 2
ACU-10
WBT-1
ACU-11
FB-1
F2SSW-1
PBDSW-3
RWMI-4
See pg 9 for G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
138 137 136 135 134 133 115 CCU2 J2 Pins A-F
17 11 17 11 11 11 8 CCU2-J2 (G-M) 10
700437-10_A_MK5
105
SERVICE MANUAL MK V
106
F2SSW-1 1 2 F2SSW-2
SERVICE MANUAL MK V
10 137 CCU2J2-J2 WH/BL 0.75 D2-W WBT-1 WH/BL 1.5 F2SP-1 F2SP-2 BK 1.5
AE
G SPRING APPLIED FRONT 2 SPEED SWITCH

AIR RELEASED LN H (NORMALLY CLOSED)
(B50D ONLY [NOT B50D S/S])
t
W D5-N PL/WH 0.75 CCU2J2-H2 134 10
10 131 CCU2J2-K2 BK/YL 0.75 WBT-2 BK/YL 1.5
WET BRAKE
TEMPERATURE
SENDER 40°C-120°C
3 HZDSW-3 3 PBDSW-3
HZDSW-2 2 PBDSW-2 2
1 1
HZDSW-8 +8 -7 HZDSW-7 PBDSW-8 +8 -7 PBDSW-7
BK 1.5 BK 1.5
E6 E5
GN 0.75
BN 0.75
GN/BK 0.75
RD 0.75
BL 0.75
BL/GY 0.75
HAZARD PARK BRAKE

DASH SWITCH DASH SWITCH
E6 (See pg 29 for Hazard
M Switch Circuit for 4206D)
10 135 CCU2J2-H4 FB-1 OR/WH 0.75 FB-2 BK 0.75
FLASHING
FUSE 10-2
LIND-1
CCU2J2-D2
FUSE 36-2
CCU2J1-F3&F4
CCU2J2-H1
BEACON LIGHT
20 139 117 66 107 133

Figure 11 : CCU 2 J2 Circuit (Page 2)
1 13 9 3 7 10
11
700437-11_C_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

CCU2J3
2806D-2306D
ARLHT-2 ARLHT-1 GN/BL 0.75 BK 0.75 RD 1.5 FUSE 31-2 59 3
RD 1.5 FUSE 31-2 58 3
Doc. No. 872272 : Rev 0

ARTIC REVERSE LIGHT E2
RD 1.5
RD 1.5
YL 0.75
BK 0.75
BN 0.75
OR 0.75
RD 0.75
YL/BL 0.75
BL/YL 0.75
BK/YL 0.75
GY/BL 0.75
BK/YL 0.75
PL/GN 0.75
GN/PL 0.75
YL/GN 0.75
GN/YL 0.75
RD/PK 0.75
BN/YL 0.75
RD/BN 0.75
RD/GY 0.75
BK/WH 0.75
GN/WH 0.75
WH/GN 0.75
RD 1.5 FUSE 30-2 57 3
E2
RD 1.5 FUSE 30-2 56 3
17 143 ACU-7 RD/BN 0.75 RD 0.75 FUSE 36-2 67 3
18 144 CS8-4 YL/BL 0.75 BL/YL 0.75 ACU-12 140 17

13 145 LIND-1 BN 0.75 WH/GN 0.75 BIN-A 168 17
SCHOTTKY DIODE
13 146 LBP-B GY/BL 0.75 1A/100V
8 112 FWMD-2 OR 0.75

PARK BRAKE
D2-X
13 147 RIND-1 YL 0.75 SOLENOID
E5
2
27 148 RMIR-2 RD/GY 0.75 BN/YL 0.75 BK 0.75
PBSOL-1 1 PBSOL-2
27 149 LMIR-2 RD/GY 0.75
87a
30 87
BK 1.5
RD/PK 0.75
SCHOTTKY DIODE E3
1A/100V M M
RWASH-2 FWASH-2
YL/GN 0.75
BK/YL 0.75
85 86
SCHOTTKY DIODE
RWASH-1 1A/100V
FWASH-1
HTS-1
D5-H
D5-J
BK 0.75
BK 0.75
RELAY 4
Large Trucks Only

REAR WIPER FRONT WIPER
OVERSPEED
2 WASHER PUMP WASHER PUMP
YL/GN 1.5 BK/YL 1.5 AE
BD-1 1 BD-2
E3 E3 2
RD/PK 0.75
D2-H BK/WH 1.5 BK 1.5

HCS-1 1 HCS-2
GN/WH 1.5
BIN UP
G SCHOTTKY DIODE
SOLENOID 1A/100V
BK/YL 0.75
GN/YL 0.75
HTS-A HYDRAULIC
CUT SOLENOID
t
ADM18-16
BK/WH 0.75
Large Trucks Only W
D5-L
D5-K
10 130 CCU2J2-K2 BK/YL 1.5 HTS-2

HTS-B 1 141
CS8-5
BK/YL 1.5 GN/YL 1.5

BD-2 2 BD-1 18
HYDRAULIC
TEMPERATURE BIN DOWN 142
SENDER 40°C-120°C SOLENOID 18
12
700437-12_C_MK5
107
SERVICE MANUAL MK V
108
11 12 29
139 145 150

AE
BK 1.5 LSIND-2 LSIND-1 BN 1.5 BK 1.5 AHP-F BK 1.5 RHP-F BK 1.5 TCI-1 BK 1.5 TC2-1
TCI-3 BN 1.5 TC2-3

EE FRONT LEFT SIDE INDICATOR B20D Only
TCI-5 YL 1.5 TC2-5 TRAILER
HZDSW-8
CCU2J3-B2
IQAN-5
CONNECTOR 2
BK 1.5 LIND-2 LIND-1 BN 1.5 D3-8 TCI-2 BL 1.5 TC2-2 (Used on 2306D)
SERVICE MANUAL MK V
TCI-6 BL 1.5 TC2-6

EE FRONT LEFT INDICATOR
BN 0.75
BN 0.75
BN 0.75
TCI-4 GY/BL 1.5 TC2-4
YL 0.75
BN 0.75
BL 1.5
RHP-K LLEDS-4 INDL-1 INDL-2 BN 1.5
GY/BL 1.5
4206D Only
AE
BK 1.5 AHP-F BK 1.5 RHP-F BK 1.5 TCI-1 BK 1.5 TC1-1
BN 0.75
REAR LEFT INDICATOR LIGHT (LED)
BK 1.5
LLEDS-1
BN 1.5 TCI-3 BN 1.5 TC1-3
4206D Only
AE
RHP-F AHP-F D2-J YL 1.5 TCI-5 YL 1.5 TC1-5 TRAILER
CONNECTOR 1
TCI-2 BL 1.5 TC1-2 (Used on T17D F/D,
T17D T/D & 2306D)
29 153 TCI1-3 BN 1.5 BN 1.5 TCI-6 BL 1.5 TC1-6
TCI-4 GY/BL 1.5 TC1-4
29 154 TCI1-5 YL 1.5 YL 1.5 GY/BL 1.5 TCI1-4 151 29

BL 1.5
RHP-H AHP-H D2-K
D2-E AHP-C RHP-C LLEDS-2 LBP-B

4206D Only
RLEDS-1
4206D Only
BK 1.5
4206D Only
YL 0.75
RHP-K RLEDS-4 INDR-1 INDR-2 YL 1.5 D2-P AHP-J RHP-J LLEDS-3 LBP-C LBP-A LLEDS-4
4206D Only 4206D Only
D3-9
REAR RIGHT INDICATOR LIGHT (LED) LEFT BRAKE / PARK LIGHTS
BK 1.5
RHP-K AHP-K
AE AE
BL 0.75
GY/BL 1.5
GY/BL 0.75
BL 1.5
BL 1.5
YL 0.75
BK 1.5 RIND-2 RIND-1 YL 1.5 RLEDS-2 RBP-B
4206D Only
EE FRONT RIGHT INDICATOR

BK 1.5
4206D Only
RLEDS-3 RBP-C RBP-A RLEDS-4
E4 NPL-2 NPL-1 4206D Only
CCU2J3-C2
CCU2J3-B4
CCU2J1-F3 & F4
TCI1-2
BK 1.5 RSIND-2 RSIND-1 YL 1.5 BK 1.5

RIGHT BRAKE / PARK LIGHTS
B20D Only
RHP-K AHP-K
EE FRONT RIGHT SIDE INDICATOR NUMBER PLATE LIGHT AE
147 146 109 152 (Used on B20D, T17D T/D, T17D F/D)
12 12 7 29
13
700437-13_A_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

2806D-2306D
SCHOTTKY DIODE
1A/100V
BFI-3 BN/BL 1.5 FAN2-1 M
BFI-4 BK 1.5 FAN2-2
Doc. No. 872272 : Rev 0

EE BONNET FAN 2
(B50D ONLY)
D3-20
RD 1.5 FUSE 18-2 34 2
17 155 ACU-3 RD/BL 0.75 RD 1.5 FUSE 18-2 35 2
17 156 ACU-2 RD/GN 0.75 BK/WH 1.5 KL50 4 1
BN/BL 0.75
17 157 ACU-1 RD/GY 1.5 RD 1.5 FUSE 19-2 36 2
RD 1.5 FUSE 19-2 37 2
BN/BK 0.75
OEU J1
D3-19
Figure 14 : OEU J1 Circuit
SCHOTTKY DIODE
1A/100V
BFI-2 BN/BK 1.5 FAN1-1 M
BFI-4 BK 1.5 FAN1-2

EE
BONNET FAN 1
(B50D ONLY)
14
700437-14_A_MK5
109
SERVICE MANUAL MK V
110
ZF ALLISON
23 23 1 2 2 2 2 2 23 & 24
TCU TCU
158 159 10 38 40 42 39 41 161
TCU-9
TCU-12
FUSE 3-1
FUSE 20-2
FUSE 21-2
FUSE 22-2
FUSE 20-2
FUSE 21-2
TCU-7
SERVICE MANUAL MK V
E2
YL/PK 0.75
BK 1.5
RD 1.5
RD 2.5
RD 2.5
GN 1.5
RD 1.5
RD 1.5
GN/BK 0.75
PL/WH 0.75
87a
30 87
JD 250/300D Only BK 0.75
85 86
20 200 ADM21-19 E3
20 201 ADM21-21 G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
OEU J2 RELAY 3
20 202 ADM21-20 A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
AUTO NEUTRAL
18 162 ADM21-19
18 163 ADM21-21 YL/PK 0.75
18 164 ADM21-20
RD
WH/GY 0.75 OBWWL-3
YL
9 124 CCU2J2-A1 YL 0.75 WH/GN 0.75 OBWWL-2

GN
9 125 CCU2J2-B1 GN 0.75 WH/BL 0.75 OBWWL-1
9 123 CCU2J2 BK 0.75 SCHOTTKY DIODE BK 1.5 OBWWL-4

1A/100V E6
BK/BL 0.75 ON BOARD WEIGHING
WARNING LIGHTS. OPTIONAL.
87a
30 87
BK 0.75 2
GN/PL 0.75 BK 0.75
2SSOL-1 1 2SSOL-2
85 86
TCU-8
E3 BK/BL 0.75
E5
2 SPEED
187 SOLENOID
RELAY 2 (B50D ONLY)
ZF ALLISON GEAR HOLD 15
23 & 24
TCU TCU 700437-15_C_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

SCHOTTKY DIODE SCHOTTKY DIODE SCHOTTKY DIODE
1A/100V 1A/100V 1A/100V
2806D-2306D
ENGINE
COOLING FAN
1 2 2
BK 1.5 PL/GN 1.5 RD/BN 1.5 BK 1.5 OR/WH 1.5 BK 1.5
LSS-2 2 LSS-1 LSD-1 1 LSD-2 LSD-1 1 LSD-2
AE M AE AE
Doc. No. 872272 : Rev 0

LOW SPEED LEFT STRUT DOWN RIGHT STRUT DOWN
SOLENOID SOLENOID SOLENOID
(Large Trucks Only) (B50D Only) (B50D Only)
SCHOTTKY DIODE SCHOTTKY DIODE SCHOTTKY DIODE

1A/100V 1A/100V 1A/100V
1 2 2
BL/YL 1.5
BK/YL 1.5
BK 1.5 BL/GY 1.5 PK/GY 1.5 BK 1.5 GY/OR 1.5 BK 1.5
FCS-2 2 FCS-1 LSU-1 1 LSU-2 LSU-1 1 LSU-2
AE AE AE
FAN CUT LEFT STRUT UP RIGHT STRUT UP
SOLENOID SOLENOID SOLENOID
(Large Trucks Only) (B50D Only) (B50D Only)
ECF-1
ECF-2
SUS-5
SUS-3
SUS-4
SUS-2
17 167 ACU-4 BN/RD 0.75
SCHOTTKY DIODE BL/YL 1.5 BK/YL 1.5

1A/100V
D3-17
D3-18
D5-A
D5-C
D5-D
D5-B
D5-G
D5-E
1
BK 1.5 BK/GN 1.5
MSS-2 2 MSS-1
RD/OR 0.75 ACU-6 165 17
AE
MEDIUM SPEED RD/YL 0.75 ACU-5
D5-F
166 17
SOLENOID
(Large Trucks Only) RD 1.5 FUSE 23-2 43 2
RD 1.5 FUSE 23-2 44 2
BK 1.5 RD 1.5 FUSE 24-2 45 2
BL/YL 0.75
OR/WH 0.75
BK/YL 0.75
GY/OR 0.75
PK/GY 0.75
PL/GN 0.75
BK/GN 0.75
BL/GY 0.75
RD/BN 0.75
BN/RD 0.75
RD/OR 0.75
RD/YL 0.75
RD 1.5 FUSE 24-2 46 2

E2
OEU J3
16
700437-16_C_MK5
111
SERVICE MANUAL MK V
112
RESISTOR
M
1.2 3.5
1 2 THERMOFUSE
BK 1.5
*E5
FAN/BLOWER
SERVICE MANUAL MK V
4 5 *NOTE:
E5 - HVAC CASE EARTH. EYE TERMINAL
THROUGH BOLT UNDER 12 WAY BULKHEAD 10
HVAC SECTION OF CONNECTED TO CAB EARTH THROUGH
EYE TERMINAL ON CAB HARNESS. 8
SEALED SWITCH MODULE
7
ACU-1 FAN HIGH SPEED - 24V FROM BELL CONTROLLER
14 157 OEUJ1-B3 & B4 RD/GY 1.5 HEAT VALVE
ACU-2 FAN MEDIUM SPEED - 24V FROM BELL CONTROLLER ACTUATOR
14 156 OEUJ1-C3 & C4 RD/GN 1.5
ACT 1 - 12v Power
ACU-3 FAN LOW SPEED - 24V FROM BELL CONTROLLER

14 155 OEUJ1-E3 & E4 RD/BL 1.5 10
ACT 1 - 0v-12v Signal
ACU-4 ACTUATOR 1 - 24V PWM FROM BELL CONTROLLER

16 167 OEUJ3-A2 BN/RD 0.75 1 7 8
16 166 OEUJ3-E2 RD/YL 0.75 2 8 7
16 165 OEUJ3-D2 RD/OR 0.75 3 9 FEET
ACU-7 ACTUATOR 4 - 24V PWM FROM BELL CONTROLLER ACTUATOR
12 143 CCU2J3-A2 RD/BN 0.75 4 10
ACU-8 24V
3 65 FUSE 35-2 RD 0.75 6 11 10
ACU-9 CONTROLLER POWER RETURN
10 132 CCU2J2-K2 BK/YL 0.75 5 12 8
ACTUATOR
ACU-10 0 Ohm - 10K Ohm TO BELL CONTROLLER
10 138 CCU2J2-J3 GY/RD 0.75 SIGNAL BOARD 13 7
ACU-11 0 Ohm - 10K Ohm TO BELL CONTROLLER
10 136 CCU2J2-J1 RD/BK 0.75 14 MID/DEMIST
ACU-12 24V TO BELL CONTROLLER ACTUATOR
12 140 CCU2J3-F2 BL/YL 0.75
10
12 168 CCU2J3-E3 WH/GN 0.75 REC. AIR

Figure 17 : Air Conditioner Circuit
ACTUATOR
BK 1.5
t
P *E5
EE *NOTE:
E5 - HVAC CASE EARTH. EYE TERMINAL
BK 1.5 WH/GN 1.5 D3-12 WH/GN 0.75 t t THROUGH BOLT UNDER 12 WAY BULKHEAD
BIN-B BIN-A CONNECTED TO CAB EARTH THROUGH
THERMO EYE TERMINAL ON CAB HARNESS.
BINARY SWITCH A/C EVAPORATOR A/C INLET AIR

AIRCON COMPRESSOR SWITCH TEMPERATURE TEMPERATURE
CLUTCH SOLENOID
17
700437-17_0_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

15 15 15
2806D-2306D
+ GN 0.75 FUSE2-2 9 1
164 163 162
(6)
6 120 OHM 3 WAY
PL 0.35 ACCP-6 DEUTSCH CAN
EE EE
(4)
CSTS-2 CSTS-1 CSSOL-1 CSSOL-2
CANT1-C
TERMINATOR
CANT1-A
CABT1-B
2 4
BK 2.5 BK 2.5 GN 0.35 ACCP-4 21-1
PWM
1
3
_
(3)
t WH 0.35 ACCP-3 OEUJ2-A1 YL 0.75 21-19
COLD START + 5
RD 0.35 ACCP-5 OEUJ2-B1 GN 0.75 21-21
(5)
COLD START SOLENOID
Doc. No. 872272 : Rev 0

GY/WH 2.5
GY/BK 2.5
2
(2)
TEMP SENDER YL 0.35 ACCP-2 OEUJ2 BK 0.75 21-20
PWM
1
BN 0.35 ACCP-1 BK/YL 0.75 21-14
_
(1)
D1 - X
D1 - Y
BL/GN 0.75 21-13
ACCELERATOR BL/YL 0.75 21-12
PEDAL
BK 0.75 21-3
E3
CS8-7 RD 0.75 21-2
CS8-6
CS8-3 BK 2.5 BL/RD 0.75 15-5

E1
CS8-2 MR-1 D3 - 14 YL/GN 0.75 15-13
CS8-8 MR-3 D3 - 13 BK 0.75 BK 0.75 15-14
CS8-5 MR-4 D3 - 24 BK 0.75

Fuel
CS8-4 Temp MR-2 D3 - 25 BN 0.75 15-15
Sender
CS8-1 MR-9 BK 2.5 RD/YL 0.75 15-6
Cool. EE
Temp
Sender MR-11
Oil
CS4-4 Temp MR-15 D3 - 5 18-9
E3
Sender
CS4-3 MR-5 BK 0.75 18-11
Oil
Press
CS4-2 Sender MR-6 18-16
Air
D1 - W
CS4-1 Temp MR-12
Figure 18 : Mercedes Engine
Sender
MR-13 PL 1.5 D3 - 28 12-2
Air
COLD START Press
Sender
Oil
ADM - MERCEDES ECU
Level OR 0.75 DIAG-H 169 25
RD 1.5
RD 1.5
RD 1.5
RD 1.5
GN 2.5
GN 2.5
PL 0.75
Sender Sub.
BL/WH 2.5
YL/BL 0.75
BK/WH 1.5
BK/WH 0.75
Pump
OR/GN 0.75
RD/PK 0.75 R4-87 141 12
Top Dead
Centre Sub.
Position MR - Pump
Sensor
EE ENGINE ECU
Sub.
BK 2.5 Position Pump EVBSOL-1 EVBSOL-2
STAR-50
DIAG-J
MCB-1
MCB-1
FUSE 17-2
FUSE 17-2
Indicator 2
FUSE 16-2
FUSE 16-2
CCU2J3-E2
MDU2J2-J
CCU2J3-A4
CSGP BK 0.75
GPE 1 E5
Sub.
GLOW PLUG Pump
31 30 144 142 90 4 Outputs for Air 170 3 6 5 33 32

Motor Motor EXHAUST BRAKE SOLENOID
VTG Waste Gate,
Start Stop
2 2 12 12 5 Hydraulic Exhaust 25 1 1 1 2 2
18
Brake Solenoid
700437-18_A_MK5
113
SERVICE MANUAL MK V
Doc. No. 872272 : Rev 0 114
TCU-11 CAB-11
26
AG-3 BN/RD 0.75

186
RD 1.0
K
CCU2J1-F3&F4 BL 0.75 TCU-6 CAB-6

106
N
BK 1.0
L
C
B
A
15
R3-87 YL/PK 0.75 TCU-7 CAB-7

F
15
R2-87 BK/BL 0.75 TCU-8 CAB-8

56
28
J
15
OEUJ2-G4 GN/BK 0.75 TCU-9 CAB-9

D
2
SHIFT SELECTOR
FUSE 15-2 RD 1.5 TCU-3 CAB-3 RD 1.5

H
15
OEUJ2-J4 PL/WH 0.75 TCU-12 CAB-12

45 64
161 187 158 29 159

E
BK 1.5 TCU-1 CAB-1 BK 1.5

E1
G
1
8
FUSE 1-2 GN 1.5 TCU-2 CAB-2 GN 1.5

50 42 41 21
P
23 68
DIAG1-1 GN 1.0
DIAG1-3
DIAG1-7
ZF-20
DIAG1-6
ZF DIAGNOSTIC
6
25
DIAG-F YL/BK 0.75 TCU-4 CAB-4 DIAG2-2 ZF-6

25 DIAG-G YL/BL 0.75 TCU-5 CAB-5 DIAG2-4 ZF-19
188 189 DIAG1-5 ZF-24
48 47 15 60 18
30 29 54
19 24 22
3
9
ZF EOL-2 PK/GY 0.75 TCU-10 CAB-10 ZF-22
84
5
ZF-11
4
ZF-12
11 12 13
ZF-13
9
ZF-9
10 11
10
ZF-10
2
GE2
ZF-2
ZF - TCU
BR2
ZF-17
17 18
ZF-18
1
RT1
ZF-1
57 16 34 49 62
TRANSMISSION VALVE BODY
BL1
15
ZF-15
4
ZF-4
14
ZF-14
TCU CAN
8
9
CCU2J2 BK 0.75 TCUCAN-C ZF-8
27 58 51
9
CCU2J2-A1 YL 0.75 TCUCAN-A
20 21
9
CCU2J2-B1 GN 0.75 TCUCAN-B
25 26
126 127 128

25
MM15A
ZF-21
25
MM15A-10
3
25
MM15A-9 ZF-31 BK 1.0
46
190 191 192

2
6
ZF-30
SOLENOID
RETARDER
3
ZF-28
2
TEMP
ZF-29
24
TRANS
BK 1.0
700437-23_B_MK5
23
Figure 23 : ZF Transmission
3 1 1 3 4 23 23 23 5 5 5
MEMORY MODULE
74 12 13 68 86 191 190 192 95 93 94
(MM21C) (MM18E) (MM21B) (MM15A)

2806D-2306D
1 5 16 2 6 15 2 3 2 1 6 5 4 7 8 10 9
TCUCAN-A
TCUCAN-B
TCUCAN-C
MDU2J1
MDU2J1-K
MDU2J1-C
FUSE 37-2
FUSE 5-2
FUSE 5-2
FUSE 36-2
FUSE 46-2
Doc. No. 872272 : Rev 0

BK 0.75
BK 0.75
GN 0.75
GN 0.75
GN 0.75
GN 0.75
RD 0.75
RD 0.75
RD 0.75
E3 E3
RD/YL 0.75
YL/RD 0.75
YL/RD 0.75
YL/RD 0.75
OR/BN 0.75
PL/WH 0.75
RD/OR 0.75
RD/OR 0.75
GN/RD 0.75
WH/RD 0.75
WH/RD 0.75
YL 1.0
GN 1.0
SHIELD
BK 0.75 SHIELD DIAGNOSTIC PIGTAIL
E3 CAN
SATC-4 GN 1.0 DIAG-D GN 0.75 CAN-B
SATC-3 YL 1.0 DIAG-C YL 0.75 CAN-A
DID-1
DID-3
DID-2
DID-4
SATC-2
SATC-1 BK 0.75
DAIM CRYSLER
E6 DIAG
12 4 3 OR 0.75 DIAG-H OR 0.75 DC-14
PL 0.75 DIAG-J PL 0.75 DC-5
BK 0.5
BN 0.5
OR 0.5
WH 0.5
RD 0.75 DIAG-E RD 0.75 DC-2
DRIVER ID
GN 0.75 DIAG-B GN 0.75 DC-3
10 9 4 3 E3 BK 0.75 DIAG-A BK 0.75 DC-1
YL/BL 0.75 DIAG-G

ZF
DIAG
SATC - MT2000 YL/BK 0.75 DIAG-F ZF-3
ZF-1
ADM12-2
MR-13
FUSE 32-2
FUSE 7-2
TCU-5
TCU-4
YL/BL 0.75 ZF-4

Figure 25: Diagnostic, Memory Module, Driver I.D. & SATC Circuits
YL/BK 0.75 ZF-2

169 170 60 15 189 188
18 18 3 1 23 23 25
700437-25_B_MK5
115
SERVICE MANUAL MK V
116
3 23 3
1. Electric motor of the pump 80 186 81

2. Solenoid valve
3. Minimum-level switch
4. Test pushbutton
5. Control unit
TCU-11
6. Pump body
FUSE 40-2
FUSE 39-2
Automatic Greaser
Pigtail,
not on B50D.
AE
SERVICE MANUAL MK V
RD 1.5
PUMP AG-2 BK 1.5
RD 1.5
1 1
AG-1
BN/RD 0.75
2 1 2 J1 BK 1.5
3 L
E5
1 2 J2
ESEAT-1
ESEAT-2
D2 - S
2 2 2
------
------
J6 J5 J4
1 1 1
3 1 2
4 1 AG-3 BN/RD 1.5 P
7 AGPS-1 1 2 AGPS-2
5 2 AG-7 OR/BL 1.5 AHP-V RHP-V OR/BL 1.5
5
2 3 8
AG-8 OR/BL 1.5 AHP-W RHP-W OR/BL 1.5 3
6 J3 6 ELECTRICAL SEAT
AG-6 OR/GN 1.5
4
AUTOMATIC GREASER
AUTOMATIC GREASER PRESSURE SWITCH
D2 - D
OR/GN 0.75
3 75 FUSE 37-2 RD 0.75 BK 0.75
E5
AGI-A
AGI-B
AGI-C
ILHT-A ILHT-B
GN 0.75 BK 0.75
E6
GY 1.5
GY 1.5
GY 1.5
INTERIOR
LIGHT
1 3 2
FUSE 10-2
AUTOMATIC GREASER 18
INDICATOR 26
(Optional. Standard Fitment on B50D Only) 1
TD0006019
700437-026_0
Figure 26: Automatic Greaser, Electrical Seat & Interior Lights Circuits
2806D-2306D
Doc. No. 872272 : Rev 0

E6
RD/GY 0.75 LMIR-2 RD 1.0 BK 1.0 LMIR-1 BK 0.75
2806D-2306D
LEFT MIRROR
DEMISTER
RD/GY 0.75 CCU2J3-D2 149 12

E5
BK 0.75
1 _
Doc. No. 872272 : Rev 0

RD 0.75 2 +
M
L R
UP
DOWN
MIRROR SERVO
YL 1.0
M
SUPPLY
SUPPLY
SUPPLY
MIRROR SERVO
SUPPLY
L R
LEFT MIRROR L R
MIRROR
SWITCH
BN 1.0 LMIR-5 GN/BL 0.75

3 COMMON
GN 1.0 LMIR-4 OR/GN 0.75
8 LEFT HORIZONTAL
YL 1.0 RMIR-4 OR/BN 0.75
6 RIGHT HORIZONTAL
M 5 LEFT VERTICAL
OR 1.0 LMIR-3 YL/GN 0.75
7 RIGHT VERTICAL
BN 1.0 RMIR-3 GN/YL 0.75
OR 1.0 RMIR-5
MIRROR SERVO UP
GN 1.0
Figure 27: Electrical Mirrors Circuit
DOWN
M
RD 0.75 FUSE 35-2 64 3
E6
RD/GY 0.75 RMIR-2 RD 1.0 BK 1.0 RMIR-1 BK 0.75
MIRROR SERVO
RIGHT MIRROR
RIGHT MIRROR DEMISTER
RD/GY 0.75 CCU2J3-D2 148 12
27
700437-27_0_MK5
117
SERVICE MANUAL MK V
118
OBW-3 BL 1.5 LSG-3
OBW-2 BL 1.5 RSG-2 BL 1.5 1

OBW-3 OBW-1 YL/GN 1.5 RSG-1 YL/GN 1.5 11
+ - PL/GN 1.5 LSG-1 PL/GN 1.5 12

GY 1.5 RSG-3 GY 1.5 2
SERVICE MANUAL MK V
sig sig GY 1.5 LSG-2 AHP-U RHP-U BK 1.5 3

AE
LSG-4 BK 1.5 RHP-U AHP-U 7
AE
- +
RSG-4 BK 1.5 RHP-U AHP-U 6
AE
LEFT STRAIN RIGHT STRAIN ON BOARD
GAUGE 5 WEIGHING
GAUGE
NOT ON 4206D
9
OBW-2 8
OBW-1 10
24 195 SSCAN-C SHIELD CANA-C SHIELD AHP-T RHP-T RD 1.5 FUSE 41-2 82 3
24 193 SSCAN-A YL 1.0 CANA-A YL 1.0 AHP-R RHP-R SHIELD CANTERM-C
24 194 SSCAN-B GN 1.0 CANA-B GN 1.0 AHP-S RHP-S YL 1.0 CANTERM-A
GN 1.0 CANTERM-B
120 OHM 3 WAY
DEUTSCH CAN
TERMINATOR
RD 1.5 FUSE 41-2 83 3
OPTION
4206D Only
TPM-3 2
TPM-1 12
TPM-2 11
AE
AHP-U RHP-U BK 1.5 TPM-4 4
GN/GY 1.5
FIDLSW-1 1 2 1 2
9 122 IDLPS-1 GN/GY 1.5 FDL-1 FDL-2 AHP-E GN/GY 1.5 RHP-E MAP1-3 MAP1-2 RHP-U BK 1.5 AHP-U
TYRE PRESSURE
RIDL-1 RIDL-2
AE MONITOR
FIDLSW-2
DISENGAGED DISENGAGED
ENGAGED ENGAGED
FRONT INTERAXLE DIFFLOCK REAR INTERAXLE DIFFLOCK
(NORMALLY OPEN) (NORMALLY OPEN)
(NOT ON B50D S/S)
28
700437-28_A_MK5
2806D-2306D
Doc. No. 872272 : Rev 0

AE
TC1-1 TCI1-1 BK 1.5 RHP-F AHP-F
2806D-2306D
TC1-2 TCI1-2 BL 1.5 LBP-C 152 13

0 TWIST TO TC1-3 TCI1-3 BN 1.5 INDL-2 153 13
RELEASE TRAILER
1
CONNECTOR 1 TC1-4 TCI1-4 GY/BL 1.5 LBP-B 151 13
B (Used on28 06D)
1 IQAN CUT SWITCH
RD 1.5 TC1-5 TCI1-5 YL 1.5 INDR-2 154 13
RD 1.5
2 A TC1-6 TCI1-6 BL 1.5
Doc. No. 872272 : Rev 0

A 3
SCRAPE CUT SWITCH
4 B TC2-6 TCI2-6 BL 1.5
TC2-5 TCI2-5 YL 1.5
TC2-4 TCI2-4 GY/BL 1.5

TRAILER
GN/WH 1.5
GN/WH 1.5
CONNECTOR 2 TC2-3 TCI2-3 BN 1.5
(Used on28 06D)
TC2-2 TCI2-2 BL 1.5
AE
GN/WH 0.75 TC2-1 TCI2-1 BK 1.5 RHP-F AHP-F
3 SDSW-3
BK 1.5 IQAN-2
2
3 HZDSW-3
SDSW-2
HZDSW-2 2
1 E6
SDSW-8 +8 -7 SDSW-7
1
HZDSW-8 +8 -7 HZDSW-7
HYDSW-1 HYDSW-2 BK 1.5 IQAN-2 BK 1.5
HYD-1 HYD-1 BK 1.5
SCRAPE
Figure 29:2806 D Circuit

DASH SWITCH E6
Q
IQAN-1
IQAN-4
IQAN-3
IQAN-6
IQAN-5
2806D Only E3 HAZARD

RD 1.5 DASH SWITCH
BL/YL 1.5
HYDRAULIC LEVEL 2806D Only
SWITCH
2806D Only
D3 - 23
RD 1.5
RD 1.5
BN 0.75
GN 1.5
GN/BK 0.75
GN/WH 0.75
MDU2J2-L
MDM 5/6
FUSE 34-2
CCU2J1-E1
FUSE 9-2
CCU2J3-B2
CCU2J2-D2
63 196 104 91 17 150 116

29
TD0006825
3 30 7 5 1 13 9
119
SERVICE MANUAL MK V
Doc. No. 872272 : Rev 0 120
TD0006826 Figure 30: 2806 D IQAN
PL/RD 1.5
HYD VALVE 1
WH/BN 1.5
HV1-2
HV1-1
1
2
D8-1 YL D7-1
D8-19 WH/GY D7-19
1
15
HYD VALVE 2
2
BL/YL 1.5
HV2-2
LEVER
HV2-1
1
2
D8-2 BN D7-2 CONTROL 1

L1-3
22
L1-2
8
L1-4
HYD VALVE 3
HV3-2
HV3-1
1
3
D8-3 RD/GN D7-3 YL/BL 1.5 LEVER

36 23
CONTROL 2
L2-3
L2-2
9
D8-20 WH/RD D7-20

HYD VALVE 4
L2-4
HV4-2
HV4-1
1
2
D8-4 GN/RD D7-4

4
OR/BL 1.5 LEVER

CONTROL 3
L3-3
L3-2
HYD VALVE 5
HV5-2
HV5-1
1
2
D8-5 GY D7-5 L3-4

5
BL/OR 1.5 LEVER

D8-21 WH/BL D7-21 CONTROL 4
L4-3
HYD VALVE 6 L4-2
HV6-2
HV6-1
1
2
XD8-6 OR D7-6
L4-4
BL/GY 1.5
16
LEVER
HYD VALVE 7 CONTROL 5
L5-3
HV7-2
HV7-1
L5-2
1
2
D8-7 PK D7-7
L5-4
D8-22 WH/GN D7-22
GY/BL 1.5
17
HYD VALVE 8 LEVER

37 24 10 38 25 11 39 26 12 40 27 13 41
HV8-2
CONTROL 6
HV8-1
1
2
D8-8 PL D7-8 L6-3

L6-2
L6-4
HYD VALVE 9
HV9-2
HV9-1
1
2
D8-9 YL/BK D7-9
D8-23 GY/WH D7-23
HYD VALVE 10
HV10-2
HV10-1
1
2
D8-10 BN/YL D7-10
(X347)
XP CAN 1 XP CAN 2
HYD VALVE 11
HV11-2
HV11-1
1
6
2
2
D8-11 RD/BL D7-11
D8-24 RD/WH D7-24
5
1
2
6
EXPANSION MODULE
HYD VALVE 12
HV12-2
HV12-1
1
2
D8-12 BL/RD D7-12
X345
120 OHM
HYD VALVE 13
HV13-2
HV13-1
1
TERMINATOR
2
D8-13 GY/BK D7-13
BK 1.5
RD 1.5
YL/BK 1.5
BK/YL 1.5
42
29
28
14
D8-25 BL/WH D7-25

HYD VALVE 14
1
HV14-2
HV14-1
1
2
D8-14 OR/BK D7-14
4
3
BK 1.5
RD 1.5
HYD VALVE 15
HV15-2
HV15-1
1
2
D8-15 PK/BK D7-15
IQAN-2
D8-26 GN/WH D7-26
HYD VALVE 16
E6
HV16-2
HV16-1
1
2
D8-16 PL/WH D7-16
6
RD 1.5
MASTER DISPLAY MODULE
RD 1.5
LASER-1 RD 1.5 D8-17 D7-17 RD 1.5
RD 1.5
LASER-2 BK 1.5 D8-18
LASER
196 29SDSW-8
30
SECTION 2. CONNECTORS
2WR ACC
ACC
2WR 1
1 2
BOSCH, 1 WAY, PLUG & SOCKETS -
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - AIRCON COMPRESSOR. (Not on JD 250/300D).
2 WAY RADIO. (Connector as viewed from the back).
(Connector as viewed from the back).
PAGE WIRE COLOUR FUNCTION PAGE WIRE COLOUR FUNCTION
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 4 WHITE/RED 1.5 12V 2 Way Radio 1 17 WHITE/GREEN 1.5 Airconditioner Compressor Clutch Solenoid
2 4 BLACK 1.5 Earth
ACC_2_WAY
2SPPS
ACC
2 1 A B DELPHI PACKARD, 2 WAY, RECEPTACLE & PINS -

3
AIRCON COMPRESSOR (JD).
2SPPS
PAGE WIRE COLOUR FUNCTION
HIRSCHMANN, 4 WAY, FLUSH & SOCKETS -
TERMINAL
2 SPEED PRESSURE SWITCH. (B50D Only).

(Connector as viewed from the front).
? GN 1.5 ?
TERMINAL
A 17 WHITE/GREEN 1.5 Aircon Compressor
? GN 1.5 ? B 17 BLACK 1.5 Earth
1
2
7 PURPLE/WHITE 0.75 2 Speed Pressure Switch ACCP
3 7 RED 0.75 Ignition Supply
4
7 4 1
ACCP
2SPSOL 8 5 2
9 6 3
AMP, 9 WAY, RECEPTACLE & PINS -
ACCELERATOR PEDAL.
2 1
3
2SPSOL PAGE WIRE COLOUR FUNCTION
TERMINAL

2 SPEED SOLENOID. (B50D Only).
? GN 1.5 ?
1 18 BLACK/YELLOW 0.75 Accelerator Pedal PWM Return 1
TERMINAL
2 18 BLUE/YELLOW 0.75 Accelerator Pedal PWM Signal 1

3 18 BLACK/YELLOW 0.75 Accelerator Pedal PWM Return 2
? GN 1.5 ? 4 18 BLUE/GREEN 0.75 Accelerator Pedal PWM Signal 2
5 18 BLUE/RED 0.75 Ignition Supply - ADM2
1 15 GREEN/PURPLE 0.75 2 Speed Solenoid 6 18 BLUE/RED 0.75 Ignition Supply - ADM2
2 15 BLACK 0.75 Earth 7
3 8
4 9
12V_A_&_12V_B
12V-A & 12V-B
1
AMP, 1 WAY, PLUG & SOCKETS -

12V POWER SUPPLY.

TERMINAL
? GN 1.5 ?
A 4 WHITE/RED 1.5 12V Battery Supply
B 4 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 121

ACU ADM_15A
7 8 9 10 12
11
ACU
DT DEUTSCH, 12 WAY, PLUG & SOCKETS -

AIRCON UNIT. 1 4 7 10 13
6 5 4 3 2 1 (Connector as viewed from the back).
ADM15A
2 5 8 11 14
3 6 9 12 15 AMP, 15 WAY, PLUG & SOCKETS -
TERMINAL
ADM2, 15 PIN.
? GN 1.5 ?
TERMINAL
1 17 RED/GREY 1.5 Fan High Speed
2
3
17
17
RED/GREEN 1.5
RED/BLUE 1.5
Fan Medium Speed
Fan Low Speed
? GN 1.5 ?
4 17 BROWN/RED 0.75 Heater Valve
5 17 RED/YELLOW 0.75 Feet Actuator Valve 1
6 17 RED/ORANGE 0.75 Middle/Demist Actuator
2
7 17 RED/BROWN 0.75 Recirculation Flap 3
8 17 RED 0.75 Ignition Supply 4
9 17 BLACK/YELLOW 0.75 Controller Power Return 18 Accelerator Pedal Ignition Supply 1
5 BLUE/RED 0.75
10 17 GREY/RED 0.75 Inlet Air Temperature 18 RED/YELLOW 0.75 Exhaust Brake
6
11 17 RED/BLACK 0.75 Evaporator Output Temperature 7
12 17 BLUE/YELLOW 0.75 Thermo Switch 8
9
10
11
ACUE 12
13 18 YELLOW/GREEN 0.75 IES CAN - High
ACUE 14 18 BLACK 0.75 IES CAN - Earth
GHW, MMM LUG - 15 18 BROWN 0.75 IES CAN - Low
AIRCON UNIT EARTH.
(Isometric view).
ADM_15B
TERMINAL
? GN 1.5 ? 13 10 7 4 1 ADM15B
14 11 8 5 2
ACEU 17 BLACK 1.5 Earth (Aircon) 15 12 9 6 3 AMP, 15 WAY, RECEPTACLE & PINS -
ADM2, 15 PIN INTERFACE (JD).
ADM_12
TERMINAL
? GN 1.5 ?
1
2
1 4 7 10
3
ADM12 4
2 5 8 11
5 18 RED 0.75 5V Excitation +
6
3 6 9 12 AMP, 12 WAY, PLUG & SOCKETS -
7
ADM2, 12 PIN.
(Connector as viewed from the front). 8
9
PAGE WIRE COLOUR FUNCTION 10
11
TERMINAL
12
13
? GN 1.5 ? 14
15
1 18 ORANGE 0.75 Diagnostic H

2
3
4
5
6
7
8
9
10
11
12
122 Doc. No. 872272 : Rev 0

ADM_18 ADM_21B
ADM21B
1 4 7 10 13 16 19 16 13 10 7 4 1
ADM18 20 17 14 11 8 5 2
2 5 8 11 14 17 AMP, 21 WAY, RECEPTACLE & PINS -
21 18 15 12 9 6 3
ADM2, 21 PIN INTERFACE (JD).
3 6 9 12 15 18 AMP, 18 WAY, PLUG & SOCKETS - (Connector as viewed from the back).
3 6 9 12 15 18 ADM2, 18 PIN.
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 20 GREEN 0.75 Battery Supply
1 2 20 RED 0.75 Ignition Supply
2 3 20 BLACK 0.75 Earth
3 4
4
5
5
6
6
7
7
8
8
10 10
12 12
13 13 20 BLUE/GREEN 0.75 PWM - Signal 2
14 14 20 BLACK/YELLOW 0.75 PWM - Earth
15 15
16 18 RED/PINK 0.75 Throttle Inhibit (Overspeed) 16
17 17
18
18
19 20 YELLOW 0.75 CAN - High
20 20 BLACK 0.75 CAN - Shield
21 20 GREEN 0.75 CAN - Low
ADM_21A
AFP
1 4 7 10 13 16 19
ADM21A
2 5 8 11 14 17 20 AFP
AMP, 21 WAY, PLUG & SOCKETS - 2
3 6 9 12 15 18 21 1
ADM2, 21 PIN INTERFACE.
6 12 18 (Connector as viewed from the back). DT DEUTSCH, 2 WAY, PLUG & SOCKETS -
ARTIC FUEL PLUG. (Used on the B18D & B20D).
PAGE WIRE COLOUR FUNCTION (Connector as viewed from the back).

TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ?
3 18 BLACK 0.75 Earth 1 5 GREY/WHITE 1.5 Fuel Sensor Signal
4 2 BLACK 1.5 Earth
5
5
6
7
8
9 AFP_2_WAY
10
11
12 18 BLUE/YELLOW 0.75 PWM - Signal 1 AFP
13 18 BLUE/GREEN 0.75 PWM - Signal 2
2 1
14 18 BLACK/YELLOW 0.75 PWM - Earth
15 DT DEUTSCH, 2 WAY, RECEPTACLE & PINS -
ARTIC FUEL PLUG. (Small Trucks).
16
17
18 PAGE WIRE COLOUR FUNCTION
19 18 YELLOW 0.75 CAN - High
20 18 BLACK 0.75 CAN - Shield
TERMINAL
21 18 GREEN 0.75 CAN - Low

? GN 1.5 ?
1 5 BLUE/WHITE 1.5 Fuel Sensor Signal
2 5 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 123

AG AGI
AG
5 6 7 8
B A
AGI
4 3 2 1 DT DEUTSH, 8 WAY, PLUG & SOCKETS -
AUTOMATIC GREASER. (Not on B50D).
C
(Connector as viewed from the back). DT DEUTSCH, 3 WAY, PLUG & SOCKETS -
AUTO GREASING INDICATOR.

TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ?
1 26 RED 1.5 Ignition supply
2 26 BLACK 1.5 Earth
A 26 RED 0.75 Ignition Supply
3 26 BROWN/RED 1.5 Neutral Signal
B 26 BLACK 0.75 Earth
4
5 C 26 ORANGE/GREEN 0.75 Auto Greasing Indicator Signal
6 26 ORANGE/GREEN 1.5 Automatic Greaser Indicator
7 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch Signal
8 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch Signal AGPS
AG_1
1 2
AGPS
AG1
8 7 6 5
1 2 3 4 M24, 2 WAY, 90° BAYONET, SOCKETS -

DT DEUTSH, 8 WAY, RECEPTACLE & PINS - AUTOMATIC GREASER PRESSURE SWITCH
AUTOMATIC GREASER 1. (Connector as viewed from the front).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch
1 26 ORANGE 1.5 Ignition Supply
2 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch
3 26 BLUE 1.5 Neutral Signal
4
5 AH
6 26 BROWN 1.5 Automatic Greaser Indicator
7 26 GREEN/YELLOW 1.5 Automatic Greaser Pressure Switch Signal
8 26 PURPLE 1.5 Automatic Greaser Pressure Switch Signal
1 2
AH
AG_AG2 DT DEUTSCH, 2 WAY, PLUG & SOCKETS -

AIR HEATER.

4
3 5
TERMINAL
8
2 6
1 7 ? GN 1.5 ?
AG / AG2
1 6 RED 2.5 Ignition Supply (Air Heater)
GROENEVELD, 8 WAY, PLUG & SOCKETS - 2 6 BLACK 2.5 Earth
AUTOMATIC GREASER .

TERMINAL
? GN 1.5 ?
1 26 ORANGE 1.5 Ignition Supply
3 26 BLUE 1.5 Neutral Signal
4
5
6 26 BROWN 1.5 Automatic Greaser Indicator
7 26 GREEN/YELLOW 1.5 Automatic Greaser Pressure Switch Signal
8 26 PURPLE 1.5 Automatic Greaser Pressure Switch Signal
124 Doc. No. 872272 : Rev 0

AHFP_RHFP AJR
H H
X J X J
W K W G K
G B B
V L V L
F A C F A C
U M
U M
T
E D
N
AHFP / RHFP E D
AJR
T N
S P
R S P
R
HDP DEUTSCH, 21 WAY, RECEPTACLE & SOCKETS -
ARTIC/REAR HARNESS FEMALE PLUG. HDP DEUTSCH, 21 WAY, PLUG & SOCKETS -
(Connector as viewed from the back). ARTIC JUMP, REAR.
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
A 7 YELLOW/GREEN 1.5 Reverse Signal
B 7 BLUE/YELLOW 1.5 Middle 2 Speed Switch (B50D) A 7 YELLOW/GREEN 1.5 Reverse Signal & Backup Alarm
C 13 GREY/BLUE 1.5 Brake Lights
B 7 BLUE/YELLOW 1.5 Middle 2 Speed Switch (B50D)
D 7 WHITE/ORANGE 1.5 Rear 2 Speed Switch(B50D)
E 28 GREEN/GREY 1.5 Middle IDL Position Switch (B50D)
D 7 WHITE/ORANGE 1.5 Rear 2 Speed Switch (B50D)
F 13/29 BROWN 1.5 Left Indicator
G E 28 GREEN/GREY 1.5 Middle IDL Position Switch (B50D)
H 13 YELLOW 1.5 Right Indicator F 13 BROWN 1.5 Left Indicator
J 13 BLUE 1.5 Park Lights G
K 13/7 BLACK 2.5 Earth H 13 YELLOW 1.5 Right Indicator
L 9 PURPLE/GREEN 1.5 Bin Position Sensor Signal J 13 BLUE 1.5 Park Lights
L 9 BLACK/YELLOW 1.5 Artic Sensor Earth (4206D) K 7/13 Earth
BLACK 1.5
M 10 RED/ORANGE 1.5 Bin Position 5V Supply Bin Position Sensor Signal
L 9 PURPLE/GREEN 1.5
M 10 PURPLE/RED 1.5 Artic Sensor Signal (4206D)
M 10 RED/ORANGE 1.5 Bin Position 5V Supply
N 10 BLACK/YELLOW 1.5 Bin Position Sensor Return
N 10 RED/YELLOW 1.5 Artic Sensor 5V Supply (4206D)
3 P 3 RED 1.5 Ignition Supply (OBW, TPM)
P RED 1.5 Ignition Supply (OBW & TPM)
R 28 YELLOW 1.0 CAN High R 28 YELLOW 1.5 CAN High
S 28 GREEN 1.0 CAN Low S 28 GREEN 1.5 CAN Low
T 28 BLACK 1.5 CAN Shield T 28 BLACK 1.5 CAN Shield
U 7/28 BLACK 1.5 Earth (Large) U 28 BLACK 1.5 Earth
V 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch V 26 ORANGE/BLUE 1.5 Automatic Greaser Press Switch
W 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch Automatic Greaser Press Switch
W 26 ORANGE/BLUE 1.5
X
X
AJA
H
J X
K B W
G
L V
C A F
M D E U
N T AJA
P R S
HDP DEUTSCH, 21 WAY, PLUG & PINS -

ARTIC JUMP, ARTIC.

TERMINAL
? GN 1.5 ?
A 7 YELLOW/GREEN 1.5 Reverse Signal & Backup Alarm

D 7 WHITE/ORANGE 1.5 Rear 2 Speed Switch (B50D)
E 28 GREEN/GREY 1.5 Middle IDL Position Switch (B50D)
F 13 BROWN 1.5 Left Indicator
G
H 13 YELLOW 1.5 Right Indicator
J 13 BLUE 1.5 Park Lights
K 7/13 BLACK 1.5 Earth
L 9 PURPLE/GREEN 1.5 Bin Position Sensor Signal
M 10 RED/ORANGE 1.5 Bin Position 5V Supply
P 3 RED 1.5 Ignition Supply (OBW, TPM)
R 28 YELLOW 1.5 CAN High
S 28 GREEN 1.5 CAN Low
T 28 BLACK 1.5 CAN Shield
U 28 BLACK 1.5 Earth
V 26 ORANGE/BLUE 1.5 Automatic Greaser Press Switch
W 26 ORANGE/BLUE 1.5 Automatic Greaser Press Switch
X
Doc. No. 872272 : Rev 0 125

AL_1 ALL
20 8 31 31 8 20
21 9 19 30
10 2 18 30 19 9 21
22 3 7 29 18 2 10
1 29 7 3 22
23 11 4 6 17 28 1
5 28 17 6 4 11 23
12 13 15 16 AL1 15
5
13 ALL
24 27 16 12
25 14 26 27 24
HD DEUTSCH, 31 WAY, RECEPTACLE & PINS - 26 14 25
HD DEUTSCH, 31 WAY, PLUG & SOCKETS -
ALLISON FIREWALL. ALLISON FIREWALL.
(Connector as viewed from the back). (Connector as viewed from the back).

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 24 BROWN/BLACK 0.75 High Side Driver 2 1 24 BROWN/BLACK 0.75 High Side Driver 2
2 24 GREEN/RED 0.75 Retarder Solenoid
2 24 GREEN/RED 0.75 Retarder Solenoid
3
3
4 24 GREEN/ORANGE 0.75 Oil Level Excitation
4 24 GREEN/ORANGE 0.75 Oil Level Excitation
5
5
6 24 WHITE/YELLOW 0.75 TCC Solenoid
7 24 WHITE/GREEN 0.75 Press Control Solenoid 1
8 24 BROWN/GREEN 0.75 High Side Driver 1
9 24 ORANGE/WHITE 0.75 Main Mod Solenoid
9 24 ORANGE/WHITE 0.75 Main Mod Solenoid
10 24 BROWN/YELLOW 0.75 Press Control Solenoid 4
11 24 YELLOW/BROWN 0.75 S Solenoid 1
12 24 BLUE/GREEN 0.75 Press Control Solenoid 2
13 24 PURPLE/BLACK 0.75 Sensor Return
13 24 PURPLE/BLACK 0.75 Sensor Return
14 24 BROWN/RED 0.75 Sump Temperature
14 24 BROWN/RED 0.75 Sump Temperature
15 24 WHITE/GREY 0.75 Output Speed Sensor +
15 24 WHITE/GREY 0.75 Output Speed Sensor +
16 24 BLACK/BROWN 0.75 Engine Speed Sensor +
16 24 BLACK/BROWN 0.75 Engine Speed Sensor +
17 24 ORANGE/GREEN 0.75 Engine Speed Sensor -
17 24 ORANGE/GREEN 0.75 Engine Speed Sensor -
18 24 BLUE/PURPLE 0.75 Turbine Speed Sensor -
19 24 BLUE/ORANGE 0.75 Turbine Speed Sensor +
19 24 BLUE/ORANGE 0.75 Turbine Speed Sensor +
20 24 YELLOW/RED 0.75 Transmission ID
21 24 WHITE/BLUE 0.75 Pressure Switch 1
22 24 BLUE/WHITE 0.75 Oil Level Signal
22 24 BLUE/WHITE 0.75 Oil Level Signal
23 24 GREEN/BLUE 0.75 Output Speed Sensor -
23 24 GREEN/BLUE 0.75 Output Speed Sensor -
24 24 BLUE/RED 0.75 Retarder Accumulator Solenoid
25 24 ORANGE/GREY 0.75 Retarder Temperature Sensor
25 24 ORANGE/GREY 0.75 Retarder Temperature Sensor
26 24 GREEN/WHITE 0.75 Press Control Solenoid 3
26 24 GREEN/WHITE 0.75 Press Control Solenoid 3
27 27
28 24 BROWN/BLUE 0.75 Power Return
28 24 BROWN 0.75 Power Return
29
29
30
30
31 31
ALT
ALT
1 2 3 4 5 GHW, 5 WAY, PLUG & SOCKETS -

ALTERNATOR. (B50D & 300D Only).

TERMINAL
? GN 1.5 ?
1
2
3 1 YELLOW/RED 1.5 Alternator D+
4
5
ALT_D+
ALT D+
GHW, 4MM LUG -
ALTERNATOR D+.
(Isometric View).

TERMINAL
? GN 1.5 ?
ALTD+ 1 YELLOW/RED 1.5 ALTERNATOR D+ Signal
126 Doc. No. 872272 : Rev 0

ALT_AMP BAT1_2
ALT BAT1-2
GHW, 8MM LUG -
AMP, SOCKET - BATTERY 1 POS (12V).
ALTERNATOR. (Not on JD 250/300D & B50D). (Isometric View).
(Isometric View).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
ALT
BAT1-2 1 WHITE 2.5 12V Battery Supply
1 YELLOW/RED 1.5 Alternator Signal
ALT_B+ BB
ALT B+
GHW, 12MM LUG -
ALTERNATOR BAT. POS BB
(Isometric View). 6 1
5 2
PAGE WIRE COLOUR FUNCTION DT DEUTSCH, 6 WAY, PLUG & SOCKETS -
4 3
BATTERY BALANCER.
TERMINAL
? GN 1.5 ? PAGE WIRE COLOUR FUNCTION
TERMINAL
ALT-B+ 1 GREEN 16.0 Battery Supply (Alternator)
? GN 1.5 ?
ALT_E 1 4 BLACK 1.5 Earth
2 4 GREEN 1.5 Battery Supply 24V
ALT E 3
GHW, 12MM LUG - 4 4 WHITE/RED 1.5 12V Ignition Supply
ALTERNATOR EARTH. 5
(Isometric View).
6 4 RED/BLACK 1.5 Ignition Status Input (Ground)
TERMINAL
? GN 1.5 ? BD
BD
ALT-E 1 BLACK 16.0 Earth (Alternator)
1 2 AMP, 2 WAY, PLUG & SOCKETS -

BIN DOWN SOLENOID. (Not on 4206D, 2306D & T17D F/D).
ARLHT (Connector as viewed from the front).

TERMINAL
ARLHT
1 2 ? GN 1.5 ?
ARTIC REVERSE LIGHT.
(Connector as viewed from the back). 1 12 GREEN/YELLOW 1.5 Bin Down Solenoid
2 12 BLACK/YELLOW 1.5 Bin Down Return
TERMINAL
? GN 1.5 ? BFI
1 12 GREEN/BLUE 0.75 Artic Reverse Light
2 12 BLACK 0.75 Earth BFI
4 1
3 2
BONNET FAN INTERFACE. (B50D Only).
AS PAGE WIRE COLOUR FUNCTION

TERMINAL
AS
? GN 1.5 ?
C B A DELPHI PACKARD, 3 WAY, PLUG & PINS -
ARTIC SENSOR. (B50D & 4206D).
(Connector as viewed from the back). 1 9 YELLOW/PURPLE 1.5 Bonnet Fan Temperature Switch
2 14 BROWN/BLACK 1.5 Bonnet Fan 1
PAGE WIRE COLOUR FUNCTION 3 14 BROWN/BLUE 1.5 Bonnet Fan 2
4 9/14 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
A 10 BLACK/YELLOW 0.75 Artic Position Sensor Return
B 10 PURPLE/RED 0.75 Artic Position Sensor Signal
C 10 RED/YELLOW 0.75 Artic Position Sensor 5V Supply
Doc. No. 872272 : Rev 0 127

BFI_4_WAY BPR
BPR
BFI
1 4
DT DEUTSCH, 4 WAY, RECEPTACLE & PINS - BIN PRESSURE REDUCTION SOLENOID. (Large Trucks).
2 3
BONNET FAN INTERFACE. (B50D). (Connector as viewed from the front).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 9 GREEN/PURPLE 1.5 Bin Pressure Reduction Solenoid
1 9 YELLOW/PURPLE 1.5 Bonnet Fan Temperature Switch
2 9 BLACK 1.5 Earth
3 14 BROWN/BLUE 1.5 Bonnet Fan 2
4 9/14 BLACK 1.5 Earth
BPS
BPS
BIN_A_&_BIN_B
C B A DELPHI PACKARD, 3 WAY, PLUG & PINS -
BIN-A & BIN-B BIN POSITION SENSOR.
GHW, 1 WAY, PUSH ON TERMINAL -
BINARY SWITCH. PAGE WIRE COLOUR FUNCTION
(Isometric view).
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ? A 10 BLACK/YELLOW 1.5 Bin Position Sensor Return

B 10 PURPLE/GREEN 1.5 Bin Position Sensor Signal
C 10 RED/ORANGE 1.5 Bin Position Sensor 5V Supply
A 17 WHITE/GREEN 0.75 Binary Switch Signal To CCU2
B 17 WHITE/GREEN 0.75 Binary Switch To AC Clutch
BU
BU
BL
BIN UP SOLENOID. (Not on 4206D, 2306D & T17D F/D).
6 1
BL
5 2
TERMINAL
4 3
BIN LEVER. (Not used on T17D F/D & 4206D).
? GN 1.5 ?
1 12 YELLOW/GREEN 1.5 Bin Up Solenoid
TERMINAL
2 12 BLACK/YELLOW 1.5 Bin Up Return

? GN 1.5 ?
1 10 BLACK/YELLOW 0.75 Sensor Return
2 10 RED/ORANGE 0.75 5V Sensor Supply
BUA
3 10 ORANGE/GREEN 0.75 Bin Lever Position Signal
4
BUA
5 Earth GHW, 4MM LUG -
10 BLACK 0.75
BACK UP ALARM.
6 10 PURPLE/RED 0.75 Bin Lever Latch (Isometric View).

BLS
TERMINAL
? GN 1.5 ?
BLS
1 2
A 7 YELLOW/GREEN 1.5 Back Up Alarm
B 7 BLACK 1.5 Earth
BRAKE LIGHT SWITCH.
BUZ
TERMINAL
? GN 1.5 ?
BUZ
1 2
DT DEUTSH, 2 WAY, PLUG & SOCKETS -
2 9 GREY/GREEN 0.75 Brake Light Switch Signal BUZZER.

TERMINAL
? GN 1.5 ?
1 5 BLACK/RED 0.75 Buzzer Ignition Control
2 5 ORANGE/WHITE 0.75 Buzzer Earth Control
128 Doc. No. 872272 : Rev 0

CAB CAN_A, 3_WAY
CAB CAN A
6 5 4 3 2 1 A
7 8 9 10 11 12
DT DEUTSCH, 12 WAY, RECEPTACLE & PINS - C B
HD10 DEUTSCH, 3 WAY, PLUG & SOCKETS -
TRANSMISSION INTERFACE. (ALLISON). CAN ARTIC.

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 23 BLACK 1.5 System Ground
Battery Supply
A 28 YELLOW 1.5 CAN High
2 23 GREEN 1.5
3 23 RED 1.5 Ignition Supply B 28 GREEN 1.5 CAN Low
4 23 YELLOW/BLACK 0.75 Diagnostic - K (J1708+) C 28 BLACK 1.5 CAN Shield
5 23 YELLOW/BLUE 0.75 Diagnostic - L (J1708-)
6 23 BLUE 0.75 Shift Selector Back Light
7 23 YELLOW/PINK 0.75 Auto Neutral (Allison Only)
Gear Hold (Allison Only)
8
9
23
23
BLACK/BLUE 0.75
GREEN/BLACK 0.75 3rd Shift Programme (Allison Only)
CAN_TERM
10 23 PINK/GREY 0.75 ZF EOL Prog. Pin (ZF Only)
11 23 BROWN/RED 0.75 Neutral Signal
12 23 PURPLE/WHITE 0.75 Laden/Unladen (Primary/Secondary Shift Programme)
B A
CAN TERM
C
CAN_1 CAN TERMINATOR.

CAN1
TERMINAL
5 6
3 4
AMP, 6 WAY, PLUG & SOCKETS - ? GN 1.5 ?
1 2 EXPANSION CAN. (4206D).
B 28 GREEN 1.5 CAN Low
TERMINAL
C 28 BLACK 1.5 CAN Shield
? GN 1.5 ?
1 8 BLACK 1.5 Earth CANT_1
2 8 YELLOW/BLACK 1.5 Iqan CAN High
3
4
5 8 RED 1.5 Ignition Supply B A
CANT1
6 8 BLACK/YELLOW 1.5 Iqan CAN Low
C
CAN TERMINATOR 1.
CAN_A PAGE WIRE COLOUR FUNCTION

TERMINAL
? GN 1.5 ?
A CANA
B C
HD DEUTSCH, 3 WAY, RECEPTACLE & PINS - A 18 YELLOW 0.75 CAN - High
FIREWALL, CAN ARTIC. B 18 GREEN 0.75 CAN - Low
C 18 BLACK 0.75 CAN - Shield
TERMINAL
? GN 1.5 ? CB_1
CB1
B CAN Low
GHW, 5MM LUG -
28 GREEN 0.75
CIRCUIT BREAKER 1.
C 28 BLACK 0.75 CAN Shield (Isometric View).

TERMINAL
? GN 1.5 ?
CB1-1 1 WHITE 2.5 12V Battery Supply

CB1-2 1 WHITE 2.5 12V Battery Supply
Doc. No. 872272 : Rev 0 129

CB_2, 5mm CCU2_J2

CB2
GHW, 5MM LUG - A BCDEFGH J K L M
CIRCUIT BREAKER 2. 4
(Isometric View). 3
2
1
PAGE WIRE COLOUR FUNCTION L K J HG FE DC B A M
CCU2J2 CINCH, 48 WAY, PLUG & SOCKETS -
CHASSIS CONTROL UNIT (J2).
TERMINAL
TERMINAL
CB2-1 1 RED 4.0 Ignition Supply
CB2-1 1 RED 2.5 Ignition Supply ? GN 1.5 ?
A1 9 YELLOW 0.75 CAN High
CCU2_J1 A2
A3
A4 9 GREY/GREEN 0.75 Brake Lights Switch
B1 9 GREEN 0.75 CAN Low
A B CD E F G H
B2
4
B3
3 CCU2J1 B4 9 GREEN/BLUE 0.75 IDL Solenoid
2
C1 9 YELLOW/PURPLE 0.75 Bonnet Fan Temperature Switch
1 G F E D C B A H
CINCH BN, 32 WAY, PLUG & SOCKETS - C2
CHASSIS CONTROL UNIT (J1). C3 9 PURPLE/BLUE 0.75 Left Height Position Sensor
C4 9 GREEN/PURPLE 0.75 Bin Pressure Reduction Solenoid
PAGE WIRE COLOUR FUNCTION D1
D2 9 GREEN/BLACK 0.75 Hazard Dash Switch
TERMINAL
D3 9 PURPLE/YELLOW 0.75 Right Height Position Sensor

D4 9 ORANGE/YELLOW 0.75 Bin Lever Latch
? GN 1.5 ? E1 9 PINK/BLUE 0.75 Rear Wiper Park Signal Input
E2 9 PINK 0.75 Front Wiper Park Signal Input
E3 9 PURPLE/RED 0.75 Artic Angle Position Sensor
A1
E4 9 YELLOW/GREEN 0.75 Pneumatic Blow Off Solenoid
A2
F1 9 PURPLE/GREEN 0.75 Bin Position Sensor
A3 7 GREY/WHITE 0.75 Headlight Dips
F2 9 GREEN/GREY 0.75 IDL Pressure Switch
A4 7 GREY/WHITE 0.75 Headlight Dips
F3
B1
F4 9 ORANGE/BROWN 0.75 CTD Solenoid
B2
G1 10 ORANGE/GREEN 0.75 Bin Lever Position Sensor
B3 7 WHITE/GREY 0.75 Headlight Brights
G2
B4 7 WHITE/GREY 0.75 Headlight Brights
G3
C1 7 ORANGE/WHITE 0.75 System Air Pressure
G4 10 ORANGE/BLUE 0.75 Rear Wiper High Speed
C2 7 BLACK/GREEN 0.75 Start Signal
H1 10 BLUE/GREY 0.75 Park Brake Dash Switch
C3 7 YELLOW/GREEN 0.75 Reverse
H2 10 PURPLE/WHITE 0.75 Front 2 Speed Switch
C4 7 YELLOW/GREEN 0.75 Reverse
H3
D1 7 WHITE/ORANGE 0.75 Rear 2 Speed Switch
H4 10 ORANGE/WHITE 0.75 Flashing Beacon Light
D2 7 BLUE/YELLOW 0.75 Middle 2 Speed Switch
J1 10 RED/BLACK 0.75 Aircon Evaporator Temperature
D3 7 YELLOW/GREY 0.75 Rear Wiper Low Speed
J2 10 WHITE/BLUE 0.75 Wet Disk Brake Temperature
D4 7 YELLOW/GREY 0.75 Rear Wiper Low Speed
J3 10 GREYRED 0.75 Cab Temperature
E1 7 GREEN/WHITE 0.75 Scraper Dash Switch
J4 10 BLUE/GREEN 0.75 Horn
E2 7 PURPLE/WHITE 0.75 Pressure 2 Speed Switch
K1 10 RED/YELLOW 0.75 Left/Right Height /Artic Position Sensor
E3 7 RED/ORANGE 0.75 Front Wiper Lo Speed
K2 10 BLACK/YELLOW 0.75 Left/Right Height/Artic Position Sensor, Wet Disk Brake/
E4 7 RED/ORANGE 0.75 Front Wiper Lo Speed
Evaporator/Cab/System Air/Hydraulic Temperature
F1 7 WHITE/RED 0.75 12V Ignition Power
F2 K3 10 BLACK/YELLOW 0.75 Bin Position/Bin Lever Position Sensor
7 GREEN/BLACK 0.75 Horn Switch
K4 10 RED/ORANGE 0.75 Bin Position/Bin Lever Position Sensor
F3 7 BLUE 0.75 Park Lights
L1 10 GREEN 1.5 28V Battery (KL30)
F4 7 BLUE 0.75 Park Lights
L2 10 BLACK 1.5 Ground (KL31)
G1
L3 10 RED 1.5 Ignition Supply to Outputs
G2
L4 10 RED 1.5 Ignition Supply to Outputs
G3 7 RED 1.5 Ignition Supply to Outputs
M1 10 RED 1.5 28V Ignition (KL15)
M2 10 BLACK 1.5 Ground (KL31)
H1 7 RED/WHITE 1.5 Work Lights
H2 M3 10 RED 1.5 Ignition SUpply to Outputs
7 RED/WHITE 1.5 Work Lights
M4 10 RED 1.5 Ignition Supply to Outputs
H3 7 RED 1.5 Ignition Supply to Outputs
130 Doc. No. 872272 : Rev 0

CCU2_J3 COL
3
2 1
4 COL
A B CD E F G H
4
3 CCU2J3 HARNESSFLEX, 4 WAY, M27, SOCKETS -
2 COOLANT LEVEL.
1 (Connector as viewed from the front).
G F E D C B A H
CINCH BL, 32 WAY, PLUG & SOCKETS -
CHASSIS CONTROL UNIT (J3).
(Connector as viewed from the back). PAGE WIRE COLOUR FUNCTION
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ?
2 6 BLACK 1.5 Earth
A1 12 GREEN/BLUE 0.75 Artic Reverse Light
3 6 WHITE/BLUE 1.5 Low Coolant Level Signal
A2 12 RED/BROWN 0.75 Recirculation Flap
4
A3 12 YELLOW/GREEN 0.75 Bin Up Solenoid
A4 12 YELLOW/BLUE 0.75 Engine Running
B1 12 PURPLE/GREEN 0.75 Rear Washer Pump
B2 12 BROWN 0.75 Left Indicator Light
B3 COL_PLUG
B4 12 GREY/BLUE 0.75 Brake Light
C1 12 ORANGE 0.75 Front Wiper High Speed
C2 12 YELLOW 0.75 Right Indicator Light COL
C3
C4 12 BLACK/YELLOW 0.75 Bin Down Return
12 Front Washer Pump 2 1 AMP, 2 WAY, PLUG & SOCKETS -
D1 GREEN/PURPLE 0.75
COOLANT LEVEL. (Small Trucks).
D2 12 RED/GREY 0.75 Mirror Heating (Connector as viewed from the back).
D3 12 BLACK/YELLOW 0.75 Bin Up Return
D4 12 GREEN/YELLOW 0.75 Bin Down Solenoid PAGE WIRE COLOUR FUNCTION
E1 12 RED/PINK 0.75 Overspeed Control
TERMINAL
E2 12 BLACK/WHITE 0.75 Hydraulic Cut Solenoid

E3 12 WHITE/GREEN 0.75 Aircon Clutch Solenoid
E4 12 GREEN/WHITE 0.75 Hydraulic Temperature Sensor ? GN 1.5 ?
F1 12 BROWN/YELLOW 0.75 Park Brake Solenoid
F2 12 BLUE/YELLOW 0.75 Aircon Thermo Switch
1 6 WHITE/BLUE 1.5 Low Coolant Level Signal
F3
F4 12 RED 0.75 Hardware Detection 2 6 BLACK 1.5 Earth
G3
G4
COOLT
H1 12 BLACK 1.5 Power Ground
H2 12 BLACK 1.5 Power Ground
H3 12 RED 1.5 Ignition Supply to Outputs COOLT
A B DELPHI PACKARD, 2 WAY, PLUG & SOCKETS -

COOLANT TEMPERATURE (JD).
CIAT PAGE WIRE COLOUR FUNCTION

TERMINAL
? GN 1.5 ?
CIAT
A 21 ORANGE/GREY 1.5 Coolant Temperature Signal

B 21 BLACK/YELLOW 1.5 Excitation #2-
COMPRESSOR INLET AIR TEMPERATURE (JD).
CRANK
TERMINAL
? GN 1.5 ?
CRANK
A 21 RED/GREEN 1.5 Compressed Inlet Air Signal
B 21 BLACK/YELLOW 1.5 Excitation #2-
CRANK SENSOR (JD).
CL PAGE WIRE COLOUR FUNCTION

TERMINAL
? GN 1.5 ?
CL
2
UTILUX, 2 WAY, PLUG & SOCKETS - A 22 BROWN/YELLOW 1.5 Crank Speed Sensor +
1
CIGARETTE LIGHTER. B 22 YELLOW/GREEN 1.5 Crank Speed Sensor -

TERMINAL
? GN 1.5 ?
1 4 WHITE/RED 1.5 12V Ignition Supply
2 4 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 131

CS_4_Cold_Start CSTS
CS4
4 3
1 2
2 1 COLD START, 4 PIN. (Not on JD 250/300D).
CSTS
M24, 2 WAY, 90° BAYONET PLUG & SOCKETS -
COLD START TEMPERATURE SENDER. (Not on JD 250/300D).
TERMINAL
? GN 1.5 ?
TERMINAL
1
2 ? GN 1.5 ?
3 18 BLUE/WHITE 2.5 Module Output to Glow Plug
1 18 GREY/WHITE 2.5 Cold Start Temperature Sender Signal
CS_8_Cold_Start
CTDPS
CS8
8 7 6 5

4 3 2 1
COLD START, 8 PIN. (Not on JD 250/300D). 2 1
(Connector as viewed from the back). 3
PAGE WIRE COLOUR FUNCTION CTDPS

TERMINAL
? GN 1.5 ? CONTROL TRACTION DEVICE PRESSURE SWITCH.


TERMINAL

3
4
18
18
BLACK 2.5
YELLOW/GREEN 1.5
Earth
Engine Running Input
? GN 1.5 ?
5 18 BLACK/WHITE 1.5 Start Signal
6 18 GREY/BLACK 2.5 Cold Start Fuel Solenoid 1 9 ORANGE/BLUE 0.75 CTD Switch
7 18 GREY/WHITE 2.5 Cold Start Temperature Sensor 2
8 18 ORANGE/BLACK 1.5 Cold Start Light 3 9 BLACK 0.75 Earth
4
CSGP CTDSOL
CSGP
GHW, 5MM LUG
2 1
COLD START GLOW PLUG. (Not on JD 250/300D).
(Isometric View). 3
CTDSOL
TERMINAL
CONTROL TRACTION DEVICE SOLENOID.

? GN 1.5 ?
TERMINAL
CSGP 18 BLUE/WHITE 2.5 Cold Start Glow Plug Supply
? GN 1.5 ?
CSSOL 1
2
9
9
ORANGE/BROWN 0.75 CTD Solenoid
BLACK 0.75 Earth
3
4
1 4
3 2
CSSOL
AMP, 4 WAY, BAYONET, PLUG & SOCKETS -

COLD START FUEL SOLENOID. (Not on JD 250/300D).

TERMINAL
? GN 1.5 ?
1 18 GREY/BLACK 2.5 Cold Start Fuel Solenoid
3
4
132 Doc. No. 872272 : Rev 0

D1A_Firewall_Power D2AFirewall - Arctic
T X
W K
U S V J L
H B
U M
V R Z G A C
T N
D1A F
E
D D2A
W Y S O
X R P
Q
HDP DEUTSCH, 9 WAY, RECEPTACLE & PINS - HDP DEUTSCH, 23 WAY, RECEPTACLE & SOCKETS -
FIREWALL, POWER. FIREWALL, ARTIC.

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
R 1 BLACK 16.0 Earth
A 5 RED/GREY 0.75 Low Brake Accumulator
S 1 RED 10.0 Ignition Supply
T 1 WHITE 2.5 Battery Supply 12V Battery Balancer B 5 ORANGE/BLACK 0.75 Emergency Steering
U 1 GREEN 10.0 Battery Supply 24V C 7 YELLOW/GREEN 1.5 Reverse Signal
V 1 RED/BLACK 2.5 Isolation Solenoid to Ignition Switch D 26 ORANGE/GREEN 0.75 Automatic Greaser Indicator
W 18 BLUE/WHITE 2.5 Cold Start Glow Plug E 13 GREY/BLUE 0.75 Brake Lights
X 18 GREY/BLACK 2.5 Cold Start Fuel Solenoid F
Y 18 GREY/WHITE 2.5 Cold Start Temperature Sender G
Z H 12 BLACK/WHITE 0.75 Hydraulic Cut
J 13 BROWN 0.75 Left Indicator
K 13 YELLOW 0.75 Right Indicator
D1B L
M
10
9
BLACK/YELLOW 0.75
PURPLE/RED 0.75
Artic Sensor Return
Artic Sensor Signal
N 3 RED 1.5 Signal Fuse - Exterior
O 10 RED/YELLOW 0.75 Artic Sensor 5V Supply
P 13 BLUE 1.5 Park Lights
T Q 5 BLUE/WHITE 0.75 Hydraulic Filter Pressure
S U R 3 RED 1.5 Auto Greaser Ignition Supply
S 26 BROWN/RED 0.75 Auto Greaser Neutral Signal
Z R V
D1B T 9 PURPLE/GREEN 0.75 Bin Position Sensor Signal
Y W U 10 RED/ORANGE 0.75 Bin Position 5V Supply
X V 10 BLACK/YELLOW 0.75 Bin Position Sensor Return
HDP DEUTSCH, 9 WAY, PLUG & SOCKETS -
FIREWALL, POWER. W 11 WHITE/BLUE 0.75 Wet Disc Brake Temperature
(Connector as viewed from the back). X 12 GREEN/WHITE 0.75 Hydraulic Temperature
D2B
TERMINAL
? GN 1.5 ?
R 1 BLACK 16.0 Earth K X

W
S 1 RED 10.0 Ignition Supply L J V
B H
T 1 WHITE 2.5 Battery Supply 12V Battery Balancer M U
C A G
U 1 GREEN 10.0 Battery Supply 24V N T
V 1 RED/BLACK 2.5 Isolation Solenoid to Ignition Switch D F D2B
O E S
W 18 BLUE/WHITE 2.5 Cold Start Glow Plug P
Q
R
X 18 GREY/BLACK 2.5 Cold Start Fuel Solenoid HDP DEUTSCH, 23 WAY, PLUG & PINS -
Y 18 GREY/WHITE 2.5 Cold Start Temperature Sender FIREWALL, ARTIC & REAR.
Z

TERMINAL
? GN 1.5 ?
A 5 RED/GREY 0.75 Low Brake Accumulator

B 5 ORANGE/BLACK 0.75 Emergency Steering
C 7 YELLOW/GREEN 1.5 Reverse Signal
D 26 ORANGE/GREEN 0.75 Automatic Greaser Indicator
E 13 GREY/BLUE 0.75 Brake Lights
F
G
H 12 BLACK/WHITE 0.75 Hydraulic Cut
J 13 BROWN 0.75 Left Indicator
K 13 YELLOW 0.75 Right Indicator
L 10 BLACK/YELLOW 0.75 Artic Sensor Return
M 9 PURPLE/RED 0.75 Artic Sensor Signal
N 3 RED 1.5 Signal Fuse - Exterior
O 10 RED/YELLOW 0.75 Artic Sensor 5V Supply
P 13 BLUE 1.5 Park Lights
Q 5 BLUE/WHITE 0.75 Hydraulic Filter Pressure
R 3 RED 1.5 Auto Greaser Ignition Supply
S 26 BROWN/RED 0.75 Auto Greaser Neutral Signal
T 9 PURPLE/GREEN 0.75 Bin Position Sensor Signal
U 10 RED/ORANGE 0.75 Bin Position 5V Supply
V 10 BLACK/YELLOW 0.75 Bin Position Sensor Return
W 11 WHITE/BLUE 0.75 Wet Disc Brake Temperature
X 12 GREEN/WHITE 0.75 Hydraulic Temperature
Doc. No. 872272 : Rev 0 133

D3A Firewall - Engine D3B
20 31
21 8 30
31 20 9 19
30 8 21 10 2 18
19 9 22 3 7 29
18 2 10 11 1 17
29 7 3 22 23 4 6 28
17 1 11 12 5 16 D3B
28 6 4 23 13 15
16
15
5
13
12
D3A 24 14
26
27
25
27 14 24 HDP DEUTSCH, 31 WAY, PLUG & PINS -
26 25
FIREWALL, ENGINE.
HDP DEUTSCH, 31 WAY, RECEPTACLE & SOCKETS - (Connector as viewed from the back).
FIREWALL, ENGINE.
TERMINAL
? ?
TERMINAL
GN 1.5
? GN 1.5 ?
1
2 6 WHITE/BLUE 0.75 Engine Coolant Level Switch
1
3 1 YELLOW/RED 0.75 D+
2 6 WHITE/BLUE 0.75 Engine Coolant Level Switch
4 9 YELLOW/GREEN .075 Pneumatic Blow Off Solenoid
3 1 YELLOW/RED 0.75 D+
5 18 RED 1.5 MR Ignition Supply
4 9 YELLOW/GREEN .075 Pneumatic Blow Off Solenoid
6 1 BLACK/WHITE 1.5 Starter Signal - KL50 (JD 250D/300D)
5 18 RED 1.5 MR Ignition Supply
7
6 1 BLACK/WHITE 1.5 Starter Signal - KL50 (JD 250D/300D)
8 13 BROWN 0.75 Left Indicator
7 13 Right Indicator
9 YELLOW 0.75
8 13 BROWN 0.75 Left Indicator 10 7 WHITE/GREY 1.5 Brights
9 13 YELLOW 0.75 Right Indicator 11 7 GREY/WHITE 1.5 Dips
10 7 WHITE/GREY 1.5 Brights 12 17 WHITE/GREEN 0.75 Aircon - Clutch
11 7 GREY/WHITE 1.5 Dips 13 18 IES CAN: BLACK 0.75 IES CAN - Shield
12 17 WHITE/GREEN 0.75 Aircon - Clutch 14 18 IES CAN: YL/GN 0.75 IES CAN - High
13 18 IES CAN: BLACK 0.75 IES CAN - Shield 15 10 BLUE/GREEN 0.75 Horn
14 18 IES CAN: YL/GN 0.75 IES CAN - High 16
15 10 BLUE/GREEN 0.75 Horn 17 16 BLUE/YELLOW 0.75 Engine Hyd Cooler Fan Solenoid (B50D)
16 18 16 BLACK/YELLOW 0.75 Engine Hyd Cooler Fan PWM Return (B50D)
17 16 BLUE/YELLOW 0.75 Engine Hyd Cooler Fan Solenoid (B50D) 19 14 BROWN/BLACK 0.75 Bonnet Fan 1 (B50D)
18 16 BLACK/YELLOW 0.75 Engine Hyd Cooler Fan PWM Return (B50D) 20 14 BROWN/BLUE 0.75 Bonnet Fan 2 (B50D)
19 14 BROWN/BLACK 0.75 Bonnet Fan 1 (B50D) 21
20 14 BROWN/BLUE 0.75 Bonnet Fan 2 (B50D) 22
21 23 29 YELLOW/BLUE 0.75 Hydraulic Level Switch
22 24 18 IES CAN: BLACK 0.75 IES CAN - Shield
23 29 YELLOW/BLUE 0.75 Hydraulic Level Switch 25 18 IES CAN: BROWN 0.75 IES CAN - Low
24 18 IES CAN: BLACK 0.75 IES CAN - Shield 26 8 BLUE 1.5 Park Lights
25 18 IES CAN: BROWN 0.75 IES CAN - Low 27 5 BLUE/WHITE 0.75 Fuel Level Sender
26 8 BLUE 1.5 Park Lights 28 18 PURPLE 0.75 MR Diagnostic
27 5 BLUE/WHITE 0.75 Fuel Level Sender 29
28 18 PURPLE 0.75 MR Diagnostic 30 5 PURPLE/GREEN 0.75 Engine Air Intake Filter Press SW (B50D)
29 31 9 YELLOW/PURPLE 0.75 Bonnet Fan Temperature Switch (B50D)
30 5 PURPLE/GREEN 0.75 Engine Air Intake Filter Press SW (B50D)
31 9 YELLOW/PURPLE 0.75 Bonnet Fan Temperature Switch (B50D)
D4A_A
W XK
V J L
H B
U M
G A C
T N
F D
S E O D4A A
R Q P
HDP DEUTSCH, 23 WAY, RECEPTACLE & SOCKETS -

FIREWALL, JOHN DEERE A.

TERMINAL
? GN 1.5 ?
A 19 GREEN/WHITE 1.5 Injector 0, 4 & 2+ (Supply Line)

B 19 GREEN/PURPLE 1.5 Injector 1, 3 & 5+
C 19 PURPLE/GREEN 1.5 H Bridge 1+
D 19 RED/GREY 1.5 H Bridge 1-
E 19 GREY/BLUE 1.5 Pump Solenoid+
F 19 YELLOW/BLUE 1.5 Pump Solenoid-
G 19 WHITE/BLUE 1.5 H Bridge 2+ / H Bridge 2-
H
J 21 GREEN/GREY 0.75 Injector 5 (Cylinder 4)
K 21 GREEN/ORANGE 0.75 Injector 4 (Cylinder 2)
L 21 GREEN/RED 0.75 Injector 3 (Cylinder 6)
M 21 GREEN/BLUE 0.75 Low Press Fuel Pump Current
N 19 GREEN/BROWN 0.75 Injector 2 (Cylinder 3)
O 19 GREY/ORANGE 0.75 Low Press Fuel Pump, Speed Comm
P 19 BLACK 0.75 ERGV Shield
Q 19 ORANGE/BLUE 0.75 Low Press Fuel Pump, Power On Sig
R 19 GREEN/YELLOW 0.75 Injector 0 (Cylinder 1)
S 19 PINK/BLUE 0.75 Low Press Fuel Pump, Status
T 19 GREEN/PINK 0.75 Injector 1 (Cylinder 5)
U
V 19 BLACK 0.75 PCV Shield
W 19 BLACK 0.75 FI Shield
X
134 Doc. No. 872272 : Rev 0

D4A_B D4B_A
XK 33
W 32 16 17
V J L 6 18
H B 31 15 7 19
30 14 5 1 20
U G A C M 8
13 2 21
29 4
F D N 3 9
T E
O
D4A-B 28 12 22 D4B A
S P
27 11 10
R Q 2625 23
24
HDP DEUTSCH, 23 WAY, PLUG & PINS, 90° - HDP DEUTSCH, 33 WAY, RECEPTACLE & SOCKETS -
FIREWALL, JOHN DEERE ENGINE A. FIREWALL, JOHN DEERE B.

TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
A 19 GREEN/WHITE 1.5 Injector 0, 4 & 2+ (Supply Line)
B 19 GREEN/PURPLE 1.5 Injector 1, 3 & 5+ 1 19 GREY/BLACK 1.5 Ether Start
C 19 PURPLE/GREEN 1.5 H Bridge 1+ 2
D 19 RED/GREY 1.5 H Bridge 1- 3 19 BLUE/GREY 0.75 Turbo Speed In-
E 19 GREY/BLUE 1.5 Pump Solenoid+ 4 19 GREY/GREEN 0.75 Turbo Speed In+
F 19 YELLOW/BLUE 1.5 Pump Solenoid- 5
G 19 WHITE/BLUE 1.5 H Bridge 2+ / H Bridge 2- 6 19 ORANGE/BLACK 1.5 Excitation +
H 19 Rail Pressure Sensor Return
7 BLACK/YELLOW 1.5
J 21 GREEN/GREY 0.75 Injector 5 (Cylinder 4)
8 19 BLACK/ORANGE 1.5 Cam Speed+
K 21 GREEN/ORANGE 0.75 Injector 4 (Cylinder 2)
9 19 YELLOW/PINK 1.5 Cam Speed-
L 21 GREEN/RED 0.75 Injector 3 (Cylinder 6)
10 19 BLACK/YELLOW 1.5 Excitation 2-
M 21 GREEN/BLUE 0.75 Low Press Fuel Pump Current
N 21 GREEN/BROWN 0.75 Injector 2 (Cylinder 3) 11 19 RED/ORANGE 1.5 Excitation 2+
O 00 GREY/ORANGE 0.75 Low Press Fuel Pump, Speed Comm 12
P 00 BLACK 0.75 ERGV Shield 13
Q 00 ORANGE/BLUE 0.75 Low Press Fuel Pump, Power On Sig 14 19 ORANGE/RED 0.75 5V Excitation+
R 00 GREEN/YELLOW 0.75 Injector 0 (Cylinder 1) 15 19 BLACK/YELLOW 0.75 5V Excitation-
S 00 PINK/BLUE 0.75 Low Press Fuel Pump, Status 16 19 BLUE/WHITE 0.75 EGR Position 1
T 00 GREEN/PINK 0.75 Injector 1 (Cylinder 5) 17 21 GREY/WHITE 0.75 Fuel Temp Signal
U 18 21 BLACK/YELLOW 0.75 Temp Return
V 00 BLACK 0.75 PCV Shield 19 21 BROWN/RED 0.75 Rail Pressure Signal
W 00 BLACK 0.75 FI Shield
20 21 ORANGE/BROWN 0.75 Fuel Pressure Signal
X
21 21 BROWN/BLUE 0.75 Engine Oil Pressure Signal
22 21 PINK/GREY 0.75 Manifold Air Pressure Signal
23 21 RED/GREEN 0.75 Compressed Inlet Air Signal
24 21 PURPLE/WHITE 0.75 Water In Fuel Signal
25 21 ORANGE/GREY 0.75 Coolant Temp Signal
26 21 WHITE/BLUE 0.75 Exhaust Pressure Signal
27 21 WHITE/GREEN 0.75 EGR Exhaust Temperature Signal
28 21 ORANGE/WHITE 0.75 Actuator Comm+
29 21 PURPLE/BLUE 0.75 Manifold Air Temp Signal
30 21 RED/BLUE 0.75 Charge Air Temp Signal
31 21 YELLOW/GREEN 0.75 Crank Speed Sensor+
32 21 BROWN/YELLOW 0.75 Crank Speed Sensor-
33
Doc. No. 872272 : Rev 0 135

D4B_B D5A_Firewall_Special_Artic
17 33
18 1632 H
15 31 X J
19 6 14
W K
20 7 1 5 30 G B
13
8 V L
21 2 4 29 F A C
3 12
22 9 28 D4B-B U M
23 10 11
T
E D
N
D5A
27
24 25
26 S P
R
HDP DEUTSCH, 33 WAY, PLUG & PINS, 90° -
FIREWALL, JOHN DEERE ENGINE B. HDP DEUTSCH, 21 WAY, RECEPTACLE & SOCKETS -
(Connector as viewed from the back). FIREWALL, SPECIAL ARTIC & REAR.
TERMINAL
TERMINAL
? GN 1.5 ? ?
? GN 1.5
1 19 GREY/BLACK 1.5 Ether Start

A 16 BLUE/GREY 0.75 Fan Cut Solenoid (Large)
2
B 16 PINK/GREY 0.75 Left Strut Up (B50)
3 19 BLUE/GREY 0.75 Turbo Speed In-
C 16 PURPLE/GREEN 0.75 Fan Low Solenoid (Large)
4 19 GREY/GREEN 0.75 Turbo Speed In+
D 16 RED/BROWN 0.75 Left Strut Down (B50)
5
6 E 16 GREY/ORANGE 0.75 Right Strut Up (B50)
19 ORANGE/BLACK 1.5 Excitation +
F 16 BLACK/GREEN 0.75 Fan Medium Solenoid (Large)
7 19 BLACK/YELLOW 1.5 Rail Pressure Sensor Return
G 16 ORANGE/WHITE 0.75 Right Strut Down (B50)
8 19 BLACK/ORANGE 1.5 Cam Speed+
H 12 YELLOW/GREEN 0.75 Bin Up Solenoid
9 19 YELLOW/PINK 1.5 Cam Speed-
J 12 BLACK/YELLOW 0.75 Bin Up Return
K 12 GREEN/YELLOW 0.75 Bin Down Solenoid
11 19 RED/ORANGE 1.5 Excitation 2+
L 12 BLACK/YELLOW 0.75 Bin Down Return
12
M 9 GREEN/GREY 0.75 IDL Position Switch (B50D)
13
N 11 PURPLE/WHITE 0.75 Front 2 Speed Switch (B50D)
14 19 ORANGE/RED 0.75 5V Excitation+
P 7 BLUE/YELLOW 0.75 Middle 2 Speed Switch (B50D)
15 19 BLACK/YELLOW 0.75 5V Excitation-
19 R 7 WHITE/ORANGE 0.75 Rear 2 Speed Switch (B50D)
16 BLUE/WHITE 0.75 EGR Position 1
S 10 RED/YELLOW 0.75 Left/Right Height Pos Sensors 5V Supply (B50)
17 21 GREY/WHITE 0.75 Fuel Temp Signal
T 9 PURPLE/BLUE 0.75 Left Height Position Signal (B50)
18 21 BLACK/YELLOW 0.75 Temp Return
U 9 PURPLE/YELLOW 0.75 Right Height Position Signal (B50)
19 21 BROWN/RED 0.75 Rail Pressure Signal
V 10 BLACK/YELLOW 0.75 Left/Right Height Pos Sensor Return (B50)
20 21 ORANGE/BROWN 0.75 Fuel Pressure Signal
W 9 GREEN/PURPLE 0.75 Bin Pressure Reduction Solenoid
21 21 BROWN/BLUE 0.75 Engine Oil Pressure Signal
X 3 RED 1.5 OBW/TPM Ignition Supply
22 21 PINK/GREY 0.75 Manifold Air Pressure Signal
23 21 RED/GREEN 0.75 Compressed Inlet Air Signal
24 21 PURPLE/WHITE 0.75 Water In Fuel Signal
25
26
21
21
ORANGE/GREY 0.75
WHITE/BLUE 0.75
Coolant Temp Signal
Exhaust Pressure Signal
D5B
27 21 WHITE/GREEN 0.75 EGR Exhaust Temperature Signal
28 21 ORANGE/WHITE 0.75 Actuator Comm+
29 21 PURPLE/BLUE 0.75 Manifold Air Temp Signal
30 21 RED/BLUE 0.75 Charge Air Temp Signal
31 21 YELLOW/GREEN 0.75 Crank Speed Sensor+ H
J X
32 21 BROWN/YELLOW 0.75 Crank Speed Sensor- K B W
G
33 L V
C A F
M D E U
N T D5B
P R S

FIREWALL, SPECIAL ARTIC & REAR.

TERMINAL
? GN 1.5 ?
A 16 BLUE/GREY 0.75 Fan Cut Solenoid (Large)

B 16 PINK/GREY 0.75 Left Strut Up (B50)
C 16 PURPLE/GREEN 0.75 Fan Low Solenoid (Large)
D 16 RED/BROWN 0.75 Left Strut Down (B50)
E 16 GREY/ORANGE 0.75 Right Strut Up (B50)
F 16 BLACK/GREEN 0.75 Fan Medium Solenoid (Large)
G 16 ORANGE/WHITE 0.75 Right Strut Down (B50)
H 12 YELLOW/GREEN 0.75 Bin Up Solenoid
J 12 BLACK/YELLOW 0.75 Bin Up Return
K 12 GREEN/YELLOW 0.75 Bin Down Solenoid
L 12 BLACK/YELLOW 0.75 Bin Down Return
M 9 GREEN/GREY 0.75 IDL Position Switch (B50D)
M 9 BLACK 1.5 EARTH
N 11 PURPLE/WHITE 0.75 Front 2 Speed Switch (B50D)
P 7 BLUE/YELLOW 0.75 Middle 2 Speed Switch (B50D)
R 7 WHITE/ORANGE 0.75 Rear 2 Speed Switch (B50D)
S 10 RED/YELLOW 0.75 Left/Right Height Pos Sensors 5V Supply (B50)
T 9 PURPLE/BLUE 0.75 Left Height Position Signal (B50)
U PURPLE/YELLOW 0.75 Right Height Position Signal (B50)
V 10 BLACK/YELLOW 0.75 Left/Right Height Pos Sensor Return (B50)
W 9 GREEN/PURPLE 0.75 Bin Pressure Reduction Solenoid
X 3 RED 1.5 OBW/TPM Ignition Supply
136 Doc. No. 872272 : Rev 0

D6A D7A
T
31 20
U S 30 8 21
19 9
18 2 10
V R Z 29 7 3 22
D6A 17 1 11
28 6 4 23
W Y 16 5 12 D7A
X 15 13
HDP DEUTSCH, 9 WAY, PLUG & PINS - 27 14 24
26 25
BATTERY BOX INTERFACE. HDP DEUTSCH, 31 WAY, RECEPTACLE & SOCKETS -
(Connector as viewed from the back). FIREWALL, ELECTRICAL / HYDRAULIC. (4206D).

TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ?
R 1 GREEN 16.0 Battery Supply
S 1 RED 10.0 Main Ignition
T 1 WHITE 2.5 Main 12V Supply 1 30 YELLOW 1.5 Iqan Current Output A+
U 1 GREEN 10.0 Main Battery Power Supply 2 30 BROWN 1.5 Iqan Current Output A-
V 1 RED/BLACK 2.5 Ignition Key Signal 3 30 RED/GREEN 1.5 Iqan Current Output B+
W 1 GREEN 2.5 Battery Supply 4 30 GREEN/RED 1.5 Iqan Current Output B-
X 1 GREEN 2.5 Battery Supply
5 30 GREY 1.5 Iqan Current Output C+
Y 1 RED 2.5 Ignition Supply / Ether Start Power (300D)
6 30 ORANGE 1.5 Iqan Current Output C-
Z 9 YELLOW/GREEN 2.5 Pneumatic Blow Off Solenoid (Small Trucks)
7 30 PINK 1.5 Iqan Current Output D+
8 30 PURPLE 1.5 Iqan Current Output D-
9 30 YELLOW/BLACK 1.5 Iqan Current Output E+
D6B 10 30 BROWN/YELLOW 1.5 Iqan Current Output E-
11 30 RED/BLUE 1.5 Iqan Current Output F+
12 30 BLUE/RED 1.5 Iqan Current Output F-
13 30 GREY/BLACK 1.5 Spare
14 30 ORANGE/BLACK 1.5 Spare
T 15 30 PINK/BLACK 1.5 Spare
S U 16 30 PURPLE/WHITE 1.5 Spare
Z R V 17 30 RED 2.5 Ignition Supply
D6B 18 30 BLACK 2.5 Spare
Y W
X 19 30 WHITE/GREY 1.5 Iqan Common - A
HDP DEUTSCH, 9 WAY, RECEPTACLE & SOCKETS - 20 30 WHITE/RED 1.5 Iqan Common - B
BATTERY BOX (INTERIOR)
(Connector as viewed from the back). 21 30 WHITE/BLUE 1.5 Iqan Common - C
22 30 WHITE/GREEN 1.5 Iqan Common - D
PAGE WIRE COLOUR FUNCTION 23 30 GREY/WHITE 1.5 Iqan Common - E
24 30 RED/WHITE 1.5 Iqan Common - F
TERMINAL
25 30 BLUE/WHITE 1.5 Spare

? GN 1.5 ? 26 30 GREEN/WHITE 1.5 Spare
27
28 30 PURPLE/GREEN 1.5 Spare
R 1 GREEN 16.0 Battery Supply
29 30 BLUE/GREY 1.5 Spare
S 1 RED 10.0 Main Ignition
T 1 WHITE 2.5 Main 12V Supply 30 30 BLACK/GREEN 1.5 Spare
U 1 GREEN 10.0 Main Battery Power Supply 31 30 BLACK 1.5 Spare
V 1 RED/BLACK 2.5 Ignition Key Signal
W 1 GREEN 2.5 Battery Supply
X 1 GREEN 2.5 Battery Supply
Y 1 RED 2.5 Ignition Supply, CB2
Z 9 YELLOW/GREEN 2.5 Pneumatic Blow Off Solenoid (Small Trucks)
Doc. No. 872272 : Rev 0 137

D7B D8A
20 31
21 8 30 31 20
9 19 30 8 21
10 2 18 19 9
22 3 7 29 18 2 10
11 1 17 29 7 3 22
23 4 6 28 1
12 5 16 D7B 28
17
6 4
11
23
13 15
27
16 5 12 D8A
24 14 15 13
25 26 27 14 24
HDP DEUTSCH, 31 WAY, PLUG & PINS - 26 25
HYDRAULIC / ELECTRICAL. (4206D). HD DEUTSCH, 31 WAY, PLUG & SOCKETS -
(Connector as viewed from the back). ELECTRICAL / HYDRAULIC. (4206D).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 30 YELLOW 1.5 Iqan Current Output A+
2 30 BROWN 1.5 Iqan Current Output A- 1 30 YELLOW 1.5 Iqan Current Output A+
3 30 RED/GREEN 1.5 Iqan Current Output B+ 2 30 BROWN 1.5 Iqan Current Output A-
4 30 GREEN/RED 1.5 Iqan Current Output B- 3 30 RED/GREEN 1.5 Iqan Current Output B+
5 30 GREY 1.5 Iqan Current Output C+ 4 30 GREEN/RED 1.5 Iqan Current Output B-
6 30 ORANGE 1.5 Iqan Current Output C- 5 30 GREY 1.5 Iqan Current Output C+
7 30 PINK 1.5 Iqan Current Output D+ 6 30 ORANGE 1.5 Iqan Current Output C-
8 30 PURPLE 1.5 Iqan Current Output D- 7 30 PINK 1.5 Iqan Current Output D+
9 30 YELLOW/BLACK 1.5 Iqan Current Output E+ 8 30 PURPLE 1.5 Iqan Current Output D-
10 30 BROWN/YELLOW 1.5 Iqan Current Output E- 9 30 YELLOW/BLACK 1.5 Iqan Current Output E+
11 30 RED/BLUE 1.5 Iqan Current Output F+ 10 30 BROWN/YELLOW 1.5 Iqan Current Output E-
12 30 BLUE/RED 1.5 Iqan Current Output F- 11 30 RED/BLUE 1.5 Iqan Current Output F+
13 30 GREY/BLACK 1.5 Spare 12 30 BLUE/RED 1.5 Iqan Current Output F-
14 30 ORANGE/BLACK 1.5 Spare 13 30 GREY/BLACK 1.5 Spare
15 30 PINK/BLACK 1.5 Spare 14 30 ORANGE/BLACK 1.5 Spare
16 30 PURPLE/WHITE 1.5 Spare 15 30 PINK/BLACK 1.5 Spare
17 30 RED 2.5 Ignition Supply 16 30 PURPLE/WHITE 1.5 Spare
18 30 BLACK 2.5 Spare 17 30 RED 2.5 Ignition Supply
19 30 WHITE/GREY 1.5 Iqan Common - A 18 30 BLACK 2.5 Spare
20 30 WHITE/RED 1.5 Iqan Common - B 19 30 WHITE/GREY 1.5 Iqan Common - A
21 30 WHITE/BLUE 1.5 Iqan Common - C 20 30 WHITE/RED 1.5 Iqan Common - B
22 30 WHITE/GREEN 1.5 Iqan Common - D 21 30 WHITE/BLUE 1.5 Iqan Common - C
23 30 GREY/WHITE 1.5 Iqan Common - E 22 30 WHITE/GREEN 1.5 Iqan Common - D
24 30 RED/WHITE 1.5 Iqan Common - F 23 30 GREY/WHITE 1.5 Iqan Common - E
25 30 BLUE/WHITE 1.5 Spare 24 30 RED/WHITE 1.5 Iqan Common - F
26 30 GREEN/WHITE 1.5 Spare 25 30 BLUE/WHITE 1.5 Spare
27 26 30 GREEN/WHITE 1.5 Spare
28 30 PURPLE/GREEN 1.5 Spare 27
29 30 BLUE/GREY 1.5 Spare 28
30 30 BLACK/GREEN 1.5 Spare 29
31 30 BLACK 1.5 Spare 30
31
138 Doc. No. 872272 : Rev 0

D8B DIAG_1
3 2 1 DIAG 1
20 31 6 5 4
21 8 30
9 19 AMP, 9 WAY, RECEPTACLE & PINS -
10 2 18 9 8 7
22 3 7
ZF DIAGNOSTIC 1.
29
11 1 17 (Connector as viewed from the back).
23 4 6 28
12 5 16 D8B
13 15 PAGE WIRE COLOUR FUNCTION
24 14 27
25 26
TERMINAL
ELECTRICAL/HYDRAULIC. (4206D).
? GN 1.5 ?
1 901 GREEN 0.75 VPE 2

TERMINAL
23
2 23 415 0.75 SDDK
? GN 1.5 ? 3 23 902 BLACK 0.75 VM1
4 23 460 0.75 SDDL
1 24 BROWN/BLACK 0.75 High Side Driver 2 5 23 418 0.75 EURP
2 24 GREEN/RED 0.75 Retarder Solenoid 6 23 -RT5 0.75 CANBH
3 7 23 -SW5 0.75 CANBL
4 24 GREEN/ORANGE 0.75 Oil Level Excitation 8
5 9
9 24 ORANGE/WHITE 0.75 Main Mod Solenoid DIAG_2
13 24 PURPLE/BLACK 0.75 Sensor Return 3 2 1 DIAG2
14 24 BROWN/RED 0.75 Sump Temperature 6 5 4
15 24 WHITE/GREY 0.75 Output Speed Sensor + AMP, 9 WAY, PLUG & SOCKETS -
16 24 BLACK/BROWN 0.75 Engine Speed Sensor + 9 8 7 ZF DIAGNOSTIC 2.
17 24 ORANGE/GREEN 0.75 Engine Speed Sensor - (Connector as viewed from the back).
19 24 BLUE/ORANGE 0.75 Turbine Speed Sensor + PAGE WIRE COLOUR FUNCTION
TERMINAL

22
23
24
24
BLUE/WHITE 0.75
GREEN/BLUE 0.75
Oil Level Signal
Output Speed Sensor -
? GN 1.5 ?
25 24 ORANGE/GREY 0.75 Retarder Temperature Sensor 1
26 24 GREEN/WHITE 0.75 Press Control Solenoid 3 Diagnostic - K (J1708+)
2 23 907 0.75
27
3
28 24 BROWN 0.75 Power Return
4 23 908 0.75 Diagnostic - L (J1708-)
29
5
30
6
31
7
8
9
DIAG
DID
C
D E DID
B A F DIAG
4 1
G
J H DT DEUTSCH, 4 WAY, PLUG & SOCKETS -
3 2
AMPHENOL, 9 WAY, PLUG & SOCKETS - DRIVER IDENTITY.
DIAGNOSTIC. (Connector as viewed from the back).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
A 25 BLACK 0.75 Earth 1 25 RED 0.75 Ignition Supply

B 25 GREEN 0.75 Battery Supply (Fuse 7) 2 25 PURPLE/WHITE 0.75 K-Line
C 25 YELLOW 0.75 Can High 3 25 BLACK 0.75 Earth
25 BLACK 0.75 Can Shield 4 25 GREEN/RED 0.75 Memory Module - LED
D 25 GREEN 0.75 Can Low
E 25 RED 0.75 Ignition Supply (Fuse 32)
F 25 YELLOW/BLACK 0.75 TCU , Sci Hi
G 25 YELLOW/BLUE 0.75 TCU, Sci, Lo
H 25 ORANGE 0.75 ADM Diagnostic Line
J 25 PURPLE 0.75 MR Diagnostic Line
Doc. No. 872272 : Rev 0 139

E_1 E_5
E1
GHW, 10MM LUG -
E5
EARTH POINT 1. GHW, 10MM LUG -
(Isometric view). EARTH POINT 5.
(Isometric view).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
E1 05 BLACK 1.5 Earth (CTD Press Switch)
E1 18 BLACK 2.5 Earth (Cold Start) E5 06 BLACK 1.5 Earth (Sealed Switch Module)
E1 23 BLACK 1.5 Earth (ZF TCU) E5 08 BLACK 1.5 Earth (Rear Wiper Motor)
E1 24 BLACK 1.5 Earth (Allison-TCU) E5 09 BLACK 0.75 Earth (Inter Axle Diff Lock Solenoid)
E5 09 BLACK 1.5 Earth (CTD Solenoid)
E5 10 BLACK 1.5 Earth (Horn Solenoid)
E5 10 BLACK 0.75 Earth (Bin Lever)
E_2 E5 11 BLACK 1.5 Earth (Park Brake Dash Switch)
E5 12 BLACK 0.75 Earth (Park Brake Solenoid)
E2 E5 15 BLACK 0.75 Earth (2 Speed Solenoid)
GHW, 10MM LUG - E5 17 BLACK 1.5 Earth (Actuator Signal Board)
EARTH POINT 2. E5 17 BLACK 1.5 Earth (Fan/Blower)
(Isometric view). E5 18 BLACK 0.75 Earth (Exhaust Brake Solenoid)
E5 26 BLACK 0.75 Earth (Automatic Greaser Indicator)
PAGE WIRE COLOUR FUNCTION E5 26 BLACK 1.5 Earth (Electrical Seat)
TERMINAL
? GN 1.5 ?
E_6
E2 04 BLACK 1.5 Earth (2 Way Radio)
E2 04 BLACK 1.5 Earth (12V Radio)
E2 04 BLACK 1.5 Earth (Battery Balancer) E6
E2 04 BLACK 1.5 Earth (12V Power Supply) GHW, 10MM LUG -
EARTH POINT 6.
E2 10 BLACK 1.5 Earth (CCU-J2)
(Isometric view).
E2 12 BLACK 0.75 Earth (Artic Reverse Light)
E2 12 BLACK 0.75 Earth (CCU-J3)
E2 15 BLACK 1.5 Earth (OEU-J2)
16
TERMINAL
E2 BLACK 1.5 Earth (OEU-J3)
? GN 1.5 ?
E_3 E6 04 BLACK 1.5 Earth (Cigarette Lighter)
E6 04 BLACK 1.5 Earth (Reverse Monitor)
E3
E6 08 BLACK 1.5 Earth (Worklight Interface)
GHW, 10MM LUG -
E6 11 BLACK 0.75 Earth (Flashing Beacon Light)
EARTH POINT 3.
(Isometric view). E6 11 BLACK 1.5 Earth (Hazard Dash Switch)
E6 15 BLACK 1.5 Earth (On Board Weighing Warning Light)
PAGE WIRE COLOUR FUNCTION E6 25 BLACK 0.75 Earth (SATC-MT2000)
E6 26 BLACK 0.75 Earth (Interior Light)
TERMINAL
E6 27 BLACK 0.75 Earth (Left Mirror Demister)

? GN 1.5 ? E6 27 BLACK 0.75 Earth (Right Mirror Demister)
E6 29 BLACK 1.5 Earth (Scraper Dash Switch)
E6 29 BLACK 1.5 Earth (Hazard Dash Switch)
E3 01 BLACK 1.5 Earth (Ignition Switch)
E3 04 E6 30 BLACK 1.5 Earth (Expansion Module)
BLACK 1.5 Earth (Relay 1 12V Supply)
E3 05 BLACK 1.5 Earth (MDU)
E3 06 BLACK 2.5 Earth (Fuel Filter)
E3 06 BLACK 1.5 Earth (Steering Column Switch)
E3 08 BLACK 1.5 Earth (Front Wiper Motor)
E3 12 BLACK 0.75 Earth (Rear Wiper Washer Pump) EBP
E3 12 BLACK 0.75 Earth (Front Wiper Washer Pump)
E3 12 BLACK 1.5 Earth (Relay 4 Overspeed)
E3 15 BLACK 0.75 Earth (Relay 2 Gear Hold)
E3 15 BLACK 0.75 Earth (Relay 3 Auto Neutral)
E3 18 BLACK 0.75 Earth (ADM 21)
E3 18 BLACK 0.75 Earth (ADM18) EBP
E3 20 BLACK 1.5 Earth (JDECU-J2) A B
E3 25 BLACK 0.75 C
Earth (MM21C) DELPHI PACKARD, 3 WAY, RECEPTACLE & SOCKETS -
E3 25 BLACK 0.75 Earth (MM21B) EXHAUST BRAKE PRESSURE (JD).
E3 25 BLACK 0.75 Earth (Driver ID) (Connector as viewed from the back).
E3 25 BLACK 0.75 Earth (Diagnostic)
E3 29 BLACK 1.5 Earth (Hydraulic Level Switch) PAGE WIRE COLOUR FUNCTION
TERMINAL
E_4 ? GN 1.5 ?
E4 A 21 BLACK/YELLOW 0.75 Excitation #2-
GHW, 10MM LUG - B 21 RED/ORANGE 0.75 Excitation #2+
EARTH POINT 4.
(Isometric view). C 21 WHITE/BLUE 0.75 Exhaust Pressure Signal

TERMINAL
? GN 1.5 ?
E4 13 BLACK 1.5 Earth (Number Plate Light)
140 Doc. No. 872272 : Rev 0

ECAM EGRA
EGRA
ECAM
A B DELPHI PACKARD, 2 WAY, PLUG & SOCKETS - EGR MANIFOLD AIR TEMPERATURE (JD).
ENGINE CAM POSITION SENSOR (JD). (Connector as viewed from the back).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
A 22 YELLOW/PINK 1.5 Cam Speed + A 22 PURPLE/BLUE 0.75 Manifold Air Temperature Signal
B 22 BLACK/ORANGE 1.5 Cam Speed - B 22 BLACK/YELLOW 0.75 Fuel Temperature Signal
EGRE
ECF
EGRE
ECF
A B DELPHI PACKARD, 2 WAY, RECEPTACLE & SOCKETS -
1 2
EGR EXHAUST TEMPERATURE (JD).
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - (Connector as viewed from the back).
ENGINE COOLING FAN. (ENGINE HARNESS)
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
A 22 WHITE/GREEN 0.75 ERG Exhaust Temperature Signal
1 16 BLUE/YELLOW 1.5 Engine Hyd Cooler Fan Solenoid B 22 BLACK/YELLOW 0.75 Fresh Air Temp B
2 16 BLACK/YELLOW 1.5 Engine Hyd Cooler Fan PWM Return
EGRF
ECFP
EGRF
ECFP
2 1
DEUTSCH, 2 WAY, RECEPTACLE & PINS - EGR FRESH AIR (JD).
ENGINE COOLING FAN PIGTAIL. (Connector as viewed from the back).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
A 22 RED/BLUE 0.75 Charge Air Temperature Signal
1 16 BLUE/YELLOW 1.5 Engine Hyd Cooler Fan Solenoid
B 22 BLACK/YELLOW 0.75 Exhaust Temperature B
2 16 BLACK/YELLOW 1.5 Engine Hyd Cooler Fan PWM Return
EGRV
ECF (AMP)
EGRV
1 2 3 4 5 6
FCI, 6 WAY, PLUG & SOCKETS -
ECF EGR VALVE (JD).
1 4 (Connector as viewed from the front).
3 2
AMP, 2 WAY, RECEPTACLE & PINS -
ENGINE COOLING FAN.
TERMINAL

? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 19 ORANGE/RED 0.75 5V Excitation #5+

2
3 19 PURPLE/GREEN 0.75 H Bridge 1+
1
2 4 19 RED/GREY 0.75 H Bridge 1-
3 16 BLUE/YELLOW 1.5 Engine Hyd Cooler Fan Solenoid 5 19 BLACK/YELLOW 0.75 5V Excitation #5-
4 16 BLACK/YELLOW 1.5 Engine Hyd Cooler Fan PWM Return 6 19 BLUE/WHITE 0.75 ERG Position 1
Doc. No. 872272 : Rev 0 141

EH ESEAT
EH
ESEAT
GHW, 1 WAY, PUSH ON TERMINAL - 1 2
ELECTRIC HOOTER. DT DEUTSCH, 2 WAY, PLUG & SOCKETS -
(Isometric View). ELECTRICAL SEAT.
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 10 BLUE/GREEN 1.5 Electric Hooter
2 10 BLACK 1.5 Earth 1 26 RED 1.5 Ignition Supply
EOP
ESS
EOP
ESS
A B
C
DELPHI PACKARD, 3 WAY, RECEPTACLE & SOCKETS -
ENGINE OIL PRESSURE (JD). A B DELPHI PACKARD, 2 WAY, PLUG & SOCKETS -
(Connector as viewed from the back). ENGINE SPEED SENSOR.
TERMINAL
TERMINAL
? GN 1.5 ? ?
? GN 1.5
A 21 BLACK/YELLOW 0.75 Excitation #2-

A 24 ORANGE/GREEN 0.85 Engine Speed Sensor -
B 21 RED/ORANGE 0.75 Excitation #2+
B 24 BLACK/BROWN 0.85 Engine Speed Sensor +
C 21 BROWN/BLUE 0.75 Engine Oil Pressure Signal
ES_1 ETH
2
1 3 9 10
6 3
4
ES1
5 2 ETH
BRADHARRISON, 4 WAY, 90°, SOCKETS -
EMERGENCY STEERING 1.
ETHER START SWITCH (JD).
7 8
TERMINAL
? ?
TERMINAL
GN 1.5
? GN 1.5 ?
2
1
2 20 GREY/BLACK 1.5 Ether Start Signal
4 5 ORANGE/BLACK 0.75 Emergency Steering Signal
2 20 GREY/BLACK 1.5 Ether Start Dash Illumination
4
5
ES_2 6
7 20 GREY/BLACK 1.5 Ether Start Dash Illumination
ES2 9
1 2 10
EMERGENCY STEERING 2.

ETHER
TERMINAL
ETHER
? GN 1.5 ?
B A DELPHI PAKARD, 2 WAY, PLUG & SOCKETS -
ETHER START UNIT (JD).
1 5 ORANGE/BLACK 1.5 Emergency Steering Signal
2 5 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
A 20 GREY/BLACK 1.5 Ether Start
B 20 RED 1.5 Ignition Supply
142 Doc. No. 872272 : Rev 0

EVBSOL FAN_1
FAN1
2 1
1 2
3
EVBSOL DT DEUTSCH, 2 WAY, PLUG & SOCKETS -
COOLING FAN 1. (B50D).
EXHAUST BRAKE SOLENOID.
(Connector as viewed from the front). PAGE WIRE COLOUR FUNCTION
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ?
1 18 RED/YELLOW 0.75 Exhaust Brake Solenoid
3
4
FAN_2
F2S FAN2
1 2
COOLING FAN 2. (B50D).
F2S (Connector as viewed from the back).
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - PAGE WIRE COLOUR FUNCTION
FRONT 2 SPEED PIGTAIL. (B50D).
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 14 BROWN/BLUE 1.5 Bonnet Fan 2

1 11 PURPLE/WHITE 1.5 2 Speed Switch Signal

FB
F2SP FB
1 2
F2SP FLASHING BEACON.
2 1
DT DEUTSCH, 2 WAY, RECEPTACLE & PINS -
FRONT 2 SPEED PIGTAIL. (B50D) PAGE WIRE COLOUR FUNCTION
TERMINAL

? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 11 ORANGE/WHITE 0.75 Flashing Beacon

1 11 PURPLE/WHITE 1.5 2 Speed Switch Signal
FB_A_&_FB_B
F2SSW
FB-A & FB-B
1

F2SSW FLASHING BEACON.
DELPHI PACKARD, 2 WAY, PLUG & PINS -
B A
FRONT 2 SPEED SWITCH. (B50D) PAGE WIRE COLOUR FUNCTION
TERMINAL

? GN 1.5 ?
TERMINAL
? GN 1.5 ? A 11 ORANGE/WHITE 1.5 Flashing Beacon

1 7 PURPLE/WHITE 1.5 Front 2 Speed Switch Signal
2 7 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 143

FBI FI
FBI
2 1
3 5
DEUTSCH, 2 WAY, RECEPTACLE & PINS - 2 4 6
FLASHING BEACON INTERFACE.
(Connector as viewed from the back). 1 7 FI
PAGE WIRE COLOUR FUNCTION 10 9 8
TYCO, 10 WAY, PLUG & SOCKETS -
TERMINAL
FUEL INJECTORS (JD).

? GN 1.5 ?
TERMINAL
1 11 ORANGE/WHITE 1.5 Flashing Beacon
? GN 1.5 ?
FCS 1 19 GREEN/YELLOW 0.75 Injector 0 (Cylinder 1)

2 19 GREEN/ORANGE 0.75 Injector 4 (Cylinder 2)
3 19 GREEN/BROWN 0.75 Injector 2 (Cylinder 3)
FCS
4
5 19 GREEN/GREY 0.75 Injector 5 (Cylinder 4)
1 2 AMP, 2 WAY, PLUG & SOCKETS - 6 19 GREEN/PINK 0.75 Injector 1 (Cylinder 5)
FAN CUT SOLENOID. (Large Trucks).
(Connector as viewed from the front). 7 19 GREEN/RED 0.75 Injector 3 (Cylinder 6)
8 19 GREEN/WHITE 1.5 Injector 0,4,2+
10 19 GREEN/PURPLE 1.5 Injector 1,3,5+
TERMINAL
? GN 1.5 ?
FIDLP
1 16 BLUE/GREY 1.5 Fan Cut Solenoid
FIDLP
2 1

FDL FRONT DIFF LOCK PIGTAIL. (B50D).

FDL
TERMINAL
1 2
FRONT DIFFLOCK PIGTAIL. (B50D).
? GN 1.5 ?
1 28 GREEN/GREY 1.5 IDL Switch Signal

2 28 GREEN/GREY 1.5 Earth (Via Front & Rear IDL Switch)
TERMINAL
? GN 1.5 ?
FIDLSW
1 28 GREEN/GREY 1.5 IDL Position Switch (Dropbox)
2 28 GREEN/GREY 1.5 IDL Position Switch (Dropbox) FIDLSW
DELPHI PACKARD, 2 WAY, PLUG & SOCKETS -

1 2 FRONT DIFF LOCK SWITCH. (B50D)
FF (Connector as viewed from the back).

FF
TERMINAL
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - ? GN 1.5 ?
FUEL FILTER.
1 28 GREEN/GREY 1.5 IDL Switch Signal
PAGE WIRE COLOUR FUNCTION Earth (Via Front & Rear IDL Switch)
2 28 GREEN/GREY 1.5
TERMINAL
? GN 1.5 ?
FS
2 6 BLACK 2.5 Earth FS
1 2
FUEL SENDER. (B20D & B18D).

TERMINAL
? GN 1.5 ?
1 5 GREY/WHITE 1.5 Fuel Sender Signal
2 5 BLACK 1.5 Earth
144 Doc. No. 872272 : Rev 0

FTS FUELT
FTS FUELT
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - 2 1
FAN TEMPERATURE SWITCH. (B50D). AMP, 2 WAY, PLUG & SOCKETS -
(Connector as viewed from the back). FUEL TEMPERATURE (JD).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 9 YELLOW/PURPLE 1.5 Bonnet Fan Temp Switch Signal
2 9 BLACK 1.5 Earth A 21 GREY/WHITE 0.75 Excitation #2-
B 21 BLACK/YELLOW 0.75 Fuel Temperature Signal
FUEL
FUELTP
FUEL
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - FUELTP
FUEL SENDER. 6 1
5 2
PAGE WIRE COLOUR FUNCTION 4 3
FUEL TRANSFER PUMP (JD).
TERMINAL
TERMINAL
1
2
5
5
BLUE/WHITE 1.5
BLACK 1.5
Fuel Level Sensor Signal
Earth
? GN 1.5 ?
1 19 GREY/ORANGE 0.75 Speed CMD
FUEL_2_WAY 2
3
19
19
GREEN/BLUE 0.75
PINK/BLUE 0.75
Current Out
Status Out
4 19 ORANGE/BLUE 0.75 PWR On Signal
5 19 GREEN 2.5 Power
FUEL
2 1
6 19 BLACK 1.5 Ground

FUEL SENDER. (B20D & B18D).
PAGE WIRE COLOUR FUNCTION FWASH

TERMINAL
? GN 1.5 ?
FWASH
2
1 5 GREY/WHITE 1.5 Fuel Level Sensor Signal

1
UTILUX, 2 WAY, PLUG & SOCKETS -
2 5 BLACK 1.5 Earth FRONT WASHER.

FUELP
TERMINAL
? GN 1.5 ?
1 12 GREEN/PURPLE 0.75 Front Wiper Washer Pump
FUELP
A B
C
FUEL PRESSURE (JD).
FWMD
TERMINAL
? GN 1.5 ? 6 1
FWMD
5 2
A 21 BLACK/YELLOW 0.75 Excitation #2- FRONT WIPER MOTOR DOGA.
4 3
B 21 RED/ORANGE 0.75 Cam Speed - (Connector as viewed from the back).
C 21 ORANGE/BROWN 0.75 Fuel Pressure Signal

TERMINAL
? GN 1.5 ?
1 8 PINK 0.75 Park Signal
2 8 ORANGE 0.75 Front Wiper High Speed
4 8 RED/ORANGE 0.75 Front Wiper Low Speed
5
Doc. No. 872272 : Rev 0 145

GPE HLSP
GPE HLSP
2 1
AMP, FLAG TERMINAL, 11MM - DT DEUTSCH, 2 WAY, RECEPTACLE & PINS -
GLOW PLUG EARTH. (Small Trucks Only, Not on JD) HYDRAULIC LEVEL SWITCH PIGTAIL. (4206D).

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
GPE 18 BLACK 2.5 Earth (Glow Plug) 1 29 YELLOW/BLUE 1.5 Hydraulic Level Switch Signal
HCS
HCS
HSL
1 2 AMP, 2 WAY, PLUG & SOCKETS - HSL

HYDRAULIC CUT SOLENOID. 3 2 1
(Connector as viewed from the front). 6 5 4
PAGE WIRE COLOUR FUNCTION HEIGHT SENSOR LHS. (B50D).
TERMINAL

? GN 1.5 ?
TERMINAL
1 12 BLACK/WHITE 1.5 Hydraulic Cut Solenoid ? GN 1.5 ?

2
HFP 3
4 10 PURPLE/YELLOW 1.5 Left Height Sensor Signal
5 10 RED/ORANGE 1.5 Sensor 5V Supply
HFP
6
1 2
HYDRAULIC FILTER PRESSURE.

HSOL
TERMINAL
? GN 1.5 ? 2
3
1
HSOL
1 5 BLUE/WHITE 1.5 Hydraulic Filter Pressure Signal
2 HIRSCHMANN, 4 WAY, FLUSH & SOCKETS -
5 BLACK 1.5 Earth
HORN SOLENOID.
HLS PAGE WIRE COLOUR FUNCTION

TERMINAL
HLS ? GN 1.5 ?
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - 1 10 BLUE/GREEN 0.75 Horn Solenoid
HYDRAULIC LEVEL SWITCH. (Used on 4206D only).
(Connector as viewed from the back). 2 10 BLACK 1.5 Earth
3
TERMINAL
? GN 1.5 ?
HSR
1 29 YELLOW/BLUE 1.5 Hydraulic Level Switch Signal HSR
2 29 BLACK 1.5 Earth 3 2 1
6 5 4
HEIGHT SENSOR RHS. (B50D).
HLSA (Connector as viewed from the back).
HLSA
TERMINAL
1 2
? GN 1.5 ?
HYDRAULIC LEVEL SWITCH A. (4206D).
3
TERMINAL
4 10 PURPLE/YELLOW 1.5 Right Height Sensor Signal
? GN 1.5 ? 5
6
10 RED/ORANGE 1.5 Sensor 5V Supply
1 29 YELLOW/BLUE 1.5 Hydraulic Level Switch Signal

146 Doc. No. 872272 : Rev 0

HTS1 HZDSW
HTS1 9 10
1 2 6 3
HYDRAULIC TEMP SENDER (IN-LINE CONNECTOR - ARTIC HARNESS).
(Connector as viewed from the back). 5 2 HZDSW
TERMINAL
HAZARD DASH SWITCH.

7 8
? GN 1.5 ?
1 12 GREEN/WHITE 1.5 Hydraulic Temperature Sender Signal
TERMINAL
2 12 BLACK/YELLOW 1.5 Hydraulic Temperature Sender Return
? GN 1.5 ?
HTS2 1
3 29 GREEN/BLACK 0.75 Hazard Dash Switch Signal
HTS2 4
2 1 5
DEUTSCH, 2 WAY, RECEPTACLE & PINS - 6
HYDRAULIC TEMP SENDER (IN-LINE CONNECTOR - ENGINE HARNESS).
8 29 BROWN 0.75 Front Left Indicator
9
TERMINAL
10
? GN 1.5 ?
1 12 GREEN/WHITE 1.5
2 12 BLACK/YELLOW 1.5
Hydraulic Temperature Sender Signal
Hydraulic Temperature Sender Return HZDSW_4206
9 10
HV1- HV16 6 3
5 2 HZDSW
HV1 - HV16
HAZARD DASH SWITCH. (4206D).
1 2 2 WAY, AMP CONNECTOR, PLUG & SOCKETS - 7 8 (Connector as viewed from the back).
HYDRAULIC VALVE, 1 TO 16. (4206D).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1
HV1-1 30 WHITE/GREY 1.5 Iqan Common - A 2 29 GREEN 0.75 Battery Supply
HV1-2 30 YELLOW 1.5 Iqan Current Output A+ 3 29 GREEN/BLACK 0.75 Hazard Dash Switch Signal
HV2-1 30 WHITE/GREY 1.5 Iqan Common - A
HV2-2 30 BROWN 1.5 Iqan Current Output A- 4
HV3-1 30 WHITE/RED 1.5 Iqan Common - B 5
HV3-2 30 RED/GREEN 1.5 Iqan Current Output B+ 6
HV4-1 30 WHITE/RED 1.5 Iqan Common - B 7 29 BLACK 0.75 Earth
HV4-2 30 GREEN/RED 1.5 Iqan Current Output B-
8 29 BROWN 0.75 Front Left Indicator
HV5-1 30 WHITE/BLUE 1.5 Iqan Common - C
9
HV5-2 30 GREY 1.5 Iqan Current Output C+
HV6-1 30 WHITE/BLUE 1.5 Iqan Common - C
HV6-2 30 ORANGE 1.5
10
Iqan Current Output C-
HV7-1 30 WHITE/GREEN 1.5 Iqan Common - D
HV7-2 30 PINK 1.5 Iqan Current Output D+
HV8-1 30 WHITE/GREEN 1.5 Iqan Common - D ICS
HV8-2 30 PURPLE 1.5 Iqan Current Output D-
HV9-1 30 GREY/WHITE 1.5 Iqan Common - E ICS
HV9-2 30 YELLOW/BLACK 1.5 Iqan Current Output E+
HV10-1 30 GREY/WHITE 1.5 Iqan Common - E
HELLERMAN TYTON, BOOTLACE TERMINAL -
HV10-2 30 BROWN/YELLOW 1.5 Iqan Current Output E- IQAN CUT SWITCH. (4206D).
HV11-1 30 RED/WHITE 1.5 Iqan Common - F (Isometric View).
HV11-2 30 RED/BLUE 1.5 Iqan Current Output F+
HV12-1 30 RED/WHITE 1.5 Iqan Common - F PAGE WIRE COLOUR FUNCTION
HV12-2 30 BLUE/RED 1.5 Iqan Current Output F-
TERMINAL
HV13-1 30 BLUE/WHITE 1.5 Spare

HV13-2
HV14-1
30
30
GREY/BLACK 1.5
BLUE/WHITE 1.5
Spare
Spare
? GN 1.5 ?
HV14-2 30 ORANGE/BLACK 1.5 Spare
HV15-1 30 GREEN/WHITE 1.5 Spare ICS A 29 RED 1.5 Ignition Supply
HV15-2 30 PINK/BLACK 1.5 Spare ICS B 29 RED 1.5 Ignition Supply
HV16-1 30 GREEN/WHITE 1.5 Spare
HV16-2 30 PURPLE/WHITE 1.5 Spare
Doc. No. 872272 : Rev 0 147

IDLPS IGNS_30_&_IGNS_87
IGNS-30 & IGNS-87
GHW, 6MM LUG -
2 1
IGNITION SOLENOID.
3 (Isometric View).
IDLPS
TERMINAL
INTERAXLE DIFFLOCK PRESSURE SWITCH.
(Connector as viewed from the front). ? GN 1.5 ?
TERMINAL
? GN 1.5 ? 87
87
1 RED 10.0
RED 4.0
Ignition Supply
Ignition Supply
1
1 9 GREEN/GREY 0.75 IDL Pressure Switch

2
3 9 GREEN/GREY 0.75 Interaxle Difflock Position Switch (B50D SS Only)
4 9 BLACK 0.75 Earth (All Other Trucks)
ILHT_A_&_ILHT_B
ILHT-A & ILHT-B
1
IDLSOL BOSCH, 1 WAY, PLUG & SOCKETS -

INTERIOR LIGHT.

2 1
3
TERMINAL
IDLSOL
? GN 1.5 ?
INTERAXLE DIFFLOCK SOLENOID.
(Connector as viewed from the front). A 26 GREEN 0.75 Interior Light
TERMINAL
? GN 1.5 ? INDL
1 9 GREEN/BLUE 0.75 Interaxle Difflock Solenoid
2 9 BLACK 0.75 Earth INDL
3 1 2
4 DT DEUTSCH, 2 WAY, PLUG & SOCKETS -

REAR INDICATOR LEFT.

IGN_Switch
TERMINAL
6 4
? GN 1.5 ?
2
IGN
5 3 1 13 BLACK 1.5 Earth
2 13 BROWN 1.5 Left Indicator
1 IGNITION SWITCH.

INDR
TERMINAL
? GN 1.5 ?
INDR
1 2
1 1 BLACK 1.5 Earth
2 1 BLACK/GREEN 0.75 Start Signal
REAR INDICATOR RIGHT.
3 1 RED/BLACK 2.5 Ignition Solenoid Supply (Connector as viewed from the back).
4
6
TERMINAL
? GN 1.5 ?
IGNS 1 13 BLACK 1.5 Earth
2 13 YELLOW 1.5 Right Indicator
IGNS

2 1
IGNITION SOLENOID.

TERMINAL
? GN 1.5 ?
1 (86) 1 GREEN 2.5 Battery Supply
2 (85) 1 RED/BLACK 2.5 Ignition Key Signal
148 Doc. No. 872272 : Rev 0

IQAN L2
L2
4 3 2 1
1 6
IQAN MOLEX, 4 WAY, PLUG & SOCKETS -
LEVER CONTROL 2. (4206D).
2 5 (Connector as viewed from the back).
3 4 ELEC/HYD CONTROL INTERFACE. (4206D).
(Connector as viewed from the back). PAGE WIRE COLOUR FUNCTION
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ?
1
2 30 PURPLE/RED 1.5 5V Supply
3 30 YELLOW/BLUE 1.5 Lever 2 Signal (0-5V)
3 Battery Supply 4 30 WHITE/BROWN 1.5 Supply Return
29 GREEN 1.5
4 29 GREEN/WHITE 0.75 Scraper Dash Switch Signal
6 29 BROWN 0.75 Left Indicator Light
L3
L3
4 3 2 1
IQAN_A MOLEX, 4 WAY, PLUG & SOCKETS -


IQAN A
TERMINAL
6 1
5 2
4 3
IQAN, ELEC/HYD CONTROL INTERFACE.
? GN 1.5 ?

TERMINAL
? GN 1.5 ? 4 30 WHITE/BROWN 1.5 Supply Return

L4
4 29 GREEN/WHITE 0.75 Scraper Dash Switch Signal L4
4 3 2 1
6 29 BROWN 0.75 Left Indicator Light MOLEX, 4 WAY, PLUG & SOCKETS -
ISW PAGE WIRE COLOUR FUNCTION

TERMINAL
ISW
GHW, 13MM LUG - ? GN 1.5 ?
ISOLATOR SWITCH.
(Isometric View).
1
PAGE WIRE COLOUR FUNCTION 2 30 PURPLE/RED 1.5 5V Supply
TERMINAL
4 30 WHITE/BROWN 1.5 Supply Return

? GN 1.5 ?
1-IN 1 GREEN 16.0 Battery Supply (Battery) L5
1-OUT 1 GREEN 16.0 Battery Supply (Main CB)
2-OUT 1 BLACK 2.5 Earth (Small Trucks Only)
L5
4 3 2 1
MOLEX, 4 WAY, PLUG & SOCKETS -
L1 (Connector as viewed from the back).
L1
TERMINAL
4 3 2 1
MOLEX, 4 WAY, PLUG & SOCKETS - ? GN 1.5 ?
1
PAGE WIRE COLOUR FUNCTION 5V Supply
2 30 PURPLE/RED 1.5
TERMINAL

? GN 1.5 ?

3 30 BLUE/YELLOW 1.5 Lever 1 Signal (0-5V)
Doc. No. 872272 : Rev 0 149

L6 LBP
L6
4 3 2 1 B A
LBP
MOLEX, 4 WAY, PLUG & SOCKETS -
LEVER CONTROL 6. (4206D). C
(Connector as viewed from the back). DT DEUTSCH, 3 WAY, PLUG & SOCKETS -
LEFT BRAKE & PARK LIGHTS.
TERMINAL
TERMINAL
? GN 1.5
? GN 1.5 ?
1
2 30 PURPLE/RED 1.5 5V Supply A 13 BLACK 1.5 Earth
3 30 YELLOW/BLUE 1.5 Lever 6 Signal (0-5V) B 13 GREY/BLUE 1.5 Left Brake Lights
4 30 WHITE/BROWN 1.5 Supply Return C 13 BLUE 1.5 Left Park Lights
LABP_1 LFS_1_&_RFS_1
2 LFS-1 & RFS-1
1 3
4
SUMITOMO, 3MM PUSH-ON -
LABP1 LEFT & RIGHT FRONT SPEAKERS.
BRADHARRISON, 4 WAY, 90°, SOCKETS - PAGE WIRE COLOUR FUNCTION

LOW ACCUMULATOR BRAKE PRESSURE 1.
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ? LFS-1
RFS-1
4
4
BLACK 1.5
BLACK 1.5
Left Front Speaker Return
Right Front Speaker Return

2
3 5 BLACK 0.75 Earth LFS_2_&_RFS_2
4 5 RED/GREY 0.75 Low Accumulator Brake Pressure Signal
LFS-2 & RFS-2
LABP_2 AMP, 4.8MM PUSH-ON -

LEFT & RIGHT FRONT SPEAKERS.
LABP2 PAGE WIRE COLOUR FUNCTION

1 2
TERMINAL

LOW ACC BRAKE PRESSURE 2.
(Connector as viewed from the back). ? GN 1.5 ?
LFS-2 4 BLACK/BLUE 1.5 Left Front Speaker
TERMINAL
RFS-2 4 BLACK/GREEN 1.5 Right Front Speaker
? GN 1.5 ?
1 5 RED/GREY 1.5 Low Acc Brake Pressure Signal LHL
2 5 BLACK 1.5 Earth
LHL
2
LASER 1 UTILUX, 3 WAY, PLUG & SOCKETS -

LEFT HEADLIGHT.
3
LASER
1 2
TERMINAL
HD DEUTSCH, 2 WAY, PLUG & SOCKETS -

LASER SYSTEM SUPPLY. (4206D).
(Connector as viewed from the back). ? GN 1.5 ?
1 7 BLACK 1.5 Earth
TERMINAL
2 7 WHITE/GREY 1.5 Headlight - Bright
? GN 1.5 ? 3 7 GREY/WHITE 1.5 Headlight - Dips

150 Doc. No. 872272 : Rev 0

LIND LREV
LIND LREV
1
1 2
LEFT INDICATOR.
LEFT REVERSE LIGHT.
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 13 BROWN 1.5 Indicator - Left
2 13 BLACK 1.5 Earth 1 7 YELLOW/GREEN 1.5 Left Reverse Light
2 7 BLACK 1.5 Earth
LLEDS LSD
LSD
LLEDS
1 2
4 1 DT DEUTSCH, 2 WAY, PLUG & SOCKETS -
DT DEUTSCH, 4 WAY, PLUG & SOCKETS - LEFT STRUT DOWN. (B50D).
3 2
LEFT REAR LED LIGHTS. (4206D). (Connector as viewed from the back).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 13 BROWN 1.5 Indicator Light 1 16 RED/BROWN 2.5 Left Strut Down Solenoid
2 13 GREY/BLUE 1.5 Brake Light 2 16 BLACK 1.5 Earth
3 13 BLUE 1.5 Park Light
LSG
LSG
LMIR
4 1
3 2 LEFT STRAIN GAUGE. (Not on T17D F/D).
LMIR
6 1 PAGE WIRE COLOUR FUNCTION
5 2
TERMINAL
4 3 LEFT MIRROR.
? GN 1.5 ?
1 28 PURPLE/GREEN 1.5 Right Strain Gauge Signal

TERMINAL
2 28 GREY 1.5 +5V Excitation

? GN 1.5 ? 3 28 BLUE/WHITE 1.5 Sensor Return

2 27 RED/GREY 0.75 Mirror Demister
3 27 YELLOW/GREEN 0.75 Left Vertical LSIND
4 27 ORANGE/GREEN 0.75 Left Horizontal
5 27 GREEN/BLUE 0.75 Common
6 LSIND
1 2
LEFT SIDE INDICATOR. (Used on the B20D).
LPLHT PAGE WIRE COLOUR FUNCTION
TERMINAL
LPLHT
? GN 1.5 ?
LEFT PARK LIGHT.
(Isometric View).
1 13 BROWN 1.5 Indicator Left
PAGE WIRE COLOUR FUNCTION 2 13 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
1 8 BLUE 1.5 Parklights - Left Parklight
2 8 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 151

LSS MAP
LSS
1 2 AMP, 2 WAY, PLUG & SOCKETS MAP

LOW SPEED SOLENOID. (Large Trucks).
(Connector as viewed from the front). A B
C
PAGE WIRE COLOUR FUNCTION MANIFOLD AIR PRESS (JD).
TERMINAL

? GN 1.5 ?
TERMINAL
1 16 PURPLE/GREEN 1.5 Fan Low Solenoid ? GN 1.5 ?
2 21 RED/ORANGE 0.75 Excitation 2+
LSU 3 21 PINK/GREY 0.75 Manifold Air Pressure Signal
LSU
1 2 MAP_1
LEFT STRUT UP. (B50D).
B A
MAP1
C
TERMINAL
MID AXLE PIGTAIL 1. (B50D).

? GN 1.5 ? (Connector as viewed from the back).

1 16 PINK/GREY 2.5 Left Strut Up Solenoid
TERMINAL

? GN 1.5 ?
LWL 1 28 BLUE/YELLOW 1.5 Mid 2 Speed Switch
3 28 GREEN/GREY 1.5 Mid IDL Position Switch
LWL
1 2
LEFT WORK LIGHTS.
MAP_2
A B
MAP2
TERMINAL
? GN 1.5 ? C
MID AXLE PIGTAIL 2. (B50D).
1 8 RED/WHITE 1.5 Left Worklights
2 8 BLACK 1.5 Earth
TERMINAL
M2SSW ? GN 1.5 ?
1 7/28 PURPLE/GREEN 1.5 Middle 2 Speed Switch Signal
M2SSW 2 7/28 BLACK 1.5 Earth
3 7/28 GREEN/GREY 1.5 Rear IDL Switch Signal
A
DELPHI PACKARD, 2 WAY, PLUG & PINS -
B
MID 2 SPEED SWITCH. (B50D).
MCB_1
MCB1
TERMINAL
GHW, 6MM LUG -

? GN 1.5 ? MAIN CIRCUIT BREAKER 1.
(Isometric View).
PURPLE/GREEN 1.5 Middle 2 Speed Switch Signal PAGE WIRE COLOUR FUNCTION
1 7
2 7 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
MCB-1 1 GREEN 16.0 Battery Supply (Main Circuit Breaker)
152 Doc. No. 872272 : Rev 0

MCB_2 MDU2_J2
MCB2
GHW, 6MM LUG -
MAIN CIRCUIT BREAKER 2. A B C D E F G MDU2J2
(Isometric View).
PAGE WIRE COLOUR FUNCTION H J K L M N P MONITOR DISPLAY UNIT (J2).
TERMINAL

? GN 1.5 ?
TERMINAL
2-A
2-B
1
1
GREEN 10.0 Battery Supply (Main Circuit Breaker) ? GN 1.5 ?
GREEN 10.0 Battery Supply (Main Circuit Breaker)
2-C 1 GREEN 4.0 Battery Supply
A 5 BLUE/WHITE 0.75 Hydraulic Filter Pressure
B
MDM C
D
5
5
RED/GREY 0.75
ORANGE/BLUE 0.75
Low Acc Brake Pressure
CTD Brake Press Switch
E 5 ORANGE/BLACK 0.75 Emergency Steering Press Switch
F 5 WHITE/GREY 0.75 Headlight Bright Switch
G 5 GREY/WHITE 0.75 Headlight Dip Switch
1 4 MDM H 5 WHITE/BLUE 0.75 Engine Coolant Level Switch
2 5 J 5 ORANGE/GREEN 0.75 Cold Start Light
K
MASTER DISPLAY MODULE. (4206D). L 5 YELLOW/BLUE 0.75 Hydraulic Level Switch
(Connector as viewed from the back). M 5 BLUE/YELLOW 0.75 Park Brake Pressure Switch
N 5 PURPLE/GREEN 0.75 Engine Air Intake Filter Press Switch
P
TERMINAL
? GN 1.5 ? MM_15A
1 30 BLUE/YELLOW 1.5 Iqan CAN Low
2
4 30 YELLOW/BLACK 1.5 Iqan CAN High
1 4 7 10 13
2 5 8 11 14
MM15A
3 6 9 12 15 AMP, 15 WAY, PLUG & SOCKETS -

MEMORY MODULE 15, 15 PIN.
MDU2_J1 (Connector as viewed from the back).

TERMINAL
A B C D E F G H
MDU2J1 ? GN 1.5 ?
J K L M N P R S MONITOR DISPLAY UNIT (J1). 1
(Connector as viewed from the back). 2
3
5
TERMINAL
6
? GN 1.5 ? 7 25 YELLOW/RED 0.75 RS232 TX - MT2000 (RX)
8 25 RED/YELLOW 0.75 RS232 RX - MT2000 (TX)
9 25 GREEN 0.75 CAN Low
A 5 GREEN 0.75 Battery Power Supply 10 25 YELLOW 0.75 CAN High
B 25 BLACK 0.75 CAN Shield
C 5 YELLOW 0.75 CAN High 11
D 5 ORANGE/WHITE 0.75 Buzzer Negative 12
E 13
F 14
G 15
H
J
K 5 GREEN 0.75 CAN Low
5 BLACK 0.75 CAN Shield
L 5 RED 0.75 Ignition Supply
M 5 BLACK/RED 0.75 Buzzer Positive
N 5 BLUE/WHITE 0.75 Fuel Sensor Signal
P 5 BLACK 0.75 Earth
R 5 BROWN/RED 0.75 Left Indicator Switch
S 5 YELLOW/RED 0.75 Right Indicator Switch
Doc. No. 872272 : Rev 0 153

MM_18E MM_21C
1 4 7 10 13 16 19
MM21C
1 4 7 10 13 16 2 5 8 11 14 17 20
MM18E AMP, 21 WAY, PLUG & SOCKETS -

3 6 9 12 15 18 21
2 5 8 11 14 17 MEMORY MODULE 21C, 21 PIN.
3 6 9 12 15 18 AMP, 18 WAY, PLUG & SOCKETS -
MEMORY MODULE 18, 18 PIN. PAGE WIRE COLOUR FUNCTION
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 25 WHITE/RED 0.75 MM 12V Input

2 25 PURPLE/WHITE 0.75 K-Line - DID
3
1 4
2 25 GREEN/RED 0.75 DID - LED 5 25 RED 0.75 Memory Module Ignition Status
3 25 YELLOW/RED 0.75 Wake-Up Synchronisation 6 25 RED/ORANGE 0.75 Wake-Up Input
4 7
5 8
6 9
7 10
8 11
9 12
10 13
11 14
13 16 25 GREEN 0.75 Battery Supply
14 17
18
15
19
16
20
17
21
18
MM_21B MR
MR
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
1 4 7 10 13 16 19
MM21B AMP, 15 WAY, PLUG & SOCKETS -
ENGINE MR ECU. (Not on JD 250/300D).
2 5 8 11 14 17 20
3 6 9 12 15 18 21
MEMORY MODULE 21B, 21 PIN. PAGE WIRE COLOUR FUNCTION
TERMINAL

? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 18 CAN CABLE YL/GN 1.0 IES CAN - High

2 18 CAN CABLE BN 1.0 IES CAN - Low
3 18 CAN CABLE BK 1.0 IES CAN - Shield
1 25 GREEN 0.75 Supply to Wake-Up Module
4 18 CAN CABLE BL 1.0 IES CAN - Shield
2 25 BLACK 0.75 Earth (Wake-Up Module)
4 25 ORANGE/BROWN 0.75 7.5V Supply To MT2000
7
5 25 RED/ORANGE 0.75 Wake-Up Output 8
6 25 YELLOW/RED 0.75 Synchronisation Input 18
9 BLACK 2.5 Earth
7 10
9 12 18 BLACK/WHITE 1.5 Start Signal to Starter Motor
10 13 18 PURPLE 1.5 Diagnostic K-Line
11 14
13
14
15
16 MSS
17
18 MSS
19
20 AMP, 2 WAY, PLUG & SOCKETS -
1 2
21 MEDIUM SPEED SOLENOID. (Large Trucks).

TERMINAL
? GN 1.5 ?
1 16 BLACK/GREEN 1.5 Fan Medium Solenoid
154 Doc. No. 872272 : Rev 0

MSW OBWW
OBW
MSW 1 2 3 4 5 6
2 4 6 8
12 11 10 9 8 7
1 3 5 7 YAZAKI, 8 WAY, PLUG & SOCKETS -
MIRROR SWITCH.

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 27 BLACK 0.75 Earth 1 28 BLUE 1.5 +5V Excitation

2 27 RED 0.75 Ignition Supply 2 28 GREY 1.5 Sensor Return
3 27 GREEN/BLUE 0.75 Common 3 28 BLACK 1.5 Earth
5 27 YELLOW/GREEN 0.75 Left Vertical 5 28 WHITE/BLUE 1.5 OBW Green Light
6 27 ORANGE/BROWN 0.75 Right Horizontal 6 28 WHITE/GREEN 1.5 OBW Yellow Light
7 27 GREEN/YELLOW 0.75 Right Vertical 7 28 WHITE/GREY 1.5 OBW Red Light
8 27 ORANGE/GREEN 0.75 Left Horizontal 8 28 YELLOW 1.0 CAN High
9 28 GREEN 1.0 CAN Low
10 28 CAN SHIELD CAN Shield
11 28 YELLOW/GREEN 1.5 Signal (Left)
12 28 PURPLE/GREEN 1.5 Signal (Right)
MT2000
MT2000
5 1 OBWWL
10 6
15 11 DB, 15 WAY, PLUG & SOCKETS -
SATELLITE MODULE.
(Connector as viewed from the front). OBWWL
4 1
3 2
OBW WARNING LIGHTS. (Not on T17D F/D & 4206D).
TERMINAL

TERMINAL
3
2
25 BLACK 1.0 Earth
? GN 1.5 ?
4 25 ORANGE 1.0 MT2000 RX
5 1 15 WHITE/BLUE 0.75 OBW Green Light
6 2 15 WHITE/GREEN 0.75 OBW Yellow Light
7 3 OBW Red Light
15 WHITE/GREY 0.75
8
9 25 WHITE 1.0 MT2000 RX
10 25 BROWN 1.0 7.5V Supply
11
12
13
14
15
NPL
NPL

2 1
NUMBER PLATE LIGHT. (B20D, T17D T/D & T17D F/D).

TERMINAL
? GN 1.5 ?
A 13 BLUE 1.5 Number Plate Light
Doc. No. 872272 : Rev 0 155

OEUJ1 OEU_J2
A BCDEFGH J K L M
4
3
A B CD E F G H
4 2
1
3 OEUJ1 L K J HG FE DC B A M
OEUJ2 CINCH, 48 WAY, PLUG & SOCKETS -
2 OUTPUT EXPANSION UNIT (J2).
1 (Connector as viewed from the back).
G F E D C B A H
CINCH BR, 32 WAY, PLUG & SOCKETS -
OUTPUT EXPANSION UNIT (J1). PAGE WIRE COLOUR FUNCTION
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ? A1 15 YELLOW 0.75 CAN High

A2
A3
A1 A4
A2 B1 15 GREEN 0.75 CAN Low
A3 14 BROWN/BLACK 0.75 Bonnet Fan 1 15 BLACK 0.75 CAN Shield
A4 14 BROWN/BLACK 0.75 Bonnet Fan 1 B2
B1 B3
B2 B4 15 BLACK/BLUE 0.75 Gear Hold
B3 14 RED/GREY 0.75 Blower Speed 3 C1
B4 14 RED/GREY 0.75 Blower Speed 3 C2
C1 C3
C2 C4 15 GREEN/PURPLE 0.75 Two Speed Diff
C3 14 RED/GREEN 0.75 Blower Speed 2 D1
D2
C4 14 RED/GREEN 0.75 Blower Speed 2
D1 D3
D2 D4 15 WHITE/BLUE 0.75 Load Light Yellow
E1
D3
E2
D4
E3
E1
E4 15 WHITE/GREEN 0.75 Load Light Green
E2
F1
E3 14 RED/BLUE 0.75 Blower Speed 1 F2
E4 14 RED/BLUE 0.75 Blower Speed 1
F3
F1 15
F4 YELLOW/PINK 0.75 Automatic Neutral
F2
G1
F3 14 BROWN/BLUE 0.75 Bonnet Fan 2 G2
F4 14 BROWN/BLUE 0.75 Bonnet Fan 2 G3
G1 G4 15 GREEN/BLACK 0.75 Engine Overheat/Pre-select 2nd
G2 H1
G3 14 RED 1.5 Ignition Supply To Outputs H2
G4 14 RED 1.5 Ignition Supply To Outputs H3
H1 14 BLACK/WHITE 1.5 JD Starter H4 15 WHITE/GREY 0.75 Load Light Red
H2 14 BLACK/WHITE 1.5 JD Starter J1
H3 14 RED 1.5 Ignition Supply To Outputs J2
H4 14 RED 1.5 Ignition Supply To Outputs J3
J4 15 PURPLE/WHITE 0.75 Laden/Unladen
K1
K2
K3
K4
L1 15 GREEN 1.5 28V Battery (KL30)
L2 15 BLACK 1.5 Earth (KL31)
L3 15 RED 1.5 Ignition Supply To Outputs
L4 15 RED 1.5 Ignition Supply To Outputs
M1 15 RED 1.5 28V Ignition (KL15)
M2 15 BLACK 1.5 Earth (KL31)
M3 15 RED 1.5 Ignition Supply To Outputs
M4 15 RED 1.5 Ignition Supply To Outputs
156 Doc. No. 872272 : Rev 0

OEUJ3 PBDSW
9 10
6 3
A B CD E F G H
4
3 OEUJ3 5 2 PBDSW
2
1 G F E D C B A H
CINCH BL, 32 WAY, PLUG & SOCKETS - 4 1 AMP, 10 WAY, PLUG & SOCKETS -
OUTPUT EXPANSION UNIT (J3). PARK BRAKE DASH SWITCH.
(Connector as viewed from the back). 7 8

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
A1 16 BLACK/GREEN 0.75 Fan Medium Solenoid
1
A2 16 BROWN/RED 0.75 Heater Valve
A3 16 BLUE/YELLOW 0.75 Engine Cooler Fan Solenoid
3 11 BLUE/GREY 0.75 Park Brake Dash Switch Signal
A4 16 BLUE/GREY 0.75 Fan Cut Solenoid
16 4
B1 PURPLE/GREEN 0.75 Fan Low Solenoid
B2 5
B3 6
B4 7 11 BLACK 0.75 Earth
C1 16 RED/BROWN 0.75 Left Strut Down 8 11 BLUE 0.75 Park Lights
C2 9
C3 10
C4
D1 16 PINK/GREY 0.75 Left Strut Up
D2
D3
16
16
RED/ORANGE 0.75
BLACK/YELLOW 0.75
Middle/Demist Actuator
Engine Cooler Fan PWM Return
PBOS
D4
E1 16 ORANGE/WHITE 0.75 Right Strut Down
E2 16 RED/YELLOW 0.75 Feet Actuator
E3 2 1
E4 3
F1 16 GREY/ORANGE 0.75 Right Strut Up PBOS

F2
F3
HIRSHMANN, 4 WAY, FLUSH, SOCKETS -
F4
PNEUMATIC BLOW OFF SOLENOID.
G1 16 RED 1.5 Ignition Supply To Outputs (Connector as viewed from the front).
G2 16 RED 1.5 Ignition Supply To Outputs
G3 PAGE WIRE COLOUR FUNCTION
G4
TERMINAL
H1 16 BLACK 1.5 Earth

H2 16
H3 16
BLACK 1.5
RED 1.5
Earth
Ignition Supply To Outputs ? GN 1.5 ?
H4 16 RED 1.5 Ignition Supply To Outputs
1 9 YELLOW/GREEN 1.5 Pneumatic Blow Off Solenoid

2 9 BLACK 1.5 Earth
3
OSS
PBPS
OSS
2 1
A B DELPHI PACKARD, 2 WAY, PLUG & SOCKETS - 3
OUTPUT SPEED SENSOR.
(Connector as viewed from the back). PBPS

PARK BRAKE PRESSURE SWITCH.
TERMINAL

? GN 1.5 ?
TERMINAL
A 24 WHITE/GREY 0.85 Output Speed Sensor +

B 24 GREEN/BLUE 0.85 Output Speed Sensor -
? GN 1.5 ?
1 6 BLUE/YELLOW 0.75 Park Brake Light Signal
2 6 RED 0.75 Earth
3
4
Doc. No. 872272 : Rev 0 157

PBSOL PSEN_B
PSEN-B
2 1
GHW, 6MM LUG -
PNEUMATIC PRESSURE SENSOR.
3
(Isometric view).
PBSOL
PARK BRAKE SOLENOID.
TERMINAL
? GN 1.5 ?
TERMINAL
B 7 BLACK/YELLOW 0.75 Sensor Return (Air Pressure)
? GN 1.5 ?
1 12 BROWN/YELLOW 0.75 Park Brake Solenoid
R2SP_1
3
R2SP1
4
1 2
PCV REAR 2 SPEED PIGTAIL1. (B50D).

PCV
TERMINAL
SUMITOMO, 2 WAY, RECEPTACLE & PINS -
A B
PUMP CONTROL VALVE (JD). ? GN 1.5 ?
PAGE WIRE COLOUR FUNCTION 1 7 WHITE/ORANGE 1.5 2 Speed Switch Signal

2 7 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
R2SP_2
A 19 GREY/BLUE 1.5 Pump Solenoid+
B 19 YELLOW/BLUE 1.5 Pump Solenoid-
R2SP2
1 2
PD REAR 2 SPEED PIGTAIL 2. (B50D).

PD
TERMINAL
1 2
PULL DOWN (JD). ? GN 1.5 ?
PAGE WIRE COLOUR FUNCTION 1 7 WHITE/ORANGE 1.5 2 Speed Switch Signal

2 7 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
R2SSW
R2SSW
PSEN_A B A PACKARD, 2 WAY, PLUG & PINS -

REAR 2 SPEED SWITCH. (B50D).
PSEN-A
GHW, 4MM LUG - PAGE WIRE COLOUR FUNCTION
PNEUMATIC PRESSURE SENSOR.
TERMINAL
(Isometric view).
PAGE WIRE COLOUR FUNCTION ? GN 1.5 ?

TERMINAL
1 7 WHITE/ORANGE 1.5 2 Speed Switch Signal

? GN 1.5 ? 2 7 BLACK 1.5 Earth
A 7 ORANGE/WHITE 0.75 Air Pressure Sensor Signal
158 Doc. No. 872272 : Rev 0

RACC RADI_B
RACC RADIB
A B
1 2
C
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - DT DEUTSCH, 3 WAY, RECEPTACLE & PINS -
RETARDER ACC RESISTOR. RADIO INTERFACE.

TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
2 24 BROWN/BLUE 0.85 SupplyReturn A 4 WHITE 1.5 12V Battery Supply (Radio)
B 4 WHITE/RED 1.5 12V Ignition Supply (Radio)
C 4 BLACK 1.5 Earth
RAD RAIL
RAIL
3 2 1 AMP, 3 WAY, RECEPTACLE & PINS -

2 1 2 1
RAD RAIL PRESSURE (JD).
4 3 4 3 (Connector as viewed from the back).
6 5 6 5
FRAMATONE, 16 WAY, PLUG & SOCKETS - PAGE WIRE COLOUR FUNCTION
8 7 8 7
RADIO.
TERMINAL
? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 22 BLACK/YELLOW 0.75 Rail Pressure Sensor Return

2 22 BROWN/RED 0.75 Rail Pressure Signal
3 22 ORANGE/BLACK 0.75 Excitation 1+
A1
A2
A3
A4 4 WHITE 1.5 12V Battery Supply (Radio)
A5
A6
RBP
A7 4 WHITE/RED 1.5 12V Ignition Supply (Radio)
A8 4 BLACK 1.5 Earth
B1
B2 B A
RBP
B3 4 BLACK/GREEN 1.5 Right Speaker
4 C
B4 BLACK 1.5 Right Speaker Return DT DEUTSCH, 3 WAY, PLUG & SOCKETS -
B5 4 BLACK/BLUE 1.5 Left Speaker RIGHT BRAKE & PARK LIGHTS.
B6 4 BLACK 1.5 Right Speaker Return (Connector as viewed from the back).
B7
B8
TERMINAL
? GN 1.5 ?
RADI_A
A 13 BLACK 1.5 Earth
B 13 BLACK/RED 1.5 Right Brake Lights
C 13 BLUE 1.5 Right Park Lights
B A
RADIA
C
RADIO INTERFACE A.
(Connector as viewed from the back). RHL
RHL
TERMINAL
? GN 1.5 ? 1 UTILUX, 3 WAY, PLUG & SOCKETS -

RIGHT HEADLIGHT.
3
A 4 WHITE 1.5 12V Battery Supply

B 4 WHITE/RED 1.5 12V Ignition Supply
C 4 BLACK 1.5 Earth
TERMINAL
? GN 1.5 ?
1 7 BLACK 1.5 Earth
2 7 WHITE/GREY 1.5 Headlight - Bright
3 7 GREY/WHITE 1.5 Headlight - Dips
Doc. No. 872272 : Rev 0 159

RHMP RIDL
RIDL
1 2
H REAR DIFFLOCK SWITCH. (B50D).
J X (Connector as viewed from the back).
K B W
G
L V
C A F PAGE WIRE COLOUR FUNCTION
M D E U
TERMINAL
N T
P S RHMP
R
? GN 1.5 ?
HD DEUTSCH, 21 WAY, RECEPTACLE & PINS -
REAR HARNESS MALE PLUG.
(Connector as viewed from the back). 1 28 GREEN/GREY 1.5 Rear Difflock Switch Signal
TERMINAL
RIND
? GN 1.5 ?
RIND
7 YELLOW/GREEN 1.5 Reverse Signal
1
A
C 13 GREY/BLUE 1.5 Brake Lights RIGHT INDICATOR.
D 7 WHITE/ORANGE 1.5 Rear 2 Speed Switch(B50D) (Connector as viewed from the back).
E 28 GREEN/GREY 1.5 Rear IDL Position Switch (B50D)
F 13/29 BROWN 1.5 Left Indicator PAGE WIRE COLOUR FUNCTION
G
TERMINAL
J 13
13/7
BLUE 1.5
BLACK 2.5
Park Lights
Earth
? GN 1.5 ?
K
L 9 PURPLE/GREEN 1.5 Bin Position Sensor Signal
L 9 BLACK/YELLOW 1.5 Artic Sensor Earth (4206D) 1 13 YELLOW 1.5 Indicator - Right
M 10 RED/ORANGE 1.5 Bin Position 5V Supply 2 13 BLACK 1.5 Earth
M 10 PURPLE/RED 1.5 Artic Sensor Signal (4206D)
N 10 RED/YELLOW 1.5 Artic Sensor 5V Supply (4206D)
P 3 RED 1.5 Ignition Supply (OBW & TPM) RLEDS
RLEDS
U 7/28 BLACK 1.5 Earth (Large)
V 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch 4 1
W 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch DT DEUTSCH, 4 WAY, PLUG & SOCKETS -
3 2
RIGHT REAR LED LIGHTS. (4206D).
X (Connector as viewed from the back).
RHMP_4206D
TERMINAL
? GN 1.5 ?
H
1 13 BROWN/YELLOW 1.5 Right Indicator
J X
W
2 13 GREY/BLUE 1.5 Brake Lights
K B G
3 13 BLUE 1.5 Park Lights
L V
C A F Earth
4 13 BLACK 1.5
M D E U
N T RHMP
P R S
HD DEUTSCH, 21 WAY, PLUG & PINS -

REAR HARNESS MALE PLUG. (4206D)
RM
RM
TERMINAL
1 2
? GN 1.5 ? DT DEUTSCH, 2 WAY, PLUG & SOCKETS -
REVERSE MONITOR.
A 7 YELLOW/GREEN 1.5 Reverse Signal
B
TERMINAL
D
E ? GN 1.5 ?
F 13/29 BROWN 1.5 Left Indicator
G
1 4 WHITE/RED 1.5 12V Ignition Supply
2 4 BLACK 1.5 Earth
J 13 BLUE 1.5 Park Lights
K 13/7 BLACK 2.5 Earth
L 9 BLACK/YELLOW 1.5 Artic Sensor Earth
M 10 PURPLE/RED 1.5 Artic Sensor Signal
N 10 RED/YELLOW 1.5 Artic Sensor 5V Supply
P 3 RED 1.5 Ignition Supply (OBW & TPM)
U
V 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch
W 26 ORANGE/BLUE 1.5 Automatic Greaser Pressure Switch
X
160 Doc. No. 872272 : Rev 0

RMIR RSD
RSD
1 2
6 1
RMIR
5 2
DT DEUTSH, 6 WAY, PLUG & SOCKETS - RIGHT STRUT DOWN. (B50D).
4 3 RIGHT MIRROR. (Connector as viewed from the back).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 16 GREY/ORANGE 2.5 Right Strut Down Solenoid
1 27 BLACK 0.75 Earth 2 16 BLACK 1.5 Earth
2 27 RED/GREY 0.75 Mirror Demister
3 27 GREEN/YELLOW 0.75 Right Vertical
4 27 ORANGE/BROWN 0.75 Right Horizontal
5 27 GREEN/BLUE 0.75 Common RSG
6
RSG
4 1
RIGHT STRAIN GAUGE. (Not on T17D F/D).
RPLHT 3 2

RPLHT
TERMINAL
RIGHT PARK LIGHT. ? GN 1.5 ?
(Isometric View).
PAGE WIRE COLOUR FUNCTION 1 28 YELLOW/GREEN 1.5 Right Strain Guage Signal
2 28 BLUE/WHITE 1.5 +5V Excitation
TERMINAL
3 28 GREY 1.5 Sensor Earth

? GN 1.5 ? 4 28 BLACK 1.5 Earth
1 8 BLUE 1.5 Parklights - Right Headlight

2 8 BLACK 1.5 Earth
RSIND
RREV RSIND
1 2
RIGHT SIDE INDICATOR. (Used on the B20D).
RREV (Connector as viewed from the back).
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - PAGE WIRE COLOUR FUNCTION
RIGHT REVERSE LIGHT.
TERMINAL

? GN 1.5 ?
TERMINAL
? GN 1.5 ? 1 13 YELLOW 1.5 Indicator Right

1 7 YELLOW/GREEN 1.5 Right Reverse Light

2 7 BLACK 1.5 Earth
RSOL
RS 1 4
3 2
RSOL
RS
RETARDER SOLENOID.
A B DELPHI PACKARD, 2 WAY, PLUG & SOCKETS - (Connector as viewed from the front).
RETARDER SOLENOID.
TERMINAL
?
TERMINAL
? GN 1.5
? GN 1.5 ?
1 23 406 1.5 Retarder Solenoid
A 24 GREEN/RED 0.85 Retarder Solenoid 2 23 902 1.5 Earth
B 24 BROWN/BLUE 0.85 Supply Return 3
4
Doc. No. 872272 : Rev 0 161

RSU RWWMD
RSU
6 1
RWMD
1 2
DT DEUTSCH, 2 WAY, PLUG & SOCKETS - 5 2
RIGHT STRUT UP. (B50D). DT DEUTSCH, 6 WAY, PLUG & SOCKETS -
4 3
(Connector as viewed from the back). REAR WIPER MOTOR PIGTAIL (Rear Wiper).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 16 GREY/ORANGE 2.5 Right Strut Up Solenoid Rear Wiper Motor Park
1 8 PINK/BLUE 0.75
2 8 ORANGE/BLUE 0.75 Rear Wiper High Speed
4 8 YELLOW/GREY 1.5 Rear Wiper Low Speed
RTS 5
6 8 BLACK 1.5 Earth
RTS
RWMI
RETARDER TEMP SENSOR.
6 1
RWMI
5 2
TERMINAL
4 3 REAR WIPER MOTOR INTERFACE.

? GN 1.5 ?
A ORANGE/GREY 0.85 Retarder Temperature Sensor Signal

TERMINAL
24
B 24 PURPLE/BLACK 0.85 Sensor Return
? GN 1.5 ?
1 8 PINK/BLUE 0.75 Rear Wiper Motor Park
RWASH 2 8 ORANGE/BLUE 0.75 Rear Wiper High Speed
3 8 RED 0.75 24V Ignition Power
4 8 YELLOW/GREY 1.5 Rear Wiper Low Speed
5
6 8 BLACK .15 Earth
RWASH
2
1
UTILUX, 2 WAY, PLUG & SOCKETS -
REAR WASHER.
(Connector as viewed from the back). RWMP
TERMINAL
RWMP
1 6
? GN 1.5 ? 2 5
3 4 REAR WIPER MOTOR PIGTAIL.
1 12 PURPLE/GREEN 0.75 Rear Washer Pump
2 12 BLACK 0.75 Earth PAGE WIRE COLOUR FUNCTION
TERMINAL
RWL ? GN 1.5 ?
1 8 PINK/BLUE 0.75 Rear Wiper Motor Park
RWL 2 8 ORANGE/BLUE 0.75 Rear Wiper High Speed
2
1
DT DEUTSH, 2 WAY, PLUG & SOCKETS - 4 8 YELLOW/GREY 1.5 Rear Wiper Low Speed
RIGHT WORK LIGHTS. 5

TERMINAL
SATC_MT2000
? GN 1.5 ?
SATC
1 8 RED/WHITE 1.5 Right Worklights
4 1
2 8 BLACK 1.5 Earth DT DEUTSCH, 4 WAY, PLUG & SOCKETS -
3 2
SATC - MT2000.

TERMINAL
? GN 1.5 ?
2 25 RED/YELLOW 0.75 RS232 MM:RX - MT2000:TX (Orange)
3 25 YELLOW/RED 0.75 RS232 MM:TX - MT2000:RX (White)
4 25 ORANGE/BROWN 0.75 7.5V Supply From MM
162 Doc. No. 872272 : Rev 0

SATC_Sat_To_Harness SDSW
SATC 9 10
1 4 6 3
2 3
SATC - SATELLITE TO HARNESS. 5 2 SDSW
PAGE WIRE COLOUR FUNCTION 4 1 AMP, 10 WAY, PLUG & SOCKETS -

SCRAPER DASH SWITCH. (4206D).
7 8 (Connector as viewed from the back).
TERMINAL
TERMINAL
2 25 RED/YELLOW 0.75 RS232 MM:RX - MT2000:TX (Orange) ? GN 1.5 ?
3 25 YELLOW/RED 0.75 RS232 MM:TX - MT2000:RX (White)
4 25 ORANGE/BROWN 0.75 7.5V Supply From MM
1
2 29 GREEN/WHITE 1.5 Scraper Dash Switch Signal
29 GREEN/WHITE 1.5 Scraper Cut Switch
SCS
SCS 7 GREEN/WHITE 1.5 Iqan Cut Switch
29
HELLERMAN TYTON, BOOTLACE TERMINAL - 9
SCRAPER CUT SWITCH. (4206D).
(Isometric View).
10
TERMINAL
? GN 1.5 ? SHIFT
A 29 GREEN/WHITE 1.5 Scraper Cut Switch
B 29 GREEN/WHITE 1.5 Scraper Cut Switch
1 2 3 4 5 6 7 8
SHIFT
9 10 1112 13 1415 16 DELPHI PACKARD, 16 WAY, PLUG & SOCKETS -

SCS_12 SHIFT SELECTOR.

7 8 9 10 11 12
SCS12
TERMINAL

STEERING COLUMN SWITCH, 12 PIN.
? GN 1.5 ?

2
TERMINAL
3 24 BLUE 0.75 Back Lighting

4
? GN 1.5 ? 5 24 BLACK 0.75 Earth
6
2 6 GREEN/BLACK 0.75 Horn Switch Signal 8 24 YELLOW 0.75 CAN High
3 6 WHITE/GREY 0.75 Headlight Brights Signal 9
5 6 GREY/WHITE 0.75 Headlight Dips Signal 11 24 PINK/BLUE 0.75 Direct Signal
8 14 24 BLACK 0.75 CAN Shield
9 6 BROWN/RED 0.75 Left Indicator Signal 15 24 GREEN 0.75 CAN Low
10 6 YELLOW/RED 0.75 Right Indicator Signal 16
SREV
SREV
1 2
SPARE REVERSE LIGHTS. (2306D).

TERMINAL
? GN 1.5 ?
1 7 YELLOW/GREEN 1.5 Right Reverse Light
2 7 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 163

SS STUD_1
STUD1
GHW, 6MM LUG -
STUD POINT 1.
P
(Isometric view).
N E
D
M F PAGE WIRE COLOUR FUNCTION
C A
L G
TERMINAL
B
K H
SS
J
? GN 1.5 ?
HDP DEUTSCH, 14 WAY, PLUG & SOCKETS -
SHIFT SELECTOR. (ZF).
(Connector as viewed from the back). S1-B 1 GREEN 6.0 Battery Supply (Fuse 1)
S1-C 1 GREEN 6.0 Battery Supply (Fuse 8)
PIN /SOCKET
? GN 1.5 ? STUD_1_&_STUD_2
SS-?
A 23 421 0.75 ED10 STUD1 & STUD2

B 23 442 0.75 ED11 GHW, 6MM LUG -
C 23 428 0.75 ED12 STUD POINT 1 & STUD POINT 2.
D 450 0.75 ED13 (Isometric view).
23
E 23 441 0.75 ED14
F 23 911 0.75 Neutral
G
TERMINAL
H
J 23 900 RED 0.75 Ignition Supply ? GN 1.5 ?
K 23 948 0.75 Shift Selector Lights
L 23 456 0.75 ADVP
M S1-A 1 GREEN 10.0 Battery Supply
N 902 BLACK 0.75 System Ground S2-A 1 RED 10.0 Ignition Supply
23
P 23 900 RED 0.75 Ignition Supply
SSCAN STUD_2
SSCAN STUD2
A B
GHW, 6MM LUG -
C
STUD POINT 2.
DT DEUTSCH, 3 WAY, RECEPTACLE & PINS - (Isometric view).
SHIFT SELECTOR CAN.
TERMINAL
? ?
TERMINAL
GN 1.5
? GN 1.5 ?
S2-B 1 RED 6.0 Ignition Supply (Fuse 15)
A CAN High S2-B 1 RED 6.0 Ignition Supply (Fuse 22)
24 YELLOW 0.75
B CAN Low S2-C 1 REDN 6.0 Ignition Supply (Fuse 29)
24 GREEN 0.75
C 24 BLACK 0.75 CAN Shield S2-C 1 RED 6.0 Ignition Supply (Fuse 36)
SSM
SUS
SSM
4 1 SUS
3 2
SEALED SWITCH MODULE. 1 2 3 4 5 6
(Connector as viewed from the back). 12 DT DEUTSCH, 12 WAY, PLUG & SOCKETS -
11 10 9 8 7
SUSPENSION PIGTAIL. (B40D)
TERMINAL
? GN 1.5 ?
TERMINAL

? GN 1.5 ?
3 6 YELLOW 0.75 CAN High 1 10 BLACK/YELLOW 1.5 Artic Position Sensor Return
4 6 GREEN 0.75 CAN Low 2 16 PINK/GREY 2.5 Left Strut Up
6 BLACK 0.75 CAN Shield
3 16 RED/BROWN 2.5 Left Strut Down
4 16 GREY/ORANGE 2.5 Right Strut Up
5 16 ORANGE/WHITE 2.5 Right Strut Down
STAR_50 6
7 10 RED/YELLOW 1.5 Left & Right Height Sensor 5V Supply
STAR-50 8 9 PURPLE/BLUE 1.5 Left Height Position Signal
GHW, 6MM LUG - 9 10 PURPLE/YELLOW 1.5 Right Height Position Signal
STARTER KL50.
(Isometric View). 10 10 PURPLE/RED 1.5 Artic Sensor Signal
11 10 RED/YELLOW 1.5 Artic Sensor 5V Supply
PAGE WIRE COLOUR FUNCTION 12 10 BLACK/YELLOW 1.5 Left/Right Height Position Sensor Return
TERMINAL
? GN 1.5 ?
STAR-50 1 BLACK/WHITE 1.5 Start Signal to Starter Motor
164 Doc. No. 872272 : Rev 0

TC_1 TCI_2
TCI2
TC1 6 1
1 6
5 2
2 5
DT DEUTSCH, 6 WAY, RECEPTACLE & PINS - DT DEUTSCH, 6 WAY, PLUG & SOCKETS -
4 3 TRAILER CONNECTOR INTERFACE 2. (4206D & 2306D).
3 4 TRAILER CONNECTOR 1. (4206D & 2306D).
TERMINAL
TERMINAL
? GN 1.5 ? ? GN 1.5 ?
1 29 BLACK 1.5 Earth 1 29 BLACK 1.5 Earth
2 29 BLUE 1.5 Park Lights 2 29 BLUE 1.5 Park Lights
3 29 BROWN 1.5 Indicator Left 3 29 BROWN 1.5 Indicator Left
4 29 GREY/BLUE 1.5 Brake Lights 4 29 GREY/BLUE 1.5 Brake Lights
5 29 YELLOW 1.5 Indicator Right 5 29 YELLOW 1.5 Indicator Right
6 29 BLUE 1.5 Park Lights 6 BLUE 1.5 Park Lights
29
TC_2 TCU
1 2 3 4 5 6
TCU

1 TRANSMISSION INTERFACE.
2 6 12 11 10 9 8 7 (Connector as viewed from the back).
7 TC2
3 5
HELLA, 7 WAY, CONNECTOR & SOCKETS - TERMINAL
TRAILER CONNECTOR 2. (4206D & 2306D).
? GN 1.5 ?
TERMINAL
1 23/24 BLACK 1.5 System Ground

? GN 1.5 ? 2 23/24 GREEN 1.5 Battery Supply
3 23/24 RED 1.5 Ignition Supply
4 23/24 YELLOW/BLACK 0.75 Diagnostic - K (J1708+)
1 15 BLACK 1.5 Earth 5 23/24 YELLOW/BLUE 0.75 Diagnostic - L (J1708-)
2 15 BLUE 1.5 Park Light 6 23/24 BLUE 0.75 Shift Selector Back Light
3 15 BROWN 1.5 Indicator Left 7 23/24 YELLOW/PINK 0.75 Auto Neutral (Allison Only)
4 15 GREY/BLUE 1.5 Brake Light 8 23/24 BLACK/BLUE 0.75 Gear Hold (Allison Only)
5 15 YELLOW 1.5 Indicator Right 9 23/24 GREEN/BLACK 0.75 3rd Shift Programme (Allison Only)
6 15 BLUE 1.5 Park Light 10 23/24 ZF EOL Prog. Pin (ZF Only)
PINK/GREY 0.75
11 23/24 BROWN/RED 0.75 Neutral Signal
12 23/24 PURPLE/WHITE 0.75 Laden/Unladen (Primary/Secondary Shift Programme)
TCI_1
TCU_CAN
6 1
TCI1 TCU CAN
A B
5 2
DT DEUTSCH, 6 WAY, PLUG & SOCKETS - C
4 3 TRAILER CONNECTOR INTERFACE 1. (4206D & 2306D). DT DEUTSCH, 3 WAY, RECEPTACLE & PINS -
(Connector as viewed from the back). TCU CAN INTERFACE.
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
2 29 BLUE 1.5 Park Lights A 24 YELLOW 0.75 CAN High
3 29 BROWN 1.5 Indicator Left B 24 GREEN 0.75 CAN Low
4 29 GREY/BLUE 1.5 Brake Lights C 24 BLACK 0.75 CAN Shield
5 29 YELLOW 1.5 Indicator Right
6 29 BLUE 1.5 Park Lights
TCUCAN
B A
TCUCAN
C
TCU CAN.

TERMINAL
? GN 1.5 ?
B 23 GREEN 0.75 CAN Low
C 23 BLACK 0.75 CAN Shield
Doc. No. 872272 : Rev 0 165

TPM TT
TPM
1 4
4 1 3 2
DT DEUTSCH, 4 WAY, PLUG & SOCKETS - TT
3 2
TYRE PRESSURE MONITOR.
PAGE WIRE COLOUR FUNCTION TRANSMISSION TEMPERATURE.
TERMINAL

? GN 1.5 ?
TERMINAL
28 BLACK 1.5 CAN Shield ? GN 1.5 ?
1 28 YELLOW 1.0 CAN High
2 28 GREEN 1.0 CAN Lo
1 23 403 1.5 Temperature Sensor Retarder
2 23 904 1.5 Earth
3
4
TR
VIGA
1 2 3 4 5 6
7 10
VTGA
4 1
3 2 VTG ACTUATOR (JD).
11 14
15 16 17 18 19 20
TR PAGE WIRE COLOUR FUNCTION

TERMINAL
AFL AUTOMATIVE, 20 WAY, PLUG & SOCKETS -

TRANSMISSION BLOCK.
(Connector as viewed from the front). ? GN 1.5 ?
1 19 WHITE/BLUE 1.5 H Bridge 2 +
19
TERMINAL
2 BLACK 1.5 Earth

3
? GN 1.5 ? 4 19 ORANGE/WHITE 0.75 Actuator Comm +

3 24 WHITE/BLUE 0.85 Press Switch 1 VTGSS
6 24 BROWN/BLACK 0.85 High Side Driver 2
VTGSS
7
8 24 ORANGE/WHITE 0.85 Main Mod Solenoid 1 2 3
9 24 GREEN/WHITE 0.85 Press Control Solenoid 3 AMP, 3 WAY, PLUG & SOCKETS -
VTG SPEED SENSOR (JD).
11 24 BROWN/BLUE 0.85 High Side Driver 3
12 24 WHITE/YELLOW 0.85 TCC Solenoid PAGE WIRE COLOUR FUNCTION
13 24 Twisted Pair BL/OR 0.85 Turbine Speed Sensor +
TERMINAL
14 24 Twisted Pair BL/PL 0.85 Turbine Speed Sensor -

15
16
24
24
BLUE/WHITE 0.85 Oil Level Signal
GREEN/ORANGE 0.85 Oil Level Excitation
? GN 1.5 ?
17
18 24 BROWN/RED 0.85 Sump Temperature 1 19 GREY/GREEN 0.75 Turbo Speed In +
19 24 PURPLE/BLACK 0.85 Sensor Return 2 19 BLACK/GREY 0.75 Turbo Speed In -
20 24 YELLOW/RED 0.85 Transmission ID 3
TSS WBT
WBT
TSS
1 2
A B DELPHI PACKARD, 2 WAY, PLUG & SOCKETS - WET BRAKE TEMPERATURE.
TURBINE SPEED SENSOR. (Connector as viewed from the back).
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 11 WHITE/BLUE 1.5 Wet Brake Temperature Sensor Signal
A 24 BLACK/ORANGE 0.85 Turbine Speed Sensor + 2 11 BLACK/YELLOW 1.5 Sensor Return
B 24 BLUE/PURPLE 0.85 Turbine Speed Sensor -
166 Doc. No. 872272 : Rev 0

WBT_1 XPM
WBT1
GHW, 5MM LUG -
WET BRAKE TEMPERATURE 1. 42 29
(Isometric View).
28 15
PAGE WIRE COLOUR FUNCTION 14 1
TERMINAL
? GN 1.5 ?
1 11 WHITE/BLUE 1.5 Wet Brake Temperature
TERMINAL
? GN 1.5 ?
WBT_2
1 19 WHITE/BROWN 1.5 - VREF (IQAN)
2 19 BLUE/YELLOW 1.5 Lever 1 Signal (0-5V)
WBT2
GHW, 6MM LUG -
WET BRAKE TEMPERATURE 1. 4 19 ORANGE/BLUE 1.5 Lever 3 Signal (0-5V)
(Isometric View). 5 19 BLUE/ORANGE 1.5 Lever 4 Signal (0-5V)
6
7
8 19 WHITE/GREY 1.5 Iqan Common - A
TERMINAL
9 19 WHITE/RED 1.5 Iqan Common - B

? GN 1.5 ? 10 19 WHITE/BLUE 1.5 Iqan Common - C
11 19 WHITE/GREEN 1.5 Iqan Common - D
12 19 GREY/WHITE 1.5 Iqan Common - E
2 11 BLACK/YELLOW 1.5 Signal Return
13 19 RED/WHITE 1.5 Iqan Common - F
15 19 PURPLE/RED 1.5 + VREF (IQAN)
WBT_2, WAY 16 19 BLUE/GREY 1.5 Lever 5 Signal (0-5V)
17 19 GREY/BLUE 1.5 Lever 6 Signal (0-5V)
18
WBT 19
1 2 20
DT DEUTSCH, 2 WAY, RECEPTACLE & PINS - 21
WET BRAKE TEMPERATURE. 22 19 YELLOW 1.5 Iqan Current Output A+
23 19 RED/GREEN 1.5 Iqan Current Output B+
24 19 GREY 1.5 Iqan Current Output C+
25 19 PINK 1.5 Iqan Current Output D+
TERMINAL
26 19 YELLOW/BLACK 1.5 Iqan Current Output E+

27 19 RED/BLUE 1.5 Iqan Current Output F+
? GN 1.5 ? 28 19 RED 1.5 Fused Ignition Supply
29 19 RED 1.5 Fused Ignition Supply
1 11 WHITE/BLUE 1.5 Wet Brake Temperature Pigtail 30
2 11 BLACK/YELLOW 1.5 Signal Return 31
32
33
34
WIF 35
WIF
A B
XPM_Cont
DELPHI PACKARD, 2 WAY, RECEPTACLE & PINS -
WATER IN FUEL (JD). XPM
PAGE WIRE COLOUR FUNCTION AMP, 42 WAY, PLUG & SOCKETS -

EXPANSION MODULE. (4206D).
TERMINAL
(Connector Viewed from the front).

TERMINAL
A 21 BLACK/YELLOW 1.5 Excitation 2+

B 21 PURPLE/WHITE 0.75 Water In Fuel Signal ? GN 1.5 ?
36 19 BROWN 1.5 Iqan Current Output A-
37 19 GREEN/RED 1.5 Iqan Current Output B-
WLHT 38 19 ORANGE 1.5 Iqan Current Output C-
39 19 PURPLE 1.5 Iqan Current Output D-
40 19 BROWN/YELLOW 1.5 Iqan Current Output E-
41 19 BLUE/RED 1.5 Iqan Current Output F-
B A
WLHT 42 19 RED 1.5 Fused Ignition Supply
C
WORKLIGHT INTERFACE.

TERMINAL
? GN 1.5 ?
A 8 RED/WHITE 1.5 Left Work Light
B 8 RED/WHITE 1.5 Right Work Light
C 8 BLACK 1.5 Earth
Doc. No. 872272 : Rev 0 167

ZF_1 ZF_Artic
20 8 31
21 9 19 30 31 20
10 2 18 30 8 21
22 3 7 29
19 9
1 18 2 10
23 11 4 6 17 28
29 7 3 22
5
12 13 15 16 ZF1 17 1 11
28 6 4 23
24 27 16 5 12 ZF
25 14 26 15 13
27 14 24
HD DEUTSCH, 31 WAY, RECEPTACLE & PINS - 26 25
ZF FIREWALL. HD DEUTSCH, 31 WAY, PLUG & SOCKETS -
(Connector as viewed from the back). ZF ARTIC.
TERMINAL
TERMINAL
? GN 1.5 ?
? GN 1.5 ?
1 23 -RT1 0.75 EF1
2 23 -GE2 0.75 EF2 1 23 -RT1 0.75 EF1
3 2 23 -GE2 0.75 EF2
4 23 427 0.75 ER2 3
5 4 23 427 0.75 ER2
6 23 430 0.75 AD1 5
7 6 23 430 0.75 AD1
8 23 451 0.75 AD8 7
9 23 411 0.75 (AD16) AID2 8 23 451 0.75 AD8
10 23 457 0.75 (AD15) AID1 9 23 411 0.75 (AD16) AID2
11 23 405 0.75 AD5 10 23 457 0.75 (AD15) AID1
12 23 404 0.75 AD6 11 23 405 0.75 AD5
13 23 410 0.75 AD7 12 23 404 0.75 AD6
14 23 458 0.75 ADMR 13 23 410 0.75 AD7
15 23 -BL1 0.75 VMG1 14 23 458 0.75 ADMR
16 15 23 -BL1 0.75 VMG1
17 23 -BR2 0.75 VMG2 16
18 23 449 0.75 ER3 17 23 -BR2 0.75 VMG2
19 23 429 0.75 AD2 18 23 449 0.75 ER3
20 23 902 BLACK 0.75 System Ground 19 23 429 0.75 AD2
21 23 902 BLACK 0.75 System Ground 20 23 902 BLACK 0.75 System Ground
22 23 409 0.75 AD4 21 23 902 BLACK 0.75 System Ground
23 22 23 409 0.75 AD4
24 23 454 0.75 AD3 23
25 24 23 454 0.75 AD3
26 25
27 26
28 23 403 0.75 ER1 27
29 23 904 0.75 VMGA 28 23 403 0.75 ER1
30 23 406 0.75 AIP3 29 23 904 0.75 VMGA
31 23 902 BLACK 0.75 System Ground 30 23 406 0.75 AIP3
31 23 902 BLACK 0.75 System Ground
168 Doc. No. 872272 : Rev 0

SECTION 3. GENERAL FUNCTIONS
FUNCTIONAL Speed Limit (Factory, Site & Tyre Factory, Site & Tyre
SOFTWARE FUNCTION Limit, Speed Limit 1 & Speed Limit 2) speed limits have
DESCRIPTION
been implemented
Engine Start Stop (ESS) If the VIN num- to enable the pre-
ber is valid, the vention of machines
controllers are exceeding their
end of line pro- rated maximum
grammed, the speeds due to site
Start Signal is or machine limita-
ON (crank positions, this is done
tion on the igni- by limiting engine
tion switch), the rpm and then dis-
transmission (ac- abling the accelera-
tual gear and tor pedal and then
range) is in neu- applying the trans-
tral, the engine mission retarder
RPM < 400 and and finally by apply-
the truck is not ing the engine
immobilised; brake depending on
then the engine requirement. Tyre
start message limits are linked to
will be transmit- the tyre table, the
ted until the en- Factory limit is set
gine RPM > 400 in factory mode and
RPM for 500 ms. the Site limit is set
in service mode.
If the Ignition sta-
Speed Limit 1 & 2
tus is OFF (off
are available to the
position on igni-
operator in order to
tion switch), then
limit the machine to
the engine stop
the two different
message will be
speeds while driv-
transmitted until
ing, these limits can
the CCU
be useful in certain
switches off.
situation such as
driving downhill.
The limits are easily
accessible by
holding down the
retarder buttons.
Battery Charge Fault Code If the batteries are

not being charged
after the alternator
should have been
excited (after the
engine rpm has ex-
ceeded 2000 rpm
for more than or
equal to 2 seconds)
then a fault code
will be logged and
the main warning
light and buzzer will
be turned on.
GPS Fault Code If the truck is mov-

ing for 5 minutes or
more and there is
no GPS fix then a
fault code will be
logged.
Doc. No. 872272 : Rev 0 169

Battery Imbalance Active after the engine has been running for 10 seconds. If the two battery voltages
are not within 1.5V from one another then a fault code will be logged and the main
warning light and buzzer will be turned on.
Battery Saving If the engine rpm is less than 400rpm (not running) but the ignition is on and the
MDU2/SSM controls are inactive for more than 10 minutes then the main current
drawing outputs (ON THE CCU2: headlight dips & brights, worklights, reverse lights,
front & rear wiper low & high speeds, flashing beacon, arctic reverse light, front & rear
washer, mirror heating, a© clutch, ON THE OEU: Load lights (Rd, Gn & Yl), Low Med
& high speed blowers, bonnet fan) are turned off to protect the batteries from being
discharged.
IDL Protection If the accelerator pedal position is more than or equal to 10 % then the IDL will not be
activated. If the Output Shaft Speed is more than or equal to 60 on the large trucks
then the IDL will not be activated. If the IDL is active then the main buzzer will beep
once every minute along with a pop-up message to remind the operator that the
Inter-Axle Diff Lock is engaged.
Geo-Fencing By selecting a GPS position & radius on the MDU2 the operator can set up a
'Geo-Fence'. If the machine exits this Geo-Fence area the buzzer will sound and the
MDU2 will display the distance outside of the Geo-Fence e.g. "0.4 km Outside Area
Bounds". This can be used to prevent theft of the machine.A Fleetmatic event will be
sent on exit and on entry of the Geo-Fenced area.
Fleetmatic With Fleetm@tic the customer can have regular reported feedback (via e-mail) of pro-
duction/use & abuse information regarding their fleet of machines and can track each
machine via the online interactive mapping service.
Truck Immobiliser If the Immobilisation command is given by the MMU (Waiting for Driver ID key) then
the park brake is applied, the accelerator is ignored and the engine crank command is
disabled.
Gear Hold Refer to OEU Output (Gear Hold) for function.
Indicator Fault Indication If there is a fault with the indicator light system then the indicator-on LED will flash at
twice the normal rate.
OEU & CCU2 Swap Out If one of the Inputs or certain Outputs of the CCU2 happens to fail or if certain Outputs
of the OEU happen to fail then the CCU2 and the OEU can be swapped until a re-
placement part is available. The CCU2 and OEU have hardware detection pins to al-
low them to detect which position they are in. The OEU will self-erase so that it will
correctly ROM recover the end-of-line details from the MDU2 if it is swapped with the
CCU2.
Outputs Test Service personnel can turn CCU2 and OEU outputs ON or OFF via the MDU2 in ser-
vice mode, this can be used for diagnostic use. The engine should not be running and
the output shaft speed needs to be less than 275rpm for this override function to work.
Neutral Park Brake (Option) PARK BRAKE FUNCTION - Refer to latest SIB
170 Doc. No. 872272 : Rev 0

MDU2 PIN LAYOUT

16 PIN CONNECTOR - J1
PIN NUMBER VEHICLE FUNCTION FUNCTIONAL DESCRIPTION
J1 -A Battery Power Supply Fuse 8
J1 -C CAN High This is the connection point between the MDU2 Can high
and the truck Can high.
J1 -D Buzzer Negative This is the return line for the warning buzzer signal.
J1 -K CAN Low This is the connection point between the MDU2 Can low
and the truck Can low.
J1 -L Ignition Power Supply Fuse 33
J1 -M Buzzer Positive This is the output line for the warning buzzer signal. (24v)
J1 -N Fuel Sensor Signal This is the analogue input line for the fuel sensor signal.
J1 -P Power Ground KL31
J1 -R Left Indicator Switch This is the input signal from the indicator switch for indi-
cating a left hand turn. Ground signal for indication.
J1 -S Right Indicator Switch This is the input signal from the indicator switch for indi-
cating a right hand turn. Ground signal for indication.
NOTE: Pin numbers not listed are not used on this connector.
14 PIN CONNECTOR - J2
J2 - A Hydraulic Filter Press Switch This is the input signal from the hydraulic filter pressure
switch
J2 - C Low Brake Press Switch This is the input signal from the low brake pressure
switch
J2 - D CTD Press Switch This is the input signal from the Control Traction Device
pressure switch
J2 - E Emergency Steering Press Switch This is the input signal from the Emergency Steering
pressure switch
J2 - F Headlight Bright Switch This is the input signal from the indicator switch to turn
the Headlight Brights on.
J2 - G Headlight Dip Switch This is the input signal from the indicator switch to turn
the Headlight Dips on.
J2 - H Engine Coolant Level Switch This is the input signal from the engine coolant level
switch
J2 - J Cold Start Light This is the input signal from the cold start unit displaying
the cold start status
J2 - K Transmission Filter Bypass Press Switch
J2 - L Hydraulic Level Switch This is the input signal from the hydraulic level switch
J2 - M Park Brake Pressure Switch This is the input signal from the park brake pressure
switch
J2 - N Engine Air Intake Filter Press Switch This is the input signal from the engine air intake pres-
sure switch
Doc. No. 872272 : Rev 0 171

CCU2 PIN LAYOUT

32 PIN CONNECTOR - J1 (BROWN)
J1 - A3J1 - A4 Headlight Dips This is the Output signal from the CCU2 for the Headlight
Dip (24v)
J1 - B3J1 - B4 Headlight Brights This is the Output signal from the CCU2 for the Headlight
Brights (24v)
J1 - C1 System Air Pressure This is the analog input signal from the pneumatic pres-
sure sensor
J1 - C2 Start Signal If the VIN number is valid, the controllers are end of line
programmed, the Start Signal is ON (crank position on
the ignition switch), the transmission (actual gear and
range) is in neutral, the engine RPM < 400 and the truck
is not immobilised; then the engine start message will be
transmitted until the engine RPM > 400 RPM for 500 ms.
If the Ignition status is OFF (off position on ignition
switch), then the engine stop message will be transmitted
until the CCU switches off
J1 - C3J1 - C4 Reverse If the selected gear is less than 0, indicating reverse,

then this output is turned ON, otherwise it is turned OFF
J1 - D3J1 - D4 Rear Wiper Lo Speed This is the Output signal from the CCU2 for the Rear
Wiper Low Speed.
J1 - E1 Scraper Dash Switch Ground input from switch.
J1 - E3J1 - E4 Front Wiper Lo Speed This is the Output signal from the CCU2 for the Front
Wiper Low Speed.
J1 - F1 12 V This input is connected to the centre tap of the battery

set for the CCU2 to measure the lower battery '12V' volt-
age level.
J1 - F2 Horn Switch This is the ground input signal from the steering column
switch indicating a horn request from the operator
J1 - F3J1 - F4 Park Lights If the SSM park light LED status is ON, then the output is
ON, otherwise the output is OFF.
J1 - G3 Ignition Supply to Outputs Valve Power (Ignition Supply, Fuse 25) for the following
CCU2 Outputs: (J2-B4/C4 & J1-D3/D4/E3/E4)
J1 - G4 Ignition Supply to Outputs Valve Power (Ignition Supply, Fuse 25) for the following
CCU2 Outputs: (J2-B4/C4 & J1-D3/D4/E3/E4)
J1 - H1 Work Lights If the SSM work light LED status is ON and the Work
light option is enabled, then the output is ON, otherwise
the output is OFF.
J1 - H3 Ignition Supply to Outputs Valve Power (Ignition supply - Fuse 26) for the following
outputs: (J1-F3, F4, H1, H2)
J1 - H4 Ignition Supply to Outputs Valve Power (Ignition supply - Fuse 26) for the following
outputs: (J1-F3, F4, H1, H2)
172 Doc. No. 872272 : Rev 0

48 PIN CONNECTOR - J2 (BROWN)

J2 - A1 CAN High
J2 - A4 Brake Light Switch 24v Input from brake light switch (Fuse 10)
J2 - B1 CAN Low
J2 - B4 IDL Solenoid For output state change OFF to ON to occur, the acceler-
ator pedal must less than 10% and the SSM IDL LED
status must be ON and additionally for large trucks, the
output shaft speed must be less than 60 RPM. The main
buzzer will beep once a minute with a pop up message
to remind the operator that this function is active. Under
any conditions, if the SSM IDL LED status is OFF, then
the output must be OFF. The output status for a B50D
2-Speed is inverted.
J2 - D2 Hazards Dash Switch This is a 24v input from the hazard switch (Fuse 10).
J2 - E1 Rear Wiper Park Signal Input 24v input from wiper motor (Fuse 37)
J2 - E2 Front Wiper Park Signal Input 24v input from wiper motor (Fuse 37)
J2 - F2 IDL Press Switch
J2 - G4 Rear Wiper High Speed 24v output to wiper motor.
J2 - H1 Park Brake Dash Switch 24v input from park brake switch (Fuse 36).
J2 - H4 Flashing Beacon Light If the SSM Flashing Beacon Light LED status is ON, and
the Flashing Beacon option is enabled, then the output is
ON, otherwise the output is OFF. (24v output)
J2 - J1 Aircon Evaporator Temperature Analog input from evaporator temp sensor (0-5v).
J2- J3 Cab Temperature Analog input from cab temp sensor (0-5v).
J2 - J4 Horn If the Horn input is ON, then the output must be ON, oth-
erwise the output must be OFF. (24v output)
J2 - L1 28 V Battery (KL30) Fuse 4.
J2 - L2 Ground (KL31) E2
J2 - L3 Ignition Supply to Outputs Valve Power, (Ignition supply - Fuse 27) for the following
outputs: (J2-D4-E4-F4-G4)
J2 - L4 Ignition Supply to Outputs Valve Power, (Ignition supply - Fuse 28) for the following
outputs: (J1-A3, A4, B3, B4, J2-H4, J4)
J2 - M1 28V Ignition (KL15) Fuse 29
J2 - M2 Ground (KL31) E2
J2 - M3 Ignition Supply to Outputs Valve Power, (Ignition supply - Fuse 27) for the following
outputs: (J2-D4-E4-F4-G4)
J2 - M4 Ignition Supply to Outputs Valve Power, (Ignition supply - Fuse 28) for the following
outputs: (J1-A3, A4, B3, B4, J2-H4, J4)
Doc. No. 872272 : Rev 0 173

32 PIN CONNECTOR - J3 (BLUE)

J3 - A1 Arctic Reverse Light If selected gear < 0 (reverse), output ON, otherwise out-
put OFF 24v output.
J3 -A2 Recirculation Flap True 24v PWM signal from CCU to actuator signal board.
J3 - A4 Engine Running If the engine speed > 400 RPM, output is ON, otherwise
output is OFF. 24v output.
J3 - B1 Rear Washer Pump 24v output to rear washer pump.
J3 - B2 Left Indicator Light If MDU left indicator status is ON, then this output must
flash ON and OFF at 500ms intervals. If the Hazard in-
put status is ON, then this output must flash ON and OFF
at 500ms intervals unless the MDU right indicator status
is ON, then this output must be ON without flashing. 24v
output.
J3 - B4 Brake Light If the Service Brake input status is ON, or if any of the re-
tarders actual torque values > -10%, then this output
must be ON, otherwise this output must be OFF. 24v
output.
J3 - C1 Front Wiper High Speed 24v output to front wiper.
J3 - C2 Right Indicator Light If MDU right indicator status is ON, then this output must
flash ON and OFF at 500ms intervals. If the Hazard in-
put status is ON, then this output must flash ON and OFF
at 500ms intervals unless the MDU left indicator status is
ON, then this output must be ON without flashing. 24v
output.
J3 - D1 Front Washer Pump 24v output to front washer pump.
J3 - D2 Mirror Heating If the SSM Mirror Heating LED status is ON and the Mir-
ror Heating option is enabled, then the output is ON, oth-
erwise the output is OFF. 24v ouput.
J3 - E1 Overspeed Control For large trucks, if the engine speed exceeds 2270 RPM,
turn this output ON until the output drops below 2100
RPM, then switch the output OFF.For small trucks, if the
engine speed exceeds 2800 RPM, turn this output ON
until the output drops below 2600 RPM, then switch the
output OFF.If the output is ON, simultaneously send
TSC1 to address 16, with a retardation torque request of
-100%. 24v output.
J3 - E2 Hydraulic Cut Solenoid If the Start Signal Input is TRUE switch the output ON
and leave ON until 2 seconds after the Start Signal Input
has been switched off or 400RPM has been exceeded.
24v output.
J3 - E3 Aircon Clutch Solenoid 24v output to clutch solenoid.
J3 - E4 Hydraulic Temperature Sensor Analog ground input from hyd temp sensor.
J3 - F1 Park Brake Solenoid PARK BRAKE FUNCTION - Refer to latest SIB
J3 - F2 Aircon Thermo Switch 24v input from thermo switch (Fuse 35)
J3 - F4 Hardware Detection 24v input (Fuse 36) allows CCU to detect what position it
is in.
J3 - G1 Ignition Supply to Outputs Valve Power (Ignition Supply - Fuse 30) for the following
CCU2 Outputs: (J3-B1/A1/D1/C1/F1/E1)
J3 - G2 Ignition Supply to Outputs Valve Power (Ignition Supply - Fuse 30) for the following
CCU2 Outputs: (J3-B1/A1/D1/C1/F1/E1)
J3 - H1 Power Ground
174 Doc. No. 872272 : Rev 0

J3 - H2 Power Ground
J3 - H3 Ignition Supply to Outputs Valve power (ignition supply - Fuse 31) for the following
CCU2 outputs: J3-A2, D2, E2, E3.
J3 - H4 Ignition Supply to Outputs Valve power (ignition supply - Fuse 31) for the following
CCU2 outputs: J3-A2, D2, E2, E3.
OEU - OUTPUT EXTENSION UNIT

J1 - BROWN (32 PIN)
J2 - BROWN (48 PIN)
J3 - BLUE (32 PIN)
J2 - L1 28 V Battery (KL30) Fuse 3.
J2 - M1 28V Ignition (KL15) Fuse 22.
J2 - L2 Ground(KL31) E2.
J2 - M2 Ground (KL31) E2.
J2 - A1 CAN High
J2 - B1 CAN Low
J3 - H3 Ignition Supply to Outputs Valve power (Ignition supply for outputs - Fuse 24) for
the following outputs: J3-A2, E3, E2, D2.
the following outputs:J3-A2, E3, E2, D2.
J3 - H1 Power Ground E2
J3 - H2 Power Ground E2
J3 - G1 Ignition Supply to Outputs Valve power (Ignition supply for outputs - Fuse 23) for
the following outputs: J3-B1, A2, D1, D1, F1, E1.
the following outputs: J3-B1, A2, D1, D1, F1, E1.
the following outputs: J2-B4, C4 / J1-D3, D4, E3, E4.
the following outputs: J2-B4, C4 / J1-D3, D4, E3, E4.
J2 - L3 Ignition Supply to Outputs Valve power (Ignition supply for outputs - Fuse 20) for
the following outputs: J2-F4, G4, D4, E4, / J1-C3, C4.
J2 - M3 Ignition Supply to Outputs Valve power (Ignition supply for outputs - Fuse 20) for
the following outputs: J2-F4, G4, D4, E4, / J1-C3, C4.
J2 - L4 Ignition Supply to Outputs Valve power (Ignition supply for outputs - Fuse 21) for
the following outputs: J2-H4, J4 / J1-A3, A4, B3, B4.
J2 - M4 Ignition Supply to Outputs Valve power (Ignition supply for outputs - Fuse 21) for
the following outputs: J2-H4, J4 / J1-A3, A4, B3, B4.
the following outputs: J1-H1, H2, F3, F4.
the following outputs: J1-H1, H2, F3, F4.
Doc. No. 872272 : Rev 0 175

J2 - B4 Gear Hold 24v output to Relay 2 (Gear Hold). If the Gear Hold re-
quest status is ON, then the output is ON and TC1 CAN
message must be transmitted to indicate the upshift in-
hibit, otherwise the output is OFF and the TC1 CAN mes-
sage must change back to allow upshift. The gear hold
request status can be set by any one of the following
sources: The SSM Gear Hold button or using the iqan
scraper function, which will hold the transmission in first
gear.
J2 - G4 Engine Overheat/Preselect 2ndLockup Con- 24v output. The software will auto-detect if this output is
trol being used for the Engine Overheat / pre-Select 2nd
function or for the Lockup Control function. This auto de-
tection scheme puts this output On after the ignition
switch is turned on; when the driver selects Forward gear
with the engine running and the output shaft speed less
than 60 rpm it switches the output off and disables all
gear hold requests, if, at this point, the gear range goes
to '2' then Engine Overheat / pre-Select 2nd is detected
and the output is switched back On, alternatively if the
gear range does not go to '2' after 750ms then Lockup
control is detected, at this point all gear hold ingibits are
removed. In Engine Overheat / pre-Select 2nd mode this
output must always be ON unless the engine tempera-
ture > 98°C. In Lockup Control mode to protect the en-
gine from damage due to overspeed conditions (3750
rpm output shaft speed) the transmission lockup clutch
can be opened (Lockup Output ON) to prevent engine
damage. There is hysteresis on this output - it will be
turned OFF again when the output shaft speed goes
below 3330rpm.
J3 -A2 Heater Valve 24v true PWM signal to actuator signal board.
J3 - E2 Feet Actuator 24v ON/OFF signal to feet actuator.
J3 - D2 Middle/Demist Actuator 24v ON/OFF signal to actuator.
MM
15 PIN CONNECTOR - A
A-7 RS 232 Communication protocol with MT2000
A-8 RS 232 Communication protocol with MT2000
A-9 CAM Lo (A) J1939 Can Bus
A - 10 CAM High (A) J1939 Can Bus
21 PIN CONNECTOR - B
B-1 Battery power Fuse 5
B-2 Ground E3
B-4 Output to MT 2000 7.5v (2 amp) output for MT2000 power supply.
B-5 Wake up output 24v wake up output MM21C, Pin 6.
B-6 Pulsed input Synchronization input from MM18E, pin 3.
176 Doc. No. 872272 : Rev 0

21 PIN CONNECTOR - C
C-1 12v supply 12v ignition input from fuse 46.
C-2 Output (12v max) Output to driver ID.
C-4 24v Supply
C-5 24v Input Ignition status from fuse 36.
C-6 Not Used 24v wake up input from MM21B, pin 5.
C - 15 Ground E3.
C - 16 24v Supply 24v battery supply fronfuse 5.
18 PIN CONNECTOR - E
E-2 24V output Driver ID LED
E-3 24V output Wake up syncronization to MM21B, Pin 6.
DID
4 PIN CONNECTOR
K1 - 1 24v input Ignition input from Fuse 37.
K1 - 2 12v max input Input from MM21C, pin 2.
K1 - 3 Ground E3.
K1 - 4 24v input LED input from MM18E, pin 2.
Doc. No. 872272 : Rev 0 177

SSM
1 2 3 4 5
1 2 3
8
7 9
4 5 6
18
10
7 8 9
A
11 17
. 0
12 13 15 14 16
TD0006456
FUNCTION ASSOCIATED OUTPUT
1 AIRCON CCUJ3-E3
2 AIRCON RECIRCULATION CCUJ3-A2
3 AIRCON FAN SPEED OEUJ1-E3/E4 OEUJ1-C3/C4 OEUJ1-H1/H2
4 DIFFLOCK (CTD) CCU2 J2-F4
5 INTER-AXLE DIFFLOCK (IDL) CCU2 J2-B4

TEMP CONTROL
6 OEU J3-A2
7 AIR FLOW SELECTOR OEU J3-E2 OEU J3-D2
8 HIGH RANGE OEU J2-C4 (NOT USED)
9 GEAR HOLD OEU J2-B4
10 BIN RESTRICTION & PRODUCTION

OPTIONS
11 DRIVELINE ASSIST/HARD STOPS
12 FLASHING BEACON CCU2 J2-H4
13 MIRROR HEATING CCU2 J3-D2
14 PARK LIGHTS/HEAD LIGHTS CCU2 J1-F3/F4 CCU2 J1 A3/A4 (DIPPED BEAM) CCU2 J1-B3/B4
(BRIGHTS)
15 WORK LIGHT CCU2 J1-H1/H2 (OPTIONAL)
16 REAR WIPER WASHER CCU2 J3-B1 REAR WASHER PUMP CCU2 J1-D3/D4 REAR
WIPER LOW SPEED
178 Doc. No. 872272 : Rev 0

17 FRONT WIPER WASHER CCU2 J3-D1 FRONT WASHER PUMP CCU2 J1-E3/E4 FRONT
WIPER LOW SPEED
18 RETARDER CONTROL CAN MESSAGE: TSC1 TO TCU
Doc. No. 872272 : Rev 0 179

MDU2 GAUGES
30 40 50
20 60
10 70
0 20 30 80
km/h 10 40
mph 0 50
COOLANT RPM
TEMP
n/min
4 3 2
TRANS
TEMP FUEL
5 1 TD0006457
FUNCTION INPUT ORIGIN BUZZER MAIN IDIOT LIGHT POP UP TEXT
1 FUEL (PERCENT- ANALOG INPUT ON 1 SEC CONTIN- NOT ACTIVE "LOW FUEL" SHOULD
AGE - %) THE MDU2 J1-N. UOUS WHEN BE DISPLAYED FOR 3
THE LED IS SECONDS AFTER THE
SWITCHED ON. ENGINE IS STARTED.
2 ENGINE RPM J1939 MESSAGE CONTINUOUS 0.5 SEC INTERMIT- NONE

FROM THE ECU. TENT
3 SPEEDOMETER J1939 MESSAGE NONE NONE NONE

(KM/H, MPH) FROM CCU CCIS.
4 ENGINE COOL- J1939 MESSAGE 1.) 0.5 SEC. IN- NOT ACTIVE NONE
ANT TEMPERA- FROM ECU. TERMITTENT
TURE
2.) CONTINU- 2.) 0.5 SEC. INTERMIT- NONE

OUS TENT
5 TRANSMISSION A.) J1939 MESSAGE 1.) 0.5 SEC. IN- NOT ACTIVE NONE
OIL TEMPERA- FROM TCU. TERMITTENT
TURE
2.) CONTINU- 2.) 0.5 SEC. INTERMIT- NONE

OUS TENT
180 Doc. No. 872272 : Rev 0

MDU2 WARNING LIGHTS
1 2 3 4 5 6 7 8 9 10 11

START LEVEL FAULT STEERING BRAKE PRESSURE TEMP
r/min
TYRE TRANS RETARDER ENGINE BATTERY BIN INTER-AXLE DIFF HIGH

12 13 14 15 16 17 18 19 20 21 22
TD0006458
MAIN IDIOT
FUNCTION INPUT ORIGIN TRIGGER LIGHT STATUS BUZZER
LIGHT
1 COLD START SWITCHING IN- ACTIVE LOW CONTINUOUS NOT ACTIVE NOT ACTIVE
PUT TO MDU2 ON
J2-J.
2 LOW ENGINE SWITCHING IN- ACTIVE HIGH CONTINUOUS CONTINUOUS 0.5 SEC. INTER-
COOLANT PUT TO MDU2 OR OPEN FOR 5 ON ON MITTENT
LEVEL J2-H SEC
3 ENGINE FAIL- J1939 MESSAGE, NORMAL: LAMP CONTINUOUS CONTINUOUS 0.5 SEC. INTER-
URE DM1 - LAMP STA- STATUS = ON ON MITTENT
TUS 00DM1 MES-
SAGE WITH
STOP LAMP
AND PROTECT
LAMP ONLY.
4 EMERGENCY SWITCHING IN- ACTIVE LOW 0.5 SEC. INTER- CONTINUOUS 0.5 SEC. INTER-
STEERING PUT TO MDU2 MITTENT ON MITTENT
ONLY J2-E.
5 MAIN GENERAL 1.) AS PER ACTIVATION OF COLUMN "MAIN IDIOT LIGHT".2.) WHEN GAUGES ARE AT 2ND
WARNING / ID- LEVEL WARNING IN RED ZONE.
IOT LIGHT
6 HEADLIGHTS J1939 MESSAGE IF THE BRIGHT CONTINUOUS NOT ACTIVE NOT ACTIVE
BRIGHT FROM THE CCU OUTPUT ON ON
OUTPUT. THE CCU IS AC-
TIVE.
7 ENGINE J1939 MESSAGE ENGINE RPM CONTINUOUS CONTINUOUS 0.5 SEC. INTER-
OVERREV FROM ECU. HIGHER THAN ON ON MITTENT
XXXX RPM.
Doc. No. 872272 : Rev 0 181

8 PARK BRAKE SWITCHING IN- ACTIVE LOW CONTINUOUS NOT ACTIVE NOT ACTIVE.
PUT TO MDU2 ON WHEN IN NEU-
J2- M. TRAL AND
INETERMITTAN
T WHEN IN
GEAR.
9 LOW ACCUMU- SWITCHING IN- ACTIVE LOW 0.5 SEC. INTER- CONTINUOUS 0.5 SEC. INTER-
LATOR PRES- PUT TO MDU2 MITTENT ON MITTENT
SURE J2- C.
10 WET DISC J1939 MESSAGE TRIGGER 1: > 0.5 SEC. INTER- 0.5 SEC. INTER- NOT ACTIVE.
BRAKE TEM- FROM CCU. 95 DEG C FOR MITTENT MITTENT
PERATURE LONGER THAN
5 SEC.
TRIGGER 2: > CONTINUOUS CONTINUOUS 0.5 SEC. INTER-

100 DEG C FOR ON ON MITTENT
LONGER THAN
5 SEC.
11 HYDRAULIC SWITCHING IN- ACTIVE LOW CONTINUOUS 0.5 SEC. INTER- NOT ACTIVE.
PUT TO MDU2 ON MITTENT
J2- L.(HYDRAU-
LIC LEVEL)
SWITCHING IN- ACTIVE LOW CONTINUOUS 0.5 SEC. INTER- NOT ACTIVE.
PUT TO MDU2 ON MITTENT
J2- A.(HYDRAU-
LIC FILTER)
J1939 MESSAGE TRIGGER 1: > CONTINUOUS 0.5 SEC. INTER- NOT ACTIVE.
FROM CCU.(HY- 95 DEG C FOR ON MITTENT
DRAULIC OIL LONGER THAN
TEMP) 5 SEC.
TRIGGER 2: > CONTINUOUS CONTINUOUS 0.5 SEC. INTER-

100 DEG C FOR ON ON MITTENT
LONGER THAN
5 SEC.
12 DIRECTION J1939 MESSAGE IF THE LEFT IN- IN PHASE WITH NOT ACTIVE. NOT ACTIVE.
LEFT FROM CCU OUT- DICATOR OUT- THE OUTPUT
PUT STATUS. PUT ON THE
CCU IS ACTIVE.
13 TYRE PRESS J1939 MESSAGE, NORMAL: LAMP CONTINUOUS NOT ACTIVE. NOT ACTIVE.
INDICATOR DM1 - LAMP STA- STATUS = ON
TUS 00DM1 MES-
SAGE WITH
ANY LAMP STA-
TUS = 01
14 TRANSMISSION J1939 MESSAGE, NORMAL: LAMP CONTINUOUS CONTINUOUS 0.5 SEC. INTER-
FAILURE DM1 - LAMP STA- STATUS = ON ON MITTENT
TUS 00DM1 MES-
SAGE WITH
STOP LAMP
AND PROTECT
LAMP ONLY.
15 EXHAUST A.) J1939 MES- IF THE ACTUAL CONTINUOUS NOT ACTIVE NOT ACTIVE
BRAKE / SAGE FROM RETARDER ON
TRANSMISSION TRANSMISSION TORQUE IS
RETARDER RETARDER.B.) LESS THAN
J1939 MESSAGE -5%.
FROM ENGINE
RETARDER.
16 ENGINE AIR FIL- SWITCHING IN- ACTIVE LOW CONTINUOUS 0.5 SEC. INTER- NOT ACTIVE.
TER BYPASS PUT TO MDU2 ON MITTENT
J2- N.
182 Doc. No. 872272 : Rev 0

17 BATTERY J1939 MESSAGE, NORMAL: LAMP CONTINUOUS 0.5 SEC. INTER- NOT ACTIVE.
CHARGE DM1 - LAMP STA- STATUS = ON MITTENT
TUS AND BAT- 00DM1 MES-
TERY SPN. SAGE WITH
ANY LAMP STA-
TUS = 01 AND
SPN =158
18 BIN UP J1939/PROPRI- IF THE BIN CONTINUOUS NOT ACITVE. NOT ACTIVE.

ETY MESSAGE POSITION IS > ON
FROM CCU. 5%.
19 INTER-AXLE J1939 MESSAGE IF THE IDL CONTINUOUS NOT ACTIVE. NOT ACTIVE.
DIFFLOCK (IDL) FROM THE IDL PRESS SWITCH ON
PRESS SWITCH. STATUS IS ON.
20 CONTROL SWITCHING IN- ACTIVE LOW CONTINUOUS NOT ACTIVE. NOT ACTIVE.
TRACTION DE- PUT TO MDU2 ON
VICE (CTD) J2- D.
21 HIGH RANGE J1939 MES- IF THE 4 STA- CONTINUOUS NOT ACITVE. NOT ACTIVE.
SAGES FROM TUS CHANGE ON
THE CCU.(2 FROM OFF TO
SPEED PRESS ON AND WHEN
SWITCH FRONT THE 4 STATUS
2 SPEED CHANGE FROM
SWITCH MIDDLE ON TO OFF.
2 SPEED
SWITCH REAR 2
SPEED SWITCH)
22 DIRECTION J1939 MESSAGE IF THE RIGHT IN FASE WITH NOT ACTIVE. NOT ACTIVE.
RIGHT FROM CCU OUT- INDICATOR THE OUTPUT
PUT STATUS. OUTPUT ON
THE CCU IS AC-
TIVE.
Doc. No. 872272 : Rev 0 183

184 Doc. No. 872272 : Rev 0

SECTION 4. REFERENCES
ENGINE FAULT CODES (ADM)
ADM2 fault
ADM2 fault
codes
codes Description Remedial action Pin
(J1939)
(k-line)
SPN/FMI
45/3 10003 Decompression valve Open circuit - Check wiring 15/10

MBR_KD - Check solenoid valve
45/4 10004 Decompression valve Shorted to ground - Check wiring 15/10

MBR_KD - Check solenoid valve
84/3 10103 Vehicle speed signal Open circuit - Check wiring 15/03
C3 - Check parameter 08/01
84/4 10104 Vehicle speed signal Shorted to ground - Check wiring 15/03
C3
84/14 10114 Vehicle speed signal Value not plausible - Check parameter 08/01 15/03
C3
91/0 10200 Analog accelerator Accelerator pedal not - Restart accelerator pedal 21/11
pedal adjusted adjustment routine
- Check wiring
- Limit value idle operation
position:
5,0 V
- Limit value kickdown
position: 4,9 V
91/2 10202 Analog accelerator Voltage not plausible - Pedal unit exchange, if 21/11
pedal defective
- Check wiring
position:
5,0 V
position: 4,9 V
91/3 10203 Analog accelerator Voltage too high or - Pedal unit exchange, if 21/11
pedal shorted to battery voltage defective
- Check wiring
position:
5,0 V
position: 4,9 V
91/4 10204 Analog accelerator Voltage too low or shorted - Pedal unit exchange, if 21/11
pedal AFPS to ground defective
- Check wiring
position:
5,0 V
position: 4,9 V
Doc. No. 872272 : Rev 0 185

ADM2 fault
ADM2 fault
codes
(J1939)
(k-line)
SPN/FMI
98/0 10400 Oil level Oil level to high - Oil discharge with to strong PLD-MR
overstocking.
- Remark: This problem can
occur also if in PLD-MR the
false type of oil pan were
programmed.
98/1 10401 Oil level Low oil level - Refill oil PLD-MR
98/14 10414 Oil level Oil level too low - Refill oil PLD-MR
- Remark: This problem can
occur also if in PLD-MR the
false type of oil pan were
programmed.
100/1 10501 Oil pressure sensor Low oil pressure - Check oil pump and oil PLD-MR
circuit
100/14 10514 Oil pressure sensor Oil pressure too low - Check oil pump and oil PLD-MR
circuit.
107/0 10800 Air filter sensor Air pressure too high - Check wiring. 15/08
107/3 10803 Air filter sensor Open circuit - Check wiring. 15/08
107/4 10804 Air filter sensor Shorted to ground - Check wiring. 15/08
110/0 10900 Coolant temperature High coolant temperature - Cooling-water level and PLD-MR
cooling circuit check.
110/14 10914 Coolant temperature Coolant temperature too - Cooling-water level and PLD-MR
high cooling circuit check.
111/1 11001 Coolant level Low coolant level - Refill coolant 15/07
- Check wiring
111/3 11003 Coolant level Open circuit - Check wiring 15/07

- Voltage must be larger than
2,0 V.
111/4 11004 Coolant level Shorted to ground - Check wiring. 15/07
158/0 11100 Terminal 15 (ignition) Over voltage - Check battery voltage 21/02
- Check parameter 2/08
(24V/12V selection)
158/1 11101 Terminal 15 (ignition) Under voltage - Check battery voltage 21/02
- Check parameter 2/08
(24V/12V selection)
558/1 11701 Idle switch (analog Wiring idle validation - Check wiring 21/12 and
pedal) switch GAS1 and GAS2 - Pedal unit exchange, if 21/13 or
twisted or open circuit at defective 21/14
potentiometer ground FP-
558/5 11705 Idle switch (analog Both switches open circuit - Check wiring 21/12 and
pedal) (GAS2 + GAS1 open) - Pedal unit exchange, if 21/13
defective
558/12 11712 Idle switch (analog Both switches closed - Check wiring 21/12 and
pedal) (GAS2 + GAS1 closed) - Pedal unit exchange, if 21/13
defective
599/12 11812 Cruise control switch Both switches closed - Check wiring 18/04 and
CC+ and CC- - Check cruise control switch 18/05
186 Doc. No. 872272 : Rev 0

ADM2 fault
ADM2 fault
codes
(J1939)
(k-line)
SPN/FMI
601/12 11912 Cruise control switch Both switches closed - Check wiring 18/04 and
CC+ and CC- - Check cruise control switch 18/05
620/3 12103 Power supply analog Voltage too high - Supply voltage 21/09
pedal (AFP+) > 5,2 V.
620/4 12104 Power supply analog Voltage too low - Supply voltage 21/09
pedal (AFP+) < 4,8 V.
625/2 12202 CAN link ADM2 - MR No communication with - Check wiring (engine CAN) -
MR - Check configuration:
MR parameter (../..) And

ADM2 parameter 1/01 to be
set to equal functionality (0ne
wire capability)
625/14 12214 CAN link ADM2 - MR One wire mode - Check wiring (engine CAN) -
- check configuration:
MR parameter (../..)
And ADM2 parameter
1/01 to be set to equal
functionality (0ne wire
capability)
629/12 12312 ADM2 Internal error - -
677/5 13305 Output relay 1 Open circuit - Check wiring 15/12

- Check relay 1
677/6 13306 Output relay 1 Shorted to ground - Check wiring 15/12

- Check relay 1
730/0 13900 Output relay 2 Grid heater: no increasing - Check wiring 15/09
boost temperature after - Check relay 2
activation
- Check grid heater
730/1 13901 Output relay 2 Grid heater: relay - Check wiring 15/09
permanently closed - Check relay 2
730/2 13902 Output relay 2 Grid heater: relay - Check wiring 15/09
permanently closed - Check relay 2
730/3 13903 Output relay 2 Voltage too high or - Check wiring 15/09
shorted to battery voltage
730/4 13904 Output relay 2 Voltage too low or shorted - Check wiring 15/09
to ground - Check relay 2
974/2 14202 Remote pedal Supply voltage out of - limit values for the supply 18/17
HFG range voltage of the HFG:
Minimum value: 4,8 V and
maximum value: 5,2 V.
974/3 14203 Remote pedal HFG Voltage too high or - Check wiring 18/18
shorted to battery voltage - Check remote pedal
974/4 14204 Remote pedal Voltage too low or shorted - Check wiring 18/18
HFG to ground - Check remote pedal
1004/3 14403 Output relay 4 Open circuit - Check wiring 18/01

- Check relay 4
Doc. No. 872272 : Rev 0 187

ADM2 fault
ADM2 fault
codes
(J1939)
(k-line)
SPN/FMI
1004/4 14404 Output relay 4 Shorted to ground - Check wiring 18/01

- Check relay 4
1005/3 14503 Output PWM pedal Open circuit - Check wiring. 15/05
supply or
transmission
1005/4 14504 Output PWM pedal Shorted to ground - Check wiring. 15/05
supply or
transmission
1006/3 14603 Exhaust brake valve Open circuit - Check wiring 15/06
MBR_BK - Check exhaust brake valve
1006/4 14604 Exhaust brake valve Shorted to ground - Check wiring 15/06
MBR_BK - Check exhaust brake valve
639/2 14902 J1939 CAN- interface CAN identifiers ETC#1 or - PGN ETC1 was received
ACC#1 missing only once and did not
disappear.
1015/1 15001 PWM accelerator No supply voltage - Check wiring 15/05

pedal
1015/2 15002 PWM accelerator Both signals missing - Check wiring

pedal (GAS1 and GAS2) - Pins 21/13, 21/12, 15/05 ,
21/14.
1015/3 15003 PWM accelerator Signal GAS2, not - Check wiring

pedal available - Pins 21/13, 15/05 , 21/14.
1015/4 15004 PWM accelerator Signal GAS1, not - Check wiring

pedal available - Pins 21/12, 15/05 , 21/14.
1015/5 15005 PWM accelerator Accelerator pedal not - Restart accelerator pedal -
pedal adjusted adjustment routine
1015/6 15006 PWM accelerator Idle position out of - Restart accelerator pedal -
pedal adjusted range adjustment routine
1015/7 15007 PWM accelerator Accelerator pedal out of - Restart accelerator pedal -
pedal adjusted range adjustment routine
188 Doc. No. 872272 : Rev 0

ENGINE FAULT CODES (PLD-MR)
Fault-codes
Fault-codes
SAE J1939 Description Repair instructions
PLD-MR
SPN/FMI
45/12 16409D Heater flange Open circuit fault (heater The heating flange becomes after
flange defective) Kl. 15 uniquely briefly switched
on. Here if no break-down of the
battery voltage is recognized, the
heating flange is classified as
defective. Error threshold and
cyclic duration are deposited in
the data record.
94/0 11715 Fuel pressure sensor or Measuring range exceeded If a fuel pressure sensor or a
fuel pressure & or short circuit to terminal 30 combination sensor fuel pressure
temperature sensor / terminal 15. & temperature is fitted to the
engine depends on the engine
make
94/1 11716 Combination input (FPS, Remains under measuring

P-DK) range or short circuit to
ground.
94/2 11717 Combination input (FPS, Signal not plausible.

P-DK)
94/3 13015 Combination input (FPS, Open circuit

P-DK)
94/4 13016 Combination input (FPS, Short circuit to ground

P-DK)
94/14 11917 Fuel line signal not Measured value not

plausible * plausible
98/2 02026 Engine oil circulation* Fluid level too high / too low - Message via CAN: Warning oil
level too high (=98/0) or advance
warning (=98/1) or Warning oil
level too low (=98/1)
02517 Oil level sensor (up to Measured value not - Check oil level, correct if
diagnosis version 4) plausible necessary.
- Check wire if shorted to battery,
repair or replace if necessary.
- Check oil level sensor, replace if
necessary. nominal value: 20-25
Ohm
- Perform functional check.
98/4 02515 Oil level sensor ** Measuring range exceeded - Check oil level, correct if
necessary.
- Check wire for ground short,
necessary. Nominal value: 20-25
Ohm
98/3 02516 Oil level sensor ** Measured value not - Check oil level, correct if
plausible necessary.
- Check wire for ground short,
necessary. Nominal value: 20-25
Ohm
Perform functional check.
Doc. No. 872272 : Rev 0 189

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
98/5 02509 Oil level sensor ** Open circuit fault - Check oil level sensor - replace
if necessary.
- Check wire for open circuit fault,
Perform functional check
100/2 11617 Oil pressure sensor Signal not plausible - Check oil level, correct if
necessary.
- Check wire for open circuit fault,
- Check oil pressure sensor,
replace if necessary.
100/3 11615 Oil pressure sensor Measuring range exceeded - Check oil pressure sensor,
- Check wire for open circuit fault
or if shortened to battery voltage -
repair if necessary.
100/4 11616 Oil pressure sensor Remains under measuring - Check oil pressure sensor -
range replace if necessary.
- Check wire for short circuit to
ground - repair if necessary.
100/14 02020 Engine oil circulation ** Pressure too low Message via CAN: Oil pressure
advance warning or warning
102/0 11820 Booster path * Boost pressure too high - If fault codes 11415 or11417 are
also present, process them first.
- Boost pressure system (boost
air tubes, boost air cooler) visual
check
102/1 11818 Booster path* Booster path defective - Check tubes and connections
between turbo charger, boost air
cooler and the boost air tubes for
leakage.
- Check boost air cooler.
102/2 11417 Boost pressure sensor Measured value not - Check wire for open circuit fault -
plausible repair if necessary.
- Check boost pressure sensor,
- If fault code 01315 or 01316
also actual: replace and calibrate
ECU engine control (e.g.
MR-PLD).
102/3 11415 Boost pressure sensor Measuring range exceeded - Check boost pressure, replace if
necessary.
and if shorted to battery voltage,
190 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
102/4 11416 Boost pressure sensor Remains under measuring - Unplug the connector from
range combination sensor. fault codes
01215 and 11415 actual: replace
combination sensor.
ground, repair if necessary.
102/13 11873 Booster path / boost Max. output of booster

pressure control ** speed balancing governor
102/13 11874 oder Booster path / boost Set value deviation too high (with power reduction)
01874 pressure control - Check booster path fault codes
11874* - 01874**
102/13 11875 Booster path / boost Boost pressure deviation too

pressure control* high
102/13 11876 Booster path / boost Braking power too low

pressure control *
102/13 12415 Scavenging gradient (boost pressure) measuring - Check sensor - replace if
sensor (P2S-P3)** range exceeded necessary.
- Check wire for open circuit
102/13 12416 Scavenging gradient (boost pressure) remains - Check sensor - replace if
sensor (P2S-P3)** under measuring range necessary.
- Check wire for open circuit
103/7 12612 No speed booster 1** No engine speed
103/14 12712 No speed booster 2** No engine speed
105/0 01822 Booster path ** Temperature to high - Temperature of boost pressure

too high
105/3 11215 Boost temperature sensor Measuring range exceeded - Check temperature sensor -
- Nominal value: 2.4 kOhm
(corresponds to 21°C)
- Check wire if connected to
battery voltage and if open circuit
fault - repair if necessary.
105/4 11216 Boost temperature sensor Remains under measuring - Check temperature sensor -
range replace if necessary.
110/0 02122 Coolant temperature Temperature too high

sensor *
110/3 11515 Coolant temperature Measuring range exceeded - Check sensor - repair or replace
sensor if necessary.
or if shortened to battery voltage -
Doc. No. 872272 : Rev 0 191

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
110/4 11516 Coolant temperature Remains under measuring - Check sensor - repair or replace
sensor range if necessary.
- Check wire for open circuit fault -
158/2 12219 Terminal 15 detection * Inconsistency MRFR - Check fuse - replace if

terminal 15 necessary.
- Check wires and plug
connectors for open circuit fault -
158/2 12319 Terminal 50 detection* Inconsistency MRFR - Check wires and plug
terminal 50 connectors for open circuit fault -
- Check wires and plug
connectors for open circuit fault -
168/3 07542 Terminal 30, battery Nominal range exceeded - 24 V-Mode: 30 V, 12 V-Mode:
voltage 16 V
- Alternator or governor defect
168/4 07543 Terminal 30, battery Remains below nominal - 24 V-Mode: 22 V, 12 V-Mode:
voltage range 10 V
- Battery defect
- Alternator, governor or fuse
defect
174/3 11115 Fuel temperature sensor Measuring range exceeded - Check wire - repair or replace if
necessary.
- Check wire if shortened to
battery voltage and if open circuit
fault - repair if necessary.
- Perform functional check
174/4 11116 Fuel temperature sensor Remains under measuring - Check sensor - repair or replace
range if necessary.
175/3 01015 Oil temperature sensor Measuring range exceeded - Check oil temperature sensor
and replace if necessary.
(corresponds to 21 °C)
- Check wire for ground short -
192 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
175/4 01016 Oil temperature sensor Remains under measuring - Check oil temperature sensor
range B11 and replace if necessary.
(corresponds to 21 °C)
- Check wire for ground short -
190/0 10530 Engine speed Engine speed too high - Inform about authorized engine
speed
- Delete fault memory
609/11 04056 Internal fault* Backup control defective* - Check all affected connectors,
plug connections and electrical
components for damage, loose
contact, corrosion etc. and repair
if necessary.
- If fault code is still present,
renew and program control unit
609/12 01315 Ambient pressure sensor Measuring range exceeded - If fault codes 11415 or 11416
are present - remove them first
- Fault code 01315 remains
present: read out actual values
014 and 015 and compare with
each other.
- Actual value should be inside
tolerance band (+/- 10%) while
engine stops.
609/12 01316 Ambient pressure sensor Remains under measuring - If fault codes 11415 or 11416
range are present - remove them first
present: read out actual values
014 and 015 and compare with
each other.
- Actual value inside tolerance
band (+/- 10%) while engine
stops: replace and program ECU
engine control (e.g. MR-PLD).
609/12 04024 Internal fault Auxiliary controller defective - Check all affected connectors,
if necessary.
609/12 14034D Internal fault** HS-transistor PVB1 Change control unit

high-resistance High
side-Transistor
609/12 14035D Internal fault** HS-transistor PVB2 Change control unit**

high-resistance
609/12 14036D Internal fault HS-transistor PV5 Change control unit**

high-resistance
Doc. No. 872272 : Rev 0 193

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
609/12 04038 Internal fault* High resistance starter Present, remove this fault code
driver (redundant-/auxiliary first.
path) - Check all affected connectors,
if necessary.
609/12 14038 Internal fault** Starter driver - Check all affected plugs, plug
high-resistance (main path) connectors and electrical
if necessary.
609/12 14039 Internal fault* Starter driver low-resistance - Check all affected plugs, plug
(main path or auxiliary path) connectors and electrical
if necessary.
609/12 04040 Internal fault Level detection starter - Check all affected plugs, plug
defective connectors and electrical
if necessary.
609/12 14041 Internal fault (till diagnosis PV- High side- transistor - Check all affected plugs, plug
version 4) defective connectors and electrical
if necessary.
609/12 14054 Internal fault CAN-data area defective - Check all affected plugs, plug
connectors and electrical
if necessary.
- If fault code is still present -
replace and program control unit.
609/12 18039 Internal fault** Starter output stage with low Main branch: During the controller
impedance (main branch or initialization the two transistors of
branch of emergency) or the main branch are alternating
load (relay) also to high switched on briefly. The level at
resistance and/or to high the starter output changes
inductance. thereby on „High“, the main
branch is classified as low
impedance.
Backup branch: If that changes
for clamp 50 signal on „High“ and
follows this level change a
change of the level at the starter
output before the starter output
stage was activated, the backup
branch is classified as low
impedance.
194 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
609/14 04037 Internal fault Cylinder number implausible - Check all affected connectors,
if necessary.
609/14 04047 Internal fault Characteristic data map - Check all affected connectors,
defective plug connections and electrical
if necessary.
609/14 04048 Internal fault Cylinder number implausible - Check all affected connectors,
if necessary.
609/14 14049 Internal fault ** Parametrization fault - Check all affected plugs, plug
if necessary.
609/14 04050 Internal fault Incorrect hardware detection - Check all affected connectors,
if necessary.
609/14 04051 Internal fault EEPROM: Checksum failure - Check all affected connectors,
1 (memory fault) plug connections and electrical
if necessary.
609/14 14052 Internal fault EEPROM: CKS- fault 2 - Check all affected plugs, plug
(groups vehicle parameters) connectors and electrical
if necessary.
- If fault code is still present -
replace and program control unit.
609/14 24053 Internal fault ** EEPROM: Checksum- fault - Check all affected connectors,
3 (block production or plug connections and electric
immobilizer) components for damage, loose
contact, corrosion etc., and repair
if necessary.
- If fault code still present, renew
and calibrate control unit.
611/4 06506 Oil separator* Short circuit to ground

diagnostic line
611/12 06564 Oil separator* Oil separator defective
Doc. No. 872272 : Rev 0 195

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
625/2 10102 CAN connection CAN data not plausible - Work off actual faults of SG FRE
apart from CAN data bus fault
codes 10201; 00202 and 10203.
625/2 10104 CAN connection No connection to CAN - Check CAN connection to SG

FRE
- Check cables, connectors, plug
components for damage, correct
connection, loose contact and
corrosion, repair if necessary.
- Remove engine CAN bus fault in
the SG FRE
- Communication with the ECU
engine control (e.g. MR-PLD)
restored: check calibration of
ECU engine control (e.g.
MR-PLD) for one wire capability.
625/14 10100 CAN connection CAN-High defective - Check for open circuit fault -
- Switch on ignition
- Delete fault memory in ECU
- Delete fault memory in SG FRE
625/14 10101 CAN connection CAN-Low defective - Check wire for open circuit fault,
repair of replace if necessary
- Switch on ignition
- Delete fault memory in ECU
- Delete fault memory in SG FRE
625/14 10149 CAN connection Parameter fault CAN - Check parameters and
636/1 10310 Crankshaft position sensor Crankshaft level too low - Pull out position sensor while
engine is stopped and perform
visual check.
- Remove metal pieces / shavings
if necessary.
- Replace position sensor in the
case of mechanical damage
(clear stress marks)
- Replace clamping sleeve of the
position sensor if necessary.
- Press-in speed (position) sensor
during engine standstill until
mechanical limit stop.
636/3 10309 Crankshaft position Crankshaft sensor open - Check wire and position sensor
circuit fault for open circuit fault - Replace if
necessary nominal value 1.2
kOhm
196 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
636/4 10308 Crankshaft position Crankshaft sensor ground - Check wire and position sensor
for ground short - replace if
necessary
Nominal value 1.2 kOhm
636/7 10311 Crankshaft position sensor Crankshaft/camshaft signal - Pull out position sensor during
assignment not plausible engine standstill and perform
visual check.
(clear stress marks).
- Check crankshaft and camshaft
position sensor for tight fitting -
replace clamping sleeve if
necessary.
- Check wires at plug connection
for damage, correct connection
and corrosion, repair if necessary.
- Check crankshaft- and camshaft
position sensor at plug for
interchanging.
636/8 10312 Crankshaft position Crankshaft timeout - no - Press in speed (position) sensor
crankshaft signal during engine standstill until
Timeout mechanical limit stop.
- Fault code 10309 actual: work
off this fault code.
- Fault code 10312 actual: check
crankshaft position sensor,
Nominal value 1.2 kOhm
636/14 10313 Crankshaft position Crankshaft sensor wrong - Connect the position sensor
polarity correctly
651/3 24805 Control solenoid valve** Shortened to battery voltage - Switch off solenoid valves bank
High side bank 1 1
651/3 24905 Control solenoid valve** Shortened to battery voltage - Switch off solenoid valves bank
High side bank 2 2
651/4 24806 Control solenoid valve** Ground short Low side bank - Switch off solenoid valves bank
1 1
651/4 24906 Control solenoid valve** Ground short Low side bank - Switch off solenoid valves bank
2 2
651/5 15027 Control failure Control cylinder 1 disturbed Important note:

injector-/solenoid valve - Upon removing mechanical or
electrical faults at the injector
valves, the engine-smoothness
control has to be set to zero.
651/6 25028 Solenoid valve cylinder 1** Short circuit injector Important note:
solenoid valve cylinder 1 - Upon removing mechanical or
valves, the engine smoothness
651/7 15026 contact recognition No contact cylinder 1 Important note:

injector-/solenoid valve - Upon removing mechanical or
Doc. No. 872272 : Rev 0 197

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
651/12 09044 Engine-smoothness LRR-limitation cylinder 1 Important note:

cylinder 1 - Upon removing mechanical or
651/14 09045 Individual cylinder adaption EZA-limitation cylinder 1 Important note:

- Upon removing mechanical or
control has to be set to zero
652/5 15127 Injector-/solenoid valve Control cylinder 2 disturbed - Upon removing mechanical or
cylinder 2 / failure electrical faults at the injector
- The engine-smoothness control
can be set to zero in the menu
“controls” at the menu level
“check engine-smoothness
control”.
652/6 25128 Solenoid valve cylinder 2** Short circuit injector-/ - Check electrical screw
connections of the affected
injector valve for short circuit.
- Disconnect electrical screw
injector valve.
652/7 15126 Contact recognition No contact cylinder 2 - Upon removing mechanical or

injector-/solenoid valve electrical faults at the injector
cylinder 2 valves, the engine-smoothness
- The engine-smoothness control
can be set to zero in the menu
“controls” at the menu level
“check engine-smoothness
control”.
652/12 09144 Injector-/solenoid valve Engine-smoothness control: Important note:

cylinder 2 LRR-limitation cylinder - Upon removing mechanical or
652/14 09145 Injector-/solenoid valve Individual cylinder Important note:

cylinder adaptation: EZA-limitation - Upon removing mechanical or
cylinder electrical faults at the injector
653/5 15227 Injector-/solenoid valve Control cylinder 3 disturbed Important note:

cylinder 3 / failure - Upon removing mechanical or
653/6 25228 Injector-/solenoid valve Short circuit injector-/ - Check electrical screw
cylinder 3** solenoid valve cylinder 3 connections of the affected
injector valve.
198 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
653/7 15226 Injector-/solenoid valve Contact recognition Important note:

cylinder 3 injector-/solenoid valve: no - Upon removing mechanical or
contact cylinder 3 electrical faults at the injector
653/12 09244 Injector-/solenoid valve: Engine-smoothness control: Important note:

cylinder 3 LRR-limitation cylinder - Upon removing mechanical or
653/14 09245 Injector-/solenoid valve: Individual cylinder Important note:

cylinder 3 adaptation: EZA-limitation - Upon removing mechanical or
cylinder 3 electrical faults at the injector
654/5 15327 Control failure Contact recognition Important note:

injector-/solenoid valve injector-/solenoid valve: no - Upon removing mechanical or
injector valve.


cylinder 4 LRR-limitation cylinder 4 - Upon removing mechanical or
654/14 09345 Injector-/solenoid valve Individual cylinder adaption: Important note:

cylinder 4 EZA-limitation cylinder 4 - Upon removing mechanical or

cylinder 5 ** solenoid valve cylinder 5 connections of the affected
injector valve.
Doc. No. 872272 : Rev 0 199

Fault-codes
Fault-codes
PLD-MR
SPN/FMI



656/5 15527 Injector-/solenoid valve Control failure Important note:

cylinder 6 injector-/solenoid valve: - Upon removing mechanical or
control cylinder 6 disturbed electrical faults at the injector
injector valve.


656/14 09545 Injector-/solenoid valve Individual cylinder adaption: Important note:

cylinder 6 EZA-limitation cylinder 6 - Upon removing mechanical or

cylinder 7 injector-/solenoid valve - Upon removing mechanical or
injector valve.
200 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI




cylinder 8 injector-/solenoid valve: - Upon removing mechanical or
control cylinder 8 disturbed electrical faults at the injector
injector valve.



677/3 18005 Starter control (PLD-MR)** Starter relay external current - Check wire - terminal 50 input of
supply starter relay if shortened to
battery voltage, repair or replace if
necessary.
- Check starter relay, replace if
necessary.
- Restore electrical connection(s)
677/5 18009 Starter control (PLD-MR)** Starter relay external current - Check of starter relay if
supply shortened to battery voltage,
necessary.
- Restore electrical connection(s)
Doc. No. 872272 : Rev 0 201

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
677/6 18008 Starter control (PLD-MR)** Short circuit to ground - Check wire - terminal 50 input of
the starter relay for short circuit to
ground, repair or replace if
necessary.
necessary.
677/7 18086 Starter control (PLD-MR)** Starter does not engage - Check starter electrically and
mechanically perform functional
check.
677/14 18033 Starter control Starter relay Starter relay fixed in closed - Check starter relay, replace if
(PLD-MR)** position necessary.
- Perform functional test
697/3 17007D Proportional valve Shortened to battery voltage - Set output off
(MBR-BK) (-lead)
17705 Proportional valve bank 1 Shortened to battery voltage - Set output off 1 2 3 4
PVB (+lead)*
697/4 17708 Proportional valve bank 1 Short circuit to ground - Set output off 1 2 3 4
(PVB 1) (+lead)**
697/5 17009 Proportional valve 1 Open circuit fault** ECU - Check parametrization.
(MBR-BK) engine control (e.g. - Parameter 06 has to be set to
MR-PLD) wrong calibration. NOT ACTIVE
- If not, then the data set of ECU
engine control (e.g. MR-PLD) is
wrong
- Replace and program ECU
697/6 17006 Proportional valve 1 Short circuit to ground - Check parametrization.

(MBR-BK) (-lead) ECU engine control - Parameter 06 has to be set to
(e.g. MR-PLD) wrong NOT ACTIVE
calibration.
- If not, then the data set of ECU
engine control (e.g. MR-PLD) is
wrong
698/3 17305C Proportional valve 2 Shortened to battery voltage - Set output off
17307D (MBR-KD) (-lead) High Side
698/5 17317C Proportional valve 2 Open circuit fault Low Side - Set output off
17309D (MBR-KD)
698/6 17306 Proportional valve 2 Short circuit to ground - Check calibration, correct if
Activation: engine brake (-lead) High Side wrong necessary. Parameter 007 has to
decompression valve calibration be set to NOT ACTIVE.
(MBR-KD) - If not, then the data set of the
control unit MR is wrong.
699/3 17107D Proportional valve 3 Shortened to battery voltage - Set output off
(-lead)*
202 Doc. No. 872272 : Rev 0

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
699/5 17109 Proportional valve 3 Open circuit fault wrong - Check calibration, correct if
calibration necessary. Parameter 008 has to
be set to NOT ACTIVE.
NOTE:- If a Linnig-fan is installed,
the following calibration applies:
a) parameters 8 and 9 have to be
set to ACTIVE.
b) parameter 14 has to be set to
“Type 0".
699/6 17106 Proportional valve 3 Short circuit to ground - Check calibration, correct if
(-lead) ECU engine control necessary. Parameter 008 has to
(e.g. MR-PLD) wrong be set to NOT ACTIVE.
calibration / short circuit to - If the calibration is OK, check
ground wire for short circuit to ground -
- If still no fault can be detected -
replace and program ECU engine
control (e.g. MR-PLD).
700/3 17207** Proportional valve 4 Shortened to battery voltage - Set output off
(-lead)*
700/5 17209 Proportional valve 4 Open circuit fault NOTE:ECU engine control (e.g.
MR-PLD) wrong calibration / open
circuit fault
- Check calibration, correct if
necessary. Parameter 009 has to
NOTE:- If a Linnig-fan is installed,
the following calibration applies:
a) parameters 8 and 9 have to be
set to ACTIVE.
b) parameter 14 has to be set to
“Type 0".
actual: check wires for open
circuit fault, repair or replace if
necessary.
- If no fault can be detected -
control (e.g. MR-PLD)
- Set output off
700/6 17206 Proportional valve 4 Short circuit to ground NOTE:ECU engine control (e.g.
(-lead) MR-PLD) wrong calibration / short
circuit to ground.
- Check calibration, correct if
- If the calibration is OK, check
wire for short circuit to ground,
- If still no fault can be detected,
control (e.g. MR-PLD).
705/3 17405 Proportional valve 5 Shortened to battery voltage - Set output off.
(+lead)*
Doc. No. 872272 : Rev 0 203

Fault-codes
Fault-codes
PLD-MR
SPN/FMI
705/4 17408 Proportional valve 5 Short circuit to ground - Set output off for valve 6 and 5.
(+lead)*
705/11 17805 Proportional valve bank 2 Shortened to battery voltage - Set output off for valve 6 and 5.
PVB 2 (+lead)*
705/11 17808 Proportional valve bank 2 Short circuit to ground - Set output off for valve 6 and 5.
PVB 2 (+lead)*
706/3 17609 Proportional valve 6 Open circuit fault * - Set output off for valve 6
723/3 10409 Camshaft position Camshaft sensor open - Check wire for open circuit -
circuit fault replace if necessary
723/4 10408 Camshaft position sensor Camshaft sensor ground - Check wire and position sensor
short for ground short - replace if
necessary.
723/8 10412 Camshaft position sensor Camshaft time-out (no cam - If fault codes 10408 and 10409
shaft signal) Timeout are current, remove them first
- Pull out position sensor during
engine standstill and perform
visual check
- Remove metal pieces/shavings
if necessary.
(clear stress marks).
- Press in speed (position) sensor
during engine standstill until
mechanical limit stop.
723/14 10413 Camshaft position Camshaft sensor wrong - Position sensor correctly with pin
polarity Sensor verpolt of the ECU engine control (e.g.
MR-PLD)
986/8 17112 Fan speed No signal (timeout) Timeout Currently not fan speed detection
installed.
Check calibration, correct if
be set to “Type 0".
204 Doc. No. 872272 : Rev 0

DM1 FAULT CODES
GENERAL - All Controllers

LAMPST
PIN VEHICLE
TRIGGER SPN FMI A- TEXT
NUMBER FUNCTION
TUS
Bootmode Controller in 628 12 ON Controller Is In Bootmode

Bootmode
MDU2
LAMPST
PIN VEHICLE
TRIGGER SPN FMI A- TEXT
NUMBER FUNCTION
TUS
J1-N Fuel Sensor Voltage above 830 0 Fuel Sensor Above Normal
normal
Voltage below 1 Fuel Sensor Below Normal

normal
ECU Can error No CAN 2000 19 ON Loss Of ECU Can Messages

messages for 5
sec
TCU Can error No CAN 2003 19 ON Loss Of TCU Can Messages

messages for 5
sec
CCU Can error No CAN 2033 19 ON Loss Of CCU2 Can Messages

messages for 5
sec
OEU Can error No CAN 2049 19 ON Loss Of OEU Can Messages

messages for 5
sec
TPM Can error No CAN 2051 19 Loss Of TPM Can Messages

messages for 5
sec
OBW Can error No CAN 2064 19 Loss Of OBW Can Messages

messages for 5
sec
SSM Can error No CAN 2140 19 ON Loss Of SSM Can Messages

messages for 5
sec
MMU Can error No CAN 2251 19 Loss Of MM Can Messages

messages for 5
sec
System Can No CAN 639 19 ON Loss Of All Can Messages

Error - bus off messages for 5
and high error sec
rate
Vin Mismatch VIN not the same 237 13 ON Vin Mismatch Between Mdu2 And Ccu2
as on the CCU2
EOL Error CRC not the same 630 13 ON EOL Not Programmed Correctly
as CCU2
Steering If Headlight 7000 31 STEERING COLUMN SUPPLY

Column Supply Brights and VOLTAGE. CHECK FUSE 37
Headlight Dips
inputs are both off
Doc. No. 872272 : Rev 0 205

Left Indicator Voltage above 7001 0 J1R: LEFT INDICATOR SWITCH

Switch normal VOLTAGE TOO HIGH
Right Indicator Voltage above 7002 0 J1S: RIGHT INDICATOR SWITCH

Switch normal VOLTAGE TOO HIGH
Low Brake Voltage above 7003 0 J2C: LOW BRAKE PRESSURE SWITCH
Accumulator normal VOLTAGE TOO HIGH
Pressure
Switch
Emergency Voltage above 7004 0 J2E: EMERGENCY STEERING SWITCH

Steering Switch normal VOLTAGE TOO HIGH
Headlight Voltage above 7005 1 J2F: HEADLIGHT BRIGHT SWITCH

Brights Switch normal VOLTAGE TOO LOW
Headlight Dips Voltage above 7006 1 J2G: HEADLIGHT DIP SWITCH

Switch normal VOLTAGE TOO LOW
Low Engine Voltage above 7007 0 J2H: ENGINE COOLANT LEVEL

Coolant Level normal SWITCH VOLTAGE TOO HIGH
Switch
Cold Start Input Voltage above 7008 0 J2J: COLD START INPUT VOLTAGE
normal TOO HIGH
CCU2
PIN VEHICLE TRIGGER SPN FMI LAMP TEXT
NUMBER FUNCTION STA-
TUS
J1 - A3/A4 Headlight Dips Current Below 8000 5 J1-A3,A4: Headlight Dip Open Circuit
Normal or Open
Circuit
Current Above 6 ON J1-A3,A4: Headlight Dip Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-A3,A4: Headlight Dip Less Than

that allows less Normal Current
than Normal
current, but not
Open Circuit
J1 - B3/B4 Headlight Current Below 8001 5 J1-B3,B4: Headlight Bright Open Circuit
Brights Normal or Open
Circuit
Current Above 6 ON J1-B3,B4: Headlight Bright Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-B3,B4: Headlight Brights Less Than

than Normal
current, but not
Open Circuit
J1 - C1 System Air Voltage above 8002 0 J1-C1: System Air Pressure Voltage Too
Pressure normal High
Voltage below 1 J1-C1: System Air Pressure Voltage Too

normal Low
J1 - C2 Start Signal Voltage above 8003 0 J1-C2: Start Signal Voltage Too High
Normal
J1 - C3/C4 Reverse Current Below 8004 5 J1-C3,C4: Reverse Open Circuit

Normal or Open
Circuit
206 Doc. No. 872272 : Rev 0

Current Above 6 ON J1-C3,C4: Reverse Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-C3,C4: Reverse Less Than Normal

that allows less Current
than Normal
current, but not
Open Circuit
J1 - D1 Rear Two Voltage above 8005 0 J1-D1: Rear Two Speed Switch Voltage
Speed Switch Normal Too High
J1 - D2 Middle Two Voltage above 8006 0 J1-D2: Middle Two Speed Switch Voltage
J1 - D3/D4 Rear Wiper Lo Current Below 8007 5 J1-D3,D4: Rear Wiper Lo Speed Open
Speed Normal or Open Circuit
Circuit
Current Above 6 ON J1-D3,D4: Rear Wiper Lo Speed Short

Normal or Short Circuit
Circuit
Partial problem 18 J1-D3,D4: Rear Wiper Lo Speed Less

that allows less Than Normal Current
than Normal
current, but not
Open Circuit
J1 - E1 Scraper Dash Voltage above 8008 0 J1-E1: Scraper Dash Switch Voltage Too
Switch Normal High
J1 - E2 Pressure Two Voltage below 8009 1 J1-E2: Pressure Two Speed Switch
Speed Switch normal Voltage Too High
J1 - E3/E4 Front Wiper Lo Current Below 8010 5 J1-E3,E4: Front Wiper Lo Speed Open
Speed Normal or Open Circuit
Circuit
Current Above 6 ON J1-E3,E4: Front Wiper Lo Speed Short

Normal or Short Circuit
Circuit
Partial problem 18 J1-E3,E4: Front Wiper Lo Speed Less

that allows less Than Normal Current
than Normal
current, but not
Open Circuit
J1 - F1 Battery Voltage above 8011 0 ON J1-F1: 12V Battery Voltage Too High
Imbalance Normal
Voltage below 1 ON J1-F1: 12V Battery Voltage Too Low

normal
J1 - F2 Horn Switch Voltage above 8012 0 J1-F2: horn switch voltage too high
Normal
J1 - F3/F4 Park Lights Current Below 8013 5 J1-F3,F4: park lights open circuit
Normal or Open
Circuit
Current Above 6 ON J1-F3,F4: Park Lights Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-F3,F4: Park Lights Less Than Normal

than Normal
current, but not
Open Circuit
Doc. No. 872272 : Rev 0 207

J1 - G3/G4 Ignition Power Voltage below 8014 1 ON J1-G3,G4: Ignition Supply Via Fuse 25
3 (VP3) normal Voltage Too Low
J1 - H1/H2 Work Lights Current Below 8015 5 J1-H1,H2: Work Lights Open Circuit
Normal or Open
Circuit
Current Above 6 ON J1-H1,H2: Work Lights Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-H1,H2: Work Lights Less Than Normal

than Normal
current, but not
Open Circuit
J1 -H3/H4 Ignition Power Voltage below 8016 1 ON J1-H3,H4: Ignition Supply Via Fuse 26
J2 - A4 Brake Light Voltage below 8017 1 J2-A4: Brake Light Switch Voltage Too
Switch normal Low
J2 - B4 IDL Solenoid Voltage above 8018 3 J2-B4,J2-C4: IDL Solenoid Or Bin

normal or shorted Pressure Reduction Solenoid Voltage Too
to System Voltage High
Current Below 5 J2-B4,J2-C4: IDL Solenoid Or Bin

Normal or Open Pressure Reduction Solenoid Open
Circuit Circuit Or Short Circuit
J2 - C1 Bonnet Fan Voltage above 8019 0 J2-C1: Bonnet Fan Temp Switch Voltage
Temp Switch Normal Too High
J2 - C2 NOT USED 8020
J2 - C3 Left Height Voltage above 8021 0 ON J2-C3: Left Height Position Sensor
Position Sensor Normal Voltage Too High
Voltage below 1 ON J2-C3: Left Height Position Sensor

normal Voltage Too Low
J2 - C4 Bin Pressure Voltage above 8018 3 J2-B4,J2-C4: IDL Solenoid Or Bin

Reduction normal or shorted Pressure Reduction Solenoid Voltage Too
Solenoid to System Voltage High
Current Below 5 J2-B4,J2-C4: IDL Solenoid Or Bin

Normal or Open Pressure Reduction Solenoid Open
J2 - D2 Hazards Dash Voltage below 8022 1 J2-D2: Hazard Dash Switch Voltage Too
Switch normal Low
J2 - D3 Right Height Voltage above 8023 0 ON J2-D3: Right Height Position Sensor
Voltage below 1 ON J2-D3: Right Height Position Sensor

J2 - D4 Bin Lever Latch Voltage above 8024 3 J2-D4, J2-E4: Bin Lever Latch Or
normal or shorted Pneumatic Blow Off Solenoid Voltage Too
to System Voltage High
Current Below 5 J2-D4, J2-E4: Bin Lever Latch Or

Normal or Open Pneumatic Blow Off Solenoid Open
J2 - E3 Arctic Angle Voltage above 8025 0 J2-E3: Arctic Angle Position Sensor
Voltage below 1 J2-E3: Arctic Angle Position Sensor

208 Doc. No. 872272 : Rev 0

J2 - E4 Pneumatic Voltage above 8024 3 J2-D4, J2-E4: Bin Lever Latch Or

Blow Off normal or shorted Pneumatic Blow Off Solenoid Voltage Too
Solenoid to System Voltage High
Current Below 5 J2-D4, J2-E4: Bin Lever Latch Or

Normal or Open Pneumatic Blow Off Solenoid Open
J2 - F1 Bin Position Voltage above 8026 0 ON J2-F1: Bin Position Sensor Voltage Too
Sensor Normal High
Voltage below 1 ON J2-F1: Bin Position Sensor Voltage Too

normal Low
J2 - F4 CTD Solenoid Voltage above 8027 3 J2-F4,J2-G4: CTD Solenoid Or Rear

normal or shorted Wiper High Speed Voltage Too High
to System Voltage
Current Below 5 J2-F4,J2-G4: CTD Solenoid Or Rear

Normal or Open Wiper High Speed Open Circuit Or Short
Circuit Circuit
J2 - G1 Bin Lever Voltage above 8028 0 J2-G1: Bin Lever Position Sensor Voltage
Position Sensor Normal Too High
Voltage below 1 J2-G1: Bin Lever Position Sensor Voltage

normal Too Low
J2 - G2 NOT USED 8029
J2 - G4 Rear Wiper Voltage above 8027 3 J2-F4,J2-G4: CTD Solenoid Or Rear

High Speed normal or shorted Wiper High Speed Voltage Too High
to System Voltage
Current Below 5 J2-F4,J2-G4: CTD Solenoid Or Rear

Normal or Open Wiper High Speed Open Circuit Or Short
Circuit Circuit
J2 - H1 Park Brake Voltage below 8030 1 J2-H1: Park Brake Dash Switch Voltage
Dash Switch normal Too Low
J2 - H2 Front Two Voltage above 8031 0 J2-H2: Front Two Speed Switch Voltage
J2 - H4 Flashing Voltage above 8032 3 J2-H4,J2-J4: Flashing Beacon Light Or

Beacon Light normal or shorted Horn Voltage Too High
to System Voltage
Current Below 5 J2-H4,J2-J4: Flashing Beacon Light Or

Normal or Open Horn Open Circuit Or Short Circuit
Circuit
J2 - J1 Aircon Voltage above 8033 0 J2-J1: Aircon Evaporator Temperature

Evaporator Normal Voltage Too High
Temp
Voltage below 1 J2-J1: Aircon Evaporator Temperature

J2 - J2 Wet Disk Brake Voltage above 8034 0 J2-J2: Wet Disk Brake Temperature
Temp Normal Voltage Too High
Voltage below 1 J2-J2: Wet Disk Brake Temperature

J2- J3 Cab Temp Voltage above 8035 0 J2-J3: Cab Temperature Voltage Too
Normal High
Voltage below 1 J2-J3: Cab Temperature Voltage Too Low

normal
J2- J4 Horn Voltage above 8032 3 J2-H4,J2-J4: Flashing Beacon Light Or

normal or shorted Horn Voltage Too High
to System Voltage
Doc. No. 872272 : Rev 0 209

Current Below 5 J2-H4,J2-J4: Flashing Beacon Light Or

Normal or Open Horn Open Circuit Or Short Circuit
Circuit
J2 - K1 5V SUPPLY Voltage above 8036 0 J2-K1: 5 Volt Supply To Position Sensors

TO Normal Too High
-Left Height
Position Sensor
-Right Height
Position Sensor
-Arctic Position
Sensor
Voltage below 1 J2-K1: 5 Volt Supply To Position Sensors

normal Too Low
J2 - K4 5V SUPPLY Voltage above 8037 0 J2-K4 5 Volt Supply To Bin Sensors Too
TO Normal High
-Bin Position
Sensor
-Bin Lever
Position Sensor
Voltage below 1 J2-K4 5 Volt Supply To Bin Sensors Too

normal Low
J2 - L3/M3 Ignition Power Voltage below 8038 1 ON J2-L3,M3: Ignition Power Via Fuse 27
J2 - L4/M4 Ignition Power Voltage below 8039 1 ON J2-L4,M4: Ignition Power Via Fuse 28
J2 - M1 Main Ignition Voltage above 8040 0 ON J2-M1: Alternator Voltage Via Fuse 29
Power Normal Too High
(Alternator
Voltage)
Voltage below 1 ON J2-M1: Alternator Voltage Via Fuse 29

normal Too Low
J3 - A1 Arctic Reverse Voltage above 8041 3 J3-A1,J3-B1: Arctic Reverse Light Or

Light normal or shorted Rear Washer Pump Voltage Too High
to System Voltage
Current Below 5 J3-A1,J3-B1: Arctic Reverse Light Or

Normal or Open Rear Washer Pump Open Circuit Or Short
Circuit Circuit
J3 - A2 Recircula- Voltage above 8042 3 J3-A2,J3-E3: Recirculation Flap Or Aircon

tion Flap normal or shorted Clutch Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-A2,J3-E3: Recirculation Flap Or Aircon

Normal or Open Clutch Solenoid Open Circuit Or Short
Circuit Circuit
J3 - A3 Bin Up Current Below 8043 5 J3-A3: Bin Up Solenoid Open Circuit

Solenoid Normal or Open
Circuit
Current Above 6 J3-A3: Bin Up Solenoid Short Circuit

Normal or Short
Circuit
J3 - A4 Engine Voltage above 8044 3 J3-A4,J3-B4: Engine Running Or Brake

Running normal or shorted Light Output Voltage Too High
to System Voltage
Current Below 5 J3-A4,J3-B4: Engine Running Or Brake

Normal or Open Light Output Open Circuit Or Short Circuit
Circuit
210 Doc. No. 872272 : Rev 0

J3 - B1 Rear Washer Voltage above 8041 3 J3-A1,J3-B1: Arctic Reverse Light Or

Pump normal or shorted Rear Washer Pump Voltage Too High
to System Voltage
Current Below 5 J3-A1,J3-B1: Arctic Reverse Light Or

Normal or Open Rear Washer Pump Open Circuit Or Short
Circuit Circuit
J3 - B2 Left Indicator Voltage above 8045 3 J3-B2,J3-C3: Left Indicator Light Or Right
Light normal or shorted Indicator Light Voltage Too High
to System Voltage
Current Below 5 J3-B2,J3-C3: Left Indicator Light Or Right

Normal or Open Indicator Light Open Circuit Or Short
Circuit Circuit
J3 - B4 Brake Light Voltage above 8044 3 J3-A4,J3-B4: Engine Running Or Brake

Output normal or shorted Light Output Voltage Too High
to System Voltage
Current Below 5 J3-A4,J3-B4: Engine Running Or Brake

Normal or Open Light Output Open Circuit Or Short Circuit
Circuit
J3 - C1 Front Wiper Voltage above 8046 3 J3-C1,J3-D1: Front Wiper Hi Speed Or

High Speed normal or shorted Front Washer Pump Voltage Too High
to System Voltage
Current Below 5 J3-C1,J3-D1: Front Wiper Hi Speed Or

Normal or Open Front Washer Pump Open Circuit Or
Circuit Short Circuit
J3 - C2 Right Indicator Voltage above 8045 3 J3-B2,J3-C3: Left Indicator Light Or Right
Light normal or shorted Indicator Light Voltage Too High
to System Voltage
Current Below 5 J3-B2,J3-C3: Left Indicator Light Or Right

Normal or Open Indicator Light Open Circuit Or Short
Circuit Circuit
J3 - D1 Front Washer Voltage above 8046 3 J3-C1,J3-D1: Front Wiper Hi Speed Or

Pump normal or shorted Front Washer Pump Voltage Too High
to System Voltage
Current Below 5 J3-C1,J3-D1: Front Wiper Hi Speed Or

Normal or Open Front Washer Pump Open Circuit Or
J3 - D2 Mirror Heating Voltage above 8047 3 J3-D2,J3-E2: Mirror Heating Or Hydraulic

normal or shorted Cut Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-D2,J3-E2: Mirror Heating Or Hydraulic

Normal or Open Cut Solenoid Open Circuit Or Short
Circuit Circuit
J3 - D4 Bin Down Current Below 8048 5 J3-D4: Bin Down Solenoid Open Circuit
Solenoid Normal or Open
Circuit
Current Above 6 ON J3-D4: Bin Down Solenoid Short Circuit

Normal or Short
Circuit
J3 - E1 Overspeed Voltage above 8049 3 J3-E1,J3-F1: Overspeed Control Or Park

Control normal or shorted Brake Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-E1,J3-F1: Overspeed Control Or Park

Normal or Open Brake Solenoid Open Circuit Or Short
Circuit Circuit
Doc. No. 872272 : Rev 0 211

J3 - E2 Hydraulic Cut Voltage above 8047 3 J3-D2,J3-E2: Mirror Heating Or Hydraulic

Solenoid normal or shorted Cut Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-D2,J3-E2: Mirror Heating Or Hydraulic

Normal or Open Cut Solenoid Open Circuit Or Short
Circuit Circuit
J3 - E3 Aircon Clutch Voltage above 8042 3 J3-A2,J3-E3: Recirculation Flap Or Aircon

Solenoid normal or shorted Clutch Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-A2,J3-E3: Recirculation Flap Or Aircon

Normal or Open Clutch Solenoid Open Circuit Or Short
Circuit Circuit
J3 - E4 Hydraulic Temp Voltage above 8050 0 J3-E4: Hydraulic Temperature Sensor

Sensor Normal Voltage Too High
Voltage below 1 J3-E4: Hydraulic Temperature Sensor

J3 - F1 Park Brake Voltage above 8049 3 J3-E1,J3-F1: Overspeed Control Or Park

Solenoid normal or shorted Brake Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-E1,J3-F1: Overspeed Control Or Park

Normal or Open Brake Solenoid Open Circuit Or Short
Circuit Circuit
J3 - G1/G2 Ignition Power Voltage below 8051 1 ON J3-G1,G2: Ignition Power Voltage Via
2 (VP2) normal Fuse 30 Too Low
J3 - H3/H4 Ignition Power Voltage below 8052 1 ON J3-H3,H4: Ignition Power Voltage Via
OEU2
PIN VEHICLE TRIGGER SPN FMI LAMPST TEXT
NUMBER FUNCTION A-
TUS
J1 - A3/A4 Bonnet Fan 1 Current Below 9000 5 J1-A3,A4: Bonnet Fan 1 Open Circuit
Normal or Open
Circuit
Current Above 6 ON J1-A3,A4: Bonnet Fan 1 Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-A3,A4: Bonnet Fan 1 Less Than

than Normal
current, but not
Open Circuit
J1 - B3/B4 Blower Speed Current Below 9001 5 J1-B3,B4: Blower Speed 3 Open Circuit
3 Normal or Open
Circuit
Current Above 6 ON J1-B3,B4: Blower Speed 3 Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-B3,B4: Blower Speed 3 Less Than

than Normal
current, but not
Open Circuit
J1 - C3/C4 Blower Speed Current Below 9002 5 J1-C3,C4: Blower Speed 2 Open Circuit
2 Normal or Open
Circuit
212 Doc. No. 872272 : Rev 0

Current Above 6 ON J1-C3,C4: Blower Speed 2 Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-C3,C4: Blower Speed 2 Less Than

than Normal
current, but not
Open Circuit
J1 - D3/D4 NOT USED Current Below 9003 5

Normal or Open
Circuit
Current Above 6 ON
Normal or Short
Circuit
Partial problem 18
that allows less
than Normal
current, but not
Open Circuit
J1 - E3/E4 Blower Speed Current Below 9004 5 J1-E3,E4: Blower Speed 1 Open Circuit
1 Normal or Open
Circuit
Current Above 6 ON J1-E3,E4: Blower Speed 1 Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-E3,E4: Blower Speed 1 Less Than

than Normal
current, but not
Open Circuit
J1 - F3/F4 Bonnet Fan 2 Current Below 9005 5 J1-F3,F4: Bonnet Fan 2 Open Circuit
Normal or Open
Circuit
Current Above 6 ON J1-F3,F4: Bonnet Fan 2 Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-F3,F4: Bonnet Fan 2 Less Than

than Normal
current, but not
Open Circuit
J1 - G3/G4 Ignition Power Voltage below 9006 1 ON J1-G3,G4: Ignition Supply Voltage Via
J1 - H1/H2 JD Starter Current Below 9007 5 J1-H1,H2: JD Starter Open Circuit

Normal or Open
Circuit
Current Above 6 ON J1-H1,H2: JD Starter Short Circuit

Normal or Short
Circuit
Partial problem 18 J1-H1,H2: JD Starter Less Than Normal

than Normal
current, but not
Open Circuit
J1 -H3/H4 Ignition Power Voltage below 9008 1 ON J1-H3,H4: Ignition Supply Voltage Via
Doc. No. 872272 : Rev 0 213

J2 - B4 Gear Hold Voltage above 9009 3 J2-B4,J2-C4: Gear Hold Or Two Speed
normal or shorted Diff Voltage Too High
to System Voltage
Current Below 5 J2-B4,J2-C4: Gear Hold Or Two Speed

Normal or Open Diff Open Circuit Or Short Circuit
Circuit
J2 - C4 Two Speed Diff Voltage above 9009 3 J2-B4,J2-C4: Gear Hold Or Two Speed
normal or shorted Diff Voltage Too High
to System Voltage
Current Below 5 J2-B4,J2-C4: Gear Hold Or Two Speed

Normal or Open Diff Open Circuit Or Short Circuit
Circuit
J2 - D4 Load Light Voltage above 9010 3 J2-D4,J2-E4: Load Light Yellow Or Load
Yellow normal or shorted Light Green Voltage Too High
to System Voltage
Current Below 5 J2-D4,J2-E4: Load Light Yellow Or Load

Normal or Open Light Green Open Circuit Or Short Circuit
Circuit
J2 - E4 Load Light Voltage above 9010 3 J2-D4,J2-E4: Load Light Yellow Or Load
Green normal or shorted Light Green Voltage Too High
to System Voltage
Current Below 5 J2-D4,J2-E4: Load Light Yellow Or Load

Normal or Open Light Green Open Circuit Or Short Circuit
Circuit
J2 - F4 Automatic Voltage above 9011 3 J2-F4,J2-G4: Automatic Neutral Or

Neutral normal or shorted Pre-Select 2nd Gear Voltage Too High
to System Voltage
Current Below 5 J2-F4,J2-G4: Automatic Neutral Or

Normal or Open Pre-Select 2nd Gear Open Circuit Or
J2 - G4 Engine Voltage above 9011 3 J2-F4,J2-G4: Automatic Neutral Or

Overheat/Prese normal or shorted Pre-Select 2nd Gear Voltage Too High
lect 2nd to System Voltage
Current Below 5 J2-F4,J2-G4: Automatic Neutral Or

Normal or Open Pre-Select 2nd Gear Open Circuit Or
J2 - H4 Load Light Red Voltage above 9012 3 J2-H4,J2-J4: Load Light Red Or
normal or shorted Laden-Unladen Voltage Too High
to System Voltage
Current Below 5 J2-H4,J2-J4: Load Light Red Or

Normal or Open Laden-Unladen Open Circuit Or Short
Circuit Circuit
J2- J4 Laden / Voltage above 9012 3 J2-H4,J2-J4: Load Light Red Or

Unladen normal or shorted Laden-Unladen Voltage Too High
to System Voltage
Current Below 5 J2-H4,J2-J4: Load Light Red Or

Normal or Open Laden-Unladen Open Circuit Or Short
Circuit Circuit
J2 - L3/M3 Ignition Power Voltage below 9013 1 ON J2-L3,M3: Ignition Power Voltage Via
J2 - L4/M4 Ignition Power Voltage below 9014 1 ON J2-L4,M4: Ignition Power Voltage Via
J2 - M1 Main Ignition Voltage above 9015 0 ON J2-M1: Alternator Voltage Via Fuse 22
Power Normal Too High
214 Doc. No. 872272 : Rev 0

Voltage below 1 ON J2-M1: Alternator Voltage Via Fuse 22

normal Too Low
J3 - A1 Fan Medium Voltage above 9016 3 J3-A1,J3-B1: Fan Medium Solenoid Or

Solenoid normal or shorted Fan Low Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-A1,J3-B1: Fan Medium Solenoid Or

Normal or Open Fan Low Solenoid Open Circuit Or Short
Circuit Circuit
J3 - A2 Heater Valve Voltage above 9017 3 J3-A2,J3-E3: Heater Value Voltage Too
normal or shorted High
to System Voltage
Current Below 5 J3-A2,J3-E3: Heater Value Open Circuit

Normal or Open Or Short Circuit
Circuit
J3 - A3 NOT USED 9018
J3 - A4 Fan Cut Voltage above 9019 3 J3-A4,J3-B4: Fan Cut Solenoid Voltage
Solenoid normal or shorted Too High
to System Voltage
Current Below 5 J3-A4,J3-B4: Fan Cut Solenoid Open

Normal or Open Circuit Or Short Circuit
Circuit
J3 - B1 Fan Low Voltage above 9016 3 J3-A1,J3-B1: Fan Medium Solenoid Or

Solenoid normal or shorted Fan Low Solenoid Voltage Too High
to System Voltage
Current Below 5 J3-A1,J3-B1: Fan Medium Solenoid Or

Normal or Open Fan Low Solenoid Open Circuit Or Short
Circuit Circuit
J3 - B2 NOT USED 9020
J3 - B4 NOT USED Voltage above 9019 3 J3-A4,J3-B4: Fan Cut Solenoid Voltage
normal or shorted Too High
to System Voltage
Current Below 5 J3-A4,J3-B4: Fan Cut Solenoid Open

Normal or Open Circuit Or Short Circuit
Circuit
J3 - C1 Left Strut Down Voltage above 9021 3 J3-C1,J3-D1: Left Strut Down Or Left
normal or shorted Strut Up Voltage Too High
to System Voltage
Current Below 5 J3-C1,J3-D1: Left Strut Down Or Left

Normal or Open Strut Up Open Circuit Or Short Circuit
Circuit
J3 - C2 NOT USED 9020
J3 - D1 Left Strut Up Voltage above 9021 3 J3-C1,J3-D1: Left Strut Down Or Left
to System Voltage
Current Below 5 J3-C1,J3-D1: Left Strut Down Or Left

Circuit
J3 - D2 Middle/Demist Voltage above 9022 3 J3-D2,J3-E2: Middle-Demist Actuator Or

Actuator normal or shorted Feet Actuator Voltage Too High
to System Voltage
Current Below 5 J3-D2,J3-E2: Middle-Demist Actuator Or

Normal or Open Feet Actuator Open Circuit Or Short
Circuit Circuit
J3 - D4 NOT USED 9023
Doc. No. 872272 : Rev 0 215

J3 - E1 Right Strut Voltage above 9024 3 J3-E1,J3-F1: Right Strut Down Or Right
Down normal or shorted Strut Up Voltage Too High
to System Voltage
Current Below 5 J3-E1,J3-F1: Right Strut Down Or Right

Circuit
J3 - E2 Feet Actuator Voltage above 9022 3 J3-D2,J3-E2: Middle-Demist Actuator Or

normal or shorted Feet Actuator Voltage Too High
to System Voltage
Current Below 5 J3-D2,J3-E2: Middle-Demist Actuator Or

Normal or Open Feet Actuator Open Circuit Or Short
Circuit Circuit
J3 - E3 NOT USED Voltage above 9017 3 J3-A2,J3-E3: Heater Value Voltage Too
normal or shorted High
to System Voltage
Current Below 5 J3-A2,J3-E3: Heater Value Open Circuit

Normal or Open Or Short Circuit
Circuit
J3 - F1 Right Strut Up Voltage above 9024 3 J3-E1,J3-F1: Right Strut Down Or Right
to System Voltage
Current Below 5 J3-E1,J3-F1: Right Strut Down Or Right

Circuit
J3 - G1/G2 Ignition Power Voltage below 9025 1 ON J3-G1,G2: Ignition Power Voltage Via
J3 - H3/H4 Ignition Power Voltage below 9026 1 ON J3-H3,H4: Ignition Power Voltage Via
VEHICLE SPECIFIC
PIN VEHICLE TRIGGER SPN FMI LAMP TEXT
NUMBER FUNCTION STA-
TUS
Faulty GPS 841 13 INVALID GPS POSITION
Wet Disk Brake 8014 31 ON WET DISK BRAKE TEMPERATURE

Temp. Too TOO HIGH
High
Boost Pressure 8100 31 ON Boost Pressure Protection Is Activated

Protection
Free Wheeling 8101 31 ON Free Wheeling Event Detected
Excessive Idle 8102 31 Engine Is Idling For More Than 20

Minutes
Engine 8103 31 Engine r.p.m Exceeded Allowable Limit

Overspeed
Output Shaft 8104 31 Output Shaft Speed Exceeded Allowable

Speed Too Limit
High
Overloading 8105 31 Bin Is Overloaded
Harsh Braking 8106 31 Harsh Braking Detected
Coolant Temp 8107 31 Engine Coolant Temperature Too High

Too High
Engine Oil 8108 31 Engine Oil Pressure Too Low

Press Low
216 Doc. No. 872272 : Rev 0

Trans Sump 8109 31 Transmission Sump Temperature Too

Temp Too High High
TCU CAL 8110 31 ON Allison Tcu Calibration Mismatch

Mismatch
Dynamic Park > 300 rpm 8111 31 Park Brake Burnout Event Detected
Brake
Application
OBW - Strain 8112 OBW Strain Gauge Error

Gauge
Hydraulic 8113 31 ON HYDRAULIC TEMPERATURE TOO

Temp. to High HIGH
Doc. No. 872272 : Rev 0 217

218 Doc. No. 872272 : Rev 0

SECTION 6. SPECIFICATIONS
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests

Pneumatic Pressure Switches
Park Brake Pressure Switch (B18) Pressure

· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Contacts are closed at and above 550 kPa (5.5 bar) (79.8 psi)
Inter-Axle Lock Pressure Switch (B25) Pressure
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Contacts are closed at and above 550 kPa (5.5 bar) (79.8 psi)
Differential Lock Pressure Switch (B26) Pressure
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Contacts are closed at and above 550 kPa (5.5 bar) (79.8 psi)
System Air Pressure Sensor
Air Pressure at 0 kPa (0 bar) (0 psi) Resistance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10 Ohms

Air Pressure at 200 kPa (2 bar) (29 psi) Resistance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 51 Ohms
The following tests require a regulated air source applied to port (2).
To do this, remove the existing coupler assembly (1).
Install an appropriate coupler using a ¼ NPT adapter and attach a regulated air supply to the newly
installed coupler.
Doc. No. 872272 : Rev 0 219

Pneumatic Pressure Switches Test
Disconnect wire harness connector from pressure switch to be tested.
With no air pressure applied to pressure switch, continuity must exist across terminals (1 and 2), but
continuity must NOT exist across terminals (1 and 3).
NOTE:Before performing this part of the continuity check, make sure the related pneumatic
solenoid and the pneumatic system is functioning properly.
Apply 550 kPa (5.5 bar) (79.8 psi) air pressure to the external port of the pneumatic manifold, then
perform the following:
‹ CAUTION
Chock wheels to prevent vehicle from moving. Park brake may disengage when performing this
test.
• For park brake pressure switch (B18), turn key switch to ON position, then move park brake lever to
the DISENGAGE position.
• For inter-axle lock pressure switch (B25), turn key switch to ON position, then push inter-axle lock
switch to the ENGAGE position.
For differential lock pressure switch (B26), turn key switch to ON position, then push differential lock
pressure switch to the ENGAGE position. The differential lock circuit will energize for 30 seconds then will
automatically deactivate.
220 Doc. No. 872272 : Rev 0

With air pressure applied to pressure switch, Hydraulic Pressure Switches Test
continuity must NOT exist across terminals (1
and 2), but continuity must exist across terminals
(1 and 3). Specifications
Service Brake Low Pressure Switch (B23) Pressure
System Air Pressure Sensor (B15) . . . . . . . . . . . Contacts are closed at and above
Test . . . . . . . . . . . . 123 00 kPa (123 bar) (1784 psi)
Secondary Steering Pressure Switch (B24) Pressure

. . . . . . . . . . . Contacts are closed at and above
. . . . . . . . . . . . . . . 500 kPa (5 bar) (72.5 psi)
Stop Light Pressure Switch (B27) Pressure

. . . . . . . . . . . Contacts are closed at and above
. . . . . . . . . . . . . . . . 600 kPa (6 bar) (87 psi)
Remove pressure switch.
NOTE:1. The normally closed contacts are

used on service brake low pressure (B23) and
secondary steering pressure (B24).
2. The stop light pressure switch (B27) is a
Apply specified air pressure to sensor (at external normally open switch.
port of manifold) while checking resistance
across sensor terminals. Replace sensor if not to With no pressure applied to pressure switch,
specification. check for continuity across the switch terminals.
Pneumatic Solenoid Test
Disconnect wire harness from solenoid.
1
Service Brake Low Pressure Switch (B23)
and Secondary Steering Pressure Switch (B24)
24V
2
40D1002CV
Stop Light Pressure Switch (B23)
40D1003CFM
Apply 24 volts across solenoid terminals (1 and
2).
For service brake low pressure switch (B23) and
Replace solenoid if solenoid does not click when secondary steering pressure switch (B24),
voltage is applied. replace switch if no continuity is indicated.
For stop light pressure switch (B27), replace

switch if continuity is indicated.
Doc. No. 872272 : Rev 0 221

Apply specified pressure to switch while checking for continuity across the switch terminals.
For service brake low pressure switch (B23) and secondary steering pressure switch (B24), replace
switch if continuity is indicated.
For stop light pressure switch (B27), replace switch if no continuity is indicated.
Hydraulic Temperature Sensors Test
Specification
Temperature at 40°C (104°F) - Resistance
. . . . . . . . . . . . . . . . . . . 287.4 Ohms
. . . . . . . . . . . . . . . . . . . 193.6 Ohms
. . . . . . . . . . . . . . . . . . . . 134 Ohms
. . . . . . . . . . . . . . . . . . . . 92.5 Ohms
. . . . . . . . . . . . . . . . . . . . 69.1 Ohms
. . . . . . . . . . . . . . . . . . . . 51.3 Ohms
. . . . . . . . . . . . . . . . . . . . 38.6 Ohms
. . . . . . . . . . . . . . . . . . . . 29.4 Ohms
. . . . . . . . . . . . . . . . . . . . 22.7 Ohms
Remove sensor.
40D1004CFM
Apply specified heat to sensor while checking resistance between sensor terminal and body of sensor.
Replace sensor if not to specification.
222 Doc. No. 872272 : Rev 0

Steering Column Switch Test

POSITION CONNECTOR SCS
1 2 3 4 5 6 7 8 9 10 11 12
Turn Left
Signals
R
Right 2
Drive High Beam 1

Lights
Low Beam
Momentary 0
High Beam
Horn
Remove the steering column switch assembly.

terminal (4) is not to specification, replace
While operating the switch functions, check for retarder voltage regulator.
continuity across terminals as indicated in the
switch legend.
Transmission Speed Sensors Test
Replace the switch assembly if continuity is not
according to the switch legend. Specifications
Apply the service brakes while checking for Transmission Temperature at 40°C (-40°F)
voltage at terminal (4). With the service brakes Resistance . . . . . . . . . . . . . . . . . . 200 Ohms.
applied, voltage at terminal (4) must be at
maximum output voltage (approximately 4.3 Transmission Temperature at 20°C (68°F)
volts). Resistance . . . . . . . . . . . . . . . . . . 300 Ohms.
Transmission Temperature at 110°C (230°F)
Stop engine. Install relay socket array. If Resistance . . . . . . . . . . . . . . . . . . 400 Ohms.
specified voltages exist at terminals (1,2, and 5)
and ground exists at terminal 3, but voltage at Disconnect speed sensor connector.
Doc. No. 872272 : Rev 0 223

Measure resistance across sensor terminals (1).
Replace sensor if not within specification.
224 Doc. No. 872272 : Rev 0

NOTE: Resistance values may change

with rising or dropping temperatures.
On solenoid valves the resistance value rises with
rising temperature
On the temperature sensor B14 the resistance value drops
with rising temperature
A4
Brakes, Clutches, Ohm meter
Test specimen Inductive sensors Nominal Readings
Resistors
Marking Pin
Solenoid Valve Y17 Clutch A A 13 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y16 Clutch B1 B 12 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y15 Clutch B2 C 11 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y14 Brake D D 22 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y13 Brake E E 24 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y12 Brake F F 19 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y11 Brake G/F2 G 6 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y18 Clutch WK WK 9 _ 4 Ohm At 20° C

approx. 67 +
RET 8 _ 4 Ohm At 20° C

approx. 67 +
Solenoid Valve Y19 Retarder
D1-
Prop-Solenoid D1 Valve DI 10 approx. 8,6 _
+ 0,5 Ohm At 20° C
Y20
Inductive sensor N Output nAB 2 approx. 850 _
+ 100 Ohm At 20° C
B11
Retarder Resistor Retarder

RET.K 18 1.96 to 150 kOhm
B16 recognition
Oil Level Sensor Oil Level 23 PWM%, VPE 5 Volt

Oil
B15 Display
Temp Sensor Sump approx. 125 _

+ 5 kOhm At 20° C
Temperature TG 4
B14
Inductive sensor N Turbine nT 1 approx . 850 _

+ 100 Ohm At 20° C
B12
Ground / Earth_ GMI1 15
Ground / Earth_ GMI2 17
VMI1 21
Ground / Earth_ 20
VMI2
TD0006823
Doc. No. 872272 : Rev 0 225

226 Doc. No. 872272 : Rev 0

CHAPTER 4. TRANSMISSION ZF 6 HP 592 C PLUS
GENERAL DESCRIPTIONS
ZF 6 HP 592 C PLUS
• ECOMAT 2 PLUS · · · · · · · · · · · · · · · · · · · · SECOND FAMILY OF THE ECOMAT RANGE

• 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUMBER OF FORWARD RANGES
• HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH POWER
• 592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 SERIES (MODEL 592)
• C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAN BUS COMPATIBLE
ZF 6 HP 592 C Transmission
4
1
6 7 TR000278
1. Output Flange. 5. Clutch Test Points.

2. Oil Filler. 6. Sump Internal Control Valve.
3. Identification Plate. 7. Cooler Ports.
4. Temperature Sensor.
Doc. No. 872272 : Rev 0 227

Transmission Identification Operational Overview
The torque converter provides a

hydro-mechanical coupling that supplies
rotational input from the engine to the
transmission’s gearing.
Torque Converter Operation
The HD torque converter has four main

components:
• Pump.
• Stator.
• Turbine.
The transmission identification plate is located on • Lock-up clutch.
the left-rear side of the transmission. The
identification plate shows the transmission Type / The converter’s pump is bolted to the converter
Model, Parts List No., Serial number, Customer cover.
Spec No, Total Ratio Of All Gears, P.T.O Ratio,
Oil Capacity and Oil Grade. The pump rotates at engine speed
Quote These numbers when ordering parts and • As the pump rotates, fluid enters from around
remember to quote TCU number when ordering the pump hub.
new Electronic Control Units. • Centrifugal force causes fluid to be thrown
around the outside of the pump and over to
the converter turbine.
• Once the force reaches a certain point, the
fluid begins to spin the turbine.
The converter’s turbine is splined to the

transmission turbine shaft.
• Fluid from the converter pump strikes the

turbine’s vanes and eventually forces the
turbine to rotate.
• Since the turbine is splined to the turbine
shaft, the turbine shaft rotates and supplies
input to the transmission’s gearing.
Torque Converter • Fluid exits the turbine near its hub and flows to
the stator.
1. Pump.
2. Stator. The stator redirects fluid back to the converter
pump.
3. Turbine.
4. Lock-up Clutch. • When fluid from the turbine hits the front of the
stator blades, the stator locks against its
one-way clutch.
• Fluid leaving the locked stator is directed back
to the pump at an accelerated rate, increasing
torque.
228 Doc. No. 872272 : Rev 0

• As the turbine gains speed, it directs oil to the Vortex Flow

back side of the stator blades, causing the
stator to “freewheel”.
• Fluid flowing through the freewheeling stator is
no longer accelerated and does not increase
torque.
• As turbine speed increases, flow through the
stator becomes smoother and eventually
stops.
Stator One-way Clutch Operation
• Vortex flow occurs when the stator is in the

locked position.
• The turbine is still stalled or moving slowly.
• Fluid exiting the turbine strikes the front face of
the stator blades.
• This locks the stator
• The locked stator directs fluid back to the
pump at an accelerated rate.
• This helps the pump increase torque by
adding an extra “push.”
The stator’s one-way clutch provides locking and
freewheeling action. Rotary Flow
• A series of rollers and springs are located
inside the stator.
• When fluid strikes the front of the stator
blades, the stator tries to rotate in a counter
clockwise direction.
• This wedges the rollers into the small side of
the tapered cavity, the stator is locked and
can’t rotate that direction.
• When fluid strikes the back side of the stator
blades, the stator begins to rotate in a
clockwise direction.
• The wedged rollers are released, and the Rotary flow occurs when the stator is in the
one-way clutch’s design allows the stator to freewheeling position.
rotate in a clockwise direction.
• As the turbine begins to rotate and its speed
increases, the fluid exiting the turbine strikes
the back of the stator blades.
• This frees the one-way clutch and allows the
stator to rotate.
• The fluid flow through the stator becomes
much smoother and slowly ceases.
• This eliminates the torque increase.
Doc. No. 872272 : Rev 0 229

Lock-up Clutch Operation
During stall test, compare actual engine speed at

full throttle stall with established engine
manufacturer’s specifications.
Stall Protection
The D Series machines have been fitted with stall

protection software to protect the transmission
Torque convertor / oil Pump from Damage.
The Software installed allows the operator to stall

only when certain conditions have been met.
Firstly the vehicle must be in the stationary
position for more than 6 seconds. The Engine
torque must be more than 50 % for 6 Seconds.
The torque converter’s fluid coupling will never
The Park brake or service brake must be applied
allow turbine speed to equal engine speed.
(Or Both) for more than 6 seconds If these
parameters are active for more than 6 seconds
• Once rotary flow has been achieved and the CCU Knows that the vehicle is in a stall
certain speed and range requirements are condition and will allow the stall to continue up till
met, the torque converter attains “lock-up.” a total of 15 seconds have past .
• This physical connection between the
converter turbine and pump allows the turbine After 15seconds the CCU will command the ADM
to rotate at engine speed. to 0% Torque or Low Idle for 50 Seconds. If
• Lock-up clutch components include: Neutral is selected while in the 50 Second cool
• The backing plate always rotates at engine off period is active the CCU will command a
speed. speed restriction of 1250 rpm for the remainder of
the 50 Seconds.
• A torsional damper and lock-up clutch plate
assembly - located next to the backing plate. Stall Test Procedure
It’s splined directly to the turbine.
• The lock-up clutch piston - located inside the To bring oil temperature up to stall testing
converter front cover. temperature:
• It’s splined to the converter front cover and
always rotates at engine speed. • Before starting check that the oil on the
• Hydraulic fluid forced between the front cover dipstick is within the safe operating band.
and lock-up clutch piston causes the piston to • Place chocks in front and behind wheels.
move. This “sandwiches” the clutch plate • Ensure that no person is working on or under
between the piston and backing plate, forcing the machine.
the clutch plate to rotate at engine speed. • Start the engine and let it idle.
• Since the clutch plate is splined to the turbine, MDU can be used by selecting “Actual
the transmission’s input equals engine RPM. Values “ and pressing “Select” and then
“Next”, taking you to “Transmission values”
Stall Testing . Press “select” and this will bring you to
“Transmission Temp”. The transmission
Stall testing is performed to determine whether a sump temperature must be monitered at all
power complaint is due to an engine problem or times during stall test.
transmission malfunction. • Remove foot from accelerator pedal and select
neutral.
Stall speed is the maximum engine RPM
attainable when the engine is at full throttle and
when the torque converter turbine is not moving,
or “stalled.”
230 Doc. No. 872272 : Rev 0

• Push accelerator until engine is running at Analysing Stall Test Results

1500RPM and hold for approximately 30
seconds. (This will allow the oil to circulate, If stall test readings are 150 RPM higher or lower
preventing a large temperature difference than specifications...
within the pump, thus preventing any damage
to the pump). • The stall test readings are acceptable.
• Remove foot from accelerator pedal. • Stall test readings may vary slightly above or
• Repeat steps 9 to 13 until the sump below specifications, depending on ambient
temperature stabilizes around 70 ºC - 80 ºC temperature, altitude, tachometer variations
(160 ºF- 175 ºF). and other conditions.
Checking of stall RPM: If stall test readings are 200 RPM or more below
specifications...
• Bring sump temperature as described above.
• Select first gear and apply foot brake pedal • The engine may be down on power.
and keep it down. • The engine may not be attaining full fuel.
• Push accelerator pedal all the way down.
If stall test readings are extremely low (about
• After 10 - 15 seconds the RPM will 30% lower than specifications...)
stabilize.(Do not exceed 20 seconds).
• This stabilised RPM will be the stall RPM. • The engine may be severely down on power.
(Refer to table:1 in the next column.) • The engine may not be attaining full fuel.
• Remove foot from accelerator pedal. • The converter stator may be freewheeling.
• Select neutral. Accelerate to 1500RPM for 2
minutes to cool the transmission. If stall test readings are 200 RPM or more above
• Let engine idle for at least 1 minute before specifications...
switching off.
NOTE: • The transmission may have slipping clutches.
• Transmission oil level might be too low or high.
1. Never stall for longer than 20 seconds. • Converter out pressure may be too low due to
2. If you have a prolink available the optimum internal transmission problem.
range to stall in is fourth range.
3. Always refer to latest service bulletin for If stall test readings are normal, but there are
stall speed specifications. high converter out temperatures after cool
down...
STALL SPEEDS • The converter stator may be stuck.

• The transmission cooling system may not be
operating properly.
Low High Stall • The engine cooling system may not be
Model
idle idle speed operating properly.
2306D 600 rpm 2680 rpm 1941rpm
Trouble Shooting A Freewheeling
2806D 600 rpm 2680 rpm 1941rpm Stator
TABLE 1 A freewheeling stator can cause extremely low

stall speeds.
• To verify a freewheeling stator prior to tear

down, road test the vehicle.
• If the vehicle has no power at low speed, but
performs normally at high speeds, the stator
may be freewheeling.
Doc. No. 872272 : Rev 0 231

• Elevated oil temperatures or no full-throttle PLANETARY GEARS AND

up-shifts can also indicate a freewheeling
stator. POWER FLOWS
Troubleshooting A Stuck Stator Planetary Gear Sets
A stuck stator can cause high converter out

temperatures after cool down, despite normal
stall test readings.
• A stuck stator can also prevent the vehicle

from reaching its top speed and/or
transmission overheating at highway speeds.
• To verify a stuck stator prior to tear down, stall
test as follows:
• Stall until converter out temperature reaches
120 - 130°C (250 - 270 ° F.)
• Place the transmission in neutral, then
accelerate the engine to between 1200 and
1500 - RPM for 2 to 3 minutes.
• If the converter out temperature doesn’t drop,
the stator may be stuck or the engine/
transmission cooling system may be
malfunctioning. The HD transmission uses three sets of planetary
gears.
If tests confirms that the converter stator is
suspect, remove the transmission, disassemble • Understanding basic planetary gear operation
the torque converter and inspect the stator, is critical to understanding the HD’s operating
springs, rollers and race. principles.
• Planetary gear sets consist of a sun gear,
Stall Torque Ratio planetary pinion gears (held by a carrier) and a
ring gear.
Stall torque ratio reflects the amount of turbine
shaft torque the converter develops compared to Gear relationships:
the amount of torque the engine develops.
When two gears with external teeth mesh, their
Example: If the converter configuration provides rotation is opposite each other.
a 2:1 stall torque ratio, the torque converter is
capable of delivering twice the engine’s torque to Example - the sun gear and pinion gears.
the transmission gearing.
When a gear with external teeth meshes with a
NOTE: gear with internal teeth, they rotate in the same
The Stall Torque Ratio Of The B50D Is 1.58: 1 direction.
Example - the pinion gears and the ring gear.
These gear relationships provide the basis for

planetary gear operation.
232 Doc. No. 872272 : Rev 0

THE BASIC LAWS OF PLANETARY GEAR SETS
SUN CARRIER RING SPEED TORQUE DIRECTION
MAXIMUM SAME AS
INPUT OUTPUT HELD INCREASE
REDUCTION INPUT
MINIMUM SAME AS
HELD OUTPUT INPUT INCREASE
REDUCTION INPUT
MAXIMUM SAME AS
OUTPUT INPUT HELD REDUCTION
INCREASE INPUT
MINIMUM SAME AS
HELD INPUT OUTPUT REDUCTION
INCREASE INPUT
OPPOSITE OF
INPUT HELD OUTPUT REDUCTION INCREASE
INPUT
OPPOSITE OF
OUTPUT HELD INPUT INCREASE REDUCTION
INPUT
NOTE: Clutches
When any two members are held together
speed and direction are same as input. The
ratio will be 1:1
When one planetary component is held and

another is rotated, or “input,” the third member
becomes an output mechanism.
Depending on which components are held and

input, the planetary gear set can develop various
output ratios:
• Decrease input speed

• Increase input speed
• Provide direct, 1:1 drive
• Create reverse TR000041
Clutches provide the input and holding power

planetary gear sets required for operation.
Clutches in the HD transmission can be either

rotating or stationary.
Rotating clutches supply rotational input to other

shafts or components.
The HD transmission’s rotating clutches are

located in the rotating clutch module.
Doc. No. 872272 : Rev 0 233

• Stationary clutches hold components in place, • Even though the plates are intertwined, they
allowing other components to be input and rotate independently, when not applied.
output. • The clutch assembly has a piston and spring
• The HD has three stationary clutches that hold assembly.
planetary gear components. • When the clutch is applied, the piston forces
• Clutches consist of two intertwined sets of The intertwined plates together as one unit.
clutch plates and a piston. • When the clutch is released, the spring
• Two kinds of plates are used - fibre, assembly returns the piston.
“friction,” plated and steel, “reaction” plates. • If one of the components splined to the clutch
• Plates are alternated in the clutch assembly so plates is stationary, the clutch is a “stationary
that they sandwich each other. clutch”.
• One set of clutch plates is splined to an inner • If both components splined to the clutch plates
component, the other is splined to an outer are capable of rotating the clutch is a
component (The housing). “rotating clutch.”
ECOMAT TRANSMISSION PLANETARY CONFIGURATION
The Ecomat transmission has four sets of planetery gear sets:
Each Stationary Clutch namely D,E,F,G has a corresponding ring gear wihch is held staionary when the
clutch is applied.
Rotating Clutchs A,B,C are connected to the turbine shaft when applied.They apply a rotational input into
the transmission.
234 Doc. No. 872272 : Rev 0

TRANSMISSION CLUTCH CONFIGURATION

B C D E F G
GDS3233CV
Each ring gear has a corresponding clutch.
• Clutches are labelled D (holds the P1 sun gear), E (holds the P2 ring gear and P1 carrier) and F (holds
the P3 ring gear, P2 carrier and P1 ring) and G (holds the P4 ring gear).
• Three rotating clutches are located inside the rotating clutch module.
• A is the smaller inner clutch - when applied, it transmits rotational input to the main shaft.
• B is the larger outer clutch - when applied, it rotates the P1 ring, P2 carrier and P3 ring gear.
• C is a larger outer clutch - when applied rotates P1 sun gear.
Doc. No. 872272 : Rev 0 235

CLUTCH CONFIGURATION TABLE
The following table illustrates the different clutches that are applied to get a
moving range.
Note: Two clutches must be applied to obtain a moving range.
CLUTCHES A B C D E F G
NEUTRAL
FIRST X X
SECOND X X
THIRD X X
FOURTH X X
FIFTH X X
SIXTH X X
REVERSE X X
236 Doc. No. 872272 : Rev 0

TRANSMISSION CROSS SECTIONAL DIAGRAM
TR000279
6 HP 592 C
Doc. No. 872272 : Rev 0 237

238
ZF ECOMAT 2 POWER FLOW
B C D E F G INPUT ROTATING CLUTCH MODULE
Power Flow
(INPUT CLUTCHES A,B,C)

MAIN SHAFT( WITH P2,P3 & P4 SUN
GEARS CONNECTED TO CLUTCH A)
SERVICE MANUAL MK V
P3 PLANET CARRIER CONNECTED TO

A P4 PLANET CARRIER TO OUTPUT SHAFT
P4 RING GEAR (STAND ALONE)
P1 P2 P3 P4 P3 RING GEAR CONNECTED TO P2
PLANET CARRIER CONNECTED P1
RING GEAR CONNECTED TO CLUTCH B
P2 RING GEAR CONNECTED TO P1

PLANET CARRIER
P1 RING GEAR CONNECTED TO

CLUTCHES C & D RESPECTIVELY
B C D E F G
Note: Clutches A,B,C
are rotating Clutches
They supply rotational
input.
Clutchs D,E,F,G are A

Stationary Clutches
and Hold components INPUT OUTPUT
Stationary
1ST 2ND 3RD 4TH 5TH 6TH R A

RATIO 5.60 3.43 2.01 1.42 1.00 0.83 4.84 P1 P2 P3 P4
TOTAL RATIO: 5.60-0.83
TR000330
B C D E F G TR000280
2806D-2306D
Doc. No. 872272 : Rev 0

HYDRAULICS electrical signal at proportional solenoid 18 . This

limmits amount of pressure in R3 adjusting the
Hydraulic systems retarder effect (limmits the flow to the retarder).
Pressure R3 passes through the cooler
How the hydraulic system works change-over valve and cooler into the retarder.
Please refer to the hydraulic system diagrams. • Throttle pressure valve 17

Eccomat Hydraulic1 - disengaged. Normal operation: - HYDRAULIC 1 -
Eccomat Hydraulic2 - engaged. Depending on the engine load condition, pressure
For the clarification of how the components are D1 is created at this proportional solenoid valve and
connected. This text explains the function of fed to pressure control vavle 9.2.
individual components. Retarder operation: - HYDRAULIC 2 -
Depending on the R2 pressure (retarder braking
Description of hydraulic system torque), pressure D1 is created and fed to the
pressure control valve 9.2.• Valve unit 9 (clutches,
• Pump 14 and fliter 13 brakes)
The pump 14 draws oil from the sump through filter After the solenoid valve 9.1 and shut-off valve 9.3
13. This only works when engine is running. are energized, a shift pressure is created from main
pressure P in the pressure control valve 9.2.
• Main pressure valve 12 The amount of pressure during the pressure control
The main pressure valve 12 sets the necessary process is controlled by the pressure control spring
system pressure depending on whether the lock-up and throttle pressure D1.
clutch is open or closed. After the pressure control process is complete,
main pressure P is available at the clutches and
• Torque converter relief valve 3 brakes 10.• Torque converter lock-up clutch
The torque converter relief valve, 3, limits pressure valve unit 8
D2 towards the torque converter to a specified This control process is identical to that of valve unit
value. 9 (clutches, brakes), with one exception: During the
pressure control process, the amount of shift
• Converter counter-pressure valve 16
pressure is controlled by the pressure control spring
Pressurised oil from the torque converter flows to
and A8 pressure (torque converter internal
the converter counter-pressure valve 16. This valve
pressure.)• HYDRAULIC 1 -During disengagement
sets converter internal pressure A8 to a specified of clutches, brakes and torque converter lock-up
value. A8 pressure is transmitted to the torque clutch, solenoid valves 8.1 and 9.1 and shut-off
converter lock-up clutch valve unit 8. valves 8.3 and 9.3 vent pressure lines to
• Lubrication pressure valve 15 - HYDRAULIC 1 -
(retarder not operating)
Pressure D4 downstream of the converter
counterpressure valve is transmitted through the
cooler change-over valve 5, through the cooler
back through the cooler change-over valve 5 to the
lubrication pressure valve 15 and reduced there to
a specified lubrication pressure. Pressure D7 is fed
to the planetary gear section, 7 to lubricate parts.
• Lubrication pressure valve 15 - HYDRAULIC 2 -

(retarder operating)
Solenoid 18 is used to actuate the retarder control
valve 11. This exhausts the pressure from on top of
the spool in the cooler change-over valve 5 via
control line D8 .The spring force forces the spool
up. Pressure D4 downstream of the converter
counter pressure valve 16 is transmitted through
the cooler changeover valve 5 to the lubrication
pressure valve 15 as pressure D7 and fed to the
planetary gear section, 7 to lubricate parts.
• Retarder control valve 11 - HYDRAULIC 2

Pressure D2 is a supply pressure at the retarder
control valve. Pressure R3 is set according to the
Doc. No. 872272 : Rev 0 239

240
ZF-ECOMAT 2 HYDRAULIC 1
D2
2 RETARDER
SCHEMATIC 1
SERVICE MANUAL MK V
R2
R1
5
R3
1 12 15
TORQUE MAIN
PRESSURE PVW LUBRICATION
CONVERTER PRESSURE
VALVE
P CONVERTER
A8 COOLER
COUNTER CHANGEOVER
PRESSURE
the various shift elements.VALVE
VALVE
WK R3 3 16
TORQUE CONVERTER
SAFETY VALVE
PP R R3
14 PUMP D8
PLANET
GEAR
13 7 TRAIN
FILTER
CLUTCHES/
RETARDER 11 BRAKES
CONTROL
VALVE 10
SOLENOID
SOLENOID VALVE
8.1 VALVE 9.1 PRESSURE
CONTROL PSCH
PRESSURE TRANSMISSION
CONTROL VALVE
COOLER
8.2 VALVE 9.2 THROTTLE 6
PRESSURE
VALVE
17
017 727
8.3 9.3
SHUTOFF SHUTOFF D1
VALVE VALVE D1
A8
TD0006766
2806D-2306D
Doc. No. 872272 : Rev 0

ECOMAT-2 HYDRALIC 2
2806D-2306D
D2
2 RETARDER
Doc. No. 872272 : Rev 0

R2
R1
5
VALVE SCHEMATIC 2
COOLER
CHANDEOVER
R3 VALVE
1 LUBRICATION
TORQUE MAIN 12 15 PRESSURE
CONVERTER PRESSURE
VALVE PVW
P CONVERTER
A8
R3 COUNTER
PRESSURE
WK 3 16
TORQUE
CONVERTER
SAFETY
VALVE
PP R R3
14 PUMP D8
PLANET
GEAR CHANGER
13 7
FILTER
RETARDER CLUTCHES/
CONTROL
11 BRAKES
VALVE 10
SOLENOID VALVE UNIT
SOLENOID VALVE
VALVE CLUTCHES/
WK VALVE BRAKES
8.1 8 UNIT 9.1 9 PSCH
TRANSMISSION
PRESSURE PRESSURE CONTROL
CONTROL VALVE COOLER
8.2 VALVE 9.2 THROTTLE 6
PRESSURE
VALVE
17
017 728
8.3 9.3
SHUTOFF SHUTOFF
VALVE VALVE D1
D1
A8
TD0006767
241
SERVICE MANUAL MK V
HYDRAULIC PRESSURES
Pressure tests with transmission installed in

vehicle.
Remove plug and fit test fitting to respective

pressure point. Pressure point size is : M10 X 1. Fit
gauge.
1 = Main pressure P H
2 = Throttle pressure P D1
3 = Pressure before converter P D2
4 = Pressure after cooler P D6 / D7
5 = Retarder pressure P R3
6 = Retarder control pressure P RR3
4 = Retarder “ON “ = P D6
4 = Retarder “OFF “ = P D6 = P D7 = Lubrication

oil pressure.
1
6 5 3
2
TR000413
After pressure test is completed remove test

equipment and fit screw plugs with new copper seal
rings.Tightening torque : 9ft-lbs (12 Nm).
242 Doc. No. 872272 : Rev 0

PRESSURE CHART
All pressures are in bar & temperatures in degrees C.
P R3
LOAD GEAR WK R.P.M. TEMP PH P D1 P D2 P D6/D7
P RR3
Idling N Open 700 20 - 40 7 - 15 4 4 - 5.5 0.8 - 1.8
Idling N to D Open 550 20 - 40 7 - 15 0.2 - 0.1 4 - 5.5 0.8 - 1.8

C
for 2 sec
O
Full N Open 2000 - 20 - 40 18 - 21 4 6 -8.5 1.8 - 2.5 L
Load 2500
D
Full Shifted Closed 2000 - 20 - 40 10 - 12 4 6 -8.5 1.8 - 2.8
Load 2500
Idling N Open 700 80 - 90 7 - 15 4 3 - 4.5 0.1 - 0.8
Idling N to D Open 550 80 - 90 7 - 15 0.2 - 0.1 3 - 4.5 0.1 - 0.8

H
for 2 sec
O
Full N Open 2000 - 80 - 90 16 - 20 4 6 -8.5 1.8 - 2.5 T
Load 2500
Full Shifted Closed 2000 - 80 - 90 10 - 12 4 6 -8.5 1.8 - 2.5

Load 2500
Check the Transmission Fluid Level
‹ WARNING
DO NOT: start the engine until the presence of transmission fluid has been confirmed.
A cold check must be performed before start-up and the presence of sufficient transmission fluid has
been confirmed. Ensure that the machine is parked on a level surface and the park/emergency brake is
applied.
See TRANSMISSION for more information on checking transmission oil level.
Doc. No. 872272 : Rev 0 243

RETARDER
Structure and function of retarder
STATOR
STATOR RING
ROTOR
TR000421
The ZF retarder integrated in your Ecomat transmission is a single-flow hydrodynamic continuous brake
located between the torque converter and planetary gear section.
The retarder consists of the following conventional main components: rotor, stator and hydraulic
proportional valve and hydraulic control. The rotor and stator are both constructed as impellers.
244 Doc. No. 872272 : Rev 0

How the retarder works
The retarder regulator valve is activated by the A

proportional solenoid dependant on the electrical
signal sent by the retarder lever.
This allows oil to flow freely in the retarder circuit.

The rotor is driven by the vehicle through its axle,
propshaft, transmission and clutch and its
rotation causes the retarder oil to undergo
centrifugal acceleration, making the oil circulate
in the retarder.
TR000419
Additionally, the ZF retarder has a special feature

in that a vane ring is rotatably fixed in the tator.
This reduces any posible loss when the retarder Retarder applied:
is not engaged by 25%.
A - Stator Ring with the application of the retarder
The rotor (turning part of the retarder) is the ring is totally closed.
connected to the transmission input shaft, and so
when a gear is engaged, the rotor is also
connected to the driving axle of the vehicle. The RETARDER LEVER
stator is firmly fixed to the Ecomat housing.
The retarder can be found on the sealed switch
The basic advantage of the ZF retarder is its module on the dash.
infinitely variable control. The braking force can
be divided into one or several levels.
Brake operation
The friction of the oil flow is converted into heat.
This heat is conveyed to the cooling water by the When the service brake is applied the retarder
cooler in liquid cooled engines. will automatically be brought on at 50%.This is
done via the brake pressure switch to the CCU
which intern sends a CAN signal to the TCU
which brings on the retarder at 50%.
A If the switch is in any of the stages between 0% &
40% the retardation will be brought upto 50%
when the service brake is applied.
If the switch is in any of the stages between 60%

& 100% the retardation will be at what ever stage
is selected.
TR000418
Retarder not applied :
A - Stator Ring Oil flow enters the retarder hitting

the vane which allows the oil to redirected back
to the rotor allowing oil to circulate without
resistance.
Doc. No. 872272 : Rev 0 245

ZF GEAR SHIFT CONTROL Schematic Views Of The Shift Tower

LEVER Pin J and P on the shift tower connector power
up the shift tower via Fuse 1 provided the
The shift tower can be found on the right hand Ignition is turned on. Pin G on the shift tower
side of the cab. To select a gear the service connector is not connected to any wire on the
brake or the park brake must be applied. If one of circuit.
these functions are not done the transmission will
not take gear. Gear: Neutral
R
N
D
3
2 Switches activated: SN Power directed out of
1
pin F to the Automatic Greaser, Pin 3. No power
is directed to the TCU in neutral.
Gear Drive:
TR000400
R Reverse (one reverse gear )

N Neutral
D Drive (Will automatically shift through all six
gears).
3 Drive 3 (Will automatically shift through the
first three gears but will limmit you to third).
2 Drive 2 (Will automatically shift through the Switches activated: SV, S1Power directed out
first two gears but will limmit you to second). of pin A to pin 21 on the TCU & pin D to pin 50
1 Drive 1(Will limmit you to first). on the TCU. These two signals together at the
TCU tell the tansmission to select Drive mode.
The gear shift control lever is equiped with a (Provided the service brake or park brake is
lighting unit which is activated by the headlight applied).
switch on the sealed switch module via pin K on
the shift selector plug. This enables the driver to
see the ranges on the shift tower when the
headlights are activated.
It features a magnetic lock which is activated by

the TCU when certain perameters are not met.
The pin connections are pin 56 on the TCU to pin
L on the shift tower plug.
246 Doc. No. 872272 : Rev 0

Gear Reverse: These two signals together at the TCU tell the
tansmission to select Drive 2 mode (Provided the
service brake or park brake is applied).
Gear Drive 1
Switches activated: SR, S1Power directed out

of pin A to pin 21 on the TCU & pin E to pin 41 on
the TCU. These two signals together at the TCU
tell the tansmission to select Reverse (Provided
the service brake or park brake is applied). Switches activated: SV, S3, S2 Power directed
out of pin C to pin 28 on the TCU, pin D to pin 50
Gear Drive 3 on the TCU & pin B to pin 42 on the TCU. These
three signals together at the TCU tell the
tansmission to select Drive 1 mode (Provided
the service brake or park brake is applied).
Legend For The Gear Sift Selector
Pin POSITION
No
R N D 3 2 1
A
B
FUNCTION
Switches activated:SV, S1, S2 Power directed

out of pin A to pin 21on the TCU, pin D to pin 50 C
on the TCU & pin B to pin 42 on the TCU. These D
three signals together at the TCU tell the
tansmission to select Drive 3 mode (Provided the E
service brake or park brake is applied).
F
Gear Drive 2 G
H
SR X
SWITCHES
SN X
SV X X X X
S1 X X X
S2 X X X
S3 X
TR000404
Switches activated: SV, S2 Power directed out

of pin D to pin 50 on the TCU & pin B to pin 42
on the TCU.
Doc. No. 872272 : Rev 0 247

Doc. No. 872272 : Rev 0 248
26
AG-3 BN/RD 0.75 TCU-11 CAB-11

186
RD 1.0
K
CCU2J1-F3&F4 BL 0.75 TCU-6 CAB-6

106
N
BK 1.0
L
C
B
A
15
R3-87 YL/PK 0.75 TCU-7 CAB-7

F
15
R2-87 BK/BL 0.75 TCU-8 CAB-8

56
28
J
15
OEUJ2-G4 GN/BK 0.75 TCU-9 CAB-9

D
2
SHIFT SELECTOR
FUSE 15-2 RD 1.5 TCU-3 CAB-3 RD 1.5

H
15
OEUJ2-J4 PL/WH 0.75 TCU-12 CAB-12

45 64
161 187 158 29 159

E
BK 1.5 TCU-1 CAB-1 BK 1.5

E1
G
1
8
FUSE 1-2 GN 1.5 TCU-2 CAB-2 GN 1.5

50 42 41 21
P
23 68
DIAG1-1 GN 1.0
DIAG1-3
DIAG1-7
ZF-20
DIAG1-6
ZF DIAGNOSTIC
6
25
25 DIAG-F YL/BK 0.75 TCU-4 CAB-4 DIAG2-2 ZF-6
188 189 DIAG-G YL/BL 0.75 TCU-5 CAB-5 DIAG2-4 ZF-19
DIAG1-5 ZF-24
48 47 15 60 18
30 29 54
19 24 22
3
9
ZF EOL-2 PK/GY 0.75 TCU-10 CAB-10 ZF-22
84
5
ZF-11
4
ZF-12
11 12 13
ZF-13
9
ZF-9
10 11
10
ZF-10
2
GE2
ZF-2
ZF - TCU
BR2
ZF-17
17 18
ZF-18
1
RT1
ZF-1
57 16 34 49 62
TRANSMISSION VALVE BODY
BL1
15
ZF-15
4
ZF-4
14
ZF-14
TCU CAN
8
9
CCU2J2 BK 0.75 TCUCAN-C ZF-8
27 58 51
9
CCU2J2-A1 YL 0.75 TCUCAN-A
20 21
9
CCU2J2-B1 GN 0.75 TCUCAN-B
25 26
126 127 128

25
MM15A
ZF-21
25
MM15A-10
3
25
MM15A-9 ZF-31 BK 1.0
46
190 191 192

2
6
ZF-30
SOLENOID
RETARDER
3
ZF-28
2
TEMP
ZF-29
24
TRANS
BK 1.0
23
700437-23_B
TD0006028_B
Transmission Electrical Schematic
INTERNAL SOLENOIDS
Removing solenoids
‹CAUTION 1
Before unscrewing cable harness from
transmission, remove any dirt and dust from
the area around the cable harness connector.
TR000391
Drain the oil from the transmission.
‹CAUTION
Make sure the converter drain valve (1) is
used to drain the converter.
TR000385
Release cable harness connector by turning locking ring

anti-clockwise.
1
TR000360
Remove the filters and bolts around sump. The

two hex bolts (1) at the middle of the front end of
the oil pan require copper washers. Use steel
1 washers for the rest of the oil pan bolts.
TR000386
When replacing the bolts back the tightening
Unscrew the two M8 hex bolts (1) fit washers torque is 23 Nm (17ft-lbs).
from the KOSTAL socket.
Doc. No. 872272 : Rev 0 249

‹CAUTION
Do not damage the converter drain valve
actuation bolt (1) when removing the oil pan.
TR000390
Loosen, but do not remove, the 39 M8 torx bolts

which hold the shift control module in the
transmission housing.They are different lengths 30
TR000387
M8x43 screws and 9 M8x35. The tightening
torques of the bolts is: 23 Nm (17ft-lbs).
Actuation bolt (1). ‹WARNING

When the control module is release, oil will
spurt out. Protect yourself and especially your
eyes from the oil. Let the oil continue to drip
out and be sure to catch all of it.The shift
5 control module weighs approx. 18kg (40 lbs.).
Ensure it is well supported so that it cannot fall
and injure you or other persons under the
vehicle.
1 4 3
TR000388
Use a screw driver to snap flat connector for

inductive sensor output (1) and flat connector for
retarder resistance (2) off valve body and
disconnect from connector bush.
NOTE: The sump temperature sensor is

integrated in the connector (3). Only remove if
necessary.
Guide cable for sump temperature sensor (4) out of

protective sleeve (5).
250 Doc. No. 872272 : Rev 0

REMOVE VALVE BODY
Solenoid Table
RESPECTIVE
SOLENOID PIN NO RESISTANCE
CLUTCH
Y11 G 6 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y12 F 19 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y13 E 24 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y14 D 22 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y15 C 11 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y16 B 12 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y17 A 13 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y18 WK 9 approx. 67 +/- 4 ohlms...... @ 20 deg C
Y20 D1 10 approx. 8.6 +/- 0.5 ohlms.... @ 20 deg C
NOTE: The solenoid resistance is dependant on the temperature of the oi. When checking for a
faulty solenoid measure the resistance of a few solenoids to get the correct resistance and then
test the suspected faulty solenoid.
Doc. No. 872272 : Rev 0 251

RENEWING SENSORS 4
Output Sensor
1 2 3
TR000352
Remove o-ring (1), spacers (2) and TORX screw

(3) from inductive sensor (4).
TR000349
Remove cover (1) from inductive sensor.
1 1
2
TR000353
Turn output flange until gearing (1) on planet

carrier in the center of the bore for the inductive
sensor becomes visible.
TR000350
Disconnect cables (1) on inductive sensor. They

have flat-pin plugs and are to be pulled out with a 1
straight pull.
‹ CAUTION
Use suitable pliers and pull on the plugs & 2
not on the wires.
Screw out TORX screw (2) and remove iductive

sensor. 4 3
TR000354
Fit measuring tool (1) into the bore of the

inductive sensor and screw-tighten (2).
252 Doc. No. 872272 : Rev 0

Tightening torque . . . . . . . . 9.5Nm (7ft-lbs).
Push the slide of the measuring tool (3) down until it

comes up against the the tooth of the Planet carrier.
Secure the slide by adjusting the screw (4). C
Remove screw (2) and carefully remove measuring

tool (1).
TR000357
b
Measure distance from contact surface of inductive

sensor to contact suface of the measuring tool.
Note the dimension as “dimension c”.
Tr000355 2 3
Measure the distance between were the slide

protrudes to the contact surface of the of the
measuring tools holder. Note the dimension down
as “dimension b”.
1
a 5
4
TR000358
Inductive dimension distance “dimension a” must

be between 0.5 and 0.7mm.
Adjust with spacers.
Measuring Formula
c -b = d
d + a = thickness “S” of spacer.
Measuring Example
TR000356 Dimension “c” = 52.6 mm

Dimension “b” = 51.3 mm
Insert sensor into measuring block and tighten to
9.5 Nm (7ft-lbs) Dimension “a” = 0.6 mm
Calculation Example
52.6mm - 51.3mm = 1.3 mm

1.3 mm + 0.6mm = 1.9 mm
Doc. No. 872272 : Rev 0 253

Determined thickness “S” of spacer = 1.9 mm

1 Gearing of planet carrier 1
2 Output cover of housing
3 Inductive sensor
4 Spacers
5 Fixing bolt of inductive sensor.
TR000349
Renew o-ring on cover and fasten cover using

two M6 hex nuts and washers.
1 2 3 Tightening torque . . . . . . . . . 6 Nm (5 ft-lbs).
TR000352
Insert the TORX screw (3) into the bore on the Turbine Sensor
inductive sensor (4). Slide spacers as determined
(2) onto the TORX screw and secure with o-ring
(1).
1
1
2
TR000360
TR000350 Drain oil and remove oil pan.
Connect plug (1) to the inductive sensor. Insert

inductive sensor and tighten with TORX screw
M6 x 45 (2).
Tightening torque . . . . . . . . 9.5 Nm (7ft-lbs).
254 Doc. No. 872272 : Rev 0

1 1
TR000361 TR000363
Remove M42 x 2 screw plug (1). Using a large screw driver or similar tool, turn the
torque converter and at the same time use a
small screwdriver to find the raised points on the
sensor induction ring (1).
‹ CAUTION
1
It is important to measure onto a raised point
on the induction ring, otherwise the sensor
2 will be damaged by the raised points on the
ring when the engine is started.
TR000362
Disconnect cable connector (1) from sensor.

These are blade connectors which should be
pulled off straight.
Unscrew socket - head bolt (2) and remove

inductive sensor.
When one of these raised points is in line with the

bore for the sensor, measure gap a ”between”
the sensor (3) and raised point of the induction
ring (1).
1 2 3
TR000352
Remove o-ring (1), spacers (2) and socket - head

bolt (3) from inductive sensor (4).
Doc. No. 872272 : Rev 0 255

Tr000355
Measure the distance between were the slide

protrudes to the contact surface of the of the
measuring tools holder.
TR000367
Note the dimension down as “dimension b”.
Fit measuring tool into the bore of the inductive

sensor and screw-tighten (1).
Tightening torque . . . . . . . . 9.5Nm (7ft-lbs).
TR000356
Insert sensor into measuring block and tighten to

9.5 Nm (7ft-lbs).
TR000365
Push the slide of the measuring tool (1) down

until it comes up against the the raised section of
the pulse sensor ring. Secure the slide by C
adjusting the screw (2). Remove screw (3) and
carefully remove measuring tool.
TR000357
Measure distance from contact surface of

inductive sensor to contact suface of the
measuring tool.
Note the dimension as “dimension c”.
256 Doc. No. 872272 : Rev 0

1 2 3
TR000352
Inductive dimension distance “dimension a” Insert the socket - head bolt (3) into the bore on
must be between 0.6 and 0.8mm. the inductive sensor (4). Slide spacers as
determined (2) onto the socket - head bolt and
Adjust with spacers. secure with o-ring(1).
Measuring formula
1
c -b = d
d + a = thickness “S”of spacer. 2
Measuring example
3
Dimension “c” = 52.6 mm
Dimension “b” = 50.9 mm
Dimension “a” = 0.7 mm
Calculation example
52.6mm - 50.9mm = 1.7 mm TR000365
1.7 mm + 0.7mm = 2.4 mm Insert inductive sensor and tighten with socket -
head bolt M6 x 45 (1).
Determined thickness “S” of spacer = 2.4 mm
Tightening torque . . . . . . . . 9.5 Nm (7ft-lbs).
1 = Sensor induction ring
Connect plug (2) to the inductive sensor.
2 = Mounting plate
3 = Inductive sensor
4 = Shim washers
5 = Socket-head bolt.
Doc. No. 872272 : Rev 0 257

TR000372
TR000361
Slide copper seal ring (1) onto temperature

Fit M42 x 2 screw plug (1) into duct plate and sensor. Screw in the temperature sensor.
tighten.
Tightening torque 35 Nm (26ft - lbs).
Tightening torque . . 67 - 74 ft-lbs (90 -100 Nm)
Fit back pan and filter to transmission.

1
TR000373
TR000371 Reconnect the 2-core cable connector to the

temperature sensor (1).
Release the 2-core cable connector from the
temperature sensor and remove temperature
sensor.
258 Doc. No. 872272 : Rev 0

EXTERNAL SOLENOIDS
Retarder Solenoid
TR000376
Tighten both M8 x 22 hex bolts.
TR000374
Tightening torque . . . . . . . 23 Nm (17 ft- lbs).
Disconnect cable connector (1) from solenoid DIAGNOSTIC CODES

valve.
Unscrew two M8 hex bolts (2). Refer to the the electrical section for all the
transmission fault codes as they are sent via the
‘CANBUS” to the MDU.
This is discussed in detail under the MDU

menu’s.
Refer to the electrical schematic for the ECOMAT

1 2 for the Fault diagnostic on the electrical system
2
and the hydraulic section of the transmission for
the hydraulic pressures.
Please note that the fault codes are displayed

according to the J1939 fault code system and
may differ from fault codes in a ZF workshop
manual.
TR000375
Remove solenoid valve (1) and insert new

solenoid valve with new o-ring (2).
Doc. No. 872272 : Rev 0 259

WIRING HARNESSES
External Wiring Harness
The transmission uses a single external wiring

harness to connect the various electronic system
components.
Control system configuration for various

vocations may be adapted to operator needs and
to vehicle requirements.
The basic harness provides connections to the

TCU from the following:
• Shift selector.
• Transmission bulkhead connector.
• Serial Communication Interface (SCI) data link
(J1939 CANBUS).
• Engine speed sensor.
• Transmission output speed sensor.
• Diagnostic data reader (DDR).
• Vehicle interface wiring.
• Retarder connectors.
Internal Wiring Harness
The internal wiring harness provides connection

between the external harness and the solenoids,
C3 pressure switch, transmission fluid level
sensor, and the sump temperature sensor.
260 Doc. No. 872272 : Rev 0

CHAPTER 4. TRANSMISSION ZF 6 HP 592 C
SECTION 2. DIAGNOSTIC INFORMATION
DIAGNOSTIC PROCEDURE
Follow the six basic steps below to carry out trouble Perform Operational Check-out.
shooting efficiently.
Check all systems and functions on the machine.
Know The System Use the helpful diagnostic information in the
check-out to pinpoint the possible cause of the
Study the machine technical manual. Understand problem.
the system and circuits. Use schematics,
component location drawings and theory of Perform Troubleshooting
operation for each circuit and circuit components
work. Connect laptop computer, if available. The
self-diagnostic function lists any service codes and
Ask The Operator give corrective action information.
Before starting troubleshooting, first check battery

What type of work was the machine doing when the
voltage, circuit breakers and fuses.
trouble was noticed?
Go to test groups to check pressures and voltages.
Did the trouble start suddenly or has it been getting
Make sure adjustments are correct.
worse?
Did the machine have any previous problem? if so, Trace And Cause
which parts were repaired?
Before reaching a conclusion, check the most
Inspect The Machine probable and simplest to verify. Use the flow charts
and symptom, problem, solution charts to help
Check all daily maintenance points. Check identify probable problem components.
batteries, fuses, circuit breaker and electrical
connections. Make a plan for appropriate repair to avoid other
malfunctions.
Doc. No. 872272 : Rev 0 261

DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS

NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to
least likely and most difficult to verify.
Axle Breather Leaking. Differential oil level incorrect. Adjust oil level.
Final Drive Overheating. Final drive oil level incorrect. Adjust oil level.
Final Drive Noisy. Final drive oil level incorrect. Adjust oil level.
Final Drive Leaking Oil. Final drive cover cap screws loose. Tighten cap screws
Drain plug loose. Tighten drain plug.
Damaged O-Ring on cover. Replace O-ring.
Breather plugged. Clean or replace breather.
Differential Assembly Noisy Differential oil level incorrect. Adjust oil level.
and/or Overheating. Differential oil type Incorrect. Drain and refill with correct
type oil.
Differential Lock Bearing Used Use differential lock only
Excessively. when needed.
Internal Differential Failure. Disassemble and repair.
Inter axle diff. lock not releasing. Low or no air pressure. Refer to “DIAGNOSE
PNEUMATIC SYSTEM
MALFUNCTIONS”.
Actuator leaking. Check and repair if
necessary.
Actuator switch faulty. Replace switch.
Harness damaged. Check harness and repair.
Poor Braking Performance. Worn or damaged disks. Disassemble and replace

brake disks.
Overheated seals and/or disks. Disassemble and replace

piston seals and/or disks.
Brake valve failed. Replace brake valve.
Poor Braking Performance. Retarder not coming on. Service code diagnostics -
TCU.
Brake Noise and Vibration. Brakes produce noise, chatter and Replace.
vibration - Incorrect axle oil.
Brakes Overheat. Low or no axle oil. Check for oil leaks.
Service Brakes Do Not Release Piston return spring damaged. Disassemble and
Fully. repair/replace spring
assembly.
Brake valve failed. Replace brake valve.
262 Doc. No. 872272 : Rev 0

Park Brake Does Not Release. Chassis Control Unit (CCU). Check CCU.
Park brake control valve failed. Replace park brake control
valve
Air pressure low. Check system air pressure.
Park brake relay does not energize. Check park brake relay.
Park brake solenoid will not Check park brake solenoid .
energize.
Park brake actuator failed. Replace actuator.
Park brake incorrectly adjusted. Adjust park brake.
Park Brake Will Not Hold. Park brake pads oily. Replace pads and clean
disk.
Park brake incorrectly adjusted. Adjust park brake.
Park brake control valve failed. Replace park brake control
valve.
Engine Will Not Start (Turn Over). Gear selector not in neutral. Push N (Neutral) on gear
selector panel.
Shift Control failed. Replace shift control.
Voltage to TCU too low or not Recharge or replace
present. batteries. Check and repair
open harness.
TCU failed. Replace TCU.
Machine Will Not Move. Transmission or vehicle harness Connect, repair or replace
disconnected or failed. harness.
Transmission Will Not Shift to Engine speed to high. Calibrate accelerator pedal.
Forward or Reverse. Oil level to low. Adjust to correct level.
Accelerator pedal failed. Replace accelerator pedal.
Transmission harness Connect, repair or replace
disconnected or failed. harness.
Voltage to TCU too low. Check battery voltage, or
repair open harness.
Speed sensor failed. Replace speed sensor.
Excessive Creep in First and Engine idle speed too high. Calibrate accelerator pedal.
Reverse.
No Response To Shift Selector. Transmission oil level low. Add transmission oil.
Shift selector failed. Replace shift selector.
Transmission main oil pressure Transmission pump or
low. pressure regulator failed.
Check transmission
pressure.
Machine Moves Backward in C3 Clutch failed. Disassemble and repair.

Neutral.
Doc. No. 872272 : Rev 0 263

Machine Moves Forward in C1 Clutch failed. Disassemble and repair.

Neutral.
Engine Speed too High during C1 Clutch failed. Disassemble and repair.
Torque Convertor Stall. C5 Clutch failed. Disassemble and repair.
Engine power too high. Calibrate accelerator pedal
Engine Speed too Low During Engine power low. Determine Cause of low
Torque Converter Stall. power.
Torque convertor failure. Replace torque convertor.
Low Transmission Lube Transmission oil level low. Add Transmission oil.
Pressure. Lube filter plugged. Replace lube filter.
Torque converter regulator valve Disassemble and repair.
failed.
Transmission cooler lines restricted Repair or replace cooler
or damaged. lines.
Lube pressure regulator failed. Disassemble and replace
regulator.
Transmission cooler plugged. Clean or replace cooler.
Low Main Pressure in All Gears. Transmission oil level low. Add transmission oil.
Transmission oil filter plugged Replace filter.
(”Knocked”).
Transmission pump suction filter Disassemble and clean filter.
plugged.
Transmission oil pressure gauge Replace MDU.
failed.
Transmission main pressure Repair or replace main
regulator sticking or failed. pressure regulator.
Control module leaking. Disassemble, check gaskets
and housing.
Low Main Pressure in All Gears. Transmission pump failed. Disassemble and replace
pump.
Excessive Clutch Slippage and Accelerator pedal mis-calibrated. Calibrate accelerator pedal.
Chatter. Transmission oil level low. Add transmission oil.
Transmission main pressure Repair or replace main
regulator sticking or failed. pressure regulator.
Transmission control solenoid F Disassemble control valve
sticking. and clean or replace
solenoid F.
Torque converter lockup clutch Disassemble torque
failed. converter.
Green Wire 107-T22 failed. and repair wire.
White Wire 107-T22 failed. and repair wire.
264 Doc. No. 872272 : Rev 0

Excessive Slippage and Clutch C1 Clutch failed. Disassemble and repair.

Chatter in 1st, 2nd, 3rd and 4th
Gears Only.

Chatter in 1st and Reverse Gears
Only.

Chatter in 2nd and 6th Gears
Only.

Chatter in 3rd, 5th and Reverse
Gears Only.

Chatter in 4th, 5th and 6th Gears
Only.
Oil Comes Out of Transmission Dipstick loose or seal failed. Install dipstick correctly or
Oil Fill Tube. replace.
Incorrect dipstick. Replace dipstick.
Transmission oil level high. Drain oil to correct level.
Transmission breather clogged. Remove and clean breather.
Transmission oil contaminated. Drain oil, replace filters and
refill oil.
Buzzing Noise Coming From Transmission oil level too high. Drain oil to correct level.
Transmission. Transmission filter plugged. Replace filter.
Transmission pump suction filter Clean filter.
plugged.
Main pressure low. Check transmission main
pressure.
Transmission Overheating in All Transmission oil level too low or too Adjust oil level.
Gears. high.
Transmission oil cooler plugged. Clean or replace cooler.
Check cooling fan.
Shift Selector Displays N Transmission harness connector Reconnect harness

(Neutral) and Machine Will Not disconnected. connector.
Move. Electrical failure. See “Service Code
Diagnostics -Transmission
Control Unit (TCU).
Transmission shift control failed. Replace transmission shift
control.
Doc. No. 872272 : Rev 0 265

Transmission Will Not Shift to Transmission harness Connect harness.

Forward or Reverse (Stays in disconnected.
Neutral). Transmission oil level low. Add transmission oil.
Accelerator pedal failed. Replace accelerator pedal.
TCU input voltage too low. Reset circuit breaker.
Transmission shift control failed. Replace transmission shift
control.
Transmission Not Shifting Engine slow idle speed too high. Calibrate accelerator pedal.
Properly (Rough Shifts, Shifting Accelerator pedal mis-calibrated. Calibrate accelerator pedal.
at Too Low or Too High Speed).
Transmission ratio calibration See “Service Code
incorrect. Diagnostics -Transmission
Control Unit (TCU).
TCU voltage too low or too high. Check charging system
voltage and circuit breakers.
Transmission oil level low. Adjust oil level.
Transmission Will Not Make a Transmission oil level low. Adjust oil level.
Specific Shift. Engine power low. Check engine power.
Transmission temperature sensor Replace sensor.
failed.
Harness failure. Check wire harness.
Transmission overheating (Will Not Clean plugged oil cooler.
Shift).
Transmission ratio calibration See “Service Code
incorrect. Diagnostics -Transmission
Control Unit (TCU)”.
Transmission shift control failed. Replace shift control.
Transmission Oil Leaking Into Transmission pump seal worn. Replace seal.
Torque Converter Housing. Rear engine seal leaking. Replace seal.
Transmission Retarder Does Not Solenoid H open circuit. Replace solenoid.

Function. Retarder regulator valve sticking. Replace regulator valve.
Retarder relay valve sticking. Replace relay valve.
Retarder flow valve sticking. Replace flow valve.
Accelerator pedal greater than 1%. Calibrate accelerator pedal.
Codes 64-12 or 64-23. Check codes (See “Service
Code Diagnostics
-Transmission Control Unit
(TCU)”.
Transmission output speed Check output speed.
incorrect.
266 Doc. No. 872272 : Rev 0

Transmission Retarder Weak. Solenoid H open circuit or leaking. Replace solenoid.

Retarder regulator valve sticking. Replace regulator valve.
Retarder temperature sensor Replace temperature sensor.
damaged.
Retarder intensity spring damaged. Disassemble retarder control
valve.
Transmission charge pump worn. Disassemble transmission
charge pump.
Worn components causing internal Disassemble retarder
leak. housing.
Retarder Stays On When Not Solenoid H open circuit. Replace solenoid.

Requested. Retarder regulator valve sticking. Replace regulator valve.
Transmission Retarder Too Retarder intensity spring damaged. Disassemble retarder control
Aggressive. valve.
Retarder regulator valve sticking. Disassemble retarder control
valve.
CHECK THE TRANSMISSION FLUID LEVEL

Always check the fluid level at least twice. If the readings are not consistent, check and clean the
transmission breather.
The normal operating temperature of the transmission fluid is 71°C to 93°C (160°F to 200°F), measured
at the transmission sump.
Replenish or drain the transmission fluid as required. Refer to Change the Transmission Fluid and
Filter (Part 2 of this manual).
Doc. No. 872272 : Rev 0 267

TRANSMISSION CONTROL UNIT ERROR CODES
Description of the Error Codes
Abbreviations
O.C. . . . open circuit

S.C. . . . short circuit
OP-Mode . operation mode
TCU . . . transmission control unit
ABS . . . anti-blocking system
ASR . . . anti-slipping regulation
EEC . . . electronic engine controller
PTO . . . power take-off
CCO . . . clutch cutoff
Definition of Operation Modes
Normal:
There is no failure detected in the transmission system or the failure has no (or only a minor) effect on the
transmission control. The TCU will function without (or in special cases with little) limitations. See
following table.
Substitute Clutch Control
The TCU cannot change gears or the direction under the control of the normal clutch modulation. The
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
Limp-home
The detected failure in the system has strong limitations to transmission control. The TCU can engage
only one gear in each direction. In some cases only one direction will be possible.
268 Doc. No. 872272 : Rev 0

The TCU will shift the transmission into neutral at the first occurrence of the failure. The operator must
select neutral.
If the output speed is less than a threshold for neutral to gear and the operator selects forward or reverse,
the TCU will select the limp-home gear.
If output speed is less than a threshold for reverse speed and the TCU has changed into the limp-home
gear and the operator selects a shuttle shift, the TCU will immediately shift into the limp-home gear of the
selected direction.
If output speed is greater than the threshold, the TCU will shift the transmission into neutral. The operator
must slow down the machine and select neutral.
Transmission Shutdown
The TCU has detected a severe failure that disables control of the transmission.
The TCU will shut off the solenoid valves for the clutches and the common power supply (VPS 1).
The transmission shifts to neutral. The park brake will operate normally, as will the other functions which
use ADM 1 to ADM 8.
The operator must slow down the machine. The transmission will remain in neutral.
Doc. No. 872272 : Rev 0 269

TABLE OF ERROR CODES
Code - Symptom Problem Solution
5014.3 - Retarder Retarder controller (A7). Replace retarder controller.

Controller Voltage Wiring or connections. Check transmission control harness (W12).
Above High Limit (4.5
Volts) TCU (A5). Replace TCU..
Retarder disabled
5014.4 - Retarder Retarder controller (A7). Replace retarder controller.

Controller Voltage Wiring or connections. Check transmission control harness (W12).
Below Low Limit (2
Volts) TCU (A5) Replace TCU.
Retarder disabled.
5017.3 - Retarder Retarder temperature sensor Check sensor. See Temperature Sensor
Temperature Sensor (B11). Test (this group).
(B11) Open Circuit. Wiring or connections. Wiring or connections. Check transmission
Retarder disabled. control harness (W12) and transmission
harness (W13).
TCU (A5). Replace TCU.
5017.4 - Retarder Retarder temperature sensor Check sensor. See Temperature Sensor
Temperature Sensor (B11). Test (this group).
(B11) Short to Ground. Wiring or connections. Wiring or connections. Check transmission
Retarder disabled. control harness (W12) and transmission
harness (W13).
5018.3 - Sump Sump temperature sensor Check sensor. See Transmission Retarder
Temperature Sensor (B11). Temperature Sensor Tests (this group).
(B12) Open Circuit. Wiring or connections. Check transmission control harness (W12)
All range solenoids and transmission harness (W13).
deactivated.
Transmission shifts to TCU (A5). Replace TCU.
neutral.
5018.4 - Sump Sump temperature sensor Check sensor. See Transmission Solenoids,
Temperature Sensor (B12). Speed Sensors, Sump Temperature Sensor
(B12) Short To Ground and Retarder Temperature Resistor Tests
Retarder Disabled. (this group).
Wiring or connections. Check transmission control harness (W12),
transmission harness (W13), and
transmission control module harness (W19).
5021.3 - A Clutch Wiring or connections. Check transmission control harness (W12),

Solenoid (Y7) Open transmission harness (W13), and
Circuit. transmission control module harness (W19).
All range solenoids TCU (A5). Replace TCU.
deactivated.
Transmission shifts to
neutral.
270 Doc. No. 872272 : Rev 0

5021.3 - A Clutch Wiring or connections. Check transmission control harness (W12),

Solenoid (Y7) Short To transmission harness (W13), and
Power. transmission control module harness (W19).
deactivated.
neutral.
5021.4 - A Clutch A clutch solenoid (Y7). Check solenoid. See Transmission

Solenoid (Y7) Short To Solenoids, Speed Sensors, Sump
Ground. Temperature Sensor and Retarder
All range solenoids Temperature Resistor Tests.
deactivated. Wiring or connections. Check transmission control harness (W12),
Transmission shifts to transmission harness (W13), and
neutral. transmission control module harness (W19).
TCU (A5) Replace TCU.
5021.5 - A Clutch A clutch solenoid (Y7). Check solenoid. See Transmission

Solenoid (Y7) Open Solenoids, Speed Sensors, Sump
Circuit. Temperature Sensor and Retarder
All range solenoids Temperature Resistor Tests
deactivated. Check transmission control harness (W12),
Transmission shifts to Wiring or connections. transmission harness (W13), and
5022.3 - B Clutch Wiring or connections. Check transmission control harness (W12),

deactivated.
neutral.
5022.4 - B Clutch B clutch solenoid (Y6). Check solenoid. See Transmission

All range solenoids Temperature Resistor Tests (this
deactivated. Chapter).
Transmission shifts to Wiring or connections. Check transmission control harness (W12),
neutral. transmission harness (W13), and
5022.5 - B Clutch B clutch solenoid (Y6). Check solenoid. See Transmission

deactivated.
Transmission shifts to Wiring or connections. Check transmission control harness (W12),
neutral. transmission harness (W13), and
Doc. No. 872272 : Rev 0 271

5023.3 - C Clutch Wiring or connections. Check transmission control harness (W12),

deactivated.
neutral.
5023.4 - C Clutch C clutch solenoid (Y5). Check solenoid. See Transmission

Power. Temperature Sensor and Retarder
5023.5 - C Clutch C clutch solenoid (Y5). Check solenoid. See Transmission

5024.3 - D Clutch Wiring or connections. Check transmission control harness (W12),

deactivated.
neutral.
5024.4 - D Clutch D clutch solenoid (Y4). Check solenoid. See Transmission

5024.5 - D Clutch D clutch solenoid (Y4). Check solenoid. See Transmission

272 Doc. No. 872272 : Rev 0

5025.3 - E Clutch Wiring or connections. Check transmission control harness (W12),

deactivated.
neutral.
5025.4 - E Clutch E clutch solenoid (Y3). Check solenoid. See Transmission

5025.5 - E Clutch E clutch solenoid (Y3). Check solenoid. See Transmission

5026.3 - F Clutch Wiring or connections. Check transmission control harness (W12),

deactivated.
neutral.
5026.4 - F Clutch F clutch solenoid (Y2). Check solenoid. See Transmission

5026.5 - F Clutch F clutch solenoid (Y2). Check solenoid. See Transmission

Doc. No. 872272 : Rev 0 273

5027.3 - G Clutch Wiring or connections. Check transmission control harness (W12),

deactivated.
neutral.
5027.4 - G Clutch G clutch solenoid (Y1). Check solenoid. See Transmission

5027.5 - G Clutch G clutch solenoid (Y1). Check solenoid. See Transmission

5028.3 - WK (Lock Up) Wiring or connections. Check transmission control harness (W12),
Clutch Solenoid (Y8) transmission harness (W13), and
Short To Power. transmission control module harness (W19).
System goes into
“limp-home” mode. TCU (A5). Replace TCU.
5028.4 - WK (Lock Up) WK clutch solenoid (Y8). Check solenoid. See Transmission
Clutch Solenoid (Y8) Solenoids, Speed Sensors, Sump
Short To Ground. Temperature Sensor and Retarder
System goes into Temperature Resistor Tests.
“limp-home” mode. Wiring or connections. Check transmission control harness (W12),
5028.5 - WK (Lock Up) WK clutch solenoid (Y8). Check solenoid. See Transmission
Clutch Solenoid (Y8) Solenoids, Speed Sensors, Sump
Open Circuit. Temperature Sensor and Retarder
System goes into Temperature Resistor Tests.
274 Doc. No. 872272 : Rev 0

5039.3 - Shifter Lock Transmission shift control Perform Transmission Shift Control Test.
Solenoid Short To (A4).
Power. Wiring or connections. Check transmission control harness (W12).
Output switch OFF. TCU (A5). Replace TCU.
Shifter lock solenoid
deactivated.
5039.4 - Shifter Lock Transmission shift control Perform Transmission Shift Control Test.
Solenoid Short To (A4).
Ground. Wiring or connections. Check transmission control harness (W12).
Shifter lock solenoid
deactivated.
5039.5 - Shifter Lock Transmission shift control Perform Transmission Shift Control Test
Solenoid Open Circuit. (A4).
Output switch OFF. Wiring or connections. Check transmission control harness (W12).
Shifter lock solenoid TCU (A5). Replace TCU.
deactivated.
5044.2 - D1 Clutch D1 clutch solenoid (Y9). Check solenoid. See Transmission

Solenoid (Y9) Solenoids, Speed Sensors, Sump
Resistance. Temperature Sensor and Retarder
System activates Resistor Tests.
Transmission service transmission harness (W13), and
light ON. transmission control module harness (W19).
5044.3 - D1 Clutch Wiring or connections. Check transmission control harness (W12),

System activates TCU (A5). Replace TCU.
“limp-home” mode.
5044.4 - D1 Clutch D1 clutch solenoid (Y9). Check solenoid. See Transmission

System activates Resistor Tests.
5045.2 - Retarder Retarder proportional Check solenoid. See Retarder Proportional

Proportional Solenoid solenoid (Y11). Solenoid Test.
(Y11) Resistance. Wiring or connections. Check transmission control harness (W12)
Retarder disabled. and transmission harness (W13).
Transmission service
light ON.
Doc. No. 872272 : Rev 0 275

5045.3 - Retarder Wiring or connections. Check transmission control harness (W12)

Proportional Solenoid and transmission harness (W13).
(Y11) Short To Power.
Output switch OFF.
Retarder mode not
possible. TCU (A5). Replace TCU.
5045.4 - Retarder Retarder Proportional Check solenoid. See Retarder Proportional

Proportional Solenoid Solenoid (Y11). Solenoid Test.
(Y11) Short To Wiring or connections. Check transmission control harness (W12)
Ground. and transmission harness (W13).
Output switch OFF.
Retarder mode not TCU (A5). Replace TCU.
possible.
5045.5 - Retarder Retarder Proportional Check solenoid. See Retarder Proportional

Proportional Solenoid Solenoid (Y11). Solenoid Test
(Y11) Open Circuit. Wiring or connections. Check transmission control harness (W12)
Output switch OFF. and transmission harness (W13).
Retarder mode not TCU (A5). Replace TCU.
possible.
5046.2 - Transmission Wiring or connections. Check transmission control harness (W12).

Shift Control Signal
Malfunction.
Transmission goes to Transmission shift control Perform Transmission Shift Control Test.
neutral. (A4).
light ON.
5049.2 - Hour Counter TCU (A5). Replace TCU.

Malfunction.
Hour counter resets to
zero.
light ON.
5051.2 - TCU Memory TCU (A5). Replace TCU.

Malfunction.
All codes in memory
queue deleted.
light ON.
5052.11 - TCU System Loss of power to TCU. Check fuses and circuit breakers.
Malfunction. Check cab main harness (W10) and
All output switches transmission control harness (W12).
OFF. TCU (A5). Replace TCU.
Transmission goes to
neutral.
276 Doc. No. 872272 : Rev 0

5055.2 - CAN Data Component malfunction. Check and replace malfunctioning

Link Malfunction. components.
Transmission service Wiring or connections. Check transmission control harness (W12),
light ON. transmission harness (W13), and
5056.3 - Retarder on Wiring or connections. Check transmission control harness (W12),

Solenoid (Y10) Short transmission harness (W13), and
To Power. transmission control module harness (W19).
Retarder mode not
possible.
5056.4 - Retarder on Retarder on solenoid (Y10). Check solenoid. See Transmission

Solenoid (Y10) Short Wiring or connections. Solenoids, Speed Sensors, Sump
To Ground. Temperature Sensor and Retarder
TCU (A5). Resistor Tests.
Output switch OFF.
Retarder mode not Check transmission control harness (W12),
possible. transmission harness (W13), and
Replace TCU.
5056.5 - Retarder on Retarder on solenoid (Y10). Check solenoid. See Transmission

Solenoid (Y10) Open Wiring or connections. Solenoids, Speed Sensors, Sump
Output switch OFF. Resistor Tests.
Retarder mode not Check transmission control harness (W12),
possible. transmission harness (W13), and
5058.2 - Output Speed Output speed sensor (B14). Check resistance of speed sensor. See
Sensor (B14) Signal Transmission Solenoids, Speed Sensors,
Malfunction. Sump Temperature Sensor and Retarder
System goes into Resistor Tests
Forward only. Reverse transmission harness (W13), and
is not possible. transmission control module harness (W19).
Highest gear is TCU (A5). Replace TCU.
engaged. Then
downshift every 2.5
seconds until lowest
gear is reached, as
long as transmission
input speed is below
defined threshold.
light ON.
Doc. No. 872272 : Rev 0 277

5058.11 - Output Output speed sensor (B14). Check resistance of speed sensor. See
Speed Sensor (B14) Transmission Solenoids, Speed Sensors,
Signal Overflow. Sump Temperature Sensor and Retarder
Calculated sum to Resistor Tests.
large. Wiring or connections. Check transmission control harness (W12),
5059.2 - Turbine Turbine speed sensor (B13). Check resistance of speed sensor. See
Signal Malfunction. Sump Temperature Sensor and Retarder
Transmission service Resistor Tests.
light ON. Wiring or connections. Check transmission control harness (W12),
Replace TCU.
TCU (A5).
5059.11 - Turbine Turbine speed sensor (B13). Check resistance of speed sensor. See
Signal Overflow. Sump Temperature Sensor and Retarder
System goes into Resistor Tests.
5061.11 - Checksum TCU (A5). Replace TCU..

Malfunction.
Statistics date deleted.
5062.3 - Retarder Retarder resistor (R8). Check retarder resistor. See Transmission
Resistor (R8) Open Solenoids, Speed Sensors, Sump
Possible reduction in Resistor Tests.
retarder torque. Wiring and connections. Check transmission control harness (W12),
5062.4 - Retarder Retarder resistor (R8). Check retarder resistor. See Transmission
Resistor (R8) Short To Solenoids, Speed Sensors, Sump
Possible reduction in Resistor Tests.
retarder torque. Wiring and connections. Check transmission control harness (W12),
278 Doc. No. 872272 : Rev 0

5063.14 - TCU (A5). Replace TCU.

Transmission I.D.
Code.
Transmission goes to
neutral.
5065.0 - Retarder Oil Transmission oil low. Add oil as required. For oil spec. and
Temperature Over quantities.
Limit. Transmission oil cooler fan Check and replace fan relay.
Retarder temperature relay.
is over 160° C (320° Transmission oil cooler fan Check and replace cooler fan motor.
F). motor.
Retarder torque Retarder temperature sensor Check and replace sensor. See Retarder
reduced. (B11). Temperature Sensor Test (This Group).
Over temp. alarm
activated.
5065.14 - Retarder Oil Transmission oil low. Add oil as required. For oil spec. and
Over Temperature. quantities.
Retarder temperature Transmission oil cooler fan Check and replace fan relay.
is over 145° C (293° relay.
F). Transmission oil cooler fan Check and replace cooler fan motor.
Retarder torque motor.
reduced. Retarder temperature sensor Check and replace sensor. See Retarder
(B11). Temperature Sensor Test.
5066.0 - Transmission Transmission oil low. Add oil as required. For oil spec. and
Sump Temperature quantities.
Over Limit. Transmission oil cooler fan Check and replace fan relay.
Sump temperature is relay.
over 105° C (221° F). Transmission oil cooler fan Check and replace cooler fan motor.
reduced. Engine overheating. Check cause of engine overheating. See
Over temp. alarm diagnose engine malfunction.
activated. Transmission oil cooler is Check oil cooler.
restricted.
Retarder temperature sensor Check and replace sensor. See Retarder
Doc. No. 872272 : Rev 0 279

5066.14 - Transmission oil low. Add oil as required. For oil spec. and
Transmission Sump quantities.
Over Temperature. Transmission oil cooler fan Check and replace fan relay.
Sump temperature is relay.
over 100° C (212° F). Transmission oil cooler fan Check and replace cooler fan motor.
reduced. Transmission oil too hot due Check cause of engine overheating.
to engine overheating.
Transmission oil cooler is Check oil cooler.

restricted.
Retarder temperature sensor Check and replace sensor. See Retarder
5067.3 - Unused TCU (A5). Replace TCU.

Output Short To
Power.
5068.12 - Central Cut Wiring or connections. Check cab main harness (W10) and
Off Malfunction. transmission control harness (W12). See
Transmission remains “Cab Main Harness And Electric Mirror
in neutral. Interface Harness”
5075.12 - Retarder Wiring or connections. Check transmission control harness (W12).

Controller (A7) Signal
Malfunction.
No signal received Retarder controller (A7). Replace retarder controller.
from the retarder
controller.
5076.0 - Slip Time Oil level too low or too high. Add or remove oil to obtain correct level.
Under Load During 1st Worn oil pump. Repair pump.
to 2nd Upshift.
Turbine speed sensor (B13). Check resistance of speed sensor. See
Residual slip after end Transmission Solenoids, Speed Sensors,
of shift. Sump Temperature Sensor and Retarder
Resistor Tests (This Group).
Output speed sensor (B14). Check resistance of speed sensor. See
Transmission Solenoids, Speed Sensors,
Sump Temperature Sensor and Retarder
Resistor Tests.
Damage valve body gaskets Replace gaskets. Clean or replace valves as
or stuck (or sticky) valves. necessary.
Worn or damaged clutches. Repair or replace transmission.
280 Doc. No. 872272 : Rev 0

Under Load During Worn oil pump. Repair pump.
2nd to 3rd Upshift.
Residual slip after end
of shift. Turbine speed sensor (B13). Check resistance of speed sensor. See
Resistor Tests.
Resistor Tests.
Under Load During 3rd Worn oil pump. Repair pump.
to 4th Upshift.
Resistor Tests.
Resistor Tests.
Doc. No. 872272 : Rev 0 281

Under Load During 4th Worn oil pump. Repair pump.
to 5th Upshift.
Resistor Tests.
Resistor Tests .
TCU (A5). Replace TCU..
Under Load During 5th Worn oil pump. Repair pump.
to 6th Upshift.
Turbine speed sensor (B13). Check resistance of speed sensor.
Residual slip after end
of shift. Output speed sensor (B14). Check resistance of speed sensor. See
Resistor Tests.
5079.3 - Operating Alternator. Check alternator. Replace if necessary.

Voltage Above Limits.
5079.4 - Operating Loose or corroded Check connections of wire harnesses (W6

Voltage Below Limits. connections. and W9).
Batteries. Check batteries. Recharge or replace if
necessary.
Alternator. Check alternator. Replace if necessary.
EEPROM Correction TCU (A5). Replace TCU.

Parameter Checksum.
Initialization of default
settings from data field.
light ON.
282 Doc. No. 872272 : Rev 0

Doc. No. 872272 : Rev 0 283

CHAPTER 4. TRANSMISSION ZF 6 HP 592 C
SECTION 3. ADJUSTMENTS AND TESTS
TRANSMISSION WARM-UP PROCEDURE
‹ WARNING
Never stall torque converter for more than 15 seconds. Do not allow transmission temperature to
exceed 100° C (212° F). Transmission damage will result if temperature is allowed to exceed the
specification.
‹ CAUTION
Perform procedure in an open area away from other people or machines. Machine may move
unexpectedly.
• Apply park brake.

• Start engine.
• Select transmission temperature on the MDU. (See MDU - menu functions in Chapter 8 of the OMM).
Watch transmission temperature and tachometer display).
• Allow air pressure buzzer to go off.
• Push service brake pedal and hold it down during warm-up.
• Shift transmission into 1st gear. Accelerate throttle to 1500 r.p.m. and hold (approximately 15
seconds). After 15 seconds the CCU will decrease the engine speed to approximately 800 r.p.m.
Release the accelerator pedal and select neutral on gear selector.
• Push down on accelerator pedal. Engine will only accelerate to 1200 rpm until completing a cool-down
period of 50 seconds.
• Repeat steps 4 and 5 until transmission temperature reaches 80° C (176° F).
284 Doc. No. 872272 : Rev 0

Transmission Pressure Test
This test will check the performance of the transmission charge pump and main pressure regulator.
1. (Retarder ON) Pressure/(Retarder OFF)

Lubrication Pressure (D6/D7 Unmarked).
2. Main Pressure (P).
3. Retarder pressure (R3).
4. Pressure Before Convertor (D2).
5. Trottle Pressure (D1).
6. Retarder Control Pressure
(RR3 Unmarked).
Doc. No. 872272 : Rev 0 285

SPECIFICATIONS Transmission Pressure 2570 - 2670 r.p.m., 400 kPa {4 bar (58
Gear - 1, Lockup psi)}.
Transmission Oil 80 - 90° C (176 - 194° Clutch Engaged, Port
Temperature F) D1 Pressure.
Slow idle 780 - 820 700 - 1500 kPa {7.0 - 2570 - 2670 r.p.m., 600 - 850 kPa {6.0 -
r.p.m., Gear - Neutral, 15.0 bar (101 - 218 Gear - 1, Lockup 8.5 bar (87 - 123 psi)}.
Port P Pressure. psi)}. Clutch Engaged, Port
D2 Pressure.
Slow idle 780 - 820 400 kPa {4 bar (58
r.p.m., Gear - Neutral, psi)}. 2570 - 2670 r.p.m., 180 - 250 kPa {1.8 -
Port D1 Pressure. Gear - 1, Lockup 2.5 bar (26 - 36 psi)}.
Clutch Engaged, Port
Slow idle 780 - 820 300 - 450 kPa {3.0 - D6/D7 Pressure.
r.p.m., Gear - Neutral, 4.5 bar (44 - 65 psi)}.
Port D2 Pressure.
SERVICE
Slow idle 780 - 820 10 - 80 kPa {0.1 - 0.8
ESSENTIAL TOOLS EQUIPMENT AND
r.p.m., Gear - Neutral, bar (1.5 - 11.6 psi)}.
TOOLS
Port D6/D7 Pressure.
202839 1/8 x 7/16-20 4136 kPa {41.4 bar
Slow idle 780 - 820 700 - 1500 kPa {7.0 -
M ORB Quick Coupler. (600 psi)} Gauge
r.p.m., Gear - 15.0 bar (101 - 218
Neutral-to-Drive, Port psi)}. Parker No.
P Pressure. M10-4F80HG5 7/16-20
F x M10 x 1 Adapter.
Slow idle 780 - 820 20 - 10 kPa {0.2 - 15.0
r.p.m., Gear - bar (3.0 - 1.5 psi)} for 2
Neutral-to-Drive, Port seconds.
D1 Pressure.
Slow idle 780 - 820 300 - 450 kPa {3.0 -

r.p.m., Gear - 4.5 bar (44 - 65 psi)}.
Neutral-to-Drive, Port
D2 Pressure.
Slow idle 780 - 820 10 - 80 kPa {0.1 - 0.8

r.p.m., Gear - bar (1.5 - 11.6 psi)}.
Neutral-to-Drive, Port
D6/D7 Pressure.
2570 - 2670 r.p.m., 1600 - 2000 kPa {16.0

Gear - Neutral, Port P - 20.0 bar (232 - 290
Pressure. psi)}.
2570 - 2670 r.p.m., 400 kPa {4 bar (58

Gear - Neutral, Port D1 psi)}.
Pressure.
2570 - 2670 r.p.m., 600 - 850 kPa {6.0 -

Gear - Neutral, Port D2 8.5 bar (87 - 123 psi)}.
Pressure.
2570 - 2670 r.p.m., 180 - 250 kPa {1.8 -

Gear - Neutral, Port 2.5 bar (26 - 36 psi)}.
D6/D7 Pressure.
2570 - 2670 r.p.m., 1000 - 1200 kPa {10.0

Gear - 1, Lockup - 12.0 bar (145 - 174
Clutch Engaged, Port psi)}.
P Pressure.
286 Doc. No. 872272 : Rev 0

Shut engine OFF and apply park brake.
Remove plugs and install adapter and quick coupler in pressure ports (1; 2, 4 and 5).
Attach hoses and gauges to fittings.
Start machine and warm transmission to specification. See “Transmission Warm-up Procedure”.
‹ CAUTION
Perform procedure on a hard flat surface, away from other people or machines.
NOTE: Torque converter lockup occurs when turbine speed is approximately 80% of engine
speed.
Operate machine in gear specified and record transmission pressures as indicated. (Table on previous
page).
To take clutch pressure readings in a specific gear, e.g. 4th:
If transmission pressures are not to specification, check transmission charge pump and/or main pressure
regulator. See Disassemble and Assemble Front Input Control Element and Disassemble and Assemble
Control Valve.
Torque Converter Stall Test
Torque Converter Stall Test Specification
Engine Slow Idle - Speed: . . . . 680 ± 20 r.p.m.

Engine Fast Idle - Speed . . . . 2680 ± 50 r.p.m.
Stall Speed 2306D . . . . . . . 1941 ± 50 r.p.m.
Stall Speed 2806D . . . . . . . 1941 ± 50 r.p.m.
‹ WARNING
1. Never stall torque converter for more than 30 seconds. Do not allow transmission temperature
to exceed 100° C (212° F). Transmission damage will result if temperature is allowed to exceed the
specification.
2. Never perform stall test in reverse. Drive shaft or transfer case damage may result. Reverse
gear ratio and excessive torque will be transferred to the drive shaft, transfer case or differential.
Doc. No. 872272 : Rev 0 287

‹ CAUTION
Perform test in an open area away from other
people and machines. Machine may move
unexpectedly during test.
Perform test in an open area away from other

people and machines.
Ensure that all oil levels are correct.
Ensure that engine slow and fast idle speeds are

correct.
Place chocks in front and behind all wheels.
Start engine and let air pressure build to normal

operating pressure.
Do the transmission warm-up procedure to heat

transmission oil. See “Transmission Warm-up
Procedure”.
‹ CAUTION
Do not allow transmission oil temperature to
remain above 100° C (212° F) for long periods
of time. Damage to the transmission may
occur.
Check stall speed.
• Hold service brakes so machine cannot roll.

• Shift transmission into 1st gear. Push
accelerator pedal to the floor and hold it for 10
- 15 seconds until the engine sped stabilizes.
Record this stall speed. (See stall speed
specification on this page).
Shift transmission into neutral and run engine at

slow idle to cool for one minute before turning off.
If engine stall speed is below specification and

the engine is smoking, it may be low on power.
If engine stall speed is above specification, the

transmission may be slipping.
If engine stall speed is below specification and

the engine is not smoking, the torque converter
stator could be stuck.
If engine stall speed is a little below specification,

but the transmission oil overheats during normal
operation and will not cool down while idling, the
torque converter stator could be stuck.
288 Doc. No. 872259 : Rev 0

Torque Converter Stator Test Stuck Stator Test
Torque Converter Stator Specification A stuck stator will cause transmission oil to
overheat and not cool to normal temperature
Freewheeling Stator Transmission during non-operation.
Oil Temperature . . . . 71 - 93° C (160 - 200° F)
Transmission will overheat at fast operating
Stuck Stator Transmission speeds.
Oil Temperature . . . . . . . . . 100° C (212° F)
Machine may not reach full operating speeds.
The torque converter stator clutch can fail in two
ways: Torque converter stall test results will be normal.
• Freewheeling, when the clutch will not lock. Perform transmission warm-up procedure to
• Locked, when the clutch will not release. warm transmission oil. See “Transmission
Warm-up Procedure”.
Freewheeling Stator Test Shift transmission to neutral and run engine at
1200 - 1500 r.p.m. for two to three minutes.
A freewheeling stator can cause sluggish slow Monitor transmission temperature.
speed operation, but machine will seem to
operate normally at high speeds. If transmission temperature does not cool to
normal operating temperature, stator may be
Transmission oil will get hot or overheat quickly. stuck.
Transmission may not upshift with engine at full NOTE: Ensure transmission cooler or radiator
speed. is not clogged.
• Operate loaded machine in a normal manner Torque converter must be removed and repaired.
and monitor transmission oil temperature.
• While operating machine, notice how and
when transmission upshifts.
• If transmission temperature is hotter than
normal and transmission upshifts sluggishly or
not at all, stator is freewheeling. Torque
converter must be repaired.
Doc. No. 872259 : Rev 0 289

290 Doc. No. 872259 : Rev 0

CHAPTER 5. PNEUMATIC SYSTEM
PNEUMATIC SYSTEM
OPERATION
All pneumatic functions are supplied pressurized air
by the engine driven compressor.
Air from the compressor passes through the air

dryer to remove moisture and avoid contamination
of pneumatic components.
The air dryer contains an unloader valve that

regulates system pressure.
After air leaves the dryer it goes to the pneumatic

manifold and is throughout the pneumatic system.
Doc. No. 872272 : Rev 0 291

PNEUMATIC SYSTEM SCHEMATIC WITH TRAILER BRAKE.
22
41
42
TRAILER SERVICE BRAKE

21
TBX
10
TD0006808
292 Doc. No. 872272 : Rev 0

1. Air Compressor. 12. Pneumatic Exhuast Silencer.

2. Cooler Pipe. 13. Horn Solenoid.
3. Air Dryer and Unloader Valve. 14. Horn.
4. Purging Reservoir. 15. System Air Pressure Sensor (VDO Sender).
5. Air Reservoir. 16. Park Brake Solenoid.
6. Drain Solenoid. 17. Park Brake Pressure Switch.
7. Seat Lever Control Valve. 18. IDL Solenoid.
8. Seat Cylinder. 19. IDL Pressure Switch.
9. EV and EVB Solenoid. 20. IDL Actuator.
10. Park Brake Actuator. 21. Trailer Brake Valve.
11. Exhaust Brake Cylinder. 22. Air / Hydraulic Brake Valve.
Doc. No. 872272 : Rev 0 293

Air Pressure Supply Circuit Operation
TD0006645
1 Air Compressor. 4 Purging Reservoir.

2 Cooler Pipe. 5 Air Reservoir.
3 Air Dryer and Unloader Valve. 6 Moisture Drain Solenoid.
Compressor Air Dryer and Unloader Valve
The compressor (1) is gear driven off the engine The air dryer and unloader valve has four
and is a single cylinder piston-type compressor. functions.
Air is drawn into the compressor through the

engine air filter, compressed and sent through a
Drying The Air:
cooling pipe (2), then delivered to the air dryer
and unloader valve (3). As air from the compressor comes into the air
dryer and unloader valve it passes through a fine
The drain solenoid (6) is controlled by the CCU. screen filter and desiccant.
After each new engine start the CCU timer is set.
Moisture collects on the surface of the desiccant
After the timer reaches 10 minutes the drain and is prevented from going to the air system
solenoid valve is activated for a half second. components.
A new engine start is when the key switch is set

to the OFF position and it has been at least 10
minutes from the last engine start.
294 Doc. No. 872272 : Rev 0

Unloading The Compressor: 3. Bypass Spring.

4. Desiccant.
When air pressure reaches a specified amount, 5. Check Valve.
the unloader valve acts as a relief valve and will
“BLOW OFF”, out port 3, regulating air system 6. Port 21.
pressure. 7. Unloader Valve.
8. Regeneration Air Reservoir.
Charging The Regeneration Air
Reservoir 9. Port 22.
10. Port 3.
Air coming into the air dryer and unloader valve is
11. Purge Valve.
sent out port 22 to the regeneration air reservoir.
Compressed air from the compressor goes to
The unloader valve, acting as a relief valve,
port 1 (1) into chamber A. Air passes through a
maintains system pressure in the regeneration air
fine screen filter (2) and along the outside of the
reservoir.
desiccant cartridge (4).
The regeneration air reservoir air supply is used
Air passes through the desiccant, moisture is
to blow backwards through the desiccant
removed and collects on the outside of the
cartridge and purge collected moisture from the
desiccant cartridge.
cartridge.
Air flows through the desiccant, unseats check
Supplying The Pneumatic Manifold valve (5) then goes out port 21 (6) to the air
reservoir.
System pressure air is sent to the pneumatic
manifold for distribution to all pneumatic circuits. From the reservoir air flows to the pneumatic
manifold where it is distributed to the pneumatic
system.
Air Dryer and Unloader Valve
Air also flows out port 22 (9) and pressurizes the
Charging The Pneumatic System regeneration air reservoir (8).
If the desiccant cartridge becomes clogged, filter

3 bypass spring (3) will compress, allowing the
desiccant cartridge to move up.
Air would then come in port 1 through chamber

A, flow under the cartridge through chamber B
4 and out port 21 to the reservoir. The air will not
be dried, but the system will function.
2
5
B
1 1
A 6
C 21
22
8
11
10 GD4035CV
1. Port 1.
2. Filter.
Doc. No. 872272 : Rev 0 295

Purging The Air Dryer System air pressure is sensed through chamber
C on the unloader valve (7). As the system is
charging, pressurized air is also being sent to the
3
regeneration air reservoir (8) through port 22 (9).
When system pressure reaches 810 kPa (8.1

bar) (117 psi), air pressure on the diaphragm of
the unloader valve forces the diaphragm against
the spring, which opens a port to allow pressure
4 to assist in opening the purge valve (11).
As the purge valve is opening it allows air

pressure from the regeneration air reservoir to
escape up to chamber B and passes through the
2 desiccant and filter, carrying the collected
5 moisture with it.
1 1
21 6
Any additional moisture collected in chamber A is
7
also picked up, sent by purge valve and then out
exhaust port 3.
22 8
11
When the pressure in chamber B drops below
810 kPa (8.1 bar) (117 psi), check valve (5) will
9 close maintaining system pressure in chamber C
and in the air reservoir.
10 GD3036CV
When purge valve (11) is open, compressed air
1. Port 1 from compressor entering through port 1 into
chamber A is sent directly out exhaust port 3
2. Filter. (10).
3. Bypass Spring.
There is zero pressure in regeneration air
4. Desiccant. reservoir while system is in the “unloading”
5. Check Valve. stage. When system pressure drops
approximately 48 kPa (0.48 bar) (7 psi), check
6. Port 21. valve (5) opens, spring in unloader valve (7)
7. Unloader Valve. pushes against the diaphragm, closing the port to
purge valve (11) and starts the charging cycle
8. Regeneration Air Reservoir. again.
9. Port 22.
10. Port 3. Pneumatic Manifold
11. Purge Valve. The pneumatic manifold receives pressurized air
from the air reservoir and distributes it throughout
During the charging cycle, moisture is removed the pneumatic system.
from the air going to the system and collects on
the fine screen filter and the outside of the Exhaust air is routed through the pneumatic
desiccant cartridge. manifold and exits out the exhaust silencers and
orifice outside the cab.
296 Doc. No. 872272 : Rev 0

Pneumatic Circuit If the engine is started with the park brake switch
in the OFF position, even if the system air
pressure specification has been met, the park
Exhaust Brake and Exhaust Valve Brake brake switch must be cycled to the ON position
Circuit for the park brake to release.
Air from the pneumatic manifold goes to the Inter-Axle Lock Circuit
exhaust brake solenoid (9). The solenoid is
energized when all the following conditions NOTE:1. The inter-axle diff locks are air
occur: applied, spring released.
2. IDL Engaged: Pressure switch is in closed
• Accelerator pedal is in the slow idle position. position: MDU IDL Light ON.
• Torque converter is in lock-up. 3. IDL Disengaged: Pressure switch is in open
• There must be no electrical failure. position: MDU IDL Light OFF.
4. IDL “Engaged” status detected by CCU
If any of the above items change while the when IDL pressure switch is closed.
exhaust brakes are applied, the exhaust brake
solenoid will de-energize, the quick release valve The inter-axle lock is located in the transfer case.
will open to vent and the exhaust valve system The purpose of the inter-axle lock is to lock the
will disengage. front and rear axles together so power is applied
evenly to all axles.
Park Brake Circuit
The inter-axle lock cannot be engaged unless the
The park brake is spring applied and air pressure accelerator pedal is in the low idle position (Less
released. The function of the park brake circuit is than 10% throttle position and output shaft speed
to engage and disengage the park brake by less than 60 RPM.)
controlling the flow of the compressed air to park
brake actuator (10). When the inter-axle lock switch is pushed to the
ENGAGE position, the inter-axle lock solenoid
System air pressure from the pneumatic manifold (18) is energized, allowing compressed air to flow
is available at park brake solenoid valve (16). to the inter-axle lock actuator and the inter-axle
lock will be applied.
When the park brake switch is switched to the
OFF (brake disengage) position, the CCU sends The compressed air between the inter-axle lock
power to energise park brake solenoid (16). The solenoid and the inter-axle lock actuator closes
valve will open and allow compressed air to flow the contacts of the inter-axle lock pressure switch
into the park brake actuator, releasing the park (19).
brake.
When the inter-axle lock switch is pushed to the
When the park brake switch is switched ON DISENGAGE position, the inter-axle lock
(brake engaged), the CCU de-energized the park solenoid de-energizes. The de-energized
brake solenoid (16) and compressed air in the solenoid allows the compressed air to vent via
park brake pneumatic circuit vents to atmosphere the exhaust of the IDL solenoid to the
through the park brake exhaust (12) causing the atmosphere and the spring will release the inter
park brake to engage. axle differential lock. On machines equiped with a
scraper function, the IDL will be engaged
In the event of the system air pressure dropping automatically when the scraper function is
below 600 kPa (6bar) (87psi), the CCU will activated.
de-energise the park brake solenoid, causing the
park brake to engage. Air Circuit Air Horn (Optional)
When the park brake is engaged, park brake
Pushing the horn button, energizes air horn
pressure switch (17) causes the MDU park brake
solenoid (13), which causes compressed air to
light to illuminate.
flow to air horn (14).
Releasing the horn button de-energizes the horn

solenoid, causing the compressed air to vent to
atmosphere through the air horn solenoid.
Doc. No. 872272 : Rev 0 297

298 Doc. No. 872272 : Rev 0

DIAGNOSTIC PROCEDURE Perform Operational Check-out
Follow the six basic steps below to carry out Check all systems and functions on the machine.
troubleshooting efficiently: Use the helpful diagnostic information in the
problem.
Know The System
Study the machine technical manual. Understand Perform Troubleshooting

the system and circuits. Use schematics,
component location drawings and theory of Check for diagnostic codes on the MDU. The
operation for each circuit and circuit components self-diagnosing function lists any service codes
to better understand how the system, circuits and and gives corrective action information.
components work.
Before starting any trouble shooting, first check
battery voltage, circuit breakers and fuses.
Ask The Operator
Go to test groups to check pressures and
What type of work was the machine doing when voltages. Make sure adjustments are correct.
the trouble was noticed?
Did the trouble start suddenly or has it been Trace a Cause

getting worse?
Did the machine have any previous problem ? If probable and simplest to verify. Use the flow
so, which parts were repaired? charts and symptom, problem, solution charts to
help identify probable problem components.
Inspect the machine Make a plan for appropriate repair to avoid other
malfunctions.
Check all daily maintenance points. (See OM).
Check batteries, fuses circuit breakers and
electrical connections.
Doc. No. 872272 : Rev 0 299

DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS

NOTE:Diagnose Malfunction charts are arranged from most probable and simplest to verify, to
least likely and most difficult to verify.
System Does Not Reach Air dryer and unloader valve Adjust air dryer and unloader
Operating Pressure. not adjusted correctly. valve. Do Pneumatic System
Main Pressure Test And
Adjustment.
Leakage at fittings or from Tighten fittings. Repair lines.
lines.
Air reservoir drain valve. Check drain valve for leakage.
Repair or replace drain valve.
Hoses and lines connected to Connect hoses and lines to the
wrong ports. correct ports. See “Pneumatic
Manifold”.
System air pressure sensor. Test sensor. Do Pneumatic
System Solenoids, Pressure
Switches And Sensor Tests.
Park brake actuator. Check park brake pressure.
Unloader valve. Check pressure setting. Do
Pneumatic System Main
Pressure Test And Adjustment..
Air compressor. Repair or replace compressor.
Park Brake Light Does Not Go Park brake pressure switch Test park brake pressure switch.
Off. failed. Do Pneumatic System Solenoids,
Pressure Switches and Sensor
Tests.
Park Brake Does Not Hold. Park brake calliper adjustment. Adjust park brake calliper. Do
Park Brake Adjustment.
Park brake disc and pads. Checks thickness of pads. Do
Park Brake Pad Thickness
Check.
Park brake solenoid. Test park brake solenoid. Do
Pneumatic System Solenoids,
Tests.
Park brake valve. Test park brake pressure. Do
Park Brake Pressure Test.
Engine Valve Brakes or Exhaust Exhaust brake solenoid. Test exhaust brake solenoid. Do
Brakes Not Operating Correctly. Pneumatic System Solenoids,
Tests.
Engine valve brakes. Check engine valve brakes for
binding, not opening.
Exhaust brakes. Check engine exhaust brake
adjustment. Do Exhaust Brake
Adjustment.
300 Doc. No. 872272 : Rev 0

Horn not Working. Horn solenoid. Test horn solenoid. Do

Pneumatic System Solenoids,
Tests.
Horn switch. Test horn switch. Do Steering
Column Switch Test.
Inter axle diff. lock not releasing. Low or no air pressure. Check pneumatic system for
leaks and pressure.
Actuator leaking. Repair the leak or replace
actuator.
Doc. No. 872272 : Rev 0 301

302 Doc. No. 872272 : Rev 0

SECTION 3. ADJUSTMENTS AND TESTS
PNEUMATIC SYSTEM MAIN

PRESSURE TEST AND
ADJUSTMENT
Pneumatic System Main Specification

Pneumatic System Pressure
. . . . . . . . . . . 810 kPa {8.1 bar (117 psi)}.
Adjusting Screw ½ Turn Equals
. . . . . . . . . . . . . 50 kPa {0.5 bar (7 psi)}.
Essential Tools
Tee fitting
. . . . . . . . 202862 ¾-16 M 37° x ¾-16 F 37°
. . . . . . . . . . . . . . . . Sw x 7/16-20 M 37°
Service Equipment and Tools

Gauge . . . . . . 2068 kPa {20.6 bar (300 psi)}.
Stop machine and lower front bottom guard.
‹ CAUTION
Discharge pneumatic system completely
before removing any fittings or components.
Discharge air pressure from front pneumatic

system by pulling the drain plug ring on the
regeneration air reservoir. Connect “T” fitting (1) to dryer/unloader valve
and air line.
Disconnect air line from port 21 of air dryer and
unloader valve. Connect pressure gauge to tee fitting.
Start engine and observe air pressure on gauge.
Doc. No. 872272 : Rev 0 303

Record pressure when unloader valve

“unloads”.
Adjust pressure that unloader valve “unloads”

by turning adjusting screw (2) with a 3mm hex.
wrench. Turning screw clockwise will increase
unloading pressure.
If pressure be adjusted within specification,

replace air dryer and unloader valve.
PARK BRAKE PRESSURE TEST

Move park brake switch to the ON position to
engage park brake and relieve system pressure
from park brake circuit. Shut off engine.
‹CAUTION
1. Install articulation locking bar before
working in pivot area.
2. Discharge pneumatic system completely Disconnect line from park brake actuator and
before removing any fittings or components. install tee fitting (1). Connect gauge to fitting.
Start engine and observe pressure on gauge.

Install articulation lock bar. (see OM, Chapter 7)
Pressure must remain at zero with park brake
Move park brake switch to the On position to switch ON. If pressure is more than zero, park
engage park brake and relieve system pressure brake valve is leaking internally and must be
from park brake circuit. Shut off engine. replaced.
With engine running, release park brake and

observe pressure on gauge.
Observe system pressure on gauge.
Park Brake Pressure Specifications

Park Brake Switch ON
. . . . . . . . . . . . . . . 0 kPa {0 bar (0 psi)}.
Park Brake Switch OFF . . . . 810 kPa {8.1 bar)
. . . . . . . . . . . . . . . . . . . . . (117 psi)}.
Essential Tools
Tee fitting . . . 202862 ¾-16 M 37° x ¾-16 F 37°
. . . . . . . . . . . . . . . . Sw x 7/16-20 M 37°
304 Doc. No. 872272 : Rev 0

Service Equipment and Tools

Gauge . . . . . . 2068 kPa {20.6 bar (300 psi)}.
Park the machine on a level surface and chock

the wheels to prevent machine from rolling.
If pressure is low, go to “Pneumatic System

Main Pressure Test And Adjustment”.
PARK BRAKE ADJUSTMENT
Park Brake Adjustment Specification

Air System Pressure
. . . . . . . . . . . . 807 kPa {8.1 bar (117 psi)}
Actuator Rod Travel Distance
. . . . . . . . . . . . . . . . 50.8 mm (2”)} max.
Equipment and Tools

Remove plug and washer (1) covering the
• 6mm Allen Key adjusting screw.
Move the machine to a level surface. NOTE:Plug is located on the back side of the
park brake actuator bracket.
‹ CAUTION
Machine may roll when park brake is
released. Chock all wheels in front of and
behind wheels to keep machine from rolling
when park brake is released.
Release park brake.
Remove release stud (1), nut (2) and washer (3) Insert a 6 mm Allen Key into the adjusting screw
from storage position (4). and turn counter clockwise until resistance is felt.
Install release stud in hole at rear of park brake

actuator housing and rotate a ¼ turn to lock into
place.
Install washer and nut onto release stud and

tighten until park brake releases.
Doc. No. 872272 : Rev 0 305

NOTE:A clicking sound is heard as adjusting Re-take actuator rod travel measurements. If
screw is turned. travel is still more than 51mm (2 inches), actuator
has failed and must be replaced.
Turn Allen Key clockwise until resistance is felt.
If actuator rod travel is less than 22mm (0.88
Finally turn Allen Key counter clockwise seven inches), readjust the brake.
clicks.
Park brake Test
Remove Allen Key and install adjuster plug and
washer.
‹ CAUTION
Remove park brake release stud from actuator.
Perform test in an open area away from
Start engine. Allow air system to increase to people and other machines. Machine may
normal operating pressure (See specification). move unexpectedly during this test.
Apply park brake.
Apply inter-axle lock to prevent wheel slippage.
Move shift selector to D (Drive).
Release service brakes.
Increase engine speed to fast idle for a few

seconds.
Park brake must not let machine move.
If machine moves, check pad brake thickness

and park brake adjustment. (See Park Brake
Pad Thickness and Park Brake Adjustment
Procedure in this SECTION).
Park Brake Pad Thickness Check

Release the park brake. Measure from bottom of
park brake actuator to centre of clevis on actuator ‹ CAUTION
rod. This distance should be approximately
37mm (1.46 inches). Machine may roll when park brake is
released. Chock all wheels in front of and
Record measurement. behind wheels to keep machine from rolling
when park brake is released.
Apply park brake. Measure from bottom of park
brake actuator to centre of clevis on actuator rod. Park Brake Pad Thickness Specification
Subtract smallest measurement from the largest Park Brake Pad Thickness Min. . 3mm (0.118 “).
to get actuator rod travel.
If actuator rod travel is more than 51mm (2

inches), start engine; release and apply park
brake 20 times to help seat parts.
306 Doc. No. 872272 : Rev 0

Measure park brake pad thickness. Change park

brake pads when they are less than specification.
Checking the cable Vehicle power

connector / Connector plug.
Disconnect the plug-in connection (Vehicle power

connector Suspension - Vehicle) and measure
resistance.
• Resistance: > 4.6 W or £4.6 W

Pull the handle for seat height adjustment
upwards and measure resistance.
4.6 W correct
< 4.6 W (short-circuit) or
> 4.6 W (break)
Doc. No. 872272 : Rev 0 307

308 Doc. No. 872272 : Rev 0

CHAPTER 6. HYDRAULIC SYSTEM
HYDRAULIC SYSTEM CIRCUIT SYMBOLS
PUMPS Valves Solenoid, Single Winding
Hydraulic Pump: Fixed Displacement

Unindirectional
Check Reversing Motor M
Hydraulic Pump: Variable Displacement

ON - OFF (Manual Shut - OFF) Pilot Pressure Remote Supply
Unindirectional
MOTORS and CYLINDERS Pressure Relief Internal Supply
Hydraulic Pump: Fixed Displacement

Unindirectional
Pressure Reducing Lines
Hydraulic Pump: Variable Displacement Flow Control Adjustable
Unindirectional Non Compensated Lines Connecting
Three Position
Cylinder Single Acting Line With Fixed Restriction
Four Connection
Cylinder Double Acting Flow Control Adjustable

Single End Rod (Temperature and Line, Flexible
Pressure Compensated)
Two Position Station, Testing, Measurement

Double End Rod
Two Connection Or Power Take - Off
Two Position
Temperature Cause or Effect
Three Connection
Two Position
Differential Piston Reservoir Vented
Four Connection
Two Position
Miscellaneous Units In Transition
Reservoir Pressurized
Electric Motor Valves Capable Of Infinite Line To Reservoir Above Fluid Level
M
Positioning (Horizontal Bars
Indicate Infinite Positions
Accumulator, Spring Loaded Ability) Line To Reservoir Below Fluid Level
Accumulator, Gas Charged Methods of Operation Line, Working (Main)
Heater Spring Line, Pilot (For Control)
Cooler Manual Line, Liquid Drain
Hydraulic
Temperature Controller Push Button Flow Direction
Pneumatic
Filter Strainer Push - Pull Lever Lines Crossing or
Pressure Switch Pedal or Treadle
Pressure Indicator Mechanical
Temperature Indicator Detent
Direction Of Shaft Rotation

Assume Arrow On Near Side Pressure Compensated
Of Shaft HyGD0001CFM
Doc. No. 872272 : Rev 0 309

Hydraulic Schematic 2306D and 2806D Without Power Beyond
TRAILER BRAKE VALVE

TO TRAILER BRAKES
TO IPM
HYD/AIR
QUICK COUPLERS
REAR CHASSIS
2806
2306
PILOT PRESSURE
TD0006794
310 Doc. No. 872272 : Rev 0

2806D-2306D
PILOT PRESSURE
TO NEXT PAGE
T P LS TP
Doc. No. 872272 : Rev 0

235
210
LS - 6
2306D
2806D
T1 - 16
Hydraulic Schematic 2806D With Power Beyond
TO TRAILER BRAKES
TO IPM
TRAILER BRAKE VALVE

HYD/AIR
TD0006795
311
SERVICE MANUAL MK V
Doc. No. 872272 : Rev 0
2806D-2306D
TD0006796
Hydraulic Schematic 2806D With Power Beyond (Cont)
QUICK QUICK QUICK QUICK QUICK QUICK 8 BAR QUICK

COUPLER COUPLER COUPLER COUPLER COUPLER COUPLER ACCUMULATOR COUPLER
A B A B A B A B A B A B PS
TP
35 BAR
280
SERVICE MANUAL MK V
(OPTIONAL) (OPTIONAL)
PRESSURE DIFFERENTIAL RELIEF VALVE SETTING IS 25% HIGHER
THAN THE REDUCING VALVE SETTING
T P TP LS
TO PREVIOUS PAGE
312
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION
4
7
3
2 9
10
1 11
12
13
TD0006845
1. Brake Caliper. 9. Left Steering Cylinder.

2. Foot Brake Valve. 10. Hydraulic System Manifold.
3. Orbital Valve (Steering). 11. Secondary Steering Pump.
4. Right Steering Cylinder. 12. Main Hydraulic Pump.
5. Return Filter. 13. Front and Rear Brake Accumulators.
6. Hydraulic Tank. (Three used for B30D with wet disc brakes)
7. Suction Screen.
Doc. No. 872272 : Rev 0 313

The articulated hauler hydraulic system is a variable displacement (flow amplification) with
closed-centre, load-sensing system and consists integrated anti-cavitation relief valves.
of the steering circuit, secondary steering circuit,
and service brake circuit. The effective displacement of the steering valve
depends on the speed at which the valve is
The system oil is stored in the hydraulic reservoir turned. The steering valve routes and controls
(6). The suction strainer removes any large hydraulic oil to the left steering cylinder (9) and
particles that may have collected in the hydraulic right steering cylinder (4).
reservoir before the oil is sent to the main
hydraulic pump (12). The load sense passage is used to send a signal
from the work port to the hydraulic system
The main hydraulic pump is a manifold and then to the pump regulator valve
variable-displacement, axial-piston pump with when the valve is actuated.
load sensing and a pressure compensating
regulator valve. A ground driven secondary steering system is
used to provide supply oil flow for the steering
The regulator valves controls the pump flow rate circuit while the machine is still moving in the
by changing swash plate angle to meet load event there is a malfunction of the engine or main
demand of functions actuated and to de-stroke hydraulic pump.
the pump to residual (low stand-by) pressure
when all functions are in neutral. The system consists of the secondary steering
pump (11), check valve manifold mounted on the
The pump is mounted to and driven by the pump, and two check valves located in the
transmission PTO assembly. hydraulic system manifold. The pump is a
variable-displacement, axial-piston pump with a
The main hydraulic pump provides oil flow to the load sensing and pressure compensating
steering, service brake and auxiliary control valve regulator valve.
or L90LS control valve if fitted.
The residual pressure setting for the secondary
The hydraulic system manifold (10) controls and steering pump is lower than the residual pressure
distributes hydraulic oil through outlet ports to all setting for the main hydraulic pump. The pump is
components in the hydraulic system. mounted on the transfer case and is ground
driven as long as the gear train is being turned by
The manifold is a replaceable the moving machine.
cartridge-valve-type manifold. The steering and
brake accumulator charging circuits are given The check valves, in the hydraulic manifold are
priority by a valve located in the manifold. used to isolate the main hydraulic circuit and the
secondary steering circuit. The secondary
The auxiliary control valve is a closed-centre steering pump anti-cavitation check valve
valve with a load sense passage. The valve is manifold provides a path for oil flow from the
mounted on the hydraulic system manifold. suction side of pump to the outlet side when the
machine is moving in reverse.
The function of the auxiliary control valve is to
route hydraulic oil to the quick couplers at the The accumulators are not serviceable. The
rear of the hauler. function of the small brake accumulator is to
provide a signal to the brake accumulator charge
On the 2806D, an optional L90LS valve may be valve, regulating load sense signal to main
fitted at the rear of the machine for multi auxiliary hydraulic pump to maintain the pressure of brake
functions. In this case, the auxiliary valve on the accumulators between a lower and upper charge
hydraulic system manifold will be replaced with a limit.
power beyond block, which routes pump flow to
the L90LS control valve. The front and rear brake accumulators are used
to store brake oil under pressure which is then
The L90LS is a stackable, multi-section, load used to apply the service brakes when the brake
sensing, pressure control valve and controlled by valve is actuated, as well as providing a signal to
a stand alone IQAN controller. the brake accumulator charge valve.
The load sense passage is open to return when
the valve is in neutral.
The orbital valve (3) is a closed-centre valve with

a load sense passage. The valve is a wide angle,
314 Doc. No. 872272 : Rev 0

The brake valve (2) is a dual circuit, modulated valve.
The function of the valve is to control the charged brake oil from the accumulators to actuate the service
brake callipers or internal brake pistons.
The top valve section is for the front axle brakes and the bottom valve section is for the rear axle or axles.
The brake valve supplies charged brake oil to the rear brake callipers and then to the front brake
callipers.
Return filter (5) is used to filter return oil before entering the hydraulic reservoir.
Main Hydraulic Pump Operation
5
2
14
9
4 3 15
12
11
High Pressure Oil

5 6 Return Oil(Case drain)
Load Sense Oil
Suction Oil
7
6
1 Hydraulic Pump Housing

8 Input Shaft
2 Pump Control Valve
9 Swash Plate
3 Control Piston
10 Residual Spool
4 Pumping Piston
11 Compensating Spool
5 High Pressure Outlet
12 Load Sense Port
6 Suction Port
14 Residual Pressure Adjusting Screw
7 Bias Spring and Piston
15 Compensating Pressure Adjusting Screw
Doc. No. 872272 : Rev 0 315

The main hydraulic pump is a The piston bores are filled with oil through the
variable-displacement, axial-piston pump with a inlet port (6) as the pistons move out of their
load-sensing and pressure-compensating pump bores. The pistons moving into their bores push
regulator valve (2). The pump is driven by the oil out through the valve plate to the outlet port
Transmission auxiliary drive. (5) and to the control piston.
Pump displacement is varied by the angle of Pressure compensation is a constant pressure

swash plate (9). Swash plate angle is controlled system that requires a closed-centre hydraulic
by the control piston (3) and bias spring and system. As soon as the engine is started, supply
piston (7). oil flows from the pump to the closed-centre
valves. The pressure in the hydraulic system
The bios piston has supply oil (5) pressure and increases and causes the residual valve to
spring tension applied to it at all times trying to destroke the pump at residual pressure.
keep the pump at maximum displacement.
The residual pressure ensures that immediate
Supply oil is applied to or released from the system pressure is available on demand when a
control piston by the residual valve (10) varying function is actuated.
pump displacement per load demand. At full
system pressure the compensator valve (11) Load sense system pressure is used to regulate
shifts to route supply oil to the control piston the residual valve to stroke or destroke the pump
destroking the pump. as needed.
As the angle of swash plate is increased, the No matter what the load demand is, even when
pistons move in and out of their bores. The using more than one function, as long as the total
pistons move out of their bores during the first demand does not exceed the pumps capability,
half of each revolution, and into their bores during the pump will deliver the exact amount of oil
the last half of the revolution. required to move the load.
Main Hydraulic Pump Load Sense Operation

12 13
10 14
11
15
16
19
18 17
High Pressure Oil
Return Oil
Load Sense Oil Pump Control Valve
10 - Residual Pressure spool 15 - Compensating Pressure Adjusting Screw

11 - Compensating Pressure Spool 16 - Compensating Pressure Spring
12 - Load Sense Pressure 17 - Outlet to Control Piston
13 - Residual Pressure Spring 18 - Pump Pressure Inlet
14 - Residual Pressure Adjusting Screw 19 - Drain to Pump Case
316 Doc. No. 872272 : Rev 0

Residual Pressure Compensating Pressure
As soon as pump is driven, supply oil (9) flows to As the hydraulic system needs are met and the
pump regulator (1) which consists of the residual supply oil (9) pressure continues to rise, the
valve and compensating valve. increasing supply oil pressure starts to overcome
the compensator spring (4), sliding the
As the supply oil pressure rises, the residual compensator spool (5) toward the spring.
spool (2) having the smaller spring will start to
shift. The spool will then direct the high pressure
supply oil into the control piston (7) destroking
The spool will shift toward the residual spring (3) the pump but providing enough flow to maintain
until it allows supply oil to be directed into the compensating pressure in the system.
control piston (7), destroking the pump and
reducing flow until the pressure at the pump Compensating pressure is set lower than the
outlet (8) is equal to the residual pressure setting. system relief valve pressure. The system relief
valve is used to protect the system against
The pump will maintain this residual pressure sudden pressure spikes.
until the hydraulic system’s needs are greater
(function actuated). High system pressure oil is also conveyed into
the load sense circuit. The high pressure load
When hydraulic functions are not actuated the sense oil (10) plus the force of the residual spring
pump produces only enough flow to maintain the (3) will keep residual spool (2) shifted away from
residual pressure. The load sense oil at this time the spring.
is at a minimal pressure because the load sense
circuits are open to return.
Working Pressure
When a function is actuated, load sense oil

pressure (10) to the pump regulator (2) rises.
This rising load sense pressure and the force of

the residual spring tension work together to
overcome the pressure of the supply oil (5) on
the opposite side of the residual spool (10).
The spool will then slide over (away from spring),

opening the control piston (7) to case drain (19).
Doc. No. 872272 : Rev 0 317

Steering Valve Operation

1
2
5
6
11
7 8 8
10
L R 9
13
3 12
19
LS 14
4
15
9 11
16
T P
1 NEUTRAL 17
18 STEERING VALVE Hy40D0012CFM
1 Neutral. 10 From Hydraulic System Manifold Port P3.

2 Steering Cylinder. 11 Inlet Check Valve.
3 Gerotor. 12 Anti-Cavitation Valve.
4 Load Sense Port to Hydraulic System 13 Relief Valve.
Manifold Port L3.
14 Supply Oil.
5 Sleeve.
15 Work Pressure Oil.
6 Spool.
16 Trapped Oil.
7 Steering Shaft.
17 Return Oil.
8 Return.
18 Steering Valve.
9 Make-Up Check Valve. 19 Orifice.
318 Doc. No. 872272 : Rev 0

The steering valve (18) is a As steering operation is stopped, the centring

variable-displacement (flow amplification), spring and gerotor continue to turn the sleeve
closed-centre valve. Main valve components are until the sleeve and spool are in alignment,
the spool (6) inside a sleeve (5) within a housing stopping the flow of oil through the spool to the
and the gerotor (3). gerotor. At this point, the valve is in neutral and
remains there until the steering wheel and shaft
Also included are the make-up check valve (9), are turned again.
inlet check valve (11), anti-cavitation valves (12),
and relief valves (13). The valve’s variable-displacement (flow
amplification) is proportional to the speed at
When the steering wheel is not being turned, the which the steering wheel is turned.
valve is in neutral (1). In neutral, the spool and
sleeve are held in alignment by the centring When the steering wheel is turned slowly, the
spring blocking the flow of supply oil (14) through valve only measures oil through the gerotor to the
the sleeve to the spool and gerotor. steering cylinders and thus the effective
displacement is equal to the gerotor
Oil at the left and right work ports to the steering displacement.
cylinders is trapped (16) by the sleeve holding
the machine frames stationary. When the steering wheel is turned rapidly, the
spool moves more, relative to the sleeve opening
Turning the steering wheel and shaft (7) left or passages, so additional oil is allowed to bypass
right turns the spool relative to the sleeve, the gerotor, thus increasing the effective valve
opening passages so supply oil flows from the displacement, hence flow amplification occurs.
hydraulic system manifold port P3 (10) through
the sleeve into the spool. Relief valves (13) are used to relieve high
pressure oil from a pressure spike created in the
From the spool, work pressure oil (15) flows to steering cylinders while steering is in neutral. In
the gerotor (3) causing the gerotor gear and neutral, the steering valve blocks the flow of oil to
sleeve to turn. Work pressure oil flow is and from the cylinders.
measured by the gerotor back into the spool
where it is routed through the sleeve and out the A pressure spike is created by the impact of the
left or right work port to the respective ends of the front or rear wheels against an obstacle, which is
steering cylinders turning the machine. transmitted to the steering cylinders causing
slight cylinder movement.
Work pressure oil also flows out the load sense
port (4) and orifice (19), sending a load sense The cylinder movement that caused the pressure
signal back through the hydraulic system spike also causes a pressure drop and a void in
manifold port L3 to the main hydraulic pump the opposite end of the cylinders. Because of the
regulator valve to regulate pump flow. Load pressure differential across the anti-cavitation
sense signal also goes to the spring chamber of valve (12), the pressure in the return passage
the priority valve and to the steering load sense pushes the valve open and oil flows into the void
relief valve. preventing cavitation.
Return oil (17) flows back from steering cylinders, Oil not used flows out port T and then back to the
through the right or left work port, through the hydraulic reservoir.
sleeve and spool to the return circuit (8).
Doc. No. 872272 : Rev 0 319

Secondary Steering Pump Operation
5 7
6 X
B
4
3 4
1 2
S L
10
9
10
11
8
5
12 4
13
17
18
19
16
14 15
Hy40D0013CFM
1 From Pump Outlet. 10 Control Piston.

2 To Control Piston. 11 Pump Regulator Valve.
3 To Case Drain. 12 Swash Plate.
4 Compensator Valve. 13 Spring.
5 Residual Valve. 14 Piston.
6 To Hydraulic System Manifold Port P2. 15 Cylinder Block Oil.
7 From Hydraulic System. 16 Valve Plate.
8 From Main Hydraulic Pump Manifold 17 Supply Oil.
Port L2.
18 Load Sense Oil.
9 Transfer Case.
19 Return or Pressure-Free Oil.
320 Doc. No. 872272 : Rev 0

The secondary steering hydraulic pump is a The piston bores are filled with oil through the
load-sensing, pressure-compensating, valve plate (16) as the pistons move out of the
variable-displacement axial-piston pump. bores.
Pump displacement is varied by the angle of the The pistons moving into their bores push oil out
swash plate (12). The swash plate angle is through the valve plate, through the secondary
controlled by the control piston (10) and spring steering pump anti-cavitation valve, and to the
(13). hydraulic system manifold port P2 (6).
Spring pressure is applied to the swash plate at The pump displacement is regulated by the
all times, trying to keep the pump at maximum compensator valve and residual valve (load
displacement. Secondary supply oil (17) is sensing).
applied to or released from the control piston by
the residual valve (5) in response to load sense Normal leakage to the pump case through
signal from hydraulic system manifold port L2 to clearance between the pistons, valve plate and
load sense port X, varying displacement per load cylinder block provides cooling and lubrication
demand. before flowing back to the hydraulic reservoir.
At full system pressure, the compensator valve The secondary steering pump is mounted on the
(4) is shifted to route secondary supply oil to the transfer case (9) and is ground driven as long as
control piston, de-stroking the pump. the gear train is being turned by the moving
machine.
As the angle of the swash plate is increased, the
pistons (14) move in and out of their bores and When the machine is not moving, there is no
displace oil as the cylinder block (15) is turned. secondary steering pump flow. The secondary
steering pump will not operate when machine is
The pistons move into their bores during the first moving in reverse.
half of each revolution, and out of their bores
during the last half of the revolution.
Doc. No. 872272 : Rev 0 321

Hydraulic System Manifold With Auxiliary Spool (Top View)
‹ WARNING
No repairs or welding to be done on the VOAC block. If faulty, refer to BELL PRODUCT SUPPORT
Representative.
1 Pressure Reducing Valve (Xb) S4 Low Brake Pressure Switch

6 Brake Pressure Charge Valve (X4) SP1 Emergency Steering Pressure Switch
10 Priority Valve MR Pilot Pressure Reducing Valve Test Point
13 Shuttle Valve Access MP1 Main Pump Pressure Test Point(Remote
Access Behind Cab)
15 Steering Load Sense Relief Valve (X3)
MP2 Secondary Steering Pump Pressure
16 Auxiliary Spool Solenoid (Remote Access Behind Cab)
17 Auxiliary Spool Solenoid MP3 Main Pump Pressure Test Point
18 A4 Accumulator Charge Orifice Access (Ø ML3 Steering Load Sense Test Point
0.6mm)
ML1 Load Sense To Pump Test Point
19 A4 Accumulator Charge Orifice Access (Ø
0.6mm)
322 Doc. No. 872272 : Rev 0

Hydraulic System Manifold Without Auxiliary Spool (Top View)
‹ WARNING
No repairs or welding to be done on the VOAC block. If faulty, refer to BELL PRODUCT SUPPORT
Representative.
P T
TD0006797
1 Pressure Reducing Valve (Xb) S4 Low Brake Pressure Switch

6 Brake Pressure Charge Valve (X4) SP1 Emergency Steering Pressure Switch
10 Priority Valve MR Pilot Pressure Reducing Valve Test Point
13 Shuttle Valve Access MP1 Main Pump Pressure Test Point(Remote
15 Steering Load Sense Relief Valve (X3) Access Behind Cab)
16 Auxiliary Spool Solenoid MP2 Secondary Steering Pump Pressure
(Remote Access Behind Cab)
17 Auxiliary Spool Solenoid
MP3 Main Pump Pressure Test Point
18 A4 Accumulator Charge Orifice Access (Ø
0.6mm) ML3 Steering Load Sense Test Point
19 A4 Accumulator Charge Orifice Access (Ø ML1 Load Sense To Pump Test Point
0.6mm)
Doc. No. 872272 : Rev 0 323

Hydraulic System Manifold With Auxiliary Spool (Front View)
32
30
L1 Load Sense Port To Main Pump

P4 Optional Outlet To Adaptive
L2 Load Sense Port To Secondary Steering Suspension
Pump
12 Secondary Steering Check Valve
P1 Pressure Supply Port From Main Pump
30 Aux Load Sense Bleed Orifice Access
P2 Pressure Supply Port From Secondary
Steering Pump 32 Plug
324 Doc. No. 872272 : Rev 0

Hydraulic System Manifold Without Auxiliary Spool (Front View)
32
32
TD0006798
L2 Load Sense Port To Secondary Steering

Pump P4 Optional Outlet To Adaptive
Suspension.
P1 Pressure Supply Port From Main Pump
P2 Pressure Supply Port From Secondary
Steering Pump 30 Aux Load Sense Bleed Orifice Access
32 Plug
Doc. No. 872272 : Rev 0 325

Hydraulic System Manifold With Auxiliary Spool (Rear View)
A4 Brake Charge Signal Accumulator Port(Wet

Disk Brake Only) M5 Brake Accumulator Pressure Test Point
A5 Pressure Outlet To Rear Brake 2 Brake Accumulator Charge Orifice
Accumulators Access(Ø2,0mm)
A6 Pressure Outlet To Front Brake 3 Brake Accumulator Check Valve
Accumulators 7 Main Pressure Relief Valve
B5 Pressure Outlet To Foot Brake Valve 8 Hydraulic Cut Solenoid
B6 Pressure Outlet To Foot Brake Valve 31 Plug
326 Doc. No. 872272 : Rev 0

Hydraulic System Manifold Without Auxiliary Spool (Rear View)
TD0006799
A5 Pressure Outlet To Rear Brake M5 Brake Accumulator Pressure Test Point

Accumulators
2 Brake Accumulator Charge Orifice
A6 Pressure Outlet To Front Brake Access(Ø2,0mm)
Accumulators
3 Brake Accumulator Check Valve
B5 Pressure Outlet To Foot Brake Valve
7 Main Pressure Relief Valve
B6 Pressure Outlet To Foot Brake Valve
8 Hydraulic Cut Solenoid
31 Plug
Doc. No. 872272 : Rev 0 327

Hydraulic System Manifold With Auxiliary Spool (Right View)
4 Flow Fuse Shuttle Valve

P3 Outlet Supply To Orbital Valve(Steering)
5 Pilot Pressure Reducing Valve
L3 Load Sense Input From Orbital Valve
9 Brake Charge Load Sense Orifice(Ø0,7mm)
M4 Brake Pressure Test Port(Remote Behind
11 Secondary Steering Check Valve Cab)
14 Shuttle Valve Access M6 Brake Accumulator Test Point
328 Doc. No. 872272 : Rev 0

Hydraulic System Manifold Without Auxiliary Spool (Right View)
TD0006800
5 Pilot Pressure Reducing Valve P3 Outlet Supply To Orbital Valve(Steering)

9 Brake Charge Load Sense Orifice(Ø0,7mm) L3 Load Sense Input From Orbital Valve
11 Secondary Steering Check Valve M4 Brake Pressure Test Port(Remote Behind
Cab)
14 Shuttle Valve Access
M6 Brake Accumulator Test Point
Doc. No. 872272 : Rev 0 329

Manifold Schematic With Auxiliary Spool
32
31
34
30
33
TD0006763
1 Pressure Reducing Valve (XB) 13 Shuttle Valve

2 Brake Accumulator Charge Orifice 14 Shuttle Valve
(Ø2,0mm)
3 Brake Accumulator Check Valve 15 Steering Load Sense Relief Valve (3)
4 Flow Fuse Shuttle Valve 16 Aux Solenoid
5 Pilot Pressure Reducing Valve 17 Aux Solenoid
6 Brake Pressure Charge Valve (X4) 18 A4 Accumulator Charge Orifice (Ø 0.6mm)
7 Main Pressure Relief Valve 19 A4 Accumulator Charge Orifice (Ø 0.6mm)
8 Hydraulic Cut Solenoid 30 Aux Load Sense Bleed Orifice
9 Brake Charge Load Sense Orifice 31 Aux SPOOL

(Ø0,7mm) 32 Aux Relief And Anti Cavitation Check
10 Priority Valve Valve
11 Secondary Steering Check Valve 33 Aux Relief And Anti Cavitation Check
Valve
12 Secondary Steering Check Valve 34 Logic Valves
330 Doc. No. 872272 : Rev 0

Manifold Schematic Without Auxiliary Spool
P
210
235
TD0006801
1 Pressure Reducing Valve (XB)

13 Shuttle Valve
2 Brake Accumulator Charge Orifice
(Ø2,0mm) 14 Shuttle Valve
3 Brake Accumulator Check Valve 15 Steering Load Sense Relief Valve (3)
4 Flow Fuse Shuttle Valve 16- Solenoid (not used)
5 Pilot Pressure Reducing Valve 17 Solenoid (not used)
6 Brake Pressure Charge Valve (X4) 18 A4 Accumulator Charge Orifice (Ø 0.6mm)
7 Main Pressure Relief Valve 19 A4 Accumulator Charge Orifice (Ø 0.6mm)
8 Hydraulic Cut Solenoid
9 Brake Charge Load Sense Orifice
(Ø0,7mm)
10 Priority Valve
Doc. No. 872272 : Rev 0 331

L90LS Auxiliary Hydraulic Manifold
332 Doc. No. 872272 : Rev 0

35 Main Relief 41 Aux. Function Proportional Solenoids

36 Load sense Copy Valve 42 Pressure Compensator Valve With
Integrated Load Hold Check
37 Pilot Pressure Reducing Valve
43 Aux. Function Spool
38 Pilot Pressure Relief Valve
44- Pilot Restrictors Oriface (0.8mm)
39 Pilot Pressure Filter
45 Shuttle Valve
40 Pilot Pressure Accumulator (8 Bar)
46 Aux. Caution Check Valve
19 A4 Accumulator Charge Orifice (Ø 0.6mm)
Doc. No. 872272 : Rev 0 333

General Description The switch actuates the brake low pressure

indicator light.
The hydraulic system manifold controls and The priority valve (10) gives priority to the
distributes hydraulic oil through outlet ports to all steering valve and brake accumulator charging
components in the hydraulic system. circuit over the auxiliary control valve if supply oil
flow from main hydraulic pump is not enough to
The hydraulic system manifold is a replaceable satisfy the load demand.
cartridge-valve type manifold. The auxiliary
control valve is mounted on the hydraulic system During operation the priority valve remains open
manifold. if the pressure to operate the brake accumulator
charging and steering circuits is less than that of
Numbers and letters are stamped on the manifold the aux function circuit.
to help locate and identify components and ports.
The illustrated views given are with the hydraulic Oil takes the path of least resistance, meeting the
system manifold installed in the machine. load demand of charging and steering circuits.
Test ports ML1, ML3, MP3, M5, and M6 are When pressure to operate the brake accumulator
equipped with high pressure quick couplers for charging or steering circuits is higher, their higher
making test connections to hydraulic system. load sense signal assists the priority valve spring
to move the valve spool, reducing the flow of oil
Supply oil flows from the main pump to the main to the auxiliary control valve.
inlet port, L1.
The main hydraulic pump can now meet the
Supply oil flows from the secondary steering charging or steering circuit load demand.
pump to the secondary steering pump port, P2.
The priority valve signal shuttle valve (13) routes
The secondary steering pump check valve (12) the higher load sense signal from the steering
blocks supply oil flow from the main hydraulic valve or brake accumulator charging circuit to the
pump to the secondary steering pump. spring chamber of the priority valve and to the
main hydraulic pump signal shuttle valve.
It also functions as the closed-centre valve for the
secondary steering pump. The steering load sense relief valve, X3 (15)
relieves excess load sense signal from the
The check valve will open when the main steering valve.
hydraulic pump flow is low enough so that
pressure drops below the pressure of the The secondary steering pressure switch, SP1, is
secondary steering pump, allowing the a normally open switch and closes when the
secondary steering pump to supply oil to the main hydraulic pressure reaches 5 bar. The
steering valve as long as the machine is moving. switch actuates the secondary steering indicator
light. The brake accumulator charge valve, X4
The load sense signal from the main hydraulic maintains brake charge in the main accumulators
pump load sense port, L1 to the main hydraulic between an upper and lower charge band.
pump port, X causes the pump to go into stroke.
The brake accumulator pressure reducing valve,
The load sense signal from the secondary XB (1) limits pressure to the brake accumulators.
steering load sense port, L2 to the secondary The brake accumulator charge check valve (3)
steering hydraulic pump port, X. holds charge pressure in the brake charge
accumulator so oil does not flow to the steering
Test ports MP1, MP2, and M4 are connected by
and aux control circuits when system pressure is
hydraulic lines to a test port manifold located
less than charge pressure.
behind the cab.
The brake low pressure switch, S4 closes when

brake accumulator pressure decreases below
123 bar.
334 Doc. No. 872272 : Rev 0

Auxiliary Spool Operation When current is applied to either of the solenoids,

the spool will move to the required position.
Standby oil will now flow through the spool and
The auxiliary control valve assembly is mounted out of Port A or B, depending on spool position.
on the hydraulic system manifold. The assembly Return oil from the auxiliary circuit will then flow
consists of the following. through either Port A or B, through the spool to
tank. At the same time, a pilot signal from the
• Port A and Port B circuit relief and spool will also be sent to one of the logic valves.
anti-cavitation relief valves(32,33) As the logic valve shifts, system pressure passes
• Logic valves(34) – Load sense copying through and becomes a load sense signal. This
load sense signal will then flow through shuttle
• Aux control spool(31)
valve (14), and out through port L1 to stroke in
the main pump.
Port B circuit relief and anti-cavitation valve(32)
relieves oil in the cylinder rod end of the auxiliary
When the control spool returns to neutral, the
function and at a lower pressure than Port A.
pilot signal to the logic valve is cut off by the
spool and the LS pressure is then released to
Port A circuit relief and anti-cavitation valve(33)
tank via orifice 30, causing the pump to
relieves oil in the cylinder rod head end of the
de-stroke.
auxiliary function and at a higher pressure than
Port B.
The incorporated anti-cavitation check valves,

prevent air from being drawn into the circuit if the
auxiliary cylinder is extended or retracted while
the control valve is in neutral or the engine not
running.
Port A and B are routed to quick couplers at the

rear of the machine for an auxiliary fuction.
The two Logic valves(34), are controlled via a

pilot signal from control spool(31). They are
supplied with system pressure and are used to
copy the load sense signal when the spool is
shifted. Main pressure is then routed as a load
sense signal to the pump. The purpose of these
valves is to prevent a pressure drop of the LS
signal across the spool. A larger signal is
therefore sent to the pump.
The control spool (31), is a spring centered, five

position, pilot operated spool. The movement of
the spool is determined by varying pilot pressure
on each end, and this is controlled by two
proportional solenoid valves (16, 17). Reduced
pilot pressure is supplied to these valves via a
pressure reducing valve(5). The movement of the
spool is then proportional to the current applied to
the solenoid valves.
Doc. No. 872272 : Rev 0 335

L90LS Directional Control Valve Control valve

Breakaway min. 260 mA
Assembly Operation. Fully actuated max. 510mA
General To give gentle control characteristics, soleniod

spool actuators are fitted with pilot restrictors[44],
which serves to give a kind of ramp function.
The L90LS is a stackable, multi section,
load-sensing, pressure-compensated directional Pressure compensator/ load-hold check valve
valve. The spools in the L90LS are actuated
[42]
directly by means of electro-hydraulic
proportional solenoids. These solenoids are When there are demands for very good
controlled via a stand alone IQAN controller fitted simultanious-operating characteristics or
to the machine intensive, multi-section operability and
responsiveness, individual spool-sections in the
The L90LS control valve assembly consists of an
L90LS are equipped with integral
inlet section, stackable multi spool section and
pressure-compensators. Sections are then not
end section.
influenced by other simultaneously operated
machine functions, regardless of the variations in
Inlet Section loads, provided there is sufficient pump capacity.
Responding to the instantaneous value of the
The inlet section is equiped with a load signal, the pressure compensator regulates
non-adjustable, direct-acting main pressure relief continuously the flow through the spool to
valve, [35], which protects the pump and inlet maintain a constant pressure-differential between
side of the valve. The interchangeable cartridge the pump and service-port sides of the spool.
is factory set. The cartridge has a make-up This results in a constant flow to the function for a
function, which means that oil is able to flow from given spool. This results in a constant flow to the
the tank gallery to the pump gallery in the event function for a given spool stroke, regardless of
of negative pressure in the pump circuit. the load pressure or any activity in other spool
sections.
Although the inlet section is also equipped with a
copy function of the load signal, it is not utilised Anti-cavitation valves [46]
on the 2806D. This is done by using the LS port
to pump and not the PL port. This will send the The make-up function enables oil to flow from the
load sense signal directly from the auxiliary tank gallery to the service-port side in the event
spools to the pump and not via the copy spool. of negative pressure in the service ports, in order
to prevent cavitation.
Copy spool function if utilised.
Load sense shuttle valves [45]
The load signal acts on a copy spool [36], which
sends a copied load signal to the LS connection. The load sense system of the L90LS consists of
The copying system permits a certain a number of shuttle valves, which compare the
consumpsion in the load-signal line to the pump load signals from the spool sections. The highest
regulator, without the load signal being load pressure is transmitted and controls the
influenced. Due to drainage in the pump LS variable pump via the copy spool [36]
regulator, the system gives better winter
operating characteristics with faster response,
since the oil in the LS circuit is always warm. End section
Moreover, it prevents the tendency for the load to
sink slightly at the beginning of the lifting phase. The end section houses internal pilot pressure
reducing valve [37], with incorporated pressure
differential relief valve [38], as well as the pilot
Stackable Multi Spool Section filter and pilot pressure accumulator [40] port.
the auxiliary function control spools [42] are The internal pilot-pressure reducing valve works
proportional, electro-hydraulically controlled as both a pressure regulator and a pressure relief
spool actuators, closed centre with spring valve in the pilot circuit. For safety reasons, the
centering to neutral. They are controlled remotely cartridge has also been equipped with a seperate
by the IQAN control system. Pilot-pressure oil is relief valve [38] that prevents the maximum
led to the proportional control solenoids [41] permissable reduced pressure from being
through internal ducts in the directional valve. exceeded. A check valve prevents pilot oil from
leaking back to the pump, and therefore enables
336 Doc. No. 872272 : Rev 0

the pressure in the pilot circuit to be maintained motor, the generated load sense signal through
in the event of a temporary fall in pump pressure, orifice (9) is released to return through Hydraulic
e,g during a rapid lowering movement. This is cut solenoid (8).
also assisted by accumulator [40]
Pilot oil also passes through a coarse filter with

Charged System
bypass function. The filter protects the pilot circuit
from dirt, especially during start-up of the system. When all accumulators are charged, charge oil
pressure in the brake accumulators holds the
accumulators charge check valve (3) closed. The
Service Brake System Operation brake accumulator charge oil pressure keeps the
accumulator charge valve (6) open allowing
pump load sense oil to flow back to tank.
Charging System
The rear and front brake accumulator circuits are
When operating the service brake valve, charge separated by the flow fuse shuttle valve (4) and
oil pressure in the front brake accumulators and hold charge oil in the rear and front brake
rear brake accumulators decreases. accumulators and brake valve. The flow fuse
shuttle valve enables the circuits to work
The decrease of charge oil pressure in the brake independently of each other in the event of a
accumulators is sensed by the accumulator malfunction in either circuit.
charge valve (6).
The pressure setting of the accumulator charge
When the accumulator charge oil pressure valve and accumulator pressure reducing valve is
decreases below the lower pressure setting of critical to operation of the main hydraulic pump. If
the accumulator charge valve, the charge valve pressure setting of accumulator charge valve is
spring shifts the spool, blocking the flow of load higher than accumulator pressure reducing valve,
sense oil to the return circuit. the load sense signal to the main hydraulic pump
will remain high because the charge oil pressure
System oil continues to flow through the brake from brake accumulator cannot open the charge
accumulator charge orifice (9), increasing load valve allowing load sense oil to flow to return.
sense pressure.
The pump will remain in stroke and not return to
The increasing load sense pressure shifts the low stand-by (residual) pressure when all
priority valve signal shuttle valve (13) and main functions are in neutral.
hydraulic pump signal shuttle valve (14) sending
the load sense signal out of port L1 to the main
hydraulic pump port X, stroking the pump, Brake Valve - Neutral
increasing flow, causing supply oil pressure to
increase. The service brake valve is a dual circuit,
modulated valve. The function of this valve is to
This supply oil then flows through the control the charge oil from the rear and front
accumulator pressure reducing valve (1), brake accumulators to actuate the service
accumulator orifice (2), and accumulator charge brakes.
check valve (3) charging the brake accumulator.
The brake valve contains two separate circuits,
As pressure increases, accumulators are each supplied by their own set of accumulators.
charged via flow valve (4). Pressure to the The top valve is for the front axle brakes and the
accumulators is limited by accumulator pressure bottom valve is for the rear axle brakes.
reducing valve. The accumulator orifice controls
the rate of oil flow to charge the accumulators. The brake valve supplies charged oil to the rear
brakes first and then the front brakes. In neutral,
When brake accumulator charge oil pressure charge oil is blocked by the brake valve spools
increases to the upper pressure setting of and the brake pistons are open to return.
accumulator charge valve (6), the charge valve
spool shifts to the open position allowing load
Brake Valve - Actuated
sense oil to flow to return, decreasing the load
sense signal to the main hydraulic pump. The
pump de-strokes decreasing supply oil flow to the When service brakes are actuated, the charge oil
accumulators. in the accumulators flows through the brake valve
to the brake pistons, applying the brakes.
To prevent pump from stroking in during machine
start up, causing excess strain on the starter
Doc. No. 872272 : Rev 0 337

The pressure applied at the pistons and the force Low oil flow may occur during an attempt to
applied to the spring by the brake pedal act on rapidly steer machine at slow engine speed.
opposite ends of the spools in the brake valve.
Under normal steering operation, the pressure of
The pressure to the pistons is proportional to the secondary steering pump at port P2 is just below
force applied to the brake pedal (pressure to the that of the main hydraulic pump at port P1
pistons increases as the force on the brake pedal creating a differential pressure across secondary
increases). steering pump check valve (12).
The pressure on the end of the spools balances The load sense signal to the secondary steering
against the spring force modulating the pressure pump via port L2 is the same as that of the main
to the pistons. The charge oil pressure is reduced hydraulic pump at port L1, enabling the pressure
by the amount of oil it takes to move the pistons. of the secondary steering pump at port P2 to
increase and overcome the pressure differential
Each application of the brake pedal reduces the across secondary steering pump check valve
charge pressure until the brake accumulator (12).
charge circuit is actuated by the accumulator
charge valve (6). Flow from the secondary steering pump, via port
P2, eventually supplements the flow from the
main hydraulic pump to the steering valve via
Steering And Secondary port P3.
Steering System Operation
The rpm of the secondary steering pump is
dependent on the machine travel speed. Supply
The function of the steering system is to route
oil flow available to steer the machine is reduced
supply oil from the main hydraulic pump to the
proportionately as the travel speed decreases.
steering orbital valve. The steering orbital valve
then controls the oil flow used to extend and
The secondary steering pump is a
retract the steering cylinders.
variable-displacement, axial-piston pump with a
load sensing and pressure compensating
When the steering wheel is turned, the load
regulator valve.
sense signal from the steering valve enters the
hydraulic system manifold at port L3. The load
Operation of the secondary steering pump is
sense signal is then sensed at the secondary
similar to the main hydraulic pump. The residual
steering pump via port L2.
valve pressure setting for the secondary steering
pump is lower than the residual valve pressure
At the same time, the load sense signal shifts the
setting for the main hydraulic pump.
shuttle valves (13 & 14), pressurizes the spring
chamber of priority valve (10), and sends a signal
When the machine is moving, the pressure at test
to the main hydraulic pump via port L1.
port MP2 remains just below the pressure at test
port MP1. The secondary steering pump is
The load sense signal will not exceed the
mounted on the transfer case and is
steering load sense relief valve (15) pressure
ground-driven.
setting. The main hydraulic pump supplies the
required flow rate through port P1, main hydraulic
The secondary steering pump check valve (12) is
pump check valve (11), and out of port P3 to
used to block oil flow from the main hydraulic
steering valve port P.
pump to the secondary steering pump circuit.
When the steering wheel is not being turned, the
In the event of a malfunction, main hydraulic
load sense signal is open to hydraulic reservoir
pump check valve (11) blocks flow from the
through the steering valve and the main hydraulic
secondary steering pump to the main hydraulic
pump will return to residual pressure.
pump, fan drive valve, aux control valve, and
brake accumulator charging circuit.
The oil in the steering cylinders is trapped and
the machine is held at that relative position. The
ground driven secondary steering pump will
assist with oil flow to steer the machine if main
hydraulic pump cannot deliver the flow required.
(Machine must be moving for secondary steering
pump to work.)
338 Doc. No. 872272 : Rev 0

DIAGNOSTIC PROCEDURE Perform troubleshooting
Follow the six basic steps below to carry out Connect the laptop computer with diagnostic
troubleshooting efficiently. software, if available. The self-diagnosing
function lists any service codes.
Know the system Before starting any troubleshooting, first check
battery voltage, battery disconnect switch, fuses,
Study the machine technical manual. Understand and circuit breakers.
the system and circuits.
Go to test groups to check pressures and
Use schematics, component location drawings, voltages. Make sure adjustments are correct.
and theory of operation for each circuit and circuit
components to better understand how the
system, circuits, and components work. Trace a cause

Ask the operator probable and simplest to verify.
What type of work was the machine doing when Use the symptom, problem, solution charts to
the trouble was noticed? help identify probable problem components.
Did the trouble start suddenly or has it been Make a plan for appropriate repair to avoid other
getting worse? malfunctions.
Did the machine have any previous problem ? If
so, which parts were repaired?
Inspect the machine
Check all daily maintenance points. (Refer to the

OM). Check batteries, battery disconnect switch,
circuit breakers, fuses, and electrical
connections.
Perform Operational Check-out
Check all systems and functions on the machine.

Use the helpful diagnostic information in the
problem.
Doc. No. 872272 : Rev 0 339

DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS

NOTE: DIAGNOSE system malfunction charts are arranged from most probable and simplest to
verify. Remember the following steps when troubleshooting a problem:
Step 1. Operational Check-out Procedure.

Step 2. Diagnose System Malfunction Charts in this group.
Step 3. Tests.
Hydraulic System Malfunctions
No Hydraulic Functions Low or no oil. Check oil level in hydraulic

reservoir. Add hydraulic oil.
Pump suction strainer restricted. Clean pump Suction Strainer.
All Hydraulic Functions Slow Oil level low. Check oil level in hydraulic
Wrong oil in system. Wrong oil in system. Use
recommended hydraulic oil.
Speed too slow. Check engine Slow and Fast
Idle Adjustment.
Cold hydraulic oil. Do Hydraulic System Warm-up.
Air leak in pump suction line. Check for air bubbles in oil.
Tighten clamps, replace
“O”-rings as necessary.
All Hydraulic Functions Slow Pump suction strainer restricted. Clean pump suction strainer.
Residual valve pressure setting Check residual valve pressure
too low or malfunctioning. setting. Do Main Hydraulic Pump
Residual and Compensator
Valves Test and Adjustment.
Inspect Residual Valve.
Compensator valve pressure Check compensator valve
setting too low or malfunctioning. pressure setting. Do Main
Hydraulic Pump Residual and
Compensator Valves Test and
Adjustment.
System relief valve pressure too Inspect Compensator Valve.
low or malfunctioning.
Main hydraulic pump worn. Check system relief valve
pressure setting (not
adjustable). Do System Relief
Valve and Auxiliary function
Circuit Relief Valve Test.
Inspect System Relief Valve.
Check cycle times. Do Cycle
time Test.
340 Doc. No. 872272 : Rev 0

Hydraulic Oil Overheats. Oil level too low. Check oil level in hydraulic
Wrong oil in system. Use recommended hydraulic oil.
Return filter plugged. Replace Hydraulic System Oil
Return Filter.
System relief valve. Check system relief valve
pressure setting (Not
adjustable). Do System Relief
Valve and Aux. function
Circuit Relief Valve Test.
Main hydraulic pump Inspect System Relief Valve.
compensator valve setting too
high.
Brake accumulator charge valve Check compensator valve
pressure setting too high. pressure setting. Do Main
Hydraulic Pump Residual and
Compensator Valves Test and
Adjustment.
Cylinder leakage. Check brake accumulator
charge valve pressure setting.
Do Brake Accumulator Charge
Valve Test and Adjustment.
Main hydraulic pump stuck at Check cylinders for hot spot
maximum displacement. indicating oil bypassing piston.
Main hydraulic pump worn. Disassemble and inspect main
hydraulic pump.
Check using cycle times. do
Cycle Time Test.
The pressures don’t change The harness has been Connect harness correctly.
when the adjustment screw is connected incorrectly.
being turned. The incorrect MDU setting has Select correct MDU2 settings
been selected.
Hoses are connected incorrectly. Connect Hoses correctly.
Main Hydraulic Pump Noisy. Oil level low. Check oil level in hydraulic
reservoir. Add hydraulic oil
Wrong oil in system. Use recommended hydraulic oil.
Pump suction strainer restricted. Clean pump suction strainer
Air leak in pump suction line. Check for air bubbles in oil.
Tighten clamps, replace
“O”-rings as necessary.
Main hydraulic pump drive shaft Check oil seal.
oil seal.
Doc. No. 872272 : Rev 0 341

Service Brake System Malfunction
Poor or no Service Brakes. Service brake pedal. Check brake pedal for
obstructions around and under
pedal. Check that the pedal can
be pushed down to the end of its
stroke and returns to released
position.
Air in system. Check for foamy oil. Tighten
loose fitting. Replace damaged
lines and “O”-rings. Bleed
Service Brake Hydraulic System.
Low or no oil pressure. Check brake accumulator
pressure reducing valve and
brake accumulator charge
valve.
Service Brake Discs Wearing Driving technique - constantly Allow the exhaust brake to slow
Excessively. using service brakes to slow the the machine.
machine.
Exhaust brake. Check exhaust brake operation.
Service brake valve. Spools sticking or binding in
valve housing. Repair or replace
brake valve
Restriction in service brake Check return lines for restriction.
valve return lines.
Time Between Brake Brake accumulators. Gas charge in brake

Accumulator Charging Cycles accumulators too low. Check
Too Short accumulator operation. Do
“BRAKE LOW PRESSURE
SWITCH AND BRAKE,
ACCUMULATOR TEST,”
“BRAKE ACCUMULATOR
CHARGE VALVE TEST AND
ADJUSTMENT,” “FRONT AND
REAR BRAKE
ACCUMULATORS PRESSURE
TEST AND CHARGE
PROCEDURE”
342 Doc. No. 872272 : Rev 0

Charge pressure can not be set Pump is stroking in all the time. Check for a load signal from
somewhere.
Hoses are connected incorrectly. Correct.
The pump compensating Check that the pump is set to
pressure is set too low and the the correct pressure.
pump does not provide enough
pressure to reach the upper limit
of the charge band.
The pressure on the brake Set the pressure on XB.
circuit’s pressure limiting valve
(Valve XB) is set lower than the
upper limit of X4.
X4 valve be faulty. Replace X4.
The pump strokes rapidly after Orifice 18 has not been installed. Install.
each application of the foot The brake charge accumulators Check their charge and replace
valve. have a very low charge or recharge them if necessary.
pressure.
The brakes don’t recharge at all. The pump compensating Set pressures.
pressure is set below the
residual pressure.
Orifice 9 might be blocked. Remove and clean it/replace it if
necessary.
The hydraulic cut solenoid could Unplug the connector to see if it
be energized or jammed open. makes a difference. If it does,
there might be a software
problem.
Doc. No. 872272 : Rev 0 343

Steering System Malfunctions
Slow or No Steering Function Articulation locking bar installed. Disconnect articulation locking
bar and place in storage
position.
Oil level low. Check hydraulic oil level. Add
hydraulic oil.
Steering load sense relief valve Check steering load sense relief
pressure setting too low or valve pressure.
malfunctioning.
Inspect steering load sense
Steering lines damaged. relief valve.
Priority valve in hydraulic system Inspect and replace lines.

manifold.
Steering valve. Check priority valve operation.
Do Priority Valve Test.
Steering cylinders piston seals. Remove priority valve and
inspect.
Check steering cylinder for
leakage.
Check steering cylinder for
leakage.
Replace piston seals as needed.
Constant Steering to Maintain Air in steering system. Check for foamy oil. Tighten
Straight Travel. loose fittings. Replace damaged
lines. .
Steering cylinder piston seals. Check steering cylinders for
leakage.
Replace piston seals as needed.
Steering valve. Disassemble steering valve and

inspect.
Erratic Steering. Air in steering system. Check for foamy oil. Tighten
loose fittings. Replace damaged
lines.
hydraulic oil.
Cylinder piston loose. Disassembly cylinder and
inspect.
Steering valve. Disassemble steering valve and
inspect.
Spongy or Soft Steering. Air in steering system. Check for foamy oil. Tighten
loose fittings. Replace damaged
lines.
hydraulic oil.
344 Doc. No. 872272 : Rev 0

Free Play at Steering Wheel. Steering wheel-to-shaft nut Tighten nut.

loose.
Splines on steering shaft or Inspect and replace worn or
valve worn or damaged. damaged parts.
Steering Locks Up. Large particles of contamination Inspect return filters for
in steering valve. contamination. Repair cause of
contamination. Replace
Hydraulic System Oil Return
Filter.
Flush hydraulic system.
Disassemble steering valve and
inspect.
Abrupt Steering Wheel Steering valve gerotor not Time gerotor gear.
Oscillation. limited correctly.
Steering Wheel Turns by Itself. Lines connected to wrong ports. Connect lines to correct ports.
Machine Turns in Opposite Lines to steering cylinders Connect lines to correct ports.
Direction. connected to wrong ports at
steering valve.
Machine Turns When Steering Steering valve leakage. Disassemble steering valve and
Valve is in Neutral. inspect.
The pressure does not want to The pump compensating Check that the pump is set to
rise to 195 Bar. pressure is set too low and the the correct pressure.
pressure to reach the upper limit
of the charge band.
X3 valve might be faulty. Replace X3.
The steering is very heavy. The pump compensating Check that the pump is set to
pressure is set too low and the the correct pressure.
pressure to turn the steering
wheel.
X3 is set very low. Turn X3 in (clockwise) all the
way and see if this lightens up
the steering.
X3 valve might be faulty. Replace X3.
Hoses are connected incorrectly. Correct.
The steering orbitrol is faulty. Replace the orbitrol.
Doc. No. 872272 : Rev 0 345

346 Doc. No. 872272 : Rev 0

SECTION 3. TESTS
DIGITAL THERMOMETER Transducers are temperature sensitive. Allow

INSTALLATION transducer to warm to system temperature.
After transducer is warmed and no pressure

applied, push sensor zero button for one second to
set the true zero point.
When using for different pressures, turn selector to

OFF for two seconds and then to the pressure
range. Readings are inaccurate if proper range for
transducer is not used.
Transducers:
1. Temperature Probe 3400 kPa (35 bar) (500 psi)
2. Cable 34 000 kPa (350 bar) (5000 psi)

3. Digital Thermometer 70 000 kPa (700 bar) (10,000 psi) Install cranking
device DC280088.
Fasten temperature probe (1) to a bare metal
hydraulic line using a tie band.
HYDRAULIC OIL CLEANUP
Wrap temperature probe and line with a shop towel. PROCEDURE USING PORTABLE
FILTER CADDY
DIGITAL ANALOGUE
PRESSURE/TEMPERATURE Specifications
ANALYSER INSTALLATION
Hydraulic Reservoir Capacity
. . . . . . . . . . . . . . 78.8 L (20.8 USGAL)
Hydraulic Reservoir Filtering Time
. . . . . . . . . . . . . . . . . . . . 7 minutes
approximate.
Engine Speed . . . . . . . . . . 2750 ±30r.p.m.

Hydraulic System Capacity . 155 L (41 USGAL)
Hydraulic System Filtering Time
. . . . . . . . . . . . . . 25 minutes approximate.

1. Digital Pressure/Temperature Analyser.
2. Transducers. • Portable Filter Caddy
• Two 3658 mm (12 ft) x 3/4 in. ID 100R1 Hoses with
Use the digital pressure/temperature analyser (1) 3/4 M NPT Ends
and transducers (2) in place of analog gauges and • Quick Disconnect Fittings
a separate temperature reader.
• Suction Wand
Discharge Wand
Doc. No. 872272 : Rev 0 347

This procedure must be used to clean complete Check oil level in hydraulic reservoir; add hydraulic
hydraulic system after any major component failure. oil if necessary.
Install new return filter elements.

HYDRAULIC SYSTEM WARM-UP
NOTE: 1. For a failure that creates a lot of PROCEDURE
debris, remove access cover from hydraulic
reservoir. Drain the hydraulic reservoir. Connect
filter caddy suction line to drain port. Add a Service Equipment And Tools
minimum of 19 L (5 gal) of oil to the hydraulic
reservoir. Operate filter caddy and wash out the • Digital Thermometer
hydraulic reservoir. NOTE: If machine temperature is below – 18°C
2. The minimum ID for a connector is 1/2 in. to (0°F), start procedure with engine running at 1/2
prevent cavitation of filter caddy pump. speed. Failure to do this could cause pump
cavitation. Once oil temperature is above -18°C
Put filter caddy suction and discharge wands into (0°F) the engine speed can be increased to fast
the hydraulic reservoir filler hole so ends are as far idle.
apart as possible to obtain a thorough cleaning of
oil. Below -18°C (0°F) an extended warm-up period
may be necessary. Hydraulic function will move
Start the filter caddy. Check to be sure oil is flowing
slowly and lubrication of parts may not be adequate
through the filters. Operate filter caddy until all oil in
with cold oil.
the hydraulic reservoir has been circulated through
the filter a minimum of four times. Do not attempt normal machine operation until
hydraulic functions move at or close to normal cycle
NOTE: Filtering time for hydraulic reservoir is
times.
0.089 minute x number of litres (0.33 minutes x
number of gallons). Operate functions slowly and avoid sudden
movements until engine and hydraulic oils are
Leave filter caddy operating for the next step. thoroughly warmed.
Start the engine and run it at specification. Operate a function by moving it a short distance in
each direction. Continue operating the function
Specification increasing the distance travelled in each cycle until
full stroke is reached.
Engine - Speed . . . . . . . . . 2240 ± 20 r.p.m.
Use correct viscosity hydraulic oil to minimize
NOTE: For the most effective results, cleaning warm-up period. (See CHAPTER 1 in the OM for
procedure must start with the smallest capacity oil specifications.)
circuit then proceed to the next larger capacity
circuit. Connect digital thermometer. Install temperature
probe on hydraulic reservoir-to-pump inlet line.
Starting with the smallest capacity circuit, operate
each function through a complete cycle. ‹ CAUTION
Repeat procedure until the total system capacity Avoid possible serious injury from machine
has circulated through filter caddy seven times. movement during warm-up procedure. Clear the
area of all bystanders before doing the warm-up
Each function must go through a minimum of three procedure.
complete cycles for a thorough cleaning of oil.
NOTE: Filtering time for complete hydraulic

system is 0.158 minute x number of litres (0.6
minute x number of gallons). Filtering time for
machines with auxiliary hydraulic functions
must be increased because system capacity is
larger.
Stop engine. Remove filter caddy.
Install new return filter elements.
348 Doc. No. 872272 : Rev 0

Clear the area of all bystanders to allow for Equipment Required

machine movement.
Start engine. Do not accelerate engine rapidly Spanners:

during warm-up. Run engine at 1/2 speed for
approximately 5 minutes before operating any 2 x 24 mm - To loosen cab bolts
functions. 1 x 19 mm
2 x 17 mm
Engage park brake. 1 x 10 mm
1 x 13 mm
1 x 11/16
‹ CAUTION
Holding a function over relief for more than 10 Allen Keys:
seconds can cause damage to control valve.
1 x 6 mm
Operate steering and auxiliary raise and lower 1 x 3 mm
functions over relief to heat hydraulic system. 1 x 3/16 "
Once oil temperature is above –18°C (0°F), Pressure Gauge:

increase engine speed to fast idle.
1 x 10 to 300 Bar
Stop periodically and operate all hydraulic
functions to distribute the heated oil.
Setting Hydraulic Pressure
‹WARNINGS
Ensure that the machine is parked on level
ground and away from any overhead objects.
Do not wear loose clothing which may
becaught up in the prop shaft. Also en sure
that all tools and equipment is stored safely
away from the prop shaft area. Ensure that
the cab stay is secured before working under
the tilted cab.Ensure that the articulation lock
is installed while doing the steering pressure
checks and adjustments.
Check that the hydraulic oil is at the correct level

before starting the pressure checks and adjust
ments.
Ensure that the park brake is applied while doing

the checks and adjustments.
Do not loosen any hoses, connectors or fittings

while the machine is running. Switch off the ma
chine and depressurise the hydraulic system by
pressing the brake valve until it goes soft,before
loosening any hose or connector in the hydraulic
system.
Doc. No. 872272 : Rev 0 349

Set the Emergency Steering 12. Lock the screw with the locking nut once the
correct pressure has been set.
Pump Pressures
13. Select Neutral for the transmission and only
Note: Main pump pressures and steering pres then apply the park brake
sure will need to be reset after setting the emer
gency steering pump. 14. Connect the pneumatic hose onto the IDL on
the drop box.
Set the Emergency Steering 15. Re-connect the IDLSOL connector to the IDL
solenoid on the rear of the pneumatic manifold.
Pump Residual Pressure
Fault Finding
‹WARNINGS
Fault:
This procedure requires coming into close
prox imity of rotating prop shafts ensure Can't set the residual pressure.
correct PPE is used. En sure the truck is on
level ground and that the wheels are secure Possible Causes:
from rolling as the park brake will need to be
released. 1. The compensating pressure is set below the
residual pressure. Turn the compensator set
1. Uncouple the rear output shaft from the drop screw in (clock wise) all the way to in crease the
box. compensating pressure. Follow the steps de
tailed in next procedure to set the correct
2. Remove electrical connector IDLSOL, lacated compensating pressure once the residual
on the rear of the pneumatic manifold. (this will pressure has been set.
release the permanently applied inter-axle lock)
2. Confirm that the transmission is in "Drive"
3. Remove the pneumatic hose of the when the pressures are being measured.
IDLactuator on the drop box
3. Ensure that X3 (steering relief valve) is not set
4. Start the truck. too low.
5. Connect the pressure gauge to Test point MP2 4. The pump controller might be faulty. Replace
the pump controller.
6. Ensure that the inter-axle difflock is not
activated
7. While applying the service brake, select

"Drive" on the transmission shift selector. Re
lease the park brake and use the gear hold
button to hold the transmission in second gear
when it reaches second gear.
8. At full rpm in second gear the speed on the

MDU should read +-16kph, the gauge should
read the pump residual pressure of 22 Bar (+-1).
If the pressure is in correct, the pump needs to
be adjusted.
9. Remove the cap on the residual pressure

adjustment screw of the pump controller. Be
careful not to lose the dowty washer.
10. Loosen the locking nut on the adjustment

screw.
11. At 16kph read off the MDU, turn the screw

clock wise to increase the pressure and
anti-clock wise to decrease the residual pressure.
350 Doc. No. 872272 : Rev 0

Set the Emergency Steering 14. Loosen the locking nut on the adjustment
screw.
Pump Compensating Pressure:
While holding the steering against the artic lock,
and revving the engine to full rpm with the trans
‹WARNINGS mission held in second gear, turn the screw clock
This procedure requires coming into close wise to increase the pressure and anti-clock wise
proximity of rotating propshafts ensure to decrease the residual pressure.
correct PPE is used. Ensure the truck is on
level ground and that the wheels are secure 15. Lock the screw with the locking nut once the
from rolling as the park brake will need to be correct pressure has been set.
released.
16. Select Neutral for the transmission and only
then apply the park brake
1. Uncouple the rear output shaft from the
dropbox. 17. Connect the Pneumatic hose onto the IDL on
the drop box.
2. Remove electrical connector IDLSOL, lacated
on the rear of the pneumatic manifold. (this will 18. The Main Steering will now need to be set,
release the permanently applied inter-axle lock) see next procedure, before proceeding ensure
that the main pump compensator pressure is
3. Remove the pneumatic hose of the IDL
reset to its correct set point.
actuator on the drop box
19. Re-connect the IDLSOL connector to the IDL
4. Start the truck.
solenoid on the rear of the pneumatic manifold.
5. Activate service mode
Fault Finding
6. Follow procedure to set the compensating
Fault:
pressure on the main pump, but set the pressure
down to 120 Bar. Can't set the compensating pressure.
7. Loosen the lock nut on Valve X3 and turn the Possible Causes:
adjusting screw clock wise until it bottoms out (do
not apply excessive force once it has bottomed 1. Confirm that the transmission is in "Drive"
out) when the pressures are being measured.
8. En sure that the park brake is applied and that 2. Ensure that X3 (steering relief valve) is not set
the inter axle diff lock is not acti vated. too low.
9. Install the articulation lock. 3. The pump controller might be faulty. Replace
the pump controller.
10. Connect the pressure gauge to Test Point
MP2. 4. The anti-cavitation check valve on the pump is
not seating correctly and is allowing oil to
11. While applying the service brake, select by-pass.
"Drive" on the trans mission shift selector. Re
lease the park brake and use the gear hold but
ton to hold the transmission in second gear when Set the Main Pump Residual
it reaches second gear by revving the engine.
Pressures 2306D/2806D
12. Turn the steering wheel to the left and hold it
against the articulation lock, take the engine to 1. Start the truck.
full rpm. The gauge should read the pump com
pensating pressure of 210 Bar (+-3bar). If the 2. Connect the pressure gauge to Test Point MP1
pressure is in correct, the compenstor pressure
needs to be adjusted. 3. The gauge should read the pump residual
pressure of 25 Bar. If the pressure is incorrect,
13. Remove the cap on the compensator pres the pumps need to be ad justed.
sure adjustment screw of the pump controller. Be
careful not to lose the dowtywasher. 4. Loosen the locking nut on the adjustment
screw.
Doc. No. 872272 : Rev 0 351

5. At idle, turn the screw clock wise to increase 4. Use the auxiliary control to move the function
the pressure and anti-clock wise to decrease the all the way up until the cylinders bottom out or,
residual pressure. the pressure builds up against the quick couplers
at the rear of the chassis.
6. Lock the screw with the locking nut once the
correct pressure has been set. 5. While holding the function in this position, read
the pressure on the gauge. The gauge should
7. Put back the cap on the residual pressure read the pump compensating pressures of
adjust ment screw and tighten. 2306D = 250 bar, 2806D = 270 bar. If the
pressure is in correct, the compensating pressure
Fault Finding needs to be adjusted.
Fault: 6. Remove the caps on the compensator

pressure ad just ment screws of the pump con
Can't set the residual pressure because the trollers. Be careful not to lose the dowty washers.
pump is stroking to a higher pressure all the time.
7. Loosen the locking nuts on the adjustment
Possible Causes: screws.
1. Hoses are connected incorrectly. 8. While holding the function in the fully ex
tended position. Turn the screw clock wise to in
2. The brake charge valve pressure could be set crease the pressure and anti-clock wise to
higher than the pump compensating pressure. decrease the pressure.
Either try to set the brake charge pressure lower
by turning the X4 valve anti-clock wise (see "Set 9. Lock the screw with the lock ing nut once the
ting the Brake Pressures for more info), or turn correct pressure has been set.
the compensator set screw clock wise until the
pump stops stroking - see Set the Main Pump Set the Steering Pressure
Compensator Pressure for more info.
1. Start the truck.
3. The steering wheel is turned slightly. Give the
steering wheel a slight tug to see if the pump 2. En sure that the pump pressures have been
de-strokes. set using the procedures detailed above.
Fault: 3. Connect the pressure gauge to Test Point

MP1.
Can't set the residual pressure
4. Turn the steering wheel to the left and hold it
Possible Causes: against the arctic lock. The pressure on the
gauge should rise to 195 bar (+-3 bar). If it
1. The compensating pressure is set below the doesn't, the pressure needs to be adjusted on the
residual pressure. Turn the compensator adjust steering LS relief valve - Valve X3 on the main
ment screw in (clock wise) all the way to increase hydraulic manifold.
the compensating pressure. Follow the steps
detailed in procedure to set the correct compen 5. Loosen the locking nut on X3.
sating pressure once the residual pressure has
been set. 6. While holding the steering against the stop, ad
just the steering LS relief setting by turning the ad
2. The pump controller might be faulty. Replace just ment screw clock wise to in crease the pres
the controller. sure and anti-clock wise to reduce the pressure.

Set the Main Pump correct pressure has been set.
Compensating Pressure
Fault Finding
2306D/2806D
Fault:
1. Start the truck.
The pressure does not want to rise to 190 bar.
2. Connect the pressure gauge to Test Point
MP1. Possible Causes:
3. Set the pump residual pressure.
352 Doc. No. 872272 : Rev 0

1. The pump compensating pressure is set too 7. Lock the screw with the locking nut once the
low and the pump does not provide enough pres correct pressure has been set.
sure to reach the upper limit of the charge band.
Check that the pump is set to the correct Fault Finding
pressure.
Fault:
2. X3 valve might be faulty. Replace X3.
The desired charge pressure can not be set be
Fault: cause the pump is stroking in all the time.
The steering is very heavy. Possible Causes:
Possible Causes: The pump will only stay stroked in if it is receiving

a load signal from somewhere. Check the follow
1. The pump compensating pressure is set too ing to try and resolve the problem:
low and the pump does not provide enough pres
sure to turn the steering wheel. Check that the 1. Hoses are connected in correctly.
pump is set to the correct pressure.
2. The Hyd Pump setting has not been selected.
2. X3 is set very low. Turn X3 in (clock wise) all
the way and see if this lightens up the steering. 3. The pump compensating pressure is set too
low and the pump does not provide enough pres
3. X3 valve might be faulty. Replace X3.4. Hoses sure to reach the upper limit of the charge band.
are connected in correctly. Check that the pump is set to the correct pres
sure. Another check could be to turn the pres
5. The steering orbital is faulty. Replace the sure on X4 lower, If the pump stops stroking, you
orbital. know that you need to adjust the pump pressure.
4. The pressure on the brake circuit's pressure

Set the Brake Circuit Pressures: limiting valve (Valve XB) is set lower than the up
per limit of X4. Set the pressure on XB and then
Set X4: try to set X4's pressure.
1. Start the truck. 5. X4 valve might be faulty. Replace X4.Fault The

pump strokes rapidly after each application of the
2. Ensure that the pump pressures have been set foot valve.
using the procedures detailed above.
Possible Causes:
3. Connect the pressure gauge to Test Point M4.
1. Orifice 18 has not been in stalled.
4. Push the service brake repeatedly until the ac
cumulators start to charge. The gauge should 2. The brake charge accumulators have a very
read 2306D = 165 bar and 2806D = 195 bar (+- 3 low charge pressure. Check their charge and re
bar) when the accumulators stop charg ing. If the place or recharge them if necessary.
pressure is incorrect, the pressure needs to be
ad justed on the accumulator charge valve - 3. X4 valve might be faulty. Replace X4.
Valve X4 on the main hydraulic manifold.
Fault
5. Loosen the locking nut on X4.
The brakes don't recharge at all.
6. Adjust the brake charge pressure by turning
the adjustment screw clockwise to in crease the Possible Causes:
pres sure and anti-clock wise to reduce the pres
sure. It is important to note that the pressure on 1. The pump compensating pressure is set be
the gauge will not change during the adjust lowt he residual pressure. Set the pump
ments. The brake accumulators first need to be pressures.
discharged to see the effect of each adjustment.
The charge band for the accumulators should be 2. Orifice 9 might be blocked. Remove the orifice
from approximately 2306D = 130 bar to 165 bar and clean it/replace it if necessary.
and 2806D = 165 to 195 bar. The lower limit of
the charge band is not adjustable. 3. The hydraulic cut solenoid could be energised
or jammed open. Unplug the connector to see if it
Doc. No. 872272 : Rev 0 353

makes a difference. If it does, there might be a Set the Auxiliary Spool Pilot Pressure
software problem.
1. Start the truck.
4. X4 valve might be faulty. Replace X4.
2. Connect the pressure gauge to test point MR
Set XB on the main hydraulic block
1. Start the truck. 3. Use the tip control to move the function all the
way up until the cylinders bottom out or pressure
2. Ensure that the pump pressures have been set builds up against the quick couplers at the rear
using the procedures detailed above. chassis. While hold ing the cylinders in the fully
extended position, read the pressure on the
3. Connect the pressure gauge to Test Point M4. gauge. The gauge should read a Pilot Pressure
of 35 bar (+-1bar). If the pressure is in correct it
4. Install the articulation lock. will need to be adjusted.
5. Turn the steering wheel to the left. The pres 4. Loosen the lock nut on Valve No. 5
sure on the gauge should rise to 2306D = 190
bar and 2806D = 210 bar (+- 3 bar). If it does not, 5. For a pressure that was too high turn the ad
the pressure needs to be adjusted on the brake justment screw on valve No. 5 out anticlockwise
pressure reduction valve - Valve XB on the main reducing the pressure. For pressures too low go
hy draulic manifold. to step 7
6. Loosen the locking nut on XB. 6. Gradually in crease the pilot pressure to the
set point of 35 bar by turn ing the adjustment
7. While hold ing the steering against the stop, ad screw in clock wise.
just the brake reduction set ting by turning the ad
justment screw clock wise to increase the pres 7. Once the correct pressure of 35 bar is
sure and anti-clock wise to reduce the pressure. achieved lock the screw with the locking nut.
If the pressure was higher than 190 bar, the pres
sure in the brake circuit needs to be released
first. This is done by pushing the service brake re
peatedly. Once the pressure has been released,
turn XB anti-clock wise and steer against the
stops again. If the pressure is still higher than
specification, repeat the steps de ailed above un
til a lower pressure is achieved. To set the pres
sure higher, simply turn XB clock wise, (while the
steering is held against the stop) until
specification is reached. If the pressure is set
past specification, the steps detailed above need
to be followed to set the pressure lower again.

correct pressure has been set.
Fault Find ing
Fault:
The pressure does not rise to specification.
Pos si ble Causes:
1. The pump compensating pressure is set too

low and the pump does not pro vide enough pres
sure to reach the upper limit of the charge band.
Check that the pump is set to the correct pres
sure.
2. XB valve might be faulty. Re place XB.
354 Doc. No. 872272 : Rev 0

Cycle Time Test

Specifications
Hydraulic Oil Temperature = 50 ± 5°C (120±

10°F).
Engine Speed (Slow Idle)
Steering Wheel Stop-to-Stop Cycle Time= 7 - 8

sec.
Steering Wheel Stop-to-Stop = 4.7 Turns
Test is used as an indication of hydraulic circuit

performance. A slow cycle time is an indication of
a restriction or leakage in that circuit.
Cycle times are also a general indication of hy

draulic pump performance. Always record the av
erage of at least three complete cycle times using
a stop watch.
Do Hydraulic System Warm-Up Procedure to

heat hydraulic oil to specified temperature. Use
monitor display menu to monitor hydraulic oil tem
perature.
‹WARNING
Avoid possible serious injury from machine
movement. Clear area of all bystanders before
performing test.
Doc. No. 872272 : Rev 0 355

356 Doc. No. 872272 : Rev 0

CHAPTER 7. HEATING AND AIR CONDITIONING
AIR CONDITIONING SYSTEM CYCLE OF OPERATION
1 Evaporator Core. 6 Receiver-Dryer.

2 Compressor. 7 High Pressure Liquid.
3 Condenser Core. 8 High Pressure Gas.
4 Circulation Blower Motor. 9 Low Pressure Liquid.
5 Expansion Valve. 10 Low Pressure Gas.
11 Air Flow.
The compressor is belt driven and engaged by an Compressor draws low pressure gas from
electromagnetic clutch. The air conditioning evaporator and compresses it into high pressure
circuit automatically controls compressor gas. This causes temperature of refrigerant to
engagement or disengagement when system is rise higher than that of outside air.
in operation. (See Air Conditioning).
Doc. No. 872272 : Rev 0 357

• High pressure gas leaves compressor and Low pressure gas is drawn from evaporator by
flows through condenser where heat is compressor and cycle is repeated. A freeze
removed and transferred to outside air being control switch senses temperature of evaporator
drawn through condenser core by engine fan. coil through a capillary tube.
Cooling refrigerant causes it to condense and
refrigerant leaves condenser as high pressure This prevents the evaporator from becoming cold
enough to freeze moisture that condenses on
liquid.
evaporator coil. Condensed moisture is drained
High pressure liquid flows into receiver-dryer away through drain tubes connected to drain pan
where moisture and contaminants (acid, solids, under evaporator.
etc.) are removed.
System pressure is monitored by high/low
Receiver-dryer contains a colour moisture pressure switch, located on high pressure side of
indicator. Blue indicates no moisture is present. expansion valve. If pressure becomes too high or
Pink indicates moisture is present. too low the switch opens and stops compressor,
interrupting the cycle.
Should moisture be combined with refrigerant,
hydrofluoric and hydrochloric acids are formed. Accumulator (if equipped) is located between
These acids are very corrosive to metal surfaces evaporator and compressor in low pressure gas
and leakage will eventually develop. hose to retain a quantity of oil to protect
compressor from a dry start after long periods of
Receiver-dryer also stores refrigerant allowing a not being used.
longer period of time before additional refrigerant
is needed. Refrigerant hoses allow a small HEATER CORE OPERATION
amount of refrigerant to migrate through their
walls. Refrigerant flows from receiver-dryer
through expansion valve to evaporator. The heater core is located near evaporator in
heating and air conditioning module on right side
Expansion valve senses refrigerant temperature of cab.
and pressure to modulate refrigerant flow.
Expansion valve changes refrigerant to low Filtered air flows through evaporator removing
pressure liquid entering evaporator. moisture before flowing though heater core.
Actual cooling and drying of cab air takes place The heater core uses warm engine coolant to
at evaporator. Heat absorbed by evaporator and heat a mixture of inside cab air as well as outside
transferred to refrigerant causes refrigerant to air pulled across heater core.
vaporize into low pressure gas.
Coolant flow through the heater core is regulated
by the heater valve. The heater valve is regulated
by an actuator which is controlled by the heater
valve control module in response to the position
of temperature control switch. (See “Heating/Air
Conditioning Component Location).
358 Doc. No. 872272 : Rev 0

DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS

Diagnostic charts are arranged from most probable and simplest to verify, to least likely more difficult to
verify.
Air Conditioning System Does Air - heater blower fuse. Replace fuse.
Not Operate Blower motor switch. Check switch.
Air - heater ON/OFF switch. Check switch
Air - freeze control switch. See “Air FREEZE CONTROL
SWITCH TEST”.
Air - high/low pressure switch. See “Air HIGH/LOW
PRESSURE SWITCH TEST”.
Air compressor clutch. See “Air COMPRESSOR
CLUTCH TEST”.
Wiring harness. Check engine and side console
harness wiring.
Drive belt is broken. Replace drive belt.
Air Conditioner Does Not Cool Fresh air filter restricted. Clean or replace filter.
Interior of Cab. Condenser fins restricted witch Clean condenser fins.
debris.
Re circulating air filter Clean or replace filter.
restricted.
Compressor belt loose. Tighten Fan Belt..
Refrigerant hose kinked, Re-route or re-index hoses.
pinched or collapsed. Replace collapsed hoses.
Heater or evaporator core fins Clean heater or evaporator core
restricted with dirt or dust. fins.
Air heater blower motor failed Check blower motor.
or operating too slowly.
Compressor clutch slipping or Inspect and/or replace
failed. compressor clutch.
Warm outside air leaking into Inspect, repair or replace door
cab. and rear cab shield.
Doc. No. 872272 : Rev 0 359

Air Conditioner Does Not Cool Cab heat deflectors missing or Inspect, repair or replace cowl
Interior of Cab (Continues). damaged. baffle and rear cab shield.
Heater valve remains open. Inspect, repair, adjust or replace
heater valve or cable. See
“HEATING/AIR CONDITIONING
COMPONENT LOCATION”.
System refrigerant (R134A) Do “R134A AIR
charge low. CONDITIONING SYSTEM
TEST”. Freeze control switch
capillary tube not positioned
correctly in evaporator coil.
Evaporator fins frosting or Do “Air FREEZE CONTROL
freezing. SWITCH TEST”.
Air Conditioner Runs Constantly, Temperature control switch. Inspect, replace temperature
Too Cold. control switch.
Heater valve. Valve is stuck closed,. Inspect.
Freeze control switch, capillary Replace heater valve.
tube not positioned in
evaporator properly.
Compressor clutch engaged Reposition capillary tube in
constantly. evaporator coil. See “Air
FREEZE CONTROL SWITCH
TEST”.
Interior Windows Continue To Fresh air filter restricted. Clean or replace filter.
Fog. Air system off. Move Air - heater ON/OFF
switch to Air position.
360 Doc. No. 872272 : Rev 0

HEATING/AIR CONDITIONING COMPONENT LOCATION
9 10
11
6
8
5
2 3
AirGD0001CV
1 Compressor. 7 Low Pressure Charging Port.

2 Condenser. 8 Expansion Valve Heater Core.
3 Heater Return Line. 9 Heater Control Valve.
4 Heater Supply Line. 10 Heater Core.
5 Receiver-Dryer. 11 Evaporator Core.
6 Air Conditioning High/Low Pressure Switch.
Doc. No. 872272 : Rev 0 361

18
17
10
11
12
16
15
14
13
AirGD0002CV
8 Expansion Valve. 14 Blower Motor and Housing.

9 Heater Control Valve. 15 Floor Vent Actuator.
10 Heater Core. 16 Defrost Actuator.
11 Evaporator Core. 17 Freeze Control Switch.
12 Air Intake Filter. 18 Relay Box.
13 Re circulating Damper.
362 Doc. No. 872272 : Rev 0

SECTION 3. TESTS
AIR CONDITIONING Are compressor mounting brackets in good

OPERATIONAL CHECKS condition, and bracket mounting cap screws
tight?
Visual Inspection of Components Are electrical connections to compressor clutch

clean and tight? Is wiring to compressor in good
NOTE:Do visual inspection of component condition?
checks prior to diagnosis and component
tests. These conditions may affect diagnostic Yes: Check complete.
and test results.
No: Repair or replace components as required.
All Lines and Hoses

Condenser Check
Inspect all lines and hoses.(See “Heating/Air
Inspect condenser core.
Conditioning Component Location”.
Is condenser core free of dirt or debris?
Are all lines and hoses straight, NOT kinked,
worn from rubbing on other machine parts or Does condenser show signs of leakage, dust
“weather checked”? accumulation or oily areas?
Are hose and line connections clean, NOT Are condenser fins straight, not bent or
showing signs of leakage, such as oil or dust damaged?
accumulation at fittings?
Inspect condenser fan or fan blade.
All hose and line clamps must be in place and
tight. Clamps must have rubber inserts or Are fan blades in good condition, not worn, bent,
cushions in place to prevent clamps from broken or missing?
crushing or wearing into hoses or lines.
Yes: Check complete.
No: Clean, repair or replace condenser core.
No: Reposition hoses or lines and tighten or Replace condenser fan or fan blade.
replace clamps. Tighten fittings or replace
O-rings in fittings. Replace hoses or lines as
required. Heater/Evaporator Core Check
Inspect core.
Air Conditioner Compressor Check
Are fins straight?
Inspect compressor.
Is core free of dirt and debris?
Is compressor drive belt tight?
Are evaporator drain tubes plugged?
Is belt in good condition, NOT frayed, worn or
glazed? Yes: Check complete.
Is belt tensioner worn or damaged? No: Repair, replace or clean heater/evaporator

core and drain tubes.
Is compressor belt pulley in good condition and in
line with engine pulley?
Doc. No. 872272 : Rev 0 363

Freeze Control Switch Capillary Tube High Side Refrigerant - Pressure

. . . . . . . 800 kPa (8 bar) (116 psi) minimum
Check . . . . 2 100 kPa (21 bar) (304.5 psi) maximum
Inspect freeze control switch capillary tube.

Is capillary tube straight, NOT kinked or broken?
• Prism Pro Refrigerant Identification Instrument
Is capillary tube properly positioned and inserted • Thermometer
securely in place in evaporator core?
‹ WARNING
Use correct refrigerant recovery, recycling
No: If capillary tube is kinked, replace freeze and charging stations. Never use refrigerant,
control switch. hoses, fittings, components or refrigerant oils
intended for R12 refrigerant systems. Identify
No: If capillary tube is positioned in evaporator refrigerant before recovering, recycling and
incorrectly, see Air Freeze Control Switch Test. charging system.
Cab Door and Window Seals Check Stop the engine.
Follow refrigerant cautions and proper handling

Open and close door and windows. Inspect
procedures.
seals.
Identify refrigerant type using refrigerant
Do door and windows contact seals evenly?
identification instrument.
Are seals in position and in good condition?
Connect refrigerant recovery, recycling and
Yes: Check complete. charging station.
Open both low and high pressure valves on

No: Adjust door and windows to close against
refrigerant recovery, recycling and charging
seals properly. Replace seals as necessary.
station.
Filter Check Open cab doors and windows.
Inspect fresh air filter and re circulating filter. Follow manufacturer’s instructions when using
the refrigerant recovery, recycling and charging
Are filters clean and free of debris? system.
Yes: Check complete. Start engine and run at rated engine high idle
speed.
No: Clean or replace filters.
Move A/C-heater switch to Air position.
R134A AIR CONDITIONING Turn temperature control switch to maximum

SYSTEM TEST cooling position.
Turn blower switch to high speed.

Specifications
Check sight glass (if equipped) in receiver-dryer.
R134a Air Conditioner System Test - Engine
Speed High Idle Run unit for at least 5 minutes.
Low Side Refrigerant - Pressure

. . . . . . . 80 kPa (0.8 bar) (11.6 psi) minimum
. . . . . . . . 200 kPa (2 bar) (29 psi) maximum
364 Doc. No. 872272 : Rev 0

Measure and record air temperature at OPERATING PRESSURE

condenser air inlet and at air ducts in air
conditioning unit. DIAGNOSTIC CHART
Observe low-side pressure and high-side Do the following procedures in 1830 to service
pressure on gauges. Air system:
Compare pressures and air duct temperature to • Recover R134a Refrigerant (CHAPTER 12,
specifications.
SECTION 3 in the Repair Manual.).
NOTE:Because low pressure switch is • Evacuate R134a System (CHAPTER 12,
located on high pressure side of expansion SECTION 3 in the Repair Manual.).
valve, the low pressure gauge reading shown • Charge R134a System (CHAPTER 12,
does not affect the low pressure switch SECTION 3 in the Repair Manual.).
operating range.
• Air conditioner set at maximum cooling.

• Air conditioner compressor clutch engaged.
• Operate at maximum setting for minimum of
12 minutes.
• Air duct temperature should be below 12° C
(53.5° F) with ambient temperature at 26° C
(79° F) and 60% relative humidity. Refrigerant
pressure within specification.
Diagnose malfunction using Operating Pressure

Diagnostic Chart.
Doc. No. 872272 : Rev 0 365

Low Side High Side

Sight Suction Receiver-D Liquid Discharge Discharge
Condition kPa (bar) kPa (bar)
Glass Line rier Line Line Air
(psi) (psi)
Lack of Very Low Very Low Clear Slightly Slightly Slightly Slightly Warm
Refrigerant Cool Warm Warm Warm
Loss of Low Low Bubbles Cool Warm to Warm Warm to Slightly

Refrigerant Hot Hot Cool
High Side Low Low Clear Cool Cool, Cool, Hot to Point Slightly
Restriction Sweating Sweating of Cool
or Frosting or Frosting Restriction
Expansion Low Low Clear Cold, Warm Warm Hot Slightly

Valve Sweating Cool
Closed or Frosting
Heavily at
Valve
Outlet
Loose Belt Low Low Clear Cool Warm Warm Hot Slightly
or Cool
Compressor
Failure
Condenser High Low Clear Slightly Hot Hot Hot Warm

Malfunction Cool to
Warm
Refrigerant High High Clear to Warm to Warm Warm Hot Warm

Contaminate Occasional Hot
d and Air in Bubbles
System
Expansion High High Clear Cold, Warm Warm Hot Slightly

Valve Open Sweating Cool
or Frosting
Heavily
Plugged High High Clear Cool Warm Warm Hot Slightly

Condenser, Cool
Overcharge
of
Refrigerant
Moisture in Normal Normal Clear Cool Warm Warm Hot Cool to

System (May (May Warm
Drop) Drop)
Heater Normal Normal Clear Cool Warm Warm Hot Warm

Valve Stuck
Open
Lack of Normal Normal Occasional Warm to Warm Warm Warm Slightly

Refrigerant (May Bubbles HOt Cool
and Air in Drop)
System
366 Doc. No. 872272 : Rev 0

Air FREEZE CONTROL SWITCH Air COMPRESSOR CLUTCH

TEST TEST
Specifications Disconnect harness from clutch.
Freeze Control Switch Opens (Normally Closed) Connect battery voltage to connector terminal for
- Temperature Drops Temperature
. . . . . . . . . . . . . . . 1 - 3°C (34 - 37.5°F)
Freeze Control Switch Closes (Normally Closed)
- Temperature Rises Temperature
. . . . . . . . . . . . . . . 1 - 3°C (34 - 37.5°F)
Key switch OFF.
Mark position of capillary tube. Tube should be

near centre of evaporator.
Disconnect and remove freeze control switch.
With freeze control switch at room temperature,
orange wire. Ground terminal for black wire.
Does clutch “click”?
Yes: Clutch coil is good. Check wiring harness.
No: Replace clutch coil.
Air HIGH/LOW PRESSURE

SWITCH TEST
connect terminals to ohmmeter and measure Specifications
continuity between terminals.
Air Low Pressure Switch (Normally Open) -
Is continuity measured? Closes on Increasing Pressure
. . . 207 ± 30 kPa (2.1 ± 0.3 bar) (30.5 ± 4.4 psi)
Yes: Switch is good. Check wiring harness.
Air Low Pressure Switch (Normally Open) -
No: Replace freeze control switch. Opens on Decreasing Pressure
. . . . 200 ± 20 kPa (2.0 ± 0.2 bar) (29 ± 2.9 psi)
Put freeze control switch in freezer. Temperature
must be below 1° - 3°C (34° - 37.5°F). Switch Air High Pressure Switch (Normally Closed) -
must be open and continuity must not be read. Opens on Increasing Pressure
. . 2700 ± 200 kPa (27 ± 2 bar) (391.6 ± 29 psi)
Remove switch from freezer and put sensing Air High Pressure Switch (Normally Closed) -
tube into a glass of warm water. As switch warms Closes on Decreasing Pressure
it must close and continuity must be read. . . 2100 ± 200 kPa (21 ± 2 bar) (304.6 ± 29 psi)
Doc. No. 872272 : Rev 0 367

Service Equipment And Tools Connect an air conditioning gauge set to service
fittings at compressor. Cover condenser with
paper or plastic to stop air flow.
• Hydraulic Hand Pump
• Volt-Ohm-Amp Meter Operate air conditioner on maximum cooling.
• Volt-Ohm-Amp Meter Note high-side pressure when Air high pressure
• Air Conditioning Gauge Set switch opens and then closes.
NOTE:The line that attaches Air high/low
pressure switch has a valve under it to Air EXPANSION VALVE TEST
prevent discharging air conditioning system
when switch is removed. Specifications
Engine Speed . . . . . . . . . . . . . High Idle
Blower Speed . . . . . . . . . . . . . . . . High
Temperature Control Switch Position
. . . . . . . . . . . . . . . . Maximum Cooling
Essential Tools
• Refrigerant Recovery, Recycling and Charging

System
• Thermometer
‹ WARNING
Use correct refrigerant recovery/recycling and
charging stations. DO NOT mix refrigerant,
Remove Air high/low pressure switch (1). hoses, fittings, components or refrigerant
oils.
Connect a portable pressure source, such as a
regulated air supply or a hydraulic hand pump, to Follow Refrigerant Cautions and Proper Handling
Air high/low pressure switch. procedures.
Switch must not have continuity between Connect refrigerant recovery, recycling and
terminals until pressure increases to low charging system.
pressure switch specification.
Remove insulating tape from expansion valve
Slowly release pressure. Switch must have sensing bulb.
continuity until pressure decreases to switch
opening pressure specification.
Switch must have continuity between terminals

until pressure increases to high pressure opening
specification.
Slowly release pressure. Switch must not have

continuity until pressure decreases to switch
closing pressure specification.
NOTE:The switch can also be checked when

installed in air conditioning system; however,
pressure is slow to increase to test
specification.
368 Doc. No. 872272 : Rev 0

Remove sensing bulb (1). Service Equipment And Tools
• Air Conditioning Gauge Set

Follow Refrigerant Cautions and Proper Handling
procedures.
Remove expansion valve. See Remove and

Install Expansion Valve.
Start engine and run at high idle.
Turn blower motor switch on high. Turn

temperature control switch to maximum cooling.
Warm sensing bulb in the hand for one minute.

Note low-side pressure.
Cool sensing bulb in ice water. Note low-side

pressure. If low-side pressure decreases when
sensing bulb is cooled, expansion valve is
operating. If low-side pressure does not
decrease, do Expansion Valve Bench Test.
Before fastening sensing bulb to evaporator

outlet line, make sure line and bulb are not
corroded. Fasten sensing bulb to side of line with
clamp. Install insulating tape to completely cover
sensing bulb and line.
EXPANSION VALVE BENCH

TEST
Connect Air expansion valve to air conditioning
Specifications gauge set using fittings (A - C).
Connect yellow hose to a regulated air supply.

High-Side Valve Pressure Setting Pressure
. . . . . . . . . . . . 520 kPa (5.2 bar) (75 psi)
Close low-side valve and open high-side valve.
Expansion Valve - Opens on increasing Pressure
. . . . 280 - 380 kPa (2.8 - 3.8 bar) (40 - 55 psi) Adjust pressure on high-side valve to 520 kPa
(5.2 bar) (75 psi) using a pressure regulator or by
Expansion Valve - Closes on Decreasing adjusting high-side valve.
Pressure . . . . . . 140 - 170 kPa (1.4 - 1.7 bar)
. . . . . . . . . . . . . . . . . . . . (20 - 25 psi) Hold sensing bulb in hand until pressure on
low-side gauge stops increasing. Pressure must
Essential Tools be 280 - 380 kPa (2.8 - 3.8 bar) (40 - 55 psi).
Put sensing bulb in a container of ice water until

• Air Conditioning Service Fitting Kit pressure on low-side gauge stops decreasing.
Pressure must be 140 - 170 kPa (1.4 - 1.7 bar)

(20 - 25 psi).
Doc. No. 872272 : Rev 0 369

REFRIGERANT LEAK TEST
Specifications
Leak Detector Probe Movement Speed Some refrigerant manufacturers add dye to
. . . . . . . . . . . . . 25 mm (1 in.) per second refrigerant to aid in leak detection.
Inspect all lines, fittings, and components for oily Avoid breathing in the air conditioner refrigerant
or dusty spots. When refrigerant leaks from and lubricant vapour or mist. Exposure may
system, a small amount of oil is carried out with irritate the eyes, nose and throat.
it.
The refrigerant is under high pressure and the
A soap and water solution can be sprayed on the system must be serviced by qualified personnel
components in system to form bubbles at source only. Improper service methods may cause
of leak. injury.
If a leak detector is used, move leak detector If accidental system discharge occurs, ventilate
probe under hoses and around connections at a the work area before resuming work.
rate of 25 mm (1 in.) per second.
Additional health and safety information may be
obtained from your refrigerant and lubricant
manufacturers.
370 Doc. No. 872272 : Rev 0

PART 2
SERVICE AND MAINTENANCE
Doc. No. 872272 : Rev 0 371

372 Doc. No. 872272 : Rev 0

CHAPTER 8. MAINTENANCE SCHEDULES

Preventative maintenance is very important. It includes lubrication, checks and adjustments which the
operator can perform. Scheduled services are to be performed by BELL EQUIPMENT Product Support.
Engine Oil 228.3= This is a multigrade oil that is approved for

Mercedes engines that are not in an application
The engine oil is an important, integral design where the engine is under extreme load and the
factor, which affects the operation and the service fuel sulphur content must be low. The quality level
life of the engine. The oil must be constantly of this oil is similar to ACEA B2/E3.
optimized in accordance with the engine's most
up-to-date technical quality standard. For this 228.5= This is a multigrade oil that is approved by
reason, only service products that have been tested Mercedes for diesel engines that are operating
and approved by Daimler Chrysler may be used. under extreme conditions. The requirements
include engine wear, sludge, and oil protection in
The scope and frequency of maintenance work both pre Euro 2 and Euro 2 engines.
depend primarily on the engine's operating
conditions and the oil grade used. Another factor Diesel Change:
that affects the frequency of maintenance is the
sulphur content of the fuel that is used. If the fuel Diesel is continually changing. Low sulphur diesel
used has a sulphur content exceeding 0.3% by should be used where possible. If low sulphur
weight, the replacement intervals for engine oil and diesel is not used, it is imperative to use the
filters should be halved. If the sulphur content highest-grade oil suitable for the engine. Lower
exceeds 0.8% by weight, the replacement intervals sulphur diesel is cleaner, safer and allows new
should be reduced to 30% of the values listed. If a engine technologies to be used. Many new engine
different oil grade is used to top up to the correct emissions technologies require lower sulphur diesel
capacity, the replacement interval is determined by in order to operate. These new technologies will
the lower oil grade. This is why you should always help to reduce several harmful emissions and
only use engine oils of the same grade. increase engine efficiency. Diesel currently has
large amounts of sulphur in it. That sulphur, when
The engine oil change and filter replacement used in a diesel engine, produces sulphur oxides
interval depends on the: and particulates. Both sulphur oxides and
particulates are absorbed by the oil. The oil can
• Engine oil grade only absorb a certain amount of sulphur oxides and
particulates. If a lower grade oils is used, then
• Fuel: Diesel/FAME (bio-diesel fuel) and fuel these sulphur oxides and particulates cannot be
sulphur content absorbed at the correct rate, thus breaking down
and sludging occurs.
• Engine load
The maximum oil change interval is only achieved if

engine oils of a particularly high grade are used
(such as oils complying with 228.5 of the
Mercedes-Benz Specifications for Service The effect sulfur has on diesel and how this
Products). The maximum oil change interval is affects the engine:
reduced if a lower grade engine oil is used for the
oil change or for topping up (e.g. oil complying with During the combustion process in a diesel engine,
228.3). The intervals for the other maintenance the presence of sulfur in the fuel can give rise to
items are not affected. The SAE class (viscosity) of corrosive wear. This can be minimised by using
the engine oil must be selected according to the suitable operating conditions. Considerable work
average ambient air temperature for the time of has been undertaken by the various engine
year. The use of non-approved engine oils will limit manufacturers to ensure the cylinder liner surfaces
your warranty entitlement. Information is available do not approach the dew point. This is the
from any Bell Service Center. Before operation with temperature at which acidic gases from combustion
any FAME fuel, the oil spec sheet must be referred condense into liquid. In a diesel engine, the sulfur in
too. (SIB2008/1079) the fuel first burns to SO2, then combines with
excess oxygen to form SO3. In the presence of
Use only engine oils complying with Bell water vapour the SO3 is converted to sulfuric acid,
Specifications for Service. which then forms on the cylinder walls, if the
temperature is below the dew point for the
condensation of acid at the prevailing pressure.
Doc. No. 872272 : Rev 0 373

This dew point is a function of the fuel’s sulfur

content and the pressure in the cylinder. Only a
relatively small proportion of sulfur is normally
converted in this way and the remaining sulfur
oxides pass out of the cylinder with the exhaust
gases. Variation in the sulfur level will affect the
rate of corrosive wear. High sulfur levels will
increase the rate of TBN depletion, especially for
engine designs that have a low oil consumption
rate.
What will happen to oil in its damaged process:
Petroleum-based motor oils (not the synthetics) are

very stable, high molecular mass hydrocarbon
mixtures to which additives are incorporated to
enhance the lubricity and anti-wear properties of
the blend. Motor oil molecules are fairly tough and
resistant to breakdown. The oil becomes
contaminated with water from combustion of the
fuel. The water dissolves acids from the sulfur in
the fuel and from air-derived nitrogen oxides. Acids
are detrimental to engine life. Finally, motor oils
accumulate toxic metal particles from the normal
wear of engine bearings and scrubbing surfaces.
There are many guides as to the sulfur values in
different countries but the only accurate way to find
out the sulfur content of the fuel being used on site
is to send a fuel sample to be analyzed.
Most of these ser vice mea sures are sim ple to

carry out and do not need any de tailed ex pla na
tion. The in struc tions which re quire spe cific pro
ce dures are de tailed in Chap ter 9 to 17 of this
manual.
374 Doc. No. 872272 : Rev 0

Maintenance Schedule in Running Hours

Rev Details Daily Every Every Every Every Every Every As
150 500 1000 2000 3000 4000 Required
1. Engine
1.1 Change the oil and filters. x (J) x
1.2 Drain water from the primary fuel filter. x
(Check cold, drain before starting engine)
1.3 Change Fuel depth filter. (B50D only) x (J) x
1.4 Change the primary fuel filter/water separa- x (J) x
tor. (RACOR)
1.5 Change secondary fuel filter. FILTER SITU- x (J) x
ATED ON ENGINE
1.6 Clean/replace the fuel "pre -filter" screen. x
(OM 906 LA)
1.7 Clean/replace the primer pump fuel screen. x
1.8 Clean crankcase breather filter. x (F)
1.9 Check the coolant level. x
1.10 Check the coolant mixture. x (A)
1.11 Change the coolant. x (A)
1.12 Adjust the valve clearance. (Every second oil x
change)
1.13 Replace Fuel tank breather filter. (B50D x (E) x (D)
only)
1.14 Replace Fan belt. (ALL HAULERS - SEE x
POINT 1.15 FOR B50D)
1.15 Replace both fan belts on B50D(OM502LA) x
1.16 Check fan belt condition. (ALL Haulers) x
1.17 Change the air cleaner primary filter. x
1.18 Change the air cleaner secondary filter. x
1.19 Clean the air intake pre-cleaner assembly. x
1.20 Check the air cleaner service indicator. x
1.21 Replace jockey pulley bearing x
(Note: B50 change both)
1.22 Change aircon pulley bearing and inspect x
pulley grooves for excessive wear. (S/Ex
parts available)
2. Transmission - Allison HD
2.1 Check for oil leaks. x
2.2 Check oil level. x
2.3 Change the Transmission oil. x (B)
2.4 Replace Transmission Filters. x
2.5 Replace breather. x
3 Transmission - ZF Ecomat 6 HP 592C
3.1 Check for oil leaks. x
3.2 Check oil level. (CLEAN OFF TOP OF THE x
DIPSTICK / BREATHER)
3.3 Change the Transmission oil & filter. x (B)
4 Transfer Case
4.1 Change drop box oil filter. (B50D, B40D, x
B35D, 4206D only)
4.2 Check the oil level. (sight glass) x
4.3 Change the oil. x (B)
Doc. No. 872272 : Rev 0 375


5 Hydraulics
5.1 Check the oil level. x
5.2 Change the oil. x (B)
5.3 Change the return filter. x
5.4 Change the breather filter. x (E) x (D)
5.5 Replace suction screens. x
5.6 Clean hydraulic/Transmission cooler fan x
5.7 Test the brake accumulator function. x
6 Axles, Chassis & Suspension
6.1 Check the oil level in the differentials and fi- x
nal drives. (Excl B50D & B35D with Bell Wet
Brakes)
6.2 Change all axle oils, clean any debris off x (B)
drain plug magnets.
6.3 B50D & B35D with Bell wet brakes change x (O)(B)
all axle oils, clean any debris off drain plug
magnets.
6.4 Replace through drive diff axle oil filter (B50 x
WITH TWO SPEED DIFF ONLY)
6.5 Clean intermediate diff oil strainer (B50 x
WITH TWO SPEED DIFF ONLY. Refer to
chapter 14 for procedure.)
6.6 Change wet disk brake cooler oil & filter. (if x (B)
applicable)
6.7 Check service brake pad wear. (if applicable) x
6.8 Check service brake disc thickness. x

6.9 Check park brake pad wear. x
6.1 Check & adjust bin shock pad clearance. x (H)
6.11 Check susp strut height, oil leaks & gen. x
cond.
6.12 Check condition of all drive shafts. x
6.13 Check front hubs for cracks. (B20D front x (I)
hubs only)
6.14 Change all axle driveline cross and rollers. x (K)
6.15 Replace breathers. x
6.16 B30D with wet disk brakes, change axle x
filters
7 Cab, Pneumatics & Electrical
7.1 Change the air drier filter. x
7.2 Check operator controls, buzzers and instru- x
ments.
7.3 Check working lights, reverse buzzer. x
7.4 Check electrical connections and wire rout- x
ing for chaffing.
7.5 Replace Pneumatic block breather (silencer) x
filters. (Situated on Pneumatic block)
7.6 Record & Delete fault codes found on MDU x
display.
7.7 Clean or replace air conditioner filter. x (C)
7.8 Check air conditioner receiver air drier site x(N)
glass.
Replace air drier when indicated.
7.9 Check the fan purging system functionality. x(R)
(large trucks only)
376 Doc. No. 872272 : Rev 0

8 Lubrication - Large ADT's

8.1 Grease hinges x(M)
8.2 Grease all remaining lube points. (if applica- x(M) x
ble)
8.3 Check the grease level in the auto greasing x(M) x
system. (if applicable)
8.4 Change the auto greasing filler filter. (if appli- x
cable)
8.5 Grease PTO propshaft universal at engine x (G)
side with high temp grease ,50 ton machine
only.
8.6 Grease Transmission to drop box propshaft. x (G)
(L)
8.7 Carry out oscillation joint maintenance x (P)
procedure
9 Lubrication - Small ADT's
9.1 Grease hinges. x(M)
9.2 Grease all remaining lube points. x(M)
9.3 Grease propshaft slip joint (shaft between x(M)
dropbox and osc. Joint and between park
brake and mid diff)
10 General
10.1 Check and clean coolers. x
10.2 Check and clean the breathers on Transmis- x
sion, drop box & axles.
10.3 Check and clean headlights x (Q)
11 Tyres
11.1 Check tyre pressures. x
Reference Guide
A Refer to SIB 2000/033 regarding coolant ad-
ditive specification.
B Drain intervals can be extended by oil sam-
pling. (Use kit 261677 for oil sampling Allison
Transmissions)
C Daily depending on site conditions
D To be changed in wet & muddy conditions.
(NOTE SERVICE KIT APPLICABLE FOR
THIS CONDITION)
E To be changed in dry & dusty conditions.
(NOTE SERVICE KIT AVAILABLE FOR
THIS CONDITION)
F Refer to SIB 2004/1018.
G Refer to SIB 2007/1062 for grease specifica-
tions.
H See SIB 2007/1066 for details of thickness.
I See SIB 2004/1067 for details of procedure.
J To be changed as indicated when running on
FAME/Bio-diesel. Refer to SIB 2007/1062 for
more information on FAME use.
K Cross & Roller replacement on all mechanic
joints, when operating in submerged or dusty
conditions and replace every 6000hrs under
normal conditions.
L In severe conditions, halve lubrication inter-
vals.
Doc. No. 872272 : Rev 0 377

M All grease points to be checked daily and

greased if necessary.
N Replacement of air conditioner receiver drier
to be done by a qualified air conditioner spe-
cialist.
O When using Borate oils, servicing can be ex-
tended to 1500Hrs.
P Refer to SIB 2001/1057 to carry out oscilla-
tion joint maintenance.
Q Refer to SIB 2001/1074 to carry out head-

light cleaning procedure.
R Refer to SIB 2001/1081 to carry out test pro-
cedure for fan purging system.
Note: The Daily Maintenance tasks are detailed in the Operators Manual.
DAILY OR 10 HOURLY SERVICE CHECKS

NOTE:For information on the daily (10 Hourly Service Checks) Refer to Chapter 11 in the
Operator’s Manual.
378 Doc. No. 872272 : Rev 0

CHAPTER 9. 150 HOURS SERVICE AND CHECKS
INTRODUCTION LOWER AND RAISE THE BELLY

PLATE
The 150 hours service and checks must be
performed by qualified service personnel. To perform some maintenance tasks it is
necessary to lower the belly plate for access.
SERVICE INSTRUCTIONS
The belly plate assembly has two access hatches
that allow access to certain areas.
Ensure that the machine is in the service
position. Refer to Pre-service Instructions, The complete assembly can be lowered if it is
CHAPTER 7 In The OM. required.
ENGINE Lower the Belly Plate Assembly

Change Engine Oil And Replace Filter The following procedures must be used to lower
the belly plate:
NOTE: For further engine information or
details not shown in this manual, refer to the
Mercedes-Benz Manual OM 906LA.
‹ WARNING
Be careful when draining hot engine oil. Hot
engine oil can cause burns to unprotected
skin.
NOTE: The engine oil will drain easier when

the engine is warm.
Run engine to warm oil slightly. Stop engine.
Open the bonnet.

• Loosen the three Belly Plate securing bolts (1).
• One person should support the belly plate.
• A second person should help supporting the
belly plate while removing the bolts (1). Lower
the Belly Plate Assembly (2) to the ground.
‹ WARNING
The Belly Plate is very heavy. Be careful when
lowering the belly plate as it can cause injury
or even death.
Remove engine oil filler cap (1). Clean and

inspect the seal ring. Replace seal ring if
necessary.
Doc. No. 872272 : Rev 0 379

Open Access Hatch Lower
Attach a hose to drain valve (1) with a hose

Loosen the two bolts (1) securing the hatch (2). clamp. Place the end of the hose in a container.
Lower the hatch (2). Loosen nut (2) and valve stem (3). Drain oil into
container.
Opening Access Hatch Top NOTE: Dispose of waste properly.
Tighten valve stem and nut. Remove hose clamp

and hose. Wipe drain valve clean.
Loosen and remove the two bolts (1) securing the Remove engine oil filter cap (1) and element (2).
hatch.
Lift slowly to allow residual oil to drain from
Swing hatch open. element.
NOTE: Closing is the reverse of opening. Do not clean inside surfaces of engine oil filter
housing.
Raise the Belly Plate Assembly
Remove the oil filter cap from the element.
Remove the O-ring from engine oil filter cap.
The following procedures must be used to raise
the belly plate: Install new O-ring on oil filter cap. Install new oil
filter onto filter cap. Place filter element and cap
‹ WARNING assembly into filter housing and tighten to
specification.
Be careful when raising the belly plate as it
can cause injury or even death if it slips off
the trolley jack.
• Manoeuvre a trolley jack under the belly plate

so that the belly plate can be safely raised.
• Install the bolts and remove the trolley jack.
380 Doc. No. 872272 : Rev 0

Do not overfill the engine with oil. Fill primary fuel fitter with clean fuel.
Add the new oil at the fill port. Install lid and retaining screw.
Replace engine oil filler cap. Prime fuel system.
Start engine and let it run at slow idle for 1 -Start engine and let it run for 1 minute. Check for
minute. Stop the engine and check for leaks at leaks around lid. Tighten lid only enough to stop
filler cap and drain valve. Tighten only enough to leaks.
stop leaks.
Check engine oil level.

Replace Secondary Fuel Filter
Raise and tighten belly plate. Open the bonnet.
Replace Primary Fuel Filter (Water

Separator)
Clean dirt and debris from final fuel filter cap (1)
and surrounding area.
Remove the filter cap (1) and element (3). Lift

Open the bonnet. slowly to allow excess fuel to drain from element.
Clean dirt and debris from primary fuel filter (1) Turn the directional valve to the “UP” position
and surrounding area. and operate the pump to lift the cab.
Remove the cab prop and install in storing

position.
Turn the directional valve handle to the

“LOWERING” position.
Operate the pump to lower the cab.
Refit securing bolts and tighten.
Relieve the pressure in the system by rotating the

directional valve handle 180 degrees.
Remove retaining screw (2) and lid (3). Stow the wheel nut spanner.
Remove element (1).
Install new element and ensure element is

properly seated.
Doc. No. 872272 : Rev 0 381

382 Doc. No. 872272 : Rev 0

CHAPTER 10. 500 HOURS SERVICE AND CHECKS
INTRODUCTION Check The Coolant Level
The 500 hours service and checks must be See Chapter 11 in the OM.
performed by qualified service personnel.
Drain the Racor Fuel Filter
NOTE: The engine must be running when the
Ensure that the machine is in the service water is drained from the Racor Fuel Filter.
position. Refer to Part 2: Service and
Maintenance, CHAPTER 1. SERVICE
INSTRUCTIONS, In The OM.
ENGINE
Change Engine Oil And Replace Filter
See Change Oil And Oil Filter, Chapter 10.
‹ WARNING
Be careful when draining hot engine oil. Hot
engine oil can cause burns to unprotected
skin.
Check engine oil level. (See Check Engine Oil

Level in Chapter 11 in the OM).
Check for oil, fuel and water leaks.
Check Engine Air Intake System
Connect a pipe to the outlet (1) and hang the

other point in a container.
Loosen the nut (2) on the Racor fuel filter.

Check the service indicator (1) is not showing a
red flag .If the window shows a red flag, the air Drain the accumulated water.
cleaner filter element must be changed.
Check rubber elbows, clamps and pipes for

tightness, cracks or damage.
Doc. No. 872272 : Rev 0 383

Tighten the wing nut when fuel flows out water NOTE: The cab tilt pump is located on the left
free. hand side under the bonnet on the bonnet
catch cross bar.
Remove the pipe.
TRANSMISSION
Check for oil leaks
Tilt and lower the cab
‹ WARNING
Never re-use loosened cab mounting bolts.
Always replace bolts after loosening.
Close the cab and right hand side external

compartment door and open the bonnet.
Place directional valve lever (1) in “Cab Raise”
Mirrors to be in normal operating position. position.
The machine’s cab is hinged so that it may be Insert the brace into the cab tilt pump and start
tilted for access to the hydraulics and pumping.
transmission systems below.
Install the cab prop (2).
Loosen Cab Mounting Bolts Front And Rear
Left Hand Side Change the directional valve handle to the
lowering position and lower the cab till cab is
secure.
‹ WARNING
Do not work under the raised cab unless the
cab prop is fitted.
Ensure directional valve handle is in “Cab

Lower” position.
Stow the brace.
The cab can be raised to two different heights:
Unscrew the mounting bolts (1) on the left hand

side front and rear of cab.
384 Doc. No. 872272 : Rev 0

The Transmission Fluid Level
Always check the fluid level at least twice. If the

readings are not consistent, check and clean the
transmission breather.
Check transmission fluid level as follows:
• The dipstick check when the transmission fluid

is cold.
• The dipstick check when the transmission fluid
is hot.
Dipstick Check - Transmission Fluid

COLD (Cold Check)
‹ CAUTION
Do not start the engine until the presence of
transmission fluid has been confirmed.
The Cold Check determines if the transmission

has sufficient fluid to be operated safely until a
Hot Check can be made.
Half raised (1) - for quick access to Main A cold check must be performed before start-up.
Hydraulic Pump, etc. and fully Raised (2) - for full The sump fluid temperature is then typically 16°C
access to the area underneath the cab. to 49°C (60°F to 120°F)
Lower The Cab
Ensure that the area is free of obstructions.
Ensure all doors are closed and mirrors are in

operating position.
Turn the directional valve to the “Cab Raise”

0
position and operate the pump to lift the cab until
peg has disengage from cab prop.
Pull the cab prop away from engine

0
compartment.
GD0033CFM
Turn the directional valve handle to the

“lowering” position.
• Ensure that the machine is parked on a level
surface and the park brake is applied.
Lowering cab until properly seated. • Ensure that the transmission is in Neutral (N)
for approximately 1 minute.
‹ WARNING • Shift to D (Drive) and then to R (Reverse) to
expel all air from the transmission circuits and
Ensure both mountings are locked into fill the system with fluid.
position with new mounting bolts and nuts. • Shift to N (Neutral) and leave engine at idle.
Never re-use loosened mounting bolts and
nuts.
Install and torque new locking bolts. (See

Chapter 1 in OM for correct torque
specifications).
Doc. No. 872272 : Rev 0 385

‹ CAUTION
1. The fluid level rises as the fluid
temperature increases. DO NOT fill above the
“Hot” mark if the transmission fluid is below
normal operating temperatures. Normal
operating temperature is 80°C to 95°C (176°F
to 203°F). The oil level at 80°C (176°F) is valid
and must not be exceeded.
2. The transmission must not be operated for
extended periods until a “Hot Check” has
verified proper fluid level.
Dipstick Check - Transmission Fluid

HOT (Hot Check)
• With the engine running unscrew and remove
the dipstick (1) from the tube and wipe clean. The Hot Check verifies proper fluid level.
• Clean the end of the tube before inserting the
dipstick. • Ensure that the transmission fluid has reached
• Insert the dipstick into the tube and remove to normal operating temperature; 85°C to 95°C
check the fluid level. (176°F to 203°F)
• Repeat the check procedure to verify the • Check the transmission fluid temperature on
reading. the master display unit.
• Ensure that the machine is parked on a level
NOTE: Hold the dipstick upright with the
surface and the park brake is applied.
point pointing downward when checking the
oil level. • Allow the engine to run at idle (500 to 700
r.p.m.) in N (Neutral).
• Unscrew and remove the dipstick from the
tube and wipe clean.
• Clean the end of the tube before inserting the
dipstick.
• Insert the dipstick into the tube and remove to
check the fluid level.
Repeat the check procedure to verify the reading.
• If the fluid level is on the ENGINE STOP mark

(1) the transmission may be operated until the
fluid is hot enough to perform a “Hot Check”.
• If the fluid level is not on the ENGINE STOP
mark, add or drain transmission fluid as
necessary to bring it to this mark.
The safe operating fluid level is between mark (2)

and mark (3).
If the fluid level is not between mark (2) and (3),

add or drain transmission fluid as necessary to
bring it to the mark.
386 Doc. No. 872272 : Rev 0

BRAKES Remove brake shields if fitted.
Check Park Brake Pad Wear
If either brake pads (1) has worn to minimum

specified thickness, both brake pads must be
replaced. (Refer to BELL EQUIPMENT Product
Support).
Minimum pad thickness: 3mm (0.12”).
Install brake shield if fitted.
Repeat for each wheel.
Measure the thickness of the park brake pads.

TRANSFER CASE
Replace both park brake pads if one has worn to
minimum specified thickness. (Refer to BELL Check The Transfer Case Fluid Level
EQUIPMENT Product Support).
Minimum thickness of pads: 3mm (0.118”).

1
Minimum thickness of disc: 22.5mm (0.886”).
Replace disc before disc reach the minimum
size.
Check Service Brake Pad Wear
NOTE:
1. If operating in wet or muddy conditions,
check wear indicators every 250 hours.
2. Front axles have two sets of inner and
outer wear indicators per side while the rear
TD0006748
axles have only one set per side. Only the
inner wear indicator is visible with tire Check the transfer case fluid level at the sight
installed. Inner and outer pads wear normally glass (1).
evenly. Checking the inner wear indicator is a
good indication of the wear of both pads. Drain or add oil as necessary.
Doc. No. 872272 : Rev 0 387

Check Suspention Struts ‹ WARNING

DO NOT spray steam, water or cleaning
solution directly at breathers. Spray could be
MACHINE ‘A’(mm) ‘B’(mm) forced into housing.
2306D 631 146
2806D 631 146
NOTE: Breathers should be checked daily in
DIM ‘B’ TOL : ± 2mm adverse conditions. The amount of dust and
DIM ‘B’: ROD END TO BARREL dirt encountered will determine the frequency
of breather cleaning.
GENERAL CHECK DRIVE LINE &

SUSPENSION FASTENERS
Check drive line and suspension fasteners
FIGURE 1 TD0006760
condition and security.
Torque specification for breathers: 12 - 16 Nm

‹CAUTION (106 - 142 lb.in.).
To install, check heights or to charge and
setup the suspention struts may present an
extreme safety hazard. these actions should
TRANSFER CASE BREATHER
only be carried out by suitably qualified (LOCATED UNDER THE
personnel and by adherence to sound HYDRAULIC RESERVOIR)
workshop safety principles. If in doubt, please
consult the supplier of this equipment.
The measuremet should always be taken on level

ground at 0% articulation, and to ensure that the
struts are properly seated. The following
procedure should be followed before each
measurement and after each adjustment:
NOTE: Struts must be checked at ambient
temperature, ie when the truck has not been
operating during the work shift.
STEP 1
From standstil and 0% steer (articulation lock
installed), drive straight forward aggressively for
approx 5-10 meters and bring the vehicle to a
stand still using the service brakes.
STEP 2
Then reverse the vehicle gently and bring the Clean dirt and debris away from breather (1) and
vehicle back to it`s original position, but without surrounding areas.
applying any brakes (maybe just at the last
minute to effect complete stand still). Inspect breather for clogging, damage and
STEP 3 proper installation. If necessary, remove clogged
Repeat Step 1 and Step 2 breathers from machine and clean with water.
STEP 4 Dry thoroughly before re-installing.
Once the vehicle has come to a stop, apply the
park brake and switch off the engine. Replace damaged breathers and breathers that
STEP 5 cannot be cleaned. Tighten to specification.
The strut height may now be measured (refer to
Figure 1, dimension "B" above).
388 Doc. No. 872272 : Rev 0

TRANSMISSION BREATHER Rear Axle Breather

AND AXLE BREATHERS
Transmission And Front Axle 1
TD0006761
Clean dirt and debris away from rear axle

breather (1) and surrounding areas.
Clean dirt and debris away from front axle Inspect breather for clogging, damage and
breather (1) and transmission breather (2) and proper installation. If necessary, remove clogged
surrounding areas. breathers from machine and clean with water.
Dry thoroughly before re-installing.
Inspect breathers for clogging, damage and
proper installation. If necessary, remove clogged Replace damaged breathers and breathers that
breathers from machine and clean with water. cannot be cleaned. Tighten to specification.
Dry thoroughly before re-in stalling.
Replace damaged breathers and breathers that

INSPECT, CLEAN AND
cannot be cleaned. Tighten to specification. REPLACE CAB AIR FILTER
Move the seat forward.
Turn latches (1) 1/4 turn counter clockwise.
Doc. No. 872272 : Rev 0 389

‹ CAUTION
Use compressed air to 207kPa (30psi) to
clean filter element. Do not use high pressure
air, element may be damaged or personal
injury may result.
Clean element if necessary. Remove large debris

by hand. Blow compressed air through element
from opposite direction of normal air flow.
If element is moist, allow to dry before

re-installing. Do not apply heat to element.
Install element. Ensure that “Air Flow” decal is

at top and arrows point towards front of machine.
Close access door. Turn latches 1/4 turn

clockwise and ensure latches are locked.
Close parts catalogue compartment door.
CHECK BATTERIES, CLEAN

AND TIGHTEN TERMINALS
Open the access door (1).
Open side panel.
Remove cap screws (1) and open top access

door.
Clean debris from battery compartment.
Inspect battery disconnect switch for damage and

Remove element (1). Inspect element for dust, secure installation. Tighten mounting hardware if
debris, moisture and damage. necessary. Replace damaged components.
(Refer to BELL EQUIPMENT Product
Replace element if damaged. Support).
390 Doc. No. 872272 : Rev 0

CHECK WORK LIGHTS,

REVERSE BUZZER AND HORNS
Check the work lights, reverse buzzer and horns
functioning.
Check the operator controls, buzzers and

instruments.
RECORD & DELETE FAULT

CODES ON THE MDU
For more information See CHAPTER 8 in the
OM and Chapter 3 in this manual.
Inspect and clean terminals (1). Ensure that
posts are secure in battery housings. Ensure that
cables are securely installed on posts.
CHECK THE OPERATOR
CONTROLS AND INSTRUMENTS
Ensure that mounting bracket (2) is secure.
Tighten nuts if necessary. Check the operator controls (Functioning) and
instruments.
Check battery charge indicator (3) on each
battery. The colours are as follows:
GREASE ALL GREASE POINTS
• Green: - Battery is fully charged.
• Black: - Battery charge is low and must be
charged.
• Yellow: - Battery life has expired. Replace
battery.
Start engine. After bulb check, verify that battery

charge indicator on instrument panel is not lit.
Verify battery voltage on MDU.
CHECK ELECTRICAL
CONNECTORS, HARNESSES
AND LOOMS
Check for worn, frayed and damaged harnesses.
Check for loose, corroded and damaged

electrical connections.
Doc. No. 872272 : Rev 0 391

Articulation Joints, Oscilation Tube HYDRAULICS

Through Drive Shaft Bearing Front
And Steering Cylinders Rear Pivot Check Hydraulic Oil Level
Points
Switch off the engine.
Check the hydraulic fluid level in the sight

glass.
The fluid level must be on the mark (1) with the

engine shut down and the machine parked on
level surface and hydraulic oil cold.
Grease each point (1,2,3,4 and 5) until grease
escapes from joint. If the machine has been standing for a while or
has not worked over-night, the hydraulic oil level
might lie at the “HOT” oil level mark. This is
Oscillation Tube And Oscilation normal. Once the machine has been started, the
Tube Through Drive Shaft level should drop to the “Cold” oil level mark.
Bearing Rear.
TD0006749
392 Doc. No. 872272 : Rev 0

If necessary replenish the fluid in the hydraulic

tank. Refer to Specifications, CHAPTER 1 -
Recommended Lubricants and Coolants In
The OM.
3 1
Service Brake Accumulator Routine 2

Test
NOTE: 1. If less than two full applications,

have the system checked by a BELL
EQUIPMENT serviceman.
• Start engine. Wait until main pump has fully

charged the accumulators (Listen to the tone
of the engine, while charging the engine
revolutions will be lower).
• Apply the service brakes repeatedly to make TD0006754
the pump re-charge a few times. Discontinue
applying the brakes in a re-charge cycle while
the pump is still charging (to ensure the brakes Unscrew hydraulic reservoir breather (1) and
are not consuming oil after the pump stops, remove from machine.
wait 4 seconds while listening to the engine.
Engine revolutions must go up after pump Install new hydraulic reservoir breather.
stops). Hand-tighten.
• Switch off the engine.
Install access panel and cap screws.
• Switch the ignition on an wait until the warning
lights extinguishes.
Grease Prop Shaft Slip Joint
• Fully apply the service brakes and count the
number of applications before the accumulator
low pressure light illuminates.
REPLACE HYDRAULIC
RESERVOIR BREATHER
NOTE: Hydraulic reservoir breather should be
replaced at scheduled intervals or whenever
found to be damaged or clogged.
Fit grease pump nozzle to grease nipple (1) and

grease prop shaft slip joint.
2
1
TD0006750
Remove bolts (1) and access panel (2).
Doc. No. 872272 : Rev 0 393

394 Doc. No. 872272 : Rev 0

CHAPTER 11. 1 000 HOURS SERVICE AND CHECKS
INTRODUCTION
The 1 000 hours service and checks must be Turn screws (1) 90° to unlock screws.
Push in the locks on the side and remove the
cover.
Remove Tappet Cover
position. Refer to Pre-service Instructions, NOTE: Be carefull not to damage the tappet
Chapter 7 in the OM. cover seal when removing the tappet cover.
Engine
Mercedes-Benz Manual OM 906LA.
Adjust Engine Valve Clearance
See "Valve Clearance Adjustment."
Replace Primary Fuel Filter (Water

Separator)
See Replace Primary Fuel Filter.

Loosen the allen screws (1) on top of the cover.
Replace Secondary Fuel Filter Remove tappet cover.
See Replace Secondary Fuel Filter. Clean dirt and debris away from breather cover
and surrounding areas.
Replace Crankcase Breather Filter
‹ CAUTION
NOTE: To open the cover for cleaning or Be carefull when removing the cover. There is
replacing the crank case breather filter, the a spring inside that can fall out when cover is
tappet cover has to be removed first. removed.
Remove Tappet Cover
Unscrew the three screws (1) and remove the

breather cover.
Remove Side Cover.
Doc. No. 872272 : Rev 0 395

Inspect cover seal ring and diaphram (1) for

damage. Replace if necessary.
Place cover seal ring and diaphram in position.
Replace the cover and tighten the screws.
Replace tappet cover and tighten screws.
Replace side cover and lock in position.
Change the Primary Filter Element
Remove first element (1).
Loosen the clips (1) and remove the end cover

TD0006751 from the air cleaner housing.
Use wire hook to remove second breather

element.
NOTE: Dispose of waste properly.
Install element (1) and (2).
Fit spring.
396 Doc. No. 872272 : Rev 0

Remove the primary filter element (1) from the air

cleaner housing.
Discard the primary filter element, do not re-use.
Clean the air filter housing inside and the end

cover with a damp cloth and inspect for damage.
Check the end cover to ensure that it is fitted

correctly and secure with clips.
Remove the filler cap (2) and test the coolant in
Check Coolant Condition the coolant tank (1).
Use a 3-way heavy duty coolant test kit to test

Check coolant every 1000 hours or 6 months or
the coolant. Follow the instructions on the kit.
when replacing 1/3 or more of coolant. Add
coolant conditioner as necessary.
‹ WARNING
Open the bonnet. To prevent machine damage, ensure that all
coolant additives are compatible with coolant
‹ WARNING that the system is currently filled with. (See
1. Explosive release of fluids from Chapter 1 for coolant specification).
pressurized cooling system can cause
serious burns. Add coolant conditioner or equivalent
2. Remove fill cap only when engine is cold or non-chromatic conditioner/rust inhibitor as
when cool enough to touch with bare hands. necessary. Follow instructions on the container
for amount.
Slowly loosen cap to first stop to relieve
pressure before removing completely. Install fill cap.
Doc. No. 872272 : Rev 0 397

Check The Fan Belt Condition
Open the bonnet.

3 1
TD0006754
Turn hydraulic reservoir breather (1) counter

clockwise and remove from machine.
‹ WARNING
Avoid personal injury. Remove return filter
element cover carefully. Spring is under load.
Check fan belt (1) condition.
Loosen and remove opposite sets of bolts and
washers (2) in sequence to keep spring load
REPLACE HYDRAULIC distributed evenly. Hold return filter access cover
RESERVOIR BREATHER (3) securely in place while removing last 2 cap
screws and washers. Release slowly to relieve
spring load.
See Replace Hydraulic Reservoir Breather,
Chapter 10 in this manual. Inspect access cover seal ring (1) for damage
Replace Hydraulic Oil Return Filter
2
1
and wear. Replace if necessary.
TD0006750
Grasp spring and remove spring and return filter
assembly.
Remove bolts (1) and access cover (2) Clean filter seat. Do not allow dirt, debris or
foreign objects to fall into hydraulic reservoir.
Clean top of tank from debris, dust and foreign
materials. Remove retaining screw (1) and remove filter
element (2).
398 Doc. No. 872272 : Rev 0

Inspect shoulder seal ring (3) and face seal ring CHECK FINAL DRIVE OIL
(4) for damage and wear. Replace if necessary.
LEVELS
NOTE: Use only recommended filters which
have the correct micron filtration rating for NOTE: Perform this procedure for each final
the hydraulic system. (Refer to BELL drive. The procedure is the same for all final
EQUIPMENT Product Support). drives.
Install new element. Install retaining screw.

Ensure that element is centred on face seal ring.
Install spring and filter assembly. Ensure that

shoulder seal ring is properly seated in filter seat.
Install return filter access cover and washers and

cap screws. Ensure that return filter access cover
is free of dirt and debris before installing. Tighten
opposite cap screws and washers in sequence to
ensure that access cover seal ring is compressed
uniformly.
Replace cap screws access cover. Rotate wheel until check and drain plug (1) is in a
horizontal position.
Tighten cap screws.
Remove the plug and check the oil level. Oil level
must be level with bottom edge of check plug.
CHECK AXLE OIL LEVEL
If necessary, add oil. (See Change Final Drive
NOTE: Oil In Chapter 12 and See Chapter 1 in OM for
1. Perform this procedure for all axles. recommended oils and quantities).
2. Dispose of waste properly.
Install check and drain plug tightly.
TD0006755
Clean axle housing around check and fill plug (1).
Remove check and fill plug from axle housing.
Oil must be level with bottom of check and fill

port.
Add oil through check and fill port if necessary.

(See Change Axle Oil in Chapter 13).
Install check and fill plug.
Doc. No. 872272 : Rev 0 399

400 Doc. No. 872272 : Rev 0

INTRODUCTION Install primary filter element, ensure that it is

firmly and evenly seated.
The 2 000 hours service and checks must be
performed by qualified service personnel. Install air cleaner cover and fasten clasps.
Press top of service indicator to reset flag.

Change Transmission Oil
position. Refer to Pre-service Instructions,
Chapter 7 in OM. ‹ WARNING
Be careful when draining hot transfer case
oil. Hot oil can cause burns to unprotected
ENGINE skin.
NOTE: 1. For further engine information or NOTE: 1. It is not necessary to change the
details not shown in this manual, refer to the transmission oil until a contaminated sample
Mercedes-Benz Manual OM 906LA. is indicated. Draw sample from transmission
2. To remove the secondary filter element, oil at drain plug. For convenience, install a
remove the primary filter element first. (See sampling valve in the drain port.
Chapter 12 of this manual). 2. Samples should be taken initially at 1 000
hours, followed by every 500 hours of
Change the Secondary Filter Element operation.
3. See your authoriz3d dealer for more
NOTE: At minimum, secondary element must information.
be replaced every third time primary filter is 4. Dispose of waste properly.
replaced.
Remove primary filter first.
Remove drain plug (1) and drain oil into a

container.
Install drain plug and remove container.
Wipe drain plug and transmission clean.

Remove and inspect secondary element (1).
Replace the element. Drain Transmission Oil Cooler
Wipe housing clean with a lint free cloth. Lower the belly plate.
Squeeze unloader valve to empty air cleaner
housing of dust and debris.
Install secondary filter element, ensure that it is

evenly and firmly seated.
Doc. No. 872272 : Rev 0 401

Place container under the cooler. Remove cap screws (1).
Remove filter assembly (2). Drain oil into a

‹ WARNING container.
oil. Hot oil can cause burns to unprotected Remove filter element (3). Discard filter element.
skin.
Install new filter element.
Replace filter cover “O”-Ring.
Install filter assemblies and cap screws. Tighten

to specification.
Cap Screw Torque: . . . . . . . 25 Nm (18 lb.ft.).
Fill Transmission
With the engine in vertical position, remove the

dipstick and fill up to the STOP mark on the oil
dipstick.
Start the engine. Turn off the engine after ca. 30

Remove the drain plug (1) and allow oil to drain seconds. Top up to the STOP mark.
into container.
Warm up transmission to oil sump temperature
After cooler has been drained completely, 60°C - 70 °C. With the engine idling, cool down to
replace the drain plug and tighten. 50 °C and set oil level to MAX mark (at idling
speed).
Replace Transmission Oil Filters
Drive vehicle in all operating points (all gears,
retarder). Re-check oil level at 50 °C and adjust if
necessary (only high oil throughputs result in the
cooler lines being fully vented).
(See Chapter 1 in Operator Manual for

recommended oil specification and
quantities).
Place a container under the transmission filter

assemblies.
402 Doc. No. 872272 : Rev 0

Change Transfer Case Oil Replace the fill plug and seal.
Start the engine and drive the machine in 1st

‹ WARNING gear for one minute. Stop the machine and
re-check the oil level.
oil. Hot oil can cause burns to unprotected Add or remove oil to get the right oil level.
skin.
Check for oil leaks at the drain and fill plugs.
Tighten only enough to stop leaks.
Change Axle Oil
NOTE: 1. Perform this procedure for all axles.

TD0006764
Remove fill plug and seal ring (1). Clean fill plug
and seal ring. Inspect seal ring.
Replace seal ring if necessary.

Clean boot axle housing around check and fill
Place a container under the drain plug (1). Clean plug (1) and drain plug (2).
drain plug and surrounding area. Remove the
drain plug and drain oil into the container. Remove check and fill plug (1) from axle housing.
Replace the drain plug. Place a container under the drain plug (2) and
remove drain plug.
Remove the container.
Drain oil into the container
Tighten the drain plug.
Replace the drain plug and tighten
Fill the transfer case with oil. (See Chapter 1 for
recommended oil and capacities). Remove the container and wipe the drain plug
and axle housing clean.
Add oil through check and fill port. (See Chapter

1 for recommended oils and quantities).
Fill until oil just starts to flow from fill port.

2
Install check and fill plug and wipe clean.
TD0006765
Check the oil level at the sight glass (2). Oil

should be in the centre sight glass.
Doc. No. 872272 : Rev 0 403

Change Final Drive Oil Jack the relevant wheel up and remove the
wheel.
NOTE: 1. Perform this procedure for all axles.
Rotate wheel until drain plug (1) is at lowest point

and fill/check plug (2) is in horizontal position.
Place a container under the drain plug.
Remove the drain plug from the final drive and Measure the service brake disc thickness (A).
allow oil to drain into the container.
Specification
Clean final drive housing.
Minimum Thickness A . . . . . 23mm (0.91inch)
Replace drain plug and tighten.
Replace the disc when thickness is out of
Remove the fill plug (2) and fill final drive with specification. (See Repair Manual for
clean oil. (See Chapter 1 for recommended oils procedure).
and fill capacities).
‹ WARNING
Oil must just begin to flow from fill/check plug.
Torque wheel nuts to specification. (See
Replace fill plug and tighten. Chapter 1 in OM for correct torque
specification).
Wipe final drive housing clean.
Replace wheel when finished and repeat
procedure for other wheels.
Check Service Brake Disc Thickness
Check Front Hubs
‹ WARNING
Wheels are heavey and special care must be Check front hubs for cracks.
taken not to hurt one self. Use suitable jack.
Chock all wheels. Loosen wheel nuts.
404 Doc. No. 872272 : Rev 0

REPLACE PNEUMATIC SYSTEM

DRYER FILTER
Relieve pneumatic pressure
Remove old element (1) from head. Discard old

element.
Inspect O-ring on head for damage and wear.

Open side panel. Clean or replace O-ring if necessary.
Pull the ring on the resevoir and hold untill

hissing stops.
Doc. No. 872272 : Rev 0 405

406 Doc. No. 872272 : Rev 0

INTRODUCTION Remove Idler Pulley Assembly

Ensure that the machine is in the position as
described in the OM, CHAPTER 7.
Change jockey pulley bearing

(Tensioner Pulley)
Remove the fan belt. (See Chapter 15).
Loosen the bolt (1) retaining the idler pulley

assembly (2).
Remove the idler key pulley assembly.
Fit new idler pulley assembly.
Tighten the bolt to specification.

Loosen the bolt (1) retaining the jockey pulley
assembly (2). Tightening Torque . . . . . . 50Nm (36.88 ft.lb).
Remove the jockey pulley assembly. Fit the fan belt and fan guard.
Remove the circlip and tap out the bearing.
Replace the bearing and circlip.
Fit jockey pulley assembly.
Tighten the bolt to specification.
Tightening Torque . . . . . . 50Nm (36.88 ft.lb).
Doc. No. 872272 : Rev 0 407

Change Aircon Pulley Assemby Replace The Suction Screen
Relieve the tension of the fan belt and rtemove Remove hydraulic tank cover. See "Change
the fan belt from the airconditioner pump pulley. Hydrualic Oil Return Filter", Chapter 11.
NOTE: Take care not to damage the cover

seal.
Loosen the bolt (1).
Remove the pulley assembly and disconnect the

clutch harness connectors.
Connect the new pulley assembly clutch harness. TD0006756
Install the new pulley assembly. Loosen and remove all the bolts (1) securing the
cover to the tank.
Thigten the bolt.
Remove the cover.
Install the fan belt.
Change all axle driveline cross and

rollers
Loosen the bolts retaining the drive shaft to axle.
Repeat for second end.
Remove the drive shaft.
Remove the cross and roller assembly and

replace with new cross and roller assembly.
Thighten bolts to specification.

Unscrew the suction screen (1).
Fit drive shaft to machine and replace the bolts.
Apply thread sealing tape to the thread and
Tighten the bolts to specification. screw the new screen on.
Repeat procedure for all drive shafts. Replace the cover and tighten with bolts.
Fill hydraulic reservoir with new oil.
Close hydraulic reservoir cover.
Check for leaks at the drain valve. Ensure that

valve is fully closed. Tighten plug just enough to
stop leaks.
408 Doc. No. 872272 : Rev 0

INTRODUCTION
Ensure that the machine is in the position as
described in the OM, CHAPTER 7.
REPLACE FAN BELT

Open bonnet.
Open and lowe the belly plate.

Move the fan assembly as far forward as
possible.
‹ CAUTION
1. Explosive release of fluids from Fit socket with ratchet onto the tensioner nut (1)
pressurized cooling system can cause and release the belt tension.
serious burns.
2. Remove fill cap only when engine is cold or Remove the belt from the pulleys.
when cool enough to touch with bare hands.
Slowly loosen cap to fist stop to relieve Fit new belt and allow the tensioner to tension the
pressure before removing completely. belt. Remove the socket and ratchet and
assemble in reverse order.
Drain coolant. (See Change Coolant.
Fill the coolant system with the correct coolant.
Loosen clamps (1) and remove coolant hose (2). (See Chapter 1 in the OM for correct
specification and quantities).
Loosen bolts (3) and remove fan guard.
Loosen the nuts (1) on the fan mounting shaft.
Doc. No. 872272 : Rev 0 409

Change Hydraulic Oil Change Pneumatic Block Breather

Filters
2
1
TD0006757
Install a drain hose and clamp to drain valve (1).

Remove circlip (1).
Loosen nut (2) and valve stem (3) to open drain
valve. Remove breather (2).
Drain hydraulic oil. Replace breather and circlip.
Tighten valve stem and nut to close drain valve.
Remove the hose and hose clamp from drain

valve.
Fill Hydraulic Tank
TD0006758
Remove fill cap (1). Fill hydraulic reservoir with

new hydraulic oil.
Check hydraulic oil level.
Check for leaks at the drain valve. Tighten only

enough to stop leaks.
410 Doc. No. 872272 : Rev 0

CHAPTER 15. AS REQUIRED SERVICE
INTRODUCTION
This chapter details services which are described Check the alternator for security.
in the maintenance schedule as tasks which are
performed as required.
Some unscheduled maintenance tasks are also

included in this chapter.
position. Refer to Pre-service Instructions,
Chapter 7 in the OM.
Engine

Mercedes-Benz Manual OM 906LA
Check all electrical connections to alternator for
Check the Engine Compartment proper tight installation.
Components
Perform a general, visual check on the engine

and components in the engine compartment as
follows:
NOTE: Photo taken without engine mounting

for clarity.
Ensure that the starter motor (1) is mounted

securely and not damaged.
Ensure all battery cables are tightly fastened on

the starter motor, earth bosses and batteries.
Ensure that the pipes and hoses and all linkages

are secure and not damaged.
Check the air conditioner compressor pump (1)
for cracks and security.
Inspect the alternator, air conditioner compressor

and water pump drive belt for cracks, fraying,
wear and tension.
Doc. No. 872272 : Rev 0 411

Clean/Replace Primer Pump Fuel

Screen
Open the bonnet.
‹ CAUTION
Avoid damage to components. Handle fuel
screen and O-ring with care. Do not twist or
squeeze fuel screen. Do not over-stretch or
cut O-ring.
Remove fuel screen (2) and O-ring (1). Pull fuel
screen straight down.
Rins fuel screen and O-ring with clean diesel

fuel.Inspect fuel screen and O-ring for damage.
Replace if necessary.
Install O-ring and fuel screen. Push fuel screen

straight up. Ensure that O-ring and fuel screen
are properly installed.
Install sediment bowl. Tighten until O-ring is

firmly compressed.
Prime fuel system
The fuel system must be primed after performing

service procedure on the fuel system.
Pockets of air may still be trapped in the fuel

system after priming. Even after priming, engine
may engine start hart and run rough for
approximately one minute after performing
Hold a container under sediment bowl (2).
service procedure on fuel system. If engine does
Remove sediment bowl from primer (1). Empty
not start or run “rough” after approximately one
waste fuel into container.
minute, stop the engine. Correct the problem
Wipe debris and moisture from sediment bowl before starting.
with a lint free cloth.
• Ensure that all filters and fittings are tight.
Inspect sediment bowl for damage. Replace if • Ensure that the air tank is at least 1/4 full.
necessary.
Operate primer using long, firm strokes until a
significant increase in resistance is felt.
Check for leaks at all filters and fittings. Tighten

only enough to stop leaks. If leaks cannot be
stopped, Refer to BELL EQUIPMENT Product
Support.
412 Doc. No. 872272 : Rev 0

Change Engine Coolant
NOTE: Replace engine coolant every 4 years.
Open the bonnet.
‹ CAUTION
1. Explosive release of fluids from
pressurized cooling system can cause
serious burns.
2. Remove fill cap only when engine is cold or
when cool enough to touch with bare hands.
Slowly loosen cap to fist stop to relieve
pressure before removing completely.
Attach hose to the drain valve (1).
Loosen drain valve stem (2) and drain coolant

into a container.
NOTE: 1. Dispose of waste properly.

2. See Chapter 1 for coolant
recommendations and fill capacities.
Tighten drain valve stem. Do not over tighten.
Remove hose.
Engine coolant is often sold in concentrated form

and must be mixed with water to obtain correct
specific gravity. Verify correct mixture before
filling.
Add new engine coolant at expansion tank fill

port. Do not over fill.
Do not install fill cap. Start engine. Run engine at

slow idle for 3 minutes to purge air pockets from
engine cooling system. Stop engine.
Check for leaks at the drain valve. Tighten just

enough to stop leaks.
Close access door and install cap screws and

Remove fill cap (2) from expansion tank (1).
washers.
Check coolant level in tank. Cold coolant should

not be below ADD mark and hot coolant not
above the FULL mark.
Add more coolant if necessary.
Install fill cap securely.
Remove cap screws and washers (1) and open

access door (2).
Doc. No. 872272 : Rev 0 413

Check the transmission cooler for damage and

security.
Check the hoses and clamps for damage and

security.
Clean Cooling System
Turn battery disconnect switch OFF.
‹ CAUTION
Use a pressure washer and a mild detergent
that is not caustic to aluminium. Do not spray
cooling system fins at an angle. Fins may
bend.
Remove the lid (1) and bowl (2) from the
pre-cleaner body (3).
Raise hood and wash front cooling system,
spraying from the engine side to the front. Remove the dirt from the bowl and clean the bowl
with a lint-free cloth.
Remove access covers and wash hydraulic
cooling system from the fan side out. Install first the bowl then the lid onto the
pre-cleaner body and secure them with the wing
Clean cooling systems and grilles and keep them nut.
clean.
Check for Oil and Fuel Leaks CLEAN AIR CONDITIONING

FILTERS
Perform a visual inspection for oil and fuel leaks
on and around the engine and components See Chapter 11, Page in this Manual.
inside the engine compartment.
Clean the Air Cleaner Pre-cleaner GREASE HINGES

Bowls
Grease all Hinges fitted with grease nipples.
CHECK AND CLEAN COOLERS

Clean all coolers and check for damage and
wear.
Remove the wing nut (1) securing the lid (2) to

the bowl (3).
414 Doc. No. 872272 : Rev 0

CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS
INTRODUCTION
The miscellaneous service and checks must be 5. Open battery box and turn battery disconnect
performed by qualified service personnel. switch to OFF position.
Install the bottle jack under the appropriate axle

SERVICE INSTRUCTIONS and side.
Ensure that the machine is in the service Start Jacking the machine while noting the jack
position. Refer to Pre-service Instructions, for sagging into the surface.
Chapter 7 in the OM.
NOTE: If the jack is pushing into the surface,
lower the jack and fit a wider base under the
ENGINE jack.
Inspect Serpentine Belt Start jacking the machine again. Follow the same
procedure as before.
Inspect serpentine belt for wear, fraying, splitting,
NOTE: If the jack and base is pushing into the
cracking, damage, dirt and debris.
surface, lower the jack and move machine to
Replace serpentine belt if necessary. a more solid area.
Loosen the wheel nuts.

WHEELS
Jack the machine until wheel is lifted off the
ground.
Change Wheels
Remove the wheel with the appropriate tools and
‹ WARNING method.
Wheels are heavy. Follow safety instruction to Install new wheel.
avoid injury.
Tighten the wheel nuts.
Slow Puncture
Lower the machine and torque the wheel nuts to
NOTE: If the truck is loaded and it is not 650 Nm.
possible to pump the wheel and drove it to
the point of dumping, dump the load and Remove the jack (and base plate if used).
drove the machine to a safe position.
NOTE: Torque wheel nuts again after 50
1. Machine must be parked on a flat solid surface hours.
that will be able to support the weight of the
machine on the jack without jack being pushed USING BATTERY CHARGER
into the ground.
2. Chock wheels to prevent truck from moving ‹ WARNING

forward or backwards.
1. Disconnect battery earth before you charge
3. Install articulation lock bar. the batteries in the machine to prevent
damage to the electrical components.
4. Switch OFF the machine and remove the key. 2. A frozen battery may explode when
charged. Warm battery to 16°C (60°F)before
charging.
Doc. No. 872272 : Rev 0 415

A battery charger may be used as a booster to For each terminal, lift rubber terminal cover and
start the engine. remove the nut, washer and ring connector.
Move all cables aside.
‹ CAUTION Loosen and remove the three nuts and washers
Do not use a battery charger as a booster if holding the brtacket (2).
the battery has a 1.15 specific gravity reading
or lower. Turn the charger off before Remove the mounting bracket (2).
connecting or disconnecting the charger.
Lift and remove the two batteries.
Replace the batteries Install new battery left with the negative terminal
facing the engine side of the machine. Install right
Open the bonnet. battery with the negative terminal facing the left
side of the machine. Install and tighten the
mounting bracket.
Install all cables and tighten. Pull rubber terminal

covers over the terminals.
Turn battery disconnect switch ON.
Start engine after bulb check. Verify that battery

charge indicator on instrument panel is not lit.
Verify battery voltage on MDU.
Replace Front Turn Signal Bulb,

Headlight Bulb and Front Park Light
Open the side access door (1) and turn the Bulb
battery disconnect switch OFF.
Remove the screws and open the top access ‹ CAUTION

door.
Prevent bulb damage. Use a clean cloth or
Clean debris from battery compartment. tissue paper to handle bulbs. If touched,
clean glass thoroughly with alcohol and lint
NOTE: Ensure that all cables are connected free cloth. Do not use a halogen bulb that is
properly. Note all connections while removing not clean.
the batteries, to prevent incorrect
connections while installing batteries.
Remove the cap screws (1) and grill (3) (If

equipped) from headlight assembly.
Remove screws (2) securing headlight assembly

to fender.
Disconnect all cables (1) from terminals, Swing headlight assembly out of fender.
beginning at the negative (-) terminal of battery.
Work clockwise.
416 Doc. No. 872272 : Rev 0

Replace front turn signal bulb Remove the bulb from the headlight assembly.
Install new headlight bulb.
Swing retaining clips upward. Squeeze retaining

clips to fasten.
Attach connector to headlight bulb.
Replace Front Park Light Bulb
Detach wires leads (4) from park light bulb (5).
Turn park light bulb counter clockwise to loosen

bulb. Remove the park light bulb from headlight
Detach wire leads (3) from front turn signal bulb assembly.
(2).
Install new park light bulb. Fit into headlight
Squeeze tabs (1) and remove front signal bulb assembly. turn park light bulb clockwise to fasten.
from headlight assembly.
Attach wire leads to park light bulb.
Install new front turn signal bulb.
Attach wire leads. Reassemble Headlight assembly
Swing headlight assembly into fender.

Replace Headlight Bulb
Install screws to secure headlight assembly to
fender.
Adjust headlights. (See next procedure).
Install headlight grill and cap screws, if equipped.
Detach connector (1) from headlight bulb (3).
Squeeze retaining clips (2) to loosen. Swing

retaining clips downward.
Doc. No. 872272 : Rev 0 417

ADJUST HEADLIGHTS
2
GD1026CV
The headlights must be adjusted to correct height

so that the operator can safely operate the • Measure width between centres of headlights.
machine at night or in poor light conditions. Mark grill with tape at centre point.
• Measure height from ground to centre point
When properly adjusted, headlight beams are between headlights.
parallel, angled neither right nor left and low • Use string line and tape to mark wall at
beams are angled downward at a 1% grade. centres of headlights.
• Verify that the tires are at the correct pressure. • Activate low-beam headlights. Turn vertical
adjustment screw (2) to aim each headlight so
(See tire decal).
the centre of each beam is 5cm (2”) lower than
• Drive machine onto a level surface, directly the tape mark.
facing a vertical wall with frames steered
straight. Stop machine with headlights 5m
• Activate high-beam headlights. Adjust
horizontal adjustment screw (1) to aim each
(16.4 ft.) from wall.
headlight directly toward tape mark.
418 Doc. No. 872272 : Rev 0

Replace Backup Light and Work Light

(If Equipped)
Remove screws (1).
3 2
TD0006759
Pry gently around edges of lamp (1) to remove

Remove bezel (2), lamp (3) and rubber seal (5) from rubber seal (2).
from housing (7).
Disconnect connector (3) and discard lamp.
Disconnect wire lead (4) from connector (6).
Disconnect connector from terminal (8). Connect connector to new lamp.
Remove bezel and rubber seal from lamp and Install lamp in rubber seal. Index lamp so “TOP”
discard the lamp. marking is at top. Push lamp into rubber seal with
firm, even pressure. Ensure that lamp is securely
Install bezel and rubber seal on the new lamp. seated.
Connect connector to terminal. NOTE: Procedure is the same for both the tail
and brake light and the turn signal light.
Connect wire to the connector.
Install rubber seal, lamp and bezel in housing. Replace Dome Light Bulb and Circuit
Breaker Compartment Light Bulb
Install screws.
Adjust position of light for best illumination. If ‹ WARNING

housing is loose, tighten mounting hardware (Not Do not use excessive force when removing
shown). lens cover, or plastic may become damaged.
Replace Tail and Brake Light and Rear

Turn Signal Light
‹ WARNING
Do not use excessive force when removing
lamp or rubber may become damaged.
Pry gently along edges of lens cover to remove.
Remove and replace dome light bulb (1) or fuse

compartment light bulb (2).
Install lens cover. Push with gentle, even

pressure until lens cover“snaps” into place. Lens
cover should rock back and forth between 3
Doc. No. 872272 : Rev 0 419

detent positions. ( ALSO SEE SIB 2009/1074 FOR

HEADLIGHT CLEANING PROCEDURE )
420 Doc. No. 872272 : Rev 0

CHAPTER 17. TROUBLE SHOOTING
SECTION 1. SYMPTOMS AND REMEDIES
INTRODUCTION
It is important to properly operate and maintain the machine and its components and to immediately
rectify any faults which may occur.
Further information regarding the measures listed under “Remedy” can be obtained from the Service
Manual or your BELL EQUIPMENT Product Support Representative.
NOTE:These lists are not exhaustive. If in doubt contact your BELL EQUIPMENT Product Support
Representative.
Engine
Symptom Possible Cause Remedy
Starter pinion Battery insufficiently charged. Charge battery.

does not turn or Connecting cable to starter loose. Tighten cable at terminal; if necessary,
turns too slowly. solder on a new terminal.
Carbon brushes shorting to earth, Clean carbon brushes with a clean cloth
jamming in guides, or poor contact. moistened in diesel (do not use emery
paper); have the brushes renewed if
necessary. Refer to BELL EQUIPMENT
Product Support.
Solenoid switch of starter faulty. Refer to BELL EQUIPMENT Product
Support.
Freewheel clutch of starter slipping. Refer to BELL EQUIPMENT Product
Support.
Hydraulic cut out solenoid faulty or not Refer to BELL EQUIPMENT Product
working. Support
Engine does not Fuel tank almost or completely empty. Refuel and bleed system.
start, or stops Fuel filter clogged. Clean filter; renew element, if necessary.
immediately.
Fuel line, pre-cleaner or strainer Clean and bleed system.
clogged.
Leak in fuel system or in filter seals. Seals bleed.
Fuel with insufficient fluidity. Wash off wax deposits on strainer and
filters, or renew filter element and use
winter-grade fuel matched to outside
temperature.
Outside temperature too low. Observe measures for winter operation.
Engine hard to Starter motor turns engine to slowly. Check battery charge. Charge or replace
start when cold. batteries.
Cold start function do not work properly. Check function and repair.
Engine turns but Insufficient fuel in tank. Fill tank and bleed system.
does not start.
Doc. No. 872272 : Rev 0 421

Engine
Engine runs Fuel tank almost or completely empty. Refuel and bleed system.
irregularly, cuts Fuel filter clogged. Clean filter; renew element, if necessary.
out or has poor
performance. Fuel line, pre-cleaner or strainer Clean and bleed system.
clogged.
Leak in fuel system or in filter seals. Seal, bleed.
Fuel with insufficient fluidity. Wash off wax deposits on strainer and
filters, or renew filter element and use
winter-grade fuel matched to outside
temperature.
Outside temperature too low. Observe measures for winter operation.
Bypass valves in fuel filter or in injection Check, renew if necessary.
pump do not maintain pressure.
Vent in fuel tank filler cap clogged. Clean cap.
Start of delivery of injection pump Check and adjust start of delivery.
incorrectly set.
Injection nozzles jam or do not atomise. Renew nozzles.
Insufficient air at higher speeds Clean air filter.
(because air filter fouled).
Throttle linkage or control lever not at full Check, set correctly if necessary.
stop.
Exhaust valve for exhaust brake, one or Check position of exhaust valves; clear
both cylinder banks, or valve at end of jamming valves.
exhaust line is closed or jammed.
Air filter restriction. Service air filter system.
Black exhaust Injection nozzles are damaged or fouled Renew nozzles.

smoke. by carbon deposits.
Start of delivery of injection pump Set correctly.
incorrectly set.
Excessive fuel delivery. Check injection pump.
Air filter fouled. Clean.
Exhaust valve for exhaust brake, one or Check position of exhaust valves; clear
both cylinder banks, or valve at end of jamming valves.
exhaust line is closed or jammed.
Blue exhaust Oil level in engine or in oil bath air filter Correct oil level.
smoke. too high.
Engine oil in combustion chamber Refer to BELL EQUIPMENT Product
(because piston rings jamming, cylinder Support.
liners are scored or excessive play in
valve guides, or valve stem seals
leaking).
White exhaust Cylinder head or cylinder head gasket Measure compression pressure to
smoke. leaking, coolant in combustion chamber. determine defective cylinder and rectify
damage or refer to BELL EQUIPMENT
Product Support.
422 Doc. No. 872272 : Rev 0

Engine
Engine pinking. Leak in nozzle holder or nozzles not Renew nozzles. Tighten nut of nozzle
properly atomising. holder.
Start of delivery of injection pump Check and adjust start of delivery.
incorrectly set.
Engine Bearing damage to crankshaft or Switch off engine immediately and refer
knocking. damage to piston. to BELL EQUIPMENT Product Support.
Coolant Insufficient coolant or cooling system not Replenish, vent.

temperature too properly vented.
high. Belt for driving coolant pump or fan Tension or renew.
insufficiently tensioned or broken.
Radiator fouled or clogged with deposits Clean or flush out deposits.
on inside; radiator fouled on outside.
Automatic fan coupling of viscous fan Block fan temporarily and refer to BELL
faulty. EQUIPMENT Product Support.
Thermostats faulty. Renew.
Engine oil
pressure low. ‹ CAUTION
If pressure drops rapidly, switch off
engine immediatelyOil level in sump
too low.
Oil level in sump too low. Replenish oil to correct level.

Engine oil too thin. Refill with correct grade of oil. Refer to
Chapter 1, Specifications -
Recommended Lubricants and
Coolant Additives Chart; Check for
presence of water or fuel in oil.
Pressure relief valve blocked or leaking
when open, oil pump faulty, oil pressure Refer to BELL EQUIPMENT Product
gauge faulty, wear causing excessive Support.
bearing play, damage to bearings.
Engine oil Incorrect oil used. Change oil and oil filters.
pressure high
Engine oil Incorrect grade of oil used. Replace oil with correct grade.
sludge. Engine operating temperature incorrect. Check and correct cooling system.
Oil in service to long. Change oil and oil filters.
Abnormal oil Engine over filled. Drain to proper level. Check drained oil
consumption. for presence of other oils in oil.
Engine oil leaks. Locate and repair the leaks.
Incorrect grade engine oil. Replace oil and filters.
Engine oil level to low. Fill to correct level.
Doc. No. 872272 : Rev 0 423

Engine
Alternator Bulb faulty or electric lead interrupted. Replace bulb or rectify interruption.
indicator
warning light
does not
illuminate when
engine is not
running.
Alternator Drive belt not tensioned correctly. Check, correct belt tension.
indicator Drive belt broken. Replace drive belt.
warning light
illuminates when Alternator, rectifier or regulator faulty. Check, renew faulty parts, refer to BELL
engine is EQUIPMENT Product Support.
running.
Transmission
Low clutch Low oil level. Refill transmission. Refer to Chapter 1,

pressure. Specifications - Recommended
Lubricants and Coolant Additives
Chart.
Low converter Low oil level. Refill transmission. Refer to Chapter 1,

charging pump Specifications - Recommended
output. Lubricants and Coolant Additives
Chart.
Suction screen blocked. Clean the suction screen.
Overheating. Low oil level. Refill transmission. Refer to Chapter 1,

Specifications - Recommended
Chart.
Axles
Final drive Loose or damaged oil plugs. Tighten or replace the oil plugs.
leaking oil. Oil level too high. Drain oil to the correct level.
Final drive bolts loose. Tighten the final drive bolts to the correct
torque.
Axle breather blocked. Clean the axle breather.
Noisy final drive. Low oil level in the final drive. Refill the final drive. Refer to Chapter 1,
Chart.
424 Doc. No. 872272 : Rev 0

Axles
Final drive Oil level too high. Drain oil to the correct level.
overheating. Oil level too low. Refill the final drive. Refer to Chapter 1,
Chart.
Differential Bolts loose on main housing. Tighten bolts to the correct torque.
assembly
leaking oil.
Differential Oil level too low. Refill the differential. Refer to Chapter
assembly noisy. 1, Specifications - Recommended
Chart.
Differential Oil level too high. Drain the oil to the correct level.
assembly Oil level too low. Refill the differential. Refer to Chapter
overheating. 1, Specifications - Recommended
Chart.
Axle breather blocked. Clean the axle breather.
Wheels
Wheel Wheel bent or damaged. Change the wheel.

misalignment.
Wheel cracked. Impact damage. Change the wheel.
Tyres
Tyres wearing in Tyres over inflated. Reduce the tyre pressure to the correct
tread centre. level.
Tyres wearing Tyres under inflated. Increase the tyre pressure to the correct
on both sides of level.
the tread.
Tyres loose Tyre punctured. Repair the puncture or change the tyre.
pressure.
Cracks, splits or Impact damage. Change the tyre.

bulges in the Defective tyre. Change the tyre.
tyre sidewall.
Tyre over inflated. Change the tyre.
Tyre under inflated. Change the tyre.
Doc. No. 872272 : Rev 0 425

Tyres
Rapid tyre wear. Excessive speed. Instruct the operator on proper driving.
Change the tyre.
Poor road surface conditions. Recommend road surface maintenance.
Change the tyre.
Tyre component Excessive speed. Instruct the operator on proper driving.

heat separation. Change the tyre
Cracks in the Incorrect tyre pressure. Change the tyre if separation occurs.
tyre tread
grooves.
Wet Disc Brakes
Truck does not Damaged hydraulic system. Repair hydraulic system.

move.
Brakes More than 20psi (1.4 bar) pressure Repair hydraulic system so that pressure
dragging. applied when brakes are released. is less than 20psi (1.4 bar) when brakes
are released and while machine is
operating in any mode
Damaged piston return spring assembly. Repair or replace piston return spring
assembly.
Piston not returning. Check piston seals and seal separator
for swelling or damage. replace as
necessary.
Wrong axle and/or actuating fluid used. Check piston seals and separator for
swelling or damage. Replace as
necessary. Purge and use specified
fluid. See Chapter 1 in the OM.
Noticeable Inadequate actuation fluid supply to Replenish fluid in hydraulic system.

change or brakes. Check for leakage and correct cause.
decrease in Inadequate pressure to apply brakes. Check front and rear apply systems.
stopping Check for leakage in brake system or
performance. brakes and correct cause.
Worn or damaged discs. Inspect and replace discs if necessary.
As disc wear occurs, make sure brake
system can supply adequate fluid to fully
apply brakes.
Overheated seals and/or discs. Inspect and replace discs and seals if
necessary.
Dirty or contaminated cooling fluid Drain and flush cooling fluid from brakes
and entire system and refill.
Brakes do not Damaged hydraulic system. Repair hydraulic system.

fully apply. Leakage of brake actuation fluid. See “Brake Leaks Actuation Fluid”.
426 Doc. No. 872272 : Rev 0

Wet Disc Brakes
Brakes feel Brakes or brake system not properly Bleed brakes and brake system.
spongy/soft. bled.
Internal leak: Worn or damaged piston seal. Replace piston seal.

Fluid bypasses Melted or extruded piston seals. Correct cause of overheating and
seals into brake replace seals.
cavity, fills axle
with fluid and Corrosion, pitting, wear or other Clean, smooth, rework or replace
blows out damage, marks, scratches to piston affected parts.
breather. and/or brake housing bore in area of
seal/sealing seats.
Coolant leaking Face seal damaged, worn or improperly Reinstall and/or face seal.
out of brake installed. Face seals are supplied as matching
housing. pairs and must be replaced accordingly.
Loose drain plug, fill plug, or forced Tighten plug.
cooling plug. Replace plug.
Damaged plug. Disassemble, clean, re-seal and
Deteriorated or inadequate sealant used re-assemble joint.
at joint.
Brakes produce Incorrect axle oil and/or friction material Use only BELL EQUIPMENT specified
noise, chatter, used. or approved materials.
and vibration. Drain axle oil. Replace axle oil. Refer to
Chapter 1 in the OM for
Specifications.
Replace all friction discs. Thoroughly
clean or replace stationary discs.
Overheating due Inadequate coolant flow or heat Contact BELL EQUIPMENT PRODUCT
to excessive exchange. Support.
duty cycle.
Low or no Improper fill or leaks. Check for proper fill level.

coolant. Leaking face seal. Replace or reinstall face seal assembly.
Loose or damaged plugs. Tighten or replace plug.
Deteriorated or inadequate sealant used Disassemble, clean, re-seal and
at joint. reassemble brake housing joint.
Doc. No. 872272 : Rev 0 427

Wet Disc Brakes
Brake drags. More than 1.4 bar (20psi) pressure Repair hydraulic system so pressure is
applies when brakes released. less than 1.4 bar (20psi) when brakes
are released and while machine is
operating in any mode.
Damaged piston return spring assembly. Repair or replace piston return spring
assembly.
Piston not returning. Check piston seals and seal separator.
Wrong cooling and/or actuating fluid Check piston seals and seal separator
used. for swelling or damage. replace as
necessary. Purge system and use
correct fluid.
Tight or damaged splines (Eg. friction Repair or replace parts.
disc-to-hub driver).
Hydraulics
Pump not Hydraulic fluid in hydraulic tank is too Refill the hydraulic tank. Refer to
delivering low. Chapter 1, Specifications -
hydraulic fluid. Recommended Lubricants and
Coolant Additives Chart.
Outlet pipe from the tank to the pump is Check the suction strainer for blockages.
blocked. Clean if necessary.
Hydraulic fluid viscosity and type is Drain and refill the hydraulic system.
incorrect. Refer to Chapter 1, Specifications -
Pump making Pump intake is partially blocked. Clean the hydraulic tank strainer. Check
noise. the hydraulic fluid condition, if necessary
drain and flush the system and refill.
Refer to Chapter 1, Specifications -
Breather is blocked. Replace the breather filter.
Electrical
Gauge not Circuit breaker tripped. Reset circuit breaker.

working Loose or broken connections. Tighten or repair the connections.
properly.
Gauge defective. Change the gauge.
Switch not Circuit breaker tripped. Reset circuit breaker.

working Loose or broken connections Tighten or repair the connections.
properly.
Switch defective Change the switch.
428 Doc. No. 872272 : Rev 0

Electrical
Warning Warning indicator bulb defective. Change the bulb.

indicator not Circuit breaker tripped Reset circuit breaker.
working.
Loose or broken connections Tighten or repair the connections
Alternator Warning indicator bulb defective. Change the bulb.

charge warning
indicator not
illuminated when
master switch is
in the ON
position.
Alternator Alternator drive belt is loose or broken. Adjust drive belt tension or fit new drive
charge warning belt.
indicator Poor battery connections. Clean and check the battery
illuminated when connections.
engine is ON.
Batteries do not Battery cells dry. Check the battery electrolyte and top up.
hold a charge. Short running time with lights on. Remove the batteries and charge or fit
new batteries.
Starter motor Batteries are flat. Charge the batteries.

does not turn or Batteries defective or damaged. Change the batteries.
turns very
slowly. Battery terminals loose or damaged. Tighten or clean the battery terminals.
Ignition switch defective or damaged. Change the start button.
Starter motor Ignition switch defective or damaged. Change the start button.
does not
disengage after
the engine has
started.
Headlights do Circuit breaker tripped. Reset circuit breaker.

not work. Headlight bulb defective. Change the bulb.
Light switch defective. Change the switch.
Loose or broken connections. Tighten or repair the connections.
Only high beam Headlight bulb defective. Change the bulb.

or low beam Loose or broken connection. Tighten or repair the connections.
comes on.
One headlight Headlight bulb defective. Change the bulb.

does not come Loose or broken connection. Tighten or repair the connections.
on (high or low
beam).
Doc. No. 872272 : Rev 0 429

Electrical
High beam Indicator bulb defective. Change the bulb.

indicator light Loose or broken connection. Tighten or repair the connections.
does not
illuminate when
high beam is
selected.
Tail lights do not Tail light defective. Change the light.

come on. Light switch defective. Change the light switch.
Loose or broken connection. Tighten or repair the connections.
Stop lights do Stop light defective. Change the light

not come on. Loose or broken connection. Tighten or repair the connections.
Turn indicator Circuit breaker tripped. Reset the circuit breaker.

and horn does
not work.
Right turn Bulb defective. Change the bulb.

indicator does Loose or broken connection. Tighten or repair the connections.
not work.
Left turn Bulb defective. Change the bulb.

indicator does Loose or broken connection. Tighten or repair the connections.
not work.
Windscreen Circuit breaker tripped. Reset the circuit breaker.

wiper does not Wiper switch defective. Change the switch.
work.
Loose or broken connections. Tighten or repair the connections.
Rear Frame and Cab Trouble Shooting
Excessive cab Loose or missing mounting bolt(s) or Tighten or replace the mounting bolts
movement while rubbers. and/or rubbers.
machine is
operating.
A smear Wiper blade damaged. Replace the wiper blade.

remains on the Oil or grease on the windscreen. Clean the windscreen.
windscreen
when the
windscreen
wiper is in
operation.
Seat is difficult Obstruction in the seat runner. Remove the obstruction.

to adjust. Lack of lubricant. Lubricate the seat runners.
430 Doc. No. 872272 : Rev 0

Rear Frame and Cab Trouble Shooting
Excessive Loose or missing retaining bolts. Tighten or replace the retaining bolts.
movement of the
wing mirrors
while machine is
operating.
Wing mirror Damaged wing mirror arm. Replace wing mirror arm.
difficult to view. Incorrect adjustment. Adjust as necessary.
Wing mirror damaged. Replace the wing mirror.
Doc. No. 872272 : Rev 0 431

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ARTICULATED HAULER

THIS MANUAL IS APPLICABLE TO :

Revision 0: November 2009

IMPORTANT: Due to BELL EQUIPMENT’S policy of

Technical Services: Documentation Unit

2 Doc. No. 872272 : Rev 0

TO THE SERVICE PERSONNEL

Doc. No. 872272 : Rev 0 3

WARNING AND CAUTION SYMBOL

4 Doc. No. 872272 : Rev 0

Abbreviation Meaning Abbreviation Meaning

ºF degrees Fahrenheit psi pounds per square inch

A ampere PTO Power Take-Off

ADT Articulated Dump Truck R Reverse

Ah ampere hours r.p.m. revolutions per minute

CB circuit breaker ROPS Roll Over Protective

ft foot (feet) yd³ cubic yard

ft lb foot pound OBW On Board Weighing

ISO International Standards

km/hr kilometres per hour

kPa kilo pascal

LCD Liquid Crystal Display

LED Light Emitting Diode

m.p.h. miles per hour

MSDS Material Safety Data

Doc. No. 872272 : Rev 0 5

Amendment Record Sheet

6 Doc. No. 872272 : Rev 0

See OM for address list.

Doc. No. 872272 : Rev 0 7

8 Doc. No. 872272 : Rev 0

1. ROPS/FOPS Cab Protection. 7. Articulation locking Bar (on left side of

4. Body service lock. 14. Safety Belt Retractors.

5. Backup Alarm. 15. Mirrors.

6. Independent Parking Brake. 16. Large Windshield Wiper With Washer.

Doc. No. 872272 : Rev 0 9

MATERIAL SAFETY DATA SHEETS (MSDS)

UNAUTHORISED MODIFICATIONS OF THE ROLL OVER PROTECTIVE

LOOSENING OR REMOVAL OF THE ROLL OVER PROTECTIVE

NOISE EMISSION LEVELS

10 Doc. No. 872272 : Rev 0

SAFETY REGULATION Operate Only On Solid Footing

Operate only on solid footing with strength

Mounting And Dismounting The Keep Riders Off the Machine

Always use the handrails and steps provided to

Use extra care when mud, snow, or moisture

Keep a first aid kit and fire extinguishers handy

Avoid Overhead Power Lines

Never move any part of the machine within 3 m

Doc. No. 872272 : Rev 0 11

Keep all fuels and lubricants in properly marked

Store oily rags and other flammable material in a

HD0007CFM Do not weld or flame cut pipes or tubes that have

Use prearranged hand signals to communicate.

Handle Chemical Products And Flammable

Exposure to hazardous chemicals can cause

If uncertain about safe handling or use of these