No Response when the

Automatic-gear Wide-body
Truck Puts into Gear
Department: Heavy Equipment BU

Prepared by: Reviewed by: Approved by:

 2

Table of contents

Trouble Phenomenon

How to Troubleshoot

Troubleshooting Preparations

Troubleshooting Process

Troubleshooting Conclusions
 3

I. Trouble Phenomenon:

Model: SKT090S Wide-body Truck

Trouble Descriptions: The truck cannot put into gear, Gear-1, Gear-2, Gear-3
and Gear-4 all have no response and the there is no trouble code when starting
 Gear C1 C2 C3 C4 C5 4

II. Troubleshooting Ideas: N ●

There are 4 reasons why the truck cannot put R ● ●
into gear: 1 ● ●
(1) C1 battery valve is damaged;
2 ● ●
(2) The gearbox controller or harness is damaged;
(3) The main pressure is insufficient; 3 ● ●
(4) The gearbox is damaged inside. 4 ● ●
5 ● ●
6 ● ●

Whether C1 Yes Inspect whether Yes Inspection or

1 battery valve is 2 the gearbox 3 main pressure
normal controller or C1 pressure
harness is normal inspection

No No No
N
o
Replace C1 Replace the The gearbox is
battery valve gearbox controller damaged inside
or harness
 5

III. Troubleshooting Preparations:

List of tools to be used are as follows:

Universal Metric Slotted blade FGST

meter spanner screwdriver, cross- diagnostic tool
head screwdriver
 6

III. Troubleshooting Preparations:

Locations of Parts: C1 battery valve

C1 battery
valve
 7

III. Troubleshooting Preparations:

Locations of Parts: Controller and harness
Gearbox
controller

Gearbox
harness
 8
。 Video 1: Operations of replacing ECPC valve
IV. Troubleshooting Process: olenoid valve)
Step 1 Inspect the C1 battery valve: Replace spare parts if
available; if no, exchange them with other battery valves
(solenoid valves such as C2)
Method of replacing the solenoid valve:
1) Remove the harness connector of ECPC valve, separately
disassemble two letter bolts of ECPC valve, put the new seal
ring into the seal groove of the new ECPC valve, install the
new ECPC valve, and tighten it with a torque spanner. The
tightening torque is 30±4N.M;
2) Connect the harness connector of ECPC valve. Pay attention to the installation
of the seal ring
Notes:
(1) Before disassembly, please wipe the dusts or dirt
around the solenoid valve with a clean paper towel or
cloth;
(2) The installation port of ECPC valve on the gearbox
shall be kept clean;
(3) The chamber of the new ECPC valve should be kept
clean;
(4) The seal ring and the installation groove of seal ring
shall be kept clean
(5) The engine cannot start when replacing ECPC valve Note that the torque is 30±4N.M
 9
Video 2: Operations of replacing the controller
Video 3: Operations of replacing the controller harn
IV. Troubleshooting Process: ess
Step 2 Inspect the controller and harness
Notice to replace the shock pad when Note that the earth point must be
Do it with FGST installing the new controller connected firmly
1. Diagnose if there is any trouble
problem;
2. Inspect the trouble code of the
diagnosis;
3. Inspect the activated trouble code and
historical trouble codes;
4. Inspect the status of each configuration
parameter;
5. Clear the activated trouble codes and
historical trouble codes;
6. Write programs and make the Note that the gearbox must be
debugging; connected solidly at the earth
7. Output state report. point

Notices: If the controller requires to be

replaced, the truck configuration
parameters must be guaranteed identical
Controller without written software requires
an installation program.
If any abnormal code is discovered during
inspection, the controller needs to be
 Video 4: Operations of measuring the 10
pressure of the gearbox
IV. Troubleshooting Process:
Pressure measuring port of solenoid
Step 3 Measure the main pressure and C1 pressure
valve of gearbox
C1 pressure 325PSI (2240KPa), and main pressure (350PSI)
2400KPa:

The truck was parked horizontally on the trench and the engine is
turned off
Unscrew the plug of the pressure measuring port required to be
tested. The unscrew speed should be slow. Note that there will be oil
outflow, and do well in protection
Connect the pressure measuring port of the oil pressure gauge with
the pressure measuring port of solenoid valve;
Start the engine, observe the reading of the oil pressure gauge, turn
off the engine and unplug the connector of the oil pressure gauge
(note: unplugging the connector of the oil pressure gauge when the
engine is on fire is strictly prohibited).
When measuring the oil pressure of clutches C& C5, inlet oil pressure
of torque converter (TC IN), outlet oil pressure of torque converter (TC
OUT) and main oil pressure (MAIN), start the engine, step on the
brake, put the gearbox into forward gear D, push the pedal down, and
then observe the value of the oil pressure gauge; note that there must
be no obstacles in front of the truck to avoid any danger when the C1 pressure 325PSI (2240KPa) and
truck rushes out. main pressure (350PSI) 2400KPa
 11

IV. Troubleshooting Process:

Step 4 Hoist the gearbox
Please refer to the Guide Book of FC6A210-250 Gearbox Hoisting for the hoisting of the gearbox.
Note: Make use of the threaded mounting holes of the gearbox to install 2 or more hooks, and use a crane or
manual hoist to hoist the gearbox.

Hoisting threaded hole M16 of

gearbox
 12

V. Troubleshooting Conclusions:

1. The wide-body truck must be used in accordance with operation

specifications.
2. Avoid overloading or overspeed to avoid many gearbox troubles.
3. Inspect the oil level of the gearbox before each shift of operation.
4. Timely gearbox maintenance can effectively reduce the possibility
of troubles.
 13

V. Troubleshooting Conclusions:
 14

V. Troubleshooting Conclusions:
Working principles of FC6A210/250
Input speed Output speed
tc Clutch 1# Clutch 2# Clutch 3# Clutch 4# Clutch 5#

Controller

Torque t
5
converter c 1 2 3 4

Oil pump