Otm B25D B30D

B25D & B30D 6 X 6
ARTICULATED DUMP TRUCK
OPERATION AND TEST MANUAL

Document Part Number 872106
LEFT BLANK INTENSIONALLY
TO THE SERVICE PERSONEL
n 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.
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.
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.
n CALIFORNIA PROPOSITION 65 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.
B25D and B30D 6X6
ARTICULATED DUMP TRUCK
OPERATION AND TEST MANUAL
THIS MANUAL IS APPLICABLE TO
B25D 6X6 (E410814)

B30D 6X6 (E409836)
Document Part Number 872106
Issue:0
(Revised:)
Technical Documentation
BELL EQUIPMENT COMPANY
Richards Bay
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 equipment.
B25D & B30D 6X6 OPERATION AND TEST 872106
SAFETY
Specification
This machine complies to the CE Specification.
Safety Features
3 2 14 15 12
1 16 11
5
30D0002CFM
6
7 13 9 10
8
1. ROPS/FOPS Cab Protection. The Roll Over 7. Articulation locking Bar.

Protective Structure has been certified to meet
8. Secondary Steering. Ground driven,
specified test requirements according to SAE
continuously in operation. Secondary steering
J1040 and ISO 3471. The Falling Objects
indicator light will light when activated.
Structure has been certified to meet specified test
requirements according to SAE J/ISO 3449 and 9. Horn.
ISO 3449.
10. Halogen Lights and Turn Signals.
2. Cab with Heater/Defroster. Positive
pressure ventilation system circulates both 11. Engine Fan Guard.
outside and inside air through filters for a clean
12. Bypass Start Protection.
working environment. Built in defroster vents direct
air flow for effective window de-fogging/de-icing. 13. Exhaust Brake and Transmission
Retarder (If Equipped).
3. Bin Service Lock.
14. Safety Belt Retractors.
4. Stop/Back lights. Highly visible lights.
15. Mirrors.
5. Backup Alarm.
16. Large Windshield Wiper With Washer.
6. Independent Parking Brake.
ISSUE 0 I
872106 OPERATION AND TEST B25D & B30D 6X6
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.
Safety Regulation
Every country (State) has its own safety regulations. It is the obligation of the operator to know and follow
these. This also applies to local regulations covering different types of work. Should the recommendations
in this manual deviate from those of your country, your local safety regulations should be followed.
II ISSUE 0
Mounting and Dismounting the 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 or supplies.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of
grease, oil and foreign objects.
ISSUE 0 III
Avoid Work Site Hazards Prepare for Emergencies
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.
Avoid Backing Over Accidents
GD0014CFM
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.
Operate Only On Solid Footing

Operate only on solid footing with strength GD0016CFM
sufficient to support machine. Be alert working
near embankments, excavations and with bin Make sure all persons are clear of machine path
raised. Avoid working on surfaces that could before moving the machine. Where conditions
collapse under machine. permit, raise bin for better visibility to the rear. Use
mirrors to assist in checking all round machine.
Use caution when backing up to berms before
dumping load. Keep windows, mirrors and backup alarm clean
and in good condition.
Keep Riders Off the Machine
Use a signal person when backing if view is
obstructed and/or in close quarters. Keep signal
person in view at all times.
Use prearranged hand signals to communicate.
Handle Chemical Products And Flam-

mable Fluids Safety
Exposure to hazardous chemicals can cause
GD0015CFM
serious injury. Under certain conditions,
Do not allow unauthorised personnel on the lubricants, coolants, paints and adhesives used
machine. with this machine may be hazardous.
IV ISSUE 0
If uncertain about safe handling or use of these

chemical products, contact your authorized dealer
Clean the Machine Regularly
for a Material Safety Data Sheet (MSDS). Wait until the engine has cooled before removing
trash from areas such as the engine, radiator,
batteries, hydraulic lines, fuel tank and operators
cab. Remove any grease, oil or debris build-up.
Keep the machine, especially the walkways and
steps, free of foreign material, such as debris, oil,
tools and other items which are not part of the
machine.
Prevent Battery Explosions and Acid

Burns
GD0019CFM
GD0018CFM The standard battery supplied with the machine is

Handle fuel with care, as it is highly flammable. Do a sealed type that does not need maintenance.
not smoke or go near an open flame or sparks keep sparks and flames away from the batteries.
while refuelling. Always stop the engine before If a non-sealed battery is subsequently installed,
refuelling the machine and fill the fuel tank keep sparks and flames away from the batteries.
outdoors. Use a flashlight to check the battery electrolyte
Keep all fuels and lubricants in properly marked level. Use a voltmeter or hydrometer to check
containers and away from all unauthorised battery charge. Never place a metal object across
persons. Do not smoke in the storage areas. the posts. Always remove the grounded (Negative
-) battery clamp first and replace it last.
Store oily rags and other flammable material in a
protective container, in a safe place. Do not smoke in areas where batteries are being
charged.
Do not weld or flame cut pipes or tubes that have
contained flammable fluids. Clean them Sulphuric acid in battery electrolyte is poisonous
thoroughly with nonflammable solvent before and is strong enough to burn skin, eat holes in
welding or flame cutting them. clothing and cause blindness if splashed into the
eyes.
Starting fluid is highly flammable. Keep all sparks
and flames away when using it. To prevent Avoid the hazard by:
accidental discharge when storing the pressurised • Filling the batteries in a well ventilated area.
can, keep the cap on the can and store it in a cool • Wearing eye protection and rubber gloves.
protected place. Do not burn or puncture a starting • Avoid breathing fumes when electrolyte is
fluid container. added.
• Avoid spilling or dripping electrolyte.
ISSUE 0 V
If you spill acid on yourself: Avoid High Pressure Fluids

• Flush your skin with water.
• Apply baking soda or lime to help neutralise Escaping fluid under pressure can penetrate the
the acid. skin causing serious injury. Relieve the pressure
• Flush your eyes with water for 10 - 15 minutes before disconnecting hydraulic or other lines.
and get medical attention immediately. Tighten all connections before applying pressure.
Keep hands and body away from pinholes and
If acid is swallowed: nozzles which eject fluids under high pressure.
Use a piece of cardboard or paper to search for
• Drink large amounts of water or milk.
leaks.
• Then drink milk of magnesia, beaten eggs, or
vegetable oil. If any fluid is injected into the skin it must be
• Get medical attention immediately. surgically removed within a few hours by a doctor
who is familiar with this type of injury or gangrene
Wear Protective Equipment may result.
Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious
injury.
Stop engine before examining, adjusting or

maintaining any part of the machine with moving
parts.
Keep guards and shields in place. Replace any

guard or shield that has been removed for access
GD0013CFM
as soon as service or repair is complete.
Wear a hard hat, protective glasses and other
protective equipment as required by the job
Beware of Toxic Fumes
conditions. Do not wear loose clothing or jewellery
that can catch on controls or other parts of the
machine.
When you drive connecting pins in or out, guard

against injury from flying pieces of debris by
wearing goggles or protective glasses. Prolonged
exposure to loud noise can cause impairment or
loss of hearing. Wear a suitable hearing protective
device such as earmuffs or earplugs. Wear gloves
when handling wire rope cable.
Use the Seat Belt GD0020CFM
Use a seat belt at all times to minimise the chance Prevent asphyxiation. Engine exhaust fumes can
of injury in an accident. cause sickness or death.
The seat belt must not be altered or modified in Operate only in well ventilated indoor areas. Avoid
any way. Such changes can render the belt hazardous fumes by first removing paint on
ineffective and unsafe. painted surfaces before welding.
The seat belt is designed and intended for the Wear an approved respirator when sanding or
seat’s occupant to be of adult build and for one grinding painted surfaces.
occupant of the seat only.
If a solvent or paint stripper is used, wash surface
with soap and water. Remove solvent or paint
containers before welding and allow at least 15
minutes before welding or heating.
VI ISSUE 0
Dispose of Waste Properly Use extra care when bin is raised. Machine
stability is greatly reduced when bin is raised.
Improper disposal of waste can threaten the Drive slowly, avoid sharp turns and uneven
environment. Fuel, oils, coolants, filters and ground.
batteries used with this machine may be harmful if
Do not over load the machine.
not disposed of properly.
Before operating machine after it has tipped,
Never pour waste onto the ground, down a drain or
carefully inspect all hydraulic and electrical lines.
into any water source.
Air conditioning refrigerants can damage the Operating on Slopes

atmosphere. Government regulations may require
using a certified service centre to recover and
recycle used refrigerants.
If uncertain about the safe disposal of waste,

contact your local environmental centre or your
dealer for more information.
Start Only From Operator’s Seat
GD0023CFM
Avoid side slope travel whenever possible.
Check service brakes frequently when operating

on slopes
The maximum slope will be limited by the ground

conditions.
Welding Repairs
NOTE:Disable electrical power before welding.
Turn off main battery switch or disconnect positive
battery cable. Separate harness connectors to
engine, alternator and vehicle microprocessors.
GD0022CFM
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.
Never attempt to start engine from the ground. Do

not attempt to start engine by shorting across the
starter solenoid terminals.
Lower bin during work interruptions, apply park

brake and be careful not to accidentally actuate
GD0021CFM
controls when co-workers are present.
Avoid welding near fluid lines. Do not let heat go
Operating The Machine beyond work area near fluid lines.
Avoid Tip Over Remove paint properly. Wear eye protection and
protective equipment when welding.
Use safety belt at all times. Do not jump from
machine if it tips. Do not inhale dust or fumes.
ISSUE 0 VII
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.
15 m
(49'3")
Use a safety cage if available
Do not stand over the tyre, use a clip-on chuck and extension hose
500 m
(1 640 ft)
GC0002FM
NOTE:It is recommended that only trained

personnel service and change tyres and rims.
Inspect and Maintain ROPS Drive Metal Pins

A damages roll-over protective structure (ROPS) Always wear protective goggles or safety glasses
should be replaced, not reused. and other safety equipment.
If the ROPS was loosened or removed for any Use soft hammer or a brass bar between hammer
reason, inspect it carefully before operating the and object to prevent chipping.
machine again.
To Maintain the ROPS:

• Replace missing hardware using correct grade
hardware.
• Check hardware torque.
• Check isolation mounts for damage, loose-
ness or wear; Replace if necessary.
• Check ROPS for cracks or physical damaged.
VIII ISSUE 0
B25D & B30D 6X6 872106
ABBREVIATION LIST
The table below lists the abbreviations used in this manual:
Abbreviation Meaning Abbreviation Meaning
ºC degrees Celsius m metre
cubic metre
ºF degrees Fahrenheit m3
A ampere N Neutral
ADT Articulated Dump Truck m.p.h. miles per hour
Ah ampere hours MSDS Material Safety Data Sheet
CB circuit breaker Nm Newton metre
d diagnostic psi pounds per square inch
D drive PTO Power Take-Off
DNS Do Not Shift R Reverse
ECU Electronic Control Unit r.p.m. revolutions per minute
FOPS Falling Objects Protective ROPS Roll Over Protective

Structure Structure
ft foot (feet) SMR Service Meter Reading
ft lb foot pound USGAL United States Gallon
HP Horsepower V Volt
ISO International Standards cubic yard

Organisation yd 3
kg kilogram
km kilometre
km/h kilometres per hour
kPa kilo pascal
kW kilowatt
lb pound
LCD Liquid Crystal Display
LED Light Emitting Diode
ISSUE 0 A
872106 B25D & B30D 6X6
B ISSUE 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
ISSUE 0 a
TECHNICAL DOCUMENTATION BULLETIN RECORD

INSERTED BY
BULLETIN NO. SUBJECT
NAME SIGNATURE DATE
b ISSUE 0
TABLE OF CONTENTS
SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
Material Safety Data Sheets (MSDS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects Pro-
tective Structure (FOPS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Noise Emission Levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
General Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Safety Regulation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Mounting and Dismounting the Machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - III
Avoid Work Site Hazards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -IV
Keep Riders Off the Machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -IV
Prepare for Emergencies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -IV
Avoid Backing Over Accidents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -IV
Handle Chemical Products And Flammable Fluids Safety - - - - - - - - - - - - - - - - - - - - - - - - - -IV
Clean the Machine Regularly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - V
Prevent Battery Explosions and Acid Burns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - V
Wear Protective Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VI
Use the Seat Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VI
Avoid High Pressure Fluids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VI
Stay Clear Of Moving Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VI
Beware of Toxic Fumes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VI
Dispose of Waste Properly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII
Start Only From Operator’s Seat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII
Operating The Machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII
Welding Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII
Tyre Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
Inspect and Maintain ROPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
Drive Metal Pins - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
USER’S INFORMATINON FEEDBACK FORM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE- - - - - - - - - - - - - - - - - - - 1

OPERATIONALCHECK-OUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
OPERATIONAL CHECKS - KEY SWITCH ON, ENGINE OFF - - - - - - - - - - - - - - - - - - - - - - - - - - 1
OPERATIONAL CHECKS - ENGINE ON - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
CHAPTER 2. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
SECTION 1. THEORY OF OPERATION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Electronic Unit Injector Fuel System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Cold Start Option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - 13
a
TABLE OF CONTENTS
SECTION 3. ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
DISPLAY MENU TACHOMETER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
SLOW AND FAST IDLE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
VALVE CLEARANCE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
EXHAUST BRAKE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
SECTION 4. TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
CYLINDER COMPRESSION TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
FUEL PUMP PRESSURE TEST DOWNSTREAM OF FUEL FILTER - - - - - - - - - - - - - - - - - - - - - 20
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
Service Equipment And Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
Special Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
Special Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
OIL PUMP PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Service Equipment And Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
CHAPTER 3. ELECTRICAL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
SECTION 1. SYSTEM INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

Electrical Schematic Symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
HARNESSES AND COMPONENT LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
EXPLANATION OF WIRE MARKINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
Wire Colour - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
Multiple Wire Colours - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
Circuit Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
SECTION 2. SYSTEMS AND SUB-SYSTEM THEORY OF OPERATION AND DIAGNOS-

TICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
STARTING AND CHARGING CIRCUIT THEORY OF OPERATION - - - - - - - - - - - - - - - - - - - - - 69
Starting Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Charging Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Flame Start Theory Of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
Electronic Unit Injector Controller Circuit Theory Of Operation - - - - - - - - - - - - - - - - - - - - - - 70
Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
Pressure Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
Engine Control Unit Circuit Theory Of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
Transmission Control Unit And Retarder Circuit Theory Of Operation - - - - - - - - - - - - - - - - - 73
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TABLE OF CONTENTS
Chassis Control Unit Circuit Theory Of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

Bin Control And Range Hold Circuit Theory Of Operation - - - - - - - - - - - - - - - - - - - - - - - - - 79
Range Hold Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
Park Brake And Exhaust Brake Circuit Theory Of Operation - - - - - - - - - - - - - - - - - - - - - - - 81
Turn Signal and 4- Way Flasher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
Unloader Valve Heater Circuit Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
SECTION 3. REFERENCES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
SERVICE CODE DIAGNOSTICS - AFTER MACHINE REPAIR - - - - - - - - - - - - - - - - - - - - - - - - 93
Service Code Diagnostics - How Codes Are Displayed On Menu Display Unit - - - - - - - - - - 93
Service Code Diagnostics -Engine Control Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Key Switch Test 123
Relay Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Diode Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
Hydraulic Pressure Switches Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127
Hydraulic Temperature Sensors Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
Bin Position Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 129
Retarder Voltage Regulator Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131
Transmission Solenoids, Speed Sensors, Sump Temperature Sensor, and Retarder Resistor
Tests - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132
Retarder Proportional Solenoid Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133
Retarder Temperature Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133
Transmission Shift Control Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 133
Remove and Install Engine Control Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135
Remove and Install Cold Start Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
Remove and Install Chassis Control Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
Disconnect harness connectors (4 and 5). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
Remove and Install Transmission Control Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137
Remove and Install Battery Balancer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137
Remove and Install Menu Display Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 138
Replace Menu Display Unit Bulbs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 138
Remove, Install, and Calibrate Accelerator Pedal Position Sensor - - - - - - - - - - - - - - - - - - 140
Replace DEUTSCH™ Rectangular or Triangular Connectors - - - - - - - - - - - - - - - - - - - - - 140
Replace DEUTSCH™ Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141
Install DEUTSCH™ Contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
Replace WEATHER PACK™ Connector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
Install WEATHER PACK™ Contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
Replace (Pull Type) Metri-Pack™ Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 144
Replace (Push Type) Metri-Pack™ Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145
Remove Connector Body from Blade Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145
CHAPTER 4. POWER TRAIN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
SECTION 1. THEORY OF OPERATION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147

TRANSMISSION EXTERNAL COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
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TABLE OF CONTENTS
TRANSMISSION CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148

Retarder Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 156
SECTION 2. DIAGNOSTIC INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159

DIAGNOSTIC PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
Know The System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
Ask The Operator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
Inspect The Machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
Perform Operational Check-out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
Perform Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
Trace And Cause - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - 160
SECTION 3. TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171

TRANSMISSION WARM-UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
Transmission Pressure Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
Torque Converter Stall Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 173
Torque Converter Stator Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 174
Transmission Oil-to-Air Cooler Restriction Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 174
Transmission Oil-to-Water Cooler Restriction Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175
Front Suspension Strut Leakage Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175
Park brake Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175
Park Brake Pad Thickness Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
Park Brake Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
CHAPTER 5. PNEUMATIC SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179

PNEUMATIC SYSTEM OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179
All pneumatic functions are supplied pressurized air by the engine driven compressor. - - - - - - - 179
PNEUMATIC SYSTEM SCHEMATIC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 180
Air Pressure Supply Circuit Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 182
Air Dryer and Unloader Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 183
Pneumatic Manifold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 184
Pneumatic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 190
CHAPTER 5. PNEUMATIC SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 193

DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 194
SECTION 3. TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 199

PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT - - - - - - - - - - - - - - - - - - 199
Pneumatic System Main Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 199
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 199
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TABLE OF CONTENTS
Service Equipment and Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 199

PARK BRAKE PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
Park Brake Pressure Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
Service Equipment and Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
CHAPTER 6. HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201

ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION - - - - - - - - - - - - - - - - - 201

Know the system. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
Ask the operator. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
Inspect the machine. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
Perform Operational Check-out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
Perform troubleshooting. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
Trace a cause. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238
Hydraulic System Malfunctions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238
Service Brake System Malfuntion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 242
Steering System Malfunctions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 243
HYDRAULIC SYSTEM COMPONENT LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246
SECTION 3. TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252

JT05800 DIGITAL THERMOMETER INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252
JT02156A DIGITAL PRESSURE/TEMPERATURE ANALYZER INSTALLATION - - - - - - - - - - - 252
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY - - - - - - - - - - 252
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252
Service Equipment And Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252
Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 253
HYDRAULIC SYSTEM WARM-UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 253
CYCLE TIME TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 254
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 254
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT
255
Specifications Residual Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 255
Compensator Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 255
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 255
Residual Valve Pressure Setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 255
Compensator Valve Pressure Setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 256
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TABLE OF CONTENTS
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST - - - - - - - - - - - - - - 256
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 256
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 256
Service Equipment And Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 256
PRIORITY VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 257
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 257
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 257
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT - - - - - - - - - - - - 257
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 257
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 257
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT - - - - - - - - - - - - - - - - - 258
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 258
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 258
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST - - - - - - - - - - - - - - - 259
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 259
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 259
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE -
260
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 260
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 260
SERVICE BRAKE VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 260
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 260
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 260
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT - - - - - - - - - - - - - - - - - - - 261
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 261
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 261
STEERING CYLINDER LEAKAGE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 262
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 262
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUST-
MENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 262
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 262
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 262
Residual Valve Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 263
Compensator Valve Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 263
BIN LOWER CIRCUIT RELIEF VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 264
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 264
f
TABLE OF CONTENTS
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 264

CHAPTER 7. HEATING AND AIR CONDITIONING - - - - - - - - - - - - - - - - - - - - - - 265

AIR CONDITIONING SYSTEM CYCLE OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - 265
HEATER CORE OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 266

DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - 267
DIAGNOSE HEATER SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 269
HEATING/AIR CONDITIONING COMPONENT LOCATION - - - - - - - - - - - - - - - - - - - - - - - - 270
SECTION 3. TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273

AIR CONDITIONING OPERATIONAL CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273
Visual Inspection of Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273
R134A AIR CONDITIONING SYSTEM TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 274
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 274
OPERATING PRESSURE DIAGNOSTIC CHART - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 275
A/C FREEZE CONTROL SWITCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
A/C COMPRESSOR CLUTCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
A/C HIGH/LOW PRESSURE SWITCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
A/C EXPANSION VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 278
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 278
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 278
EXPANSION VALVE BENCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 279
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 279
Essential Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 279
REFRIGERANT LEAK TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 280
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 280
g
TABLE OF CONTENTS
h
USER’S INFORMATINON FEEDBACK FORM

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or omissions, then we would like to know.
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Operator Maintenance Manual.
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ISSUE 0 i
ii ISSUE 0
B25D & B30D 6X6 CHAPTER 1 872106
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE

OPERATIONALCHECK-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.
Compete 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
Checks Questions/Tasks Results

Gauges and Turn battery disconnect switch ON. Turn key switch to ON YES: Go to next
Indicator Lights position. check.
Do all indicator lights come ON or flash? NO: Check circuit

breakers and
Do all gauges and speedometer move to centre position? fuses. Reset circuit
Do all sections of monitor liquid crystal display’s appear? breakers and/or
replace fuses as
Do all sections of transmission control display and mode necessary.
button indicator light come ON?
Check indicator
Does audible alarm come ON? light bulbs. Replace
if necessary.
NOTE:1. Cold start indicator light will remain ON for a
maximum of 20 seconds in low ambient Go to “Menu
temperature conditions. Display Unit
2. Air pressure indicator may remain ON, Circuit Theory Of
depending on system air pressure. Operation” on
page 83.
Do all gauges and displays return to normal operation mode
and audible alarm go OFF after 3 seconds?
Do all indicator lights, except for secondary steering (marked

emergency steering), battery charge and park brake go OFF?
ISSUE 0 1
872106 CHAPTER 1 B25D & B30D 6X6

Transmission YES: Go to next
Shift Control check.
7 NO: Replace
transmission shift
control.
1
2 6
3 4 5
With engine OFF and key switch OFF, move transmission shift control (7)
through all positions (1 - 6).
Does lever move smoothly to all positions?
Does lever detent securely in all positions?
Fuel cap YES: Go to next

check.
NO: Replace parts

5
as needed or
1 replace fuel tank
cap.
2
4
Remove fuel tank cap.
Does centre of vacuum valve (1) move freely?
Is screen (2) clean and not plugged?
Is rubber seal (3) not damaged?
Does ball in pressure valve (4) moves freely?
Is vent hole (5) not plugged?
Are all parts in serviceable condition?
2 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 1 872106
OPERATIONAL CHECKS - ENGINE ON

Gauges and Start engine. YES: Go to next
Indicator Lights check.
NOTE:1. Low air pressure alarm will be ON until air
pressure reaches normal operating pressure. NO: Go to “Menu
2. Transmission oil temperature gauge will not Display Unit
begin to indicate temperature until transmission Circuit Theory Of
oil is close to operating temperature. Operation” on
page 83.
Do all the indicator lights, except park brake indicator light, go
OFF after the engine starts?
Does the menu display unit show engine speed?
Check engine oil pressure gauge.
Does needle of gauge indicate pressure is increasing to

green (normal)?
Check air pressure gauge immediately after the engine is

started.
Does needle of gauge indicate pressure is increasing to

green (normal)?
Service Brake Start engine and apply brakes repeatedly until main hydraulic YES: Go to next
Accumulator. pump strokes to charge accumulators. When accumulators check.
are fully charged, pump will destroke. Turn engine “OFF”.
NO: Go to “FRONT
Turn key switch “ON” again and wait for indicator lights to go AND REAR
“OFF” BRAKE
ACCUMULATORS
Apply the service brakes, counting the number of applications PRESSURE TEST
until the accumulator low pressure light illuminates. AND CHARGE
Does the light illuminates after nine brake applications PROCEDURE” on
(Minimum)? page 260.
ISSUE 0 3
872106 CHAPTER 1 B25D & B30D 6X6

Service Brake. NOTE: Perform this check in an open area where YES: Go to next
machine can travel at full speed. check.
Drive machine slowly. NO: Go to

“Service Brake
Apply brake pedal to stop machine. System
Malfuntion” on
Release the brake pedal. page 242.
Does brake pedal push easily without binding?
Does brake pedal return to the released position so brakes

are not dragging?
Do brakes stop machine in a reasonable distance without

pulling to one side or making noise?
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 noise?
n
Park Brake YES: Continue
CAUTION check.
Machine will stop abruptly during this check. Fasten
NO: Go to
seat belt. Perform check in open area.
“DIAGNOSE
POWER TRAIN
Start engine. SYSTEM
MALFUNTIONS”
Move park brake lever forward on page 160.
Drive machine at slow idle in 1 st gear at ~ 5 km/h (3 m.p.h.).

Pull park brake lever rearward until it locks into position.
Does park brake indicator light illuminates?
Does park engages and machine stops
With engine “ON”, transmission in “N” (Neutral) and park YES: Go to next
brake “ON” move park brake forward. check.
Shift transmission to “D” (Drive). NO: Go to

“DIAGNOSE
Slowly increase engine speed. POWER TRAIN
Does machine move when engine speed is just above slow SYSTEM
idle? MALFUNTIONS”
on page 160.
Return engine to slow idle.
Shift transmission to “N” (Neutral).
4 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 1 872106

Steering Park machine in an open area, on a hard level surface. YES: Continue
check.
Turn inter-axle switch to the “OFF” position.
NO: Go to
Release park brake. “Steering System
Release service brakes. Malfunctions” on
page 243.
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: Go to next

check.
Turn steering wheel fully left then right.
NO: Go to
Does machine turn smoothly in both directions. “Steering System
Malfunctions” on
page 243.
ISSUE 0 5
872106 CHAPTER 1 B25D & B30D 6X6
n
Bin YES: Continue
CAUTION check.
Avoid possible serious injury from machine movement.
NO: Go to
Clear area of all bystanders before performing test.
“DIAGNOSE
Area must have enough overhead clearance to raise bin
HYDRAULIC
to full height of 7226 mm (23 ft. 8.5 in.). Do not perform
SYSTEM
this test within 4 m (13ft.) of high voltage power lines.
MALFUNCTIONS”
on page 238.
Perform this check in an open area, clear of bystanders.
Position the machine frames straight.
Operate the engine at 1500 r.p.m.
Pull bin control lever rearward to raise bin.
When bin is almost complete up, reduce engine speed to

slow idle.
Does bin raise to full height smoothly?
Release bin control lever. YES: Continue

check.
Does bin control lever return to neutral position?
NO: Go to Bin
Control Valve
Operation. (See
CHAPTER 14,
SECTION 1 in
Repair Manual).
Push bin control lever to full forward detent bin float position YES: Go to next
and release lever. check.
Does the control lever stay in the float position until the last NO: Go to “Bin
5% (3.5°) of bin travel, at which time the lever returns to Control And
neutral position? Range Hold
Circuit Theory Of
Dos bin lower to full down position smoothly? Operation” on
page 79.
6 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 1 872106

Viscous Fan NOTE:Engine must be cool or fan may not turn freely YES: Do to next
Drive by hand. check.
Allow engine to cool. NO: Replace

viscous fan drive.
Turn fan by hand, feel for rough bearing or fan not turning
freely.
Does fan turn freely and smoothly?
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 warms?
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: Repair engine.
Go to “SECTION 2.
Observe exhaust colour. DIAGNOSE
No smoke is normal. ENGINE
MALFUNCTIONS”
Blue smoke indicates faulty or stuck piston rings. on page 13.
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 colour?
Engine Speed Start engine and warm to normal operating temperature. YES: Check
complete.
Run engine at slow idle; Record r.p.m.
NO: Go to “SLOW
Is engine speed 600 ± 20 r.p.m? AND FAST IDLE
Increase engine speed to fast idle. Record r.p.m. ADJUSTMENT”
on page 17.
Is engine speed 2750 ± 20 r.p.m.
ISSUE 0 7
872106 CHAPTER 1 B25D & B30D 6X6
LEFT BLANK INTENTIONALLY
8 ISSUE 0
B25D & B30D 6X6 CHAPTER 2 872106
CHAPTER 2. ENGINE
SECTION 1. THEORY OF OPERATION
ENGINE
8 3 10 16 2 6 4 7
11
14
12
15
1. Final Fuel Filter (Not Shown). 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 (Not Shown). 13. Alternator (Not Shown).
6. Fuel Delivery Nozzle. 14. Fuel Pump.
7. Electronic Unit Injector (EUI). 15. Flywheel.
8. Intake Manifold. 16. Dip Stick.
The engine is a 6 cylinder inline liquid cooled cast iron block and cast iron cylinderhead engine. It has
overhead valves, 3 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.
ISSUE 0 9
872106 CHAPTER 2 B25D & B30D 6X6
Electronic Unit Injector Fuel System Fuel Delivery

Suction Stage
1 2
4 3
5
12
The EUI system is designed to precisely control:

11 6
• The start of injection,
• 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, 40D3001CFM
• Control System.
1. Fuel Delivery Nozzle.
The electronic unit injector fuel system has these 2. Connector Pipe.
notable features: 3. EUI (Electronic Unit Injector).
4. Valve.
• Precision control of timing and fuel delivery, 5. Solenoid.
• Field proven reliability, 6. Supply Gallery in Crankcase.
• Electronic control of each cylinder, 7. High Pressure Chamber.
• One unit injector per cylinder, 8. Pump Plunger.
• High injection pressures, 9. Engine Camshaft.
• Low emissions, 10. Pressure Relief Chamber.
• Compact design, 11. Return Flow Gallery in Crankcase.
• Eliminates injection pump, 12. Bleed-Off Chamber.
• No injection timing adjustment required. 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. There are
passages in the block that route fuel to and from
the EUI’s. The fuel delivery nozzles (1) are located
in the cylinder head and are positioned directly
above the pistons. A connector pipe (2) is used to
direct fuel from the EUI’s to the nozzles. Internal
passages in the cylinder heads allow excess fuel
from the nozzles to be bled off. A solenoid (5)
controls the fuel metering valve (4). For complete
electrical theory of the EUI See “Electronic Unit
Injector Controller Circuit Theory Of
Operation” on page 70.
10 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
During the suction stage, the pump plunger (8) Delivery Stage
moves down. As a result of the constant fuel
excess pressure of approximately 600kPa (6 bar) 1 2
(87 psi) in the fuel low pressure circuit, the high 4 3
5
pressure chamber (7) of the unit pump is fitted with
fuel through the supply gallery (6).
Pre-Delivery Stage
1 2
4 3
5 12
11 6
7
10
8
12 13 RETURN FUEL
14 LOW PRESSURE
15 HIGH PRESSURE
11 6 9 40D3003CFM
7 1. Fuel Delivery Nozzle.
10 2. Connector Pipe.
8 3. EUI (Electronic Unit Injector).
4. Valve.
13 5. Solenoid.
6. Supply Gallery in Crankcase.
14 7. High Pressure Chamber.
9
40D3002CFM 8. Pump Plunger.
1. Fuel Delivery Nozzle. 9. Engine Camshaft.
2. Connector Pipe. 10. Pressure Relief Chamber.
3. EUI (Electronic Unit Injector). 11. Return Flow Gallery in Crankcase.
4. Valve. 12. Bleed-Off Chamber.
5. Solenoid. 13. Return Fuel.
6. Supply Gallery in Crankcase. 14. Low Pressure.
7. High Pressure Chamber. 15. High Pressure.
8. Pump Plunger.
9. Engine Camshaft. As soon as the valve (4) is closed while the pump
10. Pressure Relief Chamber. plunger (8) is moving towards its top dead centre,
11. Return Flow Gallery in Crankcase. the unit pump is in the delivery stroke. Fuel
12. Bleed-Off Chamber. injection into the combustion chamber takes place
13. Return Fuel. in the delivery stage. During this stage the fuel
14. Low Pressure. pressure in the high pressure chamber (7) rises to
a pressure approximately 160 000 kPa (1600 bar)
During the pre-delivery stage, the pump plunger (23 206 psi).
(8) moves up. As the valve (4) is not yet closed, the
fuel is first forced into the pressure relief chamber
(10), then into the return gallery(11).
ISSUE 0 11
872106 CHAPTER 2 B25D & B30D 6X6
Residual Stage Cold Start Option

1 2
4 3
5
12
11 6
7 2
10
8
13 RETURN FUEL
14 LOW PRESSURE 1. Glow Plug.

9 2. Cold Start Jet.
40D3004CFM
The cold start system operates only when the
1. Fuel Delivery Nozzle. engine coolant temperature is below 15° C (59° F).
2. Connector Pipe.
3. EUI (Electronic Unit Injector). When the key switch is tuned to the “ON” the
4. Valve. position, the glow plug (1) begins to heat up and
5. Solenoid. the indicator light on the dash will light up. Light will
6. Supply Gallery in Crankcase. stay on and the glow plug will continue to heat up
7. High Pressure Chamber. for approximately twenty seconds.
8. Pump Plunger.
9. Engine Camshaft. When the key switch is turned to the START
10. Pressure Relief Chamber. position, the solenoid (2) is energized, allowing
11. Return Flow Gallery in Crankcase. fuel to flow to the cold start jet (3). The fuel from
12. Bleed-Off Chamber. the jet is sprayed on the glow plug causing the fuel
13. Return 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. The remaining fuel delivery by
the pump plunger (8) up to the apex of the
camshaft (9), is again forced into the pressure
relief chamber (10) and the return flow gallery (11).
The pressure relief chamber serves as an

expansion chamber for the pressure peaks of the
unit pump in the residual stage. This prevents the
pressure ratio of the adjacent unit pumps being
affected through the return flow gallery.
12 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
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” on
page 222 in this manual.
Hard starting when cold Defective cold start aid. See “Cold Start Option” on
page 12.
Incorrect valve clearance. Adjust valve clearance (See

“VALVE CLEARANCE
ADJUSTMENT” on page 17.)
Compression too low. Test compression (See

“CYLINDER COMPRESSION
TEST” on page 19.)
Engine turns but does not start Insufficient fuel in fuel tank. Fill tank and bleed system.

Low fuel pump pressure. Test fuel pump pressure (See

“FUEL PUMP PRESSURE
TEST DOWNSTREAM OF
FUEL FILTER” on page 20.)
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.

TEST DOWNSTREAM OF
Electronic Unit Injector. Check fault codes.
ISSUE 0 13
872106 CHAPTER 2 B25D & B30D 6X6
Engine misfires Incorrect valve clearance. Adjust valve clearance (See

“VALVE CLEARANCE
ADJUSTMENT” on page 17.)


TEST DOWNSTREAM OF
Low engine oil pressure Failed pressure gauge. Test fuel pump pressure (See
TEST DOWNSTREAM OF
Incorrect grade of oil. Change oil.
Low pump output. Test oil pump pressure
Pressure relief valve stuck. Install new pressure relief valve

(See Remove and Install Oil
Pressure relief valve in
CHAPTER 4,SECTION 5 of
Repair Manual.)
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 (See

scored. “CYLINDER COMPRESSION
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

(See Remove and Install Fuel
Delivery Nozzles in CHAPTER
4, SECTION 8 in repair
manual).
14 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
White smoke from exhaust. Engine running too cold. Check that thermostats are not
stuck open.
Worn fuel delivery nozzles. Replace fuel delivery nozzles

(See Remove and Install Fuel
Delivery Nozzles in CHAPTER
4, SECTION 8 in repair
manual).
Pistons, rings or liners scored. Test compression (See

Coolant entering cylinder bores. Check cylinder head gasket.

Replace cylinder head gasket.
(See Cylinder Head in
CHAPTER 4, SECTION 6 in
repair manual).
Cold start solenoid defective. Test solenoid. (See “Flame

Start Theory Of Operation” on
page 70).
ISSUE 0 15
872106 CHAPTER 2 B25D & B30D 6X6
16 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
CHAPTER 2. ENGINE
SECTION 3. ADJUSTMENTS
DISPLAY MENU TACHOMETER
bell b25D 1
0N
7 1 2 n/min
2
2 3 1 4
2 7. 7 volts
GD1032CFM
1
The tachometer on the Menu Display Unit is
accurate enough for test work. (See Operators
Manual CHAPTER 2 for more information and
CHAPTER 8 for detail operating the Menu
Display Unit).
SLOW AND FAST IDLE ADJUSTMENT

Remove rocker arm cover.
There is no slow or fast idle adjustment. If slow or
Install cranking device DC280088.
fast idle is not within specification, check for an
engine mechanical problem or an electrical failure. There is 36 equi-spaced holes (1) machined in the
flywheel. A 37th hole (2) is machined in the centre
Slow Idle Speed RPM’s- - - - - - - - - - - - - - - - -600 ± 20
of two equi-spaced holes. This is the TDC timing
Fast Idle Speed RPM’s - - - - - - - - - - - - - - - -2750 ± 20 mark. Turn engine in the direction of rotation until
If no mechanical failure is found and the controller TDC timing mark (2) on flywheel lines up in centre
is suspected, See “Engine Control Unit Circuit of the window in timing case.
Theory Of Operation” on page 72 and
NOTE:All valves can be adjusted in two
“Electronic Unit Injector Controller Circuit
crankshaft positions.
Theory Of Operation” on page 70.
VALVE CLEARANCE ADJUSTMENT Rocker arms and push rods for number one
cylinder should be loose. If not, rotate engine 360°.
Engine must be at TDC on the compression stroke
n CAUTION for number one cylinder.
To prevent accidental starting of the engine
NOTE:When adjusting valve clearance, the
while performing valve adjustments, always
bolt on the valve bridge should on no
turn battery disconnect switch to “OFF”
account be loosened.
NOTE:Check and adjust valve clearance

only when engine is COLD.
ISSUE 0 17
872106 CHAPTER 2 B25D & B30D 6X6
Measure the valve clearance between the rocker EXHAUST BRAKE ADJUSTMENT
arm and the valve bridge with a feeler gauge.
1 2 1
1
3
2
1
4
2
2
5
With engine off, check the clearance between the
control arm (1) and the stop (2). In the brake valve
6
“OFF” position, the control arm should be resting
FLYWHEEL on the stop.
I E
30D3005FM
Disconnect the air line (3) from the cylinder.
With number one cylinder on TDC, Check the Connect a regulated air supply line to the cylinder.
valve clearance on cylinder one - intake and Regulate air pressure so pressure is
exhaust, cylinder two - intake, cylinder three - approximately 740 - 810 kPa (7.4 - 8.1 bar) (107 -
exhaust, cylinder four - intake and cylinder five - 117 psi).
exhaust.
Crank engine until cylinder six is on TDC (cylinder 4

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

cylinder three - intake, cylinder four - exhaust,
cylinder five - intake and cylinder six - intake and 3
exhaust.
Intake Valve Clearance - - - - - - - - -0.40 mm (0.016in.) 2

Exhaust Valve Clearance - - - - - - - -0.60 mm (0.024in.) 1
Locknut tightening torque - - - - - - - - - - 50Nm (37 lb-ft) Check control arm (1) to stop (2) clearance. The
To adjust clearance: Loosen locknut (2) and turn control arm must not rest on the stop. There must
adjusting screw (1) in or out depending on gap to be slight clearance between the control arm and
big or small. stop to ensure that exhaust brake is fully closed.
Tighten locknut to specification while holding If adjustment is needed, loosen locknut (3),
adjusting screw in position. remove clip (4) and disconnect cylinder from
control arm. Turn rod end (5) for adjustment.
Adjust valves in same order used for checking.
Check clearance again after tightening locknut.
18 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
CHAPTER 2. ENGINE
SECTION 4. TESTS
CYLINDER COMPRESSION TEST

NOTE: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.
Remove fuel delivery nozzle from cylinder being tested. See CHAPTER 4, SECTION 8 of repair Manual
“Remove and Install Fuel Delivery Nozzle”
Install JDG1599 compression tester adapter (1) into cylinder head.
Install holddown clamp (2) using an M10 x 1.5 x 70 mm long cap screw (3).
Install compression tester to adapter.
n CAUTION
Engine must not be started with fuel line from EUI disconnected. Remove the F16 ECU/EUI Power
Relay fuse to prevent engine from starting.
Remove the F16 ECU/EUI Power Relay Fuse.
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).
ISSUE 0 19
872106 CHAPTER 2 B25D & B30D 6X6
Parker No. 0502-12-12: 1 1/16 - 12M x 3/4 - 14NPT F

FUEL PUMP PRESSURE TEST Adapter.
DOWNSTREAM OF FUEL FILTER Parker No. 3/4 x 1/2 PTR: 3/4 - 14 NPT M x 1/2 - 14
NPT F Pipe Thread Reducer.
Specification Parker No. 1/2 x 3/8 PTR: 1/2 - 14 NPT M x 3/8 - 18
NPT F Pipe Thread Reducer.
Pressure At Slow Idle- - - - >430 kPa (4.3 bar) (62 psi).
Parker No. 30182-6-6: 3/8 - 18 NPT M x 3/8 Barb
Pressure At Fast Idle (2500r.p.m.)- - - - - -400 - 650kPa Fitting.
- - - - - - - - - - - - - - - - - - - - - (4 - 6.5 bar) (58 - 94 psi).
Service Equipment And Tools
Essential Tools
JT07148 Digital Hydraulic Tester.
Parker No. 34982-16-6: Banjo Union.
JT07156 0.5 to 15 GPM Lt. Flow Meter.
6
1
2
30D3006CFM
NOTE:904 engine shown.

Install ring piece (5), pressure gauge (6) and
Remove cover (1). measuring hose (7) on adapter piece (4).
Unplug wiring harness connecter (2) from Connect wiring harness connecter plug to
temperature sensor (3). temperature sensor and attach on engine.
Remove temperature sensor (3). Start engine and compare to specification.
Install adapter piece (4) with seal ring on If out of specification, repair.
crankcase.
20 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
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 - - - - - - -< 0.3 l/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 - 1.7 l/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
1
4
4 2
3
5
7
9
8
13 9 3
12
11 6
14 10
NOTE:904 engine shown.

Install transparent fuel line (9) on ring piece (5)
Remove cover (1). and guide into a clean container (8).
Disconnect fuel return line (4) on bypass valve (6). Disconnect fuel return line (14) on fuel filter
Steady bypass valve (6) when loosening the fuel housing (12), connection “RL” and install
return line (3). transparent fuel line (13).
Seal fuel return line (3) with banjo bolt (2) and lock The support (11) with opening clamp (arrow) must
nut (7). press the non-return valve into the connection.
Detach ring piece (5) from bypass valve (6). Guide fuel return line (13) into a clean container
Steady bypass valve (6) when tightening bolts. (10).
Start engine and compare to specification.
ISSUE 0 21
872106 CHAPTER 2 B25D & B30D 6X6
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
1
2
2
5
2
7
4
4
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.
22 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 2 872106
FUEL SYSTEM LOW PRESSURE FUEL CIRCUIT LEAK TEST
Specification
Test pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1000 kPa (10 bar) (145 psi)
Test time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 Minutes
Pressure drop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -<250 kPa (0.25 bar) (36 psi)
Special Tools
Pressure gauge 1500kPA (15 bar) (218 psi).
2
13
14
5
12
6
8 6
10
4
9
11
Remove cover (1). Detach fuel return line (9) on fuel filter housing
(12), connection “RL” and seal with cap (8).
Remove fuel temperature sensor harness (2) and
fuel temperature sensor (3). Detach fuel supply line (14) on fuel pre-filter
housing, connection “VL” and install connection
Install adapter piece (4) with seal ring on line (10) with shut-off cock (11).
crankcase.
Install ring piece (5), measuring hose (6) and

pressure gauge (13) on adapter piece (4).
ISSUE 0 23
872106 CHAPTER 2 B25D & B30D 6X6
OIL PUMP PRESSURE TEST

2
Specification
Engine Oil Pressure at Slow Idle - - - - -50 kPa (0.5 bar)
(7.3psi).
Engine Oil Pressure at Fast Idle - - - -250 kPa (2.5 bar)
(36.3psi).
Essential Tools
1
Parker No. 8M16F80MX: M 16 x 1.5 M x 3/4 - 16 M 37°
Adapter.
JT03132: 3/4 - 16 M 37° x 3/4 - 16 F 37° Sw 90° Elbow.
JT03003: 7/16 - 20 M 37° x 3/4 - 16 F 37° Reducer.
Service Equipment And Tools Install adapter (1) and connect gauges (2) to
fittings.
413 kPa (4.1 bar) (60psi) Gauge.
NOTE:To achieve an accurate oil pressure
reading, warm engine to 105° C (220°
F).
Run engine at slow idle. Compare reading to

specification.
Run engine at fast idle. Compare reading to

1 specification.
NOTE: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).
24 ISSUE 0
B25D & B30D 6X6 CHAPTER 3 872106
CHAPTER 3. ELECTRICAL SYSTEM

SECTION 1. SYSTEM INFORMATION
Electrical Schematic Symbols
Kl50
K l30
2
1 DFM L S 15 W Circuit
0
AC C
IGN
Breaker
ST
0
M B+ A B- 1
GND
2
B AT
Isolator
Switch Starter Alternator
12 V Cigarette H
Lighter / Accessory Ignition Switch
8
Fuse Socket
5 Horn
Battery 6 2
2
3
86 30
4 Radio / Cassette Player
C o ntin u e 6
P
3
85 87 1
Diode
2 1
Temperature Pressure
1
Ignition Solenoid
Battery Balancer Sender Sender
Head Light
P
Switch
2 Pressure
1 2 Switch 87a
1 87
3 30
Engine Speed Sensor 85 86
2 1
Pressure
“-"
Switch Latch
Relay
Switch
“+"
CW
12 V Two Way Radio 1 2

Speaker
Light
Compressor Clutch
Solenoid
Pot
Solenoid
2 1 2 1 B A
Monitor 0
H Sol
1
V7 V6
Headlight Diode Light 1
Retarder Accum. Retarder Temp Retarder
Resistor Sensor Solenoid 5
Diode Bank
0 (OFF ) Switch
1 (L) 3
C T h e rm a l 4
2 (M) A B C
P ro te c tio n
3 (H) B
M
1 2
Motor Speed
Switch Position Sensor Switch M
Demister
Ig n ition
2 1
E a r th
Pa rk
+
(6)
M M 6
2 4 1 3
(4 )
4
PWM
Wiper motor M IR R O R S ERVO

3
(3 )
_
Fan / Blower Pump & Motor + 5

M
(5)
2
PW M
(2)
1
DIP/B RIGHTS
IN DICATO RS
(1)
_
2 1 0 J L R
W ASH ER
M IR R O R S ERVO
W IPER S
HO RN
PWM Accelerator
DIPS BR IGH TS Pedal
Steering Column Switch
Symbols Elec
ISSUE 0 25
872106 CHAPTER 3 B25D & B30D 6X6
HARNESSES AND COMPONENT LOCATION
Main Power Harness
X124
F23
X123
F24 X130
K20
F25
X132
X126 X133
X127
X125 X128
X129
X1B
4
G1 W6
G1
W5
3 2
W1
S2
G1 1
G1
Ele30D2001CFM
26 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
1 Detail of 2-Battery Configuration. X120Main Ground (W1) Connector.???

2 Starter Negative Terminal. X121Battery (G1) 24-Volt Connector.???
3 Starter Positive Terminal. X122Battery (G1) 12-Volt Connector.???
4 Detail of Optional 4-Battery Configuration. X123Circuit Breaker (F24) Connector.
F23 Main Circuit Breaker (60-Amp). X124Main Circuit Breaker (F23) Connector.
F24 Fuel Filter Heater, Unloader Valve Heater X125Main Circuit Breaker (F23) Connector.
and Low Coolant Level Circuit Breaker (20- X126Circuit Breaker (F25) Connector.
Amp). X127Circuit Breaker (F25) Connector.
F25 Battery Balancer Circuit Breaker (20-Amp). X128Battery Relay (K20) Terminal 30 (Contact)
G1 Batteries (2 used; standard) (4 used; Connector.
optional). X129Battery Relay (K20) Terminal 30 (Contact)
K20 Battery Relay. Connector.
S2 Battery Disconnect Switch. X130Battery Relay (K20) Terminal 87 (Contact)
W1 Main Ground. Connector.
W5 Engine Starter-to-Frame Ground Strap. X132Battery Relay (K20) Connector Terminal 86
W6 Main Power Harness. (Coil) Connector.
X1B Main Power Harness-to-Cab Power X133Battery Relay (K20) Terminal 85 (Coil)
Harness Connector. Connector.
X117Start Aid Connector.???
ISSUE 0 27
872106 CHAPTER 3 B25D & B30D 6X6
Front Frame/Engine Harness
X100 K22
X154B
X154A
X98
X113A X113B
B28
X106 X112
B20
X111 E21
E3
E1
X97A
X97B
W7
X204 B27
G2
X108 X156A
X107
X115 X156B
X116
E4
X114A
E2
X114B
E22
Ele30D2002CFM
28 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
B20 Engine Coolant Low Level Sensor. X103A/C Compressor Clutch (Y20) Connector.
B28 Stop Light Pressure Switch. X104Starter Solenoid (BK/WH Wire) Connector.
E1 Left Front Park Light. X105Alternator B+ to Starter Solenoid (GN) Wire
E2 Right Front Park Light. Connector.
E3 Left Headlight. X106Electronic Unit Injector Controller (A2) 16-
E4 Right Headlight. Pin Connector.
E21 Left Front Turn Signal. X107Alternator (G2) B+ Terminal Connector.
E22 Right Front Turn Signal. X108Alternator (G2) Ground Terminal
F23 Main Circuit Breaker (60-Amp). Connector.
F24 Fuel Filter Heater, Unloader Valve Heater X111Left Front Park Light (E1) Connector.
and Low Coolant Level Circuit Breaker (20- X112Left Headlight (E3) Connector.
Amp). X113ALeft Front Turn Signal Light (E21)
G2 Alternator. (Positive) Connector.
M3 Washer Pump Motor. X113BLeft Front Turn Signal Light (E21)
R5 Unloader Valve Heater. (Ground) Connector.
R6 Fuel Filter Heater (Optional). X114ARight Front Turn Signal Light (E22)
W1 Main Ground. (Positive) Connector.
W7 Front Frame/Engine Harness. X114BRight Front Turn Signal Light (E22)
X38BFront Frame/Engine Harness-to-Cab Main (Ground) Connector.
Harness Connector. X115Right Headlight (E4) Connector.
X96 Engine Coolant Low Level Sensor (B20) X116Right Front Park Light (E2) Connector.
Connector. X154AStop Light Pressure Switch (B28) (GY/GN
X97AFuel Sensor (B19) (Signal) Connector. Wire) Connector.
X97BFuel Sensor (B19) (Ground) Connector. X154BStop Light Pressure Switch (B28) (GN
X98 Unloader Valve Heater (R5) Connector. Wire) Connector.
X99 Air System Drain Solenoid (Y16) Connector X155Washer Pump Motor (M3) Connector.
X100Circuit Breaker (F24) Connector. X161Optional Fuel Filter Heater (R6) Connector.
X101Main Circuit Breaker (F23) Connector. X156AElectric Horn (B27) Connector.
X156BElectric Horn (B27) (Ground) Connector.
X204Alternator (G2) 5-Pin Connector.
Y16 Air System Drain Solenoid.
Y20 A/C Compressor Clutch.
ISSUE 0 29
872106 CHAPTER 3 B25D & B30D 6X6
Cab Power Harness and Controller Area Network (CAN)
F3
F1
X182
X178
R4
X93 X13B
X94
W11
X1A W9 R3
X18B
X95
W2
X19B
X16B
X109
Ele30D1002CFM
F1 Stop Light, Interior Light, Hazard Light, and X16BDiagnostic CAN Connector.
Turn Signal Circuit Breaker (15-Amp). X18BChassis Control Unit CAN Connector.
F3 Switched Power to Fuses F11, F14—F16 X19BEngine Control Unit CAN Connector.
Circuit Breaker (20-Amp). X91BCold Start and Run Circuits Power
W2 Cab Firewall Ground. Connector.
W9 Cab Power Harness. X93 120 Ohm (R4) CAN Terminator Connector.
R3 120 Ohm CAN Termination. X94 120 Ohm (R3) CAN Terminator Connector.
R4 120 Ohm CAN Termination. X95 Transmission Control Unit CAN Connector.
W2 Cab Firewall Ground. X109Cab Firewall Ground Connector.
W11 CAN Harness. X178Circuit Breaker (F1) Connector.
X1A Main Power Harness-to-Cab Power X182Circuit Breaker (F3) Connector.
Harness Connector.
30 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
Cab Main Harness And Electric Mirror Interface Harness
DETAIL A
W3
W10
W2
DETAIL C
DETAIL B
Ele30D2004CFM
W2 Cab Roof Ground.

W3 Cab Firewall Ground.
W10 Cab Main Harness.
ISSUE 0 31
872106 CHAPTER 3 B25D & B30D 6X6
Cab Main Harness And Electric Mirror Interface Harness (Continues)
E30
X54
X48
X131
X53A
W3
X50B X59
X60
X50A
X65
E25
S16 X66
X51B
R10 E17
X51A
S18
X30 S19
E26
S17 X90 E18
X89
F6 X187 X188
F7 X189 X190
F1 X177 X178
F8 X191 X192
V1 V2 V3 V4 F2 X179 X180
F9 X193 X194
V5 V6 V7 R1 X195
F3 X181 X182
F11 F12 F15 F17 F19 F21 X196
F4 X183 X184
F13 F14 F16 F18 F20 F22
K1 K2 K3 K4 X197 F5 X185 X186
K5 K6 K7 K8 X198
K9 K10 K11 K12 X199
K13 K14 K15 K16 X200
X47 X52A
X49
X57
X56
X157
X58
X55
X201 K17 K18 K19 M1

Ele40D1003CFM
32 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
E17 Backlight (A/C On/Off Switch). K1 Neutral Start Relay.

E18 Backlight (Air Re circulation Switch). K2 Start Relay.
E25 Dome Light. K3 Headlights and A/C Cutout Relay.
E26 Fuse/Relay Compartment Light. K4 Backup Relay.
E30 Articulation Backup Light. K5 Stop Light Relay.
F1 Circuit Breaker - Stop Light, Interior Light, K6 Exhaust Brake Relay.
Hazard Light and Turn Signal (15-Amp) K7 Park Brake Relay.
(SE9). K8 Range Hold Relay.
F2 Circuit Breaker - Unswitched Power to K9 Left Turn Relay.
Fuses F12, F13, F18 - F21 (30-Amp). K10 Right Turn Relay.
F3 Circuit Breaker - Switched Power to Fuses K11 Low Beam Relay.
F11 and F14—F16 (20-Amp) (SE1). K12 High Beam Relay.
F4 Circuit Breaker - Headlight, Work Light, K13 Body Float Relay.
Backup Light and Beacon (30-Amp). K14 Intermittent Wiper Relay.
F5 Circuit Breaker - Headlight and A/C (25- K15 Accessory Relay.
Amp). K16 ECU/EUI Power Relay.
F6 Circuit Breaker - Park Brake, Differential K17 MDU/CCI Power Relay.
Lock, Fan Drive, Body Down Detent, and K18 Blank Relay Socket.
Range Hold (15-Amp). K19 Auxiliary Relay Socket.
F7 Circuit Breaker - Wiper, Washer, Horn, and N1 Retarder Voltage Regulator.
Mirror (25-Amp) (SE7) (W10). R1 Air Pressure Sensor Pull-Up Resistor.
F8 Circuit Breaker - Cold Start (25-Amp) (SE2) R10 Temperature Control.
(W10). S16 Air Conditioning On/Off Switch.
F9 Circuit Breaker - Start, Neutral, MDU/CCU S17 Air Re circulation Switch.
Power, Exhaust Brake and Body Float (15- S18 Blower Motor Speed Control Switch.
Amp). S19 Air Flow Control Switch.
F11 Retarder/Voltage Regulator Fuse (10- V1 Retarder Stop Light Control Diode (3-Amp).
Amp). V2 Stop Light Control Diode (3-Amp).
F12 Transmission Control Unit (TCU) Fuse (10- V3 Alternator Excitation Diode (3-Amp).
Amp). V4 Intermittent Wiper Control Diode (3-Amp).
F13 MDU/CCU Power and Hazard Fuse (5- V5 Washer/Wiper Control Diode (3-Amp).
Amp). V6 Hazard Control Diode (3-Amp).
F14 Alternator Excitation Fuse (5-Amp). V7 MDU/CCU Power Diode (3-Amp).
F15 Program/Diagnostic Fuse (10-Amp).
F16 ECU/EUI Power Relay Fuse (10-Amp).
F17 AM/FM Radio Fuse (10-Amp).
F18 ECU Fuse (10-Amp).
F19 MDU Fuse (5-Amp).
F20 Diagnostic Fuse (10-Amp).
F21 Battery Balancer/Accessories Fuse (10-
Amp).
F22 2-Way Radio Fuse (15-Amp).
ISSUE 0 33
872106 CHAPTER 3 B25D & B30D 6X6
X5A
X5B
X6A X18A
X4 A8
X7
X8
X10
X32B
X32A
A9
A3
X31
X14
X17
X16A
X15
Ele30D1003CFM
34 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
A1 Cold Start Module. X15 Diagnostic (Service ADVISOR ™)

A3 Engine Control Unit (ECU). Connector.
A8 Chassis Control Unit (CCU). X16ADiagnostic CAN Connector.
A9 Battery Balancer. X17 Chassis Control Unit (A8) Programming 6-
X4 Chassis Control Unit (A8) J3 Connector. Pin Connector.
X5A Chassis Control Unit (A8) J1A Connector. X18AChassis Control Unit (A8) CAN Connector.
X5B Chassis Control Unit (A8) J1L Connector. X19AEngine Control Unit (A3) CAN Connector.
X6A Transmission Control Harness-to-Cab Main X27 Cold Start Module (A1) 8-Pin Connector.
Harness Connector. X28 Cold Start Module (A1) 4-Pin Connector.
X7 Engine Control Unit (A3) 21-Pin Connector. X31 Battery Balancer (A9) Connector.
X8 Engine Control Unit (A3) 18-Pin Connector. X32A12-Volt Accessory Power Socket
X9 Engine Control Unit (A3) 15-Pin Connector. Connector.
X10 Engine Control Unit (A3) 12-Pin Connector. X32B12-Volt Accessory Power Socket Ground
X14 Monitor Display Unit (H2) Programming 4 Connector.
Pin Connector.
ISSUE 0 35
872106 CHAPTER 3 B25D & B30D 6X6
S13 E5 S14 S15 E13

X61 X62 X71 X79 X80
S11 X75
X67
X76
X82
E7
X68
S12 X81
X84
X73 X83
E10 E9
X74 S20 X72
E12
X77
X78
X21
S10
X33 R9
X11
X20 X23
X22
H2
H1
X12
X91A
X35 X13A
S8
E6 B25 X25
X63
X64 X160A X39
X87 X45 B18
X160B X36
B16
X88
B10
W17
X2A
S6
X85 X46B
S21
S9
E14 X69
E8 X46C
X86
X70 W10
X37 X41A
X39
Y19 X110
Y15
X42
W2
Y10 X44
Y14 X3A
Ele30D1001CFM
36 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
B10 Accelerator Pedal Position Sensor. X21 Steering Column Switch (S10) 4-Pin
B16 Body Up Pressure Switch. Connector.
B18 Park Brake Pressure Switch. X22 Audible Alarm (H1) Connector.
B25 Inter-Axle Lock Pressure Switch. X23 Wiper Motor (M2) Connector.
B26 Differential Lock Pressure Switch. X25 Accelerator Pedal Position Sensor (B10)
B31 Air Conditioning High/Low Pressure Switch. Connector.
E5 Backlight (Interior Light Switch). X26 Key Switch (S1) Connector.
E6 Backlight (Inter-Axle Lock Switch). X29 Cab Main Harness-to-A/C Actuator
E7 Backlight (Headlight Switch). Harness (W18) 21-pin Connector.
E8 Backlight (Differential Lock Switch). X33 Lighter (R9) Connector.
E9 Backlight (Rotating Beacon Switch). X34 Not Used.
E10 Backlight (Hazard Light Switch). X35 Body Down Detent Magnet (Y13)
E12 Backlight (Mirror Defroster Switch). Connector.
E13 Backlight (Work Light Switch). X36 Park Brake Pressure Switch (B18)
E14 Backlight (Range Hold Switch). Connector.
H1 Audible Alarm. X37 Air Horn Solenoid (Y19) Connector.
H2 Menu Display Unit (MDU). X38 Inter-Axle Lock Solenoid (Y15) Connector.
M2 Wiper Motor. X39 Inter-Axle Lock Pressure Switch (B25)
R9 Lighter. Connector.
S1 Key Switch. X40 Differential Lock Solenoid (Y18) Connector.
S6 Range Hold Switch. X41ASystem Air Pressure Sensor (B15)
S7 Park Brake Latch Switch. Connector.
S8 Inter-Axle Lock Switch. X41BSystem Air Pressure Sensor (B15)
S9 Differential Lock Switch. Connector.
S10 Steering Column Switch. X42 Exhaust Brake Solenoid (Y10) Connector.
S11 Headlight Switch. X43 Body Up Pressure Switch (B16) Connector.
S12 4-Way Flasher Switch. X44 Park Brake Solenoid (Y14) Connector.
S13 Interior Light Switch. X45 Park Brake Latch Switch (S7) Connector.
S14 Rotating Beacon Switch. X46ACab Harness-To-Mirror Positioning Switch
S15 Work Light Switch. Interface Harness Connector (W10).
S20 Mirror Defroster Switch. X46BMirror Positioning Switch Interface
S21 Mirror Positioning Switch. Harness-To-Cab Harness Connector
W2 Cab Firewall Ground. (W10).
W10 Cab Main Harness. X46CMirror Positioning Switch Connector (W10).
X2A Hydraulic Harness-to-Cab Main Harness X61 Interior Light Switch (S13) Connector.
Connector. X62 Interior Light Switch Backlight (E5)
X3A Front Frame/Engine Harness-to-Cab Main Connector.
Harness Connector. X63 Inter-Axle Lock Switch (S8) Connector.
X4 Chassis Control Unit (A8) J3 Connector. X64 Inter-Axle Lock Switch Backlight (E6)
X11 Monitor Display Unit (H2) 10-Pin Connector.
Connector. X67 Headlight Switch (S11) Connector.
X12 Monitor Display Unit (H2) 6-Pin Connector. X68 Headlight Switch Backlight (E7) Connector.
X13 Monitor Display Unit (H2) CAN Connector. X69 Differential Lock Switch (S9) Connector.
X20 Steering Column Switch (S10) 12 - Pin X70 Differential Lock Switch Backlight (E8)
Connector. Connector.
ISSUE 0 37
872106 CHAPTER 3 B25D & B30D 6X6
X71 Rotating Beacon Switch (S14) Connector. X85 Range Hold Switch (S6) Connector.
X72 Rotating Beacon Switch Backlight (E9) X86 Range Hold Switch Backlight (E14)
Connector. Connector.
X73 4-Way Flasher Switch (S12) Connector. X87 Not Used
X74 4-Way Flasher Switch Backlight (E10) X88 Not Used.
Connector. X91ACold Start and Run Circuits Power
X75 Not Used. Connector.
X76 Not Used. X92 Differential Lock Pressure Switch (B26)
X77 Mirror Defroster Switch (S20) Connector. Connector.
X78 Mirror Defroster Switch Backlight (E12) X110Cab Firewall Ground (W2) Connector.
Connector. X160AAir Conditioning High/Low Pressure
X79 Work Light Switch (S15) Connector. Switch (B31) Connector.
X80 Work Light Switch Backlight (E13) X160B Air Conditioning High/Low Pressure
Connector. Switch (B31) Connector.
X81 Not Used. Y10 Exhaust Brake Solenoid.
X82 Not Used. Y13 Body Down Detent Magnet.
X83 Not Used. Y14 Park Brake Solenoid.
X84 Not Used. Y15 Inter-Axle Lock Solenoid.
Y18 Differential Lock Solenoid.
Y19 Air Horn Solenoid.
38 ISSUE 0
B25D & B30D 6X6 CHAPTER 3 872106
ISSUE 0 39
872106 CHAPTER 3 B25D & B30D 6X6
Transmission Control Harness
X169
X170
A7
A4
X164
X163
W12
X162A
X6B
A5
X168 X167
Ele30D1005CFM
40 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
A4 Transmission Shift Control. X163Transmission Shift Control (A4) Connector.

A5 Transmission Control Unit (TCU). X164—Retarder Control (A7) Connector.
A7 Retarder Control. X167TCU (A5) CAN Connector.
W12 Transmission Control Harness. X168Blue TCU (A5) Connector.
X6B Transmission Control Harness-to-Cab Main X169Transmission Diagnostic Connector.
Harness Connector. X170Transmission Diagnostic Connector.
X162ATransmission Control Harness-to-
Transmission Harness Connector.
ISSUE 0 41
872106 CHAPTER 3 B25D & B30D 6X6
Transmission Harness
B11
X174
X162B
Y11
X176
W13
A6
X171
Ele30D3001CFM
42 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
A6 Transmission Control Module. X171Transmission Control Module Harness (A6)

B11 Retarder Temperature Sensor. To Transmission Harness Connector.
W13 Transmission Control Harness. X174Retarder Temperature Sensor (B11)
X162BTransmission Control Harness-to- Connector.
Transmission Harness Connector. X176Retarder Proportional Solenoid (Y11)
Connector.
Y11 Retarder Proportional Solenoid.
ISSUE 0 43
872106 CHAPTER 3 B25D & B30D 6X6
Hydraulic Harness
X142
X144A
Y13 X143B X209
B24
X139 X143A
B21
X141
X138 Y18
B23 W4
W14
X2B
Ele30D4001CFM
44 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
B21 Hydraulic Temperature Sensor. X139Secondary Steering Pressure Switch (B24)

B23 Service Brake Low Pressure Switch. Connector.
B24 Secondary Steering Pressure Switch. X140Not Used.
W4 Front Frame Ground (Under Cab). X141Hydraulic Cut-Off Solenoid (Y18)
W14 Hydraulic Harness. Connector.
X2B Hydraulic Harness-to-Cab Main Harness X142Body Float Solenoid (Y13) Connector.
Connector. X143AHydraulic Temperature Sensor (B21)
X134AWet Brake Temperature Sensor (B22) (Signal) Connector.
(Signal) Connector. X143BHydraulic Temperature Sensor (B21)
X135Not Used. Connector.
X136Front Frame Ground Connector (Under X144AHydraulic Harness-to-Rear Frame
Cab). Harness Connector.
X138Service Brake Low Pressure Switch (B23) Y13 Body Float Solenoid.
Connector. Y18 Fan Drive Solenoid.
ISSUE 0 45
872106 CHAPTER 3 B25D & B30D 6X6
Rear Frame Harness
E23
X146
E19
B17 X147
X150
E31
X148
E20 E32
H3
E24
X149
X152 H3
S5
X153
S5 X145
W15
X144B
Ele30D2003CFM
46 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
B17 Body Position Sensor. X144BRear Frame Harness-to-Hydraulic

E19 Left Stop/Park Light. Harness Connector.
E20 Right Stop/Park Light. X145Body Up Switch (S5) Connector.
E23 Left Rear Turn Signal. X146Left Rear Turn Signal (E23) Connector.
E24 Right Rear Turn Signal. X147Left Stop/Park Light (E19) Connector.
E31 Left Backup Light. X148Left Backup Light (E31) Connector.
E32 Right Backup Light. X149Right Backup Light (E32) Connector.
H3 Backup Alarm. X150Body Position Sensor (B17) Connector.
S5 Body Up Switch. X152Right Stop/Park Light (E20) Connector.
W15 Rear Frame Harness. X153Right Rear Turn Signal (E24) Connector.
Work Light Harness
X52B
W16
X203
X53B
W16
E28
E29 X202
Ele40D1008CFM
E28 Left Work Light. X53BLeft Work Light Harness-to-Cab Harness

E29 Right Work Light. Connector.
W16 Work Light Harness. X202Left Work Light (E28) Connector.
X52BRight Work Light Harness-to-Cab Harness X203Right Work Light (E29) Connector.
Connector.
ISSUE 0 47
872106 CHAPTER 3 B25D & B30D 6X6
Air Conditioning Actuator Harness
A11
K21
X650
X652
U1
X651
X653
X29 M7 M8
M5
R11
M4
B32
M6
Ele40D1009CFM
48 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
A11 A/C Relay Panel. R11 Blower Motor Resistor/Thermofuse.

B32 Air Conditioning Freeze Control Switch. X29 Cab Main Harness-to-A/C Actuator
K21 High Fan (Blower) Speed Relay. Harness 21-Pin Connector.
M4 Blower Motor. X650A/C Relay Panel (A11) 12-Pin Connector.
M5 Heater Control Valve Actuator. X651A/C Relay Panel (A11) 6-Pin Connector.
M6 Recirculation Vent Actuator. X652DC/DC Converter Input Connector.
M7 Middle and Defroster Vent Actuator. X653DC/DC Converter Output Connector.
M8 Floor Vent Actuator. U1 DC/DC Converter.
ISSUE 0 49
872106 CHAPTER 3 B25D & B30D 6X6
Transmission Control Module Harness
Y7
Y5
Y9 B13
Y8 Y10
X540
Y2 X541
X171
W19
Y6
Y3
X524A
X524B
X523A
B14 X523B
Y1 B12
R8 X522B
Y4 X522A
Ele30D3002CFM
50 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
B12 Sump Temperature Sensor. X524ATransmission Control Module Harness-to-

B13 Turbine Speed Sensor. Output Speed Sensor Harness Connector.
B14 Output Speed Sensor. X524BOutput Speed Sensor Harness-to-
R8 Retarder Resistor. Transmission Control Module Harness
W19 Transmission Control Module Harness. Connector.
X171Transmission Control Module Connector. X540Sump Temperature Sensor (B12), Turbine
X522ATransmission Control Module Harness-to- Speed Sensor (B13) and Connector X171
Sump Temperature Sensor Harness Ground Splice.
Connector. X541Solenoids (Y1—Y10) and Connector X171
X522BSump Temperature Sensor Harness-to- Ground Splice.
Transmission Control Module Harness Y1 Clutch G Solenoid.
Connector. Y2 Clutch F Solenoid.
X523ATransmission Control Module Harness-to- Y3 Clutch E Solenoid.
Retarder Resistor Harness Connector. Y4 Clutch D Solenoid.
X523BRetarder Resistor Harness-to- Y5 Clutch C Solenoid.
Transmission Control Module Harness Y6 Clutch B Solenoid.
Connector. Y7 Clutch A Solenoid.
Y8 Clutch WK Solenoid.
Y9 Throttle Pressure D1 Solenoid.
Y10 Retarder On Solenoid.
ISSUE 0 51
872106 CHAPTER 3 B25D & B30D 6X6
EXPLANATION OF WIRE MARKINGS Circuit Breakers
Wire Colour
6 7 8 9 10
The wire colour (Two character code) is simply an
abbreviation of the wire colour.
SCHEMATIC
WIRE COLOUR
ABBREVIATION
Black BK
Blue BL
Brown BN 1 2 3 4 5
Green GN 1. F1 - Stop Light; Interior Light; Hazard Light

and Turn Signal Circuit Breaker (15 Amp).
Gray GY 2. F2 - Unswitched Power to Fuses F12; F13;
F18; F19; F20 and F21 Circuit
Orange OG
Breaker (30 Amp).
Pink PK 3. F3 - Switched Power to Fuses F11; F14;
F15 and F16 Circuit Breaker (20Amp).
Purple PL 4. F4 - Headlight; Work Light; Backup Light
and Rotating Beacon Circuit
Red RD
Breaker (3 Amp).
White WH 5. F5 - Headlight and A/C Circuit
Breaker (25 Amp).
Yellow YL 6. F6 - Park Brake; Differential Lock; Fan
Drive; Body Down Detent and Range Hold
Multiple Wire Colours Circuit Breaker (15 Amp).
7. F7 - Wiper; Washer; Horn and Mirror Circuit
Wires with more than one colour abbreviation will Breaker (25 Amp).
have a stripe running parallel to the wire. 8. F8 - Cold Start Circuit Breaker (25 Amp).
9. F9 - Start; Neutral; MDU/CCU Power;
The first colour abbreviation will be the main
Exhaust Brake and Body Float Circuit
colour, the second abbreviation will be the colour
Breaker (15 Amp).
of the stripe.
10. F10 - Blank.
Example: WH/BK represents a white wire with a
black stripe.
Wires with three colour abbreviations will have two

stripes running parallel to the wire. The second
and third colour abbreviations will be the colour of
the stripes.
Example: BK/WH/GN represents a black wire with

a white and green stripe.
52 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
Diodes/Resistors and Fuses
3 1 2 4 6 13 14 15
DIODES /
RESISTORS FUSES 16
V1 3A F11 10A
5 3A 10A
V2 F12
V3 3A F13 5A 17
V4 3A F14 5A
7 V5 3A F15 10A
V6 3A F16 10A
18
V7 F17 *
3A 10A
F18 10A 19
SPARE
F19 5A
SPARE
F20 10A 20
SPARE
F21
10A
R2 30k F22
15A
R1 830
G D 10 33 CF M
11 10 21 22 24 23
8 9 12
1. V1 - Retarder; Exhaust Brake Light Control 14. F12 - Transmission Control Unit (TCU)
Diode (3 Amp). Fuse (10 Amp).
2. V2 - Stop Light Control Diode (3 Amp). 15. F13 - MDU/CCU power and Hazard Fuse
3. V3 - Alternator Excitation Diode (3 Amp). (5 Amp).
4. V4 - Intermittent Wiper Control 16. F14 - Alternator Excitation Fuse (5 Amp).
Diode (3 Amp). 17. F15 - Program/Diagnostic Fuse (10 Amp).
5. V5 - Washer/Wiper Control Diode (3 Amp). 18. F16 - ECU/EUI Power Relay Fuse
6. V6 - Hazard Control Diode (3 Amp). (10 Amp).
7. V7 - MDU/CCU Power Diode (3 Amp). 19. F17 - AM/FM Radio Fuse (10 Amp).
8. Spare. 20. F18 - ECU Fuse (10 Amp).
9. Spare. 21. F19 - MDU Fuse (5 Amp).
10. Spare. 22. F20 - Diagnostic Fuse (10 Amp).
11. R2 - Not Used (30 K Ohm). 23. F21 - Battery Balancer/Accessories Fuse
12. R1 - Air Pressure Sensor Pull-Up Resistor (10 Amp).
(830 Ohm). 24. F22 - 2-Way Radio Fuse (15 Amp).
13. F11 - Retarder/Voltage Regulator Fuse
(10 Amp).
ISSUE 0 53
872106 CHAPTER 3 B25D & B30D 6X6
Relays/Voltage Regulator
6 5 9 10 13 17
1
14
K1 K5 K9 K13 K17
2
18
K2 K6 K10 K14 K18
3
K3 K7 K11 K15 K19 19
K4 K8 K12 K16 N1 20
**
4
7 8 12 11 16 15
1. K1 - Neutral Start Relay. 11. K11 - Low Beam Relay.

2. K2 - Start Relay. 12. K12 - High Beam Relay.
3. K3 - Headlights and A/C Cutout Relay. 13. K13 - Body Float Relay.
4. K4 - Backup Relay. 14. K14 - Intermittent Wiper Relay.
5. K5 - Stop Light Relay. 15. K15 - Accessory Relay.
6. K6 - Exhaust Brake Relay. 16. K16 - ECU/EUI Power Relay.
7. K7 - Park Brake Relay. 17. K17 - MDU/CCI Power Relay.
8. K8 - Range Hold Relay. 18. K18 - Blank Relay Socket.
9. K9 - Left Turn Relay. 19. K19 - Blank Relay Socket.
10. K10 - Right Turn Relay. 20. N1 - Retarder Voltage Regulator.
54 ISSUE 0
ISSUE 0
MR - Engine ECU 10 Aw MR-5 & MR-6 GN 2.5
(F1) GN 2.5 GN 1.5 SW 4-2 A 3 Headlight Switch
(F23) GN 10.0 CB1 15A
MCB1 60A GN 1.5 SW1-1 B 4 Interior Light Switch
X101
X125
GN 16.0 GN 16.0 X178 X177
GN 1.5 R3-30 C 12 Stop Light Relay
B25D & B30D 6X6
X124
GN 1.5 R15-30 D 3 Left Indicator
BN 70.0 RD/BK 2.5
Circuit Diagrams
(F2) GN 1.5 R16-30 E 3 Right Indicator
X1 - U
GN 6.0
RD/GN 1.5 IGNITION CB2 30A
BN 70.0 (S1) GN 1.5 X3-18 F 12 Stop Light Switch
SOLENOID
X121 BK/GN 1.5 GN 1.5 FUSE 2-2 G 2 ZF Ecomat Interface
X180 X179
2.5
GN
X128 GN 1.5 FUSE 3-2 MDU / CCU Power Relay, Hazard Switch
X26-5
X26-3
X26-2
H 2
X132 X129
X91 - 2
86 30 GN 2.5 GN 1.5 FUSE 8-2 J 2 ADM Power
(F3)
ST
GN 1.5
ACC
0
FUSE 9-2 MDU Power
IGN
CB3 20A K 2
CONT
GN 1.5 FUSE 10-2 L 2 Diagnostic Connector
85 87 X182 X181
GN 1.5 FUSE 11-2 M 2 Battery Balancer, Accessory Relay
BAT GND
X133 X130 RD 2.5 RD 1.5 FUSE 1-2 N 2 Ecomat 31, Gear Hold
BATTERY 12V
E1 X1 - S
(F4) RD 1.5 FUSE 4-2 P 2 Alternator Diode
X26-1 X1 - V
RD 6.0
CB4 30A
BK 1.5 RD 1.5 FUSE 5-2 Q 2 CCU, MDU, Diagnostic
OPTIONAL BATTERY 12V

IGNITION SWITCH X184 X183 RD 1.5 FUSE 6-2 R 2 ADM / MR Supply Relay
X122 RD 2.5 RD 1.5 R2-30 S 12 Reverse Relay Contact
RD 4.0
(F5) RD 1.5 X3-16 T 3 Headlight Ignition power
CB12 20A
RD 6.0
(G1) RD 2.5 CB5 25A RD 1.5 SW 10-5 U 14 Worklight Switch
BN 70.0
(F24)
BN 70.0
BN 70.0
RD 2.5 RD 1.5 RD 1.5 SW 6-5 V 14 Flashing Beacon
X123 X186 X185
X100 RD 2.5 R11-30 W 4 Lights / Acc Cut Out Relay
RD 2.5
Figure 1
RD 1.5 R13-30 X 6 Park Brake Relay
RD 2.5 (F6)
CHAPTER 3
RD 2.5 RD 1.5 R14-86 Gear Hold
RD 6.0
CB6 15A Y 6
CB11 20A (F25)
RD 1.5 BL-2 Z 6 Bin Down Latch Solenoid
X127 X126
WH 2.5 X1 - T WH 2.5 X188 X187
RD 1.5 WM-3 Aa 4 Wiper Motor
RD 1.5 SCS12-8 Ab 3 Wiper Motor Switch
BK/WH 1.5
BATTERY 12V
(F7) RD 2.5 RD 1.5 SW9-1 Ac 13 Mirror Defrost Switch
RD 6.0
YL/RD 1.5 CB7 25A

GN 2.5 RD 1.5 JDS-1 Ad 14 Pneumatic Seat Pump
OPTIONAL BATTERY 12V

X190 X189 RD 1.5 SW13-2 Ae 13 Mirror Switch
RD 1.5 SCS4-1 Af 3 Washer / Horn Supply
X3 - 3
Diode3-Out
MR ECU-12
BATB-4
FSOL-30
FF-1
COL-A
PU-1
R7-85
R8-85
BN 70.0
GN 16.0 (G2) (F8) RD 1.5 R10-87 Ag 4 Intermittent Relay
CB8 25A
RD 6.0
X105 X104 RD 4.0 RD 2.5 CS4-4 Ah 10 Cold Start (4 pin connector)

(M1) KL50 KL30 1 2 Ar As At Av 3 4
RD 2.5 CS8-1 Aj 10 Cold Start (8 pin connector)
0
X204
2 10 2 7 7 7 7 8 2 X192 X191
BN 70.0
DFM L S 15 W
RD 1.5 R4-30 Ak 6 Bin Float Relay
1
RD 1.5 R1-30 Al 8 Neutral Relay
E3 B+ A B- X108 (F9)
CB9 15A RD 2.5 RD 1.5 CCUJ1A-J1 Am 6 CCU - Ignition Status Input
RD 6.0
BN 70.0 X107
M RD 1.5 R7-30 An 8 Start(KL50) Relay
(S2) BK 16.0
BK 16.0
X194 X193
BN 70.0
RD 1.5 R5-30 Ap 8 Exhaust Brake Relay
ISOLATOR Diode 6,MDU/CCU Power
STARTER E3
To Fuse 4
Engine MR ECU
Battery Balancer
Fan Solenoid
Fuel Filter
Low Coolant Level
Switch
Purging Unit
Start Relay
Accessory Relay
SWITCH E3 ALTERNATOR E3 RD 1.5 Diode 6-In Aq 5 Relay

700112-01CFM
55
872106
56
872106
1 1 1 1 1 1 1 1 1 1 1
"-"
CUSTOMER SUPPLIED M L K J R Q 1 P H G N
"+"
12V TWO WAY RADIO
RD 1.5 ECO31-1 5 9 Ecomat Interface 31
(F11) FUSE1 10A
LEFT SPEAKER CB3-1 RD 1.5 RD 1.5 RD 1.5 ECO31-4 6 9 Ecomat Interface 31
"-" (F12) FUSE2 10A

CB2-1 GN 1.5 GN 1.5 ECO31-2 7 9 Ecomat Interface 31
"+"
(F13) FUSE3 5A
CB2-1 GN 1.5 GN 1.5 GN 1.5 R6-30 8 5 MDU / CCU Power Relay
X60 - 1
X60 - 2
RIGHT SPEAKER
X59 - 1
X59 - 2
X57 - 1
X57 - 2
GN 1.5 SW7-6 9 4 Hazards Switch
(F14) FUSE4 5A
BK 1.5 CB3-1 RD 1.5
BK 1.5 E2 X196(FUSE BANK)
1.5
E2
(V3) DIODE3 3A
RD 1.5
RD
BK 1.0
BL 1.0
BK 1.0
GN 1.0
ALT-D+ YL/RD 1.5 RD 1.5 MDUP-3 10 5 Monitor Display Unit Program
X195(DIODE BANK)
REVERSE RD 1.5 CCUP-4 11 7 Chassis Control Unit Program
MONITOR (F15)FUSE5 10A
CB3-1 RD 1.5 RD 1.5 RD 1.5 DIAG-B 12 8 Diagnostic Connector
X58 - 1
X58 - 2
X56 - 1
X56 - 2
X55 - 2
X55 - 3
X55 - 1
(F16) FUSE6 10A
CB3-1 RD 1.5 RD 1.5 R12-87 13 10 ADM / MR Supply Relay
(F17) FUSE8 10A

CB2-1 GN 1.5 GN 1.5 ADM21-1 14 10 ADM (21 pin connector)
Figure 2
CHAPTER 3
(F18) FUSE9 5A
CUSTOMER SUPPLIED CB2-1 GN 1.5 GN 1.5 MDUJ2-G 15 5 Monitor Display Unit (10 pin)
12V RADIO/CASSETTE PLAYER
X24 - 2 X24 - 1
(F19) FUSE10 10A
CB2-1 GN 1.5 GN 1.5 DIAG-E 16 8 Diagnostic connector
BK 1.5
X31 E2 (F20) FUSE11 10A GN 1.5
CB2-1 GN 1.5
5 GN/RD 1.5 GN 2.5
X196(FUSE BANK)
2 GN 2.5 87a
WH/RD 1.5 87
3 WH/RD 2.5
RD 1.5 WH/RD 1.5 30
4 WH 2.5 X91 - 1 X33-1 86
WH/RD 1.5 RD/GN 1.5
6 RD 1.5
12V 85
WH/RD 2.5
(F21)
1 BK 2.5 FUSE7 10A
IGN-5
RD 1.5
CB11-2
CCUJ1-A3
X32A GN 1.5
X33-2
K15
BK 1.5 12V POWER RELAY 8
E2 (X200 RELAY
1.5
BATTERY CIGARETTE SUPPLY (F22) BANK) ACCESSORY

Ar 17 4
WH/RD
(A9)
BALANCER E2 LIGHTER 1 FUSE12 15A
1 6 X32B 1
BK 1.5 WH/RD 1.5
E1 X196(FUSE BANK)
700112-02CFM
ISSUE 0
B25D & B30D 6X6
ISSUE
ISSUE 0
1 1 1 6 6 BN 1.5 SW7-5 20 4
X62-1
E3
PLHT 1 BK 1.5 BL 1.5 X111 - 1 X111 - 2 BK 1.5 A E D 18 19 BN 1.5 INDL-2 21 4
X62-2
BN 1.5 X3 - 8 X113 - 1 X113 - 2 BK 1.5
FRONT LEFT PARKLIGHT RELAY 15 E3
X64-1
B25D & B30D 6X6
PLHT 2 BL 1.5
LEFT
CB1-1
CB1-1
CB1-1
(E21) FRONT LEFT INDICATOR
X64-2 INDICATORS
E3 YL 1.5 INDR-2
RELAY 22 4
CCUJ3-C1
CCUJ3-D1
BL 1.5 X116 - 1 X116 - 2 BK 1.5
(K9) (X199
BANK)
X66-1
87a YL 1.5 X3 - 9 X114 - 1 X114 - 2 BK 1.5
GN 1.5
GN 1.5
GN 1.5
PLHT 3 E3
X66-2 30 87
FRONT RIGHT PARKLIGHT BN 1.5
(E22) FRONT RIGHT INDICATOR
X68-1
85 86 WM-2 OR 1.5 23 4
BL 1.5
PLHT 4 BN/RD 1.5
X68-2
CB7-1 RD 1.5 Ab 1
0
BK 1.5
X70-1 CCUJ1L-T2 BL/RD 1.5
X3 - 26
24 6
PLHT 5 1
X70-2 E2 R10-30 PK 1.5 25 4
2
X72-1 87a 26 4
PLHT 6
X72-2 8 30 87
YL 1.5 27 6
X67-6 X67-2
X76-1 BL 1.5 85 86 28 6
6 2 (S11) YL/RD 1.5
PLHT 8
X76-2 Af 1
SW4 (K10)
BK 1.5
X78-1 HEADLIGHT (X199 RELAY 29 4
RELAY 16 BANK)
PLHT 9 X67-3 SWITCH E2
X78-2
BN 1.5
RIGHT 30 4
3 X67-1
INDICATORS
YL/GY 1.5
RD 1.5
BK 1.5
X80-1 1 E1 E1
Figure 3
PLHT 10
X80-2
BK 1.5
CHAPTER 3
1.5
GN 9-IN
PL/ DIODE
WM-4
CCUJIL-X2
CCUJIL-W1 YL/BK 1.5
CB7-1
K11
PL/GN 1.5 WASH-1
WH/BK 1.5
X84-1
X21-1
X21-2
X20-2
X20-9
X20-11
X20-6
X20-7
X20-8
X20-4
X20-12
X20-1
PLHT 12 RELAY 17 (X199) 87a

X84-2 DIPS 30
87
BK 1.5
X86-1 E2
PLHT 14 2 1 0 J L R
X86-2
85 86
HORN
WASHER
DIPS
DIP/BRIGHTS
X88-1 BRIGHTS
WIPERS
INDICATORS
X112 - 2 X112 - 3
PLHT 15
RD 1.5
X88-2
GY/WH 1.5
X112 - 1
GY/WH 1.5
PLHT 16 X90-1 HEADLIGHT STEERING COLUMN SWITCH (S10)
X20-5
BK 1.5 X3 - 11
X20-3
X21-4
E1 LEFT WH/GY 1.5

X20-10
X90-2
BK 1.5
RD 1.5
87a
E2 30 (K12)
11 37 ACCP-12 BL 1.5 X3 - 10 87
X115 - 1 BK 1.5 (X199 RELAY
9 36 ECO31-18 BL 1.5 BANK) E1
HORN-1 GN/BK 1.5
MDUJ2-E
X115 - 2 X115 - 3 85 86
R11-87
WH/GY 1.5 RD 1.5 R11-87

12 35 X2-P BL 1.5 31 4
RELAY 18
WH/GY 1.5
HEADLIGHT 34 BRIGHTS 33 32
1 T CB4-1 X3-16 RD 1.5 RIGHT 4 4 5 700112-03CFM
57
872106
58
872106
1 3 6 3 (M2) WINDSCREEN 3 1 3
G N/BK 1.5
Ag 30 38 23 WIPER MOTOR 26 Aa 31 X156-A
Thermal H
Protection
OPTIONAL X156-B
CB7-1
SCS12-7
CCUJ3-J1
SCS12-1
SCS12-2
CB7-1
SCS4-4
X3 - 15
M ELECTRIC HORN BK 1.5
E3
2 1
PL/GN 1.5
RD/BL 1.5
OR 1.5
RD 1.5
YL/GY 1.5
1 2
Park
Earth
Ignition
2 4 1 X210 3 GN/BK 1.5 BK 1.5
X37-1 X37-2
E1
(K14) X23 - 2 RD 1.5 GN 1.5 X23 - 4

87a HORN
PK 1.5 X23 - 1 BL 1.5 BK 1.5 X23 - 3 SOLENOID
30 87
3 25 SCS12-6 PK 1.5 RD 1.5
V5 DIODE9 3A
85 86
PL 1.5
(F23)
V4 DIODE4 3A
BK 1.5
X146 - 2 X146 - 1 X144 - 8
PL 1.5
RELAY 10
E2 X195 (DIODE BANK)
REAR LEFT
INTERMITTANT
BK 1.5
(X200 RELAY
INDICATOR (LED)
BANK)
E4
(M3) (F24)
1
Figure 4
M X153 - 2 X153 - 1 X144 - 8
0
X155-1 X155-2
CHAPTER 3
3 29 SCS12-7 PL/GN 1.5 X3 - 7 REAR RIGHT

BK 1.5
INDICATOR (LED)
2 X73-2
E4 X73-6
BK 1.5
6
X144 - 4
X144 - 5
WINDSCREEN E3 1 8
(K3) WASHER PUMP
87a 0 3
30 87 1 X73-5 5
1 W CB5-1 RD 2.5 RD 2.5
X2 - J
X2 - K
X61-1 1
85 86 GN 1.5 X61-5 X50-B X50-A
GN/RD 1.5 BK 1.5 X74-1 10
5 E2
GN 1.5
BN 1.5
GN/BK 1.5
GN/BK 1.5
BK 1.5
INTERIOR
RD 1.5
RD 1.5
RD 1.5
RD 1.5
RD 1.5
RD 1.5
SWITCH 1
BN 1.5
YL 1.5
RELAY 11 LIGHT 1 SW7
BK 1.5
E2 LIGHTS/ACC INTERIOR HAZARD

LIGHT
GN/RD 1.5
CUT OUT SWITCH

(X197 RELAY
CB1-1
R16-87
FUSE3-1
R15-87
DIODE5-IN
CCUJ1A-D1
R 7-87a
AC U-S
AC CP-4
SW 16-5
R 17-86
R 18-86
R 15-87
X51-B X51-A (S12)
BANK) E1
BK 1.5 E2
44 43 42 41 34 33 21 22 B 9 20 40 39
INTERIOR
8 11 11 11 3 3 3 3 1 LIGHT 2 2 3 5 6
700112-04CFM
ISSUE 0
B25D & B30D 6X6
ISSUE
ISSUE 0
2 2 6 6 6 6 6 1 4
10 8 45 46 47 48 49 Aq 40
B25D & B30D 6X6
MENU
CB9-1
SW7-2
FUSE5-1
FUSE3-1
DISPLAY MENU
CCUJ3-A3
CCUJ3-K1
CCUJ1A-A1
CCUJ1A-A2
RES1-1
UNIT
(J1 & J2) BACK
RD 1.5
RD 1.5
GN 1.5
GN/BK 1.5
(H2))
NEXT
RD 1.5
RD 1.5
RD 1.5
RD 1.5
RD 1.5
SELECT
DIODE6 3A
DIODE5 3A
87a V7 V6
30 87
A B C D E F G H J K A B C D E F
X11
85
X12
86
BK 1.5 GN/YL 1.5
6 55 BPS-A X195(DIODE BANK)
(B23) (K17)
E2 (X201 RELAY BANK)
7 54 HTS-2 P
RELAY 6
X138-2 2 1 X138-1
6 53 CCUJ1L-P1 X2 - V RD/GY 1.5 X2 - A MDU/CCU POWER
RD 1.5
LOW ACC BRAKE X14 - 3

PRESSURE
WH/BL 1.5 X14 - 2
MDU
BK/YL 1.5
Figure 5
(B24) RD/BL 1.5 X14 - 1 PROGRAM
CHAPTER 3
P
X139-2 2 1 X139-1 E2 BK 1.5 X14 - 4
OR/BK 1.5 X2 - B
GN 1.0 MDU CAN - B 50 8
YL 1.0 MDU CAN - A 51 8
EMERGENCY
STEERING SHIELD MDU CAN - C 52 8
BK 1.5
E1
(B23)
P GN 1.5 FUSE9-1 15 2
X39-1 1 2
BK 1.5 WH/GY 1.5 SCS12-3 32 3
E1
3
GN/GY 1.5
X39-3
X22
INTER AXLE DIFF "+"
RD 1.5 1 B
LOCK PRESSURE (H1)
"-"
BK/RD 1.5 2 DOUBLE
"+"
3 BUZZER
"-" B
4
700112-05CFM
59
872106
60
872106
X5 X4 YL/GN 1.5 CS8-4 56 10

5 47 R6-87 RD 1.5
(J1A) (J3) RD 1.5 R6-87 46 5
5 48 R6-87 RD 1.5 OR/BL 1.5 CCUP-3 57 7
2 17 BATB-3 WH/RD 1.5 RD/BL 1.5 DIODE4-IN 38 4
8 79 R7-87 BK/WH 1.5 GY/YL 1.5 DIODE1-IN 58 12
BK 1.5 YL/RD 1.5 R16-86 19 3
E2
BK 1.5 BN/RD 1.5 R15-86 18 3
4 39 SW7-2 GN/BK 1.5 RD 1.5 R6-87 45 5
8 78 CCUCAN-A YL 1.0 YL/BN 1.5
8 77 CCUCAN-C SHIELD BK 1.5 RD 1.5 CB6-1 X 1

E2
8 76 CCUCAN-B GN 1.0 BK 1.5 PARK BRAKE
87a 0
SOLENOID
J2 K2 K3 A1 A3 C1 D1 H3 J1 J3 K1 G3
7 75 CCUP-2 WH/BN 1.5 BK/GN 1.5
30 87 X44-1 X44-2 (S6)
2 1
CCUP-1 BN/YL 1.5 BK 1.5 SW14
7 74 RD/BL 1.5 E2 1 E1
(B17) K7
85 86 (X198 RELAY 5 GEAR HOLD SWITCH
1 Am CB9-1 RD 1.5 BANK) (Y15)
BK 1.5
RELAY 13 X85-5 BK 1.5
8 73 EBSOL-1 RD/GN 1.5 E1
BIN POSITION 1 X85-1
C B A PARK BRAKE
7 72 CCUP-3 OR/BL 1.5 SENSOR
BK/BL 1.5
5 D2-V BK/YL 1.5
X150
53 X5
(J1L) BK/BL 1.5
7 71 PSEN-2 BK/YL 1.5
87a
14 70 ASP2-4 BL/WH 1.5 RD/OR 1.5 X2 - U X144-10 30
(S5) 87
BK 1.5
7 69 HYDTS-1 GN/WH 1.5 PL/GN 1.5 X2 - T X144-9 X145-3 3 4 X145-4 E1
BK/BL 1.5 85 86
Figure 6
7 68 FUELS-1 GY/WH 1.5 BK/GN 1.5 RD 1.5 CB6-1 Y 1
BK/BL 1.5 X145-1
CHAPTER 3
3 24 SCS4-2 BL/RD 1.5 GY/YL 1.5 X144-3 X2 - F

1 2 X145-2 (K8)
3 28 SCS12-11 YL/BK 1.5 GN/BL 1.5 (X198 RELAY
RELAY 14 BANK
GN/BL 1.5 BIN DOWN
BK 1.5
7 67 SW2-1 BL/GN 1.5
BIN UP GEAR HOLD
BL/GY 1.5
X144-7
SWITCH LATCH 2
3 27 SCS12-9 BN 1.5 BL/YL 1.5 E4 SOLENOID RD 1.5 CB6-1 Z 1
X35-1 1 X35-2
7 66 COL-B WH/BL 1.5 GN/BK 1.5 (Y14)
(B18)
10 65 CS8-8 OR/BK 1.5 P
W3 L1 X3 Y3 N1 M1 T1 M2 M3
E1 RD 1.5 CB9-1 Ak 1
X36-1 1 2
7 64 PSEN-1 OR/WH 1.5
R3 Y2 Y1 X2 X1 W1 T2 S3 R2 R1 P2 P1 K2 K1 J1 G3 F3 E3 E2 D3 D1 C2 C1 B3 A3 A2 A1
BK 1.5
X36-2
X144-11
3 87a P
X2 - L
OR/WH 1.5 CHASSIS 30 87 1 X142-1 X43-1 1 2 X43-2
YL/GN 1.5
GY/GN 1.5
PARK BRAKE GN/YL 1.5 X2 - G X2 - N YL/GN 1.5 BK 1.5
RESISTOR 1 CONTROL X142-2 2 E1
830 (R1) UNIT (A8) PRESSURE SWITCH 85 86 3
RD 1.5
(Y13)
BK/YL 1.5
(X195 DIODE BANK)

TANK VALVE
(S7) SOLENOID BIN UP (B16)
DIODE2-IN
PUBO-2
R6-87
ECO31-6
IDLSOL-1
HCS-1
D2-V
(X200 RELAY
E1 X45-2 BANK)
RELAY 4 PRESSURE SWITCH
BK 1.5 BIN FLOAT
2 1 X45-1
49 63 62 61 60 59 55
PARK BRAKE
5 12 7 9 8 7 5
LATCH SWITCH
700112-06CFM
ISSUE 0
B25D & B30D 6X6
ISSUE
ISSUE 0
CCUJ1A-F3 WH/BN 1.5 6 6
-
75
X
1
7
2
6 CCUJ1A-G3 RD/BL 1.5 59 62
-
74
X
1
7
1
6 CCUJ1A-K2 OR/BL 1.5
-
72 0
X
1
7
3
CCU
B25D & B30D 6X6
6 57 CCUJ3-J3 OR/BL 1.5 PROGRAM 1

2 FUSE5-1 RD 1.5
E1 X63-5
-
11 5
X
1
7
4
CCUJ1L-M1
CCUJ1L-L1
BK 1.5 X63-1
BL/GN 1.5 CCUJ1-X1
-
BK 1.5 67 6
X
1
7
5
E1 1
_ SW2 (S8)
BK 1.5
-
GY/YL 1.5
YL/GN 1.5
X
9
6
E3
C
X141-1 X141-2
E4 X99-2 X99-1 INTERAXLE LOCK
2 1
6 CCUJ1-Y1
-
WH/BL 1.5 BK 1.5 BK 1.5
-
-
-
66 SIG
X
3
2
X
9
6
X
2
X
3
4
B
H
1 2 E3
1 Au CB12-2 RD 1.5 +
-
X
9
6
A
(Y18)
HYDRAULIC PURGING UNIT
CUT SOLENOID BLOW OFF
-
BK 1.5
e
chs
tu
3D
C
A-
WH/BL 1.5
e
chs
tu
3D
E3
X97B X97A
B-
-
RD 1.5 BK 1.5 GY/WH 1.5 CCUJ1-S3
3
chs
68 6
tu
eD
3X
27
(B20)
LOW COOLANT (K22)
LEVEL SWITCH (B19)
FUEL SENDER
6 64 CCUJ1-R3 OR/WH 1.5
X164 30 87 X165 X163-1 M
RD/OR 2.5
X163-2
Figure 7
RD
CHAPTER 3
1.5
86 85
CONT
X41A X166 X167
BK 2.5 COOLER FAN
E3 (M11) X98-2 X98-1
AIR PRESSURE RD 2.5 CB12-2 Av 1
6 71 CCUJ1-P2 BK/YL 1.5 SENDER 0-10bar FAN
X41B (B15) SOLENOID
BK 2.5
OR/BL 1.5
PURGING UNIT
E3
6 CCUJ1L-R2 GN/WH 1.5
-
69
2X
X
12- 3X
RD 2.5
X143A
X161-2 X161-1
(B21) RD 2.5 CB12-2 At 1
CB12-2
ECO31-8
HYDRAULIC
5 54 X2-V BK/YL 1.5
BK 2.5
TEMPERATURE
X143B
FUEL FILTER
SENDER 40°C-120°C As 94 E3 ELEMENT
1 9
700112-07CFM
61
872106
62
872106
R3
79 CCUJ1A-B3 BK/WH 1.5
87 MR-8 BK/W H 1.5 120 OHM 3 WAY

DEUTSCH CAN
ADM12-1 BK/W H 1.5 TERMINATOR
86
X94 - A
X94 - C
X94 - B
85 CS8-5 BK/WH 1.5
44 R11-86 RD 1.5
CCU CAN
X18 - C SHIELD CCUJ1A-E2 77 6
BK/WH 2.5
87a X18 - B GN 1.0 CCUJ1A-E3 76 6
30 87
An CB9-1 RD 1.5 X18 - A YL 1.0 CCUJ1A-D3 78 6
X42-2 X42-1
85 86 1
BK 1.5
3 IGN-2 BK/GN 1.5 E1 2 ECU CAN
(Y12) X19 - C SHIELD ADM21-20 88 10
(K2)
RELAY 7 EXHAUST X19 - B GN 1.0 ADM21-21 89 10
START BRAKE X19 - A YL 1.0 ADM21-19 90 10
(X197 RELAY
RD/GN 1.5
SOLENOID
BANK)
RD/BL 1.5
SHIELD
YL 1.0
GN 1.0
TCU CAN
87a 87a SHIELD X95 - C
30 30
87
Al CB9-1 RD 1.5 X95 - B GN 1.0 TCU-7 91 9
87
85 86 85 86 X95 - A YL 1.0 TCU-25 92 9
Figure 8
BK 1.5 BK 1.5
E2 E2
CHAPTER 3
DIAG CAN
(K1) (K6)
RELAY 1 RELAY 5 X16 - C SHIELD X15
NEUTRAL EXHAUST X16 - B GN 1.0 D
(X197 RELAY BRAKE
BANK)
(X198 RELAY X16 - A YL 1.0 C
BANK)
MDU CAN G
X13 - C BL/GY 1.5 F

X13 - B GN 1.5 E
X38-1 X38-2
2
BN/RD 1.5
RD 1.5
RD/YL 1.5
RD/GN 1.5
GN/BL 1.5 BK 1.5 X13 - A PL 1.5 J
1 E1
OR 1.5 H
(Y16)
INTER AXLE RD 1.5 B
120 OHM 3 WAY DIAGNOSTIC
DIFF LOCK
CCUJ1L-N1
DEUTSCH CAN BK 1.5 A
ECO31-11
CB9-1
ADM15-6
CCUJ1A-K1
MDUJ1-A
MDUJ1-B
SHIELD
SOLENOID TERMINATOR
X93 - C
X93 - A
X93 - B
ECO31-12
FUSE10-1
MR-13
ADM12-2
FUSE5-1
E2
60 84 Ap 83 73 51 50 52 82 16 81 80 12
R4
6 9 1 10 6 5 5 5 9 2 10 10 2
700112-08CFM
ISSUE 0
B25D & B30D 6X6
63 ISSUE 0
Figure 9
X2
ZF-
K
N
(A4)
L
C
SHIFT SELECTOR
B
A
F
J
D
2
5
FUSE1-1 RD 1.5 X6-1 ZF-X3-1

H
12
R2-86 WH/RD 1.5 X6-10 ZF-X3-10

E
R1-86 BN/RD 1.5 X6-11 ZF-X3-11

G
SW4-6 BL 1.5 X6-18 ZF-X3-18

93 84 36
28 50 42 41 21
P
2
6
FUSE1-1 RD 1.5 X6-4 ZF-X3-4

45
X6-17 ZF-X3-17
X6
BN/BL 1.5 X6-16 ZF-X3-16

ZF-
X18/19-20
2
7
FUSE2-1 GN 1.5 X6-2 ZF-X3-2 X18/19-6

56 23
X18/19-19
X18/19-24
GN 1.5 X6-3 ZF-X3-3
30 29 54 9
X18/19-22
6
CCUJ1L-N1 GN/BL 1.5 X6-6 ZF-X3-6
68 64
5
X18/19-11
8
DIAG-F BL/GY 1.5 X6-12 ZF-X3-12 X18/19-12
61 82
X18/19-13
1
X6-30 ZF-X3-30
X18/19-9
X6-31 ZF-X3-31
X18/19-10
GE2
X18/19-2
BK 1.5
(A5)
BR2
X18/19-17
E2
ZF-X1 - TCU
X18/19-18
RT1
X18/19-1
X6-5 ZF-X3-5 BL1
X18/19-15
X6-7 ZF-X3-7 X18/19-4
7
F-SOL-85 OR/BL 1.5 X6-8 ZF-X3-8 X18/19-14
94
X18/19-8
4 10 11 57 16 34 49 62 2 27 58 51
X6-9 ZF-X3-9
TRANSMISSION VALVE BODY
X6-15 ZF-X3-15
43 67 13 53 59
6 19 24 22 11 12 13 9 10 2 17 18 1 15 4 14 8 20 21
X6-13 ZF-X3-13
X6-14 ZF-X3-14
E2
X8
ZF-
(Y10)
X18/19-31
2
46 6
X18/19-30
(Y11)
SOLENOID
RETARDER
X7
ZF-
8
TCU CAN-A YL 1.0
1
25
3
X18/19-28
8
2
7
TCU CAN-B GN 1.0
TEMP
92 91
(B11)
TRANS
26
ZF-
X18/19-29
X14
2
4
(A7)
18
60
15
3
24 61 33
LEVER
RETARDER
X18/19-21
ZF-X26-2
ZF-X26-4
DIAG2
ZF-X25-1
ZF-X25-2
ZF-X25-3
DIAG1
ZF-X25-4
ZF-X25-5
700112-09CFM
872106 CHAPTER 3 B25D & B30D 6X6
ISSUE
64
872106
8 8 8
88 89 90 GN 1.5 FUSE8-1 14 2
X119-2 X119-1 X118-1 X118-2
1
BK 2.5 BK 2.5 +
E3 2 E3 X7
(6)
6
t PL 0.35 X25 - 6 21-1
(4)
(Y2) 4
COLD GN 0.35 X25 - 4 YL 1.0 21-19
PWM
GY/WH 2.5
GY/BK 2.5
START 3
_
COLD START
(3)
WH 0.35 X25 - 3 GN 1.0 21-21
TEMP SENDER SOLENOID 5
+
RD 0.35 X25 - 5 SHIELD 21-20
(5)
2
X1 - X
X1 - Y
(2)
YL 0.35 X25 - 2 BK/YL 1.5 21-14
PWM
1
BN 0.35 X25 - 1 BL/GN 1.5 21-13
_
(1)
(B10)
BL/YL 1.5 21-12
(A1)
P1 - 5
P1 - 4
PWM - BK 1.5 21-3
X27 ACCELERATOR E2
7 PEDAL RD 1.5 21-2
6 (A2) X9
X106 BL/RD 1.5 15-5
3 BK 2.5
E2 MR-1 X3 - 14 YL/GN 1.0 15-13
2
Fuel MR-3 X3 - 13 BK 1.0
8 Temp
Sender MR-4 X3 - 24 BL 1.0 15-14
5 Cool.
Temp MR-2 X3 - 25 BN 1.0 15-15
4 Sender
Oil MR-9 BK 2.5 15-6

E3
Figure 10
1 Temp
Sender
CHAPTER 3
MR-11 X8
X28 Oil 18-2
4 Press MR-15 X3 - 5 RD 1.5
E1 (A3)
Sender BK 1.5 18-9
3 Air GN 2.5
Temp X10 ADM -
FLAME START 2 Sender MR-6 GN 2.5 MERCEDES
12-1
CONTROL Air ENGINE
X91 - 3
MODULE 1 Press MR-8 X3 - 6 BK/WH 1.5 12-2
Sender CONTROL UNIT
Oil MR-12 BK/WH 1.5
Level
Sender MR-13 X3 - 28 PL 1.5
X1 - W
Top Dead OR 1.5 DIAG-H 80 8
Centre
Position Sub. BK/WH 1.5 R7-87 86 8
RD 2.5
RD 2.5
BK/WH 1.5
YL/GN 1.5
Sensor Pump
RD/YL 1.5 R5-86 83 8
Position Sub.
(R7) Indicator MR - Pump
RD 1.5 87a
BL/WH 2.5
ENGINE ECU BK 1.5
Sub. 30 E2
CB8-1
CB8-1
R7-87
CCUJ1L-Y2 OR/BK 1.5
CCUJ3-G3
Pump 87
DIAG-J
START-K150
R7-87
MCB1-2
X117 RD 1.5 RD 1.5 FUSE6-1 13 2

Sub.
Pump 85 86 RELAY 12 K16
GLOW PLUG BK 1.5 (X200 RELAY BANK)
RD 1.5 ADM / MR
Ah Aj 56 85 65 4 Outputs for Air 81 2 87 Aw E2
Motor Motor
VTG Waste Gate, SUPPLY
Start Stop
Hydraulic Exhaust
1 1 6 8 6 8 1 8 1
Brake Solenoid
700112-10CFM
ISSUE 0
B25D & B30D 6X6
ISSUE
ISSUE 0
4
AIRCON CONTROL PANEL 42 RESISTOR

2 WAY
M L 24V
X65-5
SW3 RD/OR 1.5 A
(S16) 1.2 3.5
B25D & B30D 6X6
AIRCON B THERMOFUSE
SWITCH 5 (R11)
0 1
(B31)
FAN/BLOWER
P BINARY (M4)
1 SWITCH 87a
30
YL/GN 1.5
87
X160 - B X160 - A
X65-1
(R10) 85 86
HEATER
VALVE POT CW
X29
YL/GN 1.5
A (U1)
X30 - 1 WH 1.5
2 WAY RELAY 1
CCW C
X30 - 2 WH/GN 1.5 1 24VDC 24V (K21)
F
2
X30 - 3 BK 1.5 DC - DC HEAT VALVE
MOTOR SPEED (S18) H
CONVERTER ACTUATOR
X30 - 4 RD 1.5 1 12VDC
SWITCH 0 (OFF)
2 10 (M5)
J GND
1(L) X30 - 5 RD/BK 1.5
C
2 (M) K 8
X30 - 6 RD/BL 1.5
3 (H) B 7
L
X30 - 7 RD/GN 1.5
M
MODE (S19) X30 - 8 RD/GY 1.5 FEET
SWITCH 0(OFF) N ACTUATOR
X30 - 9 RD/BN 1.5
1(L) 10 (M8)
C P
Figure 11
2 (M) X30 - 10 RD/YL 1.5
CHAPTER 3
3 (H) R 8
B X30 - 11 BK 1.5
E1 (A11)
12 WAY 6 WAY 7
S
X30 - 12 1 I1 01 1
T 2 I2 02 2
YL/BL 1.5 3 I3 03 3 MID/DEMIST
SW16 (S17) 4 I4 04 4
X89-1 U ACTUATOR
RECIRC 5 I5 05 5
RD 1.5
SWITCH 1 6 I6 06 6 10 (M7)
V
7 I7 07
(Y20) W 8 I8 08 8
0 1 9 I9
5 X 10 I10 RELAY 7
X89-5
11 I11 BOARD
B 12 I12
RD/WH 1.5
REC. AIR
X103
D ACTUATOR
X3 - 12 (B32) (M6)
RD 1.5
BL 1.5
E THERMO 10
t
SWITCH 8
G
R11-87
SW4-6
R11-87
7
AIRCON COMPRESSOR
CLUTCH SOLENOID
41 37 43
4 3 4
700112-11CFM
65
872106
66
872106
WH/RD 1.5 BACK UP

BK/RD 1.5 X151B ALARM
(H3)
B
BK 1.5
X151A
E4
BK 1.5 X144-8
X147-C BL 1.5 X147-A X144-8
3 35 SW4-6 X2 - P BL 1.5 X144-6

(E20) E4
X152-C LEFT
BRAKE / PARK LIGHTS
E4
X147-B WH/RD 1.5 X149-1 X149-2 BK 1.5 X144-8
X144-2 (E32)
X152-B BK/RD 1.5 RIGHT REVERSE LIGHT
E4
BK 1.5
WH/RD 1.5 X148-1 X148-2 BK 1.5 X144-8
BK/RD 1.5
BL 1.5 X152-A X144-8 (E31)
LEFT REVERSE LIGHT
E4
RIGHT
X144-1
BRAKE / PARK LIGHTS
X2 - E
Figure 12
87a (B28)
CHAPTER 3
X195(DIODE BANK)
P
30 87
X2 - C
X154-A
(V2) GY/GN 1.5 X3 - 17 X3 - 18
1 2 X154-B
85 86
GY/BL 1.5
STOP LIGHT 87a
GY/BL 1.5 DIODE 2 WH/RD 1.5 X54 - 1 X54 - 2 BK 1.5
SWITCH
BK 1.5
(K5) 30 87
RELAY 3 (E30) E2
STOP LIGHT GY/GN 1.5 85 86 ARTIC REVERSE LIGHT
(X198 RELAY BANK) BK 1.5
GN 1.5
E2
DIODE 1
(V1) E2
RELAY 2
RD 1.5
GY/YL 1.5
GY/GN 1.5
BN X213-A (K4)
WH/RD 1.5
GN 1.5
+ REVERSE
GN 1.5
BK X213-B (X197 RELAY
sig BANK)
BL X213-C
gnd
CB1-1
CB4-1
CCUJ3-H3
CB1-1
CCUJ1L-W3
ECO31-10
PROXIMITY E3
SWITCH
C 58 63 F S 93
1 6 6 1 1 9
700112-12_ACFM
ISSUE 0
B25D & B30D 6X6
ISSUE
ISSUE 0
(R12)
E2
RD/GY 1.5 X48 - 2 GN 1.0 WH 1.0 X48 - 1 BK 1.5
B25D & B30D 6X6
LEFT MIRROR
DEMISTER
BL 1.0 RD 1.5 CB7-1 Ac 1

(M9)
E1
X46 - 1
1 _
BK 1.5 BK 1.5
X46 - 2 RD 1.5
2 +
M
BK 1.0 L R
UP
DOWN
MIRROR SERVO 0
RD 1.5
1
M X77-5 5
X77-1
SW 9 (S20)
SUPPLY
SUPPLY
SUPPLY
MIRROR SERVO MIRROR

SUPPLY
DEMISTER L R (S21)
LEFT MIRROR SWITCH L R
Figure 13
SW 13
CHAPTER 3
MIRROR
SWITCH
X48 - 5 GN/BL 1.5 X46 - 3 GN/BL 1.5
3 COMMON
X48 - 4 OR/GN 1.5 X46 - 8 OR/GN 1.5
8 LEFT HORIZONTAL
X47 - 4 OR/BN 1.5 X46 - 6 OR/BN 1.5
6 RIGHT HORIZONTAL
M BL 1.0
BN 1.0 X48 - 3 YL/GN 1.5 X46 - 5 YL/GN 1.5
5 LEFT VERTICAL
7 RIGHT VERTICAL
YL 1.0 X47 - 3 GN/YL 1.5 X46 - 7 GN/YL 1.5
X 47 - 5 GN/BL 1.5
MIRROR SERVO UP
DOWN
M
RD 1.5 CB7-1 Ae 1
MIRROR SERVO (R13) E2

RD/GY 1.5 X47 - 2 GN 1.0 WH 1.0 X47 - 1 BK 1.5
RIGHT MIRROR
RIGHT MIRROR
DEMISTER
BK 1.0
700112-13CFM
67
872106
68
872106
70
0 X205 - 1 PK/GY 1.5 X2 - D PK/BL 1.5 X209 - 1

ARTIC ARTIC
1 X52 - 1 X52 - 2 BK 1.5
E2 SPARE X205 - 2 PK/BK 1.5 X2 - O PK/BK 1.5 X209 - 2 SPARE
X79-5 WORKLIGHT 2 PLUG PLUG 2
5 X205 - 3 PK/BL 1.5 X2 - Q PK/BL 1.5 X209 - 3
CCUL1L-R1
1 U CB4-1 RD 1.5
RD/WH 1.5 X53 - 1 X53 - 2 BK 1.5 BL/WH 1.5 X2 - W BL/WH 1.5 X209 - 4
1 X79-1 E2
WORKLIGHT 1
SWITCH 10
WORK
LIGHTS
ENGINE X159 - 1 OR/WH 1.5 X3 - 19 OR/WH 1.5 X208 - 1 ENGINE
SPARE SPARE
PLUG X159 - 2 OR/GN 1.5 X3 - 20 OR/GN 1.5 X208 - 2 PLUG 2
SWITCH
5
1 Ad CB7-1 RD 1.5 X34 - 1
1 M
X207 - 1 PL/WH 1.5 X157 - 1
E1
X207 - 2 PL/GN 1.5 X157 - 2
BK 1.5 X34 - 2 SPARE ROOF
PLUG 1 X207 - 3 PL/RD 1.5 X157 - 3 SPARE
JD PNEUMATIC X207 - 4 PL/YL 1.5 X157 - 4
SEAT PUMP
Figure 14
CHAPTER 3
87a
X83-1 1
0 30 87
X158 - 1 WH/BN 1.5 X206 - 1 GN/BL 1.5
X83-2 5
1 X158 - 4 WH/YL 1.5 85 86 X206 - 2 GN/RD 1.5
SPARE SPARE
X83-3 6
X71-5 5 (RELAY) PLUG 2
E2 X158 - 3 WH/RD 1.5 X206 - 3 GN/WH 1.5
1 V CB4-1 RD 1.5 X49-2 X49-1
X83-4 7
OR/WH 1.5 M BK 1.5 X158 - 2 WH/GN 1.5 X206 - 4 GN/YL 1.5
1 X71-1 RELAY 20
SPARE
K19
SWITCH 6 (X201 RELAY BANK)
SW12
FLASHING
FLASHING SPARE
BEACON
BEACON LIGHT
700112-14CFM
ISSUE 0
B25D & B30D 6X6
B25D & B30D 6X6 CHAPTER 3 872106

SECTION 2. SYSTEMS AND SUB-SYSTEM THEORY OF OPERATION AND
DIAGNOSTICS
STARTING AND CHARGING CIRCUIT

When the CCU (A8; Figure 6) receives current at
THEORY OF OPERATION
terminal B3 of connector X5A, the CCU sends
The tachometer on the Menu Display Unit is current out terminal M1 of CCU connector X5B to
accurate enough for test work. (See Operators hydraulic cut-off solenoid (Y18; Figure 7),
Manual CHAPTER 2 for more information and energizing the solenoid.
CHAPTER 8 for detail operating the Menu
With hydraulic cut-off solenoid (Y18; Figure 7)
Display Unit).
energized, the hydraulic pump is destroked, which
allows the engine to crank easier.
Starting Circuit
When key switch (S1; Figure 1) is turned to the ON The start signal at terminal B3 of connector X5A
position, ignition solenoid is activated and power also causes the CCU to apply the park brake.
becomes available at terminal 30 of neutral start
NOTE:1. For information on operation of the
relay (K1; Figure 8).
hydraulic pump and the load sensing
At the same time, current flows across the circuit, See “Main Hydraulic Pump
normally closed contact of start relay (K2; Figure Operation” on page 204.
8) to the coil of headlight and A/C cutout relay (K3; 2. For more information on the park
Figure 4), energizing the relay. brake, See “Park Brake Circuit” on
page 81 and “Exhaust Brake Circuit”
With relay (K3; Figure 4) energized, current is on page 82.
allowed to flow to the headlight and air
conditioning circuits, allowing these circuits to During engine cranking, current flow to headlight
function as needed. and A/C cutout relay (K3; Figure 4) is interrupted,
thus de-energizing the relay.
With the transmission shift selector (A4; Figure 9)
in the neutral position, this will allow current to flow With relay (K3; Figure 4) de-energized, current to
out terminal F of the transmission shift selector the headlight and air conditioning circuits is
connector ZF-X2 to the coil of neutral start relay interrupted, deactivating these systems (if
(K1; Figure 8), energizing the relay. activated).
With relay (K1; Figure 8) energized, power is now Deactivating the headlights and the air
available at the coil of start relay (K2; Figure 8). conditioning reduces the cranking load on the
Turning key switch (S1; Figure 1) to the START engine during start-up.
position provides a ground to the coil of start relay
(K2; Figure 8), energizing the relay. An optional ether injection system is available to
assist engine starts in cold weather.
With relay (K2; Figure 8) energized, current flows
to the starter solenoid of starter motor (M1; Figure Charging Circuit
1), energizing the starter solenoid, causing the
Alternator (G2; Figure 1) provides power to all
starter motor to crank the engine.
machine circuits and charges the batteries when
Current from start relay (K2; Figure 8) also flows to the engine is running. Terminal B+ of the
the engine control unit (ECU) (A3; Figure 10) and alternator is connected to battery positive (+) at all
chassis control unit (CCU) (A8; Figure 6) to signal times.
these controllers that the engine is being started.
When key switch (S1; Figure 1) is in the “ON”
NOTE:For more information on the ECU, position, current from circuit breaker (F3; Figure 1)
see “Engine Control Unit Circuit is sent to terminal D+ on the alternator to excite the
Theory Of Operation” on page 72. alternator field windings.
ISSUE 0 69
872106 CHAPTER 3 B25D & B30D 6X6
Alternator excitation diode (V3; Figure 2) prevents During a flame start, glow plug (R7; Figure 10) will
current feedback from the alternator if the become hot and the flame start light will lit for
alternator circuitry is improperly connected or has approximately 20 seconds then go OFF, signalling
a major failure. the engine is ready to be cranked.
The battery charge light on the MDU will come ON During cranking, current from start relay (K2;
if any of the following occur: Figure 8) flows to terminal 5 of connector X27 to let
Flame Start Control Module (A1; Figure 10) know
• Key Switch (S1; Figure 1) is in the “ON” that the engine is being cranked. During this time,
position with engine speed less than 400 Flame Start Control Module (A1; Figure 10) sends
r.p.m. current to flame start solenoid (Y2; Figure 10) to
• Alternator (G2; Figure 1) has malfunctioned. allow a small amount of fuel to be sprayed over the
• Alternator output less than 25.5 volts or more hot glow plug, this producing a flame in the
than 29.5 volts. combustion chamber located in the intake
• Difference between single battery voltage and manifold.
1/2 system voltage is more than 1.5 volts.
(See “Battery Balancer And 12-Volt The flame pre-heats the air evenly for all cylinders,
Accessory Circuit Theory of Operation” on which helps reduce fuel consumption during
page 88). warm-up. This process of glow plug heating and
fuel spray will continue until the engine reaches a
During normal machine operation, system voltage
temperature of 23° C (73° F), then the flame start
is shown on the menu display.
system will deactivate automatically.
NOTE:The battery charge status is digitally
The flame start system will also deactivate if the
displayed in the menu structure of the
engine cranking begins before the FLAME START
MDU, when accessed. For more
light goes OFF, or if the engine is not stared within
information on the menu structure, See
30 seconds after the flame start light goes OFF. To
CHAPTER 8 in Operator’s Manual.
let the flame start module know the engine is
running, the CCU sends a signal out G3 of
Flame Start Theory Of Operation connector X4 to terminal 4 of flame start module
connector X27.
When the key switch is turned to the “ON” position,
power from flame start circuit breaker (F8; Figure
1) is provided at terminal 1 of connector X27 and
Electronic Unit Injector Controller
terminal 4 of connector X28 on Flame Start Circuit Theory Of Operation
Control Module (A1; Figure 10). The Flame Start The electronic unit injector (EUI) controller (A2;
Control Module (A1; Figure 10) will send a signal Figure 10) receives unswitched battery power at
out terminal 8 of connector X27 to terminal Y2 of terminals 5 and 6 of connector X106.
connector X5B on CCU (A8; Figure 6).
Switched power from the ECU/EUI power relay
The CCU will then send the signal through the
fuse (F16; Figure 2) is provided at terminal 15 of
CAN data line to menu display unit (MDU) (H2;
connector X106.
Figure 5), which will cause the FLAME START
light to come ON. The EUI controller constantly analyses all relevant
engine data (start of injection, load on engine,
If the ambient air temperature is below 15°C
ambient conditions, etc.) from the engine sensors
(59°F) the flame start system will remain ON for
and data from the engine control unit (ECU), (e.g.,
approximately 20 seconds.
accelerator pedal position). For information on the
ECU, See “Engine Control Unit Circuit Theory
If the ambient air temperature is above 15° C
Of Operation” on page 72.
(59°F), the flame start light will go OFF after 2
seconds.
NOTE:The flame start status is displayed in

the menu structure of the MDU, when
accessed. For more information, See
CHAPTER 8 in the OMM.
70 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
The data is stored in the EUI controller and The camshaft and crankshaft position sensors
compared with the controller’s pre-programmed allow the EUI controller to precisely determine
software. The controller then computes the piston position in relation to TDC so that the EUI
quantity of fuel needed (delivery angle) and the controller can command the correct EUI solenoid
optimal injection time (start of delivery), then at the correct time. The EUI controller then
actuates each injector solenoid of the individual controls the fuel delivery by energizing and de-
cylinders accordingly. For more information on energizing the individual solenoids that open and
how the Electronic Unit Injectors Function, See close the EUI spill valves.
CHAPTER 2, SECTION 1.
Temperature Sensors
The EUI controller limits the torque request if the
governed speed or a specific engine limit is All engine related temperature sensors used on
reached. the B25D and B30D ADT’s have a negative
temperature coefficient (i,e., sensor resistance
The EUI controller has to detect the following decreases as temperature increases).
variables in order to calculate proper start of
delivery: The EUI controller sends a low reference voltage
to the sensor, monitors the voltage drop across the
• Engine Speed. sensor, then compares the voltage drop to pre-
• Specified Torque. programmed values in the EUI controller memory
• Engine coolant temperature. to determine the temperature.
• Intake manifold air temperature (MAT).
•
•
Intake manifold air pressure (MAP).
Atmospheric pressure. n WARNING
• Top dead centre (TDC) of cylinder #1. Do not apply battery voltage to any of the en-
• Start signal to starter solenoid. gine temperature sensors. Damage to the
sensor will occur.
Engine Speed and TDC
Engine crankshaft position sensor (B9) is the
primary sensor for detecting engine speed. It is Engine Coolant Temperature Sensor
also used as a backup for detecting top dead The EUI controller monitors the signal from engine
centre (TDC) of cylinder #1 should engine coolant temperature sensor (B2) for:
camshaft position sensor (B8) malfunction.
• Engine protection purposes.
To detect engine speed, 36 holes have been • Starting fuel quantity determination (The EUI
machined into the outer edge of the flywheel at 10 controller will adjust the amount of fuel
degree intervals. A 37th hole, located 65 degrees delivered during start-up based on initial
before top dead centre, is used for the detection of engine coolant temperature).
TDC. • Start of fuel delivery determination (The EUI
controller will adjust the timing of fuel delivered
Engine camshaft position sensor (B8) is the during start-up based on initial engine coolant
primary sensor for TDC of cylinder #1. It is also temperature).
used as backup for detecting engine speed should • Specified torque calculation (Limits engine
the engine crankshaft position sensor (B9) output).
Malfunction.
The EUI controller also sends the engine coolant
To detect the engine speed, 12 holes has been temperature information to the engine control unit
machined into the outer edge of the camshaft gear (ECU).
at 30-degree intervals. A 13th hole, located 55
degrees before TDC, is for detecting the TDC. The ECU transmits the information through the
CAN data line to the MDU where the information is
displayed on the COOLANT TEMP. gauge.
ISSUE 0 71
872106 CHAPTER 3 B25D & B30D 6X6
NOTE:1. For more information on the Engine Oil Pressure Sensor

COOLANT TEMP. gauge and the
The EUI controller monitors the signal from engine
MDU, See “Menu Display Unit Circuit
oil pressure sensor (B5) and passes the
Theory Of Operation” on page 83.
information to the engine control unit (ECU).
2. The engine coolant temperature
status is digitally displayed in the The ECU sends the information through the CAN
menu structure of the MDU, when data line to the Menu Display Unit where the
accessed. For more information on information is displayed on the Engine Oil
the Menu Display Unit Menu Pressure Gauge.
Function, See CHAPTER 8 in
Operator’s & Maintenance Manual. When engine oil pressure becomes less than a
predetermined low pressure setting, the red
Engine Oil Temperature Sensor: Service light will flash and an audible alarm will
The EUI controller monitors the signal from engine sound.
oil temperature sensor (B7). The sensor varies
voltage with respect to temperature change as NOTE:For more information on the Engine
follows: Oil Pressure gauge and low oil
pressure alarm, See “Menu Display
Oil Temperature @ 130° C (266° F)- - - - - - - 0,41 volts Unit Circuit Theory Of Operation” on
page 83. The engine oil pressure
Oil Temperature @ 115° C (239° F) - - - - - - - 0,56 volts
status is digitally displayed in the
Oil Temperature @ 90° C (194° F) - - - - - - - 0,97 volts menu structure of the MDU, when
Oil Temperature @ 70° C (158° F) - - - - - - - 1,50 volts accessed. For more information on
Oil Temperature @ 10° C (50° F) - - - - - - - - 3,96 volts the menu structure, See CHAPTER 8
of the Operator’s & Maintenance
Oil Temperature @ -5° C (23° F) - - - - - - - - - 4.41 volts
Manual.
Oil Temperature @ -20° C (4° F) - - - - - - - - - 4,71 volts
Oil Temperature @ -40° C (-40° F) - - - - - - - 4.90 volts Switches
Manifold Air Temperature (Mat) Sensor Engine remote stop switch (S4), located at the
right side of the engine, has a direct connection to
The MAT sensor is an integral part of the intake
the EUI controller for remote engine shut-down.
manifold air pressure/temperature sensor (B6).
Engine remote start switch (S3), located next to
The EUI controller monitors the intake manifold air
the stop switch, is disabled and has no function.
temperature in conjunction with the manifold air
pressure to determine air density, then adjust the
Engine Control Unit Circuit Theory Of
fuel delivery accordingly.
Operation
Pressure Sensors When the key switch is in the ON position, power
Manifold Air Temperature (MAP) Sensor for ECU (A3; Figure 10) comes from ECU/EUI
power relay fuse (F16; Figure 2). The ECU stores
The MAP sensor is an integral part of the intake vehicle specific data for operation of the engine
manifold air pressure/temperature sensor (B6). and any engine related service codes.
The EUI controller monitors the intake manifold air It constantly monitors data from the EUI controller,
pressure in conjunction with the manifold air the accelerator pedal position sensor and the start
temperature to determine air density, then adjust circuit. For information on the start circuit, See
the fuel delivery accordingly. “STARTING AND CHARGING CIRCUIT
THEORY OF OPERATION” on page 69.
The EUI controller compares the MAP sensor data
with data from an atmospheric pressure sensor The ECU transmits any engine service codes that
located inside the EUI controller. may occur through the CAN data line to the MDU,
causing the engine service light to come ON and
The comparing of manifold pressure with the service code to be displayed.
atmospheric pressure is used for diagnostics
purposes and to protect the engine when
operating at full throttle above certain altitudes.
72 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
NOTE:1. To diagnose service codes, See In the event of an overspeed condition or when
“Service Code Diagnostics -Engine engine speed is above 800r.p.m., the torque
Control Unit” on page 94. convertor is locked up and the accelerator pedal
2. The ECU status is digitally position is less than 10%, the ECU will send
displayed in the menu structure of current to the coil of exhaust brake relay (K6;
the MDU, when accessed. For More Figure 8), energizing the relay and activating the
information on the MDU menu engine exhaust brake. (For more information on
functions - See CHAPTER 8 of the the engine exhaust brake, See “Park Brake And
Operator’s & Maintenance Manual. Exhaust Brake Circuit Theory Of Operation” on
page 81).
The engine speed is controlled automatically.
There is no mechanical link between the engine Transmission Control Unit And
and the accelerator pedal. Accelerator pedal Retarder Circuit Theory Of Operation
position sensor (B10; Figure 10) communicates
accelerator position to the ECU using pulse width Transmission Control Unit
modulation (PWM). Transmission control unit (TCU) (A5; Figure 9)
receives unswitched battery power from TCU and
The ECU receives the PWM signal and compares
diagnostic fuse (F12) at terminals 23 and 68 of
it to pre-programmed limit values. It then passes a
connector ZF-X1.
torque request through the CAN data line to the
EUI controller. The EUI controller processes the When the key switch is in the ON position, power
information along with data from the other engine from transmission shift control, retarder control
inputs to control the EUI solenoid accordingly. For fuse (F11) is provided to terminal 45 of TCU
information on the EUI controller, (See connector ZF-X1, terminal 1 of retarder controller
“Electronic Unit Injector Controller Circuit (A7; Figure 9), and terminal P of transmission shift
Theory Of Operation” on page 70). control (A4; Figure 9).
Engine slow idle and fast idle speeds are pre- The TCU receives and processes information
programmed into the ECU. When at the maximum defining:
speed, the ECU requests only the torque which is
necessary for maintaining the speed even if the • Shift Selector Position (direction of travel and
accelerator is at the full throttle position. drive range).
• Accelerator Pedal Position.
Whenever the ECU or the accelerator pedal • Engine Speed and Load.
position sensor is replaced, it may be necessary to • Turbine Speed.
calibrate the accelerator pedal position. • Transmission Output Speed.
• Transmission Sump Temperature.
An acceptable margin of error between pedal
• Retarder Oil Temperature.
movement relative to percentage read-out on the
• Percentage of Retardation.
MDU will differ from operator to operator. Because
• Range Hold.
of this, the need for re-calibration will be
determined by operator preference. The TCU uses this information to control the
transmission solenoids and valves, supply system
To program the ECU, a special diagnostic tool status, and provide diagnostic information such as
(The Mini Diag II Version B) is required. The Mini service codes.
Diag II is capable of reading and deleting engine
related service codes and calibrating accelerator
pedal position.
The Mini Diag II can be acquired from BELL

EQUIPMENT Part No. 280479. Follow the
instructions that come with the diagnostic tool.
ISSUE 0 73
872106 CHAPTER 3 B25D & B30D 6X6
NOTE:1. The engine control unit (ECU) R (Reverse)

sends the accelerator pedal position
and engine speed data through the • When the transmission shift control lever is in
CAN data line to the TCU. the REVERSE position and the key switch is in
2. For information on the ECU and the ON position, current flows out terminals A
related components, see “Engine and E of connector ZF-X2 to the TCU at
Control Unit Circuit Theory Of terminals 21 and 41 (respectively) of
Operation” on page 72). connector (ZF-X1).
3. The chassis control unit (CCU) When these two signals are received at the
sends range hold information and same time, the TCU knows that reverse mode
service brake information through is requested. In this mode, the TCU activates
the CAN data line to the TCU. For solenoids [Y5 (clutch C) and Y2 (clutch F)].
information on how the range hold • When the transmission shift control lever is in
circuit functions, see “Bin Control the REVERSE position and the key switch is in
And Range Hold Circuit Theory Of the ON position, current flows out terminal H of
Operation” on page 79. connector (ZF-X2) to the coil of backup relay
(K4; Figure 12), energizing the relay.
Transmission solenoids (Y1 - Y8) activate the With the backup relay energized, the backup
transmission clutches. The TCU energizes two of alarm and lights are activated. For more
these solenoids at a time depending on the range information of the backup alarm and light
selected. For shift modulation, the TCU uses pulse circuit, See “Backup Alarm and Backup
width modulation (PWM) which varies the duty Light Circuit Theory of Operation” on
cycle (ON time) to throttle pressure solenoid (Y9). page 86.
D (Drive)
The transmission shift control (A4; Figure 9)
interfaces with the TCU to provide the following • When the transmission shift control lever is in
functions: the DRIVE position and the key switch is in the
ON position, current flows out terminals A and
N (Neutral)
D of connector (ZF-X2) to the TCU at terminals
• When the transmission shift control lever is in 21 and 50 (respectively) of connector (ZF-X1).
the NEUTRAL position and the key switch is in When these two signals are received at the
the ON or START position, current flows out same time, the TCU knows that drive mode is
terminal F of connector ZF-X2 to the coil of requested.
neutral start relay (K1; Figure 8), energizing In drive mode, the transmission starts in first
the relay. range and automatically shifts through all six
This allows the engine to be started only when ranges.
the transmission shift control is in the - 1st range = solenoids [Y7 (clutch A) and Y1
NEUTRAL position. (clutch G)] energized.
For more information of the start circuit, see - 2nd range = solenoids [Y7 (clutch A) and Y2
Starting and Charging Circuit Theory of (clutch F)] energized.
Operation (this group). - 3rd range = solenoids [Y7 (clutch A) and Y3
• When the transmission shift control lever is in (clutch E)] energized.
the NEUTRAL position and engine speed is - 4th range = solenoids [Y7 (clutch A) and Y4
more than 1100 rpm, the TCU sends current (clutch D)] energized.
out terminal 56 of connector (ZF-X1) to the - 5th range = solenoids [Y7 (clutch A) and Y6
transmission shift control at terminal L of (clutch B)] energized.
connector ZF-X2. - 6th range = solenoids [Y6 (clutch B) and Y4
This current causes a solenoid (located inside (clutch D)] energized.
the transmission shift control) to energize,
locking the shift control lever in the NEUTRAL
position.
• When the transmission shift control lever is in
the NEUTRAL position, there are no signals
sent from the transmission shift control to the
TCU - all transmission clutch solenoids are de-
energized.
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B25D & B30D 6X6 CHAPTER 3 872106
• 3 (Drive-3)
- When the transmission shift control lever is in When the service brakes are not applied, the
the DRIVE-3 position and key switch is in the amount of retardation is controlled only by retarder
ON position, current flows out terminals A, B controller (A7; Figure 9).
and D of connector (ZF-X2) to the TCU at
The retarder control lever has seven positions, 0
terminals 21, 42, and 50 (respectively) of
through 6.
connector (ZF-X1).
When these three signals are received at the
When the control lever is at position 0, the retarder
same time, the TCU knows that DRIVE-3
controller sends 0.70 ± 0.05 volts to terminal 61 of
mode is requested.
TCU connector (ZF-X1). When this level of voltage
In DRIVE-3 mode, the transmission starts in
is received at terminal 61, the TCU knows not to
first range and automatically shifts through the
send current to retarder on solenoid (Y10; Figure
first three ranges, but is limited to the third
9) and retarder proportional solenoid (Y11; Figure
range.
9).
• 2 (Drive-2)
- When the transmission shift control lever is in This effectively turns the retarder off (0%
the DRIVE-2 position and key switch is in the retardation).
ON position, current flows out terminals B and
D of connector (ZF-X2) to the TCU at terminals When the control lever is moved to each
42 and 50 (respectively) of connector (ZF-X1). sequential higher position (1 through 6), the
When these two signals are received at the retarder controller sends a higher level of voltage
same time, the TCU knows that DRIVE-2 to terminal 61 of TCU connector (ZF-X1).
mode is requested.
In DRIVE-2 mode, the transmission starts in This causes the TCU to send a corresponding
first range and is allowed to automatically shift PWM signal out terminal 6 of connector (ZF-X1) to
to the second range and no further. retarder proportional solenoid (Y11; Figure 9).
• 1 (Drive-1)
- When the transmission shift control lever is in At the same time, the TCU also sends current out
the DRIVE-1 position and key switch is in the terminal 51 of connector (ZF-X1) to retarder on
ON position, current flows out terminals B, C solenoid (Y10; Figure 9), energizing this solenoid.
and D of connector (ZF-X2) to the TCU at With solenoid (Y10; Figure 9) energized, retarder
terminals 42, 28, and 50 (respectively) of oil is allowed to flow fully through the transmission
connector (ZF-X1). cooler to provide maximum oil cooling during
When these three signals are received at the retarder activation.
same time, the TCU knows that DRIVE-1
Retarder Controller Output Voltage and Percentage of
mode is requested. Retardation - Specification.
In DRIVE-1 mode, the transmission is limited
Lever Position 0 (0%) - Voltage - - - 0.70 ± 0.05 Volts.
to the first range.
Retarder Control Lever Position 2 (40%) - Voltage - - - 1.50 ± 0.09 Volts.
The retarder system is activated whenever the Lever Position 3 (60%) - Voltage - - - 2.00 ± 0.11 Volts.
retarder control lever is at position 1 (or higher)
and the accelerator pedal is fully released to the
slow idle position after output sensor (B14) detects Lever Position 6 (100%) - Voltage - - 4.05 ± 0.17 Volts.
rotation from transmission output shaft. Applying the service brakes causes the stop light
pressure switch to send a signal to the chassis
Applying the service brakes will also activate the
control unit (CCU).
retarder system, regardless of position of retarder
control lever. The CCU communicates this information through
the CAN data line to the TCU.
Activating the retarder will cause the stop lights to
come ON. For more information concerning stop If the retarder control lever is at position 0, 1, or 2
lights activation, See “Stop Light Circuit Theory when the service brakes are applied, the TCU will
of Operation” on page 86. request 50% retardation.
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872106 CHAPTER 3 B25D & B30D 6X6
If the retarder control lever is at position 3, 4, 5, or If the sump temperature sensor (B12) senses
6 when the service brakes are applied, the transmission oil temperature is equal to or greater
percentage of retardation will stay the same as than 105°C (221°F) or retarder temperature
indicated by the position of the retarder control sensor (B11) senses retarder oil temperature is
lever. equal to or greater than 160°C (320°F), the TCU
will log a service code and send the information to
If the TCU receives an over-temperature signal the menu display unit (MDU), which then displays
from retarder temperature sensor (B11), the TCU the code. For more information on the
will shorten the duty cycle signal to retarder transmission oil temperature and the MDU, See
proportional solenoid (Y11; Figure 9) to reduce oil “Menu Display Unit Circuit Theory Of
flow to the retarder, then log the appropriate Operation” on page 83.
service codes.
If the retarder is engaged, the TCU will shorten the
NOTE:The retarder status is digitally duty cycle signal to retarder proportional solenoid
displayed in the menu structure of (Y11; Figure 9) as necessary to reduce oil flow to
the MDU, when accessed. For more the retarder.
information on the menu structure,
see Menu Display Unit - Menu Service Codes and Limp-Home Mode
Function (CHAPTER 8 of operator’s
The TCU stores both active and historical service
manual).
codes.
Transmission Cooler Fan Control An active code is any code that is current in the
When sump temperature sensor (B12) senses TCU decision making process. Historical codes
transmission oil temperature is equal to or greater are codes that are retained in the TCU’s memory
than 100°C (212°F) and/or retarder temperature and will not necessarily affect the TCU decision
sensor (B11) senses retarder oil temperature is making process.
equal to or greater than 145°C (293°F), the TCU
provides a ground at terminal 13 of connector (ZF- Historical codes are useful in determining if a
X1) for the coil of transmission cooler fan relay problem is isolated, intermittent, or results from a
(K22; Figure 7), energizing the relay. previous malfunction.
With relay (K22; Figure 7) energized, current from Service codes can be accessed and cleared using
circuit breaker (F24; Figure 1) is allowed to flow to menu display unit (H2; Figure 5) or the Service
transmission cooler fan motor (M11; Figure 7), ADVISOΡ application.
activating the fan motor.
Active codes are cleared when power to the TCU
Transmission Sump Temperature - Specification is removed. Some codes are self-clearing when
the condition which caused the code is no longer
Over-Temperature (Cooler Fan Activation) -
Temperature - - - - - - - - - - - - - - - - - - - 100°C (212°F). detected by the TCU.
Over-Limit Temperature (Alarm Activation) - Other codes must be manually removed.
Temperature - - - - - - - - - - - - - - - - - - - 105°C (221°F).
For most transmission related service codes, the
Retarder Oil Temperature - Specification TCU will send a signal through the CAN data line
to the menu display unit (MDU), causing the
Over-Temperature (Cooler Fan Activation) -
Temperature - - - - - - - - - - - - - - - - - - - -145°C (293°F). TRANSMISSION SERVICE light to come ON.
Over-Limit Temperature (Alarm Activation) - NOTE:To diagnose TCU related service
Temperature - - - - - - - - - - - - - - - - - - - -160°C (320°F).
codes, See “Service Code
Diagnostics -Transmission Control
Unit (TCU)” on page 101.
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B25D & B30D 6X6 CHAPTER 3 872106
• Intermittent Wipers - See Wiper/Washer

The transmission status is digitally displayed in the Circuit Theory of Operation.
menu structure of the MDU, when accessed. For • Hydraulic Cut-Off - See Starting and Charging
more information on the menu structure, (See Circuit Theory of Operation.
Menu Display Unit - Menu Function CHAPTER • Battery Charge and Battery Balance - See
8 of operator’s manual). Battery Balancer and 12-Volt Accessory
Circuit Theory of Operation.
When the WK lockup clutch solenoid (Y8) circuit,
• Inter-Axle Lock
throttle pressure D1 solenoid (Y9) circuit, and/or
• System Air.
output speed sensor (B14) circuit malfunctions,
• Engine Coolant Level.
the TCU goes into what is called the “limp home”
• Fuel Level.
mode. In this mode, the TCU allows only certain
• Hydraulic Temperature.
transmission functions and gear selections so the
vehicle can be driven to a place where the Inter-Axle Lock Circuit
malfunction can be more easily repaired.
NOTE:1. For information on the mechanical
Chassis Control Unit Circuit Theory Of operation of the inter-axle lock, See
Operation 2. For information on the pneumatic
Unswitched power is available at terminal 30 of operation of the inter-axle lock, See
MDU/CCU power relay (K17; Figure 5). turning the Inter-Axle Lock Circuit in Pneumatic
key switch to the ON position, sends current from Circuit CHAPTER 5, SECTION 1.
circuit breaker (F9) to the coil of MDU/CCU power
relay (K17; Figure 5), energizing the relay. The Putting the inter-axle lock switch (S8; Figure 7) in
current also flows to chassis control unit (CCU) the ON position connects terminal X1 of CCU
(A8; Figure 6) at terminal J1 of connector X5A. connector X5B to ground. When this happens and
if the engine speed is 900 r.p.m. or less, the CCU
With MDU/CCU power relay (K17; Figure 5) sends current out terminal N1 of connector X5B to
energized, current from MDU/CCU power and inter-axle lock solenoid (Y16; Figure 8), energizing
hazard fuse (F13) is sent to the CCU at the the solenoid.
following terminals:
The current also flows to terminal 64 of TCU
• Terminals A3 and K1 of connector X4 connector (ZF-X1) to let the TCU know the inter-
• Terminals A1 and A2 of connector X5A axle lock has been activated.
CCU programming connector (X17) is provided so With solenoid (Y16; Figure 8) energized, the
software can be down loaded to the CCU using a planetary gear set (inside the transfer case) locks
RS232 interface and laptop computer. The up, causing the front and rear drive shafts to turn
connector receives switched power from program/ in unison.
diagnostic fuse (F15) at terminal 4.
When the inter-axle lock is engaged, the inter-axle
NOTE:To diagnose CCU related service lock pressure switch (B25; Figure 5) (See “Menu
codes, See “Service Code Display Unit Circuit Theory Of Operation” on
Diagnostics - Chassis Control Unit page 83) sends a signal to the MDU, causing the
(CCU)” on page 97. Inter-Axle Lock Light to come ON.
The following functions are controlled or Once engaged, the inter-axle lock will stay
monitored by the CCU: engaged as long as the inter-axle lock switch (S8;
Figure 7) is in the ON position, even if the engine
• Park Brake and Exhaust Brake - See Park speed increases above 900 r.p.m.
Brake and Exhaust Brake Circuit Theory of
Operation.
• Bin Control and Range Hold - See Bin Control,
and Range Hold Circuit Theory of Operation.
• Turn Signal and Four-Way Flashers - See
Turn Signal and Four-Way Flasher Circuit
Theory of Operation.
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872106 CHAPTER 3 B25D & B30D 6X6
NOTE:1. For more information on the inter- The air pressure sensor varies resistance with
axle lock pressure switch (B25; respect to air pressure as follows:
Figure 5), Inter-Axle Lock Light and
the MDU, See “Menu Display Unit • 0 kPa {0 bar (0 psi)} = 10 Ohms
Circuit Theory Of Operation” on • 200 kPa {2 bar (29 psi)} = 51 Ohms
page 83. • 400 kPa {4 bar (58 psi)} = 86 Ohms
2. The inter-axle lock status is • 600 kPa {6 bar (87 psi)} = 122 Ohms
digitally displayed in the menu • 800 kPa {8 bar (116 psi)} = 152 Ohms
structure of the MDU, when • 1000 kPa {10 bar (145 psi)} = 180 Ohms
accessed. For more information on
Fuel Level Sensor
the menu structure, See CHAPTER 8
of the OMM. The fuel level sensor (B19; Figure 7) is a variable
resistor that sends an analog signal to the CCU at
Sensors terminal S3 of connector X5B.
System Air Pressure Sensor
The CCU sends the signal through the CAN data
The system air pressure sensor (B15; Figure 7) line to the MDU where a gauge displays the
detects system air pressure and sends an analog amount of fuel to the operator.
signal representing the amount of air pressure
back to the CCU. When the fuel reaches a pre-determined low level,
the MDU will activate the audible alarm.
The sensor is connected in series with air pressure
sensor pull-up resister (R1; Figure 6) so when the NOTE:1. For more information on the fuel
key switch is in the ON position, current flows gauge and MDU. See “Menu Display
through the 830 ohm resister (R1; Figure 6) and Unit Circuit Theory Of Operation” on
sensor (B15; Figure 7), then to terminal P2 page 83.
(ground reference) of CCU connector X5B. 2. The fuel level status is digitally
displayed in the menu structure of
The pull-up resistor is required because the CCU the MDU, when accessed. For more
does not send out a reference voltage of its own to information on the MDU - menu
the sensor. Instead, an external voltage (system function, See CHAPTER 8 in OMM.
voltage) is used as the reference voltage.
When the fuel tank is empty, the fuel level sensor
The pull-up resister absorbs most of the system measures 75 ohms of resistance. When the fuel
voltage so the voltage drop across the pressure tank is full, the sensor measures 7.5 ohms of
sensor will be with-in the 0-5 volts required by the resistance.
CCU.
Engine Coolant Level Sensor
The signal representing the air pressure is
measured across sensor (B15; Figure 7), then The engine coolant level low sensor (B20; Figure
sent to terminal R3 of CCU connector X5B. The 7) consists of two components: a capacitance
CCU sends the information through the CAN data probe and an interface module.
line to the MDU where a gauge displays the
amount of air pressure to the operator. The probe detects water level using the “principle
of capacitance”. When two electrically conductive
NOTE:1. For more information on the air materials are separated by an electrical insulator,
pressure gauge and MDU. See “Menu a capacitance will exist between the two
Display Unit Circuit Theory Of conductors. The amount of capacitance is directly
Operation” on page 83. proportional to the area of the two plates.
2. The system air pressure status is
digitally displayed in the menu The probe consists of a brass rod (1st plate)
structure of the MDU, when covered with polytetrafluoroethylene (PTFE) (the
accessed. For more information on insulator). When the probe is covered in water, the
the MDU - menu function, See water acts as the 2nd plate.
CHAPTER 8 in OMM.
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B25D & B30D 6X6 CHAPTER 3 872106
Maximum capacitance is obtained when the probe The temperature sensor varies resistance with
is fully submersed in water. Minimum capacitance respect to temperature as follows:
exists when the probe is completely out of the
water. • 40° C (104° F) = 287.4 Ohms
• 50° C (122° F) = 193.6 Ohms
When little or no coolant contacts the probe, the • 60° C (140° F) = 134.0 Ohms
interface module will send a signal (2.5 volts) to • 70° C (158° F) = 95.2 Ohms
terminal Y1 of CCU connector X5B. • 80° C (176° F) = 69.1 Ohms
• 90° C (194° F) = 51.3 Ohms
With an input at terminal Y1, the CCU will send a • 100° C (212° F) = 38.6 Ohms
signal through the CAN data line to the MDU, • 110° C (230° F) = 29.4 Ohms
causing the Coolant Level light to come ON. • 120° C (248° F) = 22.7 Ohms
NOTE:The engine coolant low level status Bin Control And Range Hold Circuit
is digitally displayed in the menu
Theory Of Operation
structure of the MDU, when
accessed. For more information on Bin Control Circuit
the MDU - menu function, See
When the key switch is in the ON position, power
CHAPTER 8 in OMM.
from circuit breaker (F9) is available to terminal 30
of body float relay (K13; Figure 6).
Hydraulic Temperature Sensor
The hydraulic temperature sensor (B21; Figure 7) Power from circuit breaker (F6) is available to bin
sends an analog signal to terminal R2 of CCU down detent magnet (Y14; Figure 6) and range
connector X5B. The CCU will send the signal hold relay (K8; Figure 6).
through the CAN data line to the MDU where the
Bin Up Mode
signal is digitally displayed in the menu structure.
For information on accessing the menu Moving the bin control lever to the Bin Up position
structure of the MDU, See CHAPTER 8 in OMM. sends air pressure to the bin hydraulic control
valve, which in turn, sends hydraulic oil to the bin
When the hydraulic temperature reaches 90° C tip cylinders to raise the bin.
(194° F) the red Service indicator on the MDU will
flash, audible alarm (H1; Figure 5) will sound NOTE:1. For information on the pneumatic
intermittently and the Hydraulic Temperature Light control of the bin, See “Bin Pilot
on the MDU will flash. Control Valve Circuit” on page 192 in
Pneumatic Circuit CHAPTER 5.
When the hydraulic temperature reaches 95° C
2. For information on the hydraulic
(203° F) the red Service indicator will flash, audible
control of the bin, See “Bin Control
alarm (H1; Figure 5) will sound continuously, and
Valve Operation” on page 230.
the Hydraulic Temperature Light will flash.
When air pressure in the Bin Up side of the bin
NOTE:1. The hydraulic temperature status
pneumatic control circuit reaches 550 kPa (5.5
is digitally displayed in the menu
bar) (79.8 psi), the contacts of bin up pressure
structure of the MDU, when
switch (B16; Figure 6) open. With the contacts of
accessed. For more information on
switch (B16; Figure 6) open, ground is no longer
accessing the menu on the MDU -
available to bin float solenoid (Y13; Figure 6).
menu function, See CHAPTER 8 in
OMM.
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872106 CHAPTER 3 B25D & B30D 6X6
When the angle of the bin increases to more than Float Mode
5%, as sensed by bin position sensor (B17; Figure
When the actuator rod of bin up switch (S5; Figure
6), the following occurs:
6) makes contact with the bin the following occurs:
1. The actuator rod of bin up switch (S5; Figure 6)
• Ground is removed from bin down detent
no longer makes contact with the bin causing the
magnet (Y14; Figure 6) causing the relay to
following to occur:
de-energize. Bin tip control lever returns to
• Ground is provided to bin down detent magnet Neutral position.
(Y14; Figure 6), energizing the magnet. • Ground is removed from range hold relay (K8;
• Ground is provided to range hold relay (K8; Figure 6) causing the relay to de-energize.
Figure 6), energizing the relay. (Transmission is allowed to upshift).
• Ground is removed from bin float relay (K13; • Ground is provided to coil of bin float relay
Figure 6), de-energizing the relay. (K13; Figure 6).
2. The CCU removes power from terminal J2 of When bin position sensor (B17; Figure 6) senses
connector X4 to ensure bin float relay (K13; Figure the angle of the bin to be 5% or less, the CCU
6) is de-energizing when body angle is more than sends power out terminal J2 of connector X4 to the
5%. coil of bin float relay (K13; Figure 6), energizing
the relay.
With range hold relay (K8; Figure 6) energized, the
transmission is prevented from upshifting to a With relay (K13; Figure 6) energized and the
higher gear. For more information, See “Bin contacts of bin up pressure switch (B16; Figure 6)
Control And Range Hold Circuit Theory Of closed, current flows from circuit breaker (F9) to
Operation” on page 79. bin float solenoid (Y13; Figure 6), energizing the
solenoid.
With bin down detent magnet (Y13; Figure 6)
energized, the bin tip control lever can be held in With solenoid (Y13; Figure 6) energized, oil at the
the Bin Down position by the detent magnet. head end of the bin tip cylinders will bypass the
hydraulic control valve and flow directly to the oil
Bin Down Mode reservoir. This allows the bin to gently lower (float)
to the frame when the bin tip control lever is in the
When the bin tip control lever is moved to the
neutral position.
Neutral or Bin Down position, air pressure
exhausts from the Bin Up side of the Bin Range Hold Circuit
pneumatic control circuit, causing the contacts of
bin up pressure switch (B16; Figure 6) to close. When in range hold mode, the TCU prevents the
transmission from upshifting to a higher gear than
With the bin tip control lever in the Bin Down the gear selected at the time of activation, thus
position, the energized bin down detent magnet preventing any further increase in machine speed.
(Y14; Figure 6) will hold the bin tip control lever in Normal down shifting is allowed when in range
the Bin Down position. The detent magnet holds hold mode.
the control lever in this position until the bin
contacts the actuator rod of the bin up switch (S5; Putting range hold switch (S6; Figure 6) in the ON
Figure 6) or if the operator moves the lever. position or raising the bin more than 5%, will
connect terminal T1 of CCU connector X5B to
ground.
When the CCU senses this ground input, the CCU

will communicate this information through the CAN
data line to the TCU to enable range hold mode.
The range hold switch allows the operator to

manually activate range hold mode. The range
hold relay allows the bin up circuit to activate
range hold mode.
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B25D & B30D 6X6 CHAPTER 3 872106
Activation of the range hold circuit by the bin up To release the park brake, the CCU (A8; Figure 6)
circuit automatically prevents the transmission must detect the following:
from upshifting when the bin is in the raised
position. • An “engine running” signal from the ECU (sent
through the CAN data line).
Park Brake And Exhaust Brake Circuit • An analog signal at terminal R3 of CCU
Theory Of Operation connector X5B indicating system air pressure
is more than 550 kPa (5.5 bar) (79.8 psi).
Park Brake Circuit • A signal at terminal Y3 of CCU connector X5B
NOTE:The park brake is spring applied, indicating the park brake lever is in the Park
pneumatically released. Release position. (This signal must be
received only after the analog signal at
The park brake will engage if any of the following terminal R3 indicates air pressure is more than
events occur: 550 kPa (5.5 bar) (79.8 psi).
The analog signal at terminal R3 comes from

• Park brake lever moved to the PARK position.
system air pressure sensor (B15; Figure 7). When
• Key switch turned to the OFF position.
the analog input indicates system air pressure is
• Engine speed becomes less than 50 r.p.m.
more than 550 kPa (5.5 bar) (79.8 psi), the CCU
and ground speed less than 1 km/h (0.62
starts monitoring the input at terminal Y3
m.p.h.).
connector X5B.
• System air pressure drops to less than 550
kPa (5.5 bar) (79.8 psi) The park brake latch switch (S7; Figure 6)) is
• Starting the engine (input exists at terminal B3 mechanically connected to the park brake lever
of connector X5A). valve. Because of this, moving the park brake
If any of these events occur, the chassis control lever to the Park Release position causes switch
unit (CCU) (A8; Figure 6) will not allow an output (S7; Figure 6)) to send a signal to terminal Y3.
at terminal A1 of CCU connector X4. With no
If this signal is present before system air pressure
output at terminal A1, park brake relay (K7; Figure
reaches specification, the CCU will not allow an
6) will not energize and thus park brake solenoid
output at terminal A1 of connector X4. With no
(Y15; Figure 6) will not energize.
output at terminal A1, park brake relay (K7; Figure
The de-energized solenoid blocks air pressure to 6) will not energize, thus the park brake will not
the park brake actuator. It also allows the air in the release.
actuator to vent to atmosphere, ensuring the
When this happens, the park brake lever must first
spring inside the actuator applies the park brake.
be returned to the Park position, then moved to the
The park brake pressure switch (B18; Figure 6) is Park Release position to release the park brake.
located between park brake solenoid and park
When the CCU has all the required inputs and in
brake actuator. Because of this, switch (B18;
the right order, the CCU will allow current to flow
Figure 6) senses only atmospheric pressure
out terminal A1 of connector X4 to the coil of park
during the time solenoid (Y15; Figure 6) is de-
brake relay (K7; Figure 6), energizing the relay.
energized.
With relay (K7; Figure 6) energized, current flows
This causes the contacts of switch (B18; Figure 6)
from circuit breaker (F6) to park brake solenoid
to close, allowing terminal X3 of CCU connector
(Y15; Figure 6), energizing the solenoid.
X5B to connect to ground. When this happens and
if the key switch is in the ON position, the CCU will With park brake lever valve in the Park Release
send a signal though the CAN data line to the position and solenoid (Y15; Figure 6), energized,
MDU, which in turn, causes the Park Brake Light air pressure is supplied to the park brake actuator.
to come ON.
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872106 CHAPTER 3 B25D & B30D 6X6
When air pressure in the park brake actuator With solenoid (Y12; Figure 8) energized, air
reaches 550 kPa (5.5 bar) (79.8 psi), the contacts pressure is directed to the exhaust flapper valve
of park brake pressure switch (B18; Figure 6) actuator. For more information of operation of the
open, interrupting the ground to terminal X3 of flapper valve, see General Engine Operation
CCU connector X5B. This causes the CCU to (CTM86).
send a signal through the CAN data line to the
Menu display unit, which in turn, causes the Park With relay (K6; Figure 8) energized, current from
Brake Light to go OFF. circuit breaker (F9) also flows to terminal K1 of
CCU connector X5A, causing the CCU to activate
Exhaust Brake Circuit the stop lights. For information on operation of the
NOTE:The engine control unit (ECU) (A3) stop lights, See “Stop Light Circuit Theory of
monitors engine speed and the Operation” on page 86.
accelerator pedal position. For more
The exhaust brake will also apply if engine speed
information on the accelerator pedal
exceeds rated speed (engine overspeed
position sensor and the ECU, See
condition), regardless of position of accelerator
“Engine Control Unit Circuit Theory
pedal.
Of Operation” on page 72.
The torque converter does not have to be in locked
When the accelerator pedal is returned to the slow up for this to happen. When an engine overspeed
idle (0%) position after engine speed has reached condition is detected, the red ENGINE
900 rpm or higher and the torque converter OVERSPEED light on the monitor display unit
achieved lock up, the ECU will provide a ground to comes ON.
the coil of exhaust brake relay (K6; Figure 8),
energizing the relay.
With relay (K6; Figure 8) energized, current is

allowed to flow from circuit breaker (F9) to exhaust
brake solenoid (Y12; Figure 8), thus energizing the
solenoid.
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Menu Display Unit Circuit Theory Of Operation

Menu Display Unit
EM ERGEN CY PARK
EN GINE BRAKE
COOLANT STEERING BRAKE BRAKE
COLD FAULT PR ESSURE
LEVEL TEM P HYDRAULIC
STA RT
TEM P
BATTERY RETARDER TRANSMISSION BIN INTER -AXLE DIFF

CHARGE FAULT UP DIFF LOC K LOCK
ENGINE OIL
PRESSURE
COOLA NT
TEM P
20
30
40
km/h
20 30
50
60
0 MENU
mph
RPM
BACK
10 40
10 70
0 50
NEXT
0 80
HOURS
AIR TRANS OIL
PRESSURE TEM P
FUEL
VOLTS volts
SELECT
GD1022CFM
NOTE:For a description of all the MDU When two seconds have elapsed, and if the write
indicators and their function, See operation is completed, the MDU signal is disabled
Instrument Panel Functions in causing the internal relay to de-energize and the
CHAPTER 8 of the OMM. MDU to shut down.
The MDU (H2; Figure 5) is used to display the When the head light switch is in the ON position
status of machine functions. It is controlled by and the drive lights switch inside steering column
signals received from the TCU, CCU (A8; Figure switch (S10; Figure 3) is set to High Beam
6) and ECU. The signals are transmitted across position, terminal E of MDU connector X11 is
the CAN data line. connected to ground. When this happens, the
High Beam indicator on the MDU will come ON.
Unswitched power is available at terminal G of
MDU connector X11 and terminal 30 of MDU/CCU MDU programming connector (X14) is provided so
Power Relay (K17; Figure 5). Turning the key software can be down loaded to the MDU using an
switch to the ON position, sends current from RS232 interface and laptop computer.
circuit breaker (F9) to the coil of MDU/CCU power
relay (K17; Figure 5), energizing the relay. With
MDU/CCU power relay (K17; Figure 5) energized,
n CAUTION
current from MDU/CCU power and hazard fuse When a critical warning is detected, the red
(F13) flows to terminal J of MDU connector X11. Service light will come ON (or flash) and the
audible alarm will sound. The machine and
If the MDU detects switched system voltage at engine must be stopped immediately or
terminal J of MDU connector X11 to be less than serious damage may result. The flashing
17.5 ± 5 volts, the MDU will assume that a power Service light and audible alarm alerts the
down is in process. operator to a critical service code condition
indicated on the MDU display.
If the MDU is writing data to memory, it sends a
signal to energize an internal relay. This relay uses
unswitched power from terminal G of MDU
connector X11 so that the write operation can be
completed.
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Gauges Transmission Oil Temperature

The MDU contains a speedometer and the When the transmission temperature reaches
following gauges: 101°C (214°F) (gauge needle at start of red), the
red SERVICE indicator will come ON and audible
• Engine Oil Pressure.
alarm (H1; Figure 5) will sound intermittently.
• System Air Pressure.
“TRANS TEMP TOO HIGH” will scroll across the
• Engine Coolant Temperature.
message display.
• Transmission Oil Temperature.
• Fuel Level. When the transmission temperature reaches
The sensors for these gauges provide analog 103°C (217°F) (gauge needle at middle of red), the
inputs to CCU (A8; Figure 6). The CCU calculates red SERVICE indicator will come ON and audible
the temperature, pressure and fuel level then alarm (H1; Figure 5) will sound continuously.
sends the data across the CAN data line to the “TRANS TEMP TOO HIGH” will scroll across the
MDU. message display.
When the MDU receives the sensor data, it Air System Pressure
displays the value on the appropriate gauge as a When the system air pressure is at 550 kPa (5.5
needle position, then moves the associated bar) (79.8 psi) (gauge needle at start of red) or
needle to such position. less, the red SERVICE indicator will flash and
audible alarm (H1; Figure 5) will sound
The needle of the fuel, pressure and temperature
intermittently. “LOW AIR PRES” will appear (flash)
gauges will deflect to the far left of the scale when
on the message display.
communications across the CAN data line are lost
or if a sensor error is detected. Speedometer
Engine Oil Pressure The speedometer is calibrated to show the
machine speed in m.p.h. and km/h. The
The red Service indicator will flash and audible
transmission output shaft speed sensor sends a
alarm (H1; Figure 5) will sound continuously when
signal to the TCU representing the speed of the
the engine oil pressure is less than a specified
output shaft.
pressure at a given engine r.p.m.
The TCU transmits the speed sensor data to the
• 50 r.p.m. = 20 kPa {0.2 bar (3.0 psi)}
MDU across the CAN Data Line. The MDU uses
• 600 r.p.m. = 50 kPa {0.5 bar (7.3 psi)}
the data to move the speedometer needle in
• 1000 r.p.m. = 90 kPa {0.9 bar (13.0 psi)}
correlation to machine travel speed.
• 1400 r.p.m. = 130 kPa {1.3 bar (18.9 psi)}
• 1800 r.p.m. = 160 kPa {1.6 bar (23.2 psi)} NOTE:If the speedometer seems to be
• 2200 r.p.m. = 200 kPa {2.0 bar (29.0 psi)} miscalibrated, check machine model
• 2600 r.p.m. = 250 kPa {2.5 bar (36.3 psi)} on the MDU at start-up and check the
• 3000 r.p.m. = 250 kPa {2.5 bar (36.3 psi)} tire size in the menu structure of the
Engine Coolant Temperature MDU. For information on accessing
the menu structure, see Menu
When the engine coolant temperature reaches Display Unit - Menu Function
113°C (235.4°F) (gauge needle at start of red), the CHAPTER 8 of operator’s manual).
red SERVICE indicator will come ON and audible
alarm (H1; Figure 5) will sound intermittently. Pressure Switches
“ENG TEMP TOO HIGH” will scroll across the
message display. The following pressure switches send their signals
directly to the MDU:
When the engine coolant temperature reaches
119°C (226°F) (gauge needle at middle of red), the • Service Brake Low Pressure Switch (B23;
red SERVICE indicator will come ON and audible Figure 5).
alarm (H1; Figure 5) will sound continuously. • Secondary Steering Pressure Switch (B24;
“ENG TEMP TOO HIGH” will scroll across the Figure 5).
message display. • Inter-Axle Lock Pressure Switch (B25; Figure
5).
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Service Brake Low Pressure Switch Turn Signal

The contacts of service brake low pressure switch Moving the lever of steering column switch (S10;
(B23; Figure 5) are open during normal operation. Figure 3) to the left-turn position connects terminal
X2 of CCU (A8; Figure 6) connector X5B to
When oil pressure in the service brake system ground.
decreases to 12 300 kPa (123 bar) (1784 psi), the
contacts of pressure switch (B23; Figure 5) will When this happens, the CCU sends pulsing DC
close, sending a signal to terminal A of MDU current out terminal C1 of connector X4 to the coil
connector X11. of left turn relay (K9; Figure 3), causing the relay to
continuously energize and de-energize.
When this happens, the BRAKE PRESSURE light
on the MDU will come ON, the SERVICE light will The energizing and de-energizing relay causes
flash, and audible alarm (H1; Figure 5) will sound. current from circuit breaker (F1) to pulse as it flows
to left front turn signal (E21; Figure 3) and left rear
Secondary Steering Pressure Switch turn signal (E23; Figure 4), causing these lights to
flash. The CCU also sends a signal across the
The contacts of secondary steering pressure CAN data line to the MDU, causing the Left Turn
switch (B24; Figure 5) are open during normal Arrow to flash.
operation.
Moving the lever of steering columns witch (S10;
When oil pressure in the main hydraulic system Figure 3) to the right-turn position connects
decreases to 500 kPa (5 bar) (72.5 psi) the terminal W1 of CCU connector X5B to ground.
contacts of pressure switch (B24; Figure 5) close,
sending a signal to terminal B of MDU connector When this happens, the CCU sends pulsing DC
X11. current out terminal D1 of connector X4 to the coil
of the right turn relay (K10; Figure 3), causing the
When this happens, the secondary steering relay to continuously energize and de-energize.
(marked EMERGENCY STEERING) light on the
MDU will come ON, the SERVICE light will flash, The energizing and de-energizing relay causes
and audible alarm (H1; Figure 5) will sound. current from circuit breaker (F1) to pulse as it flows
to right front turn signal (E22; Figure 3) and right
Inter-axle Lock Pressure Switch rear turn signal (E24; Figure 4), causing these
When the inter-axle lock is engaged, the air lights to flash. The CCU also sends a signal across
pressure to the inter-axle lock actuator is sensed the CAN data line to the MDU, causing the Right
by inter-axle lock pressure switch (B25; Figure 5). Turn Arrow to flash.
When the air pressure reaches 550 kPa (5.5 bar) Four-Way Flasher
(79.8 psi) the pressure switch contacts close, Because the CCU and MDU are essential for the
connecting terminal C of MDU connector X11 to 4-way flashers to function, it is necessary that the
ground. When this happens, the INTER-AXLE CCU and MDU receive power during 4-way
DIFF LOCK light on the MDU will come ON. flashers activation whether key switch is in the ON
or OFF position.
Turn Signal and 4- Way Flasher
When the key switch is in the ON position, current
Unswitched power from circuit breaker (F1) is from circuit breaker (F9) flows to the coil of the
available at terminal 30 of left turn relay (K9; MDU/CCU power relay (K17; Figure 5), energizing
Figure 3) and right turn relay (K10; Figure 3). the relay. With relay (K17; Figure 5) energized,
Unswitched power from MDU/CCU power and current from MDU/CCU power and hazard fuse
hazard fuse (F13) is available at terminal 6 of 4- (F13) flows to the CCU and MDU, powering the
way flasher switch (S12; Figure 4) and terminal 30 controllers.
of MDU/CCU power relay (K17; Figure 5).
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872106 CHAPTER 3 B25D & B30D 6X6
If the key switch is in the OFF position, but 4-way NOTE:Contacts of stop light pressure
flasher switch (S12; Figure 4) is moved to the ON switch (B28; Figure 12) open and
position, unswitched current from fuse (F13) flows close at 500 kPa {5 bar (72.5 psi)}.
into terminal 6 of 4-way flasher switch (S12; Figure
4), then flows out terminal 2 to the coil of relay With the contacts of stop light pressure switch
(K17; Figure 5), energizing the relay. (B28; Figure 12) closed, current also flows to
terminal W3 of CCU (A8; Figure 6) connector X5B
With relay (K17; Figure 5) energized current from and terminal 1 of retarder voltage regulator (N1).
fuse (F13) flows to the CCU and MDU. During this The signal to the CCU lets the control system
time the 4-way flasher switch provides the know the service brakes are applied.
necessary power to the CCU and MDU.
The signal to voltage regulator (N1) puts the
From terminal 2 of 4-way flasher switch (S12; retarder system at 100% retardation. For more
Figure 4), current also flows to terminal D1 of CCU information on the retarder system, See
connector X5A. When this happens, the CCU “Transmission Control Unit” on page 73 And
sends pulsing current out both terminals C1 and “Retarder Control” on page 75.
D1 of connector X4. The pulsing current
simultaneously energizes and de-energizes left The retarder and/or exhaust brake will activate the
turn relay (K9; Figure 3) and right turn relay (K10; stop lights if the service brakes are not applied.
Figure 3). The relays, in turn, cause current from During the time the retarder and/or exhaust brake
circuit breaker (F1) to pulse as it flows to turn is active, the CCU sends current out terminal H3 of
signals (E21 - E24), causing all four lights to flash. connector X4 to the coil of the stop relay (K5;
Figure 12), energizing the relay, which causes the
This pulsing current also flows back to 4-way stop lights to come ON.
flasher switch (S12; Figure 4) at terminal 5,
causing the light in the 4-way flasher switch to The retarder stop light control diode (V1; Figure
flash. The CCU also sends a signal across the 12) prevents current from stop light pressure
CAN data line to the MDU, causing both the Left switch (B28; Figure 12) from reaching terminal H3
Turn Arrow and the Right Turn Arrow to flash. of CCU connector X4 whenever the service brakes
are applied.
If the lever of the steering column switch (S10;
Figure 3) is moved to left-turn position with the 4- Stop light control diode (V2; Figure 12) prevents
way flasher switch in the ON position, the CCU current flowing from terminal H3 of CCU connector
causes the left turn signals to flash while the right X4 from reaching terminal 1 of voltage regulator
turn signals stay continuously lit. (N1) and terminal W3 of CCU connector X5B
whenever the retarder and/or exhaust brake is
The opposite is true when the steering column active, but service brakes are not applied.
switch lever is moved to the right-turn position with
4-way flasher switch in the ON position. Backup Alarm and Backup Light Circuit
Theory of Operation
Stop Light Circuit Theory of Operation When the key switch is in the ON position, power
Unswitched power from circuit breaker (F1) is from circuit breaker (F4) is available to terminal 30
available at stop light pressure switch (B28; Figure and 86 of backup relay (K4; Figure 12).
12), brake light proximity switch (S22; Figure 12)
and terminal 30 of stop light relay (K5; Figure 12). When the operator selects revers gear, the TCU
(A5; Figure 9) supplies a ground to relay (K4;
When the service brakes are applied, hydraulic Figure 12), energizing the relay.
pressure closes the contacts of stop light pressure
switch (B28; Figure 12), allowing current from With relay (K4; Figure 12) energized, current flows
circuit breaker (F1) to flow to the coil of stop light to left and right backup lights (E31 and E32; Figure
relay (K5; Figure 12), thus energizing the relay. 12) and, if equipped, to articulation backup light
(E30; Figure 12), causing the lights to come ON.
With relay (K5; Figure 12) energized, current flows Current also flows to backup alarm (H3; Figure
from circuit breaker (F1) to left and right stop/park 12), activating the backup alarm.
light (E20; Figure 12), causing the stop lights to
come ON.
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Wiper/Washer Circuit Theory of Operation Low and High Speed Wiper Control
When the key switch is in the ON position, power When the wiper control sleeve on the steering
from circuit breaker (F7) is available at the column switch lever is turned to position “I”,
following locations: current from circuit breaker (F7) flows in terminal 8
of connector X20, then out terminal 2 of connector
• Intermittent Wiper Relay (K14; Figure 4) - X20 to terminal 4 of connector X23 on wind shield
Terminal 87 wiper motor (M2; Figure 4), activating the motor in
• Steering Column Switch (S10; Figure 3) - low speed.
Terminal 8 of connector (X20)
• Steering Column Switch (S10; Figure 3) - When the wiper control sleeve on the steering
Terminal 1 of connector (X21) column switch lever is turned to position “II”,
• Windshield Wiper Motor (M2; Figure 4) - current from circuit breaker (F7) flows in terminal 8
Terminal 3 of connector (X23) of connector X20, then out terminal 1 of connector
X20 to terminal 2 of connector X23 on wind shield
Intermittent Wiper Control wiper motor (M2; Figure 4), activating the motor in
When the wiper control sleeve on the steering high speed.
column switch lever is turned to position “J”,
current from circuit breaker (F7) flows in terminal 8 Washer Control
of connector X20, then out terminal 2 of connector Pushing the momentary wind shield washer button
X21, to terminal T2 of CCU (A8; Figure 6) allows current from circuit breaker (F7) to flow in
connector X5B. terminal 1 of connector X21, then out terminal 7 of
connector X20 to washer pump motor (M3; Figure
The CCU will then send an intermittent current out
4), activating the washer pump motor.
terminal J1 of connector X4 to the coil of
intermittent wiper relay (K14; Figure 4), energizing At the same time, current flows through washer/
the relay intermittently. wiper control diode (V5; Figure 4) to the coil of
intermittent wiper relay (K14; Figure 4), energizing
During the time intermittent wiper relay (K14; the relay.
Figure 4) is energized, current from circuit breaker
(F7) will flow across the relay contacts, to terminal With relay (K14; Figure 4) energized, current from
6 of connector X20. circuit breaker (7) will flow across the relay
contacts, to terminal 6 of connector X20. The
The current then flows out terminal 2 of wind shield
current then flows out terminal 2 of connector X20
wiper motor (M2; Figure 4), activating the motor
to terminal 4 of connector X23 on wind shield
intermittently.
wiper motor (M2; Figure 4), temporarily activating
the wiper motor.
The purpose of intermittent wiper control diode
(V4) is to block current flow to terminal J1 of CCU
The purpose of washer/wiper control diode (V5;
connector X4 when only the washer circuit is
Figure 4) is to block current flow to the washer
activated.
pump when only the intermittent wiper circuit is
activated.
The timing intervals of the intermittent wipers can
be adjusted so the wiper will actuate anywhere
Wiper Park Control
between3 and 20 seconds.
When the wiper control sleeve on the steering
NOTE:The intermittent wipers status and column switch lever is turned to position ”0” and
timing is digitally displayed in the the wiper is not at Park position, the contacts in
menu structure of the MDU, when wind shield wiper motor (M2; Figure 4) are closed.
accessed. For information on
accessing the menu structure, See
MDU - Menu Function CHAPTER 8 in
the OMM.
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872106 CHAPTER 3 B25D & B30D 6X6
With the wiper motor contacts closed, current from If the difference is more than 1.5 volts, the CCU
circuit breaker (F7) is allowed to flow to terminal 3 sends a signal through the CAN data line to the
of wiper motor connector X23, across the wiper MDU (H2; Figure 5), causing the Battery Charge
motor contacts, then out terminal 1 of connector Light to come ON.
X23 to terminal 87A of intermittent wiper relay
(K14; Figure 4). The current flows across the NOTE:1. The battery charge voltage is
normally closed relay contacts to terminal 6 of digitally displayed in the MDU, when
connector X20. accessed. For more information on
accessing the menu structure, see
Because the wiper switch is in the OFF position, MDU function, CHAPTER 8 in the
current will flow out terminal 2 of connector X20 to OMM.
terminal 4 of connector X23, activating the wiper 2. When the battery disconnect
motor. When the wiper reaches the Park position, switch is turned to OFF position,
the wiper motor contacts open, thus deactivating there is no 12-volt power available
the wiper motor. for the AM/FM radio station memory
presets and clock. As a result, any
Battery Balancer And 12-Volt Accessory station preset and clock setting are
Circuit Theory of Operation lost. The station presets will need to
The main function of battery balancer (A9; Figure be reprogrammed and the clock
2) is to equalize the charge between the two reset when the battery disconnect
batteries. It does this by directing more charging switch is turned to the ON position.
current to the bottom battery voltage equals 1/2
system voltage. Air Conditioning Circuit Theory of
Operation
The battery balancer accomplishes this by
When the key switch is in the ON position, current
sensing unswitched single battery voltage (12+
flows from circuit breaker (F9), across the normally
volts) at terminal 4. It divides the system voltage
closed contacts of start relay (K2; Figure 8), to the
by two, then compares the results with the single
coil of head light and A/C cut-out relay (K3; Figure
battery voltage.
4), energizing the relay. With relay (K3; Figure 4)
energized, current from circuit breaker (F5) is
If a difference exists, the battery balancer will take
available at the following components:
current available at terminal 2 and send the extra
current out terminal 4 to the bottom battery until • Air re-circulation switch (S17; Figure 11).
the batteries are “balanced” within 0.5 volts. • Blower motor speed control switch (S18;
Figure 11).
Turning the key switch to the ON position, sends
• Air flow control switch (S19; Figure 11).
system voltage to terminal 6 of the battery
• DC/DC convertor (U1; Figure 11).
balancer. The voltage at terminal 6 energizes an
• High fan speed relay (K21; Figure 11).
internal relay that connects terminals 3 and 4 of
• A/C relay panel (A11; Figure 11).
the battery voltage balancer.
Whenever the engine is cranked, current flowing
When this happens, the single battery voltage
from circuit breaker (F9) to the coil of head light
(12+ volts) is sent to the AM/FM radio (A10) 12-
and A/C cut-out relay (K3; Figure 4) is interrupted,
Volt accessory power socket (X32), lighter (R9), 2-
causing the relay to de-energize.
way radio power connector (X60) and to terminal
A3 of connector X5A on CCU (A8; Figure 6). With relay (K3; Figure 4) de-energized, the air
conditioning system de-activates so the starting
The CCU senses the single battery voltage (12+ load on the engine is reduced. For more
volts) from terminal 3 and also the system voltage information on the starting circuit, See
(24+ volts). It then divides the system voltage by “STARTING AND CHARGING CIRCUIT
two, then compares the results with the single THEORY OF OPERATION” on page 69.
battery voltage.
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Air Conditioning System Blower Motor Speed Control Switch

For the air conditioning system to operate, A/C on/ When the blower motor speed control switch (S18;
off switch (S16; Figure 11) must be in the ON Figure 11) is in the LOW position, current flows
position and blower motor speed control switch from terminal 5 of the blower switch to terminals I-
(S18; Figure 11) must be in any position but the 6 and I-11 of A/C relay panel (A11; Figure 11). The
OFF position. current at terminal I-11 energizes a relay on the A/
C relay panel.
As long as the contacts of air conditioning high/low
pressure switch (B31; Figure 11) and A/C freeze With this “onboard” relay energized, current is
control switch (B32; Figure 11) are closed, current allowed to flow in terminal I-12 of the A/C relay
from circuit breaker (F5) will flow to blower motor panel, then out terminal O-5 to Blower Motor
speed control switch (S18; Figure 11) at terminal Resistor/Thermofuse (R11; Figure 11).
B.
The current flows through the 3.5 ohm resistor, the
The current flows out terminal C of the blower 1.2 ohm resistor and the thermofuse, then to
switch, through A/C on/off switch (S16; Figure 11) blower motor (M4; Figure 11), activating the motor
and A/C freeze control switch (B32; Figure 11), to in low speed. At the same time, current at terminal
A/C compressor clutch (Y20; Figure 11), I-6 energizes another onboard relay that directs
energizing the clutch. current from the 14 volt system out terminal O-3,
to terminal 8 of re-circulation vent actuator (M6;
Air Conditioning High/Low Pressure Switch Figure 11).
The air conditioning high/low pressure switch If air re-circulation switch (S17; Figure 11) is in the
(B31; Figure 11) protects the A/C system if the ON position, the vent actuator will cause the re-
refrigerant pressure becomes too high. It also circulation flapper door to move to the fully open
protects the A/C system if the pressure becomes position, thus allowing outside air to enter the cab.
too low caused by loss of refrigerant. If either of
these conditions occur, the switch contacts will When the blower motor speed control switch (S18;
pen and cause A/C clutch compressor (Y20; Figure 11) is in the MEDIUM position, current
Figure 11) to de-energize. flows from terminal 6 of the blower switch directly
to blower motor resistor/thermofuse (R11; Figure
A/C Freeze Control Switch 11). The current flows through the 1.2 ohm resistor
The A/C freeze control switch (B32; Figure 11) and the thermofuse, then to blower motor (M4;
senses the temperature in the evaporator core Figure 11), activating the motor in medium speed.
through a gas-filled capillary tube. The switch
If air re-circulation switch (S17; Figure 11) is in the
closes when the evaporator temperature is above
ON position and blower speed switch in the
the switch setting and opens when the evaporator
MEDIUM position, the re-circulation flapper door
is cooled to the switch setting.
will move to the half-way position.
DC/DC Converter
When the blower motor speed control switch (S18;
The heater valve actuator and the tree vent Figure 11) is in the HIGH position, current flows
actuators require approximately 14 volts to from terminal 7 of the blower switch to the coil of
operate. Because of this, DC/DC convertor (U1; high fan speed relay (K21; Figure 11), energizing
Figure 11) is needed to convert the system voltage the relay.
(27.5 ± 1.5 volts) to the required voltage.
With relay (K21; Figure 11) energized, current
The 14 volts is supplied to terminal I-1 of A/C relay flows to blower motor resistor/thermofuse (R11;
panel (A11; Figure 11), terminal 1 of temperature Figure 11). The current only flows through the
control (R10; Figure 11) and to terminal 10 on all thermofuse, then to blower motor (M4; Figure 11),
the actuators. activating the motor in high speed. At the same
time, current flows to terminal I-7 of A/C relay
panel (A11; Figure 11), energizing an onboard
relay that connects system ground to terminal O-3.
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872106 CHAPTER 3 B25D & B30D 6X6
If air re-circulation switch (S17; Figure 11) is in the The current energizes an onboard relay that
ON position, the ground is supplied to terminal 8 of directs current from the 14 volt system out terminal
Re-circulation vent actuator (M6; Figure 11), O-1 and O-2 to terminal 8 of middle and defroster
causing actuator (M6; Figure 11) to move the re- vent actuator (M7; Figure 11) and feet vent
circulation flapper door to the fully closed position. actuator (M8; Figure 11), activating both vent
Air is re-circulated through the cab. actuators and causing air flow to be directed to
both the middle vents and the floor vents.
Air Re-circulation Switch
When air re-circulation switch (S17; Figure 11) is Temperature Control
in the OFF position, no current flows from the The temperature control (R10; Figure 11) is a
switch. The re-circulation flapper door stays in the variable resistor that sends an analog current from
fully open position regardless of blower speed the 14 volt system to terminal I-9 of A/C relay
setting. panel (A11; Figure 11).
When the air re-circulation switch is in the ON The current flows through an onboard fixed
position, current flows to terminal I-8 of A/C relay resistor, out terminal O-4 of the relay panel, to
panel (A11; Figure 11). The current energizes an terminal 8 of heater control valve actuator (M5;
onboard relay that directs current from the 14 volt Figure 11), activating the valve actuator.
system out terminal O-3 to terminal 8 of re-
circulation vent actuator (M6; Figure 11), The actuator opens and closes a valve in the
activating the vent actuator. heater core line. The movement of the valve
corresponds directly with the position of
The vent actuator moves the re-circulation flapper temperature control (R10; Figure 11).
door to the fully closed position, causing the air to
re-circulate through the cab. Electric Mirror Circuit Theory of Operation
Mirror Positioning Circuit
Air Flow Control Switch
Movement of the optional electric mirrors is
When air flow control switch (S19; Figure 11) is in
controlled by mirror positioning switch (S21;
the DEFROST position, no vent actuators are
Figure 13). The mirror positioning switch is a multi-
activated. Air flow is directed to the wind shield.
functional switch consisting of a mirror selector
When the air flow control switch is in the FLOOR switch and a mirror direction switch.
VENT position, current flows out terminal I-3 of A/
The mirror selector switch enables the circuitry of
C relay panel (A11; Figure 11). The current
the mirror to be adjusted. Moving the switch to the
energizes an onboard relay that directs current
left detent allows the left mirror to be adjusted.
from the 14 volt system out terminal O-1 to
Moving the switch to the right detent allows the
terminal 8 of floor vent actuator (M8; Figure 11),
right mirror to be adjusted. Moving the switch to
activating the vent actuator and causing air flow to
the centre detent disables both the mirrors.
be directed to the floor vents.
The mirror switch is a four-way switch that
When the air flow control switch is in the MIDDLE
operates two servo motors in each mirror. One
VENT position, current flows out terminal 9 of air
servo motor controls the mirror up and down
flow switch to terminal I-4 of the A/C relay panel.
movement. The other servo motor controls mirror
The current energizes an onboard relay that side-to-side movement.
directs current from the 14 volt system out terminal
NOTE:The following discusses the
O-2 to terminal 8 of the middle and de-froster vent
operation of the left mirror.
actuator (M7; Figure 11), activating the vent
Operation of the right mirror is
actuator and causing air flow to be directed to the
similar.
middle vents.
When the air flow control switch is in the FLOOR/

MIDDLE VENT position, current flows out terminal
10 of air flow switch to terminal I-5 of the A/C relay
panel.
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Up/Down Positioning When the mirror selector switch is at position “L”

and the mirror direction switch is moved to the
When the mirror selector switch is at position “L”
RIGHT, ground is supplied to left servo motors
and the mirror direction switch is moved to the UP
(M9; Figure 13) at terminals 4 of connector X48.
position, ground is supplied to left servo motors
(M9; Figure 13) at terminals 4 and 5 of connector At the same time, power is available at terminal 3
X48. and 5 of connector X48. Because of this, current
flows through the side-to-side motor of left mirror
At the same time, power is available at terminal 3 servo motors (M9; Figure 13), but in the opposite
of connector X48. Because of this, current flows direction. This causes the motor to activate in
through the up/down motor of left mirror servo reverse which rotates the mirror lens to the right.
motors (M9; Figure 13), activating the motor which
causes the mirror lens to rotate upward. The up/down motor of left mirror servo motor (M9;
Figure 13) does not activate because ground is
The side-to-side motor of left mirror servo motor
supplied to both sides of the motor during this
(M9; Figure 13) does not activate because ground
time.
is supplied to both sides of the motor during this
time. Mirror Defroster Circuit
When the mirror selector switch is at position “L” The optional electrical mirrors contain a heating
and the mirror direction switch is moved to the element that is attached to the mirror’s reflective
DOWN position, ground is supplied to left mirror lens for defrosting and defogging purposes.
servo motors (M9; Figure 13) at terminal 3 of
connector X48. At the same time, power is With both the key switch and mirror defroster
available at terminals 4 and 5 of connector X48. switch (S20; Figure 13) in the ON position, current
flows through left mirror defroster (R12; Figure 13)
Because of this, current flows through the up/down and right mirror defroster (R13; Figure 13). Heat is
motor of left mirror servo motors (M9; Figure 13), produced because of resistance in the heater
but in the opposite direction. This causes the elements.
motor to activate in reverse which rotates the
mirror lens downward. Unloader Valve Heater Circuit Theory
of Operation
The side-to-side motor of left mirror servo motors
(M9; Figure 13) does not activate because power The unloader valve, located inside the air dryer,
is supplied to both sides of the motor during this contains unloader valve heater (R5). The purpose
time. of this heating element is to prevent the unloader
valve from freezing so the purge cycle can
Left/Right Positioning continue to remove moisture from the pneumatic
system.
When the mirror selector switch is at position “L”
and the mirror direction switch is moved to the
The heating element is controlled by an internal
LEFT, ground is supplied to left servo motors (M9;
temperature switch. The temperature switch
Figure 13) at terminals 3 and 5 of connector X48.
contacts are closed when the temperature is
below 4.4° C (40° F). The contacts are open when
At the same time, power is available at terminal 4
the temperature is above 29.5° C (85° F).
of connector X48. Current flows through the side-
to-side motor of left mirror servo motors (M9;
When the temperature is below 4.4° C (40° F) and
Figure 13), activating the motor which causes the
the key switch is in the ON position, current flows
mirror lens to rotate to the left.
through circuit breaker (F24; Figure 1) to unloader
valve heater (R5).
The up/down motor of left mirror servo motor (M9;
Figure 13) does not activate because ground is The current flowing through the heating element
supplied to both sides of the motor during this warms the unloader valve to prevent moisture
time. from freezing inside the valve.
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SECTION 3. REFERENCES
SERVICE CODE DIAGNOSTICS -

AFTER MACHINE REPAIR Service Code Diagnostics - How
Codes Are Displayed On Menu Display
After repairing a malfunction involving a service Unit
code, deletion of the service code is necessary to
verify if malfunction was indeed repaired.
• To delete a service code that displays on the

MDU, See Delete MDU Displayed Service
Codes. 1
• To delete a service code that displays on the
transmission shift control, See Delete
Transmission Shift Control Displayed Service
Codes. 2
NOTE:Service codes can be read and
deleted by one of the following
methods: the service codes that display on the MDU follow
the J1939 standard. The code consists of a
Suspect Parameter Number (SPN) (2) and a
• Menu display unit
Failure Mode Identifier (FMI) (1). The SPN number
• Service ADVISOΡ application. (See instruc- is a two- to four-digit code and the FMI is a one or
two-digit code.
tions that come with Service ADVISOR.)
In order to determine the exact malfunction, both
To delete all service codes from memory using the
parts (SPN and FMI) of the code are needed.
menu display unit (MDU), perform the following:
The SPN identifies the system or the component
Go to the Diagnostics Menu “C 01” in the menu
that has malfunctioned (e.g., SPN 1702 indicates
structure of the MDU. For information on
a malfunction in the dump body position sensor
accessing the Diagnostic Menu, (See Menu
circuit).
Display Unit - Menu Function CHAPTER 8 inthe
Operator’s Manual). The FMI identifies the type of malfunction that has
occurred (e.g., FMI 4 indicates value below
Display the service code, then press and hold the
normal).
SELECT key. The monitor will beep and the
service code will be cleared. Combining SPN 1702 with FMI 4 yields dump
body position below normal.
Repeat step 2 for each service code until END is
displayed. These codes are written with the SPN number
first, a period, then the FMI number (e.g., 1702.4).
Operate the machine, then access the Diagnostic
Menu on the MDU to make sure the problem has
been corrected and that the previously repaired
service code or a new service code is not
displayed.
If a new service code exists, diagnose and repair

the malfunction that is displayed, then repeat
steps 1 - 3.
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Service Code Diagnostics -Engine

Control Unit
NOTE:For information on how the service code is displayed on the menu display unit, See
“Service Code Diagnostics - How Codes Are Displayed On Menu Display Unit” on page 93.
Code - Symptom Problem Solution
45.3 - Constant Exhaust Brake Relay (K6). Check relay. (See “Relay Test” on
Throttle (EVB) Open page 190).
Circuit.
Broken or poor wire Check cab main harness (W10).
connection between ECU
and exhaust brake relay
(K6).
45.5 - Constant Exhaust Brake Relay (K6). Check relay. (See “Relay Test” on
Throttle (EVB) Closed page 123).
Circuit.
Shorted wire between ECU Check cab main harness (W10).
(K6).
98.0 - Oil Level Too Excessive oil in crankcase. Drain oil from crankcase until proper oil level
High. is obtained.
98.1 - Oil Level Too Too little oil in crankcase. Add oil to proper level. For type of oil, (See
Low.
CHAPTER 1 in the OMM).
98.14 - Oil Level Oil leak. Drain oil. Repair oil leak. Fill with correct
Dangerously Low. viscosity oil. (See CHAPTER 1 in the OMM).
Worn engine. Repair or replace engine. (See Engine,
CHAPTER 4, SECTION 1 in the Repair
Manual).
100.1 - Oil Pressure Oil pressure sensor (B5). Replace oil pressure sensor.
Low.
100.14 - Oil Pressure Oil pressure sensor (B5). Replace oil pressure sensor.
Very low.
Broken wire or poor Check front frame/engine harness (W7),
connection. engine main harness (W8) and cab main
harness(W10).
EUI controller or ECU. Replace control unit.
158.0 - Switched Alternator. Check alternator. Replace if necessary.

Voltage To Engine EUI
Controller and ECU
Too High.
158.1 - Switched Alternator. Check alternator. Replace if necessary.

Voltage To Engine EUI
Controller and ECU Batteries. Check batteries. Recharge or re[place as
Too Low. necessary.
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625.2 - CAN Data Line Broken or shorted wire; poor Check front frame/engine harness (W7) and
Error Between EUI connection. cab harness (W10).
Controller And ECU.
625.14 - CAN Data Broken wire or poor Check front frame/engine harness (W7) and
Line Error With One connection. cab harness (W10).
Wire Capability
Between EUI
COntroller And ECU.
629.12 - ECU Internal Faulty ECU. Replace ECU. (See “Remove and Install
Failure. Engine Control Unit” on page 135).
1005.3 - Pulse Width Accelerator pedal position Check accelerator pedal position sensor.
Modulation sensor (B10). Replace sensor.
Accelerator Pedal
Position Sensor PWM Broken wire or poor Check cab main harness (W10).
Output Malfunction connection.
Open Circuit.
Accelerator Pedal
Position Sensor PWM Shorted wire. Check cab main harness (W10).
Output Malfunction
Closed Circuit.
1006.3 - Exhaust Exhaust brake relay (K6). Check relay. (See “Relay Test” on
Brake Open Circuit. page 123).
Broken or poor wire Check cab main harness (W10).

connection between ECU
(K6).
1006.4 - Exhaust Exhaust brake relay (K6). Check relay. (See “Relay Test” on
Brake Short To page 123).
Ground.
Shorted wire between ECU Check cab main harness (W10).
(K6).
1015.1 - Pulse Width Broken wire or poor Check connections of cab power harness
Modulation connection. (W9) and main cab harness (W10).
Accelerator Pedal
Position Sensor No
Input Voltage.
Accelerator Pedal
Position Sensor Both Broken wire or poor Check cab main harness (W10).
PWM Signal #2 connection.
Missing.
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Accelerator Pedal
Position Sensor Both Broken wire or poor Check cab main harness (W10).
PWM Signal #1 connection.
Missing.
1015.5 - Pulse Width ECU not properly Program ECU.

Modulation programmed for accelerator
Accelerator Pedal pedal position sensor.
Position Sensor Both
PWM Signal Not Set
or Programmed.

Position Sensor Slow
Idle Not Set or
Programmed.

Position Sensor Fast
Idle Not Set or
Programmed.
Service Code Diagnostics - Electronic Unit Injector (EUI) Controller

NOTE:For information on how the service code is displayed on the menu display unit, (See
“Service Code Diagnostics - How Codes Are Displayed On Menu Display Unit” on
page 93).
98.2 - Engine Oil Level Broken wire or poor Check front frame/engine harness(W7) and
Sensor Value Not connection. cab main harness(W10).
Recognized.
98.3 - Oil Level Sensor Engine oil level sensor (B3). Check oil level sensor. Replace sensor.
Out Of Range High.
Wire shorted to positive. Check engine main harness (W8).
Out Of Range Low.
Wire shorted to ground. Check engine main harness (W8).
Open Circuit.
Broken wire or poor Check engine main harness (W8).
connection.
100.2 - Engine Oil Broken wire or poor Check front frame/engine harness (W7) and
Pressure Sensor connection. Cab Main harness (W10).
Value Not
Recognized.
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100.3 - Engine Oil Engine oil pressure sensor Check oil pressure sensor. Replace sensor.
Pressure Sensor Out (B5).
of Range High.
Wire shorted to positive. Check engine main harness (W8).
100.4 - Engine Oil Engine oil pressure sensor Check oil pressure sensor. Replace sensor.
Pressure Sensor Out (B5).
of Range Low.
Wire shorted to ground. Check engine main harness (W8).
102.2 - Manifold Air Broken wire or poor Check front frame/engine harness (W7) and
Pressure (MAP) connection.
Cab Main harness (W10).
Sensor Value Not
Recognized.
102.3 - Manifold Air Intake manifold air pressure/ Check intake manifold air pressure/
Pressure (MAP) temperature sensor (B6). temperature sensor. Replace sensor.
Sensor out Of Range
High. Wire shorted to positive. Check engine main harness (W8).
102.4 - Manifold Air Intake manifold air pressure/ Check intake manifold air pressure/
Pressure (MAP) temperature sensor (B6). temperature sensor. Replace sensor.
Sensor out Of Range
Low. Wire shorted to ground. Check engine main harness (W8).
Service Code Diagnostics - Chassis Control Unit (CCU)

NOTE:For information on how the service code is displayed on the menu display unit, (See
“Service Code Diagnostics - How Codes Are Displayed On Menu Display Unit” on
page 93).
1702.3 - Bin Position Bin position sensor (B17) not Calibrate bin position sensor. (See menu
Above Normal. calibrated. function D04 in the MDU menu structure
in CHAPTER 8 in the OMM).
Wiring or connections. Check rear frame harness (W15), hydraulic

harness (W14) and cab main harness (W10).
Bin position sensor (B17). Check bin position sensor. (See “Bin
Position Sensor Test” on page 129).
CCU (A8). Replace CCU.
1702.3 - Bin Position Bin position sensor (B17) not Calibrate bin position sensor. (See menu
Below Normal. calibrated. function D04 in the MDU menu structure
in CHAPTER 8 in the OMM).
Wiring or connections. Check rear frame harness (W15), hydraulic

harness (W14) and cab main harness (W10).
Bin position sensor (B17). Check bin position sensor. (See “Bin
Position Sensor Test” on page 129).
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1703.3 - System Air Wiring or connections. Check cab main harness (W10).
Pressure Above
Normal. System air pressure sensor Check system air pressure sensor. (See
(B15). “Pneumatic System Solenoids, Pressure
Switches, and Sensor Tests” on
page 125).
1703.4 - System Air Wiring or connections. Check cab main harness (W10).
Pressure Below
Normal. System air pressure sensor Check system air pressure sensor. (See
(B15). “Pneumatic System Solenoids, Pressure
Switches, and Sensor Tests” on
page 125).
1704.3 - Hydraulic Wiring or connections. Check cab main harness (W10) and hydraulic
Temperature Above harness (W14).
Normal.
Hydraulic temperature Check hydraulic temperature sensor. (See
sensor (B21). “Hydraulic Temperature Sensors Test” on
page 128).
1704.4 - Hydraulic Wiring or connections. Check cab main harness (W10) and hydraulic
Temperature Below harness (W14).
Normal.
Hydraulic temperature Check hydraulic temperature sensor. (See
sensor (B21). “Hydraulic Temperature Sensors Test” on
page 128).
1705.3 - Wet Disk Wiring or connections. Check cab main harness (W10) and hydraulic
Brake Temperature harness (W14).
Above Normal. (B40D
Only). Wet disk brake temperature Check wet disk brake temperature sensor.
sensor (B22). (See “Hydraulic Temperature Sensors
Test” on page 128).
1705.4 - Wet Disk Wiring or connections. Check cab main harness (W10) and hydraulic
Brake Temperature harness (W14).
Below Normal. (B40D
Only). Wet disk brake temperature Check wet disk brake temperature sensor.
sensor (B22). (See “Hydraulic Temperature Sensors
Test” on page 128).
96.3 - Engine Oil Wiring or connections. Check front frame/engine harness (W7) and
Pressure Sensor Out cab main harness (W10).
of Range High.
Fuel level sensor (B19). Check level sensor.
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96.4 - Engine Oil Wiring or connections. Check front frame/engine harness (W7) and
Pressure Sensor Out cab main harness (W10).
of Range Low.
Fuel level sensor (B19). Check level sensor.
2000.2 - VIN Number CCU (A8) has incorrect Install correct program in CCU.
Mismatch. program.
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Service Code Diagnostics -Transmission Control Unit (TCU)
5014.3 - Retarder Retarder controller (A7). Replace retarder controller.

Controller Voltage Wiring or connections. Check transmission control harness (W12).
Above High Limit (4.5 See “Transmission Control Harness” on
page 40. (W12)
Volts)
TCU (A5). Replace TCU. See “Remove and Install
Retarder disabled.
Transmission Control Unit” on page 137.
5014.4 - Retarder Retarder controller (A7). Replace retarder controller.

Controller Voltage Wiring or connections. Check transmission control harness (W12).
Below Low Limit (2 See “Transmission Control Harness” on
page 40 (W12).
Volts)
Replace TCU. See “Remove and Install
Retarder disabled.
TCU (A5). Transmission Control Unit” on page 137.
5017.3 - Retarder Retarder temperature sensor Check sensor. See Temperature Sensor
Temperature Sensor (B11). Test (this group).
(B11) Open Circuit.
Retarder disabled. Wiring or connections. Wiring or connections. Check transmission

control harness (W12) and transmission
harness (W13). See “Transmission Control
Harness” on page 40 (W12) and
“Transmission Harness” on page 42
(W13).

5017.4 - Retarder Retarder temperature sensor Check sensor. See Temperature Sensor
Temperature Sensor (B11). Test (this group).
(B11) Short to Ground.
Retarder disabled. Wiring or connections. Wiring or connections. Check transmission

control harness (W12) and transmission
harness (W13). See “Transmission Control
Harness” on page 40 (W12) and
“Transmission Harness” on page 42
(W13).

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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)
and transmission harness (W13). See
All range solenoids “Transmission Control Harness” on
deactivated. page 40 (W12) and “Transmission
Transmission shifts to Harness” on page 42 (W13).
neutral.
TCU (A5). Replace TCU. (See “Remove and Install
Transmission Control Unit” on page 137).
5018.4 - Sump Sump temperature sensor Check sensor. See Transmission Solenoids,
Temperature Sensor (B12). Speed Sensors, Sump Temperature Sensor
(B12) Short To and Retarder Temperature Resistor Tests
Ground (this group).
Retarder Disabled Wiring or connections. Check transmission control harness (W12),

transmission harness (W13), and
transmission control module harness (W19).
See “Transmission Control Harness” on
page 40 (W12), “Transmission Harness”
on page 42 (W13) and “Transmission
Control Module Harness” on page 50
(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 on page 42 and “Transmission Control
deactivated. Module Harness” on page 50 (W19).
Transmission shifts to
neutral. TCU (A5). Replace TCU. (See “Remove and Install
5021.3 - A Clutch Wiring or connections. Check transmission control harness (W12),

Solenoid (Y7) Short transmission harness (W13), and
To Power. transmission control module harness (W19).
All range solenoids page 40 (W12), “Transmission Harness”
deactivated. on page 42 (W13) and “Transmission
Transmission shifts to Control Module Harness” on
neutral. page 50(W19).

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5021.4 - A Clutch A clutch solenoid (Y7). Check solenoid. See Transmission

Solenoid (Y7) Short Solenoids, Speed Sensors, Sump
To Ground. Temperature Sensor and Retarder
Temperature Resistor Tests (this group).
All range solenoids
deactivated. Wiring or connections. Check transmission control harness (W12),
Transmission shifts to transmission harness (W13), and
neutral. transmission control module harness (W19).
Control Module Harness” on
page 50(W19).

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
page 50(W19).

5022.3 - B Clutch Wiring or connections. Check transmission control harness (W12),


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5022.4 - B Clutch B clutch solenoid (Y6). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5022.5 - B Clutch B clutch solenoid (Y6). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5023.3 - C Clutch Wiring or connections. Check transmission control harness (W12),


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5023.4 - C Clutch C clutch solenoid (Y5). Check solenoid. See Transmission

To Power. Temperature Sensor and Retarder
All range solenoids
page 50(W19).

5023.5 - C Clutch C clutch solenoid (Y5). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5024.3 - D Clutch Wiring or connections. Check transmission control harness (W12),


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5024.4 - D Clutch D clutch solenoid (Y4). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5024.5 - D Clutch D clutch solenoid (Y4). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5025.3 - E Clutch Wiring or connections. Check transmission control harness (W12),


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5025.4 - E Clutch E clutch solenoid (Y3). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5025.5 - E Clutch E clutch solenoid (Y3). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5026.3 - F Clutch Wiring or connections. Check transmission control harness (W12),


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5026.4 - F Clutch F clutch solenoid (Y2). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5026.5 - F Clutch F clutch solenoid (Y2). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5027.3 - G Clutch Wiring or connections. Check transmission control harness (W12),


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5027.4 - G Clutch G clutch solenoid (Y1). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5027.5 - G Clutch G clutch solenoid (Y1). Check solenoid. See Transmission

All range solenoids
page 50(W19).

5028.3 - WK (Lock Wiring or connections. Check transmission control harness (W12),

Up) Clutch Solenoid transmission harness (W13), and
(Y8) Short To Power. transmission control module harness (W19).
System goes into page 40 (W12), “Transmission Harness”
“limp-home” mode. on page 42 (W13) and “Transmission
page 50(W19).

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5028.4 - WK (Lock WK clutch solenoid (Y8). Check solenoid. See Transmission

Up) Clutch Solenoid Solenoids, Speed Sensors, Sump
(Y8) Short To Ground. Temperature Sensor and Retarder
System goes into
“limp-home” mode. Wiring or connections. Check transmission control harness (W12),
page 50(W19).

5028.5 - WK (Lock WK clutch solenoid (Y8). Check solenoid. See Transmission

Up) Clutch Solenoid Solenoids, Speed Sensors, Sump
(Y8) Open Circuit. Temperature Sensor and Retarder
System goes into
page 50(W19).

5039.3 - Shifter Lock Transmission shift control Perform Transmission Shift Control Test
Solenoid Short To (A4). (This Group).
Power.
Wiring or connections. Check transmission control harness (W12).
Output switch off. See “Transmission Control Harness” on
Shifter lock solenoid page 40 (W12).
deactivated.
Solenoid Short To (A4). (This Group).
Ground.
Wiring or connections. Check transmission control harness (W12).
Output switch off. See “Transmission Control Harness” on
Shifter lock solenoid page 40 (W12).
deactivated.
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Solenoid Open Circuit. (A4). (This Group).
Output switch off. Wiring or connections. Check transmission control harness (W12).
Shifter lock solenoid See “Transmission Control Harness” on
deactivated. page 40 (W12).

5044.2 - D1 Clutch D1 clutch solenoid (Y9). Check solenoid. See Transmission

Solenoid (Y9) Solenoids, Speed Sensors, Sump
Resistance. Temperature Sensor and Retarder Resistor
Tests (this group).
System activates
Transmission service transmission control module harness (W19).
light ON. See “Transmission Control Harness” on
page 50(W19).
5044.3 - D1 Clutch Wiring or connections. Check transmission control harness (W12),

System activates page 40 (W12), “Transmission Harness”
“limp-home” mode. on page 42 (W13) and “Transmission
page 50(W19).

5044.4 - D1 Clutch D1 clutch solenoid (Y9). Check solenoid. See Transmission

To Ground. Temperature Sensor and Retarder Resistor
Tests (this group).
System activates
page 50(W19).

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5045.2 - Retarder Retarder proportional Check solenoid. See Retarder Proportional

Proportional Solenoid solenoid (Y11). Solenoid Test (This Group).
(Y11) Resistance.
Retarder disabled. and transmission harness (W13). See
“Transmission Control Harness” on
Transmission service page 40 (W12) and “Transmission
light ON. Harness” on page 42 (W13).
5045.3 - Retarder Wiring or connections. Check transmission control harness (W12)

Proportional Solenoid and transmission harness (W13). See
(Y11) Short To Power. “Transmission Control Harness” on
page 40 (W12) and “Transmission
Output switch OFF. Harness” on page 42 (W13).
Retarder mode not TCU (A5). Replace TCU. (See “Remove and Install
possible. Transmission Control Unit” on page 137).
5045.4 - Retarder Retarder Proportional Check solenoid. See Retarder Proportional

Proportional Solenoid Solenoid (Y11). Solenoid Test (This Group).
(Y11) Short To
Ground. Wiring or connections. Check transmission control harness (W12)
and transmission harness (W13). See
Output switch OFF. “Transmission Control Harness” on
page 40 (W12) and “Transmission
Retarder mode not Harness” on page 42 (W13).
possible.
5045.5 - Retarder Retarder Proportional Check solenoid. See Retarder Proportional

Proportional Solenoid Solenoid (Y11). Solenoid Test (This Group).
(Y11) Open Circuit.
Output switch OFF. and transmission harness (W13). See
Retarder mode not page 40 (W12) and “Transmission
possible. Harness” on page 42 (W13).

5046.2 - Transmission Wiring or connections. Check transmission control harness (W12).

Shift Control Signal See “Transmission Control Harness” on
Malfunction. page 40 (W12)
Transmission goes to Transmission shift control Perform Transmission Shift Control Test
neutral. (A4). (This group).
Transmission service
light ON.
5049.2 - Hour Counter TCU (A5). Replace TCU. (See “Remove and Install
Malfunction. Transmission Control Unit” on page 137).
Hour counter resets to

zero.
light ON.
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B25D & B30D 6X6 CHAPTER 3 872106
5051.2 - TCU Memory TCU (A5). Replace TCU. (See “Remove and Install
All codes in memory

queue deleted.
light ON.
5052.11 - TCU Loss of power to TCU. Check fuses and circuit breakers. See Fuse
System Malfunction. Specifications (Group 9015-10)
All output switches off. Check cab main harness (W10) and
transmission control harness (W12). See
Transmission goes to “Cab Main Harness And Electric Mirror
neutral. Interface Harness” on page 31 and
page 40.

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
See Transmission Control Harness (W12)
Component Location, Transmission
Harness (W13) Component Location, and
Transmission Control Module Harness
(W19) Component Location, (Group 9015-
10).
5056.3 - Retarder on Wiring or connections. Check transmission control harness (W12),

Output switch off. page 40 (W12), “Transmission Harness”
Retarder mode not on page 42 (W13) and “Transmission
possible. Control Module Harness” on
page 50(W19).

ISSUE 0 113
872106 CHAPTER 3 B25D & B30D 6X6
5056.4 - Retarder on Retarder on solenoid (Y10). Check solenoid. See Transmission

To Ground. Temperature Sensor and Retarder Resistor
Tests (this group).
Output switch off.
Retarder mode not Wiring or connections. Check transmission control harness (W12),
possible. transmission harness (W13), and
page 50(W19).

5056.5 - Retarder on Retarder on solenoid (Y10). Check solenoid. See Transmission

Circuit. Temperature Sensor and Retarder Resistor
Tests (this group).
Output switch off.
Retarder mode not Wiring or connections. Check transmission control harness (W12),
possible. transmission harness (W13), and
page 50(W19).

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
Resistor Tests (this group).
System goes into
Forward only. Reverse transmission control module harness (W19).
is not possible. See “Transmission Control Harness” on
Highest gear is page 40 (W12), “Transmission Harness”
engaged. Then on page 42 (W13) and “Transmission
downshift every 2.5 Control Module Harness” on
seconds until lowest page 50(W19).
gear is reached, as TCU (A5). Replace TCU. (See “Remove and Install
long as transmission Transmission Control Unit” on page 137).
input speed is below
defined threshold.
light ON.
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
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
large. Wiring or connections. Check transmission control harness (W12),
page 50(W19).

5059.2 - Turbine Turbine speed sensor (B13). Check resistance of speed sensor. See
Signal Malfunction. Sump Temperature Sensor and Retarder
light ON. Wiring or connections. Check transmission control harness (W12),
page 50(W19).

5059.11 - Turbine Turbine speed sensor (B13). Check resistance of speed sensor. See
Signal Overflow. Sump Temperature Sensor and Retarder
System goes into
page 50(W19).

5061.11 - Checksum TCU (A5). Replace TCU. (See “Remove and Install
Statistics date deleted.
ISSUE 0 115
872106 CHAPTER 3 B25D & B30D 6X6
5062.3 - Retarder Retarder resistor (R8). Check retarder resistor. See Transmission
Resistor (R8) Open Solenoids, Speed Sensors, Sump
Circuit. Temperature Sensor and Retarder Resistor
Tests (this group).
Possible reduction in
retarder torque. Wiring and connections. Check transmission control harness (W12),
page 50(W19).
5062.4 - Retarder Retarder resistor (R8). Check retarder resistor. See Transmission
Resistor (R8) Short To Solenoids, Speed Sensors, Sump
Ground. Temperature Sensor and Retarder Resistor
Tests (this group).
Possible reduction in
retarder torque. Wiring and connections. Check transmission control harness (W12),
page 50(W19).
5063.14 - TCU (A5). Replace TCU. (See “Remove and Install

Transmission I.D. Transmission Control Unit” on page 137).
Code.
Transmission goes to
neutral.
5065.0 - Retarder Oil Transmission oil low. Add oil as required. For oil spec. and
Temperature Over quantities, See Chapter 1 in the OMM.
Limit.
Transmission oil cooler fan Check and replace fan relay.
Retarder temperature relay.
is over 160° C (320°
F). Transmission oil cooler fan Check and replace cooler fan motor.
motor.
Retarder torque
reduced. Retarder temperature sensor Check and replace sensor. See Retarder
(B11). Temperature Sensor Test (Group 9015-20).
Over temp. alarm
activated.
5065.14 - Retarder Oil Transmission oil low. Add oil as required. For oil spec. and
Over Temperature. quantities, See Chapter 1 in the OMM.
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
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B25D & B30D 6X6 CHAPTER 3 872106
5066.0 - Transmission Transmission oil low. Add oil as required. For oil spec. and
Sump Temperature quantities, See Chapter 1 in the OMM.
Over Limit.
Sump temperature is relay.
over 105° C (221° F).
reduced.
Engine overheating. Check cause of engine overheating. See
Over temp. alarm diagnose engine malfunction (Group 9010-
activated. 15).
Transmission oil cooler is Check oil cooler. See “Transmission Oil-to-

restricted. Air Cooler Restriction Specification” on
page 174 and “Transmission Oil-to-Water
Cooler Restriction Specification” on
page 175.

5066.14 - Transmission oil low. Add oil as required. For oil spec. and
Transmission Sump quantities, See Chapter 1 in the OMM.
Over Temperature.
Sump temperature is relay.
over 100° C (212° F).
reduced.
Transmission oil too hot due Check cause of engine overheating. See
to engine overheating. “SECTION 2. DIAGNOSE ENGINE
MALFUNCTIONS” on page 13.
Transmission oil cooler is Check oil cooler. See “Transmission Oil-to-

restricted. Air Cooler Restriction Test” on page 174
and “Transmission Oil-to-Water Cooler
Restriction Test” on page 175.

5067.3 - Unused TCU (A5). Replace TCU. (See “Remove and Install
Output Short To Transmission Control Unit” on page 137).
Power.
5068.12 - Central Cut Wiring or connections. Check cab main harness (W10) and
Off Malfunction. transmission control harness (W12). See
“Cab Main Harness And Electric Mirror
Transmission remains Interface Harness” on page 31 and
in neutral. “Transmission Control Harness” on
page 40.

ISSUE 0 117
872106 CHAPTER 3 B25D & B30D 6X6
5075.12 - Retarder Wiring or connections. Check transmission control harness (W12).

Controller (A7) Signal See “Transmission Control Harness” on
Malfunction. page 40.
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
to 2nd Upshift. Worn oil pump. Repair pump. See Disassemble
Transmission CHAPTER 3, SECTION 3 in
Residual slip after end repair manual).
of shift.
Turbine speed sensor (B13). Check resistance of speed sensor. See
Transmission Solenoids, Speed Sensors,
Sump Temperature Sensor and Retarder
Resistor Tests (This Group).
Output speed sensor (B14). Check resistance of speed sensor. See

Wiring or connections. Check transmission control harness (W12),

page 40, T“Transmission Harness” on
page 42, and “Transmission Control
Module Harness” on page 50.
Damage valve body gaskets Replace gaskets. Clean or replace valves as

or stuck (or sticky) valves. necessary. See Disassemble and
Assemble Control Valve (CHAPTER 3,
SECTION 3 in repair manual).
Worn or damaged clutches. Repair or replace transmission. See Remove

And Install Transmission CHAPTER 3,

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B25D & B30D 6X6 CHAPTER 3 872106
Under Load During
2nd to 3rd Upshift. Worn oil pump. Repair pump. See Disassemble
Transmission CHAPTER 3, SECRTION 3 in
of shift.


page 40, “Transmission Harness” on



ISSUE 0 119
872106 CHAPTER 3 B25D & B30D 6X6
Under Load During
3rd to 4th Upshift. Worn oil pump. Repair pump. See Disassemble
Transmission (CHAPTER 3, SECTION 3 in
of shift.


page 40, T“Transmission Harness” on



120 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
Under Load During 4th
to 5th Upshift. Worn oil pump. Repair pump. See Disassemble
Transmission (CHAPTER #, SECTION 3 in
of shift.





ISSUE 0 121
872106 CHAPTER 3 B25D & B30D 6X6
Under Load During 5th
to 6th Upshift. Worn oil pump. Repair pump. See Disassemble
Transmission (CHAPTER #, SECTION 3 in
of shift.



or stuck (or sticky) valves. necessary. See Disassemble and Assemble
Control Valve (CHAPTER 0350, SECTION
0350 in repair manual).


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. (See “Remove and Install
Parameter Checksum. Transmission Control Unit” on page 137).
Initialization of default
settings from data
field.
light ON.
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B25D & B30D 6X6 CHAPTER 3 872106
Key Switch Test

Relay Test
Key Switch Terminals
Remove relay.
2
86
87A 87
1 30
3
85
5
4
1. ACC
2. GRD 40D1001CFM
3. GN
4. BAT (B) With relay de-energized, check for continuity
5. ST across terminals 30, 87A and 87 as shown.
Replace relay if checks indicated the following:
Remove key switch.
• • No continuity across terminals 30 and 87A.
With key switch in the OFF position, check for • • Continuity exists across terminals 30 and 87.
continuity across all terminals (1 - 5). If continuity
is indicated, replace switch.
24V
86
Position B ACC IG ST 87A 87
ACC 30
OFF
85
ON
START
40D1001CFM
Put key switch in each position (ACC, ON,
START) and check for continuity across
Energize relay by grounding terminal 85 and
appropriate terminals (see legend). Replace key
applying 24 volts to terminal 86.
switch if continuity is not indicated between
terminals as shown in legend.
With relay energized, check for continuity across
terminals 30, 87A and 87 as shown. Replace
relay if checks indicated the following:
• • No continuity across terminals 30 and 87
• • Continuity exists across terminals 30 and
87A.
ISSUE 0 123
872106 CHAPTER 3 B25D & B30D 6X6
Diode Test
Remove diode.
Check for continuity across terminals (1 and 2),

then reverse test leads and repeat continuity
check.
• If continuity is indicated in one check and not

the other, diode is good.
• If continuity is indicated in both checks, diode
is shorted, replace diode.
• If no continuity is indicated in either check,
diode is open, replace diode.
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B25D & B30D 6X6 CHAPTER 3 872106
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests
1 2
TLX
8
PBA PBX
3 3
S AA3
1
2 TLV
TLA
7 PBS
1 AT
TLD
5 4
Pne30D4001CFM
ISSUE 0 125
872106 CHAPTER 3 B25D & B30D 6X6
1. Inter-Axle Lock Solenoid. 5. Park Brake Solenoid.

2. Horn Solenoid. 6. Park Brake Pressure Switch.
3. System Air Pressure Sensor. 7. Bin Up Pressure Switch.
4. Exhaust Brake Solenoid. 8. Inter-Axle Lock Pressure Switch.
Specifications
Pneumatic Pressure Switches

Bin Up Pressure Switch (B16) Pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Contacts are closed at and below
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -550 kPa (5.5 bar) (79.8 psi)
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

Pneumatic Pressure Switches (B16, B18,
Air Pressure at 0 kPa (0 bar) (0 psi) Resistance B25, B26) Test
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10 Ohms
Disconnect wire harness connector from pressure
Air Pressure at 200 kPa (2 bar) (29 psi) Resistance switch to be tested.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51 Ohms
Air Pressure at 400 kPa (4 bar) (58 psi) Resistance NOTE:1. Body up pressure switch (B16)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -86 Ohms uses the normally closed contacts.
Air Pressure at 600 kPa (6 bar) (87 psi) Resistance 2. Park brake pressure switch (B18),
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 122 Ohms inter-axle lock pressure switch (B25),
Air Pressure at 800 kPa (8 bar) (116 psi) Resistance and differential lock pressure switch
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152 Ohms (B26) use the normally open
contacts.
Air Pressure at 1000 kPa (10 bar) (145 psi) Resistance
180 Ohms
2
1
3
1
The following tests require a regulated air source

applied to port (2). To do this, remove the existing
coupler assembly (1). With no air pressure applied to pressure switch,
continuity must exist across terminals (1 and 2),
Install an appropriate coupler using a 1/4 NPT but continuity must NOT exist across terminals (1
adapter and attach a regulated air supply to the and 3).
newly installed coupler.
NOTE:Before performing this part of the
continuity check, make sure the
related pneumatic solenoid and the
pneumatic system is functioning
properly.
126 ISSUE 0
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B25D & B30D 6X6 CHAPTER 3 872106
Apply 550 kPa (5.5 bar) (79.8 psi) air pressure to Pneumatic Solenoid Test
the external port of the pneumatic manifold, then
Disconnect wire harness from solenoid.
perform the following:
• For body up pressure switch (B16), move and

hold body up control lever in the RAISE 1
position.
n CAUTION
Chock wheels to prevent vehicle from
moving. Park brake may disengage when 24V
performing this test. 2
• 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.
40D1002CFM
For differential lock pressure switch (B26), turn
key switch to ON position, then push differential Apply 24 volts across solenoid terminals (1 and 2).
lock pressure switch to the ENGAGE position. The
differential lock circuit will energize for 30 seconds Replace solenoid if solenoid does not click when
then will automatically deactivate. voltage is applied.
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 Specifications
and 3). Service Brake Low Pressure Switch (B23) Pressure
- - - - - - - - - - - - - - - Contacts are closed at and above
System Air Pressure Sensor (B15) Test - - - - - - - - - - - - - - - 11 000 kPa (110 bar) (1595.4 psi)
Secondary Steering Pressure Switch (B24) Pressure
2 - - - - - - - - - - - - - - - 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)
1 Remove pressure switch.
NOTE:1. The normally closed contacts are

used on service brake low pressure
(B23) and secondary steering
pressure (B24).
Apply specified air pressure to sensor (at external 2. The stop light pressure switch
port of manifold) while checking resistance across (B27) is a normally open switch.
sensor terminals. Replace sensor if not to
specification.
ISSUE 0 127
872106 CHAPTER 3 B25D & B30D 6X6
With no pressure applied to pressure switch, Hydraulic Temperature Sensors Test

check for continuity across the switch terminals.
NOTE:This test applies to both the
Hydraulic Temperature Sensor (B21)
and Wet Brake Temperature Sensor
(B22).
Specification
Temperature at 40°C (104°F) - Resistance
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -287.4 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -193.6 Ohms
Service Brake Low Pressure Switch (B23) Temperature at 60°C (140°F) - Resistance
and Secondary Steering Pressure Switch (B24) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 134 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92.5 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69.1 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51.3 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38.6 Ohms
Stop Light Pressure Switch (B23) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29.4 Ohms
40D1003CFM
• For service brake low pressure switch (B23) Temperature at 120°C (248°F) - Resistance
and secondary steering pressure switch (B24), - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22.7 Ohms
replace switch if no continuity is indicated. Remove sensor.
• For stop light pressure switch (B27), replace
switch if continuity is indicated.
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.
40D1004CFM
Apply specified heat to sensor while checking

resistance between sensor terminal and body of
sensor. Replace sensor if not to specification.
128 ISSUE 0
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B25D & B30D 6X6 CHAPTER 3 872106
Measure resistance across terminals A and C of

Bin Position Sensor Test body position sensor. Replace sensor if not to
specification.
Specifications
Check Resistance Across Terminals A and C Insert shaft of support and lever (2) into body
Resistance - - - - - - - - - - - - - - - - - 5000 ± 1000 Ohms position sensor (3) and rotate lever fully clockwise
Check Terminals A and B (Sensor Lever Rotated Fully (as viewed from lever side of sensor). Measure
Clockwise) Resistance - - - - - - - - - - - - 350 ± 70 Ohms resistance across sensor terminals A and B, then
Check Terminals B and C Ohms (Sensor Lever across terminals B and C.
Rotated Fully Clockwise) Resistance - - - - 5350 ± 1070
Replace sensor if resistance is not to specification.
Check Terminals A and B (Sensor Lever Rotated Fully
Counter clockwise) Resistance - - - 5350 ± 1070 Ohms
With test leads of ohmmeter attached to terminals
Check Terminals B and C (Sensor Lever Rotated Fully A and B or B and C, slowly rotate sensor lever fully
Counter clockwise) Resistance - - - - - - 350 ± 70 Ohms counter clockwise (as viewed from lever side of
sensor).
1
The change in resistance from stop-to-stop must
be smooth and continuous in correlation to lever
movement.
Replace sensor if resistance is not to specification

when lever is fully rotated or if change in
resistance is uneven or stops changing as sensor
2
lever is rotated.
Install body position sensor (3), support and lever

(2), and cap screws and nuts. Make sure O-rings
(1) are in position.
Connect linkage (2) and wire connector (1).

Disconnect wire connector (2) and linkage (1) from
sensor lever. NOTE:The body position sensor needs to
be calibrated whenever the sensor,
NOTE:It is necessary to remove sensor
CCU, or MDU is replaced. The sensor
from mounting bracket to give the
may also need re-calibrating if the
sensor lever full travel.
key switch is turned to the ON
position while sensor is
Remove cap screws and nuts (3).
disconnected.
Calibrate sensor to the full body down and full

body up positions.
1 To calibrate sensor:
• Start engine. Make sure bin is at the full down

position.
• Access menu function D041 on menu display
unit (MDU). For information on accessing the
• MDU menu structure, (See CHAPTER 8 in
3 2
the OMM).
• Push and hold the SELECT button on the
MDU for a least 3 seconds to set the 0%
position.
• Raise bin to the full raised position.
Remove sensor by separating support and lever
• Access menu function D042. Push and hold
(2) from body position sensor (3).
the SELECT button for at least 3 seconds to
set the 100% position.
• Lower bin fully. Stop engine.
ISSUE 0 129
872106 CHAPTER 3 B25D & B30D 6X6
Steering Column Switch Test
CONNECTOR
CONNECTOR X20
X21
POSITION
1 2 3 4 5 6 7 8 9 10 11 12 1 2 4
Wipers Intermittent J
Off 0
Low Speed 1
High Speed 2
Washer L
Turn Left
Signals
R
Right 2
Drive High Beam 1
Lights
Low Beam
Momentary 0
High Beam
Horn
Remove the steering column switch assembly.
X21
X20
While operating the switch functions, check for

continuity across terminals as indicated in the
switch legend.
Replace the switch assembly if continuity is not

according to the switch legend.
130 ISSUE 0
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B25D & B30D 6X6 CHAPTER 3 872106
Retarder Voltage Regulator Test Check for voltage at terminal (2) while slowly
moving retarder controller lever to each detent
Specifications At Terminal 2 and 4 position.
Control Lever at Position 0 (12%) voltage
- - - - - - - - - - 0.8 volts at terminal 2 of Voltage regulator Voltage should be approximately as
- - - - - - - - - - 1.6 volts at terminal 4 of voltage regulator specifications.
Control Lever at Position 1 voltage
- - - - - - - - - - 1.2 volts at terminal 2 of Voltage regulator Start engine. Check terminal (1) for voltage while
- - - - - - - - - - 1.6 volts at terminal 4 of voltage regulator applying the service brakes, then check for voltage
Control Lever at Position 2 voltage while brakes are released.
- - - - - - - - - - 1.6 volts at terminal 2 of Voltage regulator
- - - - - - - - - - 1.7 volts at terminal 4 of voltage regulator System voltage must be measured when service
brakes are applied. Zero voltage must be
Control Lever at Position 3 Voltage
- - - - - - - - - - 2.1 volts at terminal 2 of voltage regulator measured when brakes are released.
- - - - - - - - - - 2.1 volts at terminal 4 of voltage regulator
If these conditions do not occur as described,
- - - - - - - - - - 2.7 volts at terminal 2 of voltage regulator check the stop light circuit.
Stop engine. Key switch at OFF position.
Install retarder voltage regulator.
Control Lever at Position 6 (100%) Voltage Remove the four mounting screws to access the
- - - - - - - - - - 4.2 volts at terminal 2 of voltage regulator backside of the right relay socket array.
Turn key switch to ON position.
3
1
5 2
4
1. Terminal 1 (Voltage from Stop Light

Pressure Switch).
2. Terminal 2 (Input Control Voltage).
3. Terminal 3 (Ground).
4. Terminal 4 (Output Control Voltage).
5. Terminal 5 (System Voltage). Check for voltage at terminal (4) while slowly
moving retarder controller lever to each detent
Remove retarder voltage regulator.
position.
Check for continuity between ground and terminal
Voltage should be approximately as
(3) of retarder voltage regulator socket. If
specifications.
continuity is not indicated, check cab main
harness (W10). Start engine and move the retarder controller lever
to position 0 (12% retardation).
NOTE:The battery disconnect switch must
be in the ON position when Apply the service brakes while checking for
performing the following checks. voltage at terminal (4). With the service brakes
applied, voltage at terminal (4) must be at
Turn key switch to ON position and check for maximum output voltage (approximately 4.3
system voltage at terminal (5). If system voltage is volts).
not measured, check fuse F11 and circuit breaker
F3. If OK, check cab main harness (W10).
ISSUE 0 131
872106 CHAPTER 3 B25D & B30D 6X6
Stop engine. Install relay socket array.
If specified voltages exist at terminals (1,2, and 5)

and ground exists at terminal 3, but voltage at
terminal (4) is not to specification, replace retarder
voltage regulator.
Transmission Solenoids, Speed

Sensors, Sump Temperature Sensor,
and Retarder Resistor Tests
Disconnect transmission control module
connector X171.
X171
Measure resistance of each component across
1 B13
appropriate terminals of connector X171.
2 B14
Transmission Solenoids, Speed Sensors, B12

Sump Temperature Sensor, and Retarder 4
Resistor Tests Specification

6 Y1
A Clutch Solenoid (Y7) ( X171 Terminals 13 and 20,
21) Resistance - - - - - - - - 67 ± 4 Ohms at 20°C (68°F)
8 Y10
B Clutch Solenoid (Y6) (X171 Terminals 12 and 20, 21)
Resistance - - - - - - - - - - - 67 ± 4 Ohms at 20°C (68°F)
9 Y8
10 Y9
C Clutch Solenoid (Y5) (X171 Terminals 11 and 20, 21) 11 Y5
Resistance - - - - - - - - - - - 67 ± 4 Ohms at 20°C (68°F) 12 Y6
D Clutch Solenoid (Y4) (X171 Terminals 22 and 20, 21) 13 Y7
Resistance - - - - - - - - - - - 67 ± 4 Ohms at 20°C (68°F) 14
E Clutch Solenoid (Y3) (X171 Terminals 24 and 20, 21) 15

17
F Clutch Solenoid (Y2) (X171 Terminals 19 and 20, 21) R8
19 Y2
G Clutch Solenoid (Y1) (X171 Terminals 6 and 20, 21) 20
WK Clutch Solenoid (Y8) (X171 Terminals 9 and 20, 22 Y4

Y3
Retarder On Solenoid (Y10) (X171 Terminals 8 and 20, 24

D1 Throttle Pressure Solenoid (Y9) (X171 Terminals 10
and 20, 21) Resistance - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - 8.6 ± 0.5 Ohms at 20°C (68°F) GDS1001CFM
Sump Temperature Sensor (B12) (X171 Terminals 4

and 14, 15) Resistance - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - - 125 ± 5 Ohms at 20°C (68°F)
Turbine Speed Sensor (B13) (X171 Terminals 1 and
14, 15) Resistance- - - - - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - 850 ± 100 Ohms at 20°C (68°F)
Output Speed Sensor (B14) (X171 Terminals 2 and 17)
Resistance - - - - - - - - 850 ± 100 Ohms at 20°C (68°F)
Retarder Resistor (R8) (X171 Terminals 17 and 18)
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B25D & B30D 6X6 CHAPTER 3 872106
Retarder Proportional Solenoid Test Retarder Temperature Sensor Test

Specification
Temperature at 50°C (122°F) Resistance - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8500 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7300 Ohms
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5020 Ohms
1 Temperature at 80°C (176°F) Resistance - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3520 Ohms
1 Temperature at 90°C (194°F) Resistance - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2510 Ohms
Temperature at 100°C (212°F) Resistance - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2000 Ohms
Temperature at 110°C (230°F) Resistance - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1340 Ohms
Disconnect retarder proportional solenoid (1). Temperature at 120°C (248°F) Resistance - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1000 Ohms
Measure resistance of across solenoid terminals
(2). Transmission Shift Control Test
Replace solenoid if not to specifications.
Retarder Proportional Solenoid Test

Specification
Retarder Proportional Solenoid Resistance- - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - 25 Ohms (Approximate)
Retarder Temperature Sensor Test
2 1. Terminal A.
2. Terminal B.
3. Terminal C.
4. Terminal D.
5. Terminal E.
6. Terminal F.
7. Terminal G.
8. Terminal H.
9. Terminal J.
Disconnect retarder temperature sensor (2). 10. Terminal K (backlights).
11. Terminal L (shift lock solenoid).
Measure resistance of across sensor terminals
12. Terminal M (not used).
(1).
13. Terminal N (ground).
Replace sensor if not to specifications. 14. Terminal P.
Disconnect the transmission shift control

connector.
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872106 CHAPTER 3 B25D & B30D 6X6
Connector X163 Terminal

Shifter
Position
A B C D E F G H J K L N P

1

2

3

D

N

R

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B25D & B30D 6X6 CHAPTER 3 872106
At each shifter lever position, check for continuity

1
across terminals as indicated in the transmission
shift control legend. Replace transmission shift
control if continuity is not as indicated in legend.
5
To check shifter lock solenoid, measure resistance
across terminals L and N. Replace transmission
shift control if not to specification.
Transmission Shift Control Specification 4
Shifter Lock Solenoid (Terminals L and N) Resistance

- - - - - - - - - - - - - - - - - - - - - - 73 Ohms (Approximate) 3
To check backlight bulbs, measure resistance
across terminals K and N. If more than 40 ohms is
measured, one bulb is probably burned out. If an Remove lock nuts, washers, and cap screws (1) to
open circuit is indicated, both bulbs are most likely separate ECU (2) from mounting plate (5).
burned out.
Disconnect harness connectors (3 and 4).
Transmission Shift Control Specification
Fasten ECU to mounting plate and connect
Backlights (Terminals K and N) Resistance - - - - - - - - - harness connectors.
- - - - - - - - - - - - - - - - - - - - - - 37 Ohms (Approximate)
Connect harness connectors (3 and 4).
Remove and Install Engine Control
Unit Install the ECU and mounting plate as an
assembly in slot provided in controller
Turn key switch and battery disconnect switch to compartment.
OFF position.
Install controller access panel.
Remove controller access panel located under left
console. Turn battery switch to ON position.
Turn key switch to ON position and access the

1 MDU menu function B013. For information on
accessing the MDU menu structure, (See
While observing the number that represents pedal

position as a percentage on the MDU data display,
depress accelerator pedal fully to fast idle position,
2 then allow pedal to return fully to slow idle position.
Movement of the accelerator pedal (slow idle to

the fast idle) should correspond from 0% to 100%
3 on the data display.
NOTE:An acceptable margin of error

Remove cap screw (1). Remove engine control between pedal movement relative to
unit (ECU) (2) and mounting plate (3) as an percentage read-out will differ from
assembly. operator to operator. Because of
this, the need for re-calibration will
be determined by operator
preference.
If the percentage read-out relative to pedal

movement is not acceptable, calibration of
accelerator pedal position sensor is required. To
perform this procedure, a special diagnostic tool
called the MiniDiag II (Version B) is needed. The
ISSUE 0 135
872106 CHAPTER 3 B25D & B30D 6X6
MiniDiag II can be acquired from BELL Fasten cold start module to mounting plate and
EQUIPMENT Product Support. connect harness connectors.
NOTE:1. The MiniDiag II is capable of Install the cold start module and mounting plate as
reading and deleting engine related an assembly in slot provided in controller
service codes and calibrating compartment.
accelerator pedal position. Follow
the instructions that come with the Install controller access panel.
diagnostic tool.
2. Call DTAC (BELL EQUIPMENT Remove and Install Chassis Control
Product Support) for additional help. Unit
Remove and Install Cold Start Module Turn key switch and battery disconnect switch to
OFF position.
Turn key switch and battery disconnect switch to
OFF position. Remove controller access panel located under left
console.
console.
1
1
5
2
2
4
3
3
Remove cap screw and washer (1). Remove
chassis control unit (CCU) (2) and mounting plate
Remove cap screw and washer (1). Remove cold as an assembly.
start module (2) and mounting plate (3) as an
assembly.
2
1 2
1
3
3
4
4
5
40D1005CFM
4 5 6
Remove lock nuts (5), washers (4), and cap
Disconnect harness connectors (1 and 2). screws (3) to separate CCU (2) from mounting
plate (1).
Remove cap screws, washers, and nuts (3) to
separate cold start module (4) from mounting plate Fasten CCU to mounting plate and connect
(5). harness connectors.
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B25D & B30D 6X6 CHAPTER 3 872106
Install CCU and mounting plate as an assembly in Fasten TCU to mounting plate and connect
slot provided in controller compartment. harness connectors.
Install controller access panel. Install TCU and mounting plate as an assembly in
slot provided in controller compartment.
Remove and Install Transmission
Control Unit Install controller access panel.
Turn key switch and battery disconnect switch to Remove and Install Battery Balancer
OFF position.
Remove controller access panel located under left OFF position.
console.
console.
1
2 1
2
4 3
Remove cap screw and washer (1). Remove

transmission control unit (TCU) (4) and mounting
plate (2) as an assembly. Remove cap screw and washer (2). Remove
battery balancer (3) and mounting plate (1) as an
Disconnect harness connectors (3). assembly.
Disconnect harness connector.

5
4
3
4
2 5
2
2
2 3
1
40D1007CFM
30D1001CFM
Remove nuts (5), washers (2), and cap screws (1)
Remove lock nuts (1), washers (2), and cap to separate battery balancer (3) from mounting
screws (4) to separate TCU (5) from mounting plate (4).
plate (3).
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872106 CHAPTER 3 B25D & B30D 6X6
Fasten battery balancer to mounting plate and

connect harness connector.
Install battery balancer/mounting plate assembly

in slot provided in controller compartment.
Install controller access panel.
Remove and Install Menu Display Unit

Turn key switch and battery disconnect switch to 2
OFF position. 1 1
Remove screws (1) and pivot front console (2)

upward to access backside of MDU.
4
2
2 1 3
1 1
Remove screws (1) and pivot front console (2)

upward to access backside of MDU.
5
1
2 Remove four screws (1) to remove back panel (2).
Remove screws (2 and 3) to remove MDU.
Install MDU and fasten with screws (2 and 3).

Make sure screws with four washers (2) are at
bottom (connector) side of MDU.
Connector harness connectors (4 and 5).
Close front console and fasten with three screws.
Replace Menu Display Unit Bulbs

OFF position.
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19 1 2 3 4 5
6 7
8
9 11
18 10
12
17 16
15 13
20
14
20
20
1. Hydraulic Temperature Light.

NOTE:MDU shown removed for illustration
2. Brake Temperature Light.
purposes only.
3. Brake Pressure Light.
4. Park Brake Light.
Replace bulb(s) as necessary.
5. Right Turn Indicator.
6. Engine Overspeed Light.
Install MDU back panel and connector harness
7. High Beam Indicator.
connectors.
8. Service Required Light.
9. Left Turn Indicator. Close front console and fasten with three screws.
10. Secondary Steering (Marked Emergency
Steering) Light.
11. Engine Service (Marked Engine Fault)
Light.
12. Coolant Level Light.
13. Cold Start Light.
14. Battery Charge Light.
15. Transmission Retarder Light.
16. Transmission Service (Marked
Transmission Fault) Light.
17. Bin Raised Light (Marked Bin Up) Light.
18. Inter-Axle Lock Light.
19. Differential Lock Light.
20. Back Lights.
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872106 CHAPTER 3 B25D & B30D 6X6
Remove, Install, and Calibrate If the percentage read-out relative to pedal

Accelerator Pedal Position Sensor movement is not acceptable, calibration of
accelerator pedal position sensor is required. To
NOTE:The accelerator pedal position perform this procedure, a special diagnostic tool
sensor connector is accessed called the MiniDiag II (Version B) is needed. The
through the A/C compartment door MiniDiag II can be acquired from BELL
located on right side of cab. EQUIPMENT Product Support.
NOTE:The MiniDiag II is capable of reading

and deleting engine related service
codes and calibrating accelerator
pedal position. Follow the
instructions that come with the
1 2 diagnostic tool. Call DTAC (BELL
EQUIPMENT Product Support) for
additional help.
3 Replace DEUTSCH™ Rectangular or

Triangular Connectors
NOTE:Connector shown is the female half
or a 4-pin square connector. Other
similar styles of Deutsch connectors
Disconnect harness connector (2) located in the can be serviced using the same
air conditioning compartment. procedure.
Remove two cap screws and lock nuts (1) to
remove accelerator pedal position sensor (3).
Install sensor and connect harness connector.
Turn key switch to ON position and access the

1
MDU menu function B013. For information on
accessing the MDU menu structure, (See
While observing the number that represents pedal 2

position as a percentage on the MDU data display,
depress accelerator pedal fully to fast idle position,
then allow pedal to return fully to slow idle position. Pull connector (1) apart. Inspect and clean
connector seal and contacts.
Movement of the accelerator pedal (slow idle to
the fast idle) should correspond from 0% to 100% Remove locking wedge (2) from connector using
on the data display. hook on JDG1383 service tool.
NOTE:An acceptable margin of error

between pedal movement relative to
percentage read-out will differ from
operator to operator. Because of
this, the need for re-calibration will
be determined by operator
preference.
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
1 1
1
Start correct size extractor tool over wire at handle

Release primary locking latch (1) next to the pin to (1).
be removed using screwdriver on JDG1383
service tool. Slide extractor tool rearward along wire until tool
tip snaps onto wire.
Gently pull wire out from back of connector.
Replace connector contact as necessary. See
“Install DEUTSCH™ Contact” on page 142.
n CAUTION
Do NOT twist tool when inserting in
Install wire terminal back into connector until it connector.
clicks into place.
NOTE:Locking wedge in 2-pin connector is Slide extractor tool along wire into connector body
not symmetrical. Position latch until it is positioned over terminal contact.
shoulder next to terminals.
Pull wire out of connector body, using extractor
Install locking wedge until it snaps into place. tool.
Replace DEUTSCH™ Connectors

n WARNING
1. Select correct size extractor tool for size of wire Install contact in proper location using cor-
to be removed: rect size grommet.
• JDG361 Extractor Tool for 12 to 14 gauge

wire.
• JDG362 Extractor Tool for 16 to 18 gauge
wire.
• JDG363 Extractor Tool for 20 gauge wire.
Push contact straight into connector body until

positive stop is felt.
ISSUE 0 141
872106 CHAPTER 3 B25D & B30D 6X6
Pull on wire slightly to be certain contact is locked n WARNING

in place.
Contact must remain centred between in-
Transfer remaining wires to correct terminal in new dentures while crimping.
connector.
Install DEUTSCH™ Contact

Strip 6 mm (1/4 in.) insulation from wire.
3
2
Insert wire in contact and crimp until handle

touches stop.
1 Release handle and remove contact.
Adjust selector (1) on JDG360 Crimper for correct

wire size.
n WARNING
If all wire strands are not crimped into con-
Loosen lock nut (2) and turn adjusting screw (3) in tact, cut off wire at contact and repeat con-
until it stops. tact installation procedures.
n WARNING NOTE:Readjust crimping tool for each

Select proper size contact "sleeve" or "pin" crimping procedure.
to fit connector body.
1
2 3
Inspect contact to be certain all wires are in
crimped barrel.
Insert contact (1) and turn adjusting screw (4) until
contact is flush with cover (2).
Tighten lock nut (3).
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
Replace WEATHER PACK™ Pull on wire slightly to be certain contact is locked

Connector in place.
n
Transfer remaining wires to correct terminal in new
WARNING connector.
Identify wire colour locations with connec-
tor terminal letters. Close connector body.
Install WEATHER PACK™ Contact

Open connector body.
NOTE:Cable seals are colour coded for
three sizes of wire:
Green - 18 to 20 gauge wire
Gray - 14 to 16 gauge wire
Blue - 10 to 12 gauge wire
Insert JDG364 Extraction Tool over terminal

contact in connector body.
Hold extractor tool fully seated and pull wire from

connector body.
Slip correct size cable seal on wire.
NOTE:If terminal cannot be removed, insert
wire or nail through extractor tool Strip insulation from wire to expose 6 mm (1/4 in.)
handle and push terminal contact and align cable seal with edge of insulation.
from connector.
NOTE:Contacts have numbered
n WARNING
identification for two sizes of wire:
a) #15 for 14 to 16 gauge wire
Carefully spread contact lances to assure b) #19 for 18 to 20 gauge wire
good seating on connector body.
NOTE:Connector bodies are "keyed" for

proper contact mating. Be sure
contacts are in proper alignment.
Put proper size contact on wire and crimp in place

with a "W" type crimp, using JDG783 Terminal
Applicator.
Push contact into new connector body until fully

seated.
ISSUE 0 143
872106 CHAPTER 3 B25D & B30D 6X6
n WARNING
1
Proper contact installation for "sleeve" (1)
and "pin” (2) is shown.
1
2
Insert a “T” pin (2) 6.4 mm (1/4 in.) into connector

body socket (1).
NOTE:Use JDG777 Terminal Extraction

Tool or “T” pin to remove terminals.
Secure cable seal to contact as shown, using
JDG783 Terminal Applicator.
1
Replace (Pull Type) Metri-Pack™
Connectors
1
2
Angle “T” pin so pin tip slides close to the plastic

socket edge pushing terminal locking tab (1)
inward.
Remove “T” pin and push terminal (2) out of

Disconnect the Metri-Pack connector (1). Remove socket.
tie bands and tape.
Remove terminal, cut strip and crimp wire through
connector.
Check to make sure locking tab on new terminal is

in outward position, then pull on wire until terminal
locks in connector body socket.
NOTE:Terminal will seat only one way. If

terminal does not pull into the
connector body socket, check to
make sure terminal is aligned
correctly.
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872106
Replace (Push Type) Metri-Pack™ Remove Connector Body from Blade

Connectors Terminals
Disconnect the Metri-Pack connector. Remove the
tie bands and tape.
3 1
1
2 1
2 2
4
Depress locking tang (1) on terminal, using a small
5
screw driver. Slide connector body off.
Remove the connector lock (1), and mark wire Be sure to bend locking tang back to its original
colours for identification. position (2) before installing connector body.
Identify wire colour locations with connector

terminal letters.
Insert JDG776 or JDG777 Terminal Extraction

Tool (2) into connector body socket (3) pushing
the terminal locking tab inward.
NOTE:Use JDG776 Extraction Tool with 56,

280 and 630 series METRI-PACK
terminals. Use JDG777 Extraction
Tool with 150 series METRI-PACK
terminals.
Remove extraction tool and pull terminal (4) out of

the socket.
Replace terminal. Make sure locking tab (5) on the

new terminal is in the outward position.
Push terminal into connector body socket until

terminal locks.
ISSUE 0 145
872106 CHAPTER 3 B25D & B30D 6X6
146 ISSUE 0
B25D & B30D 6X6 CHAPTER 4 872106
CHAPTER 4. POWER TRAIN

TRANSMISSION EXTERNAL COMPONENTS
12
11 1 13
2 3 5
16
15
9 10 8 7 4 14
6
1. Retarder Temperature Sensor. 10. Main Pressure.

2. Port Out-To-Cooler. 11. Retarder (ON) Pressure/Lube Pressure
3. Port In-From-Cooler. (Retarder OFF).
4. Dipstick Port. 12. Auxiliary Drive.
5. Pressure Before Converter. 13. Identification Plate.
6. Throttle Pressure. 14. Transmission Wire Harness Connector.
7. Retarder Pressure. 15. Breather (Filler).
8. Retarder Control Pressure. 16. Output Shaft.
9. Retarder Solenoid.
ISSUE 0 147
872106 CHAPTER 4 B25D & B30D 6X6
TRANSMISSION CONTROL SYSTEM
TRANSMISSION
RETARDER
MACHINE CONTROL
TCU
INPUTS/OUTPUTS
SHIFT
CONTROL
CCU DIAGNOSTIC
MACHINE
INPUTS/OUTPUTS ACCELERATOR
CAN BUS ECU POSITION
SIGNAL
MDU
ENGINE
INPUTS/OUTPUTS
OUTPUTS
BUFFER
MDU INPUTS
GD3003CFM
The transmission control system consists of the • Transmission Shift Control.

following components: • Transmission Control Module.
- Pressure Switch.
• Transmission Control Unit (TCU). - Temperature Sensor.
• Chassis Control Unit (CCU). - Oil Level Sensor.
• Accelerator Position Sensor. - Solenoid Valves.
• Transmission Speed Sensors: - Retarder Control.
- Input Speed Sensor. • Diagnostic Data Control.
- Turbine Speed Sensor.
- Output Speed Sensor.
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B25D & B30D 6X6 CHAPTER 4 872106
The accelerator position sensor, speed sensor Each shift is measured and stored by the TCU so
and transmission shift control send information via the optimum shift rate is adapted for present
wiring harnesses to the TCU. operating conditions.
The TCU processes this information and sends The TCU has the ability to “learn” quickly as
signals to the transmission control module to conditions change and refine shifts at a slower rate
actuate specific solenoid valves. as conditions remain constant.
These solenoid valves control oncoming and A CAN data line signal is used to communicate
offgoing clutch pressures to provide transmission between the TCU and CCU. The CCU provides a
shifts that match engine speed and operating signal for “bin up” which allows the TCU not to
conditions to protect the transmission from upshift the transmission above first gear.
damage.
The TCU provides the CCU with a signal to
The TCU has the ability to adapt or “learn” while it activate the neutral start circuit and the backup
operates. alarm circuit.
ISSUE 0 149
872106 CHAPTER 4 B25D & B30D 6X6
Transmission Cross Sectional Diagram
16
17
18
15 19
20
21
14
22
13
23
12
24
11
10
9
25
8
26
7
6 27
5
4
2 28
1
29
GD3004CFM
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ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
1. Drive Flange. 16. Output Shaft.

2. Torque Converter Turbine. 17. Output Speed Sensor.
3. Torque Converter Stator. 18. Clutch G.
4. Torque Converter Pump. 19. Clutch F.
5. Auxiliary Drive Gear. 20. Pressure Test Port.
6. Control Element. 21. Clutch E.
7. Oil Supply Flange. 22. Shift Control Unit.
8. Auxiliary Drive. 23. Clutch D.
9. Clutch A. 24. Turbine Sensor.
10. Clutch B. 25. Oil Sump.
11. Clutch C. 26. Retarder.
12. Planetary Gear Set 1. 27. Primary Pump.
13. Planetary Gear Set 2. 28. Converter Lockup Clutch.
14. Planetary Gear Set 3. 29. Turbine Shaft.
15. Planetary Gear Set 4.
Torque Convertor Operation
The torque converter contains: the torque converter acts as a hydraulic coupling
between the engine and transmission.
• Pump.
• Turbine. A lockup clutch is contained in the torque
• Stator. convertor and contains the following:
The pump is the input element and is driven by the • Piston.

engine. The turbine is the output element and • Clutch Plate/Damper.
hydraulicaly driven by the pump. The turbine turns • Backplate.
the transmission input shaft. The stator is the
reaction element or torque multiplying element When the pump and turbine are turning at almost
when the pump turns faster than the turbine. the same speed, the TCU sends a signal to
transmission solenoid F to engage the lockup
When turbine speed approaches pump speed, the clutch. When the lockup clutch is engaged, it acts
stator begins to rotate with the pump and turbine. as a solid coupling and the torque converter turns
When this occurs, torque multiplication stops and at engine speed.
ISSUE 0 151
872106 CHAPTER 4 B25D & B30D 6X6
Transmission Clutch Engagement (Retarder Activated)
24
COOLED
WATER
14
COOLED
AIR
13
16
Psch
12
D8
4 15
D1
11
10
20
D1
A8
D2
17
PVW
R1
19 18
R2
R3
22
R3
P
RR3
21
23
27
2 26 25
WK
A8
RP
28
1 Hy30D3001CFM
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ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
Transmission Clutch Engagement (Retarder De-activated)
COOLED
WATER
24
14
COOLED
AIR
D8
13 16
P SCH
12
4
D1
15
11
10
20
A8
D1
D2
17
R1
P VW
19 18
R3
22
R3
R2
RR3
P
P
R3
21
26 25 23
27
WK
2
A8
PP
28
1 Hy30D3002CFM
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872106 CHAPTER 4 B25D & B30D 6X6
1. Torque Converter. 15. Throttle Pressure Valve.

2. Retarder. 16. Throttle Pressure Test Port.
3. Main Pressure Valve. 17. Clutch G Solenoid Valve.
4. Lube Pressure Valve. 18. Torque Converter Relief Valve.
5. Cooler Charge-Over Valve. 19. Torque Converter Pressure Test Port.
6. Clutch Pack A. 20. Converter Counter Pressure Valve.
7. Clutch Pack B. 21. Retarder Control Pressure Test Port.
8. Clutch Pack C. 22. Retarder Control Valve.
9. Clutch Pack D. 23. Clutch A Solenoid.
10. Clutch Pack E. 24. Cooler Water.
11. Clutch Pack F. 25. Sump.
12. Clutch Pack G. 26. Filter.
13. Retarder (ON) Pressure/Lube Pressure 27. Pump.
(Retarder/OFF) Test Port. 28. Main Pressure Test Port.
14. Cooler Air.
1st gear shown. Refer to Transmission Engagement Chart for other gears.
Transmission Engagement Chart
Gear Solenoids Clutches Engaged
1st Y11 & Y17 Energized A&G
2nd Y12 & Y17 Energized A&F
3rd Y13 & Y17 Energized A&E
4th Y14 & Y17 Energized A&D
5th Y16 & Y17 Energized A&B
6th Y14 & Y16 Energized D&B
Reverse Y12 & Y15 Energized C&F
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B25D & B30D 6X6 CHAPTER 4 872106
Transmission Retarder Operation
2
3
4 5 6
GD3005CFM
1. Stator. 4. Clutch Pack B.

2. Stator Ring. 5. Clutch Pack C.
3. Rotor. 6. Clutch Pack A.
ISSUE 0 155
872106 CHAPTER 4 B25D & B30D 6X6
The transmission retarder system consists of the Retarder Deactivated

following components:
• Rotor.
• Stator.
1
• Stator Ring.
• Retarder Control Valve.
The rotor (3) is splined to the output shaft and is

driven at output shaft speed. The retarder stator
(1), and stator ring (2) have integral vanes. The
rotor rotates between the stationary stator and
stator ring.
Retarder intensity is determined by one of six

positions of the retarder hand control lever,
transmission output speed, retarder oil
temperature, and the transmission gear attained.
When the retarder is deactivated, oil flow enters
The retarder hand control lever sends a signal to the retarder, hitting the stator ring vane (1).
the transmission control unit (TCU) which controls
The vane is open, which allows the oil to be
the retarder control valve. The control valve sends
redirected back to the rotor, allowing the oil to
the proper amount of transmission oil to the
circulate without resistance.
retarder for the intensity of retardation selected by
the retarder hand control lever. Retarder Activated
For electrical operation of retarder (See
“Transmission Control Unit And Retarder
Circuit Theory Of Operation” on page 73) 2
Retarder Operation
The retarder control valve is activated by the
proportional solenoid, dependent on the electrical
signal sent by the retarder lever.
The rotor is connected to the transmission input

shaft, so when a gear is engaged, the rotor is also
connected to the driving axles of the vehicle. The
stator is fixed to the transmission housing.
When the retarder is activated, the stator ring

vanes (2) close. The rotor forces the oil into the
blades of the stator.
The direction of the oil flow is reversed and

slowed. Due to the reverse of oil flow direction in
the stator, the rotation of the rotor is also slowed,
as is the vehicle speed.
Transmission oil used in the retarder is sent to the

cooler and then returned to the transmission
sump. During retarder operation, torque converter
oil is routed directly to the lube circuit.
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ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
Inter-Axle Lock Operation

The inter-axle lock is a planetary gear set in the
transfer case. The planetary gear set allows the
front and rear axles to turn at different speeds due
to a differential action.
The inter-axle lock will only activate if the throttle

position is less than 10 percent. When the inter-
axle lock collar is engaged, the planetary goes into
a lockup configuration and torque is 1:1 front and
rear. With the inter-axle lock in lockup, both axles
turn at the same speed and equal power is sent to
all three axles.
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872106 CHAPTER 4 B25D & B30D 6X6
158 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
CHAPTER 4. POWER TRAIN
SECTION 2. DIAGNOSTIC INFORMATION
DIAGNOSTIC PROCEDURE
Perform Operational Check-out.
Follow the six basic steps below to carry out
trouble shooting efficiently. Check all systems and functions on the machine.
Use the helpful diagnostic information in the
Know The System check-out to pinpoint the possible cause of the
problem.
Study the machine technical manual. Understand
the system and circuits. Use schematics, Perform Troubleshooting
component location drawings and theory of
operation for each circuit and circuit components Connect laptop computer, if available. The self-
work. diagnostic function lists any service codes and
give corrective action information.
Ask The Operator
Before starting troubleshooting, first check battery
What type of work was the machine doing when voltage, circuit breakers and fuses.
the trouble was noticed?
Go to test groups to check pressures and
Did the trouble start suddenly or has it been voltages. Make sure adjustments are correct.
getting worse?
Trace And Cause
Did the machine have any previous problem? if so,
which parts were repaired? Before reaching a conclusion, check the most
probable and simplest to verify. Use the flow
Inspect The Machine charts and symptom, problem, solution charts to
help identify probable problem components.
Check all daily maintenance points. (See Section
3-4min the Operators Manual). Check batteries, Make a plan for appropriate repair to avoid other
fuses, circuit breaker and electrical connections. malfunctions.
ISSUE 0 159
872106 CHAPTER 4 B25D & B30D 6X6
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS

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 (See CHAPTER
15, SECTION 2 in the OMM).
Final Drive Overheating. Final drive oil level incorrect. Adjust oil level (See CHAPTER
Final Drive Noisy. Final drive oil level incorrect. Adjust oil level (See CHAPTER
Final Drive Leaking Oil. Final drive cover cap screws Tighten cap screws (See Axle
loose. Outboard Planetaries in
CHAPTER 2, SECTION 5 of
Repair Manual).
Drain plug loose. Tighten drain plug.
Damaged O-Ring on cover. Replace O-ring (See Axle

Outboard Planetaries in
Repair Manual).
Breather plugged. Clean or replace breather.
Differential Assembly Noisy and/ Differential oil level incorrect. Adjust oil level (See CHECK
or Overheating. AXLE OIL LEVELS in
OMM).
Differential oil type Incorrect. Drain and refill with correct type
oil (See Change Axle Oil in
OMM).
Differential Lock Bearing Used Use differential lock only when

Excessively. needed.
Internal Differential Failure: Disassemble and repair (See

Repair Manual).
Premature Brake Pad Wear. Operator “Riding” the brakes Instruct operator on proper
brake usage.
Brake mud guard missing. Replace mud guard (See

Service Brakes CHAPTER 9,
SECTION 1 in Repair Manual).
Mud or sand getting into brake Replace mud guard (See

pads. Service Brakes CHAPTER 9,
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B25D & B30D 6X6 CHAPTER 4 872106
Poor Braking Performance Brake pads worn. Replace brake pads (See
Service Brakes CHAPTER 9,
SECTION 1 in Repair Manual)
Brake valve failed. Replace brake valve (See Brake

Valve in CHAPTER 9,
Brake calliper sticking. Clean and repair calliper (See

Service Brakes - B35D in
CHAPTER 1011, SECTION
1011 in Repair Manual).
Retarder not comming ON. “Service Code Diagnostics -

Transmission Control Unit
(TCU)” on page 101.
Service Brakes Do Not Release Brake calliper piston sticking. Clean or replace pistons (See
Fully Service Brakes CHAPTER 9,
SECTION 1 in Repair Manual)
Brake valve failed Replace brake valve (See Brake

Valve in CHAPTER 9,
Park Brake Does Not Release Chassis Control Unit (CCU) Check CCU (See “Remove and
Install Chassis Control Unit”
on page 136).
Park brake control valve failed Replace park brake control

valve (See Remove and Install
Park Brake Control Valve in
Repair Manual).
Air pressure low Check system air pressure (See

Park Brake Pressure Test in
CHAPTER 5, “SECTION 3.
TESTS” on page 199).
Park brake relay does not Check park brake relay (See
energize “Park Brake And Exhaust
Brake Circuit Theory Of
Operation” on page 81).
Park brake solenoid will not Check park brake solenoid (See
energize “Park Brake And Exhaust
Brake Circuit Theory Of
Park brake actuator failed Replace actuator (See Remove

and Install Park Brake
Actuator in CHAPTER 2262,
SECTION 2262 in Repair
Manual).
Park brake incorrectly adjusted Adjust park brake (See “Park

Brake Adjustment” on
page 176).
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872106 CHAPTER 4 B25D & B30D 6X6
Park Brake Will Not Hold Park brake pads oily Replace pads and clean disk
(See Park Brake in CHAPTER
10, SECTION 1 in Repair
Manual).
Park brake incorrectly adjusted Adjust park brake (See “Park

Brake Adjustment” on
page 176).
Park brake control valve failed Replace park brake control

valve (See Remove And Install
Park Brake Control Valve,
Repair Manual).
Engine Will Not Start (Turn Gear selector not in neutral Push N (Neutral) on gear
Over) selector panel.
Shift Control failed Replace shift control
Voltage to TCU too low or not Recharge or replace batteries

present Check and repair open harness
TCU failed Replace TCU (See “Remove

and Install Transmission
Control Unit” on page 137).
Machine Will Not Move Transmission or vehicle harness Connect, repair or replace
disconnected or failed. harness.
TCU failed. Replace TCU (See “Remove

Transmission Will Not Shift to Oil level to low Adjust to correct level (See
Forward or Reverse Check Transmission Oil Level
in CHAPTER 15, SECTION 2 in
the OMM).
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.
TCU failed Replace TCU (See “Remove

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 pressure

low regulator failed. Check
transmission pressure (See
“Transmission Pressure Test”
on page 171).
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B25D & B30D 6X6 CHAPTER 4 872106
Engine Speed too Low During Engine power low. Determine Cause of low power.
Torque Converter Stall.
Torque convertor failure Replace torque convertor (See
Disassemble Transmission in
repair manual.
Low Transmission Lube Transmission oil level low. Add Transmission oil.
Pressure.
Lube filter plugged. Replace lube filter (See Replace
Transmission Oil Filters in
CHAPTER 15, SECTION 2 van
OMM).
Torque converter regulator valve Disassemble and repair. (See

failed. Disassemble and Assemble
Control Valve in CHAPTER 3,
Transmission cooler lines Repair or replace cooler lines.

restricted or damaged.
Lube pressure regulator failed. Disassemble and replace

regulator (See Disassemble
and Assemble Control Valve
repair manual).
Transmission cooler plugged. Clean or replace cooler (See

Remove and Install
Transmission Oil Cooler
Repair Manual).
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872106 CHAPTER 4 B25D & B30D 6X6
Low Main Pressure in All Gears Transmission oil level low. Add transmission oil.
Transmission oil filter plugged. Replace filter (See Replace

OMM).
Transmission pump suction filter Disassemble and clean filter

plugged. (See Replace Transmission
Oil Filters in CHAPTER 15,
SECTION 2 in OMM).
Transmission oil pressure gauge Replace MDU (See “Remove

failed. and Install Menu Display Unit”
on page 138).
Transmission main pressure Repair or replace main pressure

valve sticking or failed. valve (See Disassemble and
Assemble Control Valve in
CHAPTER 3, SECTION 3 in the
Repair Manual).
Transmission pump failed. Disassemble and replace pump

(See Disassemble
Transmission in CHAPTER 3,
SECTION 3 in the Repair
Manual).
Excessive Clutch Slippage and Transmission oil level low. Add transmission oil.
Chatter.
Transmission main pressure Repair or replace main pressure
valve sticking or failed. valve (See Disassemble and
Repair Manual).
Torque converter lockup clutch Disassemble torque converter

failed. (See Disassemble and
Assemble Torque Converter
the Repair Manual).
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B25D & B30D 6X6 CHAPTER 4 872106
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 (See

Change Transmission Oil in
the OMM).
Transmission breather clogged. Remove and clean breather

(See Clean, Check and
Replace Breathers in
the OMM).
Transmission oil contaminated. Drain oil, replace filters and refill

oil (See Change Transmission
Oil in CHAPTER 15, SECTION
2 in the OMM).
Buzzing Noise Coming From Transmission oil level too high Drain oil to correct level (See
Transmission. Change Transmission Oil in
the OMM).
Transmission filter plugged. Replace filter (See Replace

OMM).
Transmission pump suction filter Clean filter (See Replace

plugged. Transmission Oil Filters in
OMM).
Main pressure low. Check transmission main

pressure (See “Transmission
Pressure Test” on page 171).
Transmission Overheating in All Transmission oil level too low or Adjust oil level (See Change
Gears. too high. Transmission Oil in CHAPTER
Transmission oil cooler plugged. Clean or replace cooler (See

Remove and Install
Transmission Oil Cooler
Repair Manual).
Oil cooler fan failed. Check cooling fan (See

“Transmission Control Unit
And Retarder Circuit Theory
Of Operation” on page 73).
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872106 CHAPTER 4 B25D & B30D 6X6
Shift Selector Displays N Transmission harness connector Reconnect harness connector.

(Neutral) and Machine Will Not disconnected.
Move
Electrical failure. “Service Code Diagnostics -
Transmission Control Unit
(TCU)” on page 101).

Transmission shift control failed. Replace transmission shift

control.
Transmission Will Not Shift to Transmission harness Connect harness.

Forward or Reverse (Stays in disconnected.
Neutral)
Transmission oil level too low. Add transmission oil (See
CHAPTER 1 in the OMM for oil
specification and quantities).
TCU input voltage to low. Reset circuit breaker.
Transmission shift control failed. Replace transmission shift

control.

Transmission Not Shifting Engine slow idle speed too high. Calibrate accelerator pedal (See
Properly (Rough Shifts, Shifting “Remove, Install, and
at Too Low or Too High Speed). Calibrate Accelerator Pedal
Position Sensor” on
page 140).
TCU voltage too low or too high. Check charging system voltage
and circuit breakers.
Transmission oil level low. Adjust oil level.
TCU failed. Replace TCU (See Remove

“Remove and Install
Transmission Control Unit”
on page 137).
Transmission Will Not Make a Transmission oil level low. Adjust oil level.
Specific Shift.
Engine power low. Check engine power (See
“Torque Converter Stall Test”
on page 173).

Harness failure. Check wire harness.
Transmission shift control failed. Replace shift control.
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B25D & B30D 6X6 CHAPTER 4 872106
Transmission Oil Leaking Into Transmission pump seal worn. Replace seal (See
Torque Converter Housing. Disassemble Transmission
and Assemble Transmission
the Repair Manual).
Rear engine seal leaking. Replace seal (See Crankshaft

Oil Seals in CHAPTER 4,
Manual).
Transmission Retarder Does Solenoid Y10 Solenoid Failed. Replace solenoid (See
Not Function. Disassemble and Assemble
Manual).
External Proportional Y11 Replace solenoid.

Solenoid Failed.
Retarder control valve failed. Replace retarder control valve

(See Disassemble and
Assemble Control Valve
Group in CHAPTER 3,
Manual).
Transmission output speed Check output speed (See

incorrect. “Transmission Solenoids,
Speed Sensors, Sump
Temperature Sensor, and
Retarder Resistor Tests
Specification” on page 132).
ISSUE 0 167
872106 CHAPTER 4 B25D & B30D 6X6
Transmission Retarder Weak. Solenoid Proportional Y11 Replace solenoid. (See

solenoid sticking. Disassemble and Assemble
Manual).
Retarder control valve sticking Replace control valve (See

Disassemble and Assemble
Manual).
Retarder temperature sensor Replace temperature sensor.

damaged.
Retarder intensity spring Disassemble retarder control

damaged. valve (See Disassemble and
Assemble Retarder and P3
Planetary in CHAPTER 3,
Manual).
Transmission charge pump Disassemble transmission

worn. charge pump (See
Disassemble Transmission
Charge Pump in CHAPTER 3,
Manual).
Worn components causing Disassemble retarder housing

internal leak. (See Disassemble
Transmission in CHAPTER 3,
Manual).
Retarder Stays On When Not Solenoid Proportional Y11 Replace solenoid (See
Requested. solenoid sticking.. Disassemble and Assemble
Manual).
Retarder control valve sticking. Replace control valve (See

Disassemble and Assemble
Manual).
Transmission Retarder Too Retarder control valve sticking. Replace retarder control valve
Aggressive. (See Disassemble and
Repair Manual).
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ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
Power Train Component Location Diagram
11
4
8
3 2
9
10
1
GD3001CFM
ISSUE 0 169
872106 CHAPTER 4 B25D & B30D 6X6
1. Front Axle. 6. Walking Beam.

2. Transmission. 7. Rear Axle.
3. Transfer Case. 8. Suspension Absorber.
4. Park Brake. 9. Oil-to-Air Cooler.
5. Middle Axle. 10. Oil-to-Water Cooler.
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B25D & B30D 6X6 CHAPTER 4 872106
CHAPTER 4. TRANSMISSION
SECTION 3. TESTS
TRANSMISSION WARM-UP
PROCEDURE Transmission Pressure Test
This test will check the performance of the
n CAUTION transmission charge pump and main pressure
regulator.
Perform procedure in an open area away
from other people or machines. Machine
may move unexpectedly.
n WARNING
1
Never stall torque converter for more than

15 seconds. Do not allow transmission tem-
perature to exceed 100° C (212° F). Trans-
mission damage will result if temperature is
allowed to exceed the specification.
• Apply park brake. 3

• Start engine. 2
• Select transmission temperature on the MDU. 4
(See MDU - menu functions in Chapter 8 of 5
the OMM). Watch transmission temperature
and tachometer display).
• Allow air pressure buzzer to go off. 6
• Push service brake pedal and hold it down
during warm-up. 1. (Retarder ON) Pressure/(Retarder OFF)
• Shift transmission into 1st gear. Accelerate Lubrication Pressure (D6/D7 Unmarked).
throttle to 1500 r.p.m. and hold (approximately 2. Main Pressure (P).
15 seconds). After 15 seconds the CCU will 3. Retarder pressure (R3).
decrease the engine speed to approximately 4. Pressure Before Convertor (D2).
800 r.p.m. Release the accelerator pedal and 5. Trottle Pressure (D1).
select neutral on gear selector. 6. Retarder Control Pressure (RR3
• Push down on accelerator pedal. Engine will Unmarked).
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).
ISSUE 0 171
872106 CHAPTER 4 B25D & B30D 6X6
SPECIFICATIONS Transmission Pressure
Transmission Oil Temperature 80 - 90° C (176 - 194° F)
Slow idle 780 - 820 r.p.m., Gear - Neutral, Port P 700 - 1500 kPa {7.0 - 15.0 bar (101 - 218 psi)}.
Pressure.
Slow idle 780 - 820 r.p.m., Gear - Neutral, Port D1 400 kPa {4 bar (58 psi)}.
Pressure.
Slow idle 780 - 820 r.p.m., Gear - Neutral, Port D2 300 - 450 kPa {3.0 - 4.5 bar (44 - 65 psi)}.
Pressure.
Slow idle 780 - 820 r.p.m., Gear - Neutral, Port D6/ 10 - 80 kPa {0.1 - 0.8 bar (1.5 - 11.6 psi)}.
D7 Pressure.
Slow idle 780 - 820 r.p.m., Gear - Neutral-to-Drive, 700 - 1500 kPa {7.0 - 15.0 bar (101 - 218 psi)}.
Port P Pressure.
Slow idle 780 - 820 r.p.m., Gear - Neutral-to-Drive, 20 - 10 kPa {0.2 - 15.0 bar (3.0 - 1.5 psi)} for 2
Port D1 Pressure. seconds.
Slow idle 780 - 820 r.p.m., Gear - Neutral-to-Drive, 300 - 450 kPa {3.0 - 4.5 bar (44 - 65 psi)}.
Port D2 Pressure.
Slow idle 780 - 820 r.p.m., Gear - Neutral-to-Drive, 10 - 80 kPa {0.1 - 0.8 bar (1.5 - 11.6 psi)}.
Port D6/D7 Pressure.
2570 - 2670 r.p.m., Gear - Neutral, Port P 1600 - 2000 kPa {16.0 - 20.0 bar (232 - 290 psi)}.
Pressure.
2570 - 2670 r.p.m., Gear - Neutral, Port D1 400 kPa {4 bar (58 psi)}.
Pressure.
2570 - 2670 r.p.m., Gear - Neutral, Port D2 600 - 850 kPa {6.0 - 8.5 bar (87 - 123 psi)}.
Pressure.
2570 - 2670 r.p.m., Gear - Neutral, Port D6/D7 180 - 250 kPa {1.8 - 2.5 bar (26 - 36 psi)}.
Pressure.
2570 - 2670 r.p.m., Gear - 1, Lockup Clutch 1000 - 1200 kPa {10.0 - 12.0 bar (145 - 174 psi)}.
Engaged, Port P Pressure.
2570 - 2670 r.p.m., Gear - 1, Lockup Clutch 400 kPa {4 bar (58 psi)}.
Engaged, Port D1 Pressure.
Engaged, Port D2 Pressure.
Engaged, Port D6/D7 Pressure.
ESSENTIAL TOOLS SERVICE EQUIPMENT AND TOOLS
202839 1/8 x 7/16-20 M ORB Quick Coupler. 4136 kPa {41.4 bar (600 psi)} Gauge
Parker No. M10-4F80HG5 7/16-20 F x M10 x 1

Adapter.
Remove plugs and install adapter and quick

Shut engine OFF and apply park brake. coupler in pressure ports (1; 2, 4 and 5).
172 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
Attach hoses and gauges to fittings. Perform test in an open area away from other
people and machines.
Start machine and warm transmission to
specification. (See “TRANSMISSION WARM-UP Ensure that all oil levels are correct.
PROCEDURE” on page 171).
Ensure that engine slow and fast idle speeds are
n
correct.
CAUTION
Perform procedure on a hard flat surface, Place chocks in front and behind all wheels.
away from other people or machines.
Start engine and let air pressure build to normal
operating pressure.
NOTE:Torque converter lockup occurs
Do the transmission warm-up procedure to heat
when turbine speed is approximately
transmission oil, (See “TRANSMISSION WARM-
80% of engine speed.
UP PROCEDURE” on page 171).
Operate machine in gear specified and record
transmission pressures as indicated. (Table on n CAUTION
previous page).
Do not allow transmission oil temperature to
To take clutch pressure readings in a specific remain above 100° C (212° F) for long
gear, e.g. 4th: periods of time. Damage to the transmission
may occur.
If transmission pressures are not to specification,
check transmission charge pump and/or main
pressure regulator. (See Disassemble and Check stall speed.
Assemble Front Input Control Element and
• Hold service brakes so machine cannot roll.
Disassemble and Assemble Control Valve
• Shift transmission into 1st gear. Push
CHAPTER 3, SECTION 3 in the Repair Manual).
accelerator pedal to the floor and hold it for 10
- 15 seconds until the engine sped stabilizes.
Torque Converter Stall Test
Record this stall speed. (See stall speed
Torque Converter Stall Test Specification specification on this page).
Engine Slow Idle - Speed: - - - - - - - - - - 800 ± 20 r.p.m. Shift transmission into neutral and run engine at
Engine Fast Idle - Speed- - - - - - - - - - 2620 ± 50 r.p.m. slow idle to cool for one minute before turning off.
Stall Speed B25D - - - - - - - - - - - - - - - 1941 ± 50 r.p.m. If engine stall speed is below specification and the
Stall Speed B30D - - - - - - - - - - - - - - - 1941 ± 50 r.p.m. engine is smoking, it may be low on power.
n WARNING If engine stall speed is above specification, the

transmission may be slipping.
1. Never stall torque converter for more than
30 seconds. Do not allow transmission tem- If engine stall speed is below specification and the
perature to exceed 100° C (212° F). Trans- engine is not smoking, the torque converter stator
mission damage will result if temperature is could be stuck.
allowed to exceed the specification.
2. Never perform stall test in reverse. Drive If engine stall speed is a little below specification,
shaft or transfer case damage may result. but the transmission oil overheats during normal
Reverse gear ratio and excessive torque will operation and will not cool down while idling, the
be transferred to the drive shaft, transfer torque converter stator could be stuck.
case or differential.
n CAUTION
Perform test in an open area away from
other people and machines. Machine may
move unexpectedly during test.
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872106 CHAPTER 4 B25D & B30D 6X6
Torque Converter Stator Test If transmission temperature does not cool to

normal operating temperature, stator may be
Torque Converter Stator Specification stuck.
Freewheeling Stator Transmission
NOTE:Ensure transmission cooler or
Oil Temperature- - - - - - - - - - 71 - 93° C (160 - 200° F)
radiator is not clogged.
Stuck Stator Transmission
Oil Temperature- - - - - - - - - - - - - - - - - 100° C (212° F)
Torque converter must be removed and repaired.
The torque converter stator clutch can fail in two
ways: Transmission Oil-to-Air Cooler
Restriction Test
• Freewheeling, when the clutch will not lock.
• Locked, when the clutch will not release. Transmission Oil-to-Air Cooler Restriction
Specification
Freewheeling Stator Test
Transmission Oil Temperature - - - - - - -80° C (176° F).
A freewheeling stator can cause sluggish slow
Engine Speed: Fast Idle- - - - - - - - - - -2000 ± 50 r.p.m.
speed operation, but machine will seem to operate
normally at high speeds. Cooler Flow: Flow-Rate - - - - - - - 60 l/min (16 gal/min).
Specified Test Pressure
Transmission oil will get hot or overheat quickly. Pressure - - - - - - - - - - - - - - 200 kPa {2.0 bar (30 psi)}
Transmission may not upshift with engine at full Equipment and Tools
speed. Digital Hydraulic Tester - - - - - - - - - - - - - - - -JT07148.
• Operate loaded machine in a normal manner The transmission out-to-cooler restriction test
and monitor transmission oil temperature. allows the technician to diagnose a restricted
• While operating machine, notice how and transmission oil cooler.
when transmission upshifts.
• If transmission temperature is hotter than
normal and transmission upshifts sluggishly or 1
4
not at all, stator is freewheeling. Torque
converter must be repaired.
Stuck Stator Test

A stuck stator will cause transmission oil to
overheat and not cool to normal temperature 5
during non-operation.
6
Transmission will overheat at fast operating
2
speeds.
Machine may not reach full operating speeds.
Torque converter stall test results will be normal.

3
GD3003CFM
Perform transmission warm-up procedure to warm
transmission oil, (See “TRANSMISSION WARM- Disconnect transmission out-to-cooler hose (5)
UP PROCEDURE” on page 171 and and cooler connecting hose (4) from transmission
specification on this page). oil-to-water cooler (6).
Shift transmission to neutral and run engine at Connect hoses (4 and 5) together using the
1200 - 1500 r.p.m. for two to three minutes. necessary fittings.
Monitor transmission temperature.
Disconnect return-to-transmission hose (2) from
oil-to-air cooler (3) and install flow meter between
hose (2) and cooler.
174 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
Front Suspension Strut Leakage

Start machine and warm transmission to
specification temperature.
Check
Operate engine at fast idle and read flow at

specified pressure.
If flow rate is less than specification, the cooler is

restricted.
Transmission Oil-to-Water Cooler

Restriction Test
Transmission Oil-to-Water Cooler
Restriction Specification 1
Transmission Oil Temperature - - - - - - - 80° C (176° F).
Engine Speed: Fast Idle - - - - - - - - - - 2000 ± 50 r.p.m.
Cooler Flow: Flow-Rate - - - - - - -60 l/min (16 gal/min).
Specified Test Pressure
Pressure - - - - - - - - - - - - - - 200 kPa {2.0 bar (30 psi)}
Equipment and Tools

Digital Hydraulic Tester - - - - - - - - - - - - - - - JT07148. If machine is lower on one side than the other,
check front struts for oil leakage.
The transmission oil cooler restriction test allows
the technician to diagnose a restricted If struts are not leaking oil, recharge struts with dry
transmission oil cooler. nitrogen.
Remove bottom clamp (1) from boot.

1
4
Slide boot up to expose strut rod. Any oil leakage
will accumulate in boot.
A light coating of oil on strut rod is OK. Recharge

strut with dry nitrogen.
5 Any oil accumulated in boot indicates a leak.

Replace strut.
6
2 Park brake Test
n CAUTION
Perform test in an open area away from
3 people and other machines. Machine may
GD3003CFM move unexpectedly during this test.
Disconnect cooler connecting hose (4) and return-
to-transmission hose (2) from oil-to-air cooler (3). Apply park brake.
Install flow meter between hoses (2 and 4). Apply inter-axle lock to prevent wheel slippage.
Start machine and warm transmission to Move shift selector to D (Drive).
specification temperature.
Release service brakes.
Operate engine at fast idle and read flow at
specified pressure. Increase engine speed to fast idle for a few
seconds.
If flow rate is less than specification, the cooler is
restricted.
ISSUE 0 175
872106 CHAPTER 4 B25D & B30D 6X6
Park brake must not let machine move. Move the machine to a level surface.
n
If machine moves, check pad brake thickness and
park brake adjustment. (See Park Brake Pad CAUTION
Thickness and Park Brake Adjustment Always install the bin prop when working
Procedure in this SECTION). under the raised bin. Personal injury may
result if the bin lowers unexpectedly.
Park Brake Pad Thickness Check
Park Brake Pad Thickness Specification Raise bin and install bin prop. (See Install Bin
prop in CHAPTER 7, SECTION 1 in the OMM).
n CAUTION
Always install bin prop when working under n CAUTION
the raised bin. Personal injury may result if
Machine may roll when park brake is
the bin lowers unexpectedly.
released. Chock all wheels in front of and
behind wheels to keep machine from rolling
Raise bin and install bin prop. (See Install Bin when park brake is released.
Prop in CHAPTER 7, SECTION 1 in the OMM).
Park Brake Pad Thickness Specification Release park brake.
Park Brake Pad Thickness Min. - - - - - - 3mm (0.118 “).

5
3 4
2
Remove release stud (1), nut (2) and washer (3)

from storage position (4).
Install release stud in hole at rear of park brake

3mm actuator housing and rotate a 1/4 turn to lock into
3mm place.
(0.118”)
(0.118”) Install washer and nut onto release stud and
tighten until park brake releases.
Measure park brake pad thickness. Change park
brake pads when they are less than specification
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

6mm Allen Key
176 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 4 872106
Remove Allen Key and install adjuster plug and

washer.
Remove park brake release stud from actuator.
1 Start engine. Allow air system to increase to

normal operating pressure (See specification).
Release the park brake. Measure from bottom of

park brake actuator to centre of clevis on actuator
rod.
Remove plug and washer (1) covering the

adjusting screw.
NOTE:Plug is located on the back side of

the park brake actuator bracket.
Record measurement.
Apply park brake. Measure from bottom of park

brake actuator to centre of clevis on actuator rod.
Subtract smallest measurement from the largest to

get actuator rod travel.
If actuator rod travel is more than specified, start

engine; release and apply park brake 20 times to
help seat parts.
Re-take actuator rod travel measurements. If

travel is still more than specification, actuator has
failed and must be replaced.
Insert a 6 mm Allen Key into the adjusting screw

and turn counter clockwise until resistance is felt.
NOTE:A clicking sound is heard as

adjusting screw is turned.
Tun Allen Key clockwise until resistance is felt.
Then turn Allen Key counter clockwise seven

clicks.
ISSUE 0 177
872106 CHAPTER 4 B25D & B30D 6X6
178 ISSUE 0
B25D & B30D 6X6 CHAPTER 5 872106
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.
ISSUE 0 179
872106 CHAPTER 5 B25D & B30D 6X6
PNEUMATIC SYSTEM SCHEMATIC
INSIDE OUTSIDE
CAB CAB
10 11
H
12
TC
13
8
TLD TVD
TLU TVU
TLX
15 14
6
TLA
5 28
29
16 27
4 25
1
17
26
3 3
PBS
PB
19
PBX
18 24
PBA
22
2
21
EB
23
22
20
21
1
AS
Pne30D4002CFM
180 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
1. Exhaust Brake Solenoid. 16. Exhaust Orifice.

2. System Air Pressure Sensor. 17. Quick Coupler.
3. Park Brake Valve. 18. Park Brake Actuator.
4. Park Brake Solenoid. 19. Exhaust Silencer.
5. Park Brake Pressure Switch. 20. Exhaust Brake Cylinder.
6. Bin Pilot Control Valve. 21. Exhaust Silencer.
7. Bin Up Pressure Switch. 22. Drain Solenoid.
8. Inter-Axle Lock Solenoid. 23. Air Reservoir.
9. Inter-Axle Lock Pressure Switch. 24. Regeneration Air Reservoir.
10. Seat Valve. 25. Air Dryer and Unloader Valve.
11. Horn Solenoid. 26. Exhaust Port.
12. Horn. 27. Cooling Pipe.
13. Inter-Axle Lock Actuator. 28. Air Compressor.
14. Bin Control Valve. 29. Engine Air Filter.
15. Exhaust Silencer.
ISSUE 0 181
872106 CHAPTER 5 B25D & B30D 6X6
Air Pressure Supply Circuit Operation
21 1
8 2
7
22 3
5
1
PNeGD0001CFM
1. Engine Air Filter 5. Exhaust Port.

2. Air Compressor. 6. Regeneration Air Reservoir.
3. Cooling Pipe. 7. Drain Solenoid.
4. Air Dryer and Unloader Valve. 8. Air Reservoir.
Compressor
Air Dryer and Unloader Valve
The compressor (2) is gear driven off the engine
and is a single cylinder piston-type compressor. The air dryer and unloader valve has four
functions.
Air is drawn into the compressor through the
engine air filter (1), compressed and sent through Drying The Air:
a cooling pipe (3), then delivered to the air dryer As air from the compressor comes into the air
and unloader valve (4). dryer and unloader valve it passes through a fine
screen filter and desiccant.
The drain solenoid (7) is controlled by the CCU.
After each new engine start the CCU timer is set. Moisture collects on the surface of the desiccant
and is prevented from going to the air system
After the timer reaches 10 minutes the drain components.
solenoid valve is activated for two seconds.
Unloading The Compressor:
A new engine start is when the key switch is set to
the OFF position and it has been at least 10 When air pressure reaches a specified amount,
minutes from the last engine start. the unloader valve acts as a relief valve and will
“blow off”, out port 3 (5), regulating air system
pressure.
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Charging The Regeneration Air Reservoir: Compressed air from the compressor goes to port
Air coming into the air dryer and unloader valve is 1 (1) into chamber A. Air passes through a fine
sent out port 22 to the regeneration air reservoir. screen filter (2) and along the outside of the
desiccant cartridge (4).
The unloader valve, acting as a relief valve,
maintains system pressure in the regeneration air Air passes through the desiccant, moisture is
reservoir. removed and collects on the outside of the
desiccant cartridge.
The regeneration air reservoir air supply is used to
blow backwards through the desiccant cartridge Air flows through the desiccant, unseats check
and purge collected moisture from the cartridge. valve (5) then goes out port 21 (6) to the air
reservoir.
Supplying The Pneumatic Manifold:
From the reservoir air flows to the pneumatic
System pressure air is sent to the pneumatic
manifold where it is distributed to the pneumatic
manifold for distribution to all pneumatic circuits.
system.
Air Dryer and Unloader Valve Air also flows out port 22 (9) and pressurizes the
regeneration air reservoir (8).
Charging The Pneumatic System
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 and
out port 21 to the reservoir. The air will not be
4 dried, but the system will function.
2
B 5
1 1 A 6
21
C
7
11
8
22
9
10
GD4035CFM
1. Port 1
2. Filter.
3. Bypass Spring.
4. Desiccant.
5. Check Valve.
6. Port 21.
7. Unloader Valve.
8. Regeneration Air Reservoir.
9. Port 22.
10. Port 3.
11. Purge Valve.
ISSUE 0 183
872106 CHAPTER 5 B25D & B30D 6X6
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 to
4 assist in opening the purge valve (11).
As the pure valve is opening it allows air pressure

from the regeneration air reservoir to escape up to
chamber B and passes through the desiccant and
2 filter, carrying the collected moisture with it.
5
1 1 6 Any additional moisture collected in chamber A is
21
7 also picked up, sent by purge valve and then out

exhaust port 3.
11
22 8 When the pressure in chamber B drops below 810
kPa (8.1 bar) (117 psi), check valve (5) will close
maintaining system pressure in chamber C and in
the air reservoir.
9
10 When purge valve (11) is open, compressed air
GD3036CFM
from compressor entering through port 1 into
1. Port 1 chamber A is sent directly out exhaust port 3 (10).
2. Filter.
3. Bypass Spring. There is zero pressure in regeneration air
4. Desiccant. reservoir while system is in the “unloading” stage.
5. Check Valve. When system pressure drops approximately 48
6. Port 21. kPa (0.48 bar) (7 psi), check valve (5) opens,
7. Unloader Valve. spring in unloader valve (7) pushes against the
8. Regeneration Air Reservoir. diaphragm, closing the port to purge valve (11)
9. Port 22. and starts the charging cycle again.
10. Port 3.
11. Purge Valve. Pneumatic Manifold
During the charging cycle, moisture is removed The pneumatic manifold receives pressurized air
from the air going to the system and collects on the from the air reservoir and distribute s it throughout
fine screen filter and the outside of the desiccant the pneumatic system.
cartridge.
Exhaust air is routed through the pneumatic
manifold and exits out the exhaust silencers and
orifice outside the cab for the park brake, bin pilot
control valve and exhaust brake. Inter axle lock
and horn is exhausted through the solenoid
mounted on the manifold.
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ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
ISSUE 0 185
872106 CHAPTER 5 B25D & B30D 6X6
Pneumatic Manifold - Outside Cab
PB
7
EB
AT
10
TVD
11
5
TVU
AA2
12
4
A2
TC
3
DS
13
DS2
TC2
30D4001CFM
186 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
1. Bin Pilot Control Valve Exhaust. 8. Park Brake.

2. Park Brake Exhaust. 9. Exhaust Brake.
3. Inter - Axle Lock. 10. Exhaust Brake Exhaust.
4. Park Brake Check Valve. 11. Quick Coupler.
5. Bin Pilot Control Valve Up. 12. Pneumatic System Supply.
6. Park Brake Exhaust Orifice. 13. Air Horn.
7. Bin Pilot Control Valve Down.
ISSUE 0 187
872106 CHAPTER 5 B25D & B30D 6X6
Pneumatic Manifold - Inside Cab
11 12
10
TLD
AT
13
14
PBS
TLA
8
15
7
TLV
AA3
16
6
PBA
PBX
5
TLX
4 3 2
30D4002CF
188 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
1. Bin Pilot Control Valve Exhaust. 10. Exhaust Brake and Exhaust Valve Brake
2. Park Brake Supply. Solenoid.
3. Inter-Axle Lock Solenoid. 11. Park Brake Solenoid.
4. Air Horn Solenoid. 12. Bin Pilot Control Valve Down.
5. Park Brake Exhaust. 13. Park Brake Pressure Switch.
6. System Air Pressure Sensor. 14. Park Brake Solenoid Supply.
7. Seat Valve Supply. 15. Bin Up Pressure Switch.
8. Bin Pilot Control Valve Up. 16. Inter-Axle Lock Pressure Switch.
9. Bin Pilot Control Valve Supply.
ISSUE 0 189
872106 CHAPTER 5 B25D & B30D 6X6
Pneumatic Circuit
INSIDE OUTSIDE
CAB CAB
10 11
H
12
TC
13
8
TLD TVD
TLU TVU
TLX
15 14
6
TLA
16
17
3
PBS
PB
PBX
19
18
PBA
2
EB
20
21
1
AS
Pne30D4003CFM
190 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
1. Exhaust Brake Solenoid. 12. Horn.

2. System Air Pressure Sensor. 13. Inter-Axle Lock Actuator.
3. Park Brake Valve. 14. Bin Control Valve.
4. Park Brake Solenoid. 15. Exhaust Silencer.
5. Park Brake Pressure Switch. 16. Exhaust Orifice.
6. Bin Pilot Control Valve. 17. Quick Coupler.
7. Bin Up Pressure Switch. 18. Park Brake Actuator.
8. Inter-Axle Lock Solenoid. 19. Exhaust Silencer.
9. Inter-Axle Lock Pressure Switch. 20. Exhaust Brake Cylinder.
10. Seat Valve. 21. Exhaust Silencer.
11. Horn Solenoid.
The pneumatic circuit contains the following: When the CCU receives the appropriate signals
from the system air pressure sensor and the park
• Exhaust Brake Circuit. brake latch switch, the CCU energizes the park
• Park Brake Circuit. brake relay, which in turn energizes the park brake
• Bin Pilot Control Valve Circuit. solenoid.
• Inter-Axle Lock Circuit.
• Seat Circuit. With the park brake solenoid energized,
• Air Horn Circuit. compressed air flows to park brake actuator (18),
releasing the park brake.
Exhaust Brake Circuit.
Air from the pneumatic manifold goes to the When the park brake valve lever is moved to the
exhaust brake solenoid (1). The solenoid is ON (brake engaged) position, compressed air in
energized when all the following conditions occur: the park brake pneumatic circuit vents to
atmosphere through the park brake solenoid and
• Accelerator pedal is in the slow idle position. park brake valve. It exits out the exhaust silencer
• Torque converter is in lock-up. (21).
• There must be no electrical failure.
If the key switch is turned to the OFF position with
If any of the above items change while the exhaust the park brake valve lever in the OFF position, the
brakes are applied, the exhaust brake solenoid will park brake solenoid will de-energize and the
de-energize, the quick release valve will open to compressed air from the actuator will exit out of
vent and the exhaust valve system will disengage. exhaust orifice (16), causing the park brake to
engage.
Park Brake Circuit
The park brake is spring applied and released with If the system air pressure falls below 550 kPa (5.5
compressed air. The function of the park brake bar) (81 psi), the CCU will de-energize the park
circuit is to engage and disengage the park brake brake solenoid, causing the park brake to engage.
by controlling the flow of the compressed air to
When the park brake is engaged, park brake
park brake actuator (18).
pressure switch (5) causes the park brake light,
System air pressure from the pneumatic manifold located on the MDU, to come on.
is available at park brake valve (3). When the park
If the engine is started with the park brake valve
brake valve lever is moved to the OFF (brake
lever in the OFF position, even if the system air
disengage) position, compressed air is sent to
pressure specification has been met, the park
park bake solenoid (4).
brake valve lever must be cycled to the ON
position for the park brake to release.
ISSUE 0 191
872106 CHAPTER 5 B25D & B30D 6X6
Bin Pilot Control Valve Circuit Seat Circuit

The function of the body control valve is to raise Seat suspension stiffness is dependent on the
and lower the bin. Actuating the bin pilot control amount of air pressure in the seat accumulator.
valve (6) routes compressed air to the air cylinder
on the bin control valve (14), shifting the spool. To increase the air pressure in the seat
suspension accumulator, move seat valve (10) to
The spool routes supply oil to and return oil from the INCREASE position.
the bin tip cylinders to raise or lower the bin.
To decrease air pressure in the seat suspension
Inter-Axle Lock circuit accumulator, move seat valve (10) to the VENT
The inter-axle lock is similar to the differential lock, position. The spring loaded seat valve holds the
but is located in the transfer case. The purpose of seat at the desired position.
the inter-axle lock is to lock the front and rear axles
Horn Circuit
together so power is applied evenly to all axles.
Pushing the horn button, energizes air horn
The inter-axle lock can not be engaged unless the solenoid (11), which causes compressed air to
accelerator pedal is in the slow idle position. It can flow to air horn (12).
be disengaged at any time.
Releasing the horn button de-energizes the horn
When the inter-axle lock rocker switch is pushed to solenoid, causing the compressed air to vent to
the EGAGE position, the inter-axle lock solenoid atmosphere through the air horn solenoid.
(8) is energized, allowing compressed air to flow to
the inter-axle lock actuator (13), which applies the
inter-axle locks.
The compressed air between the inter-axle lock

solenoid and the inter-axle lock actuator closes the
contacts of the inter-axle lock pressure switch (9).
The closed contacts allow an electrical current to

flow to a light on the MDU, causing the light to
come on.
When the inter-axle lock rocker switch is pushed to

the DISENGAGE position, the inter-axle lock
solenoid de-energizes. The de-energized solenoid
blocks the flow of compressed air to the actuator
and allows the compressed air within the inter-axle
lock circuit to vent to atmosphere, thus allowing
the spring inside the actuator to move the inter-
axle lock to the release position.
192 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
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
check-out to pinpoint the possible cause of the
Know The System problem.
• Study the machine technical manual.
Understand the system and circuits. Use Perform Troubleshooting
schematics, component location drawings and Connect laptop computer, if available. The self-
theory of operation for each circuit and circuit diagnosing function lists any service codes and
components to better understand how the gives corrective action information.
system, circuits and components work.
Before starting any trouble shooting, first check
Ask The Operator battery voltage, circuit breakers and fuses.
What type of work was the machine doing when
the trouble was noticed? Go to test groups to check pressures and
voltages. Make sure adjustments are correct.
Did the trouble start suddenly or has it been
getting worse? Trace a Cause.
Before reaching a conclusion, check the most
Did the machine have any previous problems? 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
Check all daily maintenance points (See Make a plan for appropriate repair to avoid other
CHAPTER 12 in OMM). Check batteries, fuses malfunctions.
circuit breakers and electrical connections.
ISSUE 0 193
872106 CHAPTER 5 B25D & B30D 6X6
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 not Adjust air dryer and unloader
Operating Pressure. adjusted correctly. valve. Do Pneumatic System
Main Pressure Test See
“SECTION 3. TESTS” on
page 199
Leakage at fittings or from lines. Tighten fittings. Repair 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” on page 184).
System air pressure sensor. Test sensor. “Pneumatic

System Solenoids, Pressure
Switches, and Sensor Tests”
on page 125.
Park brake actuator. Check park brake pressure. Do

Park Brake Pressure Test (See
“PARK BRAKE PRESSURE
TEST” on page 200).
Unloader valve. Check pressure setting. Do

Pneumatic System Main
Pressure Test And Adjustment.
(See “PNEUMATIC SYSTEM
MAIN PRESSURE TEST AND
ADJUSTMENT” on page 199).
Air compressor Repair or replace compressor.

(See remove and install air
compressor in CHAPTER 15,
SECTION 1 of the Repair
Manual).
Park Brake Light Does Not Go park brake pressure switch Test park brake pressure switch.
Off. failed. Do “Pneumatic System
Solenoids, Pressure
on page 125.
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B25D & B30D 6X6 CHAPTER 5 872106
Park Brake Does Not Hold Park brake calliper adjustment. Adjust park brake calliper. Do
“Park Brake Adjustment” on
page 176.
Park brake disc and pads. Checks thickness of pads. Do

“Park Brake Pad Thickness
Check” on page 176.
Park brake solenoid. Test park brake solenoid. Do

“Pneumatic System
Solenoids, Pressure
on page 125.
Park brake valve. Test park brake pressure. Do

“PARK BRAKE PRESSURE
TEST” on page 200).
Inter-Axle Lock Not Working. Inter-axle lock switch. Test inter-axle lock switch.
Inter-axle lock solenoid. Test inter-axle lock solenoid. Do

“Pneumatic System
Solenoids, Pressure
on page 125.
Inter-axle lock actuator. Check inter-axle lock actuator

for binding internally (See
Transfer Case in CHAPTER 7,
Manual).
Horn not Working Horn solenoid. Test horn solenoid. Do

“Pneumatic System
Solenoids, Pressure
on page 125.
Horn switch. Test horn switch. Do “Steering

Column Switch Test” on
page 130.
ISSUE 0 195
872106 CHAPTER 5 B25D & B30D 6X6
Pneumatic System Component Location Diagram
13
10
12 14
11
7
6
15
2
5 4
Pne30D4004CFM
196 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
1. Horn. 9. Bin Control Valve.

2. Exhaust Brake Cylinder. 10. Inter-Axle Lock.
3. Air Compressor. 11. Air Compressor Outlet Line.
4. Auxiliary Quick Coupler. 12. Cooling Pipe.
5. Pneumatic Manifold. 13. Air Dryer And Unloader Valve.
6. Bin Pilot Control Valve. 14. Regeneration Air Reservoir.
7. Park Brake Valve. 15. Air Reservoir (2 Used).
8. Park Brake Actuator.
ISSUE 0 197
872106 CHAPTER 5 B25D & B30D 6X6
PBX
TLA
PBA TLV PBS

TLD
TLX
Pne30D4005CFM
1. Pneumatic Manifold. 4. Seat Air Spring.

2. Bin Pilot Control Valve. 5. Air Compressor Output Line.
3. Park Brake Valve.
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ISSUE
B25D & B30D 6X6 CHAPTER 5 872106
SECTION 3. TESTS
PNEUMATIC SYSTEM MAIN

PRESSURE TEST AND ADJUSTMENT
Pneumatic System Main Specification
Pneumatic System
Pressure - - - - - - - - - - - - - 850 kPa {8.5 bar (123 psi)}.
Adjusting Screw
1/2 Turn Equals - - - - - - - - - - - 50 kPa {0.5 bar (7 psi)}.
Essential Tools 2
Tee fitting - - - - - - 202862 3/4-16 M 37° x 3/4-16 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. 1
n CAUTION
Discharge pneumatic system completely
before removing any fittings or 2
components.
Discharge air pressure from front pneumatic

system by pulling the drain plug ring on the
regeneration air reservoir.
3
Disconnect air line from port 21 of air dryer and
unloader valve.
Disconnect “T” fitting (1) to dryer/unloader valve
and air line.
Connect pressure gauge to tee fitting.
Start engine and observe air pressure on gauge.
Record pressure when unloader valve “unloads”.
Adjust pressure that unloader valve “unloads” by

removing rubber boot, loosening locknut (3) and
turning adjusting screw (2) with a 3mm hex.
wrench. Turning screw clockwise will increase
unloading pressure.
If pressure cannot be adjusted within specification,

replace air dryer and unloader valve.
ISSUE 0 199
872106 CHAPTER 5 B25D & B30D 6X6
PARK BRAKE PRESSURE TEST
Park Brake Pressure Specifications

Park Brake Lever ON - - - - - - - - 0 kPa {0 bar (0 psi)}.
Park Brake Lever OFF - - - 850 kPa {8.5 bar (123 psi)}.
Essential Tools
Tee fitting - - - - - - 202862 3/4-16 M 37° x 3/4-16 F 37°
- - - - - - - - - - - - - - - - - - - - - - - - - Sw x 7/16-20 M 37°
Service Equipment and Tools

Gauge - - - - - - - - - - - - -2068 kPa {20.6 bar (300 psi)}.
Park the machine on a level surface and chock the Raise the bin and install the bin prop.
wheels to prevent machine from rolling.
Move park brake lever to the ON position to
n CAUTION engage park brake and relieve system pressure
1. Install articulation locking bar before from park brake circuit. Shut off engine.
working in pivot area.
2. Discharge pneumatic system completely
before removing any fittings or
components.
Install articulation lock bar.
n CAUTION Disconnect line from park brake actuator and

Always install the bin prop when working install tee fitting (1). Connect gauge to fitting.
under the raised bin. Personal injury may
Start engine and observe pressure on gauge.
result if the body lowers unexpectedly.
Pressure must remain at zero with park brake
lever ON. If pressure is more than zero, park brake
valve is leaking internally and must be replaced.
With engine running, release park brake and

observe pressure on gauge.
Observe system pressure on gauge.
If pressure is low, go to “PNEUMATIC SYSTEM

MAIN PRESSURE TEST AND ADJUSTMENT”
on page 199.
200 ISSUE 0
B25D & B30D 6X6 CHAPTER 6 872106
CHAPTER 6. HYDRAULIC SYSTEM

ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION
4 7
1 9
10
12 11
13
Hy30D0001CFM
1. Brake Caliper. 8. Bin Tip Cylinders.

2. Brake Valve. 9. Left Steering Cylinder.
3. Steering Valve. 10. Hydraulic System Manifold.
4. Right Steering Cylinder. 11. Secondary Steering Pump.
5. Return Filter. 12. Main Hydraulic Pump.
6. Hydraulic Reservoir. 13. Front And Rear Brake Apply Accumulators.
7. Suction Screen.
ISSUE 0 201
872XXX CHAPTER 6 B25D & B30D 6X6
The articulated dump truck hydraulic system is a The steering valve (3) is a closed-centre valve with
closed-centre, load-sensing system and consists a load sense passage. The valve is a wide angle,
of the steering circuit, secondary steering circuit, variable displacement (flow amplification) with
bin control circuit and service brake circuit. integrated anti-cavitation and relief valves.
The system oil is stored in the hydraulic reservoir The effective displacement of the steering valve
(6). The suction strainer (7) removes any large depends on the speed at which the valve is turned.
particles that may have collected in the hydraulic The steering valve routes and controls hydraulic
reservoir before the oil is sent to the main oil to the left steering cylinder (9) and right steering
hydraulic pump (12). cylinder (4).
The main hydraulic pump is a variable- The load sense passage is used to send a signal
displacement, axial-piston pump with a pressure from the work port to the hydraulic system
compensating regulator valve. manifold and then to the pump regulator valve
when the valve is actuated.
The regulator valve controls pump flow rate by
changing swash plate angle to meet load demand The load sense passage is open to return when
of functions actuated and to destroke the pump to the valve is in neutral. The steering cylinders are
residual (low stand-by) pressure when all double-acting cylinders that steer the truck by
functions are in neutral. (See “Main Hydraulic articulating the front and rear frames. (See
Pump Load Sense Operation” on page 206). “Steering And Secondary Steering System
The pump is driven by the transmission auxiliary
drive. The pump provides hydraulic oil flow to the A ground driven secondary steering system is
steering, service brake and bin control circuits. used to provide supply oil flow for the steering
(See “Main Hydraulic Pump Operation” on circuit while the machine is still moving in the event
page 204). there is a malfunction of the engine or main
hydraulic pump.
The hydraulic system manifold (10) controls and
distributes hydraulic oil through outlet ports to all The system consists of the secondary steering
components in the hydraulic system. pump (11), anti-cavitation valve, and two check
valves located in the hydraulic system manifold.
The manifold is a replaceable cartridge-valve-type The pump is a variable-displacement, axial-piston
manifold. The steering and brake circuits are given pump with a load sensing and pressure
priority by the priority valve located in the manifold. compensating regulator valve.
(See “Hydraulic System Manifold Operation”
on page 222). The residual pressure setting for the secondary
steering pump is lower than the residual pressure
The bin control valve is a closed-centre valve with setting for the main hydraulic pump. The pump is
a load sense passage. The valve is mounted on mounted on the transfer case and is ground driven
the hydraulic system manifold. as long as the gear train is being turned by the
moving machine.
The function of the bin control valve is to route
hydraulic oil to the right and left bin cylinders (8). The check valves are used to isolate the main
hydraulic circuit and the secondary steering circuit.
The bin tip cylinders are double-acting cylinders The secondary steering pump anti-cavitation valve
that raise and lower the bin. The load sense provides a path for oil flow from the suction side of
passage is used to send a signal from the work pump to the outlet side when the machine is
ports through the hydraulic system manifold to the moving in reverse.
pump regulator valve when the valve is actuated.
The brake accumulator, which is attached to the
The load sense passage is open to return when
hydraulic system manifold is a diaphragm type,
the valve is in neutral. The valve also contains a
nitrogen charged accumulator and the front and
bin raise circuit relief valve and bin lower circuit
rear brake accumulators (13), are piston type,
relief valve. (See “Bin Control Valve Operation”
nitrogen charged accumulators.
on page 230).
202 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872XXX
The accumulators are not serviceable. The

function of the brake accumulator is to provide a
signal to the brake accumulator charge valve,
regulating load sense signal to main hydraulic
pump to maintain the pressure of brake
accumulators between a lower and upper charge
limit.
The front and rear brake accumulators are used to

store brake oil under pressure which is then used
to apply the service brakes when the brake valve
(2) is actuated. 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 (1). The valve contains two
separate circuits, each supplied by its own
accumulator.
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 first and then to the front
brake callipers. (See “Service Brake System
Return filter (5) is used to filter return oil before

entering the hydraulic reservoir.
ISSUE 0 203
Main Hydraulic Pump Operation
3 4 5
3
13
6 7
14
4
15
3
X
12 2
11
1
10
B
11
8
6
7
S L1 L
9
30D4003CFM
204 ISSUE 0
ISSUE
1. Compensator Valve. 9. Small Control Piston.

2. Residual Valve. 10. Swash Plate.
3. Pump Regulator Valve. 11. Large Control Piston.
4. Load Sense Port. 12. Cylinder Block Oil.
5. Spring. 13. Supply Oil.
6. Inlet Port. 14. Load Sense Oil.
7. Outlet Port. 15. Return or Pressure Free.
8. Hydraulic System Manifold.
The piston bores are filled with oil through the inlet
The main hydraulic pump is a variable- port (6) and valve plate as the pistons move out of
displacement, axial-piston pump with a load- their bores.
sensing and pressure-compensating pump
regulator valve (3). The pistons moving into their bores push oil out
through the valve plate to the outlet port (7) and
Pump displacement is varied by the angle of then to small control piston, pump regulator valve,
swash plate (10). Swash plate angle is controlled and hydraulic system manifold (8).
by the small control piston (9) and large control
piston (11). The pump is driven by the transmission auxiliary
drive.
The small control piston has supply oil (13)
pressure and spring pressure applied to it at all Pressure compensation is a constant pressure
times trying to keep the pump at maximum system that requires a closed-center hydraulic
displacement. system.
Supply oil is applied to or released from the large As soon as the engine is started, supply oil flows
control piston by the residual valve (2) varying from the pump to the closed-center valves. The
pump displacement per load demand. pressure in the hydraulic system increases and
causes the residual valve to destroke the pump at
At full system pressure the compensator valve (1) residual pressure.
shifts to route supply oil to the large control piston
destroking the pump. The residual pressure ensures that immediate
system pressure is available on demand when a
As the angle of swash plate is increased, the function is actuated.
pistons move in and out of their bores and displace
oil as the cylinder block (12) is turned by the pump Load sense system pressure is used to regulate
drive shaft. the residual valve to stroke or destroke the pump
as needed.
The pistons move into their bores during the first
half of each revolution, and out of their bores No matter what the load demand is, even when
during the last half of the revolution. using more than one function, as long as the total
demand does not exceed the pumps capability,
the pump will deliver the exact amount of oil
required to move the load.
ISSUE 0 205
Main Hydraulic Pump Load Sense Operation
1 2 3
9
10
8 7 6 5 4
11
Hy40D0007CFM
1. Pump Regulator. 7. To Control Piston.
2. Residual Spool. 8. From Pump Outlet (Minimal Pressure).
3. Residual Spring. 9. Supply Oil.
4. Compensator Spring. 10. Load Sense Oil
5. Compensator Spool. 11. Return Oil.
6. Case Drain.
Residual Pressure
As soon as pump is driven, supply oil (9) flows to The pump will maintain this residual pressure until
pump regulator (1) which consists of the residual the hydraulic system’s needs are greater (function
valve and compensating valve. actuated).
As the supply oil pressure rises, the residual spool When hydraulic functions are not actuated the
(2) having the smaller spring will start to shift. pump produces only enough flow to maintain the
residual pressure.
The spool will shift toward the residual spring (3)
until it allows supply oil to be directed into the The load sense oil (10) at this time is at a minimal
control piston (7), destroking the pump and pressure because the load sense circuits are open
reducing flow until the pressure at the pump outlet to return.
(8) is equal to the residual pressure setting.
206 ISSUE 0
ISSUE
1 2 3
9
10
8 7 6 5 4
11
Hy40D0008CFM
1 Pump Regulator. 7 To Control Piston.
2 Residual Spool. 8 From Pump Outlet.
3 Residual Spring. 9 Supply Oil.
4 Compensator Spring. 10 Load Sense Oil (Mid-Range Pressure).
5 Compensator Spool. 11 Return Oil.
6 Case Drain.
Working Pressure
When a function is actuated, load sense oil The spool will then slide over (away from spring),
pressure (10) to the pump regulator (1) rises. opening the control piston (7) to case drain (6),
stroking the pump and increasing flow as needed.
This rising load sense pressure and the force of
the residual (3) work together to overcome the
pressure of the supply oil (9) on the opposite side
of the residual spool (2).
ISSUE 0 207
1 2 3
9
10
8 7 6 5 4
11
Hy40D0009CFM
1 Pump Regulator. 7 To Control Piston.
2 Residual Spool. 8 From Pump Outlet.
3 Residual Spring. 9 Supply Oil.
4 Compensator Spring. 10 Load Sense Oil (High Pressure).
5 Compensator Spool. 11 Return Oil.
6 Case Drain.
Compensating Pressure
Compensating pressure is set lower than the
As the hydraulic system needs are met and the
system relief valve pressure. The system relief
supply oil (9) pressure continues to rise, the
valve is used to protect the system against sudden
increasing supply oil pressure starts to overcome
pressure spikes.
the compensator spring (4), sliding the
compensator spool (5) toward the spring. High system pressure oil is also conveyed into the
load sense circuit. The high pressure load sense
The spool will then direct the high pressure supply
oil (10) plus the force of the residual spring (3) will
oil into the control piston (7) destroking the pump
keep residual spool (2) shifted away from the
but providing enough flow to maintain
spring.
compensating pressure in the system.
208 ISSUE 0
ISSUE
ISSUE 0 209
Service Brake System Operation
P1 2
B1
T1
P2
B2
T2
4 3
5
17 A4
S4 M6 M5
M4 B6 A6 A5 B5 P7
16 6
15 8
XB 14
13 7
X4
1
12
1
1
11 10 9
Hy30D0002CFM
210 ISSUE 0
ISSUE
1. Brake Valve . 12. From Main Hydraulic Pump.

2. Service Brakes. 13. Accumulator Pressure Reducing Valve.
3. Front Brake Apply Accumulator. 14. Accumulator Charge Orifice 0.7 mm.
4. Rear Brake Apply Accumulator. 15. Accumulator Orifice 2.5 mm.
5. Brake Charge Accumulator. 16. Accumulator Charge Check Valve.
6. Hydraulic System Manifold. 17. Brake Low Pressure Switch.
7. Rear Brake Accumulator Check Valve. 18. Supply Oil.
8. Front Brake Accumulator Check Valve. 19. Charge Oil.
9. Accumulator Charge Valve. 20. Load Sense Oil.
10. Main Hydraulic Pump Signal Shuttle Valve. 21. Return Oil.
11. Priority Valve Signal Shuttle Valve.
Charging System
When operating the service brake valve (1), harge When brake accumulator charge oil pressure
oil (19) pressure in the front brake apply increases to the upper pressure setting of
accumulator (3), rear brake apply accumulator (4) accumulator charge valve, the charge valve spool
and brake charge accumulator (5) decreases. shifts to the open position allowing load sense oil
to flow to return, decreasing the load sense signal
The decrease of charge oil pressure in the brake to the main hydraulic pump.
accumulators is sensed by the accumulator
charge valve (9). The pump destrokes decreasing supply oil flow to
the accumulators.
When the accumulator charge oil pressure
decreases below the lower pressure setting of the Charged System
accumulator charge valve, the charge valve spring When all accumulators are charged, charge oil
shifts the spool, blocking the flow of load sense oil (19) pressure in the brake charge accumulator (5)
(20) to the return circuit. holds the accumulator charge check valve (16)
closed.
Charge oil continues to flow through the brake
accumulator charge orifice (14), increasing load The brake accumulator charge oil pressure keeps
sense pressure. the accumulator charge valve (9) open allowing
pump load sense oil (20) to flow to return.
The increasing load sense pressure shifts the
priority valve signal shuttle valve (11) and main The rear and front brake accumulator check
hydraulic pump signal shuttle valve (10) sending valves (7 and 8) separate the circuits and hold
the load sense signal out of port L1 to the main charge oil in the front and rear brake apply
hydraulic pump port X, stroking the pump, accumulators (3 and 4) and brake valve (1).
increasing flow, causing supply oil (18) pressure to
increase. The check valves enable the circuits to work
independently of each other in the event of a
This supply oil then flows through the accumulator malfunction in either circuit.
pressure reducing valve (13), accumulator orifice
(15), and accumulator charge check valve (16) The pressure setting of the accumulator charge
charging the brake charge accumulator. valve and accumulator pressure reducing valve
(13) is critical to operation of the main hydraulic
As pressure increases, the rear and front brake pump.
accumulator check valves (7 and 8) are opened
allowing the rear and front brake apply If pressure setting of accumulator charge valve is
accumulators to be charged. higher than accumulator pressure reducing valve,
the load sense signal to the main hydraulic pump
Pressure to the accumulators is limited by will remain high because the charge oil pressure
accumulator pressure reducing valve. The from brake charge accumulator cannot open the
accumulator orifice controls the rate of oil flow to charge valve allowing load sense oil to flow to
charge the accumulators. return.
The pump will remain in stroke and not return to

low standby (residual) pressure when all functions
are in neutral.
ISSUE 0 211
Brake Valve—Neutral Brake Valve—Actuated

The service brake valve (1) is a dual circuit, When service brakes (2) are actuated, the charge
modulated valve. oil (19) in the brake apply accumulators flows
through the brake valve (1) to the brake pistons,
The function of valve is to control the charge oil applying the brakes.
(19) from the front and rear brake apply
accumulators (3 and 4) to actuate the service The pressure applied at the pistons and the force
brakes (2). applied to the brake valve spring by the brake
pedal act on opposite ends of the spools in the
The brake valve contains two separate circuits, brake valve.
each supplied by their own brake apply
accumulator. The pressure to the pistons is proportional to the
force applied to the brake pedal (pressure to the
The top valve is for the front axle brakes and the pistons increases as the force on the brake pedal
bottom valve is for the rear axle brakes. The brake increases).
valve supplies charged oil to the rear brakes first
and then the front brakes. The pressure on the end of the spools balances
against the spring force modulating the pressure
In neutral, charge oil is blocked by the brake valve to the pistons.
spools and the brake pistons are open to return.
The charge oil pressure is reduced by the amount
of oil it takes to move the pistons. Each application
of the brake pedal reduces the charge pressure
until the brake accumulator charge circuit is
actuated by the accumulator charge valve (9).
212 ISSUE 0
ISSUE
ISSUE 0 213
Steering And Secondary Steering System Operation
3
L
S 7
1
1 8
TP1
6 MP1
L R
SP1
L R
P1 9
4
MP2
P2 P3 L3 L1 L2 T3
MP3 ML3 ML1
LS
T P
X
13
10
B
11
M 14
15
S L
12 16
17
18
Hy30D0003CFM
214 ISSUE 0
ISSUE
1. Steering Cylinders. 10. From Hydraulic Reservoir Suction Strainer.

2. Secondary Steering Pump. 11. To Hydraulic Reservoir.
3. Anti-Cavitation Valve. 12. Main Hydraulic Pump.
4. Secondary Steering Pump Check Valve. 13. Steering Valve.
5. Main Hydraulic Pump Check Valve. 14. Supply Oil.
6. Secondary Steering Pressure Switch. 15. Secondary Supply Oil.
7. Hydraulic System Manifold. 16. Load Sense Oil.
8. Priority Valve. 17. Trapped Oil.
9. Steering Load Sense Relief Valve. 18. Return Oil.
The function of the steering system is to route When the main hydraulic pump cannot meet the
supply oil (14) from the main hydraulic pump (12) flow requirements to steer the machine, the
to the steering valve (13). pressure in the main hydraulic pump circuit
decreases the load sense signal at port L1.
The steering valve then controls the oil flow used
to extend and retract the steering cylinders (1). The load sense signal to the secondary steering
When the steering wheel is turned, the load sense pump via port L2 is the same as that of the main
signal from the steering valve enters the hydraulic hydraulic pump at port L1, enabling the pressure
system manifold (7) at port L3. of secondary steering pump at port P2 to increase
and overcome the pressure differential across
The load sense signal is then sensed at the secondary steering pump check valve.
secondary steering pump (2) via port L2. At the
same time, the load sense signal shifts the shuttle Flow from the secondary steering pump, via port
valves, pressurizes the spring chamber of priority P2, eventually supplements the flow from the main
valve (8), and sends a signal to the main hydraulic hydraulic pump to the steering valve via port P3.
pump via port L1.
The r.p.m. of the secondary steering pump is
The load sense signal will not exceed the steering dependent on the machine travel speed. Supply oil
load sense relief valve (9) pressure setting. The flow available to steer the machine is reduced
main hydraulic pump supplies the required flow proportionately as the travel speed decreases.
rate through port P1, main hydraulic pump check
valve (5), and out of port P3 to steering valve port When the machine stops, there is no secondary
P. steering pump flow. The secondary steering
system is also used to provide oil flow to the
When the steering wheel is not being turned, the steering circuit (while the machine is still moving)
load sense signal is open to hydraulic reservoir in the event there is a malfunction of the engine,
through the steering valve and the main hydraulic transmission, or main hydraulic pump.
pump will return to residual pressure.
The system consists of the secondary steering
The oil in the steering cylinders is trapped and the pump, main hydraulic pump check valve,
machine is held at that relative position. The secondary steering pump check valve, and
ground driven secondary steering pump will assist secondary steering pump anti-cavitation valve (3).
with oil flow to steer the machine if main hydraulic
pump cannot deliver the flow required. The secondary steering pump is a variable-
displacement, axial-piston pump with a load
Low oil flow may occur during an attempt to rapidly sensing and pressure compensating regulator
steer machine at slow engine speed. (Machine valve.
must be moving for secondary steering pump to
work.) Operation of the secondary steering pump is
similar to the main hydraulic pump. The residual
Under normal steering operation, the pressure of valve pressure setting for the secondary steering
secondary steering pump at port P2 is just below pump is lower than the residual valve pressure
that of the main hydraulic pump at port P1 creating setting for the main hydraulic pump.
a differential pressure across secondary steering
pump check valve (4). When the machine is moving, the pressure at test
port MP2 remains just below the pressure at test
port MP1.
ISSUE 0 215
The secondary steering pump is mounted on the When the machine is moving, the pressure at test
transfer case and is ground-driven as long as the port MP2 remains just below the pressure at test
gear train is being turned by the moving machine. port MP1. The secondary steering pump is
mounted on the transfer case and is ground-driven
The system consists of the secondary steering as long as the gear train is being turned by the
pump, main hydraulic pump check valve, moving machine.
secondary steering pump check valve, and
secondary steering pump anti-cavitation valve (3). The secondary steering pump check valve is used
to block oil flow from the main hydraulic pump to
The secondary steering pump is a variable- the secondary steering pump circuit.
displacement, axial-piston pump with a load
sensing and pressure compensating regulator In the event of a malfunction, main hydraulic pump
valve. check valve blocks oil flow from the secondary
steering pump to the main hydraulic pump, bin
Operation of the secondary steering pump is control valve, and brake accumulator charging
similar to the main hydraulic pump. The residual circuit.
valve pressure setting for the secondary steering
pump is lower than the residual valve pressure The secondary steering pump anti-cavitation valve
setting for the main hydraulic pump. provides a path for oil flow from the suction side of
the pump to the outlet side, forming a loop circuit
when the machine is travelling in reverse.
216 ISSUE 0
ISSUE
ISSUE 0 217
Steering Valve Operation
1
2
5
6
11
7 8 8
10
L R 9
13
12
LS 14
15
9 11
T P
16
1 NEUTRAL 17
18 STEERING VALVE Hy40D0012CFM
218 ISSUE 0
ISSUE
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.
The steering valve (18) is a variable-displacement As steering operation is stopped, the centring
(flow amplification), closed-centre valve. Main spring and gerotor continue to turn the sleeve until
valve components are the spool (6) inside a sleeve the sleeve and spool are in alignment, stopping
(5) within a housing and the gerotor (3). the flow of oil through the spool to the gerotor. At
this point, the valve is in neutral and remains there
Also included are the make-up check valve (9), until the steering wheel and shaft 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 which
When steering the wheel is not being turned, the the steering wheel is turned.
valve is in neutral (1). In neutral, the spool and
sleeve are held in alignment by the centring spring When the steering wheel is turned slowly, the
blocking the flow of supply oil (14) through the valve only meters oil through the gerotor to the
sleeve to the spool and gerotor. steering cylinders and thus the effective
displacement is equal to the gerotor displacement.
Oil at the left and right work ports to the steering
cylinders is trapped (16) by the sleeve holding the When the steering wheel is turned rapidly, the
machine frames stationary. spool moves more, relative to the sleeve opening
passages, so additional oil is allowed to bypass
Turning the steering wheel and shaft (7) left or the gerotor, thus increasing the effective valve
right turns the spool relative to the sleeve, opening displacement, hence flow amplification occurs.
passages so supply oil flows from the hydraulic
system manifold port P3 (10) through the sleeve Relief valves (13) are used to relieve high
into the spool. pressure oil from a pressure spike created in the
steering cylinders while steering is in neutral. In
From the spool, work pressure oil (15) flows to the neutral, the steering valve blocks the flow of oil to
gerotor (3) causing the gerotor gear and sleeve to and from the cylinders.
turn. Work pressure oil flow is metered by the
gerotor back into the spool where it is routed A pressure spike is created by the impact of the
through the sleeve and out the left or right work front or rear wheels against an obstacle, which is
port to the respective ends of the steering transmitted to the steering cylinders causing slight
cylinders turning the machine. cylinder movement.
Work pressure oil also flows out the load sense The cylinder movement that caused the pressure
port (4) sending a load sense signal back through spike also causes a pressure drop and a void in
the hydraulic system manifold port L3 to the main the opposite end of the cylinders. Because of the
hydraulic pump regulator valve to regulate pump pressure differential across the anti-cavitation
flow. Load sense signal also goes to the spring valve (12), the pressure in the return passage
chamber of the priority valve and to the steering pushes the valve open and oil flows into the void
load sense 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).
ISSUE 0 219
Secondary Steering Pump Operation
5 7
6 X
B
4
3 4
1 2
S L
10
10 9
11
8
5
12 4
13
17
18
19
16
14 15
Hy40D0013CFM
220 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
1 From Pump Outlet. 11 Pump Regulator Valve.

2 To Control Piston. 12 Swash Plate.
3 To Case Drain. 13 Spring.
4 Compensator Valve. 14 Piston.
5 Residual Valve. 15 Cylinder Block Oil.
6 To Hydraulic System Manifold Port P2. 16 Valve Plate.
7 From Hydraulic System. 17 Supply Oil.
8 From Main Hydraulic Pump Manifold Port 18 Load Sense Oil.
L2. 19 Return or Pressure-Free Oil.
9 Transfer Case.
10 Control Piston.
The secondary steering hydraulic pump is a load- The piston bores are filled with oil through the
sensing, pressure-compensating, variable- valve plate (16) as the pistons move out of the
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 all The pump displacement is regulated by the
times, trying to keep the pump at maximum compensator valve and residual valve (load
displacement. Secondary supply oil (17) is applied sensing).
to or released from the control piston by the
residual valve (5) in response to load sense signal Normal leakage to the pump case through
from hydraulic system manifold port L2 to load clearance between the pistons, valve plate and
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 (4) The secondary steering pump is mounted on the
is shifted to route secondary supply oil to the transfer case (9) and is ground driven as long as
control piston, destroking 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.
ISSUE 0 221
872106 CHAPTER 6 B25D & B30D 6X6
Hydraulic System Manifold Operation
4 10 5 6 3 16 2 1
M6 M5 S4
XB
X3
11 X4
ML1
SP1
7
ML3
12
PARKER
MP2 PARKER
VOAC
14 MP3
MP1
8
13 9
15 17
XB XA
Hydraulic System Manifold - Top View
3 4
A4
5
41
S4
M6 M5
2 M4 B6 A6 A5 B5
6 42
1 43
B A
XB
44
17 X4
45
TP1
MP1
SP1
7
16 P1
T2
15
X3
MP2
P2 P3 L3 L1 L2 T3
8
MP3 M L3 ML1
14
13 12 11 10 9
Hy30D0004CFM
222 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
1 Accumulator Pressure Reducing Valve, XB. 10 Steering Load Sense Relief Valve, X3.
2 Accumulator Charge Check Valve. 11 Test Port, ML1.
3 Brake Low Pressure Switch, S4. 12 Test Port, ML3.
4 Test Port, M6. 13 Test Port, MP3.
5 Test Port, M5. 14 Test Port, MP2.
6 Accumulator Charge Valve, X4. 15 Priority Valve.
7 Priority Valve Signal Shuttle Valve. 16 Secondary Steering Pressure Switch, SP1.
8 Bin Control Valve. 17 Test Port, MP1.
9 Bin Float Solenoid Valve.
The hydraulic system manifold controls and The main hydraulic pump can now meet the
distributes hydraulic oil through outlet ports to all charging or steering circuit load demand.
components in the hydraulic system.
The priority valve signal shuttle valve (7) routes
The hydraulic system manifold is a replaceable the higher load sense signal from the steering
cartridge-valve-type manifold. The bin control valve or brake accumulator charging circuit to the
valve (8) are mounted on the hydraulic system spring chamber of the priority valve and to the
manifold. Numbers and letters are stamped on the main hydraulic pump signal shuttle valve (37).
manifold to help locate and identify components
and ports. The steering load sense relief valve, X3 (10)
relieves excess load sense signal from the
The illustrated views given are with the hydraulic steering valve.
system manifold installed in the machine. Test
ports ML1 (11), ML3 (12), MP3 (13), M5 (5), and The secondary steering pressure switch, SP1 (16)
M6 (4) are equipped with high pressure quick closes when the main hydraulic pump loses
couplers for making test connections to hydraulic pressure.
system.
The switch actuates the secondary steering
Test ports MP1 (17), MP2 (14), and M4 (34) are indicator light.
connected by hydraulic lines to a test port manifold
located behind the cab. The brake accumulator charge valve, X4 (6)
maintains brake accumulator, A4 (26) pressure
The brake low pressure switch, S4 (3) closes between upper and lower limit of the charge band.
when brake accumulator pressure decreases
below the lower limit of accumulator charge valve The brake accumulator pressure reducing valve,
band. XB (1) limits pressure to the brake accumulators.
The switch actuates the brake low pressure The brake accumulator charge check valve (2)
indicator light. The priority valve (15) gives priority holds charge pressure in the brake accumulator so
to the steering valve and brake accumulator oil does not flow to the steering and bin control
charging circuit over the fan drive and bin control circuits when system pressure is less than charge
valves if supply oil flow from main hydraulic pump pressure.
is not enough to satisfy the load demand.
The bin float solenoid valve (9) (when energized)
During bin raise operation the priority valve opens, allowing the bin cylinder head end circuit to
remains open if the pressure to operate the brake dump into the hydraulic reservoir. (See “Bin
accumulator charging and steering circuits is less Control Valve Operation” on page 230).
than that of the bin raise circuit.
Oil takes the path of least resistance, meeting the

load demand of charging and steering circuits.
When pressure to operate the brake accumulator
charging or steering circuits is higher, their higher
load sense signal assists the priority valve spring
to move the valve spool, reducing the flow of oil to
the bin control valve.
ISSUE 0 223
872106 CHAPTER 6 B25D & B30D 6X6
20 22
21
P2
L1
23
L2
P1
T3
19
18
Hydraulic System Manifold - Rear View
41
A4
S4
42
M6 M5
M4 B6 A6 A5 B5
43
B A 44
XB
45
X4
TP1
MP1
18 SP1
P1
T2
23 X3
MP2
P2 P3 L3 L1 L2 T3
MP3 ML3 ML1
22 20 19
21
Hy30D0005CFM
224 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
18 Inlet Port, P1. 21 Main Hydraulic Pump Load Sense Port, L1.
19 Return Port, T3 (not used). 22 Secondary Steering Pump Supply Port, P2
20 Secondary Steering Load Sense Port, L2. 23 Secondary Steering Pump Check Valve.
Supply oil (41) flows from the main hydraulic pump The check valve will open when the main hydraulic
to the inlet port P1 (18). pump flow is low enough so that pressure drops
below the pressure of the secondary steering
Supply oil flows from the secondary steering pump pump, allowing the secondary steering pump to
to the secondary steering pump port, P2 (22). supply oil to the steering valve as long as the
machine is moving.
The secondary steering pump check valve (23)
blocks supply oil flow from the main hydraulic The load sense signal from the main hydraulic
pump to the secondary steering pump. pump load sense port, L1 (21) to the main
hydraulic pump ports, X causes the pump to go
It also functions as the closed-centre valve for the into stroke.
secondary steering pump.
The load sense signal from the secondary steering
load sense port, L2 (20) to the secondary steering
hydraulic pump port, X.
ISSUE 0 225
872106 CHAPTER 6 B25D & B30D 6X6
26 25 32
31
A4
B6
B5
27
O2
A6
A5
30
28
29
24
Hydraulic System Manifold - Front View
28 32
26 41
27 31 29 30
A4
42
S4
M6 M5
43
M4 B6 A6 A5 B5
25
44
B A
24
XB 45
X4
TP1
MP1
SP1
P1
T2
X3
MP2
P2 P3 L3 L1 L2 T3
MP3 ML3 ML1
Hy30D0006CFM
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ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
24 System Relief Valve. 29 Front Brake Apply Accumulator, A5.

25 Brake Accumulator Orifice, 2.5 mm. 30 Front Brake Supply Port, B5.
26 Brake Accumulator, A4. 31 Rear Brake Check Valve.
27 Rear Brake Supply Port, B6. 32 Front Brake Check Valve.
28 Rear Brake Apply Accumulator, A6.
The system relief valve (24) relieves supply oil Supply oil flows from front brake supply port, B5
pressure spikes to the return circuit. (30) to the rear brake valve.
The brake accumulator orifice, 2.5 mm (25) The rear brake check valve (31) separates and
controls the rate of supply oil flow to the charge holds charged oil for the rear brake circuit from the
accumulators. front brake circuit.
Supply oil flows from the rear brake supply port B6 This enables the circuit to work independently in
(27) to the front brake valve. the event of a malfunction in the other circuit.
Supply oil flows from port A6 (28) to the rear brake The front brake check valve (32) separates and
accumulators. holds charged oil for the front brake circuit from the
rear brake circuit.
Supply oil flows from port A5 (29) to the front brake
accumulators. This enables the circuit to work independently in
the event of a malfunction in the other circuit.
ISSUE 0 227
872106 CHAPTER 6 B25D & B30D 6X6
36 38 33
L3 TP1
PARKER
39
09 P3
35 M4
34
37
40
Hydraulic System Manifold - Left View
34 A4
41
S4
M6
42
M5
M4 B6 A6 A5 B5
36 43
33 44
B A
XB
0.7 m m 45
X4
TP1
MP1
SP1
40 P1
T2
X3
MP2
P2 P3 L3 L1 L2 T3
MP3 ML3 ML1
39 38 37
Hy30D0007CFM
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ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
33 System Pressure Port, TP1. 40 Main Hydraulic Pump Check Valve.

34 Test Port, M4. 41 Supply Oil.
35 Brake Accumulator Charge Orifice, 0.7 mm. 42 Secondary Supply Oil.
36 Hydraulic Cutoff Solenoid Valve. 43 Load Sense Oil.
37 Main Hydraulic Pump Signal Shuttle Valve. 44 Trapped Oil.
38 Steering Load Sense, L3. 45 Return Oil.
39 Steering Supply Port, P3.
The brake accumulator charge orifice, 0.7 mm (35) The main hydraulic pump signal shuttle valve (37)
controls the rate of oil flow through the routes the higher load sense signal from the bin
accumulator charge valve, X4 (6) to the return control valve (8) or the priority valve signal shuttle
circuit when the brake accumulator, A4 (26) is valve (7) to the main hydraulic pump port, X.
charged.
The steering load sense port, L3 (38) receives the
The hydraulic cutoff solenoid valve (36) prevents load sense signal from the steering valve port, LS.
the brake accumulator and front and rear brake The steering supply port, P3 (39) sends supply oil
accumulators from being charged while starting to the steering valve port, P.
the engine by opening the load sense signal to the
return circuit. The main hydraulic pump check valve (40),
prevents supply oil flow from the secondary
steering pump from entering the brake charging
circuit, fan drive circuit, and bin control circuit.
ISSUE 0 229
872106 CHAPTER 6 B25D & B30D 6X6
Bin Control Valve Operation
1
2
3
B A
10
9 11
T2
12
13
6
8
7
Hy30D0008CFM
1 To Bin Cylinder Rod End. 8 Hydraulic System Manifold.

2 To Bin Cylinder Head End. 9 Bin Float Solenoid Valve.
3 Bin Lower Circuit Relief and Anti-Cavitation 10 Supply Oil.
Valve. 11 Load Sense Oil.
4 Air Actuated Spool Valve. 12 Trapped Oil.
5 Bin Control Valve. 13 Return Oil.
6 To Hydraulic Reservoir Return Filter.
7 Bin Raise Circuit Relief and Anti-Cavitation
Valve.
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B25D & B30D 6X6 CHAPTER 6 872106
The dump body control valve (5) is mounted on the Port A is connected to the dump body cylinder
hydraulic system manifold (8). head end (2). The dump body raise circuit relief
and anti-cavitation valve (7), relieves pressure in
The dump body lower circuit relief and anti- the dump body cylinder head end circuit.
cavitation valve (3) relieves pressure in the dump
body cylinder rod end circuit. The anti-cavitation valve prevents cavitation in the
circuit if the cylinder is extended while the control
The relief valve pressure setting is lower than the valve is in neutral.
pressure setting for dump body raise circuit relief
valve. The air actuated spool valve (4) uses air pressure
from the pneumatic system to shift the spool to the
The anti-cavitation valve prevents cavitation from raise or lower position.
occurring when lowing the dump body with the
engine not running. The spool is self-centering into the neutral position
whenever the valve is not actuated. A magnetic
Port B is connected to the dump body cylinder rod dump body down detent is also provided.
end (1). Return oil (13) flows from port T2 to
hydraulic reservoir return filter (6). When the dump body is lowered or stopped at
approximately the last 5% (3.5°) of travel, the
In neutral, the load sense circuit for the dump body dump body float solenoid valve (9) will energize
control valve is connected to return port T2 so (open), allowing the dump body cylinder head end
there is no load sense signal. circuit to dump into hydraulic reservoir.
The dump body will then float down until it contacts

the frame. See “Bin Control And Range Hold
Circuit Theory Of Operation” on page 79.
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872106 CHAPTER 6 B25D & B30D 6X6
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 Crossing
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 Four Connection
Reservoir Vented
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
232 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
ISSUE 0 233
234
872106
11 DUMP BODY CYLINDERS

6
5 STEERING CYLINDERS TEST PORT
ANTI-CAVITATION
X MANIFOLD
VALVE
M P2 M P1 M 4 9 8
3
REAR FRONT
BRAKE APPL Y BRAKE APPL Y
4 L R ACCUMULATOR ACCUMULATOR
TRANSFER
CASE STEERING VALVE L R
P1
B1
1
T1
Hydraulic System Schematic
BRAKE LO W
B PRESSURE
SWITCH 10 BRAKE CHARGE
A4 ACCUMULATOR
7
S
P2
S4
M6 M5
L B2
2 SECONDARY M4 B6 A6 A5 B5 P7 T2
STEERING PUMP
13 SERVICE
BRAKES
12 BRAKE VALVE
B A
LS XB
X4
TP1
T P
MP1
SP1
CHAPTER 6
P1
20
SECONDARY
STEERING
T2
PRESSURE X3
B SWITCH
MP2
P2 P3 T3
L3 L1 L2
18
MP3 ML3 ML1
M 19 HYDRAULIC 15
DUMP BODY
SYSTEM CONTROL BREATHER 22 SUPPLY OIL
MANIFOLD VALVE 14
RETURN 23 SECONDARY
S L
FILTER SUPPLY OIL
21 MAIN HYDRAULIC PUMP
24 LOAD SENSE OIL
SUCTION 25 TRAPPED OIL

STRAINER 17 26 RETURN OIL
16 HYDRAULIC RESERVOIR
Hy30D4001CFM
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B25D & B30D 6X6
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
1. Transfer Case. 14. Return Filter.

2. Secondary Steering Pump. 15. Breather.
3. Anti-Cavitation Valve. 16. Hydraulic Reservoir.
4. Steering Valve. 17. Suction Strainer.
5. Steering Cylinders. 18. Bin Control Valve.
6. Test Port Manifold. 19. Hydraulic System Manifold.
7. Brake Low Pressure Switch, S4. 20. Secondary Steering Pressure Switch, SP1.
8. Front Brake Apply Accumulator. 21. Main Hydraulic Pump.
9. Rear Brake Apply Accumulator. 22. Supply Oil.
10. Brake Charge Accumulator, A4. 23. Secondary Supply Oil.
11. Bin Cylinders. 24. Load Sense Oil.
12. Brake Valve. 25. Trapped Oil.
13. Service Brakes. 26. Return Oil.
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872106 CHAPTER 6 B25D & B30D 6X6
236 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
CHAPTER 6. HYDRAULIC SYSTEM
Follow the six basic steps below to carry out
troubleshooting efficiently. Check all systems and functions on the machine.
Use the helpful diagnostic information in the
Know the system. check-out to pinpoint the possible cause of the
problem.
Study the machine technical manual. Understand
the system and circuits. Perform troubleshooting.
Use schematics, component location drawings, Connect the laptop computer with diagnostic
and theory of operation for each circuit and circuit software, if available. The self-diagnosing function
components to better understand how the system, lists any service codes.
circuits, and components work.
Before starting any troubleshooting, first check
Ask the operator. battery voltage, battery disconnect switch, fuses,
and circuit breakers.
What type of work was the machine doing when
the trouble was noticed? Go to test groups to check pressures and
voltages. Make sure adjustments are correct.
Did the trouble start suddenly or has it been
getting worse? Trace a cause.
Did the machine have any previous problems? If Before reaching a conclusion, check the most
so, which parts were repaired? probable and simplest to verify.
Inspect the machine. Use the symptom, problem, solution charts to help
identify probable problem components.
Check all daily maintenance points. (See
CHAPTER 12 in the OMM). Check batteries, Make a plan for appropriate repair to avoid other
battery disconnect switch, circuit breakers, fuses, malfunctions.
and electrical connections.
ISSUE 0 237
872106 CHAPTER 6 B25D & B30D 6X6
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 (See CHAPTER 6, SECTION 3).
Step 2. Diagnose System Malfunction Charts in this group.
Step 3. Tests and Adjustments (See CHAPTER 6, SECTION 3).
Hydraulic System Malfunctions
No Hydraulic Functions Low or no oil. Check oil level in hydraulic

reservoir. Add hydraulic oil. (See
Hydraulic Oil and Wet Disk
Brake Cooling Oil in Section 3-1
of operator’s manual.)
Main Hydraulic Pump drive Inspect Hydraulic Pump Drive

shaft. Shaft. (See CHAPTER 14,
SETION 1 in the Repair
Manual).
Pump suction strainer restricted. Clean pump Suction Strainer.

(See CHAPTER 14,
SECTION 1 in the Repair Man-
ual).
All Hydraulic Functions Slow Oil level low. Check oil level in hydraulic
reservoir. Add hydraulic oil. (See
Hydraulic Oil in CHAPTER 1,
of operator’s manual.)
Cold hydraulic oil. Do Hydraulic System Warm-Up

Procedure to heat hydraulic oil.
(See “HYDRAULIC SYSTEM
WARM-UP PROCEDURE” on
page 253.)
Wrong oil in system. Use recommended Hydraulic

Oil. (See Hydraulic Oil in
CHAPTER 1, of operator’s
manual.)
Engine speed too slow. Check engine Slow and Fast

Idle Adjustment. (See “SLOW
AND FAST IDLE
ADJUSTMENT” on page 17)
Bin control function too slow. For bin control function, (See
“DIAGNOSE PNEUMATIC
SYSTEM MALFUNCTIONS” on
page 194.)
Air leak in pump suction line. Check for air bubbles in oil.
Tighten clamps, replace “O”-
rings as necessary.
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B25D & B30D 6X6 CHAPTER 6 872106
All Hydraulic Functions Slow Pump suction strainer restricted. Clean pump suction strainer
(See CHAPTER 14, SECTION 1
in the Repair Manual).
Residual valve pressure setting Check residual valve pressure

too low or malfunctioning. setting. See “MAIN
HYDRAULIC PUMP RESIDUAL
AND COMPENSATOR VALVES
TEST AND ADJUSTMENT” on
page 255.
Inspect Residual Valve (See

Main Hydraulic Pump
the Repair Manual).
Compensator valve pressure Check compensator valve

setting too low or pressure setting. See “MAIN
malfunctioning. HYDRAULIC PUMP RESIDUAL
page 255.
Inspect Compensator Valve

(See Main Hydraulic Pump
the Repair Manual).
System relief valve pressure too Check system relief valve

low or malfunctioning. pressure setting (not
adjustable). See “SYSTEM
RELIEF VALVE AND BIN
RAISE CIRCUIT RELIEF
VALVE TEST” on page 256.
Inspect System Relief Valve

(See Hydraulic System
Manifold Assembly,
the Repair Manual).
Main hydraulic pump worn. Check cycle times. See

“CYCLE TIME TEST” on
page 254.
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872106 CHAPTER 6 B25D & B30D 6X6
Hydraulic Oil Overheats. Oil level too low. Check oil level in hydraulic
reservoir. Add hydraulic oil (See
CHAPTER 1 in OMM for
specifications and oil
quantities).
Wrong oil in system. Use recommended hydraulic oil.

(See CHAPTER 1 in OMM for
quantities).
Return filter plugged. Replace Hydraulic System Oil

Return Filter (See CHAPTER
System relief valve. Check system relief valve

pressure setting (Not
Inspect System Relief Valve

Manifold Assembly,
the Repair Manual).
Main hydraulic pump Check compensator valve

compensator valve setting too pressure setting. See “MAIN
high. HYDRAULIC PUMP RESIDUAL
page 255.
Brake accumulator charge valve Check brake accumulator

pressure setting too high. charge valve pressure setting.
See“BRAKE ACCUMULATOR
CHARGE VALVE TEST AND
ADJUSTMENT” on page 258.
Cylinder leakage. Check cylinders for hot spot

indicating oil bypassing piston.
(See steering Cylinder
CHAPTER 8, SECTION 2 and
Body Lift Cylinder, CHAPTER
16, SECTION 2 in the Repair
Manual).
Main hydraulic pump stuck at Disassemble and inspect main

maximum displacement. hydraulic pump. (See
CHAPTER 14, SECTION 1).
Main hydraulic pump worn. Check using cycle times. Do

Cycle Time Test. (See“CYCLE
TIME TEST” on page 254).
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ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
Main Hydraulic Pump Noisy. Oil level low. Check oil level in hydraulic
reservoir. Add hydraulic oil (See
CHAPTER 1 in OMM for
quantities).
Wrong oil in system. Use recommended hydraulic oil.

(See CHAPTER 1 in OMM for
quantities).
Pump suction strainer restricted. Clean pump suction strainer

(See CHAPTER 14, SECTION 1
in the Repair Manual).
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. (See Main
oil seal. hydraulic Pump, CHAPTER
Manual).
Main hydraulic pump drive shaft Assemble drive shafts so yokes

yokes not aligned. are aligned. (See Hydraulic
Pump Drive Shaft, CHAPTER
14, SECTION 1.
Bin Will Not Rise. Main hydraulic pump Check compensator valve
compensator valve setting too pressure setting. See “MAIN
low. HYDRAULIC PUMP RESIDUAL
page 255).
System relief valve. Check system relief valve

pressure setting (Not
If pressure is low, replace

system relief valve. If pressure is
still low, replace bin raise circuit
relief valve. (See Hydraulic
System Manifold Assembly,
Repair Manual).
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872106 CHAPTER 6 B25D & B30D 6X6
Service Brake System Malfuntion
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.
Service brake calliper pads and/ Check service brake calliper

or disks. pads and/or disks for wear.
Replace worn pads and/or disks.
(See service brakes CHAPTER
Manual).
Service brake calliper piston Check for leakage at brake

seals. calliper piston. Replace seals.
(See Service Brakes
Repair Manual).
Air in system. Check for foamy oil. Tighten

loose fitting. Replace damaged
lines and “O”-rings. Bleed
Service Brake Hydraulic
System. (See CHAPTER 9,
Manual).
Low or no oil pressure. Check brake accumulator

pressure reducing valve and
brake accumulator charge valve.
(See “ACCUMULATOR
PRESSURE REDUCING
VALVE TEST AND
Service Brake Pads and Disks Driving technique - constantly Allow the exhaust brake to slow
using service brakes to slow the the machine.
machine.
Exhaust brake. Check exhaust brake circuit

operation. (See “PNEUMATIC
SYSTEM OPERATION” on
page 179).
Service brake valve. Spools sticking or binding in

valve housing. Repair or replace
brake valve (See CHAPTER 9,
Manual).
Restriction in service brake Check return lines for restriction.

valve return lines.
242 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
Time Between Brake Brake accumulators. Gas charge in brake

Accumulator Charging Cycles accumulators too low. Check
Too Short accumulator operation. (See
“BRAKE LOW PRESSURE
SWITCH AND BRAKE
ACCUMULATOR TEST” on
page 259).
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. (See CHAPTER 1
in the OMM for recommended
oils).
Steering load sense relief valve Check steering load sense relief
pressure setting too low or valve pressure. (See
malfunctioning. “STEERING RELIEF VALVE
PRESSURE TEST AND
Inspect steering load sense

relief valve. (See hydraulic
System Manifold Assembly
the Repair Manual).
Steering lines damaged. Inspect and replace lines.
Priority valve in hydraulic system Check priority valve operation.

manifold. (See “PRIORITY VALVE TEST”
on page 257).
Steering valve. Disassemble steering valve and

inspect. (See Steering Valve
Repair Manual).
Steering cylinders piston seals. Check steering cylinder for

leakage. (See “STEERING
CYLINDER LEAKAGE TEST”
on page 262).
Replace piston seals as needed.

(See Steering Cylinder
Repair Manual).
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872106 CHAPTER 6 B25D & B30D 6X6
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. (See “STEERING
CYLINDER LEAKAGE TEST”
on page 262).
Replace piston seals as needed.

(See Steering Cylinder
Repair Manual).

Repair Manual).
Erratic Steering Air in steering system. Check for foamy oil. Tighten
loose fittings. Replace damaged
lines.

oils).
Cylinder piston loose. Disassembly cylinder and

inspect. (See Steering Cylinder
Repair Manual).

Repair Manual).
Spongy or Soft Steering. Air in steering system. Check for foamy oil. Tighten
loose fittings. Replace damaged
lines.

oils).
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. (See Steering
Valve CHAPTER 8, SECTION 2
in Repair Manual).
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B25D & B30D 6X6 CHAPTER 6 872106
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. (See CHAPTER 16,
SECTION 1 in the OMM).
Flush hydraulic system. Using

portable Filter Caddy. (See
“HYDRAULIC OIL CLEANUP
PROCEDURE USING
PORTABLE FILTER CADDY”
on page 252).
Disassemble steering valve and

Repair Manual).
Abrupt Steering Wheel Steering valve gerotor not Time gerotor gear. (See
Oscillation. limited correctly. Steering Valve CHAPTER 8,
Steering Wheel Turns by Itself. Lines connected to wrong ports. Connect lines to correct ports.
Schematic CHAPTER 6,
SECTION 3).
Machine Turns in Opposite Lines to steering cylinders Connect lines to correct ports.
Direction. connected to wrong ports at (See Hydraulic System
steering valve. Schematic CHAPTER 6,
SECTION 3).
Machine Turns When Steering Steering valve leakage. Disassemble steering valve and
Valve is in Neutral. inspect. (See Steering Valve
Repair Manual).
ISSUE 0 245
872106 CHAPTER 6 B25D & B30D 6X6
HYDRAULIC SYSTEM COMPONENT LOCATION
Hy30D0009CFM
1. Main Hydraulic Pump. 4. Suction Strainer.

2. Return Filter. 5. Secondary Steering Pump.
3. Hydraulic Reservoir.
6.Hydraulic System Manifold.
246 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
HYDRAULIC SYSTEM COMPONENT LOCATION (Continues)
Hy30D0015CFM
1. Brake Valve. 2. To Hydraulic Reservoir.
ISSUE 0 247
872106 CHAPTER 6 B25D & B30D 6X6
3. Brake Charge Accumulator. 6. Hydraulic System Manifold.

4. Brake Low Pressure Switch. 7. Rear Brake Apply Accumulator.
5. Secondary Steering Pressure Switch. 8. Front Brake Apply Accumulator..
9. Brake Calliper.
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B25D & B30D 6X6 CHAPTER 6 872106
Hy30D0016CFM
ISSUE 0 249
872106 CHAPTER 6 B25D & B30D 6X6
1. Steering Valve. 5. Secondary Steering Pump.

2. Right Steering Cylinder. 6. Suction Hose.
3. Left Steering Cylinder. 7. Hydraulic System Manifold.
4. Case Drain Hose To Reservoir.
250 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
5 6
Hy30D0012CFM
1. Bin Tip Control Valve. 5. MP 2 Test Port Line.

2. MP 1 Test Port Line. 6. M 4 Test Port Line.
3. Right Bin Tip Cylinder. 7. Hydraulic System Manifold.
4. Left Bin Tip Cylinder.
ISSUE 0 251
872106 CHAPTER 6 B25D & B30D 6X6
CHAPTER6. HYDRAULIC SYSTEM
SECTION 3. TESTS
JT05800 DIGITAL THERMOMETER After transducer is warmed and no pressure

INSTALLATION 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.
1 Transducers:
• 3400 kPa (35 bar) (500 psi)

3 • 34 000 kPa (350 bar) (5000 psi)
• 70 000 kPa (700 bar) (10,000 psi)
2
HYDRAULIC OIL CLEANUP
1. Temperature Probe PROCEDURE USING PORTABLE
2. Cable FILTER CADDY
3. JT05800 Digital Thermometer
Specifications
Fasten temperature probe (1) to a bare metal
hydraulic line using a tie band. Hydraulic Reservoir Capacity - - 78.8 L (20.8 USGAL)
Hydraulic Reservoir
Wrap temperature probe and line with a shop Filtering Time - - - - - - - - - - - - 7 minutes approximate.
towel.
Engine Speed - - - - - - - - - - - - - - - - - -2750 ± 30 r.p.m.
JT02156A DIGITAL PRESSURE/ Hydraulic System Capacity - - - - - - 155 L (41 USGAL)
TEMPERATURE ANALYZER Hydraulic System
Filtering Time - - - - - - - - - - - 25 minutes approximate.
INSTALLATION
Portable Filter Caddy
Two 3658 mm (12 ft) x 3/4 in. ID 100R1 Hoses with 3/4
M NPT Ends
Quick Disconnect Fittings
1 Suction Wand
Discharge Wand
2 This procedure must be used to clean complete
hydraulic system after any major component
failure.
Install new return filter elements.
1. JT02156A Digital Pressure/Temperature

Analyser.
2. Transducers.
Use the digital pressure/temperature analyser (1)

and transducers (2) in place of analog gauges and
a separate temperature reader.
Transducers are temperature sensitive. Allow

transducer to warm to system temperature.
252 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
NOTE:1. For a failure that creates a lot of Stop engine. Remove filter caddy.
debris, remove access cover from
hydraulic reservoir. Drain the Install new return filter elements.
hydraulic reservoir. Connect filter
caddy suction line to drain port. Add Check oil level in hydraulic reservoir; add hydraulic
a minimum of 19 L (5 gal) of oil to the oil if necessary. (See CHAPTER 1 of the OMM for
hydraulic reservoir. Operate filter oil specifications and quantities).
caddy and wash out the hydraulic
reservoir. HYDRAULIC SYSTEM WARM-UP
2. The minimum ID for a connector is PROCEDURE
1/2 in. to prevent cavitation of filter
caddy pump. Service Equipment And Tools
JT05800 Digital Thermometer
Put filter caddy suction and discharge wands into
the hydraulic reservoir filler hole so ends are as far NOTE:If machine temperature is below –
apart as possible to obtain a thorough cleaning of 18°C (0°F), start procedure with
oil. engine running at 1/2 speed. Failure
to do this could cause pump
Start the filter caddy. Check to be sure oil is cavitation. Once oil temperature is
flowing through the filters. Operate filter caddy above -18°C (0°F) the engine speed
until all oil in the hydraulic reservoir has been can be increased to fast idle.
circulated through the filter a minimum of four
times. Below –18°C (0°F) an extended warm-up period
may be necessary. Hydraulic function will move
NOTE:Filtering time for hydraulic reservoir slowly and lubrication of parts may not be
is 0.089 minute x number of litres adequate with cold oil.
(0.33 minutes x number of gallons).
Do not attempt normal machine operation until
Leave filter caddy operating for the next step. hydraulic functions move at or close to normal
cycle times.
Start the engine and run it at specification.
Operate functions slowly and avoid sudden
Specification movements until engine and hydraulic oils are
Engine - Speed - - - - - - - - - - - - - - - - 2750 ± 30 r.p.m. thoroughly warmed.
NOTE:For the most effective results, Operate a function by moving it a short distance in
cleaning procedure must start with each direction. Continue operating the function
the smallest capacity circuit then increasing the distance travelled in each cycle until
proceed to the next larger capacity full stroke is reached.
circuit.
Use correct viscosity Hydraulic Oil to minimize
Starting with the smallest capacity circuit, operate warm-up period. (See CHAPTER 1 of operator’s
each function through a complete cycle. manual.)
Repeat procedure until the total system capacity Use monitor display menu “B034” to monitor
has circulated through filter caddy seven times. hydraulic oil temperature. See Menu Display Unit -
Menu Function (in CHAPTER 8 of operator’s
Each function must go through a minimum of three manual). Or connect digital thermometer.
complete cycles for a thorough cleaning of oil.
Install temperature probe on hydraulic reservoir-
NOTE:Filtering time for complete hydraulic to-pump inlet line. (See “JT05800 DIGITAL
system is 0.158 minute x number of THERMOMETER INSTALLATION” on
litres (0.6 minute x number of page 252).
gallons). Filtering time for machines
with auxiliary hydraulic functions
must be increased because system
capacity is larger.
ISSUE 0 253
872106 CHAPTER 6 B25D & B30D 6X6
n CAUTION Service Equipment And Tools

Avoid possible serious injury from machine Stop Watch
movement during warm-up procedure. Clear
the area of all bystanders before doing the Test is used as an indication of hydraulic circuit
warm-up procedure. performance. A slow cycle time is an indication of
a restriction or leakage in that circuit.
Clear the area of all bystanders to allow for Cycle times are also a general indication of
machine movement. hydraulic pump performance. Always record the
average of at least three complete cycle times.
Start engine. Do not accelerate engine rapidly
during warm-up. Run engine at 1/2 speed for Do Hydraulic System Warm-Up Procedure to heat
approximately 5 minutes before operating any hydraulic oil to specified temperature. (See
functions. “HYDRAULIC SYSTEM WARM-UP
PROCEDURE” on page 253.) Use menu display
Engage park brake. menu “B 034” to monitor hydraulic oil temperature.
(See Menur Display Unit - Menu Function in
n CAUTION
CHAPTER 8 of OMM).
n
Holding a function over relief for more than
10 seconds can cause damage to control CAUTION
valve. Avoid possible serious injury from machine
movement. Clear area of all bystanders
before performing test. Area must have
Operate steering and dump body raise and lower enough overhead clearance to raise bin to
functions over relief to heat hydraulic system. full height of 7226 mm (23 ft. 8.5 in.). Do not
perform this test within 4 m (13 ft.) of high
Once oil temperature is above –18°C (0°F), voltage power lines.
increase engine speed to fast idle.
Stop periodically and operate all hydraulic

Park machine on level ground in the straight
functions tribute the heated oil.
ahead position.
CYCLE TIME TEST Bin
Specifications Select “N” (Neutral) on gear shift control and
engage park brake.
Hydraulic Oil Temperature - - - - 50 ± 5°C (120± 10°F).
Engine Speed - - - - - - - - - - - - - - - - - -2620 ± 50 r.p.m. Operate machine at specification.
Bin Raise Actuate bin control valve to full stroke for each
(New Pump) Cycle Time- - - - - - - - - - - - - - - - 11.9 sec.
function. Record cycle times.
Bin Lower
(New Pump) Cycle Time - - - - - - - - - - - - - - - - - 6 sec. Steering
Bin Raise
Select “N” (Neutral) on gear shift control and
(Used Pump) Cycle Time - - - - - - - - - - - - - - -14.9 sec.
disengage park brake.
Bin Lower
(Used Pump) Cycle Time - - - - - - - - - - - - - - - - - 8 sec. Operate machine at specification.
Engine Speed - - - - - - - - - - - - - - - - - - - - - - Slow Idle.
Steering Wheel Starting with machine turned against the left or
Stop-to-Stop Turns- - - - - - - - - - - - - - - - - - - 4.7 Turns right stop, turn steering wheel to opposite stop.
Record the time and number of steering wheel

turns stop-to-stop. Repeat several times, in both
directions, to verify count.
254 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
MAIN HYDRAULIC PUMP RESIDUAL Residual Valve Pressure Setting

AND COMPENSATOR VALVES TEST
Do Hydraulic System Warm-Up Procedure to heat
AND ADJUSTMENT hydraulic oil to specified temperature. (See
“HYDRAULIC SYSTEM WARM-UP
Specifications Residual Valve PROCEDURE” on page 253.) Use menu display
Hydraulic Oil menu “B 034” to monitor hydraulic oil temperature.
Temperature - - - - - - - - - - - - - - 50 ± 5°C (120± 10°F) (See Menu Display Unit - Menu Function in
Engine Speed - - - - - - - - - - - - - - - - - - - - - Slow Idle. CHAPTER 8 of OMM).
Residual Valve Pressure Run engine at specification.
- - - - - - - - 2500 ± 100 kPa (25 ± 1 bar) (363 ± 14.5 psi)
Record pressure reading. Adjust pressure as
Compensator Valve necessary.
Hydraulic Oil
Tilt cab for access to main hydraulic pump. Do Tilt
Temperature - - - - - - - - - - - - - - - 50 ± 5°C (120± 10°F)
and lower the cab procedure. (See CHAPTER 7,
Engine Speed - - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m. SECTION 1 in OMM.)
First Compensator Valve Pressure - - - - - - - - - - - - - - -
n
- - - - - - - - - - - - - - - - - - - - - - - - - - - 24 000 ± 500 kPa
- - - - - - - - - - - - - - - - - -(240 ± 5 bar) (3625—3770 psi) CAUTION
Second Compensator Valve Pressure Beware of rotating drive shaft when making
- - - - - - - - - - - - - - - - - - - - - - - - - 25 000—26 000 kPa adjustment on main hydraulic pump. Keep
- - - - - - - - - - - - - - - - (250—260 bar) (3481 ± 72.5 psi) all tools and equipment stored away from
openings so they do not fall into the drive
Essential Tools shaft. Wear close fitting clothing.
JT03482 High Pressure Test Hose Kit.

JT02156A Digital Pressure/Temperature Analyser
1
The purpose of test is to check the residual valve
and compensator valve pressure settings and
adjust as necessary.
Residual (low stand-by) pressure is maintained by 2

the pump when no functions are actuated. The
compensator valve destrokes the pump at full 3
system pressure, thereby limiting system
pressure.
4
n CAUTION 2
To perform this test, machine MUST be
parked in an area that will allow bin to be 1
raised to full height.
Install articulation locking bar.
Connect digital pressure/temperature analyser

and transducer or a gauge to port MP1 of test port
manifold.
Remove both residual valve cap, loosen nut, and

adjust valve (2) to specification. Turn adjusting
screw in to increase pressure.
ISSUE 0 255
872106 CHAPTER 6 B25D & B30D 6X6
Tighten nut and install cap. n CAUTION
Compensator Valve Pressure Setting To perform this test, machine MUST be

parked in an area that will allow bin to be
Do Hydraulic System Warm-Up Procedure to heat raised to full height.
hydraulic oil to specified temperature. (See
PROCEDURE” on page 253.) Use monitor Install articulation locking bar.
display menu “B 034” to monitor hydraulic oil
temperature. (See Menu Display Unit - Menu
Function in CHAPTER 8 of OMM).
manifold.
Run engine at specification.
Raise the bin to full height. hydraulic oil to specified temperature. (See
Actuate bin raise function over relief. PROCEDURE” on page 253.) Use menu display
menu “B 034” to monitor hydraulic oil temperature.
Record pressure reading. Adjust as necessary. (See Menu Display Unit - Menu Function in
CHAPTER 8 of OMM).
Remove compensator valve cap, loosen nut, and
adjusting compensator (1) to specification. Run engine at specification.
Turn adjusting screw in to increase pressure. Raise the bin to full height.
Tighten nut and install cap. Actuate bin raise function over relief.
SYSTEM RELIEF VALVE AND BIN

RAISE CIRCUIT RELIEF VALVE TEST n CAUTION
Compensator valve MUST be adjusted to
Specifications specification after test is complete.
Hydraulic Oil Temperature - - - - - 50 ± 5°C (120± 10°F)

Engine Speed - - - - - - - - - - - - - - - - - 1500 ± 20 r.p.m. While monitoring pressure gauge, adjust one main
System Relief Valve Pressure hydraulic pump compensator valve IN to increase
- - - - - - - - - - - - - - - - - - - - - - - 28 000 + 2000 - 0 kPa pressure. The point at which the pressure ceases
- - - - - - - - - - - - (280 + 20 - 0 bar) (4061 + 290 - 0 psi) to increase is the system and bin raise circuit relief
Bin Raise Circuit Relief Valve Pressure - - - - - - - - - - - valves setting.
- - - - - - - - - - - - - - - - - - - - - - - 28 000 + 2000 - 0 kPa
- - - - - - - - - - - - (280 + 20 - 0 bar) (4061 + 290 - 0 psi)
Essential Tools 1
A4
Service Equipment And Tools B6

B5
JT02156A Digital Pressure/Temperature Analyser. O2
A6
A5
The purpose of this test is to check the pressure
settings of the system relief valve and the bin raise
circuit relief valve.
System and bin raise circuit relief valves are not 2

adjustable. It will be necessary to replace relief Hy30D0013CFM
valve(s) if not within specification.

If pressure reading is low, replace system relief
valve (2) and repeat test. If pressure reading is still
low replace bin raise circuit relief valve (1).
256 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
Adjust compensator valve to specification. (See ACCUMULATOR PRESSURE

“MAIN HYDRAULIC PUMP RESIDUAL AND
COMPENSATOR VALVES TEST AND
REDUCING VALVE TEST AND
ADJUSTMENT” on page 255). ADJUSTMENT
PRIORITY VALVE TEST Specifications

Hydraulic Oil Temperature- - - - - 50 ± 5°C (120± 10°F)
Specifications
Engine Speed - - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m.
Hydraulic Oil Temperature - - - - - 50 ± 5°C (120± 10°F) Accumulator Pressure Reducing Valve Pressure- - - - -
Engine Speed - - - - - - - - - - - - - - - - - - - - - Slow Idle. - - - - - - - - - - - - - - - - - - - - - - - - 18 500 - 19 500 kPa
Main Hydraulic Pump Load Sense Pressure - - - - - - - - - - - - - - - - - - - - - - (185 - 195 bar) (2685 - 2830 psi).
- - - - - - - - - - - - - 1500 kPa (15 bar) (218 psi) minimum
Essential Tools
Essential Tools
JT03482 High Pressure Test Hose Kit
The purpose of this test is to check the
Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - 0 - 1000 psi accumulator pressure reducing valve pressure
The purpose of this test is to verify the operation of setting and adjust as necessary.
the priority valve.

n CAUTION
and transducer or a gauge to port ML1 of hydraulic To avoid injury from escaping fluid under
system manifold. (See “Hydraulic System pressure, stop engine and relieve pressure
Manifold Operation (Top View)” on page 354). in the system before disconnecting
hydraulic lines. Tighten all connections
Do Hydraulic System Warm-Up Procedure to heat before applying pressure.
PROCEDURE” on page 253.) Use menu display Apply and release brake pedal approximately 35 -
menu “B 034” to monitor hydraulic oil temperature. 40 times to relieve pressure from system.
(See Menu Display Unit - Menu Function in
CHAPTER 8 of OMM). Connect digital pressure/temperature analyser
and transducer or a gauge to port M4 of test port
Run engine at specification. manifold.
Starting with machine against right or left steering Do Hydraulic System Warm-Up Procedure to heat
stop, steer machine in opposite direction as fast as hydraulic oil to specified temperature. (See
the hydraulics will allow. “HYDRAULIC SYSTEM WARM-UP
Read pressure gauge while steering. Pressure menu “B 034” to monitor hydraulic oil temperature.
should be no less than specification. If pressure is (See Menu Display Unit - Menu Function in
less, replace priority valve. (See Hydraulic CHAPTER 8 of OMM).
System Manifold Assembly CHAPTER 14,
SECTION 1 in the Repair Manual). Run engine at specification.
ISSUE 0 257
872106 CHAPTER 6 B25D & B30D 6X6
n CAUTION n CAUTION
Brake accumulators must be completely To avoid injury from escaping fluid under
charged before taking pressure reading. pressure, stop engine and relieve pressure
in the system before disconnecting
Actuate brake pedal repeatedly until main before applying pressure.
hydraulic pump goes into stroke to charge brake
accumulators. Allow accumulators to charge
completely. Apply and release brake pedal approximately 35 -
40 times to relieve pressure from system.

manifold.
VO AC PAR KER
ML1 M6
ML3 X3
M5
MP3
MP2 X4
S4
SP1 “HYDRAULIC SYSTEM WARM-UP
MP1 PROCEDURE” on page 253.) Use menu display
PARKER
XB
1 CHAPTER 8 of OMM).
XB XA
NOTE:Main hydraulic pump will go into

stroke and charge pressure will start
to rise at approximately 13 000 kPa
Hy30D0014CFM
(130 bar) (1885 psi). This pressure
cannot be adjusted.
Actuate bin raise function over relief. Record
pressure reading. Adjust accumulator pressure Actuate brake pedal repeatedly until main
reducing valve XB (1) as necessary. hydraulic pump goes into stroke to charge brake
accumulators.
BRAKE ACCUMULATOR CHARGE
.
VALVE TEST AND ADJUSTMENT

Specifications
Hydraulic Oil Temperature - - - - - 50 ± 5°C (120± 10°F) 1
VO AC PAR KER
ML1 M6
Engine Speed - - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m. ML3 X3
M5
MP3
Accumulator Circuit MP2 X4
S4
Charge Pressure - - - - - - - - - - - - -16 500 - 17 000 kPa SP1
- - - - - - - - - - - - - - - -(165 - 170 bar) (2393 - 2466 psi) MP1
Essential Tools
PARKER
XB
XB XA

JT02156A Digital Pressure/Temperature Analyser.
The purpose of this test is to check the brake

accumulator charge valve pressure setting and
adjust as necessary. Hy30D0014CFM
The pressure will rise until accumulators are fully

charged. Take pressure reading at this time.
258 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
If reading is not to specification, adjust Turn key switch to ON position. DO NOT start
accumulator charge valve X4 (1) as necessary. engine.
Accumulators must be discharged and main NOTE:Other indicator lights may be ON or

hydraulic pump allowed to go to stroke after each flashing but buzzer does not sound
adjustment to obtain proper reading. because engine is not running.
BRAKE LOW PRESSURE SWITCH Apply and release brake pedal until brake low
AND BRAKE ACCUMULATOR TEST pressure indicator light comes ON. Record the
pressure reading when indicator light comes ON.
Specifications
NOTE:Other indicator lights may be ON or
Hydraulic Oil Temperature - - - - - 50 ± 5°C (120± 10°F) flashing but buzzer does not sound
Brake Low Pressure Indicator because engine is not running.
Light Actuation Pressure - - - - - - - 12 300 - 12 500 kPa
- - - - - - - - - - - - - - - - - 123 - 125 bar) (1785 - 1815 psi) Apply and release brake pedal until brake low
Brake Accumulator Gas pressure light comes ON. Record the pressure
Charge Pressure - - - - - - - - - - - - - - - 6000 ± 350 kPa reading when indicator light comes ON.
- - - - - - - - - - - - - - - - - - - - (60 ± 3.5 bar) (870 ± 50 psi)
NOTE:Brake charge accumulator is not
Essential Tools serviceable.

JT02156A Digital Pressure/Temperature Analyser.
The purpose of this test is to check operation of VO AC PAR KER
ML1 M6
brake low pressure switch S4 and to check the gas ML3 X3

M5
charge pressure of the brake accumulator in port MP3
MP2 X4
S4
A4 of hydraulic system manifold. SP1
MP1
1
n CAUTION
PARKER
XB
To avoid injury from escaping fluid under
pressure, stop engine and relieve pressure
XB XA

before applying pressure.
Apply and release brake pedal approximately 35 - Hy30D0014CFM

If indicator light does not come ON at specification,
Connect digital pressure/temperature analyser replace brake low pressure switch S4 (1).
manifold.

CHAPTER 8 of OMM).
Stop engine.
ISSUE 0 259
872106 CHAPTER 6 B25D & B30D 6X6
FRONT AND REAR BRAKE n CAUTION

ACCUMULATORS PRESSURE TEST Loosen outer nut ONLY to open charging
AND CHARGE PROCEDURE valve. DO NOT loosen the inner nut, to do so
will remove charging valve fitting. If
Specifications charging valve fitting is removed with
pressure in accumulator, personal injury
Accumulator Pre-Charge Pressure may result.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - 8000 ± 350 kPa
- - - - - - - - - - - - - - - - - - (80 ± 3.5 bar) (1160 ± 50 psi)
Essential Tools Turn outer nut (3) of charging valve counter

clockwise to open. Do not loosen inner nut.
JT03522 Charging Adapter
Record accumulator pre-charge pressure. Charge
The purpose of this test is to measure pre-charge
accumulator to specification if necessary.
pressure in each individual front and rear brake
charge accumulator and charge if necessary. Apply and release brake pedal approximately 3 - 4
times to relieve any pressure buildup in system.
Apply and release brake pedal approximately 35 -
40 times to relieve pressure from system. Turn outer nut of charging valve clockwise to
close.
Close nitrogen regulator and remove charging

adapter and hose.
1
2 Install charging valve cap and guard.
Repeat procedure for each accumulator.

3 SERVICE BRAKE VALVE TEST
Specifications
Engine Speed - - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m.
Full Pedal Travel Pressure - - - - - - - 12 000 ± 500 kPa
Remove accumulator charging valve guard (1) - - - - - - - - - - - - - - - - - - - (120 ± 5 bar) (1740 ± 70 psi)
and cap (2). Pedal Released Pressure - - - - - - - - - - - - - - - 70 kPa
- - - - - - - - - - - - - - - - - - - - - (0.70 bar) (10 psi) or less
n WARNING Essential Tools

USE ONLY dry nitrogen to charge brake ac-
38H1031 (-6M x -6M x -6F ORFS)
cumulators. DO NOT use compressed air or (Parker No. 6R6LO) Swivel Run Tee
any other gas as they may be combustible or
JT03478 (1/2 Male Quick Coupler x -8 F ORFS)
cause oxidation and condensation in the ac- Adapter
cumulator.
Connect charging adapter and hose to charging JT05412 Pressure Test Kit
valve of accumulator. JT02156A Digital Pressure/Temperature Analyser
The purpose of this test is to check operation of

the brake valve and record brake pressures at full
pedal travel and with pedal released.
260 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
n CAUTION The pressure must increase gradually and reach

To avoid injury from escaping fluid under specification at full pedal travel and gradually
pressure, stop engine and relieve pressure decrease to specification upon pedal release.
If pressure is not to specification with pedal
depressed, do “ACCUMULATOR PRESSURE
before applying pressure.
REDUCING VALVE TEST AND ADJUSTMENT”
on page 257 and “BRAKE ACCUMULATOR
CHARGE VALVE TEST AND ADJUSTMENT”
Apply and release brake pedal approximately 35 -
on page 258.
If pressure does not increase or decrease
gradually as pedal is depressed and released,
inspect brake valve. See Disassemble and
Assemble Brake Valve. CHAPTER 9, SECTION
2 in the Repair Manual).
STEERING RELIEF VALVE PRESSURE

TEST AND ADJUSTMENT
Specifications
1 Engine Speed - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m.)
2 Steering Relief Valve Pressure
- - - - - - - - - - - - - - - - 19 500 kPa (195 bar) (2828 psi)
Disconnect front axle brake line (1), or rear axle Essential Tools
brake line (2).
and transducer or a gauge to brake line using Service Equipment And Tools
swivel run tee and adapter. JT02156A Digital Pressure/Temperature Analyser
Do Hydraulic System Warm-Up Procedure to heat The purpose of this test is to check the steering
hydraulic oil to specified temperature. (See relief valve pressure setting and adjust as
“HYDRAULIC SYSTEM WARM-UP necessary.
menu “B 034” to monitor hydraulic oil temperature. Connect digital pressure/temperature analyser
(See Menu Display Unit - Menu Function in and transducer or a gauge to port MP1 of test port
CHAPTER 8 of OMM). manifold.
Run engine at specified speed. Do Hydraulic System Warm-Up Procedure to heat

n CAUTION
Brake pressure must decrease to 70 kPa menu “B 034” to monitor hydraulic oil temperature.
(0.70 bar) (10 psi) or less after brake pedal (See Menu Display Unit - Menu Function in
release to prevent excessive drag which CHAPTER 8 of OMM).
causes premature wear to brake pads and
disks. Run engine at specification.
Turn machine left or right against steering stop,

While observing pressure reading, slowly depress allowing steering circuit to go over relief. Record
brake pedal to the end of its travel and then slowly pressure reading.
release the pedal.
Adjust pressure as necessary.
Record pressure reading at end of pedal travel
and after pedal is released.
ISSUE 0 261
872106 CHAPTER 6 B25D & B30D 6X6
Tilt cab for access to main hydraulic pump. Do Tilt NOTE:Check steering cylinder for leakage
and lower the cab procedure. (See CHAPTER 7, in fully extend position. In retracted
SECTION 1 in OMM.) position, piston contacts head end of
cylinder, blocking leakage flow
n CAUTION
across piston seal to head end port.
Beware of rotating drive shaft when making Turn machine left or right against steering stop to
adjustment on the hydraulic system extend steering cylinder to be checked. Stop
manifold. Keep all tools and equipment engine.
stored away from openings so they do not
fall into the drive shaft. Wear close fitting Disconnect line from rod end port of the extended
clothing. cylinder. Install plug in open line. Place a
graduated measuring container under open
cylinder port to catch leakage.
1
Start engine and run at specification.
Turn steering wheel against stop in same direction

M6
VO AC PAR KER
ML1 as machine is turned. Hold against stop for 20

ML3 X3
M5 seconds. Record leakage and multiply reading by
MP3
MP2 X4
S4
three (x 3).
SP1
MP1
If leakage is over specification, inspect Steering
Cylinder piston seals. (See CHAPTER 8,
SECTION 2 in the Repair Manual.)
PARKER
XB
SECONDARY STEERING PUMP

XB XA
RESIDUAL AND COMPENSATOR

VALVES TEST AND ADJUSTMENT
Specifications
Hy30D0014CFM Hydraulic Oil Temperature - - - - - 50 ± 5°C (120± 10°F)
Engine Speed - - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m.
Adjust steering relief valve X3 (1) to specification.
Special Test Steering Relief Pressure - - - - -23000 kPa
STEERING CYLINDER LEAKAGE - - - - - - - - - - - - - - - - - - - - - - - - -(230 bar) (3336 psi).
TEST Engine Speed - - - - - - - - - - - - - - - - - 1500 ± 20 r.p.m

Residual Valve Pressure - - - - - - - - - - 2200 ± 100 kPa
Specifications - - - - - - - - - - - - - - - - - - - - -(22 ± 1 bar) (319 ± 15 psi)
Compensator Valve Pressure - - - - - - - - - 21 000 kPa
Hydraulic Oil Temperature - - - - - 50 ± 5°C (120± 10°F) - - - - - - - - - - - - - - - - - - - - - - - - - (210 bar) (3045 psi)
Engine Speed - - - - - - - - - - - - - - - - - - - - - - Slow Idle. Engine Speed - - - - - - - - - - - - - - - - - 1000 ± 20 r.p.m.
Steering Against Stop Time - - - - - - - - - - - 20 seconds Steering Relief Pressure - - - - - - - - - - - - - -19500 kPa
Piston Seal Leakage - - - - - - - 15 mL/min (1/2 oz/min) - - - - - - - - - - - - - - - - - - - - - - - - -(195 bar) (2828 psi).
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - approximate.
Essential Tools
The purpose of this test is to measure steering
cylinder piston seal leakage. JT03482 High Pressure Test Hose Kit
Do Hydraulic System Warm-Up Procedure to heat Service Equipment And Tools

hydraulic oil to specified temperature. (See JT02156A Digital Pressure/Temperature Analyser
PROCEDURE” on page 253.) Use menu display The purpose of this test is to check the residual
menu “B 034” to monitor hydraulic oil temperature. and compensator valve pressure settings and
(See Menu Display Unit - Menu Function in adjust as necessary.
CHAPTER 8 of OMM).
262 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 6 872106
Install articulation locking bar.
n CAUTION
Inter-axle lock MUST be disengaged and
1
transfer case-to-oscillation joint drive shaft 2
MUST be removed to prevent movement of
machine while performing this test.
Apply park brake and put inter-axle lock switch into

the disengage position.
Remove transfer case-to-oscillation joint drive

shafts. (See CHAPTER 2, SECTION 3 in the
Without turning the steering wheel, record
Repair Manual.)
pressure reading. Adjust residual valve (1) to
Connect digital pressure/temperature analyser specification. Turn adjusting screw in to increase
and transducer or a gauge to port MP1 of test port pressure.
manifold.
Tighten nut and install cap.
Compensator Valve Adjustment
“HYDRAULIC SYSTEM WARM-UP PROCE- Turn machine left or right against steering stop,
DURE” on page 253.) Use menu display menu allowing steering circuit to go over relief. Record
“B 034” to monitor hydraulic oil temperature. (See pressure reading. Adjust compensator valve (2) to
Menu Display Unit - Menu Function in CHAP- specification.
TER 8 of OMM).
Specification
Run engine at specification. Turn machine left or Compensator Valve - Pressure - - - - - - - - - 21 000 kPa
right against locking bar, allowing steering circuit - - - - - - - - - - - - - - - - - - - - - - - - - 210 bar) (3045 psi)
to go over relief. Adjust X3 steering relief to special
Tighten nut and install cap.
test specification.
Connect digital pressure/temperature analyzer

n CAUTION
manifold. After secondary steering pump residual and

compensator valves are adjusted, steering
Start machine and shift to “D” (forward), range “1”, relief valve X3 MUST be adjusted to
and activate “Range Hold” function. Run engine at standard machine specification.
specification.
Residual Valve Adjustment Run engine at specification. Turn machine left or

right against locking bar, allowing steering circuit
Specification to go over relief.
Residual Valve - Pressure - - - - - - - - 2200 ± 100 kPa
- - - - - - - - - - - - - - - - - - - - - (22 ± 1 bar) (319 ± 15 psi) Adjust X3 steering relief to standard machine
specification. (See “STEERING RELIEF VALVE
PRESSURE TEST AND ADJUSTMENT” on
page 261). Install transfer case-to-oscillation joint
drive shaft. (See Drive Shafts CHAPTER 2,
SECTION 3 in repair manual.)
ISSUE 0 263
872106 CHAPTER 6 B25D & B30D 6X6
BIN LOWER CIRCUIT RELIEF VALVE

TEST
Specifications
Engine Speed - - - - - - - - - - - - - - - - - - 600 ± 20 r.p.m.
Bin Lower Circuit Pressure - - - - - - 8000 - 10 000 kPa
- - - - - - - - - - - - - - - - -(80 - 100 bar) (1160 - 1450 psi)
Essential Tools

The purpose of this test is to check that the bin

lower circuit relief valve is operating within its
specified range.

manifold.

CHAPTER 8 of OMM).
Hold bin tip lever in the lower position until bin

lower circuit is over relief. Record pressure
reading. Replace bin lower circuit relief valve (1) if
pressure reading is not within specification.
264 ISSUE 0
B25D & B30D 6X6 CHAPTER 7 872106
CHAPTER 7. HEATING AND AIR CONDITIONING

AIR CONDITIONING SYSTEM CYCLE OF OPERATION
4
5
7
8
6
9
10
11
GD1031CFM
1 Evaporator Core. 7 High Pressure Liquid.

2 Compressor. 8 High Pressure Gas.
3 Condenser Core. 9 Low Pressure Liquid.
4 Circulation Blower Motor. 10 Low Pressure Gas.
5 Expansion Valve. 11 Air Flow.
6 Receiver-Dryer.
The compressor is belt driven and engaged by an High pressure gas leaves compressor and flows
electromagnetic clutch. The air conditioning circuit through condenser where heat is removed and
automatically controls compressor engagement or transferred to outside air being drawn through
disengagement when system is in operation. (See condenser core by engine fan. Cooling refrigerant
“Air Conditioning Circuit Theory of Operation” causes it to condense and refrigerant leaves
on page 88.) condenser as high pressure liquid.
Compressor draws low pressure gas from

evaporator and compresses it into high pressure
gas. This causes temperature of refrigerant to rise
higher than that of outside air.
ISSUE 0 265
872106 CHAPTER 7 B25D & B30D 6X6
High pressure liquid flows into receiver-dryer System pressure is monitored by high/low
where moisture and contaminants (acid, solids, pressure switch, located on high pressure side of
etc.) are removed. expansion valve. If pressure becomes too high or
too low the switch opens and stops compressor,
Receiver-dryer contains a colour moisture interrupting the cycle.
indicator. Blue indicates no moisture is present.
Pink indicates moisture is present. . Accumulator (if equipped) is located between
evaporator and compressor in low pressure gas
Should moisture be combined with refrigerant, hose to retain a quantity of oil to protect
hydrofluoric and hydrochloric acids are formed. compressor from a dry start after long periods of
These acids are very corrosive to metal surfaces not being used. (See “HEATING/AIR
and leakage will eventually develop. CONDITIONING COMPONENT LOCATION” on
page 270.
Receiver-dryer also stores refrigerant allowing a
longer period of time before additional refrigerant HEATER CORE OPERATION
is needed. Refrigerant hoses allow a small amount
of refrigerant to migrate through their walls. The heater core is located near evaporator in
Refrigerant flows from receiver-dryer through heating and air conditioning module on right side
expansion valve to evaporator. of cab.
Expansion valve senses refrigerant temperature Filtered air flows through evaporator removing
and pressure to modulate refrigerant flow. moisture before flowing though heater core.
Expansion valve changes refrigerant to low
pressure liquid entering evaporator. The heater core uses warm engine coolant to heat
a mixture of inside cab air as well as outside air
Actual cooling and drying of cab air takes place at pulled across heater core.
evaporator. Heat absorbed by evaporator and
transferred to refrigerant causes refrigerant to Coolant flow through the heater core is regulated
vaporize into low pressure gas. by the heater valve. The heater valve is regulated
by an actuator which is controlled by the heater
Low pressure gas is drawn from evaporator by valve control module in response to the position of
compressor and cycle is repeated. A freeze temperature control switch. (See “HEATING/AIR
control switch senses temperature of evaporator CONDITIONING COMPONENT LOCATION” on
coil through a capillary tube. page 270).
This prevents the evaporator from becoming cold
enough to freeze moisture that condenses on
evaporator coil. Condensed moisture is drained
away through drain tubes connected to drain pan
under evaporator.
266 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS

NOTE:Diagnostic charts are arranged from most probable and simplest to verify, to least likely
more difficult to verify.
Air Conditioning System Does Not A/C - heater blower fuse. Replace fuse.
Operate
Blower motor switch. Check switch.
A/C - heater ON/OFF switch. Check switch
A/C freeze control switch. See “A/C FREEZE CONTROL SWITCH

TEST” on page 277.
A/C high/low pressure switch. See “A/C HIGH/LOW PRESSURE

SWITCH TEST” on page 277.
A/C compressor clutch. See “A/C COMPRESSOR CLUTCH

Wiring harness. Check engine and side console harness

wiring.
Air Conditioner Does Not Cool Interior of Fresh air filter restricted. Clean or replace filter.
Cab.
Condenser fins restricted witch debris. Clean condenser fins.
Re circulating air filter restricted. Clean or replace filter.
Compressor belt loose. See Fan Belt in CHAPTER 5, SECTION

1 in the Repair Manual.
Refrigerant hose kinked, pinched or Re-route or re-index hoses. Replace

collapsed. collapsed hoses.
Heater or evaporator core fins restricted Clean heater or evaporator core fins.
with dirt or dust.
A/C heater blower motor failed or Check blower motor.
operating too slowly.
See “HEATING/AIR CONDITIONING

COMPONENT LOCATION” on
page 270.
Compressor clutch slipping or failed. Inspect and/or replace compressor

clutch.
Warm outside air leaking into cab. Inspect, repair or replace door and rear
cab shield.
ISSUE 0 267
872106 CHAPTER 7 B25D & B30D 6X6
Air Conditioner Does Not Cool Interior of Cab heat deflectors missing or Inspect, repair or replace cowl baffle and
Cab (Continues). damaged. rear cab shield.
Heater valve remains open. Inspect, repair, adjust or replace heater

valve or cable.
See “HEATING/AIR CONDITIONING

COMPONENT LOCATION” on
page 270.
System refrigerant (R134A) charge low. Do R134A Air Conditioning System Test
Evaporator fins frosting or freezing. Freeze control switch capillary tube not
positioned correctly in evaporator coil.
Do A/C Freeze Control Test “A/C

FREEZE CONTROL SWITCH TEST”
on page 277.
Air Conditioner Runs Constantly, Too Temperature control switch. Inspect, replace temperature control
Cold. switch.
Heater valve. Valve is stuck closed,. Inspect.

Replace heater valve.
Freeze control switch, capillary tube not Reposition capillary tube in evaporator
positioned in evaporator properly. coil.
Compressor clutch engaged constantly. See “A/C FREEZE CONTROL SWITCH

Interior Windows Continue To Fog. Fresh air filter restricted. Clean or replace filter.
A/C system off. Move A/C - heater ON/OFF switch to

A/C position.
268 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
DIAGNOSE HEATER SYSTEM MALFUNCTIONS
Heater System Does Not Operate. A/C - heater blower fuse. Replace fuse.
Blower motor switch/blower motor fan Check switch.
switch (if required).
Wiring harness. Check side console harness and roof

harness wiring.
Heater Does Not Warm Interior of Cab. Engine coolant temperature cold. Engine must be at operating
temperature.
Fresh air filter restricted. Clean or replace filter.
Re circulating air filter restricted. Clean or replace filter.
Heater hose kinked, pinched or Re-route or re-index hoses. Replace

collapsed. collapsed hoses.
Heater coil fins clogged with dirt or dust. Clean heater fins.
A/C heater blower motor or heater Check motor. See H“HEATING/AIR

blower motor (if equipped) failed or CONDITIONING COMPONENT
operating too slowly. LOCATION” on page 270.
Heater valve does not open. Inspect, repair, adjust or replace heater
valve or cable.
Air Conditioner Runs Constantly, Too Temperature control switch. Inspect, replace temperature control
Cold. switch.
Heater valve. Valve is stuck closed,. Inspect.

Replace heater valve.
Freeze control switch, capillary tube not Reposition capillary tube in evaporator
positioned in evaporator properly. coil.
Compressor clutch engaged constantly. See “A/C FREEZE CONTROL SWITCH

Interior Windows Continue To Fog. Fresh air filter restricted. Clean or replace filter.
A/C system off (If Equipped). Move A/C - heater ON/OFF switch to A/
C position.
ISSUE 0 269
872106 CHAPTER 7 B25D & B30D 6X6
HEATING/AIR CONDITIONING COMPONENT LOCATION
11
10
7 9
5 8
3
2
AirGD0001CFM
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.
270 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
18
10
17
11
12
16
15
14
13
AirGD0002CFM
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.
ISSUE 0 271
872106 CHAPTER 7 B25D & B30D 6X6
272 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
SECTION 3. TESTS
AIR CONDITIONING OPERATIONAL

Is compressor belt pulley in good condition and in
CHECKS
line with engine pulley?
Visual Inspection of Components Are compressor mounting brackets in good
NOTE:Do visual inspection of component condition, and bracket mounting cap screws tight?
checks prior to diagnosis and
Are electrical connections to compressor clutch
component tests. These conditions
clean and tight? Is wiring to compressor in good
may affect diagnostic and test
condition?
results.
Yes: Check complete.
All Lines and Hoses
Inspect all lines and hoses. (See “HEATING/AIR No: Repair or replace components as required.
CONDITIONING COMPONENT LOCATION” on
page 270). Condenser Check
Inspect condenser core.
Are all lines and hoses straight, NOT kinked, worn
from rubbing on other machine parts or "weather Is condenser core free of dirt or debris?
checked"?
Does condenser show signs of leakage, dust
Are hose and line connections clean, NOT accumulation or oily areas?
showing signs of leakage, such as oil or dust
accumulation at fittings? Are condenser fins straight, not bent or damaged?
All hose and line clamps must be in place and Inspect condenser fan or fan blade.
tight. Clamps must have rubber inserts or
cushions in place to prevent clamps from crushing Are fan blades in good condition, not worn, bent,
or wearing into hoses or lines. broken or missing?
Yes: Check complete. Yes: Check complete.
No: Reposition hoses or lines and tighten or No: Clean, repair or replace condenser core.
replace clamps. Tighten fittings or replace O-rings Replace condenser fan or fan blade.
in fittings. Replace hoses or lines as required.
Heater/Evaporator Core Check
Air Conditioner Compressor Check Inspect core.
Inspect compressor.
Are fins straight?
Is compressor drive belt tight?
Is core free of dirt and debris?
Is belt in good condition, NOT frayed, worn or
Are evaporator drain tubes plugged?
glazed?
Is belt tensioner worn or damaged?
No: Repair, replace or clean heater/evaporator
core and drain tubes. (See Remove and Install
Heater Core and Evaporator Core CHAPTER
12, SECTION 3 in Repair Manual).
ISSUE 0 273
872106 CHAPTER 7 B25D & B30D 6X6
Freeze Control Switch Capillary Tube

Check
n WARNING
Use correct refrigerant recovery, recycling
Inspect freeze control switch capillary tube. and charging stations. Never use refriger-
ant, hoses, fittings, components or refriger-
Is capillary tube straight, NOT kinked or broken?
ant oils intended for R12 refrigerant
Is capillary tube properly positioned and inserted systems. Identify refrigerant before recover-
securely in place in evaporator core? ing, recycling and charging system.

Stop the engine.
No: If capillary tube is kinked, replace freeze
control switch. Follow refrigerant cautions and proper handling
procedures. (See Refrigerant Cautions and
No: If capillary tube is positioned in evaporator Proper Handling in CHAPTER 12, SECTION 3 in
incorrectly, See “A/C FREEZE CONTROL the Repair Manual.)
SWITCH TEST” on page 277.
Identify refrigerant type using JT02167A
Cab Door and Window Seals Check refrigerant identification instrument.
Open and close door and windows. Inspect seals. Connect refrigerant recovery, recycling and
charging station. (See R134a Refrigerant
Do door and windows contact seals evenly?
Recovery/Recycling and Charging Station
Are seals in position and in good condition? Installation Procedure in CHAPTER 12,
SECTION 12 in the Repair Manual.)
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.
Start engine and run at rated engine high idle
speed.
No: Clean or replace filters.
Move A/C-heater switch to A/C position.
R134A AIR CONDITIONING SYSTEM
TEST Turn temperature control switch to maximum
cooling position.
Specifications
Turn blower switch to high speed.
R134a Air Conditioner System Test
Engine Speed High Idle Check sight glass (if equipped) in receiver-dryer.
Low Side Refrigerant - Pressure
- - - - - - - - - - - - - 80 kPa (0.8 bar) (11.6 psi) minimum Run unit for at least 5 minutes.
- - - - - - - - - - - - - - -200 kPa (2 bar) (29 psi) maximum Measure and record air temperature at condenser
High Side Refrigerant - Pressure air inlet and at air ducts in air conditioning unit.
- - - - - - - - - - - - - - 800 kPa (8 bar) (116 psi) minimum
- - - - - - - - - - 2 100 kPa (21 bar) (304.5 psi) maximum Observe low-side pressure and high-side
pressure on gauges.
JT02167A Prism Pro Refrigerant Identification
Instrument
Thermometer
274 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
Compare pressures and air duct temperature to Diagnose malfunction using Operating Pressure
specifications. Diagnostic Chart.
NOTE:Because low pressure switch is OPERATING PRESSURE DIAGNOSTIC

located on high pressure side of CHART
expansion valve, the low pressure
gauge reading shown does not affect Do the following procedures in 1830 to service
the low pressure switch operating A/C system:
range.
• Recover R134a Refrigerant (CHAPTER 12,
• Air conditioner set at maximum cooling. SECTION 3 in the Repair Manual.).
• Air conditioner compressor clutch engaged. • Evacuate R134a System (CHAPTER 12,
• Operate at maximum setting for minimum of SECTION 3 in the Repair Manual.).
12 minutes. • Charge R134a System (CHAPTER 12,
• Air duct temperature should be below 12° C SECTION 3 in the Repair Manual.).
(53.5° F) with ambient temperature at 26° C
(79° F) and 60% relative humidity. Refrigerant
pressure within specification.
ISSUE 0 275
872106 CHAPTER 7 B25D & B30D 6X6
Low Side High Side Discharge

Sight Suction Receiver- Liquid Discharge
Condition kPa (bar) kPa (bar) Air
Glass Line Drier Line Line
(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 Slightly
Restriction Sweating Sweating Point 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

Contaminat Occasional Hot
ed and Air Bubbles
in 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 (No Drop) Bubbles HOt Cool
and Air in
System
276 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
A/C FREEZE CONTROL SWITCH TEST A/C COMPRESSOR CLUTCH TEST

Specifications Disconnect harness from clutch.
Freeze Control Switch Opens (Normally Closed) -
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.
Connect battery voltage to connector terminal for

orange wire. Ground terminal for black wire.
Does clutch "click"?
Yes: Clutch coil is good. Check wiring harness.
No: Replace clutch coil.
A/C HIGH/LOW PRESSURE SWITCH

With freeze control switch at room temperature, TEST
connect terminals to ohmmeter and measure
continuity between terminals. Specifications
A/C Low Pressure Switch (Normally Open) - Closes on
Is continuity measured? Increasing Pressure
- - - - - - - 207 ± 30 kPa (2.1 ± 0.3 bar) (30.5 ± 4.4 psi)
Yes: Switch is good. Check wiring harness.
A/C Low Pressure Switch (Normally Open) - Opens on
Decreasing Pressure
No: Replace freeze control switch. - - - - - - - - - 200 ± 20 kPa (2.0 ± 0.2 bar) (29 ± 2.9 psi)
Put freeze control switch in freezer. Temperature A/C High Pressure Switch (Normally Closed)—Opens
on Increasing Pressure
must be below 1° - 3° C (34°—37.5° F). Switch
- - - - - - - 2700 ± 200 kPa (27 ± 2 bar) (391.6 ± 29 psi)
must be open and continuity must not be read.
A/C High Pressure Switch (Normally Closed)—Closes
Remove switch from freezer and put sensing tube on Decreasing Pressure
- - - - - - - 2100 ± 200 kPa (21 ± 2 bar) (304.6 ± 29 psi)
into a glass of warm water. As switch warms it
must close and continuity must be read. Service Equipment And Tools
Hydraulic Hand Pump
Volt-Ohm-Amp Meter
Volt-Ohm-Amp Meter
Air Conditioning Gauge Set
ISSUE 0 277
872106 CHAPTER 7 B25D & B30D 6X6
NOTE:The line that attaches A/C high/low Connect an air conditioning gauge set to service
pressure switch has a valve under it fittings at compressor. Cover condenser with
to prevent discharging air paper or plastic to stop air flow.
conditioning system when switch is
removed. Operate air conditioner on maximum cooling. Note
high-side pressure when A/C high pressure switch
opens and then closes.
A/C EXPANSION VALVE TEST
Specifications
Engine Speed - - - - - - - - - - - - - - - - - - - - - - - High Idle
Blower Speed - - - - - - - - - - - - - - - - - - - - - - - - - High
2 Temperature Control Switch Position
- - - - - - - - - - - - - - - - - - - - - - - - - - Maximum Cooling
1
Essential Tools
Refrigerant Recovery, Recycling and Charging System

Thermometer
n WARNING
Use correct refrigerant recovery/recycling
Remove A/C high/low pressure switch (1).
and charging stations. DO NOT mix refriger-
Connect a portable pressure source, such as a ant, hoses, fittings, components or refriger-
regulated air supply or a hydraulic hand pump, to ant oils.
A/C high/low pressure switch.
Switch must not have continuity between Follow Refrigerant Cautions and Proper Handling
terminals until pressure increases to low pressure procedures CHAPTER 12, SECTION 3 in the
switch specification. Repair Manual.
Slowly release pressure. Switch must have Connect refrigerant recovery, recycling and
continuity until pressure decreases to switch charging system. (See R134a Refrigerant
opening pressure specification. Recovery/Recycling and Charging Station
Installation Procedure CHAPTER 12, SECTION
Switch must have continuity between terminals 3 in the Repair Manual).
until pressure increases to high pressure opening
specification. Recover R134a Refrigerant (CHAPTER 12,
SECTION 3 in the Repair Manual).
Slowly release pressure. Switch must not have
continuity until pressure decreases to switch Remove insulating tape from expansion valve
closing pressure specification. sensing bulb.
NOTE:The switch can also be checked

when installed in air conditioning
system; however, pressure is slow to
increase to test specification.
278 ISSUE 0
ISSUE
B25D & B30D 6X6 CHAPTER 7 872106
Follow Refrigerant Cautions and Proper Handling

procedures (CHAPTER 12, SECTION 3 in the
Repair Manual).
1
Remove expansion valve. See Remove and Install
Expansion Valve (CHAPTER 12, SECTION 3 in
the Repair Manual).
Remove sensing bulb (1).
Start engine and run at high idle.
Turn blower motor switch on high. Turn

temperature control switch to maximum cooling. A
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, B
do Expansion Valve Bench Test. C
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 A/C expansion valve to air conditioning
gauge set using fittings (A - C).
Specifications
High-Side Valve Pressure Setting Pressure
Connect yellow hose to a regulated air supply.
- - - - - - - - - - - - - - - - - - - - - 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
Expansion Valve—Closes on Decreasing Pressure bar) (75 psi) using a pressure regulator or by
- - - - - - - - - - 140 - 170 kPa (1.4 - 1.7 bar) (20 - 25 psi) adjusting high-side valve.
Essential Tools Hold sensing bulb in hand until pressure on low-
JT05419 Air Conditioning Service Fitting Kit side gauge stops increasing. Pressure must be
280 - 380 kPa (2.8 - 3.8 bar) (40 - 55 psi).
Put sensing bulb in a container of ice water until
Air Conditioning Gauge Set pressure on low-side gauge stops decreasing.
Pressure must be 140 - 170 kPa (1.4 - 1.7 bar) (20

- 25 psi).
ISSUE 0 279
872106 CHAPTER 7 B25D & B30D 6X6
REFRIGERANT LEAK TEST
Specifications
Leak Detector Probe Movement Speed
- - - - - - - - - - - - - - - - - - - - - 25 mm (1 in.) per second
Inspect all lines, fittings, and components for oily

or dusty spots. When refrigerant leaks from
system, a small amount of oil is carried out with it.
A soap and water solution can be sprayed on the

components in system to form bubbles at source
of leak.
If a leak detector is used, move leak detector

probe under hoses and around connections at a
rate of 25 mm (1 in.) per second.
NOTE:Some refrigerant manufacturers add

dye to refrigerant to aid in leak
detection.
280 ISSUE 0
INDEX
A
ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
AIR CONDITIONING SYSTEM CYCLE OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - 265
B
Backup Alarm and Backup Light Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
Battery Balancer And 12-Volt Accessory Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
Bin Control, Fan Drive and Range Hold Circuit Theory - - - - - - - - - - - - - - - - - - - - - - - - - - - 79
Bin and Fan Drive Control Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79
Bin Down Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
Bin Up Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79
Float Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
Range Hold Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
Bin Position Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 129

BULLETINS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a
C
Charging Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Chassis Control Unit Circuit Theory - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
D
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - 194
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS - - - - - - - - - - - - - - - - - - - - - - - - 160
E
ELECTRICAL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Cold Start Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
DIAGNOSTICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Electrical Schematic Symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Electronic Unit Injector Controller Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
Engine Control Unit Circuit Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
Key Switch Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Service Code Diagnostics -Transmission Control Unit (TCU) - - - - - - - - - - - - - - - - - - - - - - - - - - 101
Starting Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
SYSTEM INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
a
INDEX
Cold Start Option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

DIAGNOSE ENGINE MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Electronic Unit Injector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
EXHAUST BRAKE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
SLOW AND FAST IDLE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
COMPRESSION TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
FUEL PUMP PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
OIL PUMP PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
THEORY OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
VALVE CLEARANCE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Exhaust Brake and Exhaust Valve Brake Circuit. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 191
F
Front Suspension Strut Leakage Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175
H
HEATING AND AIR CONDITIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 265
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - 267
DIAGNOSE HEATER SYSTEM MALFUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 269
HEATER CORE OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 266
HEATIN/AIR CONDITIONING COMPONENT LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 270
TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273
A/C COMPRESSOR CLUTCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
A/C EXPANSION VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 278
A/C FREEZE CONTROL SWITCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
A/C HIGH/LOW PRESSURE SWITCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 277
AIR CONDITIONING OPERATIONAL CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273
EXPANSION VALVE BENCH TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 279
OPERATING PRESSURE DIAGNOSTIC CHART - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 275
R134A AIR CONDITIONING SYSTEM TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 274
REFRIGERANT LEAK TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 280
THEORY OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 265
HEATING/AIR CONDITIONING COMPONENT LOCATION - - - - - - - - - - - - - - - - - - - - - 270

HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY - - 252
Hydraulic Pressure Switches Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127
HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201
Bin Control Valve Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230
COMPONENT LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246
CYCLE TIME TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 254
b
INDEX

FRONT AND REAR BRAKE ACCUMULATORS CHARGE PROCEDURE - - - - - - - - - - - - - - - - 260
Main Hydraulic Pump Load Sense Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 206
Main Hydraulic Pump Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 204
Malfunctions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238
Manifold Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222
OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201
Secondary Steering Pump Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220
Steering And Secondary Steering System Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214
Steering Valve Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 218
TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT - - - - - - - - - 257
BIN LOWER CIRCUIT RELIEF VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 264
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT - - - - - - - - - - - - - - - 258
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST - - - - - - - - - - - - - 259
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST - - - - - - - - - - - - - - - - - - 260
PRIORITY VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 257
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND AD-
JUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 262
SERVICE BRAKE VALVE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 260
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT - - - - - - - - - - - - - - - - - 261
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST - - - - - - - - - - - - 256
Hydraulic System Manifold Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222

HYDRAULIC SYSTEM WARM-UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 253
I
Install WEATHER PACK™ Contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
Inter-Axle Lock Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
J
JT02156A DIGITAL PRESSURE/TEMPERATURE ANALYZER INSTALLATION - - - 252
JT05800 DIGITAL THERMOMETER INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - 252
M
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND AD-
JUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 255
Manifold Air Temperature (MAP) Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
Menu Display Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83
Engine Coolant Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
Engine Oil Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
Gauges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
c
INDEX
Transmission Oil Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
O
OPERATIONAL CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
ENGINE ON - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
KEY SWITCH ON, ENGINE OFF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
OPERATIONALCHECK-OUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
P
Park Brake Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
Park Brake and Exhaust Brake Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
Park Brake Pad Thickness Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
Park brake Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175
PNEUMATIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179
Air Dryer and Unloader Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 183
Air Pressure Supply Circuit Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 182
Component Location Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 196
DIAGNOSTIC PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 193
Pneumatic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 190
TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 199
MAIN PRESSURE TEST AND ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 199
PARK BRAKE PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
THEORY OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179
PNEUMATIC SYSTEM OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179

PNEUMATIC SYSTEM SCHEMATIC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 180
POWER TRAIN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
DIAGNOSTIC PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
TRANSMISSION EXTERNAL COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
Power Train Component Location Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 169

Pressure Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
R
Relay Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Relays/Voltage Regulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
Remove Connector Body from Blade Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145
Remove, Install, and Calibrate Accelerator Pedal Position Sensor - - - - - - - - - - - - - - - - 140
Replace (Pull Type) Metri-Pack™ Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 144
d
INDEX
Replace (Push Type) Metri-Pack™ Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145

Replace DEUTSCH‰ Rectangular or Triangular Connectors - - - - - - - - - - - - - - - - - - - - 140
Replace WEATHER PACK™ Connector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
Retarder Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75
S
SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Material Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Protective Clothing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -VI
Unauthorised Modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Engine Coolant Level Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Fuel Level Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Hydraulic Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79
System Air Pressure Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Service Code Diagnostics -Engine Control Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94

SLOW AND FAST IDLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Steering Column Switch Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 130
Stop Light Circuit Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
System Air Pressure Sensor (B15) Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127
T
TACHOMETER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
Torque Convertor Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151
TRANSMISSION
TESTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
Torque Converter Stall Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 173
Torque Converter Stator Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 174
Transmission Oil Cooler Restriction Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 174
Transmission Pressure Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
Transmission Clutch Engagement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152

TRANSMISSION CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148
Transmission Control Unit and Retarder Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
Transmission Cross Sectional Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 150
e
INDEX
Transmission Oil Cooler Restriction Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 174

TRANSMISSION WARM-UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
Turn Signal and 4- Way Flasher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
Turn Signal And 4-Way Flasher Circuit
Four-Way Flasher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
Turn Signal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
Tyre Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
W
Wiper/Washer Circuit Theory - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
Intermittent Wiper Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
Low and High Speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
Washer Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
Wiper Park Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
WIRE MARKINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

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Otm B25D B30D

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B25D & B30D 6 X 6

ARTICULATED DUMP TRUCK

OPERATION AND TEST MANUAL

WARNING AND CAUTION SYMBOL

n CALIFORNIA PROPOSITION 65 WARNING

THIS MANUAL IS APPLICABLE TO

B25D 6X6 (E410814)

Document Part Number 872106

1. ROPS/FOPS Cab Protection. The Roll Over 7. Articulation locking Bar.

Material Safety Data Sheets (MSDS)

Unauthorised Modifications of the Roll Over Protective Structure

Noise Emission Levels

Mounting and Dismounting the Machine

Avoid Work Site Hazards Prepare for Emergencies

Keep a first aid kit and fire extinguishers handy

Avoid Backing Over Accidents

Avoid Overhead Power Lines

Operate Only On Solid Footing

Use prearranged hand signals to communicate.

Handle Chemical Products And Flam-

If uncertain about safe handling or use of these

Prevent Battery Explosions and Acid

GD0018CFM The standard battery supplied with the machine is

If you spill acid on yourself: Avoid High Pressure Fluids

Stay Clear Of Moving Parts

Stop engine before examining, adjusting or

Keep guards and shields in place. Replace any

When you drive connecting pins in or out, guard

Use the Seat Belt GD0020CFM

Air conditioning refrigerants can damage the Operating on Slopes

If uncertain about the safe disposal of waste,

Start Only From Operator’s Seat

Avoid side slope travel whenever possible.

Check service brakes frequently when operating

The maximum slope will be limited by the ground

Avoid unexpected machine movement. Start

Never attempt to start engine from the ground. Do

Lower bin during work interruptions, apply park

Use a safety cage if available

NOTE:It is recommended that only trained

Inspect and Maintain ROPS Drive Metal Pins

To Maintain the ROPS:

Abbreviation Meaning Abbreviation Meaning

ºC degrees Celsius m metre

ADT Articulated Dump Truck m.p.h. miles per hour

Ah ampere hours MSDS Material Safety Data Sheet

CB circuit breaker Nm Newton metre

d diagnostic psi pounds per square inch

D drive PTO Power Take-Off

DNS Do Not Shift R Reverse

ECU Electronic Control Unit r.p.m. revolutions per minute

FOPS Falling Objects Protective ROPS Roll Over Protective

ft foot (feet) SMR Service Meter Reading

ft lb foot pound USGAL United States Gallon

ISO International Standards cubic yard

km/h kilometres per hour

kPa kilo pascal

LCD Liquid Crystal Display

LED Light Emitting Diode

LEFT BLANK INTENSIONALLY

TECHNICAL DOCUMENTATION BULLETIN RECORD

TECHNICAL DOCUMENTATION BULLETIN RECORD

USER’S INFORMATINON FEEDBACK FORM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i