TM 10-3920-675-23-1 RTCH RT 240

ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 VOLUME 1
TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR
ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4 NSN 3930-01-473-3998 NSN 3930-01-522-7364
*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS 01 OCTOBER 2012 PCN 184 110783 00
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TM 10-3930-675-23-1
WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.
EXPLANATION OF SAFETY WARNING ICONS
ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present. May result in death or injury to personnel.
FLYING PARTICLES - Arrows bouncing off face with face shield shows that particles flying through the air will harm face. May result in death or injury to personnel.
HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb. May result in death or injury to personnel.
HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm. May result in death or injury to personnel.
HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique. May result in death or injury to personnel.
HOT AREA - Hand over object radiating heat shows that part is hot and can burn. May result in death or injury to personnel.
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WARNING SUMMARY - Continued

GENERAL SAFETY WARNING DESCRIPTIONS
WARNING
COMPRESSED AIR Compressed air used for cleaning or drying purposes, or for cleaning restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel.
WARNING
ELECTRICAL SYSTEM MAINTENANCE Remove all jewelry, watches, rings, etc. prior to disconnecting cables from batteries or other electrical source. Items can come in contact with battery or electrical source and cause electrical shock. Failure to follow this warning may result in injury or death to personnel.
WARNING
HYDRAULIC SYSTEM DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
WARNING
IR LIGHTS DO NOT look directly at IR source without eye protection and maintain a minimum of 12 inches from energized IR lights to prevent possible eye discomfort or damage.
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GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
LIFTING HEAVY COMPONENTS Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to perform maintenance. DO NOT get under vehicle after it is raised unless it is properly supported with blocks or other suitable cribbing. Failure to observe this warning may result in death or injury to personnel. Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel. Improper use of lifting equipment and improper attachment of cables to vehicle can result in serious personnel injury and equipment damage. Observe all standard rules of safety.
WARNING
SLAVE STARTING When slave starting RTCH, use NATO slave cable that DOES NOT have loose or missing insulation. DO NOT proceed if suitable cable is not available. DO NOT use civilian-type jumper cables.
TM 10-3930-675-23-1
EXPLANATION OF HAZARDOUS MATERIALS ICONS
BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.
CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.
EYE PROTECTION - Person with goggles shows that the material will injure the eyes.
FIRE - Flame shows that a material may ignite and cause burns.
HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human figure shows that fluid escaping under great pressure can cause injury or death.
RADIOACTIVE - Identifies a material that emits radioactive energy and can injure human tissue or organs.
VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.
TM 10-3930-675-23-1

HAZARDOUS MATERIALS DESCRIPTIONS
WARNING
BATTERY Remove all jewelry, such as rings, I.D. tags, rings, bracelets, etc. If jewelry contacts a battery terminal, a direct short will result causing instant heating of jewelry. Failure to follow this warning may result in serious injury or death to personnel. Seek medical attention in the event of an injury. Battery acid (electrolyte) is extremely dangerous. Always wear eye protection and rubber gloves when performing battery checks or inspections. Serious injury to personnel will result if battery acid contacts skin or eyes. Failure to follow this warning may result in injury or death to personnel. Seek medical attention in the event of an injury. DO NOT perform battery system checks or inspections while smoking or near fire, flames, or sparks. Battery gases may explode. Failure to follow this warning may cause serious injury or death to personnel. Seek medical attention in the event of an injury. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow this warning may cause injury to personnel. Seek medical attention in the event of an injury. a. Eyes. Flush with cold water for no less than 15 minutes and immediately seek medical attention. b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Immediately seek medical attention. d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia. California Proposition 65 Warning. Battery posts, terminals, and related accessories contain lead and lead components. These chemicals are known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Failure to follow this warning may result in injury or death to personnel. Seek medical attention in the event of an injury.
TM 10-3930-675-23-1

HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL! Carbon monoxide is a colorless, odorless, deadly poisonous gas which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death may result from severe exposure. Seek medical attention in the event of an injury. Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of RTCH is operated for any purpose. 1. DO NOT operate RTCH engine in enclosed areas. Good ventilation is essential. 2. BE ALERT at all times for exhaust odors. 3. BE ALERT for exhaust poisoning symptoms. They are: Headache Dizziness Drowsiness
Loss of muscular control 4. If you see another person with exhaust poisoning symptoms: Remove person from area. Expose person to fresh air. Keep person warm. DO NOT permit physical exercise. Administer cardiovascular pulmonary resuscitation (CPR), if necessary.
Notify a medic. 5. BE AWARE: The field protective mask for chemical-biological-radiological-nuclear (CBRN) protection will not protect you from carbon monoxide poisoning. 6. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation. 7. Failure to follow this warning may result in injury or death to personnel. 8. Seek medical attention in the event of an injury.
TM 10-3930-675-23-1

WARNING
CBRN EXPOSURE If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may cause injury or death to personnel. Seek medical attention in the event of an injury.
To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083
WARNING
CLEANING AGENTS Improper cleaning methods and use of unauthorized cleaning agents can injure personnel and damage equipment. To prevent this, refer to TM 9-247 for further instructions.
TM 10-3930-675-23-1

WARNING
DIESEL FUEL HANDLING DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. Wear fuel-resistant gloves when handling fuels and promptly wash exposed skin and change fuel-soaked clothing.
WARNING
CLEANING COMPOUND, SOLVENT Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately.
WARNING
ETHER COLD START Ether is extremely flammable and explosive. DO NOT perform ether cold start system checks, inspections or maintenance while smoking or near fire, flames or sparks. Failure to follow this warning may cause a fire and explosion, causing serious injury or death to personnel. Avoid breathing cold start system fluid vapors. Wear goggles and fuel-resistant gloves when handling fluid. Failure to follow this warning may result in serious injury or death to personnel.
TM 10-3930-675-23-1

WARNING
FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher in cab may result in temporary breathing difficulty during and immediately after the discharge event. If at all possible, discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry.
WARNING
HAZARDOUS WASTE DISPOSAL When servicing this vehicle, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-327-3845. Failure to follow this warning may result in death or injury to personnel.
WARNING
PRESSURIZED COOLING SYSTEM DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to follow this warning may cause serious burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to follow this warning may result in injury.
TM 10-3930-675-23-1

WARNING
R-134A REFRIGERANT Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Take care to prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if you come in contact with liquid refrigerant. Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with compressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, which could cause personnel injury.
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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. Zero in the "Change No." column indicates an original page or work package. This manual has two volumes. Date of issue for the original manual is: Original 01 OCTOBER 2012
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 112 AND TOTAL NUMBER OF WORK PACKAGES IS 134 CONSISTING OF THE FOLLOWING: Page/WP No. VOLUME 1 Front Cover Promulgation Letter (2 pages) Warning Summary (10 pages) Title Block Page (2 pages) Table Of Contents (66 pages) How to Use This Manual (4 pages) Chapter 1 Title Page WP 0001 (4 pages) WP 0002 (8 pages) WP 0003 (4 pages) Chapter 2 Title Page WP 0004 (44 pages) WP 0005 (18 pages) WP 0006 (100 pages) WP 0007 (56 pages) WP 0008 (18 pages) WP 0009 (6 pages) WP 0010 (14 pages) WP 0011 (4 pages) WP 0012 (10 pages) WP 0013 (12 pages) WP 0014 (8 pages) WP 0015 (8 pages) WP 0016 (22 pages) WP 0017 (16 pages) WP 0018 (8 pages) WP 0019 (14 pages) WP 0020 (26 pages) WP 0021 (12 pages) WP 0022 (14 pages) WP 0023 (14 pages) WP 0024 (8 pages) WP 0025 (6 pages) WP 0026 (10 pages) WP 0027 (16 pages) WP 0028 (10 pages) WP 0029 (6 pages) WP 0030 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0031 (6 pages) WP 0032 (16 pages) WP 0033 (6 pages) WP 0034 (16 pages) WP 0035 (2 pages) WP 0036 (4 pages) WP 0037 (4 pages) WP 0038 (10 pages) WP 0039 (10 pages) WP 0040 (10 pages) WP 0041 (8 pages) WP 0042 (10 pages) WP 0043 (10 pages) WP 0044 (6 pages) WP 0045 (8 pages) WP 0046 (10 pages) Chapter 3 Title Page WP 0047 (2 pages) WP 0048 (8 pages) Chapter 4 Title Page WP 0049 (2 pages) WP 0050 (20 pages) WP 0051 (8 pages) WP 0052 (18 pages) WP 0053 (6 pages) WP 0054 (10 pages) WP 0055 (10 pages) WP 0056 (24 pages) WP 0057 (4 pages) WP 0058 (4 pages) WP 0059 (4 pages) WP 0060 (14 pages) WP 0061 (6 pages) WP 0062 (6 pages) WP 0063 (6 pages) WP 0064 (4 pages) WP 0065 (8 pages) WP 0066 (8 pages) WP 0067 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

Page/WP No. WP 0068 (4 pages) WP 0069 (6 pages) WP 0070 (4 pages) WP 0071 (6 pages) WP 0072 (8 pages) WP 0073 (8 pages) WP 0074 (4 pages) WP 0075 (4 pages) WP 0076 (4 pages) WP 0077 (10 pages) WP 0078 (10 pages) WP 0079 (6 pages) WP 0080 (4 pages) WP 0081 (8 pages) WP 0082 (8 pages) WP 0083 (12 pages) WP 0084 (2 pages) WP 0085 (2 pages) WP 0086 (2 pages) WP 0087 (4 pages) WP 0088 (6 pages) WP 0089 (6 pages) WP 0090 (8 pages) WP 0091 (4 pages) WP 0092 (4 pages) WP 0093 (6 pages) WP 0094 (14 pages) WP 0095 (8 pages) WP 0096 (4 pages) WP 0097 (14 pages) WP 0098 (4 pages) WP 0099 (4 pages) WP 0100 (8 pages) WP 0101 (2 pages) WP 0102 (10 pages) WP 0103 (16 pages) WP 0104 (16 pages) WP 0105 (8 pages) WP 0106 (4 pages) WP 0107 (4 pages) WP 0108 (24 pages) WP 0109 (6 pages) WP 0110 (6 pages) WP 0111 (6 pages) WP 0112 (8 pages) WP 0113 (8 pages) WP 0114 (4 pages) WP 0115 (4 pages) WP 0116 (2 pages) WP 0117 (2 pages) WP 0118 (12 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0119 (4 pages) WP 0120 (6 pages) WP 0121 (6 pages) WP 0122 (4 pages) WP 0123 (10 pages) WP 0124 (4 pages) WP 0125 (8 pages) WP 0126 (4 pages) WP 0127 (4 pages) WP 0128 (4 pages) WP 0129 (6 pages) WP 0130 (4 pages) WP 0131 (4 pages) WP 0132 (4 pages) WP 0133 (2 pages) WP 0134 (6 pages) Index (4 pages) Back Cover VOLUME 2 WP Front Cover (6 pages) Warning Summary (10 pages) Title Block Page (2 pages) Table Of Contents (4 pages) How To Use This Manual (4 pages) Chapter 5 Title Page WP 0135 (20 pages) WP 0136 (6 pages) WP 0137 (4 pages) WP 0138 (4 pages) WP 0139 (4 pages) WP 0140 (10 pages) WP 0141 (8 pages) WP 0142 (6 pages) WP 0143 (8 pages) WP 0144 (4 pages) WP 0145 (8 pages) WP 0146 (8 pages) WP 0147 (6 pages) WP 0148 (4 pages) WP 0149 (10 pages) WP 0150 (4 pages) WP 0151 (4 pages) WP 0152 (2 pages) WP 0153 (4 pages) WP 0154 (4 pages) WP 0155 (16 pages) WP 0156 (4 pages) WP 0157 (4 pages) WP 0158 (6 pages) WP 0159 (4 pages) WP 0160 (8 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Page/WP No. WP 0161 (4 pages) WP 0162 (6 pages) WP 0163 (8 pages) WP 0164 (4 pages) WP 0165 (4 pages) WP 0166 (10 pages) WP 0167 (4 pages) WP 0168 (6 pages) WP 0169 (4 pages) WP 0170 (2 pages) WP 0171 (4 pages) WP 0172 (4 pages) WP 0173 (6 pages) WP 0174 (4 pages) WP 0175 (6 pages) WP 0176 (12 pages) WP 0177 (10 pages) WP 0178 (2 pages) WP 0179 (24 pages) WP 0180 (4 pages) WP 0181 (4 pages) WP 0182 (4 pages) WP 0183 (4 pages) WP 0184 (4 pages) WP 0185 (4 pages) WP 0186 (8 pages) WP 0187 (6 pages) WP 0188 (4 pages) WP 0189 (2 pages) WP 0190 (10 pages) WP 0191 (8 pages) WP 0192 (2 pages) WP 0193 (4 pages) WP 0194 (14 pages) WP 0195 (6 pages) WP 0196 (16 pages) WP 0197 (6 pages) WP 0198 (4 pages) WP 0199 (8 pages) WP 0200 (4 pages) WP 0201 (4 pages) WP 0202 (2 pages) WP 0203 (2 pages) WP 0204 (4 pages) WP 0205 (6 pages) WP 0206 (6 pages) WP 0207 (4 pages) WP 0208 (2 pages) WP 0209 (8 pages) WP 0210 (10 pages) WP 0211 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0212 (20 pages) WP 0213 (8 pages) WP 0214 (8 pages) WP 0215 (4 pages) WP 0216 (4 pages) WP 0217 (6 pages) WP 0218 (10 pages) WP 0219 (2 pages) WP 0220 (2 pages) WP 0221 (2 pages) WP 0222 (2 pages) WP 0223 (2 pages) WP 0224 (2 pages) WP 0225 (2 pages) WP 0226 (2 pages) WP 0227 (6 pages) WP 0228 (44 pages) WP 0229 (4 pages) WP 0230 (4 pages) WP 0231 (8 pages) WP 0232 (4 pages) WP 0233 (4 pages) WP 0234 (6 pages) WP 0235 (8 pages) WP 0236 (8 pages) WP 0237 (4 pages) WP 0238 (4 pages) WP 0239 (4 pages) WP 0240 (4 pages) WP 0241 (4 pages) WP 0242 (4 pages) WP 0243 (14 pages) WP 0244 (2 pages) WP 0245 (8 pages) WP 0246 (4 pages) WP 0247 (4 pages) WP 0248 (6 pages) WP 0249 (2 pages) WP 0250 (4 pages) WP 0251 (4 pages) WP 0252 (16 pages) WP 0253 (4 pages) WP 0254 (4 pages) WP 0255 (6 pages) WP 0256 (8 pages) WP 0257 (10 pages) WP 0258 (18 pages) WP 0259 (16 pages) WP 0260 (14 pages) WP 0261 (6 pages) WP 0262 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Page/WP No. WP 0263 (20 pages) WP 0264 (8 pages) WP 0265 (2 pages) WP 0266 (4 pages) WP 0267 (20 pages) WP 0268 (10 pages) WP 0269 (2 pages) WP 0270 (4 pages) WP 0271 (6 pages) WP 0272 (62 pages) Change No. 0 0 0 0 0 0 0 0 0 0 Page/WP No. Chapter 6 Title Page WP 0273 (2 pages) WP 0274 (4 pages) WP 0275 (28 pages) WP 0276 (6 pages) WP 0277 (8 pages) WP 0278 (10 pages) Index (8 pages) Back Cover Change No. 0 0 0 0 0 0 0 0 0
*TM 10-3930-675-23-1 ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 01 OCTOBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL
ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4 NSN 3930-01-473-3998 NSN 3930-01-522-7364
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring service, should be submitted as follows: (a) Army (A) - The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) website. The Internet address is https://tulsa.tacom.army.mil. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA website will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. (b) Marine Corps (MC) - Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC may be submitted using either of the following: a. The preferred method of submittal is using https://portal.logcom.usmc.mil/sites/pubs/ URL which will allow direct connection to the LOGCOM SharePoint Pubs site (LOGCOM SharePoint access and CAC required) where the form can be filled out and be submitted to the NAVMC SharePoint database. Problems or questions regarding the NAVMC 10772 program should be reported by calling DSN 567-7628 or DSN 567-5017 (Commercial number is (229) 639-7628 or (229) 639-5017). b. The alternate method of submittal does not require a Common Access Card (CAC) to access the form. Click on http://navalforms.daps.dla.mil/web/public/forms, select the "Keyword Search" button, enter "10772" in the Search Criteria Box. Under "type" click on download page button. Click on PDF icon. Enter user data in the appropriate fields. Must have users contact information block filled with Unit address and telephone number. Click on the 'Envelope' icon in the tool bar. Select "Send Copy click on "OK". When the PDF document is created, an Outlook Email screen will open with the .PDF as an attachment. On the TO: line type SMB.LOG.Tech.Pubs.fct@usmc.mil. In the body of the email, type any additional information you wish to provide. Click SEND. c. A reply will be furnished to you.
*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PCN 184 110783 00
FOR
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TABLE OF CONTENTS
Page No. WP Sequence No. Volume 1 HOW TO USE THIS MANUAL .......................................................................................................................... lxix Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2
EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Table 1. Figure 2. Table 2. Figure 3. Table 3. Major Components............................................................................................................... 0002-2 Description of Major Components........................................................................................ 0002-2 Major Components............................................................................................................... 0002-3 Description of Major Components........................................................................................ 0002-3 Major Components............................................................................................................... 0002-4 Description of Major Components........................................................................................ 0002-4
THEORY OF OPERATION.......................................................................................................................... WP 0003 Chapter 2 - TROUBLESHOOTING PROCEDURES ERROR CODE REFERENCES................................................................................................................... WP 0004 Table 1. Table 2. Table 3. Table 4. Driver Action Icons............................................................................................................... 0004-1 Type of Fault Icons............................................................................................................... 0004-1 Function Icons...................................................................................................................... 0004-2 Error Code Reference Index................................................................................................ 0004-4
TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0005 TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)................................................................. WP 0006 Figure 1. Starter Motor........................................................................................................................ 0006-3
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING................................................................... WP 0007 Figure 1. Figure 2. Figure 3. Figure 4. Actuator Harness Test.......................................................................................................... 0007-3 Actuator Harness Test.......................................................................................................... 0007-5 Actuator Harness Test.......................................................................................................... 0007-8 Actuator Harness Test........................................................................................................ 0007-11
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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Actuator Harness Test........................................................................................................ 0007-13 Actuator Harness Test........................................................................................................ 0007-16 Actuator Harness Test........................................................................................................ 0007-18 Actuator Harness Test........................................................................................................ 0007-19 Actuator Harness Test........................................................................................................ 0007-20 15-Pin Connector Test....................................................................................................... 0007-21 15-Pin Connector Test....................................................................................................... 0007-22 Solenoid Connector Test.................................................................................................... 0007-23 Actuator Harness Test........................................................................................................ 0007-24 Actuator Harness Connector Test...................................................................................... 0007-25 Actuator Harness Connector Test...................................................................................... 0007-26 Injector Wiring Test............................................................................................................ 0007-27 Actuator Harness Test........................................................................................................ 0007-28 Solenoid Connector Test.................................................................................................... 0007-29 Actuator Harness Test........................................................................................................ 0007-30 Actuator Harness Test........................................................................................................ 0007-31 Actuator Harness Test........................................................................................................ 0007-32 Injector Wiring Test............................................................................................................ 0007-33 Injector Wiring Test............................................................................................................ 0007-34 Injector Wiring Test............................................................................................................ 0007-35 Actuator Harness Test........................................................................................................ 0007-36 Actuator Harness Test........................................................................................................ 0007-37 Actuator Harness Test........................................................................................................ 0007-38 Injector Wiring Test............................................................................................................ 0007-39 Actuator Harness Test........................................................................................................ 0007-40 Actuator Harness Test........................................................................................................ 0007-41 Actuator Harness Test........................................................................................................ 0007-42
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Page No. WP Sequence No. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Actuator Harness Test........................................................................................................ 0007-43 Actuator Harness Test........................................................................................................ 0007-44 Actuator Harness Test........................................................................................................ 0007-45 Actuator Harness Test........................................................................................................ 0007-46 Actuator Harness Test........................................................................................................ 0007-47 Actuator Harness Test........................................................................................................ 0007-48 Actuator Harness Test........................................................................................................ 0007-49 Actuator Harness Test........................................................................................................ 0007-50 Actuator Harness Test........................................................................................................ 0007-51 Actuator Harness Test........................................................................................................ 0007-52 Actuator Harness Test........................................................................................................ 0007-53 Cylinder #1 Supply and Return.......................................................................................... 0007-54 Cylinder #5 Supply and Return.......................................................................................... 0007-54 Cylinder #3 Supply and Return.......................................................................................... 0007-55 Cylinder #6 Supply and Return.......................................................................................... 0007-55 Cylinder #2 Supply and Return.......................................................................................... 0007-56 Cylinder #4 Supply and Return.......................................................................................... 0007-56
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING............................................................ WP 0008 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Accelerator Pedal Wiring Test.............................................................................................. 0008-3 Accelerator Pedal Wiring Test.............................................................................................. 0008-4 OEM Harness Connector Test............................................................................................. 0008-5 OEM Harness Connector Test............................................................................................. 0008-5 OEM Harness Connector Test............................................................................................. 0008-6 Accelerator Pedal Wiring Test.............................................................................................. 0008-8 Accelerator Pedal Wiring Test.............................................................................................. 0008-9 OEM Wiring Harness Test.................................................................................................. 0008-10 OEM Wiring Harness Test.................................................................................................. 0008-10
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Page No. WP Sequence No. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Accelerator Pedal Calibration............................................................................................. 0008-11 Accelerator Pedal Test....................................................................................................... 0008-12 Accelerator Pedal Resistance Test.................................................................................... 0008-13 Idle Validation Circuit Voltage Test.................................................................................... 0008-13 Idle Validation Circuit Voltage Test.................................................................................... 0008-14 TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-16 TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-17
COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING............................................. WP 0009 Figure 1. Cooling Fan Diagnostics...................................................................................................... 0009-5
OVERLOAD PROTECTION TROUBLESHOOTING................................................................................... WP 0010 Figure 1. Figure 2. Overload Protection Diagnostics........................................................................................ 0010-12 Overload Protection Diagnostics........................................................................................ 0010-13
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING............................... WP 0011 Figure 1. Tophandler ECU Diagnostics............................................................................................... 0011-3
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING.................................... WP 0012 Figure 1. Figure 2. Figure 3. ECU Input Diagnostics......................................................................................................... 0012-8 ECU Input Diagnostics......................................................................................................... 0012-9 ECU Input Diagnostics....................................................................................................... 0012-10
ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING....................................................................... WP 0013 STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING................................................................................................................................. WP 0014 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Use Test Lead Kit................................................................................................................. 0014-4 Engine ECU Circuit Test...................................................................................................... 0014-5 Engine ECU Circuit Test...................................................................................................... 0014-6 Engine ECU Circuit Test...................................................................................................... 0014-7 Engine ECU Test.................................................................................................................. 0014-8
ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING................................ WP 0015 INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING.............................. WP 0016
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Page No. WP Sequence No. ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING......................................... WP 0017 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-2 Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-3 Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-4 Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-5 Sensor Voltage Supply Test................................................................................................. 0017-6 Sensor Voltage Supply Test................................................................................................. 0017-7 Sensor Voltage Supply Test................................................................................................. 0017-7 Sensor Voltage Supply Test................................................................................................. 0017-8 Sensor Voltage Supply Test................................................................................................. 0017-9 Sensor Voltage Supply Test................................................................................................. 0017-9 Sensor Voltage Supply Test............................................................................................... 0017-10 Sensor Voltage Supply Test............................................................................................... 0017-11 Sensor Voltage Supply Test............................................................................................... 0017-12 Sensor Voltage Supply Test............................................................................................... 0017-13 OEM Harness Connector Circuit Check............................................................................. 0017-15 Oil Pressure/Temperature Sensor Circuits......................................................................... 0017-15
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING.............................................................. WP 0018 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Engine Harness Circuit Resistance Check........................................................................... 0018-3 Engine Harness Circuit Resistance Check........................................................................... 0018-4 Engine Harness Circuit Resistance Check........................................................................... 0018-6 Engine Harness Circuit Resistance Check........................................................................... 0018-7 Engine Position Sensor Circuits........................................................................................... 0018-8
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING...................................................................... WP 0019 Figure 1. Figure 2. Figure 3. Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-2 Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-3 Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-4 Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-5 Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-6 Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-7 Oil Pressure Sensor Test..................................................................................................... 0019-7 Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-8 Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-9 Oil Pressure Sensor Circuit Resistance Test..................................................................... 0019-10 Oil Pressure Sensor Circuit Failure Test............................................................................ 0019-11 Oil Pressure Sensor Circuit Identification........................................................................... 0019-13
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING......................................... WP 0020 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Coolant Temperature Sensor Test....................................................................................... 0020-3 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-4 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-5 Coolant Temperature Sensor Resistance Test.................................................................... 0020-6 Coolant Temperature Sensor Resistance Test.................................................................... 0020-7 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-8 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-9 Intake Air Temperature Sensor Resistance Test............................................................... 0020-10 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-11 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-12 Intake Air Temperature Sensor Resistance Test............................................................... 0020-13 Intake Air Temperature Sensor Resistance Test............................................................... 0020-13 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-14 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-15 Oil Temperature Sensor Resistance Test.......................................................................... 0020-17 Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-18
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Page No. WP Sequence No. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-19 Oil Temperature Sensor Resistance Test.......................................................................... 0020-20 Oil Temperature Sensor Resistance Test.......................................................................... 0020-21 Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-22 Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-23 Engine Sensors Replacement............................................................................................ 0020-24 Intake Manifold Temperature Sensor Circuit Information................................................... 0020-25
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING.......................... WP 0021 Figure 1. Figure 2. Table 1. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Table 2. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Ambient Air Temperature Sensor Voltage Test.................................................................... 0021-3 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-3 Altitude (Ft.) vs. Voltage....................................................................................................... 0021-4 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-4 Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5 Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-6 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-7 Altitude (Ft.) vs. Voltage....................................................................................................... 0021-8 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-8 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-9 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-9 Ambient Air Temperature Sensor Circuit Resistance Test................................................. 0021-10 Ambient Air Temperature Sensor Circuit Test.................................................................... 0021-11
ENGINE PRESSURE SENSOR TROUBLESHOOTING............................................................................. WP 0022 Figure 1. Figure 2. Figure 3. Figure 4. Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-4 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-4
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-5 Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-6 Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-7 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-8 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-9 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-9 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-11 Intake Manifold Pressure Sensor Circuit Test.................................................................... 0022-11 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-13 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-13 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-14 Intake Manifold Pressure Sensor Circuit Information......................................................... 0022-14
ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING...................................... WP 0023 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Fuel Shutoff Solenoid Post Inspection................................................................................. 0023-2 Fuel Shutoff Solenoid Voltage Test...................................................................................... 0023-2 Fuel Shutoff Valve Actuator Wire......................................................................................... 0023-3 Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-4 Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-5 Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-5 Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-6 Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-7 Fuel Inlet Restriction Sensor Circuit Resistance Test.......................................................... 0023-8 Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9 Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9 Fuel Inlet Restriction Sensor Circuit Voltage Test.............................................................. 0023-10
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Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-11 Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-12 Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-13
ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING............................................................ WP 0024 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. OEM Harness Circuit Resistance Test................................................................................. 0024-3 Starter Solenoid Lockout Relay Circuit Resistance Test...................................................... 0024-6 Starter Solenoid Lockout Relay Circuit Continuity Test........................................................ 0024-7 Battery Cranking Voltage Test............................................................................................. 0024-8 Alternator Charging Amperage Test..................................................................................... 0024-8
TRANSMISSION TEMPERATURE TROUBLESHOOTING........................................................................ WP 0025 Figure 1. Component Locations.......................................................................................................... 0025-6
TRANSMISSION SPEED SENSORS TROUBLESHOOTING..................................................................... WP 0026 Figure 1. Component Locations........................................................................................................ 0026-10
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING..................................................................... WP 0027 MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING..................................................... WP 0028 INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING............................... WP 0029 BRAKE SYSTEM TROUBLESHOOTING.................................................................................................... WP 0030 Figure 1. Component Locations.......................................................................................................... 0030-6
AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING........................................................................ WP 0031 STEERING VALVE CIRCUIT TROUBLESHOOTING................................................................................. WP 0032 Figure 1. Connector 770 Numbering................................................................................................. 0032-14
MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING........................................ WP 0033 STEERING SENSOR TROUBLESHOOTING............................................................................................. WP 0034 HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING................................................................................................................................. WP 0035 Figure 1. Component Locations.......................................................................................................... 0035-2
AUXILIARY PUMP TROUBLESHOOTING.................................................................................................. WP 0036 HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING................................................................ WP 0037
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Page No. WP Sequence No. Figure 1. Component Locations.......................................................................................................... 0037-3
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING...................................................................... WP 0038 Figure 1. Figure 2. Component Locations.......................................................................................................... 0038-8 Component Locations.......................................................................................................... 0038-9
BOOM LIFTING/LOWERING TROUBLESHOOTING................................................................................. WP 0039 Figure 1. Figure 2. Component Locations.......................................................................................................... 0039-9 Component Locations........................................................................................................ 0039-10
BOOM IN/OUT TROUBLESHOOTING........................................................................................................ WP 0040 Figure 1. Figure 2. Component Locations.......................................................................................................... 0040-7 Component Locations.......................................................................................................... 0040-8
TOPHANDLER SLEWING TROUBLESHOOTING...................................................................................... WP 0041 Figure 1. Figure 2. Component Locations.......................................................................................................... 0041-7 Component Locations.......................................................................................................... 0041-8
TOPHANDLER TILT TROUBLESHOOTING............................................................................................... WP 0042 Figure 1. Figure 2. Component Locations.......................................................................................................... 0042-9 Component Locations........................................................................................................ 0042-10
TOPHANDLER LEVELING TROUBLESHOOTING..................................................................................... WP 0043 Figure 1. Figure 2. Component Locations. ........................................................................................................ 0043-8 Component Locations. ........................................................................................................ 0043-9
TOPHANDLER SIDESHIFT TROUBLESHOOTING................................................................................... WP 0044 Figure 1. Component Locations.......................................................................................................... 0044-6
TOPHANDLER SPREADER TROUBLESHOOTING.................................................................................. WP 0045 Figure 1. Component Locations.......................................................................................................... 0045-7
TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING.................................... WP 0046 Figure 1. Figure 2. Figure 3. Tophandler Twistlocks Indication Failure............................................................................. 0046-3 Component Locations.......................................................................................................... 0046-8 Component Locations.......................................................................................................... 0046-9
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Page No. WP Sequence No. Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction...................................... WP 0047 Table 1. Leakage Definitions for PMCS............................................................................................. 0047-1
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0048 Table 1. Table 2. Preventive Maintenance Checks and Services (PMCS) for the RTCH................................ 0048-1 PMCS Mandatory Replacement Parts List........................................................................... 0048-8
Chapter 4 - MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT......................................................................................................................... WP 0049 ENGINE ASSEMBLY REPLACEMENT....................................................................................................... WP 0050 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Engine Removal................................................................................................................... 0050-3 Engine Removal................................................................................................................... 0050-4 Engine Removal................................................................................................................... 0050-5 Engine Removal................................................................................................................... 0050-5 Engine Removal................................................................................................................... 0050-6 Engine Removal................................................................................................................... 0050-7 Engine Removal................................................................................................................... 0050-7 Engine Removal................................................................................................................... 0050-8 Engine Removal................................................................................................................... 0050-9 Engine Removal................................................................................................................. 0050-10 Engine Installation.............................................................................................................. 0050-12 Engine Installation.............................................................................................................. 0050-13 Engine Installation.............................................................................................................. 0050-13 Engine Installation.............................................................................................................. 0050-14 Engine Installation.............................................................................................................. 0050-14 Engine Installation.............................................................................................................. 0050-15 Engine Installation.............................................................................................................. 0050-16 Engine Installation.............................................................................................................. 0050-17
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Page No. WP Sequence No. Figure 19. Figure 20. Engine Installation.............................................................................................................. 0050-18 Engine Installation.............................................................................................................. 0050-19
ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT............................................................... WP 0051 Figure 1. Figure 2. Figure 3. Figure 4. Lifting Brackets Removal...................................................................................................... 0051-2 Lifting Brackets Installation................................................................................................... 0051-3 Front Engine Mount Installation............................................................................................ 0051-5 Rear Engine Mount Removal............................................................................................... 0051-7
CYLINDER HEAD REPLACEMENT............................................................................................................ WP 0052 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Table 1. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Cylinder Head Removal....................................................................................................... 0052-1 Cylinder Head Removal....................................................................................................... 0052-2 Cylinder Head Removal....................................................................................................... 0052-2 Cylinder Head Removal....................................................................................................... 0052-3 Cylinder Head Removal....................................................................................................... 0052-3 Cylinder Head Removal....................................................................................................... 0052-4 Cylinder Head Removal....................................................................................................... 0052-4 Cylinder Head Removal....................................................................................................... 0052-5 Cylinder Head Removal....................................................................................................... 0052-5 Cylinder Head Removal....................................................................................................... 0052-6 Cylinder Head Inspection..................................................................................................... 0052-8 Cylinder Head Inspection..................................................................................................... 0052-9 Cylinder Head Inspection................................................................................................... 0052-10 Cylinder Head Flatness Measurements............................................................................. 0052-10 Cylinder Head Inspection................................................................................................... 0052-11 Cylinder Head Inspection................................................................................................... 0052-11 Cylinder Head Installation.................................................................................................. 0052-12 Cylinder Head Installation.................................................................................................. 0052-13 Cylinder Head Installation.................................................................................................. 0052-13
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Page No. WP Sequence No. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Cylinder Head Installation.................................................................................................. 0052-14 Cylinder Head Installation.................................................................................................. 0052-14 Cylinder Head Installation.................................................................................................. 0052-15 Cylinder Head Installation.................................................................................................. 0052-15 Cylinder Head Removal..................................................................................................... 0052-16 Cylinder Head Installation.................................................................................................. 0052-16
VIBRATION DAMPER REPLACEMENT..................................................................................................... WP 0053 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Vibration Damper Removal.................................................................................................. 0053-2 Thickness Measure.............................................................................................................. 0053-3 Eccentricity Check................................................................................................................ 0053-3 Wobble Check...................................................................................................................... 0053-4 Vibration Damper Installation............................................................................................... 0053-5
FLYWHEEL ASSEMBLY REPLACEMENT................................................................................................. WP 0054 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Table 1. Figure 6. Figure 7. Flywheel Assembly Removal............................................................................................... 0054-2 Flywheel Assembly Removal............................................................................................... 0054-3 Flywheel Assembly Removal............................................................................................... 0054-4 Flywheel Assembly Inspection............................................................................................. 0054-5 Flywheel Assembly Inspection............................................................................................. 0054-6 Flywheel Face Runout.......................................................................................................... 0054-7 Flywheel Assembly Installation............................................................................................ 0054-8 Flywheel Assembly Installation............................................................................................ 0054-9
REAR MAIN OIL SEAL REPLACEMENT.................................................................................................... WP 0055 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Rear Main Oil Seal Removal................................................................................................ 0055-2 Wear Sleeve Removal.......................................................................................................... 0055-3 Wear Sleeve Removal.......................................................................................................... 0055-3 Wear Sleeve Removal.......................................................................................................... 0055-4 Wear Sleeve Removal.......................................................................................................... 0055-4
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-5 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-6 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-6 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-7 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-7 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-8 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-9
ROCKER ARM ASSEMBLY MAINTENANCE............................................................................................. WP 0056 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Push Rods and Push Tubes Removal................................................................................. 0056-2 Key Stock Installation........................................................................................................... 0056-2 Front Rocker Arm Assembly Removal................................................................................. 0056-3 Rocker Levers Removal....................................................................................................... 0056-4 Rocker Lever Disassembly................................................................................................... 0056-4 Rocker Lever Bushing Measurement................................................................................... 0056-5 Rocker Lever Shaft Measurement........................................................................................ 0056-5 Rocker Arm Shaft Assembly................................................................................................ 0056-6 Rocker Arm Shaft Assembly................................................................................................ 0056-7 Rocker Arm Shaft Assembly................................................................................................ 0056-7 Rocker Arm Shaft Assembly................................................................................................ 0056-8 Rocker Arm Shaft Installation............................................................................................... 0056-8 Rocker Arm Shaft Installation............................................................................................... 0056-9 Rocker Arm Shaft Installation............................................................................................... 0056-9 Rocker Arm Shaft Installation............................................................................................. 0056-10 Rocker Arm Shaft Installation............................................................................................. 0056-10 Rocker Arm Shaft Installation. ........................................................................................... 0056-11 Rocker Arm Shaft Installation............................................................................................. 0056-11 Rocker Arm Shaft Installation............................................................................................. 0056-12
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Page No. WP Sequence No. Figure 20. Figure 21. Figure 22. Table 1. Figure 23. Figure 24. Table 2. Figure 25. Figure 26. Table 3. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Rocker Arm Shaft Installation............................................................................................. 0056-12 Rocker Arm Shaft Installation............................................................................................. 0056-13 Valve Lash Check.............................................................................................................. 0056-14 Injector and Valve Measurement Sequence...................................................................... 0056-15 Valve Lash Check.............................................................................................................. 0056-15 Valve Lash Check.............................................................................................................. 0056-16 M Series Valve Lash Recheck Limits................................................................................. 0056-16 Injector Lash Check............................................................................................................ 0056-17 Injector Lash Check............................................................................................................ 0056-18 M Series Injector Lash Recheck Limits.............................................................................. 0056-18 Injector Adjustment............................................................................................................. 0056-19 Injector Adjustment............................................................................................................. 0056-19 Valve Adjustment............................................................................................................... 0056-20 Valve Adjustment............................................................................................................... 0056-21 Valve Adjustment............................................................................................................... 0056-21 Valve Adjustment............................................................................................................... 0056-22 Valve Adjustment............................................................................................................... 0056-22 Valve Adjustment............................................................................................................... 0056-23
ROCKER ARM COVER AND GASKET REPLACEMENT........................................................................... WP 0057 Figure 1. Figure 2. Rocker Arm Cover and Gasket Replacement...................................................................... 0057-2 Rocker Arm Cover Tightening Sequence............................................................................. 0057-3
OIL PAN REPLACEMENT........................................................................................................................... WP 0058 Figure 1. Figure 2. Figure 3. Oil Pan Removal.................................................................................................................. 0058-2 Oil Pan Installation............................................................................................................... 0058-3 Oil Pan Installation............................................................................................................... 0058-3
ENGINE OIL AND OIL FILTER REPLACEMENT........................................................................................ WP 0059 Figure 1. Drain Engine Oil................................................................................................................... 0059-2
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Page No. WP Sequence No. Figure 2. Oil Filter and Gasket............................................................................................................. 0059-3
OIL FILTER HEAD AND OIL COOLER MAINTENANCE............................................................................ WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2 Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2 Oil Filter Head and Oil Cooler Removal............................................................................... 0060-3 Oil Filter Head and Oil Cooler Disassembly......................................................................... 0060-5 Oil Cooler Testing................................................................................................................. 0060-7 Oil Cooler Cleaning.............................................................................................................. 0060-8 Oil Cooler Pressure Test...................................................................................................... 0060-9 Oil Filter Head Assembly...................................................................................................... 0060-9 Oil Filter Head Assembly.................................................................................................... 0060-10 Oil Filter Head Installation.................................................................................................. 0060-10 Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-11 Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-12 Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-12
ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT..................................................... WP 0061 Figure 1. Figure 2. Figure 3. Engine Oil Dipstick Replacement and Fill Hose Removal.................................................... 0061-3 Oil Dipstick Cover and Cylinder Block Cleaning................................................................... 0061-4 Engine Oil Dipstick and Fill Hoses Installation..................................................................... 0061-5
OIL SAMPLING VALVES AND HOSES REPLACEMENT.......................................................................... WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Oil Sampling Valve............................................................................................................... 0062-2 Engine Oil Sampling Valve Hose......................................................................................... 0062-3 Transmission Oil Sampling Valve Hose............................................................................... 0062-4 Hydraulic System Oil Sampling Valve Hose......................................................................... 0062-5
EXHAUST MANIFOLD REPLACEMENT.................................................................................................... WP 0063 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0063-1 Exhaust Manifold Removal................................................................................................... 0063-2
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Exhaust Manifold Installation................................................................................................ 0063-3 Exhaust Manifold Installation................................................................................................ 0063-4 Exhaust Manifold Installation................................................................................................ 0063-5
INTAKE MANIFOLD REPLACEMENT........................................................................................................ WP 0064 Figure 1. Figure 2. Figure 3. Intake Manifold Removal...................................................................................................... 0064-1 Intake Manifold Installation................................................................................................... 0064-2 Intake Manifold Sequence.................................................................................................... 0064-2
FRONT GEAR COVER REPLACEMENT.................................................................................................... WP 0065 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Front Gear Cover Removal.................................................................................................. 0065-2 Front Gear Cover Removal.................................................................................................. 0065-3 Front Gear Cover Removal.................................................................................................. 0065-3 Front Gear Cover Installation............................................................................................... 0065-4 Front Gear Cover Installation............................................................................................... 0065-5 Front Gear Cover Installation............................................................................................... 0065-5 Front Gear Cover Installation............................................................................................... 0065-6 Front Gear Cover Tightening Sequence.............................................................................. 0065-7
FRONT MAIN OIL SEAL REPLACEMENT.................................................................................................. WP 0066 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Front Main Oil Seal Removal............................................................................................... 0066-1 Front Main Oil Seal Removal............................................................................................... 0066-2 Unitized Front Crankshaft Main Oil Seal Removal............................................................... 0066-2 Unitized Front Crankshaft Main Oil Seal Removal............................................................... 0066-3 Cleaning and Inspection....................................................................................................... 0066-3 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-4 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-5 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-5 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-6 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-7
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Page No. WP Sequence No. FUEL INJECTOR REPLACEMENT............................................................................................................. WP 0067 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Push Rods and Push Tubes Removal................................................................................. 0067-2 Injector Hold-Down Clamp Removal.................................................................................... 0067-3 Injector Removal.................................................................................................................. 0067-3 Injector Installation............................................................................................................... 0067-4 Injector Installation............................................................................................................... 0067-5 Push Rods and Push Tubes Installation.............................................................................. 0067-5
FUEL PUMP ASSEMBLY REPLACEMENT................................................................................................ WP 0068 Figure 1. Fuel Pump Removal............................................................................................................. 0068-3
FUEL HOSES, LINES, AND FITTINGS REPLACEMENT........................................................................... WP 0069 Figure 1. Figure 2. Figure 3. Figure 4. Cooling Plate-to-Cylinder Head Fuel Line............................................................................ 0069-2 Fuel Pump-to-Cooling Plate Fuel Line................................................................................. 0069-3 Engine Fuel Return Line....................................................................................................... 0069-4 Fuel Return Hose................................................................................................................. 0069-5
FUEL SOLENOID SHUTOFF VALVE REPLACEMENT.............................................................................. WP 0070 Figure 1. Figure 2. Figure 3. Fuel Solenoid Shutoff Valve Removal.................................................................................. 0070-2 Fuel Solenoid Shutoff Valve Installation............................................................................... 0070-3 Fuel Solenoid Shutoff Valve Installation............................................................................... 0070-3
ENGINE AIR CLEANER MAINTENANCE................................................................................................... WP 0071 Figure 1. Figure 2. Figure 3. Figure 4. Engine Air Cleaner............................................................................................................... 0071-2 Engine Air Cleaner Filter Elements Removal....................................................................... 0071-3 Engine Air Cleaner Filter Elements Removal and Installation.............................................. 0071-4 Engine Air Cleaner Filter Elements Removal and Installation.............................................. 0071-5
ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT................................................................... WP 0072 Figure 1. Figure 2. Figure 3. Air Cleaner-to-Turbocharger Hoses and Tubes................................................................... 0072-3 Turbocharger-to-Charge Air Cooler Hoses and Tubes........................................................ 0072-5 Charger Air Cooler-to-Engine Air Intake Manifold Hoses and Tubes................................... 0072-7
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Page No. WP Sequence No. TURBOCHARGER REPLACEMENT.......................................................................................................... WP 0073 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Clamps Removal.................................................................................................................. 0073-2 Turbocharger Removal......................................................................................................... 0073-2 Turbocharger Removal......................................................................................................... 0073-3 Turbocharger Removal......................................................................................................... 0073-3 Turbocharger Axial Clearance Check.................................................................................. 0073-4 Turbocharger Radial Bearing Clearance Check................................................................... 0073-5 Turbocharger Installation...................................................................................................... 0073-6 Turbocharger Installation...................................................................................................... 0073-6 Turbocharger Installation...................................................................................................... 0073-7 Turbocharger Installation...................................................................................................... 0073-7
FUEL TANK REPLACEMENT..................................................................................................................... WP 0074 Figure 1. Figure 2. Fuel Tank Removal.............................................................................................................. 0074-2 Fuel Tank Replacement....................................................................................................... 0074-3
FUEL SUPPLY AND RETURN HOSES REPLACEMENT.......................................................................... WP 0075 Figure 1. Fuel Supply Hose................................................................................................................. 0075-3
FUEL FILTER/WATER SEPARATOR REPLACEMENT............................................................................. WP 0076 Figure 1. Figure 2. Figure 3. Fuel Pump Ball Valve........................................................................................................... 0076-2 Fuel Filter............................................................................................................................. 0076-3 Fuel Pump Ball Valve........................................................................................................... 0076-4
ETHER COLD START SYSTEM MAINTENANCE...................................................................................... WP 0077 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Ether Canister Removal....................................................................................................... 0077-1 Ether Canister Gasket.......................................................................................................... 0077-2 Ether Canister Installation.................................................................................................... 0077-3 Cold Start Activation Solenoid Removal............................................................................... 0077-4 Cold Start Activation Solenoid Removal............................................................................... 0077-5 Cold Start Activation Solenoid Removal............................................................................... 0077-5
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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Cold Start Activation Solenoid Removal............................................................................... 0077-6 Cold Start Activation Solenoid Installation............................................................................ 0077-7 Cold Start Activation Solenoid Installation............................................................................ 0077-8 Cold Start Activation Solenoid Installation............................................................................ 0077-9
THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT........................................ WP 0078 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-1 Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-2 Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-2 Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-3 Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-3 Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-4 Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-5 Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-6 Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-7 Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-8 Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-9 Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-9
MUFFLER AND EXHAUST PIPE REPLACEMENT.................................................................................... WP 0079 Figure 1. Figure 2. Muffler and Exhaust Pipe Removal...................................................................................... 0079-3 Muffler and Exhaust Pipe Installation................................................................................... 0079-5
DRAINING AND FILLING RADIATOR ASSEMBLY.................................................................................... WP 0080 Figure 1. Figure 2. Figure 3. Figure 4. Drain Radiator Assembly...................................................................................................... 0080-2 Fill Radiator Assembly.......................................................................................................... 0080-3 Fill Radiator Assembly.......................................................................................................... 0080-3 Check Coolant Level............................................................................................................ 0080-4
RADIATOR ASSEMBLY MAINTENANCE................................................................................................... WP 0081 Figure 1. Angle Plate Removal............................................................................................................ 0081-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Radiator Grille Removal....................................................................................................... 0081-3 Radiator Removal................................................................................................................. 0081-4 Radiator Installation.............................................................................................................. 0081-5 Radiator Grille Installation.................................................................................................... 0081-6 Angle Plate Installation......................................................................................................... 0081-7
COOLING SYSTEM EXPANSION TANK MAINTENANCE......................................................................... WP 0082 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cooling System Expansion Tank Removal.......................................................................... 0082-2 Cooling System Expansion Tank Removal.......................................................................... 0082-3 Cooling System Expansion Tank Removal.......................................................................... 0082-4 Cooling System Expansion Tank Assembly and Installation................................................ 0082-5 Cooling System Expansion Tank Installation....................................................................... 0082-6 Cooling System Expansion Tank Installation....................................................................... 0082-7
COOLING SYSTEM HOSES REPLACEMENT........................................................................................... WP 0083 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Cab Interface Unit-to-Water Pump Hose.............................................................................. 0083-2 Cab Interface Unit-to-Engine Block Hose............................................................................. 0083-3 Coolant Reservoir-to-Radiator Hose.................................................................................... 0083-4 Coolant Reservoir-to-Water Manifold Hose.......................................................................... 0083-5 Coolant Reservoir-to-Water Pump Hose.............................................................................. 0083-6 Transmission Oil Cooler-to-Radiator Hoses......................................................................... 0083-7 Transmission Oil Cooler-to-Water Pump Hoses.................................................................. 0083-8 Transmission Oil Cooler-to-Water Pump Return Hose........................................................ 0083-9 Transmission Oil Cooler U-Hose........................................................................................ 0083-10 Water Manifold-to-Radiator Hoses..................................................................................... 0083-11
RADIATOR SPLASH SHIELD REPLACEMENT......................................................................................... WP 0084 Figure 1. Radiator Splash Shield Installation....................................................................................... 0084-2
RADIATOR TOP GRATING REPLACEMENT............................................................................................. WP 0085 Figure 1. Radiator Top Grating Replacement...................................................................................... 0085-2
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Page No. WP Sequence No. RADIATOR FILL COVER PLATE REPLACEMENT.................................................................................... WP 0086 Figure 1. Radiator Fill Cover Replacement......................................................................................... 0086-1
THERMOSTAT REPLACEMENT................................................................................................................ WP 0087 Figure 1. Figure 2. Figure 3. Figure 4. Thermostat Removal............................................................................................................ 0087-1 Thermostat Removal............................................................................................................ 0087-2 Thermostat Removal and Installation................................................................................... 0087-2 Thermostat Installation......................................................................................................... 0087-3
WATER PUMP REPLACEMENT................................................................................................................. WP 0088 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Water Pump Pulley Removal............................................................................................... 0088-2 Dust and Oil Seal Removal.................................................................................................. 0088-3 Water Pump Removal.......................................................................................................... 0088-3 Needle Bearing Inspection................................................................................................... 0088-4 Water Pump Installation....................................................................................................... 0088-5 Oil and Dust Seal Installation............................................................................................... 0088-5 Water Pump Pulley Installation............................................................................................ 0088-6
HYDRAULIC COOLING FAN MAINTENANCE........................................................................................... WP 0089 Figure 1. Figure 2. Cooling Fan Removal........................................................................................................... 0089-3 Cooling Fan Installation........................................................................................................ 0089-5
COOLANT FILTER AND FILTER HEAD REPLACEMENT......................................................................... WP 0090 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Coolant Filter Removal......................................................................................................... 0090-2 Coolant Filter Preparation.................................................................................................... 0090-3 Coolant Filter Tightening...................................................................................................... 0090-4 Turn Coolant Filter Head Valve ON...................................................................................... 0090-5 Coolant Filter Head Replacement........................................................................................ 0090-7
ALTERNATOR REPLACEMENT................................................................................................................. WP 0091 Figure 1. Figure 2. Alternator Removal............................................................................................................... 0091-1 Alternator Removal............................................................................................................... 0091-2
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Page No. WP Sequence No. Figure 3. Alternator Installation............................................................................................................ 0091-3
ALTERNATOR DRIVE BELT MAINTENANCE............................................................................................ WP 0092 Figure 1. Figure 2. Figure 3. Alternator Drive Belt Removal.............................................................................................. 0092-1 Alternator Drive Belt Installation........................................................................................... 0092-2 Alternator Drive Belt Adjustment.......................................................................................... 0092-3
STARTER MOTOR REPLACEMENT.......................................................................................................... WP 0093 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Starter Removal................................................................................................................... 0093-2 Starter Removal................................................................................................................... 0093-3 Starter Removal................................................................................................................... 0093-3 Starter Installation................................................................................................................ 0093-4 Starter Installation................................................................................................................ 0093-5
INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT............................ WP 0094 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Switch/Gauge Panel Removal.............................................................................................. 0094-2 Rocker Switch Removal....................................................................................................... 0094-3 Switch/Gauge Panel Removal.............................................................................................. 0094-4 Rotary Switch Removal........................................................................................................ 0094-5 Rotary Switch Removal and Installation............................................................................... 0094-7 Switch/Gauge Panel Installation........................................................................................... 0094-7 Rotary Switch Installation..................................................................................................... 0094-8 Gauge Removal................................................................................................................... 0094-9 Switch/Gauge Panel Installation......................................................................................... 0094-10 Instrument Panel Lamp Installation.................................................................................... 0094-11 Instrument Panel Lamp Installation.................................................................................... 0094-12 12/24 Connector Removal.................................................................................................. 0094-13 12/24V Connector Installation............................................................................................ 0094-14
TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT............................................ WP 0095 Figure 1. Separate Housing................................................................................................................. 0095-1
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Transmission and Accessory Control Levers Removal........................................................ 0095-2 Panel Removed.................................................................................................................... 0095-3 Panel Removal..................................................................................................................... 0095-3 Transmission and Accessory Control Levers Removal........................................................ 0095-4 Transmission and Accessory Control Levers Installation..................................................... 0095-5 Panels Installation................................................................................................................ 0095-6 Panels Installation................................................................................................................ 0095-6 Housing Installation.............................................................................................................. 0095-7
ECS DISPLAY SCREEN REPLACEMENT................................................................................................. WP 0096 Figure 1. Figure 2. Figure 3. ECS Display Screen Removal.............................................................................................. 0096-1 ECS Display Screen Installation........................................................................................... 0096-2 ECS Display Screen Installation........................................................................................... 0096-3
TOPHANDLER JUNCTION BOX MAINTENANCE..................................................................................... WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Tophandler ECU Removal................................................................................................... 0097-2 Tophandler ECU Installation................................................................................................ 0097-3 Relay Installation.................................................................................................................. 0097-4 Tophandler Junction Box Removal...................................................................................... 0097-5 Tophandler Junction Box Removal...................................................................................... 0097-5 Tophandler Junction Box Removal...................................................................................... 0097-6 Tophandler Junction Box Removal...................................................................................... 0097-7 Tophandler Junction Box Removal...................................................................................... 0097-8 Tophandler Junction Box Removal...................................................................................... 0097-9 Tophandler Junction Box Replacement............................................................................. 0097-10 Tophandler Junction Box Installation................................................................................. 0097-11 Tophandler Junction Box Installation................................................................................. 0097-12 Tophandler Junction Box Installation................................................................................. 0097-13 Tophandler Junction Box Installation................................................................................. 0097-13
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Page No. WP Sequence No. TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT............................................ WP 0098 Figure 1. Figure 2. Figure 3. Tophandler Junction Box Cover Removal............................................................................ 0098-1 Tophandler Junction Box Replacement............................................................................... 0098-3 Tophandler Junction Box Cover Installation......................................................................... 0098-4
ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT............................................................ WP 0099 Figure 1. ECU Replacement................................................................................................................ 0099-3
ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT........................................................................ WP 0100 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Access Panels Removal....................................................................................................... 0100-1 Transmission ECU Removal................................................................................................ 0100-2 Access Panels Removal....................................................................................................... 0100-3 Steering System ECU Removal........................................................................................... 0100-4 Seat Base Cover Removal................................................................................................... 0100-5 Hydraulic Servo System ECU Removal............................................................................... 0100-6 Hydraulic Servo System ECU Installation............................................................................ 0100-7 Seat Base Cover Installation................................................................................................ 0100-8
ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT........................................................................... WP 0101 Figure 1. Figure 2. Joystick Removal................................................................................................................. 0101-1 Joystick Installation.............................................................................................................. 0101-2
ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT.......................................... WP 0102 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Joystick Wiring Harness Removal........................................................................................ 0102-2 Joystick Wiring Harness Removal........................................................................................ 0102-3 Joystick Wiring Harness Removal........................................................................................ 0102-4 Seat Base Cover Removal................................................................................................... 0102-5 Joystick Wiring Harness Removal........................................................................................ 0102-5 Joystick Wiring Harness Removal........................................................................................ 0102-6 Joystick Wiring Harness Installation..................................................................................... 0102-7 Seat Base Cover Installation................................................................................................ 0102-7
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Page No. WP Sequence No. Figure 9. Figure 10. Joystick Wiring Harness Installation..................................................................................... 0102-8 Joystick Wiring Harness Installation..................................................................................... 0102-9
CIRCUIT BREAKERS AND RELAYS REPLACEMENT.............................................................................. WP 0103 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Access Panel Removal........................................................................................................ 0103-1 Circuit Breaker/Relay Box Opening...................................................................................... 0103-2 Circuit Breaker Panel Separation......................................................................................... 0103-3 Circuit Breaker Removal...................................................................................................... 0103-3 Circuit Breaker Removal...................................................................................................... 0103-4 Relay Removal..................................................................................................................... 0103-5 Relay Replacement.............................................................................................................. 0103-6 Relay Connection................................................................................................................. 0103-7 Circuit Breaker Connection.................................................................................................. 0103-8 Circuit Breaker Installation................................................................................................... 0103-9 Circuit Breaker Panel Installation......................................................................................... 0103-9 Circuit Breaker Panel Installation....................................................................................... 0103-10 Access Panel Installation................................................................................................... 0103-11 Circuit Breaker Installation................................................................................................. 0103-13 Starter Relay Installation.................................................................................................... 0103-14 Fuse Block Installation....................................................................................................... 0103-15
TOPHANDLER PROXIMITY SWITCHES REPLACEMENT........................................................................ WP 0104 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Twistlock Proximity Switch Removal.................................................................................... 0104-2 Junction Box Cover Removal............................................................................................... 0104-3 Twistlock Proximity Switch Installation................................................................................. 0104-5 Junction Box Cover Installation............................................................................................ 0104-5 Twistlock Proximity Switch Installation................................................................................. 0104-6 Forklift Interlock Proximity Switch Removal......................................................................... 0104-7 Junction Box Cover Removal............................................................................................... 0104-7
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Page No. WP Sequence No. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Forklift Interlock Proximity Switch Removal......................................................................... 0104-8 Forklift Interlock Proximity Switch Removal......................................................................... 0104-9 Junction Box Cover Installation............................................................................................ 0104-9 Twistlock Proximity Switch Installation............................................................................... 0104-10 Spreader Beam Proximity Switch Removal........................................................................ 0104-11 Spreader Beam Proximity Switch Removal........................................................................ 0104-11 Spreader Beam Proximity Switch Removal........................................................................ 0104-12 Spreader Beam Proximity Switch Installation..................................................................... 0104-13 Spreader Beam Proximity Switch Installation..................................................................... 0104-14 Spreader Beam Proximity Switch Installation..................................................................... 0104-15
CAB POSITION PROXIMITY SWITCHES REPLACEMENT....................................................................... WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Cab-Mounted Proximity Switch Removal............................................................................. 0105-1 Cab-Mounted Proximity Switch Removal............................................................................. 0105-2 Cab-Mounted Proximity Switch Replacement...................................................................... 0105-3 Cab-Mounted Proximity Switch Installation.......................................................................... 0105-4 Cab Support-Mounted Proximity Switch Removal............................................................... 0105-5 Cab Support-Mounted Proximity Switch Installation............................................................ 0105-7 Cab-Support Mounted Proximity Switch Installation............................................................ 0105-8
SOLAR CHARGER REPLACEMENT (IF EQUIPPED)................................................................................ WP 0106 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Solar Charger Replacement................................................................................................. 0106-1 Solar Charger Replacement................................................................................................. 0106-2 Solar Charger Replacement................................................................................................. 0106-3 Solar Charger Replacement................................................................................................. 0106-3 Solar Charger Replacement................................................................................................. 0106-4
BOOM WIRING HARNESSES REPLACEMENT........................................................................................ WP 0107 Figure 1. Figure 2. Boom Wiring Harness Removal........................................................................................... 0107-1 Boom Wiring Harness Removal........................................................................................... 0107-2
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Page No. WP Sequence No. Figure 3. Boom Wiring Harness Installation........................................................................................ 0107-3
TOPHANDLER WIRING HARNESSES REPLACEMENT........................................................................... WP 0108 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Wiring Harness A Removal.................................................................................................. 0108-2 Wiring Harness A Removal.................................................................................................. 0108-3 Wiring Harness A Removal.................................................................................................. 0108-3 Wiring Harness A Installation............................................................................................... 0108-5 Wiring Harness A Installation............................................................................................... 0108-5 Wiring Harness B Removal.................................................................................................. 0108-6 Wiring Harness B Removal.................................................................................................. 0108-7 Wiring Harness B Installation............................................................................................... 0108-8 Wiring Harness B Installation............................................................................................... 0108-9 Wiring Harness C Removal................................................................................................ 0108-10 Wiring Harness C Removal................................................................................................ 0108-11 Wiring Harness C Installation............................................................................................. 0108-12 Wiring Harness C Installation............................................................................................. 0108-13 Wiring Harness D Removal................................................................................................ 0108-13 Wiring Harness D Removal................................................................................................ 0108-14 Wiring Harness D Removal................................................................................................ 0108-15 Wiring Harness D Removal................................................................................................ 0108-16 Wiring Harness D Installation............................................................................................. 0108-17 Wiring Harness D Installation............................................................................................. 0108-18 Wiring Harness D Installation............................................................................................. 0108-18 Wiring Harness E Removal................................................................................................ 0108-19 Wiring Harness E Removal................................................................................................ 0108-20 Wiring Harness E Removal................................................................................................ 0108-21 Wiring Harness E Installation............................................................................................. 0108-22 Wiring Harness E Installation............................................................................................. 0108-23
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Page No. WP Sequence No. Figure 26. Wiring Harness E Installation............................................................................................. 0108-23
HEADLIGHT MAINTENANCE..................................................................................................................... WP 0109 Figure 1. Figure 2. Figure 3. Figure 4. Headlight Reflector Insert Removal...................................................................................... 0109-2 Headlight Bulb Replacement................................................................................................ 0109-3 Headlight Reflector Insert Installation................................................................................... 0109-3 Light Removal and Installation............................................................................................. 0109-5
BACKUP LIGHT AND WORK LIGHT MAINTENANCE............................................................................... WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Reflector Insert Removal...................................................................................................... 0110-2 Bulb Replacement................................................................................................................ 0110-3 Reflector Insert Installation................................................................................................... 0110-3 Light Removal and Installation............................................................................................. 0110-5
BLACKOUT LIGHT MAINTENANCE........................................................................................................... WP 0111 Figure 1. Figure 2. Figure 3. Figure 4. Bulb/Reflector Replacement................................................................................................. 0111-2 Bulb/Reflector Replacement................................................................................................. 0111-3 Bulb/Reflector Replacement................................................................................................. 0111-3 Blackout Light Replacement................................................................................................. 0111-5
DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE....................................................... WP 0112 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Lens Removal...................................................................................................................... 0112-2 Bulb and LED Replacement................................................................................................. 0112-3 Lens Installation................................................................................................................... 0112-3 Directional Light Replacement............................................................................................. 0112-5 Side Marker Light Cover Removal....................................................................................... 0112-6 Bulb Replacement................................................................................................................ 0112-7
TWISTLOCK INDICATOR LIGHTS MAINTENANCE.................................................................................. WP 0113 Figure 1. Figure 2. Figure 3. Twistlock Indicator Light Bulb Replacement. ....................................................................... 0113-2 Twistlock Indicator Light Bulb Replacement......................................................................... 0113-3 Twistlock Indicator Light Removal........................................................................................ 0113-4
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Page No. WP Sequence No. Figure 4. Figure 5. Twistlock Indicator Light Installation..................................................................................... 0113-5 Twistlock Infrared (IR) Light Replacement........................................................................... 0113-7
CAB INTERIOR LIGHT MAINTENANCE..................................................................................................... WP 0114 Figure 1. Figure 2. Cab Interior Light Bulb Removal.......................................................................................... 0114-1 Cab Interior Light Bulb Installation....................................................................................... 0114-3
INFRARED (IR) LIGHTS REPLACEMENT.................................................................................................. WP 0115 Figure 1. Figure 2. Infrared (IR) Light Removal.................................................................................................. 0115-2 Infrared (IR) Light Installation............................................................................................... 0115-3
FORDING WATER LEVEL SENSOR REPLACEMENT.............................................................................. WP 0116 Figure 1. Figure 2. Water Level Sensor Removal............................................................................................... 0116-1 Water Level Sensor Installation............................................................................................ 0116-2
WHEEL TEMPERATURE SENSOR REPLACEMENT................................................................................ WP 0117 Figure 1. Wheel Temperature Sensor Replacement........................................................................... 0117-2
ENGINE SENSORS REPLACEMENT......................................................................................................... WP 0118 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Coolant Temperature Sensor Replacement......................................................................... 0118-3 Engine Position Sensor Removal......................................................................................... 0118-4 Intake Air Temperature Sensor Replacement...................................................................... 0118-5 Intake Manifold Pressure Sensor Replacement................................................................... 0118-6 Ambient Air Pressure Sensor Replacement......................................................................... 0118-7 Ambient Air Pressure Sensor Removal (New Style)............................................................ 0118-8 Ambient Temperature Sensor Installation (New Style)........................................................ 0118-9 Oil Pressure/Temperature Sensor Replacement............................................................... 0118-10
HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT............................................................... WP 0119 Figure 1. Hydraulic Cylinder Filter Indicator Sensor Replacement...................................................... 0119-3
TRANSMISSION SENSORS REPLACEMENT........................................................................................... WP 0120 Figure 1. Figure 2. Transmission Sensors.......................................................................................................... 0120-2 Transmission Sensor Connector.......................................................................................... 0120-3
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Transmission Sensor Removal............................................................................................ 0120-3 Transmission Sensor Installation......................................................................................... 0120-4 Transmission Sensor Connector.......................................................................................... 0120-5
BOOM ANGLE SENSOR REPLACEMENT................................................................................................. WP 0121 Figure 1. Figure 2. Figure 3. Figure 4. Boom Angle Sensor Removal.............................................................................................. 0121-2 Boom Angle Sensor Removal.............................................................................................. 0121-3 Boom Angle Sensor Removal.............................................................................................. 0121-4 Boom Angle Sensor Installation........................................................................................... 0121-5
BOOM EXTENSION SENSOR REPLACEMENT........................................................................................ WP 0122 Figure 1. Figure 2. Figure 3. Figure 4. Boom Extension Sensor Removal........................................................................................ 0122-1 Boom Extension Sensor Removal........................................................................................ 0122-2 Boom Extension Sensor Removal........................................................................................ 0122-3 Boom Extension Sensor Installation..................................................................................... 0122-4
TOPHANDLER ANGLE SENSOR REPLACEMENT................................................................................... WP 0123 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Tophandler Angle Sensor Removal..................................................................................... 0123-2 Tophandler Angle Sensor Removal..................................................................................... 0123-3 Tophandler Angle Sensor Removal..................................................................................... 0123-4 Tophandler Angle Sensor Removal..................................................................................... 0123-5 Tophandler Angle Sensor Installation.................................................................................. 0123-6 Tophandler Angle Sensor Installation.................................................................................. 0123-7 Tophandler Angle Sensor Installation.................................................................................. 0123-8 Tophandler Angle Sensor Installation.................................................................................. 0123-9
HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT....................................... WP 0124 Figure 1. Figure 2. Figure 3. Temperature Sensor Replacement...................................................................................... 0124-2 Pressure Sensor Replacement............................................................................................ 0124-3 Lift Cylinder Sensor Replacement........................................................................................ 0124-4
STEERING SYSTEM WHEEL SENSOR REPLACEMENT......................................................................... WP 0125
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Table 1. Table 2. Figure 5. Figure 6. Steering System Wheel Sensor Removal............................................................................ 0125-2 Steering System Wheel Sensor Removal............................................................................ 0125-3 Steering System Wheel Sensor Removal............................................................................ 0125-4 Steering System Wheel Sensor Installation......................................................................... 0125-5 Rear Junction Box X167 Wire Connections......................................................................... 0125-6 Front Junction Box X192 Wire Connections......................................................................... 0125-6 Steering System Wheel Sensor Installation......................................................................... 0125-7 Steering System Wheel Sensor Installation......................................................................... 0125-8
SEAT WARNING BUZZER REPLACEMENT.............................................................................................. WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Seat Warning Buzzer Replacement..................................................................................... 0126-1 Seat Warning Buzzer Replacement..................................................................................... 0126-2 Seat Warning Buzzer Replacement..................................................................................... 0126-3 Seat Warning Buzzer Replacement..................................................................................... 0126-4
ELECTRIC HORN REPLACEMENT............................................................................................................ WP 0127 Figure 1. Electric Horn Replacement................................................................................................... 0127-2
BATTERY MAINTENANCE......................................................................................................................... WP 0128 Figure 1. Figure 2. Figure 3. Battery Replacement............................................................................................................ 0128-2 Battery Service..................................................................................................................... 0128-3 Battery Installation................................................................................................................ 0128-4
BATTERY CABLES REPLACEMENT......................................................................................................... WP 0129 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Battery Cables Replacement................................................................................................ 0129-2 Solar Charger Disconnect.................................................................................................... 0129-2 Battery Cables Replacement................................................................................................ 0129-3 Battery Cables Replacement................................................................................................ 0129-4 Solar Charger Connection.................................................................................................... 0129-5 Battery Cables Replacement................................................................................................ 0129-5
MASTER BATTERY SWITCH REPLACEMENT......................................................................................... WP 0130
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Master Battery Switch Replacement.................................................................................... 0130-1 Master Battery Switch Replacement.................................................................................... 0130-2 Master Battery Switch Replacement.................................................................................... 0130-3
AMBIENT TEMPERATURE SENSOR REPLACEMENT............................................................................. WP 0131 Figure 1. Figure 2. Ambient Temperature Sensor Removal............................................................................... 0131-2 Ambient Temperature Sensor Installation............................................................................ 0131-3
FUEL LEVEL SENDING UNIT REPLACEMENT......................................................................................... WP 0132 Figure 1. Figure 2. Figure 3. Fuel Level Sending Unit Connector Removal...................................................................... 0132-1 Fuel Level Sending Unit Removal........................................................................................ 0132-2 Fuel Level Sending Unit Installation..................................................................................... 0132-3
BACKUP ALARM REPLACEMENT............................................................................................................. WP 0133 Figure 1. Figure 2. Backup Alarm Removal........................................................................................................ 0133-1 Backup Alarm Installation..................................................................................................... 0133-2
SLAVE STARTING RECEPTACLE REPLACEMENT................................................................................. WP 0134 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Index Volume 2 Chapter 5 - MAINTENANCE INSTRUCTIONS TRANSMISSION ASSEMBLY MAINTENANCE.......................................................................................... WP 0135 Figure 1. Figure 2. Figure 3. Figure 4. Transmission Sensors Removal........................................................................................... 0135-3 Transmission Hoses Removal.............................................................................................. 0135-4 Transmission Oil Fill Tube Removal..................................................................................... 0135-5 Flywheel Housing Access Cover.......................................................................................... 0135-5 Right Slave Starting Receptacle Replacement.................................................................... 0134-1 Right Slave Starting Receptacle Replacement.................................................................... 0134-2 Right Slave Starting Receptacle Replacement.................................................................... 0134-3 Left Slave Starting Receptacle Replacement....................................................................... 0134-4 Left Slave Starting Receptacle Replacement....................................................................... 0134-5
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Flywheel-to-Damper Plate Access Cover Removal............................................................. 0135-6 Damper Plates-to-Flywheel Screw Removal........................................................................ 0135-7 Flywheel Housing Screws Removal..................................................................................... 0135-7 Transmission-to-Mounting Bracket Removal....................................................................... 0135-8 Electrical Connectors Removal............................................................................................ 0135-9 Transmission Sensors Installation...................................................................................... 0135-10 Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-12 Flywheel-to-Damper Plate Screw Installation..................................................................... 0135-13 Flywheel Housing Screws Installation................................................................................ 0135-13 Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-14 Flywheel Housing Access Cover Installation...................................................................... 0135-15 Flywheel-to-Damper Plate Access Cover Installation........................................................ 0135-15 Transmission Oil Fill Tube Installation................................................................................ 0135-16 Transmission Hoses Installation......................................................................................... 0135-17 Transmission Electrical Connectors................................................................................... 0135-18
TRANSMISSION CALIBRATION................................................................................................................. WP 0136 Figure 1. Figure 2. Table 1. Table 2. Calibration............................................................................................................................ 0136-2 Calibration............................................................................................................................ 0136-3 Main Transmission Calibration Codes.................................................................................. 0136-4 Sub Transmission Calibration Codes................................................................................... 0136-5
TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT.................................. WP 0137 Figure 1. Figure 2. Transmission Assembly Hose and Pipe Location Diagram.................................................. 0137-2 Transmission Hose and Pipe Location................................................................................. 0137-3
TRANSMISSION OIL DIPSTICK HOSE AND PIPE REPLACEMENT........................................................ WP 0138 Figure 1. Transmission Oil Dipstick Hose and Pipe Replacement...................................................... 0138-3
TRANSMISSION TORQUE CONVERTER REPLACEMENT...................................................................... WP 0139 Figure 1. Damper Plates Removal...................................................................................................... 0139-1
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Page No. WP Sequence No. Figure 2. Torque Converter Removal.................................................................................................. 0139-3
TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD MAINTENANCE....................................... WP 0140 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Transmission Oil Draining and Filling................................................................................... 0140-3 Transmission Oil Filters Replacement.................................................................................. 0140-5 Transmission Oil Filter Head Replacement.......................................................................... 0140-6 Transmission Oil Filter Head Replacement.......................................................................... 0140-7 Transmission Internal Coarse Oil Filter Removal................................................................. 0140-8 Transmission Internal Coarse Oil Filter Installation............................................................ 0140-10
TRANSMISSION OIL COOLER REPLACEMENT....................................................................................... WP 0141 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Transmission Oil Coolers Removal...................................................................................... 0141-2 Transmission Oil Coolers Removal...................................................................................... 0141-3 Transmission Oil Coolers Removal...................................................................................... 0141-4 Transmission Oil Coolers Removal...................................................................................... 0141-5 Transmission Oil Coolers Installation................................................................................... 0141-6 Transmission Oil Coolers Installation................................................................................... 0141-7 Transmission Oil Coolers Installation................................................................................... 0141-8
TRANSMISSION OIL FILTER HOSES AND OIL COOLER HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0142 Figure 1. Figure 2. Transmission-to-Oil Cooler Hoses Replacement................................................................. 0142-3 Transmission-to-Oil Filter Hose Replacement. .................................................................... 0142-5
FRONT AND REAR PROPELLER SHAFTS REPLACEMENT................................................................... WP 0143 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Propeller Shaft Removal............................................................................................. 0143-2 Front Propeller Shaft Removal. ........................................................................................... 0143-3 Rear Propeller Shaft Removal.............................................................................................. 0143-4 Rear Propeller Shaft Removal.............................................................................................. 0143-5 Rear Propeller Shaft Installation. ......................................................................................... 0143-7
UNIVERSAL JOINT REPLACEMENT......................................................................................................... WP 0144 Figure 1. Propeller Shaft Universal Joint Replacement....................................................................... 0144-3
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Page No. WP Sequence No. FRONT AXLE ASSEMBLY REPLACEMENT.............................................................................................. WP 0145 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Axle Removal.............................................................................................................. 0145-2 Front Axle Removal.............................................................................................................. 0145-3 Front Axle Removal.............................................................................................................. 0145-4 Front Axle Removal.............................................................................................................. 0145-5 Front Axle Removal.............................................................................................................. 0145-6 Front Axle Installation........................................................................................................... 0145-7
TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT.................................. WP 0146 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Axle Vent Hose Removal............................................................................................ 0146-2 Front Axle Vent Hose Replacement..................................................................................... 0146-3 Rear Axle Vent Hose Replacement...................................................................................... 0146-4 Rear Axle Vent Hose Replacement...................................................................................... 0146-5 Transmission Vent Hose Replacement................................................................................ 0146-7
REAR AXLE ASSEMBLY MAINTENANCE................................................................................................. WP 0147 Figure 1. Figure 2. Figure 3. Rear Axle Rigging................................................................................................................ 0147-2 Rear Axle Removal.............................................................................................................. 0147-3 Rear Axle Installation........................................................................................................... 0147-5
CAGING AND UNCAGING PARKING BRAKE........................................................................................... WP 0148 Figure 1. Figure 2. Figure 3. Caging Parking Brake.......................................................................................................... 0148-2 Caging Parking Brake.......................................................................................................... 0148-2 Caging Parking Brake.......................................................................................................... 0148-3
PARKING BRAKE CYLINDER REPLACEMENT........................................................................................ WP 0149 Figure 1. Figure 2. Figure 3. Figure 4. Parking Brake Cylinder Removal......................................................................................... 0149-3 Parking Brake Cylinder Installation...................................................................................... 0149-5 Parking Brake Rotor Removal.............................................................................................. 0149-7 Parking Brake Bracket Replacement................................................................................... 0149-9
PARKING BRAKE PADS MAINTENANCE.................................................................................................. WP 0150
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Page No. WP Sequence No. Figure 1. Parking Brake Pad Replacement. ....................................................................................... 0150-3
PARKING BRAKE CONTROL VALVE REPLACEMENT............................................................................ WP 0151 Figure 1. Figure 2. Figure 3. Parking Brake Control Valve Removal................................................................................. 0151-1 Parking Brake Control Valve Replacement.......................................................................... 0151-3 Parking Brake Control Valve Installation.............................................................................. 0151-4
PARKING BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT.............................. WP 0152 SERVICE BRAKE CONTROL VALVE REPLACEMENT............................................................................. WP 0153 Figure 1. Service Brake Control Valve Replacement.......................................................................... 0153-2
BRAKE ACCUMULATOR REPLACEMENT................................................................................................ WP 0154 Figure 1. Figure 2. Figure 3. Brake Accumulators and Valve Block Replacement............................................................ 0154-2 Brake Accumulators and Valve Block Replacement............................................................ 0154-3 Brake Accumulators and Valve Block Replacement............................................................ 0154-4
BRAKE AND STEERING ACCUMULATOR SERVICE............................................................................... WP 0155 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Brake Accumulator Testing.................................................................................................. 0155-2 Brake Accumulator Testing.................................................................................................. 0155-3 Brake Accumulator Testing.................................................................................................. 0155-4 Brake Accumulator Testing.................................................................................................. 0155-5 Brake Accumulator Testing.................................................................................................. 0155-5 Brake Accumulator Charging............................................................................................... 0155-6 Brake Accumulator Charging............................................................................................... 0155-7 Brake Accumulator Charging............................................................................................... 0155-7 Brake Accumulator Charging............................................................................................... 0155-8 Brake Accumulator Charging............................................................................................... 0155-9 Brake Accumulator Charging............................................................................................... 0155-9 Brake Accumulator Charging............................................................................................. 0155-10 Brake Accumulator Charging............................................................................................. 0155-11 Brake Accumulator Testing................................................................................................ 0155-12
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Page No. WP Sequence No. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Brake Accumulator Charging............................................................................................. 0155-12 Brake Accumulator Charging............................................................................................. 0155-13 Brake Accumulator Charging............................................................................................. 0155-13 Brake Accumulator Charging............................................................................................. 0155-14 Steering Accumulator Pre-charge Pressure Check............................................................ 0155-15
BRAKE SYSTEM CHARGING VALVE PRESSURE ADJUSTMENT.......................................................... WP 0156 Figure 1. Brake System Charging Valve Pressure Adjustment........................................................... 0156-3
SERVICE BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT............................... WP 0157 Figure 1. Service Brake System Hydraulic Hoses and Fittings Replacement..................................... 0157-3
BRAKE COOLING FILTER AND FILTER HEAD REPLACEMENT............................................................. WP 0158 Figure 1. Figure 2. Figure 3. Brake Cooling Filter Replacement........................................................................................ 0158-2 Brake Cooling Filter Head Removal..................................................................................... 0158-3 Brake Cooling Filter Head Installation.................................................................................. 0158-4
BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT................................................................ WP 0159 Figure 1. Figure 2. Figure 3. Left Lower Panel Removal................................................................................................... 0159-2 Right Lower Panel Removal................................................................................................. 0159-2 Brake Light and Pressure Switch Replacement................................................................... 0159-3
STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE.......................................................... WP 0160 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Steering Column Base Removal.......................................................................................... 0160-1 Steering Column Base Removal.......................................................................................... 0160-2 Steering Column Base Removal.......................................................................................... 0160-2 Steering Column Base Disassembly.................................................................................... 0160-3 Steering Column Base Disassembly.................................................................................... 0160-4 Steering Column Base Disassembly.................................................................................... 0160-4 Steering Column Base Assembly......................................................................................... 0160-5 Steering Column Base Installation....................................................................................... 0160-6 Steering Column Base Installation....................................................................................... 0160-6
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Page No. WP Sequence No. Figure 10. Steering Column Base Installation....................................................................................... 0160-7
BRAKE INCHING SWITCH REPLACEMENT............................................................................................. WP 0161 Figure 1. Figure 2. Figure 3. Brake Inching Switch Removal............................................................................................. 0161-2 Brake Inching Switch Removal............................................................................................. 0161-3 Brake Inching Switch Installation.......................................................................................... 0161-4
WHEEL ASSEMBLY REPLACEMENT........................................................................................................ WP 0162 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Raise Front Axle................................................................................................................... 0162-2 Raise Front Axle................................................................................................................... 0162-3 Raise Front Axle................................................................................................................... 0162-3 Raise Front Axle................................................................................................................... 0162-4 Wheel and Tire Replacement............................................................................................... 0162-5
BOGIE WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0163 Figure 1. Figure 2. Figure 3. Figure 4. Lower Bogie Wheel.............................................................................................................. 0163-1 Bogie Wheel Replacement................................................................................................... 0163-3 Screw Assembly Removal and Installation.......................................................................... 0163-5 Bogie Wheel Frame Replacement....................................................................................... 0163-7
DOLLY WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0164 Figure 1. Figure 2. Dolly Wheel Disassembly..................................................................................................... 0164-2 Dolly Wheel Assembly.......................................................................................................... 0164-3
STEERING WHEEL REPLACEMENT......................................................................................................... WP 0165 Figure 1. Figure 2. Figure 3. Steering Wheel Removal...................................................................................................... 0165-1 Steering Wheel Replacement............................................................................................... 0165-2 Steering Wheel Installation................................................................................................... 0165-3
STEERING COLUMN REPLACEMENT...................................................................................................... WP 0166 Figure 1. Figure 2. Figure 3. Steering Column Removal................................................................................................... 0166-1 Steering Column Removal................................................................................................... 0166-2 Steering Column Removal................................................................................................... 0166-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Steering Column Removal................................................................................................... 0166-3 Steering Column Removal................................................................................................... 0166-4 Steering Column Removal and Installation.......................................................................... 0166-5 Steering Column Installation................................................................................................ 0166-6 Steering Column Installation................................................................................................ 0166-7 Steering Column Installation................................................................................................ 0166-8 Steering Column Installation................................................................................................ 0166-9
STEERING COLUMN REPAIR.................................................................................................................... WP 0167 Figure 1. Steering Column Disassembly and Assembly...................................................................... 0167-3
STEERING SENSOR REPLACEMENT...................................................................................................... WP 0168 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Steering Column Sensor Removal....................................................................................... 0168-1 Steering Column Sensor Removal....................................................................................... 0168-2 Steering Column Sensor Removal....................................................................................... 0168-3 Steering Column Sensor Installation.................................................................................... 0168-3 Steering Column Sensor Installation.................................................................................... 0168-4 Steering Column Sensor Installation.................................................................................... 0168-5
EMERGENCY STEERING PUMP REPLACEMENT................................................................................... WP 0169 Figure 1. Emergency Steering Pump Replacement............................................................................ 0169-3
STEERING SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT......................................... WP 0170 FRONT AND REAR AXLE STEERING CYLINDERS REPLACEMENT...................................................... WP 0171 Figure 1. Front and Rear Steering Cylinder Replacement.................................................................. 0171-3
STEERING ACCUMULATOR REPLACEMENT.......................................................................................... WP 0172 Figure 1. Steering Accumulator Replacement..................................................................................... 0172-3
STEERING CONTROL VALVE REPLACEMENT....................................................................................... WP 0173 Figure 1. Figure 2. Steering Control Valve Removal.......................................................................................... 0173-3 Steering Control Valve Removal and Installation................................................................. 0173-5
STEERING CALIBRATION.......................................................................................................................... WP 0174
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Page No. WP Sequence No. TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT............................................... WP 0175 Figure 1. Figure 2. Figure 3. Figure 4. Skid Plate Replacement....................................................................................................... 0175-3 Front Access Cover Replacement........................................................................................ 0175-4 Middle Access Cover and Cab Support Replacement......................................................... 0175-5 Rear Access Cover Replacement........................................................................................ 0175-6
BOOM SUPPORT MAINTENANCE............................................................................................................ WP 0176 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Boom Support Removal....................................................................................................... 0176-2 Boom Support Removal....................................................................................................... 0176-3 Boom Support Removal....................................................................................................... 0176-3 Boom Support Removal....................................................................................................... 0176-4 Boom Support Removal....................................................................................................... 0176-5 Boom Support Removal....................................................................................................... 0176-6 Boom Support Installation.................................................................................................... 0176-7 Boom Support Installation.................................................................................................... 0176-8 Boom Support Installation.................................................................................................... 0176-9 Boom Support Installation.................................................................................................... 0176-9 Boom Support Installation.................................................................................................. 0176-10 Boom Support Installation.................................................................................................. 0176-11
FLEXIBLE CONVEYOR MAINTENANCE................................................................................................... WP 0177 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Boom Wiring Harness and Cable Removal.......................................................................... 0177-2 Boom Wiring Harness and Cable Removal.......................................................................... 0177-3 Boom Wiring Harness and Cable Removal.......................................................................... 0177-3 Hydraulic Hoses Removal.................................................................................................... 0177-4 Conveyor Removal............................................................................................................... 0177-5 Conveyor Installation............................................................................................................ 0177-6 Hydraulic Hoses Installation................................................................................................. 0177-7 Wiring Harness and Cable Installation................................................................................. 0177-7
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Page No. WP Sequence No. Figure 9. Figure 10. Wiring Harness and Cable Installation................................................................................. 0177-8 Connect Cable and Wiring Harness..................................................................................... 0177-9
PINTLE HOOK MAINTENANCE.................................................................................................................. WP 0178 Figure 1. Tow Pintle Replacement...................................................................................................... 0178-2
CAB LIFT FRAME MAINTENANCE............................................................................................................ WP 0179 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Cab Transport Lift System Inspection.................................................................................. 0179-2 Cab Transport Lift System Inspection.................................................................................. 0179-3 Cab Transport Lift System Inspection.................................................................................. 0179-3 Cab Transport Lift System Inspection.................................................................................. 0179-4 Cab Adjustment: Operational Position................................................................................. 0179-5 Cab Adjustment: Operational Position................................................................................. 0179-6 Cab Adjustment: Operational Position................................................................................. 0179-7 Cab Adjustment: Operational Position................................................................................. 0179-7 Cab Adjustment: Operational Position................................................................................. 0179-8 Cab Adjustment: Transport Position..................................................................................... 0179-9 Cab Adjustment: Transport Position................................................................................... 0179-10 Cab Adjustment: Transport Position................................................................................... 0179-11 Cab Adjustment: Transport Position................................................................................... 0179-12 Cab Transport Lift Removal............................................................................................... 0179-13 Cab Transport Lift Removal............................................................................................... 0179-14 Cab Transport Lift Removal............................................................................................... 0179-15 Cab Transport Lift Installation............................................................................................ 0179-16 Cab Transport Lift Installation............................................................................................ 0179-17 Cab Transport Lift Installation............................................................................................ 0179-18 Cab Transport Lift Structure Removal................................................................................ 0179-19 Cab Transport Lift Structure Removal................................................................................ 0179-20 Cab Transport Lift Structure Removal................................................................................ 0179-21
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Page No. WP Sequence No. Figure 23. Figure 24. Figure 25. Cab Transport Lift Structure Installation............................................................................. 0179-22 Cab Transport Lift Structure Installation............................................................................. 0179-23 Cab Transport Lift Structure Installation............................................................................. 0179-24
RIGHT-SIDE STEP ASSEMBLY REPLACEMENT..................................................................................... WP 0180 Figure 1. Right-Side Step Assembly Removal.................................................................................... 0180-2
LEFT-SIDE STAIR ASSEMBLY REPLACEMENT....................................................................................... WP 0181 Figure 1. Figure 2. Figure 3. Left-Side Step Assembly Replacement................................................................................ 0181-1 Left-Side Stair Assembly Removal....................................................................................... 0181-2 Left-Side Stair Assembly Replacement................................................................................ 0181-3
STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT.................................................. WP 0182 Figure 1. Figure 2. Figure 3. Storage Compartment Door Removal.................................................................................. 0182-1 Storage Compartment Door Removal and Installation......................................................... 0182-2 Storage Compartment Door Installation............................................................................... 0182-3
BATTERY AND DOLLY WHEELS STORAGE COMPARTMENT REPLACEMENT................................... WP 0183 Figure 1. Battery and Dolly Wheels Storage Compartment Replacement.......................................... 0183-3
REMOTE HYDRAULIC CONTROL COMPARTMENT REPLACEMENT.................................................... WP 0184 Figure 1. Remote Hydraulic Control Compartment Replacement....................................................... 0184-2
ENGINE COVER MAINTENANCE.............................................................................................................. WP 0185 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Engine Cover Removal........................................................................................................ 0185-1 Engine Cover Disassembly.................................................................................................. 0185-2 Engine Cover Disassembly.................................................................................................. 0185-2 Engine Cover Disassembly.................................................................................................. 0185-3 Engine Cover Assembly....................................................................................................... 0185-4
CAB DOOR ASSEMBLY MAINTENANCE.................................................................................................. WP 0186 Figure 1. Figure 2. Figure 3. Cab Door Assembly Removal.............................................................................................. 0186-1 Cab Door Assembly Removal.............................................................................................. 0186-2 Cab Door Disassembly......................................................................................................... 0186-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Cab Door Disassembly and Assembly................................................................................. 0186-4 Cab Door Installation............................................................................................................ 0186-5 Cab Door Installation............................................................................................................ 0186-6 Cab Door Installation............................................................................................................ 0186-7
CAB DOOR WEATHERSEAL REPLACEMENT.......................................................................................... WP 0187 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cab Door Weatherseal Removal.......................................................................................... 0187-1 Cab Door Weatherseal Removal.......................................................................................... 0187-2 Cab Door Weatherseal Removal.......................................................................................... 0187-3 Cab Door Weatherseal Installation....................................................................................... 0187-4 Cab Door Weatherseal Installation....................................................................................... 0187-5 Cab Door Weatherseal Installation....................................................................................... 0187-5
WINDSHIELD AND WINDOW GLASS REPLACEMENT............................................................................ WP 0188 Figure 1. Figure 2. Window Removal and Installation........................................................................................ 0188-3 Window Removal and Installation........................................................................................ 0188-4
MUDGUARD REPLACEMENT.................................................................................................................... WP 0189 Figure 1. Mudguard Replacement....................................................................................................... 0189-2
FENDER ASSEMBLY REPLACEMENT...................................................................................................... WP 0190 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Fender and Fender Bracket Removal (RT 240V1)............................................................... 0190-2 Fender and Fender Bracket Replacement (RT 240V1)........................................................ 0190-3 Front Fender and Fender Bracket Removal (RT 240V1R)................................................... 0190-4 Front Fender and Fender Bracket Replacement (RT 240V1R)............................................ 0190-5 Rear Fender and Fender Bracket Removal (RT 240V2 and RT 240V3).............................. 0190-6 Rear Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)....................... 0190-7 Front Fender and Fender Bracket Removal (RT 240V2 and RT 240V3)............................. 0190-8 Front Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)...................... 0190-9 Front Bracket Mounting Plate Replacement....................................................................... 0190-10
SEAT ASSEMBLY MAINTENANCE............................................................................................................ WP 0191
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Seat Removal....................................................................................................................... 0191-2 Seat Disassembly................................................................................................................. 0191-3 Seat Disassembly and Assembly......................................................................................... 0191-5 Seat Assembly..................................................................................................................... 0191-7 Seat Installation.................................................................................................................... 0191-8
SEAT BELT REPLACEMENT...................................................................................................................... WP 0192 Figure 1. Seatbelt Replacement.......................................................................................................... 0192-2
REARVIEW MIRRORS REPLACEMENT.................................................................................................... WP 0193 Figure 1. Figure 2. Figure 3. Interior Rearview Mirror Replacement.................................................................................. 0193-1 Exterior Rearview Mirror Removal....................................................................................... 0193-2 Exterior Rearview Mirror Removal and Installation.............................................................. 0193-3
WINDSHIELD WIPER MAINTENANCE...................................................................................................... WP 0194 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Front Windshield Wiper and Motor Removal........................................................................ 0194-2 Front Windshield Wiper and Motor Removal........................................................................ 0194-3 Front Windshield Wiper and Motor Removal........................................................................ 0194-3 Front Windshield Wiper and Motor Installation..................................................................... 0194-4 Front Windshield Wiper and Motor Installation..................................................................... 0194-5 Front Windshield Wiper and Motor Installation..................................................................... 0194-6 Rear Windshield Wiper and Motor Removal........................................................................ 0194-7 Rear Windshield Wiper and Motor Removal........................................................................ 0194-7 Rear Windshield Wiper and Motor Removal and Installation............................................... 0194-9 Rear Windshield Wiper and Motor Installation..................................................................... 0194-9 Roof Window Windshield Wiper and Motor Removal......................................................... 0194-10 Roof Window Windshield Wiper and Motor Removal......................................................... 0194-11 Roof Window Windshield Wiper and Motor Removal and Installation............................... 0194-12 Roof Window Windshield Wiper and Motor Installation...................................................... 0194-13 Roof Window Windshield Wiper and Motor Installation...................................................... 0194-14
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Page No. WP Sequence No. WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT....................................................... WP 0195 Figure 1. Figure 2. Figure 3. Figure 4. Windshield Washer Reservoir Replacement........................................................................ 0195-3 Windshield Washer Pump Removal..................................................................................... 0195-4 Windshield Washer Pump Replacement.............................................................................. 0195-5 Windshield Washer Pump Installation.................................................................................. 0195-6
HEATER HOSES REPLACEMENT............................................................................................................. WP 0196 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Engine Heater Hoses Removal............................................................................................ 0196-2 Engine Heater Hoses Removal............................................................................................ 0196-3 Engine Heater Hoses Removal............................................................................................ 0196-3 Engine Heater Hoses Removal............................................................................................ 0196-4 Engine Heater Hoses Removal............................................................................................ 0196-5 Engine Heater Hoses Removal............................................................................................ 0196-5 Engine.................................................................................................................................. 0196-6 Engine Heater Hoses Removal............................................................................................ 0196-7 Cab Heater Hoses Removal RT 240V1 and RT 240V1R.................................................. 0196-8 Cab Heater Hoses Removal RT 240V2 and RT 240V3 Vehicles...................................... 0196-8 Cab Heater Hoses Removal................................................................................................. 0196-9 Cab Heater Hoses Removal............................................................................................... 0196-10 Cab Heater Hoses Removal............................................................................................... 0196-10 Cab Heater Hoses Removal............................................................................................... 0196-11 Cab Heater Hoses Installation............................................................................................ 0196-12 Cab Heater Hoses Installation............................................................................................ 0196-13 Cab Heater Hoses Installation............................................................................................ 0196-13 Cab Heater Hoses Installation RT 240V1 and RT 240V1R Vehicles.............................. 0196-14 Cab Heater Hoses Installation RT 240V2 and RT 240V3 Vehicles................................. 0196-14
CAB HEATER/AIR CONDITIONING UNIT MAINTENANCE....................................................................... WP 0197 Figure 1. Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-3 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-4 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-5 Cab Heater/Air Conditioning Unit Installation....................................................................... 0197-6
CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT................................ WP 0198 Figure 1. Figure 2. Figure 3. Figure 4. Front Panel Removal............................................................................................................ 0198-1 Cover Removal..................................................................................................................... 0198-2 Blower Motor and Fan Replacement.................................................................................... 0198-3 Blower Motor and Fan Installation........................................................................................ 0198-4
CAB AIR FILTERS REPLACEMENT........................................................................................................... WP 0199 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Grille Removal.............................................................................................................. 0199-2 Cab Side Air Filter Removal................................................................................................. 0199-3 Cab Side Air Filter Installation.............................................................................................. 0199-4 Left Lower Panel Removal RT 240V1 and RT 240V1R Vehicles Only............................. 0199-5 Cab Interior Air Filter Removal............................................................................................. 0199-5 Cab Interior Air Filter Removal............................................................................................. 0199-6 Left Lower Panel Installation RT 240V1 and RT 240V1R Vehicles Only.......................... 0199-7 Cab Interior Air Filter Installation.......................................................................................... 0199-8
CAB AUXILIARY FAN REPLACEMENT...................................................................................................... WP 0200 Figure 1. Figure 2. Figure 3. Access Panel Removal........................................................................................................ 0200-1 Auxiliary Fan Replacement.................................................................................................. 0200-2 Access Cover Installation..................................................................................................... 0200-3
AUTOLUBE SYSTEM MAINTENANCE....................................................................................................... WP 0201 Figure 1. Figure 2. Figure 3. Autolube Tube Replacement................................................................................................ 0201-2 Autolube Pump Replacement............................................................................................... 0201-3 Autolube Distribution Valve Replacement............................................................................ 0201-4
FIRE EXTINGUISHER BRACKET REPLACEMENT................................................................................... WP 0202
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Page No. WP Sequence No. Figure 1. Fire Extinguisher Bracket Replacement............................................................................... 0202-1
DATA PLATE REPLACEMENT................................................................................................................... WP 0203 Figure 1. Data Plate Replacement...................................................................................................... 0203-2
RELIEVING HYDRAULIC SYSTEM PRESSURE....................................................................................... WP 0204 Figure 1. Figure 2. Figure 3. Steering Accumulator Evacuation Valve.............................................................................. 0204-2 Steering Accumulator Evacuation Valves............................................................................ 0204-3 Float Control and Emergency Control Valves...................................................................... 0204-3
BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT....................................................... WP 0205 Figure 1. Figure 2. Pump Replacement.............................................................................................................. 0205-3 Pump Installation.................................................................................................................. 0205-5
COOLING FAN HYDRAULIC PUMP REPLACEMENT............................................................................... WP 0206 Figure 1. Figure 2. Pump Removal..................................................................................................................... 0206-3 Pump Installation.................................................................................................................. 0206-5
SERVO CONTROL VALVE REPLACEMENT............................................................................................. WP 0207 Figure 1. Servo Control Valve Replacement....................................................................................... 0207-3
HYDRAULIC SYSTEM COOLING HOSES AND FITTINGS REPLACEMENT........................................... WP 0208 AUXILIARY HYDRAULIC PUMP REPLACEMENT..................................................................................... WP 0209 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cover Removal..................................................................................................................... 0209-2 Hose and Wire Disconnects................................................................................................. 0209-3 Ground Strap and Power Cable Disconnects....................................................................... 0209-3 Pump Removal..................................................................................................................... 0209-4 Pump Installation.................................................................................................................. 0209-5 Ground Strap and Power Cable Connections...................................................................... 0209-5 Hose and Wire Connections................................................................................................. 0209-6 Cover Installation.................................................................................................................. 0209-7
TOPHANDLER HYDRAULIC SLEWING MOTORS MAINTENANCE......................................................... WP 0210 Figure 1. Turning Plate Cover Removal.............................................................................................. 0210-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Hydraulic Manifold and Hose Removal................................................................................ 0210-3 Hydraulic Manifold and Hose Removal................................................................................ 0210-3 Slewing Motor and Pinion Gear Removal............................................................................ 0210-5 Slewing Motor and Hydraulic Manifold Installation............................................................... 0210-6 Secure Hydraulic Manifold................................................................................................... 0210-7 Hoses and Fittings Installation and Connection................................................................... 0210-8 Protective Cover Installation................................................................................................. 0210-9
SLEWING MOTOR BRAKE REPLACEMENT............................................................................................. WP 0211 Figure 1. Figure 2. Figure 3. Spur Gear Removal.............................................................................................................. 0211-1 Slewing Motor Brake Removal and Replacement................................................................ 0211-3 Slewing Motor Gear Replacement....................................................................................... 0211-4
TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT............................... WP 0212 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Pump Removal..................................................................................................................... 0212-2 Pump Removal..................................................................................................................... 0212-3 Pump Removal..................................................................................................................... 0212-3 Pump Removal..................................................................................................................... 0212-4 Pump Removal..................................................................................................................... 0212-4 Pump Removal..................................................................................................................... 0212-5 Pump Removal..................................................................................................................... 0212-6 Pump Removal..................................................................................................................... 0212-7 Pump Removal..................................................................................................................... 0212-7 Pump Removal..................................................................................................................... 0212-8 Pump Removal..................................................................................................................... 0212-9 Pump Installation................................................................................................................ 0212-10 Pump Installation................................................................................................................ 0212-11 Pump Installation................................................................................................................ 0212-11 Pump Installation................................................................................................................ 0212-12
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Page No. WP Sequence No. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Pump Installation................................................................................................................ 0212-13 Pump Installation................................................................................................................ 0212-14 Pump Installation................................................................................................................ 0212-14 Pump Installation................................................................................................................ 0212-15 Pump Installation................................................................................................................ 0212-16 Pump Installation................................................................................................................ 0212-17 Pump Installation................................................................................................................ 0212-18
TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT.................................................... WP 0213 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-2 Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-3 Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-4 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-5 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-6 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-7
MAIN CONTROL VALVE REPLACEMENT................................................................................................. WP 0214 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Main Control Valve Removal................................................................................................ 0214-2 Main Control Valve Removal................................................................................................ 0214-3 Main Control Valve Removal................................................................................................ 0214-5 Main Control Valve Installation............................................................................................. 0214-6 Main Control Valve Installation............................................................................................. 0214-7
BOOM FOLDING CONTROL VALVE REPLACEMENT.............................................................................. WP 0215 Figure 1. Boom Folding Control Valve Replacement.......................................................................... 0215-3
CAB TRANSPORT CONTROL VALVE REPLACEMENT........................................................................... WP 0216 Figure 1. Cab Transport Control Valve Replacement.......................................................................... 0216-3
CONTROL VALVE SOLENOIDS REPLACEMENT..................................................................................... WP 0217 Figure 1. Figure 2. Control Valve Solenoid Replacement Type A................................................................... 0217-3 Control Valve Solenoid Replacement Type B................................................................... 0217-4
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Page No. WP Sequence No. Figure 3. Figure 4. Control Valve Solenoid Replacement Type C................................................................... 0217-5 Control Valve Solenoid Replacement Type D................................................................... 0217-6
BOOM FOLDING CYLINDERS REPLACEMENT....................................................................................... WP 0218 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Boom Folding Cylinder Replacement................................................................................... 0218-3 Boom Folding Cylinder Installation....................................................................................... 0218-4 Boom Folding Cylinder installation....................................................................................... 0218-5 Boom Folding Cylinder Installation....................................................................................... 0218-6 Boom Folding Cylinder Installation....................................................................................... 0218-7 Boom Folding Cylinder Installation....................................................................................... 0218-8
CAB PARKING AND SERVICE BRAKE HYDRAULIC HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0219 MAIN HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................................... WP 0220 HYDRAULIC SERVO SYSTEM HOSES AND FITTINGS REPLACEMENT............................................... WP 0221 HYDRAULIC SYSTEM TEST POINT HOSES AND FITTINGS REPLACEMENT....................................... WP 0222 CAB TRANSPORT HYDRAULIC HOSES AND FITTINGS REPLACEMENT............................................. WP 0223 BOOM HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................................. WP 0224 TOPHANDLER HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................... WP 0225 FORKLIFT KIT HYDRAULIC HOSES AND FITTINGS REPLACEMENT.................................................... WP 0226 HYDRAULIC SYSTEM OIL FILTERS REPLACEMENT.............................................................................. WP 0227 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Reservoir Return Oil Filter Removal..................................................................... 0227-2 Reservoir Return Oil Filter Installation.................................................................................. 0227-3 Hydraulic Reservoir Breather Filter Installation.................................................................... 0227-4 Hydraulic System In-Line Filters and Filter Head Replacement........................................... 0227-5
HYDRAULIC SYSTEM VALVE MAINTENANCE......................................................................................... WP 0228 Figure 1. Figure 2. Figure 3. Figure 4. Pump Shut-Off Valve Removal............................................................................................ 0228-3 Shift Valve Removal............................................................................................................. 0228-5 Boom Support/Bogie Supply Valve Removal....................................................................... 0228-6 Boom Support/Bogie Supply Valve Installation.................................................................... 0228-7
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Servo Pressure Regulator Valve Removal........................................................................... 0228-9 Bogie/Boom Support Flow Control Valve Removal............................................................ 0228-11 Boom Support Locking Pin Check Valve Removal............................................................ 0228-12 Boom Support Locking Pin Check Valve Installation......................................................... 0228-13 Bogie Pressure Ball Valve Removal................................................................................... 0228-15 Extension Cylinder Over-Center Valve Replacement........................................................ 0228-17 Parking Brake Hold Flow Control Valve Removal.............................................................. 0228-18 Parking Brake Hold Flow Control Valve Installation........................................................... 0228-19 Brake Charging Valve Replacement.................................................................................. 0228-21 Brake Drain Shut-Off Valve Replacement.......................................................................... 0228-23 Brake Circuit Safety Regulating Valve Replacement......................................................... 0228-25 Front Brake Cooling Bypass Valve Replacement.............................................................. 0228-27 Rear Brake Cooling Bypass Valve Replacement............................................................... 0228-29 Cooling Fan Control Valve Removal.................................................................................. 0228-30 Emergency Steering Pressure Balancing Valve Removal................................................. 0228-33 Moderation and Tilt Manifold Valve Removal..................................................................... 0228-34 Tilt Over-Center Valve Removal......................................................................................... 0228-36 Tilt Over-Center Installation................................................................................................ 0228-37 Oscillation Over-Center Valve Installation.......................................................................... 0228-39 Oscillation Float Lock Flow Control Valve Removal........................................................... 0228-40 Twistlock Double Pilot Operated Check Valve Removal.................................................... 0228-42
LIFT CYLINDER CONTROL VALVE REPLACEMENT............................................................................... WP 0229 Figure 1. Lift Cylinder Control Valve Replacement.............................................................................. 0229-3
TOPHANDLER CONTROL VALVES REPLACEMENT............................................................................... WP 0230 Figure 1. Tophandler Control Valve Replacement.............................................................................. 0230-3
BOOM LIFT CYLINDER REPLACEMENT.................................................................................................. WP 0231 Figure 1. Boom Lift Cylinder Removal................................................................................................. 0231-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Boom Lift Cylinder Removal................................................................................................. 0231-3 Boom Lift Cylinder Removal................................................................................................. 0231-4 Boom Lift Cylinder Removal................................................................................................. 0231-5 Boom Lift Cylinder Installation.............................................................................................. 0231-6 Boom Lift Cylinder Installation.............................................................................................. 0231-7 Boom Lift Cylinder Installation.............................................................................................. 0231-7
CAB LIFTING CYLINDER REPLACEMENT................................................................................................ WP 0232 Figure 1. Cab Lifting Cylinder Replacement........................................................................................ 0232-3
CAB SLIDING CYLINDER REPLACEMENT............................................................................................... WP 0233 Figure 1. Cab Sliding Cylinder Replacement....................................................................................... 0233-2
BOGIE WHEEL LIFT CYLINDERS REPLACEMENT.................................................................................. WP 0234 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Cylinders Replacement........................................................................................ 0234-3 Hydraulic Cylinders Replacement........................................................................................ 0234-3 Hydraulic Cylinders Replacement........................................................................................ 0234-4 Hydraulic Cylinders Replacement........................................................................................ 0234-5
BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT............................... WP 0235 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Locking Pin Cylinder Removal............................................................................................. 0235-2 Locking Pin Cylinder Removal............................................................................................. 0235-3 Locking Pin Cylinder Removal............................................................................................. 0235-4 Locking Pin Cylinder Installation.......................................................................................... 0235-5 Locking Pin Cylinder Installation.......................................................................................... 0235-6 Locking Pin Cylinder Installation.......................................................................................... 0235-7
LOCKING PIN BUSHING REPLACEMENT................................................................................................ WP 0236 Figure 1. Figure 2. Figure 3. Figure 4. Frame Bushings Removal.................................................................................................... 0236-2 Frame Bushings Installation................................................................................................. 0236-3 Boom Support Bushings Removal....................................................................................... 0236-4 Boom Support Bushings Removal....................................................................................... 0236-5
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Boom Support Bushings Installation.................................................................................... 0236-6 Boom Support Bushings Installation.................................................................................... 0236-7 Boom Support Bushings Installation.................................................................................... 0236-8
TOPHANDLER TILT CYLINDERS REPLACEMENT.................................................................................. WP 0237 Figure 1. Tophandler Tilt Cylinder Replacement................................................................................. 0237-3
TOPHANDLER SIDESHIFT CYLINDERS REPLACEMENT....................................................................... WP 0238 Figure 1. Tophandler Sideshift Cylinder Replacement........................................................................ 0238-3
TOPHANDLER LEVELING CYLINDERS REPLACEMENT........................................................................ WP 0239 Figure 1. Tophandler Leveling Cylinder Removal............................................................................... 0239-3
TOPHANDLER TWISTLOCK CYLINDERS REPLACEMENT..................................................................... WP 0240 Figure 1. Tophandler Twistlock Cylinder Replacement....................................................................... 0240-3
TOPHANDLER TWISTLOCK REPLACEMENT.......................................................................................... WP 0241 Figure 1. Figure 2. Tophandler Twistlock Removal............................................................................................ 0241-2 Tophandler Twistlock Replacement..................................................................................... 0241-3
DRAINING AND FILLING HYDRAULIC RESERVOIR................................................................................ WP 0242 Figure 1. Figure 2. Draining Hydraulic Reservoir................................................................................................ 0242-2 Filling Hydraulic Reservoir.................................................................................................... 0242-3
HYDRAULIC RESERVOIR MAINTENANCE............................................................................................... WP 0243 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Hydraulic Reservoir Removal............................................................................................... 0243-3 Hydraulic Reservoir Removal............................................................................................... 0243-3 Hydraulic Reservoir Removal............................................................................................... 0243-4 Hydraulic Reservoir Removal............................................................................................... 0243-5 Hydraulic Reservoir Removal............................................................................................... 0243-6 Hydraulic Reservoir Removal............................................................................................... 0243-7 Hydraulic Reservoir Removal............................................................................................... 0243-7 Hydraulic Reservoir Removal............................................................................................... 0243-8 Hydraulic Reservoir Installation............................................................................................ 0243-9
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Page No. WP Sequence No. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Hydraulic Reservoir Installation............................................................................................ 0243-9 Hydraulic Reservoir Installation.......................................................................................... 0243-10 Hydraulic Reservoir Installation.......................................................................................... 0243-10 Hydraulic Reservoir Installation.......................................................................................... 0243-11 Hydraulic Reservoir Installation.......................................................................................... 0243-12 Hydraulic Reservoir Installation.......................................................................................... 0243-13 Hydraulic Reservoir Installation.......................................................................................... 0243-13 Hydraulic Reservoir Installation.......................................................................................... 0243-14
HYDRAULIC RESERVOIR SIGHT GAUGE REPLACEMENT.................................................................... WP 0244 Figure 1. Figure 2. Hydraulic Reservoir Sight Gauge Removal.......................................................................... 0244-1 Hydraulic Reservoir Sight Gauge Installation....................................................................... 0244-2
HYDRAULIC SYSTEM TEST POINT PROCEDURES................................................................................ WP 0245 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic System Test Points.............................................................................................. 0245-2 System Drain Valves............................................................................................................ 0245-3 Steering Accumulator Drain Valve....................................................................................... 0245-4 Engine Driven Pump Test Point........................................................................................... 0245-7
FORKLIFT CYLINDERS REPLACEMENT.................................................................................................. WP 0246 Figure 1. Forklift Cylinder Replacement.............................................................................................. 0246-3
RIFLE MOUNTING BRACKET REPLACEMENT........................................................................................ WP 0247 Figure 1. Figure 2. Figure 3. Rifle Mounting Bracket Removal.......................................................................................... 0247-1 Rifle Mounting Bracket Replacement................................................................................... 0247-2 Rifle Mounting Bracket Installation....................................................................................... 0247-3
AIR CONDITIONING SYSTEM MAINTENANCE........................................................................................ WP 0248 Figure 1. Figure 2. System Recovery................................................................................................................. 0248-3 Nitrogen Purging.................................................................................................................. 0248-5
AIR CONDITIONER LEAK TEST................................................................................................................ WP 0249 AIR CONDITIONING COMPRESSOR REPLACEMENT............................................................................ WP 0250
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Air Conditioner Compressor Removal.................................................................................. 0250-2 Air Conditioner Compressor Replacement........................................................................... 0250-3 Air Conditioner Compressor Installation............................................................................... 0250-4
AIR CONDITIONING COMPRESSOR DRIVE BELTS REPLACEMENT.................................................... WP 0251 Figure 1. Drive Belts Replacement...................................................................................................... 0251-3
AIR CONDITIONER HOSES REPLACEMENT........................................................................................... WP 0252 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Chassis A/C Hoses Removal............................................................................................... 0252-1 Chassis A/C Hoses Removal and Installation...................................................................... 0252-2 Chassis A/C Hoses Removal Replacement......................................................................... 0252-3 Chassis A/C Hoses Installation............................................................................................ 0252-3 Cab Rear A/C Hose Removal.............................................................................................. 0252-4 Cab Rear A/C Hose Removal.............................................................................................. 0252-5 Cab Rear A/C Hose Replacement....................................................................................... 0252-6 Cab Rear A/C Hose Installation........................................................................................... 0252-7 Cab Interior A/C Hoses Removal......................................................................................... 0252-8 Cab Interior A/C Hoses Removal......................................................................................... 0252-9 Cab Interior A/C Hoses Removal......................................................................................... 0252-9 Cab Interior A/C Hoses Removal....................................................................................... 0252-10 Cab Interior A/C Hoses Removal....................................................................................... 0252-11 Cab Interior A/C Hoses Replacement................................................................................ 0252-12 Cab Interior A/C Hoses Installation.................................................................................... 0252-13 Cab Interior A/C Hoses Installation.................................................................................... 0252-14 Cab Interior A/C Hoses Installation.................................................................................... 0252-15
AIR CONDITIONER CONDENSER REPLACEMENT................................................................................. WP 0253 Figure 1. Figure 2. Figure 3. Air Conditioner Condenser Removal.................................................................................... 0253-1 Air Conditioner Condenser Removal.................................................................................... 0253-2 Air Conditioner Condenser Replacement............................................................................. 0253-3
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Page No. WP Sequence No. Figure 4. Air Conditioner Condenser Installation................................................................................. 0253-4
AIR CONDITIONER RECEIVER/DRYER REPLACEMENT........................................................................ WP 0254 Figure 1. Figure 2. Figure 3. Air Conditioner Receiver/Dryer Removal............................................................................. 0254-1 Air Conditioner Receiver/Dryer Replacement...................................................................... 0254-2 Air Conditioner Receiver/Dryer Installation.......................................................................... 0254-3
AIR CONDITIONER FANS MAINTENANCE............................................................................................... WP 0255 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Condenser Fan Box Cover Removal.................................................................................... 0255-1 Air Conditioner Fan Replacement........................................................................................ 0255-2 Condenser Fan Box Cover................................................................................................... 0255-3 Relays Replacement............................................................................................................ 0255-4 Resistors Replacement........................................................................................................ 0255-5 Condenser Fan Box Cover Installation................................................................................. 0255-6
BOOM ASSEMBLY REPLACEMENT.......................................................................................................... WP 0256 Figure 1. Figure 2. Figure 3. Figure 4. Boom Assembly Removal.................................................................................................... 0256-2 Boom Assembly Removal.................................................................................................... 0256-3 Boom Assembly Installation................................................................................................. 0256-6 Boom Assembly Installation................................................................................................. 0256-7
BOOM AND TOPHANDLER CALIBRATION............................................................................................... WP 0257 Table 1. Figure 1. Table 2. Figure 2. Table 3. Figure 3. Table 4. Figure 4. Table 5. Range 600-800..................................................................................................................... 0257-2 Boom and Tophandler Calibration........................................................................................ 0257-2 Range 200-400..................................................................................................................... 0257-2 Boom and Tophandler Calibration........................................................................................ 0257-2 Range 200-400..................................................................................................................... 0257-3 Boom and Tophandler Calibration........................................................................................ 0257-3 Range 600-800..................................................................................................................... 0257-4 Boom and Tophandler Calibration........................................................................................ 0257-4 Range 35-150....................................................................................................................... 0257-5
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Page No. WP Sequence No. Figure 5. Table 6. Figure 6. Table 7. Figure 7. Table 8. Figure 8. Table 9. Table 10. Boom and Tophandler Calibration........................................................................................ 0257-5 Range 400-550..................................................................................................................... 0257-6 Boom and Tophandler Calibration........................................................................................ 0257-6 Range 500-650..................................................................................................................... 0257-7 Boom and Tophandler Calibration........................................................................................ 0257-7 Range 800-950..................................................................................................................... 0257-8 Boom and Tophandler Calibration........................................................................................ 0257-8 Load Check.......................................................................................................................... 0257-8 Boom Calibration Completed............................................................................................... 0257-9
BOOM ASSEMBLY WEAR PLATES (SLIDE PLATE) REPLACEMENT..................................................... WP 0258 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Boom Wear Plates Locations............................................................................................... 0258-2 Style A Wear Plate Removal................................................................................................ 0258-3 Style A Wear Plate Removal................................................................................................ 0258-4 Style A Wear Plate Installation............................................................................................. 0258-5 Style A Wear Plate Installation............................................................................................. 0258-6 Style B Wear Plate Removal................................................................................................ 0258-7 Style B Wear Plate Removal................................................................................................ 0258-8 Style B Wear Plate Removal................................................................................................ 0258-9 Style B Wear Plate Removal.............................................................................................. 0258-10 Style B Wear Plate Removal.............................................................................................. 0258-11 Style B Wear Plate Installation........................................................................................... 0258-12 Style B Wear Plate Installation........................................................................................... 0258-13 Style B Wear Plate Installation........................................................................................... 0258-14 Style B Wear Plate Installation........................................................................................... 0258-15 Style B Wear Plate Installation........................................................................................... 0258-16 Style C (RT 240V1 and RT 240V1R) Wear Plate Replacement........................................ 0258-17 Style D (RT 240V2 and RT 240V3 ONLY) Wear Plate Replacement................................ 0258-18
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Page No. WP Sequence No. TOPHANDLER REPLACEMENT................................................................................................................ WP 0259 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Tophandler Removal............................................................................................................ 0259-2 Tophandler Removal............................................................................................................ 0259-3 Tophandler Removal............................................................................................................ 0259-3 Tophandler Removal............................................................................................................ 0259-4 Tophandler Removal............................................................................................................ 0259-5 Tophandler Removal............................................................................................................ 0259-5 Tophandler Removal............................................................................................................ 0259-6 Tophandler Removal............................................................................................................ 0259-6 Tophandler Removal............................................................................................................ 0259-7 Tophandler Removal............................................................................................................ 0259-7 Tophandler Removal............................................................................................................ 0259-8 Tophandler Removal............................................................................................................ 0259-9 Tophandler Removal............................................................................................................ 0259-9 Tophandler Removal.......................................................................................................... 0259-10 Tophandler Installation....................................................................................................... 0259-10 Tophandler Installation....................................................................................................... 0259-11 Tophandler Installation....................................................................................................... 0259-11 Tophandler Installation....................................................................................................... 0259-12 Tophandler Installation....................................................................................................... 0259-13 Tophandler Installation....................................................................................................... 0259-13 Tophandler Installation....................................................................................................... 0259-14 Tophandler Installation....................................................................................................... 0259-14
SPREADER CHAIN MAINTENANCE.......................................................................................................... WP 0260 Figure 1. Figure 2. Figure 3. Access Panels Removal....................................................................................................... 0260-1 Protective Plate Removal..................................................................................................... 0260-2 Sliding Beam Removal from Main Beam.............................................................................. 0260-2
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Sliding Beam Reference Mark.............................................................................................. 0260-3 Chain Tensioner Removal.................................................................................................... 0260-3 Locking Plate Removal......................................................................................................... 0260-4 Chain Anchor Access........................................................................................................... 0260-5 Beam and Tensioner Locknut Removal............................................................................... 0260-5 Hydraulic/Electrical Hose Power Track Support Removal................................................... 0260-6 Chain Anchor Removal........................................................................................................ 0260-7 Position Slide Beam............................................................................................................. 0260-8 Assemble Chain Anchor....................................................................................................... 0260-9 Idler Shaft Locking Plate Installation.................................................................................... 0260-9 Chain Adjustment............................................................................................................... 0260-10 Chain Tension Adjustment................................................................................................. 0260-11 Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-12 Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-13
SPREADER 20 AND 40 FOOT ADJUSTMENT.......................................................................................... WP 0261 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Measurement and Adjustment - 20 Ft.................................................................................. 0261-1 Measurement and Adjustment - 20 Ft.................................................................................. 0261-2 Measurement and Adjustment - 20 Ft.................................................................................. 0261-3 Measurement and Adjustment - 20 Ft.................................................................................. 0261-3 Measurement and Adjustment - 40 Ft.................................................................................. 0261-4 Measurement and Adjustment - 40 Ft.................................................................................. 0261-4 Measurement and Adjustment - 40 Ft.................................................................................. 0261-5 Measurement and Adjustment - 40 Ft.................................................................................. 0261-5
SPREADER MAINTENANCE...................................................................................................................... WP 0262 Figure 1. Figure 2. Hydraulic Motor Replacement.............................................................................................. 0262-2 Gear Installation................................................................................................................... 0262-3
TOPHANDLER WEAR PLATES (SLIDE PLATE) REPLACEMENT............................................................ WP 0263
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Tophandler Wear Plate Locations........................................................................................ 0263-3 Tophandler Wear Plate Locations........................................................................................ 0263-4 Style A Wear Plate Removal................................................................................................ 0263-5 Style A Wear Plate Replacement......................................................................................... 0263-6 Style B Wear Plate Removal................................................................................................ 0263-7 Style B Wear Plate Removal................................................................................................ 0263-8 Style B Wear Plate Removal................................................................................................ 0263-9 Style B Wear Plate Removal.............................................................................................. 0263-10 Style B Wear Plate Installation........................................................................................... 0263-11 Style B Wear Plate Installation........................................................................................... 0263-12 Style B Wear Plate Installation........................................................................................... 0263-13 Style C Wear Plate Replacement....................................................................................... 0263-15 Style D Wear Plate Replacement....................................................................................... 0263-17 Style E Wear Plate Replacement....................................................................................... 0263-18
TOPHANDLER HYDRAULIC SPREADER MOTOR MAINTENANCE........................................................ WP 0264 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Tophandler Access Panels Removal................................................................................... 0264-2 Tophandler Access Panels Removal................................................................................... 0264-3 Chain Adjuster Measurement and Removal......................................................................... 0264-3 Tophandler Hydraulic Spreader Removal............................................................................ 0264-4 Tophandler Hydraulic Spreader Installation......................................................................... 0264-5 Chain Adjuster Installation and Measurement...................................................................... 0264-6 Access Panels Installation.................................................................................................... 0264-6 Access Panels Installation.................................................................................................... 0264-7
PREPARATION FOR ARCTIC OPERATION.............................................................................................. WP 0265 Figure 1. Twistlock Cylinder Bypass Valve.......................................................................................... 0265-2
PREPARATION FOR STORAGE OR SHIPMENT...................................................................................... WP 0266 ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS..................................................................... WP 0267
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Multi-Pin Connector Identifier............................................................................................... 0267-2 Multi-Pin Connector Identifier............................................................................................... 0267-3 Multi-Pin Connector Identifier............................................................................................... 0267-4 Multi-Pin Connector Identifier............................................................................................... 0267-5 Connector Repair................................................................................................................. 0267-6 Connector Repair................................................................................................................. 0267-6 Sealed Connector Repair..................................................................................................... 0267-7 Receptacle Connector Repair.............................................................................................. 0267-8 Waterproof Connector Repair.............................................................................................. 0267-9 Military Connector Repair................................................................................................... 0267-10 Ring Terminal Repair......................................................................................................... 0267-11 Wire Splicing...................................................................................................................... 0267-12 Electrical Ground Points..................................................................................................... 0267-13 Multimeter Usage............................................................................................................... 0267-14 Multimeter Usage............................................................................................................... 0267-15 Multimeter Usage............................................................................................................... 0267-16 Multimeter Usage............................................................................................................... 0267-17 Multimeter Usage............................................................................................................... 0267-18 Relay Inspection and Test.................................................................................................. 0267-19 Solenoid Inspection and Test............................................................................................. 0267-20
GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0268 Table 1. Table 2. Table 3. Table 4. Table 5. Boss Type O-rings................................................................................................................ 0268-7 Flat-Face Type O-rings........................................................................................................ 0268-8 O-ring/Retainer Type Fitting Seals....................................................................................... 0268-8 Split Flange Type O-rings..................................................................................................... 0268-8 Hydraulic Hose Torque Chart............................................................................................... 0268-9
ILLUSTRATED LIST OF MANUFACTURED ITEMS................................................................................... WP 0269
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Page No. WP Sequence No. Figure 1. Stud, Guide.......................................................................................................................... 0269-1
TORQUE LIMITS......................................................................................................................................... WP 0270 Figure 1. Table 1. Torque Patterns.................................................................................................................... 0270-2 Torque Limits........................................................................................................................ 0270-2
LOAD TESTING PROCEDURE................................................................................................................... WP 0271 Figure 1. Table 1. Figure 2. Figure 3. Figure 4. Table 2. Boom Cylinder Drift Test...................................................................................................... 0271-2 Reference Readings 1.......................................................................................................... 0271-3 Boom Cylinder Drift Test...................................................................................................... 0271-3 Extension Cylinder Drift Test................................................................................................ 0271-4 Extension Cylinder Drift Test................................................................................................ 0271-5 Reference Readings 2.......................................................................................................... 0271-5
SCHEMATICS............................................................................................................................................. WP 0272 Figure 1. Figure 1. Figure 1. Figure 2. Figure 2. Figure 2. Figure 2. Figure 2. Figure 3. Figure 3. Figure 4. Figure 4. Figure 4. Figure 4. Figure 5. ECS Display/CAN-BUS (A34647.0200). (Sheet 1 of 3) ...................................................... 0272-7 ECS Display/CAN-BUS (A34647.0200). (Sheet 2 of 3) ...................................................... 0272-8 ECS Display/CAN-BUS (A34647.0200). (Sheet 3 of 3) ...................................................... 0272-9 ECS Electrical Servo (A34648.0200). (Sheet 1 of 5) ........................................................ 0272-10 ECS Electrical Servo (A34648.0200). (Sheet 2 of 5) ........................................................ 0272-11 ECS Electrical Servo (A34648.0200). (Sheet 3 of 5) ........................................................ 0272-12 ECS Electrical Servo (A34648.0200). (Sheet 4 of 5) ........................................................ 0272-13 ECS Electrical Servo (A34648.0200). (Sheet 5 of 5) ........................................................ 0272-14 ECS Engine (A34648.0200). (Sheet 1 of 2) ...................................................................... 0272-15 ECS Engine (A34648.0200). (Sheet 2 of 2) ...................................................................... 0272-16 ECS Transmission (A34650.0200). (Sheet 1 of 4) ............................................................ 0272-17 ECS Transmission (A34650.0200). (Sheet 2 of 4) ............................................................ 0272-18 ECS Transmission (A34650.0200). (Sheet 3 of 4) ............................................................ 0272-19 ECS Transmission (A34650.0200). (Sheet 4 of 4) ............................................................ 0272-20 ECS Steering (A34651.0200). (Sheet 1 of 7) .................................................................... 0272-21
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Page No. WP Sequence No. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 6. Figure 6. Figure 6. Figure 6. Figure 6. Figure 6. Figure 7. Figure 7. Figure 8. Figure 8. Figure 8. Figure 8. Figure 9. Figure 10. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 14. Figure 14. ECS Steering (A34651.0200). (Sheet 2 of 7) .................................................................... 0272-22 ECS Steering (A34651.0200). (Sheet 3 of 7) .................................................................... 0272-23 ECS Steering (A34651.0200). (Sheet 4 of 7) .................................................................... 0272-24 ECS Steering (A34651.0200). (Sheet 5 of 7) .................................................................... 0272-25 ECS Steering (A34651.0200). (Sheet 6 of 7) .................................................................... 0272-26 ECS Steering (A34651.0200). (Sheet 7 of 7) .................................................................... 0272-27 ECS Attachment to Tophandler (A34652.0200). (Sheet 1 of 6) ........................................ 0272-28 ECS Attachment to Tophandler (A34652.0200). (Sheet 2 of 6) ........................................ 0272-29 ECS Attachment to Tophandler (A34652.0200). (Sheet 3 of 6) ........................................ 0272-30 ECS Attachment to Tophandler (A34652.0200). (Sheet 4 of 6) ........................................ 0272-31 ECS Attachment to Tophandler (A34652.0200). (Sheet 5 of 6) ........................................ 0272-32 ECS Attachment to Tophandler (A34652.0200). (Sheet 6 of 6) ........................................ 0272-33 Hydraulics (A34654.0200). (Sheet 1 of 2) ......................................................................... 0272-34 Hydraulics (A34654.0200). (Sheet 2 of 2) ......................................................................... 0272-35 Current Supply (A34738.0200). (Sheet 1 of 4) .................................................................. 0272-36 Current Supply (A34738.0200). (Sheet 2 of 4) .................................................................. 0272-37 Current Supply (A34738.0200). (Sheet 3 of 4) .................................................................. 0272-38 Current Supply (A34738.0200). (Sheet 4 of 4) .................................................................. 0272-39 Shifting (A34739.0200). (Sheet 1 of 1) .............................................................................. 0272-40 Sender (A34740.0200). (Sheet 1 of 2) .............................................................................. 0272-41 Sender (A34740.0200). (Sheet 2 of 2) .............................................................................. 0272-42 Wipers (A34741.0200). (Sheet 1 of 1) ............................................................................... 0272-43 AC and Fan (A34742.0200). (Sheet 1 of 1) ....................................................................... 0272-44 Cab (A34743.0200). (Sheet 1 of 1) ................................................................................... 0272-45 Lights (A34744.0200). (Sheet 1 of 5) ................................................................................ 0272-46 Lights (A34744.0200). (Sheet 2 of 5) ................................................................................ 0272-47 Lights (A34744.0200). (Sheet 3 of 5) ................................................................................ 0272-48
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Page No. WP Sequence No. Figure 14. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Lights (A34744.0200). (Sheet 4 of 5) ................................................................................ 0272-49 Lights (A34744.0200). (Sheet 5 of 5) ................................................................................ 0272-50 Work Lights (A34745.0200). (Sheet 1 of 1) ....................................................................... 0272-51 Auxiliary Pump (A34746.0200). (Sheet 1 of 1) .................................................................. 0272-52 Auto Lubrication (A48665.0100). (Sheet 1 of 1) ................................................................ 0272-53 Information (A34749.0200). (Sheet 1 of 2) ........................................................................ 0272-54 Information (A34749.0200). (Sheet 2 of 2) ........................................................................ 0272-55 Steering System................................................................................................................. 0272-56 Brake System..................................................................................................................... 0272-57 Main System....................................................................................................................... 0272-58 Tophandler System............................................................................................................ 0272-59 Autolube System Tubing Layout........................................................................................ 0272-60 Electrical Symbols.............................................................................................................. 0272-61 Hydraulic Symbols.............................................................................................................. 0272-62
Chapter 6 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0273 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.............................................................. WP 0274 MAINTENANCE ALLOCATION CHART FOR THE RTCH.......................................................................... WP 0275 Table 1. Table 2. Table 3. Maintenance Allocation Chart (MAC)................................................................................... 0275-1 Tools and Test Equipment................................................................................................. 0275-24 Remarks............................................................................................................................. 0275-27
EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0276 Table 1. Expendable and Durable List for the RTCH......................................................................... 0276-1
TOOL IDENTIFICATION LIST..................................................................................................................... WP 0277 Table 1. Tool Identification List........................................................................................................... 0277-1
MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0278 Table 1. Index Mandatory Replacement Parts List...................................................................................... 0278-1
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HOW TO USE THIS MANUAL
INTRODUCTION 1. This manual is designed to help you perform Field level Maintenance and Troubleshooting on all variants of the RT 240 Rough Terrain Container Handler (RTCH). For model-specific information, see matrix below: RT 240V1 (NSN 3930-01-473-3998) S/N range T34112.0003 to T35112.0373 RT 240V1R (NSN 3930-01-473-3998) S/N range T34112.0003(R) to T35112.0373(R) RT 240V2 (NSN 3930-01-522-7364, and 3930-01-473-3889) S/N range T5112.0401 to T35112.0742 RT 240V3 (NSN 3930-01-522-7364, and 3930-01-473-3889) S/N range S112.00801 to current
NOTE
RT 240V2 and V3 models are identical, the only difference between the two models, are the RT 240V3 machines were built in the United States. Any models that have been reset will have one or more "R" stamped at the end of their S/N or the RESET date will be stamped in the Data plate. For model specific information, the configuration name (RT 240V1, RT 240V1R, RT 240V2/3) will be specified in the task title in parentheses (for maintenance tasks) and in the table/errors code title in parentheses (for Troubleshooting procedures). If there is no designation, the task/troubleshooting procedure applies to all models.
2. The Repair Parts and Special Tools List (RPSTL), TM 10-3930-675-24P, is to be used in conjunction with this manual to locate and obtain the repair parts and special tools needed to maintain this equipment. 3. This manual is written in Work Package format: a. Chapters divide the manual into major categories of information (e.g., General Information, Theory of Operation, Troubleshooting Procedures, Maintenance Instructions, and Supporting Information). b. Each Chapter is divided into Work Packages, which are identified by a 4-digit number (e.g., 0001, 0002) located on the upper right-hand corner of each page. The Work Package page number (e.g., 0001-1, 0001-2) is located centered at the bottom of each page. c. If a Change Package is issued to this manual, added Work Packages use the 5th and 6th digits of their number to indicate new material. For instance, Work Packages inserted between WP 0001 and WP 0002 are numbered WP 0001 01, WP 0001 02, etc. 4. This manual is published in two volumes: Volume I covers Chapters 1 and 2, Work Packages 0001 through WP 0048 and includes all troubleshooting, Chapter 6: Supporting Information is included in Volumes I and II. Volume II includes Chapters 3 through 6, WP 0049 through WP 0292. 5. Scan through this manual to become familiar with its organization and contents before attempting to maintain the equipment.
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HOW TO USE THIS MANUAL - Continued
CONTENTS OF THIS MANUAL 1. A Warning Summary is located at the beginning of each volume of the manual. Become familiar with these warnings before operating or performing troubleshooting or maintenance on the vehicle. 2. A Table of Contents in Volume I lists the contents of Volumes I and II. The Table of Contents in Volume II lists the contents of Volume II only. a. The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA Form 2028 addresses, for the submittal of corrections to the manual. b. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual. The alphabetical Index for each volume lists only those Work Packages found in that volume. 3. Chapter 1, General Information, Equipment Description, and Theory of Operation, provides general information on the manual and the equipment. 4. Chapter 2, Troubleshooting Procedures, contains all applicable troubleshooting and a complete listing of Error Codes resident on the RTCH. 5. a. Before attempting to perform troubleshooting, carefully read the information in WP 0004, Troubleshooting Introduction. It explains how to perform both non-error code and error code-driven troubleshooting. Included at the end of this Work Package are locator diagrams of all electrical and hydraulic components that may be hard to locate. b. The error code reference index in WP 0004 provides a numerical list of error codes. c. The Troubleshooting Symptom Index in WP 0005 is divided into three sections. The first is an Alphabetical Error Code Symptom Index", the second is a Numerical Error Code Symptom Index", and the third is a Non-Error Code Symptom Index". d. The corrective action for certain malfunctions is to notify SRA". Refer to Table 3 in the Maintenance Allocation Chart (MAC) (Volume 2, WP 0275) for further information about the Specialized Repair Activity for the RTCH. 6. Chapter 3 covers all Maintenance Instructions. In each chapter, work packages are organized in the same Functional Group Code (FGC) sequence as the MAC found in Chapter 6 of both volumes. 7. Chapter 6 includes Supporting Information: References, MAC Introduction, MAC, Expendable and Durable Items List, Load Testing Procedure, and Foldouts of Hydraulic Systems. 8. An alphabetical index completes the manual. FEATURES OF THIS MANUAL 1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid. 2. a. WARNING indicates a hazard which may result in death or serious injury to personnel. b. CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment. c. NOTE is a statement containing information that will make the procedures easier to perform. 3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis. 4. Within a procedural step, reference may be made to another Work Package in this manual or to another manual. These references indicate where you should look for more complete information. 5. a. If you are told: Replace engine ECU (WP 0079)", go to the Table of Contents in Volume II of this manual for instructions on replacing the engine ECU. Be sure to read the Initial Setup" on page 1 of the Work Package, to determine contents of Work Package as well as information regarding tools and equipment, spare parts, and personnel required, etc. b. If you are told: Check coolant level (TM 10-3930-675-10)", go to TM 10-3930-675-10. Use the Table of Contents or alphabetical Index in TM 10-3930-675-10 to find the procedure.
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HOW TO USE THIS MANUAL - Continued

FEATURES OF THIS MANUAL - Continued 6. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art may be text or numbers, whichever method is easier for the soldier. 7. Numbers located at lower right corner of art (e.g., 350-001; 434-0002) are art control numbers and are used for tracking purposes. Disregard these numbers. 8. Dashed leader lines used in illustrations indicate that called out items are not visible in the view depicted (i.e., they are located within or behind the structure). 9. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual.
NOTE
If at any time you are unsure how to use this manual or you cannot locate the information you need, notify your Supervisor.
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TM 10-3930-675-23-1
CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
TM 10-3930-675-23-1
0001
FIELD MAINTENANCE GENERAL INFORMATION
SCOPE 1. Type of Manual. This manual is designed for use in performing field maintenance and troubleshooting on the Rough Terrain Container Handler (RTCH) (all models).
NOTE
RT 240V2 and RT 240V3 models are identical; the only difference between the two models is that the RT 240V3 machines were built in the United States. Any models that have been reset will have one or more "R" stamped at the end of their S/N or the RESET date will be stamped in the Data plate. RT 240V1 (NSN 3930-01-473-3998) S/N range T34112.0003 to T35112.0373 RT 240V1R (NSN 3930-01-473-3998) S/N range T34112.0003(R) to T35112.0373(R) RT 240V2 (NSN 3930-01-522-7364, and 3930-01-473-3998) S/N range T5112.0401 to T35112.0742 RT 240V3 (NSN 3930-01-522-7364, and 3930-01-473-3998) S/N range S112.00801 to current 2. Purpose of Equipment. The RTCH (all models) is designed to lift and stack 20 and 40 ft International Standard Organization (ISO) containers, loaded to a gross weight of 53,000 lb (24,062 kg). MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for the equipment will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your RTCH set needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about the equipment. Let us know why you do not like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to http://www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm. The Internet form lets you submit a Product Quality Deficiency Report (PQDR). You may also submit your information using an SF Form 368, Product Quality Deficiency Report. You can send your SF 368 via e-mail, regular mail, or facsimile directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSRD-TAR-E/PDQR, MS 268, 6501 E. 11 mile Road, Warren, MI 48397-5000. The e-mail address is dami_tacomdrs@conus.army.mil. The fax number is DSN 786-5666 or Commercial 586-282-5666.
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0001
CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. OZONE DEPLETING SUBSTANCES Listing to be provided by requiring activity. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use, refer to TM 750-244-6. PREPARATION FOR STORAGE OR SHIPMENT For preparation for storage or shipment procedures, refer to TM 10-3930-675-10. WARRANTY INFORMATION The vehicles are warranted by Kalmar RT in accordance with TB 10-3930-675-14. Warranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defects in material or workmanship to your Supervisor, who will take appropriate action. LIST OF ABBREVIATIONS/ACRONYMS
NOTE
Refer to ASME Y14.38 for standard abbreviations. Table 1. List of Abbreviations/Acronyms. ABBREVIATIONS/ACRONYMS DEFINITION AAL BII C CAN-BUS CBRN CID cm Additional Authorization List Basic Issue Items Centigrade or Celsius Controller Area Network-BUS Chemical, Biological, Radiological and Nuclear Cubic Inch Displacement Centimeter 0001-2
TM 10-3930-675-23-1
0001
LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. List of Abbreviations/Acronyms - Continued.
ABBREVIATIONS/ACRONYMS DEFINITION COEI CPC ECM ECS ECU EEPROM F FGC ft GCWR GVWR IETM hp in ISO kg km kPa kph kW L lb lb-ft lph Components of End Item Corrosion Prevention and Control Electronic Control Module Electronic Control System Electronic Control Units Electrically-Erasable Programmable Read-Only Memory Fahrenheit Functional Group Code Feet Gross Combination Weight Rating Gross Vehicle Weight Rating Interactive Electronic Technical Manual Horsepower Inch International Standards Organization Kilogram Kilometer Kilopascal Kilometers per Hour Kilowatt Liter Pound Pound Foot Liters per Hour
0001-3
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0001
LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. List of Abbreviations/Acronyms - Continued.
ABBREVIATIONS/ACRONYMS DEFINITION m MAC mm mph NATO Nm OEM PMCS PTO RTCH SOP SPORT SRA TAMMS ULLS-G V yd QUALITY OF MATERIAL Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of material requirements are not stated in this manual, the material must meet the requirements for the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment. END OF WORK PACKAGE Meter Maintenance Allocation Chart Millimeter Mile Per Hour North Atlantic Treaty Organization Newton Meter Original Equipment Manufacturer Preventive Maintenance Checks and Services Power Take-Off Rough Terrain Container Handler Standard Operating Procedure Soldiers Portable On-System Repair Tool Specialized Repair Activity The Army Maintenance Management System Unit Level Logistics System - Ground Volt(s) Yard
0001-4
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0002
FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 1. Characteristics. a. The Rough Terrain Container Handler (RTCH) is designed to lift, move, stack, or unstack 20 and 40 ft (6.10 to 12.19 m) by 8 ft (2.44 m) wide ISO containers. b. The RTCH has a lift capacity of 53,000 lb (24,040 kg) and operates on hard and/or unimproved surfaces, to include beach operations. c. The RTCH can be utilized as a forklift with an operator-installed forklift kit. 2. Capabilities and Features. a. Capabilities. (1) Container handling capabilities: Stack or unstack 8 ft (2.44 m) high ISO containers stacked three (3) high with a gross weight of 53,000 lb (24,040 kg) in the first row. Stack or unstack 8 ft (2.44 m) high ISO containers stacked three (3) high with a gross weight of 27,500 lb (12,474 kg) in the second row. Stack or unstack 4.3 ft (1.31 m) high ISO containers stacked seven (7) high. Container tophandler adjusts to 20 or 40 ft (6.10 to 12.19 m) ISO container lengths. Container tophandler oscillates 7 degrees left and right. Container tophandler rotates 195 degrees clockwise and 105 degrees (145 degrees for RT 240V2 and RT 240V3) counterclockwise. Container tophandler tilts 8 degrees forward and 12 degrees to the rear. Container tophandler side shifts 15 in. ( 381 mm) from the center. (2) Forklift kit is operator-installed and attaches to the tophandler. The forktines are adjustable from 24 in. (61cm) center-to-center to 81.5 in. (207 cm) center-to-center. Lift capacity is 44,000 lb (19,958 kg). (3) Maximum speed of RTCH is 23 mph (37 kph) on level ground with NO LOAD; maximum speed on level ground LOADED is 15 mph (24 kph). (4) Maximum fording depth is 60 in. (1.52 m). (5) Operation in temperatures from -25F (-32C) to +125F (+52C), and to -40F (-40C) with arctic kit installed. b. Features. (1) Electronically-controlled 400 hp, six-cylinder turbocharged engine. (2) Electronic semi-automatic shift controlled transmission with 4 ranges forward and 3 reverse. Operator selects range and ECM controls shift points. (3) The drive axles provide traction for 2-wheel or 4-wheel drive. (4) Limited slip differentials and multi-disc wet brakes are an integral part of the axle assemblies. Multi-disc wet brakes are hydraulically cooled to prevent overheating. Accumulators store energy for the emergency braking system. (5) The steering system is capable of 2-wheel, 4-wheel, crab, and emergency modes of operation. (6) The parking brake is hydraulically released and spring-applied by disc brake assemblies mounted on the front and rear differentials. (7) The operator's cab has a fully adjustable operator's seat, fresh air (filtered) ventilation system, and heater/defroster/air conditioning systems. (8) Operator's controls include: adjustable steering wheel; accelerator and brake pedals; transmission range selector; steering mode selection rocker switches; and a single joystick control for all boom, tophandler, and forklift operations.
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0002
c.
Transport Modes.
NOTE
Refer to TM 10-3930-675-10 for detailed instructions to prepare the RTCH for transport. Self Deployment Highway Transport Rail Transport Marine Transport Air Transport
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

2 3 4 5 1
G0007JCH
Figure 1. Table 1. KEY 1 COMPONENT Tophandler
Major Components.
Description of Major Components
DESCRIPTION Electro-hydraulically operated 20 to 40 ft (6.10 to 12.19 m) tophandler. Capable of sideshifting, rotation, forward/rear tilting, left/right tilting, and load position leveling and locking. Also interfaces with forklift attachment. Electro-hydraulically operated heavy duty steel boom designed for moving, lifting, and stacking 20 to 40 ft (6.10 to 12.19 m) ISO containers. Electro-hydraulically operated cylinders raise, lower, and support the boom assembly. Contains all driving and container handling controls as well as heating, air conditioning, and filtered ventilation system controls. During air transport operations, the cab is moved to the left side of the chassis, then lowered and secured in place.
Boom Assembly
Boom Lift Cylinders
Operator's Cab
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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 1. KEY 5 COMPONENT Boom Support Description of Major Components - Continued DESCRIPTION Rear support and pivot point for the boom to include an unlocking device that allows the boom assembly to be lowered into the transport position. A heavy-duty steel construction with tie-downs, towing lugs, and pintle hook. Location of selected hydraulic remote controls. Also access to hydraulic system test and sampling ports.
Frame
Remote Hydraulic Control Compartment
12
11
10
8
G0005JCH
Figure 2. Table 2. KEY 8 COMPONENT Dolly Wheels Storage Compartment Master Battery Switch
Major Components.
DESCRIPTION Storage location for the attachable tophandler air transport dolly wheels.
ON/OFF control of electrical power from batteries to vehicle electrical system. Provides an electrical connection for slave starting. A receptacle is located on each side of the RTCH. Stores four 12V batteries and required cabling. Batteries are accessible from the side and/or the top. Electro-hydraulically operated and monitored ISO twistlocks, located at each corner of the tophandler. Also utilized to attach forklift attachment to tophandler.
10
Slave Receptacle
11
Battery Compartment
12
Twistlocks
0002-3
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0002
13 18 20 19 17 16 15 14 10
G0006JCH
Figure 3. Table 3. KEY 13 COMPONENT Front Service and Blackout Lights Coolant Expansion Tank
Major Components.
DESCRIPTION Headlight, blackout drive light, and composite turn signal with blackout markers. Contains cooling system overflow. Provides means to visually check coolant level and add coolant to system. Houses the six-cylinder turbocharged diesel engine that supplies power for the automotive, electrical, and hydraulic systems. Stores and vents system hydraulic oil. Visual indicator of hydraulic oil level. If oil is NOT visible in sight gauge with boom completely lowered and tophandler retracted, DO NOT start engine. Stores fuel supply for vehicle. Composite tail, stop, and blackout markers; turn signals; and backup lights. Allow weight of machine to be distributed over more wheel area during aircraft loading and transport.
14
15
Engine Compartment
16 17
Hydraulic Reservoir Hydraulic Reservoir Sight Gauge
18 19
Fuel Tank Rear Service and Blackout Lights Bogie Wheels
20
0002-4
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0002
EQUIPMENT DATA Engine: Manufacturer Model Horsepower @ 2,150 RPM Torque @ 1,200 RPM Cylinders Displacement Weight Fuel System Cooling System, Thermostat Range NOTE RT 240V1R machines will either use 6WG-260 or 4WG-310 depending on what they received during RESET. Transmission: Manufacturer Model RT 240V1 Model RT 240V2 and RT 240V3 Type Range Selection ZF-Hydromedia 6WG-260 4WG-310 4 forward and 3 reverse speeds Automatic, electronically controlled Cummins QSM 11 400 hp (298 kW) 1,450 lb-ft (1,966 Nm) 6 661 CID (10.8 L) 2,070 lb (940 kg) Fully electronic 180 to 200F (82 to 93C)
0002-5
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EQUIPMENT DATA - Continued Axles: Manufacturer Model: Front (RT 240V1, RT 240V1R, and RT 240V2) Rear (RT 240V1, RT 240V1R, and RT 240V2) Front (RT 240V3) Rear (RT 240V3) Weight: Front Rear Tires: Front and Rear: Manufacturer Size Inflation Weight RT 240V1 Weight RT 240V1R, RT 240V2, and RT 240V3 Bogie Wheels (Transport Operations): Manufacturer Size Inflation Dolly Wheels (Tophandler Transport): Manufacturer Size Inflation Michelin 225/75 R 10 XZR 85 psi (586 kPa) Michelin 355/65 R 15 XZM 85 psi (586 kPa) Bridgestone 29.5 35 Series 85 psi (586 kPa) 2,315 lb (1,050 kg) 2,750 lb (1,247 kg) 8,379 lb (3,800 kg) 5,733 lb (2,600 kg) LT102PL341/528NLB4650 Kessler
LT102PL341/528NLB4460
LT102PL341/528NLB5550 LT102PL341/528NLB4460-1
0002-6
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EQUIPMENT DATA - Continued Dimensions: Length: Tophandler Lateral Tophandler Longitudinal Height: Operational w/Boom Level Highway Transport Mode Width, Tophandler Longitudinal Weights: GVWR w/All Fluids RT 240V1 GVWR w/Forklift Kit RT 240V1 GVWR Operational w/All Fluids (RT 240V1R, RT 240V2, and RT 240V3) GVWR Operational w/Forklift Kit and/all Fluids (RT 240V1R, RT 240V2, and RT 240V3) Capacities: Fuel Tank Cooling System Cooling, Engine Only Hydraulic Oil Reservoir Engine Crankcase w/Filter Transmission w/Filter Electrical System: Type Battery Manufacturer Model Hawker, Armasafe Plus Armasafe Plus Battery 24V, negative ground 103 gal. (390 L) 23.7 gal. (90.1 L) 3.4 gal. (12.9 L) 180 gal. (680 L) 38.6 qt (36.5 L) 36 qt (34 L) 118,000 lb (53,524 kg) 128,400 lb (58,241 kg) 118,500 lb (53,751 kg) 13.1 ft (4.0 m) 9.8 ft (3.0 m) 12 ft (3.66 m) 37.7 ft (11.0 m) 49.2 ft (15.0 m)
130,050 lb (58,990 kg)
0002-7
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EQUIPMENT DATA - Continued Voltage Plates per cell Rating Cold Cranking Amps (CCA SAE) Mass Number of batteries per vehicle Temperature at time of full charge Miscellaneous: Maximum Lifting Capacity: First Stacking Row Second Stacking Row Maximum Lift Height Maximum Lifting Capacity, w/Forklift Kit: First Stacking Row Second Stacking Row Maximum Lift Height, w/Forklift Kit 44,000 lb (19,958 kg) 24,600 lb (11,158 kg) 21.8 ft (6.65 m) 53,000 lb (24,040 kg) 27,500 lb (12,474 kg) 33 ft (10.06 m) 12V 6 Cell lead acid 120 A/h, electrical capacity 1,225 Amps per battery 86 lb (39 kg) 4 68 F (20 C)
Forklift Kit, Fork Tines Center-to-Center Range 24 to 81.5 inch (61 to 207 cm) Maximum Forward Reach (Boom Level) Curb-to-Curb Turning Circle: 4-Wheel Steering Ground Clearance Fording Depth Maximum Travel Speeds: Empty Loaded 23 mph (37 kph) 15 mph (24 kph) 65 ft (19.8 m) 18 inch (45.7 cm) 60 inch (1.5 m) 20.6 ft (6.28 m)
END OF WORK PACKAGE
0002-8
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0003
FIELD MAINTENANCE THEORY OF OPERATION
INTRODUCTION 1. The Rough Terrain Container Handler (RTCH) consists of the following major components and functional systems: drive train, fuel system, exhaust system, cooling system, electrical and electronic systems, steering and brake systems, hydraulic system, cab system, and lifting boom with tophandler. A forklift kit may be added as required. 2. This work package explains how the components and systems of the RTCH work together. A functional description is provided for each major component and system. DRIVE TRAIN 1. The engine is a six-cylinder turbocharged diesel which supplies power to the transmission. The engine cooling system is pressurized and includes a thermostat, controlled bypass, and coolant expansion tank. Engine lubrication is pressurized and full-flow filters continuously clean oil. 2. The transmission is a semi-automatic electronically-controlled unit. The operator electronically selects range of gears and the transmission electronic control module (ECM) controls shift points up to the highest selected gear. A shift inhibitor circuit controls downshifts in forward and reverse gears. The transmission can be manually or electronically shifted through 4 forward and 3 reverse gears. A torque converter provides interface to the engine. 3. The driveshafts transmit rotation of the transmission output to the front and rear axles. Connections at both ends are made through universal joints to compensate for any misalignment due to operating on uneven surfaces. 4. The front and rear axles are identical in operating principles. Both axles are hydraulically steered with planetary wheel ends and wet-disc brakes. The rear axle oscillates above and below horizontal to allow for operation on uneven surfaces. FUEL SYSTEM 1. Fuel to power the engine is pumped from the fuel tank by a fuel transfer pump to the electronically controlled fuel injector nozzles. 2. The engine ECM manages, monitors, and stores key engine functions, to include engine idle speed, limits maximum engine speed, and engine diagnostic data. 3. The engine-mounted fuel/water separator is a spin-on replaceable type with drain. EXHAUST SYSTEM The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow into exhaust pipes and muffler to the atmosphere along the right side and to the rear of the operator's cab. COOLING SYSTEM 1. The cooling system consists of an engine-mounted circulating pump, 180 to 200F (82 to 93C) thermostat, oil cooler/aftercooler manifolds, a radiator, engine-mounted coolant filter, and hydraulically-driven cooling fan. 2. The cooling system cools the engine by means of circulating pressurized ethylene glycol-based coolant through the engine and radiator.
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ELECTRICAL SYSTEM 1. The system voltage is 24V. Four 12V batteries, connected in series-parallel and charged by an alternator across electronic rectifying and voltage stabilization circuits, provide the voltage. 2. The negative and positive poles are both connected across the master battery switch. The negative pole is connected to the chassis. 3. NATO slave-starting receptacles are provided. STEERING SYSTEM 1. The electro-hydraulic steering system provides three modes of steering control: 2-wheel steer, 4-wheel steer, and crab steer. 2. The variable rate steering system utilizes two front and two rear hydraulic steering cylinders and electronic wheel position sensors connected to an ECM to maintain direction and control. The variable rate system allows the system to change or adjust to different modes of operation. 3. An emergency steering pump is provided in the event the engine is inoperative. If the engine quits while operating the RTCH, the emergency steering pump provides sufficient hydraulic pressure to control the RTCH until it is brought to a safe stop. BRAKE SYSTEM 1. The brakes are totally enclosed within the front and rear drive axle housings, next to the wheel ends. 2. The brake system is a wet brake system that is comprised of three separate hydraulic circuits: service brake circuit, cooling circuit, and parking brake circuit. 3. The brake system also includes six pressurized accumulators that provide adequate stored energy to stop the RTCH in the event of engine shutdown. 4. The service brake circuit is applied by depressing either the left or right floor-mounted hydraulic brake pedals. Brake pressure is applied to eight cylinders per side within the front axle and one cylinder per side in the rear axle. 5. The brake system cooling circuit cools the brake disks using oil pumped from the main hydraulic system through brake chambers during operation. 6. The parking brake assemblies are mounted at the input flanges of the front and rear axles. The brakes are applied by spring pressure and released hydraulically. A warning buzzer sounds if the driver leaves the seat without applying the parking brakes. The parking brake should never be applied as an emergency brake or while the vehicle is moving. Application of the parking brake while the vehicle is moving can result in major drive train damage. HYDRAULIC SYSTEM 1. The RTCH hydraulic system is comprised of the following major components that provide hydraulic power to operate and control the container tophandler, boom, steering, and brake systems. In addition the hydraulic system is used to place the cab and bogie wheels into transport mode. a. Three variable piston-type hydraulic pumps are driven by the transmission power take-off (PTO). The pumps provide hydraulics for the steering system and tophandler. b. One double vane-type pump is driven by the transmission PTO. It provides hydraulics for the boom cylinders, service, and parking brake systems. c. One single-vane pump is driven by the engine. It provides hydraulics for a cooling fan. d. Main valves control the main hydraulics. The valves are controlled by an electro-hydraulic servo system from the joystick control in the operator's cab. e. High-pressure oil filters clean hydraulic oil before returning oil to the reservoir. Breather filters allow venting of the hydraulic reservoir. f. Hydraulic system oil cooler and fan maintain and control hydraulic oil temperature. The cooling fan is powered by hydraulics from an engine-driven hydraulic pump. g. Emergency systems: one ground-driven hydraulic pump maintains steering control in the event of engine failure; a 24V electric hydraulic pump provides power to lower boom and release the twist
0003-2
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HYDRAULIC SYSTEM - Continued locks in the event of engine failure. The electric pump also provides a means to place the operator's cab into the transport mode. CAB SYSTEM 1. The operator's cab is a sound and weather insulated unit that provides the operator with the systems to control and monitor both standard automotive functions and container handling functions. The following components or systems are also contained within the cab: a. Adjustable steering column and adjustable suspension seat. b. Heater, air conditioning, and filtered ventilation system. c. Portable fire extinguisher and rifle mount. AIR CONDITIONING SYSTEM The air conditioning system unit is part of the heater and is mounted at the front of the cab. It is a single unit consisting of a heater core, air conditioning evaporator coil, blower motor, control valves, and air ducts. The system is turned on by the air conditioning control switch on the instrument panel in the cab. The three-speed blower switch controls flow rate. An even cab temperature is maintained by using the air conditioner temperature control switch to control the refrigerant flow through the evaporator coil. ELECTRONIC SYSTEM The RTCH is equipped with several electronic modules, all connected using CAN-BUS technology. The modules can be diagnosed using the OEM testing equipment. They assist in the operation of major systems such as engine, transmission shifting, steering mode and wheel position, the safe working load control, and many related functions that require data input to operate correctly for the intended uses of the RTCH. LIFTING BOOM AND TOPHANDLER The lifting boom and tophandler is an electro-hydraulic operated heavy-duty telescoping boom and spreader assembly, designed to lift, move, and stack/unstack 20 to 40 ft (6.10 to 12.19 m) ISO containers. The operator joystick provides complete control of the lifting boom and tophandler during container handling operations. The boom provides lifting/lowering, extending/retracting operations. The tophandler or spreader provides for sideshifting, rotation, forward/rear tilting, left/right tilting, and load leveling and locking operations. The tophandler also provides interface capability with a forklift attachment. FORKLIFT KIT The forklift kit is attached to the tophandler twistlocks and two hydraulic hose quick-disconnects. Forklift operation is controlled from the tophandler joystick to include adjustable forktines. The forktines and vertical support beams fold under the forklift framework for transport. END OF WORK PACKAGE
0003-3/4 blank
TM 10-3930-675-23-1
CHAPTER 2 TROUBLESHOOTING PROCEDURES
TM 10-3930-675-23-1
0004
FIELD MAINTENANCE ERROR CODE REFERENCES
EXPLANATION OF ERROR CODE DISPLAY
NOTE
There are three kinds of information in the Electronic Control System (ECS) display 1. Icons in the lower left corner of the display describe what the driver should do. Table 1 defines each of the three driver actions. Table 1. Driver Action Icons. ICON DESCRIPTION STOP VEHICLE IMMEDIATELY in a safe way. Can be a safety issue. Machine performance may be restricted. Read operators manual for instructions. Contact maintenance personnel. Any active Stop" type error code will de-rate the engine to 1,000 RPMs. The ignition must be shut off to clear the engine de-rate. Any engine temperature or oil pressure codes will de-rate the engine to 1,000 RPMs for 30 seconds and then shut the engine down. WARNING - DEGRADED OPERATION, stop vehicle in a safe way. Read operator's manual (TM 10-3930-675-10) for instructions. Contact maintenance personnel. Confirm that error message is acknowledged by pressing RESET button. Error will appear every three minutes as long as error is active. It can be reset every time it shows. INFORMATION/MAINTENANCE action is needed. Error code shows once when vehicle starts up. Acknowledge error message by pressing RESET. These error codes may be deactivated for driver, so that they only show when maintenance personnel activate them. RT 240V1R, RT 240V2 and RT 240V3. The information/maintenance icon will appear in the ECS display operational screen (weight/load center) to alert the maintenance personnel of potential service. 2. Icons in the center of the display identify the type of fault. Table 2 describes the five fault types used in the display. Table 2. ICON DESCRIPTION Sensor Type of Fault Icons. ICON DESCRIPTION Lever
Valve
Temperature
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EXPLANATION OF ERROR CODE DISPLAY - Continued Table 2. ICON DESCRIPTION Pressure Type of Fault Icons - Continued. ICON DESCRIPTION
3. Icons in the right of the display identify what function or vehicle system the fault is related to. Table 3 lists the various functions or vehicle systems used in the display. Table 3. ICON DESCRIPTION Battery Function Icons. ICON DESCRIPTION Twistlock
Forklift Kit
Up/Down
Emergency Stop or Battery
In/Out
Rotation RT 240V1R, RT 240V2, and RT 240V3 only ECS display; lockout indication Hydraulic Filter
Transmission RT 240V1R, RT 240V2, and RT 240V3 ECS display; lockout indication Fan
Communication
Engine
0004-2
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0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 3. ICON DESCRIPTION Sideshifting Function Icons - Continued. ICON DESCRIPTION No Overload Protection
Oscillation (leveling)
Brake
Spreading
Tilt RT 240V1R, RT 240V2, and RT 240V3 ECS display; lockout indication
Steering
0004-3
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0004
EXPLANATION OF ERROR CODE DISPLAY - Continued
Table 4. Error Code Reference Index. ERROR DISPLAY CODE LAYOUT 1 TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0038) ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Lifting/lowering boom. Hydraulic filter clogged. Information/Maintenance Steering. Hydraulic filter clogged. Information/Maintenance Tophandler attachment. Hydraulic filter clogged. Information/Maintenance Return filter. Hydraulic filter clogged. Information/Maintenance Appears during replacement of ECU. Software not compatible with other software in system. VEHICLE LIMITATIONS None.
(WP 0038)
None.
(WP 0038)
None.
(WP 0038)
None.
103
(WP 0013)
Undesired functions and not relevant error codes may appear. Operating system not responding. Boom and tophandler may not work. Operating system not responding. Boom and tophandler may not work. No redundancy in ECS system of boom, display, and tophandler function
105
(WP 0013)
Stop Vehicle Immediately ECU 790 not responding. Circuit breaker tripped. Cable defective. ECU 790 defective.
106
(WP 0013)
Stop Vehicle Immediately ECU 791 not responding. Circuit breaker tripped. Cable defective. ECU 791 defective.
107
(WP 0013)
Information/Maintenance Communication, cable segment 1 between ECU 795 and 791. Cable between ECU 795 - 791 interrupted or short circuited.
0004-4
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EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 108 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Communication, cable segment 2 between ECU 791 and 790. Cable between ECU 791 - 790 interrupted or short circuited. Information/Maintenance Communication, cable segment 3 between ECU 790 and 795. Cable between ECU 790 - 795 interrupted or short circuited. VEHICLE LIMITATIONS No redundancy in ECS system of boom, display, and tophandler function. No redundancy in ECS system of boom, display, and tophandler function.
TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0013)
109
(WP 0013)
110
(WP 0013)
Stop Vehicle Immediately Steering may not Communication, ECU 792 function properly. steering computer not responding. Circuit breaker tripped. Cable defective. ECU 792 defective. Stop Vehicle Immediately Transmission Communication, ECU 793 may not function transmission computer not properly responding. Circuit breaker tripped. Cable defective. ECU 793 defective. Stop Vehicle Immediately Engine may not ECU 794 - engine computer not function properly. responding. Circuit breaker tripped. Cable defective. ECU 794 defective. Stop Vehicle Immediately No pressure/signal - both brake systems. Circuit breaker tripped. Hydraulic failure. Warning - Degraded Operation No pressure - brake circuit 1. Hydraulic failure. Warning - Degraded Operation No pressure - brake circuit 2. Hydraulic failure. Brakes may not function properly.
111
(WP 0013)
112
(WP 0013)
118
(WP 0030)
119
(WP 0030)
Only half brake capability available. Only half brake capability available.
120
(WP 0030)
0004-5
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EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 121 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Supply voltage - ECU 790. Emergency stop engaged. Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Supply voltage - CAN 790. Circuit breaker tripped. Cable defective. VEHICLE LIMITATIONS Operating system and boom function not working. Operating system and boom function not working. Operating system and boom function not working. None if code clears. Operating system and boom function not working. Lift/lower does not function properly (hydraulic stops).
122
(WP 0012)
123
(WP 0012)
Stop Vehicle Immediately Ref. voltages 10V - ECU 790. Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Memory fault, check ECU 790. Circuit breaker tripped. Cable defective.
125
(WP 0035)
126
(WP 0039)
Stop Vehicle Immediately Signal for lifting/lowering, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning. Stop Vehicle Immediately Signal for boom in/out, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning. Stop Vehicle Immediately Signal for slewing, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning. Stop Vehicle Immediately Signal for tilt in/out, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning.
127
(WP 0040)
Boom in/out does not function properly (hydraulic stops).
128
(WP 0043)
Slewing does not function properly (hydraulic stops).
129
(WP 0042)
Tilt does not function properly (hydraulic stops).
0004-6
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0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 130 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Overload protection error. Error codes 131 - 136 or 210 have been active. Stop Vehicle Immediately Boom sensor - boom length out of range or no signal change when boom is moving. Cable defective. Short circuit. Potentiometer damaged. Hydraulic failure. Stop Vehicle Immediately Boom sensor - boom angle out of range or no signal change when lowering/lifting boom. Sensor bracket or lever damaged. Cable defective. Short circuit. Potentiometer damaged. Hydraulic failure. Stop Vehicle Immediately Left lift cylinder pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. Stop Vehicle Immediately Right lift cylinder pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. Stop Vehicle Immediately Left lift cylinder return pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. VEHICLE LIMITATIONS No overload protection system. Reduced hydraulic speed. No overload protection system. Reduced hydraulic speed.
131
(WP 0010)
132
(WP 0010)
No overload protection system. Reduced hydraulic speed.
133
(WP 0010)
134
(WP 0010)
135
(WP 0010)
Stop Vehicle Immediately Left lift cylinder return pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. Pressure sensor, signal out of range Cable defective. Short
136
(WP 0010)
Stop Vehicle Immediately Right lift cylinder return pressure sensor, signal out of range. Cable
0004-7
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EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION defective. Short circuit. Pressure sensor defective. VEHICLE LIMITATIONS circuit. Pressure sensor defective. No overload protection system. Reduced hydraulic speed. Possible ECU malfunction. Other codes will also show. Possible ECU malfunction. Other codes will also show. Boom cannot be lowered with joystick. Emergency lowering is necessary. Boom cannot be lowered with joystick. Emergency lowering is necessary. Lifting is impossible.
TROUBLESHOOTING PROCEDURE WORK PACKAGE
141
(WP 0035)
Information/Maintenance Communication fault - ECU 790. Computer hardware fault.
142
(WP 0035)
Information/Maintenance Communication fault - ECU 790. Computer hardware fault.
151
(WP 0039)
Stop Vehicle Immediately Locking valve, broken circuit. Cable to valve defective.
152
(WP 0039)
Stop Vehicle Immediately Locking valve, short circuit. Cable to valve defective.
154
(WP 0039)
Stop Vehicle Immediately Lifting valve, broken circuit. Cable to valve defective.
155
(WP 0039)
Stop Vehicle Immediately Uncontrolled selfLifting valve, short circuit. Cable to lifting may occur. valve defective. Stop Vehicle Immediately Lowering valve, broken circuit. Cable to valve defective. Boom cannot be lowered with joystick. Emergency lowering is necessary.
157
(WP 0039)
0004-8
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0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 158 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS
Stop Vehicle Immediately Boom cannot be Lowering valve, short circuit. Cable lowered with to valve defective. joystick. Emergency lowering is necessary. Uncontrolled selflifting may occur. Stop Vehicle Immediately Boom in valve, broken circuit. Cable to valve defective. Boom cannot be retracted.
160
(WP 0040)
161
(WP 0040)
Stop Vehicle Immediately Boom cannot be Boom in valve, short circuit. Cable retracted. to valve defective. Uncontrolled selfretraction may occur. Stop Vehicle Immediately Boom out valve, broken circuit. Cable to valve defective. Stop Vehicle Immediately Boom out valve, short circuit. Cable to valve defective. Boom cannot be extended.
163
(WP 0040)
164
(WP 0040)
Boom cannot be extended. Uncontrolled selfextension may occur. Cooling fan will run at full speed. No fording activities possible. Cooling fan may run at any speed. No fording activities possible. Overheating may occur. No hydraulic emergency operation is possible.
166
(WP 0009)
Warning - Degraded Operation Cooling fan valve, broken circuit. Cable to valve defective.
167
(WP 0009)
Warning - Degraded Operation Cooling fan valve, short circuit. Cable to valve defective.
169
(WP 0036)
Warning - Degraded Operation Emergency hydraulic valve, broken circuit. Cable to valve defective.
0004-9
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0004
Information/Maintenance May be difficult to Pump turn off valve, broken circuit. start because of Cable defective. engaged pumps. Stop Vehicle Immediately Temperature in front wheel end above 203F (95C). Cable defective. No cooling. Stop Vehicle Immediately Temperature in rear wheel end above 203F (95C) Cable defective. No cooling. Stop Vehicle Immediately Supply voltage, ECU 791. Emergency stop engaged. Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Supply voltage, CAN 791. Circuit breaker tripped. Cable defective. Brakes may overheat at front axle.
191
(WP 0031)
192
(WP 0031)
Brakes may overheat at rear axle.
201
(WP 0012)
Tophandler not working.
202
(WP 0012)
Operating system and tophandler not working. Operating system not working. None if code clears. Operating system and tophandler not working. Generate error code 130.
203
(WP 0012)
Stop Vehicle Immediately Ref. voltages 10V-791/ Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Memory fault - check ECU 791. Circuit breaker tripped. Cable defective.
205
(WP 0011)
210
(WP 0010)
Stop Vehicle Immediately Tilt angle sensor, signal out of range. Potentiometer damaged. Cable defective. Short circuit. Stop Vehicle Immediately Logical error - left twistlock. Short circuit. Signal from both 7204L and 7205L.
212
(WP 0046)
Both locked and unlocked twistlock at the same time. Safe operation is not possible.
0004-10
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EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 213 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Logical error - right twistlock. Short circuit. Signal from both 7204R and 7205R. VEHICLE LIMITATIONS Both locked and unlocked twistlock at the same time. Safe operation is not possible. Operation of forklift is not possible.
214
(WP 0046)
Stop Vehicle Immediately Logical error - forklift sensors. Cable defective. Signal from 7206-1 or 7206-2. Warning - Degraded Operation One pulse signal to the steering wheel interrupted. Clock 1. Clock 2.
220
(WP 0011)
Stop vehicle by switching to neutral. Steering system will operate but is not redundant. The steering computer uses non interrupted signal to steer the vehicle. Possible ECU malfunction. Other codes will also show.
221
(WP 0011)
Information/Maintenance Communication fault - ECU 791, connector 2. Computer hardware fault.
225
(WP 0044)
Warning - Degraded Operation Left sideshift is Left sideshift, open circuit. Cable to not possible. valve defective. Warning - Degraded Operation Uncontrolled left Left sideshift, short circuit. Cable to sideshift may valve defective. occur. Warning - Degraded Operation Right sideshift is Right sideshift, open circuit. Cable not possible. to valve defective. Warning - Degraded Operation Uncontrolled Right sideshift, short circuit. Cable right sideshift to valve defective. may occur.
226
(WP 0044)
228
(WP 0044)
229
(WP 0044)
0004-11
TM 10-3930-675-23-1
0004
Warning - Degraded Operation Spreading from 20 to 40 valve, open circuit. Cable 20 to 40 ft is not to valve defective. possible. Warning - Degraded Operation Spreading from 20 to 40 valve, short circuit. Cable 20 to 40 ft is not to valve defective. possible. Warning - Degraded Operation Spreading from 40 to 20 valve, open circuit. Cable 40 to 20 ft is not to valve defective. possible. Warning - Degraded Operation Spreading from 40 to 20 valve, short circuit. Cable 20 to 40 ft is not to valve defective. possible. Warning - Degraded Operation Tophandler Active tilt valve, open circuit. Cable locked, not to valve defective. automatically leveled. Warning - Degraded Operation Active pile slope, open circuit. Cable to valve defective. Warning - Degraded Operation Twistlock valve lock, open circuit. Cable to valve defective. Warning - Degraded Operation Twistlock valve unlock, open circuit. Cable to valve defective. Information/Maintenance Communication fault - ECU 791, connector 3. Computer hardware fault. Information/Maintenance Communication fault - ECU 791, connector 3. Computer hardware fault. Warning - Degraded Operation Slewing clockwise valve, open circuit. Cable to valve defective. Tophandler locked, not free oscillated. Impossible to lock twistlock.
232
(WP 0045)
234
(WP 0045)
235
(WP 0045)
237
(WP 0042)
240
(WP 0043)
243
(WP 0046)
246
(WP 0046)
Impossible to unlock twistlock.
250
(WP 0011)
Possible ECU malfunction. Other codes will also show. Possible ECU malfunction. Other codes will also show. Slewing clockwise is not possible.
251
(WP 0011)
255
(WP 0041)
0004-12
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 256 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Slewing clockwise valve, short circuit. Cable to valve defective. Warning - Degraded Operation Slewing counterclockwise valve, open circuit. Cable to valve defective. Warning - Degraded Operation Slewing counterclockwise valve, short circuit. Cable to valve defective. VEHICLE LIMITATIONS Uncontrolled slewing may occur. Slewing clockwise is not possible.
258
(WP 0041)
259
(WP 0041)
Uncontrolled slewing may occur.
261
(WP 0042)
Warning - Degraded Operation Tilt out is not Tilt out valve, open circuit. Cable to possible. valve defective. Warning - Degraded Operation Uncontrolled tilt Tilt out valve, short circuit. Cable to may occur. valve defective. Warning - Degraded Operation Tilt in valve, open circuit. Cable to valve defective. Warning - Degraded Operation Tilt in valve, short circuit. Cable to valve defective. Tilt in is not possible.
262
(WP 0042)
264
(WP 0042)
265
(WP 0042)
Uncontrolled tilt may occur.
267
(WP 0043)
Warning - Degraded Operation Right oscillation Right oscillation valve, open circuit. (leveling) is not Cable to valve defective. possible. Warning - Degraded Operation Uncontrolled Right oscillation valve, short circuit. oscillation Cable to valve defective. (leveling) may occur. Warning - Degraded Operation Left oscillation valve, open circuit. Cable to valve defective. Warning - Degraded Operation Left oscillation (leveling) is not possible. Uncontrolled oscillation
268
(WP 0043)
270
(WP 0043)
271
(WP 0043)
0004-13
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS
Left oscillation valve - short circuit. (leveling) may Cable to valve defective occur. 300 (WP 0014) Stop Vehicle Immediately Steering system malfunction. Steering computer - hardware error (EEPROM, watchdog, reference voltages, etc.) No steering or driving functions are available. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant.
301 302 303 304 305 306 307 308
(WP 0034)
Warning - Degraded Operation One track of actual value potentiometer out of range (e.g., cable interrupted). Wheel 1, track 1. Wheel 2, track 1. Wheel 3, track 1. Wheel 4, track 1. Wheel 1, track 2. Wheel 2, track 2. Wheel 3, track 2. Wheel 4, track 2. Stop Vehicle Immediately Both tracks of actual value potentiometer out of range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.
309 310 311 312
(WP 0034)
Stop vehicle by switching to NEUTRAL. Faulty wheel is locked immediately. Other wheels remain operational. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Reduced power and engine speed.
313 314 315 316
(WP 0034)
Stop Vehicle Immediately Deviation between two potentiometer tracks, but both inside tolerance range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.
0004-14
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 317 318 319 320 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Steering deviation between set point and actual value (tracking error). Wheel 1. Wheel 2. Wheel 3. Wheel 4. VEHICLE LIMITATIONS Stop vehicle by switching to NEUTRAL. Steering remains active and tries to close up to set point. System will be active as soon as deviating wheel has closed up. Reduced power and engine speed. This error prohibits driving after steering calibration if calibration was not successful or calibration values are out of range. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering computer cannot control wheel with broken cable. Faulty wheel has to be aligned by manual operation of valve. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering computer cannot control wheel
321 322 323 324
(WP 0033)
Stop Vehicle Immediately Wheel alignment values out of range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.
325 326 327 328
(WP 0032)
Stop Vehicle Immediately Break in cable to proportional valve. Wheel 1. Wheel 2. Wheel 3. Wheel 4.
329 330 331
(WP 0032)
Stop Vehicle Immediately Cable to proportional valve - short circuit. Wheel 1. Wheel 2. Wheel 3.
0004-15
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 332 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Wheel 4. VEHICLE LIMITATIONS with broken cable. Faulty wheel has to be aligned by manual operation of valve. Reduced power and engine speed. Steering system out of order. No steering or driving functions are available. Stop vehicle by switching to NEUTRAL. Steering system will operate in a degraded mode. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Steering computer uses one of two counters to steer vehicle. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Steering computer uses uninterrupted
339
(WP 0032)
Stop Vehicle Immediately Steering wheel sensor malfunction. Possible loss of ground.
340
(WP 0032)
Warning - Degraded Operation Supply pressure below 1450 psi (100 bar). Leaking hydraulics.
341
(WP 0032)
Stop Vehicle Immediately Steering wheel signals inconsistent (e.g., two incremental counters deviating). Cables defective. Steering column sensor defective.
342
(WP 0032)
Warning - Degraded Operation
0004-16
TM 10-3930-675-23-1
0004
One pulse signal to steering wheel signal to steer interrupted. Cables defective. vehicle. Steering column sensor defective. (WP 0032) Stop Vehicle Immediately Both pulse signals to steering wheel interrupted. Cables defective. Steering column sensor defective. Stop vehicle by switching to NEUTRAL. Steering system will not operate. Reduced power and engine speed.
344
345
(WP 0013)
Warning - Degraded Operation Error codes from No CAN communication to display. steering ECU will Cable defective. not show on display. Steering function is operational. Warning - Degraded Operation No CAN communication to transmission. Cables defective. It is not possible to change from 2WD to 4WD or vice versa. Steering system remains operational, but steering features dependent on driving speed are not available. To keep vehicle in full operation, steering program selection is allowed at this time. None.
346
(WP 0013)
347
(WP 0032)
Information/Maintenance No valid steering program selected. Stop Vehicle Immediately Steering valve solenoid.
350 351 352
(WP 0016)
Stop vehicle by switching to NEUTRAL. Steering system
0004-17
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 353 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION This error code occurs if the solenoid or circuit resistance differs from the preset value. (WP 0016) Stop Vehicle Immediately Start-up failure in steering system. This error code is caused by incorrect parameter settings in steering computer. VEHICLE LIMITATIONS will not operate properly.
354 355 356 357
Stop vehicle by switching to NEUTRAL. Steering system will not operate properly. Fully operational. History storage of error codes may not be possible.
399
(WP 0016)
Warning - Degraded Operation EEPROM parameter error in steering computer. One or more parameter values inside EEPROM are out of range.
401
(WP 0016)
Warning - Degraded Operation Transmission will Digital output short circuit - Enable not go into neutral driving" (no neutral gear from automatically. steering ECU). Cables defective. Information/Maintenance Digital output short circuit - Control lamp, front wheel steering." Cables defective. Information/Maintenance Digital output short circuit - Control lamp, four wheel steering." Cables defective. Information/Maintenance Digital output short circuit - Control lamp, crab steering" Cables defective. Control lamp on steering selection switch is not working. Control lamp on steering selection switch is not working. Control lamp on steering selection switch is not working.
404
(WP 0016)
405
(WP 0016)
406
(WP 0016)
408
(WP 0016)
Information/Maintenance Control lamp on Digital output short circuit - Control steering column lamp, unlocked twistlock." Cables is not working. defective. Information/Maintenance Control lamp on Digital output short circuit - Control steering column lamp, locked twistlock." Cables is not working. defective.
409
(WP 0016)
0004-18
TM 10-3930-675-23-1
0004
Information/Maintenance Control lamp on Digital output short circuit - Control steering column lamp, alignment." Cables is not working. defective. Information/Maintenance Digital output short circuit Auxiliary hydraulic pump." Cables defective. Cab cannot be moved. No emergency operation of boom or tophandler available. Ether start not working.
411
(WP 0036)
412
(WP 0016)
Information/Maintenance Digital output short circuit - Ether start kit." Cables defective. Information/Maintenance Digital output short circuit - Oil supply valve, boom folding." Cables defective. Warning - Degraded Operation Digital output short circuit - Drive axle cooling, bypass valves." Cables defective.
413
(WP 0016)
Boom cannot be folded.
414
(WP 0031)
Brakes may be overheated. Error codes 191 and 192 will show if brakes have overheated. Reduced power and engine speed. Steering pressure failure cannot be detected, error code 340. Auxiliary hydraulic pump cannot be started.
415
(WP 0016)
Stop Vehicle Immediately Digital output short circuit.
416
(WP 0016)
Stop Vehicle Immediately Digital input not read correctly Steering pressure." Cables defective.
417
(WP 0036)
Information/Maintenance Digital input not read correctly Auxiliary hydraulic pump switch." Cables defective.
0004-19
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 418 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Digital input not read correctly Front wheel steering switch." Cables defective. Warning - Degraded Operation Digital input not read correctly Four wheel steering switch" Cables defective. Warning - Degraded Operation Digital input not read correctly Crab steering switch." Cables defective. VEHICLE LIMITATIONS 2WD cannot be selected.
419
(WP 0016)
4WD cannot be selected.
420
(WP 0016)
Crab steering cannot be selected.
422
(WP 0016)
Information/Maintenance Boom folding is Digital input not read correctly not possible. Sensor, cab in transport position." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Ether start switch." Cables defective. Steering computer damaged. Warning - Degraded Operation Digital input not read correctly Fording level switch." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Tophandler work light switch." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Hydraulic filter indication (lift/ lower; boom in/out)." Cables defective. Steering computer damaged. Ether injection is not possible.
423
(WP 0016)
426
(WP 0009)
Fording operations are not possible.
427
(WP 0016)
Work lights on tophandler do not function.
432
(WP 0038)
None.
0004-20
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 433 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Digital input not read correctly Hydraulic filter indication, steering." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Hydraulic filter indication, tophandler." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Hydraulic filter indication, return oil." Cables defective. Steering computer damaged. Information/Maintenance Error on power supply for steering wheel sensor error code can be caused by: Short circuit of analog output terminal 38 to +24V. Short circuit of analog output terminal 38 to ground. Fault in steering computer output. Warning - Degraded Operation Ambient temperature too high. Temperature sensor defective. ECU 792 defective. VEHICLE LIMITATIONS None.
434
(WP 0038)
None.
435
(WP 0038)
None.
440
(WP 0016)
Steering wheel has no end positions or steering resistance.
450
(WP 0016)
None.
451
(WP 0015)
Warning - Degraded Operation Stop vehicle by Supply voltage too high. Alternator switching to defective. neutral. Warning - Degraded Operation Supply voltage too low. Power supply off. Alternator defective Stop Vehicle Immediately Supply voltage for wheel sensors out of range. The +5 supply voltage for angle transducer track 2 is too low. Error code can be caused by short circuit Stop vehicle by switching to neutral The vehicle is stopped by switching to neutral gear. If error code 454 is also active, all
452
(WP 0015)
453
(WP 0015)
0004-21
TM 10-3930-675-23-1
0004
in one or more angle transducer wheels are tracks or low impedance to ground. locked. 454 (WP 0015) Stop Vehicle Immediately Supply voltage for wheel sensors out of range. The +5 supply voltage for angle transducer track 1 is too low. Error code can be caused by short circuit in one or more angle transducer tracks or low impedance to ground. Warning - Degraded Operation Logical error at direction select signal - transmission ECU detected incorrect signal combination for the direction. Cables defective. Shift lever defective. Information/Maintenance Logical error at axle connection axle connection feedback measured by transmission ECU and output signal do not match. Cables defective. Switch defective. Mechanical error. The vehicle is stopped by switching to neutral gear. If error code 454 is also active, all wheels are locked. Stop vehicle by switching to neutral.
618
(WP 0028)
622
(WP 0028)
When shifting from 2WD to 4WD or vice versa, engage forward drive and immediately return to neutral. Turn the ignition switch off for at least 30 seconds, then turn switch back on.
637
(WP 0025)
Information/Maintenance None. Short circuit to battery voltage or open circuit at transmission sump temperature sensor input - voltage too high. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance Short circuit to ground at transmission sump temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken. None.
638
(WP 0025)
0004-22
TM 10-3930-675-23-1
0004
Information/Maintenance None. Short circuit to battery voltage or open circuit at converter output temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance None. Short circuit to battery voltage or open circuit at converter output temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance Short circuit to battery voltage or open circuit at engine speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance Short circuit to ground at engine speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective. Information/Maintenance Logical error at engine speed input - transmission ECU measures engine speed over a threshold and the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size. Warning - Degraded Operation Short circuit to battery voltage or open circuit at turbine speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).
640
(WP 0025)
649
(WP 0026)
650
(WP 0026)
Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).
651
(WP 0026)
652
(WP 0026)
Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed,
0004-23
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION defective. Incorrect sensor gap size. VEHICLE LIMITATIONS transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).
653
(WP 0026)
Warning - Degraded Operation Short circuit to ground at turbine speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.
654
(WP 0026)
Warning - Degraded Operation Logical error at turbine speed input - transmission ECU measures turbine speed over a threshold and at the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size.
655
(WP 0026)
Information/Maintenance Short circuit to battery voltage or open circuit at internal speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor defective. Information/Maintenance Short circuit to ground at internal speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.
656
(WP 0026)
Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).
0004-24
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 657 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Logical error at internal speed input - transmission ECU measures internal speed over a threshold and at the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size. VEHICLE LIMITATIONS Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If
658
(WP 0026)
Warning - Degraded Operation Short circuit to battery voltage or open circuit at output speed input transmission ECU measures a voltage higher than 12.5V at speed input pin. Cables defective. Sensor defective.
659
(WP 0026)
Warning - Degraded Operation Short circuit to battery voltage at output speed input - transmission ECU measures a voltage less than 1.0V at speed input pin. Cables defective. Sensor defective.
660
(WP 0026)
Warning - Degraded Operation Logical error at output speed input - transmission ECU measures internal speed over a threshold and at the next moment the measured
0004-25
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION speed is zero. Cables defective. Sensor defective. VEHICLE LIMITATIONS there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Error codes from transmission ECU will not show. Error codes from transmission ECU will not show. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.
662
(WP 0026)
Warning - Degraded Operation Output speed does not fit other speed signals. If transmission is not in neutral and shifting has finished, transmission ECU measures output speed as zero and turbine or internal speed as not equal to zero. Cables defective. Sensor defective. Incorrect sensor gap size.
684
(WP 0013)
Warning - Degraded Operation CAN message time-out from display computer. Cable defective. Defective display computer. Warning - Degraded Operation CAN message time-out from display computer. Cable defective. Defective steering computer. Stop Vehicle Immediately Short circuit to battery voltage at clutch K1 - measured valve resistance is beyond limit, voltage at K1 valve is too high. Cables defective. Regulator defective.
685
(WP 0013)
713
(WP 0027)
0004-26
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 714 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Short circuit to ground at clutch K1 - measured valve resistance is beyond limit, voltage at K1 valve is too low. Cables defective. Regulator defective. VEHICLE LIMITATIONS Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down.
715
(WP 0027)
Stop Vehicle Immediately Open circuit at clutch K1 measured valve resistance is beyond limit. Cables defective. Regulator defective.
716
(WP 0027)
Stop Vehicle Immediately Short circuit to battery voltage at clutch K2 - measured valve resistance is beyond limit, voltage at K2 valve is too high. Cables defective. Regulator defective.
717
(WP 0027)
Stop Vehicle Immediately Short circuit to ground at clutch K2 - measured valve resistance is beyond limit, voltage at K2 valve is
0004-27
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION too low. Cables defective. Regulator defective. VEHICLE LIMITATIONS Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at
718
(WP 0027)
719
(WP 0027)
720
(WP 0027)
Stop Vehicle Immediately Short circuit to ground at clutch K3 - measured valve resistance is beyond limit, voltage at K3 valve is too low. Cables defective. Regulator defective.
721
(WP 0027)
Stop Vehicle Immediately Open circuit at clutch K3 measured valve resistance is
0004-28
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION beyond limit. Cables defective. Regulator defective. VEHICLE LIMITATIONS another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.
729
(WP 0027)
730
(WP 0027)
Stop Vehicle Immediately Short circuit to ground at clutch K4 - measured valve resistance is beyond limit, voltage at K4 valve is too low. Cables defective. Regulator defective.
731
(WP 0027)
0004-29
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 732 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Short circuit to battery voltage at clutch KV - measured valve resistance is beyond limit, voltage at KV valve is too high. Cables defective. Regulator defective. VEHICLE LIMITATIONS Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down.
733
(WP 0027)
Stop Vehicle Immediately Short circuit to ground at clutch KV - measured valve resistance is beyond limit, voltage at KV valve is too low. Cables defective. Regulator defective.
734
(WP 0027)
Stop Vehicle Immediately Open circuit at clutch KV measured valve resistance is beyond limit. Cables defective. Regulator defective.
735
(WP 0027)
Stop Vehicle Immediately Short circuit to battery voltage at clutch KR - measured valve resistance is beyond limit, voltage
0004-30
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION at KR valve is too high. Cables defective. Regulator defective. VEHICLE LIMITATIONS Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.
736
(WP 0027)
Stop Vehicle Immediately Short circuit to ground at clutch KR - measured valve resistance is beyond limit, voltage at KR valve is too low. Cables defective. Regulator defective.
737
(WP 0027)
Stop Vehicle Immediately Open circuit at clutch KR measured valve resistance is beyond limit. Cables defective. Regulator defective.
745
(WP 0028)
Information/Maintenance None. Short circuit to ground at reverse warning alarm relay - transmission ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Backup alarm device defective. Information/Maintenance None. Short circuit to battery voltage at reverse warning alarm relay transmission ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Backup alarm device defective.
746
(WP 0028)
0004-31
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 747 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Open circuit at reverse warning alarm relay - transmission ECU detected incorrect voltage at output pin that looks like an open circuit for this output pin. Cables defective. Backup alarm device defective. VEHICLE LIMITATIONS None.
761
(WP 0028)
Warning - Degraded Operation Switching from Short circuit to ground at axle 2WD to 4WD is connection solenoid - transmission not possible. ECU detected incorrect voltage at output pin that looks like a short circuit to vehicle ground. Cables defective. Axle connection solenoid defective. Warning - Degraded Operation Switching from Short circuit to battery voltage axle 2WD to 4WD is connection solenoid - transmission not possible. ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Axle connection solenoid defective. Warning - Degraded Operation Open circuit at axle connection solenoid - transmission ECU detected incorrect voltage at output pin that looks like an open circuit for this output pin. Cables defective. Axle connection solenoid defective. Stop Vehicle Immediately Slippage at clutch K1 transmission ECU calculates a differential speed at closed clutch K1. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Switching from 2WD to 4WD is not possible.
762
(WP 0028)
763
(WP 0028)
777
(WP 0029)
Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power
0004-32
TM 10-3930-675-23-1
0004
Sensor defective. Incorrect sensor and engine gap size. Clutch defective. speed. 778 (WP 0029) Stop Vehicle Immediately Slippage at clutch K2 transmission ECU calculates a differential speed at closed clutch K2. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to
779
(WP 0029)
Stop Vehicle Immediately Slippage at clutch K3 transmission ECU calculates a differential speed at closed clutch K3. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.
780
(WP 0029)
Stop Vehicle Immediately Slippage at clutch K4 transmission ECU calculates a differential speed at closed clutch K4. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.
781
(WP 0029)
Stop Vehicle Immediately Slippage at clutch KV transmission ECU calculates a differential speed at closed clutch KV. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure.
0004-33
TM 10-3930-675-23-1
0004
Sensor defective. Incorrect sensor neutral. ECU will gap size. Clutch defective. shut down. Reduced power and engine speed. 782 (WP 0029) Stop Vehicle Immediately Slippage at clutch KR transmission ECU calculates a differential speed at closed clutch KR. If this calculated value is outside of range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.
783
(WP 0025)
Warning - Degraded Operation None. Overheated sump - transmission ECU measured temperature in oil sump that is over 212F (100C). Low oil level. Temperature sensor defective. Information/Maintenance None. Oil filter differential pressure transmission ECU measured a voltage at differential pressure switch outside allowable range. Oil filter polluted. Cable/connector defective. Differential switch defective. Warning - Degraded Operation None. Overheated converter output ECU measured oil temperature at converter output that is over 248F (120C). Low oil level. Temperature sensor defective. Stop Vehicle Immediately Low power at battery - measured voltage at power supply is lower Transmission ECU shifts to neutral. ECU will shut down. Reduced power
786
(WP 0038)
795
(WP 0025)
811
(WP 0015)
0004-34
TM 10-3930-675-23-1
0004
than 18V. Cable defective. Battery and engine defective. Connector defective. speed. 812 (WP 0015) Stop Vehicle Immediately High power at battery - measured voltage at power supply is higher than 32.5V. Cable defective. Battery defective. Connector defective. Transmission ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. None.
813
(WP 0015)
Stop Vehicle Immediately Error at shift valve power supply (VPS1). Cable defective. Connector defective. ECU defective.
814
(WP 0015)
Stop Vehicle Immediately Error at shift valve power supply (VPS2). Cable defective. Connector defective. ECU defective.
841
(WP 0014)
Information/Maintenance General EEPROM fault - ECU cannot read memory. ECU defective. Stop Vehicle Immediately Application error. ECU defective.
843
(WP 0014)
Transmission stays in neutral. ECU will shut down. Reduced power and engine speed. Transmission stays in neutral. ECU will shut down. Reduced power and engine speed.
845
(WP 0029)
Stop Vehicle Immediately Clutch failure - AEB was not able to adjust clutch filling parameters. Clutch defective.
846
(WP 0029)
Information/Maintenance None. Clutch adjustment data lost - ECU was not able to read correct adjustment parameters.
0004-35
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Interference during data saving process. 1111 (WP 0014) Stop Vehicle Immediately ECM internal memory error. Hardware defective. Internal microprocessor communication failure. Stop Vehicle Immediately No engine speed signal detected in either engine position sensor circuits. Engine will not start. Reduced power and engine speed. VEHICLE LIMITATIONS
1115
(WP 0018)
Engine will shut down and will not start. Reduced power and engine speed.
1121
(WP 0018)
Warning - Degraded Operation None. No engine speed signal detected in one engine position sensor circuit. Warning - Degraded Operation High voltage detected in intake manifold pressure sensor circuit. Warning - Degraded Operation Low voltage detected in intake manifold pressure sensor circuit. Stop Vehicle Immediately High voltage detected in throttle position sensor circuit. Reduced engine power output.
1122
(WP 0022)
1123
(WP 0022)
Reduced engine power output.
1131
(WP 0008)
Severe power and speed loss. Limp home power only. Reduced power and engine speed. Severe power and speed loss. Limp home power only. Reduced power and engine speed. Oil pressure warning not working.
1132
(WP 0008)
Stop Vehicle Immediately Low voltage detected in throttle position sensor circuit.
1135
(WP 0019)
Warning - Degraded Operation High voltage detected in oil pressure sensor circuit.
0004-36
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1141 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Low voltage detected in oil pressure sensor circuit. VEHICLE LIMITATIONS Oil pressure warning not working.
1143
(WP 0019)
Stop Vehicle Immediately Reduced power Oil pressure signal indicates low oil and speed. pressure. Engine will shut down in 30 to 45 seconds. Warning - Degraded Operation High voltage detected in coolant temperature circuit. Warning - Degraded Operation Low voltage detected in coolant temperature circuit. Stop Vehicle Immediately Coolant temperature signal indicated coolant temperature above critical threshold. Temperature warning not functioning. Temperature warning not functioning. Reduced power and speed. Engine will shut down in 30 to 45 seconds. Possible white smoke. No engine protection for intake manifold temperature. Possible white smoke. No engine protection for intake manifold temperature. Reduced power and speed. Engine will shut down in 30 to 45 seconds.
1144
(WP 0020)
1145
(WP 0020)
1151
(WP 0020)
1153
(WP 0020)
Warning - Degraded Operation High voltage detected in intake manifold temperature sensor circuit.
1154
(WP 0020)
Warning - Degraded Operation Low voltage detected in intake manifold temperature sensor circuit.
1155
(WP 0020)
Stop Vehicle Immediately Intake manifold temperature signal indicated coolant temperature above critical threshold.
0004-37
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1187 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Low voltage detected on ECM voltage supply line to some sensors. Warning - Degraded Operation High voltage detected in oil temperature sensor circuit. Warning - Degraded Operation Low voltage detected in oil temperature sensor circuit. Stop Vehicle Immediately Oil pressure signal indicates temperature above critical threshold. Information/Maintenance High voltage detected in ambient air pressure sensor circuit. Information/Maintenance Low voltage detected in ambient air pressure sensor circuit. Warning - Degraded Operation High voltage detected on ECM voltage supply line to some sensors. Stop Vehicle Immediately Engine speed signal indicates engine speed greater than 2,730 RPM. VEHICLE LIMITATIONS Engine will run degraded. No protection for oil pressure. No engine protection for oil temperature. No engine protection for oil temperature. Reduced power and speed.
1212
(WP 0020)
1213
(WP 0020)
1214
(WP 0020)
1221
(WP 0021)
Reduced power and speed.
1222
(WP 0021)
Reduced power and speed.
1227
(WP 0017)
Engine will run degraded. No protection for oil pressure. Fuel shutoff valve is closed until engine speed drops. Fuel shutoff valve will open when engine speed falls below 2,184 RPM. Reduced power and engine speed. ECM turns off FSO supply voltage. Engine will shut down.
1234
(WP 0018)
1254
(WP 0023)
Stop Vehicle Immediately
0004-38
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Less than 6V detected at fuel shutoff driver. Excessive current draw. Power supply faulty. 1255 (WP 0023) Warning - Degraded Operation Externally supplied voltage detected going to fuel shutoff supply circuit. Warning - Degraded Operation Information from multiplexed device not received by ECM or received too late. Warning - Degraded Operation Only a portion of information from multiplexed device received by ECM. VEHICLE LIMITATIONS Reduced power and engine speed. No performance limitations. Fuel shutoff valve stays open. At least one multiplexed device will not operate properly. At least one multiplexed device will not operate properly.
1285
(WP 0013)
1286
(WP 0013)
1287
(WP 0017)
Stop Vehicle Immediately The engine will Data error received while only idle. multiplexing throttle pedal and IVS. Reduced power and engine speed. Information/Maintenance Engine is Ambient air pressure sensor circuit degraded to no error detected by ECM. air setting. Stop Vehicle Immediately Reduced power Intake system indicates air cleaner and speed. is clogged. Information/Maintenance Injector for Current detected at injector for cylinder #1 cylinder #1 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #5 cylinder #5 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #3 cylinder #3 when voltage is turned turned OFF. OFF.
1295
(WP 0021)
1298
(WP 0021)
1311
(WP 0007)
1312
(WP 0007)
1313
(WP 0007)
0004-39
TM 10-3930-675-23-1
0004
Information/Maintenance Injector for Current detected at injector for cylinder #6 cylinder #6 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #2 cylinder #2 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #4 cylinder #4 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for No current detected at injector for cylinder #1 cylinder #1 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for No current detected at injector for cylinder #5 cylinder #5 when voltage is turned turned ON. ON. Information/Maintenance Injector for Current detected at injector for cylinder #3 cylinder #3 when voltage is turned turned ON. ON. Information/Maintenance Injector for Current detected at injector for cylinder #6 cylinder #6 when voltage is turned turned ON. ON. Information/Maintenance Injector for No current detected at injector for cylinder #2 cylinder #2 when voltage is turned turned ON. ON. Information/Maintenance Injector for No current detected at injector for cylinder #4 cylinder #4 when voltage is turned turned OFF. ON.
1315
(WP 0007)
1321
(WP 0007)
1322
(WP 0007)
1323
(WP 0007)
1324
(WP 0007)
1325
(WP 0007)
1331
(WP 0007)
1332
(WP 0007)
0004-40
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1341 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Severe loss of data from ECM. VEHICLE LIMITATIONS No noticeable performance effects possible. Possibility of engine stopping or difficulty in starting engine. No noticeable performance effects possible. May encounter severe loss of power. Possibly too short of time for ECM to power down, less than 30 seconds. Engine is degraded to no air setting.
1343
(WP 0014)
Warning - Degraded Operation Microprocessor communication error inside ECM.
1346
(WP 0014)
Information/Maintenance Software error in ECM.
1352
(WP 0017)
Warning - Degraded Operation Low voltage detected at sensor. Faulty power supply.
1415
(WP 0019)
Stop Vehicle Immediately Reduced power Oil pressure signal indicates below and speed. critical threshold. Engine will shut down in 30 to 45 seconds. Information/Maintenance Error in intake manifold pressure sensor signal detected by ECM. Engine is degraded to no air setting.
1419
(WP 0022)
1431
(WP 0008)
Information/Maintenance None. Both idle validation off-idle and onidle signals indicate the same voltage reading. Warning - Degraded Operation Idle validation switch voltages are opposite (complementary) but disagree with a valid throttle position sensor. Engine will only idle.
1432
(WP 0008)
0004-41
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1433 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Intake manifold pressure sensor voltage indicates a high pressure reading. Warning - Degraded Operation Battery voltage too low or insufficient amount of time for battery power to ECM for powering down after key off. VEHICLE LIMITATIONS Engine is degraded to no air setting.
1434
(WP 0024)
No noticeable performance effects possible. Possibility of engine stopping or difficulty in starting engine. None. No engine protection for oil pressure. No noticeable performance effects possible. Possibility of rough idle. None.
1435
(WP 0019)
Warning - Degraded Operation ECM detects error in oil pressure sensor signal. Warning - Degraded Operation Battery voltage below normal operating level.
1441
(WP 0024)
1442
(WP 0024)
Warning - Degraded Operation Battery voltage above normal operating level. Warning - Degraded Operation Low voltage detected on ECM voltage supply line to throttle. Warning - Degraded Operation Low voltage detected in starter lockout relay circuit when energized or voltage detected when circuit de-energized. Warning - Degraded Operation No voltage detected simultaneously in both idle validation off-idle and on-idle circuits. Warning - Degraded Operation High voltage detected in fuel inlet pressure sensor circuit.
1443
(WP 0017)
Engine will only idle.
1474
(WP 0024)
None.
1551
(WP 0008)
Engine will only idle.
1581
(WP 0023)
None.
0004-42
TM 10-3930-675-23-1
0004
EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1596 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Battery voltage above normal operating range. Warning - Degraded Operation Battery voltage below normal operating range. Stop Vehicle Immediately Very low battery voltage - critical level. VEHICLE LIMITATIONS None.
1597
(WP 0024)
None.
1598
(WP 0024)
Engine is degraded to no air setting.
1697
(WP 0020)
Information/Maintenance None. High voltage detected in ECM internal temperature sensor circuit. Information/Maintenance None. Low voltage detected in ECM internal temperature sensor circuit. Information/Maintenance Power imbalance between cylinders detected by ECM. Engine may rough idle or misfire.
1698
(WP 0020)
1951
(WP 0007)
1999
Stop Vehicle Immediately Engine is More than 6 errors active on J1939 degraded to no bus to display. air setting.
END OF WORK PACKAGE
0004-43/44 blank
TM 10-3930-675-23-1
0005
FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX
ERROR CODE SYMPTOM INDEX Malfunction/Symptom Troubleshooting Procedure
AUXILIARY PUMP 1. 2. 3. Error Code 169 - Tophandler Emergency Function Supply Valve, Open or Short Circuit Failure ................................................................................................. WP 0036 Error Code 411 - Auxiliary Pump Control, Short Circuit Failure ....................................................... WP 0036 Error Code 417 - Auxiliary Pump Switch, Circuit Input Error ............................................................ WP 0036
AXLE BRAKE COOLING SYSTEM 1. 2. 3. Error Code 191 - Temperature in Front Axle Above Critical Threshold ......................................................................................................................................... WP 0031 Error Code 192 - Temperature in Rear Axle Above Critical Threshold ......................................................................................................................................... WP 0031 Error Code 414 - Brake Cooling Bypass Valve, Short Circuit Failure .............................................................................................................................................. WP 0031
BOOM IN/OUT 1. 2. 3. 4. 5. 6. Error Code 127 - Joystick-to-ECU (790) Failure .............................................................................. WP 0040 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0040 Error Code 160 - Extension Cylinder Boom IN Control, Wiring Circuit Failure ................................................................................................................................... WP 0040 Error Code 161 - Extension Cylinder Boom IN Control, Component Failure ........................................................................................................................... WP 0040 Error Code 163 - Extension Cylinder Boom OUT Control Valve, Wiring Circuit Failure ........................................................................................................................ WP 0040 Error Code 164 - Extension Cylinder Boom OUT Control Valve, Component Failure ........................................................................................................................... WP 0040
BOOM LIFTING/LOWERING 1. 2. 3. 4. 5. Error Code 126 - Joystick-to-ECU (790) Failure .............................................................................. WP 0039 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0039 Error Code 151 - Lift Cylinder Locking Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039 Error Code 152 - Lift Cylinder Locking Valve, Component Failure ................................................... WP 0039 Error Code 154 - Lift Cylinder Boom Up Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039
0005-1
TM 10-3930-675-23-1
0005
ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure
6. 7. 8.
Error Code 155 - Lift Cylinder Boom Up Valve, Component Failure .............................................................................................................................................. WP 0039 Error Code 157 - Lift Cylinder Boom Down Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039 Error Code 158 - Lift Cylinder Boom Down Valve, Component Failure .............................................................................................................................................. WP 0039
BRAKE SYSTEM 1. 2. 3. Error Code 118 - Brake System Pressure, Circuit 1 and Circuit 2 Failure ........................................................................................................................................... WP 0030 Error Code 119 - Brake System Pressure, Circuit 1 Failure ............................................................. WP 0030 Error Code 120 - Brake System Pressure, Circuit 2 Failure ............................................................. WP 0030
COOLING FAN OPERATION AND FAN CONTROL 1. 2. 3. Error Code 166 - Cooling Fan Speed, Wiring Circuit Failure ........................................................... WP 0009 Error Code 167 - Cooling Fan Speed, Short Circuit Failure ............................................................. WP 0009 Error Code 426 - Fording Level Switch, Circuit Input Error .............................................................. WP 0009
ECU-TO-ECU COMMUNICATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Error Code 103 - ECU (790) Not Responding (RT 240V1R, RT 240V2 and RT 240V3) ..................................................................................................................... WP 0013 Error Code 105 - ECU (790) Not Responding .................................................................................. WP 0013 Error Code 106 - ECU (791) Not Responding .................................................................................. WP 0013 Error Code 107 - Cable Failure Between Tophandler ECU (791) and Display ECU (795) .................................................................................................................... WP 0013 Error Code 108 - Cable Failure Between Tophandler ECU (791) and Servo ECU (790) ....................................................................................................................... WP 0013 Error Code 109 - Cable Failure Between Servo ECU (790) and Display ECU (795) ........................................................................................................................... WP 0013 Error Code 110 - Communication Failure Between Display ECU (795) and Steering ECU (792) ......................................................................................................... WP 0013 Error Code 111 - Communication Failure Between Display ECU (795) and Transmission ECU (793) .................................................................................................. WP 0013 Error Code 112 - Communication Failure Between Display ECU (795) and Engine ECU (794) ............................................................................................................ WP 0013 Error Code 345 - Communication Failure Between Steering ECU (792) and Display ECU (795) ................................................................................................... WP 0013
0005-2
TM 10-3930-675-23-1
0005
ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 11. 12. 13. 14. 15. Troubleshooting Procedure
Error Code 346 - Communication Failure Between Steering ECU (792) and Transmission ECU (793) ......................................................................................... WP 0013 Error Code 684 - Communication Failure Between Transmission ECU (793) and Display ECU (795) ............................................................................ WP 0013 Error Code 685 - Communication Failure Between Transmission ECU (793) and Steering ECU (792) ........................................................................... WP 0013 Error Code 1285 - Engine Detects a Communication Failure on the J1939 Datalink ........................................................................................................................... WP 0013 Error Code 1286 - Engine Detects a Communication Failure on the J1939 Datalink ........................................................................................................................... WP 0013
ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 451 - Voltage Supply Too High for Steering ECU (792) ................................................................................................................................................. WP 0015 Error Code 452 - Voltage Supply Too Low for Steering ECU (792) ................................................................................................................................................. WP 0015 Error Code 453 - Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0015 Error Code 454 - Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0015 Error Code 811 - Voltage Supply Too Low for Transmission ECU (793) ........................................................................................................................................ WP 0015 Error Code 812 - Voltage Supply Too High for Transmission ECU (793) ........................................................................................................................................ WP 0015 Error Code 813 - Voltage Failure at Transmission Gearshift Valve Supply .................................................................................................................................... WP 0015 Error Code 814 - Voltage Failure at Transmission Gearshift Valve Power Supply ......................................................................................................................... WP 0015
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE 1. 2. 3. 4. 5. 6. Error Code 121 - Supply Voltage to Servo ECU (790) Failure ......................................................... WP 0012 Error Code 122 - Supply Voltage to Servo ECU (790) Failure ......................................................... WP 0012 Error Code 123 - 10V Reference Voltage for Servo ECU (790) Short Circuit Failure ......................................................................................................................... WP 0012 Error Code 201 - Supply Voltage to Tophandler ECU (791) Failure .............................................................................................................................................. WP 0012 Error Code 202 - Supply Voltage to Tophandler ECU (791) Failure .............................................................................................................................................. WP 0012 Error Code 203 - 10V Reference Voltage for Tophandler ECU (791) Failure ..................................................................................................................................... WP 0012
0005-3
TM 10-3930-675-23-1
0005
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS 1. 2. 3. 4. Error Code 1221 - High Voltage Detected at Ambient Air Pressure Sensor Circuit ................................................................................................................... WP 0021 Error Code 1222 - Low Voltage Detected at Ambient Air Pressure Sensor Circuit ................................................................................................................... WP 0021 Error Code 1295 - Ambient Air Pressure Sensor Circuit Failure ...................................................... WP 0021 Error Code 1298 - High Intake Air Restriction or Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0021
ENGINE BATTERY VOLTAGE CIRCUITS 1. 2. 3. 4. 5. Error Code 1434 - Unswitched Battery Supply Circuit Failure ......................................................... WP 0024 Error Code 1441 - Unswitched Battery Supply Circuit Failure ......................................................... WP 0024 Error Code 1442 - Unswitched Battery Supply Circuit Failure. ........................................................ WP 0024 Error Code 1474 - Starter Solenoid Lockout Relay Driver Circuit Failure .............................................................................................................................................. WP 0024 Error Code 1596 - Voltage Monitor, High Voltage Failure ................................................................ WP 0024
ENGINE FUEL INJECTOR CIRCUITS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Error Code 1311 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1312 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1313 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1314 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1315 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1321 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1322 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1323 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1324 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1325 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1331 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1332 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1951 - Injector Circuit Failure ......................................................................................... WP 0007
ENGINE FUEL PRESSURE SENSORS AND CIRCUITS 1. Error Code 1254 - Fuel Shutoff Solenoid Circuit Failure .................................................................. WP 0023
0005-4
TM 10-3930-675-23-1
0005
ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. Troubleshooting Procedure
Error Code 1255 - Fuel Shutoff Solenoid External Voltage Detected on Circuit ........................................................................................................................... WP 0023 Error Code 1581 - Fuel Inlet Restriction Sensor Circuit Failure ....................................................... WP 0023
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) 1. 2. 3. 4. 5. Error Code 1187 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1227 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1287 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1352 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1443 - Low Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0017
ENGINE OIL PRESSURE 1. 2. 3. 4. 5. Error Code 1135 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1141 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1143 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1415 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1435 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019
ENGINE POSITION SENSOR CIRCUITS 1. 2. 3. Error Code 1115 - Engine Position Sensor Circuit Failure ............................................................... WP 0018 Error Code 1121 - Engine Position Sensor Circuit Failure ............................................................... WP 0018 Error Code 1234 - Engine Overspeed Failure .................................................................................. WP 0018
ENGINE PRESSURE SENSOR 1. 2. 3. 4. Error Code 1122 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022 Error Code 1123 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022 Error Code 1419 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022 Error Code 1433 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022
ENGINE TEMPERATURE SENSORS AND CIRCUITS 1. Error Code 1144 - Coolant Temperature Sensor Circuit Failure ...................................................... WP 0020
0005-5
TM 10-3930-675-23-1
0005
ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Troubleshooting Procedure
Error Code 1145 - Coolant Temperature Sensor Circuit Failure ...................................................... WP 0020 Error Code 1151 - Coolant Temperature Above Critical Threshold ......................................................................................................................................... WP 0020 Error Code 1153 - Intake Air Temperature Sensor Circuit Failure ................................................... WP 0020 Error Code 1154 - Intake Air Temperature Sensor Circuit Failure ................................................... WP 0020 Error Code 1155 - Intake Air Temperature Above Critical Threshold ......................................................................................................................................... WP 0020 Error Code 1212 - Oil Temperature Sensor Circuit Failure .............................................................. WP 0020 Error Code 1213 - Oil Temperature Sensor Circuit Failure .............................................................. WP 0020 Error Code 1214 - Oil Temperature Above Critical Threshold ......................................................... WP 0020 Error Code 1697 - ECU Internal Temperature Sensor Circuit Failure .............................................................................................................................................. WP 0020 Error Code 1698 - ECU Internal Temperature Sensor Circuit Failure .............................................................................................................................................. WP 0020
ENGINE TPS AND IDLE VALIDATION SWITCH 1. 2. 3. 4. 5. Error Code 1131 - High Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0008 Error Code 1132 - Low Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0008 Error Code 1431 - High Voltage Detected at Both Idle Validation Signal Circuits .................................................................................................................................. WP 0008 Error Code 1432 - Wrong Voltage Signals Detected at Throttle Position Sensor and Idle Validation Circuits ..................................................................................... WP 0008 Error Code 1551 - No Voltage Detected at Both Idle Validation Signal Circuits .................................................................................................................................. WP 0008
HYDRAULIC FILTER INDICATORS 1. 2. 3. 4. 5. Error Code 1 - Boom Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 2 - Steering Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 3 - Tophandler Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 4 - Hydraulic Reservoir Return Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 432 - Boom Hydraulic Filter Sensor, Circuit Error Input ................................................................................................................................................. WP 0038
0005-6
TM 10-3930-675-23-1
0005
ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 6. 7. 8. 9. Troubleshooting Procedure
Error Code 433 - Steering Hydraulic Filter Sensor, Circuit Input Error ................................................................................................................................................. WP 0038 Error Code 434 - Tophandler Hydraulic Filter Sensor, Circuit Input Error ........................................................................................................................................ WP 0038 Error Code 435 - Hydraulic Reservoir Return System Filter Sensor, Circuit Input Error ................................................................................................................ WP 0038 Error Code 786 - Transmission Hydraulic System Sensor Indicating Clogged Filter .................................................................................................................. WP 0038
HYDRAULIC PISTON PUMP CUT-OFF 1. Error Code 172 - Hydraulic Piston Pump Cut-Off, Open or Short Circuit Failure ................................................................................................................................... WP 0037
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) 1. 2. 3. Error Code 125 - Memory Failure ..................................................................................................... WP 0035 Error Code 141 - Internal Communication Failure ............................................................................ WP 0035 Error Code 142 - Internal Communication Failure ............................................................................ WP 0035
INPUT AND OUTPUT SIGNALS FOR STEERING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Error Code 350 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 351 - Right Rear Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 352 - Left Rear Wheel Valve Solenoid Error .................................................................. WP 0016 Error Code 353 - Left Front Wheel Valve Solenoid Error ................................................................. WP 0016 Error Code 354 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 355 - Right Rear Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 356 - Left Rear Wheel Valve Solenoid Error .................................................................. WP 0016 Error Code 357 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 399 - EEPROM Parameter Error in ECU (792) ............................................................. WP 0016 Error Code 401 - Transmission Neutral Signal from Steering ECU (792) Short Circuit Failure ........................................................................................................ WP 0016 Error Code 404 - 2WD Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 405 - 4WD Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 406 - Crab Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016
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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Troubleshooting Procedure
Error Code 408 - Unlocked Twistlock Control Lamp, Short Circuit Failure ................................................................................................................................... WP 0016 Error Code 409 - Locked Twistlock Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 410 - Alignment Control Lamp, Short Circuit Failure ..................................................... WP 0016 Error Code 412 - Autolube Pump Control, Short Circuit Failure (RT 240V2 and RT 240V3) .............................................................................................................. WP 0016 Error Code 413 - Boom Folding Supply Valve, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 415 - Drag Restriction, Short Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3) ................................................................................................. WP 0016 Error Code 416 - Steering Pressure Switch, Circuit Input Error ....................................................... WP 0016 Error Code 418 - 2WD Steering Selection Switch, Circuit Input Error ................................................................................................................................................. WP 0016 Error Code 419 - 4WD Steering Selection Switch, Circuit Failure .................................................... WP 0016 Error Code 420 - Crab Steering Selection Switch, Circuit Failure .................................................... WP 0016 Error Code 422 - Cab in Transport Proximity Switch, Circuit Input Error ........................................................................................................................................ WP 0016 Error Code 423 - Ether Start Switch, Circuit Failure ......................................................................... WP 0016 Error Code 427 - Tophandler Work Light Switch, Circuit Input Error ................................................................................................................................................. WP 0016 Error Code 440 - Steering Wheel Sensor, Power Supply Error (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0016 Error Code 450 - Temperature Inside Steering ECU (792) Above Critical Threshold [184F (85C)] .......................................................................................... WP 0016
INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 777 - Internal Transmission Failure at Clutch K1 ........................................................... WP 0029 Error Code 778 - Internal Transmission Failure at Clutch K2 ........................................................... WP 0029 Error Code 779 - Internal Transmission Failure at Clutch K3 ........................................................... WP 0029 Error Code 780 - Internal Transmission Failure at Clutch K4 ........................................................... WP 0029 Error Code 781 - Internal Transmission Failure at Clutch KV .......................................................... WP 0029 Error Code 782 - Internal Transmission Failure at Clutch KR .......................................................... WP 0029 Error Code 845 - Clutch Failure Detected During Calibration .......................................................... WP 0029 Error Code 846 - Clutch Adjustment Data Lost ................................................................................ WP 0029
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MECHANICAL OR HYDRAULIC STEERING FAILURE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 317 - Right-Front Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 318 - Right-Rear Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 319 - Left-Rear Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 320 - Left-Front Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 321 - Right-Front Wheel is Not Calibrated Correctly ..................................................... WP 0033 Error Code 322 - Right-Rear Wheel is Not Calibrated Correctly ...................................................... WP 0033 Error Code 323 - Left-Rear Wheel is Not Calibrated Correctly ........................................................ WP 0033 Error Code 324 - Left-Front Wheel is Not Calibrated Correctly ........................................................ WP 0033
MISCELLANEOUS TRANSMISSION FAILURE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 618 - Signal from Gear Selector Not Correct ................................................................. WP 0028 Error Code 622 - Feedback Signal from 2WD/4WD Switch Not Correct ............................................................................................................................................. WP 0028 Error Code 745 - Backup Alarm Control Circuit, Short Circuit to Chassis Failure ................................................................................................................................ WP 0028 Error Code 746 - Backup Alarm Control Circuit, Short Circuit to Battery Failure .................................................................................................................................. WP 0028 Error Code 747 - Backup Alarm Control Circuit, Open Circuit Failure .............................................................................................................................................. WP 0028 Error Code 761 - 2WD/4WD Connection Valve Circuit, Short Circuit to Chassis Failure ................................................................................................................. WP 0028 Error Code 762 - 2WD/4WD Connection Valve Circuit, Short Circuit to Battery Failure ................................................................................................................... WP 0028 Error Code 763 - 2WD/4WD Connection Valve Circuit, Open Circuit Failure ................................................................................................................................... WP 0028
OVERLOAD PROTECTION 1. 2. 3. 4. Error Code 130 - Overload Protection System Failure ..................................................................... WP 0010 Error Code 131 - Boom Extension Sensor or Circuit Failure ............................................................ WP 0010 Error Code 132 - Boom Angle Sensor or Circuit Failure .................................................................. WP 0010 Error Code 133 - Left Lift Cylinder Pressure Sensor or Circuit Failure .............................................................................................................................................. WP 0010
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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 5. 6. 7. 8. Troubleshooting Procedure
Error Code 134 - Right Lift Cylinder Pressure Sensor or Circuit Failure .............................................................................................................................................. WP 0010 Error Code 135 - Left Lift Cylinder Piston Pressure Sensor or Circuit Failure ................................................................................................................................... WP 0010 Error Code 136 - Right Lift Cylinder Piston Pressure Sensor or Circuit Failure ................................................................................................................................... WP 0010 Error Code 210 - Tophandler Angle Sensor or Circuit Failure ......................................................... WP 0010
STEERING ECU (732), TRANSMISSION ECU (793), AND ENGINE ECU (794) 1. 2. 3. 4. 5. 6. 7. Error Code 300 - Steering ECU (792) Hardware Failure .................................................................. WP 0014 Error Code 841 - Transmission ECU (793) Memory Failure ............................................................ WP 0014 Error Code 843 - Application Error Failure ....................................................................................... WP 0014 Error Code 1111 - Engine ECU (794) Memory Failure .................................................................... WP 0014 Error Code 1341 - Engine ECU (794) Loss of Data Failure ............................................................. WP 0014 Error Code 1343 - Engine ECU (794) Internal Communication Failure .............................................................................................................................................. WP 0014 Error Code 1346 - Engine ECU (794) Software Failure ................................................................... WP 0014
STEERING SENSOR 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Error Code 301 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 302 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 303 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 304 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034 Error Code 305 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 306 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 307 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 308 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034 Error Code 309 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 310 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 311 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 312 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034 Error Code 313 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 314 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 315 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 316 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034
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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 17. Troubleshooting Procedure
Error Code 339 - Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3) ............................................................................................ WP 0034
STEERING VALVE CIRCUIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Error Code 325 - Right-Front Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 326 - Right-Rear Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 327 - Left-Rear Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 328 - Left-Front Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 329 - Right-Front Wheel Valve Solenoid, Short Circuit Failure ................................................................................................................................... WP 0032 Error Code 330 - Right-Rear Wheel Valve Solenoid, Short Circuit Failure ................................................................................................................................... WP 0032 Error Code 331 - Left-Rear Wheel Valve Solenoid, Short Circuit Failure .............................................................................................................................................. WP 0032 Error Code 332 - Left-Front Wheel Valve Solenoid, Short Circuit Failure .............................................................................................................................................. WP 0032 Error Code 339 - Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3) ............................................................................................ WP 0032 Error Code 340 - Hydraulic Steering Pressure Below Threshold [1,450 psi (100 Bar)] ......................................................................................................................... WP 0032 Error Code 341 - Steering Wheel Signal Not Consistent ................................................................. WP 0032 Error Code 342 - One Steering Wheel Signal is Interrupted ............................................................ WP 0032 Error Code 343 - One Steering Wheel Signal is Interrupted ............................................................ WP 0032 Error Code 344 - Both Steering Wheel Signals are Interrupted ....................................................... WP 0032 Error Code 347 - No Steering Mode Selected .................................................................................. WP 0032
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) 1. 2. 3. 4. 5. Error Code 205 - Memory Failure ..................................................................................................... WP 0011 Error Code 220 - Internal Communication Failure, Connector 2 ...................................................... WP 0011 Error Code 221 - Internal Communication Failure, Connector 2 ...................................................... WP 0011 Error Code 250 - Internal Communication Failure, Connector 3 ...................................................... WP 0011 Error Code 251 - Internal Communication Failure, Connector 3 ...................................................... WP 0011
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TOPHANDLER LEVELING 1. 2. 3. 4. 5. 6. 7. Error Code 128 - Joystick-to-ECU (790) Failure .............................................................................. WP 0043 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0043 Error Code 240 - Tophandler Leveling Locking Control, Wiring Circuit Failure ................................................................................................................................... WP 0043 Error Code 267 - Tophandler Leveling Right, Open Circuit Failure .............................................................................................................................................. WP 0043 Error Code 268 - Tophandler Leveling Right, Short Circuit Failure .............................................................................................................................................. WP 0043 Error Code 270 - Tophandler Leveling Left, Open Circuit Failure .................................................... WP 0043 Error Code 271 - Tophandler Leveling Left, Short Circuit Failure .................................................... WP 0043
TOPHANDLER SIDESHIFT 1. 2. 3. 4. Error Code 225 - Tophandler Sideshift Left, Open Circuit Failure .................................................... WP 0044 Error Code 226 - Tophandler Sideshift Left, Short Circuit Failure .................................................... WP 0044 Error Code 228 - Tophandler Sideshift Right, Open Circuit Failure .............................................................................................................................................. WP 0044 Error Code 229 - Tophandler Sideshift Right, Short Circuit Failure .............................................................................................................................................. WP 0044
TOPHANDLER SLEWING 1. 2. 3. 4. 5. 6. Error Code 128 - Joystick-to-ECU (790) Failure .............................................................................. WP 0041 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0041 Error Code 255 - Tophandler Clockwise Slewing, Wiring Circuit Failure .............................................................................................................................................. WP 0041 Error Code 256 - Tophandler Clockwise Slewing, Component Failure .............................................................................................................................................. WP 0041 Error Code 258 - Tophandler Counterclockwise Slewing, Wiring Circuit Failure ................................................................................................................................... WP 0041 Error Code 259 - Tophandler Counterclockwise Slewing, Component Failure ........................................................................................................................... WP 0041
TOPHANDLER SPREADER 1. 2. Error Code 231 - Tophandler Spreader Opening, Open Circuit Failure .............................................................................................................................................. WP 0045 Error Code 232 - Tophandler Spreader Opening, Short Circuit Failure .............................................................................................................................................. WP 0045
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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 3. 4. Troubleshooting Procedure
Error Code 234 - Tophandler Spreader Closing, Open Circuit Failure .............................................................................................................................................. WP 0045 Error Code 235 - Tophandler Spreader Closing, Short Circuit Failure .............................................................................................................................................. WP 0045
TOPHANDLER TILT 1. 2. 3. 4. 5. 6. 7. Error Code 129 - Joystick-to-ECU (790) Failure .............................................................................. WP 0042 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0042 Error Code 237 - Tophandler Tilt Locking Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042 Error Code 261 - Tophandler Tilt OUT Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042 Error Code 262 - Tophandler Tilt OUT Control, Component Failure .............................................................................................................................................. WP 0042 Error Code 264 - Tophandler Tilt IN Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042 Error Code 265 - Tophandler Tilt IN Control, Component Failure .................................................... WP 0042
TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR 1. 2. 3. 4. 5. Error Code 212 - Tophandler Left Twistlocks Indication Failure ...................................................... WP 0046 Error Code 213 - Tophandler Right Twistlocks Indication Failure .................................................... WP 0046 Error Code 214 - Tophandler Forklift Sensor Indication Failure ....................................................... WP 0046 Error Code 243 - Tophandler Twistlock Locking Circuit Failure ....................................................... WP 0046 Error Code 246 - Tophandler Twistlock Unlocking Circuit Failure .................................................... WP 0046
TRANSMISSION CLUTCH CIRCUIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Error Code 713 - Clutch K1 Short Circuit to Battery Failure ............................................................. WP 0027 Error Code 714 - Clutch K1 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 715 - Clutch K1 Open Circuit Failure ............................................................................. WP 0027 Error Code 716 - Clutch K2 Short Circuit to Battery Failure ............................................................. WP 0027 Error Code 717 - Clutch K2 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 718 - Clutch K2 Open Circuit Failure ............................................................................. WP 0027 Error Code 719 - Clutch K3 Open Circuit to Battery Failure ............................................................. WP 0027 Error Code 720 - Clutch K3 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 721 - Clutch K3 Open Circuit Failure ............................................................................. WP 0027 Error Code 729 - Clutch K4 Short Circuit to Battery Failure ............................................................. WP 0027
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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 11. 12. 13. 14. 15. 16. 17. 18. Troubleshooting Procedure
Error Code 730 - Clutch K4 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 731 - Clutch K4 Open Circuit Failure ............................................................................. WP 0027 Error Code 732 - Clutch KV Short Circuit to Battery Failure ............................................................ WP 0027 Error Code 733 - Clutch KV Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 734 - Clutch KV Open Circuit Failure ............................................................................. WP 0027 Error Code 735 - Clutch KR Short Circuit to Battery Failure ............................................................ WP 0027 Error Code 736 - Clutch KR Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 737 - Clutch KR Open Circuit Failure ............................................................................ WP 0027
TRANSMISSION SPEED SENSORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Error Code 649 - Engine Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026 Error Code 650 - Engine Speed Sensor Failure, Short Circuit to Chassis ............................................................................................................................................ WP 0026 Error Code 651 - Engine Speed Sensor Failure, Logical Error ........................................................ WP 0026 Error Code 652 - Turbine Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026 Error Code 653 - Turbine Speed Sensor Failure, Short Circuit to Chassis ........................................................................................................................................ WP 0026 Error Code 654 - Turbine Speed Sensor Failure, Logical Error ....................................................... WP 0026 Error Code 655 - Internal Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026 Error Code 656 - Internal Speed Sensor Failure, Short Circuit to Chassis ........................................................................................................................................ WP 0026 Error Code 657 - Internal Speed Sensor Failure, Logical Error ....................................................... WP 0026 Error Code 658 - Output Speed Sensor Failure, Open Circuit or Short Circuit to Battery ..................................................................................................................... WP 0026 Error Code 659 - Output Speed Sensor Failure, Short Circuit to Chassis ............................................................................................................................................ WP 0026 Error Code 660 - Output Speed Sensor Failure, Logical Error ......................................................... WP 0026 Error Code 662 - Output Speed Sensor Failure, Logical Speed Error ................................................................................................................................................. WP 0026
TRANSMISSION TEMPERATURE 1. 2. Error Code 637 - Transmission Sump Temperature Sensor Failure, Open Circuit or Short Circuit to Battery ............................................................................... WP 0025 Error Code 638 - Transmission Sump Temperature Sensor Failure, Short Circuit to Chassis ....................................................................................................... WP 0025
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3. 4. 5. 6.
Error Code 639 - Converter Output Temperature Sensor Failure, Open Circuit or Short Circuit to Battery ............................................................................... WP 0025 Error Code 640 - Converter Output Temperature Sensor Failure, Short Circuit to Chassis ....................................................................................................... WP 0025 Error Code 783 - Sump Temperature Critical Threshold [212F (100C)] Failure ................................................................................................................................ WP 0025 Error Code 795 - Converter Output Temperature Critical Threshold [248F (120C)] Failure ................................................................................................... WP 0025
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Engine Will Not Crank ...................................................................................................................... WP 0006 Engine Will Crank but Will Not Start (Exhaust Smoke or No Exhaust Smoke) ............................................................................................................................... WP 0006 Excessive Exhaust Smoke - White ................................................................................................... WP 0006 Excessive Exhaust Smoke - Black ................................................................................................... WP 0006 Engine Acceleration - Poor .............................................................................................................. WP 0006 Engine Deceleration - Poor .............................................................................................................. WP 0006 Engine Performance (Power) - Low ................................................................................................. WP 0006 Engine Runs Rough ......................................................................................................................... WP 0006 Engine Speed Surges (Idle or Under Load) ..................................................................................... WP 0006 Engine Shuts Off Unexpectedly ....................................................................................................... WP 0006 Engine Starts but Will Not Keep Running ......................................................................................... WP 0006 Engine Vibration Excessive .............................................................................................................. WP 0006 Fuel Consumption Excessive ........................................................................................................... WP 0006 Engine Overheats ............................................................................................................................ WP 0006 Engine Oil Pressure - Low ............................................................................................................... WP 0006 Engine Oil Pressure - High ............................................................................................................... WP 0006 Engine Cold Start System Not Working ........................................................................................... WP 0006
ELECTRICAL TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. Headlight(s) (High or Low Beam) Do Not Operate When Switch is Turned On .................................................................................................................................... WP 0006 Front/Rear Side Marker Light(s) or Taillight(s) Do Not Operate When Headlight Switch is Turned On .............................................................................................. WP 0006 Stoplight(s) Do Not Operate When Brake Pedal is Pressed ............................................................ WP 0006 Turn Signals or Emergency Flashers are Not Working .................................................................... WP 0006
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5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Blackout Drive and Marker Lights Do Not Operate When Switch is Turned On .................................................................................................................................... WP 0006 Blackout Stoplights Not Working ...................................................................................................... WP 0006 Horn Will Not Sound When Button is Pressed ................................................................................. WP 0006 Backup Lights/Alarm Does Not Operate When Vehicle Placed in Reverse ........................................................................................................................................ WP 0006 Boom Work Light(s) Do Not Operate When Switch is Turned On .................................................... WP 0006 Tophandler Work Light(s) Do Not Operate When Switch is Turned On ........................................................................................................................................ WP 0006 Infrared (IR) Work Light(s) Do Not Operate When Switch is Turned On. ....................................................................................................................................... WP 0006 Front Windshield Wiper Motor Not Working ..................................................................................... WP 0006 Rear Windshield Wiper Motor Not Working ...................................................................................... WP 0006 Roof Windshield Wiper Motor Not Working ...................................................................................... WP 0006 Windshield Washer Not Working ...................................................................................................... WP 0006 Cab Interior Light Not Working ......................................................................................................... WP 0006 12V Utility Plug Not Working ............................................................................................................ WP 0006 Blower Motor Not Working ............................................................................................................... WP 0006 Heater/Defroster Producing Low or No Heat .................................................................................... WP 0006 A/C System Not Cooling Properly .................................................................................................... WP 0006 Fuel Gauge Not Working Properly ................................................................................................... WP 0006 Drivers ECS Display Screen Will Not Display ................................................................................. WP 0006 After Key On" Functions Not Working (No Crank, Display, etc.). .................................................... WP 0006 Proximity Switches - Tophandler and Cab ....................................................................................... WP 0006 Normal Functions Operate in Blackout Mode ................................................................................... WP 0006 Multiple Boom or Tophandler Functions Not Working (Multiple Error Codes) ..................................................................................................................................... WP 0006 Function(s) Work Uncontrolled ......................................................................................................... WP 0006
BRAKE SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. Braking is Poor or Nonexistent ......................................................................................................... WP 0006 Parking Brake Will Not Release ....................................................................................................... WP 0006 Parking Brake Will Not Engage ........................................................................................................ WP 0006
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STEERING SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Steering Control is Poor or Nonexistent ........................................................................................... WP 0006
OPERATORS CAB TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Operators Cab Will Not Move To or From Transport Position Properly ............................................................................................................................................ WP 0006
AUXILIARY PUMP TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Auxiliary Pump Not Working ............................................................................................................. WP 0006
BOOM SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. Boom Will Not Lift or Lower Properly ............................................................................................... WP 0006 Boom Will Not Extend or Retract Properly ....................................................................................... WP 0006 Boom Folding Cylinders Not Working .............................................................................................. WP 0006 Boom Locking Pin Cylinders Not Working ........................................................................................ WP 0006
TOPHANDLER SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. 5. Tophandler Will Not Tilt Forward or Rearward Properly ................................................................... WP 0006 Tophandler Will Not Oscillate (Level) Properly ................................................................................. WP 0006 Tophandler Spreader Will Not Open or Close Properly ................................................................... WP 0006 Tophandler Will Not Rotate Left or Right Properly ........................................................................... WP 0006 Tophandler Twistlocks Will Not Rotate Properly .............................................................................. WP 0006
BOGIE WHEEL SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Bogie Wheels Will Not Lift or Lower ................................................................................................. WP 0006
FORKLIFT KIT TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Fork Functions Not Working Properly .............................................................................................. WP 0006
AUTOLUBE SYSTEM NOT LUBRICATING PROPERLY (IF EQUIPPED) TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. Autolube System Not Lubricating Properly (If Equipped) ................................................................. WP 0006 Autolube Pump Not Working (If Equipped) ...................................................................................... WP 0006
END OF WORK PACKAGE
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0006
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)
INITIAL SETUP: References FO-10 (Volume 2, WP 0272) LO 10-3930-675-13 TM 10-3930-675-10 WP 0004 WP 0008 WP 0013 WP 0018 WP 0020 WP 0026 WP 0047 WP 0050 WP 0051 WP 0052 WP 0069 WP 0070 WP 0071 WP 0072 WP 0073 WP 0076 WP 0077 WP 0080 References (cont.) WP 0081 WP 0083 WP 0088 WP 0093 WP 0094 WP 0095 WP 0103 WP 0109 WP 0110 WP 0114 WP 0115 WP 0123 WP 0127 WP 0129 WP 0133 Volume 2, WP 0159 Volume 2, WP 0194 Volume 2, WP 0195 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to (WP 0004) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) SYMPTOM ENGINE WILL NOT CRANK MALFUNCTION Transmission Shift Lever is NOT in Neutral. CORRECTIVE ACTION Place transmission shift lever in Neutral.
0006-1
03/15/2011 Rel(1.8) root(tswp) wpno(T00011)
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Master battery switch is off. CORRECTIVE ACTION Place master battery switch to on position. MALFUNCTION Circuit breaker numbers 2 and 8 are tripped. CORRECTIVE ACTION Reset circuit breakers as required (WP 0103). MALFUNCTION Damaged or loose battery connections. CORRECTIVE ACTION
WARNING
To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electrical shock, damage to equipment, and injury to personnel. Tighten or repair battery connections (WP 0129). MALFUNCTION Check battery voltage. Normal voltage can be 23 to 27V. CORRECTIVE ACTION Test batteries.
0006-2
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION No voltage at starter terminal 30. CORRECTIVE ACTION
WARNING
Eye protection must be worn when working under vehicle to avoid injury to personnel. Check wiring back to master battery switch and batteries (Figure 8 (Volume 2, WP 0272)). MALFUNCTION No voltage (24V) at starter solenoid on starter at wire W11 of S terminal while turning the ignition switch to crank (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. Check circuit breaker numbers F50-1 and F50-2 for loose or damaged connections. If voltage is present (24V), replace shorted or damaged starter and solenoid (WP 0093).
T0040JCH
Figure 1. Starter Motor MALFUNCTION Starter relay 360 defective or damage (Volume 2, WP 0267). CORRECTIVE ACTION Replace shorted open or damaged relay (WP 0103).
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION No voltage (24V) at XK2 pin 7 while turning the ignition switch to crank (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. 3. 4. Check voltage at X8 pin 3 (Figure 8 (Volume 2, WP 0272)). Unplug X8 and check continuity between pin 2 and 3 with the ignition switch turned to crank (Figure 8 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty ignition switch (WP 0094).
MALFUNCTION No voltage (24V) at XKI2 pin 4 while turning the ignition switch to crank. CORRECTIVE ACTION 1. 2. 3. 4. Check voltage (24V) at XK2 pin 2 (Figure 8 (Volume 2, WP 0272)) X28 pins 4, 9, and 7 (Figure 9 (Volume 2, WP 0272)) with ignition switch on. Check continuity of shift lever at the loose part of X28 between pin 9 and 7 with the shift lever in Neutral (Figure 9 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace shift lever (WP 0095).
MALFUNCTION Defective relays. CORRECTIVE ACTION Replace relay (WP 0103). SYMPTOM ENGINE WILL CRANK BUT WILL NOT START (EXHAUST SMOKE OR NO EXHAUST SMOKE) MALFUNCTION Fuel line shutoff valve at fuel filter closed. CORRECTIVE ACTION Open fuel line shutoff valve.
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Circuit breaker F13 tripped CORRECTIVE ACTION Reset F13 circuit breaker (WP 0013). MALFUNCTION Damaged or leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace fuel/water separator (WP 0076). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service or replace air cleaner element (WP 0071). MALFUNCTION Perform cold starting procedures (TM 10-3930-675-10). CORRECTIVE ACTION See cold starting system maintenance (WP 0077). MALFUNCTION Fuel solenoid shutoff valve (FSOV) inoperative. CORRECTIVE ACTION 1. 2. 3. Check for voltage at FSOV (12V). Repair or replace damaged wires or connectors. Replace fuel solenoid shutoff valve (WP 0070).
0006-5
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued SYMPTOM EXCESSIVE EXHAUST SMOKE - WHITE MALFUNCTION Low engine operating temperature (ambient temperature). CORRECTIVE ACTION 1. 2. Allow engine to warm to operating temperature. Check cooling fan operation. Enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.
MALFUNCTION Engine temperature sensor malfunctioning. CORRECTIVE ACTION 1. 2. Perform troubleshooting procedure for ERROR CODES 1144 and 1145 for the coolant temperature sensor (WP 0020). Perform troubleshooting procedure for ERROR CODES 1153 and 1154 for the intake air temperature sensor (WP 0020).
MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION 1. 2. SYMPTOM EXCESSIVE EXHAUST SMOKE - BLACK MALFUNCTION Monitor engine operating temperature (low ambient temperature). CORRECTIVE ACTION 1. 2. Allow engine to warm to operating temperature. Check cooling fan operation. Enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures. Compare fuel used with type and grade specifications (TM 10-3930-675-10). lf problem still exists, replace engine assembly (WP 0050).
0006-6
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Engine temperature or pressure sensor malfunctioning. CORRECTIVE ACTION 1. 2. Perform troubleshooting procedure for ERROR CODES 1144 and 1145 for the coolant temperature sensor (WP 0020). Perform troubleshooting procedure for ERROR CODES 1122, 1123, and 1433 for the intake manifold pressure sensor (WP 0022).
MALFUNCTION Check for poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. Dirty or clogged air cleaner element CORRECTIVE ACTION 1. 2. 3. Check quality of fuel, type, and grade. Repair air intake hoses, lines, and clamps (WP 0072). Service or replace air cleaner element (WP 0071).
MALFUNCTION Plugged crankcase ventilation system. CORRECTIVE ACTION Clean crankcase breather and tube (WP 0057). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073).
0006-7
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued
SYMPTOM ENGINE ACCELERATION - POOR MALFUNCTION ERROR CODES or conditions that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE(s)/condition. MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076).
0006-8
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE DECELERATION - POOR MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069).
0006-9
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Restrictions in fuel lines, hoses, and fittings. CORRECTIVE ACTION Replace any damaged or restricted fuel line, hose, or fitting (WP 0069). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE PERFORMANCE (POWER) - LOW MALFUNCTION ERROR CODES or conditions that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE(s)/condition. MALFUNCTION Parasitic loads on engine. CORRECTIVE ACTION Check for brakes dragging, hydraulic malfunctions, etc. MALFUNCTION Incorrect engine oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (WP 0047). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076).
0006-10
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Leaking fuel lines, hoses, and fittings, or restricted fuel lines (supply and return). CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008).
0006-11
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0006
SYMPTOM ENGINE RUNS ROUGH MALFUNCTION Monitor engine operating temperature (low ambient temperature). CORRECTIVE ACTION 1. 2. Allow engine to warm to operating temperature. Incorrect cooling fan operation. Enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.
MALFUNCTION Loose or damaged engine mounts. CORRECTIVE ACTION 1. 2. Tighten loose engine mounts. Replace engine mounts (WP 0051).
MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings that may allow air into fuel system. Restricted fuel lines (supply and return). CORRECTIVE ACTION 1. 2. Tighten or repair fuel lines, hoses, and fittings (WP 0069). Replace clogged fuel/water separator (WP 0076).
MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Engine Position Sensor (EPS) or circuit malfunction. CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODES 1115 and 1121 (WP 0018).
0006-12
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE SPEED SURGES (IDLE OR UNDER LOAD) MALFUNCTION Engine idle speed set too low or idling with excessive load. CORRECTIVE ACTION Monitor idle speed; should be around 700 RPM. Check for excessive hydraulic loads at idle. MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings. Restricted fuel lines (supply and return). CORRECTIVE ACTION 1. 2. Tighten or repair fuel lines, hoses, and fittings (WP 0069). Replace clogged fuel/water separator (WP 0076).
MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal.
0006-13
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Engine Position Sensor (EPS) circuit malfunction CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODES 1115 and 1121 (WP 0018). SYMPTOM ENGINE SHUTS OFF UNEXPECTEDLY MALFUNCTION ERROR CODES that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures. MALFUNCTION Incorrect battery voltage. CORRECTIVE ACTION Service batteries and connections (WP 0129).
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Circuit breakers F13, F4, and F5 tripped. CORRECTIVE ACTION Replace faulty circuit breaker (WP 0103). MALFUNCTION No voltage at X16 pin 9 and EUC (794) pin 38 with the ignition on. CORRECTIVE ACTION Repair or replace wires or connectors (Figure 3 (Volume 2, WP 0272)). MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076). MALFUNCTION Check for restricted fuel lines (supply and return). CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE STARTS BUT WILL NOT KEEP RUNNING MALFUNCTION ERROR CODES that de-rate engine RPM and shut down after 30 seconds (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures.
0006-15
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect battery voltage. CORRECTIVE ACTION Service batteries and connections. MALFUNCTION Tripped circuit breakers F13, F4, and F5. CORRECTIVE ACTION Replace faulty circuit breaker (WP 0103). MALFUNCTION No voltage at X16 pin 9 and EUC (794) pin 38 with the ignition on. CORRECTIVE ACTION Repair or replace wires or connectors (Volume 2, WP 0267). MALFUNCTION Parasitic loads on engine. CORRECTIVE ACTION Check for hydraulic malfunctions, etc., that cause loading on engine. MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). SYMPTOM ENGINE VIBRATION EXCESSIVE MALFUNCTION Engine misfiring. CORRECTIVE ACTION Perform troubleshooting procedure for Engine Runs Rough in this work package.
0006-16
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Belt-driven accessories malfunctioning. CORRECTIVE ACTION Check alternator and air conditioner compressor operation. MALFUNCTION Loose or damaged engine mounts. CORRECTIVE ACTION 1. 2. Tighten loose engine mounts. Replace engine mounts (WP 0051).
MALFUNCTION Loose or damaged engine vibration damper. CORRECTIVE ACTION 1. 2. SYMPTOM FUEL CONSUMPTION EXCESSIVE MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). Tighten loose engine vibration damper. Replace vibration damper (WP 0053).
0006-17
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (WP 0047). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE OVERHEATS MALFUNCTION Coolant level low. CORRECTIVE ACTION Fill the coolant to the proper level in the coolant expansion tank (LO 10-3930-675-13). MALFUNCTION Incorrect engine oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (LO 10-3930-675-13).
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Radiator, radiator cap, and louvers damaged or obstructed. CORRECTIVE ACTION 1. 2. 3. Clean dirt and debris from radiator and louvers. Replace leaking radiator cap (WP 0080). Replace louvers (WP 0081).
MALFUNCTION Coolant system hoses loose, damaged, leaking, or collapsed. CORRECTIVE ACTION 1. 2. Inspect and tighten any loose clamps. Replace any damaged, leaking, or collapsed hoses (WP 0083).
MALFUNCTION Incorrect cooling fan operation. CORRECTIVE ACTION 1. 2. Start engine and enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Change the fan speed and observe if fan speed changes properly (0%, 33%, 66%, and 100%). If fan does not change speeds, check hydraulic pressure of engine driven pump (WP 0214).
MALFUNCTION Incorrect status of fording switch. CORRECTIVE ACTION 1. 2. Enter into EXTRA FUNCT 4(13)" in the diagnostic menu. WATER LEVEL" should indicate 1". If 0" is indicated, perform troubleshooting of fording switch circuit (Figure 7 (Volume 2, WP 0272)).
0006-19
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect thermostat operation. CORRECTIVE ACTION 1. 2. 3. 4. 5. With the engine cold, connect a 3/8 in. (10 mm) hose to the barbed bleeder valve on the metal line coming from top of hose to radiator thermostat housing. Open the coolant expansion tank and place the other end of the hose in the top of the tank and hold. Open the bleeder valve. Start the engine and observe the coolant flow from the hose. Coolant flow should not exceed 4 oz (0.12 L) per minute. Run the engine until it reaches operating temperature. The coolant flow should increase when the thermostat opens. Replace the thermostat if the coolant does not flow at operating temperature or flow exceeds 4 oz (0.12 L) per minute with the engine cold.
MALFUNCTION Incorrect water pump operation. CORRECTIVE ACTION 1. 2. Inspect water pump for leakage at weep hole. Unplug the weep hole if found plugged with debris. If no flow is observed in the coolant expansion tank or the pump is leaking, replace water pump (WP 0088).
SYMPTOM ENGINE OIL PRESSURE - LOW MALFUNCTION ERROR CODES that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures. MALFUNCTION Engine oil is contaminated. CORRECTIVE ACTION 1. 2. Take an oil sample and have it tested for contaminants, type, and specifications (WP 0047). Change oil and filter (LO 10-3930-675-13).
0006-20
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0006
SYMPTOM ENGINE OIL PRESSURE - HIGH MALFUNCTION Engine oil is contaminated. CORRECTIVE ACTION Replace engine oil and filter (LO 10-3930-675-13). SYMPTOM ENGINE COLD START SYSTEM NOT WORKING MALFUNCTION Circuit breaker F17 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. Replace faulty circuit breaker (WP 0103).
MALFUNCTION Cold start ether canister, system tubing, activation solenoid, or engine temperature sensor damaged. CORRECTIVE ACTION 1. 2. 3. Replace empty or missing canister (WP 0077). Replace any damaged or disconnected tubing (WP 0077). Replace damaged activation solenoid or engine temperature sensor (WP 0077).
MALFUNCTION Cold start system wiring damaged. CORRECTIVE ACTION Repair any loose or missing connections (Volume 2, WP 0267).
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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Cold start system inoperative. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. The resistance should be 3 to 4 Ohms. Unplug the activation solenoid and check resistance between the two pins. Check continuity between each pin and ground. Unplug the engine temperature sensor and check continuity between the two pins. There should not be any continuity. There should be continuity up to 120F (49C). Replace open or shorted activation solenoid or engine temperature sensor (WP 0077).
MALFUNCTION Incorrect cold start system voltage. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. If voltage (24V) is found at activation solenoid, replace activation solenoid (WP 0077). If no voltage (24V) is found, check continuity of wires 162, W12B, and W12A where they connect to 360 start solenoid pin 85. Remove the ether canister from activation solenoid. Press the cold start switch. You should hear the activation solenoid click". Unplug the activation solenoid and check for voltage (24V) while pressing the cold start system switch. Enter EXTRA FUNC 8(13)" in the diagnostic menu. a. b. If 1", go to Incorrect voltage (24V) at X16 pin 2 with ignition on". If 1" indication does not appear, go to Incorrect voltage (24V) at X67 pin 1&4 with ignition on".
MALFUNCTION Incorrect voltage (24V) at X67 pin 1 and 4 with the ignition on (Figure 16 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. 3. 4. 5. If no voltage is found at X67 pin 1, check circuit breaker F17 and continuity of wire A678 and A671 (Figure 15 (Volume 2, WP 0272)). Replace faulty circuit breaker (WP 0103). If no voltage (24V) is found at X67 pin 4, check continuity of wires 671, 671A, 674, A479, 479, and A17415, and test continuity of cold start system switch (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace cold start system switch if faulty (WP 0094).
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0006
ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect voltage (24V) at X16 pin 2 with the ignition on (Figure 16 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. If no voltage (24V) is found at X16 pin 2, check continuity of wires A17415A, 16011, A1508, 294, and A162A (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Electrical Troubleshooting Procedures (Non-Error Code) SYMPTOM HEADLIGHT(S) (HIGH OR LOW BEAM) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F16, F18, F19, F20, and F21 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION Headlights are damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged headlight (WP 0109).
MALFUNCTION Headlight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).
0006-23
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X6 pin 2 with the headlight switch turned on. CORRECTIVE ACTION 1. 2. Replace damaged or faulty switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X19 pin 5 with the headlight switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wire A62 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X19 pin 6 and 7 with the headlight switch turned on and operating the HI/LO beams. CORRECTIVE ACTION 1. 2. 3. 4. Check continuity of wires 195, 196, and 197 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Check accessory control lever for damage and continuity (Figure 14 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167).
MALFUNCTION No voltage (24V) at X11 pin 7 and X12 pin 6 with the headlight switch turned on and in LOW beam. CORRECTIVE ACTION 1. 2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X11 pin 8 and X12 pin 8 with the headlight switch turned on and in HIGH beam. CORRECTIVE ACTION 1. 2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
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0006
Electrical Troubleshooting Procedures (Non-Error Code) - Continued SYMPTOM FRONT/REAR SIDE MARKER LIGHT(S) OR TAILLIGHTS(S) DO NOT OPERATE WHEN HEADLIGHT SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F22 and F23 are tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breakers as required. Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION Marker and taillights are damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged marker or taillights (WP 0109).
MALFUNCTION Marker and taillight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X6 pin 1 with the headlight switch turned on (headlights working). CORRECTIVE ACTION 1. 2. 3. Remove headlight switch from the instrument panel and check for continuity. Replace damaged or faulty switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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0006
Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at F22 and F23 with the headlight switch on. CORRECTIVE ACTION Replace damaged or faulty circuit breaker (WP 0103). MALFUNCTION No voltage (24V) at X11 pin 1, X12 pin 7, X14 pin 2, X14 pin 9, X15 pin 2, and X15 pin 7 with the headlight switch turned on. CORRECTIVE ACTION 1. 2. Check continuity, using the wiring diagram, of wires A149, A157, A149B, A149A, A157A, and A157B (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION Check continuity, using the wiring diagram, of the marker and taillight wiring harnesses from X11 pin 1 to left front marker, X12 pin 7 to the right front marker, X15 pin 2 to the left rear marker, X14 pin 2 to the right rear marker, X14 pin 9 to the right taillight, and X15 pin 7 to the left taillight. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM STOPLIGHT(S) DO NOT OPERATE WHEN BRAKE PEDAL IS PRESSED MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.
0006-26
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F10 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (Volume 2, WP 0267).
MALFUNCTION Damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged stoplights (Volume 2, WP 0159).
MALFUNCTION Stoplight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X26 pin 2 and 3 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION 1. 2. 3. Remove the kick panel in front of the steering column and check brake light switch 216 for continuity while depressing the brake pedal (Volume 2, WP 0159). Replace damaged or faulty switch (Volume 2, WP 0159). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at XK13 pin 6 and 9 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION Replace damaged or faulty relay 3010 (WP 0103).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity between XK13 pin 9 and 3010 terminal 30, and XK 13 pin 6 and 3010 terminal 87a. CORRECTIVE ACTION Replace damaged or faulty relay board (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK14 pin 4 and 7 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up). CORRECTIVE ACTION Replace relay 3015R (Volume 2, WP 0267). MALFUNCTION No continuity of wires A036 and A263 (Figure 14 & Figure 10 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No continuity between XK14 pin 7 and 3015R terminal 30, and XK14 pin 4 and 3015R terminal 87a with the 3015R relay removed. CORRECTIVE ACTION Replace relay board (WP 0103). MALFUNCTION No voltage (24V) at XK15 pin 4 and 7 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A036 and A263 (Figure 14 & Figure 10 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Incorrect continuity between XK15 pin 7 and 3015L terminal 30, and XK15 pin 4 and 3015L terminal 87a with the 3015L relay removed. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No continuity of the stoplight wiring harnesses from XK14 pin 7 to the right stoplight and XK15 pin 7 to the left stoplight (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM TURN SIGNALS OR EMERGENCY FLASHERS ARE NOT WORKING MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F2 and F6 are tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Volume 2, WP 0272). Replace any shorted or grounded harnesses (Volume 2, WP 0267).
MALFUNCTION Inspect signal lights for damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged signal lights (WP 0109).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Signal light wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X19 pin 1, 2, and 3 while operating the turn signal lever. There should be voltage (24V) at pin 2 when signaling left and at pin 3 for right. CORRECTIVE ACTION 1. 2. Check circuit breaker F6 and wire A191 (Figure 14 (Volume 2, WP 0272)). If no voltage (24V) is found at X19 pin 2 or 3 while operating the signal lever; check accessory control lever for damage and continuity and check continuity of wires 191, 192, and 193 (Figure 14 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
3. 4.
MALFUNCTION No voltage (24V) at XK14 pin 8 and XK15 pin 8 while operating the turn signal lever. There should be voltage at pin XK15 pin 8 when signaling left and at XK14 pin 8 for right. CORRECTIVE ACTION 1. 2. Check continuity of wires A192 and A193 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at XK1 pin 5 and pin 1 while operating the turn signals. There should be constant voltage at pin 5 and flashing voltage at pin 1. CORRECTIVE ACTION 1. 2. Check blackout drive/marker light switch and circuit from circuit breaker F2 (Figure 13 (Volume 2, WP 0272)). Replace damaged or faulty 323 flasher relay (WP 0103).
0006-30
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity, with 323 flasher relay removed, between XK1 pin 5 and 323 terminal 49, and XK1 pin 1 and 323 terminal 49a, and XK1 pin 2 and 323 terminal 31. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No voltage (24V) at XK14 pin 3 and XK15 pin 3 while operating the turn signals. There should be flashing voltage at XK14 pin 3 for signaling right and a XK15 pin 3 for left. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage (24V) at XK14 pin 7 and XK15 pin 7 while operating the turn signals. There should be flashing voltage at XK14 pin 7 for signaling right and at XK15 pin 7 for left. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No continuity of the signal wiring harnesses from XK14 pin 7 to the right rear and XK14 pin 3 for the right front, and XK15 pin 7 to the left rear and XK15 pin 3 for the left front (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X6 pin 4, 5, and 6 with the emergency flasher switch depressed. CORRECTIVE ACTION 1. 2. SYMPTOM BLACKOUT DRIVE AND MARKER LIGHTS DO NOT OPERATE WHEN SWITCH IS TURNED ON Check continuity, using the wiring diagram, of wires 64, 65, and 66 (Figure 14 (Volume 2, WP 0272)). Replace damaged or faulty switch (WP 0094).
0006-31
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Circuit breakers F24 and F25 are tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. If any breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 14 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
3.
MALFUNCTION Blackout drive and marker lights damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged blackout lights (WP 0109).
MALFUNCTION Blackout drive and marker light wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X7 pin 9 and 6 with the blackout drive marker light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of the wires A79, 79, 76 and A76, (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X11 pin 3, X11 pin 9, X12 pin 1, X14 pin 1, and X15 pin 1 with the blackout drive marker light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A113, A153, A119, A121, and A141 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No continuity of the blackout drive marker light wiring harnesses from X11 pin 3 to left front blackout position light, X12 pin 1 to right front blackout position light, X14 pin 1 to right blackout taillight, X15 pin 3 to the left blackout taillight, and X11 pin 9 to blackout headlight. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM BLACKOUT STOPLIGHTS NOT WORKING MALFUNCTION Check the operation of the normal stoplights. CORRECTIVE ACTION If stoplights are not working, perform troubleshooting procedure for Stop Light (s) Do Not Operate When Brake Pedal is Pressed" in this work package. MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Stoplights are damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged blackout stoplights (WP 0109).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Blackout stoplight wiring harnesses or connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK13 pin 3 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up). CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No continuity of the blackout drive marker light wiring harnesses from XK13 pin 3 to right and left blackout stoplights. (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM HORN WILL NOT SOUND WHEN BUTTON IS PRESSED MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Check circuit breaker F9 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION Horn, connectors, or wiring damaged. CORRECTIVE ACTION 1. Test horn using 24V source.
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). Replace damaged horn (WP 0127).
MALFUNCTION No voltage (24V) at X20 pin 1 and 2 with the horn switch depressed. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire A201 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X20 pin 2, check accessory control lever for damage and continuity (Figure 13 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167).
MALFUNCTION No voltage (24V) at X13 pin 9 with the horn switch depressed. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires 202, A202, and A139 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
MALFUNCTION No voltage (24V) between the two pins of the harness with the horn switch depressed. CORRECTIVE ACTION 1. 2. SYMPTOM BACKUP LIGHTS/ALARM DOES NOT OPERATE WHEN VEHICLE PLACED IN REVERSE MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. Check continuity of wires 139 and 135B (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F10 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 14 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
3.
MALFUNCTION Backup lights and alarm damaged or burned out lamps. CORRECTIVE ACTION 1. 2. 3. Replace burned out lamps (WP 0110). Replace damaged backup lights (WP 0110). Replace damaged backup alarm (WP 0133).
MALFUNCTION Backup lights/alarm wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK5 pin 1 and 7 with the ignition on and the transmission control lever placed in Reverse. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire A57 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
MALFUNCTION No voltage (24V) at XK13 pin 4 and 7 with the ignition on and the transmission control lever placed in Reverse. CORRECTIVE ACTION 1. 2. Check continuity of wire A51 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 3. Replace damaged or faulty relay (WP 0103).
MALFUNCTION No voltage (24V) at XK5 pin 5 with the ignition on while switching transmission control lever between Neutral and Reverse. There should be voltage (24V) when in Neutral and no voltage (OV) when in Reverse. CORRECTIVE ACTION 1. 2. 3. 4. Check continuity of wires A55 and 293 (Figure 14 (Volume 2, WP 0272)). Check continuity of wires 16010 and A17710 (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (793).
MALFUNCTION No continuity, using the wiring diagram, of the backup light/alarm wiring harnesses from X14 and X15 to the backup lights and alarm. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). SYMPTOM BOOM WORK LIGHTS(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F12 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 15 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION Boom work lights damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0110). Replace damaged lights (WP 0110).
MALFUNCTION Boom work lights wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X7 pin 1 and 3 with the boom work light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of wires A73, 73, 71, and A71 (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).
MALFUNCTION Inoperative relay 3013 (Volume 2, WP 0267). CORRECTIVE ACTION Replace relay (WP 0103).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at XK11 pin 6, X31 pin 1, X151 pin 1, X157 pin 5, and X169 pin 5 with the boom work light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A311, 311, A1511, and YE (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION High resistance between two GY wires at X169 pin 5 and ground. CORRECTIVE ACTION 1. 2. SYMPTOM TOPHANDLER WORK LIGHTS(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F17 in cab distribution box and F43, located in the tophandler junction box tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 15 & Figure 16 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Replace boom work light wiring harness (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
3.
MALFUNCTION Work lights damaged or burned out lamps. CORRECTIVE ACTION 1. Replace burned out lamps (WP 0110).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. Replace damaged tophandler work lights (WP 0110).
MALFUNCTION Work lights wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION Work light switch inoperative. CORRECTIVE ACTION Enter EXTRA FUNC 5(13)" in the diagnostic menu. Press the tophandler work light switch. Should have a 1" next to WORK LIGHT ATTACH". a. b. If there is a 0", go to No voltage (24V) at X67 pin 8 and 9 with the tophandler work light switch turned on." If there is a 1", go to Inoperative relay 3017."
MALFUNCTION No voltage (24V) at X67 pin 8 and 9 with the tophandler work light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of the wires A678, 678, and 679 (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).
MALFUNCTION No voltage (24V) at X46 pin 6, X174 pin 11, and ECU (792) pin 102 with the tophandler work light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A466, 466, and A17411 (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Inoperative relay 3017 (Volume 2, WP 0267). CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage at relay 3017 socket pin 30. CORRECTIVE ACTION 1. 2. Check continuity of wires A513 and A1861B (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage at 3017 socket pin 86. CORRECTIVE ACTION 1. 2. Check continuity of wire A3018A (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No resistance between pin A and B, or C and D on the loose part of X194. (Ensure the tophandler work light lamps are not burned out). CORRECTIVE ACTION 1. 2. Replace X194 harness to tophandler work lights (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No continuity of wires A194A, A194B, A194C, and A194D (Figure 6 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No voltage at pin 14 of ECU connector 2 with the ignition on. CORRECTIVE ACTION 1. Check continuity of wire A18052B (Figure 6 (Volume 2, WP 0272)).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. SYMPTOM INFRARED (IR) WORK LIGHT(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Circuit breaker F2 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. If any breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 13 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
3.
MALFUNCTION IR work lights damaged or burned out lights. (A digital camera can be used to check the operation of IR lights.) CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0115). Replace damaged IR light (WP 0115).
MALFUNCTION IR work light wiring harnesses or connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X6 pin 8 and X7 pin 7 with the blackout drive marker light switch and IR work light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of wires A77, 77, 1211, and 68 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).
MALFUNCTION No voltage (24V) at X15 pin 5, X11 pin 5, X31 pin 3, X151 pin 3, X157 pin 7, and X169 pin 7 with the blackout drive marker light switch and IR work light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A155, A115, A313, 313, A1513, and WH (Figure 13, Figure 14 & Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No continuity of the IR work light wiring harnesses from X16 pin 7 to left and right boom IR work lights, X15 pin 5 to left rear IR work light, and X11 pin 5 to left front IR work light (Figure 14 & Figure 15 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM FRONT WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F6 and F9 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 10 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0123).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1. 2. Correct binding wiper arm (Volume 2, WP 0194). Replace damage wiper arm (Volume 2, WP 0194).
MALFUNCTION No voltage (24V) at X20 pin 1, 4, and 5 with the ignition on while operating the front wiper control switch. CORRECTIVE ACTION 1. There should be voltage (24V) at pin 4 for intermittent wiper and at pin 5 for continuous wiper. If no voltage (24V) is found at X20 pin 1, check circuit breaker F9 and continuity of wire A201 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X20 pin 4 or 5 while operating the front wiper control switch, check accessory control lever for damage and continuity and check continuity of wires 201, 204, and 205 (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
2.
3. 4.
MALFUNCTION Defective relay 316. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). MALFUNCTION No continuity between XK2 pin 9 and terminal 30, XK2 pin 3 and terminal 87, XK2 pin 6 and terminal 87a, XK2 pin 8 and terminal 86, and XK3 pin 5 and terminal 85. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No voltage (24V) at X27 pin 6 and 7 with the ignition on while operating the front wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1. Check circuit breaker F6 and continuity of wires A276, A66, and A191 (Figure 14 (Volume 2, WP 0272)).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. If no voltage (24V) is found at X27 pin 7 while operating the front wiper control switch to the "CONTINUOUS" position, check continuity of wires A23 and A29 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
3.
MALFUNCTION Intermittent relay 321-1 damaged. CORRECTIVE ACTION 1. Disconnect relay plug and check voltage (24) at pin 3 and 5 with the ignition on while operating the front wiper control switch to the "INTERMITTENT" position. If no voltage (24V) is found at 321-1 pin 3 or 5, check continuity of wires A201A, A204, A26, and A278 (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
2. 3.
MALFUNCTION No voltage (24V)at XS4 pin 3 and 4 with the ignition on while operating the front wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1. 2. 3. 4. SYMPTOM REAR WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F15 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Volume 2, WP 0272). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Check continuity of wires 276, 277, and 278 (Figure 11 (Volume 2, WP 0272)). Check ground connection at wiper motor. Check continuity of wires 279, A279, and ground connection at 37-1 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty front wiper motor (Volume 2, WP 0194).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1. 2. Correct binding wiper arm (Volume 2, WP 0194). Replace damaged wiper arm (Volume 2, WP 0194).
MALFUNCTION No voltage (24V) at X9 pin 1, 2, and 3 with the ignition on while operating the rear wiper control switch. There should be voltage (24V) at pin 1 (intermittent voltage) and 2 for intermittent wiper. CORRECTIVE ACTION 1. 2. Check circuit breaker F15 and continuity of wires A89 and A89A (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X9 pin 1 or 2 while operating the rear wiper control switch, check rear wiper switch for damage and continuity and check continuity of wires 91, 92, 93, 94, and A94 (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty rear wiper switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
3. 4.
MALFUNCTION No voltage (24V) at pin 3 and 5 with the ignition on while operating the rear wiper control switch to the "INTERMITTENT" position. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A91, A92, A93, A138, A136, A246, and A84B (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at XS5 pin 2 and 3 with the ignition on while operating the rear wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1. 2. 3. 4. Check continuity of wires 136, 137, and 138 (Figure 11 (Volume 2, WP 0272)). Check ground connection at wiper motor. Check continuity of wire 135 and ground connection at 37-1 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty rear wiper motor (Volume 2, WP 0194).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued SYMPTOM ROOF WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F15 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 10 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1. 2. Correct binding wiper arm (Volume 2, WP 0194). Replace damage wiper arm (Volume 2, WP 0194).
MALFUNCTION No voltage (24V) at X8 pin 7, 8, and 9 with the ignition on while operating the roof wiper control switch. CORRECTIVE ACTION 1. 2. There should be voltage (24V) at pin 8 and 9, and intermittent voltage at pin 7. Check circuit breaker F15 and continuity of wire A89 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X8 pin 7 or 8 while operating the roof wiper control switch, check roof wiper switch for damage and continuity and check continuity of wires 87, 88, and 89 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty roof wiper switch (WP 0094).
3. 4.
MALFUNCTION No voltage (24V) at XS6 pin 2 and 3 with the ignition on while operating the roof wiper control switch. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A89A, A93, A246, 246, A88, 249, A87, and 244 (Figure 11 (Volume 2, WP 0272)). Check ground connection at wiper motor. Check continuity of wire 241A and ground connection at 37-2 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Figure 11 (Volume 2, WP 0272)).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 4. SYMPTOM WINDSHIELD WASHER NOT WORKING MALFUNCTION Washer reservoir damaged or washer solvent level low. CORRECTIVE ACTION 1. 2. Fill washer reservoir with proper washer solvent (TM 10-3930-675-10). Replace damaged washer reservoir (Volume 2, WP 0195). Replace damaged or faulty rear wiper motor (Volume 2, WP 0194).
MALFUNCTION Washer pump, tubing, fittings, connectors, or wiring damaged. CORRECTIVE ACTION 1. 2. 3. Replace damaged tubing or fittings (Volume 2, WP 0195). Replace damaged washer pump (Volume 2, WP 0195). Repair or replace damaged harnesses or connectors (Volume 2, WP 0195).
MALFUNCTION Circuit breaker F9 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION No voltage (24V) at X20 pin 1 and 3 with the ignition on and the washer switch depressed. CORRECTIVE ACTION 1. 2. 3. 4. Check circuit breaker F9 and check continuity of wire A201 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X20 pin 3, check continuity of wires 201 and 203 (Figure 13 (Volume 2, WP 0272)). Check accessory control lever for damage and continuity (Figure 13 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage between the two pins if the harness with the ignition on and the washer switch depressed. CORRECTIVE ACTION 1. 2. Check continuity of wires A203, 131, A135A, and ground connection of wire A132D at 37-1 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connector (Volume 2, WP 0267).
MALFUNCTION No resistance of the pump. CORRECTIVE ACTION If there is no resistance or pump fails test, replace washer pump (Volume 2, WP 0195). Resistance should be 3 to 4 Ohms. SYMPTOM CAB INTERIOR LIGHT NOT WORKING MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Emergency flashers inoperative. CORRECTIVE ACTION 1. 2. Perform troubleshooting procedure Turn Signals or Emergency Flashers Not Working" in this work package. Continue with Step 3.
MALFUNCTION Cab interior light damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0114). Replace damaged cab interior light (WP 0114).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at cab interior light between the gray and white wires. CORRECTIVE ACTION 1. 2. SYMPTOM 12V UTILITY PLUG NOT WORKING MALFUNCTION Circuit breaker F14 tripped. CORRECTIVE ACTION Replace circuit breaker as required. MALFUNCTION No voltage at the 12V utility plug, CORRECTIVE ACTION 1. With the ignition on, between pins 1 and 4. There should be 12V. Check voltage between pins 2 and 4. There should be 24V. If voltage (24V) is found at pin 2 and none at pin 1, remove the cab electrical distribution box to gain access to the voltage converter. If no voltage (24V) is found at pin 2, check circuit breaker F14 and continuity of wires 108, A108A, 101, 102, and A102 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). If no voltage (24V) is found, check continuity of wires 248, A69, 241B, and connection at 37-2 (Figure 13 (Volume 2, WP 0272)). Check continuity of light switch. If the switch is damaged or faulty, replace cab interior light (WP 0114).
2. 3.
MALFUNCTION The 5 amp fuse on the voltage converter blown. CORRECTIVE ACTION Replace the 5 amp fuse if blown. MALFUNCTION No input voltage (24V) of the voltage converter to one of the two middle pins on the converter. CORRECTIVE ACTION 1. With ignition on if no input voltage (24V) is found, check circuit breaker F14 and check continuity of wire A108 (Figure 13 (Volume 2, WP 0272)).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. 4. SYMPTOM BLOWER MOTOR NOT WORKING MALFUNCTION Circuit breaker F11 tripped. (For rear blower troubleshooting, go to Binding blower wheel or damage to the motor or wiring.") CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 12 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Reinstall jumper wire A101B and check wires A101A and A101 continuity/ground connection at 37-5 (Figure 13 (Volume 2, WP 0272)). With the ignition on, check the output voltage (12V) of the converter to one of the two middle pins on the converter. If no output voltage from converter is found, replace voltage converter (WP 0103).
MALFUNCTION Blower damaged or blower wheel binding (Volume 2, WP 0198). CORRECTIVE ACTION Replace damaged or binding blower motor/assembly (Volume 2, WP 0198). MALFUNCTION Blower assembly wiring and connectors damaged (Volume 2, WP 0198). CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X9 pin 6 and 9 with the ignition on while operating the fan control switch. CORRECTIVE ACTION 1. 2. There should be varied voltage (14 to 24V) at pin 6. If no voltage (24V) is found at X9 pin 9, check circuit breaker F11 and continuity of wires A99 and 99 (Figure 12 (Volume 2, WP 0272)). If no voltage (14 to 24V) is found at X9 pin 6 at any on speed, remove fan control switch and check for continuity (WP 0094).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 3. 4. 5. Replace damaged or faulty switch (Volume 2, WP 0272). If switch is good, check the continuity of wires 96, 97, 98, A96, A97, and A98 (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X657 pin 2, 3, and 4 with the ignition on while operating the fan control switch. CORRECTIVE ACTION 1. 2. There should be voltage (24V) at pin 2 for LOW, pin 4 for MED, and pin 3 for HIGH. If no voltage is found, check continuity of wires, 271, 272, and 273 (Figure 12 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No ground connection for the white wire at X657 pin 1 and at 37-10. CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No voltage between the two blower motor connectors with the ignition on while operating the fan control switch to HIGH speed. CORRECTIVE ACTION 1. 2. Replace the internal blower assembly harness (Volume 2, WP 0198). Replace blower motor/assembly (Volume 2, WP 0198).
MALFUNCTION Binding blower wheel or damage to the motor or wiring (Volume 2, WP 0198). CORRECTIVE ACTION 1. 2. Replace damaged or binding blower motor/assembly (Volume 2, WP 0198). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X69 pin 1 with the ignition on while operating the fan control switch. CORRECTIVE ACTION There should be varied voltage (14 to 24V). If no voltage is found and front blower operates properly, check continuity of wires A691 and A692 (Figure 10 (Volume 2, WP 0272)). MALFUNCTION No voltage (24V) X657-1 with the ignition on while operating the fan control switch to HIGH speed. CORRECTIVE ACTION 1. 2. SYMPTOM HEATER/DEFROSTER PRODUCING LOW OR NO HEAT MALFUNCTION Incorrect operating temperature of engine. CORRECTIVE ACTION 1. 2. Perform proper PMCS for coolant system (TM 10-3930- 675-10). Warm engine to proper operating temperature (TM 10-3930-675-10). Check continuity of wires BU and BK (Figure 10 (Volume 2, WP 0272)). If voltage is found, replace rear blower motor/assembly (Volume 2, WP 0198).
MALFUNCTION Heater hoses between the cab and chassis kinked. CORRECTIVE ACTION 1. 2. Straighten any kinked hoses (Volume 2, WP 0198). Replace any damaged hoses or kinked hose that will not straighten (Volume 2, WP 0196).
MALFUNCTION Inoperative blower. CORRECTIVE ACTION If blower not functioning, perform troubleshooting procedure for Blower Motor Not Working" in this work package.
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Inoperative heater temperature control switch and heater/defroster selection switch operation. CORRECTIVE ACTION 1. 2. Replace damaged or binding heater temperature control switch (WP 0094). Replace damaged or binding heater/defroster selection switch (WP 0094).
MALFUNCTION Heater control valve and cable inoperative. CORRECTIVE ACTION 1. 2. 3. Replace bent or kinked control cable (WP 0094) and (Volume 2, WP 0198). Replace damaged, leaking, or non-operational heater control valve (Volume 2, WP 0196). Correct any binding of air flow door and cable.
MALFUNCTION Inoperative air flow door while operating the heater/defrost selection switch. CORRECTIVE ACTION Replace damaged or binding heater/defrost selection switch. MALFUNCTION Air conditioning ducts damaged. CORRECTIVE ACTION Repair or replace any damaged or separated ducts. MALFUNCTION Restricted airflow through heater core. CORRECTIVE ACTION If air flow is very low through heater core, perform A/C system maintenance (Volume 2, WP 0248). SYMPTOM A/C SYSTEM NOT COOLING PROPERLY
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Blower inoperative. CORRECTIVE ACTION If blower not functioning, perform troubleshooting procedure for Blower Motor Not Working" in this work package. MALFUNCTION Poor condition of the A/C compressor belts. CORRECTIVE ACTION Replace and/or adjust belts as required (Volume 2, WP 0251). MALFUNCTION Improper A/C operation. CORRECTIVE ACTION 1. 2. 3. 4. If compressor operates and condenser fans are on, go to Step 4. If compressor does not operate, go to malfunction AA. If condenser fans do not operate, go to malfunction BB. Run the A/C system for about 15 minutes to stabilize. Feel the air coming from the condenser fans; it should be warmer than the ambient temperature. Feel the temperature of the larger pipe connected to the compressor; it should be cool or cold and possibly sweating. a. b. If condenser air is warm and the compressor pipe is cool/ cold, check if the heater control valve is fully closed and the air is properly flowing through the ducts (Volume 2, WP 0251). If condenser air is not warm and the compressor pipe is not cool/cold, perform A/C system maintenance (Volume 2, WP 0248).
MALFUNCTION Malfunction AA: No voltage (24V) at X27 pin 4 and 5 while operating the A/C system to maximum cool. CORRECTIVE ACTION 1. 2. 3. At X27 pin 4, remove the A/C control switch and check continuity of wires 99A, 95, and A95 (Figure 12 (Volume 2, WP 0272)). At X27 pin 5, remove A/C temperature control switch and check continuity of wires 274 and 275 (Figure 12 (Volume 2, WP 0272)). Replace damaged or faulty switch (WP 0094).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X17 pin 8 while operating the A/C system to maximum cool. CORRECTIVE ACTION 1. 2. At X17 pin 8, check continuity of wires A327, 327, 328, and A178 (Figure 12 (Volume 2, WP 0272)). At X17 pin 8 and all wires are functioning properly, remove the cover of the condenser and unplug the pressure switch. Check continuity of the pressure switch between wires RD/WH and BK/WH (X810 pins 3 and 4). If no continuity is found at pressure switch, perform A/C system maintenance (Volume 2, WP 0248) to check the refrigerant charge of the system.
3.
MALFUNCTION No voltage (24V) at compressor clutch while operating the A/C system to maximum cool. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire 178 (Figure 12 (Volume 2, WP 0272)). If voltage (24V) is found, check the resistance of the compressor clutch to ground. Resistance should be 12 to 16 Ohms. If resistance of compressor clutch is not as specified, replace compressor (Volume 2, WP 0250).
MALFUNCTION Malfunction BB: Circuit breaker F1 tripped. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Reset circuit breaker as required. Unplug X810 and check voltage (24V) at X810 pins 1 and 2 while operating the A/C system. If no voltage (24V) is found at X810 pin 2, check continuity of wires A95A and 322 (Figure 12 (Volume 2, WP 0272)). If no voltage (24V) is found at X810 pin 3, check circuit breaker F1 and continuity of wires A323 and 323 (Figure 12 (Volume 2, WP 0272)). Check continuity of wires (X810 pin 6) 329, A329, and ground connection at 37-5 (Figure 12 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION Fans, Relay or wiring damage. CORRECTIVE ACTION 1. Replace damaged or faulty relay (WP 0103).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. Replace damaged fans (Volume 2, WP 0254). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION Resistance out of range for fans and resistors. CORRECTIVE ACTION Resistance should be 2 Ohms. If resistance is not as specified replace faulty fan(s) or resistor(s) (Volume 2, WP 0254). SYMPTOM FUEL GAUGE NOT WORKING PROPERLY MALFUNCTION Circuit breaker F7 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION Fuel level sending unit damaged. CORRECTIVE ACTION Replace fuel level sending unit. MALFUNCTION Fuel gauge damaged. Remove the dash panel to access the fuel gauge. CORRECTIVE ACTION Replace damaged fuel gauge (WP 0094). MALFUNCTION Wire connector damaged (WP 0094). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at the + terminal of the gauge. CORRECTIVE ACTION Check circuit breaker F7 and continuity of wires A211, A104, and 104 (Figure 10 (Volume 2, WP 0272)). MALFUNCTION Float for damaged, sticking, or waterlog." CORRECTIVE ACTION Replace damaged fuel level sending unit (WP 0132). MALFUNCTION Incorrect resistance of fuel level sending unit. CORRECTIVE ACTION 1. 2. 3. 4. Float at bottom = 110 Ohms, float in middle = approx. 50 Ohms, and float at top = <1 Ohm. If resistance is not as specified, replace faulty fuel level sending unit (WP 0132). If resistance checks good, check continuity of wires 258, 259, A105, 105, and ground wire A132D at the 37-1 ground connection (Figure 10 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION Improper operation of the gauge. CORRECTIVE ACTION 1. 2. If gauge does not react to float movement, replace faulty gauge (WP 0094). If gauge does react but does not match with the float level, try adjusting the small adjustment screw on gauge to empty" with the float at the bottom. Retest float/gauge reactions.
SYMPTOM DRIVERS ECS DISPLAY SCREEN WILL NOT DISPLAY MALFUNCTION Circuit breaker F31 tripped. CORRECTIVE ACTION Reset circuit breaker as required.
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X150 pin 3 with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check circuit breaker F31 and continuity of wires A303 and 303 (Figure 8 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION No voltage (24V) at X152 pin 3 with the ignition on. CORRECTIVE ACTION 1. 2. Check continuity of wire A1503B (Figure 1 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0103).
MALFUNCTION No voltage (24V) at X795 pins 7 and 8 with the ignition on. CORRECTIVE ACTION 1. 2. 3. SYMPTOM After Key On" FUNCTIONS NOT WORKING (NO CRANK, DISPLAY, ETC.). MALFUNCTION With the battery master switch turned on and the ignition turned off, turn signals/emergency flashers and cab interior light inoperative. CORRECTIVE ACTION 1. 2. If all of these functions work properly, go to malfunction DD. If none of these functions work properly, go to malfunction CC. Check continuity of wires 1523A and 1523B (Figure 1 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). If voltage (24V) is found, replace the ECS display screen (WP 0096).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Malfunction CC: No voltage (24V) at X80 all pins. CORRECTIVE ACTION 1. 2. 3. Check circuit breakers F50-1 and F50-2 located at upper left rear of engine, and continuity of wires 801 and 803 (Figure 8 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION No voltage (24V) at batteries, master battery switch, or starter solenoid on the starter (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. 3. Service batteries (WP 0128). Repair or replace damaged or faulty battery cables (WP 0129). Replace damaged or faulty master battery switch (WP 0129).
MALFUNCTION Malfunction DD: No voltage (24V) at X8 pins 3 and 4 with the ignition on. CORRECTIVE ACTION 1. 2. 3. 4. If no voltage (24V) is found at X8 pin 3, check circuit breaker F2 and continuity of wire A83 (Figure 8 (Volume 2, WP 0272)). If no voltage (24V) is found at X8 pin 4, check ignition switch for damage and continuity and check continuity of wire 84 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty ignition switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at relay 315 terminal 30 and 87 (two brass terminals) and terminal 86 (white plug; gray wires) with ignition on. CORRECTIVE ACTION 1. 2. 3. 4. At 315 terminal 30, check continuity of wire A804 (Figure 8 (Volume 2, WP 0272)). At 315 terminal 86, check continuity of wire A84 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged or loose wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity of wire A84C and its ground connection at 37-1 (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged or loose wires or connectors (Volume 2, WP 0267). MALFUNCTION Damaged wiring. CORRECTIVE ACTION 1. 2. SYMPTOM PROXIMITY SWITCHES - TOPHANDLER AND CAB MALFUNCTION Inoperative proximity switches: CORRECTIVE ACTION Repair or replace damaged or loose wires or connectors (Volume 2, WP 0267). Check jumper connections between circuit breakers (Figure 8 (Volume 2, WP 0272)).
NOTE
All proximity switches on the RTCH operate and are connected the same way. Many non-ERROR CODE problems may be caused by a faulty proximity switch or the proximity switch signal not reaching its destination. "DIAG ATTACHMENT 3(16)", "DIAG ATTACHMENT 4(16)", "DIAG ATTACHMENT 5(16)", and "DIAG EXTRA FUNCT 8(13)" screens can be used to verify the signal inputs into the ECU (790) or (791). All Proximity Switches - General operation. Each proximity switch has three wires: - Brown = voltage (24V) input - Blue = ground - Black = signal; voltage (24V) output when activated Activation = metal within 5 mm of end of proximity switch. Indicator = small Light Emitting Diode (LED) comes on when activated. Voltage (24V) to proximity switches comes from circuit breaker F42 (2) in the tophandler junction box. The main grounding point is 37-54 (Figure 6 (Volume 2, WP 0272)). 1. 2. 3. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X182 between pins 4 and 5 (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A181A, A181B, and wires 4 and 5 in the X181 to X182 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X181 to X182 cable (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X183 between pins 3 and 4 (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires 3 and 4 in the X182 to X183 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X182 to X183 cable, electrical general maintenance (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X184 between pins 3 and 4 (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires 3 and 4 in the X182 to X184 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X182 to X183 cable, electrical general maintenance (Volume 2, WP 0267).
MALFUNCTION Indicator LED on the switch inoperative. CORRECTIVE ACTION
NOTE
The 7225-1 proximity switch operation can be quickly tested by turning on the tophandler work lights and rotating the tophandler clockwise (CW) toward the longitudinal position. 7225-1, when deactivated, turns off the tophandler work lights beyond 40 degrees of CW rotation. 1. 2. If no LED indicator when activated, check voltage and ground inputs and adjustment first. Replace proximity switch (WP 0104).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage at ECU (791) connector 1 at pins 30 through 40 with ignition on. CORRECTIVE ACTION 1. 2. 3. 4. 5. Check continuity of wires A181C through A181K (Figure 6 (Volume 2, WP 0272)) and A194G for RT 240V1R, RT 240V2 and RT 240V3. Check continuity of specific wire in X181 to X182 cable (Figure 6 (Volume 2, WP 0272)). Check continuity of specific wire in X182 to X183 cable or X182 to X184 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X181 to X182 cable, or X183 cable, or X182 to X184 cable or X194 cable (Volume 2, WP 0267).
MALFUNCTION Circuit breaker F29 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X195 between pins 7 and 9 (Figure 7 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. Check continuity of wires A473, 473, A1743B, A1743C, and A1957A (WP 0048). For RT 240V1R, RT 240V2 and RT 240V3, check wires A475, 475, A174B1A, A174B1B, and A1957A (WP 0048). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
2.
MALFUNCTION No voltage (24V) at X198 between pins 1 and 3 (Figure 7 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. Check continuity of wires GY and RD in the X195 to X198 cable (Figure 7 (Volume 2, WP 0272)). Replace X195 to X198 cable (Volume 2, WP 0267).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) between X195 pin 5 and 7 (WP 0048). Check LED indicator on the switch. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire OR in the X195 to X198 cable (WP 0048). If no LED indicator when activated, replace proximity switch (WP 0105). Replace X195 to X198 cable (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X175 between pins 1 and 3 (WP 0048) with the ignition on. CORRECTIVE ACTION 1. 2. Check continuity of wires A1743D, A1957B, and for RT 240V1R, RT 240V2 and RT 240V3, wire A174B1C (Figure 7 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) between X175 pin 2 and 3 (Figure 7 (Volume 2, WP 0272)). Check LED indicator. CORRECTIVE ACTION Replace proximity switch (WP 0105). SYMPTOM NORMAL FUNCTIONS OPERATE IN BLACKOUT MODE MALFUNCTION Inoperative horn operation in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3016 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
MALFUNCTION No backup lights/alarm in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3011 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No boom work light operation in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3013 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
MALFUNCTION No stoplight operation in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3010 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
MALFUNCTION Seat buzzer in blackout mode inoperative. CORRECTIVE ACTION 1. 2. SYMPTOM MULTIPLE BOOM OR TOPHANDLER FUNCTIONS NOT WORKING (MULTIPLE ERROR CODES) MALFUNCTION Check for emergency stop in engaged position. (Multiple ERROR CODES Will display if the emergency stop button is engaged during crank and start.). CORRECTIVE ACTION Disengage emergency stop button (ERROR CODES 121 and 201 will normally be one of the ERROR CODES displayed). MALFUNCTION No boom functions, hydraulic pumps engaged when cranking (slow or hard crank), cooling fan at full speed. Multiple ERROR CODES. CORRECTIVE ACTION Erratic voltage (24V) at X159 pin 1 with the ignition on. a. If voltage is 6V or less, unplug X158, turn the ignition off, then back on after 3 minutes. Recheck voltage. Remove relay 3016 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued b. c. d. e. If the voltage (24V) returns to X159 pin 1, check continuity of each pin of the loose part of X158 to ground (Figure 2 (Volume 2, WP 0272)). If the voltage (24V) does not return, unplug X159, turn the ignition off, then back on after 3 minutes. Recheck voltage. If the voltage (24V) returns to X159 pin 1, check continuity of each pin 1 and 2 of the loose part of X159 to ground (Figure 2 (Volume 2, WP 0272)). If continuity to ground found at any pin(s), follow the circuit of the pin/wire to the component it goes to. Unplug the component and recheck for continuity to ground. Replace grounded harness (Figure 2 (Volume 2, WP 0272)).
MALFUNCTION No sideshift, no 20/40 spread, and no twistlock operation. Multiple ERROR CODES. CORRECTIVE ACTION Erratic Voltage (24) at X180 pin 15 with the ignition on. a. b. c. d. e. lf voltage is 6V or less, unplug X188, turn the ignition off, then back on after 3 minutes. Recheck voltage. If the voltage (24V) returns to X180 pin 15, check continuity of each pin J, K, L, M, N, and P of the loose part of X188 to ground (Figure 6 (Volume 2, WP 0272)). If the voltage (24V) does not return to X189, turn the ignition off, then back on, after 3 minutes. Check voltage. If the voltage (24V) returns to X180 pin 15, check continuity of each pin A, B, C, D, J, K, L, M, N, and P of the loose part of X189 to ground (Figure 6 (Volume 2, WP 0272)). If continuity to ground is found at any pin(s), follow the circuit of the pin/wire to the component it goes to. Unplug the component and recheck for continuity to ground. Replace grounded harness (Figure 6 (Volume 2, WP 0272)). If no trouble found, go to No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector with the ignition on."
f.
MALFUNCTION No rotate, no tilt, no oscillate, and no twistlock lights on boom. Multiple ERROR CODES. CORRECTIVE ACTION Erratic Voltage (24) at X180 pin 13 with the ignition on. a. b. c. lf voltage is 6V or less, unplug X188, turn the ignition off, then back on after 3 minutes. Recheck voltage. If the voltage (24V) returns to X180 pin 13, check continuity of each pin A, B, C, D, E, F, G, and H of the loose part of X188 to ground (Figure 6 (Volume 2, WP 0272)). lf voltage (24V) does not return, unplug X189, turn the ignition off, then back on after 3 minutes. Recheck voltage.
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued d. lf continuity to ground is found at any pin(s), follow the circuit of the pin/wire to the component it goes to. Unplug the component and recheck for continuity to ground. Replace grounded harness (Figure 6 (Volume 2, WP 0272)). If no trouble found, go to No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector with the ignition on."
e.
MALFUNCTION No sideshift, no 20/40 spread, no rotate, no tilt, no oscillate, no twistlock operation, no twistlock lights on boom, multiple ERROR CODES. CORRECTIVE ACTION No Voltage (24V) at 3009-3 relay socket pins 30 and 86 (Figure 6 (Volume 2, WP 0272)) with the ignition on. a. b. c. d. e. f. Replace damaged or faulty 3009-3 relay (WP 0103). Check circuit breaker F41 (1) and continuity of wires A51J, A51B, and A51D (Figure 6 (Volume 2, WP 0272)). Check operation of relay 315-1 (Figure 6 (Volume 2, WP 0272)), replace damaged or faulty 315-1 relay (WP 0103). If no voltage (24V) is found at 3009-3 pin 86, check continuity of wire A1803C (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). If no trouble found, go to No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector with the ignition on."
MALFUNCTION No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. SYMPTOM FUNCTIONS(S) WORK UNCONTROLLED Check continuity of wires A511, A51H, 791I, and 7912 (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Test for electrical or hydraulic fault. Start the engine (TM 10-3930-675-10) and engage the emergency stop button. lf the uncontrolled function stops, its electrical. If the function does not stop, its hydraulic. CORRECTIVE ACTION Disengage the emergency stop button after test. MALFUNCTION Boom functions. Top handler functions. (An uncontrolled function is usually caused by a short to ground or a stuck hydraulic solenoid). CORRECTIVE ACTION 1. Enter DIAG SERVO 5(13)" in the diagnostic menu. The voltage should be 5V. a. If voltage is not 5V: (1) (2) b. Check joystick. Enter DIAG SERVO 9(13)" and DIAG SERVO 10(13)" in the diagnostic menu. The INPUT and OUTPUT should be <5mA With no joystick input. lf mA values > 51mA appear without operating the joystick, replace the joystick (WP 0101).
If voltage is 5V: (1) (2) No continuity of the pins of the harness to ground for the affected function solenoid (Figure 2 (Volume 2, WP 0272)). Replace grounded harness (Figure 2 (Volume 2, WP 0272)).
2.
Check boom functions. Unplug the affected function hydraulic solenoid and start engine. a. b. If function still works, shut down engine and remove the affected solenoid. Check for debris or broken O-rings. Replace servo control valve (Volume 2, WP 0207). Replace main control valve (Volume 2, WP 0214).
3.
Test voltage. Enter DIAG SERVO 6(13)" in the diagnostic menu. The Voltage should be 5V. a. lf Voltage is not 5V: (1) (2) b. Check amperage. Enter DIAG SERVO 12(13) and DIAG SERVO 13(13)" in the diagnostic menu. The INPUT and OUTPUT should be <5mA With no joystick input. If mA values >5mA appear Without operating the joystick, replace joystick (WP 0101).
lf Voltage is 5V: (1) Test for button stuck on condition. Enter DIAG SERVO screens 2 (13)" and DIAG SERVO 3 (13)" in the diagnostic menu. Each Value should be 0" With no joystick buttons pressed. If a button appears to be stuck on, replace joystick (WP 0101).
(2) 4.
No continuity of the pins of the harness to ground for the affected function (Figure 6 (Volume 2, WP 0272)). Replace grounded harness (WP 0101).
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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 5. Unplug the affected function hydraulic solenoid and start engine. If function still Works, shut down engine and remove the affected solenoid. Check for debris or broken O-rings. Replace faulty solenoid (Volume 2, WP 0217). Brake System Troubleshooting Procedures (Non-Error Code). SYMPTOM BRAKING IS POOR OR NONEXISTENT MALFUNCTION Accumulator shutoff valves are in CLOSED position. CORRECTIVE ACTION Close shutoff valves as required (Volume 2, WP 0204). MALFUNCTION Brake pedals are damaged or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Repair or replace damaged brake pedal (Volume 2, WP 0160).
MALFUNCTION Hydraulic brake lines and hoses damaged or signs of leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Repair or replace damaged or leaking lines and hoses (Volume 2, WP 0157).
MALFUNCTION Incorrect brake charging valve opening pressure for brake system circuits 1 and 2, test points 1 and 2 (Volume 2, WP 0245). CORRECTIVE ACTION 1. 2. 3. 4. If accumulator pre-charge nitrogen pressures are not normal, service accumulators (Volume 2, WP 0154). Replace service brake control valve (Volume 2, WP 0153). lf operating pressure is low, replace boom and brake system pump (Volume 2, WP 0205). Test operating pressures for brake system circuits 1 and 2, test points 4
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Brake System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued and 5 (Volume 2, WP 0245). 5. SYMPTOM PARKING BRAKE WILL NOT RELEASE MALFUNCTION Accumulator shutoff valves are in CLOSED position. CORRECTIVE ACTION Close shutoff valve as required (Volume 2, WP 0204). MALFUNCTION Parking brake control lever damaged or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged parking brake control valve (Volume 2, WP 0151). Replace service brake control valve (Volume 2, WP 0153).
MALFUNCTION Hydraulic brake hoses and lines for damaged or signs of leakage. CORRECTIVE ACTION 1. 2. 3. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0152). Test brake charging valve opening pressure for brake system circuit 2, test point 4 (Volume 2, WP 0245). a. b. Check parking brake calipers for parking brake release if pressure check is normal. Check pad adjustment (Volume 2, WP 0150). If parking brakes do not release at the calipers, replace the parking brake control valve (Volume 2, WP 0151).
MALFUNCTION Transmission will not engage. CORRECTIVE ACTION If transmission will engage but brake seems to be engaged, replace the parking brake flow control valve located next to the brake system accumulator shutoff valves.
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Brake System Troubleshooting Procedures (Non-Error Code) - Continued. SYMPTOM PARKING BRAKE WILL NOT ENGAGE MALFUNCTION Front and rear parking brake assemblies and brake pads worn or damaged. CORRECTIVE ACTION 1. 2. Replace Worn parking brake pads (Volume 2, WP 0150). Notify Direct Support (DS) maintenance if parking brake assembly is damaged.
MALFUNCTION Parking brake pads not properly adjusted. CORRECTIVE ACTION Adjust parking brake pad clearance (Volume 2, WP 0150). MALFUNCTION Parking brake control lever obstructed or damaged. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged parking brake control lever (Volume 2, WP 0151).
MALFUNCTION Hydraulic brake hoses and lines damaged or signs of leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0152).
Steering System Troubleshooting Procedures (Non-Error Code). SYMPTOM STEERING CONTROL IS POOR OR NONEXISTENT
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Steering System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Has active steering error code(s). CORRECTIVE ACTION Perform troubleshooting for active error code(s) (WP 0004). MALFUNCTION Dump valve open. CORRECTIVE ACTION Close steering system dump valve (Volume 2, WP 0204). MALFUNCTION Steering system components, lines, hoses, and cylinders for damage, leaks, or obstructions. CORRECTIVE ACTION 1. 2. 3. 4. Remove any obstructions. Replace any damaged lines, hoses, or fittings, and tighten loose connections (Volume 2, WP 0170). Replace any damaged or leaking steering cylinder (Volume 2, WP 0171). Check for proper operation, Enter into EXTRA FUNCT 2(13)" in the diagnostic menu. Operate the pump cutoff function and observe any change in engine sound. lf no notable change is heard or felt while turning the pumps on and off perform troubleshooting procedure for the 611 valve hydraulic/electrical circuit (Figure 2 & Figure 18 (Volume 2, WP 0272)). 5. Check steering system hydraulic pressures at test points 3, 6, and 7 (Volume 2, WP 0245). a. b. Compare the hydraulic pressures of the test points. All three should be the same 430 to 3,045 psi (2,965 to 20,995 kPa). If pressures are not as specified, replace steering/tophandler pump assembly (Volume 2, WP 0212).
Operators Cab Troubleshooting Procedures (Non-Error Code). SYMPTOM OPERATORS CAB WILL NOT MOVE TO OR FROM TRANSPORT POSITION PROPERLY
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Operators Cab Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Auxiliary pump improper operation (TM 10-3930-675-10). CORRECTIVE ACTION lf auxiliary pump does not work, use the troubleshooting procedure Auxiliary Pump Not Working" in this work package to correct the problem. MALFUNCTION Cab lift slide rails, rollers, and cab transport lift damaged or obstructed. CORRECTIVE ACTION 1. 2. Repair or replace damaged cab lift slide rails, rollers, or cab transport lift (Volume 2, WP 0179). Remove obstructions and clean as required.
MALFUNCTION Cab lift and sideshift cylinders, hoses, and cab transport control valve damaged or leaking. CORRECTIVE ACTION 1. 2. 3. 4. Replace any damaged or leaking cylinder (Volume 2, WP 0232) and (Volume 2, WP 0233). Replace damaged hoses and tighten loose fittings (Volume 2, WP 0221). Replace damaged or leaking cab transport control valve (Volume 2, WP 0216). Check for proper operation. Use (Volume 2, WP 0245) test point 10 to check auxiliary pump pressure. Ensure the supply valve on the hydraulic tank for the auxiliary pump is open. a. b. Open supply valve (FO-10) (Volume 2, WP 0272). Pump pressure should be around 750 psi (5,171 kPa) no load and 1,595 psi (10,997 kPa) While holding control at full LIFT position. lf pressure is not as specified, replace auxiliary pump (Volume 2, WP 0209).
Auxiliary Pump Troubleshooting Procedures (Non-Error Code). SYMPTOM AUXILIARY PUMP NOT WORKING MALFUNCTION Circuit breaker F17 for Reset circuit breaker as tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground
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Auxiliary Pump Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued (Figure 15 & Figure 16 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). 3. Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION Auxiliary pump damaged. CORRECTIVE ACTION Replace damaged auxiliary pump (Volume 2, WP 0209). MALFUNCTION Auxiliary pump switch inoperative. CORRECTIVE ACTION 1. 2. Replace damaged or inoperable switch (WP 0094). Check for proper operation. Enter EXTRA FUNC 3(13)" in the diagnostic menu. Press the auxiliary pump switch. Should have a 1" for INPUT" then a 1" for OUTPUT". (1) (2) (3) If no 1" for INPUT", continue with No voltage (24V) at X67 pin 1 and 2 while pressing the auxiliary pump switch." If no 1" for OUTPUT", replace ECU 792 (WP 0100). If 1" for OUTPUT", continue with No voltage (24V) at 350-1 solenoid located on top of the auxiliary pump motor."
MALFUNCTION No Voltage (24V) at X67 pin 1 and 2 while pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. 3. 4. At X67 pin 1, check circuit breaker FI7 and continuity of wires A678 and A671 (Figure 15 (Volume 2, WP 0272)). At X67 pin 2, remove auxiliary pump switch and check for damage and continuity, and check continuity of wires 671 and 672 (Volume 2, WP 0272). Replace damaged or faulty switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Auxiliary Pump Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION No voltage at ECU 792 pin 48 while pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. At ECU 792 pin 48, check continuity of wires A474, 474, and A1744 (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at 350-1 solenoid located on top of the auxiliary pump motor. CORRECTIVE ACTION Should have voltage (24V) at the large terminal with the cable (W30) connected to it. a. b. c. Check voltage (24V) at the circuit breakers (F51-1 and FS1-2) mounted under the auxiliary pump (Figure 8 & Figure 16 (Volume 2, WP 0272)). Replace damaged or faulty circuit breakers (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) between motor +terminal and motor ground terminal with auxiliary pump switch pressed. CORRECTIVE ACTION 1. 2. 3. 4. Test 350-1 solenoid (Volume 2, WP 0267). If 350-1 solenoid damaged or faulty, replace auxiliary pump (Volume 2, WP 0209). Replace auxiliary pump (Volume 2, WP 0209). Repair loose or disconnected ground cables (Figure 16 (Volume 2, WP 0272)).
MALFUNCTION No voltage (24V) at 350-1 solenoid pin 86 (top spade terminal) while pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. 3. 4. At 350-1 pin 86, remove relay 350 and test Electrical General Maintenance Instructions (Volume 2, WP 0267) and Figure 16 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Check continuity of wires 251, 252, A251, A251A, and A671A (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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Auxiliary Pump Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION No voltage (24V) at XK3 pin 8 While pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. 3. At XK3 pin 8, check continuity of wires A469, 469, and A1745 (Figure 16 (Volume 2, WP 0272)). Check Wire connection and voltage (24V With switch pressed) at ECU 792 pin 61 (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Boom System Troubleshooting Procedures (Non-Error Code). SYMPTOM BOOM WILL NOT LIFT OR LOWER PROPERLY MALFUNCTION Active boom system error code(s). CORRECTIVE ACTION Perform troubleshooting procedures to clear error code(s) (WP 0004). MALFUNCTION Boom locked (red) twistlock indicator light is off. CORRECTIVE ACTION 1. 2. Use the override switch to move twistlocks into proper position (TM 10-3930-675-10). If twistlock lights do not operate correctly, perform troubleshooting procedure for Proximity Switches - Tophandler and Cab" in this work package.
MALFUNCTION Lift cylinders are damaged, leak, or have obstructions. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged or leaking cylinders (Volume 2, WP 0231).
MALFUNCTION Lift cylinder hydraulic lines and hoses damaged and signs of leakage. CORRECTIVE ACTION 1. Tighten loose connections.
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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued 2. Replace damaged or leaking lines and hoses (Volume 2, WP 0224).
MALFUNCTION Lift cylinder emergency and float valves are not in closed position. CORRECTIVE ACTION Close emergency and float valves as required (TM 10-3930-675-10). MALFUNCTION Boom and tophandler out of calibration (Volume 2, WP 0257). CORRECTIVE ACTION 1. 2. Calibrate boom and tophandler as required (Volume 2, WP 0257). Check test boom control system. Operate the auxiliary pump using the procedure Lower Boom (Extended or Loaded with a Container)" (TM 10-3930-675-10) to test boom control system. (The boom movements will be extremely slow). a. b. 3. If boom system operates normally, the boom control system is not at fault, check boom and brake pump pressure (Volume 2, WP 0245). If boom system does not operate normally, check boom control system.
Test boom system operating pressures at test points 8 and 9 (Volume 2, WP 0245). a. b. c. If test point 9 pressure is not normal, replace servo pressure reducing valve first, then the servo control valve (Volume 2, WP 0207) if needed. lf boom will extend and retract normally, but not lift or lower, replace the main control valve assembly (Volume 2, WP 0214). lf test point 8 pressure is not normal, replace boom and brake system hydraulic pump (Volume 2, WP 0205).
SYMPTOM BOOM WILL NOT EXTEND OR RETRACT PROPERLY MALFUNCTION Active boom system error code(s). CORRECTIVE ACTION Perform troubleshooting procedures to clear error code(s) (WP 0004).
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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Extension cylinder damage or leakage. CORRECTIVE ACTION
NOTE
Extension cylinder leaks appear to be coming from inside boom assembly. Notify SRA to replace damaged or leaking extension cylinder. MALFUNCTION Extension cylinder hydraulic lines and hoses damage or leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0224).
MALFUNCTION Boom wear plates worn or damaged. CORRECTIVE ACTION Replace worn or damaged boom wear plates (Volume 2, WP 0258). MALFUNCTION Boom and tophandler calibration (Volume 2, WP 0257). CORRECTIVE ACTION 1. 2. Calibrate boom and tophandler as required (Volume 2, WP 0257). Test boom control system. Operate the auxiliary pump using the procedure Lower boom (Extended or Loaded with a Container)" (TM 10-3930-675-10) to test boom control system. (The boom movements will be extremely slow). a. b. 3. lf boom system operates normally, the boom control system is not at fault, check boom and brake pump pressure (Volume 2, WP 0245). lf boom system does not operate normally, check boom control system.
Test boom system operating pressures, test points 8 and 9 (Volume 2, WP 0245). a. b. c. If test point 9 pressure is not normal, replace servo pressure reducing valve first, then the servo control valve (Volume 2, WP 0207) if needed. If boom will extend and retract normally, but not lift or lower, replace the main control valve assembly (Volume 2, WP 0214). lf test point 8 pressure is not normal, replace boom and brake system hydraulic pump (Volume 2, WP 0205).
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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. SYMPTOM BOOM FOLDING CYLINDERS NOT WORKING MALFUNCTION Inoperative tophandler functions. CORRECTIVE ACTION 1. 2. 3. 4. Check operation of all tophandler functions lf no tophandler functions operate, check tophandler pump pressure at test point no. 11 (Volume 2, WP 0245). Troubleshooting pump control circuit (611 solenoid) (Figure 18 & Figure 2 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).
MALFUNCTION Incorrect clearance of cab proximity switch (7210) between cab and frame. CORRECTIVE ACTION Move cab closer to the frame. MALFUNCTION Cab position incorrect. CORRECTIVE ACTION Adjust cab or proximity switch (7210) to correct clearance. MALFUNCTION Boom folding control valve damaged or leakage. CORRECTIVE ACTION
NOTE
DO NOT adjust proximity switch (7210) beyond end of enclosure. Replace damaged or leaking boom folding control valve(s) (Volume 2, WP 0215). MALFUNCTION Damaged boom folding cylinders. CORRECTIVE ACTION Replace damaged or leaking boom folding (Volume 2, WP 0218).
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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Hydraulic lines and hoses and boom folding control valve for damage and signs of leakage. CORRECTIVE ACTION 1. 2. 3. 4. SYMPTOM BOOM LOCKING PIN CYLINDER NOT WORKING MALFUNCTION Incorrect operation of all tophandler functions. CORRECTIVE ACTION 1. 2. 3. If no tophandler functions operate, check tophandler pump pressure at test point no. 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212). Replace damaged or leaking lines and hoses (Volume 2, WP 0223). Replace damaged or leaking boom folding control valve (Volume 2, WP 0215). Tighten loose connections. Replace the over-center valve (Volume 2, WP 0224).
MALFUNCTION Incorrect clearance of cab proximity switch (7210) between cab and frame. CORRECTIVE ACTION
NOTE
Move the cab to the transport position (TM 10-3930-675-10). Raise boom folding cylinders to release pressure on locking pins before operating locking pin cylinders. 1. 2. Move cab closer to the frame. Adjust cab or proximity switch (7210) to correct clearance.
MALFUNCTION Boom folding control valve damaged and signs of leakage. CORRECTIVE ACTION Replace damaged or leaking boom folding control valve(s) (WP 0118).
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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Damaged cab proximity switch (7210). CORRECTIVE ACTION
NOTE
DO NOT adjust proximity switch (7210) beyond end of enclosure. Replace damaged or inoperative proximity switch (WP 0105). MALFUNCTION Solenoid valve (6043) operation and wiring (Figure 7 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or faulty solenoid valve (Volume 2, WP 0217). MALFUNCTION Damaged locking pin cylinders CORRECTIVE ACTION Replace damaged or leaking locking pin cylinder(s) (Volume 2, WP 0235). MALFUNCTION Hydraulic line and hoses damaged or signs of leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0220).
MALFUNCTION Locking pins damaged. CORRECTIVE ACTION Check for frame or boom support damage. MALFUNCTION Damaged double pilot operated check valve mounted on the locking pin cylinder. CORRECTIVE ACTION Replace double pilot operated check valve (Volume 2, WP 0224).
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Tophandler System Troubleshooting Procedures (Non-Error Code). SYMPTOM TOPHANDLER WILL NOT TILT FORWARD OR REARWARD PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).
MALFUNCTION Damaged tophandler control valves, lines, hoses. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Tilt cylinders damaged, leaking or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0245). Replace damaged or leaking tilt cylinder (Volume 2, WP 0237).
MALFUNCTION Tophandler control valve solenoids 6010 and 6011 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).
WARNING
Injury or death can occur during manual operation of the hydraulic function.
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued
CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6010 and 6011 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use jewelers screwdriver to press the button momentarily to manually activate the tilt function. Check both solenoids the same way. a. b. SYMPTOM TOPHANDLER WILL NOT OSCILLATE (LEVEL) PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active error code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the tilt-over cylinder valve.
MALFUNCTION Damaged tophandler control valve. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Lines hoses, and oscillation cylinders damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking oscillation or tophandler.
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Oscillation wear plates damaged and worn. CORRECTIVE ACTION Replace any worn or damaged wear plates. MALFUNCTION Tophandler control valve solenoids 6035 and 6036 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).
WARNING
Injury or death can occur during manual operation of the hydraulic function. 2. Check for proper operation. Start the engine (TM 10-3930-675-10). Disconnect the connector from the 6035 and 6036 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the oscillate function. Check both solenoids the same way. a. b. c. If the function does not activate, remove the solenoid and inspect (Volume 2, WP 0217). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the oscillate over-center valve.
MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active ERROR CODE(s). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).
MALFUNCTION Damaged tophandler control valve. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225).
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Lines, hoses, and sideshift cylinders damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking oscillation or tophandler control valve (Volume 2, WP 0230).
MALFUNCTION Sideshift wear plates damaged or worn. CORRECTIVE ACTION Replace any worn or damaged wear plates (Volume 2, WP 0263). MALFUNCTION Tophandler control valve solenoids 6020 and 6021 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).
WARNING
CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6020 and 6021 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. Replace damaged or faulty solenoid (Volume 2, WP 0217). SYMPTOM TOPHANDLER SPREADER WILL NOT OPEN OR CLOSE PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. Perform troubleshooting for active error code(s) (WP 0004).
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued 2. Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).
MALFUNCTION Incorrect position of twistlocks. CORRECTIVE ACTION Place twistlocks in the UNLOCKED position. If twistlocks do not operate, ensure cab is in operational position. MALFUNCTION Incorrect operation of the forklift kit proximity switches and cam mechanism. CORRECTIVE ACTION Ensure both proximity switches are activated and cam mechanism operates properly. MALFUNCTION Damaged lines, hoses. CORRECTIVE ACTION Replaced damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Spreader motor damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking, spreader motor (WP 0126).
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Spreader chains and sprockets damaged, wear, tightness, or obstructions. CORRECTIVE ACTION Replace or adjust damaged, worn, or loose spreader chains (Volume 2, WP 0260). MALFUNCTION Spreader wear plates damaged or wear. CORRECTIVE ACTION Replace any worn or damaged wear plates (Volume 2, WP 0263). MALFUNCTION Tophandler control valve solenoids 6018 and 6019 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).
WARNING
CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6018 and 6019 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. a. b. c. SYMPTOM TOPHANDLER WILL NOT ROTATE LEFT OR RIGHT PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. Perform a troubleshooting for active error code(s) (WP 0004). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the spreader motor over-center valve (WP 0126). Replace spreader motor assembly (WP 0126).
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued 2. Check operation of all tophandler functions. a. b. c. If not tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).
MALFUNCTION Damaged tophandler control valve. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Lines, hoses, and slewing motors damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking slewing motor (Volume 2, WP 0210).
MALFUNCTION Slewing gear and pinions damaged, worn, or obstructed. CORRECTIVE ACTION 1. 2. Replace any worn or damaged slewing motor and pinion (Volume 2, WP 0210). Replace damaged or worn slewing gear (Volume 2, WP 0210).
WARNING
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued
CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6008 and 6009 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. a. b. c. d. SYMPTOM TOPHANDLER TWISTLOCKS WILL NOT ROTATE PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active error code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212). If the function does not activate, remove the solenoid and inspect (Volume 2, WP 0217). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the slewing motor over center valve (Volume 2, WP 0210). Replace slewing motor assembly (Volume 2, WP 0210).
MALFUNCTION Incorrect position of the cab. CORRECTIVE ACTION Place cab operational position (TM 10-3930-675-10). MALFUNCTION Incorrect position of twistlocks cylinder bypass valves. CORRECTIVE ACTION Place both valves in proper position.
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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Damaged bypass valves, lines, hoses. CORRECTIVE ACTION Replace any damaged bypass valve lines, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Twistlock cylinders damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged or leaking twistlock cylinder (Volume 2, WP 0240).
MALFUNCTION Twistlocks and linkage arms damaged or obstructions. CORRECTIVE ACTION 1. 2. Remove obstructions. Replace damaged twistlocks or linkage (Volume 2, WP 0203).
WARNING
CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6039 and 6040 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. a. b. c. If the function does not activate, remove the solenoid and inspect (Volume 2, WP 0217). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace twistlock double pilot operated check valve (Volume 2, WP 0240).
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Bogie Wheel System Troubleshooting Procedures (Non-Error Code). SYMPTOM BOGIE WHEELS WILL NOT LIFT OR LOWER MALFUNCTION Tophandler functions inoperative. CORRECTIVE ACTION Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test. Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering ad tophandler pump assembly (Volume 2, WP 0212).
MALFUNCTION Incorrect clearance of cab proximity switch (7210) between cab and frame. CORRECTIVE ACTION
NOTE
Move the cab to the transport position (TM 10-3930-675-10). DO NOT adjust proximity switch (7210) beyond end of enclosure. 1. 2. Move cab closer to the frame. Adjust cab or proximity switch (7210) to correct clearance.
MALFUNCTION Bogie wheel slide rails and locking collar/bogie screw obstructions. CORRECTIVE ACTION Remove obstructions and clean as required. MALFUNCTION Incorrect position of bogie pressure valve. CORRECTIVE ACTION Place bogie pressure valve in the CLOSED position (TM 10-3930-675-10).
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Bogie Wheel System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Boom folding control valve damaged or leakage. CORRECTIVE ACTION Replace damaged or leaking boom folding control valve (Volume 2, WP 0215). MALFUNCTION Inoperative cab proximity switch (7210). CORRECTIVE ACTION Replace damaged or inoperative proximity switch (WP 0105). MALFUNCTION Solenoid valve (6043) operation or wiring damaged (Figure 7 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or faulty solenoid valve (Volume 2, WP 0217). MALFUNCTION Damaged bogie wheel cylinders. CORRECTIVE ACTION Replace damaged or leaking lines and hoses (Volume 2, WP 0224). MALFUNCTION Hydraulic lines and hoses and boom folding control valve damaged or signs of leakage. CORRECTIVE ACTION 1. 2. 3. 4. Tighten loose connections. Replace damaged or leaking boom folding control valve (Volume 2, WP 0215). Replace damaged or leaking bogie wheel cylinder(s) (Volume 2, WP 0234). Replace the over-canter valve (Volume 2, WP 0224).
Forklift Kit Troubleshooting Procedures (Non-Error Code). SYMPTOM FORK FUNCTIONS NOT WORKING PROPERLY
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Forklift Kit Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Active tophandler error code(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active error code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. 3. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).
Check operation of forklift kit proximity switches ad cam mechanism. Ensure both proximity switches are active and cam mechanism operates properly.
MALFUNCTION Damaged lines, hoses. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Cylinders damaged or leaking. CORRECTIVE ACTION 1. 2. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace any damaged or leaking cylinders (Volume 2, WP 0246).
MALFUNCTION Fork wear plates and shaft sliding surfaces damaged, worn, or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace any worn or damaged wear plates.
MALFUNCTION Forklift hydraulic valves damaged or leaking. CORRECTIVE ACTION Replace any damaged or leaking hydraulic valves (Volume 2, WP 0226).
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TM 10-3930-675-23-1
0006
Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code). SYMPTOM AUTOLUBE SYSTEM NOT LUBRICATING PROPER MALFUNCTION Autolube pump inoperative. CORRECTIVE ACTION 1. 2. Initiate a manual pump cycle (WP 0047). Perform troubleshooting procedure for Autolube Pump Not Working (RT 240V2 and RT 240V3)" in this is not work package.
MALFUNCTION Main distribution valve damaged. CORRECTIVE ACTION 1. 2. Observe if the pin is moving in and out during a manual cycle. Replace damaged main distribution valve.
MALFUNCTION Lubricant leaking from pressure limiting valve. CORRECTIVE ACTION 1. 2. 3. Disconnect each outlet tube one at a time at the distribution valve. Identify the tube that had pressure on it when disconnected. Reconnect the tubes and run a manual lube cycle.
MALFUNCTION Use the Autolube tubing layout diagram (Figure 23 (Volume 2, WP 0272)) to trace the identified tube to the secondary distribution valve. CORRECTIVE ACTION 1. 2. 3. 4. Disconnect each outlet tube at the secondary distribution valve one at a time until you identify the one with pressure on it. Use the tubing layout diagram to trace identified tube to the plugged" lube point. If no plugged" lube points are found, run a manual lube cycle and disconnect the inlet tube at each secondary distribution valve to identify the tube with pressure in it. Replace non-functioning or plugged" secondary distribution valve.
0006-94
TM 10-3930-675-23-1
0006
Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Autolube system tubing and fittings damaged or worn. CORRECTIVE ACTION Replace any damaged or worn tubing or fittings. SYMPTOM AUTOLUBE PUMP NOT WORKING MALFUNCTION Circuit breaker F43 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (WP 0103).
MALFUNCTION Autolube pump damaged. CORRECTIVE ACTION 1. 2. 3. Replace damaged Autolube pump. Enter EXTRA FUNC 10(13)" in the diagnostic menu. Use the +/- keys to activate pump control circuit. SET OUTPUT SIG" should be 1" when activated. Remove the plastic plug from the front of the Autolube pump. Check the left LED light on the pump printed circuit board is on. Push the button on the PC board for two seconds to activate a manual cycle.
MALFUNCTION No voltage (24V) at X174B pin 2. CORRECTIVE ACTION 1. 2. 3. 4. At X174B pin 2, check connection of wire A174B2 at ECU (792) pin 60. Check continuity of wire A174B2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (729) (WP 0100).
0006-95
TM 10-3930-675-23-1
0006
Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Access the relay boards inside the cab distribution box. Activate the pump control. No voltage (24V) at XK1 pin 8 when pump control activated. CORRECTIVE ACTION 1. 2. If no voltage (24V) is found at XK1 pin 8, check continuity of wires 476 and A476. Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION Relay 3018 damaged. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage (24V) at XK1 pin 9 and pin 3 while activating the pump control. CORRECTIVE ACTION 1. 2. 3. At XK1 pin 9, check circuit breaker F34 and continuity of wire A341. If no voltage (24V) is found at XK1 pin 3, replace relay 3018. Repair or replace damaged wires or connectors (Volume 2, WP 0267).
MALFUNCTION No voltage (24V) at X31 pin 8 with pump activated. CORRECTIVE ACTION 1. 2. 3. At X31 pin 8, check continuity of wire A318. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Unplug connector at pump and check for 24V between the two pins. a. b. c. If voltage (24V) is present, replace the Autolube pump. If voltage (24V) is not present, check the continuity of wires GY and BK in the pump harness and the ground connections of wire A319 and 371 in the cab distribution box in the cab. Replace damaged or open Autolube harness.
MALFUNCTION Solar panel damaged. CORRECTIVE ACTION Replace damaged solar panel (WP 0106).
0006-96
TM 10-3930-675-23-1
0006
Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Wiring connections damaged. CORRECTIVE ACTION Replace/repair damaged wires (Volume 2, WP 0267). MALFUNCTION Blown 2 amp fuse located in the fuse holder on the RED wire connected to the master battery switch battery side terminal (Figure 2 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace blown 2 amp fuse (WP 0106). MALFUNCTION 24V Pulse module or connection damaged (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. Blinking red LED on 24V Pulse module indicates voltage is connected and unit is operating. Replace damaged non-functioning 24V Pulse module (WP 0106).
END OF WORK PACKAGE
0006-97/98 blank
TM 10-3930-675-23-1
0007
FIELD MAINTENANCE ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0057 WP 0067 WP 0099 WP 0100 Volume 2, WP 0267
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components.
0007-1
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0007
TROUBLESHOOTING PROCEDURE ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. SYMPTOM
ERROR CODE 1311 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION 1. Place ignition switch in OFF position and disconnect actuator harness from engine Electronic Control Unit (ECU) and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2.
Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 9 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 9 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
0007-2
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0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
>100K OHMS
>100K OHMS
T0041JCH
Figure 1. Actuator Harness Test. c. Measure resistance from actuator harness connector pin 10 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
3.
Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
4.
Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 1 injector solenoid. a. Measure resistance from 15-pin connector pin 1 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from 15-pin connector pin 2 to all other pins in connector. Resistance should be greater than 100k Ohms.
0007-3
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) 5. 6. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).
7. 8.
Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).
SYMPTOM
ERROR CODE 1312 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
0007-4
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks. a. Measure resistance from actuator harness connector pin 3 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
c.
Measure resistance from actuator harness connector pin 4 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
d.
>100K OHMS
T0042JCH
Figure 2. Actuator Harness Test.
0007-5
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 5 injector solenoid. a. Measure resistance from 15-pin connector pin 9 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from 15-pin connector pin 10 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
5. 6.
7. 8.
0007-6
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0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued
SYMPTOM
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
0007-7
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 6 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
>100K OHMS
T0043JCH
Figure 3. Actuator Harness Test. b. Measure resistance from actuator harness connector pin 6 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 16 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
d.
0007-8
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from15-pin connector and from no. 3 injector solenoid. a. Measure resistance from 15-pin connector pin 5 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
5. 6.
Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).
7. 8.
0007-9
TM 10-3930-675-23-1
0007
SYMPTOM
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required Electrical General Maintenance Instructions (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals Electrical General Maintenance Instructions (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 2 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 2 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
0007-10
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. Measure resistance from actuator harness connector pin 1 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
>100K OHMS
T0044JCH
Figure 4. Actuator Harness Test. 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 6 injector solenoid. a. Measure resistance from 15-pin connector pin 5 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).
0007-11
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) b. If internal actuator harness requires replacement, notify SRA.
c.
5. 6.
Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).
7. 8.
SYMPTOM
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover.
0007-12
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 7 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
>100K OHMS
T0045JCH
Figure 5. Actuator Harness Test. b. Measure resistance from actuator harness connector pin 7 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
0007-13
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. Measure resistance from actuator harness connector pin 8 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
3.
Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals Electrical General Maintenance Instructions (Volume 2, WP 0267).
4.
Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 2 injector solenoid. a. Measure resistance from 15-pin connector pin 3 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
5. 6.
7. 8.
0007-14
TM 10-3930-675-23-1
0007
SYMPTOM
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 26 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
c.
Measure resistance from actuator harness connector pin 36 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).
0007-15
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0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) d. If internal actuator harness requires replacement, notify SRA.
>100K OHMS
T0056JCH
Figure 6. Actuator Harness Test. 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 4 injector solenoid. a. Measure resistance from 15-pin connector pin 7 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from 15-pin connector pin 8 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).
0007-16
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0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) 5. 6. If internal actuator harness requires replacement, notify SRA.
7. 8.
SYMPTOM
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
0007-17
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0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15pin connector at front of engine below rocker arm cover. Install jumper wire from pin 1 to pin 2 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 9 to actuator harness connector pin 10. Resistance should be less than 10 Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
<10 OHMS
T0047JCH
Figure 7. Actuator Harness Test. 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from ECU engine. a. Measure resistance from actuator harness connector pin 9 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 9 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
c.
Measure resistance from actuator harness connector pin 10 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
0007-18
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0007
>100K OHMS
>100K OHMS
T0048JCH
Figure 8. Actuator Harness Test. d. Measure resistance from actuator harness connector pin 10 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
0007-19
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0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 9 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 10 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
>100K OHMS
T0049JCH
Figure 9. Actuator Harness Test. 5. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 1 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 6. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 1 injector solenoid.
0007-20
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (WP 0100). If internal actuator harness requires replacement, notify SRA.
Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
<10 OHMS
T0050JCH
Figure 10. 15-Pin Connector Test. 7. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.
Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.
0007-21
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector. a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
>100K OHMS
>100K OHMS
T0051JCH
Figure 11. 15-Pin Connector Test. 9. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 1 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
0007-22
TM 10-3930-675-23-1
0007
>100K OHMS
T0052JCH
Figure 12. Solenoid Connector Test. 10. 11. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no.1 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU.
0007-23
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 9 to pin 10 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 3 to pin 4. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
3.
<10 OHMS
T0053JCH
Figure 13. Actuator Harness Test. 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness connector pin 3 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 3 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms.
0007-24
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
d.
>100K OHMS
T0042JCH
Figure 14. Actuator Harness Connector Test.
0007-25
TM 10-3930-675-23-1
0007
>100K OHMS
T0054JCH
Figure 15. Actuator Harness Connector Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 5 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 5 injector solenoid.
0007-26
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
<10 OHMS
T0055JCH
Figure 16. Injector Wiring Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.
0007-27
TM 10-3930-675-23-1
0007
>100K OHMS
T0056JCH
Figure 17. Actuator Harness Test. 10. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 5 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
0007-28
TM 10-3930-675-23-1
0007
>100K OHMS
T0057JCH
Figure 18. Solenoid Connector Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no.5 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).
WARNING
0007-29
TM 10-3930-675-23-1
0007
3.
<10 OHMS
T0058JCH
0007-30
TM 10-3930-675-23-1
0007
d.
>100K OHMS
T0059JCH
Figure 20. Actuator Harness Test. 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 6 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
0007-31
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Measure resistance from actuator harness connector pin 16 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
>100K OHMS
T0043JCH
Figure 21. Actuator Harness Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 3 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 3 injector solenoid. a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
0007-32
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
<10 OHMS
T0055JCH
Figure 22. Injector Wiring Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.
0007-33
TM 10-3930-675-23-1
0007
>100K OHMS
T0056JCH
Figure 23. Injector Wiring Test. 10. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 3 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
0007-34
TM 10-3930-675-23-1
0007
>100K OHMS
T0057JCH
Figure 24. Injector Wiring Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 3 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).
WARNING
0007-35
TM 10-3930-675-23-1
0007
3.
<10 OHMS
T0058JCH
0007-36
TM 10-3930-675-23-1
0007
d.
>100K OHMS
T0059JCH
Figure 26. Actuator Harness Test. 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 1 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
0007-37
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Measure resistance from actuator harness connector pin 2 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
>100K OHMS
T0060JCH
Figure 27. Actuator Harness Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057)). Disconnect injector solenoid connector from no. 6 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 6 injector solenoid. a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the No. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.
Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the No. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms.
0007-38
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If resistance is not as specified, notify SRA to replace internal actuator harness.
<10 OHMS
T0061JCH
Figure 28. Injector Wiring Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires (Volume 2, WP 0267).
Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires (Volume 2, WP 0267).
0007-39
TM 10-3930-675-23-1
0007
>100K OHMS
>100K OHMS
T0062JCH
0007-40
TM 10-3930-675-23-1
0007
>100K OHMS
T0063JCH
Figure 30. Actuator Harness Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 6 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).
WARNING
0007-41
TM 10-3930-675-23-1
0007
3.
<10 OHMS
T0064JCH
0007-42
TM 10-3930-675-23-1
0007
d.
>100K OHMS
T0065JCH
0007-43
TM 10-3930-675-23-1
0007
>100K OHMS
T0066JCH
0007-44
TM 10-3930-675-23-1
0007
<10 OHMS
T0067JCH
Figure 34. Actuator Harness Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.
0007-45
TM 10-3930-675-23-1
0007
>100K OHMS
>100K OHMS
T0068JCH
0007-46
TM 10-3930-675-23-1
0007
>100K OHMS
T0069JCH
Figure 36. Actuator Harness Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 2 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM ERROR CODE 1332 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).
WARNING
Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins.
0007-47
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 7 to pin 8 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 26 to pin 36. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
3.
<10 OHMS
T0070JCH
0007-48
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. Measure resistance from actuator harness connector pin 36 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
>100K OHMS
T0071JCH
0007-49
TM 10-3930-675-23-1
0007
>100K OHMS
T0072JCH
0007-50
TM 10-3930-675-23-1
0007
<10 OHMS
T0073JCH
Figure 40. Actuator Harness Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.
9.
Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector.
0007-51
TM 10-3930-675-23-1
0007
ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
>100K OHMS
>100K OHMS
T0074JCH
Figure 41. Actuator Harness Test. 10. Place ignition switch in OFF position and, with rockerarm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 4 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.
0007-52
TM 10-3930-675-23-1
0007
>100K OHMS
T0075JCH
Figure 42. Actuator Harness Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 4 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).
ERROR CODE 1951 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION Notify SRA.
0007-53
TM 10-3930-675-23-1
0007
T0076JCH
Figure 43. Cylinder #1 Supply and Return.
T0077JCH
0007-54
TM 10-3930-675-23-1
0007
T0078JCH
T0079JCH
0007-55
TM 10-3930-675-23-1
0007
T0080JCH
T0081JCH
Figure 48. Cylinder #4 Supply and Return. END OF WORK PACKAGE
0007-56
TM 10-3930-675-23-1
0008
FIELD MAINTENANCE ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 48) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0078 WP 0100 Volume 2, WP 0185 Volume 2, WP 0267 Volume 2, WP 0272 Volume 2, WP 0277
NOTE
0008-1
TM 10-3930-675-23-1
0008
TROUBLESHOOTING PROCEDURE ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING SYMPTOM
ERROR CODE 1131 MALFUNCTION High Voltage Detected at Throttle Position Sensor Circuit. CORRECTIVE ACTION
NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). a. b. 4. If resistance is not as specified, continue with Step 4. Repair or replace damaged connector (Volume 2, WP 0267).
2. 3.
Check resistance on the loose part of connector X23 between pins 3 and 4. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, continue with Step 5. Check connector. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness. Check for continuity. Disconnect X690 and inspect for damage. Check resistance on the accelerator pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. Resistance should be 2,000 to 3,000 Ohms and there should be no continuity to ground (Figure 3 (Volume 2, WP 0272)).
5. 6.
0008-2
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
2000-3000 OHMS
PIN 5 X690 BK 6 RD 5 WH 4 PIN 4 USE TEST LEAD KIT P/N 3823994

T0082JCH
1 OR 2 GN 3 BU
Figure 1. Accelerator Pedal Wiring Test.
0008-3
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 7. Check resistance on the accelerator pedal part of connector X690 between pins 5 and 6. Check each pin for continuity to ground. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms With the pedal depressed. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). a. b. c. d. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). If resistance is as specified, check continuity and for continuity to ground for wires 233, 234, and 235 (Figure 3 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
1500-3000 OHMS RELEASED 250-1500 OHMS DEPRESSED
PIN 6 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3823994 PIN 5
X690 1 OR 2 GN 3 BU
T0083JCH
Figure 2. Accelerator Pedal Wiring Test. 8. Inspect pins. Reconnect connector X23 and connector X690. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).
0008-4
TM 10-3930-675-23-1
0008
1500-3000 Ohms
USE TEST LEAD KIT P/N 3822758
T0084JCH
Figure 3. OEM Harness Connector Test. 9. Check resistance at the OEM harness connector between pins 48 and 49. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, proceed with Step 10. Check resistance at the OEM harness connector between pins 47 and 48. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, proceed with Step 11.
10.
>1500-3000 OHMS RELEASED 250-1500 Ohms DEPRESSED
T0085JCH
Figure 4. OEM Harness Connector Test.
0008-5
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11. Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA. Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a. b. 13. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open, or grounded wires.
12.
Check for continuity. Disconnect the OEM harness connector and connector X16. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector. There should be continuity between pins. If there is continuity between pin 47 and any other pin in the OEM harness connector, notify SRA.
>1500-3000 OHMS RELEASED 250-1500 Ohms DEPRESSED
T0085JCH
Figure 5. OEM Harness Connector Test.
0008-6
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1132 MALFUNCTION Low Voltage Detected at Throttle Position Sensor Circuit. CORRECTIVE ACTION
NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). a. b. 4. If resistance is not as specified, continue with Step 4. Repair or replace damaged connector (Volume 2, WP 0267).
2. 3.
Check continuity on the loose part of connector X23 between pin 3 and ground and pin 4 and ground. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found continue with Step 5. Inspect wiring. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness.
5.
0008-7
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check for continuity. Disconnect connector X690 and inspect for damage. Check resistance on the acceleration pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. Resistance should be 2,000 to 3,000 Ohms and there should not be continuity to ground (Figure 3 (Volume 2, WP 0272)). a. b. If resistance is not as specified; replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).
2000-3000 OHMS
PIN 4 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3823996 PIN 5
X690 1 OR 2 GN 3 BU
T0087JCH
Figure 6. Accelerator Pedal Wiring Test. 7. Check continuity on the accelerator pedal part of connector X690 between pin 5 and ground and pin 6 and ground. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). a. b. c. d. If continuity to ground is found, replace accelerator pedal assembly (WP 0078). If continuity to ground is not found, check continuity and for continuity to ground for wires 233, 234, and 235 (Figure 3 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
0008-8
TM 10-3930-675-23-1
0008
X690 BK 6 RD 5 WH 4 1 OR 2 GN 3 BU
T0088JCH
PIN 5 AND PIN 6 USE TEST LEAD KIT P/N 3823996
Figure 7. Accelerator Pedal Wiring Test. 8. Inspect pins. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a. b. 9. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).
Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA. Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open or grounded wires.
10.
0008-9
TM 10-3930-675-23-1
0008
T0089JCH
Figure 8. OEM Wiring Harness Test. 11. Check for continuity. Disconnect the OEM harness connector and connector Xl6. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector and between pin 48 and all of the other pins in the connector. There should be continuity between pins. If there is continuity between pin 47 or 48 and any other pin in the OEM harness connector, notify SRA.
T0090JCH
Figure 9. OEM Wiring Harness Test.
0008-10
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 1431 MALFUNCTION Voltage Detected at Both Idle Validation Signal Circuits. CORRECTIVE ACTION
NOTE
Use test lead, female - part number Volume 2, WP 0277, Table 1, Item 47 to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Check calibration. Turn the ignition on and depress and release the accelerator pedal three times to calibrate the pedal. If ERROR CODE remains active continue with Step 2.
3 TIMES
T0091JCH
Figure 10. Accelerator Pedal Calibration. 2. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Inspect connector X23 for damage. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Repair or replace damaged connector (Volume 2, WP 0267). Check resistance on the loose part of connector X23 between pins 6 and 9. Resistance should be <125 Ohms with the pedal released. Check resistance between 7 and 9. Resistance should be <125 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified continue with Step 5.
3.
4.
0008-11
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check continuity on the loose part of connector X23 between pins 6 and 7 while depressing and releasing the pedal. There should be continuity (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, continue with Step 6. Check for resistance. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness. a. b. 7. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).
6.
Check for resistance. Disconnect connector X690 and inspect for damage. Check resistance on the accelerator pedal part of connector X690 between pins 1 and 3. Resistance should be <125 Ohms with the pedal released. Check resistance between pins 1 and 2. Resistance should be <125 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). a. b. c. d. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). If resistance is as specified, check continuity and for continuity between wires for wires 233, 234, and 235. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
<125 OHMS <125 OHMS
1,3 X690 BK 6 RD 5 WH 4 1 OR 2 GN 3 BU
1,2
T0092JCH
Figure 11. Accelerator Pedal Test. 8. Check resistance on the accelerator pedal part of connector X690 between pins 2 and 3 while depressing and releasing the pedal. There should be continuity (Figure 3 (Volume 2, WP 0272)). a. b. If voltage (4.75V to 5.25V) is not as specified, continue with Step 9. Repair or replace damaged connector (Volume 2, WP 0267).
0008-12
TM 10-3930-675-23-1
0008
>100K OHMS
X690 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3822917 1 OR 2 GN 3 BU
2,3
T0093JCH
Figure 12. Accelerator Pedal Resistance Test. 9. Inspect connector X16 for damage. Reconnect connector X23 and disconnect connector X16. Turn the ignition on and check for voltage at connector X16 between pin 3 and ground and pin 13 and ground (Figure 3 (Volume 2, WP 0272)). There should be 4.75V to 5.25V at each pin. a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).
4.75-5.25V
T0094JCH
Figure 13. Idle Validation Circuit Voltage Test.
0008-13
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 10. Inspect the OEM harness connector and ECU pins for damage, dirt or corrosion. Remove engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity of wires 166, 167, and 168 (Figure 3 (Volume 2, WP 0272)). a. b. c. 12. If continuity at any one wire is not found, replace engine and transmission wiring harness Electrical General Maintenance Instructions (Volume 2, WP 0267)). Perform voltage check in Step 9 again. Replace ECU (794) (WP 0100) if Step 9 voltage check fails.
11.
Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A166, A167, and A168 (Figure 3 (Volume 2, WP 0272)). a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open, or grounded wires.
13.
Check for continuity. Disconnect the OEM harness connector and connector X16. Check for continuity on the OEM harness connector between pin 3 and all of the other pins in the connector. Check continuity between pin 13 and all of the other pins in the connector. There should not be continuity between pins. If there is continuity between pin 3 or pin 13 and any other pin in the OEM harness connector, notify SRA.
>100K OHMS >100K OHMS
T0095JCH
Figure 14. Idle Validation Circuit Voltage Test.
0008-14
TM 10-3930-675-23-1
0008
SYMPTOM
ERROR CODE 1432 MALFUNCTION Wrong Voltage Signals Detected at Throttle Position Sensor and Idle Validation Circuits. CORRECTIVE ACTION
NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Check calibration. Turn the ignition on and depress and release the accelerator pedal three times to calibrate the pedal. If ERROR CODE remains active, continue with the troubleshooting procedure. 2. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Check resistance on the loose part of connector X23 between pins 3 and 4. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). The difference in the two resistance values must be at least 1,000 Ohms. a. b. 5. If resistance is not as specified, continue with Step 5. Repair or replace damaged connector (Volume 2, WP 0267).
3. 4.
Check connector. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness. Check connector X690 for damage. Repair or replace damaged connector (Volume 2, WP 0267).
0008-15
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check resistance on the accelerator pedal part of connector X690 between pins 5 and 6. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). The difference in the two resistance values must be least 1,000 Ohms. a. b. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).
USE TEST LEAD KIT P/N 3822917 1500-3000 OHMS RELEASED 250-1500 OHMS DEPRESSED
X690 BK 6 RD 5 WH 4 1 OR 2 GN 3 BU
5,6
NOTE: RELEASED VALUE MUST BE AT LEAST 1000 OHMS GREATER THAN DEPRESSED VALUE
T0096JCH
Figure 15. TPS and Idle Validation Circuit Voltage Test. 7. Check continuity of wires 233, 234, and 235 between connector X690 and connector X23 (Figure 3 (Volume 2, WP 0272)). a. b. 8. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
Inspect the OEM harness connector and ECU pins for damage, dirt or corrosion. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).
9.
Disconnect connector X16 and the OEM harness connector. Check continuity of wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity of any wire is not found, replace engine and transmission wiring harness (Volume 2, WP 0267).
0008-16
TM 10-3930-675-23-1
0008
ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 10. Check connector and wires. Disconnect connector X16 and inspect for damage. Check continuity of wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a. b. 11. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open, or grounded wires.
Check for continuity. Disconnect the OEM harness connector and connector Xl6. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector, between pin 48 and all the other pins in the connector and between pin 49 and all of the other pins in the connector. There should not be continuity between pins. If there is continuity between pin 47, 48, or 49 and any other pin in the OEM harness connector, replace the engine and transmission wiring harness (Volume 2, WP 0267).
>100K OHMS
T0097JCH
Figure 16. TPS and Idle Validation Circuit Voltage Test.
0008-17
TM 10-3930-675-23-1
0008
SYMPTOM
ERROR CODE 1551 MALFUNCTION No Voltage Detected at Both Idle Validation Signal Circuits. CORRECTIVE ACTION
NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. Perform the troubleshooting procedure for ERROR CODE 1431. END OF WORK PACKAGE
0008-18
TM 10-3930-675-23-1
0009
FIELD MAINTENANCE COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0100 WP 0116 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.
0009-1
TM 10-3930-675-23-1
0009
TROUBLESHOOTING PROCEDURE COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING SYMPTOM
TEST OR INSPECTION11(13) DIAG SERVO OUTPUT/INPUT FAN 0mA 0mA BL.VALVE 0.00V 0mA
ERROR CODE 166 MALFUNCTION Cooling Fan Speed, Wiring Circuit Failure. CORRECTIVE ACTION 1. Enter DIAG SERVO 11(13)" in the diagnostic menu and observe the FAN" OUTPUT" and INPUT" should have mA values. a. b. 2. If no OUTPUT" mA values display, enter into diagnostic menus to check vehicle temperature sensors for proper operation. If no INPUT" mA values display, continue with Step 2.
Enter DIAG EXTRA FUNCT 11(13)". Check voltage at X158 between pin 10 and ground while changing the fan speed using the +/- menu selection buttons (Figure 2 (Volume 2, WP 0272)). The voltage should vary with fan speed; 10 to 22V. a. b. c. d. If no voltage (10 to 22V) is found, disconnect X158 and check the resistance on the loose part of X158 between 9 and pin 10. Resistance should be 8 to 10 Ohms. If voltage (10 to 22V) is found, disconnect ECU (790) connector 2 and check pin 13 for damage and check continuity of wire A15810 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
3.
Remove the rear radiator top grating to access to the cooling fan flow control valve. Unplug the harness and check the resistance of the valve solenoid (6037). Should be 8 to 10 Ohms. a. b. c. If resistance (8 to 10 Ohms) is not as specified, replace the cooling fan flow control valve (Volume 2, WP 0228). If specified resistance is found, check continuity of wires 1589 and 15810 (Figure 2 (Volume 2, WP 0272)). Replace damaged open or shorted harness (Volume 2, WP 0267).
0009-2
TM 10-3930-675-23-1
0009
COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING - Continued SYMPTOM
DIAG SERVO 11(13) OUTPUT/INPUT 0mA 0mA FAN BL.VALVE 0.00V 0mA
ERROR CODE 167 MALFUNCTION Cooling Fan Speed, Short Circuit Failure. CORRECTIVE ACTION 1. Enter DIAG SERVO 11(13)" in the diagnostic menu and observe the FAN OUTPUT" and INPUT" should have mA values. a. b. 2. If no OUTPUT" mA values display, enter into diagnostic menus to check vehicle temperature sensors for proper operation. If no INPUT" mA values display, continue with Step 2.
Enter DIAG EXTRA FUNCT 11(13)". Check voltage at X158 between pin 10 and ground while changing the fan speed using the +/- menu selection buttons (Figure 2 (Volume 2, WP 0272)). The voltage should vary with fan speed; 10 to 22V. a. If no voltage (10 to 22V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 9 and pin 10. Resistance should be 8 to 10 Ohms. Check continuity of each pin to ground. If voltage (10-22V) is found, disconnect ECU (790) connector 2 and check pin 13 for damage and check continuity of wire A15810 and continuity of wire to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged, shorted wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
b.
c. d. 3.
Remove the rear radiator top grating to access to the cooling fan flow control valve. Unplug the harness and check the resistance of the valve solenoid (6037). Should be 8 to 10 Ohms. Check solenoid for short to ground. a. b. c. If resistance (8 to 10 Ohms) is not as specified or shorted to ground, replace the cooling fan flow control valve (Volume 2, WP 0228). If specified resistance is found, check continuity of wires 1589 and 15810 (Figure 2 (Volume 2, WP 0272)). Replace damaged open or shorted harness (Volume 2, WP 0267).
0009-3
TM 10-3930-675-23-1
0009
COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 426 MALFUNCTION Fording Level Switch, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 426 is an information type ERROR CODE. It may not activate for the operator. Enter DIAG STEERING 2(16)" in the diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activate if the voltage input is not stable due to a bad connection. 1. 2. Inspect the fording level switch for damage and connection. Replace damaged fording level switch (WP 0116). Inspection connectors X195 and X198 (located under the cab and rear cover plate) for connection or damage. a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires BK, GY, and WH (Figure 7 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire or replace X198 to X195 cable, electrical general maintenance (Volume 2, WP 0267).
Check ECU (792) pin 103 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A19512 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).
4.
Check for wire connection. Disconnect wire A19512 from ECU (792) and recheck for active 426 ERROR CODE. a. b. Replace ECU (792) (WP 0100) if ERROR CODE 426 is still ACTIVE. Replace fording level switch (WP 0116).
0009-4
TM 10-3930-675-23-1
0009
COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0100JCH
Figure 1. Cooling Fan Diagnostics. END OF WORK PACKAGE
0009-5/6 blank
TM 10-3930-675-23-1
0010
FIELD MAINTENANCE OVERLOAD PROTECTION TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 48) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0006 WP 0100 WP 0121 WP 0122 WP 0124 Volume 2, WP 0245 Volume 2, WP 0257 Volume 2, WP 0258 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) to for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component location. TROUBLESHOOTING PROCEDURE OVERLOAD PROTECTION TROUBLESHOOTING SYMPTOM
ERROR CODE 130 MALFUNCTION Overload Protection System. CORRECTIVE ACTION Overload protection system is not working due to an earlier failure 131 to 136 (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Troubleshoot original ERROR CODES 131 to 136.
0010-1
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 131 MALFUNCTION
DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT
1(13) 24.00V 24.00V 24.00V 10.00V
Boom Extension Sensor or Circuit Failure. CORRECTIVE ACTION 1. Look inside the small inspection hole at the rear of the boom and check if the extension steel cable is attached and the harness is connected. a. b. c. 2. Remove rear boom cover and reattach steel cable to boom extension, inspect sensor and harness for damage (WP 0122). Reconnect disconnected harness (WP 0122). Replace damaged boom extension sensor (WP 0122).
Check boom wear plates and for sticking boom extension or retraction while operating. (A sticking boom, especially in the fully lowered position, will activate ERROR CODE 131.) a. b. Clean boom wear plate surfaces and replace any worn or damaged wear plates (Volume 2, WP 0258). Check boom system hydraulic pressures (Volume 2, WP 0245) and perform hydraulic system troubleshooting (WP 0006).
3.
Enter DIAG SERVO 7(13)" in the diagnostic menu and check length sensor voltage. The voltage should be around <1 to 4V retracted to extended. a. b. If no voltage (<1 to 4V) is found, check voltage (10V) at X157 between pins 2 and 3 (Figure 2 (Volume 2, WP 0272)). If no voltage (10V) is found at X157 between pins 2 and 3, check continuity of wires A15514A, A15514B, A15514C, A15513D, A15513B, A15513A, and A1571 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
c. 4.
Inspect ECU (790) connector 1 pins 13, 26, and 27 and connector for damage. a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
5.
Check voltage (10V) at X169 between pins 2 and 3 and voltage (<1 to 4V) between pins 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)).
0010-2
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. c. 6. If no voltage (10V) is found at X169 between pins 2 and 3, check continuity of wires BK, RD and GY (Figure 2 (Volume 2, WP 0272)). If no voltage is (<1 to 4V) found, (Step 6), replace boom extension sensor (WP 0122). Replace damaged or open harness (Volume 2, WP 0267).
Remove the rear boom cover to gain access to the boom extension sensor (WP 0122). Inspect sensor and harness for damage. a. b. c. Disconnect the sensor harness and inspect pins and check continuity of harness wires. Inspect the steel cable by pulling it slowly from the sensor and retracting. Replace damaged or faulty boom extension sensor (WP 0122).
SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 132 MALFUNCTION Boom Angle Sensor or Circuit Failure. CORRECTIVE ACTION 1. Look under the rear of the boom and check the boom angle sensor for damage and proper mounting. Replace damaged boom angle sensor (WP 0121). Enter DIAG SERVO 7(13)" in the diagnostic menu and check angle sensor voltage. The voltage should be around 8V with the boom fully lowered. a. b. If no voltage (8V) is found, check voltage (10V) at X157 between pins 2 and 3 (Figure 2 (Volume 2, WP 0272)). If no voltage (10V) is found at X157 between pins 2 and 3, check continuity of wires A15514A, A15514B, A15514C, A15513D, A15513C, A15513B, A15513A, and A1571 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
2.
c.
0010-3
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Inspect ECU (790) connector 1 pins 16, 26, and 27 and connector for damage. a. b. 4. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
Check voltage (10V) at X169 between pins 2 and 3 and voltage (8V) (boom fully lowered between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (10V) is found at X169 between pins 2 and 3, check continuity of wires BK, RD and BU (Figure 2 (Volume 2, WP 0272)). If no voltage (8V) is found, replace boom angle sensor (WP 0121). Replace damaged or open harness (Volume 2, WP 0267).
SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 133 MALFUNCTION Left Lift Cylinder Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the left lift cylinder locking valve and pressure sensors for damage and connections. a. b. 2. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).
Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should be 3 to 6V depending on boom position. a. Check PRESS LE PRESS" and RETURN" voltages. If the PRESS" voltage (3 to 6V) is not found and RETURN" voltage is <2V, switch the pressure sensor harness leads (768-2 and 768-4) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. If the RETURN" voltage (<2) appears at PRESS", replace 768-2 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.
b. 3.
Check voltage (24V) at X159 between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)).
0010-4
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. 4. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Make sure the boom is slightly raised. Check voltage (3 to 6V) at X159 between pins 6 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If voltage (3 to 6V) is found, continue with Step 5. If voltage (3 to 6V) is found, disconnect ECU (790) connector 1 and check pin 17 and connector for damage and check continuity of wire A1596 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (Volume 2, WP 0267).
c. d. 5.
Disconnect sensor harness 768-2 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, continue with Step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal and tight fit. Replace damaged sensor and harness (WP 0124).
6.
Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (3 to 6V) between pins 17 and 19 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and GN (Figure 2 (Volume 2, WP 0272)). If no voltage (3 to 6V) is found at X167 between pins 17 and 19, check continuity of 768-2 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).
0010-5
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued
SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 134 MALFUNCTION Right Lift Cylinder Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the right lift cylinder locking valve and pressure sensors for damage and connections. a. b. 2. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).
Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should be 3 to 6V depending on boom position. a. Check PRESS RI PRESS" and RETURN" voltages. If the PRESS" voltage (3-6V) is not found and RETURN" voltage is <2V, switch the pressure sensor harness leads (768-1 and 768-3) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. If the RETURN" voltage (<2) appears at PRESS", replace 768-1 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.
b. 3.
Check voltage (24V) at X159 between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
4.
Make sure the boom is slightly raised. Check voltage (3 to 6V) at X159 between pins 5 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (3 to 6V) is found, continue with Step 5. If voltage (3 to 6V) is found, disconnect ECU (790) connector 1 and check pin 18 and connector for damage and check continuity of wire A1595 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
c.
0010-6
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued d. 5. Replace damaged ECU (790) (WP 0100).
Disconnect sensor harness 768-1 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, continue with Step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal, and tight fit. Replace damaged sensor and harness (WP 0124).
6.
Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (3 to 6V) between pins 17 and 18 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and YE (Figure 2 (Volume 2, WP 0272)). If no voltage (3 to 6V) is found at X167 between pins 17 and 18, check continuity of 768-1 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).
SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 135 MALFUNCTION Left Lift Cylinder Piston Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the left lift cylinder locking valve and pressure sensors for damage and connections. a. b. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).
0010-7
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should be normally <2V at all boom positions. a. Check PRESS RI PRESS" and RETURN" voltages. If the RETURN" voltage (<2V) is not found and PRESS" voltage is 3 to 6V, switch the pressure sensor harness leads (768-2 and 768-4) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. IF the PRESS" voltage (3 to 6V) appears at RETURN", replace 768-4 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.
b. 3.
Check voltage (24V) at X159 between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
4.
Make sure the boom is slightly raised. Check voltage (<2V) at X159 between pins 7 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. If no voltage (<2V) is found, continue with Step 5. If voltage (<2V) is found, disconnect ECU (790) connector 1 and check pin 19 and connector for damage and check continuity of wire A1597 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
5.
Disconnect sensor harness 768-4 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, continue with step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal, and tight fit. Replace damaged sensor and harness (WP 0124).
6.
Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (<2V) between pins 17 and 21 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and BN (Figure 2 (Volume 2, WP 0272)). If no voltage (2V) is found at X167 between pins 17 and 21, check continuity of 768-4 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).
0010-8
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 136 MALFUNCTION Right Lift Cylinder Piston Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the right lift cylinder locking valve and pressure sensors for damage and connections. a. b. 2. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).
Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should normally be <2V at all boom positions. a. Check PRESS RI PRESS" and RETURN" voltages. If the RETURN" voltage (<2V) is not found and PRESS" voltage is 3 to 6V, switch the pressure sensor harness leads (768-1 and 768-3) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. If the PRESS" voltage (3 to 6V) appears at RETURN", replace 768-3 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.
b. 3.
Check voltage (24V) at X159 between pins 3 and 4 with the ignition. a. b. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0124).
4.
Make sure the boom is slightly raised. Check voltage (<2V) at X159 between pins 8 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. If no voltage (<2V) is found, continue with Step 5. If voltage (<2V) is found, disconnect ECU (790) connector 1 and check pin 20 and connector for damage and check continuity of wire A1598 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
0010-9
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect sensor harness 768-3 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. 6. If no voltage (24V) is found, continue with Step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal, and tight fit. Replace damaged sensor and harness (WP 0124).
Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (<2V) between pins 17 and 20 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and WH (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X167 between pins 17 and 20, check continuity of 768-3 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).
SYMPTOM
DIAG ATTACH 1(16) SYSTEM POWER 24.00V POWER RI CAN 24.00V POWER LE CAN 24.00V 10 V REF OUT 10.00V
ERROR CODE 210 MALFUNCTION Tophandler Angle Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect tophandler angle sensor and lever and bracket for damage and secure mounting. Tighten loose mounting bracket, replace damaged angle sensor or mounting bracket (WP 0122). Enter DIAG ATTACHMENT 2(16)" in the diagnostic menu. Check tilt angle voltage. With boom fully lowered and tophandler level, voltage should be 4 to 6V. Check lever clocking" on angle sensor (Volume 2, WP 0257). Remove the cover from the tophandler junction box to gain access. Check tilt angle sensor cable connections at X180 pins 10, 11, and 12 (Figure 6 (Volume 2, WP 0272)).
2.
3.
0010-10
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued Repair damaged wires or connectors (Volume 2, WP 0267). 4. Check voltage (10V) at X180 between pins 10 and 12 (Figure 6 (Volume 2, WP 0272)) with the ignition ON. a. b. c. 5. If no voltage (10V) is found, check continuity of wires A18010, A1801, and A1802 (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
Check voltage at X180 between pins 10 and 11 (Figure 6 (Volume 2, WP 0272)) with the ignition ON. Voltage should be 0.3 to 9.5V, depending on tophandler tilt. a. b. c. If voltage is not as specified, replace tilt angle sensor (WP 0122). If voltage is as specified, disconnect ECU (791) connector 1 and inspect ECU and connector pins 9, 26, and 27 for damage. Replace ECU (791) (WP 0100).
0010-11
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0108JCH
Figure 1. Overload Protection Diagnostics.
0010-12
TM 10-3930-675-23-1
0010
OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0109JCH
Figure 2. Overload Protection Diagnostics. END OF WORK PACKAGE
0010-13/14 blank
TM 10-3930-675-23-1
0011
FIELD MAINTENANCE TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING
INITIAL SETUP: References TM 10-3930-675-10 WP 0005 References (cont.) WP 0100 Volume 2, WP 0267
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING SYMPTOM
ERROR CODE 205 MALFUNCTION Memory Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (WP 0100). SYMPTOM
ERROR CODE 220 MALFUNCTION Internal Communication Failure, Connector 2. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (WP 0100).
0011-1
TM 10-3930-675-23-1
0011
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING - Continued SYMPTOM ERROR CODE 221 MALFUNCTION Internal Communication Failure, Connector 2. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (Volume 2, WP 0267). SYMPTOM
ERROR CODE 250 MALFUNCTION Internal Communication Failure, Connector 3. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (Volume 2, WP 0267). SYMPTOM
ERROR CODE 251 MALFUNCTION Internal Communication Failure, Connector 2. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (Volume 2, WP 0267).
0011-2
TM 10-3930-675-23-1
0011
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0110JCH
Figure 1. Tophandler ECU Diagnostics. END OF WORK PACKAGE
0011-3/4 blank
TM 10-3930-675-23-1
0012
FIELD MAINTENANCE ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0097 WP 0098 WP 0100 WP 0101 WP 0102 References (cont.) WP 0103 WP 0107 WP 0121 WP 0122 WP 0123 WP 0129 WP 0130 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING SYMPTOM
ERROR CODE 121 MALFUNCTION Supply Voltage to Servo ECU 1 (790) Failure. CORRECTIVE ACTION 1. Check for emergency stop in engaged position. (Multiple ERROR CODES will display if the emergency stop button is engaged during crank and start.) Disengage emergency stop button. (ERROR CODES 121 and 201 will normally be one of the ERROR CODES displayed.) Check voltage (24V) at X154 pins 4 and 1 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. If no voltage (24V) is found at X154 pin 4, gain access to emergency stop switch and check connections and continuity (WP 0101) and check continuity of wires 1541 and 1544 (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X154 pin 1, check circuit breaker F30 and continuity of wires A1501 and 301 (Figure 2 (Volume 2, WP 0272)).
2.
b.
0012-1
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. d. e. 3. Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0243). Replace damaged or faulty emergency stop switch (WP 0101).
Disconnect ECU (790) connector 1 and check voltage (24V) at pins 1 and 15 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Inspect ECU (790) connector 1 pins and connector for damage. a. b. c. If no voltage (24V) is found, check continuity of wires A1544A and A1544B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 122 MALFUNCTION Supply Voltage to Servo ECU (790) Failure. CORRECTIVE ACTION 1. 2. Check circuit breaker F32 for trip. Reset circuit breaker as required. Check voltage (24V) at X150 pin 2 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. 3. If no voltage (24V) is found, check circuit breaker F32 and continuity of wire 302 (Figure 2 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Disconnect ECU (790) connector 1 and check voltage (24V) at pins 7 and 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Inspect ECU (790) connector 1 pins and connector for damage. a. b. c. If no voltage (24V) is found, check continuity of wires A1502A and A1502B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
0012-2
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued SYMPTOM
1(13) 24.00V 24.00V 24.00V 10.00V
ERROR CODE 123 MALFUNCTION 10V Reference Voltage for Servo ECU (790) Short Circuit Failure. CORRECTIVE ACTION 1. lnspect ECU (790) connector 1. Check connector, harness, and ECU (790) for damage. a. b. 2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
Enter DIAG SERVO 1(13)" in the diagnostic menu. The 10V REF OUT" voltage should be around 10V. If voltage is <1V, unplug X155 and X157 and recheck 10V REF OUT" voltage. If voltage (10V) returns, continue with Step 3. Reconnect X155 and but leave X157 unplugged. Enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. a. b. If voltage is <1V, unplug the joystick (WP 0102) and recheck 10V REF OUT" voltage. If voltage (10V) returns, replace joystick (WP 0101). If voltage is 10V, continue with Step 4.
3.
4.
Reconnect X157 and enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. a. b. c. If voltage is <1V, disconnect the BK wire from X169 pin 2 (Figure 2 (Volume 2, WP 0272)) and recheck 10V REF OUT" voltage. If voltage (10V) returns, continue with Step 5. If voltage (10V) does not return, check wire BK for short to ground (Volume 2, WP 0267). Replace shorted harness (Volume 2, WP 0267).
5.
Reconnect X169 pin 2 wire BK. Disconnect wire GY from X169 pin 2 (Figure 2 (Volume 2, WP 0272)). Enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. If voltage is <1V, disconnect X169 pin 2 wire GN and recheck 10V REF OUT" voltage. If voltage (10V) returns, replace boom angle sensor (WP 0121). Reconnect X169 pin 2 wire GY. Disconnect wire GN from X169 pin 2 (Figure 2 (Volume 2, WP 0272)). Enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. If voltage is <1V, disconnect X169 pin 2 wire GY again and recheck 10V REF OUT" voltage. If voltage (10V) returns, replace boom extension sensor (WP 0122).
6.
0012-3
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 201
DIAG ATTACHMENT 1(16) SYSTEM POWER 24.00V POWER RI CAN 24.00V POWER LE CAN 24.00V 10 V REF OUT 10.00V
MALFUNCTION Supply Voltage to Tophandler ECU (791) Failure. CORRECTIVE ACTION 1. Check for emergency stop in engaged position. (Multiple ERROR CODES Will display if the emergency stop button is engaged during crank and start.) Disengage emergency stop button. (ERROR CODES 121 and 201 will normally be one of the ERROR CODES displayed.) Check voltage (24V) at X154 pins 2 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. If no voltage (24V) is found at X154 pin 3, gain access to emergency stop switch and check connections and continuity (WP 0102) and check continuity of wires 1542 and 1543A (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X154 pin 1, check circuit breaker F30 and continuity of wires A1504 and 304 (Figure 2 (Volume 2, WP 0272)). Replace damaged of faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty emergency stop switch (WP 0102)).
2.
b. c. d. e. 3.
Check voltage (24V) at X155 pin 11 (Figure 2 (Volume 2, WP 0272)) and X161 pin 3 (Figure 2 (Volume 2, WP 0272)) with the ignition ON. a. b. c. If no voltage (24V) is found at X155 pin 11, check continuity of wire 1542 and 1543A (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X161 pin 3, check continuity of wire A1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
4.
Remove the cover from the tophandler junction box to gain access. Check voltage (24V) at X180 pin 3 (Figure 6 (Volume 2, WP 0272)) with the ignition ON. a. If no voltage (24V) is found at X180 pin 3, check continuity of wire GY between X180 and X185 (Figure 6 (Volume 2, WP 0272)) and wire GY between X185 and X161 and wire A1543C (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
b.
0012-4
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. 5. Replace damaged open or shorted harness (Volume 2, WP 0267) and (WP 0107).
Check voltage (24V) between X186 pins 1 and 2 (Figure 6 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found, check circuit breaker F40 located under the auxiliary pump (Figure 8 (Volume 2, WP 0272)). If no voltage (24V) is found, check continuity of wires W28 (Figure 8 (Volume 2, WP 0272)) and wire RD between X187 and X186 pin 1 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged open or shorted harness (WP 0129), (WP 0130), and (WP 0107).
6.
Remove relay 3009-1 and test (Volume 2, WP 0267). Check voltage (24V) and 3009-1 relay socket pins 30 and 86 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. b. c. d. e. Replace damaged or faulty 3009-1 relay (WP 0097). If no voltage (24V) is found at 3009-1 pin 30, check circuit breaker F41 (1) and continuity of wires A51B, A51J and A1861A (Figure 6 (Volume 2, WP 0272)). Check operation of relay 315-1 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty 315-1 relay (WP 0097). If no voltage (24V) is found at 3009-1 pin 86, check continuity of wire A1803A (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
7.
Disconnect ECU (791) connector 1 and check voltage (24V) at pins 1 and 15 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at ECU (791) connector 1 pins 1 and 15, check operation of relay 3009-2 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty 3009-2 relay (WP 0098). If no voltage (24V) is found at ECU (791) connector 1 pins 1 and 15, check continuity of wires A51E, A51F, A51G, and A1803B (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
b. c. d.
0012-5
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 202
DIAG ATTACHMENT 1(16) SYSTEM POWER 24.00V POWER RI CAN 24.00V POWER LE CAN 24.00V 10 V REF OUT 10.00V
MALFUNCTION Supply Voltage to Tophandler ECU (791) Failure. CORRECTIVE ACTION 1. Remove the cover from the tophandler junction box cover to gain access. Check voltage (24V) circuit breaker F41 (1) (Figure 6 (Volume 2, WP 0272)) with the ignition ON. a. b. c. 2. If no voltage (24V) is found at F41 (1), check continuity of wire A511 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0098). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Disconnect ECU (791) connector l and check voltage (24V) at pins 7 and 8 with the ignition ON (Figure 6 (Volume 2, WP 0272)). Inspect ECU and connector pins for damage. a. b. c. If no voltage (24V) is found at ECU (791) connector 1 pins 7 and 8, check continuity of wires A51A, A51B, and A51C (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0012-6
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 203 MALFUNCTION 10V Reference Voltage for Tophandler ECU (791) Failure. CORRECTIVE ACTION 1. Enter DIAG ATTACHMENT 1(16)" in the diagnostic menu. Check 10V REF OUT" value. a. b. 2. Should be around 10V. If no voltage (10V) is found, proceed with Step 2.
Remove the cover from the tophandler junction box to gain access. Check tilt angle sensor and cable for damage (Figure 6 (Volume 2, WP 0272)). Replace damaged tilt angle sensor (WP 0123)). Disconnect the tilt angle sensor from X180 (Figure 6 (Volume 2, WP 0272)) and recheck voltage (10V) in the diagnostic menu. a. b. c. If voltage (10V) returns, replace tilt angle sensor (WP 0123). If voltage (10V) does not return, check continuity to ground for wires A18010, A18011, and A18012 Diagrams (Volume 2, WP 0272). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
3.
4.
Disconnect ECU (791) connector 1 and inspect ECU and connector pins for damage. a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0012-7
TM 10-3930-675-23-1
0012
ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0115JCH
Figure 1. ECU Input Diagnostics
0012-8
TM 10-3930-675-23-1
0012
T0116JCH
Figure 2. ECU Input Diagnostics
0012-9
TM 10-3930-675-23-1
0012
T0117JCH
Figure 3. ECU Input Diagnostics END OF WORK PACKAGE
0012-10
TM 10-3930-675-23-1
0013
FIELD MAINTENANCE ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 References (cont.) WP 0005 WP 0096 WP 0100 WP 0103 WP 0107 WP 0129 WP 0130 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING SYMPTOM
ERROR CODE 103 MALFUNCTION ECU (790) Not Responding (RT 240V1R, RT 240V2 and RT 240V3 only). CORRECTIVE ACTION 1. Check ECU (790) connector 1 for damage or proper connection. a. b. 2. Repair or replace damaged connector (Volume 2, WP 0267). Reconnect disconnected connector.
Check for voltage. Disconnect ECU (790) connector 1 and check voltage (24V) at pins 1, 15, 7, and 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If voltage (24V) is not found at any of the pins, use the wiring diagram to check each circuit (Figure 2 (Volume 2, WP 0272)). If voltage (24V) is found on all pins, replace ECU (790) (WP 0096). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
0013-1
TM 10-3930-675-23-1
0013
ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 105 MALFUNCTION ECU (790) Not Responding. CORRECTIVE ACTION 1. Check ECU (790) connector 1 damage or proper connection. a. b. 2. Repair or replace damaged connector (Volume 2, WP 0267). Reconnect disconnected connector.
Disconnect ECU (790) connector 1 and check voltage (24V) at pins 1, 15, 7, and 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If voltage (24V) is not found at any of the pins, use the wiring diagram to check each circuit (Figure 2 (Volume 2, WP 0272)). If voltage (24V) is found on all pins, replace ECU (790) (WP 0096). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
SYMPTOM
ERROR CODE 106 MALFUNCTION ECU (791) Not Responding. CORRECTIVE ACTION 1. Check voltage (24V) at X161 pin 6 with the ignition ON (Figure 1 (Volume 2, WP 0272)). a. b. 2. If no voltage (24V) is found at X161 pin 6, check continuity of wire A1503A (Figure 1 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Remove the cover from the tophandler junction box. Check voltage (24V) between X186 pin 1 and pin 2 and between pin 1 and ground. Check circuit breaker F41 (1) for trip (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at X186 pin 1, check circuit breaker F40 located under the auxiliary pump and continuity of cables RD, 1862, W28, and W29 (Figure 6 and Figure 8 (Volume 2, WP 0272)). Repair or replace damaged connectors (Volume 2, WP 0267). Replace damaged cable (WP 0129).
b. c.
0013-2
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0013
ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued d. 3. Reset or replace damaged or faulty circuit breaker (WP 0103).
Check voltage (24V) at X180 pin 6 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. b. If no voltage (24V) is found at X180 pin 6, check continuity of wire YE between X180 and X185 and YE between X185 and X161 pin 6 (Figure 6 (Volume 2, WP 0272)). Replace damaged cable (WP 0107).
4.
Unplug relay 315-l. Check voltage (24V) between the two pins of the connector with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found, check continuity of wire A1806 and the ground connection of wire A1806E at 37 - 55. For RT 240V1R, RT 240V2 and RT 240V3 check continuity of wires A1806, 194H, and A194J (X194 pins H and J) and ground connection of wire A1806E at 37 - 55 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found, check relay 315-1 (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).
b. c. d. 5.
Unplug ECU (791) connector 1. Check voltage (24V) at pins 7 and 8 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at ECU (791) connector 1 pins 7 or 8, check circuit breaker F41 (1) (Volume 2, WP 0267) and continuity of wires A51A, A51B, and A51C (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Reset or replace damaged or faulty circuit breaker (WP 0103).
b. c. 6.
Check voltage (24V) at pins 1 and 15 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at ECU (791) connector 1 pins 1 or 15, check relays 3009-1 and 3009-2 (Volume 2, WP 0267) and continuity of wires A51E, A51F, and A51G (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103). If voltage (24V) is found at all ECU (791) connector 1 pin checks, replace ECU 791 (WP 0100).
b. c. d.
0013-3
TM 10-3930-675-23-1
0013
ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 107 MALFUNCTION Cable Failure Between Tophandler ECU (791) and Display ECU (795). CORRECTIVE ACTION 1. Inspect the CAN-BUS cable and connector (X185) that is mounted on the right side of the boom for damage. Replace damaged cable (WP 0107). Check continuity between X152 pin 1 and X161 pin 4, and X152 pin 2 and X161 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X161 pin 4 and X185 pin 4, and X161 pin 5 and X185 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (Volume 2, WP 0267). Remove the cover to the tophandler junction box. Check continuity between X185 pin 4 and X180 pin 4, and X185 pin 5 and X180 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (WP 0107). Check continuity between X180 pin 4 and ECU (791) connector 1 pin 2, and X180 pin 5 and ECU (791) connector 1 pin 3 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (WP 0096). Check continuity between (795) pin 11 and X152 pin 1, and between (795) pin 10 and X152 pm 2 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (790). Replace ECU (795) (WP 0100).
2.
3.
4.
5.
6.
0013-4
TM 10-3930-675-23-1
0013
SYMPTOM
ERROR CODE 108 MALFUNCTION Cable Failure Between Tophandler ECU (791) and Servo ECU (790). CORRECTIVE ACTION 1. Inspect the CAN-BUS cable and connector (X185) that is mounted on the right side of the boom for damage. Replace damaged cable (WP 0107). Check continuity between X161 pin 1 and ECU (790) connector 1 pin 2, and X161 pin 2 and ECU (790) connector 1 pin 3 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X161 pin 1 and X185 pin 1, and X161 pin 2 and X185 pin 2 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (Volume 2, WP 0267). Remove the cover to the tophandler junction box. Check continuity between X185 pin 1 and X180 pin 1, and X185 pin 2 and X180 pin 2 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (WP 0107). Check continuity between X180 pin 1 and ECU (791) connector 1 pin 4, X180 pin 2 and ECU (791) connector 1 pin 5 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (791) (WP 0100). Replace ECU (790) (WP 0100).
2.
3.
4.
5.
0013-5
TM 10-3930-675-23-1
0013
SYMPTOM
ERROR CODE 109 MALFUNCTION Cable Failure Between Servo ECU (790) and Display ECU (795). CORRECTIVE ACTION 1. Check continuity between X152 pin 4 and ECU (790) connector 1 pin 4, and X152 pin 5 and ECU (790) connector 1 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-23). Check continuity between (795) pin 13 and X152 pin 4, and between (795) pin 12 and X152 pin 5 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (790) (WP 0100). Replace ECU (795) (WP 0100).
2.
0013-6
TM 10-3930-675-23-1
0013
SYMPTOM
ERROR CODE 110 MALFUNCTION Communication Failure Between Display ECU (795) and Steering ECU (792). CORRECTIVE ACTION 1. 2. 3. 4. Enter EXTRA FUNC 9(13)" in the diagnostic menu. Should have a 1" next to RX 792 STEERING" If there is a 0", continue with Step 2. Check steering ECU (792) terminal board for loose or damaged connections. Replace damaged terminal board or tighten connections. Check ECU (792) pins 159 and 160 for loose connection (Figure 5 (Volume 2, WP 0272)). Tighten loose connections. Inspect jumpers between terminal connections at X179. Check continuity between (792) pin 159 and X179 pin L, and between (792) pin 160 and X179 pin H (Figure 1 (Volume 2, WP 0272)). a. b. 5. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace missing or damaged jumpers.
Check continuity between X179 pin L and X177 pin 8, and between X179 pin H and X177 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X177 pin 8 and X160 pin 8, and between X177 pin 7 and X160 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X160 pin 8 and X152 pin 8, and between X160 pin 7 and X152 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-10). Check continuity between (795) pin 6 and X152 pin 7, and between (795) in 5 and X152 pin 8. a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (792) (WP 0096). Replace ECU (795) (WP 0096).
6.
7.
8.
0013-7
TM 10-3930-675-23-1
0013
SYMPTOM
ERROR CODE 111 MALFUNCTION Communication Failure Between Display ECU (795) and Transmission ECU (793). CORRECTIVE ACTION 1. 2. 3. 4. Enter EXTRA FUNC 9(13)" in the diagnostic menu. Should have a 1" next to RX 793 GEARBOX". If there is a 0", continue with Step 2. Check transmission ECU (793) for loose or damaged connectors. Replace damaged connector or ECU (793) (WP 0100). Check ECU (793) pins 25 and 26 for loose connectors. Repair any loose or missing connectors (Volume 2, WP 0267). Inspect jumpers between terminal connectors at X179. Check continuity between (793) pin 25 and X179 pin H, and between (793) pin 26 and X179 pin L (Figure 1 (Volume 2, WP 0272)). a. b. 5. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace missing or damaged jumpers.
Check continuity between X179 pin L and X177 pin 8, and between X179 pin H and X177 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X177 pin 8 and X160 pin 8, and between X177 pin 7 and X160 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X160 pin 8 and X152 pin 8, and between X160 pin 7 and X152 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-10). Check continuity between (795) pin 6 and X152 pin 7, and between (795) pin 5 and X152 pin 8 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (793) (Volume 2, WP 0267). Replace ECU (795) (WP 0100).
6.
7.
8.
0013-8
TM 10-3930-675-23-1
0013
SYMPTOM
ERROR CODE 112 MALFUNCTION Communication Failure Between Display ECU (795) and Engine ECU (794). CORRECTIVE ACTION 1. Check circuit breaker F13 for trip. a. b. c. d. 2. 3. 4. Reset F13 circuit breaker. Engine will not start if F13 is off. If engine will not start, check voltage at F13, X16 pin 9 and ECU (794) OEM connector pin 38 with the ignition switch ON. If no voltage present, check continuity of wires A169 and 169 (Figure 3 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103).
Enter EXTRA FUNC 9(13)" in the diagnostic menu. Should have a 1" next to RX 794 ENGINE". If there is a 0", continue with Step 3. Check engine ECU (794) for loose or damaged connectors (Figure 3 (Volume 2, WP 0272)). Replace damaged connector or ECU (794) (WP 0100). Check ECU (794) OEM connector pins 37, 38, and 46 for dirty, corroded, bent, broken, pushed back, or extended pins (Figure 3 (Volume 2, WP 0272)). Clean and repair connector as required (Volume 2, WP 0267). Locate X202 attached the harness just below the ECU (794) OEM connector (Figure 1 (Volume 2, WP 0272)). a. b. c. Check X202 plug connector for damage or loose connection. Unplug X202 and check resistance on the plugged part of the connector between pin 1 and 4. Resistance should be 122 Ohms. Clean and repair connector as required (Volume 2, WP 0267). Replace if damaged.
5.
6.
Inspect jumpers between terminal connectors at X179. Check continuity between (794) OEM pin 37 and X179 pin L, and between (794) OEM pin 46 and X179 pin H (Figure 1 (Volume 2, WP 0272)). a. b. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace missing or damaged jumpers.
7.
Check continuity between X179 pin L and X177 pin 8, and between X179 pin H and X177 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267).
0013-9
TM 10-3930-675-23-1
0013
ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Check continuity between X177 pin 8 and X160 pin 8, and between X177 pin 7 and X160 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X160 pin 8 and X152 pin 8, and between X160 pin 7 and X152 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-10). Check continuity between (795) pin 6 and X152 pin 7, and between (795) pin 5 and X152 pin 8 (Figure 1 (Volume 2, WP 0272)). a. b. c. SYMPTOM If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (794) (WP 0100). Replace ECU (795) (WP 0100).
9.
10.
ERROR CODE 345 MALFUNCTION Communication Failure Between Steering ECU (792) and Display ECU (795). CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 110. SYMPTOM
ERROR CODE 346 MALFUNCTION Communication Failure Between Steering ECU (792) and Transmission ECU (793). CORRECTIVE ACTION 1. 2. Check circuit breakers F27 and F28 for trip. Reset circuit breaker as required. Perform troubleshooting procedure for ERROR CODE 111.
0013-10
TM 10-3930-675-23-1
0013
SYMPTOM
ERROR CODE 684 MALFUNCTION Communication Failure Between Transmission ECU (793) and Display ECU (795). CORRECTIVE ACTION 1. Perform troubleshooting procedure for ERROR CODE 111.
NOTE
Ensure you disconnect and isolate each connector/circuit mentioned in ERROR CODE 111 steps before checking for continuity to ground. 2. Perform each continuity check for continuity to ground. Replace any wire found to have continuity to ground.
SYMPTOM
ERROR CODE 685 MALFUNCTION ERROR CODE 685 - Communication Failure Between Transmission ECU (793) and Steering ECU (792). CORRECTIVE ACTION 1. Check steering ECU (792) and transmission ECU (793) for loose or damaged connectors. Replace damaged connector (Volume 2, WP 0267) or ECU (792), ECU (793) (WP 0100). Check ECU (792) pins 159 and 160 for loose connection. Tighten loose connections. Inspect jumpers between terminal connections at X179. Check continuity and for continuity to ground between (792) pin 159 and X179 pin L, and between (792) pin 160 and X179 pin H. a. b. c. If continuity is not present, repair any loose or missing connections. Replace missing or damaged jumpers. Replace any grounded wire.
2. 3.
0013-11
TM 10-3930-675-23-1
0013
ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check continuity and for continuity to ground between X179 pin L and (793) pin 26, and between X179 pin H and (793) pin 25. a. b. c. d. SYMPTOM If continuity is not present, repair any loose or missing connections. Replace any grounded wire. Replace ECU (793) (WP 0100). Replace ECU (792) (WP 0100).
ERROR CODE 1285 MALFUNCTION Engine Detects a Communication Failure on the J1939 Datalink. CORRECTIVE ACTION Perform the troubleshooting procedures for ERROR CODE 112. SYMPTOM
ERROR CODE 1286 MALFUNCTION Engine Detects a Communication Failure on the J1939 Datalink. CORRECTIVE ACTION Perform the troubleshooting procedures for ERROR CODE 112. END OF WORK PACKAGE
0013-12
TM 10-3930-675-23-1
0014
FIELD MAINTENANCE STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0099 WP 0100 WP 0103 WP 0128 Volume 2, WP 0267 Volume 2, WP 0272
TROUBLESHOOTING PROCEDURE STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING
NOTE
Refer Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. SYMPTOM
ERROR CODE 300 MALFUNCTION Steering ECU (792) Hardware Failure Troubleshooting Procedures. CORRECTIVE ACTION
NOTE
If the engine is cranked and not started, then recranked without turning the ignition OFF, ERROR CODE 300 may be displayed. Turn off ignition for 30 seconds and restart. 1. 2. Check circuit breakers F26 and F29 for trip. Reset circuit breakers as required (WP 0103). Check Voltage (24V) at X174 pin 3 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. c. If no Voltage (24V) is found, check circuit breaker F 29 and continuity of wires A473 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
0014-1
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. lf circuit breaker F29 trips during operation, check voltage output circuits from ECU (792) for short circuit, brake cooling, auxiliary pump, twistlock, and steering indicator lights. (For RT 240V2 and RT 240V3 Autolube system.) (RT 240V1 only 7208 and 7210 cab proximity switches, filter indicators). Perform appropriate troubleshooting and repairs for short circuit. Check voltage (24V) at X174 pin 14 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. c. 5. If no voltage (24V) is found, check circuit breaker F26 and continuity of wires A48 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
4.
Check voltage (24V) at ECU (792) pin 1 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. lf no voltage (24V) is found, check continuity of wire A17414 and jumper wire 7923 (Figure 5 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
6.
Check voltage (24V) at ECU (792) pin 5 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. c. If no voltage (24V) is found, check continuity of wire A17414 and jumper wire 7923 (Figure 5 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0103). Replace ECU (792) (WP 0100).
SYMPTOM
ERROR CODE 841 MALFUNCTION Transmission ECU (793) Memory Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace transmission ECU (793) if ERROR CODE is still present (WP 0100).
0014-2
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 843 MALFUNCTION Application Error Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace transmission ECU (793) if ERROR CODE still present (WP 0100). SYMPTOM
ERROR CODE 1111 MALFUNCTION Engine ECU (794) Memory Failure. CORRECTIVE ACTION Turn ignition switch to OFF position for 30 seconds and then back to ON position. Replace engine ECU (794) if ERROR CODE still appears (WP 0099). SYMPTOM
ERROR CODE 1341 MALFUNCTION Engine ECU (794) Loss of Data Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect OEM harness from engine ECU (794) and perform the following resistance checks: If resistance is not as specified, repair engine harness connectors (Volume 2, WP 0267). Notify Sustainment Maintenance to replace engine harness. a. b. Measure resistance from OEM harness connector pin 7 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from OEM harness connector pin 8 to positive (+) battery terminal. Resistance should be less than 10 Ohms.
0014-3
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. d. e. Measure resistance from OEM harness connector pin 17 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from OEM harness connector pin 18 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from OEM harness connector pin 28 to positive (+) battery terminal. Resistance should be less than 10 Ohms.
<10 OHMS
T0118JCH
Figure 1. Use Test Lead Kit. 2. Turn ignition switch to ON position and check battery voltage by placing positive (+) probe of multimeter on positive (+) battery terminal and touch negative (-) probe to negative (-) battery terminal while trying to start engine. Voltage should be at least (+) 12V during normal conditions and at least (+) 6V during cranking. Check each battery in the same way. If voltage is not as required, charge or replace battery (WP 0128).
0014-4
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0119JCH
Figure 2. Engine ECU Circuit Test. 3. 4. Turn ignition switch to OFF position and check battery terminals for secure connection. Clean terminals and tighten loose battery terminal connections. Check circuit breakers 51-F4 and 51-F5. a. b. SYMPTOM Reset circuit breakers, if tripped. If circuit breakers will not reset, notify SRA.
ERROR CODE 1343 MALFUNCTION Engine ECU (794) Internal Communication Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position and check all engine and vehicle power and ground connections for corrosion and loose connections. a. b. 2. Tighten loose connections. Repair or replace damaged connections (Volume 2, WP 0267).
With ignition switch in OFF position, disconnect OEM harness from engine ECU (794). Disconnect positive (+) and negative (-) battery cables from battery.
0014-5
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. 4. Check engine ECU (794) connectors for moisture. Dry connectors as required. Check all power resistances: If resistance is not as specified, repair engine harness connectors (Volume 2, WP 0267). Notify SRA to replace engine harness. a. b. c. d. e. Measure resistance from engine harness connector pin 7 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 8 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 17 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 18 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 28 to positive (+) battery terminal. Resistance should be less than 10Ohms.
<10 OHMS
T0120JCH
Figure 3. Engine ECU Circuit Test.
0014-6
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check all ground resistances: If resistance is not as specified, repair engine harness. Notify SRA to replace engine harness. a. b. c. Measure resistance from engine harness connector pin 29 to negative (-) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 30 to negative (-) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 39 to negative (-) battery terminal. Resistance should be less than 10 Ohms.
<10 OHMS
T0121JCH
Figure 4. Engine ECU Circuit Test. d. e. Measure resistance from engine harness connector pin 40 to negative (-) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 50 to negative (-) battery terminal. Resistance should be less than 10 Ohms.
0014-7
TM 10-3930-675-23-1
0014
STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1346 MALFUNCTION Engine ECU (794) Software Failure. CORRECTIVE ACTION Turn ignition switch to OFF position for 30 seconds and then back to ON position. Replace engine ECU (794) if ERROR CODE still appears (WP 0099).
T0122JCH
Figure 5. Engine ECU Test. END OF WORK PACKAGE
0014-8
TM 10-3930-675-23-1
0015
FIELD MAINTENANCE ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0091 WP 0092 References (cont.) WP 0100 WP 0103 WP 0125 WP 0128 WP 0129 Volume 2, WP 0267 Volume 2, WP 0272
TROUBLESHOOTING PROCEDURE ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. SYMPTOM
ERROR CODE 451 MALFUNCTION Voltage Supply Too High for Steering ECU (792). CORRECTIVE ACTION Check output voltage from alternator. If output voltage is greater than 33V, replace alternator (WP 0091).
0015-1
TM 10-3930-675-23-1
0015
ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 452 MALFUNCTION Voltage Supply Too Low for Steering ECU (792). CORRECTIVE ACTION 1. 2. Ensure circuit breakers F26 and F29 are not tripped. Reset circuit breaker(s). Check voltage (22V to 26V) at connector X174 at pins 3 and 14 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 3. If voltage is found but less than 18V, check the condition and charge of the vehicle batteries. Check voltage output of alternator at either NATO slave receptacle. Charge or replace discharged vehicle batteries (WP 0128) and Battery Cables Replacement (WP 0129). Replace non-operational alternator (WP 0091).
Check for voltage (22V to 26V) at connector X174 at pins 3 and 14 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. If no voltage (22V to 26V) is found at either pin, check circuit breakers F26 and F29 and continuity of wires A473, A478 (Figure 5 (Volume 2, WP 0272)). Replace damaged or non-operational circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
4.
Check for voltage (22V to 26V) at ECU (792) at pins 1, 3, 4, and 5 with the ignition ON (Figure 5 (Volume 2, WP 0272)). a. b. c. d. If voltage (22V to 26V) is found, replace ECU (792) (WP 0100). If no voltage (22V to 26V) is found at any one pin, check continuity of wires Al74l4, 7923 and A1743A 00-16). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
0015-2
TM 10-3930-675-23-1
0015
SYMPTOM
ERROR CODE 453 MALFUNCTION Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION 1. Check for voltage (5V) at connector X171 between pins 4 and 6, and 12 and 14 (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 2. If voltage (5V) is not found, perform the following checks: Disconnect connector X170 and recheck for voltage at X171 between pins 4 and 6, and 12 and 14. If voltage (5V) is still not found, perform Step 2. If voltage (5V) returns after disconnecting X170, perform Step 3.
Check for voltage (5V) at connector X170 at pins 4 and 6, and 12 and 14 (Figure 5 (Volume 2, WP 0272)). a. b. c. If voltage (5V) is not found, perform the following checks: Disconnect connector X171 and recheck for voltage at X170 between pins 4 and 6, and 12 and 14. b. If voltage (5V) is still not found, perform Step 5.
3.
Check for continuity. Disconnect connector X170 and check for continuity to ground at pins 4 and 12 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found at pin 4, disconnect wire BU from connector X192 pin 4 and recheck (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at pin 12, disconnect wire OR from connector X192 pin 12 and recheck (Figure 5 (Volume 2, WP 0272)). Replace grounded X170 to X192 cable (Volume 2, WP 0267).
4.
Check for continuity. Disconnect all of the numbered wires from connector X192 and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X171 and check for continuity to ground at pins 4 and 12 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found at pin 4, disconnect wire BU from connector X167 pin 4 and recheck (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at pin 12, disconnect wire OR from connector X167 pin 12 and recheck (Figure 5 (Volume 2, WP 0272)). Replace grounded X171 to X167 cable (Volume 2, WP 0267).
5.
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ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check for continuity. Disconnect all of the numbered wires from connector X167 that go to the front wheel sensors and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X170 and X171. Disconnect ECU (792) pins 138, 139, 140 and 141. Check wires A1714, A17112 (Figure 5 (Volume 2, WP 0272)), A1704, and A17012 (Figure 5 (Volume 2, WP 0272)) for continuity to ground. a. b. c. d. SYMPTOM Replace grounded wire. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).
7.
ERROR CODE 454 MALFUNCTION Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION 1. Check for voltage (5V) at connector X171 between pins 1 and 3 and 9 and 11 (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 2. If voltage (5V) is not found, perform the following checks: Disconnect connector X170 and recheck for voltage at X171 between pins 1 and 3 and 9 and 11. If voltage (5V) is still not found, perform Step 2. If voltage (5V) returns after disconnecting X170, perform Step 3.
Check for voltage (5V) at connector X170 between pins 1 and 3, and 9 and 11 (Figure 5 (Volume 2, WP 0272)). a. b. c. If voltage (5V) is not found, perform the following checks: Disconnect connector X171 and recheck for voltage at X170 between pins 1 and 3, and 9 and 11. If voltage (5V) is still not found, perform Step 5.
3.
Check for continuity. Disconnect connector X170 and check for continuity to ground at pins 1 and 9 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. If continuity to ground is found at pin 1, disconnect wire GY from connector X192 pin 1 and recheck (Figure 5 (Volume 2, WP 0272)).
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ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. c. 4. If continuity to ground is found at pin 9, disconnect wire BN from connector X192 pin 9 and recheck (Figure 5 (Volume 2, WP 0272)). Replace grounded X170 to X192 cable (Volume 2, WP 0267).
Check for continuity. Disconnect all of the numbered wires from connector X192 and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X171 and check for continuity to ground at pins 1 and 9 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found at pin 9, disconnect wire BN from connector X167 pin 12 and recheck (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at pin 9, disconnect wire BN from connector X167 pin 12 and recheck Figure 5 (Volume 2, WP 0272)). Replace grounded X171 to X167 cable (Volume 2, WP 0267).
5.
6.
Check continuity. Disconnect all of the numbered wires from connector X167 that go to the front wheel sensors and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X170 and X171. Disconnect ECU (792) pins 86, 87, 88, and 89. Check wires A1711, A1719 (Figure 5 (Volume 2, WP 0272)), A1701, and A1709 (Figure 5 (Volume 2, WP 0272)) for continuity to ground. a. b. c. d. Replace grounded wire. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).
7.
SYMPTOM
ERROR CODE 811 MALFUNCTION Voltage Supply Too Low for Transmission ECU (793). CORRECTIVE ACTION 1. Ensure circuit breakers F27 and F28 are not tripped. Reset circuit breaker(s).
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ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check for voltage (22V to 26V) at connector X174 at pins 1 and 2 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 3. If voltage is found but less than 18V, check the condition and charge of the vehicle batteries. Check voltage output of alternator at either NATO slave receptacle. Charge or replace discharged vehicle batteries (WP 0128) and (WP 0129). Replace defective alternator (WP 0091) and Alternator Drive Belt Maintenance (WP 0092).
Check for voltage (22V to 26V) at connector 174 at pins 1 and 2 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. If no voltage (22V to 26V) is found at either pin, check circuit breakers F27 and F28 and continuity of wires A471 and A472 (Figure 4 (Volume 2, WP 0272)). Replace damaged or defective circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
4.
Check for voltage (22V to 26V) at ECU (793) at pins 23, 45, and 68 with the ignition ON (Figure 4 (Volume 2, WP 0272)). a. b. c. d. If voltage (22V to 26V) is found, replace ECU (793) (WP 0100). If no voltage (22V to 26V) is found at any one pin, check continuity of wires A1741A, A1741B, and A1742A (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
SYMPTOM
ERROR CODE 812 MALFUNCTION Voltage Supply Too High for Transmission ECU (793). CORRECTIVE ACTION Check output voltage from alternator. If output voltage is higher than 26V, replace alternator (WP 0091).
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SYMPTOM
ERROR CODE 813 MALFUNCTION Voltage Failure at Transmission Gearshift Valve Supply. CORRECTIVE ACTION 1. 2. Ensure circuit breaker F27 is not tripped. Reset circuit breakers. Check for voltage (22V to 26V) at connector X174 at pin 1 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 3. If no voltage (22V to 26V) is found, check circuit breaker F27 and continuity of wires A471 (Figure 8 (Volume 2, WP 0272)) and 471 (Figure 4 (Volume 2, WP 0272)) Replace damaged or defective circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
Disconnect ECU (793) and inspect ECU and connector pins for damage. Check for voltage (22V to 26V) on the ECU (793) connector at pins 23 and 68 with the ignition ON (Figure 4 (Volume 2, WP 0272)). a. b. c. d. If no voltage (22V to 26V) is found at any one pin, check continuity of wires A1471A and A1741B (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire. If voltage (22V to 26V) is found, replace ECU (793) (WP 0100).
SYMPTOM ERROR CODE 814 MALFUNCTION Voltage Failure at Transmission Gearshift Valve Power Supply. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 813 in this work package. END OF WORK PACKAGE
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FIELD MAINTENANCE INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 WP 0032 WP 0094 WP 0100 References (cont.) WP 0101 WP 0103 WP 0105 Volume 2, WP 0169 Volume 2, WP 0170 Volume 2, WP 0179 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING SYMPTOM
ERROR CODE 350 MALFUNCTION Right Front Wheel Valve Solenoid Error. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 329 (WP 0032).
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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 351 MALFUNCTION Right Rear Wheel Valve Solenoid Error. CORRECTIVE ACTION
NOTE
ERROR CODE 351 activates when the resistance of the solenoid or circuit is out of range from the preset value. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Perform troubleshooting procedure for ERROR CODE 330 (WP 0032). SYMPTOM
ERROR CODE 352 MALFUNCTION Left Rear Wheel Valve Solenoid Error. CORRECTIVE ACTION
NOTE
ERROR CODE 352 activates when the resistance of the solenoid or circuit is out of range from the preset value. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Perform troubleshooting procedure for ERROR CODE 331 (WP 0032).
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SYMPTOM
ERROR CODE 353 MALFUNCTION Left Front Wheel Valve Solenoid Error. CORRECTIVE ACTION
NOTE
ERROR CODE 353 activates when the resistance of the solenoid or circuit is out of range from the preset value. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Perform troubleshooting procedure for error code 332 (WP 0032). SYMPTOM
ERROR CODE 354 MALFUNCTION Right Front Wheel Valve Solenoid Error. CORRECTIVE ACTION
NOTE
ERROR CODE 354 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100).
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SYMPTOM
NOTE
ERROR CODE 355 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100). SYMPTOM
ERROR CODE 356 MALFUNCTION Left Rear Wheel Valve Solenoid Error. CORRECTIVE ACTION
NOTE
ERROR CODE 356 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100).
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SYMPTOM
NOTE
ERROR CODE 357 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100). SYMPTOM
ERROR CODE 399 MALFUNCTION EEPROM Parameter Error in ECU (792). CORRECTIVE ACTION
NOTE
ERROR CODE 399 activates when one or more EEPROM parameter values are out of range. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) Electronic Control Units (ECU) Replacement (WP 0100).
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SYMPTOM
ERROR CODE 401 MALFUNCTION Transmission Neutral Signal from Steering ECU (792) Short Circuit Failure. CORRECTIVE ACTION Check for continuity to ground on wire A79344 between steering ECU (792) pin 71 (Figure 5 (Volume 2, WP 0272)) and transmission ECU (793) pin 44 (Figure 4 (Volume 2, WP 0272)). If continuity is present, replace wire A79344. SYMPTOM
ERROR CODE 404 MALFUNCTION 2WD Steering Control Lamp, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 404 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type code in the Initialization menu. 1. 2. Inspect the 2-wheel drive selection switch for damage. Replace damaged steering selection switch (WP 0094). Inspect light bulb. Remove the screws from the menu selection button panel on the steering column console. Lift the panel to access the 2-wheel drive selection button. Pull the light socket down and out from the console. Remove the light bulb and inspect (WP 0094). Replace damaged or shorted light bulb (WP 0094). Disconnect connector X177 located in the middle panel. Should not have continuity to ground. Check for continuity to ground on the loose part of X177 at pin 1 (Figure 5 (Volume 2, WP 0272)). a. b. c. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1601 and A1531 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1531.
3.
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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check for continuity to ground on the loose part of X153 at pin 1 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 5. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1771 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1771.
Check ECU (792) pin 68 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).
SYMPTOM
ERROR CODE 405 MALFUNCTION 4WD Steering Control Lamp, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 405 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type code in the Initialization menu. 1. 2. Inspect the 4-wheel drive selection switch for damage. Replace damaged steering selection switch (WP 0094). Inspect light bulb. Remove the screws from the menu selection button panel on the steering column console. Lift the panel to access the 4-wheel drive selection button. Pull the light socket down and out from the console. Replace damaged or shorted light bulb (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 2 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. d. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1602 and A1532 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1531. Replace grounded X177 to X160 cable or grounded wire A1532.
3.
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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check for continuity to ground on the loose part of X153 at pin 2 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 5. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1772 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1772.
SYMPTOM
ERROR CODE 406 MALFUNCTION Crab Steering Control Lamp, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 406 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the crab steering selection switch for damage. Replace damaged steering selection switch (WP 0094). Inspect light bulb. Remove the screws from the menu selection button panel on the steering column console. Lift the panel to access the crab steering selection button. Pull the light socket down and out from the console. Replace damaged or shorted light bulb (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 3 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1603 and A1533 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A 1533.
3.
Check for continuity to ground on the loose part of X153 at pin 3 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. If continuity to ground is found, replace the X153 to steering column harness (WP 0094).
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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. c. 5. If continuity to ground is not found, check wire A1733 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1733.
SYMPTOM
ERROR CODE 408 MALFUNCTION Unlocked Twistlock Control Lamp, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 408 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the twistlock indicator lights for damage. Replace damaged twistlock indicator light(s) (WP 0094). Check light fixtures. Access twistlock indicator lights (WP 0094) in the steering column console. Inspect twistlock indicator light sockets, bulbs, and wiring. Replace damaged or shorted light bulb, socket, or wiring (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 4 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. d. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1604 and A1534 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1534. Replace grounded X177 to X160 cable or grounded wire A 1533.
3.
Check for continuity to ground on the loose part of X153 at pin 4 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1774 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1774.
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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check ECU (792) pin 64 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. SYMPTOM Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).
ERROR CODE 409 MALFUNCTION Locked Twistlock Control Lamp, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 409 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the twistlock indicator lights for damage. Replace damaged twistlock indicator light(s) (WP 0094). Check light fixtures. Access twistlock indicator lights (WP 0094) in the steering column console. Inspect twistlock indicator light sockets, bulbs, and wiring. Replace damaged or shorted light bulb, socket, or wiring (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 6 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1606 and A1536 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1536.
3.
5.
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SYMPTOM
ERROR CODE 410 MALFUNCTION Alignment Control Lamp, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 410 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the twistlock indicator lights for damage. Replace damaged twistlock indicator light(s) (WP 0094). Check light fixtures. Access twistlock indicator lights (WP 0094) in the steering column console. Inspect twistlock indicator light sockets, bulbs, and wiring. Replace damaged or shorted light bulb, socket, or wiring (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 5 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1605 and A1535 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1535.
3.
5.
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SYMPTOM
ERROR CODE 412 MALFUNCTION Autolube Pump Control, Short Circuit Failure (RT 240V2/3 only). CORRECTIVE ACTION
NOTE
ERROR CODE 412 is an information type ERROR CODE. It may not activate for the operator. The operator may report the auto lube pump is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. Test relay. Remove the plastic cover from the right rear of the cab to access the cab distribution box (WP 0103). Open the cab distribution box to access the relay boards. Remove relay 3018 and test (Volume 2, WP 0267). Replace relay if resistance between terminals 85 and 86 is not 290 to 350 Ohms. Check for continuity. Disconnect connector X174B located in the middle panel. Check for continuity to ground on the loose part of X174B at pin 2. There should not be continuity to ground. a. b. c. 3. If continuity to ground is found, disconnect X47 and recheck. If continuity to ground is still found, check wire 476 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X174B to X47 cable (Volume 2, WP 0267).
2.
Check for continuity. Disconnect connector X47 and connector XK1 located on one of the relay boards. Check for continuity to ground on the loose part of XK1 at pin 8. There should not be continuity to ground. a. b. c. If continuity to ground is found, replace wire A476. If continuity to ground is not found, check wire A174B2 for continuity to ground (Figure 17 (Volume 2, WP 0272)). Replace grounded wire A174B2.
4.
0016-12
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SYMPTOM
ERROR CODE 413 MALFUNCTION Boom Folding Supply Valve, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 413 is an information type ERROR CODE. It may not activate for the operator. The operator may report the boom folding system is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. Test for resistance. Open the door to the remote hydraulic compartment. Locate the 6043 boom folding supply valve on the left side wall. Disconnect the connector and check the resistance of the solenoid coil. Resistance should be 40 to 50 Ohms. Replace 643 boom folding supply valve if damaged or resistance is not as specified (Volume 2, WP 0228). Check for continuity. Disconnect connector X195 located in the middle panel and disconnect the 6043 boom folding supply valve. Check for continuity to ground on the loose part of X195 at pin 8 (Figure 7 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 3. If continuity to ground is found, move the cab to the transport position to access X198 under the cover plate. Disconnect X198 pin 9 wire VT and recheck. If continuity to ground is still found, check wire VT for continuity to ground (Figure 7 (Volume 2, WP 0272)). Replace grounded X195 to X198 cable (Volume 2, WP 0267).
2.
Check for continuity. Disconnect connector X198 pin 9 wire GY and disconnect the 6043 boom folding supply valve. Check wire GY for continuity to ground (Figure 7 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace wire X198 to 6043 cable (Volume 2, WP 0267). If continuity to ground is not found, check wire A195B for continuity to ground (Figure 7 (Volume 2, WP 0272)). Replace grounded wire A195B.
4.
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SYMPTOM
ERROR CODE 415 MALFUNCTION Drag Restriction, Short Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3 only). CORRECTIVE ACTION 1. Check continuity. Disconnect X174B located in the middle panel behind the operators seat. Check the diode for continuity of the loose part of X174B between pins 14 and 15. There should be continuity from pin 15 to pin 14 and not from pin 14 to pin 15 (Figure 4 (Volume 2, WP 0272)). Replace the diode if continuity is found in both directions. Check wire A174B15 for continuity to ground. There should not be continuity to ground (Figure 5 (Volume 2, WP 0272)). a. b. 3. If continuity to ground is found, replace wire A174B15. Repair or replace damaged connector (Volume 2, WP 0267).
2.
Check ECU (792) pin 57 for connection or damage. a. b. Replace damaged ECU (792) terminal board. Replace ECU (792) (WP 0100).
SYMPTOM
ERROR CODE 416 MALFUNCTION Steering Pressure Switch, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 416 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. ERROR CODE 340 may be active with this ERROR CODE. 1. Place the cab in the transport position (TM 10-3930-675-10) and remove the hydraulic pump access cover. Inspect the steering pressure switch (245) mounted on the steering valve for damage and connection. Replace damaged steering pressure switch (Volume 2, WP 0170).
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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check connectors X47, X174, and X197 for connection or damage (RT 240V1 only). a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires A473, 473, A1743B, 1973, and 1974 for continuity (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.
Check connector X47, X174B, and X197 for connection or damage (RT 240V1R, RT 240V2 and RT 240V3 only). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires A475, 475, A174B1A, 1973, and 1974 for continuity (Figure 5 (Volume 2, WP 0272)) Replace or repair open or damaged wire.
4.
5.
Check wire. Disconnect wire A1974 from ECU (792) and recheck for active 416 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 416 is still active.
SYMPTOM
ERROR CODE 418 MALFUNCTION 2WD Steering Selection Switch, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 418 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the 2WD steering selection switch for damage and connection. Replace damaged 2WD steering selection switch (WP 0101). Inspect connectors X177, X160, and X153 for connection or damage. a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 15313, A15313, and 16013 (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.
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0016
INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Check ECU (792) pin 47 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. 4. Check wire A17713 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).
Check wire connection. Disconnect wire A17713 from ECU (792) and recheck for active 418 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 418 is still active.
SYMPTOM
ERROR CODE 419 MALFUNCTION 4WD Steering Selection Switch, Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 419 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the 4WD steering selection switch for damage and connection. Replace damaged 4WD steering switch (WP 0101). Inspect connectors X177, X160, and X153 for connection or damage. a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 1529C, 15314, A15314, and 16014 (Figure 5 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire.
Check ECU (792) pin 46 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A17714 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100)).
4.
0016-16
TM 10-3930-675-23-1
0016
SYMPTOM
ERROR CODE 420 MALFUNCTION Crab Steering Selection Switch, Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 420 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the crab steering selection switch for damage and connection. Replace damaged crab steering switch (WP 0101). Inspect connectors X177, X160, and X153 for connection or damage. a. b. c. d. 3. Inspect connectors X177, X160, and X153 for connection or damage. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 1529D, 15315, A15315, and 16015 (Figure 5 (Volume 2, WP 0272)) for continuity. Repair or replace open or damaged wire.
4.
0016-17
TM 10-3930-675-23-1
0016
SYMPTOM
ERROR CODE 422 MALFUNCTION Cab in Transport Proximity Switch, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 422 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the cab transport proximity switch (7210) located at the right rear of cab for damage. Replace damaged cab in transport proximity switch (WP 0105). Check for proper operation. Place cab in transport position (TM 10-3930-675-10) and check for proper gap and engagement of proximity switch against the frame. Proximity switch should not extend beyond the end of the protective enclosure. Adjust proximity switch or cab to obtain the proper gap (5 mm) (WP 0105) and (Volume 2, WP 0179). Inspect connectors X175, X195, A174, A47, and X174B (RT 240V1R, RT 240V2 and RT 240V3) for connection damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267)). If connectors are found to be in good condition, check wires A1957A, A1957B, (Figure 7 (Volume 2, WP 0272)), A1743C, A1743D A174B1B and A174B1C (RT 240V1R, RT 240V2 and RT 240V3) (Figure 7 (Volume 2, WP 0272)) and A1743B, A1743C, A174B1A, A475, and 475 (RT 240V1R, RT 240V2 and RT 240V3) (Figure 5 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire.
3.
c. 4.
Check ECU (792) pin 43 for connection or damage (Figure 7 (Volume 2, WP 0272)). a. b. Check wire A1752 for continuity (Figure 7 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100)).
5.
Check wire connection. Disconnect wire A1752 from ECU (792) and recheck for active 422 ERROR CODE. a. b. Replace ECU (792) (WP 0100) if ERROR CODE 422 is still active. Replace proximity switch (7210) (WP 0105).
0016-18
TM 10-3930-675-23-1
0016
SYMPTOM
ERROR CODE 423 MALFUNCTION Ether Start Switch, Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 423 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the ether start switch for damage and connection. Replace damaged ether start switch (WP 0094). Inspect connectors X174, X47, and X67 for connection or damage. a. b. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 674, A479, and d479 (Figure 16 (Volume 2, WP 0272)) for continuity.
Check ECU (792) pin 42 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. c. Check wire A17415 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100). Replace or repair open or damaged wire (Volume 2, WP 0267).
4.
Check for wire connection. Disconnect wire A17415 from ECU (792) and recheck for active 423 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 423 is still active.
0016-19
TM 10-3930-675-23-1
0016
SYMPTOM
ERROR CODE 427 MALFUNCTION Tophandler Work Light Switch, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 427 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect tophandler work light switch for damage and connection. Replace damaged tophandler work light switch (WP 0094). Inspect connectors X174, X46, and X67 for connection or damage. a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 679, A466 (Figure 15 (Volume 2, WP 0272)), and 466 (Figure 5 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire (Volume 2, WP 0267).
4.
SYMPTOM
ERROR CODE 440
0016-20
TM 10-3930-675-23-1
0016
INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued MALFUNCTION Steering Wheel Sensor, Power Supply Error (RT 240V1R, RT 240V2 and RT 240V3 only). CORRECTIVE ACTION
NOTE
ERROR CODE 440 is an information type ERROR CODE. It may not activate for the operator. The operator may report the steering wheel has no resistance and does not stop at the full turning radius. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. Inspect the steering wheel sensor and connector cable located at the bottom of the steering column for damage. Replace damaged steering wheel sensor or connector cable (Volume 2, WP 0169). Disconnect the connector from the steering wheel sensor and connector X176 located in the middle panel behind the operators seat. Check each wire in the cable for continuity, continuity to ground, and for continuity between each wire (Figure 5 (Volume 2, WP 0272)). Replace damaged, grounded, or shorted steering wheel sensor to X176 cable (Volume 2, WP 0169). Check for continuity to ground or continuity between each wire on the mounted part of connector X176 for pins 1 through 8 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground or continuity between wires. a. b. 4. Replace any grounded or shorted wire(s). Repair or replace damaged connector (Volume 2, WP 0267).
2.
3.
Check ECU (792) pins, 23, 40, 113, 96, 41, 38, 132, 97, and 56 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).
SYMPTOM
ERROR CODE 450 MALFUNCTION Temperature Inside Steering ECU (792) Above Critical Threshold [184F (85C)]. CORRECTIVE ACTION 1. 2. Check if temperature at steering ECU (792) is extremely high. If temperature is extremely high, allow ECU to cool down. Place ignition switch in OFF position for a minimum of 30 seconds, and then back in ON position. Replace steering ECU (792) if ERROR CODE is still present (WP 0100).
END OF WORK PACKAGE
0016-21/22 blank
TM 10-3930-675-23-1
0017
FIELD MAINTENANCE ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0078 WP 0099 WP 0100 WP 0118 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.
0017-1
TM 10-3930-675-23-1
0017
TROUBLESHOOTING PROCEDURE ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING SYMPTOM
ERROR CODE 1187 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION 1. 2. 3. Disconnect sensor harness from oil pressure/temperature sensor (WP 0118). Place ignition switch in ON position. Measure voltage from oil pressure/temperature sensor connector pin A to pin B. Voltage should be less than 4.5V. If voltage is not as specified, replace oil pressure/temperature sensor (WP 0118).
<4.5V USE TEST LEAD KIT P/N 3822758
T0124JCH
Figure 1. Oil Pressure/Temperature Sensor Voltage Test. 4. Place ignition switch in OFF position and disconnect sensor harness connector from engine ECU. a. Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required Electrical General Maintenance Instructions). Check engine harness and engine ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
0017-2
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect sensor harness and actuator harness from engine ECU. Place ignition switch to ON position. a. Measure voltage between engine ECU sensor port pin 18, pin 25, pin 45, and ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099). Measure voltage between engine ECU actuator port pin 19 and pin 29 and ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).
ACTUATOR PORT: PINS 19 AND 29 TO ENGINE BLOCK GROUND 4.75-5.25V SENSOR PORT: PINS 18,25,45 TO ENGINE BLOCK GROUND 4.75-5.25V
b.

T0125JCH
Figure 2. Oil Pressure/Temperature Sensor Voltage Test.
0017-3
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position. Disconnect sensor harness and actuator harness from engine ECU. a. Measure resistance from sensor harness connector pins 18, 25, and 45 to engine block ground. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pins 19 and 29 to engine block ground. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
ACTUATOR HARNESS: PINS 19 AND 29 TO ENGINE BLOCK GROUND >100K OHMS
b.
SENSOR HARNESS: PINS 18,25,45 TO ENGINE BLOCK GROUND >100K OHMS
T0126JCH
Figure 3. Oil Pressure/Temperature Sensor Voltage Test. 7. Place ignition switch in OFF position. Disconnect sensor harness and actuator harness from engine ECU. Disconnect oil pressure/temperature sensor and coolant level sensor jumpers. a. Measure resistance from sensor harness connector pin 18 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 25 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 45 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pin 19 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pin 29 to all other pins in connector. Resistance should be more than 100k Ohms.
b.
c.
d.
e.
0017-4
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If engine harness requires replacement, notify SRA.
SENSOR HARNESS: PINS 18,25,45 TO ALL OTHER PINS >100K OHMS ACTUATOR HARNESS: PINS 19 AND 29 TO ALL OTHER PINS >100K OHMS
T0127JCH
Figure 4. Oil Pressure/Temperature Sensor Voltage Test. SYMPTOM ERROR CODE 1227 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION 1. Place ignition switch in OFF position and disconnect sensor harness connector from engine ECU. a. Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and engine ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
0017-5
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Disconnect sensor harness and actuator harness from engine ECU. Place ignition switch to ON position. a. Measure supply voltage out of engine ECU sensor port at pins 18, 25, and 45 to ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V SENSOR PORT 4.75-5.25V
ACTUATOR PORT
T0128JCH
Figure 5. Sensor Voltage Supply Test. b. Measure supply voltage out of engine ECU actuator port at pins 19 and 29 to ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).
3.
Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Measure resistance from sensor harness connector pin 18 to all sensor harness connector pins. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 25 to all sensor harness connector pins. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 45 to all sensor harness connector pins. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
b.
c.
0017-6
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0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
USE TEST LEAD KIT P/N 3822758 >100K OHMS
T0129JCH
Figure 6. Sensor Voltage Supply Test. 4. Place ignition switch in OFF position and disconnect sensor harness and OEM harness connector from engine ECU. a. Measure resistance from sensor harness connector pin 18 to pin 7 of OEM harness connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 25 to pin 7 of OEM harness connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 45 to pin 7 of OEM harness connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
b.
c.
SENSOR HARNESS
>100K OHMS
OEM HARNESS
T0130JCH
Figure 7. Sensor Voltage Supply Test.
0017-7
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. If resistance was not as specified in Step 4, turn ignition switch to OFF position and disconnect 31-pin OEM harness connector (round) and OEM harness from engine ECU. Measure resistance from 31- pin OEM harness connector pin 7 to OEM harness connector pin 7. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
>100K OHMS
OEM HARNESS
31-PIN OEM HARNESS
T0131JCH
Figure 8. Sensor Voltage Supply Test. 6. Place ignition switch in OFF position and disconnect actuator harness connector from engine ECU. a. Inspect engine ECU and actuator harness connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine ECU and actuator harness connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
7.
Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness pin 19 to all other pins in actuator harness. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
0017-8
TM 10-3930-675-23-1
0017
>100K OHMS
T0132JCH
Figure 9. Sensor Voltage Supply Test. b. Measure resistance from actuator harness pin 29 to all other pins in actuator harness. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
8.
Place ignition switch in OFF position and disconnect actuator harness and OEM harness from engine ECU. a. Measure resistance from actuator harness connector pin 19 to OEM harness connector pin 7. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pin 29 to OEM harness connector pin 7. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
b.
USE TEST LEAD KIT P/N 3822758 >100K OHMS
T0133JCH
Figure 10. Sensor Voltage Supply Test.
0017-9
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Turn ignition key to OFF position and disconnect 31-pin OEM (round) harness connector and OEM harness from engine ECU. Measure resistance from 31- pin OEM harness connector pin 7 to OEM harness connector pin 14. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
>100K OHMS
OEM HARNESS
31-PIN OEM HARNESS
T0134JCH
Figure 11. Sensor Voltage Supply Test. SYMPTOM
ERROR CODE 1287 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION Perform Troubleshooting Procedures for ERROR CODES: 1131, 1132, 1551, 1431, 1432, and 1443. Notify SRA.
0017-10
TM 10-3930-675-23-1
0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued
SYMPTOM ERROR CODE 1352 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION 1. 2. Disconnect sensor harness from intake manifold pressure sensor and place ignition switch in ON position. Measure voltage from intake manifold pressure connector pin A to pin B. Voltage should be less than 4.5V. If voltage is not specified, replace intake manifold pressure sensor (WP 0118).
<4.5V
T0135JCH
Figure 12. Sensor Voltage Supply Test. 3. 4. Disconnect sensor harness from ambient air pressure sensor and place ignition switch in ON position. Measure voltage from ambient air pressure connector pin A to pin B. Voltage should be less than 4.5V. If voltage is not as specified, replace ambient air pressure sensor (WP 0118). Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Inspect engine ECU and sensor harness connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine ECU and sensor harness connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
5.
b.
0017-11
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0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. 7. Disconnect sensor harness from engine ECU and place ignition switch in ON position. Measure voltage from engine ECU connector pins 17 and 37 to ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V
T0136JCH
Figure 13. Sensor Voltage Supply Test. 8. 9. Place ignition switch in OFF position and disconnect sensor harness from engine ECU, ambient air pressure sensor, and intake manifold pressure sensor. Measure resistance from sensor harness pins 17 and 37 to engine block ground. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Place ignition switch in OFF position and disconnect sensor harness from engine ECU, ambient air pressure sensor, and intake manifold pressure sensor. a. Measure resistance from sensor harness pin 17 to all other pins in sensor harness. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness pin 37 to all other pins in sensor harness. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
10.
b.
0017-12
TM 10-3930-675-23-1
0017
>100K OHMS
T0137JCH
Figure 14. Sensor Voltage Supply Test. SYMPTOM Error Code 1443 MALFUNCTION Low Voltage Detected at Throttle Position Sensor Circuit CORRECTIVE ACTION
NOTE
Use test lead, female to test connector X690. Use test lead, male to test the OEM harness connector. 1. Inspect the accelerator pedal assembly for damage and wiring harness connection (Volume 2, WP 0267). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Volume 2, WP 0272). a. b. 4. If resistance is not as specified, continue with Step 4. Repair or replace damaged connector (Volume 2, WP 0267).
2. 3.
Check continuity on the loose part of connector X23 between pin 3 and ground and pin 4 and ground. There should not be continuity to ground (Volume 2, WP 0272). If continuity to ground is found, continue with Step 5. Check connector wiring harness. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness.
5.
0017-13
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0017
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check for resistance. Disconnect connector X690 and inspect for damage. Check resistance on the accelerator pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. There should be a resistance of 2,000 to 3,000 Ohms and no continuity to ground (Volume 2, WP 0272). a. b. 7. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).
Check continuity of the accelerator pedal part of connector X690 between pin 5 and ground and pin 6 and ground. There should not be continuity to ground (Volume 2, WP 0272). a. b. c. d. If continuity to ground is found, replace accelerator pedal assembly (WP 0078). If continuity to ground is not found, check continuity and for continuity to ground for wires 233, 234, and 235 (Volume 2, WP 0272). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
8.
Remove the engine cover (Volume 2, WP 0272). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).
9.
Inspect connector X16 for damage. Disconnect connector X16. Turn the ignition ON and check for voltage at connector X16 between pin 4 and ground. Voltage should be 4.75V to 5.25V at each pin. a. b. If voltage (4.75V to 5.25V) is not as specified, continue with Step 10. Repair or replace damaged connector (Volume 2, WP 0267).
10.
Check continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Volume 2, WP 0272). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA to replace engine and transmission wiring harness (Volume 2, WP 0267). Check continuity. Disconnect connector X16. Check continuity and for continuity to ground for wires A163, A164, and A165 (Volume 2, WP 0272). Replace any damaged, open, or grounded wires. Check continuity. Disconnect the OEM harness connector and connector X16. Check for continuity on the OEM harness connector between pin 48 and ground and between pin 48 and pin 49. There should not be continuity between pins. If continuity is found between pin 48 and ground or continuity between pin 48 and pin 49, notify SRA to replace the engine and transmission wiring harness (Volume 2, WP 0267).
11.
12.
0017-14
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0017
>100K OHMS
48
T0138JCH
Figure 15. OEM Harness Connector Circuit Check.
NOTE
The RTCH does not have a coolant level or oil level sensor. 13.
T0139JCH
Figure 16. Oil Pressure/Temperature Sensor Circuits. END OF WORK PACKAGE
0017-15/16 blank
TM 10-3930-675-23-1
0018
FIELD MAINTENANCE ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Tools and Special Tools (cont.) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0118 Volume 2, WP 0267
NOTE
0018-1
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0018
TROUBLESHOOTING PROCEDURE ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING SYMPTOM
ERROR CODE 1115 MALFUNCTION Engine Position Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Ensure ignition switch is in OFF position. Disconnect engine harness from engine position sensor (WP 0118). Inspect engine harness and engine position sensor connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and engine position sensor for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Check for short circuit to ground: If resistance is not as specified, replace engine position sensor (WP 0118). a. b. 5. Measure resistance from engine position sensor connector pin A to engine block ground. Resistance should be greater than 100k Ohms. Measure resistance from engine position sensor connector pin B to engine block ground. Resistance should be greater than 100k Ohms.
3.
4.
Remove engine position sensor from engine block (WP 0118). Inspect engine position sensor for damage, including metal debris on end of sensor, damage to end of sensor caused by camshaft gear or flywheel ring gear, oil leakage, or insulation problems such as swelling, and damaged electrical potting in sensing end of sensor. Replace damaged engine position sensor (WP 0118). Check resistance of engine position sensor: If resistance is not as specified, replace engine position sensor (WP 0118). a. b. Measure resistance from pin A to pin D of engine position sensor. Resistance should be 1,000 to 2,000 Ohms. Measure resistance from pin B to pin C of engine position sensor. Resistance should be 1,000 to 2,000 Ohms.
6.
7.
Check for a short circuit between coils by measuring resistance from pin A to pin B of engine position sensor. Resistance should be greater than 100k Ohms. If resistance is not as specified, replace engine position sensor (WP 0118).
0018-2
TM 10-3930-675-23-1
0018
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. 9. Disconnect sensor harness from engine ECU (794). Inspect engine harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Check for short circuit to ground: If engine harness requires replacement, notify SRA. a. b. Measure resistance from engine harness connector pin 47 to engine block ground. Resistance should be greater than 100k Ohms. Measure resistance from engine harness connector pin 50 to engine block ground. Resistance should be greater than 100k Ohms.
10.
11.
>100K Ohms
T0140JCH
Figure 1. Engine Harness Circuit Resistance Check.
0018-3
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0018
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 12. Check for short circuit from pin to pin: If resistance is not as specified, notify SRA to replace harness. a. b. c. d. Measure resistance from pin 47 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 48 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 49 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 50 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms.
>100K Ohms
T0141JCH
Figure 2. Engine Harness Circuit Resistance Check. 13. Reconnect sensor harness to engine position sensor. Check for open circuit: If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 49 to pin 50 of engine harness connector. Resistance should be 1,000 to 2,000 Ohms. Measure resistance from pin 47 to pin 48 of engine harness connector. Resistance should be 1,000 to 2,000 Ohms.
0018-4
TM 10-3930-675-23-1
0018
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1121 MALFUNCTION Engine Position Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Ensure that ignition switch is in OFF position. Disconnect engine harness from engine position sensor Engine Sensors Replacement (WP 0118). Inspect engine harness and engine position sensor connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and engine position sensor for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Check for short circuit to ground: If resistance is not as specified, replace engine position sensor (WP 0118). a. b. 5. Measure resistance from engine position sensor connector pin A to engine block ground. Resistance should be greater than 100k Ohms. Measure resistance from engine position sensor connector pin B to engine block ground. Resistance should be greater than 100k Ohms.
3.
4.
Remove engine position sensor from the engine block (WP 0118). Inspect engine position sensor for damage, including metal debris on end of sensor, damage to end of sensor caused by camshaft gear or flywheel ring gear, oil leakage, or insulation problems such as swelling, and damaged electrical potting in sensing end of sensor. Replace damaged engine position sensor (WP 0118). Check resistance of engine position sensor: If resistance is not as specified, replace engine position sensor (WP 0118). a. b. Measure resistance from pin A to pin D of engine position sensor. Resistance should be 1,000 to 2,000 Ohms. Measure resistance from pin B to pin C of engine position sensor. Resistance should be 1,000 to 2,000 Ohms.
6.
7.
Check for a short circuit between coils by measuring resistance from pin A to pin B of engine position sensor. Resistance should be greater than 100k Ohms. If resistance is not as specified, replace engine position sensor (WP 0118). Disconnect sensor harness from engine ECU (794). Inspect engine harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).
8. 9.
0018-5
TM 10-3930-675-23-1
0018
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 10. Check engine harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Check for short circuit to ground: If engine harness requires replacement, notify SRA. a. b. Measure resistance from engine harness connector pin 47 to engine block ground. Resistance should be greater than 100k Ohms. Measure resistance from engine harness connector pin 50 to engine block ground. Resistance should be greater than 100k Ohms.
11.
>100K Ohms

T0142JCH
Figure 3. Engine Harness Circuit Resistance Check. 12. Check for short circuit from pin to pin: If resistance is not as specified, notify SRA to replace harness. a. b. c. d. Measure resistance from pin 47 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 48 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 49 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 50 of engine harness connector to all other pins. Resistance should be greater than 100k Ohms.
0018-6
TM 10-3930-675-23-1
0018
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0144JCH
Figure 4. Engine Harness Circuit Resistance Check. 13. Reconnect sensor harness to engine position sensor. Check for open circuit: If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 49 to pin 50 of engine harness connector. Resistance should be 1,000 to 2,000 Ohms. Measure resistance from pin 47 to pin 48 of engine harness connector. Resistance should be 1,000 to 2,000 Ohms.
0018-7
TM 10-3930-675-23-1
0018
ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1234 MALFUNCTION Engine Overspeed Failure. CORRECTIVE ACTION Notify SRA.
NOTE
Engine position sensor is located on left side of engine, below A/C compressor.
T0144JCH
Figure 5. Engine Position Sensor Circuits. END OF WORK PACKAGE
0018-8
TM 10-3930-675-23-1
0019
FIELD MAINTENANCE ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0006 WP 0099 WP 0118 Volume 2, WP 0267
NOTE
0019-1
TM 10-3930-675-23-1
0019
TROUBLESHOOTING PROCEDURE ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING SYMPTOM
ERROR CODE 1135 MALFUNCTION Oil Pressure Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect engine harness from oil pressure/ temperature sensor (WP 0118). a. Inspect engine harness and oil pressure/temperature sensor connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and oil pressure/temperature sensor for dirt or moisture in or on connectors and for missing or damaged connector seals (Volume 2, WP 0267). Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2. 3.
Install breakout cable between sensor and engine harness connector. Place ignition switch in ON position. Measure supply voltage from pin A (or RED) to pin B (or BLACK) of breakout cable. Voltage should be 4.75 to 5.25V. If voltage is not as specified, proceed to Step 4.
4.75-5.25V
T0145JCH
Figure 1. Oil Pressure Sensor Voltage Supply Test.
0019-2
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. 5. Disconnect sensor harness connector from engine ECU. Place ignition switch in ON position. Measure voltage at ECU from pin 45 to pin 43 of ECU sensor port. Voltage should be 4.75 to 5.25V. a. b. If voltage is as specified, proceed to Step 6. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V
T0147JCH
Figure 2. Oil Pressure Sensor Voltage Supply Test. 6. 7. Install breakout cable between sensor and engine harness connector. Place ignition switch in ON position. Measure supply voltage from pin C (or YELLOW) to pin B (or BLACK) of breakout cable. Voltage should be 0.50 to 1.40V. If voltage is not as specified, proceed with the following steps.
0.50-1.40V
T0148JCH
Figure 3. Oil Pressure Sensor Voltage Supply Test.
0019-3
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Ensure ignition switch is in OFF position. Disconnect sensor harness from engine ECU. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267)
b.
9. 10.
Place ignition switch in OFF position and disconnect sensor harness from engine ECU. Measure resistance from pin 44 of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
>100K Ohms
T0149JCH
Figure 4. Oil Pressure Sensor Circuit Resistance Test.
0019-4
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11. 12. Place ignition switch in OFF position. Disconnect sensor harness from engine ECU and disconnect engine harness from oil pressure/temperature sensor. Measure resistance from pin 43 of sensor harness connector to pin B (or 2) on harness side of oil pressure temperature sensor connector. Resistance should be less than 10 Ohms. a. b. c. If resistance is as specified, replace oil pressure/ temperature sensor Engine Sensors Replacement (WP 0118). If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
<10 Ohms
T0150JCH
0019-5
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1141 MALFUNCTION Oil Pressure Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect engine harness from oil pressure/ temperature sensor (WP 0118). a. Inspect engine harness and oil pressure/temperature sensor connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and oil pressure/temperature sensor for dirt or moisture in or on the connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2. 3.
Install breakout cable between sensor and engine harness connector. Place ignition switch in ON position. Measure supply voltage from pin A (or RED) to pin B (or BLACK) of breakout cable. Voltage should be 4.75 to 5.25V. If voltage is not as specified, proceed with the following steps.
4.75-5.25V
T0151JCH
Figure 6. Oil Pressure Sensor Circuit Voltage Test.
0019-6
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. 5. Disconnect sensor harness connector from engine ECU. Place ignition switch in ON position. Measure voltage at ECU from pin 45 to pin 43 of ECU sensor port. Voltage should be 4.75 to 5.25V. a. b. If voltage is as specified, proceed to Step 6. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V
T0152JCH
Figure 7. Oil Pressure Sensor Circuit Voltage Test. 6. 7. Install breakout cable between sensor and engine harness connector. Place ignition switch in ON position. Measure supply voltage from pin C (or YELLOW) to pin B (or BLACK) of breakout cable. Voltage should be 0.50 to 1.40V. If voltage is not as specified, proceed with the following steps.
0.50-1.40V
T0153JCH
Figure 8. Oil Pressure Sensor Test.
0019-7
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. 9. Ensure that ignition switch is in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness from engine ECU. Measure resistance from pin 44 (or pressure signal) of sensor harness connector to chassis ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace engine harness.
>100K Ohms
T0154JCH
Figure 9. Oil Pressure Sensor Circuit Resistance Test. 10. 11. Ensure ignition switch is in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness from engine ECU. Measure resistance from pin 44 (or pressure signal) of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms. a. b. If resistance is as specified, replace oil pressure/ temperature sensor (WP 0118). If resistance is not as specified, notify SRA to replace engine harness.
0019-8
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
>100K Ohms
T0155JCH
0019-9
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 12. Ensure ignition switch is in OFF position. Disconnect sensor harness from engine ECU. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267)
b.
13. 14.
Place ignition switch in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness from engine ECU. Measure resistance from pin 44 (or pressure signal) of sensor harness connector to pin C (or 3) of oil pressure/ temperature sensor connector on harness side. Resistance should be less than 10 Ohms. a. b. If engine harness requires replacement, notify SRA. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).
<10 Ohms
T0156JCH
0019-10
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 15. 16. Disconnect sensor harness connector from engine ECU. Place ignition switch in ON position. Install a jumper wire between engine ECU sensor port pins 44 and 45, with 5V supply applied. Error code 1135 should be displayed. If error code 1135 was not displayed, replace engine ECU Engine Electronic Control Module (ECM) Replacement (WP 0099).
ERROR CODE 1135
T0157JCH
Figure 12. Oil Pressure Sensor Circuit Failure Test. SYMPTOM
ERROR CODE 1143 MALFUNCTION Oil Pressure Sensor Circuit Failure. CORRECTIVE ACTION Perform Troubleshooting procedure for Engine Oil Pressure - Low" (WP 0006).
0019-11
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1415 MALFUNCTION Oil Pressure Sensor Circuit Failure. CORRECTIVE ACTION Perform Troubleshooting procedure for Engine Oil Pressure - Low" (WP 0006). SYMPTOM
ERROR CODE 1435 MALFUNCTION Oil Pressure Sensor Circuit Failure. CORRECTIVE ACTION Perform Troubleshooting procedure for ERROR CODEs 1135 and 1141 in this work package.
NOTE
Oil pressure/temperature sensor is located on left side of engine, at rear of A/C compressor.
0019-12
TM 10-3930-675-23-1
0019
ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0158JCH
Figure 13. Oil Pressure Sensor Circuit Identification. END OF WORK PACKAGE
0019-13/14 blank
TM 10-3930-675-23-1
0020
FIELD MAINTENANCE ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) Test Set, Electrical Cable (Volume 2, WP 0277, Table 1, Item 81) References TM 10-3930-675-10 References (cont.) WP 0005 WP 0006 WP 0081 WP 0083 WP 0116 WP 0118 Volume 2, WP 0267
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component location.
0020-1
TM 10-3930-675-23-1
0020
TROUBLESHOOTING PROCEDURE ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING
WARNING
DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to follow this warning may result in serious burns. SYMPTOM
ERROR CODE 1144 MALFUNCTION Coolant Temperature Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect sensor harness from coolant temperature sensor (WP 0118). a. Inspect coolant temperature sensor and sensor harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check coolant temperature sensor and sensor harness for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2. 3.
Place ignition switch in OFF position and disconnect engine harness from coolant temperature sensor. Measure resistance from pin A (or 1) to pin B (or 2) of coolant temperature sensor. Resistance should be 300 to 90k Ohms. If resistance is not as specified, replace coolant temperature sensor (WP 0118).
0020-2
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
300-90K Ohms

T0159JCH
Figure 1. Coolant Temperature Sensor Test. 4. Ensure ignition switch is in OFF position. Disconnect sensor harness connector from engine ECU. a. Inspect engine ECU and sensor harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine ECU and sensor harness for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
0020-3
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Place ignition switch in OFF position. Disconnect engine harness from coolant temperature sensor and disconnect sensor harness connector from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 2 of sensor harness connector to all other pins. Resistance should be greater than 100k Ohms. Measure resistance from pin 3 of sensor harness connector to all other pins. Resistance should be greater than 100k Ohms.
>100K Ohms
T0160JCH
Figure 2. Coolant Temperature Sensor Circuit Resistance Test.
0020-4
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position. Disconnect engine harness from coolant temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks.
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 2 of sensor harness connector to pin B (or 2) of coolant temperature sensor connector. Resistance should be less than 10 Ohms. Measure resistance from pin 3 of sensor harness connector to pin A (or 1) of coolant temperature sensor connector. Resistance should be less than 10 Ohms.
<10 Ohms
T0161JCH
Figure 3. Coolant Temperature Sensor Circuit Resistance Test.
0020-5
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1145 MALFUNCTION Coolant Temperature Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect sensor harness from coolant temperature sensor (Volume 2, WP 0267). a. Inspect coolant temperature sensor and sensor harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check coolant temperature sensor and sensor harness for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (WP 0118).
b.
2. 3.
Place ignition switch in OFF position and disconnect engine harness from coolant temperature sensor. Measure resistance from pin A (or 1) to pin B (or 2) of coolant temperature sensor. Resistance should be 300 to 90k Ohms. If resistance is not as specified, replace coolant temperature sensor (WP 0118).
300-90K Ohms

T0162JCH
Figure 4. Coolant Temperature Sensor Resistance Test.
0020-6
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Place ignition switch in OFF position and disconnect engine harness from coolant temperature sensor. Perform the following resistance checks:
NOTE
If resistance is not as specified, replace coolant temperature sensor (WP 0118). a. b. Measure resistance from pin A (or 1) of coolant temperature sensor to engine block ground. Resistance should be greater than 100k Ohms. Measure resistance from pin B (or 2) of coolant temperature sensor to engine block ground. Resistance should be greater than 100k Ohms.
>100K Ohms

T0163JCH
Figure 5. Coolant Temperature Sensor Resistance Test. 5. 6. Place ignition switch in OFF position. Disconnect sensor harness from engine ECU. Ensure ignition switch is in OFF position. Disconnect sensor harness from coolant temperature sensor. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
0020-7
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 7. Place ignition switch in OFF position. Disconnect engine harness from coolant temperature sensor and disconnect sensor harness connector from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. Measure resistance from pin 2 of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms.
>100K Ohms
T0164JCH
Figure 6. Coolant Temperature Sensor Circuit Resistance Test. b. 8. Measure resistance from pin 3 of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms.
Place ignition switch in OFF position. Disconnect engine harness from coolant temperature sensor and disconnect sensor harness connector from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 2 of sensor harness connector to engine block ground. Resistance should be greater than 100k Ohms. Measure resistance from pin 3 of sensor harness connector to engine block ground. Resistance should be greater than 100k Ohms.
0020-8
TM 10-3930-675-23-1
0020
>100K Ohms
3,2
T0165JCH
Figure 7. Coolant Temperature Sensor Circuit Resistance Test. SYMPTOM
ERROR CODE 1151 MALFUNCTION Coolant Temperature Above Critical Threshold. CORRECTIVE ACTION 1. 2. 3. 4. Check coolant level (TM 10- 3930-675-10). Add coolant as required (TM 10- 3930-675-10). Check radiator top and side grille for mud, snow, or obstructions. Clear obstructions. Check for loose coolant hoses and clamps. Tighten or replace as required (WP 0083). Enter DIAG EXTRA FUNCT 4(13)" menu and check water level sensor setting. Enter 0" to shut off and 1" to run cooling fan. Check if fording water level sensor is clogged or damaged. a. b. Clean and/or replace fording water level sensor (WP 0116). Perform Troubleshooting Procedure for Engine OVERHEATS" (WP 0006).
0020-9
TM 10-3930-675-23-1
0020
SYMPTOM
ERROR CODE 1153 MALFUNCTION Intake Air Temperature Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect sensor harness from intake manifold temperature sensor. a. Inspect intake manifold temperature sensor and sensor harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check intake manifold temperature sensor and sensor harness for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2. 3.
Place ignition switch in OFF position and disconnect sensor harness from intake manifold temperature sensor. Measure resistance from pin A to pin B of air intake temperature sensor. Resistance should be 175 to 244k Ohms. If resistance is not as specified, replace coolant temperature sensor (WP 0118).
175-244K Ohms
T0166JCH
Figure 8. Intake Air Temperature Sensor Resistance Test.
0020-10
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
5.
Place ignition switch in OFF position. Disconnect engine harness from intake air temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 38 of sensor harness connector to all other pins in sensor harness. Resistance should be more than 100k Ohms. Measure resistance from pin 40 of sensor harness connector to all other pins in sensor harness. Resistance should be more than 100k Ohms.
>100K Ohms
T0167JCH
Figure 9. Intake Air Temperature Sensor Circuit Resistance Test.
0020-11
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position. Disconnect engine harness from intake air temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 40 of sensor harness connector to pin 1 (or A) of intake air temperature sensor connector, harness side. Resistance should be less than 10 Ohms. Measure resistance from pin 38 of sensor harness connector to pin 2 (or B) of intake air temperature sensor connector, harness side. Resistance should be less than 10 Ohms.
<10 Ohms
T0168JCH
Figure 10. Intake Air Temperature Sensor Circuit Resistance Test. SYMPTOM
ERROR CODE 1154 MALFUNCTION Intake Air Temperature Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect sensor harness from intake air temperature sensor. a. Inspect intake air temperature sensor and sensor harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).
0020-12
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Check intake air temperature sensor and sensor harness for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
2. 3.
Place ignition switch in OFF position and disconnect sensor harness from intake air temperature sensor. Measure resistance from pin A (or 1) to pin B (or 2) of intake air temperature sensor. Resistance should be 175 to 244k Ohms. If resistance is not as specified, replace intake air temperature sensor (WP 0118).
175-244K Ohms
T0169JCH
Figure 11. Intake Air Temperature Sensor Resistance Test. 4. 5. Place ignition switch in OFF position and disconnect sensor harness from intake air temperature sensor. Measure resistance from pin A of intake air temperature sensor to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, replace intake air temperature sensor (WP 0118).
>100K Ohms

T0170JCH
Figure 12. Intake Air Temperature Sensor Resistance Test.
0020-13
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
7.
Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
8.
Place ignition switch in OFF position. Disconnect sensor harness from intake air temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 40 of sensor harness connector to all other pins in sensor harness. Resistance should be greater than 100k Ohms. Measure resistance from pin 38 of sensor harness connector to all other pins in sensor harness. Resistance should be greater than 100k Ohms.
>100K Ohms

T0171JCH
0020-14
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Place ignition switch in OFF position. Disconnect sensor harness from intake air temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks:
NOTE
>100K Ohms
T0172JCH
0020-15
TM 10-3930-675-23-1
0020
SYMPTOM
ERROR CODE 1155 MALFUNCTION Intake Air Temperature Above Critical Threshold. CORRECTIVE ACTION 1. 2. 3. 4. Check coolant level (TM 10- 3930-675-10). Add coolant as required (TM 10-3930-675-10). Check radiator top and side grille for mud, snow, or obstructions. Clear obstructions. Check for loose coolant hoses and clamps. Tighten or replace as required (WP 0083). Enter "DIAG EXTRAFUNCT 4(13)" menu and check water level sensor setting. Enter 0" to shut off and 1" to run cooling fan. Check if fording water level sensor is clogged or damaged a. b. SYMPTOM Clean and/or replace fording water level sensor (WP 0116). Clean radiator assembly (WP 0081).
ERROR CODE 1212 MALFUNCTION Oil Temperature Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure that ignition switch is in OFF position. Disconnect engine harness from oil pressure/ temperature sensor (WP 0118). a. Inspect oil pressure/temperature sensor and engine harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check oil pressure/temperature sensor and engine harness for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals.
b.
2. 3.
Place ignition switch in OFF position and disconnect engine harness from oil pressure/temperature sensor. Measure resistance from pin 4 (or D) to pin 2 (or B) of oil pressure temperature sensor. Resistance should be 300 to 90k Ohms.
0020-16
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If resistance is not as specified, replace oil pressure/temperature sensor (WP 0118).
300-90K Ohms
T0173JCH
Figure 15. Oil Temperature Sensor Resistance Test. 4. Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Inspect sensor harness and engine ECU connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and engine ECU for dirt or moisture in or on connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
0020-17
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Place ignition switch in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 42 of sensor harness connector to all other pins in sensor harness. Resistance should be more than 100k Ohms. Measure resistance from pin 43 of sensor harness connector to all other pins in sensor harness. Resistance should be more than 100k Ohms.
>100K Ohms
>100K Ohms
T0174JCH
Figure 16. Oil Temperature Sensor Circuit Resistance Test.
0020-18
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness from engine ECU. Perform the following resistance checks:
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 42 of sensor harness connector to pin 4 (or D) of oil pressure/ temperature sensor connector, harness side. Resistance should be less than 10 Ohms. Measure resistance from pin 43 of sensor harness connector to pin 2 (or B) of oil pressure/ temperature sensor connector, harness side. Resistance should be less than 10 Ohms.
<10 Ohms
<10 Ohms
T0175JCH
Figure 17. Oil Temperature Sensor Circuit Resistance Test.
0020-19
TM 10-3930-675-23-1
0020
SYMPTOM
ERROR CODE 1213 MALFUNCTION Oil Temperature Sensor Circuit Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect engine harness from oil pressure/ temperature sensor (WP 0118). a. Inspect oil temperature sensor and engine harness connectors for dirty, corroded, bent, broken, and pushed back or extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check oil temperature sensor and engine harness for dirt or moisture in or on the connectors and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2. 3.
Place ignition switch in OFF position and disconnect engine harness from oil pressure/ temperature sensor. Measure resistance from pin 4 (or D) to pin 2 (or B) of oil pressure/temperature sensor. Resistance should be 300 to 90k Ohms. If resistance is not as specified, replace oil pressure/temperature sensor (WP 0118).
300-90K Ohms

T0176JCH
Figure 18. Oil Temperature Sensor Resistance Test.
0020-20
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. 5. Place ignition switch in OFF position and disconnect engine harness from oil pressure/ temperature sensor. Measure resistance from pin 4 (or D) of oil pressure/ temperature sensor to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, replace oil pressure/temperature sensor (WP 0118).
>100K Ohms

T0177JCH
Figure 19. Oil Temperature Sensor Resistance Test.
0020-21
TM 10-3930-675-23-1
0020
ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness connector from engine ECU. Perform the following resistance checks.
NOTE
If engine harness requires replacement, notify SRA. a. b. Measure resistance from pin 42 of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms. Measure resistance from pin 43 of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms.
>100K Ohms
>100K Ohms
T0178JCH
Figure 20. Oil Temperature Sensor Circuit Resistance Test. 7. Place ignition switch in OFF position. Disconnect engine harness from oil pressure/ temperature sensor and disconnect sensor harness connector from engine ECU. Perform the following resistance checks.
NOTE
0020-22
TM 10-3930-675-23-1
0020
>100K Ohms
>100K Ohms
T0179JCH
Figure 21. Oil Temperature Sensor Circuit Resistance Test. SYMPTOM
ERROR CODE 1214 MALFUNCTION Oil Temperature Above Critical Threshold. CORRECTIVE ACTION 1. 2. 3. 4. Check coolant level (TM 10-3930-675-10). Add coolant as required (TM 10-3930-675-10). Check radiator top and side grille for mud, snow, or obstructions. Clear obstructions. Check for loose coolant hoses and clamps. Tighten or replace as required (WP 0083). Enter "DIAG EXTRA FUNCT 4(13)" menu and check water level sensor setting. Enter 0" to shut off and 1" to run cooling fan. Check if fording water level sensor is clogged or damaged. a. b. Clean and/or replace fording water level sensor (WP 0116). If problem continues, notify SRA.
0020-23
TM 10-3930-675-23-1
0020
SYMPTOM
ERROR CODE 1697 MALFUNCTION ECU Internal Temperature Sensor Circuit Failure. CORRECTIVE ACTION Notify SRA. SYMPTOM
ERROR CODE 1698 MALFUNCTION ECU Internal Temperature Sensor Circuit Failure. CORRECTIVE ACTION Notify SRA.
NOTE
Location of engine sensors is illustrated in Engine Sensors Replacement (WP 0118).
T0343JCH
Figure 22. Engine Sensors Replacement.
0020-24
TM 10-3930-675-23-1
0020
T0180JCH
Figure 23. END OF WORK PACKAGE
Intake Manifold Temperature Sensor Circuit Information.
0020-25/26 blank
TM 10-3930-675-23-1 FIELD MAINTENANCE ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING
0021
INITIAL SETUP: Tools and Special Tools Adapter Set, Cable Breakout (Volume 2, WP 0277, Table 1, Item 3) Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 References (cont.) WP 0005 WP 0099 WP 0100 WP 0118 WP 0131 Volume 2, WP 0267
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. Ambient air pressure sensor is mounted to bracket on left side of engine, to right rear of engine Electronic Control Units (ECU). For RT 240V2 and RT 240V3 only, the breakout cable is not used due to new style sensor. Perform troubleshooting procedures for Steps 1 thru 3 and 7 thru 13. Ambient Air Pressure Sensor replacement part will be new style sensor with adapter cable. The breakout cable can be used to troubleshoot new style replacement sensor.
0021-1
TM 10-3930-675-23-1 TROUBLESHOOTING PROCEDURE ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING SYMPTOM
0021
ERROR CODE 1221 MALFUNCTION High Voltage Detected at Ambient Air Pressure Sensor Circuit. CORRECTIVE ACTION 1. 2. Ensure ignition switch is in OFF position and disconnect engine harness from ambient air pressure sensor. Inspect ambient air pressure sensor and sensor harness connectors for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check ambient air pressure sensor and sensor harness for dirt and moisture in connector. Remove dirt and moisture from connector. Replace missing or damaged connector (Volume 2, WP 0267). lnstall breakout cable between sensor and sensor harness connector. Place ignition switch in ON and measure supply voltage from pin A to pin B of breakout cable. Voltage should be 4.75 to 5.25\/. If voltage is not as specified, proceed with the following steps.
3.
4.
0021-2
TM 10-3930-675-23-1
0021
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
4.75-5.25V A C B Use Breakout Cable P/N 3824776

T0181JCH
Figure 1. Ambient Air Temperature Sensor Voltage Test. 5. Disconnect sensor harness connector from ECU and place ignition in ON position. Measure voltage at ECU sensor port from pin 17 to pin 31 of ECU sensor port. Voltage should be at 4.75 to 5.25V. a. b. c. If engine harness requires replacement, notify SRA. If voltage is not as specified, replace engine ECU (WP 0100). Reconnect ECU.
4.75-5.25V
T0182JCH
Figure 2. Ambient Air Temperature Sensor Circuit Voltage Test.
0021-3
TM 10-3930-675-23-1
0021
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Install breakout cable between sensor and sensor harness connector and place ignition switch in ON position. Measure signal voltage from pin C to pin B of breakout cable. Voltage should be as follows: Table 1. 0 3K 6K 9K 12K Altitude (Ft.) vs. Voltage. = = = = = 3.4 to 4.5V 2.8 to 3.8V 2.2 to 3.2V 1.7 to 2.7V 1.2 to 2.2V
If voltage is not as specified, proceed with the following steps.
Use Breakout Cable P/N 3824776

T0183JCH
Figure 3. Ambient Air Temperature Sensor Circuit Voltage Test. 7. 8. Place ignition switch in OFF position and disconnect sensor harness connector from ECU. Inspect sensor harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and ECU for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Place ignition switch in OFF position and disconnect sensor harness connector from ECU. Measure resistance from pin 6 of sensor harness connector to all other pins in the connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
9.
10. 11.
0021-4
TM 10-3930-675-23-1
0021
>100K Ohms
Use Test Lead Kit P/N 3822758

T0184JCH
Figure 4. Ambient Air Temperature Sensor Circuit Resistance Test. 12. Place ignition switch in OFF position and disconnect sensor harness connector from ECU and disconnect engine harness from ambient air pressure sensor. Clean and repair connector(s) as required (Volume 2, WP 0267). Check for open circuit in return wire by measuring resistance from pin 31 of sensor harness connector to engine block ground. Resistance should be less than 10 Ohms. a. b. If resistance is as specified, replace ambient air pressure sensor (WP 0118). If engine harness requires replacement, notify SRA.
13.
Use Test Lead Kit P/N 3822758
<10 Ohms
T0185JCH
Figure 5. Ambient Air Temperature Sensor Circuit Resistance Test.
0021-5
TM 10-3930-675-23-1
0021
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 1222 MALFUNCTION Low Voltage Detected at Ambient Air Pressure Sensor Circuit. CORRECTIVE ACTION 1. 2. Ensure ignition switch is in OFF position and disconnect engine harness from ambient air pressure sensor. Inspect ambient air pressure sensor and sensor harness connectors for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check ambient air pressure sensor and sensor harness for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Install breakout cable between sensor and sensor harness connector. Place ignition switch in ON position and measure supply voltage from pin A to pin B of breakout cable. Voltage should be 4.75 to 5.25V. If voltage is not as specified, proceed with the following steps.
3.
4.
Use Breakout Cable P/N 3824776 4.75-5.25V

T0186JCH
0021-6
TM 10-3930-675-23-1
0021
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect sensor harness connector from ECU and place ignition switch in ON position. Measure voltage at ECU sensor port from pin 17 to pin 31 of ECU sensor port. Voltage should be 4.75 to 5.25V. If voltage is not as specified, proceed with the following steps.
4.75-5.25V Use Test Lead Kit P/N 3822758

T0187JCH
0021-7
TM 10-3930-675-23-1
0021
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Install breakout cable between sensor and sensor harness connector and place ignition switch in ON position. Measure signal voltage from pin C to pin B of breakout cable. Voltage should be as follows: Table 2. 0 3K 6K 9K 12K Altitude (Ft.) vs. Voltage = = = = = 3.4 to 4.5V 2.8 to 3.8V 2.2 to 3.2V 1.7 to 2.7V 1.2 to 2.2V
If voltage is not as specified, proceed with the following steps.
T0411JCH
Figure 8. Ambient Air Temperature Sensor Circuit Voltage Test. 7. 8. Place ignition switch in OFF position and disconnect ambient air pressure sensor from engine harness. Disconnect sensor harness connector from ECU. Measure resistance from pin 6 of sensor harness connector to chassis ground. Measurement should be greater than 100k Ohms. If measurement is not as specified, notify SRA to replace engine harness.
0021-8
TM 10-3930-675-23-1
0021
>100K Ohms
T0188JCH
Figure 9. Ambient Air Temperature Sensor Circuit Voltage Test. 9. 10. Place ignition switch in OFF position. Disconnect engine harness from ambient air pressure sensor and disconnect sensor harness connector from engine ECU. Measure resistance from pin 6 of sensor harness connector to all other pins in connector. Resistance should be greater than 100k Ohms. a. b. If resistance is as specified, replace ambient air pressure sensor (WP 0131). If engine harness requires replacement, notify SRA.
>100K Ohms
T0189JCH
0021-9
TM 10-3930-675-23-1
0021
ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11. 12. Place ignition switch in OFF position. Disconnect sensor harness connector from ECU. Inspect sensor harness and ECU connectors for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check sensor harness and ECU for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Place ignition switch in OFF position. Disconnect ambient air pressure sensor. Disconnect ECU sensor harness connector. Measure resistance from sensor harness connector pin 6 to ambient air pressure sensor signal pin C. Measurement should be less than 10 Ohms. If engine harness requires replacement, notify SRA.
13.
14.
T0090JCH
Figure 11. Ambient Air Temperature Sensor Circuit Resistance Test. 15. 16. Disconnect sensor harness connector from ECU and place ignition switch in ON position. Install jumper wire between ECU sensor port pin 6 and pin 17. Check ERROR CODE display. ERROR CODE 1221 should be displayed. If ERROR CODE 1222 is displayed, replace engine ECU (WP 0099).
0021-10
TM 10-3930-675-23-1
0021
ERROR CODE 1221
T0191JCH
Figure 12. Ambient Air Temperature Sensor Circuit Test. SYMPTOM
ERROR CODE 1295 MALFUNCTION Ambient Air Pressure Sensor Circuit Failure. CORRECTIVE ACTION Perform Troubleshooting procedure for ERROR CODEs 1221 and 1222 in this work package. SYMPTOM
ERROR CODE 1298 MALFUNCTION High Intake Air Restriction or Circuit Failure (RT 240V1R, RT 240V2 or RT 240V3 only). CORRECTIVE ACTION 1. Check air filter restriction indicator for restriction indication (TM 10-3930-675-10). If air filter indicator is tripped or indicates a restriction of 20 in. water column or more, service or replace the air filter element.
0021-11
TM 10-3930-675-23-1
0021
NOTE
If the intake air restriction is at or above 25 in. water column the engine will de-rate to 1,000 RPM and activate ERROR CODE 1298. 2. Locate the air pressure sensor (754) on the intake pipe crossing over the engine valve cover. Inspect sensor for damage and connection. a. b. 3. Reconnect disconnected sensor. Replace damaged air pressure sensor (WP 0118).
Check for continuity. Disconnect the air pressure sensor and check continuity between the two pins of the sensor. There should be continuity when the engine is not running. If air pressure sensor does not have continuity, replace air pressure sensor (WP 0118). Follow the harness of the sensor down the side of the engine block to the connector where the sensor joins the engine harness (switched output A connector). Inspect connector for connection or damage. Repair or replace damaged connector (Volume 2, WP 0267). Check continuity of the two wires between the air pressure sensor harness connector and the switched output A connector (pins 1 and 3). If no continuity found on either wire, replace the air pressure sensor harness (Volume 2, WP 0267). Check for voltage. Disconnect the switched output A connector. Turn the ignition and check voltage at pin 1 to ground. Voltage should be 4.75V to 5.25V. a. b. If voltage is not as specified, check continuity of wires between the switched output A connector pins 1 and 3 and ECU (794) sensor connector harness pins 18 and 20. If no continuity found at either wire, contact Sustainment Maintenance to replace engine harness.
4.
5.
6.
7.
Inspect connector and ECU. Disconnect the ECU (794) sensor harness connector. Inspect the sensor harness connector and ECU for damage, dirt, or corrosion. a. b. Clean and repair connector and required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).
8.
Check for voltage. Turn the ignition on and check voltage at pin 18 on the ECU (794) and ground. Voltage should be 4.75V to 5.25V. If voltage is not as specified, replace ECU (794) (WP 0100).
END OF WORK PACKAGE
0021-12
TM 10-3930-675-23-1
0022
FIELD MAINTENANCE ENGINE PRESSURE SENSOR TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Adapter Set, Cable Breakout (Volume 2, WP 0277, Table 1, Item 3) Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Tools and Special Tools (cont.) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0099 WP 0118 Volume 2, WP 0267
0022-1
TM 10-3930-675-23-1
0022
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE ENGINE PRESSURE SENSOR TROUBLESHOOTING SYMPTOM
ERROR CODE 1122 MALFUNCTION Intake Manifold Pressure Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Ensure ignition switch is in OFF position. Disconnect engine harness from intake manifold pressure sensor (WP 0118). Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and sensor connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Disconnect all pressure and temperature sensors from engine harness. Disconnect coolant level sensor jumper wires no. 5 and 6 from 31 pin OEM connector, located on left side of engine to rear of ECU. Install breakout cable. Place ignition switch in ON position. Check intake manifold pressure sensor supply voltage. Check voltage between lead A and B of breakout cable. Voltage should be 4.75 to 5.25V. If voltage is not as specified, perform the following steps.
3.
4.
5.
0022-2
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
4.75-5.25V
T0193JCH
Figure 1. Intake Manifold Pressure Sensor Circuit Voltage Test. a. Disconnect all pressure and temperature sensors from sensor harness. Disconnect coolant level sensor jumper wires no. 5 and 6 from 31- pin OEM connector. Place ignition switch in ON position. Install breakout cable but do not connect to sensor. Check intake manifold pressure sensor supply voltage. Check voltage between lead A and B of breakout cable. Voltage should be 4.75 to 5.25V. If voltage is as specified, replace intake manifold pressure sensor (WP 0118).
b.
4.75-5.25V
A B C
T0194JCH
Figure 2. Intake Manifold Pressure Sensor Circuit Voltage Test. c. Disconnect sensor harness connector from engine ECU and place ignition switch in ON position.
0022-3
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Measure voltage from ECU sensor port connector pin 40 to connector pin 37. Voltage should be 4.75 to 5.25V. a. b. If voltage is as specified, replace intake manifold pressure sensor (WP 0118). If voltage is not as specified, replace engine ECU (WP 0099).
T0195JCH
Figure 3. Intake Manifold Pressure Sensor Circuit Voltage Test. 7. 8. 9. Disconnect all sensors from sensor harness except intake manifold pressure sensor. Reconnect sensor harness connector to ECU. Disconnect coolant level sensor jumper wires. Install breakout cable. Place ignition switch in ON position. Check intake manifold pressure sensor signal voltage. Check voltage between leads C and B of breakout cable. Voltage should be 0.70 to 1.40V. If voltage is not as specified, proceed to following steps.
0.70-1.40V C B A
T0196JCH
Figure 4. Intake Manifold Pressure Sensor Circuit Voltage Test.
0022-4
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 10. Place ignition switch in OFF position, disconnect sensor harness from engine ECU, and disconnect all sensors and coolant level jumper wires no. 5 and 6. Disconnect intake manifold pressure sensor. a. Measure resistance from sensor harness connector pin 40 to all other pins in connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 39 to all other pins in connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 37 to all other pins in connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
b.
c.
>100K Ohms
40 39 37
T0197JCH
Figure 5. Intake Manifold Pressure Sensor Circuit Resistance Test.
0022-5
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11. Check for resistance in sensor harness. a. Measure resistance from sensor harness connector pin 37 to sensor connector pin A. Resistance should be less than 10 Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 40 to sensor connector pin B. Resistance should be less than 10 Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 39 to sensor connector pin C. Resistance should be less than 10 Ohms. If engine harness requires replacement, notify SRA.
b.
c.
<10 Ohms
40 TO B 39 TO C 37 TO A
T0198JCH
0022-6
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 12. Place ignition switch in OFF position and disconnect sensor harness connector from engine ECU. a. Measure resistance from pin 39 to pin 40 at sensor port of ECU. (1) (2) b. If resistance is less than 100k Ohms, replace intake manifold pressure sensor (WP 0118). If resistance is greater than 100k Ohms, replace engine ECU (WP 0099).
Measure resistance from pin 39 of ECU sensor port to engine block ground. If resistance is greater than 100k Ohms, replace engine ECU (WP 0099).
39 TO GND <100K Ohms
39 TO GND <100K Ohms
T0199JCH
0022-7
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1123 MALFUNCTION Intake Manifold Pressure Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Ensure ignition switch is in OFF position. Disconnect engine harness from intake manifold pressure sensor (WP 0118). Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and sensor connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Install breakout cable. Place ignition switch in ON position. Check intake manifold pressure sensor supply voltage. Check voltage between lead A and B of breakout cable. Voltage should be 4.75 to 5.25V. If voltage is not as specified, proceed to the following steps.
3.
4.
4.75-5.25V C
T0200JCH
0022-8
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. 6. Disconnect sensor harness connector from engine ECU and place ignition switch to ON position. If voltage is not as specified, proceed with the following steps. Measure voltage from ECU sensor port connector pin 40 to connector pin 37. Voltage should be 4.75 to 5.25V. a. b. If engine harness requires replacement, notify SRA. If voltage is not as specified, replace engine ECU (WP 0099).
40
37
4.75-5.25V
T0412JCH
Figure 9. Intake Manifold Pressure Sensor Circuit Voltage Test. 7. Install breakout cable. Place ignition switch in ON position and check intake manifold pressure sensor signal voltage. Check voltage between lead B and C of breakout cable. Voltage should be 0.42 to 0.58V. If voltage is not as specified, proceed with the following steps.
0.42-0.58V C A B
T0201JCH
0022-9
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Place ignition switch in OFF position. Disconnect intake manifold pressure sensor from engine harness and disconnect sensor harness from engine ECU. a. Measure resistance from sensor harness connector pin 39 to chassis ground. Resistance should be more than 100k Ohms. If resistance is not as specified, notify SRA.
USE TEST LEAD KIT P/N 3822758 39 >100K OHMS
T0202JCH
Figure 11. Intake Manifold Pressure Sensor Circuit Resistance Test. b. Measure resistance from sensor harness connector pin 39 to all other pins in connector. Resistance should be more than 100k Ohms. (1) (2) If resistance is as specified, replace intake manifold pressure sensor (WP 0118). If resistance is not as specified, notify SRA.
39
TEST ALL PINS

T0203JCH
0022-10
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. 10. Turn ignition switch to OFF position, disconnect intake manifold pressure sensor from engine harness, and disconnect sensor harness from engine ECU. Measure resistance from sensor harness connector pin 39 to intake manifold pressure sensor connector pin C. Resistance should be less than 10 Ohms. If engine harness requires replacement, notify SRA.
39 <10 OHMS

T0204JCH
Figure 13. Intake Manifold Pressure Sensor Circuit Resistance Test. 11. Disconnect sensor harness connector from engine ECU. Place ignition switch in ON position. Install jumper wire between ECU sensor port pin 37 and 39. ERROR CODE 1122 should be displayed. If ERROR CODE 1122 is not displayed, replace engine ECU (WP 0099).
37
39
ERROR CODE 1122
T0205JCH
Figure 14. Intake Manifold Pressure Sensor Circuit Test.
0022-11
TM 10-3930-675-23-1
0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 1419 MALFUNCTION Intake Manifold Pressure Sensor Circuit Failure. CORRECTIVE ACTION Notify SRA. SYMPTOM
ERROR CODE 1433 MALFUNCTION Intake Manifold Pressure Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Ensure ignition switch is in OFF position. Disconnect engine harness from intake manifold pressure sensor (WP 0118). Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and sensor connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Place ignition switch in OFF position and disconnect sensor harness connector from engine ECU. Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and engine ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). Place ignition switch in OFF position. Disconnect sensor harness from intake manifold pressure sensor, and disconnect sensor harness from engine ECU. Measure resistance from sensor harness connector pin 40 to intake manifold pressure sensor connector pin 2. Resistance should be less than 10 Ohms. If engine harness requires replacement, notify SRA.
3.
4. 5.
6.
7. 8.
0022-12
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0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
40 B
<10 OHMS
T0206JCH
Figure 15. Intake Manifold Pressure Sensor Circuit Resistance Test. 9. Place ignition switch in OFF position. Disconnect sensor harness from intake manifold pressure sensor and from engine ECU. Measure resistance from sensor harness connector pin 39 to all other pins in connector. Resistance should be more than 100k Ohms. a. b. If resistance is as specified, replace intake manifold pressure sensor (WP 0118). If resistance is not as specified, notify SRA.
39 >100K OHMS TEST ALL PINS USE TEST LEAD KIT P/N 3822758
T0207JCH
Figure 16. Intake Manifold Pressure Sensor Circuit Resistance Test. 10. Place ignition switch in OFF position. Disconnect sensor harness from intake manifold pressure sensor and from engine ECU.
0022-13
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0022
ENGINE PRESSURE SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11. Measure resistance from pin 39 in sensor harness to engine block ground. Resistance should be greater than 100k Ohms. a. If resistance is as specified, replace intake manifold pressure sensor (WP 0118).
NOTE
Intake manifold pressure sensor is located on top right side of engine under air intake tube. b. If resistance is not as specified, notify SRA.
39
>100K OHMS USE TEST LEAD KIT P/N 3822758

T0208JCH
T0209JCH
Figure 18. Intake Manifold Pressure Sensor Circuit Information. END OF WORK PACKAGE
0022-14
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0023
FIELD MAINTENANCE ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Cable Assembly, Special Purpose, E (Volume 2, WP 0277, Table 1, Item 12) Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Tools and Special Tools (cont.) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0070 WP 0099 WP 0118 Volume 2, WP 0267
NOTE
0023-1
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0023
TROUBLESHOOTING PROCEDURE ERROR CODE 1254 - FUEL SHUTOFF SOLENOID CIRCUIT FAILURE TROUBLESHOOTING PROCEDURES SYMPTOM ERROR CODE 1254 MALFUNCTION Fuel Shutoff Solenoid Circuit Failure. CORRECTIVE ACTION 1. Check fuel shutoff solenoid for corrosion. Clean solenoid post and wire post terminal as required.
T0210JCH
Figure 1. Fuel Shutoff Solenoid Post Inspection. 2. 3. Disconnect actuator harness from fuel shutoff solenoid. Place ignition switch in ON position. Measure voltage from fuel shutoff control wire connectors to engine block ground. Voltage should be greater than 6V. If engine harness requires replacement, contact SRA.
>6V
T0211JCH
Figure 2. Fuel Shutoff Solenoid Voltage Test.
0023-2
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0023
ERROR CODE 1254 - FUEL SHUTOFF SOLENOID CIRCUIT FAILURE TROUBLESHOOTING PROCEDURES Continued CORRECTIVE ACTION - Continued 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a. Inspect engine ECU and actuator harness connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine ECU and actuator harness connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
5.
Place ignition switch in OFF position and disconnect actuator wire from fuel shutoff solenoid and disconnect actuator harness connector from engine ECU. Measure resistance from actuator harness pin 33 to fuel shutoff control wire. Resistance should be less than 10 Ohms. If engine harness requires replacement, notify SRA.
<10 Ohms
T0212JCH
Figure 3. Fuel Shutoff Valve Actuator Wire.
0023-3
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0023
ERROR CODE 1254 - FUEL SHUTOFF SOLENOID CIRCUIT FAILURE TROUBLESHOOTING PROCEDURES Continued CORRECTIVE ACTION - Continued 6. 7. Place ignition switch in OFF position. Disconnect actuator harness from engine ECU. Disconnect actuator wire from fuel shutoff valve. Measure resistance from pin 33 of actuator harness connector to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA.
>100K Ohms
33 TEST ALL PINS
T0213JCH
Figure 4. Fuel Shutoff Solenoid Circuit Resistance Test. 8. 9. Disconnect actuator harness from engine ECU. Place ignition switch in ON position. Measure voltage from engine ECU pin 33 to engine block ground. Voltage should be greater than 6V. a. b. If engine harness requires replacement, notify SRA. If voltage is not as specified, replace engine ECU (WP 0099).
0023-4
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0023
ERROR CODE 1254 - FUEL SHUTOFF SOLENOID CIRCUIT FAILURE TROUBLESHOOTING PROCEDURES Continued CORRECTIVE ACTION - Continued
>6V
T0214JCH
Figure 5. Fuel Shutoff Solenoid Circuit Voltage Test. 10. 11. Place ignition switch in OFF position and disconnect actuator harness from fuel shutoff solenoid. Measure resistance from fuel shutoff solenoid to engine block ground. Resistance should be 7 to 8 Ohms for 12V solenoids. If resistance is not as specified replace fuel shutoff solenoid (WP 0070).
12V = 7-8 Ohms
T0215JCH
Figure 6. Fuel Shutoff Solenoid Circuit Resistance Test.
0023-5
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0023
ERROR CODE 1255 - Fuel Shutoff Solenoid External Voltage Detected on Circuit Troubleshooting Procedures SYMPTOM
ERROR CODE 1255 MALFUNCTION Fuel Shutoff Solenoid External Voltage Detected on Circuit. CORRECTIVE ACTION 1. Place ignition switch in OFF position and disconnect actuator harness connector from engine ECU. a. Inspect harness connector and engine ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check harness and engine ECU for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
2. 3.
Disconnect actuator harness connector from engine ECU. Place ignition switch in ON position. Measure voltage from actuator harness connector pin 33 to engine block ground. Voltage should be less than 1.5V. If voltage is not as specified, proceed with the following steps.
<1.5V
T0216JCH
Figure 7. Fuel Shutoff Solenoid Circuit Voltage Test.
0023-6
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0023
ERROR CODE 1255 - Fuel Shutoff Solenoid External Voltage Detected on Circuit Troubleshooting Procedures - Continued CORRECTIVE ACTION - Continued 4. 5. Place ignition switch in OFF position, disconnect actuator harness connector from engine ECU, and disconnect actuator wire from fuel shutoff solenoid. Measure resistance from actuator harness connector pin 33 to all other pins in connector. Resistance should be greater than 100k Ohms. Notify SRA to replace engine harness.
>100K Ohms
T0217JCH
Figure 8. Fuel Shutoff Solenoid Circuit Resistance Test.
0023-7
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0023
ERROR CODE 1581 - Fuel Inlet Restriction Sensor Circuit Failure Troubleshooting Procedures SYMPTOM
ERROR CODE 1581 MALFUNCTION Fuel Inlet Restriction Sensor Circuit Failure. CORRECTIVE ACTION 1. Place ignition switch in OFF position and disconnect fuel inlet restriction sensor from engine harness (WP 0118). a. Inspect fuel inlet restriction sensor connector and engine harness connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check fuel inlet restriction sensor and engine harness for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
>100K Ohms
T0218JCH
Figure 9. Fuel Inlet Restriction Sensor Circuit Resistance Test.
0023-8
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0023
ERROR CODE 1581 - Fuel Inlet Restriction Sensor Circuit Failure Troubleshooting Procedures - Continued CORRECTIVE ACTION - Continued 2. 3. Install breakout cable between sensor and harness connector. Place ignition switch in ON position. Measure supply voltage at pin 1 or A (red) and pin 2 or B (black). Voltage should be 4.75 to 5.25V. a. b. c. If voltage is as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V
T0219JCH
Figure 10. Fuel Inlet Restriction Sensor Circuit Voltage Test. 4. Disconnect actuator harness connector from engine ECU. Turn ignition switch to ON position and measure voltage from engine ECU pin 29 to pin 27 at actuator port of ECU. Voltage should be 4.75 to 5.25\/. a. b. c. If voltage is as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V
T0220JCH
Figure 11. Fuel Inlet Restriction Sensor Circuit Voltage Test.
0023-9
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0023
ERROR CODE 1581 - Fuel Inlet Restriction Sensor Circuit Failure Troubleshooting Procedures - Continued CORRECTIVE ACTION - Continued 5. 6. Install breakout cable between sensor and harness connector. Place ignition switch in ON position. Measure signal voltage at pin 3 or C and pin 2 or B. Voltage should be 0.5 to 4.16V. a. b. c. If voltage is as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA. If voltage is not as specified, replace engine ECU (WP 0099).
0.5-4.16V
T0221JCH
Figure 12. Fuel Inlet Restriction Sensor Circuit Voltage Test.
0023-10
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0023
ERROR CODE 1581 - Fuel Inlet Restriction Sensor Circuit Failure Troubleshooting Procedures - Continued CORRECTIVE ACTION - Continued 7. Place ignition switch in OFF position and disconnect actuator harness connector from engine ECU. a. Inspect harness connector and engine ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check harness and engine ECU for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).
b.
8. 9.
Place ignition switch in OFF position, disconnect actuator harness connector from engine ECU, and disconnect fuel inlet restriction sensor from engine harness. Measure resistance from actuator harness connector pin 27 to pin B (or 2) of 3 pin connector at sensor. Resistance should be less than 10 Ohms. a. b. If resistance is as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
<10 Ohms
T0222JCH
0023-11
TM 10-3930-675-23-1
0023
ERROR CODE 1581 - Fuel Inlet Restriction Sensor Circuit Failure Troubleshooting Procedures - Continued CORRECTIVE ACTION - Continued 10. 11. Place ignition switch in OFF position, disconnect actuator harness connector from engine ECU, and disconnect fuel inlet restriction sensor from engine harness. Measure resistance from actuator harness connector pin 27 to engine block ground. Resistance should be greater than 100k Ohms. a. b. If resistance is as specified, repair or replace connectors (Volume 2, WP 0267). Measure resistance from actuator harness connector pin 28 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) c. If resistance is as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
Measure resistance from actuator harness connector pin 29 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.
>100K Ohms
T0223JCH
0023-12
TM 10-3930-675-23-1
0023
ERROR CODE 1581 - Fuel Inlet Restriction Sensor Circuit Failure Troubleshooting Procedures - Continued CORRECTIVE ACTION - Continued 12. Place ignition switch in OFF position, disconnect actuator harness connector and sensor harness connector from engine ECU, and disconnect fuel inlet restriction sensor from engine harness. a. Measure resistance from actuator harness connector pin 27 to all other pins in actuator connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is as specified, replace fuel inlet restriction sensor (Volume 2, WP 0267). If resistance is not as specified, notify SRA to replace engine harness.
Measure resistance from actuator harness connector pin 27 to all other pins in sensor connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is as specified, replace fuel inlet restriction sensor (WP 0118). If resistance is not as specified, notify SRA to replace engine harness.
c.
Measure resistance from actuator harness connector pin 28 to all other pins in actuator connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is as specified, replace fuel inlet restriction sensor (WP 0118). If resistance is not as specified, notify SRA to replace engine harness.
>100K Ohms
>100K Ohms
T0224JCH
Figure 15. Fuel Inlet Restriction Sensor Circuit Resistance Test. END OF WORK PACKAGE
0023-13/14 blank
TM 10-3930-675-23-1
0024
FIELD MAINTENANCE ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) Lead, Test Female (Volume 2, WP 0277, Table 1, Item 47) Lead, Test Male (Volume 2, WP 0277, Table 1, Item 49) Probe-Lead Assembly, Test (Volume 2, WP 0277, Table 1, Item 57) References WP 0005 References (cont.) WP 0091 WP 0099 WP 0103 WP 0118 WP 0128 Volume 2, WP 0185 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component location. TROUBLESHOOTING PROCEDURE ERROR CODE 1434 - UNSWITCHED BATTERY SUPPLY CIRCUIT FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 1434 MALFUNCTION Unswitched Battery Supply Circuit Failure. CORRECTIVE ACTION
NOTE
Use test lead, male and test lead, female to test the OEM harness connector. 1. Check condition and charge of batteries. Check the voltage of each battery while cranking the engine. a. b. If the battery voltage of any one battery drops below 6V when cranking, service, charge, or replace battery. Clean battery connections.
0024-1
TM 10-3930-675-23-1
0024
ERROR CODE 1434 - UNSWITCHED BATTERY SUPPLY CIRCUIT FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Ensure circuit breakers F4 and F5 are not tripped. Reset circuit breakers as required.
NOTE
ERROR CODE 1434 can be activated by turning off the master battery switch when the ignition switch is on. 3. Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0103). a. b. 4. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0118).
Check for voltage. Turn the ignition ON and check for voltage (22V to 26V) at the OEM connector harness at pins 7, 8, 17, 18, and 28 (Figure 3 (Volume 2, WP 0272). a. b. If voltage (22V to 26V) is not found at any one pin, check circuit breakers F4 and F5 (WP 0103). Replace non-operational circuit breaker (WP 0103).
5.
Inspect connector X17 for damage. Access the cab distribution box in the panel behind the operator's seat. Pull the box out and disconnect connector X17. Repair or replace damaged connector (Volume 2, WP 0267). Check continuity of wires 174, 175, 176, 177, and 179 between X17 and the OEM harness connector (Figure 3 (Volume 2, WP 0272)). If continuity not found at any one wire, notify SRA to replace engine and transmission wiring harness. Check for voltage. Disconnect connector X17. Turn the ignition ON. Check voltage (22V to 26V) at the mounted part of X17 at pins 4, 5, 6, 7, and 9 (Figure 3 (Volume 2, WP 0272)). a. b. If voltage (22V-26V) not found at any one pin, check continuity of wires A174A, A147B, A174C, A177A, and A177B (Figure 3 (Volume 2, WP 0272)). Replace damaged or open wire.
6.
7.
8.
Check continuity. Disconnect the OEM harness connector from ECU (794). Check continuity to ground at pins 29, 30, 39, 40, and 50 (Figure 10 (Volume 2, WP 0272)). a. b. If continuity to ground is not found at any one pin, check wire W19 for proper connection on the main grounding stud on the end of the starter. Notify SRA to replace engine and transmission wiring harness.
9.
Check for short (continuity) between pins in the OEM harness. Disconnect X17 and the OEM harness connector. Check for continuity between each listed pin and all of the other pins in the OEM harness connector: 7, 8, 17, 18, 29, 30, 40, and 50 (Figure 10 (Volume 2, WP 0272)). If a short (continuity) found between any two or more pins, notify SRA to replace engine and transmission wiring harness.
0024-2
TM 10-3930-675-23-1
0024
ERROR CODE 1434 - UNSWITCHED BATTERY SUPPLY CIRCUIT FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
24-30V

T0225JCH
Figure 1. OEM Harness Circuit Resistance Test. ERROR CODE 1441 - UNSWITCHED BATTERY SUPPLY CIRCUIT FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 1441 MALFUNCTION Unswitched Battery Supply Circuit Failure. CORRECTIVE ACTION Perform the troubleshooting procedures for ERROR CODE 1434 in this work package.
0024-3
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0024
ERROR CODE 1442 - UNSWITCHED BATTERY SUPPLY CIRCUIT FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 1442 MALFUNCTION Unswitched Battery Supply Circuit Failure. CORRECTIVE ACTION
NOTE
Use test lead, male and test lead, female to test the OEM harness connector. 1. Check condition and charge of batteries. Check the voltage of each battery while cranking the engine. a. b. 2. 3. If the battery voltage of any one battery drops below 6V when cranking, service, charge, or replace battery. Clean battery connections.
Check output voltage from alternator If output voltage is higher than 26V, replace alternator (WP 0091). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0099). a. b. Clean and repair connector as required Electrical General Maintenance Instructions (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0099).
4.
Check for continuity. Disconnect the OEM harness connector from ECU (794). Check continuity to ground at pins 29, 30, 39, 40, and 50 (Figure 3 (Volume 2, WP 0272)). a. b. If continuity to ground is not found at any one pin, check wire W19 for proper connection on the main grounding stud on the end of the starter. Notify SRA to replace engine and transmission wiring harness.
0024-4
TM 10-3930-675-23-1
0024
ERROR CODE 1474 - STARTER SOLENOID LOCKOUT RELAY DRIVER CIRCUIT FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 1474 MALFUNCTION Starter Solenoid Lockout Relay Driver Circuit Failure. CORRECTIVE ACTION
NOTE
Use test lead, male and test lead, female to test the OEM harness connector. 1. Inspect the 31-pin OEM harness connector and pins for damage, dirt, or corrosion. Remove the engine cover (Volume 2, WP 0185). Disconnect the 31-pin OEM harness connector from engine harness (WP 0099). a. b. 2. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0099).
Check for voltage. Disconnect the 31-pin OEM harness connector. Turn the ignition ON and check for voltage (22V to 26V) at the loose part of the 31-pin OEM connector harness at pin 20 (Volume 2, WP 0272). If voltage (22V to 26V) is not found, continue with Step 3. Inspect connector X16 for damage. Access the cab distribution box in the panel behind the operators seat. Pull the 31-pin OEM harness connector (Volume 2, WP 0272). Repair or replace damaged connector (Volume 2, WP 0267). Check continuity and for continuity to ground of wire 161 between X16 and the 31-pin OEM harness connector (Volume 2, WP 0272). If continuity is not found or continuity to ground is found, notify SRA to replace engine and transmission wiring harness. Check voltage (22V to 26V) at connector X16 pin 1 (Volume 2, WP 0272). Disconnect connector X16 and turn the ignition ON. Open the cab distribution box to gain access to relay 330-1 (WP 0103).
3.
4.
5.
0024-5
TM 10-3930-675-23-1
0024
ERROR CODE 1474 - STARTER SOLENOID LOCKOUT RELAY DRIVER CIRCUIT FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check for resistance. Remove relay 330-1 and inspect. Check resistance between 330-1 pins 85 and 86. Should be 290 to 350 Ohms. If resistance is not as specified, or relay is damaged, replace 330-1 relay (WP 0103).
330-1 RELAY
85
86
T0226JCH
Figure 2. Starter Solenoid Lockout Relay Circuit Resistance Test. 7. Check for continuity. With the 330-1 relay removed, check continuity at the 330-1 relay socket between pins 85 and XK12 pin 5, and between 86 and XK12 pin 2 (Figure 8 (Volume 2, WP 0272)). a. b. 8. If continuity is not found at either check, remove the relay board and inspect for damage. Replace damaged relay board (WP 0103).
Inspect connectors for damage, dirt, or corrosion. Disconnect the 31- pin OEM harness connector and the actuator harness connector from ECU (794). a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0099).
9.
Check continuity and for continuity to ground between the mounted part 31-pin OEM harness connector pin 20 and the actuator harness connector pin 46. If continuity is not found or continuity to ground is found, notify SRA to replace engine harness. Check continuity. Disconnect the 31-pin harness connector, actuator harness connector and sensor harness connector. Check for continuity between pin 20 and all of the other pins in the 31-pin OEM harness connector. If a short (continuity) is found between any of the pins, notify SRA to replace engine harness.
10.
0024-6
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0024
ERROR CODE 1474 - STARTER SOLENOID LOCKOUT RELAY DRIVER CIRCUIT FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
>100K Ohms
T0227JCH
Figure 3. Starter Solenoid Lockout Relay Circuit Continuity Test. ERROR CODE 1596 - VOLTAGE MONITOR, HIGH VOLTAGE FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 1596 MALFUNCTION Voltage Monitor, High Voltage Failure. CORRECTIVE ACTION 1. 2. Check battery and alternator cable connections for loose connections and corrosion. Tighten battery connections and clean battery terminals as required. Turn ignition switch to OFF position and measure battery voltage from positive (+) terminal to negative (-) terminal. Voltage should be at least 12V. Check each battery in system. If voltage is not as required, charge or replace battery (WP 0128). Turn ignition switch to OFF position and measure battery voltage from positive (+) terminal to negative (-) terminal. Voltage should be +12V. Check voltage while trying to start engine. Voltage should be at least +6V during cranking. Check each battery in system. If voltage is not as required, charge or replace battery (WP 0128).
3.
0024-7
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0024
ERROR CODE 1596 - VOLTAGE MONITOR, HIGH VOLTAGE FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
+12V = STATIC
+6V = START
T0228JCH
Figure 4. Battery Cranking Voltage Test. 4. Place ignition switch in OFF position and install ammeter between alternator and battery. Perform the following to check charging rate of alternator. a. b. c. Check battery voltage at slave receptacle with engine off. Start engine and recheck voltage. Voltage should be slightly higher than voltage checked with engine off. Turn on lights. Check amperage reading on ammeter with engine on. Ammeter should have a positive (more or less) reading depending on charge of batteries. If alternator is not charging properly, replace alternator (WP 0091).
VOLTAGE ENGINE ON> VOLTAGE ENGINE OFF
+AMPERAGE CHARGE WITH ENGINE ON
B+
DC AMMETER LIGHTS ON SLAVE RECEPTACLE

T0229JCH
Figure 5. Alternator Charging Amperage Test. END OF WORK PACKAGE
0024-8
TM 10-3930-675-23-1
0025
FIELD MAINTENANCE TRANSMISSION TEMPERATURE TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0083 WP 0098 WP 0100 References (cont.) WP 0116 WP 0120 Volume 2, WP 0135 Volume 2, WP 0142 Volume 2, WP 0175 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Schematics (Volume 2, WP 0272) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE TRANSMISSION TEMPERATURE TROUBLESHOOTING SYMPTOM
ERROR CODE 637 MALFUNCTION Transmission Sump Temperature Sensor Failure, Open Circuit or Short Circuit to Battery. CORRECTIVE ACTION 1. Check resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 8 and 9 (Figure 4 (Volume 2, WP 0272)). The resistance should be 800 to 1,500 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Inspect connector. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 8 and 9 (Figure 4 (Volume 2, WP 0272)). The resistance should be 800 to 1,500 Ohms. If resistance is not as specified, or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135).
2.
0025-1
TM 10-3930-675-23-1
0025
TRANSMISSION TEMPERATURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1728 and 1729 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check continuity. Disconnect ECU (793). Check the connector and ECU pins 39 and 46 for damage. Check continuity of wires A1728 and A1729A Diagrams, (Figure 4 (Volume 2, WP 0272)). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (WP 0098). Replace open or shorted wire.
4.
ERROR CODE 638 MALFUNCTION Transmission Sump Temperature Sensor Failure, Short Circuit to Chassis. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 8 and 9 and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 800 to 1,500 Ohms and there should be no continuity to ground. If resistance is not as specified, or continuity to ground is present, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check connector and pins. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 8 and 9 and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 800 to 1,500 Ohms and there should be no continuity to ground. If resistance is not as specified, continuity to ground is present, or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity and for continuity to ground of wires 1728 and 1729 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, continuity to ground is present, or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 39 and 46 for damage. Check continuity and for continuity to ground of wires 1728 and A1729A (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0025-2
TM 10-3930-675-23-1
0025
TRANSMISSION TEMPERATURE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 639 MALFUNCTION Converter Output Temperature Sensor Failure, Open Circuit or Short Circuit to Battery. CORRECTIVE ACTION 1. Check resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 12 and 13 (Figure 4 (Volume 2, WP 0272)). Resistance should be 10k to 200k Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check resistance. Disconnect and inspect the 766 temperature sensor located on the transmission bell housing. Check resistance of the 766 temperature sensor between the two pins (Figure 4 (Volume 2, WP 0272)). The resistance should be 10k to 200k Ohms. If resistance is not as specified, or the 766 temperature sensor is damaged, replace the 766 temperature sensor (WP 0120). Inspect the 766 connector and pins for damage and proper connection. Check continuity of wires 17212 and 17213 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire or connector 766 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 46 and 49 for damage. Check continuity of wires A1729A, A1729B, and A17212 (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
2.
3.
4.
0025-3
TM 10-3930-675-23-1
0025
TRANSMISSION TEMPERATURE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 640 MALFUNCTION Converter Output Temperature Sensor Failure, Short Circuit to Chassis. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 12 and 13 and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 10k to 200k Ohms and there should be no continuity to ground. If resistance is not as specified, or continuity to ground is present, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check connector and pins. Disconnect and inspect the 766 temperature sensor located on the transmission bell housing. Check resistance of the 766 temperature sensor between the two pins and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 10k to 200k Ohms and there should be no continuity to ground. If resistance is not as specified, continuity to ground is present, or the 766 temperature sensor is damaged, replace the 766 temperature sensor (WP 0120). Inspect the 766 connector and pins for damage and proper connection. Check continuity and for continuity to ground of wires 17212 and 17213 Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, continuity to ground is present or connector 766 is damaged, notify SRA replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 46 and 49 for damage. Check continuity and for continuity to ground of wires A1729A, A1729B, and A17212 Figure 4 (Volume 2, WP 0272)). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
ERROR CODE 783 MALFUNCTION Sump Temperature Critical Threshold [212F (100C)] Failure.
0025-4
TM 10-3930-675-23-1
0025
TRANSMISSION TEMPERATURE TROUBLESHOOTING - Continued CORRECTIVE ACTION 1. 2. 3. 4. 5. Allow engine and transmission to cool. Check coolant level (TM 10- 3930-675-10). Add coolant as required (TM 10- 3930-675-10). Check radiator top and side grille for mud, snow, or obstructions. Clear obstructions. Check loose coolant hoses and clamps. Tighten or replace as required (WP 0083) and (Volume 2, WP 0142). With engine idling, transmission selector lever in N (Neutral) position, parking brake applied, and engine at operating temperature, check transmission fluid level (TM 10-3930-675-10). Add transmission fluid as required (TM 10-3930-675-10). Enter DIAG EXTRA FUNCT 4(13)" menu and check water level sensor setting. Enter 1" to shut off and 0" to run cooling fan. Check if fording water level sensor is clogged or damaged. Clean and/or replace fording water level sensor (WP 0116).
6.
SYMPTOM
ERROR CODE 795 MALFUNCTION Converter Output Temperature Critical Threshold [248F (120C)] Failure. CORRECTIVE ACTION 1. 2. 3. 4. 5. Allow engine and transmission to cool. Check coolant level (TM 10- 3930-675-10). Add coolant as required (TM 10-3930-675-10). Check radiator top and side grille for mud, snow, or obstructions. Clear obstructions. Check loose coolant hoses and clamps. Tighten or replace as required (WP 0083) and (Volume 2, WP 0142). With engine idling, transmission selector lever in N (Neutral) position, parking brake applied, and engine at operating temperature, check transmission fluid level (TM 10-3930-675-10). Add transmission fluid as required (TM 10-3930-675-10). Enter DIAG EXTRA FUNCT 4(13)" menu and check water level sensor setting. Enter 1" to shut off and 0" to run cooling fan. Check if fording water level sensor is clogged or damaged. Clean and/or replace fording water level sensor (WP 0116).
6.
0025-5
TM 10-3930-675-23-1
0025
TRANSMISSION TEMPERATURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0231JCH
Figure 1. Component Locations. END OF WORK PACKAGE
0025-6
TM 10-3930-675-23-1
0026
FIELD MAINTENANCE TRANSMISSION SPEED SENSORS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0100 WP 0118 WP 0120 Volume 2, WP 0175 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE TRANSMISSION SPEED SENSORS TROUBLESHOOTING SYMPTOM
ERROR CODE 649 MALFUNCTION Engine Speed Sensor Failure, Open Circuit or Short Circuit to Battery. CORRECTIVE ACTION 1. Check resistance. Disconnect connector X173 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X173 between pins 4 and 5 (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check resistance. Disconnect and inspect the 761 engine speed sensor located on the left side of the transmission. Check resistance of the 761 engine speed sensor between the two pins (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms. If resistance is not as specified or the 761 engine speed sensor is damaged, replace the 761 engine speed sensor (WP 0118). Inspect the 761 connector and pins for damage and proper connection. Check continuity of wires 1734 and 1735 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire or connector 761 is damaged, notify SRA to replace engine and transmission wiring harness.
2.
3.
0026-1
TM 10-3930-675-23-1
0026
TRANSMISSION SPEED SENSORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 3 and 19 for damage. Check continuity of wires A1734 and A1735A (Figure 4 (Volume 2, WP 0272)). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
ERROR CODE 650 MALFUNCTION Engine Speed Sensor Failure, Short Circuit to Chassis. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X173 located in the middle panel behind the operators seat. Check resistance at the loose part of connector X173 between pins 4 and 5 and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). The resistance should be 950 to 1,150 Ohms with no continuity to ground. If resistance is not as specified or continuity to ground is present, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check resistance. Disconnect and inspect the 761 engine speed sensor located on the left side of the transmission. Check resistance of the 761 engine speed sensor between the two pins and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms with no continuity to ground. If resistance is not as specified, continuity to ground is present, or the 761 engine speed sensor is damaged, replace the 761 engine speed sensor (WP 0118). Inspect the 761 connector and pins for damaged and proper connection. Check continuity to ground of wires 1734 and 1735 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, continuity to ground is present, or connector 761 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 3 and 19 for damage. Check continuity and continuity to ground of wires A1734 and A1735A (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0026-2
TM 10-3930-675-23-1
0026
TRANSMISSION SPEED SENSORS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 651 MALFUNCTION Engine Speed Sensor Failure, Logical Error. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back to ON position. If ERROR CODE is still present, perform troubleshooting procedures for ERROR CODE 649 in this work package. SYMPTOM
ERROR CODE 652 MALFUNCTION Turbine Speed Sensor Failure, Open Circuit or Short Circuit to Battery. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X173 located in the middle panel behind the operator seat. Check resistance at the loose part of connector X173 between pins 6 and 7 (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check resistance. Disconnect and inspect the 751 turbine speed sensor located on the left side of the transmission. Check resistance of the 751 turbine speed sensor between the two pins (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms. If resistance is not as specified or the 751 turbine speed sensor is damaged, replace the 751 turbine speed sensor (WP 0120). Inspect the 751 connector and pins for damaged and proper connection. Check continuity of wires 1736 and 1737 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire or connector 751 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 3 and 41 for damage. Check continuity and for continuity to ground of wires A1736, A1735A, and A1735B (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0026-3
TM 10-3930-675-23-1
0026
TRANSMISSION SPEED SENSORS TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 653 MALFUNCTION Turbine Speed Sensor Failure, Short Circuit Chassis. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X173 located in the middle panel behind the operators seat. Check resistance at the loose part of connector X173 between pins 6 and 7 and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms with no continuity to ground. If resistance is not as specified or continuity to ground is present, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Inspect sensor. Disconnect and inspect the 751 turbine speed sensor located on the left side of the transmission. Check resistance of the 751 turbine speed sensor between the two pins and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms with no continuity to ground. If resistance is not as specified, continuity to ground is present, or the 751 turbine speed sensor is damaged, replace the 751 turbine speed sensor (WP 0120). Inspect the 751 connector and pins for damage and proper connection. Check continuity and for continuity to ground of wires 1736 and 1737 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, continuity to ground is present, or connector 751 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 3 and 41 for damage. Check continuity and for continuity to ground of wires A1736, A1735A, and A1735B (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0026-4
TM 10-3930-675-23-1
0026
SYMPTOM
ERROR CODE 654 MALFUNCTION Turbine Speed Sensor Failure, Logical Error. CORRECTIVE ACTION Place ignition switch to OFF position for 30 seconds and then back to ON position. If ERROR CODE is still present, perform troubleshooting procedures for ERROR CODE 652 in this work package. SYMPTOM
ERROR CODE 655 MALFUNCTION Internal Speed Sensor Failure, Open Circuit or Short Circuit to Battery. CORRECTIVE ACTION 1. Check resistance. Disconnect connector X173 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X173 between pins 8 and 9 (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check sensor. Disconnect and inspect the 752 internal gear speed sensor located on the left side of the transmission. Check resistance of the 752 internal gear speed sensor between the two pins (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms. If resistance is not as specified or the 752 internal gear speed sensor is damaged, replace the 752 internal gear speed sensor (WP 0120). Inspect the 752 connector and pins for damage and proper connection. Check continuity of wires 1738 and 1739 (Figure 4 (Volume 2, WP 0272). If continuity is not present in either wire or connector 752 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 3 and 42 for damage. Check continuity of wires A1738, A1735A, A1735B, and A1735C (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
2.
3.
4.
0026-5
TM 10-3930-675-23-1
0026
TRANSMISSION SPEED SENSORS TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 656 MALFUNCTION Internal Speed Sensor Failure, Short Circuit to Chassis. CORRECTIVE ACTION 1. Disconnect connector X173 located in the middle panel behind the operators seat. Check resistance at the loose part of connector X173 between pins 8 and 9 and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms with no continuity to ground. If resistance is not as specified or continuity to ground is present, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check sensor and pins. Disconnect and inspect the 752 internal gear speed sensor located on the left side of the transmission. Check resistance of the 752 internal gear speed sensor between the two pins and check pin for continuity to ground (Figure 4 (Volume 2, WP 0272)). Resistance should be 950 to 1,150 Ohms with no continuity to ground. If resistance is not as specified, continuity to ground is present, or the 752 internal gear speed sensor is damaged, replace the 752 internal gear speed sensor (WP 0120). Inspect the 752 connector and pins for damage and proper connection. Check continuity and for continuity to ground of wires 1738 and 1739 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, continuity to ground is present, or connector 752 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 3 and 42 for damage. Check continuity and for continuity to ground of wires A1738, A1735A, and A1735C (Figure 4 (Volume 2, WP 0272)). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
ERROR CODE 657 MALFUNCTION Internal Speed Sensor Failure, Logical Error. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back to ON position.
0026-6
TM 10-3930-675-23-1
0026
TRANSMISSION SPEED SENSORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If ERROR CODE is still present, perform troubleshooting procedures for ERROR CODE 655 in this work package. SYMPTOM
ERROR CODE 658 MALFUNCTION Output Speed Sensor Failure, Open Circuit or Short Circuit to Battery. CORRECTIVE ACTION 1. 2. Ensure circuit breaker F28 is not tripped. Reset circuit breaker. Check for voltage. Access middle panel behind seat and disconnect X173. Turn the ignition on and check voltage (24V) on the mounted part of X173 pin 3 to ground. a. If no voltage (24V) is found, check continuity of wires A472, 472 (Figure 8 (Volume 2, WP 0272)), A1742B (Figure 4 (Volume 2, WP 0272)), and A1742C (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace open or shorted wire.
b. c. 3.
Check connector. Disconnect and inspect the 760 output speed sensor located on the back side of the transmission (Figure 4 (Volume 2, WP 0272)). If the 760 output speed sensor is damaged, replace the 760 output speed sensor (WP 0120). Inspect the 760 connector and pins for damage and proper connection. Check continuity of wires 1731, 1732, and 1733 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in any one wire or connector 761 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector and pins. Disconnect ECU (793). Check the connector and ECU pins 4 and 62 for damage. Check continuity of wires A1731 and A1732 (Figure 4 (Volume 2, WP 0272)). a. b. c. d. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire. Replace the 760 output speed sensor (WP 0120).
4.
5.
0026-7
TM 10-3930-675-23-1
0026
SYMPTOM
ERROR CODE 659 MALFUNCTION Output Speed Sensor Failure, Short Circuit to Chassis. CORRECTIVE ACTION 1. 2. Ensure circuit breaker F28 is not tripped. Reset circuit breaker. Check for voltage. Access middle panel behind seat and disconnect X173. Turn the ignition on and check voltage (24V) on the mounted part of X173 pin 3 to ground. a. If no voltage (24V) is found, check continuity and continuity to ground of wires A472, 472 (Figure 8 (Volume 2, WP 0272)), A1742B (Figure 4 (Volume 2, WP 0272)), and A1742C (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace open or grounded wire.
b. c. 3.
Check for continuity. Disconnect and inspect the 760 output speed sensor located on the back side of the transmission (Figure 4 (Volume 2, WP 0272)). Check each pin of the sensor for continuity to ground. If the 760 output speed sensor is damaged or grounded, replace the 760 output speed sensor (WP 0120). Check connector and pins. Inspect the 760 connector and pins for damage and proper connection. Check continuity and for continuity to ground of wires 1731, 1732, and 1733 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in any one wire, continuity to ground is present, or connector 760 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector pins and wires. Disconnect ECU (793). Check the connector and ECU pins 4 and 62 for damage. Check continuity and for continuity to ground of wires A1731 and A1732 (Figure 4 (Volume 2, WP 0272)). a. b. c. d. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (WP 0100). Replace open or grounded wire. Replace the 760 output speed sensor (WP 0120).
4.
5.
0026-8
TM 10-3930-675-23-1
0026
SYMPTOM
ERROR CODE 660 MALFUNCTION Output Speed Sensor Failure, Logical Error. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back to ON position. If ERROR CODE is still present, perform troubleshooting procedures for ERROR CODE 658 in this work package. SYMPTOM
ERROR CODE 662 MALFUNCTION Output Speed Sensor Failure, Logical Speed Error. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back to ON position. If ERROR CODE is still present, perform troubleshooting procedures for ERROR CODE 652, ERROR CODE 655, and/or ERROR CODE 658.
0026-9
TM 10-3930-675-23-1
0026
TRANSMISSION SPEED SENSORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0231JCH
0026-10
TM 10-3930-675-23-1
0027
FIELD MAINTENANCE TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0099 WP 0100 Volume 2, WP 0135 Volume 2, WP 0175 Volume 2, WP 0267
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING SYMPTOM
ERROR CODE 713 MALFUNCTION Clutch K1 Short Circuit to Battery Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 3 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 3 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1723 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness.
2.
3.
0027-1
TM 10-3930-675-23-1
0027
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check continuity between the loose part of X172 pin 3 and each other pin of X172. First, ensure connectors X172 and 827 are disconnected. There should not be continuity between the pins. If continuity is present in any pin combination continuity check, notify SRA to replace shorted engine and transmission wiring harness. Check connector, pins, and wires. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 32 for damage. Check continuity of wires A1723, A1727A, and A1727b (Volume 2, WP 0267). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (WP 0100). Replace open or shorted wire.
5.
ERROR CODE 714 MALFUNCTION Clutch K1 Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X172 located in the middle seat panel behind the operator's seat. Check for continuity to ground at the loose part of connector X172 at pins 3 and 7. There should not be continuity to ground. If continuity to ground is found, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for continuity. Disconnect and inspect connector 827 located on the top of the transmission. Check continuity at the mounted part of connector 827 between pin 3 and ground and pin 7 and ground (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check for continuity to ground for wires 1723 and 1727 (Volume 2, WP 0267). If continuity to ground is present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 12, 13, and 32 for damage. Check for continuity to ground for wires A1723, A1727A, and A1727B (Volume 2, WP 0267). There should not be continuity to ground. a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0027-2
TM 10-3930-675-23-1
0027
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 715 MALFUNCTION Clutch K1 Open Circuit Failure. CORRECTIVE ACTION 1. Check resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 3 and 7 (Volume 2, WP 0267). Resistance should be 18 to 29 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 3 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1723 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector, pins, and wires. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 32 for damage. Check continuity of wires A1723, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267) . Replace damaged ECU (793) (WP 0100). Replace open, damaged, or shorted wire.
2.
3.
4.
0027-3
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 716 MALFUNCTION Clutch K2 Short Circuit to Battery Failure. CORRECTIVE ACTION 1. Check connector and pins. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 6 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check connector and pins. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 87 between pins 6 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1726 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Ensure connector X172 and 827 are disconnected. Check continuity between the loose part of X172 pin 6 and each other pin of X172. There should not be continuity between the pins. If continuity is present in any pin combination continuity check, notify SRA to replace shorted engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 51 for damage. Check continuity of wires A1726, A1727A, and A1727B (Volume 2, WP 0267) a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
2.
3.
4.
5.
0027-4
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 717 MALFUNCTION Clutch K2 Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Check for continuity. Disconnect connector X172 located in the middle panel behind the operator's seat. Check for continuity to ground at the loose part of connector X172 at pins 6 and 7 (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for continuity. Disconnect and inspect connector 827 located on the top of the transmission. Check continuity at the mounted part of connector 827 between pin 6 and ground and pin 7 and ground (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check for continuity to ground for wires 1726 and 1727 (Volume 2, WP 0267). If continuity to ground is present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 12, 13, and 51 for damage. Check for continuity to ground for wires A1726, A1727A, and A1727B (Volume 2, WP 0267). There should not be continuity to ground. a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0027-5
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 718 MALFUNCTION Clutch K2 Open Circuit Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 6 and 7 (Volume 2, WP 0267). Resistance should be 18 to 29 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 6 and 7 (Volume 2, WP 0267). Resistance should be 18 to 29 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1726 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 51 for damage. Check continuity of wires A1726, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (WP 0100). Replace open, damaged, or shorted wire.
2.
3.
4.
0027-6
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 719 MALFUNCTION Clutch K3 Open Circuit to Battery Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 4 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 4 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Check for continuity. Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1724 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Ensure connectors X172 and 827 are disconnected. Check continuity between the loose part of X172 pin 4 and each other pin of X172. There should not be continuity between the pins. If continuity is present in any pin combination continuity check, notify SRA to replace shorted engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 55 for damage. Check continuity of wires A1724, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (WP 0100). Replace open or shorted wire.
2.
3.
4.
5.
0027-7
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 720 MALFUNCTION Clutch K3 Short Circuit to Chassis Failure CORRECTIVE ACTION 1. Check for continuity. Disconnect connector X172 located in the middle panel behind the operator's seat. Check for continuity to ground at the loose part of connector X172 at pins 4 and 7 (Volume 2, WP 0267). There should not be continuity to ground. Check for continuity. Disconnect and inspect connector 827 located on the top of the transmission. Check continuity at the mounted part of connector 827 between pin 4 and ground and pin 7 and ground (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1724 and 1727 (Volume 2, WP 0267). If continuity is present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 12, 13, and 55 for damage. Check for continuity to ground for wires A1724, A1727A, and A1727B (Volume 2, WP 0267) . There should not be continuity to ground. a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
ERROR CODE 721 MALFUNCTION Clutch K3 Open Circuit Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 4 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0267).
0027-8
TM 10-3930-675-23-1
0027
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 4 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1724 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 55 for damage. Check continuity of wires A1724, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open, damaged, or shorted wire.
3.
4.
ERROR CODE 729 MALFUNCTION Clutch K4 Short Circuit to Battery Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 2 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 2 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1722 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Ensure connectors X172 and 827 are disconnected. Check continuity between the loose part of X172 pin 2 and each other pin of X172. There should not be continuity between the pins. If continuity is present in any pin combination continuity check, notify SRA to replace shorted engine and transmission wiring harness.
2.
3.
4.
0027-9
TM 10-3930-675-23-1
0027
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 51 for damage. Check continuity of wires A1722, A1727A, and A1727B (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
6.
SYMPTOM
ERROR CODE 730 MALFUNCTION Clutch K4 Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Check for continuity. Disconnect connector X172 located in the middle panel behind the operator's seat. Check for continuity to ground at the loose part of connector X172 at pins 2 and 7 (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for continuity. Disconnect and inspect connector 827 located on the top of the transmission. Check continuity at the mounted part of connector 827 between pin 2 and ground and pin 7 and ground (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check for continuity to ground for wires 1722 and 1727 (Volume 2, WP 0267). If continuity to ground is present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 12, 13, and 56 for damage. Check for continuity to ground for wires A1722, A1727A, and harness (Volume 2, WP 0267). There should not be continuity to ground. a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0027-10
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 731 MALFUNCTION Clutch K4 Open Circuit Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 2 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 2 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1722 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness (Volume 2, WP 0267). Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 56 for damage. Check continuity of wires A1722, A1727A, and A1727B (Volume 2, WP 0267). a. b. SYMPTOM Replace damaged ECU (793) (WP 0100). Replace open, damaged, or shorted wire.
2.
3.
4.
ERROR CODE 732 MALFUNCTION Clutch KV Short Circuit to Battery Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector pins 5 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175).
0027-11
TM 10-3930-675-23-1
0027
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check for resistance. Disconnect and inspect connector 827 located on top of the transmission. Check resistance at the mounted part of connector 827 between pins 5 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damaged and proper connection. Check continuity of wires 1725 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness (Volume 2, WP 0267). Check for continuity. ensure connector X172 and 827 are disconnected. Check continuity between the loose part of X172 pin 5 and each other pin of X172. There should not be continuity between the pins. If continuity is present in any pin combination continuity check, notify SRA to replace shorted engine and transmission wiring harness (Volume 2, WP 0267). Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 9 for damage. Check continuity of wires A1725, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
3.
4.
5.
ERROR CODE 733 MALFUNCTION Clutch KV Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Check for continuity. Disconnect connector X172 located in the middle panel behind the operator's seat. Check for continuity to ground at the loose part of connector X172 at pins 5 and 7 (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found, move the cab to transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for continuity. Disconnect and inspect connector 827 located on the top of the transmission. Check continuity at the mounted part of connector 827 between pin 5 and ground and pin 7 and ground (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity to ground for wires 1725 and 1727 (Volume 2, WP 0267). If continuity to ground is present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness (Volume 2, WP 0267).
2.
3.
0027-12
TM 10-3930-675-23-1
0027
TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 12, 13, and 9 for damage. Check for continuity to ground for wires A1725, A1727A, and A1727B (Volume 2, WP 0267). There should be no continuity. a. b. c. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0099). Replace open, grounded, or shorted wire.
ERROR CODE 734 MALFUNCTION
CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 5 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 5 and 7 (Volume 2, WP 0267). Resistance should be between 18 and 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1725 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 9 for damage. Check the continuity of wires A1725, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open, damaged, or shorted wire.
2.
3.
4.
0027-13
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 735 MALFUNCTION Clutch KR Short Circuit to Battery Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 1 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 1 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pin for damage and proper connection. Check continuity of wires 1721 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Ensure connectors X172 and 827 are disconnected. Check continuity between the loose part of X172 pin 1 and each other pin of X172. There should not be continuity between the pins. If continuity is present in any pin combination continuity check, notify SRA to replace shorted engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 10 for damage. Check continuity of wires A1721, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
2.
3.
4.
5.
0027-14
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 736 MALFUNCTION Clutch KR Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Check for continuity. Disconnect connector X172 located in the middle panel behind the operator's seat. Check for continuity to ground at the loose part of connector 172 at pins 1 and 7 (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for continuity. Disconnect and inspect connector 827 located on the top of the transmission. Check continuity at the mounted part of connector 827 between pin 1 and ground and pin 7 and ground (Volume 2, WP 0267). There should not be continuity to ground. If continuity to ground is found or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check for continuity to ground for wires 1721 and 1727 (Volume 2, WP 0267). If continuity to ground is present in either wire or connector 827 is damaged, notify SRA to replace grounded engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 12, 13, and 10 for damage. Check for continuity to ground for wires A1721, A1727A, and A1727B (Volume 2, WP 0267). There should not be continuity to ground. a. b. c. Repair or replace damaged harness (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
2.
3.
4.
0027-15
TM 10-3930-675-23-1
0027
SYMPTOM
ERROR CODE 737 MALFUNCTION Clutch KR Open Circuit Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operator's seat. Check resistance at the loose part of connector X172 between pins 1 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified, move the cab to the transport position (TM 10-3930-675-10) and remove the transmission front access cover (Volume 2, WP 0175). Check for resistance. Disconnect and inspect connector 827 located on the top of the transmission. Check resistance at the mounted part of connector 827 between pins 1 and 7 (Volume 2, WP 0267). Resistance should be 18 to 20 Ohms. If resistance is not as specified or the 827 connector is damaged, replace the transmission (Volume 2, WP 0135). Inspect the 827 connector and pins for damage and proper connection. Check continuity of wires 1721 and 1727 (Volume 2, WP 0267). If continuity is not present in either wire or connector 827 is damaged, notify SRA to replace engine and transmission wiring harness. Check for continuity. Disconnect ECU (793). Check the connector and ECU pins 12, 13, and 10 for damage. Check continuity of wires A1721, A1727A, and A1727B (Volume 2, WP 0267). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (Volume 2, WP 0267). Replace open, damaged, or shorted wire.
2.
3.
4.
END OF WORK PACKAGE
0027-16
TM 10-3930-675-23-1
0028
FIELD MAINTENANCE MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0004 References (cont.) WP 0100 WP 0103 WP 0132 Volume 2, WP 0217 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to (WP 0004) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 618 MALFUNCTION Signal from Gear Selector Not Correct. CORRECTIVE ACTION 1. Check position signals. Enter "DIAG GEARBOX 2(12)" in the diagnostic menu and check the shift lever position signals. If signals from shift lever are not correct, continue with next steps. Check connection to cab distribution box behind the left rear panel of the cab. Disconnect X28 from the back of the cab distribution box.
2.
0028-1
TM 10-3930-675-23-1
0028
MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Check continuity. On the loose end of X28 check continuity between specified pins and continuity of each pin to ground (Figure 4 (Volume 2, WP 0272)). a. With the shift lever in neutral, check continuity between X28 pin 9 and X28 pin 7. There should be continuity between each specified pin and shift lever combination and no continuity to ground. With the shift lever in forward, check continuity between X28 pin 9 and X28 pin 8. If continuity is not found on any of the checks, gain access to XS1 by removing the kick panels in front of the steering column. Make the same continuity checks on connector XS1 using the same pin numbering and shifter lever positions (Figure 9 (Volume 2, WP 0272)). With the shift lever in reverse, check continuity between X28 pin 9 and X28 pin 6. If continuity checks are not as specified, replace shift lever (Volume 2, WP 0267).
b.
c. 4.
Check voltage. Reconnect X28 and check voltage (24V) at X28 pin 9 with the ignition ON (Figure 9 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, check continuity of wires A284, A284A, and 289 (Figure 9 (Volume 2, WP 0272)). Repair or replace damaged connectors (Volume 2, WP 0267). Replace open or shorted wire.
5.
Check for voltage (24V) at the following pins with the ignition on (Figure 9 (Volume 2, WP 0272)): a. With the shift lever in neutral, X174 pin 7. If no voltage (24V) is found at any one pin, check continuity of wires 288, 287, 286, A288, A287, A286, 461, 462, and 463 (Figure 9 (Volume 2, WP 0272)). With the shift lever in forward, X174 pin 6. Repair or replace damaged connector (Volume 2, WP 0267). With the shift lever in reverse, X174 pin 8. Replace open or shorted wire or harness (Volume 2, WP 0267).
b. c. 6.
Inspect connector X174 pins 6, 7, and 8 for connection or damage (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Check continuity. Disconnect ECU (793). Check the connector and ECU pins 43, 64, and 67 for damage. Check continuity of wires A1746, A1747, and A1748 (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
7.
0028-2
TM 10-3930-675-23-1
0028
MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 622 MALFUNCTION Feedback Signal from 2WD/ 4WD Switch Not Correct. CORRECTIVE ACTION 1. Check for proper signals. Enter "DIAG GEARBOX 8(12)" in the diagnostic menu and check the drive position signals while switching between 2WD and 4WD steering modes. If signals do not change, continue with next steps. Ensure circuit breaker F28 is not tripped. Reset circuit breaker. Check for voltage. Access middle panel behind seat and disconnect X173. Turn the ignition on and check voltage (24V) on the mounted part of X173 pin 3 and pin 10 to ground. a. If no voltage (24V) is found, check continuity of wires A472, 472 (Figure 8 (Volume 2, WP 0272)), A1724B (Figure 4 (Volume 2, WP 0272)), and A1742C (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace open or shorted wire.
2. 3.
b. c. 4.
Check voltage (24V) at X173 pin 11 (Figure 4 (Volume 2, WP 0272)) with the engine running and switching back and forth between 2WD and 4WD steering modes. Voltage (24V) should be present while in 2WD and no voltage while in 4WD steering mode. If voltage checks are not correct: a. Locate the 7207 sensor at the bottom of the transmission. Check the connector for proper connection to 7207 sensor. Check continuity of wires 17310 and 17311 (Figure 4 (Volume 2, WP 0272)). If wires 17310 and 17311 are open or shorted, notify SRA to replace engine and transmission wiring harness. If connection and wire continuity is correct, replace 7207 sensor (WP 0132).
b. c. 5.
Check the connector and ECU pin 29 for damage. Disconnect ECU (793). Check continuity of wire A17311 (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or shorted wire.
0028-3
TM 10-3930-675-23-1
0028
SYMPTOM
ERROR CODE 745 MALFUNCTION Backup Alarm Control Circuit, Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Ensure circuit breaker F10 is not tripped.
NOTE
This ERROR CODE may be active if the backup alarm/lights remain on. Reset circuit breaker. 2. Check for ERROR CODE displayed. Access the middle panel behind operators seat and disconnect X177. Turn the ignition on and check for ERROR CODE 745. (There may be several ERROR CODES that display when connector X177 is disconnected). a. b. c. 3. If ERROR CODE 745 is no longer active, continue with Step 3. If ERROR CODE 745 is still active, check for continuity to ground for wire A17710 (Figure 4 (Volume 2, WP 0272)). If wire A17710 is not grounded, replace ECU (793) (WP 0100).
Check for continuity. Access relay 305 in the cab distribution box. Remove the 305 relay and disconnect connector X177. Check for continuity to ground for wires 16010 (Figure 4 (Volume 2, WP 0272)), A1507 (Figure 5 (Volume 2, WP 0272)), 293, and A55 (Figure 14 (Volume 2, WP 0272)). a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace grounded wire.
0028-4
TM 10-3930-675-23-1
0028
SYMPTOM
ERROR CODE 746 MALFUNCTION Backup Alarm Control Circuit, Short Circuit to Battery Failure. CORRECTIVE ACTION 1. 2. Backup Alarm Control Circuit, Short Circuit to Battery Failure. Reset circuit breaker. Check for ERROR CODE displayed. Access the middle panel behind operators seat and disconnect X177. Turn the ignition on and check for ERROR CODE 746 (there may be several ERROR CODES that display when connector X177 is disconnected). a. If ERROR CODE 746 is no longer active, access relay 305 in the cab distribution box. Remove the 305 relay and test the resistance between pins 85 and 86. Resistance should be 290 to 350 Ohms. Replace relay if resistance is not as specified (WP 0103). If ERROR CODE 746 is still active, replace ECU (793) (WP 0100).
b. c.
0028-5
TM 10-3930-675-23-1
0028
SYMPTOM
ERROR CODE 747 MALFUNCTION Backup Alarm Control Circuit, Open Circuit Failure. CORRECTIVE ACTION 1. 2. Ensure circuit breaker F10 is not tripped. Reset circuit breaker. Check for resistance. Access relay 305 in the cab distribution box. Remove the 305 relay and check resistance between pins 85 and 86. Resistance should be 290 to 350 Ohms. Replace relay if resistance is not as specified (WP 0103). Check for voltage. With the 305 relay still removed, check voltage (24V) at relay socket pin 86 with the ignition on. a. b. c. d. 4. If no voltage (24V) is found, check circuit breaker F10 and continuity of wires A57 and A57A (Figure 14 (Volume 2, WP 0272)). Replace damaged or nonoperational circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
3.
Check for continuity. With the 305 relay still removed, check continuity between the 305 relay socket pin 86 and connector XK5 pin 2 and 305 relay socket pin 85 and connector XK5 pin 5. a. b. If no continuity is found at either check, remove the relay board and check the underside for damage. Replace damaged relay board (WP 0103).
5.
Inspect connectors X29, X160, and X177 for damage and connection. Check continuity of wires A55, 293 (Figure 14 (Volume 2, WP 0272)), 16010, and A17710 (Figure 4 (Volume 2, WP 0272)). a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.
0028-6
TM 10-3930-675-23-1
0028
SYMPTOM
ERROR CODE 761 MALFUNCTION 2WD/4WD Connection Valve Circuit, Short Circuit to Chassis Failure. CORRECTIVE ACTION 1. Check for continuity. Disconnect connector X172 located in the middle panel behind the operators seat. Check for continuity to ground at the loose part of connector X172 at pins 14 and 15 (Figure 4 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. 2. If continuity to ground is found, locate the 2WD/4WD connection valve at the left rear of the transmission. Inspect the solenoid (606) and connector for damage. Replace damaged 606 solenoid (Volume 2, WP 0217).
Check for continuity. Disconnect and inspect connector 606. Check continuity at the 606 solenoid between each pin and ground (Figure 4 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. If continuity to ground, replace grounded 606 solenoid (Volume 2, WP 0217). If the 606 connector is damaged, notify SRA to replace engine and transmission wiring harness.
3.
Inspect the 606 connector and pins for damaged and proper connection. Check for continuity to ground for wires 17214 and 17215 (Figure 4 (Volume 2, WP 0272)). If continuity to ground is present in either wire or connector 606 is damaged, notify SRA to replace engine and transmission wiring harness. Check connector, pins, and wires. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 11 and 53 for damage. Check for continuity to ground for wires A17214 and A17215 (Figure 4 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
4.
0028-7
TM 10-3930-675-23-1
0028
SYMPTOM
ERROR CODE 762 MALFUNCTION 2WD/4WD Connection Valve Circuit, Short Circuit to Battery Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operators seat. Check for resistance at the loose part of connector X172 at pins 14 and 15 (Figure 4 (Volume 2, WP 0272)). Resistance should be 30 to 40 Ohms. a. b. 2. If resistance is not as specified, locate the 2WD/4WD connection valve at the left rear of the transmission. Inspect the solenoid (606) and connector for damage. Replace damaged 606 solenoid (Volume 2, WP 0217).
Check for resistance. Disconnect and inspect connector 606. Check resistance of the 606 solenoid between each pin of the solenoid (Figure 4 (Volume 2, WP 0272)). Resistance should be 30 to 40 Ohms. a. b. If resistance is not as specified, replace 606 solenoid (Volume 2, WP 0217). If the 606 connector is damaged, notify SRA to replace engine and transmission wiring harness.
3.
Check for continuity. Disconnect the 606 connector and connector X172. Check for continuity on the loose part of X172 pin 14 and all of the other pins of the connector. Do the same check for pin 15 (Figure 4 (Volume 2, WP 0272)). There should not be continuity between the pins. If continuity is present between pins, notify SRA to replace engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 11 and 53 for damage. Check for continuity of wires A17214 and A17215 (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open or grounded wire.
4.
0028-8
TM 10-3930-675-23-1
0028
SYMPTOM
ERROR CODE 763 MALFUNCTION 2WD/4WD Connection Valve Circuit, Open Circuit Failure. CORRECTIVE ACTION 1. Check for resistance. Disconnect connector X172 located in the middle panel behind the operators seat. Check for resistance at the loose part of connector X172 at pins 14 and 15 (Figure 4 (Volume 2, WP 0272)). Resistance should be 30 to 40 Ohms. a. b. 2. If resistance is not as specified, locate the 2WD/4WD connection valve at the left rear of the transmission. Inspect the solenoid (606) and connector for damage. Replace damaged 606 solenoid (Volume 2, WP 0217).
Check for resistance. Disconnect and inspect connector 606. Check resistance of the 606 solenoid between each pin of the solenoid (Figure 4 (Volume 2, WP 0272)). Resistance should be 30 to 40 Ohms. a. b. If resistance is not as specified, replace 606 solenoid (Volume 2, WP 0217). If the 606 connector is damaged, notify SRA to replace engine and transmission wiring harness.
3.
Inspect the 606 connector and pins for damage and proper connection. Check continuity of wires 17214 and 17215 (Figure 4 (Volume 2, WP 0272)). If continuity is not present in either wire, notify SRA to replace engine and transmission wiring harness. Check for continuity. Disconnect ECU (793) and connector X172. Check the connector and ECU pins 11 and 53 for damage. Check continuity of wires A17214 and A17215 (Figure 4 (Volume 2, WP 0272)). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (793) (WP 0100). Replace open wire.
4.
END OF WORK PACKAGE
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TM 10-3930-675-23-1
0029
FIELD MAINTENANCE INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING
INITIAL SETUP: References LO 10-3930-675-13 WP 0005 WP 0047 References (cont.) Volume 2, WP 0135 Volume 2, WP 0136
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 777 MALFUNCTION Internal Transmission Failure at Clutch K1. CORRECTIVE ACTION 1. Check transmission oil level. a. b. 2. Consult the Lubrication Instructions (LO 10-3930-675-13) for the proper oil type and filling procedure. Fill transmission to proper oil level.
Inspect all electrical connections on the transmission for loose or unplugged connectors. a. b. Connect disconnected electrical connectors. Notify SRA to replace engine and transmission wiring harness.
3.
Perform troubleshooting procedure for ERROR CODES 655, 656, 658, and 659. a. b. Correct any problems found during the ERROR CODE troubleshooting procedures. Replace transmission assembly (Volume 2, WP 0135).
0029-1
TM 10-3930-675-23-1
0029
INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING - Continued
SYMPTOM
3.
SYMPTOM
3.
Perform troubleshooting procedure for ERROR CODES 655, 656, 658, and 659. Correct any problems found during the ERROR CODE troubleshooting procedures. Replace transmission assembly (Volume 2, WP 0135).
0029-2
TM 10-3930-675-23-1
0029
INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING - Continued SYMPTOM
3.
Perform troubleshooting procedure for ERROR CODEs 655, 656, 658, and 659. a. b. Correct any problems found during the ERROR CODE troubleshooting procedures. Replace transmission assembly (Volume 2, WP 0135).
SYMPTOM
ERROR CODE 781 MALFUNCTION Internal Transmission Failure at Clutch KV. CORRECTIVE ACTION 1. Check transmission oil level. a. b. 2. Consult the Lubrication Instructions (LO 10-3930-675-13) for the proper oil type and filling procedure . Fill transmission to proper oil level.
3.
0029-3
TM 10-3930-675-23-1
0029
INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 782 MALFUNCTION Internal Transmission Failure at Clutch KR. CORRECTIVE ACTION 1. Check transmission oil level. a. b. 2. Consult the Lubrication Instructions for the proper oil type and filling procedure (WP 0047) (TM 10-3930-675-10). Fill transmission to proper oil level.
3.
SYMPTOM
ERROR CODE 845 MALFUNCTION Clutch Failure Detected During Calibration. CORRECTIVE ACTION
NOTE
ECU (793) will indicate which clutch is affected on the display with this ERROR CODE. Perform transmission calibration several times to see if the calibration process will complete (Volume 2, WP 0136). If calibration procedure continues to trip ERROR CODE 845, replace the transmission (Volume 2, WP 0135).
0029-4
TM 10-3930-675-23-1
0029
INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 846 MALFUNCTION Clutch Adjustment Data Lost. CORRECTIVE ACTION
NOTE
ECU (793) is not able to read the correct clutch adjustment parameters due to a replacement of ECU (793) or a problem during the last data saved. Perform transmission calibration (Volume 2, WP 0136). END OF WORK PACKAGE
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TM 10-3930-675-23-1
0030
FIELD MAINTENANCE BRAKE SYSTEM TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0005 References (cont.) WP 0103 Volume 2, WP 0159 Volume 2, WP 0204 Volume 2, WP 0245 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.
0030-1
TM 10-3930-675-23-1
0030
TROUBLESHOOTING PROCEDURE BRAKE SYSTEM TROUBLESHOOTING SYMPTOM
ERROR CODE 118 MALFUNCTION Brake System Pressure, Circuit 1 and Circuit 2 Failure CORRECTIVE ACTION 1. 2. Check if accumulator evacuation valves are open (Volume 2, WP 0204). Close accumulator evacuation valves. Start engine and allow brake pressure to build up. Press on the service brake pedal several times to check for pressure. If no pressure felt on service brake pedal, perform brake pressure tests (Volume 2, WP 0245)and troubleshooting (WP 0004). Enter EXTRA FUNC 7(13)" in the diagnostic menu and check status of both brake circuits. A 0" at either brake circuit would indicate an open pressure switch due to low brake pressure, faulty pressure switch or open circuit. Check circuit breaker F3 for trip. Reset circuit breaker as required. Start engine and allow brake pressure to build up. Check voltage (24V) at X150 pins 9 and 10 (Figure 2 (Volume 2, WP 0272)). a. b. 6. If no voltage (24V) is found, proceed with step 6. If voltage (24V) is present, disconnect ECU (790) connector 1 and inspect pins 40 and 41 for damage (Figure 2 (Volume 2, WP 0272)).
3.
4. 5.
Check voltage (24V) at X18 pin 1 (Figure 10 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, check circuit breaker F3 and continuity of wires A266 and A181. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
7.
Check voltage (24V) at X18 pins 2 and 3 (Figure 10 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found at either pin, remove panel in front of the brake pedals and check connections at the brake pressure switches 204-1 and 204-2 (Volume 2, WP 0159). With the brake pressure built up, check continuity of pressure switches 204-1 and 204-2 (Volume 2, WP 0267). Replace faulty pressure switch (Volume 2, WP 0159).
8.
Check continuity of wires 181, 182, 183, A182, A183, 295, 296, A1509, and A15010 (Figure 2 and Figure 10 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
0030-2
TM 10-3930-675-23-1
0030
BRAKE SYSTEM TROUBLESHOOTING - Continued SYMPTOM
EXTRA FUNCT.
7(13) 0 0
BRAKE CIRCUIT 1 BRAKE CIRCUIT 2
ERROR CODE 119 MALFUNCTION Brake System Pressure, Circuit 1 Failure CORRECTIVE ACTION 1. 2. 3. Check if accumulator evacuation valves are open (Volume 2, WP 0204). Close accumulator evacuation valves. Check brake system pressures at test points 1 and 2 (Volume 2, WP 0245). If pressure not as specified, perform brake system troubleshooting (WP 0004). Enter EXTRA FUNC 7(13)" in the diagnostic menu and check status of both brake circuits. A 0" at either brake circuit would indicate an open pressure switch due to low brake pressure, faulty pressure switch, or open circuit. Check circuit breaker F3 for trip. Reset circuit breaker as required. Start engine and allow brake pressure to build up. Check voltage (24V) at X150 pin 9 (Figure 2 (Volume 2, WP 0272)). a. b. 6. If no voltage (24V) is found, proceed with step 6. If voltage (24V) is present, disconnect ECU (790) connector 1 and inspect pin 40 for damage (Figure 2 (Volume 2, WP 0272)).
4. 5.
Check voltage (24V) at X18 pin 1 (Figure 10 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, check circuit breaker F3 and continuity of wires A266 and A181. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
7.
Check voltage (24V) at X18 pin 2 (Figure 10 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, remove panel in front of the brake pedals and check connections at the brake pressure switches 204-1 and 204-2 (Volume 2, WP 0159). With the brake pressure built up, check continuity of pressure switch 204-1 (Volume 2, WP 0267). Replace faulty pressure switch (Volume 2, WP 0159).
0030-3
TM 10-3930-675-23-1
0030
BRAKE SYSTEM TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Check continuity of wires 181, 182, A182, 295, and A1509 (Figure 2 and Figure 10 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
SYMPTOM
EXTRA FUNCT.
7(13) 0 0
BRAKE CIRCUIT 1 BRAKE CIRCUIT 2
ERROR CODE 120 MALFUNCTION Brake System Pressure, Circuit 2 Failure CORRECTIVE ACTION 1. 2. 3. Check if accumulator evacuation valves are open (Volume 2, WP 0204). Close accumulator evacuation valves. Check brake system pressures at test points 1 and open (Volume 2, WP 0245). If pressure not as specified, perform brake system troubleshooting (WP 0005). Enter EXTRA FUNC 7(13)" in the diagnostic menu and check status of both brake circuits. A 0" at either brake circuit would indicate an open pressure switch due to low brake pressure, faulty pressure switch or open circuit.
0030-4
TM 10-3930-675-23-1
0030
BRAKE SYSTEM TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. 5. Check circuit breaker F3 for trip. Reset circuit breaker as required. Start engine and allow brake pressure to build up. Check voltage (24V) at X150 pin 10 (Volume 2, WP 0272). a. b. 6. If no voltage (24V) is found, proceed with step 6. If voltage (24V) is present, disconnect ECU (790) connector 1 and inspect pin 41 for damage (Volume 2, WP 0272).
Check voltage (24V) at X18 pin 1 damage (Volume 2, WP 0272). a. b. c. If no voltage (24V) is found, check circuit breaker F3 and continuity of wires A266 and A181. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).
7.
Check voltage (24V) at X18 pin 3 (Volume 2, WP 0272). a. b. c. If no voltage (24V) is found, remove panel in front of the brake pedals and check connections at the brake pressure switches 204-1 and 204-2 (Volume 2, WP 0159). With the brake pressure built up, check continuity of pressure switch 204-2 (Volume 2, WP 0267). Replace faulty pressure switch (Volume 2, WP 0159).
8.
Check continuity of wires 181, 183, A183, 296, and A15010 (Volume 2, WP 0272). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
0030-5
TM 10-3930-675-23-1
0030
BRAKE SYSTEM TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0233JCH
0030-6
TM 10-3930-675-23-1
0031
FIELD MAINTENANCE AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0009 WP 0048 WP 0084 WP 0088 References (cont.) WP 0100 WP 0117 WP 0131 Volume 2, WP 0175 Volume 2, WP 0208 Volume 2, WP 0214 Volume 2, WP 0267 Volume 2, WP 0272
WARNING
Use caution when checking wheel and hub for extreme heat. Failure to do so may cause serious burns.
NOTE
0031-1
TM 10-3930-675-23-1
0031
TROUBLESHOOTING PROCEDURE AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING SYMPTOM
ERROR CODE 191 MALFUNCTION Temperature in Front Axle Above Critical Threshold. CORRECTIVE ACTION 1. Enter diagnostic menu "EXTRA FUNCT 12(13)". Check the temperature of "WHEEL END FRONT". a. b. c. 2. The normal temperature should be under 95F (35C). If the temperature reads between 95 to 120F (35 to 49C), check the wheel hubs for temperature above 203F (95C). A reading of 155 indicates a possible short across the temperature sensor or circuit.
Enter diagnostic menu "EXTRA FUNCT 12(13)" to determine the brake cooling status. a. b. Under normal or higher ambient temperatures, the "BRAKE COOLING" should be "1". Temperature should be under 95F (35C). If the value is "0", perform troubleshooting procedure for ERROR CODE 414 in Table 3 of this work package.
3.
Enter diagnostic menu "EXTRA FUNCT 4(13)" to determine the status of the fording switch. (Fording switch will cut off the cooling fan.). a. b. The normal value should be "1". If the value is "0", perform troubleshooting procedure for ERROR CODE 426 (WP 0009).
4.
Locate the temperature sensor 762-1 inside the left front hub. Disconnect the sensor and check the resistance of the sensor. Check resistance to ground. a. b. c. The sensor should have a measurable resistance but not shorted or open. The sensor should not have continuity to ground. Replace sensor if grounded, shorted, or open (WP 0117).
5.
Disconnect the ECU (790) connector 1 and the 762-1 sensor. Check for continuity to ground at ECU (790) connector 1 at pin 23 (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If continuity to ground, isolate and check the following wires. Check for continuity to ground at wire A1562 (Figure 2 (Volume 2, WP 0272) ). Check for continuity to ground at X156 pin 2 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace shorted sensor harness (WP 0117).
6.
Enter the diagnostic menu "EXTRA FUNCT 11(13)". Check the fan operation. Use the +/- keys to change the fan speed and observe if the fan speed changes.
0031-2
TM 10-3930-675-23-1
0031
AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. 7. If fan speed does not change, perform troubleshooting procedures for ERROR CODE 166 and 167 (WP 0009). If fan operates properly, replace front brake cooling bypass valve and filter (Volume 2, WP 0208).
Check hydraulic pressure at cooling fan hydraulic pump located at the left front of engine. Pressure should be 2,540 psi (175 bar) at full throttle with the fan at 100% "EXTRA FUNCT 11(13)". a. b. If pressure is not as specified or pressure does not change when changing fan speeds, replace cooling fan flow control valve (Volume 2, WP 0214). Perform cooling fan hydraulic pump maintenance and/or replacement (WP 0088).
SYMPTOM
ERROR CODE 192 MALFUNCTION Temperature in Rear Axle Above Critical Threshold. CORRECTIVE ACTION 1. Enter diagnostic menu "EXTRA FUNCT 12(13)". Check the temperature of WHEEL END REAR. a. b. c. 2. The normal temperature should be under 95F (35C). If the temperature reads between 95 to 120F (35 to 49C), check the wheel hubs for temperature above 203F (95C). A reading of 155 indicates a possible short across the temperature sensor or circuit.
Enter diagnostic menu "EXTRA FUNCT 12(13)" to determine the brake cooling status. a. b. Under normal or higher ambient temperatures, the "BRAKE COOLING" should be "1". Temperature should be under 95F (35C). If the value is "0", perform troubleshooting procedure for ERROR CODE 414 in Table 3 of this work package.
3.
Enter diagnostic menu "EXTRA FUNCT 4(13)" to determine the status of the fording switch. (Fording switch will cut off the cooling fan.) a. b. The normal value should be "1". If the value is "0", perform troubleshooting procedure for ERROR CODE 426 (WP 0009).
4.
Locate the temperature sensor 762-1 inside the left front hub. Disconnect the sensor and check the resistance of the sensor. Check resistance to ground. a. b. c. The sensor should have a measurable resistance but not be shorted or open. The sensor should not have continuity to ground. Replace sensor if grounded, shorted, or open (WP 0117).
0031-3
TM 10-3930-675-23-1
0031
AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect the ECU (790) connector 1 and the 762-2 sensor. Check for continuity to ground at ECU (790) connector 1 at pin 29 (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. f. 6. If continuity to ground, isolate and check the following wires. Check for continuity to ground at wire A1561 (Figure 2 (Volume 2, WP 0272)). Check for continuity to ground at X156 pin 1 (Figure 2 (Volume 2, WP 0272) ). Check for continuity to ground at X168 pin 1 (WP 0048)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace shorted sensor harness (WP 0131).
Enter the diagnostic menu "EXTRA FUNCT 11(13)". Check the fan operation. Use the +/- keys to change the fan speed and observe if the fan speed changes. a. b. If fan speed does not change, perform troubleshooting procedures for ERROR CODE 166 and 167 (WP 0009). If fan operates properly, replace front brake cooling bypass valve and filter (Volume 2, WP 0208).
7.
Check hydraulic pressure at cooling fan hydraulic pump located at the left front of engine. Pressure should be 2,540 psi (175 bar) at full throttle with the fan at 100% "EXTRA FUNCT 11(13)". a. b. If pressure is not as specified or pressure does not change when changing fan speeds, replace cooling fan flow control valve (Volume 2, WP 0214). Perform cooling fan hydraulic pump maintenance and/or replacement (WP 0088).
SYMPTOM
ERROR CODE 414 MALFUNCTION Brake Cooling Bypass Valve, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 414 is an information type ERROR CODE. If may not activate for the operator. The operator may report the ERROR CODES 191 or 192 (brake overheating). Enter "DIAG STEERING 2(16)" in the diagnostic menu to verify the code or enable the information type codes in the Initialization menu. 1. Test circuit. Place a jumper wire at connector X156 between pins 2 and 3 on the mounted part of the connector. DO NOT disconnect X156. This will activate the brake cooling circuit.
0031-4
TM 10-3930-675-23-1
0031
AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check voltage (24V) at X156 pin 4 (Figure 2 (Volume 2, WP 0272)). a. b. c. 3. If no voltage (24V) is found, move the cab to the transport position to access X168 under the cover plate. Disconnect X168 pin 4 wire BU and recheck. If voltage is still not found, disconnect X156 and check wire BU for continuity to ground (Figure 2 (Volume 2, WP 0272)). Replace grounded X156 to X168 cable (Volume 2, WP 0267).
Check resistance. Disconnect the rear brake cooling bypass solenoid 6049-2 located under the vehicle just behind the cab. Check resistance at X168 between pins 3 and 4. Resistance should be 26 to 32 Ohms. a. b. c. d. If resistance is not as specified, remove the radiator splash shield to access the front brake cooling bypass valve (WP 0084). Disconnect brake cooling bypass solenoid 6049-1 and check resistance of solenoid coil. Resistance should be 36 to 32 Ohms with no continuity to ground. If resistance is as specified, check wires GY and BK to the 6049-1 connector for short or ground (Figure 2 (Volume 2, WP 0272)). Replace shorted or grounded front brake cooling bypass valve or connector cable (Volume 2, WP 0267).
4.
Check resistance. Disconnect the rear brake cooling bypass solenoid 6049-2 and check resistance of solenoid coil. Resistance should be 26 to 32 Ohms with no continuity to ground. a. b. c. If resistance is not as specified, replace the rear brake cooling bypass valve (Volume 2, WP 0175). If resistance is as specified, check wires GY and BK to the 6049-2 connector for short or ground (Figure 2 (Volume 2, WP 0272)). Replace shorted or grounded 6049-2 connector cable (Volume 2, WP 0267).
5.
Check wire A1564 (Figure 2 (Volume 2, WP 0272)) and wires 16012 and A17712 (Figure 5 (Volume 2, WP 0272)) for continuity and for continuity to ground. a. b. Replace damaged or grounded wire. Repair or replace damaged connector (Volume 2, WP 0267).
6.
END OF WORK PACKAGE
0031-5/6 blank
TM 10-3930-675-23-1
0032
FIELD MAINTENANCE STEERING VALVE CIRCUIT TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 WP 0037 WP 0100 WP 0103 Volume 2, WP 0155 References (cont.) Volume 2, WP 0168 Volume 2, WP 0170 Volume 2, WP 0175 Volume 2, WP 0204 Volume 2, WP 0212 Volume 2, WP 0217 Volume 2, WP 0245 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
0032-1
TM 10-3930-675-23-1
0032
TROUBLESHOOTING PROCEDURE STEERING VALVE CIRCUIT TROUBLESHOOTING SYMPTOM
ERROR CODE 325 MALFUNCTION Right-Front Wheel Valve Solenoid, Broken Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 located behind seat in the middle panel. Check the resistance between pin 1 and 2 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
Check resistance at X196 between pins 3 and 4 (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. c. If resistance is not as specified, continue with troubleshooting procedure. If resistance is as specified, inspect the mounted part of X196 for damage or pushed back pins. Continue with step 6. Repair or replace damaged connector (Volume 2, WP 0267).
3. 4.
Move cab to the transport position (TM 10-3930-675-10). Remove the hydraulic pump cover. Locate the steering valve on the inside of the left frame rail. Disconnect the 6026 connector and check the resistance of the 6026 solenoid. The resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1961 and 1962 (Figure 5 (Volume 2, WP 0272)). Replace open or damaged X196 wiring harness (Volume 2, WP 0267).
5.
Disconnect the 6027 connector and check the resistance of the 6027 solenoid. Resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1961 and 1962 (Figure 5 (Volume 2, WP 0272)). Replace open or damaged X196 wiring harness (Volume 2, WP 0267).
6.
Inspect ECU (792) pins 8, 10, 27, and 28 for connection or damage. Check continuity of wires A1961, A1962, A1963, and A1964 (Figure 5 (Volume 2, WP 0272)).
0032-2
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. SYMPTOM Replace damaged ECU (792) terminal board (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
ERROR CODE 326 MALFUNCTION Right-Rear Wheel Valve Solenoid, Broken Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 located behind seat in the middle panel. Check the resistance between pin 9 and 10 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
3. 4.
5.
Disconnect the 6031 connector and check the resistance of the 6031 solenoid. Resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 19611 and 19612 (Figure 5 (Volume 2, WP 0272)).
0032-3
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. 6. Replace open or damaged X196 wiring harness (Volume 2, WP 0267).
Inspect ECU (792) pins 9, 11, 12, and 13 for connection or damage. Check continuity of wires A1969, A19610, A19611, and A19612 (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
SYMPTOM
ERROR CODE 327 MALFUNCTION Left-Rear Wheel Valve Solenoid, Broken Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 and X197 located behind seat in the middle panel. Check the resistance between pin 13 and 14 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
Check resistance at X197 between pins 1 and 2 (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. c. If resistance is not as specified, continue with troubleshooting procedure. If resistance is as specified, inspect the mounted part of X196 and X197 for damage or pushed back pins. Continue with step 6. Repair or replace damaged connector (Volume 2, WP 0267).
3. 4.
5.
Disconnect the 6033 connector and check the resistance of the 6033 solenoid. Resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. If resistance is not as specified, replace open, shorted, or grounded
0032-4
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0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued solenoid (Volume 2, WP 0217). b. c. 6. If resistance is as specified, check continuity of wires 1971 and 1972 (Figure 5 (Volume 2, WP 0272)). Replace open or damaged X197 wiring harness (Volume 2, WP 0267).
SYMPTOM
ERROR CODE 328 MALFUNCTION Left-Front Wheel Valve Solenoid, Broken Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 located behind seat in the middle panel. Check the resistance between pin 5 and 6 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
3. 4.
0032-5
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect the 6029 connector and check the resistance of the 6029 solenoid. Resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. 6. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1967 and 1968 (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace open or damaged X196 wiring harness.
SYMPTOM
ERROR CODE 329 MALFUNCTION Right-Front Wheel Valve Solenoid, Short Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 located behind seat in the middle panel. Check the resistance between pin 1 and 2 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
3. 4.
Move cab to the transport position (TM 10-3930-675-10). Remove the hydraulic pump cover. Locate the steering valve on the inside of the left frame rail. Disconnect the 6026 connector and check the resistance of the 6026 solenoid. The resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217).
0032-6
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. c. 5. If resistance is as specified, check continuity of wires 1961 and 1962 to ground and between each other (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace shorted, grounded, or damaged X196 wiring harness.
Disconnect the 6027 connector and check the resistance of the 6027 solenoid. Resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1963 and 1964 to ground and between each other (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace shorted, grounded, or damaged X196 wiring harness.
6.
Inspect ECU (792) pins 8, 10, 27, and 28 for connection or damage. Check continuity of wires A1961, A1963, and A1964 to ground between each other (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Repair or replace shorted, grounded, damaged wires, or connectors (Volume 2, WP 0267).
SYMPTOM
ERROR CODE 330 MALFUNCTION Right-Rear Wheel Valve Solenoid, Short Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 located behind seat in the middle panel. Check the resistance between pin 9 and 10 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
3.
Move cab to the transport position (TM 10-3930-675-10). Remove the hydraulic pump cover. Locate the steering valve on the inside of the left frame rail.
0032-7
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Disconnect the 6030 connector and check the resistance of the 6030 solenoid. The resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. 5. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1969 and 19610 to ground and between each other (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace shorted, grounded, or damaged X196 wiring harness.
0032-8
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Inspect ECU (792) pins 9, 11, 12, and 13 for connection or damage. Check continuity of wires A1969, A19610, A1911, and A1912 to ground and between each other (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Repair or replace shorted, grounded, damaged wires, or connectors (Volume 2, WP 0267).
SYMPTOM
ERROR CODE 331 MALFUNCTION Left-Rear Wheel Valve Solenoid, Short Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 and X197 located behind seat in the middle panel. Check the resistance between pin 13 and 14 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
Check resistance at X197 between pins 1 and 2 (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. c. If resistance is not as specified, continue with troubleshooting procedure. If resistance is as specified, inspect the mounted part of X196 and X197 for damage or pushed back pins. Continue with step 6. Repair or replace damaged connector (Volume 2, WP 0267).
3.
Move cab to the transport position (TM 10-3930-675-10). Remove the hydraulic pump cover. Locate the steering valve on the inside of the left frame rail.
0032-9
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Disconnect the 6032 connector and check the resistance of the 6032 solenoid. The resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. 5. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 19613 and 19614 to ground and between each other (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace shorted, grounded, or damaged X196 wiring harness.
6.
Inspect ECU (792) pins 14, 15, 16, and 18 for connection or damage. Check continuity of wires A19613, A19614, A1971, and A1972 to ground and between each other (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100)). Repair or replace shorted, grounded, damaged wires, or connectors (Volume 2, WP 0267).
0032-10
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 332 MALFUNCTION Left-Front Wheel Valve Solenoid, Short Circuit Failure. CORRECTIVE ACTION 1. Disconnect X196 located behind seat in the middle panel. Check the resistance between pin 5 and 6 on the loose part of the X196 connector (Figure 5 (Volume 2, WP 0272)). Resistance should be 12 to 14 Ohms. a. b. 2. If resistance is not as specified, continue with step 3. If resistance is as specified, continue with troubleshooting procedure.
3. 4.
Move cab to the transport position (TM 10-3930-675-10). Remove the hydraulic pump cover. Locate the steering valve on the inside of the left frame rail. Disconnect the 6028 connector and check the resistance of the 6028 solenoid. The resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1965 and 1966 and between each other (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace open or damaged X196 wiring harness.
5.
Disconnect the 6029 connector and check the resistance of the 6029 solenoid. Resistance should be 12 to 13 Ohms. Check resistance of each pin to ground. There should not be continuity to ground. a. b. c. If resistance is not as specified, replace open, shorted, or grounded solenoid (Volume 2, WP 0217). If resistance is as specified, check continuity of wires 1967 and 1968 to ground and between each other (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace open or damaged X196 wiring harness.
6.
Inspect ECU (792) pins 17, 19, 20, and 22 for connection or damage. Check continuity of wires A1965, A1966, A1967, and A1968 (Figure 5 (Volume 2, WP 0272)). a. Replace damaged ECU (792) terminal board (WP 0100).
0032-11
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0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. SYMPTOM Repair or replace damaged wires or connectors (Volume 2, WP 0267).
ERROR CODE 339 MALFUNCTION Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3 Only). CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE in this work package. SYMPTOM
ERROR CODE 340 MALFUNCTION Hydraulic Steering Pressure Below Threshold [1,450 psi (100 Bar)]. CORRECTIVE ACTION 1. 2. Ensure that steering accumulator evacuation valve is closed. Close steering accumulator evacuation valve as required (Volume 2, WP 0204). Check pumps. Enter "DIAG EXTRA FUNCT 2(13)" in the diagnostic menu. Use the +/- keys to turn pumps off and then back on. a. b. 3. 4. Listen for a change in engine loading when pumps are turned off and on. If no change is heard or felt, perform troubleshooting procedure for ERROR CODE 172 (WP 0037).
Enter "DIAG STEERING 5(16)" in the diagnostic menu and check the status of the pressure switch. If the steering pressure is above 1,450 psi (100 bar), the status will be 1". Check steering pressure at test point 3 (Volume 2, WP 0245). a. b. c. If no or low stabilized pressure, check pressure at test points 6 and 7 (Volume 2, WP 0245). If steering response is slow at idle or pressure is unstable, check the nitrogen pressure and charge the steering accumulator (Volume 2, WP 0155). If no or low pressure at test point 6 or 7, replace the steering and tophandler pump assembly (Volume 2, WP 0212).
0032-12
TM 10-3930-675-23-1
0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Move cab to the transport position (Volume 2, WP 0175) and remove the middle access cover to access the steering valve. Check pressure switch (245) mounted on the top of the steering valve for damage and connection. a. b. 6. Replace damaged pressure switch (245) (Volume 2, WP 0170). Repair connector (Volume 2, WP 0267).
Pin 3 with the ignition ON. a. If no voltage (24V) is found, check circuit breaker F29 and continuity of wires A473 (Figure 5 (Volume 2, WP 0272)), 473, and A1743B ( (Figure 5 (Volume 2, WP 0272)) (RT 240V1 only). If no voltage (24V) is found, check circuit breaker F33 and continuity of wires A475, 475, and A174B1A (Figure 5 (Volume 2, WP 0272)) (RT 240V1R, RT 240V2 and RT 240V3). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
b. c. d. 7.
Check voltage (24V) at X197 pin 4 with the engine running. a. b. If no voltage (24V) is found, check continuity of wires 1973 and 1974 (Figure 5 (Volume 2, WP 0272)). Notify SRA to replace open or damaged X197 harness.
8.
Disconnect pressure switch (245). Open the steering accumulator evacuation valve and drain off the pressure (Volume 2, WP 0204). Close the valve. Check continuity between the two pins of pressure switch (245). There should not be continuity. Start the engine (TM 10-3930-675-10) and recheck continuity after the steering pressure stabilizes. There should be continuity. a. b. c. d. If pressure switch (245) does not have continuity after engine start, replace pressure switch (245) (Volume 2, WP 0170). If pressure switch (245) does have continuity after engine start, check continuity of wire A1974 and condition and connection at ECU (792) pin 49. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (792) terminal board (WP 0100).
0032-13
TM 10-3930-675-23-1
0032
SYMPTOM
ERROR CODE 341 MALFUNCTION Steering Wheel Signal Not Consistent. CORRECTIVE ACTION 1. Check steering column sensor (770) for damage and connection. a. b. 2. 3. Reconnect sensor cable if loose or disconnected. Replace damaged steering column sensor (770) (Volume 2, WP 0168).
Check connector X176 located in the middle panel for damage and connection. Repair or replace damaged connector (Volume 2, WP 0267). Disconnect steering column sensor (770) cable and connector X176. Check continuity of wires BN (pin 1), YE (pin 2), BU (pin 3), GN (pin 4), GY (pin 5), WH (pin 6), RD (pin 7), PK (pin 8), and shield (pin 9) (Figure 5 (Volume 2, WP 0272)). If continuity is not found at any one wire, replace X176 to (770) cable (Volume 2, WP 0168).
9 (HIDDEN) 8
6 7 1
3 5 2 CONNECTOR 770
Figure 1. Connector 770 Numbering.
0032-14
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0032
STEERING VALVE CIRCUIT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check continuity of wires A1761, A1762, A1763, A1764, A1765, A1766, A1767, A1768, and A1769 (Figure 5 (Volume 2, WP 0272)). If continuity is not found at any one wire, replace damaged wire or connector (Volume 2, WP 0267). Check ECU (792) pins 23, 38, 40, 41, 56, 96, 97, 113, and 132 for damage or connection (Figure 5 (Volume 2, WP 0272)). a. b. Reconnect loose or disconnected wire or replace damaged ECU (792) terminal board. If all connections and continuity checks are correct, replace steering column sensor (770) (Volume 2, WP 0168).
5.
SYMPTOM
ERROR CODE 342 MALFUNCTION One Steering Wheel Signal is Interrupted. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 341 in this work package. SYMPTOM
ERROR CODE 343 MALFUNCTION One Steering Wheel Signal is Interrupted. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 341 in this work package.
0032-15
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0032
SYMPTOM
ERROR CODE 344 MALFUNCTION Both Steering Wheel Signals are Interrupted. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 341 in this work package. SYMPTOM
ERROR CODE 347 MALFUNCTION No Steering Mode Selected. CORRECTIVE ACTION Select a steering mode (TM 10-3930-675-10). END OF WORK PACKAGE
0032-16
TM 10-3930-675-23-1
0033
FIELD MAINTENANCE MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING
INITIAL SETUP: References LO 10-3930-675-13 WP 0005 Volume 2, WP 0171 Volume 2, WP 0174 References (cont.) Volume 2, WP 0212 Volume 2, WP 0213 Volume 2, WP 0245
NOTE
0033-1
TM 10-3930-675-23-1
0033
TROUBLESHOOTING PROCEDURE MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING SYMPTOM
ERROR CODE 317 MALFUNCTION Right-Front Wheel Angle Cannot Reach Set Point Value. CORRECTIVE ACTION 1. Check for obstructions that will not allow the wheel to move through the full steering range. a. b. c. 2. Remove any obstructions. Lubricate (GAA) the axle steering knuckle pins (LO 10-3930-675-13). Check operating surface conditions for excessive tire friction or obstruction.
Check condition of steering cylinders. Replace damaged or leaking steering cylinder (Volume 2, WP 0171).
NOTE
Operating the vehicle with a load and steering to extremes when not rolling on rough pavement type surfaces may cause ERROR CODE 317. 3. Check hydraulic pressure at test points no. 3, 6, and 7 (Volume 2, WP 0245). Pressure should be 3,045 psi (210 bar). If pressure is not as specified, adjust steering pump pressure (Volume 2, WP 0213) or replace steering pump (Volume 2, WP 0212).
0033-2
TM 10-3930-675-23-1
0033
MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 318 MALFUNCTION Right-Rear Wheel Angle Cannot Reach Set Point Value Troubleshooting Procedures. CORRECTIVE ACTION 1. Check for obstructions that will not allow the wheel to move through the full steering range. a. b. c. 2. Remove any obstructions. Lubricate (GAA) the axle steering knuckle pins (LO 10-3930-675-13). Check operating surface conditions for excessive tire friction or obstruction.
NOTE
0033-3
TM 10-3930-675-23-1
0033
SYMPTOM
ERROR CODE 319 MALFUNCTION Left-Rear Wheel Angle Cannot Reach Set Point Value Troubleshooting Procedures. CORRECTIVE ACTION 1. Check for obstructions that will not allow the wheel to move through the full steering range. a. b. c. 2. Remove any obstructions. Lubricate (GAA) the axle steering knuckle pins (LO 10-3930-675-13). Check operating surface conditions for excessive tire friction or obstruction.
NOTE
SYMPTOM
ERROR CODE 320 MALFUNCTION Left-Front Wheel Angle Cannot Reach Set Point Value. CORRECTIVE ACTION 1. Check for obstructions that will not allow the wheel to move through the full steering range. a. b. c. 2. Remove any obstructions. Lubricate (GAA) the axle steering knuckle pins (LO 10-3930-675-13). Check operating surface conditions for excessive tire friction or obstruction.
0033-4
TM 10-3930-675-23-1
0033
MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
NOTE
SYMPTOM
ERROR CODE 321 MALFUNCTION Right-Front Wheel is Not Calibrated Correctly. CORRECTIVE ACTION Calibrate steering wheel (Volume 2, WP 0174). SYMPTOM
ERROR CODE 322 MALFUNCTION Right-Rear Wheel is Not Calibrated Correctly. CORRECTIVE ACTION Calibrate steering wheel (Volume 2, WP 0174).
0033-5
TM 10-3930-675-23-1
0033
SYMPTOM
ERROR CODE 323 MALFUNCTION Left-Rear Wheel is Not Calibrated Correctly. CORRECTIVE ACTION Calibrate steering wheel (Volume 2, WP 0174). SYMPTOM
ERROR CODE 324 MALFUNCTION Left-Front Wheel is Not Calibrated Correctly. CORRECTIVE ACTION Calibrate steering wheel (Volume 2, WP 0174). END OF WORK PACKAGE
0033-6
TM 10-3930-675-23-1
0034
FIELD MAINTENANCE STEERING SENSOR TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0032 WP 0100 WP 0125 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
0034-1
TM 10-3930-675-23-1
0034
TROUBLESHOOTING PROCEDURE STEERING SENSOR TROUBLESHOOTING SYMPTOM
ERROR CODE 301 MALFUNCTION Right-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check right-front wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Test signal. Enter "DIAG STEERING 8(16)" in the diagnostic menu. Observe if signal 1 changes when steering in both directions. If signal 1 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Remove the engine cover to access X167. Disconnect wires 1, 2, and 3 from pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-front wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Inspect X167 wiring and terminals for damage. Inspect connector X171 for damage. Check resistance of wires GY, BK, and RD between X167 pins 1, 2, and 3 and X171 pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X171 to X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 37, 86, and 90 for connection or damage. Check continuity of wires A1711, A1712, and A1713 (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace right-front wheel sensor (WP 0125).
0034-2
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 302 MALFUNCTION Right-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check right-front wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Check resistance. Enter "DIAG STEERING 9(16)" in the diagnostic menu. Observe if signal 1 changes when steering in both directions. If signal 1 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Disconnect wires 1, 2, and 3 from X192 pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Inspect X167 wiring and terminals for damage. Inspect connector X170 for damage. Check resistance of wires GY, BK, and RD between X192 pins 1, 2, and 3 and X170 pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X170 to X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 36, 87, and 92 for connection or damage. Check continuity of wires A1701, A1702, and A1703 (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace right-rear wheel sensor (WP 0125).
0034-3
TM 10-3930-675-23-1
0034
SYMPTOM
ERROR CODE 303 MALFUNCTION Left-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check left-rear wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Enter "DIAG STEERING 10(16)" in the diagnostic menu. Observe if signal 1 changes when steering in both directions. If signal 1 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Disconnect wires 1, 2, and 3 from X192 pins 8, 9, and 10 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Inspect X192 wiring and terminals for damage. Inspect connector X170 for damage. Check resistance of wires BN, WH, and VT between X192 pins 8, 9, and 10 and X170 pins 9, 10, and 11 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X170 and X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 35, 88, and 94 for connection or damage. Check continuity of wires A1709, A17010, A17011A, and A17011B (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace left-rear wheel sensor (WP 0125).
SYMPTOM
ERROR CODE 304 MALFUNCTION Left-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. Check left-front wheel sensor and wire for damage.
0034-4
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued Replace sensor if damaged (WP 0125). 2. Enter "DIAG STEERING 11(16)" in the diagnostic menu. Observe if signal 1 changes when steering in both directions. If signal 1 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Remove the engine cover to access X167. Disconnect wires 1, 2, and 3 from pins 8, 9, and 10 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Inspect X167 wiring and terminals for damage. Inspect connector X171 for damage. Check resistance of wires BN, WH, and VT between X167 pins 8, 9, and 10 and X171 pins 9, 10, and 11 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X171 and X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 34, 89, and 95 for connection or damage. Check continuity of wires A1719, A17110, A17111A, and A17111B (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace left-rear wheel sensor (WP 0125).
SYMPTOM
ERROR CODE 305 MALFUNCTION Right-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check right-front wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Test signal. Enter "DIAG STEERING 8(16)" in the diagnostic menu. Observe if signal 2 changes when steering in both directions. If signal 2 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Remove the engine cover to access X167. Disconnect wires 4, 5, and YE/ GN from pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/ GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms.
3.
0034-5
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0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If resistance is not as specified, replace right-front wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/ GN after checking. 4. Inspect X167 wiring and terminals for damage. Inspect connector X171 for damage. Check resistance of wires BU, YE, and GN between X167 pins 4, 5, and 6 and X171 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X171 to X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
Inspect ECU (792) pins 33, 91, and 138 for connection or damage. Check continuity of wires A1714, A1715, and A1716 (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace right-front wheel sensor (WP 0125).
SYMPTOM
ERROR CODE 306 MALFUNCTION Right-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check right-rear wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Enter "DIAG STEERING 9(16)" in the diagnostic menu. Observe if signal 2 changes when steering in both directions. If signal 2 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Disconnect wires 4, 5, and YE/GN from X192 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X192 wiring and terminals for damage. Inspect connector X170 for damage. Check resistance of wires BU, YE, and GN between X192 pins 4, 5, and 6 and X170 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X170 and X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 32, 93, and 139 for connection or damage. Check continuity of wires A1704, A1705, and A1706 (Figure 5 (Volume 2, WP 0272)). a. Replace damaged ECU (792) (WP 0100).
0034-6
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. c. SYMPTOM Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace right-rear wheel sensor (WP 0125).
ERROR CODE 307 MALFUNCTION Left-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check left-rear wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Enter "DIAG STEERING 10(16)" in the diagnostic menu. Observe if signal 2 changes when steering in both directions. If signal 2 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Disconnect wires 4, 5, and YE/GN from X192 pins 11, 12, and 13 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X192 wiring and terminals for damage. Inspect connector X170 for damage. Check resistance of wires OR, WH/BK, and WH/RD between X192 pins 11, 12, and 13 and X170 pins 12, 13, and 14 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X170 and X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 31, 94, and 140 for connection or damage. Check continuity of wires A17012, A17013, and A17011B (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace left-rear wheel sensor (WP 0125).
0034-7
TM 10-3930-675-23-1
0034
SYMPTOM
ERROR CODE 308 MALFUNCTION Left-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION 1. 2. Check left-front wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Enter "DIAG STEERING 11(16)" in the diagnostic menu. Observe if signal 2 changes when steering in both directions. If signal 2 is around 70 and does not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Remove the engine cover to access X167. Disconnect wires 4, 5, and YE/GN from pins 11, 12, and 13 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-front wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X167 wiring and terminals for damage. Inspect connector X171 for damage. Check resistance of wires OR, WH/BK, and WH/RD between X167 pins 11, 12, and 13 and X171 pins 12, 13, and 14 (Figure 5 (Volume 2, WP 0272)). a. b. 5. If continuity is not found at any one wire, notify SRA to replace X171 and X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
Inspect ECU (792) pins 30, 95, and 141 for connection or damage. Check continuity of wires A17112, A17113, and A17111B (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace left-front wheel sensor (WP 0125).
0034-8
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0034
SYMPTOM
ERROR CODE 309 MALFUNCTION Right-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 301 and 305 may be activated with ERROR CODE 309. 1. 2. Check right-front wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Test signal. Enter "DIAG STEERING 8(16)" in the diagnostic menu. Observe if signals 1 and 2 change when steering in both directions. If signals 1 and 2 are around 70 and do not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Check resistance. Remove the engine cover to access X167. Disconnect wires 1, 2, and 3 from pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-front wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Check resistance. Disconnect wires 4, 5, and YE/GN from X167 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-front wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X167 wiring and terminals for damage. Inspect connector X171 for damage. Check resistance of wires GY, BK, and RD between X167 pins 1, 2, and 3 and X171 pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). a. b. 6. If continuity is not found at any one wire, notify SRA to replace X171 and X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
5.
Check resistance of wires BU, YE, and GN between X167 pins 4, 5, and 6 and X171 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). a. b. If continuity is not found at any one wire, notify SRA to replace X171 to X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
7.
Inspect ECU (792) pins 37, 86, and 90 for connection or damage. Check continuity of wires A1711, A1712, and A1713 (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
0034-9
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Inspect ECU (792) pins 33, 91, and 138 for connection or damage. Check continuity of wires A1714, A1715, and A1716 (Figure 5 (Volume 2, WP 0272)). a. b. c. SYMPTOM Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace right-front wheel sensor (WP 0125).
ERROR CODE 310 MALFUNCTION Right-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 302 and 306 may be activated with ERROR CODE 310. 1. 2. Check right-rear wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Test signal. Enter "DIAG STEERING 9(16)" in the diagnostic menu. Observe if signals 1 and 2 change when steering in both directions. If signals 1 and 2 are around 70 and do not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Disconnect wires 1, 2, and 3 from X192 pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Disconnect wires 4, 5, and YE/GN from X192 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace right-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X192 wiring and terminals for damage. Inspect connector X170 for damage. Check resistance of wires GY, BK, and RD between X192 pins 1, 2, and 3 and X170 pins 1, 2, and 3 (Figure 5 (Volume 2, WP 0272)). a. b. 6. If continuity is not found at any one wire, notify SRA to replace X170 and X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
3.
4.
5.
Check resistance of wires BU, YE, and GN between X192 pins 4, 5, and 6 and X170 pins 4, 5, and 6 (Figure 5 (Volume 2, WP 0272)). a. If continuity is not found at any one wire, notify SRA to replace X170 to X192 harness.
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TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. 7. Repair or replace damaged connectors (Volume 2, WP 0267).
Inspect ECU (792) pins 36, 87, and 92 for connection or damage. Check continuity of wires A1701, A1702, and A1703 (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
8.
Inspect ECU (792) pins 32, 93, and 139 for connection or damage. Check continuity of wires A1704, A1705, and A1706 (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace right-rear wheel sensor (WP 0125).
SYMPTOM
ERROR CODE 311 MALFUNCTION Left-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 303 and 307 may be activated with ERROR CODE 311. 1. 2. Check left-rear wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Test signal. Enter "DIAG STEERING 10(16)" in the diagnostic menu. Observe if signals 1 and 2 change when steering in both directions. If signals 1 and 2 are around 70 and do not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Disconnect wires 1, 2, and 3 from X192 pins 8, 9, and 10 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking. Disconnect wires 4, 5, and YE/GN from pins 11, 12, and 13 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-rear wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X192 wiring and terminals for damage. Inspect connector X170 for damage. Check resistance of wires BN, WH, and VT between X192 pins 8, 9, and 10 and X170 pins 9, 10, and 11 (Figure 5 (Volume 2, WP 0272)).
3.
4.
5.
0034-11
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. 6. If continuity is not found at any one wire, notify SRA to replace X170 and X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
Check resistance of wires OR, WH/BK, and WH/RD between X192 pins 11, 12, and 13 and X170 pins 12, 13, and 14 (Figure 5 (Volume 2, WP 0272)). a. b. If continuity is not found at any one wire, notify SRA to replace X170 to X192 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
7.
Inspect ECU (792) pins 35, 88, and 94 for connection or damage. Check continuity of wires A1709, A17010, A17011A, and A17011B (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
8.
Inspect ECU (792) pins 31, 94, and 140 for connection or damage. Check continuity of wires A17012, A17013, and A17011B (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace left-rear wheel sensor (WP 0125).
SYMPTOM
ERROR CODE 312 MALFUNCTION Left-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 304 and 308 may be activated with ERROR CODE 312. 1. 2. Check left-front wheel sensor and wire for damage. Replace sensor if damaged (WP 0125). Test signal. Enter "DIAG STEERING 11(16)" in the diagnostic menu. Observe if signals 1 and 2 change when steering in both directions. If signals 1 and 2 are around 70 and do not change, this indicates a break in the circuit or in the wheel sensor. Continue with step 3. Remove the engine cover to access X167. Disconnect wires 1, 2, and 3 from pins 8, 9, and 10 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 1 and 3. Resistance should be around 2k Ohms. Check resistance between wires 1 and 2. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-front wheel sensor (WP 0125). Reconnect wheel sensor wires 1, 2, and 3 after checking.
3.
0034-12
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Disconnect wires 4, 5, and YE/GN from pins 11, 12, and 13 (Figure 5 (Volume 2, WP 0272)). Check resistance between wires 4 and YE/GN. Resistance should be around 2k Ohms. Check resistance between wires 4 and 5. Resistance should be 2k to 4k Ohms. If resistance is not as specified, replace left-front wheel sensor (WP 0125). Reconnect wheel sensor wires 4, 5, and YE/GN after checking. Inspect X167 wiring and terminals for damage. Inspect connector X171 for damage. Check resistance of wires BN, WH, and VT between X167 pins 8, 9, and 10 and X171 pins 9, 10, and 11 (Figure 5 (Volume 2, WP 0272)). a. b. 6. If continuity is not found at any one wire, notify SRA to replace X171 and X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
5.
Check resistance of wires OR, WH/BK, and WH/RD between X167 pins 11, 12, and 13 and X171 pins 12, 13, and 14 (Figure 5 (Volume 2, WP 0272)). a. b. If continuity is not found at any one wire, notify SRA to replace X171 to X167 harness. Repair or replace damaged connectors (Volume 2, WP 0267).
7.
Inspect ECU (792) pins 34, 89, and 95 for connection or damage. Check continuity of wires A1719, A17110, A17111A, and A17111B (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
8.
Inspect ECU (792) pins 30, 95, and 141 for connection or damage. Check continuity of wires A17112, A17113, and A17111B (Figure 5 (Volume 2, WP 0272)). a. b. c. Replace damaged ECU (792) (WP 0100). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace left-front wheel sensor (WP 0125).
SYMPTOM
ERROR CODE 313 MALFUNCTION Right-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 301 and 305 may be activated with ERROR CODE 313. Perform troubleshooting procedures for ERROR CODE 309 in this work package.
0034-13
TM 10-3930-675-23-1
0034
SYMPTOM
ERROR CODE 314 MALFUNCTION Right-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 302 and 306 may be activated with ERROR CODE 314. Perform troubleshooting procedures for ERROR CODE 310 in this work package. SYMPTOM
ERROR CODE 315 MALFUNCTION Left-Rear Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 303 and 307 may be activated with ERROR CODE 3154. Perform troubleshooting procedures for ERROR CODE 311 in this work package. SYMPTOM
ERROR CODE 316 MALFUNCTION Left-Front Wheel Sensor Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODES 304 and 308 may be activated with ERROR CODE 316. Perform troubleshooting procedures for ERROR CODE 312 in this work package.
0034-14
TM 10-3930-675-23-1
0034
STEERING SENSOR TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 339 MALFUNCTION Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT240V3). CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODE 341 (WP 0032). END OF WORK PACKAGE
0034-15/16 blank
TM 10-3930-675-23-1
0035
FIELD MAINTENANCE HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING
INITIAL SETUP: References WP 0005 WP 0100
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING SYMPTOM
ERROR CODE 125 MALFUNCTION Memory Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU (790) if ERROR CODE is still present (WP 0100). SYMPTOM
ERROR CODE 141 MALFUNCTION Internal Communication Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU (790) if ERROR CODE is still present (WP 0100).
0035-1
TM 10-3930-675-23-1
0035
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 142 MALFUNCTION Internal Communication Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU (790) if ERROR CODE is still present (WP 0100).
T0235JCH
0035-2
TM 10-3930-675-23-1
0036
FIELD MAINTENANCE AUXILIARY PUMP TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0094 WP 0100 WP 0103 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
0036-1
TM 10-3930-675-23-1
0036
TROUBLESHOOTING PROCEDURE AUXILIARY PUMP TROUBLESHOOTING SYMPTOM
DIAG SERVO 12(13) VALVES OUTPUT/INPUT ATTACH 0.00V 0mA PUMP OFF 0.00V 0mA
ERROR CODE 169 MALFUNCTION Tophandler Emergency Function Supply Valve, Open or Short Circuit Failure. CORRECTIVE ACTION 1. Place ignition switch to ON but do not start engine. Access the diagnostic menu "DIAG SERVO 12 (13)". Turn on auxiliary pump and operate one of the tophandler functions. The "ATTACH" output value should have voltage (24V) and the "INPUT" value (mA) should rise while operating a tophandler function. Check voltage at X158 between pin 11 and pin 12 with the ignition and the auxiliary pump on (Figure 2 (Volume 2, WP 0272)). Should have (21 to 24V) while operating one of the tophandler functions. a. If voltage (21 to 24V) found continuously, disconnect X158 and check the resistance on the loose part of X158 between pin 11 and pin 12. Resistance should be 40 to 43 Ohms. Check resistance to ground at either pin. If no voltage (21 to 24V) is found, disconnect ECU (790) connector 2 and check pin 14 for damage and check continuity of wire A15812 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
2.
b. c. d. 3.
Remove the engine hood (TM 10-3930-675-10). Locate the tophandler supply valve solenoid 6041, located on frame rail above engine starter. Check resistance of 6041 solenoid. Should be 40 to 43 Ohms. Check resistance of each pin to ground. a. If resistance (40 to 43 Ohms) is not as specified or solenoid is shorted to ground, replace tophandler supply valve (6041) ( Hydraulic System Valve Maintenance (Volume 2, WP 0228)). If specified resistance is found, check continuity of wires 15811 and 15812 (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged or open harness. Replace ECU (790) (WP 0100).
b. c. d.
0036-2
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0036
AUXILIARY PUMP TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 411 MALFUNCTION Auxiliary Pump Control, Short Circuit Failure. CORRECTIVE ACTION
NOTE
ERROR CODE 411 is an information type ERROR CODE. It may not activate for the operator. The operator may report the auxiliary pump is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the Initialization menu. 1. Test relay. Remove the plastic cover from the right rear of the cab to access the cab distribution box (WP 0103). Open the cab distribution box to access the relay boards. Remove relay 350 and test (Volume 2, WP 0267). Replace relay if resistance between terminals 85 and 86 is not 290 to 350 Ohms (WP 0103). Check for continuity. Disconnect connector X174 located in the middle panel. Check for continuity to ground on the loose part of X174 at pin 5 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 3. If continuity to ground is found, disconnect X46 and recheck. If continuity to ground is still found, check wire 469 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X174 to X46 cable (Volume 2, WP 0267).
2.
Check for continuity. Disconnect connector X46 and connector XK3 located on one of the relay boards. Check for continuity to ground on the loose part of XK3 at pin 8 (Figure 16 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace wire A469. If continuity to ground is not found, check wire A1745 for continuity to ground (Volume 2, WP 0272). Replace grounded wire A1745.
4.
Check ECU (792) pin 61 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) (WP 0100). Replace ECU (792) (WP 0100).
0036-3
TM 10-3930-675-23-1
0036
AUXILIARY PUMP TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 417 MALFUNCTION Auxiliary Pump Switch, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 417 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the auxiliary pump switch for damage and connection. Replace damaged auxiliary pump switch (WP 0094). Inspect connectors X67, X47, and X174 for connection or damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires A678 (Figure 8 (Volume 2, WP 0272)), A671 (Figure 15 (Volume 2, WP 0272)), 671, 672 (Figure 16 (Volume 2, WP 0272)), A474 and 474 for continuity (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire (WP 0100).
c. 3.
Check ECU (792) pin 48 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A1744 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) (WP 0100).
4.
Check wire connection. Disconnect wire A1744 from ECU (792) and recheck for active ERROR CODE 417. Replace ECU (792) (WP 0100) if ERROR CODE 417 is still active.
END OF WORK PACKAGE
0036-4
TM 10-3930-675-23-1
0037
FIELD MAINTENANCE HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 References (cont.) WP 0005 WP 0100 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING SYMPTOM
TEST OR INSPECTIONEXTRA FUNCT. 2(13) CUT-OFF THE HYDRAULIC PUMP 0
ERROR CODE 172 MALFUNCTION Hydraulic Piston Pump Cut-Off, Open or Short Circuit Failure. CORRECTIVE ACTION 1. Place ignition switch to ON but do not start engine. Enter "DIAG SERVO 12(13)" in the Diagnostic menu. The "PUMP OFF" "OUTPUT" value should have voltage (24V) and the "INPUT" value should have (mA). (Slow cranking of the engine is a sign the pumps are engaged during engine start). a. b. Start engine. The voltage (24V) and (mA) values should go away when the pumps engage. If values do not go away, ensure the engine cold start function is not activated (TM 10-3930-675-10).
0037-1
TM 10-3930-675-23-1
0037
HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. 2. If values still do not go away, Replace ECU (790) (WP 0100).
Check voltage at X158 between pin 13 and pin 14 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should have voltage (21 to 24V). a. If voltage (21 to 24V) is found continuously, disconnect X158 and check the resistance on the loose part of X158 between pin 13 and pin 14. Resistance should be 40 to 43 Ohms. Check resistance to ground at either pin. If no voltage (21 to 24V) is found, disconnect ECU (790) connector 2 and check pin 6 for damage and check continuity of wire A15814 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
b. c. d. 3.
Remove the engine hood (TM 10-3930-675-10). Locate the hydraulic pump cut-off valve solenoid 611, located on frame rail above engine starter. Check resistance of 611 solenoid. Should be 40 to 43 Ohms. Check resistance of each pin to ground. a. b. c. d. If resistance (40 to 43 Ohms) is not as specified or solenoid is shorted to ground, replace hydraulic pump cut-off valve (611) (Volume 2, WP 0228). If specified resistance is found, check continuity of wires 15813 and 15814 (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged or open harness. Replace ECU (790) (WP 0100).
0037-2
TM 10-3930-675-23-1
0037
HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0239JCH
0037-3/4 blank
TM 10-3930-675-23-1
0038
FIELD MAINTENANCE HYDRAULIC FILTER INDICATORS TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0100 References (cont.) WP 0119 WP 0125 Volume 2, WP 0140 Volume 2, WP 0227 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE HYDRAULIC FILTER INDICATORS TROUBLESHOOTING SYMPTOM
EXTRA FUNCT. 6(13) HYD.FILTER BOOM 0 HYD.FILTER STEERING0 HYD.FILTER ATTACH 0 HYD.FILTER RET.OIL 0
ERROR CODE 1 MALFUNCTION Boom Hydraulic System Sensor Indicating Clogged Filter. CORRECTIVE ACTION Replace filters (Volume 2, WP 0227).
0038-1
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 2 MALFUNCTION Steering Hydraulic System Sensor Indicating Clogged Filter. CORRECTIVE ACTION Replace filters (Volume 2, WP 0227). SYMPTOM
ERROR CODE 3 MALFUNCTION Tophandler Hydraulic System Sensor Indicating Clogged Filter. CORRECTIVE ACTION Replace filters (Volume 2, WP 0227).
0038-2
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 4 MALFUNCTION Hydraulic Reservoir Return Sensor Indicating Clogged Filter. CORRECTIVE ACTION Replace filters (Volume 2, WP 0227). SYMPTOM
ERROR CODE 432 MALFUNCTION Boom Hydraulic Filter Sensor, Circuit Error Input. CORRECTIVE ACTION
NOTE
ERROR CODE 432 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. Inspect the boom hydraulic filter sensor (755-1) for damage and connection. Replace damaged boom hydraulic sensor (755-1) (WP 0119).
0038-3
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Inspect connectors X198 (located under the cab and rear cover plate), X195, X197, X174 (X174B RT 240V1R only), and X47 for connection or damage. a. b. Repair or replace damaged connector ( Electrical General Maintenance Instructions (Volume 2, WP 0267)). If connectors are found to be in good condition, check wires BK, BU, GY, A1743C (Figure 7 (Volume 2, WP 0272)), A1743B, 473 (Figure 5 (Volume 2, WP 0272)), A473 (Figure 11 (Volume 2, WP 0272)), A174B1B, A174B1A, 475, and A475 RT 240V1R only for continuity (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.
c. 3.
4.
SYMPTOM
ERROR CODE 433 MALFUNCTION Steering Hydraulic Filter Sensor, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 433 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the steering hydraulic filter sensor (755-1) for damage and connection. Replace damaged steering hydraulic sensor (755-2) (WP 0119). Inspect connectors X198 (located under the cab and rear cover plate), X195, X197, X174 (X174B RT 240V1R only), and X47 for connection or damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires BK, BU, GY, A1743C (Figure 7 (Volume 2, WP 0272)), A1743B, 473 (Figure 5 (Volume 2, WP 0272)), A473, A174B1B, A174B1A, 475, and A475 RT 240V1R only (WP 0125) for continuity (Figure 11 (Volume 2, WP 0272)).
0038-4
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. 3. Check wire A1952 for continuity (WP 0125).
Check ECU (792) pin 153 for connection or damage (Figure 7 (Volume 2, WP 0272)). a. b. Check wire A1952 for continuity (WP 0125). Replace damaged ECU (792) (WP 0100).
4.
SYMPTOM
ERROR CODE 434 MALFUNCTION Tophandler Hydraulic Filter Sensor, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 434 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the tophandler hydraulic filter sensor (755-3) for damage and connection. Replace damaged tophandler hydraulic sensor (755-3) (WP 0119). Inspect connectors X198 (located under the cab and rear cover plate), X195, X197, X174 (X174B RT 240V1R only), and X47 for connection or damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires BK, BU, GY, A1743C (Figure 7 (Volume 2, WP 0272)), A1743B, 473 (Figure 5s (Volume 2, WP 0272)), A473 (Figure 11 (Volume 2, WP 0272)), A174B1B, A174B1A, 475, and A475 RT 240V1R only for continuity (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.
c. 3.
4.
0038-5
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 435 MALFUNCTION Hydraulic Reservoir Return System Filter Sensor, Circuit Input Error. CORRECTIVE ACTION
NOTE
ERROR CODE 435 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the return hydraulic filter sensor (755-4) for damage and connection. Replace damaged return hydraulic sensor (755-4) (WP 0119). Inspect connectors X198 (located under the cab and rear cover plate), X195, X197, X174 (X174B RT 240V1R only), and X47 for connection or damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires BK, BU, GY, A1743C (Figure 7 (Volume 2, WP 0272)), A1743B, 473 (Figure 5 (Volume 2, WP 0272)), A473 ( (Figure 11 (Volume 2, WP 0272)), A174B1B, A174B1A, 475, and A475 RT 240V1R only for continuity (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.
c. 3.
4.
0038-6
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued
SYMPTOM
ERROR CODE 786 MALFUNCTION Transmission Hydraulic System, Sensor Indicating Clogged Filter. CORRECTIVE ACTION Replace filters (Volume 2, WP 0140).
0038-7
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0242JCH
Figure 1. Component Locations. 0038-8
TM 10-3930-675-23-1
0038
HYDRAULIC FILTER INDICATORS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0243JCH
Figure 2. Component Locations. END OF WORK PACKAGE 0038-9/10 blank
TM 10-3930-675-23-1
0039
FIELD MAINTENANCE BOOM LIFTING/LOWERING TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 WP 0100 References (cont.) WP 0101 WP 0102 Volume 2, WP 0207 Volume 2, WP 0231 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component location. TROUBLESHOOTING PROCEDURE BOOM LIFTING/LOWERING TROUBLESHOOTING SYMPTOM
DIAG SERVO LIFT/LOWER BOOM IN/OUT
5(13) 5.00V 5.00V
ERROR CODE 126 MALFUNCTION Joystick-to-ECU (790) Failure. CORRECTIVE ACTION 1. Enter diagnostic menu "DIAG SERVO 5(13)" and check "LIFT/LOWER" voltage. Voltage should be around 5V with no movement of the joystick. a. b. Operate the joystick lift and lower function slowly. Should have 1 to 9V over the full range of function. If the voltage suddenly goes out of range, replace joystick (WP 0101). If no voltage (5V) is found, continue with step 2.
0039-1
TM 10-3930-675-23-1
0039
BOOM LIFTING/LOWERING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Inspect ECU (790) connector 1. Check connector, harness, and ECU (790) for damage. Check ECU tray ground wires a. b. 3. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (WP 0100).
Check voltage (10V) at X155 between pins 12 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (10V) is found, check continuity of wires A15514A, A15514B, and A15513A (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
4.
Check voltage (10V) at X155 between pins 1 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be around 5V. a. b. c. If no voltage (5V) is found, check continuity of wires 15512, 1551, A1551, and 15513 (Figure 2 (Volume 2, WP 0272)). Replace damaged or open joystick harness (WP 0102). Replace joystick (WP 0101).
SYMPTOM
ERROR CODE 130 MALFUNCTION Overload Protection System Failure. CORRECTIVE ACTION
NOTE
Overload protection system failure occurs due to an earlier failure (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Perform troubleshooting procedures for the original ERROR CODE (ERROR CODEs 131 to 136) Overload Protection Troubleshooting (WP 0010).
0039-2
TM 10-3930-675-23-1
0039
BOOM LIFTING/LOWERING TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 151 MALFUNCTION Lift Cylinder Locking Valve, Wiring Circuit Failure. CORRECTIVE ACTION 1. Enter "DIAG SERVO 11(13)" in the diagnostic menu. Should have (24V) when activating boom lowering function. Inspect locking valve solenoids for damage and proper connector. Disconnect the connectors from 6001 and 6002 from the lift cylinder locking valves. Check voltage between the two pins of each connector with the ignition ON. Should have voltage (24V) during the lowering function. a. b. If no voltage (24V) is found, check continuity of locking valve harness. If voltage (24V) is found, check resistance of locking valve solenoids 6001 and 6002. The resistance should be 18 to 20 Ohms for RT 240V1 and RT 240V1R or 40 to 50 ohms for RT 240V2 and RT 240V2 units. Replace damaged or open locking valve harness. Replace locking valve (Volume 2, WP 0231).
2.
c. d. 3.
Check voltage (24V) at X159 pin 2 with the ignition ON. Should have (24V) (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, disconnect ECU (790) connector 2 and check pin 3 for damage and check continuity of wire A1592 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
4.
Remove the engine cover to access X167 and check voltage (24V) at X167 pin 14 and 15 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. If no voltage (24V) at X167 pin 15, check continuity of wires GY and BK going to X159 (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X167 pin 14, check locking valves 6001 and 6002 solenoid harness for damage and continuity (Figure 2 (Volume 2, WP 0272)). Replace damaged or open locking valve harness. Notify SRA to replace damaged or open X159 to X167 harness.
0039-3
TM 10-3930-675-23-1
0039
ERROR CODE 152 MALFUNCTION Lift Cylinder Locking Valve, Component Failure. CORRECTIVE ACTION 1. Enter "DIAG SERVO 11(13)" in the diagnostic menu. Should have (24V) when activating boom lowering function. Inspect locking valve solenoids for damage and proper connection. 2. Disconnect the connectors from 6001 and 6002 from the lift cylinder locking valves. Check voltage between the two pins of each connector with the ignition ON. Should have voltage (24V) during the lowering function. a. b. If no voltage (24V) is found, check continuity of locking valve harness. If voltage (24V) is found, check resistance of locking valve solenoids 6001 and 6002. The resistance should be 18 to 20 Ohms for RT 240V1 and RT 240V1R or 40 to 50 ohms for RT 240V2 and RT 240V3 units. Replace damaged or shorted locking valve harness. Replace locking valve (Volume 2, WP 0231).
c. d. 3.
Check voltage (24V) at X159 pin 2 with the ignition ON. Should have (24V) (Figure 2 (Volume 2, WP 0272)). a. b. c. If voltage (24V) is found, disconnect ECU (790) connector 2 and check pin 3 for damage and check wire A1592 for continuity to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
4.
Remove the engine cover to access X167 and check voltage (24V) at X167 pin 14 and 15 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. If no voltage (24V) is found at X167 pin 15, check wires GY and BK going to X159 for continuity to ground (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X167 pin 14, check locking valves 6001 and 6002 solenoid harnesses for damage and continuity to ground (Figure 2 (Volume 2, WP 0272)). Replace damaged or shorted locking valve harness. Replace damaged or open X159 to X167 harness (Volume 2, WP 0267).
0039-4
TM 10-3930-675-23-1
0039
DIAG SERVO 9(13) OUTPUT/INPUT LIFT 0mA 0mA LOWER 0mA 0mA
ERROR CODE 154 MALFUNCTION Lift Cylinder Boom Up Valve, Wiring Circuit Failure. CORRECTIVE ACTION 1. Enter DIAG SERVO 9(13)" in the diagnostic menu and activate the boom lifting function. "LIFT" "OUTPUT" and INPUT" should have mA values during lifting function. a. b. 2. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 126. If no INPUT" mA values display, continue with step 2.
Check voltage at X158 between pin 1 and pin 2 with the ignition on" (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the lifting function. a. b. c. d. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 1 and pin 2. Resistance should be 23 to 25 Ohms. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check pin 11 for damage and check continuity of wire A1582 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267)). Replace damaged ECU (WP 0100)).
3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6005 solenoid. Resistance should be 23 to 25 Ohms. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified, replace servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1581 and 1582 (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged or open harness. Replace ECU (790) (WP 0100).
0039-5
TM 10-3930-675-23-1
0039
ERROR CODE 155 MALFUNCTION Lift Cylinder Boom Up Valve, Component Failure. CORRECTIVE ACTION 1. Enter "DIAG SERVO 9(13)" in the diagnostic menu and activate the boom lifting function. "LIFT" OUTPUT" and INPUT" should have mA values during lifting function. a. b. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 126. If no INPUT" mA values display, continue with step 2.
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Check voltage at X158 between pin 1 and pin 2 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the lifting function. a. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 1 and pin 2. Resistance should be 23 to 25 Ohms. Check continuity of each pin to ground. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check pin 11 for damage and check continuity of wire A1582 and continuity of wire to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged shorted wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
b.
c. d. 3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6005 solenoid. Resistance should be 23 to 25 Ohms. Check solenoid for short to ground. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified or shorted to ground, replace servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1581 and 1582 and check continuity of each wire to ground (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged or open harness. Replace ECU (790) (WP 0100).
0039-6
TM 10-3930-675-23-1
0039
ERROR CODE 157 MALFUNCTION Lift Cylinder Boom Down Valve, Wiring Circuit Failure. CORRECTIVE ACTION 1. Enter "DIAG SERVO 9(13)" in the diagnostic menu and activate the boom lifting function. "LIFT" OUTPUT" and INPUT" should have mA values during lifting function. a. b. 2. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 126. If no INPUT" mA values display, continue with step 2.
Check voltage at X158 between pin 3 and pin 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the lowering function. a. b. c. d. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 3 and pin 4. Resistance should be 23 to 25 Ohms. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check pin 4 for damage and check continuity of wire A1584 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6004 solenoid. Resistance should be 23 to 25 Ohms. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified, replace servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1583 and 1584 (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged or open harness. Replace ECU (790) (WP 0100).
0039-7
TM 10-3930-675-23-1
0039
ERROR CODE 158 MALFUNCTION Lift Cylinder Boom Down Valve, Component Failure. CORRECTIVE ACTION 1. Enter "DIAG SERVO 9(13)" in the diagnostic menu and activate the boom lifting function. "LIFT" OUTPUT" and INPUT" should have mA values during lifting function. a. b. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 126 in this work package. If no INPUT" mA values display, continue with step 2.
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Check voltage at X158 between pin 3 and pin 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the lowering function. a. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 3 and pin 4. Resistance should be 23 to 25 Ohms. Check continuity of each pin to ground. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check continuity of wire A1584 and continuity of wire to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged shorted wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
b. c. d. 3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6004 solenoid. Resistance should be 23 to 25 Ohms. Check solenoid for short to ground. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified or shorted to ground, replace servo control valve Servo Control Valve Replacement (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1583 and 1584 and check continuity of each wire to ground (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged or open harness. Replace ECU (790) (WP 0100).
0039-8
TM 10-3930-675-23-1
0039
BOOM LIFTING/LOWERING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0247JCH
Figure 1. Component Locations.
0039-9
TM 10-3930-675-23-1
0039
BOOM LIFTING/LOWERING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0248JCH
Figure 2. Component Locations. END OF WORK PACKAGE 0039-10
TM 10-3930-675-23-1
0040
FIELD MAINTENANCE BOOM IN/OUT TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0100 WP 0101 WP 0102 Volume 2, WP 0207 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component locations. TROUBLESHOOTING PROCEDURE BOOM IN/OUT TROUBLESHOOTING SYMPTOM
5(13) 5.00V 5.00V
ERROR CODE 127 MALFUNCTION Joystick-to-ECU (790) Failure CORRECTIVE ACTION 1. Enter diagnostic menu DIAG SERVO 5(13)" and check "IN/OUT" voltage. Voltage should be around 5V with no movement of the joystick. a. b. 2. Operate the joystick extend and retract function slowly. Should have 1 to 9V over the full range of function. If the voltage suddenly goes out of range, replace joystick (WP 0101). If no voltage (5V) is found, continue with step 2.
Inspect ECU (790) connector 1. Check connector, harness, and ECU (790) for damage. Check ECU tray ground wires.
0040-1
TM 10-3930-675-23-1
0040
BOOM IN/OUT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. 3. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
Check voltage (10V) at X155 between pins 12 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (10V) is found, check continuity of wires A15514A, A15514B, and A15513A (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
4.
Check voltage (10V) at X155 between pins 2 and pin 13 with ignition ON (Figure 2 (Volume 2, WP 0272)). Should be around 5V. a. b. c. If no voltage (5V) is found, check continuity of wires 15512, 1552, A1552, and 15513 (Figure 2 (Volume 2, WP 0272)). Replace damaged or open joystick harness (WP 0102). Replace joystick (WP 0101).
SYMPTOM
5(13) 5.00V 5.00V
ERROR CODE 130 MALFUNCTION Overload Protection System Failure CORRECTIVE ACTION
NOTE
Overload protection system failure occurs due to an earlier failure (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Perform troubleshooting procedures for the original ERROR CODE (ERROR CODES 131 to 136).
0040-2
TM 10-3930-675-23-1
0040
BOOM IN/OUT TROUBLESHOOTING - Continued SYMPTOM
DIAG SERVO 10(13) OUTPUT/INPUT BOOM IN 0mA 0mA BOOM OUT 0mA 0mA
ERROR CODE 160 MALFUNCTION Extension Cylinder Boom IN Control, Wiring Circuit Failure CORRECTIVE ACTION 1. Enter "DIAG SERVO 10(13)" in the diagnostic menu and activate the boom in function. "BOOM IN" OUTPUT" and INPUT" should have mA values during boom in function. a. b. 2. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 127 in this work package. If no INPUT" mA values display, continue with Step 2.
Check voltage at X158 between pin 5 and pin 6 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6-16V during the boom IN function. a. b. c. d. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 5 and pin 6. Resistance should be 23 to 25 Ohms. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check pin 12 for damage and check continuity of wire A1586 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (WP 0100).
3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6007 solenoid. Should be 23 to 25 Ohms. Check solenoid for short to ground. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified, replace servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1585 and 1586 (Figure 2 (Volume 2, WP 0272)). Notify Specialized Repair Activity (SRA) to replace damaged open or shorted harness. Replace ECU (790) (WP 0100).
0040-3
TM 10-3930-675-23-1
0040
ERROR CODE 161 MALFUNCTION Extension Cylinder Boom IN Control, Component Failure CORRECTIVE ACTION 1. Enter "DIAG SERVO 10(13)" in the diagnostic menu and activate the boom in function. "BOOM IN" OUTPUT" and INPUT" should have mA values during boom in function. a. b. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 127 in this work package. If no INPUT" mA values display, continue with step 2.
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Check voltage at X158 between pin 5 and pin 6 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the boom IN function. a. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 5 and pin 6. Resistance should be 23 to 25 Ohms. Check continuity of each pin to ground. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check continuity of wire A1586 and continuity of wire to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
b. c. d. 3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6007 solenoid. Should be 23 to 25 Ohms. Check solenoid for short to ground. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified or shorted to ground, replace servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1585 and 1586 and check continuity of each wire to ground (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged open or shorted harness. Replace ECU (790) (WP 0100).
0040-4
TM 10-3930-675-23-1
0040
ERROR CODE 163 MALFUNCTION Extension Cylinder Boom OUT Control Valve, Wiring Circuit Failure CORRECTIVE ACTION 1. Enter "DIAG SERVO 10(13)" in the diagnostic menu and activate the boom in function. "BOOM IN" OUTPUT" and INPUT" should have mA values during boom in function. a. b. 2. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 127 in this work package. If no INPUT" mA values display, continue with step 2.
Check voltage at X158 between pin 7 and pin 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the boom OUT function. a. b. c. d. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 7 and pin 8. Resistance should be 23 to 25 Ohms. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check pin 5 for damage and check continuity of wire A1588 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6006 solenoid. Should be 23 to 25 Ohms. Check solenoid for short to ground. a. b. If resistance (23 to 25 Ohms) is not as specified, replace servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1587 and 1588 (Figure 2 (Volume 2, WP 0272)).
4.
Notify SRA to replace damaged open or shorted harness. Replace ECU (790) (WP 0100).
0040-5
TM 10-3930-675-23-1
0040
ERROR CODE 164 MALFUNCTION Extension Cylinder Boom OUT Control Valve, Component Failure CORRECTIVE ACTION 1. Enter "DIAG SERVO 10(13)" in the diagnostic menu and activate the boom in function. "BOOM IN" OUTPUT" and INPUT" should have mA values during boom in function. a. b. If no OUTPUT" mA values display, perform troubleshooting steps for ERROR CODE 127 in this work package. If no INPUT" mA values display, continue with Step 2.
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Check voltage at X158 between pin 7 and pin 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be 0V with the joystick in the neutral position and 6 to 16V during the boom OUT function. a. If voltage (16 to 24V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 7 and pin 8. Resistance should be 23 to 25 Ohms. Check continuity of each pin to ground. If no voltage (6 to 16V) is found, disconnect ECU (790) connector 2 and check continuity of wire A1588 and continuity of wire to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged, wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).
b. c. d. 3.
Move the cab to the transport position (TM 10-3930-675-10). Remove the thin cover plate just in front of the cab hose tray to gain access to the servo solenoids. Check resistance of 6006 solenoid. Should be 23 to 25 Ohms. Check solenoid for short to ground. a. b. c. d. If resistance (23 to 25 Ohms) is not as specified or shorted to ground, replace the servo control valve (Volume 2, WP 0207). If specified resistance is found, check continuity of wires 1587 and 1588 and check continuity of each wire to ground (Figure 2 (Volume 2, WP 0272)). Notify SRA to replace damaged open or shorted harness. Replace ECU (790) (WP 0100).
0040-6
TM 10-3930-675-23-1
0040
BOOM IN/OUT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0251JCH
0040-7
TM 10-3930-675-23-1
0040
BOOM IN/OUT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0252JCH
0040-8
TM 10-3930-675-23-1
0041
FIELD MAINTENANCE TOPHANDLER SLEWING TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0005 WP 0010 References (cont.) WP 0100 WP 0101 WP 0102 WP 0108 Volume 2, WP 0217 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE TOPHANDLER SLEWING TROUBLESHOOTING SYMPTOM
ERROR CODE 128 MALFUNCTION Joystick-to-ECU (790) Failure CORRECTIVE ACTION 1. Enter diagnostic menu "DIAG SERVO 6(13)" and check "SLEW CW/CCW" voltage. Voltage should be around 5V with no joystick activations. a. Operate the joystick slewing CW and CCW function slowly. Should have 1 to 9V over the full range of function. If the voltage suddenly goes out of range, replace joystick (WP 0101). If no voltage (5V) is found, continue with step 2.
b. 2.
Inspect ECU (790) connector 1. Check connector, harness, and ECU (790) for damage. Check ECU tray ground wires. a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0101).
0041-1
TM 10-3930-675-23-1
0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Check voltage (10V) at X155 between pins 12 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. 4. If no voltage (10V) is found, check continuity of wires A15514A, A15514B, and A15513A (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Check voltage at X155 between pins 3 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Voltage should be around 5V. a. b. c. If no voltage (5V) is found, check continuity of wires 15512, 1553, A1553A, and 15513 (Figure 2 (Volume 2, WP 0272)). Replace damaged or open joystick harness (WP 0102). Replace joystick (WP 0101).
SYMPTOM
NOTE
Overload protection system failure occurs due to an earlier failure (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Perform troubleshooting procedures for the original ERROR CODE (ERROR CODES 131 to 136) (WP 0010). SYMPTOM
DIAG TOP LIFT 12(16) OUTPUT/INPUT SLEW CW 0mA 0mA SLEW CCW 0mA 0mA
ERROR CODE 255
0041-2
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0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued MALFUNCTION Tophandler Clockwise Slewing, Wiring Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 12(16)" in the diagnostic menu. Activate the CW slew function. If no INPUT mA values display, continue with troubleshooting procedure. Disconnect connector 6008 from the tophandler CW slewing solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 188A and 188B (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6008 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X188 to solenoids wiring harness to solenoids wiring harness (Volume 2, WP 0267).
4.
Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins A and B. a. b. If no voltage (15 to 18V) is found, check continuity of wires A188AA and A188B (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0041-3
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0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 256 MALFUNCTION Tophandler Clockwise Slewing, Component Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6008 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X188 from tophandler junction box and disconnect solenoid 6018. Check for short to ground at loose part of X188 at pin B (wire 188B) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108).
3.
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. Check wire A188B (pin 3) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0041-4
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0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 258 MALFUNCTION Tophandler Counterclockwise Slewing, Wiring Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 12(16)" in the diagnostic menu. Activate the CCW slew function. If no INPUT mA values display, continue with troubleshooting procedure. Disconnect connector 6009 from the tophandler CCW slewing solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 188C and 188D (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6009 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X188 to solenoids wiring harness to solenoids wiring harness (WP 0108).
4.
Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins C and D. a. b. If no voltage (15 to 18V) is found, check continuity of wires A188AA, A188AB and A188D (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. a. Repair or replace damaged connector (Volume 2, WP 0267).
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0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. SYMPTOM Replace ECU (791) (WP 0100).
ERROR CODE 259 MALFUNCTION Tophandler Counterclockwise Slewing, Component Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6009 from the tophandler CCW slewing solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X188 from tophandler junction box and disconnect solenoid 6009. Check for short to ground at loose part of X188 at pin D (wire 188D) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108).
3.
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. Check wire A188D (pin 11) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0041-6
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0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0254JCH
0041-7
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0041
TOPHANDLER SLEWING TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0255JCH
0041-8
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0042
FIELD MAINTENANCE TOPHANDLER TILT TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0005 WP 0100 References (cont.) WP 0101 WP 0102 WP 0108 Volume 2, WP 0217 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
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0042
TROUBLESHOOTING PROCEDURE TOPHANDLER TILT TROUBLESHOOTING SYMPTOM
ERROR CODE 129 MALFUNCTION Joystick-to-ECU (790) Failure CORRECTIVE ACTION 1. Enter diagnostic menu DIAG SERVO 6(13)" menu and check "TILT IN/OUT" voltage. Voltage should be around 5V with no joystick activations. a. b. 2. Operate the joystick tilt IN and OUT function slowly. Should have 1 to 9V over the full range of function. If the voltage suddenly goes out of range, replace joystick (WP 0101). If no voltage (5V) is found, continue with Step 2.
3.
Check voltage (10V) at X155 between pins 12 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (10V) is found, check continuity of wires A15514A, A15514B, and A15513A (Figure 2 (Volume 2, WP 0272).) Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check voltage at X155 between pins 3 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be around 5V. a. b. c. SYMPTOM If no voltage (5V) is found, check continuity of wires 15512, 1554, A1554, and 15513 (Figure 2 (Volume 2, WP 0272)). Replace damaged or open joystick harness (WP 0102). Replace joystick (WP 0101).
NOTE
Overload protection system failure occurs due to an earlier failure (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Perform troubleshooting procedures for the original ERROR CODE (ERROR CODES 131 to 136). SYMPTOM
DIAG ATTACHMENT 15(16) ACTIVE OUTPUT/INPUT 24.00V 900mA OSC. TILT 24.00V 900mA
ERROR CODE 237 MALFUNCTION Tophandler Tilt Locking Control, Wiring Circuit Failure
0042-3
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued CORRECTIVE ACTION 1. Check wires and connectors at moderation and tilt control valve mounted on the nose of the boom and tophandler junction box for damage. a. b. 2. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 15(16)" in the diagnostic menu. Activate the tilt floatlock function. If no "INPUT" mA values display or values less than 600 mA, continue with troubleshooting procedure. Disconnect connector 6012-1 and 6012-2 from the tophandler tilt floatlock solenoids. Turn the ignition ON and check voltage (20 to 24V) between both pins of the connector. Check both connectors. a. b. If no voltage (20 to 24V) is found, check continuity of wires BK and GY of the solenoid harnesses (Figure 6 (Volume 2, WP 0272)). If voltage (20 to 24V) is found, check resistance of 6012-1 and 6012-2 solenoids. The top mounted solenoid should be 25 to 35 Ohms and the front mounted solenoid should be 35 to 45 Ohms. If solenoid is open or shorted, replace moderation and tilt control valve (Volume 2, WP 0228). Replace solenoid wiring harness (WP 0097).
3.
c. d. 4.
Remove the cover from the tophandler junction box. Turn the ignition ON. Check voltage (20 to 24V) at X180 between pins 14 and 15. a. b. If no voltage (20 to 24V) is found, check continuity of wires A3018A through A3018J and A18014 (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0042-4
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued
SYMPTOM
DIAG ATTACHMENT 13(16) OUTPUT/INPUT TILT IN 0mA 0mA TILT OUT 0mA 0mA
ERROR CODE 261 MALFUNCTION Tophandler Tilt OUT Control, Wiring Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 13(16)" in the diagnostic menu. Activate the tilt OUT function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6010 from the tophandler tilt OUT solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 188E and 188F (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6010 solenoid. Voltage should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X188 to solenoids wiring harness (WP 0108).
4.
Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins E and F. a. b. If no voltage (15 to 18V) is found, check continuity of wires A188AA, A188AB, A188AC, and A188F (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage.
0042-5
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
ERROR CODE 262 MALFUNCTION Tophandler Tilt OUT Control, Component Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6010 from the tophandler tilt OUT solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X188 from tophandler junction box and disconnect solenoid 6010. Check for short to ground at loose part of X188 at pin F (wire 188F) (Figure 6 (Volume 2, WP 0272)). Replace open or shorted/ grounded X188 to solenoids wiring harness (WP 0108).
3.
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. Check wire A188F (pin 4) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0042-6
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued SYMPTOM
ERROR CODE 264 MALFUNCTION Tophandler Tilt IN Control, Wiring Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 13(16)" in the diagnostic menu. Activate the tilt IN function. If no INPUT mA values display, continue with troubleshooting procedure. Disconnect connector 6011 from the tophandler tilt IN solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 188G and 188H (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6011 solenoid. Voltage should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X188 to solenoids wiring harness (WP 0108).
4.
Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins G and H. a. b. If no voltage (15 to 18V) is found, check continuity of wires A188AA, A188AB, A188AC, A188AD, and A188H (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. a. Repair or replace damaged connector (Volume 2, WP 0267).
0042-7
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TOPHANDLER TILT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. SYMPTOM Replace ECU (791) (WP 0100).
ERROR CODE 265 MALFUNCTION Tophandler Tilt IN Control, Component Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6011 from the tophandler tilt solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 3. Disconnect connector X188 from tophandler junction box and disconnect solenoid 6011. Check for short to ground at loose part of X188 at pin H (wire 188H) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108). 4. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. Check wire A188H (pin 12) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0042-8
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0258JCH
0042-9
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0042
TOPHANDLER TILT TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
T0259JCH
0042-10
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0043
FIELD MAINTENANCE TOPHANDLER LEVELING TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0005 WP 0010 WP 0100 References (cont.) WP 0101 WP 0102 WP 0108 Volume 2, WP 0217 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE SYMPTOM
ERROR CODE 128 MALFUNCTION Joystick-to-ECU (790) Failure CORRECTIVE ACTION 1. Enter diagnostic menu DIAG SERVO 6(13)" and check "SLEW CW/CCW" voltage. Voltage should be around 5V with no joystick activations. a. Operate the joystick slewing CW and CCW function slowly. Should have 1 to 9V over the full range of function. If the voltage suddenly goes out of range, replace joystick (WP 0101). If no voltage (5V) is found, continue with step 2.
b. 2.
3.
Check voltage (10V) at X155 between pins 12 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)).
0043-1
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CORRECTIVE ACTION - Continued a. b. 4. If no voltage (10V) is found, check continuity of wires A15514A, A15514B, and A15513A (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
Check voltage at X155 between pins 3 and 13 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Should be around 5V. a. b. c. If no voltage (5V) is found, check continuity of wires 15512, 1553, A1553A, and 15513 (Figure 2 (Volume 2, WP 0272)). Replace damaged or open joystick harness (WP 0102). Replace joystick (WP 0101).
SYMPTOM
NOTE
Overload protection system failure occurs due to an earlier failure (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Perform troubleshooting procedures for the original ERROR CODE (ERROR CODES 131 to 136) (WP 0010). SYMPTOM
DIAG ATTACHMENT 15(16) ACTIVE OUTPUT/INPUT 24.00V 900mA OSC. TILT 24.00V 900mA
ERROR CODE 240
0043-2
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0043
MALFUNCTION Tophandler Leveling Locking Control, Wiring Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at leveling floatlock control valve mounted at the right of the tophandler control valve and tophandler junction box for damage. a. b. 2. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harnesses to solenoids wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 15(16)" in the diagnostic menu. Activate the leveling floatlock function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6034-1 and 6034-2 from the tophandler leveling floatlock solenoids. Turn the ignition ON and check voltage (20 to 24V) between both pins of the connector. Check both connectors. a. b. c. d. If no voltage (20 to 24V) is found, check continuity of wires 188N, 188P, 189N, and 189P (Figure 6 (Volume 2, WP 0272)). If voltage (20 to 24V) found, check resistance of 6034-1 and 6034-2 solenoids. The voltage should be 40 to 50 Ohms. If solenoid is open or shorted, replace leveling floatlock control valve (Volume 2, WP 0228). Replace X188 or X189 wiring harness to solenoids wiring harness (WP 0108).
3.
4.
Disconnect connector X188 and X189 from the tophandler junction box. Turn the ignition ON. Check voltage (20 to 24V) at the mounted part of the connector between pins N and P. Check both connectors. a. b. If no voltage (20 to 24V) is found, check continuity of wires A3018A through A3018I, A189P, and A188P (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
0043-3
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SYMPTOM
DIAG ATTACHMENT 14(16) OSC, RI OSC, LE
ERROR CODE 267 MALFUNCTION Tophandler Leveling Right, Open Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 14(16)" in the diagnostic menu. Activate the leveling right function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6035 from the tophandler leveling right solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15-18V) is found, check continuity of wires 189E and 189F (Figure 6 (Volume 2, WP 0272)). If voltage (15-18V) is found, check resistance of 6035 solenoid. Voltage should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X189 to solenoids wiring harness (WP 0108).
4.
Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins E and F. a. b. If no voltage (15 to 18V) is found, check continuity of wires A188AA through A188AE, and A189F (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0108).
NOTE
0043-4
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SYMPTOM
ERROR CODE 268 MALFUNCTION Tophandler Leveling Right, Short Circuit Failure CORRECTIVE ACTION
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 1. Check wires and cables from tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6035 from the tophandler leveling right solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X189 from the tophandler junction box and disconnect solenoid 6035. Check for short to ground at loose part of X189 at pin F (wire 189F) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X189 to solenoids wiring harness (WP 0108). Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. Check wire A189F (pin 5) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
3.
4.
0043-5
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0043
SYMPTOM
ERROR CODE 270 MALFUNCTION Tophandler Leveling Left, Open Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 14(16)" in the diagnostic menu. Activate the leveling left function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6036 from the tophandler leveling left solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 189G and 189H (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6036 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X189 to solenoids wiring harness (WP 0108).
4.
Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins G and H. a. b. If no voltage (15 to 18V) is found, check continuity of wires A188AA through A188AF and A189H (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
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SYMPTOM
ERROR CODE 271 MALFUNCTION Tophandler Leveling Left, Short Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6036 from the tophandler leveling left solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X189 from tophandler junction box and disconnect solenoid 6036. Check for short to ground at loose part of X189 at pin H (wire 189H) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X189 to solenoids wiring harness (WP 0108).
3.
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4. Disconnect ECU (791) connector 3. Inspect ECU and connector pins for damage. Check wire A189H (pin 13) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
0043-7
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0043
CORRECTIVE ACTION - Continued
T0263JCH
Figure 1.
Component Locations.
0043-8
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0043
T0265JCH
Figure 2. END OF WORK PACKAGE
Component Locations.
0043-9/10 blank
TM 10-3930-675-23-1
0044
FIELD MAINTENANCE TOPHANDLER SIDESHIFT TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0005 References (cont.) WP 0100 WP 0108 Volume 2, WP 0217 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.
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0044
TROUBLESHOOTING PROCEDURE SYMPTOM
DIAG ATTACHMENT 7(16) SIDE SH.OUTPUT/INPUT 0.00mV 0mA LEFT RIGHT 0.00mV 0mA
ERROR CODE 225 MALFUNCTION Tophandler Sideshift Left, Open Circuit Failure CORRECTIVE ACTION
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE Refs (WP 0004) for troubleshooting multiple ERROR CODES.) 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 7(16)" in the diagnostic menu. Activate the left sideshift function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6020 from the tophandler left sideshift solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 189A and 189B (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6020 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X189 to solenoids wiring harness (WP 0108).
4.
Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins A and B. a. b. If no voltage (15 to18V) is found, check continuity of wires A3018A, A3018B, and A189B (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
5.
Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
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0044
SYMPTOM
ERROR CODE 226 MALFUNCTION Tophandler Sideshift Left, Short Circuit Failure CORRECTIVE ACTION
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE Refs (WP 0004) for troubleshooting multiple ERROR CODES.) 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6020 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X189 from tophandler junction box and disconnect solenoid 6020. Check for short to ground at loose part of X189 at pin B (wire 189B) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X189 to solenoids wiring harness (WP 0108). Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. Check wire A189B (pin 3) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
3.
4.
0044-3
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0044
SYMPTOM
ERROR CODE 228 MALFUNCTION Tophandler Sideshift Right, Open Circuit Failure CORRECTIVE ACTION
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE Refs (WP 0004) for troubleshooting multiple ERROR CODES.) 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. 3. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 7(16)" in the diagnostic menu. Activate the left sideshift function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6021 from the tophandler left sideshift solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 189C and 189D (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6021 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X189 to solenoids wiring harness (WP 0108).
4.
Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins C and D. a. b. If no voltage (15 to 18V) is found, check continuity of wires A3018A, A3018B, and A3018C and A189D (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
5.
Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
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0044
SYMPTOM
ERROR CODE 229 MALFUNCTION Tophandler Sideshift Right, Short Circuit Failure CORRECTIVE ACTION
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE Refs (WP 0004) for troubleshooting multiple ERROR CODES.) 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6021 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X189 from tophandler junction box and disconnect solenoid 6021. Check for short to ground at loose part of X189 at pin D (wire 189D) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X189 to solenoids wiring harness (WP 0108). Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. Check wire A189D (pin 11) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
3.
4.
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0044
T0268JCH
0044-6
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0045
FIELD MAINTENANCE TOPHANDLER SPREADER TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0004 WP 0005 References (cont.) WP 0100 WP 0108 Volume 2, WP 0217 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.
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0045
TROUBLESHOOTING PROCEDURE SYMPTOM
DIAG ATTACHMENT 8(16) OUTPUT INPUT 20->40 0mA 0mA 40->20 0mA 0mA
ERROR CODE 231 MALFUNCTION Tophandler Spreader Opening, Open Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 8(16)" in the diagnostic menu. Activate the spreader opening function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6018 from the tophandler spreading out solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 188J and 188K (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6018 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X188 to solenoids wiring harness to solenoids wiring harness (WP 0108).
3.
4.
Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins J and K. a. b. If no voltage (15 to 18V) is found, check continuity of wires A3018A through H, and A188K (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
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0045
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a. b. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267)). Replace ECU (791) (WP 0100).
ERROR CODE 232 MALFUNCTION Tophandler Spreader Opening, Open Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6018 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X188 from tophandler junction box and disconnect solenoid 6018. Check for short to ground at loose part of X188 at pin K (wire 188K) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108).
3.
0045-3
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0045
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4. Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. Check wire A188K (pin 4) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. SYMPTOM Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
ERROR CODE 234 MALFUNCTION Tophandler Spreader Closing, Open Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 8(16)" in the diagnostic menu. Activate the spreader opening function. If no "INPUT" mA values display, continue with troubleshooting procedure. Disconnect connector 6019 from the tophandler spreading out solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 188L and 188M (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6019 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X188 to solenoids wiring harness to solenoids wiring harness (WP 0108).
3.
4.
Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins L and M.
0045-4
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0045
CORRECTIVE ACTION - Continued a. b. If no voltage (15 to 18V) is found, check continuity of wires A3018A through H, and A188M (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a. b. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
ERROR CODE 235 MALFUNCTION Tophandler Spreader Closing, Open Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
CAUTION
Uncontrolled function may occur with this ERROR CODE. 2. Disconnect connector 6019 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217). Disconnect connector X188 from tophandler junction box and disconnect solenoid 6019. Check for short to ground at loose part of X188 at pin M (wire 188M) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108).
3.
0045-5
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0045
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4. Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. Check wire A188M (pin 12) for short to ground (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace shorted wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
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0046
FIELD MAINTENANCE TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0004 WP 0005 References (cont.) WP 0100 WP 0104 WP 0108 Volume 2, WP 0217 Volume 2, WP 0267 Volume 2, WP 0272
NOTE
Refer to (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component location. TROUBLESHOOTING PROCEDURE SYMPTOM
DIAG ATTACHMENT 4(16) TWIST LOCK LE UNL. 1 RI UNL. 1 LE LOCK 0 RI LOCK 0
ERROR CODE 212 MALFUNCTION Tophandler Left Twistlocks Indication Failure CORRECTIVE ACTION 1. Enter "DIAG ATTACHMENT 4(16)" in the diagnostic menu. Check the left twistlocks "LOCKED" and "UNLOCKED" status. (Logical Error indicates both twistlock signals are ON at the same time.) a. Use the override switch to operate the twistlocks (TM 10-3930-675-10). Observe the status indication in the diagnostic menu screen. Observe the changing of the twistlock indicator lights. If both "LOCKED" and "UNLOCKED" are 1" at the same time, continue with step 2.
b. 2.
Inspect the left twistlock proximity switches for damage, obstructions, and adjustments.
0046-1
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0046
CORRECTIVE ACTION - Continued a. b. c. 3. Replace damaged proximity switch (WP 0104). Remove any obstructions and clean proximity switch ends. Check and adjust proximity switch gap (5 mm) (WP 0104).
Remove cover to X183. Inspect wire connections at pins 5 and 6 (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)). Make sure the twistlocks are in the UNLOCKED position. Check voltage (24V) between X183 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 6, replace left twistlock LOCKED proximity switch (WP 0104). Make sure the twistlocks are in the LOCKED position. Check voltage (24V) between X183 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 5, replace left twistlock locked" proximity switch (WP 0104). Remove the cover to X182. Inspect wire connections (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. a. b. c. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)). Check cable X182 to X183 for damage, continuity, or shorts between wires (Volume 2, WP 0267). Replace X182 to X183 cable (WP 0108).
4.
5.
6.
7.
Check X182 to X181 cable for damage, continuity, or shorts between wires (Volume 2, WP 0267). If X182 and X181 cable is damaged, has no continuity, or is shorted between wires, replace X182 to X181 cable (WP 0108). Disconnect ECU (791) connector 1. Inspect ECU and connector pins for damage. Check continuity and for shorts between wires of the wiring from connector 1 (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100)).
8.
SYMPTOM ERROR CODE 213
0046-2
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0046
SYMPTOM - Continued
>100K Ohms
T0171J
Figure 1. MALFUNCTION Tophandler Right Twistlocks Indication Failure CORRECTIVE ACTION 1.
Tophandler Twistlocks Indication Failure.
Enter "DIAG ATTACHMENT 4(16)" in the diagnostic menu. Check the right twistlocks "LOCKED" and "UNLOCKED" status. (Logical Error indicates both twistlock signals are on" at the same time.) a. Use the override switch to operate the twistlocks (TM 10-3930-675-10). Observe the status indication in the diagnostic menu screen. Observe the changing of the twistlock indicator lights. If both "LOCKED" and "UNLOCKED" are 1" at the same time, continue with Step 2.
b. 2.
Inspect the left twistlock proximity switches for damage, obstructions, and adjustments. a. b. c. Replace damaged proximity switch (WP 0104). Remove any obstructions and clean proximity switch ends. Check and adjust proximity switch gap (5 mm) (WP 0104)).
3.
Remove cover to X184. Inspect wire connections at pins 5 and 6 (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)). Make sure the twistlocks are in the UNLOCKED position. Check voltage (24V) between X184 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 6, replace left twistlock LOCKED proximity switch (WP 0104). Make sure the twistlocks are in the LOCKED position. Check voltage (24V) between X184 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 6, replace left twistlock LOCKED proximity switch (WP 0104).
4.
5.
0046-3
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0046
CORRECTIVE ACTION - Continued 6. Remove the cover to X182. Inspect wire connections (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. a. b. c. 7. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)). Check cable X182 to X184 for damage, continuity, or shorts between wires (Volume 2, WP 0267). Replace X182 to X184 cable (WP 0108).
Check X182 to X181 cable for damage, continuity, or shorts between wires (Volume 2, WP 0267). If X182 and X181 cable is damaged, has no continuity, or is shorted between wires, replace X182 to X181 cable (WP 0108). Disconnect ECU (791) connector 1. Inspect ECU and connector pins for damage. Check continuity and for shorts between wires of the wiring from connector X181 to ECU (791) connector 1 (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
8.
SYMPTOM
DIAG ATTACHMENT 5(16) Rotation Damping Attachment Attachment 4/-25 20/40 SIG 1 SIG 2
ERROR CODE 214 MALFUNCTION Tophandler Forklift Sensor Indication Failure CORRECTIVE ACTION 1. Enter "DIAG ATTACHMENT 5(16)" in the diagnostic menu. Check the attachment signal 1 and 2 status. (Logical Error indicates one attachment sig. is not ON when both signals should be ON at the same time.) a. b. c. 2. Check the actuating plunger by pushing up on the bottom of the shaft. Clean and lubricate stuck actuating plunger. If one attachment signal is 0", push the actuating plunger several times to observe any indication changes.
Inspect the forklift sensor proximity switches for damage, obstructions, and adjustment (WP 0104). a. Replace damaged proximity switch (WP 0104).
0046-4
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0046
CORRECTIVE ACTION - Continued b. c. 3. Remove any obstructions and clean proximity switch ends. Check and adjust proximity switch gap (5 mm) (WP 0104).
Remove the cover to X183. Inspect wire connections at pins 3, 4, 7, and 8 (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)). Check voltage (24V) between X183 pins 4 and 7 (Figure 6 (Volume 2, WP 0272)). If no voltage (24V) is found between pins 4 and 7, replace proximity switch 7206-1 (WP 0104). Check voltage (24V) between X183 pins 4 and 8 (Figure 6 (Volume 2, WP 0272)). If no voltage (24V) is found between pins 4 and 8, replace proximity switch 7206-2 (WP 0104). Remove the cover to X182. Inspect wire connections (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. a. b. c. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)). Check cable X182 to X183 for damage, continuity, or shorts between wires (Volume 2, WP 0267). Replace X182 to X183 cable (WP 0108).
4.
5.
6.
7.
Check X182 to X181 cable for damage, continuity, or shorts between wires (Volume 2, WP 0267). If X182 to X181 cable is damaged, has no continuity, or is shorted between wires, replace X182 to X181 cable (WP 0108). Disconnect ECU (791) connector 1. Inspect ECU and connector pins for damage. Check continuity and for shorts between wiring from connector X181 to ECU (791) connector 1 (Figure 6 (Volume 2, WP 0272)). a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
8.
SYMPTOM
DIAG ATTACHMENT 6(16) TW-LOCK OUTPUT INPUT 0Ma UNLOCKED 0.00V LOCKED 0.00V 0mA
ERROR CODE 243
0046-5
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0046
MALFUNCTION Tophandler Twistlock Locking Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler junction box for damage. a. b. 2. Repair or replace connectors (Volume 2, WP 0267). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 6(16)" in the diagnostic menu. Activate the twistlock function (override twistlocks). If no INPUT mA values display, continue with troubleshooting procedure. Disconnect connector 6040 from the tophandler twistlock locking solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 189L and 189M (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6040 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X189 to solenoids wiring harness (WP 0108).
3.
4.
Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins L and M. a. b. If no voltage (15 to 18V) is found, check continuity of wires A3018A through A3018F and A189M (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).
NOTE
Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5. Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a. b. SYMPTOM Repair or replace damaged connector (Volume 2, WP 0267). Replace ECU (791) (WP 0100).
DIAG ATTACHMENT 6(16) TW-LOCK OUTPUT INPUT 0Ma UNLOCKED 0.00V LOCKED 0.00V 0mA
ERROR CODE 246
0046-6
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0046
MALFUNCTION Tophandler Twistlock Unlocking Circuit Failure CORRECTIVE ACTION 1. Check wires and connectors at tophandler control valve and tophandler junction box for damage. a. b. 2. Repair or replace connectors (Volume 2, WP 0267)). Replace damaged wiring harness (WP 0108).
Enter "DIAG ATTACHMENT 6(16)" in the diagnostic menu. Activate the twistlock function (override twistlocks). If no INPUT mA values display, continue with troubleshooting procedure. Disconnect connector 6039 from the tophandler twistlock unlocking solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector. a. b. c. d. If no voltage (15 to 18V) is found, check continuity of wires 189J and 189K (Figure 6 (Volume 2, WP 0272)). If voltage (15 to 18V) is found, check resistance of 6039 solenoid. Resistance should be 18 to 26 Ohms. Replace open or faulty solenoid (Volume 2, WP 0217). Replace X189 to solenoids wiring harness (WP 0108).
3.
4.
Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins J and K. If no voltage (15 to 18V) is found, check continuity of wires A3018A through A3018E, and A189K (Figure 6 (Volume 2, WP 0272)).
NOTE
0046-7
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CHAPTER 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TM 10-3930-675-23-1
0047
FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES 1. Always perform PMCS in the same order so it gets to be a habit. Once you've had some practice, you'll spot anything wrong in a hurry. If any deficiency is discovered, perform the appropriate troubleshooting task in Chapter 2 of this manual. If any component or system is not serviceable, or if the given service does not correct the deficiency, notify your Supervisor. 2. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all tools needed to make all checks. Have several clean rags handy. Perform ALL inspections at the applicable interval. a. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use Detergent and water when you clean. b. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and apply a light coat of lubricating oil OE/HDO 10. Report it to your Supervisor. c. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, and for missing, bent, or broken condition. You can't try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find a fastener you think is loose, tighten it. d. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your Supervisor. e. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors and ensure wires are in good condition. f. Hydraulic Hoses and Lines. Look for wear, damage, and signs of leaks. Ensure clamps and fittings are tight. Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, tighten it. If something is broken or worn out, correct it if authorized by the Maintenance Allocation Chart (MAC) (Volume 2, WP 0275). If not authorized, notify your Supervisor. g. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your vehicle. The following are definitions of the types/classes of leakage you need to know to be able to determine the status of your vehicle. Learn and be familiar with them, and remember: when in doubt, notify your Supervisor. Table 1. Class I Class II Leakage Definitions for PMCS.
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item being checked/inspected. Leakage of fluid great enough to form drops that fall from item being checked/inspected.
Class III
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0047
PMCS INITIAL SETUP 1. General a. This paragraph lists tools, materials, and personnel required for PMCS and lubrication. b. Mandatory replacement parts for PMCS and lubrication are listed after PMCS, in Table 2, Preventive Maintenance Checks and Services (PMCS) (WP 0048). 2. Tools. a. Tool Kit, General Mechanics 3. Materials. a. Detergent b. Grease, Automotive and Artillery, GAA c. Rag, Wiping 4. Personnel. a. Driver/Operator b. Field Maintenance Mechanic GENERAL 1. To ensure the RTCH is ready for operation at all times, it must be lubricated and inspected on a regular basis so defects may be found before they result in serious damage, equipment failure, or injury to personnel. 2. The types, amounts, and temperature ranges of the lubricants required for specified intervals are contained in Lubrication Order (LO 10-3930-675-13). 3. Table 1 in Preventive Maintenance Checks and Services (PMCS) (WP 0048) contains systematic instructions on lubrications, inspections, adjustments, and corrections to be performed by Field Maintenance to keep the vehicles in good operating condition and ready for their primary mission. 4. Table 2 in Preventive Maintenance Checks and Services (PMCS) (WP 0048) lists PMCS mandatory replacement parts, by interval. EXPLANATION OF TABLE ENTRIES 1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers also appear in the order you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the Procedure column. Intervals are based on calendar dates and hours (in parentheses). a. Quarterly procedures must be done every three months. b. Semi-annual procedures must be done once every six months. c. Biennial procedures must be done once every two years. 3. Item to Checked or Serviced Column. This column identifies the item to be checked or serviced.
NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. These WARNINGs and CAUTIONs must be observed to prevent serious injury to yourself and others or to prevent your equipment from being damaged. 4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item to Check/Service column to know if the equipment is ready or available for its intended mission or for operation. You must perform the procedure at the time stated in the Interval column. 5. Equipment Not Ready/Available If: Column. Information in this column tells you what fault will keep your equipment from being capable of performing its primary mission. If you perform PMCS procedures that show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or reporting equipment failure. END OF WORK PACKAGE
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0048
FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Socket Set, 3/4 in. Drive, Regular Length, Standard (Volume 2, WP 0277, Table 1, Item 71) Wrench, Torque, Click, Ratcheting, 3/4 in. Drive, 600 lb-ft (Volume 2, WP 0277, Table 1, Item 96) References LO 10-3930-675-13 TM 10-3930-675-10 References (cont.) WP 0090 WP 0128 Volume 2, WP 0140 Volume 2, WP 0150 Volume 2, WP 0155 Volume 2, WP 0158 Volume 2, WP 0227 Volume 2, WP 0245 Volume 2, WP 0248 Volume 2, WP 0258
Table 1.
Preventive Maintenance Checks and Services (PMCS) for the RTCH.

EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
ITEM TO BE CHECKED OR SERVICED
PROCEDURE
WARNING
Perform all lubrication and preventive maintenance checks and services with vehicle on level ground, transmission in N (Neutral), parking brake applied, and engine off. Failure to follow this warning may result in personnel injury.
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0048
Table 1.
Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued.
ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
PROCEDURE
WARNING
Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. Failure to comply may cause injury or death to personnel.
CAUTION
Operation is allowable with Class I and Class II leakage, except for fuel. WHEN IN DOUBT, NOTIFY YOUR SUPERVISOR. When operating with Class I or Class II leaks, check fluid levels more frequently. Class III leaks must be reported immediately to your Supervisor. Failure to do this will result in damage to vehicle and/or components.
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0048
Table 1.
ITEM NO.
INTERVAL
PROCEDURE
NOTE
DO NOT lubricate boom and tophandler wear plates. After initial 100 hours of operation, Field Maintenance must perform 100-hour initial break-in services as indicated in Lubrication Order (LO 10-3930-675-13). Field Maintenance shall also check torque of wheel nuts [497 lb-ft (650 Nm)] and torque of boom wear plate mounting hardware (Volume 2, WP 0258). 1 Quarterly Engine Oil and (300 Hours) Filter Access engine compartment and change engine oil filter. (1) Start engine and bring to operating temperature (TM 10-3930-675-10). (2) Shut down engine (TM 10-3930-675-10). Drain engine oil and replace filter Lubrication Order (LO 10-3930-675-13). 2 Quarterly Engine Fuel (300 Hours) Filter/Water Separator
WARNING
DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. a. Replace fuel filter/water separator (WP 0076). b. Inspect fuel lines, fuel tank, and fuel system components for leaks and damage. If authorized, replace damaged components. Any fuel leaks are evident.
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0048
Table 1.
ITEM NO. 3
INTERVAL
PROCEDURE
Quarterly Engine Coolant (300 Hours) Filter
WARNING
DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap/surge tank when engine is hot. Allow engine to cool down. Failure to follow this warning may cause serious burns. Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warning may result in injury. a. Replace coolant filter (WP 0090). b. Inspect cooling system for leaks and damage. If authorized, replace damaged components. 4 5 Quarterly Front and Rear (300 Hours) Propeller Shafts Quarterly Tophandler (300 Hours) Pinion and Ring Gear SemiAnnual Pre-Service Checks Lubricate front and rear propeller shafts. Lubrication Order (LO 10-3930-675-13). Lubricate pinion and ring gear. Lubrication Order (LO 10-3930-675-13). PRIOR TO ROAD TEST a. Perform all BEFORE operator/crew PMCS listed in TM 10-3930-675-10 on the machine. Starter is inoperative or b. Start engine (TM 10-3930-675-10). Ensure starter engages smoothly and turns the engine at normal makes excessive grinding noise. cranking speed. DURING OPERATIONAL TEST Any Class III coolant leaks are evident.
NOTE
While performing Operational Driving test, operate vehicle in a location large enough to simulate normal operating conditions of the RTCH. c. Perform all DURING operator/crew PMCS listed in TM 10-3930-675-10 on the machine.
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0048
Table 1.
ITEM NO.
INTERVAL
PROCEDURE
d. Observe response to accelerator pedal. Listen Accelerator pedal does for unusual noises. Observe for hesitation, varying idle not respond to commands, engine hesitates, idle is speed, and sticking or binding of accelerator pedal. not steady or pedal is sticking or binding. e. Be alert of excessive vibration and the smell of Engine knocks, rattles, or smokes excessively. fuel, oil, coolant, and excessive exhaust smoke. f. Ensure transmission is engaging and shifting smoothly through all gear ranges. Be alert for unusual noises and difficulty shifting in all gear ranges g. Check operation of steering modes (TM 10-3930-675-10). Ensure steering modes engage smoothly without grinding or vibration. Transmission shifts improperly, does not shift, or makes excessive noise during operation. Any steering mode inoperative or excessive grinding noise.
h. Turn steering wheel to left, then right, to detect Steering binds, grabs, wanders, or has excessive hard steering, steering backlash, or shimmy. Vehicle play. should respond instantly. With vehicle moving on straight, level terrain, lightly hold steering wheel to check for pull and wandering. Brakes chatter, pull to one i. Apply brake pedal with steady force. Vehicle side, or are inoperative. should slow and stop without pulling to one side or jerking. Release brake pedal. The brakes should release immediately and without difficulty. j. Bring vehicle to a full stop. Engage parking brake Parking brake does not while transmission is in high range and engine is at idle hold vehicle stationary. speed. k. Shift transmission into N (Neutral), engage parking brake. Stop engine (TM 10-3930-675-10). AFTER ROAD TEST Engine will not stop.
NOTE
Ensure vehicle has been cleaned of mud, gravel, etc., from the underbody, outside, and crew compartment area. l. Perform all AFTER operator/crew PMCS listed in the TM 10-3930-675-10 on machine. 7 SemiTransmission Oil Remove and replace transmission oil filters and oil Annual (900 Filter (Volume 2, WP 0140) and Lubrication Order (LO Hours) 10-3930-675-13). SemiAnnual Transmission Vent Hose Replace servo filter and top off hydraulic fluid (Volume 2, WP 0227) and Lubrication Order (LO 10-3930-675-13).
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0048
Table 1.
ITEM NO. 9
INTERVAL
PROCEDURE Replace servo filter and top off hydraulic fluid (Volume 2, WP 0227) and Lubrication Order (LO 10-3930-675-13).
SemiHydraulic Annual (900 System Servo Hours) Filter
10
SemiHydraulic Replace pressure filters and top off hydraulic fluid Annual (900 System Pressure (Volume 2, WP 0227) and Lubrication Order (LO Hours) Filters 10-3930-675-13). SemiHydraulic Replace breather filters (Volume 2, WP 0227) and Annual (900 System Breather Lubrication Order (LO 10-3930-675-13). Hours) Filters SemiHydraulic Replace return filters and top off hydraulic fluid and Annual (900 Reservoir Return Lubrication Order (LO 10-3930-675-13). Hours) Filters SemiHydraulic Annual (900 System Ball Hours) Valves a. Inspect all Hydraulic system ball valves for leaks, Hydraulic system ball valves are not operational. cracks, and loose or missing hardware. b. Check operation of all hydraulic system ball valves.
11
12
13
14
SemiFront Axle Brake Replace front axle brake cooling filters (Volume 2, Annual (900 Cooling Filters WP 0158) and Lubrication Order (LO 10-3930-675-13). Hours) SemiFront Axle Drain and refill front axle differential housing and hub end Annual (900 Differential and Lubrication Order (LO 10-3930-675-13). Hours) Housing and Hub End SemiRear Axle Brake Annual (900 Cooling Filters Hours) Replace rear axle brake cooling filter and Lubrication Order (LO 10-3930-675-13).
15
16
17
SemiRear Axle Drain and refill rear axle differential housing and hub Annual (900 Differential end. Lubrication Order (LO 10-3930-675-13). Hours) Housing and Hub End SemiAnnual SemiAnnual SemiAnnual Front and Rear Axle Vent Hoses Inspect for plugged hoses and valves. Clean if necessary.
18 19
Hydraulic Perform Hydraulic System Test Point Procedures. Test Any pressure outside the Pressure Checks Points 1 through 12 (Volume 2, WP 0245). limits specified in (Volume 2, WP 0245). Parking Brakes Perform parking brake checks (Volume 2, WP 0150).
20 21
SemiTophandler Gear Drain and refill. Lubrication Order (LO 10-3930-675-13). Annual (900 Motors Hours)
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0048
Table 1.
ITEM NO. 22
INTERVAL
PROCEDURE
SemiEngine Bell Annual (900 Housing Hours) SemiAnnual SemiAnnual Bogie Wheel Assembly Cab Tracks and Locking Bars
Remove drain plug from bell housing and check for signs If any Class III leaks are of oil or water. If water or oil is noted, investigate source evident. and correct. Exercise bogie wheel assembly (TM 10-3930-675-10). Inspect and clean as required. Place cab and boom in transport mode (TM 10-3930-675-10) and check for free movement of cab rollers in tracks. Clean and inspect for damage. Replace any damaged component (Volume 2, WP 0179).
23 24
25 26
SemiAnnual SemiAnnual SemiAnnual SemiAnnual
Cab Drain Valves Inspect two drain valves under cab. Press valve with two fingers to drain water. Front and Rear Propeller Shafts Cab Air Filters Cab Air Conditioner Perform cleaning inspection procedures of drive shafts IAW (Volume 2, WP 0143). Service cab air filters (Volume 2, WP 0199). Remove plug from condenser fan box behind cab. With engine and air conditioner running, inspect sight gauge on top of receiver-drier for bubbles. If bubbles are present, recharge air conditioning system IAW (Volume 2, WP 0248). Remove drain plug from bottom of fuel tank to drain water and debris (WP 0074). Perform battery service IAW (WP 0128). If one or more batteries fail test. If hold-down brackets or hardware or slide-out trays are bent or damaged, and would prevent the batteries from being properly secured. Any pressure readings outside limits specified in (Volume 2, WP 0155). Any pressure readings outside limits specified in (Volume 2, WP 0155). Drive shaft is damaged, missing hardware, or damaged U Joints.
27 28
29
SemiFuel Tank Annual (900 Hours) SemiBatteries Annual (900 Hours)
30
31
Annual
Brake Accumulators Steering Accumulators Boom Support Locking Pin Bellows Hydraulic System Oil
Perform brake accumulator pre-charge check IAW (Volume 2, WP 0155). Perform steering accumulator pre-charge check IAW (Volume 2, WP 0155). Replace boom support pin rubber bellows IAW (Volume 2, WP 0235). Drain and refill. Lubrication Order (LO 10-3930-675-13).
32
Annual
33
Biennial
34
Biennial
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0048
Table 2. ITEM NO. PART NUMBER Quarterly 1 2 3 LF9080 FS1000 WF207100
PMCS Mandatory Replacement Parts List. NOMENCLATURE QTY
NSN
Filter, Engine Oil Filter, Fuel Filter, Engine Coolant
1 1 1
Semi-Annual 4 5 6 7 8 9 10 11 12 13 9238280610 9238990289 9230710001 9230710002 9216890009 920130009 9231100668 9231100669 9238990684 9238990685 Filter, Transmission Oil Filter, Transmission Oil, Internal, Coarse Filter, Servo, Hydraulic System Filter, Pressure, Hydraulic System Filter, Pressure, Hydraulic System Filter, Hydraulic Reservoir, Breather Filter, Hydraulic Reservoir, Return Filter, Brake Cooling, Axles Washer, Copper, Hydraulic Motor Drain Plug Washer, Copper, Hydraulic Motor Drain Plug 2 1 1 2 1 2 2 2 2 3
END OF TASK END OF WORK PACKAGE
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CHAPTER 4 MAINTENANCE INSTRUCTIONS
TM 10-3930-675-23-1
0049
FIELD MAINTENANCE SERVICE UPON RECEIPT
INITIAL SETUP: References DA Form 5986-E DD Form 1397 SF Form 364 References (cont.) TM 10-3930-675-10 WP 0048
GENERAL
1. 2.
When a new, used, or reconditioned RTCH is first received, determine whether it has been properly prepared for service and is in condition to perform its mission. Follow the inspection and servicing instructions below.
INSPECTION INSTRUCTIONS 1. 2. 3. 4. 5. Read and follow all precautions and instructions on DD Form 1397. Remove all packing and shipping material, such as tape, tiedowns, protective covers, and shipping seals. Inspect equipment for any damage incurred during shipment. Check if equipment has been modified. Check equipment against packing slip to ensure shipment is complete. Report any discrepancies on SF Form 364. Remove all Basic Issue Item (BII), Additional Authorization List (AAL), and Components of End Item (COEI) equipment and stow IAW TM 10-3930-675-10.
END OF TASK SERVICING INSTRUCTIONS 1. 2. Service the vehicle IAW TM 10-3930-675-10 and Preventive Maintenance Checks and Services (PMCS) (WP 0048). Schedule the next PMCS on DA Form 5986-E. Refer to TM 10-3930-675-10 and perform functional checks of all major vehicle systems.
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0050
FIELD MAINTENANCE ENGINE ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Barring Tool, Engine (Volume 2, WP 0277, Table 1, Item 7) Guide, Electrical Connector (Volume 2, WP 0277, Table 1, Item 35) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Plate, Surface Adapter, Engine Stand (Volume 2, WP 0277, Table 1, Item 55) Sling, Engine and Transmission (Volume 2, WP 0277, Table 1, Item 68) Stand, Engine Rebuild (Volume 2, WP 0277, Table 1, Item 75) Stand, Maintenance, Automotive Engine Support (Volume 2, WP 0277, Table 1, Item 76) Wrench, Torque, Click, Ratcheting, 3/8 In. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Wrench, Torque, Click, Ratcheting, 1/2 In. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Lifting device, 3,000 lb minimum lifting capacity Materials/Parts Compound, Gasket Forming, Silicone (Volume 2, WP 0276, Table 1, Item 13) Diesel Fuel, DF-2 (Volume 2, WP 0276, Table 1, Item 21) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Gasket (Volume 2, WP 0278, Table 1, Item 19) Gasket (Volume 2, WP 0278, Table 1, Item 24) Materials/Parts (cont.) Nut, Self-Locking (Volume 2, WP 0278, Table 1, Item 87) Washer, Lock (Volume 2, WP 0278, Table 1, Item 96) Qty: 12 Personnel Required (2) References WP 0051 WP 0089 Volume 2, WP 0139 Volume 2, WP 0143 Equipment Condition Boom raised to maximum angle (TM 10-3930-675-10) Cab in transport position (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185) Access covers and skid plates removed (Volume 2, WP 0175) Battery cables disconnected (WP 0129) Alternator removed (WP 0091) Coolant drained and coolant lines disconnected from engine (WP 0080) Oil drained from engine (WP 0059) Oil sampling supply hose disconnected (WP 0062) Transmission dipstick removed (Volume 2, WP 0138) Fuel supply and drain return hoses disconnected (WP 0075) Air intake ducts removed (WP 0072) Exhaust system disconnected from turbocharger (WP 0079) Turbocharger removed (WP 0073) Electrical interface wiring harness disconnected (WP 0100) Electrical wiring harness and leads disconnected from starter (WP 0093) Ether cold start system removed (WP 0077) Air conditioning compressor drive belt removed (Volume 2, WP 0251)
0050-1
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0050
CAUTION
If engine and/or transmission is not operational and boom must be elevated, auxiliary pump can be used to provide hydraulic power for boom operation. Operate pump for not more than four minutes and allow pump to cool for not less than two minutes. Perform operate and cool cycle as many times as needed to elevate boom. Failure to allow pump to cool may cause damage to pump. DO NOT begin engine assembly replacement without first having all required tools and equipment to complete the procedure. This will help in reducing the time boom must remain at maximum elevation.
NOTE
Remove engine from front of vehicle using suitable lift. REMOVAL
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel. Engine weighs 2,070 lb (940 kg). Lifting device must have sufficient capacity to lift engine. Failure to follow this warning may result in death or injury to personnel. Improper use of lifting equipment and improper attachment of cables to vehicle can result in serious personnel injury and equipment damage. Observe all standard rules of safety. Fuel lines and hoses may contain residual amounts of fuel that may be spilled. To prevent personnel injury from slipping on spilled fuel, spilled fuel should be cleaned up immediately.
NOTE
If A/C compressor is being removed for access, it is not necessary to disconnect refrigerant lines. 1. 2. 3. Remove all tiedown straps and clamps securing A/C refrigerant lines to engine. Discard tiedown straps. Remove screw (Figure 1, Item 5), washer (Figure 1, Item 6), and nut (Figure 1, Item 7) securing drive belt adjustment arm (Figure 1, Item 8) to A/C compressor (Figure 1, Item 4). Remove screw (Figure 1, Item 5), washer (Figure 1, Item 6), and nut (Figure 1, Item 7) securing drive belt adjustment arm (Figure 1, Item 8) to engine mount bracket (Figure 1, Item 9). Remove drive belt adjustment arm and retain for installation. Remove screw (Figure 1, Item 1), washer (Figure 1, Item 2), and nut (Figure 1, Item 3) securing A/C compressor to engine mount bracket (Figure 1, Item 10).
4.
0050-2
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0050
REMOVAL - Continued
NOTE
When positioning A/C compressor and refrigerant lines free of engine, ensure refrigerant line connections are not loosened or broken, allowing refrigerant to escape from system. 5. With assistance, remove A/C compressor (Figure 1, Item 4) with refrigerant lines attached and position free of engine compartment.
4
1,2,3 5,6,7
10
5,6,7
M0647JCH
Figure 1.
Engine Removal.
0050-3
TM 10-3930-675-23-1
0050
REMOVAL - Continued 6. Remove screw (Figure 2, Item 4), two washers (Figure 2, Item 3), locknut (Figure 2, Item 2), hose clamp (Figure 2, Item 5), and transmission vent hose (Figure 2, Item 6) from bracket (Figure 2, Item 1). Secure vent hose free of engine and discard locknut.
2,3,4 1 5 6
M0648JCH
Figure 2.
Engine Removal.
NOTE
Tag transmission coolant lines to ensure correct installation. 7. 8. Loosen hose clamp (Figure 3, Item 8) and disconnect coolant inlet hose (Figure 3, Item 7) from transmission oil cooler (Figure 3, Item 6). Loosen hose clamp (Figure 3, Item 8) and disconnect coolant outlet hose (Figure 3, Item 9) from transmission oil cooler (Figure 3, Item 6).
NOTE
When removing transmission oil cooler for access, it is not necessary to disconnect oil hoses from transmission oil cooler. 9. 10. 11. 12. Remove hose clamps, screws, washers, and nuts as needed to release transmission oil hoses. Disconnect hydraulic hose (Figure 3, Item 2). Remove three screws (Figure 3, Item 3) and washers (Figure 3, Item 4) securing transmission oil cooler bracket (Figure 3, Item 5) to flywheel housing (Figure 3, Item 1). With assistance, remove transmission oil cooler (Figure 3, Item 6) with hoses attached from flywheel housing (Figure 3, Item 1). Position transmission oil cooler and hoses free of engine lift area.
0050-4
TM 10-3930-675-23-1
0050
REMOVAL - Continued
3,4 5 2 1 6
8 9 8
M0649JCH
Figure 3.
Engine Removal.
NOTE
When removing transmission oil filters and bracket for access, it is not necessary to disconnect transmission oil hoses from filters. 13. 14. Remove two screws (Figure 4, Item 2) and washers (Figure 4, Item 3) securing transmission oil filter bracket (Figure 4, Item 4) to flywheel housing (Figure 4, Item 1). Remove transmission oil filters (Figure 4, Item 5) and bracket (Figure 4, Item 4) from flywheel housing (Figure 4, Item 1). Position free of engine lift area.
1 2,3 4
M0650JCH
Figure 4.
Engine Removal
0050-5
TM 10-3930-675-23-1
0050
REMOVAL - Continued
NOTE
When removing cooling fan hydraulic pump from engine, it is not necessary to disconnect two hydraulic hoses attached. 15. Remove cooling fan hydraulic pump from drive adapter of engine and set pump aside (WP 0089).
WARNING
Engine weighs 2,070 lb (940 kg). Lifting device must have sufficient capacity to lift engine. Failure to follow this warning may result in death or injury to personnel. 16. 17. Connect engine lifting fixture and suitable lifting device to engine front and rear lifting brackets. Take slack out of chains. Remove four screws (Figure 5, Item 4), access cover (Figure 5, Item 1), and gasket (Figure 5, Item 2) from bottom of flywheel housing (Figure 5, Item 3). Discard gasket.
2 3
M0651JCH
Figure 5.
Engine Removal.
0050-6
TM 10-3930-675-23-1
0050
REMOVAL - Continued 18. Remove 12 screws (Figure 6, Item 1) and lockwashers (Figure 6, Item 2) securing transmission to engine flywheel housing (Figure 6, Item 3). Discard lockwashers.
1,2
M0652JCH
Figure 6.
Engine Removal.
NOTE
Ensure engine weight is supported by lifting device. 19. Remove four screws (Figure 7, Item 2) securing right rear engine and transmission mounting bracket (Figure 7, Item 1) to flywheel housing (Figure 7, Item 3).
2 1
3
M0653JCH
Figure 7.
Engine Removal.
0050-7
TM 10-3930-675-23-1
0050
REMOVAL - Continued 20. Remove four screws (Figure 8, Item 2) securing left rear engine and transmission mounting bracket (Figure 8, Item 3) to flywheel housing (Figure 8, Item 1).
2 2
M0654JCH
Figure 8. 21.
Engine Removal.
Disconnect front engine mounts from engine and frame. Move front engine mounts forward to gain access to remove engine (WP 0051).
NOTE
Damper plates and torque converter should remain with engine during engine removal. It may be necessary to tap on transmission-to-engine connection point with plastic-faced hammer to break seal between two units. 22. Carefully separate engine from transmission and lift engine from vehicle.
0050-8
TM 10-3930-675-23-1
0050
REMOVAL - Continued
NOTE
If replacement engine is being installed, inspect removed engine for components to be removed and transferred to replacement engine. 23. 24. Secure engine on suitable stand or in container. Remove two screws (Figure 9, Item 2), cover (Figure 9, Item 3), and gasket (Figure 9, Item 1) from flywheelto-damper plate mounting screw access.
3
M0655JCH
Figure 9.
Engine Removal.
0050-9
TM 10-3930-675-23-1
0050
REMOVAL - Continued
NOTE
Flywheel is secured to transmission damper plates with 12 screws. 25. 26. 27. 28. With assistance, bar engine in clockwise direction using accessory drive while observing through access hole. Stop rotation when screw is visible through access hole. Remove screw (Figure 10, Item 1) securing flywheel to damper plate. Repeat Steps 25 and 26 to remove remaining eleven screws (Figure 10, Item 1). Upon removal of last screw, insert guide stud and secure to damper plate.
M0656JCH
Figure 10.
Engine Removal.
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel. 29. Remove torque converter and damper plates from engine.
END OF TASK
0050-10
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0050
INSTALLATION
WARNING
Engine weighs 2,070 lb (940 kg). Lifting device must have sufficient capacity to lift engine. Failure to follow this warning may result in death or injury to personnel.
NOTE
Ensure all bracket mounting, engine mating, and transmission mating surfaces have been cleaned and are free of old gasket forming compound and gasket material. Prior to lowering engine into vehicle, ensure flywheel-to-damper plate screw hole is visible through access hole in flywheel housing. 1. 2. 3. Install torque converter and damper plates on transmission (Volume 2, WP 0139). Using suitable lifting device and engine lifting fixture, lower engine into vehicle. Apply coat of silicone gasket forming compound to engine and transmission mating surface.
NOTE
It may be necessary to adjust transmission damper plate by hand to align guide stud with mating flywheel screw hole. 4. Position engine to allow damper plate guide stud to pass through flywheel-to-damper screw hole and flywheel housing access.
0050-11
TM 10-3930-675-23-1
0050
INSTALLATION - Continued
NOTE
Flywheel and damper plates are secured with 12 screws; final tightening is done after all screws are installed. 5. 6. 7. 8. Remove guide stud and install screw (Figure 11, Item 1). Tighten screw hand-tight. Bar engine over until next screw hole is visible and install screw (Figure 11, Item 1). Tighten screw hand-tight. Repeat Step 6 for remaining screws until 12 screws are installed securing flywheel to damper plate. Bar engine over clockwise and tighten each screw (Figure 11, Item 1) to 48 ft-lb (65 Nm).
M0656JCH
Figure 11.
Engine Installation.
0050-12
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 9. Install 12 screws (Figure 12, Item 1) and new lockwashers (Figure 12, Item 2) to secure transmission to flywheel housing (Figure 12, Item 3). Tighten screw to 38 ft-lb (52 Nm).
1,2
M0652JCH
Figure 12. 10.
Install access cover (Figure 13, Item 1) and new gasket (Figure 13, Item 2) on bottom of flywheel housing (Figure 13, Item 3) with four screws (Figure 13, Item 4).
2 3
M0651JCH
Figure 13.
0050-13
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 11. Install cover (Figure 14, Item 3) and new gasket (Figure 14, Item 1) with two screws (Figure 14, Item 2) over flywheel-to-damper plate screw access.
3
M0655JCH
Figure 14. 12.
Apply gasket forming compound to mounting surface and install four screws (Figure 15, Item 2) to secure right rear engine and transmission mounting bracket (Figure 15, Item 1) to flywheel housing (Figure 15, Item 3). Tighten screws to 116 ft-lb (157 Nm).
2 1
3
M0653JCH
Figure 15.
0050-14
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 13. Apply gasket forming compound to mounting surface and install four screws (Figure 16, Item 2) to secure left rear engine and transmission mounting bracket (Figure 16, Item 3) to flywheel housing (Figure 16, Item 1). Tighten screws to 116 ft-lb (157 Nm).
2 2
M0654JCH
Figure 16.
0050-15
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 14. 15. 16. Install front engine mounts on frame and engine (WP 0051). Release tension on engine lifting fixture chains and disconnect lifting device and lifting fixture from engine lifting brackets. Apply gasket forming compound to mounting surface on flywheel housing (Figure 17, Item 1) and install two screws (Figure 17, Item 2) and washers (Figure 17, Item 3) to secure transmission oil filter bracket (Figure 17, Item 4) with transmission oil filters (Figure 17, Item 5) and hoses in place. Tighten screws to 116 ft-lb (157 Nm).
1 2,3 4
M0650JCH
Figure 17.
0050-16
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 17. 18. Install cooling fan hydraulic pump on drive adapter of engine (WP 0089). Apply gasket forming compound to mounting surface on flywheel housing (Figure 18, Item 1) and install three screws (Figure 18, Item 3) and washers (Figure 18, Item 4) to secure transmission oil cooler bracket (Figure 18, Item 5) with oil cooler (Figure 18, Item 6) and transmission oil hoses. Tighten screws to 116 ft-lb (157 Nm). Connect hydraulic hose (Figure 18, Item 2). Install hose clamps, screws, washers, and nuts as necessary to secure transmission oil hoses. Install coolant inlet hose (Figure 18, Item 7) and coolant hose outlet (Figure 18, Item 9) on transmission oil cooler (Figure 18, Item 6) and secure with hose clamps (Figure 18, Item 8).
3,4 5 2 1 6
19. 20. 21.
8 9 8
M0649JCH
Figure 18.
0050-17
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 22. Install transmission vent hose (Figure 19, Item 6), hose clamp (Figure 19, Item 5), screw (Figure 19, Item 4), two washers (Figure 19, Item 3), and new locknut (Figure 19, Item 2) on bracket (Figure 19, Item 1).
2,3,4 1 5 6
M0648JCH
Figure 19.
0050-18
TM 10-3930-675-23-1
0050
INSTALLATION - Continued 23. Position A/C compressor (Figure 20, Item 4) with refrigerant lines on engine mount bracket (Figure 20, Item 10) and secure with screw (Figure 20, Item 1), washer (Figure 20, Item 2), and nut (Figure 20, Item 3). Position drive belt adjustment arm (Figure 20, Item 8) and secure one end to engine mount bracket (Figure 20, Item 9) and opposite end to A/C compressor (Figure 20, Item 4) with two screws (Figure 20, Item 5), washers (Figure 20, Item 6), and nuts (Figure 20, Item 7).
4
24.
1,2,3 5,6,7
10
5,6,7
M0647JCH
Figure 20. END OF TASK
0050-19
TM 10-3930-675-23-1
0050
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install and adjust A/C compressor drive belt (Volume 2, WP 0251). Install ether cold start system (WP 0077). Connect electrical wiring harness and leads to starter (WP 0093). Connect electrical interface wiring harness to ECU (WP 0100). Install turbocharger (WP 0073). Connect exhaust system to turbocharger (WP 0079). Install air intake ducts (WP 0072). Connect fuel supply and drain return hoses (WP 0075). Install transmission dipstick (Volume 2, WP 0138). Connect oil sampling supply hose to engine (WP 0062). Connect coolant lines to engine (WP 0080). Install alternator (WP 0091). Connect battery cables (WP 0129). Check and fill all fluids (fuel, coolant, engine oil, transmission oil) to proper level (WP 0047).
CAUTION
If normal engine oil pressure is not indicated within 15 seconds, shut down engine immediately. Failure to follow this caution may result in serious engine damage. 15. 16. 17. 18. 19. Operate engine for three minutes, shut down, and check for fluid leaks and proper indications (TM 10-3930-675-10). Operate engine to normal temperature and check operation (TM 10-3930-675-10). Install access covers and skid plates (Volume 2, WP 0175). Install engine cover (Volume 2, WP 0185). Return cab to operational position and lower boom (TM 10-3930-675-10).
0050-20
TM 10-3930-675-23-1
0051
FIELD MAINTENANCE ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Stand, Vehicle Support (Volume 2, WP 0277, Table 1, Item 77) Wrench, Torque, Click, Ratcheting, 3/4 in. Drive, 600 ft-lb (Volume 2, WP 0277, Table 1, Item 96) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Sealing Compound Dissimilar Metal Protection (Volume 2, WP 0276, Table 1, Item 58) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Personnel Required (2) Equipment Condition Engine cover removed (Volume 2, WP 0185) Cab in transport position (TM 10-3930-675-10) Access covers removed (Volume 2, WP 0175)
0051-1
TM 10-3930-675-23-1
0051
LIFTING BRACKETS REMOVAL 1. 2. Remove four screws (Figure 1, Item 1) securing front lifting bracket (Figure 1, Item 2) and two screws (Figure 1, Item 4) securing rear lifting bracket (Figure 1, Item 3). Remove front and rear lifting brackets (Figure 1, Items 2 and 3) from cylinder head (Figure 1, Item 5).
2 3 1
5
Figure 1. END OF TASK Lifting Brackets Removal.
M0657JCH
0051-2
TM 10-3930-675-23-1
0051
LIFTING BRACKETS INSTALLATION
CAUTION
DO NOT use or install a cracked, bent, or otherwise damaged lifting bracket. Do not weld a cracked bracket. Doing so may cause severe equipment damage during lifting operations.
NOTE
Ensure lifting brackets are not cracked or bent and are clean and free of dirt. 1. 2. Position front lifting bracket (Figure 2, Item 2) and secure with four screws (Figure 2, Item 1). Tighten screws to 35 ft-lb (47 Nm). Position rear lifting bracket (Figure 2, Item 3) and secure with two screws (Figure 2, Item 4). Tighten screws to 60 ft-lb (81 Nm).
2 3 1
5
Figure 2. END OF TASK Lifting Brackets Installation.
M0657JCH
0051-3
TM 10-3930-675-23-1
0051
FRONT ENGINE MOUNT REMOVAL
CAUTION
Position trestle under front of engine to assist with supporting weight while front engine mounts are not in place. DO NOT, however, position trestle under oil pan. Damage to oil pan may result. 1. Position suitable lifting device and attach to engine front lifting bracket (Figure 2, Item 2).
NOTE
Right and left front engine shock mounts are removed in the same manner. Perform steps 2 thru 5 on both front engine shock mounts. 2. Loosen two jamnuts (Figure 3, Item 9) and adjusting screws (Figure 3, Item 8).
NOTE
Adjust lifting device to support weight of engine without applying tension on mounting hardware. 3. 4. 5. Remove screw (Figure 3, Item 5) and washer (Figure 3, Item 6) securing front engine mount (Figure 3, Item 4) to shock mount (Figure 3, Item 7). Remove two nuts (Figure 3, Item 13), four washers (Figure 3, Items 11 and 12), and two screws (Figure 3, Item 10) securing shock mount (Figure 3, Item 7) in place. Lift engine (Figure 3, Item 1) slightly to relieve pressure on shock mount (Figure 3, Item 7). Remove shock mount.
NOTE
To remove front engine mount, perform steps 6 and 7. 6. 7. Remove six screws (Figure 3, Item 2) and washers (Figure 3, Item 3) securing front engine mount (Figure 3, Item 4) to engine (Figure 3, Item 1). Remove front engine mount (Figure 3, Item 4) from vehicle.
END OF TASK
0051-4
TM 10-3930-675-23-1
0051
FRONT ENGINE MOUNT INSTALLATION
NOTE
If front engine mount was removed, perform step 1 to reinstall. 1. Apply a light coat of sealing compound to front engine mount (Figure 3, Item 4) and install on engine (Figure 3, Item 1) with six washers (Figure 3, Item 3) and screws (Figure 3, Item 2). Tighten screws to 50 ft-lb (68 Nm).
NOTE
Ensure engine is supported by suitable lifting device and remove trestle from under front of engine. 2. 3. 4. Position shock mount (Figure 3, Item 7) and secure in place with two screws (Figure 3, Item 10), four washers (Figure 3, Items 11 and 12), and two nuts (Figure 3, Item 13). Tighten nuts to 125 ft-lb (169 Nm). Position front engine mount (Figure 3, Item 4) over shock mount (Figure 3, Item 7) and secure with screw (Figure 3, Item 5) and washer (Figure 3, Item 6). Tighten screw to 288 ft-lb (390 Nm). Set front engine mount adjusting screws (Figure 3, Item 8) for a clearance of 0.12 in. (3 mm) and tighten jamnuts (Figure 3, Item 9).
1 2,3 4 5,6 7 8 8 9 10,11,12,13 9
0.12 in. (3 mm)

M0658JCH
Front Engine Mount Installation.
0051-5
TM 10-3930-675-23-1
0051
REAR ENGINE MOUNT REMOVAL
CAUTION
Position trestle under rear of engine to assist with supporting weight while rear engine mount is not in place. DO NOT, however, position trestle under oil pan. Damage to oil pan may result. 1. Position suitable lifting device and attach to engine lifting brackets.
NOTE
Left and right rear engine shock mounts are removed in the same manner. 2. Loosen two jamnuts (Figure 4, Item 10) and adjusting screws (Figure 4, Item 9).
NOTE
Adjust lifting device to support weight of engine without applying tension on mounting hardware. 3. 4. 5. 6. 7. Remove four screws (Figure 4, Item 5) and washers (Figure 4, Item 6) to disconnect rear support bracket (Figure 4, Item 4) from engine. Remove two screws (Figure 4, Item 7) and washers (Figure 4, Item 8) to disconnect rear support bracket (Figure 4, Item 4) from transmission. Remove screw (Figure 4, Item 2) and washer (Figure 4, Item 3) securing rear support bracket (Figure 4, Item 4) to shock mount (Figure 4, Item 1). With assistance, lift rear support bracket (Figure 4, Item 4) from installed location. Remove two nuts (Figure 4, Item 14), four washers (Figure 4, Items 12 and 13), two screws (Figure 4, Item 11), and shock mount (Figure 4, Item 1).
END OF TASK
0051-6
TM 10-3930-675-23-1
0051
REAR ENGINE MOUNT INSTALLATION 1. Position shock mount (Figure 4, Item 1) and secure in place with two screws (Figure 4, Item 11), four washers (Figure 4, Items 12 and 13), and two nuts (Figure 4, Item 14). Tighten nuts to 125 ft-lb (169 Nm).
NOTE
Ensure engine and transmission are supported by suitable lifting device and remove trestle from under engine. 2. With assistance, lower rear support bracket (Figure 4, Item 4) into position over shock mount (Figure 4, Item 1) and secure with screw (Figure 4, Item 2) and washer (Figure 4, Item 3). Tighten screw to 288 ft-lb (390 Nm). Position rear support bracket (Figure 4, Item 4) on engine and secure four screws (Figure 4, Item 5) and washers (Figure 4, Item 6). Tighten screws to 115 ft-lb (156 Nm). Position rear support bracket (Figure 4, Item 4) on transmission and secure with two screws (Figure 4, Item 7) and washers (Figure 4, Item 8). Tighten screws to 100 ft-lb (135 Nm). Set rear support bracket adjusting screws (Figure 4, Item 9) for a clearance of 0.12 in. (3 mm) and tighten jamnuts (Figure 4, Item 10).
3. 4. 5.
4 2,3 1 5,6 5,6 7,8
10 9
11,12,13,14
10 9
0.12 in. (3 mm)

M0659JCH
Rear Engine Mount Removal.
0051-7
TM 10-3930-675-23-1
0051
FOLLOW-ON MAINTENANCE 1. 2. 3. Install access covers (Volume 2, WP 0175). Return cab to operational position (TM 10-3930-675-10). Install engine cover (Volume 2, WP 0185).
0051-8
TM 10-3930-675-23-1
0052
FIELD MAINTENANCE CYLINDER HEAD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Expansion Plug Driver (Volume 2, WP 0277, Table 1, Item 25) Gage, Capscrew, Cylinder Head (Volume 2, WP 0277, Table 1, Item 26) Lifting Bracket, Cylinder Head (Volume 2, WP 0277, Table 1, Item 51) Straight Edge (36 in. Length) (Volume 2, WP 0277, Table 1, Item 78) Materials/Parts Abrasive Pad (Volume 2, WP 0276, Table 1, Item 1) Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Diesel Fuel, DF-2 Grade Bulk (Volume 2, WP 0276, Table 1, Item 21) Materials/Parts (cont.) Oil, Lubricating, Engine (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 71) References TM 10-3930-675-10 WP 0056 Equipment Condition Air intake ducts removed (WP 0072) Rocker arm cover removed (WP 0057) Turbocharger removed (WP 0073) Exhaust manifold removed (WP 0063) Cooling system drained (WP 0080)
REMOVAL 1. Remove four screws (Figure 1, Item 1) securing front lifting bracket (Figure 1,Item 2) and two screws (Figure 1, Item 4) securing rear lifting bracket (Figure 1, Item 3) to cylinder head (Figure 1, Item 5).
2 3 1
5
Figure 1. Cylinder Head Removal.
M0657JCH
0052-1
TM 10-3930-675-23-1
0052
REMOVAL - Continued 2. Disconnect connector (Figure 2, Item 1) of cylinder head wiring harness (Figure 2,Item 3) from engine harness (Figure 2, Item 2).
3
M0660JCH
NOTE
Tag wiring harness to identify injector connections and positions prior to removal to ensure correct connection on installation. 3. 4. Disconnect six fuel injector connectors (Figure 3, Item 4) from cylinder head wiring harness (Figure 3, Item 1). Remove screws (Figure 3, Item 2) securing clamps (Figure 3, Item 3) and cylinder head wiring harness (Figure 3, Item 1) in place and remove cylinder head wiring harness.
2 3 1
M0661JCH
Figure 3.
Cylinder Head Removal.
0052-2
TM 10-3930-675-23-1
0052
REMOVAL - Continued
NOTE
Mark position of valve push tubes and injector push rods. Push tubes and rods must be installed in the same positions during installation. 5. Loosen rocker lever adjusting screws (Figure 4, Item 1). Remove valve push tubes (Figure 4, Item 3) and injector push rods (Figure 4, Item 2).
1 2
M0662JCH
Figure 4. 6. Remove rocker arm assembly (WP 0056).
NOTE
Mark position of crossheads prior to removal. Crossheads must be installed in the same position during assembly. 7. Remove crossheads (Figure 5, Item 1).
1
M0663JCH
Figure 5.
0052-3
TM 10-3930-675-23-1
0052
REMOVAL - Continued
NOTE
Rocker lever housing and intake manifold are removed as a single unit. 8. Remove 24 screws (Figure 6, Item 1) securing rocker lever housing (Figure 6, Item 2) and gasket (Figure 6, Item 3) to cylinder head (Figure 6, Item 4). Remove rocker lever housing and intake manifold as a single unit.
1 2
M0664JCH
Figure 6. 9. 10.
Disconnect fuel supply line (Figure 7, Item 1) and fuel drain line (Figure 7, Item 3) from cylinder head (Figure 7, Item 5). Remove seven 12-point cylinder head screws (Figure 7, Item 2) and sealing washers (Figure 7, Item 4) from fuel pump side of engine.
2 3 4 2 2
M0665JCH
Figure 7.
0052-4
TM 10-3930-675-23-1
0052
REMOVAL - Continued
NOTE
Three cylinder head screws are located inside intake ports. 11. Remove remaining 32 cylinder head screws in sequence shown in Figure 8.
22 28 26 32 18 16 12 8 6 2 4 7 20 10 14 17 24 27 30
29 31 25 21 15 11 3 1 5 9 13 19 23
M0666JCH
Figure 8. 12.
Install cylinder head lifting bracket (Figure 9, Item 1) on cylinder head (Figure 9, Item 2) and secure with two rocker lever support mounting screws and two long rocker housing screws. Tighten screws to 35 ft-lb (47 Nm).
1
M0667JCH
Figure 9.
0052-5
TM 10-3930-675-23-1
0052
REMOVAL - Continued
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel.
CAUTION
Place cylinder head on wooden blocks to prevent damage to combustion face. 13. Attach lifting device to cylinder head lifting bracket (Figure 10, Item 1). Lift cylinder head (Figure 10, Item 2) from engine and place on wooden blocks. Remove and discard head gasket (Figure 10, Item 3).
1
M0668JCH
Figure 10. Cylinder Head Removal. END OF TASK
0052-6
TM 10-3930-675-23-1
0052
CLEANING
WARNING
Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. Failure to comply may cause injury or death to personnel.
NOTE
Place clean, lint-free rags over cam followers and above pistons to prevent dirt and other foreign matter from entering engine. Plug or cover coolant and oil passages in cylinder block deck. 1. Remove all gasket material from cylinder block deck surface.
CAUTION
DO NOT use caustic or acid solutions to clean cylinder head screws. Doing so will result in damage to equipment. 2. Clean threads of cylinder head screws with cleaning compound, solvent and wire brush.
WARNING
When using steam cleaner, wear protective clothing and eye protection. Hot steam will cause serious burns. Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel. 3. 4. Steam clean cylinder head and dry with compressed air. Use Abrasive Pad to clean exhaust gasket surface, rocker housing gasket surface, and combustion face of cylinder head.
END OF TASK
0052-7
TM 10-3930-675-23-1
0052
INSPECTION 1. Visually inspect fuel drillings and water passages for restrictions or foreign material. Remove any obstructions.
NOTE
If conditions in steps 2 and 3 below are found, cylinder head must be disassembled and repaired. If conditions are not noted, proceed to step 4. 2. 3. Visually inspect valves (Figure 11, Item 1) and valve springs (Figure 11, Item 4) for cracks, bent or broken valve stems (Figure 11, Item 2), broken valve spring collets (Figure 11, Item 3), or other damage. Visually inspect valves (Figure 11, Item 1) for indications of leakage or burning.
1 2 3 4
M0669JCH
Figure 11. 4.
Cylinder Head Inspection.
Perform leak test for exhaust valves as follows: a. b. c. d. Place cylinder head (Figure 12, Item 1) on work bench with exhaust ports facing up. Pour fuel into exhaust port (Figure 12, Item 2) until full. If fuel drips (Figure 12, Item 3) or runs down face of head within 30 seconds, disassemble and repair cylinder head. Perform steps b and c for each exhaust port.
0052-8
TM 10-3930-675-23-1
0052
INSPECTION - Continued
1 2
M0670JCH
Figure 12. 5.
Perform leak test for intake valves as follows: a. b. Place cylinder head on work bench with exhaust ports facing up. Pour fuel into one intake port until full.
NOTE
Each intake port supplies two cylinders on M Series cylinder heads. c. d. If fuel drips or runs down face of cylinder head within 30 seconds, disassemble and repair cylinder head. Perform steps b and c for all six cylinders.
0052-9
TM 10-3930-675-23-1
0052
NOTE
Dimensions CC and DD must be checked from front to rear of cylinder head if head is going to be rebuilt. 6. Measure flatness of cylinder head combustion face surface as follows: a. b. c. d. AA and BB (corner to corner). CC (across combustion face). DD (across entire head surface). Measurements must be as noted in Table 1.
D B
C
Figure 13.
A
M0671JCH
Table 1. CYLINDER HEADFLATNESS AA and BB CC DD MM 0.200 0.076 0.127
Cylinder Head Flatness Measurements. MAXIMUM MAX MAX MAX ALLOWABLE DEVIATION IN. 0.008 0.003 0.005
0052-10
TM 10-3930-675-23-1
0052
NOTE
Use slot marked for L10 cylinder head screws when checking M11 cylinder head screws. 7. Check free length of 32 cylinder head screws (Figure 14, Item 2) using screw length gauge (Figure 14, Item 1). If end of screw touches foot of gauge, screw is too long and must be replaced. If there is clearance between end of screw and bottom base of gauge, screw can be reused.
1
Clearance
2
M0672JCH
Figure 14. 8.
Inspect push rods (Figure 15, Item 2) and push tubes (Figure 15, Item 1) for excessive or uneven wear and bending. If push rod or tube is bent, shows excessive wear, or is filled with oil, it must be replaced.
1
Figure 15. END OF TASK Cylinder Head Inspection.
M0673JCH
0052-11
TM 10-3930-675-23-1
0052
INSTALLATION
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel.
CAUTION
DO NOT drop cylinder head on gasket. Gasket material can be damaged.
NOTE
Ensure shipping plug and plastic insert are removed from fuel inlet and fuel drain passage. If plastic insert is not removed from passage of fuel inlet line connection, engine will not start. 1. 2. Position new cylinder head gasket (Figure 16, Item 5) on engine block and set cylinder head (Figure16, Item 1) in place. Apply a light coating of clean lubricating oil to thread (Figure 16, Item 4) and flange (Figure 16, Item 3) area of cylinder head screws (Figure 16, Item 2).
NOTE
Ensure three cylinder head screws are installed inside intake ports. 3. Install and hand-tighten 32 cylinder head screws (Figure 16, Item 2).
4
Figure 16. Cylinder Head Installation.
M0686JCH
0052-12
TM 10-3930-675-23-1
0052
INSTALLATION - Continued 4. Tighten cylinder head screws to 100 ft-lb (136 Nm) in sequence shown in Figure 17. Repeat sequence and tighten to 160 ft-lb (217 Nm).
22 28 26 32 18 16 12 8 6 2 4 7 20 10 14 17 24 27 30
29 31 25 21 15 11 3 1 5 9 13 19 23
M0687JCH
Figure 17. 5. 6. 7.
Cylinder Head Installation.
Tighten cylinder head screws (Figure 18, Item 2) an additional 90 degrees after completing step 4. Install seven new sealing washers (Figure 18, Item 4) and screws (Figure 18, Item 2) on fuel pump side of cylinder head (Figure 18, Item 5). Connect fuel supply line (Figure 18, Item 1) and fuel drain line (Figure 18, Item 3).
2 3 4 2 2
M0665JCH
Figure 18.
0052-13
TM 10-3930-675-23-1
0052
INSTALLATION - Continued 8. Tighten cylinder head screws to 50 ft-lb (68 Nm) in sequence shown in Figure 19.
M0688JCH
Figure 19.
NOTE
Ensure rocker lever housing is clean and free of old gasket material. 9. 10. Install new gasket (Figure 20, Item 3) and rocker lever housing (Figure 20, Item 2) on cylinder head (Figure 20, Item 4). Install and tighten 24 screws (Figure 20, Item 1) to 25 ft-lb (34 Nm) in sequence shown in Figure 21. Repeat sequence, tightening to 45 ft-lb (61 Nm).
1 2
M0664JCH
Figure 20.
0052-14
TM 10-3930-675-23-1
0052
15 19 11 7 1 3 5 22 13 17
24
21 20 16 12 9 8 2 4 6 10 14 18 23
M0690JCH
Figure 21. 11. 12. Install rocker arm assembly (WP 0056).
Position cylinder head wiring harness (Figure 22, Item 3). Connect cylinder head wiring harness connector (Figure 22, Item 1) to engine wiring harness (Figure 22, Item 2).
3
Figure 22. Cylinder Head Installation.
M0660JCH
0052-15
TM 10-3930-675-23-1
0052
INSTALLATION - Continued 13. 14. Install wire clamps (Figure 23, Item 3) and secure cylinder head wiring harness (Figure 23, Item 1) in place with screws (Figure 23, Item 2). Tighten screws to 15 ft-lb (20 Nm). Connect six fuel injector connectors (Figure 23, Item 4) to cylinder head wiring harness (Figure 23, Item 1).
2 3 1
M0661JCH
NOTE
Crossheads must be installed in the same position from which they were removed. 15. 16. Install crossheads (Figure 23, Item 1). Apply a light coat of clean lubricating oil to ball end of valve push tubes (Figure 23, Item 2) and injector push rods (Figure 23, Item 3).
NOTE
Injector push rods are smaller diameter and longer than valve push tubes. Both push rods and push tubes must be installed as noted during removal. 17. Install valve push tubes (Figure 23, Item 2) and injector push rods (Figure 23, Item 3) as noted during removal.
1 2
M0691JCH
Figure 24.
0052-16
TM 10-3930-675-23-1
0052
INSTALLATION - Continued 18. Adjust valves and injectors (WP 0056).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install exhaust manifold (WP 0063). Install turbocharger (WP 0073). Install rocker arm cover (WP 0057). Install air intake ducts (WP 0072). Fill cooling system (WP 0080). Operate engine and check for leaks (TM 10-3930-675-10).
0052-17/18 blank
TM 10-3930-675-23-1
0053
FIELD MAINTENANCE VIBRATION DAMPER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Barring Tool, Engine (Volume 2, WP 0277, Table 1, Item 7) Guide Roller and Pin Kit Assy (Volume 2, WP 0277, Table 1, Item 36) Indicator, Dial (Volume 2, WP 0277, Table 1, Item 40) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)
0053-1
TM 10-3930-675-23-1
0053
REMOVAL 1. 2. Remove two screws (Figure 1, Item 1) from clamping plate (Figure 1, Item 3). Install guide studs (Figure 1, Item 2) in holes. Remove three remaining screws (Figure 1, Item 1) and replace with guide studs (Figure 1, Item 2).
CAUTION
DO NOT use hammer or screwdriver to remove vibration damper. These tools can damage vibration damper. 3. Remove clamping plate (Figure 1, Item 3), crankshaft pulley (Figure 1, Item 5), and vibration damper (Figure 1, Item 4) from engine.
3 4
M0700JCH
Figure 1. Vibration Damper Removal. END OF TASK INSPECTION
NOTE
Ensure vibration damper has been cleaned and is free of dirt, grease, and other foreign matter. 1. 2. Check mounting web for cracks and housing for dents or raised surfaces. If any of these conditions are noted, vibration damper must be replaced. Scrape paint from four locations on either side of vibration damper as shown.
NOTE
Thickness check will result in a total of eight measurements. If thickness recorded varies more than 0.010 in. (0.25 mm) between any of eight measurements, or if thickness at any one point exceeds 1.772 in. (45 mm), replace vibration damper. 3. Measure and record thickness of vibration damper at two places on each of four selected locations as follows: a. Measure thickness at 0.125 in. (3.18 mm) from outer lip.
0053-2
TM 10-3930-675-23-1
0053
INSPECTION - Continued b. Measure thickness at 1.0 in. (25.4 mm) from outer lip.
1 in. (25.4 mm)

Figure 2. Thickness Measure
0.125 in. (3.18 mm)
M0701JCH
NOTE
Eccentricity (out of round) and wobble (face alignment) checks are performed to verify correct installation and serviceability of vibration damper. If either check exceeds 0.011 in. (0.28 mm), vibration damper is defective and must be replaced. 4. Attach dial indicator to front cover as indicated and "0" dial indicator. Manually bar engine over one complete revolution (360 degrees) and record total movement of dial indicator.
ECCENTRICITY CHECK
M0702JCH
Figure 3.
Eccentricity Check.
0053-3
TM 10-3930-675-23-1
0053
NOTE
Ensure crankshaft is to front or rear of engine and 0" dial indicator. 5. Position dial indicator to measure wobble (face alignment) as shown. Manually bar engine over one complete revolution (360 degrees) and record total indicator movement.
WOBBLE CHECK
M0703JCH
Wobble Check.
0053-4
TM 10-3930-675-23-1
0053
INSTALLATION
NOTE
Ensure mounting surface of crankshaft is clean and free of dirt. 1. Position vibration damper (Figure 5, Item 4) over guide studs (Figure 5, Item 2) and slide in place.
NOTE
Ensure mounting screw threads are lubricated with clean oil prior to installation. 2. 3. Install clamping plate (Figure 5, Item 3) and crankshaft pulley (Figure 5, Item 5). Remove three guide studs (Figure 5, Item 2) and install screws (Figure 5, Item 1) hand-tight. Remove two guide studs (Figure 5, Item 2) and install remaining screws (Figure 5, Item 1). Tighten all screws in a star pattern to 150 ft-lb (203 Nm).
3 4
3
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Start engine (TM 10-3930-675-10) and check operation. Install engine cover (Volume 2, WP 0185). Vibration Damper Installation.
M0704JCH
0053-5/6 blank
TM 10-3930-675-23-1
0054
FIELD MAINTENANCE FLYWHEEL ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Attachment Dial (Volume 2, WP 0277, Table 1, Item 6) Barring Tool, Engine (Volume 2, WP 0277, Table 1, Item 7) Guide Roller and Pin Kit Assy (Volume 2, WP 0277, Table 1, Item 36) Indicator, Dial (Volume 2, WP 0277, Table 1, Item 40) Tools and Special Tools (cont.) Stand, Maintenance, Automotive Engine Support (Volume 2, WP 0277, Table 1, Item 76) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Personnel Required (2) Equipment Condition Engine removed (WP 0050)
0054-1
TM 10-3930-675-23-1
0054
REMOVAL
NOTE
Two screws are installed into tapped holes in flywheel and are used to loosen flywheel from crankshaft. 1. 2. Install two screws (Figure 1, Item 1) at positions A" and B" on flywheel (Figure 1, Item 4). Remove two mounting screws (Figure 1, Item 3) and replace with guide pins (Figure 1, Item 2).
A B 1
4 1
2
M0705JCH
Figure 1. Flywheel Assembly Removal.
0054-2
TM 10-3930-675-23-1
0054
REMOVAL - Continued
NOTE
T-handles, or similar devices, are used to provide attachment points for lifting device sling. T-handles are normally fabricated using bar stock. Suitably-sized bolts or eyebolts may also be used. Check torque converter mounting holes for thread size and use appropriate T-handles. Normal U. S. customary thread sizes are 3/8-16 in., 7/16-20 in., and -13 in., Ensure correct size is used. 3. 4. Install two T-handles (Figure 2, Item 3) into flywheel (Figure 2, Item 1) at opposite points suitable for lifting. Remove remaining mounting screws (Figure 2, Item 2) from flywheel (Figure 2, Item 1).
1 2
M0706JCH
Figure 2.
Flywheel Assembly Removal.
0054-3
TM 10-3930-675-23-1
0054
REMOVAL - Continued
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel. Flywheel weighs 50 lb (23 kg) or more. Use suitable lifting device or assistance to lift flywheel. 5. 6. Install nylon sling on T-handles and attach to suitable lifting device. Tighten screws (Figure 3, Item 3) in alternating sequence to loosen and remove flywheel (Figure 3, Item 2) from crankshaft (Figure 3, Item 1).
1 2
M0707JCH
Figure 3. Flywheel Assembly Removal. END OF TASK
0054-4
TM 10-3930-675-23-1
0054
INSPECTION
NOTE
Flywheel bore runout and face runout checks confirm serviceability and proper installation of flywheel. If flywheel does not meet requirements of either check, flywheel must be replaced. 1. Install dial indicator (Figure 4, Item 2) and attachments (Figure 4, Item 1) and check flywheel bore runout.
2 2
Figure 4. Flywheel Assembly Inspection.
M0708JCH
0054-5
TM 10-3930-675-23-1
0054
INSPECTION - Continued 2. Rotate flywheel, using engine barring tool, one revolution and record indication. Total indicator reading MUST NOT exceed 0.0050 in. (0.127 mm).
NOTE
Flywheel face runout check results in five readings. If any one of the readings exceeds the maximum, flywheel must be replaced. 3. Measure flywheel face runout as follows: a. b. Install dial indicator (Figure 5, Item 3) and attachments (Figure 5, Item 1). Push flywheel (Figure 5, Item 2) forward to remove crankshaft end thrust.
3
Figure 5. Flywheel Assembly Inspection.
M0709JCH
0054-6
TM 10-3930-675-23-1
0054
INSPECTION - Continued c. d. e. Zero and position dial indicator at radius indicated in Table 1, Flywheel Face Runout. Rotate crankshaft, using engine barring tool, one revolution and record total indicator reading. Repeat steps a thru d for each radius setting listed in Table 1, Flywheel Face Runout. Table 1. RADIUS (A) MM 203 254 305 356 406 END OF TASK IN. 8 10 12 14 16 Flywheel Face Runout. MAXIMUM TIR MM 0.203 0.254 0.305 0.356 0.406 IN. 0.008 0.010 0.012 0.014 0.016
0054-7
TM 10-3930-675-23-1
0054
INSTALLATION
NOTE
Ensure flywheel mounting surface and crankshaft is free of dirt. 1. Install guide pin (Figure 6, Item 1).
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel. Flywheel weighs 50 lb (23 kg) or more. Use suitable lifting device or assistance to lift flywheel. 2. Using nylon sling, T-handles, and suitable lifting device, position flywheel (Figure 6, Item 2) on guide pin (Figure 6, Item 1).
2
Figure 6. Flywheel Assembly Installation.
M0710JCH
0054-8
TM 10-3930-675-23-1
0054
INSTALLATION - Continued 3. 4. 5. Secure flywheel (Figure 7, Item 1) in place with seven screws (Figure 7, Item 4) hand-tight. Disconnect lifting device and sling. Remove T-handles (Figure 7, Item 3). Remove guide pin (Figure 7, Item 2) and install last mounting screw (Figure 7, Item 4). Tighten screws in star pattern to 135 ft-lb (183 Nm).
2 1 3
3 4
4
Figure 7. END OF TASK FOLLOW-ON MAINTENANCE Install engine (WP 0050). END OF TASK END OF WORK PACKAGE Flywheel Assembly Installation.
M0711JCH
0054-9/10 blank
TM 10-3930-675-23-1
0055
FIELD MAINTENANCE REAR MAIN OIL SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Tool Kit, Internal Combustion Engine (Volume 2, WP 0277, Table 1, Item 86) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Cloth, Abrasive, Emery (Volume 2, WP 0276, Table 1, Item 12) Materials/Parts (cont.) Oil, Lubricating, Engine (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Retainer, Seal (Volume 2, WP 0278, Table 1, Item 50) Equipment Condition Flywheel assembly removed (WP 0054)
0055-1
TM 10-3930-675-23-1
0055
REMOVAL
NOTE
The rear main oil seal contact surface of the crankshaft may have a wear sleeve installed. Check for presence of wear sleeve by inspecting the end of the crankshaft to determine if wear sleeve was previously installed. If wear sleeve is NOT present, follow steps 1 through 3 only below to remove the oil seal. If there IS a wear sleeve present, follow steps 4 through 14 only, instructions for Rear Main Oil Seal with Wear Sleeve. 1. Remove 12 screws (Figure 1, Item 3).
NOTE
Ensure oil seal and dust seal are removed as a unit. 2. 3. Remove oil seal (Figure 1, Item 2) and dust seal (Figure 1, Item 4) from crankshaft (Figure 1, Item 5). Discard oil seal and dust seal. Remove and discard gasket (Figure 1, Item 1) .
1 2 3 4
M0696JCH
Figure 1. Rear Main Oil Seal Removal.
NOTE
The rear main oil seal contact surface of the crankshaft may have a wear sleeve installed. Check for presence of wear sleeve by inspecting the end of the crankshaft to determine if wear sleeve was previously installed. If wear sleeve is present, follow Steps 4 through 14 below to remove the wear sleeve and oil seal. 4. 5. 6. 7. 8. 9. Position thick wear sleeve and oil seal mandrel tool (Figure 2, Item 5) onto crankshaft (Figure 3, Item 4) against thick wear sleeve (Figure 2, Item 5). Rotate each of three jaw pullers (Figure 3, Item 3) until the large flat edge is aligned with the thick wear sleeve (Figure 2, Item 5) and slot in end is positioned straight up and down. Insert each jaw puller (Figure 2, Item 3) into its bore, as shown in Figure 2, until it bottoms. Rotate each jaw puller (Figure 2, Item 3) clockwise 90 degrees. This will lock the jaw pullers with the thick wear sleeve. Install three flat washers (Figure 2, Item 2) onto each of the jaw pullers (Figure 2, Item 3). Install three nuts (Figure 2, Item 1) to jaw pullers (Figure 2, Item 3). Tighten nuts to 100 in-lb (11 Nm).
0055-2
TM 10-3930-675-23-1
0055
REMOVAL - Continued
3 4,5
2 1
M1754JCH
Figure 2. 10.
Wear Sleeve Removal.
Lubricate the tip of the forcing screw (Figure 3, Item 1) and install into center of thick wear sleeve and oil seal mandrel tool (Figure 3, Item 2). Rotate forcing screw until it is finger-tight.
2 1
M1755JCH
Figure 3.
0055-3
TM 10-3930-675-23-1
0055
REMOVAL - Continued 11. Rotate forcing screw (Figure 4, Item 1) clockwise until rear crankshaft thick wear sleeve (Figure 4, Item 2) and rear main oil seal (Figure 4, Item 3) are removed.
2,3 1
M1756JCH
Figure 4. 12. 13. 14.
Remove the thick wear sleeve and oil seal mandrel tool (Figure 5, Item 2), thick wear sleeve (Figure 5, Item 3) and rear main oil seal (Figure 5, Item 4) as an assembly. Loosen the 3 nuts (Figure 5, Item 5) on the jaw pullers (Figure 5, Item 1). Rotate each of the three jaw pullers (Figure 5, Item 1) 90 degrees counter-clockwise to unlock the wear sleeve (Figure 5, Item 3).
2 3 3 1
4 5
5
M1757JCH
0055-4
TM 10-3930-675-23-1
0055
CLEANING AND INSPECTION
NOTE
If crankshaft sealing surface is found to be scored or grooved when rear main oil seal is removed, or if a wear sleeve was removed, it will be necessary to install a thick wear sleeve and new oil seal together. Perform Steps 7 through 15 of Installation Procedures only. 1. 2. 3. Clean and inspect all parts IAW General Maintenance Instructions. Check the crankshaft sealing surface for nicks, burrs and grooves. Remove any nicks and/or burrs using crocus cloth. If crankshaft sealing surface is damaged, and a wear sleeve is needed, or if a wear sleeve was removed, clean and inspect crankshaft sealing surface and thick wear sleeve and oil seal mandrel tool with crocus cloth to remove any dirt or deposits on both tool and crankshaft sealing surface. Use a lint-free cloth to remove any traces of oil from crankshaft flange and oil seal mandrel tool.
4.
END OF TASK INSTALLATION 1. Install three studs (Figure 6, Item 1) into three threaded holes in end of crankshaft (Figure 6, Item 2) as shown in Figure 6 until finger-tight.
M1758JCH
Figure 6. Rear Main Oil Seal and Thick Wear Sleeve Installation.
0055-5
TM 10-3930-675-23-1
0055
NOTE
Do NOT separate oil seal from thick wear sleeve at any time during assembly process. A new thick wear sleeve and seal assembly MUST be used. 2. Do NOT use any lubricant to install oil seal (Figure 7, Item 1). lip of oil seal and crankshaft (Figure 7, Item 2) MUST be oil free and dry for proper installation of oil seal.
2 1
4
M1759JCH
NOTE
Yellow lip of oil seal must face outward (towards you). Thick wear sleeve, oil seal, and gasket MUST be installed as one assembly. 3. Position thick wear sleeve (Figure 8, Item 2), main oil seal (Figure 8, Item 1), gasket (Figure 8, Item 3), into proper counter-bore location in thick wear sleeve and oil seal mandrel tool (Figure 8, Item 4).
3
M1760JCH
0055-6
TM 10-3930-675-23-1
0055
INSTALLATION - Continued 4. Position thick wear sleeve (Figure 9, Item 2), main oil seal (Figure 9, Item 3), gasket (Figure 9, Item 3), and thick wear sleeve mandrel tool (Figure 9, Item 4) against crankshaft flange (Figure 9, Item 6).
1 2,3
6 5
4
M1761JCH
Figure 9. Rear Main Oil Seal and Thick Wear Sleeve Installation. 5. 6. Lubricate one side of each of three flat washers (Figure 10, Item 2), and install so that lubricated side faces toward thick wear sleeve and oil seal mandrel tool (Figure 10, Item 3). Install three nuts (Figure 10, Item 1) onto studs (Figure 10, Item 4). Tighten three nuts finger-tight.
2 1 3
M1762JCH
Figure 10.
Rear Main Oil Seal and Thick Wear Sleeve Installation.
0055-7
TM 10-3930-675-23-1
0055
CAUTION
When installing oil seal and thick wear sleeve into bore area, make certain that thick wear sleeve remains parallel to housing when tightening three nuts. Failure to do so can result in damage to oil seal and thick wear sleeve. 7. Tighten three nuts (Figure 11, Item 2) one-half turn at a time, alternately, in a clockwise pattern until thick wear sleeve and oil seal mandrel tool (Figure 11, Item 1) seats against crankshaft flange (Figure 11, Item 3) as shown in Figure 11. Tighten nuts (Figure 11, Item 2) to 50 ft-lb (68 Nm) in a clockwise pattern.
1
2
M1763JCH
Figure 11. 8. 9.
Remove three nuts (Figure 12 Item 1), three washers (Figure 12, Item 2), mandrel tool (Figure 12, Item 7) and three studs (Figure 12, Item 6) from crankshaft flange (Figure 12, Item 5). Install 12 screws (Figure 12, Item 4) through oil seal (Figure 12, Item 3). Tighten in a star-shaped pattern to 60 lb-in (7 NM).
0055-8
TM 10-3930-675-23-1
0055
4 3
5 2 1
M1764JCH
Figure 12. END OF TASK FOLLOW-ON MAINTENANCE
Install flywheel assembly (WP 0054). END OF TASK END OF WORK PACKAGE
0055-9/10 blank
TM 10-3930-675-23-1
0056
FIELD MAINTENANCE ROCKER ARM ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Adjustment Kit, Injector (Volume 2, WP 0277, Table 1, Item 4) Crowfoot Attachment Set, Socket Wrench, 3/8 in. Female Sq. Dr. (Volume 2, WP 0277, Table 1, Item 20) Caliper, Micrometer, Outside (1-2 in.) (Volume 2, WP 0277, Table 1, Item 13) Gauge, Thickness (0.051 to 1.00 mm) (Volume 2, WP 0277, Table 1, Item 31) Gauge, Telescoping (1.250 to 2.125 in.) (Volume 2, WP 0277, Table 1, Item 30) Indicator, Dial (Volume 2, WP 0277, Table 1, Item 40) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Tools and Special Tools (cont.) Wrench, Pipe (Volume 2, WP 0277, Table 1, Item 92) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Engine cover removed (Volume 2, WP 0185) Rocker arm cover removed (WP 0057)
0056-1
TM 10-3930-675-23-1
0056
REMOVAL
NOTE
Tag or mark all items removed or disassembled while performing these procedures. For proper operation and adjustment, items must be assembled and installed in the location from which they were removed. 1. Loosen rocker lever adjusting screws (Figure 1, Item 1) and remove push rods (Figure 1, Item 3) and push tubes (Figure 1, Item 2).
3
Figure 1. Push Rods and Push Tubes Removal. 2.
M0722JCH
Position x 18 in. key stock (Figure 2, Item 1) or similar item on top of rocker lever assembly supports (Figure 2, Items 3 and 4). Secure in place with four screws (Figure 2, Item 2).
1 2
M0723JCH
Figure 2.
Key Stock Installation.
0056-2
TM 10-3930-675-23-1
0056
REMOVAL - Continued 3. Loosen four rocker shaft screws (Figure 3, Item 1). Remove front section of rocker arm assembly.
1 1
FRONT SECTION
REAR SECTION
M0724JCH
Figure 3. Front Rocker Arm Assembly Removal. 4. Repeat steps 1 thru 3 and remove rear section of rocker arm assembly.
END OF TASK
0056-3
TM 10-3930-675-23-1
0056
DISASSEMBLY
NOTE
Mark or tag each rocker lever, shaft, and support with relative position in rocker assembly. 1. 2. 3. Remove four rocker shaft screws (Figure 4, Item 1) and retaining clamps (Figure 4, Item 5). Lift shaft (Figure 4, Item 8) and three rocker levers (Figure 4, Items 2, 3, and 4) out of supports (Figure 4, Items 7, 9, and 6). Remove three rocker levers (Figure 4, Items 2, 3, and 4) from shaft (Figure 4, Item 8).
1 5 5 1 2 5 9 3 4 2 3 4 2 1 5 3 4 6 1
M0725JCH
Figure 4. Rocker Levers Removal. 4. Remove adjusting nut (Figure 5, Item 2) and adjusting screw (Figure 5, Item 1) from each rocker lever (Figure 5, Items 3, 5, and 4).
2 2
1 3,4
M0726JCH
Figure 5. Rocker Lever Disassembly. END OF TASK
0056-4
TM 10-3930-675-23-1
0056
INSPECTION
NOTE
If the following conditions are noted or specifications are not met, item being inspected must be replaced. 1. Ensure components have been thoroughly cleaned and visually inspect rocker levers for these conditions: a. b. c. 2. 3. 4. 5. Cracks, excessive pitting, or other visible damage. Thread damage to adjusting screw threads. Sockets and pads for cracks, pits, wear, or other damage.
Visually inspect adjusting nut and adjusting screw for damaged threads. Visually inspect shaft for pitting, scoring, or other damage. Visually inspect supports for cracks, pitting, or other damage. Measure rocker lever bushing inside diameter. Measurement must be 1.3735 to 1.3776 in. (34.887 to 34.99 mm). If not within range, replace bushing.
INSIDE DIAMETER, ROCKER LEVER BUSHING
M0727JCH
Figure 6. 6.
Rocker Lever Bushing Measurement.
Measure outside diameter of rocker lever shaft. Diameter must be 1.3715 to 1.3726 in. (34.837 to 34.864 mm). If diameter is not within range, replace rocker lever shaft.
OUTSIDE DIAMETER, ROCKER LEVER SHAFT
M0728JCH
Rocker Lever Shaft Measurement.
0056-5
TM 10-3930-675-23-1
0056
ASSEMBLY
CAUTION
Ensure rocker lever shafts are installed in support with arrow on end of shaft pointed down. Failure to install rocker lever shafts with arrow down will have an adverse effect on rocker lever lubrication and may cause damage to rocker arm assemblies.
NOTE
Ensure rocker lever shafts are oriented according to marking on shaft ends. 1. 2. Apply a light coat of clean lubricating oil to each rocker lever shaft (Figure 8, Item 2) and install front end support (Figure 8, Item 4) on each rocker lever shaft. Install screw (Figure 8, Item 1) and retaining clamp (Figure 8, Item 3) to secure rocker lever shaft (Figure 8, Item 2) to front end support (Figure 8, Item 4).
2 3
M0729JCH
Figure 8. Rocker Arm Shaft Assembly. 3. Install adjusting screw (Figure 9, Item 4) and adjusting nut (Figure 9, Item 9) in three rocker levers (Figure 9, Items 2, 3, and 4) and position rocker levers on shaft (Figure 9, Item 6) in correct sequence as noted in disassembly. Position one center support (Figure 9, Item 9) and secure in place with retaining clamp (Figure 9, Item 5) and screw (Figure 9, Item 7). Install three rocker levers (Figure 9, Items 1, 2, and 3) and remaining support (Figure 9, Item 8) with rocker levers in correct position as noted in disassembly.
4. 5.
0056-6
TM 10-3930-675-23-1
0056
ASSEMBLY - Continued
5 2 1 3 4 6
8 9 9 4
M0730JCH
Figure 9. 6.
Rocker Arm Shaft Assembly.
Install support (Figure 10, Item 8) and remaining retaining clamps (Figure 10, Item 2) and screws (Figure 10, Item 3) on front and rear sections of rocker arm assembly (Figure 10, Items 7 (1,2,3,4,5,6,8, and 9).
7
1 8
9 8 9 1
M0731JCH
Figure 10.
Rocker Arm Shaft Assembly.
0056-7
TM 10-3930-675-23-1
0056
ASSEMBLY - Continued 7. Position key stock (Figure 11, Item 1) used to remove assembly on top of supports and secure in place with four screws (Figure 11, Item 2).
1 2
M0732JCH
Figure 11. Rocker Arm Shaft Assembly. END OF TASK INSTALLATION
NOTE
Rocker arm assembly must be installed in same position from which it was removed. 1. Position rocker arm assembly (Figure 12, Item 1) on cylinder head (Figure 12, Item 3). Hand-tighten eight screws (Figure 12, Item 2) and remove key stock (Figure 12, Item 4).
1 2 2 2
4 3
M0733JCH
Figure 12. Rocker Arm Shaft Installation.
0056-8
TM 10-3930-675-23-1
0056
NOTE
Rocker lever side clearance MUST be adjusted before screws are fully tightened. 2. Set side clearance for rear section of rocker arm assembly as follows: a. Tap number five rocker lever support (Figure 13, Item 1) toward front of engine. Tighten mounting screw (Figure 13, Item 2) to 45 in-lb. (5 Nm).
1 2
FRONT OF ENGINE
REAR SECTION
M0734JCH
Figure 13. b. c.
Rocker Arm Shaft Installation.
Insert 0.020 in. (0.50 mm) feeler gauge between number five support (Figure 14, Item 3) and intake lever for number four cylinder. Push or tap number six support (Figure 14, Item 1) toward front of engine. Tighten mounting screw (Figure 14, Item 2) to 45 in-lb. (5 Nm).
0.20 in. (.50 mm) 1
3 INTAKE LEVER
2
M1144JCH
Figure 14.
0056-9
TM 10-3930-675-23-1
0056
INSTALLATION - Continued d. e. f. Insert 0.020 in. (0.50 mm) feeler gauge between number six support (Figure 15, Item 2) and exhaust lever for number five cylinder. Push or tap number seven support (Figure 15, Item 2) toward front of engine. Tighten mounting screw (Figure 15, Item 1) to 45 in-lb. (5 Nm). Insert 0.020 in. (0.50 mm) feeler gauge between number seven support (Figure 15, Item 2) and intake lever for number six cylinder.
0.20 in. (.50 mm) EXHAUST LEVER 1
FRONT OF ENGINE
M0735JCH
Figure 15. Rocker Arm Shaft Installation. g. h. Push or tap number eight support (Figure 16, Item 1) toward front of engine. Push or tap number eight support Figure 16, Item 13) toward front of engine. Fully tighten four support mounting screws (Figure 16, Item 2) to 135 ft-lb (183 Nm).
0.20 in. (.50 mm) INTAKE LEVER
M0736JCH
0056-10
TM 10-3930-675-23-1
0056
INSTALLATION - Continued 3. Set side clearance for front section of rocker arm assembly as follows: a. Push or use hammer to tap number four support (Figure 17, Item 2) toward rear of engine. Tighten mounting screw (Figure 17, Item 1) to 45 in-lb (5 Nm).
FRONT SECTION
REAR OF ENGINE
M0737JCH
Figure 17. b. c.
Insert 0.020 in. (0.50 mm) feeler gauge between number four support (Figure 18, Item 2) and intake lever of number three cylinder. Push or tap number three support (Figure 18, Item 1) toward rear of engine. Tighten mounting screw (Figure 18, Item 2) to 45 in-lb. (5 Nm).
INTAKE LEVER 1
0.20 in. (.50 mm)
3 2
REAR OF ENGINE
M0738JCH
Figure 18.
0056-11
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0056
INSTALLATION - Continued d. e. Insert 0.020 in. (0.50 mm) feeler gauge between number three support (Figure 19, Item 1) and exhaust lever for number two cylinder. Push or tap number two support (Figure 19, Item 1) toward rear of engine. Tighten mounting screw (Figure 19, Item 2) to 45 in-lb. (5 Nm).
0.20 in. (.50 mm) EXHAUST LEVER 1
REAR OF ENGINE
M0739JCH
Figure 19. Rocker Arm Shaft Installation. f. g. h. Insert 0.020 in. (0.50 mm) feeler gauge between number two support (Figure 20, Item 2) and intake lever for number one cylinder. Push or tap number one support (Figure 20, Item 1) toward rear of engine. Fully tighten four support mounting screws (Figure 20, Item 3) to 135 ft-lb (183 Nm).
0.20 in. (.50 mm) INTAKE LEVER 1 2
REAR OF ENGINE 3 3
M0740JCH
0056-12
TM 10-3930-675-23-1
0056
NOTE
Injector push rods are smaller in diameter and longer than valve push tubes. 4. Apply a light coat of clean lubricating oil to ball end of push rods (Figure 21, Item 3) and push tubes (Figure 21, Item 2).
NOTE
Ensure push rods and tubes are installed in position as noted in removal. 5. Install valve push tubes (Figure 21, Item 2) and injector push rods (Figure 21, Item 3) and tighten adjusting screws (Figure 21, Item 1) enough to hold push rods and tubes in position.
2 3 2
Figure 21. 6. Adjust valves and injectors. Rocker Arm Shaft Installation.
M0741JCH
END OF TASK
0056-13
TM 10-3930-675-23-1
0056
VALVE LASH CHECK
NOTE
All overhead valve and injector lash measurements and adjustments MUST be made when engine is cold. Valve set marks A", B", and C" are located on accessory drive pulley. Marks align with pointer on gear housing. Engine cylinders are numbered from front to rear 1-2-3-4-5-6. Crankshaft rotation is clockwise when viewed from front of engine. Firing order is 1-5-3-6-2-4. One pair of valves and one injector are checked or adjusted at each pulley index mark before rotating accessory drive to next mark. Two crankshaft rotations are required to check or adjust all valves and injectors. 1. 2. Perform valve lash check on each cylinder until all cylinders have been checked. Rotate accessory drive clockwise until valve set mark A" is aligned with pointer on gear cover.
GEAR COVER
GEAR COVER POINTER
VALVE SET MARK
M0742JCH
Figure 22.
Valve Lash Check.
0056-14
TM 10-3930-675-23-1
0056
VALVE LASH CHECK - Continued
NOTE
Each cylinder has three rocker levers: long lever (E)exhaust valve; middle leverinjector; short lever (I)intake valve. 3. Observe rocker lever arms of cylinder and compare rocker lever arm positions to Table 1. Intake and exhaust valves must be closed and injector plunger must be at bottom of stroke for cylinder 1. If this is not correct, cylinder 6 must be ready to check. Table 1. Injector and Valve Measurement Sequence. SET CYLINDER BAR ENGINE DIRECTION OF ROTATION PULLEY POSITION INJECTOR Start Advance to Advance to Advance to Advance to Advance to Firing Order: 1-5-3-6-2-4
GEAR COVER
VALVE 1 5 3 6 2 4
A B C A B C
1 5 3 6 2 4
GEAR COVER POINTER
VALVE SET MARK
M0742JCH
Figure 23.
Valve Lash Check.
0056-15
TM 10-3930-675-23-1
0056
VALVE LASH CHECK - Continued
NOTE
Ensure rocker levers on both intake and exhaust valves of cylinder being checked can be rattled" or push tubes can be freely rotated. 4. With thickness gauge, measure and record amount of clearance between crosshead and rocker lever nose for both intake and exhaust valve.
ROCKER LEVER NOSE THICKNESS GAGE
CROSSHEAD (HIDDEN)
M0744JCH
Figure 24. 5.
Valve Lash Check.
If valve lash clearance is not within specifications listed in Table 2, valves must be adjusted. Table 2. MM INTAKE 0.10 0.41 EXHAUST 0.46 0.76 MIN MAX MIN MAX M Series Valve Lash Recheck Limits. IN. 0.004 0.016 0.018 0.030
END OF TASK
0056-16
TM 10-3930-675-23-1
0056
INJECTOR LASH CHECK
NOTE
To ensure accurate measurement, securely tighten all hold-down screws and thumbscrews. 1. 2. Install dial indicator on cylinder being checked to measure injector rocker arm lever. Adjust and set dial indicator for reading as follows: a. b. c. Set tip of dial indicator to rest on rocker lever directly above socket. Loosen height adjustment thumbscrew and lower indicator against injector rocker lever until stem is fully compressed. Raise indicator approximately 0.500 in. (12.7 mm) and tighten height adjustment thumbscrew to hold position.
ROCKER LEVER STEM HEIGHT ADJUSTMENT THUMBSCREW
M0745JCH
Figure 25.
Injector Lash Check.
0056-17
TM 10-3930-675-23-1
0056
INJECTOR LASH CHECK - Continued
WARNING
Injector plunger is under spring tension. DO NOT allow tool to slip. Serious personal injury can result. 3. 4. With actuator, operate injector plunger three or four times to ensure fuel has been removed from injector assembly. With actuator, operate lever again and, while holding injector plunger to bottom of travel, set dial indicator at 0" (zero).
Figure 26. 5.
Injector Lash Check.
Slowly release actuator and check dial indicator travel. Record measured value. If injector lash setting is not within specifications listed in Table 3, injector must be adjusted. Table 3. MM 0.51 2.04 MIN MAX M Series Injector Lash Recheck Limits. IN. 0.020 0.080
END OF TASK INJECTOR ADJUSTMENT
NOTE
Set injectors on cylinders before setting valves. Adjustment may begin with any valve set mark. Position A" is described in the following steps. 1. Rotate accessory drive clockwise until A" valve set mark on accessory drive pulley is aligned with pointer on gear cover.
0056-18
TM 10-3930-675-23-1
0056
INJECTOR ADJUSTMENT - Continued

GEAR COVER
GEAR COVER POINTER
VALVE SET MARK
M0747JCH
Figure 27. 2.
Injector Adjustment.
With valve set mark A" aligned with pointer, observe both valve rocker levers for cylinder 1. Intake and exhaust valves for cylinder must be closed. If condition is not met, then cylinder 6 injector and valves must be ready to set. Adjust injector as follows: a. b. Loosen injector adjusting screw locknut. Bottom injector plunger three or four times to remove fuel.
3.
NOTE
DO NOT use excessive force when bottoming plunger. c. d. e. Turn adjusting screw in until you can feel it lightly bottom plunger. Back out adjusting screw two flats or 120 degrees. Hold adjusting screw and tighten locknut to 45 ft-lb (61 Nm).
ADJUSTING SCREW LOCKNUT
ADJUSTING SCREW
120
INJECTOR PLUNGER
Injector Adjustment.
M0748JCH
Figure 28.
0056-19
TM 10-3930-675-23-1
0056
INJECTOR ADJUSTMENT - Continued 4. Perform valve adjustments on same cylinder.
END OF TASK VALVE ADJUSTMENT
NOTE
Ensure valve set mark A" is aligned with pointer on gear cover and both valves are closed on cylinder to be adjusted. 1. 2. Loosen adjusting screw locknuts on intake and exhaust valves. Select thickness gauge for correct valve lash specification listed: a. b. Intake valve0.014 in. (0.36 mm) Exhaust valve0.027 in. (0.69 mm)
GAGE, INTAKE VALVE
0.14 in. (0.36 mm)
0.27 in. (0.69 mm) GAGE, EXHAUST VALVE ADJUSTING SCREW LOCKNUTS
Figure 29. Valve Adjustment.
M0749JCH
0056-20
TM 10-3930-675-23-1
0056
VALVE ADJUSTMENT - Continued 3. Insert thickness gauge between top of crosshead and rocker lever pad.
NOTE
Two methods of adjusting valve lash can be used. The first method, which is preferred, is described in steps 4 thru 7 and uses the inch-pound torque wrench; the second method is described in steps 8 thru 11. 4. With inch-pound torque wrench, tighten adjusting screw to 6 in-lb. (0.7 Nm).
ROCKER LEVER TORQUE WRENCH THICKNESS GAGE
M0750JCH
Figure 30. 5. 6.
Valve Adjustment.
Hold adjusting screw in position and tighten locknut. With adapter, tighten locknut to 35 ft-lb (47 Nm).
ADJUSTING SCREW LOCKNUT ADAPTER

M0751JCH
Figure 31.
Valve Adjustment.
0056-21
TM 10-3930-675-23-1
0056
VALVE ADJUSTMENT - Continued 7. Check adjustment by ensuring thickness gauge will slide backward and forward with only slight drag.
ROCKER LEVER NOSE THICKNESS GAGE
CROSSHEAD (HIDDEN)
M0752JCH
Figure 32. 8.
Valve Adjustment.
Tighten adjusting screw until a slight drag is felt on thickness gauge.
THICKNESS GAGE
ADJUSTING SCREW
M0753JCH
Figure 33.
Valve Adjustment.
0056-22
TM 10-3930-675-23-1
0056
VALVE ADJUSTMENT - Continued 9. 10. Hold adjusting screw and tighten locknut. With adapter, tighten locknut to 35 ft-lb (47 Nm).
ADJUSTING SCREW LOCKNUT ADAPTER

M0754JCH
Figure 34. 11. 12.
Valve Adjustment.
Check adjustment by attempting to insert a 0.001 in. (0.03 mm) feeler gauge between crosshead and rocker lever pad. Valve lash is not correct if gauge can be inserted. Perform injector and valve adjustments for remaining cylinders.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install rocker arm cover (WP 0057). Install engine cover (Volume 2, WP 0185).
0056-23/24 blank
TM 10-3930-675-23-1
0057
FIELD MAINTENANCE ROCKER ARM COVER AND GASKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Seal, Plain (Volume 2, WP 0278, Table 1, Item 29) Materials/Parts (cont.) Gasket (Volume 2, WP 0278, Table 1, Item 59) Spacer, Straight (Volume 2, WP 0278, Table 1, Item 60) Qty: 6 Equipment Condition Air intake tubes and hoses removed from intake manifold (WP 0072)
0057-1
TM 10-3930-675-23-1
0057
REMOVAL
NOTE
For ease in removing rocker arm cover, wiring harness bracket may be removed from left front of engine and set aside. 1. 2. 3. 4. Disconnect crankcase breather tube (Figure 1, Item 9) from breather tube adapter (Figure 1, Item 5). Remove breather tube adapter (Figure 1, Item 5) and grommet seal (Figure 1, Item 6) from rocker arm cover (Figure 1, Item 1). Discard grommet seal. Remove 16 screws (Figure 1, Item 3), noise isolators (Figure 1, Item 2), and spacers (Figure 1, Item 4) from rocker arm cover (Figure 1, Item 1). Discard noise isolators. Remove rocker arm cover (Figure 1, Item 1) and gasket (Figure 1, Item 7) from engine (Figure 1, Item 8). Discard gasket.
3 4 1 2 5,6
9 8
M0007JCH
Figure 1. END OF TASK INSTALLATION
Rocker Arm Cover and Gasket Replacement.
NOTE
Ensure all gasket material has been removed from rocker arm cover surface and rocker housing. 1. 2. Install rocker arm cover (Figure 1, Item 1) and new gasket (Figure 1, Item 7) on engine (Figure 1, Item 8). Install 16 screws (Figure 1, Item 3), new noise isolators (Figure 1, Item 2), and spacers (Figure 1, Item 4) on rocker arm cover (Figure 1, Item 1). Tighten screws to 130 in-lb (15 Nm) in sequence shown in Figure 2.
0057-2
TM 10-3930-675-23-1
0057
14 10 6 2 4 8 12 16
13 9
15 5 1 3 7 11
M0008JCH
Figure 2. Rocker Arm Cover Tightening Sequence. 3. 4. Install new grommet seal (Figure 1, Item 6) and breather tube adapter (Figure 1, Item 5) on rocker arm cover (Figure 1, Item 1). Connect crankcase breather hose (Figure 1, Item 9) to breather tube adapter (Figure 1, Item 5).
END OF TASK FOLLOW-ON MAINTENANCE Install air intake tubes and hoses on intake manifold (WP 0072). END OF TASK END OF WORK PACKAGE
0057-3/4 blank
TM 10-3930-675-23-1
0058
FIELD MAINTENANCE OIL PAN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Hammer Set, Holder and Inserts (Volume 2, WP 0277, Table 1, Item 37) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Sealant, Silicone (Volume 2, WP 0276, Table 1, Item 53) Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 27) Qty: 2 Gasket (Volume 2, WP 0278, Table 1, Item 46) References TM 10-3930-675-10 Equipment Condition Engine oil drained (WP 0059) Front propeller shaft disconnected from front axle flange only (Volume 2, WP 0143)
0058-1
TM 10-3930-675-23-1
0058
REMOVAL 1. Remove 32 screws (Figure 1, Item 1) securing oil pan (Figure 1, Item 2) to engine block.
NOTE
It may be necessary to tap lightly on oil pan with a plastic-faced hammer to break seal between oil pan and engine block. 2. 3. 4. 5. Lower oil pan (Figure 1, Item 2) and remove from engine. Remove and discard oil pan gasket (Figure 1, Item 5). Remove screw (Figure 1, Item 3) from oil pan suction tube (Figure 1, Item 4) and remove from oil pan (Figure 1, Item 7). Remove two O-ring seals (Figure 1, Item 2) and oil transfer tube (Figure 1, Item 1) from oil pan suction tube (Figure 1, Item 4). Discard O-ring seals.
3 4 2
M0756JCH
Figure 1. END OF TASK INSTALLATION 1. 2.
Oil Pan Removal.
Apply sealant on block joints as shown in Figure 2. Install oil transfer tube (Figure 1, Item 1) with two new O-ring seals (Figure 1, Item 2).
0058-2
TM 10-3930-675-23-1
0058
CYLINDER BLOCK-TO-GEAR HOUSING JOINT
FLYWHEEL HOUSING-TO-CYLINDER BLOCK JOINT

Figure 2. 3. 4. Oil Pan Installation.
M0757JCH
Place new gasket (Figure 1, Item 5) on oil pan (Figure 1, Item 7) mounting flange. Install oil pan suction tube (Figure 1, Item 4) to oil pan (Figure 1, Item 7) with screw (Figure 1, Item 3).
CAUTION
During installation, carefully align transfer tube to connection on block. Failure to properly align could cause connector to break and result in low/no oil pressure. 5. 6. Align oil suction tube (Figure 1, Item 4) with engine block and install oil pan (Figure 1, Item 7) on engine block. Secure oil pan (Figure 1, Item 2) with 32 screws (Figure 1, Item 1). Tighten screws to 35 ft-lb (47 Nm) in sequence shown in Figure 3.
32 31 30 28 18 14 10 6 2 4 8 12 16 20 22 24 27 26
TIGHTENING SEQUENCE
M0758JCH
29 19 15 11 7 3 1 5 9 13 17 21 23 25
Oil Pan Installation.
0058-3
TM 10-3930-675-23-1
0058
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill engine oil (WP 0059). Start engine (TM 10-3930-675-10) and build up oil pressure. Shut down engine. Check oil pan for leaks. Connect front propeller shaft (Volume 2, WP 0143).
0058-4
TM 10-3930-675-23-1
0059
FIELD MAINTENANCE ENGINE OIL AND OIL FILTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Oil Filter, Strap (Volume 2, WP 0277, Table 1, Item 91) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Lubricating Oil, Gear OE/HDO 10 (Volume 2, WP 0276, Table 1, Item 45) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Filter Element, Fluid (Volume 2, WP 0278, Table 1, Item 174) References LO 10-3930-675-13 TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)
0059-1
TM 10-3930-675-23-1
0059
REMOVAL
WARNING
Hot oil can cause serious burns. Allow engine to cool before draining oil or changing oil filter element. Engine oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
NOTE
Engine oil change and filter replacement should be performed on a warm engine. 1. 2. Place suitable container under engine oil pan (Figure 1, Item 1) to catch draining oil. Remove plug (Figure 1, Item 3) and washer (Figure 1, Item 2) from bottom of engine oil pan (Figure 1, Item 1) and allow oil to drain. Dispose of oil in accordance with standard operating procedures (SOP). Check condition of washer and plug.
2 3
M0009JCH
Figure 1.
Drain Engine Oil.
NOTE
Ensure oil pan plug and oil pan threads are clean and free of deposits. 3. Install washer (Figure 2, Item 2) and plug (Figure 2, Item 3) in oil pan (Figure 2, Item 1). Tighten plug to 65 ft-lb (88 Nm).
NOTE
Position drain pan to catch oil from oil filter head as needed. 4. 5. Remove oil filter (Figure 2, Item 1) and gasket from filter head (Figure 2, Item 2) with strap wrench. Discard filter with gasket. Clean filter head sealing surface (Figure 2, Item 3) with a rag.
0059-2
TM 10-3930-675-23-1
0059
REMOVAL - Continued
2
1
M0010JCH
Oil Filter and Gasket.
CAUTION
Ensure new oil filter is filled with clean engine oil prior to installation. Lack of lubrication to engine during delay to fill filter when starting engine may cause damage to engine. 1. Apply a light coat of clean engine oil to filter gasket and fill new oil filter (Figure 2, Item 1) with clean engine oil.
NOTE
Ensure old gasket material has been removed from sealing surface on filter head. 2. Install oil filter (Figure 2, Item 1) on filter head (Figure 2, Item 2) and hand tighten until gasket contacts sealing surface (Figure 2, Item 3).
CAUTION
Overtightening of filter can distort threads or damage filter element seal. 3. 4. Tighten oil filter (Figure 2, Item 1) turn with strap wrench. Add engine oil to required level (LO 10-3930-675-13).
END OF TASK
0059-3
TM 10-3930-675-23-1
0059
FOLLOW-ON MAINTENANCE 1. 2. 3. Start vehicle (TM 10-3930-675-10) and check for oil leaks. Recheck oil level (LO 10-3930-675-13). Install engine cover (Volume 2, WP 0185).
0059-4
TM 10-3930-675-23-1
0060
FIELD MAINTENANCE OIL FILTER HEAD AND OIL COOLER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Accessory Kit, Test Set Lubricating Oil Cooler 120 (Volume 2, WP 0277, Table 1, Item 1) Pliers Set, Retaining Ring (Volume 2, WP 0277, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) O-Ring (Volume 2, WP 0278, Table 1, Item 8) Qty: 2 Gasket (Volume 2, WP 0278, Table 1, Item 52) Gasket (Volume 2, WP 0278, Table 1, Item 65) Qty: 2 Materials/Parts (cont.) Spacer, Straight (Volume 2, WP 0278, Table 1, Item 60) Qty: 2 Ring, Retaining Ring, Retaining Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Oil filter removed (WP 0059) Radiator drained (WP 0080) Turbocharger removed (WP 0073)
0060-1
TM 10-3930-675-23-1
0060
REMOVAL 1. Disconnect turbocharger oil supply line (Figure 1, Item 2) and remove elbow fitting (Figure 1, Item 1) from oil filter head (Figure 1, Item 3).
1 2
M0759JCH
Figure 1. 2.
Oil Filter Head and Oil Cooler Removal.
Remove four screws (Figure 2, Item 1) securing oil cooler thermostat housing flange (Figure 2, Item 3) to thermostat housing (Figure 2, Item 2).
1
M0760JCH
Figure 2.
Oil Filter Head and Oil Cooler Removal.
0060-2
TM 10-3930-675-23-1
0060
REMOVAL - Continued
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may result in injury to personnel.
NOTE
When removing oil filter head and oil cooler as a unit, ensure oil cooler thermostat housing flange, O-ring adapters, and thermostat housing flange O-rings are removed with oil cooler. 3. Remove six screws (Figure 3, Item 5) and washers (Figure 3, Item 6) securing oil filter head (Figure 3, Item 4) to engine and, with assistance, remove oil cooler (Figure 3, Item 1) and oil filter head as a unit from engine. Discard oil filter head gasket (Figure 3, Item 3) and two oil cooler thermostat housing flange O-rings (Figure 3, Item 2).
1 2
3 5,6 4 5,6
M0761JCH
Figure 3. Oil Filter Head and Oil Cooler Removal. END OF TASK
0060-3
TM 10-3930-675-23-1
0060
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Slide seal retainer (Figure 4, Item 3) and two seal retainers (Figure 4, Item 2) from oil cooler (Figure 4, Item 5). Remove and discard two oil cooler inlet (Figure 4, Item 1) and outlet O-rings (Figure 4, Item 4). Remove four screws (Figure 4, Item 6) securing oil cooler (Figure 4, Item 5) to oil filter head (Figure 4, Item 13). Remove oil cooler (Figure 4, Item 5) and two gaskets (Figure 4, Item 14) from oil filter head (Figure 4, Item 13). Discard gaskets. Remove retaining ring (Figure 4, Item 11) securing oil filter head thermostat (Figure 4, Item 12) in oil filter head (Figure 4, Item 13). Remove thermostat. Discard retaining ring. Remove retaining ring (Figure 4, Item 10) securing bypass valve plunger (Figure 4, Item 7) in oil filter head (Figure 4, Item 13). Discard retaining ring. Remove washer (Figure 4, Item 9), spring (Figure 4, Item 8), and bypass valve plunger (Figure 4, Item 7) from oil filter head (Figure 4, Item 13).
0060-4
TM 10-3930-675-23-1
0060
DISASSEMBLY - Continued
5 3 4 2 1 4
14
7 13 8 9
12 11
Figure 4. Oil Filter Head and Oil Cooler Disassembly. END OF TASK
10
M0762JCH
0060-5
TM 10-3930-675-23-1
0060
CLEANING
WARNING
Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. Failure to comply may cause injury or death to personnel. Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel. 1. Clean thermostat and bypass valve plunger with solvent and dry with compressed air.
NOTE
Ensure oil filter head open passages are cleaned and dried. 2. 3. Clean oil filter head with solvent and dry with compressed air. Clean all mating surfaces of oil cooler, oil filter head, and engine to remove old gasket material.
0060-6
TM 10-3930-675-23-1
0060
CLEANING - Continued 4. Clean oil cooler as follows: a. Install pressure test plate (Figure 5, Item 2), gasket (Figure 4, Item 7), and two screws (Figure 5, Item 1), washers (Figure 5, Item 3), and nuts (Figure 5, Item 4) on one of two oil passage openings in oil cooler (Figure 5, Item 6).
WARNING
Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel. b. Attach air pressure line to pressure test plate (Figure 5, Item 2) and clear oil from inside oil passage.
1 2 5
3 7 4
M0763JCH
Figure 5.
Oil Cooler Testing.
0060-7
TM 10-3930-675-23-1
0060
CLEANING - Continued c. Install pressure test plate (Figure 6, Item 2), gasket (Figure 6, Item 3), and two screws (Figure 6, Item 1) washers (Figure 6, Item 4), and nuts (Figure 6, Item 5) on second oil passage opening in oil cooler (Figure 6, Item 6).
NOTE
Both oil passage openings must be sealed before cleaning oil cooler water core. d. Use water pressure, attached to outlet side of housing, to clean oil cooler water core.
2 3 4 5 OUTLET
M0764JCH
Figure 6. Oil Cooler Cleaning. END OF TASK INSPECTION 1. 2. 3. Inspect oil filter head for cracks or other damage. If damaged, replace oil filter head. Inspect oil thermostat and bypass valve for cracks or other damage. If damaged, replace. Inspect oil cooler for cracks or other damage. If damaged, replace.
END OF TASK
0060-8
TM 10-3930-675-23-1
0060
TEST
NOTE
Oil cooler is not a repairable component. If oil cooler is defective, it must be replaced. To determine oil cooler serviceability, perform pressure test as follows 1. Ensure both oil passages are sealed with pressure test plates and install air pressure line to one pressure test plate. 2. Place oil cooler in tank of water heated to 180F (82C). 3. Apply air pressure not to exceed 60 psi (414 kPa) and observe oil cooler. If leaks are detected, oil cooler is defective and must be replaced.
OIL COOLER PRESSURE TEST

Figure 7. END OF TASK ASSEMBLY 1. Oil Cooler Pressure Test.
M0765JCH
Install thermostat (Figure 8, Item 1) in oil filter head (Figure 8, Item 2) and secure with new retaining ring (Figure 8, Item 3).
3
Figure 8. Oil Filter Head Assembly.
M0766JCH
0060-9
TM 10-3930-675-23-1
0060
ASSEMBLY - Continued 2. Install bypass valve plunger (Figure 9, Item 2), spring (Figure 9, Item 3), and washer (Figure 9, Item 4) in oil filter head (Figure 9, Item 1) and secure with new retaining ring (Figure 9, Item 5).
1
5 2 3 4
M0767JCH
Figure 9. Oil Filter Head Assembly. END OF TASK INSTALLATION 1. 2. With assistance, position oil filter head (Figure 10, Item 2) with new gasket (Figure 10, Item 1) on engine. Secure oil filter head (Figure 10, Item 2) with six washers (Figure 10, Item 4) and screws (Figure 10, Item 3). Tighten screws to 35 ft-lb (47 Nm).
M0768JCH
Figure 10. Oil Filter Head Installation.
0060-10
TM 10-3930-675-23-1
0060
INSTALLATION - Continued 3. Lubricate two new O-rings (Figure 11, Item 4) with clean engine oil and install on oil cooler inlet and outlet tubes.
NOTE
Ensure seal retainer flat sides are facing each other when inserted into seal retainer. 4. 5. 6. 7. Place seal retainer (Figure 11, Item 3) on oil cooler (Figure 11, Item 5) and insert, as far as possible, two seal retainers (Figure 11, Item 2). Lubricate two new O-rings (Figure 11, Item 1) with clean engine oil and insert into seal retainers (Figure 11, Item 2). Position new gaskets (Figure 11, Item 7) on oil filter head (Figure 11, Item 8). Install oil cooler (Figure 11, Item 5) into thermostat housing and on oil filter head (Figure 11, Item 8). Secure oil cooler to oil filter head with four screws (Figure 11, Item 6). Tighten screws to 35 ft-lb (47 Nm).
5 3 4 2 1 4
M0769JCH
Figure 11. Oil Filter Head and Oil Cooler Installation.
0060-11
TM 10-3930-675-23-1
0060
INSTALLATION - Continued 8. Secure oil cooler thermostat housing flange (Figure 12, Item 3) in thermostat housing (Figure 12, Item 2) with four screws (Figure 12, Item 1). Tighten screws to 35 ft-lb (47 Nm).
1
M0770JCH
Figure 12. Oil Filter Head and Oil Cooler Installation. 9. Install elbow fitting (Figure 13, Item 1) on oil filter head (Figure 13, Item 3) and connect turbocharger oil supply line (Figure 13, Item 2).
M0771JCH
Figure 13. Oil Filter Head and Oil Cooler Installation. END OF TASK
0060-12
TM 10-3930-675-23-1
0060
FOLLOW-ON MAINTENANCE 1. Install turbocharger (WP 0073).
NOTE
Ensure cooling system drains are closed. 2. 3. 4. Fill cooling system (WP 0080). Install oil filter (WP 0059). Top off oil (LO 10-3930-675-13).
CAUTION
Engine oil pressure MUST be indicated on gauge within 15 seconds after starting. If oil pressure is not registered within 15 seconds, shut off engine immediately to avoid engine damage. 5. 6. Start engine (TM 10-3930-675-10). Operate engine at idle for 3 minutes to check for leaks. Install engine cover (Volume 2, WP 0185).
0060-13/14 blank
TM 10-3930-675-23-1
0061
FIELD MAINTENANCE ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Gasket (Volume 2, WP 0278, Table 1, Item 62) O-ring (Volume 2, WP 0278, Table 1, Item 82) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Equipment Condition Engine cover removed (Volume 2, WP 0185)
NOTE
Engine oil dipstick hose and transmission oil dipstick hose are at same location. Engine oil dipstick is indicated by a data plate with an engine symbol. Note location of data plate for ease in installation.
0061-1
TM 10-3930-675-23-1
0061
ENGINE OIL DIPSTICK HOSE REMOVAL 1. 2. 3. 4. 5. 6. Remove dipstick (Figure 1, Item 2) from engine oil dipstick hose Figure 1, Item 15). Remove upper end of dipstick hose (Figure 1, Item 15), nipple (Figure 1, Item 3), washer (Figure 1, Item 4) and data plate (Figure 1, Item 5) from bracket (Figure 1, Item 1). Remove lower end of dipstick hose (Figure 1, Item 15) from adapter (Figure 1, Item 17). Remove locknut (Figure 1, Item 12), screw (Figure 1, Item 16), two washers (Figure 1, Item 13), and release dipstick hose (Figure 1, Item 15) from clamps (Figure 1, Item 14). Discard locknut. Remove dipstick hose (Figure 1, Item 15) from vehicle. Remove adapter (Figure 1, Item 17) and O-ring (Figure 1, Item 18) from cover (Figure 1, Item 21). Discard O-ring.
END OF TASK ENGINE OIL DIPSTICK HOSE INSTALLATION 1. 2. 3. 4. 5. Install new O-ring (Figure 1, Item 18) and adapter (Figure 1, Item 17) on cover (Figure 1, Item 21). Position dipstick hose (Figure 1, Item 15) on vehicle. Connect lower end of dipstick hose (Figure 1, Item 15) to adapter (Figure 1, Item 17). Connect upper end of dipstick hose (Figure 1, Item 15) to bracket (Figure 1, Item 1) with washer (Figure 1, Item 4) and nipple (Figure 1, Item 3). Secure dipstick hose (Figure 1, Item 15) with clamps (Figure 1, Item 14), screw (Figure 1, Item 16), two washers (Figure 1, Item 13), and new locknut (Figure 1, Item 12). Ensure clamp is positioned on hose so dipstick (Figure 1, Item 2) can be installed into hose. Install dipstick (Figure 1, Item 2) into dipstick hose (Figure 1, Item 15).
6.
END OF TASK OIL FILL HOSE REMOVAL 1. 2. 3. 4. 5. 6. Remove cap (Figure 1, Item 6) from socket (Figure 1, Item 7). Loosen hose clamp (Figure 1, Item 10) and disconnect upper end of oil fill hose (Figure 2, Item 9) from fitting (Figure 1, Item 8). Remove fitting (Figure 1, Item 8), and socket (Figure 1, Item 7) from bracket (Figure 2, Item 1). Loosen hose clamp (Figure 1, Item 22) and disconnect lower end of oil fill hose (Figure 2, Item 11) from cover (Figure 1, Item 21). Remove remaining clamps (Figure 1, Item 14) and remove oil fill hose (Figure 1, Item 11) from vehicle. Remove four capscrews (Figure 1, Item 20) and cover (Figure 1, Item 21). Remove and discard gasket (Figure 1, Item 19).
0061-2
TM 10-3930-675-23-1
0061
OIL FILL HOSE REMOVAL - Continued

2 6
4 5
ENGI
OI LL L FI
Engine Oil Dipstick Replacement and Fill Hose Removal.
NE
NE ENGI TICK PS
DI
10 15 11
12 13 14 13 11 16 22 21 17 18 14 15
19
20
M1705JCH
0061-3
TM 10-3930-675-23-1
0061
CLEANING
WARNING
Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. Failure to comply may cause injury or death to personnel. 1. 2. Clean and inspect all parts IAW General Maintenance Instructions. Clean oil dipstick cover (Figure 2, Item 1) and cylinder block gasket surfaces (Figure 2, Item 2). Remove all gasket material from cover and cylinder block.
2
M2991JCH
Figure 2. END OF TASK OIL FILL HOSE INSTALLATION 1. 2. 3. 4. 5. 6. 7.
Oil Dipstick Cover and Cylinder Block Cleaning.
Install four capscrews (Figure 3, Item 20) and cover (Figure 3, Item 21) with new gasket (Figure 3, Item 19). Tighten capscrews to 35 ft-lb (47 Nm). Position oil fill hose (Figure 3, Item 11) on vehicle. Connect lower end of oil fill hose (Figure 3, Item 11) to cover (Figure 3, Item 21) and tighten hose clamp (Figure 3, Item 22). Install socket (Figure 3, Item 7), and fitting (Figure 3, Item 8) on bracket (Figure 3, Item 1). Connect upper end of oil fill hose (Figure 3, Item 9) to fitting (Figure 3, Item 8) and tighten hose clamp (Figure 3, Item 10). Install cap (Figure 3, Item 6) on socket (Figure 3, Item 7). Install remaining clamps (Figure 3, Item 14) to secure oil fill hose (Figure 3, Item 11) to vehicle.
0061-4
TM 10-3930-675-23-1
0061
OIL FILL HOSE INSTALLATION - Continued

2 6
4 5
ENGI
OI LL L FI
NE
NE ENGI TICK PS
DI
10 15 11
12 13 14 13 11 16 22 21 17 18 14 15
19
20
M1705JCH
Engine Oil Dipstick and Fill Hoses Installation
0061-5
TM 10-3930-675-23-1
0061
FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE
0061-6
TM 10-3930-675-23-1
0062
FIELD MAINTENANCE OIL SAMPLING VALVES AND HOSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO 10 (Volume 2, WP 0276, Table 1, Item 45) Oil, Lubricating Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References TM 10-3930-675-10 Volume 2, WP 0268 Equipment Condition Engine OFF (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185)
NOTE
Refer to General Maintenance Instructions (Volume 2, WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. Ensure controls are in neutral and vehicle engine is OFF prior to removal of oil sampling valves or hoses. Note number and location of tiedown straps to aid in installation.
0062-1
TM 10-3930-675-23-1
0062
OIL SAMPLING VALVE REMOVAL
NOTE
Oil sampling valves for engine, transmission, and hydraulic system are located in remote hydraulic control compartment. Removal is the same for all three oil sampling valves. Engine oil sampling valve is detailed. 1. 2. Hold fitting jamnut in place and disconnect engine oil sampling valve from fitting. Cover fitting with protective cap.
TRANSMISSION OIL SAMPLING VALVE HYDRAULIC SYSTEM OIL SAMPLING VALVE
ENGINE OIL SAMPLING VALVE
M0012JCH
Figure 1. END OF TASK OIL SAMPLING VALVE INSTALLATION
Oil Sampling Valve.
Remove protective cap and install oil sampling valve. END OF TASK
0062-2
TM 10-3930-675-23-1
0062
ENGINE OIL SAMPLING VALVE HOSE REMOVAL
NOTE
Tag and trace routing of oil sampling valve hose prior to disconnecting. 1. 2. 3. Remove tiedown straps and clamps as necessary. Discard tiedown straps. Disconnect hose from oil sampling valve fitting and engine fitting. Remove hose. Remove engine fitting.
HOSE CONNECTION, ENGINE OIL SAMPLING
M0013JCH
Engine Oil Sampling Valve Hose.
ENGINE OIL SAMPLING VALVE HOSE INSTALLATION 1. 2. 3. Install engine fitting. Connect hose to engine fitting and route to oil sampling valve. Connect hose to oil sampling valve fitting and secure hose with new tiedown straps and clamps as necessary.
END OF TASK
0062-3
TM 10-3930-675-23-1
0062
TRANSMISSION OIL SAMPLING VALVE HOSE REMOVAL
NOTE
Tag and trace routing of oil sampling valve hose prior to disconnecting. 1. 2. 3. 4. Move cab to transport position (TM 10-3930-675-10). Remove tiedown straps and clamps as necessary. Discard tiedown straps. Disconnect hose from oil sampling valve fitting and transmission fitting. Remove hose. Remove transmission fitting.
TRANSMISSION OIL SAMPLING VALVE HOSE
M0014JCH
Transmission Oil Sampling Valve Hose.
TRANSMISSION OIL SAMPLING VALVE HOSE INSTALLATION 1. 2. 3. Install transmission fitting. Connect hose to transmission fitting and route to oil sampling valve. Connect hose to oil sampling valve fitting and secure hose with new tiedown straps and clamps as necessary.
END OF TASK
0062-4
TM 10-3930-675-23-1
0062
HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE REMOVAL
NOTE
Tag and trace routing of oil sampling valve hose prior to disconnecting. 1. 2. 3. 4. Move cab to transport position (TM 10-3930-675-10). Remove tiedown straps and clamps as necessary. Discard tiedown straps. Disconnect hose from oil sampling valve fitting and hydraulic control valve fitting. Remove hose. Remove hydraulic control valve fitting.
INNER SURFACE OF RIGHT FRAME HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE
FORWARD MAIN CONTROL VALVE

M0015JCH
Figure 4. Hydraulic System Oil Sampling Valve Hose. END OF TASK
0062-5
TM 10-3930-675-23-1
0062
HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE INSTALLATION 1. 2. 3. Install hydraulic control valve fitting. Connect hose to hydraulic control valve fitting and route to oil sampling valve. Connect hose to oil sampling valve fitting and secure hose with new tiedown straps and clamps as necessary.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine cover (Volume 2, WP 0185). Start engine (TM 10-3930-675-10) and check for oil leaks. Return cab to operation position (TM 10-3930-675-10).
0062-6
TM 10-3930-675-23-1
0063
FIELD MAINTENANCE EXHAUST MANIFOLD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Guide, Electrical Connector (Volume 2, WP 0277, Table 1, Item 35) Wrench, Torque, Click, Ratcheting, 3/8in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Antiseize Compound (Volume 2, WP 0276, Table 1, Item 7) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 44) Qty: 2 References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Air duct removed (WP 0072) Turbocharger removed (WP 0073)
REMOVAL 1. Remove three cap screws (Figure 1, Item 3), heat shield (Figure 1, Item 1), clamp (Figure 1, Item 2), and three long spacers (Figure 1, Item 4) from front of exhaust manifold (Figure 1, Item 5).
1 2 3 4
5
M0772JCH
Figure 1.
Exhaust Manifold Removal.
0063-1
TM 10-3930-675-23-1
0063
REMOVAL - Continued 2. 3. 4. Remove two screws (Figure 2, Item 2) and spacers (Figure 2, Item 4) from end sections of exhaust manifold (Figure 2, Item 5). Install guide pins (Figure 2, Item 1) in place of removed screws (Figure 2, Item 2). Remove ten remaining screws (Figure 2, Item 2), spacers (Figure 2, Item 4), exhaust manifold (Figure 2, Item 5), and six gaskets (Figure 2, Item 3). Discard gaskets.
3 1 1 2 3 3
4 2
M0773JCH
Exhaust Manifold Removal.
0063-2
TM 10-3930-675-23-1
0063
INSTALLATION
NOTE
Ensure exhaust manifold is free of cracks or other damage. If cracks are present, replace exhaust manifold. Ensure old gasket material is removed from exhaust ports and exhaust manifold mating surfaces. 1. If guide pins (Figure 3, Item 1) were removed, install guide pins in outside top holes of exhaust ports.
NOTE
DO NOT use adhesive of any kind to hold gaskets in place. 2. 3. Place new gasket (Figure 3, Item 3) on each guide pin (Figure 3, Item 1). Position exhaust manifold (Figure 3, Item 5) on guide pins (Figure 3, Item 1).
NOTE
Apply a light coat of antiseize compound to screw threads only. 4. 5. Install four new gaskets (Figure 3, Item 3), ten spacers (Figure 3, Item 4), and screws (Figure 3, Item 2) to secure exhaust manifold (Figure 3, Item 5) in place. Tighten screws hand-tight. Remove guide pins (Figure 3, Item 1) and replace with two spacers (Figure 3, Item 4) and screws (Figure 3, Item 2). Tighten screws hand-tight.
3 1 1 2 3 3
4 2
M0773JCH
Figure 3.
Exhaust Manifold Installation.
0063-3
TM 10-3930-675-23-1
0063
INSTALLATION - Continued 6. Tighten screws (Figure 3, Item 2) in two steps following sequence shown in Figure 4. a. b. First step: 20 ft-lb (27 Nm). Second step: 35 ft-lb (47 Nm).
9 5 1 4 8 12
10
11
2
M0774JCH
TIGHTENING SEQUENCE
Figure 4.
0063-4
TM 10-3930-675-23-1
0063
INSTALLATION - Continued 7. Install clamp (Figure 5, Item 2), three long spacers (Figure 5, Item 4), heat shield (Figure 5, Item 1), and three cap screws (Figure 5, Item 3) at front of exhaust manifold (Figure 5, Item 5).
1 2 3 4
5 (HIDDEN)
M0775JCH
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install turbocharger (WP 0073). Install air ducts (WP 0072).
Start engine (TM 10-3930-675-10). Operate engine and check for exhaust leaks. Install engine cover (Volume 2, WP 0185).
0063-5/6 blank
TM 10-3930-675-23-1
0064
FIELD MAINTENANCE INTAKE MANIFOLD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Detergent General Purpose Liquid (Volume 2, WP 0276, Table 1, Item 15) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 31) References TM 10-3930-675-10 Equipment Condition Air duct removed (WP 0072) Engine sensors removed from intake manifold (WP 0118)
REMOVAL 1. 2. Remove 24 screws (Figure 1, Item 2) securing intake manifold (Figure 1, Item 1) in position. Remove intake manifold (Figure 1, Item 1) and gasket (Figure 1, Item 3). Discard gasket.
2 ROCKER ARM HOUSING
M0776JCH
Intake Manifold Removal.
0064-1
TM 10-3930-675-23-1
0064
INSTALLATION
NOTE
Ensure intake manifold and rocker arm housing mating surfaces have been cleaned and all old gasket material removed. 1. 2. Position new gasket (Figure 2, Item 3) and intake manifold (Figure 2, Item 1). Secure intake manifold (Figure 2, Item 1) with 24 screws (Figure 2, Item 2).
2 ROCKER ARM HOUSING
M0776JCH
Figure 2. Intake Manifold Installation. 3. Tighten screws (Figure 2, Item 2) in sequence shown in Figure 3 to 35 ft-lb (47 Nm).
6 10 18 14 11 7 22 24 23 21 19 3 2 13 17 20
16
12
15
M0778JCH
TIGHTENING SEQUENCE
Figure 3. Intake Manifold Sequence. END OF TASK
0064-2
TM 10-3930-675-23-1
0064
FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine sensors on intake manifold (WP 0118). Install air ducts (WP 0072). Start engine (TM 10-3930-675-10). Operate engine at high idle and use a solution of soapy water to check for air leaks.
0064-3/4 blank
TM 10-3930-675-23-1
0065
FIELD MAINTENANCE FRONT GEAR COVER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Seal, Rectangular Ring (Volume 2, WP 0278, Table 1, Item 38) Qty: 6 O-Ring (Volume 2, WP 0278, Table 1, Item 55) Retainer, Packing (Volume 2, WP 0278, Table 1, Item 56) Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 58) Seal, Plain Encased (Volume 2, WP 0278, Table 1, Item 63) Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Alternator drive belt and pulley removed (WP 0092) A/C compressor drive belt and pulley removed (Volume 2, WP 0251) Vibration damper removed (WP 0053) Front main oil seal removed (WP 0066) Water pump oil seal removed (WP 0088) Front engine mount removed (WP 0051)
0065-1
TM 10-3930-675-23-1
0065
REMOVAL
NOTE
Wiring harness attachment brackets and belt tensioning arm bracket are mounted to front cover. Ensure these additional items and accessories are tagged or marked for location prior to removal. 1. Remove three flange head screws (Figure 1, Item 1) securing wiring harness brackets (Figure 1, Item 6). Remove two screws (Figure 1, Item 3) and washers (Figure 1, Item 4) securing belt tensioning arm bracket (Figure 1, Item 5) to front cover (Figure 1, Item 2).
1
3,4
M0779JCH
Figure 1. Front Gear Cover Removal. 2. 3. Remove 17 remaining flange head screws (Figure 2, Item 1) securing front cover (Figure 2, Item 3) to gear housing (Figure 2, Item 2). With assistance, remove front cover (Figure 2, Item 3) from gear housing (Figure 2, Item 2).
0065-2
TM 10-3930-675-23-1
0065
REMOVAL - Continued
1 2
M0780JCH
Figure 2. 4. 5. 6. 7.
Front Gear Cover Removal.
Remove six rectangular seals (Figure 3, Item 5) at crankshaft seal mounting. Discard seals. Remove two rectangular seals (Figure 3, Items 1 and 3) at accessory drive mounting and water pump mounting. Discard seals. Remove O-ring (Figure 3, Item 4) from hydraulic drive idler retainer. Discard O-ring. Remove front gear cover seal (Figure 3, Item 2) from gear housing groove. Discard seal.
2 2
M0781JCH
Front Gear Cover Removal.
0065-3
TM 10-3930-675-23-1
0065
CLEANING
WARNING
DRY CLEANING SOLVENT Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 20F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. 1. 2. Clean mating surface of front cover and gear housing with cleaning solvent and remove old gasket material. Clean seal grooves with cleaning solvent and remove all residue of old seals.
END OF TASK INSTALLATION
NOTE
Ensure O-ring and seal grooves are clean and free of old material. Apply a light coat of lubricating oil to new O-ring and seals prior to installing. 1. 2. 3. Install two new rectangular seals (Figure 4, Items 1 and 2) in grooves around water pump mounting and accessory drive mounting. Install six new rectangular seals (Figure 4, Item 4) at crankshaft seal mounting. Install new O-ring (Figure 4, Item 3) at hydraulic drive idler retainer.
2
M0782JCH
Figure 4. Front Gear Cover Installation.
0065-4
TM 10-3930-675-23-1
0065
INSTALLATION - Continued 4. Install new front gear cover seal (Figure 5, Item 2) in gear housing groove. Apply silicone sealant to overlap joint at top of gear housing (Figure 5, Item 1).
1 2
M0783JCH
Figure 5. 5.
Front Gear Cover Installation.
With assistance, position gear cover (Figure 6, Item 2) on gear housing (Figure 6, Item 1).
1
M0784JCH
Figure 6.
Front Gear Cover Installation.
0065-5
TM 10-3930-675-23-1
0065
INSTALLATION - Continued 6. Install three wiring harness brackets (Figure 7, Item 6) and belt tensioning arm bracket (Figure 7, Item 5) on front cover (Figure 7, Item 2). Secure in place with three flange head screws (Figure 7, Item 1) and two washers (Figure 7, Item 4) and screws (Figure 7, Item 3). Tighten screws to 55 in-lb. (6 Nm).
1
3,4
M0785JCH
Figure 7. Front Gear Cover Installation. 7. 8. Apply silicone sealant to threads of screws at locations 3, 4, and 23 in Figure 8. Install remaining flange head screws. Tighten screws to 55 in-lb. (6Nm). Tighten all front cover screws in sequence as shown in Figure 8. a. b. Screws 1 to 22: 15 ft-lb (20 Nm) Screws 23 to 28: 50 ft-lb (68 Nm)
0065-6
TM 10-3930-675-23-1
0065
21 20 18 16 14 8 7 12 10 13 11 9 6 5 28 4 15 22 19 17
26 24 1
2 25 27 23
3
M0786JCH
Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8.
Front Gear Cover Tightening Sequence.
Install front engine mount (WP 0051). Install front main oil seal (WP 0066). Install vibration damper (WP 0053). Install water pump oil seal (WP 0088). Install and adjust A/C compressor drive belt and pulley (Volume 2, WP 0251). Install and adjust alternator drive belt and pulley (WP 0092). Start and run engine to operational temperature (TM 10-3930-675-10). Shut down and check for leaks. Install engine cover (Volume 2, WP 0185).
0065-7/8 blank
TM 10-3930-675-23-1
0066
FIELD MAINTENANCE FRONT MAIN OIL SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Tool Kit, Internal Combustion Eng (Volume 2, WP 0277, Table 1, Item 86) Wrench, Torque, Dial, 3/8 in. Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Cloth, Abrasive, Emery, Fine (Volume 2, WP 0276, Table 1, Item 12) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Sealant, Silicone (Volume 2, WP 0276, Table 1, Item 53) Sealing Compound (Volume 2, WP 0276, Table 1, Item 55) Equipment Condition Vibration damper removed (WP 0053)
REMOVAL
NOTE
The front main oil seal contact surface of the crankshaft may have a wear sleeve installed. Check for presence of wear sleeve by inspecting the end of the crankshaft to determine if a wear sleeve was previously installed. If wear sleeve is NOT present, follow Steps 1 through 3 only below to remove the front main crankshaft oil seal. If there IS a wear sleeve present, follow Steps 4 through 8 only, to remove unitized front main crankshaft oil seal with wear sleeve. This unitized seal requires the use of a special tool to remove and install it. 1. 2. 3. Remove six screws (Figure 1, Item 1) and clamping ring (Figure 1, Item 2). Remove oil seal (Figure 1, Item 3) and dust seal (Figure 1, Item 5) together. Discard oil seal and dust seal. Remove and discard gasket (Figure 1, Item 4).
4 2 1 5
Figure 1. Front Main Oil Seal Removal.
M0692JCH
0066-1
TM 10-3930-675-23-1
0066
REMOVAL - Continued
NOTE
Steps 4 through 8 below are for models which are equipped with a unitized front main oil seal with wear sleeve. For models WITHOUT a wear sleeve, use Steps 1 through 3 above to remove the front crankshaft main oil seal. The unitized front crankshaft main oil seal (with wear sleeve) requires the use of the Unitized Oil Seal Installation and Removal Tool to remove and install the unitized front crankshaft main oil seal and wear sleeve. Use Steps 4 through 8 below to remove the unitized front main oil seal and wear sleeve. 4. Remove six mounting screws (Figure 2, Item 1) from front main oil seal (Figure 2, Item 2).
1 2
M1766JCH
Figure 2. 5.
Front Main Oil Seal Removal.
Position seal replacer (Figure 3, Item 1) over crankshaft nose (Figure 3, Item 4) and oil seal flange (Figure 3, Item 2).
NOTE
It may be necessary to use additional sheet metal screws if the seal is difficult to remove. 6. Using hand drill, drive three sheet metal screws (Figure 3, Item 3) into front main oil seal (Figure 3, Item 2) using small holes in seal replacer (Figure 3, Item 1).
4
Figure 3.
M1767JCH
Unitized Front Crankshaft Main Oil Seal Removal.
0066-2
TM 10-3930-675-23-1
0066
REMOVAL - Continued 7. 8. Assemble the base (Figure 4, Item 1) and center-screw (Figure 4, Item 7) of the puller to the replacer (Figure 4, Item 3) using two washers (Figure 4, Item 5), and two 3/8-16 capscrews (Figure 4, Item 6). Turn the center screw (Figure 4, Item 7) of the puller to remove the unitized front main oil seal and wear sleeve (Figure 4, Item 2) from the front gear housing (Figure 4, Item 4).
2 1 3
5 6 4 7
6
Figure 4. END OF TASK CLEANING AND INSPECTION 1. 2.
M1768JCH
Unitized Front Crankshaft Main Oil Seal Removal.
Clean the front crankshaft oil seal gasket surface (Figure 5, Item 1) of the gear cover (Figure 5, Item 2). Inspect the front crankshaft sealing surface (Figure 5, Item 2) for nicks, burrs, and grooves. Dress the front crankshaft sealing surface with crocus cloth. Remove metal shavings with a magnet.
M1769JCH
Cleaning and Inspection.
0066-3
TM 10-3930-675-23-1
0066
INSTALLATION
CAUTION
The wear sleeve must NOT be disassembled from the front main oil seal prior to (or during) seal installation. If the wear sleeve and front main oil seal become separated during installation, the assembly must be discarded. The unitized crankshaft front main oil seal/wear sleeve must be installed when replacing any crankshaft front main oil seal. The capscrew hole spacing on the unitized crankshaft front oil seal/wear sleeve is NOT symmetrical. 1. Start 3 60 mm X 2 in. setscrews (Figure 6, Item 4) into 3 holes in the front gear cover (Figure 6, Item 3) as shown in Figure 6.
NOTE
The gear cover, unitized front crankshaft oil seal/wear sleeve, and gasket are each marked with an arrow, located at approximately the three-o'clock location. 2. Align gear cover (Figure 6, Item 3), unitized crankshaft oil seal/wear sleeve (Figure 6, Item 1), and gasket (Figure 6, Item 2), with all three arrows aligned and pointing in a clockwise direction.
1 2
M1770JCH
Figure 6. Front Unitized Crankshaft Main Oil Seal Installation.
NOTE
Confirm orientation of the installer took, seal, gasket, and gear cover holes. Make sure they all align. 3. Position the unitized crankshaft front main oil seal/wear sleeve (Figure 7, Item 3) and seal replacer (Figure 7, Item 2) over the three setscrews (Figure 7, Item 1) together, to avoid accidentally separating the oil seal from the wear sleeve. Install three washers (Figure 7, Item 4), and three nuts (Figure 7, Item 5) onto setscrews (Figure 7, Item 1).
4.
0066-4
TM 10-3930-675-23-1
0066
1 2
M1771JCH
CAUTION
When tightening the nuts to install the oil seal onto the crankshaft, make certain that the seal remains perfectly parallel to the front gear cover. Failure to follow this Caution may result in damage to the oil seal. 5. 6. Tighten three nuts (Figure 8, Item 1) one revolution at a time, alternately, in a clockwise pattern until the seal (Figure 8, Item 3) and installer tool (Figure 8, Item 2) seat against the front gear cover (Figure 8, Item 4). Tighten the three nuts (Figure 8, Item 1) to 62 in-lb (7 Nm).
1 2
4
M1772JCH
0066-5
TM 10-3930-675-23-1
0066
INSTALLATION - Continued 7. 8. Apply sealing compound to three bolts (Figure 9, Item 1). Install three bolts through holes (Figure 9, Item 3) of replacer plate tool (Figure 9, Item 2). Tighten bolts to 62 in-lb (7 Nm) in a circular pattern. Remove three nuts (Figure 9, Item 4), bolts (Figure 9, Item 5), installer tool plate Figure 9, Item 2), and three setscrews from front gear case (Figure 9, Item 6).
1 2
6 5 4 3
M1773JCH
0066-6
TM 10-3930-675-23-1
0066
INSTALLATION - Continued 9. 10. 11. Apply sealing compound to three remaining bolts (Figure 10, Item 1) and install to unitized front crankshaft main oil seal (Figure 10, Item 2). Tighten three bolts to 62 in-lb (7 Nm). Tighten all six unitized front crankshaft oil seal bolts (Figure 10, Item 2) to final torque of 177 in-lb (20 Nm) in a star-shaped pattern. Check the difference in the installed height of the new wear sleeve versus the crankshaft flange. The difference must not exceed 0.04 in. (1 mm).
1 2
M1774JCH
Figure 10. Front Unitized Crankshaft Main Oil Seal Installation. END OF TASK FOLLOW-ON MAINTENANCE Install vibration damper (WP 0053). END OF TASK END OF WORK PACKAGE
0066-7/8 blank
TM 10-3930-675-23-1
0067
FIELD MAINTENANCE FUEL INJECTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Gloves, Rubber, Industrial (Volume 2, WP 0277, Table 1, Item 32) Puller, Mechanical (Volume 2, WP 0277, Table 1, Item 59) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 32) O-Ring (Volume 2, WP 0278, Table 1, Item 33) O-Ring (Volume 2, WP 0278, Table 1, Item 34) References WP 0056 Equipment Condition Rocker arm cover removed (WP 0057)
WARNING
DIESEL FUEL HANDLING DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. Wear fuel-resistant gloves when handling fuels and promptly wash exposed skin and change fuel- soaked clothing.
0067-1
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0067
REMOVAL
NOTE
Due to engine operating characteristics, adjustments, and alignments, mark or tag push rods, push tubes, crossheads, and injector assemblies for identification as they are removed. If removed, these items MUST be replaced in original locations during installation. Some push rods are under compression due to valve position. To relieve spring tension, hold push rod while rotating crankshaft CLOCKWISE with accessory drive. 1. Loosen injector and valve adjusting screws (Figure 1, Item 1) and remove push rods (Figure 1, Item 3) and push tubes (Figure 1, Item 2) on cylinder requiring injector replacement.
1 2
3
M0825JCH
Figure 1. Push Rods and Push Tubes Removal.
0067-2
TM 10-3930-675-23-1
0067
REMOVAL - Continued 2. 3. Remove crossheads (Figure 2, Item 1) and disconnect injector connector (Figure 2, Item 4). Remove screw (Figure 2, Item 2) and injector hold-down clamp (Figure 2, Item 3).
1 2
4 3
M0826JCH
Figure 2. Injector Hold-Down Clamp Removal. 4. 5. Using injector tool (Figure 3, Item 1), remove injector (Figure 3, Item 2) from cylinder head. Remove three O-rings (Figure 3, Item 3) from injector and discard.
1
M0827JCH
Injector Removal.
0067-3
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0067
INSTALLATION 1. 2. 3. 4. Install three new O-rings (Figure, 4, Item 3) on injector. O-rings are color coded for location as follows: red top, white middle, blue bottom. Lubricate three new O-rings (Figure 4, Item 3) with clean engine oil. Position injector (Figure 4, Item 1) in cylinder head injector bore with solenoid valve toward intake port. Align injector (Figure 4, Item 1) between valve springs.
CAUTION
DO NOT drive injector in by striking solenoid valve area. This can damage solenoid or cause injector to be out of alignment in bore, which will result in O-ring damage. 5. Using injector tool (Figure 4, Item 2), seat injector (Figure 4, Item 1) in bore.
2 1
M0828JCH
Figure 4.
Injector Installation.
CAUTION
Injector must be fully seated before installing hold-down clamp. Engine damage can occur if injector is not fully seated. 6. 7. Install injector hold-down clamp (Figure 5, Item 2) and screw (Figure 5, Item 1). Tighten screw to 55 ft-lb (75 Nm). Connect injector connector (Figure 5, Item 3). Check lock tab to ensure connector is locked in place.
0067-4
TM 10-3930-675-23-1
0067
1 2 3
M1117JCH
Figure 5.
Injector Installation.
NOTE
Ensure crossheads are installed in the same positions from which they were removed. 8. Install crossheads (Figure 6, Item 1) on intake and exhaust valves.
NOTE
Ensure push rods and push tubes are installed in the same positions from which they were removed. 9. Rotate rocker arms down and install push rods (Figure 6, Item 2) and push tubes (Figure 6, Item 3).
1
M0829JCH
Figure 6. Push Rods and Push Tubes Installation. 10. Adjust valves and injectors (WP 0056).
END OF TASK
0067-5
TM 10-3930-675-23-1
0067
FOLLOW-ON MAINTENANCE Install rocker arm cover (WP 0057). END OF TASK END OF WORK PACKAGE
0067-6
TM 10-3930-675-23-1
0068
FIELD MAINTENANCE FUEL PUMP ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Diesel Fuel, DF-2 Grade (Volume 2, WP 0276, Table 1, Item 21) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 69) References TM 10-3930-675-10 Volume 2, WP 0185 Equipment Condition Battery cables disconnected (WP 0129) Fuel line and hose disconnected from fuel pump (WP 0069) Fuel filter/water separator removed (WP 0076) Wire lead disconnected from fuel solenoid shutoff valve (WP 0070)
WARNING
DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. Some residual fuel may remain in fuel lines and hoses. Spilled fuel is slippery and must be cleaned up as soon as possible. Failure to clean up spills may result in injury to personnel.
0068-1
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0068
REMOVAL
NOTE
If not replacing the fuel pump, replace filter element. 1. 2. Remove four screws (Figure 1, Item 2), nuts (Figure 1, Item 7), and eight washers (Figure 1, Item 6) securing fuel pump (Figure 1, Item 1) to accessory drive. Remove fuel pump (Figure 1, Item 1), gasket (Figure 1, Item 5), and jaw coupling spider (Figure 1, Item 4) from accessory drive. Discard gasket.
END OF TASK INSPECTION 1. 2. Inspect fuel pump mounting flange for cracks and other damage. If cracks are found, replace fuel pump. Inspect jaw coupling spider and jaw coupling hub for wear and other damage. If either component is worn or damaged, replace component.
NOTE
Ensure both fuel pump and accessory drive mating flanges are clean and free of old gasket material. 1. 2. Install jaw coupling spider (Figure 1, Item 4), new gasket (Figure 1, Item 5), and fuel pump (Figure 1, Item 1) on accessory drive. Secure in place with four screws (Figure 1, Item 2), nuts (Figure 1, Item 7), and eight washers (Figure 1, Item 6). Tighten screws to 35 ft-lb (47 Nm).
0068-2
TM 10-3930-675-23-1
0068
1
4 5 6 3
M1706JCH
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1.
Fuel Pump Removal.
Connect wire lead to fuel solenoid shutoff valve (WP 0070).
NOTE
To reduce engine cranking time, fill fuel filter with fuel prior to installation. 2. 3. 4. 5. 6. Install fuel filter/water separator (WP 0076). Connect fuel hose from fuel tank to pump. Connect fuel line from fuel pump to cylinder head (WP 0069). Connect battery cables (WP 0129). Operate engine (TM 10-3930-675-10) and check for fuel leaks. Install engine cover (Volume 2, WP 0185).
0068-3/4 blank
TM 10-3930-675-23-1
0069
FIELD MAINTENANCE FUEL HOSES, LINES, AND FITTINGS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Sealing Compound Pipe (Volume 2, WP 0276, Table 1, Item 59) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)
WARNING
DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel.
0069-1
TM 10-3930-675-23-1
0069
NOTE
Fuel lines and hoses may contain residual amounts of fuel which may be spilled when replacing fuel lines. Spilled fuel should be cleaned up immediately. Ensure all lines and fittings are clear of debris and excess pipe sealing compound does not enter lines or fittings. COOLING PLATE-TO-CYLINDER HEAD FUEL LINE REMOVAL 1. 2. Disconnect fuel line (Figure 1, Item 2) from cooling plate (Figure 1, Item 1) and cylinder head fitting (Figure 1, Item 3). Remove fitting (Figure 1, Item 3) from cylinder head (Figure 1, Item 4).
END OF TASK COOLING PLATE-TO-CYLINDER HEAD FUEL LINE INSTALLATION 1. 2. Apply a light coat of sealing compound to fitting (Figure 1, Item 3) and install in cylinder head (Figure 1, Item 4). Connect fuel line (Figure 1, Item 2) to cylinder head fitting (Figure 1, Item 3) and cooling plate (Figure 1, Item 1).
2 1 3
M0028JCH
Figure 1. Cooling Plate-to-Cylinder Head Fuel Line. END OF TASK
0069-2
TM 10-3930-675-23-1
0069
FUEL PUMP-TO-COOLING PLATE FUEL LINE REMOVAL 1. 2. Disconnect fuel line (Figure 2, Item 2) from cooling plate (Figure 2, Item 3) and fuel pump fitting (Figure 2, Item 1). Remove fitting (Figure 2, Item 1) from fuel pump (Figure 2, Item 4).
END OF TASK FUEL PUMP-TO-COOLING PLATE FUEL LINE INSTALLATION 1. 2. Apply a light coat of sealing compound to fitting (Figure 2, Item 1) and install in fuel pump (Figure 2, Item 4). Connect fuel line (Figure 2, Item 2) to fuel pump fitting (Figure 2, Item 1) and cooling plate (Figure 2, Item 3).
2
1 4
M0029JCH
Figure 2. Fuel Pump-to-Cooling Plate Fuel Line. END OF TASK
0069-3
TM 10-3930-675-23-1
0069
ENGINE FUEL RETURN LINE REMOVAL 1. 2. Disconnect fuel return line (Figure 3, Item 2) from cylinder head fitting (Figure 3, Item 1). Remove fitting from cylinder head (Figure 3, Item 5). Disconnect fuel return line (Figure 3, Item 4) from elbow adapter fitting (Figure 3, Item 3).
END OF TASK ENGINE FUEL RETURN LINE INSTALLATION 1. 2. 3. Apply a light coat of sealing compound to cylinder head fitting (Figure 3, Item 1) and install fitting in cylinder head (Figure 3, Item 5). Connect fuel return line (Figure 3, Item 2) to cylinder head fitting (Figure 3, Item 1). Connect fuel return line (Figure 3, Item 4) to elbow adapter fitting (Figure 3, Item 3).
1 2 3 4
M0030JCH
Figure 3. Engine Fuel Return Line. END OF TASK FUEL RETURN HOSE REMOVAL
NOTE
Fuel tank must be drained prior to removal of fuel return hose. Fuel lines may retain small amounts of fuel. 1. 2. 3. 4. Remove fuel tank drain plug (Figure 4, Item 6) and drain fuel into a suitable clean container. Replace plug. Disconnect fuel return hose (Figure 4, Item 4) and remove elbow (Figure 4, Item 1) and adapter (Figure 4, Item 2). Trace and tag fuel return hose (Figure 4, Item 4) from fuel tank (Figure 4, Item 7) to elbow adapter fitting (Figure 4, Item 3). Remove hose clamps (Figure 4, Item 5) as required and disconnect fuel return hose (Figure 4, Item 4)
0069-4
TM 10-3930-675-23-1
0069
FUEL RETURN HOSE REMOVAL - Continued from elbow adapter fitting (Figure 4, Item 3). END OF TASK FUEL RETURN HOSE INSTALLATION 1. 2. 3. 4. Apply a thin coat of sealing compound to elbow (Figure 4, Item 1) and adapter (Figure 4, Item 2) and install in fuel tank (Figure 4, Item 7). Install fuel return hose (Figure 4, Item 4) on elbow (Figure 4, Item 1). Route fuel return hose (Figure 4, Item 4) and connect to elbow adapter fitting (Figure 4, Item 3). Secure fuel return hose (Figure 4, Item 4) in place with hose clamps (Figure 4, Item 5) as needed.
1 2 3
M0032JCH
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.
Fuel Return Hose.
Replace fuel in fuel tank, start engine, and check for fuel leaks (TM 10-3930-675-10). Install engine cover (Volume 2, WP 0185).
0069-5/6 blank
TM 10-3930-675-23-1
0070
FIELD MAINTENANCE FUEL SOLENOID SHUTOFF VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) O-Ring (Volume 2, WP 0278, Table 1, Item 10) Qty: 2 References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)
WARNING
0070-1
TM 10-3930-675-23-1
0070
REMOVAL 1. 2. 3. Remove nut (Figure 1, Item 3) and disconnect wire lead (Figure 1, Item 2) from fuel shutoff valve (Figure 1, Item 4). Replace nut hand-tight on terminal. Remove four screws (Figure 1, Item 1) securing fuel shutoff valve (Figure 1, Item 4) to fuel pump (Figure 1, Item 5). Remove fuel shutoff valve (Figure 1, Item 4), spacer (Figure 1, Item 6), and O-ring seal (Figure 1, Item 7) from fuel pump (Figure 1, Item 5). Discard O-ring seal.
1 2
7 3 6
5 1 4
M0016JCH
Figure 1. Fuel Solenoid Shutoff Valve Removal. END OF TASK INSTALLATION
NOTE
Assemble components of new fuel shutoff valve in the following order. Ensure coil is a single-terminal coil. 1. 2. 3. 4. 5. 6. Place spacer (Figure 2, Item 3) with O-ring groove, coil side up, on clean surface and install new O-ring seal (Figure 2, Item 2). Install actuator disc (Figure 2, Item 4) with cup side toward coil (Figure 2, Item 8). Install valve disc (Figure 2, Item 5) with raised area up. Install spring washer (Figure 2, Item 6) with cup side toward coil (Figure 2, Item 8). Install fuel shield (Figure 2, Item 7) and coil (Figure 2, Item 8). Hold assembly together and install with new O-ring seal (Figure 2, Item 2) on fuel pump (Figure 2, Item 1).
0070-2
TM 10-3930-675-23-1
0070
1 2 3 2 4 5 6 7 8
M0017JCH
Figure 2. 7. 8.
Fuel Solenoid Shutoff Valve Installation.
Secure fuel shutoff valve (Figure 3, Item 4) to fuel pump (Figure 3, Item 5) with four screws (Figure 3, Item 1). Tighten screws to 30 in-lb. (3.4 Nm). Connect wire lead (Figure 3, Item 2) to fuel shutoff valve (Figure 3, Item 4) with nut (Figure 3, Item 3). Tighten nut to 25 in-lb. (2.8 Nm).
1 2
5 1 4
M0018JCH
Fuel Solenoid Shutoff Valve Installation.
Start engine, run, and check for leaks (TM 10-3930-675-10). Install engine cover (Volume 2, WP 0185).
0070-3/4 blank
TM 10-3930-675-23-1
0071
FIELD MAINTENANCE ENGINE AIR CLEANER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Filter Element, Intake Air Cleaner (Volume 2, WP 0278, Table 1, Item 113) Filter Element, Intake Air Cleaner (Volume 2, WP 0278, Table 1, Item 114)
WARNING
CBRN EXPOSURE If Chemical, Biological, Radiological and Nuclear (CBRN) exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may cause injury or death to personnel. Seek medical attention in the event of an injury.
To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083
0071-1
TM 10-3930-675-23-1
0071
FILTER ELEMENTS REPLACEMENT 1. Open six spring clips (Figure 1, Item 1) and remove cover (Figure 1, Item 2) from end of engine air cleaner (Figure 1, Item 3).
1
M0019JCH
Figure 1.
Engine Air Cleaner.
0071-2
TM 10-3930-675-23-1
0071
FILTER ELEMENTS REPLACEMENT - Continued 2. 3. 4. 5. Remove primary filter element (Figure 2, Item 2) and secondary filter element (Figure 2, Item 3) from air cleaner (Figure 2, Item 1). Discard filter elements. Using rags, wipe interior of air cleaner (Figure 2, Item 1) free of dust and dirt. Install new secondary filter element (Figure 2, Item 3) and new primary filter element (Figure 2, Item 2) in air cleaner (Figure 2, Item 1). Install cover (Figure 1, Item 2) on air cleaner (Figure 1, Item 3) and close six spring clips (Figure 1, Item 1).
1 2 1
M0020JCH
Figure 2. Engine Air Cleaner Filter Elements Removal. END OF TASK
0071-3
TM 10-3930-675-23-1
0071
AIR CLEANER REMOVAL 1. 2. 3. 4. 5. Loosen clamp (Figure 3, Item 3) and remove cap (Figure 3, Item 2) from air cleaner (Figure 3, Item 1). Remove vacuum indicator (Figure 3, Item 4) and nipple (Figure 3, Item 5) from air cleaner (Figure 3, Item 1). Loosen clamp (Figure 3, Item 7) holding elbow (Figure 3, Item 6) to air cleaner (Figure 3, Item 1). Remove four nuts (Figure 3, Item 8), washers (Figure 3, Item 9), screws (Figure 3, Item 10), and air cleaner (Figure 3, Item 1) from elbow (Figure 3, Item 6) and top of vehicle. Remove rubber dust vent (Figure 3, Item 11) from cover (Figure 3, Item 12).
1 2 3 4,5
12
11
8, 9,10
M0021JCH
Figure 3. Engine Air Cleaner Filter Elements Removal and Installation. END OF TASK
0071-4
TM 10-3930-675-23-1
0071
AIR CLEANER INSTALLATION 1. 2. 3. 4. 5. Install rubber dust vent (Figure 4, Item 11) on cover (Figure 4, Item 12) of air cleaner (Figure 4, Item 1). Position air cleaner (Figure 4, Item 1) on top of vehicle and elbow (Figure 4, Item 6) and install four screws (Figure 4, Item 10), washers (Figure 4, Item 9), and nuts (Figure 4, Item 8). Tighten clamp (Figure 4, Item 7) holding elbow (Figure 4, Item 6) to air cleaner (Figure 4, Item 1) Install nipple (Figure 4, Item 5) and vacuum indicator (Figure 4, Item 4) in air cleaner (Figure 4, Item 1). Install cap (Figure 4, Item 2) on air cleaner (Figure 4, Item 1) and tighten clamp (Figure 4, Item 3).
1 2 3 4,5
12
11
8, 9,10
M0021JCH
Figure 4. Engine Air Cleaner Filter Elements Removal and Installation. END OF TASK END OF WORK PACKAGE
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TM 10-3930-675-23-1
0072
FIELD MAINTENANCE ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Clamp, Hose (Volume 2, WP 0278, Table 1, Item 101) Qty: As needed References WP 0084 WP 0085 Equipment Condition Engine cover removed (Volume 2, WP 0185)
NOTE
Note position of elbows and tubes to aid in installation. Inspect all hose clamps. If damaged, replace as necessary. Metal rings installed over hoses may be replaced as necessary.
0072-1
TM 10-3930-675-23-1
0072
AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES REMOVAL 1. Loosen six hose clamps (Figure 1, Item 9) and remove elbow (Figure 1, Item 8), 7 1/4-in. tube (Figure 1, Item 11), rubber elbow (Figure 1, Item 12), 4 1/2-in. tube (Figure 1, Item 13), and rubber elbow (Figure 1, Item 14) from air cleaner (Figure 1, Item 10). Remove clamp (Figure 1, Item 6) holding 7 1/4-in. tube (Figure 1, Item 7) to bracket (Figure 1, Item 15). Loosen two hose clamps (Figure 1, Item 4) and remove 71/4-in. tube (Figure 1, Item 7) and elbow (Figure 1, Item 5) from 25-in. tube (Figure 1, Item 3). Remove clamp (Figure 1, Item 16) holding 25-in. tube (Figure 1, Item 3) to bracket (Figure 1, Item 17). Loosen four hose clamps (Figure 1, Item 2) and remove 25-in. tube (Figure 1, Item 3), rubber elbow (Figure 1, Item 1), tube (Figure 1, Item 20), and rubber elbow (Figure 1, Item 19) from turbocharger (Figure 1, Item 18).
2. 3. 4. 5.
END OF TASK AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES INSTALLATION 1. 2. 3. 4. Install rubber elbow (Figure 1, Item 19), tube (Figure 1, Item 20), rubber elbow (Figure 1, Item 1), and 25-in. tube (Figure 1, Item 3) to turbocharger (Figure 1, Item 18) and tighten four hose clamps (Figure 1, Item 2). Install 25-in. tube (Figure 1, Item 3) on bracket (Figure 1, Item 17) with clamp (Figure 1, Item 16). Install elbow (Figure 1, Item 5) and 7 1/4-in. tube (Figure 1, Item 7) on 25-in. tube (Figure 1, Item 3) and tighten two hose clamps (Figure 1, Item 4). Install 7 1/4-in. tube (Figure 1, Item 7) on bracket (Figure 1, Item 15) with clamp (Figure 1, Item 6).
0072-2
TM 10-3930-675-23-1
0072
AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES INSTALLATION - Continued
CAUTION
Ensure there is clearance between rubber elbow and sheet metal or a hole will develop in rubber elbow. 5. Install rubber elbow (Figure 1, Item 14), 4 1/2-in. tube (Figure 1, Item 13), rubber elbow (Figure 1, Item 12), 7 1/4-in. tube (Figure 1, Item 11), and elbow (Figure 1, Item 8) on air cleaner (Figure 1, Item 10) and tighten six hose clamps (Figure 1, Item 9).
10 1 2 20 2 19 17 16 15 2 9 18 14 9 13 9
M0022JCH
4 45
8 67
9 11 9 12
SIDE VIEW
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK Air Cleaner-to-Turbocharger Hoses and Tubes.
0072-3
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0072
TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES REMOVAL 1. 2. 3. 4. 5. Remove radiator top grating (WP 0085). Loosen four hose clamps (Figure 2, Item 3) and remove hose (Figure 2, Item 4), tube (Figure 2, Item 5), and hose (Figure 2, Item 6) from turbocharger (Figure 2, Item 2) and tube (Figure 2, Item 7). Loosen two hose clamps (Figure 2, Item 8) and remove hose (Figure 2, Item 9) from tube (Figure 2, Item 10) and tube (Figure 2, Item 7). Remove U-clamp (Figure 2, Item 11) holding tube (Figure 2, Item 10) to bracket (Figure 2, Item 1). Loosen two hose clamps (Figure 2, Item 12) and remove tube (Figure 2, Item 10) and hose (Figure 2, Item 13) from charge air cooler (Figure 2, Item 14).
END OF TASK TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES INSTALLATION 1. 2. 3. 4. 5. Install hose (Figure 2, Item 13) and tube (Figure 2, Item 10) on charge air cooler (Figure 2, Item 14) and tighten two hose clamps (Figure 2, Item 12). Install tube (Figure 2, Item 10) on bracket (Figure 2, Item 1) with U-clamp (Figure 2, Item 11). Install hose (Figure 2, Item 9) on tube (Figure 2, Item 10) and tube (Figure 2, Item 7) and tighten two hose clamps (Figure 2, Item 8). Install hose (Figure 2, Item 6), tube (Figure 2, Item 5), and hose (Figure 2, Item 4) on tube (Figure 2, Item 7) and turbocharger (Figure 2, Item 2) and tighten four clamps (Figure 2, Item 3). Install radiator top grating (WP 0085).
0072-4
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0072
TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES INSTALLATION - Continued
TOP VIEW
2 3 4 3 5 3 6 3
7 12 13 12 14 11 10 8 9 8
M0023JCH
Figure 2. Turbocharger-to-Charge Air Cooler Hoses and Tubes. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK
0072-5
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0072
CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove radiator top grating (WP 0085). Remove radiator splash shield (WP 0084). Loosen two hose clamps (Figure 3, Item 2) and remove hose (Figure 3, Item 3) from charge air cooler (Figure 3, Item 1) and tube (Figure 3, Item 5). Remove U-clamp (Figure 3, Item 4) holding tube (Figure 3, Item 5) to bracket (Figure 3, Item 17). Loosen two hose clamps (Figure 3, Item 6) and remove tube (Figure 3, Item 5) and hose (Figure 3, Item 7) from tube (Figure 3, Item 8). Loosen two hose clamps (Figure 3, Item 9) and remove hose (Figure 3, Item 10) from tube (Figure 3, Item 8) and tube (Figure 3, Item 8). Remove U-clamp (Figure 3, Item 12) holding tube (Figure 3, Item 11) to bracket (Figure 3, Item 13). Loosen two hose clamps (Figure 3, Item 14) and remove tube (Figure 3, Item 11) and hose (Figure 3, Item 15) from air intake connector (Figure 3, Item 16) of engine air intake manifold.
END OF TASK CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install hose (Figure 3, Item 15) and tube (Figure 3, Item 11) on air intake connector (Figure 3, Item 16) of engine air intake manifold and tighten two hose clamps (Figure 3, Item 14). Install tube (Figure 3, Item 11) on bracket (Figure 3, Item 13) with U-clamp (Figure 3, Item 12). Install hose (Figure 3, Item 10) on tube (Figure 3, Item 11) and tube (Figure 3, Item 8) and tighten two hose clamps (Figure 3, Item 9). Install hose (Figure 3, Item 7) and tube (Figure 3, Item 5) on tube (Figure 3, Item 8) and tighten two hose clamps (Figure 3, Item 6). Install tube (Figure 3, Item 5) on bracket (Figure 3, Item 17) with U-clamp (Figure 3, Item 4). Install hose (Figure 3, Item 3) on tube (Figure 3, Item 5) and charge air cooler (Figure 3, Item 1) and tighten two hose clamps (Figure 3, Item 2). Install radiator splash shield (WP 0084). Install radiator top grating (WP 0085).
0072-6
TM 10-3930-675-23-1
0072
CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES INSTALLATION Continued
6 5 1 2 3 2 4
6 8 9 10 9 11 12 13
14 15 14 16 17
TOP VIEW
M0024JCH
Figure 3. Charger Air Cooler-to-Engine Air Intake Manifold Hoses and Tubes. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE
0072-7/8 blank
TM 10-3930-675-23-1
0073
FIELD MAINTENANCE TURBOCHARGER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (Volume 2, WP 0277, Table 1, Item 85) Gage, Depth (Volume 2, WP 0277, Table 1, Item 27) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Antiseize Compound (Volume 2, WP 0276, Table 1, Item 7) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) O-Ring (Volume 2, WP 0278, Table 1, Item 28) Materials/Parts (cont.) Gasket (Volume 2, WP O-Ring (Volume 2, WP Gasket (Volume 2, WP O-Ring (Volume 2, WP Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) 0278, Table 1, Item 36) 0278, Table 1, Item 61) 0278, Table 1, Item 67) 0278, Table 1, Item 68)
WARNING
DO NOT perform maintenance on turbocharger unless engine has been allowed to cool down. Turbocharger maintenance involves working around exhaust system. Exhaust manifold and pipes may be hot and will cause serious burns.
0073-1
TM 10-3930-675-23-1
0073
REMOVAL 1. Loosen hose clamp screws (Figure 1, Item 3) and remove clamps (Figure 1, Item 2) from exhaust and intake pipes (Figure 1, Items 1 and 4) and from turbocharger (Figure 1, Item 5).
3 1 2 2 3
5 4
M0833JCH
Figure 1. 2.
Clamps Removal.
Disconnect oil supply line (Figure 2, Item 4) from fitting (Figure 2, Item 1) on top of turbocharger (Figure 2, Item 6). Remove fitting and two O-ring seals (Figure 2, Items 2 and 3) from turbocharger. Discard O-ring seals. Remove two screws (Figure 2, Item 8) securing oil drain line (Figure 2, Item 5) and gasket (Figure 2, Item 7) to bottom of turbocharger (Figure 2, Item 6). Disconnect oil drain line. Discard gasket.
4 1,2,3 5 6
3.
M0834JCH
Figure 2. Turbocharger Removal.
0073-2
TM 10-3930-675-23-1
0073
REMOVAL - Continued 4. Remove v-band clamp (Figure 3, Item 1), discharge elbow (Figure 3, Item 2), and O-ring seal (Figure 3, Item 3) from turbocharger (Figure 3, Item 4). Discard O-ring seal.
1
M0835JCH
Figure 3. 5.
Turbocharger Removal.
Remove four nuts (Figure 4, Item 4) securing turbocharger (Figure 4, Item 3) to exhaust manifold (Figure 4, Item 1). With assistance, remove turbocharger and gasket (Figure 4, Item 2) from exhaust manifold. Discard gasket.
1 2
M0839JCH
Turbocharger Removal.
0073-3
TM 10-3930-675-23-1
0073
INSPECTION 1. Perform turbocharger axial clearance check as follows: a. b. c. d. Loosen hose clamp screws and remove intake and exhaust pipes from turbocharger. Install dial depth gage as shown and push rotor assembly away from gauge. Set gauge to zero. Push rotor assembly toward gauge and record reading. Recorded reading must be 0.0015 to 0.0035 in. (0.038 to 0.089 mm). If axial clearance reading is not within specified range, replace turbocharger.
AXIAL CLEARANCE CHECK

Figure 5. 2. Turbocharger Axial Clearance Check.
M0837JCH
Perform turbocharger radial bearing clearance check as follows: a. b. c. d. Loosen hose clamp screws and remove intake and exhaust pipes from turbocharger. Push compressor wheel toward compressor housing. Measure clearance with gauge and record reading. Push compressor wheel away from housing. Measure clearance, in same location, with gauge and record reading. Subtract smaller clearance from larger clearance to obtain radial bearing clearance reading. Radial bearing clearance must be 0.006 to 0.025 in. (0.152 to 0.635 mm). If reading is not within specified range, replace turbocharger.
0073-4
TM 10-3930-675-23-1
0073
RADIAL BEARING CLEARANCE CHECK

Figure 6. Turbocharger Radial Bearing Clearance Check. 3. 4. 5.
M0838JCH
Inspect compressor impeller blades and turbine wheel for damage. If damage is found, replace turbocharger. Visually check turbine and compressor housings for cracks. If cracks exist on outer walls, replace turbocharger. Visually check turbocharger intake and discharge for oil. If noted on turbine side, and oil discharge line is not restricted, replace turbocharger. If oil is on intake side and no restriction is found, replace turbocharger.
NOTE
Mounting flanges must be inspected after removal of turbocharger from engine. 6. Visually check mounting flange surfaces for cracks. Cracks longer than 0.6 in. (15.2 mm) or cracks which extend to mounting holes are not acceptable. Cracks of any length which extend through divider are acceptable only if separated by at least 0.5 in. (12.7 mm).
END OF TASK
0073-5
TM 10-3930-675-23-1
0073
INSTALLATION
NOTE
Ensure mounting flanges on exhaust manifold and turbocharger are clean and free of old gasket material. 1. 2. Apply a thin coat of antiseize compound to exhaust manifold (Figure 7, Item 1) mounting studs. With assistance, install new gasket (Figure 7, Item 2) and turbocharger (Figure 7, Item 3) on exhaust manifold (Figure 7, Item 1). Secure with four nuts (Figure 7, Item 4). Tighten nuts to 45 ft-lb (61 Nm).
1 2
M0839JCH
Figure 7. 3.
Turbocharger Installation.
Install discharge elbow (Figure 8, Item 2), v-band clamp (Figure 8, Item 1), and new O-ring seal (Figure 8, Item 3) on turbocharger (Figure 8, Item 4). Tighten v-band clamp.
1
M0840JCH
Figure 8. 4. 5.
Install oil drain line (Figure 9, Item 5) and new gasket (Figure 9, Item 7) on turbocharger (Figure 9, Item 6) with two screws (Figure 9, Item 8). Tighten screws to 20 ft-lb (27 Nm). Pour 2 to 3 oz (50 to 60 cc) of clean engine oil into turbocharger inlet port.
0073-6
TM 10-3930-675-23-1
0073
INSTALLATION - Continued 6. Install fitting (Figure 9, Item 1) and new O-ring seals (Figure 9, Items 2 and 3) on turbocharger inlet port and connect oil supply line (Figure 9, Item 4) to fitting.
4 1,2,3 5 6
M0841JCH
Figure 9. 7.
Install exhaust and intake pipes (Figure 10, Items 1 and 4) and clamps (Figure 10, Item 2) on turbocharger (Figure 10, Item 5). Tighten hose clamp screws (Figure 10, Item 3).
3 1 2 2 3
5 4
M0842JCH
0073-7
TM 10-3930-675-23-1
0073
FOLLOW-ON MAINTENANCE 1. 2. Start engine (TM 10-3930-675-10). Check for air, exhaust, coolant, and oil leaks. Install engine cover (Volume 2, WP 0185).
0073-8
TM 10-3930-675-23-1
0074
FIELD MAINTENANCE FUEL TANK REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Lifting Device (300 lb minimum capacity) Sling, Nylon (Volume 2, WP 0277, Table 1, Item 70) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 5 Personnel Required (3) References TM 10-3930-675-10 Equipment Condition Fuel level sending unit removed (WP 0132) Muffler removed (WP 0079) Fuel drained from fuel tank (TM 10-3930-675-10) Fuel supply and return hoses disconnected from fuel tank (WP 0075) Right-side step removed (Volume 2, WP 0180) Cab sliding cylinder disconnected from fuel tank (Volume 2, WP 0233)
WARNING
DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel.
NOTE
Fuel tank may contain residual amounts of fuel, which may be spilled when replacing tank. Spilled fuel should be cleaned up immediately.
0074-1
TM 10-3930-675-23-1
0074
REMOVAL 1. 2. Attach a nylon sling to lifting eyes at top of fuel tank (Figure 1, Item 4) and to suitable lifting device. Take up slack in sling. Remove three locknuts (Figure 1, Item 1), screws (Figure 1, Item 2), and six washers (Figure 1, Item 3) from fuel tank (Figure 1, Item 4) and frame. Discard locknuts.
1,2,3 4
M0843JCH
Figure 1. Fuel Tank Removal. 3. Remove two locknuts (Figure 2, Item 2), screws (Figure 2, Item 1), and four spacer washers (Figure 2, Item 3) from fuel tank (Figure 2, Item 4) and bracket (Figure 2, Item 5). Discard locknuts.
CAUTION
Use caution not to allow fuel tank to contact hydraulic reservoir or other components of RTCH as it is being removed. 4. Raise fuel tank (Figure 2, Item 4) to clear bracket (Figure 2, Item 5) and remove from frame.
END OF TASK
0074-2
TM 10-3930-675-23-1
0074
INSTALLATION 1. Attach a nylon sling to lifting eyes at top of fuel tank (Figure 2, Item 4) and to suitable lifting device. Take up slack in sling.
CAUTION
Use caution not to allow fuel tank to contact hydraulic reservoir or other components of RTCH as it is being installed. 2. 3. 4. Raise fuel tank (Figure 2, Item 4) and position fuel tank at frame. Secure fuel tank (Figure 2, Item 4) to frame with three screws (Figure 2, Item 2), six washers (Figure 2, Item 3), and three new locknuts (Figure 2, Item 1). Install four spacer washers (Figure 2, Item 7), two screws (Figure 2, Item 5), and new locknuts (Figure 2, Item 6) on fuel tank (Figure 2, Item 4) and bracket (Figure 2, Item 8).
1 2 3 4
5
M0844JCH
Fuel Tank Replacement.
0074-3
TM 10-3930-675-23-1
0074
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Connect cab sliding cylinder to fuel tank (Volume 2, WP 0233). Install right-side step (Volume 2, WP 0180). Connect fuel supply and return hoses to fuel tank (WP 0075). Install muffler (WP 0079). Install fuel level sending unit (WP 0132). Fill fuel tank (TM 10-3930-675-10). Start engine (TM 10-3930-675-10) and check for leaks.
0074-4
TM 10-3930-675-23-1
0075
FIELD MAINTENANCE FUEL SUPPLY AND RETURN HOSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Equipment Condition Engine cover removed (Volume 2, WP 0185)
0075-1
TM 10-3930-675-23-1
0075
REMOVAL
NOTE
Fuel tank must be drained prior to removal of fuel supply hose. Fuel lines may retain small amounts of fuel. Spilled fuel should be cleaned up immediately. Fuel tank may contain residual amounts of fuel, which may be spilled when replacing tank. Spilled fuel should be cleaned up immediately. 1. 2. 3. 4. Remove fuel tank drain plug (Figure 1, Item 6) and drain fuel into a suitable clean container. Replace plug. Disconnect fuel supply hose (Figure 1, Item 4) and remove elbow (Figure 1, Item 1) and adapter (Figure 1, Item 2). Trace and tag fuel supply hose (Figure 1, Item 4) from fuel tank (Figure 1, Item 7) to fuel filter (Figure 1, Item 5). Remove hose clamps (Figure 1, Item 3) as required and disconnect fuel supply hose (Figure 1, Item 4) from fuel filter (Figure 1, Item 5).
END OF TASK
0075-2
TM 10-3930-675-23-1
0075
INSTALLATION 1. 2. 3. 4. 5. Apply a thin coat of sealing compound to elbow (Figure 1, Item 1) and adapter (Figure 1, Item 2) and install in fuel tank (Figure 1, Item 7). Install fuel supply hose (Figure 1, Item 4) on elbow (Figure 1, Item 1). Route fuel supply hose (Figure 1, Item 4) and connect to fuel filter (Figure 1, Item 5). Secure fuel supply hose (Figure 1, Item 4) in place with hose clamps (Figure 1, Item 3) as needed. Replace fuel in fuel tank, start engine, and check for fuel leaks (TM 10-3930-675-10).
1 2
M0031JCH
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE
Fuel Supply Hose.
0075-3/4 blank
TM 10-3930-675-23-1
0076
FIELD MAINTENANCE FUEL FILTER/WATER SEPARATOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Wrench, Oil Filter, Strap (Volume 2, WP 0277, Table 1, Item 91) Materials/Parts Diesel Fuel, DF-1 Grade (Volume 2, WP 0276, Table 1, Item 18) Diesel Fuel, DF-2 (Volume 2, WP 0276, Table 1, Item 21) Materials/Parts (cont.) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Filter Element, Fluid (Volume 2, WP 0278, Table 1, Item 173) References TM10-3930-675-10
WARNING
0076-1
TM 10-3930-675-23-1
0076
REMOVAL
NOTE
Step 1 applies to RT 240V1R, RT 240V3 and RT 240V1R vehicles only. 1. Close ball valve (Figure 1, Item 2) on fuel pump (Figure 1, Item 1).
M0025JCH
Figure 1. 2.
Fuel Pump Ball Valve.
Open drain valve (Figure 2, Item 3) on fuel filter (Figure 2, Item 2) and drain fluid into a suitable container. Dispose of drained fluid in accordance with SOP.
NOTE
For RT 240V1 vehicle, fuel will drain from fuel pump as fuel filter is removed. Be prepared to install new fuel filter quickly to minimize fuel spillage. 3. 4. Remove fuel filter (Figure 2, Item 2) from fuel pump (Figure 2, Item 1). Discard fuel filter. Remove threaded adapter seal ring (Figure 2, Item 4) from fuel pump (Figure 2, Item 1). Discard seal ring.
END OF TASK
0076-2
TM 10-3930-675-23-1
0076
INSTALLATION
NOTE
Ensure fuel pump sealing surface is clean and free of old gasket material. 1. 2. 3. Install new threaded adapter seal ring (Figure 2, Item 4) provided with new fuel filter on fuel pump (Figure 2, Item 1). Apply a light coat of lubricating oil to new filter gasket and fill fuel filter with correct fuel. Install new fuel filter (Figure 2, Item 2) on fuel pump (Figure 2, Item 1) and tighten until gasket contacts fuel pump surface.
CAUTION
Overtightening of filter can distort threads and damage fuel filter seal. 4. Tighten fuel filter (Figure 2, Item 3) an additional to turn.
1 2
M0026JCH
Figure 2.
Fuel Filter.
0076-3
TM 10-3930-675-23-1
0076
NOTE
Step 4 applies to RT 240V1R , RT 240V2 and RT 240V3 vehicles only. 5. Open ball valve (Figure 3, Item 2) on fuel pump (Figure 3, Item 1).
M0027JCH
Fuel Pump Ball Valve.
Start engine and check for leaks (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE
0076-4
TM 10-3930-675-23-1
0077
FIELD MAINTENANCE ETHER COLD START SYSTEM MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185)
WARNING
Ether is extremely flammable and explosive. DO NOT perform ether cold start system checks, inspections or maintenance while smoking or near fire, flames or sparks. Failure to follow this warning may cause a fire and explosion, causing serious injury or death to personnel. ETHER CANISTER REMOVAL 1. Loosen clamp screw (Figure 1, Item 3) and turn canister (Figure 1, Item 1) counterclockwise to remove from clamp (Figure 1, Item 2) and solenoid (Figure 1, Item 4).
1 2
M0033JCH
Figure 1.
Ether Canister Removal.
0077-1
TM 10-3930-675-23-1
0077
ETHER CANISTER REMOVAL - Continued 2. Inspect gasket (Figure 2, Item 1) for damage. Remove and discard only if damaged.
M0034JCH
Ether Canister Gasket.
0077-2
TM 10-3930-675-23-1
0077
ETHER CANISTER INSTALLATION 1. 2. 3. Ensure gasket (Figure 3, Item 1) is positioned inside top of solenoid (Figure 3, Item 2). Position canister (Figure 3, Item 1) inside clamp (Figure 3, Item 2). Install on solenoid (Figure 3, Item 4) by turning canister clockwise. Tighten clamp screw (Figure 3, Item 3).
1 2
M0035JCH
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK
Ether Canister Installation.
0077-3
TM 10-3930-675-23-1
0077
COLD START ACTIVATION SOLENOID REMOVAL
NOTE
Remove and discard tiedown straps. 1. 2. Remove canister. Refer to Ether Canister Removal in this work package. Disconnect connector (Figure 4, Item 2) of solenoid harness from wiring harness connector (Figure 4, Item 1).
M0036JCH
Figure 4. Cold Start Activation Solenoid Removal. 3. 4. 5. Disconnect ether supply tube (Figure 5, Item 1) from elbow on underside of solenoid (Figure 5, Item 3). Remove two screws (Figure 5, Item 4), washers (Figure 5, Item 5), and solenoid (Figure 5, Item 3) from mounting bracket (Figure 5, Item 2). Remove elbow from bottom of solenoid (Figure 5, Item 3).
0077-4
TM 10-3930-675-23-1
0077
COLD START ACTIVATION SOLENOID REMOVAL - Continued
2 1
4,5
M0037JCH
Figure 5. Cold Start Activation Solenoid Removal. 6. If replacing ether supply tube (Figure 6, Item 1), disconnect tube from fitting (Figure 6, Item 2) at air intake elbow (Figure 6, Item 3).
2 1 3
M0038JCH
Figure 6. Cold Start Activation Solenoid Removal.
0077-5
TM 10-3930-675-23-1
0077
COLD START ACTIVATION SOLENOID REMOVAL - Continued 7. Remove ether supply tube (Figure 7, Item 1) through grommet (Figure 7, Item 3) in mounting bracket (Figure 7, Item 2).
END OF TASK COLD START ACTIVATION SOLENOID INSTALLATION 1. If removed, feed ether supply tube (Figure 7, Item 1) through grommet (Figure 7, Item 3) in mounting bracket (Figure 7, Item 2).
3 2 1
M0039JCH
Figure 7. Cold Start Activation Solenoid Removal.
0077-6
TM 10-3930-675-23-1
0077
COLD START ACTIVATION SOLENOID INSTALLATION - Continued 2. Connect ether supply tube (Figure 8, Item 1) to fitting (Figure 8, Item 2) at air intake elbow (Figure 8, Item 3).
2 1 3
M0040JCH
Figure 8. Cold Start Activation Solenoid Installation.
0077-7
TM 10-3930-675-23-1
0077
COLD START ACTIVATION SOLENOID INSTALLATION - Continued 3. 4. 5. Install elbow on bottom of solenoid (Figure 9, Item 3). Connect other end of ether supply tube (Figure 9, Item 1) to elbow. Position solenoid (Figure 9, Item 3) on mounting bracket (Figure 9, Item 2) and install two washers (Figure 9, Item 5) and screws (Figure 9, Item 4).
2 1
4,5
M0037JCH
Figure 9. Cold Start Activation Solenoid Installation.
0077-8
TM 10-3930-675-23-1
0077
COLD START ACTIVATION SOLENOID INSTALLATION - Continued 6. 7. 8. Connect connector (Figure 10, Item 2) of solenoid harness to wiring harness connector (Figure 10, Item 1). Install canister. Refer to Ether Canister Installation in this work package. Install new tiedown straps.
M0041JCH
Cold Start Activation Solenoid Installation.
Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE
0077-9/10 blank
TM 10-3930-675-23-1
0078
FIELD MAINTENANCE THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
RT 240V1 AND RT 240V1R - REMOVAL 1. 2. Remove three screws (Figure 1, Item 1), washers (Figure 1, Item 2), and left lower panel (Figure 1, Item 3) from vehicle. Remove three screws (Figure 1, Item 4), washers (Figure 1, Item 5), and right lower panel (Figure 1, Item 6) from vehicle.
1,2 3 4,5 6
RT 240V1 AND RT 240V1R VEHICLES
M0042JCH
Figure 1. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.
0078-1
TM 10-3930-675-23-1
0078
RT 240V1 AND RT 240V1R - REMOVAL - Continued 3. Remove four screws (Figure 2, Item 2), washers (Figure 2, Item 3), and cover (Figure 2, Item 1) from right side of cab floor.
1
2,3
M0044JCH
Figure 2. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R. 4. 5. Disconnect connector (Figure 3, Item 3) of throttle position sensor wiring harness (Figure 3, Item 1) from Electronic Control Module (ECM) wiring harness connector (Figure 3, Item 4). Remove two screws (Figure 3, Item 5) and throttle position sensor assembly (Figure 3, Item 2) from vehicle.
2 3 4
M0045JCH
Figure 3. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R. END OF TASK
0078-2
TM 10-3930-675-23-1
0078
RT 240V2 AND RT 240V3 - REMOVAL 1. 2. Remove three screws (Figure 4, Item 1), washers (Figure 4, Item 2), and left lower panel (Figure 4, Item 3) from vehicle. Remove three screws (Figure 4, Item 4), washers (Figure 4, Item 5), and right lower panel (Figure 4, Item 6) from vehicle.
1,2 3 4,5 6
RT 240V2 AND RT 240V3 VEHICLES
M0043JCH
Figure 4. Throttle Position Sensor Removal - RT 240V2 and RT 240V3. 3. Remove four screws (Figure 5, Item 2), washers (Figure 5, Item 3), and cover (Figure 5, Item 1) from right side of cab floor.
1
2,3
M0044JCH
Figure 5. Throttle Position Sensor Removal - RT 240V2 and RT 240V3.
0078-3
TM 10-3930-675-23-1
0078
RT 240V2 AND RT 240V3 - REMOVAL - Continued 4. 5. Disconnect connector (Figure 6, Item 3) of throttle position sensor wiring harness (Figure 6, Item 1) from Electronic Control Module (ECM) wiring harness connector (Figure 6, Item 4). Remove two screws (Figure 6, Item 5) and throttle position sensor assembly (Figure 6, Item 2) from vehicle.
2 3 4
M0045JCH
Figure 6. Throttle Position Sensor Removal - RT 240V2 and RT 240V3. END OF TASK
0078-4
TM 10-3930-675-23-1
0078
RT 240V2 AND RT 240V3 - INSTALLATION 1. 2. Install throttle position sensor assembly (Figure 7, Item 2) on vehicle with two screws (Figure 7, Item 5). Connect connector (Figure 7, Item 3) of throttle position sensor wiring harness (Figure 7, Item 1) to ECM wiring harness connector (Figure 7, Item 4).
2 3 4
M0045JCH
Figure 7. Throttle Position Sensor Installation - RT 240V2 and RT 240V3.
0078-5
TM 10-3930-675-23-1
0078
RT 240V2 AND RT 240V3 - INSTALLATION - Continued 3. Install cover (Figure 8, Item 1) on right side of cab floor with four washers (Figure 8, Item 3) and screws (Figure 8, Item 2).
1
2,3
M0044JCH
Figure 8. Throttle Position Sensor Installation - RT 240V2 and RT 240V3.
0078-6
TM 10-3930-675-23-1
0078
RT 240V2 AND RT 240V3 - INSTALLATION - Continued 4. 5. Install right lower panel (Figure 9, Item 6) in vehicle with three washers (Figure 9, Item 5) and screws (Figure 9, Item 4). Install left lower panel (Figure 9, Item 3) in vehicle with three washers (Figure 9, Item 2) and screws (Figure 9, Item 1).
1,2 3 4,5 6
M0043JCH
Figure 9. Throttle Position Sensor Installation - RT 240V2 and RT 240V3. END OF TASK
0078-7
TM 10-3930-675-23-1
0078
RT 240V1 AND RT 240V2 - INSTALLATION 1. 2. Install throttle position sensor assembly (Figure 10, Item 2) on vehicle with two screws (Figure 10, Item 5). Connect connector (Figure 10, Item 3) of throttle position sensor wiring harness (Figure 10, Item 1) to ECM wiring harness connector (Figure 10, Item 4).
2 3 4
M0045JCH
Figure 10. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R. 3. Install cover (Figure 11, Item 1) on right side of cab floor with four washers (Figure 11, Item 3) and screws (Figure 11, Item 2).
0078-8
TM 10-3930-675-23-1
0078
RT 240V1 AND RT 240V2 - INSTALLATION - Continued

1
2,3
M0044JCH
Figure 11. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R. 4. 5. Install right lower panel (Figure 12, Item 6) in vehicle with three washers (Figure 12, Item 5) and screws (Figure 12, Item 4). Install left lower panel (Figure 12, Item 3) in vehicle with three washers (Figure 12, Item 2) and screws (Figure 12, Item 1).
1,2 3 4,5 6
M0042JCH
Figure 12. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R. END OF TASK END OF WORK PACKAGE
0078-9/10 blank
TM 10-3930-675-23-1
0079
FIELD MAINTENANCE MUFFLER AND EXHAUST PIPE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Equipment Condition Engine cover removed (Volume 2, WP 0185)
0079-1
TM 10-3930-675-23-1
0079
REMOVAL
WARNING
Exhaust system components may be hot to the touch. Avoid contact with any part of exhaust system until sufficiently cool. Failure to do so could result in injury to personnel. 1. 2. 3. Remove eight nuts (Figure 1, Item 4), washers (Figure 1, Item 5), four U-bolts (Figure 1, Item 1), and heat shield (Figure 1, Item 3) from exhaust pipe (Figure 1, Item 2). Remove four nuts (Figure 1, Item 4), washers (Figure 1, Item 5), and two U-bolts (Figure 1, Item 6) holding exhaust pipe (Figure 1, Item 2) to two brackets (Figure 1, Item 7). While supporting muffler (Figure 1, Item 13), remove two nuts (Figure 1, Item 10), four washers (Figure 1, Item 2), and muffler (Figure 1, Item 13) from vehicle.
NOTE
Perform Step 4 to remove support brackets. 4. 5. 6. 7. 8. 9. 10. Remove four nuts (Figure 1, Item 10), eight washers (Figure 1, Item 9), screws (Figure 1, Item 8), and two brackets (Figure 1, Item 7) from vehicle. Remove six nuts (Figure 1, Item 4) and washers (Figure 1, Item 5), three U-bolts (Figure 1, Item 1), and heat shield (Figure 2, Item 24) from exhaust pipe (Figure 1, Item 23) and exhaust hose (Figure 1, Item 21). Loosen two clamps (Figure 1, Item 20) on exhaust hose (Figure 1, Item 21). Remove two nuts (Figure 1, Item 4) and washers (Figure 2, Item 5), U-bolt (Figure 1, Item 6), exhaust pipe (Figure 1, Item 23), and exhaust hose (Figure 1, Item 21) from bracket (Figure 1, Item 22). Remove two bolts (Figure 1, Item 14), four washers (Figure 1, Item 5), and two spacers (Figure 1, Item 16) from bracket (Figure 1, Item 15). Remove two nuts (Figure 1, Item 18), four washers (Figure 1, Item 5), two bolts (Figure 1, Item 17), and two brackets (Figure 1, Item 15) from machine. Loosen clamp (Figure 1, Item 20) and remove exhaust pipe (Figure 1, Item 19) from turbocharger.
NOTE
Perform Step 11 to remove exhaust system support bracket. 11. Remove nut (Figure 1, Item 4), washer (Figure 1, Item 5), U-clamp (Figure 1, Item 6), screw (Figure 1, Item 17), and bracket (Figure 1, Item 22) from vehicle.
0079-2
TM 10-3930-675-23-1
0079
REMOVAL - Continued
4 1 1 2 1 6 6 7 8 7 11 9 25 9 10 12 11 9 9 10 5 4 5 4 1 5
3 3
RT 240V2 AND RT 240V3 ONLY
17 4 5 24 5
14 5 15 5 16
13
9 10 14 5
23 6 1 6 1 18 5 22 20 6 22 5 4 17 21 20 15
17 19 5 16 20
M1710JCH
Muffler and Exhaust Pipe Removal.
0079-3
TM 10-3930-675-23-1
0079
INSTALLATION
NOTE
Perform Step 1 to install exhaust system support bracket, if removed. 1. 2. 3. 4. 5. 6. 7. Install bracket (Figure 2, Item 22) on vehicle with screw (Figure 2, Item 17), washer (Figure 2, Item 5), and nut (Figure 2, Item 4), and U-clamp (Figure 2, Item 6). Install exhaust pipe (Figure 2, Item 19) on turbocharger and tighten clamp (Figure 2, Item 20). Install two brackets (Figure 2, Item 15), two bolts (Figure 2, Item 17), four washers (Figure 2, Item 5), and two nuts (Figure 2, Item 18). Install bracket (Figure 2, Item 15), two spacers (Figure 2, Item 16), four washers (Figure 2, Item 5), and two bolts (Figure 2, Item 14). Install exhaust hose (Figure 2, Item 21) and exhaust pipe (Figure 2, Item 23) on bracket (Figure 2, Item 22) with U-bolt (Figure 2, Item 6), two washers (Figure 2, Item 5), and nuts (Figure 2, Item 4). Tighten two clamps (Figure 2, Item 20) on exhaust hose (Figure 2, Item 21). Install heat shield (Figure 2, Item 24) on exhaust hose (Figure 2, Item 21) and exhaust pipe (Figure 2, Item 23) with three U-bolts (Figure 2, Item 1), six washers (Figure 2, Item 5), and nuts (Figure 2, Item 4).
NOTE
Perform Step 8 to install support brackets. 8. 9. Install two brackets (Figure 2, Item 9) on vehicle with four screws (Figure 2, Item 15), washers (Figure 2, Item 14), and nuts (Figure 2, Item 13). While supporting muffler (Figure 2, Item 13), install muffler and exhaust pipe (Figure 2, Item 2) on vehicle with two clamps (Figure 2, Items 12 and 25), two screws (Figure 2, Item 11), four washers (Figure 2, Item 9), and two nuts (Figure 2, Item 10). Install exhaust pipe (Figure 2, Item 2) on two brackets (Figure 2, Item 7) with two U-bolts (Figure 2, Item 6), four washers (Figure 2, Item 5), and nuts (Figure 2, Item 4). Install heat shield (Figure 2, Item 3) on exhaust pipe (Figure 2, Item 2) with four U-bolts (Figure 2, Item 1), eight washers (Figure 2, Item 5), and nuts (Figure 2, Item 4).
10. 11.
0079-4
TM 10-3930-675-23-1
0079
4 1 1 2 1 6 6 7 8 7 11 9 25 9 10 12 11 9 9 10 5 4 5 4 1 5
3 3
RT 240V2 AND RT 240V3 ONLY
17 4 5 24 5
14 5 15 5 16
13
9 10 14 5
23 6 1 6 1 18 5 22 20 6 22 5 4 17 21 20 15
17 19 5 16 20
M1710JCH
Muffler and Exhaust Pipe Installation.
0079-5
TM 10-3930-675-23-1
0079
FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE
0079-6
TM 10-3930-675-23-1
0080
FIELD MAINTENANCE DRAINING AND FILLING RADIATOR ASSEMBLY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Antifreeze Ethylene Glycol (Volume 2, WP 0276, Table 1, Item 5) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) References TM 10-3930-675-10 Equipment Condition Radiator splash shield removed (WP 0084)
WARNING
DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns.
0080-1
TM 10-3930-675-23-1
0080
DRAINING
NOTE
Bottom of radiator has two drain fittings. Fitting toward rear of vehicle is for draining coolant. Drain fitting toward front of vehicle is for draining possible condensation from engine air intake system. 1. Attach drain hose to drain fitting (Figure 1, Item 2) at bottom of radiator assembly (Figure 1, Item 1).
NOTE
Cooling system capacity is 23.7 gal. (90.1 L). 2. 3. Open drain fitting (Figure 1, Item 2) and allow coolant to drain into a suitable container. Close drain fitting (Figure 1, Item 2) and remove drain hose.
1 2
M0050JCH
Figure 1. END OF TASK FILLING 1.
Drain Radiator Assembly.
Remove four screws (Figure 2, Item 1), washers (Figure 2, Item 2), and fill cover plate (Figure 2, Item 3) from top of vehicle.
0080-2
TM 10-3930-675-23-1
0080
FILLING - Continued
3
1,2
M0051JCH
Figure 2. 2. Remove radiator cap (Figure 3, Item 1).
Fill Radiator Assembly.
NOTE
Use type of coolant appropriate to the anticipated ambient temperature. 3. 4. Add coolant through filler opening (Figure 3, Item 2) at top of radiator assembly (Figure 3, Item 3) until coolant level reaches bottom of filler opening. Install radiator cap (Figure 3, Item 1).
1 2
M0052JCH
Figure 3.
Fill Radiator Assembly.
0080-3
TM 10-3930-675-23-1
0080
FILLING - Continued 5. 6. 7. 8. Install fill cover plate (Figure 2, Item 3) on top of vehicle with four washers (Figure 2, Item 2) and screws (Figure 2, Item 1). Start engine (TM 10-3930-675-10) and allow engine to reach operating temperature. Note coolant level in expansion tank (Figure 4, Item 1). Level should be between MIN and MAX lines on tank when engine is at operating temperature. Add coolant to expansion tank as needed. Stop engine (TM 10-3939-675-10).
M0053JCH
Figure 4. Check Coolant Level. END OF TASK FOLLOW-ON MAINTENANCE Install radiator splash shield (WP 0084). END OF TASK END OF WORK PACKAGE
0080-4
TM 10-3930-675-23-1
0081
FIELD MAINTENANCE RADIATOR ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Lifting Device (1,000 lb capacity) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0276, Table 1, Item 9) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 4 Washer, Lock (Volume 2, WP 0278, Table 1, Item 120) Qty: 6 Personnel Required (2) References WP 0072 References (cont.) WP 0083 Volume 2, WP 0220 Volume 2, WP 0227 Volume 2, WP 0268 Equipment Condition Radiator assembly drained (WP 0080) Fording water level sensor removed (WP 0116) Hydraulic system pressure relieved (Volume 2, WP 0204)
WARNING
DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
0081-1
TM 10-3930-675-23-1
0081
REMOVAL 1. Remove eight screws (Figure 1, Item 1), washers (Figure 1, Item 2), and angle plate (Figure 1, Item 3) from top of vehicle.
1,2
M0845JCH
Figure 1. 2. 3. 4. 5. 6.
Angle Plate Removal.
Disconnect air intake hoses and tubes from radiator assembly (WP 0072). Disconnect cooling system hoses from radiator assembly (WP 0083). Disconnect hydraulic cooling fan hoses and fittings from radiator assembly (Volume 2, WP 0220). Disconnect hydraulic hoses from cooling fan motor and bypass valve (Volume 2, WP 0220). Disconnect electrical connection from bypass valve and remove wiring harness from radiator fan support.
0081-2
TM 10-3930-675-23-1
0081
REMOVAL - Continued
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy objects supported only by a lifting device. Failure to follow this warning may result in injury or death to personnel. Lifting device must have a capacity of approximately 1,000 lb (454 kg) to lift radiator grille and radiator. Failure to follow this warning may result in injury or death to personnel. 7. 8. Attach a suitable lifting device to radiator grille (Figure 2, Item 3). Remove six screws (Figure 2, Item 1), washers (Figure 2, Item 2), and radiator grille (Figure 2, Item 3) from side of vehicle.
1,2 3
M0846JCH
Figure 2.
Radiator Grille Removal.
0081-3
TM 10-3930-675-23-1
0081
REMOVAL - Continued 9. 10. 11. 12. Attach a suitable lifting device to top of radiator assembly (Figure 3, Item 4) with two bolts. Remove two locknuts (Figure 3, Item 1), washers (Figure 3, Item 2), and screws (Figure 3, Item 3) to separate radiator bracket (Figure 3, Item 8) from vehicle. Discard locknuts. Remove six screws, lockwashers, rubber bushings, and radiator assembly (Figure 3, Item 4) from frame. Remove two bolts and lifting device. Discard lockwashers. Remove two screws (Figure 3, Item 6), washers (Figure 3, Item 7), radiator bracket (Figure 3, Item 8), and two rubber bushings (Figure 3, Item 5) from radiator assembly (Figure 3, Item 4).
1,2,3
6,7
M0847JCH
Figure 3. END OF TASK INSTALLATION 1.
Radiator Removal.
Install two rubber bushings (Figure 4, Item 5) and radiator bracket (Figure 4, Item 8) on radiator assembly (Figure 4, Item 4) with two washers (Figure 5, Item 7) and screws (Figure 4, Item 6).
0081-4
TM 10-3930-675-23-1
0081
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy objects supported only by a lifting device. Failure to follow this warning may result in injury or death to personnel. Lifting device must have a capacity of approximately 1,000 lb (454 kg) to lift radiator grille and radiator. Failure to follow this warning may result in injury or death to personnel. 2. 3. 4. Attach a suitable lifting device to top of radiator assembly (Figure 4, Item 4) with two bolts. Install radiator assembly (Figure 4, Item 4) on frame with six rubber bushings, new lockwashers, and screws. Remove two bolts and lifting device. Secure radiator bracket (Figure 4, Item 8) to vehicle with two screws (Figure 4, Item 3), washers (Figure 4, Item 2), and new locknuts (Figure 4, Item 1).
1,2,3
6,7
M0848JCH
Figure 4.
Radiator Installation.
0081-5
TM 10-3930-675-23-1
0081
INSTALLATION - Continued 5. 6. Attach lifting device to radiator grille (Figure 5, Item 3). Install radiator grille (Figure 5, Item 3) on side of vehicle with six washers (Figure 5, Item 2) and screws (Figure 5, Item 1).
1,2 3
M0846JCH
Figure 5. Radiator Grille Installation. 7. Connect electrical connection to bypass valve. Screw wiring to radiator fan support.
NOTE
Refer to General Maintenance Instructions (Volume 2, WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 8. 9. 10. 11. 12. Connect hydraulic hoses to cooling fan motor and bypass valve (Volume 2, WP 0220). Connect hydraulic cooling fan hoses and fittings to radiator assembly (Volume 2, WP 0220). Connect cooling system hoses to radiator assembly (WP 0083). Connect air intake hoses and tubes to radiator assembly (WP 0072). Install angle plate (Figure 6, Item 3) on top of vehicle with eight washers (Figure 6, Item 2) and screws (Figure 6, Item 1).
0081-6
TM 10-3930-675-23-1
0081
1,2
M0849JCH
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. Install fording water level sensor (WP 0116).
Angle Plate Installation.
NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (Volume 2, WP 0227). 2. Fill radiator (WP 0080).
0081-7/8 blank
TM 10-3930-675-23-1
0082
FIELD MAINTENANCE COOLING SYSTEM EXPANSION TANK MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Detergent General Purpose Liquid (Volume 2, WP 0276, Table 1, Item 15) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown (Volume 2, WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 83) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 4 Gasket (Volume 2, WP 0278, Table 1, Item 95) References WP 0080
WARNING
DO NOT perform maintenance on cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns.
NOTE
Tag hoses to aid in installation. Use a suitable container to catch any draining coolant. Clean coolant spills immediately.
0082-1
TM 10-3930-675-23-1
0082
REMOVAL 1. 2. 3. 4. Loosen two hose clamps (Figure 1, Item 5) and disconnect two hoses (Figure 1, Items 6 and 7) from top side of expansion tank (Figure 1, Item 9). Remove four locknuts (Figure 1, Item 4), screws (Figure 1, Item 2), eight washers (Figure 1, Item 3), and two clamps (Figure 1, Item 1) from expansion tank (Figure 1, Item 9). Discard locknuts. Empty coolant from expansion tank (Figure 1, Item 9) by pouring coolant from two openings at top side of tank. Release two hoses (Figure 1, Items 6 and 7) by removing two tiedown straps (Figure 1, Item 8). Discard tiedown straps.
2,3 1 5 3,4
M0064JCH
Figure 1. Cooling System Expansion Tank Removal.
0082-2
TM 10-3930-675-23-1
0082
REMOVAL - Continued 5. 6. 7. Loosen two hose clamps (Figure 2, Item 4) and disconnect two hoses (Figure 2, Item 5) from underside of expansion tank (Figure 2, Item 3). Remove expansion tank (Figure 2, Item 3). Loosen clamp (Figure 2, Item 2) and remove hose (Figure 2, Item 1) from bottom side of expansion tank (Figure 2, Item 3).
2 3 4
M0065JCH
Figure 2. Cooling System Expansion Tank Removal.
0082-3
TM 10-3930-675-23-1
0082
REMOVAL - Continued 8. Remove two nuts (Figure 3, Item 4), four washers (Figure 3, Item 5), two screws (Figure 3, Item 6), and expansion tank mounting bracket (Figure 3, Item 3).
END OF TASK DISASSEMBLY 1. 2. Remove cover (Figure 3, Item 1) and rubber ring (Figure 3, Item 2). Remove nipple (Figure 3, Item 7), O-ring (Figure 3, Item 8), plug (Figure 3, Item 9), and gasket (Figure 3, Item 10) from underside of expansion tank (Figure 3, Item 11). Discard O-ring and gasket.
1 2
11
7,8 9,10 4,5,6

M0067JCH
Figure 3. Cooling System Expansion Tank Removal. END OF TASK CLEANING Wash expansion tank with soap and water. Rinse thoroughly. END OF TASK
0082-4
TM 10-3930-675-23-1
0082
INSPECTION 1. 2. Inspect expansion tank for cracks that could cause leaks. Replace if tank is cracked or otherwise damaged. Inspect all other removed components for damage. Replace if damaged.
END OF TASK ASSEMBLY 1. 2. Install new gasket (Figure 4, Item 10), plug (Figure 4, Item 9), new O-ring (Figure 4, Item 8), and nipple (Figure 4, Item 7) on underside of expansion tank (Figure 2, Item 11). Install rubber ring (Figure 4, Item 2) and cover (Figure 4, Item 1).
END OF TASK INSTALLATION 1. Install expansion tank mounting bracket (Figure 4, Item 3) with two screws (Figure 4, Item 6), four washers (Figure 4, Item 5), and two nuts (Figure 4, Item 4).
1 2
11
7,8 9,10 4,5,6

M0067JCH
Figure 4. Cooling System Expansion Tank Assembly and Installation.
0082-5
TM 10-3930-675-23-1
0082
INSTALLATION - Continued 2. 3. Install hose (Figure 5, Item 6) on bottom side of expansion tank (Figure 5, Item 3) and tighten clamp (Figure 5, Item 2). Position expansion tank (Figure 5, Item 3) and connect two hoses (Figure 5, Item 5) to underside of tank. Tighten two hose clamps (Figure 5, Item 4).
2 3 4
5
M0068JCH
Figure 5. 4.
Cooling System Expansion Tank Installation.
Secure expansion tank (Figure 6, Item 9) to mounting bracket (Figure 4, Item 3) with two clamps (Figure 6, Item 1), four screws (Figure 6, Item 2), eight washers (Figure 6, Item 3), and four new locknuts (Figure 6, Item 4). Connect two hoses (Figure 6, Items 6 and 7) to top side of expansion tank (Figure 6, Item 9). Tighten two hose clamps (Figure 6, Item 5). Install two new tiedown straps (Figure 6, Item 8) to secure hoses (Figure 6, Items 6 and 7) together.
5. 6.
0082-6
TM 10-3930-675-23-1
0082
2,3 1 5 3,4
M0069JCH
Cooling System Expansion Tank Installation.
Check coolant level and add as necessary (WP 0080). END OF TASK END OF WORK PACKAGE
0082-7/8 blank
TM 10-3930-675-23-1
0083
FIELD MAINTENANCE COOLING SYSTEM HOSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) References WP 0085 Volume 2, WP 0175 Equipment Condition Cooling system drained (WP 0080) Equipment Condition (cont.) Remove radiator top grating (WP 0085) Remove transmission access covers (Volume 2, WP 0175)
NOTE
Note location of hose support clamps for installation. Remove hose support clamps, as necessary.
0083-1
TM 10-3930-675-23-1
0083
CAB INTERFACE UNIT-TO-WATER PUMP HOSE REMOVAL 1. 2. Loosen clamp (Figure 1, Item 5) and disconnect hose (Figure 1, Item 4) from cab interface unit (Figure 1, Item 1) at rear of cab. Loosen clamp (Figure 1, Item 2) and remove other end of hose (Figure 1, Item 4) from water pump (Figure 1, Item 3).
END OF TASK CAB INTERFACE UNIT-TO-WATER PUMP HOSE INSTALLATION 1. 2. Install hose (Figure 1, Item 4) on water pump (Figure 1, Item 3) and tighten clamp (Figure 1, Item 2). Connect other end of hose (Figure 1, Item 4) to cab interface unit (Figure 1, Item 1) at rear of cab and tighten clamp (Figure 1, Item 5).
2
3 1
4 RIGHT SIDE
M0054JCH
Cab Interface Unit-to-Water Pump Hose.
0083-2
TM 10-3930-675-23-1
0083
CAB INTERFACE UNIT-TO-ENGINE BLOCK HOSE REMOVAL 1. 2. Loosen clamp (Figure 2, Item 2) and disconnect hose (Figure 2, Item 3) from cab interface unit (Figure 2, Item 1) at rear of cab. Loosen clamp (Figure 2, Item 4) and remove other end of hose (Figure 2, Item 3) from engine block (Figure 2, Item 5).
END OF TASK CAB INTERFACE UNIT-TO-ENGINE BLOCK HOSE INSTALLATION 1. 2. Install hose (Figure 2, Item 3) on engine block (Figure 2, Item 5) and tighten clamp (Figure 2, Item 4). Connect other end of hose (Figure 2, Item 3) to cab interface unit (Figure 2, Item 1) and tighten clamp (Figure 2, Item 2).
3 4 5
RIGHT SIDE
M0055JCH
Cab Interface Unit-to-Engine Block Hose.
0083-3
TM 10-3930-675-23-1
0083
COOLANT RESERVOIR-TO-RADIATOR HOSE REMOVAL 1. 2. Loosen clamp (Figure 3, Item 4) and disconnect hose (Figure 3, Item 5) from coolant reservoir (Figure 3, Item 3). Loosen clamp (Figure 3, Item 2) and remove other end of hose (Figure 3, Item 5) from radiator (Figure 3, Item 1).
END OF TASK COOLANT RESERVOIR-TO-RADIATOR HOSE INSTALLATION 1. 2. Install hose (Figure 3, Item 5) on radiator (Figure 3, Item 1) and tighten clamp (Figure 3, Item 2). Connect other end of hose (Figure 3, Item 5) to coolant reservoir (Figure 3, Item 3) and tighten clamp (Figure 3, Item 4).
3
2 1
FRONT VIEW
M0056JCH
Coolant Reservoir-to-Radiator Hose.
0083-4
TM 10-3930-675-23-1
0083
COOLANT RESERVOIR-TO-WATER MANIFOLD HOSE REMOVAL 1. 2. Loosen clamp (Figure 4, Item 2) and disconnect hose (Figure 4, Item 1) from coolant reservoir (Figure 4, Item 3). Loosen clamp (Figure 4, Item 4) and remove other end of hose (Figure 4, Item 1) from water manifold (Figure 4, Item 5).
END OF TASK COOLANT RESERVOIR-TO-WATER MANIFOLD HOSE INSTALLATION 1. 2. Install hose (Figure 4, Item 1) on water manifold (Figure 4, Item 5) and tighten clamp (Figure 4, Item 4). Connect other end of hose (Figure 4, Item 1) to coolant reservoir (Figure 4, Item 3) and tighten clamp (Figure 4, Item 2).
2 3 1 4 1 5
FRONT VIEW
RIGHT SIDE
M0057JCH
Figure 4. Coolant Reservoir-to-Water Manifold Hose. END OF TASK
0083-5
TM 10-3930-675-23-1
0083
COOLANT RESERVOIR-TO-WATER PUMP HOSE REMOVAL 1. 2. Loosen clamp (Figure 5, Item 1) and disconnect hose (Figure 5, Item 3) from coolant reservoir (Figure 5, Item 2). Loosen clamp (Figure 5, Item 5) and remove other end of hose (Figure 5, Item 3) from water pump (Figure 5, Item 4).
END OF TASK COOLANT RESERVOIR-TO-WATER PUMP HOSE INSTALLATION 1. 2. Install hose (Figure 5, Item 3) on water pump (Figure 5, Item 4) and tighten clamp (Figure 5, Item 5). Connect other end of hose (Figure 5, Item 3) to coolant reservoir (Figure 5, Item 2) and tighten clamp (Figure 5, Item 1).
2 1 3 4
FRONT VIEW
RIGHT SIDE 5
M0058JCH
Coolant Reservoir-to-Water Pump Hose.
0083-6
TM 10-3930-675-23-1
0083
TRANSMISSION OIL COOLER-TO-RADIATOR HOSES REMOVAL 1. 2. Loosen six clamps (Figure 6, Item 4). Remove three hoses (Figure 6, Items 5, 6, and 8) and two cooling pipes (Figure 6, Items 1 and 3) between transmission oil cooler (Figure 6, Item 2) and radiator (Figure 6, Item 7).
END OF TASK TRANSMISSION OIL COOLER-TO-RADIATOR HOSES INSTALLATION 1. 2. Install two cooling pipes (Figure 6, Items 1 and 3) and three hoses (Figure 6, Items 5, 6, and 8) between radiator (Figure 6, Item 7) and transmission oil cooler (Figure 6, Item 2). Tighten six clamps (Figure 6, Item 4).
2 3 4 5
8 TOP VIEW
7
M0059JCH
Figure 6. Transmission Oil Cooler-to-Radiator Hoses. END OF TASK
0083-7
TM 10-3930-675-23-1
0083
TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES REMOVAL 1. 2. Loosen four clamps (Figure 7, Item 2). Remove two hoses (Figure 7, Items 3 and 5) and pipe (Figure 7, Item 4) between transmission oil cooler (Figure 7, Item 6) and water pump (Figure 7, Item 1).
END OF TASK TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES INSTALLATION 1. 2. Install pipe (Figure 7, Item 4) and two hoses (Figure 7, Items 3 and 5) between water pump (Figure 7, Item 1) and transmission oil cooler (Figure 7, Item 6). Tighten four clamps (Figure 7, Item 2).
5 2
6 TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES

M0060JCH
Figure 7. Transmission Oil Cooler-to-Water Pump Hoses. END OF TASK
0083-8
TM 10-3930-675-23-1
0083
TRANSMISSION OIL COOLER-TO-WATER PUMP RETURN HOSE REMOVAL 1. 2. Loosen clamp (Figure 8, Item 5) and disconnect hose (Figure 8, Item 1) from transmission oil cooler (Figure 8, Item 4). Loosen clamp (Figure 8, Item 3) and remove other end of hose (Figure 8, Item 1) from water pump (Figure 8, Item 2).
END OF TASK TRANSMISSION OIL COOLER-TO-WATER PUMP RETURN HOSE INSTALLATION 1. 2. Install hose (Figure 8, Item 1) on water pump (Figure 8, Item 2) and tighten clamp (Figure 8, Item 3). Connect other end of hose (Figure 8, Item 1) to transmission oil cooler (Figure 8, Item 4) and tighten clamp (Figure 8, Item 5).
3 5 1
4 RIGHT SIDE
M0061JCH
Figure 8. Transmission Oil Cooler-to-Water Pump Return Hose. END OF TASK
0083-9
TM 10-3930-675-23-1
0083
TRANSMISSION OIL COOLER U-HOSE REPLACEMENT 1. 2. Loosen two clamps (Figure 9, Item 2) and remove U-hose (Figure 9, Item 1) from transmission oil cooler (Figure 9, Item 3). Install U-hose (Figure 9, Item 1) on transmission oil cooler (Figure 9, Item 3) and tighten two clamps (Figure 9, Item 2).
2 1 3
2 RIGHT SIDE
M0062JCH
Figure 9. Transmission Oil Cooler U-Hose. END OF TASK WATER MANIFOLD-TO-RADIATOR HOSES REMOVAL 1. 2. 3. Loosen six clamps (Figure 10, Item 1). Remove two U-clamps (Figure 10, Item 3) from cooling pipe (Figure 10, Item 2). Remove three hoses (Figure 10, Items 5, 8, and 9) and two cooling pipes (Figure 10, Items 2 and 6) from water manifold (Figure 10, Item 4) and radiator (Figure 10, Item 7).
END OF TASK WATER MANIFOLD-TO-RADIATOR HOSES INSTALLATION 1. 2. 3. Install two cooling pipes (Figure 10, Items 2 and 6) and three hoses (Figure 10, Items 5, 8, and 9) between radiator (Figure 10, Item 7) and water manifold (Figure 10, Item 4). Install two U-clamps (Figure 10, Item 3) on cooling pipe (Figure 10, Item 2). Tighten six clamps (Figure 10, Item 1).
0083-10
TM 10-3930-675-23-1
0083
WATER MANIFOLD-TO-RADIATOR HOSES INSTALLATION - Continued

2 3 1 4 1 5
6 TOP VIEW
M0063JCH
Figure 10. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.
Water Manifold-to-Radiator Hoses.
Install transmission access covers (Volume 2, WP 0175). Install radiator top grating (WP 0085). Refill cooling system (WP 0080).
0083-11/12 blank
TM 10-3930-675-23-1
0084
FIELD MAINTENANCE RADIATOR SPLASH SHIELD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Locknut (Volume 2, WP 0278, Table 1, Item 2) Personnel Required (2)
0084-1
TM 10-3930-675-23-1
0084
REMOVAL 1. 2. Remove locknut (Figure 1, Item 1) and washer (Figure 1, Item 2) from stud of bracket at left front corner of radiator splash shield (Figure 1, Item 3). Discard locknut. Remove four screws (Figure 1, Item 4), washers (Figure 1, Item 5), and radiator splash shield (Figure 1, Item 3) from vehicle.
END OF TASK INSTALLATION 1. 2. Position radiator splash shield (Figure 1, Item 3) on vehicle and install four washers (Figure 1, Item 5) and screws (Figure 1, Item 4). Install washer (Figure 1, Item 2) and new locknut (Figure 1, Item 1) on stud of bracket.
1,2
4,5
M0416JCH
Figure 1. END OF TASK END OF WORK PACKAGE
Radiator Splash Shield Installation.
0084-2
TM 10-3930-675-23-1
0085
FIELD MAINTENANCE RADIATOR TOP GRATING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)
WARNING
Exhaust and cooling system components may be hot to the touch. Ensure these components have cooled down before replacing radiator top grating. Failure to follow this warning may result in serious burns.
0085-1
TM 10-3930-675-23-1
0085
REPLACEMENT
NOTE
Radiator top grating closest to front of vehicle has five mounting screws and hold-down brackets. 1. 2. Remove four screws (Figure 1, Item 1), eight washers (Figure 1, Item 2), four hold-down brackets (Figure 1, Item 3), and grating (Figure 1, Item 4) from vehicle frame. Install grating (Figure 1, Item 4) on vehicle frame with four hold-down brackets (Figure 1, Item 3), eight washers (Figure 1, Item 2), and four screws (Figure 1, Item 1).
1,2,3
M0417JCH
Figure 1. Radiator Top Grating Replacement. END OF TASK END OF WORK PACKAGE
0085-2
TM 10-3930-675-23-1
0086
FIELD MAINTENANCE RADIATOR FILL COVER PLATE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)
WARNING
Exhaust and cooling system components may be hot to the touch. Ensure these components have cooled down before replacing radiator top grating. Failure to follow this warning may result in serious burns. REPLACEMENT 1. 2. Remove four screws (Figure 1, Item 1), washers (Figure 1, Item 2), and fill cover plate (Figure 1, Item 3) from plate (Figure 1, Item 4). Install fill cover plate (Figure 1, Item 3) on plate (Figure 1, Item 4) with four washers (Figure 1, Item 2) and screws (Figure 1, Item 1).
1,2 3
M0418JCH
Radiator Fill Cover Replacement.
0086-1/2 blank
TM 10-3930-675-23-1
0087
FIELD MAINTENANCE THERMOSTAT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Seal, Thermo (Volume 2, WP 0278, Table 1, Item 20) Suitable container References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Radiator splash shield removed (WP 0084) Alternator removed (WP 0091) Engine coolant drained (WP 0080)
REMOVAL 1. 2. Loosen coolant bypass hose clamps (Figure 1, Item 1) on upper and lower hoses (Figure 1, Items 2 and 4). Remove upper hose (Figure 1, Item 2) and lower hose (Figure 1, Item 4) from thermostat housing (Figure 1, Item 3). Ensure flow restriction disc (Figure 1, Item 5) is retained for installation.
2 1
3 5
M0070JCH
Figure 1.
Thermostat Removal.
0087-1
TM 10-3930-675-23-1
0087
REMOVAL - Continued 3. 4. Remove four screws (Figure 2, Item 3) securing thermostat housing (Figure 2, Item 1) to housing support (Figure 2, Item 2). Remove thermostat housing (Figure 2, Item 1) from housing support (Figure 2, Item 2).
1
2
M0071JCH
Figure 2. Thermostat Removal. 5. Remove thermostat (Figure 3, Item 1) and seal (Figure 3, Item 2) from thermostat housing (Figure 3, Item 3). Discard seal.
1 2 3
M0072JCH
Thermostat Removal and Installation.
0087-2
TM 10-3930-675-23-1
0087
INSTALLATION
NOTE
Ensure sealing surfaces of thermostat housing and housing support are clean and free of all material. 1. 2. 3. Install thermostat (Figure 3, Item 1) and new seal (Figure 3, Item 2) in thermostat housing (Figure 3, Item 3). Position thermostat housing (Figure 2, Item 3) on housing support (Figure 2, Item 2) and secure with four screws (Figure 2, Item 2). Tighten screws to 40 ft-lb (54 Nm). Connect upper hose (Figure 4, Item 2) and lower hose (Figure 4, Item 4) to thermostat housing (Figure 4, Item 3) and secure with hose clamps (Figure 4, Item 1). Ensure flow restriction disc (Figure 4, Item 5) is installed.
1 2
3 5
M0073JCH
Thermostat Installation.
NOTE
Ensure radiator draincock is closed. 1. 2. 3. 4. 5. 6. Replace coolant in system (WP 0080). Install alternator (WP 0091). Install radiator splash shield (WP 0084). Start engine (TM 10-3930-675-10) and check for leaks. Top off coolant level as needed (WP 0080). Install engine cover (Volume 2, WP 0185).
0087-3/4 blank
TM 10-3930-675-23-1
0088
FIELD MAINTENANCE WATER PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Puller Attachment, Mechanical (Volume 2, WP 0277, Table 1, Item 58) Puller, Mechanical (Volume 2, WP 0277, Table 1, Item 60) Puller, Mechanical (Volume 2, WP 0277, Table 1, Item 61) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Wrench, Torque, Dial, 3/8 in. Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Oil, Lubricating,Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Sealant, Silicone (Volume 2, WP 0276, Table 1, Item 53) Gasket (Volume 2, WP 0278, Table 1, Item 25) Seal, Oil (Volume 2, WP 0278, Table 1, Item 37) Gasket (Volume 2, WP 0278, Table 1, Item 41) O-Ring (Volume 2, WP 0278, Table 1, Item 57) O-Ring (Volume 2, WP 0278, Table 1, Item 64) Seal, Dust (Volume 2, WP 0278, Table 1, Item 66) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Alternator removed (WP 0091) Thermostat housing removed (WP 0087)
0088-1
TM 10-3930-675-23-1
0088
REMOVAL
WARNING
DO NOT perform maintenance on cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns.
NOTE
Use a drain pan to catch any remaining coolant. 1. Remove water pump pulley retaining screw (Figure 1, Item 1).
NOTE
Ensure puller mounting screws are threaded all the way through puller before applying pressure to puller screw. 2. Use mechanical puller (Figure 1, Item 2) to remove water pump pulley (Figure 1, Item 3).
3 1
M0074JCH
Figure 1.
Water Pump Pulley Removal.
NOTE
Dust seal is removed as seal carrier is removed, or use a heel bar or similar tool to pry dust seal away from seal case, then remove by hand. 3. 4. Remove dust seal (Figure 2, Item 1). Discard dust seal. Remove five screws (Figure 2, Item 5), clamping ring (Figure 2, Item 4), oil seal (Figure 2, Item 3), and gasket (Figure 2, Item 2). Discard oil seal and gasket.
0088-2
TM 10-3930-675-23-1
0088
REMOVAL - Continued
1 2
4 5
M0075JCH
Figure 2. 5. 6.
Dust and Oil Seal Removal.
Remove two water pump transfer connection screws (Figure 3, Item 1). Remove three water pump mounting screws (Figure 3, Item 7).
NOTE
Rotate water pump outward to access transfer connection for removal. 7. Disconnect water transfer connection (Figure 3, Item 4) and gasket (Figure 3, Item 3) from engine and remove transfer connection and seal (Figure 3, Item 5) from water pump (Figure 3, Item 2). Discard gasket and seal.
NOTE
Water pump must be rotated outward and angled downward while being removed to allow pump to pass thermostat housing support. 8. Remove water pump (Figure 3, Item 2) and seal (Figure 3, Item 6). Discard seal.
1 2
3 4 6 5
M0076JCH
Figure 3.
Water Pump Removal.
0088-3
TM 10-3930-675-23-1
0088
REMOVAL - Continued 9. Inspect needle bearing (Figure 4, Item 1) in front cover (Figure 4, Item 2) for damage.
1
M0077JCH
Needle Bearing Inspection.
NOTE
Water pump must be rotated outward from the top until transfer outlet clears thermostat housing support during installation. 1. 2. 3. 4. 5. Install new seal (Figure 5, Item 6) on water pump (Figure 5, Item 2) and install water pump. Install new seal (Figure 5, Item 5) on transfer connection (Figure 5, Item 4) and install transfer connection into water pump (Figure 5, Item 2). Rotate water pump (Figure 5, Item 2) inward and install three water pump mounting screws (Figure 5, Item 7). Tighten screws to 35 ft-lb (47 Nm). Install new gasket (Figure 5, Item 3) on water pump transfer connection (Figure 5, Item 4). Position transfer connection (Figure 5, Item 4) and secure in place with two screws (Figure 5, Item 1). Tighten screws to 18 ft-lb (24 Nm).
0088-4
TM 10-3930-675-23-1
0088
1 2
3 4 6 5
M0078JCH
Figure 5.
Water Pump Installation.
NOTE
Oil seal must be installed with lip of seal and shaft clean and dry. Yellow lip of seal must face out. 6. Install new gasket (Figure 6, Item 2) and new oil seal (Figure 6, Item 3).
NOTE
To prevent oil leakage, use sealant on clamping ring mounting screws. 7. 8. Install clamping ring (Figure 6, Item 4) and secure in place with five screws (Figure 6, Item 5). Tighten screws to 60 in-lbs. (7 Nm). Repeat tightening screws to 180 in-lbs. (20 Nm). Apply a light coat of oil to inside of new dust seal (Figure 6, Item 1) and install dust seal.
1 2
4 5
M0079JCH
Figure 6.
Oil and Dust Seal Installation.
0088-5
TM 10-3930-675-23-1
0088
INSTALLATION - Continued 9. 10. Using pusher adapter and pulley pusher, install water pump pulley (Figure 7, Item 2). Install water pump pulley retaining screw (Figure 7, Item 1). Tighten screw to 55 ft-lb (75 Nm).
2
M0080JCH
Figure 7. Water Pump Pulley Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install thermostat and thermostat housing (WP 0087). Install alternator (WP 0091). Start engine and check for operation and leaks (TM 10-3930-675-10). Ensure cooling system is topped off (WP 0080). Install engine cover (Volume 2, WP 0185).
0088-6
TM 10-3930-675-23-1
0089
FIELD MAINTENANCE HYDRAULIC COOLING FAN MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 75) Qty: 2 Pin, Cotter (Volume 2, WP 0278, Table 1, Item 169) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Washer, Lock (Volume 2, WP 0278, Table 1, Item 119) Qty: 2 Washer, Lock (Volume 2, WP 0278, Table 1, Item 23) Qty: 4 Personnel Required (2) Equipment Condition Radiator assembly removed from vehicle (WP 0081)
0089-1
TM 10-3930-675-23-1
0089
REMOVAL 1. Remove eight screws (Figure 1, Item 2), four lockwashers (Figure 1, Item 4), and nuts (Figure 1, Item 11) securing fan support frame (Figure 1, Item 3) to radiator assembly (Figure 1, Item 14) and fan shroud (Figure 1, Item 1). Discard lockwashers.
NOTE
Fan motor, blade, bracket with bypass valve, and fan support frame are removed as a unit from radiator assembly. 2. With assistance, lift cooling fan from radiator assembly (Figure 1, Item 14) and place on work surface with fan blade (Figure 1, Item 10) facing up.
0089-2
TM 10-3930-675-23-1
0089
REMOVAL - Continued
14 2
12,13 3
2 11
5 4 9 10 7 8 4 2 2
M1704JCH
Cooling Fan Removal.
0089-3
TM 10-3930-675-23-1
0089
DISASSEMBLY 1. 2. Remove cotter pin (Figure 2, Item 12) and castle nut (Figure 2, Item 13), and lift fan blade (Figure 2, Item 10) from hydraulic motor (Figure 2, Item 5). Discard cotter pin. Remove two locknuts (Figure 2, Item 9), screws (Figure 2, Item 8), lockwashers (Figure 2, Item 7), and hydraulic motor (Figure 2, Item 5), and bracket (Figure 2, Item 6) with bypass valve from fan support frame (Figure 2, Item 3). Discard locknuts and lockwashers.
END OF TASK ASSEMBLY 1. Install bracket (Figure 2, Item 6) with bypass valve and hydraulic motor (Figure 2, Item 5) on fan support frame (Figure 2, Item 3) with two screws (Figure 2, Item 8), new lockwashers (Figure 2, Item 7), and new locknuts (Figure 2, Item 9). Install fan blade (Figure 2, Item 10) on hydraulic motor (Figure 2, Item 5) and secure with castle nut (Figure 2, Item 13) and new cotter pin (Figure 2, Item 12).
2.
NOTE
Fan motor, blade, bracket with bypass valve, and fan support frame are installed as a unit on radiator assembly. 1. 2. With assistance, install cooling fan on radiator assembly (Figure 2, Item 14) and secure with eight screws (Figure 2, Item 2), new lockwashers (Figure 2, Item 4), and nuts (Figure 2, Item 11). Rotate fan blade (Figure 2, Item 10) by hand to ensure blade turns freely in fan shroud.
0089-4
TM 10-3930-675-23-1
0089
14 2
12,13 3
2 11
5 4 9 10 7 8 4 2 2
M1704JCH
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install radiator assembly (WP 0081). END OF TASK END OF WORK PACKAGE
Cooling Fan Installation.
0089-5/6 blank
TM 10-3930-675-23-1
0090
FIELD MAINTENANCE COOLANT FILTER AND FILTER HEAD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Antiseize Compound 1 Pound Can (Volume 2, WP 0276, Table 1, Item 7) Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Sealing Compound Pipe (Volume 2, WP 0276, Table 1, Item 59) Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 40) Qty: 2 O-Ring (Volume 2, WP 0278, Table 1, Item 51) References TM 10-3930-675-10 Volume 2, WP 0185 Equipment Condition Engine cover removed (Volume 2, WP 0185) Drain engine coolant (WP 0080)
0090-1
TM 10-3930-675-23-1
0090
COOLANT FILTER REMOVAL
WARNING
DO NOT perform maintenance on cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. 1. 2. Turn valve (Figure 1, Item 3) on cooling filter head (Figure 1, Item 2) to OFF position. Remove and discard coolant filter (Figure 1, Item 1).
2 3
1
M0081JCH
Figure 1. Coolant Filter Removal. END OF TASK
0090-2
TM 10-3930-675-23-1
0090
COOLANT FILTER INSTALLATION
NOTE
Ensure coolant filter sealing surface is free of old gasket material. 1. Apply light coat of lubricating oil to gasket sealing surface (Figure 2, Item 1) of new coolant filter (Figure 2, Item 2).
M0082JCH
Figure 2.
Coolant Filter Preparation.
0090-3
TM 10-3930-675-23-1
0090
COOLANT FILTER INSTALLATION - Continued 2. Install coolant filter (Figure 3, Item 2) on filter head (Figure 3, Item 1) and tighten until gasket (Figure 3, Item 3) contacts filter head surface.
CAUTION
Overtightening can distort filter threads or damage filter head 3. Tighten coolant filter (Figure 3, Item 2) an additional 1/2 to 3/4 turn.
1
2
M0083JCH
Figure 3.
Coolant Filter Tightening.
0090-4
TM 10-3930-675-23-1
0090
COOLANT FILTER INSTALLATION - Continued
NOTE
Coolant filter head valve must be in ON position to prevent damage to engine. 4. Turn coolant filter head valve (Figure 4, Item 1) to ON.
1
M0084JCH
Turn Coolant Filter Head Valve ON.
0090-5
TM 10-3930-675-23-1
0090
COOLANT FILTER HEAD REMOVAL 1. 2. 3. 4. 5. 6. 7. Drain engine coolant (WP 0080). Remove coolant coolant filter (Coolant Filter Removal, in this work package). Remove two capscrews (Figure 5, Item 5), washers (Figure 5, Item 6), capscrew (Figure 5, Item 10), washer (Figure 5, Item 9) and coolant filter head (Figure 5, Item 1) from engine. On backside of coolant filter head (Figure 5, Item 1) remove and discard two O-rings (Figure 5, Item 7). Remove pipe nipple (Figure 5, Item 8) from bottom of coolant filter head (Figure 5, Item 1). Remove capscrew (Figure 5, Item 11), washer (Figure 5, Item 12), and control valve (Figure 5, Item 2) from coolant filter head (Figure 5, Item 1). Remove spring washer (Figure 5, Item 4) and O-ring (Figure 5, Item 3) from control valve (Figure 5, Item 2).
END OF TASK CLEANING AND INSPECTION 1. 2. 3. Clean coolant filter head and control valve with cleaning solvent and a brush. Inspect coolant filter head for cracks or other damage. Replace as necessary. Inspect control valve and control valve bore for corrosion or pitting. Replace control valve and/or coolant filter housing as necessary.
END OF TASK COOLANT FILTER HEAD INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Lubricate new control valve O-ring (Figure 5, Item 3) with a film of anti-seize compound. Install new control valve O-ring (Figure 5, Item 3) to place on control valve (Figure 5, Item 2). Install spring washer (Figure 5, Item 4) and control valve (Figure 5, Item 2) to the coolant filter head (Figure 5, Item 1). Install washer (Figure 5, Item 12) and capscrew (Figure 5, Item 11) to coolant filter head (Figure 4, Item 1). Tighten capscrew to 90 in-lbs (10 Nm). Coat pipe nipple (Figure 5, Item 8) with pipe sealing compound, and install to coolant filter head (Figure 5, Item 1). Lubricate two new O-rings (Figure 5, Item 7) with clean engine oil. Install the O-rings to the backside of the coolant filter head (Figure 5, Item 1). Install coolant filter head (Figure 5, Item 1) with O-rings (Figure 5, Item 7) in place, two washers (Figure 5, Item 6) and capscrews (Figure 5, Item 5). Tighten capscrews to 40 ft-lb (54 Nm). Install washer (Figure 5, Item 9) and capscrew (Figure 5, Item 10) to coolant filter head (Figure 5, Item 1). Tighten capscrew to 40 ft-lb (54 Nm). Install coolant filter to coolant filter head (Coolant Filter Replacement, in this work package). Turn control valve (Figure 5, Item 2) to ON position.
0090-6
TM 10-3930-675-23-1
0090
COOLANT FILTER HEAD INSTALLATION - Continued
2 5 1 3 4 6
12 11 7
10
9 8
M1726JCH
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill cooling system (WP 0080).
Coolant Filter Head Replacement.
Start engine and check for leaks (TM 10-3930-675-10). Check and fill coolant level as necessary (WP 0080). Install engine cover (Volume 2, WP 0185).
0090-7/8 blank
TM 10-3930-675-23-1
0091
FIELD MAINTENANCE ALTERNATOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 175) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Battery cables disconnected (WP 0129) Alternator drive belt removed (WP 0092)
REMOVAL
NOTE
Tag wire leads prior to disconnection to ensure proper connection on installation. 1. Remove two nuts (Figure 1, Item 2) and bolt (Figure 1, Item 5) and disconnect four wiring harness leads (Figure 1, Items 1, 3, 4, and 6) from alternator (Figure 1, Item 7). Replace hardware on alternator terminal.
1 2 3 4
M0085JCH
Figure 1.
Alternator Removal.
0091-1
TM 10-3930-675-23-1
0091
REMOVAL - Continued 2. 3. Remove adjusting link screw (Figure 2, Item 2) securing alternator (Figure 2, Item 1) to adjusting bracket (Figure 2, Item 3). With assistant holding alternator (Figure 2, Item 1), remove mounting screw (Figure 2, Item 4), locknut (Figure 2, Item 6), and washer (Figure 2, Item 7) securing alternator to mounting bracket (Figure 2, Item 5). Remove alternator and discard locknut.
2 3
6,7
M0086JCH
Figure 2. END OF TASK INSTALLATION 1. 2. 3.
Alternator Removal.
Position alternator (Figure 2, Item 1) on mounting bracket (Figure 2, Item 5) and secure with screw (Figure 2, Item 4), washer (Figure 2, Item 7), and new locknut (Figure 2, Item 6). Tighten hand-tight. Install adjusting link screw (Figure 2, Item 2). Tighten hand-tight. Connect four wiring harness leads (Figure 3, Items 1, 3, 4, and 6) to alternator (Figure 3, Item 7) and secure with two nuts (Figure 3, Item 2) and bolt (Figure 3, Item 5).
0091-2
TM 10-3930-675-23-1
0091
1 2 3 4
M0087JCH
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install and adjust alternator belt (WP 0092). Connect battery cables (WP 0129).
Alternator Installation.
Start engine (TM 10-3930-675-10) and verify operation of alternator. Install engine cover (Volume 2, WP 0185).
0091-3/4 blank
TM 10-3930-675-23-1
0092
FIELD MAINTENANCE ALTERNATOR DRIVE BELT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Belt, Tension Gauge (Volume 2, WP 0277, Table 1, Item 9) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 175) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Master battery switch in OFF position
REMOVAL 1. 2. 3. 4. 5. Loosen jamnut (Figure 1, Item 2). Loosen adjusting link retaining screw (Figure 1, Item 3). Loosen alternator mounting screw (Figure 1, Item 5) and locknut (Figure 1, Item 6). Discard locknut. Turn adjusting screw (Figure 1, Item 1) counterclockwise to release alternator drive belt (Figure 1, Item 4) tension. Remove alternator drive belt (Figure 1, Item 4).
3
M0088JCH
Alternator Drive Belt Removal.
0092-1
TM 10-3930-675-23-1
0092
INSTALLATION
CAUTION
Do not roll drive belt over pulley or pry on drive belt with tools. Rolling or prying on belt can cause damage and shorten life of belt.
NOTE
Ensure sufficient slack adjustment has been allowed to install drive belt. 1. 2. 3. 4. 5. Install drive belt (Figure 2, Item 4). Position alternator (Figure 2, Item 7) to remove slack in drive belt (Figure 2, Item 4) and tighten adjusting link retaining screw (Figure 2, Item 3) to hold alternator in place. Turn adjusting screw (Figure 2, Item 1) clockwise to increase belt tension and tighten jamnut (Figure 2, Item 2) (refer to Adjustment) in this work package. Tighten retaining screw (Figure 2, Item 3) to 60 ft-lb (81 Nm). Tighten alternator mounting screw (Figure 2, Item 5) and new locknut (Figure 2, Item 6) to 35 ft-lb (47 Nm).
3
M0089JCH
Figure 2. Alternator Drive Belt Installation. END OF TASK ADJUSTMENT
NOTE
Belt tension for new alternator drive belt should be 140 ft-lb (190 Nm). For a used belt, adjustment range on belt tension is 60-110 ft-lb (81-149 Nm). A drive belt which has been in service more than 10 minutes is considered a used belt. 1. 2. Measure belt tension with gauge (Figure 3, Item 4). If measurement is within specified range, no adjustment is required. If measurement is not as specified, proceed to next step. Loosen jamnut (Figure 3, Item 2).
0092-2
TM 10-3930-675-23-1
0092
ADJUSTMENT - Continued
NOTE
Turn adjusting screw clockwise to increase tension. Turn adjusting screw counterclockwise to decrease tension. 3. 4. 5. Turn adjusting screw (Figure 3, Item 1) to obtain correct tension. Tighten jamnut (Figure 3, Item 2). Tighten retaining screw (Figure 3, Item 3) to 60 ft-lb (81 Nm). Tighten alternator mounting screw (Figure 2, Item 5) and locknut (Figure 2, Item 6) to 35 ft-lb (47 Nm).
3 4
1
M0090JCH
Alternator Drive Belt Adjustment.
Turn master battery switch to ON position (TM 10-3930-675-10). Start engine (TM 10-3930-675-10) and run for approximately 10 minutes. Shut engine down and check belt tension. Readjust belt tension as required. Install engine cover (Volume 2, WP 0185).
0092-3/4 blank
TM 10-3930-675-23-1
0093
FIELD MAINTENANCE STARTER MOTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 1/2 Inch Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Gasket (Volume 2, WP 0278, Table 1, Item 26) Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Battery cables disconnected (WP 0129)
0093-1
TM 10-3930-675-23-1
0093
REMOVAL
WARNING
Remove all jewelry, watches, rings, etc., prior to disconnecting cables from batteries or other electrical source. Items can come in contact with battery or electrical source and cause electrical shock. Failure to follow this warning may result in personnel injury or death.
NOTE
Tag cables prior to disconnection to ensure proper connection on installation. Remove tiedown straps and discard. Perform Step 1 at rear of starter solenoid. 1. Remove nut (Figure 1, Item 1), washer (Figure 1, Item 2), and terminals of cables (Figure 1, Item 3) from solenoid (Figure 1, Item 4). Reinstall washer and nut.
3
4 1,2
M0091JCH
Figure 1.
Starter Removal.
NOTE
Perform Step 2 at rear of starter. 2. Remove nut (Figure 2, Item 1), washer (Figure 2, Item 2), and terminals of cables (Figure 2, Item 4) from starter (Figure 2, Item 3). Reinstall washer and nut.
0093-2
TM 10-3930-675-23-1
0093
REMOVAL - Continued
1,2
M0092JCH
Figure 2. 3.
Starter Removal.
Remove three screws (Figure 3, Item 4), starter (Figure 3, Item 1), and gasket (Figure 3, Item 2) from engine (Figure 3, Item 3). Discard gasket.
2
M0093JCH
Starter Removal.
0093-3
TM 10-3930-675-23-1
0093
INSTALLATION
NOTE
Ensure all old gasket material has been removed from mating surfaces. 1. Install new gasket (Figure 3, Item 2) and starter (Figure 3, Item 1) on engine (Figure 3, Item 3) with three screws (Figure 3, Item 4). Tighten screws to 140 ft-lb (190 Nm).
NOTE
Perform Step 2 at rear of starter. 2. Install terminals of cables (Figure 4, Item 4) to starter (Figure 4, Item 3) with washer (Figure 4, Item 2) and nut (Figure 4, Item 1).
1,2
M0092JCH
Figure 4.
Starter Installation.
0093-4
TM 10-3930-675-23-1
0093
NOTE
Perform Step 3 at rear of starter solenoid. 3. 4. Install terminals of cables (Figure 5, Item 3) on solenoid (Figure 5, Item 4) with washer (Figure 5, Item 2) and nut (Figure 5, Item 1). Install new tiedown straps.
3
4 1,2
M0091JCH
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0129).
Starter Installation.
Perform operational check of engine (TM 10-3930-675-10). Install engine cover (Volume 2, WP 0185).
0093-5/6 blank
TM 10-3930-675-23-1
0094
FIELD MAINTENANCE INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
NOTE
Instrument panel switches, gauges, and panel lamps are replaced the same way, except where minor differences are noted. Remove and discard tiedown straps as required. Use new tiedown straps on installation. Tag wires and connectors as required.
0094-1
TM 10-3930-675-23-1
0094
ROCKER SWITCH REMOVAL
NOTE
Perform Step 1 for left or right switch/gauge panel. Left panel (shown) has 10 screws. Right panel has five screws. To replace switch/gauge panel, perform Switch/Gauge Removal and Installation procedure for each panel component per this work package. Prior to reinstalling switches and gauges, replace panel. 1. 2. Remove 10 screws (Figure 1, Item 3) from switch/gauge panel (Figure 1, Item 1). Lift switch/gauge panel (Figure 1, Item 1) upward from instrument panel (Figure 1, Item 2) to gain access to rear of panel.
1 2 3
M0096JCH
Figure 1. 3. 4. 5.
Switch/Gauge Panel Removal.
Lift tab of instrument panel wiring harness connector (Figure 2, Item 1) and disconnect connector from switch (Figure 2, Item 2). To remove switch lamp, refer to Instrument Panel Lamp Removal in this work package. Depress tabs at sides of switch (Figure 2, Item 2) and push switch upward and out of switch/gauge panel (Figure 2, Item 3).
END OF TASK
0094-2
TM 10-3930-675-23-1
0094
ROCKER SWITCH INSTALLATION 1. 2. 3. 4. 5. 6. Push switch (Figure 2, Item 2) down into switch/gauge panel (Figure 2, Item 3) until flush with panel. To install switch lamp, refer to Instrument Panel Lamp Installation in this work package. Connect instrument panel wiring harness connector (Figure 2, Item 1) to switch (Figure 2, Item 2). Install switch/gauge panel (Figure 2, Item 1) on instrument panel (Figure 2, Item 2) with 10 screws (Figure 2, Item 3). Turn master battery switch to on position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
1 2 3
M0097JCH
Rocker Switch Removal.
0094-3
TM 10-3930-675-23-1
0094
ROTARY SWITCH REMOVAL 1. 2. Remove 10 screws (Figure 3, Item 3) from switch/gauge panel (Figure 3, Item 1). Lift switch/gauge panel (Figure 3, Item 1) upward from instrument panel (Figure 3, Item 2).
1 2 3
M0096JCH
Figure 3.
Switch/Gauge Panel Removal.
0094-4
TM 10-3930-675-23-1
0094
ROTARY SWITCH REMOVAL - Continued 3. 4. Remove six screws (Figure 4, Item 4) and washers (Figure 4, Item 5) from instrument panel (Figure 4, Item 2) to gain access to switches (Figure 4, Item 3). Remove three screws (Figure 4, Item 1) to separate switch plate (Figure 4, Item 6) from instrument panel (Figure 4, Item 2) and pull switch plate downward for access to switches (Figure 4, Item 3).
1 2
6 4,5 3
M0100JCH
Figure 4.
Rotary Switch Removal.
0094-5
TM 10-3930-675-23-1
0094
ROTARY SWITCH REMOVAL - Continued 5. 6. Loosen setscrew (Figure 5, Item 3) and remove knob (Figure 5, Item 1) from switch (Figure 5, Item 4) to be replaced. Remove nut (Figure 5, Item 2) and switch (Figure 5, Item 4) from switch plate (Figure 5, Item 10).
NOTE
Perform Step 7 for switches with electrical connectors. 7. Disconnect connector(s) (Figure 5, Item 5) of instrument panel wiring harness from rear of switch (Figure 5, Item 4).
NOTE
Perform Steps 8 and 9 for switches with control cables. 8. 9. Remove pushnut (Figure 5, Item 8) and disconnect control cable (Figure 5, Item 7) from rear of switch (Figure 5, Item 9). Remove tiedown strap, lift tab of clip (Figure 5, Item 6), and remove clip and control cable (Figure 5, Item 7) from switch (Figure 5, Item 9). Discard tiedown strap.
END OF TASK ROTARY SWITCH INSTALLATION
NOTE
Perform Steps 1 and 2 for switches with control cables. 1. 2. Install control cable (Figure 5, Item 7) on switch (Figure 5, Item 9) with clip (Figure 5, Item 6) and install new tiedown strap. Connect control cable (Figure 5, Item 7) to rear of switch (Figure 5, Item 9) and install pushnut (Figure 5, Item 8).
NOTE
Perform Step 3 for switches with electrical connectors. 3. 4. 5. Connect instrument panel wiring harness connector(s) (Figure 5, Item 5) to rear of switch (Figure 5, Item 4). Push switch (Figure 5, Item 4) upward through hole in switch plate (Figure 5, Item 10) and install nut (Figure 5, Item 2). Press knob (Figure 5, Item 1) onto shaft of switch (Figure 5, Item 4) and tighten setscrew (Figure 5, Item 3).
0094-6
TM 10-3930-675-23-1
0094
ROTARY SWITCH INSTALLATION - Continued

1 2 3 4
10
M0101JCH
Figure 5. 6. 7.
Rotary Switch Removal and Installation.
Install switch plate (Figure 6, Item 5) on instrument panel (Figure 6, Item 2) with three screws (Figure 6, Item 1). Install instrument panel (Figure 6, Item 2) with six washers (Figure 6, Item 4) and screws (Figure 6, Item 3).
1 2 3
M0103JCH
Figure 6.
Switch/Gauge Panel Installation.
0094-7
TM 10-3930-675-23-1
0094
ROTARY SWITCH INSTALLATION - Continued 8. 9. 10. Install switch/gauge panel (Figure 7, Item 1) on instrument panel (Figure 7, Item 2) with 10 screws (Figure 7, Item 3). Turn master battery switch to ON position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
1 2
3,4
M0102JCH
Figure 7. Rotary Switch Installation. END OF TASK
0094-8
TM 10-3930-675-23-1
0094
GAUGE REMOVAL 1. 2. Perform Steps 1 and 2 of Rocker Switch Removal in this work package to gain access to rear of gauge. To remove gauge lamp, refer to Instrument Panel Lamp Removal in this work package.
NOTE
Perform Steps 3 and 4 for fuel gauge. 3. 4. Disconnect instrument panel wiring harness connector (Figure 8, Item 8) from rear of gauge (Figure 8, Item 1). Remove retainer (Figure 8, Item 2) and gauge (Figure 8, Item 1) from switch/gauge panel (Figure 8, Item 3).
NOTE
Perform Steps 5 and 6 for hour meter gauge. 5. 6. Disconnect instrument panel wiring harness connector (Figure 8, Item 7) from rear of gauge (Figure 8, Item 4). Remove two nuts (Figure 8, Item 6), retainer (Figure 8, Item 5), and gauge (Figure 8, Item 4) from switch/gauge panel (Figure 8, Item 3).
1 2 3 4
5 8 6
M0104JCH
Gauge Removal.
0094-9
TM 10-3930-675-23-1
0094
GAUGE INSTALLATION
NOTE
Perform Steps 1 and 2 for hour meter gauge. 1. 2. Install gauge (Figure 8, Item 4) on switch/gauge panel (Figure 8, Item 3) with retainer (Figure 8, Item 5) and two nuts (Figure 8, Item 6). Connect instrument panel wiring harness connector (Figure 8, Item 7) to gauge (Figure 8, Item 4).
NOTE
Perform Steps 3 and 4 for fuel gauge. 3. 4. 5. 6. 7. 8. Install gauge (Figure 8, Item 1) on switch/gauge panel (Figure 8, Item 3) with retainer (Figure 8, Item 2). Connect instrument panel wiring harness connector (Figure 8, Item 8) to gauge (Figure 8, Item 1). To install gauge lamp, refer to Instrument Panel Lamp Installation in this work package. Install switch/gauge panel (Figure 9, Item 1) on instrument panel (Figure 9, Item 2) with 10 screws (Figure 9, Item 3). Turn master battery switch to ON position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
1 2 3
M0105JCH
Switch/Gauge Panel Installation.
0094-10
TM 10-3930-675-23-1
0094
INSTRUMENT PANEL LAMP REMOVAL 1. 2. 3. Perform Steps 1 and 2 of Rocker Switch Removal in this work package to gain access to instrument panel lamps. Disconnect lamp (Figure 10, Item 1), with connector (Figure 10, Item 2) attached, from switch or gauge. Remove lamp (Figure 10, Item 1) from connector (Figure 10, Item 2).
M0106JCH
Instrument Panel Lamp Installation.
0094-11
TM 10-3930-675-23-1
0094
INSTRUMENT PANEL LAMP INSTALLATION 1. 2. 3. 4. 5. Install lamp (Figure 11, Item 1) on connector (Figure 11, Item 2). Connect lamp (Figure 11, Item 1), with connector (Figure 11, Item 2) attached, to switch or gauge. Install switch/gauge panel (Figure 11, Item 1) on instrument panel (Figure 11, Item 2) with 10 screws (Figure 11, Item 3). Turn master battery switch to ON position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
1 2 3
M0108JCH
Figure 11. Instrument Panel Lamp Installation. END OF TASK
0094-12
TM 10-3930-675-23-1
0094
12/24V CONNECTOR REMOVAL 1. 2. 3. Perform Steps 1 and 2 of Rocker Switch Removal in this work package to gain access to 12/24V connector (Figure 12, Item 6). Remove three nuts (Figure 12, Item 3), two screws (Figure 12, Item 5), and 12/24V connector (Figure 12, Item 6) from switch/gauge panel (Figure 12, Item 4). Loosen three screws (Figure 12, Item 2) and disconnect three wires (Figure 12, Item 1) from rear of 12/24V connector (Figure 12, Item 6).
1 2 3 4
5 6
M0109JCH
12/24 Connector Removal.
0094-13
TM 10-3930-675-23-1
0094
12/24V CONNECTOR INSTALLATION 1. 2. 3. 4. 5. 6. Thread three wires (Figure 13, Item 1) through switch/gauge panel (Figure 13, Item 4). Connect three wires (Figure 13, Item 1) to rear of 12/24V connector (Figure 13, Item 6) and tighten three screws (Figure 13, Item 2). Install 12/24V connector (Figure 13, Item 6) on switch/gauge panel (Figure 13, Item 4) with two screws (Figure 13, Item 5) and three nuts (Figure 13, Item 3). Install switch/gauge panel (Figure 13, Item 1) on instrument panel (Figure 13, Item 2) with 10 screws (Figure 13, Item 3). Turn master battery switch to ON position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
1 2 3
M0108JCH
Figure 13. 12/24V Connector Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Turn master battery switch to ON position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
0094-14
TM 10-3930-675-23-1
0095
FIELD MAINTENANCE TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering wheel removed Volume 2, WP 0165
REMOVAL 1. Remove eight screws (Figure 1, Item 1) and washers (Figure 1, Item 2) and separate two halves of plastic housing (Figure 1, Item 3).
1,2 3
M0300JCH
Figure 1.
Separate Housing.
0095-1
TM 10-3930-675-23-1
0095
REMOVAL - Continued
NOTE
Mark position of transmission control lever and accessory control lever on steering column for installation. 2. Remove two screws (Figure 2, Item 4) to free transmission control lever (Figure 2, Item 1) and accessory control lever (Figure 2, Item 3) from steering column (Figure 2, Item 2).
1 2 3
4
M0301JCH
Figure 2. 3. 4. 5.
Transmission and Accessory Control Levers Removal.
Remove seven screws (Figure 3, Item 7), washers (Figure 3, Item 8), and two halves of steering column housing (Figure 3, Item 9). Remove three screws (Figure 3, Item 1), washers (Figure 3, Item 2), and left lower panel (Figure 3, Item 3). Remove three screws (Figure 3, Item 4), washers (Figure 3, Item 5), and right lower panel (Figure 3, Item 6).
0095-2
TM 10-3930-675-23-1
0095
REMOVAL - Continued
1,2 3 4,5 6 7,8
9
M0302JCH
Figure 3.
1,2 3
Panel Removed.
4,5 6 7,8
M0303JCH
Figure 4.
Panel Removal.
0095-3
TM 10-3930-675-23-1
0095
REMOVAL - Continued
NOTE
Perform Steps 6 and 7 to remove transmission control lever. Remove and discard tiedown straps as necessary. 6. 7. Disconnect connector (Figure 5, Item 1) of transmission control lever (Figure 5, Item 1) from instrument panel wiring harness (Figure 5, Item 2). Remove transmission control lever (Figure 5, Item 1) from steering column (Figure 5, Item 2).
NOTE
Perform Steps 8 and 9 to remove accessory control lever. Remove and discard tiedown straps as necessary. 8. 9. Disconnect two connectors (Figure 5, Item 3) of accessory control lever (Figure 5, Item 3 ) from instrument panel wiring harness (Figure 5, Item 2). Remove accessory control lever (Figure 5, Item 3) from steering column (Figure 5, Item 2).
2 1
M0304JCH
Transmission and Accessory Control Levers Removal.
0095-4
TM 10-3930-675-23-1
0095
INSTALLATION
NOTE
Perform Steps 1 and 2 to install accessory control lever. Install new tiedown straps as necessary. Control lever bracket should be positioned 3/4-inch (20 mm) from bracket to top edge of column tube to which it secures. 1. 2. Install accessory control lever (Figure 6, Item 3) on steering column (Figure 6, Item 2). Connect two connectors (Figure 6, Item 3) of accessory control lever (Figure 6, Item 3) to instrument panel wiring harness (Figure 6, Item 2).
NOTE
Perform Steps 3 and 4 to install transmission control lever. Install new tiedown straps as necessary. Control lever bracket should be positioned 3/4-in. (20 mm) from bracket to top edge of column tube to which it secures. 3. Install transmission control lever (Figure 6, Item 1) and accessory control lever (Figure 6, Item 3) on steering column (Figure 6, Item 2), in position marked, with two screws (Figure 6, Item 4). Tighten screws.
1 2 3
4
M0305JCH
Figure 6. Transmission and Accessory Control Levers Installation.
0095-5
TM 10-3930-675-23-1
0095
INSTALLATION - Continued 4. 5. 6. Connect connector (Figure 7, Item 1) of transmission control lever (Figure 7, Item 3) to instrument panel wiring harness (Figure 5, Item 2). Install right lower panel (Figure 7, Item 1) with three screws (Figure 7, Item 2) and washers (Figure 7, Item 3). Install left lower panel (Figure 7, Item 4) with three screws (Figure 7, Item 5) and washers (Figure 7, Item 6).
1,2 3 4,5 6 7,8
M0306JCH
Figure 7. 7.
Panels Installation.
Install two halves of steering column housing (Figure 8, Item 9) with seven washers (Figure 8, Item 8) and screws (Figure 8, Item 7).
1,2 3 4,5 6 7,8
M0307JCH
Figure 8.
Panels Installation.
0095-6
TM 10-3930-675-23-1
0095
INSTALLATION - Continued 8. Install two halves of plastic housing (Figure 9, Item 3) together with eight washers (Figure 9, Item 2) and screws (Figure 9, Item 1).
1,2 3
M0308JCH
Figure 9. END OF TASK FOLLOW-ON MAINTENANCE Install steering wheel (Volume 2, WP 0165). END OF TASK END OF WORK PACKAGE
Housing Installation.
0095-7/8 blank
TM 10-3930-675-23-1
0096
FIELD MAINTENANCE ECS DISPLAY SCREEN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) References WP 0094 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering wheel removed Volume 2, WP 0165
NOTE
To replace exterior panels (Figure 1, Items 1 and 2), proceed with this work package as instructed. Prior to reinstalling exterior panels (Figure 1, Items 1 and 2), replace with new components as required. Refer to Instrument Panel Switches, Gauges, and Panel Lamps Replacement (WP 0094) for Rocker Switch and Instrument Panel Light Removal and Installation instructions. REMOVAL 1. Remove eight screws (Figure 1, Item 3) and washers (Figure 1, Item 4) to separate top plastic housing (Figure 1, Item 1) from bottom plastic housing (Figure 1, Item 2). Raise front of top plastic housing (Figure 2, Item 2) upward for access to display screen (Figure 2, Item 3).
2 1
3,4
M0159JCH
Figure 1.
ECS Display Screen Removal.
0096-1
TM 10-3930-675-23-1
0096
REMOVAL - Continued 2. 3. Disconnect two-wire ground connector (Figure 2, Item 5) from display screen (Figure 2, Item 3). Disconnect multi-pin connector (Figure 2, Item 4) from display screen (Figure 2, Item 3).
NOTE
Display screen is a unit consisting of display screen, flat wire connector, and touch pad. Note position of display screen for installation. 4. Remove two screws (Figure 2, Item 1) and display screen (Figure 2, Item 3) from top plastic housing (Figure 2, Item 2).
NOTE
Ensure four hexagonal studs are positioned against the display protective window before tightening display securing screws. 1. 2. 3. 4. Install display screen (Figure 2, Item 3) in top plastic housing (Figure 2, Item 2) with two screws (Figure 2, Item 1). Connect multi-pin connector (Figure 2, Item 4) to display screen (Figure 2, Item 3). Connect two-wire ground connector (Figure 2, Item 5) to display screen (Figure 2, Item 3). Lower front of top plastic housing (Figure 2, Item 2).
2 3
1 5
M0160JCH
Figure 2. ECS Display Screen Installation.
0096-2
TM 10-3930-675-23-1
0096
INSTALLATION - Continued 5. Install top plastic housing (Figure 3, Item 1) on bottom plastic housing (Figure 3, Item 2) with eight washers (Figure 3, Item 4) and screws (Figure 3, Item 3).
2 1
3,4
M0161JCH
ECS Display Screen Installation.
Install steering wheel (Volume 2, WP 0165). END OF TASK END OF WORK PACKAGE
0096-3/4 blank
TM 10-3930-675-23-1
0097
FIELD MAINTENANCE TOPHANDLER JUNCTION BOX MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 6 O-Ring (Volume 2, WP 0278, Table 1, Item 143) Qty: 8 Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References WP 0113 Volume 2, WP 0257 Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0097-1
TM 10-3930-675-23-1
0097
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) REMOVAL
NOTE
Tophandler ECU is located inside junction box at end of boom, above tophandler. Tophandler ECU is identified as No. 791on system electrical diagrams (Volume 2, WP 0272). 1. 2. Loosen six screws (Figure 1, Item 1) and remove cover (Figure 1, Item 2) from tophandler junction box (Figure 1, Item 4). Three circuit breakers (Figure 1, Item 5) should be in ON position. Inspect rubber seal (Figure 1, Item 3) on cover (Figure 1, Item 2). Replace seal only if damaged.
2 1 3 5
M0145JCH
Figure 1.
Tophandler ECU Removal.
NOTE
Perform Step 3 for each of three connectors. Tag connectors for installation. 3. 4. With a flat-tip screwdriver, slide red latch segment (Figure 2, Item 3) on connector away from black connector (Figure 2, Item 2) and remove connector from tophandler ECU (Figure 2, Item 1). Remove four screws (Figure 2, Item 5), washers (Figure 2, Item 6), and tophandler ECU (Figure 2, Item 1) from tophandler junction box (Figure 2, Item 4).
END OF TASK
0097-2
TM 10-3930-675-23-1
0097
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) INSTALLATION
CAUTION
DO NOT overtighten screws or damage to screws will result. 1. Install tophandler ECU (Figure 2, Item 1) in tophandler junction box (Figure 2, Item 4) with four washers (Figure 2, Item 6) and screws (Figure 2, Item 5).
NOTE
Perform Step 2 for each of three connectors. 2. 3. Position black connector (Figure 2, Item 2) on tophandler ECU (Figure 2, Item 1) and connect connector by sliding red latch segment (Figure 2, Item 3) of connector inward. Install cover (Figure 1, Item 2) on tophandler junction box (Figure 1, Item 4) and tighten six screws (Figure 1, Item 1).
3 4
5,6
M0146JCH
Figure 2. 4.
Tophandler ECU Installation.
Perform boom and tophandler calibration (Volume 2, WP 0257).
END OF TASK
0097-3
TM 10-3930-675-23-1
0097
RELAY REMOVAL
NOTE
All five relays are removed the same. 1. 2. 3. Loosen six screws (Figure 3, Item 1) and remove cover (Figure 3, Item 2) from tophandler junction box (Figure 3, Item 4). Three circuit breakers (Figure 3, Item 5) should be in ON position. Inspect rubber seal (Figure 3, Item 3) on cover (Figure 3, Item 2). Remove and discard seal only if damaged. Remove relay (Figure 3, Item 6) from relay holder (Figure 3, Item 7).
END OF TASK RELAY INSTALLATION
NOTE
All five relays are installed the same. 1. 2. 3. Install relay (Figure 3, Item 6) in relay holder (Figure 3, Item 7). If removed, install new rubber seal (Figure 3, Item 3) on cover (Figure 3, Item 2). Install cover (Figure 3, Item 2) on tophandler junction box (Figure 3, Item 4) and tighten six screws (Figure 3, Item 1).
2 1 3 5 6
M0147JCH
Figure 3. END OF TASK TOPHANDLER JUNCTION BOX REMOVAL 1.
Relay Installation.
Loosen six screws (Figure 4, Item 2) and remove cover (Figure 4, Item 1) from tophandler junction box
0097-4
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX REMOVAL - Continued (Figure 4, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged.
M0876JCH
Figure 4. 2.
Tophandler Junction Box Removal.
Remove two plastic covers (Figure 5, Item 1).
M0877JCH
Figure 5.
0097-5
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX REMOVAL - Continued
NOTE
Tag wires to ensure proper connection on installation. Remove and discard tiedown straps as necessary. 3. At top of junction box (Figure 6, Item 5), remove locknut (Figure 6, Item 1) and washer (Figure 6, Item 2) and disconnect terminal of large black wire (Figure 6, Item 3), marked black", and terminal of small white wires (Figure 6, Item 4) from terminal stud. Discard locknut. Remove locknut (Figure 6, Item 12) and washer (Figure 6, Item 13) and disconnect terminal of large black wire (Figure 6, Item 11), marked red", and terminal of small black wires (Figure 6, Item 10) from terminal stud. Discard locknut.
4.
NOTE
Note location of fittings for installation. 5. 6. 7. 8. Loosen cap (Figure 6, Item 7) on each of five fittings (Figure 6, Item 6) and remove fittings from junction box (Figure 6, Item 5). Pull large black wires (Figure 6, Items 3 and 11) out from junction box (Figure 6, Item 5). Trace route of each wire (Figure 6, Item 9) in three cables (Figure 6, Item 8) to connecting point and disconnect wire. Note connecting point. Pull each wire (Figure 6, Item 9) out from junction box (Figure 6, Item 5).
1,2 3 4 5 6
12,13
11
10
M0878JCH
Figure 6.
0097-6
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX REMOVAL - Continued 9. 10. 11. 12. At bottom of junction box (Figure 7, Item 2), disconnect connectors (Figure 7, Item 6) of four cables (Figure 7, Item 7). Loosen cap (Figure 7, Item 5) on fitting (Figure 7, Item 4) and remove fitting from junction box (Figure 7, Item 2). Trace route of three wires (Figure 7, Item 1) of cable (Figure 7, Item 3) to connecting point and disconnect wires. Note connecting point. Pull cable (Figure 7, Item 3) out from junction box (Figure 7, Item 2).
1 2
4 5
M0879JCH
Figure 7.
0097-7
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX REMOVAL - Continued 13. 14. 15. 16. Loosen cap (Figure 8, Item 1) on fitting (Figure 8, Item 2) and remove fitting from junction box (Figure 8, Item 3). Trace route of eight wires (Figure 8, Item 4) of cable (Figure 8, Item 8) to connecting point and disconnect wires. Note connecting point. Pull cable (Figure 8, Item 8) out from junction box (Figure 8, Item 3). Remove two screws (Figure 8, Item 5), washers (Figure 8, Item 6), and twistlock indicator light assembly (Figure 8, Item 7) from side of junction box (Figure 8, Item 3). Also remove twistlock indicator IR lights (WP 0113).
1 2
4 5
M0880JCH
Figure 8.
0097-8
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX REMOVAL - Continued 17. For RT 240V1 and RT 240V1R vehicles, remove four screws (Figure 9, Item 1), washers (Figure 9, Item 2), loop clamp (Figure 9, Item 8), and 791 junction box (Figure 9, Item 9), with two brackets (Figure 9, Item 6) from tophandler. For RT 240V1 and RT 240V1R vehicles, remove four locknuts (Figure 9, Item 3), screws (Figure 9, Item 4), eight washers (Figure 9, Item 5), two brackets (Figure 9, Item 6), and four rubber grommets (Figure 9, Item 7) from 791 junction box (Figure 9, Item 9). Discard locknuts.
1,2 3,4,5 6 7
18.
M0881JCH
Figure 9.
0097-9
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX REMOVAL - Continued 19. For RT 240V2 and RT 240V3 vehicles, remove four capscrews (Figure 10, Item 1), washers (Figure 10, Item 2), spacers (Figure 10, Item 3), eight O-rings (Figure 10, Item 4), and junction box (Figure 10, Item 5) from boom. Discard O-rings.
END OF TASK TOPHANDLER JUNCTION BOX INSTALLATION 1. For RT 240V2 and RT 240V3 vehicles, install junction box (Figure 10, Item 5) with four capscrews (Figure 10, Item 1), washers (Figure 10, Item 2), spacers (Figure 10, Item 3), and eight new O-rings (Figure 10, Item 4).
1,2,3,4
M0882JCH
Figure 10. Tophandler Junction Box Replacement.
0097-10
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX INSTALLATION - Continued 2. For RT 240V1 and RT 240V1R vehicles, install four rubber grommets (Figure 11, Item 7) and two brackets (Figure 11, Item 6) in junction box (Figure 11, Item 9) with eight washers (Figure 11, Item 5), four screws (Figure 11, Item 4), and four new locknuts (Figure 11, Item 3). For RT 240V1 and RT 240V1R vehicles, install two brackets (Figure 11, Item 6), junction box (Figure 11, Item 9), and loop clamp (Figure 11, Item 8) on tophandler with four washers (Figure 11, Item 2) and screws (Figure 11, Item 1).
1 2
3.
6
M0883JCH
Figure 11.
Tophandler Junction Box Installation.
0097-11
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX INSTALLATION - Continued 4. Install twistlock indicator light assembly (Figure 12, Item 7) on side of junction box (Figure 12, Item 3) with two washers (Figure 12, Item 6) and screws (Figure 12, Item 5). Also install twistlock indicator IR lights (WP 0113). Push twistlock indicator light assembly cable (Figure 12, Item 8) into junction box (Figure 12, Item 3). Connect eight wires (Figure 12, Item 4) of cable (Figure 12, Item 8) to connecting points, as noted during removal. Install fitting (Figure 12, Item 2) in junction box (Figure 12, Item 3) and tighten cap (Figure 12, Item 1).
1,2 3 4 5 6
5. 6. 7.
12,13
11
10
M0884JCH
Figure 12. Tophandler Junction Box Installation. 8. 9. 10. 11. 12. 13. 14. 15. 16. Push cable (Figure 13, Item 3) into junction box (Figure 13, Item 2). Connect three wires (Figure 13, Item 1) of cable (Figure 13, Item 3) to connecting points, as noted during removal. Install fitting (Figure 13, Item 4) in junction box (Figure 13, Item 2) and tighten cap (Figure 13, Item 5). At bottom of junction box (Figure 13, Item 2), connect connectors (Figure 13, Item 6) of four cables (Figure 13, Item 7). Push wires (Figure 12, Item 9) of three cables (Figure 12, Item 8) into junction box (Figure 12, Item 5). Connect wires (Figure 12, Item 9) of three cables (Figure 12, Item 8) to connecting points, as noted during removal. Push wires (Figure 12, Items 3 and 11) into junction box (Figure 12, Item 5). Install five fittings (Figure 12, Item 6) in junction box (Figure 12, Item 5) and tighten five caps (Figure 12, Item 7). Connect terminal of small black wires (Figure 12, Item 10) and terminal of large black wire (Figure 12, Item 11), marked red", to terminal stud and install washer (Figure 12, Item 13) and new locknut (Figure 12, Item 12).
0097-12
TM 10-3930-675-23-1
0097
TOPHANDLER JUNCTION BOX INSTALLATION - Continued 17. 18. Connect terminal of small white wires (Figure 12, Item 4) and terminal of large black wire (Figure 12, Item 3), marked black", to terminal stud and install washer (Figure 12, Item 2) and new locknut (Figure 12, Item 1). Install two plastic covers (Figure 13, Item 1).
M0885JCH
Figure 13. 19.
Install cover (Figure 14, Item 1) on tophandler junction box (Figure 14, Item 3) and tighten six screws (Figure 14, Item 2).
M0886JCH
0097-13
TM 10-3930-675-23-1
0097
FOLLOW-ON MAINTENANCE
NOTE
Calibration must be performed only if ECU inside tophandler junction box is new. 1. 2. Perform boom and tophandler calibration (Volume 2, WP 0257). Operate tophandler to check operation (TM 10-3930-675-10).
0097-14
TM 10-3930-675-23-1
0098
FIELD MAINTENANCE TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Wrench, Torque, Dial, 3/8 Inch Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
NOTE
The following procedure is for tophandler junction boxes. The procedure is identical for boom junction box. REMOVAL 1. 2. Loosen four screws (Figure 1, Item 1) and remove cover (Figure 1, Item 2) from junction box (Figure 1, Item 3). Inspect rubber seal (Figure 1, Item 4) on cover (Figure 1, Item 2). Replace seal only if damaged.
2 1 3 4
M0148JCH
Figure 1.
Tophandler Junction Box Cover Removal.
0098-1
TM 10-3930-675-23-1
0098
REMOVAL - Continued
NOTE
Perform Steps 3 and 4 in five places. 3. Loosen cable nut (Figure 2, Item 11) and slide cable nut and grommet (Figure 2, Item 9) back on cable (Figure 2, Item 8).
NOTE
Tag wires for installation. 4. 5. Using a jewelers screwdriver, disconnect wires (Figure 2, Item 5) from terminal blocks (Figure 2, Item 3) and pull cables (Figure 2, Item 8) with wires from junction box (Figure 2, Item 4). Remove two screws (Figure 2, Item 8), terminal block holder (Figure 2, Item 2), and terminal blocks (Figure 2, Item 3) from junction box (Figure 2, Item 4).
NOTE
Perform Step 6 in five places. 6. 7. Remove plastic nut (Figure 2, Item 7) and fitting (Figure 2, Item 9) from bottom of junction box (Figure 2, Item 4). Remove four screws (Figure 2, Item 10) and junction box (Figure 2, Item 4) from tophandler.
END OF TASK
0098-2
TM 10-3930-675-23-1
0098
INSTALLATION 1. Install junction box (Figure 2, Item 4) on tophandler with four screws (Figure 2, Item 10).
NOTE
Perform Step 2 in five places. 2. 3. Install fitting (Figure 2, Item 6) and plastic nut (Figure 2, Item 7) on bottom of junction box (Figure 2, Item 4). Install terminal blocks (Figure 2, Item 3) and terminal block holder (Figure 2, Item 2) on junction box (Figure 2, Item 4) with two screws (Figure 2, Item 1).
NOTE
Perform Steps 4 and 5 in five places. 4. 5. Push cable (Figure 2, Item 8) into junction box (Figure 2, Item 4) and use jewelers screwdriver to connect wires (Figure 2, Item 5) to terminal blocks (Figure 2, Item 3). Install grommet (Figure 2, Item 9) and cable nut (Figure 2, Item 11) on junction box (Figure 2, Item 4). Tighten cable nut.
2 1 3
M0150JCH
Figure 2.
Tophandler Junction Box Replacement.
0098-3
TM 10-3930-675-23-1
0098
INSTALLATION - Continued 6. Install cover (Figure 3, Item 2) on junction box (Figure 3, Item 3) with four screws (Figure 3, Item 1).
2 1 3
M0150JCH
Figure 3. Tophandler Junction Box Cover Installation. END OF TASK END OF WORK PACKAGE
0098-4
TM 10-3930-675-23-1
0099
FIELD MAINTENANCE ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 Inch Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed Volume 2, WP 0185
NOTE
Engine ECU is located on left side of engine. Engine ECU is identified as No. 794 on system electrical diagrams (Volume 2, WP 0272).
0099-1
TM 10-3930-675-23-1
0099
REMOVAL
NOTE
Tag wires prior to disconnection to ensure correct connection on installation. 1. Loosen three connector captive screws (Figure 1, Item 13) and disconnect actuator harness connector (Figure 1, Item 6), sensor harness connector (Figure 1, Item 8), and OEM harness connector (Figure 1, Item 4) from ECU (Figure 1, Item 5). Disconnect wiring harness (Figure 1, Item 11) from 32-pin connector (Figure 1, Item 12).
2.
NOTE
Note type and location of mounting hardware to aid in installation. 3. 4. Remove screw (Figure 1, Item 9) and washer (Figure 1, Item 3) securing 32-pin connector (Figure 1, Item 12) and bracket (Figure 1, Item 10) to ECU (Figure 1, Item 5). Remove screw (Figure 1, Item 2), washer (Figure 1, Item 3), and cable clamp (Figure 1, Item 1) securing engine wiring harness (Figure 1, Item 14) to ECU (Figure 1, Item 5). Reposition engine wiring harness and OEM wiring harness. Remove remaining screws (Figure 1, Items 2 and 9) and washers (Figure 1, Item 3) securing ECU (Figure 1, Item 5) to cooling plate (Figure 1, Item 7). Remove ECU (Figure 1, Item 5) from cooling plate (Figure 1, Item 7).
5. 6.
END OF TASK INSTALLATION 1. Position ECU (Figure 1, Item 5) on cooling plate (Figure 1, Item 7).
NOTE
If ECU is new, ensure it contains the correct program. Ensure mounting screws are installed as noted in removal. 2. Temporarily secure ECU (Figure 1, Item 5) to cooling plate (Figure 1, Item 7) with screws (Figure 1, Items 2 and 9) and washers (Figure 1, Item 3).
NOTE
Ensure connectors are clean and dry prior to connection to ECU. Apply light coat of electrical grease to connectors prior to connecting. 3. 4. 5. Position actuator harness connector (Figure 1, Item 6), sensor harness connector (Figure 1, Item 8), and 32-pin connector (Figure 1, Item 12) with bracket (Figure 1, Item 10). Install screw (Figure 1, Item 9) and washer (Figure 1, Item 3) to secure bracket (Figure 1, Item 10) to ECU (Figure 1, Item 5). Tighten captive screws (Figure 1, Item 13) to 25 in-lb (3 Nm) to secure connectors. Position engine wiring harness (Figure 1, Item 14) and OEM wiring harness. Secure engine wiring harness with cable clamp (Figure 1, Item 1), screw (Figure 1, Item 2), and washer (Figure 1, Item 3). Tighten captive screw (Figure 1, Item 13) on OEM wiring harness to 25 in-lb (3 Nm). Connect wiring harness (Figure 1, Item 11) to 32-pin connector (Figure 1, Item 12). Fully tighten ECU screws (Figure 1, Items 2 and 9) evenly to 180 in-lb (20 Nm).
6. 7.
0099-2
TM 10-3930-675-23-1
0099
4 5 6 7 8 3,9 10 2,3
11
12
14
13
M0151JCH
ECU Replacement.
Turn master battery switch to ON position (TM 10-3930-675-10). Start engine and check for proper operation (TM 10-3930-675-10). Install engine cover (Volume 2, WP 0185).
0099-3/4 blank
TM 10-3930-675-23-1
0100
FIELD MAINTENANCE ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) References Volume 2, WP 0136 Volume 2, WP 0174 References (cont.) Volume 2, WP 0257 Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) REMOVAL
NOTE
Transmission ECU is located in cab behind drivers seat, behind right-rear panel. Transmission ECU is identified as No. 793 on system electrical diagrams (Volume 2, WP 0272). 1. Lift and remove two access panels (Figure 1, Items 1 and 2) from rear of cab.
1
M0152JCH
Figure 1.
Access Panels Removal.
0100-1
TM 10-3930-675-23-1
0100
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) REMOVAL - Continued 2. 3. 4. 5. Remove duct (Figure 2, Item 10) from rear outlet connector. Disconnect connector (Figure 2, Item 9) of wiring harness (Figure 2, Item 7) from transmission ECU (Figure 2, Item 1) by sliding out handle of connector. Remove two screws (Figure 2, Item 2) and plate (Figure 2, Item 8) with transmission ECU (Figure 2, Item 1) from electrical panel (Figure 2, Item 3). Remove four nuts (Figure 2, Item 4), screws (Figure 2, Item 5), 8 washers (Figure 2, Item 6), and transmission ECU (Figure 2, Item 1) from plate (Figure 2, Item 8).
1 10
4,6 5,6
M0153JCH
Transmission ECU Removal.
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) INSTALLATION 1. 2. 3. 4. 5. Install transmission ECU (Figure 2, Item 1) on plate (Figure 2, Item 8) with four washers (Figure 2, Item 6), screws (Figure 2, Item 5), and nuts (Figure 2, Item 4). Position plate (Figure 2, Item 8) with transmission ECU (Figure 2, Item 1) on electrical panel (Figure 2, Item 3) and install two screws (Figure 2, Item 2). Connect connector (Figure 2, Item 9) of wiring harness (Figure 2, Item 7) to transmission ECU (Figure 2, Item 1) by sliding in handle of connector. Reattach the duct (Figure 2, Item 10) to rear outlet connector. Install access panels (Figure 3, Items 1 and 2) in rear of cab.
0100-2
TM 10-3930-675-23-1
0100
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) INSTALLATION - Continued

1
M0154JCH
Figure 3.
Access Panels Removal.
NOTE
If transmission ECU was removed only for access to steering system ECU, no transmission calibration is required. END OF TASK
0100-3
TM 10-3930-675-23-1
0100
STEERING SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL
NOTE
Steering system ECU is located in cab behind drivers seat, behind right-rear panel and behind transmission ECU. Steering system ECU is identified as No. 792 on system electrical diagrams (Volume 2, WP 0272). 1. 2. 3. 4. Perform Transmission Electronic Control Unit (ECU) Removal in this work package for access to steering system ECU (Figure 4, Item 3). Disconnect 3 ECU electrical connectors (Figure 4, Item 4) from steering system ECU (Figure 4, Item 3). Loosen four flanged-head nuts (Figure 4, Item 2) to free steering system ECU (Figure 4, Item 3). Slide steering ECU (Figure 4, Item 3) to right (toward passenger side of vehicle) and remove from panel (Figure 4, Item 1) over four flanged-head nuts (Figure 4, Item 2).
1 2
M0155JCH
Figure 4. Steering System ECU Removal. END OF TASK
0100-4
TM 10-3930-675-23-1
0100
STEERING SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION 1. 2. 3. 4. Position steering system ECU (Figure 4, Item 3) over four flanged-head nuts (12) and slide left (towards driver side of vehicle). Tighten four flanged-head nuts (Figure 4, Item 2) to secure steering system ECU (Figure 4, Item 3). Connect 3 electrical connectors (Figure 4, Item 4) to steering system ECU (Figure 4, Item 3). Perform Transmission Electronic Control Unit (ECU) Installation in this work package.
END OF TASK HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL
NOTE
Hydraulic servo system ECU is located in cab under drivers seat. Hydraulic servo system ECU is identified as No. 790 on system electrical diagrams (Volume 2, WP 0272). 1. Rotate three turnbuttons (Figure 5, Item 1) and remove cover (Figure 5, Item 3) from seat base (Figure 5, Item 2).
M0156JCH
Figure 5.
Seat Base Cover Removal.
0100-5
TM 10-3930-675-23-1
0100
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL - Continued 2. Slide electrical tray (Figure 6, Item 6) outward from seat base (Figure 6, Item 2).
NOTE
Perform Step 3 for each of two connectors. 3. 4. Disconnect connector (Figure 6, Item 3) from hydraulic servo system ECU (Figure 6, Item 1) by sliding out red latch of connector. Remove four screws (Figure 6, Item 4), washers (Figure 6, Item 5), and hydraulic servo system ECU (Figure 6, Item 1) from electrical tray (Figure 6, Item 6).
2 1
6 3
4,5
M0157JCH
Hydraulic Servo System ECU Removal.
0100-6
TM 10-3930-675-23-1
0100
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION
CAUTION
DO NOT overtighten screws or damage to screws will result. 1. Install hydraulic servo system ECU (Figure 7, Item 1) on electrical tray (Figure 7, Item 6) with four washers (Figure 7, Item 5) and screws (Figure 7, Item 4).
NOTE
Perform Step 2 for each of two connectors. 2. 3. Connect connector (Figure 7, Item 3) to hydraulic servo system ECU (Figure 7, Item 1) by sliding in red latch of connector. Slide electrical tray (Figure 7, Item 6) into seat base (Figure 7, Item 2).
2 1
6 3
4,5
M0158JCH
Figure 7. Hydraulic Servo System ECU Installation.
0100-7
TM 10-3930-675-23-1
0100
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION - Continued 4. Install cover (Figure 8, Item 3) on seat base (Figure 8, Item 2) and rotate three turnbuttons (Figure 8, Item 1).
2 3
M0114JCH
Seat Base Cover Installation.
NOTE
If transmission ECU was removed only for access to steering system ECU, no transmission calibration is required. 1. 2. 3. 4. Perform transmission calibration (Volume 2, WP 0136). Perform boom and tophandler calibration (Volume 2, WP 0257). Turn master battery switch to ON position (TM 10-3930-675-10). Check gauges/switches for proper operation (TM 10-3930-675-10).
0100-8
TM 10-3930-675-23-1
0101
FIELD MAINTENANCE ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) References WP 0102
REMOVAL 1. 2. 3. 4. Remove three socket screws (Figure 1, Item 3), screws (Figure 1, Item 4), and small half of joystick housing (Figure 1, Item 2). Disconnect plug for override switch. Remove emergency switch and wiring harness from joystick (WP 0102). Remove large half of joystick housing (Figure 1, Item 1) from joystick bracket (Figure 1, Item 7). Remove four screws (Figure 1, Item 5) and joystick (Figure 1, Item 6) from joystick bracket (Figure 1, Item 7).
2 3
5 1 7 4
M0162JCH
Joystick Removal.
0101-1
TM 10-3930-675-23-1
0101
INSTALLATION 1. 2. 3. 4. Install joystick (Figure 2, Item 6) on joystick bracket (Figure 2, Item 7) with four screws (Figure 2, Item 5). Install large half of joystick housing (Figure 2, Item 1) on joystick bracket (Figure 2, Item 7). Install emergency switch and wiring harness at joystick (WP 0102). Connect plug for override switch and install small half of joystick housing (Figure 2, Item 2) with three screws (Figure 2, Item 4) and socket screws (Figure 2, Item 3).
2 3
1 4
M0163JCH
Figure 2. Joystick Installation. END OF TASK END OF WORK PACKAGE
0101-2
TM 10-3930-675-23-1
0102
FIELD MAINTENANCE ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
NOTE
Refer to wiring diagrams (Volume 2, WP 0272) and use marker tags, as necessary, to ensure proper connection of connectors. Note position of washers on release lever to aid in installation.
0102-1
TM 10-3930-675-23-1
0102
REMOVAL 1. 2. 3. Turn joystick positioning lever (Figure 1, Item 1) counterclockwise and lift joystick assembly upward to free joystick assembly from seat. Turn joystick housing (Figure 1, Item 5) over for access to bottom of joystick housing. Remove screw (Figure 1, Item 4) and clamp (Figure 1, Item 2) from protective cover of joystick wiring harness (Figure 1, Item 3).
2
M0164JCH
Figure 1. Joystick Wiring Harness Removal 4. Loosen two screws (Figure 2, Item 2) and disconnect connector (Figure 2, Item 7) of joystick wiring harness (Figure 2, Item 8) from bottom of joystick (Figure 2, Item 1).
NOTE
Remove emergency stop switch to allow remaining cover to be removed. 5. Move lever (Figure 2, Item 5) on emergency stop switch (Figure 2, Item 6) left to release switch from push button knob (Figure 2, Item 3). Pull switch down and away from push button knob.
NOTE
Note position of the window on top of emergency stop switch before removing knob. Window should be toward right wall of cab. 6. Unscrew push button knob (Figure 2, Item 3) from plastic nut (Figure 2, Item 4).
0102-2
TM 10-3930-675-23-1
0102
REMOVAL - Continued
5 3 2 1 4
6 8
7
M0165JCH
Figure 2.
Joystick Wiring Harness Removal.
0102-3
TM 10-3930-675-23-1
0102
REMOVAL - Continued
NOTE
If emergency stop switch is to be replaced, perform Steps 7 and 8. If not, proceed to Step 9. Mark or tag position of all wires on emergency stop switch. 7. 8. Loosen four screws (Figure 3, Item 2) and disconnect wires (Figure 3, Item 1) from connector (Figure 3, Item 3). Insert four wires (Figure 3, Item 1) into new connector (Figure 3, Item 3) and tighten four screws (Figure 3, Item 2).
1 2
M0166JCH
Figure 3. Joystick Wiring Harness Removal. 9. Loosen three turnbuttons (Figure 4, Item 3) and remove cover (Figure 4, Item 2) from seat base (Figure 4, Item 1).
0102-4
TM 10-3930-675-23-1
0102
REMOVAL - Continued
1
2 3
M0167JCH
Figure 4. 10.
Seat Base Cover Removal.
Slide electrical tray (Figure 5, Item 5) out from seat base (Figure 5, Item 2) for access to underside of tray.
NOTE
Remove and discard tiedown straps as necessary. 11. Depress tabs of two connectors (Figure 5, Item 3) and disconnect two connectors of joystick wiring harness (Figure 5, Item 4) from two terminal blocks (Figure 5, Item 1).
1 2
M0168JCH
Figure 5.
Joystick Wiring Harness Removal.
0102-5
TM 10-3930-675-23-1
0102
REMOVAL - Continued 12. Remove nut (Figure 6, Item 1) from inside seat base (Figure 6, Item 2) and remove joystick wiring harness (Figure 6, Item 3) from vehicle.
1
M0169JCH
Figure 6. Joystick Wiring Harness Removal. END OF TASK INSTALLATION 1. Position joystick wiring harness (Figure 7, Item 4) inside seat base (Figure 7, Item 2) and install nut (Figure 6, Item 1).
NOTE
Install new tiedown straps as necessary. 2. 3. Connect two connectors (Figure 7, Item 3) of joystick wiring harness (Figure 7, Item 4) to two terminal blocks (Figure 7, Item 1). Slide electrical tray (Figure 7, Item 5) into seat base (Figure 7, Item 2).
0102-6
TM 10-3930-675-23-1
0102
1 2
M0168JCH
Figure 7. Joystick Wiring Harness Installation. 4. Install cover (Figure 8, Item 2) on seat base (Figure 8, Item 1) and tighten three turnbuttons (Figure 8, Item 3).
1
2 3
M0170JCH
Figure 8.
Seat Base Cover Installation.
0102-7
TM 10-3930-675-23-1
0102
INSTALLATION - Continued 5. Align push button knob (Figure 9, Item 3) in housing (Figure 9, Item 5).
NOTE
Ensure window of push button is in proper position when tight. 6. 7. 8. Install plastic nut (Figure 9, Item 4) from bottom and rotate push button knob (Figure 9, Item 3) to tighten Position emergency stop switch (Figure 9, Item 7) over push button (Figure 9, Item 3) shaft and slide lever (Figure 9, Item 6) right to secure. Connect connector (Figure 9, Item 8) of joystick wiring harness (Figure 9, Item 9) to bottom of joystick (Figure 9, Item 1) and tighten two screws (Figure 9, Item 2).
6 3 2 1 5 4
7 9
8
M0171JCH
Figure 9. Joystick Wiring Harness Installation.
0102-8
TM 10-3930-675-23-1
0102
INSTALLATION - Continued 9. Install clamp (Figure 10, Item 2) on protective cover of joystick wiring harness (Figure 10, Item 3) with screw (Figure 10, Item 4).
NOTE
Note position of washers on release lever when removed. 10. Position joystick housing (Figure 10, Item 5) on seat and turn joystick positioning lever (Figure 10, Item 1) clockwise to secure.
2
M0172JCH
Joystick Wiring Harness Installation.
0102-9/10 blank
TM 10-3930-675-23-1
0103
FIELD MAINTENANCE CIRCUIT BREAKERS AND RELAYS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References WP 0129 Volume 2, WP 0185 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL
NOTE
All circuit breakers and relays are replaced the same way, except where minor differences are noted. 1. Lift and remove access panel (Figure 1, Item 1) from left rear of cab.
1
M0110JCH
Figure 1.
Access Panel Removal.
0103-1
TM 10-3930-675-23-1
0103
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued 2. Disconnect elastic loop (Figure 2, Item 1) from top of circuit breaker/relay box (Figure 2, Item 2). Tilt box forward.
1 2
M0111JCH
Figure 2. Circuit Breaker/Relay Box Opening. 3. Remove two screws (Figure 3, Item 2) from side of circuit breaker/relay box (Figure 3, Item 3) and separate circuit breaker panel (Figure 3, Item 1) from relay panel (Figure 3, Item 4).
0103-2
TM 10-3930-675-23-1
0103
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued

1
4
M0112JCH
Figure 3.
Circuit Breaker Panel Separation.
NOTE
Each of 34 circuit breakers is removed the same way. 4. Remove two screws (Figure 4, Item 2) and washers (Figure 4, Item 3) from circuit breaker panel (Figure 4, Item 1) (RT 240V1 and RT 240V1R) or remove the nut (Figure 4, Item 4) from the circuit breaker (RT 240V2 and RT 240V3).
1
2,3
M0113JCH
Figure 4.
Circuit Breaker Removal.
0103-3
TM 10-3930-675-23-1
0103
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued 5. Push circuit breaker (Figure 5, Item 1) downward through hole in circuit breaker panel (Figure 5, Item 2).
NOTE
Tag connectors for installation. 6. Disconnect three connectors (Figure 5, Item 3) of wiring harness (Figure 5, Item 4) from rear of circuit breaker (Figure 5, Item 1). Remove circuit breaker.
2 3
M0114JCH
Figure 5.
Circuit Breaker Removal.
0103-4
TM 10-3930-675-23-1
0103
NOTE
Perform Step 7 to remove each of 15 relays. 7. Disconnect relay (Figure 6, Item 2) from terminal block (Figure 6, Item 3) of relay panel (Figure 6, Item 1).
M0115JCH
Figure 6.
Relay Removal.
0103-5
TM 10-3930-675-23-1
0103
NOTE
Perform Step 8 to remove each of two relays. 8. Remove screw (Figure 7, Item 1) and disconnect connector (Figure 7, Item 3) of wiring harness (Figure 7, Item 4) from relay (Figure 7, Item 2).
END OF TASK CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION
NOTE
Perform Step 1 to install each of two relays. 1. Connect connector (Figure 7, Item 3) of wiring harness (Figure 7, Item 4) to relay (Figure 7, Item 2) and install screw (Figure 7, Item 1).
2 3
4 1
M0116JCH
Figure 7. Relay Replacement.
0103-6
TM 10-3930-675-23-1
0103
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued
NOTE
Perform Step 2 to install each of 15 relays. 2. Connect relay (Figure 8, item 2) to terminal block (Figure 8, Item 3) of relay panel (Figure 8, Item 1).
M0115JCH
Figure 8.
Relay Connection.
0103-7
TM 10-3930-675-23-1
0103
NOTE
Each of 34 circuit breakers is installed the same way. 3. 4. Connect three connectors (Figure 9, Item 3) of wiring harness (Figure 9, Item 4) to rear of circuit breaker (Figure 9, Item 1). Push circuit breaker (Figure 9, Item 1) upward through hole in circuit breaker panel (Figure 9, Item 2).
2 3
M0114JCH
Figure 9. Circuit Breaker Connection. 5. Install circuit breaker (Figure 10, Item 5) with two washers (Figure 10, Item 3) and screws (Figure 10, Item 2) (RT 240V1 and RT 240V1R) or install circuit breaker (Figure 10, Item 5) with nut (Figure 10, Item 4) (RT 240V2 and RT 240V3) to circuit breaker panel (Figure 10, Item 1).
0103-8
TM 10-3930-675-23-1
0103

1
2,3
M0119JCH
Figure 10. 6.
Circuit Breaker Installation.
Position circuit breaker panel (Figure 11, Item 1) on relay panel (Figure 11, Item 3) and install two screws (Figure 11, Item 2).
1
3
M0120JCH
Figure 11.
Circuit Breaker Panel Installation.
0103-9
TM 10-3930-675-23-1
0103
NOTE
Ensure all circuit breakers remain in ON position while circuit breaker/relay box is secured. 7. Tilt circuit breaker/relay box (Figure 12, Item 2) rearward and connect elastic loop (Figure 12, Item 1) to top of box.
1 2
M0121JCH
Figure 12. Circuit Breaker Panel Installation.
0103-10
TM 10-3930-675-23-1
0103
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued 8. Install access panel (Figure 13, Item 1) on cab.
1
M0122JCH
Access Panel Installation.
0103-11
TM 10-3930-675-23-1
0103
50A CIRCUIT BREAKERS REMOVAL 1. 2. Remove engine cover (Volume 2, WP 0185). Disconnect battery cables (WP 0129).
NOTE
Tag wires for installation. 3. 4. 5. Remove protective covers (Figure 14, Item 2) from 50A circuit breaker terminals. Remove nuts (Figure 14, Item 3), washers (Figure 14, Item 4), and terminal leads (Figure 14, Item 5) from circuit breakers (Figure 14, Item 6). Remove screws (Figure 14, Item 7), nuts (Figure 14, Item 8), washers (Figure 14, Item 9), and circuit breakers (Figure 14, Item 6) from mounting plate (Figure 14, Item 1).
END OF TASK 50A CIRCUIT BREAKERS INSTALLATION 1. 2. 3. 4. 5. Position 50A circuit breakers (Figure 14, Item 6) on mounting plate (Figure 14, Item 1) and secure with screws (Figure 14, Item 7), nuts (Figure 14, Item 8), and washers (Figure 14, Item 9). Connect terminal leads (Figure 14, Item 5) to circuit breakers (Figure 14, Item 6) and secure with nuts (Figure 14, Item 3) and washers (Figure 14, Item 4). Place protective covers (Figure 14, Item 2) over circuit breaker terminals. Reconnect battery cables (WP 0129). Install engine cover (Volume 2, WP 0185).
0103-12
TM 10-3930-675-23-1
0103
50A CIRCUIT BREAKERS INSTALLATION - Continued

1 2 3,4,5 6,7,8,9
M0123JCH
Circuit Breaker Installation.
0103-13
TM 10-3930-675-23-1
0103
STARTER RELAY REMOVAL 1. 2. Remove engine cover (Volume 2, WP 0185). Disconnect battery cables (WP 0129).
NOTE
Tag wires for installation. 3. 4. Remove nuts (Figure 15, Item 6), washers (Figure 15, Item 7), and terminal leads (Figure 15, Item 8) from starter relay (Figure 15, Item 5). Remove screws (Figure 15, Item 2), nuts (Figure 15, Item 3), washers (Figure 15, Item 4), and starter relay (Figure 15, Item 5) from mounting brackets (Figure 15, Item 1).
END OF TASK STARTER RELAY INSTALLATION 1. 2. 3. 4. Position starter relay (Figure 15, Item 5), on mounting brackets (Figure 15, Item 1) and secure with screws (Figure 15, Item 2), nuts (Figure 15, Item 3), and washers (Figure 15, Item 4). Connect terminal leads (Figure 15, Item 8) to starter relay (Figure 15, Item 5) and secure with nuts (Figure 15, Item 6) and washers (Figure 15, Item 7). Connect battery cables (WP 0129). Install engine cover (Volume 2, WP 0185).
6,7,8
2,3,4
M0124JCH
Starter Relay Installation.
0103-14
TM 10-3930-675-23-1
0103
150A FUSE BLOCK REMOVAL (RT 240V1R, RT 240V2 and RT 240V3) 1. 2. 3. Open battery compartment door. Disconnect battery cables (WP 0129). Remove plastic fuse cover (Figure 16, Item 1).
NOTE
Tag wires for installation. 4. 5. Remove nuts (Figure 16, Item 2), washers (Figure 16, Item 3), terminal leads (Figure 16, Item 4), and fuse (Figure 16, Item 9) from fuse block (Figure 16, Item 6). Remove screws (Figure 16, Item 7), washers (Figure 16, Item 8), and fuse block from mounting bracket (Figure 16, Item 5).
END OF TASK 150A FUSE BLOCK INSTALLATION (RT 240V1R, RT 240V2 and RT 240V3) 1. 2. 3. 4. 5. Position fuse block (Figure 16, Item 6) on mounting bracket (Figure 16, Item 9) and secure with screws (Figure 16, Item 7) and washers (Figure 16, Item 8). Install fuse (Figure 16, Item 5) and connect terminal leads (Figure 16, Item 4) to fuse block (Figure 16, Item 6) and secure with nuts (Figure 16, Item 2) and washers (Figure 16, Item 3). Install plastic fuse cover (Figure 16, Item 1). Connect battery cables (WP 0129). Close battery compartment door.
1 4 2,3 9 4
5 7,8 6
M0125JCH
Fuse Block Installation.
0103-15/16 blank
TM 10-3930-675-23-1
0104
FIELD MAINTENANCE TOPHANDLER PROXIMITY SWITCHES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Wrench, Torque, Dial, 3/8 Inch Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0104-1
TM 10-3930-675-23-1
0104
TWISTLOCK PROXIMITY SWITCH REMOVAL
NOTE
These steps cover eight twistlock proximity switches at middle and at each end of spreader beam. To aid in gaining access to junction box in Step 3, spreader beam may be extended. 1. Remove two jamnuts (Figure 1, Item 2) and proximity switch (Figure 1, Item 1) from mounting bracket (Figure 1, Item 3).
1 2 3
M0126JCH
Figure 1. Twistlock Proximity Switch Removal.
0104-2
TM 10-3930-675-23-1
0104
TWISTLOCK PROXIMITY SWITCH REMOVAL - Continued 2. Loosen four screws (Figure 2, Item 3) and remove cover (Figure 2, Item 1) from junction box (Figure 2, Item 2). Inspect rubber seal in groove of cover. Replace only if damaged.
1 2 3
M0127JCH
Figure 2.
Junction Box Cover Removal.
0104-3
TM 10-3930-675-23-1
0104
TWISTLOCK PROXIMITY SWITCH REMOVAL - Continued 3. Loosen cable nut (Figure 3, Item 6) and slide cable nut and grommet (Figure 3, Item 5) back on proximity switch (Figure 3, Item 4) cable.
CAUTION
To avoid damage to junction box, a fine-tipped jewelers screwdriver should be used when disconnecting proximity switch wires. DO NOT use a punch.
NOTE
Tag wires for installation. 4. Using a jewelers screwdriver, disconnect proximity switch wires (Figure 3, Item 3) from terminal blocks (Figure 3, Item 2).
NOTE
Remove cable clamps and tiedown straps as needed. Discard tiedown straps. 5. Remove proximity switch (Figure 3, Item 4) with cable from tophandler.
END OF TASK
0104-4
TM 10-3930-675-23-1
0104
TWISTLOCK PROXIMITY SWITCH INSTALLATION 1. 2. 3. Position proximity switch (Figure 3, Item 4) with cable on tophandler. Using a jewelers screwdriver, connect proximity switch wires (Figure 3, Item 3) to terminal blocks (Figure 3, Item 2). Install grommet (Figure 3, Item 5) and cable nut (Figure 3, Item 6) on junction box (Figure 3, Item 1). Tighten cable nut.
1 2
4 5
M0128JCH
Figure 3. Twistlock Proximity Switch Installation. 4. Install cover (Figure 4, Item 1) on junction box (Figure 4, Item 2) and tighten four screws (Figure 4, Item 3).
1 2 3
M0127JCH
Figure 4.
Junction Box Cover Installation.
0104-5
TM 10-3930-675-23-1
0104
TWISTLOCK PROXIMITY SWITCH INSTALLATION - Continued 5. Loosely install proximity switch (Figure 5, Item 1) and two jamnuts (Figure 5, Item 2) on mounting bracket (Figure 5, Item 3).
CAUTION
Overtightening jamnuts will damage proximity switch threads.
NOTE
Plunger must be raised in order to properly make adjustment. 6. Position proximity switch (Figure 5, Item 1) so a gap of 0.20 inch (5.08 mm) is obtained from the containerindicator plunger (Figure 5, Item 4). Tighten two jamnuts (Figure 5, Item 2) to 177 in-lb (20 Nm).
1 2 3
5 MM
M0129JCH
Figure 5. 7.
Twistlock Proximity Switch Installation.
Install cable clamps and new tiedown straps as needed.
END OF TASK
0104-6
TM 10-3930-675-23-1
0104
FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL 1. Remove two screws (Figure 6, Item 4), plastic clamp (Figure 6, Item 3), and proximity switch (Figure 6, Item 2) from tophandler (Figure 6, Item 1).
1 2 3 4
M0130JCH
Figure 6. Forklift Interlock Proximity Switch Removal. 2. Loosen four screws (Figure 7, Item 3) and remove cover (Figure 7, Item 1) from junction box (Figure 7, Item 2). Inspect rubber seal in groove of cover. Replace seal only if damaged.
1 2 3
M0131JCH
Figure 7.
Junction Box Cover Removal.
0104-7
TM 10-3930-675-23-1
0104
FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL - Continued 3. Loosen cable nut (Figure 8, Item 6) and slide cable nut and grommet (Figure 8, Item 5) back on proximity switch (Figure 8, Item 2) cable.
CAUTION
NOTE
Tag wires for installation. 4. Using a jeweler's screwdriver, disconnect proximity switch wires (Figure 8, Item 3) from terminal blocks (Figure 8, Item 2).
1 2
4 5
M0132JCH
Figure 8. Forklift Interlock Proximity Switch Removal.
NOTE
Remove cable clamps and tiedown straps as needed. Discard tiedown straps. 5. Remove proximity switch (Figure 9, Item 2) with cable from tophandler.
0104-8
TM 10-3930-675-23-1
0104
FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL - Continued

1 2 3 4
M0130JCH
Figure 9. Forklift Interlock Proximity Switch Removal. END OF TASK FORKLIFT INTERLOCK PROXIMITY SWITCH INSTALLATION 1. 2. 3. Position proximity switch (Figure 10, Item 2) with cable on tophandler. Using a jeweler's screwdriver, connect proximity switch wires (Figure 10, Item 3) to terminal blocks (Figure 10, Item 2). Install grommet (Figure 10, Item 5) and cable nut (Figure 10, Item 6) on junction box (Figure 10, Item 1). Tighten cable nut.
1 2 3
M0131JCH
Figure 10.
Junction Box Cover Installation.
0104-9
TM 10-3930-675-23-1
0104
FORKLIFT INTERLOCK PROXIMITY SWITCH INSTALLATION - Continued 4. Install cover (Figure 11, Item 1) on junction box (Figure 11, Item 2) and tighten four screws (Figure 11, Item 3).
1 2 3
5 MM
M0129JCH
Figure 11. Twistlock Proximity Switch Installation. 5. 6. 7. Loosely install proximity switch (Figure 12, Item 2) on tophandler with plastic clamp (Figure 12, Item 3) and two screws (Figure 12, Item 4). Position proximity switch (Figure 12, Item 2) so a gap of 0.20 inch (5.08 mm), between end of proximity switch and ring (Figure 12, Item 1) of actuating plunger, is obtained. Tighten two screws (Figure 12, Item 4). Install cable clamps and new tiedown straps as needed.
END OF TASK SPREADER BEAM PROXIMITY SWITCH REMOVAL 1. 2. 3. Remove two screws (Figure 12, Item 1), washers (Figure 12, Item 2), and proximity switch plate (Figure 12, Item 6) from top of tophandler spreader beam (Figure 12, Item 5). Measure position of proximity switch (Figure 12, Item 3) in proximity switch plate (Figure 12, Item 6), to ensure correct installation. Record measurement. Remove two jamnuts (Figure 12, Item 4) and proximity switch (Figure 12, Item 3) from proximity switch plate (Figure 12, Item 6).
0104-10
TM 10-3930-675-23-1
0104
SPREADER BEAM PROXIMITY SWITCH REMOVAL - Continued

3 1,2
M0133JCH
Figure 12. 4.
Spreader Beam Proximity Switch Removal.
Loosen four screws (Figure 13, Item 1) and remove cover (Figure 13, Item 2) from junction box (Figure 13, Item 3). Inspect rubber seal in groove of cover. Replace seal only if damaged.
1 2
M0134JCH
Figure 13.
0104-11
TM 10-3930-675-23-1
0104
SPREADER BEAM PROXIMITY SWITCH REMOVAL - Continued 5. Loosen cable nut (Figure 14, Item 5) and slide cable nut and grommet (Figure 14, Item 4) back on proximity switch (Figure 14, Item 6) cable.
CAUTION
NOTE
Tag wires for installation. 6. Using a jewelers screwdriver, disconnect proximity switch wires (Figure 14, Item 3) from terminal blocks (Figure 14, Item 2).
NOTE
Remove tiedown straps as needed. Discard tiedown straps. 7. 8. Remove proximity switch (Figure 14, Item 6) with cable from tophandler. Remove cable cover (Figure 14, Item 7) from proximity switch (Figure 14, Item 6) cable.
1 2
5 6
M0135JCH
0104-12
TM 10-3930-675-23-1
0104
SPREADER BEAM PROXIMITY SWITCH INSTALLATION 1. 2. 3. 4. Install cable cover (Figure 15, Item 7) on proximity switch (Figure 15, Item 6) cable. Position proximity switch (Figure 15, Item 6) with cable on tophandler. Using a jeweler's screwdriver, connect proximity switch wires (Figure 15, Item 3) to terminal blocks (Figure 15, Item 2). Install grommet (Figure 15, Item 4) and cable nut (Figure 15, Item 5) on junction box (Figure 15, Item 1). Tighten cable nut.
1 2
5 6
M0136JCH
Figure 15.
Spreader Beam Proximity Switch Installation.
0104-13
TM 10-3930-675-23-1
0104
SPREADER BEAM PROXIMITY SWITCH INSTALLATION - Continued 5. Install cover (Figure 16, Item 2) on junction box (Figure 16, Item 3) and tighten four screws (Figure 16, Item 1).
1 2
M0137JCH
Figure 16. 6.
Loosely install proximity switch (Figure 17, Item 3) on proximity switch plate (Figure 17, Item 6) with two jamnuts (Figure 17, Item 4).
CAUTION
Overtightening jamnuts will damage proximity switch threads. 7. Place proximity switch (Figure 17, Item 3) in same position measured during removal and tighten two jamnuts (Figure 17, Item 4) to 177 in-lb (20 Nm).
NOTE
Clearance between sensor end of proximity switch and flat rod below should be 0.20 inch (5.08 mm). 8. Install proximity switch (Figure 17, Item 3) and proximity switch plate (Figure 17, Item 6) on spreader beam (Figure 17, Item 5) with two washers (Figure 17, Item 2) and screws (Figure 17, Item 1).
0104-14
TM 10-3930-675-23-1
0104
SPREADER BEAM PROXIMITY SWITCH INSTALLATION - Continued

3 1,2
M0138JCH
Figure 17. 9. Install new tiedown straps.
0104-15/16 blank
TM 10-3930-675-23-1
0105
FIELD MAINTENANCE CAB POSITION PROXIMITY SWITCHES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 2 Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References Volume 2, WP 0175 Equipment Condition Cab in transport position, but not lowered (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10)
CAB-MOUNTED PROXIMITY SWITCH REMOVAL
NOTE
Note position of proximity switch relative to cab to ensure accurate installation. 1. From outside of cab, remove jamnut (Figure 1, Item 2) from proximity switch (Figure 1, Item 1).
1 2
M0139JCH
Figure 1.
Cab-Mounted Proximity Switch Removal.
0105-1
TM 10-3930-675-23-1
0105
CAB-MOUNTED PROXIMITY SWITCH REMOVAL - Continued 2. From inside rear of cab, remove right access panel (Figure 2, Item 1) and middle access panel (Figure 2, Item 2).
2
M0140JCH
Figure 2. 3. 4. 5.
Cab-Mounted Proximity Switch Removal.
Pull proximity switch (Figure 3, Item 1) out from side of cab and remove jamnut (Figure 3, Item 2) from proximity switch. Disconnect connector (Figure 3, Item 4) of proximity switch (Figure 3, Item 1) from electrical panel (Figure 3, Item 3). Remove proximity switch (Figure 3, Item 1) from cab.
END OF TASK
0105-2
TM 10-3930-675-23-1
0105
CAB-MOUNTED PROXIMITY SWITCH INSTALLATION 1. 2. 3. Position proximity switch (Figure 3, Item 1) on cab. Connect connector (Figure 3, Item 4) of proximity switch (Figure 3, Item 1) to electrical panel (Figure 3, Item 3). Install jamnut (Figure 3, Item 2) on proximity switch (Figure 3, Item 1) and push proximity switch outside of cab.
3
4 1,2
M0141JCH
Figure 3. Cab-Mounted Proximity Switch Replacement.
0105-3
TM 10-3930-675-23-1
0105
CAB-MOUNTED PROXIMITY SWITCH INSTALLATION - Continued 4. Outside of cab, install jamnut (Figure 4, Item 2) on proximity switch (Figure 4, Item 1). DO NOT fully tighten jamnut.
NOTE
Proximity switch should be positioned and adjusted flush with the end of protector collar. 5. 6. Adjust position of proximity switch (Figure 4, Item 1), as noted during removal, by adjusting position of jamnuts (Figures 3 and 4, Item 2). Tighten jamnut (Figure 4, Item 2).
1 2
M0142JCH
Cab-Mounted Proximity Switch Installation.
0105-4
TM 10-3930-675-23-1
0105
CAB SUPPORT-MOUNTED PROXIMITY SWITCH REMOVAL 1. Remove middle and rear transmission access covers (Volume 2, WP 0175).
NOTE
Note position of proximity switch relative to bracket to ensure accurate installation. 2. 3. Remove upper jamnut (Figure 5, Item 6) from proximity switch (Figure 5, Item 5) and push proximity switch downward from bracket (Figure 5, Item 4). Remove jamnut (Figure 5, Item 7) from proximity switch (Figure 5, Item 5).
NOTE
Perform Step 4 to remove bracket from cab support. 4. 5. Remove two locknuts (Figure 5, Item 8), screws (Figure 5, Item 9), four washers (Figure 5, Item 10), and bracket (Figure 5, Item 4) from cab support (Figure 5, Item 11). Discard locknuts. Loosen four screws (Figure 5, Item 2) and remove cover (Figure 5, Item 3) from junction box (Figure 5, Item 1).
3 4 5
11
8,9,10
M0143JCH
Figure 5. Cab Support-Mounted Proximity Switch Removal.
0105-5
TM 10-3930-675-23-1
0105
CAB SUPPORT-MOUNTED PROXIMITY SWITCH REMOVAL - Continued
NOTE
Tag wires for installation. 6. 7. Using a jeweler's screwdriver, disconnect three wires of cable (Figure 6, Item 6) from terminal blocks (Figure 6, Item 1) of junction box (Figure 6, Item 2). Loosen cable nut (Figure 6, Item 5) and slide cable nut, grommet (Figure 6, Item 4), and bushing (Figure 6, Item 3) back on cable (Figure 6, Item 6).
NOTE
Remove tiedown straps as needed. Discard tiedown straps. 8. 9. Remove cable (Figure 6, Item 6) from junction box (Figure 6, Item 2). Remove proximity switch (Figure 7, Item 5) from vehicle.
END OF TASK CAB SUPPORT-MOUNTED PROXIMITY SWITCH INSTALLATION 1. 2. 3. 4. Position proximity switch (Figure 7, Item 5) on vehicle. Feed cable (Figure 6, Item 6) through cable nut (Figure 6, Item 5), grommet (Figure 6, Item 4), and bushing (Figure 6, Item 3) and into junction box (Figure 6, Item 2). Using a jeweler's screwdriver, connect three wires of cable (Figure 6, Item 6) to terminal blocks (Figure 6, Item 1) of junction box (Figure 6, Item 2). Install bushing (Figure 6, Item 3), grommet (Figure 6, Item 4), and cable nut (Figure 6, Item 5) on junction box (Figure 6, Item 2).
0105-6
TM 10-3930-675-23-1
0105
CAB SUPPORT-MOUNTED PROXIMITY SWITCH INSTALLATION - Continued

1 2
M0144JCH
Figure 6.
Cab Support-Mounted Proximity Switch Installation.
0105-7
TM 10-3930-675-23-1
0105
CAB SUPPORT-MOUNTED PROXIMITY SWITCH INSTALLATION - Continued 5. Install cover (Figure 7, Item 3) on junction box (Figure 7, Item 1) and tighten four screws (Figure 7, Item 2).
NOTE
Perform Step 6 to install bracket to cab support. 6. 7. 8. 9. 10. 11. Install bracket (Figure 7, Item 4) on cab support (Figure 7, Item 11) with four washers (Figure 7, Item 10), two screws (Figure 7, Item 9), and new locknuts (Figure 7, Item 8). Loosely install jamnut (Figure 7, Item 7) on proximity switch (Figure 7, Item 5). Position proximity switch (Figure 7, Item 5) upward through bracket (Figure 7, Item 4) and loosely install upper jamnut (Figure 7, Item 6). Adjust two jamnuts (Figure 7, Items 6 and 7) to position proximity switch (Figure 7, Item 5) as noted during removal and tighten jamnuts. Correct dimension is 1.20 inch (30 mm) from bracket to tip of sensor. Install new tiedown straps as needed. Install middle and rear transmission access covers (Volume 2, WP 0175).
3 4 5
11
8,9,10
M0143JCH
Cab-Support Mounted Proximity Switch Installation.
Return cab to operational position (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE
0105-8
TM 10-3930-675-23-1
0106
FIELD MAINTENANCE SOLAR CHARGER REPLACEMENT (IF EQUIPPED)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 87) Qty: 4 Equipment Condition Battery compartment door open (TM 10-3930-675-10)
REMOVAL 1. Inside battery compartment (Figure 1, Item 1), disconnect connector (Figure 1, Item 3) and wire (Figure 1, Item 2) of solar charger from connector (Figure 1, Item 4).
1 2 3 4
M0262JCH
Figure 1.
Solar Charger Replacement.
0106-1
TM 10-3930-675-23-1
0106
REMOVAL - Continued 2. At top of battery compartment (Figure 2, Item 1), remove four locknuts (Figure 2, Item 2), screws (Figure 2, Item 3), and washers (Figure 2, Items 4 and 5) to separate solar charger (Figure 2, Item 8) and grating (Figure 2, Item 7) from four grommets (Figure 2, Item 6). Discard locknuts. Remove large grommet (Figure 2, Item 9), wire (Figure 2, Item 10) of solar charger (Figure 2, Item 8), grating (Figure 2, Item 7), and solar charger from vehicle. Remove four grommets (Figure 2, Item 6) from top of battery compartment (Figure 2, Item 1).
2,3,4,5,6 1 7 8 9,10
3. 4.
M0263JCH
Figure 2.
0106-2
TM 10-3930-675-23-1
0106
REMOVAL - Continued
NOTE
Perform Steps 5 and 6 to remove pulse generator. Only one fuse completes circuit. Other fuse is a spare. 5. Separate two halves of fuse holder (Figure 3, Item 1) and remove two fuses (Figure 3, Item 2).
2 1
M0264JCH
Figure 3. 6.
Remove two bolts (Figure 4, Item 3), washers (Figure 4, Item 4), and pulse generator (Figure 4, Item 2) from battery compartment (Figure 4, Item 1).
2
3,4
M0265JCH
0106-3
TM 10-3930-675-23-1
0106
INSTALLATION
NOTE
Perform Steps 1 and 2 to install pulse generator. 1. 2. 3. 4. Install pulse generator (Figure 4, Item 2) in battery compartment (Figure 4, Item 1) with two washers (Figure 4, Item 4) and bolts (Figure 4, Item 3). Install two fuses (Figure 3, Item 2) and connect two halves of fuse holder (Figure 3, Item 1). Install four grommets (Figure 2, Item 6) in top of battery compartment (Figure 2, Item 1). Install wire (Figure 2, Item 10) of solar charger (Figure 2, Item 8) and large grommet (Figure 2, Item 9) on top of battery compartment (Figure 2, Item 1) and position grating (Figure 2, Item 7) and solar charger on four grommets (Figure 2, Item 6). Install grating (Figure 2, Item 7) and solar charger (Figure 2, Item 8) on four grommets (Figure 2, Item 6) with four washers (Figure 2, Item 5), washers (Figure 2, Item 4), screws (Figure 2, Item 3), and new locknuts (Figure 2, Item 2). Inside battery compartment (Figure 5, Item 1), connect wire (Figure 5, Item 2) and connector (Figure 5, Item 3) of solar charger to connector (Figure 5, Item 4).
1 2 3 4
5.
6.
M0266JCH
Close battery compartment door (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE
0106-4
TM 10-3930-675-23-1
0107
FIELD MAINTENANCE BOOM WIRING HARNESSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) References WP 0097 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
REMOVAL 1. 2. Disconnect wiring harness (Figure 1, Item 5) connector (Figure 1, Item 8) from chassis wiring harness connector (Figure 1, Item 9) on side of boom (Figure 1, Item 6). Remove four screws (Figure 1, Item 2). Disconnect wiring harness (Figure 1, Item 4) connector (Figure 1, Item 3) from chassis wiring harness connector (Figure 1, Item 1).
NOTE
Note routing of wiring harnesses and positioning of tiedown straps to assist in installation. 3. Trace wiring harnesses (Figure 1, Items 4 and 5) along boom (Figure 1, Item 6), removing and discarding all tiedown straps that secure wiring harnesses to channels (Figure 1, Item 7).
1 2 3 4 4,5 6
M0850JCH
Figure 1.
Boom Wiring Harness Removal.
0107-1
TM 10-3930-675-23-1
0107
REMOVAL - Continued 4. 5. Trace wiring harnesses (Figure 2, Items 2 and 3) to tophandler junction box (Figure 2, Item 4) and disconnect from junction box (WP 0097). Remove and discard tiedown straps that secure wiring harnesses (Figure 2, Items 2 and 3) together at tophandler junction box (Figure 2, Item 4).
NOTE
Note routing of wiring harnesses through middle portion of flexible conveyer. 6. 7. Pull wiring harnesses (Figure 2, Items 2 and 3) toward front of vehicle, pulling them through box channel (Figure 2, Item 1) and flexible conveyer. Remove wiring harnesses (Figure 2, Items 2 and 3) from vehicle.
1 2,3
M0851JCH
Figure 2. Boom Wiring Harness Removal. END OF TASK
0107-2
TM 10-3930-675-23-1
0107
INSTALLATION 1. Starting from rear of flexible conveyer (Figure 3, Item 7) and working toward tophandler, feed wiring harnesses (Figure 3, Items 4 and 5) through middle portion of flexible conveyer and into box channel (Figure 3, Item 11), until wiring harness ends reach tophandler junction box (Figure 3, Item 12). Connect wiring harnesses (Figure 3, Items 4 and 5) to tophandler junction box (Figure 3, Item 12) (WP 0097). Install new tiedown straps to secure wiring harnesses (Figure 3, Items 4 and 5) together at tophandler junction box (Figure 3, Item 12). Position wiring harnesses (Figure 3, Items 4 and 5) inside channels (Figure 3, Item 8) along boom (Figure 3, Item 6), until ends of wiring harnesses reach connection points to chassis wiring harnesses. Connect wiring harness (Figure 3, Item 4) connector (Figure 3, Item 3) to chassis wiring harness connector (Figure 3, Item 1). Install four screws (Figure 3, Item 2). Connect wiring harness (Figure 3, Item 5) connector (Figure 3, Item 9) to chassis wiring harness connector (Figure 3, Item 10). Secure wiring harnesses (Figure 3, Items 4 and 5) to channels (Figure 3, Item 8) with new tiedown straps.
1 2 3 4 4,5 6 7
2. 3. 4. 5. 6. 7.
10
M0852JCH
Boom Wiring Harness Installation.
0107-3/4 blank
TM 10-3930-675-23-1
0108
FIELD MAINTENANCE TOPHANDLER WIRING HARNESSES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Wire, Nonelectrical (Volume 2, WP 0276, Table 1, Item 70) Seal, Nonmetallic Strip (Volume 2, WP 0278, Table 1, Item 157) Personnel Required (2) References Volume 2, WP 0257 Volume 2, WP 0272 Equipment Condition Boom and tophandler fully lowered (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10)
NOTE
Replacement of wiring harnesses D and E is easier to perform with tophandler extended to 40 ft (12.2 m) width.
0108-1
TM 10-3930-675-23-1
0108
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 REMOVAL 1. Disconnect wiring harness A (Figure 1, Item 2) connector from tophandler junction box (Figure 1, Item 1) connector.
M0853JCH
Figure 1. Wiring Harness A Removal. 2. 3. 4. Trace routing of wiring harness A (Figure 2, Item 2). Loosen cable clamps (Figure 2, Item 1) and cut tiedown straps as needed to gain free movement of harness A. Unwrap upper and lower cable guard (Figure 2, Item 6) from harness A (Figure 2, Item 2) routing. Retain for installation. Loosen four screws (Figure 2, Item 4) and remove cover (Figure 2, Item 3) from junction box 182 (Figure 2, Item 5). Inspect rubber seal in groove of cover. Replace only if damaged.
0108-2
TM 10-3930-675-23-1
0108
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 REMOVAL - Continued

1 2
5 6
M0854JCH
Figure 2.
Wiring Harness A Removal.
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 5. 6. Using jewelers screwdriver, disconnect wiring harness A (Figure 3, Item 1) leads from junction box 182 (Figure 3, Item 3) terminal block (Figure 3, Item 2). Remove retainer nut (Figure 3, Item 4), grommet (Figure 3, Item 5), sleeve (Figure 3, Item 6), and wiring harness A (Figure 3, Item 1) from junction box 182 (Figure 3, Item 3). Retain retainer nut, grommet, and sleeve for installation.
2 1 3
4,5,6
M0855JCH
Figure 3.
Wiring Harness A Removal.
0108-3
TM 10-3930-675-23-1
0108
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 REMOVAL - Continued 7. From tophandler junction box end, with assistance, pull wiring harness A (Figure 4, Item 2) from routing until wiring harness A is approximately 18 in. (46 cm) from tophandler carriage frame above control valve.
NOTE
Nonelectrical wire is secured to wiring harness to be used as a guide wire during installation of new harness. 8. 9. 10. Secure approximately 6 ft (183 cm) of nonelectrical wire to wiring harness A (Figure 4, Item 2). With assistance, continue to pull wiring harness A (Figure 4, Item 2) and nonelectrical wire through cable routing until wiring harness is free of tophandler carriage frame. Remove wiring harness A (Figure 4, Item 2) from nonelectrical wire leaving nonelectrical wire in place through wiring harness routing.
END OF TASK WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 INSTALLATION
CAUTION
Ensure sufficient length of wiring harness is coiled within tophandler opening, so that tophandler can rotate freely in both directions without damaging harness. 1. 2. 3. 4. Attach junction box 182 (Figure 4, Item 5) end of wiring harness A (Figure 4, Item 2) to nonelectrical wire at tophandler junction box. With assistance, pull other end of nonelectrical wire and wiring harness A (Figure 4, Item 2) through tophandler carriage frame until approximately 18 in. (46 cm) of wiring harness A is exposed. Remove nonelectrical wire from wiring harness A (Figure 4, Item 2) and continue to route wiring harness A to junction box 182 (Figure 4, Item 5). Install wiring harness A (Figure 4, Item 2) through retainer nut (Figure 3, Item 4), grommet (Figure 3, Item 5), sleeve (Figure 3, Item 6), and use a jewelers screwdriver to connect leads to terminal block (Figure 3, Item 2) as noted during removal. Tighten retainer nut. Install cover (Figure 4, Item 3) on junction box 182 (Figure 4, Item 5) and tighten four screws (Figure 4, Item 4). Tighten cable clamps (Figure 4, Item 1) and install new tiedown straps as needed to secure wiring harness A (Figure 4, Item 2). Install upper and lower cable guard (Figure 4, Item 6).
5. 6. 7.
0108-4
TM 10-3930-675-23-1
0108
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 INSTALLATION - Continued

1 2
5 6
M0856JCH
Figure 4. 8.
Wiring Harness A Installation.
Connect connector of wiring harness A (Figure 5, Item 2) to connector of tophandler junction box (Figure 5, Item 1).
M0857JCH
Wiring Harness A Installation.
0108-5
TM 10-3930-675-23-1
0108
WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL 1. Disconnect wiring harness B (Figure 6, Item 2) connector from tophandler junction box (Figure 6, Item 1) connector.
M0860JCH
Figure 6. Wiring Harness B Removal. 2. 3. Remove upper cable guard from wiring harness B (Figure 7, Item 1). Retain cable guard for installation. Remove screw (Figure 7, Item 3) and cable clamp (Figure 7, Item 4) from wiring harness B (Figure 7, Item 1) grommet.
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and ensure diagram or record of wire lead connections is made prior to disconnection to ensure correct connection of leads. 4. At control valve, locate these wire leads, press in on retaining clips, and disconnect leads from solenoids (Figure 7, Item 2) as follows: WIRE NUMBER 6008 6009 6010 6011 6018 6019 SOLENOID FUNCTION Rotation Clockwise Rotation Counterclockwise Tilt Out Tilt In Spreader Out Spreader In
0108-6
TM 10-3930-675-23-1
0108
WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL - Continued 5. Disconnect wire lead 6034-1 from leveling lock solenoid (Figure 7, Item 5).
NOTE
Nonelectrical wire is secured to wiring harness to be used as a guide wire during installation of new harness. 6. 7. 8. Secure all loose leads of wiring harness B (Figure 7, Item1) to nonelectrical wire. With assistance, pull wiring harness B (Figure 7, Item 1) up through tophandler carriage until nonelectrical wire is exposed approximately 18 in. (46 cm). Remove wiring harness B (Figure 7, Item 1) from nonelectrical wire, leaving nonelectrical wire in place as a guide wire.
3,4 2 1 1
M0858JCH
Wiring Harness B Removal.
0108-7
TM 10-3930-675-23-1
0108
WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION
CAUTION
Ensure sufficient length of wiring harness is coiled within tophandler opening, so that tophandler can rotate freely in both directions without damaging harness. 1. 2. 3. 4. Attach wiring harness B (Figure 8, Item 1) control valve wire leads to upper end of nonelectrical wire. With assistance, pull nonelectrical wire and wiring harness B (Figure 8, Item 1) down through tophandler carriage frame. Remove wiring harness B (Figure 8, Item 1) leads from nonelectrical wire. Connect wire leads to solenoids (Figure 8, Item 2) as follows: WIRE NUMBER 6008 6009 6010 6011 6018 6019 5. 6. SOLENOID FUNCTION Rotation Clockwise Rotation Counterclockwise Tilt Out Tilt In Spreader Out Spreader In
Connect lead 6034-1 to leveling lock solenoid (Figure 8, Item 5). Install cable clamp (Figure 8, Item 4) on wiring harness B (Figure 8, Item 1) grommet with screw (Figure 8, Item 3).
3,4 2 1 1
M0858JCH
Figure 8. Wiring Harness B Installation.
0108-8
TM 10-3930-675-23-1
0108
WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION - Continued 7. Connect wiring harness B (Figure 9, Item 2) connector to tophandler junction box (Figure 9, Item 1) connector and install cable guard.
M0860JCH
Wiring Harness B Installation.
0108-9
TM 10-3930-675-23-1
0108
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL 1. Disconnect wiring harness C (Figure 10, Item 2) connector from tophandler junction box (Figure 10, Item 1) connector.
M0862JCH
Figure 10. Wiring Harness C Removal. 2. 3. Remove upper cable guard from wiring harness C (Figure 11, Item 1). Retain cable guard for installation. Remove screw (Figure 11, Item 2) and cable clamp (Figure 11, Item 3) from wiring harness C (Figure 11, Item 1) grommet.
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and ensure a diagram or record of wire lead connections is made prior to disconnection to ensure correct connection of leads. 4. At control valve, locate these wire leads, press in on retaining clips, and disconnect leads from solenoids (Figure 11, Item 4) as follows: WIRE NUMBER 6020 6021 6035 6036 6039 6040 SOLENOID FUNCTION Sideshift Left Sideshift Right Leveling Right Leveling Left Unlock Twistlocks Lock Twistlocks
0108-10
TM 10-3930-675-23-1
0108
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL - Continued 5. Disconnect wire lead 6034-2 from leveling lock solenoid (Figure 11, Item 5).
NOTE
Nonelectrical wire is secured to wiring harness to be used as a guide wire during installation of new harness. 6. 7. 8. Secure all loose leads of wiring harness C (Figure 11, Item 1) to nonelectrical wire. With assistance, pull wiring harness C (Figure 11, Item 1) up through tophandler carriage until nonelectrical wire is exposed approximately 18 in. (46 cm). Remove wiring harness C (Figure 11, Item 1) from nonelectrical wire and leave nonelectrical wire in place as a guide wire.
2,3 4
5 1
M0861JCH
Wiring Harness C Removal.
0108-11
TM 10-3930-675-23-1
0108
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION
CAUTION
Ensure sufficient length of wiring harness is coiled within tophandler opening, so that tophandler can rotate freely in both directions without damaging harness. 1. 2. 3. 4. Attach wiring harness C (Figure 12, Item 1) control valve wire leads to upper end of nonelectrical wire. With assistance, pull nonelectrical wire and wiring harness C (Figure 12, Item 1) down through tophandler carriage frame. Remove wiring harness C (Figure 12, Item 1) leads from nonelectrical wire. Connect wire leads to solenoids (Figure 12, Item 5) as follows: WIRE NUMBER 6020 6021 6035 6036 6039 6040 5. 6. SOLENOID FUNCTION Sideshift Left Sideshift Right Leveling Right Leveling Left Unlock Twistlocks Lock Twistlocks
Connect lead 6034-2 to leveling lock solenoid (Figure 12, Item 5). Install cable clamp (Figure 12, Item 3) on wiring harness C (Figure 12, Item 1) grommet with screw (Figure 12, Item 2).
2,3 4
5 1
M0861JCH
Figure 12. Wiring Harness C Installation.
0108-12
TM 10-3930-675-23-1
0108
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION - Continued 7. Connect wiring harness C (Figure 13, Item 2) connector to tophandler junction box (Figure 13, Item 1) connector and install cable guard.
M0862JCH
Wiring Harness C Installation.
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL 1. Loosen four screws (Figure 14, Item 1) and remove cover (Figure 14, Item 2) from junction box 182 (Figure 14, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged.
1 2
M0863JCH
Figure 14.
Wiring Harness D Removal.
0108-13
TM 10-3930-675-23-1
0108
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL - Continued 2. Remove retainer nut (Figure 15, Item 3), grommet (Figure 15, Item 4), and sleeve (Figure 15, Item 5).
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 3. Using jewelers screwdriver, disconnect wiring harness D (Figure 15, Item 6) leads from junction box 182 (Figure 15, Item1) terminal block (Figure 15, Item 2). Remove harness from junction box.
1 2
3,4,5
M0864JCH
Figure 15. Wiring Harness D Removal.
0108-14
TM 10-3930-675-23-1
0108
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL - Continued 4. Trace wiring harness D (Figure 16, Item 1) from junction box 182 (Figure 15, Item 1) to junction box 183 (Figure 16, Item 4). Cut tiedown straps and loosen clamps, as needed, to gain free movement of wiring harness. Discard tiedown straps. Loosen four screws (Figure 16, Item 3) and remove cover (Figure 16, Item 2) from junction box 183 (Figure 16, Item 4). Inspect rubber seal in groove of cover. Replace only if damaged.
2 3
5.
M0865JCH
Figure 16.
Wiring Harness D Removal.
0108-15
TM 10-3930-675-23-1
0108
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL - Continued 6. Remove retainer nut (Figure 17, Item 4), grommet (Figure 17, Item 5), and sleeve (Figure 17, Item 6).
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 7. 8. Using jewelers screwdriver, disconnect wiring harness D (Figure 17, Item 1) leads from junction box 183 (Figure 17, Item 2) terminal block (Figure 17, Item 3). Remove harness from junction box. Remove wiring harness D (Figure 17, Item 1) from cable guard (Figure 17, Item 7) along cable routing. Retain cable guard.
2
4,5,6 7
M0866JCH
Figure 17. Wiring Harness D Removal. END OF TASK
0108-16
TM 10-3930-675-23-1
0108
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 INSTALLATION 1. 2. 3. 4. 5. Install wiring harness D (Figure 17, Item 1) through cable guard (Figure 17, Item 7) and position wiring harness along cable routing. Position retainer nut (Figure 17, Item 4), grommet (Figure 17, Item 5), and sleeve (Figure 17, Item 6) on wiring harness D (Figure 17, Item 1) at junction box 183 (Figure 17, Item 2). Install harness into junction box. Using jewelers screwdriver, connect wiring harness D (Figure 17, Item 1) leads to terminal block (Figure 17, Item 3). Install sleeve (Figure 17, Item 6), grommet (Figure 17, Item 5), and retainer nut (Figure 17, Item 4). With wiring harness D (Figure 18, Item 1) secured, install cover (Figure 18, Item 2) on junction box 183 (Figure 18, Item 4) and tighten four screws (Figure 18, Item 3).
2 3
M0867JCH
Figure 18.
Wiring Harness D Installation.
0108-17
TM 10-3930-675-23-1
0108
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 INSTALLATION - Continued 6. Position retainer nut (Figure 19, Item 3), grommet (Figure 19, Item 4), and sleeve (Figure 19, Item 5) on other end of wiring harness D (Figure 19, Item 6) at junction box 182 (Figure 19, Item 1). Install harness into junction box. Using jewelers screwdriver, connect wiring harness D leads to terminal block (Figure 19, Item 2). Install sleeve (Figure 19, Item 5), grommet (Figure 19, Item 4), and retainer nut (Figure 19, Item 3).
1 2
7. 8.
3,4,5
M0868JCH
Figure 19. Wiring Harness D Installation. 9. Install cover (Figure 20, Item 2) on junction box 182 (Figure 20, Item 3) and tighten four screws (Figure 20, Item 1).
2 3
M0869JCH
Figure 20. Wiring Harness D Installation.
0108-18
TM 10-3930-675-23-1
0108
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 INSTALLATION - Continued 10. Secure wiring harness D along cable routing by tightening clamps and installing new tiedown straps as needed.
END OF TASK WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 REMOVAL 1. 2. Loosen four screws (Figure 20, Item 1) and remove cover (Figure 20, Item 2) from junction box 182 (Figure 20, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged. Remove retainer nut (Figure 21, Item 3), grommet (Figure 21, Item 4), and sleeve (Figure 21, Item 5).
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 3. 4. Using jewelers screwdriver, disconnect wiring harness E (Figure 21, Item 6) leads from junction box 182 (Figure 21, Item 1) terminal block (Figure 21, Item 2). Remove harness from junction box. Trace wiring harness E (Figure 21, Item 6) from junction box 182 (Figure 21, Item 1) through conduit along top of tophandler to junction box 184 (Figure 22, Item 3).
1 2
3,4,5
6
M0870JCH
Figure 21.
Wiring Harness E Removal.
0108-19
TM 10-3930-675-23-1
0108
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 REMOVAL - Continued 5. Loosen four screws (Figure 22, Item 2) and remove cover (Figure 22, Item 1) from junction box 184 (Figure 22, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged.
1 2
M0871JCH
Figure 22. Wiring Harness E Removal.
0108-20
TM 10-3930-675-23-1
0108
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 REMOVAL - Continued 6. Remove retainer nut (Figure 23, Item 4), grommet (Figure 23, Item 5), and sleeve (Figure 23, Item 6).
NOTE
Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 7. 8. 9. 10. Using jewelers screwdriver, disconnect wiring harness E (Figure 23, Item 1) leads from junction box 184 (Figure 23, Item 2) terminal block (Figure 23, Item 3). Remove harness from junction box. Secure all loose leads of wiring harness E (Figure 23, Item 1) to nonelectrical wire. With assistance, pull wiring harness E (Figure 23, Item 1) out from conduit until approximately 18 in. (46 cm) of nonelectrical wire is exposed. Remove wiring harness E (Figure 23, Item 1) leads from nonelectrical wire and leave nonelectrical wire in place as a guide wire.
2
4,5,6
M0872JCH
Wiring Harness E Removal.
0108-21
TM 10-3930-675-23-1
0108
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 INSTALLATION 1. 2. 3. 4. 5. 6. 7. At junction box 182 (Figure 23, Item 2), secure all loose leads of wiring harness E (Figure 23, Item 1) to nonelectrical wire. With assistance, pull wire harness E (Figure 24, Item 4) through conduit until sufficient length is exposed to reach junction box 184 (Figure 24, Item 3). Remove wiring harness E (Figure 24, Item 4) from nonelectrical wire. Position retainer nut (Figure 24, Item 4), grommet (Figure 24, Item 5), and sleeve (Figure 24, Item 6) on wiring harness E (Figure 24, Item 4) at junction box 184 (Figure 24, Item 3). Install harness into junction box. Using jewelers screwdriver, connect wiring harness E (Figure 24, Item 4) leads to terminal block (Figure 24, Item 3). Install sleeve (Figure 24, Item 6), grommet (Figure 24, Item 5), and retainer nut (Figure 24, Item 4). Install cover (Figure 24, Item 1) on junction box 184 (Figure 24, Item 3) and tighten four screws (Figure 24, Item 2).
1 2
M0873JCH
Figure 24. 8.
Wiring Harness E Installation.
Position retainer nut (Figure 25, Item 3), grommet (Figure 25, Item 4), and sleeve (Figure 25, Item 5) on other end of wiring harness E (Figure 25, Item 6) at junction box 182 (Figure 25, Item 1). Install harness into junction box. Using jewelers screwdriver, connect wiring harness E (Figure 25, Item 6) leads to terminal block (Figure 25, Item 2). Install sleeve (Figure 25, Item 5), grommet (Figure 25, Item 4), and retainer nut (Figure 25, Item 3).
9. 10.
0108-22
TM 10-3930-675-23-1
0108
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 INSTALLATION - Continued

1 2
3,4,5
M0874JCH
Figure 25. 11.
Install cover (Figure 26, Item 2) on junction box 182 (Figure 26, Item 3) and tighten four screws (Figure 26, Item 1).
1 2
M0875JCH
0108-23
TM 10-3930-675-23-1
0108
FOLLOW-ON MAINTENANCE 1. 2. Perform boom and tophandler calibration (Volume 2, WP 0257). Perform operational check of tophandler (TM 10-3930-675-10).
0108-24
TM 10-3930-675-23-1
0109
FIELD MAINTENANCE HEADLIGHT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Washer, Lock (Volume 2, WP 0278, Table 1, Item 14) References Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0109-1
TM 10-3930-675-23-1
0109
BULB REPLACEMENT 1. Remove reflector insert (Figure 1, Item 2) from rubber ring (Figure 1, Item 1) on light housing (Figure 1, Item 3) with medium flat-tip screwdriver.
1 2
M0173JCH
Figure 1. Headlight Reflector Insert Removal. 2. 3. 4. 5. Disconnect black plastic connector (Figure 2, Item 2) from rear of bulb (Figure 2, Item 3). Release wire clip (Figure 2, Item 4) at rear of reflector insert (Figure 2, Item 1) and remove bulb (Figure 2, Item 3). Place new bulb (Figure 2, Item 3) into rear of reflector insert (Figure 2, Item 1) and fasten wire clip (Figure 2, Item 4). Connect black plastic connector (Figure 2, Item 2) to rear of bulb (Figure 2, Item 3).
0109-2
TM 10-3930-675-23-1
0109
BULB REPLACEMENT - Continued

1 2
M0174JCH
Figure 2. 6.
Headlight Bulb Replacement.
Position reflector insert (Figure 3, Item 2) on rubber ring (Figure 3, Item 1) on light housing (Figure 3, Item 3) and push into place.
1 2
3
M0175JCH
Headlight Reflector Insert Installation.
0109-3
TM 10-3930-675-23-1
0109
LIGHT REMOVAL
NOTE
Use marker tags to ensure proper connection of connectors. Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1. 2. 3. Remove bulb (refer to Bulb Replacement in this work package). Remove nut (Figure 4, Item 5), lockwasher (Figure 4, Item 6), and light assembly (Figure 4, Item 2) from bracket (Figure 4, Item 3). Discard lockwasher. Disconnect two connectors (Figure 4, Item 7) from black plastic connector (Figure 4, Item 1) and remove two wires (Figure 4, Item 4) with connectors from rear of light assembly (Figure 4, Item 2).
END OF TASK LIGHT INSTALLATION 1. 2. 3. Route two connectors (Figure 4, Item 7) and wires (Figure 4, Item 4) through rear of light assembly (Figure 4, Item 2) and connect two connectors to black plastic connector (Figure 4, Item 1). Install light assembly (Figure 4, Item 2) on bracket (Figure 4, Item 3) with new lockwasher (Figure 4, Item 6) and nut (Figure 4, Item 5). Install bulb (refer to Bulb Replacement in this work package).
0109-4
TM 10-3930-675-23-1
0109
LIGHT INSTALLATION - Continued
5,6
M0176JCH
Light Removal and Installation.
Turn master battery switch to ON position (TM 10-3930-675-10). Check light for proper operation (TM 10-3930-675-10).
0109-5/6 blank
TM 10-3930-675-23-1
0110
FIELD MAINTENANCE BACKUP LIGHT AND WORK LIGHT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Washer, Lock (Volume 2, WP 0278, Table 1, Item 106) References Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0110-1
TM 10-3930-675-23-1
0110
BULB REPLACEMENT 1. Remove reflector insert (Figure 1, Item 2) from rubber ring (Figure 1, Item 1) on light housing (Figure 1, Item 3) with medium flat tip screwdriver.
1 2
M0177JCH
Figure 1. Reflector Insert Removal. 2. 3. 4. 5. Disconnect connector (Figure 2, Item 2) of bulb (Figure 2, Item 3) from connector of wiring harness (Figure 2, Item 1). Release wire clip (Figure 2, Item 5) at rear of reflector insert (Figure 2, Item 4) and remove bulb (Figure 2, Item 3). Place new bulb (Figure 2, Item 3) into rear of reflector insert (Figure 2, Item 4) and fasten wire clip (Figure 2, Item 5). Connect connector (Figure 2, Item 2) of bulb (Figure 2, Item 3) to connector of wiring harness (Figure 2, Item 1).
0110-2
TM 10-3930-675-23-1
0110
BULB REPLACEMENT - Continued

1 2 3
M0178JCH
Figure 2. 6.
Bulb Replacement.
Position reflector insert (Figure 3, Item 2) on rubber ring (Figure 3, Item 1) on light housing (Figure 3, Item 3) and push into place.
1 2
3
M0179JCH
Reflector Insert Installation.
0110-3
TM 10-3930-675-23-1
0110
LIGHT REMOVAL
NOTE
Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1. 2. 3. Remove bulb (Figure 2, Item 3) (refer to Bulb Replacement in this work package). Remove nut (Figure 4, Item 5), lockwasher (Figure 4, Item 6), and light assembly (Figure 4, Item 2) from bracket (Figure 4, Item 1). Discard lockwasher. Remove wire of wiring harness (Figure 4, Item 3) with connector (Figure 4, Item 4) from rear of light assembly (Figure 4, Item 2).
END OF TASK LIGHT INSTALLATION 1. 2. 3. Route connector (Figure 4, Item 4) and wire of wiring harness (Figure 4, Item 3) through rear of light assembly (Figure 4, Item 2). Install light assembly (Figure 4, Item 2) on bracket (Figure 4, Item 1) with new lockwasher (Figure 4, Item 6) and nut (Figure 4, Item 5). Install bulb (refer to Bulb Replacement in this work package).
0110-4
TM 10-3930-675-23-1
0110
LIGHT INSTALLATION - Continued
2 1
5,6
M0180JCH
Light Removal and Installation.
0110-5/6 blank
TM 10-3930-675-23-1
0111
FIELD MAINTENANCE BLACKOUT LIGHT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) References Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0111-1
TM 10-3930-675-23-1
0111
BULB/REFLECTOR REPLACEMENT
NOTE
RT 240V1R, RT 240V2 and RT 240V3 blackout lights are replaced using the same procedure. 1. Loosen three screws (Figure 1, Item 4) and remove bulb/reflector assembly (Figure 1, Item 1) with ring (Figure 1, Item 2) from blackout light housing (Figure 1, Item 3).
1 2
3 4
M0187JCH
Figure 1. Bulb/Reflector Replacement. 2. 3. 4. 5. Disconnect terminal plug (Figure 2, Item 3) and connector (Figure 2, Item 4) from inside blackout light housing (Figure 2, Item 2). Remove two spring clips (Figure 2, Item 6) and remove bulb/reflector assembly (Figure 2, Item 5) from ring (Figure 2, Item 1). Install new bulb/reflector assembly (Figure 2, Item 5) on ring (Figure 2, Item 1) and install two spring clips (Figure 2, Item 6). Connect connector (Figure 2, Item 4) and terminal plug (Figure 2, Item 3) inside blackout light housing (Figure 2, Item 2).
0111-2
TM 10-3930-675-23-1
0111
BULB/REFLECTOR REPLACEMENT - Continued

1 2 3 4
M0188JCH
Figure 2. 6.
Bulb/Reflector Replacement.
Install bulb/reflector assembly (Figure 3, Item 1) with ring (Figure 3, Item 2) in blackout light housing (Figure 3, Item 3) and tighten three screws (Figure 3, Item 4).
1 2
3 4
M0189JCH
Bulb/Reflector Replacement.
0111-3
TM 10-3930-675-23-1
0111
BLACKOUT LIGHT REMOVAL
NOTE
Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1. 2. At rear of bracket (Figure 4, Item 1), disconnect connector (Figure 4, Item 3) of wiring harness from rear of blackout light (Figure 4, Item 2). Remove nut (Figure 4, Item 4), washer (Figure 4, Item 5), and blackout light (Figure 4, Item 2) from bracket (Figure 4, Item 1).
END OF TASK BLACKOUT LIGHT INSTALLATION 1. Install blackout light (Figure 4, Item 2) on bracket (Figure 4, Item 1) with washer (Figure 4, Item 5) and nut (Figure 4, Item 4).
NOTE
Apply electrically conductive grease to connector before connection is made. 2. At rear of bracket (Figure 4, Item 1), connect connector (Figure 4, Item 3) of wiring harness to rear of blackout light (Figure 4, Item 2).
0111-4
TM 10-3930-675-23-1
0111
BLACKOUT LIGHT INSTALLATION - Continued
4,5
M0190JCH
Blackout Light Replacement.
0111-5/6 blank
TM 10-3930-675-23-1
0112
FIELD MAINTENANCE DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Materials/Parts (cont.) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 86) Qty: 2 Washer, Lock (Volume 2, WP 0278, Table 1, Item 105) Qty: 2 References Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0112-1
TM 10-3930-675-23-1
0112
DIRECTIONAL LIGHT BULB AND LED REPLACEMENT 1. Loosen five screws (Figure 1, Item 1) and remove lens assembly (Figure 1, Item 2) from light housing (Figure 1, Item 3).
1 2 3
M0181JCH
Figure 1. 2. 3. 4. 5. 6. 7.
Lens Removal.
Remove two bulbs (Figure 2, Items 1 and 2) from lamp holder (Figure 2, Item 3) To remove Light Emitting Diode (LED) (Figure 2, Item 4), pull outward on LED panel until panel just separates from black plastic section of connector. Grasp black plastic and push in and rotate connector slightly counterclockwise and remove LED (Figure 2, Item 4) from socket. To install LED (Figure 2, Item 4), grasp black plastic section of connector and insert connector into socket. Push in and rotate slightly clockwise. Push LED (Figure 2, Item 4) panel over black plastic until fully seated. Install two new bulbs (Figure 2, Items 1 and 2) in lamp holder (Figure 2, Item 3).
0112-2
TM 10-3930-675-23-1
0112
DIRECTIONAL LIGHT BULB AND LED REPLACEMENT - Continued

1 2 3
M0182JCH
Figure 2. 8.
Bulb and LED Replacement.
Install lens assembly (Figure 3, Item 2) on light housing (Figure 3, Item 3) and tighten five screws (Figure 3, Item 1).
1 2 3
M0183JCH
Lens Installation.
0112-3
TM 10-3930-675-23-1
0112
DIRECTIONAL LIGHT REMOVAL
NOTE
Front and rear directional lights are removed the same way. Use marker tags to ensure proper connection of connectors. Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1. 2. 3. Remove directional light bulbs and LED(s) (refer to Directional Light Bulb and LED Replacement in this work package). Disconnect two connectors (Figure 4, Item 6) of directional light (Figure 4, Item 1) from connectors of wiring harness (Figure 4, Item 5). Remove two screws (Figure 4, Item 7), ground terminals (Figure 4, Item 2) of wiring harness (Figure 4, Item 5), washers (Figure 4, Item 3), and directional light (Figure 4, Item 1) from bracket (Figure 4, Item 4).
END OF TASK DIRECTIONAL LIGHT INSTALLATION
NOTE
Front and rear directional lights are installed the same way. 1. 2. 3. Install directional light (Figure 4, Item 1) and ground terminals (Figure 4, Item 2) of wiring harness (Figure 4, Item 5) on bracket (Figure 4, Item 4) with two washers (Figure 4, Item 3) and screws (Figure 4, Item 7). Connect two connectors (Figure 4, Item 6) of directional light (Figure 4, Item 1) to connectors of wiring harness (Figure 4, Item 5). Install bulbs and LED(s) (refer to Directional Light Bulb and LED Replacement in this work package).
0112-4
TM 10-3930-675-23-1
0112
DIRECTIONAL LIGHT INSTALLATION - Continued

1 2, 3 4 5
M0184JCH
Directional Light Replacement.
0112-5
TM 10-3930-675-23-1
0112
SIDE MARKER LIGHT BULB REPLACEMENT 1. Pry cover (Figure 5, Item 2) of side marker light from lamp housing (Figure 5, Item 1).
1 2
M0185JCH
Figure 5. Side Marker Light Cover Removal. 2. 3. 4. Remove bulb (Figure 6, Item 4) from lamp housing (Figure 6, Item 1). Install new bulb (Figure 6, Item 4) in lamp housing (Figure 6, Item 1). Install cover (Figure 5, Item 2) on lamp housing (Figure 5, Item 1).
END OF TASK SIDE MARKER LIGHT REMOVAL
NOTE
Front and rear side marker lights are removed the same way. 1. 2. Remove side marker light bulb (refer to Side Marker Light Bulb Replacement in this work package). Remove two locknuts (Figure 6, Item 6), washers (Figure 6, Item 7), screws (Figure 6, Item 8), white wire terminal (Figure 6, Item 5), and lamp housing (Figure 6, Item 1) from bracket (Figure 4, Item 4). Discard locknuts. Remove black wire terminal (Figure 6, Item 3) from lamp housing (Figure 6, Item 1).
3.
END OF TASK
0112-6
TM 10-3930-675-23-1
0112
SIDE MARKER LIGHT INSTALLATION
NOTE
Front and rear side marker lights are installed the same way. 1. 2. 3. Install black wire terminal (Figure 6, Item 3) on lamp housing (Figure 6, Item 1). Install lamp housing (Figure 6, Item 1) and white wire terminal (Figure 6, Item 5) on bracket (Figure 6, Item 2) with two screws (Figure 6, Item 8), washers (Figure 6, Item 7), and new locknuts (Figure 6, Item 6). Install side marker light bulb (refer to Side Marker Light Bulb Replacement in this work package).
1 2 3 4
6,7,8
M0186JCH
Bulb Replacement.
Turn master battery switch to ON position (TM 10-3930-675-10). Test light for operation (TM 10-3930-675-10).
0112-7/8 blank
TM 10-3930-675-23-1
0113
FIELD MAINTENANCE TWISTLOCK INDICATOR LIGHTS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 2 References Volume 2, WP 0267 Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0113-1
TM 10-3930-675-23-1
0113
WARNING
DO NOT look directly at IR source without proper eye protection and maintain a minimum distance of 12 in. from energized IR lights to prevent possible eye discomfort or damage.
NOTE
Electrical connectors of lights may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). TWISTLOCK INDICATOR LIGHT BULB REPLACEMENT
NOTE
Each of three twistlock indicator light bulbs is replaced the same way. 1. Remove two screws (Figure 1, Item 1) and lens (Figure 1, Item 2) from lamp housing (Figure 1, Item 3).
1 2
M0191JCH
Figure 1.
Twistlock Indicator Light Bulb Replacement.
0113-2
TM 10-3930-675-23-1
0113
TWISTLOCK INDICATOR LIGHT BULB REPLACEMENT - Continued 2. 3. 4. Remove bulb (Figure 2, Item 1) from lamp housing (Figure 2, Item 2). Install new bulb (Figure 2, Item 1) in lamp housing (Figure 2, Item 2). Install lens (Figure 1, Item 2) on lamp housing (Figure 1, Item 3) with two screws (Figure 1, Item 1).
1 2
M0192JCH
Twistlock Indicator Light Bulb Replacement.
0113-3
TM 10-3930-675-23-1
0113
TWISTLOCK INDICATOR LIGHT REMOVAL
NOTE
Each of three twistlock indicator lights is removed the same way. Top (red) indicator light is shown. 1. 2. Remove bulb from indicator light (refer to Twistlock Indicator Light Bulb Replacement in this work package). Disconnect connector (Figure 3, Item 4) and connector (Figure 3, Item 6) from lamp housing (Figure 3, Item 3).
NOTE
Cable clamp at rear of top (red) indicator light housing will also be removed as screws and locknuts are removed. 3. Remove two locknuts (Figure 3, Item 1), screws (Figure 3, Item 2), and lamp housing (Figure 3, Item 3) from light bracket (Figure 3, Item 5). Discard locknuts.
1,2 3
M0193JCH
Twistlock Indicator Light Removal.
0113-4
TM 10-3930-675-23-1
0113
TWISTLOCK INDICATOR LIGHT INSTALLATION
CAUTION
For proper operation of twistlock indicator light, bend two metal tabs at lamp housing mounting screws 180 degrees to prevent grounding lamp housing to light bracket.
NOTE
Cable clamp at rear of top (red) indicator light housing will also be installed as screws and new locknuts are installed. 1. 2. 3. Install lamp housing (Figure 4, Item 4) on light bracket (Figure 4, Item 6) with two screws (Figure 4, Item 3) and new locknuts (Figure 4, Item 2). Connect connector (Figure 4, Item 5) and connector (Figure 4, Item 1) to lamp housing (Figure 4, Item 4). Install bulb on indicator light (refer to Twistlock Indicator Light Bulb Replacement in this work package).
2,3
M0194JCH
Twistlock Indicator Light Installation.
0113-5
TM 10-3930-675-23-1
0113
TWISTLOCK INFRARED (IR) LIGHT REMOVAL
NOTE
If one IR light needs replacing, all six IR lights MUST be replaced. Remove tiedown straps as required and discard. 1. 2. Loosen nut (Figure 5, Item 2) and remove IR light (Figure 5, Item 1) from IR light bracket (Figure 5, Item 6). Repeat step 1 for five remaining IR lights (Figure 5, Item 1).
NOTE
Refer to wiring diagrams for assistance (Volume 2, WP 0272). 3. Trace wiring harness (Figure 5, Item 3) for IR lights (Figure 5, Item 1) to tophandler junction box and disconnect wires of wiring harness. Remove wiring harness from tophandler junction box. Remove IR lights from vehicle.
END OF TASK TWISTLOCK INFRARED (IR) LIGHT INSTALLATION 1. Position IR lights (Figure 5, Item 4) on IR light bracket (Figure 5, Item 6) and tighten nuts (Figure 5, Item 5).
NOTE
Refer to wiring diagrams for assistance (Volume 2, WP 0272). 2. 3. Position wiring harness (Figure 5, Item 3) for IR lights (Figure 5, Item 4) at tophandler junction box and connect wires of wiring harness. Install new tiedown straps as required.
0113-6
TM 10-3930-675-23-1
0113
TWISTLOCK INFRARED (IR) LIGHT INSTALLATION - Continued

1,2
1,2
3 4,5
M0195JCH
Twistlock Infrared (IR) Light Replacement.
0113-7/8 blank
TM 10-3930-675-23-1
0114
FIELD MAINTENANCE CAB INTERIOR LIGHT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
BULB REPLACEMENT 1. Remove interior light (Figure 1, Item 1) from cab.

1
M0196JCH
Figure 1.
Cab Interior Light Bulb Removal.
0114-1
TM 10-3930-675-23-1
0114
BULB REPLACEMENT - Continued 2. 3. 4. Remove two bulbs (Figure 2, Item 2) from interior light (Figure 2, Item 1). Install two bulbs (Figure 2, Item 2) in interior light (Figure 2, Item 1). Install interior light (Figure 1, Item 1) in cab.
END OF TASK CAB INTERIOR LIGHT REMOVAL 1. Remove interior light and two bulbs from cab (refer to Bulb Replacement in this work package).
NOTE
Tag wires prior to disconnection to ensure proper connection on installation. 2. Disconnect two wiring harness connectors (Figure 2, Item 3) from interior light (Figure 2, Item 1) and remove light.
END OF TASK CAB INTERIOR LIGHT INSTALLATION 1. 2. Connect two wiring harness connectors (Figure 2, Item 3) to interior light (Figure 2, Item 1). Install two bulbs and interior light in cab (refer to Bulb Replacement in this work package).
0114-2
TM 10-3930-675-23-1
0114
CAB INTERIOR LIGHT INSTALLATION - Continued

2
M0197JCH
Cab Interior Light Bulb Installation.
Turn master battery switch to ON position (TM 10-3930-675-10). Check operation of light (TM 10-3930-675-10).
0114-3/4 blank
TM 10-3930-675-23-1
0115
FIELD MAINTENANCE INFRARED (IR) LIGHTS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) References WP 0113 Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
WARNING
DO NOT look directly at IR source without proper eye protection and maintain a minimum distance of 12 in. from energized IR lights to prevent possible eye discomfort or damage.
NOTE
Twistlock indicator infrared (IR) lights are replaced in Twistlock Indicator Lights Maintenance (WP 0113). IR lights at front and rear of vehicle and on each side of boom are replaced the same way. Electrical connectors may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267).
0115-1
TM 10-3930-675-23-1
0115
REMOVAL 1. 2. Disconnect connector (Figure 1, Item 5) of IR light (Figure 1, Item 1) from connector (Figure 1, Item 4) of wiring harness. Remove locknut (Figure 1, Item 2) and washer (Figure 1, Item 3) from rear of IR light (Figure 1, Item 1). Discard locknut.
1 2,3
M0198JCH
Figure 1. Infrared (IR) Light Removal.
0115-2
TM 10-3930-675-23-1
0115
REMOVAL - Continued 3. Remove IR light (Figure 2, Item 1) from bracket (Figure 2, Item 2).
END OF TASK INSTALLATION 1. 2. 3. Position IR light (Figure 2, Item 1) on bracket (Figure 2, Item 2). Install washer (Figure 1, Item 3) and new locknut (Figure 1, Item 2) on rear of IR light (Figure 1, Item 1). Connect connector (Figure 1, Item 5) of IR light (Figure 1, Item 1) to connector (Figure 1, Item 4) of wiring harness.
1 2
M0199JCH
Infrared (IR) Light Installation.
0115-3
TM 10-3930-675-23-1
0115
FOLLOW-ON MAINTENANCE 1. 2. Turn master battery switch to ON position (TM 10-3930-675-10). Check infrared lights for proper operation (TM 10-3930-675-10).
0115-4
TM 10-3930-675-23-1
0116
FIELD MAINTENANCE FORDING WATER LEVEL SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 87) Qty: 2 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Radiator splash shield removed (WP 0084)
REMOVAL 1. 2. 3. Disconnect sensor connector (Figure 1, Item 9) from wiring harness connector (Figure 1, Item 10). Remove screw (Figure 1, Item 5), washer (Figure 1, Item 6), and clamp (Figure 1, Item 7) from fan shroud (Figure 1, Item 8) and sensor cable (Figure 1, Item 11). Remove two locknuts (Figure 1, Item 2), washers (Figure 1, Item 3), and screws (Figure 1, Item 4), and remove clamp (Figure 1, Item 1) and sensor (Figure 1, Item 12) from fan shroud (Figure 1, Item 8). Discard locknuts.
2,3,4 5,6 7 8 9 10
12
FORWARD
11
M0200JCH
Water Level Sensor Removal.
0116-1
TM 10-3930-675-23-1
0116
INSTALLATION 1. 2. 3. Install sensor (Figure 2, Item 12) on fan shroud (Figure 2, Item 8) with clamp (Figure 2, Item 1), two screws (Figure 2, Item 4), washers (Figure 2, Item 3), and new locknuts (Figure 2, Item 2). Connect sensor connector (Figure 2, Item 9) to wiring harness connector (Figure 2, Item 10). Secure sensor cable (Figure 2, Item 11) to fan shroud (Figure 2, Item 8) with clamp (Figure 2, Item 7), washer (Figure 2, Item 6), and screw (Figure 2, Item 5).
2,3,4 5,6 7 8 9 10
12
FORWARD
11
M0201JCH
Figure 2. Water Level Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE Install radiator splash shield (WP 0084). END OF TASK END OF WORK PACKAGE
0116-2
TM 10-3930-675-23-1
0117
FIELD MAINTENANCE WHEEL TEMPERATURE SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Attachment Set, Torx (Volume 2, WP 0277, Table 1, Item 65) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
NOTE
Each of two wheel temperature sensors (left front and left rear) is replaced the same way on RT 240V1, RT 240V1R, and RT 240V2.
0117-1
TM 10-3930-675-23-1
0117
REMOVAL 1. 2. Disconnect connector (Figure 1, Item 4) of wheel temperature sensor (Figure 1, Item 2) from connector (Figure 1, Item 5) of vehicle wiring harness. Remove wheel temperature sensor (Figure 1, Item 2) and copper washer from adapter (Figure 1, Item 1) of brake housing (Figure 1, Item 3).
END OF TASK INSTALLATION 1. 2. Install copper washer and wheel temperature sensor (Figure 1, Item 2) on adapter (Figure 1, Item 1) of brake housing (Figure 1, Item 3). Connect connector (Figure 1, Item 5) of vehicle wiring harness to connector (Figure 1, Item 4) of wheel temperature sensor (Figure 1, Item 2).
4 3 2 5
M0204JCH
Figure 1. Wheel Temperature Sensor Replacement. END OF TASK END OF WORK PACKAGE
0117-2
TM 10-3930-675-23-1
0118
FIELD MAINTENANCE ENGINE SENSORS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Installation Tool, ESP (Volume 2, WP 0277, Table 1, Item 41) Socket, Socket Wrench, 1/2" DR, 6PT, Long, 1-1/4" (Volume 2, WP 0277, Table 1, Item 73) Wrench, Torque, Dial, 3/8" Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Oil, Lubricating, 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 28) Qty: 2 O-Ring (Volume 2, WP 0278, Table 1, Item 30) O-Ring (Volume 2, WP 0278, Table 1, Item 45) Qty: 2 References WP 0080 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185)
NOTE
Tag wiring harness leads to ensure correct installation. Use electrically conductive grease on all electrical connections before they are made.
0118-1
TM 10-3930-675-23-1
0118
COOLANT TEMPERATURE SENSOR REMOVAL
WARNING
DO NOT perform maintenance on cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam, hot water or coolant will cause serious burns. 1. 2. 3. Drain cooling system (WP 0080). Disconnect connector (Figure 1, Item 3) of engine wiring harness (Figure 1, Item 2) from coolant temperature sensor (Figure 1, Item 4). Remove coolant temperature sensor (Figure 1, Item 4) with O-ring seal (Figure 1, Item 5) from engine (Figure 1, Item 1). Discard O-ring seal.
END OF TASK COOLANT TEMPERATURE SENSOR INSTALLATION
NOTE
Ensure new sensor has O-ring seal installed. 1. 2. Apply a light coat of lubricating oil to new O-ring seal (Figure 1, Item 5). Install O-ring seal (Figure 1, Item 5) and coolant temperature sensor (Figure 1, Item 4) on engine (Figure 1, Item 1). Tighten sensor to 120 in-lb (14 Nm).
0118-2
TM 10-3930-675-23-1
0118
COOLANT TEMPERATURE SENSOR INSTALLATION - Continued
NOTE
Ensure locking tab on connector snaps in place. 3. 4. Connect connector (Figure 1, Item 3) of engine wiring harness (Figure 1, Item 2) to coolant temperature sensor (Figure 1, Item 4). Fill cooling system and check for leaks (WP 0080).
1 2
M0205JCH
Figure 1. Coolant Temperature Sensor Replacement. END OF TASK
0118-3
TM 10-3930-675-23-1
0118
ENGINE POSITION SENSOR REMOVAL 1. 2. Disconnect connector (Figure 2, Item 4) of engine position sensor (Figure 2, Item 3) from engine wiring harness connector (Figure 2, Item 5). Remove engine position sensor (Figure 2, Item 3) and O-ring seal (Figure 2, Item 2) from engine front cover (Figure 2, Item 1). Discard O-ring seal.
END OF TASK ENGINE POSITION SENSOR INSTALLATION
NOTE
Ensure engine position sensor is free of debris and is not chipped, cracked, or damaged. 1. 2. Install new O-ring seal (Figure 2, Item 2) on engine position sensor (Figure 2, Item 3). Install engine position sensor (Figure 2, Item 3) on engine front cover (Figure 2, Item 1). Tighten sensor to 216 in-lb (24 Nm).
NOTE
Ensure locking tab on connector snaps in place. 3. Connect engine wiring harness connector (Figure 2, Item 5) to connector (Figure 2, Item 4) of engine position sensor (Figure 2, Item 3).
1 2 3
M0206JCH
Engine Position Sensor Removal.
0118-4
TM 10-3930-675-23-1
0118
INTAKE AIR TEMPERATURE SENSOR REMOVAL 1. 2. Disconnect connector (Figure 3, Item 2) of engine wiring harness (Figure 3, Item 1) from intake air temperature sensor (Figure 3, Item 3). Remove intake air temperature sensor (Figure 3, Item 3) and O-ring seal (Figure 3, Item 4) from intake manifold (Figure 3, Item 5). Discard O-ring seal.
END OF TASK INTAKE AIR TEMPERATURE SENSOR INSTALLATION 1. 2. Install new O-ring seal (Figure 3, Item 4) on intake air temperature sensor (Figure 3, Item 3). Install intake air temperature sensor (Figure 3, Item 3) on intake manifold (Figure 3, Item 5). Tighten sensor to 120 in-lb (14 Nm).
NOTE
Ensure locking tab on connector snaps in place. 3. Connect connector (Figure 3, Item 2) of engine wiring harness (Figure 3, Item 1) to intake air temperature sensor (Figure 3, Item 3).
1 2
M0208JCH
Intake Air Temperature Sensor Replacement.
0118-5
TM 10-3930-675-23-1
0118
INTAKE MANIFOLD PRESSURE SENSOR REMOVAL 1. Disconnect connector (Figure 4, Item 2) of engine wiring harness (Figure 4, Item 1) from intake manifold (Figure 4, Item 3).
NOTE
Ensure a 1-1/4-in. deep well socket is used for removal and installation of intake manifold pressure sensor. 2. Remove intake manifold pressure sensor (Figure 4, Item 5) and O-ring seal (Figure 4, Item 4) from intake manifold (Figure 4, Item 3). Discard O-ring seal.
END OF TASK INTAKE MANIFOLD PRESSURE SENSOR INSTALLATION 1. 2. Install new O-ring seal (Figure 4, Item 4) on intake manifold pressure sensor (Figure 4, Item 5). Install intake manifold pressure sensor (Figure 4, Item 5) on intake manifold (Figure 4, Item 3). Tighten sensor to 120 in-lb (14 Nm).
NOTE
Ensure locking tab on connector snaps in place. 3. Connect connector (Figure 4, Item 2) of engine wiring harness (Figure 4, Item 1) to intake manifold pressure sensor (Figure 4, Item 5).
1 2
M0208JCH
Figure 4. Intake Manifold Pressure Sensor Replacement. END OF TASK
0118-6
TM 10-3930-675-23-1
0118
AMBIENT AIR PRESSURE SENSOR REMOVAL
NOTE
The ambient air pressure sensor is located on a bracket on the left side of the engine to the right-rear of the engine ECU. It is replaced in the same manner as the intake manifold pressure sensor. 1. 2. Disconnect connector of engine wiring harness (Figure 5, Item 1) from ambient air pressure sensor (Figure 5, Item 2). Remove ambient air pressure sensor (Figure 5, Item 2) from mounting bracket (Figure 5, Item 3).
END OF TASK AMBIENT AIR PRESSURE SENSOR INSTALLATION 1. Install ambient air pressure sensor (Figure 5, Item 2) on mounting bracket (Figure 5, Item 3). Tighten sensor to 120 in-lb (14 Nm).
NOTE
Ensure locking tab on connector snaps in place. 2. Connect connector of engine wiring harness (Figure 5, Item 1) to air pressure sensor (Figure 5, Item 2).
NOTE
RT 240V2 sensor does not have harness connector adapter. Sensor is connected to engine harness and attached to harness using tiedown straps.
1 2
M0209JCH
Figure 5. Ambient Air Pressure Sensor Replacement. END OF TASK
0118-7
TM 10-3930-675-23-1
0118
AMBIENT AIR PRESSURE SENSOR REMOVAL (NEW STYLE) 1. 2. Disconnect connector of engine wiring harness (Figure 6, Item 1) from ambient air pressure sensor (Figure 6, Item 2). Remove old style ambient air pressure sensor (Figure 6, Item 2) from mounting bracket (Figure 5, Item 3).
1 2
M0210JCH
Figure 6. Ambient Air Pressure Sensor Removal (New Style). END OF TASK
0118-8
TM 10-3930-675-23-1
0118
AMBIENT AIR PRESSURE SENSOR INSTALLATION (NEW STYLE) 1. Install new style ambient air pressure sensor (Figure 7, Item 3) on to harness connector adapter (Figure 7, Item 2).
NOTE
Ensure locking tab on connector snaps in place. RT 2402 sensor does not have harness connector adapter. Sensor is connected to engine harness and attached to harness using tiedown straps. 2. 3. Connect connector of engine wiring harness (Figure 7, Item 1) to sensor harness connector adapter (Figure 7, Item 2). Attach sensor and harness connector adapter to engine wiring harness using tiedown straps.
1 2 3
M0211JCH
Figure 7. Ambient Temperature Sensor Installation (New Style). END OF TASK
0118-9
TM 10-3930-675-23-1
0118
OIL PRESSURE/TEMPERATURE SENSOR REMOVAL 1. 2. Disconnect connector (Figure 8, Item 4) of engine wiring harness (Figure 8, Item 5) from oil pressure/ temperature sensor (Figure 8, Item 2). Remove oil pressure/temperature sensor (Figure 8, Item 2) and O-ring seal (Figure 8, Item 1) from engine (Figure 8, Item 3). Discard O-ring seal.
END OF TASK OIL PRESSURE/TEMPERATURE SENSOR INSTALLATION 1. 2. Install new O-ring seal (Figure 8, Item 1) on oil pressure/temperature sensor (Figure 8, Item 2). Install oil pressure/temperature sensor (Figure 8, Item 2) on engine (Figure 8, Item 3). Tighten sensor to 120 in-lb (14 Nm).
NOTE
Ensure locking tab on connector snaps in place. 3. Connect connector (Figure 8, Item 4) of engine wiring harness (Figure 8, Item 5) to sensor (Figure 8, Item 2).
1 2
M0212JCH
Oil Pressure/Temperature Sensor Replacement.
0118-10
TM 10-3930-675-23-1
0118
FOLLOW-On MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE
0118-11/12 blank
TM 10-3930-675-23-1
0119
FIELD MAINTENANCE HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Cab in transport position (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10) Transmission access cover(s) removed (Volume 2, WP 0175) Hydraulic system pressure relieved (Volume 2, WP 0204)
WARNING
DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing switches. Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
0119-1
TM 10-3930-675-23-1
0119
REMOVAL
NOTE
There are three filter indicator sensors located in filter heads of high-pressure hydraulic filters. Ease of access to remove these sensors varies. In some cases, it may be necessary to remove both filter and filter head to access sensor. Remove and discard tiedown straps. Tag wires to ensure correct installation. 1. 2. 3. 4. 5. Trace electrical cable (Figure 1, Item 3) from sensor (Figure 1, Item 10) located on filter head (Figure 1, Item 11) back to junction box (Figure 1, Item 12). Loosen four screws (Figure 1, Item 2) and remove cover (Figure 1, Item 1) from junction box (Figure 1, Item 12). Inspect rubber seal in groove of cover. Replace seal only if damaged. Loosen cable nut (Figure 1, Item 8) and slide cable nut and grommet (Figure 1, Item 7) back on cable (Figure 1, Item 9). Using a jewelers screwdriver, disconnect cable wires (Figure 1, Item 6) from terminal blocks (Figure 1, Item 5). Remove cable (Figure 1, Item 9) from junction box (Figure 1, Item 4). Remove sensor (Figure 1, Item 10) with cable (Figure 1, Item 3) from filter head (Figure 1, Item 11).
END OF TASK
0119-2
TM 10-3930-675-23-1
0119
INSTALLATION
NOTE
Use electrically conductive grease on wire connections before connections are made. Install new tiedown straps as necessary. 1. 2. 3. 4. 5.
1
Install sensor (Figure 1, Item 10) on filter head (Figure 1, Item 11). Feed cable (Figure 1, Item 6) through grommet (Figure 1, Item 7) and cable nut (Figure 1, Item 8) and into junction box (Figure 1, Item 1). Using a jewelers screwdriver, connect cable wires (Figure 1, Item 6) to terminal blocks (Figure 1, Item 5). Install grommet (Figure 1, Item 7) and cable nut (Figure 1, Item 8) on junction box (Figure 1, Item 4). Tighten cable nut. Install cover (Figure 1, Item 1) on junction box (Figure 1, Item 12) and tighten four screws (Figure 1, Item 2).
2 4 5
10
6 7
11
12
M1711JCH
Figure 1. Hydraulic Cylinder Filter Indicator Sensor Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install transmission access cover(s) (Volume 2, WP 0175). Return cab to operational position (TM 10-3930-675-10). Check hydraulic system for proper operation (TM 10-3930-675-10).
0119-3/4 blank
TM 10-3930-675-23-1
0120
FIELD MAINTENANCE TRANSMISSION SENSORS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8" Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 144) Qty: 3 O-Ring (Volume 2, WP 0278, Table 1, Item 147) Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 151) O-Ring (Volume 2, WP 0278, Table 1, Item 153) References Volume 2, WP 0136 Equipment Condition Cab in transport position (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10) Transmission access covers removed (Volume 2, WP 0175)
NOTE
Transmission has provisions for seven sensors: turbine speed, internal gear speed, engine speed, output speed, gearbox temperature, 2WD/4WD, and filter indicator sensor. Each sensor is replaced in the same manner. A locator diagram is provided to aid in locating each sensor. Procedures for gearbox temperature sensor are detailed as an example. Tag connectors to ensure correct connection on installation.
0120-1
TM 10-3930-675-23-1
0120
REMOVAL 1. Using locator diagram, locate sensor to be removed.

GEARBOX TEMPERATURE SENSOR GEARBOX CONNECTOR
FRONT ENGINE SPEED SENSOR
OUTPUT SPEED SENSOR 2WD/4WD VALVE
2WD/4WD DRIVE SENSOR
FILTER INDICATOR SENSOR
TURBINE SPEED SENSOR
INTERNAL GEAR SPEED SENSOR
RIGHT SIDE
LEFT SIDE
M0216JCH
Figure 1. Transmission Sensors. 2. Press in on connector retaining clip and disconnect electrical connector from sensor.
0120-2
TM 10-3930-675-23-1
0120
REMOVAL - Continued
CONNECTOR
SENSOR RETAINING CLIP

M0217JCH
Figure 2.
Transmission Sensor Connector.
CAUTION
Engine speed, internal gear speed, turbine speed, and output speed sensors are installed and positioned with spacers. Spacers are removed with their respective sensor and must be retained for installation. Failure to follow this caution may result in damage to equipment or improper sensor operation. 3. Remove sensor and O-ring from transmission. Discard O-ring.
SENSOR
O-RING
M0218JCH
Transmission Sensor Removal.
0120-3
TM 10-3930-675-23-1
0120
INSTALLATION
CAUTION
Spacers removed with sensors must be reinstalled with same sensor. If sensor is replaced, spacer must be replaced with the same type and quantity when installing sensor. Failure to follow this caution may result in damage to equipment or improper sensor operation.
NOTE
If reinstalling sensor, ensure new O-ring seal is used. If installing new sensor, ensure new O-ring provided is installed. 1. Install sensor with new O-ring in transmission. Tighten sensors as follows: a. b. Outspeed speed sensor: 204 in-lb (23 Nm). All other sensors: 265 in-lb (30 Nm).
SENSOR
O-RING
M0219JCH
Figure 4. Transmission Sensor Installation.
NOTE
Ensure connector and sensor key are aligned prior to connection. 2. Connect electrical connector to sensor.
0120-4
TM 10-3930-675-23-1
0120
CONNECTOR
SENSOR
M0220JCH
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Transmission Sensor Connector.
If any sensor except for gearbox temperature or filter indicator sensor was replaced, perform transmission calibration (Volume 2, WP 0136). Perform operational check (TM 10-3930-675-10). Install transmission access covers (Volume 2, WP 0175). Return cab to operational position (TM 10-3930-675-10).
0120-5/6 blank
TM 10-3930-675-23-1
0121
FIELD MAINTENANCE BOOM ANGLE SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References Volume 2, WP 0257 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0121-1
TM 10-3930-675-23-1
0121
REMOVAL 1. 2. 3. Remove two screws (Figure 1, Item 1), washers (Figure 1, Item 2), and boom angle sensor (Figure 1, Item 4) assembly from boom and bolt (Figure 1, Item 9). Loosen setscrew (Figure 1, Item 5) of lever (Figure 1, Item 8) and remove lever from boom angle sensor (Figure 1, Item 4). Remove three screws (Figure 1, Item 6), washers (Figure 1, Item 7), and bracket (Figure 1, Item 3) from boom angle sensor (Figure 1, Item 4).
1,2 3 4
6,7
M0227JCH
Figure 1. Boom Angle Sensor Removal.
0121-2
TM 10-3930-675-23-1
0121
REMOVAL - Continued 4. Loosen four screws (Figure 2, Item 2) and remove cover (Figure 2, Item 1) from junction box (Figure 2, Item 3), located on right side of boom. Inspect rubber seal in groove of cover. Replace seal only if damaged.
1 2 3
M0228JCH
Figure 2.
Boom Angle Sensor Removal.
0121-3
TM 10-3930-675-23-1
0121
REMOVAL - Continued 5. Loosen cable nut (Figure 3, Item 4) and slide cable nut, grommet (Figure 3, Item 5), and bushing (Figure 3, Item 6) back on cable (Figure 3, Item 3) of boom angle sensor (Figure 4, Item 4).
CAUTION
To avoid damage to junction box, a fine-tipped jewelers screwdriver should be used when disconnecting wires. DO NOT use a punch.
NOTE
Tag wires for installation. 6. Using a jewelers screwdriver, disconnect three wires of cable (Figure 3, Item 3) from terminal blocks (Figure 3, Item 1) of junction box (Figure 3, Item 2).
NOTE
Remove tiedown straps as needed. Discard tiedown straps. 7. Remove boom angle sensor (Figure 4, Item 4) with cable (Figure 3, Item 3) from vehicle.
1 2
M0229JCH
Figure 3. Boom Angle Sensor Removal END OF TASK
0121-4
TM 10-3930-675-23-1
0121
INSTALLATION 1. 2. 3. 4. Position boom angle sensor (Figure 4, Item 4) with cable (Figure 3, Item 3) on vehicle. Using a jewelers screwdriver, connect three wires of cable (Figure 3, Item 3) to terminal blocks (Figure 3, Item 1) of junction box (Figure 3, Item 2). Install bushing (Figure 3, Item 6), grommet (Figure 3, Item 5), and cable nut (Figure 3, Item 4) on junction box (Figure 3, Item 2). Install cover (Figure 2, Item 1) on junction box (Figure 2, Item 3) and tighten four screws (Figure 2, Item 2).
NOTE
Position angle sensor wire and nut between six and nine oclock position. 5. 6. 7. 8. Install boom angle sensor (Figure 4, Item 4) on bracket (Figure 4, Item 3) with three washers (Figure 4, Item 7) and screws (Figure 4, Item 6). Install lever (Figure 4, Item 8) on boom angle sensor (Figure 4, Item 4) and tighten setscrew (Figure 4, Item 5). Position boom angle sensor (Figure 4, Item 4) assembly on bolt (Figure 4, Item 9) and boom and install two washers (Figure 4, Item 2) and screws (Figure 4, Item 1). Tighten screws. Install new tiedown straps.
1,2 3
6,7
8
M0230JCH
Boom Angle Sensor Installation.
0121-5
TM 10-3930-675-23-1
0121
FOLLOW-ON MAINTENANCE Perform boom and tophandler calibration (Volume 2, WP 0257). END OF TASK END OF WORK PACKAGE
0121-6
TM 10-3930-675-23-1
0122
FIELD MAINTENANCE BOOM EXTENSION SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) References Volume 2, WP 0257 Equipment Condition Boom fully retracted (TM 10-3930-675-10) Master battery switch in OFF position (TM 103930-675-10)
REMOVAL 1. Remove two screws (Figure 1, Item 2), washers (Figure 1, Item 3), and cover plate (Figure 1, Item 1) from rear of boom (Figure 1, Item 4).
1
2,3
M0231JCH
Figure 1.
Boom Extension Sensor Removal.
0122-1
TM 10-3930-675-23-1
0122
REMOVAL - Continued 2. Open cable connector (Figure 2, Item 2) and remove cable connector to disconnect ring of cable (Figure 2, Item 1) from rear of extension boom (Figure 2, Item 3).
1 2 3
M0232JCH
Figure 2. Boom Extension Sensor Removal. 3. 4. 5. While holding ring of cable (Figure 2, Item 1), allow cable to retract into boom extension sensor (Figure 3, Item 2). Disconnect connector (Figure 3, Item 1) of wiring harness from boom extension sensor (Figure 3, Item 2). Remove two screws (Figure 3, Item 3), washers (Figure 3, Item 4), and boom extension sensor (Figure 3, Item 2) from boom (Figure 3, Item 5).
END OF TASK
0122-2
TM 10-3930-675-23-1
0122
INSTALLATION 1. 2. 3. 4. Install boom extension sensor (Figure 3, Item 2) on boom (Figure 3, Item 5) with two washers (Figure 3, Item 4) and screws (Figure 3, Item 3). Connect connector (Figure 3, Item 1) of wiring harness to boom extension sensor (Figure 3, Item 2). Extend ring of cable (Figure 2, Item 1) from boom extension sensor (Figure 3, Item 2). Install ring of cable (Figure 2, Item 1) on rear of extension boom (Figure 2, Item 3) with cable connector (Figure 2, Item 2). Close cable connector.
1 2 3,4 5
M0233JCH
Figure 3.
Boom Extension Sensor Removal.
0122-3
TM 10-3930-675-23-1
0122
INSTALLATION - Continued 5. Install cover plate (Figure 4, Item 1) on rear of boom (Figure 4, Item 4) with two washers (Figure 4, Item 3) and screws (Figure 4, Item 2).
1
2,3
M0234JCH
Figure 4. Boom Extension Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE Perform boom and tophandler calibration (Volume 2, WP 0257). END OF TASK END OF WORK PACKAGE
0122-4
TM 10-3930-675-23-1
0123
FIELD MAINTENANCE TOPHANDLER ANGLE SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References Volume 2, WP 0257 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0123-1
TM 10-3930-675-23-1
0123
REMOVAL
NOTE
If removing tophandler, perform Step 1 only. 1. Remove two screws (Figure 1, Item 1), washers (Figure 1, Item 2), and tophandler angle sensor (Figure 1, Item 4) assembly from boom extension and bolt (Figure 1, Item 3).
1,2
M0235JCH
Figure 1. Tophandler Angle Sensor Removal.
0123-2
TM 10-3930-675-23-1
0123
REMOVAL - Continued 2. 3. Loosen setscrew (Figure 2, Item 3) of lever (Figure 2, Item 5) and remove lever from tophandler angle sensor (Figure 2, Item 6). Remove three screws (Figure 2, Item 1), washers (Figure 2, Item 2), and bracket (Figure 2, Item 4) from tophandler angle sensor (Figure 2, Item 6).
3 4
1,2
M0236JCH
Figure 2.
Tophandler Angle Sensor Removal.
0123-3
TM 10-3930-675-23-1
0123
REMOVAL - Continued 4. 5. 6. Remove three screws (Figure 3, Item 7), washers (Figure 3, Item 8), cable (Figure 3, Item 6), and three cable clamps (Figure 3, Item 9) from boom extension. Loosen cable nut (Figure 3, Item 5) and slide cable nut and grommet (Figure 3, Item 4) back on cable (Figure 3, Item 6) of tophandler angle sensor (Figure 2, Item 6). Loosen six screws (Figure 3, Item 1) and remove cover (Figure 3, Item 2) from tophandler junction box (Figure 3, Item 3). Inspect rubber seal in groove of cover. Replace seal only if damaged.
2 1 3 4 5
7,8,9
M0237JCH
Figure 3. Tophandler Angle Sensor Removal.
0123-4
TM 10-3930-675-23-1
0123
REMOVAL - Continued 7. Remove plastic covers (Figure 4, Item 4) to expose cable (Figure 4, Item 1) of tophandler angle sensor (Figure 2, Item 6).
NOTE
Tag wires for installation. 8. 9. Using a jewelers screwdriver, disconnect three wires of cable (Figure 4, Item 1) from terminal block (Figure 4, Item 2) in tophandler junction box (Figure 4, Item 3). Remove tophandler angle sensor (Figure 2, Item 6) with cable (Figure 4, Item 1) from vehicle.
2 1 3
1
M0238JCH
Tophandler Angle Sensor Removal.
0123-5
TM 10-3930-675-23-1
0123
INSTALLATION 1. 2. 3. Position tophandler angle sensor (Figure 2, Item 6) with cable (Figure 5, Item 1) on vehicle. Using a jewelers screwdriver, connect three wires of cable (Figure 5, Item 1) to terminal block (Figure 5, Item 2) in tophandler junction box (Figure 5, Item 3). Install plastic covers (Figure 5, Item 4) over excess cable (Figure 5, Item 1) of tophandler angle sensor (Figure 2, Item 6).
2 1 3
1
M0239JCH
Figure 5.
Tophandler Angle Sensor Installation.
0123-6
TM 10-3930-675-23-1
0123
INSTALLATION - Continued 4. 5. 6. Install cover (Figure 6, Item 2) on tophandler junction box (Figure 6, Item 3) and tighten six screws (Figure 6, Item 1). Install grommet (Figure 6, Item 4) and tighten cable nut (Figure 6, Item 5). Install cable (Figure 6, Item 6) on boom extension with three cable clamps (Figure 6, Item 9), washers (Figure 6, Item 8), and screws (Figure 6, Item 7).
2 1 3 4 5
7,8,9
M0240JCH
Figure 6.
0123-7
TM 10-3930-675-23-1
0123
NOTE
Position angle sensor wire and nut between three and six oclock position. 7. 8. Install tophandler angle sensor (Figure 7, Item 6) on bracket (Figure 7, Item 4) with three washers (Figure 7, Item 2) and screws (Figure 7, Item 1). Install lever (Figure 7, Item 5) on tophandler angle sensor (Figure 7, Item 6) and tighten setscrew (Figure 7, Item 3).
3 4
1,2
M0241JCH
Figure 7.
0123-8
TM 10-3930-675-23-1
0123
INSTALLATION - Continued 9. Position tophandler angle sensor (Figure 8, Item 4) assembly on bolt (Figure 8, Item 3) and boom extension and install two washers (Figure 8, Item 2) and screws (Figure 8, Item 1). Tighten screws.
1,2
M0242JCH
Perform boom and tophandler calibration (Volume 2, WP 0257). END OF TASK END OF WORK PACKAGE
0123-9/10 blank
TM 10-3930-675-23-1
0124
FIELD MAINTENANCE HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8" Drive,75 ftlb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Cap Set, Protective Dust and Moisture Seal (Volume 2, WP 0276, Table 1, Item 9) Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Lubricating, Oil, OE/HDO 10 (Volume 2, WP 0276, Table 1, Item 45) Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) References Volume 2, WP 0242 Volume 2, WP 0257 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Hydraulic system pressure relieved (Volume 2, WP 0204)
WARNING
DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing switches. Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.
0124-1
TM 10-3930-675-23-1
0124
NOTE
Remove and discard tiedown straps. Apply electrically conductive grease to connectors before connections are made. New o-rings and gaskets are included with new sensors. TEMPERATURE SENSOR REPLACEMENT 1. 2. 3. Drain hydraulic reservoir (Volume 2, WP 0242). Disconnect connector (Figure 1, Item 2) of temperature sensor (Figure 1, Item 4) from wiring harness (Figure 1, Item 1). Remove temperature sensor (Figure 1, Item 4) and copper washer (Figure 1, Item 5) from hydraulic reservoir (Figure 1, Item 3).
1
M0243JCH
4,5
Figure 1. Temperature Sensor Replacement. 4. 5. Install copper washer (Figure 1, Item 5) and hydraulic temperature sensor (Figure 1, Item 4) on hydraulic reservoir (Figure 1, Item 3). Connect connector (Figure 1, Item 2) of temperature sensor (Figure 1, Item 4) to wiring harness (Figure 1, Item 1).
END OF TASK
0124-2
TM 10-3930-675-23-1
0124
PRESSURE SENSOR REPLACEMENT 1. 2. 3. Remove four socket head screws (Figure 2, Item 3) from flange (Figure 2, Item 4). Remove flange (Figure 2, Item 4), sensor (Figure 2, Item 2), and O-ring (Figure 2, Item 5) from hydraulic reservoir (Figure 2, Item 1). Discard O-ring. Trace sensor cable (Figure 2, Item 6) back to junction box. Disconnect wires of cable from terminal blocks. Remove cable from junction box.
NOTE
Replacement sensor comes with new O-ring. 4. Lubricate new O-ring (Figure 2, Item 5) with lubricating oil. Install O-ring and sensor (Figure 2, Item 2) on hydraulic reservoir (Figure 2, Item 1) with flange (Figure 2, Item 4) and four socket head screws (Figure 2, Item 3). Position sensor cable (Figure 2, Item 6) in junction box. Connect wires of sensor cable to terminal blocks in junction box. Secure sensor cable (Figure 2, Item 6) with new tiedown straps.
1 2 3
5. 6.
4,5
M0244JCH
Pressure Sensor Replacement.
0124-3
TM 10-3930-675-23-1
0124
LIFT CYLINDER SENSOR REPLACEMENT 1. 2. Disconnect electrical connector (Figure 3, Item 1) from sensor (Figure 3, Item 2). Remove sensor (Figure 3, Item 2) and O-ring from locking valve (Figure 3, Item 4) at base of lift cylinder (Figure 3, Item 3). Discard O-ring.
NOTE
Replacement sensor comes with new O-ring. 3. 4. Lubricate new O-ring with lubricating oil. Install O-ring and sensor (Figure 3, Item 2) to locking valve (Figure 3, Item 4). Tighten sensor to 35 ft-lb (47 Nm). Connect electrical connector (Figure 3, Item 1) to sensor (Figure 3, Item 2).
1
M0245JCH
Lift Cylinder Sensor Replacement.
Fill hydraulic reservoir (Volume 2, WP 0242). Calibrate boom and tophandler (Volume 2, WP 0257).
0124-4
TM 10-3930-675-23-1
0125
FIELD MAINTENANCE STEERING SYSTEM WHEEL SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 87) Qty: 3 References Volume 2, WP 0174 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering hydraulic system pressure relieved (Volume 2, WP 0204) Engine cover removed (to replace front wheel sensors) (Volume 2, WP 0185)
WARNING
Do not stand between wheel and frame if engine is running or steering system pressure has not been relieved. Failure to follow this warning may result in injury or death to personnel.
NOTE
Four steering system wheel sensors are replaced the same way. Left front sensor is shown.
0125-1
TM 10-3930-675-23-1
0125
REMOVAL
NOTE
Remove and discard tiedown straps as needed. 1. 2. 3. Remove screw (Figure 1, Item 12), washer (Figure 1, Item 13), and clamp (Figure 1, Item 14). Remove two screws (Figure 1, Item 9) and washers (Figure 1, Item 10) to loosen bracket (Figure 1, Item 1) from axle. Remove two screws (Figure 1, Item 6) and washers (Figure 1, Item 7) from sensor mounting flange (Figure 1, Item 8).
NOTE
Note position of sensor assembly on bracket for installation. 4. 5. Remove three locknuts (Figure 1, Item 2), six washers (Figure 1, Item 3), three screws (Figure 1, Item 4), and sensor (Figure 1, Item 5) assembly from bracket (Figure 1, Item 1). Discard locknuts. Remove protective covering (Figure 1, Item 11) from cable (Figure 1, Item 15) of sensor (Figure 1, Item 5).
1 2,3,4 5
6,7 15 12,13,14 11
9,10
M0248JCH
Figure 1.
Steering System Wheel Sensor Removal.
0125-2
TM 10-3930-675-23-1
0125
REMOVAL - Continued 6. Loosen four screws (Figure 2, Item 1) and remove cover (Figure 2, Item 2) from front (or rear) junction box (Figure 2, Item 3).
1 2 3
M0249JCH
Figure 2.
0125-3
TM 10-3930-675-23-1
0125
REMOVAL - Continued
NOTE
Tag wires for installation. 7. 8. 9. Using a jewelers screwdriver, disconnect seven wires of cable (Figure 3, Item 3) from terminal blocks (Figure 3, Item 1) in junction box (Figure 3, Item 2). Loosen cable nut (Figure 3, Item 4) and slide cable nut and grommet (Figure 3, Item 5) back on cable (Figure 3, Item 3). Remove cable (Figure 3, Item 3) from junction box (Figure 3, Item 2).
NOTE
Before removing, string may be tied to end of sensor cable to aid in installation. 10. Remove sensor (Figure 1, Item 5) assembly with cable (Figure 1, Item 15) from vehicle.
1 2
M0250JCH
0125-4
TM 10-3930-675-23-1
0125
INSTALLATION 1. 2. 3. Position cable (Figure 4, Item 3) with sensor assembly in vehicle. Position cable (Figure 4, Item 3) in junction box (Figure 4, Item 2). Install grommet (Figure 4, Item 5) and cable nut (Figure 4, Item 4) in junction box (Figure 4, Item 2).
NOTE
Use electrically conductive grease on wire connections before connections are made. 4. Connect seven wires of cable (Figure 4, Item 3) to terminal blocks (Figure 4, Item 1) in junction box (Figure 4, Item 2) as follows:
1 2
M0251JCH
Figure 4. Steering System Wheel Sensor Installation.
0125-5
TM 10-3930-675-23-1
0125
Table 1.
Rear Junction Box X167 Wire Connections. RIGHT-REAR SENSOR Black No. 1 across from Gray Black No. 2 across from Black Black No. 3 across from Red Black No. 4 across from Blue Black No. 5 across from Yellow Yellow/Green across from Green Silver to Silver
LEFT-REAR SENSOR Black No. 1 across from Brown Black No. 2 across from White Black No. 3 across from Violet Black No. 4 across from Orange Black No. 5 across from White/Black Yellow/Green across from White/Red Silver to Ground Terminal
Table 2.
Front Junction Box X192 Wire Connections. RIGHT-FRONT SENSOR Black No. 1 across from Gray Black No. 2 across from Black Black No. 3 across from Red Black No. 4 across from Blue Black No. 5 across from Yellow Yellow/Green across from Green Silver to Silver
LEFT-FRONT SENSOR Black No. 1 across from Brown Black No. 2 across from White Black No. 3 across from Violet Black No. 4 across from Orange Black No. 5 across from White/Black Yellow/Green across from White/Red Silver to Ground Terminal
0125-6
TM 10-3930-675-23-1
0125
INSTALLATION - Continued 5. Install cover (Figure 5, Item 2) on front (or rear) junction box (Figure 5, Item 3) and tighten four screws (Figure 5, Item 1).
1 2 3
M0252JCH
Figure 5. Steering System Wheel Sensor Installation.
0125-7
TM 10-3930-675-23-1
0125
INSTALLATION - Continued 6. 7. 8. 9. 10. 11. Install protective covering (Figure 6, Item 11) on cable (Figure 6, Item 15). Install sensor (Figure 6, Item 5) assembly on bracket (Figure 6, Item 1), in position noted during removal, with three screws (Figure 6, Item 4), six washers (Figure 6, Item 3), and three new locknuts (Figure 6, Item 2). Install sensor mounting flange (Figure 6, Item 8) with two washers (Figure 6, Item 7) and screws (Figure 6, Item 6). Install bracket (Figure 6, Item 1) on axle with two washers (Figure 6, Item 10) and screws (Figure 6, Item 9). Install clamp (Figure 6, Item 14) with washer (Figure 6, Item 13) and screw (Figure 6, Item 12). Install new tiedown straps as needed.
1 2,3,4 5
6,7 15 12,13,14 11
9,10
M0253JCH
Figure 6. Steering System Wheel Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install engine cover (Volume 2, WP 0185). Perform steering calibration (Volume 2, WP 0174).
0125-8
TM 10-3930-675-23-1
0126
FIELD MAINTENANCE SEAT WARNING BUZZER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
REMOVAL 1. 2. Remove approximately eight plastic rivets (Figure 1, Item 1) from rubber bellows (Figure 1, Item 2) under seat (Figure 1, Item 3). Pull rubber bellows (Figure 1, Item 2) downward to access underside of seat (Figure 1, Item 3).
1 2 3
M0257JCH
Figure 1.
Seat Warning Buzzer Replacement.
0126-1
TM 10-3930-675-23-1
0126
REMOVAL - Continued 3. 4. Loosen nut (Figure 2, Item 1) and screw (Figure 2, Item 2) on seat warning buzzer holder (Figure 2, Item 3). Pull seat warning buzzer (Figure 2, Item 4) downward from seat warning buzzer holder (Figure 2, Item 3).
1 2 3
M0258JCH
Figure 2.
NOTE
Tag wires for installation. 5. Remove two nuts (Figure 3, Item 6) and washers (Figure 3, Item 7) and disconnect two wires (Figure 3, Items 1 and 2) from seat warning buzzer (Figure 3, Item 3).
NOTE
Perform Step 6 to disconnect two connectors from seat warning buzzer switch. 6. Disconnect two connectors (Figure 3, Item 5) from seat warning buzzer switch (Figure 3, Item 4).
END OF TASK
0126-2
TM 10-3930-675-23-1
0126
INSTALLATION
NOTE
Perform Step 1 to connect two connectors to seat warning buzzer switch. 1. 2. 3. 4. Connect two connectors (Figure 3, Item 5) to seat warning buzzer switch (Figure 3, Item 4). Connect two wires (Figure 3, Items 1 and 2) to seat warning buzzer (Figure 3, Item 3) with two washers (Figure 3, Item 7) and nuts (Figure 3, Item 6). Push seat warning buzzer (Figure 2, Item 4) upward into seat warning buzzer holder (Figure 2, Item 3). Tighten screw (Figure 2, Item 2) and nut (Figure 2, Item 1) on seat warning buzzer holder (Figure 2, Item 3).
1 2 3 4
6,7
M0259JCH
Figure 3.
0126-3
TM 10-3930-675-23-1
0126
INSTALLATION - Continued 5. 6. Pull rubber bellows (Figure 4, Item 2) upward to seat (Figure 4, Item 3). Install rubber bellows (Figure 4, Item 2) on seat (Figure 4, Item 3) with approximately eight plastic rivets (Figure 4, Item 1).
1 2 3
M0260JCH
Turn master battery switch to ON position (TM 10-3930-675-10). Check seat warning buzzer for proper operation (TM 10-3930-675-10).
0126-4
TM 10-3930-675-23-1
0127
FIELD MAINTENANCE ELECTRIC HORN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position
0127-1
TM 10-3930-675-23-1
0127
REMOVAL
NOTE
Tag wires for installation. 1. 2. Disconnect two connectors (Figure 1, Item 1) from rear of electric horn (Figure 1, Item 2). Remove screw (Figure 1, Item 4), washer (Figure 1, Item 5), and electric horn (Figure 1, Item 2) with bracket (Figure 1, Item 3) from vehicle.
END OF TASK INSTALLATION 1. 2. Install electric horn (Figure 1, Item 2) with bracket (Figure 1, Item 3) on vehicle with washer (Figure 1, Item 5) and screw (Figure 1, Item 4). Connect two connectors (Figure 1, Item 1) to rear of electric horn (Figure 1, Item 2).
1 2
4,5
M0254JCH
Figure 1. Electric Horn Replacement. END OF TASK
0127-2
TM 10-3930-675-23-1
0127
FOLLOW-ON MAINTENANCE 1. 2. Turn master battery switch to ON position (TM 10-3930-675-10). Test electric horn for proper operation (TM 10-3930-675-10).
0127-3/4 blank
TM 10-3930-675-23-1
0128
FIELD MAINTENANCE BATTERY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Apron, Utility (Volume 2, WP 0277, Table 1, Item 5) Battery Kit, Service (Volume 2, WP 0277, Table 1, Item 8) Gloves, Rubber, Industrial (Volume 2, WP 0277, Table 1, Item 32) Goggles, Industrial (Volume 2, WP 0277, Table 1, Item 34) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 80) Qty: 4 References TB 9-6140-252-13 TM 10-3930-675-10 Equipment Condition Battery cables removed (WP 0129)
WARNING
To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or serious injury to personnel. 1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. 2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. 4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.
0128-1
TM 10-3930-675-23-1
0128
REMOVAL 1. Remove four locknuts (Figure 1, Item 1), eight washers (Figure 1, Item 2), four bolts (Figure 1, Item 3), and two battery holddown straps (Figure 1, Item 4) from across top of batteries (Figure 1, Item 5). Discard locknuts.
NOTE
Note position of batteries in battery compartment for installation. 2. Remove four batteries (Figure 1, Item 5) from battery compartment (Figure 1, Item 6).
1,2,3 4 5
M0261JCH
Figure 1. END OF TASK SERVICE
Battery Replacement.
WARNING
To avoid injury, wear eye protection when working around batteries. The gasses produced by a lead-acid battery can explode. Do not smoke, have open flames, or make a spark if filler caps are off. Remove all jewelry, such as rings, ID tags, watches, and bracelets. If jewelry contacts a battery terminal, a direct short will result in instant heating and may cause severe injury to personnel and/or damage equipment.
NOTE
If battery compartment is corroded, it will be necessary to remove batteries and clean compartment to remove acid residues and corrosion. Buildup of dirt or corrosion on batteries can lead to electrical malfunctions.
0128-2
TM 10-3930-675-23-1
0128
SERVICE - Continued Service batteries as follows: 1. 2. 3. 4. 5. 6. 7. 8. Access batteries (Figure 2, Item 2) inside battery box (Figure 2, Item 1) on left side of machine. Check battery hold-downs (Figure 2, Item 3) for looseness, corrosion or damage. Tighten if loose. Clean top of batteries (Figure 2, Item 2) with clean water and a rag. Flush batteries (Figure 2, Item 2), battery tray (Figure 2, Item 4) and battery box (Figure 2, Item 1) with water until clean of debris. Inspect batteries (Figure 2, Item 2) for evidence of cracks, dents, leaking or swelling of battery case and/or lid. Disconnect battery cables (WP 0129). As required, use a battery terminal cleaner or wire brush to remove any corrosion or acid film from battery post clamps. As required, use a battery terminal cleaner or wire brush to remove any corrosion or acid film from battery post. Test batteries using Pulsetech battery tester. Follow the on-screen instructions.
NOTE
If a battery is suspect it may need follow-on testing or charging; refer to TB 9-6140-252-13. These follow-on tests may require the batteries to be removed from vehicle.
1 2 3 2
M1727JCH
Battery Service.
0128-3
TM 10-3930-675-23-1
0128
INSTALLATION 1. 2. Position four batteries (Figure 3, Item 5) in battery compartment (Figure 3, Item 6) as noted during removal. Install two battery holddown straps (Figure 3, Item 4) across top of batteries (Figure 3, Item 5) with four bolts (Figure 3, Item 3), eight washers (Figure 3, Item 2), and four new locknuts (Figure 3, Item 1).
1,2,3 4 5
M0261JCH
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install battery cables (WP 0129). Connect battery cables (WP 0129).
Battery Installation.
0128-4
TM 10-3930-675-23-1
0129
FIELD MAINTENANCE BATTERY CABLES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Apron, Utility (Volume 2, WP 0277, Table 1, Item 5) Battery Kit, Service (Volume 2, WP 0277, Table 1, Item 8) Materials/Parts Grease, Automotive and Artillery, GAA (Volume 2, WP 0276, Table 1, Item 27) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 80) References WP 0130
WARNING
To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or serious injury to personnel. 1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. 2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. 4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.
0129-1
TM 10-3930-675-23-1
0129
REMOVAL
NOTE
Tag battery cables prior to removal to aid in installation. Cut tiedown straps and remove protective covering from battery cables as necessary. Perform Steps 1 thru 5 only to disconnect battery cables when performing any electrical maintenance task on vehicle. 1. 2. Remove each of four locking pins (Figure 1, Item 2) from studs of battery compartment (Figure 1, Item 1). Remove battery compartment cover (Figure 1, Item 3) from battery compartment (Figure 1, Item 1) and position aside to gain access to battery compartment.
1 2
M1723JCH
Figure 1. 3.
Battery Cables Replacement.
Inside battery compartment (Figure 2, Item 1), disconnect connector (Figure 2, Item 3) and wire (Figure 2, Item 2) of solar charger from connector (Figure 2, Item 4).
1 2 3 4
M0262JCH
Figure 2. Solar Charger Disconnect.
0129-2
TM 10-3930-675-23-1
0129
REMOVAL - Continued
WARNING
Disconnect NEGATIVE battery cables first to avoid electrical shock. 4. 5. 6. 7. 8. 9. 10. 11. At end of two NEGATIVE battery cables (Figure 3, Item 17), raise plastic cap (Figure 3, Item 16) and loosen nut (Figure 3, Item 14) and screw (Figure 3, Item 15) on battery cable clamp. Disconnect NEGATIVE battery cables (Figure 3, Item 17) from two of four batteries (Figure 3, Item 13) and remove cables. Remove locknut (Figure 3, Item 3) and washer (Figure 3, Item 2) and disconnect four NEGATIVE cables (Figure 3, Item 1) from side of battery compartment (Figure 3, Item 4). Discard locknut. At ends of two battery cables (Figure 3, Item 8), raise plastic cap (Figure 3, Item 5) and loosen nut (Figure 3, Item 6) and screw (Figure 3, Item 7) on battery cable clamp. Remove two battery cables (Figure 3, Item 8) from four batteries (Figure 3, Item 13). At end of two POSITIVE battery cables (Figure 3, Item 9), raise plastic cap (Figure 3, Item 10) and loosen nut (Figure 3, Item 11) and screw (Figure 3, Item 12) on battery cable clamp. Disconnect POSITIVE battery cables (Figure 3, Item 9) from two of four batteries (Figure 3, Item 13). Disconnect POSITIVE battery cables (Figure 3, Item 9) from master battery switch (WP 0130) and remove.
1 2,3 4 5 6,7 8
9 1
10 17 11,12
16
14,15
13
M0269JCH
0129-3
TM 10-3930-675-23-1
0129
CLEANING AND INSPECTION 1. 2. Clean batteries and battery posts with a wire brush. Wipe clean with rags. Inspect for corrosion or other damage.
END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Connect two POSITIVE battery cables (Figure 4, Item 9) to master battery switch (WP 0130). Connect POSITIVE battery cables (Figure 4, Item 9) to two of four batteries (Figure 4, Item 13). At end of two POSITIVE battery cables (Figure 4, Item 9), raise plastic cap (Figure 4, Item 10) and tighten screw (Figure 4, Item 12) and nut (Figure 4, Item 11) on battery cable clamp. Install two battery cables (Figure 4, Item 9) on four batteries (Figure 4, Item 13). At ends of two battery cables (Figure 4, Item 8), raise plastic cap (Figure 4, Item 5) and tighten screw (Figure 4, Item 7) and nut (Figure 4, Item 6) on battery cable clamp. Connect four NEGATIVE cables (Figure 4, Item 1) to side of battery compartment (Figure 4, Item 4) with washer (Figure 4, Item 2) and new locknut (Figure 4, Item 3). Connect NEGATIVE battery cables (Figure 4, Item 17) to two of four batteries (Figure 4, Item 13). At end of two NEGATIVE battery cables (Figure 4, Item 17), raise plastic cap (Figure 4, Item 16) and tighten screw (Figure 4, Item 15) and nut (Figure 4, Item 14) on battery cable clamp.
1 2,3 4 5 6,7 8
9 1
10 17 11,12
16
14,15
13
M0269JCH
Figure 4.
0129-4
TM 10-3930-675-23-1
0129
INSTALLATION - Continued 9. Position battery compartment cover close enough to battery compartment (Figure 5, Item 1) to allow connection of solar charger connector (Figure 5, Item 3) and wire (Figure 5, Item 2) to vehicle connector (Figure 5, Item 4).
1 2 3 4
M0262JCH
Figure 5. 10. 11.
Solar Charger Connection.
Install battery compartment cover (Figure 6, Item 3) on battery compartment (Figure 6, Item 1). Install each of four locking pins (Figure 6, Item 2) on studs of battery compartment (Figure 6, Item 1).
1 2
M1723JCH
0129-5/6 blank
TM 10-3930-675-23-1
0130
FIELD MAINTENANCE MASTER BATTERY SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 86) Qty: 2 Equipment Condition Battery compartment door open (TM 10-3930-675-10) NEGATIVE battery cables disconnected (WP 0129)
WARNING
Remove all jewelry, watches, rings, etc., prior to disconnecting cables from batteries or other electrical source. Items can come in contact with battery or electrical source and cause electrical shock. Failure to follow this warning may result in personnel injury or death. REMOVAL 1. Remove handle (Figure 1, Item 2) from master battery switch (Figure 1, Item 1).
1 2
M0273JCH
Figure 1.
Master Battery Switch Replacement.
0130-1
TM 10-3930-675-23-1
0130
REMOVAL - Continued
NOTE
Note orientation of master battery switch prior to removal to ensure correct installation. 2. Remove two locknuts (Figure 2, Item 2), washers (Figure 2, Item 3), screws (Figure 2, Item 4), and master battery switch (Figure 2, Item 5) from mounting plate (Figure 2, Item 1). Discard locknuts.
1 2,3,4 5
M0274JCH
Figure 2.
NOTE
Tag cables prior to disconnection to ensure proper connection on installation. Also note switch terminal to which cables are connected. 3. Pull back two rubber boots (Figure 3, Item 5) and remove two nuts (Figure 3, Item 3), washers (Figure 3, Item 4), and four cables (Figure 3, Item 1) from terminals of master battery switch (Figure 3, Item 2).
0130-2
TM 10-3930-675-23-1
0130
REMOVAL - Continued
1
3,4
M0275JCH
Figure 3. END OF TASK INSTALLATION 1. 2.
Install four cables (Figure 3, Item 1), two washers (Figure 3, Item 4), and nuts (Figure 3, Item 3) on terminals of master battery switch (Figure 3, Item 2). Install two rubber boots (Figure 3, Item 5). Position master battery switch (Figure 2, Item 5) with shaft through opening in mounting plate (Figure 2, Item 1). Install two screws (Figure 2, Item 4), washers (Figure 2, Item 3), and new locknuts (Figure 2, Item 2). Install boot and handle (Figure 1, Item 2) on shaft of master battery switch (Figure 1, Item 1).
3.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect NEGATIVE battery cables (WP 0129). Close battery compartment door (TM 10-3930-675-10).
0130-3/4 blank
TM 10-3930-675-23-1
0131
FIELD MAINTENANCE AMBIENT TEMPERATURE SENSOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
0131-1
TM 10-3930-675-23-1
0131
REMOVAL
NOTE
If necessary, remove and discard tiedown straps. 1. 2. Disconnect connector (Figure 1, Item 6) of ambient temperature sensor (Figure 1, Item 5) from connector of cab wiring harness (Figure 1, Item 1). Remove screw (Figure 1, Item 2), clip (Figure 1, Item 3), and ambient temperature sensor (Figure 1, Item 5) from bracket (Figure 1, Item 4).
2,3,4
M0202JCH
Figure 1. Ambient Temperature Sensor Removal. END OF TASK
0131-2
TM 10-3930-675-23-1
0131
INSTALLATION
NOTE
If removed, use new tiedown straps during installation. 1. 2. Install ambient temperature sensor (Figure 2, Item 5) on bracket (Figure 2, Item 4) with clip (Figure 2, Item 3). Install screw (Figure 2, Item 2). Connect connector (Figure 2, Item 6) of ambient temperature sensor (Figure 2, Item 5) to connector of cab wiring harness (Figure 2, Item 1).
2,3,4
M0203JCH
Figure 2. Ambient Temperature Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE Turn master battery switch to ON position (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE
0131-3/4 blank
TM 10-3930-675-23-1
0132
FIELD MAINTENANCE FUEL LEVEL SENDING UNIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts O-Ring (Volume 2, WP 0278, Table 1, Item 172) Transmitter, Liquid Quantity (Volume 2, WP 0278, Table 1, Item 172) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
REMOVAL 1. Trace cable (Figure 1, Item 1) of fuel level sending unit (Figure 1, Item 3) back to point of connection, at rear corner of fuel tank (Figure 1, Item 2).
1 2
M0213JCH
Figure 1.
Fuel Level Sending Unit Connector Removal.
0132-1
TM 10-3930-675-23-1
0132
REMOVAL - Continued 2. Disconnect connector (Figure 3, Item 1) of fuel level sending unit (Figure 3, Item 4) from wiring harness connector (Figure 2, Item 2).
M0214JCH
Figure 2. Fuel Level Sending Unit Removal. 3. 4. Remove two clamps (Figure 3, Item 1) and release cable (Figure 3, Item 2) from top of fuel tank (Figure 3, Item 3). Rotate fuel level sending unit (Figure 3, Item 4) counterclockwise to remove from top of fuel tank (Figure 3, Item 3). Remove and discard O-ring.
END OF TASK
0132-2
TM 10-3930-675-23-1
0132
INSTALLATION
NOTE
Replacement fuel level sending unit comes with two new O-rings. During installation, ensure sending unit is positioned in pipe at bottom of fuel tank. 1. 2. 3. Install fuel level sending unit (Figure 3, Item 4) with new O-ring in top of fuel tank (Figure 3, Item 3). Connect connector (Figure 2, Item 1) of fuel level sending unit (Figure 3, Item 4) to wiring harness connector (Figure 2, Item 2). Secure cable (Figure 3, Item 2) to frame and fuel tank (Figure 3, Item 3) with two clamps (Figure 3, Item 1).
1 2 3
M0215JCH
Fuel Level Sending Unit Installation.
Turn on master switch (TM 10-3930-675-10). Check for proper operation of fuel sending unit (TM 10-3930-675-10).
0132-3/4 blank
TM 10-3930-675-23-1
0133
FIELD MAINTENANCE BACKUP ALARM REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 80) Qty: 2 Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)
REMOVAL
NOTE
Remove and discard tiedown straps as necessary. 1. 2. Disconnect connector (Figure 1, Item 2) of backup alarm (Figure 1, Item 1) from connector (Figure 1, Item 3) of wiring harness. Remove two locknuts (Figure 1, Item 4), four washers (Figure 1, Item 5), two screws (Figure 1, Item 6), and backup alarm (Figure 1, Item 1) from right rear light bracket (Figure 1, Item 7). Discard locknuts.
1 2 3 4,5,6 7
M0255JCH
Backup Alarm Removal.
0133-1
TM 10-3930-675-23-1
0133
INSTALLATION 1. 2. Install backup alarm (Figure 2, Item 1) on right rear light bracket (Figure 2, Item 7) with two screws (Figure 2, Item 6), four washers (Figure 2, Item 5), and two new locknuts (Figure 2, Item 4). Connect connector (Figure 2, Item 2) of backup alarm (Figure 2, Item 1) to connector (Figure 2, Item 3) of wiring harness.
1 2 3 4,5,6 7
M0256JCH
Backup Alarm Installation.
Turn master battery switch to ON position (TM 10-3930-675-10). Check operation of backup alarm (TM 10-3930-675-10).
0133-2
TM 10-3930-675-23-1
0134
FIELD MAINTENANCE SLAVE STARTING RECEPTACLE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Materials/Parts (cont.) Nut, Self-Locking, Clinch (Volume 2, WP 0278, Table 1, Item 86) Qty: 8 Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 4 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) NEGATIVE battery cables disconnected (WP 0129)
RIGHT SLAVE STARTING RECEPTACLE REMOVAL 1. 2. Remove cap (Figure 1, Item 1) from slave starting receptacle (Figure 1, Item 2). Remove four locknuts (Figure 1, Item 3), eight washers (Figure 1, Item 4), four screws (Figure 1, Item 5), and bracket (Figure 1, Item 6) from vehicle. Pull bracket downward to access rear of slave starting receptacle (Figure 1, Item 2). Discard locknuts.
1,2 3,4,5
M0276JCH
Figure 1. Right Slave Starting Receptacle Replacement.
0134-1
TM 10-3930-675-23-1
0134
RIGHT SLAVE STARTING RECEPTACLE REMOVAL - Continued 3. Remove four locknuts (Figure 2, Item 1), eight washers (Figure 2, Item 2), four screws (Figure 2, Item 3), slave starting receptacle (Figure 2, Item 8), and cord of cap (Figure 2, Item 7) from bracket (Figure 1, Item 6). Discard locknuts. Remove two screws (Figure 2, Item 4), lockwashers (Figure 2, Item 5), and two cables (Figure 2, Item 6) from rear of slave starting receptacle (Figure 2, Item 8).
1,2,3 4,5 6
4.
M0277JCH
Figure 2. Right Slave Starting Receptacle Replacement. END OF TASK
0134-2
TM 10-3930-675-23-1
0134
RIGHT SLAVE STARTING RECEPTACLE INSTALLATION
NOTE
New slave starting receptacle comes with new lockwashers. 1. Position slave starting receptacle (Figure 2, Item 8) on bracket (Figure 1, Item 6) and install two cables (Figure 2, Item 6) on rear of slave starting receptacle with two new lockwashers (Figure 2, Item 5) and screws (Figure 2, Item 4). Install slave starting receptacle (Figure 2, Item 8) and cord of cap (Figure 2, Item 7) on bracket (Figure 1, Item 6) with four screws (Figure 2, Item 3), eight washers (Figure 2, Item 2), and four new locknuts (Figure 2, Item 1). Install bracket (Figure 3, Item 6) on vehicle with four screws (Figure 3, Item 5), eight washers (Figure 3, Item 4), and four new locknuts (Figure 3, Item 3). Install cap (Figure 3, Item 1) on slave starting receptacle (Figure 3, Item 2).
1,2 3,4,5
2.
3. 4.
M0278JCH
Figure 3. Right Slave Starting Receptacle Replacement. END OF TASK
0134-3
TM 10-3930-675-23-1
0134
LEFT SLAVE STARTING RECEPTACLE REMOVAL 1. 2. 3. Remove two screws (Figure 4, Item 8), lockwashers (Figure 4, Item 9), and cables (Figure 4, Item 1) from rear of slave starting receptacle (Figure 4, Item 2). Discard lockwashers. Remove cap (Figure 4, Item 3) from slave starting receptacle (Figure 4, Item 2). Remove four locknuts (Figure 4, Item 4), eight washers (Figure 4, Item 5), four screws (Figure 4, Item 6), slave starting receptacle (Figure 4, Item 2), and cord of cap (Figure 4, Item 3) from mounting plate (Figure 4, Item 7). Discard locknuts.
2 3
10
8,9
4,5,6
M0279JCH
Figure 4. Left Slave Starting Receptacle Replacement. END OF TASK
0134-4
TM 10-3930-675-23-1
0134
LEFT SLAVE STARTING RECEPTACLE INSTALLATION 1. Install slave starting receptacle (Figure 5, Item 2) and cord of cap (Figure 5, Item 3) on mounting plate (Figure 5, Item 7) with four screws (Figure 5, Item 6), eight washers (Figure 5, Item 5), and four new locknuts (Figure 5, Item 4). Install cap (Figure 5, Item 3) on slave starting receptacle (Figure 5, Item 2). Connect two cables (Figure 5, Item 1) to rear of slave starting receptacle (Figure 5, Item 2) with two new lockwashers (Figure 5, Item 9) and screws (Figure 5, Item 8).
2 3
2. 3.
10
8,9
4,5,6
M0279JCH
Figure 5. Left Slave Starting Receptacle Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect NEGATIVE battery cables (WP 0129). Close battery compartment door (TM 10-3930-675-10).
0134-5/6 blank
TM 10-3930-675-23-1
INDEX
Subject WP Sequence No.-Page No.
A
ALTERNATOR DRIVE BELT MAINTENANCE................................................................. ALTERNATOR REPLACEMENT...................................................................................... AMBIENT TEMPERATURE SENSOR REPLACEMENT.................................................. AUXILIARY PUMP TROUBLESHOOTING....................................................................... AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING............................................. WP 0092-1 WP 0091-1 WP 0131-1 WP 0036-1 WP 0031-1
B
BACKUP ALARM REPLACEMENT.................................................................................. BACKUP LIGHT AND WORK LIGHT MAINTENANCE.................................................... BATTERY CABLES REPLACEMENT.............................................................................. BATTERY MAINTENANCE.............................................................................................. BLACKOUT LIGHT MAINTENANCE................................................................................ BOOM ANGLE SENSOR REPLACEMENT...................................................................... BOOM EXTENSION SENSOR REPLACEMENT............................................................. BOOM IN/OUT TROUBLESHOOTING............................................................................. BOOM LIFTING/LOWERING TROUBLESHOOTING....................................................... BOOM WIRING HARNESSES REPLACEMENT.............................................................. BRAKE SYSTEM TROUBLESHOOTING......................................................................... WP 0133-1 WP 0110-1 WP 0129-1 WP 0128-1 WP 0111-1 WP 0121-1 WP 0122-1 WP 0040-1 WP 0039-1 WP 0107-1 WP 0030-1
C
CAB INTERIOR LIGHT MAINTENANCE.......................................................................... CAB POSITION PROXIMITY SWITCHES REPLACEMENT............................................ CIRCUIT BREAKERS AND RELAYS REPLACEMENT................................................... COOLANT FILTER AND FILTER HEAD REPLACEMENT.............................................. COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING................... COOLING SYSTEM EXPANSION TANK MAINTENANCE.............................................. COOLING SYSTEM HOSES REPLACEMENT................................................................ CYLINDER HEAD REPLACEMENT................................................................................. WP 0114-1 WP 0105-1 WP 0103-1 WP 0090-1 WP 0009-1 WP 0082-1 WP 0083-1 WP 0052-1
D
DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE............................ DRAINING AND FILLING RADIATOR ASSEMBLY......................................................... WP 0112-1 WP 0080-1
E
ECS DISPLAY SCREEN REPLACEMENT....................................................................... ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING............................................ ELECTRIC HORN REPLACEMENT................................................................................. ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING......... ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING...... ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT.............................................. ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT................................................ ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT............... ENGINE AIR CLEANER MAINTENANCE........................................................................ ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT........................................ ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING...................................................................................................... ENGINE ASSEMBLY REPLACEMENT............................................................................ ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING.................................. WP 0096-1 WP 0013-1 WP 0127-1 WP 0012-1 WP 0015-1 WP 0100-1 WP 0101-1 WP 0102-1 WP 0071-1 WP 0072-1 WP 0021-1 WP 0050-1 WP 0024-1
Index-1
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TM 10-3930-675-23-1
Subject
WP Sequence No.-Page No. WP 0017-1 WP 0099-1 WP 0007-1 WP 0023-1 WP 0051-1 WP 0059-1 WP 0061-1 WP 0019-1 WP 0018-1 WP 0022-1 WP 0118-1 WP 0020-1 WP 0008-1 WP 0002-1 WP 0004-1 WP 0077-1 WP 0063-1
ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING............... ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT................................. ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING........................................ ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING........... ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT.................................... ENGINE OIL AND OIL FILTER REPLACEMENT............................................................. ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT.......................... ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING........................................... ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING................................... ENGINE PRESSURE SENSOR TROUBLESHOOTING.................................................. ENGINE SENSORS REPLACEMENT.............................................................................. ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING.............. ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING................................. EQUIPMENT DESCRIPTION AND DATA........................................................................ ERROR CODE REFERENCES........................................................................................ ETHER COLD START SYSTEM MAINTENANCE........................................................... EXHAUST MANIFOLD REPLACEMENT..........................................................................
F
FLYWHEEL ASSEMBLY REPLACEMENT...................................................................... FORDING WATER LEVEL SENSOR REPLACEMENT................................................... FRONT GEAR COVER REPLACEMENT......................................................................... FRONT MAIN OIL SEAL REPLACEMENT....................................................................... FUEL FILTER/WATER SEPARATOR REPLACEMENT.................................................. FUEL HOSES, LINES, AND FITTINGS REPLACEMENT................................................ FUEL INJECTOR REPLACEMENT.................................................................................. FUEL LEVEL SENDING UNIT REPLACEMENT.............................................................. FUEL PUMP ASSEMBLY REPLACEMENT..................................................................... FUEL SOLENOID SHUTOFF VALVE REPLACEMENT................................................... FUEL SUPPLY AND RETURN HOSES REPLACEMENT................................................ FUEL TANK REPLACEMENT.......................................................................................... WP 0054-1 WP 0116-1 WP 0065-1 WP 0066-1 WP 0076-1 WP 0069-1 WP 0067-1 WP 0132-1 WP 0068-1 WP 0070-1 WP 0075-1 WP 0074-1
G
GENERAL INFORMATION............................................................................................... WP 0001-1
H
HEADLIGHT MAINTENANCE.......................................................................................... HYDRAULIC COOLING FAN MAINTENANCE................................................................ HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT..................................... HYDRAULIC FILTER INDICATORS TROUBLESHOOTING............................................ HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING...................................... HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT............ HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING...................................................................................................... WP 0109-1 WP 0089-1 WP 0119-1 WP 0038-1 WP 0037-1 WP 0124-1 WP 0035-1
I
INFRARED (IR) LIGHTS REPLACEMENT....................................................................... INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING...................................................................................................... INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT............................................................................................................... INTAKE MANIFOLD REPLACEMENT.............................................................................. WP 0115-1 WP 0016-1 WP 0094-1 WP 0064-1
Index-2
TM 10-3930-675-23-1
Subject
WP Sequence No.-Page No. WP 0029-1
INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING....
M
MASTER BATTERY SWITCH REPLACEMENT.............................................................. MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING.............. MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING.......................... MUFFLER AND EXHAUST PIPE REPLACEMENT......................................................... WP 0130-1 WP 0033-1 WP 0028-1 WP 0079-1
O
OIL FILTER HEAD AND OIL COOLER MAINTENANCE................................................. OIL PAN REPLACEMENT................................................................................................ OIL SAMPLING VALVES AND HOSES REPLACEMENT................................................ OVERLOAD PROTECTION TROUBLESHOOTING........................................................ WP 0060-1 WP 0058-1 WP 0062-1 WP 0010-1
P
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)............................... PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction........... WP 0048-1 WP 0047-1
R
RADIATOR ASSEMBLY MAINTENANCE........................................................................ RADIATOR FILL COVER PLATE REPLACEMENT......................................................... RADIATOR SPLASH SHIELD REPLACEMENT.............................................................. RADIATOR TOP GRATING REPLACEMENT.................................................................. REAR MAIN OIL SEAL REPLACEMENT......................................................................... ROCKER ARM ASSEMBLY MAINTENANCE.................................................................. ROCKER ARM COVER AND GASKET REPLACEMENT................................................ WP 0081-1 WP 0086-1 WP 0084-1 WP 0085-1 WP 0055-1 WP 0056-1 WP 0057-1
S
SEAT WARNING BUZZER REPLACEMENT................................................................... SERVICE UPON RECEIPT.............................................................................................. SLAVE STARTING RECEPTACLE REPLACEMENT...................................................... SOLAR CHARGER REPLACEMENT (IF EQUIPPED)..................................................... STARTER MOTOR REPLACEMENT............................................................................... STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING...................................................................................................... STEERING SENSOR TROUBLESHOOTING.................................................................. STEERING SYSTEM WHEEL SENSOR REPLACEMENT.............................................. STEERING VALVE CIRCUIT TROUBLESHOOTING...................................................... WP 0126-1 WP 0049-1 WP 0134-1 WP 0106-1 WP 0093-1 WP 0014-1 WP 0034-1 WP 0125-1 WP 0032-1
T
THEORY OF OPERATION............................................................................................... THERMOSTAT REPLACEMENT..................................................................................... THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT.............. TOPHANDLER ANGLE SENSOR REPLACEMENT........................................................ TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING...................................................................................................... TOPHANDLER JUNCTION BOX MAINTENANCE........................................................... TOPHANDLER LEVELING TROUBLESHOOTING.......................................................... TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT................. TOPHANDLER PROXIMITY SWITCHES REPLACEMENT............................................. TOPHANDLER SIDESHIFT TROUBLESHOOTING......................................................... TOPHANDLER SLEWING TROUBLESHOOTING........................................................... WP 0003-1 WP 0087-1 WP 0078-1 WP 0123-1 WP 0011-1 WP 0097-1 WP 0043-1 WP 0098-1 WP 0104-1 WP 0044-1 WP 0041-1
Index-3
TM 10-3930-675-23-1
Subject
WP Sequence No.-Page No. WP 0045-1 WP 0042-1 WP 0046-1 WP 0108-1 WP 0095-1 WP 0027-1 WP 0120-1 WP 0026-1 WP 0025-1 WP 0006-1 WP 0005-1 WP 0073-1 WP 0113-1
TOPHANDLER SPREADER TROUBLESHOOTING........................................................ TOPHANDLER TILT TROUBLESHOOTING.................................................................... TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING......... TOPHANDLER WIRING HARNESSES REPLACEMENT................................................ TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT................. TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING.......................................... TRANSMISSION SENSORS REPLACEMENT................................................................ TRANSMISSION SPEED SENSORS TROUBLESHOOTING.......................................... TRANSMISSION TEMPERATURE TROUBLESHOOTING............................................. TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)....................................... TROUBLESHOOTING SYMPTOM INDEX....................................................................... TURBOCHARGER REPLACEMENT................................................................................ TWISTLOCK INDICATOR LIGHTS MAINTENANCE.......................................................
V
VIBRATION DAMPER REPLACEMENT.......................................................................... WP 0053-1
W
WATER PUMP REPLACEMENT...................................................................................... WHEEL TEMPERATURE SENSOR REPLACEMENT..................................................... WP 0088-1 WP 0117-1
Index-4
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.
Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).
DATE Date you filled out this form.
TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
FROM (Activity and location) (Include ZIP Code)
Your mailing address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE
TM Number
ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO.
Date of the TM
Title of the TM
RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)
0007-3
Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).
0018-2
SAMPLE
TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
SIGNATURE
Your Name
DA FORM 2028, FEB 74
Your Phone Number
Your Signature
APD V4.00
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
DATE Date you filled out this form
Your Address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE
TM Number
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER
Date of the TM
Title of the TM
RECOMMENDED ACTION
TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED
SAMPLE
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
Your Name
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION
Your Phone Number
Your Signature
APD V4.00

For use of this form, see AR 25-30; the proponent agency is OAASA
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field Maintenance 01 October 2012 TM 10-3930-675-23-1 Manual PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field 01 October 2012 TM 10-3930-675-23-1 Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED
RECOMMENDED ACTION
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field Maintenance 01 October 2012 TM 10-3930-675-23-1 Manual ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
RECOMMENDED ACTION
PART III REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
RECOMMENDED ACTION
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field 01 October 2012 TM 10-3930-675-23-1 Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00
By Order of the Secretary of the Army:
Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1224104
RAYMOND T. ODIERNO General, United States Army Chief of Staff
By Order of the Marine Corps: MARK T. BRINKMAN

Program Manager, Infantry Weapons (PMM-132) Marine Corps Systems Command
MICHAEL W. HAGEE.
Commandant of the Marine Corps
Distribution: To be distributed in accordance with the initial distribution number (IDN) 391061 requirements for TM 10-3930-675-23-1.
MARINE CORPS PCN: 184 110783 00
THE METRIC SYSTEM AND EQUIVALENTS Linear Measure Square Measure
1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles Inches 1 Kilometer = 1000 Meters = 0.621 Miles Cubic Measure Weights 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric T = 1000 Kilograms = 1 Megagram = 1.1 Short on T ons Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature 5/9 ( - 32) = F C 212Fahrenheit is equivalent to 100Celsius 90Fahrenheit is equivalent to 32.2Celsius 32Fahrenheit is equivalent to 0Celsius 9/5 +32 = C F
APPROXIMATE CONVERSION FACTORS To Change Inches Feet Yards Miles Sq Inches Sq Feet Sq Yards Sq Miles Acres Cubic Feet Cubic Yards Fluid Ounces Pints Quarts Gallons Ounces Pounds Short T ons Pound-Feet Pounds per Sq Inch Miles per Gallon Miles per Hour To Centimeters Meters Meters Kilometers Sq Centimeters Sq Meters Sq Meters Sq Kilometers Sq Hectometers Cubic Meters Cubic Meters Milliliters Liters Liters Liters Grams Kilograms Metric T ons Newton-Meters Kilopascals Kilometers per Liter Multiply By 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 0.425 To Change Centimeters Meters Meters Kilometers Sq Centimeters Sq Meters Sq Meters Sq Kilometers Sq Hectometers Cubic Meters Cubic Meters Milliliters Liters Liters Liters Grams Kilograms Metric T ons Newton-Meters Kilopascals Kilometers per Liter To Inches Feet Yards Miles Sq Inches Sq Feet Sq Yards Sq Miles Acres Cubic Feet Cubic Yards Fluid Ounces Pints Quarts Gallons Ounces Pounds Short T ons Pound-Feet Pounds per Sq Inch Miles per Gallon Multiply By 0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145 2.354 0.621
Kilometers per Hour 1.609
Kilometers per Hour Miles per Hour
PIN: 087211-000

TM 10-3920-675-23-1 RTCH RT 240

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ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 VOLUME 1

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

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TRANSMISSION TEMPERATURE TROUBLESHOOTING........................................................................ WP 0025 Figure 1. Component Locations.......................................................................................................... 0025-6

TRANSMISSION SPEED SENSORS TROUBLESHOOTING..................................................................... WP 0026 Figure 1. Component Locations........................................................................................................ 0026-10

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TOPHANDLER SIDESHIFT TROUBLESHOOTING................................................................................... WP 0044 Figure 1. Component Locations.......................................................................................................... 0044-6

TOPHANDLER SPREADER TROUBLESHOOTING.................................................................................. WP 0045 Figure 1. Component Locations.......................................................................................................... 0045-7

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