Freightliner Con Ddec PDF

TM 9-2320-302-20
UNIT MAINTENANCE MANUAL

FOR
TRUCK, TRACTOR, LINE HAUL:

52,000 GVWR, 6 X 4, M915A3
(NSN 2320-01-432-4847)
Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
May 2001
This page is intentionally left blank
This page is blank.

TM 9-2320-302-20
LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE
A vertical line in the outer margins of the page indicates the portion of text affected by the change. Changes
to illustrations are indicated by miniature pointing hands. Change to wiring diagrams is indicated by shaded
areas.
Dates of issue for original and change pages/work packages are:
Original 28 May 2001

Change Not Applicable
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 52 AND TOTAL NUMBER OF WORK PACK-
AGES IS 236 CONSISTING OF THE FOLLOWING:
Page/WP *Change
No. No.
Cover (Back Blank) 0

A (B Blank) 0
a to h 0
i to vii (viii Blank) 0
WP 0001 00 to 0236 00 0
Index-1 to Index-18 0
FO-1 and FO-2 0
Authentication Page (Back Blank) 0
Sample DA Form 2028-2 0
Blank DA Form 2028-2 0
Metric Conversion Chart 0
Back Cover 0
* Zero in this column indicates an original page or work package.
A
TM 9-2320-302-20
This Page Intentionally Left Blank.
B
TM 9-2320-302-20
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 man-
ual.
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.
EAR PROTECTION - headphones over ears shows that noise level will harm ears.
ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows
that shock hazard is present.
EYE PROTECTION - person with goggles shows that the material will injure the eyes.
FIRE - flame shows that a material may ignite and cause burns.
FLYING PARTICLES - arrows bouncing off face with face shield shows that particles flying
through the air will harm face.
HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from
improper lifting technique.
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TM 9-2320-302-20
HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or
limb.
HOT AREA - hand over object radiating heat shows that part is hot and can burn.
VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.
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TM 9-2320-302-20
FOR INFORMATION ON FIRST AID, REFER TO FM 21-11.
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL!
• Carbon monoxide is a colorless, odorless, deadly poison 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 can result from severe exposure.
• Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of inadequate ventilation. The following precau-
tions must be observed to ensure safety of personnel when engine of truck is operated.
1. DO NOT operate truck engine in enclosed areas.

2. DO NOT idle truck engine without adequate ventilation.
3. DO NOT drive truck with inspection plates or cover plates removed.
4. BE ALERT for exhaust poisoning symptoms. They are:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:
• Remove person from area.

• Expose to fresh air.
• Keep person warm.
• Do not permit physical exercise.
• Administer cardiopulmonary resuscitation (CPR), if necessary.

• Notify a medic.
6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection will not protect you from car-
bon monoxide poisoning.
The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!
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TM 9-2320-302-20
WARNING
ADHESIVES AND SEALING COMPOUNDS
Adhesives and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and
clothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If adhesive or
sealing compound contacts skin or clothing, wash immediately with soap and water.
WARNING
AIR LINES AND FITTINGS
• DO NOT disconnect any air system lines or fittings unless vehicle engine is shut down and air system
pressure is relieved. Failure to follow this warning could result in serious injury to personnel.
• Ensure that all air lines and fittings are clear of debris and excess pipe sealing compound does not enter
air lines or fittings. Failure to follow this warning could result in injury to personnel and damage to
equipment.
• Always wear eye protection when disconnecting air lines. Residual air will be expelled. Failure to fol-
low this warning may result in serious eye injury.
WARNING
BATTERIES
• To avoid eye injury, eye protection is required 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,
injury to personnel, and damage to equipment.
• 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 immedi-
ately.
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 bak-
ing soda or household ammonia.
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TM 9-2320-302-20
WARNING
BRAKES
• When caging brakes, block wheels to keep truck from moving when brakes are released. Failure to fol-
low this warning may result in death or injury to personnel or damage to equipment.
• Brake chamber contains spring under great pressure. To prevent personnel injury, never work directly
behind chamber. If caging bolt will not engage properly, spring may be broken.
• DO NOT remove clamp ring around spring brake chamber. It is under tension and can cause personnel
injury if released.
• When spring brakes are applied, vehicle will stop quickly which could result in injury to personnel.
Also, vehicle cannot be driven again until malfunction is repaired and enough air supply is present for
operation of service brakes.
WARNING
COMPRESSED AIR
Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi
(207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to person-
nel.
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 injury or death to personnel and damage to vehicle.
• Fuel vapors are toxic. Avoid prolonged exposure or breathing of fumes. Work in a well-ventilated area.
Failure to follow this warning could result in serious injury to personnel.
WARNING
ETHER QUICK-START SYSTEM
Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated
area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and
avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities
of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation.
Failure to follow this warning may cause death or serious injury to personnel.
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TM 9-2320-302-20
WARNING
FIRE EXTINGUISHER
Discharging large quantities of dry chemical fire extinguisher in cab may result in temporary breathing diffi-
culty 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,
transmission 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 1-800-872-3845.
WARNING
HEARING PROTECTION
Hearing protection is required when operating vehicle at more than 45 mph (72 kph) with windows open for
an extended period of time. Hearing protection is also required when personnel are within 1 meter (3.1 ft) of
vehicle when operating at low engine idle (600 rpm) and within 3.5 meters (11 ft) of vehicle when operating
at high idle (1600 rpm). Failure to follow this warning may result in hearing damage.
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TM 9-2320-302-20
WARNING
NBC EXPOSURE
If NBC exposure is suspected, all air cleaner media should be handled by personnel wearing protective
equipment. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.
WARNING
IF NBC EXPOSURE IS SUSPECTED ALL AIR
FILTER MEDIA WILL BE HANDLED BY PER-
SONNEL WEARING FULL NBC PROTEC-
TIVE EQUIPMENT. SEE OPERATOR/
MAINTENANCE MANUAL.
7690-01-114-3702
To order this NBC decal use:

National Stock Number (NSN) - 7690-01-114-3702
Part Number (PN) - 12296626
Commercial and Government Entity Code (CAGEC) - 19207
WARNING
PRESSURIZED COOLING SYSTEM

DO NOT remove radiator cap or drain antifreeze unless engine is cold. Remove radiator cap in two steps.
First, place a thick cloth over cap and slowly turn cap left to first stop. Pause and allow pressure to escape.
Turn cap further left until it can be removed. This is a pressurized cooling system and escaping steam, hot
water or coolant will cause serious burns.
WARNING
R-134A REFRIGERANT
• Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Use care
to prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if you
come in contact with refrigerant.
• Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with com-
pressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, which
could cause personnel injury.
• DO NOT work in an area where refrigerant may contact an open flame or burning material such as a
cigarette. When refrigerant contacts extreme heat, refrigerant breaks down into poisonous phosgene gas
which, if breathed, causes severe respiratory irritation. DO NOT breathe fumes from an open flame leak
detector.
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TM 9-2320-302-20
WARNING
SLAVE STARTING
• When slave starting truck, 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.
WARNING
TIRE CHANGING
Whenever wheel lug nuts require tightening or a wheel has been removed and replaced, lug nuts must be
tightened to the required torque. Failure to follow this warning may result in serious injury to personnel and
damage to equipment.
WARNING
TOWING
Brakes will be released when air is applied to a disabled vehicle. DO NOT connect air lines to a disabled
vehicle without blocking wheels and connecting tow bar between vehicles. Failure to follow this warning
could result in death or injury to personnel and damage to equipment.
WARNING
WORK SAFETY
• Hydraulic jack is intended only for lifting truck, not for supporting vehicle to perform maintenance.
DO NOT get under truck after it is raised unless it is properly supported with blocks or jackstands.
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 dur-
ing procedure. Ensure that any lifting device used is in good condition and of suitable load capac-
ity. 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 seri-
ous personnel injury and equipment damage. Observe all standard rules of safety.
• ALWAYS install hood prop after opening hood. Failure to follow this warning could result in
severe injury to personnel.
h
TM 9-2320-302-20
TECHNICAL MANUAL HEADQUARTERS

TM 9-2320-302-20 DEPARTMENT OF THE ARMY
Washington, D.C., 28 May 2001
UNIT MAINTENANCE MANUAL
FOR
TRUCK, TRACTOR, LINE HAUL:

52,000 GVWR, 6 X 4, M915A3
(NSN 2320-01-432-4847)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the pro-
cedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical
Publications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet
address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST
FORM”. The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out
the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your com-
ments and better manage the DA Form 2028 program. You may also mail, fax or e-mail your letter, DA Form
2028 direct to: AMSTA-LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-
7630. The e-mail address is: [email protected]. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.
Table of Contents
Page
Number
Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION
WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

WP 0002 00 Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
WP 0003 00 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
CHAPTER 2 UNIT TROUBLESHOOTING PROCEDURES
WP 0004 00 Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

WP 0005 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
WP 0006 00 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
WP 0007 00 DDEC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-1
WP 0008 00 Exhaust System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
WP 0009 00 Cooling System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1
WP 0010 00 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
WP 0011 00 Transmission and Driveline Systems Troubleshooting . . . . . . . . . . . . . . . . . . . 0011 00-1
WP 0012 00 Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
WP 0013 00 Anti-lock Brake System (ABS) Troubleshooting and Testing . . . . . . . . . . . . . 0013 00-1
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TM 9-2320-302-20
Table of Contents - Continued

Page
Number
WP 0014 00 Air System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1

WP 0015 00 Steering System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
WP 0016 00 Chassis and Fifth Wheel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
WP 0017 00 Air Conditioning System Troubleshooting and Testing . . . . . . . . . . . . . . . . . . 0017 00-1
WP 0018 00 Collision Warning System (CWS) Troubleshooting . . . . . . . . . . . . . . . . . . . . . 0018 00-1
CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS
WP 0019 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1

WP 0020 00 Unit Preventive Maintenance Checks and Services (PMCS) Introduction . . . . 0020 00-1
WP 0021 00 Unit Preventive Maintenance Checks and Services (PMCS). . . . . . . . . . . . . . . 0021 00-1
WP 0022 00 Oil Fill Tube Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
WP 0023 00 Oil Level Dipstick, Tube, and Adapter Replacement . . . . . . . . . . . . . . . . . . . . 0023 00-1
WP 0024 00 Oil Filter Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1
WP 0025 00 Oil Cooler and Oil Filter Adapter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
WP 0026 00 Oil Sample Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
WP 0027 00 Air Compressor Discharge Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
WP 0028 00 Air Compressor Governor Replacement and Adjustment . . . . . . . . . . . . . . . . . 0028 00-1
WP 0029 00 Air Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
WP 0030 00 Fuel Hoses and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
WP 0031 00 Fuel Strainer and Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
WP 0032 00 Fuel Filter Adapters Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
WP 0033 00 Fuel Tank and Mounting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0033 00-1
WP 0034 00 Fuel Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1
WP 0035 00 Automatic Ether Starting Aid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
WP 0036 00 Air Cleaner, Air Intake Duct, and Turbo Bypass Valve Maintenance. . . . . . . . 0036 00-1
WP 0037 00 Air Intake Tubes and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
WP 0038 00 Charge Air Cooler and Air Recirculation Shield Replacement . . . . . . . . . . . . . 0038 00-1
WP 0039 00 Exhaust System Muffler, Stack, and Heat Shield Replacement . . . . . . . . . . . . 0039 00-1
WP 0040 00 Exhaust System Flex Pipe, Clamps, and Heat Shield Replacement . . . . . . . . . 0040 00-1
WP 0041 00 Drain and Fill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
WP 0042 00 Coolant Hoses, Pipes, and Clamps Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
WP 0043 00 Thermostat and Thermostat Housing Cover Replacement . . . . . . . . . . . . . . . . 0043 00-1
WP 0044 00 Radiator Support Rod Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1
WP 0045 00 Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 00-1
WP 0046 00 Fan Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
WP 0047 00 Fan Impeller and Shroud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1
WP 0048 00 Fan Clutch Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00-1
WP 0049 00 Fan Clutch and Drive Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
WP 0050 00 Water Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-1
WP 0051 00 Water Filter Adapter and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1
WP 0052 00 Water Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1
WP 0053 00 Spindle and Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
WP 0054 00 Alternator Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1
WP 0055 00 Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
WP 0056 00 Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
WP 0057 00 Voltage Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
WP 0058 00 Battery Equalizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
WP 0059 00 Starter Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1
ii
TM 9-2320-302-20

Page
Number
WP 0060 00 Left Panel Gages and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1

WP 0061 00 Center Gage Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
WP 0062 00 Right Gage Panel and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1
WP 0063 00 Upper Right Dash Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00-1
WP 0064 00 Left Hand Switch Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
WP 0065 00 Right Hand Switch Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
WP 0066 00 Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
WP 0067 00 Heater and Air Conditioning Control Panel Replacement . . . . . . . . . . . . . . . . . 0067 00-1
WP 0068 00 12V Power Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1
WP 0069 00 Fiber Optic Light Source Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
WP 0070 00 Check Engine Switch and Jumper Harness Replacement . . . . . . . . . . . . . . . . . 0070 00-1
WP 0071 00 Fuse, Relay, Circuit Breaker, and Holder Replacement . . . . . . . . . . . . . . . . . . 0071 00-1
WP 0072 00 Master Battery Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
WP 0073 00 Turn Signal Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
WP 0074 00 Electronic Throttle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
WP 0075 00 Electronic Control Module Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
WP 0076 00 NATO Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1
WP 0077 00 Utility Power Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1
WP 0078 00 Trailer Electrical Receptacles Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
WP 0079 00 Parking Brake Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
WP 0080 00 Water Level Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1
WP 0081 00 Water Level Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
WP 0082 00 Headlamp Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
WP 0083 00 Headlamp and Headlight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
WP 0084 00 Blackout Drive, Marker Light, and Wiring Harness Replacement . . . . . . . . . . 0084 00-1
WP 0085 00 Right Front Blackout Marker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1
WP 0086 00 Rear Blackout Marker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
WP 0087 00 Taillight Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
WP 0088 00 Side Marker/Turn Signal Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
WP 0089 00 Clearance Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
WP 0090 00 Utility Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00-1
WP 0091 00 Interior Light Unit and Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
WP 0092 00 Fuel Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1
WP 0093 00 Fuel Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
WP 0094 00 Fuel Level Sending Unit Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1
WP 0095 00 Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
WP 0096 00 Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
WP 0097 00 Oil Pressure Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1
WP 0098 00 Water Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1
WP 0099 00 Water Level Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1
WP 0100 00 Fan Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1
WP 0101 00 Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
WP 0102 00 Turbo Boost Sensor (TBS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
WP 0103 00 Timing Reference Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
WP 0104 00 Synchronous Reference Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1
WP 0105 00 Air Pressure Sending Units (Primary/Secondary) Replacement . . . . . . . . . . . . 0105 00-1
WP 0106 00 Front Anti-lock Brake System (ABS) Sensor Replacement . . . . . . . . . . . . . . . 0106 00-1
iii
TM 9-2320-302-20

Page
Number
WP 0107 00 Rear Anti-lock Brake System (ABS) Sensor Replacement . . . . . . . . . . . . . . . . 0107 00-1
WP 0108 00 Anti-lock Brake System (ABS) Electronic Control Unit Replacement . . . . . . . 0108 00-1
WP 0109 00 Brake Light/Trailer Brake Light Sending Unit Replacement . . . . . . . . . . . . . . 0109 00-1
WP 0110 00 Collision Warning System (CWS) Antenna Alignment . . . . . . . . . . . . . . . . . . 0110 00-1
WP 0111 00 Collision Warning System (CWS) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
WP 0112 00 Electric Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
WP 0113 00 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
WP 0114 00 Battery Box Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1
WP 0115 00 Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
WP 0116 00 Stop/Tail/Backup Lights Wiring Harness Replacement . . . . . . . . . . . . . . . . . . 0116 00-1
WP 0117 00 Automatic Ether Starting Aid Wiring Harnesses Replacement . . . . . . . . . . . . . 0117 00-1
WP 0118 00 Cab-to-Frame Ground Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0118 00-1
WP 0119 00 Electrical Connectors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
WP 0120 00 Shift Selector and Shift Tower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
WP 0121 00 Transmission Oil Fill/Level Check Tube Replacement . . . . . . . . . . . . . . . . . . . 0121 00-1
WP 0122 00 Transmission Oil Cooler Lines and Fittings Replacement. . . . . . . . . . . . . . . . . 0122 00-1
WP 0123 00 Transmission Oil Filter Elements Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
WP 0124 00 Transmission Electronic Control Unit (ECU) Replacement . . . . . . . . . . . . . . . 0124 00-1
WP 0125 00 Transmission Electronic Control Unit (ECU) Wiring Harness Replacement . . 0125 00-1
WP 0126 00 Transmission Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
WP 0127 00 Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1
WP 0128 00 Transmission Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1
WP 0129 00 Driveline Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1
WP 0130 00 Driveline U-Joints and Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
WP 0131 00 Front Axle Toe in Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
WP 0132 00 Front Axle Stop Cushion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
WP 0133 00 Rear Axle Breather Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
WP 0134 00 Brake Pedal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1
WP 0135 00 Front Brakeshoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1
WP 0136 00 Front Brake Spider and Brake Chamber Bracket Replacement. . . . . . . . . . . . . 0136 00-1
WP 0137 00 Rear Brakeshoe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1
WP 0138 00 Rear Brake Spider and Brake Chamber Bracket Replacement . . . . . . . . . . . . . 0138 00-1
WP 0139 00 Slack Adjuster Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1
WP 0140 00 Slack Adjuster and S-cam Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1
WP 0141 00 Front Air Brake Chamber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1
WP 0142 00 Rear Air Brake Chamber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1
WP 0143 00 Primary I Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1
WP 0144 00 Primary II Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
WP 0145 00 Secondary Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
WP 0146 00 Air Supply Tank And Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
WP 0147 00 Air Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00-1
WP 0148 00 Constant Air Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
WP 0149 00 Cab Air Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
WP 0150 00 Tractor Protection Valves Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
WP 0151 00 Rear Relay Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
WP 0152 00 Front Service Brake Relay Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
WP 0153 00 Front Gladhands Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
WP 0154 00 Rear Gladhand Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00-1
iv
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Page
Number
WP 0155 00 Front Quick-release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1

WP 0156 00 Rear Quick-release Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
WP 0157 00 Air Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
WP 0158 00 Air Dryer Canister Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
WP 0159 00 Trailer Hand Brake Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
WP 0160 00 Parking Brake and Trailer Air Supply Valve Replacement . . . . . . . . . . . . . . . 0160 00-1
WP 0161 00 Foot Brake Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
WP 0162 00 Front Anti-lock Brake System (ABS) Air Solenoid Replacement. . . . . . . . . . . 0162 00-1
WP 0163 00 Rear Anti-lock Brake System (ABS) Air Solenoid Replacement . . . . . . . . . . . 0163 00-1
WP 0164 00 Front and Dual Rear Wheel Lug Nut Installation . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
WP 0165 00 Front Hub, Drum, Wheel Bearings, and Seal Replacement . . . . . . . . . . . . . . . . 0165 00-1
WP 0166 00 Rear Hub, Drum, Wheel Bearings, and Seal Replacement . . . . . . . . . . . . . . . . 0166 00-1
WP 0167 00 Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1
WP 0168 00 Universal Shaft Replacement and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
WP 0169 00 Pitman Arm and Drag Link Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
WP 0170 00 Power Steering Reservoir and Hose Maintenance . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
WP 0171 00 Right Step Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
WP 0172 00 Left Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
WP 0173 00 Left Side Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
WP 0174 00 Right Rear Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
WP 0175 00 Front Bumper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
WP 0176 00 Spare Wheel Hoist Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
WP 0177 00 Rear Tie Down Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
WP 0178 00 Fifth Wheel Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
WP 0179 00 Pintle Hook Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1
WP 0180 00 Towing Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
WP 0181 00 Taillight Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
WP 0182 00 Front Shock Absorber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
WP 0183 00 Rear Shock Absorber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1
WP 0184 00 Brush Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
WP 0185 00 Engine Hood Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
WP 0186 00 Hood Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1
WP 0187 00 Hood Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
WP 0188 00 Hood Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
WP 0189 00 Hood Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1
WP 0190 00 Hood Prop and Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1
WP 0191 00 Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-1
WP 0192 00 Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
WP 0193 00 Seat Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
WP 0194 00 Front Splash Guard and Fender Extension Maintenance . . . . . . . . . . . . . . . . . . 0194 00-1
WP 0195 00 Rear Fender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-1
WP 0196 00 Mud Flap Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1
WP 0197 00 Personal Gear Storage Box and Mounting Bracket Replacement . . . . . . . . . . . 0197 00-1
WP 0198 00 Basic Issue Items (BII) Storage Box and Mounting Bracket Replacement . . . . 0198 00-1
WP 0199 00 Storage Box Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
WP 0200 00 Rear Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
WP 0201 00 Floor Mats Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1
v
TM 9-2320-302-20

Page
Number
WP 0202 00 Cab Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1

WP 0203 00 Head Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1
WP 0204 00 Cab Overhead Storage Compartment Replacement . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
WP 0205 00 Steering Column Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
WP 0206 00 Cab Door Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
WP 0207 00 Transmission Tunnel Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1
WP 0208 00 Rear View Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-1
WP 0209 00 Spotter Mirror Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
WP 0210 00 Windshield Wiper Motor and Linkage Replacement . . . . . . . . . . . . . . . . . . . . . 0210 00-1
WP 0211 00 Windshield Washer Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00-1
WP 0212 00 Windshield Wiper and Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . 0212 00-1
WP 0213 00 Vehicle Jack Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0213 00-1
WP 0214 00 Air Horn and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-1
WP 0215 00 Data and Instruction Plates Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1
WP 0216 00 M16 Rifle Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216 00-1
WP 0217 00 Cup Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0217 00-1
WP 0218 00 Cab Roof Air Deflector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1
WP 0219 00 HVAC Air Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219 00-1
WP 0220 00 HVAC Blower Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00-1
WP 0221 00 HVAC Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221 00-1
WP 0222 00 Air Conditioner Resister Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-1
WP 0223 00 Air Conditioner Thermostatic Switch Replacement . . . . . . . . . . . . . . . . . . . . . 0223 00-1
WP 0224 00 Air Conditioner Binary Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00-1
WP 0225 00 Air Conditioner Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00-1
WP 0226 00 Air Conditioner Compressor Magnetic Clutch Replacement . . . . . . . . . . . . . . 0226 00-1
WP 0227 00 M13 Decontamination Kit Mounting Bracket Replacement . . . . . . . . . . . . . . . 0227 00-1
WP 0228 00 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00-1
WP 0229 00 Arctic Heater Replacement (WEBASTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00-1
WP 0230 00 Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230 00-1
WP 0231 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231 00-1
CHAPTER 4 SUPPORTING INFORMATION
WP 0232 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0232 00-1

WP 0233 00 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . 0233 00-1
WP 0234 00 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234 00-1
WP 0235 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-1
WP 0236 00 Tool Identification List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0236 00-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
DDEC III/IV Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-1
OEM Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-2
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HOW TO USE THIS MANUAL
This manual is designed to help you maintain the M915A3 Tractor Truck.
FEATURES OF THIS MANUAL:
• A Table of Contents is provided at the beginning of this manual.

• WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted
in BOLD print as a visual aid.
WARNING
A WARNING indicates a hazard which results in death or serious injury.
CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result
in damage to equipment.
NOTE
A NOTE is a statement containing information that will make the procedures easier to perform.
• Statements and words of particular importance are printed in CAPITAL LETTERS to create empha-
sis.
• Instructions are located with illustrations that show the specific task on which the mechanic is work-
ing.
• Dashed leader lines used in illustrations indicate that called out items are not visible (i.e. they are
located within the structure). Dashed leader lines in the Lubrication Chart indicate that lubrication is
required on BOTH sides of the equipment.
• Technical instructions include metric units in addition to standard units. A metric conversion chart is
provided on the inside back cover.
• An alphabetical index is provided at the end of the manual to assist in locating information not readily
found in the Table of Contents.
FOLLOW THESE GUIDELINES WHEN YOU THIS MANUAL:
• Read through this manual and become familiar with its contents before attempting to maintain the
vehicle.
• A Warning Summary is provided at the beginning of this manual and should be read before attempting
to maintain the vehicle.
vii
TM 9-2320-302-20
viii
TM 9-2320-302-20
CHAPTER 1
INTRODUCTORY INFORMATION WITH
THEORY OF OPERATION
TM 9-2320-302-20

TM 9-2320-302-20
GENERAL INFORMATION 0001 00
SCOPE
1. Type of Manual. This manual is for use in performing Unit Maintenance on the M915A3 Tractor Truck.
2. Equipment Name and Model Number. Truck, Tractor, Line Haul: 52,000 GVWR, 6 X 4, M915A3.
3. Purpose of Equipment. The M915A3 Tractor Truck is a 6 X 4 prime mover of semitrailers used primarily to transport
containers, bulk cargo, and petroleum products over primary and secondary roads under worldwide climatic conditions
in a military environment.
MAINTENANCE FORMS, RECORDS, AND REPORTS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738-750,
Functional User’s Manual for the Army Maintenance Management System (TAMMS), as contained in the Maintenance Man-
agement Update.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS)
If your truck needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t
like about your equipment. Let us know why you don’t like the design or performance. Put it on an SF Form 368 (Product
Quality Deficiency Report). Mail it to us at: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN:
AMSTA-LC-CIP-WT, Rock Island, Illinois 61299-7630. We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
1. 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.
2. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as
rubber and plastic. Unusual cracking, softening, swelling or breaking of these materials may be a corrosion problem.
3. If a corrosion problem is identified, it can be reported using SF Form 368 (Product Quality Deficiency Report). Use of
key words such as “corrosion,” “rust,” “deterioration,” or “cracking” will ensure that the information is identified as a
CPC problem. The form should be submitted to the address specified in DA Pam 738-750.
OZONE DEPLETING SUBSTANCES (ODS)
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 740-90-1 and MIL-V-62038D.
WARRANTY INFORMATION
The vehicle is warranted by Freightliner Corporation in accordance with TB 9-2320-302-15. 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.
0001 00-1
TM 9-2320-302-20
GENERAL INFORMATION - CONTINUED 0001 00
NOMENCLATURE CROSS-REFERENCE LIST
COMMON NAME OFFICIAL NOMENCLATURE
Cold Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ether Quick-start System

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antifreeze, Ethylene Glycol Mixture
Gladhand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Disconnect Coupling
Jake Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Brake
Komfort Loc®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat Belt Adjustment
TufTrac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension System
LIST OF ABBREVIATIONS
NOTE
Refer to MIL-STD-12D for standard abbreviations.
ABBREVIATION DEFINITION
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-lock Brake System
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centigrade or Celsius
CEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check Engine Light
CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Inch Displacement
cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter
CWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Collision Warning System
DDEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detroit Diesel Electronic Controlled
DDL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Data Link
DDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diagnostic Data Reader
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Control Unit
F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit
GCWR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Combination Weight Rating
GVWR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight Rating
kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram
km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilometer
kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal
kph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour
kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilowatt
l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liter
lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pound
lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound foot
lph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters per Hour
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter
mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter
MTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movement Tracking System
0001 00-2
TM 9-2320-302-20
GENERAL INFORMATION - CONTINUED 0001 00
LIST OF ABBREVIATIONS - CONTINUED

ABBREVIATION DEFINITION
Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meter
PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services
psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pounds per Square Inch
rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Revolutions per Minute
0001 00-3
TM 9-2320-302-20
0001 00-4
TM 9-2320-302-20
EQUIPMENT DESCRIPTION AND DATA 0002 00
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

1. Characteristics.
a. The M915A3 Tractor Truck is used to transport M871, M872, and M1062 semitrailers on line haul missions.
b. It has a Gross Vehicle Weight Rating (GVWR) of 52,000 lb (23,608 kg) and is equipped with a two-way oscillat-
ing, sliding fifth wheel compatible with a two-inch kingpin. Maximum towed load on kingpin is 30,000 lb (13,620
kg).
2. Capabilities and Features.
a. While operating on Class I roads, the fully loaded M915A3 can maintain a speed of 65 mph (105 kph) on level
roads and 29 mph (47 kph) while ascending a 3 percent grade. It has a minimum turning diameter, curb-to-curb, of
53 ft 9 in (16.4 m).
b. Average cruising ranges at Gross Combination Weight Rating (GCWR) with a full tank of fuel will vary based on
conditions (e.g., varying loads, prolonged idle, and climatic conditions). Cruising range is optimally 400 miles
(640 km).
c. The M915A3 is equipped with an instrument panel mounted speedometer and tachometer which register truck
ground speed and engine speed.
d. The M915A3 has the following capabilities and features:
(1) air-activated front and rear non-asbestos cam brakes with a four-channel anti-lock brake system (ABS) to
provide significantly improved handling and braking during emergency stops
(2) operation in temperatures from -25°F (-32°C) to +125°F (+52°C), and to -40°F (-40°C) with arctic kit
installed
(3) start and climb capability of a 20 percent grade at GCWR in both forward and reverse directions
(4) fording capability up to 20 in (51 cm) deep for 5 minutes without damage or requiring maintenance before
operations can continue
(5) two-passenger aluminum corrosion-proof cab with a 90 degree tilt-forward hood for service accessibility
(6) six cylinder, 12.7 liter, 430 horsepower, in-line turbocharged diesel engine built by Detroit Diesel
(7) Allison HD 4560P six-speed automatic transmission
(8) Collision Warning System (CWS) that warns the driver of potentially dangerous driving situations by acti-
vating visual and audible alerts.
e. For operation in arctic conditions, the M915A3 can be equipped with an arctic heater mounted under the cab,
above the battery box. This provides heat for the cab and engine cooling system. The arctic heater may be operated
prior to starting the engine to provide preheating of engine block.
0002 00-1
TM 9-2320-302-20
EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
1
2
4
5 6
15 7
14
10
13 11 10 9 8
12
KEY COMPONENT DESCRIPTION
1 Marker Clearance Indicate outline of truck.

Lights
2 Side Mirrors (Heated) Provide driver with a view of sides of truck and
semitrailer, if towing.
3 Grabhandles Provide a hand hold for personnel climbing on truck.
4 Utility Power Supplies power for work lights. Located on both sides of
Receptacle truck.
5 Air Horn Provides an audible alert.
6 Master Battery Switch Provides battery power to truck.
7 Spare Wheel and Tire Extra wheel and tire used in case of a flat tire.
8 Battery Box and Steps Holds vehicle batteries and provides steps to access cab.
9 Front Service Lights Include headlights and turn signals.
10 Bumper Extensions Provide adjustable attachment point for slings.
11 Blackout Lights Used during blackout conditions. Include marker and

drive lights.
12 Towing Eyes Provide attachment points for towing device.
0002 00-2
TM 9-2320-302-20
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
13 CWS Antenna Forward looking collision warning system antenna.
14 Brush Guard Protects front of hood and components under hood from
damage.
15 Spotting Mirrors Provide added visibility to sides and front of truck.
0002 00-3
TM 9-2320-302-20
19 20
21
18
22
17
16
23
24
25
31 27
29 30 29 28
26
16 Ramp Sloped surface serves as an approach to fifth wheel and

facilitates coupling of semitrailer.
17 Fifth Wheel Coupling device for semitrailers with kingpins.
18 Utility Lights Illuminate area in back of cab. There is one light on each
side of cab.
19 Strobe Warning Light Strobe light alerts other vehicles of presence of truck.
20 Intervehicular Contains 12-volt commercial, 24-volt military, and

Receptacles Installation trailer ABS receptacles.
21 Antenna Mount Mount for radio antenna.
22 Exhaust Muffler Deadens noise of engine exhaust.
23 Hood Latch Locks hood closed. Located on both sides of hood.
24 CWS Side Sensor Side looking collision warning system sensor.
25 Fuel Tank Holds fuel. Steps mounted to tank provide access to cab.
26 Storage Boxes Provide stowage area for BII and other items.
27 Mud Flaps Prevent water and debris from spraying up on passers by

or towed semitrailer.
0002 00-4
TM 9-2320-302-20
28 Blackout Lights Used during blackout conditions.
29 Trailer Gladhands Provide air supply for trailer brakes.
30 Pintle Hook Coupling device for trailers with lunettes.
31 Taillights Contain composite tail, stop, backup, and turn signal

lights.
0002 00-5
TM 9-2320-302-20
EQUIPMENT DATA
Dimensions:
Length (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 in (701 cm)
Height (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 in (300 cm)
Width (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in (254 cm)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 in (411 cm)
Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 in (23 cm)
Angle of Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27°
Weights:
Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,080 lb (8662 kg)
GVWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52,000 lb (23,608 kg)
GCWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105,000 lb (46,670 kg)
Front Axle (Loaded). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 lb (5448 kg)
Rear Axle (Loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000 lb (18,160 kg)
Capacities:
Engine Oil (Refill w/Filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 qt (38.8 l)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 qt (61.5 l)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 gal. (378.5 l)
Power Steering Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 qt (1.9 l)
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 qt (48 l)
Rear Axle (Forward/Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/14.5 qt (12.3/13.7 l)
Engine:
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detroit Diesel
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-stroke, in-line
turbocharged diesel
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DDEC IV
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755 CID (12.7 l)
Torque @ 1200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 lb-ft (1898 Nm)
Maximum Horsepower @ 2100 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 (320.6 kW)
Maximum Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Oil Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 full flow,
replaceable elements
Oil Filter Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel System:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel fuel injected
Fuel Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 primary, 1 secondary
replaceable element
Air Cleaner:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry element
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
0002 00-6
TM 9-2320-302-20
EQUIPMENT DATA - CONTINUED

Cooling System:
Radiator Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 psi (69 kPa)
Coolant Inhibitor Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 replaceable element
Electrical System:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual 12/24 volt
Batteries:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
Transmission:
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allison
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HD 4560P
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-speed automatic
Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pushbutton
Front Axle:
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-beam, FF961
Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 lb (5448 kg)
Maximum Steering Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32°
Rear Axle (Tandem):
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell, RT 40-145P
Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,000 lb (17,252 kg)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44:1
Inter-axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bevel gear
Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air controlled
Brake System:
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air-mechanical
Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120 psi (414-827 kPa)
Airbrake Chambers:
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 on front axle
Failsafe (Spring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 on forward-rear
and rear-rear axles
ABS (Anti-lock Brake System):
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-channel
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . front axle and rear-rear axle
Wheels:
Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 x 8.25 in
Number of Studs/Stud Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/1.125 in
Tires:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tubeless, radial
on-highway
Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11R22.5
Ply Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14PR
Load Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H
0002 00-7
TM 9-2320-302-20

Tires - Continued:
Inflation Pressure (Maximum Load):
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 psi (724 kPa)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (690 kPa)
Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 psi (724 kPa)
Steering:
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRW
Steering Gear Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . single gear
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic power booster
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton B165R
Turning Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 ft 9 in (16.4 m)
Steering Column and Wheel:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tilt, telescoping
Tilt Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15°
Telescoping Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5/8 in (67 mm)
Suspension:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single leaf spring
w/shock absorbers
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TufTrac
w/shock absorbers
Towing Attachments:
Pintle Hook:
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holland
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no. 760
Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 tons
(27.2 metric tons)
Towing Eyes:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 front, 2 rear
Maximum Load Capacity, Each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,000 lb (27,240 kg)
(Up to 45° Angle Front Long. Axis)
Fifth Wheel:
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holland
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 in (91.4 cm)
diameter, 2-way
oscillating, low lube
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000 lb (13,620 kg)
Height (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 in (132.1 cm)
Pitch (Fwd/Aft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/10°
Kingpin Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 in (5.1 cm)
Cab:
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freightliner
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-passenger,
tilt-forward hood
Air Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adjustable
0002 00-8
TM 9-2320-302-20

Accessories:
Utility Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 fixed, top rear of cab
Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, under cab
Military Load Classification:
Vehicle w/o Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Vehicle w/Trailer:
M871. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/35
(unloaded/loaded)
M872. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/46
(unloaded/loaded)
M1062. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/34
(unloaded/loaded)
0002 00-9
TM 9-2320-302-20
0002 00-10
TM 9-2320-302-20
THEORY OF OPERATION 0003 00
INTRODUCTION
1. The M915A3 Tractor Truck consists of the following functional systems: drive train, fuel system, exhaust system, cool-
ing system, electrical system, air system, brake system, steering system, traction control system, suspension system, air
conditioning system, and collision warning system.
2. This work package explains how the components and systems of the M915A3 work together. A functional description is
provided for each major component and system.
DRIVE TRAIN
The drive train of the M915A3 consists of a Detroit Diesel, DDEC IV engine and an Allison 6-speed automatic transmission
connected to RT 40-145P rear tandem axles.
REAR-
REAR AXLE
FORWARD-
REAR AXLE
TRANSMISSION
ENGINE
FUEL SYSTEM
1. Fuel to power the engine is pumped out of the fuel tank by an engine-mounted fuel pump. The engine fuel system con-
sists of one electronic unit injector per cylinder, a transfer pump, low-pressure fuel lines, and primary and secondary
fuel filters.
2. The engine is governed by an electronic control system. The system controls idle speed and limits engine maximum
speed. The driver controls engine speed through the position of the electronic throttle position sensor (foot pedal).
3. Fuel filters are spin-on types. The primary fuel filter has a hand fuel primer pump and a water drain.
4. Fuel may be drained from the tank through the drain port located on the bottom of the tank.
5. There is a computer-controlled ether quick-start system for use in cold weather.
0003 00-1
TM 9-2320-302-20
THEORY OF OPERATION - CONTINUED 0003 00
FUEL SYSTEM - CONTINUED
CYLINDER
HEAD
RESTRICTED
FITTING
(UPPER
FITTING)
FUEL
PUMP
PRIMARY
FUEL FILTER
WITH HAND
PRIMER
SECONDARY
WATER FUEL FILTER
DRAIN
FUEL TANK
EXHAUST SYSTEM
The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow
into exhaust pipes and a muffler to the atmosphere above the cab.
EXHAUST MANIFOLD
TURBOCHARGER
MUFFLER
EXHAUST PIPES
0003 00-2
TM 9-2320-302-20
COOLING SYSTEM
The cooling system consists of one circulating pump, a remote-mounted coolant filter, two 180°F (82°C) thermostats for con-
trolling fluid flow, a transmission oil cooler, a radiator, and a belt-driven fan. The cooling system cools the engine by circulat-
ing pressurized ethylene-glycol based coolant through the engine and radiator.
TWO
THERMOSTATS
CIRCULATING
PUMP
INLET
(FROM RADIATOR)
DDEC IV ENGINE
ELECTRICAL SYSTEM
1. Four 12-volt batteries connected in series-parallel supply the 12-volt electrical system and provide 24 volts for the
starter motor, blackout lights, accessories, and trailer connectors.
2. The Dual Voltage Alternator Control (DUVAC), mounted on the firewall in the engine compartment, regulates the dis-
tribution of 12 and 24 volts.
0003 00-3
TM 9-2320-302-20
ELECTRICAL SYSTEM - CONTINUED
0003 00-4
TM 9-2320-302-20
AIR SYSTEM
The air system consists of the air compressor, air dryer, air reservoirs, and various air lines. Also included in the air system are
air pressure gages, located on the instrument panel, for monitoring air pressure for safe operation of all air-operated compo-
nents of the vehicle.
AIR GAGES
PRIMARY SECONDARY
HOLDING TANKS
AIR COMPRESSOR 342-008
BRAKE SYSTEM
1. The dual air brake system consists of two independent air brake systems that use a single set of brake controls. Each sys-
tem has its own reservoirs, plumbing, and brake chambers. The primary system operates the service brakes on the rear
axle and the secondary system operates the service brakes on the front axle. On tractor-trailer configurations, service
brake signals from both systems are sent to the trailer.
2. Loss of air pressure in the primary system causes the rear service brakes to become inoperative. Front brakes will con-
tinue to be operated by secondary system air pressure. In addition, trailer brakes will be operated by the secondary sys-
tem. Loss of secondary system air pressure causes the front axle brakes to become inoperative. Rear service brakes and
trailer brakes will be operated by the primary system.
0003 00-5
TM 9-2320-302-20
BRAKE SYSTEM - CONTINUED

3. The warning light and buzzer inside the cab are activated if air pressure drops below 64 psi (441 kPa) in either brake
system. If this happens, check air pressure gages to determine which system has low air pressure. Although vehicle
speed can be reduced using the foot brake control pedal, either the front or rear service brakes will not operate, resulting
in a longer stopping distance. Bring vehicle to a safe stop and have the air system repaired before continuing.
4. If the primary brake system becomes inoperative, the spring parking brakes automatically apply when air pressure drops
to 35-45 psi (241-310 kPa).
5. The vehicle has a four-channel anti-lock brake system (ABS) and cam-operated service brakes with non-asbestos brake-
shoes.
6. The M915A3 has automatically adjusting slack adjusters. On all axles, brake chambers have a stroke alert indicator
which allows the operator to monitor brakeshoe wear.
AIR CONTROLS
TRAILER
TRAILER PARKING
HAND BRAKE AIR BRAKE
BRAKE
CONTROL
REAR AXLE SPRING
BRAKE CHAMBERS
FRONT AXLE
BRAKE CHAMBERS 342-008
COMPRESSOR
0003 00-6
TM 9-2320-302-20
STEERING SYSTEM
1. The power steering system consists of an integral steering gear (which includes a manual steering mechanism and
hydraulic control valve), hydraulic hoses, power steering pump, reservoir, and other components.
2. The power steering pump, driven by the engine, provides the power-assist for the steering system.
POWER STEERING PUMP
STEERING GEAR
RESERVOIR
TRACTION CONTROL SYSTEM

The inter-axle differential lock is controlled by the air operated lever labeled INTER-AXLE DIFFERENTIAL on the driver’s
instrument panel. Under normal driving conditions, the control lever should be in the UNLOCKED position. During poor driv-
ing conditions, the control lever may be moved to the LOCKED position to improve traction. When the inter-axle differential
lock is applied, the drive shaft becomes a solid connection between the two rear axles.
0003 00-7
TM 9-2320-302-20
REAR SUSPENSION SYSTEM

The TufTrac rear suspension system consists two parabolic taper-leaf springs and two shock absorbers per side and an arrange-
ment of torque rods. The suspension system is designed to provide a high degree of ground clearance and articulation while
maintaining an equal load over each wheel. Ride characteristics are similar, whether loaded or unloaded.
0003 00-8
TM 9-2320-302-20
AIR CONDITIONING SYSTEM

1. The air conditioning unit is part of the heater and is mounted under the glove compartment. It is a single unit consisting
of a heater core, air conditioning evaporator coil, blower motor, control valves, and air ducts.
2. The system is turned on by the mode control lever on the instrument panel in the cab. The four-speed blower switch con-
trols flow rate.
3. An even cab temperature is maintained by controlling the coolant flow through the heater core, or refrigerant flow
through the evaporator coil.
THERMOSTATIC
HEATER SWITCH
CONDENSER
CORE
EXPANSION
VALVE
EVAPORATOR
COIL
COMPRESSOR
RECEIVER
DRYER
0003 00-9
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS)

1. The Collision Warning System (CWS) consists of an antenna assembly, central processing unit, driver display unit, side
sensor, side sensor display, and wiring harness.
2. The CWS is a forward and side looking radar system that transmits and receives signals reflected off of objects to the
front and side of the tractor.
3. The forward looking antenna assembly determines distance, azimuth, and approximate speed of vehicle forward of the
tractor.
4. The side sensor detects vehicles or objects from two to ten feet, moving or stationary, alongside the tractor.
SIDE
SENSOR
SIDE SENSOR
DISPLAY
DRIVER CENTRAL
DISPLAY UNIT PROCESSING UNIT
ANTENNA
ASSEMBLY WIRING HARNESS
0003 00-10
TM 9-2320-302-20
CHAPTER 2
UNIT TROUBLESHOOTING PROCEDURES
TM 9-2320-302-20

TM 9-2320-302-20
TROUBLESHOOTING INTRODUCTION 0004 00
INTRODUCTION
Troubleshooting procedures are grouped by work packages, containing information you need to fault locate malfunc-
tions on the M915A3 Tractor Truck. A troubleshooting symptom index in WP 0005 00 is provided to aid in locating a mal-
function or symptom and direct you to the appropriate troubleshooting table (work package) containing a listing of
malfunctions, test and inspection procedures, and corrective actions. The corrective action column further directs you to the
required corrective maintenance procedure within this manual by work package number. However, if the required mainte-
nance procedure is beyond Unit Maintenance capabilities, the direction is to notify Direct Support Maintenance.
PRELIMINARY TROUBLESHOOTING PROCEDURES
NOTE
Fluid leaks are classified as either Class I, Class II or Class III
Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II: Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item
being checked/inspected.
Class III: Leakage of fluid great enough to form drops that fall from item being checked/inspected.
Before starting any specific troubleshooting procedures, perform the following:

a. Visually check for ruptured oil hoses or tubes and for Class II or Class III leaks.
b. Check for mechanical jamming or binding caused by rocks or other foreign matter.
c. Check fluid levels in subject area and service as required (TM 9-2320-302-10 or WP 0021 00).
ELECTRICAL TROUBLESHOOTING
1. Analyze the symptoms and conditions and use common sense and logic to determine the most likely cause for the prob-
lem, then troubleshoot that circuit first. The more information you have concerning the problem, the easier it will be to
troubleshoot.
2. Isolate to the subsystem level (in cases where more than one subsystem is involved); next isolate the problem to a single
circuit within the subsystem; then, isolate the problem to the faulty component using the troubleshooting symptom index
(WP 0005 00).
3. Frayed, broken, loose or corroded wiring is a common source of problems in any electrical circuit. Always make visual
inspection before starting detail troubleshooting. Observe in particular contacts to ground. Components with case
grounds are especially troublesome.
CAUTION
When making continuity checks, make sure the test equipment is isolated from power source.
4. Most of the checks are made by voltage checks. Pay particular attention to the voltages being checked in the procedures.
This equipment has a combination of 12 and 24 volt systems. Instructions prior to the step instruct to disconnect at test
point from the potential malfunctioning component. Once the check has been made, either repair the component or go to
the referenced step. If going to another step, reconnect connection or do as otherwise instructed, such as install jumper
wires using Jumper Wire Kit. When ready to make the prescribed check, apply power to the circuit (if required). A
helper may be required if the switch or power source is out of reach. Release the power function prior to going on, to
avoid damage to equipment.
0004 00-1
TM 9-2320-302-20
TROUBLESHOOTING INTRODUCTION - CONTINUED 0004 00
DDEC ENGINE TROUBLESHOOTING

1. Troubleshooting the DDEC engine and related systems is preformed by locating the malfunction within the trouble-
shooting symptom index (WP 0005 00), then referring to WP 0006 00 or WP 0007 00 for the required test or inspection
steps. The troubleshooting table in WP 0006 00 contains general procedures to identify and correct an engine or engine
related malfunction. The table also references the use of Check Engine Lights (CEL) and Stop Engine Lights (SEL)
flash codes to identify a problem. The information to utilize a Diagnostic Data Reader is also provided to aid in identify-
ing a malfunction.
2. Also available to troubleshoot the DDEC engine is The Detroit Diesel Data Link diagnostic CD Rom, used with a PC or
the SPORT computer.
0004 00-2
TM 9-2320-302-20
TROUBLESHOOTING SYMPTOM INDEX 0005 00
Malfunction/Symptom Page Number
ENGINE
1. Engine Fails to Crank or Cranks Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
2. Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
3. Engine Cranks, But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-2
4. Engine Stops, But Is Not Seized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-2
5. Erratic Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-3
6. Excessive Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-3
7. Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-4
8. High Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-4
9. Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-4
ELECTRICAL SYSTEM
Engine Brake System
Engine Brake (Jake Brake) Inoperative or Operates Erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
Engine Fan Circuit
Engine Fan Does Not Operate or Fails to Start at 190°F-210°F (87°C-98°C) . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
Charging Circuits
1. Batteries Not Charging, Voltmeter Does Not Indicate Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
2. +12 VDC Circuits Not Charging, +24 VDC Circuits Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
3. +24 VDC Circuits Not Charging, +12 VDC Circuits Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
Headlight Circuits
1. Neither Headlight Operates When Switch Is Turned On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-3
2. Left/Right Headlight Fails to Operate When Switch Is Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-3
3. Neither Headlight Low/High Beam Operates When Turn Signal Switch Lever Is Set. . . . . . . . . . . . . . . . . . . 0010 00-3
4. Left/Right High Beam Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-4
5. Left/Right Low Beam Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-4
Marker and Taillight Circuits
1. None of Marker and Taillights Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-4
2. Left/Right Front Marker Light Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-4
3. One or More Cab Marker Lights Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-5
4. Both Taillights Do Not Operate, But All Marker Lights Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-5
Blackout Light Circuits
1. None of Blackout (B/O) Lights Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-5
2. None of Blackout (B/O) Stoplights Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-5
3. One or None of Blackout (B/O) Marker Lights Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-6
4. One or None of Blackout (B/O) Drive Lights Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-6
Turn Signal and Stoplight Circuits
1. Stoplights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-7
2. Left/Right Stoplight Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-7
3. Flasher Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-8
0005 00-1
TM 9-2320-302-20
TROUBLESHOOTING SYMPTOM INDEX - CONTINUED 0005 00

Turn Signal and Stoplight Circuits - Continued
4. Turn Signal Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-8
5. Turn Signal Indicator Light Does Not Operate, But Turn Signals Operate Normally . . . . . . . . . . . . . . . . . . . . 0010 00-8
Dome Light Circuits
1. Dome Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-8
2. One Dome Light Operates, But Other Dome Light Does Not Operate in Either Mode . . . . . . . . . . . . . . . . . . 0010 00-9
3. Dome Light Operates in On/Off Switch Mode Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-9
Auxiliary Light Circuits
1. Auxiliary Lights or Accessory Circuits Do Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-9
2. No Power to Auxiliary Heater Fan Power Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-10
Worklight Power Receptacle Circuits
1. Worklight Power Receptacles Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-10
2. One Worklight Power Receptacle Does Not Operate, But Other Receptacle Operates Normally . . . . . . . . . 0010 00-10
Backup Light Circuits
1. Backup Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-11
2. Right/Left Backup Light Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-11
Utility Light Circuits
1. Utility Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-11
2. Only One Utility Light Operates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-12
3. Utility Light Indicator Light Does Not Operate, But Utility Lights Operate Normally . . . . . . . . . . . . . . . . . 0010 00-12
Electrical Horn Circuits
Electrical Horn Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-12
Tractor Beacon Light Circuits
Tractor Beacon Light Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-13
Panel Lights Circuits
1. Panel Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-14
2. Heater Control Light Does Not Operate, But Other Heater Circuits Operate Normally . . . . . . . . . . . . . . . . . 0010 00-14
3. One or More Gage Lights Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-14
4. Fiber Optics Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-14
5. Panel Lights Do Not Dim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-14
6. Panel Lights Do Not Brighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-14
Radio Circuits
Power Source for 24VDC Radio Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-15
Instrument Wiring Circuits
1. Instruments on Dashboard Do Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-15
2. Water Temperature Gage Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-15
3. Transmission Oil Temperature Gage Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-15
4. Fuel Level Gage Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-16
0005 00-2
TM 9-2320-302-20

Instrument Wiring Circuits - Continued
5. Voltmeter Does Not Operate, But Warning Light Operates Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-16
6. Axle Lock Indicator Light Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-16
Ether Cold-start Circuit
Ether Cold-Start Does Not Operate When Container Has Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-17
Air Dryer Heater Circuit
Air Dryer Heater Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-17
Standard Heater Circuits
Heater Fan Does Not Operate at Any Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-17
TRANSMISSION AND DRIVELINE SYSTEMS
Transmission
1. Shift Selector Display Is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
2. Vehicle Does Not Start (Engine Does Not Crank). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
Transmission Shifting
1. DO NOT SHIFT Light Will Not Go Out at Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
2. DO NOT SHIFT Light Flashes Intermittently . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-2
3. No DO NOT SHIFT Light at Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-2
4. ECU Will Not Turn Off When Ignition Switch Is Turned Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-2
5. Transmission Will Not Shift to Forward or Reverse (Stays In Neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-2
6. Transmission Will Not Stay in Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-2
7. Transmission Will Not Make a Specific Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
8. Transmission Does Not Shift Properly (Rough Shifts, Shifts Occurring at
Too Low or Too High Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
Abnormal Activities or Responses from Transmission
1. Excessive Creep in First and Reverse Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
2. No Response to Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
3. Vehicle Moves Forward in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
4. Vehicle Move Backward in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
5. Engine Overspeed on Full-throttle Upshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-3
6. Excessive Slippage and Clutch Chatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-4
7. Abnormal Stall Speeds (Stall in First Range - 6 Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-4
8. Overheating in All Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-4
9. Fluid Comes out Fluid Fill Tube and/or Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-4
10. Noise Occurring Intermittently (Buzzing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-5
11. Leaking Fluid (Output Shaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-5
12. Transmission Leaks (Input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-5
13. Dirty Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-5
0005 00-3
TM 9-2320-302-20
TRANSMISSION AND DRIVELINE SYSTEMS - CONTINUED
Forward-rear Axle and Rear-rear Axle Driveline Assemblies
1. No Drive at Forward-rear Axle and/or Rear-rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-5

2. Vibration or Noise During or While Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-6
BRAKE SYSTEM
1. Vehicle Does Not Slow Down Quickly Enough When Brakes Are Applied. . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
2. Brakes Do Not Release or Release Too Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
3. Brakes Are Uneven, Drag or Pull When Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
ANTI-LOCK BRAKE SYSTEM
Refer to Anti-lock Brake System (ABS) Troubleshooting and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1
AIR SYSTEM
1. Loss of Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1

2. Loss of Air Supply Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
3. Air Dryer Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
4. Air Dryer Fails to Absorb Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
STEERING SYSTEM
1. Loss of Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1

2. Difficult Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
3. Tie Rod, Drag Link or Pitman Arm Fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
4. Hose Assembly Fail (Leaks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
5. Power Steering Reservoir Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
CHASSIS AND FIFTH WHEEL
1. Pintle Will Not Lock or Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1

2. Trailer Will Not Couple or Becomes Uncoupled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
3. Restricted Motion Between Tractor and Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
AIR CONDITIONING SYSTEM
Refer to Air Conditioning System Troubleshooting and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1
COLLISION WARNING SYSTEM (CWS)
Refer to Collision Warning System (CWS) Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
0005 00-4
TM 9-2320-302-20
ENGINE TROUBLESHOOTING 0006 00
Table 1. Engine Troubleshooting Procedures.
MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

1. Engine Fails to Crank or Cranks Slowly. 1. Check for damaged or loose Tighten or repair battery connec-
battery connections. tions as required (WP 0115 00).
2. Check battery voltage. 22-26 If voltage is below 22 volts,
volts are required. service batteries (TM 9-6140-
200-14).
3. With ignition ON and engine a. If CEL comes on and stays
OFF, press Check Engine on, perform step 4 and read
Button and observe Check Active Flash Codes.
Engine Light (CEL).
b. If CEL comes on for up to
five seconds and then turns
off, perform step 4 and read
Inactive Flash Codes.
c. If CEL comes on, but is
erratic or intermittent, refer
to DDEC faults code
system 10.4 (WP 0007 00).
4. Connect Diagnostic Data Perform DDEC system diagnostic
Reader (DDR) to Diagnostic troubleshooting. Refer to section
Data Link (DDL) connector. number that matches flash code
logged (WP 0007 00).
2. Engine Does Not Crank. 1. Check for damaged or loose Tighten or repair battery connec-
battery connections. tions as required (WP 0115 00).
2. Check battery voltage. 22-26 If voltage is below 22 volts,
volts are required. service batteries (see TM 9-6140-
200-14).
3. Check electrical connections at Tighten or repair connections as
the starter motor. required (WP 0056 00).
Engine Light (CEL).
to DDEC system fault code
10.4 (WP 0007 00).
0006 00-1
TM 9-2320-302-20
Table 1. Engine Troubleshooting Procedures - Continued.

2. Engine Does Not Crank - Continued. 5. Connect Diagnostic Data Perform DDEC system diagnostic
3. Engine Cranks, But Does Not Start. 1. Check position of fuel shutoff If closed, open valve (WP
valve. 0030 00).
2. Check fuel lines and hoses for Tighten or replace fuel lines and
leaks and damage. hoses as necessary (WP 0030 00).
3. Check for clogged fuel/water Service or replace fuel filters (WP
separator and clogged 0031 00).
secondary fuel filter.
4. Confirm fuel system is primed. Using fuel/water separator primer
pump, prime system (TM 9-2320-
302-10).
5. Check for clogged or restricted Service air cleaner (WP 0036 00).
air cleaner element.
Engine Light (CEL).
10.4 (WP 0007 00).
7. Connect Diagnostic Data Perform DDEC system
4. Engine Stops, But Is Not Seized. 1. Check for clogged fuel/water Service or replace fuel filters (WP
2. Check fuel lines and hoses for Tighten or replace fuel lines and
Engine Light (CEL).
0006 00-2
TM 9-2320-302-20

4. Engine Stops, But Is Not Seized - Continued. c. If CEL comes on, but is
10.4 (WP 0007 00)
Reader (DDR) to Diagnostic troubleshooting by referring to the
Data Link (DDL) connector. section number that matches the
flash code logged (WP 0007 00).
5. Erratic Engine Operation. 1. Check fuel lines and hoses for Tighten or replace fuel lines and
3. Confirm fuel system is primed. Using fuel/water separator primer
pump, prime fuel system (TM 9-
2320-302-10).
4. Check for clogged or restricted Service air cleaner (WP 0036 00).
Button and observe Check Active Codes.
Engine Light (CEL).
to DDEC system fault code,
10.4 (WP 0007 00).
6. Excessive Exhaust Smoke. 1. Check for clogged or restricted Service air cleaner (WP 0036 00).
Engine Light (CEL).
0006 00-3
TM 9-2320-302-20

6. Excessive Exhaust Smoke- Continued. b. If CEL comes on for five
seconds and then turns off,
perform step 4 and read
10.4 (WP 0007 00).
7. Low Oil Pressure. 1. Check engine oil level. Fill to proper level (TM 9-2320-
302-10).
Engine Light (CEL).
c. If CEL comes on but is
10.4 (WP 0007 00).
8. High Oil Consumption. 1. Check for overfilled crankcase. Drain oil to proper level (TM 9-
2320-302-10).
2. Check for oil in air reservoir If oil is found in air reservoirs,
tanks. replace air compressor assembly
(WP 0029 00).
3. Check for indications of oil at If oil is found, notify Direct
turbocharger outlet and inlet. Support Maintenance.
9. Engine Overheats. 1. Check coolant level. Fill coolant to proper level (TM 9-
2320-302-10).
2. Check for loose or missing fan Adjust or replace fan belts as
belts. required (WP 0046 00).
3. Check radiator clamps and Replace or tighten radiator clamps
hoses for leaks. and hoses as necessary (WP 0042
00).
0006 00-4
TM 9-2320-302-20

9. Engine Overheats - Continued. 4. Remove and test thermostats. Replace failed thermostats (WP
0043 00).
5. Visually check radiator for If radiator fins are clogged,
signs of clogged fins, leaks, and remove obstructions. Replace
damage. leaking or damaged radiator (WP
0045 00).
Engine Light (CEL).
c. If CEL comes on but is
10.4 (WP 0007 00).
0006 00-5
TM 9-2320-302-20
0006 00-6
TM 9-2320-302-20
DDEC ENGINE TROUBLESHOOTING 0007 00
INTRODUCTION
1. The DDEC Troubleshooting Manual is provided in its entirety as part of this work package. For ease of use, this manual
retains its original format and page numbering.
2. A DDEC Engine Troubleshooting Index has been developed to assist the user in finding general information on DDEC
troubleshooting and locating specific diagnostic flash codes.
3. Note that the flash codes in the index are electronically linked to the flash codes within the DDEC Troubleshooting
Manual.
DDEC ENGINE TROUBLESHOOTING AND FLASH CODE INDEX
SECTION PAGE
NUMBER TITLE NUMBER
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 (CHG) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 (CHG) ECM and Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4 Basic Knowledge Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5 (CHG) Flash Codes vs. SAE Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6 (CHG) Testing/Service Tools/Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7 (CHG) DDEC ECM Software Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8 (UPDATE) Connectors, Terminals, and Splicing . . . . . . . . . . . . . . . . . . . . . 8-1
9 (CHG) Diagnosing a DDEC System Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10 (CHG) Intermittent Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11 Flash Code 11 – VSG Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12 Flash Code 12 – VSG High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13 (CHG) Flash Code 13 – CLS Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
14 (CHG) Flash Code 14 – Temp Sensor High. . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15 (CHG) Flash Code 15 – Temp Sensor Low . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
16 (CHG) Flash Code 16 – CLS High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
17 (CHG) Flash Code 17 – Throttle Valve High . . . . . . . . . . . . . . . . . . . . . . . 17-1
18 (CHG) Flash Code 18 – Throttle Valve Low . . . . . . . . . . . . . . . . . . . . . . . . 18-1
19 Flash Code 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
20 Flash Code 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
21 Flash Code 21 – TPS High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
22 Flash Code 22 – TPS Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
23 (CHG) Flash Code 23 – Fuel Temp Sensor High . . . . . . . . . . . . . . . . . . . . 23-1
24 (CHG) Flash Code 24 – Fuel Temp Sensor Low . . . . . . . . . . . . . . . . . . . . . 24-1
25 Flash Code 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
26 Flash Code 26 – Auxiliary Input Active . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-1
27 (CHG) Flash Code 27 – Air Temp Sensor High . . . . . . . . . . . . . . . . . . . . . 27-1
28 (CHG) Flash Code 28 – Air Temp Sensor Low . . . . . . . . . . . . . . . . . . . . . . 28-1
29 Flash Code 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-1
30 Flash Code 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
0007 00-1
TM 9-2320-302-20
DDEC ENGINE TROUBLESHOOTING - CONTINUED 0007 00
DDEC ENGINE TROUBLESHOOTING AND FLASH CODE INDEX - CONTINUED

SECTION PAGE
NUMBER TITLE NUMBER
31 (CHG) Flash Code 31 – Engine Brake Fault Code . . . . . . . . . . . . . . . . . . . 31-1
32 Flash Code 32 – CEL/SEL Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-1
33 (CHG) Flash Code 33 – TBS High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-1
34 (CHG) Flash Code 34 – TBS Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-1
35 Flash Code 35 – OPS High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
36 Flash Code 36 – OPS Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-1
37 Flash Code 37 – FPS High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-1
38 Flash Code 38 – FPS Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1
39 Flash Code 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-1
40 Flash Code 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
41 (CHG) Flash Code 41 – Too Many SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-1
42 (CHG) Flash Code 42 – Too Few SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1
43 Flash Code 43 – Coolant Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-1
44 Flash Code 44 – Temp High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-1
45 Flash Code 45 – Oil Pressure Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
46 Flash Code 46 – Battery Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-1
47 (CHG) Flash Code 47 – Air/Fuel Pressure High . . . . . . . . . . . . . . . . . . . . . 47-1
48 (CHG) Flash Code 48 – Air/Fuel Pressure Low . . . . . . . . . . . . . . . . . . . . . 48-1
49 Flash Code 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-1
50 Flash Code 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
51 (CHG) Flash Code 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-1
52 (CHG) Flash Code 52 – ECM Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-1
53 Flash Code 53 – ECM Memory Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-1
54 Flash Code 54 – VSS Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-1
55 (CHG) Flash Code 55 – J1939 Data Link Fault. . . . . . . . . . . . . . . . . . . . . . 55-1
58 (CHG) Flash Code 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-1
59 Flash Code 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-1
60 Flash Code 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
61 (CHG) Flash Code 61 – Injector Response Long . . . . . . . . . . . . . . . . . . . . 61-1
62 Flash Code 62 – Output Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-1
63 Flash Code 63 – PWM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-1
64 (CHG) Flash Code 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-1
65 (CHG) Flash Code 65 – Throttle Valve Fault . . . . . . . . . . . . . . . . . . . . . . . 65-1
66 (CHG) Flash Code 66 – Knock Sensor Fault. . . . . . . . . . . . . . . . . . . . . . . . 66-1
67 (CHG) Flash Code 67 – Map Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . 67-1
0007 00-2
TM 9-2320-302-20
DDEC ENGINE TROUBLESHOOTING - CONTINUED 0007 00
DDEC ENGINE TROUBLESHOOTING AND FLASH CODE INDEX - CONTINUED

SECTION PAGE
NUMBER TITLE NUMBER
68 Flash Code 68 – Idle Validation Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-1
69 Flash Code 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-1
70 Flash Code 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
71 (CHG) Flash Code 71 – Injector Response Short . . . . . . . . . . . . . . . . . . . . 71-1
72 Flash Code 72 – Vehicle Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-1
73 Flash Code 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-1
74 Flash Code 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1
75 Flash Code 75 – Battery Volt High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1
76 Flash Code 76 – Engine Overspeed/Brake . . . . . . . . . . . . . . . . . . . . . . . . . 76-1
77 Flash Code 77 – Fuel Temp High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-1
78 (CHG) Flash Code 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-1
79 Flash Code 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-1
80 Flash Code 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
81 (CHG) Flash Code 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-1
82 (CHG) Flash Code 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-1
83 (CHG) Flash Code 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-1
84 (CHG) Flash Code 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-1
85 Flash Code 85 – Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-1
86 Flash Code 86 – PGS Sensor High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-1
87 Flash Code 87 – PGS Sensor Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-1
88 (CHG) Flash Code 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-1
89 Flash Code 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-1
90 (CHG) Engine Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
91 (CHG) Vehicle Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91-1
92 (CHG) Engine Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-1
93 (CHG) Vehicle Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-1
94 (CHG) DDEC Pro-link Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94-1
0007 00-3
TM 9-2320-302-20
0007 00-4
DDEC TROUBLESHOOTING
ENGINE EXHAUST
Consider the following before servicing engines:
Engine exhaust may be harmful to your health if inhaled.
Please note this caution and remember:

3 Always start and operate the engine in a well ventilated area.
3 If in an enclosed area, vent the exhaust to the outside.
3 Do not modify or tamper with the exhaust system.
All information subject to change without notice.

6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION i

ii 6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION
GENERAL INFORMATION
Section Page
ABSTRACT ................................................................................................ 3

2 6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION
ABSTRACT
This manual provides instruction for troubleshooting the Detroit Diesel Electronic Controlled
(DDEC®) engines, with two or three (multiple) ECMs.
Specifically covered in this manual are troubleshooting and repair steps that apply to the DDEC
III and DDEC IV systems.
To reduce the chance of personal injury and/or property

damage, the following instructions must be carefully
observed. Proper service and repair are important to
the safety of the service technician and the safe, reliable
operation of the engine. If part replacement is necessary, the
part must be replaced with one of the same part number or
with an equivalent part number. Do not use a replacement
part of lesser quality. The service procedures recommended
and described in this manual are effective methods of
performing repair. Some of these procedures require the
use of specially designed tools. Accordingly, anyone who
intends to use a replacement part, procedure or tool which
is not recommended, must first determine that neither
personal safety nor the safe operation of the engine will
be jeopardized by the replacement part, procedure or tool
selected. It is important to note that this manual contains
various "Cautions" and "Notices" that must be carefully
observed in order to reduce the risk of personal injury
during repair, or the possibility that improper repair may
damage the engine or render it unsafe. It is also important
to understand that these "Cautions" and "Notices" are not
exhaustive, because it is impossible to warn personnel of
the possible hazardous consequences that might result
from failure to follow these instructions.

6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION 3

4 6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION
1 INTRODUCTION
1-2 6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION
1.1 INTRODUCTION
Detroit Diesel Corporation is the world leader in diesel engine electronics. DDC has made
technological leaps in engine performance and fuel economy. Today, we build the most
dependable electronically controlled diesel engine in the industry.
Our goal at Detroit Diesel is to be the most customer focused and most responsive engine
manufacturer in the world.

6SE497 9709 Copyright © 1997 DETROIT DIESEL CORPORATION 1-3
1.2 TROUBLESHOOTING INFORMATION
1.2 TROUBLESHOOTING INFORMATION
Troubleshooting of the DDEC III system and the DDEC IV system is identical. At the time of this
printing, the available features are the same in both systems. The DDEC IV system allows for an
increased processor speed and increased memory. DDEC III ECMs and DDEC IV ECMs are
not interchangeable.
Instructions for repair in this manual are generic. For example, "Repair Open" is used to advise
the technician that a particular wire has been determined to be broken. In some cases it may
not be best to try and locate the open. It may be that the best repair technique is to replace a
complete harness. The technician should make the determination of the proper repair, with the
best interest of the customer in mind.
Instructions to "Contact Detroit Diesel Technical Service" indicate that at the time of this
publication, all known troubleshooting checks have been included. Review any recent Service
Information Bulletins (SIB) or Service Information letters before calling.
It is also suggested that other DDC outlets be contacted. e.g. if you are a dealer or user, contact
your closest DDC Distributor.
Ensure you have the engine serial number when you call. The FAX number for Detroit Diesel
Technical Service is 313-592-7888.
Instructions in this manual may suggest replacing a non DDC component. It may be required
to contact the supplier of the component, e.g. truck manufacturer for a TPS concern, to obtain
approval to replace the component.
Instructions to check terminals and connectors should include checking for proper contact tension.
Using a mating terminal, a modest force should be required to remove a terminal from its mate.
Replace terminals with poor tension.
After completing any repair, always clear fault codes that may have been generated during the
troubleshooting process.
Important:
To ensure you receive updates to this manual should the need arise, you must fill out the
Information Card in the front of this manual.
NOTE:
Be aware that troubleshooting in this manual is mostly concerned with DDEC related
codes. Codes associated with other components, e.g. construction and industrial, EDM
and AIM, can be found in the related publication. Refer to section 2.4.

2 (CHG) OPERATION
2.1 DDEC BENEFITS
CHANGES NEEDED. All Detroit Diesel On-Highway engines come standard with Detroit Diesel
Electronic Controls (DDEC®). The state of the art Electronic Control Module (ECM) allows
precise control of the engine management system that provides:
3 Excellent engine performance
3 Optimum fuel economy
3 Emissions to meet current laws without after treatment
3 Engine diagnostics
3 Simple programming

2.2 FEATURES
2.2 FEATURES
The following features are part of the DDEC system:

3 Engine Protection System
3 Cruise Control
3 Cruise Power
3 Cruise Control Automatic Resume
3 Progressive Engine Braking In Cruise Control
3 Fan Controls
3 Engine Fan Braking
3 Progressive Shifting
3 Vehicle Speed Limiting
3 Vehicle Overspeed Diagnostics
3 Vehicle ID Number
3 Pressure Governor
3 Starter Lockout
3 Remote Throttle - PTO - Control
3 High Idle Controls
3 DDEC Ether Start
3 Optimized Idle
3 Idle Adjustment
3 Idle Timer Shutdown
3 Air Temperature Shutdown
3 Auxiliary Engine Protection
3 Customer Password
3 Rating Security
3 Maximum Security
3 Low DDEC Voltage Light
3 Low Coolant Light
3 Low Oil Pressure Light
3 High Oil Temperature Light
3 High Coolant Temperature Light
3 De-acceleration Light
3 12-volt or 24-volt ECM
3 Communications Links SAE J1587, J1922, J1939

2.3 DDEC SYSTEM--HOW IT WORKS
The major components of the DDEC system consist of the electronic control module (ECM),
the electronic unit injectors (EUI) and the various system sensors. The purpose of the sensors is
to provide information to the ECM regarding various engine performance characteristics. The
information sent to the ECM is used to instantaneously regulate engine and vehicle performance.
2.3.1 Electronic Unit Injector
An electronic unit injector incorporates a solenoid operated poppet valve which performs the
injection timing and metering functions. When the solenoid valve is closed, pressurization and
fuel injection is initiated. Opening the solenoid valve releases injection pressure, ending injection.
The duration of valve closure determines the quantity of fuel injected. See Figure 2-1.
Figure 2-1 Electronic Unit Injector
2.3.2 Electrical Connectors
Provide water-tight connections for the harnesses between the sensors and the ECM.

2.3 DDEC SYSTEM–HOW IT WORKS
2.3.3 Air Temperature Sensor
The air temperature sensor is located in the air intake manifold and monitors the air temperature
entering the engine. The ECM adjusts the engine timing to reduce white smoke, improve cold
starts, and provide engine protection. See Figure 2-2.
Figure 2-2 Air Temperature Sensor

2.3.4 Coolant Temperature Sensor
The coolant temperature sensor is located on the right side of the engine. The engine protection
feature will be triggered if the coolant temperature exceeds the specified limits. See Figure 2-3.
Figure 2-3 Coolant Temperature Sensor

2.3.5 Fire Truck Pump Pressure Sensor
The fire truck pump pressure sensor is used to monitor water pressure for the Pressure Governor
System in the DDEC system. The signal back to the ECM changes r/min which allows the fire
truck water pump to maintain a steady water pressure during pumping operation in fire trucks.
See Figure 2-4.
Figure 2-4 Fire Truck Pump Pressure Sensor

2.3.6 The Synchronous Reference Sensor and Timing Reference Sensor
These sensors control the timing of the engine. The SRS sensor provides a "once per cam
revolution" signal and the TRS sensor provides a "36 per crankshaft revolution" signal. Working
together, these sensors tell the ECM which cylinder is at top-dead-center for cylinder firing.
Precise monitoring of piston position allows for optimum injection timing, resulting in excellent
fuel economy and performance with low emissions. See Figure 2-5 for the SRS and the TRS.
Figure 2-5 Timing Reference Sensor and Synchronous Reference Sensor
2.3.7 Oil and Fuel Temperature Sensors
The oil temperature sensor optimizes idle speed and injection timing to improve cold startability
and reduce white smoke. This sensor will activate the engine protection system if the oil
temperature is higher than normal.

The fuel temperature sensor provides a signal to the ECM. The ECM utilizes the fuel temperature
signal to adjust the fueling for changes in the fuel density as a function of temperature to maintain
horsepower. See Figure 2-6.
Figure 2-6 Oil and Fuel Temperature Sensors
2.3.8 Electronic Control Module
The ECM is the brain of the computer system, receiving electronic inputs from the operator as
well as from the engine and vehicle mounted sensors. See Figure 2-7.

Figure 2-7 Electronic Control Module

2.3.9 Coolant Level Sensor
The engine protection feature will be triggered if the coolant level sensor detects a low coolant
level. See Figure 2-8.
Figure 2-8 Coolant Level Sensor

2.3.10 Throttle Position Sensor
The electronic foot pedal assembly instantaneously converts the operator's throttle input into a
signal to the ECM. The throttle response is fast and accurate. This sensor is self-calibrated,
and requires no maintenance. See Figure 2-9.
Figure 2-9 Throttle Position Sensor

2.3.11 Vehicle Speed Sensor
The vehicle speed sensor provides the ECM with the vehicle road speed for use with cruise
control, vehicle speed limiting, and progressive shifting. See Figure 2-10.
Figure 2-10 Vehicle Speed Sensor

2.3.12 Turbo Boost Sensor
In monitoring turbocharger compressor discharge, the turbo boost sensor provides air pressure
data to the ECM for smoke control during engine acceleration. See Figure 2-11.
Figure 2-11 Turbo Boost Sensor

2.3.13 Oil Pressure Sensor
The oil pressure sensor will activate the engine protection system when the oil pressure falls
below a normal oil pressure at a given engine r/min. See Figure 2-12.
Figure 2-12 Oil Pressure Sensor

2.3.14 Fuel Pressure Sensor
The fuel pressure sensor monitors fuel pressure to warn the operator of impending power loss.
This feature is optional. It is not used in international applications. See Figure 2-13.
Figure 2-13 Fuel Pressure Sensor

2.4 DDEC RELATED PUBLICATIONS
2.4 DDEC RELATED PUBLICATIONS
The following manuals, listed in Table 2-1, should be used for reference when troubleshooting
DDEC components.
Publication Number
DDEC III Application and Installation manual 7SA800
Optimized Idle Installation and Troubleshooting 7SA734
Optimized Idle User Manual 6SE518
Optimized Idle Troubleshooting and Reprogramming 18SA366
Engine Synchro Shift (ESS) Troubleshooting Manual 6SE498
Construction and Industrial EDM and AIM 7SA801
Installation and Troubleshooting
Construction and Industrial EDM and AIM User Manual 6SE710
DDC Ether Start 7SA727
Series 50G Application and Installation Engineering 18SA365
Guidelines, Bulletin 53
DDEC III Automotive Code Chart, 3 color, 8.5 x 11 7SE444
DDEC III Codes, Reference Pamphlet 7SE414
DDEC II Troubleshooting Manual 6SE489
DDEC II Application and Installation manual 7SA707
Series 60 Driving Tips (includes VHS video) 25STV0161
Table 2-1 DDEC Related Publications

3 (CHG) ECM AND SENSOR LOCATIONS
3.1 ECM AND SENSOR LOCATIONS
For the DDEC system ECM see Figure 3-1.
Figure 3-1 DDEC System ECM

For the Series 60® sensor locations, see Figure 3-2.
Figure 3-2 Series 60 Diesel ECM and Sensor Locations

For the Series 50® diesel engine sensor locations, see Figure 3-3.
1.Timing Reference Sensor 6.Oil Temperature Sensor

2.Fuel Temperature Sensor 7.Oil Pressure Sensor
3.Coolant Temperature Sensor 8.Turbo Boost Sensor
4.Synchronous Reference Sensor 9.Air Inlet Temperature Sensor
5.ECM
Figure 3-3 Series 50 Diesel ECM and Sensor Locations

For the Series 50® gas engine sensor locations, see Figure 3-4.
1.Coolant Temperature Sensor 6.Oil Temperature Sensor

2.Air Temperature Sensor 7.Oil Pressure Sensor
3.Fuel Temperature Sensor 8.Synchronous Reference Sensor
4.Manifold Air Pressure (MAP) Sensor 9.SNEF Module
5.Knock Sensor 10.Timing Reference Sensor
Figure 3-4 Series 50 Gas ECM and Sensor Locations

For the Series 55™ engine sensor locations, see Figure 3-5.
1.Coolant Temperature Sensor 5.Synchronous Reference Sensor

2.Fuel Temperature Sensor 6.Timing Reference Sensor
3.Air Inlet Temperature Sensor 7.Oil Temperature Sensor
4.Turbo Boost Sensor 8.Oil Pressure Sensor
Figure 3-5 Series 55 Engine Sensor Locations


4 BASIC KNOWLEDGE REQUIRED
4.1 DDEC DIAGNOSTIC CODE
Troubleshooting of the DDEC III system and the DDEC IV system is identical. At the time of this
printing, the available features are the same in both systems. The DDEC IV system allows for an
increased processor speed and increased memory. DDEC III ECMs and DDEC IV ECMs are
not interchangeable.
A diagnostic code indicates a problem in a given circuit (i.e. diagnostic Code 14 indicates
a problem in the oil or coolant temperature sensor circuit). This includes the oil or coolant
temperature sensor, connector, harness, and Electronic Control Module (ECM). The procedure
for finding the problem can be found in Flash Code 14, refer to section 14.3. Similar sections
are provided for each code. Remember, diagnosis should always begin at the start of the section.
For an oil or coolant temperature sensor problem, it will quickly lead you to section 14, but
first you verify the code or symptom.
Since the self-diagnostics do not detect all possible faults, the absence of a code does not mean
there are not problems in the system. If a DDEC problem is suspected, even in the absence of a
code, refer to section 9.1, anyway. This section can lead you to other sections that can aid in the
troubleshooting process - where DDEC problems may occur, but do not generate a code. Basic
mechanical checks are not covered in this manual.

4.2 GENERAL DIAGNOSTIC INFORMATION
4.2 GENERAL DIAGNOSTIC INFORMATION
As a bulb and system check, the Check Engine Light (CEL) and Stop Engine Light (SEL) will
come on for five seconds when the ignition switch is first turned on. If the unit is programmed for
the cruise control feature, the "Cruise Active" light (if equipped) will also turn on for five seconds.
If the CEL comes on during vehicle operation, it indicates the self diagnostic system has detected
a fault.
When the diagnostic request switch is held, the diagnostic system will flash the yellow or red
light located on the dash of the vehicle. The light will be flashing the code(s) indicating the
problem areas. If the SEL comes on during vehicle operation, it indicates the DDEC System has
detected a potential engine damaging condition. The engine should be shut down immediately
and checked for the problem.
Active codes will be flashed on the SEL in numerical flash code order. If there are no active
codes, a code 25 will be flashed.
Inactive codes will be flashed on the CEL in most recent to least recent order. If there are no
inactive codes, a Code 25 will be flashed.

4.3 READING CODES WITH DIAGNOSTIC DATA READER
Flash codes are used for operator convenience to advise of an engine fault or sensor failure. SAE
specific codes are read with the Diagnostic Data Reader (DDR). In some cases, one flash code
may be used to cover more than one component fault. For this reason the DDR (or Diagnostic
Data Link, DDL) must be used to identify the specific code.
The Diagnostic Code Menu selections are defined as follows.
3 Active codes
3 Inactive codes
3 Clear codes
To read codes, start with the Menu Selection screen.
1. To call up active codes:
[a] Select ENGINE and ENTER three times.
2. To call up inactive codes:
[a] Select ENGINE and ENTER twice.
[b] Select INACTIVE CODES and ENTER.
3. To clear codes:
[a] Select ENGINE and push ENTER twice.
[b] Go down and select CLEAR CODES and ENTER.
[c] Left to YES, and ENTER.
[d] Wait and then push FUNC three times.
[e] Go to lines 1 and 2 of the Engine Data List, Active and Inactive Codes, and verify
that both lines display NO.
4.3.1 Active Codes
Active codes are conditions that are presently occurring and causing the CEL to be illuminated.
All current active codes will be displayed for the entire system, including single, dual and triple
ECM applications. The display for each code is as follows:
Line 1: ## MID: XXX XXXXXXXX
Line 2: PID Description
Line 3: FMI Description
Line 4: ↑ A## PID: XXX FMI: XX ↓
Explanation:
##: Indicates the DDC diagnostic flash code number
MID: Message Identification Character
PID: Parameter Identification Character

4.3 READING CODES WITH DIAGNOSTIC DATA READER
FMI: Failure Mode Identifier

A##: Numerical count of active codes
↑↓: Indicates additional codes are stored in ECM memory
4.3.2 Inactive Codes
Inactive codes are faults that have occurred previously. All current inactive codes will be
displayed for the entire system, including single, dual, and triple ECM applications. The display
for each code is as follows:
SCREEN #1; SCREEN #2
Line 1: ## MID: XXX XXXXXX XX ; Line 5: 1st: Last:
Line 2: PID Description; Line 6: Total#:
Line 3: FMI Description; Line 7: Total Time:
Line 4: ↑ |## PID: XXX FMI: XX ↓; Line 8: Min/Max:
Explanation:
##: Indicates the DDC diagnostic flash code number
|##: Numerical Count of inactive codes
1st: First occurrence of the diagnostic code in engine hours
Last: Last occurrence of the diagnostic code in engine hours
Total#: Total number of occurrences
Total Time: Total engine seconds that the diagnostic code was active
Min/Max: Minimum/Maximum value recorded during diagnostic condition
4.3.3 Clear Codes
This feature allows diagnostic codes stored in the ECMs to be erased. An audit trail of when the
codes were last erased will be displayed in engine hours.
Engine Hours of Last Clear Codes: XXXX
4.3.4 Message Identification Descriptions
MID: 128 ENGINE, Single ECM applications

MID: 175 ENGINE, R1 Dual ECM application - engine #2 with first receiver ECM
MID: 183 ENGINE, R2 Triple ECM application - engine #3 w/second receiver ECM
MID: 184 PING, Pilot Injection Natural Gas ECM application

Diagnostic codes with Subsystem Identification Characters (SIDs) that reference Auxiliary
Outputs # 1-8 (SIDs: 26, 40, 51, 52, 53, 54, 55, 56) will look up the parameter text description in
a table to identify the function assigned to the auxiliary output channel.
Diagnostic codes with SIDs that reference PWM Outputs #1 through #4 (SIDs: 57, 58, 59 &
60) will look up the parameter text description in a table to identify the function assigned to
the PWM output channel.
Injector Response Time Codes Long and Injector Response Time Codes Short will use a table of
injector numbering to identify the appropriate engine cylinder number.

4.4 ELECTRICAL CIRCUITS
4.4 ELECTRICAL CIRCUITS
Before using this manual, you should understand the theory of electricity and know the meaning
of voltage and ohms. You should understand what happens in a circuit with an open or shorted
wire. You should be able to read and understand a wiring diagram.
You should be able to use jumper wires to make circuit checks.

4.5 USE OF DIGITAL VOLT-OHM METER
Before using this manual, you should be familiar with the digital volt-ohm meter (VOM). You
should be able to measure voltage and resistance. You should be familiar with the controls of the
meter and how to use it correctly.
For use of a typical digital volt-ohm meter, refer to section 4.5.1, refer to section 4.5.2, and
refer to section 4.5.3.
4.5.1 Resistance Measurements
Perform the following steps to measure resistance:

1. Connect the red test lead to the V-
(Volt-Ohm) input connector and the black lead
to the com input connector on the meter.
2. Set the function/range switch to the desired
position. If the magnitude of the resistance
is not known, set the switch to the highest range, then reduce until a satisfactory reading is
obtained.
3. If the resistance being measured is connected to a circuit, turn off the power to the circuit
being tested. Turn off the ignition.
4. Connect the test leads to the circuit being measured. When measuring high resistance, be
careful not to contact adjacent points, even if they are insulated. Some insulators have a
relatively low insulation resistance which can affect the resulting measurement.
5. Read the resistance value on the digital display.
4.5.2 Continuity Checks
In addition to measuring the specific resistance value of a circuit, some meters will also register if
a continuous electrical path exists. If a path exists, the circuit is said to have continuity. (This
continuity check can be used in any section of this troubleshooting guide where the test is looking
for greater than, less than, or equal to 5 ohms.) An open circuit (broken electrical path) would have
∞ resistance and would not have continuity. To utilize the continuity feature of certain meters:
1. Place the function/range switch in any
range.
2. Connect the red lead to the V-
connector and the black lead to the com connector on the
meter. With the test leads separated or measuring an out-of-range resistance, the digital
display will indicate OL (over limit) Some meters show "1 +, 1, or ↑."
3. Put one test probe at one end of the wire or circuit to be tested. Use the other test lead
to trace the circuit. When continuity is established, an ohm (
) symbol will display
in the upper left corner of the digital display. If contact in the wire is maintained long
enough (about 1/4 second), the OL will disappear and the resistance value of the wire
or circuit will display next to the symbol.
4. If your VOM does not work in the manner described above, you must know how your
VOM operates in order to use this troubleshooting guide.

4.5 USE OF DIGITAL VOLT-OHM METER
4.5.3 Voltage Measurements
Perform the following steps to measure voltage.

1. Connect the red test lead to the V-
connector and the black lead to the com input on the
meter. If a DC-AC switch is present, ensure it is switched to the DC position.
2. Set the function range/switch to the desired volts position. If the magnitude of the voltage
is not known, set the switch to a range that will be able to read most voltages seen on
a vehicle. Typically, a 20V range will do. Then, reduce the range until a satisfactory
reading is obtained.
3. Connect the test leads to the circuit being measured. In the DDEC system diagnostic
procedures, voltage measurements are always given as being taken at pins, sockets, battery
+, or ground. Following the voltage measurement point, the color test lead to be used
is given in parenthesis (red is the V-
connection, and black is the com connection).
Example: If the procedure displays, "Take voltage reading at socket A3 (red lead) to
socket C3 (black lead)", see Figure 4-1 for the hook-up.
1.Red Lead 2.Black Lead
Figure 4-1 Voltage Measurement Hook-up

4.6 IMPORTANT INFORMATION
The following items must be read and thoroughly understood before using this manual.
1. The engine and ignition should always be off before the harness connectors are
disconnected or reconnected.
2. When disconnecting harness connectors, ensure the pulling force is applied to the
connectors themselves and not the wires extending from them.
NOTICE:
To avoid damage to the harness connectors, ensure the
pulling force is applied to the connections themselves and
not the wires extending from them.
3. After harness connectors are reconnected to the DDEC system, the codes logged should
be ignored and cleared.
4. In most all areas of repair/troubleshooting, a DDR will be required.
5. In diagnosing an intermittent problem, wiggling wires or harnesses may allow the fault to
be repeated. This may allow a technician to better isolate the problem area.

4.7 EXPLANATION OF ABBREVIATIONS AND TERMS
The following abbreviations and terms listed in Table 4-1, will be used throughout the electrical
flowcharts.
Abbreviations Terms
A/C Air Conditioning
ACG Air Compressor Governor
A/D Analog to Digital: The computer inside the ECM uses
an A/D converter to convert a sensor voltage into a
number with which the computer can work.
ASR Anti-Skid Regulation: Data supplied by the ECM for
use with ABS (anti-lock braking system).
ATI Auxiliary Timed Input
ATS Air Temperature Sensor: Monitors engine
air temperature.
BAT Battery
BOI Beginning of Injection: The number of crank angle
degrees, before top-dead-center (TDC), where the
ECM is requesting the injectors be turned on.
BPS Bypass Position Sensor
CAN Controller Area Network: J 1939 high speed
control data link.
CCM Crankcase Monitor Sensor: Monitors crankcase
pressure (currently on 149 engines only).
CCPS Crankcase Pressure Sensor
CEL * Check Engine Light: Typically mounted on the
instrument panel. The CEL has two functions:1. It is
used as a warning lamp to inform the operator of the
vehicle that a fault has occurred and the unit should
be taken in for service as soon as possible.2. It is
used by the operator or technician to "flash out inactive
trouble codes to help diagnose a problem.
CKT Circuit
CLS Coolant Level Sensor: Monitors coolant level at the
radiator top tank or heat exchanger.
COM Common
CPS Coolant Pressure Sensor: Monitors coolant presssure.
CTS Coolant Temperature Sensor: Monitors
coolant temperature.
DDEC Detroit Diesel Electronic Controls
DDEC III Third generation Detroit Diesel Electronic Controls
DDEC IV Fourth generation Detroit Diesel Electronic Controls

Abbreviations Terms
DDL Diagnostic Data Link: The lines (wires) over which
the ECM transmits information that can be read
by a Diagnostic Data Reader.
DDL+ Data Link, positive side: J 1587 data link.
DDL- Data Link, negative side: J 1587 data link.
DDR Diagnostic Data Reader: The hand held tool
used for troubleshooting the DDEC system.
MPSI PRO-LINK 9000.
ECM Electronic Control Module: The controller of DDEC
system. It reads the engine and vehicle inputs, sensors
and switches, calculates injector firing and duration,
and fires injectors at appropriate times.
EEPROM Electrically Erasable Programmable Read Only Memory.
EFC Electronic Fire Commander
EFPA Electronic Foot Pedal Assembly: Contains the
throttle position sensor.
EOP Engine Over-temperature Protection
ESH Engine Sensor Harness
ESS Engine Synchro Shift
EUI Electronic Unit Injector
FEI Fuel Economy Incentive
FPS Fuel Pressure Sensor: Monitors fuel pressure.
FTS Fuel Temperature Sensor: Monitors fuel temperature.
GND Ground
INJ Injector (fuel)
ISD Idle Shutdown: Programmable feature of
the DDEC system.
IVS Idle Validation Switch: A switch used to establish
the idle speed position.
LSG Limiting Speed Governor.
MPG Miles Per Gallon
N/A Not Applicable.
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor: Monitors oil level.
OPS Oil Pressure Sensor: Monitors oil pressure.
OTS Oil Temperature Sensor: Monitors oil temperature.
PGS Pressure Governor System: Regulates engine speed
to maintain a selected external pump pressure.

Abbreviations Terms
PTO Power Take-Off. Also, referred to as VSG
(Variable Speed Governor).
PW Pulsewidth
PWM Pulsewidth Modulated: Modulated signal provided
by the DDEC system.
RES/ACCEL Resume/Accelerate Switch used for cruise control.
SEL † Stop Engine Light: Typically mounted on the instrument
panel. It has two functions:1.It is used as warning to the
operator that a potential engine damaging condition has
been detected. If the DDEC system is programmed for
shutdown, the engine will shutdown on its own within
30 seconds. The engine should not be run until the
condition is corrected.2.It is used by the operator or
technician to "flash" out active trouble codes.
SEO Stop Engine Override: Allows the stop engine condition
to be overridden in case it is required.
SET/COAST Set/Coast Switch: Used in cruise control.
SRS Synchronous Reference Sensor: Indicates a
specific cylinder in the firing order.
TBS Turbocharger Boost Sensor: Monitors turbo boost.
TBD To be determined.
TD Tachometer Driver: An output from the ECM for
electronic tachometers and or data loggers.
TPS Throttle Position Sensor: Used to detect throttle request
(a component of the EFPA). Also, referred to as LSG.
TRS Timing Reference Sensor: Used to detect whenever
any cylinder is about to be fired.
VIH Vehicle Interface Harness (OEM Wiring)
VIN Vehicle Identification Number
VSG Variable Speed Governor. Also, referred to as
PTO (Power Take-Off).
VSS Vehicle Speed Sensor: Used to detect vehicle speed.
VSS OC Vehicle Speed Sensor Open Collector: An ECM
input which must be used in addition to the VSS
positive input when certain types of vehicle speed
sensors are used. Refer to the Application and
Installation manual for installation.
* As a light bulb check and system check, the check engine light will come on for about 5 seconds when the ignition is turned on. If
the CEL remains on, or comes back on, the self diagnostic system has detected a problem. If the problem goes away, the light will
go out, but a trouble code will be stored in the ECM as an inactive code.
† As a light bulb check and system check, the stop engine light will come on for about 5 seconds when the ignition is turned on.
Table 4-1 Abbreviations and Terms

5 (CHG) FLASH CODES VS SAE CODES
5.1 READING THE DIAGNOSTIC CODES - FLASH METHOD
The following steps describe the flash method to interpret diagnostic codes:
NOTE:
If you are here to begin diagnosis of a problem and already know how to read codes, as
well as understand active and inactive codes, refer to section 9.1.
1. Active versus Inactive codes:

[a] Active codes are the codes which are currently keeping the "Check or Stop Engine"
light on. Active codes are flashed via the Stop Engine Light (SEL).
[b] Inactive codes are all the codes previously logged in the ECM. These codes can be
cleared by using the DDR. Inactive codes are flashed via the Check Engine Light
(CEL).
NOTE:
The Diagnostic Request Switch reads codes on the CEL and SEL when an DDR is not
available. The following steps will enable you to obtain codes.
2. Turn vehicle ignition switch ON.

3. Depress and hold the diagnostic request switch.
[a] As an example, observe Code 13 (active) and Code 21 (inactive) flashing out on the
CEL and SEL; see Figure 5-1.
[b] If input used is SEO/Diagnostic Request, press and release the switch.

5.1 READING THE DIAGNOSTIC CODES - FLASH METHOD
[c] If input used is Diagnostic Request, press and hold switch.
Figure 5-1 Flash Code Method
5.1.1 Clearing Codes
Fault codes can only be cleared using the DDR.
NOTE:
Removing the battery cables will not clear codes.

5.2 READING CODES
For instructions for using the DDR or Pro-Link 9000 ®, ( see Figure 5-2), refer to the Pro-Link
Users Manual. For a list of Flash Codes and SAE Fault Codes, refer to section 5.3. Refer to
flowchart.
Figure 5-2 Pro-Link 9000
NOTE:
Active codes are flashed in ascending numerical flash code order. Inactive codes are
flashed in most recent to least recent order.

5.3 DDEC DESCRIPTIONS
To read codes, use the diagnostic data reader or depress and hold the diagnostic request switch
with the ignition ON, engine at idle or not running. Active codes will be flashed on the SEL.
Inactive codes will be flashed on the CEL. The cycle will repeat until the operator releases the
diagnostic request switch. Flash codes and descriptions are listed in Table 5-1.
Flash Codes DDEC Description

11 VSG sensor input voltage low
12 VSG sensor input voltage high
13 Coolant level sensor input voltage low
14 Oil, coolant, or intercooler, temperature sensor
input voltage high
15 Oil, coolant, or intercooler, temperature sensor
input voltage low
16 Coolant level sensor input voltage high
17 Bypass or throttle, valve position sensor input voltage high
18 Bypass or throttle, valve position sensor input voltage low
21 TPS input voltage high
22 TPS input voltage low
23 Fuel temperature sensor input voltage high
24 Fuel temperature sensor input voltage low
25 No active codes
26 Auxiliary shutdown #1, or #2, input active
27 Air inlet or intake air, temperature sensor
input voltage high
28 Air inlet or intake air, temperature sensor input voltage low
31 Auxiliary high side output open circuit or short to ground
32 CEL or SEL short to battery (+) or open circuit
33 Turbo boost sensor input voltage high
34 Turbo boost sensor input voltage low
35 Oil pressure sensor input voltage high
36 Oil pressure sensor input voltage low
37 Fuel pressure sensor input voltage high
38 Fuel pressure sensor input voltage low
41 Too many SRS (missing TRS)
42 Too many SRS (missing SRS)
43 Coolant level low
44 Oil, coolant, intercooler or intake air, temperature high
45 Oil pressure low


46 ECM battery voltage low
47 Fuel, air inlet, or turbo boost, pressure high
48 Fuel or air inlet pressure low
52 ECM A/D conversion fault
53 ECM non volatile memory fault
54 Vehicle speed sensor fault
55 J1939 data link fault
58 Torque overload
61 Injector response time long
62 Auxiliary output short to battery (+) or open
circuit, or mechanical fault
63 PWM drive short to battery (+) or open circuit
64 Turbo speed sensor input fault
65 Throttle valve position input fault
66 Engine knock sensor input fault
67 Coolant or air inlet, pressure sensor input voltage fault
68 TPS idle validation switch open circuit or short to ground
71 Injector response time short
72 Vehicle overspeed
73 Gas valve position input fault or ESS fault
74 Optimized idle safety loop short to ground
75 ECM battery voltage high
76 Engine overspeed with engine brake
77 Fuel temperature high
81 Oil level, crankcase pressure, dual fuel BOI, or
exhaust temperature voltage high
82 Oil level, crankcase pressure, dual fuel BOI, or
exhaust temperature voltage low
83 Oil level, crankcase pressure, exhaust temperature,
or external pump pressure high
84 Oil level or crankcase pressure low
85 Engine overspeed
86 External pump or barometer pressure sensor
input voltage high


87 External pump or barometer pressure sensor
input voltage low
88 Coolant pressure low
Table 5-1 Flash Codes and Description
SAE faults and flash codes with descriptions are listed in Table 5-2.
SAE Faults Flash Code DDEC Description

p051 0 65 Throttle valve position above
normal range
p051 1 65 Throttle valve position below
normal range
p051 3 17 Throttle valve input voltage high
p051 4 18 Throttle valve input voltage low
p051 7 65 Throttle valve not responding
p052 0 44 Intercooler temperature high
p052 3 14 Intercooler sensor input voltage high
p052 4 15 Intercooler sensor input voltage low
p070 4 74 Optimized idle safety loop short
to ground
p072 3 17 Bypass position sensor input
voltage high
p072 4 18 Bypass position sensor input
voltage low
p073 0 83 External pump pressure high
p073 3 86 Pump pressure sensor input
voltage high
p073 4 87 Pump pressure sensor input
voltage low
p084 0 72 Vehicle overspeed (fueled)
p084 11 72 Vehicle overspeed (absolute)
p084 12 54 Vehicle speed sensor failure
p091 3 21 Throttle position sensor input
voltage high
p091 4 22 Throttle position sensor input
voltage low
p092 0 58 Torque overload
p094 0 47 Fuel pressure high
p094 1 48 Fuel pressure low


p094 3 37 Fuel pressure sensor input
voltage high
p094 4 38 Fuel pressure sensor input
voltage low
p098 0 83 Oil level high
p098 1 84 Oil level low
p098 3 81 Oil level sensor input voltage high
p098 4 82 Oil level sensor input voltage low
p100 1 45 Oil pressure low
p100 3 35 Oil pressure sensor input
voltage high
p100 4 36 Oil pressure sensor input voltage low
p101 0 83 Crankcase pressure high
p101 1 84 Crankcase pressure low
p101 3 81 Crankcase pressure sensor
input voltage high
p101 4 82 Crankcase pressure sensor
input voltage low
p102 0 47 Turbo boost pressure high
p102 3 33 Turbo boost pressure sensor
input voltage high
p102 4 34 Turbo boost pressure sensor
input voltage low
p103 8 64 Turbo speed sensor input failure
p105 0 44 Intake air temperature high
p105 3 27 Intake air temperature sensor
input voltage high
p105 4 28 Intake air temperature sensor
input voltage low
p106 0 47 Air inlet pressure high
p106 1 48 Air inlet pressure low
p106 3 67 Air inlet pressure sensor input
voltage high
p106 4 67 Air inlet pressure sensor input
voltage low
p108 3 86 Barometer pressure sensor
input voltage high
p108 4 87 Barometer pressure sensor
input voltage low
p109 1 88 Coolant pressure low


p109 3 67 Coolant pressure sensor input
voltage high
p109 4 67 Coolant pressure sensor input
voltage low
p110 0 44 Coolant temperature high
p110 3 14 Coolant temperature sensor
input voltage high
p110 4 15 Coolant temperature sensor
input voltage low
p111 1 43 Coolant level low
p111 3 16 Coolant level sensor input
voltage high
p111 4 13 Coolant level sensor input voltage low
p121 0 76 Engine overspeed with engine brake
p168 0 75 ECM battery voltage high
p168 1 46 ECM battery voltage low
p172 3 27 Air temperature sensor input
voltage high
p172 4 28 Air temperature sensor input
voltage low
p173 0 83 Exhaust temperature high
p173 3 83 Exhaust temperature sensor
input voltage high
p173 4 83 Exhaust temperature sensor
input voltage low
p174 0 77 Fuel temperature high
p174 3 23 Fuel temperature sensor input
voltage high
p174 4 24 Fuel temperature sensor input
voltage low
p175 0 44 Oil temperature high
p175 3 14 Oil temperature sensor input
voltage high
p175 4 15 Oil temperature sensor input
voltage low
p187 3 12 VSG sensor input voltage high
p187 4 11 VSG sensor input voltage low
p187 7 11 VSG switch system not responding
p190 0 85 Engine overspeed
p251 10 - Clock module abnormal rate


p251 13 - Clock module fault
s001 0 61 Injector #1 response time long

s001 1 71 Injector #1 response time short
d004 0 61 Injector #4 response time long
d007 0 61 Injector #7 response time long
s020 3 81 Dual fuel BOI input voltage high
s020 4 82 Dual fuel BOI input voltage low
s021 0 41 Too many SRS (missing TRS)


s021 1 42 Too few SRS (missing SRS)
s025 11 26 Auxiliary engine shutdown #1
input active
s026 3 62 Auxiliary output #1 short to battery (+)
s026 4 62 Auxiliary output #1 open circuit
s026 7 62 Auxiliary output #1 mechanical
system not responding properly
s 040 7 62 Auxiliary output #2 mechanical
s051 4 31 Auxiliary output #3 short to ground
s052 4 31 Auxiliary output #4 short to ground


s057 3 63 PWM driver #1 short to battery (+)
s057 4 63 PWM driver #1 open circuit
s061 11 26 Auxiliary engine shutdown #2
input active
s072 0 61 #21 injector response time long
s072 1 71 #21 injector response time short
s076 0 66 Engine knock level above
normal range
s076 3 66 Engine knock sensor input
voltage high
s076 4 66 Engine knock sensor input
voltage low
s076 7 66 Engine knock sensor torque
reduction
s077 0 73 Gas valve position above
normal range
s077 1 73 Gas valve position below
normal range
s077 3 73 Gas valve position input voltage high
s077 4 73 Gas valve position input voltage low
s151 14 73 System Diagnostic Code #1 (ESS)
s226 11 73 Transmission Neutral Switch (ESS)
s227 4 73 Auxiliary analog input #1 voltage
low (ESS)
s227 3 73 Auxiliary analog input #1 voltage
high (ESS)
s227 2 73 Auxiliary analog input #1 data erratic,
intermittent or incorrect (ESS)


s230 5 68 TPS idle validation switch open circuit
s230 6 68 TPS idle validation switch short
to ground
s231 12 55 J1939 data link fault
s238 3 32 SEL short to battery (+)
s238 4 32 SEL open circuit
s239 3 32 CEL short to battery (+)
s239 4 32 CEL open circuit
s240 2 - Fram checksum incorrect
s248 8 55 Proprietary data link fault (master)
s248 9 55 Proprietary data link fault (slave)
s253 2 53 Non volatile memory data incorrect
s253 12 53 Non volatile memory fault
s253 13 - Incompatible calibration version
s254 0 - External failed RAM
s254 1 - Internal failed RAM
s254 6 - Entered boot via switches
s254 12 52 ECM A/D conversion fail
Table 5-2 SAE Faults and Flash Codes

6 (CHG) TESTING / SERVICE TOOLS / TIPS
6.1 BASICS
CHANGES NEEDED. The following listed items should be checked prior to starting any
troubleshooting:
3 Ensure engine serial number on the ECM matches the serial number on the cylinder block.
3 Walk around the vehicle. Look for obvious problems such as leaks (air or liquid).
3 Inspect ECM for worn isolators, debris or bolts lodged between ECM and cylinder block.
3 Broken wiring connectors.
3 Fuel Supply - Full on.
3 Fuel tank level.
3 Vehicle damage.
3 Investigate into any prior repairs, if applicable.
3 Check for poor mating of the connector halves or terminals not fully seated in the
connector body (backed out terminals).
3 Look for improperly formed or damaged terminals. All connector terminals in the problem
circuit should be carefully inspected to determine proper contact tension. Use a mating
terminal to test the contact tension.
3 Electrical system interference caused by a defective relay, ECM driven solenoid, or a
switch causing an electrical surge. Look for problems with the charging system (alternator,
etc.). In certain cases, the problem can be made to occur when the faulty component is
operated as in the case of a relay.
3 Verify alternator grounds are clean and making good contact. Disconnect the alternator
belt to test.
3 Wiggle wires and harnesses to try to make the problem active, or re-occur.

6.1 BASICS
6.1.1 ECM Programming
The following label is attached to the ECM. See Figure 6-1.
Figure 6-1 ECM Label
3 Every DDEC system engine serial number has its own file in the DDC Mainframe.
NOTICE:
Failure to match the serial number on the engine with
the ECM programming may result in incorrect calibration
results and engine damage.
3 ECM programming must be done to match the serial number you are currently working on.
Failure to do so may result in incorrect calibration and engine damage.
3 Programming a DDEC III ECM must be done with an engine file set up for the DDEC III
system.
3 Programming a DDEC IV ECM must be done with an engine file set up for the DDEC IV
system.
3 For a summary of features and how to change them, refer to section 7.

6.2 OPERATOR INFORMATION
This section should serve as a guideline for the technician:

3 Intermittent Problems - Talk to the operator/driver. Be specific!
3 Develop your own Driver Questionnaire. Refer to section 6.2.1.
6.2.1 Driver Questionnaire
Ask the driver to answer the following questions before attempting to repair an intermittent
problem, or a problem with symptoms but no diagnostic codes. Use this and the response
guideline to these questions.
1. How often does the problem occur? Can you and the driver take the vehicle and
demonstrate the problem in a short time?
2. Has the vehicle been to other shops for the same problem? If so, what was done there?
3. Did the radio, dash gages, or lights momentarily turn OFF when the problem occurred?
4. Does the problem occur only at specific operating conditions? If so, at what load? Is it
light, medium, or heavy?
5. Does the problem occur at a specific engine operating temperature? If so, at what engine
temperature?
6. Does the problem occur only when above or below specific outside temperatures? In
what temperature range?
7. Does the problem occur during other conditions e.g. during or after rain, spray washing,
snow?
8. Did the problem occur at a specific vehicle speed? If so, at what vehicle speed?
9. Does the problem occur at specific engine r/min? If so, at what engine r/min?
6.2.2 Questionnaire Response Guideline
The following are typical responses to the Driver Questionnaire:

1. If the problem is repeatable, take the vehicle for a drive with the DDR connected and
note the conditions when the problem occurs. Be prepared to take snapshot data using
the DDR. Ensure you operate the vehicle after correcting the problem and duplicate the
operating conditions before releasing the unit, to verify the problem is corrected.
2. If the vehicle has been to other shops for the same problem, call the other shops and find
out what has been done. Avoid replacing the same components again unless absolutely
sure they are the problem! It is unlikely a component will fail again following a recent
replacement.
3. If other vehicle devices are affected, this indicates there may be something wrong with
the ignition wiring. Refer to section 91.2 for information on inspecting the ECM battery
connections.

6.2 OPERATOR INFORMATION
4. Operate the engine under similar load conditions. Check the fuel system for restrictions,
primary filter, and fuel tanks for foreign objects blocking the fuel supply. Also, check the
air system. Utilize the DDR snapshot feature.
5. Operate the engine at this temperature while attempting to duplicate the problem. Use
the snapshot feature on the DDR.
6. If possible, troubleshoot the problem in this temperature range.
7. If the problem seems to occur during or after the engine is subjected to rain/spray washing,
thoroughly inspect the connectors for moisture entry.
8. If the problem occurs at a specific vehicle speed, check the parameters affecting vehicle
speed to verify they are programmed close to the vehicle speed where the problem occurs.
Check Vehicle Speed and watch the DDR (snapshot) for changes to see if the pulse wheel
(VSS signal) is loose.
9. If the problem occurs at a specific engine r/min, unplug the oil, coolant, and air
temperature sensors, and note any changes to the problem. Gather this data and contact
Detroit Diesel Technical Service.

6.3 SERVICE TOOLS
Listed in Table 6-1 are the service tools required to perform troubleshooting procedures for
the DDEC-equipped engine.
Tool Number Tool Name

J 39299 Volt-Ohm Meter; see Figure 6-2.
J 38500 Pro-Link ® Diagnostic Data Reader; see Figure 6-3.
J 41005 DDEC III Vehicle Interface Module; see Figure 6-4.
J 38480 Pro-Link Printer; see Figure 6-5.
J 38852 or J 39848 Crimping Tools; see Figure 6-6
23516937 Digital Diesel Sensor Simulator; see Figure 6-7
(Optional Tool)
J 35751 Jumper Wire Kit
Table 6-1 Service Tools
Figure 6-2 Volt-Ohm Meter, J 39299

6.3 SERVICE TOOLS
Figure 6-3 Pro-Link Diagnostic Data Reader, J 38500

Figure 6-4 DDEC III Vehicle Interface Module, J 41005 (Will Operate DDEC
IV Also)

6.3 SERVICE TOOLS
Figure 6-5 Pro-Link 9000 Printer, J 38480

Figure 6-6 Crimping Tool, J 38852 or J 39848

6.3 SERVICE TOOLS
Figure 6-7 Digital Diesel Sensor Stimulator, P/N: 23516937

7 (CHG) DDEC ECM SOFTWARE FEATURES
7.1 DDEC ECM SOFTWARE FEATURES
This section is a brief description of DDEC system ECM software features and what is required to
activate the feature (DDR, PC, etc.).
NOTE:
For a complete description of features, refer to publication 7SA800, DDEC III Application
and Installation manual.
7.1.1 Air Compressor Governor System
The air compressor governor system can be set on the mainframe only. This system is similar
to the pressure governor system, but for air compressor applications. 6N4C change adjusts the
engine speed to compensate for air pressure loads. ECM Software 4.01 is required.
7.1.2 Cruise Control
Cruise control can be set with the DDR or programming station.

3 Auto Resume
3 Yes or No. Will re-engage cruise if clutch switch is used to disable. Second press of
clutch must be done within 3 seconds of the disengage and cruise will resume at
the previously set speed.
3 Minimum Cruise Speed
3 Can be set with the DDR or programming station. Normally 20 mph, newer ECM
software may allow setting to as low as 10 mph.
3 Maximum Cruise Speed
3 Can be set with the DDR or programming station. Limited to the calculated gear
bound vehicle speed at rated engine r/min, or if progressive shift = yes, then max
cruise speed is limited to high gear r/min. Also limited to vehicle speed limit (if set).
3 Engine Brake Cruise
3 Can be set with the DDR or programming station. Refer to engine brake information.
Refer to section 7.1.5.
7.1.3 Cruise Switch Variable Speed Governor
The cruise switch can be set with the DDR or programming station. Requires Vehicle Speed
Sensor (VSS) set to Yes.
3 Initial r/min= 1000 r/min default, initial r/min to ramp up to when set.
3 R/min incr= 25 r/min default, r/min increase when res/accl switch is enabled.
7.1.4 Data Pages
Enable data pages on the mainframe (up to 7.00 ECM software). This is automatic with ECM
software level 20.xx or higher.

7.1.5 Engine Brake (Jake Brake)
Enabling the engine brake is done on the mainframe. Once turned on, output cavities S3 and T3
are automatically configured to provide voltage to the brake solenoids when the ECM calibrated
parameters are met allowing activation.
Also requires two inputs, engine brake low and engine brake med.
Several options are available (programming station or DDR set) relative to engine brake
operations:
3 Dynamic Fan Braking
3 Enables the cooling fan whenever the engine brake is in high mode. This feature is
able to be configured with the programming station or DDR. (DDR software level
2.0 or higher.)
3 Engine Brake / Service Brake
3 This feature forces the operator to, in addition to the normal requirements, press the
service brake in order to initiate the engine brake(s). Can be set with the DDR or
programming station.
3 Engine Brake Minimum MPH
3 This feature allows the customer to set a minimum mph to allow the engine brake to
activate. Can be set with the DDR or programming station.
3 Engine Brake Cruise
3 Allows engine brakes to activate to programmed levels automatically based on vehicle
speed increases. Initial speed is low. The speed of the increments is medium, then
high. Level (high, med, low) is limited by dash position switch.
3 Can be set with the DDR or programming station.
7.1.6 Engine Protection Features
Engine protection features can be set with the DDR or programming station. Three features are
available:
3 Shutdown
3 Rampdown
3 Warning
7.1.7 Engine Synchro Shift
Engine Synchro Shift ™ (ESS) can be set with the programming station. ESS is a joint
development between DDC and Rockwell.
The ESS system automatically synchronizes the transmission by matching the engine r/min speed
to the road speed of the vehicle, eliminating the need to use the clutch pedal for shifting gears.
Refer to publication number 6SE498, Engine Synchro Shift (ESS) Troubleshooting Manual .
Requires an ESS transmission type, two inputs (in gear and in neutral), and two outputs (high
range solenoid and low range solenoid).

7.1.8 Ether Start
Ether start can be set with the programming station only. Requires ECM software level to be
greater than 3.00, and enable output for Ether Start. Refer to Ether Start manual, 7SA727.
7.1.9 Fan Controls
Fan type is set in the mainframe; None; Single; Dual; Two Speed; are the allowed types. The
correct inputs (if any are needed or desired) and outputs must be configured to an available
cavity with the programming station.
3 Required Outputs: Configure to any output cavity
3 Fan control #1 for Single
3 Fan control #1 and Fan control #2 for Dual or Two-Speed types
3 Inputs are optional: Configure to any input cavity with the programming station
3 Auxiliary Fan Control
3 Fan Override
7.1.10 Fuel Economy Incentive
Fuel Economy Incentive (FEI) can be set with the DDR or programming station.
FEI is a DDEC feature that allows vehicle owners to set driver goals of fuel economy while
offering the driver an incentive which is a result of his/her good driving habits. The FEI will
automatically allow a higher vehicle speed (speed increase is dependent on the customer selected
settings) than is set in the road speed limiting area of the ECM. FEI was released with ECM
software level 5.00.
There are four items relative to FEI:
3 Minimum MPG (MIN MPG)
3 This would be defined as the customer's minimum fuel economy goal. Any fuel
economy obtained by the driver greater than this figure would result in a allowed
speed increase. Each increase of 0.1 mpg will provide the speed increase dictated by
the Conversion factor (or Scaler MPH/MPG).
3 Maximum MPH (MAX MPH)
3 This would be the absolute maximum speed increase to which the customer wants
the vehicle limited. The value is an increase above the vehicle speed limit. The
allowed values are 0 to 20. A value of 0 disables the FEI feature. A value of 1 to 20
enables the FEI feature.
3 Conversion Factor (Scaler MPH/MPG)
3 The miles per hour you want to allow for each full mile per gallon above the minimum
mpg. Example: a value of 10 will allow the driver to go 10 mph above the road speed
limit for each full (1) mile per gallon above the minimum mpg. If the minimum mpg
is 7.0, and the driver is getting 7.1 mpg, then the system will allow one additional mile
per hour increase, etc. The unit will still be limited to the maximum MPH.
3 Calculation Type (CALC TYPE)

3 Two choices can be found under this item; FILTERED, or TRIP. This is what you want
the FEI to use to base its calculations. Filtered bases the calculations on the fuel
information, by periodic sampling of fuel consumption, recorded in the ECM. Trip
bases the calculations on the trip portion of the fuel usage information.
FEI is only able to be set by the customer or service outlet and only with the DDR or programming
station. Requires MPSI DDR version 5.0 or higher.
7.1.11 Fuel Pressure Sensor
Fuel pressure sensing is currently only configured for some industrial engines. It is not available
on all series. The fuel pressure sensor used is the same as the oil pressure sensor.
7.1.12 Full Power Continuous Override
Full Power Continuous Override allows the operator to override the shutdown protection and
maintain full power rather than ramp down to a reduced performance. This is set on the mainframe.
7.1.13 Function Lockout
Function Lockout was added to the release of 4.00 ECM and DDR software.
The purpose of this new option is to allow users to have a selected area or areas of the customer
parameters password protected. For example, a customer can now function lockout the cruise
control parameters with a user entered password, and still have the other areas accessible with the
DDR with no (four zeros) password.
The function lockout parameters are able to be selected and customized to the customers request.
The areas that are able to be protected by function lockout are:
3 Idle Shutdown
3 VSG Configuration
3 Engine Protection
3 Cruise Control
3 Progressive Shift
3 Engine Droop
3 Engine/Vehicle Options
3 Air Compressor
3 ESS Transmission
When making changes with the DDR under the Reprogram Calibration section, you will already
have entered a password to get past this step. If any of the functions in the selection list are
function lockout protected, the DDR will ask for the function lockout password after that
selection is made.
7.1.14 Half Engine Enable
Half engine enable can be set with the DDR for ECMs with 7.00 ECM software or higher. A
current DDR is required. Half engine options are:

3 No half engine - (OFF)

3 Half engine when cold air inlet temperature is less than 12.5C (55F), with parking
brake set - (IF COLD)
3 Half engine all the time, whenever park brake is set - (ON)
3 N/A is displayed when changing half engine with the DDR or laptop is not allowed in
the engine calibration. The engine may have half engine program as part of that engine
calibration. View "Diagnostic Data List" to see if the engine is currently operating in
half engine mode.
7.1.15 Idle Shutdown
Idle shutdown can be set with the DDR or programming station.

3 Enabled: Yes/No
3 Time: 01 - 99 minutes
3 Enabled on VSG: Yes/No; this determines if you want the idle timer to shut the engine
down during idle only
3 No
3 Yes (Idle and High Idle)
3 Override:
3 Yes/No, will flash the CEL 90 seconds before shutdown to allow the driver to press
the pedal that will cancel the idle shutdown, and run until the key is cycled or by
pressing the pedal again.
3 Ambient Air Temp disallows override: Can be set with the DDR or programming
station. (Override Temp Disable) Lower Limit = XX; Upper Limit =XX. (When upper
and lower limits are set, the operator will only be able to override ISD if the calculated
ambient air temperature is above or below these temperatures. Upper and lower limit
both set to 167F=disables the feature.
3 Adding Ambient Temp Sensor: DDC offers an actual ambient temperature sensor.
NOTE:
If the override temperature disable function is wanted by a customer, it is recommended
that this be added (Kit P/N: 23518521, with instructions 18SP397).
7.1.16 Idle Speed
Idle speed can be set on the mainframe for some industrial applications to a maximum of 1000
r/min. It is a fixed speed for on-highway engines.
7.1.17 Idle Speed Offset
The Idle Speed Offset is read by the DDR as Idle Adjust.

Idle speed offset can be adjusted from + 100 r/min, to - 25 r/min using the DDR. Maximum
combined speed for automatic transmission applications is 700 r/min. (Some special applications
allow 750 r/min.)

7.1.18 Injector Calibration Codes
Injector calibration codes can be set with the DDR or programming station only. Codes are
password protected. Allowed range is 01 - 99.
7.1.19 Input Functions
DDEC has twelve digital input ports listed in Table 7-1, located on the Vehicle Interface Harness.
These digital inputs can be configured for various functions, listed in Table 7-2. These functions
can be ordered at the time of engine order. Any digital input function is able to be customized by
programming the ECM with a the programming station.
Input Cavities Input Cavities

E1#451 G2#543
F1#542 H2#524
G1#528 J2#531
H1#523 K2#583
J1#541 G3#545
F2#544 K3#979
Table 7-1 Input Cavities
Functions Functions Functions

None Limiting Torque Curve Trans Retarder Status
Engine Brake Low Diagnostic Request Dual Throttle (LSG)
Engine Brake Med Alt Min VSG/Fast Idle A/C Fan Status
Aux Shutdown #1 Service Brake Release Aux CLS
Aux Shutdown #2 Clutch Released Fan Control Override
Park Brake / ISD Set Coast OFF DDEC II VSG Station Change
Idle Validation Set / Coast ON VSG Station Complement
Pressure / RPM Mode Resume/Accel OFF DDEC II Air Load Switch
Throttle Inhibit Resume / Accel ON In Neutral Switch
RPM Sync (Marine) Cruise Enable In Gear Switch
RPM Freeze (Marine) PGS System Enable KD Brake
Rating Switch #1 SEO / DIAG Request Gas Valve Diagnostic
Rating Switch #2 Engine Brake Disable -
Table 7-2 Available Input Functions
7.1.20 Jake Brake (See Engine Brake)
For information on the Jake Brake®, refer to section 7.1.5.

7.1.21 Optimized Idle Feature
The Optimized Idle ® feature can be set with the mainframe. Refer to the Optimized Idle
Installation and Troubleshooting Manual , 7SA734, for all required information.
7.1.22 Output Functions
The DDEC system has three digital output ports located on the vehicle interface harness and three
digital output ports located on a pigtail off the engine sensor harness. These digital outputs can
be configured for various functions. The digital output cavities are listed in Table 7-3. These
functions can be ordered at the time of engine order. The digital output functions available are
listed in Table 7-4. Any digital output function can be customized by programming the ECM with
the programming station.
Output Cavities Output Cavities

VIH ESH
A1 #988 W3 #563
A2 #555 X3 #564
F3 #499 Y3 #565
Table 7-3 Output Cavities

No Function Fan Control #2 Turbo Recirc Valve
Low DDEC Volt Deceleration Light Optimized Idle Active
RPM Sync Active Engine Brake Active Low Range Solenoid (ESS)
PGS Active Light VSG Active Indication High Range Solenoid (ESS)
Vehicle Power Down Oil Pressure Low Light Shift Solenoid (Top2)
Starter Lockout Oil Temp High Light Shift Lockout (Top2)
Ext Brake Enable Coolant Temp High Light Gas Throttle Actuator
Trans Retarder Enable Air Comp Solenoid Fuel Supply Solenoid
Coolant Level Low Light Crankcase Pressure High KD Brake Solenoid
Cruise Active Light Coolant Pressure Low -
Fan Control #1 Ether Start -
Table 7-4 Available Output Functions
7.1.23 Passwords
DDEC ECMs have the ability to have unique and separate passwords in the following areas:
3 Update customer calibration (calibration change)
3 Rating change

3 Function lockout (4.00 or higher ECM software function)

3 Injector calibration (Only the DDR will change this password)
7.1.23.1 Changing Passwords Using the Diagnostic Data Reader
DDR software level must be 2.00 or higher.

1. In the event a customer loses or forgets his/her password, contact a Detroit Diesel Regional
Office, or the Detroit Diesel Technical Service Department with the engine serial number.
These contacts can provide an alternate (backdoor) password. You should also ensure that
there is not any "maximum" or "rating" security enabled on the mainframe for that unit.
2. Using the DDR select the Password Change option in the area that you need to change.
Password changing for Customer Password can be found in the "ENGINE" section, under
"Calibration Change". Changing the password for engine rating and function lockout is
found under their respective headings under the "Reprogram Cal" menu. Changing the
injector password is found in the "ENGINE" section, under "Fuel Injector Information".
3. Enter the alternate password as the current password. The alternate password is a six
character alpha numeric code. Enter alpha characters with the DDR by using the up or
down arrow keys, that scroll you through the alphabet. Use the side arrow keys to move
the cursor to the next position, or to back up to correct an entry.
4. Once all six positions are filled press the enter key.
5. Enter the new password you wish to enter (maximum four positions). Press enter.
6. Depending on the area you are changing, you will get a message that the password is
successfully changed, or prompt you to confirm that this is what you really want to do.
7. Turn the ignition off, unplug the DDR.
7.1.24 Pressure Governor System (Fire Truck)
The pressure governor system allows the engine speed to fluctuate to maintain a steady water
pump outlet pressure.
NOTE:
This system can be set on the mainframe only (Fire Truck Applications 6N4C change).
The system requires the mainframe to be set to enable the feature. A pressure transducer is
required.
NOTE:
The same transducer is used for DDEC II systems and III systems.
Control of the system can be done with switches/Mastermind for DDEC II systems or with
Switches/Mastermind or Electronic Fire Commander (EFC) for DDEC III systems. Basic
operation is the same for all systems.
The mastermind part number differs for DDEC II systems vs. DDEC III systems.

7.1.25 Progressive Shift Configuration
Progressive shift configuration can be set with the DDR or programming station and can be used
to force shifting. It is also useful to limit engine r/min in certain gears, to force shifting to a higher
gear. Use Spec Manager to determine values to enter.
7.1.26 Rating Selections
Ratings can be selected with DDR or programming station. Selections are limited to ratings
available within the 6N4D group.
7.1.27 Top 2 (Eaton)
Top 2 can be set with the programming station. Two outputs are required - shift solenoid and
shift lockout. The transmission type is manual.
7.1.28 Transmission Type
Transmission type can be set with the programming station only. Choices at time of print (may be
limited by the application code) are listed in Table 7-5.
Transmission Transmission Transmission

00 Manual 14 Other Automatic 20 Rockwell RSX9-R
01 Allison Hydraulic 15 GE Statex III 21 Rockwell RS10
03 Voith 16 Autoshift / J1939 22 Rockwell RSX10
04 Z-F Ecomat 17 Rockwell RS9 23 Reserved - RSX10-C
09 Allison Electronic 18 Rockwell RSX9-A -
12 Allison WT 19 Rockwell RSX9-B -
Table 7-5 Available Transmission Selections
7.1.29 Vehicle Overspeed Parameters
Vehicle overspeed parameters can be set with the DDR or programming station. Customer
decided parameters log vehicle overspeed codes. The parameter is typically set for +3 mph and +5
mph greater than the current vehicle speed limit; e.g. vehicle speed limit 65. Maximum overspeed
limit is 68 and maximum speed no fuel is 70. Setting both to zero disables the function.
NOTE:
Remember to review these figures if Fuel Economy Incentive is activated.
7.1.30 Vehicle Speed Limiting
Vehicle speed limiting can be set with the DDR or programming station. Requires VSS set to Yes.

Vehicle Speed Limit = Yes/No; Maximum speed = XX mph. Limited to the calculated gear bound
vehicle speed at rated engine r/min, or if progressive shift = yes, then max cruise speed is limited
to high gear r/min. (XX refers to customer selections.)
7.1.31 Variable Speed Governor or Limited Speed Governor Vehicle Speed

Limiting Diagnostics
If low side diagnostics need to be enabled or disabled, this is set on the mainframe.
Low side diagnostics refers to throttle position sensor (TPS) or variable speed governor (VSG)
"low volt" codes. This occurs when an ECM is configured to be looking for a signal at one of
these items, but nothing is wired to it.
7.1.32 Vehicle Speed Sensor Anti-Tamper
Vehicle Speed Sensor (VSS) anti-tamper can be set with the DDR, or special ECM software
available via parts.
Once set, VSS anti-tamper requires 5.0 level DDR or higher to disable.

7.2 DDEC FEATURE SUMMARY
The "x" in a column indicates that this feature has always been available. The numbers indicate
the software release that the feature was introduced. A number in the DDR column represents
the ECM software release that made the feature available, or able to be changed with the tool
listed in the comments column. Parameters that are configured in the Application Code Only
are listed in Table 7-6.
Parameter APPL Code

Mainframe Only Prog Station DDR/DDL Comments
Name 6N4C Only
Air Compressor
4 - - - -
Governor System
Air Temp Sensor x - - - -
Air Temp Torque
3 - - - -
Reduction
Barometric
x - - - -
Pressure Sensor
Coolant Level
x - - - -
Sensor
Coolant Pressure
x - - - -
Sensor
Crankcase
x - - - -
Pressure Sensor
Cruise MIN r/min x - - - Typically 1100 r/min
Disable EOP
x - - - Typically fire trucks only
on VSG
Methanol engines;
Dual Fuel BOI x - - - replaces fuel pressure
sensor
May be Jakes, KD
Enable Engine
x - - - (S55) or DVB (S55)
Brakes
beginning w/R4
Engine power limiting
Engine Overtemp
x - - - based on high engine
Protection
temps OTS, CTS, ICTS
Engine Protection Temp limits F & amt of
x - - -
Configuration power/speed reduction
Engine Sync x - - - -
Engine Sync
x - - - Typically 12
Pulses
Fan Control Includes activation
x - - -
Configuration temps
Fuel Pressure
x - - - -
Sensor

Parameter APPL Code

Name 6N4C Only
Glow Plugs x - - - Methanol engines
Typically set
Idle Operation at
x - - - for on-highway
Zero VSG
applications
Intercooler Temp
x - - - -
Sensor
LSG Low Side
Diagnostics (Code x - - - -
22)
LSG Override
x - - - -
VSG
Oil Pressure
x - - - -
Sensor
Oil Temp Sensor x - - - -
Pressure
x - - - Fire truck applications
Governor System
Assigned to PWM4
w/R3; can be
PWM Fan Control 3 - - -
programmed for PWM2
or PWM4 w/R4*
Includes duty
PWM Fan Control
3 - - - cycle levels and
Configuration
temperatures
VSG x - - - -
VSG Low Side Typically not set
Diagnostics (Code x - - - for on-highway
11) applications
VSG Operation
at Higher Vehicle 5 - - - Typically set to 3 mph
Speeds
VSG Using Foot Changes scale of r/min
x - - -
Pedal per count
* Typically PWM2 for S149; PWM4 for S50/S60
Table 7-6 Parameters That Are Configured in Application Code Only

The parameters that are configured in the mainframe screens only are listed in Table 7-7.
Parameter APPL Code Program

Mainframe Only DDR/DDL Comments
Name 6N4C Only Station
6N4C Group - x - - -
6N4D Group - x - - -
None or TURBO SPD
ATI Port - 4 - - or NAT GAS or VSG
FREQ (Pin X-1)
Utilizes selection of a
Digital Torque
- 5 - - predefined torque curve
Limiting
and/or speed
Fan Type (Digital
- x - - -
Output)
Full Power
Continuous - x - - -
Override
Some industrial only
Hot Idle Speed - x - -
max 1400 r/min
Max Cold Idle Restricted for automatic
- 3 - -
Speed trans to 700 r/min
Maximum
- x - - -
Security
Override CCPS
- 3 - - Intended for EMD
Faults
Override OPS
- 3 - - Intended for EMD
Low Faults
Rating Security - x - - -
Starter Lockout Allows use of this out-
- 5 - -
Speed Settings put for other functions
VSG is Primary - x - - -
Table 7-7 Parameters that are Configured in the Mainframe Screens Only
Parameters that can be configured by the OEM, programming station, and/or the DDR are
listed in Table 7-8.

Parameter APPL Code

Name 6N4C Only
ACG Integral
- 4 4 - Air Compressor Gov
Gain
ACG Pressure
- 4 4 - -
Increment
ACG Proportional
- 4 4 - -
Gain
Engine Sensor
Harness Outputs - x x - -
(3)
Typically set to 180
Fan A/C Timer - 5 5 -
seconds (3 minutes)
PGS Cavitation
- x x - -
Time Out
PGS Engine
- x x - -
Speed Increment
PGS Integral
- x x - -
Gain
PGS Proportional
- x x - -
Gain
PGS Pump
Pressure - x x - -
Increment
Vehicle Interface
Harness Inputs - x x - -
(12)
Vehicle Interface
Harness Outputs - x x - -
(3)
ACG Delta
- 4 4 4 Air Compressor Gov
Pressure to Load
ACG Delta
Pressure to - 4 4 4 -
Unload
ACG Maximum
- 4 4 4 -
Pressure - 1,2,3
ACG Minimum
- 4 4 4 -
Pressure - 1.2.3
Auxiliary Stop 1
or 2 Protection - x x x -
Level
Coolant Level
- x x x -
Protection Level

Parameter APPL Code

Name 6N4C Only
Crankcase
Pressure - x x x -
Protection Level
Cruise Auto
- x x x -
Resume
Cruise Control
- x x x -
Enable
Cruise Maximum
- x x x -
Speed
Cruise Minimum
- x x x -
Speed
Dynamic Fan
- x 2 2 -
Braking
Engine Brake
- x x x -
Cruise
Engine Brake
- x x x -
Increment
Engine Brake
- x x x -
Low
Engine When set requires
Brake-Svc Brake - - 5 5 tap of svc brake to
Activation activate Jakes
Allows deactivation
Engine Brake -
- - 5 5 of Jakes below a
Minimum mph
vehicle speed
FEI - Calculation Fuel Economy
- 5 5 5
Type Incentive
FEI Conversion
Factor, mph per - 5 5 5 -
mpg
FEI - Maximum
- 5 5 5 -
mph
FEI - Minimum
- 5 5 5 -
mpg
Feature
Password - 5 4 (Function Lockout)
Protection
Enable/disable Half
Half Engine
- - - 7 engine idle, Off, If
Enable
Cold, On, N/A
Idle Shutdown
- x x x -
Override

Parameter APPL Code

Name 6N4C Only
Idle Adjust Normal
Idle Speed Offset - - - x
+100 to -25 rpm
Idle Timer - x x x -
Idle Timer Idle Gov only, or Idle
- x x x
Operates ON and VSG Governor
Idle Timer
Override Defeat, - 2 2 2 -
max temp
Idle Timer
Override Defeat, - 2 2 2 -
min temp
Idle Timer
- x x x -
Shutdown
Injector
Calibration - - - x -
Codes
Intercooler Temp
- x x x -
Protection Level
LSG Droop - x x x -
Max Vehicle
Overspeed with - x x x -
Fuel
Max Vehicle
Overspeed w/o - x x x -
Fuel
Oil Pressure
- x x x -
Protection Level
Oil Temp
- x x x -
Protection Level
Progressive Shift
- x x x -
Configuration
Rating Selection
- 6N4M x x -
(Rating Override)
Transmission
- x x x -
Type (PWM #1)
Unit Number - - - 4 -
Vehicle Speed
- x x x -
Limiting
Vehicle Speed
- x x x -
Max
Vehicle Speed
- x x x -
Sensor

Parameter APPL Code

Name 6N4C Only
VIN - - x x -
VSG Alt Min RPM - x x x -
VSG Cruise Init
- x x x -
Speed
VSG Cruise RPM
- x x x -
Increment
VSG Droop - x x x -
VSG Maximum
- x x x -
RPM
VSG Minimum
- x x x -
RPM
VSG Using
- x x x -
Cruise Switch
VSS Anti Tamper - - 7 5 -
VSS Axle Ratio - x x x -
VSS Final Gear
- x x x -
Ratio
VSS Number
- x x x -
of Teeth
Typically tailshaft; also
VSS Sensor Type - x x x
wheel or J1939
Typically magnetic;
VSS Signal Type - 2 2 2 also open-
collector/switch
VSS Tire
- x x x -
Revolutions
Table 7-8 Parameters that can be Configured by the OEM, Programming

Station, and/or the DDR

DDEC Features, code 6N5, are listed in Table 7-9.
Parameter Code Mainframe Program DDR Comments

Name Only Station
No DDEC 6N5-NONE - - - -
Feature
ECM Data Pages 6N5-0001 - - - -
Only
Optimized Idle 6N5-0002 - - - -
Only
Data Pages and 6N5-0003 - - - -
Optimized Idle
Table 7-9 6N5 - DDEC Features

8 (UPDATE) CONNECTORS, TERMINALS, AND
SPLICING
8.1 CRIMP AND REMOVAL TOOLS
Crimp tools and connector removing tools can be purchased from Kent-Moore. The part and
associated part numbers are listed in Table 8-1.
Connector Tool Part Number

Metri-Pack 150 Removing J 35689
Crimp J 35123
Weather Pack Removing J 36400-5
Crimp J 35606
Metri-Pack 280 Removing (18 AWG) J 33095
Crimp (18 AWG) J 38125-6
Removing (12 AWG - Used for
J 33095
power harness)
Crimp (12 AWG - Used for
J 39848
power harness)
Deutsch Removing (12 AWG) J 37451
Removing (16-18 AWG) J 34513
Crimp J 34182
Table 8-1 Crimp and Removal Tools

8.2 METRI-PACK 150 CONNECTORS
Metri-Pack 150 series connectors are "pull-to-seat" connectors. Each wire must be pushed
through the connector prior to crimping the terminal. Cable seals are inserted into the shell of the
connector and hold many wires. Metri-Pack 150 connectors are listed in Table 8-2.
ECM Engine Harness ECM Vehicle Interface Harness

Connector P/N: 12034400 Connector P/N: 12034398
Terminal P/N: 12103881 Terminal P/N: 12103881
Seal In Connector Seal In Connector
Plug P/N: 12034413 Plug P/N: 12034413
ECM Communication Harness Connector Temperature Sensor Harness
Plug P/N: 12034413 Plug P/N: Not Applicable
Pressure Sensor Harness Fire Truck Pressure Sensor (PGS)
Plug P/N: Not Applicable Plug P/N: Not Applicable
SRS Harness TRS Harness
Injector (Gray) Injector (Black)
Seal P/N: Not Applicable Seal P/N: Not Applicable
Plug P/N: 12034413 Plug P/N: 12034413
Table 8-2 Metri-Pack 150 Connector Part Numbers
8.2.1 Installation
Metri-Pack 150 connectors are of the "pull-to-seat" design. The cable is pushed through the
seal and correct cavity of the connector before crimping the terminal to the cable. It should be
stripped of insulation after it is placed through the seal and connector body. Use the following
instructions for terminal installation:

1. Position the cable through the seal and correct cavity of the connector. See Figure 8-1.
Figure 8-1 Inserting Wire in Connector
2. Strip the end of the cable using wire strippers to leave 5.0 ± 0.5 mm (0.2 ± 0.02 in.)
of bare conductor.
3. Squeeze the handles of the crimping tool together firmly to cause the jaws to automatically
open.
4. Hold the "wire side" facing you.
5. Push the terminal holder to the open position and insert the terminal until the wire
attaching portion of the terminal rests on the 20-22 anvil. Be sure the wire core wings and

the insulation wings of the terminal are pointing toward the upper jaw of the crimping
tool. See Figure 8-2.
Figure 8-2 Terminal and Crimping Tool Position

6. Insert the cable into the terminal until the stripped portion is positioned in the wire core
wings, and the insulation portion ends just forward of the insulation wings. See Figure 8-3.
Figure 8-3 Cable to Terminal Alignment
7. Compress the handles of the crimping tool until the ratchet automatically releases and the
crimp is complete.

NOTE:
For faster, more efficient crimping operation, a bracket or bench rest may be used to
cradle one handle of the tool. The operator can apply the terminals by grasping and
actuating only one handle of the tool. See Figure 8-4.
Figure 8-4 Crimping Operation
8. Release the crimping tool with the lock lever located between the handles, in case of
jamming.
9. Align the locking tang of the terminal with the lettered side of the connector.

10. Pull the cable back through the connector until a click is heard.See Figure 8-5. Position
the seal into the connector.
Figure 8-5 Pulling the Terminal to Seat
NOTE:
For ECM 30-pin connectors, put locking tang opposite lettered side.
8.2.2 Removal and Repair
A tang on the terminal locks into a tab molded into the plastic connector to retain the cable
assembly. Remove Metri-Pack 150 terminals using the following instructions.

1. Insert the removal tool into the cavity of the connector, placing the tip of the tool between
the locking tang of the terminal and the wall of the cavity. See Figure 8-6.
Figure 8-6 Terminal Removal
2. Depress the tang of the terminal to release it from the connector.

3. Push the cable forward through the terminal until the complete crimp is exposed.
4. Cut the cable immediately behind the damaged terminal to repair it.
5. Follow the installation instructions for crimping the terminal and inserting it into the
connector.

8.3 WEATHER PACK AND METRI-PACK 280 CONNECTORS
Weather Pack and Metri-Pack 280 series connectors are push-to-seat. The terminal is crimped
onto each wire before it is inserted into the connector. A cable seal is crimped on each wire at the
same time the terminal is crimped onto the wire. Weather Pack connectors use a secondary lock
on both male and female connector bodies and the lock snaps into place over the cable seals after
installation. Some Metri-Pack connectors have secondary locks as well. Weather Pack connectors
and their associated part numbers are listed in Table 8-3. Metri-Pack 280 connectors and their
associated part numbers are listed in Table 8-4.
Turbo Boost Pressure Sensor Harness Engine Brake Connector, Series 60

Connector P/N: 12015384 Connector P/N: 12010973 / 12162000
Terminal P/N: 12089040 Terminal P/N: 12048074 / 12045773
Seal P/N: 12015323 - -
Throttle Position Sensor Harness Side Throttle Position Sensor Sensor Side
Seal P/N: 12015323 Seal P/N: 12015323
Ignition Connector Power Harness Side Ignition Connector Vehicle Interface Harness Side
Allison Interface Module Allison Interface Module Maximum Feature
Seal P/N: 12015323 Seal P/N: 12015323
Plug P/N: 12010300
Table 8-3 Weather Pack Connectors and Part Numbers
Coolant Level Sensor Connector Power Harness

Seal P/N: 12015323 Seal P/N: 12015193
Secondary Lock P/N: 15300014 Secondary Lock P/N: 12052816
Table 8-4 Metri-Pack 280 Connectors and Part Numbers

8.3.1 Installation
Use the following instructions for terminal installation:

1. Insert the terminal into the locating hole of the crimping tool using the proper hole
according to the gage of the cable to be used. See Figure 8-7.
Figure 8-7 Terminal Position

2. Insert the cable into the terminal until the stripped portion is positioned in the cable
core wings, and the seal and insulated portion of the cable are in the insulation wings.
See Figure 8-8.
Figure 8-8 Cable and Terminal Position Before and After Crimping
3. Compress the handles of the crimping tool until the ratchet automatically releases and the
crimp is complete. A properly crimped terminal is shown. See Figure 8-8.
4. Release the crimping tool with the lock lever located between the handles, in case of
jamming.

5. Push the crimped terminal into the connector until it clicks into place. Gently tug on the
cable to make sure it is secure. See Figure 8-9.
Figure 8-9 Inserting Terminal in Connector
8.3.2 Removal and Repair
Two locking tangs are used on the terminals to secure them to the connector body. Use the
following instructions for removing terminals from the connector body.
1. Disengage the locking tang, securing the connector bodies to each other. Grasp one half of
the connector in each hand and gently pull apart.

2. Unlatch and open the secondary lock on the connector. See Figure 8-10.
Figure 8-10 Unlatched Secondary Lock
3. Grasp the cable to be removed and push the terminal to the forward position.
4. Insert the removal tool straight into the front of the connector cavity until it resists
on the cavity shoulder.

5. Grasp the cable and push it forward through the connector cavity into the tool while
holding the tool securely in place. See Figure 8-11.
Figure 8-11 Removal Tool Procedure
6. The tool will press the locking tangs of the terminal. Pull the cable rearward (back through
the connector). Remove the tool from the connector cavity.
7. Cut the wire immediately behind the cable seat and slip the new cable seal onto the wire.

8. Strip the end of the cable using strippers to leave 5.0 ± 0.5 mm (0.2 ± 0.02 in.) of bare
conductor. Position cable seal as shown. See Figure 8-12.
Figure 8-12 Proper Cable Seal Position
9. Crimp new terminal onto wire using the crimp tool. See Figure 8-13.
Figure 8-13 Crimping Procedure

8.4 DEUTSCH CONNECTORS
Deutsch connectors have cable seals molded into the connector. These connectors are push to
seat connectors with cylindrical terminals. The diagnostic connector terminals are gold plated for
clarity. Deutsch connectors and their associated part numbers are listed in Table 8-5.
Diagnostic Connector
Connector P/N: 23513052
Terminal P/N: 23513053
Protective Cap P/N: 23413054
Plug P/N: 23507136
Engine Minder
Plug P/N: 23507136
Mastermind - Power and Communication Link
Plug P/N: 23507136
Mastermind - Inputs and Outputs
Plug P/N: 23507136
Table 8-5 Deutsch Connectors and Part Numbers
8.4.1 Installation
Use the following instructions for installation:

1
1. Strip approximately 4 in.(6 mm) of insulation from the cable.
2. Remove the lock clip, raise the wire gage selector, and rotate the knob to the number
matching the gage wire that is being used.
3. Lower the selector and insert the lock clip.

4. Position the contact so that the crimp barrel is 1/32 of an inch above the four indenters.
See Figure 8-14. Crimp the cable.
Figure 8-14 Setting Wire Gage Selector and Positioning the Contact
5. Grasp the contact approximately one inch behind the contact crimp barrel.

6. Hold the connector with the rear grommet facing you. See Figure 8-15.
Figure 8-15 Pushing Contact Into Grommet
7. Push the contact into the grommet until a positive stop is felt. See Figure 8-15. A slight
tug will confirm that it is properly locked into place. See Figure 8-16.
Figure 8-16 Locking Terminal Into Connector

8.4.2 Removal
The appropriate size removal tool should be used when removing cables from connectors. The
proper removal tool size is listed in Table 8-1.
1. With the rear insert toward you, snap the appropriate size remover tool over the cable of
contact to be removed. See Figure 8-17.
Figure 8-17 Removal Tool Position

2. Slide the tool along the cable into the insert cavity until it engages and resistance is felt.
Do not twist or insert tool at an angle. See Figure 8-18.
Figure 8-18 Removal Tool Insertion
3. Pull contact cable assembly out of the connector. Keep reverse tension on the cable
and forward tension on the tool.

8.5 SPLICING GUIDELINES
The following are guidelines which may be used for splices. The methods described are not the
only acceptable methods. Any method should produce a high quality, tight splice with durable
insulation which can be expected to last the life of the vehicle.
The selection of crimpers and splice connectors is optional. Select a high quality crimper
equivalent to the Kent-Moore tool, J 38706, and commercially available splice clips.
8.5.1 Tools Required
The following is a list of tools required for splicing wires:

3 Soldering iron
3 Rosin core solder
3 Wire strippers
3 Heat shrink tubing
3 Splice clips
3 Crimp pliers

8.6 STRAIGHT LEADS
8.6 STRAIGHT LEADS
To splice straight leads:

1. Locate broken wire.
2. Remove insulation as required; be sure exposed wire is clean and not corroded.
3. Slide a sleeve of shrink wrap on the wire long enough to cover the splice and overlap the
wire insulation, about 14 in. on both sides.
4. Insert one wire into splice clip (P/N: 0597428 or equivalent) and crimp.
5. Insert the other wire into splice and crimp. See Figure 8-19.
Figure 8-19 Spliced Wire

8.7 SOLDER
Soldering splice connectors is optional. To solder splice connectors:

1. You must use rosin core solder.
2. Check the exposed wire before the splice is crimped in its connector. The exposed wire
must be clean before the splice is crimped.
3. Use a suitable electronic soldering iron to heat the wires. Apply the solder to the heated
wire (not to the soldering iron) allowing sufficient solder flow into the splice joint.
4. Pull on connection to assure crimping and soldering integrity.

8.8 SHRINK WRAP
8.8 SHRINK WRAP
Shrink wrap is required. Alpha FIT-300, Raychem TAT-125 or any equivalent heat shrink dual
wall epoxy encapsulating adhesive polyolefin is required.
Alpha Wire Corp 711 Lidgerwood Ave, P.O. Box 711 Elizabeth; New Jersey 07207-0711;
1-800-52ALPHA
Raychem Corporation, Thermofit Div 300 Constitution Drive, Bldg. B; Menlo Park, CA
94025; 415-361-3860
To heat shrink wrap a splice:
1. Select the correct diameter to allow a tight wrap when heated. The heat shrink wrap must
be long enough to overlap the wire insulation about 14 in. on both sides of the splice.
2. Heat the shrink wrap with a heat gun; do not concentrate the heat in one location, but play
the heat over the entire length of shrink wrap until the joint is complete.

8.9 MULTIPLE BROKEN WIRES
To splice multiple broken wires:

1. Stagger the position of each splice as illustrated. See Figure 8-20.
2. You must stagger positions to prevent a large bulge in the harness and to prevent the wires
from chafing against each other.
Figure 8-20 Multiple Splices

8.10 THREE-WIRE SPLICE
8.10 THREE-WIRE SPLICE
Three-way splice connectors are commercially available to accommodate three-wire splices. The
technique is the same as a single butt splice connector. See Figure 8-21.
Figure 8-21 Three-Way Splice

9 (CHG) DIAGNOSING A DDEC SYSTEM FAULT
9.1 FIRST STEP FOR DIAGNOSING A FAULT WITHIN THE DDEC SYSTEM
The following procedure is the starting point for diagnosing DDEC codes using the Diagnostic
Data Reader (DDR).
9.1.1 Check Engine Light
Perform the following steps to check the Check Engine Light (CEL):
1. Turn the ignition on while at the same time observing the Check/Stop Engine light (engine
not running).
[a] If the CEL comes on and stays on, refer to section 9.1.2.
[b] If the CEL comes on for up to five seconds, and then turns off, refer to section 9.1.3.
[c] If the CEL does come on, but the condition of light is erratic or intermittent,
refer to section 10.4.
[d] If the CEL does not come on, refer to section 10.4.
9.1.2 Read Active Codes
Perform the following steps to read the active codes.

1. Turn ignition on. Plug DDR into DDL connector. See Figure 9-1.
Figure 9-1 Diagnostic Connector

9.1 FIRST STEP FOR DIAGNOSING A FAULT WITHIN THE DDEC SYSTEM
2. Read active codes by selecting the DIAGNOSTIC CODE MENU (ACTIVE CODES)
on the DDR.
[a] If active codes are displayed on the DDR, follow the appropriate diagnostic
procedures for the codes received. Refer to the section number that is the same as
the Flash Code number.
[b] If the DDR display is blank or random, refer to section 10.5.
[c] If DDR displays NO DATA or DDEC Info not available, refer to section 10.8.
[d] If the DDR display reads "No Active Codes", refer to section 10.8.
9.1.3 Read Inactive Codes
Perform the following steps to read inactive codes.

1. Plug DDR into the DDL connector.
2. Read inactive codes. (Select inactive codes on the DDR.)
[a] If DDR displays no inactive codes, the problem may be intermittent.
Refer to section 10.1.
[b] If DDR display is blank or random, refer to section 10.5.
[c] If DDR displays NO DATA or DDEC Info not available, refer to section 10.5.
[d] If the DDR displays any inactive codes, clear the codes and refer to section 9.1.4.
9.1.4 Attempt to Make Codes Active
Perform the following steps to make codes active.

1. Start and run the engine for eight minutes. Warm the engine. Coolant/oil temperature
must be greater than 140 F (60 C).
2. If required, perform road test with an assistant.
[a] If CEL or SEL illuminate, read codes and refer to the section number that matches
the flash code number logged.
[b] If CEL or SEL do not illuminate and no codes log, return to service.
[c] If CEL or SEL do not illuminate but symptom occurs, refer to section 10.1, and
Diagnosis by Symptom.

10 (CHG) INTERMITTENT FAULT
10.1 INTERMITTENT CODE OR A SYMPTOM AND NO CODES
The following procedure will diagnose an intermittent code or symptom.
10.1.1 Diagnosis by Symptom
Perform the following steps to diagnose an intermittent code or symptom.
NOTE:
Do not use any other procedures (except for the suggestions listed in this manual) when
trying to solve an intermittent problem. Use of any other procedures for this type of
problem can result in the replacement of non-defective parts.
Many intermittent problems are caused by faulty electrical connectors or wiring. Diagnosis
must include a careful inspection of the indicated circuit wiring and connectors. For example,
an intermittent code 35 (Oil Pressure Sensor High Voltage) would indicate a problem in the
following areas associated with the Oil Pressure Sensor.
3 Wires #530 (signal line), #416 (+5 volt line), or #452 (ground line)
3 The Oil Pressure Sensor connector or ECM connector
3 An intermittent problem in the Oil Pressure Sensor (least likely)
Use the following checklist:
1. Check for poor mating of the connector halves or terminals not fully seated in the
connector body (backed out terminals).
2. Look for improperly formed or damaged terminals. All connector terminals in the problem
circuit should be carefully inspected to determine proper contact tension. Use a mating
terminal to test the contact tension.
3. Electrical system interference caused by a defective relay, ECM driven solenoid, or a
switch causing an electrical surge. Look for problems with the charging system (alternator,
etc.). In certain cases, the problem can be made to occur when the faulty component is
operated as in the case of a relay.
4. Verify alternator grounds are clean and making good contact. Disconnect the alternator
belt to test.
5. Wiggle wires and harnesses to try to make the problem active, or re-occur.
10.1.2 Verify Repairs
Perform the following steps to verify repairs.

1. Clear codes.
2. Confirm the CEL does not come on (except for the five second ignition ON bulb check).
3. Run the engine for one minute.
4. If the CEL stays ON, refer to section 9.1.2.

10.2 ENGINE CRANKS BUT WILL NOT START
The following procedures will diagnose engine cranks but will not start.
10.2.1 Check Engine Light
Perform the following steps to check the CEL:

1. Turn ignition on while observing the Check/Stop Engine Light.
[a] If the light comes on and stays on, refer to section 9.1.
[b] If the light comes on for up to five seconds, and then goes off, refer to section 10.2.2.
[c] If the lights are off, refer to section 10.2.14.
10.2.2 Fuel Check
Perform the following steps to check the fuel supply:

1. Disconnect the fuel return line.
2. Check for fuel flow while cranking the engine.
[a] If fuel flow is okay, refer to section 10.2.3.
[b] If fuel supply is not okay, refuel the vehicle. The system may need to be re-primed.
Refer to the appropriate engine service manual.
10.2.3 White Smoke Check
Perform the following steps to check for white smoke:

1. Reconnect fuel return line.
2. Look for white smoke coming out of the exhaust stack while cranking the engine.
[a] If white smoke is present, refer to section 10.2.4.
[b] If white smoke is not present, refer to section 10.2.28.
10.2.4 Check Timing Reference Sensor Status
Perform the following steps to check the TRS status via a r/min readout:
1. Select engine speed and active codes on the DDR.
2. Crank the engine for ten seconds while observing DDR display. A battery voltage surge
while cranking with electric starters may blank or reset the DDR.
[a] If the display reads greater than or equal to 60 r/min, refer to section 10.2.9.
[b] If the display reads less than 60 r/min or constantly reads 60 r/min,

[c] If code 41 is displayed, refer to section 41.3.1.

[d] If code 42 is displayed, refer to section 42.3.1.
10.2.5 Check Timing Reference Sensor
Perform the following steps to check the TRS:

1. Turn vehicle ignition OFF.
2. Disconnect engine harness connector at the ECM.
3. Measure resistance between sockets T1 and T2 at the engine harness connector.
[a] If the resistance measurement is greater than 200
, refer to section 41.3.3.
[b] If the resistance measurement is less than 100
[c] If the resistance measurement is between 100 and 200
10.2.6 Check Synchronous Reference Sensor / Timing Reference Sensor

Mounting
Perform the following steps to check the SRS/TRS mounting and the bracket:
1. Inspect SRS/TRS mounting.
[a] If the sensor and mount are secure, refer to section 10.2.7.
[b] If the sensor and mount are not secure, tighten the bolt or replace if necessary.
10.2.7 Check Pulse Wheel
Perform the following steps to check the pulse wheel:

1. Inspect DDEC ® pulse wheel for loose wheel or chipped or missing teeth.
[a] If the pulse wheel is damaged, repair or replace as necessary. Refer to section 10.2.27.
[b] If the pulse wheel is not damaged, refer to section 10.2.8.
10.2.8 Check ECM Connectors
Perform the following steps to check the ECM connectors:

2. Disconnect all connectors at the ECM.
3. Check terminals at all ECM connectors (both the ECM and harness side) for damaged,
bent, corroded or unseated pins or sockets.
[a] If the terminals and connectors are damaged, repair them. Refer to section 10.2.27.

[b] If the terminals and connectors are not damaged, replace the ECM.
Refer to section 10.2.27. (Try a test ECM first.)
10.2.9 Check for Good Synchronous Reference Sensor Signal
Perform the following steps to check for a good SRS signal:

1. Select engine data list on DDR.
2. Crank engine while observing DDR display of SRS received. Battery voltage surges while
cranking with electric starters may blank or reset the DDR.
[a] If the SRS RECEIVED signal is YES, refer to section 10.2.11.
[b] If the SRS RECEIVED signal is NO, refer to section 10.2.10.
10.2.10 Check Synchronous Reference Sensor
Perform the following steps to check the SRS:

3. Measure resistance between sockets S1 and S2 at the engine harness connector.
10.2.11 Check for Open
Perform the following steps to check if the injector return wires are open:
1. Turn ignition OFF.
2. Disconnect the 5-way injector harness connector at the ECM.
3. Measure resistance between the injector return pin and all the power driver pins on both
harness connectors.
on any reading, an open exists in one
of the injector power driver or return wires. Repair the open. Refer to section 10.2.27.
[b] If the resistance measurement is less than or equal to 5
on any reading,
10.2.12 Short to Ground
Perform the following steps to check if the injector lines are shorted to the ground:
1. Disconnect the 5-way injector harness connector at the ECM.

2. Measure resistance between socket D of the 5-way power harness connector to the
following sockets on the injector harness connector: A, B, C, D, E, G, H, J, K and L.
[a] If the resistance measurement is greater than or equal to 10,000
or open on all
readings, refer to section 10.2.13.
[b] If the resistance measurement is less than 10,000
on any reading, there is a short
to ground on the wire where resistance was less than 10,000
. Repair the short
and refer to section 10.2.27.
10.2.13 Injector Drive Pulses
Perform the following steps to check the injector drive pulses:

2. Reconnect all ECM connectors. See Figure 10-1.
3. Remove rocker covers.
4. Disconnect return wire #619 or #620 from one injector.
5. Place a 6-volt test light across the previously disconnected injector return side and a
good ground.
6. Crank engine and note the test light to see if it lights (flashes).
7. Reconnect the return wire.
8. Repeat the above procedure with all other injectors until all have been tested or until
one test fails.
[a] If all tests pass, the problem does not appear to be in the DDEC system.
[b] If all tests do not pass and the test light is flashing for one or more tests, check for
proper parts (e.g. bull gear) then try a test ECM. Refer to section 10.2.27.

[c] If all tests do not pass and the test light is not flashing for one or more tests,
Figure 10-1 5-Way ECM Power Harness Connector
10.2.14 Check DDEC Fuses
Perform the following steps to check the DDEC fuses:

1. Check both ECM power fuses or circuit breakers.
[a] If both fuses are okay, refer to section 10.2.15.
[b] If either fuse is not okay, refer to section 10.2.25.
10.2.15 Battery Volts Check
Perform the following steps to check for battery volts at the 5-way connector:
NOTE:
A high resistance in these wires may prevent engine starting but measure correct voltage.
Proper resistance based on wire length and size is listed in Table 46-2.

2. Disconnect the 5-way power harness connector at the ECM. See Figure 10-2.
3. Measure voltage from socket A (red lead) of 5-way power harness connector to a good
ground.

4. Measure voltage from socket C (red lead) of 5-way power harness connector to a good
ground.
[a] If the voltage measurement is greater than 11.5 volts on all readings,
[b] If the voltage measurement is less than 11.5 volts on any readings,
10.2.16 ECM Power Line Check
Perform the following steps to check if the ECM power lines are open:
1. Measure voltage between battery side of one ECM fuse or circuit breaker (red lead)
and a good ground (black lead).
2. Measure voltage at other ECM fuse or circuit breaker. Note that battery side does not
contain #240 or #241 wires. See Figure 10-3.
[a] If the voltage measurement is less than 11.5 volts on any reading,

[b] If the voltage measurement is greater than 11.5 volts on all readings, an open exists in
either power wire (#240 or #241). Repair the open; refer to section 10.2.27.
Figure 10-3 Power Harness Diagram

10.2.17 Check Battery
Perform the following steps to check the battery:

1. Connect all connectors.
2. Turn ignition ON.
3. Measure voltage at battery (+) terminal (red lead) to the battery (-) terminal (black lead).
[a] If the voltage reading is less than 11.5 volts, service the discharged battery.
[b] If the voltage reading is greater than or equal to 11.5 volts, an open or short to ground
exists in the battery (+) line. Repair the open. Refer to section 10.2.27.
10.2.18 Check Volts at Ignition Wire
Perform the following steps to check for +12 or +24 volts at the ignition wire:
2. Disconnect the vehicle harness connector at the ECM. For vehicle harness schematic,
see Figure 10-4.
4. Measure voltage between socket B3 on the vehicle harness connector (red lead) and a
good ground (black lead).
[a] If the voltage measurement is greater than or equal to 11.5 volts,

[b] If the voltage measurement is less than 11.5 volts, refer to section 10.2.20.
Figure 10-4 ECM Vehicle Harness Connector
10.2.19 Ground Wire Check
Perform the following steps to check for a good ground wire:

1. Measure voltage between socket B3 on the vehicle harness connector (red lead) and
sockets D and E of the 5-way power harness connector. For 5-way ECM power harness
schematic, see Figure 10-5.
[a] If the voltage measurement is greater than or equal to 11.5 volts, refer to section 10.2.8.

[b] If the voltage measurement is less than 11.5 volts, the ECM ground wire (ck#150) is
open or has a poor connection. Repair open; refer to section 10.2.27.
10.2.20 Check Ignition Fuse
Perform the following steps to check the ignition fuse:

2. Check 5-amp ignition fuse or circuit breaker.
[a] If both the fuse and circuit breaker are okay, refer to section 10.2.21.
[b] If the fuse or circuit breaker are not okay, refer to section 10.2.22.
Perform the following steps to check if the ignition wire is open:

1. Measure voltage between battery side (hot side) of the 5-amp ignition fuse (red lead)
and a good ground (black lead).
[a] If the voltage measurement is less than 11.5 volts, refer to section 10.2.24.
[b] If the voltage measurement is greater than or equal to 11.5 volts, the ignition line
(circuit #439) is open. Repair the open; refer to section 10.2.27.

10.2.22 Check for Ground
Perform the following steps to check if the ignition wire is shorted to ground:
1. Replace blown fuse or reset open circuit breaker.
2. Turn ignition ON for ten seconds.
3. Run engine for one minute.
5. Check 5-amp ignition fuse or circuit breaker again.
[a] If both the fuse and circuit breaker are okay, refer to section 10.2.23.
[b] If the fuse and circuit breaker are not okay, the ignition line (circuit #439) is shorted
to ground. Repair the short; refer to section 10.2.27.
10.2.23 Check Fuse or Circuit Breaker
Perform the following steps to check if the ignition fuse or breaker is okay:
1. Reconnect all harness connectors at the ECM.
2. Start the engine.
3. Run engine for one minute.
5. Check 5-amp ignition fuse or circuit breaker again. For 5-way ECM power harness
schematic, see Figure 10-6.
[a] If both the fuse and circuit breaker are okay, no short is currently present. Be warned
of an intermittent short that could shut down the engine or blow a fuse due to reverse
voltage at the battery. Refer to section 10.2.27.

10.2.24 Check Battery
Perform the following steps to check the battery:

1. Disconnect the battery cables at the battery.
2. Measure voltage at the battery (+) terminal (red lead) to the battery (-) terminal (black
lead).
[a] If the voltage measurement is less than 11.5 volts, service the discharged battery.
[b] If the voltage measurement is greater than or equal to 11.5 volts, an open or short to
ground exists in unfused ignition line. Repair the open. Refer to section 10.2.27.
10.2.25 Check for Blown Fuses
Perform the following steps to check for blown fuses:

2. Disconnect the 5-way power harness connector at the ECM.
3. Replace blown fuse(s) or reset the circuit breaker(s).
4. Wait ten seconds.
5. Check whether fuse(s) or circuit breaker(s) have blown or opened up again.

[a] If the fuse and circuit breaker are okay, refer to section 10.2.23.
10.2.26 Check for Short to Ground
Perform the following steps to check for a short to ground:

1. Disconnect the batteries.
2. Measure resistance between #240 and a good ground (black lead).
3. Measure resistance between #241 and a good ground (black lead).
[a] If the resistance measurement is greater than or equal to 10,000
on all readings,
on any readings, a short to
ground exists. Repair the short. Refer to section 10.2.27.
Perform the following steps to verify repairs:

2. Reconnect all connectors.
4. Clear codes.
5. Start and run the engine for one minute.
6. Stop the engine.
7. Read inactive codes.
[a] If the engine starts and no codes are displayed, troubleshooting is complete.
[b] If the engine does not start, refer to section 10.2.1.
[c] If the engine starts and codes display, refer to section 9.1.
10.2.28 Check Fuel Filters
Perform the following steps to check fuel filters:

2. Check primary and secondary fuel filters to be sure they are not clogged and they are
filled with clean fuel.
[a] If the fuel filters are clean, refer to section 10.2.4.
[b] If the fuel filters are not clean, replace the filters. Prime the system if required.

NOTE:
For information concerning Fuel Filters, refer to section 29.4.11 in the appropriate service
manual. For information concerning Fuel Filter Replacement, refer to section 18 in
the appropriate service manual.

10.3 ERRATIC PERFORMANCE AND NO CODES
10.3 ERRATIC PERFORMANCE AND NO CODES
The following troubleshooting chart resolves erratic performance and no codes displayed. For
troubleshooting procedures, refer to the appropriate engine service manual.
10.3.1 Erratic Performance and No Codes
Check the following symptoms to determine possible fault, listed in Table 10-1.
Symptom Possible Fault

Cannot get full power. Plugged fuel filters. Hose not connected to Turbo Boost
Sensor. Verify injector calibration(s) are correct.
Cannot get full throttle. Mis-calibrated Throttle Position Sensor.
Runs rough; misses and occasionally stalls. Improper gapping of Timing Reference and Synchronous
Reference Sensor. Fuel leaks. Loose battery power,
ignition or ground wires Injector failure. Vehicle speed
sensor failure. Injector harness failure.
Engine idles high after warm-up or hangs. Incorrect calibration of Throttle Position Sensor.
TPS linkage or pedal problem. VSG signal wire
shorted to voltage source.
Low road speed. Determine road speed specifications for vehicle
manufacturer data. If road speed is less than specified
and all mechanical checks are correct, then cruise
control calibration is suspected.
Vehicle surges or bucks. VSS may be supplying incorrect data to the ECM.
Table 10-1 Troubleshooting Erratic Performance and No Code

10.4 CHECK ENGINE LIGHT AND STOP ENGINE LIGHT FAULT
The following steps will troubleshoot a fault with the check engine or stop engine lights. These
lights are used to alert the operator of engine faults; flash any trouble codes stored in the ECM;
and illuminate for five seconds and then go out during a start sequence, as a bulb check.
10.4.1 Determine Fault
Perform the following to determine fault:

1. If the CEL or SEL is always on, refer to section 10.4.2.
2. If the CEL or SEL never lights, refer to section 10.4.5.
10.4.2 Display ECM Light Status
Perform the following steps to display light status:

1. While the light is lit, plug in the DDR (ignition ON).
2. Select switch light status.
3. View the displayed status for the problem light.
[a] If status reads OFF, refer to section 10.4.4.
[b] If status reads ON, refer to section 10.4.3.
10.4.3 Determine Reason for ECM Request
Perform the following steps to determine the reason the ECM is requesting the light to be ON:
1. Verify the diagnostic request is not ON.
[a] If the diagnostic request is ON, refer to section 10.10.
[b] If the diagnostic request is not ON, refer to section 9.1, (troubleshoot code).
10.4.4 Check for Grounded Wire
Perform the following steps to check for a grounded wire:

2. Unplug VIH 30-pin connector.
[a] If the light stays on, drive (#509 or #419) wire is shorted to the ground. Repair or
replace the wire. Refer to section 10.4.9.
[b] If the light goes off, clean the connectors of the VIH 30-pin and assemble again.
Then, refer to section 10.4.9.

10.4 CHECK ENGINE LIGHT AND STOP ENGINE LIGHT FAULT
10.4.5 Activate Light With Diagnostic Data Reader
Perform the following steps to activate the light with the DDR:
2. Plug in DDR.
3. Select Activate Outputs.
4. Activate affected light; watch status.
[a] If the light stays off. Refer to section 10.4.6.
[b] If the light illuminates, the problem no longer exists. Refer to DDEC III Application
and Installation manual, 7SA800, to review the light operation.
10.4.6 Check Bulb
Perform the following steps to check the bulb:

2. Refer to OEM recommendations for checking bulb.
[a] If the bulb is bad, replace the bulb and refer to section 10.4.9.
[b] If the bulb is okay, refer to section 10.4.7.
10.4.7 Check for Voltage Supply
Perform the following steps to check the voltage supply:

1. Disconnect the power supply to the light.
3. Measure voltage between the removed connection and battery ground.
[a] If the voltage is correct based on the system of the vehicle (12/24V),
[b] If the voltage is too low to expect the bulb to light, refer to the OEM recommendations
to resolve the problem. Refer to section 10.4.9.
10.4.8 Check for Open Output Wire
Perform the following steps to check for an open output wire:

1. Measure the resistance between the ground side of the connector of the light and the
battery ground.
[a] If the measured resistance is 45,000 to 48,000
, clean the connections.

[b] If the measured resistance is less than 45,000

or greater than 48,000
, the wire is
shorted to voltage, or is opened. Repair wire. Refer to section 10.4.9.

1. Ensure all removed connections are installed.
[a] If the light comes on for five seconds, then goes out, troubleshooting is complete.
[b] If the light comes on and stays on, refer to section 10.4.1.
[c] If the light does not turn on, all troubleshooting is complete. Review this section and
contact Detroit Diesel Technical Service.

10.5 NO DATA TO DIAGNOSTIC DATA READER
Before using this procedure, all basic mechanical checks and physical inspections should have
been performed with no problem found. Also the diagnosis of the DDEC system in Section 9
referred you to this section.
10.5.1 Read Codes on the Check Engine Light
Perform the following steps to read the codes on the CEL or SEL:
1. Unplug the DDR.
2. Ignition should be ON; engine not running.
3. Enable diagnostic request switch.
4. Read codes flashing on the CEL and SEL.
[a] If codes are flashing out, refer to section 10.5.4.
NOTE:
If you wish to bypass diagnosis of a potential data line of the DDR problem for now,
diagnose the active code by referring to the section that matches the code number.
[b] If CEL and SEL are not flashing out codes, refer to section 10.5.2.
10.5.2 Check Diagnostic Request Circuit
Perform the following steps to check the diagnostic request circuit:

1. Ensure ignition is ON.
2. Plug in DDR.
3. Select Calibration Configuration.
4. Determine port assigned to Diagnostic Request on the ECM input switches.
5. Go to switch light status.
6. Depress and hold the diagnostic request switch.
7. Read status of diagnostic request.
[a] If the switch reads OFF, the diagnostic request circuit (#528) is open or the ground is
poor or open. Repair the open wire or the bad ground. Refer to section 10.5.8.
[b] If the switch reads ON, refer to section 10.5.3.
Follow this procedure to check the ECM connectors:

1. Check the terminals at the vehicle harness and 5-way power harness connectors (both
ECM and harness side) for damage: bent, corroded and unseated pins or sockets.
See Figure 10-7.
[a] If terminals and connectors are okay, replace the ECM. Refer to section 10.5.8.
[b] If the terminals and connectors are damaged, repair them. Refer to section 10.5.8.
Perform the following steps to check for an open:

2. Place a jumper wire across pins A (#900) and B (#901) of the DDL connector. Unplug the
vehicle harness connector and measure resistance between sockets C1 and C2.
3. Turn ignition ON, and again measure resistance between sockets C1 and C2.
See Figure 10-8.
[a] If both readings are greater than 5
, one or both data wires (circuit #900 or #901)
are open. Repair the open and refer to section 10.5.8.

[b] If either reading is less than 5

Figure 10-8 Diagnostic Connector
10.5.5 Check for Short
Perform the following steps to check for a short:

1. Remove the jumper wire from the DDL connector.
2. Measure resistance between sockets C1 (#901) and C2 (#900) of the vehicle harness
connector.
[a] If the resistance measurement is less than 5
, two data wires (circuit #900 or #901)
are shorted together. Repair the short and refer to section 10.5.8.
[b] If the measured resistance is greater than 5
10.5.6 Check for Short to Ignition and Ground
Perform the following steps to check for a short to ignition and ground:
1. Remove all jumpers for the DDL connector.
2. Measure resistance between sockets A (#900) and C (ignition switch), A (#900) and E
(ground), B (#901) and E (ground), and B (#901) and C (ignition switch) of the DDL
connector.
[a] If the measured resistance is less than 5
on any reading, a short exists between the
data wires and ignition or ground. Repair the short and refer to section 10.5.8.
[b] If the measured resistance is greater than 5

10.5.7 Check Diagnostic Data Reader on Another Engine
Follow this procedure to check the DDR on another engine:

1. Connect the DDR to another engine and read any parameter in the menu.
[a] If the procedure worked okay, refer to section 10.5.8.
[b] If the procedure did not work, the DDR is probably defective. Refer to the DDR
instruction manual for repair.

4. Clear codes.
7. Note status of CEL.
[a] If the DDR display reads NO DATA BEING RECEIVED FROM DATA LINK or
DDEC SYSTEM NOT RESPONDING, all system diagnostics are complete. Review
this section from the first step to find the error. Refer to section 10.5.1.
[b] If the engine starts and no codes are read on the DDR, repairs are complete.
[c] If the engine starts and code displays, refer to section 9.1.

10.6 DIAGNOSTIC REQUEST SWITCH INOPERATIVE
10.6 DIAGNOSTIC REQUEST SWITCH INOPERATIVE
10.6.1 Check Diagnostic Request Circuit
Perform the following steps to check the diagnostic request circuit:

1. Turn ignition ON; engine not running.
2. Plug in DDR.
3. Select Switch/Light Status.
4. Depress and hold diagnostic request switch.
5. Observe the Diagnostic Request Status on the DDR.
[a] If the display reads ON, refer to section 10.6.2.
[b] If the display reads OFF, the diagnostic request line (#528) is open, or is not being
grounded when the switch is depressed. Check the #528 wire and ground for
diagnostic request switch. Repair the problem; refer to section 10.6.4.
[c] If no diagnostic request on the DDR input list, the ECM is not configured for
diagnostic request operation. Refer to the DDEC Application and Installation
manual, 7SA800.
10.6.2 Check Stop Engine Light and Check Engine Light Bulbs
Perform the following steps to check the SEL and CEL bulbs:
2. Remove CEL and SEL bulbs. Check to see if either is burned out or damaged.
[a] If the bulbs are okay, refer to section 10.6.3.
[b] If the bulbs are defective, replace the bulbs. Refer to section 10.6.4.
10.6.3 Check 12 / 24V Ignition Line
Perform the following steps to check the 12/24V ignition line:

2. Disconnect vehicle harness connector at ECM.
3. Measure voltage at cavity B3 (#439).
[a] If voltage measurement is less than 11.5V, the 5 amp fuse or circuit breaker is blown,
and the ignition line could be open or shorted to ground.

[b] If the voltage measurement is greater than 11.5V, the circuit #419 or #509 is open.
Repair the open. Refer to section 10.6.4.

3. Press diagnostic request switch.
[a] If codes flash, the system is working. Repairs are complete. If any other problems
exist, refer to section 9.1.
[b] If the system does not function, all system diagnostics are complete. Review this
section to find the error. Refer to section 10.6.1.

10.7 CRUISE CONTROL INOPERATIVE
10.7.1 Determine Type of Cruise Control System
Perform the following to determine the type of cruise control system:

1. Check that this is a DDEC cruise control system.
3. Plug DDR into DDL connector.
4. Select calibration configuration (cruise control).
5. Is cruise control enabled?
[a] If cruise control is enabled, refer to section 10.7.3.
[b] If cruise is not enabled, refer to DDEC III Installation and Application manual,
7SA800, for requirements of installing cruise control.
Perform the following to check the ECM connectors:

1. Disconnect the vehicle harness connector at the ECM.
2. Check the terminals at the ECM vehicle harness connector (both ECM and harness side)
for damaged, corroded, or unseated pin or sockets.
[a] If terminals and connectors are not damaged, reprogram the ECM.
[b] If the terminals or connectors are damaged, repair them. Refer to section 10.7.16.
10.7.3 Check Pin Assignments
Perform the following to check pin assignments:

2. Plug in the DDR.
3. Select calibration configuration (ECM Ins/Outs).
4. Write/print pin assignments.

[a] An example listed in Table 10-2 shows pins, wires and functions.
Pin Wire Function

J1 #541 set/coast on
F2 #544 cruise enable
G2 #543 svc brk rel
J2 #531 clutch rel
G3 #545 res/accel on
Table 10-2 Pin Assignments
[b] If the functions are not assigned, reprogram the ECM. Refer to section 10.7.16.
10.7.4 Checking Out of Cruise Control Switch and Wiring
To speed up the checking out of cruise control switches, quick check tables have been developed.
These tests are to be run with the ignition ON, and the engine not running. A DDR must be
plugged into the connector. All three quick check tables must be gone through to completely
check out the cruise control wiring and switches.
For Example: Listed in Table 10-3, step 2, you would do the following:
1. Ignition ON; engine not running; DDR plugged in.
2. Turn the cruise enable switch to ON.
3. Select switch/light status on the DDR.
4. Note the DDR display; if ON, check out brake and clutch switch as listed in Table 10-4.

Step Cruise Set / Res / DDR DDR Okay Go To

Enable Coast Accel Readout Display
Switch Switch Switch Being
Looked At
1. Off Off Off Cruise OffOn YesNo Refer to
Enable step 2 Refer
to section
10.7.5
2. On Off Off Cruise OffOn NoYes Refer to
Enable section
10.7.6Listed
in Table
10-4, step 1
Table 10-3 Cruise Control Quick Check Table I, Check Out Cruise Enable Switch
and Wiring (Ignition ON Not Running)
Step Cruise Brake Clutch DDR DDR Okay Go To

Enable Pedal Pedal Readout Display
Switch Being
Looked At
1. On Released Released Service On Off Yes No Refer to
Brake step 2 Refer
Release to section
10.7.7
2. On Depressed Released Service On Off No Yes Refer to
Brake section
Release 10.7.8
Refer to
step 3
3. On Released Released Clutch On Off Yes No Refer to
Release step 4 Refer
to section
10.7.9
4. On Released Depressed Clutch On Off No Yes Refer to
Release section
10.7.10Listed
in Table
10-5, step 1
Table 10-4 Cruise Control Quick Check Table II, Check Out Brake and Clutch
Switch and Wiring (Ignition ON Not Running)

Step Cruise Set / Res / DDR DDR Okay Go To

Enable Coast Accel Readout Display
Switch Switch Switch Being
Looked At
1. On Off Off Set/Coast Off On Yes No Refer to
On step 2 Refer
to section
10.7.11
2. On On Off Set/Coast Off On No Yes Refer to
On section
10.7.12
Refer to
step 3
3. On Off Off Res/Ac- Off On Yes No Refer to
celOn step 4 Refer
to section
10.7.13
4. On Off On Res/Accel Off On No Yes Refer to
On section
10.7.14Refer
to section
10.7.15
Table 10-5 Cruise Control Quick Check Table III, Check Out Set/Coast and
Resume/Accel Switches and Wiring (Ignition ON Not Running)
10.7.5 Check for Short at the Cruise Enable Circuit
Perform the following steps to check for a short at the cruise enable circuit:
2. Turn cruise engage switch to off.
4. Measure resistance between the cruise enable cavity (i.e. F2) on the vehicle harness
connector and a good ground.
[a] If the resistance measurement is less than or equal to 10,000
, reconnect the
vehicle harness. Turn the ignition on. Then run steps listed in Table 10-4; and
listed in Table 10-5. If any DDR display received is not okay, refer to the indicated
step. If all steps listed in Table 10-4 and listed in Table 10-5, pass, then the cruise
engage wire is shorted to the ground. Repair the short, or replace the switch.
[b] If the resistance measurement is greater than 10,000
10.7.6 Check for Open at the Cruise Enable Circuit
Perform the following steps to check for an open at the cruise enable circuit:


3. Turn cruise enable switch to ON.
4. Measure resistance between the cruise enable cavity (i.e. F2) on the vehicle harness
, or open, the cruise engage switch is
bad, circuit #953 is open or the cruise enable wire is open. Repair the open or replace
the switch. Refer to section 10.7.16.
10.7.7 Check for Open or Miswired Brake Switch
Perform the following steps to check for an open or miswired brake switch:
3. Ensure the service brake is not engaged.
4. Measure resistance between the service brake cavity (i.e. G2) on the vehicle harness
, or open, the brake switch is
miswired or faulty, circuit #953 is open or the ground is bad. Repair the open, rewire
or replace the switch. Refer to section 10.7.16.
10.7.8 Check for Short at the Brake Switch or Circuit
Perform the following steps to check for a short at the brake switch or circuit:
3. Engage the service brake.
4. Measure resistance between the service brake cavity (i.e. G2) on the vehicle harness
, the brake switch is
miswired or the service brake circuit is shorted to ground. Rewire, repair the short or
replace the switch. Refer to section 10.7.16.
, or open, refer to section 10.7.2.
10.7.9 Check for Open or Miswired Clutch Switch
Perform the following steps to check for an open or miswired clutch switch:


3. Ensure the clutch is not engaged.
4. Measure resistance between the clutch cavity (i.e. J2) on the vehicle harness connector
and a good ground.
, or open, the clutch switch is
miswired or faulty, circuit #953 is open, or there is a bad battery ground. Rewire,
repair the short or replace the switch. Refer to section 10.7.16.
10.7.10 Check for Short at the Clutch Service/Circuit

3. Engage the clutch.
4. Measure resistance between the clutch cavity (i.e. J2) on the vehicle harness connector
and a good ground.
[a] If the resistance measurement is less than or equal to 100
, the clutch switch is
miswired or faulty, or the clutch circuit is shorted to ground. Rewire, repair the short
[b] If the resistance measurement is greater than 100
10.7.11 Check for Short at the Set/Coast Circuit

3. Measure resistance between the set/coast cavity (i.e. J2) and a good ground.
, the set/coast switch is
shorted, or a short to ground exists in the set/coast circuit (i.e. #541). Repair the short
10.7.12 Check for Open at the Set/Coast Circuit



3. Find a means to press and hold the set/coast switch.
4. Measure resistance between the set/coast cavity (i.e. J1) and a good ground.
, or open, the set/coast switch is
open or miswired, circuit #953 is open, or there is a bad battery ground. Rewire,
repair the short or replace the switch. Refer to section 10.7.16.
10.7.13 Check for Short at the Res/Accel Circuit

3. Measure resistance between the Res/Accel cavity (i.e. G3) and a good ground.
, the Res/Accel switch is
shorted, or a short to ground exists in the Res/Accel circuit (i.e. #541). Repair the
short or replace the switch. Refer to section 10.7.16.
10.7.14 Check for Open at the Res/Accel Circuit

3. Find a means to press and hold the Res/Accel switch.
4. Measure resistance between the Res/Accel cavity (i.e. G3) and a good ground.
, or open, the Res/Accel switch is
open or miswired, circuit #953 is open or the battery ground is bad. Repair the short,
replace the switch, or rewire. Refer to section 10.7.16.
10.7.15 Verify Problem Still Exists
Perform the following steps to verify the problem still exists:

1. If you were referred to this step, you have completed the switch checkout process without
detecting a fault.
2. Take the vehicle for a road test and check the cruise control operation.

[a] If the cruise control operates correctly, the problem no longer exists. If any other
problems exist, refer to section 9.1.
[b] If the cruise control does not operate correctly, check the vehicle speed sensor.

3. Road test the vehicle.
[a] If the cruise control operates correctly, troubleshooting is complete.
[b] If the cruise control does not operate correctly, all system diagnostics are complete.
Review this section from the start to find the error. Refer to section 10.7.1.

10.8 FAN OPERATIONAL CONCERN (ON/OFF TYPE)
This section covers only the DDEC controlled fan operation, (fan type single, dual or two-speed).
If the function is assigned, see description of DDEC fan control logic, listed in Table 10-6.
Cavity Wire# Function Output/Input

X# # Fan Control 1 Output - Required
X# # Aux. Fan Control Input - Optional
X# # Fan Override Input - Optional
Table 10-6 DDEC Fan Control Logic Description
10.8.1 Digital Fan Operation
Items used in digital fan operation include:

1. The ECM provides ground (output Fan Control 1) and should be wired such that when this
cavity grounds, the fan should turn off. When the circuit goes open, the fan should turn on.
2. When Aux. Fan Control is configured (input), this wire must be connected to battery
ground, or the fan will always be on. Typically, this is used with an air conditioning
pressure switch. High pressure opens this circuit, and turns the fan on for a minimum time
that can be set with the programming station on later ECM software versions.
3. Fan Override - Grounding this wire will turn the fan on. This would normally be an
OEM supplied switch on the dash.
Other than these items, the ECMs fan control output opens, turning the fan on due to engine
temperatures that are above the programmed limits. Once a fan output turns the fan on for
whatever reason, all fan off temperatures must be met before the fan will turn off.
Temperatures for most highway applications are listed in Table 10-7.
Fan Control Actual Fan Status Coolant Temp Oil Temp Air Temp

Fan Control - 1 Fan ON 96 C / 204 F 110 C / 230 F 66 C / 150 F

Fan Control - 2 Fan ON 98 C / 208 F 113 C / 235 F N/A

Fan Control - Fan OFF 92 C / 197 F 104 C / 219 F 49 C / 120 F
Table 10-7 Highway Application Temperatures
These temperature limits are only changeable in the base calibration.
10.8.2 Check Output Status
Perform the following steps to troubleshoot a fan operation problem:

1. Start engine.

2. Ensure the air conditioning of the vehicle is OFF.

3. Run engine for at least three minutes.
4. Plug in DDR.
5. Select switch / light status.
6. Check the status of the Fan Control #1 while noting the actual fan status as
Status Status Status Status

Fan Control #1 ON OFF ON OFF
Actual Fan State OFF ON ON OFF
Refer to section Refer to section Refer to section Refer to section
10.8.3. 10.8.4. 10.8.6 10.8.7
Table 10-8 Troubleshooting Fan
10.8.3 Fan Information
The steps that led to this procedure do not indicate a problem with the fan control logic in the
ECM. The fan operation is normal if the steps that you checked led you to this section.
The fan status is correct according to what the ECM is requesting.
If you believe the fan state should be different, review the DDEC application and installation
manual for information on fan control configuration.
10.8.4 Check Input Status
Read the status of the inputs used for fan operation listed in Table 10-9. (Note both together.)
Status Status Status

Aux. Fan Control OFF ON ON
Fan Override OFF ON OFF
Refer to section 10.8.5 Refer to section 10.8.8 Refer to section 10.8.3
Table 10-9 Input Status
10.8.5 Check for Input Open

2. Disconnect vehicle 30-pin connector at the ECM.

4. Measure resistance between auxiliary fan control wire and a good ground.
[a] If the measured resistance is greater than 1,000
, an open exists in the auxiliary
fan control wire, or auxiliary fan control is configured and not wired, or the switch
is bad. Repair open or replace the switch if an auxiliary fan control is used. If this
feature is not to be used, disable the auxiliary fan control with the programming
station. Refer to section 10.8.10.
[b] If the measured resistance is less than or equal to 1,000
Perform the following steps to troubleshoot fan always on. The steps that led to this procedure do
not indicate a problem with the fan control logic in the ECM. The fan operation is normal if the
steps that you checked led you to this section.
10.8.6 Check for Output Open
Perform the following steps to check for an output open:

1. With ignition off, locate OEM supplied wire used for Fan Control #1.
2. Determine where the wire terminates. (e.g. fan solenoid, relay, data module, etc.)
3. Disconnect the Fan Control #1 wire at the solenoid/relay.
5. Measure resistance between the fan control #1 wire and a good ground, battery (-).
or open, an open exists in the
FC#1 wire. Repair the open. Refer to section 10.8.10.
10.8.7 Check for Output Short
Perform the following steps to check for an output short:

1. With ignition off, locate OEM supplied wire used for Fan Control #1.
2. Determine where the wire terminates. (e.g. fan solenoid, relay, data module, etc.)
3. Disconnect the Fan Control #1 wire at the solenoid/relay.
4. Measure resistance between the fan control #1 wire and a good ground, battery (-).
or open, refer to section 10.8.9.
, the output wire is
shorted to ground, keeping the fan off. Repair the short or replace the wire.
10.8.8 Check Override Request
Perform the following steps to check the fan override switch:

1. Is the fan override switch on?

[a] If the fan override is on, and the fan override is requesting fan on, this is normal.
[b] If the fan override is not on, the fan override wire is shorted to ground, repair the short
or re-configure the input if this is an error in programming. Refer to section 10.8.10.
10.8.9 Check Connectors
Perform the following steps to check the connectors:

1. Check connectors for damaged, bent, or corroded terminals.
[a] If the pins and terminals are not damaged, the problem may be due to the solenoid,
ECM, or OEM device that operates the fan. Contact the OEM for further information
or instructions. The ECM and wiring between the ECM and device appear to be
operating correctly and in good repair. The ECM is requesting the fan operation
correctly and the checks indicate the ECM and wire between the ECM and OEM
device is okay.
[b] If the pins or terminals are damaged, repair or replace them. Refer to section 10.8.10.

1. Connect any removed connectors.
2. Start engine.
3. Operate engine under conditions that brought you to this section.
4. Check fan operation.
[a] If the fan operates correctly, troubleshooting is complete.
[b] If the fan does not operate correctly, review this section from the first step to find
the error.

10.9 FAN OPERATIONAL CONCERN (VARIABLE SPEED TYPE)
The DDEC system via a PWM (Pulsewidth Modulation) signal will go to a high voltage (7-8 volts
on a 12-volt system) on a cold engine for a low speed, and to a low voltage (0.8 - 1.0 volts on
a 12-volt system) for a high speed.
Fan speed is ramped up as temperatures increase, as listed in Table 10-10. Calibrations can
vary. The table is provided only as a guide.
Coolant Temperature Speed

up to 197 F Low speed

about 203 F Medium speed
208F and above High speed
Table 10-10 Fan Speed vs Temperature
10.9.1 Verify Correct DDEC Configuration
Perform the following steps to verify the configuration:

2. Plug in DDR.
3. Select "View Calibration" (ECM Ins/Outs).
4. Review PWM functions to determine correct pin assignment for PWM fan.
[a] If the cavity is assigned to PWM Fan, refer to section 10.9.2.
[b] If the cavity is not programmed, reprogram the ECM and refer to section 10.9.7.
10.9.2 Check for Signal
Perform the following steps to check for signal:

1. Start and run the engine at idle.
2. Plug in DDR.
3. Review engine data list and watch the pulsewidth modulation number x wire = # of fan
assignment (normally PWM#4).
4. Verify coolant, oil and air temperatures are cooler, less than 150 F. Verify the air
conditioning input is grounded (On).
[a] If the PWM value is 80 to 90% and the fan is at Low Speed, refer to section 10.9.3.
[b] If the PWM value is 80 to 90% and the fan is at High Speed, refer to section 10.9.4.

10.9.3 Check Signal Engine Hot
Perform the following steps to check the signal status:

1. Start engine and warm up. Road test (until coolant temp is about 200 F).
2. View DDR data list display, Coolant Temp/PWM # (normally #4).
[a] If PWM % decreases as the temperature increases, all checks appear normal. If this is
an intermittent high speed operation, check A/C Freon pressure switch or wiring for
an intermittent open. Refer to section 10.9.7.
[b] If PWM % decreases as the temperature increases, but the fan speed stays low,

2. Unplug PWM wire at the fan control valve.
3. Install a jumper between the PWM wire and the battery (-).
4. Unplug the engine harness connector.
5. Measure resistance between the PWM cavity and the battery (-).
, the wire is open. Repair the
open and refer to section 10.9.7.
, the valve or wiring (voltage supply) to
the valve is defective. Replace.

3. Measure resistance between the PWM cavity and several ground sources (battery, chassis,
etc.).
at any time, the wiring is shorting.
Replace the wire and refer to section 10.9.7.
Perform the following steps to check the connectors:

1. Check for damaged, bent or corroded connectors, pins, and terminals.

[a] If the connectors, pins, and terminals are not damaged, contact the OEM or fan
valve supplier for instructions on further troubleshooting. If the ECM and wiring
to the component appear to be okay, the problems could be with the control valve
or battery and wiring.
[b] If the connectors, pins or terminals are damaged, repair or replace them and

1. Connect all removed connectors, etc.
2. Start and run the engine from cold to hot, while watching the fan speed operation.
[a] If the operation is normal, troubleshooting is complete.
[b] If the operation is not normal, all system diagnostics are complete. Review this
section to find the error. Refer to section 10.9.1.

10.10 ENGINE BRAKE INOPERATIVE
The following procedure will troubleshoot DDEC controlled Engine Brake Inoperative.
10.10.1 Engine Brake Inoperative
Perform the following steps to troubleshoot the inoperative engine brake:

2. Plug in DDR.
3. View Diagnostic Data List to see if the correct application is programmed into the ECM.
4. Next to Engine Brake, the display should read ON or OFF. If it reads N/A, the DDC
mainframe must be changed and the ECM must be reprogrammed after the change is made.
5. If the ECM is correctly configured, go to the view calibration area with the DDR and
check to ensure that the two required inputs (Engine Brake Low and Engine Brake
Medium) are configured.
6. If the inputs are not configured, or incorrectly configured, this must be corrected using the
DDEC reprogramming station.
7. If the inputs are configured correctly, print or write down the inputs and outputs for future
reference. Refer to section 10.10.2. Refer to the appropriate Application and Installation
manual for engine brake operation.
10.10.2 Check Switches
Perform the following steps to troubleshoot the switches:

2. Plug in DDR.
3. Select Switch Light status - Inputs.
4. View DDR display of Eng Brk Low and Eng Brk Med.
NOTE:
Set brake dash switch position on low.
[a] If Eng Brake Low is ON and Eng Brake Med is OFF, refer to section 10.10.3.
[b] If Eng Brake Low is ON and Eng Brake Med is ON, medium and low inputs are
shorted to each other. Repair. Refer to section 10.10.9.
[c] If Eng Brake Low is OFF and Eng Brake Med is ON, input wires are reversed.
Correct and refer to section 10.10.9.
[d] If Eng Brake Low is OFF and Eng Brake Med is OFF, refer to section 10.10.4.
5. Turn brake enable dash switch on.

10.10.3 View Diagnostic Data Reader Display
Perform the following steps to troubleshoot the inoperative engine brake:

1. View DDR display.
NOTE:
Set brake dash switch position on medium.
[a] If Eng Brake Low is OFF and Eng Brake Med is ON, refer to section 10.9.5.
[b] If Eng Brake Low is ON and Eng Brake Med is ON, medium and low inputs are
shorted to each other. Repair. Refer to section 10.10.9.
[c] If Eng Brake Low is ON and Eng Brake Med is OFF, input wires are reversed.
Correct and refer to section 10.10.9.
[d] If Eng Brake Low is OFF and Eng Brake Med is OFF, refer to section 10.10.4.

2. Turn engine brake switch to low.
3. Measure resistance between the engine brake low switch and a good ground (ECM side).
4. Set switch to Med. Measure resistance between medium input and a good ground.
[a] If the measured resistance is less than 10,000
, either the switch is bad or the wire
from the switch to the battery ground is bad. Replace the switch or repair the open.
[b] If the measured resistance is greater than 10,000
, or open, an open exists in the
input wire. Repair the open. Refer to section 10.10.9.
10.10.5 View Calibration - Engine Configuration
Perform the following steps to view calibration - engine configuration:

1. Go to View Cal-Eng Configuration. Check status of Eng Brk Serv Brk and Eng Brk mph.
If Eng Brk Serv Brk indicates YES, or Eng Brk Min mph has number other than "0",
check with the operator to ensure he or she understands how these functions operate.
[a] If the Eng Brk Serv Brk indicates YES, the application of service brake is required
for engine brake operation.
[b] If the Eng Brk Min mph has a number other than "0", the brakes will not operate
below this mph.
NOTE:
These two functions may work separately or together.

[c] If the Eng Brk Svc Brk indicate No, and Eng Brk Min mph indicate 0,
10.10.6 Check Engine Brake Operation
Perform the following steps listed in Table 10-11 to check out the brake and clutch switch, and
the wiring.
NOTE:
If table below leads to section 10.11, troubleshoot clutch and brake inputs. Then check
operation of engine brake. If engine brake is still inoperative, refer to section 10.10.7.
1. Turn ignition ON. Engine must not be running.

2. Plug in DDR. Select switch/light status.
Step Brake Pedal Clutch DDR DDR Status OK

Pedal Readout Display
Looked At
1. Released Released Service Brake On Off Yes No refer to Step
(Release) 2 refer to
section 10.11
2. Depressed Released Service Brake On Off No Yes refer to
Release section 10.11
refer to Step 3
3. Released Released Clutch On Off Yes No refer to Step
Release 4 refer to
section 10.11
4. Released Depressed Clutch On Off No Yes refer to
Release section
10.11refer
to section
10.10.7
Table 10-11 Engine Brake Operation
10.10.7 Check Brake Solenoids
Perform the following steps to troubleshoot the brake solenoids:

1. Check engine brake solenoids. Refer to OEM guidelines.
[a] If solenoids are okay, refer to section 10.10.8.
[b] If solenoids are bad, repair or replace the solenoids. Refer to section 10.10.9.
10.10.8 Verify Conditions
Perform the following steps to verify conditions:

1. Verify proper conditions are being met to enable engine brake:

[a] TPS % = 0 %
[b] Pulse width = 0 (or less)
[c] Engine speed >850 r/min
[d] Clutch release (input) = ON (if configured)
[e] Engine brake disable (input) = OFF (Auto Trans)
2. Are the conditions listed in 1a through 1e met?
[a] If conditions are not met, correct the problem (i.e. TPS). Refer to section 10.10.9.
[b] If the conditions are met, reprogram the ECM. Contact the OEM for possible TPS
repair. Then, refer to section 10.10.9.

1. Reinstall all connectors.
2. Test drive vehicle to see if the problem is corrected.
[a] If engine brakes operate correctly, troubleshooting is complete.
[b] If engine brakes do not operate, all system diagnostic checks are complete. Review
this section to find the error. Refer to section 10.10.1, or contact Detroit Diesel
Technical Service for possible ECM replacement.

10.11 MISCELLANEOUS DIGITAL INPUT FAULT
The following procedure will cover miscellaneous input switch faults. All faults function in the
same manner, allowing the same troubleshooting process to be used regardless of the function.
There are 12 digital input cavities, listed in Table 10-12, available on a DDEC ECM. Any
available function can be assigned (programmed with the Programming Station) to any of the
available cavities.
When a digital input wire is switched to battery ground (usually #953), it is a request to the
ECM to activate the function assigned to that wire. Additional conditions may need to be met
for the feature to activate. Refer to the appropriate Application and Installation Manual for
these conditions.
Input Cavities Input Cavities

E1 #451 G2 #543
F1 #542 H2 #524
G1 #528 J2 #531
H1 #523 K2 #583
J1 #541 G3 #545
F2 #544 K3 #979
Table 10-12 Input Cavities
Available functions are listed in Table 10-13.

None Limiting Torque Curve Trans Retarder Status
Engine Brake Low Diagnostic Request Dual Throttle (LSG)
Engine Brake Med Alt Min VSG/Fast Idle A/C Fan Status
Aux Shutdown #1 Service Brake Release Aux CLS
Aux Shutdown #2 Clutch Released Fan Control Override
Park Brake / ISD Set Coast OFF DDEC II VSG Station Change
Idle Validation Set / Coast ON VSG Station Complement
Pressure / RPM Mode Resume/Accel OFF DDEC II Air Load Switch
Throttle Inhibit Resume / Accel ON In Neutral Switch
RPM Sync (Marine) Cruise Enable In Gear Switch
RPM Freeze (Marine) PGS System Enable KD Brake
Rating Switch #1 SEO / DIAG Request Gas Valve Diagnostic
Rating Switch #2 Engine Brake Disable -
Table 10-13 Available Input Functions

10.11 MISCELLANEOUS DIGITAL INPUT FAULT
The following procedure will troubleshoot an input fault.
10.11.1 Verify Switch Status
Follow these steps to verify the switch status.

2. Plug in DDR.
3. Select switch light status.
4. Operate the engine or vehicle that would allow the feature to activate (e.g. activate
switch, set brake, etc.).
5. Observe the status when the feature is active (or supposed to be active). See Figure 10-9.
[a] The feature always reads OFF. Refer to section 10.11.2.
[b] The feature switches from OFF to ON. Refer to section 10.11.3.
[c] The feature always reads ON. This indicates the input wire is shorted to ground or the
switch is faulty. Repair wire or replace switch. Refer to section 10.11.4.

2. Unplug the vehicle interface harness connector at the ECM.

3. Operate switch. Enable the feature.

4. Measure the resistance between the input cavity affected and the battery ground.
, the input wire or ground
wire is open, or the switch is bad. Repair the open or replace the switch.
10.11.3 Review the Operation of the Feature
Perform the following steps to check the operation of the feature:

1. The step that led you here indicates the input, wire, and switch, are operating correctly.
Review the intended operation of the feature to determine if any other conditions need to
be met for the feature to operate. (e.g. appropriate Application and Installation manual for
the engine). Refer to section 2.4, for a list of related troubleshooting publications.
2. To verify the repairs to the feature, refer to section 10.11.4.

1. Hook up all connectors that were previously removed.
2. Operate the engine or vehicle.
3. Activate the feature.
[a] If the input feature operates correctly, troubleshooting is complete.
[b] If the input feature is not operating, contact Detroit Diesel Technical Service.

10.12 MISCELLANEOUS DIGITAL OUTPUT FAULT
This section is designed to diagnose an output fault (feature not functioning). Since all outputs
operate in the same manner, this troubleshooting section can be used regardless of the function
assigned.
10.12.1 DDEC ECM
The DDEC ECM has six available digital output cavities. Three are located at the engine harness
connector and three at the vehicle harness connector. Output functions (features) are assigned
(programmed with the programming station) to any available cavity. The ECM switches the
cavity to battery (-) to allow the function to activate. Some output activation is dependent on other
parameters being met. (e.g. minimum, r/min, etc.) Perform the following steps to check the DDR
for codes. Available output cavities are listed in Table 10-14.
Additional outputs could be added at a later date. Available functions are listed in Table 10-15.
Output Cavities Output Cavities

VIH ESH
A1 #988 W3 #563
A2 #555 X3 #564
F3 #499 Y3 #565
Table 10-14 Output Cavities

No Function Fan Control #2 Turbo Recirc Valve
Low DDEC Volt Deceleration Light Optimized Idle Active
RPM Sync Active Engine Brake Active Low Range Solenoid (ESS)
PGS Active Light VSG Active Indication High Range Solenoid (ESS)
Vehicle Power Down Oil Pressure Low Light Shift Solenoid (Top2)
Starter Lockout Oil Temp High Light Shift Lockout (Top2)
Ext Brake Enable Coolant Temp High Light Gas Throttle Actuator
Trans Retarder Enable Air Comp Solenoid Fuel Supply Solenoid
Coolant Level Low Light Crankcase Pressure High KD Brake Solenoid
Cruise Active Light Coolant Pressure Low -
Fan Control #1 Ether Start -
Table 10-15 Available Output Functions
10.12.2 Activate Output
Perform the following steps to attempt activation to troubleshoot an output fault.


2. Plug in DDR. Select ACTIVATE OUTPUTS.
3. Activate output associated with the fault.
NOTE:
Service any other codes first.
[a] If the feature operates (e.g. light illuminates or solenoid activates, etc.) review the
Application and Installation manual for the operation of the designated feature.
Operation is dependent on other parameters. Refer to section 10.12.6.
[b] If the feature does not operate or cannot be activated, refer to section 10.12.3.
Perform the following steps to check for open:

2. Locate device end of output wire (e.g. light) and disconnect wire.
4. Measure resistance between the disconnected wire and battery (-).
[a] If the measured resistance is less than 46,000-48,000
, the wire is open.
10.12.4 Check for Voltage
Perform the following steps to check the voltage:

1. Measure voltage between the disconnected wire and a good ground.
[a] If voltage measurement is less than 2 volts, refer to section 10.12.5.
[b] If voltage measurement is greater than 2 volts, the output is shorted to a voltage
source. Replace the wire and refer to section 10.12.6.
10.12.5 Check for Resistance
Perform the following steps to check for resistance at the ECM:

2. Disconnect 30-pin connector that houses the wire/function you are checking (e.g.
X3-engine harness connector, A1-VIH).
3. Measure resistance between the pin on the ECM and the ECM case.

[a] If the measured resistance is 46,000 to 48,000

, contact the OEM or the hardware of
the supplier of the features. For further troubleshooting, all output wiring and ECM
operation appear to be operating correctly.
[b] If greater than 48,000
, try a test ECM. Refer to section 10.12.6.

2. Test the vehicle and attempt to operate the feature.
[a] If the feature works correctly, troubleshooting is complete.
[b] If the feature still does not work correctly, review this section to find the error.

10.13 FIRE TRUCK PRESSURE GOVERNOR FAULT
The following procedure will troubleshoot fire truck pressure governor fault.
10.13.1 Pressure Governor Operation
The Pressure Sensor Governor (PSG) System is a DDEC feature, programmed to allow the engine
speed to change in order to maintain a steady water pump pressure (pressure mode) or hold a
steady engine speed (RPM Mode).
10.13.2 Verify Correct Pressure Sensor Governor Configuration
Perform the following steps to verify the PSG configuration. Refer to the Application and
Installation manual for the appropriate engine model to ensure correct inputs and outputs are
configured. Required In / Outs are listed in Table 10-16.
2. Plug in DDR.
3. View H2 O governor enabled (engine configuration).
4. View In / Outs. Verify correct configuration.
[a] If the system is enabled and the in/outs are correctly configured,
[b] If the problem was found, correct the settings and retest. Refer to the DDEC III
Application And Installation manual, 7SA800 and refer to section 10.13.10.3.
Inputs Outputs
PGS Mode, (Press / RPM) PGS Active
PGS Enable Cruise Active
Res / Accel -
Set / Coast -
Table 10-16 Required In / Outs
10.13.3 Identify Problem
Use the following procedure to identify the problem with the PSG:
3 Does not operate; refer to section 10.13.4.
3 No pressure mode, refer to section 10.13.6.
3 No increase function refer to section 10.13.7.
3 No decrease function refer to section 10.13.8.
3 EFC Fault Information refer to section 10.13.9.

10.13.4 Check System Ground
Perform the following steps to check the system ground:

1. Start engine.
2. Turn ON pump control switch.
3. Verify all interlocks are set (parking brake, transmission neutral, etc.).
4. Plug in DDR. Select Switch/Light status.
5. Observe the displays and PGS ENABLE.
[a] If PGS ENABLE reads OFF, the PGS ENABLE input (circuit #543) is not grounded.
Check circuit #543 for an open between battery ground or a short to a voltage source.
Repair fault and retest. Refer to section 10.13.5.
[b] If PGS ENABLE reads ON, refer to section 10.13.7.
10.13.5 Check Sensor Wiring
Perform the following steps to identify the problem:

1. Compare pressure sensor harness wiring to the diagram.
[a] If the wiring is correct, refer to section 10.13.9. If the EFC tests okay,
[b] If the wiring is incorrect, correct the wiring and retest.
10.13.6 Verify Mode Selector Operation

1. Start engine.
5. Observe the displays and PGS MODE.
[a] If DDR displays ON when Pressure Mode is selected, the mode selector (circuit
#523) is functioning properly. Check for possible intermittent open or short to
voltage source. Check for faulty pressure transducer. Refer to section 10.13.5.
See Figure 10-10.

[b] If the DDR displays OFF when Pressure Mode is selected, the mode selector wire
(circuit #523) or switch is open or shorted to a voltage source. Repair the fault and
retest. If the EFC tests okay, refer to section 10.13.9.
Figure 10-10 Pressure Transducer and Harness Connector
10.13.7 Check Resume / Accel Switch

1. Start engine.
5. Observe the displays and Res/Accel, while depressing the increase switch.
[a] If DDR displays OFF to ON when increase is depressed, check the EFC.
[b] If the DDR displays OFF when increase is depressed, circuit #541 is open or shorted
to a voltage source. Repair the fault and retest.
10.13.8 Check Set / Coast Switch

1. Start engine.


3. Verify all interlocks are set (parking brake, transmission neutral, etc.)
5. Observe the displays and Set/Coast, while depressing the decrease switch.
[a] If DDR displays OFF to ON when Set/Coast decrease is depressed, check the EFC.
[b] If the DDR displays OFF when decrease is depressed, circuit #541 is open or shorted
to a voltage source. Repair the fault and retest.
10.13.9 Electronic Fire Commander
The Detroit Diesel Electronic Fire Command ™ (EFC) is designed to support Detroit Diesel
engines in the fire fighting market. It combines a Pressure Sensor Governor (PSG) controller, a
system monitor, and a display for vital engine operating parameters into one compact, durable
package. It also provides complete control and monitoring of the DDEC engine control system on
a fire truck when pumping.
10.13.9.1 Pressure Sensor Governor Operating Modes
The EFC commands the Detroit Diesel PSG system to operate in one of two modes. The RPM
Mode controls the engine speed to a constant number of revolutions per minute, and the Pressure
Mode varies the engine speed to maintain a constant pump discharge pressure. The operating
mode of the PSG can be changed from RPM Mode to Pressure Mode and back by pressing the
MODE button. When the unit is first turned on, the RPM Mode is active. Pressing MODE switch
engages the Pressure Mode and another press brings the system back to RPM Mode. The PSG
system utilizes the engine speed or pump pressure that is current at the time the button is pressed.
In the Pressure Mode, the PSG system operates like cruise control for the water pump pressure,
and maintains the pressure at a chosen setting. Engine speed is constantly adjusted to maintain the
desired pump discharge pressure. A pressure sensor in the output side of the fire pump is used to
measure and feed this pressure back to the DDEC Electronic Control Module (ECM).
The RPM Mode keeps the engine speed constant even when the load varies within the engine's
operating capability. The pump output pressure may vary in this mode, but the engine speed does
not. The driver/engineer uses the EFC to choose which of these two modes the PSG uses. The
EFC also allows the driver/engineer to finely adjust the pressure setting or the engine speed
setting to match prevailing conditions.
10.13.9.2 Setting the Revolutions Per Minute Mode
Perform the following steps to set the RPM Mode:

1. Start engine and ensure the EFC is ON.
2. Ensure the conditions are met for the Throttle Ready lamp to be ON. (These are usually
interlocks necessary to allow increased throttle operation.)

3. The RPM Mode lamp should be lit, indicating the system is in RPM Mode.
4. Engine speed can be adjusted using the following buttons:
3 Press the PRESET button to command the engine to go to the preset speed.
3 Press the INC button to increase engine speed in 25 RPM increments each time
the button is pressed.
3 Press and hold the INC button to increase the speed at a faster rate equivalent to 2
increments per second.
3 Press the DEC button to decrease engine speed in 25 RPM increments.
3 Press and hold the DEC button to decrease the speed at a faster rate equivalent to 2
3 Press the IDLE button to immediately return the engine to the normal idle speed.
10.13.9.3 Setting the Pressure Mode
Perform the following steps to set the Pressure Mode:

1. Start engine and adjust the system to run in the RPM Mode as described in the previous
sections.
2. Ensure conditions are met for the PUMP ENGAGED and OKAY TO PUMP and
THROTTLE READY lamps to be on. (This usually requires that required safety interlocks
for engine speed increase and pump operation are met.)
3. Press the MODE button and the PRESSURE lamp will illuminate.
4. Pump discharge pressure can now be adjusted with the following buttons.
3 Press the PRESET button to command the engine to go to the preset pump pressure.
3 Press the INC button to increase discharge pressure in 4 PSI increments each time
the button is pressed.
3 Press and hold the INC button to increase the pressure at a faster rate equivalent to 2
3 Press the DEC button to decrease discharge pressure in 4 PSI increments.
3 Press and hold the DEC button to decrease the pressure at a faster rate equivalent to 2
3 Press the IDLE button to return the engine immediately to the normal idle speed.
10.13.9.4 Cavitation
If the water pump discharge pressure falls below 30 psi and the engine r/min rises a minimum of
400 r/min above the current setpoint for more than five seconds, the system considers cavitation to
have occurred. It takes the following actions:
3 The engine will return to idle.
3 The current engine speed and discharge pressure setpoints will be cleared.
3 The check engine light will illuminate and a cavitation code will be logged.

10.13.9.5 Engine Parameter Display
Engine r/min, oil pressure, temperature, and system voltage are displayed continuously while
the EFC is in operation. In addition, any diagnostic code accompanying a Check Engine or Stop
Engine condition will be displayed on the Information Center message display. An audible alarm
will also be activated with the code.
10.13.10 Programming the Electronic Fire Commander
Programming the EFC is simply a matter of selecting items from a menu:

3 To enter the programming menu, press and hold the MODE and MENU buttons at the
same time until "Press Idle to Exit" is displayed on the information center, then release
both buttons.
3 Moving through the menu is accomplished by pressing the MENU button.
3 Changing a selection in the menu is performed by using the INC and DEC switches.
3 Exiting the programming menu is accomplished in one of two ways.
3 Press IDLE to exit the menu and save changes.
3 Press MODE to exit the menu without saving changes.

10.13.10.1 Programming Menu Options
As you scroll through the menu by repeatedly pressing the MENU button, the following items,
listed in Table 10-17, will appear sequentially in the Information Center display.
Item Explanation
RPM Preset Point preset engine speed
Pressure Set (PSI) preset PSI
Engine Hour meter information only
Pump Hour meter information only
Engine degrees oil or coolant
Pump Pressure (PSI) pressure reading, if active
DDEC Software Version ECM revision level
EFC Software Version EFC revision level
Fire Commander I/O Test test switches and outputs
Press Test Lights tests display panel
Set Time Clock set clock
Units of Measure English/Metric
Welcome Message enable/disable
Codes Currently Active information
Connector Data displays connection information
Save? [Idle Y] exit and save options
Table 10-17 Information Center Menu
10.13.10.2 Additional Information
Engine r/mi
3 The Information Center displays DDEC ECM diagnostic codes and limited engine
information as well as PGS status.
3 The Information Center display can be used as an aid to troubleshooting the Pressure
Governor System and the Electronic Fire Commander.
3 The Fire Commander I/O Test checks the outputs as well as the switches. It automatically
runs through a test and displays the results for your information in troubleshooting.
3 The connector data displays the cavities of inputs and outputs necessary for correct
system operation.
3 The interlock lamps show which interlock circuits have been closed and if that part of
the system is ready for operation.

10.13.10.3 Troubleshooting the Electronic Fire Commander
This section lists some of the common troubles encountered during the installation and check out
of the Electronic Fire Commander. These conditions are listed and the suggested actions follow
each one. The Electronic Fire Commander wiring is listed in Table 10-18, listed in Table 10-19,
1. Condition: The EFC will not light up.
3 Check if the necessary switches are turned on.
3 Check if there is a 12 VDC between pins #1 and #2 at the EFC 4-pin connector.
2. Condition: The throttle will not increase in RPM Mode.
3 Check if the THROTTLE READY lamp is on. The EFC will not respond in RPM
mode unless the OEM safety interlock requirements that enable the throttle are met.
3 Press the PRESET and then the INC switches. Does the EFC indicate it is increasing
RPM on the data display?
3 Check the switch and outputs in the Menu I/O test.
3 Re-initialize the EFC. (Remove power to the EFC; wait ten seconds and then power
the unit and try again.)
NOTE:
The EFC performs a "self-test" when it is powered up. This is indicated on the EFC by a
momentary lighting of all the display segments.
3. Condition: The throttle will not increase in Pressure Mode.

3 Check that all three lamps: PUMP ENGAGED, OKAY TO PUMP, and THROTTLE
READY are on.
3 Press the INC and then the PRESET buttons to increase pump pressure.
3 Check for a pump discharge pressure reading in the Menu.
3 Re-initialize the EFC.
4. Condition: The Engine Data Display is showing all zeroes.
3 Check that the connections at pins #3 and #4 of the EFC 4-pin connector are secure.
3 Check there is continuity on the 900 and 901 circuits from the ECM connector
to the EFC connector.
5. Condition: The THROTTLE READY lamp will not turn on.
3 Check that the parking brake is on.
3 Check that the transmission is in neutral, or the hand throttle (PTO) is engaged.
3 Check for 12 VDC at pin #2 of the EFC 12-pin connector.
6. Condition: The PUMP ENGAGED and OKAY TO PUMP lamps do not turn on.
3 Check that all OEM safety requirements for pump operation are fulfilled.
3 Is the parking brake on?
3 Is the transmission in the proper range for pump operation?
3 Is the hand throttle (PTO) engaged?
3 Is there an OK to PUMP indication in the cab?
3 Check for 12 VDC at pin #10 of the EFC 12-pin connector.
7. Condition: The mode will not change from RPM to Pressure.

3 Check: Are the PUMP ENGAGED and OKAY TO PUMP lamps on?
3 Does the MODE switch pass in the menu I/O test?
8. Condition: The PRESET switch doesn't work.
3 Check that the proper lamps are on for the mode you want to operate.
3 Is there a valid preset programmed into the menu? If not, refer to section 10.13.10 and
complete the steps given there.

3 Does the PRESET switch pass the menu I/O test?
Connector 1: Deutsch DT06-4S

Cavity Circuit Description DDC# EFC Input/Output
1 DDEC Accessory Power 439 (+) System Power
2 DDEC Accessory Ground 953 (-) System Ground
3 DDEC 1708 Data Link (+) 900 J1587 Serial Link
4 DDEC 1708 Data Link (-) 901 J1587 Serial Link
Table 10-18 Electronic Fire Commander Wiring
Connector 2: DT06-12S
Cavity Circuit Description DDC# EFC Input/Output
1 DDEC PGS Mode Select 523 Output (ground) to DDEC
2 OEM Interlock from OEM - Input (+12 VDC)
3 Cavity plug - No connection
4 DDEC PGS Mode 499 Input (ground) from DDEC
5 DDEC PGS Enable - Output (ground) to DDEC
6 DDEC PGS Increase - Output (ground) to DDEC
7 DDEC PGS Decrease - Output (ground) to DDEC
8 DDEC PGS Active - Input (ground) from DDEC
9 Alarm - Output (ground) to DDEC
10 PTO Engaged - Input (+12 VDC) from OEM
11 Cavity Plug - No connection
12 Low fuel - Input (ground) from DDEC
Pressure Sensor
Connector:
Circuit Cavity Wire Color Description
916 B Red/Black Sensor Supply 5 VDC
749 C Yellow Fire Pump Pressure
952 A Black Sensor Return

10.14 OPTIMIZED IDLE FEATURE DOES NOT FUNCTION
The following procedure will troubleshoot Optimized Idle not functioning.
To avoid personal injury from the engine starting

accidently, do not replace the ECM with an ECM that is
not programmed with Optimized Idle.
To avoid personal injury from the engine starting while

working in the engine compartment, remove the starter
relay from the relay holder before performing any service
or troubleshooting to the Optimized Idle system.
10.14.1 Check Diagnostic Data Reader for Codes
Perform the following steps to check the DDR for codes.

1. Plug DDR into connector.
3. Check the active and inactive codes for any Optimized Idle codes.
NOTE:
Service any code first.
[a] If an Optimized Idle code 62, 63, or 74 is logged, go to the appropriate flash code
section, based on Optimized Idle code logged.
[b] If an Optimized Idle code 62, 63 or 74 is not logged, refer to section 10.14.2.
10.14.2 Heater and Air Conditioning Fans Do Not Function
Perform the following steps to troubleshoot the heater and A/C fans.
1. Check the heater and A/C blower fuse.
3. Plug in DDR.

4. Check the vehicle power down relay switch. Select switch light status (VEH PWR
DOWN).
[a] If the output status reads ON, check the relay and relay connections for proper
operation. Refer to section 10.14.3.
[b] If the output status does not read ON, install a test ECM. Refer to section 10.14.11.
10.14.3 Check Optimized Idle Active Light
The Optimized Idle active light should flash when all of the following occur:
1. Engine idling.
2. The transmission is in NEUTRAL and high-range, if equipped.
3. The hood is closed and the park brake is set.
4. The cruise switch is turned ON.
[a] If the active light is not flashing, refer to section 10.14.4.
[b] If the light is flashing, after the engine shuts down, turn the thermostat on. When the
light flashes, if the alarm turns ON and the engine starts, the system is OK.
[c] If the light is flashing, after the engine shuts down, turn the thermostat on. When
the light flashes, if the alarm does not turn ON and the engine does not start,
10.14.4 Check Idle Condition
Perform the following steps to troubleshoot Optimized Idle:

1. Check idle condition.
2. Verify the engine is at idle and not running on VSG. Optimized idle will not function if the
engine is running on VSG, unless the idle timer is enabled on VSG.
[a] If the engine is not at idle, turn off the ISD on the VSG. Refer to section 10.14.11.
[b] If the engine is at idle, refer to section 10.14.5.
10.14.5 Check Idle Shutdown Enabled

1. Check for idle shutdown enabled.
2. Using the DDR, view the calibration.
[a] If idle shutdown is not enabled, enable the idle shutdown and set a shutdown time.
[b] If the idle shutdown is enabled, refer to section 10.14.6.

10.14.6 Check lnput Status

1. Check for input status.
2. Using the DDR, check the park brake input status with the hood closed, the transmission
in NEUTRAL (and high-range if equipped) and the park brake set.
[a] If the park brake status is ON, refer to section 10.14.9.
[b] If the park brake status is not ON, refer to section 10.14.7.
10.14.7 Check Hood Switch
Perform the following steps to troubleshoot the hood switch:

1. Check hood switch.
2. Measure the resistance across the hood switch contacts with the hood closed.
See Figure 10-11.
[a] If the resistance measures less than 100

[b] If the resistance measures greater than 100

, replace or adjust the hood switch.
Figure 10-11 Optimized Idle Schematic

10.14.8 Check Park Brake Switch
Perform the following steps to troubleshoot the park brake switch and other OEM interlock
devices.
1. Check the park brake switch and other OEM interlock devices (e.g. high-range switch).
2. Measure resistance across the park brake switch contacts with the park brake set.
[a] If the measured resistance is less than 100
, the 953 ground wire is open somewhere
between the ECM and the battery. Repair the open. Refer to section 10.14.11.
[b] If the measured resistance is more than 100
, replace the park brake switch or other
OEM interlock devices. Refer to section 10.14.11.
10.14.9 Check the Thermostat
Perform the following steps to check the thermostat operation:

2. Plug in the DDR.
3. Select switch light status OPIDL T-STAT.
[a] If the display reads ON with the thermostat enabled and the alarm is turned ON and
the reader shows the switch status for the starter as ON after the alarm turns OFF,
check the relay and starter solenoid connections. Refer to section 10.14.11.
[b] If the display reads ON with the thermostat enabled and the alarm is turned ON and
the reader does not show the switch status for the starter as ON after the alarm turns
OFF, refer to section 10.14.10.
[c] If the display reads ON with the thermostat enabled and the alarm OFF, replace
the alarm. Refer to section 10.14.11.
[d] If the display does not read ON with the thermostat enabled, the thermostat
input wire #958 is open between the thermostat and the ECM. Repair the open.
10.14.10 Oil Temperature Sensor Connection Check
Perform the following steps to troubleshoot the OTS connection:

1. Check the OTS connection.
[a] If the OTS connector is plugged into the oil temperature sensor, reprogram the
ECM. Refer to section 10.14.11.
[b] If the OTS connector is not plugged into the OTS, plug in the OTS connector.


3. Close the hood; set the park brake; put the transmission in NEUTRAL and the high-range,
if equipped.
4. Start the engine.
5. Turn the cruise master switch to the ON position. If it was on before the vehicle started,
turn the switch to OFF and then to ON.
6. Wait for the engine to shut down. After the idle timer expires, the engine will either
shutdown or continue to run to charge the battery or keep the oil temperature between
60F (16C) and 104F (40C).
7. Turn the thermostat on, if installed. Change the set point and heating/cooling mode until
the thermostat requires the engine to start. The icons will flash. If the thermostat is not
installed, wait for the lube oil temperature to fall below 60F (16C).
8. The alarm will sound and the engine will start. Vehicle power (blower fans) will turn on
approximately 30 seconds after the engine starts, due to the thermostat.
[a] If Optimized Idle operates properly, troubleshooting is complete.
[b] If Optimized Idle does not operate properly, troubleshooting is complete. Review this
section from the first step to find the error. Refer to section 10.14.1.

10.15 TRANSMISSION INTERFACE FAULT
Numerous transmissions utilize the DDEC ECM to receive signals that are used to determine
shift points, and/or other information.
10.15.1 Transmission Fault
Transmissions that currently utilize data links:

3 J1587 - Allison World Transmissions
3 J1939 Eaton, Allison
3 J1922 Ceemat
3 Advanced Interface
3 ESS ™, Rockwell - Refer to ESS Troubleshooting Manual
3 Top2, Eaton - Refer to MISC Output Troubleshooting
3 PWM Signal Type - DDEC provides a PWM signal that is used by the transmission or
its components
10.15.2 Verify Transmission Type
Perform the following steps to check the transmission type.

2. Plug in DDR.
3. Check transmission origination.
[a] If a manual transmission, Allison hydraulic, Allison Electronic, Voith, ZF,
[b] If a J 1939/autoshift, Allison WT, Rockwell RXX-X, refer to the troubleshooting
guide of the transmission manufacturer to troubleshoot the fault.
[c] If the transmission type does not match the transmission correctly, reprogram and
10.15.3 Review PWM #1 Signal
Perform the following steps to check the DDR for codes.

1. Perform road test with assistant.
2. Plug in DDR.
3. Watch PWM #1 signal.
[a] If the PWM varies with the load changes, Alison Electric, Voith or ZF, the signal is
normal. Review the wiring or transmission.
[b] If the PWM signal is 0% or 100% when the signal is for Allison Hydraulic with
load changes, the program is normal. Review the transmission, wiring or relay.

10.15 TRANSMISSION INTERFACE FAULT
Perform the following steps to verify repairs. Start with the Menu Selection. An assistant is
needed for the following procedure.
1. Perform road test.
[a] If the problem is resolved, troubleshooting is complete.
[b] If the problem still exists, contact the OEM or transmission supplier. The steps that
led you here do not indicate a problem with the PWM #2 output or output wire.
Verify the correct configuration. Refer to the DDEC Application and Installation
manual, 7SA800, for the appropriate engine.

11 FLASH CODE 11 - VSG LOW
11.1 DESCRIPTION OF FLASH CODE 11
Flash Code 11 indicates that the Variable Speed Governor (VSG) input to the ECM has dropped
below 5% (normally < 0.25 volts) of the sensor supply voltage. This diagnostic condition is
typically:
3 Open sensor signal circuit (No VSG throttle control installed.)
3 Open sensor +5 volt supply circuit
3 Sensor signal is shorted to the sensor return circuit or to ground
3 Sensor +5 volt supply is shorted to sensor return circuit or to ground (This condition will
result in numerous sensor codes.)

11.2 SAE J1587 EQUIVALENT CODE FOR FLASH CODE 11
The SAE J 1587 equivalent code for Flash Code 11 is p 187 4, Variable Speed Governor (VSG)
input low.

11.3 TROUBLESHOOTING FLASH CODE 11
The following procedure will troubleshoot Flash Code 11.
11.3.1 Multiple Code Check
Perform the following steps to check for multiple codes.

2. Plug in DDR.
3. Read active codes.
[a] If code 187/4 is logged and there are no VSG controls used, call DDC with the engine
serial number to determine if re-calibration is necessary.
[b] If code 187/4 was logged and there are VSG controls used primarily,
[c] If flash codes 100/4 and 91/4 were logged, refer to section 91.2.
11.3.2 Sensor Wiring Check
Perform the following steps to check the sensor and wiring:

2. Disconnect VSG throttle sensor connector.
3. Install a jumper wire between sockets B (#510 signal) and C (5V-#916) of the VSG
harness connector. See Figure 11-1.
NOTE:
Cavities of throttle controls may vary depending on the OEM.

5. Enable VSG throttle. Refer to OEM guidelines.
6. Read DDR for active codes.
[a] If active code 187/3 and any other codes are logged, refer to section 11.3.3.

[b] If active code 187/4 and any other codes are logged, refer to section 11.3.6.
Figure 11-1 Variable Speed Governor Circuit
11.3.3 Check Hand Throttle Sensor Adjustment
Perform the following steps to check the hand throttle sensor:

1. Remove jumper and reconnect hand throttle sensor.
3. Plug in DDR.
4. Select VSG COUNTS on the DDR.
5. Enable VSG. Set to idle position.
6. Read counts.
[a] If the count value set at idle (minimum throttle) is greater than 48 counts,
[b] If the count value set at idle (minimum throttle) is less than 48 counts,
11.3.4 Adjust Hand Throttle Sensor
Perform the following steps to adjust the hand throttle sensor:


2. If a variable hand throttle sensor is installed, adjust idle position (low-speed) stops on
the hand throttle sensor.
3. If fixed resistors are installed, replace with new resistors. (Minimum counts MUST
be greater than 48.)
5. Read VSG counts with throttle at low-speed position.
[a] If the idle count reading is greater than 48 counts, refer to section 11.3.12.
[b] If the idle count reading is less than 48 counts, refer to section 11.3.5.
11.3.5 Check Hand Throttle Sensor Connectors
Perform the following steps to check the hand throttle sensor connectors.
2. Inspect the terminals at the hand throttle sensor connectors (sensor side and harness side)
for bent, corroded and unseated pins or sockets. See Figure 11-2.
[a] If the terminals and connectors are not damaged, replace hand throttle sensor.
[b] If the terminals and connectors are damaged, repair as necessary.

11.3.6 Check for +5 volts
Perform the following steps to check for +5 volts:

2. Enable VSG. Refer to OEM guidelines.
3. Measure voltage on the hand throttle sensor harness connector, socket C (5V #916, red
lead) to socket A (return #952, black lead). See Figure 11-3.
[a] If the voltage reading is between 4 to 6 volts, refer to section 11.3.7.
[b] If the voltage reading is greater than 6 volts, refer to section 12.1.
[c] If the voltage reading is less than 4 volts, refer to section 11.3.10.

4. Measure resistance between sockets A (return #952) and B (signal #525) on the hand
throttle sensor harness connector. For VSG circuit, see Figure 11-4.
[a] If the resistance is greater than 1,000

[b] If the resistance is less than or equal to 1,000

, the signal line #525 is shorted to the
return line. Repair the short. Refer to section 11.3.12.
11.3.8 Check for Open Signal
Perform the following steps to check for open signal:

1. Install a jumper wire between sockets A and B of the hand throttle sensor harness
connector. See Figure 11-4.
3. Measure resistance between sockets D1 (#510) and C3 (#952) on the vehicle harness
connector.
[a] If the resistance is less than or equal to 5
[b] If the resistance is greater than 5
or open and the signal line (#510) or return line
(#952) is open, repair the open. Refer to section 11.3.12.
Perform the following steps to check for signal open:

1. Check terminals at the ECM vehicle harness connector (both the ECM and harness side)
for bent, corroded, and unseated pins or sockets. See Figure 11-5.
[a] If the terminals and connectors are damaged, repair the terminals, connectors, or
both. Refer to section 11.3.12.

[b] If the terminals and connectors are not damaged, contact DDC Technical Service.
Figure 11-5 Electronic Control Module Vehicle Harness Connector
11.3.10 Check for Short to 5 Volt

3. Disconnect the connector at the hand throttle sensor.
4. Measure resistance between sockets A and C on the hand throttle sensor harness connector.
See Figure 11-6.
[a] If the resistance measurement is greater than 1,000

[b] If the resistance measurement is less than or equal to 1,000

, the vehicle +5 volt line
(#916) is shorted to the return line (#952). Repair short. Refer to section 11.3.12.
11.3.11 Check for Open +5 Volt Line
Perform the following steps to check for an open +5 volt line.

1. Install a jumper wire between sockets A and C of the hand throttle sensor harness
2. Measure resistance between sockets A3 (#916) and C3 (#952) on the vehicle connector.
, or open, the vehicle +5 volt line
(#916) is open. Repair open. Refer to section 11.3.12.
11.3.12 Verify Repair

4. Clear codes.

6. Stop engine.
7. Check for logged codes.
[a] If no codes are logged, troubleshooting is complete.
[b] If code 187/4 is not logged, and other codes are logged, refer to section 9.1.
[c] If code 187/4 is logged, and other codes are logged, systems diagnostics are complete.
Please review this section from the first step to find the error. Refer to section 11.3.1.

12 FLASH CODE 12 - VSG HIGH
Flash Code 12 indicates that the Variable Speed Governor (VSG) input to the ECM has exceeded
95% (normally >4.75 volts) of the sensor supply voltage. This diagnostic condition is typically:
3 Open sensor return circuit
3 Sensor signal circuit is shorted to the sensor +5 volt supply
3 Throttle sensor not adjusted properly at full throttle

The SAE J1587 equivalent code for Flash Code 12 is p 187 3, Variable Speed Governor (VSG)
input high.

Perform the following steps to check for multiple codes:

1. Turn ignition ON. (For VSG circuit, see Figure 12-1.)
2. Plug in DDR.
[a] If active code 187/3 and any other codes except 91/3 or 100/3 are logged,
[b] If active code 187/3 and codes 91/3 or 100/3 are logged, refer to section 91.2.
12.3.2 Sensor Check
Perform the following steps to check the sensor:

2. Unplug the VSG throttle connector. (For VSG circuit, see Figure 12-1.)

[a] If active code 187/4 is logged, and code 187/3 only occurs when the throttle is moved
at or near full throttle (when connected), refer to section 12.3.3.
[b] If active code 187/3 is logged, and the code appears when the throttle is not at or near
full throttle (when connected), refer to section 12.3.4.
12.3.3 Check Calibration
Perform these additional steps to check the calibration of the sensor:

1. Plug in the VSG throttle connector.
3. Plug in DDR.
4. Display VSG counts.
5. Dial throttle to Full Throttle.
[a] If the VSG counts are greater than 968, adjust the maximum throttle travel. If not
adjustable, replace the throttle control.
[b] If the VSG counts are less than 968, refer to section 12.3.4.
12.3.4 Return Circuit Check
Perform these steps to check the return circuit:

1. Place the transmission in neutral.
3. Install a jumper wire between pin A (return #952) and pin B (signal #510/525) of the
VSG throttle harness connector.
5. Enable VSG control. (This may require the ignition be turned on.)
6. Measure resistance between sockets C3 (#952) and D1 (#510) on the vehicle harness


, the return line (#952) is open, repair the open.
Figure 12-2 Typical Variable Speed Governor Circuit
12.3.5 Variable Speed Governor Throttle Connector Check
Perform these steps to check the VSG throttle connectors:

1. Inspect terminals at the VSG connectors (sensor side and harness side) for bent, corroded
and unseated pins or sockets.
[a] If the VSG connector terminals are damaged, repair terminals and/or connectors.
[b] If the VSG connector terminals are in good condition with no signs of damage,
12.3.6 Check for Short to Battery (+)
Perform these steps to check for short to battery (+).

2. Unplug VSG connector.
4. Measure voltage between B (signal #525/#510) and battery ground. See Figure 12-3.
[a] If measured voltage is less than or equal to 0.2 volts, refer to section 12.3.7.

[b] If measured voltage is greater than 0.2 volts, signal wire is shorted to 12/24 volt
source. Repair or replace #510/#525 circuit. Refer to section 12.3.8.
To check for short, perform the following:

2. Unplug vehicle 30-pin connector and the VSG connector.
5. Measure resistance between A3 (#916) and D1 (#510). See Figure 12-4.
[a] If resistance is greater than 5
, check ECM connector. Refer to section 12.3.8.

[b] If resistance is less than 5

, wire #916 (5-volt supply) is shorted to #510/#525
(signal). Repair short or replace wire. Refer to section 12.3.8 to verify repairs.

3. Set parking brake, transmission in Neutral.
5. Clear codes.
7. Stop engine.
8. Check DDR for codes.
[a] If no codes are displayed, no further troubleshooting is required.
[c] If code 187/3 is logged, and other codes are logged, refer to section 12.3.1.


13 (CHG) FLASH CODE 13 - CLS LOW

Flash Code 13 indicates that the Coolant Level Sensor (CLS) input to the ECM has dropped
below 5% (normally < 0.25 volts) of the sensor supply voltage. See Figure 13-1. This diagnostic
condition is typically:
3 Deteriorated coolant

The SAE J1587 equivalent code for Flash Code 13 is p 111 4, coolant level circuit low.

13.3.1 Sensor Check
Perform the following steps to check the sensor.

2. Disconnect Coolant Level Sensor (CLS).
4. Start engine.
5. Read logged codes.
6. Stop engine.
[a] If code P111/3 is logged, refer to section 13.3.2.
[b] If code P111/4 is logged, refer to section 13.3.3.
13.3.2 Check Coolant Level Sensor Connector
Perform the following steps to check the CLS connector.

1. Inspect terminals at the CLS connector for bent, corroded and unseated pins or sockets.
Ensure wires are not reversed at the CLS. See Figure 13-2.
[a] If terminals and connectors are damaged, repair both. Refer to section 13.3.4.

[b] If terminals and connectors are not damaged, replace the CLS. Refer to section 13.3.4.
Figure 13-2 Coolant Level Sensor and Circuits
Perform the following steps to check for a short.

3. Measure resistance between sockets A and B on the CLS harness connector. Also measure
resistance between socket A and battery ground; and socket A and chassis ground.
See Figure 13-2.
[a] If the resistance is greater than 10,000
[b] If the resistance is less than or equal to 10,000
, the signal wire (#115) is shorted to
the ground (#953), or to chassis ground. Repair short; refer to section 13.3.4.

4. Clear DDR codes.


6. Stop engine.
[a] If no codes are displayed, troubleshooting is complete.
[c] If code 111/4 is logged, refer to section 13.3.5.
13.3.5 Code 111/4 Logged
Perform the following steps to troubleshoot Code 111/4.

1. Remove CLS.
2. Plug opening.
3. Locate sensor probe in clean water.
[a] If code 111/4 is logged, all system diagnostics are complete. Review this section to
find the error. Refer to section 13.3.1.
[b] If code 111/4 is not logged, reprogram the ECM and replace the coolant with new.
Repeat the test. Refer to section 13.3.4.


14 (CHG) FLASH CODE 14 - TEMP SENSOR HIGH
Figure 14-1 Coolant Temperature Sensor (Oil Temperature Sensor similar)

Flash Code 14 indicates that the engine Coolant Temperature Sensor (CTS) or Oil Temperature
Sensor (OTS), See Figure 14-1, input to the ECM has exceeded 95% (normally >4.75 volts) of
the sensor supply voltage.
NOTE:
This code will only be logged during warm engine operation.
This diagnostic condition is typically:

3 Open sensor signal circuit

14.2 SAE J1587 EQUIVALENT CODES FOR FLASH CODE 14
The SAE J1587 equivalent codes for Flash Code 14 are:

3 p 110 3 - coolant temperature circuit high
3 p 175 3 - oil temperature circuit high

14.3.1 Code Check
Perform the following steps to check for codes.

1. Turn vehicle ignition ON.
2. Plug in diagnostic data reader (DDR) and determine which code is logged.
[a] If codes PID 110-FMI 3 is logged, refer to section 14.3.2.
[b] If codes PID 175-FMI 3 is logged, refer to section 14.3.3.
14.3.2 Coolant Temperature Sensor Check
Perform the following steps to check the coolant temperature sensor (CTS).
2. Disconnect CTS and install a jumper between the CTS connector sockets A and B.
See Figure 14-2.
[a] If code 110/4 or any other codes except 110/3 are logged, refer to section 14.3.8.

[b] If code 110/3 is logged and any codes except code 110/4 are logged,
Figure 14-2 Temperature Sensor Circuits
14.3.3 Oil Temperature Sensor Check
Perform the following steps to check the oil temperature sensor (OTS).
2. Disconnect OTS and install a jumper between OTS connector sockets A and B.
See Figure 14-3.
[a] If code 175/4 is logged, refer to section 14.3.9.

[b] If code 175/3 is logged and any codes except code 175/4 are logged,
14.3.4 Check for Signal Short to +5 Volt Line
Perform the following steps to check for a short to the +5 volt line.
2. Remove jumper wire.
3. Disconnect the engine harness connector at the ECM.
4. Measure resistance between sockets P3 #133 and W1 #416 on the engine harness


, the signal line (#133) is
shorted to the engine +5 volt line (#416). Repair the short and refer to section 14.3.11.
Figure 14-4 ECM Engine Harness Connector
14.3.5 Check for Signal Short to +5 Volt Line
4. Measure resistance between sockets R2 #120 and W1 #416 on the engine harness
[a] If the resistance measurement is greater than or equal to 5
, the signal line (#120) is shorted to the
engine +5 volt line (#416). Repair the short and refer to section 14.3.11.
14.3.6 Check Coolant Temperature Sensor Connectors
Perform the following steps to check the CTS connectors.

1. Check terminals at the CTS connector (both sensor and harness side) for damage; bent,
corroded and unseated pins or sockets. See Figure 14-5.

[a] If terminals and connectors are in good condition, replace the CTS.
14.3.7 Check Oil Temperature Sensor Connectors
Perform the following steps to check the OTS connectors.

1. Check terminals at the OTS connector (both sensor and harness side) for damage: bent,
[a] If terminals or connectors are damaged, repair them. Refer to section 14.3.11.

[b] If terminals and connectors are not damaged, replace the OTS.
14.3.8 Open Line Check
Perform the following steps to check for an open line.

2. Disconnect the engine harness connector at the ECM. Leave the jumper wire between A
and B of the Temperature Sensor Connector.
3. Measure resistance between sockets P3 (#133) and Y2 (#452) on the engine harness


or open, the signal line (#133) or
return line (#452) is open. Repair the open. Refer to section 14.3.11.

2. Disconnect the engine harness connector at the ECM. Leave the jumper wire between A
and B of the Temperature Sensor Connector.
3. Measure resistance between sockets R2 (#120) and Y2 (#452) on the engine harness
Perform the following steps to check the ECM connectors.

1. Check terminals at the ECM engine harness connector (both ECM and harness side) for
damage: bent, corroded and unseated pins or sockets. See Figure 14-8.

[b] If terminals and connectors are not damaged, replace the CTS/OTS.

4. Clear codes.
5. Start and run the engine for eight minutes.
6. Stop engine.
[b] If code 110/3 or 175/3 and any other codes are logged, all system diagnostics are
complete. Review this section to find the error. Refer to section 14.3.1.
[c] If any codes except code 110/3 or 175/3 are logged, refer to section 9.1.

15 (CHG) FLASH CODE 15 - TEMP SENSOR LOW

Flash Code 15 indicates that the Coolant Temperature Sensor (CTS), or Oil Temperature Sensor
(OTS), see Figure 15-1, input to the ECM has dropped below 5% (normally < 0.25 volts) of
the sensor supply voltage.


3 p 110 4 - coolant temperature circuit low
3 p 175 4 - oil temperature circuit low

15.3.1 Code Check

2. Plug in diagnostic data reader (DDR) and determine which code is logged.
[a] If codes PID 110-FMI 4 are logged, refer to section 15.3.2.
[b] If codes PID 175-FMI 4 are logged, refer to section 15.3.3.
15.3.2 Coolant Temperature Sensor Check
Perform the following steps to check the coolant temperature sensor (CTS).
2. Disconnect (unplug) CTS connector.
4. Read active codes with engine still running.
[a] If code 110/4 or any other codes are logged, refer to section 15.3.4.
[b] If any codes except code 110/4 are logged, refer to section 15.3.6.
15.3.3 Oil Temperature Sensor Check
Perform the following steps to check the oil temperature sensor (OTS).
2. Disconnect OTS connector. See Figure 15-2.
4. Read active codes with engine running.

15.3.4 Check Coolant Temperature Sensor Connectors
Perform the following steps to check the CTS connectors.

1. Check terminals at the CTS connector (both sensor and harness side) for damage; bent,
[a] If terminals and connectors are in good condition, replace the CTS.

15.3.5 Check Oil Temperature Sensor Connectors
Perform the following steps to check the OTS connectors.

1. Check terminals at the OTS connector (both sensor and harness side) for damage: bent,

[b] If terminals and connectors are not damaged, replace the OTS.

3. Measure resistance between sockets P3 (#133) and Y2 (#452) on the engine harness
4. Measure resistance between socket P3 and a good ground.
[a] If the resistance measurement between sockets P3 and Y2, or P3 and battery ground,
is less than or equal to 5
, the signal line (#133) is shorted to the return line (#452)
or battery ground. Repair the short. Refer to section 15.3.10.

[b] If the resistance measurement between sockets P3 and Y2 is greater than 5

or open,
and the resistance measurement between sockets P3 and a good ground is greater
than or equal to 5

3. Measure resistance between sockets R2, (#120) and Y2 (#452) on the engine harness
4. Measure resistance between socket R2 and a good ground.
[a] If the resistance measurement between sockets R2 and Y2, or R2 and battery (-) is
less than or equal to 5
, the signal line (#120) is shorted to the return line (#452) or
battery ground. Repair the short. Refer to section 15.3.10.

[b] If the resistance measurement between socket R2 and Y2 is greater than 5

or open,
and the resistance measurement between socket R2 and a good ground is greater than
or equal to 5

1. Check terminals at the ECM engine harness connector (both ECM and harness side)
for damage: bent, corroded and unseated pins or sockets. Check terminals P3 and Y2
of the ECM connector. See Figure 15-7.

[b] If terminals and connectors are not damaged, reprogram the ECM.

1. Check terminals at the ECM engine harness connector (both sensor and harness side)
for damage: bent, corroded and unseated pins or sockets. Check terminals R2 and Y2
of the ECM connector. See Figure 15-8.

[b] If terminals and connectors are not damaged, reprogram the ECM. Contact Detroit
Diesel Technical Service Group. Refer to section 15.3.10.

4. Clear codes
6. Stop engine.
[b] If code 110 or 175/4 and any other codes are logged, all system diagnostics are
complete. Review this section to find the error. Refer to section 15.3.1.
[c] If any codes except code 110 or 175/4 are logged, refer to section 9.1.

16 (CHG) FLASH CODE 16 - CLS HIGH

Flash Code 16 indicates that the engine Coolant Level Sensor (CLS), see Figure 16-1, input to the
ECM has exceeded 95% (normally >4.75 volts) of the sensor supply voltage.
3 Open sensor ground circuit

The SAE J1587 equivalent code for Flash Code 16 is p 111 3, coolant level circuit high.

16.3.1 Sensor Check

2. Disconnect Coolant Level Sensor (CLS) connector and install a jumper between sockets
A and B of the CLS harness connector.
3. Attempt to start and run engine at idle.
4. Read DDR for active codes.
[a] If active code 111/3 and any other codes except code 111/4 are logged,
[b] If active code 111/4 and any other codes are logged, refer to section 16.3.4.
5. Stop engine.
16.3.2 Signal Circuit Check
Perform the following steps to check the signal circuit.

2. Disconnect the CLS.
3. Disconnect the vehicle harness connector.
4. Measure resistance between socket H3 (#115) on the vehicle harness connector and A
(#115 signal) of the CLS connector.
, or the signal line #115 is open,
repair the open. Refer to section 16.3.7.
16.3.3 Ground Circuit Check
Perform the following steps to check the ground circuit.

1. Measure resistance between cavity B (battery ground) of the CLS connector and battery
ground.
, or open, the ground circuit is
open. Repair and refer to section 16.3.7.

16.3.4 Signal Short to Ignition Check
Perform the following steps to check for a signal short to ignition.

2. Remove the jumper wire at the CLS harness connector.
4. Measure voltage at cavity A (#115 signal) of the CLS connector and battery ground.
See Figure 16-2.
[a] If the voltage measurement is less than or equal to 6 volts, refer to section 16.3.5.
[b] If the voltage measurement is greater than 6 volts, the CLS signal line (#115)
is shorted to the 12/24 volt DC line. Repair the short or replace the #115 wire.
Figure 16-2 Coolant Level Sensor and Circuits
16.3.5 ECM Connectors Check

1. Inspect terminals at the vehicle harness connector (both the sensor and harness side) for
bent, corroded and unseated pins or sockets. Check terminal and pin H3 at the ECM and
all terminals and pins in the CLS connector. See Figure 16-3.
[a] If terminals and connectors are not damaged, replace the CLS. Refer to section 16.3.7.
If this is a repeated failure of the CLS, refer to section 16.3.6.

[b] If terminals and connectors are damaged, repair both. Refer to section 16.3.7.
Figure 16-3 Vehicle Harness Connector
16.3.6 Alternator Ground Check
Perform the following steps to check the alternator ground.

2. Remove alternator belt or disable alternator from charging.
3. Start and run the engine.
[a] If no codes are logged, repair the alternator ground circuit. Refer to section 16.3.7.
[b] If codes are logged, replace CLS. Refer to section 16.3.7.
Perform the following steps to verify the repairs.

4. Clear DDR codes.

6. Stop the engine.

[c] If code 111/3 is logged, and other codes are logged, refer to section 16.3.1, and
perform tasks.

17 (CHG) FLASH CODE 17 - THROTTLE VALVE HIGH
Flash Code 17 is currently used for gas fueled engines only. This code indicates that the Throttle
Plate Input Voltage has exceeded 95% of the sensor supply voltage (normally >4.75 volts).
Typically, the problem is an open sensor return, a short to the sensor supply or throttle body
power is low.

The SAE J1587 equivalent code for Flash Code 17 is p 051/3, throttle plate input voltage high.

17.3.1 Check Actuator
Perform the following steps to check the actuator.

1. Unplug throttle actuator connector.
3. Plug in DDR.
[a] If code p 051/3 is logged, refer to section 17.3.3.
[b] If code p 051/4 is logged, refer to section 17.3.5.
Perform the following steps to check the connectors.

2. Check connectors, ECM side and throttle actuator side, for damaged, bent or broken pins.
[a] If the connectors are not damaged, replace the actuator. Refer to section 17.3.6.
[b] If the connectors are damaged, bent or have broken pins, repair or replace the
connectors or pins; refer to section 17.3.6.
17.3.3 Check Sensor

2. Unplug the engine sensor harness.
3. Measure resistance between W1 and R1. See Figure 17-1.
, the wires are
shorted to each other. Repair the short or replace the engine sensor harness.


Figure 17-1 Gas Engine Sensor Harness
Perform the following steps to check for voltage.

1. Reconnect the engine sensor harness.
2. Measure voltage between cavity R1 and battery (-), ground.
[a] If the voltage measurement is greater than 4.5 volts, the wire is shorted to the voltage
supply. Replace the #907 wire, or replace the harness. Refer to section 17.3.6.
[b] If the voltage is less than 4.5 volts, refer to section 17.3.5.

Perform the following steps to check for open.

1. Turn ignition OFF. Disconnect engine sensor harness.
2. Place a jumper wire between cavity F and D of the throttle actuator connector.
3. Measure resistance between R1 (#907) and Y2 (#452).
, the return line (#452) is open.
Repair the open and refer to section 17.3.6.

1. Plug in all connectors.
2. Clear the codes.
4. Operate at idle and rated speed.
6. Plug in DDR and read the codes.
[b] If any codes are logged, review this section to find the error. Then, contact Detroit
Diesel Technical Services.


18 (CHG) FLASH CODE 18 - THROTTLE VALVE LOW
Flash Code 17 is currently used for gas fueled engines only. This code indicates that the Throttle
Valve Plate Input Voltage has dropped below the 5% sensor supply voltage (normally < 0.25
volts). Typically, the problem is an open signal or an open sensor supply.

The SAE J1587 equivalent code for Flash Code 18 is p 051/4, throttle plate input voltage low.

18.3.1 Check Actuator
Perform the following steps to check the actuator.

1. Unplug throttle actuator harness connector.
2. Install a jumper wire between cavity F and C.
4. Plug in DDR. Read the codes.
[a] If code p 051/3 and any other codes are logged, refer to section 18.3.2.
[b] If code p 051/4 is logged, refer to section 18.3.3.

3. Check connectors, both ECM and throttle actuator side, for bent, broken, or loose
connections.
[a] If the connectors are not damaged, replace the actuator and refer to section 18.3.7.
[b] If the connectors are damaged, bent or have broken pins, repair or replace them.

2. Move jumper wire from cavity F and C to cavity F and D.
3. Remove engine harness connector.
4. Measure resistance between Y2 (#452) and R1 (#907). See Figure 18-1.
, wire #907 is open. Repair the
open or replace the harness and refer to section 18.3.7.


Figure 18-1 Gas Engine Sensor Harness
18.3.4 Check for Short to Return
Perform the following steps to check for a short to the return line.
1. Remove jumper.
2. Measure resistance between Y2 (#452) and R1 (#907), and Y2 (#452) and W1 (#416).
[a] If either measured resistance is less than 1,000
, those wires are shorted to each
other. Replace the harness and refer to section 18.3.7.
[b] If both measured resistance are greater than 1,000

18.3.5 Check for Short to Battery (-)
Perform the following steps to check for a short to the battery (-).
1. Measure resistance between R1 (#907) and battery ground, and W1 (#416) and battery
ground.
[a] If either measured resistance is less than 1,000
, then that wire is shorted to the
battery (-). Replace the harness and refer to section 18.3.7.
18.3.6 Check for 5 Volt Open
Perform the following steps to check for a 5 volt open.

1. Plug in the 30-pin connector for the engine sensor harness.
3. Measure voltage between cavity D (#452) and C (#416) of the actuator connector.
[a] If the measurement is less than 4.5 volts, wire #416 is open. Repair the open or
replace the harness. Refer to section 18.3.7.
[b] If the measurement is between 4.5 and 5.5 volts, refer to section 18.3.2.

1. Plug all connectors in.
3. Plug in the DDR and read the codes.
[b] If code p 051/4 is logged, please review this section from the first step to find the
error. Refer to section 18.3.1. Then, contact Detroit Diesel Technical Services.


19 FLASH CODE 19
This manual was designed to have the section number equal to the Flash Code for troubleshooting.
This section is intentionally left blank.
No DDEC code is currently assigned to this number. If changes occur, notification will be sent
from DDC.


20 FLASH CODE 20
from DDC.


21 FLASH CODE 21 - TPS HIGH

Flash Code 21 indicates that the Throttle Position Sensor (TPS), see Figure 21-1, input to the

The SAE J1587 equivalent code for Flash Code 21 is p 091 3, TPS circuit high.
21.2.1 General Throttle Information (Limiting Speed Governor)
The correct TPS counts for DDEC III engines at idle should be 64 - 205 counts.
1. Typical DDEC III foot pedals today, at idle, provide 102 - 205 counts.
2. DDEC II foot pedals can be used on DDEC III engines. The counts from the DDEC II
style pedal may go as low as 64 counts at idle, but this is still acceptable.
3. The DDEC system will log a TPS low volt code (PID 091, FMI 4, Flash Code 22) if the
TPS counts go below 48.
4. The DDEC system will log a TPS high volt code (PID 091, FMI 3, Flash Code 21) if the
TPS counts go above 968 counts.
5. In order to go from 0% to 100% throttle, the counts have to increase 546 above the idle
count, or 100 counts, whichever is greater.
6. If an idle validation switch (IVS) is configured, to go from 0% to 100% throttle, the
counts have to increase 546 above the counts at which the IVS opens or 100 counts,
whichever is greater.
7. If 0% throttle is attained with the foot off the pedal, and if 100% throttle is attained
with the pedal to the floor, then the pedal should not be considered a factor for low
power complaints.


2. Plug in DDR.
[a] If active code 91/3 and no other active codes are logged, refer to section 21.3.2.
[b] If any or all of the following codes are logged, 91/3, 91/4, 187/3, 100/3,
[c] If any codes except 91/3 are logged, refer to section 21.3.3.
21.3.2 Sensor Check

2. Unplug the TPS connector.
4. Read for active codes.
[b] If code 91/4 is logged, refer to section 21.3.3.
Perform the following steps to check the return circuit.

2. Install a jumper wire between pin A (return #952) and pin B (signal #417) of the TPS
harness connector.
4. Measure resistance between sockets C3 and D2 on the vehicle harness connector. For
Throttle Position Sensor schematic, See figure 21-2.


, and the return line #952 is open,
repair the open and refer to section 21.3.10.
21.3.4 Check Throttle Position Sensor Adjustment
Perform the following steps to check for TPS adjustment.

1. Reconnect vehicle harness connector and plug in the TPS.
2. Hook up DDR to the DDL connector and select Throttle Sensor Display.
3. Measure Throttle Counts at both no throttle and full throttle. Take several readings.
[a] If TPS counts are ever greater than 968 counts, refer to section 21.3.5.
[b] If TPS counts stay less than 968 counts, refer to section 21.3.6.
21.3.5 Throttle Position Sensor Adjustment
Perform the following steps to attempt TPS adjustment.

1. Check for pedal or linkage interferences.
2. Loosen the TPS screws and attempt to adjust for the correct throttle reading (64 - 205
counts). Do not attempt to adjust by bending the pedal mechanism.
3. Recheck counts at idle and at full throttle.
[a] If the throttle counts are not correct, refer to section 21.3.6.
[b] If the throttle counts are now correct, refer to section 21.3.10.

21.3.6 Check Throttle Position Sensor Connectors
Perform the following steps to check the TPS connectors.

1. Check terminals at the TPS connector (both sensor and harness side) for bent, corroded
and unseated pins or sockets. See Figure 21-3.
[a] If the terminals or connectors are damaged, repair both and refer to section 21.3.10.
[b] If the terminals or connectors are not damaged, replace the TPS;

2. Disconnect the vehicle harness connector at the ECM. Unplug the TPS connector.
3. Read resistance between sockets D2 and A3 on the vehicle harness connector. For ECM
vehicle harness connector, see Figure 21-4.
[a] If the resistance is greater than 100

[b] If the resistance is less than or equal to 100

, the signal line (#417) is shorted to the
vehicle +5 volt line (#916). Repair the short and refer to section 21.3.10.
21.3.8 Check for Short to Battery
Perform the following steps to check for a short to the battery.

1. Remove both fuses to the ECM.
2. Disconnect the 5-way power harness and vehicle harness connectors at the ECM.
3. Measure resistance between socket D2 on the vehicle harness connector and the 5-way
power connector sockets A and C. See Figure 21-5.
[a] If the resistance is greater than 100

[b] If the resistance is less than or equal to 100

, a short exists between sockets
where less than 100
resistance was read. Repair short and reinsert fuses.
Figure 21-5 5-Way ECM Power Connector

1. Check terminals at the ECM harness connector (both ECM and harness side) for bent,
[a] If terminals and connectors are damaged, repair them. Refer to section 21.3.10.

[b] If terminals and connectors are not damaged, refer to section 21.3.1, to review this
section. If review leads back here, install a test ECM or contact Detroit Diesel
Technical Service.

4. Clear DDR codes.
5. Start and run the engine for one minute. Check idle position and full throttle.
6. Stop engine.
[c] If code 91/3 is logged, and other codes are logged, all system diagnostics are
complete. If a problem still exists, review this section from the first step to
troubleshoot the error, refer to section 21.3.1.

22 FLASH CODE 22 - TPS LOW

Flash Code 22 indicates that the Throttle Position Sensor (TPS), see Figure 22-1, input to the
ECM has dropped below 5% (normally < 0.25 volts) of the sensor supply voltage.
3 Sensor signal is shorted to sensor return circuit or to ground

The SAE J1587 equivalent code for Flash Code 22 is p 091 4, Throttle Position Sensor (TPS)
circuit low.
22.2.1 General Throttle Information (Limiting Speed Governor)
The correct TPS counts for DDEC III engines at idle should be 64 - 205 counts.
1. Typical DDEC III foot pedals today, at idle, provide 102 - 205 counts.
2. DDEC II foot pedals can be used on DDEC III engines. The counts from the DDEC II
style pedal may go as low as 64 counts at idle, but this is still acceptable.
3. The DDEC system will log a TPS low volt code (PID 091, FMI 4, Flash Code 22) if the
TPS counts go below 48.
4. The DDEC system will log a TPS high volt code (PID 091, FMI 3, Flash Code 21) if the
TPS counts go above 968 counts.
5. In order to go from 0% to 100% throttle, the counts have to increase 546 above the idle
count, or 100 counts, whichever is greater.
6. If an idle validation switch (IVS) is configured, to go from 0% to 100% throttle, the
counts have to increase 546 above the counts at which the IVS opens or 100 counts,
whichever is greater.
7. If 0% throttle is attained with the foot off the pedal, and if 100% throttle is attained
with the pedal to the floor, then the pedal should not be considered a factor for low
power complaints.


2. Plug in DDR.
[b] If code 91/4 and any or all of the following codes are logged, 91/3, 187/4, or 100/4,
[c] If codes other than the above are logged, refer to section 9.1.
22.3.2 Check for Device
Perform the following steps to check for device.

1. If there is a throttle (LSG) wired to use the 417 (LSG) circuit, refer to section 22.3.3.
2. If there is no throttle (LSG) wired to use the 417 (LSG) circuit, contact Detroit Diesel
Technical Service, for possible change to the calibration.
[a] If required, reprogram the ECM after the mainframe is changed and
22.3.3 Sensor Check

2. Disconnect the TPS connector.
3. Install a jumper wire between sockets B (signal #417) and C (5V supply #916);
see Figure 22-2.
[a] If code 91/4 and any other codes are logged, refer to section 22.3.7.

[b] If code 91/3 and any other codes are logged, refer to section 22.3.4.
22.3.4 Check Throttle Position Sensor Adjustment
Perform the following steps to check the TPS adjustment:

1. Remove jumper and reconnect TPS.
2. Hook DDR to the DDL connector and select TPS - Counts.
3. Read Throttle Counts at both no throttle and full throttle positions. Take several readings.
[a] If at any time counts go lower than 49 counts, refer to section 22.3.5.
[b] If counts never go lower than 49 counts, refer to section 22.3.6.
22.3.5 Attempt Throttle Position Sensor Adjustment
Perform the following steps to attempt a TPS adjustment:

1. Check for pedal or linkage interferences.
2. Loosen the TPS screws and attempt to adjust for the correct throttle reading (normal range
- 64-205 counts). Do not attempt to adjust by bending the pedal mechanism.
3. Recheck counts at idle and at full throttle.
[a] If the throttle count has been corrected, refer to section 22.3.15.
[b] If the problem could not be corrected, refer to section 22.3.6.

22.3.6 Check Throttle Position Sensor Connectors
Perform the following steps to check the TPS connectors:

1. Check terminals at the TPS connector (both sensor and harness side) for bent, corroded,
and unseated pins or sockets.
[a] If the terminals or the connectors are damaged, repair them. Refer to section 22.3.15.
[b] If the terminals and connectors are not damaged, replace the TPS and
22.3.7 Check for +5 Volts
Perform the following steps to check for +5 volts:

3. Measure voltage on TPS harness connector, socket C (5V supply #916) (red lead) to
socket A (return #952) (black lead).
[a] If measured voltage is greater than 6 volts, refer to section 22.3.13.
[b] If measured voltage is less than 4 volts, refer to section 22.3.11.
[c] If measured voltage is between 4 and 6 volts, refer to section 22.3.8.

3. Measure resistance between sockets A (return #952) and B (signal #417) at the TPS
harness connector. See Figure 22-3.
4. Measure resistance between socket B (signal #417) and a good ground (battery ground
and chassis ground).
[a] If resistance measurement is less than or equal to 100
, the signal line #417 is shorted
to the return line #952 or battery ground. Repair short. Refer to section 22.3.15.

[b] If resistance measurement on both readings is greater than 100

or open,
22.3.9 Check for Signal Open
Perform the following steps to check for signal open:

1. Install a jumper wire between sockets A (return #952) and B (signal #417) of the TPS
harness connector.
2. Measure resistance between sockets D2 and C3 on the vehicle connector.
or open, the signal line (#417) or return line
(#952) are open, repair the open. Refer to section 22.3.15.

corroded, and unseated pins or sockets. See Figure 22-4.

[b] If terminals and connectors are not damaged, call Detroit Diesel Technical Service
for assistance.

3. Measure resistance between sockets A (return #952) and C (5V #916) on the TPS harness
[a] If resistance between sockets A and C is greater than 1,000
or open,

[b] If resistance between sockets A and C is less than or equal to 1,000

or
open, the 5V wire (#916) is shorted to the return (#952). Repair the short and
Perform the following steps to check for an open +5 volt line:

1. Install a jumper wire between sockets A (return #952) and C (5V #916) on the TPS
harness connector.
2. Measure resistance between sockets A3 and C3 on the vehicle harness connector.
See Figure 22-6.
[a] If resistance between sockets A3 and C3 is less than or equal to 5
or open,

[b] If resistance between sockets A3 and C3 is greater than or equal to 5

or open, the
vehicle +5 volt line (#916) is open. Repair the open. Refer to section 22.3.15.
22.3.13 Check for Short to Battery +
Perform the following steps to check for a short to the battery +:

2. Remove both fuses to ECM.
3. Disconnect the 5-way power connector at the ECM.
4. Measure resistance between socket D2 on the vehicle harness connector and the 5-way
power connector sockets A and C. See Figure 22-7.
[a] If measured resistance is greater than 100

[b] If measured resistance is less than or equal to 100

, a short exists between
sockets where resistance was measured. Repair short and reinsert fuses;
22.3.14 Check for Outside DDEC Battery +
Perform the following steps to check for outside DDEC battery +:

2. Remove ECM 5-pin power connector.
3. Remove ECM vehicle harness connector.
5. Measure voltage A3 (red lead) to battery ground.
6. Measure voltage C3 (red lead) to battery ground.
[a] If measured voltage is less than 0.2 volts, refer to section 22.3.10.
[b] If measured voltage is greater than 0.2 volts, outside power is spliced/shorted into
either line #952 or line #916. Remove the splice/short. Refer to section 22.3.15.



4. Clear codes with DDR.
5. Start and run the engine for one minute at all throttle positions.
6. Stop engine.
[b] If code 91/4 and any other codes are logged, all system diagnostics are complete.
Review this section from the first step to find the error. Refer to section 22.3.1.
[c] If code 91/4 is not logged, but other codes are logged, refer to section 9.1.


23 (CHG) FLASH CODE 23 - FUEL TEMP SENSOR
HIGH
Figure 23-1 Fuel Temperature Sensor

Flash Code 23 indicates that the engine Fuel Temperature Sensor (FTS), see Figure 23-1, input to
the ECM has exceeded 95% (normally >4.75 volts) of the sensor supply voltage.
NOTE:

3 Open sensor circuit return

The SAE J1587 equivalent code for Flash Code 23 is p 174 3, fuel temperature circuit high.

23.3.1 Sensor Check

2. Disconnect the FTS connector.
3. Install a jumper wire between sockets A and B of the FTS harness connector.
see Figure 23-2.
[a] If code 174/4 and any other codes except code 174/3 are logged, refer to section 23.3.2.
[b] If any code except 174/4 is logged, refer to section 23.3.4.
23.3.2 Check for Short to +5 Volt Line


4. Measure resistance between sockets R3 and W1 on the engine harness connector.
See Figure 23-3.
[a] If the measured resistance is greater than 100
[b] If the measured resistance is less than or equal to 100
, the signal line #472 is
shorted to the engine +5 volt line #416. Repair the short; refer to section 23.3.6.
23.3.3 Check Fuel Temperature Sensor Connectors
Perform the following steps to check the FTS connectors:

1. Check terminals at the FTS harness connector (both sensor and harness side) for bent,

[b] If terminals and connectors are not damaged, replace the FTS. Refer to section 23.3.6.

2. Disconnect the engine harness connector at the ECM. The jumper wire is still in place at
the FTS connector.
3. Measure resistance between sockets R3 and Y2 on the engine harness connector.
See Figure 23-5.
or open, the signal line #472 or return
line #452 is open. Repair the open; refer to section 23.3.6.

[b] If the measured resistance is less than or equal to 5



[b] If terminals and connectors are not damaged, install a test ECM.

6. Stop engine.
7. Read codes.


24 (CHG) FLASH CODE 24 - FUEL TEMP SENSOR
LOW

Flash Code 24 indicates that the engine Fuel Temperature Sensor (FTS), see Figure 24-1, input to
the ECM has dropped below 5% (normally < 0.25 volts) of the sensor supply voltage.
3 Sensor signal circuit is shorted to sensor return circuit or to ground

The SAE J1587 equivalent code for Flash Code 24 is p 174 4, fuel temperature circuit low.


2. Plug in DDR.
[b] If any or all of the following codes are logged, 110/3, 175/3, 174/3, or 102/3,
[c] If codes other than the above are logged, refer to section 24.3.2.
24.3.2 Sensor Check

2. Disconnect the FTS connector.
3. Start and run engine for eight minutes.
4. Read active codes with engine still running.
[a] If code 174/4 and any other codes are logged, refer to section 24.3.4.
[b] If code 174/3 and any other codes except 174/4 are logged, refer to section 24.3.3.
24.3.3 Check Fuel Temperature Sensor Connectors
Perform the following steps to check the FTS connectors:

1. Check terminals at the FTS connector (both sensor and harness side) for bent, corroded,

[b] If terminals and connectors are not damaged, replace the FTS. Refer to section 24.3.6.

3. Measure resistance between sockets R3 and Y2 on the engine harness connector.
See Figure 24-3.
4. Measure resistance between socket R3 and a good ground (battery ground and chassis
ground).
[a] If resistance between sockets R3 and Y2, or R3 and battery ground, is less than or
equal to 10,000
, the signal line (#472) is shorted to the return line (#452) or battery
ground. Repair short. Refer to section 24.3.6.

[b] If resistance between sockets R3 and Y2 is greater than 10,000

or open, and
resistance between socket B and a good ground is greater than 10,000
or open,
Figure 24-3 Engine Harness Connector


[b] If terminals and connectors are not damaged, contact Detroit Diesel Technical
Service. Refer to section 24.3.6.

6. Stop engine.

25 FLASH CODE 25
Code 25 will be flashed to indicate that the DDEC system has no active or inactive codes. No
troubleshooting is required.
If using the DDR, the description will read:
No Active Codes or No Inactive Codes


26 FLASH CODE 26 - AUXILIARY INPUT ACTIVE
Flash Code 26 indicates that the Auxiliary Engine Shutdown #1 switch input to the ECM is active.
The active switch input represents a low (grounded) external input circuit to the ECM.
Indicates that the Auxiliary Engine Shutdown #2 switch input to the ECM is active. The active
switch input represents a low (grounded) external input circuit to the ECM.


3 s 025 11 - auxiliary shutdown #1 active
3 s 061 11 - auxiliary shutdown #2 active


1. Turn ignition ON. Start and run the engine.
2. Plug in DDR.
[a] If codes s 25-11 or s 61-11 are logged, refer to section 26.3.2.
[b] If codes s 25-11 and s 61-11 are not logged, refer to section 9.1.
26.3.2 Check Calibration Configuration
Perform the following steps to check the calibration configuration:

1. Select ECM input/output configuration.
2. Determine cavity and wire number that is causing code to be logged.
3. Select switch/light status.
4. Determine status of that wire/cavity.
[a] If the switch reads OFF, refer to section 26.3.3.
[b] If the switch reads ON, the OEM supplied switch/relay is grounding the wire or
a short to ground exists. Determine OEM supplied device or repair the short.
[c] If no OEM device is used, remove the wire from the connector and plug, or use
programming station to disable the function.
26.3.3 Confirm Switch Status
Perform the following steps to confirm switch status:

2. Again, read switch status.
[a] If the switch reads OFF, the condition no longer exists. Contact the OEM to learn
which item is wired to this cavity. Refer to section 26.3.4.
[b] If the switch reads ON, the OEM supplied device is grounding this wire. Contact
the OEM for repair procedure. Refer to section 26.3.4.


3. Note status of CEL/SEL.
4. If CEL/SEL not on, start and run the engine for one minute.
5. Read active and inactive codes.
[b] If codes 25 or 61-11 and any other codes are logged, all system diagnostics
are complete. Review this section from the first step to find the error.
[c] If codes 25 or 61-11 are not logged, but other codes are logged, refer to section 9.1.

27 (CHG) FLASH CODE 27 - AIR TEMP SENSOR HIGH

Flash Code 27 indicates that the engine Air Temperature Sensor (ATS), see Figure 27-1, input to
the ECM has exceeded 95% (normally >4.75 volts) of the sensor supply voltage.
NOTE:


The SAE J1587 equivalent code for Flash Code 27 is p 172 3, air temperature circuit high.

27.3.1 Sensor Check

2. Disconnect ATS connector.
3. Install a jumper wire between sockets A and B of the ATS harness connector.
See Figure 27-2.
5. Start and run engine for one minute (ensure oil temp is greater than 140 F).
[a] If code 172/4 or any other codes except 172/3 are logged, refer to section 27.3.2.
1. Turn ignition/engine OFF.


4. Measure resistance between sockets N2 and W1 on the engine harness connector.
See Figure 27-3.
[b] If the resistance measurement between sockets N2 and W1 is greater than 10
or
open, refer to section 27.3.3.
27.3.3 Check Air Temperature Sensor Connectors
Perform the following steps to check the ATS connectors.

1. Check terminals at the ATS connector (both sensor and harness side) for damage; bent,

[b] If terminals and connectors are not damaged, replace the ATS. Refer to section 27.3.6.

2. Disconnect the engine harness connector at the ECM. (Jumper still in place.)
3. Measure resistance between sockets N2 and Y2 on the engine harness connector.
See Figure 27-5.

[b] If the resistance measurement between sockets N2 and W1 is greater than 5

or open, the signal line #132 or return line #452 is open. Repair the open.

1. Check terminals at the ECM engine harness connector (both ECM and harness side) for
damage: bent, corroded and unseated pins or sockets. See Figure 27-6.

[b] If terminals and connectors are not damaged, contact Detroit Diesel Technical
Service. Refer to section 27.3.6.

4. Clear codes.
6. Stop engine.
Review this section to find the error. Refer to section 27.3.1.
[c] If any codes except code 172/3 are logged, refer to section 9.1.


28 (CHG) FLASH CODE 28 - AIR TEMP SENSOR LOW

28.1 DESCRIROMPTION OF FLASH CODE 28
Flash Code 28 indicates that the engine Air Temperature Sensor (ATS), see Figure 28-1, input to
the ECM has dropped below 5% (normally < 0.25 volts) of the sensor supply voltage.
3 Sensor signal circuit is shorted to sensor return
3 Sensor signal circuit is shorted to ground

The SAE J1587 equivalent code for Flash Code 28 is p 172 4, air temperature circuit low.


2. Plug in DDR.
[a] If code 172/4 was logged and there are no other codes logged, refer to section 28.3.2.
[b] If code 172/4 and any of the following codes 110/3, 175/3, 174/3, 72/3 or 102/3 were
logged, refer to section 90.1.
[c] If code 172/4 and any code except the following were logged 110/3, 175/3, 174/3,
72/3 or 102/3, refer to section 28.3.2.
28.3.2 Sensor Check

2. Disconnect the ATS connector. See Figure 28-2.
Figure 28-2 Engine Harness to Air Temperature Sensor Connector

3. Start engine and run until Check Engine light comes on, or for eight minutes.
4. With engine still running, read active codes.
[a] If code 172/4 and any other codes were logged, refer to section 28.3.4.
[b] If flash 172/3 and any other codes except 172/4 were logged, refer to section 28.3.3.
28.3.3 Check Air Temperature Sensor Connectors
Perform the following steps to check the ATS connector.

1. Check terminals at the ATS connector (both sensor and harness side) for damage; bent,
corroded and unseated pins or sockets.
[a] If terminals and connectors are not damaged, replace ATS. Refer to section 28.3.6.
[b] If terminals and connectors are damaged, repair/replace wires and

1. Turn the ignition OFF.
3. Measure resistance between sockets N2 and Y2 on the engine harness connector.
See Figure 28-3.
4. Measure resistance between socket N2 and a good ground.
[a] If the resistance measurement between sockets N2 and Y2 and between socket N2
and a good ground is greater than 10

[b] If the resistance measurement between sockets N2 and Y2, or N2 and battery
negative, is less than or equal to 10
, the signal line #132 is shorted to the return line
#452 or battery ground. Repair short. Refer to section 28.3.6.

1. Check terminals at the ECM harness connector (both ECM and harness side) for damage;
bent, corroded and unseated pins or sockets, especially N2 and Y2 of the ECM connector.
[a] If terminals or connectors are not damaged, contact Detroit Diesel Technical Services
[b] If terminals and connectors are damaged, repair them. Refer to section 28.3.6

4. Clear codes.

6. Stop engine.
[b] If code 172/4 is logged with any other codes, all system diagnostics are complete.
Review this section from the first step to find the error.

29 FLASH CODE 29
from DDC.


30 FLASH CODE 30
from DDC.


31 (CHG) FLASH CODE 31 - ENGINE BRAKE FAULT
CODE
Flash Code 31 indicates the engine brake low or medium circuit has an open or is shorted to
battery ground.
3 Output circuit open
3 Output wire is shorted to ground

The SAE J1587 equivalent code for Flash Code 31 is s 051 3/4 or s 052 3/4.

31.3.1 Check Configuration
Perform the following steps to check configuration.

1. If the unit has engine brakes, refer to section 31.3.2.
2. If the unit does not have engine brakes, the ECM is configured for engine brakes and
shouldn't be. Contact DDC with the engine serial number to have the data changed.
Reprogram the ECM after the change. Refer to section 31.3.10.
31.3.2 Determine Failure Mode
Perform the following steps to determine failure mode.

2. Plug the diagnostic data reader (DDR) into the diagnostic data link (DDL) connector.
3. Read SAE code (051 or 052).
[a] If the reading is FMI=3, there is an open. Refer to section 31.3.3.
[b] If the reading is FMI=4, there is a short to ground. Refer to section 31.3.7.
31.3.3 Determine Engine Type
Perform the following steps to determine engine type.

1. Is this a Series 55 engine?
[a] If yes, reprogram the ECM. Then, refer to section 31.3.10.
[b] If no, refer to section 31.3.4.

2. Disconnect 2-pin connector pigtail from engine brake harness.
3. Disconnect 30-pin engine harness connector.
4. Install a jumper wire between pins #561 and #562, ECM side.
5. Measure resistance between S3 (#561) and T3 (#562) of the engine harness connector.
[a] If measured resistance is less than 50

[b] If measured resistance is greater than 50

, one or both wires are open. Repair
open. Refer to section 31.3.10.
31.3.5 Check for Open (Inside Valve Cover)
Perform the following steps to check for open in the inside valve cover.
1. Reconnect the engine harness connector. See Figure 31-1.
2. Relocate the jumper to pins A and B of the brake harness connector (brake side).
3. Remove rocker cover.
4. Disconnect the two #621 leads and the one #622 lead from the brake solenoids.
5. Measure resistance between both #621 wires and #622 wire.
or open, an open exists in one of the
wires where the check was made. Repair open or replace the injector harness.

[b] If measured resistance is less than 50

Figure 31-1 Engine Brake Harness Schematic
31.3.6 Check for Cylinder Block Ground
Perform the following steps to check for cylinder block ground.

1. If the cylinder block is connected to the battery ground, refer to section 31.3.9.
2. If the cylinder block is not connected to the battery ground, install a ground strap from the
cylinder block to the battery negative (-). Refer to section 31.3.10.



3. Measure resistance between S3 (#561) and a battery ground, and S3 (#561) and the engine
block. Repeat this check between T3 (#562) and battery ground, and T3 (#562) and
the engine block.
[a] If resistance for all measurements is greater than 5
[b] If any measured resistance is less than 5
, the wire where the measurement
was read is shorted to ground or to the engine. Repair short or replace the wire.
Perform the following steps to check for a short between wires.

1. Measure resistance between S3 (#561) and T3 (#562).
, the S3 and T3 wires are shorted to each
other. Repair short. Refer to section 31.3.10.
31.3.9 Check Brake Solenoids
Perform the following steps to check for brake solenoids.

1. Check brake solenoids. Refer to OEM guidelines.
[a] If the solenoids are in good condition, contact Detroit Diesel Technical Service.
[b] If the solenoids are damaged, repair or replace them. Refer to section 31.3.10.

1. Connect any connectors removed for troubleshooting.
2. Start and run the engine. (Operate the engine brake.)
[a] If no lights come on, and no codes are logged, the repairs are complete. No further
troubleshooting is required.
[b] If Check Engine Light displays with codes s 051 3/4 or 052 3/4, review this section to

32 FLASH CODE 32 - CEL / SEL FAULT
Flash Code 32 indicates that the wire for the SEL or CEL is open or shorted to Battery +.
3 Open/broken output wire
3 Shorted output wire

The SAE J1587 equivalent code for Flash Code 32 is:

3 s 238/3 SEL short to battery
3 s 238/4 SEL open circuit
3 s 239/3 CEL short to battery
3 s 239/4 CEL open circuit

32.3.1 Determine Failure Mode Identifier (3 or 4)
Perform the following steps to determine FMI.

2. Plug in diagnostic data reader (DDR) into the diagnostic data link (DDL).
3. Read codes.
[a] If code 238/4 or 239/4 is logged, reprogram the ECM. Refer to section 32.3.3.
[b] If code 238/3 or 239/3 is logged, refer to section 32.3.2.
Perform the following steps to determine failure.

2. Disconnect vehicle harness connector.
4. Remove CEL bulb and SEL bulb.
5. Measure voltage between B2 (#509) and a good ground. See Figure 32-1.

6. Measure voltage between B1 and a good ground.

[a] If either measurement was greater than 0.5 volts, the wire that had the reading is
shorted to some voltage source. Replace the wire(s). Refer to section 32.3.3.
[b] If no measurement was greater than 0.5 volts, contact Detroit Diesel Technical
Service.

3. Plug the diagnostic data reader (DDR) into the diagnostic data link (DDL). Read codes.
[a] If active code 32 is logged, review this section to find the error. Refer to section 32.1.
[b] If code 32 is not logged, troubleshooting is complete.

33 (CHG) FLASH CODE 33 - TBS HIGH

Flash Code 33 indicates that the engine Turbo Boost Sensor (TBS), see Figure 33-1, input to the

The SAE J1587 equivalent code for Flash Code 33 is p 102 3.


1. Plug the diagnostic data reader (DDR) into the diagnostic data link (DDL).
[a] If code 102/3 and no other codes were logged, refer to section 33.3.2.
[b] If any of the following codes are also present: 72/3 or 4, 73/3 or 4, 94/3 or 4, 100/3 or
4, 101/3 or 4, 110/3 or 4, 174/3 or 4, 175/3 or 4, refer to section 90.1.
33.3.2 Sensor Check

2. Disconnect the TBS connector. See Figure 33-2.
3. Start and run the engine at idle.
4. Read active codes logged.

[b] If active code 102/4 and any other codes except 102/3 are logged,

1. Turn ignition switch OFF.
2. Install a jumper wire between pin A and pin B of the TBS harness connector.
See Figure 33-3.
3. Disconnect the engine harness connector at the ECM. See Figure 33-4.
4. Measure resistance between sockets P1 and Y2 on the engine harness connector.

[b] If resistance measurement is greater than 5

, the return line #452 is open. Repair the
open. Refer to section 33.3.8.

33.3.4 Check Turbo Boost Sensor Connectors
Perform the following steps to check the TBS connectors.

1. Check terminals at the TBS connector (both sensor and harness side) for damage: bent,
[b] If the terminals and connectors are not damaged, replace the TBS.
Perform the following steps to check for a short to the +5 volt line:
2. Disconnect engine harness connector from the ECM.
3. Measure resistance between sockets P1 and W1 on the engine harness connector.
See Figure 33-6.
[a] If measured resistance is less than or equal to 10,000
shorted to the engine +5 volt line #416. Repair short. Refer to section 33.3.8.

[b] If measured resistance is greater than 10,000

Perform the following steps to check for a short to the battery (+):
2. Disconnect the vehicle harness and 5-way power connector harness at the ECM.
See Figure 33-7.
3. Measure resistance between sockets P1 of the engine harness connector and B3 on the
vehicle harness connector.
4. Measure resistance between socket P1 on the engine harness connector and the 5-way
power harness connector sockets A and C.
sockets where the measurement was taken. Repair short and reinsert fuses, or reset
breakers. Refer to section 33.3.8.



1. Check terminals at the ECM engine harness connector (both the ECM and harness side)
for damage: bent, corroded, and unseated pins or sockets.
[a] If terminals and connectors are damaged, repair both. Refer to section 33.3.8.
[b] If terminals and connectors are not damaged, reprogram the ECM.

4. Clear codes.
6. Stop engine.


[c] If code 102/3 is logged, and other codes are logged, refer to section 33.3.1.


34 (CHG) FLASH CODE 34 - TBS LOW

Flash Code 34 indicates that the engine Turbo Boost Sensor (TBS), see Figure 34-1, input to the
3 Sensor +5 volt supply is shorted to the sensor return circuit or ground



1. Plug the diagnostic data reader (DDR) into the diagnostic data link (DDL) connector.
[a] If code 102/4 was logged and there are no other logged codes, refer to section 34.3.2.
[b] If code 102/4 and any of the following codes 72/3 or 4, 73/3 or 4, 94/3 or 4, 100/3 or
4, 101/3 or 4, 110/3 or 4, 174/3 or 4, 175/3 or 4, were logged, refer to section 90.1.
[c] If code 102/4 was logged and none of the following codes 72/3 or 4, 73/3 or 4,
94/3 or 4, 100/3 or 4, 101/3 or 4, 110/3 or 4, 174/3 or 4, 175/3 or 4, were logged,
34.3.2 Sensor Check

2. Disconnect TBS connector.
3. Install a jumper wire between sockets B and C of the TBS harness connector.
See Figure 34-2.
5. Start engine and run until either the Check Engine Light is on, or until the engine has been
running at least one minute at greater than 1000 r/min.

[b] If active code 102/3 and any other codes except 102/4 are logged,
Figure 34-2 Turbo Boost Sensor Schematic
34.3.3 Check Turbo Boost Sensor Connectors
Perform the following steps to check the TBS connector.

1. Check terminals at the TBS connectors (both the TBS and harness side) for damage:
bent, corroded and unseated pins or sockets.
[b] If the terminals and connectors are not damaged, replace the TBS.
34.3.4 Check for +5 Volt
Perform the following steps to check for +5 volt.

1. Remove jumper.
3. Measure voltage on TBS harness connector, pin C (red lead) to pin A (black lead).
[a] If the voltage measurement is greater than 6 volts, refer to section 34.3.10.
[b] If the voltage measurement is between 4 and 6 volts, refer to section 34.3.5.
[c] If the voltage measurement is less than 4 volts, refer to section 34.3.8.

Perform the following steps to check for signal open.

3. Install a jumper wire between pins A and B of the TBS harness connector. See Figure 34-3.
, or open, and the signal line (#432)
is open, repair the open. Refer to section 34.3.11.
Perform the following steps to check for short.

1. Remove jumper.
2. Measure resistance between pins A and B on the TBS harness connector.
[a] If measured resistance between pins A and B is greater than 100
, or open, go
to step 3
[b] If measured resistance between pins A and B is less than 100
, the signal line (#432)
is shorted to the return line (#452). Repair the short. Refer to section 34.3.11.

3. Also measure resistance between socket B and a good ground.

[a] If measured resistance between socket B and a good ground is greater than 100
, or
[b] If measured resistance between socket B and a good ground is less than 100

, the signal line (#432) is shorted to the battery ground. Repair the short and

1. Check terminals at the ECM harness connector (both ECM and harness side) for damage:
bent, corroded, and unseated pins or sockets. See Figure 34-4.
[a] If terminals and connectors are damaged, repair them and refer to section 34.3.11.
Figure 34-4 Engine Harness Connector to Turbo Boost Sensor
Perform the following steps to check for open +5 volt line.

2. Disconnect the engine harness connectors at the ECM.
3. Install a jumper wire between pins A and C of the TBS harness connector. See Figure 34-5.

4. Read resistance between sockets W1 and Y2 on the engine harness connector.

, or open, the vehicle +5 volt line
(#416) is open. Repair open. Refer to section 34.3.11.

1. Remove jumper.
2. Measure resistance between pins A and C on the TBS harness connector. See Figure 34-6.
[a] If measured resistance between pins A and C is greater than 100
, or open, go
to step 3
[b] If measured resistance between pins A and C is less than 100
, the 5 volt supply
(#416) is shorted to the return line (#452). Repair the short. Refer to section 34.3.11.
3. Also measure resistance between socket C and a good ground.
[a] If measured resistance between socket C and a good ground is greater than 100
, or

[b] If measured resistance between socket C and a good ground is less than 100
,
the 5 volt supply (#416) is shorted to the battery ground. Repair the short and
Perform the following steps to check for short to battery +.

3. Disconnect the engine harness, vehicle harness, and 5-way power connectors at the ECM.
4. Measure resistance between socket W1 on the engine harness connector and socket B3 of
the vehicle harness connector, and between W1 and the 5-way power harness sockets A
and C. See Figure 34-7.
[a] If measured resistance is less than or equal to 100
sockets where less than 100
was measured. Repair short and reinsert fuses.



4. Clear codes.
6. Stop engine.
[a] If no codes are logged, no further troubleshooting is required.
Please review this section from the first step to find the error. Refer to section 34.3.1.
[c] If code 102/4 is not logged and any other codes are logged, refer to section 9.1.


35 FLASH CODE 35 - OPS HIGH

Flash Code 35 indicates that the engine Oil Pressure Sensor (OPS), see Figure 35-1, input to the
3 Failed/damaged sensor

The SAE J1587 equivalent code for Flash Code 35 is p 100 3, oil pressure circuit high.
NOTE:
Code 35 is logged if oil pressure is high, engine is warm, and engine is at idle.


3. Turn vehicle ignition to OFF.
[b] If code 100/3 and any of the following codes were logged: 73/3 or 4, 94/3 or 4, 100/4,
101/3 or 4, 102/3 or 4, 110/3 or 4, 174/3 or 4, 175/3 or 4, refer to section 90.1.
35.3.2 Sensor Check

2. Disconnect OPS connector.
5. Select engine temperature (COOLANT TEMP or OIL TEMP) on the DDR.
6. Warm up engine until engine temperature reading is greater than 60C (140F).
7. After warm-up, let engine run at idle.
[a] If active code 100/3 and any other codes were logged, refer to section 35.3.5.
[b] If code 100/4 and any other codes except 100/3 were logged, refer to section 35.3.3.

3. Install a jumper wire between pin A and pin B of the OPS harness connector.
See Figure 35-2.


, the return line (#452) is open. Repair
the open and refer to section 35.3.8.
Figure 35-2 Engine Harness Connector to Oil Pressure Sensor
35.3.4 Check Oil Pressure Sensor Connectors
Perform the following steps to check the OPS connectors.

1. Check terminals at the OPS connectors (both the sensor and harness side) for damage:
[a] If the terminals and connectors are damaged, repair them and refer to section 35.3.8.
[b] If the terminals and connectors are not damaged, replace the OPS.
35.3.5 Check for Signal Short to 5 Volt

3. Measure resistance between sockets P2 and W1 on the engine harness connector.
See Figure 35-3.


Perform the following steps to check for a short to battery (+).

2. Disconnect the vehicle harness and 5-way power connectors at the ECM. See Figure 35-4.
3. Measure resistance between socket P2 on the engine harness connector and socket B3
of the vehicle harness connector, and between P2 and the 5-way power harness sockets
A and C.
[a] If resistance measurement is greater than 100

[b] If resistance measurement is less than or equal to 100

35.3.7 Check ECM Connector
Perform the following steps to check the ECM connector:

1. Inspect the terminals at the ECM connector (ECM and harness side) for damage: bent,
corroded, and unseated pins or sockets.
[a] If the terminals and connector are damaged, repair both and refer to section 35.3.8.
[b] If the terminals and connector are not damaged, refer to section 35.3.4.

4. Clear codes.
6. Stop engine.

7. Check codes with DDR.

[b] If code 100/3 is not logged, but other codes are logged, refer to section 9.1.
[c] If code 100/3 is logged, all system diagnostics are complete. Contact Detroit Diesel
Technical Service.


36 FLASH CODE 36 - OPS LOW

Flash Code 36 indicates that the engine Oil Pressure Sensor (OPS), see Figure 36-1, input to the
3 Sensor +5 volt supply is shorted to the sensor return circuit

The SAE J1587 equivalent code for Flash Code 36 is p 100 4, oil pressure circuit low.


[b] If code 100/4 was logged and none of the following codes were logged: 110/3
or 4, 174/3 or 4, 175/3 or 4, 101/3 or 4, 102/3 or 4, 73/3 or 4, 94/3 or 4, 100/3,
[c] If code 100/4 and any of the following codes were logged: 110/3 or 4, 174/3 or 4,
175/3 or 4, 101/3 or 4, 102/3 or 4, 73/3 or 4, 94/3 or 4, 100/3, refer to section 90.1.
36.3.2 Sensor Check

2. Disconnect OPS connector and install a jumper wire between sockets B and C of the
OPS harness connector. See Figure 36-2.
5. If active codes 100/3 or 4 were logged, proceed with the following:
6. If active codes 100/3 or 4 were not logged, warm up engine until either codes are logged
or the engine temperature (COOLANT TEMP or OIL TEMP or DDR) has been greater
than 60C (140F) for one minute.

36.3.3 Check Oil Pressure Sensor Connectors
Perform the following steps to check the OPS connectors.

2. Check terminals at the OPS connectors (both the sensor and harness side) for damage:
[b] If the terminals and connectors are not damaged, replace the OPS.
Perform the following steps to check for +5 volts.

4. Measure voltage on OPS harness connector, socket C (red lead) to socket A (black lead).
[a] If the voltage measurement is less than 4 volts, refer to section 36.3.8.
[b] If the voltage measurement is greater than 6 volts, refer to section 36.3.10.

[c] If the voltage measurement is between 4 and 6 volts, refer to section 36.3.5.

2. Disconnect the engine harness connector at the ECM. See Figure 36-3.
3. Install a jumper wire between sockets A and B of the OPS harness connector.
4. Measure resistance between sockets P2 and Y2 on the engine harness connectors.
or open, the signal line (#530) is
open. Repair the open and refer to section 36.3.12.

2. Measure resistance between socket P2 and a good ground. Also measure resistance
between P2 and Y2.
[a] If both resistance measurements are greater than 100
or open, replace OPS.

[b] If either resistance measurement is less than 100

, the signal line (#530) is shorted
to the return line (#452) or battery ground. Repair short and refer to section 36.3.12.
Perform the following steps to check ECM connectors.

bent, corroded and unseated pins or sockets. Check W1, P2 and Y2 terminals and pins
at ECM.
[b] If the terminals and connectors are not damaged, reprogram the ECM.

3. Install a jumper wire between pins A and C of the OPS connector.
4. Measure resistance between sockets W1 and Y2 on the engine harness connector.
or open, the engine +5 volt line
(#416) is open. Repair the open and refer to section 36.3.12.

2. Measure resistance between sockets A and C on the OPS harness connector. Also measure
resistance between socket C and a good ground.
[a] If either resistance measurement is less than or equal to 100
, the engine +5 volt
line (#416) is shorted to the return line (#452) or battery ground. Repair the short
or open, replace OPS and
Perform the following steps to check for a short to battery.


3. Measure resistance between socket W1 on the engine harness connector and socket B3
of the vehicle harness connector, and between W1 and the 5-way power harness sockets
A and C.
, or open, replace OPS.
Perform the following steps to check for a short to ground.

See Figure 36-5.


, the signal line (#530) and
return line (#452) are shorted together. Repair the short. Refer to section 36.3.12.

4. Clear codes.
6. Stop engine.
[c] If code 100/4 is logged, and other codes are logged, all system diagnostics
are complete. Please review this section from the first step to find the error.

37 FLASH CODE 37 - FPS HIGH

Flash Code 37 indicates that the engine Fuel Pressure Sensor (FPS), see Figure 37-1, input to the
NOTE:
Require fuel pressure >60 psi.



[a] If active code 94/3 was logged, and no other codes were logged, refer to section 37.3.2.
[b] If active code 94/3 and any or all of the following codes were logged, 110/3 or
4, 174/3 or 4, 175/3 or 4, 101/3 or 4, 102/3 or 4, 100/3 or 4, 94/4, 73/3 or 4,
37.3.2 Sensor Check

2. Disconnect FPS connector. See Figure 37-2.
4. Start and run engine.
5. Select Engine Temperature (COOLANT TEMP & OIL) on DDR.
6. Warm up engine until engine temperature reading is greater than 60C (140F).
7. Leave engine running at idle after warm-up. Run for five minutes.

[b] If active code 94/4 and any other codes except 94/3 were logged,
Figure 37-2 Engine Harness Connector to Fuel Pressure Sensor

3. Install a jumper wire between pins A and B of the FPS harness connector.
4. Measure resistance between sockets M1 and Y2 on the engine harness connectors.
, or open, the return line (#452) is open.
Repair the open and refer to section 37.3.9.
37.3.4 Check Fuel Pressure Sensor Connectors
Perform the following steps to check the FPS connectors.

1. Inspect terminals at the FPS connectors (both the sensor and harness side) for damage:
bent, corroded, and unseated pins or sockets.

[b] If the terminals and connectors are not damaged, replace the FPS and

3. Measure resistance between sockets W1 and M1 on the engine harness connector.

3. Measure resistance between socket M1 on the engine harness connector and socket B3
of the vehicle harness connector, and between M1 and the 5-way power harness sockets
A and C.


sockets where less than 1,000
37.3.7 Final Check
Perform the following steps to do a final check.

3. Clear codes.
5. Stop engine.
[b] If active code 94/3 is logged, reprogram the ECM. Refer to section 37.3.9.
37.3.8 Check ECM Connector
Perform the following steps to check the ECM connector.

1. Inspect terminals at the ECM connector (both the ECM and harness side) for damage:
[b] If terminals and connectors are not damaged, replace the FPS. Refer to section 37.3.7.

4. Clear codes.
6. Stop engine.


38 FLASH CODE 38 - FPS LOW

Flash Code 38 indicates that the engine Fuel Pressure Sensor (FPS), see Figure 38-1, input to the
3 Sensor +5 volt supply is shorted to the sensor return circuit



[a] If active code 94/4 and no other codes were logged, refer to section 38.3.2.
[b] If active code 94/4 and any or all of the following codes were logged, 94/3, 100/3 or
4, 101/3 or 4, 110/3 or 4, 174/3 or 4, 175/3 or 4, refer to section 90.1.
[c] If active code 94/4 and codes other than the following codes were logged, 94/3, 100/3
or 4, 101/3 or 4, 110/3 or 4, 174/3 or 4, 175/3 or 4, refer to section 38.3.2.
38.3.2 Sensor Check

2. Disconnect FPS connector and install a jumper wire between sockets B and C of the
FPS harness connector. See Figure 38-2.
5. If active codes 94/3 or 4 are not logged, start and run the engine until either these active
codes display or engine temperature (COOLANT TEMP & OIL on DDR) has been greater
than 60C (140F) for more than one minute.

[b] If active code 94/3 and any other codes except code 94/4 are logged, check to ensure
ECM and FPS connectors are wired properly. Refer to section 38.3.3.
38.3.3 Check Fuel Pressure Sensor Connectors
Perform the following steps to check the FPS connectors.

1. Inspect terminals at the FPS connectors (both the sensor and harness side) for damage:
[b] If the terminals and connectors are not damaged, replace the FPS and

4. Measure voltage on FPS harness connector, socket C to socket A. See Figure 38-3.
[a] If the voltage measurement is greater than 6 volts, refer to section 38.3.9.
[b] If the voltage measurement is less than 4 volts, refer to section 38.3.7.

[c] If the voltage measurement is between 4 and 6 volts, refer to section 38.3.5.

3. Install a jumper wire between pins A and B of the FPS harness connector.
4. Measure resistance between sockets M1 and Y2 on the engine harness connector.
return line (#452) is open. Repair the open and refer to section 38.3.12.

bent, corroded, and unseated pins or sockets. Check W1, M1 and Y2 terminals at ECM.


3. Install a jumper wire between sockets A and C of the FPS harness connector.
See Figure 38-4.
4. Measure resistance between sockets W1 and Y2 on the engine harness connector.
or open, the engine +5 volt line
(#416) is open. Repair the open and refer to section 38.3.12.

2. Measure resistance between sockets A and C of the FPS harness connector.
, the return line (#452) is


3. Measure resistance between socket W1 on the engine harness connector and socket B3
of the vehicle harness connector, and between W1 and the 5-way power harness sockets
A and C.
sockets where less than 1,000

2. Remove jumper wires.
3. Measure resistance between sockets M1 and Y2 on the engine harness connector. Also
measure resistance between socket M1 and a good ground.

[a] If both resistance measurements are greater than 100

or open,
[b] If either resistance measurement is less than or equal to 100
, the signal line (#905)
and return line (#452) are shorted together, or the signal line (#905) is shorted to
battery ground. Repair the short. Refer to section 38.3.12.
38.3.11 Replace Fuel Pressure Sensor
Perform the following steps to replace the FPS.

2. Replace FPS.
5. Clear codes.
[a] If check engine light comes on, refer to section 38.3.6.
[b] If check engine light does not come on, refer to section 38.3.12.

4. Clear codes.
6. Stop engine.

39 FLASH CODE 39
from DDC.


40 FLASH CODE 40
from DDC.


41 (CHG) FLASH CODE 41 - TOO MANY SRS
Figure 41-1 Synchronous Reference Sensor and Timing Reference Sensor

Flash Code 41 indicates that the ECM has detected extra Synchronous Reference Sensor pulses,
or the ECM has detected missing Timing Reference Sensor pulses, see Figure 41-1.

The SAE J1587 equivalent code for Flash Code 41 is s 021 0.


2. Disconnect engine harness connector at the ECM. See Figure 41-2.
3. Read resistance between sockets T1 and T2 on the engine harness connector.
[a] If the resistance reading is less than or equal to 200
[b] If the resistance reading is greater than 200
Figure 41-2 Engine Harness Connector

1. Disconnect the TRS connector.
2. Measure resistance between sockets T1 and T2 on the engine harness connector.
See Figure 41-3.
3. Measure resistance between socket T1 and ground, and between socket T2 and ground.


#110 and #109 or where less than 10,000
resistance was read. Repair the short.
Figure 41-3 Engine Harness Connector to Timing Reference Sensor
41.3.3 Open Timing Reference Sensor Line Check
Perform the following steps to check the open TRS line.

2. Install a jumper wire between sockets A and B of the TRS harness connector.
, or open, the signal line #110 or
return line #109 is open. Repair the open. Refer to section 41.3.15.
41.3.4 Check Timing Reference Sensor Resistance
Perform the following steps to check TRS resistance.

1. Measure resistance of TRS across sensor connector pins A and B. See Figure 41-4.


41.3.5 Check Timing Reference Sensor / Synchronous Reference Sensor

Gap
Perform the following steps to check the TRS/SRS gap.

1. Bar the engine until the TRS is over a TRS tooth of the pulse wheel.
2. Check the gap between TRS and the tooth of the pulse wheel (0.020 to 0.040 in.). A
depth micrometer can be used.
[a] If the gap setting is correct, refer to section 41.3.6.
[b] If the gap setting is not correct, adjust the TRS/SRS until the gap setting is
correct. If the problem returns, the pulse wheel may be loose or bad or damaged.
41.3.6 Synchronous Reference Sensor Code Check
Perform the following steps to check for SRS code.

1. Check for SRS code.
[a] If code 21/1 is not logged, refer to section 41.3.7.

1. Check terminals at the ECM engine harness connectors (both the ECM and harness side)
for damage: bent, corroded, and unseated pins or sockets.
41.3.8 Synchronous Reference Sensor Resistance Check
Perform the following steps to check SRS resistance.

1. Measure resistance between sockets S1 and S2 on the engine harness connector.
See Figure 41-5.
[b] If measured resistance is less than 200
Figure 41-5 Engine Harness Connector to Synchronous Reference Sensor

1. Disconnect the SRS connector.
[a] If measured resistance is greater than 10,000

[b] If measured resistance is less than or equal to 10,000

shorted to the return line #112. Repair the short. Refer to section 41.3.15.
41.3.10 Open Synchronous Reference Sensor Line Check
Perform the following steps to check for an open SRS line.

2. Install a jumper wire between sockets A and B of the SRS harness connectors.
, or open, the signal line #111 or return line
#112 is open. Repair the open and refer to section 41.3.15.
41.3.11 Synchronous Reference Sensor Test
Perform the following steps to test the SRS.

1. Measure resistance of SRS across the sensor connector pins A and B.
[c] If measured resistance is between 100 and 200
41.3.12 Check Timing Reference Sensor Connectors
Perform the following steps to check TRS connectors.

1. Check terminals at the TRS (both the TRS and harness side) for damage: bent, corroded,

[b] If terminals and connectors are not damaged, replace the TRS. Refer to section 41.3.14.
41.3.13 Check Synchronous Reference Sensor Connectors
Perform the following steps to check the SRS connectors.

1. Check terminals at the SRS (both the SRS and harness side) for damage: bent, corroded,
and unseated pins or sockets, or bad contacts.
[b] If terminals and connectors are not damaged, replace the SRS. Refer to section 41.3.14.
41.3.14 Verify Synchronous Reference Sensor / Timing Reference Sensor
Perform the following steps to verify operation of the SRS/TRS.

3. Clear codes.
5. Stop engine.

[b] If code 21/0 and any other codes are logged, and the SRS was not replaced,

4. Clear codes.
6. Stop engine.
Review this section to find the error. Refer to section 41.3.1 or contact Detroit Diesel
Technical Service.


42 (CHG) FLASH CODE 42 - TOO FEW SRS
Figure 42-1 Synchronous Reference Sensor and Timing Reference Sensor

Flash Code 42 indicates that the ECM has detected missing Synchronous Reference Sensor (SRS)
pulses, or the ECM has detected extra Timing Reference Sensor (TRS) pulses, see Figure 42-1.


42.3.1 Resistance Check
Perform the following steps to check resistance.

2. Disconnect engine harness connector at ECM.
See Figure 42-2.

1. Disconnect the SRS Connector.
See Figure 42-3.
3. Measure resistance between socket S1 and ground, and between socket S2 and ground.


, a short exists. Repair
the short. Refer to section 42.3.16.
42.3.3 Open Synchronous Reference Sensor Line Check
Perform the following steps to check for an open SRS line.

2. Install a jumper wire between sockets A and B of the SRS harness connector.
See Figure 42-4.


Figure 42-4 Engine Harness Connector to Synchronous Sensor
42.3.4 Synchronous Reference Sensor Test
Perform the following steps to test the SRS.

1. Measure resistance of SRS across the sensor connector pins A and B.
42.3.5 Check Synchronous Reference Sensor Gap
Perform the following steps to check the SRS gap.

1. Bar engine until SRS is over the SRS pin.
2. Check the gap between SRS and the pin.
[a] If the gap setting is correct (0.020 - 0.040 in.), refer to section 42.3.6. A depth
micrometer can be used.
[b] If the gap setting is not correct, adjust the SRS until the gap setting is correct. If the
problem returns, the pulse wheel may be loose or bad. Refer to section 42.3.16.

42.3.6 Check for Timing Reference Sensor Code
Perform the following steps to check for TRS code.

1. Check for TRS code.
[a] If code 21/0 is not logged, refer to section 42.3.7.

1. Check terminals at the ECM engine harness connectors (both the ECM and harness side)
for damage: bent, corroded, and unseated pins or sockets. See Figure 42-5.
[b] If terminals and connectors are not damaged, refer to section 42.3.15.
Figure 42-5 Engine Harness Connector to Synchronous Sensor
42.3.8 Timing Reference Sensor Resistance Check
Perform the following steps to check TRS resistance.

1. Remove the engine harness connector.
See Figure 42-6.



[a] If measured resistance is greater than 10,000
[b] If measured resistance is less than or equal to 10,000
shorted to the return line (#109). Repair the short. Refer to section 42.3.16.
42.3.10 Open Timing Reference Sensor Line Check
Perform the following steps to check for an open TRS line.

2. Install a jumper wire between sockets A and B of the TRS harness connector.
See Figure 42-7.


, or open, the signal line (#110) or
42.3.11 Timing Reference Sensor Test
Perform the following steps to test the TRS.

1. Measure resistance of TRS across the sensor connector pins A and B.
42.3.12 Check Synchronous Reference Sensor Connectors
Perform the following steps to check the SRS connectors.

1. Check terminals at the SRS (both the SRS and harness side) for damage: bent, corroded,
and unseated pins or sockets, or a bad contact. See Figure 42-8.

[b] If terminals and connectors are not damaged, replace the SRS. Refer to section 42.3.14.
42.3.13 Check Timing Reference Sensor Connectors
Perform the following steps to check the TRS connectors.

1. Check terminals at the TRS (both the TRS and harness end) for damage: bent, corroded,
and unseated pins or sockets or bad contacts. See Figure 42-9.

[b] If terminals and connectors are not damaged, replace the TRS. Refer to section 42.3.14.
42.3.14 Verify Synchronous Reference Sensor / Timing Reference Sensor
Perform the following steps to verify operation of the SRS/TRS.

3. Clear codes.
5. Stop engine.
[b] If any codes except code 21/1 are logged, refer to section 9.1.
[c] If code 21/1 and any other codes are logged, and the TRS was not replaced,
[d] If code 21/1 and any other codes are logged, and the TRS was replaced,
42.3.15 Verify Cranking Voltage
Perform the following steps to verify cranking voltage.


3. Connect 12 volt from a fully charged battery to the 5-pin power connector.
See Figure 42-10.
4. Connect to ECM.
5. Start engine.
[a] If engine starts, check the battery. If a voltage equalizer is installed, check the
operation of the equalizer. If the equalizer is not working, refer to section 42.3.16.
[b] If the engine does not start, replace the ECM. Refer to section 42.3.16.
Figure 42-10 5-Way ECM Engine Power Connector

4. Clear codes.
6. Stop engine.


Review this section to find the error. Refer to section 42.3.1.

43 FLASH CODE 43 - COOLANT LEVEL LOW

Flash Code 43 indicates that the ECM has detected that the engine coolant level has dropped
below the recommended safe operating range, see Figure 43-1.
There is a significant difference between the coolant level sensors used in Detroit Diesel
Electronic Controls (DDEC) II and DDEC III applications.
3 Externally, the sensors physically look the same.
3 The sensor used for the DDEC II system has a black colored connector.
3 The sensor used for the DDEC III system has an off-white colored connector.
A coolant level module must be used with all coolant level sensors for DDEC II applications. All
DDEC III applications, except Volvo, do not require a coolant level module.


43.3.1 Coolant Level Low
Perform the following steps to diagnose the coolant level low.

1. Turn ignition ON; plug in DDR.
[a] If code 111-1 is logged, there is an indication of a low coolant level condition. Add
coolant to ensure coolant level probe is immersed in coolant.
[b] If code 111-1 remains active, refer to section 43.3.2.
43.3.2 Replace Coolant Level Sensor
Using the sensor tester may be of assistance. Use Tool J 37164.
NOTE:
When replacing the coolant level sensor, the CLS could be an OEM supplied part.
1. Turn ignition OFF; replace CLS.

[b] If codes are logged, refer to section 43.3.3.
43.3.3 Clean and Check Alternator Grounds
Perform the following steps to check the alternator ground.

1. If the grounds are clean and good, troubleshooting is complete.
2. If the grounds are damaged, repair the ground circuit and verify repairs.
Perform the following steps to verify repairs

4. Clear DDR codes.


6. Stop engine.
[b] If code 111/1, and any other codes are logged, refer to section 43.3.1, and repeat the
procedure, or contact Detroit Diesel Technical Service.
[c] If any code other than 111/1 is logged, refer to section 9.1.

44 FLASH CODE 44 - TEMP HIGH

Flash Code 44 indicates that the ECM has detected that the engine coolant temperature has
exceeded the recommended safe operating range. See Figure 44-1, for the sensor.
It also indicates that the ECM has detected that the engine oil temperature has exceeded the
recommended safe operating range. This normally occurs due to a mechanical fault.

The SAE J1587 equivalent code for Flash Code 44 is p 110 0, coolant temperature high.
The SAE J1587 equivalent code for Flash Code 44 is p 175 0, oil temperature high.

Perform the following steps to troubleshoot Flash Code 44.

2. Plug in the diagnostic data reader (DDR).
[a] If active codes other than 110/0 or 175/0 are logged, service them first.
[b] If active codes 110/0 or 175/0 are logged, and no other codes are logged, oil or
coolant temperature was higher than it should have been. Inspect for damage. Plug in
the reader and determine if code is coolant or oil temperature high.
[c] If active code 110/0 is logged, and the duration of this code is less than 20 seconds,
or if it has multiple occurrences which average less than 20 seconds each, contact
NOTE:
For information concerning high temperature levels, refer to section 4.1 in the service
manual.


45 FLASH CODE 45 - OIL PRESSURE LOW

Flash Code 45 indicates that the ECM has detected that the engine oil pressure has dropped below
the recommended safe operating range. See Figure 45-1 for the engine oil pressure sensor.
Conditions: ECM looks for a minimum pressure vs. speed. This can vary for each engine type.

The SAE J1587 equivalent code for Flash Code 45 is p 100 1, oil pressure low.


2. Plug in the diagnostic data reader (DDR)
[a] If codes other than 110/1 are logged, service them first.
[b] If code 110/1 is logged, and no other codes are logged, there was an engine running
condition at which oil pressure was lower than it should have been.
NOTE:
For information concerning low oil pressure level, refer to section 3.1 in the engine
service manual.


46 FLASH CODE 46 - BATTERY VOLTAGE LOW
Flash Code 46 indicates that the DDEC system has detected that the main battery supply voltage
to the ECM has dropped below the recommended operating range.
The DDEC system will operate on 12 or 24 volts.
3 Normal operating voltage of the DDEC system is 11 to 32 volts DC, measured at the ECM.
3 Operating the ECM between 6 and 11 volts may result in degraded engine operation.
(Transient operation in this range during engine starting is considered normal for 12-volt
systems.)
3 Operating the ECM over 32 volts will cause damage.
3 Reversing polarity will cause damage to the ECM if the power harness is not properly fused.


The power harness supplies 12 or 24 volts to the ECM. The system must be sourced directly
from the battery.
NOTE:
Connection to reverse polarity will damage the system if not properly fused.

46.3.1 Battery Check
Perform the following steps to check the battery.

2. Measure voltage on battery + terminal (red lead) to battery - terminal (black lead).
Recommended fuse applications are listed in Table 46-1. Power harness length criteria is
[a] If the engine does not start, inspect the battery and charging/starting system, and
proceed if okay. Refer to section 9.1.
[b] If the engine does start and the voltage measurement is less than or equal to 10.0
volts, service the discharged battery and charging/starting system.

[c] If the engine does start and the voltage measurement is greater than 10.0 volts,
Number of Cylinders Dual Fuse or Circuit Single Fuse or Circuit

Breaker Size Breaker Size
6 2 @ 15 amp 1 @ 30 amp
8 2 @ 20 amp 1 @ 40 amp
12 4 @ 15 amp 2 @ 30 amp
16 4 @ 20 amp 2 @ 40 amp
20 4 @ 15 amp2 @ 20 amp 2 @ 30 amp1 @ 40 amp
Table 46-1 Fuse Size Recommendations
Length from Minimum Wire Total Length from Minimum Wire Total
ECM to Size (Ga) * Resistance ECM to Size (Ga) † Resistance
Battery or Bus of Maximum Battery or Bus of Maximum
Bar (ft) * Length (m Bar (m) † Length (m

) *
) †
0 to 28 ‡ 12 24.8 0 to 6 ‡ 2.5 22.8
28 to 44 ‡ 10 24.57 6 to 10 ‡ 4 23.55
44 to 70 ‡ 8 24.58 10 to 14 ‡ 6 21.98
70 to 110 ‡ 6 24.7 14 to 26 ‡ 10 23.66
110 to 178 ‡ 4 25.0 26 to 40 ‡ 16 23.2
0 to 14 § 12 24.8 0 to 3 § 2.5 22.8
14 to 22 § 10 24.57 3 to 5 § 4 23.55
22 to 35 § 8 24.58 5 to 7 § 6 21.98
35 to 55 § 6 24.7 7 to 13 § 10 23.66
55 to 89 § 4 25.0 13 to 20 § 16 23.2
* United States
†International
‡ Dual Fuse
§ Single Fuse
Table 46-2 Maximum Resistance vs Power Harness Length
46.3.2 Voltage Check at ECM
Perform the following steps to check voltage at the ECM.

1. Keep engine running.
2. Select ECM INPUT VOLT on DDR.
3. Observe ECM voltage reading on DDR.

[a] If the voltage measurement is less than or equal to 10.0 volts, refer to section 46.3.3.
[b] If the voltage measurement is greater than 10.0 volts, refer to section 46.3.5.
46.3.3 Voltage Check at ECM Via Volt-Ohm Meter
Perform the following steps to check voltage at the ECM.

1. Turn the vehicle ignition OFF.
2. Disconnect 5-way power harness connector at the ECM.
3. Measure voltage from socket A and C (red lead) of 5-way power harness connector and
a good battery ground (black lead). Don't use line (#151) as a ground reference. For
5-way ECM power harness connector, see Figure 46-1. For power harness schematic,
see Figure 46-2.
[a] If the voltage measurement is less than or equal to 11.5 volts, refer to section 46.3.4.
[b] If the voltage measurement is greater than 11.5 volts, refer to section 46.3.5.

Figure 46-2 Power Harness
46.3.4 Check for Bad Battery + Line
Perform the following steps to check for a bad battery + line.

1. Remove fuse(s) to the ECM.

2. Measure voltage at socket A of one fuseholder (red lead) to a good ground (black lead).
For 5-way ECM power harness, see Figure 46-3.
3. Repeat voltage measurement at other fuseholder.
[a] If the voltage measurement is greater than 11.5 volts on both readings, the battery +
line between the fuseholder and ECM has an open, or the ECM power connector has
a corroded connection. Repair the problem. Refer to section 46.3.8.
[b] If the voltage measurement is less than or equal to 11.5 volts on either reading, the
battery + line near the battery is open, or a corroded connection exists at battery +
terminal. Repair the problem. Refer to section 46.3.8.
Figure 46-3 5-Way ECM Power Harness
46.3.5 Ground Check at ECM
Perform the following steps to check the ground at the ECM.

1. Disconnect the 5-way power harness connectors at the ECM. For 5-way ECM power
harness, see Figure 46-3.
2. Measure voltage on socket A (red lead) to socket D (black lead) and socket C of 5-way
power harness connector (red lead) to socket E, (black lead).
[a] If voltage measurement is greater than 11.5 volts on either reading,
[b] If the voltage measurement is less than or equal to 11.5 volts on either reading, the
ground wire (#150) is open or has a corroded connection. Repair ground wire, and


1. Check terminals at the ECM 5-way power harness connector (both ECM and harness side)
for damage; bent, corroded, and unseated pins or sockets.
[a] If terminals and connector are damaged, repair them. Refer to section 46.3.8.
[b] If terminals and connector are not damaged, verify the power and ground are wired
directly to the battery. Refer to section 46.3.7.
46.3.7 Code Check

1. Install the vehicle interface module.
2. Turn ignition ON; plug in DDR.
3. Check for codes.
[a] If code reoccurs, install test ECM, then refer to section 46.3.8.
[b] If code does not reoccur, check power harness wires for breaks, abrasions, etc.
Then refer to section 46.3.8.

6. Stop engine.
[c] If code 168/1 is logged, and other codes are logged, all system diagnostics are
complete. To troubleshoot the error, refer to section 46.3.1.

47 (CHG) FLASH CODE 47 - AIR / FUEL PRESSURE
HIGH

Flash Code 47 indicates that the ECM has detected that the fuel pressure, air inlet pressure, or
turbo boost pressure has exceeded a programmed operating range. This normally occurs due to
a mechanical fault in the air system or fuel system of the engine. See Figure 47-1, for the fuel
pressure sensor.
NOTE:
Not all engines use a fuel pressure sensor.
For gas engines, code 47 indicates that the air inlet pressure has exceeded a calibration limit
programmed in the ECM.
For diesel engines, code 47 indicates that the turbo boost pressure has exceeded a calibration limit
programmed in the ECM.

The SAE J1587 equivalent code for Flash Code 47 is p 094/0, fuel pressure high.
The SAE J1587 equivalent code for Flash Code 47 is p 106/0, air inlet pressure high (Gas-fueled
engines).
The SAE J1587 equivalent code for Flash Code 47 is p 102/0, turbo boost pressure high
(Diesel-fueled engines).

This code is a mechanical fault. Check for reasons for high fuel pressure. Refer to appropriate
service manual, section 5.
This (Gas-fueled engine) code is a mechanical fault. Check for reasons for high air inlet pressure.
Refer to appropriate service manual, section 6.
This (Diesel-fueled engine) code is a mechanical fault. Check for reasons for high turbo boost
pressure, e.g. wastegate bypassed. Refer to appropriate service manual, section 6.


48 (CHG) FLASH CODE 48 - AIR / FUEL PRESSURE
LOW

Flash Code 48 indicates that the ECM has detected that the Fuel Pressure has dropped below a
programmed limit. This condition is normally associated with a restriction in the fuel supply
system:
3 Plugged fuel filter
3 Low fuel supply
NOTE:
Not all engines use a fuel pressure sensor, see Figure 48-1.
For gas engines, code 48 indicates that the air inlet pressure has dropped below a calibration limit.

The SAE J1587 equivalent code for Flash Code 48 is p 094/1, fuel pressure high.
The SAE J1587 equivalent code for Flash Code 48 is p 106/1, air inlet pressure low. (Gas-fueled
engines)

This code is a mechanical fault. Check for reasons for low fuel pressure. Refer to appropriate
service manual, section 5.
This (Gas-fueled engine) code is a mechanical fault. Check for reasons for low air inlet pressure.
Refer to appropriate service manual, section 6.


49 FLASH CODE 49
from DDC.


50 FLASH CODE 50
from DDC.


51 (CHG) FLASH CODE 51
from DDC.


52 (CHG) FLASH CODE 52 - ECM FAULT
Flash Code 52 indicates that the DDEC system ECMs internal Analog to Digital (A/D) Convertor
device has malfunctioned. Intermittent diagnostic conditions of this type can be caused by faulty
external electrical system.



[a] If active codes other than 254/12 are logged, service them first.
[b] If active code 254/12 is logged, and no other codes are logged, hook up test ECM.
If code clears, replace the ECM. If code is not cleared, contact Detroit Diesel
Technical Service.
NOTE:
For information concerning ECM replacement, refer to section 2.9 in the service manual.


53 FLASH CODE 53 - ECM MEMORY FAULT
Flash Code 53 indicates that the ECM was unable to read a valid copy of an engine data record
(calibration, faults, or accumulators) stored in nonvolatile memory.
Flash Code 53 also indicates that the ECM was unable to update an engine data record
(calibration, faults, or accumulators) stored in nonvolatile memory.

The SAE J1587 equivalent code for Flash Code 53 is s 253 12, EEPROM write fail.
The SAE J1587 equivalent code for Flash Code 53 is s 253 2, nonvolatile checksum incorrect.

NOTE:
Inactive code 53 should be cleared with the DDR and the unit returned to service if
ECM SW is greater than or equal to 7.00.

[a] If codes other than 253/12 or 253/2 are logged, service them first.
[b] If codes 253/12 or 253/2 are logged, and no other codes are logged, reprogram the
ECM. Refer to section 53.3.2.
53.3.2 Test for Codes
Perform the following steps to test for codes.

2. Read active codes with DDR.
[a] If active code 253/2 is logged, and no other codes are logged, install a test ECM.
NOTE:
It is recommended that a "Test" ECM be tried first to determine the need to replace the
ECM. For information concerning ECM replacement, refer to section 2.9 in the service
manual.
[b] If no codes are logged, troubleshooting is complete.

[b] If codes are logged, contact Detroit Diesel Technical Service.


54 FLASH CODE 54 - VSS FAULT
Flash Code 54 indicates that during engine operation the vehicle speed that is measured
by the Vehicle Speed Sensor (VSS) is less than the expected value for the current engine
speed/conditions.
3 Conditions
3 Code is logged (without anti-tamper) when the mph >1500 and PW >15 and vehicle
speed < 3 mph.
3 If code is logged (with or without anti-tamper) mph will be limited.
NOTE:
Code will not be logged for the first five hours of ECMs life (total engine hours).


54.3.1 Test Drive Vehicle
Take the vehicle for a test drive with an assistant.

1. View DDR; select vehicle speed.
[a] If mph reads 0 (zero), or stays steady with the vehicle in motion, refer to section 54.3.2.
[b] If speed appears correct, refer to section 54.3.11.
54.3.2 Speed Sensor Identification
Identify the speed sensor type - type one or type two.

1. The type one sensor is a magnetic pickup and may be located in one of the following
locations: transmission tail shaft, wheel rim, mechanical speedometer cable. If you have a
type one sensor, refer to section 54.3.3. (Verify with DDR signal type - magnetic.)
2. The type two sensor communicates with square wave input and output signals and requires
the ECM to be configured correctly. Refer to section 54.3.12. (Verify with DDR signal
type - switched.)
54.3.3 Check Vehicle Speed Sensor Circuit
Perform the following steps to check the vehicle speed sensor.

1. With ignition off, disconnect the vehicle harness connector.
2. Measure resistance of VSS circuit across vehicle harness connector pins, E2 to E3.
See Figure 54-1.

[c] If the resistance measurement is between 50 and 3,000


1. Disconnect VSS connector.
2. Measure resistance between vehicle harness connector terminals E2 and E3.
See Figure 54-1.
, the signal wire #556 or
return wire #557, are shorted together. Repair the short; refer to section 54.3.13.
54.3.5 Check Vehicle Speed Sensor
Perform the following steps to check the vehicle speed sensor.

1. Measure resistance of VSS across vehicle speed sensor connector pins. See Figure 54-1.
[c] If the resistance measurement is between 50 and 3,000


1. Disconnect the ECM vehicle harness connector and VSS connector.
2. Install a jumper wire between sockets A and B of the VSS harness connector.
3. Measure resistance between sockets E2 and E3 on the ECM vehicle harness connector.
See Figure 54-2.
or open, the VSS signal line #556 or
return line #557 is open. Repair open and refer to section 54.3.13.
Perform the following steps to check for short to ground.

3. Measure resistance between sockets E2 and E3 and a good ground. See Figure 54-3.


, the signal wire #556 or
return wire #557, is shorted to ground, or wired to an unauthorized device. Repair the
short; refer to section 54.3.13.
54.3.8 Check Vehicle Speed Sensor Connectors
Perform the following steps to check the VSS connectors.

1. Check terminals at the VSS connectors (both sensor side and harness side) for bent,
[a] If the terminals and connectors are not damaged, replace the VSS.
54.3.9 Check for Short to Power
Perform the following steps to check for short to power.

2. Measure voltage at the ECM vehicle harness connector between socket E3 (#557) and
a good ground. Also measure voltage between socket E2 (#556) and a good ground.
See Figure 54-4.
[a] If both voltage measurements are less than 0.2 volts, refer to section 54.3.10.

[b] If either voltage measurement is greater than or equal to 0.2 volts, the VSS signal
(#556) or VSS return line (#557) is shorted to the battery or some other source of
voltage. Repair the short; refer to section 54.3.13.

1. Check the terminals at the ECM engine harness connectors for bent, corroded, and
unseated pins or sockets, on both the ECM and harness sides. See Figure 54-5.
[a] If the terminals and connectors are not damaged, refer to section 54.3.11.

54.3.11 Vehicle Speed Mechanical Checks
Perform the following vehicle speed mechanical checks.

1. Check for plugged fuel filters.
2. Check if any metal or debris is lodged between the VSS and the pulse wheel.
3. Check if the sensor is loose.
4. Ensure the VSS pulse wheel is in fixed position relative to magnetic pickup.
5. Check for proper air gap between magnetic pickup and pulse wheel.
[a] If all mechanical checks are okay, contact Detroit Diesel Technical Service for review
if anti-tamper = yes.
[b] If all mechanical checks are not okay, repair the mechanical failure.

2. Disconnect the ECM vehicle harness connector.
3. Measure resistance between sockets E2 and a good ground. See Figure 54-6.


or open, contact the
component supplier for instructions. The wiring is okay, but the device may be
defective. Refer to section 54.3.13.
, the VSS signal line
(#556) is shorted to ground, Repair the short; refer to section 54.3.13.

2. Reconnect all the connectors.
3. Turn the ignition ON.
4. Clear DDR codes.
5. Perform a road test with an assistant. Ensure the vehicle is loaded.
6. Stop the engine.
[c] If code 84/12 is logged, and any other codes are logged, all system diagnostics are
complete. To troubleshoot the error, refer to section 54.3.2 and perform tasks.


55 (CHG) FLASH CODE 55 - J1939 DATA LINK FAULT
Flash Code 55 indicates the ECM, see Figure 55-1, has detected a fault in the J1939 Data Link.
3 Incorrect programming
3 Wiring fault, J1939 data link wires

The SAE J1587 equivalent code for Flash Code 55 is s 231/12.

55.3.1 Check J1939 Data Link
Perform the following steps to check for J1939 data link fault.
1. Is this a J1939 transmission/engine application?
[a] If yes, contact Detroit Diesel Technical Service.
[b] If no, use programming station and go to "update customer calibration"
and select transmission to manual, or correct transmission. Save changes.

1. Start engine.
2. Plug in DDR.
3. Read codes.
[a] If active code 231/12 is not logged, troubleshooting is complete.
[b] If active code 231/12 is logged, contact Detroit Diesel Technical Service. Check
DDR software level. Update DDR software if current level is 1.2.


Flash Code 56 indicates that the J1587 (diagnostic) data link is no longer allowing the ECM,
see Figure 56-1, to transmit data.
3 Either or both of the data link circuits are open at some point in the network.
3 Either or both of the data link circuits are shorted to ground at some point in the network.
3 Either or both of the data link circuits are shorted to battery (+) at some point in the network.
3 The pair of data link circuits are shorted together.



3. Visually check the DDR for codes.
[b] If code 250/12 is logged, and no other codes are logged, Refer to section 56.3.2.
[c] If no data is logged, refer to section 9.1.
56.3.2 Clear Codes
Perform the following steps to clear codes.

1. Clear codes.
3. Observe CEL/code.
[a] If CEL is on with code 250/12 logged, refer to section 56.3.3.
[b] If no CEL code is logged, refer to section 56.3.5.
56.3.3 Check for Devices of Original Equipment Manufacturer
Perform the following steps to check for OEM devices.

2. Determine if any OEM equipment utilizes the J1587 data link. (ABS, ProDriver ®,
satellite systems, etc.
[a] If any OEM devices are installed, refer to section 56.3.4. Refer to step 1
[b] If no OEM devices are installed, refer to section 56.3.4. Refer to step 2[a]
56.3.4 Disconnect Nodes (Data Link Devices)
Perform the following steps to disconnect the nodes.

1. Disconnect OEM installed devices, one at a time e.g. ABS, satellite systems, etc. Verify
ABS switch is not in "Test" mode.

[a] If the disconnect does not solve the problem, continue the procedure.
Refer to step 2[a]
[b] If the disconnect solved the problem, go to 4b.
2. Connect vehicle interface module, J 41005.
4. Observe CEL codes.
[a] If CEL or codes displayed, and the CEL is on with code 250/12 logged, replace the
ECM with a test ECM. Refer to section 56.3.5.
[b] If no CEL or codes are displayed, contact OEM for instructions on how to proceed.

[a] If the CEL or codes are displayed, and if code 250/12 is logged, all system diagnostics
are complete. Review this section to find the error.
[b] If the CEL or codes are not displayed, troubleshooting is complete.

Flash Code 57 indicates that the J 1922 (Low Speed Powertrain) data link is no longer allowing
the ECM, see Figure 57-1, to transmit data.
3 Either or both of the data link circuits are open at some point in the network.
3 Either or both of the data link circuits are shorted to ground at some point in the network.
3 Either or both of the data link circuits are shorted to battery (+) at some point in the network.
3 The pair of data link circuits are shorted together.


57.3.1 Code Check

[b] If no codes are logged, refer to section 9.1.
[c] If code 254/12 is logged, and no other codes are logged, replace the ECM.
57.3.2 Verify Codes
Perform the following steps to verify codes.

3. Check CEL for codes.
[a] If CEL is on with code 249/12 displayed, refer to section 57.3.3.
[b] If CEL is not on and no codes are displayed, refer to section 57.3.5.
57.3.3 Check for OEM Devices
Perform the following steps to check for OEM devices.

2. Determine if any OEM equipment utilizes the J 1922 data link. See Figure 57-2.
[a] If no OEM devices are installed, refer to section 57.3.4. Refer to step 2

[b] If OEM devices are installed, refer to section 57.3.4. Refer to step 1
Figure 57-2 Communication Harness
57.3.4 Disconnect Nodes
Perform the following steps to disconnect nodes.

1. Start and run engine with OEM installed devices disconnected.
[a] If the disconnect does not solve the problem, continue the procedure. Refer to step 2
[b] If the disconnect solved the problem, Refer to step 44[a].
2. Connect vehicle interface module using J 41005.
3. Start and run engine.
4. Observe CEL codes.
[a] If no CEL or codes are displayed, contact OEM for instructions on how to proceed.
Refer to section 57.3.5. Fault is in node/wiring.
[b] If CEL is on with code 249/12 logged, install a test ECM. Refer to section 57.3.5.



6. Stop engine.
[b] If CEL is on with code 249/12 logged, all system diagnostics are complete. To
troubleshoot the error, refer to section 57.3.1.


Flash Code 58 indicates a torque overload.

This code is not covered in this manual. If changes occur, notification will be sent from DDC.

The SAE J1587 equivalent code for Flash Code 58 is p 092/0.

59 FLASH CODE 59
from DDC.


60 FLASH CODE 60
from DDC.


61 (CHG) FLASH CODE 61 - INJECTOR RESPONSE
LONG
Figure 61-1 Injectors

Flash Code 61 indicates that the time it takes from when the DDEC III ECM requests an injector,
see Figure 61-1, be turned on to when the injector solenoid valve actually closes is longer than the
high limit of the expected range. Engine oil temperature must be greater than 87F (30C).
3 Bad injector harness and or connection (high resistance)
3 Poor vehicle grounds
3 Sticky solenoid valve
NOTE:
The injector diagnostic SID (Subsystem Identifier) indicates which cylinder number has
an injector with a long response time. The injector number describes the cylinder and
or bank which has the injector with a long response time. The DDR will display the
injector text description.
Injector response times generally increase with low battery supply voltage and decrease with
high battery supply voltage. Although injector response times vary from injector to injector at a
given r/min, each individual injector response time should remain relatively consistent from one
firing to the next. Wide variations in response time (typically +/- 0.2 msec) for one injector at a
steady engine r/min may indicate an electrical problem (faulty alternator or voltage regulator,
poor or broken ground cables, etc.).

The SAE J1587 equivalent code for Flash Code 61 is s 001 0, or s 002 0, or s 003 0, or s 004 0,
or s 005 0 or s 006 0 (six cylinder engine).

61.3.1 Test Alternator Ground
Perform the following steps to test alternator ground.

1. Disable the alternator by removing the alternator belt.
2. Start and run the engine; warm to greater than 87F (30C).
3. Does the code return?
[a] If Flash Code 61 does not return, repair or replace the alternator grounds and
[b] If the code(s) return, refer to section 61.3.2.
61.3.2 Determine Cylinders With Fault
The injector location that is logging the codes is listed in Table 61-1.
#1 #2 #3 #4 #5 #6
(SID 1) (SID 2) (SID 3) (SID 4) (SID 5) (SID 6)
S55/60 1 5 3 6 2 4 cyl #
S50 1 3 4 2 - - cyl #
Table 61-1 Determine Cylinders With Fault
1. Disconnect the 5-pin injector harness connector at the ECM for those injectors logging
the codes.
2. Establish a good ECM case ground by measuring the resistance across two points on the
ECM. The resistance should measure less than or equal to 1
.
3. Once a good case ground is established, keep one of the measurement probes in place and
move the other probe to one of the five exposed male injector terminals on the ECM.
4. Measure the resistance. Repeat this procedure at each of the five terminals.
[a] If any terminals have a resistance of less than 1,000
, replace the ECM.
[b] If all terminals have a resistance of greater than 1,000

1. Locate the injector harness connector terminals associated with the codes. See Figure 61-2.

2. Measure resistance between that cavity and the cylinder block.

, the wire is shorted to the engine. Repair or
replace the harness and refer to section 61.3.5.
, go to step 3.
3. Remove the valve cover to gain access to the cylinder associated with the code.
4. Remove the connector terminals at the injector solenoid(s).
5. Measure resistance between that cavity and the appropriate return cavity (G or E).
, the wire is shorted to the return wire. Repair
or replace the harness and refer to section 61.3.5.


Figure 61-2 Injector Harness
Perform the following steps to check for an open.

1. Insert a jumper wire between the cavity associated with the code and the return for that
connector (G or E).
2. Measure resistance across the injector connectors (disconnected from injector solenoid).
, the injector wire is open. Repair or
[b] If the measured resistance is less than 5
, and the ECM software is less than 3.00,
reprogram the ECM. Refer to section 61.3.5.

1. Start and run the engine. Warm to 87F (30C).
[a] If injector codes are logged, please review this section from the first step to find
the problem. Refer to section 61.3.2.
[b] If no codes are logged, no further troubleshooting is required.

62 FLASH CODE 62 - OUTPUT FAULT
Figure 62-1 ECM

Flash Code 62 indicates that the function assigned to the Auxiliary Output #1, #2, #5, #6, #7 or #8
circuit output has an open circuit or short to battery (+). A short to battery (+) is detected when
the DDEC ECM, see Figure 62-1, is unsuccessful in turning "ON" the configured function.
The DDEC III ECM supplies a switched ground to the AUXILIARY OUTPUT circuit to turn
ON the function assigned.
Flash Code 62 may also indicate that the function assigned to the Auxiliary Output #1, #2, #5, #6,
#7 or #8 circuit output is open, shorted to ground. This diagnostic condition is detected when
the Auxiliary Output # "X" function is OFF and the DDEC III ECM measures a low voltage
on the circuit output.

The SAE J1587 equivalent codes for Flash Code 62 are listed in Table 62-1.
SAE J1587 Code Output Number Fault

s 026 3 Auxiliary output #1 Short to battery
s 026 4 Auxiliary output #1 Open circuit
Table 62-1 Auxiliary Output Open or Short to Battery

62.3.1 Code Check

3. Record codes logged.
4. Clear codes.
[a] If the code becomes active, refer to section 62.3.3.
[b] If the code does not become active, refer to section 62.3.2.
62.3.2 Intermittent Code Check
Perform the following steps to check intermittent codes.

1. Perform road test.
[a] If the code returns, refer to section 62.3.3.
[b] If the code does not display again, return the vehicle to service, or
62.3.3 Auxiliary Output Cavity Determination
Perform the following steps to determine which auxiliary output cavity is associated with the
logged codes.

1. Determine which auxiliary output cavity is associated with the code or codes being
logged. The SAE code descriptions of the flash codes and the DDC wire numbers are
listed in Table 62-2. Continue troubleshooting. Refer to section 62.3.4.
SAE Code Description - DDC Wire Number Cavity

Flash Code
Auxiliary Output #1 (026 3 or 499 F3 (VIH)*
026 4) 62
Auxiliary Output #2 (040 3 or 555 A2 (VIH)
040 4) 62
Auxiliary Output #5 (053 3 or 563 W3 (ESH) †
053 4) 62
Auxiliary Output #6 (054 3 or 564 X3 (ESH)
053 4) 62
Auxiliary Output #7 (055 3 or 565 Y3 (ESH)
055 4) 62
Auxiliary Output #8 (056 3 or 988 A1 (VIH)
056 4) 62
* Vehicle Interface Harness
† Engine Sensor Harness
Table 62-2 Auxiliary Output Cavities
62.3.4 Electrical Check
Perform the following steps to check connectors, dash light or vehicle power-down relay, or
item being driven.
1. Check the connectors of the output wire associated with the code logged at the vehicle
harness connector or engine sensor harness connector.
2. Check the connectors of the output wire associated with the code logged at the item
being driven.
[a] If the connectors are not good, repair or replace the terminals. Refer to section 62.3.6.
[b] If the connectors are good and the items being driven (e.g. relay, light) are not in
good condition, repair or replace the device. (Contact OEM for test procedure.)
[c] If the connectors are good and the items being driven (e.g. relay, light, are in good
condition, refer to section 62.3.5.
62.3.5 Measure Resistance
Perform the following steps to measure the resistance.


2. Connect the engine sensor harness or vehicle interface harness (connector with output
fault).
3. Disconnect the output wire associated with the code logged at the component.
4. Measure the resistance between the removed connector and the ECM case.
[a] If the reading is 47,000
(± 3,000
), contact Detroit Diesel Technical Service.
[b] If the reading is less than 44,000
or greater than 50,000
, this wire is shorted to
the battery or open. Repair or replace this wire. Refer to section 62.3.6.

2. Plug DDR into the connector.
3. Clear all codes.
[a] If the output code returns, refer to section 62.3.1.
[b] If the output code does not return, troubleshooting is complete.


63 FLASH CODE 63 - PWM FAULT
Flash Code 63 indicates that the pulse width modulation (PWM) output(s) used is either shorted
to battery positive or open-circuited.

The SAE J1587 equivalent code for Flash Code 63 is s 057 3, or s 057 4, or s 058 3, or s 058
4, or s 059 3, s 059 4, or s 060 3, or s 060 4.
(FMI 3 = Short to Battery; FMI 4 = Open Circuit)

63.3.1 Determine Assignment
Perform the following steps to determine assignment.

2. Plug in the DDR.
3. Select INs/OUTs. To what is PWM assigned? Write down assignment vs cavity and
code, listed in Table 63-1.
Code PWM Wire Location Wire #

S057 PWM #1 J3 #908
S058 PWM #2 Y1 #909
S059 PWM #3 E2 #910
S060 PWM #4 X2 #911
Table 63-1 PWM Assignments
4. Select code display.

5. Determine Failure Mode Identifier (FMI).
[a] If FMI 3 displays, there is a short to the battery. Refer to section 63.3.2
[b] If FMI 4 displays, refer to step 6
6. Verify function.
[a] If there is a component wired to this position, refer to section 63.3.3.
[b] If there is no component wired to this position, reprogram to eliminate the assigned
function. (A change may be required to the DDC mainframe.) Refer to section 63.3.9.
63.3.2 Verify Short to Battery
Perform the following steps to verify a short to battery:

2. Disconnect 30-pin connector: engine connector if PWM 2, 3 or 4; vehicle connector if
PWM 1.
3. Measure voltage between the cavity with the code and the good ground.
[a] If the voltage measurement is greater than 3 volts, the connector is shorted to the
battery. Repair. Refer to section 63.3.9.

[b] If the voltage measurement is less than 3 volts, contact Detroit Diesel Technical
Service.
63.3.3 Check Component Connections
Perform the following steps to check component connections:

1. Turn the vehicle ignition switch to the OFF position.
2. Inspect the connections of the PWM wire associated with the flash code logged at both
harness connector and the item being driven.
[a] If the connectors are damaged or broken, repair or replace the damaged terminals.
Verify repairs. Refer to section 63.3.9.
[b] If the connectors are not damaged or broken, ensure the item is connected to the pulse
width modulation wire. If the item is not connected, repair or replace the connector.
Verify repairs. Refer to section 63.3.9.
[c] If the item is connected, measure the resistance. Refer to section 63.3.8.
[d] If this is an Optimized Idle vehicle, refer to section 63.3.4.
63.3.4 Check Installation of the Starter Harness Overlay Kit
Perform the following steps to check for proper installation of the starter harness overlay kit when
a Code 63 is logged and the engine does not start; see Figure 63-1.
1. Turn off ignition (Optimized Idle Applications).
2. Remove relay from relay block.
3. Measure voltage between terminal 85 on the relay block and a good ground.
[a] If voltage measurement is less than 4 VDC, the power lead to the relay is open.
Verify connection of wire #439 from the starter relay harness overlay to DDEC
wire #439 in the cab.
[b] If voltage measurement is more than 4 VDC, measure voltage between terminal
86 on the relay block and a good ground. If voltage is less than 4 VDC, the
resistor built into the harness is defective. Replace the harness and verify repairs.
[c] If voltage measurement is more than 4 VDC, measure voltage between terminal 86
on the relay block and a good ground. If voltage is more than 4 VDC, the circuit

between terminal 86 on the new relay and power side of Optimized Idle starter relay
is open. Repair the open circuit and verify repairs. Refer to section 63.3.9.
Figure 63-1 Optimized Idle Schematic

63.3.5 Verify Installation of Starter Relay Harness Overlay Service Kit
Use the following procedure to verify installation of the starter relay harness overlay service
kit on Optimized Idle equipped vehicles only.
1. Turn ignition to ON position. Start engine.
2. Toggle cruise ON/OFF switch from OFF to ON. The Optimized Idle light should flash.
3. After the engine shuts down, turn the thermostat on by pressing any button.
4. Press UP or DOWN arrow until the heat or cool symbol begins to flash.
[a] If the engine starts, the repairs are complete. Refer to section 63.3.9.
[b] If the engine does not start, refer to section 63.3.6.
63.3.6 Engine Does Not Start in Optimized Idle Mode
Perform the following steps to start the engine.

1. Verify the hood is closed; the transmission is in neutral; the parking brake is set; and
the vehicle wheels are blocked.
To avoid personal injury, before starting and running the

engine, be sure that the vehicle is parked on a level surface
and that the wheels are properly blocked.
2. Remove the overlay relay from the relay block.

3. Measure voltage between terminal 85 and terminal 86 of the relay block.
[a] If voltage measurement is less than 4 VDC, the white wire in the overlay harness is
open. Repair the open circuit between the overlay harness and the hood/cab switch.
[b] If voltage measurement is more than 4 VDC, the relay is inoperative. Replace the
relay. Refer to section 8.6.5 of the proper engine Service Manual. Verify the repairs.
[c] If this is a Series 55 engine, refer to section 63.3.7.
63.3.7 Verify Harness
Perform the following steps to verify harness.

1. If this is a Series 55 engine, verify the engine harness is correct, especially PWM 3 and 4.
[a] If the harness is not correct, replace it. Refer to section 63.3.9.

[b] If the harness is correct, refer to section 63.3.8.
63.3.8 Measure Resistance Between Connector and the Electronic Control

Module Case
Perform the following steps to measure resistance between the connector and the ECM case:
1. Turn the vehicle ignition to the OFF position.
2. Ensure connector is installed on the engine harness side or vehicle harness side.
3. Disconnect the PWM wire associated with the code logged at the component.
4. Measure the resistance between the removed connector and the ECM case.
[a] If the resistance measurement is between 46,000 and 48,000
, verify the pin
assignment with wiring - view with DDR. Refer to section 63.3.9.
[b] If the resistance measurement is not between 46,000 and 48,000
, the wire is open or
shorted to battery. Repair or replace the wire. Verify repairs. Refer to section 63.3.9.
Perform the following steps to verify repairs for Flash Code 63. To check Optimized Idle, refer
to Optimized Idle Manual 6SE518.
2. Clear all codes from the DDR.
3. Plug in the DDR.
4. Turn vehicle ignition switch to the ON position.
[a] If Flash Code 63 was not logged, no further troubleshooting is required.
[b] If Flash Code 63 was logged, please review this section from the first step to find the
error. Refer to section 63.3.1.


Flash Code 64 is used to identify a turbo speed fault.


The SAE J1587 equivalent code for Flash Code 64 is p 103/0, turbo overspeed, and p 103/8, turbo
speed sensor input failure.

65 (CHG) FLASH CODE 65 - THROTTLE VALVE FAULT
For diesel-fueled engines, Flash Code 65 indicates that the air filter sensor input voltage has
exceeded or dropped below the expected range.
This code is not covered in this manual (for diesel engines). If changes occur, notification will
be sent from DDC.
For gas-fueled engines, Flash Code 65 indicates a fault in the throttle plate.

For diesel engines, the SAE J1587 equivalent codes for Flash Code 65 are 107/3, air filter sensor
voltage high, and 107/4, air filter sensor voltage low.
For gas engines, the SAE J1587 equivalent codes for Flash Code 65 is one of the following:
3 p 051/0 - Throttle plate above normal range
3 p 051/1 - Throttle plate below normal range
3 p 051/7 - Throttle plate not responding

65.3.1 Determine System and Failure
Determine system and failure as follows:

1. Is code 051/0 and system model year 1997 or older with a 24–volt power supply.
[a] Yes to both — install jumper and refer to section 65.3.8.
[b] No to either — for jumper harness already installed, refer to section 65.3.2.
Perform the following steps to check for voltage.

1. Unplug throttle actuator sensor harness connector. See Figure 65-1.
3. Measure voltage between cavity A and B of the connector.
[a] If the battery voltage reading (12v/24v) is ± 2 volts, refer to section 65.3.3.

[b] If the voltage is low, refer to section 65.3.4.
Figure 65-1 Series 50 Gas Engine Sensor Harness
Perform the following steps to check for ground:

2. Check ground wire from Cavity B to battery negative (-).
[a] If the ground wire is okay, refer to section 65.3.5.
[b] If the ground wire is bad, repair and refer to section 65.3.8.
65.3.4 Check for Supply
Perform the following steps to check for supply:


2. Unplug engine sensor harness.
3. Install a jumper between wire cavity A and F of the throttle actuator connector.
4. Measure resistance between cavity R1 and S3, then R1 and T3 at the engine sensor harness.
[a] If both readings are less than 1,000
[b] If either reading is greater than 1,000
, it indicates the #561 or #562 wire is open.
Repair or replace the wire and refer to section 65.3.8.
65.3.5 Check PWM #2
Perform the following steps to check PWM #2:

1. Move jumper to cavities E and F at the throttle activator.
2. Measure resistance between cavities R1 and Y1 of the engine sensor harness.
[a] If the measurement is less than 1,000
[b] If the measurement is greater than 1,000
, the wire #909 (PWM#2) is open. Repair
or replace the wire and refer to section 65.3.8.

1. Check both connectors for damaged, bent or broken pins or terminals.
[a] If the connectors are not damaged, refer to section 65.3.7.
[b] If the connectors are damaged, repair or replace the connectors.

1. Remove jumper.
2. Measure resistance between cavity Y1 and R1 on the engine sensor harness.
3. Measure resistance between Y1 and T3 of the engine sensor harness.
, the wires are shorted to each other.
Repair or replace the wires and refer to section 65.3.8.
, troubleshooting is complete.
Review this section or contact Detroit Diesel Technical Service to replace the
actuator. Refer to section 65.3.8.


2. With the ignition ON, plug in the DDR and clear the codes.
3. Throttle the engine through various speeds (r/min).
4. Shut the engine off.
6. Read the logged codes.
[b] If code 65 is logged with any other codes, troubleshooting is complete. Review this
section or contact Detroit Diesel Technical Service.

66 (CHG) FLASH CODE 66 - KNOCK SENSOR FAULT
Flash Code 66 indicates the oil filter sensor input to the ECM has exceeded or dropped below the
allowed range.
be sent from DDC.
For gasoline engines, Flash Code 66 indicates one or more faults have occurred in the engine
knock level circuitry.

For diesel engines, the SAE J1587 equivalent code for Flash Code 66 is p 099/3, oil filter sensor
input voltage high or p 099/4, oil filter sensor input voltage low.
For gasoline engines, the SAE J1587 equivalent code for Flash Code 66 is one of the following: s
076 0, s 076 7, s 076 3 or s 076 4.

66.3.1 Determine Failure
The following procedure will enable you to determine the failure.

1. Code s 076 0, knock level above normal range - A Failure Mode Identifier (FMI) of
0 is used to advise the user that the knock level is too high to allow the electronics to
compensate for it. Troubleshoot this as a mechanical problem.
2. Code s 076 - 7, knock level torque reduction - An FMI of 1 is used to advise the user
the loss of engine power is due to the engine electronics trying to adjust the fueling to
further reduce the knock level. Clear the code and retest. If the code continues to occur,
contact Detroit Diesel Technical Service.
3. For code s 076-3, knock sensor input voltage high, refer to section 66.3.2.
4. For code s 076-4, knock sensor input voltage low; refer to section 66.3.3.
66.3.2 Check Signal to Noise Enhancement Filter Module / Knock Sensor
Perform the following steps to check the Signal to Noise Enhancement Filter (SNEF) and knock
sensor.
1. Unplug the SNEF module.
3. Plug in DDR. Read codes.
[a] If code s 076-4 is logged, refer to section 66.3.4.
[b] If code s 076-3 is logged, refer to section 66.3.5.

1. Unplug SNEF.
2. Install a jumper wire between cavity B and E.
4. Plug in DDR. Read codes.
[a] If code s 076-3 is logged, refer to section 66.3.4.
[b] If code s 076-4 is logged, refer to section 66.3.7.


1. Check connectors at ECM and SNEF module.
[a] If the connectors are in good condition, replace the SNEF module.
[b] If the connectors are damaged, repair and refer to section 66.3.9.
66.3.5 Check for Short to (+)
Perform the following steps to check for a short to positive (+).

2. Disconnect the engine sensor harness. See Figure 66-1.
Figure 66-1 Series 50 Gas Engine Sensor Harness

3. Measure resistance between cavity A and E of the SNEF module connector.

Repair the wires and refer to section 66.3.9.
Perform the following steps to check for a ground:

1. Measure resistance between cavity D and battery ground.
, the ground wire is open. Repair
the open and refer to section 66.3.9.
, replace the SNEF module and

3. Disconnect the engine harness connector.
4. Measure resistance between cavity A of the SNEF connector and a good ground.
, the signal wire (#976) is shorted to
battery (-). Repair or replace the wire and refer to section 66.3.9.
, replace the knock sensor and
Perform the following steps to check for a signal open.

1. Insert jumper wire between E and C of the SNEF module connector.
2. Unplug the engine sensor harness connector.
3. Measure resistance between L2 (#976) and X1 (#573).
, wire #976 is open. Repair or
replace the wire and refer to section 66.3.9.

1. Hook up all connectors.

3. Operate under load. Road test.
4. Turn engine off.
6. Plug in DDR. Read logged codes.
[b] If code s 076-X is logged, all system diagnostics are complete. Please review this
section from the first step to find the problem. Refer to section 66.3.1, or contact

67 (CHG) FLASH CODE 67 - MAP SENSOR FAULT
For diesel engines, Flash Code 67 indicates that the coolant pressure input voltage to the ECM has
exceeded or dropped below the allowed range.
be sent from DDC.
For gas engines, Flash Code 67 indicates that the input voltage to the ECM from the air inlet
pressure sensor has dropped below 5%, or gone above 95% of the sensor supply voltage.

For diesel engines, the SAE J1587 equivalent codes for Flash Code 67 are 109/3, coolant pressure
sensor input voltage high, and 109/4, coolant pressure sensor input voltage low.
For gas engines, the SAE J1587 equivalent codes for Flash Code 67 are p 106/3, air inlet pressure
sensor input voltage high, and p 106/4, air inlet pressure sensor input voltage low.

67.3.1 Determine Failure
Perform the following steps to determine failure.

2. Plug in DDR.
3. Read codes.
NOTE:
Turbo Boost Sensor (TBS) references = air inlet pressure MAP (Manifold Air Pressure)
sensor for troubleshooting codes 106/3 and 106/4. The wire numbers are the same.


68 FLASH CODE 68 - IDLE VALIDATION FAULT
Figure 68-1 ECM

Flash Code 68 indicates that the ECM, see Figure 68-1, has detected a fault in the idle validation
switch (IVS) logic.

The SAE J1587 equivalent code for Flash Code 68 is s 230 5 (open circuit) or s 230 6 (short
to ground).
NOTE:
Code 230/5 (open) is set when TPS counts are less than 120 and IVS input is opened.
NOTE:
Code 230/6 (short to ground) is set when TPS counts are greater than 282 and IVS
input is grounded to battery (-).

68.3.1 Check for Idle Validation Switch Code
Perform the following steps to check for IVS active code:

2. Plug in DDR.
3. Cycle foot pedal; then read codes.
[a] If the IVS code is open (FMI=5), validate the throttle pedal application.
[b] If the IVS code is grounded (FMI=6), check the IVS switch. Refer to section 68.3.2.
68.3.2 Check the Idle Validation Switch
Perform the following step to check the idle validation switch:

1. Turn the vehicle ignition switch to the ON position.

NOTE:
Vehicle need not be moving to perform this check.
3. Plug in DDR.
4. Compare idle validation switch input status (switch light status) with the throttle position
sensor counts.
[a] If the IVS status is ON with the TPS count being greater than 282, measure for
resistance. Refer to section 68.3.3.
[b] If the IVS status is OFF with the TPS count being greater than 282, clear inactive
codes. No further troubleshooting is required. Refer to section 68.3.7.
68.3.3 Check Resistance Between Idle Validation Switch Contacts
Perform the following steps to measure resistance:

1. Turn vehicle ignition to the ON position. Refer to OEM guidelines.

2. Move TPS so counts are greater than 285.
3. Measure resistance between the ECM input (IVS) at the TPS and battery ground using
a volt-ohm meter.
[a] If the resistance was less than 100
, the idle validation input/switch is grounded or
defective. Contact OEM for repair procedure. Refer to section 68.3.7.
[b] If the resistance was greater than 100
, the fault condition no longer exists. No
further troubleshooting is required. Refer to section 68.3.7.
68.3.4 Check for Throttle Pedal Application
Perform the following steps to determine which type of TPS is being used:
1. Visually check to determine which throttle pedal has been installed that utilizes the IVS
function.
[a] If the throttle pedal has an idle validation switch installed, verify TPS count.
[b] If the throttle pedal has no idle validation switch installed, update customer
calibration using a programming station. Change the settings from idle validation to
"No Function" and save changes. Verify repairs. Refer to section 68.3.7.
68.3.5 Determine Throttle Position Sensor Counts / Idle Validation Switch

Status
Perform the following steps to determine TPS counts:

1. Turn vehicle ignition to the ON position. Refer to OEM guidelines.

2. Plug in DDR.
NOTE:
Vehicle need not be moving to determine TPS counts.
3. Compare idle validation switch status (switch light status) with the throttle position
sensor counts.
[a] If the IVS input is ON with the TPS count being less than 120, the problem no
longer exists. Refer to section 68.3.7.

[b] If the IVS input is OFF with the TPS count being less than 120, refer to section 68.3.6.
68.3.6 Check Resistance Between Idle Validation Switch Contacts
Perform the following steps to determine resistance:

1. Turn vehicle ignition switch to the ON position.
2. Measure resistance between the ECM input at the TPS/IVS end of the harness and battery
ground.
[a] If the resistance is less than 100
, the IVS is defective. Replace the switch. (Contact
the OEM for procedure.) Verify repairs. Refer to section 68.3.7.
, either the IVS input or #953 wire is open or
the IVS is defective. Replace the switch. (Contact the OEM for procedure.) Verify
repairs. Refer to section 68.3.7.

1. Clear inactive codes.


3. Depress foot pedal to at least half throttle (>290 counts).
4. Release foot pedal and allow the engine to idle.
5. Visually observe the check engine light (CEL) and DDR.
[a] If the CEL comes on, no further troubleshooting is required.
[b] If code 68 is logged, refer to section 68.3.1 to troubleshoot Flash Code 68 again.


69 FLASH CODE 69
from DDC.


70 FLASH CODE 70
from DDC.


71 (CHG) FLASH CODE 71 - INJECTOR RESPONSE
SHORT
Figure 71-1 Injectors

Flash Code 71 indicates that the time it takes from when the DDEC ECM, see Figure 71-1,
requests an injector be turned on when the injector solenoid valve actually closes is shorter than
the lower limit of the expected range.
3 Aerated fuel system
3 High system battery (+) supply voltage
3 Mechanical injector failure
3 Failed solenoid
NOTE:
The injector diagnostic SID (Subsystem Identifier) indicates which cylinder number has
an injector with a short response time. The injector number describes the cylinder and
bank that has the injector with a short response time. The DDR will display the injector
text description.
Injector response times generally increase with low battery supply voltage and decrease with
high battery supply voltage. Although injector response times vary from injector to injector at
a given r/min, each individual injector response time should remain relatively consistent from
one firing to the next. Wide variations in response time (typically ± 0.2 ms) for one injector at a
steady engine r/min may indicate an electrical problem (faulty alternator or regulator, poor or
broken ground cables, etc.).

The SAE J1587 equivalent code for Flash Code 71 is s 001 1, or s 002 1, or s 003 1, or s 004 1, or
s 005 1, or s 006 1.

71.3.1 Determine Cylinders With Fault
The injector location that is logging the codes is listed in Table 71-1.
#1 #2 #3 #4 #5 #6
(SID 1) (SID 2) (SID 3) (SID 4) (SID 5) (SID 6)
S55/60 1 5 3 6 2 4 cyl #
S50 1 3 4 2 - - cyl #
Table 71-1 Determine Cylinders With Fault
1. Disconnect the 5-pin injector harness connector at the ECM for those injectors logging
the codes.
2. Establish a good ECM case ground by measuring the resistance across two points on the
ECM. The resistance should measure less than or equal to 1
.
3. Once a good case ground is established, keep one of the measurement probes in place and
move the other probe to one of the five exposed male injector terminals on the ECM.
4. Measure the resistance. Repeat this procedure at each of the five terminals.
[a] If any terminals have a resistance of less than 1000
, replace the ECM.
[b] If all terminals have a resistance of greater than 1000

Perform the following steps to check for a short. See Figure 71-2.
Figure 71-2 Injector Harness
1. Locate the injector harness connector terminals associated with the codes.

2. Measure resistance between that cavity and the cylinder block.

3. Also, measure resistance between that cavity and the appropriate return cavity (G or E).
, the wire is shorted. Repair or replace the
harness and refer to section 71.3.5.
Perform the following steps to check for an open.

1. Insert a jumper wire between the cavity associated with the code and the return for that
connector (G or E).
2. Remove the valve cover to gain access to the cylinder associated with the code.
3. Remove the connector terminals at the injector solenoid.
4. Measure resistance between the terminal plugs.
, the injector wire is open. Repair or
[b] If the measured resistance is less than 5
, and the ECM software is less than 3.00,
reprogram the ECM. Refer to section 71.3.5.
[c] If the measured resistance is less than 5
, and the ECM software is 3.00 or higher,
remove the alternator belt to disable the actuator and refer to section 71.3.4.
71.3.4 Assemble
Perform the following steps to assemble the components.

1. Connect the connectors.
2. Install the valve cover.
4. Stop engine.
5. Does the code return?
[a] If the code does not return, repair or replace the alternator grounds and
[b] If the codes return, replace the injector and solenoid. Refer to section 71.3.5.

2. Stop engine.


[b] If injector codes are logged, all system diagnostics are complete. Please review this
section from the first step to find the error. Refer to section 71.3.1.

72 FLASH CODE 72 - VEHICLE OVERSPEED
Figure 72-1 ECM

Flash Code 72 indicates that the vehicle speed signal to the ECM (with fueling to the engine) has
exceeded the vehicle speed limit that is defined in the ECM calibration. See Figure 72-1.
Flash Code 72 also may indicate that the vehicle speed signal to the ECM (without fueling to the
engine) has exceeded a secondary vehicle speed limit that is defined in the ECM calibration.

The SAE J1587 equivalent code for Flash Code 72 is p 084 0 or p 084 11.

72.3.1 Overspeed
Perform the following steps to troubleshoot overspeed.

1. These codes indicate the vehicle speed has exceeded the limits programmed into the ECM.
Verify cruise control and VSS information.
[a] Code 84/0 - Overspeed with fuel limit has been exceeded.
[b] Code 84/11 - Overspeed without fuel limit has been exceeded.
2. Limits are a reasonable distance above the road speed limit.
[a] If the limits are a reasonable distance, go to step 3
[b] If the limits are not a reasonable distance above the road speed limit, change the
limits and perform the test. Refer to section 72.3.2.
NOTE:
For information regarding overspeed limits, refer to section 7.1.29.
3. Fuel Economy Incentive feature configured recently.

[a] If configured recently, review the limits. W/FEI limits may need to be increased.
[b] If not configured recently, the conditions are normal. The vehicle has exceeded
speed limits set.
72.3.2 Test
Perform the following steps to troubleshoot overspeed.

2. Perform a road test.
[a] If the overspeed condition has disappeared, troubleshooting is complete.
[b] If the overspeed condition still exists, review this section from the beginning to


73 FLASH CODE 73
from DDC.


74 FLASH CODE 74
from DDC.


75 FLASH CODE 75 - BATTERY VOLT HIGH
Figure 75-1 ECM

Flash Code 75 indicates that the DDEC® ECM, see Figure 75-1, has detected that the main battery
supply voltage to the ECM has exceeded the recommended operating range.


75.3.1 High Voltage
Perform the following steps to troubleshoot high voltage.

[a] If any codes other than 168/0 are received, service the other codes first.
[b] If code 168/0 and no other codes are logged, the voltage to the ECM is too high.
Check batteries and/or vehicle charging system.


76 FLASH CODE 76 - ENGINE OVERSPEED / BRAKE
Flash Code 76 indicates the engine speed exceeded a calibration limit, and the engine brake output
was active at the time the condition occurred.

The SAE J1587 equivalent code for Flash Code 76 is p 121/0, Engine Overspeed with Engine
Brake.


[b] If code 121/0 is logged, and no other codes are logged, there was an engine running
condition at which the engine r/min exceeded a calibration limit during engine
brake operation.
NOTE:
Determine the reason the engine r/min went too high.


77 FLASH CODE 77 - FUEL TEMP HIGH
Figure 77-1 ECM

Flash Code 77 indicates that the fuel temperature has exceeded a calibration limit set by DDC in
the ECM, see Figure 77-1.
At this time, this code is logged without illuminating a CEL.


There is no established procedure to troubleshoot Flash Code 77.

3 The code is used to determine if high fuel temperature may be a cause of reduced power
levels.
3 High fuel temperature will reduce available horsepower.
3 Refer to the recommendations of the vehicle manufacturer regarding the possible need for
additional fuel cooling.


from DDC.


79 FLASH CODE 79
from DDC.


80 FLASH CODE 80
from DDC.


Flash Code 81 is used to identify oil level, crankcase pressure, dual fuel BOI, or exhaust
temperature voltage high.

The SAE J1587 equivalent code for Flash Code 81 is p 098 3, oil level sensor input voltage high; p
101 3, crankcase pressure sensor input voltage high, or s 020 3, dual fuel BOI input voltage high.

Flash Code 82 is used to identify oil level, crankcase pressure, dual fuel BOI, or exhaust
temperature voltage low.

The SAE J1587 equivalent code for Flash Code 82 is p 098 4, oil level sensor input voltage low; p
101 4, crankcase pressure sensor input voltage low, or s 020 4, dual fuel BOI input voltage low.

Flash Code 83 is used to identify oil level, crankcase pressure, exhaust temperature, or external
pump pressure high.

The SAE J1587 equivalent code for Flash Code 83 is p 098 0, oil level high; p 101 0, crankcase
pressure high; p 173 0, exhaust temperature high; and p 173 3, 4, exhaust temperature sensor input.

Flash Code 84 is used to identify oil level or crankcase pressure low.


The SAE J1587 equivalent code for Flash Code 84 is p 098/1, oil level low and p 101/1, crankcase
pressure low.

85 FLASH CODE 85 - ENGINE OVERSPEED
Flash Code 85 indicates that an engine overspeed condition exists.

The SAE J1587 equivalent code for Flash Code 85 is p 190 0, engine overspeed.

85.3.1 Code Information
Perform the following steps to gather information. This code is logged whenever the engine has
been operating over 2500 r/min for at least two seconds.
2. Plug diagnostic data reader (DDR) into the diagnostic data link (DDL). For vehicle
harness connector.
3. Select inactive codes.
4. Part of the display will read as follows:
[a] First Occurrence
[b] Last Occurrence
[c] Total Number
[d] Total Time
5. If necessary, refer to section 6.2


86 FLASH CODE 86 - PGS SENSOR HIGH
Figure 86-1 Pressure Transducer

Flash Code 86 indicates that the pump pressure circuit failed high (below). For pressure
transducer and connector, see Figure 86-1,



2. Plug in DDR.
[a] If active code 73/3 was logged, and no other codes were logged, refer to section 86.3.2.
[b] If active code 73/4 and any other codes were logged, refer to section 86.3.3.
[c] If any codes other than 73/3 were logged, refer to section 91.1.
86.3.2 Sensor Check

2. Disconnect the Pressure Governor System (PGS) sensor connector.
4. Start engine and operate the PGS in the PRESSURE mode.
[b] If active code 73/4 and any other codes except 73/3 were logged,

2. Disconnect the vehicle harness connector at the ECM. See Figure 86-2.
3. Install a jumper wire between pins A and B of the PGS sensor harness connector.
4. Measure resistance between sockets D3 and C3 on the vehicle harness connectors.


, or open, the return line (circuit
#952) is open. Repair the open and refer to section 86.3.9.
86.3.4 Check Pressure Governor System Connectors
Perform the following steps to check the PGS connectors.

1. Inspect terminals at the PGS sensor connector (both the sensor and harness side) for
damage: bent, corroded, and unseated pins or sockets.
[b] If the terminals and connectors are not damaged, replace the PGS sensor and
86.3.5 Check for Short to +5 Volts
Perform the following steps to check for a short to the +5 volts.

2. Disconnect the vehicle harness connectors at the ECM.
3. Measure resistance between sockets A3 and D3 on the engine harness connector.


2. Disconnect the vehicle harness and 5-way power connectors at the ECM.
3. Measure resistance between socket D3 on the engine harness connector and battery (+).
4. Measure resistance between socket D3 of the engine harness connector, and the 5-way
power harness sockets A and C.
[a] If the resistance measurement for all readings is greater than 100
or open,
the signal line (circuit #749) and battery (+). Repair short and reinsert fuses.

1. Inspect terminals at the ECM connectors (both ECM and harness side) for damage: bent,
86.3.8 Final Check
Perform the following steps to do a final check.

3. Clear codes.
5. Stop engine.
6. Check DDR for active codes.
[b] If active code 73/3 is logged, install a test ECM. Refer to section 86.3.9.
[c] If any codes except code 73/3 are logged, refer to section 9.1, to service other codes.


4. Clear codes.
6. Stop engine.
7. Check DDR for inactive codes.
[b] If code 73/3 is not logged, and other codes are logged, refer to section 9.1, to service
other codes.
are complete. Review this section from the first step to find the problem.

87 FLASH CODE 87 - PGS SENSOR LOW
Figure 87-1 Pressure Transducer

Flash Code 87 indicates pump pressure sensor input voltage low.

The signal volts dropped below 5% (normally = <0.25 volts) of the sensor supply. For pressure
transducer and connector, see Figure 87-1.

The SAE J1587 equivalent code for Flash Code 87 is p 073/4.


2. Plug in DDR. Read the codes.
[a] If codes p 73/4, 100/3 or 4, 102/3 or 4, 110/3 or 4, 174/3 or 4 or 175/3 or 4 are
logged, refer to section 91.1.
[b] If code 073/4 is logged and no other codes are logged, refer to section 87.3.2.
[c] If code 073/4 is logged, and none of the following codes are logged: 100/3 or 4,
102/3 or 4, 110/3 or 4, 174/3 or 4 or 175/3 or 4, refer to section 87.3.2.
87.3.2 Sensor Check

2. Disconnect the pump pressure sensor connector and install a jumper between sockets B
and C of the pump pressure sensor transducer connector.
4. Start engine and operate the Pressure Governor System (PGS) in the PRESSURE mode.
[a] If code p 73/3 and any other code except p 73/4 display, check to ensure the ECM and
PGS sensor connectors are wired properly. If wired properly, refer to section 87.3.3.
[b] If code p 73/4 and any other codes display, refer to section 87.3.4.
87.3.3 Check Pressure Governor System Sensor Connectors
Perform the following steps to check the pressure governor system (PGS) sensor connectors.
2. Inspect terminals at the pump pressure sensor connectors (sensor and harness side) for
damaged, bent, corroded, and unseated pins or sockets.
[a] If the terminals and connectors are not damaged, replace the PGS sensor.

87.3.4 Check for Short to Return

3. Remove vehicle interface harness connector (30-pin).
5. Measure resistance between C3 (#952) and D3 (#749).
Replace the harness.
87.3.5 Check for Short to Battery (-)
Perform the following steps to check for a short to the battery (-).
1. Measure resistance between D3 (#749) and battery ground.
, the #749 wire is shorted to the battery.
Replace the harness and refer to section 87.3.7.
87.3.6 Check for 5 Volt Open
Perform the following steps to check for a 5 volt open.

1. Plug in the 30-pin connector for the vehicle sensor harness.
3. Measure voltage between cavity B (#952) and A (#916) of the transducer connector.
[a] If the measurement is less than 4.5 volts, wire #916 is open. Repair the open or
replace the harness. Refer to section 87.3.7.
[b] If the measurement is between 4.5 and 5.5 volts, the signal wire (#749) is open.
Repair the wire and refer to section 87.3.7.

1. Plug in all connectors.
3. Plug in DDR and read the codes.

[b] If code p 073/4 is logged, review this section to find the error. Then, contact Detroit
Diesel Technical Services.


Flash Code 88 is used to identify coolant pressure low.

This code currently is not covered in this manual. If changes occur, notification will be sent
from DDC.


89 FLASH CODE 89
from DDC.


90 (CHG) ENGINE SENSOR HARNESS
90.1 DESCRIPTION OF ENGINE SENSOR HARNESS
Referral to this section indicates a fault within the Engine Sensor Harness affecting signals of
various sensors used by the DDEC system.

90.2 TROUBLESHOOTING ENGINE SENSOR HARNESS
The following procedure will troubleshoot the engine sensor harness.
90.2.1 Check for Low Battery Voltage
Perform the following steps to check for low battery voltage.

[a] If Flash Code 168/1 is logged, refer to section 46.3.
[b] If code 168/1 is not logged, refer to section 90.2.2.

1. Turn vehicle ignition switch OFF.
2. Disconnect the Oil Pressure Sensor (OPS) and Turbo Boost Sensor (TBS) connectors.
3. If applicable, disconnect the Fuel Pressure Sensor (FPS).
5. At each sensor harness connector, measure voltage between socket C (red lead) and
socket A (black lead).
[a] If the voltage measurement is between 4.7 and 5.2 volts, the voltage reading is
correct. Check voltage at the next connector. If all connector voltage readings are
correct, refer to section 90.2.3.
[b] If the voltage measurement is less than 4.7 volts at any or all connectors,
[c] If the voltage measurement is greater than 5.2 volts at all connectors,

1. Check terminals at the ECM engine harness connector (both the ECM and harness side)
for damaged, bent, corroded and unseated pins or sockets.
[a] If the terminals and connectors are not damaged, check all sensors, especially OPS,
TBS, and TPS (on vehicle system), this indicates that there is no problem on the
engine sensor harness. Refer to section 91.1.

90.2.4 Check for +5 volts or Return Open
Perform the following steps to check for +5 volts or return open.

3. Install a jumper wire between sockets A and C of any sensor connector that reads less than
4.7 volts. Refer to section 90.2.2.
4. Measure resistance between sockets W1 and Y2 of the engine harness connector.
or open, either the engine +5 volt line
(#416), or the return line (#452) is open. Repair the open and refer to section 90.2.7.

3. Measure resistance between sockets A and C of the sensor connector.
4. Measure resistance between socket C of the sensor connector and a good ground.
[a] If the resistance measurement for both readings is greater than 1,000
, or open,
[b] If either resistance measurement is less than or equal to 1,000
, the engine +5 volt
line (#416) is shorted to either the sensor return line (#452) or to chassis ground.
Repair the short and refer to section 90.2.7.

3. Disconnect all five connectors at the ECM.
4. Measure resistance between socket W1 on the engine harness connector and B3 on the
vehicle harness connector.
5. Measure resistance between socket W1 on the engine harness connector and the battery
(+).
, or open,


, a short exists
between sockets where reading was taken. Repair the short and refer to section 90.2.7.

3. Reconnect fuses (or circuit breakers) if previously disconnected.
5. Clear codes.
6. If Check Engine Light (CEL) does not stay on, start engine and run for one minute
7. Stop engine.
8. Read inactive codes with the DDR.
[b] If codes that brought you to this section are still logged, all system diagnostics
[c] If codes except those which brought you to this section are logged, refer to section 9.1.

91 (CHG) VEHICLE HARNESS
91.1 DESCRIPTION OF VEHICLE HARNESS +5 VOLT SUPPLY
Referral to this section indicates a fault within the vehicle interface harness.
NOTE:
It is suggested that the vehicle interface module be installed for test. If the fault(s) clear,
you may wish to contact the vehicle manufacturer for instructions on troubleshooting.
Otherwise, continue with this section.

91.2 TROUBLESHOOTING VEHICLE HARNESS +5 VOLT SUPPLY
The following procedure will troubleshoot vehicle harness.
91.2.1 Check for Low Battery Voltage
Perform the following steps to check for low battery voltage.

[b] If code 168/1 is not logged, refer to section 91.2.2.
Perform the following steps to check for +5 volts at the Throttle Position Sensor (TPS).
2. Disconnect the TPS (disconnect the VSG and PGS, if applicable).
4. Measure voltage on the TPS and VSG harness connector, pin C (#916) (red lead) to pin A
(#952) (black lead), and pin A to pin B at the PGS connector, if applicable.
[a] If the voltage measurement is between 4.7 and 5.2 volts, the voltage reading is
correct. Check voltage at the next connector. If all connector voltage readings are
correct, refer to section 91.2.5.
[b] If the voltage measurement is less than 4.7 volts, refer to section 91.2.3.
[c] If the voltage measurement is greater than 5.2 volts at all connectors,
91.2.3 Check for +5 volts or Return Open
Perform the following steps to check for +5 volts or return open.

3. Install a jumper wire between pins A and C of the TPS harness connector.
4. Measure resistance between sockets A3 and C3 of the vehicle harness connector.
or open, either the vehicle +5 volt
line (#916) or the sensor return line (#952) is open. Refer to section 91.2.9.

91.2.4 Check for +5 Short to Ground
Perform the following steps to check for +5 short to ground.

2. Measure resistance between pins A and C of the TPS harness connector.
3. Measure resistance between pin C of the TPS harness connector and a good ground
(battery-).
, or open,
, wire (#916) is
shorted to wire (#952), or battery ground. Repair the short and refer to section 91.2.9.
91.2.5 Vehicle Harness 5V Check TPS
Perform the following steps to check TPS.

2. Reconnect the TPS connector.
4. Select Throttle Sensor percentage on the DDR.
5. Observe throttle percentage at both no throttle and full throttle (engine not running).
[a] If the percentage is between 0 and 100%, refer to section 91.2.7.
[b] If not getting a reading between 0 and 100%, refer to section 91.2.6.
91.2.6 Vehicle Harness 5V Check Throttle Position Sensor Connectors
Perform the following steps to check TPS connectors.

2. Disconnect the TPS.
3. Inspect terminals at the TPS connectors (sensor side and harness side) for damage; bent,
corroded and unseated pins or sockets.
[a] If the terminals and connectors are not damaged, replace TPS. Refer to section 91.2.9.

2. Disconnect the vehicle harness connector at the ECM (if not already disconnected).

3. Check terminals at the ECM vehicle harness connector (both the ECM and harness side)
for damage; bent, corroded and unseated pins or sockets (especially terminals #952, #916,
#417 and #510). Install new terminal if in doubt.
[a] If the terminals and connectors are not damaged, refer to section 90.2.2.
Perform the following steps to check for a short to battery (+).

2. Remove both fuses or circuit breakers to the ECM.
3. Disconnect the vehicle harness and the 5-pin power harness connectors at the ECM.
4. Measure resistance between sockets A3 and B3 on the vehicle harness connector.
5. Measure resistance between socket A3 on the vehicle harness connector and the battery (+).
[a] If the resistance measurement for all readings is greater than 1,000
, or open,
, a short exists between the vehicle
+5 volt line (#916) and the lines where less than 1,000 was read (either circuit #240,
#241 or #439). Repair the short and refer to section 91.2.9.

3. Reconnect fuses (or circuit breakers) if previously disconnected.
5. Clear codes.
6. If Check Engine Light (CEL) does not stay on, start engine and run for one minute.
7. Stop engine.
8. Read inactive codes with the DDR.
[b] If codes that brought you to this section are still logged, all system diagnostics
[c] If codes except those which brought you to this section are logged, refer to section 9.1.

92 (CHG) ENGINE WIRING SCHEMATICS
92.1 INJECTOR HARNESS WIRING SCHEMATIC - SERIES 50 ENGINES

WITH JAKE BRAKE
The following wire schematics support the injector harness; see Figure 92-1.
Figure 92-1 Injector Harness - Series 50 Engines With Jake Brake

For "Go To A", see Figure 92-3.
Figure 92-2 Injector Harness (Sheet 1-2) (Series 60 Shown)

Figure 92-3 Injector Harness (Sheet 2-2)

92.3 INJECTOR HARNESS WIRING SCHEMATIC - SERIES 6V92 ENGINES
92.3 INJECTOR HARNESS WIRING SCHEMATIC - SERIES 6V92 ENGINES
Figure 92-4 Injector Harness - Series 6V92 Engines

92.4 INJECTOR HARNESS WIRING SCHEMATIC - SERIES 8V92 AND 8V149

ENGINES
Figure 92-5 Injector Harness - Series 8V92 and 8V149 Engines

92.5 INTERNAL ENGINE BRAKE FOR ECM/WORLD TRANSMISSION INTERFACE
92.5 INTERNAL ENGINE BRAKE FOR ECM/WORLD TRANSMISSION

INTERFACE
The following wire schematics support the internal engine brake for ECM/World transmission
interface; see Figure 92-6.

Figure 92-6 Internal Engine Brake ECM/World Transmission Interface (Sheet

1-2)

92.5 INTERNAL ENGINE BRAKE FOR ECM/WORLD TRANSMISSION INTERFACE
Figure 92-7 Internal Engine Brake ECM/World Transmission Interface (Sheet

2-2)

92.6 INTERNAL ENGINE BRAKE FOR DDEC SYSTEM ECM
The following wire schematics support the internal engine brake; see Figure 92-8.
Figure 92-8 Internal Engine Brake (Sheet 1-2)

92.6 INTERNAL ENGINE BRAKE FOR DDEC SYSTEM ECM
Figure 92-9 Internal Engine Brake (Sheet 2-2)

92.7 ENGINE HARNESS
The following wire schematics support the engine harness; see Figure 92-10.
Figure 92-10 Engine Harness (Sheet 1-7)

92.7 ENGINE HARNESS
For "Go To B", see Figure 92-12.

For "Go To C", see Figure 92-13.

92.7 ENGINE HARNESS
For "Go To D", see Figure 92-14.

For "Go To E", see Figure 92-15.

92.7 ENGINE HARNESS
For "Go To F", see Figure 92-16.


92.7 ENGINE HARNESS

93 (CHG) VEHICLE WIRING SCHEMATICS
93.1 VEHICLE INTERFACE HARNESS
The following wire schematics support the vehicle interface harness; see Figure 93-1.
Figure 93-1 Vehicle Interface Harness (Sheet 1-9)

For "Go To B", see Figure 93-3.

For "Go To C", see Figure 93-4.

For "Go To D", see Figure 93-5.

For "Go To E", see Figure 93-6.

For "Go To F", see Figure 93-7.

For "Go To G", see Figure 93-8.

For "Go To H", see Figure 93-9.


93.2 PRESSURE GOVERNOR SYSTEM - VEHICLE INTERFACE HARNESS CONNECTOR
93.2 PRESSURE GOVERNOR SYSTEM - VEHICLE INTERFACE HARNESS

CONNECTOR
The following wire schematics support the Pressure Governor System (PGS) vehicle interface
harness connector; see Figure 93-10.
Figure 93-10 Pressure Governor System Vehicle Interface Harness Connector

93.3 ELECTRONIC FIRE COMMANDER HARNESS
The following wire schematics support the electronic fire commander harness; see Figure 93-11.
Figure 93-11 Electronic Fire Commander Harness

93.4 POWER HARNESS - SINGLE ECM, SINGLE FUSE
93.4 POWER HARNESS - SINGLE ECM, SINGLE FUSE
Figure 93-12 Power Harness - Single ECM, Single Fuse

93.5 POWER HARNESS - SINGLE ECM, DUAL FUSES
Figure 93-13 Power Harness - Single ECM, Dual Fuses

93.6 DDEC DIGITAL OUTPUT
93.6 DDEC DIGITAL OUTPUT
The following wire schematics support the DDEC digital outputs; see Figure 93-14.
Figure 93-14 DDEC Digital Outputs

93.7 COMMUNICATION HARNESS
The following wire schematics support the communication harness; see Figure 93-15.
Figure 93-15 Communication Harness

93.7 COMMUNICATION HARNESS

94 (CHG) DDEC PRO-LINK OPERATION
Figure 94-1 Pro-Link

94.1 DDEC PRO-LINK OPERATION
The following procedure will suggest several ways to use the Pro-Link ® on the DDEC system,
see Figure 94-1,
94.1.1 Diagnostic Codes
Start with the Menu Selection screen.

1. To call up active codes:
[a] Select ENGINE and ENTER three times.
2. To call up inactive codes:
[a] Select ENGINE and ENTER twice.
[b] Select INACTIVE CODES and ENTER.
3. To clear codes:
[a] Select ENGINE and push ENTER twice.
[b] Go down and select CLEAR CODES and ENTER.
[c] Left to YES, and ENTER.
[d] Wait and then push FUNC three times.
[e] Go to lines 1 and 2 of the Engine Data List, Active and Inactive Codes, and verify
that both lines display NO.
94.1.2 Cylinder Cutout Sequence

1. Select ENGINE and ENTER.
2. Go down and select FUEL INJECTOR INFO and ENTER.
3. Go to CYLINDER CUTOUT and ENTER.
4. Select NEW TEST and ENTER, or REVIEW LAST TEST and ENTER.
5. Select IDLE and ENTER or 1000 RPM and ENTER.
6. Select AUTO and ENTER, or MANUAL and ENTER three times.
7. Test is now in progress.
NOTE:
Test results stay stored in the Pro-Link memory as long as the DDR remains powered up.
94.1.3 Injector Calibration Update

94.1 DDEC PRO-LINK OPERATION

2. Go down to FUEL INJECTOR INFO and ENTER.
3. Go down to CAL UPDATE and ENTER.
4. Select VIEW and ENTER or select UPDATE and ENTER.
5. Enter password: 0000 or xxxx and ENTER twice.
6. Enter new CAL # and ENTER. Use UP/DN arrow keys to select line.
7. When finished, select FUNC, select YES, ENTER and wait.
8. ENTER to continue.
94.1.4 Reprogram Calibration

2. Down to CALIBRATION CHANGE and ENTER.
3. Select REPROGRAM CAL and ENTER.
4. Enter password: 0000 or xxxx and ENTER (xxxx=1 to 9 and A to Z).
5. Select menu to be changed with UP/DN arrow keys and ENTER twice.
6. Use RT/LT arrow keys to change a word or put in a new # and ENTER.
7. When finished, select FUNC.
8. SELECT ANOTHER MENU: left to YES and ENTER, or NO and ENTER.
9. Left to YES and ENTER.
10. Wait and then ENTER to continue.
94.1.5 Snapshot Sequence

1. Select PRO-LINK and ENTER.
2. Go up to SNAPSHOT and ENTER.
3. Go down to DATA UPDATE RATE and ENTER.
4. Type in NEW RATE and ENTER (.0 to 9.9 seconds); (90 frames will be recorded).
5. Up to TRIGGER SETUP and ENTER.
6. Select TRIGGER SOURCE and ENTER:
[a] Any Numeric Key
[b] Any code
[c] Specific PID

[d] Specific SID

7. Adjust TRIGGER POINT: NO, or select YES and ENTER; change trigger point with
RT/LT arrow keys. ENTER.
8. WAITING FOR TRIGGER. When ready to take SNAPSHOT, apply the trigger. ANY
NUMERIC KEY overrides all other triggers.
9. PROCESSING TRIGGER; Filling remaining frames (90 frames max). When all frames
are filled, the first three lines of the TRIGGER FRAME, T, will display.
[a] To do SNAPSHOT after setup is done, do items 1, 2, and 8 only, or go to QUICK
TRIGGER and ENTER.
[b] SNAPSHOT DATA stays stored in Pro-Link memory as long as the DDR remains
powered up.
94.1.6 Print Function
Print custom data list of snapshot. The printer is attached to the DDR.
1. Select PROLINK. ENTER.
2. Select RS-232 SERIAL PORT. ENTER.
3. Select PRINTER OUTPUT. ENTER.
4. Arrow up or down to SNAPSHOT DATA. ENTER.
5. Right to CUSTOM. ENTER twice.
6. Select six items from data list using arrow up or down. ENTER after each selection.
- FUNC.
7. Type 001; ENTER; 090; ENTER.

TM 9-2320-302-20
WP 0007 00

TM 9-2320-302-20
EXHAUST SYSTEM TROUBLESHOOTING 0008 00
Refer to Engine Troubleshooting WP 0006 00.
0008 00-1
TM 9-2320-302-20
0008 00-2
TM 9-2320-302-20
COOLING SYSTEM TROUBLESHOOTING 0009 00
Refer to Engine Troubleshooting WP 0006 00.
0009 00-1
TM 9-2320-302-20
0009 00-2
TM 9-2320-302-20
ELECTRICAL SYSTEM TROUBLESHOOTING 0010 00
Table 1. Electrical System Troubleshooting Procedures.

Engine Brake System
Engine Brake (Jake Brake) Inoperative or 1. Remove fuse panel cover and Replace fuse as necessary (WP
Operates Erratically. check engine brake 15A fuse. 0071 00).
OFF or at idle, press Check on, perform step 3 and read
Engine Button, observe Check Active Flash Codes.
Engine Light (CEL).
b. If CEL come on for up to
10.4 (WP 0007 00).
Engine Fan Circuit
Engine Fan Does Not Operate or Fails to Start 1. Remove fuse panel cover and If defective, replace 15A fuse (WP
at 190°F - 210°F (87°C - 98°C). check fan/modulator 15A fuse. 0071 00).
2. Check fan clutch air lines and If leaking or a damaged hose or
hoses for leaks. line is found, replace (WP
0049 00).
OFF or at idle, press Check on, perform step 4 and read
Engine Button and observe Active Flash Codes.
Check Engine Light (CEL).
b. If CEL come on for up to
10.4 (WP 0007 00).
0010 00-1
TM 9-2320-302-20
Table 1. Electrical System Troubleshooting Procedures - Continued.

Charging Circuits
1. Batteries Not Charging, Voltmeter Does Not 1. Disconnect lead 83 from If continuity is indicated, go to
Indicate Voltage. negative (-) terminal or step 2. If continuity is not
alternator. Check for indicated, repair lead 83 (WP
continuity between lead 83 and 0119 00).
ground.
2. Check for continuity between If continuity is indicated, go to
negative (-) terminal and step 3. If continuity is not
negative field (F-) terminal or indicated, replace alternator (WP
alternator. 0055 00).
3. Disconnect lead 16D from If +24 VDC is present, go to step
positive (+) terminal or 4. If voltage is not present, replace
alternator. Check for +24 VDC alternator (WP 0055 00).
at positive (+) terminal or
alternator.
4. Disconnect lead 16D from If +24 VDC is present, go to step
dual voltage control unit. 5. If voltage is not present, repair
Check for +24 VDC at lead lead 16D (WP 0119 00).
16D.
5. Disconnect lead 123 from If +24 VDC is present, go to step
positive field (F+) connector 6. If voltage is not present, replace
on alternator. Check for +24 alternator (WP 0055 00).
VDC at positive field (F+)
connector.
6. Disconnect lead 123 from If +24 VDC is present, replace
twinput voltage regulator. twinput voltage regulator (WP
Check for +24 VDC at lead 0057 00). If voltage is not present,
123. repair lead 123 (WP 0119 00).
2. +12 VDC Circuits Not Charging, +24 VDC 1. Disconnect lead 16E from If +12VDC is present, go to step 2.
Circuits Normal. connector no.1 on dual voltage If voltage is not present, replace
control unit. Check for +12 dual voltage control unit (WP
VDC at dual voltage control 0058 00).
unit.
2. Disconnect lead 16E from 12V If +12 VDC is present, repair lead
junction terminal. Check for 5. If voltage is not present, repair
+12 VDC at lead 16E. lead 16E (WP 0119 00).
3. +24 VDC Circuits Not Charging, +12 VDC 1. Disconnect lead 16F from If +24 VDC is present, go to step
Circuits Normal. connector no. 2 on dual 2. If voltage is not present, replace
voltage control unit. Check for dual voltage control unit (WP
+24 VDC at dual voltage 0058 00).
control unit.
2. Disconnect lead 16F from If +24 VDC is present, repair lead
connector at starter motor. 1. If voltage is not present, repair
Check for +24 VDC at lead lead 16F (WP 0119 00).
16F.
0010 00-2
TM 9-2320-302-20

Headlight Circuits
1. Neither Headlight Operates When Switch Is 1. Check left and right headlight If defective, replace 15A fuses
Turned On. 15A fuses. (WP 0071 00).
2. Disconnect lead 420M from If +12 VDC is present at vehicular
vehicular light switch. Check light switch, go to step 3. If voltage
for +12 VDC at pin M. is not present at vehicular light
switch, replace vehicular light
switch (WP 0063 00).
3. Disconnect left headlight If +12 VDC is present, replace left
power relay from connector. and right headlight power relay
Check for +12 VDC at (WP 0071 00). If voltage is not
connector 85. present at connector 85, repair
lead 420M (WP 0119 00).
2. Left/Right Headlight Fails to Operate When 1. Inspect headlight bulb. Replace bulb if broken or
Switch Is Turned On. defective (WP 0083 00).
2. Check left headlight 15A fuse. If defective, replace 15A fuse (WP
0071 00).
3. Disconnect lead 14 from left If +12 VDC is present, go to step
headlight 15A fuse. Check for 4. If voltage is not present, repair
+12 VDC at lead 14. lead (WP 0119 00).
4. Disconnect ground lead from If +12 VDC is present, repair
left/right headlight. Check for ground lead (WP 0119 00). If
+12 VDC at ground lead to voltage is not present, go to step 5.
left/right headlight.
5. Disconnect left/right headlight If continuity is indicated, go to
power relay from connector. step 6. If continuity is not
Check for continuity between indicated, repair ground lead (WP
connector 86 and ground. 0119 00).
6. Disconnect left/right headlight If +12 VDC is present, go to step
power relay from connector. 7. If voltage is not present, repair
Check for +12 VDC at lead 20 (WP 0119 00).
connector 30.
7. Disconnect left/right low/high If +12 VDC is present, replace left
beam relay from connector. low/high beam relay (WP
Check for +12 VDC at 0071 00). If voltage is not present,
connector 30. go to step 8.
8. Check for continuity between If continuity is present, replace left
connector 87 from left headlight power relay (WP
headlight power relay and 0071 00). If continuity is not
connector 30 from left low/ indicated, repair lead 20L (WP
high beam relay. 0119 00).
3. Neither Headlight Low/High Beam Operates 1. Disconnect ground lead from If continuity is present, go to step
When Turn Signal Switch Lever Is Set. dimmer switch lever. Check 2. If continuity is not indicated,
for continuity between lead repair ground lead (WP 0119 00).
and ground.
0010 00-3
TM 9-2320-302-20

Headlight Circuits - Continued
3. Neither Headlight Low/High Beam Operates 2. Disconnect lead 222 from If continuity is present, go to step
When Turn Signal Switch Lever Is Set - dimmer switch lever. Check 3. If continuity is not indicated,
Continued. for continuity between replace dimmer switch lever (WP
terminals of switch in both 0073 00).
positions.
3. Disconnect left low/high beam If continuity is present, replace left
relay from connector. Check low/high beam relay (WP
for continuity between 0071 00). If continuity is not indi-
connector 86 and lead 222. cated repair lead 222 (WP 0119 00).
4. Left/Right Highbeam Does Not Operate. 1. Inspect headlight bulb. Replace bulb if broken or
defective (WP 0083 00).
2. Disconnect connector from If continuity is present, go to step
left headlight. Check for 3. If no continuity is indicated,
continuity between ground replace left headlight (WP 0083
and connector on left headlight 00).
at lead 21/21D.
relay from connector. Check low/high beam relay (WP 0071
for continuity between lead 21/ 00). If no continuity is indicated,
21D and connector 87. repair lead 21/21D (WP 0119 00).
5. Left/Right Lowbeam Does Not Operate. 1. Inspect headlight bulb. Replace bulb if broken or
2. Disconnect connector from If continuity is present, go to step
left headlight. Check for 3. If continuity is not indicated,
continuity between ground replace left headlight (WP
and connector on left/right 0083 00).
headlight at lead 22/22D.
relay from connector. Check low/high beam relay (WP 0071
for continuity between lead 22/ 00). If continuity is not indicated,
22D and connector 87A. repair lead 22/22D (WP 0119 00).
Marker and Taillight Circuits
1. None of Marker and Taillights Operate. 1. Check tractor tail marker 15A Replace fuse if defective (WP
fuse. 0071 00).
2. Disconnect connector on If +12 VDC is present, repair lead
vehicular light switch. Install 420H (WP 0119 00). If voltage is
jumper wire between not present at vehicular light
connector 420F and pin F on switch, replace vehicular light
switch. Check for +12 VDC at switch (WP 0063 00).
pin H.
2. Left/Right Front Marker Light Does Not 1. Inspect light bulb. Replace bulb if broken or
Operate. defective (WP 0088 00).
0010 00-4
TM 9-2320-302-20

Marker and Taillight Circuits - Continued
2. Left/Right Front Marker Light Does Not 2. Remove lamp from socket. If continuity is indicated, go to
Operate - Continued. Check for continuity between step 3. If continuity is not
contacts of lamp. indicated, replace lamp (WP
0088 00).
socket and ground. step 4. If continuity is not
indicated, repair ground lead (WP
0119 00).
4. Disconnect lead 46E/46F from If +12 VDC is present, repair lead
lead 46. Check for +12 VDC at 46E/46F. If voltage is not present,
lead 46. repair lead 46 (WP 0119 00).
3. One or More Cab Marker Lights Does Not 1. Inspect light bulbs. Replace bulbs if broken or
2. Remove lamp(s) from If continuity is indicated, go to
defective circuit(s). Check for step 3. If continuity is not
continuity between socket and indicated, replace lamp(s) (WP
ground. 0089 00).
3. Disconnect ground lead from If continuity is indicated, repair
marker light(s). Check for lead(s) 46. If continuity is not
continuity between ground indicated, repair ground lead(s)
lead(s) and ground. (WP 0119 00).
4. Both Taillights Do Not Operate, But All Marker 1. Inspect light bulbs. Replace bulbs if broken or
Lights Operate. defective (WP 0087 00).
2. Disconnect lead 23A from If +12 VDC is present, repair
taillight terminal. Check for terminal connector (WP 0119 00).
+12 VDC at lead 23A. If voltage is not present, repair
lead 23A (WP 0119 00).
Blackout Light Circuits
1. None of Blackout (B/O) Lights Operate. Check B/O 15A fuse. Replace 15A fuse if defective (WP
0071 00).
2. None of Blackout (B/O) Stoplights Operate. 1. Inspect light bulbs. Replace bulbs if broken or
2. Disconnect B/O stoplights If +24 VDC is present, go to step
relay from connector. Check 3. If voltage is not present, repair
for +24 VDC at connector 30. lead connector 421V (WP
0119 00).
3. Check for +24 VDC at If +24 VDC is present, go to step
connector 85. 4. If voltage is not present, repair
lead 420N (WP 0119 00).
connector 86 and ground. step 5. If continuity is not
0119 00).
0010 00-5
TM 9-2320-302-20

Blackout Light Circuits - Continued
2. None of Blackout (B/O) Stoplights Operate - 5. Install jumper wires between If +24 VDC is present, repair lead
Continued. connector 30 and stoplights 421F (WP 0119 00). If voltage is
relay, connector 85 and not present, replace B/O stoplights
stoplights relay, and connector relay (WP 0071 00).
86 and stoplights relay. Check
for +24 VDC at stoplights
relay contact 87.
3. One or None of Blackout (B/O) Marker Lights 1. Inspect light bulbs. Replace bulbs if broken or
2. Disconnect B/O marker lights If +24 VDC is present, go to step
relay from connector. Check 3. If no voltage is present, repair
for +24 VDC at connector 30. lead 421V (WP 0119 00).
lead 420E (WP 0119 00).
0119 00).
5. Install jumper wires between If +24 VDC is present, repair lead
connector 30 and stoplights 421A (WP 0119 00). If voltage is
relay, connector 85 and not present, replace B/O marker
stoplights relay, and connector lights relay (WP 0071 00).
relay contact 87.
4. One or None of Blackout (B/O) Drive Lights 1. Inspect light bulbs. Replace bulbs if broken or
2. Disconnect B/O drive lights If +24 VDC is present, go to step
for +24 VDC at connector 30. lead 421V (WP 0119 00).
lead 420D (WP 0119 00).
0119 00).
5. Install jumper wires between If +24 VDC is present, repair lead
connector 30 and stoplights 421P or lead 421K (WP 0119 00).
relay, connector 85 and If voltage is not present, replace B/
stoplights relay, and connector O drive lights relay (WP 0071 00).
relay contact 87.
0010 00-6
TM 9-2320-302-20

Blackout Light Circuits - Continued
4. One or None of Blackout (B/O) Drive Lights 6. Check for +24 VDC at If +24 VDC is present,
Operate - Continued. connector 421K at trailer troubleshoot trailer circuit(s). If
receptacle(s). voltage is not present, repair
lead(s) 421K (WP 0119 00).
Turn Signal and Stoplight Circuits
1. Stoplights Do Not Operate. 1. Check stoplight 20A fuse. Replace 20A fuse if defective (WP
0071 00).
2. Inspect light bulbs. Replace bulbs if broken or
3. Disconnect leads 420A and If continuity is indicated, go to
420K from stoplight switch. step 4. If continuity is not
Check for continuity between indicated, replace stoplight switch
switch contacts while pressing (WP 0109 00).
switch.
4. Disconnect leads 420A and If continuity is indicated, go to
420K from vehicular light step 5. If continuity is not
switch. Check for continuity indicated, repair lead 420A or
between leads 420A and 420K 420K (WP 0119 00).
with stoplight switch closed.
5. Disconnect lead 420C from If continuity is indicated, go to
vehicular light switch. step 6. If continuity is not
Disconnect lead 36C from turn indicated, repair lead 420C or lead
signal switch. Check for 36C (WP 0119 00).
continuity between lead 420C
and 36C.
6. Disconnect lead 36C from If +12 VDC is present, replace turn
vehicular light switch. Check signal switch (WP 0073 00). If
for +12 VDC in lead 36C with voltage is not present, replace
stoplight switch closed. vehicular light switch (WP 0063
00).
2. Left/Right Stoplight Does Not Operate. 1. Inspect light bulb. Replace bulb if broken or
2. Remove lamp from left If continuity is indicated, go to
stoplight. Check for continuity step 3. If continuity is not
between contact points. indicated, replace lamp (WP
0087 00).
3. Remove left/right stoplight If continuity is indicated, go to
lamp. Check for continuity step 4. If continuity is not
between socket and ground. indicated, repair ground lead (WP
0119 00).
4. Check for +24 VDC at turn If +24 VDC is present, replace turn
signal switch at lead 38B/39B signal switch (WP 0073 00). If
contact point. voltage is not present, repair lead
38B/39B (WP 0119 00).
0010 00-7
TM 9-2320-302-20

Turn Signal and Stoplight Circuits - Continued
3. Flasher Lights Do Not Operate. 1. Inspect light bulbs. Replace bulbs if broken or
2. Disconnect left flasher relay If +24 VDC is present, go to step
from connector. Check for +24 3. If voltage is not present, repair
VDC at connector 30. lead 421 (WP 0119 00).
0119 00).
lead 60 (WP 0119 00).
5. Set turn signal switch in turn If +24 VDC is present, go to step
mode. Install jumper leads 6. If voltage is not present, replace
between connectors 30, 85, left flasher relay (WP 0071 00).
and 86 to their respective
connectors at left flasher relay.
Check for +24 VDC at flasher
relay connection 87.
6. Set turn signal switch in turn If voltage is not present, repair
mode. Check for +24 VDC at leads (WP 0119 00).
trailer receptacle connectors.
4. Turn Signal Lights Do Not Operate. 1. Inspect light bulb. Replace bulb if broken or
2. Remove lamp from defective If continuity is indicated, go to
left turn signal light. Check for step 3. If continuity is not
continuity between contact indicated, replace lamp (WP
points. 0088 00).
3. Remove signal light lamp. If continuity is indicated, repair
Check for continuity between lead 60. If continuity is not
socket and ground. indicated, repair ground lead (WP
0119 00).
5. Turn Signal Indicator Light Does Not Operate, 1. Inspect light bulb. Replace bulb if broken or
But Turn Signals Operate Normally. defective (WP 0061 00).
2. Disconnect lead 60A from If +24 VDC is present,
warning light bar. Check for troubleshoot warning light circuit.
+24 VDC at lead 60A. If voltage is not present, repair
lead 60A (WP 0119 00).
Dome Light Circuits
1. Dome Lights Do Not Operate. 1. Check dome/auxiliary/flasher Replace 15A fuse if defective (WP
lights 15A fuse. 0071 00).
2. Disconnect lead 420J from If +12 VDC is present, repair lead
dome/auxiliary/flasher 15A 41 (WP 0119 00). If voltage is not
fuse. Check for +12 VDC at present, go to step 3.
lead 420J.
0010 00-8
TM 9-2320-302-20

Dome Light Circuits - Continued
1. Dome Lights Do Not Operate - Continued. 3. Disconnect connector from If +12 VDC is present, repair lead
vehicular light switch. Check 420J (WP 0119 00). If voltage is
for +12 VDC at pin J. not present, replace vehicular light
switch (WP 0063 00).
2. One Dome Light Operates, But Other Dome 1. Inspect light bulb. Replace bulb if broken or
Light Does Not Operate in Either Mode. defective (WP 0091 00).
2. Disconnect lead 41 from If continuity is indicated, go to
defective dome light. Check step 3. If continuity is not
for continuity from dome light indicated, repair ground lead (WP
ground lead to ground. 0119 00).
3. Disconnect lead 41 from If +12 VDC is present, replace
defective dome light. Check dome light assembly (WP
for +12 VDC at lead 41. 0091 00). If voltage is not present,
repair lead 41 (WP 0119 00).
3. Dome Light Operates in On/Off Switch Mode 1. Inspect dome light lamp. Replace lamp if defective (WP
Only. 0091 00).
2. Check for continuity between If continuity is indicated, replace
socket and ground. dome light assembly (WP
0091 00).
Auxiliary Light Circuits
1. Auxiliary Lights or Accessory Circuits Do Not 1. Check for +12 VDC at If +12 VDC is present, repair
Operate. auxiliary light power bus. auxiliary light power bus. If
voltage is not present, go to step 2.
2. Disconnect auxiliary lights If +12 VDC is present, go to step
power relay. Check for +12 3. If voltage is not present, repair
VDC at connector 30. lead 420JC (WP 0119 00).
auxiliary lights power relay 4. If voltage is not present, check
connector 85. dome/auxiliary/flasher 15A fuse.
If defective, replace 15A fuse (WP
0071 00). Check for continuity in
lead 420JA and lead 420J. If
continuity is not indicated, repair
lead 420JA or 420J (WP 0119 00).
If +12 VDC is still not present at
connector 85, replace vehicular
light switch (WP 0063 00).
4. Disconnect auxiliary lights If +12 VDC is present, go to step
accessory lockout relay. 5. If voltage is not present, check
Check for +12 VDC at lead 420JB for continuity. If
connector 87. continuity is not indicated, repair
lead 420JB (WP 0119 00). If
voltage is still not present at
connector 87, replace auxiliary
lights power relay (WP 0071 00).
0010 00-9
TM 9-2320-302-20

Auxiliary Light Circuits - Continued
1. Auxiliary Lights or Accessory Circuits Do Not 5. Disconnect auxiliary lights If +12 VDC is present, go to step
Operate - Continued. accessory lockout relay. 6. If voltage is not present, check
Check for +12 VDC at start/auxiliary 15A fuse. If
connector 85. defective, replace 15A fuse (WP
0071 00). Check for continuity in
lead 71AA and lead 71A. If
lead 71AA and lead 71A (WP
0119 00). If voltage is still not
present at connector 85, replace
vehicular light switch (WP
0063 00).
6. Disconnect auxiliary lights If continuity is indicated, go to
accessory lockout relay. step 7. If continuity is not
Check for continuity in indicated, repair connector lead 30
connectors 30 and 86 to or connector lead 86 to ground
ground. (WP 0119 00).
7. Check for +12 VDC at If +12 VDC is not present, check
auxiliary light power bus. for continuity in lead 420JD. If
continuity is indicated, replace
auxiliary lights power relay (WP
0071 00).
2. No Power to Auxiliary Heater Fan Power Relay. Disconnect auxiliary lights If continuity is not indicated,
accessory lockout relay and heater repair lead 71AA (WP 0119 00).
fan power relay. Check for
continuity in lead 71AA.
Worklight Power Receptacle Circuits
1. Worklight Power Receptacles Do Not Operate. 1. Check worklight receptacles Replace 15A fuse if defective (WP
15A fuse. 0071 00).
2. Check for +12 VDC at lead If +12 VDC is present, go to step
420JD from auxiliary light 3. If voltage is not present, repair
power bus. lead 420JD (WP 0119 00).
3. Check for +12 VDC at lead If +12 VDC is present, repair
73F for left and right worklight ground lead from worklight power
power receptacles. receptacles. If voltage is not
present, repair lead 73F (WP
0119 00).
2. One Worklight Power Receptacle Does Not 1. Check for +12 VDC at lead If +12 VDC is present, go to step
Operate, But Other Receptacle Operates 73F to worklight power 2. If voltage is not present, repair
Normally. receptacle. lead 73F (WP 0119 00).
receptacle and ground. defective receptacle. If continuity
is not indicated, repair ground lead
(WP 0119 00).
0010 00-10
TM 9-2320-302-20

Backup Light Circuits
1. Backup Lights Do Not Operate. 1. Check backup light 15A fuse. Replace 15A fuse if defective (WP
0071 00).
2. Inspect light bulbs. Replace bulbs if broken or
3. Disconnect lead 420JD from If +12 VDC is present, go to step
backup light 15A fuse. Check 4. If voltage is not present, repair
for +12 VDC at lead 420JD. lead 420JD (WP 0119 00).
backup light switch. Check for 5. If voltage is not present, repair
+12 VDC at lead 120. lead 120 (WP 0119 00).
5. Disconnect lead 120B from If continuity is indicated, go to
backup light switch. Press step 6. If continuity is not
backup light switch. Check for indicated, replace backup light
continuity between switch switch (WP 0120 00).
contacts.
6. Disconnect lead 120B from If +12 VDC is present, go to step
chassis harness. Check for +12 7. If voltage is not present, repair
VDC at lead 120B. lead 120B between chassis and
backup light switch (WP 0119 00).
7. Check for +12 VDC at backup If +12 VDC is present, repair
receptacle socket 120B receptacle socket ground leads to
connector. ground. If voltage is not present,
repair lead 120B to chassis wiring
harness (WP 0119 00).
2. Right/Left Backup Light Does Not Operate. 1. Check backup light lamp. Replace lamp if defective (WP
0087 00).
socket and ground. backup light (WP 0087 00). If
ground lead (WP 0119 00).
3. Disconnect lead from backup If voltage is not present, repair red
light. Check for +12 VDC at lead (WP 0119 00).
lead.
Utility Light Circuits
1. Utility Lights Do Not Operate. 1. Inspect light bulbs. Replace bulbs if broken or
2. Disconnect leads 420JD and If continuity is indicated, go to
73 from 15A fuse. Check for step 3. If continuity is not
continuity between contacts of indicated, replace 15A fuse (WP
15A fuse. 0071 00).
0010 00-11
TM 9-2320-302-20

Utility Light Circuits - Continued
1. Utility Lights Do Not Operate - Continued. 3. Check for +12 VDC at lead If +12 VDC is present, go to step
4. Disconnect lead 73 from utility If +12 VDC is present, go to step
light switch. Check for +12 5. If voltage is not present, repair
VDC at lead 73. lead 73 (WP 0119 00).
5. Disconnect lead 73B from If continuity is indicated, repair
utility light switch. Activate lead 73B (WP 0119 00). If
switch. Check for continuity continuity is not indicated, replace
between switch contacts. utility light switch (WP 0064 00).
2. Only One Utility Light Operates. 1. Disconnect lead 73B from If +12 VDC is present, go to step
defective utility light. Check 2. If voltage is not present, repair
for +12 VDC at lead 73B. lead 73B (WP 0119 00).
socket and ground. utility light (WP 0090 00). If
ground lead (WP 0119 00).
3. Utility Light Indicator Light Does Not Operate, Disconnect lead 73A from pin If +12 VDC is present,
But Utility Lights Operate Normally. D16 of warning light bar. Check troubleshoot warning light circuit.
for +12 VDC at lead 73A. If voltage is not present, repair
lead 73A (WP 0119 00).
Electric Horn Circuits
Electric Horn Does Not Operate. 1. Check horn 15A fuse. Replace 15A fuse if defective (WP
0071 00).
2. Check for +12 VDC at lead If +12 VDC is present, go to step
3. Disconnect horn relay from If +12 VDC is present, go to step
connector. Check for +12 4. If voltage is not present, repair
VDC at connector 30. lead 24 (WP 0119 00).
4. Disconnect horn relay. Check If +12 VDC is present, go to step
for +12 VDC at connector 85. 5. If voltage is not present, repair
lead 24 (WP 0119 00).
5. Disconnect lead 25 from horn If +12 VDC is present, go to step
button. Check for +12 VDC at 6. If voltage is not present, replace
lead 25. horn relay (WP 0071 00).
6. Disconnect ground lead from If continuity is indicated, go to
horn button. Check for step 7. If continuity is not
continuity between ground indicated, repair ground lead (WP
lead and ground. 0119 00).
7. Disconnect lead 25 from horn If continuity is indicated, go to
button. Press horn switch. step 8. If continuity is not
Check for continuity between indicated, replace horn button
switch contacts. (WP 0112 00).
0010 00-12
TM 9-2320-302-20

Electric Horn Circuits - Continued
Electric Horn Does Not Operate - Continued. 8. Disconnect lead 26 from horn. If +12 VDC is present, go to step
Check for +12 VDC at lead 26 9. If voltage is not present,
with horn button pressed. disconnect horn relay and check
for continuity between connector
87 and lead 26. If continuity is
indicated, replace horn relay (WP
0071 00). If continuity is not
indicated, repair lead 26 (WP
0119 00).
9. Disconnect ground lead from If continuity is indicated, replace
horn. Check for continuity horn (WP 0112 00). If continuity
between ground lead and is not indicated, repair ground lead
ground. (WP 0119 00).
Tractor Beacon Light Circuits
Tractor Beacon Light Does Not Operate. 1. Check tractor beacon light Replace 15A fuse if defective (WP
15A fuse. 0071 00).
2. Remove lamp from tractor If continuity is indicated, go to
beacon light. Check for step 3. If continuity is not
continuity between contacts indicated, replace tractor beacon
on lamp. light (TM 9-2320-302-10).
3. Disconnect lead 254A from If voltage is not present, go to step
tractor beacon light. Check for 4. If +12 VDC is present, check for
+12 VDC at lead 254A with continuity between socket and
beacon light switch in on ground. If continuity is indicated,
position. replace tractor beacon light (TM
9-2320-302-10). If continuity is
not indicated, repair ground lead
(WP 0119 00).
4. Remove tractor beacon light If +12 VDC is present, go to step
15A fuse. Check for +12 VDC 5. If voltage is not present, repair
at lead 420JD fuse connector lead 420JD (WP 0119 00).
from auxiliary light power bus.
beacon light switch. Check for 6. If voltage is not present, repair
+12 VDC at lead 254. lead 254 (WP 0119 00).
6. Disconnect lead 254 and lead If continuity is indicated, go to
254A from switch. Activate step 7. If continuity is not
switch. Check for continuity indicated, replace beacon light
between contacts of switch. switch (WP 0065 00).
7. Disconnect lead 254A from If voltage is not present, repair
tractor beacon light. Check for lead 254A between beacon lights
+12 VDC at lead 254A. and beacon light switch (WP
0119 00).
0010 00-13
TM 9-2320-302-20

Panel Lights Circuits
1. Panel Lights Do Not Operate. 1. Check panel lights 15A fuse. Replace 15A fuse if defective (WP
0071 00).
2. Disconnect lead 420B from If +12 VDC is present, repair lead
electronic dimmer switch. 420B (WP 0119 00). If voltage is
Check for +12 VDC at lead not present, go to step 3.
420B from dimmer switch.
dimmer switch. Check for electronic dimmer switch (WP
continuity between ground 0064 00). If continuity is not
lead and ground. indicated, repair ground lead (WP
0119 00).
2. Heater Control Light Does Not Operate, But 1. Check heater control lamp. If defective, replace lamp (WP
Other Heater Circuits Operate Normally. 0067 00).
socket and ground. step 3. If continuity is not
0119 00).
3. Disconnect lead 29A from If +12 VDC is present, repair lead
heater control light. Check for 29A to heater control light. If
+12 VDC at lead 29A from voltage is not present, repair lead
panel fuse. 29A from fuse (WP 0119 00).
3. One or More Gage Lights Do Not Operate. Check panel gage lamp(s). Replace lamp(s) if defective (WP
0061 00 and WP 0062 00).
4. Fiber Optics Do Not Operate. 1. Check fiber optic light source Replace lamp if defective (WP
lamp. 0069 00).
lamp socket and ground. step 3. If continuity is not
0119 00).
3. Disconnect power lead to fiber If +12 VDC is present, replace
optic light source. Check for fiber optic light source light (WP
+12 VDC at power lead. 0069 00). If voltage is not present,
repair power lead (WP 0119 00).
5. Panel Lights Do Not Dim. Disconnect lead 420B from If +12 VDC is present, replace
electronic dimmer switch. Check main light switch (WP 0063 00).
for +12 VDC at lead 420B with If voltage is not present, replace
main light switch in dim mode. electronic dimmer switch (WP
0064 00).
6. Panel Lights Do Not Brighten. Disconnect lead 420B from If +12 VDC is present, replace
electronic dimmer switch. Check main light switch (WP 0063 00).
for +12 VDC at lead 420B with
main light switch in bright mode.
0010 00-14
TM 9-2320-302-20

Radio Circuits
Power Source for 24 VDC Radio Does Not 1. Check 24 VDC 25A radio Replace 25A fuse if defective (WP
Operate. fuse. 0071 00).
2. Remove 24 VDC 25A radio If +24 VDC is present, go to step
fuse. Check for +24 VDC at 3. If voltage is not present, repair
lead 421W fuse connector. lead 421W to 24 VDC constant
power bus (WP 0119 00).
ground lead and ground. step 4. If continuity is not
0119 00).
4. Check for +24 VDC at lead If +24 VDC is not present, repair
421R from radio power source lead 421R (WP 0119 00).
connector.
Instrument Wiring Circuits
1. Instruments on Dashboard Do Not Operate. 1. Check instruments 10A fuse. Replace 10A fuse if defective (WP
0071 00).
2. Check for +12 VDC at ignition If +12 VDC is present, repair lead
run power bus connector. 81C. If voltage is not present,
repair connector on ignition run
power bus (WP 00119 00).
2. Water Temperature Gage Does Not Operate. 1. Disconnect lead 81C from If +12 VDC is present, go to step
water temperature gage. 2. If voltage is not present, repair
Check for +12 VDC at lead lead 81C (WP 0119 00).
81C.
2. Disconnect ground lead from If continuity is present, go to step
water temperature gage. 3. If continuity is not indicated,
Check for continuity between repair ground lead (WP 0119 00).
lead and ground.
3. Disconnect lead 119 from If +8 to +12 VDC is present, go to
water temperature gage. step 4. If voltage is not present,
Check for +8 to +12 VDC at replace water temperature gage
water temperature gage. (WP 0060 00).
4. Disconnect lead 119 from If +8 to +12 VDC is present,
water temperature gage replace water temperature gage
sensor. Check for +8 to +12 sensor (WP 0098 00). If voltage is
VDC at lead 119. not present, repair lead 119 (WP
0119 00).
3. Transmission Oil Temperature Gage Does Not 1. Disconnect lead 81C from If +12 VDC is present, go to step
Operate. transmission oil temperature 2. If voltage is not present, repair
gage. Check for +12 VDC at lead 81C (WP 0119 00).
lead 81C.
0010 00-15
TM 9-2320-302-20

3. Transmission Oil Temperature Gage Does Not 2. Disconnect ground lead from If continuity is present, go to step
Operate - Continued. transmission oil temperature 3. If continuity is not indicated,
gage. Check for continuity repair ground lead (WP 0119 00).
between lead and ground.
3. Disconnect lead 30 from If +8 to +12 VDC is present, go to
transmission oil temperature step 4. If voltage is not present,
gage. Check for +8 to +12 replace transmission oil
VDC at transmission oil temperature gage (WP 0062 00).
temperature gage.
4. Disconnect lead 30 from If +8 to +12 VDC is present,
transmission oil temperature replace transmission oil
gage sensor. Check for +8 to temperature gage sensor (WP
+12 VDC at lead 30. 0096 00). If voltage is not present,
4. Fuel Level Gage Does Not Operate. 1. Disconnect lead 81C from fuel If +12 VDC is present, go to step
level gage. Check for +12 2. If voltage is not present, repair
VDC at lead 81C. lead 81C (WP 0119 00).
2. Disconnect ground lead from If continuity is present, go to step
fuel level gage. Check for 3. If continuity is not indicated,
continuity between ground repair ground lead (WP 0119 00).
lead and ground.
3. Disconnect lead 47 from fuel If +8 to +12 VDC is present, go to
level gage. Check for +8 to step 4. If voltage is not present,
+12 VDC at fuel level gage. replace fuel level gage (WP
0062 00).
4. Disconnect lead 47 from fuel If +8 to +12 VDC is present,
level sensor. Check for +8 to replace fuel level gage sensor (WP
+12 VDC at lead 47. 0094 00). If voltage is not present,
5. Voltmeter Does Not Operate, But Warning 1. Disconnect lead 19A from If +12 VDC is present, go to step
Light Operates Normally. voltmeter. Check for +12 VDC 2. If voltage is not present, repair
at lead 19A. lead 19A (WP 0119 00).
voltmeter. Check for voltmeter (WP 0063 00). If con-
continuity between ground tinuity is not indicated, repair
lead and ground. ground lead (WP 0119 00).
6. Axle Lock Indicator Light Does Not Operate. 1. Disconnect lead 81C from axle If +12 VDC is present, go to step
lock pressure switch. Check 2. If voltage is not present, repair
for +12 VDC at lead 81C. lead 81C (WP 0119 00).
2. Disconnect leads 87 and 81C If continuity is indicated, go to
from axle lock pressure step 3. If continuity is not
switch. Check for continuity indicated, replace axle lock
between contacts of switch. pressure switch (WP 0063 00).
0010 00-16
TM 9-2320-302-20

6. Axle Lock Indicator Light Does Not Operate - 3. Disconnect lead 87 from axle If no continuity is indicated, repair
Continued. lock pressure switch. Check lead 87 (WP 0119 00).
for continuity between lead 87
and ground.
Ether Cold-Start Circuit
Ether Cold-start Does Not Operate When 1. Check ether 10A fuse. Replace 10A fuse if defective (WP
Container Has Ether. 0071 00).
2. Remove ether 15A fuse. If +12 VDC is present, go to step
Check for +12 VDC at fuse 3. If voltage is not present, repair
connector from ignition run circuit 18 (WP 0119 00).
power bus.
ether switch. Check for +12 4. If voltage is not present, repair
VDC at lead 166. lead 166 (WP 0119 00).
4. Disconnect lead 166A at cab/ If +12 VDC is present, go to step
chassis connection. Check for 5. If voltage is not present, repair
+12 VDC at lead 166A. lead 166A (WP 0119 00).
5. Disconnect lead 166A from If +12 VDC is present, go to step
ether solenoid. Check for +12 6. If voltage is not present, repair
VDC at lead 166A. lead 166A (WP 0119 00).
ether solenoid. Check for ether solenoid (WP 0035 00). If
continuity between ground continuity is not indicated, repair
Air Dryer Heater Circuit
Air Dryer Heater Does Not Operate. 1. Check reservoir heater/power Replace 15A fuse if defective (WP
take-off 15A fuse. 0071 00).
2. Disconnect lead 94 from air If +12 VDC is present, go to step
dryer drain valve heater. 3. If voltage is not present, repair
Check for +12 VDC at lead 94. lead 94 (WP 0119 00).
air dryer drain valve heater. air dryer drain valve heater. If
Check for continuity between continuity is not indicated, repair
Standard Heater Circuits
Heater Fan Does Not Operate at Any Speed. 1. Check heater fan 30A fuse. Replace 30A fuse if defective (WP
0071 00).
2. Check start/auxiliary 15A Replace 15A fuse if defective (WP
fuse. 0071 00).
3. Remove heater fan 30A fuse. If +12 VDC is present, go to step
Check for +12 VDC at lead 14 4. If voltage is not present, repair
fuse connector. lead 14 to 12-volt constant power
bus (WP 0119 00).
0010 00-17
TM 9-2320-302-20

Standard Heater Circuits - Continued
Heater Fan Does Not Operate at Any Speed - 4. Remove start/auxiliary 15A If +12 VDC is present, go to step
Continued. fuse. Check for +12 VDC at 5. If voltage is not present, repair
lead 71A fuse connector. lead 71A (WP 0119 00).
5. Disconnect heater fan power If +12 VDC is present, go to step
for +12 VDC at connector 30. lead 98 (WP 0119 00).
6. Disconnect heater fan high If +12 VDC is present, go to step
for +12 VDC at connector 87. lead 98 (WP 0119 00).
connector 86 and ground for step 8. If continuity is not
both relays. indicated, repair ground lead (WP
0119 00).
8. Disconnect heater fan power If +12 VDC is present, go to step
for +12 VDC at connector 85. lead 71A (WP 0119 00).
heater fan control. Check for 10. If voltage is not present,
+12 VDC at lead 98. disconnect heater fan power relay.
Check for continuity in lead 98. If
continuity is indicated, replace
heater fan power relay (WP 0071
00). If continuity is not indicated,
10. Disconnect lead 98L from If +12 VDC is present, go to step
heater fan control. Check for 11. If voltage is not present,
+12 VDC at heater fan control replace heater fan control (WP
connector (D) with heater fan 0067 00).
control in high mode.
11. Disconnect heater fan high If +12 VDC is present, go to step
for +12 VDC at connector 85 lead 98L (WP 0119 00).
with heater fan control in high
mode.
12. Disconnect lead 98T from If +12 VDC is present, go to step
heater fan motor. Check for 13. If voltage is not present,
+12 VDC at lead 98T with disconnect heater fan high relay
heater fan control in high from connector. Check for
mode. continuity in lead 98T between
connector 30 and heater fan motor.
If continuity is indicated, replace
heater fan high relay (WP
0071 00). If continuity is not indi-
cated, repair lead 98T (WP 0119 00).
0010 00-18
TM 9-2320-302-20

Standard Heater Circuits - Continued
Heater Fan Does Not Operate at Any Speed - 13. Disconnect ground lead from If continuity is indicated, replace
Continued. heater fan motor. Check for heater fan motor (WP 0220 00). If
continuity between ground continuity is not indicated, repair
0010 00-19
TM 9-2320-302-20
0010 00-20
TM 9-2320-302-20
TRANSMISSION AND DRIVELINE SYSTEMS TROUBLESHOOTING 0011 00
NOTE
In addition to the transmission troubleshooting located in Table 1 below, the Allison Transmission Trouble-
shooting Manual is duplicated in its entirety and is located beginning on page 0011 00-7. An index of trou-
bleshooting diagnostic codes is on page 0011 00-36.
Table 1. Transmission and Driveline Troubleshooting Procedures.

Transmission
1. Shift Selector Display Is Blank. 1. Check if VIM fuse is blown. Replace VIM fuse (WP 0071 00).
2. Check for damaged or loose Tighten or repair battery
battery connections. connections (WP 0115 00).
3. Check for blown fuse or fusible Replace battery fuse or fusible
link at battery. link (WP 0071 00).
2. Vehicle Does Not Start (Engine Does Not 1. Check that lever is in N Place shift selector in N (Neutral)
Crank). (Neutral). position and restart vehicle (TM
9-2320-302-10).
2. Check for dead battery. Recharge battery as necessary TM
9-6140-200-14).
3. Check for damaged or loose Tighten or repair battery
battery connections. connections (WP 0115 00).
4. Faulty starter circuit. Repair vehicle starter circuit (WP
0010 00).
5. Faulty neutral start relay. Replace neutral start relay (WP
0071 00).
6. Faulty wiring in neutral start Repair wiring (WP 0119 00).
circuit.
7. Voltage to ECU too low. Check battery and charging
system voltage (WP 0010 00).
8. Faulty shift selector. Replace shift selector (WP
0120 00).
9. Lack of battery voltage on Repair circuit 123 (WP 0120 00)
circuit 123 from ECU when in or replace ECU (WP 0124 00).
neutral.
All Display Segments on Both Sides of Display No calibration installed in ECU. Check battery and charging
Lighted. Voltage to ECU too low. system voltage (WP 0010 00).
Notify Direct Support
Maintenance.
Transmission Shifting
1. DO NOT SHIFT Light Will Not Go Out at
Start-up
Vehicle Drives Normally Faulty DO NOT SHIFT light, Replace relay or repair circuit
relay, or circuit. (WP 0120 00).
0011 00-1
TM 9-2320-302-20
Table 1. Transmission and Driveline Troubleshooting Procedures - Continued.

Transmission Shifting - Continued
Vehicle Does Not Drive 1. Faulty ECU. Replace ECU (WP 0124 00).
2. Engine does not start. Repair engine starting system
(WP 0006 00).
3. Faulty harness. Repair harness (WP 0119 00) or
replace harness (WP 0125 00).
4. Faulty interface wiring to Repair wiring (WP 0119 00).
vehicle electrical system.
5. Transmission fluid temperature Warm transmission fluid.
too low.
6. Faulty ECU. Replace ECU (WP 0124 00).
2. DO NOT SHIFT Light Flashes Intermittently. 1. Intermittent power to ECU. Check connections to ECU and
correct if necessary.
2. Faulty or incorrect ground wire Repair ground circuit (WP
attachment. 0119 00).
3. No DO NOT SHIFT Light at Ignition. 1. Faulty light bulb or socket. Replace light bulb or socket (WP
0120 00).
2. Faulty wiring harness. Check wiring between ECU and
DO NOT SHIFT light. Repair
where necessary (WP 0119 00).
4. ECU Will Not Turn Off When Ignition Switch Faulty ignition switch. Replace ignition switch (WP
Is Turned Off. 0010 00). Notify Direct
Support Maintenance.
5. Transmission Will Not Shift to Forward or 1. Engine RPM too high. Reduce engine RPM.
Reverse (Stays In Neutral).
2. Low transmission fluid level. Add fluid to proper level (TM 9-
2320-302-10).
3. Transmission fluid temperature Warm transmission fluid.
too low.
4. Throttle position sensor set-up Refer to throttle position sensor
is incorrect. for correct set-up (WP 0006 00).
5. Voltage to ECU too low. Check vehicle battery and
charging system (WP 0010 00).
6. Shift selector is not functioning Replace shift selector (WP
properly. 0120 00).
7. Disconnected or dirty Perform connector checkout.
connectors.
8. Faulty wiring harnesses. Repair harness (WP 0119 00).
6. Transmission Will Not Stay in Forward or Auto-neutral or quick-to-neutral Notify Direct Support
Reverse. circuit (input function) faulty. Maintenance.
0011 00-2
TM 9-2320-302-20

Transmission Shifting - Continued
7. Transmission Will Not Make a Specific Shift. 1. Low engine power. Correct engine problem (WP
0006 00).
2. Incorrect transmission fluid Correct fluid level (TM 9-2320-
level. 302-10).
3. Extreme transmission fluid Inspect cooling system and fluid
temperature. level (WP 0006 00).
0120 00).
Maintenance.
8. Transmission Does Not Shift Properly (Rough 1. Engine idle speed too fast Adjust engine idle speed (WP
Shifts, Shifts Occurring at Too Low or Too (neutral to range shift). 0006 00).
High Speed).
2. ECU input voltage low. Check power, ground, charging
system, and battery function (WP
0010 00).
level 302-10).
4. Intermittent problems. Check wiring harnesses and
connectors (WP 0119 00). Notify
Direct Support Maintenance.
Abnormal Activities or Responses from Transmission
1. Excessive Creep in First and Reverse Gears. Engine idle speed too high. Adjust to correct idle speed
between 500-800 RPM (WP
0006 00).
2. No Response to Shift Selector. 1. Shift selector not properly Check shift selector response with
connected. diagnostic tool. If no response,
check remote connection and
replace if necessary (WP
0120 00).
0120 00).
level. 302-10).
3. Vehicle Moves Forward in Neutral. C1 clutch failed or not released. Notify Direct Support
Maintenance.
4. Vehicle Moves Backward in Neutral. C3 clutch failed or not released. Notify Direct Support
Maintenance.
5. Engine Overspeed on Full-throttle Upshifts. 1. TPS adjustment:
- Overstroke Adjust TPS (WP 0006 00).
0011 00-3
TM 9-2320-302-20

Abnormal Activities or Responses from Transmission - Continued
5. Engine Overspeed on Full-throttle Upshifts - 2. ECU input voltage low. Check electrical system and all
Continued. connections from battery and
ECU (WP 0010 00 or WP
0119 00).
level. 302-10).
4. Piston seals leaking or clutch Notify Direct Support
plates slipping in range Maintenance.
involved.
6. Excessive Slippage and Clutch Chatter. 1. Incorrect calibration. Verify calibration. Notify Direct
Support Maintenance.
2. ECU input voltage low. Check power, ground, charging
system, and battery functions (WP
0010 00).
3. Throttle position sensor out of Adjust or replace throttle position
adjustment or failed. sensor (WP 0006 00).
level. 302-10).
7. Abnormal Stall Speeds (Stall in First Range -
6-speed).
High Stall Speeds. 1. Not in gear. Select D (Drive).
2. Low fluid level, aerated fluid. Add fluid to proper level (TM 9-
2320-302-10).
3. C1 and C5 clutch slipping (6- Notify Direct Support
speed, 1st range start). Maintenance.
Low Stall Speeds. Engine not performing efficiently Refer to Engine Troubleshooting
(may be due to plugged or (WP 0006 00). Notify Direct
restricted injectors, high altitude Support Maintenance.
conditions, dirty air filters, out of
time, throttle linkage, electronic
engine controls problem).
8. Overheating in All Ranges. 1. Aerated fluid - incorrect fluid Adjust fluid to proper level (TM
level. 9-2320-302-10).
2. Engine overheat. Correct overheat situation (WP
0006 00).
3. Inaccurate temperature gage. Replace gage (WP 0062 00).
4. Fluid cooler lines restricted. Remove restrictions, clean or
replace lines (WP 0122 00).
Maintenance.
9. Fluid Comes out Fluid Fill Tube and/or 1. Dipstick loose. Tighten cap. Replace if necessary
Breather. (WP 0121 00).
0011 00-4
TM 9-2320-302-20

Abnormal Activities or Responses from Transmission - Continued
9. Fluid Comes out Fluid Fill Tube and/or 2. Transmission fluid level too Drain to proper level (TM 9-2320-
Breather - Continued. high. 302-10).
3. Transmission fluid level too Add fluid to proper level (TM 9-
low. 2320-302-10).
4. Breather clogged. Clean or replace breather (WP
0128 00).
5. Transmission fluid contam- Drain and replace fluid (WP 0021
inated with foreign liquid. 00). Locate and repair source of
contaminating fluid.
6. Dipstick or fill tube seal worn. Replace seals or dipstick (WP
0121 00).
10. Noise Occurring Intermittently (Buzzing). 1. Low transmission fluid level. Add fluid to proper level (TM 9-
2320-302-10).
2. Air leak in oil suction screen Replace oil suction screen canister
canister. (WP 0123 00).
3. Clogged filters. Replace filters (WP 0123 00).
4. Aerated fluid causes noisy Correct fluid level (TM 9-2320-
pump. 302-10). Notify Direct Support
Maintenance.
11. Leaking Fluid (Output Shaft). Faulty or missing seal at output Notify Direct Support
flange. Maintenance
12. Transmission Leaks (Input). 1. Front seal leaks Notify Direct Support
Maintenance.
2. Converter leaks. Notify Direct Support
Maintenance.
13. Dirty Transmission Fluid. 1. Failure to change fluid and Change fluid and install new
filters. filters (WP 0123 00).
2. Damaged fluid filter/seals. Replace oil filter/seals (WP
0123 00).
Forward-rear Axle and Rear-rear Axle Driveline Assemblies
1. No Drive at Forward-rear Axle and/or Rear- 1. Check propeller shaft and Replace any defective universal
rear Axle. universal joints from joint(s) (WP 0130 00). Replace
transmission rear output to defective propeller shaft (WP
forward-rear axle for broken 0129 00).
universal joint(s) and broken or
damaged tube, splines or
yoke(s).
0011 00-5
TM 9-2320-302-20

Forward-rear Axle and Rear-rear Axle Driveline Assemblies - Continued
1. No Drive at Forward-rear Axle and/or Rear- 2. Check propeller shaft and Replace any defective universal
rear Axle - Continued. universal joints from forward- joint(s) (WP 0130 00). Replace
rear axle to rear-rear axle for defective propeller shaft (WP
broken universal joint(s) and 0129 00).
broken or damaged tubes,
splines or yoke(s).
3. Check forward-rear axle and Notify Direct Support
rear-rear axle for broken axle Maintenance.
shaft(s).
2. Vibration or Noise During or While Driving. 1. Check propeller shafts and Replace any defective universal
universal joints for obvious joint(s) (WP 0130 00). Replace
wear or damage. defective propeller shaft (WP
0129 00).
2. Check wheels for looseness Tighten any loose wheel lug nuts
and obvious damage. (WP 0164 00). Replace any
damaged wheel(s).
3. If problem still exists, notify
Direct Support Maintenance.
0011 00-6
WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
FOREWORD — How to Use This Manual
This manual provides troubleshooting information for Allison Transmission Division, MD/HD/B Series
On-Highway Transmissions. Service Manuals SM2148EN and SM2457EN, plus Parts Catalogs PC2150EN and
PC2456EN may be used in conjunction with this manual.
This manual includes:
• Description of the WTEC III electronic control system.
• Description of the electronic control system components.
• Description of diagnostic codes, system responses to faults, and troubleshooting.
• Wire, terminal, and connector repair information.
Specific instructions for using many of the available or required service tools and equipment are not included in
this manual. The service tool manufacturer will furnish instructions for using the tools or equipment.
Additional information may be published from time to time in Service Information Letters (SIL) and will be
included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date information
concerning Allison Transmission products.
This publication is revised periodically to include improvements, new models, special tools, and procedures. A
revision is indicated by a letter suffix added to the publication number. Check with your Allison Transmission
service outlet for the currently applicable publication. Additional copies of this publication may be purchased from
authorized Allison Transmission service outlets. Look in your telephone directory under the heading of
Transmissions — Truck, Tractor, etc.
Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly
locating information.
NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness components as
follows:
• Repair parts for the internal wiring harness and for wiring harness components attached to the shift selector
will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your
appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for
warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained from St. Clair
Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is responsible for
warranty on these parts. SCTI recognizes ATD, manufacturers, and SCTI part numbers. SCTI provides a
technical HELPLINE at 519-627-1673 (Wallaceburg). SCTI will have parts catalogs available. The SCTI
addresses and phone numbers for parts outlets are:
St. Clair Technologies, Inc. St. Clair Technologies, Inc. St. Clair Technologies, Inc.
1050 Old Glass Road 1111 Mikesell Street c/o Mequilas Tetakawi
Wallaceburg, Ontario, Canada, N8A 3T2 Charlotte, Michigan 48813 Carr. Internationale KM 1969
Phone: (519) 627-1673 Phone: (517) 541-8166 Guadalajara – Nogales, KM2
Fax: (519) 627-4227 Fax: (517) 541-8167 Empalme, Sonora, Mexico
Phone: 011-52-622-34661
Fax: 011-52-622-34662
• St. Clair Technologies, Inc. stocks a WTEC III external harness repair kit, P/N 29532362, as a source for
some external harness repair parts. SCTI is the source for external harness repair parts.
TRADEMARKS USED IN THIS MANUAL
0011 00-7
IMPORTANT SAFETY NOTICE
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions

used in this manual. These warnings and cautions advise against using specific service
procedures that can result in personal injury, equipment damage, or cause the equipment to
become unsafe. These warnings and cautions are not exhaustive. Allison Transmission could
not possibly know, evaluate, or advise the service trade of all conceivable procedures by which
service might be performed or of the possible hazardous consequences of each procedure.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service proce-
dures used.
Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the
vehicle manufacturer and/or body builder before servicing the Allison transmission in that
vehicle.
Proper service and repair is important to the safe and reliable operation of the equipment. The
service procedures recommended by Allison Transmission and described in this manual are
effective methods for performing troubleshooting operations. Some procedures require using
specially designed tools. Use special tools when and in the manner recommended.
The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission
and not to other vehicle systems which may interact with the transmission. Be sure to review and
observe any vehicle system information provided by the vehicle manufacturer and/or body builder
at all times the Allison transmission is being serviced.
WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:
Is used when an operating procedure, practice, etc., which, if not correctly followed,
WARNING! could result in injury or loss of life.
Is used when an operating procedure, practice, etc., which, if not strictly observed, could
CAUTION: result in damage to or destruction of equipment.
NOTE: Is used when an operating procedure, practice, etc., is essential to highlight.
0011 00-8
Trademarks Used In This Manual
The following trademarks are the property of the companies indicated:
• DEXRON® is a registered trademark of General Motors Corporation.
• LPS® Cleaner is a registered trademark of LPS Laboratories.
• Loctite® is a registered trademark of the Loctite Corporation.
• Teflon® is a registered trademark of the DuPont Corporation.
• Pro-Link® is a registered trademark of MicroProcessor Systems, Inc.
SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS
Shift selector terms and displays are represented in this manual as follows:
• Button Names —⇑, ⇓, “display mode”, MODE, etc.

• Transmission Ranges — D (Drive), N (Neutral), R (Reverse), 1 (First), 2 (Second), etc.
• Displays — “o, L”; “o, K”, etc. (Display occurs one character at a time.)
0011 00-9
TABLE OF CONTENTS
Page
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-7
SAFETY INFORMATION
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-8
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-8
Trademarks Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-9
Shift Selector Terms and Display Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-9
SECTION 1. GENERAL DESCRIPTION

1–1. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-13
1–2. ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-15
1–3. SHIFT SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-15
Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-15
1–4. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-16
1–5. CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-17
1–6. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-18
A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-18
B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-20
1–7. VEHICLE INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-20
SECTION 2. DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-21
2–2. DIAGNOSTIC DATA READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-21
2–3. ABBREVIATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-22
SECTION 3. BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-25
3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-25
3–3. SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-25
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS. . . . . . . . . . 0011 00-26
3–5. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-27
SECTION 4. WIRE CHECK PROCEDURES

4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . 0011 00-29
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS
FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . . . . . . . . 0011 00-30
0011 00-10
TABLE OF CONTENTS (cont’d)
Page
SECTION 5. DIAGNOSTIC CODES

5–1. DIAGNOSTIC CODE MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-33
5–2. CODE READING AND CODE CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-33
5–3. DIAGNOSTIC CODE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-35
5–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES . . . . . . . . . . . . . . . . . . 0011 00-36
5–5. DIAGNOSTIC CODE LIST AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-36
5–6. DIAGNOSTIC CODE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-47
A. Beginning the Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-47
B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-47
C. Diagnostic Code Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-47
D. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-47
APPENDICES
A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS. . . . . . . . . . . . . . . . . . . . . 0011 00-122
B. CHECKING CLUTCH PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-125
C. SOLENOID AND CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-135
D. WIRE/CONNECTOR CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-137
E. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . 0011 00-167
F. DIAGNOSTIC TREE — WT SERIES HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 0011 00-169
G. PRO-LINK® 9000 DIAGNOSTIC DATA READER INFORMATION . . . . . . . . . . . . . . 0011 00-171
H. INPUT/OUTPUT FUNCTION WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-173
0011 00-11
0011 00-12
S ECT ION 1 — GENERAL DESCRIPTION

1–1. TRANSMISSION
The World Transmission Electronic Controls (WTEC III) system features closed-loop clutch control to provide
superior shift quality over a wide range of operating conditions. MD 3000, HD 4000, and B Series configurations
can be programmed to have up to six forward ranges, neutral, and one reverse range. The MD 3070 and HD4070
have up to seven forward ranges and one reverse range.
Figure 1–1 is a block diagram of the basic system inputs and outputs.
Figure 1–1. Electronic Control Unit Block Diagram
Figure 1–2 shows WTEC III electronic control components.
WTEC III Electronic Controls consist of the following elements:

• Remote 12/24V Max Feature Sealed Electronic Control Unit (ECU)
• Remote Pushbutton or Lever Shift Selector
• Optional Secondary Shift Selector
• Throttle Position Sensor (TPS) (or electronic engine throttle data or PWM signal)
• Engine, Turbine, and Output Speed Sensors
• Control Module (Electro-Hydraulic Valve Body)
• Wiring Harnesses
• Vehicle Interface Module (VIM)
• Autodetect Feature
• TransID Feature
• Optional Retarder Controls
• Optional Engine Coolant Temperature Input
NOTE: • All external harnesses are OEM supplied

• Some OEMs may supply their own shift selector
• The VIM is an OEM option
0011 00-13
GENERAL DESCRIPTION
Figure 1–2. WTEC III Electronic Control Components
0011 00-14
GENERAL DESCRIPTION
1–2. ELECTRONIC CONTROL UNIT (ECU)
The ECU (Figure 1–3) contains the microcomputer which is the brain of the control system. The ECU receives and
processes information defining: shift selector position, throttle position, sump/retarder temperature, engine speed,
turbine speed, and transmission output speed. The ECU uses the information to control transmission solenoids and
valves, supply system status, and provide diagnostic information.
Each ECU has a date code stamped on the label which is attached to the outer case of the ECU. This is the date
when the ECU passed final test. This date is commonly used to denote the change configuration level of the ECU.
It is normal for the ECU date displayed electronically to be a few days prior to the date shown on the label.
Figure 1–3. Electronic Control Unit (ECU)
1–3. SHIFT SELECTOR
Pushbutton and lever shift selectors for the WTEC III Series are remote mounted from the ECU and connected to
the ECU by a wiring harness. Both of these shift selectors have a single digit LED display and a mode indicator
(LED). During normal transmission operation, illumination of the LED indicator shows that a secondary or special
operating condition has been selected by pressing the MODE button. During diagnostic display mode, illumination
of the LED indicator shows that the displayed diagnostic code is active. Display brightness is regulated by the same
vehicle potentiometer that controls dash light display brightness. More information on both types of shift selectors
is continued below.
A. Pushbutton Shift Selector (Figure 1–4)
There is a full-function pushbutton shift selector and a strip pushbutton shift selector. Strip
pushbutton shift selectors are used by European OEMs. A full-function shift selector has a MODE
button and diagnostic display capability through the single digit LED display. The strip pushbutton
shift selector does not have a MODE button, diagnostic capability, or adjustable illumination. The
full-function pushbutton shift selector has six (6) pushbuttons which are R (Reverse), N (Neutral),
D (Drive), ⇓ (Down), ⇑ (Up), and MODE. Manual forward range downshifts and upshifts are made
by pressing the ⇓ (Down) or ⇑ (Up) arrow buttons after selecting D (Drive). The N (Neutral) button
has a raised lip to aid in finding it by touch. The MODE button is pressed to select a secondary or
special operating condition, such as ECONOMY shift schedule. Diagnostic information is obtained
by pressing the ⇑ (Up) and ⇓ (Down) arrow buttons at the same time. The strip pushbutton shift
selector has either three or six range selection positions as shown in Figure 1–4. When a strip
pushbutton shift selector is used, diagnostic information must be obtained by using the
Pro-Link® 9000 or a customer-furnished remote display.
0011 00-15
GENERAL DESCRIPTION
Figure 1–4. Pushbutton Shift Selectors
1–4. SPEED SENSORS (Figure 1–5)

Three speed sensors — engine speed, turbine speed, and output speed — provide information to the ECU. The
engine speed signal is generated by ribs on the shell of the torque converter pump. The turbine speed signal is
generated by the rotating-clutch housing spline contours. The output speed signal is generated by a toothed
member attached to the output shaft (except for the MD 3070, where the toothed member is the transfer case idler
gear). The speed ratios between the various speed sensors allow the ECU to determine if the transmission is in the
selected range. Speed sensor information is also used to control the timing of clutch apply pressures, resulting in
the smoothest shifts possible. Hydraulic problems are detected by comparing the speed sensor information for the
current range to that range’s speed sensor information stored in the ECU memory.
Figure 1–5. Speed Sensors
0011 00-16
GENERAL DESCRIPTION
1–5. CONTROL MODULE (Figure 1–6)

The WT Series transmission control module contains a channel plate on which is mounted: the main valve body
assembly, the stationary-clutch valve body assembly, and the rotating-clutch valve body assembly. For valve
locations, refer to SIL 27-WT-93, Rev. A. Pulse width modulated solenoids are used in the valve bodies. The
rotating-clutch valve body assembly contains A (C1), B (C2), and F (lockup) solenoids, solenoid regulator valves
controlled by the solenoids, and the C3 pressure switch. The stationary-clutch valve body assembly contains
C(C3), D (C4), and E (C5) solenoids and solenoid regulator valves controlled by the solenoids and the
C3accumulator relay valve. The main valve body assembly contains G solenoid and the C1 and C2 latch valves
controlled by the solenoid, the main and lube regulator valves, the control main and converter regulator valves, and
the converter flow valve and exhaust backfill valves. The low valve body assembly (MD 3070PT and HD4070)
contains N and J solenoids.
Figure 1–6. WTEC III Control Module
A temperature sensor (thermistor) is located in the internal wiring harness. Changes in sump fluid temperature are
indicated by changes in sensor resistance which changes the signal sent to the ECU (see chart in Section 5,
Code24).
The oil level sensor is a float type device, mounted on the control module channel plate, which senses transmission
fluid level by electronically measuring the buoyancy forces on the float. The sensor operates on 5 VDC supplied by
the ECU. The oil level sensor is required on all models with a shallow sump but is optional on other models. The
oil level sensor is not available on the MD 3070.
The C3 pressure switch is mounted on the rotating-clutch valve body assembly and indicates when pressure exists
in the C3 clutch-apply passage. An accumulator/relay valve is in-line ahead of the C3 pressure switch and prevents
high frequency hydraulic pulses generated by the C3 solenoid from cycling the C3 pressure switch.
Also mounted in the control module is the turbine speed sensor for the MD/B 300/B 400 models. The turbine speed
sensor is directed at the rotating-clutch housing. (The turbine speed sensor on the HD/B 500 models is located on
the outside of the main housing.)
0011 00-17
GENERAL DESCRIPTION
1–6. WIRING HARNESSES
A. External Wiring Harness (Figure 1–7)

WTEC III uses three external wiring harnesses to provide a connection between the ECU, the
transmission (including engine, turbine, and output speed sensors), the throttle position sensor, the
vehicle interface module (VIM), retarder control module, shift selectors, diagnostic tool connector,
retarder, retarder temperature sensor, accumulator, and vehicle interface. Many harnesses will include
a bulkhead fitting to separate cab and chassis components. Also, many different styles and materials
for harnesses are likely to be encountered.
0011 00-18
GENERAL DESCRIPTION
Figure 1–7. WTEC III External Wiring Harnesses
0011 00-19
GENERAL DESCRIPTION
B. Internal Wiring Harness (Figure 1–8)
The internal wiring harness provides connection between the external harness, the pulse width
modulated solenoids, oil level sensor, C3 pressure switch, and the temperature sensor.
Figure 1–8. WTEC III Internal Wiring Harness
1–7. VEHICLE INTERFACE MODULE (Figure 1–9)
The vehicle interface module (VIM) provides relays, fuses, and connection points for interface with the output side
of the vehicle electrical system. VIMs are available for both 12V and 24V electrical systems. The VIM for 12V
systems uses all 12V relays. The VIM for 24V systems has all 24V relays. Refer to the Parts Catalog for the
transmission assembly number that you are servicing for detailed parts information. Refer to Pages D–23 and D–24
for VIM wire number and terminal information.
Some OEMs may provide their own equivalent for the VIM which performs the same functions as the VIM shown
in Figure 1–9.
Figure 1–9. Vehicle Interface Module (VIM)
0011 00-20
S ECT ION 2 — DEFINITIONS AND ABBREVIATIONS
2–1. CHECK TRANS LIGHT

When the ECU detects a serious fault, the CHECK TRANS light (usually located on the vehicle instrument panel)
illuminates and action is automatically taken to protect operator, vehicle, and the transmission. A diagnostic code will
nearly always be registered when the CHECK TRANS light is on; however, not all diagnostic codes will turn on the
CHECK TRANS light. Codes related to the CHECK TRANS light are detailed in the code chart (refer to Section 6).
Illumination of the CHECK TRANS light indicates that a condition was detected that requires service attention.
Operation may or may not be restricted but even when restricted will allow the vehicle to reach a service assistance
location. Depending upon the cause for the CHECK TRANS light illumination, the ECU may or may not respond
to shift selector requests. The transmission may be locked in a range. That range will be shown on the shift selector
display. Both upshifts and downshifts may be restricted when the CHECK TRANS light is illuminated. Seek
service assistance as soon as possible.
Each time the engine is started, the CHECK TRANS light illuminates briefly and then goes off. This momentary
lighting shows the light circuit is working properly. If the light does not come on during engine start, request
service immediately.
2–2. DIAGNOSTIC DATA READER ( Figure 2–1)

The current Diagnostic Data Reader (DDR) is the Pro-Link® 9000 diagnostic tool which is available through
Kent-Moore Heavy-Duty Division. A portable microcomputer-based receiver/transmitter/display unit, the
Pro-Link ® transmits and receives data to and from the ECU, processes the data, and displays appropriate
information. Use the Pro-Link® during installation checkout and troubleshooting. There is a new Pro-Link ®
cartridge needed for use with WTEC III controls. The new Multi-Protocol Cartridge (MPC) contains a
programmed PCMCIA card which allows for reprogramming of GPI/GPO packages. Reprogramming includes
selection of a GPI/GPO package, enabling/disabling of wires and modification of certain data parameters.
Operating instructions are supplied with each Pro-Link® and further information is also included in Appendix N of
this manual. Connect the Pro-Link® 9000 to the diagnostic connector provided in the selector wiring harness.
Tool part numbers for the Pro-Link ® are as follows:

• Diagnostic Kit J 38538D + J 38500–313 (PROM Update) = J 38538E
• Diagnostic Cartridge J 38500-302 + J 38500–313 = J 38500–303
• MPC J 38500–1500C
• PCMCIA (Diagnostic And Reprogramming) J 38500–1700B
• PCMCIA (Diagnostic Only) J 38500–1800A
NOTE: The new MPC is usable with WTEC II controls but the old WTEC II reprogramming cartridge will
not display the WTEC III new information. The new MPC must be used to reprogram WTEC III
systems.
Figure 2–1. Pro-Link® 9000 Diagnostic Tool
0011 00-21
DEFINITIONS AND ABBREVIATIONS
2–3. ABBREVIATIONS
A/N Assembly Number
ABS Anti-lock Brake System — OEM-provided means to detect and prevent wheel stoppage to
enhance vehicle handling. Retarder and engine brakes will not apply when ABS is active.
Amp Unit of electrical current.
C3PS C3 Pressure Switch — Pressure switch to signal the presence or absence of pressure in the
C3 clutch-apply circuit.
CAN Controller Area Network — A network for all SAE J1939 communications in a vehicle
(engine, trnasmission, ABS, etc.)
COP Computer Operating Properly — Hardware protection which causes the ECU to reset if
software gets lost.
CT Closed Throttle
DDR Diagnostic Data Reader — Diagnostic tool; most current version is the Pro-Link® 9000
made by MicroProcessor Systems, Inc. Used to interrogate the ECU for diagnostic
information and for reprogramming I/O packages in a calibration.
DNA Does Not Adapt — Adaptive shift control is disabled.
DNS DO NOT SHIFT — Refers to the DO NOT SHIFT diagnostic response during which the
CHECK TRANS light is illuminated and the transmission will not shift and will not
respond to the Shift Selector.
DVOM Digital volt/ohmmeter
ECU Electronic Control Unit (also commonly referred to as the “computer”)
GPI General Purpose Input — Input signal to the ECU to request a special operating mode or
condition.
GPO General Purpose Output — Output signal from the ECU to control vehicle components
(such as PTOs, backup lights, etc.) or allow a special operating mode or condition.
J1587 Engine/transmission serial data communications link.
J1939 High-speed vehicle serial data communications link.
LED Light-Emitting Diode — Electronic device used for illumination.
NNC Neutral No Clutches — Neutral commanded with no clutches applied.
NVL Neutral Very Low — The ECU has sensed turbine speed below 150 rpm when output
speed is below 100 rpm and engine speed is above 400 rpm when N (Neutral) was selected.
This is usually caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. NVL
is attained by turning D solenoid “ON” (in addition to E solenoid) and the C4 and C5
clutches are applied to lock the transmission output.
OEM Original Equipment Manufacturer — Maker of vehicle or equipment.
Ohm Unit of electrical resistance.
OL Over Limit or Oil Level — For Over Limit see “×”. Indicates Oil Level is being displayed
on a shift selector.
0011 00-22
2–3. ABBREVIATIONS (CONTINUED)

OLS Oil Level Sensor — Electronic device (optional) on control module for indicating
transmission fluid level.
PCCS PROM Calibration Configurator System
PCMCIA Personal Computer Memory Card International Association — Memory device for use
with Pro-Link® containing Allison Transmission programming and diagnostics.
PROM Programmable Read Only Memory
PSS Primary Shift Selector — Main shift selector in a two-selector control system.
PTO Power Takeoff
PWM Solenoid Pulse Width Modulated Solenoid — Solenoids are controlled by pulse width modulation.
Solenoid control of clutch pressures is based on the solenoid’s duty cycle. Duty cycle is
determined by the ratio of solenoid’s on-time to off-time.
RMR Retarder Modulation Request — Signal from a retarder control device.
RPR Return to Previous Range — Diagnostic response in which the transmission is
commanded to return to previously commanded range.
SCI Serial Communication Interface — Used to transmit data and messages between the
diagnostic tool and the ECU and other systems such as electronically-controlled engines.
SOL OFF All SOLenoids OFF
SPI Serial Peripheral Interface — The means of communication between the microprocessor
and the interface circuits.
SSS Secondary Shift Selector — Alternate shift selector in a two-selector control system.
TID TransID — A feature which allows the ECU to know the transmission configuration and
provide the corresponding calibration required.
TPS Throttle Position Sensor — Potentiometer for signaling the position of the engine fuel
control lever.
V Version — Abbreviation used in describing ECU software levels.
VDC Volts Direct Current (DC)
VIM Vehicle Interface Module — A watertight box containing relays and fuses — interfaces the
transmission electronic control system with components on the vehicle.
VIW Vehicle Interface Wiring — Interfaces ECU programmed input and output functions with
the vehicle wiring.
Volt Unit of electrical force.
VOM Volt/ohmmeter
WOT Wide Open Throttle
WT World Transmission
× Infinity — Condition of a circuit with higher resistance than can be measured, effectively
an open circuit.
0011 00-23
0011 00-24
SECTION 3 — BASIC KNOWLEDGE
3–1. BASIC KNOWLEDGE REQUIRED
To service WTEC III Electronic Controls, the technician must understand basic electrical concepts. Technicians
need to know how to use a volt/ohmmeter (VOM) to make resistance and continuity checks. Most troubleshooting
checks consist of checking resistance, continuity, and checking for shorts between wires and to ground. The
technician should be able to use jumper wires and breakout harnesses and connectors. Technicians unsure of
making the required checks should ask questions of experienced personnel or find instruction.
The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to
identified pressure ports used in the troubleshooting process. Pressure tap locations and pressure values are shown
in Appendix B — Checking Clutch Pressures.
Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning
and may not generate a diagnostic code. A working knowledge of WT Series Electronic Controls vehicle
installation is necessary in troubleshooting installation-related problems.
Refer to Section 8 for information concerning performance complaints (non-code) troubleshooting. A complete
wiring schematic is shown in Appendix J. Refer to the WTEC III Controls and General Information Sales Tech
Data Book for information concerning electronic controls installation and the Installation Checklist. Reliable
transmission operation and performance depend upon a correctly installed transmission. Review the Installation
Checklist in the MD, HD, B 300/B 400, and B 500 Sales Tech Data Books to ensure proper installation.
3–2. USING THE TROUBLESHOOTING MANUAL
Use this manual as an aid to troubleshooting the WTEC III Electronic Controls. Every possible problem and its
solution cannot be encompassed by any manual. However, this manual does provide a starting point from which
most problems can be resolved.
Once a problem solution is discovered in the manual do not look further for other solutions. It is necessary to
determine why a problem occurred. For example, taping a wire that has been rubbing on a frame rail will not
correct the problem unless the rubbing contact is eliminated.
3–3. SYSTEM OVERVIEW
WTEC III Electronic Control functions are controlled by the ECU. The ECU reads shift selector range selection,
output speed, and throttle position to determine when to command a shift. When a shift occurs, the ECU monitors
turbine speed, output speed, and throttle position to control the oncoming and off-going clutches during the shift.
When the ECU detects an electrical fault, it logs a diagnostic code indicating the faulty circuit and may alter the
transmission operation to prevent or reduce damage.
When the ECU detects a non-electrical problem while trying to make a shift, the ECU may try that shift a second or
third time before setting a diagnostic code. Once that shift has been retried, and a fault is still detected, the ECU
sets a diagnostic code and holds the transmission in a fail-to-range mode of operation.
0011 00-25
BASIC KNOWLEDGE
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

Before beginning the troubleshooting process, read and understand the following:
• WTEC III wire identification presents the wire number followed by the ECU terminal source
(i.e., 157-S30). If there is a letter suffix following the wire number, there is a splice between the ECU
source and wire destination (i.e., 136A-S16).
• Shut off the engine and ignition before any harness connectors are disconnected or connected.
• Remember to do the following when checking for shorts and opens:

— Minimize movement of wiring harnesses when looking for shorts. Shorts involve wire-to-wire or
wire-to-ground contacts and moving the harnesses may eliminate the problem.
— Wiggle connectors, harnesses, and splices when looking for opens. This simulates vehicle
movements which occur during actual operation.
• When disconnecting a harness connector, be sure that pulling force is applied to the connector itself and
not the wires extending from the connector.
• Resistance checks involving the wiring between the ECU connectors and other components adds about
one ohm of resistance to the component resistance shown.
0011 00-26
BASIC KNOWLEDGE
• Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to
maintain firm contact.
• Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-
residue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner ® or LPS NoFlash
Electro Contact Cleaner®.
The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct
electricity. The cleaning solvent should evaporate quickly to prevent the possibility of
condensation within the connectors. Always blow or shake any excess cleaner from the
CAUTION:
connector before assembling it to its mating connector or hardware. Cleaner trapped in the
connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information
on the recommended cleaners.)
Care should be taken when welding on a vehicle equipped with electronic controls. Refer
CAUTION:
to Appendix E, Paragraph 1–1.
• Diagnostic codes displayed after system power is turned on with a harness connector disconnected, can
be ignored and cleared from memory. Refer to Section 5, Diagnostic Codes, for the code clearing
procedure.
3–5. BEGINNING THE TROUBLESHOOTING PROCESS
NOTE: Whenever a transmission is overhauled, exchanged, or has undergone internal repairs, the Electronic
Control Unit (ECU) must be “RESET TO UNADAPTED SHIFTS.” See Service Information Letter
16-WT-96, Revision A availability from Freightliner dealer for further details.
1. Begin troubleshooting by checking the transmission fluid level and ECU input voltage. Remember
that some problems may be temperature related. Do troubleshooting at the temperature level where
the problem occurs. Check diagnostic codes by:
• Using the shift selector display. (See Paragraph 5–2 for code reading.)
• Using the Pro-Link ® 9000 diagnostic tool.
2. When a problem exists but a diagnostic code is not indicated, refer to Transmission and Driveline Trou-
bleshooting WP 0011 00 for a listing of various problems, their causes, and remedies.
3. If a diagnostic code is found in the ECU memory, record all available code information and clear the
active indicator (refer to Section 5).
4. Test drive the vehicle to confirm a diagnostic code or performance complaint.
• If the code reappears, refer to the Diagnostic Code section (Section 5) and the appropriate code
chart. The Diagnostic Code section lists diagnostic codes and their description. Locate the
appropriate troubleshooting chart and follow the instructions.
0011 00-27
BASIC KNOWLEDGE
• If the code does not reappear, it may be an intermittent problem. Use the Pro-Link® and the code
display procedure described in Section 5. The code display procedure will indicate the number of
times the diagnostic code has occurred. Refer to the troubleshooting chart for possible cause(s) of
the problem.
• Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a
circuit problem is suspected.
0011 00-28
SECTION 4 — WIRE CHECK PROCEDURES
4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

(Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197)
NOTE: Please refer to Paragraph 3–5 to begin the troubleshooting process.
1. Make sure all connectors are tightly connected and re-check the circuit.
2. Disconnect and inspect all connectors.
3. Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of
the problems, reconnect the clean connectors and operate the vehicle normally. If the problem recurs,
proceed with Step (4).
The cleaning solvent must not be chlorine based, contain petroleum distillates, or
conduct electricity. The cleaning solvent should evaporate quickly to prevent the
CAUTION:
possibility of condensation within the connectors. Always blow or shake any excess
cleaner from the connector before assembling it to its mating connector or hardware.
4. Review the WTEC III wire numbering system described in Paragraph 3–4.
5. If all connectors are clean and connected correctly, determine which wires in the chassis harness are
indicated by the diagnostic code. For example, Code 4112, indicates an open or short-to-ground in
the solenoid A circuit — wires 102-T1 and 120-T4.
a. Check continuity of wires 102-T1 and 120-T4 by performing the following (refer to Figure 4–1):
(1) Disconnect the blue “T” connector from the ECU and disconnect the harness from the transmission
main connector. At one end of the harness, using jumper wire kit J39197 and connector probes in
J39775-CP, connect wire 102-T1 and 120-T4 to each other, being careful not to distort the termi-
nals. Jumping the wires together creates a circuit between wires 102-T1 and 120-T4.
Figure 4–1. Open Circuit
0011 00-29
WIRE CHECK PROCEDURES
(2) On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in a
jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested.
Locate and repair the damaged portion of the wire.
b. If the continuity check is good (0–2 Ohms resistance), remove the jumpers. Check the harness for
shorts between wires and shorts-to-ground by performing the following (refer to Figure 4–2):
(1) At the ECU end of the harness, touch one VOM probe to one wire of the circuit being tested
and touch the other probe to each terminal in the same connector, then touch the probe to chas-
sis ground and to the transmission main housing. Do this for both wires in the circuit being
tested.
(2) If at any time the VOM shows zero to low resistance, or the meter’s continuity beeper sounds,
there is a short between the two points being probed — wire-to-wire or wire-to-ground. Isolate
and repair the short.
Figure 4–2. Short Between Wires and to Ground
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS

FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND
1. Disconnect the external wiring harness from the transmission.
2. Inspect the connectors. Any terminals which are corroded or dirty must be thoroughly cleaned.
3. If the connectors are clean and connected correctly, determine which wires in the harness to test. Use
the diagnostic code system schematic to locate the wire terminals. For this example, Code 41 12 indi-
cates an open or short-to-ground in solenoid “A” circuit — wires 102-T1 and 120-T4 (refer to Figure
4–3 and 4–4).
0011 00-30
The cleaning solvent must not be chlorine based, contain petroleum distillates, or
conduct electricity. The cleaning solvent should evaporate quickly to prevent the
CAUTION: possibility of condensation within the connectors. Always blow or shake any excess
cleaner from the connector before assembling it to its mating connector or hardware.
Cleaner trapped in the connector can affect the connector seal.
a. At the transmission connector, check the resistance of the A solenoid circuit. Resistance of a
solenoid circuit should be 2.4–5 Ohms — covering a temperature range of –18°C to 149°C
(0°Fto300°F). No continuity in the circuit (infinite resistance) indicates an open in the internal
harness, the feedthrough connector, or the solenoid coil. Locate and repair the open in the internal
harness or replace the internal harness, replace the feedthrough connector, or replace the solenoid.
Figure 4–3. Checking Continuity
b. If the resistance check is good, check the harness for shorts between wires and to ground by per-
forming the following (refer to Figure 4–4):
(1) At the transmission connector, touch one probe of the VOM to one wire of the circuit being
tested and touch the other probe to each terminal in the connector and to chassis ground and
the transmission main housing. Do this for both wires in the circuit being tested.
(2) If the VOM shows zero to low resistance, or the continuity beeper sounds, there is a short
between the two points being probed, wire-to-wire or wire-to-ground. An indication of a short
may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix J
for splice locations. If the short is not a splice, then isolate and repair the short.
0011 00-31
Figure 4–4. Short Between Wires and to Ground
NOTE: When conducting circuit checks that include the external harness, add one (1) Ohm to the values
shown. Speed sensor resistance is 270–330 Ohms. C3 pressure switch resistance is two (2) Ohms
maximum when switch is closed and 20,000 Ohms minimum when switch is open.
0011 00-32
SECTION 5 — DIAGNOSTIC CODES
5–1 DIAGNOSTIC CODE MEMORY
Diagnostic codes are logged in a list in memory (sometimes referred to as the queue), listing the most recently
occurring code first and logging up to five codes. The codes contained in the list have information recorded as
shown in the table below (codes are examples). Access to the code list position, main code, subcode and active
indicator is through either the shift selector display or the Pro-Link® diagnostic tool. Access to ignition cycle
counter and event counter information is through the diagnostic tool only. Further detail on the use of Pro-Link ®
9000 DDR is presented in Appendix G of this manual.
Table 5–1. Code List
Code List Ignition Cycle

Position Main Code Subcode Active Indicator Counter Event Counter
d1 21 12 YES 00 10
d2 41 12 YES 00 04
d3 23 12 NO 08 02
d4 34 12 NO 13 01
d5 56 11 NO 22 02
Displayed on shift selector and diagnostic tool YES = LED indicator Not available on shift selector display
d = “diagnostic” illuminated
The following paragraphs define the different parts of the code list.
A. Code List Position. The position which a code occupies in the code list. Positions are displayed as
“d1” through “d5” (Code List Position #1 through Code List Position #5).
B. Main Code. The general condition or area of fault detected by the ECU.
C. Subcode. The specific area or condition related to the main code in which a fault is detected.
D. Active Indicator. Indicates when a diagnostic code is active. The MODE indicator LED on the shift
selector is illuminated or the diagnostic tool displays YES.
E. Ignition Cycle Counter. Determines when inactive diagnostic codes are automatically cleared from
the code list. The counter is increased by one each time a normal ECU power down occurs (ignition
turned off). Inactive codes are cleared from the code list after the counter exceeds 25.
F. Event Counter. Counts the number of occurrences of a diagnostic code. If a code is already in the
code list and the code is again detected, that code is moved to position d1, the active indicator is
turned on, the Ignition Cycle Counter is cleared, and 1 is added to the Event Counter.
5–2. CODE READING AND CODE CLEARING
Diagnostic codes can be read and cleared by two methods: by using the Pro-Link ® 9000 diagnostic tool or by
entering the diagnostic display mode and using the shift selector display. The use of the Pro-Link® 9000 diagnostic
tool is described in the instruction manual furnished with each tool and briefly in Appendix G of this manual. The
method of reading and clearing codes described in this section refers to entering the diagnostic display mode by the
proper button movements on the shift selector.
0011 00-33
DIAGNOSTIC CODES
The diagnostic display mode may be entered for viewing of codes at any speed. Active codes can only be cleared
when the output speed = 0 and no output speed sensor failure is active.
A. Reading Codes. Enter the diagnostic display mode by pressing the ⇑ (Up) and ⇓ (Down) arrow
buttons at the same time on a pushbutton selector, or by momentarily pressing the “display mode”
button on a lever shift selector.
NOTE: If a DO NOT SHIFT condition is present (CHECK TRANS light illuminated) at this time, the shift
selector may or may not respond to requested range changes.
NOTE: If an oil level sensor is present, then fluid level will be displayed first. Diagnostic code display is
achieved by simultaneously depressing the ⇑ (Up) and ⇓ (Down) arrow buttons a second time or the
“display mode” button a second time.
The code list or queue position is the first item displayed, followed by the main code and the subcode. Each item is
displayed for about one second. The display cycles continuously until the next code list position is accessed by
pressing the MODE button. The following list represents the display cycle using code 25 11 as an example:
1. Code list position — d, 1
2. Main code — 2, 5
3. Subcode —1, 1
4. Cycle repeats — d, 1, 2, 5, 1, 1
To view the second, third, fourth, and fifth positions (d2, d3, d4, and d5), momentarily press the MODE button as
explained above.
Momentarily press the MODE button after the fifth position is displayed to restart the sequence of code list
positions.
An active code is indicated by the illumination of the LED indicator when a code position is displayed while in the
diagnostic display mode. In the normal operating mode, the LED indicator illuminates to show a secondary mode
operation.
Any code position which does not have a diagnostic code logged will display “–” for both the main and subcodes.
No diagnostic codes are logged after an empty code position.
B. Clearing Active Indicators. A diagnostic code’s active indicator can be cleared, which allows the
code inhibit to be cleared but remains in the queue as inactive.
The active indicator clearing methods are:
1. Power down — All active indicators, except code 69 34 (refer to the code chart), are cleared at
ECU power down.
2. Self-clearing — Some codes will clear their active indicator when the condition causing the code
is no longer detected by the ECU.
0011 00-34
DIAGNOSTIC CODES
3. Manual — Some active indicators can be cleared manually, while in the diagnostic display mode,
after the condition causing the code is corrected.
If an active indicator is cleared while the transmission is locked in a forward range or

CAUTION: reverse (fail-to-range), the transmission will remain in the forward range or reverse after
the clearing procedure is completed. Neutral must be manually selected.
C. Manually Clearing Codes and Active Indicators from the Code List. To clear active indicators or
all codes:
1. Enter the diagnostic display mode.
2. Press and hold the MODE button for approximately three seconds until the LED indicator flashes.
All active indicators are cleared. To remove all inactive codes, press and hold the MODE button
for about ten seconds until the LED indicator flashes again. All active indicators will be cleared at
ECU power down.
3. Codes that cannot be manually cleared will remain.
D. Exiting the diagnostic display mode. Exit the diagnostic display mode using one of the following
procedures:
1. On a pushbutton shift selector, press the ⇑ (Up) and ⇓ ( Down) arrow buttons at the same time or
press any range button, D, N, or R. The shift (D, N, or R) is commanded if not inhibited by an
active code.
2. On a lever shift selector, momentarily press the “display mode” button or move the shift lever to any
shift position other than the one it was in when the diagnostic display mode was activated. If the
shift is inhibited, the ECU will continue to command the current transmission range attained and the
lever should be returned to its original position.
3. Wait until timeout (approximately 10 minutes) and the system will automatically return to the
normal operating mode.
4. Turn off power to the ECU (turn off the vehicle engine at the ignition switch).
5–3. DIAGNOSTIC CODE RESPONSE
The following ECU responses to a fault provide for safe transmission operation:
• Do Not Shift (DNS) Response
— Release lockup clutch and inhibit lockup operation.

— Inhibit all shifts.
— Turn on the CHECK TRANS light.
— Display the range attained.
— Ignore any range selection inputs from the pushbutton or lever shift selector.
• Do Not Adapt (DNA) Response
— The ECU stops adaptive shift control while the code is active. Do not adapt shifts when a code with
the DNA response is active.
0011 00-35
DIAGNOSTIC CODES
• SOLenoid OFF (SOL OFF) Response
— All solenoids are commanded off (turning solenoids “A” and “B” off electrically causes them to be
on hydraulically).
• Return to Previous Range (RPR) Response
— When the speed sensor ratio or C3 pressure switch tests associated with a shift are not successful,
the ECU commands the same range as commanded before the shift.
• Neutral No Clutches (NNC) Response
— When certain speed sensor ratio or C3 pressure switch tests are not successful, the ECU commands
a neutral condition with no clutches applied.
5–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES

• “Cateye” — The forward slash segments and the middle horizontal segments (-\-) may be on under the
following conditions:
— RSI link fault is active (code 23 12 or 23 14)
— When two COP timeouts occur within two seconds of each other (reference code 69 33)
— Shift selector display line fault is active (23 16)
• All Segments Displayed — All display segments will be illuminated if a severity 1 diagnostic code is
present during initialization, or if an electrical code for solenoids A, B, C, D, E, or G is logged before
initialization completes.
5–5. DIAGNOSTIC CODE LIST AND DESCRIPTION

Table 5–2. WT Series Diagnostic Codes
CHECK
Main Sub- TRANS Inhibited Operation
Code code Description Light Description
13 12 ECU input voltage, low Yes DNS, DNA, SOL OFF (hydraulic default)
(0011 00-50)
13 ECU input voltage, medium low No DNA
23 ECU input voltage, high Yes DNS, SOL OFF (hydraulic default)
14 12 Oil level sensor, failed low No None
(0011 00-53) 23 Oil level sensor, failed high No None
21 12 Throttle position sensor, failed low No Use throttle default values, DNA
(0011 00-56) 23 Throttle position sensor, failed high No Use throttle default values, DNA
22 14 Engine speed sensor reasonableness No Use default engine speed, DNA
(0011 00-59) test
15 Turbine speed sensor reasonableness Yes DNS, lock in current range, DNA
test
16 Output speed sensor reasonableness Yes (1) DNS, lock in current range, DNA
test
0011 00-36
DIAGNOSTIC CODES
Table 5–2. WT Series Diagnostic Codes (Continued)
CHECK
23 12 Primary shift selector or RSI link fault No Hold in last valid direction. May cause
(0011 00-62) “cateye” display.
13 Primary shift selector mode function No Mode change not permitted
fault
14 Secondary shift selector or RSI link No Hold in last valid direction. May cause
fault “cateye” display.
15 Secondary shift selector mode No Mode change not permitted
function fault
16 Shift Selector display line fault No None. May cause “cateye” display.
24 12 Sump fluid temperature, cold Yes DNS, lock in neutral
(0011 00-64) 23 Sump fluid temperature, hot No No upshifts above a calibration range
25 00 Output speed sensor, detected at Yes (1) DNS, lock in current range (Low), DNA
(011 00-69) 0 output rpm, Low
11 Output speed sensor, detected at Yes (1) DNS, lock in current range (1st), DNA
0 output rpm, 1st
22 Output speed sensor, detected at Yes (1) DNS, lock in current range (2nd), DNA
0 output rpm, 2nd
33 Output speed sensor, detected at Yes (1) DNS, lock in current range (3rd), DNA
0 output rpm, 3rd
44 Output speed sensor, detected at Yes (1) DNS, lock in current range (4th), DNA
0 output rpm, 4th
0 output rpm, 5th
0 output rpm, 6th
77 Output speed sensor, detected at Yes (1) DNS, lock in current range (R), DNA
0 output rpm, Reverse range
26 00 Throttle source not detected No Use throttle default values, DNA
(0011 00-71) 11 Engine coolant source not detected No Use default value of –18°C (0°F)
32 00 C3 pressure switch open, Low range Yes DNS, lock in current range (Low), DNA
(0011 00-73) 33 C3 pressure switch open, 3rd range Yes DNS, lock in current range (3rd), DNA
55 C3 pressure switch open, 5th range Yes DNS, lock in current range (5th), DNA
77 C3 pressure switch open, Reverse Yes DNS, lock in current range (R), DNA
range
33 12 Sump oil temperature sensor failed No Use default value of 93°C (200°F)
(0011 0-75) low
23 Sump oil temperature sensor failed No Use default value of 93°C (200°F)
high
0011 00-37
DIAGNOSTIC CODES
CHECK
34 12 Factory calibration compatibility Yes(5) DNS, SOL OFF (hydraulic default), DNA
(0011 00-77) number wrong
13 Factory calibration block checksum Yes(5) DNS, SOL OFF (hydraulic default), DNA
14 Power off block checksum No Use previous location, or factory
calibration and reset adaptive, DNA
15 Diagnostic queue block checksum No Use previous location, or clear diagnostic
queue, DNA
16 Real time block checksum Yes DNS, SOL OFF (hydraulic default), DNA
17 Customer modifiable constants Yes(5) DNS, SOL OFF (hydraulic default), DNA
checksum
35 00 Power interruption (code set after No None (hydraulic default during
(0011 00-79) power restored) interruption)
16 Real time write interruption Yes DNS, SOL OFF (hydraulic default), DNA
36 00 Hardware/software not compatible Yes (2) DNS, SOL OFF (hydraulic default), DNA
(0011 00-80)
01 TID not compatible with hardware/ No (2) Use TIDCAP cal
software
02 TID did not complete No Use TIDCAP cal, code 42 XX or 69 XX
may be logged
42 12 Short-to-battery, A solenoid circuit Yes DNS, SOL OFF, DNA
(0011 00-82) 13 Short-to-battery, B solenoid circuit Yes DNS, SOL OFF, DNA
14 Short-to-battery, C solenoid circuit Yes DNS, SOL OFF, DNA
15 Short-to-battery, D solenoid circuit Yes DNS, SOL OFF, DNA
16 Short-to-battery, E solenoid circuit Yes DNS, SOL OFF, DNA
21 Short-to-battery, F solenoid circuit No Lockup inhibited, DNA
22 Short-to-battery, G solenoid circuit Yes DNS, SOL OFF, DNA
23 Short-to-battery, H solenoid circuit No Differential lock inhibited (3070 only),
retarder inhibited
24 Short-to-battery, J solenoid circuit No Low and 1st inhibited
26 Short-to-battery, N solenoid circuit No Low and 1st inhibited, allow retarder
44 12 Short-to-ground, A solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
(0011 00-86)
13 Short-to-ground, B solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
14 Short-to-ground, C solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
15 Short-to-ground, D solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
16 Short-to-ground, E solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
21 Short-to-ground, F solenoid circuit No Lockup inhibited, DNA
22 Short-to-ground, G solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
0011 00-38
DIAGNOSTIC CODES
CHECK
44 (cont’d) 23 Short-to-ground, H solenoid circuit No Differential lock inhibited (3070 only),
retarder operation inhibited
24 Short-to-ground, J solenoid circuit No Low and 1st inhibited
26 Short-to-ground, N solenoid circuit No Low and 1st inhibited, retarder allowed
45 12 Open circuit, A solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
(0011 00-90) 13 Open circuit, B solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
14 Open circuit, C solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
15 Open circuit, D solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
16 Open circuit, E solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
21 Open circuit, F solenoid circuit No Lockup inhibited, DNA
22 Open circuit, G solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
23 Open circuit, H solenoid circuit No Differential lock inhibited (3070 only),
retarder inhibited
24 Open circuit, J solenoid circuit No Low and 1st inhibited
26 Open circuit, N solenoid circuit No Low and 1st inhibited, retarder allowed
46 21 Overcurrent, F solenoid circuit No Lockup inhibited, DNA
(0011 00-94) 26 Overcurrent, N and H solenoid circuit No Low and first inhibited or retarder
inhibited, DNA
27 Overcurrent, A-Hi solenoid circuit Yes DNS, SOL OFF (hydraulic default), DNA
51 01 Offgoing ratio test (during shift), Yes DNS, RPR, DNA
(0011 00-95) Low to 1
10 Offgoing ratio test (during shift), Yes DNS, RPR, DNA
1 to Low
1 to 2
2 to 1
2 to 3
2 to 4
3 to 5
4 to 2
43 Offgoing ratio test (during shift), Yes (1) DNS, RPR, DNA
4 to 3
45 Offgoing ratio test (during shift), Yes (1) DNS, RPR, DNA
4 to 5
0011 00-39
DIAGNOSTIC CODES
CHECK
51 (cont’d) 46 Offgoing ratio test (during shift), Yes DNS, RPR, DNA
4 to 6
5 to 3
6 to 4
6 to 5
XY Offgoing ratio test, X to Y (3)
52 01 Offgoing C3PS test (during shift), Yes DNS, RPR, DNA
(0011 00-97) Low to 1
08 Offgoing C3PS test (during shift), Yes DNS, NNC, DNA
Low to N1
32 Offgoing C3PS test (during shift), Yes DNS, RPR, DNA
3 to 2
3 to 4
5 to 4
5 to 6
R to 1
R to 2
R to N1
N3 to N2
XY Offgoing C3PS test, X to Y (3)
53 08 Offgoing speed test (during shift), Yes (1) DNS, NNC, DNA
(0011 00-99) L to N1
18 Offgoing speed test (during shift), Yes (1) DNS, NNC, DNA
1 to N1
2 to N1
29 Offgoing speed test (during shift), Yes (1) DNS, RPR, DNA
2 to N2
3 to N1
0011 00-40
DIAGNOSTIC CODES
CHECK
53 (cont’d) 39 Offgoing speed test (during shift), Yes (1) DNS, RPR, DNA
3 to N3
4 to N1
4 to N3
5 to N1
5 to N3
6 to N1
6 to N4
78 Offgoing speed test (during shift), Yes DNS, NNC, DNA
R to N1
99 Offgoing speed test (during shift), Yes DNS, RPR, DNA
N2 to N3 or N3 to N2
XY Offgoing speed test (during shift),
X to Y (3)
54 01 Oncoming ratio test (after shift), Yes DNS, RPR, DNA
(0011 00- L to 1
101)
07 Oncoming ratio test (after shift), Yes DNS, NNC, DNA
L to R
10 Oncoming ratio test (after shift), Yes DNS, RPR, DNA
1 to L
1 to 2
1 to R
2 to 1
2 to 3
24 Oncoming ratio test (during shift), Yes DNS, RPR, DNA
2 to 4
2 to R
3 to 2
0011 00-41
DIAGNOSTIC CODES
CHECK
54 (cont’d) 34 Oncoming ratio test (after shift), Yes DNS, RPR, DNA
3 to 4
3 to 5
4 to 2
4 to 3
45 Oncoming ratio test (after shift), Yes DNS, RPR or SOL OFF
4 to 5 (hydraulic default), DNA
4 to 6
5 to 3
5 to 4
5 to 6
6 to 4
6 to 5
R to L
R to 1
R to 2
N1 to L
N1 to 1
N1 to 2
N1 to 3
N1 to 5
N1 to 6
0011 00-42
DIAGNOSTIC CODES
CHECK
54 (cont’d) 92 Oncoming ratio test (after shift), Yes DNS, RPR, DNA
N2 to 2
N3 to 3
N3 to 5
N4 to 6
XY Oncoming ratio test (after shift),
X to Y (3)
55 07 Oncoming C3PS test (after shift), Yes (1) DNS, NNC, DNA
(0011 00- Low to R
103)
17 Oncoming C3PS test (after shift), Yes (1) DNS, NNC, DNA
1 to R
2 to R
87 Oncoming C3PS test (after shift), Yes DNS, RPR, DNA
N1 to R
NVL to R
XY Oncoming C3PS test (after shift),
X to Y (3)
56 00 Range verification test, L Yes (1) DNS, 1st, Low, or SOL OFF (Low), DNA
(0011 00- 11 Range verification ratio test, 1st Yes DNS, 6th, DNA
105)
22 Range verification ratio test, 2nd Yes (1) DNS, 6th or 5th, DNA
33 Range verification ratio test, 3rd Yes (1) DNS, 5th or SOL OFF (4th), DNA
44 Range verification ratio test, 4th Yes DNS, 3rd or 5th, DNA
55 Range verification ratio test, 5th Yes (1) DNS, SOL OFF (5th) or 3rd, DNA
66 Range verification ratio test, 6th Yes DNS, 5th, 3rd, or SOL OFF (3rd), DNA
77 Range verification ratio test, R Yes DNS, N2 or N3, DNA
57 11 Range verification C3PS test, 1st Yes DNS, SOL OFF (3rd), DNA
(0011 00- 22 Range verification C3PS test, 2nd Yes DNS, 3rd, DNA
107)
44 Range verification C3PS test, 4th Yes DNS, 5th or SOL OFF (3rd), DNA
66 Range verification C3PS test, 6th Yes DNS, SOL OFF (5th), DNA
88 Range verification C3PS test, N1 Yes DNS, N3, DNA
0011 00-43
DIAGNOSTIC CODES
CHECK
99 Range verification C3PS test, Yes DNS, N3, DNA
N2 or N4
61 00 Retarder oil temperature, hot No None
(0011 00-
108)
62 12 Retarder temperature sensor failed No None
(0011 00- low
110)
23 Retarder temperature sensor failed No None
high
32 Engine coolant sensor failed low No Use default value of 0°F
33 Engine coolant sensor failed high No Use default value of 0°F
63 00 Input function fault No Does not prevent neutral to range shifts
(0011 00- for Aux Function Range Inhibit-Special
113) when two signals required are not “on”
within 120 seconds of each other.
26 Kickdown input failed on No Kickdown operation inhibited
40 Service brake status input failed on No No auto Neutral to Drive shifts for refuse
packer. (I/O package #41). No retarder if a
TPS code is also active
41 Pump/pack and a neutral general No No auto N–D shifts for refuse packer
purpose input (I/O package #41)
64 12 Retarder modulation request sensor No Retarder operation inhibited
(0011 00- failed low
114)
23 Retarder modulation request sensor No Retarder operation inhibited
failed high
Engine rating too high Yes DNS, Lock-in-neutral, DNA
65 00 Engine rating too high Yes DNS, Lock-in-neutral
(0011 00-
117)
66 00 Serial communications interface fault No Use default throttle values, DNA
(0011 00- 11 SCI engine coolant source fault No Use default value of 0°F
118)
69 27 ECU, inoperative A-Hi switch Yes DNS, NNC, DNA
(0011 00- 28 ECU, inoperative F-Hi switch Yes Lockup inhibited, DNA
120)
29 ECU, inoperative N and H-Hi switch No Low and first inhibited, retarder inhibited,
DNA
0011 00-44
DIAGNOSTIC CODES
CHECK
69 (cont’d) 33 ECU, Computer Operating Properly No Reset ECU, shutdown ECU on 2nd
(COP) timeout occurrence (power loss; hydraulic
defaults). May cause “cateye” display or
all segments blank display, DNA (4)
34 ECU, write timeout Yes DNS, SOL OFF (hydraulic default), DNA
35 ECU, checksum test No Induce COP timeout (reset ECU), DNA(4)
36 ECU, RAM self test No Induce COP timeout (reset ECU), DNA(4)
39 Communication chip addressing error No Use defaults for J1939 data, DNA
41 ECU, I/O ASIC addressing test No Induce COP timeout (reset ECU), DNA(4)
42 SPI output failure Yes GPO 1–8 and reverse warning inoperable
43 SPI input failure Yes DNS, lock-in-range, DNA
70 12 Software, minor loop overrun No Induce COP timeout (reset ECU)
13 Illegal write to address $0000 No Induce COP timeout (reset ECU)
14 Software, major loop overrun No Induce COP timeout (reset ECU)
NOTES
(1) This code is logged to real time to protect the transmission in case a loss of power to the ECU (Power Inter-
ruption, code 35 00) occurs.
(2) The ECU hardware or software must be changed so that they are compatible.
(3) Additional codes could be logged for other shifts where X indicates range shifted from and Y indicates range
shifted to.
(4) The COP reset will clear the active inhibit.
(5) The factory calibration must be rewritten to the ECU, or a different factory calibration is required to match
the software in the ECU.
0011 00-45
DIAGNOSTIC CODES
TRANSMISSION
COMPONENT
WIRING DIAGRAMS
AND
DIAGNOSTICS
0011 00-46
DIAGNOSTIC CODES
5–6. DIAGNOSTIC CODE TROUBLESHOOTING
A. Beginning The Troubleshooting Process
1. Begin troubleshooting by checking the transmission fluid level and ECU input voltage. Check
diagnostic codes by:
• Using the shift selector display.
• Using the Pro-Link® 9000 diagnostic tool.
2. When a problem exists but a diagnostic code is not indicated, refer to the Performance Complaint
Section for a listing of various electrical and hydraulic problems, their causes, and remedies.
3. If a diagnostic code is found in the ECU memory, record all available code information and clear
the active indicator (refer to Paragraph 5–2).
4. Test drive the vehicle to confirm a diagnostic code or performance complaint.
• If the code reappears, refer to the Diagnostic Code section (Section 6) and the appropriate code
chart. The Diagnostic Code section lists diagnostic codes and their description. Locate the
appropriate troubleshooting chart and follow the instructions.
• If the code does not reappear, it may be an intermittent problem. Use the Pro-Link® and the
code display procedure described in Section 5. The code display procedure will indicate the
number of times the diagnostic code has occurred. Refer to the troubleshooting chart for
possible cause(s) of the problem.
• Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a
circuit problem is suspected.
NOTE: Information concerning specific items is contained in the appendices located in the back of this
manual. The appendices are referred to throughout the manual.
B. Solenoid Locations
Solenoid locations in the control module are as illustrated in Figure 5–1. Refer to Figure 5–1 as
necessary when using the diagnostic code schematics.
C. Diagnostic Code Schematics
The diagnostic code schematics in this section show wiring for both the optional oil level sensor and
retarder, where applicable. If your transmission is not equipped with an oil level sensor or retarder,
disregard the portions of the schematic pertaining to those optional pieces of equipment. Refer to the
appropriate transmission Service Manual for solenoid replacement procedures.
D. Wire/Terminal Numbering Scheme
WTEC III wire identification presents the wire number followed by the ECU terminal source
(i.e., 157-S30). This is done to retain the wire number/function assignments from WTEC II and
indicate the ECU connector and terminal origination for WTEC III. If there is a letter suffix following
the wire number, there is a splice between the ECU source and wire destination (i.e., 136A-S16).
0011 00-47
DIAGNOSTIC CODES
Figure 5–1. Control Module Solenoid Location
0011 00-48
CODE 13 XX — ECU INPUT

DIAGNOSTIC VOLTAGE
CODES
Figure 5–2. Code 13 Schematic Drawing
0011 00-49
CODE 13 XX — ECU INPUT

DIAGNOSTIC VOLTAGE (Figure 5–2)
CODES
Main code 13 indicates either a high or low input voltage. Low voltage is less than 8 volts. High voltage is over 33
volts.
Common causes for a low voltage code are:

• Bad batteries
• Faulty vehicle charging system
• No dedicated power and ground connection directly to the battery or through an electronic bus bar to the
battery
Common causes for the high voltage code are:

• Faulty vehicle alternator
• Faulty vehicle voltage regulator
In the event of a power loss, the transmission fails to the ranges indicated in the following, depending upon which
latch valve releases first:
Attained Range Fail to Range

Reverse and neutral Neutral
Low, 1 3C
2, 3, 4 4C usually, 3C sometimes
5 4C usually, 5C sometimes
6 5C
Main Code Subcode Meaning

13 12 Battery voltage to the ECU too low
13 13 Battery voltage to the ECU too low (medium)
13 23 Battery voltage to the ECU too high
A. Active Indicator Clearing Procedure:
• Power down
• Manual
• Self-clearing
B. Troubleshooting:
1. Connect the diagnostic tool and turn on vehicle ignition. Select Diagnostic Data to find input
voltage. Record reading.
2. Turn off vehicle ignition and remove the connectors from the ECU.
3. Check system voltage at wire 136A and 136C, pin V1 and V16. If power is low or high at this
point, and the diagnostic tool reading is also low or high, the vehicle wiring is suspect. Check for
fuse problems, lack of battery-direct power and ground, faulty charging system/batteries, and loose
or dirty connections (see Appendix A). Power may also be low or high at pins V1 and V16 (system
power) if the batteries/charging system is faulty. Bad grounds may also cause incorrect input
power readings.
0011 00-50
CODE 13 XX — ECU INPUT VOLTAGE

DIAGNOSTIC CODES (Figure 5–2)
4. If power is correct but the diagnostic tool reading indicates incorrect voltage, closely inspect
terminals V1 and V16 or S16; make sure they are not corroded or deformed. Clean or replace
as necessary.
5. If the voltage condition is intermittent, closely inspect the vehicle wiring for transmission system
power and grounds. Check for loose, dirty, or painted connections. Check the VIM for loose,
incorrect, or overheating relays or fuses (refer to Appendix E). Check for wires that are chafed
and touching other components.
6. If no other cause is found, replace the ECU. If replacing the ECU corrects the problem, reinstall
the original (bad) ECU to confirm that the problem is in the ECU. If the original ECU now works,
inspect the ECU connectors for any corrosion or damage which may cause an intermittent condi-
tion. If the original problem recurs, reinstall the replacement ECU.
Table 5–3. Voltage Chart
Voltage Condition
33.0 High Fail Limit
(High Set Point)
32.0 Maximum Continuous ECU Voltage
10.0 Cannot Compensate With Sub-Modulation (Bad Shifts). Adaptive logic stops
(Medium Low Set Point) functioning
8.0 Low Voltage Fail Limit, Set Code, DNS
7.0 Software Off (ECU loses power)
(Low Set Point)
4.5 Neutral Start Off
0011 00-51
CODE 14 XX — OIL LEVEL

DIAGNOSTIC SENSOR (OLS)
CODES
0011 00-52
CODE 14 XX — DIAGNOSTIC
OIL LEVEL SENSOR
CODES(OLS) (Figure 5–3)
The oil level sensor (OLS) must have been recognized by autodetect or manually selected using the Pro-Link ®
(see WTEC III Pro-Link ® Manual) before these codes can be logged.
Code 14 12 indicates the ECU has detected a voltage signal in the low error zone.
Code 14 12 can be caused by:
• Faulty wiring to the OLS
• A faulty OLS
• A faulty ECU
Never use a volt/ohmmeter to measure any parameters on the OLS. Damage to the OLS
CAUTION:
will result.
OLS ground wire 135B is common to the TPS and the RMR devices. A power wire short-to-ground for any of
these devices will cause “sensor failed low” codes (21 12 and 64 12) and shutdown of the electronic pushbutton or
lever selector. An OLS signal open or short-to-ground results in a code 14 12 only. Code 14 23 is programmed out
of all calibrations.
A permanent maximum voltage signal generates a steady OLS sensor maximum count and a maximum fluid level
overfill indication. A maximum overfill indication occurs if signal wire 165 or power wire 124 is shorted to battery
or the ground wire (wire 135) is open between the OLS and the sump temperature sensor branch. An open in the
ground circuit wire 135 in the portion common to the OLS, TPS and RMR devices results in code 14 12, 21 23, and
64 23.
If the ECU software supports it, Oil Level Sensor counts can be read by a DDR with Pro-Link ® version 3.0 (or
later). For a complete description of fluid level checking procedures using the oil level sensor, see Section 5.
Normal operation of the OLS can be checked as follows: Attach the DDR and display OIL LEVEL COUNTS.
Read the number of counts when the engine is not running, but the ignition is ON. The count reading should be
near 255. Start the engine and observe the counts. In normal operation, the count should be 100–200 because the oil
level drops when the engine starts and oil from the sump is delivered to other parts of the transmission.
NOTE: Intermittent connections or lack of battery-direct power and ground connections can cause this and
other electronic control codes.
Main
Code Subcode Meaning
14 12 Oil level sensor failed low
14 23 Oil level sensor failed high (not used)
• Power down
• Manual
• Self-clearing
0011 00-53
OIL LEVEL SENSOR
CODES(OLS) (Figure 5–3)
NOTE: Before troubleshooting, read Paragraph 5–6. Also, check the following:
• Fluid level, using dipstick
• Battery voltage
• ECU input voltage
• Other diagnostic codes
B. Troubleshooting:
The following procedure is to find the cause for an OLS problem. The procedure is sequential. Follow
the procedure until the cause for the OLS problem is found and repaired. Once the problem is found
and repaired, STOP. For example, if the problem is fixed in step 3, there is no need to continue to the
other steps.
1. Disconnect the external wiring harness at the transmission feedthrough connector. With the igni-
tion ON, verify there is 5.0 VDC between the OLS power and ground pins (see page D–10) on the
external harness connector. This is to verify that power and ground are getting to the OLS. If the
5.0 VDC is not present, check the wiring for the OLS power and ground circuits (wires 124–T9
and 135–T25, respectively). If there are no wiring problems (opens, shorts-to-ground, shorts-to-
battery), and if the 5.0 VDC is present, go to Step 2.
2. Observe the OIL LEVEL COUNTS on the DDR while jumpering the OLS power pin to the OLS
signal pin. If the count jumps from 0 to 250+, the OLS signal line is good and the ECU function is
good. Continue to Step 3. If the count remains at zero, locate and repair problems in the wiring of
OLS signal (wire 165–T26). If there are no wiring problems, and the count still remains at zero,
the ECU may be bad. Go to Step 5.
3. If all checks prior to this have been normal, the problem is either in the OLS itself, the internal har-
ness wires or the transmission side of the feedthrough harness connection. Inspect the transmission
feedthrough harness connector to be sure that the OLS power, ground and signal pins are not loose
or out of position. Correct any connector problems found. Reconnect the external harness to the
transmission feedthrough harness connector. See if Code 14 12 recurs before continuing to Step 4.
4. Consult the appropriate transmission Service Manual for proper procedure and remove the control
module from the transmission. Remove the OLS from the channel plate. Reconnect the external
harness to the transmission feedthrough connector, if not done in Step 3. With the ignition ON, ob-
serve OIL LEVEL COUNTS on the DDR. With the OLS in normal position, the count should be
8–35. Invert the OLS and the count should be 192–255. If the counts are abnormal, replace the
sensor. Check the new sensor in both normal and inverted positions. If the counts respond cor-
rectly, the problem should be resolved. Attach the new OLS to the channel plate and reinstall the
control module using the appropriate transmission Service Manual for proper procedure.
5. Replace the ECU. If replacing the ECU corrects the problem, reinstall the original (bad) ECU to
confirm that the problem is in the ECU. If the original ECU now works, inspect the ECU connec-
tors for any corrosion or damage which may cause an intermittent condition. If the original prob-
lem recurs, reinstall the replacement ECU.
0011 00-54
CODE 21 XX — THROTTLE OR
DIAGNOSTIC PWM FAULT
CODES
0011 00-55
CODE 21 XX — THROTTLE OR
DIAGNOSTIC PWM FAULT (Figure 5–4)
CODES
The throttle sensor must have been recognized by autodetect or manually selected using the Pro-Link® (see
WTEC III Pro-Link® Manual) before these codes can be logged. See Paragraph 1–9 for further information.
Main code 21 indicates the throttle position sensor has been retracted or extended by its linkage into an error zone.
This may be due to a fault with the sensor, or a fault in the wiring to the sensor or to the ECU. This code may also
indicate a PWM signal problem. A PWM signal is proportional to throttle position and comes from some source
other than an analog throttle position sensor. Code 21 12 is set when the ECU receives TPS counts of 14 or less.
Code 21 23 is set when the ECU senses TPS counts of 233–255. Whenever a code 21 XX condition is detected, the
system uses default throttle values and shifts will not adapt.
NOTE: Code 21 XX in conjunction with code 33 XX or code 14 XX indicates the potential loss of common
ground wire 135 between the throttle, temperature sensor, and oil level sensor.

Throttle position sensor failed low and
21 12
ECU signals throttle default value
Throttle position sensor failed high and
21 23
ECU signals a throttle default value
• Power down
• Manual
• Self-clearing
NOTE: Before troubleshooting, read Paragraph 5–6. Also, check the ECU input voltage.
B. Troubleshooting:
1. Plug in the DDR, select Diagnostic Data, and read throttle counts and percent. If the TPS failed
high (code 21 23), the problem may be toward the full throttle end of the TPS travel. If the TPS
failed low (code 21 12), the problem may be at the closed throttle end of the TPS travel.
NOTE: Code 21 12 may occur when the throttle source is J1587 or J1939 and an analog throttle source is
falsely detected. This condition may be due to a problem in an unused TPS branch of a universal
external harness. To prevent this occurrence, remove wire 156 from the ECU connector and insert a
cavity plug in the space vacated by the wire. Be sure that the unused TPS branch is routed away from
potential induced voltage sources and the connector is protected from external contamination.
NOTE: Code 21 12 can result when the +5V line (wire 124) which powers the analog sensor is shorted to
ground. Wire 124 also powers the OLS, RMR, retarder temperature sensor, sump temperature sensor,
and shift selector and is present in all three ECU connectors.
2. If counts are high but the percentage never reaches 100 percent, TPS linkage may have bound up
and overstroked the TPS to set a false 100 percent reading. After TPS overstroking ceases, the
TPS will not automatically return to 100 percent. After the TPS is correctly installed and adjusted,
use the Pro-Link ® to reset throttle calibration or cycle the ignition 5 times to reset the 0 percent
and 100 percent settings.
0011 00-56
CODE 21 XX — THROTTLE OR PWM

DIAGNOSTIC FAULT (Figure 5–4)
CODES
3. If the throttle counts do not change or are erratic, check the throttle sensor wiring for opens, shorts
between wires, or shorts-to-ground. Also check for correct TPS voltages using test wiring harness
J41339. If wiring problems are found, isolate and repair the fault.
4. If the wiring is satisfactory, replace the throttle position sensor and adjust its linkage so the counts
are not in the error zones.
5. If the throttle sensor and its linkage adjustment are correct and the wiring to the sensor is satisfac-
tory, the condition is intermittent. Replace the sensor and properly adjust the new sensor.
6. If the condition recurs, use a spare wire, if available, or provide a new wire (St. Clair P/N 200153
may be used for this purpose) for the throttle sensor circuit.
7. If the condition persists, replace the ECU. If replacing the ECU corrects the problem, reinstall the
original (bad) ECU to confirm that the problem is in the ECU. If the original ECU now works, in-
spect the ECU connectors for any corrosion or damage which may cause an intermittent condition.
If the original problem recurs, reinstall the replacement ECU.
NOTE: A good throttle position sensor should have resistance of:

(1) 9000–15,000 Ohms across terminals A and C.
(2) 500 Ohms, moving to 9000–15,000 Ohms as TPS is stroked (measured across
terminals A and B).
0011 00-57
SPEED SENSOR/CIRCUITRY
CODES FAULT
0011 00-58
CODE 22 XX — SPEED SENSOR/CIRCUITRY

DIAGNOSTIC CODES FAULT (Figure 5–5)
Main code 22 indicates a fault within a speed sensor, the wiring to a speed sensor, incorrect speed sensor gap, or
damaged bumps or teeth which create the speed signal. This fault is determined by the reasonableness of a speed
sensor signal when compared with the other two speed sensors and the commanded range. A speed sensor will not
pass the reasonableness test if there is no signal at all from that sensor when a signal should be present.
NOTE: If turbine speed is below 150 rpm when output speed is below 100 rpm and engine speed is above
400rpm, Neutral Very Low (NVL) is commanded when N (Neutral) is the range selected. NVL is
attained by turning D solenoid “ON” in addition to E solenoid. This causes the output to be locked
(C4and C5 clutch applied).
NOTE: If the engine speed sensor code (2214) is active and a range verification test is failed, the range
verification code will not be set but a DO NOT SHIFT response is commanded.
Main Code Subcode Failed Sensor

22 14 Engine Speed
22 15 Turbine Speed
22 16 Output Speed
• Power down
• Manual
• Self-clearing
B. Troubleshooting:
1. Check to see if the sensor is loose, missing, or disconnected. If not, disconnect the wiring harness
from the sensor and measure the resistance of the sensor (see chart below). Also check the termi-
nals for dirt, corrosion, or damage. If resistance is not correct, replace the sensor.
Resistance Temp °C Temp °F

200 ¾ –40 –40
300 ¾ 20 68
400 ¾ 110 230
2. Remove the transmission harness connector from the ECU. Check the sensor circuit (in the exter-
nal harness) for open wires, shorts between wires, or shorts-to-ground. Isolate and repair any
faults.
3. If no opens or shorts are found, the condition must be intermittent. Replace the sensor indicated
by the trouble code. Before replacing a speed sensor, check the sensor for physical damage or
contamination. Refer to the appropriate transmission Service Manual for proper replacement pro-
cedure.
4. If the condition recurs, install new wiring (twisted-pair) for the sensor circuit between the ECU
and the transmission. Use St. Clair P/N 200153 Service Harness Twisted Pair for this purpose.
0011 00-59
CODE 22 XX — SPEED SENSOR/CIRCUITRY

DIAGNOSTIC CODES FAULT (Figure 5–5)
5. If the condition again recurs, connect the diagnostic tool and select the speed signal indicated by
the trouble code. Drive the vehicle and watch the speed reading on the diagnostic tool. If the signal
is erratic, sensor gap, vehicle vibration, an external AC signal source, or intermittent connector
contact may be inducing the erratic signal. Inspect the sensor and its surroundings for irregularities
that would affect sensor gap. Isolate and correct any abnormal vehicle vibrations (particularly
driveline and abnormal engine torsionals. Recheck the sensor wiring for intermittent conditions
(see Appendix A).
original (bad) ECU to confirm that the problem is in the ECU. If the original ECU now works,
inspect the ECU connectors for any corrosion or damage which may cause an intermittent
condition. If the original problem recurs, reinstall the replacement ECU.
0011 00-60
CODE 23DIAGNOSTIC
XX — SHIFT SELECTOR
CODES

0011 00-61
CODE 23DIAGNOSTIC
XX — SHIFT SELECTOR
CODES (Figure 5–6)
Main code 23 indicates a fault with a shift selector or the wiring between a shift selector and the ECU.
Main
23 12 Primary shift selector fault — a “cateye” type
display may occur
23 13 Primary shift selector mode function fault.
Mode change not permitted
23 14 Secondary shift selector fault — a “cateye”
type display may occur
23 15 Secondary shift selector mode function fault.
Mode change not permitted
23 16 Shift selector display line fault

• Power down
• Manual
• Self-clearing
NOTE: Before troubleshooting, read Paragraph 5–6.
B. Troubleshooting:
1. Clear the active indicator for code 23XX. If code recurs, continue to Step (2).
2. Check for a poor connection at the shift selector.
NOTE: Code 23 12 can result when the +5V line (wire 124) which powers the shift selector is shorted to
ground. Wire 124 also powers the TPS, OLS, RMR, retarder temperature sensor, and sump oil
temperature sensor and is present in all three ECU connectors.
3. Disconnect the selector “S” harness connector from the ECU and from the shift selector and check
for opens, shorts, and shorts-to-ground between the shift selector and ECU (refer to Section 4).
4. If no problem is found with the shift selector connection or wiring, replace the shift selector.
0011 00-62
CODE 24 XX —DIAGNOSTIC
SUMP FLUIDCODES
TEMPERATURE
0011 00-63
SUMP FLUIDCODES
TEMPERATURE (Figure 5–7)
Main code 24 indicates the ECU has detected either a high or low fluid temperature in the transmission sump (via
the sump temperature sensor in the internal harness). All shifts are inhibited when code 2412 is set (only Neutral
range operation is allowed). No upshifts are allowed above a calibration range when code 2423 is set. All inhibits
are cleared when the temperature conditions are normal. A related code is 3312 which indicates a temperature
reading outside the usable range of the sensor and indicates a probable sensor failure.
NOTE: When an ECU with a version 8 calibration (CIN=0A...) is used with a TransID 2 transmission,
24 XX codes are set because the ECU does not have the proper calibrations for the TID 2 thermistors.
The ECU calibration must be updated to version 8A or later (CIN=0B).
Main
24 12 Sump fluid temperature cold
24 23 Sump fluid temperature hot
• Power down
• Manual
• Self-clearing
B. Troubleshooting:
Code 24 12:
1. If the outside temperature is between –32° C (–26°F) and –7°C (+19°F), the ECU will allow re-
verse, neutral, and second-range start operation. Only hold override upshifts are allowed. (See
Table 6–4 on next page.) The sump must be warmed to an acceptable temperature to avoid logging
codes and transmission diagnostic response.
NOTE: Code 24 12 can result when the +5V line (wire 124) which powers the sump temperature sensor is
shorted to ground. Wire 124 also powers the TPS, OLS, RMR, retarder temperature sensor, and shift
selectors and is present in all three ECU connectors.
2. After allowing the temperatures to normalize, if ambient temperature does not match the sump
temperature reading (check using diagnostic tool), compare resistance versus sump fluid temper-
ature. Refer to Figure 5–8 for TID 1 thermistors and Appendix Q for TID 2 thermistors. If resis-
tance check is acceptable, then check the sensor wiring for opens, shorts, or shorts-to-ground.
3. If the sensor wiring is satisfactory, drain the fluid, remove the control module, and replace the
temperature sensor.
4. If the condition persists, replace the ECU. If replacing the ECU corrects the problem, reinstall
the original (bad) ECU to confirm that the problem is in the ECU. If the original ECU now
works, inspect the ECU connectors for any corrosion or damage that may cause an intermittent
0011 00-64
CODE 24 XX — SUMP FLUID TEMPERATURE

Table 5–4. Transmission Operation as a Function of Temperature
Condition Version 8 Software

°C °F
Temperature sensor failed high (refer to code 33 23) 177 350
Hot fluid (code 2423) adaptive turned off; maximum range limited (not limited in
“emergency” calibration) 128 262
Output function “on” for sump over temp above this temperature 121 250
Output function “off” for sump over temp below this temperature 116 240
Cool/cold fluid; adaptive turned off 34 93
Turbine reasonableness and speed tie-up tests turned off 0 32
Medium cold fluid R, N, D allowed, 2nd range start (hold override upshifts only) –7 19
All C3 Pressure Switch tests turned off –32 –25
Temperature sensor failed low (refer to code 33 12) –45 –49
Figure 5–8. TransID 1 Temperature Sensor Chart
Code 24 23:
1. Install temperature gauges for transmission temperature and engine water temperature. Drive the
vehicle. Verify that the code can be reproduced and verify the reading shown on the diagnostic
tool. Observe the gauges and check for hot fluid when the code is produced.
2. If the fluid is not hot when the code is produced, remove the transmission “T” harness connector
at the ECU and the transmission. Check the fluid temperature sensor wiring for opens, shorts,
and shorts-to-ground. Compare the resistance readings of the sensor and the actual temperature
0011 00-65
SUMP FLUIDCODES
TEMPERATURE (Figure 5–7)
as shown on the gauge with Figure 5–8 for TID 1 thermistors and Appendix Q for TID 2
thermistors. If wiring problems or a great difference between temperature and resistance
compared with the chart are found, drain the fluid, remove the control module, and replace the
temperature sensor. If wiring problems are found, repair or replace as necessary.
3. If the fluid is hot when the code is produced, observe the gauges to see if the engine became hot
before the transmission. If the engine cooling system is overheating and heating the transmission,
the problem is with the engine or its cooling system.
4. If the transmission became hot before the engine, allow the vehicle to idle for 3–5 minutes and
check the transmission fluid level. Correct the fluid level if necessary.
5. Attach pressure gauges to the cooling system (from a “to cooler” connection to a point after the
cooling circuit filter) and check for pressure drop problems. If pressure drop is excessive (refer to
Table 5–5), check for a plugged cooler filter, collapsed lines, obstructions, etc.
6. If the fluid level is correct and the cooling circuits satisfactory, drain the fluid, remove the control
module, and inspect for damaged valve body gaskets. Replace any damaged gaskets.
7. If no problems are found in the control module area, remove the transmission and disassemble, in-
specting for causes of overheating (stuck stator, plugged orifices, dragging clutches, etc.).
Table 5–5. External Hydraulic Circuit Characteristics

Basic, PTO, 93°C (200°F) Sump Temperature
HD/B 500
CONVERTER OPERATION CONVERTER OPERATION
MAXIMUM COOLER FLOW COOLER FLOW AT MAXIMUM
AT MINIMUM PRESSURE DROP ALLOWABLE PRESSURE DROP
Input Flow Pressure Drop Input Flow Pressure Drop
rpm L/s gpm kPa psi rpm L/s gpm kPa psi
600 0.22 3.4 0 0 600 0.20 3.2 31 4.5
900 0.38 6.1 0 0 900 0.37 5.8 63 9.1
1200 0.55 8.7 0 0 1200 0.55 8.7 108 15.7
1500 0.80 12.7 0 0 1500 0.77 12.2 167 24.2
1800 1.03 16.4 0 0 1800 0.92 14.5 213 30.9
2100 1.13 18.0 0 0 2100 0.97 15.3 238 34.5
2300 1.20 19.0 0 0 2300 1.00 15.9 250 36.3
0011 00-66
CODE 24 XX — SUMP FLUID TEMPERATURE

Table 5–6. External Hydraulic Circuit Characteristics

Basic, PTO, 93°C (200°F) Sump Temperature
MD/B 300/B 400

CONVERTER OPERATION LOCKUP OPERATION
MAXIMUM COOLER FLOW MAXIMUM COOLER FLOW
AT MINIMUM PRESSURE DROP AT MINIMUM PRESSURE DROP
600 0.10 1.6 0 0 600 0.10 1.6 0 0
800 0.23 3.7 0 0 800 0.23 3.7 0 0
1200 0.47 7.4 0 0 1200 0.50 7.9 0 0
1400 0.61 9.7 0 0 1400 0.63 10.0 0 0
1600 0.74 11.7 0 0 1600 0.77 12.2 0 0
2000 0.94 14.9 0 0 2000 0.95 15.1 0 0
2400 1.19 18.9 0 0 2400 1.12 17.8 0 0
3200 1.28 20.3 0 0 2800 1.22 19.3 0 0
3200 1.28 20.3 0 0
CONVERTER OPERATION LOCKUP OPERATION

MAXIMUM ALLOWABLE MAXIMUM ALLOWABLE
PRESSURE DROP PRESSURE DROP
600 0.10 1.6 10 1.5 600 0.10 1.6 5 0.7
800 0.22 3.5 40 5.8 800 0.23 3.7 46 6.7
1200 0.45 7.1 159 23.1 1200 0.48 7.6 148 21.5
1400 0.57 9.0 252 36.5 1400 0.62 9.8 247 35.8
1600 0.67 10.6 338 49.0 1600 0.73 11.6 346 50.2
2000 0.80 12.7 481 69.8 2000 0.90 14.3 561 81.4
2400 0.85 13.5 549 79.6 2400 1.07 17.0 737 106.9
3200 0.85 13.5 549 79.6 2800 1.10 17.4 770 111.7
3200 1.10 17.4 791 114.7
0011 00-67
CODE 25 XX — OUTPUT SPEED SENSOR, DETECTED AT ZERO SPEED,

X RANGE
0011 00-68

X RANGE (Figure 5–9)
Main code 25 occurs if the output speed sensor reports a zero speed reading while both engine and turbine speeds
are approximately equal, turbine speed is above a calibration value, and neutral is not selected or commanded.
Main code 25 indicates either the output speed sensor has failed or the required oncoming clutch or clutches did not
come on. Code 2511 can be generated by a false turbine speed reading. This may be due to crosstalk between
solenoid and turbine speed sensor circuits caused by direct wire-to-wire short or by water in the electrical
connectors. See Section 4 for corrective action.
NOTE: If code 25XX is in memory at ECU initialization (ignition on), all display segments are illuminated.
Main Applied
Code Subcode Meaning Clutches
25 00 Output speed sensor, detected at zero speed, Low range C3, C6
25 11 Output speed sensor, detected at zero speed, 1st range C1, C5
25 22 Output speed sensor, detected at zero speed, 2nd range C1, C4
25 33 Output speed sensor, detected at zero speed, 3rd range C1, C3
25 44 Output speed sensor, detected at zero speed, 4th range C1, C2
25 77 Output speed sensor, detected at zero speed, Reverse C3, C5
• Power down
• Manual
• Self-clearing
NOTE: Before troubleshooting, read Paragraph 5–6. Also, check battery and ECU input voltages.
other codes.
B. Troubleshooting:
1. Check the transmission fluid level and ensure correct fluid level.
2. Check for the presence of code 2216. If code 2216 is in the code list, go to code 22XX section
and follow troubleshooting steps for code 2216.
3. Connect the Pro-Link ® 9000 with ignition on, engine off; check for indication of turbine speed. If
turbine speed is indicated, refer to Paragraph 4–2 for corrective action.
4. If the output speed sensor and wiring are satisfactory, install pressure gauges into the appropriate
clutch pressure taps (see Appendix B in this manual) and make the shift again. See if either of the
clutches has low or no pressure. Lack of pressure in C1 in first range may be due to a G solenoid
stuck closed. Lack of pressure in C5 in first range may be due to an E solenoid stuck closed.
5. If a clutch is leaking pressure, drain the fluid, remove the control module and check for damaged
valve body gaskets and stuck or sticky valves. If no problems are found, replace the solenoids for
the clutches used in the range indicated by the code (refer to Figure 5–1). Refer to the appropriate
transmission Service Manual for replacement procedure.
0011 00-69

X RANGE (Figure 5–9)
6. If, after detecting leaking pressure and replacing solenoids, the problem persists, check for worn
clutch or piston seals. Remove the transmission and repair or replace as necessary.
7. This code requires accurate output and turbine speed readings. If there were no transmission prob-
lems detected, use the diagnostic tool and watch the speed readings for noise (erratic signals) from
low speed to high speed in the range indicated by the code.
8. If a noisy sensor is found, check the sensor resistance (refer to the sensor resistance chart below)
and check its wiring for opens, shorts, and shorts-to-ground (see code 22XX). Also closely check
the terminals in the connectors for corrosion, contamination, or damage. Ensure the wiring to the
sensors is a properly twisted wire pair. Remove sensor and check for damage at the tone wheel
end. Check for looseness of the tone wheel. Replace the sensor if it is damaged or if its resistance
(refer to Service Manual for proper procedure) is incorrect and isolate and repair any noted wiring
problems. (Use St. Clair P/N 200153 Service Harness Twisted Pair for this procedure.)
Resistance Temp. °C Temp. °F

200 ¾ –40 –40
300 ¾ 20 68
400 ¾ 110 230
9. If no apparent cause for the code can be located, replace the turbine and output speed sensors.
Refer to the appropriate transmission Service Manual for proper procedure.
0011 00-70
CODE 26 XX — THROTTLE SOURCE/ENGINE COOLANT SOURCE

NOT DETECTED
Main code 26 occurs when the ECU has not detected either a throttle source or an engine coolant source.
Main
26 00 Throttle source not detected
26 11 Engine coolant source not detected
Code 26 00 means that the ECU has not detected the presence of engine throttle data or analog circuitry. For details
about or using Pro-Link® to select a throttle source, see WTEC III Pro-Link ® Manual.
Code 26 11 means that the ECU has not detected the presence of engine coolant temperature data or analog
circuitry. For details about or using Pro-Link® to select an engine coolant temperature source, see WTEC III Pro-
Link ® Manual.
A. Active Indicator Clearing Procedure

• Power down
• Manual
B. Troubleshooting
1. When code 26 00 is logged and an analog TPS is known to be installed, refer to code 21 XX for
troubleshooting steps. If a J1587 or J1939 throttle signal is used, refer to code 66 00 for trouble-
shooting steps.
2. When code 26 11 is logged and if an analog engine coolant temperature sensor is being used, refer
to code 62 XX for troubleshooting steps. If a J1587 or J1939 engine coolant temperature signal is
being used, refer to code 66 00 for troubleshooting steps.
0011 00-71
CODE 32 XX — C3 PRESSURE SWITCH
0011 00-72
CODE 32 XX — C3 PRESSURE SWITCH (Figure 5–10)
Main code 32 indicates the transmission gear ratio is correct, but the C3 pressure switch is open when it should be
closed.
NOTE: When an ECU with a version 8 or 8A calibration is used with a pre-TransID transmission, 32 XX codes
are set because the ECU sees wire 195 is open. To correct this condition, convert to a TID 1 internal
harness or install Adapter P/N 200100 available from St. Clair Technologies.
Main
32 00 C3 switch open in low range
(MD 3070 or HD 4070 only)
32 33 C3 switch open in third range
32 55 C3 switch open in fifth range
32 77 C3 switch open in reverse range
• Power down
• Manual
• Self-clearing
B. Troubleshooting:
1. Disconnect the transmission “T” harness connector at the ECU and the transmission. Check the
C3 switch circuit for opens, shorts to other wires, shorts-to-ground, or short-to-battery. If wiring
problems are found, isolate and repair. The C3 pressure switch closes at 206.8 ± 48 kPa (30±7psi);
resistance should be 2 Ohms maximum when the switch is closed and 20,000 to infinity when the
switch is open. Infinity is often indicated as OL (over limit) on a DVOM.
2. If problems are not found in the external harness, drain the fluid, remove the control module, and
check the internal harness for opens, shorts between wires, or shorts-to-ground (refer to the proper
transmission Service Manual). If wiring problems are found, isolate and repair.
3. If no wiring problems are found, replace the C3 pressure switch.
4. If the problem recurs, use a spare wire, if available, or provide a new wire (St. Clair P/N 200153
may be used for this purpose) for the C3 pressure switch circuit.
5. If the problem recurs again, replace the internal harness.
0011 00-73
CODE 33 XX — SUMP OIL TEMPERATURE SENSOR
0011 00-74
CODE 33 XX — SUMP OIL TEMPERATURE SENSOR (Figure 5–11)
NOTE: When an ECU with a version 8 calibration(CIN=0A...) is used with a Trans ID 2 transmission, 33 XX
codes are set because the ECU does not have the proper calibrations for the TID 2 thermistors.
The ECU calibration must be updated to version 8A or later (CIN=0B...).
Main code 33 indicates the sump temperature sensor is providing a signal outside the usable range of the ECU.
This code indicates the sensor failed showing abnormally high or low temperature readings. Main code 33 can be
caused by a component or circuit failure or by extremely high or low temperatures. There are no operational
inhibits related to main code 33. The ECU assumes a hardware failure and that transmission temperatures are
normal (93ºC; 200ºF). Temperatures above or below normal cause poor shift quality.
NOTE: Codeþ33 23 in conjunction with code 21þ23 indicates the loss of common ground (wire 135) between
the throttle and temperature sensors.
Main
33 12 Sump oil temperature sensor failed low
33 23 Sump oil temperature sensor failed high

• Power down
• Manual
• Self-clearing
NOTE: Before troubleshooting, read Paragraph 5–6. Also, check the transmission fluid level.
B. Troubleshooting:
NOTE: Code 33 12 can be caused when the +5V power line (wire 124) is shorted to ground or open. Wire 124
also provides power for the OLS, TPS, RMR, retarder temperature sensor, and shift selectors and is
present in all three ECU connectors.
1. If possible, check the sump temperature with a DDR. Use the fastest sample rate available on the
DDR . This is necessary to catch momentary changes due to an intermittent open or short to
ground. If a DDR is not available, use the shift selector display to determine if the code is active
(refer to Paragraph 5–2). Disconnect the transmission “T” harness at the ECU and check resistance
of the sensor and compare with Figure 6–12 for TID 1 for TID 2.
2. If Step (1) reveals that the extreme temperature indication is no longer present, the temperature
limit could have been reached due to operational or ambient temperature extremes. Also, you may
be experiencing an intermittent problem and the code will not be active. Proceed cautiously, it is
unlikely there is a sensor hardware fault.
0011 00-75
CODE 33 XX — SUMP OIL TEMPERATURE SENSOR (Figure 5–11)
Figure 5–12. Temperature Sensor Chart
3. Disconnect the external harness at the transmission. Check the connectors and terminals for dirt,
corrosion, or damage. Clean or replace as necessary.
4. Check the sensor wires in the external harness for opens (code 33 23), shorts between wires, or
shorts-to-ground (code 33 12 — refer to Section 4). If wiring problems are found, isolate and re-
pair.
5. If no harness problems are found, check the feedthrough harness for damage. If the feedthrough
harness connector is satisfactory, drain the fluid and remove the control module. Check for chafing
of the sensor wires, especially near the separator plate. Eliminate the chafe point. If no chafe point
is found, replace the sensor.
may be used for this purpose) for the temperature sensor circuit.
0011 00-76
CODE 34 XX — CALIBRATION COMPATIBILITY OR CHECKSUM FAULT
Main code 34 indicates there is a problem with the calibration.
Main
34 12 Factory calibration compatibility number wrong
34 13 Factory calibration checksum
34 14 Power off block checksum
34 15 Diagnostic queue block checksum
34 16 Real-time block checksum
34 17 Customer modifiable constants checksum

• Power down
NOTE: Copying the current calibration from the ECU and reloading it will not correct the fault. The
calibration must be downloaded directly from PCCS.
B. Troubleshooting:
1. If the code set is 34 14 and it occurs in conjunction with code 35 00, proceed to find the cause for
code 35 00 and correct it.
2. After the cause for code 35 00 has been corrected, drive the vehicle to see if code 34 14 recurs. If
code 34 14 recurs, proceed to Step (3).
3. Reprogram the correct calibration. Contact your nearest Allison distributor/dealer location quali-
fied to do recalibration. Be certain the calibration and the software level are compatible.
4. If the code recurs after reprogramming, replace the ECU.
5. If the code set is 34 17, reprogram the GPI/GPO package after re-calibration of the ECU.
0011 00-77
CODE 35 XX — POWER INTERRUPTION
0011 00-78
CODE 35 XX — POWER INTERRUPTION (Figure 5–13)
Main code 35 indicates the ECU has detected a complete power loss before the ignition was turned off or before
ECU shutdown is completed. When this happens, the ECU is not able to save the current operating parameters in
memory before turning itself off.
Main
35 00 Power interruption. (Not an active code; only appears after power is restored.)
During power interruption, DNS light is not illuminated and the transmission
will not shift.
35 16 Real-time write interruption. (Power interruption at the same time the ECU is
recording a critical code to the real-time section.)
• Power down
• Manual — except code 35 16
B. Troubleshooting:
1. If the vehicle has a master switch controlling battery power to the ECU and an ignition switch,
turning the master switch off before turning the ignition switch off can cause this code. Turning the
master switch off before ECU shutdown is completed will also cause this code. No troubleshoot-
ing is necessary.
2. If improper switch sequencing is not the cause, check ECU power and ground for opens, shorts,
and shorts-to-ground. Not using battery-direct power and battery ground connections can cause
this code. A defective charging system, or open battery fuse or fusible link can also cause this
code. The battery fuse or fusible link may be at the battery or in the VIM. Dirty, corroded, or
painted power and ground connections can also cause this code.
3. If all system power and ground connections are satisfactory and the problem persists, replace the
ECU. If replacing the ECU corrects the problem, reinstall the original (bad) ECU to confirm that
the problem is in the ECU. If the original ECU now works, inspect the ECU connectors for any
corrosion or damage which may cause an intermittent condition. If the original problem reoccurs,
reinstall the replacement ECU.
Main code 36 indicates the system has detected a mismatch between the ECU hardware and the ECU software or
that there is a TransID (TID) problem.
Main
36 00 Mismatch between ECU hardware and software
36 01 TransID not compatible with hardware/software
36 02 TransID did not complete
• Power down
0011 00-79
CODE 36 XX — HARDWARE AND SOFTWARE NOT COMPATIBLE
B. Troubleshooting:
1. Correction for code 36 00 requires the installation of software that is compatible with the ECU
hardware involved. (If a different calibration is required, update the ECU hardware to be
compatible.)
2. Correction for code 36 01 is to update the ECU calibration. Installation of the latest calibration
makes the ECU compatible with the latest TransID configuration.
3. Correction for code 36 02 is to troubleshoot TransID wire 195 for short-to-battery. Codes 42 XX or
69 XX may be associated with this code.
0011 00-80
CODE 42 XX — SHORT-TO-BATTERY IN SOLENOID CIRCUIT
0011 00-81
CODE 42 XX — SHORT-TO-BATTERY IN SOLENOID CIRCUIT (Figure 5–14)
Main code 42 indicates the ECU has detected a short-to-battery condition in a solenoid wiring circuit. The DO
NOT SHIFT response is activated when some subcodes are detected, all solenoids are turned off and the CHECK
TRANS light is illuminated. All solenoids have a driver on the low (ground) side which can turn off the solenoid.
All solenoids also have a driver on the high (power) side of the solenoid. Even though the high side driver can be
turned off, a short-to-battery means the solenoid is continuously powered at an unregulated 12V or 24V instead of
a regulated (pulse width modulated) voltage. The low side driver will not tolerate direct battery current and will
open, causing the solenoid to be deenergized.
NOTE: For subcodes 12, 13, 14, 15, 16, 22 — neutral start is inoperable; all display segments are on if the
code is logged during ECU initialization (ignition on). Subcodes 21, 23, 24, and 26 will not trigger the
CHECK TRANS light.
Main
42 12 Short-to-battery A Solenoid Circuit
42 13 Short-to-battery B Solenoid Circuit
42 14 Short-to-battery C Solenoid Circuit
42 15 Short-to-battery D Solenoid Circuit
42 16 Short-to-battery E Solenoid Circuit
42 21 Short-to-battery F Solenoid Circuit
42 22 Short-to-battery G Solenoid Circuit
42 23 Short-to-battery H Solenoid Circuit
42 24 Short-to-battery J Solenoid Circuit
42 26 Short-to-battery N Solenoid Circuit
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• Manual
NOTE: Intermittent connections or lack of battery-direct power and ground connections may cause this and
other codes.
NOTE: Energizing the solenoids and listening for ball/plunger movement is sometimes useful in
troubleshooting.
NOTE: “N” solenoid on the retarder accumulator has either a 12.5 ± 1.5 Ohm coil or a 23.5 ± 2.4 Ohm coil
and is not correlated to sump temperature.
PROBING THE CONNECTOR
When testing the control system from the feedthrough connector with the internal harness connected, the resistance
of each solenoid can be measured by using a VOM. Refer to Figure 5–15 for solenoid resistance versus
temperature.
0011 00-82
Figure 5–15. Solenoid Resistance vs. Temperature
B. Troubleshooting:
1. Make sure the transmission connector is tightly connected. If the connector is properly connected,
disconnect the wiring harness at the transmission. Check the connector for corroded or damaged
terminals. Clean or replace as necessary.
2. Test each solenoid circuit at the transmission connector for shorts between the solenoid circuit be-
ing diagnosed and all other terminals in the connector. This test may be simplified by using the
J41612 test tool. Refer to the system schematic and/or chart to identify wires in the internal har-
ness which are connected. If a short is found, isolate and repair the short. The short will probably
be in the internal wiring harness.
3. If multiple code 42s occur (4212, 4213, 4214, 42 12, 4216, 4222, and 4224), and wiring and
solenoids check okay, the A-Hi driver is probably failed open.
confirm that the problem is in the ECU. If the problem recurs, reinstall the new ECU to complete
the repair.
5. If code 4221 occurs repeatedly and the F solenoid and wiring checks okay, the F-Hi or F-Lo driver
may be failed open. Follow Step (4) above.
6. If codes 4223 and 4226 occur repeatedly and solenoids and wiring check okay, the H and N-Hi
driver may be failed open. Follow Step (4) above.
7. If the short is not found at the transmission connector, disconnect the transmission “T” harness
connector at the ECU and check the wires of the solenoid circuit for shorts between the solenoid
wires. If the short is found in one of the wires, isolate and repair it. Use a spare wire, if available,
or provide a new wire (St. Clair P/N 200153 may be used for this purpose).
0011 00-83
8. If the short is not found in either the transmission or the harness, the condition must be
intermittent.
9. Drain the fluid, remove the control module and closely inspect the internal harness for damage.
Repair or replace as necessary.
may be used for this purpose) for the solenoid circuit indicated by the trouble code.
0011 00-84
CODE 44 XX — SHORT-TO-GROUND IN SOLENOID CIRCUIT
0011 00-85
CODE 44 XX — SHORT-TO-GROUND IN SOLENOID CIRCUIT (Figure 5–16)

Main code 44 indicates the ECU has detected a short-to-ground in a solenoid or its wiring. The DO NOT SHIFT
response is activated when some subcodes are detected, all solenoids are turned off, and the CHECK TRANS light
is illuminated.
NOTE: For subcodes 12, 13, 14, 15, 16, 22 — neutral start is inoperable. Subcodes 21, 23, 24, and 26 do not
trigger the CHECK TRANS light.
Main
44 12 Short-to-ground A Solenoid Circuit
44 13 Short-to-ground B Solenoid Circuit
44 14 Short-to-ground C Solenoid Circuit
44 15 Short-to-ground D Solenoid Circuit
44 16 Short-to-ground E Solenoid Circuit
44 21 Short-to-ground F Solenoid Circuit
44 22 Short-to-ground G Solenoid Circuit
44 23 Short-to-ground H Solenoid Circuit
44 24 Short-to-ground J Solenoid Circuit
44 26 Short-to-ground N Solenoid Circuit

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• Manual
other codes.
of each solenoid can be checked using a VOM. Refer to Figure 5–17 for resistance values versus temperature.
0011 00-86
B. Troubleshooting:
1. Check the transmission connector and make sure it is tightly connected. If the connector is
properly connected, disconnect the harness at the transmission and inspect the terminals in the
transmission harness and feedthrough harness connectors. Clean or replace as necessary
(Appendix D).
2. If the connector is connected, clean, and not damaged, check the solenoid circuit in the
transmission for shorts to other wires. (Tool J41612 may be useful in making this test.) Refer to
the system schematic and/or chart to identify wires in the internal harness which are connected. If
the short circuit is found, drain the fluid, remove the control module (refer to the transmission
Service Manual), and isolate the short. The short is probably in the feedthrough harness, or the
solenoid itself (refer to Figure 5–1 for solenoid locations).
3. If the short is not found in the transmission, disconnect the transmission harness connector at the
ECU and inspect the terminals for damage or contamination. Clean or replace as necessary. If the
terminals are satisfactory, check the wires of the solenoid circuit in the transmission harness for
shorts-to-ground or shorts between wires. If a short is found in one of the wires, isolate and repair
it or use a spare wire, if available, or provide a new wire (St. Clair P/N 200153 may be used for
this purpose) in the external harness. Refer to Appendix E for connector/terminal repair
information.
4. If the short is not found in either the transmission or the harness, the condition must be
intermittent.
5. Drain the fluid, remove the control module, and closely inspect the solenoid and internal harness
for damage. Repair or replace as necessary.
0011 00-87
may be used for this purpose) for the solenoid circuit indicated by the diagnostic code.
0011 00-88
CODE 45 XX — OPEN CONDITION IN SOLENOID CIRCUIT
0011 00-89
CODE 45 XX — OPEN CONDITION IN SOLENOID CIRCUIT (Figure 5–18)
Main code 45 indicates the ECU has detected either an open circuit condition in a solenoid coil or the wiring to that
solenoid. The DO NOT SHIFT response is activated when some subcodes are detected, all solenoids are turned
off, and the CHECK TRANS light is illuminated.
Main
45 12 Open Circuit A Solenoid Circuit
45 13 Open Circuit B Solenoid Circuit
45 14 Open Circuit C Solenoid Circuit
45 15 Open Circuit D Solenoid Circuit
45 16 Open Circuit E Solenoid Circuit
45 21 Open Circuit F Solenoid Circuit
45 22 Open Circuit G Solenoid Circuit
45 23 Open Circuit H Solenoid Circuit
45 24 Open Circuit J Solenoid Circuit
45 26 Open Circuit N Solenoid Circuit

• Power down
• Manual
other codes.
of each solenoid can be checked using a VOM. Refer to Figure 5–19 for solenoid resistance values versus
temperature.
0011 00-90
B. Troubleshooting:
1. Check the transmission connector and make sure it is tightly connected. If the connector is
properly connected, disconnect the harness at the feedthrough harness connector and check the
terminals in the transmission harness and feedthrough harness connectors.
2. If the connector is connected, clean, and not damaged, check the solenoid circuit in the transmis-
sion for opens. Refer to the system schematic and/or chart to identify wires in the internal har-
ness which are connected. If the open circuit is found, drain the fluid, remove the control
module (see the transmission Service Manual), and isolate the open. The fault will be in the
feedthrough harness or the solenoid itself (see Figure 5–1 for solenoid locations).
3. If the open is not found at the transmission connector, disconnect the transmission harness
connector at the ECU and inspect the terminals in the connector and the ECU for damage or
contamination. Clean or replace as necessary. If the terminals are satisfactory, check the wires of
the solenoid circuit in the transmission harness for continuity. If the open is found in one of the
wires, isolate and repair it. If this is not feasible, use a spare wire, if available, or provide a new
wire (St. Clair P/N 200153 may be used for this purpose).
4. If multiple code 45s occur (4512, 4513, 4514, 4515, 4516, 4522, and 4524), and wiring and
solenoids check okay, the A-Hi driver is probably failed open.
confirm that the problem is in the ECU. If the problem recurs, reinstall the new ECU to complete
the repair.
6. If code 4521 occurs repeatedly and the F solenoid and wiring checks okay, the F-Hi or F-Lo driver
may be failed open. Follow Step (5) above.
0011 00-91
7. If codes 4523 and 4526 occur repeatedly and solenoids and wiring check okay, the H and N-Hi
driver may be failed open. Follow Step (5) above.
8. If the open is not found in either the transmission or the harness or the ECU drivers, the condition
must be intermittent.
9. Drain the fluid, remove the control module, and closely inspect the solenoid and internal harness
for damage. Repair or replace as necessary.
may be used for this purpose) for the solenoid circuit indicated by the diagnostic code.
0011 00-92
CODE 46 XX — OVERCURRENT TO SOLENOIDS
0011 00-93
CODE 46 XX — OVERCURRENT TO SOLENOIDS (Figure 5–20)
Main code 46 indicates that an overcurrent condition exists in one of the switches sending power to the
transmission control solenoids.
Main
46 21 Overcurrent, F-High solenoid circuit
46 26 Overcurrent, N and H-High solenoid circuit
46 27 Overcurrent, A-High solenoid circuit

• Power down
• Manual
B. Troubleshooting:
1. Probable cause is a wiring problem. A solenoid wire is probably shorted to ground or the solenoid
has a shorted coil which would cause an overcurrent condition. May also be an ECU problem.
2. Follow the troubleshooting steps for code 44 XX.
0011 00-94
CODE 51 XX — OFFGOING RATIO TEST DURING SHIFT (TIE-UP TEST)
Main code 51 indicates a failed offgoing ratio test. An offgoing ratio test occurs during a shift and uses turbine and
output speed sensor readings to calculate the ratio between them. The calculated speed sensor ratio is then compared
to the programmed speed sensor ratio of the commanded range. After a shift is commanded, the ECU, after a period
of time, expects the old ratio to be gone. If the ratio does not change properly, the ECU assumes the offgoing clutch
did not release. The shift is retried if conditions still exist to schedule the shift. If the second shift is not successfully
completed, code 51 XX is set and the ECU returns the transmission to the previous range. Additional codes could be
logged for other shifts where “X” indicates the range from and “Y” indicates the range to.
NOTE: This test is not performed below a calibrated transmission output speed of 200 rpm.
Main
51 01 Low–1 upshift
51 10 1–Low downshift
51 12 1–2 upshift
51 21 2–1 downshift
51 23 2–3 upshift
51 24 2–4 upshift
51 35 3–5 upshift
51 45 4–5 upshift
51 46 4–6 upshift
51 XY X–Y upshift or downshift
• Power down
• Manual — except subcodes 35, 42, 43, 45, 53
other codes.
B. Troubleshooting:
1. Incorrect fluid level can cause 51 series codes. Allow the vehicle to idle for 3–4 minutes and check
the transmission fluid level. If level is not correct, add or drain fluid to correct level.
2. If the fluid level is correct, connect a pressure gauge into the pressure tap for the offgoing clutch
indicated by the code (refer to solenoid and clutch chart, Appendix C). Make the shift indicated by
the subcode or use the Pro-Link ® diagnostic tool clutch test mode to put the transmission in the
off-going and oncoming ranges (refer to Appendix B for clutch pressure check information).
0011 00-95
CODE 51 XX — OFFGOING RATIO TEST DURING SHIFT (TIE-UP TEST)
3. If the offgoing clutch stays pressurized, drain the fluid, remove the control module, disassemble
the control module and clean it, inspecting for damaged valve body gaskets and stuck or sticky
valves. Inspect the transmission for signs of clutch damage indicating the need to remove and
overhaul the transmission.
4. If the problem has not been isolated, replace the solenoid for the offgoing clutch.
5. If after replacing the solenoid the problem persists, install another ECU. If this corrects the prob-
lem, temporarily reinstall the old ECU to verify the repair.
6. If this does not correct the problem, reinstall the original ECU and check for mechanical problems.
The clutch may be mechanically held (coned, burned and welded, etc.). It may be necessary to re-
move the transmission and repair or rebuild as required.
0011 00-96
CODE 52 XX — OFFGOING C3 PRESSURE SWITCH TEST DURING SHIFT
Main code 52 indicates a failed C3 pressure switch test. When a shift is commanded and C3 is the offgoing clutch,
the ECU expects the C3 pressure switch to open within a period of time after the shift is commanded. If the ECU
does not see the switch open, it assumes C3 has not released. If conditions for a shift exist, the shift is retried. If the
C3 pressure switch still remains closed, the code is logged and the DO NOT SHIFT response is commanded. If the
code is set during a direction change, neutral with no clutches is commanded, otherwise the transmission is
commanded to the previous range. Additional codes could be logged for other shifts where “X” indicates the range
from and “Y” indicates the range to.
NOTE: C3 tests are turned off below a calibrated temperature of –32ºC (–25°F).
Main
52 01 L–1 upshift
52 08 L–N1 shift
52 34 3–4 upshift
52 56 5–6 upshift
52 71 R–1 shift
52 72 R–2 shift
52 78 R–N1 shift
52 79 R–2 shift (R to NNC to 2)
52 99 N3–N2 shift
52 XY X–Y shift
• Power down
• Manual
other codes.
B. Troubleshooting:
1. Use the Pro-Link ® diagnostic tool to check the state of the C3 pressure switch.
2. Check the C3 pressure switch wiring for a short-to-ground or a switch stuck closed (refer to code
32XX). If a short is found, isolate and repair; or replace the switch if it is stuck closed.
3. If a fault is not found with the C3 pressure switch or circuitry, connect a pressure gauge to the C3
pressure tap.
4. Drive the vehicle to make the shift indicated by the subcode or use the DDR clutch test mode.
Compare actual C3 pressure value with the table of specifications in Appendix B.
0011 00-97
CODE 52 XX — OFFGOING C3 PRESSURE SWITCH TEST DURING SHIFT
5. If C3 is being held on hydraulically (C3 remains pressurized), drain the fluid, remove the control
module, disassemble and clean the control module, checking for damaged valve body gaskets or
stuck and sticky valves.
may be used for this purpose) for the C3 pressure switch in the external harness.
7. If the problem again recurs, replace the C solenoid.
0011 00-98
CODE 53 XX — OFFGOING SPEED TEST (DURING SHIFT)
Main code 53 indicates a failed offgoing speed test. The speed test during a shift is designed to ensure neutral is
attained during shifts to neutral. This test compares engine speed to turbine speed. If neutral is selected and turbine
speed is found to be much lower than engine speed, the ECU sees this as neutral not being attained. The
transmission is commanded to Neutral with No Clutches and code 53XX is set. Additional codes could be logged
for other shifts where “X” indicates the range from and “Y” indicates the range to.
NOTE: This test is not performed if neutral output is below 200 rpm or when temperatures are below a
calibrated 0°C (32°F).
Main
53 08 L–N1 shift
53 18 1–N1 shift
53 28 2–N1 shift
53 29 2–N2 shift
53 38 3–N1 shift
53 39 3–N3 shift
53 48 4–N1 shift
53 49 4–N3 shift
53 58 5–N1 shift
53 59 5–N3 shift
53 68 6–N1 shift
53 69 6–N4 shift
53 78 R–N1 shift
53 99 N3–N2 or N2–N3 shift
53 XY X–Y shift
• Power down
• Manual — subcodes 78 and 99 only
other codes.
B. Troubleshooting:
1. Be sure the transmission is warm and the fluid level is correct. Correct transmission fluid level as
necessary.
2. Using the DDR, check the engine and turbine speed sensor signals under steady conditions. If a
tachometer is available, compare the tachometer reading with the engine rpm reading on the
diagnostic tool. Check signals in neutral, at idle, high idle, and maximum no load rpm. If a signal
is erratic, check sensor wiring for opens, shorts, and shorts-to-ground (refer to code 22þXX).
Check all connections for dirt and corrosion. If wiring problems are found, repair or replace as
necessary.
0011 00-99
CODE 53 XX — OFFGOING SPEED TEST (DURING SHIFT)
3. If fluid and wiring are satisfactory, install a pressure gauge in the pressure tap for the offgoing
clutch. Make the shift indicated by the subcode using the clutch test mode of the Pro-Link®
diagnostic tool. If the pressure gauge shows clutch pressure (above 55 kPa or 8 psi) remains in the
offgoing clutch, drain the fluid and remove the control module (see the transmission Service
Manual). Disassemble and clean the control module and check for damaged valve body gaskets
and stuck or sticky valves, particularly latch valves and solenoid second-stage valves.
4. If excessive clutch pressure is not remaining in the offgoing clutch, replace the engine speed
sensor and the turbine speed sensor.
5. If the control module is removed to replace the turbine speed sensor (MD, B 300, B 400), clean the
control module and inspect for stuck or sticky valves (particularly the latch valves and solenoid G
second stage valve). Check the rotating clutch drum to which the turbine speed sensor is directed
for damage, contamination, or signs of contact between the drum and the sensor.
6. If the problem recurs, replace the solenoid(s) for the offgoing clutch(es).
7. If the problem again recurs, the offgoing clutch must be held on mechanically (coned, burned,
etc.). Remove the transmission and repair or rebuild as necessary.
0011 00-100
CODE 54 XX — ONCOMING SPEED TEST (AFTER SHIFT)
Main code 54 indicates a failed oncoming ratio test. The ratio test after a shift is failed when the ECU has
commanded the end of a shift and has not seen the transmission shift into the target range (comparing turbine and
output speeds). Erratic readings from speed sensors are a likely cause of an oncoming ratio test failure. If conditions
for a shift still exist, the shift will be retried one more time. If the ratio test is still not met, a code is logged and the
DO NOT SHIFT response is commanded. If the code is set during a direction change, Neutral with No Clutches is
commanded, otherwise the transmission is commanded to the previous range. Code 54 12 can also be caused by the
ECU being calibrated for a close ratio transmission and installed with a wide ratio transmission, or vice versa.
Additional codes could be logged for other shifts where “X” indicates the range from and “Y” indicates the range to.
NOTE: This test is not performed below a calibrated transmission output speed of 200 rpm.

54 01 L–1 upshift
54 07 L–R shift
54 10 1–L downshift
54 12 1–2 upshift — incorrect calibration, wide ratio vs. close ratio
54 17 1–R shift
54 23 2–3 upshift
54 24 2–4 upshift
54 27 2–R shift
54 34 3–4 upshift
54 35 3–5 upshift
54 45 4–5 upshift
54 56 5–6 upshift
54 70 R–L shift
54 71 R–1 shift
54 72 R–2 shift
54 80 N1–L shift
54 81 N1–1 shift
54 82 N1–2 shift
54 83 N1–3 shift
54 85 N1–5 shift
54 86 N1–6 shift
54 92 N2–2 shift
54 93 N3–3 shift
54 95 N3–5 shift
54 96 N4–6 shift
54 XY X to Y shift
0011 00-101
CODE 54 XX — ONCOMING SPEED TEST (AFTER SHIFT)
• Power down
• Manual
other codes.
B. Troubleshooting:
1. After the transmission is at operating temperature, allow the vehicle to idle on level ground for
3–4 minutes. Check transmission fluid level. If improper fluid level is found, correct as necessary.
Improper fluid level could be the cause of the code (not enough or too much fluid may produce
inadequate clutch pressure).
2. Connect a pressure gauge and check main pressure. If pressure is not adequate, the pump is
possibly worn. See Appendix B for main pressure specifications.
3. If the fluid level is correct, check the turbine and output speed sensors for accurate, steady signals
using the diagnostic tool (check with vehicle stopped and in range to confirm a zero speed reading
from the turbine and output speed sensors). Check the wiring for opens and shorts (refer to code
22XX) and the sensor coils for proper resistance. If problems are found, repair or replace as
necessary. Remove speed sensor and check for loose tone wheel.
4. If sensor and wiring resistance are acceptable, connect a pressure gauge(s) to the pressure tap for
the oncoming clutches indicated by the subcode (refer to solenoid and clutch chart in Appendix C).
Make the shift indicated by the code by operating the vehicle or by using the diagnostic tool’s
clutch test mode.
5. If the clutch pressure does not show on the gauge(s), the control module is probably not
commanding the clutch on. Drain the fluid and remove the control module. Disassemble and clean
the control module, inspect for stuck or sticking valves.
6. Internal leakage is indicated by the clutch pressure gauge showing that pressure is being sent to the
clutch but the clutch fails to hold. The fault may be: missing or damaged face seals, burnt clutch,
leaking piston sealrings, or damaged control module gaskets. Drain the fluid, remove the control
module, and inspect the face seals and control module gaskets. If the seals and gaskets are
satisfactory, replace the solenoid(s) indicated by the code. If replacing the solenoid does not
eliminate the code, remove the transmission and repair as necessary.
7. If clutch pressures are correct and the clutch appears to be holding, replace the output and turbine
speed sensors.
8. If the problem recurs, use the diagnostic tool to check the speed sensor signals for erratic readings.
Possible causes of erratic speed readings are: loose sensors, intermittent contact in the wiring,
vehicle-induced vibrations, or speed sensor wiring that is not a properly twisted-pair. If necessary,
use a twisted-pair for a new speed sensor circuit — Service Harness Twisted Pair P/N200153 is
available from St. Clair Technologies for this purpose.
0011 00-102
CODE 55 XX — ONCOMING C3 PRESSURE SWITCH (AFTER SHIFT)
Main code 55 indicates the C3 clutch is the oncoming clutch in a shift and the C3 pressure switch did not close at
the end of the shift. When this code is set, the DO NOT SHIFT response and Neutral with No Clutches is
commanded. On the N1 to R shift the transmission is commanded to the previous range. Additional codes could be
logged for other shifts where “X” indicates the range from and “Y” indicates the range to.
NOTE: When an ECU with a version 8 or 8A calibration is used with a pre-TransID transmission, 55 XX codes
are set because the ECU sees wire 195 is open. To correct this condition, convert to a TID 1 internal
harness or install Adapter P/N 200100 available from St. Clair Technologies.
Main
55 07* Oncoming C3PS (after shift), L–R shift
55 17* Oncoming C3PS (after shift), 1–R shift
55 27* Oncoming C3PS (after shift), 2–R shift
55 87 Oncoming C3PS (after shift), N1–R shift
55 97 Oncoming C3PS (after shift), N1–L to R shift
55 XY Oncoming C3PS (after shift), X to Y shift
*NOTE: When sump temperature is below 10°C (50°F), and transmission fluid is C4 (not DEXRON ®), follow
this procedure when making directional change shifts:
• To shift from forward to reverse; select N (Neutral) and then R (Reverse).
• Failure to follow this procedure may cause illumination of the CHECK TRANS light and then
transmission operation will be restricted to N (Neutral).
• Power down
• Manual — subcode 87 only
other codes.
NOTE: Check battery and ECU input voltages before troubleshooting.
B. Troubleshooting:
NOTE: Do not bring the transmission to operating temperature if the problem occurs at sump temperatures
below that level. Do troubleshooting at the temperature level where the problem occurs.
1. After the transmission is at operating temperature, allow vehicle engine to idle on level ground for
3–4 minutes. Check transmission fluid level. If improper fluid level is found, correct as necessary.
Improper fluid level could be the cause of the code (not enough or too much fluid may produce
inadequate clutch pressure).
2. Connect a pressure gauge and check main pressure. If pressure is not adequate, the pump is
possibly worn. See Appendix B for main pressure specifications.
0011 00-103
CODE 55 XX — ONCOMING C3 PRESSURE SWITCH (AFTER SHIFT)
3. If fluid level and main pressure are adequate, connect a pressure gauge to the C3 pressure tap on
the transmission and make the shift indicated by operating the vehicle using the Pro-Link ®
diagnostic tool’s CLUTCH TEST MODE.
NOTE: When using the CLUTCH TEST MODE on the Pro-Link® , be sure to use the correct pressure
specification. If testing is done with the vehicle stopped, the lockup clutch is not applied, so
use the clutch pressure specification for converter operation (see Appendix B; pressure in 3C
would be the same as in 2C). If testing is done with the vehicle moving, the lockup clutch may
be applied depending upon the vehicle speed and throttle position. Be sure to use the clutch
pressure specification for lockup operation (see Appendix B).
4. If, when making the shift and producing the code, the C3 clutch does not show any pressure, drain
the fluid and remove the control module. Disassemble, clean, and inspect the control module for
stuck or sticky valves (particularly the “C” solenoid second stage valve and C-1 latch valve). If no
obvious problems are found, replace the “C” solenoid and reassemble (see Figure 5–1 for location
of the “C” solenoid).
5. If the gauge shows inadequate pressure being sent to the clutch, the clutch is probably worn, has
leaking piston or face seals, or the control module gaskets are damaged. See Appendix B for clutch
pressure specification. Drain the fluid, remove the control module and inspect the face seals and
valve body gaskets. If the face seals or control module gaskets are not damaged, remove and repair
the transmission (refer to the transmission Service Manual for repair procedure).
6. If the gauge shows adequate clutch apply pressure, the problem is with the C3 pressure switch or
its wires. Check the C3 pressure switch wires in the transmission harness for opens, shorts, or
shorts-to-ground (see code 32þXX). If found, isolate and repair the C3 pressure switch circuit.
NOTE: A leakage problem may be temperature related. Be sure to check pressures at the sump temperature
where the problem occurred.
7. If the problem is not in the transmission harness, drain the fluid and remove the control module.
Check the feedthrough harness assembly for opens. If wiring problems are found, repair as
necessary. If no wiring problems are found, replace the C3 pressure switch (see Figure 5–1 for the
location).
0011 00-104
CODE 56 XX — RANGE VERIFICATION RATIO TEST (BETWEEN SHIFTS)
Main code 56 indicates a failed range verification speed sensor ratio test. The ratio test occurs after a shift and
determines if a clutch has lost torque carrying capability. If output speed is above programmed output speed for a
range but the correct speed sensor ratio is not present, the DO NOT SHIFT response is commanded and a range
which can carry the torque without damage is commanded or attempted. Turbine and output speed sensor readings
are used to calculate the actual ratio that is compared to the commanded ratio. Main code 56 can also be caused
by the ECU being calibrated for a close ratio transmission and installed with a wide ratio transmission, or
vice versa.
Main
56 00 Range verification ratio test (between shifts) L
56 11 Range verification ratio test (between shifts) 1
56 77 Range verification ratio test (between shifts) R
• Power down
• Manual — subcodes 11, 44, 66, 77 only
NOTE: When a code 22 16 (output speed fault) is also present, follow the troubleshooting sequence for code
22 16 first. After completing the 22 16 sequence, drive the vehicle to see if a code 56 XX recurs.
other codes.
B. Troubleshooting:
1. After the transmission is at operating temperature, allow vehicle engine to idle on level ground for
3–4 minutes. Check the transmission fluid level. If improper fluid level is found, correct as
necessary. Improper fluid level could be the cause of the code. Not enough or too much fluid may
produce inadequate clutch pressure.
2. Connect a pressure gauge and check main pressure. If the pressure is not adequate, the pump is
probably worn. See Appendix B for main pressure specifications.
3. If main pressure is adequate, check clutch pressure for the range indicated by following the
procedure in Appendix B. The transmission range indicated by the trouble code can be found by
referring to the solenoid and clutch chart in Appendix C. Drive the vehicle or use the diagnostic
tool’s clutch test mode and check clutch pressure.
4. If a clutch is leaking pressure, drain the fluid, remove the control module and check for damaged
control module gaskets and stuck or sticking valves. Also look for damaged or missing face seals.
If no problems are found, replace the solenoids for the clutches used in the range indicated by the
code.
0011 00-105
CODE 56 XX — RANGE VERIFICATION RATIO TEST (BETWEEN SHIFTS)
5. If replacing solenoids does not correct the pressure problem, a worn clutch or worn piston seals are
probably the source of the pressure leak. Remove the transmission and repair or replace as
necessary.
6. This code requires accurate output and turbine speed readings. If there were no transmission prob-
lems detected, use the diagnostic tool and check the speed sensor signals for noise (erratic signals)
from low speed to high speed in the range indicated by the code.
7. If a noisy sensor is found, check the resistance of the sensor (300 ± 30 Ohms, refer to the code
22XX temperature variation chart) and its wiring for opens, shorts, and shorts-to-ground (refer to
code 22XX). Carefully check the terminals in the connectors for corrosion, contamination, or
damage. Ensure the wiring to the sensors is a properly twisted wire pair. Replace a speed sensor if
its resistance is incorrect. Isolate and repair any wiring problems. (Use a twisted-pair if a new
speed sensor circuit is needed — Service Harness Twisted Pair P/N 200153 is available from
St.Clair Technologies for this purpose.)
8. If no apparent cause for the code can be found, replace the turbine and output speed sensors.
0011 00-106
CODE 57 XX — RANGE VERIFICATION C3 PRESSURE TEST

(BETWEEN SHIFTS)
Main code 57 indicates failure of the range verification C3 pressure switch test. This test determines if the C3
pressure switch is closed when it should be open. The test occurs when a range is commanded that does not use the
C3 clutch (neutral, 1, 2, 4, and 6). The code is set if the C3 pressure switch is closed when it should be open. If C3
clutch comes on when not needed, three clutches are applied and a transmission tie-up occurs. The ECU will
command a range which does use the C3 clutch and activate the DO NOT SHIFT response.
Main Replace
Code Subcode Meaning Solenoid
57 11 Range verification C3 pressure switch while in 1st B
57 22 Range verification C3 pressure switch while in 2nd C
57 44 Range verification C3 pressure switch while in 4th C
57 66 Range verification C3 pressure switch while in 6th A
57 88 Range verification C3 pressure switch while in N1 C
57 99 Range verification C3 pressure switch while in N2 or N4 C

• Power down
• Manual
other codes.
B. Troubleshooting:
1. Disconnect the harness from the transmission. Check the C3 pressure switch circuit at the
feedthrough harness connector for continuity (refer to code 32XX).
2. Continuity at the feedthrough harness connector indicates the C3 pressure switch is closed or the
C3 circuit is shorted together. Drain the fluid, remove the control module, and isolate the short.
The fault is either a shorted feedthrough harness or stuck C3 pressure switch. Repair or replace as
necessary.
3. If there is no continuity at the transmission, disconnect the transmission harness connector from
the ECU and check the C3 pressure switch wires in the transmission harness for shorts. Use the
system wiring diagram to identify wires which are connected. If a shorted C3 pressure switch cir-
cuit in the external harness is found, isolate and repair.
4. If the C3 pressure switch or circuit is not shorted either in the transmission or the external harness,
connect a pressure gauge in the C3 pressure tap (refer to Appendix B for pressure tap location).
Drive the vehicle in the range indicated by the code or use the diagnostic tool’s clutch test mode to
attain that range.
5. If the gauge shows C3 pressure is present in the range indicated by the subcode, drain the fluid and
remove the control module. Check for damaged valve body gaskets or stuck or sticking valves. Re-
pair or replace as necessary. If no obvious defects are found, replace the listed solenoid.
6. If the gauge shows C3 pressure is not present in the range indicated by the subcode, drain the fluid and
remove the control module. Replace the C3 pressure switch.
If the original problem reoccurs, reinstall the replacement ECU.
0011 00-107
CODE 61 XX — RETARDER OIL TEMPERATURE HOT
Main code 61 indicates the ECU has detected a hot fluid condition in the output retarder. Table 5–7 shows what
actions are taken by the ECU at elevated retarder temperatures.
Possible causes (but not all causes) for hot fluid are:
1. Prolonged retarder use.
2. TID 2 transmission with ECU prior to Version 8A.
3. Low fluid level.
4. High fluid level.
5. A retarder apply system that allows the throttle and retarder to be applied simultaneously.
6. Cooler inadequately sized for retarder.
If the validity of the hot fluid diagnosis is in question, temperature can be checked by using a temperature gauge at the
retarder-out port or by reading retarder temperature with the Pro-Link® diagnostic tool. Another method of checking
retarder temperature is to remove the “T” connector at the ECU and measure resistance (Ohms) between terminals T28
and T25. Compare the resistance value to the value in Figure 6–21 to see if the result is within the expected operating
range.
NOTE: Use the Pro-Link® diagnostic tool to determine the software version being used.
The retarder temperature sensor is located externally on the HD retarder housing and under the plate on the MD
retarder housing. When retarder temperature reaches a preset level, a retarder hot temperature light is illuminated.
NOTE: When an ECU with a version 8 calibration is used with a TransID 2 transmission, 62 XX codes are set
because the ECU does not have the proper calibrations for the TID 2 thermistors. The ECU calibration
must be updated to version 8A.
0011 00-108
CODE 61 XX — RETARDER OIL TEMPERATURE HOT
Main code 62 indicates the retarder temperature sensor or engine coolant sensor or circuitry is providing a signal
outside the usable range of the ECU. Main code 62 can be the result of a hardware failure or an actual extremely
high or low temperature condition.
Main
62 12 Retarder temperature sensor failed low (–45°C; –49°F)
62 23 Retarder temperature sensor failed high (178°C; 352°F)
62 32 Engine coolant sensor failed low
62 33 Engine coolant sensor failed high

• Power down
• Manual
• Self-clearing
NOTE: Before troubleshooting, read Paragraph 5–6. Also, check the transmission fluid level.
B. Troubleshooting:
NOTE: A combination of codes 6223, 3323, and 2123 indicates a problem with one of the branches of the
common ground wire (wire 135) between the throttle and temperature sensors.
also provides power for the OLS, TPS, RMR, sump temperature sensor, and shift selectors and is
present in all three ECU connectors.
1. Check the retarder temperature or engine coolant temperature with a DDR. If a DDR is not
available, use the shift selector display to determine if the code is active (cycle the ignition on and
off at least once since the code was logged to clear the code’s active indicator). If a condition that
is unreasonable for the current conditions exists, go to Step (3).
2. If Step (1) reveals that the extreme temperature indication is no longer present, the temperature
limit could have been reached due to operational or ambient temperature extremes. Proceed
cautiously as it is unlikely there is a sensor hardware fault.
3. Remove the connector at the ECU. Measure resistance between harness terminals T25 and T28 or
between harness terminals V9 and V24. Compare resistance value to chart (see Figure 5–21) to see
if reading is within expected operating range.
4. Disconnect the sensor connector and remove the connector at the ECU. Check the sensor and the
ECU terminals for dirt, corrosion, and damage. Clean or replace as necessary.
5. Check the temperature sensor circuit for opens (code 62 23 or 62 33), shorts between wires, and
short-to-ground (code 6212 or 62 32). If a wiring problem is found, isolate and repair.
6. If no wiring problem is found, replace the retarder or engine coolant temperature sensor.
may be used for this purpose) for the retarder or engine coolant temperature circuit.
0011 00-109
CODE 62 XX — RETARDER TEMPERATURE SENSOR
8. If the condition continues to recur, replace the ECU. If replacing the ECU corrects the problem,
reinstall the original (bad) ECU to confirm that the problem is in the ECU. If the original ECU
now works, inspect the ECU connectors for any corrosion or damage which may cause an
intermittent condition. If the original problem recurs, reinstall the replacement ECU.
Code 6300 is set when one of the two inputs for an input function Auxiliary Function Range Inhibit (Special) is in
a different state (on or off) from the other input for longer than two minutes. When this condition is detected, code
6300 is set. The transmission will not be inhibited in shifting from neutral to range.
Main
63 00 Auxiliary Function Range Inhibit (Special) inputs states are different
63 26 Kickdown input failed on (software version 8 only)
63 40 Service brake status failed on
63 41 Pump/pack and a neutral general purpose input
Subcode 26 is set when this function (Kickdown) is selected by calibration, the calibration designated input is active
for a calibration time, and throttle position is less than the calibration value defined. The kickdown shift schedule is
inhibited when subcode 26 is active. The service indicator will be turned on if it is selected by the calibration. The
kickdown shift schedule is not inhibited, the code is cleared and the service indicator will be turned off if the
kickdown input remains inactive for the calibration time period while throttle position is less than the calibration
value. This diagnostic and code has been removed from software version 8A.
Subcode 40 is set when this function (Service Brake Status) is selected by calibration, and the specified input
remains active for a calibration number of consecutive acceleration events. The service indicator will be turned on
if it is selected by the calibration. A vehicle acceleration event is defined as an increase in transmission output
speed from 1 rpm to a calibration value. The operation of the Automatic Neutral For Refuse Packer will be limited
when this code is active. The active inhibit for this code is self-cleared and the service indicator will be turned off
if the designated input for the Service Brake Status function becomes inactive.
Subcode 41 is set when the states of the calibration inputs are different for a calibration number of consecutive
updates. The inputs in this case are Pump/Pack Enable and Automatic Neutral For Refuse Packer. The service
display will also be turned ON if selected by calibration.
• Power down
• Manual — subcodes 26, 40, and 41
• Self-clearing — subcodes 26 and 40
B. Troubleshooting:
1. Code 63 00
a. Use the DDR to identify the two input wires programmed with Auxiliary Function Range
Inhibit (Special). Inspect the input wiring, connectors, and switches to determine why the input
states are different. Correct any problems which are found.
b. If the condition persists, replace the ECU. If replacing the ECU corrects the problem, reinstall
the original (bad) ECU to confirm that the problem is in the ECU. If the original ECU now
works, inspect the ECU connectors for any corrosion or damage which may cause an intermit-
tent condition. If the original problem recurs, reinstall the replacement ECU.
2. Code 63 26
Inspect kickdown switch circuit.
0011 00-110
CODE 62 XX — RETARDER TEMPERATURE SENSOR (Figure 5–21)
3. Code 63 40
Inspect service brake status switch circuit.
4. Use the DDR to identify the two wires associated with the input functions for Pump/Pack Enable
and Automatic Neutral For Refuse Packer. Inspect the input wiring, connectors, and switches to
determine why the input states are different. Correct problems which are found. There is further in-
formation on these input functions on pages H–25, H–26, H–29, and H–30.
0011 00-111
CODE 62 XX — RETARDER TEMPERATURE SENSOR (Figure 5–21)
0011 00-112
CODE 63 XX — INPUT FUNCTION FAULT
Main code 64 indicates the ECU has detected a voltage signal from the retarder modulation request sensor
(consisting of a module and a retarder control device) in either the high or low error zone. These codes can be
caused by faulty wiring, faulty connections to the resistance module or retarder control device, a faulty resistance
module, a faulty retarder control device, or a faulty ECU. Power wire 124 and ground wire 135 for the retarder
modulation request sensor are a common power and ground with the TPS and OLS devices. A short-to-ground on
the common power wire causes a “sensor failed low” code for the other devices (codes 2112, and 1412). An open
or a short-to-ground on retarder modulation request sensor signal wire 164 results in a code 6412 only.
A TPS failure changes the status of the output retarder. The retarder is enabled by the Service Brake Status
(wire 137) when a TPS code is active (21XX). If a code 6340 is also active, the Service Brake Status (wire 137)
is ignored and the retarder will not work. Retarder response problems may not cause retarder modulation request
sensor diagnostic codes. If response questions occur, test the retarder control devices for proper voltage signals at
each of the percentage of retarder application settings. Table 5–8 contains the voltage measurements for each
device’s application percentage and resistances measured across terminals A and C of the retarder request sensor.
Use test wiring harness J41339 when conducting voltage tests.
Main
64 12 Retarder Modulation Request sensor failed Low (14 counts and below)
64 23 Retarder Modulation Request sensor failed High (232 counts and above)
• Power down
other electronic control codes.
B. Troubleshooting:
also provides power for the OLS, TPS, sump temperature sensor, retarder temperature sensor, and
shift selectors and is present in all three ECU connectors..
1. Plug in the DDR and set to read retarder counts and percent (0 percent will be between 15 and 60
counts and 100 percent will be between 150 and 233 counts). A retarder request sensor failed high
code can be caused by a short-to-battery of either signal wire 164 or power wire 124 or an open on
ground wire 135. An open in the portion of the ground circuit common to the TPS and OLS devices
will also result in a code 2123 and a high fluid level reading. A retarder request sensor failed low
code can be caused by an open or short-to-ground on either signal wire 164 or power wire 124.
2. Isolate and repair any wiring problems found.
3. If no wiring or connector problems are found, check the retarder request sensor voltages for each
position on each of the retarder request sensors used on the vehicle. If two resistance modules are
used, disconnect one of them when measuring voltage signals from the other. If problems are
found, replace the resistance modules or retarder control devices.
4. If the problem persists, replace the ECU. If replacing the ECU corrects the problem, reinstall the
.
0011 00-113
CODE 64 XX — RETARDER MODULATION REQUEST DEVICE FAULT
Table 5–1. RMR Device Resistance Checks
Resistance Check in Wiring to Control

Resistance Module* Voltage Signal ** Device
Resistance % Retarder Voltage
Description Terminals ± 5% Application ± 0.2 v Device Terminal
Auto Full On A to C 12K 100 3.6 No connections
Pressure Switch
Full On A to C 32K 0 1.1 A
High 100 3.6 B
3-Step E-10R Bendix A to C 32K 0 1.1 A
Pedal 32 1.9 B
58 2.8 C
100 3.6 D
6-Step Hand Lever — A to C 32K
Off 0 1.1 +
Position 1 14 1.5 1
Position 2 Position 28 1.9 2
3 Position 4 45 2.3 3
Position 5 Position 65 2.8 4
6 82 3.2 5
100 3.6 6
Auto 1 ⁄ 2 On A to C 12K 50 2.4 No connections
3 Pressure Switches — A to C 32K 0 1.1
Low 32 1.9 A
B
Medium 68 2.8 A
B
High 100 3.6 A
B
Auto 1 ⁄ 3 On A to C 21.4K
2 Pressure Switches
Auto 32 1.9 A
Medium 68 2.8 B
High 100 3.6 A
B
Dedicated Pedal No Checks Interface not 0 0.7 – 1.2 A
a resistance 100 3.4 – 3.5 B
module C
* Resistance module must be disconnected from the wiring harness and retarder control devices
** These voltages must be measured between terminals A and B.
0011 00-114
CODE 64 XX — RETARDER MODULATION REQUEST DEVICE FAULT (Figure 5–22)
0011 00-115
CODE 64 XX — RETARDER MODULATION REQUEST DEVICE FAULT
The datalink for throttle sensor or engine coolant temperature must have been recognized by autodetect or
manually selected using the Pro-Link ® (see WTEC III Pro-Link® Manual) before these codes can be logged.
Main code 66 indicates the ECU is expecting to get its throttle position signal or engine coolant signal across a
serial communication interface from a computer-controlled engine. Either the engine computer is not sending the
throttle or engine coolant information or the wiring between the engine and transmission computers has failed.
Code 66 00 can occur when the transmission ECU remains powered when the engine ECM is powered down. The
transmission sees this as a communication link failure.
Main
66 00 SCI (Serial Communication Interface) fault
66 11 SCI Engine coolant source fault

• Power down
• Manual
• Self-clearing
B. Troubleshooting:
1. Check for a throttle signal or engine coolant signal from the engine to the transmission, an engine
computer malfunction, an engine throttle fault, or an engine coolant fault.
NOTE: Throttle position data sent from a computer-controlled engine may register a low number of counts on
the DDR, but the counts will not change as throttle percentage is changed.
2. Check wires 142 and 151 between the engine and transmission ECU for an open or short. Check
that all connectors are clean and tightly connected.
NOTE: These codes can also be set if J1939 communications fail. Check wires 183-S13, 184-S29, and
182-S12 for opens or shorts.
3. Use the Pro-Link ® to see if the ECU is receiving power when it should not.
0011 00-116
CODE 65 XX — ENGINE RATING HIGH
Main code 65 indicates the vehicle’s engine horsepower/governor speed rating is too high. This code is set only
when computer-controlled engines are used. Code 65 means the engine computer is able to tell the transmission,
the engine horsepower and/or governor speed is beyond the transmission rating or does not match the transmission
shift calibration.
When a code 65 is set, no shifts out of neutral are allowed. It is possible the transmission calibration selected for
this engine is improper. Contact local Allison Transmission Division distributor for assistance in selecting a proper
calibration.
If the engine is beyond transmission ratings, contact the vehicle OEM for correction. The local ATD regional
representative may also be contacted for assistance.
This code cannot be cleared until the proper level engine is installed or the transmission is properly calibrated.
0011 00-117
CODE 66 XX — SCI (SERIAL COMMUNICATION INTERFACE) FAULT
Main code 69 indicates a problem which has been identified as being from within the ECU.
A “cateye” display or a blank display may occur with subcode 33.
Main
69 27 ECU, Inoperative A-Hi switch
69 28 ECU, Inoperative F-Hi switch
69 29 ECU, Inoperative N-Hi and H-Hi switch
69 33 ECU, computer operating properly timeout
69 34 ECU, write timeout
69 35 ECU, checksum
69 36 ECU, RAM self-check failure
69 39 Communication chip addressing error
69 41 ECU, I/O ASIC addressing test
69 42 SPI output failure
69 43 SPI input failure

• Power down
• Manual — except subcodes 33, 35, 36, 41, 42, and 43
• Self-clearing — subcode 42 and subcodes 33, 35, 36, and 41; after an ECU reset
NOTE: Subcode 34 cannot be cleared.
B. Troubleshooting:
1. For subcodes 27, 28, and 29, check for shorts to battery before replacing the ECU. Follow the
troubleshooting steps for code 42 XX for checking shorts to battery. If no shorts are found, replace
the ECU. If replacing the ECU corrects the problem, reinstall the original (bad) ECU to confirm
that the problem is in the ECU. If the problem recurs, reinstall the new ECU to complete the repair.
2. For all other subcodes, replace the ECU.
0011 00-118
APPENDICES
Appendix A Identification of Potential Circuit Problems
Appendix B Checking Clutch and Retarder Pressures
Appendix C Solenoid and Clutch Chart
Appendix D Wire/Connector Chart
Appendix E Welding on Vehicle/Vehicle Interface Module
Appendix F Diagnostic Tree — WT Series Hydraulic System
Appendix G Pro-Link ® 9000 Diagnostic Data Reader Information
Appendix H Input/Output Function Wiring Schematics
0011 00-119
APPENDIX A — IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS
Intermittent codes are a result of faults that are detected, logged, and then disappear, only to recur later. If, when
troubleshooting, a code is cleared in anticipation of it recurring and it does not, check the items in the following list
for the fault’s source.
A. Circuit Inspection
1. Intermittent power/ground problems — can cause voltage problems during ECU diagnostic checks
which can set various codes depending upon where the ECU was in the diagnostic process.
2. Damaged terminals.
3. Dirty or corroded terminals.
4. Terminals not fully seated in the connector. Check indicated wires by uncoupling connector and
gently pulling on the wire at the rear of the connector and checking for excessive terminal move-
ment.
5. Connectors not fully mated. Check for missing or damaged locktabs.
6. Screws or other sharp pointed objects pushed into or through one of the harnesses.
7. Harnesses which have rubbed through and may be allowing intermittent electrical contact between
two wires or between wires and vehicle frame members.
8. Broken wires within the braiding and insulation.
B. Finding an Intermittent Fault Condition

To find a fault, like one of those listed, examine all connectors and the external wiring harnesses. Harness
routing may make it difficult to see or feel the complete harness. However, it is important to thoroughly
check each harness for chafed or damaged areas. Road vibrations and bumps can damage a poorly installed
harness by moving it against sharp edges and cause some of the faults. If a visual inspection does not
identify a cause, move and wiggle the harness by hand until the fault is duplicated.
The next most probable cause of an intermittent code is an electronic part exposed to excessive vibration,
heat, or moisture. Examples of this are:
1. Exposed harness wires subjected to moisture.

2. A defective connector seal allows moisture to enter the connector or part.
3. An electronic part (ECU, shift selector, solenoid, or throttle sensor) affected by vibration, heat, or
moisture may cause abnormal electrical conditions within the part.
When troubleshooting Item 3, eliminate all other possible causes before replacing any parts.
Another cause of intermittent codes is good parts in an abnormal environment. The abnormal environment
will usually include excessive heat, moisture, or voltage. For example, an ECU that receives excessive
voltage will generate a diagnostic code as it senses high voltage in a circuit. The code may not be repeated
consistently because different circuits may have this condition on each check. The last step in finding an
intermittent code is to observe if the code is set during sudden changes in the operating environment.
Troubleshooting an intermittent code requires looking for common conditions that are present whenever
the code is diagnosed.
0011 00-120
APPENDIX A — IDENTIFICATION
DIAGNOSTIC
OF POTENTIAL
CODES CIRCUIT PROBLEMS
C. Recurring Conditions
A recurring condition might be:
• Rain
• Outside temperature above or below a certain temperature
• Only on right-hand or left-hand turns
• When the vehicle hits a bump, etc.
If such a condition can be related to the code, it is easier to find the cause. If the time between code
occurrences is very short, troubleshooting is easier than if it is several weeks or more between code
occurrences.
0011 00-121
DIAGNOSTIC CODES
0011 00-122
APPENDIX B — CHECKING CLUTCH AND RETARDER PRESSURES
Checking individual clutch pressures helps to determine if a transmission malfunction is due to a mechanical or an
electrical problem. Properly making these pressure checks requires transmission and vehicle (or test stand)
preparation, recording of data, and comparing recorded data against specifications provided. These instructions are
for all WT Series transmissions.
NOTE: Check to see if there are diagnostic codes set which are related to the transmission difficulty you are
evaluating. Proceed to make mechanical preparations for checking clutch pressures after codes have
first been evaluated.
A. Transmission and Vehicle Preparation

1. Remove the plugs from the pressure tap locations where measurement is desired (refer to
Figure B–1).
Figure B–1. Clutch Pressure Check Points
Be sure that the hydraulic fittings have the same thread as the plugs removed
CAUTION: (7/16-20 UNF-2A). Also please note that these fittings must be straight thread,
O-ring style. Failure to do this will result in damage to the control module.
2. Install hydraulic fittings suitable for attaching pressure gauges or transducers.

3. Connect pressure gauges or transducers. Pressure gauge set J26417-A is available for this
purpose. See Table B–2 for pressure levels expected.
4. Check that engine speed can be monitored (Pro-Link ® 9000 diagnostic tool may be used for this
purpose).
0011 00–123
5. Be sure that transmission sump fluid temperature can be measured (Pro-Link ® 9000 diagnostic
tool may be used for this purpose).
6. Be sure that the transmission has enough fluid for cold operation until an operating temperature
fluid level can be set.
7. Bring the transmission to normal operating temperature of 71–93ºC (160–200ºF). Check for fluid
leaks in the added pressure gauge/transducer lines. Repair leaks as needed. Be sure that fluid level
is correct.
B. Recording Data
1. Use the Pro-Link ® 9000 diagnostic tool, which allows checking of individual range clutch pres-
sures, with the vehicle stationary. Consult Appendix G or the Pro-Link ® 9000 operating instruc-
tions for Action Request and select Clutch Test Mode. Follow instructions to check clutch pres-
sures in individual ranges.
NOTE: Check lockup clutch pressure by driving the vehicle in a range where lockup can be obtained. Record
the pressure values at the engine speed and sump fluid temperature values shown in Table B–1. The
lockup clutch is functioning correctly when engine speed and turbine speed values are equal as
recorded from the Pro-Link® 9000.
2. Consult Table B–1 and locate the transmission model that you are testing.
3. Operate the transmission at the conditions shown in Table B–1 and record engine speed, transmis-
sion sump fluid temperature, main hydraulic pressure, and clutch pressures in the ranges where a
problem is suspected.
Table B–1. Clutch Pressure Test Conditions

Transmission Model/ Sump Fluid
Test Type Engine rpm Temperature Range Clutches Pressurized
All (except MD 3070) 580–620 71–93ºC Neutral C5
— Idle Check (160–200ºF) Reverse C3 C5
1C C1 C5
2C (2nd range start) C1 C4
MD 3070 — Idle Check 580–620 71–93ºC Neutral C5
(160–200ºF) Reverse C3 C5
LowC C3 C6
1C C1 C5
MD (except 3070) 2080–2120 71–93ºC Reverse C3 C5
B 300/B 400 — High Speed (160–200ºF) Neutral C5
1C C1 C5
2C C1 C4
2L C1 C4 LU
3L C1 C3 LU
4L C1 C2 LU
5L C2 C3 LU
6L C2 C4 LU
0011 00–124
Table B–1. Clutch Pressure Test Conditions (Continued)

Transmission Model/ Sump Fluid
Test Type Engine rpm Temperature Range Clutches Pressurized
MD 3070 — High Speed 2080–2120 71–93ºC Reverse C3 C5
(160–200ºF) Neutral C5
LowC C3 C6
1C C1 C5
2C C1 C4
2L C1 C4 LU
3L C1 C3 LU
4L C1 C2 LU
5L C2 C3 LU
6L C2 C4 LU
HD/B500 — High Speed 1780–1820 71–93ºC Reverse C3 C5
(160–200ºF) Neutral C5
LowC** C1 C6
1C C1 C5
2C C1 C4
2L C1 C4 LU
3L C1 C3 LU
4L C1 C2 LU
5L C2 C3 LU
6L C2 C4 LU
** Only applies to HD 4070.
C. Comparing Recorded Data to Specifications

1. Be sure that engine speed and transmission sump fluid temperatures were within the values
specified in Table B–1.
2. Compare the main pressure and clutch pressure data, recorded in Step B, with the specifications in
Table B–2.
3. If clutch pressures are within specifications, return the transmission and vehicle to their original
configuration and proceed with electrical troubleshooting.
4. If clutch pressures are not within specification, take corrective action to replace the internal parts
of the transmission necessary to correct the problem. (Refer to the Transmission Service Manual
for the model being checked.)
5. Recheck pressure values after the transmission has been repaired.
6. Return the transmission to its original configuration. (Remove instrumentation and reinstall any
components removed for the pressure testing.)
0011 00–125
Table B–2. Main Pressure and Clutch Pressure Specifications
(Sump Fluid Temperature Same as in Table B–1)
W T E C II I E L E C T R O N IC C O N T R O L S T R O U B L E SH O O T IN G MA N U A L
D’BOX
Transmission Main Press. Range Clutch Conv. Out Lube LU Clutch MAIN
Model/Test Engine Clutches Spec Press. Spec* Press. Spec Press. Spec Press. Spec* Press. Spec*
Type rpm Range Applied kPa [psi] kPa [psi] kPa [psi] kPa [psi] kPa [psi] kPa [psi]
MD — Idle 580–620 Neutral C5 1400–2000 0–40 (C5) [0–5.8] —
(except 3070) [203–290]
Reverse C3 C5 1400–2000 0–40 (C3 And C5) 3.5 min.
[203–290] [0–5.8] [0.5 min.]
1C C1 C5 1300–1970 0–70 (C1) [0–10] 3.5 min.
[189–286] 0–40 (C5) [0–5.8] [0.5 min.]
2C C1 C4 1300–1970 0–70 (C1) [0–10] 3.5 min.
[189–286] 0–40 (C4) [0–5.8] [0.5 min.]
MD 3070 — Neutral C5 1400–2000 0–40 (C5) — 1400–2000
0011 0-126
Idle [203–290] [0–5.8] [203–290]

Reverse C3 C5 1400–2000 0–40 (C3 And C5) 3.5 min. 1400–2000
[203–290] [0–5.8] [0.5 min.] [203–290]
LowC C3 C6 1300–1970 0–40 (C3 And C6) 3.5 min. 1300–1970
[189–286] [0–5.8] [0.5 min.] [189–286]
1C C1 C5 1300–1970 0–70 (C1) [0–10] 3.5 min. 1300–1970
[189–286] 0–40 (C5) [0–5.8] [0.5 min.] [189–286]
MD — 2080–2120 Neutral C5 1825–1965 0–40 (C5) 310–410 150–190
High Speed [265–285] [0–5.8] [45–60] [22–28]
(except 3070) Reverse C3 C5 1825–1965 0–40 (C3 And C5) 310–410 150–190
[265–285] [0–5.8] [45–60] [22–28]
1C C1 C5 1550–1690 0–70 (C1) [0–10] 310–410 150–190
[225–245] 0–40 (C5) [0–5.8] [45–60] [22–28]
* Subtract clutch pressure from main pressure; the difference must fall within the specifications given (unless a pressure
range is supplied).
(Sump Fluid Temperature Same as in Table B–1) (Continued)
D’BOX
MD — 2080–2120 2C C1 C4 1550–1690 0–70 (C1) [0–10] 310–410 150–190
High Speed [225–245] 0–40 (C4) [0–5.8] [45–60] [22–28]
(except 3070) 2L C1 C4 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60
(cont’d) [160–180] 0–40 (C4) [0–5.8] [45–60] [22–28] [0–8.7]
3C C1 C3 1550–1690 0–70 (C1) [0–10] 310–410 150–190
[225–245] 0–40 (C3) [0–5.8] [45–60] [22–28]
3L C1 C3 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C3) [0–5.8] [45–60] [22–28] [0–8.7]
4C C1 C2 1550–1690 0–70 (C1) [0–10] 310–410 150–190
0011 00–127
[225–245] 0–70 (C2) [0–10] [45–60] [22–28]

4L C1 C2 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60
[160–180] 0–70 (C2) [0–10] [45–60] [22–28] [0–8.7]
5C C2 C3 1550–1690 0–70 (C2) [0–10] 310–410 150–190
[225–245] 0–40 (C3) [0–5.8] [45–60] [22–28]
5L C2 C3 LU 1100–1240 0–70 (C2) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C3) [0–5.8] [45–60] [22–28] [0–8.7]
6C C2 C4 1550–1690 0–70 (C2) [0–10] 310–410 150–190
[225–245] 0–40 (C4) [0–5.8] [45–60] [22–28]
6L C2 C4 LU 1100–1240 0–70 (C2) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C4) [0–5.8] [45–60] [22–28] [0–8.7]
range is supplied).
D’BOX
MD 3070 — 2080–2120 Neutral C5 1825–1965 0–40 (C5) 310–410 150–190 1440–1700
High Speed [265–285] [0–5.8] [45–60] [22–28] [209–247]
Reverse C3 C5 1825–1965 0–40 (C3 And C5) 310–410 150–190 1440–1700
[265–285] [0–5.8] [45–60] [22–28] [209–247]
LowC C3 C6 1550–1690 0–40 (C3 And C6) 310–410 150–190 1440–1700
[225–245] [0–5.8] [45–60] [22–28] [209–247]
1C C1 C5 1550–1690 0–70 (C1) [0–10] 310–410 150–190 1440–1700
[225–245] 0–40 (C5) [0–5.8] [45–60] [22–28] [209–247]
2C C1 C4 1550–1690 0–70 (C1) [0–10] 310–410 150–190 1440–1700
0011 0-128
[225–245] 0–40 (C4) [0–5.8] [45–60] [22–28] [209–247]

2L C1 C4 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60 1440–1700
[160–180] 0–40 (C4) [0–5.8] [45–60] [22–28] [0–8.7] [209–247]
3C C1 C3 1550–1690 0–70 (C1) [0–10] 310–410 150–190 1440–1700
[225–245] 0–40 (C3) [0–5.8] [45–60] [22–28] [209–247]
3L C1 C3 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60 1440–1700
[160–180] 0–40 (C3) [0–5.8] [45–60] [22–28] [0–8.7] [209–247]
4C C1 C2 1550–1690 0–70 (C1 And C2) 310–410 150–190 1440–1700
[225–245] [0–10] [45–60] [22–28] [209–247]
4L C1 C2 LU 1100–1240 0–70 (C1 And C2) 310–410 150–190 0–60 1440–1700
[160–180] [0–10] [45–60] [22–28] [0–8.7] [209–247]
5C C2 C3 1550–1690 0–70 (C2) [0–10] 310–410 150–190 1440–1700
[225–245] 0–40 (C3) [0–5.8] [45–60] [22–28] [209–247]
range is supplied).
D’BOX
MD 3070 — 2080–2120 5L C2 C3 LU 1100–1240 0–70 (C2) [0–10] 310–410 150–190 0–60 1440–1700
High Speed [160–180] 0–40 (C3) [0–5.8] [45–60] [22–28] [0–8.7] [209–247]
(cont’d)
6C C2 C4 1550–1690 0–70 (C2) [0–10] 310–410 150–190 1440–1700
[225–245] 0–40 (C4) [0–5.8] [45–60] [22–28] [209–247]
6L C2 C4 LU 1100–1240 0–70 (C2) [0–10] 310–410 150–190 0–60 1440–1700
[160–180] 0–40 (C4) [0–5.8] [45–60] [22–28] [0–8.7] [209–247]
HD — Idle 580–620 Neutral C5 1400–2000 0–40 (C5) —
[203–290] [0–5.8]
0011 00–129
Reverse C3 C5 1400–2000 0–40 (C3 And C5) 3.5 min.

[203–290] [0–5.8] [0.5 min.]
1C C1 C5 1300–1970 0–70 (C1) [0–10] 3.5 min.
[189–286] 0–40 (C5) [0–5.8] [0.5 min.]
2C C1 C4 1300–1970 0–70 (C1) [0–10] 3.5 min.
[189–286] 0–40 (C4) [0–5.8] [0.5 min.]
HD — 1780–1820 Neutral C5 1825–1965 0–40 (C5) 310–410 150–190
High Speed [265–285] [0–5.8] [45–60] [22–28]
Reverse C3 C5 1825–1965 0–40 (C3 And C5) 310–410 150–190
[265–285] [0–5.8] [45–60] [22–28]
LowC** C3 C6 1550–1690 0–40 (C3 And C6) 310–410 150–190
[225–245] [0–5.8] [45–60] [22–28]
1C C1 C5 1550–1690 0–70 (C1) [0–10] 310–410 150–190
[225–245] 0–40 (C5) [0–5.8] [45–60] [22–28]
range is supplied).
** HD 4070 Only.
D’BOX
HD — 1780–1820 2C C1 C4 1550–1690 0–70 (C1) [0–10] 310–410 150–190
High Speed [225–245] 0–40 (C4) [0–5.8] [45–60] [22–28]
(cont’d) 2L C1 C4 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C4) [0–5.8] [45–60] [22–28] [0–8.7]
3C C1 C3 1550–1690 0–70 (C1) [0–10] 310–410 150–190
[225–245] 0–40(C3) [0–5.8] [45–60] [22–28]
3L C1 C3 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C3) [0–5.8] [45–60] [22–28] [0–8.7]
4C C1 C2 1550–1690 0–70 (C1) [0–10] 310–410 150–190
0011 0-130
[225–245] 0–70 (C2) [0–10] [45–60] [22–28]

4L C1 C2 LU 1100–1240 0–70 (C1) [0–10] 310–410 150–190 0–60
[160–180] 0–70 (C2) [0–10] [45–60] [22–28] [0–8.7]
5C C2 C3 1550–1690 0–70 (C2) [0–10] 310–410 150–190
[225–245] 0–40 (C3) [0–5.8] [45–60] [22–28]
5L C2 C3 LU 1100–1240 0–70 (C2) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C3) [0–5.8] [45–60] [22–28] [0–8.7]
6C C2 C4 1550–1690 0–70 (C2) [0–10] 310–410 150–190
[225–245] 0–40 (C4) [0–5.8] [45–60] [22–28]
6L C2 C4 LU 1100–1240 0–70 (C2) [0–10] 310–410 150–190 0–60
[160–180] 0–40 (C4) [0–5.8] [45–60] [22–28] [0–8.7]
range is supplied).
D. Retarder Pressure Checks — MD/B 300/B 400 And HD/B 500

1. MD 3060/3066, B 300, B 400 Test Conditions:
Second Range Lockup, 100 Percent Retarder Apply, Input Speed = 1075–1125 rpm
2. MD 3560 Test Conditions:

Table B–3. Retarder Specifications At Above Test Conditions

Parameter To Check High Capacity Medium Capacity Low Capacity
1200–1260 1200–1260 1200–1260
Main Pressure–kPa [psi]
[174–183] [174–183] [174–183]
250–370 215–280 140–240
Retarder Charge Pressure–kPa [psi]
[36–54] [31–41] [20–35]
250–340 210–300 140–255
Cooler In Pressure–kPa [psi]
[36–49] [30–44] [20–37]
Cooler In Temperature–°C [°F] 150 [300] Max (Ref) 150 [300] Max (Ref) 150 [300] Max (Ref)
3. HD 4060/4070/B 500 Test Conditions:

4. HD 4560 Test Conditions:

Table B–4. Retarder Specifications At Above Test Conditions

Parameter To Check High Capacity Medium Capacity Low Capacity
1120–1270 1120–1270 1120–1270
Main Pressure–kPa [psi]
[162–184] [162–184] [162–184]
375–480 345–450 325–420
Retarder Charge Pressure–kPa [psi]
[54–70] [50–65] [47–61]
360–530 310–510 290–480
Cooler In Pressure–kPa [psi]
[52–77] [45–74] [42–70]
Cooler In Temperature–°C [°F] 150 [300] Max (Ref) 150 [300] Max (Ref) 150 [300] Max (Ref)
0011 00–131
0011 00–132
APPENDIX C — SOLENOID AND CLUTCH CHART
BASIC CONFIGURATION
Range Solenoid Non-Latching Modulating Clutches
A B C D E F G
N/O N/O N/C N/C N/C N/C N/C C1 C2 C3 C4 C5 LU
6 X X 0 Y Y 0
5 X X 0 X Y Y 0
4 0 X Y Y 0
3 X X 0 X Y Y 0
2 X X 0 X Y Y 0
1 X X 0 Y Y 0
N1 X X * X 0 * Y 0
NVL X X X X Y Y
N2 X X X Y
N3 X X X Y
N4 X X X Y
R X X X X Y Y
NOTE: See Page C–2 for legend.
7-SPEED CONFIGURATION (MD 3070 AND HD 4070)

Solenoid Non-Latching Modulating
N/O N/O N/C N/C N/C N/C N/C N/C N/C N/C Clutches
Range
C1 C2 C3 C4 C5 LU FWD LOW C6 DIF
A B C D E F G N J H C1 C2 C3 C4 C5 LU C6 DIF
6 X X 0 0 Y Y 0 0
5 X X 0 X 0 Y Y 0 0
4 0 X 0 Y Y 0 0
3 X X 0 X 0 Y Y 0 0
2 X X 0 X 0 Y Y 0 0
1 X X 0 0 Y Y 0 0
LO X 0 X X X 0 Y 0 Y 0
N1 X X * X 0 Y 0
N2 X X X X 0 Y 0
N3 X X X X 0 Y 0
N4 X X X X 0 Y 0
R X X X X 0 Y Y 0
NOTE: See Page C–2 for legend.
0011 00–133
APPENDIX C — SOLENOID AND CLUTCH CHART
LEGEND
X Indicates solenoid is electrically ON.
Y Indicates clutch is hydraulically applied.
Blank Indicates solenoid is electrically OFF or clutch is not hydraulically applied.
0 Optional ON or OFF.
* See NVL explanation below.
NVL As a diagnostic response:
If Turbine Speed is below 150 rpm when Output Speed is below 100 rpm and Engine Speed is
above 400 rpm, Neutral Very Low (NVL) is commanded when N1 (Neutral) is the selected
range. NVL is achieved by turning D solenoid “on” in addition to E solenoid being “on,” which
locks the output. Otherwise, D solenoid is turned off in N1 (Neutral).
0011 00–134
APPENDIX D — WIRE/CONNECTOR CHART
The connector information in this appendix is provided for the convenience of the servicing technician. The
connector illustration and pin identifications for connection to Allison Transmission components will be accurate.
Allison Transmission components are the ECU, speed sensors, retarder connectors, transmission connectors, and
shift selectors. Other kinds of connectors for optional or customer-furnished components are provided based on
typical past practice for an Allison-designed system.
Contact St. Clair Technologies, Inc. or your vehicle manufacturer for information on connectors not found in this
appendix.
NOTE: The following abbreviation guide should be used to locate connector termination points for wires in
the WTEC III wiring harness(es).
Table D–1. Appendix D Abbreviation Guide

Termination Point Abbreviation Connector Name
AGND Analog Ground
ASOL Solenoid A — Transmission Control Module
BSOL Solenoid B — Transmission Control Module
C3PS C3 Pressure Switch — Control Module
CSOL Solenoid C — Transmission Control Module
DDRD Diagnostic Connector — Deutsch
DDRP Diagnostic Connector — Packard
DSOL Solenoid D — Transmission Control Module
ECU–S Electronic Control Unit — Selector (S) Connector
ECU–S Electronic Control Unit — Vehicle (V) Connector
ECU–T Electronic Control Unit — Transmission (T) Connector
ESOL Solenoid E — Transmission Control Module
GSOL Solenoid F — Transmission Control Module
GSOL Solenoid G — Transmission Control Module
HSOL Retarder H Solenoid — Retarder Housing Or Retarder Valve Body
J1939 J1939 Datalink From ECU Selector (S) Harness
JSOL Solenoid J — Transmission Control Module (7-Speed Only)
NE Engine Speed Sensor
NO Output Speed Sensor
NSOL Retarder Accumulator Solenoid
NSOL Solenoid N — Transmission Control Module (7-Speed Only)
NT Turbine Speed Sensor
OBDII Diagnostic Connector — GMC On Board Diagnostics
OLS Oil Level Sensor
PSS Primary Shift Selector
RMOD Retarder Module (Units Built Prior To 1/98)
RMR Retarder Modulation Request Device
RNGTRM Chassis Ground Ring Terminal
RTEMP Retarder Temperature — Retarder Housing
0011 00–135
Table D–1. Appendix D Abbreviation Guide (Continued)

Termination Point Abbreviation Connector Name
SCI Serial Communication Interface
SSS Secondary Shift Selector
TCASE MD 3070 Transfer Case
TPS Throttle Position Sensor
TRANS Transmission Feedthrough Harness
VIM Vehicle Interface Module
VIWS Vehicle Interface Wiring — ECU Selector (S) Harness
VIWV Vehicle Interface Wiring — ECU Vehicle (V) Harness
0011 00–136
Figure D–1. ECU Connector “S”
ECU CONNECTOR “S” (BLACK)

Terminal No. Color Wire No. Description Termination Point(s)
1 White 142-S1 Serial Communication Interface, High DDRP-J, DDRD-A, OBDII-7
2 Tan 159-S2 Diagnostic Communication Link (ISO9141) VIWS-A
3 Pink 124-S3 Sensor Power RMR-C, PSS-N, SSS-N
4 Yellow 146-S4 Ignition Sense VIWS-E, DDRP-H, DDRD-C,
OBDII-16
5 Orange 170-S5 Primary Shift Selector, Data Bit 1 PSS-A
6 Green 171-S6 Primary Shift Selector, Data Bit 2 PSS-B
7 Blue 172-S7 Primary Shift Selector, Data Bit 4 PSS-C
8 Yellow 173-S8 Primary Shift Selector, Data Bit 8 PSS-D
9 Tan 174-S9 Primary Shift Selector, Parity PSS-E
10 Green 175-S10 Shift Selector Mode Input PSS-M, SSS-M
11 Yellow 119-S11 General Purpose Input 4 VIWS-M
12 Green 182-S12 CAN Controller Shield (J1939) J1939C
13 Pink 183-S13 CAN Controller, High (J1939) J1939A
14 Blue 180-S14 Shift Selector Display PSS-S, SSS-S
15 Orange 176-S15 General Purpose Output 6 PSS-L, SSS-L, VIWS-L
16 Pink 136-S16 Battery Power PSS-R, SSS-R
17 Blue 151-S17 Serial Communication Interface, Low DDRP-K, DDRD-B, OBDII-15
18 Tan 166-S18 General Purpose Output 7 VIWS-N
19 Green 135-S19 Analog Ground RMR-A
20 Yellow 164-S20 Retarder Modulation Request RMR-B
21 Orange 190-S21 Secondary Shift Selector, Data Bit 1 SSS-A
22 Green 191-S22 Secondary Shift Selector, Data Bit 2 SSS-B
23 Blue 192-S23 Secondary Shift Selector, Data Bit 4 SSS-C
24 Yellow 193-S24 Secondary Shift Selector, Data Bit 8 SSS-D
25 Tan 194-S25 Secondary Shift Selector, Parity SSS-E
26 Blue 169-S26 General Purpose Input 12 VIWS-S
27 Blue 163-S27 General Purpose Input 6 VIWS-R
28 Yellow 126-S28 General Purpose Input 9 VIWS-C
29 Gray 184-S29 CAN Controller, Low (J1939) J1939-B
30 Tan 157-S30 Vehicle Speed VIWS-D
31 Green 115-S31 Check Transmission VIWS-B
32 Gray 143-S32 Battery Ground PSS-P, SSS-P, VIWS-P, DDRP-A,
DDRD-E, OBDII-5
0011 00–137
Figure D–2. ECU Connector “T”
ECU CONNECTOR “T” (BLUE)

1 Orange 102-T1 Solenoid Power, Solenoids A, D, and J TRANS-A
(MD 3070 only)
2 Tan 121-T2 Solenoid Power, Solenoids B and E TRANS-H
3 Green 107-T3 Solenoid Power, Solenoid F TRANS-E
4 White 120-T4 A Solenoid, Low TRANS-G
5 Green 103-T5 C Solenoid, Low TRANS-B
6 Tan 129-T6 E Solenoid, Low TRANS-K
7 White 104-T7 G Solenoid, Low TRANS-C
8 Blue 111-T8 J Solenoid, Low TRANS-e
9 Pink 124-T9 Sensor Power TRANS-D, TPS-C, RMR-C
10 Blue 156-T10 Throttle Position Sensor TPS-B
11 Yellow 164-T11 Retarder Modulation Request RMR-B
12 White 162-T12 C3 Pressure Switch Input TRANS-X
13 Yellow 195-T13 Transmission Identification TRANS-W
14 Tan 141-T14 Engine Speed Sensor, High NE-A
15 Orange 149-T15 Turbine Speed Sensor, High NT-A (HD), TRANS-V (MD)
16 Yellow 139-T16 Output Speed Sensor, High NO-A, TCASE-C (MD 3070),
RMOD-C (MDR)
17 Yellow 130-T17 Solenoid Power, Solenoids C and G TRANS-L
18
19 Yellow 116-T19 Solenoid Power, Solenoids H and N HSOL-B, NSOL-B, TRANS-g,
TCASE-B (MD 3070),
RMOD-B (MDR)
20 Orange 128-T20 B Solenoid, Low TRANS-J
21 Blue 131-T21 D Solenoid, Low TRANS-M
22 White 110-T22 F Solenoid, Low TRANS-F
23 White 127-T23 H Solenoid, Low HSOL-A (HD), RMOD-A (MDR),
TCASE-A (MD 3070)
24 Blue 101-T24 N Solenoid, Low NSOL-A (HD and MD),
TRANS-f (MD 3070)
25 Green 135-T25 Analog Ground RMR-A, RTEMP-B (HD),
RMOD-F (MD)
26 Blue 165-T26 Oil Level Sensor Input TRANS-Y
27 Tan 147-T27 Sump Temperature Sensor Input TRANS-P
28 Orange 138-T28 Retarder Temperature Sensor Input RTEMP-A (HD), RMOD-E (MD)
29
30 Orange 150-T30 Engine Speed Sensor, Low NE-B
31 Blue 140-T31 Turbine Speed Sensor, Low NT-B, TRANS-U (MD)
32 Green 148-T32 Output Speed Sensor, Low NO-B, TCASE-D (MD 3070),
RMOD-D (MDR)
0011 00–138
Figure D–3. ECU Connector “V”
ECU CONNECTOR “V” (GRAY)

1 Pink 136-V1 Battery Power VIM-E1
2 White 114-V2 General Purpose Output 1 VIM-F3
3 Orange 132-V3 General Purpose Output 2 VIM-B1
4 White 113-V4 Reverse Warning VIM-F2
5 White 167-V5 General Purpose Output 8 VIWV-V
6 Tan 123-V6 Neutral Start VIM-D1
7
8 Pink 124-V8 Sensor Power TPS-C
9 Blue 179-V9 Engine Water Temperature VIWV-M
10 Blue 156-V10 Throttle Position Sensor TPS-B
11 Green 155-V11 General Purpose Input 1 VIWV-A
12 Yellow 153-V12 General Purpose Input 2 VIWV-B
13 Blue 118-V13 General Purpose Input 3 VIWV-C
14 Tan 177-V14 General Purpose Input 10 VIWV-S
15
16 Pink 136-V16 Battery Power VIM-E2
17 Gray 143-V17 Battery Ground VIM-A1
18 White 125-V18 General Purpose Output 4 VIM-C2
19 Green 105-V19 General Purpose Output 5 VIWV-E
20 Tan 157-V20 Vehicle Speed VIM-B2
21
22 Tan 112-V22 General Purpose Output 3 VIM-D2
23
24 Green 135-V24 Analog Ground TPS-A, VIWV-N
25 Gray 144-V25 Chassis Ground RNGTRM
26 Yellow 146-V26 Ignition Sense VIM-F1
27 White 154-V27 General Purpose Input 5 VIWV-D
28 Orange 178-V28 General Purpose Input 11 VIWV-R
29 Orange 137-V29 General Purpose Input 7 VIWV-U
30 Green 117-V30 General Purpose Input 8 VIWV-P
31 Yellow 161-V31 Digital Ground (GPI) VIWV-L
32 Gray 143-V32 Battery Ground VIM-A2
0011 00–139
Figure D–4. Deutsch Bulkhead Connector, ECD
BULKHEAD CONNECTOR FOR “S” HARNESS (Plug With Sockets, Receptacle With Pins)
Terminal No.* Color Wire No. Description Termination Points*
A Tan 159-S2 Diagnostic Communication Link (ISO 9141) ECU-S2, VIWS-A
B Green 115-S31 Check Transmission ECU-S31, VIWS-B
C Yellow 126-S28 General Purpose Input 9 ECU-S28, VIWS-C
D Pink 124-S3 Sensor Power ECU-S3, RMR-C, PSS-N, SSS-N
E Yellow 146-S4 Ignition Sense ECU-S4, VIWS-E, DDRP-H,
DDRD-C, OBDII-16
F Orange 170-S5 Primary Shift Selector, Data Bit 1 ECU-S5, PSS-A
G Pink 136-S16 Battery Power ECU-S16, PSS-R, SSS-R
H White 142-S1 Serial Communication Interface, High ECU-S1, DDRP-J, DDRD-A,
OBDII-7, SCI-A
J Blue 172-S7 Primary Shift Selector, Data Bit 4 ECU-S7, PSS-C
K Blue 151-S17 Serial Communication Interface, Low ECU-S17, DDRP-K, DDRD-B,
OBDII-15, SCI-B
L Orange 176-S15 General Purpose Output 6 ECU-S15, PSS-L, SSS-L, VIWS-L
M Yellow 119-S11 General Purpose Input 4 ECU-S11, VIWS-M
N Green 135-S19 Analog Ground ECU-S19, RMR-A
P Gray 143-S32 Battery Ground ECU-S32, PSS-P, SSS-P, VIWS-P,
DDRP-A, DDRD-E, OBDII-5
Q Green 171-S6 Primary Shift Selector, Data Bit 2 ECU-S6, PSS-B
R Blue 163-S27 General Purpose Input 6 ECU-S27, VIWS-R
S Yellow 173-S8 Primary Shift Selector, Data Bit 8 ECU-S8, PSS-D
T Tan 174-S9 Primary Shift Selector, Parity ECU-S9, PSS-E
U Green 175-S10 Shift Selector Mode Input ECU-S10, PSS-M, SSS-M
V Blue 180-S14 Shift Selector Display ECU-S14, PSS-S, SSS-S
W Tan 166-S18 General Purpose Output 7 ECU-S18, VIWS-N
X Blue 169-S26 General Purpose Input 12 ECU-S26, VIWS-S
Y Orange 190-S21 Secondary Shift Selector, Data Bit 1 ECU-S21, SSS-A
* Terminal number and termination points shown only apply when an Allison Transmission recommended harness configuration and bulk-
head connector are used.
0011 00–140
BULKHEAD CONNECTOR FOR “S” HARNESS (Plug With Sockets, Receptacle With Pins) (Contin-
Z
a Yellow 164-S20 Retarder Modulation Request ECU-S20, RMR-B
b Green 191-S22 Secondary Shift Selector, Data Bit 2 ECU-S22, SSS-B
c Blue 192-S23 Secondary Shift Selector, Data Bit 4 ECU-S23, SSS-C
d Tan 157-S30 Vehicle Speed ECU-S30, VIWS-D
e Yellow 193-S24 Secondary Shift Selector, Data Bit 8 ECU-S24, SSS-D
f Tan 194-S25 Secondary Shift Selector, Parity ECU-S25, SSS-E
g
BULKHEAD CONNECTOR FOR “T” HARNESS (Receptacle With Sockets, Plug With Pins)
A Orange 102-T1 Solenoid Power, Solenoids A, D, and J ECU-T1, TRANS-A
(MD 3070 only)
B Green 103-T5 C Solenoid, Low ECU-T5, TRANS-B
C White 104-T7 G Solenoid, Low ECU-T7, TRANS-C
D Pink 124-T9 Sensor Power ECU-T9, TRANS-D, TPS-C, RMR-C
E Green 107-T3 Solenoid Power, Solenoid F ECU-T3, TRANS-E
F White 110-T22 F Solenoid, Low ECU-T22, TRANS-F
G White 120-T4 A Solenoid, Low ECU-T4, TRANS-G
H Tan 121-T2 Solenoid Power, Solenoids B and E ECU-T2, TRANS-H
J Orange 128-T20 B Solenoid, Low ECU-T20, TRANS-J
K Tan 129-T6 E Solenoid, Low ECU-T6, TRANS-K
L Yellow 130-T17 Solenoid Power, Solenoids C and G ECU-T17, TRANS-L
M Blue 131-T21 D Solenoid, Low ECU-T21, TRANS-M
N Green 135-T25 Analog Ground ECU-T25, TRANS-N, TPS-A, RMR-A,
RTEMP-B (HD), RMOD-F (MD)
P Tan 147-T27 Sump Temperature Sensor Input ECU-T27, TRANS-P
Q Green 148-T32 Output Speed Sensor, Low ECU-T32, NO-B, TCASE-D
(MD 3070), RMOD-D (MDR)
R Yellow 139-T16 Output Speed Sensor, High ECU-T16, NO-A, TCASE-C
(MD3070), RMOD-C (MDR)
S Orange 150-T30 Engine Speed Sensor, Low ECU-T30, NE-B
T Tan 141-T14 Engine Speed Sensor, High ECU-T14, NE-A
U Blue 140-T31 Turbine Speed Sensor, Low ECU-T31, NT-B (HD), TRANS-U (MD)
V Orange 149-T15 Turbine Speed Sensor, High ECU-T15, NT-A (HD), TRANS-V (MD)
W Yellow 195-T13 Transmission Identification ECU-T13, TRANS-W
X White 162-T12 C3 Pressure Switch Input ECU-T12, TRANS-X
Y Blue 165-T26 Oil Level Sensor Input ECU-T26, TRANS-Y
Z
a Yellow 164-T11 Retarder Modulation Request ECU-T11, RMR-B
b Blue 156-T10 Throttle Position Sensor ECU-T10, TPS-B
c White 127-T23 H Solenoid, Low ECU-T23, HSOL-A (HD), RMOD-A
(MDR), TCASE-A (MD 3070)
0011 00–141
BULKHEAD CONNECTOR FOR “T” HARNESS (Receptacle With Sockets, Plug With Pins) (Contin-
d Orange 138-T28 Retarder Temperature Sensor Input ECU-T28, RTEMP-A (HD),
RMOD-E (MD)
e Blue 111-T8 J Solenoid, Low ECU-T8, TRANS-e
f Blue 101-T24 N Solenoid, Low ECU-T24, NSOL-A (HD and MD),
TRANS-f (MD 3070)
g Yellow 116-T19 Solenoid Power, Solenoids H and N ECU-T19, HSOL-B, NSOL-B,
TRANS-g, TCASE-B (MD 3070),
RMOD-B (MDR)
BULKHEAD CONNECTOR FOR “V” HARNESS (Receptacle With Sockets, Plug With Pins)

A Green 155-V11 General Purpose Input 1 ECU-V11, VIWV-A
B Yellow 153-V12 General Purpose Input 2 ECU-V12, VIWV-B
C Blue 118-V13 General Purpose Input 3 ECU-V13, VIWV-C
D Pink 124-V8 Sensor Power ECU-V8, TPS-C
E Green 105-V19 General Purpose Output 5 ECU-V19, VIWV-E
F Gray 143-V32 Battery Ground ECU-V32, VIM-A2
G Gray 143-V17 Battery Ground ECU-V17, VIM-A1
H Tan 112-V22 General Purpose Output 3 ECU-V22, VIM-D2
J White 114-V2 General Purpose Output 1 ECU-V2, VIM-F3
K Tan 123-V6 Neutral Start ECU-V6, VIM-D1
L Yellow 161-V31 Digital Ground (GPI) ECU-V31, VIWV-L
M Blue 179-V9 Engine Water Temperature ECU-V9, VIWV-M
N Green 135-V24 Analog Ground ECU-V24, TPS-A, VIWV-N
P Green 117-V30 General Purpose Input 8 ECU-V30, VIWV-P
Q White 113-V4 Reverse Warning ECU-V4, VIM-F2
R Orange 178-V28 General Purpose Input 11 ECU-V28, VIWV-R
S Tan 177-V14 General Purpose Input 10 ECU-V14, VIWV-S
T
U Orange 137-V29 General Purpose Input 7 ECU-V29, VIWV-U
V White 167-V5 General Purpose Output 8 ECU-V5, VIWV-V
W Pink 136-V16 Battery Power ECU-V16, VIM-E2
X Tan 157-V20 Vehicle Speed ECU-V20, VIM-B2
Y White 125-V18 General Purpose Output 4 ECU-V18, VIM-C2
Z
a
b Blue 156-V10 Throttle Position Sensor ECU-V10, TPS-B
c
d White 154-V27 General Purpose Input 5 ECU-V27, VIWV-D
e Yellow 146-V26 Ignition Sense ECU-V26, VIM-F1
f Orange 132-V3 General Purpose Output 2 ECU-V3, VIM-B1
g Pink 136-V1 Battery Power ECU-V1, VIM-E1
0011 00–142
Figure D–5. Deutsch Transmission Connector, ECD
DEUTSCH TRANSMISSION CONNECTOR (Plugs With Sockets, Receptacles With Pins)

A Orange 102-T1 Solenoid Power, Solenoids A, D, and J ECU-T1, ASOL-B, DSOL-B, JSOL-B
B Green 103-T5 C Solenoid, Low ECU-T5, CSOL-A
C White 104-T7 G Solenoid, Low ECU-T7, GSOL-A
D Pink 124-T9 Sensor Power ECU-T9, TPS-C, RMR-C, OLS-D
E Green 107-T3 Solenoid Power, Solenoid F ECU-T3, FSOL-A
F White 110-T22 F Solenoid, Low ECU-T22, FSOL-B
G White 120-T4 A Solenoid, Low ECU-T4, ASOL-A
H Tan 121-T2 Solenoid Power, Solenoids B and E ECU-T2, BSOL-B, ESOL-B
J Orange 128-T20 B Solenoid, Low ECU-T20, BSOL-A
K Tan 129-T6 E Solenoid, Low ECU-T6, ESOL-A
L Yellow 130-T17 Solenoid Power, Solenoids C and G ECU-T17, GSOL-B, CSOL-B
M Blue 131-T21 D Solenoid, Low ECU-T21, DSOL-A
N Green 135-T25 Analog Ground ECU-T25, TPS-A, RMR-A,
RTEMP-B (HD), RMOD-F (MD),
C3PS-B, OILT-LO, OLS-B
P Tan 147-T27 Sump Temperature Sensor Input ECU-T27, OILT-HI
Q
R
S
T
U Blue 140-T31 Turbine Speed Sensor, Low (MD, MD7 only) ECU-T31, NT-B
V Orange 149-T15 Turbine Speed Sensor, High (MD, MD7 only) ECU-T15, NT-A
W Yellow 195-T13 Transmission Identification (TransID) ECU-T13, AGND
X White 162-T12 C3 Pressure Switch Input ECU-T12, C3PS-A
0011 00–143
DEUTSCH TRANSMISSION CONNECTOR (Plugs With Sockets, Receptacles With Pins) (Continued)

Y Blue 165-T26 Oil Level Sensor Input ECU-T26, OLS-A
Z
a
b
c
d
e Blue 111-T8 J Solenoid, Low (MD7 or HD7 only) ECU-T8, JSOL-A
f Blue 101-T24 N Solenoid, Low (MD7 or HD7 only) ECU-T24, NSOL-A
g Yellow 116-T19 Solenoid Power, Solenoids H and N ECU-T19, HSOL-B, NSOL-B
(MD7 only)
0011 00–144
Figure D–6. Remote Selector Connector
REMOTE SHIFT SELECTOR CONNECTOR — PRIMARY SELECTOR

Terminal No.* Color Wire No. Description Termination Point(s)*
A Orange 170-S5 Primary Shift Selector, Data Bit 1 ECU, S5
B Green 171-S6 Primary Shift Selector, Data Bit 2 ECU, S6
C Blue 172-S7 Primary Shift Selector, Data Bit 4 ECU, S7
D Yellow 173-S8 Primary Shift Selector, Data Bit 8 ECU, S8
E Tan 174-S9 Primary Shift Selector, Parity ECU, S9
F
G
H
J
K
L Orange 176-S15 General Purpose Output 6 VIWS-L, SSS-L
M Green 175-S10 Shift Selector Mode Output SSS-M
N Pink 124-S3 Sensor Power RMR-C, SSS-N
P Gray 143-S32 Battery Ground VIWS-P, SSS-P, DDRP-A, DDRD-E,
or OBDII-5
R Pink 136-S16 Battery Power SSS-R
S Blue 180-S14 Shift Selector Display SSS-S
T White 186 Dimmer Input A SSS-T
U Yellow 187 Dimmer Input B SSS-U
V Gray 188 Dimmer Ground SSS-V
W
0011 00–145
REMOTE SHIFT SELECTOR CONNECTOR — SECONDARY SELECTOR

A Orange 190-S5 Secondary Shift Selector, Data Bit 1 ECU, S21
B Green 191-S6 Secondary Shift Selector, Data Bit 2 ECU, S22
C Blue 192-S7 Secondary Shift Selector, Data Bit 4 ECU, S23
D Yellow 193-S8 Secondary Shift Selector, Data Bit 8 ECU, S24
E Tan 194-S9 Secondary Shift Selector, Parity ECU, S25
F
G
H
J
K
L Orange 176-S15 General Purpose Output 6 VIWS-L, SSS-L
M Green 175-S10 Shift Selector Mode Output SSS-M
N Pink 124-S3 Sensor Power RMR-C, SSS-N
P Gray 143-S32 Battery Ground VIWS-P, SSS-P, DDRP-A, DDRD-E,
or OBDII-5
R Pink 136-S16 Battery Power SSS-R
S Blue 180-S14 Shift Selector Display SSS-S
T White 186 Dimmer Input A SSS-T
U Yellow 187 Dimmer Input B SSS-U
V Gray 188 Dimmer Ground SSS-V
W
0011 00–146
Figure D–7. Optional Deutsch Sensor Harness Connector
OPTIONAL DEUTSCH SENSOR HARNESS CONNECTOR

A
B
C Green 135-T25 Analog Ground ECU-T25, TRANS-N, RTEMP-B (HD),
RMOD-F (MD), TPS-A, RMR-A
D Orange 138-T28 Retarder Temperature Sensor Input ECU-T28, RTEMP-A (HD),
RMOD-E (MD)
E Yellow 116-T19 Solenoid Power, Solenoids H and N ECU-T19, HSOL-B, NSOL-B
F White 127-T23 H Solenoid, Low ECU-T23, HSOL-A
G Yellow 116-T19 Solenoid Power, Solenoids H and N ECU-T19, HSOL-B, NSOL-B
H Blue 101-T24 N Solenoid, Low ECU-T24, NSOL-B
J
K
L Blue 140-T31 Turbine Speed Sensor, Low ECU-T31, NT-B (HD)
M Orange 149-T15 Turbine Speed Sensor, High ECU-T15, NT-A (HD)
N Orange 150-T30 Engine Speed Sensor, Low ECU-T30, NE-B
P Tan 141-T14 Engine Speed Sensor, High ECU-T14, NE-A
R Green 148-T32 Output Speed Sensor, Low ECU-T32, NO-B
S Yellow 139-T16 Output Speed Sensor, High ECU-T16, NO-A
0011 00–147
Figure D–8. Speed Sensor Connector
ENGINE SPEED SENSOR CONNECTOR

A Tan 141-T14 Engine Speed Sensor Hi ECU-T14
B Orange 150-T30 Engine Speed Sensor Lo ECU-T30
TURBINE SPEED SENSOR CONNECTOR (HD/B 500 ONLY)

A Orange 149-T15 Turbine Speed Sensor Hi ECU-T15
B Blue 140-T31 Turbine Speed Sensor Lo ECU-T31
OUTPUT SPEED SENSOR CONNECTOR

A Yellow 139-T16 Output Speed Sensor Hi ECU-T16
B Green 148-T32 Output Speed Sensor Lo ECU-T32
ACCUMULATOR (N) SOLENOID

A Blue 101-T24 N Solenoid Lo ECU-T24
B Yellow 116-T19 N Solenoid Hi ECU-T19
MD RETARDER (H SOLENOID, TID 2)

A White 127-T23 H Solenoid Lo ECU-T23
B Yellow 116C-T19 H Solenoid Hi ECU-T19
0011 00–148
Figure D–9. Diagnostic Connector (Packard)
DIAGNOSTIC CONNECTOR
A Gray 143-S32 Battery (–) ECU-S32, VIWS-P, PSS-P, SSS-P
H Yellow 146-S4 Ignition Signal (+) ECU-S4, VIWS-E
J White 142-S1 Serial Communication (+) ECU-S1, SCI-A
K Blue 151-S17 Serial Communication (–) ECU-S17, SCI-B
0011 00–149
Figure D–10. Optional Deutsch DDR Connectors
OPTIONAL 6-PIN DIAGNOSTIC CONNECTOR

A White 142-S1 Serial Communication (+) ECU-S1, SCI-A
B Blue 151-S17 Serial Communication (–) ECU-S17, SCI-B
C Yellow 146-S4 Ignition Signal (+) ECU-S4, VIWS-E
D Open
E Gray 143-S32 Battery (–) ECU-S32, VIWS-P, PSS-P, SSS-P
F Open
OPTIONAL 9-PIN DIAGNOSTIC CONNECTOR

A Gray 143-S32 Battery Ground (–) ECU-S32, VIWS-P, PSS-P, SSS-P
B Yellow 146-S4 Ignition Power (+) ECU-S4, VIWS-E
B (Optional) Pink 136-S16 Battery Power (+) ECU-S16, PSS-R, SSS-R
C Pink 183-S13 J1939 High ECU-S13, J1939-A/H
D Gray 184-S29 J1939 Low ECU-S29, J1939-B/L
E Green 182-S12 J1939 Shield/Ground ECU-S12, J1939-C/S
F White 142-S1 Serial Communication (+) ECU-S1, SCI-A
G Blue 151-S17 Serial Communication (–) ECU-S17, SCI-B
0011 00–150
Figure D–11. GMC Connector for OBD-II DDR Adapter
OPTIONAL OBD–II DDR CONNECTOR

1
2
3
4
5 Gray 143-S32 Battery Ground (–) ECU-S32, VIWS-P, PSS-P, SSS-P
6
7 White 142-S1 Serial Communication Interface, Hi ECU-S1, SCI-A
8
9
10
11
12
13
14
15 Blue 151-S17 Serial Communication Interface, Lo ECU-S17, SCI-B
16 Yellow 146-S4 Ignition Sense (+) ECU-S4, VIWS-E
0011 00–151
Figure D–12. VIW Connector (Packard Micro Pack)
VIW–V CONNECTOR
A Green 155-V11 General Purpose Input 1 ECU-V11, VIWV-A
B Yellow 153-V12 General Purpose Input 2 ECU-V12, VIWV-B
C Blue 118-V13 General Purpose Input 3 ECU-V13, VIWV-C
D White 154-V27 General Purpose Input 5 ECU-V27, VIWV-D
E Green 105-V19 General Purpose Output 5 ECU-V19, VIWV-E
F
G
H
J
K
L Yellow 161-V31 Digital Ground (GPI) ECU-V31, VIWV-L
M Blue 179-V9 Engine Water Temperature ECU-V9, VIWV-M
N Green 135-V24 Analog Ground ECU-V24, TPS-A, VIWV-N
P Green 117-V30 General Purpose Input 8 ECU-V30, VIWV-P
R Orange 178-V28 General Purpose Input 11 ECU-V28, VIWV-R
S Tan 177-V14 General Purpose Input 10 ECU-V14, VIWV-S
T
U Orange 137-V29 General Purpose Input 7 ECU-V29, VIWV-U
V White 167-V5 General Purpose Output 8 ECU-V5, VIWV-V
W
0011 00–152
VIW–S CONNECTOR
Terminal No.* Color Wire No. Description Termination Point(s) *
A Tan 159-S2 Diagnostic Communication Link (ISO9141) ECU-S2, VIWS-A
B Green 115-S31 Check Transmission ECU-S31, VIWS-B
C Yellow 126-S28 General Purpose Input 9 ECU-S28, VIWS-C
D Tan 157-S30 Vehicle Speed ECU-S30, VIWS-D
E Yellow 146-S4 Ignition Sense ECU-S4, VIWS-E, DDRP-H,
DDRD-C
F
G
H
J
K
L Orange 176-S15 General Purpose Output 6 ECU-S15, VIWS-L, PSS-L, SSS-L
M Yellow 119-S11 General Purpose Input 4 ECU-S11, VIWS-M
N Tan 166-S18 General Purpose Output 7 ECU-S18, VIWS-N
P Gray 143-S32 Battery Ground ECU-S32, VIWS-P, PSS-P, SSS-P,
DDRP-A, DDRD-E
R Blue 163-S27 General Purpose Input 6 ECU-S27, VIWS-R
S Blue 169-S26 General Purpose Input 12 ECU-S26, VIWS-S
T White 186 Dimmer Input A VIWS-T, PSS-T, SSS-T
U Yellow 187 Dimmer Input B VIWS-U, PSS-U, SSS-U
V Gray 188 Dimmer Ground VIWS-V, PSS-V, SSS-V
W
0011 00–153
Figure D–13. TPS Connector
THROTTLE POSITION SENSOR CONNECTOR

A Green 135-T25 or Analog Ground ECU-T25 or V24; TRANS-N;
135-V24 RMR-A, RMOD-F or B; VIWV-N
B Blue 156-T10 or V10 TPS Signal ECU-T10 or V10
C Pink 124-T9 or V8 TPS Hi ECU-T9 or V8; RMR-C
0011 00–154
Figure D–14. VIM Connector (Harness)
VIM CONNECTOR (HARNESS)

A1 Gray 143-V17 Battery (–) ECU-V17
A2 Gray 143-V32 Battery (–) ECU-V32
A3 Reserved
B1 Orange 132-V3 GPO 2 ECU-V3
B2 Tan 157-V20 Speedometer Signal ECU-V20
B3 Reserved
C1 Reserved
C2 White 125-V18 GPO 4 ECU-V18
C3 Reserved
D1 Tan 123-V6 Neutral Start ECU-V6
D2 Tan 112-V22 GPO 3 ECU-V22
D3 Reserved
E1 Pink 136-V1 Battery (+) ECU-V1
E2 Pink 136-V16 Battery (+) ECU-V16
E3 Reserved
F1 Yellow 146-V26 Ignition Sense (+) ECU-V26
F2 White 113-V4 Reverse Warning ECU-V4
F3 White 114-V2 GPO 1 ECU-V2
0011 00–155
Figure D–15. VIM Connector (Harness)
VIM CONNECTOR (HARNESS 30-WAY)

Terminal No. Color Wire No. Description Termination Point(s)*
A1 Blue 313NO Reverse Warning Relay — Normally Open
A2 Yellow 314CM Output Wire 114 Relay — Common
A3 Blue 314NO Output Wire 114 Relay — Normally Open
B1 Yellow 313CM Reverse Warning Relay — Common
B2 Green 314NC Output Wire 114 Relay — Normally Closed
B3 Reserved
C1 Orange 346 Ignition Power
C2 Green 312NC Output Wire 112 Relay — Normally Closed
C3 Reserved
D1 Green 325NC Output Wire 125 Relay — Normally Closed
D2 Green 332NC Output Wire 132 Relay — Normally Closed
D3 Reserved
E1 Yellow 325CM Output Wire 125 Relay — Common
E2 Yellow 332CM Output Wire 132 Relay — Common
E3 Blue 332NO Output Wire 132 Relay — Normally Open
F1 Blue 323NO Neutral Start Relay — Normally Open
F2 Yellow 312CM Output Wire 112 Relay — Common
F3 Blue 312NO Output Wire 112 Relay — Normally Open
G1 Yellow 323CM Neutral Start Relay — Common
G2 Reserved
G3 Reserved
H1 Reserved
H2 White 357UF Speedometer — Unfiltered
H3 Reserved
J1 Pink 336A Battery Power
J2 Pink 336C Battery Power
J3 Reserved
K1 Gray 343A Battery Ground
K2 Gray 343C Battery Ground
K3 Reserved
* Termination Points are determined by OEM electrical system design.
0011 00–156
Figure D–16. Resistance Module Type 2 — Single Pressure Switch and SCI Interface
RESISTANCE MODULE TYPE 2
Terminal No.
A
B
SCI INTERFACE CONNECTOR

A White 142-S1 Serial Communication Interface, Hi ECU-S1, DDRP-J, DDRD-A
B Blue 151-S17 Serial Communication Interface, Lo ECU-S17, DDRP-K, DDRD-B
0011 00–157
Figure D–17. Resistance Module Type 3 — Bendix E-10R Pedal
Terminal No. Wire Color

A Blue
B Violet
C Orange
D White
0011 00–158
Figure D–18. Resistance Module Type 5 — Hand Lever

+ White
1 Blue
2 Orange
3 Violet
4 Green
5 Yellow
6 Red
0011 00–159
Figure D–19. Resistance Module Type 7 — Dedicated Pedal

A Green
B Yellow
C White
0011 00–160
Figure D–20. Resistance Module Type 8 — Three Pressure Switch
LOW PRESSURE
A White
B Blue
MEDIUM PRESSURE
A White
B Orange
HIGH PRESSURE
A White
B Violet
0011 00–161
Figure D–21. Resistance Module Type 9 — Two Pressure Switch
MEDIUM PRESSURE
A White
B Orange
HIGH PRESSURE
A White
B Violet
0011 00–162
Figure D–22. J1939 Interface Connector
J1939 INTERFACE CONNECTOR

A or H Pink 183-S13 J1939 Controller, Hi ECU-S13
B or L Gray 184-S29 J1939 Controller, Lo ECU-S29
C or S Green 182-S12 J1939 Shield ECU-S12
0011 00–163
0011 00–164
APPENDIX E — WELDING ON VEHICLE/VEHICLE INTERFACE MODULE
1–3. WELDING ON VEHICLE

When frame or other welding is required on the vehicle, take the following precautions to protect the electronic
control components:
1. Disconnect the wiring harness connectors at the transmission electronic control unit.
2. Disconnect the positive and negative battery connections, and any electronic control ground wires
connected to the frame or chassis.
3. Cover electronic control components and wiring to protect them from hot sparks, etc.
4. Do not connect welding cables to electronic control components.
Do not jump start a vehicle with arc welding equipment. Arc welding
WARNING! equipment’s dangerously high currents and voltages cannot be reduced to safe
levels.
1–4. VEHICLE INTERFACE MODULE

The Allison Vehicle Interface Module (VIM) containing all Allison system relays and fuses must be used as the
interface to all vehicle wiring. Refer to Figure E–2 for VIM component location and pin-out.To close an open VIM,
tighten the bolts in the numerical order shown in Figure E–1 to provide a sealed, water-tight box. Torque the bolts
to 5–8 N·m (4–6 lb ft).
Figure E–1. Vehicle Interface Module
0011 00–165
APPENDIX E — WELDING ON VEHICLE/VEHICLE INTERFACE MODULE
Figure E–2. VIM Components Location and Pin-Out Diagram
0011 00–166
APPENDIX F — DIAGNOSTIC TREE — WT HYDRAULIC SYSTEM
Figure F–1. Diagnostic Tree — WT Series Hydraulic System With Gauges
0011 00–167
APPENDIX F — DIAGNOSTIC TREE — WT HYDRAULIC SYSTEM
Figure F–2. Diagnostic Tree — WT Series Hydraulic System Without Gages
0011 00–168
APPENDIX G — PRO-LINK® 9000 DIAGNOSTIC DATA READER INFORMATION
Pro-link ® 9000 Diagnostic Tools
The WTEC III system will require new Pro-Link ® 9000 hardware for reprogramming and diagnostics. The
following is a list of required updates to the current Pro-Link® 9000 hardware:
Hardware Tool P/N

Diagnostic Cartridge J38500-303
PROM Update Kit J38500-313
MultiProtocol Cartridge (MPC) J38500-1500A
Reprogramming PCMCIA Card* J38500-1700
Diagnostic Card* J38500-1800
* Requires J38500-1500A to function
Limited diagnostic information for the WTEC III system can be accessed through the current WTEC II
Pro-Link ® 9000 hardware. This diagnostic information will however be limited to that information that is common
to the WTEC II and WTEC III systems. Access to information described in this SIL can only be accessed through
either the WTEC III Diagnostic Cartridge or by updating the current WTEC II Diagnostic Cartridge with the
PROM update kit or the WTEC III Reprogramming Cartridge.
The MultiProtocol Cartridge (MPC) and the Reprogramming Card are required to modify customer constants and
alter Calibration packages within the WTEC III ECU. After completing an ATD-approved training class, those
ordering a reprogramming cartridge are required to submit a copy of their completion certificate with their order.
This serves as proof of eligibility to purchase these items. Training is available from ATD and ATD distributors.
0011 00–169
APPENDIX G — PRO-LINK® 9000 DIAGNOSTIC DATA READER INFORMATION
0011 00–170
APPENDIX H — INPUT/OUTPUT FUNCTIONS

The schematics which follow were taken from the Sales Tech Data Book entitled “WTEC III Controls.” These
These schematics
schematics provide detail information needed toshow the perform
correctly intendedinput
use and
of the specified
output controls
function features which
connections.
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
WARNING! property, personalshow
injury,
the or loss of use
life.ofALLISON TRANSMISSION IS which
NOT
These schematics intended the specified controls features
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OFthat
THESE FEATURES.
features which differs from shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
OR UNINTENDED USE OF THESE FEATURES.
A. SECONDARY SHIFT SCHEDULE
USES: Provides operator selection of dual shift schedules. Can be used for performance/economy,
loaded/empty, or other shift schedule combinations.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
Figure H–1. Secondary Shift Schedule
0011 00–171
These schematics show the intended use of the specified controls features which
B. D1 SELECTION
USES: Provides a convenient means of attaining 1st range hold for pushbutton shift selectors. Range to select is
programmable for Primary and Secondary modes.
VARIABLES TO SPECIFY: Primary Mode selected range, Secondary Mode selected range (usually 1st range).
Can be used only on the MODE button.
VOCATIONS: Various
Figure H–2. D1 Selection
0011 00–172
D. SHIFT SELECTOR TRANSITION
USES: When two shift selectors are used, to select which one is active.
VOCATIONS: Various
If this function is enabled in the shift calibration, the function MUST be integrated
WARNING! into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
Figure H–3. Shift Selector Transition
0011 00–173
H. ENGINE BRAKE/PRESELECT REQUEST AND ENGINE BRAKE ENABLE

(EXHAUST BRAKE – OPTIONAL)
USES: Used with engine brakes controlled by electronic engines to signal the ECU that the brake is active and to
provide increased braking by preselecting a lower range. Also prevents engagement of engine brake with
throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is second range.
VOCATIONS: Various
Figure H–4. Engine Brake/Preselect Request and Engine Brake Enable (Exhaust Brake — Optional)
0011 00–174
H. ENGINE BRAKE/PRESELECT REQUEST AND ENGINE BRAKE ENABLE

(COMPRESSION BRAKE)
USES: Used with single-level compression brakes to signal the ECU that the brake is active and to provide
increased braking by preselecting a lower range. Also prevents engagement of engine brake with
throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is fourth range.
VOCATIONS: Various
Figure H–5. Engine Brake/Preselect Request and Engine Brake Enable (Compression Brake)
0011 00–175
I. ENGINE BRAKE/PRESELECT REQUEST AND ENGINE BRAKE ENABLE

(EXHAUST BRAKE — SPECIAL)
USES: Used with engine brakes to provide a signal to the ECU that the brake is active and to provide increased
braking by preselecting a lower range. Also prevents engagement of engine brake with throttle > 0 or
lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is second range.
VOCATIONS: Various
Figure H–6. Engine Brake/Preselect Request and Engine Brake Enable (Exhaust Brake — Special)
0011 00–176
Y. ANTI-LOCK BRAKE RESPONSE
USES: Signals the ECU when ABS function is active, so that lockup clutch and retarder will be disabled.
VOCATIONS: Various
For schematics of this function, see the ANTI-LOCK BRAKES section located in
Section C: Vehicle Electrical System Interface of SA2978, WTEC III Controls And
General Information.
0011 00–177
Y. ANTI-LOCK BRAKE RESPONSE (OPTIONAL)
USES: Provides for enhanced control of lockup and retarder during hard braking conditions. Can be used
separately or in conjunction with ABS.
VOCATIONS: Various
Figure H–7. Anti-Lock Brake Response (Optional)
0011 00–178
AI. MILITARY AUXILIARY FUNCTION RANGE INHIBIT (STANDARD)
USES: Prevents inadvertent range selection when auxiliary equipment is operating.
VOCATIONS: Military wheeled vehicles
If this function is turned “ON” in the shift calibration, the function MUST be
integrated into the vehicle wiring. If the function is available in the shift
WARNING! calibration but will not be used in the vehicle, it MUST be turned “OFF” in the
calibration.
Figure H–8. Military Auxiliary Function Range Inhibit (Standard)
0011 00–179
AQ. SELECTOR DISPLAY BLANKING
USES: Blanks the digital display and mode on indicator on the lever or pushbutton shift selectors.
VOCATIONS: Military wheeled vehicles
Figure H–9. Selector Display Blanking
0011 00–180
TM 9-2320-302-20
BRAKE SYSTEM TROUBLESHOOTING 0012 00
Table 1. Brake System Troubleshooting Procedures.

1. Vehicle Does Not Slow Down Quickly Enough 1. Check for proper lubrication Lubricate brake system (TM 9-
When Brakes Are Applied. and adjustment of brakes. 2320-302-10) or adjust brakes
(WP 0139 00) as necessary.
2. Check for heat-damaged and Replace any damaged or glazed
glazed brakeshoe linings. brakeshoes (all brakeshoes must
be replaced on an axle) (WP
0135 00 or WP 0137 00).
3. Check brake drums for Replace damaged brake drums
excessive heat damage, cracks, (WP 0165 00 or WP 0166 00).
scoring, and out-of-roundness.
4. Check for faulty air chambers. Replace faulty air chamber(s)
(WP 0141 00 or WP 0142 00).
5. Check for air pressure leakage Replace air compressor (Notify
to air chambers. Direct Support Maintenance).
2. Brakes Do Not Release or Release Too Slowly. 1. Check for proper lubrication of Lubricate brake system (TM 9-
brake system. 2320-302-10).
2. Check that foot valve returns to Remove any debris interfering
fully released position. with pedal travel.
3. Check exhaust ports on brake Clear obstructions from exhaust
foot valve, quick release valve, port(s) and vents (WP 0161 00).
and gladhand vent holes for
blockage.
4. Check for weak and broken Replace weak or broken springs
brakeshoe return springs. (WP 0135 00 or WP 0137 00).
5. Check for frozen brakeshoe Clean and lubricate sticking pins
anchor pins. or replace pins if damaged (WP
0135 00 or WP 0137 00).
6. Check for broken spring in air Replace air chamber (WP 0141 00
chamber. or WP 0142 00).
3. Brakes Are Uneven, Drag or Pull When 1. Check for uneven adjustment Adjust brakes (WP 0139 00).
Applied. between axles.
2. Check for proper wheel bearing Adjust wheel bearings (WP
adjustment. 0165 00 or WP 0166 00).
3. Check for grease-saturated or Replace brake linings (WP
worn brake linings. 0135 00 or WP 0137 00).
4. Check for out-of-round Replace brakedrum(s) (WP
brakedrum(s). 0165 00 or WP 0166 00).
5. Check for worn s-cam or roller. Replace s-cam or roller (WP
0140 00).
0012 00-1
TM 9-2320-302-20
0012 00-2
TM 9-2320-302-20
ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING AND TESTING 0013 00
INTRODUCTION
This work package contains information on troubleshooting and testing the Anti-lock Brake System (ABS) using blink
code diagnostics and Prolink. The ABS is an electronic system that monitors and controls braking only during emergency situ-
ations. The ABS controls the braking of each wheel separately, which prevents wheel locking, maintains steerability, and
reduces stopping distance. The ABS has two diagonal circuits. Each circuit connects the front wheel of one side of the vehicle
to the rear wheels of the opposite side. In case of a system fault, only half of the ABS stops working. Control of that half is
returned to the standard braking system. The ABS uses a tone ring and sensor on the hub of each monitored wheel. The sensor
sends wheel speed information to the Electronic Control Unit (ECU). The ECU signals the modulator valve for that wheel to
increase, reduce or maintain pressure in the brake chamber (Figure 1).
PRETEST INSPECTION
Prior to performing vehicle test, ensure that daily Preventive Maintenance Checks and Inspections (PMCS) has been
performed.
A. Air Lines
B. Electrical Lines
1. Cab-mounted ECU 3. ABS Modulator Valves 5. ABS Modulator Valves

2. Wheel Speed Sensors 4. Relay Valve 6. Wheel Speed Sensor
Figure 1. Location of ABS Components.
GENERAL INFORMATION
1. Rockwell WABCO ABS D Version is an electronic system that monitors and controls wheel speed during braking. The
system works with standard air brake systems. ABS monitors wheel speeds at all times and controls braking during
wheel lock situations. The system improves vehicle stability and control by reducing wheel lock during braking.
0013 00-1
TM 9-2320-302-20
ANTI-LOCK BRAKE SYSTEM TROUBLESHOOTING AND TESTING - CONTINUED 0013 00
GENERAL INFORMATION - CONTINUED

2. The ECU receives and processes signals from the wheel speed sensors. When the ECU detects a wheel lockup, the unit
activates the appropriate modulator valve, and air pressure is controlled. In the event of a malfunction in the system, the
ABS in the affected wheel(s) is disabled; that wheel still has normal brakes. The other wheels keep the ABS function.
3. An ABS warning lamp lets the driver know the status of the system. If the ECU senses a fault during normal vehicle
operation, the ABS warning lamp will come on. This lamp is also used to display blink code diagnostics.
ABS WARNING LAMP
The ABS warning lamp works as shown in Table 1. If the ECU senses a fault during normal vehicle operation, the ABS
warning lamp will come on and stay on.
Table 1. Warning Lamp Operation.
WHAT YOU DO WHAT HAPPENS WHAT IT MEANS

Turn the ignition on. The ABS lamp comes on momentarily for a bulb check, The system is okay.
then goes out.
The ABS lamp does not go out at ignition. If the lamp goes out when the vehicle is
driven above 4 mph (6 km/h), the system
is okay.
If the lamp does not go out at speeds above

4 mph (6 km/h), the ECU senses a fault in
the ABS system.
ABS MODULATOR VALVES

1. Modulator valves control the air pressure to each affected brake during an ABS function.
2. To make sure the ABS valves are working, listen to them as follows:
a. Turn on the ignition.
b. Wait for the ABS light.
NOTE
The valves will cycle in 1-2-3-4 order, then diagonally in 1-2 and 3-4 order.
c. Listen for the valves to cycle, one by one, then together diagonally (Figure 2).
0013 00-2
TM 9-2320-302-20
ABS MODULATOR VALVES - CONTINUED
NOTE: The valves will cycle in 1-2-3-4 order, then diagonally in 1-2 and 3-4 order
A. Cab
B. Curbside
Figure 2. Modulator Valve Checking.

ABS SENSORS
1. ABS sensor systems consist of a tooth wheel mounted on the hub of each monitored wheel and a sensor installed so that
its end is against the tooth wheel. The sensor continuously sends wheel speed information to the ECU. A sensor clip
holds the sensor in place at the tooth wheel.
2. The type of axle determines the sensor mounting location:
a. Steering axle sensors are installed in the steering knuckle or in a bolted-on bracket.
b. Drive axle sensors are mounted in a block attached to the axle housing or in a bolted-on bracket.
SYSTEM COMPONENTS
1. The ECU is the brain of the ABS system. It receives information from the sensors and sends signals to the ABS valves
(Figure 1).
2. A tooth wheel (Figure 3) is mounted at the hub of each sensed wheel, with a sensor installed so that its end is against the
tooth wheel. A sensor clip holds the sensor in place at the tooth wheel. The sensor and clip must be greased with Rock-
well WABCO-recommended lubricant.
0013 00-3
TM 9-2320-302-20
SYSTEM COMPONENTS - CONTINUED
1. Tooth Wheel
2. Lubricant
3. Sensor Clip
4. Sensor
Figure 3. Sensor Components.
3. An ABS modulator valve controls air pressure to each affected brake during emergency braking situations (Figure 4).
A. Out
B. In
1. Port 2
2. Port 1
Figure 4. ABS Modulator Components.
0013 00-4
TM 9-2320-302-20

4. The ABS valve package is an alternative to individual valves on the rear axles. It combines two ABS modulator valves
and one service relay valve (Figure 5).
1. Modulator
2. Relay Valve
Figure 5. ABS Valve Package.
5. Sensor cables connect the sensor to the ECU (Figure 6).
Figure 6. ABS Sensor Cable.
6. ABS modulator valve cables connect the modulator valve to the ECU (Figure 7).
0013 00-5
TM 9-2320-302-20
Figure 7. ABS Modulator Valve Cable.

LAMP BULB CHECK
To make sure the ABS lamp is operating, drivers should check the lamp every time the vehicle is started. When the vehi-
cle is started, the ABS lamp should come on momentarily. If it does not come on, it could mean a burned-out bulb.
DIAGNOSTICS
1. Diagnostic Methods. You can troubleshoot the system in the following ways:
a. Blink Code Diagnostics
b. Pro-link 9000
2. Blink Code Diagnostics. Before using blink code diagnostics, you should be familiar with a few basic terms. If you
used previous versions of Rockwell WABCO blink code diagnostics, review these definitions to identify major changes.
a. ABS Warning Lamp. This lamp serves two purposes: it alerts drivers to an ABS fault and it is used during diag-
nostics to display the blink code.
b. Blink Code. A series of blinks or flashes that describe a particular ABS system fault or condition.
c. Blink Code Cycle. A set of two flashes with each flash separated by a one-and-one-half second pause. Blink codes
are defined in Table 2.
d. Blink Code Switch. A switch that activates blink code diagnostic capabilities. Switch types and locations vary,
depending on the vehicle.
e. Clear. The process of erasing faults from the ECU.
f. Diagnostics. The process of using blink codes to determine ABS system faults.
g. Fault. An ABS malfunction detected and stored in memory by the Rockwell WABCO ECU. System faults may be
Active or Stored.
h. Active Fault. A condition that currently exists in the ABS system; for example, a sensor circuit malfunction on the
left front steering axle. An active fault must be repaired before it can be cleared from memory and before you can
display additional codes.
i. Stored Fault. There are two types of stored faults: One type is a repaired fault that has not been cleared from the
ECU. The other type is a fault that occurred, but no longer exists, for example a loose wire that makes intermittent
contact. Because stored faults are not currently active, they do not have to be repaired before they can be cleared
from memory.
j. System Configuration Code. A one digit code (Blink Code: 2) is displayed during the clear mode. Blink codes for
common ABS system configurations are shown in Figure 8.
0013 00-6
TM 9-2320-302-20
DIAGNOSTICS - CONTINUED
A. Blink Code: 1
B. Blink Code: 2
C. Blink Code: 4
Figure 8. System Configuration Codes.
Table 2. Blink Code Identification.
FIRST DIGIT (TYPE OF FAULT) SECOND DIGIT (SPECIFIC LOCATION OF FAULT)

1. No Faults 1. No Faults
2. ABS modulator valve 1. Right front steer axle (curb side)
3. Too much sensor gap 2. Left front steer axle (driver side)
4. Sensor short or open 3. Right forward/rear tandem drive axle (curb side)
5. Sensor signal erratic 4. Left forward/rear tandem drive axle (driver side)
6. Tooth wheel 5. Right rearmost tandem drive axle (curb side)
6. Left rearmost tandem drive axle (driver side)
7. System function 1. J1922 or J1939 datalink
2. ATC valve (not used on M915A3)
3. Retarder relay (third brake)
4. ABS warning lamp
5. ATC configuration (not used on M915A3)
6. Reserved for future use
8. ECU 1. Low power supply
2. High power supply
3. Internal fault
4. System configuration error
5. Ground
NOTE
Blink code switch is located on ABS Electronic Control Unit (ECU) behind passenger’s seat.
3. Diagnostic Mode. To enter the diagnostic mode, press and hold the blink code switch for one second, then release.
0013 00-7
TM 9-2320-302-20
4. Clear Mode.
a. To erase faults from the ECU, you must be in the clear mode. To enter the clear mode, press and hold the blink
code switch for at least three seconds, then release.
b. If the system displays eight quick flashes followed by a system configuration code, the clear was successful. The
ABS fault has been cleared from memory.
c. If you do not receive eight flashes, there are still active faults that must be repaired before they can be cleared.
5. Blink Code Diagnostic Procedures.
For the step-by-step blink code diagnostic procedure, see Table 3.
Table 3. Blink Code Diagnostic Procedure.
MODE PROCEDURE SYSTEM RESPONSE ACTION

Diagnostic Step 1. Turn the ignition on. The ABS warning lamp comes on No recognizable faults in the ABS. No
momentarily then goes out, action required.
indicating System Okay.
The ABS warning lamp does not Inspect the wiring. Inspect the bulb.
light, indicating possible wiring fault Make necessary repairs.
or burned-out bulb.
The ABS warning lamp stays on, Continue with the blink code
indicating there is a fault, or faults, in diagnostics. Go to the next step.
the system.
Step 2. Press and hold the The ABS warning lamp begins Determine if the fault is active or
Blink Code Switch for one flashing two-digit blink codes(s). stored:
second, then release. Active Fault: The lamp will
repeatedly display one code.
Stored Fault: The lamp will display
the code for each stored fault then stop
blinking. Faults will be displayed one
at a time.
Step 3. Count the flashes to First Digit: 1 to 8 flashes; Pause (1-1/ Turn the ignition off. Find the
determine the blink code. 2 seconds). Second Digit: 1 to 6 definition for the blink code in Table 2.
flashes; pause (4 seconds).
Step 4. Repair and record the Active Fault. Make the necessary repairs. Repeat the
faults. first three steps of this procedure until
System Okay Code (1-1) is received.
Stored Faults. Record for future reference.
NOTE: The last fault code stored is the

first fault code displayed.
Clear Step 5. Clear faults from the The ABS warning lamp flashes eight All faults are successfully cleared.
memory: Press and hold the times. Turn the ignition off.
blink code switch for at least
three seconds, then release.
Eight flashes are not received. Active faults still exist. Repeat the first
four steps of this procedure.
0013 00-8
TM 9-2320-302-20
6. Blink Codes Illustrated. Refer to the following figures for examples of typical blink codes.
a. For a typical Active Fault code, refer to Figure 9.
b. For typical Stored Fault codes, refer to Figure 10.
c. For the System Okay code, refer to Figure 11.
d. For the Stored Fault Cleared code, refer to Figure 12.
e. For the Faults Not Cleared (active faults exist) code, refer to Figure 13.
NOTE: Blink Code 2-3 is shown here: Fault in the ABS modulator valve, right side of forward-rear axle.
A. Hold 1 second C. First digit (2) E. Repeat of blink code

B. Light on D. Second digit (3) F. Continues until the ignition is turned off
1. Pause of 1.5 seconds

2. 1 to 8 flashes
3. 1 to 6 flashes
4. Pause of 4 seconds
Figure 9. Typical Active Fault Code.
NOTE: Blink Codes 5-2 and 3-4 are shown here. Code 5-2: Sensor signal erratic, left-front steer axle. Code 3-4: Too much
sensor gap, left side of forward-rear axle.
A. Hold 1 second C. First digit (5) E. Second digit (2) G. Displays all stored faults at once-
B. Light on D. First stored fault F. Second stored fault last fault stored is the first displayed

Figure 10. Stored Fault Codes.
0013 00-9
TM 9-2320-302-20
NOTE: Blink Code 1-1 is shown here: System okay.
A. Hold 1 second
B. Light on
Figure 11. System Okay Code.
NOTE: System configuration code 2 shown: 4S/4M. After the faults are cleared and the vehicle is started, the ABS lamp will
stay on until the vehicle is driven over 4 mph (6 km/h).
A. Hold 3 seconds C. 8 quick blinks - fault cleared E. Continues until the ignition is turned off
B. Light on D. System identification

Figure 12. Stored Fault Cleared Codes.
0013 00-10
TM 9-2320-302-20
A. Hold 3 seconds C. System identification D. Continues until the ignition is turned off
B. Light on
Figure 13. Faults Not Cleared Code.
7. Working with Blink Codes. If problems occur while working with blink codes, see Table 4.
Table 4. Blink Code Conditions.
CONDITION REASON ACTION

ABS lamp does not come on at ignition. Loose or burned-out bulb. Check the bulb.
Check the connections.
Make necessary repairs.
Voltage not within acceptable range (11 Make necessary repairs.
to 15 volts)
Can't use blink code diagnostics; ABS Switch not held for the proper length of Repeat procedure, hold the switch for the
lamp will not go off when blink code is time. proper length of time.
activated. 1 second - Diagnostics Mode
3 seconds - Clear All Mode
Improper or faulty wiring. Inspect and repair the wiring.
Eight flashes not received after blink Active faults still exist. Identify the active faults, then make
code switch is pressed for at least three necessary repairs. Turn the ignition off,
seconds, then released. then repeat the blink code diagnostics
(Table 3).
8. Repairs Required by Blink Codes. For the specific tests or repairs required by each blink code, see Table 5.
0013 00-11
TM 9-2320-302-20
Table 5. Troubleshooting and Repair.
BLINK CODE ACTION REQUIRED REFERENCE

2-1 Check the ABS modulator valve, valve cable, Perform resistance check.
2-2 and connections.
2-3
2-4
2-5
2-6
3-1 Adjust the wheel sensor to touch the tooth Perform sensor adjustment, sensor voltage test, or
3-2 wheel. Check the sensor gap. Check for loose Pro-link component test.
3-3 wheel bearings or excessive hub runout.
3-4
3-5
3-6
4-1 Check sensor, sensor cable, and connectors. Perform resistance check.
4-2
4-3
4-4
4-5
4-6
5-1 Check for tire size mismatch or tooth wheel Review tire size range.
5-2 difference.
5-3
5-4
5-5
5-6
6-1 Check for damaged tooth wheel.
6-2
6-3
6-4
6-5
6-6
7-1 Check for proper data link connection (J1922 Refer to wiring diagrams.
and J1939)
7-2 Check the ATC valve, valve cables, and Perform resistance check.
connectors. (Not used on M915A3)
7-3 Check the brake relay connections. Refer to wiring diagrams.
7-4 Check the ABS warning light connections.
7-5 Verify proper ATC set-up. (Not used on
M915A3)
7-6 Verify the accuracy of the blink code and clear Review blink code diagnostics.
it from the ECU memory.
8-1 Check vehicle voltage and supply to the ECU Refer to wiring diagrams. Perform voltage check.
(11 to 14 volts).
0013 00-12
TM 9-2320-302-20
Table 5. Troubleshooting and Repair - Continued.
BLINK CODE ACTION REQUIRED REFERENCE

8-2 Check the vehicle voltage (11 to 14 volts). Perform voltage check. Review blink code
Verify accuracy of blink code and clear from diagnostics.
ECU memory.
8-3 Verify accuracy of blink code and clear from Review Blink Code Diagnostics.
8-4 ECU memory.
8-4 Verify accuracy of blink code and clear from Contact Rockwell Customer Service at
ECU memory. If code does not clear, it may be 1-800-535-5560.
necessary to replace ECU.
8-5 Check ABS ground connections. Refer to wiring diagrams.
MPSI PRO-LINK 9000
NOTE
You must use the D Version cartridge with D Version ECUs.
1. The Pro-link 9000 may be used in place of blink code diagnostic procedures.
2. Use the Pro-link 900 to:
a. Diagnose system faults on ABS or ABS/ATC systems.
b. Perform component measurement and function tests.
COMPONENT TESTS
Components that may be tested with the Pro-link 9000 are:
a. Vehicle voltages
b. ABS modulator valves
c. ABS lamps
d. Sensors
e. ABS switches
0013 00-13
TM 9-2320-302-20
DIAGNOSTIC AND TESTING PROCEDURE
1. Slide Rockwell WABCO D Version cartridge into the Pro-link keypad until connection is tight (Figure 14).
Figure 14. Pro-link Cartridge Replacement.
2. Chock the wheels, apply the parking brake, and make sure the ignition power is off.
3. Locate the 6-pin diagnostic receptacle in the vehicle cab. Insert the 6-pin connector from the Pro-link into the receptacle
(Figure 15).
Figure 15. Pro-link Hook-up to Vehicle.
0013 00-14
TM 9-2320-302-20
DIAGNOSTIC AND TESTING PROCEDURES - CONTINUED
4. Turn ignition to ON/RUN position. Pro-link screen should power up. If Pro-link does not power up or if the screen indi-
cates NO DATA RECEIVED:
a. Check connections.
b. Make sure the cartridge is properly connected to the Pro-link keypad.
c. Verify 12 volts DC power and ground at the connector and ABS ECU.
d. Check the fuse panel for a blown fuse.
e. Check for proper wiring in the diagnostic connector.
PRO-LINK SCREENS
1. General. This paragraph provides basic screen explanations for the Pro-link 9000 with a Rockwell WABCO D Version
cartridge. For complete operating instructions and test information, refer to the Pro-link manual. The most commonly
used types of screens are the Fault Information screens and the Component Test screens.
2. Fault Information Screens.
a. Existing Faults. Use these screens to identify existing faults. The Pro-link screen displays a written description of
the fault, including location on the vehicle where each exists. As long as there is an active (existing) fault in the
system, Pro-link will not let you clear faults.
b. Stored Faults. Use these screens to identify faults stored in the ECU memory. Stored faults may be existing faults
that have been repaired, or faults that existed for a short time, then corrected themselves. After displaying stored
faults, Pro-link lets you erase them from memory. All stored faults are cleared at one time.
3. Using Pro-Link. The following illustrates a typical fault screen sequence for a 4S/4M ABS system with an existing
fault.
a. Figure 16 indicates existing and stored faults in the system. Press FUNC to display the menu shown in Figure 17.
Figure 16. Pro-link Screen One. Figure 17. Pro-link Screen Two.
b. Select Existing Fault to display active fault. Press ENTER to select. Screen shown in Figure 18 should appear. The
first line displays the number of existing faults (1 of 1), blink code (2-3), and number of times fault occurred (1
time). Lines two and three provide a written description of the fault.
0013 00-15
TM 9-2320-302-20
PRO-LINK SCREENS - CONTINUED
Figure 18. Pro-link Screen Three.

c. Press FUNC to exit. The screen shown in Figure 19 should appear. Remove power from the ECU, make necessary
repairs, and recycle ECU.
Figure 19. Pro-link Screen Four.

d. Press FUNC to return to vehicle ABS/ATC menu shown in Figure 20.
Figure 20. Pro-link Screen Five.
0013 00-16
TM 9-2320-302-20

e. Press ENTER to display stored faults as shown in Figure 21. A description of the stored fault appears. In this
example, only one fault is stored in memory, as indicated on line one. The blink code and number of times the fault
occurred also appear on line one. Lines two and three provide a written description of the fault. Press FUNC to
exit. The screen shown in Figure 22 appears if you try to clear a stored code with an existing fault present.
Figure 21. Pro-link Screen Six. Figure 22. Pro-link Screen Seven.
f. Remove the power from the ECU, make necessary repairs, and recycle the ECU.
4. Clearing Stored Faults. The screens you will see when clearing stored faults are illustrated in Figures 23 and 24.
a. Figure 23 shows there are no existing faults. Select stored faults to view and clear memory. Press FUNC to display
the menu shown in Figure 24.
Figure 23. Pro-link Screen Eight. Figure 24. Pro-link Screen Nine.
0013 00-17
TM 9-2320-302-20
b. Select Stored Faults, then press ENTER to display the stored faults shown in Figure 25. Pro-link displays number,
blink code, number of occurrences, and written description of the stored faults.
Figure 25. Pro-link Screen Ten.

c. Press FUNC, and the screen shown in Figure 26 will appear.
Figure 26. Pro-link Screen Eleven.

d. When the faults are cleared, Pro-link will prompt you to continue. See Figures 27 and 28.
Figure 27. Pro-link Screen Twelve.
0013 00-18
TM 9-2320-302-20
Figure 28. Pro-link Screen Thirteen.
e. Press ENTER to return to the ABS menu.
5. Component Test Screens.
a. These screens help you test ABS components. Select this function from the vehicle ABS/ATC menu (Figure 29).
Select appropriate function. Each screen has instructions to guide you through test. Refer to Pro-link service infor-
mation for complete instructions.
Figure 29. Typical Component Test Screen.
b. You can test the following components:
(1) ABS valves
(2) ABS lamp
(3) ABS switches
(4) Sensors
c. See Table 6 for definitions that explain the function of each test.
0013 00-19
TM 9-2320-302-20
Table 6. Component Test Functions.
COMPONENT TEST FUNCTION

Vehicle voltages Monitors two voltage signals powering the ECU.
ABS valves Cycles valves, one at a time. You hear each valve cycle. A menu selection lets you choose
from four or six valves. This test may also be used to verify valve locations. NOTE: The treadle
may be applied to put air in chambers.
ABS lamp Monitors commanded (on/off) states of the ATC lamp. Follow screen prompts (1 On, 2 Off)
to change the status of lamp on instrument panel.
Sensors Monitors input to ECU from wheel. Wheels must be rotated during this test.
COMPONENT TESTING
WARNING
When troubleshooting and testing the ABS system, do not damage the connector terminals. Damaged termi-
nals can result in the system not functioning correctly and subsequent vehicle accidents resulting in personal
injury to personnel and damage to equipment.
1. Voltage Check. Voltage must be between 11 and 14 volts. Ignition must be turned on for this test. Measure voltage
between pins 7 and 10, pins 8 and 11, and pins 9 and 12 on cab-mounted systems.
2. Sensor Adjustment.
a. Push sensor in until it contacts tooth wheel.
b. DO NOT pry or push sensors with sharp objects. Sensor will self-adjust after wheel rotation.
c. On steering axles, sensor is accessible on in-board side of steering knuckle.
d. On drive axles, drum assembly may have to be pulled to gain access to sensor.
3. Sensor Output Voltage Test. Voltage must be at least 0.200 volts AC at 30 rpm. Check sensor voltage as follows:
a. Turn off ignition.
b. Rotate wheel by hand at 30 rpm (2 revolutions per second).
c. Measure voltage at the points shown in Table 7.
Table 7. Voltage Test Points.
ECU SENSOR CONNECTOR PINS

Cab-mounted LF 6-pin 4 and 5
RF 9-pin 4 and 5
LR 15-pin 5 and 6
RR 15-pin 8 and 9
0013 00-20
TM 9-2320-302-20
TIRE SIZE RANGE

1. For proper ABS operation with the standard ECU, front and rear tire sizes must be within ±14% of each other. When tire
size range is exceeded without electronically modifying ECU, system performance can be affected and warning lamp
can illuminate.
2. Call Rockwell WABCO at 1-800-535-5560 if you plan a tire size difference greater than 14%. Calculate tire size with
the following equation:
% Difference = {RPM Steer divided by RPM Drive minus 1} x 100 (in this equation RPM means tire revolutions per
mile)
ABS MODULATOR VALVE TEST
1. Measure the resistance across each valve solenoid coil terminal and ground on the ABS valve to ensure 4.0 to 8.0 ohms
(Figure 30).
1. Ground Terminal
2. Solenoid
Figure 30. ABS Modulator Valve.
2. If resistance is greater than 8.0 ohms, clean electrical contacts in solenoid. Check resistance again.
3. To check cable and ABS valve as one unit, measure resistance across the pins on ECU connector of harness. Check wir-
ing diagrams of system being tested (Figures 31 through 34).
0013 00-21
TM 9-2320-302-20
Figure 31. Wiring Diagram, Power and Control Wiring.
0013 00-22
TM 9-2320-302-20
Figure 32. Wiring Diagram, Sensor and Valve Wiring.
0013 00-23
TM 9-2320-302-20
Figure 33. Wiring Diagram, Basic WABCO Wiring (Partial View).
0013 00-24
TM 9-2320-302-20
Figure 34. Wiring Diagram, Basic WABCO Wiring (Partial View).
0013 00-25
TM 9-2320-302-20
0013 00-26
TM 9-2320-302-20
AIR SYSTEM TROUBLESHOOTING 0014 00
Table 1. Air System Troubleshooting Procedures.

1. Loss of Air Pressure. 1. Check for leaks in air lines and Replace air lines and fittings as
fittings. necessary (WP 0147 00).
2. Check damaged supply tanks Replace damaged components
and components for damage. (WP 0143 00 through WP
0146 00).
2. Loss of Air Supply Function. 1. Check for blocked or kinked air Replace damaged or blocked air
lines. lines (WP 0147 00).
2. Check all valves for damage. Replace faulty valves (WP
0150 00 through WP 0156 00).
3. Air Dryer Leaks. Check for faulty filter seal. Replace filter seal (WP 0158 00).
4. Air Dryer Fails to Absorb Moisture. 1. Check for dirty air dryer Service or replace air dryer (WP
filter(s). 0158 00).
2. Check for contaminated Service or replace air dryer (WP
desiccant beads (drying beads). 0158 00).
3. Check purge valve for damage. Service or replace air dryer (WP
0158 00).
0014 00-1
TM 9-2320-302-20
0014 00-2
TM 9-2320-302-20
STEERING SYSTEM TROUBLESHOOTING 0015 00
Table 1. Steering System Troubleshooting Procedures.

1. Loss of Steering Control. 1. Check for failed mounting of Replace steering wheel or column
steering wheel to steering shaft if defective (WP 0167 00 or
column shaft. WP 0168 00).
2. Check for defective steering Replace steering wheel if
wheel. defective (WP 0167 00).
3. Check for defective universal Replace universal joint if
joint. defective (WP 0168 00).
4. Check tie rod, pitman arm, and Replace tie rod, pitman arm or
drag link for damage. drag link if damaged (WP
0169 00).
2. Difficult Steering. 1. Check universal shaft for Replace universal shaft if
damage. damaged (WP 0168 00).
2. Check for defective yoke Replace universal shaft if
assembly. defective (WP 0168 00).
3. Check for defective attaching Tighten or replace attaching
hardware. hardware if defective (WP
0168 00).
3. Tie Rod, Drag Link or Pitman Arm Fails. 1. Check for proper lubrication. Replace tie rod assembly (Notify
Direct Support Maintenance).
2. Check tie rod assembly for Replace tie rod assembly if
corrosion. corroded (Notify Direct Support
Maintenance).
4. Hose Assembly Fails (Leaks). 1. Check hose assembly for loose Tighten or replace fittings as
and damaged fittings. necessary (WP 0170 00).
2. Check hose for cracks and Replace hose assembly if cracked
brittleness. or brittle (WP 0170 00).
5. Power Steering Reservoir Leaks. 1. Check for dirty filter and Replace filter (WP 0170 00).
contamination.
2. Check for loose or damaged Replace or repair power steering
fitting connection(s). fitting (WP 0170 00).
3. Check for damaged cover Tighten or replace cover assembly
assembly and loose or damaged and wing screw as necessary (WP
wing screw. 0170 00).
4. Check power steering reservoir Replace power steering reservoir
for damage and cracks. if damaged or cracked (WP
0170 00).
0015 00-1
TM 9-2320-302-20
0015 00-2
TM 9-2320-302-20
CHASSIS AND FIFTH WHEEL TROUBLESHOOTING 0016 00
Table 1. Chassis and Fifth Wheel Troubleshooting Procedures.

1. Pintle Hook Will Not Lock or Swivel. 1. Check pintle for proper Lubricate pintle (TM 9-2320-302-
lubrication. 10).
2. Check pintle hook for damage. Replace or repair pintle hook (WP
0179 00).
2. Trailer Will Not Couple or Becomes Uncoupled. 1. Check for proper coupling by
visually inspecting fifth wheel
and trailer king pin.
2. Check fifth wheel for worn or Replace worn or damaged parts
damaged parts. (Notify Direct Support
Maintenance).
3. Check operation of fifth wheel Adjust locking mechanism (WP
locking device. 0178 00).
3. Restricted Motion Between Tractor and Check adjustment of side bracket. Adjust side bracket (WP 0178 00).
Trailer.
0016 00-1
TM 9-2320-302-20
0016 00-2
TM 9-2320-302-20
AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING 0017 00
PRELIMINARY CHECKS
Before testing operation of air conditioning system, make the following checks:
1. Ensure the refrigerant compressor drive belt is not damaged and is under proper tension (WP 0054 00). Check compres-
sor mountings for tightness.
2. Check for broken, burst, and cut hoses. Check for loose fittings on all parts.
3. Check for road debris buildup on condenser coil fins. Using air pressure and a whiskbroom or a soapy spray of water,
carefully clean condenser, using care not to bend fins.
4. Check color in moisture indicator sight glass. If color is a deep cobalt blue, refrigerant charge is dry. If moisture indica-
tor is not blue, system is contaminated with moisture. Notify your supervisor.
5. If there is not enough airflow, ensure that leaves and other debris has not entered fresh air ports under windshield. If
debris is present, it could clog fins of evaporator core and block airflow. Ensure that all ducts are connected to dash lou-
vers and air-control flaps in heater housing are moving properly (this requires removal of right and center dash panel).
SAFETY PRECAUTIONS
1. Whenever repairs are made to any air conditioner parts that hold refrigerant, it is necessary to discharge, purge or flush
(if contaminated), evacuate, charge, and leak test system. In a good system, refrigerant lines are always under pressure
and should be disconnected only after air conditioning system has been discharged to a refrigerant recovery unit through
service valves on compressor.
2. Refrigerants are safe when used under proper conditions. Always wear safety goggles and non-leather gloves while dis-
charging, purging, flushing, evacuating, charging, and leak testing system. DO NOT wear leather gloves. When refriger-
ant gas or liquid contacts leather, leather will stick to skin.
WARNING
Liquid refrigerant, when exposed to the air, quickly evaporates and will freeze skin or eye tissue. Use care to
prevent refrigerant from touching your skin or eyes. Serious injury or blindness result if you come in contact
with liquid refrigerant.
3. Refrigerant splashed in eyes should first be treated with a few drops of sterile mineral oil in eyes, and rinsed with a weak
boric acid solution. DO NOT rub eyes. Seek medical attention immediately.
4. Refrigerant splashed on skin should be treated the same as frostbite. Gently pour cool water on area, but do not rub skin.
Keep skin warm with layers of soft, sterile cloth. Seek medical attention immediately.
5. Even though refrigerant does not burn, when it contacts extreme heat or flame, poisonous phosgene gas is created. This
gas is also produced when an open flame leak detector is used. Phosgene fumes have an acrid (bitter) smell.
WARNING
DO NOT work in an area where refrigerant may contact an open flame or any burning material such as a cig-
arette. When refrigerant contacts extreme heat, refrigerant breaks down into poisonous phosgene gas which,
if breathed, causes severe respiratory irritation. DO NOT breathe fumes from an open flame leak detector.
6. You must work in an area where there is a constant flow of fresh air when system is discharged, flushed, charged, and
leak tested using an open flame leak detector.
0017 00-1
TM 9-2320-302-20
AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING - CONTINUED 0017 00
SAFETY PRECAUTIONS - CONTINUED

7. Changes in both federal and state laws will affect the way dealerships service air conditioning systems. Under current
federal laws, refrigerant must be recovered and recycled by all users to protect environment, and not released into atmo-
sphere. Many service operations not directly involving the air conditioning system require release of refrigerant charge.
Under new regulations, dealerships not having required recovery and recycling equipment (and properly trained and cer-
tified personnel) will not be allowed to do any of this service work.
8. Because of its very low boiling point, refrigerant must be stored under pressure. To prevent refrigerant cans from
exploding, never expose to temperatures higher than 125°F (52°C). Never leave refrigerant cans in the sun, and DO
NOT store them in sun-exposed areas where heat can build up (such as gloveboxes, automobile trunks, etc).
PERFORMANCE TESTS
Following is a brief description of symptoms or conditions that could exist if something goes wrong with a refrigerant
part.
1. Receiver-drier.
a. The receiver-drier is normally at outside temperature. To the touch, entire length of unit should be same tempera-
ture. If noticeable cool spots exist, notify your supervisor.
b. A blockage at receiver-drier inlet will cause high head pressures. Blockages at receiver-drier outlet will cause low
head pressures and little or no cooling.
c. If moisture indicator color is pink or white (showing system is wet), receiver-drier is saturated with moisture and
must be replaced. Notify your supervisor.
2. Cooling System.
a. Although not physically connected, a close tie exists between vehicle air conditioner and cooling system. Poor air
conditioner cooling can be the result of a problem in the cooling system.
b. If cooling system does not work correctly, heat of engine will rise to abnormal levels. The added heat will transfer
to the air conditioner, other underhood parts, and may make its way into the cab. The added heat makes it neces-
sary for air conditioner to work harder and, at the same time, reduces air conditioner ability to cool down air in cab.
Also, if water regulating valve is not closing fully, heat will enter cab, giving the impression that the air condition-
ing system is not working.
3. Expansion Valve.
a. Problems that start in expansion valve show up as follows:
(1) When expansion valve is stuck closed, evaporator coil and expansion valve will be at outside temperature.
(2) When expansion valve is stuck open, both coil and valve will be extremely cold with frost or ice buildup.
b. Because expansion valve channels are very small, blockages in system tend to be found here (valve is very sensi-
tive to contamination). Usually, contaminant is water. Less than a drop of water is all it takes to make valve inop-
erative. When water reaches valve, extreme cold that results from pressure drop freezes water, forming a block of
ice in valve. After system shuts down and valve warms up, the ice melts and valve operates again, only to freeze up
when moisture returns.
c. On-and-off operation of expansion valve means that receiver-drier is not removing moisture from system. These
contaminants should cause moisture indicator element to turn white and then pink.
4. Refrigerant Compressor.
a. Compressor problems usually show in one of four ways: abnormal noise; seizure; leakage; or low suction and dis-
charge pressures.
b. Resonant compressor noises are not causes for alarm. Irregular noise or rattles are likely to be caused by broken
parts.
0017 00-2
TM 9-2320-302-20
PERFORMANCE TESTS - CONTINUED

5. Evaporator.
a. Evaporator coils are basically trouble-free when air flow over fins is not blocked. External or, less often, internal
blockages will cause low suction pressure as well as little or no cooling.
b. If a leak exists in system and cannot be traced to other parts or fittings, suspect damage to one of evaporator coils.
Notify your supervisor.
6. Condenser.
a. The condenser is usually trouble-free. Normally, temperature of condenser outlet line is noticeably cooler than
inlet line. However, when road debris (such as leaves or dirt buildup) builds up, air flow over condenser fins is
blocked and air is not able to absorb enough heat to turn hot refrigerant gas into a liquid. High head pressures will
result. In this case, carefully clean outer surfaces of the condenser with compressed air or soap and water solution
using care not to bend fins.
b. High head pressures also occur if the condenser tubing is abnormally bent, blocking flow of refrigerant. Frost will
appear at point where flow is restricted.
c. Less common internal blockages (bits of foreign material or metallic grit buildup) will stop the flow of refrigerant.
d. A quick test to check if poor system performance is caused by condenser is to direct a spray of water onto con-
denser while system is running. If the air conditioner cools better because of the assist provided by water, the con-
denser is not working.
e. When troubleshooting a suspected condenser problem, remember that the problem may be caused by radiator
transferring high levels of heat to condenser.
7. Thermostatic Switch.
NOTE
• Before troubleshooting thermostatic switch, notify your supervisor to check for a full charge of
refrigerant in system. Compressor will not operate or will cycle too often if there is not enough
refrigerant in the system.
• Quick or delayed cycling of compressor may be caused by a thermostatic switch that is work-
ing, but is out of adjustment. If, after performing tests below, switch seems to be out of adjust-
ment, replace switch (the thermostatic switch cannot be recalibrated).
a. Ensure that compressor clutch is operating properly.
b. Expose evaporator coil.
c. Start engine. Place air conditioner control at coldest setting and turn on air conditioner and fan.
d. Place an accurate thermometer in contact with a tube on evaporator coil. Ensure that thermometer is in good con-
tact with tube or incorrect reading will result. When temperature drops below 31°F - 36°F (-1°C - 2°C), compres-
sor clutch should disengage and remain this way until temperature rises to 39°F - 44°F (4°C - 7°C).
e. If the compressor did not engage when temperature was above accepted high range, perform the following test:
(1) Connect voltmeter or test light from one terminal on thermostatic switch to ground. Repeat this test with
other terminal on switch.
(2) With engine running and air conditioner and blower on, both terminals will show voltage when compres-
sor should be engaged. One terminal will show voltage when compressor should be disengaged. If voltage
is not present, there is a problem in electrical system from batteries to thermostatic switch. Check all cir-
cuits for cause, and repair or replace necessary wiring or parts. In all other cases where compressor is not
engaging and disengaging properly, thermostatic switch is cause. Replace thermostatic switch.
0017 00-3
TM 9-2320-302-20

(3) Shut down engine and, to prevent accidental electric shock or shorting during dash assembling, disconnect
batteries.
(4) Assemble dash.
8. Line Restrictions.
a. A restricted suction line causes low suction pressure at compressor and little or no cooling. A restriction in a line
between compressor and expansion valve can cause high discharge and low suction pressure and insufficient cool-
ing.
b. Usually, areas of ice or frost buildup mean a blockage. Parts that often freeze up are probably corroded or inopera-
tive and should be replaced. Parts (such as expansion valve) that freeze up once in a while may do so because of
moisture in system, which will cause the moisture indicator element to turn white or pink. If this happens, notify
your supervisor.
0017 00-4
TM 9-2320-302-20
A To resistor block D To engine fan thermal switch

B To blower motor E From a/c clutch relay
C From engine fan thermal switch F To compressor clutch
1 Compressor 9 Ignition Switch 17 Circuit Breaker (15A)

2 Condenser 10 Start Button 18 A/C clutch Relay
3 Receiver-drier 11 Circuit Breaker (10A) 19 Diode
4 Binary Switch 12 Circuit Breaker (30A) 20 Compressor Clutch
5 Moisture Indicator 13 Power Relay 21 High-speed Relay
6 High Pressure Relief Valve 14 Blower Switch 22 Fan Cycling Switch
7 Expansion Valve 15 “On-Off” Microsoft 23 Discharger Service Valve
8 Evaporator 16 Thermostatic Switch 24 Suction Service Valve
Figure 1. Air Conditioning System Components.
0017 00-5
TM 9-2320-302-20
Figure 2. Air Conditioning System Troubleshooting.
0017 00-6
TM 9-2320-302-20
AIR CONDITIONING SYSTEM TROUBLESHOOTING
Table 1. Problem - Little or No Air Flow.
POSSIBLE CAUSE REMEDY

Blower is not operating. Check for open circuit breaker. Open circuit indicates a short in electrical system,
which must be located and repaired.
Check air conditioner relays for operation. Replace as necessary (WP 0071 00).
Blower motor switch is working. Replace if necessary.
Check wiring to blower motor. Tighten any loose connections.
Check blower motor for operation. Replace blower motor if sticking or otherwise
inoperative (WP 0220 00).
Check resistor block. Replace if necessary (WP 0222 00).
CAUTION
Never attempt to bypass fuse in resistor block. To do so could cause
blower motor to overheat, resulting in serious damage to heater/air con-
ditioning system.
Restrictions or leaks in the ducts. Examine air ducts and remove blockages. Stop any leaks or replace portion if leaks
cannot be stopped.
Ice has formed on evaporator coil. Defrost evaporator coil before resuming operation of air conditioner.
Table 2. Problem - Warm Air Flow When Air Conditioner Is On.

No refrigerant charge in system. Perform air conditioner leak test (WP 0225 00).
Refrigerant compressor is not operating. Perform air conditioner leak test (WP 0225 00).
Repair or replace drive belt (WP 0054 00).
Air conditioner microswitch is not Replace microswitch.
working.
Ice has formed on evaporator coil. Defrost evaporator coil before resuming operation of air conditioner.
Table 3. Problem - Compressor Operates Too Often or Continuously.

Too little refrigerant in system. Perform air conditioner leak test (WP 0225 00).
Ice has formed on evaporator coil. Defrost evaporator coil before resuming operation of air conditioner. Check
operation of thermostatic switch and replace as necessary.
Dirt and debris are clogging condenser Remove dirt and debris from condenser fins.
fins.
The thermostatic switch is not working. Replace thermostatic switch.
0017 00-7
TM 9-2320-302-20
AIR CONDITIONING SYSTEM TROUBLESHOOTING - CONTINUED
Table 4. Problem - Quick or Delayed Cycling of Compressor.

Thermostatic switch operates, but is out of Replace thermostatic switch. Do not attempt to adjust it.
adjustment.
Loss of refrigerant is causing a delayed Perform air conditioner leak test (WP 0225 00).
cycling of compressor.
Table 5. Problem - Temperature in Cab Too Low or No Heat.

Water regulating valve is not open. Slide temperature lever slide control toward “warm”.
Water regulating valve is not opening Adjust water regulating valve cable.
fully.
Water regulating valve is not working. Replace water regulating valve.
Heater hose is pinched or twisted. Repair or replace heater hose.
Coolant is leaking from system. Check for leakage at heater core and at all hose connections from heater core to
engine. Check radiator coolant level and add coolant if necessary (TM 9-2320-302-
10). Check and repair any leaks at the radiator.
Dust or dirt is clogging heater core fins. Remove and clean heater core.
Table 6. Problem - Condensed Water Is Leaking from Air Conditioner.

Drain tubes are plugged. Clean drain holes and drain tubes.
0017 00-8
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) TROUBLESHOOTING 0018 00
THIS WORK PACKAGE COVERS
Initial System Troubleshooting, Driver’s Display Unit Diagnostics Features, Activating/Clearing Failure Display Mode,
Prolink Diagnostic Features, CWS Troubleshooting Procedures
INITIAL SETUP
Tools and Special Tools

Cartridge, CWS (Item 7, WP 0236 00)
Multimeter, digital (Item 24, WP 0236 00)
Pro-link MPSI Reader (Item 33, WP 0236 00)
INITIAL SYSTEM TROUBLESHOOTING
1. Check CWS components and wiring harness for obvious damage.
2. Check all connectors for corrosion, damage, and missing pins. Repair connectors as necessary (WP 0119 00).
3. Check that all electrical connections and ground wires are secure.
4. Check that other vehicle components are not causing interference.
DRIVER’S DISPLAY UNIT (DDU) DIAGNOSTIC FEATURES
1. Red failure light on DDU illuminates until cause of failure is corrected.
2. Fault codes are indicated by a pattern of flashes blinked out on Driver Display Unit (DDU) red “FAIL” light indicator.
Each fault code consists of a two digit number.
3. A pause of 3/4 of one second separates blinking of first and second digit of fault code. Example: Fault code 32 is indi-
cated by 3 blinks, a 3/4 second pause, and 2 more blinks.
4. A pause of 3 seconds exists between each flash code fault.
5. Code 41 is flashed if there are no faults OR after all faults have been displayed.
ACTIVATING/CLEARING FAILURE DISPLAY MODE
1. Press in and hold DDU “VOLUME” knob for a minimum of five seconds. If knob is released before five seconds has
elapsed, system will turn off.
2. After five seconds, DDU red “FAIL” indicator will begin to blink out fault codes.
3. Code 41 is flashed if there are no faults OR after all faults have been displayed.
4. To read active fault codes, position DDU “RANGE” knob to left of center; only active fault codes will flash.
5. To read inactive fault codes, position “RANGE” knob to right of center; only inactive fault codes will flash.
6. To clear fault codes, push and hold DDU “RANGE” knob while system is in self-test (when ignition key is turned on).
0018 00-1
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) TROUBLESHOOTING - CONTINUED 0018 00
ACTIVATING/CLEARING FAILURE DISPLAY MODE - CONTINUED
Table 1. Fault Codes.
FAULT CODE SUSPECT FAILURE

11 Central Processing Unit (CPU)
13 Driver Display Unit (DDU)
14 Antenna assembly
15 Right side sensor
21 Right turn signal
23 Brake
24 Speed
31 J1587
32 J1939
33 VBUS
34 DDU communications
35 Antenna assembly communications
PROLINK DIAGNOSTIC FEATURES

1. Connect Pro-link MPSI Reader with CWS troubleshooting cartridge to vehicle.
2. Follow instructions on Pro-link MPSI Reader display.
0018 00-2
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) TROUBLESHOOTING - CONTINUED 0018 00
CWS TROUBLESHOOTING PROCEDURES
NOTE
• Perform Initial System Troubleshooting prior to replacing any component.
• Asterisk (*) indicates step requiring Pro-link w/cartridge.
Table 2. CWS Troubleshooting Procedures.

1. Red Fail Light on Driver’s Display Unit or Side 1. While performing side sensor If OK, proceed to next step. If
Sensor Display Illuminates Continuously. test, wave hand in front of side NOT OK, replace side sensor (WP
sensor and verify that correct 0111 00).
signal is received.*
2. Verify a 5-volt output at side If OK, notify supervisor. If NOT
sensor signal wire at side sensor OK, replace side sensor (WP
connector, with a target 0111 00).
present.
2. Warnings Tones Not Audible. 1. Verify volume control knob is Turn volume control knob fully
turned fully clockwise. clockwise.
2. Turn system off and back on. If tone is not heard, proceed to
Turn volume control knob and next step.
listen for tone.
3. Perform speaker test and verify If tone is not heard, proceed to
audible tone is heard from next step.
DDU speaker.*
4. Verify speed input. If OK, proceed to next step. If
NOT OK, replace DDU (WP
0111 00).
5. Perform brake test and verify If OK, notify supervisor. If NOT
correct signal is received when OK, replace DDU (WP 0111 00).
brake pedal is depressed.*
3. Warning Tones Audible When Brakes Are 1. Perform brake test and confirm If OK, proceed to next step. If
Applied. receipt of correct signal when NOT OK, replace DDU (WP
brake pedal is depressed.* 0111 00).
2. Verify brake mode setting is If OK, proceed to next step. If
correctly configured in CPU.* NOT OK, notify supervisor.
3. Verify brake logic is correctly If OK, replace DDU (WP
configured.* 0111 00). If NOT OK,
notify supervisor.
4. Side Sensor Warning Tone Audible When 1. Verify tone is not audible when If tone is heard, replace side
Brakes Are Applied. hand is waved in front of side sensor (WP 0111 00). If tone is not
sensor with only brake pedal heard, proceed to next step.
depressed (turn signal not
activated).
0018 00-3
TM 9-2320-302-20
Table 2. CWS Troubleshooting Procedures - Continued.

4. Side Sensor Warning Tone Audible When 2. Verify turn signal setting is If OK, proceed to next step. If
Brakes Are Applied - Continued. correctly configured in CPU.* NOT OK, notify supervisor.
3. Perform turn signal test and If OK, notify supervisor. If NOT
confirm receipt of correct OK, replace DDU (WP 0111 00).
signal when turn signal is
applied.*
5. Volume Knob Does Not Reduce Volume. 1. Verify MIN VOL setting is If OK, proceed to next step. If
zero.* NOT OK, notify supervisor.
2. Perform DDU test and confirm If OK, notify supervisor. If NOT
proper operation of volume OK, replace DDU (WP 0111 00).
knob.*
6. Range Knob Does Not Change Alert Levels. 1. Verify RANGE ENABLE If OK, proceed to next step. If
configuration is ON.* NOT OK, notify supervisor.
2. Perform DDU test and confirm If OK, notify supervisor. If NOT
proper operation of range OK, replace DDU (WP 0111 00).
knob.*
7. Front Antenna Detects Vehicles in an Adjacent Confirm antenna alignment (WP If proper alignment is confirmed
Lane With No Vehicle in Front of Host Vehicle. 0110 00). and fault still exists, notify
supervisor.
8. Front Antenna Detects Vehicle in Both Left and 1. Confirm antenna minimum If OK, proceed to next step. If
Right Adjacent Lanes, With No Vehicle in height requirement or above. NOT OK, notify supervisor.
Front of Host Vehicle.
2. Confirm antenna is secured to Tighten antenna if necessary (WP
mounting. 0111 00).
3. Confirm radar beam path is Clear radar beam path if
unobstructed. obstructed. If radar beam path is
not obstructed, notify supervisor.
9. Front Antenna Loses or Ignores Detected 1. Confirm antenna minimum If OK, proceed to next step. If
Vehicles Within 100 Feet in Front of Host height requirement or above. NOT OK, notify supervisor.
Vehicle.
2. Confirm antenna is secured to Tighten antenna as necessary (WP
mounting. 0111 00).
3. Confirm radar beam path is Clear radar beam path if
unobstructed. obstructed. If radar beam path is
not obstructed, notify supervisor.
10. Side Sensor Display Does Not Indicate Power, 1. Verify side sensor display If OK, proceed to next step. If
or a Detected Object. operation.* NOT OK, notify supervisor.
2. Check for correct continuity 1. If OK, notify supervisor. If
and supplied voltage readings NOT OK, replace side sensor
at connector. (WP 0111 00).
2. If fault still exists, replace CPU
(WP 0111 00).
11. DDU Blinks Out Fault Code 11 (Central Replace CPU (WP 0111 00).
Processing Unit).
0018 00-4
TM 9-2320-302-20

12. DDU Blinks Out Fault Code 13 (Driver’s Replace DDU (WP 0111 00).
Display Unit).
13. DDU Blinks Out Fault Code 14 (Antenna 1. Replace antenna (WP 0111 00).
Assembly).
2. If fault still exists, replace CPU
(WP 0111 00).
14. DDU Blinks Out Fault Code 15 (Right Side 1. While performing side sensor If OK, proceed to next step. If
Sensor). test, wave hand in front of side NOT OK, notify supervisor.
sensor and verify that correct
signal is received.*
2. Verify a 5-volt output at side If OK, proceed to next step. If
sensor signal wire at side sensor NOT OK, replace side sensor (WP
connector, with a target 0111 00).
present.
15. DDU Blinks Out Fault Code 21 (Right Turn 1. Confirm operation of exterior If OK, proceed to next step. If
Signal). turn signals. NOT OK, notify supervisor.
2. Confirm operation of turn If OK, proceed to next step. If
signal switch. NOT OK, notify supervisor.
3. Check that right turn signal If OK, proceed to next step. If
input is connected to right turn NOT OK, notify supervisor.
signal lead.
4. Perform turn signal test to If OK, proceed to next step. If
confirm correct input is NOT OK, notify supervisor.
received when right turn signal
is activated.*
5. Verify pin number 15, on top If OK, notify supervisor. If NOT
row of main harness connector, OK, replace connector (WP
receives 12 volts when right 0119 00).
signal is activated.
16. DDU Blinks Out Fault Code 23 (Brake). 1. Confirm brake source is If OK, proceed to next step. If
correctly configured in CPU.* NOT OK, notify supervisor.
2. Confirm operation of exterior If OK, proceed to next step. If
brake lights. NOT OK, notify supervisor.
3. Confirm operation of brake If OK, proceed to next step. If
switch. NOT OK, notify supervisor.
4. Perform brake test and confirm If OK, proceed to next step. If
correct signal is received when NOT OK, notify supervisor.
brake pedal is depressed.*
5. Confirm brake logic is If OK, proceed to next step. If
correctly configured.* NOT OK, notify supervisor.
6. Confirm brake input wire is If OK, proceed to next step. If
connected to proper source. NOT OK, notify supervisor.
0018 00-5
TM 9-2320-302-20

16. DDU Blinks Out Fault Code 23 (Brake) - 7. Verify pin number 9, on top Notify supervisor.
Continued. row of main harness connector,
receives 12 volts when brake is
applied.
17. DDU Blinks Out Fault Code 24 (Speed). 1. Confirm that SPEEDO BIT If OK, proceed to next step. If
setting is correcting configured NOT OK, notify supervisor.
in CPU.*
2. Confirm speed mode is If OK, proceed to next step. If
correctly configured.* NOT OK, notify supervisor.
3. Perform speedometer test to Notify supervisor.
confirm speedometer accuracy
against vehicle speed.*
18. DDU Blinks Out Fault Code 31 (J1587). Confirm proper connection of If OK, notify supervisor. If NOT
J1587 wires at pin #7 positive and OK, replace connector (WP
pin #8 negative on top row of CPU 0119 00).
connector.
19. DDU Blinks Out Fault Code 32 (J1939). Confirm proper connection of If OK, notify supervisor. If NOT
J1939 wires at pin #7 positive and OK, replace connector (WP
pin #8 negative on bottom row of 0119 00).
CPU connector.
20. DDU Blinks Out Fault Code 33 (VBUS). Check connection of J1587 wires If OK, notify supervisor. If NOT
to vehicle harness. OK, replace connector (WP
0119 00).
21. DDU Blinks Out Fault Code 34 (DDU Check connection of J1587 wires If OK, notify supervisor. If NOT
Communications). to vehicle harness. OK, replace connector (WP
0119 00).
22. DDU Blinks Out Fault Code 35 (Antenna Check connection of J1587 wires If OK, notify supervisor. If NOT
Assembly Communications). to vehicle harness. OK, replace connector (WP
0119 00).
END OF WORK PACKAGE
0018 00-6
TM 9-2320-302-20
CHAPTER 3
UNIT MAINTENANCE INSTRUCTIONS
TM 9-2320-302-20

TM 9-2320-302-20
SERVICE UPON RECEIPT 0019 00
GENERAL
1. When a new, used or reconditioned M915A3 Tractor Truck is first received, determine whether it has been properly pre-
pared for service and is in condition to perform its mission.
2. Follow the inspection and servicing instructions that follow.
INSPECTION INSTRUCTIONS
1. Read and follow all precautions and instructions on DD Form 1397.
2. Remove all packing and shipping material, such as tape, tie downs, protective covers, and shipping seals.
3. Inspect equipment for any damage incurred during shipment. Check if equipment has been modified.
4. Check equipment against packing slip to ensure that shipment is complete. Report any discrepancies on SF Form 364.
5. Remove all Basic Issue Item (BII), Additional Authorization List (AAL), and Components of End Item (COEI) equip-
ment and store in accordance with TM 9-2320-302-10.
SERVICING INSTRUCTIONS
1. Service the vehicle in accordance with TM 9-2320-302-10 and Unit PMCS (WP 0021 00). Schedule the next PMCS on
DD Form 314.
2. Refer to TM 9-2320-302-10 and perform functional checks of all major vehicle systems.
END OF WORK PACKAGE
0019 00-1
TM 9-2320-302-20
0019 00-2
TM 9-2320-302-20
UNIT PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS) INTRODUCTION 0020 00
GENERAL
1. To ensure that the M915A3 Tractor Truck is ready for operation at all times, it must be lubricated and inspected on a
regular basis so that defects may be found before they result in serious damage, equipment failure or injury to personnel.
2. Table 1 lists the types, amounts, and temperature ranges of the lubricants required for specified intervals.
3. Table 1 in WP 0021 00 contains systematic instructions on lubrications, inspections, adjustments, and corrections to be
performed by Unit Maintenance to keep the vehicles in good operating condition and ready for their primary mission.
4. Table 2 in WP 0021 00 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 2404
(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 calender dates.
a. Semiannual procedures must be done once every six months.
b. Annual procedures must be done once each year.
3. Location, Item to Check/Service Column. This column identifies the location and 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. Not Fully Mission Capable 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 check and service 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.
GENERAL LUBRICATION PROCEDURES
NOTE
These lubrication instructions are mandatory.
1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When operating under
extreme conditions, such as high or low temperatures, fording in water over 20 inches deep, or exposure to sand or dust,
lubricants should always be changed more frequently. Lubricants that have become contaminated will be changed
regardless of interval. When in doubt, notify your supervisor.
2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat. Keep container covers
clean and do not allow dust, dirt or other foreign material to mix with lubricants. Keep all lubrication equipment clean
and ready for use.
3. Maintain a good record of all lubrication performed and report any problem noted during lubrication. Refer to DA Pam
738-750 for maintenance forms and procedures to record and report any findings.
0020 00-1
TM 9-2320-302-20
UNIT PREVENTIVE MAINTENANCE CHECKS AND

SERVICES (PMCS) INTRODUCTION - CONTINUED 0020 00
GENERAL LUBRICATION PROCEDURES - CONTINUED
4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe lubrication fit-
tings with a clean rag (Item 28, WP 0235 00). After lubrication, wipe off excess oil or grease to prevent accumulation of
foreign matter.
5. Refer to FM 9-207 for lubrication instructions in cold weather.
6. Refer to AR 70-12 for use of standardized fuels and lubricants.
7. Oil filters will be changed when:
a. they are known to be contaminated or clogged;
b. service is directed by Army Oil Analysis Program (AOAP) laboratory analysis; or
c. at prescribed hardtime intervals.
8. Engine oil and transmission fluid must be sampled initially at 90 days of operation as prescribed by DA Pam 738-750.
Thereafter, engine oil and transmission fluid are sampled semiannually, unless AOAP results dictate otherwise.
9. For equipment under manufacturer’s warranty, hardtime oil service intervals shall be followed. Intervals shall be short-
ened if lubricants are known to be contaminated or if operation is under adverse conditions (i.e., longer than usual oper-
ating hours, extended idling periods or extreme dust).
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 man-
ual. 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 (Item 28, WP 0235 00) handy. Perform ALL inspections at the appli-
cable 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 (Item 11, WP 0235 00) 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 (Item 19, WP 0235 00). Report it to your supervisor.
c. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, 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 one
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 connec-
tors. Tighten loose connectors and ensure that the wires are in good condition.
0020 00-2
TM 9-2320-302-20
UNIT PREVENTIVE MAINTENANCE CHECKS AND

SERVICES (PMCS) INTRODUCTION - CONTINUED 0020 00
GENERAL PMCS PROCEDURES - CONTINUED

f. Hydraulic Hoses and Lines. Look for wear, damage, and signs of leaks. Ensure that 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 (WP 0234 00). If not authorized, notify your supervisor.
g. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your truck. The following
are definitions of the types/classes of leakage you need to know to be able to determine the status of your truck.
Learn and be familiar with them, and remember - when in doubt, notify your supervisor.
Leakage Definitions For PMCS
Class I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II Leakage of fluid great enough to form drops, but not enough to cause drops to drip from
item being checked/inspected.
Class III Leakage of fluid great enough to form drops that fall from item being checked/inspected.
CAUTION
Operation is allowable with Class I and Class II leakage. WHEN IN DOUBT, NOTIFY YOUR SUPERVI-
SOR. 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 compo-
nents.
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 Unit PMCS, Table 2, WP 0021 00.
2. Tools.
a. Common no. 1 shop set
b. General mechanic’s tool kit
c. Tensiometer, dial indicating
3. Materials.
a. Antifreeze
b. AOAP sampling kit
c. Detergent
d. GAA grease
e. Lubricating oil, OE/HDO 10
f. Lubricating oil, OE/HDO 40
g. Lubricating oil, OE/HDO 15/40
h. Lubricating oil, OE/HDO 30
i. Lubricating oil, OEA
j. Lubricating oil, GO 85/140
k. Lubricating oil, GO 80/90
l. Lubricating oil, GO 75
m. Rags
4. Personnel.
a. Driver/Operator
b. Unit Maintenance Mechanic
0020 00-3
TM 9-2320-302-20
Table 1. Lubrication Data.
EXPECTED TEMPERATURES*
LUBRICANT/ REFILL +6°F TO +122°F -4°F TO +50°F -67°F TO +32°F

COMPONENT CAPACITY (-14°C TO +50°C) (-20°C TO +10°C) (-55°C TO 0°C)
OE/HDO
(MIL-L-2104)
Lubricating Oil, ICE,
Tactical
OEA
(MIL-L-46167)
Lubricating Oil, ICE,
Arctic
Engine Crankcase w/ 41 Qt
See Chart A
Filters (38.8 l)
Power Steering Reservoir 2 Qt
See Chart A
(1.9 l)
Transmission 51 Qt
See Chart B
(48 l)
GO
(MIL-PRF-2105)
Lubricating Oil, Gear,
Multipurpose
Front Axle Wheel
See Chart C
Bearings As Reqd
Rear Axle Differential, 13 Qt
See Chart C
Forward-rear (12.3 l)
Rear Axle Differential, 14.5 Qt
See Chart C
Rear-rear (13.7 l)
GAA
(M-10924)
All Temperatures
Grease, Automotive and As Reqd
Artillery
ANTIFREEZE
(MILA46153)
Ethylene Glycol,
Inhibited, Heavy Duty
ANTIFREEZE
(MIL-A-11755)
Ethylene Glycol,
Arctic Grade
Engine Radiator 65 Qt
See Chart D
(61.5 l)
* For arctic operation, refer to FM 9-207
0020 00-4
TM 9-2320-302-20
Table 2. Chart A - Engine and Power Steering Reservoir.
EXPECTED TEMPERATURES
°F -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49
OE/HDO Lubricating Oil, ICE,

(MIL-L-2104) Tactical
OEA Lubricating Oil, ICE, Arctic

(MIL-L-46167)
OE/HDO-15/40
(0 - 1236)
OE/HDO-10 *
(0237)
OE/HDO-30
(0 - 238)
OE/HDO-40
(N/A)
OEA *
(0 - 183)
*If OEA lubricant is required to meet the low expected-temperature range, OEA lubricant is to be used in lieu of OE/HDO-10 lubricant for all
expected temperatures where OE/HDO-10 is specified.
Table 3. Chart B - Transmission.
°F -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49
OE/HDO Lubricating Oil, ICE,

(MIL-L-2104) Tactical
OEA Lubricating Oil, ICE, Arctic

(MIL-L-46167)
OE/HDO-15/40
(0 - 1236)
OE/HDO-10 *
(0 - 237)
OEA *
(0 - 183)
*If OEA lubricant is required to meet the low expected-temperature range, OEA lubricant is to be used in lieu of OE/HDO-15/40 lubricant for all
expected temperatures where OE/HDO-10 and OE/HDO-15/40 are specified.
0020 00-5
TM 9-2320-302-20
Table 4. Chart C- Front Axle Wheel Bearings and Rear Axle Differentials.
°F -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49
GO Lubricating Oil, Gear,

(MIL-PRF-2105) Multipurpose
GO-75
(0 - 186)
GO-80/90
(0 - 226)
GO-85/140
(0 - 228)
Table 5. Chart D - Antifreeze.
°F -90 -80 -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90
Lubricant °C -68 -62 -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32
MILA46153 Antifreeze, Ethylene Glycol,

Inhibited, Heavy Duty
MIL-A-11755 Antifreeze, Arctic Grade
MILA46153
MIL-A-11755
0020 00-6
TM 9-2320-302-20
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 0021 00
Table 1. Unit Preventive Maintenance Checks and Services

(PMCS) for the M915A3 Tractor Truck.
LOCATION
ITEM TO
ITEM CHECK/ NOT FULLY MISSION
NO. INTERVAL SERVICE PROCEDURE CAPABLE IF:
WARNING
Unless otherwise specified, perform all lubrication and preventive mainte-
nance checks and services with truck on level ground, transmission in N
(Neutral), parking brake applied, and engine off. Failure to follow this
warning may result in personnel injury.
NOTE
Perform all operator PMCS, as appropriate, while performing road test
(TM 9-2320-302-10). Drive at least 5 mi (8 km) to give enough time to
detect malfunctions.
1 Semi- Road Test, While starting vehicle, listen for unusual
annual Starter noises and difficult cranking of starter.
2 Semi- Road Test, a. Listen for unusual noises, hesitation, and
annual Engine and varying idle speed. Observe accelerator
Engine response.
Compartment b. Ensure that engine does not exceed maxi-
mum governed speed (2100 rpm).
c. Check instrument panel for proper opera-
tion of switches, gages, and indicator and
warning lights (TM 9-2320-302-10).
NOTE
Refer to TM 9-2320-302-10 for operation of brake components.
3 Semi- Road Test, a. Test braking response to brake pedal.
annual Brakes Response should be immediate.
b. At approximately 30 mph (48 kph),
apply brake pedal. Vehicle should stop
smoothly without noticeable side pull or
chatter.
c. After stopping vehicle, with transmission
in gear, release brake pedal. Wheel brake
release should be immediate.
d. With vehicle on downgrade and trans-
mission in N (Neutral), set parking brake.
Vehicle should not move.
0021 00-1
TM 9-2320-302-20
Table 1. Unit Preventive Maintenance Checks and Services (PMCS)

for the M915A3 Tractor Truck - Continued.
LOCATION
ITEM TO
3 Semi- Road Test, e. Start vehicle moving downhill. Engage

(Con’t) annual Brakes engine Jake brake and check operation in
all switch positions (2, 4, and 6 cylinders
braking power). Ensure that vehicle
speed drops in each position, with maxi-
mum braking power with all 6 cylinders
engaged in braking.
WARNING
Cautiously feel each wheel hub and brakedrum. Wheel hubs and brake-
drums may be hot. Failure to follow this warning may result in serious
burns.
f. Immediately after road test, carefully
check and compare each wheel hub and
brakedrum for overheating, which could
indicate a dragging brake. A cool wheel
hub and brakedrum could mean improp-
erly adjusted, defective or inoperative
brakes.
4 Semi- Road Test, Check operation of interaxle lockout.
annual Interaxle
Lockout
5 Semi- Road Test, Check vehicle response to steering wheel
annual Steering action. Vehicle should respond quickly.
With vehicle on straight level ground,
lightly hold steering wheel to check for pull
or wander. With vehicle in motion, free play
should be no more than 2 ½ in (6.4 cm) in
either direction.
6 Semi- Road Test, Observe how vehicle responds to road
annual Suspension shocks. Shifts, knocks or constant bouncing
indicate possible malfunctions.
0021 00-2
TM 9-2320-302-20

LOCATION
ITEM TO
NOTE
Engine oil must be sampled initially at 90 days of operation, as prescribed by
DA Pam 738-750. Thereafter, it is sampled semiannually unless AOAP
results indicate otherwise.
7 Semi- Engine Raise hood and take sample of engine oil:
annual Compartment, a. Start engine and bring to operating temper-
AOAP Sampling ature (TM 9-2320-302-10).
Valve
b. Remove cap from discharge port. Clean
sampling valve (1) with a rag.
c. Press knob of sampling valve (1) and col-
lect approximately 2 oz. (60 ml) into a suit-
able container. Discard oil in accordance
with local policies and regulations.
d. Collect oil sample into clean sample bottle

to approximately 1/2 in (1.3 cm) below
neck of sample bottle.
e. Install cap on discharge port and check for
leaks.
0021 00-3
TM 9-2320-302-20

LOCATION
ITEM TO
8 Semi- Engine a. With engine warm, remove drain plug (2)

annual Compartment, from oil pan and completely drain oil from
Engine crankcase.
Crankcase b. Replace all oil filters.
c. Install drain plug (2).
d. Fill crankcase with OE/HDO or OEA

(Items 16 through 21, WP 0235 00)
through filler tube (3) opening. Capacity
with filters is approximately 41 qt (38.8 l).
e. Run engine. Remove dipstick (4) and
check level of oil on dipstick. Level should
be between ADD and FULL marks on dip-
stick.
9 Semi- Engine a. Check all oil lines, fittings, and hoses for
annual Compartment, leaks.
Engine
b. Check oil filter housing, oil pan, and oil
pan drain plug for leaks. Tighten or replace
any damaged component, if authorized.
c. Check rocker arm cover for leaks. Tighten
or replace any damaged component, if
authorized.
0021 00-4
TM 9-2320-302-20

LOCATION
ITEM TO
9 Semi- Engine d. Check mounting hardware and attaching

(Con’t) annual Compartment, hardware for looseness. Tighten or replace
Engine any damaged component, if authorized.
WARNING
DO NOT perform fuel system checks, inspections or maintenance while
smoking or near fire, flame or sparks. Fuel may ignite, causing injury or
death to personnel and damage to vehicle.
10 Semi- Engine a. Replace all fuel filter elements.
annual Compartment, b. Inspect fuel lines, fuel tank, and fuel sys-
Fuel System tem components for leaks and damage. If
authorized, replace damaged components.
11 Semi- Engine a. Check for loose, missing, worn, broken,
annual Compartment, frayed or cracked drive belts (5).
Drive Belts and
Pulleys
b. Check alternator and air conditioning

compressor mounting for looseness.
Inspect brackets and attaching hardware
for cracks, bends, and loose mounting.
Replace damaged components as needed.
c. Use a dial indicating tensionmeter (Item
32, WP 0236 00) placed at the center of
the longest belt free-span to check belt
tension. Gage should register 80-100 lb-ft
(108-135 Nm) for alternator and AC com-
pressor belt. Gage should register 60-80
lb-ft (81-108 Nm) for fan belt. Adjust ten-
sion as required.
0021 00-5
TM 9-2320-302-20

LOCATION
ITEM TO
11 Semi- Engine d. Check for cracked pulleys or pulleys out

(Con’t) annual Compartment, of alignment.
Drive Belts and
Pulleys
WARNING
If NBC exposure is suspected, all air filter media should be handled by per-
sonnel wearing protective equipment. Consult your NBC Officer or NBC
NCO for appropriate handling or disposal procedures.
12 Semi- Engine a. Check air cleaner, hoses, and air cleaner
annual Compartment, seal for proper installation, cracks, breaks
Air Intake or loose connections that could let unfil-
System tered air into air intake system.
b. Check air cooler intake screen for debris

and damage.
c. Check air intake filter element for clog-
ging and wear.
NOTE
Refer to TM 750-651 for cooling system service information.
13 Semi- Engine a. Remove debris from cooling fins and
annual Compartment, check for bent fins.
Cooling System b. Inspect radiator and charge air cooler for
leaks.
c. Check radiator hoses for cracks, bulges or
soft spots. Ensure that hose clamps are
tight.
d. Check radiator cap, gaskets, and rubber
isolator mounts and fan shroud for cracks
and leaks.
e. Inspect water pump for leaks.
14 Semi- Engine a. Inspect power steering pump and reservoir
annual Compartment, (6) for leaks, cracks, loose hoses, or other
Power Steering damage.
Components
b. Remove plug (7) from reservoir (6) and
drain fluid into a suitable container.
0021 00-6
TM 9-2320-302-20

LOCATION
ITEM TO
14 Semi- Engine c. Replace filter element.

(Con’t) annual Compartment,
Power Steering
Components
d. Install plug (7). Fill reservoir (6) through
dipstick (8) opening with OE/HDO or
OEA (Items 18 through 22, WP 0235 00).
Capacity is approximately 2 qt (1.9 l).
e. Start engine (TM 9-2320-302-10). Bring
to operating temperature. Turn steering
wheel in both directions to circulate power
steering fluid.
f. Check level of fluid on dipstick (8). Add
fluid as required until level shows within
correct range on dipstick.
15 Semi- Engine a. Inspect wiring for frays, splits, missing

annual Compartment, insulation or poor connections. Make
Electrical repairs as needed, if authorized.
Components
b. Check alternator and DUVAC wiring for
frays, splits, missing insulation, and loose
terminal connections. Make repairs as
needed, if authorized.
16 Semi- Cab Floor and Remove foot brake valve from firewall.
annual Engine Lubricate sliding surfaces of plunger and
Compartment adapter bore with silicone grease (Item 16,
Firewall, WP 0235 00). Install foot brake valve.
Foot Brake Valve
0021 00-7
TM 9-2320-302-20

LOCATION
ITEM TO
WARNING
To avoid eye injury, eye protection is required when working around batter-
ies. 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, injury to personnel, and damage to
equipment.
CAUTION
To reduce battery damage, do not remove batteries from battery box unless
battery compartment is corroded (greenish/white powder) or during battery
replacement. Do not jerk or pull on battery cables during visual inspection.
Battery replacement will be performed only by Unit Maintenance person-
nel.
17 Semi- Battery Box, a. Remove batteries from battery box.
annual Batteries
b. Check for damaged or missing filler caps. b. Filler caps are damaged or
missing.
c. Check for damaged terminal posts. c. Terminal posts are damaged.
d. Check electrolyte level (TM 9-6140-200- d. Electrolyte is not at proper
14). level.
e. Check and record specific gravity of each e. Specific gravity is not within
cell in all batteries (TM 9-6140-200-14). standards.
f. Check battery cables for frays, splits, and f. Cables are missing, frayed,
breaks. split or broken.
g. Clean battery box.
h. Install batteries.
i. Coat terminals lightly with grease (Item
15, WP 0235 00).
0021 00-8
TM 9-2320-302-20

LOCATION
ITEM TO
18 Semi- Exhaust System Inspect exhaust manifold, exhaust pipes,

annual muffler, and tailpipe for leaks. Check for
damaged pipes, loose clamps, and damaged
gaskets and seals. Replace damaged compo-
nents as needed.
19 Semi- Air System, a. Fully charge air system (TM 9-2320-302-
annual Brakes 10).
b. Listen for sounds of leaks in all air lines
and at valves and fittings.
c. With air system fully pressurized, apply a
solution of detergent (Item 11, WP
0235 00) and water to air lines, valves,
and fittings. Tighten loose connections.
Make repairs as needed.
d. Ensure that all air lines are not kinked and
that they are properly supported.
20 Semi- Air Conditioning Leak test air conditioning system (WP
annual System 0225 00).
21 Semi- Under Vehicle, a. Inspect frame and side rails for cracks,
annual Frame and breaks, bends, wear, deterioration, and
Crossmembers loose bolts.
b. Inspect crossmembers for weld breaks,

wear, and missing or loose capscrews,
huckbolts, and rivets.
22 Semi- Vehicle Exterior a. Inspect for corrosion in accordance with
annual TB 43-0213.
b. Inspect cab glass and doors, fenders, stow-

age boxes, and brackets for damage.
NOTE
Transmission fluid must be sampled initially at 90 days of operation, as pre-
scribed by DA Pam 738-750. Thereafter, it is sampled semiannually unless
AOAP results indicate otherwise.
0021 00-9
TM 9-2320-302-20

LOCATION
ITEM TO
23 Semi- Transmission, Take sample of transmission fluid:

annual AOAP Sampling a. Ensure that transmission is at operating
Valve temperature.
b. Remove cap from discharge port. Clean
sampling valve (9) with a rag.
c. Press knob of sampling valve (9) and col-
lect approximately 2 oz. (60 ml) into a
suitable container. Discard fluid.
d. Collect fluid sample into clean sample

bottle to approximately 1/2 in (1.3 cm)
below neck of sample bottle.
e. Install cap on discharge port and check for
leaks.
24 Semi- Transmission a. Check transmission for leaks, loose bolts,
annual and obvious damage.
b. Check transmission output shaft seal for

damage or leaking.
NOTE
When lubricating front axle steering components, vehicle must be raised to
take weight off the suspension to permit lubrication to reach all axle bearing
surfaces.
25 Semi- Front Axle a. Apply grease (Item 15, WP 0235 00) to
annual Steering grease fittings (10) at top and bottom of
Components, steering knuckle (11) until old lubricant is
Lubrication purged and fresh grease comes out areas
indicated by arrows. Perform service at
both axle ends.
0021 00-10
TM 9-2320-302-20

LOCATION
ITEM TO
25 Semi- Front Axle

(Con’t) annual Steering 10
Components,
Lubrication
11
10
CAUTION
If excess grease accumulates at front axle ball exterior between services,
notify Direct Support Maintenance. Ball seal may be worn or leaking.
b. Lubricate two tie-rod end grease fittings
(12) with grease (Item 15, WP 0235 00).
12
0021 00-11
TM 9-2320-302-20

LOCATION
ITEM TO
25 Semi- Front Axle c. Lubricate two drag link grease fittings

(Con’t) annual Steering (13) with grease (Item 15, WP 0235 00).
Components,
Lubrication
d. Lubricate steering column fitting (14) and
two U-joint grease fittings (15) with
grease (Item 15, WP 0235 00). Observe
purging from all seals until new grease
comes out. If grease does not purge,
manipulate U-joints until purging occurs.
14
15
16
15
13
13
12
CAUTION
DO NOT use an automatic or power grease gun on fitting on trunnion side
of steering gear because the rate of flow is too high. High flow rate could
force grease inside high-pressure seal, contaminating hydraulic system and
promoting seal leakage.
e. Lubricate grease fitting (16) on trunnion
side of steering gear, near output shaft,
with grease (Item 15, WP 0235 00).
0021 00-12
TM 9-2320-302-20

LOCATION
ITEM TO
26 Semi- Front Axle a. Check for looseness in steering column U-

annual Steering joints.
Components,
Inspection
b. Check steering gear for leaks and loose
mounting bolts and components. Tighten
or replace any damaged component, if
authorized.
c. Check tie-rod and drag link for movement
by attempting to move by hand. Visually
check ball joint ends for worn or damaged
dust seals. If movement or damage is
present, make repairs if authorized.
d. Inspect all steering lines and fittings for
looseness, damage or leaks. Tighten if
loose or replace if damaged.
e. Check adjustment of front axle steering
stops (17). With brakes fully applied, turn
steering wheel to one side to end of travel.
Check both sides of vehicle for interfer-
ence at tires and wheels. Minimum clear-
ance is 1/2 in (1.3 cm) from any fixed
object and 3/4 in (1.9 cm) from any mov-
ing object. Repeat for opposite end of
steering wheel travel. Make adjustments
as required.
17
27 Semi- Front Axle, a. Inspect spring leaves for cracks and

annual Suspension breaks.
b. Inspect spring clips, saddles, saddle caps,

spring hangers, and attaching hardware for
looseness, cracks or other damage.
Tighten or replace any damaged compo-
nent, if authorized.
0021 00-13
TM 9-2320-302-20

LOCATION
ITEM TO
27 Semi- Front Axle, c. Check for loose screws and missing and
(Con’t) annual Suspension damaged front axle mounting hardware.
NOTE
When lubricating front axle suspension components, vehicle must be raised
to take weight off suspension to permit lubrication to reach bearing surfaces.
d. Lubricate three spring grease fittings (18)
with grease (Item 15, WP 0235 00).
18
18
e. Check shock absorbers and mounting

hardware for looseness or damage.
Replace damaged components, if autho-
rized.
0021 00-14
TM 9-2320-302-20

LOCATION
ITEM TO
28 Semi- Front Axle Brake Lubricate grease fitting (19) at each slack
annual Components, adjuster with grease (Item 15, WP 0235 00)
Slack Adjusters until new grease flows from pressure relief
valve in pawl capscrew (20).
20
19
29 Semi- Front Axle Brake Lubricate grease fitting (21) at each camshaft
annual Components, bracket with grease (Item 15, WP 0235 00).
Camshaft
Bushings
21
0021 00-15
TM 9-2320-302-20

LOCATION
ITEM TO
30 Semi- Drivelines a. Check for looseness or side play in front

annual and rear drivelines. There should be no
play at U-joints. Check for bends, cracks,
and missing weights. Make repairs as
needed.
b. Check that U-joint mounting screw torque
is 33-38 lb-ft (44-52 Nm).
c. Inspect for loose or worn bearings, dam-
aged seals, and damaged or missing grease
fittings. Make repairs as needed.
d. Using a hand-type grease gun, lubricate
five grease fittings (22) at each driveline
with grease (Item 15, WP 0235 00) until
purging takes place at air hole in end of
slip yoke. Cover pressure relief hole while
lubricating.
e. Inspect for damaged or leaking input or
output shaft seals (23). If damaged or leak-
ing, notify Direct Support Maintenance.
22
23
22
31 Semi- Rear Axles, a. Inspect spring pack for cracks or breaks.

annual Suspension
b. Inspect spring pack and attaching hard-
ware for looseness, cracks, or other dam-
age. Tighten or replace damaged compon-
ents, if authorized.
0021 00-16
TM 9-2320-302-20

LOCATION
ITEM TO
31 Semi- Rear Axles, c. Check torque rod rubber bushings for

(Con’t) annual Suspension splitting or deterioration. Notify Direct
Support Maintenance of any damage
found.
d. Check shock absorbers and mounting
hardware for looseness or damage.
Replace damaged component, if autho-
rized.
32 Semi- Rear Axle Brake a. Check length of spring brake chamber
annual Components, push rods. Minimum length must be 1/2 in
Slack Adjusters (12.7 mm). If not, adjust slack adjusters.
b. Lubricate grease fitting (24) at each slack

adjuster with grease (Item 15, WP
0235 00) until new grease flows from
pressure relief valve in pawl capscrew (25).
25
24
0021 00-17
TM 9-2320-302-20

LOCATION
ITEM TO
33 Semi- Rear Axle Brake Lubricate grease fitting (26) at each camshaft
annual Components, bracket with grease (Item 15, WP 0235 00).
Camshaft
Bushings
26
NOTE
Resinstall breather with tube detente toward wheel end of axle to prevent
leakage.
34 Semi- Rear Axles, Remove breather (27) from each axle. Clean
annual Breathers and reinstall.
27
Breather Tube
Detente
0021 00-18
TM 9-2320-302-20

LOCATION
ITEM TO
35 Semi- Rear Axles, Use socket (Item 29, WP 0236 00) to remove
annual Differentials filler plugs (28) and check level of fluid in
differentials. When housing is cold, level
should be even with bottom of filler plug
opening. As required, add gear lubricating oil
(Item 22 through 25, WP 0235 00). Install
filler plugs.
28
28
36 Semi- Rear of Vehicle, a. Lubricate four pintle hook grease fittings

annual Pintle Hook (29) with grease (Item 15, WP 0235 00).
b. Check pintle hook (30) for proper opera-
tion. Ensure that mounting hardware is
tight.
29 30
0021 00-19
TM 9-2320-302-20

LOCATION
ITEM TO
37 Semi- Cab Check seats and seat belts for loose mount-
annual Compartment, ings and damage. Replace seat/seat mounts if
Seats and Seat damaged. Replace seat belts if any seat belt
Belts system shows cuts, fraying, extreme wear,
abrasions to seat belt webbing or damage to
buckle or latch plate retractor hardware.
38 Annual Engine a. Test, drain, and refill cooling system in
Compartment, accordance with TB 750-651.
Cooling System b. Change water filter element.
39 Annual Air Dryer Service air dryer.
40 Annual Transmission Drain transmission fluid, replace filters, and
refill (WP 0123 00).
41 Annual Rear Axles, a. Use socket (Item 29, WP 0236 00) to
Differentials remove plugs (31) and drain fluid while
assemblies are still warm from operation.
Check magnetic drain plugs for excessive
metal particle buildup. Notify Direct Sup-
port Maintenance if this condition exists.
Clean plugs.
31
31
0021 00-20
TM 9-2320-302-20

LOCATION
ITEM TO
41 Annual Rear Axles, NOTE

(Con’t) Differentials
There may be approximately 1 pt (0.47 l) of lubricant remaining in filter ele-
ment. Be careful not to spill it when removing element.
b. Use a suitable filter strap wrench to
replace filter element (32) from forward-
rear axle differential.
c. Install plugs (31) and fill differentials with
gear lubricating oil (Item 22 through 25,
WP 0235 00) until level is even with filler
plug (28) openings. Use the following
capacities as a guide. Do not overfill:
Forward-rear 13 qt (12.3 l)
Rear-rear 14.5 qt (13.7 l)
28
32
31
42 Annual Front and Rear Remove, clean, inspect, pack, install, and
Wheels, adjust wheel bearings.
Wheel Bearings
43 Annual Front and Rear Check brakeshoe linings for a minimum
Wheels, thickness of 1/4 in (6.5 mm). Replace worn
Brakeshoe or damaged brakeshoes.
Linings
44 Annual Front Axle, Check front axle stop cushions for wear or
Stop Cushions deterioration.
45 Annual Data Plates Check data plates to ensure legibility.
46 Annual Collision Align CWS antenna (WP 0110 00).
Warning System
(CWS)
0021 00-21
TM 9-2320-302-20
Table 2. PMCS Mandatory Replacement Parts List.
ITEM
NO. PART NUMBER NSN NOMENCLATURE QTY
Semiannual
1 83213D 4330-01-330-8203 Power steering reservoir, filter element 1
2 R90-DDC-01TP916 2910-01-022-8183 Fuel filter, filter elements 2

(OEM)
3 25010495 2940-01-197-7106 Engine oil, filter element, fullflow 2
Annual
4 3280-V-8394 2940-00-586-4792 Forward-rear differential, filter element 1
5 35066 5330-01-149-9677 Front axle, oil seal 2
6 47697 Forward-rear axle, oil seal 2
7 47697 Rear-rear axle, oil seal 2
8 KAF953 4330-01-332-6058 Air dryer, canister cartridge kit 1
9 WF-2077 2910-01-274-1915 Water filter, filter element 1
10 29526899 Transmission, filter kit (first 5,000 miles 1

thereafter 25,000 miles or 18 months)
0021 00-22
TM 9-2320-302-20
OIL FILL TUBE MAINTENANCE 0022 00
Oil Fill Tube Cap Removal, Oil Fill Tube Removal, Oil Filler Hole Cover and Gasket Removal, Oil Filler Hole Cover and
Gasket Installation, Oil Fill Tube Installation, Oil Fill Tube Cap Installation
INITIAL SETUP
Tools and Special Tools Materials/Parts - Continued

Tool kit, general mechanic’s (Item 36, WP 0236 00) Compound, sealing, pipe (Item 10, WP 0235 00)
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00)
Rags, wiping (Item 28, WP 0235 00)
Materials/Parts
Gasket (P/N 8929302) References
Nut, lock (P/N MS51922-1) TM 9-2320-302-10
OIL FILL TUBE CAP REMOVAL
Remove screw (1) and oil fill tube cap (2) from oil fill tube (3).
1
2
0022 00-1
TM 9-2320-302-20
OIL FILL TUBE MAINTENANCE - CONTINUED 0022 00
OIL FILL TUBE REMOVAL

1. Remove lock nut (4), two washers (5), screw (6), and clamp (7) from standoff bracket (8). Discard lock nut.
2. Loosen two hose clamps (9) and remove filler tube (3) and hose (10) from pipe coupling (11).
NOTE
Perform step 3 only if standoff bracket is damaged.
3. Remove screw (12),washer (13), and standoff bracket (8) from engine block (14).
1
2
8 5 3
4
5
13
6
12
7
10
14 11
15
17
18
16
OIL FILLER HOLE COVER AND GASKET REMOVAL

1. Remove pipe coupling (11) and nipple (15) from oil filler hole cover (16).
2. Remove four screws (17), oil filler hole cover (16), and gasket (18) from engine block (14). Discard gasket.
OIL FILLER HOLE COVER AND GASKET INSTALLATION
NOTE
Ensure that all old gasket material has been removed from mounting surfaces.
0022 00-2
TM 9-2320-302-20
OIL FILL TUBE MAINTENANCE - CONTINUED 0022 00
OIL FILLER HOLE COVER AND GASKET INSTALLATION - CONTINUED

1. Install new gasket (18) and oil filler hole cover (16) on engine block (14) with four screws (17). Torque screws to 22-28
lb-ft (30-38 Nm).
WARNING
2. Lightly coat threads of pipe nipple (15) with pipe sealing compound. Install pipe nipple and pipe coupling (11) on oil
filler hole cover (16).
OIL FILL TUBE INSTALLATION
NOTE
Perform step 1 only if standoff bracket was removed.
1. Install standoff bracket (8) on engine block (14) with washer (13) and screw (12).
2. Position two hose clamps (9) and hose (10) on pipe coupling (11). Tighten lower hose clamp.
3. Position upper hose clamp (9) on filler tube (3) and install filler tube on hose (10). Tighten upper hose clamp.
4. Install clamp (7) on standoff bracket (8) and secure in place with screw (6), two washers (5) and new lock nut (4).
OIL FILL TUBE CAP INSTALLATION.
1. Install oil fill tube cap (2) on oil fill tube (3).
2. Secure oil fill tube cap (2) retaining chain on oil fill tube (3) with screw (1).
END OF WORK PACKAGE
0022 00-3
TM 9-2320-302-20
0022 00-4
TM 9-2320-302-20
OIL LEVEL DIPSTICK, TUBE, AND ADAPTER REPLACEMENT 0023 00
Removal, Installation
INITIAL SETUP
Tools and Special Tools References

Tool kit, general mechanic’s (Item 36, WP 0236 00) TM 9-2320-302-10
Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00) Equipment Condition
Materials/Parts Transmission oil cooler removed (WP 0127 00)
Nut, lock (P/N MS51922-1)
Compound, sealing, pipe (Item 10, WP 0235 00)
REMOVAL
1. Turn oil level dipstick (1) counterclockwise and remove from dipstick tube (2).
2. Remove lock nut (3), two washers (4), and screw (5) from cable clamp (6) to standoff bracket (7). Discard lock nut.
3. Separate cable clamp (6) from standoff bracket (7).
4. Remove dipstick tube (2) from engine block adapter (8).
5. Remove engine block adapter (8) from engine block (9).
11
9
7 12
3 4
11
1
10
4
5 2
6
8
0023 00-1
TM 9-2320-302-20
OIL LEVEL DIPSTICK, TUBE AND ADAPTER REPLACEMENT 0023 00
REMOVAL- CONTINUED
NOTE
Perform step 6 only if standoff bracket is damaged.
6. Remove lock nut (10), two washers (11), screw (12), and standoff bracket (7) from engine block (9). Discard lock nut.
INSTALLATION
NOTE
Perform step 1 only if standoff bracket was removed.
1. Install standoff bracket (7) on engine block (9) with two washers (11), screw (12), and new lock nut (10).
WARNING
2. Lightly coat threads of engine block adapter (8) with pipe sealing compound. Install engine block adapter in engine
block (9). Tighten engine block adapter to 168-216 lb-in (19-24 Nm).
3. Position cable clamp (6) on dipstick tube (2).
4. Install dipstick tube (2) on engine block adapter (8).
5. Install cable clamp (6) on standoff bracket (7) with screw (5), two washers (4), and new lock nut (3).
6. Insert oil level dipstick (1) into dipstick tube (2) and turn clockwise until locked.
9 11
3 7 12
4
11
1
10
4
5 2
6
8
7. Install transmission oil cooler (WP WP 0127 00).
END OF WORK PACKAGE
0023 00-2
TM 9-2320-302-20
OIL FILTER ELEMENT REPLACEMENT 0024 00
INITIAL SETUP
Tools and Special Tools Materials/Parts

Tool kit, general mechanic’s (Item 36, WP 0236 00) Element, full flow filter (P/N PF 2100) (2)
Pan, drain (Item 25, WP 0236 00) Oil, lubricating (Item 20, WP 0235 00)
Wrench, strap (Item 42, WP 0236 00) Rags, wiping (Item 28, WP 0235 00)
References
TM 9-2320-302-10
REMOVAL
WARNING
Hot oil can cause serious burns. Allow engine to cool before changing oil filter elements. Engine oil is very
slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.
NOTE
Oil filter element replacement should be performed on a warm engine.
0024 00-1
TM 9-2320-302-20
OIL FILTER ELEMENT REPLACEMENT - CONTINUED 0024 00
REMOVAL - CONTINUED
1. Place drain pan under two filter elements (1) to catch oil.
2. Remove two filter elements (1) with gaskets (2) from oil cooler adapter (3). Discard oil filter elements and gaskets.
INSTALLATION
1. Lightly coat two new gaskets (2) with clean lubricating oil.
2. Fill two new oil filter elements (1) with clean lubricating oil.
CAUTION
DO NOT use filter wrench for installation. Failure to follow this caution will result in damage to new filter.
3. Install oil filter elements (1) on oil cooler adapter (3) by hand until gaskets (2) touch oil cooler adapter.
4. Tighten oil filter elements (1) an additional 2/3 turn.
5. Operate engine and check for leaks (TM 9-2320-302-10).
6. Check oil level and add oil if required (TM 9-2320-302-10).
END OF WORK PACKAGE
0024 00-2
TM 9-2320-302-20
OIL COOLER AND OIL FILTER ADAPTER MAINTENANCE 0025 00
Removal, Disassembly, Assembly, Installation
INITIAL SETUP
Oil, lubricating (Item 19, WP 0235 00)
References
Materials/Parts
TM 9-2320-302-10
Gasket (P/N 23506247)
Equipment Condition
O-ring (P/N 8929289)
Oil filters removed (WP 0024 00)
Retainer, packing (P/N 8929341) (3) Radiator drained (WP 0041 00)
Seal, plain (P/N 23505902) Exhaust pipe removed for access (WP 0040 00)
REMOVAL
NOTE
Oil cooler and oil filter adapter are removed and replaced as a single unit.
1. Loosen four hose clamps (1 and 2) and remove two inlet hoses (3 and 4) and coolant pipe (5) from oil cooler (6) and
water pump (7).
6 1
5
4 7
0025 00-1
TM 9-2320-302-20
OIL COOLER AND OIL FILTER ADAPTER MAINTENANCE - CONTINUED 0025 00
REMOVAL - CONTINUED
2. Loosen two hose clamps (8) and remove two hoses (9) from hose fittings (10).
3. Remove three mounting bolts (11), bolt (13), and oil filter adapter (12) from engine block (14).
14
8 10
9
10
13
12
11
DISASSEMBLY
1. Remove seal ring (15) from oil cooler (6). Discard seal ring.
2. Remove o-ring (16) and retainer packing (17) from oil filter adapter (12). Discard o-ring and retainer packing.
3. Remove seven long bolts (18), three short bolts (19), and oil cooler (6) from oil filter adapter (12).
15
6 18
19 22
21
16
20 17
12
0025 00-2
TM 9-2320-302-20
DISASSEMBLY - CONTINUED
4. Remove two retainer packings (20) from oil filter adapter (12). Discard retainer packings.
5. Remove core (21) and gasket (22) from oil cooler (6). Discard gasket.
6. Remove three pipe plugs (23) and two hose fittings (10) from oil cooler (6).
10 23
23
7. Remove five pipe plugs (24) from oil filter adapter (12).
12
24
24
24
ASSEMBLY
WARNING
1. Lightly coat threads of five pipe plugs (24) with pipe sealing compound. Install pipe plugs in oil filter adapter (12).
0025 00-3
TM 9-2320-302-20
ASSEMBLY - CONTINUED
2. Lightly coat threads of two hose fittings (10) and three pipe plugs (23) with pipe sealing compound. Install hose fittings
and pipe plugs in oil cooler (6).
3. Lightly coat two retainer packings (20) with lubricating oil. Install retainer packings in oil filter adapter (12).
CAUTION
Ensure that all old gasket material is removed from core and oil cooler mating surfaces. Failure to follow
this caution could result in damage to engine.
4. Install new gasket (22) and core (21) in oil cooler (6).
CAUTION
Ensure retainer packings are not dislodged when installing oil cooler on oil filter adapter. Failure to follow
this could result in damage to engine.
5. Install oil cooler (6) on oil filter adapter (12) with seven long bolts (18) and three short bolts (19). Hand tighten bolts to
secure oil cooler (6) to oil filter adapter (12).
6. Torque seven long bolts (18) and three short bolts (19) to 22-28 lb-ft (30-38 Nm) in sequence shown.
15
6 18
19 22
21
16
20 17
12
7. Lightly coat new seal ring (15) with clean lubricating oil. Install seal ring on oil cooler (6).
8. Lightly coat new o-ring (16) and new retainer packing (17) with clean lubricating oil. Install o-ring and retainer packing
on oil filter adapter (12).
0025 00-4
TM 9-2320-302-20
INSTALLATION
14
8 10
9
10
6
13
12
11
NOTE
It may be necessary to tap neck of oil cooler housing with plastic or fiber mallet to force seal ring (15) into
engine block opening.
1. Install oil cooler (6) on engine block (14) with bolt (13) and three bolts (11). Torque bolts to 43-54 lb-ft (58-73 Nm).
2. Install two hoses (9) on hose fittings (10) with two hose clamps (8).
3. Install coolant pipe (5) and two inlet hoses (3 and 4) on oil cooler (6) and water pump (7) with four clamps (1 and 2).
5
4
7
0025 00-5
TM 9-2320-302-20
INSTALLATION - CONTINUED
4. Install exhaust pipe (WP 0040 00).

5. Fill radiator and cooling system (WP 0041 00).
6. Install oil filters (WP 0024 00).
END OF WORK PACKAGE
0025 00-6
TM 9-2320-302-20
OIL SAMPLE VALVES REPLACEMENT 0026 00
INITIAL SETUP

Materials/Parts
Nut, self-locking (P/N MS51922-33)
NOTE
Engine and transmission oil sample valves are replaced the same way. Engine oil sample valve is illustrated.
REMOVAL
1. Disconnect hose (1) from connector (2).

2. Remove connector (2) and bushing (3) from oil cooler.
3. Remove hose (1) from elbow (4).
4. Remove elbow (4) and sample valve (5) from bracket (6).
5. Remove lock nut (7), washer (8), screw (9), washer (10), and bracket (6) from mounting bracket (11). Discard lock nut.
6
5
11
9 8
1 10 7
2
3
0026 00-1
TM 9-2320-302-20
OIL SAMPLE VALVES REPLACEMENT - CONTINUED 0026 00
INSTALLATION
1. Install bracket (6) on mounting bracket (11) with washer (10), screw (9), washer (8), and new lock nut (7).
WARNING
2. Lightly coat threads of sample valve (5) and elbow (4) with pipe sealing compound. Install sample valve and elbow on
bracket (6).
3. Connect hose (1) to elbow (4).
4. Lightly coat threads of bushing (3) and connector (2) with pipe sealing compound. Install bushing and connector on oil
cooler.
5. Connect hose (1) to connector (2).
6
5
11
9
8 7
1 10
2
3
END OF WORK PACKAGE
0026 00-2
TM 9-2320-302-20
AIR COMPRESSOR DISCHARGE HOSE REPLACEMENT 0027 00
INITIAL SETUP

Materials/Parts Equipment Condition

Nut, lock (P/N MS51922-1) Air system drained (TM 9-2320-302-10)
Transmission tunnel access cover removed (WP
0207 00)
REMOVAL
1. Remove discharge hose (1) from air compressor elbow fitting (2).
2. Remove lock nut (3), screw (4), washer (5), and clamp (6) from mounting bracket (7). Discard lock nut.
3. Remove screw (8), washer (9), and mounting bracket (7) from engine block (10).
4. Remove nut (11), washer (12), and two hose clamps (13) and (14) from standoff bracket (15)
5. Reinstall hose clamp (13) on standoff bracket (15) with washer (12) and nut (11).
1 4
2 10
5
16
6 15
7 14
9
3
1
13 17
8 12
11
NOTE
Discharge hose from compressor to air dryer is routed in a continuous downward slope to prevent collection
of moisture in line. Hose clamps, secured to standoff mounting brackets at 12-20 in (30-51 cm) intervals, are
used to secure compressor discharge hose and other hoses in place. Replace damaged standoff bracket as
required.
6. Remove discharge hose (1) and inline fitting (16) from air dryer hose (17).
0027 00-1
TM 9-2320-302-20
AIR COMPRESSOR DISCHARGE HOSE REPLACEMENT - CONTINUED 0027 00
INSTALLATION
1. Install inline fitting (16) and discharge hose (1) on air dryer hose (17).
NOTE
Replace defective or damaged hose clamps and standoff mounting brackets as necessary to ensure discharge
hose maintains a downward slope from compressor to air dryer.
2. Remove nut (11), washer (12), and hose clamp (13) from standoff bracket (15).
3. Install two hose clamps (13 and 14) on standoff bracket (15) with washer (12) and nut (11).
4. Install mounting bracket (7) on engine block (10) with washer (9) and screw (8).
5. Install hose clamp (6), with discharge hose (1) attached, on mounting bracket (7) with washer (5), screw (4), and new
locknut (3).
6. Install air compressor discharge hose (1) on air compressor elbow fitting (2).
1 4
2 10
5
16
6 15
7 14
9
3
1
13 17
8 12
11
7. Start vehicle and allow air pressure to build (TM 9-2320-302-10). Check system for air leaks.
8. Install transmission tunnel access cover (WP 0207 00).
END OF WORK PACKAGE
0027 00-2
TM 9-2320-302-20
AIR COMPRESSOR GOVERNOR REPLACEMENT AND ADJUSTMENT 0028 00
Removal, Installation, Adjustment
INITIAL SETUP
Tools and Special Tools Personnel Required

Tool kit, general mechanic’s (Item 36, WP 0236 00) Two
Materials/Parts References
Washer, lock (P/N MS35333-41) (2)
TM 9-2320-302-10
Rags, wiping (Item 28, WP 0235 00) Equipment Condition
Tags, marker (Item 31, WP 0235 00) Air system drained (TM 9-2320-302-10)
REMOVAL
NOTE
Tag lines to an aid in installation.
1. Remove two lines (1) from elbows (2).
2. Remove two screws (3), lock washers (4), governor (5), and gasket (6) from air compressor. Discard lock washers.
3. Remove two elbows (2) from governor (5).
6
5
1
4
3
0028 00-1
TM 9-2320-302-20
AIR COMPRESSOR GOVERNOR REPLACEMENT AND ADJUSTMENT - CONTINUED 0028 00
INSTALLATION
WARNING
• Adhesives and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin
and clothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If
adhesive or sealing compound contacts skin or clothing, wash immediately with soap and water.
• Ensure that all airlines and fittings are free of debris and excess pipe sealing compound does not enter
airlines or fittings. Failure to follow this warning could result in injury to personnel and damage to
equipment.
1. Lightly coat threads of two elbows (2) with pipe sealing compound. Install elbows in governor (5).
2. Install new gasket (6) and governor (5) on compressor with two new lock washers (4) and screws (3).
3. Install two air lines (1) on elbows (2).
6
5
2
1
4
3
NOTE
Perform step 4 through 6 to verify correct operation of air compressor and governor.
4. Start vehicle (TM 9-2320-302-10). Check for air leaks.
5. Check air pressure gages when governor cuts out, stopping compression of air by compressor. Cut-out pressure should
be 115-120 psi (793-827 kPa).
6. With engine running, make a series of brake applications to reduce air pressure. Observe air pressure gages when gover-
nor cuts in compressor. Cut-in pressure should be 95-100 psi (655-690 kPa).
NOTE
Air pressure operating range is 90-120 psi (621-827 kPa). If air pressure gages do not indicate within operat-
ing range, governor requires adjustment.
0028 00-2
TM 9-2320-302-20
AIR COMPRESSOR GOVERNOR REPLACEMENT AND ADJUSTMENT - CONTINUED 0028 00
ADJUSTMENT
1. Remove cover (7) from governor (5).
2. Loosen adjusting screw lock nut (8).
5
7
NOTE
Pressure range between compressor cut-in and cut-out is not adjustable. To raise pressure settings, turn
adjusting screw counterclockwise. To lower pressure settings, turn adjusting screw clockwise.
3. While assistant monitors primary pressure gage, turn adjusting screw (9) until proper cut-out pressure is obtained. When
proper pressure is reached, tighten adjusting screw lock nut (8).
4. Install cover (7) on governor (5).
END OF WORK PACKAGE
0028 00-3
TM 9-2320-302-20
0028 00-4
TM 9-2320-302-20
AIR COMPRESSOR REPLACEMENT 0029 00

INITIAL SETUP

Grease, GAA (Item 15, WP 0235 00)
Wrench, box (Item 41, WP 0236 00)
Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00) Personnel Required
Two
References
TM 9-2320-302-10
Materials/Parts
Equipment Condition
Gasket (P/N 5110410)
Cooling system drained (WP 0041 00)
Gasket (P/N 8929299) Fuel pump removed (WP 0034 00)
Washer, lock (P/N MS35338-45) (2) Air compressor governor removed (WP 0028 00)
REMOVAL
1. Loosen hose clamp (1) and remove air inlet hose (2) from pipe flange (3).
2. Remove air supply hose (4) from elbow (5).
2
1 4
3
5
0029 00-1
TM 9-2320-302-20
AIR COMPRESSOR REPLACEMENT - CONTINUED 0029 00
REMOVAL - CONTINUED
3. Remove oil supply hose (6) from elbow (7).

4. Loosen hose clamp (8) and remove coolant outlet hose (9) from elbow (10).
5. Loosen two hose clamps (11) and remove coolant inlet hose (12) from elbows (13 and 14).
6. Remove elbow (13) from engine block (15).
7. Remove two bolts (16), bolts (17), and support bracket (18) form air compressor (19).
8. Remove bolt (20) and four bolts (21) from air compressor (19).
2
1 4
3
5
11 19
11 12 14
15 9
13
8
16
10
22
20
17
7 18
23
24
6
21
WARNING
Air compressor is heavy. Use caution during removal to prevent injury to personnel.
9. With assistance, support air compressor (19) and remove nut (22) from threaded stud (23).
10. Remove air compressor (19) and gasket (24) by sliding air compressor rearward off of threaded stud (23). Discard gas-
ket.
11. Remove four elbows (5, 7, 10, and 14) from air compressor (19).
12. Remove two bolts (25), lock washers (26), pipe flange (3), and gasket (27) from air compressor (19). Discard lock wash-
ers and gasket.
0029 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
3
26
27 5
10
25
14
19
7
INSTALLATION
WARNING
adhesive or sealing compound contacts skin or clothing, wash immediately with soap and water.
• Ensure that all airlines and fittings are free of debris and excess pipe sealing compound does not enter
airlines or fittings. Failure to follow this warning could result in injury to personnel and damage to
equipment.
1. Lightly coat pipe threads of elbows (5, 7, 10, and 14) with pipe sealing compound. Install elbows on air compressor
(19).
2. Install new gasket (27) and pipe flange (3) on air compressor (19) with two new lock washers (26) and bolts (25).
Torque bolts to 156-204 lb-in (18-23 Nm).
3. Apply a light coat of grease to bolt hole locations on new gasket (24). Install gasket on air compressor (19).
0029 00-3
TM 9-2320-302-20
WARNING
Air compressor is heavy. Use caution during installation to prevent injury to personnel.
4. Slide air compressor (19) over threaded stud (23) and install nut (22). Hand tighten nut.
5. Install four bolts (21) and one bolt (20) on air compressor (19). Hand tighten bolts.
6. Torque nut (22), four bolts (21), and bolt (20) to 75-93 lb-ft (101-126 Nm).
7. Install support bracket (18) on air compressor (19) with two bolts (16). Hand tighten bolts.
8. Install two bolts (17) and torque to 43-45 lb-ft (58-73 Nm).
9. Torque two bolts (16) to 156-204 lb-in (18-23 Nm).
10. Install elbow (13) on engine block (15).
11. Slide two hose clamps (11) on coolant inlet hose (12) and position coolant inlet hose on elbows (13 and 14).
12. Slide one hose clamp (11) to each end of coolant inlet hose (12) and tighten.
13. Install oil supply hose (6) on elbow (7).
14. Slide hose clamp (8) on coolant outlet hose (9) and install coolant outlet hose on elbow (10). Tighten hose clamp.
15. Slide hose clamp (1) on air inlet hose (2) and install air inlet hose on pipe flange (3). Tighten hose clamp.
16. Install air supply hose (4) on elbow (5).
2
1 4
3
5
11 19
11 12 14
15 9
13
8
16
10
22
20
17
7 18
23
24
6
21
0029 00-4
TM 9-2320-302-20
17. Install air compressor governor (WP 0028 00).
18. Install fuel pump (WP 0034 00).
19. Fill cooling system (WP 0041 00).
END OF WORK PACKAGE
0029 00-5
TM 9-2320-302-20
0029 00-6
TM 9-2320-302-20
FUEL HOSES AND FITTINGS REPLACEMENT 0030 00
INITIAL SETUP

Pan, drain (Item 25, WP 0236 00) Equipment Condition
Materials/Parts Transmission tunnel access cover removed (WP
Nut, lock (P/N 23-09336-006) 0207 00)

Tags, marker (Item 31, WP 0235 00)
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or
sparks. Fuel may ignite, causing injury or death to personnel and damage to vehicle.
REMOVAL
NOTE
• Ensure that drain pan is positioned to catch fuel from fuel hoses. Ensure that all spills are cleaned up.
• Tag all fuel lines and hoses to aid in installation.
1. Remove fuel hose (1) from fuel tank (2).
2. Remove lock nut (3), screw (4), washer (5), clamp (6), and clamp (7) from transmission dipstick tube (8). Discard lock
nut.
3. Remove fuel hose (1) from check valve (9).
9 2
6
4 3
5
8
7
0030 00-1
TM 9-2320-302-20
FUEL HOSES AND FITTINGS REPLACEMENT - CONTINUED 0030 00
CAUTION
Elbow is a special orifice and should be handled carefully. Failure to follow this caution may result in dam-
age to equipment.
4. Remove fuel line (10) and special elbow (11) from cylinder head (12).
5. Remove check valve (9) from fuel line (10).
6. Disconnect fuel hose (13) and elbow (14) from cylinder head (12).
12
11
10
9 2
14
16 1
15
17 13
6
18 4 3
5
8
7
13
7. Remove screw (15) and clamp (16) from engine block (17).
8. Remove fuel hose (13) from check valve (18).
9. Remove fuel hose (19) from fuel tank (2) and from primary fuel filter (20).
10. Remove fuel hose (21) from primary fuel filter (20) and fuel pump (22).
11. Remove fuel hose (23) from fuel pump (22) and secondary fuel filter (24).
12. Disconnect fuel hoses (25 and 26) from fuel pressure sensor (27) and secondary fuel filter (24).
0030 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
27
22
2
25
23
26
23
24
20
19 21
26
INSTALLATION
1. Install fuel hoses (25 and 26) on secondary fuel filter (24) and fuel pressure sensor (27).
2. Install fuel hose (23) to secondary fuel filter (24) and fuel pump (22).
3. Install fuel hose (21) to fuel pump (22) and primary fuel filter (20).
4. Install fuel hose (19) to primary fuel filter (20) and fuel tank (2).
5. Install fuel hose (13) on check valve (18).
6. Install fuel hose (13) to engine block (17) with clamp (16) and screw (15).
WARNING
7. Lightly coat threads of elbow (14) with pipe sealing compound. Install elbow on cylinder head (12).
8. Install fuel hose (13) on elbow (14).
9. Install check valve (9) on fuel line (10).
0030 00-3
TM 9-2320-302-20
WARNING
10. Lightly coat threads of special elbow (11) and fuel line (10) with pipe sealing compound. Install special elbow and fuel
line on cylinder head (12).
11. Install fuel hose (1) on check valve (9).
12. Install fuel hoses (1 and 19) on transmission dipstick tube (8) with clamps (6 and 7), washer (5), screw (4), and new lock
nut (3).
13. Install fuel hose (1) on fuel tank (2).
12
11
10
9 2
14
16 1
15
13
17 6
18 4 3
5
8 7
13

15. Prime fuel system (TM 9-2320-302-10).
END OF WORK PACKAGE
0030 00-4
TM 9-2320-302-20
FUEL STRAINER AND FILTER ELEMENT REPLACEMENT 0031 00
Fuel Strainer Element Removal, Fuel Filter Element Removal, Fuel Filter Element Installation, Fuel Strainer Element
Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Fuel, diesel (Item 14, WP 0235 00)
Pan, drain (Item 25, WP 0236 00)
Materials/Parts
Element, strainer (P/N OEM R60P) References
Element, Filter (P/N TP916) TM 9-2320-302-10
FUEL STRAINER ELEMENT REMOVAL
1. Turn fuel shut-off valve (1) to OFF position.
WARNING
sparks. Fuel may ignite, causing injury or death to personnel and damage to equipment.
0031 00-1
TM 9-2320-302-20
FUEL STRAINER AND FILTER ELEMENT REPLACEMENT - CONTINUED 0031 00
FUEL STRAINER ELEMENT REMOVAL - CONTINUED
NOTE
Ensure that drain pan is positioned to catch fuel. Ensure that all spills are cleaned up.
2. Remove plug (2) from sediment bowl (3) and allow fuel to drain.
3. Remove sediment bowl (3) and gasket (4) from strainer element (5).
4. Remove strainer element (5) and gasket (6) from adapter (7). Discard strainer element and gasket.
5
10
4
9
3 8 1
2
FUEL FILTER ELEMENT REMOVAL
1. Turn fuel shut-off valve (1) to OFF position.
WARNING
2. Remove filter element (8) and gasket (9) from adapter (10). Discard filter element and gasket.
FUEL FILTER ELEMENT INSTALLATION
1. Lightly coat new gasket (9) with lubricating oil. Set gasket aside.
2. Fill filter element (8) 2/3 full with clean diesel fuel.
3. Install new gasket (9) and filter element (8) on adapter (10) until gasket just contacts adapter.
4. Tighten filter element (8) by hand additional 1/2 turn.
0031 00-2
TM 9-2320-302-20
FUEL STRAINER AND FILTER ELEMENT REPLACEMENT - CONTINUED 0031 00
FUEL STRAINER ELEMENT INSTALLATION

1. Lightly coat new gasket (6) with lubricating oil. Set gasket aside.
2. Install gasket (4) and plug (2) on sediment bowl (3).
3. Install sediment bowl (3) on new strainer element (5).
4. Fill strainer element (5) 2/3 full with clean diesel fuel.
5. Install gasket (6) and strainer element (5) on adapter (7) until gasket just contacts adapter.
6. Tighten strainer element (5) by hand an additional 1/2 turn.
7. Turn fuel shut-off valve (1) to ON position.
8. Prime fuel system (TM 9-2320-302-10).
END OF WORK PACKAGE
0031 00-3
TM 9-2320-302-20
0031 00-4
TM 9-2320-302-20
FUEL FILTER ADAPTERS REPLACEMENT 0032 00
Fuel Strainer Adapter Removal, Fuel Filter Adapter Removal, Fuel Filter Adapter Installation, Fuel Strainer Adapter
Installation
INITIAL SETUP
Tools and Special Tools Equipment Condition

Tool kit, general mechanic’s (Item 36, WP 0236 00) Fuel strainer and filter elements removed (WP
0031 00)
Fuel hoses and fittings removed (WP 0030 00)
FUEL STRAINER ADAPTER REMOVAL
WARNING
1. Remove two screws (1), fuel strainer adapter (2), and spacer plate (3) from left side of engine.
2. Remove elbow (4), two elbows (5), and plug (6) from fuel strainer adapter (2).
1
3
4
5
6
2
5
0032 00-1
TM 9-2320-302-20
FUEL FILTER ADAPTERS REPLACEMENT - CONTINUED 0032 00
FUEL FILTER ADAPTER REMOVAL
WARNING
sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.
1. Remove engine wiring harness connector (7) from fuel pressure sensor (8).
2. Remove two screws (9) and fuel filter adapter (10) from left side of engine.
3. Remove fuel pressure sensor (8), pipe tee (11), and pipe plug (12) from fuel filter adapter (10).
4. Remove elbow (13), fuel shut-off valve (14), and connector (15) from fuel filter adapter (10).
1
3
4 7
8
11
5
6 10
2 15
14
5
13
12
FUEL FILTER ADAPTER INSTALLATION
1. Install connector (15), fuel shut-off valve (14), and elbow (13) on fuel filter adapter (10).
2. Install pipe plug (12), pipe tee (11), and fuel pressure sensor (8) on fuel filter adapter (10).
3. Install fuel filter adapter (10) on left side of engine with two screws (9).
4. Install engine wiring harness connector (7) on fuel pressure sensor (8).
5. Install fuel hoses and fittings (WP 0030 00).
6. Install fuel filter element (WP 0031 00).
0032 00-2
TM 9-2320-302-20
FUEL FILTER ADAPTERS REPLACEMENT - CONTINUED 0032 00
FUEL STRAINER ADAPTER INSTALLATION

1. Install plug (6), two elbows (5), and elbow (4) on fuel strainer adapter (2).
2. Install spacer plate (3) and fuel strainer adapter (2) on left side of engine with two screws (1).
NOTE
Perform following steps if one or both adapters were replaced.
3. Install fuel hoses and fittings (WP 0030 00).

4. Install fuel strainer element (WP 0031 00).
END OF WORK PACKAGE
0032 00-3
TM 9-2320-302-20
0032 00-4
TM 9-2320-302-20
FUEL TANK AND MOUNTING BRACKETS REPLACEMENT 0033 00
Fuel Tank Removal, Mounting Bracket Removal, Mounting Bracket Installation, Fuel Tank Installation
INITIAL SETUP

Equipment Condition
Materials/Parts
Pin, cotter (P/N MS24665-387) (2) Right step removed (WP 0171 00)
Rags, wiping (Item 28, WP 0235 00) Fuel level sending unit removed (WP 0094 00)
FUEL TANK REMOVAL
WARNING
• DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or
• Fuel vapors are toxic. Avoid prolonged exposure or breathing of fumes. Work in a well-ventilated area.
Failure to follow this warning could result in serious injury to personnel.
NOTE
Ensure that drain pan is positioned to catch fuel. Ensure that all spills are cleaned up.
1. Remove plug (1) and allow fuel to drain.

2. Remove two fuel hoses (2) and elbows (3) from fuel tank (4).
2
2
0033 00-1
TM 9-2320-302-20
FUEL TANK AND MOUNTING BRACKETS REPLACEMENT - CONTINUED 0033 00
FUEL TANK REMOVAL - CONTINUED
NOTE
Perform step 3 for each strap.
3. With assistance, support fuel tank (4) and remove two nuts (5) and washer (6). Loosen strap (7) and remove bracket
insulator (8) from fuel tank (4).
4. Move two straps (7) aside and remove fuel tank (4) from mounting brackets (9).
5. Compress spring clip (10) and remove filler cap (11).
19 12
18 13
14 17
16
5 10 11
20 6
4 15
MOUNTING BRACKET REMOVAL

1. Remove two cotter pins (12), nuts (13), washers (14), and straps (7) from two mounting brackets (9). Discard cotter
pins.
2. Remove two insulators (15) from straps (7).
3. Remove eight nuts (16), washers (17), screws (18), washers (19), and two mounting brackets (14) from frame rail (20).
0033 00-2
TM 9-2320-302-20
FUEL TANK AND MOUNTING BRACKETS REPLACEMENT - CONTINUED 0033 00
MOUNTING BRACKET INSTALLATION

1. Install two brackets (14) on frame rail (20) with eight washers (19), screws (18), washers (17), and nuts (16).
2. Install two insulators (15) on straps (7).
NOTE
Perform step 3 at far end of each bracket.
3. Install two straps (7) on mounting brackets (9) with washer (14), nut (13), and new cotter pin (12).
FUEL TANK INSTALLATION
1. Install filler cap (11) on fuel tank (4) with spring clip (10).
2. With assistance, position fuel tank (4) on two mounting brackets (9) and straps (7). Position ends of straps through
brackets.
3. Install two bracket insulators (8) on straps (7) with two washers (6) and four nuts (5).
4. Install two elbows (3) and hoses (2) on fuel tank (4).
5. Install plug (1) on fuel tank (4).
2
2
6. Install fuel level sending unit (WP 0094 00).

7. Install right step (WP 0171 00).
END OF WORK PACKAGE
0033 00-3
TM 9-2320-302-20
0033 00-4
TM 9-2320-302-20
FUEL PUMP REPLACEMENT 0034 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Gasket (P/N 23505248)
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Rags, wiping (Item 28, WP 0235 00)
References
TM 9-2320-302-10
REMOVAL
WARNING
1. Disconnect fuel inlet line (1).
2. Disconnect fuel pump-to-secondary fuel filter line (2).
3. Disconnect fuel pump-to-fuel water separator line (3).
4. Disconnect fuel pump lubrication line (4).
5. Remove elbow (5) from lubrication port of fuel pump (6).
5 1
6
10
3
2
0034 00-1
TM 9-2320-302-20
FUEL PUMP REPLACEMENT - CONTINUED 0034 00
REMOVAL - CONTINUED
6. Remove elbow (7), adapter (8), tee (9), and bushing (10) from outlet port of fuel pump (6).
7. Remove adapter (11) from inlet port of fuel pump (6).
8. Remove three bolts (12) securing fuel pump (6) to air compressor (13).
9. Remove fuel pump (6), drive coupling (14), and gasket (15). Discard gasket.
INSTALLATION
WARNING
1. Install adapter (11) in inlet port of fuel pump (6).
2. Install bushing (10), tee (9), adapter (8), and elbow (7) in outlet port of fuel pump (6).
3. Install elbow (5) to lubrication port of fuel pump (6).
4. Install new gasket (15) and drive coupling (14) on fuel pump (6).
NOTE
Fuel pump is correctly oriented for mounting when outlet fitting is in approximately 8 o’clock position as
viewed from rear. Drain opening in pump body is facing down.
13
15
14
11
5 1
6
10
12 7
9
8
3
2
5. Index drive coupling (14) with drive hub on end of air compressor (13) crankshaft and align fuel pump (6) mounting
holes with those in air compressor rear cover.
6. Seat fuel pump (6) squarely against the air compressor (13) and secure in place with three bolts (12).
0034 00-2
TM 9-2320-302-20
FUEL PUMP REPLACEMENT - CONTINUED 0034 00
7. Tighten mounting bolts (12) to 22-28 lb-ft (30-38 Nm).
8. Connect and tighten pump inlet line (1), fuel pump-to-secondary fuel filter line (2), fuel pump-to-fuel water separator
line (3), and pump lubrication line (4).
9. Prime fuel system and start vehicle (TM 9-2320-302-10). Check for proper operation of fuel pump.
END OF WORK PACKAGE
0034 00-3
TM 9-2320-302-20
0034 00-4
TM 9-2320-302-20
AUTOMATIC ETHER STARTING AID MAINTENANCE 0035 00
Fuel Cylinder Removal, Automatic Starting Aid Removal, Automatic Starting Aid Installation, Fuel Cylinder Installation
INITIAL SETUP

Materials/Parts
FUEL CYLINDER REMOVAL
WARNING
0035 00-1
TM 9-2320-302-20
AUTOMATIC ETHER STARTING AID MAINTENANCE - CONTINUED 0035 00
FUEL CYLINDER REMOVAL - CONTINUED

1. Loosen clamp (1) and unscrew fuel cylinder (2) from valve (3).
2. Remove gasket (4) from valve (3). Discard gasket.
AUTOMATIC STARTING AID REMOVAL
1. Disconnect main harness connector (5) from ether control relay harness connector (6).
2. Disconnect main harness connector (7) from harness connector (8).
3. Disconnect ether tube (9) from fitting (10).
NOTE
Fitting has left-hand threads. Turn right to remove fitting.
4. Remove fitting (10) from valve (3).
5. Disconnect ether tube (9) from atomizer (11) on intake manifold.
11
17 16 13
4 27
20
1 26
19
14
3
19 12 15
18 6
5
21
25
10 9 24
8
22 7
23
CAUTION
Note orientation of atomizer nozzle prior to removal. Orientation mark must be positioned so that orifice is
facing against air flow of intake manifold. This will ensure proper dispersal of ether. Failure to install atom-
izer nozzle with orifice orientated properly may cause damage to engine from improper dispersal of ether.
6. Remove atomizer (11) from intake manifold.
7. Remove four bolts (12), washers (13), nuts (14), and either control relay (15) from ether control relay bracket (16).
0035 00-2
TM 9-2320-302-20
AUTOMATIC STARTING AID REMOVAL - CONTINUED

8. Remove ether control relay bracket (16) from fuel cylinder bracket (17) by removing two bolts (18), four washers (19),
and two nuts (20) on right side of fuel cylinder bracket.
NOTE
• Valve with harness attached is permanently attached to fuel cylinder bracket.
• Remove fuel cylinder bracket only if damaged.
9. Remove two remaining bolts (18), four washers (19), two nuts (20), ground wire (21), and fuel cylinder bracket (17)
from frame bracket (22).
10. Remove three bolts (23), washers (24), nuts (25), and frame bracket (22) from frame.
AUTOMATIC STARTING AID INSTALLATION
1. Position frame bracket (22) on frame and install three bolts (23), washers (24), and nuts (25).
NOTE
Perform step 2 if fuel cylinder bracket was removed.
2. Position fuel cylinder bracket (17) on frame bracket (22) and install two bolts (18), ground wire (21), four washers (19)
and two nuts (20) on left side of bracket.
3. Position ether control relay bracket (16) on fuel cylinder bracket (17) and install remaining two bolts (18), four washers
(19), and two nuts (20).
4. Install clamp (1) on fuel cylinder bracket (17).
WARNING
NOTE
Fitting has left-hand threads. Turn left to install fitting.
5. Install fitting (10) on valve (3) with opening in fitting toward rear of vehicle.
6. Position ether control relay (15) on ether control relay bracket (16) and install four bolts (12), washers (13), and nuts
(14).
CAUTION
Orientation mark of atomizer nozzle must be positioned so that orifice is facing against air flow of intake
manifold. This will ensure proper dispersal of ether. Failure to install atomizer nozzle with orifice oriented
properly may cause damage to engine from improper dispersal of ether.
7. Install atomizer (11) on intake manifold.
0035 00-3
TM 9-2320-302-20
AUTOMATIC STARTING AID INSTALLATION - CONTINUED

8. Connect ether tube (9) to atomizer (11).
9. Connect ether tube (9) to fitting (10).
10. Connect ether control relay harness connector (6) to main harness connector (5).
11. Connect harness connector (8) to main harness connector (7).
12. Turn on ignition (TM 9-2320-302-10).
13. Red indicator light (26) on ether control relay (15) should be ON.
14. Run a magnet over plate (27) on ether control relay (15). Red indicator light (26) should go OFF.
FUEL CYLINDER INSTALLATION
NOTE
Replacement fuel cylinder comes with a new gasket.
1. Apply thin coat of lubricating oil to new gasket (4) and threads of new fuel cylinder (2).
2. Install gasket (4) and fuel cylinder (2) to valve (3). Tighten clamp (1).
3. Turn on ignition (TM 9-2320-302-10).
4. Red indicator light (26) on ether control relay (15) should be ON.
5. Run a magnet over plate (27) on ether control relay (15). Red indicator light (26) should go OFF.
11
17 16 13
4 27
20
1 26
19
14
3
19 12 15
18 6
5
21
25
10 9 24
8
22 7
23
END OF WORK PACKAGE
0035 00-4
TM 9-2320-302-20
AIR CLEANER, AIR INTAKE DUCT, AND TURBO BYPASS VALVE MAINTENANCE 0036 00
Air Cleaner Element Removal, Air Cleaner and Intake Duct Removal, Air Cleaner and Intake Duct Disassembly, Air
Cleaner and Intake Duct Assembly, Air Cleaner and Intake Duct Installation, Air Cleaner Element Installation, Turbo Bypass
Valve Replacement
INITIAL SETUP

Materials/Parts
Nut, lock (P/N MS51922-1) (6) References
Nut, lock (P/N MS51922-17) (4) TM 9-2320-302-10
WARNING
If NBC exposure is suspected, all air cleaner media should be handled by personnel wearing protective
equipment. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.
AIR CLEANER ELEMENT REMOVAL
Open engine compartment and release three latches (1) and remove air cleaner element (2) from air cleaner (3).
2
1
0036 00-1
TM 9-2320-302-20
AIR CLEANER, AIR INTAKE DUCT, AND TURBO BYPASS VALVE MAINTENANCE - CONTINUED 0036 00
AIR CLEANER AND INTAKE DUCT REMOVAL

1. Loosen hose clamps (4 and 5) and remove elbow (6) from air cleaner (3) and air duct tube (7).
2. Remove tubing (8) and adapter fitting (9) from tube assembly (10).
3. Remove screw (11), washer (12), lock nut (13), hose clamps (14 and 16), hose (15), and tube assembly (10) from air
intake duct assembly (17). Discard lock nut.
4. Support air cleaner (3) and remove four lock nuts (18), washers (19), screws (20), air cleaner (3), and air intake duct
assembly (7). Discard lock nuts.
10 11
9 12
16 13 17
15 18
14 20
19
6 19
4
5
20
0036 00-2
TM 9-2320-302-20
AIR CLEANER AND INTAKE DUCT DISASSEMBLY

Remove six lock nuts (21), washers (22), and air cleaner (3) from air intake duct assembly (17). Discard lock nuts.
21
17
22
3
AIR CLEANER AND INTAKE DUCT ASSEMBLY
CAUTION
Ensure air cleaner and air intake duct assembly have been thoroughly cleaned. DO NOT leave any dirt or
foreign matter inside air cleaner or air intake duct assembly. Dirt or other foreign matter may get into turbo-
charger or engine and cause damage to equipment.
Install air cleaner (3) on air intake duct assembly (17) with six washers (22) and new lock nuts (21).
AIR CLEANER AND INTAKE DUCT INSTALLATION
1. Install air cleaner (3) and intake duct assembly (17) with four new lock nuts (18), washers (19), and screws (20). Torque
lock nuts to 25-35 lb-ft (33-47 Nm).
2. Position hose clamps (14 and 16), hose (15), and tube assembly (10) on air intake duct assembly (17). Tighten hose
clamps.
3. Install screw (11), washer (12), and new lock nut (13) on tube assembly (10).
4. Install tube adapter (9) and tubing (8) on tube assembly (10).
5. Position elbow (6) and hose clamps (4 and 5) on air cleaner (3) and air duct tube (7). Tighten hose clamps.
0036 00-3
TM 9-2320-302-20
AIR CLEANER ELEMENT INSTALLATION

Install air cleaner filter element (2) on air cleaner (3) and close three latches (1).
2
1
TURBO BYPASS VALVE REPLACEMENT

1. Disconnect air line connector (23) from fitting (24).
2. Remove fitting (24), turbo bypass valve (25), and nipple (26) from air intake manifold (27).
3. Coat threads of fitting (24) and nipple (26) with pipe sealing compound and install nipple, turbo bypass valve (25) and
fitting on air intake manifold (27).
4. Connect air line connector (23) to fitting (24).
23
24
26
25
27
END OF WORK PACKAGE
0036 00-4
TM 9-2320-302-20
AIR INTAKE TUBES AND HOSES REPLACEMENT 0037 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock (P/N MS 51922-1)
References
TM 9-2320-302-10
REMOVAL
1. Remove lock nut (1), two washers (2), spacer (3), screw (4) and two clamps (5) from air intake tubes (6 and 7). Discard
lock nut.
2. Remove clamp (8) and reducer (9) from air cleaner (10).
3. Remove clamp (11) and reducer (9) from air intake tube (7).
4. Remove clamp (12) and air intake tube (7) from elbow (13). Remove pipe plug (14).
5. Remove clamp (15) and elbow (13) from turbocharger (16).
6. Remove four clamps (17), hose (18), and air intake tube (6) from turbocharger (16).
7. Remove four clamps (19), hose (20), and air intake tube (6) from charge air cooler (21).
8. Remove four clamps (22), hose (23), and air intake tube (24) from manifold (25).
9. Remove four clamps (26), hose (27), and air intake tube (24) from charge air cooler (21).
9
2 11 8
4 5 7 10
3
6
5
14
17
18
17
16
2 1
12
20 19 15 24
19
27 22 23
21 13
22
26
26
25
0037 00-1
TM 9-2320-302-20
AIR INTAKE TUBES AND HOSES REPLACEMENT - CONTINUED 0037 00
INSTALLATION
1. Install air intake tube (24) to charge air cooler (21) with hose (27) and four clamps (26).
2. Install air intake tube (24) to manifold (25) with hose (23) and four clamps (22).
3. Install air intake tube (6) to charge air cooler (21) with hose (20) and four clamps (19).
4. Install air intake tube (6) to turbocharger (16) with hose (18) and four clamps (17).
5. Install elbow (13) to turbocharger (16) with clamp (15).
6. Install pipe plug (14) to air intake tube (7) and install air intake tube to elbow (13) with clamp (12).
7. Install reducer (9) to air intake tube (17) with clamp (11).
8. Install reducer (9) to air cleaner (10) with clamp (8).
9. Install two clamps (5), screw (4), spacer (3), two washers (2) and new lock nut (1) to air intake tubes (6 and 7).
9
2 11 8
4 5 7 10
3
6
5
14
17
18
17
16
2 1
12
20 19 15 24
19
27 22 23
21 13
22
26
26
25
END OF WORK PACKAGE
0037 00-2
TM 9-2320-302-20
CHARGE AIR COOLER AND AIR RECIRCULATION SHIELD REPLACEMENT 0038 00
Charge Air Cooler Removal, Air Recirculation Shield Removal, Air Recirculation Shield Installation, Charge Air Cooler
Installation
INITIAL SETUP

Materials/Parts
Nut, lock (P/N 23-11020-006) (4)
CHARGE AIR COOLER REMOVAL
1. Remove two lock nuts (1), four washers (2), and two screws (3) from two side shields (4). Discard lock nuts.
2. Loosen four clamps (5) and remove two hoses (6) from charge air cooler (7) and air intake tubes (8).
CAUTION
Secure charge air cooler in position before performing steps 3 and 4. Failure to follow this warning will
result in damage to equipment.
3. Remove two lock nuts (9), screws (11), and washers (10) from charge air cooler (7). Discard lock nuts.
4. Remove two nuts (12), washers (13), and charge air cooler (7) from radiator (14).
7
6
12 3
2
13
9
5
4
14
9
10
11 2
0038 00-1
TM 9-2320-302-20
CHARGE AIR COOLER AND AIR RECIRCULATION SHIELD REPLACEMENT - CONTINUED 0038 00
AIR RECIRCULATION SHIELD REMOVAL

1. Remove four screws (15) and top shield (16) from radiator (14).
2. Remove six nuts (17) and two side shields (4) from radiator (14).
3. Remove four nuts (18), screws (19), and two brackets (20) from radiator (14).
4
14
17
4
16 20
17 15
19
20
18
AIR RECIRCULATION SHIELD INSTALLATION

1. Install two brackets (20) on radiator (14) with four screws (19) and nuts (18).
2. Install two side shields (4) on radiator (14) with six nuts (17).
3. Install top shield (16) on radiator (14) with four screws (15).
CHARGE AIR COOLER INSTALLATION
1. Install charge air cooler (7) on radiator (14) with two washers (13) and nuts (12).
2. Install two screws (11), washers (10), and new lock nuts (9) on charge air cooler (7).
3. Position two hoses (6) and four clamps (5) on air intake tubes (8) and charge air cooler (7). Tighten clamps.
4. Install two screws (3), four washers (2), and two new lock nuts (1) on side shields (4).
END OF WORK PACKAGE
0038 00-2
TM 9-2320-302-20
EXHAUST SYSTEM MUFFLER, STACK, AND HEAT SHIELD REPLACEMENT 0039 00
Heat Shield Removal, Exhaust Stack Removal, Muffler Removal, Muffler Mounting Brackets Removal, Muffler Mount-
ing Brackets Installation, Muffler Installation, Exhaust Stack Installation, Heat Shield Installation
INITIAL SETUP
Bushing (P/N 1449-380-55640) (4) TM 9-2320-302-10
Clamp, seal (P/N 04-19249-000)
Nut, lock (P/N 23-09900-108) (4)
WARNING
Allow exhaust sytem components to cool before performing maintenance. Handling hot exhaust system
components could cause serious burns.
HEAT SHIELD REMOVAL
1. With assistance, remove eight bolts (1), washers (2), and heat shield (3) from retaining clamps (4).
1 3
2 4
3
1 2
0039 00-1
TM 9-2320-302-20
EXHAUST SYSTEM MUFFLER, STACK, AND HEAT SHIELD REPLACEMENT - CONTINUED 0039 00
EXHAUST STACK REMOVAL

Remove four nuts (5), washers (6), two saddle clamps (7), and exhaust stack (8) from muffler (9).
MUFFLER REMOVAL
NOTE
Assistance is required to hold muffler steady while removing hardware.
1. Remove four nuts (10), washers (11), two saddle clamps (12), muffler (9), and seal clamp (13) from exhaust pipe. Dis-
card seal clamp.
2. Remove two nuts (14), bolts (15), and retaining clamps (4) from muffler (9).
6
5 18
7
8
6
19
17
7 15
21 17
2
4
16
14
9
11 1 3
10 12
15 4
20
3
19 14
17
21 12 2
1
17 16
13
MUFFLER MOUNTING BRACKETS REMOVAL

1. Remove four lock nuts (16), eight washers (17), four screws (18), and two muffler mounting brackets (19 and 20) from
vehicle. Discard lock nuts.
2. Remove four bushings (21) from two muffler mounting brackets (19 and 20). Discard bushings.
0039 00-2
TM 9-2320-302-20
EXHAUST SYSTEM MUFFLER, STACK, AND HEAT SHIELD REPLACEMENT - CONTINUED 0039 00
MUFFLER MOUNTING BRACKETS INSTALLATION

1. Position four new bushings (21) on mounting locations.
2. Install two muffler mounting brackets (19 and 20) with four screws (18), eight washers (17), and four new lock nuts
(16).
MUFFLER INSTALLATION
1. Install two retaining clamps (4) on muffler (9) with two bolts (15) and nuts (14).
NOTE
• New seal clamp may leak until exhaust system is thoroughly heated and sealed.
• Ensure muffler with heat shield retaining clamps are positioned to allow mounting of heat shield.
2. Install new seal clamp (13) and muffler (9) on exhaust pipe with two saddle clamps (12), four washers (11), and nuts
(10). Tighten seal clamp.
EXHAUST STACK INSTALLATION
NOTE
Ensure opening of exhaust stack is to the rear of the vehicle.
With assistance, install exhaust stack (8) on muffler (9) with two saddle clamps (7), four washers (6), and nuts (5).
HEAT SHIELD INSTALLATION
1. Ensure retaining clamps (4) are in place and secure.
2. With assistance, install heat shield (3) on retaining clamps (4) with eight washers (2) and bolts (1).
END OF WORK PACKAGE
0039 00-3
TM 9-2320-302-20
0039 00-4
TM 9-2320-302-20
EXHAUST SYSTEM FLEX PIPE, CLAMPS, AND HEAT SHIELD REPLACEMENT 0040 00
INITIAL SETUP
Materials/Parts
Clamp, seal (P/N 04-19249-000) (6)
Nut, lock (P/N MS 51922-33) (2)
WARNING
Allow exhaust sytem components to cool before performing maintenance. Handling hot exhaust system
components could cause serious burns.
REMOVAL
1. Open engine compartment and loosen grooved coupling clamp (1) at turbocharger exhaust outlet of exhaust pipe (2).
2. Loosen seal clamp (3) and remove exhaust pipe (2) from turbocharger exhaust outlet and exhaust hose (4). Retain
grooved coupling clamp (1).
3. Loosen seal clamp (5) and remove exhaust hose (4) and seal clamps (3 and 5) from exhaust pipe (6). Discard seal
clamps.
1
2
4
3
5
0040 00-1
TM 9-2320-302-20
EXHAUST SYSTEM FLEX PIPE, CLAMPS, AND HEAT SHIELD REPLACEMENT - CONTINUED 0040 00
REMOVAL - CONTINUED
4. Loosen seal clamps (7 and 8) and remove exhaust hose (9) from exhaust pipe (6) and exhaust connector (10). Discard
seal clamps.
5. Loosen hose clamp (11) and remove heat shield (12) from exhaust hose (9).
6. Loosen two seal clamps (13 and 14) and remove exhaust connectors (10 and 15) from muffler. Discard seal clamps.
7. Remove four nuts (16), two saddle clamps (17), and exhaust pipe (6) from two hanger brackets (18).
NOTE
Perform step 8 only if hanger brackets are damaged.
8. Remove two screws (19), four washers (20), two lock nuts (21), and two hanger brackets (18) from frame rail (22). Dis-
card lock nuts.
1
2
6 17
17 3
5 4
12
7
19 20
11
20
19
9
8 17 22
10 18
16
21
20
13 14 17
20 18
16
21
15
0040 00-2
TM 9-2320-302-20
EXHAUST SYSTEM FLEX PIPE, CLAMPS, AND HEAT SHIELD REPLACEMENT - CONTINUED 0040 00
INSTALLATION
NOTE
Perform step 1 only if hanger brackets were removed.
1. Install two new hanger brackets (18) on frame rail (22) with two screws (19), four washers (20), and two new lock nuts
(21).
NOTE
Ensure loop clamps and seal clamps are only hand tight when installed. Tighten all clamps after exhaust sys-
tem is completely installed.
2. Install exhaust pipe (6) on two hanger brackets (18) with two saddle clamps (17) and four nuts (16).
3. Install two exhaust connectors (10 and 15) and new seal clamps (13 and 14) on muffler.
WARNING
Ensure heat shield is positioned on exhaust hose between exhaust and fuel tank inlet. Failure to position heat
shield correctly could result in serious injury to personnel and damage to equipment.
4. Install heat shield (12) on exhaust hose (9) with hose clamp (11).
5. Position exhaust hose (9) and new seal clamps (7 and 8) on exhaust pipe (6) and exhaust connector (10).
6. Install new seal clamp (5) and exhaust hose (4) on exhaust pipe (6). Slide seal clamp to end of exhaust hose and tighten.
7. Position new seal clamp (3), grooved coupling clamp (1), and exhaust pipe (2) on turbo charger exhaust outlet and
exhaust hose (4). Slide seal clamp and grooved coupling clamp to ends of exhaust pipe and tighten.
NOTE
Tighten all seal clamps, saddle clamps, and grooved coupling clamp securely. New seal clamps may leak
until exhaust system is thoroughly heated and sealed.
8. Operate vehicle (TM 9-2320-302-10) and allow exhaust system to heat up and seal.
END OF WORK PACKAGE
0040 00-3
TM 9-2320-302-20
0040 00-4
TM 9-2320-302-20
DRAIN AND FILL COOLING SYSTEM 0041 00
Draining, Filling
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Antifreeze, ethylene glycol (Item 4, WP 0235 00)
Pan, drain (Item 25, WP 0236 00) Rags, wiping (Item 28, WP 0235 00)
References
TM 9-2320-302-10
DRAINING
WARNING
1. Remove radiator cap (1) from radiator (2).
NOTE
Cooling system capacity is 65 qt. (61.51 l). Have suitable drain pans available.
0041 00-1
TM 9-2320-302-20
DRAIN AND FILL COOLING SYSTEM - CONTINUED 0041 00
DRAINING - CONTINUED
2. Open draincock (3) on lower radiator pipe (4). Allow antifreeze to drain.
3. Remove plug (5) from thermostat housing (6). Allow antifreeze to drain.
4. Close draincock (3) and install plug (5).
FILLING
1. Fill radiator (2) with antifreeze in accordance with WP 0021 00.
2. Install radiator cap (1) on radiator (2).
3. Start engine and allow engine to reach operating temperature (TM 9-2320-302-10).
4. Allow antifreeze to circulate through cooling system. Check for coolant leaks.
5. Shut off engine and allow engine to cool.
WARNING
6. Remove radiator cap (1) and check antifreeze level. Add antifreeze, if necessary, in accordance with WP 0021 00.
7. Install radiator cap (1).
END OF WORK PACKAGE
0041 00-2
TM 9-2320-302-20
COOLANT HOSES, PIPES, AND CLAMPS REPLACEMENT 0042 00
INITIAL SETUP

Pliers, slip joint (Item 50, WP 0236 00) Equipment Condition
Materials/Parts Cooling system drained (WP 0041 00)
Nut, lock (P/N MS51922-1) (2)
REMOVAL
1. Loosen four clamps (1) and remove two hoses (2) and pipe (3) from thermostat housing (4) and radiator (5).
2. Remove two lock nuts (6), four washers (7), two screws (8), and four clamps (9) from radiator support rod (10) and hose
(11). Discard lock nuts.
3. Loosen two clamps (12) and remove hose (11) from radiator (5) and elbow (13).
3
1
2
12 1
13
11
4
1
2
1
8 5
79
11
12
9
7
6
10
0042 00-1
TM 9-2320-302-20
COOLANT HOSES, PIPES, AND CLAMPS REPLACEMENT - CONTINUED 0042 00
REMOVAL - CONTINUED
4. Remove elbow (13) from thermostat housing (4).

5. Loosen two clamps (14) and remove hose (15) from radiator (5) and water pump tube (16).
6. Remove water pump tube (16) from water pump (17).

7. Loosen four clamps (18) and remove two hoses (19) and pipe (20) from thermostat housing (4) and water pump (17).
15
13
14
4
18 5
20
19
18
19 18
18 16
17
15
14
8. Loosen four clamps (21) and remove hose (22), pipe (23), and hose (24) from transmission oil cooler (25) and water
pump (17).
9. Loosen four clamps (26) and remove hose (27), pipe (28), and hose (29) from engine oil cooler (30) and transmission oil
cooler (25).
10. Loosen two clamps (31) and remove hose (32) from elbow (33) and water filter (34).
11. Remove elbow (33) and adapter (35) from engine oil cooler (30).
12. Loosen two clamps (36) and remove hose (37) from water filter (34) and elbow (38).
13. Remove elbow (38) and adapter (39) from water pump (17).
14. Loosen four clamps (40) and remove hose (41), pipe (42), and hose (43) from water pump (17) and radiator (5).
15. Remove draincock (44) from pipe (42).
0042 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
23 21
21
32 22 24 21 5
31
33
17
35 28
26 38
27
21 26
26
40
26 41 40
39
36
30 29
25 43
34
31
40
36
42
32 37 44
INSTALLATION
WARNING
sealing compound contact skin or clothing, wash immediately with soap and water.
1. Lightly coat threads of draincock (44) with pipe sealing compound. Install draincock on pipe (42).
2. Install hose (43), pipe (42), and hose (41) on radiator (5) and water pump (17) with four clamps (40).
3. Lightly coat threads of adapter (39) and elbow (38) with pipe sealing compound. Install adapter and elbow on water
pump (17).
4. Install hose (37) on elbow (38) and water filter (34) with two clamps (36).
5. Lightly coat threads of adapter (35) and elbow (33) with pipe sealing compound. Install adapter and elbow on engine oil
cooler (30).
6. Install hose (32) on water filter (34) and elbow (33) with two clamps (31).
7. Install hose (29), pipe (28), and hose (27) on transmission oil cooler (25) and engine oil cooler (30) with four clamps
(26).
8. Install hose (24), pipe (23), and hose (22) on water pump (17) and transmission oil cooler (25) with four clamps (21).
0042 00-3
TM 9-2320-302-20
9. Install pipe (20) and two hoses (19) on water pump (17) and thermostat housing (4) with four clamps (18).
10. Light coat threads of water pump tube (16) with pipe sealing compound. Install water pump tube on water pump (17).
11. Install hose (15) on water pump tube (16) and radiator (5) with two clamps (14).
12. Lightly coat threads of elbow (13) with pipe sealing compound. Install elbow on thermostat housing (4).
13. Install hose (11) on elbow (13) and radiator (5) with two clamps (12).
14. Install four clamps (9) on hose (11) and radiator support rod (10) with two screws (8), four washers (7), and two new
lock nuts (6).
15. Install pipe (3) and two hoses (2) on radiator (5) and thermostat housing (4) with four clamps (1).
1
2
12 1
13 15
11
14
4
1
2 1
18 8 5
20 79
19
18 11
19 18 12
18 16 14
9
7
17
6
15
10
END OF WORK PACKAGE
0042 00-4
TM 9-2320-302-20
THERMOSTAT AND THERMOSTAT HOUSING COVER REPLACEMENT 0043 00
INITIAL SETUP

Handle, installer (Item 15, WP 0236 00) Equipment Condition
Installer, seal (Item 20, WP 0236 00) Coolant hoses, pipes, and clamps removed (WP
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) 0042 00)
Materials/Parts
Seal, thermostat (P/N 3S9643-00) (2)
REMOVAL
1. Remove nut (1), lock washer (2), and wire (3) from temperature sending unit (4).
2. Remove two screws (5), lock washers (6), and wires (7) from temperature sending unit (8).
3. Remove four bolts (9) and thermostat housing cover (10) from cylinder head (11).
4. Remove two temperature sending units (4 and 8) from thermostat housing cover (10).
5. Remove two thermostats (12) and thermostat seals (13) from thermostat housing cover (10). Discard thermostat seals.
6. Remove draincock (14) from thermostat housing cover (10).
7. Remove two pipe plugs (15) from thermostat housing cover (10).
INSTALLATION
WARNING
1. Lightly coat threads of two pipe plugs (15) with pipe sealing compound. Install pipe plugs in thermostat housing cover
(10).
2. Lightly coat threads of draincock (14) with pipe sealing compound. Install draincock in thermostat housing cover (10).
0043 00-1
TM 9-2320-302-20
THERMOSTAT AND THERMOSTAT HOUSING COVER REPLACEMENT - CONTINUED 0043 00
3. Support thermostat housing cover (10), contact side up, level on workbench.
4. Using seal installer and handle, install new thermostat seal (13) on thermostat housing cover (10).
5. Using hammer, drive thermostat seal (13) into thermostat housing cover (10) bore until tool lip is flush against housing
cover.
6. Repeat steps 4 and 5 for other new thermostat seal (13).
7. Lightly coat lips of two thermostat seals (13) with lubricating oil.
8. Install two thermostats (12) on thermostat housing cover (10), spring side up. Press thermostats into housing cover.
15 5
6
9
7
10 6
4
3
8
2
14
13
11
12
9. Install two temperature sending units (4 and 8) in thermostat housing cover (10).
NOTE
Ensure that machined mating surfaces of thermostat housing cover and cylinder head are clean and dry.
10. Install thermostat housing cover (10) on cylinder head (11) with four bolts (9). Tighten bolts to 43-54 lb-ft (58-73 Nm).
11. Install two wires (7) on temperature sending unit (8) with two new lock washers (6) and screws (5).
0043 00-2
TM 9-2320-302-20
THERMOSTAT AND THERMOSTAT HOUSING COVER REPLACEMENT - CONTINUED 0043 00
12. Install wire (3) on temperature sending unit (4) with new lock washer (2) and nut (1).
13. Install coolant hoses, pipes, and clamps (WP 0042 00).
END OF WORK PACKAGE
0043 00-3
TM 9-2320-302-20
0043 00-4
TM 9-2320-302-20
RADIATOR SUPPORT ROD REPLACEMENT 0044 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock (P/N MS51922-1) (2)
Trestle, hoist, portable (Item 38, WP 0236 00) Nut, lock (P/N MS51922-33) (4)
Personnel Required
Two
REMOVAL
1. With hood (1) in opened position, place trestle under center of hood. Adjust height of trestle to support weight of hood.
2. Loosen two nuts (2) and open two chain links (3).
3. Remove two cables (4) from chain links (3).
0044 00-1
TM 9-2320-302-20
RADIATOR SUPPORT ROD REPLACEMENT - CONTINUED 0044 00
REMOVAL - CONTINUED
4. Remove two lock nuts (5), four washers (6), two screws (7), and four clamps (8) from radiator support rod (9) and hose
7 6 10
8
6
5
9
NOTE
Note position of washers and spacer to aid in installation.
5. Remove four locknuts (11), nine washers (12), spacer (13), four screws (14), and three radiator support rods (9, 15, and
16) from two support brackets (17) and radiator (18).
17
16
15 14
17
12
13
18
12
9
11
0044 00-2
TM 9-2320-302-20
RADIATOR SUPPORT ROD REPLACEMENT - CONTINUED 0044 00
INSTALLATION
1. Install three radiator support rods (9, 15, and 16) on radiator (18) and two support brackets (17) with four screws (14),
spacer (13), nine washers (12), and four new lock nuts (11).
2. Install four clamps (8) on hose (10) and radiator support rod (9) with two screws (7), four washers (6), and two new
locknuts (5).
3. Install two cables (4) on two chain links (3).
4. Tighten two nuts (2) and close chain links (3).
5. Remove trestle from under hood (1).
END OF WORK PACKAGE
0044 00-3
TM 9-2320-302-20
0044 00-4
TM 9-2320-302-20
RADIATOR REPLACEMENT 0045 00
INITIAL SETUP

Nut, lock (P/N 32WLF51618) (3)
Engine hood removed (WP 0185 00)
Nut, lock (P/N MS51922-11) (4)
Coolant hoses, pipes, and clamps removed (WP
Nut, lock (P/N MS51922-17) (4) 0042 00)
Nut, lock (P/N MS51922-49) (2)
Water level probe removed (WP 0081 00)
Straps, tiedown (Item 30, WP 0235 00)
Charge air cooler and air recirculation shield removed
Personnel Required (WP 0038 00)
Two Radiator support rod removed (WP 0044 00)
REMOVAL
NOTE
Air conditioner condenser must be removed and set aside prior to removal of radiator. This must be done
without disconnecting, removing or opening air conditioning lines which would allow refrigerant to escape.
1. Remove four lock nuts (1), washers (2), and screws (3) from condenser (4).
2. With assistance, remove condenser (4) and cooling lines. Place condenser with coolant lines attached in engine compart-
ment away from radiator.
3. Remove four screws (5), washers (6), and fan shroud (7) from radiator (8).
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during proce-
dure. 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.
4. Using suitable lifting device, support radiator (8).

5. Remove two lock nuts (9), washers (10), and isolators (11) from screws (12). Discard lock nuts.
6. Remove lock nut (13) and ground cable (14) from radiator (8). Discard lock nut.
0045 00-1
TM 9-2320-302-20
RADIATOR REPLACEMENT - CONTINUED 0045 00
REMOVAL - CONTINUED
8 3
13
22
14
23
4
2
24
1
5
6
7
21
2
12
19
20
18
17
15
11
10
16
NOTE
Remove tiedown straps, as necessary.
7. Lift radiator (8) from vehicle and remove two isolators (15) and washers (16). Place radiator in safe area.
8. Remove four lock nuts (17) and mounting plate (18) from radiator (8). Discard lock nuts.
9. Remove two screws (12), washers (19), and plate (20) from mounting plate (18).
10. Remove two lock nuts (21), screws (22), washers (23), and air line support (24) from radiator (8). Discard lock nuts.
0045 00-2
TM 9-2320-302-20
RADIATOR REPLACEMENT - CONTINUED 0045 00
INSTALLATION
NOTE
Install new tiedown straps, as necessary.
1. Install air line support (24) on radiator (8) with two washers (23), screws (22), and new lock nuts (21).
2. Loosely install plate (20) on mounting plate (18) with two washers (19) and screws (12).
3. Install mounting plate (18) on radiator (8) with four new lock nuts (17).
WARNING
personnel.
4. Position two isolators (15), washers (16), and radiator (8) on vehicle. Remove lifting device
5. Install ground cable (14) on radiator (8) with new lock nut (13).
6. Install two isolators (11), washers (10), and new locknuts (9) on screws (12).
7. Install fan shroud (7) on radiator (8) with four washers (6) and screws (5).
8. Install radiator support rod (WP 0044 00).
9. Install charge air cooler and air recirculation shield (WP 0038 00).
10. Install condenser (4) in engine compartment with four screws (3), washers (2), and new lock nuts (1).
11. Install water level probe (WP 0081 00).
12. Install coolant hoses, pipes and clamps (WP 0042 00).
13. Install engine hood (WP 0185 00).
END OF WORK PACKAGE
0045 00-3
TM 9-2320-302-20
0045 00-4
TM 9-2320-302-20
FAN BELT REPLACEMENT AND ADJUSTMENT 0046 00
Removal, Installation, Adjustment
INITIAL SETUP

Tensiometer, dial indicating (Item 32, WP 0236 00) Equipment Condition
Wrench, torque, 50-250 lb-ft (Item 46, WP 0236 00) Fan impeller and shroud removed (WP 0047 00)
REMOVAL
1. Loosen four screws (1) on spindle and housing (2).
2. Loosen adjusting screw (3) and allow slack in three fan belts (4).
3. Remove three fan belts (4) from vehicle.
INSTALLATION
NOTE
Fan belts should only be replaced in matched sets. DO NOT mix old and new fan belts.
1. Position three fan belts (4) on vehicle.
0046 00-1
TM 9-2320-302-20
FAN BELT REPLACEMENT AND ADJUSTMENT - CONTINUED 0046 00
2. Install fan impeller and shroud (WP 0047 00).
ADJUSTMENT
1. With tensiometer placed midway between two pulleys, tighten adjusting screw (3) until fan belt (4) tension is 60-80 lbs
(266-355 N).
2. Tighten four screws (1) on spindle and housing (2) to 75-83 lb-ft (100-112 Nm).
3. Operate engine for about 30 minutes (or 15 miles) and check fan belt (4) tension. Adjust tension, as necessary.
4. Check fan belt (4) tension after 8 hours (or 250 miles). Adjust tension, as necessary.
END OF WORK PACKAGE
0046 00-2
TM 9-2320-302-20
FAN IMPELLER AND SHROUD REPLACEMENT 0047 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00)
TM 9-2320-302-10
Materials/Parts
Equipment Condition
Washer, lock (P/N 3059-00870-06) (6)
Straps, tiedown (Item 30, WP 0235 00) Radiator removed (WP 0045 00)
REMOVAL
NOTE
Remove tiedown straps, as necessary.
1. Remove six nuts (1), lock washers (2), and washers (3) from six studs (4). Discard lock washers.
NOTE
Note position of fan impeller and shroud to aid in installation.
2. Remove fan impeller (5) and radiator shroud (6) from vehicle.
3 4
1 2
0047 00-1
TM 9-2320-302-20
FAN IMPELLER AND SHROUD REPLACEMENT - CONTINUED 0047 00
INSTALLATION
NOTE
Install new tiedown straps, as necessary.
1. Position radiator shroud (6) and fan impeller (5) on vehicle.
2. Install fan impeller (5) on six studs (4) with six washers (3), new lock washers (2), and nuts (1).
3 4
1 2
3. Install radiator (WP 0045 00).
END OF WORK PACKAGE
0047 00-2
TM 9-2320-302-20
FAN CLUTCH SOLENOID REPLACEMENT 0048 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Air system drained (TM 9-2320-302-10)
References
TM 9-2320-302-10
REMOVAL
1. Disconnect air line (1) from air filter (2).
2. Disconnect air line (3) from fan clutch solenoid (4).
3. Disconnect connector (5) of fan clutch solenoid (4) from engine wiring harness connector (6).
4. Remove nut (7), screw (8), clamp (9), and fan clutch solenoid (4) from engine block (10).
5. Remove vent (11) from fan clutch solenoid (4).
4 2 11 6
5
7
10
3
INSTALLATION
1. Install vent (11) on fan clutch solenoid (4).
2. Install fan clutch solenoid (4) on engine block (10) with clamp (9), screw (8), and nut (7).
3. Connect connector (5) of fan clutch solenoid (4) to engine wiring harness connector (6).
4. Connect air line (3) to fan clutch solenoid (4).
5. Connect air line (1) to air filter (2).
END OF WORK PACKAGE
0048 00-1
TM 9-2320-302-20
0048 00-2
TM 9-2320-302-20
FAN CLUTCH AND DRIVE PULLEY REPLACEMENT 0049 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Fan impeller and shroud removed (WP 0047 00)
References Fan belts removed (WP 0046 00)

TM 9-2320-302-10 Air system drained (TM 9-2320-302-10)
REMOVAL
1. Disconnect air line (1) from spindle behind drive pulley (2).
WARNING
Compressed air used for cleaning or drying purposes, or for cleaning restrictions, should never exceed 30 psi
nel.
NOTE
Perform step 2 if six screws of fan clutch are not accessible.
2. Apply air pressure to fitting of spindle behind drive pulley (2) to access heads of six screws (3).
3. Remove six screws (3), fan clutch (4), spacer (5), and drive pulley (2) from vehicle.
1 5
4
0049 00-1
TM 9-2320-302-20
FAN CLUTCH AND DRIVE PULLEY REPLACEMENT - CONTINUED 0049 00
INSTALLATION
1. Install drive pulley (2), spacer (5), and fan clutch (4) on vehicle with six screws (3).
2. Connect air line (1) to spindle behind drive pulley (2).
1 5
4
3. Install fan belts (WP 0046 00).

4. Install fan impeller and shroud (WP 0047 00).
END OF WORK PACKAGE
0049 00-2
TM 9-2320-302-20
WATER FILTER ELEMENT REPLACEMENT 0050 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Element, filter (P/N WF-2077)
References
TM 9-2320-302-10
REMOVAL
NOTE
Use a suitable container to catch any spilled liquid.
1. Close two shutoff valves (1 and 2).

2. Remove water filter element (3) and gasket (4) from filter adapter (5). Discard water filter element and gasket.
INSTALLATION
1. Position new gasket (4) on top of new water filter element (3). Lightly coat gasket with lubricating oil.
2. Install water filter element (3) and gasket (4) on adapter (5). Hand tighten until filter side movement is not present.
0050 00-1
TM 9-2320-302-20
WATER FILTER ELEMENT REPLACEMENT - CONTINUED 0050 00
CAUTION
DO NOT use a filter wrench to tighten water filter element. Failure to follow this caution may result in dam-
age to water filter element.
3. Tighten water filter element (3) an additional 2/3 turn.
4. Open two shutoff valves (1 and 2).
5. Check coolant level (TM 9-2320-302-10).
END OF WORK PACKAGE
0050 00-2
TM 9-2320-302-20
WATER FILTER ADAPTER AND BRACKET REPLACEMENT 0051 00
INITIAL SETUP


Rags, wiping (Item 28, WP 0235 00) Cooling system drained (WP 0041 00)
Water filter element removed (WP 0050 00)
Transmission oil cooler removed (WP 0127 00)
REMOVAL
1. Loosen hose clamp (1) and remove hose (2) from angle valve (3) on oil cooler side of filter adapter (4).
2. Loosen hose clamp (5) and remove hose (6) from angle valve (7) on water pump side of filter adapter (4).
3. Remove four screws (8) and filter adapter (4) from mounting bracket (9).
4. Remove two angle valves (3 and 7) from filter adapter (4).
10 11
8 12
3
12 13
1 4
7
5
6
0051 00-1
TM 9-2320-302-20
WATER FILTER ADAPTER AND BRACKET REPLACEMENT - CONTINUED 0051 00
REMOVAL - CONTINUED
NOTE
Perform step 6 only if mounting bracket is damaged.
5. Remove two nuts (10), bolts (11), four washers (12), and mounting bracket (9) to frame (13).
INSTALLATION
NOTE
Perform step 1 only if mounting bracket was removed.
1. Install mounting bracket (9) on frame (13) with two bolts (11), four washers (12), and two nuts (10).
2. Install two angle valves (3 and 7) on filter adapter (4).

3. Install filter adapter (4) on mounting bracket (9) with four screws (8).
4. Install hose (6) on angle valve (7) on water pump side of filter adapter (4) with hose clamp (5).
5. Install hose (2) on angle valve (3) on oil cooler side of filter adapter (4) with hose clamp (1).
10 11
8 12
3
12
1 4
7
5
6
6. Install water filter element (WP 0050 00).
7. Install transmission oil cooler (WP 0127 00).

8. Fill coolant system and check for leaks (WP 0041 00).
END OF WORK PACKAGE
0051 00-2
TM 9-2320-302-20
WATER PUMP MAINTENANCE 0052 00
Water Pump Removal, Water Pump Seal Removal, Water Pump Seal Installation, Water Pump Installation
INITIAL SETUP
Tools and Special tools References

Pliers, retaining ring (Item 26, WP 0236 00) Equipment Condition
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Oil level dipstick removed (WP 0023 00)
Materials /Parts Cooling system drained (WP 0041 00)
Gasket (P/N 23520377) Radiator-to-water pump coolant line removed (WP
Seal (P/N 5101160) 0042 00)
Antifreeze, ethylene glycol (Item 4, WP 0235 00)

WATER PUMP REMOVAL
1. Loosen two hose clamps (1) and remove oil cooler hose (2) from back from water pump (3).
2. Loosen two hose clamps (4) and remove water bypass hose (5) from water pump (3).
3. Loosen two hose clamps (6) and remove water filter hose (7) and heater hose (8) from two elbows (9).
1 4
5
4
6
6
8
7
3
0052 00-1
TM 9-2320-302-20
WATER PUMP MAINTENANCE - CONTINUED 0052 00
WATER PUMP REMOVAL - CONTINUED
4. Remove two elbows (9), adapter (10), and two bushings (11) from water pump (3).
5. Remove drain valve (12) from water pump (3).
6. Remove two long bolts (13) and short bolt (14) from water pump (3) and gear case (15).
7. Pull water pump (3) straight out of gear case (15).
8. Remove gasket (16). Discard gasket.
2
14
1
4
13
5
4
13
17
18 16
19 9 15
6
6
8
10
11 7
3 12
WATER PUMP SEAL REMOVAL
WARNING
Size and tension of snap ring could cause injury to personnel if snap ring slips off snap ring pliers. Wear face
shield when removing water pump cover snap ring.
1. Remove water pump cover snap ring (17) from water pump (3).
2. Remove water pump cover (18) and seal (19) from water pump (3). Discard seal.
WATER PUMP SEAL INSTALLATION
1. Support impeller side of water pump (3) on workbench and install new seal (19) in bore of water pump (3).
2. Install water pump cover (18) on water pump (3).
0052 00-2
TM 9-2320-302-20
WATER PUMP MAINTENANCE - CONTINUED 0052 00
WATER PUMP SEAL INSTALLATION - CONTINUED
WARNING
Size and tension of snap ring could cause injury to personnel if snap ring slips off snap ring pliers. Wear face
shield when installing water pump cover snap ring.
3. Install water pump cover snap ring (17) in groove of water pump (3). Tap around inside rim of snap ring to fully seat in
groove of water pump.
WATER PUMP INSTALLATION
1. Apply a light coat of clean lubricating oil to new gasket (16). Install gasket in groove on water pump (3).
2. Position water pump (3) on gear housing (15), meshing water pump gear with gear train. Install water pump with two
long bolts (13) and short bolt (14). Tighten bolts to 43-54 lb-ft (58-73 Nm).
3. Install drain valve (12) on water pump (3).
4. Install two bushings (11), adapter (10), and two elbows (9) on water pump (3).
5. Position two hose clamps (6), heater hose (8), and water filter hose (7) on two elbows (9). Tighten hose clamps.
6. Position two hose clamps (4) and water bypass hose (5) on water pump (3). Tighten hose clamps.
7. Position two hose clamps (1) and oil coo1er hose (2) on back of water pump (3). Tighten hose clamps.
8. Install oil level dipstick (WP 0023 00).
9. Install radiator-to-water pump coolant line (WP 0042 00).
11. Operate vehicle (TM 9-2320-302-10) and check for coolant leaks.
END OF WORK PACKAGE
0052 00-3
TM 9-2320-302-20
0052 00-4
TM 9-2320-302-20
SPINDLE AND HOUSING REPLACEMENT 0053 00
INITIAL SETUP

References Fan clutch and drive pulley removed (WP 0049 00)
TM 9-2320-302-10
REMOVAL
1. Remove air hose connector (1) from coupling (2).
2. Remove adjuster bolt (3) from fan mounting support (4) and spindle housing (5).
3. Remove four screws (6), washers (7), and spindle housing (5) from fan mounting support (4).
4. Remove coupling (2) and pipe nipple (8) from spindle housing (5).
0053 00-1
TM 9-2320-302-20
SPINDLE AND HOUSING REPLACEMENT - CONTINUED 0053 00
INSTALLATION
1. Install pipe nipple (8) and coupling (2) on spindle housing (5).
NOTE
DO NOT fully tighten screws.
2. Install spindle housing (5) on fan mounting support (4) with four washers (7) and screws (6).
3. Loosely install adjuster bolt (3) on fan mounting support (4) and spindle housing (5).
4. Install air hose connector (1) on coupling (3).
5. Install fan clutch and drive pulley (WP 0049 00).
END OF WORK PACKAGE
0053 00-2
TM 9-2320-302-20
ALTERNATOR BELT REPLACEMENT AND ADJUSTMENT 0054 00
Removal, Installation, and Adjustment
INITIAL SETUP

Tensiometer, dial indicating (Item 32, WP 0236 00)
REMOVAL
1. Hold self-locking nut (1) and loosen hex cap screw (2).
2. Loosen two cap screws (3 and 4) securing adjusting rod link (5) and rod (6) to engine.
3. Loosen hex nut (7) and tighten hex nut (8) to loosen tension on drive belt (9).
NOTE
After loosening tension drive belt remains tight or is difficult to remove from pulleys, proceed to step 5.
4. Remove drive belt (9) from alternator pulley (10), air conditioning compressor pulley (11), and accessory drive pulley
(12).
5. Remove cap screw (3) and rotate alternator until drive belt (9) can be removed.
4 11
6
7
5
13 3
8
10 9
1
12
2
0054 00-1
TM 9-2320-302-20
ALTERNATOR BELT REPLACEMENT AND ADJUSTMENT - CONTINUED 0054 00
INSTALLATION
1. Position drive belt (9) on alternator pulley (10), air conditioning compressor pulley (11), and accessory drive pulley
(12).
2. Install cap screw (3) if removed. If not, proceed to step 3.
3. Tighten drive belt tension by loosening hex nut (8) and tightening hex nut (7) on adjusting rod (6) and link (5) until drive
belt is tight. Tighten hex nut (8).
4. Tighten three cap screws (2, 3, and 4) to 60-70 ft-lb (81-95 Nm).
ADJUSTMENT
1. Back off hex nut (8) and tighten hex nut (7) until belt tension measures 90-100 lb (400 N) on tensiometer (13).
2. Start engine (TM 9-2320-302-10) and operate engine for 30 minutes (or 15 miles).
3. Check belt tension and adjust as required to maintain 80-100 lb-ft (36-45 Nm). Recheck belt tension again after 8 hours
of operation and adjust as required.
4 11
6
7
5
13 3
8
10 9
1
12
2
END OF WORK PACKAGE
0054 00-2
TM 9-2320-302-20
ALTERNATOR REPLACEMENT 0055 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Alternator belt removed (WP 0054 00)
Materials/Parts Master battery switch OFF (TM 9-2320-302-10)

Washer, lock (Din 127-B10.1-4310)
NOTE
Tag all electrical leads to aid in installation.
REMOVAL
1. Remove two nuts (1) and electrical leads (2) from alternator (3).
2. Remove two nuts (4), two washers (5), two bolts (6), and two electrical leads (7) from alternator (3).
1 2 5
7
7
4
4
0055 00-1
TM 9-2320-302-20
ALTERNATOR REPLACEMENT - CONTINUED 0055 00
REMOVAL - CONTINUED
3. Remove cap screw (8), bearing washer (9), and adjusting rod link (10) from alternator (3).
25
10 24
3
21
23
22
2
11 9
13 16
18
13
17
14
13
20 12
15
19
4. Support alternator (3) and remove lock nut (11), cap screw (12), three bearing washers (13), alternator, and angle
bracket (14) from lower mount (15). Discard lock nut.
5. Hold alternator pulley (16) in vise and remove hex nut (17), key (18), and pulley from alternator (3). Retain pulley for
use on new alternator.
6. Inspect lower mounting bracket (15) for damage. If damaged, remove two bolts (19), nuts (20) and lower mounting
bracket.
7. Inspect adjusting rod (21) for damage. If damaged, remove cap screw (22), lock washer (23), spacer (24), and adjusting
rod. Discard lock washer.
8. Remove two hex nuts (25) and adjusting rod link (10) from adjusting rod (21).
INSTALLATION
1. Install pulley (16) and key (18) on alternator (3) with hex nut (17).
2. If removed, install lower mounting bracket (15) with two bolts (19) and nuts (20).
3. If removed, install adjusting rod (21), with two hex nuts (25) and adjusting rod link (10), with new lock washer (23),
spacer (24), and cap screw (22).
4. Support alternator (4) and secure to lower mounting bracket (15) with cap screw (12), three bearing washers (13), angle
bracket (14), and new lock nut (11). Do not tighten at this time.
5. Install alternator (3) on adjusting rod link (10) with bearing washer (9) and cap screw (8).
0055 00-2
TM 9-2320-302-20
ALTERNATOR REPLACEMENT - CONTINUED 0055 00
INSTALLATION - CONTINUED.
6. Install two electrical leads (7) on alternator (3) with two washers (5), two bolts (6), and nuts (4).
7. Install electrical leads (2) on alternator (3) with two nuts (1).
1 2 5
7
7
4
4
1
8. Install and adjust alternator belt (WP 0054 00).
END OF WORK PACKAGE
0055 00-3
TM 9-2320-302-20
0055 00-4
TM 9-2320-302-20
STARTER REPLACEMENT 0056 00
INITIAL SETUP

Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00)
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Equipment Condition
Wrench, torque, 50-250 lb-ft (Item 46, WP 0236 00) Master battery switch OFF (TM 9-2320-302-10)
REMOVAL
1. Remove nut (1), washer (2), cable (3), and wire (4) from threaded stud (5).
2. Remove nut (6), washer (7), cable (8), and three wires (9) from starter (10).
3. Remove nut (11), washer (12), and wire (13) from starter (10).
4. Remove nut (14), washer (15), cable (16), ground strap (17), and two wires (18) from starter (10).
5. While supporting starter (10), remove three screws (19). Remove starter from engine flywheel housing (20).
5 3 2 1
4 8
20
7
6
13
12
11
17 19
16
15
10
14
18
0056 00-1
TM 9-2320-302-20
STARTER REPLACEMENT - CONTINUED 0056 00
INSTALLATION
1. While supporting starter (10), install starter on engine flywheel housing (20) with three screws (19). Do not fully tighten
screws.
NOTE
For aluminum flywheel housings, tighten screws to 138-154 lb-ft (187-209 Nm). For cast iron flywheel
housings, tighten screws to 181-226 lb-ft (245-306 Nm).
2. Tighten three screws (19).
3. Install two wires (18), ground strap (17), cable (16), washer (15), and nut (14) on starter (10). Tighten nut to 20-25 lb-ft
(27-34 Nm).
4. Install wire (13), washer (12), and nut (11) on starter (10). Tighten nut to 16-30 lb-ft (1.8-3.4 Nm).
5. Install three wires (9), cable (8), washer (7), and nut (6) on starter (10). Tighten nut to 16-30 lb-ft (1.8-3.4 Nm).
6. Install wire (4), cable (3), washer (2), and nut (1) on threaded stud (5). Tighten nut to 16-30 lb-ft (1.8-3.4 Nm).
5 3 2 1
4
8
20
7
6
13
12
11
17 19
16
15
10
14
18
END OF WORK PACKAGE
0056 00-2
TM 9-2320-302-20
VOLTAGE REGULATOR REPLACEMENT 0057 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Battery cables disconnected (WP 0115 00)
REMOVAL
1. Disconnect plug (1) from voltage regulator (2).
2. Remove six screws (3), six washers (4), and voltage regulator (2).
4 3
INSTALLATION
1. Install voltage regulator (2) with six washers (4), and six screws (3).
2. Connect plug (1) on voltage regulator (2).
END OF WORK PACKAGE
0057 00-1
TM 9-2320-302-20
0057 00-2
TM 9-2320-302-20
BATTERY EQUALIZER REPLACEMENT 0058 00
INITIAL SETUP


Tags, marker (Item 31, WP 0235 00) Battery cables disconnected (WP 0115 00)
Personnel Required
Two
REMOVAL
NOTE
Tag wires to aid in installation.
1. Remove nut (1), two washers (2), bolt (3), and cable lead (4) from GND terminal (5).
2. Remove nut (6), two washers (7), bolt (8), and two cable leads (9) from 12V terminal (10).
3. Remove nut (11), two washers (12), bolt (13), and two cable leads (14) from 24V terminal (15).
14 12
9
13 12 11
7
8 15
10 7
6
3
2 1
2
4
0058 00-1
TM 9-2320-302-20
BATTERY EQUALIZER REPLACEMENT - CONTINUED 0058 00
REMOVAL - CONTINUED
4. Remove nut (16), two washers (17), and bolt (18) securing cable bracket (19) to equalizer bracket (20).
5. Remove remaining five nuts (16), ten washers (17), five bolts (18), and battery equalizer (21).
NOTE
Perform step 6, only if bracket is damaged.
6. Remove two nuts (22), four washers (23), two bolts (24), and bracket (20).
21
24
23
18 17
23 16
17
22
19
20
INSTALLATION
NOTE
Perform step 1, only if bracket was removed.
1. Position bracket (20) and handtighten two bolts (24), four washers (23), and two nuts (22).
2. Position battery equalizer (21) and handtighten top three nuts (16), six washers (17), and three bolts (18).
3. Position cable bracket (19) on bottom center hole and handtighten one nut (16), two washers (17), and one bolt (18).
4. Handtighten remaining two bolts (18), four washers (17), and two nuts (16).
5. Tighten eight nuts (16 and 22).
0058 00-2
TM 9-2320-302-20
BATTERY EQUALIZER REPLACEMENT - CONTINUED 0058 00
REMOVAL - CONTINUED
6. Install two cable leads (14), bolt (13), two washers (12), and nut (11) to 24V terminal (15).
7. Install two cable leads (9), bolt (8), two washers (7), and nut (6) to 12V terminal (10).
8. Install cable lead (4), bolt (3), two washers (2), and nut (1) to GND terminal (5).
14 12
9
13 12 11
7
8 15
10 7
6
3
1
2
2
4
END OF WORK PACKAGE
0058 00-3
TM 9-2320-302-20
0058 00-4
TM 9-2320-302-20
STARTER RELAY REPLACEMENT 0059 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Tags, marker (Item 31, WP 0235 00)
NOTE
REMOVAL
1. Remove lock nut (1) and wire (2) from starter relay (3).
2. Remove two nuts (4) and wires (5) from starter relay (3).
3. Remove lock nut (6) and wire (7) from starter relay (3).
4. Remove two bolts (8), nuts (9), wire (2), and starter relay (3) from vehicle firewall (10).
10
9
2 5
4
1 6
7
INSTALLATION
1. Install starter relay (3) and wire (2) on vehicle firewall (10) with two bolts (8) and nuts (9).
2. Install wire (7) on starter relay (3) with lock nut (6).
3. Install two wires (5) on starter relay (3) with two nuts (4).
4. Install wire (2) on starter relay (3) with lock nut (1).
END OF WORK PACKAGE
0059 00-1
TM 9-2320-302-20
0059 00-2
TM 9-2320-302-20
LEFT PANEL GAGES AND LAMPS REPLACEMENT 0060 00
INITIAL SETUP


REMOVAL
1. Remove four screws (1) and pull panel (2) away from dashboard.
2. Remove three lamp holders (3) from engine oil pressure gage (4), engine water temperature gage (5), and voltmeter (6).
NOTE
Tag all plugs and tubes to aid in installation.
3. Remove two plugs (7), connector (8), and two tubes (9) from engine oil pressure gage (4), engine water temperature
gage (5), and voltmeter (6). Remove panel (2).
2 1
9
5
6
3
7
0060 00-1
TM 9-2320-302-20
LEFT PANEL GAGES AND LAMPS REPLACEMENT - CONTINUED 0060 00
REMOVAL - CONTINUED
NOTE
Note location of gages to aid in installation.
4. Remove two lock nuts (10), bracket (11), and engine oil pressure gage (4) from panel (2).
5. Repeat step 4 for engine water temperature gage (5) and voltmeter (6).
6. Remove air vent (12) from panel (2).
7. Turn three lamps (13) to left and remove from lamp holders (3).
2 1
9 11
5
13 10
6
3
7
10 11
13
10
INSTALLATION
1. Install three lamps (13) in lamp holders (3). Turn lamps to right to lock in place.
2. Install air vent (12) on panel (2).
3. Install engine oil pressure gage (4) and bracket (11) on panel (2) with two lock nuts (10).
4. Repeat step 3 for engine water temperature gage (5) and voltmeter (6).
5. Install three lamp holders (3) on engine oil pressure gage (4), engine water temperature gage (5), and voltmeter (6).
6. Install two tubes (9), connector (8), and two plugs (7) on engine oil pressure gage (4), engine water temperature gage
(5), and voltmeter (6).
7. Install panel (2) on dashboard with four screws (1).
8. Run vehicle and build air pressure to proper level (TM 9-2320-302-10). Check operation of gages and check for air sys-
tem leaks.
END OF WORK PACKAGE
0060 00-2
TM 9-2320-302-20
CENTER GAGE PANEL MAINTENANCE 0061 00
INITIAL SETUP

Materials/Parts
REMOVAL
NOTE
Tag connectors to aid in installation.
2. Disconnect two connectors (3) from cab wiring harness connectors (4).
NOTE
Center gage panel has three indicator lights: parking brake, tractor ABS, and trailer ABS.
3. Remove cab wiring harness connectors (5) from indicator lights (6). Remove indicator lights.
4. Remove connector (7) from cab wiring harness connector (8). Remove panel (2).
5. Remove two screws (9), bracket (10), and tachometer (11) from panel (2). Remove lamp (12) from tachometer.
6. Remove two screws (13), bracket (14), and speedometer (15) from panel (2). Remove lamp (16) from speedometer.
15
16
1
2
14
13 12
7
8
5
11
10
3 9
4
0061 00-1
TM 9-2320-302-20
CENTER GAGE PANEL MAINTENANCE - CONTINUED 0061 00
INSTALLATION
NOTE
Panel has three indicator lights: parking brake, tractor ABS, and trailer ABS.
1. Install indicator lights (6) on panel (2).
2. Install speedometer (15) on panel (2) with bracket (14) and two screws (13). Install lamp (16) in speedometer.
3. Install tachometer (11) to panel (2) with bracket (10) and two screws (9). Install lamp (12) in tachometer.
4. Install connector (7) on cab wiring harness connector (8).
5. Install cab wiring harness connectors (5) to indicator lights (6).
6. Connect two connectors (3) to cab wiring harness connectors (4).
15
16
1
2
14
13 12
7
8
5
11
10
3 9
4
END OF WORK PACKAGE
0061 00-2
TM 9-2320-302-20
RIGHT GAGE PANEL AND LAMPS REPLACEMENT 0062 00
INITIAL SETUP

Tags, marker (Item 31, WP 0235 00) TM 9-2320-302-10
REMOVAL
NOTE
Tag all air tubes, connectors, and gages prior to removal to aid in installation.
2. Remove connector (3) from cab wiring harness connector (4).
3. Remove two connectors (5) from fuel level gage (6) and transmission oil temperature gage (7).
4. Remove two tubes (8) from air pressure gages (9). Disconnect tube (10) from air cleaner restriction indicator gage (11).
5. Remove panel (2) from dashboard.
1
2
9 11
7
10 6
4
5
3
0062 00-1
TM 9-2320-302-20
RIGHT GAGE PANEL AND LAMPS REPLACEMENT - CONTINUED 0062 00
REMOVAL - CONTINUED
6. Remove four lamp holders (12) from fuel level gage (6), transmission oil temperature gage (7), and two air pressure
gages (9).
7. Remove four lock nuts (13), ground wire (14), two brackets (15), and two air pressure gages (9) from panel (2).
8. Remove four nuts (16), washers (17), two brackets (18), fuel level gage (6), and transmission oil temperature gage (7)
from panel (2).
9. Remove two screws (19) and air cleaner restriction indicator gage (11) from panel (2).
10. Turn four lamps (20) to left and remove from lamp holders (12).
1
2
9 11 19
14 7
13 9
12
8
10 6
12
15
5
13
8
20
4 18
5 17
3 16
INSTALLATION
1. Install four lamps (20) in lamp holders (12). Turn lamps to right to lock in place.
2. Install air cleaner restriction indicator gage (11) on panel (2) with two screws (19).
3. Install fuel level gage (6) and transmission oil temperature gage (7) on panel (2) with two brackets (18), four washers
(17), and nuts (16).
4. Install two air pressure gages (9) on panel (2) with two brackets (15), ground wire (14), and four new lock nuts (13).
5. Install four lamp holders (12) on fuel level gage (6), transmission oil temperature gage (7), and two air pressure gages
(9).
6. Install two tubes (8) to air pressure gages (9). Connect tube (10) to air cleaner restriction indicator gage (11).
7. Install two connectors (5) on fuel level gage (6) and transmission oil temperature gage (7).
8. Install connector (3) on cab wiring harness connector (4).
END OF WORK PACKAGE
0062 00-2
TM 9-2320-302-20
UPPER RIGHT DASH PANEL REPLACEMENT 0063 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Parking brake and trailer air supply valve removed
(WP 0160 00)
Materials/Parts
Compound, sealing, pipe (Item 10, WP 0235 00) References
Tags, marker (Item 31, WP 0235 00) TM 9-2320-302-10
NOTE
Tag air tubes and electrical connectors to aid in installation.
REMOVAL
1. Remove connector (1) from light switch (2).
2. Remove four nuts (3), screws (4), and light switch (2) from panel (5).
3. As required, remove three screws (6), knobs (7), and washers (8) from light switch (2).
4. Remove two connectors (9) from switches (10).
5. Remove three fiber optic labels (11) from panel (5).
6. Remove three label holders (12), two nuts (13), and two switches (10) from panel (5).
7. Remove two tubes (14) and connector (15).
5
4
6,7,8
2
3 13
12
14
11
9
10 15 14
0063 00-1
TM 9-2320-302-20
UPPER RIGHT DASH PANEL REPLACEMENT - CONTINUED 0063 00
REMOVAL - CONTINUED
NOTE
Two control valves are removed the same way. One control valve is illustrated. Perform steps 8 and 9 for all
control valves.
8. Remove two screws (16), guard (17), and control valve (18) from panel (5).
9. Remove two elbows (19), sending unit (20), and tee (21) from control valve (18).
10. Remove connector (22) from driver display unit (23).
11. Remove two nuts (24), screws (25), and driver display unit (23) from panel (5).
12. Remove two air vents (26) from panel (5).
13. Remove panel (5) from dashboard.
INSTALLATION
1. Install two air vents (26) on panel (5).
2. Position panel (5) to dashboard.
3. Install driver display unit (23) to panel (5) with two screws (25) and nuts (24).
4. Install connector (22) to driver display unit (23).
WARNING
NOTE
• Two control valves are installed the same way. One control valve is illustrated. Perform steps 5 and 6 for
all control valves.
• Apply pipe sealing compound to threads of all fittings before installation.
5. Install tee (21), two elbows (19), and sending unit (20) on control valve (18).
6. Install control valve (18) and guard (17) on panel (5) with two screws (16).
7. Install two tubes (14). Install connector (15) on sending unit (20).
8. Install three label holders (12) on panel (5).
9. Install two switches (10) on panel (5) with two nuts (13).
10. Install three fiber optic labels (11) on panel (5).
11. Install two connectors (9) on switches (10).
12. If removed, install three washers (8), knobs (7), and screws (6) on light switch (2).
13. Install light switch (2) on panel (5) with four screws (4) and nuts (3).
14. Install connector (1) on light switch (2).
0063 00-2
TM 9-2320-302-20
UPPER RIGHT DASH PANEL REPLACEMENT - CONTINUED 0063 00
26
5
4
25
17 16
6,7,8
2
3 13
12
18
23 21
19
22 19
14
11
24
20
10
15 14
9
15. Install parking brake and trailer air supply valve (WP 0160 00).
END OF WORK PACKAGE
0063 00-3
TM 9-2320-302-20
0063 00-4
TM 9-2320-302-20
LEFT HAND SWITCH PANEL MAINTENANCE 0064 00
INITIAL SETUP

Materials/Parts
NOTE
Tag all connectors to aid in installation.
REMOVAL
1. Remove four screws (1) and pull panel (2) out of dashboard.
0064 00-1
TM 9-2320-302-20
LEFT HAND SWITCH PANEL MAINTENANCE - CONTINUED 0064 00
REMOVAL - CONTINUED
2. Remove plug (3) and two connectors (4) and remove panel (2).
3. Remove three fiber optic labels (5) and label holders (6) from panel (2).
4. Remove three screws (7), pigtail (8), two nuts (9), washers (10), and pigtail (11) from panel (2).
5. Remove boot (12), three nuts (13), and switches (14) from panel (2).
6 12
13
14
13
10
9 1
3
4 2
14
7
11
INSTALLATION
1. Install three switches (14) on panel (2) with three nuts (13) and boot (12).
2. Install pigtail (11), two washers (10), nuts (9), pigtail (8), and three screws (7) on panel (2).
3. Install two connectors (4) and plug (3).
4. Install three label holders (6) and fiber optic labels (5) on panel (2).
END OF WORK PACKAGE
0064 00-2
TM 9-2320-302-20
RIGHT HAND SWITCH PANEL REPLACEMENT 0065 00
INITIAL SETUP

Materials/Parts
NOTE
Tag all wires and connectors to aid in installation.
REMOVAL
2. Disconnect plug (3) and connector (4) from two switches (5).
3. Loosen two setscrews (6) and remove knob (7), two nuts (8), and switches (5) from panel (2).
4. Remove two fiber optic labels (9) and label holders (10) from panel (2).
10
8
2
6
5
3 7
1
9
0065 00-1
TM 9-2320-302-20
RIGHT HAND SWITCH PANEL REPLACEMENT - CONTINUED 0065 00
INSTALLATION
1. Install two label holders (10) and fiber optic labels (9) on panel (2).
2. Install two switches (5) on panel (2) with two nuts (8).
3. Install knob (7) on panel (2) and tighten two setscrews (6).
4. Install connector (4) and plug (3) on two switches (5).
10
8
2
6
5
3 7
1
9
END OF WORK PACKAGE
0065 00-2
TM 9-2320-302-20
CONTROL MODULE REPLACEMENT 0066 00
INITIAL SETUP

REMOVAL
1. Remove two screws (1), cover (2), and control module (3) from dashboard.
2. Remove plug (4) from control module (3).
1
2
INSTALLATION
NOTE
Observe keyways and guide pins on plug when making connection. DO NOT force connection.
1. Install plug (4) on control module (3).
2. Position control module (3) on dashboard and install cover (2) with two screws (1).
END OF WORK PACKAGE
0066 00-1
TM 9-2320-302-20
0066 00-2
TM 9-2320-302-20
HEATER AND AIR CONDITIONING CONTROL PANEL REPLACEMENT 0067 00
INITIAL SETUP

TM 9-2320-302-10
Materials/Parts
Equipment Condition
REMOVAL
1. Remove two heater control knobs (1) and six screws (2). Pull control panel (3) out from dashboard.
2. Remove fiber optic labels (4).
3
2
1
0067 00-1
TM 9-2320-302-20
HEATER AND AIR CONDITIONING CONTROL PANEL REPLACEMENT - CONTINUED 0067 00
REMOVAL - CONTINUED
NOTE
Tag tubes and wire connectors prior to removal to aid in installation.
3. Disconnect three hoses (5) and hose (6) from wiper valve (7).
4. Remove two connectors (8) and elbow (9) from wiper valve (7).
5. Loosen two setscrews (10) and remove knob (11), nut (12), and wiper valve (7) from control panel (3).
6. Disconnect six connectors (13).
7. Remove nut (14) and mirror heat switch (15) from control panel (3).
3
2
1 23
24
27 22
26 17 28
14
10
25 11
12
13 21
20 16
19
18 9
15
7
13
8
13 6
5
8. Remove heater indicator light (16).
9. Remove two nuts (17) and auxiliary heater switches (18).
10. Press three plastic discs (19) and disconnect three tubes (20) from air switch (21).
11. Remove air switch (21).
12. Loosen two setscrews (22) and remove knob (23), nut (24), and fan speed switch (25).
13. Remove indicator light (26).
0067 00-2
TM 9-2320-302-20
HEATER AND AIR CONDITIONING CONTROL PANEL REPLACEMENT - CONTINUED 0067 00
REMOVAL - CONTINUED
14. Remove ac/heater panel (27) and two label holders (28) from control panel (3).
INSTALLATION
1. Install two label holders (28) and ac/heater panel (27) to control panel (3).
2. Install indicator light (26).
3. Install fan speed switch (25), nut (24), and knob (23). Tighten two setscrews (22).
4. Install air switch (21).
5. Press three plastic discs (19) and connect three tubes (20) to air switch (21).
6. Install two auxiliary heater switches (18) with two nuts (17).
7. Install heater indicator light (16).
8. Install mirror heat switch (15) with nut (14).
9. Connect six connectors (13).
10. Install wiper valve (7), nut (12), and knob (11). Tighten two setscrews (10).
WARNING
clothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If adhesives
or sealing compound contacts skin or clothing, wash immediately with soap and water.
11. Apply pipe sealing compound to threads of elbow (9) and two connectors (8) and install elbow and connectors to wiper
valve (7).
12. Connect hose (6) and three hoses (5) to wiper valve (7).
13. Install fiber optic labels (4).
14. Install control panel (3) to dashboard with six screws (2). Install two heater control knobs (1).
END OF WORK PACKAGE
0067 00-3
TM 9-2320-302-20
0067 00-4
TM 9-2320-302-20
12V POWER RECEPTACLE REPLACEMENT 0068 00
INITIAL SETUP

REMOVAL
1. Remove wiring harness connector (1) from 12V power receptacle (2).
2. Remove 12V power receptacle (2) from cap assembly (3).
3. Remove cap assembly (3) from auxiliary panel (4).
4 2
INSTALLATION
1. Install cap assembly (3) on auxiliary panel (4).

2. Install 12V power receptacle (2) on cap assembly (3).
3. Install wiring harness connector (1) on 12V power receptacle (2).
END OF WORK PACKAGE
0068 00-1
TM 9-2320-302-20
0068 00-2
TM 9-2320-302-20
FIBER OPTIC LIGHT SOURCE REPLACEMENT 0069 00
INITIAL SETUP

TM 9-2320-302-10
Wrench set, socket attachment (Item 49, WP 0236 00)
Equipment Condition
Materials/Parts
Straps, tiedown (Item 30, WP 0235 00) Center gage panel removed (WP 0061 00)
REMOVAL
1. Remove nut (1), torx screw (2), and fiber optic light source (3).
2. Turn light socket (4) to left and remove from fiber optic light source (3).
3. Remove tiedown strap (5) and discard.
CAUTION
Do not crimp fiber optic lines. Crimping could cause lines to break internally, resulting in instrument light
failure.
4. Release two latches (6) on rear of fiber optic light source (3) and remove four fiber optic lines (7).
5
1,2
0069 00-1
TM 9-2320-302-20
FIBER OPTIC LIGHT SOURCE REPLACEMENT - CONTINUED 0069 00
INSTALLATION
CAUTION
Do not crimp fiber optic lines. Crimping could cause lines to break internally, resulting in instrument light
failure.
1. Position four fiber optic lines (7) on rear of fiber optic light source (3) and engage two latches (6).
2. Install new tiedown strap (5).
3. Install light socket (4) on fiber optic light source (3) and turn light socket to right.
4. Install fiber optic light source (3) with torx screw (2) and nut (1).
5
1,2
5. Install center gage panel (WP 0061 00).
END OF WORK PACKAGE
0069 00-2
TM 9-2320-302-20
CHECK ENGINE SWITCH AND JUMPER HARNESS REPLACEMENT 0070 00
INITIAL SETUP

Materials/Parts
REMOVAL
1. Remove nut (1) and washer (2) from switch (3).
2. Remove three screws and pull lower dash cover (4) away from dashboard.
3. Remove switch (3) from lower dash cover (4).
NOTE
4. Remove two nuts (5), lock washers (6), and wires (7) from switch (3).
5. Remove jumper harness connector (8) from vehicle harness (9).
7 8
5
6
5 9
6
1
3
4
2
INSTALLATION
1. Install jumper harness connector (8) on vehicle harness (9).
2. Install two wires (7) on switch (3) with two lock washers (6) and nuts (5).
3. Install switch (3) on lower dash cover (4) with washer (2) and nut (1).
4. Install lower dash cover (4) on dashboard with three screws.
END OF WORK PACKAGE
0070 00-1
TM 9-2320-302-20
0070 00-2
TM 9-2320-302-20
FUSE, RELAY, CIRCUIT BREAKER, AND HOLDER REPLACEMENT 0071 00
Fuse Removal, Relay Removal, Circuit Breaker Removal, Holder Removal, Holder Installation, Circuit Breaker Installa-
tion, Relay Installation, Fuse Installation
INITIAL SETUP

Materials/Parts
NOTE
• For location of fuses, relays, and circuit breakers inside cab, refer to page 0071 00-5.
• Tag or note position of all fuses, relays, circuit breakers, and connectors to aid in installation.
FUSE REMOVAL
NOTE
• To remove fuses in cab, perform steps 1 and 2.
• To remove battery box fuse, perform steps 3 and 4.
1. Rotate three turnlock fasteners (1) and remove cover (2) from cab.
0071 00-1
TM 9-2320-302-20
FUSE, RELAY, CIRCUIT BREAKER, AND HOLDER REPLACEMENT - CONTINUED 0071 00
FUSE REMOVAL - CONTINUED
2. Remove fuses (3) from holder (4).
3. Inside battery box, remove cover (5) from fuse (6).
4. Remove fuse (6) from fuse holder (7).
5 6 7
RELAY REMOVAL
Remove relays (8) from holder (4).
CIRCUIT BREAKER REMOVAL
Remove circuit breakers (9) from holder (4).
HOLDER REMOVAL
1. Remove four screws (10) and holder (4) from cab.
2. Remove connectors (11) from holder (4).
0071 00-2
TM 9-2320-302-20
HOLDER REMOVAL - CONTINUED
4
11
8
9
3
10
HOLDER INSTALLATION
1. Install connectors (11) on holder (4).
2. Install holder (4) on cab with four screws (10).
CIRCUIT BREAKER INSTALLATION
Install circuit breakers (6) on holder (4).
RELAY INSTALLATION
Install relays (5) on holder (4).
FUSE INSTALLATION
WARNING
When replacing fuses, ensure that replacement fuses are correct amperage. Fuses with incorrect amperage
could result in injury to personnel or damage to equipment.
NOTE
• To install fuses in cab, perform steps 1 and 2.
• To install battery box fuse, perform steps 3 and 4.
1. Install fuses (3) on holder (4).
2. Position cover (2) in cab and rotate three turnlock fasteners (1).
0071 00-3
TM 9-2320-302-20
FUSE INSTALLATION - CONTINUED

3. Install fuse (6) on holder (7).
4. Install cover (5) on fuse (6).
5 6 7
0071 00-4
TM 9-2320-302-20
FUSE INSTALLATION - CONTINUED
END OF WORK PACKAGE
0071 00-5
TM 9-2320-302-20
0071 00-6
TM 9-2320-302-20
MASTER BATTERY SWITCH REPLACEMENT 0072 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Battery cables disconnected (WP 0115 00)
Materials/Parts
Washer, lock (P/N 23-09318-013) (4)
REMOVAL
1. Remove four rubber boots (1).
0072 00-1
TM 9-2320-302-20
MASTER BATTERY SWITCH REPLACEMENT - CONTINUED 0072 00
REMOVAL - CONTINUED
NOTE
Tag cables to aid in installation.
2. Remove four nuts (2), four lockwashers (3), and four bolts (4) disconnecting six cables (5) from master battery switch
(6). Discard lockwashers.
3. Remove four nuts (7), eight washers (8), and four bolts (9) securing master battery switch (6) to bracket (10).
NOTE
Perform step 4, only if bracket is damaged.
4. Remove two bolts (11), four washers (12), two nuts (13), and bracket (10) from battery box (14).
12 12 11 10
13
14
4 8
6 8
5 4
2
3
5 2
0072 00-2
TM 9-2320-302-20
MASTER BATTERY SWITCH REPLACEMENT - CONTINUED 0072 00
INSTALLATION
NOTE
Perform step 1, only if bracket was removed.
1. Position bracket (10) on battery box (14) and install two bolts (11), four washers (12), and two nuts (13).
NOTE
Cables must be connected to master switch prior to master switch being mounted to bracket.
2. Install four bolts (4), six cables (5), four new lockwashers (3), and four nuts (2) securing cables to master battery switch
(6). Remove tags from cables.
3. Position master battery switch (6) on bracket (10) and install four bolts (9), eight washers (8), and four nuts (7).
4. Install four boots (1).
5. Connect battery cables (WP 0115 00).
END OF WORK PACKAGE
0072 00-3
TM 9-2320-302-20
0072 00-4
TM 9-2320-302-20
TURN SIGNAL SWITCH REPLACEMENT 0073 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Check engine switch removed (WP 0070 00)
References
TM 9-2320-302-10
REMOVAL
1. Remove five screws (1), washers (2) and cover (3).

2. Pull rubber cover (4) downward and remove screw (5) and clip (6).
3. Remove cable (7) from turn signal switch (8).
4. Remove clamp (9), turn signal switch (8), and trailer brake valve (10) from steering column (11). Set trailer brake valve
aside.
3 1,2 8
9
5,6 4 10
7 11
INSTALLATION
1. Install trailer brake valve (10) and turn signal switch (8) on steering column (11) with clamp (9). Tighten clamp.
2. Install cable (7) on turn signal switch (8).
3. Install clip (6) and screw (5). Push rubber cover (4) upward.
4. Install cover (3) with five washers (2) and screws (1).
5. Install check engine switch (WP 0070 00).
END OF WORK PACKAGE
0073 00-1
TM 9-2320-302-20
0073 00-2
TM 9-2320-302-20
ELECTRONIC THROTTLE REPLACEMENT 0074 00
INITIAL SETUP

Materials/Parts
Nut, lock (P/N 23-09900-104)
Nut, lock (P/N MS51922-1) (3)
REMOVAL
1. Rotate three turnlock fasteners (1) and remove cover (2).
NOTE
Note position of fasteners to aid in installation.
2. Remove three screws (3) and washers (4) from cover (5).
3. Remove lock nut (6), washer (7), spacer (8), screw (9), washer (10), and two covers (5 and 11). Discard lock nut.
4. Remove throttle cable connector (12) from wiring harness (13).
13
12
2
3,4
11
6,7,8 9,10
0074 00-1
TM 9-2320-302-20
ELECTRONIC THROTTLE REPLACEMENT - CONTINUED 0074 00
REMOVAL - CONTINUED
5. Remove three locknuts (14), washers (15), and electronic throttle (16) from vehicle. Discard lock nuts.
6. Remove two screws (17), clamps (18), and cable (19) from electronic throttle (16).
16
15
14
19
18
17
18
15
14
INSTALLATION
1. Install cable (19) on electronic throttle (16) with two clamps (18) and screws (17).
2. Install electronic throttle (16) on vehicle with three washers (15) and new lock nuts (14).
3. Install throttle cable connector (12) to wiring harness (13).
4. Install two covers (5 and 11) with washer (10), screw (9), spacer (8), washer (7), and new lock nut (6).
5. Install three washers (4) and screws (3) on cover (5).
6. Install cover (2) and rotate three turnlock fasteners (1).
0074 00-2
TM 9-2320-302-20
ELECTRONIC THROTTLE REPLACEMENT - CONTINUED 0074 00
13
12
2
3,4
11
9,10
6,7,8
END OF WORK PACKAGE
0074 00-3
TM 9-2320-302-20
0074 00-4
TM 9-2320-302-20
ELECTRONIC CONTROL MODULE REPLACEMENT 0075 00
INITIAL SETUP

Materials/Parts
NOTE
Tag all connectors to aid in installation.
REMOVAL
1. Remove three connectors (1 and 2) from electronic control module (3).
2. Loosen two screws (4) and remove two connectors (5) from electronic control module (3).
3. Remove four bolts (6), electronic control module (3), four isolators (7), and spacers (8) from engine.
4. Remove four isolators (7) from bolts (6).
6,7,8 4
3
2
INSTALLATION
1. Install four isolators (7) on bolts (6).
2. Install four spacers (8), isolators (7), and electronic control module (3) on engine with four bolts (6).
3. Install two connectors (5) on electronic control module (3) and tighten two screws (4).
4. Install three connectors (1 and 2) on electronic control module (3).
END OF WORK PACKAGE
0075 00-1
TM 9-2320-302-20
0075 00-2
TM 9-2320-302-20
NATO SLAVE RECEPTACLE REPLACEMENT 0076 00
INITIAL SETUP

Materials/Parts
References
Nut, lock (P/N 23-09336-005) (4)
Nut, lock (P/N MS51922-1) (3) TM 9-2320-302-10
NOTE
Tag cables prior to removal to aid in installation.
REMOVAL
1. Remove two screws (1), lock washers (2), and cables (3) from NATO slave receptacle (4).
2. Remove four lock nuts (5), washers (6), screws (7), cap (8) and NATO slave receptacle (4) from angle bracket (9). Dis-
card lock nuts.
3 2
9
5
4
6
7
8
1
3 7
0076 00-1
TM 9-2320-302-20
NATO SLAVE RECEPTACLE REPLACEMENT - CONTINUED 0076 00
REMOVAL - CONTINUED
NOTE
Perform steps 3 and 4 only if angle bracket is damaged.
3. Remove batteries (WP 0113 00).
4. Remove three lock nuts (10), washers (11), screws (12), and angle bracket (9) from battery box (13). Discard lock nuts.
INSTALLATION
NOTE
Perform steps 1 and 2 only if angle bracket was removed.
1. Install angle bracket (9) on battery box (13) with three screws (12), washers (11), and new lock nuts (10).
2. Install batteries (WP 0113 00).
3. Install NATO slave receptacle (4) and cap (8) on angle bracket (9) with four screws (7), washers (6), and new lock nuts
(5).
4. Install two cables (3) on NATO slave receptacle (4) with two lock washers (2) and screws (1).
12 13
3 2
9
5
4
6
7
8
1
11
3 7
10
END OF WORK PACKAGE
0076 00-2
TM 9-2320-302-20
UTILITY POWER RECEPTACLE REPLACEMENT 0077 00
INITIAL SETUP

Riveter, blind, hand (Item 28, WP 0236 00) Equipment Condition
Materials/Parts Cab liners removed (WP 0202 00)
Rivet, blind (P/N 23-09990-104) (2)
Washer, lock (P/N 23-09318-006) (4)
Adhesive (Item 1, WP 0235 00)
NOTE
• Cab has two utility power receptacles.
• Tag wires prior to removal to aid in installation.
REMOVAL
1. Remove two screws (1), wires (2), and four lock washers (3) from receptacle (4). Discard lock washers.
2. Remove cover (5) from receptacle (4).
NOTE
Note position of receptacle for installation.
3. Remove two rivets (6), receptacle (4), and chain (7) from cab. Discard rivets.
2
1 3
6
5
3
0077 00-1
TM 9-2320-302-20
UTILITY POWER RECEPTACLE REPLACEMENT - CONTINUED 0077 00
INSTALLATION
WARNING
1. Lightly coat mating surfaces of receptacle (4) and cab with adhesive.
2. Install receptacle (4) and chain (7) on cab with two new rivets (6).
3. Install cover (5) on receptacle (4).
4. Install four new lockwashers (3) and two wires (2) on receptacle (4) with two screws (1).
5. Install cab liners (WP 0202 00).
2
1 3
6
5
3
END OF WORK PACKAGE
0077 00-2
TM 9-2320-302-20
TRAILER ELECTRICAL RECEPTACLES REPLACEMENT 0078 00
INITIAL SETUP

WP 0119 00
REMOVAL
1. Remove four nuts (1), washers (2), and screws (3) from trailer electrical receptacle (4).
2. Remove trailer electrical receptacle (4) and cover (5) from bracket (6).
NOTE
Other two electrical receptacles use two nuts, washers, and screws.
3. Repeat steps 1 and 2 for each of two other electrical receptacles (7).
4. Refer to WP 0119 00 to remove electrical receptacles (4 or 7) from electrical cable.
6 7
7
1 4 5
0078 00-1
TM 9-2320-302-20
TRAILER ELECTRICAL RECEPTACLES REPLACEMENT - CONTINUED 0078 00
INSTALLATION
1. Refer to WP 0119 00 to install electrical receptacles (4 or 7) on electrical cable.
2. Install electrical receptacle (4) and cover (5) on bracket (6) with four screws (3), washers (2), and nuts (1).
NOTE
Other two electrical receptacles use two nuts, washers, and screws.
3. Repeat step 2 for each of two other electrical receptacles (7).
6 7
7
1 4 5
END OF WORK PACKAGE
0078 00-2
TM 9-2320-302-20
PARKING BRAKE PRESSURE SWITCH REPLACEMENT 0079 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Materials/Parts
Compound, sealing, pipe (Item 10, WP 0235 00) Air system drained (TM 9-2320-302-10)
REMOVAL
1. Remove three torx screws (1) and dashboard cover (2) from dashboard.
2. Remove five torx screws (3) and dash panel cover (4).
2 3
4
1
3. Remove wiring harness connector (5) from parking brake pressure switch (6).
6
5
0079 00-1
TM 9-2320-302-20
PARKING BRAKE PRESSURE SWITCH REPLACEMENT - CONTINUED 0079 00
REMOVAL - CONTINUED
WARNING
• DO NOT disconnect any air system lines or fittings unless vehicle engine is shut down and air system
pressure is relieved. Failure to follow this warning could result in serious injury to personnel.
• Always wear eye protection when disconnecting air lines. Residual air will be expelled. Failure to fol-
low this warning may result in serious eye injury.
4. Remove parking brake pressure switch (6) from adapter fitting (7) on tee (8).
INSTALLATION
WARNING
adhesives or sealing compound gets on skin or clothing, wash immediately with soap and water.
air lines or fittings. Failure to follow this warning could result in injury to personnel and damage to
equipment.
1. Lightly coat male threads on parking brake pressure switch (6) with pipe sealing compound.
2. Install parking brake pressure switch (6) on adapter fitting (7) on tee (8).
3. Install wiring harness connector (5) on parking brake pressure switch (6).
6 7
5
4. Start vehicle, pressurize air system, apply parking brake and check for air leaks (TM 9-2320-302-10).
NOTE
Ensure that parking brake light illuminates when parking brake is applied.
0079 00-2
TM 9-2320-302-20
PARKING BRAKE PRESSURE SWITCH REPLACEMENT - CONTINUED 0079 00
5. Shut vehicle off (TM 9-2320-302-10).
6. Install dash panel cover (4) with five torx screws (3).
7. Install dashboard cover (2) on dashboard with three torx screws (1).
2 3
4
1
END OF WORK PACKAGE
0079 00-3
TM 9-2320-302-20
0079 00-4
TM 9-2320-302-20
WATER LEVEL MODULE REPLACEMENT 0080 00
INITIAL SETUP
REMOVAL
1. Unlock three fasteners (1) and remove cover (2).
2. Remove connector (3) from vehicle wiring.
3. Remove screw (4), clamp (5), and module (6) from firewall (7).
1
7 3
2
6
INSTALLATION
1. Install module (6) on firewall (7) with clamp (5) and screw (4).
2. Install connector (3) on vehicle wiring.
3. Install cover (2) and lock three fasteners (1).
END OF WORK PACKAGE
0080 00-1
TM 9-2320-302-20
0080 00-2
TM 9-2320-302-20
WATER LEVEL PROBE REPLACEMENT 0081 00
INITIAL SETUP
Compound, sealing, pipe (Item 10, WP 0235 00) Cooling system drained (WP 0041 00)
REMOVAL
1. Disconnect wiring harness connector (1) from water level probe (2).
2. Remove water level probe (2) and bushing (3) from radiator (4).
1 3
4
0081 00-1
TM 9-2320-302-20
WATER LEVEL PROBE REPLACEMENT - CONTINUED 0081 00
INSTALLATION
WARNING
1. Lightly coat threads of bushing (3) and water level probe (2) with pipe sealing compound. Install bushing and water
level probe on radiator (4).
2. Connect wiring harness connector (1) to water level probe (2).
2
1 3
4
END OF WORK PACKAGE
0081 00-2
TM 9-2320-302-20
HEADLAMP ADJUSTMENT 0082 00
Adjustment
INITIAL SETUP

Tape, measuring, 50 feet (Item 31, WP 0236 00) Equipment Condition
Tires inflated to recommended pressure (TM 9-2320-
302-10)
NOTE
Perform adjustment procedures with no load on vehicle.
ADJUSTMENT
1. Determine center of vehicle by measuring distance between two tow brackets (1) and dividing distance by 2.
2. Measure distance determined in step 1 from either of two tow brackets (1) to center of bumper (2). Mark bumper.
1
2
3. Drive vehicle close to a light-colored wall with front bumper (2) parallel to wall.
4. Transfer center mark of bumper (2) to wall.
0082 00-1
TM 9-2320-302-20
HEADLAMP ADJUSTMENT - CONTINUED 0082 00
ADJUSTMENT - CONTINUED
5. Back vehicle in a STRAIGHT line away from wall until vehicle is 25 ft (7.63 m) from wall. Park vehicle.
6. Extend mark on wall upward and downward to floor. Ensure that line is vertical. This is vehicle centerline.
7. On vehicle centerline, measure upward 41 in (104.1 cm) from floor. Make a horizontal line parallel to floor.
8. Determine low-beam headlight center by measuring outward 36.5 in (92.7 cm) on each side of vehicle centerline. Mark
center.
9. Measure 4 in (10.2 cm) in all four directions from mark to make an 8 in (20.3 cm) square.
10. Repeat step 9 on other side of vehicle centerline.
11. Determine high-beam headlamp center by measuring inward 7.5 in (19.1 cm) on each side of vehicle center line. Mark
center.
NOTE
Low-beam and high-beam squares will overlap slightly.
12. Measure 4 in (10.2 cm) in all four directions from each mark to make two more 8 in (20.3 cm) squares.
0082 00-2
TM 9-2320-302-20
HEADLAMP ADJUSTMENT - CONTINUED 0082 00
CARDBOARD
(7.25 IN x 5 IN)
13. With low-beam headlamps on, adjust each headlamp until highest intensity point is slightly to right and slightly below
headlamp centerlines +/- 4 in (+/- 10.2 cm). To adjust intensity point up or down, rotate center adjusting screw (3) left or
right. To adjust intensity point left or right, rotate side adjusting screw (4) left or right.
14. With high-beam headlamps on, cover each low-beam headlamp with cardboard cut to 7.25 in x 5 in (18.4 cm x 13 cm).
15. Adjust each headlamp until highest intensity point is over centerline mark +/- 4 in (+/- 10.2 cm). To adjust intensity
point up or down, rotate center adjusting screw (3) left or right. To adjust intensity point left or right, rotate side adjust-
ing screw (4) left or right.
END OF WORK PACKAGE
0082 00-3
TM 9-2320-302-20
0082 00-4
TM 9-2320-302-20
HEADLAMP AND HEADLIGHT REPLACEMENT 0083 00
Headlamp Removal, Headlight Removal, Headlight Installation, Headlamp Installation
INITIAL SETUP

Materials/Parts WP 0082 00

Adhesive, silicone rubber (Item 3, WP 0235 00)
HEADLAMP REMOVAL
NOTE
Both headlamps are replaced the same way. One headlamp is illustrated.
1. Remove four screws (1) from bezel (2).

2. Disconnect turn signal light (3) and remove bezel (2) from vehicle.
3. Remove four screws (4) and headlamp retainer (5) from headlamp (6).
4. Remove headlamp (6) from vehicle.
6
4
5
4
5
6
2
1
3
0083 00-1
TM 9-2320-302-20
HEADLAMP AND HEADLIGHT REPLACEMENT - CONTINUED 0083 00
HEADLIGHT REMOVAL
1. Remove connector (7) from wiring harness (8).
2. Remove lock nut (9), screw (10), washer (11), and clamp (12) from bracket (13). Discard lock nut.
3. Remove screw (14) and clamp (15) from headlight assembly (16).
4. Remove eight screws (17) and headlight assembly (16) from vehicle.
7
14
10
11
12
15
16
13
17
5. Remove four grommets (18) from headlight assembly (16).
16
18
HEADLIGHT INSTALLATION
1. Install four grommets (18) on headlight assembly (16).
0083 00-2
TM 9-2320-302-20
HEADLAMP AND HEADLIGHT REPLACEMENT - CONTINUED 0083 00
HEADLIGHT INSTALLATION - CONTINUED
WARNING
2. Apply adhesive to mating surface of headlight assembly (16). Install headlight assembly on vehicle with eight screws
(17).
3. Install clamp (15) and screw (14) on headlight assembly (16).
4. Install clamp (12) on bracket (13) with washer (11), screw (10), and new lock nut (9).
5. Connect connector (7) on wiring harness (8).
HEADLAMP INSTALLATION
NOTE
Procedure is the same for all headlamps.
6
4
5
4
5
6
2 1 3
1. Install headlamp (6) on vehicle.
2. Install headlamp retainer (5) on headlamp (6) and four screws (4).
3. Position bezel (2) on vehicle and connect turn signal light (3).
4. Install four screws (1) on bezel (2).
5. Adjust headlamps (6) (WP 0082 00).
END OF WORK PACKAGE
0083 00-3
TM 9-2320-302-20
0083 00-4
TM 9-2320-302-20
BLACKOUT DRIVE, MARKER LIGHT, AND WIRING HARNESS REPLACEMENT 0084 00
INITIAL SETUP
Tool kit, general mechanic’s (Item 36, WP 0236 00) Washer, lock (P/N 104J005-29)
Materials/Parts Tags, marker (Item 31, WP 0235 00)
Nut, lock (P/N 233774) (2) References
Nut, lock (P/N MS51922-1) (3) TM 9-2320-302-10
REMOVAL
NOTE
Tag connectors prior to removal to aid in installation.
1. Disconnect three connectors (1).
0084 00-1
TM 9-2320-302-20
BLACKOUT DRIVE, MARKER LIGHT, AND WIRING HARNESS REPLACEMENT - CONTINUED 0084 00
REMOVAL - CONTINUED
2. Remove three lock nuts (2), washers (3), and clamp (4). Discard lock nuts.
NOTE
Quantity of wire tiedown straps may vary. Remove tiedown straps as needed and discard.
3. Remove grommet (5) and pull harness (6) through fender while removing blackout light assembly (7) from fender.
4. Remove two lock nuts (8), wire (9), marker light (10), and three screws (11). Discard lock nuts.
15
7
11
9
16
11 8
5
10 3
14 3
13 2
12
4
6
1
5. Remove nut (12), lock washer (13), ground wire (14), and blackout drive light (15) from bracket (16). Discard lock
washer.
6. Remove harness (6) from blackout drive light (15).
DISASSEMBLY
1. Loosen three screws (17) and remove door (18) from enclosure (19).
NOTE
2. Remove lamp unit (20) from enclosure (19) and disconnect two wires (21). Remove shell (22).
3. Remove washer (23), grommet (24), and adapter (25) from enclosure (19).
0084 00-2
TM 9-2320-302-20
BLACKOUT DRIVE, MARKER LIGHT, AND WIRING HARNESS REPLACEMENT - CONTINUED 0084 00
19 6
22 23 24 25
18
21
17 20
ASSEMBLY
1. Install adapter (25), grommet (24), and washer (23) on enclosure (19).
2. Install shell (22), connect two wires (21), and install lamp unit (20) on enclosure (19).
3. Position door (18) on enclosure (19) and tighten three screws (17).
INSTALLATION
NOTE
Quantity of wire tiedown straps may vary. Install new tiedown staps as needed.
4. Install blackout drive light (15) and ground wire (14) on bracket (16) with new lock washer (13) and nut (12).
5. Install harness (6) on blackout drive light (15).
6. Install three screws (11), marker light (10), wire (9), and two new lock nuts (8) on bracket (16).
7. Insert harness (6) through fender and install blackout light assembly (7), grommet (5), clamp (4), three washers (3), and
new lock nuts (2).
8. Connect three connectors (1).
END OF WORK PACKAGE
0084 00-3
TM 9-2320-302-20
0084 00-4
TM 9-2320-302-20
RIGHT FRONT BLACKOUT MARKER REPLACEMENT 0085 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Straps, tiedown (Item 30, WP 0235 00)
Materials/Parts Tags, marker (Item 31, WP 0235 00)
Nut, lock (P/N 233774) (2) References

Nut, lock (P/N MS51922-1) (3) TM 9-2320-302-10
REMOVAL
NOTE
• Tag connectors and wire to aid in installation.
• Quantity of tiedown straps may very. Remove tiedown straps as needed and discard.
1. Disconnect two connectors (1).
2. Remove three locknuts (2), washers (3), and clamp (4). Discard locknuts.
3. Remove grommet (5) and feed harness (6) through fender while removing blackout marker light assembly (7) from
fender.
4. Remove two lock nuts (8) and wire (9). Discard lock nuts.
5. Remove blackout marker (10) and three screws (11) from bracket (12).
11
7 12 8
11 9
3
10 2
5
4
3
3
2
2
0085 00-1
TM 9-2320-302-20
RIGHT FRONT BLACKOUT MARKER REPLACEMENT - CONTINUED 0085 00
INSTALLATION
NOTE
Quantity of tiedown straps may vary. Install new tiedown straps as needed.
1. Install three screws (11) and blackout marker (10) on bracket (12).
2. Install wire (9) and two new lock nuts (8).
3. Insert harness (6) through fender and install blackout marker light assembly (7), grommet (5), clamp (4), three washers
(3), and new lock nuts (2).
4. Connect two connectors (1).
11
7 12 8
11 9
3
10 2
5
4
3
3
2
2
END OF WORK PACKAGE
0085 00-2
TM 9-2320-302-20
REAR BLACKOUT MARKER REPLACEMENT 0086 00
INITIAL SETUP

Materials/Parts
Nut, lock (P/N 233774) (2)
NOTE
Rear blackout marker lights are replaced the same. Perform procedure for each rear blackout marker as
required.
REMOVAL
NOTE
Tag connectors to aid in installation.
1. Disconnect two connectors (1).

2. Remove nut (2), washer (3), and clamp (4).
3. Remove two lock nuts (5) and blackout marker (6). Discard lock nuts.
2
3
1
5
3 4
4
5
6
0086 00-1
TM 9-2320-302-20
REAR BLACKOUT MARKER REPLACEMENT - CONTINUED 0086 00
INSTALLATION
1. Install blackout marker (6) with two new lock nuts (5).
2. Install clamp (4), washer (3), and nut (2).
3. Connect two connectors (1).
2
3
1
5
3 4
4
5
6
END OF WORK PACKAGE
0086 00-2
TM 9-2320-302-20
TAILLIGHT MAINTENANCE 0087 00
Lamp Replacement, Removal, Installation
INITIAL SETUP

Materials/Parts
Nut, lock (P/N 23-10340-125) (3)
LAMP REPLACEMENT
1. Remove four screws (1) and lens (2) from taillight housing (3).
2. Inspect gasket (4) for damage. Replace gasket if damaged.
3. Remove lamps (5 and 6) by pushing in and turning clockwise.
4. Install lamps (5 and 6) by pushing in and turning clockwise.
5. Install lens (2) on taillight housing (3) with four screws (1).
5
4
6
2
0087 00-1
TM 9-2320-302-20
TAILLIGHT MAINTENANCE - CONTINUED 0087 00
NOTE
Left and right taillights are replaced the same way. Left taillight is shown.
REMOVAL
1. Disconnect taillight wiring harness connector (7) from taillight housing (3).
2. Remove three lock nuts (8), washers (9), and taillight housing (3) from bracket (10). Discard lock nuts.
9 10
3
8
INSTALLATION
1. Install taillight housing (3) on bracket (10) with three washers (9) and new lock nuts (8).
2. Connect taillight wiring harness connector (7) to taillight housing (3).
END OF WORK PACKAGE
0087 00-2
TM 9-2320-302-20
SIDE MARKER/TURN SIGNAL LIGHT REPLACEMENT 0088 00
INITIAL SETUP

Materials/Parts
Gasket (P/N GNI 9700G1)
Nut, lock (P/N 23-09336-005) (2)
NOTE
Left and right side marker/turn signal lights are replaced the same way. Left side marker/turn signal light is
shown.
REMOVAL
1. Remove two lock nuts (1), washers (2), clamp (3), two screws (4), lens cover (5), and gasket (6) from side marker/turn
signal light (7). Discard lock nuts and gasket.
2. Remove lamp (8) from side marker/turn signal light (7).
3. Disconnect connector (9) from side marker/turn signal light (7). Remove side marker/turn signal light from vehicle.
9
1
2
7
6
5
0088 00-1
TM 9-2320-302-20
SIDE MARKER/TURN SIGNAL LIGHT REPLACEMENT - CONTINUED 0088 00
INSTALLATION
1. Position side marker/turn signal light (7) on vehicle and connect connector (9).
2. Install lamp (8) on side marker/turn signal light (7).
3. Install new gasket (6), lens cover (5), and clamp (3) on side marker/turn signal light (7) with two screws (4), washers
(2), and new lock nuts (1).
9
1
2
7
6
5
4
END OF WORK PACKAGE
0088 00-2
TM 9-2320-302-20
CLEARANCE LIGHT REPLACEMENT 0089 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Head liners removed (WP 0203 00)
References
TM 9-2320-302-10
NOTE
Five clearance lights are replaced the same way. One clearance light is shown.
REMOVAL
1. Remove lens cover (1), lamp (2), two screws (3), and washers (4) from clearance light (5).
2. Remove clearance light (5).
3. Disconnect connector (6) and pull harness (7) through hole in cab (8).
4. Remove grommet (9) from cab (8).
3 2
5
4
9
7
8
6
INSTALLATION
1. Install grommet (9) on cab (8).
2. Feed harness (7) through hole in cab (8).
3. Connect connector (6).
4. Install clearance light (5), two washers (4), screws (3), lamp (2), and lens cover (1).
5. Install head liners (WP 0203 00).
END OF WORK PACKAGE
0089 00-1
TM 9-2320-302-20
0089 00-2
TM 9-2320-302-20
UTILITY LIGHT MAINTENANCE 0090 00
Lamp Removal, Light Removal, Light Installation, Lamp Installation
INITIAL SETUP
References
Materials/Parts
TM 9-2320-302-10
Nut, lock (P/N 115307A)
Equipment Conditions
Nut, lock (P/N MS51922-1) (6) Cab liners removed (WP 0202 00)
Washer, lock (P/N MS35335-36) Head liners removed (WP 0203 00)
NOTE
Right and left side utility lights are maintained the same way. Right side utility light is shown.
LAMP REMOVAL
1. Remove lens retainer (1) from utility light assembly (2).
2. Roll back rubber seal (3) and remove lamp (4), with two wires (5) attached, from utility light assembly (2).
3. Disconnect two wires (5) from lamp (4).
2 3
4
1
0090 00-1
TM 9-2320-302-20
UTILITY LIGHT MAINTENANCE - CONTINUED 0090 00
LIGHT REMOVAL
1. Disconnect utility light wiring connector (6) from cab wiring connector (7).
2. Remove rubber grommet (8) and pull utility light wiring out from inside cab.
3. Remove lock nut (9), lock washer (10), and utility light (2) from mounting bracket (11). Discard lock nut and lock
washer.
NOTE
Perform step 4 only if bracket is damaged.
4. Remove six screws (12), washers (13), lock nuts (14), and mounting bracket (11) from cab. Discard lock nuts.
2 3
7
6 4
8 1
13
14
13
10
12
9 11
LIGHT INSTALLATION
NOTE
Perform step 1 only if mounting bracket was removed.
1. Install mounting bracket (11) on cab with six screws (12), washers (13), and new lock nuts (14).
2. Install light (2) on mounting bracket (11) with new lock nut (9) and lock washer (10).
3. Feed utility light connector (6) through cab access and connect to cab wiring harness (7). Install grommet (8).
LAMP INSTALLATION
1. Connect two wires (5) to lamp (4). Position lamp in utility light assembly (2) and roll rubber seal (3) over lamp.
2. Install lens retainer (1) on utility light assembly (2).
3. Install cab liners (WP 0202 00).
4. Install head liners (WP 0203 00).
END OF WORK PACKAGE
0090 00-2
TM 9-2320-302-20
INTERIOR LIGHT UNIT AND BULB REPLACEMENT 0091 00

INITIAL SETUP

Materials/Parts
Lamp, incandescent (P/N 561)
Lamp, incandescent (P/N AN3121-1816)
REMOVAL
1. Remove two covers (1) and incandescent lamps (2 and 3) from light unit (4).
2. Remove two screws (5) and light unit (4) from mounting bracket (6).
3. Pull light unit (4) down and disconnect connector (7) from cab wiring harness.
2
4
1 5
INSTALLATION
1. Connect connector (7) to cab wiring harness.
2. Install light unit (4) on mounting bracket (6) with two screws (5).
3. Install two incandescent lamps (2 and 3) on light unit (4).
4. Install two covers (1) on light unit (4).
0091 00-1
TM 9-2320-302-20
INTERIOR LIGHT UNIT AND BULB REPLACEMENT - CONTINUED 0091 00
5. Check lamp for operation (TM 9-2320-302-10).
END OF WORK PACKAGE
0091 00-2
TM 9-2320-302-20
FUEL PRESSURE SENSOR REPLACEMENT 0092 00
INITIAL SETUP

Materials/Parts
Nut, lock (P/N MS51922-1) (2)
REMOVAL
1. Disconnect connector (1) of fuel pressure sensor (2) from wiring harness (3).
2. Remove fuel hose (4) and elbow (5) from fuel pressure sensor (2).
3. Remove fuel hose (6) and elbow (7) from fuel pressure sensor (2).
4. Remove two screws (8), washers (9), lock nuts (10), clamps (11), and fuel pressure sensor (2) from mounting plate (12).
Discard lock nuts.
5. Remove two screws (13), washers (14), and mounting plate (12) from side of engine.
10
12
11 2
7
6
14
13
3
1
5
8 9 4
0092 00-1
TM 9-2320-302-20
FUEL PRESSURE SENSOR REPLACEMENT - CONTINUED 0092 00
INSTALLATION
1. Install mounting plate (12) on side of engine with two washers (14) and screws (13).
2. Install fuel pressure sensor (2) on mounting plate (12) with two clamps (11), screws (8), washers (9), and new lock nuts
(10).
WARNING
CAUTION
Ensure that all fittings are clear of debris and excess pipe sealing compound does not enter fittings or fuel
lines. Failure to follow this caution could result in damage to equipment.
3. Lightly coat threads of elbow (7) with pipe sealing compound. Install elbow and fuel hose (6) on fuel pressure sensor
(2).
4. Lightly coat threads of elbow (5) with pipe sealing compound. Install elbow and fuel hose (4) on fuel pressure sensor
(2).
5. Connect connector (1) to wiring harness (3).
10
12
11
7 2
6
14
13
3
1
5
8 9 4
END OF WORK PACKAGE
0092 00-2
TM 9-2320-302-20
FUEL TEMPERATURE SENSOR REPLACEMENT 0093 00
INITIAL SETUP

Materials/Parts
REMOVAL
1. Disconnect engine wiring harness connector (1) from fuel temperature sensor (2).
2. Remove fuel temperature sensor (2) from elbow (3).
1 2 3
0093 00-1
TM 9-2320-302-20
FUEL TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0093 00
INSTALLATION
WARNING
CAUTION
Ensure that all fittings are clear of debris and excess pipe sealing compound does not enter fittings or fuel
lines. Failure to follow this caution could result in damage to equipment.
1. Lightly coat threads of fuel temperature sensor (2) with pipe sealing compound. Install fuel temperature sensor on elbow
(3).
2. Connect engine wiring harness connector (1) to fuel temperature sensor (2).
1 2 3
END OF WORK PACKAGE
0093 00-2
TM 9-2320-302-20
FUEL LEVEL SENDING UNIT REPLACEMENT 0094 00

INITIAL SETUP

Materials/Parts
Seal (P/N 22-27156-000)
REMOVAL
WARNING
NOTE
1. Remove screw (1), washer (2), and wire lead (3) from fuel level sending unit (4).
1,2
5
5
8
9
7
4 6
5
5 3
NOTE
Note cable and clamp position and tag wire lead to aid in installation.
2. Remove screw (5), ground lead (6), and clamp (7) from fuel level sending unit (4).
3. Remove cable (8) and clamp (7) from fuel level sending unit (4).
4. Remove four remaining screws (5), fuel level sending unit (4), and seal (9). Discard seal.
0094 00-1
TM 9-2320-302-20
FUEL LEVEL SENDING UNIT REPLACEMENT - CONTINUED 0094 00
INSTALLATION
1. Install new seal (9) and fuel level sending unit (4) with float toward rear of vehicle.
2. Install cable (8), clamp (7), and ground lead (6) on fuel level sending unit (4) with screw (5).
3. Install four remaining screws (5) on fuel level sending unit (4).
4. Install wire lead (3) on fuel level sending unit (4) with screw (1) and washer (2).
1,2
5
5
8
9
7
4 6
5
5 3
END OF WORK PACKAGE
0094 00-2
TM 9-2320-302-20
OIL PRESSURE SENSOR REPLACEMENT 0095 00
INITIAL SETUP

Materials/Parts
REMOVAL
1. Disconnect engine wiring harness connector (1) from oil pressure sensor (2) on left rear side of engine.
2. Remove oil pressure sensor (2) from engine block (3).
0095 00-1
TM 9-2320-302-20
OIL PRESSURE SENSOR REPLACEMENT - CONTINUED 0095 00
INSTALLATION
WARNINGS
CAUTION
Ensure that all fittings are clear of debris and excess pipe sealing compound does not enter fittings or lines.
Failure to follow this caution could result in damage to equipment.
1. Lightly coat threads of oil pressure sensor (2) with pipe sealing compound. Install oil pressure sensor in engine block
(3).
2. Connect engine wiring harness connector (1) to oil pressure sensor (2).
END OF WORK PACKAGE
0095 00-2
TM 9-2320-302-20
OIL TEMPERATURE SENSOR REPLACEMENT 0096 00
INITIAL SETUP

Materials/Parts
REMOVAL
1. Disconnect engine wiring harness connector (1) from oil temperature sensor (2).
2. Remove oil temperature sensor (2) from engine block (3).
1
2
0096 00-1
TM 9-2320-302-20
OIL TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0096 00
INSTALLATION
WARNING
CAUTION
Ensure that fittings are clear of debris and excess pipe sealing compound does not enter fittings or lines.
Failure to follow this caution could result in damage to equipment.
1. Lightly coat threads of oil temperature sensor (2) with pipe sealing compound. Install oil temperature sensor on engine
block (3).
2. Connect engine wiring harness connector (1) to oil temperature sensor (2).
1
2
END OF WORK PACKAGE
0096 00-2
TM 9-2320-302-20
OIL PRESSURE SENDING UNIT REPLACEMENT 0097 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Materials/Parts
Air system drained (TM 9-2320-302-10)
Compound, sealing, pipe (Item 10, WP 0235 00) Check engine switch removed (WP 0070 00)
REMOVAL
1. Remove five screws (1), washers (2), and cover (3).
2. Remove two screws (4) and cover (5).
3 1,2
3. If necessary, remove cab air junction block (WP 0149 00) to access oil pressure sending unit.
0097 00-1
TM 9-2320-302-20
OIL PRESSURE SENDING UNIT REPLACEMENT - CONTINUED 0097 00
REMOVAL - CONTINUED
4. Depress collar (6) and remove air line (7) from fitting (8).
5. Remove fitting (8) from cab air junction block (9).
6. Disconnect electrical connector (10) from oil pressure sending unit (11).
7. Remove oil pressure sending unit (11) from cab air junction block (9).
8 9
11
10
INSTALLATION
WARNING
adhesives or sealing compound contacts skin or clothing, wash immediately with soap and water.
air lines or fittings. Failure follow this warning could result in injury to personnel or damage to equip-
ment.
1. Lightly coat threads of oil pressure sending unit (11) with pipe sealing compound. Install sending unit on cab air junc-
tion block (9).
2. Connect electrical connector (10) to oil pressure sending unit (11).
3. Lightly coat threads of fitting (8) with sealing compound. Install fitting on cab air junction block (9).
4. Install air line (7) on fitting (8), completely in collar (6).
0097 00-2
TM 9-2320-302-20
OIL PRESSURE SENDING UNIT REPLACEMENT - CONTINUED 0097 00
5. If removed, install cab air junction block (WP 0149 00).
6. Install cover (5) with two screws (4).
3 1,2
5
END OF WORK PACKAGE
0097 00-3
TM 9-2320-302-20
0097 00-4
TM 9-2320-302-20
WATER TEMPERATURE SENSOR REPLACEMENT 0098 00
INITIAL SETUP


REMOVAL
1. Disconnect connector (1) from water temperature sensor (2).
2. Remove water temperature sensor (2) from cylinder head (3).
2
1
0098 00-1
TM 9-2320-302-20
WATER TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0098 00
INSTALLATION
WARNING
1. Lightly coat threads of water temperature sensor (2) with pipe sealing compound. Install water temperature sensor in
cylinder head (3).
2. Connect connector (1) to water temperature sensor (2).
2
1
END OF WORK PACKAGE
0098 00-2
TM 9-2320-302-20
WATER LEVEL SENSOR REPLACEMENT 0099 00
INITIAL SETUP

TM 9-2320-302-10
Materials/Parts
Equipment Condition
Washer, lock (P/N 3059-00874-02)
REMOVAL
1. Remove nut (1), lock washer (2), and wire (3) from water level sensor (4). Discard lock washer.
2. Remove water level sensor (4) and adapter (5) from engine block (6).
5 4
3
2
0099 00-1
TM 9-2320-302-20
WATER LEVEL SENSOR REPLACEMENT - CONTINUED 0099 00
INSTALLATION
WARNINGS
1. Lightly coat threads of adapter (5) and water level sensor (4) with pipe sealing compound. Install adapter and water level
sensor in engine block (6).
2. Install wire (3) on water level sensor (4) with new lock washer (2) and nut (1).
5 4
3
2
END OF WORK PACKAGE
0099 00-2
TM 9-2320-302-20
FAN TEMPERATURE SENSOR REPLACEMENT 0100 00
INITIAL SETUP


Compound, sealing, pipe (Item 10, WP 0235 00) Thermostat housing drained (WP 0041 00)
REMOVAL
1. Remove two screws (1), lock washers (2), and wires (3) from fan temperature sensor (4).
2. Remove fan temperature sensor (4) from thermostat housing (5).
2 3
3 2
5
0100 00-1
TM 9-2320-302-20
FAN TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0100 00
INSTALLATION
WARNING
or sealing compound gets on skin or clothing, wash immediately with soap and water.
1. Lightly coat threads of fan temperature sensor (4) with pipe sealing compound. Install in thermostat housing (5).
2. Install two wires (3) on fan temperature sensor (4) with two lock washers (2) and screws (1).
2 3
3 2
5
END OF WORK PACKAGE
0100 00-2
TM 9-2320-302-20
AIR TEMPERATURE SENSOR REPLACEMENT 0101 00
INITIAL SETUP

Materials/Parts
REMOVAL
1. Disconnect wiring harness connector (1) from sensor (2).
2. Remove sensor (2) from intake manifold (3).
0101 00-1
TM 9-2320-302-20
AIR TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0101 00
INSTALLATION
WARNING
1. Lightly coat threads of sensor (2) with pipe sealing compound.
2. Install sensor (2) on intake manifold (3).
3. Connect wiring harness connector (1) to sensor (2).
END OF WORK PACKAGE
0101 00-2
TM 9-2320-302-20
TURBO BOOST SENSOR (TBS) REPLACEMENT 0102 00
INITIAL SETUP

Seal (P/N 5182977)
References
TM 9-2320-302-10
REMOVAL
1. Disconnect engine wiring harness connector (1) from turbo boost sensor (2).
2. Remove two capscrews (3), turbo boost sensor (2), and seal (4) from intake manifold (5).
3 5
2,4
INSTALLATION
1. Install new seal (4) and turbo boost sensor (2) on intake manifold (5) with two capscrews (3). Torque capscrews to 21-
26 lb-in (2.4-3.0 Nm).
2. Connect engine wiring harness connector (1) to turbo boost sensor (2).
END OF WORK PACKAGE
0102 00-1
TM 9-2320-302-20
0102 00-2
TM 9-2320-302-20
TIMING REFERENCE SENSOR REPLACEMENT 0103 00
INITIAL SETUP

REMOVAL
1. Disconnect engine wiring harness connector (1) from timing reference sensor (2).
2. Remove capscrew (3) and timing reference sensor (2) from gear housing assembly (4).
INSTALLATION
1. Install timing reference sensor (2) in gear housing assembly (4) with capscrew (3). Tighten capscrew to 22-28 lb-ft (30-
38 Nm).
2. Connect engine wiring harness connector (1) to timing reference sensor (2).
END OF WORK PACKAGE
0103 00-1
TM 9-2320-302-20
0103 00-2
TM 9-2320-302-20
SYNCHRONOUS REFERENCE SENSOR REPLACEMENT 0104 00
INITIAL SETUP

REMOVAL
1. Disconnect engine wiring harness connector (1) from synchronous reference sensor (2).
2. Remove capscrew (3) and synchronous reference sensor (2) from gear housing assembly (4).
INSTALLATION
1. Install synchronous reference sensor (2) in gear housing assembly (4) with capscrew (3). Tighten capscrew to 22-28 lb-
ft (30-38 Nm).
2. Connect engine wiring harness connector (1) to synchronous reference sensor (2).
END OF WORK PACKAGE
0104 00-1
TM 9-2320-302-20
0104 00-2
TM 9-2320-302-20
AIR PRESSURE SENDING UNITS (PRIMARY/SECONDARY) REPLACEMENT 0105 00
INITIAL SETUP


Tags, marker (Item 31, WP 0235 00) Check engine switch removed (WP 0070 00)
REMOVAL
NOTE
Tag air lines and wires to aid in installation.
1. Disconnect engine wiring harness connector (1) from synchronous reference sensor (2).
2. Remove capscrew (3) and synchronous reference sensor (2) from gear housing assembly (4).
3
1,2
NOTE
If necessary, remove cab air junction block (WP 0149 00) for access to sensors.
0105 00-1
TM 9-2320-302-20
AIR PRESSURE SENDING UNITS (PRIMARY/SECONDARY) REPLACEMENT - CONTINUED 0105 00
REMOVAL - CONTINUED
NOTE
Perform steps 3 through 5 to remove primary air pressure sending units.
3. Remove two air lines (6) and fittings (7) from cab air junction block (8).
4. Disconnect two electrical connectors (9 and 10) from primary air pressure sending unit (11).
5. Remove primary air pressure sending unit (11) from air junction block (8).
14 12 13
9
7
10
7
8
11
NOTE
Perform steps 6 and 7 to remove secondary air pressure sending unit.
6. Disconnect two electrical connectors (12 and 13) from secondary air pressure sending unit (14).
7. Remove secondary air pressure sending unit (14) from cab air junction block (8).
INSTALLATION
WARNING
air lines or fittings. Failure to follow this warning could result in injury to personnel or damage to equip-
ment.
0105 00-2
TM 9-2320-302-20
AIR PRESSURE SENDING UNITS (PRIMARY/SECONDARY) REPLACEMENT - CONTINUED 0105 00
NOTE
Perform steps 1 and 2 to install secondary air pressure sending unit.
1. Lightly coat threads of secondary air pressure sending unit (14) with pipe sealing compound. Install sending unit on cab
air junction block (8).
2. Connect two electrical connectors (12 and 13) to secondary air pressure sending unit (14).
NOTE
Perform steps 3 through 6 to install primary air pressure sending unit.
3. Lightly coat threads of primary air pressure sending unit (11) with pipe sealing compound. Install sending unit on air
junction block (8).
4. Connect two electrical connectors (9 and 10) to primary air pressure sending unit (11).
5. Lightly coat threads of two fittings (7) with pipe sealing compound. Install fittings on cab air junction block (8).
6. Install two air lines (6) on fittings (7).
3 1,2
END OF WORK PACKAGE
0105 00-3
TM 9-2320-302-20
0105 00-4
TM 9-2320-302-20
FRONT ANTI-LOCK BRAKE SYSTEM (ABS) SENSOR REPLACEMENT 0106 00
INITIAL SETUP
Tool kit, general mechanic’s (Item 36, WP 0236 00) Grease, molybdenum disulfide (Item 17, WP 0235 00)
Materials/Parts Straps, tiedown (Item 30, WP 0235 00)
Bushing (P/N 10-12026-000) References
Nut, lock (P/N MS 1922-1) TM 9-2320-302-10
NOTE
Right- and left-front anti-lock brake system (ABS) sensors are replaced the same way. Right-front ABS sen-
sor is shown.
REMOVAL
1. Remove tiedown straps (1). Discard tiedown straps.
2. Remove lock nut (2) and clamp (3). Discard lock nut.
0106 00-1
TM 9-2320-302-20
FRONT ANTI-LOCK BRAKE SYSTEM (ABS) SENSOR REPLACEMENT - CONTINUED 0106 00
REMOVAL - CONTINUED
4. Remove clamp (4) from ABS connector (5) and wiring harness connector (6).
5. Disconnect ABS connector (5) from wiring harness connector (6).
5 4 6
6. Carefully pull body of sensor (7) from steering knuckle (8).
7. Remove bushing (9) from steering knuckle (8). Discard bushing.
8 9
0106 00-2
TM 9-2320-302-20
FRONT ANTI-LOCK BRAKE SYSTEM (ABS) SENSOR REPLACEMENT - CONTINUED 0106 00
INSTALLATION
1. Install new bushing (9) on steering knuckle (8).
2. Coat outside of sensor (7) with grease.
3. Carefully push body of sensor (7) on steering knuckle (8) until sensor is stopped by ABS tone ring.
4. Connect ABS connector (5) to wiring harness connector (6).
5. Install clamp (4) on ABS connector (5) and wiring harness connector (6).
6. Install clamp (3) and new lock nut (2).
7. Install new tiedown straps (1) as needed to secure wiring harness.
END OF WORK PACKAGE
0106 00-3
TM 9-2320-302-20
0106 00-4
TM 9-2320-302-20
REAR ANTI-LOCK BRAKE SYSTEM (ABS) SENSOR REPLACEMENT 0107 00
INITIAL SETUP


Nut, lock (P/N MS51922-1) (2) Rear dual wheels removed (TM 9-2320-302-10)
Grease, molybdenum disulfide (Item 17, WP 0235 00)
REMOVAL
1. Remove two lock nuts (1) and clamps (2). Discard lock nuts.
1,2
0107 00-1
TM 9-2320-302-20
REAR ANTI-LOCK BRAKE SYSTEM (ABS) SENSOR REPLACEMENT - CONTINUED 0107 00
REMOVAL - CONTINUED
3. Remove clamp (4) from ABS connector (5) and wiring harness connector (6).
4. Disconnect ABS connector (5) from wiring harness connector (6).
5 3
6
5. Remove drum (7) from axle (8).
7
8
6. Remove sensor (9) from mounting bracket (10).

7. Pull sensor assembly (11) through brake spider (12).
0107 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
12
11
10
INSTALLATION
1. Install sensor assembly (11) through brake spider (12).
2. Coat outside of sensor (9) with grease.
3. Carefully install sensor (9) on mounting bracket (10) until sensor is stopped by ABS tone ring.
4. Install drum (7) on axle (8).
5. Connect ABS connector (5) to wiring harness connector (6).
6. Install clamp (4) on ABS connector (5) and wiring harness connector (6).
7. Install new tiedown straps (3) as needed to secure harnesses.
8. Install two clamps (2) and secure with two new lock nuts (1).
1,2
0107 00-3
TM 9-2320-302-20
9. Install rear dual wheels (TM 9-2320-302-10).
END OF WORK PACKAGE
0107 00-4
TM 9-2320-302-20
ANTI-LOCK BRAKE SYSTEM (ABS) ELECTRONIC CONTROL UNIT REPLACEMENT 0108 00
INITIAL SETUP


Tags, marker (Item 31, WP 0235 00) Passenger seat as far forward as possible
REMOVAL
NOTE
Tag all cables to aid in installation.

2. Remove cable connectors (3) from electronic control unit (4).
3. Remove four screws (5) and electronic control unit (4).
5 4 2
1
INSTALLATION
1. Install electronic control unit (4) with four screws (5).
2. Install cable connectors (3) on electronic control unit (4).
END OF WORK PACKAGE
0108 00-1
TM 9-2320-302-20
0108 00-2
TM 9-2320-302-20
BRAKE LIGHT/TRAILER BRAKE LIGHT SENDING UNIT REPLACEMENT 0109 00
INITIAL SETUP
Tags, marker (Item 31, WP 0235 00) Engine check switch removed (WP 0070 00)
REMOVAL
3 1,2
5
3. If necessary, remove cab air junction block (WP 0149 00) to access brake light/trailer brake light sending unit.
NOTE
Tag electrical wires to aid in installation.
0109 00-1
TM 9-2320-302-20
BRAKE LIGHT/TRAILER BRAKE LIGHT SENDING UNIT REPLACEMENT - CONTINUED 0109 00
REMOVAL - CONTINUED
4. Remove two lock nuts (6) and electrical wires (7 and 8) from brake light/trailer brake light sending unit (9). Discard
lock nuts.
5. Remove brake light/trailer brake light sending unit (9) from elbow (10).
10 9 6 7
INSTALLATION
WARNING
ment.
1. Lightly coat threads of brake light/trailer brake light sending unit (9) with pipe sealing compound. Install sending unit
on elbow (10).
2. Install two electrical wires (7 and 8) on brake light/trailer brake light sending unit (9) with two new lock nuts (6).
0109 00-2
TM 9-2320-302-20
BRAKE LIGHT/TRAILER BRAKE LIGHT SENDING UNIT REPLACEMENT - CONTINUED 0109 00
3 1,2

6. Install engine check switch (WP 0070 00).
7. Check air system for leaks.
END OF WORK PACKAGE
0109 00-3
TM 9-2320-302-20
0109 00-4
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) ANTENNA ALIGNMENT 0110 00
Vertical Alignment, Horizontal Alignment
INITIAL SETUP
Test Equipment Personnel Required

Cartridge, CWS (Item 7, WP 0236 00) Three
Pro-link MPSI Reader (Item 33, WP 0236 00) Equipment Condition
Tools and Special Tools Vehicle parked on level ground (TM 9-2320-302-10)
Level, digital (Item 23, WP 0236 00)
NOTE
• To ensure accurate alignment of CWS antenna, vertical and horizontal ground surface angles must be
known in relation to level and compensated for during antenna alignment.
• Always perform vertical alignment first.
VERTICAL ALIGNMENT
1. Place digital level (3) vertically on CWS antenna (1). Take reading to determine which direction antenna must be
adjusted.
2. Loosen four screws (2) on side of CWS antenna (1) enough to allow repositioning of antenna without free travel.
3. Holding digital level (3) vertically on CWS antenna (1), pivot top or bottom of antenna until reading on level is 1 degree
below vertical (89 degrees if ground surface is level).
4. Tighten four screws (2).
0110 00-1
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) ANTENNA ALIGNMENT - CONTINUED 0110 00
HORIZONTAL ALIGNMENT
1. Using two towing eye brackets (4) as reference points, place a straight edge horizontally across face and center of CWS
antenna (1).
2. Measure distance between reference points and face of straight edge.
3. Adjust CWS antenna (1) until measurements are equal to within +/- 0.1 in (2.54 mm).
4. Determine from measurement which side of CWS antenna (1) needs adjustment.
5. If right side of CWS antenna (1) needs to come forward to make measurements equal, loosen only two right-side screws.
Pull antenna forward until measurements are equal, then tighten two screws.
6. If left side of CWS antenna (1) needs to come forward, perform step 5 on left side of antenna.
7. On Pro-link, go to Diagnostic menu.
8. Select CHECKOUT and press ENTER.
9. Select ANTENNA TEST and press ENTER.
NOTE
To perform following alignment accurately, a flat, straight stretch of road is required and both vehicles must
maintain consistent and constant lane position.
10. With support vehicle driving in front of host vehicle, observe azimuth reading on Pro-link. Reading must be +/- 0.02.
11. If reading is greater than +/- 0.02, perform steps 5 through 7.
12. Repeat vertical and horizontal alignment until criteria for both alignments are met without adjustments.
END OF WORK PACKAGE
0110 00-2
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) MAINTENANCE 0111 00
Antenna Assembly Replacement, Central Processing Unit (CPU) Replacement, Driver Display Unit (DDU) Replacement,
Side Sensor Replacement, Side Sensor Display Replacement
INITIAL SETUP

Materials/Parts
Nut, lock (P/N TBD) (4)
ANTENNA ASSEMBLY REPLACEMENT

1. Remove four nuts (1) and pull CWS antenna (2) out from bracket (3).
2. Disconnect harness connector (4) from CWS antenna (2). Remove antenna.
2
1
0111 00-1
TM 9-2320-302-20
COLLISION WARNING SYSTEM (CWS) MAINTENANCE - CONTINUED 0111 00
ANTENNA ASSEMBLY REPLACEMENT - CONTINUED
3. If damaged, remove four bolts (5), eight flat washers (6), four lock nuts (7), and bracket (3) from vehicle. Discard lock
nuts.
3
5
6 7
4. If removed, install bracket (3) on vehicle with four bolts (5), eight flat washers (6) and four new lock nuts (7).
5. Connect harness connector (4) to CWS antenna (2).
6. Install CWS antenna (2) on bracket (3) with four nuts (1).
7. Align antenna assembly (WP 0110 00).
CENTRAL PROCESSING UNIT (CPU) REPLACEMENT
1. Disconnect harness connector (8) from CPU (9).

2. Remove four screws (10) and CPU (9) from cab wall.
3. Install CPU (9) on cab wall with four screws (10).
4. Connect harness connector (8) to CPU (9)
5. Align antenna assembly (WP 0110 00).
10
0111 00-2
TM 9-2320-302-20
DRIVER DISPLAY UNIT (DDU) REPLACEMENT

1. Drain vehicle air system (TM 9-2320-302-10).
2. Disconnect parking brake and trailer air supply valves (WP 0160 00).
3. Disconnect harness connector (11) from DDU (12).
4. Remove two screws (13) and DDU (12) from dash panel.
5. Install DDU (12) on dash panel with two screws (3).
6. Connect harness connector (11) to DDU (12).
7. Connect parking brake and trailer air supply valves (WP 0160 00)
8. Perform CWS self-test (TM 9-2320-302-10).
13
12
11
0111 00-3
TM 9-2320-302-20
SIDE SENSOR REPLACEMENT

1. Disconnect harness connector (14) from side sensor connector (15).
2. Remove four screws (16) and side sensor (17) from bracket (18).
3. Install side sensor (17) on bracket (18) with four screws (16).
4. Connect harness connector (14) to side sensor connector (15).
18
16
17
14
15
SIDE SENSOR DISPLAY REPLACEMENT

1. Disconnect harness connector (19) from side sensor display (20).
2. Remove two screws (21), star washers (22), and side sensor display (20) from bracket (23).
3. Install side sensor display (20) on bracket (23) with two star washers (22) and screws (21).
4. Connect harness connector (19) to side sensor display (20).
0111 00-4
TM 9-2320-302-20
SIDE SENSOR DISPLAY REPLACEMENT - CONTINUED
23
20
21
22
19
END OF WORK PACKAGE
0111 00-5
TM 9-2320-302-20
0111 00-6
TM 9-2320-302-20
ELECTRIC HORN REPLACEMENT 0112 00
Horn Removal, Bracket Removal, Bracket Installation, Horn Installation
INITIAL SETUP

Materials/Parts
Washer, lock (P/N MS35333-40)
HORN REMOVAL
1. Disconnect connector (1) from horn (2).
2. Remove nut (3), lock washer (4), and horn (2) from bracket (5). Discard lock washer.
BRACKET REMOVAL
1. Remove nut (6), washer (7), screw (8), and bracket (5) from bracket (9).
2. Remove two nuts (10), wire (11), and bracket (9) from two studs (12).
3 4 5 1
9
8
10
12
11
0112 00-1
TM 9-2320-302-20
ELECTRIC HORN REPLACEMENT - CONTINUED 0112 00
BRACKET INSTALLATION
1. Install bracket (9) and wire (11) to two studs (12) with two nuts (10).
2. Install bracket (5) on bracket (9) with screw (8), washer (7), and nut (6).
HORN INSTALLATION
1. Install horn (2) on bracket (5) with new lock washer (4) and nut (3).
2. Connect connector (1) to horn (2).
3 4 5 1
9
8
10
12
11
END OF WORK PACKAGE
0112 00-2
TM 9-2320-302-20
BATTERY REPLACEMENT 0113 00
Battery Removal, Battery Hold-down Pin Removal, Battery Hold-down Pin Installation, Battery Installation
INITIAL SETUP


Nut, lock (P/N 23-09336-007) (6) Battery cables removed (WP 0115 00)
WARNING
0113 00-1
TM 9-2320-302-20
BATTERY REPLACEMENT - CONTINUED 0113 00
BATTERY REMOVAL
NOTE
Note position of batteries for installation.
1. Remove six lock nuts (1), washers (2), and two retaining straps (3) from battery box (4). Discard lock nuts.
2. Remove four batteries (5) from battery box (4).
1
2 2
BATTERY HOLD-DOWN PIN REMOVAL

If damaged, remove 18 lock nuts (6), 12 washers (7), and six pins (8) from battery box (4). Discard lock nuts.
BATTERY HOLD-DOWN PIN INSTALLATION
If removed, install six pins (8) on battery box (4) with 12 washers (7) and 18 new lock nuts (6).
BATTERY INSTALLATION
1. Position four batteries (5) in battery box (4).

2. Install two retaining straps (3) on battery box (4) with six washers (2) and new lock nuts (1).
3. Install battery cables (WP 0115 00).
END OF WORK PACKAGE
0113 00-2
TM 9-2320-302-20
BATTERY BOX REPLACEMENT 0114 00
INITIAL SETUP

Jack, hydraulic, hand (Item 21, WP 0236 00) Equipment Condition
Materials/Parts Batteries and battery hold-down pins removed (WP
Nut, kep (P/N 23-10340-125) (2) 0113 00)
Left step removed (WP 0172 00)
NATO slave receptacle removed (WP 0076 00)
REMOVAL
NOTE
Perform step 1 at each side of battery box.
1. Remove kep nut (1), washer (2), screw (3), and rubber latch assembly (4) from battery box (5).
2. Using suitable jack, support battery box (5).
2
4
3
0114 00-1
TM 9-2320-302-20
BATTERY BOX REPLACEMENT - CONTINUED 0114 00
REMOVAL - CONTINUED
NOTE
3. Remove three nuts (6), six washers (7), three screws (8), and bracket (9) holding battery box (5) on bracket (10).
4. Remove battery box (5) from vehicle and remove four plywood liners (11).
NOTE
Perform step 5 to remove each of two brackets from vehicle.
5. Remove four nuts (12), washers (13), screws (14), and bracket (10) from vehicle.
INSTALLATION
NOTE
Perform step 1 to install each of two brackets to vehicle.
1. Install bracket (10) on vehicle with four screws (14), washers (13), and nuts (12).
2. Install four plywood liners (11) in battery box (5).
3. Using suitable jack, position battery box on two brackets (10).
NOTE
4. Install battery box (5) and bracket (9) on bracket (10) with three screws (8), six washers (7), and three nuts (6).
5. Remove jack from battery box (5).
NOTE
6. Install rubber latch assembly (4) on battery box (5) with screw (3), washer (2), and new kep nut (1).
7. Install NATO slave receptacle (WP 0076 00).
8. Install left step (WP 0172 00).
9. Install battery hold-down pins and batteries (WP 0113 00).
0114 00-2
TM 9-2320-302-20
BATTERY BOX REPLACEMENT - CONTINUED 0114 00
11
10 9
12 8
13
7
7
7 6 14
13
14
10 5
9
7
14
8 1
2
4
3
END OF WORK PACKAGE
0114 00-3
TM 9-2320-302-20
0114 00-4
TM 9-2320-302-20
BATTERY CABLES REPLACEMENT 0115 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Battery box cover removed (WP 0114 00)
Materials/Parts
WARNING
REMOVAL
NOTE
• Perform steps 1 and 2 to safely disconnect battery cables from batteries in order to perform vehicle elec-
trical maintenance.
• Tag cables to aid in installation.
0115 00-1
TM 9-2320-302-20
BATTERY CABLE REPLACEMENT - CONTINUED 0115 00
REMOVAL - CONTINUED
1. Lift cap (1) and remove nut (2) and two cables (3) from negative battery cable (4).
2. Lift cap (5) and remove nut (6) and two cables (7) from positive battery cable (8).
5
13 14 8
10 6
9
7
11
14
12
4
1
3. Lift cap (9) and remove nut (10), two wires (11), and two cables (12) from battery cable (13).
4. Loosen eight nuts (14) and remove battery cables (4, 8, and 13) from batteries.
INSTALLATION
NOTE
Perform steps 3 through 5 to safely connect battery cables to batteries after performing vehicle electrical
maintenance.
1. Install battery cables (4, 8, and 13) on batteries and tighten eight nuts (14).
2. Install two cables (12) and wires (11) on battery cable (13) with nut (10). Install cap (9).
3. Install two cables (7) on positive battery cable (8) with nut (6). Install cap (5).
4. Install two cables (3) on negative battery cable (4) with nut (2). Install cap (1).
5. Install battery box cover (WP 0114 00).
END OF WORK PACKAGE
0115 00-2
TM 9-2320-302-20
STOP/TAIL/BACKUP LIGHTS WIRING HARNESS REPLACEMENT 0116 00
INITIAL SETUP

Materials/Parts
REMOVAL
1. Disconnect stop/tail/backup lights wiring harness connectors (1) from taillights (2).
NOTE
Wiring harness is secured in place with tiedown straps.
2. Remove tiedown straps. Discard tiedown straps.
3. Remove stop/tail/backup lights wiring harness (3) from vehicle.
2 1
3
1
INSTALLATION
1. Connect stop/tail/backup lights wiring harness connectors (1) to taillights (2).
NOTE
Install new wire tiedown straps, as necessary, to secure wiring harness.
2. Position stop/tail/backup lights wiring harness (3) on vehicle and secure with new tiedown straps.
END OF WORK PACKAGE
0116 00-1
TM 9-2320-302-20
0116 00-2
TM 9-2320-302-20
AUTOMATIC ETHER STARTING AID WIRING HARNESSES REPLACEMENT 0117 00
Main Wiring Harness Removal, Jumper Wiring Harness Removal, Main Wiring Harness Installation, Jumper Wiring Har-
ness Installation
INITIAL SETUP

Materials/Parts
NOTE
Tag wires and connectors to aid in installation.
MAIN WIRING HARNESS REMOVAL
NOTE
Remove tiedown straps, as necessary, and discard.
1. Disconnect connector (1) of main harness (2) from ether control relay harness connector (3).
2. Disconnect main harness connector (4) from valve harness connector (5).
2
3
0117 00-1
TM 9-2320-302-20
AUTOMATIC ETHER STARTING AID WIRING HARNESSES REPLACEMENT - CONTINUED 0117 00
MAIN WIRING HARNESS REMOVAL - CONTINUED
3. Remove screw (6) and terminal (7) of main harness (2) from side of engine.
4. Remove nut (8) and terminal (9) of main harness (2) from starter.
5. Disconnect main harness connector (10) from jumper harness connector (11).
6. Remove main harness (2) from vehicle.
JUMPER WIRING HARNESS REMOVAL
1. Disconnect jumper harness connector (11) from main harness connector (10).
2. Disconnect jumper harness connector (12) from ECU connector (13).
3. Disconnect jumper harness connector (14) from ECU harness connector (15).
4. Remove jumper harness (16) from vehicle.
7 6 8,9
15
10
11 13 12 14
16
MAIN WIRING HARNESS INSTALLATION
1. Position main harness (2) on vehicle.

2. Connect main harness connector (10) to jumper harness connector (11).
3. Install terminal (9) of main harness (2) to starter with nut (8).
4. Install terminal (7) of main harness (2) to side of engine with screw (6).
5. Connect main harness connector (4) to valve harness connector (5).
0117 00-2
TM 9-2320-302-20
AUTOMATIC ETHER STARTING AID WIRING HARNESSES REPLACEMENT - CONTINUED 0117 00
MAIN WIRING HARNESS INSTALLATION - CONTINUED

6. Connect connector (1) of main harness (2) to ether control relay harness connector (3).
7. Install new tiedown straps, as necessary.
JUMPER WIRING HARNESS INSTALLATION
1. Position jumper harness (16) on vehicle.
2. Connect jumper harness connector (14) to ECU harness connector (15).
3. Connect jumper harness connector (12) to ECU connector (13).
4. Connect jumper harness connector (11) to main harness connector (10).
2
3
END OF WORK PACKAGE
0117 00-3
TM 9-2320-302-20
0117 00-4
TM 9-2320-302-20
CAB-TO-FRAME GROUND WIRE REPLACEMENT 0118 00
INITIAL SETUP

Material/Parts
Nut, lock (P/N MS51922-1) (2)
REMOVAL
1. Remove lock nut (1), washer (2), screw (3), and cab-to-frame ground wire terminal (4) from cab (5). Discard lock nut.
2. Remove lock nut (6), washer (7), screw (8), and cab-to-frame ground wire terminal (9) from frame (10). Discard lock
nut.
4
2 3
10
6
9 7
INSTALLATION
1. Install cab-to-frame ground wire terminal (9) on frame (10) with screw (8), washer (7), and new lock nut (6).
2. Install cab-to-frame ground wire terminal (4) on cab (5) with screw (3), washer (2), and new lock nut (1).
END OF WORK PACKAGE
0118 00-1
TM 9-2320-302-20
0118 00-2
TM 9-2320-302-20
ELECTRICAL CONNECTORS MAINTENANCE 0119 00
Standard Military Connector Repair, Commercial Connector Repair, Splicing
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Flux, soldering (Item 12, WP 0235 00)
Gun, heat (Item 16, WP 0236 00) Solder (Item 29, WP 0235 00)
Tool kit, electrical connector repair (Item 35, WP 0236 Tags, marker (Item 31, WP 0235 00)
00)
References
TB SIG 222
TM 9-2320-302-10
NOTE
Tag cables and wires to aid in installation.
STANDARD MILITARY CONNECTOR REPAIR

1. Panel Mounting Receptacle Disassembly.
a. Unscrew nut (1) from shell (2) assembly and slide back on cable leads (3).
b. Push grommet (4) back on cable leads (3).
c. Drive contacts (5) out through rear of insert (6) with pin extractor.
d. Push insert (6) out through rear of shell (2).
e. Unsolder cable leads (3) from contacts (5).
4 5 6 2
1
3
2. Panel Mounting Receptacle Assembly.

a. Strip cable insulation equal to depth of solder wells of contacts (5).
b. Slide nut (1) over cable leads (3).
c. Slide grommet (4) over cable leads (3).
d. Insert cable leads (3) into solder wells of contacts (5) and solder.
e. Push insert (6) into shell (2) from rear until seated. Groove in insert must be aligned with guide in shell to ensure
proper fit.
0119 00-1
TM 9-2320-302-20
ELECTRICAL CONNECTORS MAINTENANCE - CONTINUED 0119 00
STANDARD MILITARY CONNECTOR REPAIR - CONTINUED
f. Push contacts (5) into insert (6) from rear until seated.
g. Push grommet (4) down cable leads (3) and over solder wells of contacts (5).
h. Screw nut (1) onto shell (2) assembly.
4 5 6 2
1
3
3. Plug Disassembly.
a. Unscrew nut (7) from shell (8) assembly and slide back on cable leads (9).
b. Push grommet (10) back on cable leads (9).
c. Slide coupling nut (11) off shell (8) assembly.
d. Drive contacts (12) out through rear of insert (13) with pin extractor.
e. Push insert (13) out through rear of shell (8).
f. Unsolder cable leads (9) from contacts (12).
10 11 12 13
7 8
9
4. Plug Assembly.
a. Strip cable insulation equal to depth of solder wells of contacts (12).
b. Slide nut (7) over cable leads (9).
c. Slide grommet (10) over cable leads (9).
d. Insert cable leads (9) into solder wells of contacts (12) and solder.
e. Push insert (13) into shell (8) from rear until seated. Groove in insert must be aligned with guide in shell to ensure
proper fit.
f. Push contacts (12) into insert (13) from rear until seated.
g. Slide coupling nut (11) onto shell (8) assembly.
h. Push grommet (10) down cable leads (9) and over solder wells of contacts (12).
i. Screw nut (7) onto shell (8) assembly.
0119 00-2
TM 9-2320-302-20
NOTE
The following procedures cover assembly of new terminals and connectors. Prepare cable by cutting off
damaged or defective terminal or connector.
5. Terminal-type Cable Connector.
a. Strip cable (14) insulation equal to depth of terminal (15) well.
b. Slide insulation (16) over cable (14).
c. Insert cable (14) into terminal (15) well and crimp.
d. Slide insulation (16) over crimped end of terminal (15).
16 15
14
6. Male Cable Connector With C-washer.

a. Strip cable (17) insulation equal to depth of terminal (18) well.
b. Slide shell (19) over cable (17).
c. Insert cable (17) into terminal (18) well and crimp.
d. Place C-washer (20) over cable (17) at crimped junction and slide shell (19) over C-washer and terminal (18).
19 20
17 18
0119 00-3
TM 9-2320-302-20

7. Female Cable Connector With Washer.
a. Strip cable (21) insulation approximately 1/8 in (3.2 mm).
b. Slide shell (22) and washer (23) over cable (21).
c. Place cable (21) in cylindrical end of terminal (24) and crimp.
d. Slide shell (22) and washer (23) over terminal (24).
21
22 23 24
8. Female Cable Connector With Sleeve.

b. Slide shell (26) and sleeve (27) over cable (25).
c. Place cable (25) in cylindrical end of terminal (28) and crimp.
d. Slide shell (26) and sleeve (27) over terminal (28).
25 27
26
28
9. Sealed Connector.
b. Slide seal (30) onto cable (29).
c. Crimp terminal (31) onto cable (29).
d. Insert terminal (31) into connector (32) and close lock.
30
29 31 32
0119 00-4
TM 9-2320-302-20
10. Panel Connector.
a. Strip cable (33) insulation.
b. Crimp terminal (34) onto cable (33).
c. Insert terminal (34) into connector (35).
33
34
35
11. Harness Connector.
a. Strip cable (36) insulation.
b. Crimp terminal (37) onto cable (36).
c. Insert terminal (37) into connector (38).
d. Install lock (39) in connector (38).
39
36
37
38
0119 00-5
TM 9-2320-302-20
COMMERCIAL CONNECTOR REPAIR

1. Crimp and Removal Tools. Crimp tools and connector removal tools can be purchased from Kent-Moore. Tools and
associated part numbers are listed in Table 1.
Table 1. Crimp and Removal Tools.
CONNECTOR TOOL PART NUMBER
Metri-Pack 150 Removing J35689
Crimp J35123
Weather Pack Removing J36400-5
Crimp J35606
Metri-Pack 280 Removing (18 AWG) J33095
Crimp (18 AWG) J38125-6
Removing (12 AWG - Used for power harness) J33095
Crimp (12 AWG - Used for power harness) J39848
Deutsch Removing (12 AWG) J37451
Removing (16-18 AWG) J34513
Crimp J34182
2. Metri-Pack 150 Connectors.

a. Connector Part Numbers.
(1) Metri-Pack 150 series connectors are “pull-to-seat” connectors. Each wire must be pushed through the
connector prior to crimping the terminal. Cable seals are inserted into the shell of the connector and hold
many wires.
(2) Metri-Pack 150 connectors are listed in Table 2.
0119 00-6
TM 9-2320-302-20
COMMERCIAL CONNECTOR REPAIR - CONTINUED
Table 2. Metri-Pack 150 Connector Part Numbers.
ECM ENGINE HARNESS ECM VEHICLE INTERFACE HARNESS
Plug P/N: 12034413 Plug P/N: 12034413
ECM COMMUNICATION HARNESS CONNECTOR TEMPERATURE SENSOR HARNESS
Plug P/N: 12034413 Plug P/N: Not Applicable
PRESSURE SENSOR HARNESS FIRE TRUCK PRESSURE SENSOR (PGS)
SRS HARNESS TRS HARNESS
INJECTOR (GRAY) INJECTOR (BLACK)
Seal P/N: Not Applicable Seal P/N: Not Applicable
Plug P/N: 12034413 Plug P/N: 12034413
0119 00-7
TM 9-2320-302-20
b. Installation. Metri-Pack 150 connectors are “pull-to-seat” design. The cable is pushed through seal and correct
cavity of connector before crimping terminal to cable. It should be stripped of insulation AFTER it is placed
through seal and connector body. Use the following instructions for terminal installation:
(1) Position cable through seal and correct cavity of connector (Figure 1).
Figure 3. Inserting Wire in Connector.
(2) Strip end of cable using wire strippers to leave 0.2 +/- 0.02 in (5.0 +/- 0.5 mm) of bare conductor.
(3) Squeeze handles of crimping tool together firmly to cause jaws to automatically open.
(4) Hold “wire side” facing you.
(5) Push terminal holder to open position and insert terminal until wire attaching portion of terminal rests on
20-22 anvil. Be sure wire core wings and insulation wings of terminal are pointing toward upper jaw of
crimping tool (Figure 2).
Figure 4. Terminal and Crimping Tool Position.
0119 00-8
TM 9-2320-302-20

(6) Insert cable into terminal until stripped portion is positioned in wire core wings and insulation portion ends
just forward of insulation wings (Figure 3).
INSULATION WINGS
WIRE CORE WINGS
Figure 5. Cable to Terminal Alignment.

(7) Compress handles of crimping tool until ratchet automatically releases and crimp is complete.
NOTE
For faster, more efficient crimping operation, a bracket or bench rest may be used to cradle one handle of
tool. Operator can apply terminals by grasping and actuating only one handle of tool (Figure 4).
FREE HANDLE END

FOR ACTUATION BY
OPERATOR
BRACKET OR BENCH REST

(TO CRADLE ONE HANDLE)
Figure 6. Crimping Operation.
0119 00-9
TM 9-2320-302-20

(8) Release crimping tool with lock lever located between handles, in case of jamming.
NOTE
For ECM 30-pin connectors, put locking tang opposite lettered side.
(9) Align locking tang of terminal with lettered side of connector.

(10) Pull cable back through connector until a click is heard (Figure 5). Position seal into connector.
PULL CABLE UNTIL

TERMINAL CLICKS
INTO PLACE
Figure 7. Pulling Terminal to Seat.

c. Removal and Repair. A tang on terminal locks into a tab molded into plastic connector to retain cable assembly.
Remove Metri-Pack 150 terminals using the following instructions:
(1) Insert removal tool into cavity of connector, placing tip of tool between locking tang of terminal and wall
of cavity (Figure 6).
0119 00-10
TM 9-2320-302-20
REMOVAL
TOOL J35689
LOCKING
TANG
BOTTOM VIEW OF TERMINAL
Figure 8. Terminal Removal.

(2) Depress locking tang of terminal to release from connector.
(3) Push cable forward through terminal until complete crimp is exposed.
(4) Cut cable immediately behind damaged terminal to repair.
(5) Follow installation instructions for crimping terminal and inserting into connector.
3. Weather Pack and Metri-Pack 280 Connectors.
(1) Weather Pack and Metri-Pack 280 series connectors are “push-to-seat design”. The terminal is crimped
onto each wire before it is inserted into the connector. A cable seal is crimped on each wire at the same
time the terminal is crimped onto the wire. Weather Pack connectors use a secondary lock on both male
and female connector bodies and the lock snaps into place over the cable seals after installation. Some
Metri-Pack connectors have secondary locks as well.
(2) Weather Pack connectors and their associated part numbers are listed in Table 3.
(3) Metri-Pack 280 connectors and their associated part numbers are listed in Table 4.
0119 00-11
TM 9-2320-302-20
Table 3. Weather Pack Connectors and Part Numbers.
TURBO BOOST PRESSURE SENSOR HARNESS ENGINE BRAKE CONNECTOR, SERIES 60
Connector P/N: 12015384 Connector P/N: 12010973/12162000
Terminal P/N: 12089040 Terminal P/N: 12048074/12045773
Seal P/N: 12015323
THROTTLE POSITION SENSOR - HARNESS SIDE THROTTLE POSITION SENSOR - SENSOR SIDE
Seal P/N: 12015323 Seal P/N: 12015323
IGNITION CONNECTOR VEHICLE INTERFACE

IGNITION CONNECTOR POWER HARNESS SIDE
HARNESS SIDE
ALLISON INTERFACE MODULE MAXIMUM

ALLISON INTERFACE MODULE
FEATURE
Seal P/N: 12015323 Seal P/N: 12015323
Plug P/N: 12010300
Table 4. Metri-Pack 280 Connectors and Part Numbers.
COOLANT LEVEL SENSOR CONNECTOR POWER HARNESS
Seal P/N: 12015323 Seal P/N: 12015193
Secondary Lock P/N: 15300014 Secondary Lock P/N: 12052816
0119 00-12
TM 9-2320-302-20
b. Installation. Use the following instructions for terminal installation:
(1) Insert terminal into locating hole of crimping tool using proper hole according to gage of cable to be used
(Figure 7).
J38706
OR EQUIVALENT
CABLE
SEAL
TERMINAL
Figure 9. Terminal Position.
(2) Insert cable into terminal until stripped position is positioned in cable core wings, and seal and insulated
portion of cable are in insulation wings (Figure 8).
CABLE CORE INSULATION WINGS

WINGS
BEFORE
AFTER
Figure 10. Cable and Terminal Position Before and After Crimping.
0119 00-13
TM 9-2320-302-20
(3) Compress handles of crimping tool until ratchet automatically releases and crimp is complete. A properly
crimped terminal is shown (Figure 8).
(4) Release crimping tool with lock lever located between handles, in case of jamming.
(5) Push crimped terminal into connector until it clicks into place. Gently tug on cable to make sure it is secure
(Figure 9).
PUSH-TO-SEAT
CONNECTOR
SEAL
Figure 11. Inserting Terminal in Connector.
c. Removal and Repair. Two locking tangs are used on terminals to secure them to the connector body. Use the fol-
lowing instructions for removing terminals from connector body:
(1) Disengage locking tang securing connector bodies to each other. Grasp one half of connector in each hand
and gently pull apart.
(2) Unlatch and open secondary lock on connector (Figure 10).
Figure 12. Unlatched Secondary Lock.
0119 00-14
TM 9-2320-302-20

(3) Grasp cable to be removed and push terminal to forward position.
(4) Insert removal tool straight into front of connector cavity until it rests on cavity shoulder.
(5) Grasp cable and push forward through connector cavity into tool while holding tool securely in place (Fig-
ure 11).
Figure 13. Removal Tool Procedure.

(6) Tool will press locking tangs of terminal. Pull cable rearward (back through connector). Remove tool from
connector cavity.
(7) Cut wire immediately behind cable seat and slip new cable seal onto wire.
(8) Strip end of cable using strippers to leave 0.2 +/- 0.02 in (5.0 +/- 0.5 mm) of bare conductor. Position cable
seal as shown (Figure 12).
Figure 14. Proper Cable Seal Position.
0119 00-15
TM 9-2320-302-20

(9) Crimp new terminal onto wire using crimp tool (Figure 13).
J37806
OR EQUIVALENT
CABLE
SEAL
TERMINAL
Figure 15. Crimping Procedure.

4. Deutsch Connectors.
(1) Deutsch connectors have cable seals molded into the connector. These connectors are “push-to-seat” con-
nectors with cylindrical terminals. The diagnostic connector terminals are gold plated for clarity.
(2) Deutsch connectors and their associated part numbers are listed in Table 5.
0119 00-16
TM 9-2320-302-20
Table 5. Deutsch Connectors and Part Numbers.
DIAGNOSTIC CONNECTOR
Protective Cap P/N: 23413054
Plug P/N: 23507136
ENGINEMINDER
Plug P/N: 23507136
MASTERMIND - POWER AND COMMUNICATION LINK
Plug P/N: 23507136
MASTERMIND - INPUTS AND OUTPUTS
Plug P/N: 23507136
b. Installation.
(1) Strip approximately 1/4 in (6.4 mm) of insulation from cable.
(2) Remove lock clip, raise wire gage selector, and rotate knob to number matching gage wire being used.
(3) Lower selection and insert lock clip.
(4) Position contact so that the crimp barrel is 1/32 in (0.8 mm) above four indenters (Figure 14). Crimp cable.
0119 00-17
TM 9-2320-302-20
.0312 in
(0.8 mm)
.25 in (6.4 mm)
Figure 16. Setting Wire Gage Selector and Positioning Contact.

(5) Grasp contact approximately 1 in (2.54 mm) behind contact crimp barrel.
(6) Hold connector with rear grommet facing you (Figure 15).
REAR VIEW OF
HOLDING GROMMET 1 in
(25.4 mm)
Figure 17. Pushing Contact into Grommet.
0119 00-18
TM 9-2320-302-20

(7) Push contact into grommet until a positive stop is felt (Figure 15). A slight tug will confirm that it is prop-
erly locked into place (Figure 16).
UNLOCKED POSITION LOCKED POSITION
Figure 18. Locking Terminal into Connector.

c. Removal. The appropriate size removal tool should be used when removal cables from connectors. The proper
removal tool size is listed in Table 1.
(1) With rear insert toward you, snap appropriate size removal tool over cable of contact to be removed (Fig-
ure 17).
Figure 19. Removal Tool Position.
0119 00-19
TM 9-2320-302-20

(2) Slide tool along cable into insert cavity until it engages and resistance is felt. DO NOT twist or insert tool
at an angle (Figure 18).
Figure 20. Removal Tool Insertion.

(3) Pull contact cable assembly out of connector. Keep reverse tension on cable and forward tension on tool.
SPLICING
1. Splicing Guidelines.
a. The following are guidelines which may be used for splices. The methods described are not the only acceptable
methods. Any method should produce a high quality, tight splice with durable insulation which can be expected to
last the life of the vehicle.
b. The selection of crimpers and splice connectors is optional. Select a high quality crimper equivalent to Kent-
Moore tool J38706 and commercially available splice clips.
c. The following is a list of tools required for splicing wires:
• Soldering iron
• Rosin core solder
• Wire strippers
• Heat shrink tubing
• Splice clips
• Crimp pliers
2. Splicing Straight Leads.
a. Locate broken wire.
b. Remove insulation as required. Ensure exposed wire is clean and not corroded.
c. Slide a sleeve of shrink wrap on wire long enough to cover splice and overlap wire insulation, about 1/4 in (6.4
mm) on both sides.
0119 00-20
TM 9-2320-302-20
SPLICING - CONTINUED
d. Insert one wire into splice clip (P/N: 0597428 or equivalent) and crimp.
e. Insert other wire into splice and crimp (Figure 19).
SHRINK WRAP
SPLICE CLIP
Figure 21. Spliced Wire.
3. Soldering Splice Connectors. Soldering splice connectors is optional. To solder splice connectors:
a. You MUST use rosin core solder.
b. Check exposed wire before splice is crimped in connector. Exposed wire MUST be clean before splice is crimped.
c. Use a suitable electronic soldering iron to heat wires. Apply solder to heated wire (not to soldering iron) allowing
sufficient solder flow into splice joint.
d. Pull on connection to ensure crimping and soldering integrity.
4. Heat Shrinkable Tubing.
a. Shrink wrap is required. Alpha FIT-300, Raychem TAT-125 or any equivalent heat shrink dual wall epoxy encap-
sulating adhesive polyolefin is required. The following are sources of supply:
Alpha Wire Corp
711 Lidgerwood Ave
P.O. Box 711
Elizabeth, New Jersey 07207-0711
1-800-5 2ALPHA
Raychem Corporation, Thermofit Div

300 Constitution Drive, Bldg. B
Menlo Park, CA 94025
415-361-3860
0119 00-21
TM 9-2320-302-20
b. To heat shrink wrap a splice:
(1) Select correct diameter to allow a tight wrap when heated. Heat shrink wrap MUST be long enough to
overlap wire insulation about 1/4 in (6.4 mm) on both sides of splice.
(2) Heat shrink wrap with a heat gun; do not concentrate heat in one location, but play heat over entire length
of shrink wrap until joint is complete.
5. Splicing Multiple Broken Wires.
a. Stagger position of each splice as illustrated (Figure 20).
b. You MUST stagger positions to prevent a large bulge in harness and to prevent wires from chafing against each
other.
2.5 in (64 mm)

MINIMUM TAPE SPLICED
BETWEEN SPLICES WIRES TOGETHER
CORRECT METHOD
INCORRECT METHOD
(BUILDING CONDUIT)
Figure 22. Multiple Splices.
0119 00-22
TM 9-2320-302-20
6. Three-Wire Splices.
a. Three-way splice connectors are commercially available to accommodate three-wire splices.
b. The technique is the same as a single butt splice connector (Figure 21).
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
Figure 23. Three-way Splices.
END OF WORK PACKAGE
0119 00-23
TM 9-2320-302-20
0119 00-24
TM 9-2320-302-20
SHIFT SELECTOR AND SHIFT TOWER REPLACEMENT 0120 00
INITIAL SETUP

REMOVAL
1. Remove eight screws (1) and separate shift tower (2) from cab floor.
2. Remove two screws (3) from rear of shift tower (2) and pull out shift selector (4).
3. Disconnect transmission wiring harness connector (5) from shift selector connector (6).
4. Remove two nuts (7), bracket (8), and two washers (9) from shift selector (4).
4 9
7
8
6
3
5
0120 00-1
TM 9-2320-302-20
SHIFT SELECTOR AND SHIFT TOWER REPLACEMENT - CONTINUED 0120 00
INSTALLATION
1. Install two washers (9) and shift selector (4) on bracket (8) with two nuts (7).
2. Connect transmission wiring harness connector (5) to shift selector connector (6).
3. Install shift selector (4) on shift tower (2) with two screws (3).
4. Install shift tower (2) on cab floor with eight screws (1).
4 9
7
8
6
3
5
END OF WORK PACKAGE
0120 00-2
TM 9-2320-302-20
TRANSMISSION OIL FILL/LEVEL CHECK TUBE REPLACEMENT 0121 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Materials/Parts
Washer, lock (P/N 23-09317-009) (2) Transmission dipstick removed (TM 9-2320-302-10)
REMOVAL
1. Remove screw (1) and clamp (2) from right side of transmission (3).
2. Remove two nuts (4), lock washers (5), U-bolt (6), and transmission oil fill/level check tube (7) from transmission
bracket (8) and transmission (3).
NOTE
Perform step 3 only if transmission bracket is damaged.
3. Remove two screws (9), washers (10), and transmission bracket (8) from transmission (3).
8 7
4,5,6,9,10
1 2 3
0121 00-1
TM 9-2320-302-20
TRANSMISSION OIL FILL/LEVEL CHECK TUBE REPLACEMENT - CONTINUED 0121 00
INSTALLATION
NOTE
Perform step 1 if transmission bracket was removed.
1. Install transmission bracket (8) on transmission (3) with two washers (10) and screws (9). Tighten screws to 54-65 lb-ft
(73-88 Nm).
2. Position clamp (2) on transmission oil fill/level check tube (7) and install transmission oil fill/level check tube on trans-
mission (3) and transmission bracket (8) with U-bolt (6), two new lock washers (5), and nuts (4).
3. Install clamp (2) on right side of transmission (3) with screw (1).
8 7
4,5,6,9,10
1 2 3
4. Install transmission dipstick (TM 9-2320-302-10).
END OF WORK PACKAGE
0121 00-2
TM 9-2320-302-20
TRANSMISSION OIL COOLER LINES AND FITTINGS REPLACEMENT 0122 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Oil, lubricating (Item 19, WP 0235 00)
Materials/Parts Straps, tiedown (Item 30, WP 0235 00)
Packing, preformed (P/N 316N552-9) (4) Equipment Condition

Compound, sealing, pipe (Item 10, WP 0235 00) Transmission oil drained (WP 0021 00)
REMOVAL
NOTE
Perform steps 1 and 2 to free two transmission oil cooler lines from each of four support brackets.
1. Remove nut (1), two washers (2), screw (3), and clamp (4) from support bracket (5).
2. Remove clamp (4) from two transmission oil cooler lines (6 and 7).
NOTE
Perform steps 3 thru 7 at front of transmission.
3. Remove nut (8) and wire terminal (9) from temperature sensor (10).
5
10 1,2,3
8
9
4 6 7
0122 00-1
TM 9-2320-302-20
TRANSMISSION OIL COOLER LINES AND FITTINGS REPLACEMENT - CONTINUED 0122 00
REMOVAL - CONTINUED
4. Remove temperature sensor (10) from elbow fitting (11).

5. Disconnect transmission oil cooler lines (6 and 7) from elbow fitting (11) and fitting (12).
6. Loosen jamnuts (13 and 14) of elbow fitting (11) and fitting (12) and remove from transmission (15).
7. Remove two preformed packings (16). Discard preformed packings.
NOTE
Perform steps 8 thru 12 at transmission oil cooler.
8. Disconnect transmission oil sample line (17) from elbow (18).

9. Remove elbow (18) from elbow (19).
10. Disconnect transmission oil cooler lines (6 and 7) from elbows (19 and 20).
NOTE
Remove tiedown straps as necessary and discard.
11. Remove transmission oil cooler lines (6 and 7) from vehicle.

12. Loosen jamnuts (21 and 22) of elbow fittings (19 and 20) and remove from transmission oil cooler (23).
13. Remove two preformed packings (24). Discard preformed packings.
17
18
19,24
21
5
10
13 11 1,2,3
16
8
9
22
23 20,24
6 7
4
16 14
15 12
INSTALLATION
NOTE
• Lightly lubricate new preformed packings with lubricating oil before installing packings.
• Perform steps 1 through 6 at transmission oil cooler.
1. Install two new preformed packings (24) to elbow fittings (19 and 20).
0122 00-2
TM 9-2320-302-20
TRANSMISSION OIL COOLER LINES AND FITTINGS REPLACEMENT - CONTINUED 0122 00
2. Install two elbow fittings (19 and 20) to transmission oil cooler (23) and tighten jamnuts (21 and 22).
3. Position transmission oil cooler lines (6 and 7) to vehicle.
4. Connect transmission oil cooler lines (6 and 7) to two elbow fittings (19 and 20).
WARNINGS
5. Apply pipe sealing compound to threads of elbow (18) and install elbow to elbow (19).
6. Connect transmission oil sample line (17) to elbow (18).
NOTE
Perform steps 7 through 11 at front of transmission.
7. Install two new preformed packings (16) to elbow fitting (11) and fitting (12).
8. Install elbow fitting (11) and fitting (12) to transmission (15) and tighten jamnuts (13 and 14).
9. Connect transmission oil cooler lines (6 and 7) to fitting (12) and elbow fitting (11).
10. Apply pipe sealing compound to threads of temperature sensor (10) and install temperature sensor to elbow fitting (11).
11. Install wire terminal (9) to temperature sensor (10) with nut (8).
NOTE
Perform steps 12 and 13 to attach two transmission oil cooler lines to each of four support brackets.
12. Position clamp (4) around transmission oil cooler lines (6 and 7).
13. Install clamp (4) to support bracket (5) with screw (3), two washers (2), and nut (1). Install new tiedown straps as neces-
sary.
14. Fill transmission oil (WP 0021 00).
END OF WORK PACKAGE
0122 00-3
TM 9-2320-302-20
0122 00-4
TM 9-2320-302-20
TRANSMISSION OIL FILTER ELEMENTS REPLACEMENT 0123 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Filter kit (P/N 29526898) (2)
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Oil, lubricating (Item 19, WP 0235 00)
NOTE
• It is not necessary to drain transmission oil if only transmission oil filter elements are being replaced.
• Perform this procedure for two transmission oil filter elements.
REMOVAL
Remove six screws (1), cover (2), preformed packing (3), seal (4), and transmission oil filter element (5) from bottom of trans-
mission (6). Discard preformed packing, seal, and transmission oil filter element.
5
5
4
3
4
3 2
2 1
1
0123 00-1
TM 9-2320-302-20
TRANSMISSION OIL FILTER ELEMENTS REPLACEMENT - CONTINUED 0123 00
INSTALLATION
1. Apply a light coat of lubricating oil to new performed packing (3) and sealing surface of new transmission oil filter ele-
ment (5).
2. Position preformed packing (3), new seal (4), and transmission oil filter element (5) on cover (2).
3. Install cover (2) on transmission (6) with six screws (1). Tighten screws to 38-45 lb-ft (52-61 Nm).
5
5
4
3
4
3 2
2 1
1
END OF WORK PACKAGE
0123 00-2
TM 9-2320-302-20
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT 0124 00
INITIAL SETUP

REMOVAL
1. Disconnect wiring harness (1) from ECU (2).
2. Remove three nuts (3) and ECU (2) from cab wall.
INSTALLATION
1. Install ECU (2) on cab wall with three nuts (3).
2. Connect wiring harness (1) to ECU (2).
END OF WORK PACKAGE
0124 00-1
TM 9-2320-302-20
0124 00-2
TM 9-2320-302-20
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) WIRING HARNESS REPLACEMENT 0125 00
INITIAL SETUP
REMOVAL
NOTE
Wiring harness and leads are secured in place by cushion clamps and screw terminals. Only remove hard-
ware securing harness or lead to be removed.
Disconnect and remove transmission ECU wiring harness using illustration as a guide.
TO SHIFT
TOWER
TRANSMISSION
ECU
TO TRANSMISSION
HARNESS
0125 00-1
TM 9-2320-302-20
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU)

WIRING HARNESS REPLACEMENT - CONTINUED 0125 00
INSTALLATION
NOTE
Wiring harness and leads are secured in place by cushion clamps and screw terminals. Ensure that harness is
secure and all hardware is tight.
Install, connect, and secure transmission ECU wiring harness using illustration as a guide.
TO SHIFT
TOWER
TRANSMISSION
ECU
TO TRANSMISSION
HARNESS
END OF WORK PACKAGE
0125 00-2
TM 9-2320-302-20
TRANSMISSION SPEED SENSOR REPLACEMENT 0126 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Packing, preformed (P/N 29503383)
REMOVAL
1. Locate speed sensor to be replaced.
2. Remove bolt (1), retainer (2), sensor (3), and preformed packing (4) from transmission. Discard preformed packing.
2
ENGINE
SPEED 3
SENSOR 4 1
TURBINE
SPEED
SENSOR
OUTPUT
SPEED
SENSOR
INSTALLATION
1. Lightly coat new preformed packing (4) with lubricating oil.
2. Install preformed packing (4) and speed sensor (3) on transmission with retainer (2) and bolt (1).
END OF WORK PACKAGE
0126 00-1
TM 9-2320-302-20
0126 00-2
TM 9-2320-302-20
TRANSMISSION OIL COOLER REPLACEMENT 0127 00
INITIAL SETUP


Nut, lock (P/N MS51922-33) (4)
Transmission oil cooler lines and fittings removed
Rags, wiping (Item 28, WP 0235 00) (WP 0122 00)
REMOVAL
WARNING
Spilled oil is very slippery. Wipe up any spilled fluid immediately. Failure to follow this warning could
result in serious injury to personnel.
1. Remove lock nut (1), washer (2), screw (3), washer (4), and oil sample valve (5). Set oil sample valve aside. Discard
lock nut.
2. Remove three lock nuts (6), washers (7), screws (8), washers (9), and transmission oil cooler (10). Discard lock nuts.
3. Remove three nuts (11), washers (12), cap screws (13), washers (14), and brackets (15).
5
1,2 11,12
10
3,4
11,12
8,9
15
6,7
13,14
13,14
15
0127 00-1
TM 9-2320-302-20
TRANSMISSION OIL COOLER REPLACEMENT - CONTINUED 0127 00
INSTALLATION
1. Install three brackets (15) with washers (14), cap screws (13), washers (12), and nuts (11).
WARNING
Spilled oil is very slippery. Wipe up any spilled fluid immediately. Failure to follow this warning could
result in serious injury to personnel.
2. Install transmission oil cooler (10) with three washers (9), screws (8), washers (7), and new lock nuts (6).
3. Install oil sample valve (5) with washer (4), screw (3), washer (2), and new lock nut (1).
5
1,2 11,12
10
3,4
11,12
8,9
15
6,7
13,14
13,14
15
4. Install transmission oil cooler lines and fittings (WP 0122 00).
END OF WORK PACKAGE
0127 00-2
TM 9-2320-302-20
TRANSMISSION BREATHER REPLACEMENT 0128 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Transmission tunnel access cover removed (WP
0207 00)
REMOVAL
Remove transmission breather (1) from transmission (2).
1
2
INSTALLATION
1. Install transmission breather (1) on transmission (2).
END OF WORK PACKAGE
0128 00-1
TM 9-2320-302-20
0128 00-2
TM 9-2320-302-20
DRIVELINE REPLACEMENT 0129 00
Main Driveline Removal, Inter-axle Driveline Removal, Main Driveline Installation, Inter-axle Driveline Installation
INITIAL SETUP

References
TM 9-2320-302-10
Materials/Parts
Screw, lock (P/N 8-73-209) (8) Equipment Condition
Screw, lock (P/N 8-73-316) (8) Vehicle wheels chocked

Grease, GAA (Item 15, WP 0235 00) Transmission shift lever set to N (TM 9-2320-302-10)
MAIN DRIVELINE REMOVAL
WARNING
Driveline is heavy. Support end of driveline as bearing straps are removed to prevent driveline from falling.
Failure to follow this warning may cause serious injury to personnel.
0129 00-1
TM 9-2320-302-20
DRIVELINE REPLACEMENT - CONTINUED 0129 00
MAIN DRIVELINE REMOVAL - CONTINUED
NOTE
Perform following step at front end of main driveline.
1. Remove four screws (1) and two bearing straps (2) from universal joint of main driveline (3). Discard screws.
NOTE
Perform following step at rear end of main driveline.
2. Remove four screws (4) and two bearing straps (5) from universal joint of main driveline (3). Discard screws.
3. Remove main driveline (3) from vehicle.
5
4
1
2
INTER-AXLE DRIVELINE REMOVAL
WARNING
Driveline is heavy. Support end of driveline as bearing straps are removed to prevent driveline from falling.
Failure to follow this warning may cause serious injury to personnel.
0129 00-2
TM 9-2320-302-20
INTER-AXLE DRIVELINE REMOVAL - CONTINUED
NOTE
Perform following steps at front end of inter-axle driveline.
1. Remove two screws (6) from each of two bearing caps (7). Discard screws.
2. Remove two bearing caps (7) from universal joint of inter-axle driveline (8).
6
7
10
9
NOTE
Perform following steps at rear end of inter-axle driveline.
4. Remove two bearing caps (10) from universal joint of inter-axle driveline (8).
5. Remove inter-axle driveline (8) from vehicle.
MAIN DRIVELINE INSTALLATION
NOTE
Perform following steps at rear end of main driveline.
1. Position main driveline (3) to vehicle.

2. Install two bearings straps (5) and four new screws (4) to universal joint of main driveline (3). Tighten screws to 125 lb-
ft (170 Nm).
NOTE
Perform following step at front end of main driveline.
3. Install two bearing straps (2) and four new screws (1) to universal joint of main driveline (3). Tighten screws to 125 lb-
ft (170 Nm).
4. Lubricate driveline (WP 0021 00).
0129 00-3
TM 9-2320-302-20
INTER-AXLE DRIVELINE INSTALLATION
NOTE
Perform following steps at rear end of inter-axle driveline.
1. Position inter-axle driveline (8) to vehicle and install two bearing caps (10).
2. Install two new screws (9) to each of two bearing caps (10). Tighten screws to 36 lb-ft (49 Nm).
6
7
10
9
NOTE
Perform following steps at front end of inter-axle driveline.
3. Position inter-axle driveline (8) to vehicle and install two bearing caps (7).
4. Install two new screws (6) to each of two bearing caps (7). Tighten screws to 36 lb-ft (49 Nm).
5. Lubricate driveline (WP 0021 00).
END OF WORK PACKAGE
0129 00-4
TM 9-2320-302-20
DRIVELINE U-JOINTS AND BEARINGS REPLACEMENT 0130 00
Main Driveline U-joints Removal, Inter-Axle Driveline U-joints Removal, Main Driveline U-joints Installation, Inter-
Axle Driveline U-joints Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Screw, lock (P/N 8-73-209) (16)
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Grease, GAA (Item 15, WP 0235 00)
Equipment Condition
Drivelines removed from vehicle (WP 0129 00)
MAIN DRIVELINE U-JOINTS REMOVAL
NOTE
Perform following steps at front end of main driveline.
1. Remove retaining wire (1) from groove of two bearings (2).
2. Remove two bearings (2) from universal joint (3).
4. Remove two bearing caps (5) and universal joint (3) from yoke (6) of main driveline (7).
5. Remove two grease fittings (8) from universal joint (3).
6
2
1
8
4
3 5
2
0130 00-1
TM 9-2320-302-20
DRIVELINE U-JOINTS AND BEARINGS REPLACEMENT - CONTINUED 0130 00
MAIN DRIVELINE U-JOINTS REMOVAL - CONTINUED
NOTE
Note matchmarks on each half of main driveline for installation. Scribe or paint matchmarks on driveline if
matchmarks are missing.
6. Remove dust seal (9) and yoke (6) from main driveline (7).
7. Remove grease fitting (10) from yoke (6).
NOTE
Perform following steps at rear end of main driveline.
8. Remove retaining wire (11) from groove of two bearings (12).

9. Remove two bearings (12) from universal joint (13).
11. Remove two bearing caps (15) and universal joint (13) from main driveline (7).
12 16
13 11
7
12
9
6
2 10
15 14
1
8
4
3 5
2
INTER-AXLE DRIVELINE U-JOINTS REMOVAL
NOTE
Perform the following steps at front end of inter-axle driveline.
2. Remove two bearing caps (18) and universal joint (19) from yoke (20) of inter-axle driveline (21).
0130 00-2
TM 9-2320-302-20
INTER-AXLE DRIVELINE U-JOINTS REMOVAL - CONTINUED
NOTE
Note matchmarks on each half of inter-axle driveline for installation. Scribe or paint matchmarks on drive-
line if matchmarks are missing.
4. Remove dust seal (23) and yoke (20) from inter-axle driveline (21).
5. Remove grease fitting (24) from yoke (20).
NOTE
Perform the following steps at rear end of inter-axle driveline.
7. Remove two bearing caps (26) and universal joint (27) from inter-axle driveline (21).
28
27
21
23
20
24 25
26
22
17
19
18
MAIN DRIVELINE U-JOINTS INSTALLATION
NOTE
Perform the following steps at rear end of main driveline.
1. Install two grease fittings (16) on universal joint (13).
2. Position universal joint (13) and two bearing caps (15) to main driveline (7).
0130 00-3
TM 9-2320-302-20
MAIN DRIVELINE U-JOINTS INSTALLATION - CONTINUED
3. Install two new screws (14) on each of two bearing caps (15). Tighten screws to 36 lb-ft (49 Nm).
4. Install two bearings (12) on universal joint (13).

5. Install retaining wire (11) in groove of two bearings (12).
6. Lubricate universal joint (13) (WP 0021 00).
NOTE
Perform the following steps at front end of main driveline.
7. Install grease fitting (10) on yoke (6).
NOTE
Align matchmarks on each half of main driveline.
8. Install dust seal (9) and yoke (6) on main driveline (7). Tighten dust seal.
10. Position universal joint (3) and two bearing caps (5) on main driveline (7).
12. Install two bearings (2) on universal joint (3).
13. Install retaining wire (1) in groove of two bearings (2).

14. Lubricate yoke (6) and universal joint (3) (WP 0021 00).
15. Install main driveline (WP 0129 00).
12 16
13 11
7
12
9
6
2 10
15 14
1
8
4
3 5
2
0130 00-4
TM 9-2320-302-20
INTER-AXLE DRIVELINE U-JOINTS INSTALLATION
NOTE
Perform the following steps at rear end of inter-axle driveline.

2. Position universal joint (27) and two bearing caps (26) on inter-axle driveline (21).
3. Install two new screws (25) on each of two bearings caps (26). Tighten screws to 36 lb-ft (49 Nm).
4. Lubricate universal joint (27) (WP 0021 00).
5. Install grease fitting (24) on yoke (20).
NOTE
Align matchmarks on each half of inter-axle driveline.
6. Install dust seal (23) and yoke (20) on inter-axle driveline (21). Tighten dust seal.
NOTE
Perform the following steps at front end of inter-axle driveline.
7. Install two grease fittings (22) to universal joint (19).

8. Position universal joint (19) and two bearing caps (18) on yoke (20) of inter-axle driveline (21).
10. Lubricate yoke (20) and universal joint (19) (WP 0021 00).
11. Install inter-axle driveline (WP 0129 00).
28
27
21
23
20
24
25
26
22
17
19
18
END OF WORK PACKAGE
0130 00-5
TM 9-2320-302-20
0130 00-6
TM 9-2320-302-20
FRONT AXLE TOE-IN ALIGNMENT 0131 00
Alignment Check, Adjustment
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Paint, white (Item 27, WP 0235 00)
Jack, hydraulic, hand (Item 21, WP 0236 00) Personnel Required
Tape, measuring, 50 feet (Item 31, WP 0236 00) Two
Trestle, hoist, portable (2) (Item 38, WP 0236 00) References
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) TM 9-2320-302-10
ALIGNMENT CHECK
1. Block rear wheels and raise front end of vehicle so that front tires can be rotated. Support front of vehicle on two tres-
tles.
2. Slowly rotate front tire and whiten center of tire around complete circumference using spray paint. Repeat for opposite
tire.
3. Rotate tire and scribe line (1) around complete circumference near center so that line is visible in whitened area. Repeat
for opposite tire.
4. Lower vehicle and remove trestles.

5. Remove chocks. Back up vehicle a few feet, then drive forward approximately 10 feet.
6. Place transmission in neutral and set parking brake (TM 9-2320-302-10).
7. At front of tires, use tape measure held at axle height to measure distance between scribed lines (1) and front of each
tire. Record measurement to nearest 1/32 in.
8. At rear of tires, use tape measure held at axle height to measure distance between scribed lines (1) on rear of each tire.
Record measurement to nearest 1/32 in.
0131 00-1
TM 9-2320-302-20
FRONT AXLE TOE-IN ALIGNMENT - CONTINUED 0131 00
ALIGNMENT CHECK - CONTINUED
9. Measurement at front of tires must be 1/16 inch or less than rear measurement for proper toe-in alignment. If measure-
ment is not as specified, perform alignment procedure.
ADJUSTMENT
NOTE
Perform steps 1 through 4 to adjust toe-in alignment.
1. Loosen screws (2) at clamps (3) on each end of tie rod (4).
2. Rotate tie rod (4) toward front of vehicle to increase toe-in or rotate tie rod toward rear of vehicle to decrease toe-in.
3. Tighten screws (2) to 40-55 lb-ft (54-75 Nm).
5
4 6
9/16 in +/- 1/16 in
4. Repeat alignment check procedure.
NOTE
• Perform steps 5 through 7 to adjust turn stop bolts.
• Steps 5 through 7 are the same for both sides.
5. Measure length of stop bolt (5). Length must be 9/16 in +/- 1/16 in (14 mm +/- 1.6 mm).
6. If measurement from step 5 is not within tolerance, loosen locknut (6) and adjust stop bolt (5) to required length.
7. Tighten locknut (6) to 28 lb-ft (38 Nm).
END OF WORK PACKAGE
0131 00-2
TM 9-2320-302-20
FRONT AXLE STOP CUSHION REPLACEMENT 0132 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Adhesive (Item 2, WP 0235 00)
REMOVAL
Remove stop cushion (1) from front axle stop (2).
INSTALLATION
1. Apply adhesive to inside diameter of front axle stop (2).
2. Install stop cushion (1) in front axle stop (2).
END OF WORK PACKAGE
0132 00-1
TM 9-2320-302-20
0132 00-2
TM 9-2320-302-20
REAR AXLE BREATHER REPLACEMENT 0133 00
INITIAL SETUP


Compound, sealing, pipe (Item 10, WP 0235 00) Vehicle wheels chocked
NOTE
Rear axle breathers are replaced the same way on both rear axles. One rear axle is shown.
REMOVAL
Remove rear axle breather (1) from rear axle (2).
0133 00-1
TM 9-2320-302-20
REAR AXLE BREATHER REPLACEMENT - CONTINUED 0133 00
INSTALLATION
WARNINGS
1. Lightly coat threads of rear axle breather (1) with pipe sealing compound.
NOTE
Position of rear axle breather is important. Install rear axle breather so that mark and tube of breather face
AWAY from differential.
2. Install rear axle breather (1) on rear axle (2).
END OF WORK PACKAGE
0133 00-2
TM 9-2320-302-20
BRAKE PEDAL REPLACEMENT 0134 00
INITIAL SETUP

Materials/Parts
Pin, cotter (P/N 213)
REMOVAL
3
1,2
0134 00-1
TM 9-2320-302-20
BRAKE PEDAL REPLACEMENT - CONTINUED 0134 00
REMOVAL - CONTINUED
3. Remove tiedown strap (6) and disconnect defroster hose (7). Discard tiedown strap.
4. Remove two screws (8), washers (9), bracket (10), and spring (11).
5. Remove four screws (12), cap (13), and brake pedal (14).
6. Remove cotter pin (15), straight pin (16), and clevis (17) from brake pedal (14). Discard cotter pin.
7. Remove two bearings (18) from cap (13).
16
6
12
15
13
8,9
18
17
13
11
10
14
18
INSTALLATION
1. Install two bearings (18) on cap (13).
2. Install clevis (17) on brake pedal (14) with straight pin (16) and new cotter pin (15).
3. Install brake pedal (14) and cap (13) with four screws (12).
4. Install spring (11) and bracket (10) with two washers (9) and screws (8).
5. Connect defroster hose (7) and install new tiedown strap (6).
0134 00-2
TM 9-2320-302-20
BRAKE PEDAL REPLACEMENT - CONTINUED 0134 00
3
1,2
END OF WORK PACKAGE
0134 00-3
TM 9-2320-302-20
0134 00-4
TM 9-2320-302-20
FRONT BRAKESHOE REPLACEMENT 0135 00
Removal, Cleaning and Inspection, Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Front hub and drum removed (WP 0165 00)
Materials/Parts
Compound, antiseize (Item 6, WP 0235 00)
REMOVAL
1. Lift upper brakeshoe (1) away from s-cam (2) and remove upper cam roller (3).
2. Push lower brakeshoe (4) away from s-cam (2) and remove lower cam roller (5).
3. Remove release spring (6) from upper and lower brakeshoes (1 and 4).
4. Grasp upper and lower brakeshoes (1 and 4) and pull to open position. Remove two brakeshoes and retaining spring (7)
from two spider anchor pins (8 and 9).
5. Remove retaining spring (7) from upper and lower brakeshoes (1 and 4).
6
1
3
9
2
7
5
CLEANING AND INSPECTION

1. Clean front brakeshoes and components in accordance with WP 0228 00.
2. Measure brake lining thickness. Thickness must be NO LESS than 1/4 in (6.4 mm). If brake lining is less than 1/4 in (6.4
mm), replace brakeshoes.
3. Measure clearance between top of brake lining and top of all rivet heads. Clearance must be a minimum of 1/32 in (0.8
mm). If clearance is less than 1/32 in (0.8 mm), replace brakeshoes.
4. Inspect remaining brakeshoe parts in accordance with WP 0228 00.
0135 00-1
TM 9-2320-302-20
FRONT BRAKESHOE AND LINING REPLACEMENT - CONTINUED 0135 00
INSTALLATION
1. Apply a thin film of antiseize compound to contact points (10, 11, 12, and 13), two spider anchor pins (8 and 9), and
small diameter of upper and lower cam rollers (3 and 5).
2. Install retaining spring (7) on each brakeshoe (1 and 4).
3. Install upper and lower brakeshoes (1 and 4) on two spider anchor pins (8 and 9).
4. Install release spring (6) on upper and lower brakeshoes (1 and 4).
5. Install upper cam roller (3) between upper brakeshoe (1) and s-cam (2).
6. Install lower cam roller (5) between lower brakeshoe (4) and s-cam (2).
1
12 6
8
2
5
7
11
10
13 4
7. Install front hub and drum (WP 0165 00).
END OF WORK PACKAGE
0135 00-2
TM 9-2320-302-20
FRONT BRAKE SPIDER AND BRAKE CHAMBER BRACKET REPLACEMENT 0136 00

INITIAL SETUP
Tools and Special Tools Materials/Part - Continued
Tool kit, general mechanic’s (Item 36, WP 0236 00) Oil, lubricating (Item 19, WP 0235 00)
Wrench, torque, 50-250 lb-ft (Item 50, WP 0236 00) References

WP 0021 00
Materials/Parts
Equipment Condition
Nut, lock (P/N MS51922-49) (7)
Front brakeshoes removed (WP 0135 00)
Seal (P/N A-1205-D-2110) (2) Front air brake chamber removed (WP 0141 00)
Washer, lock (P/N 1229-R-512) (4) Front ABS sensor removed (WP 0106 00)
Grease, GAA (Item 15, WP 0235 00) Front slack adjuster and s-cam removed (WP 0140 00)
REMOVAL
1. Remove two nuts (1), lock washers (2), and screws (3) from brake spider (4). Discard lock washers.
2. Remove two nuts (5) and lock washers (6) from brake spider (4). Discard lock washers.
3. Remove two screws (7) and 2-piece dust shield (8) from brake spider (4).
4. Remove two nuts (9), screws (10), and clamps (11) from brake spider (4).
NOTE
Note position of brake chamber bracket to aid in installation.
5. Remove two nuts (12), lock washers (13), screws (14), and brake chamber bracket (15) from brake spider (4). Discard
lock washers.
6. Remove two seals (16) and bushings (17) from brake chamber bracket (15). Discard seals.
7. Remove seven lock nuts (18), washers (19), screws (20), and brake spider (4) from axle flange (21). Discard lock nuts.
1
2
16 12 18
17
13
15
5 19
17 6
16 21
4 7
14
3
9 8
10,11
20
0136 00-1
TM 9-2320-302-20
FRONT BRAKE SPIDER AND BRAKE CHAMBER

BRACKET REPLACEMENT - CONTINUED 0136 00
INSTALLATION
1. Install brake spider (4) on axle flange (21) with seven screws (20), washers (19), and new lock nuts (18). Tighten lock
nuts to 75 lb-ft (102 Nm) in sequence shown. Tighten lock nuts again to 150-175 lb-ft (203-237 Nm) in sequence
shown.
OPEN OPEN
FOR ABS FOR ABS
18 SENSOR SENSOR
21 19
4
LEFT-FRONT SIDE RIGHT-FRONT SIDE

20
2. Apply a light coat of lubricating oil to two bushings (17) and two new seals (16).
3. Install two bushings (17), with label ends facing each other, on brake chamber bracket (15) to a depth of 3/8 in (9.5 mm)
from each end of brake chamber bracket.
4. Install two new seals (16) in brake chamber bracket (15) with lip of both seals facing toward vehicle.
5. Install brake chamber bracket (15) on brake spider (4) with two screws (14), new lock washers (13), and nuts (12).
6. Apply a light coat of GAA grease to two bushings (17) in brake chamber bracket (15).
7. Install 2-piece dust shield (8) on brake spider (4) with two screws (7).
8. Install two clamps (11), screws (10), and nuts (9) on brake spider (4).
9. Install two new lock washers (5) and nuts (4) on brake spider (4).
10. Install two screws (3), new lock washers (2), and nuts (1) on brake spider (4).
0136 00-2
TM 9-2320-302-20
FRONT BRAKE SPIDER AND BRAKE CHAMBER

16 2
12
17
15 1
10,11
17 7
16
13
4
5
14 6
8
9
3
8
11. Install front slack adjuster and s-cam (WP 0140 00).
12. Install front air brake chamber (WP 0141 00).
13. Install front ABS sensor (WP 0106 00).
14. Install front brakeshoes (WP 0135 00).
15. Apply GAA grease to brake chamber bracket (15) (WP 0021 00).
END OF WORK PACKAGE
0136 00-3
TM 9-2320-302-20
0136 00-4
TM 9-2320-302-20
REAR BRAKESHOE REPLACEMENT 0137 00
Removal, Cleaning and Inspection, Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Rear hub, drum, wheel bearings, and seal removed
(WP 0166 00)
Materials/Parts
Compound, antiseize (Item 6, WP 0235 00)
REMOVAL
1. Lift upper brakeshoe (1) and pull roller retaining clip (2).
2. Remove cam roller (3) and roller retaining clip (2).
3. Push on lower brakeshoe (4) and pull roller retaining clip (5).
4. Remove cam roller (6) and roller retaining clip (5).
2
3
5
6
4
0137 00-1
TM 9-2320-302-20
REAR BRAKESHOE REPLACEMENT - CONTINUED 0137 00
REMOVAL - CONTINUED
5. Lift lower brakeshoe (4) and remove return spring (7).
4
6. Rotate lower brakeshoe (4) away from s-cam (8).
7. Remove two retaining springs (9), upper and lower brakeshoes (1 and 4), and two anchor pins (10).
10
4
8
10
CLEANING AND INSPECTION
1. Clean rear brakeshoes and components in accordance with WP 0228 00.

2. Measure brake lining thickness. Thickness must be NO LESS than 1/4 in (6.4 mm). If brake lining is less than 1/4 in (6.4
mm), replace brakeshoes.
3. Measure clearance between top of brake lining and top of all rivet heads. Clearance must be a minimum of 1/32 in (0.8
mm). If clearance is less than 1/32 in (0.8 mm), replace brakeshoes.
4. Inspect all remaining brakeshoe parts in accordance with WP 0228 00.
INSTALLATION
1. Apply a thin film of antiseize compound to each anchor pin (10) and small diameter of two cam rollers (3 and 6).
2. Install two anchor pins (10).
0137 00-2
TM 9-2320-302-20
REAR BRAKESHOE REPLACEMENT - CONTINUED 0137 00
3. Install upper brakeshoe (1) on upper anchor pin (10).

4. Install two retaining springs (9).
5. Install lower brakeshoe (4) on lower anchor pin (10).
6. Rotate lower brakeshoe (4) toward s-cam (8).
10
1
9
8
3
6
10
4
7. Install return spring (7) between upper and lower brakeshoes (1 and 4).
8. Pull upper and lower brakeshoes (1 and 4) away from s-cam (8).
9. Install two cam rollers (3 and 6) and two roller retaining clips (2 and 5).
1
11
12
3
7 PRESS
8
6
12
4 5
NOTE
Press ears of roller retaining clips together so that retainer fits between brakeshoe webs.
10. Press each roller retaining clip (2 and 5) between brakeshoe webs (11) until ears of roller retaining clips lock in holes
(12) of brakeshoe webs.
11. Install rear hub, drum, wheel bearings, and seal (WP 0166 00).
END OF WORK PACKAGE
0137 00-3
TM 9-2320-302-20
0137 00-4
TM 9-2320-302-20
REAR BRAKE SPIDER AND BRAKE CHAMBER BRACKET REPLACEMENT 0138 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Rear brakeshoes removed (WP 0137 00)
Wrench, torque, 50-250 lb-ft (Item 46, WP 0236 00) Rear air brake chamber removed (WP 0142 00)
Materials/Parts Rear ABS sensor removed (WP 0107 00)
Nut, lock (P/N MS51922-49) (8) Rear slack adjuster and s-cam removed (WP 0140 00)
Seal (P/N A-1205-V-1556) (2)

REMOVAL
1. Remove four screws (1), washers (2), and brake chamber bracket (3) from spider (4).
2. Remove two seals (5) and bushings (6) from brake chamber bracket (3). Discard seals.
3
5
6
6
5
1
0138 00-1
TM 9-2320-302-20
REAR BRAKE SPIDER AND BRAKE CHAMBER

REMOVAL - CONTINUED
NOTE
Matchmark spider position prior to removal from axle flange to aid in installation.
3. Remove eight lock nuts (7), washers (8), flange bolts (9), washers (10), and spider (4) from axle flange (11). Discard
lock nuts.
7,8,9,10
11
INSTALLATION
NOTE
Position spider as matchmarked during removal.
1. Install spider (4) on axle flange (11) with eight washers (10), flange bolts (9), washers (8), and new lock nuts (7).
Tighten lock nuts to 150-175 lb-ft (203-237 Nm) in sequence shown.
OPEN FOR OPEN FOR

ABS SENSOR ABS SENSOR
LEFT-REAR SIDE RIGHT-REAR SIDE

2. Apply a light coat of GAA grease to two bushings (6) and new seals (5).
NOTE
Install bushings with label ends facing each other. Install bushings to a depth of 3/8 in (9.5 mm) from each
end. Install each seal with lip facing slack adjuster.
3. Install two bushings (6) and seals (5) on spider (4).
0138 00-2
TM 9-2320-302-20
REAR BRAKE SPIDER AND BRAKE CHAMBER

4. Install brake chamber (3) on spider (4) with four washers (2) and screws (1).
3
5
6
6
5
1
5. Install rear slack adjuster and s-cam (WP 0140 00).

6. Install rear air brake chamber (WP 0142 00).
7. Install rear ABS sensor (WP 0107 00).
8. Install rear brakeshoes (WP 0137 00).
9. Apply GAA grease to brake chamber bracket (3).
END OF WORK PACKAGE
0138 00-3
TM 9-2320-302-20
0138 00-4
TM 9-2320-302-20
SLACK ADJUSTER ADJUSTMENT 0139 00
Adjustment
INITIAL SETUP

Jack, hydraulic, hand (Item 21, WP 0236 00) Equipment Condition
Slack adjuster tool (WP 0230 00) Wheel jacked up and axle supported by trestle
Trestle, hoist, portable (Item 38, WP 0236 00)
ADJUSTMENT
NOTE
Whenever a new slack adjuster or air brake chamber has been installed, perform steps 1 through 7 using a
manufactured slack adjuster template (WP 0230 00).
1. Compare length of slack adjuster (1) with template (2). Marks by holes in small end of template indicate length of slack
adjuster.
0139 00-1
TM 9-2320-302-20
SLACK ADJUSTER ADJUSTMENT - CONTINUED 0139 00
CAUTION
To ensure that slack adjuster adjusts brake properly, clevis must be installed in correct position on push rod.
2. Insert large clevis pin (3) through large hole (4) of template and large holes of clevis (5).
3. Select hole (6) of template that matches length of slack adjuster. Hold that hole on center of camshaft or powershaft (7).
3
5
8
4
4. Look through slot (8) in template. Small hole (9) in clevis (5) MUST be completely visible.
5. If necessary, adjust position of clevis (5) on push rod until small hole (9) in clevis is completely visible through slot (8)
in template.
6. Tighten jamnut (10) against clevis (5) to hold clevis in correct position. For 1/2-20 threads, tighten jamnut to 20-30 lb-ft
(27-41 Nm). For 5/8-18 threads, tighten jamnut to 25-50 lb-ft (34-68 Nm).
MINIMUM 1/2 IN (12.7 MM)
MAXIMUM 1/8 IN (3.18 MM)
10
0139 00-2
TM 9-2320-302-20
SLACK ADJUSTER ADJUSTMENT - CONTINUED 0139 00
7. There must be at least 1/2 in (12.7 mm) of thread engagement between clevis and push rod. Push rod must not extend
through clevis more than 1/8 in (3.18 mm).
8. If adjustment cannot be obtained, install new air brake chamber.
9. Remove screw (11), spring (12), and pawl (13).
10. Rotate wheel and tighten screw (14) until wheel does not rotate.
NOTE
A slight amount of drag will be felt during wheel rotation.
11. Loosen screw (14) 1/4 turn and rotate wheel.
12. Install pawl (13), spring (12), and screw (11). Tighten screw to 180-240 lb-in (20-27 Nm).
13. Using flat tip screwdriver, pull slack adjuster (15) in direction away from brake chamber (16) while measuring total dis-
tance of travel between slack adjuster and brake chamber.
14
16
11,12,13
15
16
11,12,13
14 16
0.500-1.750 IN
15
0.500-1.750 IN
16
FRONT REAR
14. If total distance of travel exceeds 1-3/4 in (44.45 mm), or if total distance is not minimum of 1/2 in (12.7 mm), repeat
steps 9 through 13.
15. Remove trestle from axle.
END OF WORK PACKAGE
0139 00-3
TM 9-2320-302-20
0139 00-4
TM 9-2320-302-20
SLACK ADJUSTER AND S-CAM REPLACEMENT 0140 00
Front Slack Adjuster Removal, Rear Slack Adjuster Removal, Front Slack Adjuster Installation, Rear Slack Adjuster
Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Pin, cotter (P/N 2257-B-1094)
Indicator, dial (Item 18, WP 0236 00) Pin, cotter (P/N 2257-C-1095)
Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Compound, antiseize (Item 6, WP 0235 00)
Equipment Condition
Front brakeshoe removed (WP 0135 00)
Rear brakeshoe removed (WP 0137 00)
FRONT SLACK ADJUSTER REMOVAL

1. Remove cotter pins (1 and 2) and clevis pins (3 and 4) from front brake chamber clevis (5). Discard cotter pins.
4
2
1 5
0140 00-1
TM 9-2320-302-20
SLACK ADJUSTER AND S-CAM REPLACEMENT - CONTINUED 0140 00
FRONT SLACK ADJUSTER REMOVAL - CONTINUED
NOTE
Note position of washers for installation.
2. Remove retaining ring (6) and washers (7) from s-cam (8).
3. Remove slack adjuster (9) and washer (10) from splined shaft of s-cam (8).
4. Mark position of s-cam (8) on mounting bracket (11) and remove s-cam and special washer (12) from mounting bracket.
11
6
12 7
10 9
8
REAR SLACK ADJUSTER REMOVAL

1. Remove cotter pins (13 and 14) and clevis pins (15 and 16) from rear brake chamber clevis (17). Discard cotter pins.
17 13
15
14
16
NOTE
Note position of washers for installation.
2. Remove retaining ring (18) and washers (19) from s-cam (20).
3. Remove slack adjuster (21) and washer (22) from splined shaft of s-cam (20).
4. Mark position of s-cam (20) on mounting bracket (23) and remove s-cam and special washer (24) from mounting
bracket.
0140 00-2
TM 9-2320-302-20
SLACK ADJUSTER AND S-CAM REPLACEMENT- CONTINUED 0140 00
REAR SLACK ADJUSTER REMOVAL - CONTINUED
23
18
19
24
22 21
20
FRONT SLACK ADJUSTER INSTALLATION

1. Lightly coat splines of s-cam (8) with antiseize compound.
2. Install s-cam (8) and special washer (12) on mounting bracket (11).
3. Install washer (10) and slack adjuster (9) on s-cam (8) with head of screw (25) toward vehicle.
NOTE
If repeating installation because measurement in step 12 exceeded 0.06 in (1.5 mm), add another washer as a
spacer.
4. Install washers (7) and retaining ring (6) on s-cam (8).
25
11
6
12 7
10 9
8
0140 00-3
TM 9-2320-302-20
FRONT SLACK ADJUSTER INSTALLATION - CONTINUED
5. Remove screw (25), spring (26), and pawl (27) from slack adjuster (9).
6. Rotate adjusting screw (28) to align slack adjuster (9) with front brake chamber clevis (5).
7. Hold s-cam (8) in position and rotate adjusting screw (28) to align slack adjuster (9) with clevis (5).
8. Install clevis pins (4 and 3).
9. Install pawl (27), spring (26), and screw (25) on slack adjuster (9). Tighten screw to 15-20 lb-ft (20-27 Nm).
10. Ensure that s-cam (8) is against brake spider (29).
9
25,26,27
28
11. Attach magnetic base of dial indicator to brake spider (29) with indicator point on end surface of s-cam (8). Set dial indi-
cator to zero.
12. Push s-cam (8) outward to end of travel and check new reading on dial indicator. If reading is more than 0.06 in (1.5
mm), perform Removal steps 2 through 4 and Installation steps 1 through 12.
29
0140 00-4
TM 9-2320-302-20
FRONT SLACK ADJUSTER INSTALLATION - CONTINUED

13. Install new cotter pins (2 and 1) on clevis pins (4 and 3).
4
3
14. Install front brakeshoe (WP 0135 00).

REAR SLACK ADJUSTER INSTALLATION
1. Lightly coat splines of s-cam (20) with antiseize compound.
2. Install s-cam (20) and special washer (24) on mounting bracket (23).
3. Install washer (22) and slack adjuster (21) on s-cam (20) with head of screw (3) toward vehicle.
NOTE
If repeating installation because measurement in step 11 exceeded 0.06 in (1.5 mm), add another washer as a
spacer.
4. Install washers (19) and retaining ring (18) on s-cam (20).
30
23
18
19
24
22 21
20
0140 00-5
TM 9-2320-302-20
REAR SLACK ADJUSTER INSTALLATION - CONTINUED
5. Remove screw (30), spring (31), and pawl (32) from slack adjuster (21).
6. Hold s-cam (20) in position and rotate adjusting screw (33) to align slack adjuster (21) with rear brake chamber clevis
(17).
7. Install two clevis pins (16 and 15) on rear brake chamber clevis (17).
8. Install pawl (32), spring (31), and screw (30) on slack adjuster (21). Tighten screw to 15-30 lb-ft (20-27 Nm).
33
20
21
32,31,30
15
17
16
9. Ensure that s-cam (20) is against brake spider (34).

10. Attach magnetic base of dial indicator to brake spider (34) with indicator point on end surface of s-cam (20). Set dial
indicator to zero.
11. Push s-cam (20) outward to end of travel and check new reading on dial indicator. If reading is more than 0.06 in (1.5
mm), perform Removal steps 2 through 4 and Installation steps 1 through 11.
20
34
12. Install new cotter pins (13 and 14) on clevis pins (15 and 16).
0140 00-6
TM 9-2320-302-20
REAR SLACK ADJUSTER INSTALLATION - CONTINUED
15
16
13
14
13. Install rear brakeshoe (WP 0137 00).
END OF WORK PACKAGE
0140 00-7
TM 9-2320-302-20
0140 00-8
TM 9-2320-302-20
FRONT AIR BRAKE CHAMBER REPLACEMENT 0141 00
INITIAL SETUP

Materials/Parts
Pin, cotter (P/N 2257-B-1094)
Pin, cotter (P/N 2257-C-1095)
REMOVAL
WARNING
DO NOT disconnect any air system lines or fittings unless vehicle engine is shut off and air system pressure
is relieved. Failure to follow this warning could result in serious injury to personnel.
1. Disconnect air hose (1) from brake chamber (2).
2. Remove fitting (3) from brake chamber (2).
3. Remove two cotter pins (4) and two clevis pins (5) connecting brake chamber clevis (6) to slack adjuster (7). Discard
cotter pins.
4. Remove two nuts (8), washers (9), and brake chamber (2) from mounting bracket (10).
1 4 8,9
3 2
5
4 10
8,9
2
7
0141 00-1
TM 9-2320-302-20
FRONT AIR BRAKE CHAMBER REPLACEMENT - CONTINUED 0141 00
INSTALLATION
1. Install brake chamber (2) on mounting bracket (10) with two washers (9) and nuts (8).
2. Align brake chamber clevis (6) on slack adjuster (7) and install two clevis pins (5) and new cotter pins (4).
WARNING
ment.
3. Lightly coat threads of fitting (3) with pipe sealing compound. Install fitting on brake chamber (2).
4. Connect air hose (1) to fitting (3).
1 4 8,9
3 2
5
4 10
8,9
2
7
5. Start vehicle and build air pressure (TM 9-2320-302-10). Check for leaks.
END OF WORK PACKAGE
0141 00-2
TM 9-2320-302-20
REAR AIR BRAKE CHAMBER REPLACEMENT 0142 00
INITIAL SETUP

Materials/Parts
Equipment Condition
Pin, cotter (P/N 2257-B-1094)
Brakes caged (TM 9-2320-302-10)
Pin, cotter (P/N 2257C-1095)
Parking brake released (TM 9-2320-302-10)
Nut, lock (P/N 9002001) (2)
Compound, sealing, pipe (Item 10, WP 0235 00) Vehicle blocked
WARNING
Air brake chamber contains a powerful spring. DO NOT remove clamp rings or disassemble chambers even
with compression spring caged. Failure to follow this warning could result in serious injury to personnel.
REMOVAL
NOTE
Tag air hoses to aid in installation.
1. Disconnect service brake hose (1) and spring brake hose (2) from service brake fitting (3) and spring brake fitting (4).
2. Remove two cotter pins (5) and clevis pins (6) from brake chamber clevis (7). Discard cotter pins.
3. Remove two lock nuts (8) and washers (9). Discard lock nuts.
4. Remove brake chamber (10).
5. Remove service brake fitting (3) from brake chamber (10).
6. Remove spring brake fitting (4) from brake chamber (10).
1 2
6 3
8
4
9
10
5
7
0142 00-1
TM 9-2320-302-20
REAR AIR BRAKE CHAMBER REPLACEMENT - CONTINUED 0142 00
INSTALLATION
WARNING
• Ensure all air lines and fittings are clear of debris and excess pipe sealing compound does not enter air
lines or fittings. Failure to follow this warning could result in injury to personnel or damage to equip-
ment.
1. Lightly coat threads of service brake fitting (3) with pipe sealing compound. Install fitting on brake chamber (10).
2. Lightly coat spring brake fitting (4) with pipe sealing compound. Install fitting on brake chamber (10).
NOTE
Brake chamber is mounted in upper part of figure 8 hole.
3. Install brake chamber (10) so that service brake fitting (3) and spring brake fitting (4) are accessible.
4. Install two washers (9) and new lock nuts (8).
5. If service brake fitting (3) and spring brake fitting (4) are not properly alined with hoses (1 and 2), loosen nut (11) and
rotate brake chamber (10) until fittings and hoses are alined. Tighten nut.
6. Connect brake chamber clevis (7) to slack adjuster (12) with two clevis pins (6) and new cotter pins (5).
7. Connect service brake hose (1) and spring brake hose (2) to service brake fitting (3) and spring brake fitting (4).
8. Uncage brakes (TM 9-2320-302-10).

1 2
6 3
8
4
9
11
10
5
7
9. Start vehicle and build air pressure (Tm 9-2320-302-10). Check for leaks.
END OF WORK PACKAGE
0142 00-2
TM 9-2320-302-20
PRIMARY I AIR TANK AND FITTINGS REPLACEMENT 0143 00
INITIAL SETUP

Materials/Parts
Equipment Condition
Nut, lock (P/N MS51922-17) (6)
Tags, marker (Item 31, WP 0235 00) Rear platform removed (WP 0200 00)
REMOVAL
NOTE
Tag tubes to aid in installation.
1. Disconnect two tubes (1) from air tank (2).
2. Remove four lock nuts (3), washers (4), and air tank (2). Discard lock nuts.
NOTE
Perform steps 3 and 4 only if fittings or air tank are to be replaced.
3. Remove two lock nuts (5), screws (6), and mounting brackets (7) from air tank (2). Discard lock nuts.
4. Remove two elbows (8), check valve (9), drain valve (10), and two plugs (11) from air tank (2).
4 7
3
3
4
5
6
5
11
8
1
9
11
2
10
8 1
0143 00-1
TM 9-2320-302-20
PRIMARY I AIR TANK AND FITTINGS REPLACEMENT - CONTINUED 0143 00
INSTALLATION
WARNING
ment.
NOTE
Perform steps 1 and 2 only if fittings or air tank were replaced.
1. Lightly coat pipe threads of two plugs (11), drain valve (10), check valve (9) and two elbows (8) with pipe sealing com-
pound. Install plugs, drain valve, check valve, and elbows on air tank (2).
2. Install air tank (2) to two mounting brackets (7) with two screws (6) and new lock nuts (5).
3. Install air tank (2) with four washers (4) and new lock nuts (3).
4. Connect two tubes (1) to air tank (2).
4
3
7
3
4
5
6
5
11
8
1
9
11
2
10
1
8
5. Perform air system PMCS leak test (WP 0021 00).
6. Install rear platform (WP 0200 00).
END OF WORK PACKAGE
0143 00-2
TM 9-2320-302-20
PRIMARY II AIR TANK AND FITTINGS REPLACEMENT 0144 00
INITIAL SETUP

Materials/Parts
Equipment Condition
Nut, lock (P/N MS51922-17) (6)
Tags, marker (Item 31, WP 0235 00) Spare tire removed (TM 9-2320-302-10)
REMOVAL
NOTE
1. Disconnect three tubes (1) from air tank (2).
2. Remove four lock nuts (3), washers (4), and air tank (2). Discard lock nuts.
NOTE
3. Remove two lock nuts (5), screws (6), and mounting brackets (7) from air tank (2). Discard lock nuts.
4. Remove three elbows (8), plug (9), and drain valve (10) from air tank (2).
7
5,6
7
4
4 3
9 3
1
8 8
10
2
1
8
0144 00-1
TM 9-2320-302-20
PRIMARY II AIR TANK AND FITTINGS REPLACEMENT 0144 00
INSTALLATION
NOTE
Perform steps 1 and 2 only if fittings or air tank were replaced.
1. Install two mounting brackets (7) on air tank (2) with two screws (6) and new lock nuts (5).
WARNING
ment.
2. Lightly coat threads of drain valve (10), plug (9), and three elbows (8) with pipe sealing compound. Install drain valve,
plug, and three elbows on air tank (2).
3. Install air tank (2) with four washers (4) and new lock nuts (3).
4. Connect three tubes (1) to air tank (2).
7
5,6
7
4
4 3
9 3
1
8 8
10
2
1
8

6. Install spare tire (TM 9-2320-302-10).
END OF WORK PACKAGE
0144 00-2
TM 9-2320-302-20
SECONDARY AIR TANK AND FITTINGS REPLACEMENT 0145 00

INITIAL SETUP


Nut, lock (P/N MS51922-1) (2) Air system drained (TM 9-2320-302-10)
Nut, lock (P/N MS51922-17) (8)
REMOVAL
NOTE
1. Disconnect four tubes (1) and hose (2) from air tank (3).
2 1
1
0145 00-1
TM 9-2320-302-20
SECONDARY AIR TANK AND FITTINGS REPLACEMENT - CONTINUED 0145 00
REMOVAL - CONTINUED
2. Remove two lock nuts (4), screws (5), and air tank (3). Discard lock nuts.
3. Remove two lock nuts (6), washers (7), screws (8), and washers (9) and set cable (10) aside. Discard lock nuts.
4. Remove two lock nuts (11), washers (12), and brackets (13). Discard lock nuts.
5. Remove two lock nuts (14), washers (15), clamps (16), and mounting brackets (17). Discard lock nuts.
6. Remove two lock nuts (18), washers (19), screws (20), washers (21), and brackets (22). Discard lock nuts.
NOTE
Perform step 7 only if fittings or air tank are to be replaced.
7. Remove four elbows (23), check valve (24), plug (25), connector (26), tee (27), bushing (28), pressure protect valve
(29), and drain valve (30).
12 8 9
11 13
8 14
15
9 13 16 18
11 19 22
7
12
10 6 17
7
4,5
6 14 15
16
18
19
22 21
20
3 25
2 1
1
23
23
28
26 27 24
23
30
29
23
0145 00-2
TM 9-2320-302-20
SECONDARY AIR TANK AND FITTINGS REPLACEMENT - CONTINUED 0145 00
INSTALLATION
WARNINGS
lines or fittings. Failure to follow this warning could result in injury to personnel and damage to equip-
ment.
NOTE
Perform steps 1 and 2 only if fittings were removed from air tank.
1. Coat pipe threads of drain valve (30), pressure protect valve (29), bushing (28), tee (27), connector (26), plug (25),
check valve (24), and four elbows (23) with pipe sealing compound.
2. Install drain valve (30), pressure protect valve (29), bushing (28), tee (27), connector (26), plug (25), check valve (24)
and four elbows (23) in air tank (3).
3. Install two brackets (22) with two washers (21), screws (20), washers (19), and new lock nuts (18).
4. Install two mounting brackets (17), clamps (16), washers (15), and new lock nuts (14).
5. Install two brackets (13), washers (12), and new lock nuts (11).
6. Install cable (10), two washers (9), screws (8), washers (7), and new lock nuts (6).
7. Install air tank (3) with two screws (5), and new lock nuts (4).
8. Connect hose (2) and four tubes (1) to air tank (3).
END OF WORK PACKAGE
0145 00-3
TM 9-2320-302-20
0145 00-4
TM 9-2320-302-20
AIR SUPPLY TANK AND FITTINGS REPLACEMENT 0146 00
INITIAL SETUP


Pin, cotter (P/N MS 24665-326) Air system drained (TM 9-2320-302-10)
Nut, lock (P/N MS51922-17) (8) Rear platform removed (WP 0200 00)
REMOVAL
NOTE
1. Disconnect six tubes (1) from air supply tank (2).
2. Disconnect tube (3) from primary I air tank (4).
3. Remove four lock nuts (5) and washers (6) and set primary I air tank (4) aside. Discard lock nuts.
4. Remove cotter pin (7) and disconnect cable (8). Discard cotter pin.
5. Remove four lock nuts (9), washers (10), screws (11), washers (12), and air supply tank (2). Discard lock nuts.
9 1
1 5
10 12
11
5
2
6 12
11 4
7
8 3
0146 00-1
TM 9-2320-302-20
AIR SUPPLY TANK AND FITTINGS REPLACEMENT - CONTINUED 0146 00
REMOVAL - CONTINUED
NOTE
6. Remove five connectors (13), safety valve (14), elbow (15), two tees (16), bushing (17), check valve (18), tee (19), and
drain valve (20) from air supply tank (2).
7. Remove two screws (21), washers (22), and mounting brackets (23) from air supply tank (2).
13
15
16
14 13
17
23 2
18
22 19
21
13 20
INSTALLATION
NOTE
Perform steps 1 through 3 only if fittings or air tank were replaced.
1. Install two mounting brackets (23), washers (22), and screws (21) on air supply tank (2).
WARNING
• Adhesives and sealing compounds can burn easily, can give off harmful vapors, and are harm-
ful to skin and clothing. To avoid injury or death, keep away from open fire and use in a well-
ventilated area. If adhesives or sealing compound gets on skin or clothing, wash immediately
with soap and water.
• Ensure all air lines and fittings are clear of debris and excess pipe sealing compound does not
enter air lines or fittings. Failure to follow this warning could result in injury to personnel or
0146 00-2
TM 9-2320-302-20
AIR SUPPLY TANK AND FITTINGS REPLACEMENT - CONTINUED 0146 00
2. Coat pipe threads of drain valve (20), tee (19), check valve (18), bushing (17), two tees (16), elbow (15), safety valve
(14), and five connectors (13) with pipe sealing compound.
3. Install drain valve (20), tee (19), check valve (18), bushing (17), two tees (16), elbow (15), safety valve (14), and five
connectors (13) in air supply tank (2).
4. Install air supply tank (2), four washers (12), screws (11), washers (10) and new lock nuts (9).
5. Connect cable (8) and install new cotter pin (7).
6. Install primary I air tank (4), four washers (6) and new lock nuts (5).
7. Connect tube (3) to primary I air tank (4).
8. Connect six tubes (1) to air supply tank (2).
9 1
1 5
10 12
11
5
2
6 12
11 4
7
8 3

END OF WORK PACKAGE
0146 00-3
TM 9-2320-302-20
0146 00-4
TM 9-2320-302-20
AIR TUBE REPLACEMENT 0147 00
INITIAL SETUP

Materials/Parts
Equipment Condition
REMOVAL
NOTES
• Air tubes are replaced the same way.
• For location of air tubes, refer to Table 1, Air Tube Locator Table.
• Tag all air tubes and fittings to aid in installation.
• Remove and discard plastic tiedown straps. Install new tiedown straps.
• When replacing air tube, remove tube from vehicle and cut new tube 1/4-1/2 in (6.4 - 12.7 mm)
longer than air tube being replaced.
1. Remove nut (1) from fitting (2).
2. Remove air tube (3) from fitting (2).
NOTE
If insert remains in fitting, do not remove. Cut air tube to remove ferrule.
3. Remove insert (4), ferrule (5), and nut (1) from air tube (3). Discard ferrule.
4
5
1
0147 00-1
TM 9-2320-302-20
AIR TUBE REPLACEMENT - CONTINUED 0147 00
INSTALLATION
1. Position nut (1), new ferrule (5), and insert (4) on air tube (3).
WARNING
adhesives or sealing compound contact skin or clothing, wash immediately with soap and water.
ment.
2. Lightly coat threads of fitting (2) with pipe sealing compound. Install fitting (2) on air tube (3).
3. Install nut (1) on fitting (2).
4
5
1
0147 00-2
TM 9-2320-302-20
Table 1. Air Tube Locator Table.
TUBE
NO. FROM FROM/TO TO
001 Foot Brake Valve, D2 (1) Quick Release Valve (2)

002 Quick Release Valve (2) ABS Solenoid Valve (3)
003 ABS Solenoid Valve (3) Front Brake Chamber (4)
003 001
4
3
003
002
2
002 3
0147 00-3
TM 9-2320-302-20
Table 1. Air Tube Locator Table - Continued.
TUBE
NO. FROM FROM/TO TO
004 Foot Brake Valve, D2 (1) Rear Relay Valve, SER (5)
005 Air Junction Block, No. 18 (6) Rear Relay Valve, CONT (5)
006 Primary II Air Tank (7) Rear Relay Valve, SUP (5)
007 Rear Relay Valve, DEL (5) ABS Solenoid Valve (8)
008 ABS Solenoid Valve (8) Rear Brake Chamber (9)
007 5 8
8 008
006
008
9
7
1
004
008
9
9
005
007
0147 00-4
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
009 Air Junction Block, No. 18 (6) Tractor Protection Valve, E (10)
010 Foot Brake Valve, D2 (1) Tractor Protection Valve, S (10)
011 Tractor Protection Valve, E (10) Rear Protection Valve, E (11)
012 Tractor Protection Valve, S (10) Rear Protection Valve, S (11)
013 Rear Protection Valve, E (11) Emergency Gladhand (12)
014 Rear Protection Valve, S (11) Service Gladhand (13)
13
013
12
10
1
6 011
009
014
11
012
010
0147 00-5
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
015 Rear Quick Release Valve (14) Rear Brake Chamber (9)
016 Rear Quick Release Valve (14) Supply Air Tank (15)
017 Rear Quick Release Valve (14) Air Junction Block, No. 21 (6)
14 9
015
016
15
015
017 9
0147 00-6
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
018 Air Junction Block, No. 17 (6) Foot Brake Valve, D1 (1)
019 Air Junction Block, No. 19 (6) Foot Brake Valve, D2 (1)
020 Air Junction Block, No. 13 (6) Foot Brake Valve, S1 (1)
021 Air Junction Block, No. 22 (6) Foot Brake Valve, S2 (1)
019 020 6
021
018
0147 00-7
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
022 Air Compressor (16) Air Dryer (17)

023 Air Compressor (16) Air Dryer (17)
024 Air Compressor (16) Supply Air Tank (15)
025 Air Dryer (17) Supply Air Tank (15)
17 025
022
15
023
024
16
0147 00-8
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
026 Secondary Air Tank (18) Foot Brake Valve (1)

027 Primary II Air Tank (7) Foot Brake Valve (1)
028 Primary II Air Tank (7) Primary I Air Tank (19)
029 Supply Air Tank (15) Secondary Air Tank (18)
030 Supply Air Tank (15) Primary I Air Tank (19)
030
15
1 19
028
027
029
18
026
0147 00-9
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
031 Secondary Air Tank (18) Firewall (20)

032 Fifth Wheel (21) Junction Block Firewall (20)
033 Axle Interlock (22) Junction Block Firewall (20)
034 Front Service Gladhand (23) Foot Brake Valve (1)
035 Front Emergency Gladhand (24) Supply Air Tank (15)
033 21
032
15
1
22
035
18
20
031
034
24
23
0147 00-10
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
036 Air Junction Block, No. 15 (6) Primary Air Pressure Gage (25)
037 Air Junction Block, No. 11 (6) Secondary Air Pressure Gage (26)
038 Firewall Tee (27) Constant Air Junction Block (28)
25
26
28
037
036
038 27
6
0147 00-11
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
039 Firewall Tee (27) Air Horn Tee (29)

040 Air Horn Tee (29) Driver Seat Air Cylinder (30)
041 Air Horn Tee (29) Air Horn Valve (31) Air Horn (32)
042 Constant Air Junction Block (28) Passenger Seat Air Cylinder (33)
042
33
31
040
30
29
041
27 039
0147 00-12
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
043 Constant Air Junction Block (28) Passenger Seat Air Cylinder (34)
044 Constant Air Junction Block (28) Interaxle Lockup Valve (35)
045 Interaxle Lockup Valve (34) Firewall Fitting, No. 1 (36)
046 Constant Air Junction Block (28) Fifth Wheel Slide Valve (37)
047 Fifth Wheel Slide Valve (37) Firewall Fitting, No. 2 (38)
35
044
28 37
34
047
045
046 36
043 38
0147 00-13
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
048 Air Junction Block, No. 14 (6) Parking Brake/Trailer Air Supply, S1
(39)
049 Air Junction Block, No. 9 (6) Parking Brake/Trailer Air Supply, S2
(39)
050 Parking Brake/Trailer Air Supply, Air Junction Block, No. 12 (6)
DEL TRC (39)
051 Parking Brake/Trailer Air Supply, Air Junction Block, No. 4 (6)
DEL TRL (39)
052 Parking Brake/Trailer Air Supply, Firewall Not Connected
EXH (39)
39
052
051
050
049
048
6
0147 00-14
TM 9-2320-302-20
TUBE
NO. FROM FROM/TO TO
053 Parking Brake/Trailer Air Supply, S2 Trailer Hand Brake, S (40)

(38)
054 Trailer Hand Brake, D (40) Air Junction Block, No. 5 (6)
055 Trailer Hand Brake, E (40) Firewall Not Connected
39
055
40
053
6
054
END OF WORK PACKAGE
0147 00-15
TM 9-2320-302-20
This Page Intentionally Left Blank
0147 00-16
TM 9-2320-302-20
CONSTANT AIR JUNCTION BLOCK REPLACEMENT 0148 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Materials/Parts
REMOVAL
1. Remove six torx screws (1), dash top cover (2), and five torx screws (3). Set instrument panel (4) aside.
1 2
0148 00-1
TM 9-2320-302-20
CONSTANT AIR JUNCTION BLOCK REPLACEMENT - CONTINUED 0148 00
REMOVAL - CONTINUED
NOTE
Tag all tubes, connectors and plugs prior to disconnecting/removal to aid in installation/connecting.
2. Disconnect six tubes (5).
3. Remove two nuts (6), washers (7), screws (8), and constant air junction block (9).
4. Remove three connectors (10), connector (11), two elbows (12), and three plugs (13) from constant air junction block
(9).
7 13
8
9
6
10
13 5
12
5
5
11
13
INSTALLATION
WARNINGS
ment.
1. Coat threads with pipe sealing compound and install three plugs (13), two elbows (12), three connectors (10), and con-
nector (11) in constant air junction block (9).
0148 00-2
TM 9-2320-302-20
13
9
13
10
11
12
13
2. Install constant air junction block (9) with two screws (8), washers (7), and nuts (6).
3. Connect six tubes (5) to constant air junction block (9).
7
9
8
6
6
5
0148 00-3
TM 9-2320-302-20
5. Position instrument panel (4) and install five torx screws (3), dash top cover (2), and six torx screws (1).
1 2
END OF WORK PACKAGE
0148 00-4
TM 9-2320-302-20
CAB AIR JUNCTION BLOCK REPLACEMENT 0149 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Materials/Parts
Nut, lock (P/N 23-10340-125) (3) Check engine switch removed (WP 0070 00)
Compound, caulking (Item 7, WP 0235 00)
REMOVAL
3 1,2
0149 00-1
TM 9-2320-302-20
CAB AIR JUNCTION BLOCK REPLACEMENT - CONTINUED 0149 00
REMOVAL - CONTINUED
NOTE
Tag all tubes, fittings, and wires to aid in installation.
3. Disconnect six tubes (6) and oil line (7) from cab air junction block (8).
6
6
4. Disconnect eight tubes (9) and three plug connectors (10).

5. Remove two lock nuts (11) and two wires (12).
10 11,12
9
9 10 11
6. Remove three lock nuts (13), screws (14), washers (15), ground wire (16), and cab air junction block (8). Discard lock
nuts.
7. Remove 13 connectors (17), four sending units (18), three elbows (19), and three pipe plugs (20) from cab air junction
block (8).
0149 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
18 13
19
17 20 18
18 19
15 17
14
8
13
16
17
17
20
19
14
15
17
INSTALLATION
WARNINGS
ment.
1. Coat threads with pipe sealing compound and install 13 connectors (17), four sending units (18), three elbows (19), and
three pipe plugs (20) in cab air junction block (8).
2. Apply caulking compound to mating surface of cab air junction block (8).
3. Install cab air junction block (8), ground wire (16), three washers (15), screws (14), and new lock nuts (13).
4. Install two wires (12) with new lock nuts (11).
5. Connect three plug connectors (10) and eight tubes (9).
6. Connect six tubes (6) and oil line (7) to cab air junction block (8).
0149 00-3
TM 9-2320-302-20
8. Install cover (5) and two screws (4).
3 1,2
END OF WORK PACKAGE
0149 00-4
TM 9-2320-302-20
TRACTOR PROTECTION VALVES REPLACEMENT 0150 00
Front Tractor Protection Valve Removal, Rear Tractor Protection Valve Removal, Front Tractor Protection Valve Instal-
lation, Rear Tractor Protection Valve Installation
INITIAL SETUP

References
Materials/Parts
TM 9-2320-302-10
Nut, lock (P/N MS51922-11) (4)
Equipment Condition
FRONT TRACTOR PROTECTION VALVE REMOVAL
NOTE
1. Disconnect four tubes (1) from tractor protection valve (2).
2. Remove two coupling hoses (3), three elbows (4), connector (5), valve (6), tee (7,) and adapter (8).
3. Remove two lock nuts (9), washers (10), screws (11), washers (12), and tractor protection valve (2). Discard lock nuts.
2
9
12
10 11
7 8
6
4
5 4
1
1 1
0150 00-1
TM 9-2320-302-20
TRACTOR PROTECTION VALVES REPLACEMENT - CONTINUED 0150 00
REAR TRACTOR PROTECTION VALVE REMOVAL
NOTE
1. Disconnect four tubes (13) and remove four connectors (14) from tractor protection valve (15).
2. Remove two lock nuts (16), washers (17), screws (18), washers (19), and tractor protection valve (15). Discard lock
nuts.
13
14
17
16
19
14
13 15
18
FRONT TRACTOR PROTECTION VALVE INSTALLATION
WARNINGS
ment.
1. Install tractor protection valve (2) with two washers (12), screws (11), washers (10), and new lock nuts (9).
2. Coat threads with pipe sealing compound and install adapter (8), tee (7), valve (6), connector (5), three elbows (4), and
two coupling hoses (3).
0150 00-2
TM 9-2320-302-20
TRACTOR PROTECTION VALVES REPLACEMENT - CONTINUED 0150 00
FRONT TRACTOR PROTECTION VALVE INSTALLATION - CONTINUED
3. Connect four tubes (1) to tractor protection valve (2).

2
9
12
10 11
7 8
6
4
5 4
1
1 1
REAR TRACTOR PROTECTION VALVE INSTALLATION
1. Install tractor protection valve (15) with two washers (19), screws (18), washers (17), and new lock nuts (16).
WARNINGS
ment.
2. Coat threads with pipe sealing compound and install four connectors (14) to tractor protection valve (15). Connect four
tubes (13).
END OF WORK PACKAGE
0150 00-3
TM 9-2320-302-20
0150 00-4
TM 9-2320-302-20
REAR RELAY VALVE REPLACEMENT 0151 00
INITIAL SETUP


Nut, lock (P/N MS 51922-1) (4) Air system drained (TM 9-2320-302-10)
REMOVAL
NOTE
1. Disconnect three tubes (1) and four hoses (2) from relay valve (3).
2. Remove two lock nuts (4), washers (5), screws (6), washers (7), and relay valve (3). Discard lock nuts.
3. Remove four elbows (8) and connector (9).
4. Remove two lock nuts (10), washers (11), screws (12), washers (13), and mounting bracket (14). Discard lock nuts.
1 12
13
8
14
4
3
5
11
2 10
7
6
1
8
9
2
0151 00-1
TM 9-2320-302-20
REAR RELAY VALVE REPLACEMENT - CONTINUED 0151 00
INSTALLATION
1. Install mounting bracket (14) with two washers (13), screws (12), washers (11), and new lock nuts (10).
WARNING
ment.
2. Lightly coat pipe threads of four elbows (8) and connector (9) with pipe sealing compound.
3. Install four elbows (8) and connector (9) on relay valve (3).
1 12
13
8
14
4
3
5
11
2 10
7
6
1
8
9
2
4. Install relay valve (3) with two washers (7), screws (6), washers (5), and new lock nuts (4).
5. Connect three tubes (1) and four hoses (2) to relay valve (3).
END OF WORK PACKAGE
0151 00-2
TM 9-2320-302-20
FRONT SERVICE BRAKE RELAY VALVE REPLACEMENT 0152 00
INITIAL SETUP


REMOVAL
NOTE
1. Disconnect control tube (1), supply tube (2), and two delivery tubes (3) from relay valve (4).
4
3
2
0152 00-1
TM 9-2320-302-20
FRONT SERVICE BRAKE RELAY VALVE REPLACEMENT - CONTINUED 0152 00
REMOVAL - CONTINUED
2. Remove two lock nuts (5), washers (6), screws (7), washers (8), and relay valve (4) from crossmember (9). Discard lock
nuts.
3. Remove four elbows (10) and plug (11) from relay valve (4).
8
7
6
5
4
11
9
10
10
INSTALLATION
WARNING
ment.
1. Coat pipe threads of four elbows (10) and plug (11) with pipe sealing compound.
2. Install four elbows (10) and plug (11) in relay valve (4).
3. Install relay valve (4) on crossmember (9) with two washers (8), screws (7), washers (6), and new lock nuts (5).
4. Connect two delivery tubes (3), supply tube (2), and control tube (1) to relay valve (4).
0152 00-2
TM 9-2320-302-20
FRONT SERVICE BRAKE RELAY VALVE REPLACEMENT - CONTINUED 0152 00
4
3
2
END OF WORK PACKAGE
0152 00-3
TM 9-2320-302-20
0152 00-4
TM 9-2320-302-20
FRONT GLADHANDS REPLACEMENT 0153 00
INITIAL SETUP


Nut, lock (P/N 23-10340-125) (2) Air system drained (TM 9-2320-302-10)
Washer, lock (P/N MS 35333-49) (2)
NOTE
Tag tubes and fittings to aid in installation.
REMOVAL
1. Disconnect two tubes (1) from elbows (2).
NOTE
Note position of washers to aid in installation.
2. Remove two elbows (2), nuts (3), lock washers (4), and gladhands (5) from mounting bracket (6). Discard lock washers.
1
3
4
3
4
6
5
0153 00-1
TM 9-2320-302-20
FRONT GLADHANDS REPLACEMENT - CONTINUED 0153 00
REMOVAL - CONTINUED
3. Remove two lock nuts (7), washers (8), screws (9), washers (10), and mounting bracket (6) from bumper (11). Discard
lock nuts.
9 6
10
11
4. Remove two bulkhead fittings (12), dummy couplings (13), chains (14), and seals (15) from gladhands (5).
15 12
13
15
14
5
5
13
14
INSTALLATION
1. Install two seals (15), chains (14), and dummy couplings (13) on gladhands (5).
0153 00-2
TM 9-2320-302-20
FRONT GLADHANDS REPLACEMENT - CONTINUED 0153 00
WARNING
ment.
2. Lightly coat threads of two bulkhead fittings (12) with pipe sealing compound. Install bulkhead fittings on gladhands
(5).
3. Install mounting bracket (6) on bumper (11) with two washers (10), screws (9), washers (8), and new lock nuts (7).
4. Install two gladhands (5) on mounting bracket (6) with two new lock washers (4) and nuts (3).
5. Lightly coat threads of two elbows (2) with pipe sealing compound. Install elbows on two bulkhead fittings (12).
6. Conect two tubes (1) to elbows (2).
1
3
4
3
4
END OF WORK PACKAGE
0153 00-3
TM 9-2320-302-20
0153 00-4
TM 9-2320-302-20
REAR GLADHAND REPLACEMENT 0154 00
INITIAL SETUP

TM 9-2320-302-10
Materials/Parts
Equipment Condition
Washer, lock (P/N MS 35333-49)
NOTE
Emergency gladhand and service gladhand are replaced the same way. Emergency gladhand is shown.
REMOVAL
1. Disconnect tube (1) from connector (2).
1
2
0154 00-1
TM 9-2320-302-20
REAR GLADHAND REPLACEMENT - CONTINUED 0154 00
REMOVAL - CONTINUED
NOTE
It is not necessary to remove gladhand to replace gladhand seal.
2. Remove connector (2), nut (3), lock washer (4), and gladhand assembly (5) from bracket (6). Discard lock washer.
3. Remove dummy coupling (7), chain (8), bulkhead fitting (9), and seal (10) from gladhand (11).
1
2 6
3
4
10
11
8 7
INSTALLATION
1. Install seal (10), chain (8), and dummy coupling (7) on gladhand (11).
WARNING
ment.
2. Lightly coat threads of bulkhead fitting (9) with pipe sealing compound. Install bulkhead fitting on gladhand (11).
0154 00-2
TM 9-2320-302-20
REAR GLADHAND REPLACEMENT - CONTINUED 0154 00
3. Install gladhand assembly (5) on bracket (6) with new lock washer (4) and nut (3).
4. Lightly coat threads of connector (2) with pipe sealing compound. Install connector on bulkhead fitting (9).
5. Connect tube (1) to connector (2).
END OF WORK PACKAGE
0154 00-3
TM 9-2320-302-20
0154 00-4
TM 9-2320-302-20
FRONT QUICK-RELEASE VALVE REPLACEMENT 0155 00
INITIAL SETUP


REMOVAL
NOTE
1. Disconnect three tubes (1) from quick-release valve (2).
2 1
0155 00-1
TM 9-2320-302-20
FRONT QUICK-RELEASE VALVE REPLACEMENT - CONTINUED 0155 00
REMOVAL - CONTINUED
2. Remove two lock nuts (3), washers (4), screws (5), washers (6), and quick-release valve (2) from crossmember (7). Dis-
card lock nuts.
3. Remove three elbows (8) from quick-release valve (2).
7
6
5
2
3 4
8
INSTALLATION
WARNING
ment.
1. Lightly coat threads of three elbows (8) with pipe sealing compound. Install elbows in quick-release valve (2).
2. Install quick-release valve (2) on crossmember (7) with two washers (6), screws (5), washers (4), and new lock nuts (3).
3. Connect three tubes (1) to quick-release valve (2).
0155 00-2
TM 9-2320-302-20
FRONT QUICK-RELEASE VALVE REPLACEMENT - CONTINUED 0155 00
2 1
END OF WORK PACKAGE
0155 00-3
TM 9-2320-302-20
0155 00-4
TM 9-2320-302-20
REAR QUICK-RELEASE VALVE REPLACEMENT 0156 00
INITIAL SETUP


REMOVAL
NOTE
Tag hoses and tubes to aid in installation.
1. Disconnect four hoses (1) and two tubes (2) from quick-release valve (3).
2. Remove two lock nuts (4), washers (5), screws (6), washers (7), and quick-release valve (3). Discard lock nuts.
3. Remove two elbows (8), tees (9), connectors (10), two-way check valve (11), and pipe nipple (12) from quick-release
valve (3).
6
7
10
11
2
8 10
2
8
9
12
3 1
5
4
9
0156 00-1
TM 9-2320-302-20
REAR QUICK-RELEASE VALVE REPLACEMENT - CONTINUED 0156 00
INSTALLATION
WARNINGS
ment.
1. Coat threads with pipe sealing compound and install pipe nipple (12), two-way check valve (11), two connectors (10),
tees (9), and elbows (8) in quick-release valve (3).
2. Install quick-release valve (3) with two washers (7), screws (6), washers (5), and new lock nuts (4).
3. Connect four hoses (1) and two tubes (2) to quick-release valve (3).
6
7
10
11
2
8 10
2
8
9
12
3 1
5
4
9
END OF WORK PACKAGE
0156 00-2
TM 9-2320-302-20
AIR DRYER REPLACEMENT 0157 00
INITIAL SETUP

Materials/Parts
References
Nut, lock (P/N MS51922-17) (4)
TM 9-2320-302-10
Nut, lock (P/N MS51922-49) (2)
Compound, sealing, pipe (Item 10, WP 0235 00) Equipment Condition
REMOVAL
NOTE
Tag air lines to aid in installation.
1. Disconnect two tubes (1) and hose (2) from air dryer (3).
2. Disconnect electrical connector (4) from air dryer wiring harness connector (5).
3. Remove three elbows (6), two bushings (7), and adapter (8) from air dryer (3).
6
7
3 1
6
7
4 8
6
0157 00-1
TM 9-2320-302-20
AIR DRYER REPLACEMENT - CONTINUED 0157 00
REMOVAL - CONTINUED
NOTE
Assistance is needed to support air dryer while removing mounting hardware.
4. Support air dryer (3) and remove four lock nuts (9), eight washers (10), and four screws (11) securing air dryer to frame
rail (12). Remove air dryer and discard lock nuts.
5. If mounting plate (13) is damaged, remove two lock nuts (14), two screws (15), four washers (16), and mounting plate
11 14
16 13 12
10
16
15
10
10
9
9
INSTALLATION
1. If removed, install mounting plate (13), four washers (16), two screws (15), and new lock nuts (14).
2. With assistance, install air dryer (3) on frame rail (12) with four screws (11), eight washers (10), and four new lock nuts
(9).
WARNING
• Ensure air lines and fittings are clear of debris and excess pipe sealing compound does not enter air lines
or fittings. Failure to to follow this warning could result in injury to personnel or damage to equipment.
3. Apply pipe sealing compound to pipe threads and install adapter (8), two bushings (7), and three elbows (6) on air dryer
(3).
0157 00-2
TM 9-2320-302-20
AIR DRYER REPLACEMENT - CONTINUED 0157 00
6
7
3 1
6
7
4 8
4. Connect two tubes (1) and hose (2) to air dryer (3).
5. Connect electrical connector (4) to air dryer wiring harness connector (5).
END OF WORK PACKAGE
0157 00-3
TM 9-2320-302-20
0157 00-4
TM 9-2320-302-20
AIR DRYER CANISTER REPLACEMENT 0158 00
INITIAL SETUP


Kit, cartridge (P/N RN953) Air system drained (TM 9-2320-302-10)
REMOVAL
1. Remove tiedown strap (1) and disconnect connector (2) from air dryer harness (3). Discard tiedown strap.
2. Disconnect air line (4) from elbow (5) on bottom of air dryer canister housing (6).
NOTE
Note position of elbow to aid in installation for proper orientation of air dryer canister.
3. Remove clamp (7) and canister housing (6) from air dryer.
4. Remove nut (8), purge plate (9), spring (10), and canister (11) from air dryer.
5. Remove packing (12) from canister housing (6). Discard packing.
6. Remove packing (13 and 14) from purge plate (9). Discard packings.
8 9
14
7
10 13
11
1
4
12
5 6
2
3
0158 00-1
TM 9-2320-302-20
AIR DRYER CANISTER REPLACEMENT - CONTINUED 0158 00
INSTALLATION
1. Lightly coat new packings (13 and 14) with GAA grease. Install packings on purge plate (9).
2. Install canister (11) in air dryer canister housing (6).
3. Install spring (10) and purge plate (9) on canister housing (6) with nut (8).
4. Install new packing (12) on canister housing (6).
NOTE
Ensure elbow is positioned as noted during removal.
5. Place canister housing (6) on air dryer and tighten clamp (7).
6. Connect air line (4) to elbow (5).
7. Connect connector (2) to air dryer harness (3). Install new tiedown strap (1).
8 9
14
7
10 13
11
1
4
12
5 6
2
3
END OF WORK PACKAGE
0158 00-2
TM 9-2320-302-20
TRAILER HAND BRAKE REPLACEMENT 0159 00
INITIAL SETUP

TM 9-2320-302-10
Materials/Parts
Equipment Condition
REMOVAL
1. Remove six screws (1), washers (2), and cover (3).
1,2
0159 00-1
TM 9-2320-302-20
TRAILER HAND BRAKE REPLACEMENT - CONTINUED 0159 00
REMOVAL - CONTINUED
NOTE
Tag tubes and connectors to aid in installation.
2. Remove three tubes (4) and connectors (5) from trailer hand brake (6).
3. Remove clamp (7), trailer hand brake (6), and turn signal switch assembly (8). Set turn signal switch assembly aside.
4. Remove screw (9), handle (10), three screws (11), and bracket (12) from trailer hand brake (6).
5. Back off jamnut (13) and remove handle base (14), jamnut, and knob (15) from handle (10).
11
10 9
12
15
5
4 6
8
15 7
10
13
14
INSTALLATION
1. Install knob (15), jamnut (13), and handle base (14) on handle (10). Tighten jamnut.
2. Install bracket (12), three screws (11), handle (10), and screw (9) on trailer hand brake (6).
3. Install trailer hand brake (6) and turn signal switch assembly (8). Tighten clamp (7).
WARNING
ment.
0159 00-2
TM 9-2320-302-20
TRAILER HAND BRAKE REPLACEMENT - CONTINUED 0159 00
4. Lightly coat threads of three connectors (5) with pipe sealing compound. Install connectors and tubes (4) on trailer hand
brake (6).
6. Install cover (3) with six washers (2) and screws (1).
1,2
END OF WORK PACKAGE
0159 00-3
TM 9-2320-302-20
0159 00-4
TM 9-2320-302-20
PARKING BRAKE AND TRAILER AIR SUPPLY VALVE REPLACEMENT 0160 00
INITIAL SETUP

Wrench set, socket attachment (Item 49, WP 0236 00) Equipment Condition
Materials/Parts Air system drained (TM 9-2320-302-10)
REMOVAL
1. Remove two torx screws (1), washers (2), and defroster vent (3).
2. Remove four torx screws (4) and cover (5).
3. Remove five torx screws (6) and move panel (7) aside.
5 6
7
1,2
0160 00-1
TM 9-2320-302-20
PARKING BRAKE AND TRAILER AIR SUPPLY VALVE REPLACEMENT - CONTINUED 0160 00
REMOVAL - CONTINUED
NOTE
4. Disconnect six tubes (8) from valve (9).
5. Remove four screws (10), washers (11), and valve (9).
6. Remove five elbows (12), adapter (13), tee (14), and plug (15) from valve (9).
11
10
13 8
14
12
8
15
12
9
12
8
12
8
INSTALLATION
WARNINGS
lines or fittings. Failure to follow this warning could result in injury to personnel or damage and equip-
ment.
1. Coat threads with pipe sealing compound and install plug (15), tee (14), adapter (13), and five elbows (12) in valve (9).
2. Install valve (9) with four washers (11) and screws (10).
3. Connect six tubes (8) to valve (9).
0160 00-2
TM 9-2320-302-20
PARKING BRAKE AND TRAILER AIR SUPPLY VALVE REPLACEMENT - CONTINUED 0160 00
5. Install panel (7) with five torx screws (6).
6. Install cover (5) with four torx screws (4).
7. Install defroster vent (3) with two washers (2) and torx screws (1).
5 6
7
1,2
END OF WORK PACKAGE
0160 00-3
TM 9-2320-302-20
0160 00-4
TM 9-2320-302-20
FOOT BRAKE VALVE REPLACEMENT 0161 00
INITIAL SETUP

Materials/Parts
Equipment Condition
Gasket (P/N 12-13041-000)
Grease, silicone (Item 16, WP 0235 00) Foot brake valve plunger rod disconnected from brake
Tags, marker (Item 31, WP 0235 00) pedal (WP 0134 00)
0161 00-1
TM 9-2320-302-20
FOOT BRAKE VALVE REPLACEMENT - CONTINUED 0161 00
REMOVAL
NOTE
1. Disconnect 10 tubes (1) from elbows (3) and adapters (4). Remove tube (2).
2. Remove nine elbows (3), three adapters (4), two plugs (5), three check valves (6), three nipples (7), and elbow (8).
3. Remove two screws (9), washers (10), foot brake valve (11), and gasket (12) from firewall (13). Discard gasket.
3
3
1
1 1
5 7
13
6
3
11
4
12
8 9 10
7 6
5
7 3
4
1 6 1
1
3 3
0161 00-2
TM 9-2320-302-20
FOOT BRAKE VALVE REPLACEMENT - CONTINUED 0161 00
INSTALLATION
1. Lightly coat sliding surface of foot brake valve (11) plunger and adapter bore with silicone grease.
2. Install foot brake valve (11) and new gasket (12) on firewall (13) with two washers (10) and screws (9).
WARNING
ment.
3. Lightly coat threads with pipe sealing compound and install elbow (8), three nipples (7), three check valves (6), two
plugs (5), three adapters (4), and nine elbows (3).
4. Install tube (2). Connect 10 tubes (1) to elbows (3) and adapters (4).
5. Connect foot brake valve plunger rod to brake pedal (WP 0134 00).
END OF WORK PACKAGE
0161 00-3
TM 9-2320-302-20
0161 00-4
TM 9-2320-302-20
FRONT ANTI-LOCK BRAKE SYSTEM (ABS) SOLENOID VALVE REPLACEMENT 0162 00
INITIAL SETUP


NOTE
Right- and left-front ABS solenoid valves are replaced the same way. Right-front ABS solenoid valve is
shown.
REMOVAL
NOTE
Tag air lines to aid in installation.
1. Disconnect two electrical cables (1) from ABS valve (2).
9
2
9 6
11
10 5
7
5
1 4
0162 00-1
TM 9-2320-302-20
FRONT ANTI-LOCK BRAKE SYSTEM (ABS) SOLENOID VALVE REPLACEMENT - CONTINUED 0162 00
REMOVAL - CONTINUED
2. Disconnect three air lines (3) from ABS valve (2).

3. Remove two screws (4), four washers (5), two nuts (6), and ABS valve (2) from bracket (7).
NOTE
Do not perform next step unless bracket is damaged.
4. Remove two bolts (8), four washers (9), two nuts (10), and bracket (7) from frame (11).
9
2
9 6
11
10 5
7
5
1 4
INSTALLATION
NOTE
Do not perform next step unless bracket was removed.
1. Position bracket (7) on frame (11) and install two bolts (8), four washers (9), and two nuts (10).
2. Position ABS valve (2) on bracket (7) and install two screws (4), four washers (5), and two nuts (6).
3. Connect three air lines (3) to ABS valve (2).
4. Connect two electrical cables (1) to ABS valve (2).
5. Start vehicle (TM 9-2320-302-10) to build air pressure and check for leaks.
END OF WORK PACKAGE
0162 00-2
TM 9-2320-302-20
REAR ANTI-LOCK BRAKE SYSTEM (ABS) SOLENOID VALVE REPLACEMENT 0163 00
INITIAL SETUP


Nut, lock (P/N MS51922-11) (2) Air system drained (TM 9-2320-302-10)
Compound, sealing, pipe (Item 10, WP 0235 00) Rear platform removed (WP 0200 00)
REMOVAL
1. Disconnect two electrical cables (1) from ABS valve (2).
2. Disconnect four air lines (3) from ABS valve (2).
3. Remove two screws (4), four washers (5), two nuts (6), and ABS valve (2) from bracket (7).
NOTE
Do not perform next step unless bracket is damaged.
4. Remove two bolts (8), four washers (9), two nuts (10), and bracket (7) from frame (11).
8
9 11
3
2 7
9
10
6
5
1 5
0163 00-1
TM 9-2320-302-20
REAR ANTI-LOCK BRAKE SYSTEM (ABS) SOLENOID VALVE REPLACEMENT - CONTINUED 0163 00
INSTALLATION
NOTE
Do not perform next step unless bracket was removed.
1. Position bracket (7) on frame (11) and install two bolts (8), four washers (9), and two nuts (10).
2. Position ABS valve (2) on bracket (7) and install two screws (4), four washers (5), and two nuts (6).
3. Connect four air lines (3) to ABS valve (2).
4. Connect two electrical cables (1) to ABS valve (2).
5. Start vehicle (TM 9-2320-302-10) to build air pressure and check for leaks.
8
9 11
3
2 7
9
10
6
5
1 5
4
END OF WORK PACKAGE
0163 00-2
TM 9-2320-302-20
FRONT AND DUAL REAR WHEEL LUG NUT INSTALLATION 0164 00
Front Wheel Lug Nuts Installation, Rear Wheel Lug Nuts Installation
INITIAL SETUP


Wrench set, socket, 3/4 in drive (Item 48, WP 0236 00)
FRONT WHEEL LUG NUTS INSTALLATION
WARNING
Whenever any lug nuts require tightening or a wheel has been removed and replaced, all lug nuts must be
tightened to the required torque. Failure to follow this warning may result in serious injury to personnel or
NOTE
• Tightening pattern is the same for all wheel assemblies.
• After operating vehicle for 50-100 miles (80 to 160 km), tighten lug nuts again.
1. Install lug nut on each wheel stud and hand tighten until each lug nut is flush with face or chamfer of wheel.
2. Rotate wheel half a turn to seat parts and hand tighten each wheel lug nut again.
3. Tighten each lug nut to 50 lb-ft (68 Nm) in accordance with tightening pattern.
TIGHTENING PATTERN
0164 00-1
TM 9-2320-302-20
FRONT AND DUAL REAR WHEEL LUG NUT INSTALLATION - CONTINUED 0164 00
FRONT WHEEL LUG NUTS INSTALLATION - CONTINUED

4. Using same tightening pattern, tighten each lug nut to 450-500 lb-ft (610-678 Nm).
5. Using same tightening pattern, again tighten each lug nut to 450-500 lb-ft (610-678 Nm).
REAR WHEEL LUG NUTS INSTALLATION
WARNING
Whenever any lug nuts require tightening or a wheel has been removed and replaced, all lug nuts must be
tightened to required torque. Failure to follow this warning may result in serious injury to personnel or dam-
age to equipment.
NOTE
• Tightening pattern is the same for all wheel assemblies.
• After operating vehicle for 50-100 miles (80 to 160 km), again tighten lug nuts.
1. Install a lug nut on each wheel stud and hand tighten until each nut is flush with face or chamfer of wheel.
2. Rotate wheel half a turn to seat parts and hand tighten each wheel lug nut again.
3. Tighten each wheel lug nut to 50 lb-ft (68 Nm) in accordance with tightening pattern.
4. Using same tightening pattern, tighten each wheel lug nut to 450-500 lb-ft (610-678 Nm).
TIGHTENING PATTERN
5. Using same tightening pattern, again tighten each wheel lug nut to 450-500 lb-ft (610-678 Nm).
END OF WORK PACKAGE
0164 00-2
TM 9-2320-302-20
FRONT HUB, DRUM, WHEEL BEARINGS, AND SEAL REPLACEMENT 0165 00
Removal, Installation, Adjustment (End Play)
INITIAL SETUP

Washer, lock (P/N 1229G475)
Handle, installer (Item 15, WP 0236 00)
Indicator, dial (Item 18, WP 0236 00) Washer, lock (P/N MS 35338-140) (6)
Installation tool, ABS tone ring (Item 19, WP Oil, lubricating (Item 25, WP 0235 00)
0236 00)
Pan, drain (Item 25, WP 0236 00) References
Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00) TM 9-2320-302-10
Wrench, torque, 50-250 lb-ft (Item 46, WP 0236 00) Equipment Condition
Materials/Parts Front wheel removed (TM 9-2320-302-10)

Gasket (P/N 450755) Front anti-lock brake system (ABS) sensor removed
Seal, oil (P/N 35066) (WP 0106 00)
NOTE
Front axle ABS tone ring replacement is covered in this work package.
REMOVAL
1. Remove pressure relief screw, spring, and pawl assembly (1) from slack adjuster (2).
NOTE
Perform step 2 to obtain enough clearance between brake drum and brakeshoes to remove brake drum.
2. Turn adjusting nut (3) counterclockwise.
2
1
0165 00-1
TM 9-2320-302-20
FRONT HUB, DRUM, WHEEL BEARINGS, AND SEAL REPLACEMENT - CONTINUED 0165 00
REMOVAL - CONTINUED
3. Remove brake drum (4) from hub (5).
NOTE
Place suitable container under hub opening to catch axle oil.
4. Remove six screws (6), lock washers (7), hub cap (8), and gasket (9) from hub (5). Discard gasket and lock washers.
5. Bend back tab on lock washer (10).
6. Remove jamnut (11), lock washer (10), lock ring (12), and adjusting nut (13) from axle spindle (14). Discard lock
washer.
7. Remove outer wheel bearing (15) from axle spindle (14). Outer bearing race (16) will remain in bore of hub (5).
8. Remove hub (5) from axle spindle (14).
9. Remove oil seal (17) and inner wheel bearing (18) from hub (5). Discard oil seal.
NOTE
Perform step 10 if bearing races are damaged or if installing new bearings.
10. Remove inner bearing race (19) and outer bearing race (16) from bore of hub (5).
NOTE
ABS tone ring must be replaced if ring is damaged or if replacing hub.
11. To remove ABS tone ring (20) from hub (5), tap lightly beneath ring with a small hammer. Use a circular pattern with
light tapping to prevent ring from cocking.
14
17
18
19
5 20
16
13
10
4
8
22
15
6 12
7 9 11
0165 00-2
TM 9-2320-302-20
INSTALLATION
NOTE
Perform step 1 if new bearing races or new bearings are being installed.
1. Install outer bearing race (16) and inner bearing race (19) in bore of hub (5).
NOTE
Ensure ABS tone ring seat on hub is clean and seat is not damaged. If seat is damaged, replace hub.
2. If removed, install ABS tone ring (20) on hub (5) as follows:
a. Place ABS tone ring (20) on hub ring seat (21) with inside diameter flange of ring up.
b. Center installation tool over ABS tone ring (20).
c. Using installer handle and hammer or mallet, drive ABS tone ring (20) onto hub ring seat (21). Inspect ring to
ensure complete seating on hub (5).
5
20
21
3. Coat two wheel bearings (15 and 18) with clean gear lubricating oil.
4. Install inner wheel bearing (18) and new oil seal (17) in hub (5).
5. Apply coat of gear lubricating oil to axle spindle (14).
CAUTION
To prevent damage to equipment, do not unseat oil seal or wheel bearing when mounting hub.
6. Mount hub (5) fully over axle spindle (14).
7. Fill cavity in hub (5) with gear lubricating oil.
8. Install outer wheel bearing (15) in hub (5).
NOTE
Install adjusting nut with dimple facing out.
9. While turning hub (5), thread adjusting nut (13) on axle spindle (14) until against outer wheel bearing (15).
10. While turning hub (5) in both directions, tighten adjusting nut (13) to 100 lb-ft (136 Nm).
11. Loosen adjusting nut (13) completely to zero torque and spin wheel a few turns. Tighten adjusting nut to 50 lb-ft (68
Nm).
12. Back off adjusting nut (13) 1/6 to 1/4 turn.
0165 00-3
TM 9-2320-302-20
13. Install lock ring (12) and new lock washer (10) on axle spindle (14).
14. Install jamnut (11) on axle spindle (14). Tighten jamnut to 100-150 lb-ft (136-203 Nm).
15. Bend tab of lock washer (10) over a flat of jamnut (11).
ADJUSTMENT (END PLAY)
1. Attach dial indicator magnetic base to hub (5).

2. Adjust dial indicator so plunger is against spindle (14) end.
3. Position dial indicator parallel to axis of spindle (14).
4. Grasp hub (5) at 3 and 9 o’clock positions.
5. Push and pull hub (5) in and out while rotating hub approximately 45 degrees.
6. Not end play while rotating hub (5) until dial indicator tip is in same position before rotation began.
7. Acceptable end play is .001-.005 inches.
8. If end play is not within tolerance, loosen jamnut (11) and either back off or tighten adjusting nut (13) as required.
9. Repeat steps 1 through 7 until acceptable end play is achieved.
10. Install hub cap (8) and new gasket (9) on hub (5) and with six screws (6) and new lock washers (7). Tighten screws to
180 lb-in (20 Nm).
11. Remove hub filler cap (22) and add gear lubricating oil to level of filler hole. Wait 5 minutes and add more oil, as
needed.
12. Install hub filler cap (22).
13. Install brake drum (4) over hub (5).
14
13
10
4
8
22
7 12
6 11
9
0165 00-4
TM 9-2320-302-20
ADJUSTMENT (END PLAY) - CONTINUED

14. Install pressure relief screw, spring, and pawl assembly (1) in slack adjuster (2). Tighten to 180-240 lb-in (20-27 Nm).
2
1
3
15. Install front wheel (TM 9-2320-302-10).
16. Adjust slack adjuster (WP 0139 00).
17. Install front anti-lock brake system (ABS) sensor (WP 0106 00).
END OF WORK PACKAGE
0165 00-5
TM 9-2320-302-20
0165 00-6
TM 9-2320-302-20
REAR HUB, DRUM, WHEEL BEARINGS, AND SEAL REPLACEMENT 0166 00
Removal, Installation, Adjustment (End Play)
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Gasket (P/N 2208x440)
Handle, installer (Item 15, WP 0236 00) Seal, oil (P/N 1277701)
Indicator, dial (Item 18, WP 0236 00) Oil, lubricating (Item 25, WP 0235 00)
Installation tool, ABS tone ring (Item 19, WP References
0236 00) TM 9-2320-302-10
Equipment Condition
Socket, socket wrench (Item 29, WP 0236 00)
Rear brakes caged (TM 9-2320-302-10)
Rear wheel removed (TM 9-2320-302-10)
Rear anti-lock brake system (ABS) sensor removed
Wrench, torque, 0-600 lb-ft (Item 47, WP 0236 00) (rear-rear axle only) (WP 0107 00)
NOTE
Rear-rear axle ABS tone ring replacement is covered in this work package.
REMOVAL
NOTE
• Procedure is the same for both sides.
• Procedure is the same for both rear axles except as noted.
1. Remove brake drum (1) from hub (2).
0166 00-1
TM 9-2320-302-20
REAR HUB, DRUM, WHEEL BEARINGS, AND SEAL REPLACEMENT - CONTINUED 0166 00
REMOVAL - CONTINUED
CAUTION
Ensure axle hub studs are not damaged during axle shaft removal. If damage occurs, replace stud to allow
proper installation of tapered dowels and nuts.
NOTE
Have suitable container available to catch oil that will spill when axle shaft is removed.
2. Remove eight nuts (3), washers (4), axle shaft (5), and gasket (6). Discard gasket.
3. Remove jamnut (7), lock ring (8), and adjusting nut (9) from axle spindle (10).
4. Remove outer wheel bearing (11) from axle spindle (10).
5. Remove hub (2) from axle spindle (10).
6. Remove and discard seal (12) from hub (2).
7. Remove inner wheel bearing (13) from hub (2).
8. If damaged, remove eight studs (14) from hub (2).
NOTE
Perform step 9 if bearing cups are damaged or if installing new wheel bearings.
9. Using brass drift pin, carefully remove and discard two bearing cups (15) from hub (2).
NOTE
• The following step applies only to rear-rear axle hub.
• ABS tone ring must be replaced if ring is damaged or if replacing hub.
10. To remove ABS tone ring (16) from hub (2), use a small pry bar or hammer to gently pry off ring. Use a circular pattern
around ring to prevent cocking.
10 12
13
15 2
14
1
16
15
11
9 3
8
7
6
4
5
0166 00-2
TM 9-2320-302-20
INSTALLATION
NOTE
• Procedure is the same for both sides.
• Procedure is the same for both rear axles except as noted.
CAUTION
Bearings and bearing cups must be replaced as a set. Failure to do so could result in premature damage to
either bearings or bearing cups.
1. If removed, use a brass draft pin to carefully install two bearing cups (15) in hub (2).
2. If removed, install eight studs (14) in hub (2).
NOTE
• The following step applies only to rear-rear axle hub.
• Ensure ABS tone ring seat on hub is clean and seat is not damaged. If seat is damaged, replace hub.
3. If removed, install ABS tone ring (16) on hub (2) as follows:
a. Place ABS tone ring (16) on hub ring seat (17) with inside diameter flange of ring up.
b. Center installation tool over ABS tone ring (16).
c. Using installer handle and hammer or mallet, drive ABS tone ring (16) onto hub ring seat (17). Inspect ring to
ensure complete seating on hub (2).
2
16
17
4. Coat inner wheel bearing (13) with gear lubricating oil.

5. Install inner wheel bearing (13) in hub (2).
6. Install new oil seal (12) in hub (2).
7. Install hub (2) on axle spindle (10) and fill cavity with gear lubricating oil.
8. Coat outer wheel bearing (11) with gear lubricating oil.
9. Install outer wheel bearing (11) in hub (2).
0166 00-3
TM 9-2320-302-20
NOTE
Adjusting nut can be identified by protrusion on one side.
10. With protrusion facing out, install adjusting nut (9) until adjusting nut contacts outer wheel bearing (11).
CAUTION
Hub must be rotated in both directions while tightening adjusting nut. Failure to do so will result in prema-
ture bearing failure.
11. Tighten adjusting nut (9) to 100 lb-ft (136 Nm).
12. Loosen adjusting nut (9) completely, then tighten to 50 lb-ft (68 Nm).
13. Loosen adjusting nut (9) 1/4 turn.
NOTE
During step 13, it may be necessary to tighten adjusting nut to align protrusion with alignment hole in lock
ring.
14. Install lock ring (8) on axle spindle (10).
15. Install jamnut (7) on axle spindle (10). Tighten jamnut to 250-400 lb-ft (339-542 Nm).
ADJUSTMENT (END PLAY)
1. Attach dial indicator magnetic base to hub (2).
2. Adjust dial indicator so plunger is against spindle (10) end.
3. Position dial indicator parallel to axis of spindle (10).
4. Grasp hub (2) at 3 and 9 o’clock positions.
5. Push and pull hub (2) in and out while rotating hub approximately 45 degrees.
6. Note end play while rotating hub (2) until dial indicator tip is in same position before rotation began.
7. Acceptable end play is .001 - .005 inches.
8. If end play is not within tolerance, loosen jamnut (7) and either back off or tighten adjusting nut (9) as required.
9. Repeat steps 1 through 7 until acceptable end play is achieved.
10. Install new gasket (6) on studs (14).
NOTE
Splines on axle shaft must engage in differential before axle flange will seat against hub.
11. Install axle shaft (5) with eight washers (4) and nuts (3). Tighten nuts to 155 lb-ft (210 Nm).
12. Install brake drum (1) on hub (2).
0166 00-4
TM 9-2320-302-20
ADJUSTMENT (END PLAY) - CONTINUED
10
2
14
1
11
9 3
8
7
6
4
5
13. Remove plug (18) and check oil level in accordance with Unit PMCS. Add oil as needed (WP 0021 00).
14. Install plug (18) and tighten to 35 lb-ft (47 Nm).
18
15. Install rear wheels (TM 9-2320-302-10).

16. Install rear anti-lock brake system (ABS) sensor (rear-rear axle only) (WP 0107 00).
17. Uncage rear brakes (TM 9-2320-302-10).
END OF WORK PACKAGE
0166 00-5
TM 9-2320-302-20
0166 00-6
TM 9-2320-302-20
STEERING WHEEL REPLACEMENT 0167 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock (P/N 23-12077-000)
Puller kit, universal (Item 27, WP 0236 00) Equipment Condition

Wrench, torque, 15-75 lb-ft (Item 45, WP 0236 00) Front wheels turned straight ahead
REMOVAL
NOTE
Avoid rotating steering wheel during removal.
1. Pry cover (1) from horn button (2) and remove three springs (3).
2. Remove horn button (2) from steering wheel (4) and remove wires (5) and (6) from horn button.
3. Remove lock nut (7) from steering column (8). Discard lock nut.
3 5
7
6
0167 00-1
TM 9-2320-302-20
STEERING WHEEL REPLACEMENT - CONTINUED 0167 00
REMOVAL - CONTINUED
CAUTION
Use caution when removing steering wheel to prevent damage to wires.
4. Using universal puller kit, remove steering wheel (4) from steering column (8).
3 5
7
6
INSTALLATION
1. Align steering wheel (4) with steering column (8) and install new lock nut (7). Tighten lock nut to 60 lb-ft (81 Nm).
2. Install wires (5) and (6) on horn button (2). Press horn button on steering wheel (4).
3. Install three springs (3) and cover (1) on horn button (2).
END OF WORK PACKAGE
0167 00-2
TM 9-2320-302-20
UNIVERSAL SHAFT REPLACEMENT AND REPAIR 0168 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock, (P/N 115307A)
Drill, electric, portable (Item 11, WP 0236 00) Nut, lock (P/N 2C447622)
Drill set, twist (Item 12, WP 0236 00) Kit (P/N 5-170X) (2)
Riveter, blind, hand (Item 28, WP 0236 00) Rivet, blind (P/N 1641-0631) (10)
REMOVAL
1. Remove lock nut (1) and screw (2) from upper shaft (3). Discard lock nut.
2. Disconnect upper shaft (3) from steering column (4).
3. Support lower shaft (5) and remove grease fitting (6) from upper shaft (3).
4. Remove bushing (7) from boot (8).
5. Separate upper shaft (3) from lower shaft (5) and remove upper shaft from boot (8).
6. Remove lock nut (9), screw (10), and lower shaft (5) from steering gear (11). Discard lock nut.
7. If damaged, remove ten rivets (12) and boot (8) from firewall (13). Discard rivets.
3
4
6
8 1
5
9
10
11 7
2
12
13
0168 00-1
TM 9-2320-302-20
UNIVERSAL SHAFT REPLACEMENT AND REPAIR - CONTINUED 0168 00
DISASSEMBLY
1. Remove four snap rings (14), bearings (15), lower yoke (16), and cross (17) from lower shaft (5).
2. Repeat step 1 for upper yoke (18).
15
14 18
5
15
14
17
16 14
15
ASSEMBLY
1. Install cross (17), lower yoke (16), four bearings (15), and snap rings (14) on lower shaft (5).
2. Repeat step 1 for upper yoke (18).
INSTALLATION
1. If removed, install boot (8) on firewall (13) with ten new rivets (12).
2. Install splined end of lower shaft (5) through boot (8).
3. Install lower shaft (5) on steering gear (11).
4. Support lower shaft (5) on steering gear (11) and install screw (10) and new lock nut (9).
5. Install upper shaft (3) through boot (8) and onto lower shaft (5).
6. Install bushing (7) on boot (8).
7. Install grease fitting (6) in upper shaft (3).
8. Connect upper shaft (3) to steering column (4) and install screw (2) and new lock nut (1).
0168 00-2
TM 9-2320-302-20
UNIVERSAL SHAFT REPLACEMENT AND REPAIR - CONTINUED 0168 00
3
4
6
8 1
5
9
10
11
7
2
12
13
END OF WORK PACKAGE
0168 00-3
TM 9-2320-302-20
0168 00-4
TM 9-2320-302-20
PITMAN ARM AND DRAG LINK MAINTENANCE 0169 00
Drag Link Removal, Pitman Arm Removal, Drag Link Installation, Pitman Arm Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock (P/N MS51922-61)
Wrench, torque, 50-250 lb-ft (Item 46, WP 0236 00) Pin, cotter (P/N MS24665-379) (2)
References
TM 9-2320-302-10
DRAG LINK REMOVAL
1. Remove two cotter pins (1) and castle nuts (2) from drag link (3). Remove drag link from vehicle. Discard cotter pins.
2. Remove two grease fittings (4) from drag link (3).
PITMAN ARM REMOVAL
Remove lock nut (5), washer (6), screw (7), and pitman arm (8) from steering gear (9). Discard lock nut.
9
2
7
8
4 4
1
6 5 3
2
0169 00-1
TM 9-2320-302-20
PITMAN ARM AND DRAG LINK MAINTENANCE - CONTINUED 0169 00
DRAG LINK INSTALLATION

1. Install two grease fittings (4) in drag link (3).
NOTE
Castle nuts are tightened to 160-215 lb-ft (217-292 Nm). Castle nuts may be tightened further to allow for
cotter pin insertion. DO NOT exceed 300 lb-ft (407 Nm).
2. Install drag link (3) on vehicle with one castle nut (2) and one new cotter pin (1).
PITMAN ARM INSTALLATION
1. Install pitman arm (8) on steering gear (9) with screw (7), washer (6), and new lock nut (5). Tighten lock nut to 150-220
lb-ft (203-298 Nm).
2. Connect pitman arm (8) to drag link (3) and secure with castle nut (2) and new cotter pin (1).
9
2
7
8
4 4
1
6 5 3
2
END OF WORK PACKAGE
0169 00-2
TM 9-2320-302-20
POWER STEERING RESERVOIR AND HOSE MAINTENANCE 0170 00
INITIAL SETUP

Materials/Parts Rags, wiping (Item 28, WP 0235 00)
Filter element (P/N 83213D) References

Gasket (P/N Q-59278) TM 9-2320-302-10
REMOVAL
WARNING
Spilled hydraulic fluid is very slippery. Wipe up any spilled fluid immediately. Failure to do so could result
in serious injury to personnel.
1. Remove plug (1) and drain power steering reservoir (2).
2. Remove four clamps (3), hose (4), and elbow (5) from power steering reservoir (2).
3. Remove two hoses (6), three elbow fittings (7), protective cap (8), quick disconnect fitting (9), adapter fitting (10), and
tee (11).
4. Remove two screws (12), four washers (13), two lock nuts (14), and power steering reservoir (2). Discard lock nuts.
3
5
4
6 1 2
7
7
13
12
14
13
9 6
7
11 8
10
0170 00-1
TM 9-2320-302-20
POWER STEERING RESERVOIR AND HOSE MAINTENANCE - CONTINUED 0170 00
DISASSEMBLY
1. Remove dipstick (15), wing screw (16), washer (17), gasket (18), and cover assembly (19). Discard gasket.
2. Remove spring (20), washer (21), and filter element (22) from power steering reservoir (2). Discard filter element.
17
16 21
22
15
19
18
20
ASSEMBLY
1. Install new filter element (22), washer (21), and spring (20).
2. Install new gasket (18), cover assembly (19), washer (17), wing screw (16), and dipstick (15) in power steering reservoir
(2).
INSTALLATION
1. Position power steering reservoir (2) and secure with two screws (12), four washers (13), and two new lock nuts (14).
2. Install three elbow fittings (7), tee (11), adapter fitting (10), quick disconnect fitting (9), protective cap (8), and two
hoses (6).
3. Install elbow (5) and connect hose (4) using four clamps (3).
4. Install drain plug (1) in power steering reservoir (2).
5. Fill power steering reservoir (2) with lubricating oil in accordance with Unit PMCS (WP 0021 00). Check system for
leaks and operation.
0170 00-2
TM 9-2320-302-20
POWER STEERING RESERVOIR AND HOSE MAINTENANCE - CONTINUED 0170 00
3
5
4
6 1 2
7
7
13
12
14
13
9 6
7
11 8
10
END OF WORK PACKAGE
0170 00-3
TM 9-2320-302-20
0170 00-4
TM 9-2320-302-20
RIGHT STEP REPLACEMENT 0171 00
Step Assembly Removal, Front and Rear Mounting Bracket Removal, Step Disassembly, Step Assembly, Front and Rear
Mounting Bracket Installation, Step Assembly Installation
INITIAL SETUP

Materials/Parts
Nut, lock (P/N MS 51922-9) (8)
Nut, lock (P/N MS 51922-17) (8)
Rivet, blind (P/N 2771-0817) (8)
STEP ASSEMBLY REMOVAL

Remove six lock nuts (1), 12 washers (2), six screws (3), six retaining strap clamps (4), and step assembly (5) from vehi-
cle. Discard lock nuts.
3
2
3
2
2
4
1
2 5
2
1
0171 00-1
TM 9-2320-302-20
RIGHT STEP REPLACEMENT - CONTINUED 0171 00
FRONT AND REAR MOUNTING BRACKET REMOVAL
NOTE
Front and rear mounting brackets are removed in the same way. Front mounting bracket is shown.
1. Remove two lock nuts (6), four washers (7), two screws (8), and angle brackets (9) from front and rear mounting brack-
ets (10). Discard lock nuts.
7 6
10
9
7
8
2. Remove two lock nuts (11), four washers (12), two screws (13), and four angle brackets (14) from front and rear mount-
ing brackets (10). Discard lock nuts.
10
11
12
13
14
12
0171 00-2
TM 9-2320-302-20
FRONT AND REAR MOUNTING BRACKET REMOVAL - CONTINUED

3. Remove two lock nuts (15), four washers (16), and two bolts (17) from front and rear mounting brackets (10). Discard
lock nuts.
10
17
16
15
4. Remove four lock nuts (18), eight washers (19), four screws (20), and front and rear mounting brackets (10). Discard
lock nuts.
19
20
10
18
19
0171 00-3
TM 9-2320-302-20
STEP DISASSEMBLY
Remove eight rivets (21) and two support brackets (22) from two steps (23). Discard rivets.
22
23
22
21
21
23
STEP ASSEMBLY
Install two support brackets (22) on two steps (23) with eight new rivets (21).
FRONT AND REAR MOUNTING BRACKET INSTALLATION
1. Install front and rear mounting bracket (10) with four screws (20), eight washers (19), and four new lock nuts (18).
19
20
18
19 10
0171 00-4
TM 9-2320-302-20
FRONT AND REAR MOUNTING BRACKET INSTALLATION - CONTINUED

2. Install two bolts (17), four washers (16), and two new lock nuts (15) on front and rear mounting brackets (10).
10
17
16
15
3. Install four angle brackets (14) on front and rear mounting brackets (10) with two screws (13), four washers (12), and
two new lock nuts (11).
11
12
13
14
12
0171 00-5
TM 9-2320-302-20
FRONT AND REAR MOUNTING BRACKET INSTALLATION - CONTINUED

4. Install two angle brackets (9) on front and rear mounting brackets (10) with two screws (8), four washers (7), and two
new lock nuts (6).
STEP ASSEMBLY INSTALLATION
Install step assembly (5) on front and rear mounting brackets (10) with six screws (3), 12 washers (2), six retaining strap
clamps (4), and new lock nuts (1).
3
2
7 6
10 3
9 2
7
8
2
4
1
2 5
2
1
END OF WORK PACKAGE
0171 00-6
TM 9-2320-302-20
LEFT STEP REPLACEMENT 0172 00
INITIAL SETUP


Nut, lock (P/N MS51922-11) (2) Battery box cover removed (TM 9-2320-302-10)
WARNING
DO NOT allow tools to come in contact with batteries. Electrical shock may occur.
REMOVAL
1. Remove two lock nuts (1), washers (2), screws (3), washer (4), two clamps (5), and step (6) from front and rear step
brackets (7). Discard lock nuts.
2. Remove nuts (8), washers (9), screws (10), washers (11), and front step bracket (7).
3. Repeat step 2 for removal of rear step bracket (7).
6
8,9
5
3,4
10,11
1,2 7
INSTALLATION
1. Install front step bracket (7) with three washers (11), screws (10), washers (9), and nuts (8).
2. Repeat step 1 for installation of rear step bracket (7).
3. Install step (6) on front and rear step brackets (7) with two clamps (5), washer (4), two screws (3), washers (2), and new
lock nuts (1).
4. Install battery box cover (TM 9-2320-302-10).
END OF WORK PACKAGE
0172 00-1
TM 9-2320-302-20
0172 00-2
TM 9-2320-302-20
LEFT SIDE PLATFORM REPLACEMENT 0173 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Primary II air tank removed (WP 0144 00)
Materials/Parts
Nut, lock (P/N MS51922-49) (4)
REMOVAL
Remove four lock nuts (1), washers (2), screws (3), washers (4), and left side platform (5) from vehicle. Discard lock
nuts.
1,2,3,4
INSTALLATION
1. Install left side platform (5) on vehicle with four washers (4), screws (3), washers (2), and new lock nuts (1).
2. Install primary II air tank (WP 0144 00).
END OF WORK PACKAGE
0173 00-1
TM 9-2320-302-20
0173 00-2
TM 9-2320-302-20
RIGHT REAR STEP REPLACEMENT 0174 00
INITIAL SETUP

Materials/Parts
Nut, lock (P/N MS51922-11) (2)
Nut, lock (P/N MS51922-33) (4)
REMOVAL
1. Remove two lock nuts (1), washers (2), screws (3), clamp bars (4), and step (5) from two mounting brackets (6). Discard
lock nuts.
2. Remove four lock nuts (7), washers (8), screws (9), washers (10), and two mounting brackets (6) from storage box (11).
Discard lock nuts.
11
9,10
7 8
1,2,3
6 6
INSTALLATION
1. Install two mounting brackets (6) on storage box (11) with four washers (10), screws (9), washers (8), and new lock nuts
(7).
2. Install step (5) on two mounting brackets (6) with two clamp bars (4), screws (3), washers (2), and new lock nuts (1).
END OF WORK PACKAGE
0174 00-1
TM 9-2320-302-20
0174 00-2
TM 9-2320-302-20
FRONT BUMPER REPLACEMENT 0175 00
INITIAL SETUP

TM 9-2320-302-10
Materials/Parts
Equipment Condition
Nut, lock (P/N 23-10340-125) (2)
Collision warning system (CWS) antenna assembly
Nut, lock (P/N MS51922-49) (12) removed (WP 0111 00)
REMOVAL
1. Remove two lock nuts (1), washers (2), screws (3), washers (4), and bracket (5) from front bumper (6). Discard lock
nuts.
WARNING
personnel.
2. Attach suitable lifting device to front bumper (6) using bumper extensions (7) as attaching points.
3. Remove nut (8), bolt (9), and hook (10) from each tow bracket (11).
7
11
3
8 4
2 5
10 9
6
1
0175 00-1
TM 9-2320-302-20
FRONT BUMPER REPLACEMENT - CONTINUED 0175 00
REMOVAL - CONTINUED
NOTE
Note bolt size and location to aid in installation.
4. Remove 12 lock nuts (12), washers (13), bolts (14), washers (15), two tow brackets (11), and front bumper (6) from
5. Lower bumper (6) to ground and disconnect lifting device.
6. Remove four spring pins (16), flat washers (17), straight pins (18), and two bumper extensions (7) from front bumper
(6).
12
11 13
7
3
8 4
2 5
10 9
6
14 15
1
INSTALLATION
1. Install two bumper extensions (7) on front bumper (6) with four straight pins (18), flat washers (17), and spring pins
(16).
WARNING
personnel.
2. Attach suitable lifting device to front bumper (6) using bumper extensions (7) as attaching points.
3. Install front bumper (6) on vehicle with two tow brackets (11), 12 washers (15), bolts (14), washers (13), and new lock
nuts (12). Tighten lock nuts to 180-200 lb-ft (244-271 Nm).
4. Install hook (10) on each tow bracket (11) with bolt (9) and nut (8).
5. Install bracket (5) on front bumper (6) with two washers (4), screws (3), washers (2), and new lock nuts (1).
0175 00-2
TM 9-2320-302-20
FRONT BUMPER REPLACEMENT - CONTINUED 0175 00
6. Install collision warning system (CWS) antenna assembly (WP 0111 00).
END OF WORK PACKAGE
0175 00-3
TM 9-2320-302-20
0175 00-4
TM 9-2320-302-20
SPARE WHEEL HOIST REPLACEMENT 0176 00
INITIAL SETUP


Nut, lock (P/N MS51922-49) (4) Spare tire removed (TM 9-2320-302-10)
Compound, sealing (Item 9, WP 0235 00) Primary II air tank removed (WP 0144 00)
REMOVAL
Remove four lock nuts (1), washers (2), bolts (3), washers (4), two spacers (5), and spare wheel hoist (6). Discard lock nuts.
4 3
2 6
5
2
1
INSTALLATION
1. Install two washers (4) and two bolts (3).

2. Lightly coat both sides of two spacers (5) with sealing compound. Install spacers on two bolts (3).
3. Install spare wheel hoist (6) with four washers (4), bolts (3), washers (2), and new lock nuts (1).
4. Install primary II air tank (WP 0144 00).
5. Install spare tire (TM 9-2320-302-10).
END OF WORK PACKAGE
0176 00-1
TM 9-2320-302-20
0176 00-2
TM 9-2320-302-20
REAR TIE DOWN REPLACEMENT 0177 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock (P/N 23-0991-116) (6)
Equipment Condition Nut, lock (P/N MS51922-33) (2)
Mud flap assembly removed (WP 0196 00)
NOTE
Right- and left-rear tie downs are replaced the same way.
REMOVAL
1. Remove two lock nuts (1), washers (2), screws (3), washers (4), and mud flap bracket (5). Discard lock nuts.
2. Remove six lock nuts (6), washers (7), bolts (8), washers (9), and tie down bracket (10). Discard lock nuts.
6,7,8,9
1,2,3,4
10
INSTALLATION
1. Install tie down bracket (10) with six washers (9), bolts (8), washers (7), and new lock nuts (6).
2. Install mud flap bracket (5) with two washers (4), screws (3), washers (2), and new lock nuts (1).
3. Install mud flap assembly (WP 0196 00).
END OF WORK PACKAGE
0177 00-1
TM 9-2320-302-20
0177 00-2
TM 9-2320-302-20
FIFTH WHEEL ADJUSTMENT 0178 00
Adjustment
INITIAL SETUP

Tester, kingpin lock (Item 34, WP 0236 00)
ADJUSTMENT
1. Install kingpin lock tester (1) on fifth wheel (2) and close locks.Visually check that locks are properly closed.
2. Rotate rubber bushing (3) between adjustment nut (4) and casting (5).
4 3
HAUL LOAD
0178 00-1
TM 9-2320-302-20
FIFTH WHEEL ADJUSTMENT - CONTINUED 0178 00
NOTE
Bushing should be snug, but able to rotate. If bushing does not rotate or rotates too freely, perform step 3.
3. If bushing (3) is too tight, rotate nut (4) on yoke shank (6) counterclockwise until bushing is snug. If bushing is loose,
rotate nut clockwise until bushing is snug, but still rotates.
4 3
HAUL LOAD
4. Verify proper adjustment by locking and unlocking fifth wheel (2) several times with lock tester (1).
END OF WORK PACKAGE
0178 00-2
TM 9-2320-302-20
PINTLE HOOK REPLACEMENT AND REPAIR 0179 00
THIS WORK PACKAGE COVERS:
INITIAL SETUP
Tool kit, general mechanic’s (Item 36, WP 0236 00) Pin, cotter (P/N XB-773)
Materials/Parts Grease, GAA (Item 15, WP 0235 00)
Nut, lock (P/N XB-769) (2) References
Pin, cotter (P/N 119-1) TM 9-2320-302-10
REMOVAL
1. Remove cotter pin (1), castle nut (2), washer (3), and pintle hook (4) from vehicle. Discard cotter pin.
2. Remove two lock nuts (5), washers (6), and outer bracket (7) from vehicle. Discard lock nuts.
3. Remove two screws (8), washers (6), and inner bracket (9) from vehicle.
4. Remove two lubrication fittings (10) from inner and outer brackets (7 and 9).
4 7
2,3 10
6,8
9 5,6
1
0179 00-1
TM 9-2320-302-20
PINTLE HOOK REPLACEMENT AND REPAIR - CONTINUED 0179 00
DISASSEMBLY
1. Remove cotter pin (12), castle nut (13), fluid passage bolt (14), and latch (15) from pintle hook (4). Discard cotter pin.
2. Remove two lubrication fittings (11) from latch (15).
3. Remove screw and chain assembly (16) from pintle hook (4).
12,13
14
15
11
16
11
ASSEMBLY
1. Install latch (15) on pintle hook (4) with fluid passage bolt (14), castle nut (13), and new cotter pin (12).
2. Install two lubrication fittings (11) on latch (15).
3. Install screw and chain assembly (16) on pintle hook (4).
INSTALLATION
4 7
2,3 10
6,8
5,6
9
1
1. Install two lubrication fittings (10) on inner and outer brackets (7 and 9).
2. Install inner bracket (9) on vehicle with two washers (6) and screws (8).
0179 00-2
TM 9-2320-302-20
PINTLE HOOK REPLACEMENT AND REPAIR - CONTINUED 0179 00
3. Install outer bracket (7) on vehicle with two washers (6) and new lock nuts (5).
4. Install pintle hook (4) on vehicle with washer (3) and castle nut (2).
5. Adjust castle nut (2) to allow pintle hook (4) to rotate freely.
6. Install new cotter pin (1) through castle nut (2).
7. Lubricate pintle hook (4) with GAA grease in accordance with Unit PMCS (WP 0021 00).
END OF WORK PACKAGE
0179 00-3
TM 9-2320-302-20
0179 00-4
TM 9-2320-302-20
TOWING BRACKET REPLACEMENT 0180 00
INITIAL SETUP

Material/Parts
Nut, lock (P/N MS 51922-33) (8)
REMOVAL
Remove eight lock nuts (1), washers (2), four bolts (3), and towing bracket (4) from vehicle frame. Discard lock nuts.
2 4
1
2,3
INSTALLATION
Install towing bracket (4) on vehicle frame with four bolts (3), eight washers (2), and new lock nuts (1).
END OF WORK PACKAGE
0180 00-1
TM 9-2320-302-20
0180 00-2
TM 9-2320-302-20
TAILLIGHT BRACKET REPLACEMENT 0181 00
INITIAL SETUP


Nut, lock (P/N MS51922-33) (2) Rear blackout marker removed (WP 0086 00)
Taillight removed (WP 0087 00)
Rear gladhand removed (WP 0154 00)
NOTE
Right and left taillight brackets are replaced the same way. Left taillight bracket is shown.
REMOVAL
Remove two lock nuts (1), washers (2), bracket (3), two bolts (4), and washers (5) from vehicle. Discard lock nuts.
1
5
INSTALLATION
1. Install bracket (3) on vehicle with two washers (5), bolts (4), washers (2), and new lock nuts (1).
2. Install rear blackout marker (WP 0086 00).
3. Install taillight (WP 0087 00).
4. Install rear gladhand (WP 0154 00).
END OF WORK PACKAGE
0181 00-1
TM 9-2320-302-20
0181 00-2
TM 9-2320-302-20
FRONT SHOCK ABSORBER REPLACEMENT 0182 00
INITIAL SETUP

REMOVAL
NOTE
Note position of shock absorber and bolts to aid in installation.
Remove two lock nuts (1), washers (2), and shock absorber (3) from front of vehicle. Discard lock nuts.
1 2
1 2
INSTALLATION
Install shock absorber (3) on vehicle with two washers (2) and new lock nuts (1). Tighten lock nuts to 120-180 lb-ft
(163-244 Nm).
END OF WORK PACKAGE
0182 00-1
TM 9-2320-302-20
0182 00-2
TM 9-2320-302-20
REAR SHOCK ABSORBER REPLACEMENT 0183 00
INITIAL SETUP

REMOVAL
NOTE
Note position of shock absorber and bolts for installation.
Remove two lock nuts (1), washers (2), bolts (3), and shock absorber (4) from rear of vehicle. Discard lock nuts.
3
1 2
INSTALLATION
Install shock absorber (4) on vehicle with two bolts (3), washers (2), and new lock nuts (1). Tighten lock nuts to 241 lb-
ft (327 Nm).
END OF WORK PACKAGE
0183 00-1
TM 9-2320-302-20
0183 00-2
TM 9-2320-302-20
BRUSH GUARD REPLACEMENT 0184 00
INITIAL SETUP

Two
Materials/Parts
References
Nut, lock (P/N MS51922-11) (6)
Nut, lock (P/N SR250000 SOH) (2) TM 9-2320-302-10
REMOVAL
WARNING
dure. Failure to follow this warning may result in injury to personnel.
NOTE
Note location of mounting holes to aid in installation.
1. Remove six lock nuts (1), washers (2), screws (3), washers (4), and brush guard (5) from hood (6). Discard lock nuts.
2. Remove two lock nuts (7), washers (8), and top plate (9) from hood (6). Discard lock nuts.
9 7
4
8
3
1
2
5 6
0184 00-1
TM 9-2320-302-20
BRUSH GUARD REPLACEMENT - CONTINUED 0184 00
INSTALLATION
WARNING
1. Install top plate (9) on hood (6) with two washers (8) and new lock nuts (7).
2. Install brush guard (5) on hood (6) with six washers (4), screws (3), washers (2), and new lock nuts (1).
9 7
4
8
3
1
2
5 6
END OF WORK PACKAGE
0184 00-2
TM 9-2320-302-20
ENGINE HOOD ASSEMBLY REPLACEMENT 0185 00
INITIAL SETUP

Four
Materials/Parts
References
Nut, lock (P/N MS51922-17) (2)
Straps, tiedown (Item 30, WP 0235 00) TM 9-2320-302-10
REMOVAL
NOTE
Right side of vehicle is shown.
1. Disconnect nine connectors (1).
NOTE
Quantity of tiedown straps may vary. Remove as necessary.
2. Remove four screws (2), two washers (3), four clamps (4), and tiedown straps (5). Set wiring harness (6) aside. Discard
tiedown straps.
2,3
5
6
2,3 4 1
0185 00-1
TM 9-2320-302-20
ENGINE HOOD ASSEMBLY REPLACEMENT - CONTINUED 0185 00
REMOVAL - CONTINUED
WARNING
When removing tilt assist cables, hood must be supported to prevent damage to hood or injury to personnel.
3. Support center of hood (7).
4. Open two chain links (8) by loosening two nuts (9) and remove two tilt assist cables (10) from chain links.
10 8
9
7
10
8
9
5. Close hood (7) (TM 9-2320-302-10).
6. Remove two lock nuts (11) and screws (12) from hinges (13). Discard lock nuts.
12 11 12 11
13
0185 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
WARNING
7. Using four personnel, lift hood (7) approximately 4 in (10.2 cm) and walk toward front of vehicle until hood is clear of
vehicle.
INSTALLATION
WARNING
1. Using four personnel, install hood (7) to vehicle.
2. Install two screws (12) and new lock nuts (11) to hinges (13).
WARNING
When installing tilt assist cable, hood must be supported to prevent damage to hood or injury to personnel.
3. Open and support hood (7) (TM 9-2320-302-10).
4. Install two tilt assist cables (10) in two chain links (8) and close chain links by tightening two nuts (9).
0185 00-3
TM 9-2320-302-20
5. Position wiring harness (6) and install four clamps (4) with two washers (3) and four screws (2).
6. Connect nine connectors (1).
7. Install new tiedown straps (5) as necessary.
2,3
5
6
2,3 4 1
END OF WORK PACKAGE
0185 00-4
TM 9-2320-302-20
HOOD ASSEMBLY REPAIR 0186 00
Disassembly, Assembly
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Headlights removed (WP 0083 00)
Blackout drive and marker lights removed (WP
Materials/Parts
0084 00)
Nut, lock (P/N 23-09336-005) (4) Spotter mirrors removed (WP 0209 00)
Nut, lock (P/N MS51922-9) (2) Brush guard removed (WP 0184 00)
Nut, lock (P/N MS51922-33) (7) Engine hood assembly removed (WP 0185 00)
Nut, lock (P/N MS51988-7) Hood liners removed (WP 0189 00)
DISASSEMBLY
1. Remove two screws (1), washers (2), and brackets (3) from hood (4).
1,2
4
0186 00-1
TM 9-2320-302-20
HOOD ASSEMBLY REPAIR - CONTINUED 0186 00
NOTE
Perform step 2 for each of two hinges. Hinges may be equipped with shims. Note quantity of shims at each
hinge for installation.
2. Remove lock nut (5), two washers (6), screw (7), hinge (8), spacer (9), and shims, if equipped, from front crossmember
(10). Discard lock nut
7
6
8
10
6
3. Remove two screws (11), backing plate (12), and handle (13) from hood (4).
4. Remove two lock nuts (14), washers (15), backing plate (16), two screws (17), and latch bracket (18) from each side of
hood (4). Discard lock nuts.
5. Remove two bushings (19) from crosstie (20).
11 4
13
12 17
20 18
16
15
14
19
0186 00-2
TM 9-2320-302-20
6. Remove four lock nuts (21), screws (22), washers (23), and crosstie (20). Discard lock nuts.
7. Remove four screws (24), washers (25), bracket (26), and crosstie plate (27) from each side of hood (4).
8. Remove four screws (28), two washers (29), hood guide (30), and mount (31) from each side of hood (4).
4
24
26 25
28
29
30
31
24
25
28
27
21 23 22
20
0186 00-3
TM 9-2320-302-20
9. Remove four screws (32), washers (33), and bracket (34) from hood (4).
10. Remove spring (35), lock nut (36), screw (37), cable (38), two lock nuts (39), screws (40), and two cables (41) from
yoke (42). Discard lock nuts.
11. Remove lock nut (43), screw (44), and cable (38) from bracket (34). Discard lock nut.
12. Remove lock nut (45), screw (46), spring (35), and spacer (47) from bracket (34). Discard lock nut.
33 4
32
44
46 43
47 34
39
45
35
40
38
42
36
41
39
37 41
40
ASSEMBLY
1. Install spacer (47) and spring (35) on bracket (34) with screw (46) and new lock nut (45).
2. Feed cable (38) through spring (35) and install on bracket (34) with screw (44) and new lock nut (43).
3. Install cable (38) and two cables (41) on yoke (42) with screw (37) and new lock nut (36), two screws (40), and new
lock nuts (39). Install spring (35) to yoke.
4. Install bracket (34) on hood (4) with four washers (33) and screws (32).
5. Install mount (31) on hood guide (30) on each side of hood (4) with two washers (29) and four screws (28).
6. Install crosstie plate (27) and bracket (26) on each side of hood (4) with four washers (25) and screws (24).
0186 00-4
TM 9-2320-302-20
7. Install crosstie (20) on hood (4) with four washers (23), screws (22), and new lock nuts (21).
24 4
26 25
28
29
30
31
24
25
28
27
21 23 22
20
8. Install two bushings (19) in crosstie (20).
9. Install latch bracket (18) and backing plate (16) to each side of hood (4) with two screws (17), washers (15), and new
lock nuts (14).
10. Install handle (13) and backing plate (12) on hood (4) with two screws (11).
11 4
13
12 17
20 18
16
15
14
19
0186 00-5
TM 9-2320-302-20
NOTE
Perform step 11 for each of two hinges.
11. Install spacer (9), shims, if equipped, and hinge (8) on front crossmember (10) with screw (7), two washers (6), and new
lock nut (5).
7
6
8
10
6
12. Install two brackets (3) on hood (4) with two washers (2) and screws (1).
3
4 1,2
13. Install hood liners (WP 0189 00).

14. Install engine hood assembly (WP 0185 00).
15. Install brush guard (WP 0184 00).
16. Install spotter mirrors (WP 0209 00).
17. Install blackout drive and marker lights (WP 0084 00).
18. Install headlights (WP 0083 00).
END OF WORK PACKAGE
0186 00-6
TM 9-2320-302-20
HOOD ADJUSTMENT 0187 00
Adjustment Check, Adjustment
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Nut, lock (P/N MS 51922-33) (2)
Bar, wrecking (Item 3, WP 0236 00) Nut, lock (P/N MS 51922-9) (8)
Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00) Shim(s) (P/N 17-10320-001)
Wrench, torque, 50-250 lb-ft (Item 46, WP 0236 00) Personnel Required
Two
References
TM 9-2320-302-10
ADJUSTMENT CHECK
NOTE
Perform steps 1 through 3 to determine if hood adjustment is necessary.
1. Measure and note gap between rear edge of hood (1) and cowl (2) at seam and at 8 in (203 mm) below seam. Gap should
be 1/2-3/4 in (13-19 mm).
2. Check that front of hood (1) is centered with bumper (3). Check that space between top edge of bumper (3) and lower
edge of hood (1) is equal at both ends.
3. Ensure that hood (1) is not touching any components attached to frame. If any components are touching hood, identify
and correct problem, and repeat steps 1 and 2.
1/2-3/4 in (13-19 mm)

Clearance
1
1
2
Both Sides
Seam Equal
3 3
0187 00-1
TM 9-2320-302-20
HOOD ADJUSTMENT - CONTINUED 0187 00
ADJUSTMENT
1. Tilt hood (1) to fully open position (TM 9-2320-302-10).
NOTE
Repeat steps 2 and 3 for both sides of vehicle.
2. Loosen four lock nuts (4) just enough to allow hood (1) to slide forward and backward for adjustment.
3. Loosen lock nut (5) just enough to allow hood (1) to slide side-to-side for adjustment.
NOTE
• In step 4, lock nut must be kept tight enough for brackets to remain stationary despite pulling force of
hood tilt assist springs.
• Repeat step 4 for both nuts.
4. Loosen lock nut (6) just enough to allow hood (1) to slide for adjustment.
6
5
NOTE
Prior to performing step 5, ensure that hood is centered and that components do not touch under hood when
hood is lowered.
5. Close hood (1) and fasten two hood latches (7).
0187 00-2
TM 9-2320-302-20
ADJUSTMENT- CONTINUED
6. Measure gap between hood (1) and cowl (2) 8 in (203 mm) below seam on both sides. Gap should be 1/2-3/4 in (13-19
mm). If gap is incorrect, move hood (1) forward or backward until gap is correct on both sides.
7. Check seams on both sides of hood (1) and cowl (2) for alignment. If seams are not aligned, note distance between
seams.
NOTE
When performing step 8, use care not to disturb adjustment performed in step 6.
8. Tilt hood (1) to fully open position.
9. Loosen lock nut (5) just enough to allow installation or removal of spacers (8), as necessary.
10. Install or remove spacers (8) to raise or lower hood (1) to align seams.
11. Close hood (1) and repeat steps 7 through 10 until seam is aligned.
1/2-3/4 in (13-19 mm)

Clearance
1 8
Seam 5
NOTE
Perform steps 12 through 20 only if all spacers have been removed and seam is still not in alignment.
12. Remove lock nut (5), washer (9), bolt (10), and locator (11). Discard lock nut.
13. Remove four lock nuts (4), washers (12), and screws (13). Discard lock nuts.
10
11
13
4,12
9 5
0187 00-3
TM 9-2320-302-20
14. Remove hood guide (14) from under locator bracket (15). Install hood guide on top of locator bracket.
15. Install four screws (13), washers (12), and new lock nuts (4) just tight enough to allow forward or backward adjustment.
16. Install locator (11), bolt (10), washer (9), and new lock nut (5) just tight enough to allow for installation of spacers (8).
17. Repeat steps 8 through 11 until seam alignment is attained.
18. Tighten lock nut (5) just enough to allow side-to-side movement for adjustment.
11
10
8
15
13
14
4,12
9 5
19. Repeat steps 9 through 18 for opposite side, if necessary.

20. Repeat steps 5 and 6.
NOTE
Perform step 21 only if required.
21. Close hood (1) and fasten two hood latches (7).
22. Measure and note gap between rear edge of hood (1) and cowl (2) at 1 in (25.4 mm) below seam and at 12 in (305 mm)
below seam. Gap should be 1/2-3/4 in (13-19 mm).
2
1
1/2-3/4 in (13-19 mm)
NOTE
• Perform steps 23 through 25 if gap is not correct.
• Repeat step 23 for both nuts.
23. Loosen lock nut (6) just enough to allow for installation or removal of spacers (16).
0187 00-4
TM 9-2320-302-20
16
NOTE
When performing step 24, amount of spacers must be equal under both hood mounting brackets. DO
NOT use more than 3/4 in (19 mm) of spacers.
24. Using pry bar, raise front of hood (1) enough to insert or remove spacers (16) as needed to make gap between hood and
cowl (2) equal, as measured in step 22.
25. Repeat step 22.
26. Tighten two lock nuts (6) to 85 lb-ft (115 Nm).
NOTE
When performing step 27, be extremely careful to prevent movement of locator brackets (15).
27. Carefully tilt hood (1) to fully open position.
28. Measure distance between centerline of bolt (10) and outboard face of hood guide (14). Distance must be 2-5/8 in (67
mm). If necessary, move hood guide (14) to obtain correct measurement.
29. Tighten four lock nuts (4) to 178 lb-in (20 Nm).
30. Tighten lock nut (5) to 70 lb-ft (95 Nm).
15
5
14
2 5/8 in (67 mm)
4
10
31. Repeat steps 29 and 30 for opposite side.
END OF WORK PACKAGE
0187 00-5
TM 9-2320-302-20
0187 00-6
TM 9-2320-302-20
HOOD LATCH REPLACEMENT 0188 00
INITIAL SETUP

References Nut, lock (P/N MS51922-1) (4)
TM 9-2320-302-10
REMOVAL
NOTE
Perform the following steps for each of two hood latches.
1. Remove two lock nuts (1), washers (2), backing plate (3), two screws (4), and hood catch (5). Discard lock nuts.
2. Remove two lock nuts (6), screws (7) and hood latch (8). Discard lock nuts.
4
5
6
3
2
1 7
INSTALLATION
1. Install hood latch (8) with two screws (7) and new lock nuts (6).
2. Install hood catch (5) and backing plate (3) with two screws (4), washers (2) and new lock nuts (1).
END OF WORK PACKAGE
0188 00-1
TM 9-2320-302-20
0188 00-2
TM 9-2320-302-20
HOOD LINER REPLACEMENT 0189 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Screw, self-tapping, 1/4-20x3/4 in (6)
Drill, electric, portable (Item 11, WP 0236 00) Washer, flat 1/4 in (10)
Drill set, twist (Item 12, WP 0236 00) Tape, double-sided (Item 32, WP 0235 00)
Materials/Parts Tape, duct (Item 33, WP 0235 00)
Nut, lock (P/N MS51922-1) (26) Equipment Condition

Screw, 1/4-20x1 in (10) Engine hood assembly removed (WP 0185 00)
REMOVAL
1. Cut or remove duct tape (1) between two top liners (2) and side liners (3).
2. Remove six rivets (4), three support straps (5), and two top liners (2) from hood (6). Discard rivets.
3. Remove eight lock nuts (7), washers (8), five rivets (9), washers (10 and 11), and side liners (3) from hood (6). Discard
lock nuts, washers, and rivets.
4. Remove 10 screws (12), washers (13), and inner fender (14) from hood (6).
5. Repeat steps 3 and 4 for liner and inner fender on opposite side.
1 6
2
12 2
6 13
11
4
7
8
14 9
3
10
0189 00-1
TM 9-2320-302-20
HOOD LINER REPLACEMENT - CONTINUED 0189 00
INSTALLATION
1. Install inner fender (14) to hood (6) with 10 washers (13) and screws (12).
NOTE
Use double-sided tape to hold liners in place. Rivets are replaced with self-tapping screws. Rivets with back-
ing washers are replaced with screws and lock nuts.
2. Install side liners (3) on hood (6) with five new screws (9), washers (10 and 11), eight new washers (8), and new lock
nuts (7).
3. Repeat steps 1 and 2 for liners and inner fenders on opposite side.
4. Install two top liners (2) on hood (6) with three support straps (5) and six new self-tapping screws (4).
5. Install duct tape (1) on each seam between two top liners (2) and side liners (3).
1 6
2
12 2
6 13
11
4
7
8
14 9
3
10
6. Install engine assembly hood assembly (WP 0185 00).
END OF WORK PACKAGE
0189 00-2
TM 9-2320-302-20
HOOD PROP AND MOUNT REPLACEMENT 0190 00
Hood Prop Removal, Hood Mount Removal, Hood Mount Installation, Hood Prop Installation
INITIAL SETUP

Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00) Nut, lock (P/N MS51922-33) (2)
TM 9-2320-302-10
HOOD PROP REMOVAL
NOTE
Left and right hood props are removed and installed the same way. Right hood prop is shown.
1. While supporting hood (1) in opened position, remove nut (2) and washer (3) from rod end (4).
2. Remove rod end (4) from radiator bracket (5) and remove prop (6) from hood bracket (7).
3. Loosen jamnut (8) and remove rod end (4) and jamnut from prop (6).
4 2
3
8
6 7
1
0190 00-1
TM 9-2320-302-20
HOOD PROP AND MOUNT REPLACEMENT - CONTINUED 0190 00
HOOD PROP REMOVAL - CONTINUED

4. Remove two screws (9) and radiator bracket (5) from radiator (10). Remove decal (11).
5. Remove two screws (12) and hood bracket (7) from hood (1).
6. Remove clip (13).
10
9
13
11
4 2
3
8
6 7
1
12
HOOD MOUNT REMOVAL
NOTE
Left and right hood mounts are removed and installed the same way. Left hood mount is shown.
1. Remove lock nut (14), washer (15), screw (16), locator (17), and three spacers (18) from mounting bracket (19). Discard
lock nut.
2. Remove four lock nuts (20), washers (21), screws (22), mounting bracket (19), and hood guide (23). Discard lock nuts.
0190 00-2
TM 9-2320-302-20
HOOD PROP AND MOUNT REPLACEMENT - CONTINUED 0190 00
HOOD MOUNT REMOVAL - CONTINUED
16
18
17 19
22
15
14
23
20
21
HOOD MOUNT INSTALLATION
1. Install hood guide (23) and mounting bracket (19) with four screws (22), washers (21) and new lock nuts (20).
2. Install three spacers (18) and locator (17) to mounting bracket (19) with screw (16), washer (15) and new lock nut (14).
HOOD PROP INSTALLATION
1. Install clip (13).
2. Install hood bracket (7) to hood (1) with two screws (12). Tighten screws to 40 lb-ft (54 Nm).
3. Install radiator bracket (5) to radiator (10) with two screws (9). Tighten screws to 180 lb-in (20 Nm). Install decal (11).
4. Install jam nut (8) and rod end (4) on prop (6). Rotate prop into rod end as far as it will go, then back out two to four
turns.
5. Install rod end (4) to radiator bracket (5) with washer (3) and nut (2).
6. Install prop (6) end into hood bracket (7). End of prop should be against slot end closest to vehicle when hood is fully
open and tilt assist cables are tight.
7. If no adjustment is required, tighten jam nut (8) against rod end (4). If adjustment is required, proceed to next step.
8. Rotate prop (6) until prop is against hood bracket slot end closest to vehicle when hood is fully open and tilt assist cables
are tight.
9. Tighten jam nut (8) against rod end (4).
10. Adjust hood (WP 0187 00).
END OF WORK PACKAGE
0190 00-3
TM 9-2320-302-20
0190 00-4
TM 9-2320-302-20
SEAT REPLACEMENT 0191 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Personnel Required
Two Seat belt removed (WP 0193 00)
NOTE
Driver seat and passenger seat are replaced the same way.
REMOVAL
WARNING
DO NOT disconnect any air system lines or fittings unless vehicle engine is shut down and air system pres-
sure is relieved. Failure to follow this warning could result in serious injury to personnel.
1. Disconnect air line (1).
2. With assistance, remove four screws (2), washers (3), and seat (4) from vehicle.
2,3
INSTALLATION
1. With assistance, install seat (4) in vehicle with four washers (3) and screws (2).
2. Connect air line (1).
3. Install seat belt (WP 0193 00).
END OF WORK PACKAGE
0191 00-1
TM 9-2320-302-20
0191 00-2
TM 9-2320-302-20
SEAT REPAIR 0192 00

Disassembly, Assembly
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Parts kit (P/N 622135-001)
Wrench, torque, 0-300 lb-in (Item 44, WP 0236 00) Parts kit (P/N 622137-001)
Parts kit (P/N 622155-001)
Materials/Parts
Parts kit (P/N 1104385-002)
Parts kit (P/N 622076-001)
Parts kit (P/N 1349236-002) (3)
Parts kit (P/N 622132-001)
Parts kit (P/N 622133-001) Equipment Condition
Parts kit (P/N 622134-001) Seat removed (WP 0191 00)
DISASSEMBLY
NOTE
This task is the same for driver or passenger seat.
1. Adjust to rear position and remove two screws (1), washers (2), and shoulder bolts (3) from channel (4).
2. Remove seat (5) from channel (4).
NOTE
Perform steps 3 through 8 to disassemble seat frame.
3. Remove two screws (6) and bracket (7) from each side of upper plate (8).
4 2
1
6
8 7
3
0192 00-1
TM 9-2320-302-20
SEAT REPAIR - CONTINUED 0192 00
4. Remove two wires (9) and remove back cover (10) and pad (11) from frame (12).
5. Remove seat pad support (13) and two seat tilt blocks (14).
6. Remove two pushnuts (15) and remove linkage (16) from slide shaft (17) and adjustment block (18). Discard pushnuts.
7. Remove roll pin (19), adjustment shaft (20), spacer (21), and adjustment block (18) from frame (12). Remove knob (22)
from adjustment shaft. Discard roll pin.
8. Remove two pushnuts (23), support shaft (24), two springs (25), and slide shaft (17). Discard pushnuts.
9. Remove screw (26) and stop block (27).
10
11
22 12
20 23
26 19
25
15
24
16
17
23
13 18
21
27
14
10. With channel (4) assembly still in rear position, remove isolator spring (28) and rubber bumper (29) at rear.
11. Adjust channel (4) assembly to forward position and remove isolator spring (28) and rubber bumper (29) at front.
12. Remove three wire ties (30) from air lines (31).
13. Remove six screws (32) and lock washers (33) from sides of channel (4) and six screws (32) and lock washers (33) from
underneath channel to free two guide assemblies (34). Discard lock washers.
14. Remove two guide assemblies (34) and valve mount (35) from channel (4).
15. Remove two rollers (36) from each guide assembly (34).
16. Disconnect end of spring (37) from latch bar (38).
17. Remove bolt (39), washer (40), pivot block (41), latch bar (38), and spacer (42) from channel (4). Remove screw (43)
from latch bar.
0192 00-2
TM 9-2320-302-20
18. Separate channel (4) from upper plate (8) and disconnect spring (37) and split poly loom (44) from channel.
19. Remove lock nut (45), washer (46), control handle (47), spring (48), split poly loom (49), washer (50), and shoulder bolt
(51) from channel (4). Discard lock nut.
20. Remove spring (52), detent pin (53), pop rivet (54), and knob (55) from control handle (47). Discard pop rivet.
21. Remove two brackets (56) and tilt rod (57) from channel (4). Remove knob (58) from tilt rod.
29
39
40
56 45
28
29 28
46 41
4
57 49 30
48 31
32
58 54 47
55 50 42 33
36 51 35
53
44
34 43
52 37
38 33
32
8
0192 00-3
TM 9-2320-302-20
22. Using blocking between upper plate (8) and riser (59) to hold upper plate in fully raised position.
NOTE
Perform steps 23 and 24 to remove air spring.
23. Disconnect air line (31) from air spring (60).

24. Remove screw (61), screw (62), washer (63), and air spring (60).
NOTE
Perform steps 25 and 26 to remove damper.
25. Remove two push-on fasteners (64), washers (65), and damper (66) from lever (67) and riser (59). Discard push-on fas-
teners.
26. Press two bearings (68) from damper (66).
27. At front of upper plate (8), remove two screws (69) from bearing blocks (70).
28. At rear of riser (59), remove two screws (71) and stop blocks (72).
29. Remove blocking supporting upper plate (8).
61 80
69
81
74
75
73
78
67 79
70
77
60
65 31
68 64 72
66
59
71
82
63 76
62
30. Slide upper plate (8) forward and rearward to remove upper plate from bearing blocks (70) and slide blocks (73).
0192 00-4
TM 9-2320-302-20
31. Remove bearing blocks (70) from ends of lever (74) and remove two slide blocks (73) and spacers (75) from ends of
lever (67).
32. At front of riser (59), remove two screws (76) from bearing blocks (77).
33. Slide lever (67 and 74) assembly forward to remove two bearing blocks (77) and lever assembly from riser (59).
34. Remove bearing blocks (77) from ends of lever (67) and slide blocks (78) from ends of lever (74).
35. Remove two nuts (79) and shoulder bolts (80) to separate lever (67) and lever (74).
36. Press out two bearings (81) from lever (67).
37. Remove two rubber bumpers (82) from riser (59).
ASSEMBLY
1. Install two rubber bumpers (82) to riser (59).
2. Install two bearings (81) into lever (67) with flanges of bearings on outside of lever.
3. Install lever (74) to lever (67) with two shoulder bolts (80) and nuts (79). Tighten nuts to 192-240 lb-in (22-27 Nm).
4. Install two slide blocks (78) on rear of lever (74) and two bearing blocks (77) on front of lever (67).
5. Install lever (67 and 74) assembly into riser (59) and install two screws (76) into bearing blocks (77).
6. Install two spacers (75) and slide blocks (73) on ends of lever (67) and two bearing blocks (70) on ends of lever (74).
7. Install upper plate (8) over bearing blocks (70) and slide blocks (73).
8. Install two screws (69) to bearing blocks (70).
9. Using blocking between upper plate (8) and riser (59) to hold upper plate in fully raised position.
10. At rear of riser (59), install two stop blocks (72) with two screws (71).
NOTE
Perform steps 11 and 12 to install damper.
11. Press two bearings (68) into damper (66).
12. Install damper (66) to riser (59) and lever (67) with two washers (65) and new push-on fasteners (64).
NOTE
Perform steps 13 through 15 to install air spring.
13. Position air spring (60) with fitting facing forward.
14. Install air spring (60) with washer (63), screw (62), and screw (61). Tighten screw (61) to 180-228 lb-in (20-26 Nm).
Tighten screw (62) to 108-132 lb-in (12-15 Nm).
15. Connect air line (31) to air spring (60).
16. Remove blocking supporting upper plate (8).
0192 00-5
TM 9-2320-302-20
17. Install knob (58) to tilt rod (57) and install two brackets (56) and tilt rod to channel (4).
18. Install knob (55), new pop rivet (54), detent pin (53), and spring (52) to control handle (47).
19. Connect spring (37) and split poly loom (44) to channel (4) and position channel to upper plate (8).
20. Install screw (43) to latch bar (38) and install spacer (42), latch bar, and pivot block (41) to channel (4) with washer (40)
and bolt (39). Tighten bolt to 26-34 lb-ft (35-46 Nm).
21. Connect end of spring (37) to latch bar (38).
22. Install two rollers (36) to each of two guide assemblies (34).
23. Position valve mount (35) and two guide assemblies (34) to channel (4).
24. Install six new lockwashers (33) and screws (32) underneath channel (4) and six new lockwashers (33) and screws (32)
to sides of channel.
25. Secure air lines (31) with three wire ties (30).
26. Adjust channel (4) assembly to forward position and install front isolator spring (28) and rubber bumper (29).
27. Adjust channel (4) assembly to rear position and install rear isolator spring (28) and rubber bumper (29).
NOTE
Perform steps 28 through 33 to assemble seat frame.
29
39
40
56 45
28
29 28
46 41
4
57 49 30
48 31
32
58 54 47
55 50 42 33
36 53 51 35
44
34 43
52 37
38 33
32
8
0192 00-6
TM 9-2320-302-20
28. Install stop block (27) to seat frame (12) with screw (26).
29. Install slide shaft (17), two springs (25), support shaft (24) and two new pushnuts (23).
30. Install knob (22) to adjustment shaft (20) and install adjustment block (18), spacer (21), adjustment shaft, and new roll
pin (19).
31. Install linkage (16) to adjustment block (18) and slide shaft (17) with two new pushnuts (15).
32. Install two seat tilt blocks (14) and seat pad support (13).
33. Install pad (11) and back cover (10) to frame (12) with two wires (9).
10
11
22 12
20 23
26 19
25
15
24
16
17
23
13 18
21
27
14
0192 00-7
TM 9-2320-302-20
34. Install bracket (7) to each side of upper plate (8) with two screws (6). Tighten screws to 18-22 lb-ft (24-30 Nm). Position
seat (5) to channel (4).
35. Install two shoulder bolts (3). Tighten bolts to 18-22 lb-ft (24-30 Nm).
36. Install two washers (2) and screws (1). Tighten screws to 18-22 lb-ft (24-30 Nm).
4 2
1
6
8 7
3
37. Install seat (WP 0191 00).
END OF WORK PACKAGE
0192 00-8
TM 9-2320-302-20
SEAT BELT REPLACEMENT 0193 00

INITIAL SETUP

NOTE
Replacement mounting hardware for seat belt is supplied with new seat belt.
REMOVAL
1. Remove two lock nuts (1), washer (2), and two screws (3). Discard lock nuts.
2. Lift cover (4) and remove two lock nuts (5), screws (6), lock washers (7), washers (8), tether belts (9), and lock belt (10).
Discard lock nuts and lock washers.
3. Disconnect seat belt (11).
4. Lift cover (12) and remove lock nut (13), washer (14), and screw (15). Discard lock nut.
5. Disconnect seat belt (11) from floor (16).
6. Lift cover (17) and remove screw (18), seat belt (11), washer (19), lock (20), washer (21), and bushing (22).
17
19
18 21
22
11
10
20 8
7
6 5
6
9
7
3
8
4 5
9 15
3
12
1
14
2
16 13
1
0193 00-1
TM 9-2320-302-20
SEAT BELT REPLACEMENT - CONTINUED 0193 00
INSTALLATION
1. Install bushing (22), washer (21), lock (20), washer (19), seat belt (11), and screw (18). Close cover (17).
2. Connect seat belt (11) and install screw (15), washer (14), and new lock nut (13) in floor (16).
3. Close cover (12).
4. Connect seat belt (11) and install lock belt (10), tether belts (9), washers (8), new lock washers (7), screws (6), and new
lock nuts (5).
5. Close cover (4). Install two screws (3), washer (2), and two new lock nuts (1).
17
19
18 21
22
11
10
20 8
7
6 5
6
9
7
3
8
4 5
9 15
3
12
1
14
2
16 13
1
END OF WORK PACKAGE
0193 00-2
TM 9-2320-302-20
FRONT SPLASH GUARD AND FENDER EXTENSION MAINTENANCE 0194 00
INITIAL SETUP

Nut, lock (P/N MS51922-33) (3)
Personnel Required
References
Two
TM 9-2320-302-10
Nut, lock (P/N MS51922-9) (8) Side marker/turn signal light removed (WP 0088 00)
REMOVAL
WARNING
Front fender extension and splash guard are heavy and awkward to handle. Use assistance when removing
these items. Failure to follow this warning may result in injury to personnel.
NOTE
Procedures for right- and left-side fender extensions are the same.
Remove three lock nuts (1), six washers (2), three screws (3), and front fender extension (4) with splash guard (5) from
1,2,3,4
0194 00-1
TM 9-2320-302-20
FRONT SPLASH GUARD AND FENDER EXTENSION MAINTENANCE - CONTINUED 0194 00
DISASSEMBLY
NOTE
Cap screws are different length as needed for use. Mark location of each during removal to aid during instal-
lation.
1. Remove four nuts (6), two lock nuts (7), 12 washers (8), six cap screws (9), two braces (10), and splash guard (5). Dis-
card lock nuts.
8
5
10
8
6
9 7
8
9
8
2. Remove four lock nuts (11), washers (12), screws (13), washers (14), bracket (15), and front fender extension (4). Dis-
card lock nuts.
13 14 4
14 14
11
12
12
15
14
11 13
11 12
3. Remove two lock nuts (16), four washers (17), two cap screws (18), and two brackets (19). Discard lock nuts.
0194 00-2
TM 9-2320-302-20
4. Remove lock nut (16), two washers (17), cap screw (20), and bracket (21). Discard lock nut.
5. Remove lock nut (16), two washers (17), cap screws (22), two brackets (23 and 24), and brace (25) from bracket (26).
Discard lock nuts.
6. Remove lock nut (16), two washers (17), cap screw (29), bracket (27), brace (28), and bracket (30) from bracket (26).
Discard lock nuts.
17
27
28 16
17
21
17 17
29
30 20
16
17 17 23 25
17
19
17
22
26
18
16 24
19 17 18
ASSEMBLY
1. Install bracket (30), bracket (28), and bracket (27) on bracket (26). Secure in place with screw (29), two washers (17),
and new lock nut (16).
2. Install brace (25) and brackets (24 and 23) on bracket (26). Secure in place with cap screw (22), two washers (17), and
new lock nut (16).
3. Install bracket (21) on bracket (26) with screw (20), two washers (17), and new lock nut (16).
4. Install bracket (19) on each bracket (24 and 30). Secure with cap screw (18), two washers (17), and new lock nut (16).
5. Attach bracket (15) to front fender extension (4) and secure with screw (13), two washers (12 and 14), and new lock nut
(11).
6. Attach front fender extension (4) to brackets (23 and 27) and secure in place with three screws (13), washers (14), wash-
ers (12), and new lock nuts (11).
7. Install splash guard (5) and two braces (10) to fender extension and bracket assembly with six cap screws (9), 12 wash-
ers (8), four nuts (6), and two new lock nuts (7).
0194 00-3
TM 9-2320-302-20
INSTALLATION
WARNING
Front fender extension and splash guard are heavy and awkward to handle. Use assistance when installing
these items. Failure to follow this warning may result in injury to personnel.
1. Position front fender splash guard (5) and fender extension (4) on vehicle and secure in place with three screws (3), six
washers (2), and three new lock nuts (1).
1,2,3,4
2. Install side marker/turn signal light (WP 0088 00).
END OF WORK PACKAGE
0194 00-4
TM 9-2320-302-20
REAR FENDER REPLACEMENT 0195 00
INITIAL SETUP

NOTE
Right and left fenders are replaced the same way. Right rear fender is illustrated.
REMOVAL
Remove nut (1), washer (2), screw (3), washer (4), and rear fender (5) from vehicle.
2
1
5
4
3
INSTALLATION
Install rear fender (5) on vehicle with washer (4), screw (3), washer (2), and nut (1). Tighten nut to 200 lb-ft (271 Nm).
END OF WORK PACKAGE
0195 00-1
TM 9-2320-302-20
0195 00-2
TM 9-2320-302-20
MUD FLAP ASSEMBLY REPLACEMENT 0196 00
INITIAL SETUP

Materials/Parts
Nut, lock (P/N MS51922-17) (4)
Pin, cotter (P/N MS24665-623)
REMOVAL
1. Remove cotter pin (1) and mud flap hanger (2) from rear mounting bracket assembly (3). Discard cotter pin.
2. Remove four lock nuts (4), screws (5), mud flap (6), and reflective tape bracket (7) from mud flap hanger (2). Discard
lock nuts.
3. Remove four clamps (8) from mud flap hanger (2).
2
8
1
3
7
INSTALLATION
1. Install four clamps (8) on mud flap hanger (2).
2. Position reflective tape bracket (7) on mud flap (6) and install mud flap on mud flap hanger (2) with four screws (5) and
new lock nuts (4).
3. Install mud flap hanger (2) on rear mounting bracket assembly (3) with new cotter pin (1).
END OF WORK PACKAGE
0196 00-1
TM 9-2320-302-20
0196 00-2
TM 9-2320-302-20
PERSONAL GEAR STORAGE BOX AND MOUNTING BRACKET REPLACEMENT 0197 00
INITIAL SETUP
Nut, lock (P/N MS51922-1) (3) Basic Issue Items (BII) storage box removed (WP
0198 00)
Nut, lock (P/N MS51922-17) (11)
Spare wheel hoist removed (WP 0176 00)
Forward tractor protection valve removed (WP
Personnel Required 0150 00)
Two Trailer electrical receptacles removed (WP 0078 00)
REMOVAL
1. Remove three lock nuts (1), washers (2), and six clamps (3) and lay four air tubes (4) and two harnesses (5) aside. Dis-
card lock nuts.
1,2
3
3
5 4
1,2,3
1,2,3
0197 00-1
TM 9-2320-302-20
PERSONAL GEAR STORAGE BOX AND MOUNTING BRACKET REPLACEMENT - CONTINUED 0197 00
REMOVAL - CONTINUED
2. Remove two screws (6), four lock nuts (7), screws (8), washers (9), and personal gear storage box (10) from mounting
bracket (11). Discard lock nuts.
10 8
9
6
11
3. Remove seven lock nuts (12), washers (13), screws (14), washers (15), and mounting bracket (11) from frame (16). Dis-
card lock nuts.
11
16
13
12 14
15
4. Remove drain (17) from personal gear storage box (10).
10
20 17
21
19 19
18
0197 00-2
TM 9-2320-302-20
PERSONAL GEAR STORAGE BOX AND MOUNTING BRACKET REPLACEMENT - CONTINUED 0197 00
5. Remove three bolts (18), six washers (19), three nuts (20), and gladhand/electrical cable bracket (21) from personal gear
storage box (10).
INSTALLATION
1. Install gladhand/electrical cable bracket (21) with three bolts (18), six washers (19), and three nuts (20).
2. Install mounting bracket (11) on frame (16) with seven washers (15), screws (14), washers (13), and new lock nuts (12).
3. Install drain (17) in personal gear storage box (10).
4. Apply caulking compound to bottom of four washers (9). Install personal gear storage box (10), four washers, screws
(8), new lock nuts (7), and two screws (6) in mounting bracket (11).
5. Install four air tubes (4), two harnesses (5), six clamps (3), three washers (2), and new lock nuts (1) on personal gear
storage box (10).
1,2
3
3
5 4
1,2,3
1,2,3
6. Install forward tractor protection valve (WP 0150 00).

7. Install spare wheel hoist (WP 0176 00).
8. Install Basic Issue Items (BII) storage box (WP 0198 00).
9. Install trailer electrical receptacles (WP 0078 00).
END OF WORK PACKAGE
0197 00-3
TM 9-2320-302-20
0197 00-4
TM 9-2320-302-20
BASIC ISSUE ITEMS (BII) STORAGE BOX AND MOUNTING BRACKET REPLACEMENT 0198 00
INITIAL SETUP


Compound, caulking (Item 7, WP 0235 00) Primary I air tank removed (WP 0143 00)
Right rear step removed (WP 0174 00)
Vehicle jack mounting bracket removed (WP 0213 00)
REMOVAL
1. Remove six screws (1), washers (2), and storage box (3) from two mounting brackets (4).
2. Remove four nuts (5), washers (6), two mounting brackets (4), four spacers (7), screws (8), and washers (9) from frame
rail (10).
3. Remove drain (11) and, if damaged, door seal (12) from storage box (3).
1,2 4
10
7
3
4
12
11
5,6,8,9
0198 00-1
TM 9-2320-302-20
BASIC ISSUE ITEMS (BII) STORAGE BOX AND MOUNTING BRACKET

REPLACEMENT- CONTINUED 0198 00
INSTALLATION
1. Install drain (11) and, if removed, new door seal (12) in storage box (3).
2. Install four washers (9), screws (8), spacers (7), two mounting brackets (4), four washers (6), and nuts (5) on frame rail
(10).
3. Apply caulking compound to bottom of six washers (2). Install storage box (3), six washers (2), and screws (1) in two
mounting brackets (4).
1,2 4
10
7
3
4
12
11
5,6,8,9
4. Install vehicle jack mounting bracket (WP 0213 00).

5. Install right rear step (WP 0174 00).
6. Install primary I air tank (WP 0143 00).
END OF WORK PACKAGE
0198 00-2
TM 9-2320-302-20
STORAGE BOX LATCH REPLACEMENT 0199 00
INITIAL SETUP

TM 9-2320-302-10
Materials/Parts
Nut, lock (P/N MS51922-1) (4)
REMOVAL
Remove four lock nuts (1), washers (2), and latch (3) from storage box (4).
INSTALLATION
Install latch (3) on storage box (4) with four washers (2), and new lock nuts (1).
END OF WORK PACKAGE
0199 00-1
TM 9-2320-302-20
0199 00-2
TM 9-2320-302-20
REAR PLATFORM REPLACEMENT 0200 00
INITIAL SETUP

Materials/Parts
Nut, self-locking (P/N MS51922-1) (4)
REMOVAL
Remove four lock nuts (1), washers (2), clamps (3 and 4), and platform (5). Discard locknuts.
1 2
INSTALLATION
Install platform (5) with four clamps (3 and 4), washers (2), and new lock nuts (1).
END OF WORK PACKAGE
0200 00-1
TM 9-2320-302-20
0200 00-2
TM 9-2320-302-20
FLOOR MATS REPLACEMENT 0201 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Seats removed (WP 0191 00)
REMOVAL
1. Remove 10 screws (1), two treadplates (2), floor mats (3), and insulation pads (4) from cab.
2. Remove 10 torx screws (5), washers (6), and floor mat (7) from cab.
1
1
5
3,4
2
7 6
INSTALLATION
1. Install floor mat (7) on cab with 10 washers (6) and torx screws (5).
2. Install two insulation pads (4), floor mats (3) and treadplates (2) on cab with 10 screws (1).
3. Install seats (WP 0191 00).
END OF WORK PACKAGE
0201 00-1
TM 9-2320-302-20
0201 00-2
TM 9-2320-302-20
CAB LINERS REPLACEMENT 0202 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Seat belts removed (WP 0193 00)
Wrench set, socket attachment (Item 49, WP 0236 00) Anti-lock brake system (ABS) electronic control unit
removed (WP 0108 00)
Collision warning system (CWS) unit removed (WP
0111 00)
REMOVAL
1. Remove two screws (1) and first aid box (2) from cab.
0202 00-1
TM 9-2320-302-20
CAB LINERS REPLACEMENT - CONTINUED 0202 00
REMOVAL - CONTINUED
2. Remove five screws (3), clamps (4), and trim (5) from cab.
3. Remove 50 screws (6) and cab liners (7) from cab.
6 7 5
3,4 6
INSTALLATION
1. Install cab liners (7) on cab with 50 screws (6).

2. Install trim (5) on cab.
3. Install five clamps (4) on cab with five screws (3).
4. Install first aid box (2) on cab with two screws (1).
0202 00-2
TM 9-2320-302-20
CAB LINERS REPLACEMENT - CONTINUED 0202 00
5. Install collision warning system (CWS) unit (WP 0111 00).
6. Install anti-lock brake system (ABS) electronic control unit (WP 0108 00).
7. Install seat belts (WP 0193 00).
END OF WORK PACKAGE
0202 00-3
TM 9-2320-302-20
0202 00-4
TM 9-2320-302-20
HEAD LINERS REPLACEMENT 0203 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Interior light unit removed (WP 0091 00)
REMOVAL
1. Remove four torx screws (1), two brackets (2), and cover (3) from cab.
2. Remove 38 torx screws (4) and head liners (5) from cab.
5
5
INSTALLATION
1. Install head liners (5) on cab with 38 torx screws (4).
2. Install cover (3) and two brackets (2) on cab with four torx screws (1).
3. Install interior light unit (WP 0091 00).
END OF WORK PACKAGE
0203 00-1
TM 9-2320-302-20
0203 00-2
TM 9-2320-302-20
CAB OVERHEAD STORAGE COMPARTMENT REPLACEMENT 0204 00
INITIAL SETUP

REMOVAL
1. While supporting center of compartment (1), remove screws (2) securing compartment to cab ceiling (3).
2. Remove compartment (1) from cab.
2 1
INSTALLATION
1. Position and support center of compartment (1) against cab ceiling (3).
2. Install screws (2) securing compartment (1) to cab ceiling (3).
END OF WORK PACKAGE
0204 00-1
TM 9-2320-302-20
0204 00-2
TM 9-2320-302-20
STEERING COLUMN COVER REPLACEMENT 0205 00
INITIAL SETUP

REMOVAL
Remove four screws (1) and cover (2) from steering column.
INSTALLATION
Install cover (2) on steering column with four screws (1).
END OF WORK PACKAGE
0205 00-1
TM 9-2320-302-20
0205 00-2
TM 9-2320-302-20
CAB DOOR ADJUSTMENT 0206 00
Adjustment
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Screws, self-tapping (P/N 1901-0810) (6)
ADJUSTMENT
NOTE
If performing cab door adjustment following repair or replacement, perform step 3 through 19.
1. Remove six self-tapping screws (1), leaving two adjusting screws (2 and 3) in place. Discard self-tapping screws.
0206 00-1
TM 9-2320-302-20
CAB DOOR ADJUSTMENT - CONTINUED 0206 00
2. Remove cap nut (4) and socket head screw (5) from door check arm (6).
3. Push door check arm (6) toward dashboard (7).
4. With cab door (8) closed, measure distance between top and bottom edges of cab door and door frame (9). Measure-
ments must be equal within 3/32 in (2.38 mm).
NOTE
Perform steps 5 and 6 only if cab door requires adjustment.
5. To adjust cab door (8), loosen adjusting screws (2 and 3) just enough to allow movement of cab door (8) up and down to
required measurement. Tighten adjusting screws.
0206 00-2
TM 9-2320-302-20
6. Repeat steps 4 and 5 until cab door (8) is properly adjusted.
NOTE
Cab door is fully closed when you hear two clicks of door latch. Door should not have to be slammed shut.
If it is necessary to slam cab door shut, door must be adjusted.
7. With cab door (8) fully closed, check in-out position of top of cab door and flange (10) at hinge (11). Cab door must be
flush +/- 1/16 in (1.58 mm).
NOTE
Perform steps 8 and 9 only if top of cab door in-out position requires adjustment.
8. To adjust top of cab door (8), loosen adjusting screw (2) and move cab door in or out to required measurement. Tighten
adjusting screw.
9. Repeat steps 7 and 8 until top of cab door (8) is properly adjusted.
10. With cab door (8) fully closed, check in-out position of bottom of cab door and flange (10) at hinge (11). Cab door must
be flush +/- 1/16 in (1.58 mm)
NOTE
Perform steps 11 and 12 only if bottom of cab door in-out position requires adjustment.
11. To adjust bottom of cab door (8), loosen adjusting screw (3) and move cab door in or out to required measurement.
Tighten adjusting screw.
10 2
11
3
12. Repeat steps 10 and 11 until bottom of cab door (8) is properly adjusted.
0206 00-3
TM 9-2320-302-20
13. Install six new self-tapping screws (1) and tighten self-tapping screws and adjusting screws (2 and 3) to 120 lb-in (14
Nm) in sequence shown.
7
1
5
2 1
TIGHTENING SEQUENCE
3
1
4
3 2
6
1
8
14. Close cab door (8) to within 2 in (5.08 cm) of striker pin (12) and see if door latch jaws (13) are centered on striker pin.
8 13
12
13
0206 00-4
TM 9-2320-302-20
15. Loosen torx screw (14) and add or remove shims (15) as necessary to center striker pin (12) and door latch jaws (13).
NOTE
• Steps 16 through 19 must be performed from inside and outside of cab.
• Repeat steps 16 until door fully closes without difficulty.
16. Fully close cab door (8). If cab door was difficult to close or would not close, open cab door, loosen torx screw (14), and
move striker pin (12) inward.
17. Tighten torx screw (14) to 37-42 lb-ft (50-57 Nm).
NOTE
Repeat steps 18 until door opens without difficulty.
18. Open cab door (8). If cab door was difficult to open or would not open, loosen torx screw (14) and move striker pin (12)
outward.
19. Tighten torx screw (14) to 37-42 lb-ft (50-57 Nm).
8
8
13
14
INWARD OUTWARD
12
13
15
0206 00-5
TM 9-2320-302-20
20. Move door check arm (6) back into position.
21. Install socket head screw (5) and cap nut (4) on door check arm (6).
END OF WORK PACKAGE
0206 00-6
TM 9-2320-302-20
TRANSMISSION TUNNEL ACCESS COVER REPLACEMENT 0207 00
INITIAL SETUP
Fire extinguisher removed (TM 9-2320-302-10)
Materials/Parts
Transmission shift selector and shift tower removed
Washer, lock (P/N MS35338-44) (12) (WP 0120 00)
REMOVAL
1. Remove four nuts (1), washers (2), screws (3), and fire extinguisher bracket (4) from vehicle.
1,2,3,
2. Remove ten torx screws (5), washers (6), and floor mat (7) from vehicle.
0207 00-1
TM 9-2320-302-20
TRANSMISSION TUNNEL ACCESS COVER REPLACEMENT - CONTINUED 0207 00
REMOVAL - CONTINUED
3. Remove 12 screws (8), lock washers (9), and transmission tunnel access cover (10) from vehicle. Discard lock washers.
10
8,9
INSTALLATION
1. Install transmission tunnel access cover (10) on vehicle with 12 new lock washers (9) and screws (8).
2. Install floor mat (7) on vehicle with ten washers (6) and torx screws (5).
3. Install fire extinguisher bracket (4) on vehicle with four screws (3), washers (2), and nuts (1).
1,2,3,
0207 00-2
TM 9-2320-302-20
TRANSMISSION TUNNEL ACCESS COVER REPLACEMENT - CONTINUED 0207 00
4. Install transmission shift selector and shift tower (WP 0120 00).
5. Install fire extinguisher (TM 9-2320-302-10).
END OF WORK PACKAGE
0207 00-3
TM 9-2320-302-20
0207 00-4
TM 9-2320-302-20
REAR VIEW MIRROR REPLACEMENT 0208 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Strap, tiedown (Item 30, WP 0235 00)
Nut, lock (P/N MS51922-1) (8)
Washer, lock (P/N 23-09983-025) (3)
NOTE
Left and right rear view mirrors are replaced the same way. Left rear view mirror is shown.
REMOVAL
1. Remove tiedown straps (1) securing wiring harness (2).
2
1
0208 00-1
TM 9-2320-302-20
REAR VIEW MIRROR REPLACEMENT - CONTINUED 0208 00
REMOVAL - CONTINUED
2. Disconnect wiring harness connector (3) from mirror harness connector (4).
3. Remove cap nut (5), washer (6), screw (7), and washer (8) from mirror (9).
4. Remove lock nut (10), washer (11), screw (12), and washer (13) from mirror (9). Discard lock nut.
5. Remove three lock nuts (14), washers (15), socket head screws (16), washers (17), and spacers (18) from mirror (19).
Discard lock nuts.
6. Remove four lock nuts (19), washers (20), screws (21), washers (22), and support (23) from door. Discard lock nuts.
7. Remove two cap nuts (24), three lock washers (25), and mirror (9) from support (23). Discard lock washers.
20
19
22
21
24
23
16 25
17 18
9
17 15 2
1
18
10
11 13
12 14
7 25
8
24 4
5 6
3
INSTALLATION
1. Install mirror (9) on support (23) with three new lock washers (25) and two cap nuts (24).
2. Install support (23) on door with four washers (22), screws (21), washers (20), and new lock nuts (19).
3. Install three spacers (18), washers (17), socket head screws (16), washers (15), and new lock nuts (14) on mirror (9).
4. Install washer (13), screw (12), washer (11), and new lock nut (10) on mirror (9).
5. Install washer (8), screw (7), washer (6), and cap nut (5) on mirror (9).
0208 00-2
TM 9-2320-302-20
REAR VIEW MIRROR REPLACEMENT - CONTINUED 0208 00
6. Connect wiring harness connector (3) to mirror harness connector (4).
7. Secure wiring harness (2) using tiedown straps (1).
END OF WORK PACKAGE
0208 00-3
TM 9-2320-302-20
0208 00-4
TM 9-2320-302-20
SPOTTER MIRROR REPLACEMENT 0209 00
INITIAL SETUP

Materials/Parts Personnel Required

Nut, lock (P/N MS51922-1) (3) Two
REMOVAL
1. Remove three lock nuts (1) and washers (2) from hood liner (3). Discard lock nuts.
2. Remove three nuts (4), washers (5), screws (6), mirror assembly (7), three spacers (8), and washers (9) from hood (10).
3. Remove screw (11), washer (12), and spotter mirror (13) from mirror assembly (7).
12 13
10
7
8
11
6 5
4
9 5
1
2
INSTALLATION
NOTE
Some replacement mirrors may not have a drain hole. Drill a 1/16 inch hole at 6 o’clock position to allow
any moisture to drain.
1. Install spotter mirror (13) on mirror assembly (17) with washer (12) and screw (11).
0209 00-1
TM 9-2320-302-20
SPOTTER MIRROR REPLACEMENT - CONTINUED 0209 00
2. Install three washers (9), spacers (8) and mirror assembly (7) on hood (10) with three screws (6), washers (5), and nuts
(4).
3. Install three washers (2) and new lock nuts (1) on hood liner (3).
12 13
10
7
8
11
6 5
4
9 5
1
2
END OF WORK PACKAGE
0209 00-2
TM 9-2320-302-20
WINDSHIELD WIPER MOTOR AND LINKAGE REPLACEMENT 0210 00

INITIAL SETUP

Equipment Condition
Materials/Parts Windshield wipers and wiper arms removed (WP
Seal, rubber (P/N 908028) (2) 0212 00)
REMOVAL
1. Remove snapring (1) from linkage pivot bar (3).
2. Pry connecting link (2) from linkage pivot bar (3).
3. Remove rubber seal (4) from ball joint of linkage pivot bar (3). Discard rubber seal.
4. Disconnect wiper motor (5) wiring.
5. Remove two nuts (6) and washers (7) from brackets (8).
6. Remove two screws (9), washers (10), and spacers (11) securing bracket (8) and wiper motor (5) to firewall.
7. Remove bracket (8) and wiper motor (5).
2
4
8
7
3
6
9 10 5
11
0210 00-1
TM 9-2320-302-20
WINDSHIELD WIPER MOTOR AND LINKAGE REPLACEMENT - CONTINUED 0210 00
REMOVAL - CONTINUED
8. Disconnect short link bar (12) from wiper motor crank (13).
9. Remove three screws (14) and wiper motor (5) from bracket (8).
10. Remove two nuts (15), screws (16), and pivot assembly (17) from firewall.
11. Pry connecting link (2) from pivot assembly (17).
12. Remove rubber seal (18) from ball joint of pivot assembly (17). Discard rubber seal.
1
18
17
15
2
16
4
8
7
3
6 13
9 10 5
11
8
12
14
INSTALLATION
1. Install new rubber seal (18) to ball joint of pivot assembly (17).
2. Install connecting link (2) to pivot assembly (17).
3. Install pivot assembly (17) to firewall with two screws (16) and nuts (15).
4. Install wiper motor (5) to bracket (8) with three screws (14). Tighten screws to 55 lb-in (621 Ncm).
5. Connect short link bar (12) to wiper motor crank (13).
6. Position bracket (8) and wiper motor (5) to firewall.
7. Install two spacers (11), washers (10), and screws (9). Tighten screws to 60-84 lb-in (678-949 Ncm).
0210 00-2
TM 9-2320-302-20
WINDSHIELD WIPER MOTOR AND LINKAGE REPLACEMENT - CONTINUED 0210 00
8. Install two washers (7) and nuts (6). Tighten nuts to 60-84 lb-in (678-949 Ncm).
9. Connect wiper motor (5) wiring.
10. Install new rubber seal (4) to ball joint of linkage pivot bar (3).
11. Install connecting link (2) to linkage pivot bar (2).
12. Install snapring (1) to linkage pivot bar (3).
13. Install windshield wipers and wiper arms (WP 0212 00).
END OF WORK PACKAGE
0210 00-3
TM 9-2320-302-20
0210 00-4
TM 9-2320-302-20
WINDSHIELD WASHER RESERVOIR REPLACEMENT 0211 00
Pump Removal, Reservoir Removal, Pump Installation, Reservoir Installation
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Compound, cleaning, windshield (Item 8, WP
Pan, drain (Item 25, WP 0236 00) 0235 00)
References
TM 9-2320-302-10
PUMP REMOVAL
1. Remove wiring harness connector (1) from windshield washer reservoir pump (2).
2. Remove hose (3) from pump (2) and allow windshield washer solvent to drain into a suitable container.
3. Remove pump (2) from windshield washer reservoir (4).
6
12
9
8
11
5 2
1
7
10
3
RESERVOIR REMOVAL
1. Remove filler tube (5) from filler spout (6) and windshield washer reservoir (4).
2. Remove vent hose (7) from windshield washer reservoir (4).
3. Remove two screws (8), washers (9), and filler spout (6) from vehicle.
4. Remove four nuts (10), washers (11), screws (12), and windshield washer reservoir (4) from vehicle.
0211 00-1
TM 9-2320-302-20
WINDSHIELD WASHER RESERVOIR REPLACEMENT - CONTINUED 0211 00
PUMP INSTALLATION
1. Install pump (2) on windshield washer reservoir (4).
2. Install hose (3) on windshield washer reservoir pump (2).
3. Install wiring harness connector (1) on windshield washer reservoir pump (2).
RESERVOIR INSTALLATION
1. Install windshield washer reservoir (4) on vehicle with four screws (12), washers (11), and nuts (10).
2. Install filler spout (6) on vehicle with two washers (9) and screws (8).
3. Install vent hose (7) on windshield washer reservoir (4).
4. Install filler tube (5) on windshield washer reservoir (4) and filler spout (6).
5. Fill windshield washer reservoir (4) with windshield cleaning compound.
6
12
9
8
11
5 2
1
7
10
3
END OF WORK PACKAGE
0211 00-2
TM 9-2320-302-20
WINDSHIELD WIPER AND WIPER ARM REPLACEMENT 0212 00
INITIAL SETUP
NOTE
Left and right windshield wipers and wiper arms are replaced the same way.
REMOVAL
1. Remove nut (1), screw (2), and windshield wiper (3) from wiper arm (4).
2. Disconnect hose (5) from wiper arm (4).
3. Remove cover (6), nut (7), and wiper arm (4) from shaft (8).
2 3 4
7 6
INSTALLATION
1. Install wiper arm (4) on shaft (8) with nut (7). Install cover (6) on wiper arm.
2. Install hose (5) on wiper arm (4).
3. Install windshield wiper (3) on wiper arm (4) with screw (2) and nut (1).
END OF WORK PACKAGE
0212 00-1
TM 9-2320-302-20
0212 00-2
TM 9-2320-302-20
VEHICLE JACK MOUNTING BRACKET REPLACEMENT 0213 00
INITIAL SETUP
Materials/Parts
REMOVAL
1. Remove nut (1), two washers (2), screw (3), and latch (4) from jack storage location.
2. Remove nut (5), screw (6), two washers (7), and bracket (8) from storage box (9).
3. Remove two nuts (10), four washers (11), two screws (12), and vehicle jack mounting bracket (13) from storage box (9).
9
11
12
10
4 13
11
2
8 7
5 3
2
0213 00-1
TM 9-2320-302-20
VEHICLE JACK MOUNTING BRACKET REPLACEMENT - CONTINUED 0213 00
INSTALLATION
1. Install vehicle jack mounting bracket (13) on storage box (9) with two screws (12), four washers (11), and two nuts (10).
2. Install bracket (8) on storage box (9) with screw (6), two washers (7), and nut (5). Coat nut with caulking compound.
3. Insert latch (4) and secure on bracket (8) with screw (3), two washers (2), and nut (1). Coat nut with caulking compound.
9
11
12
10
4 13
11
2
8 7
5 3
2
END OF WORK PACKAGE
0213 00-2
TM 9-2320-302-20
AIR HORN AND VALVE REPLACEMENT 0214 00
Air Horn Removal, Air Horn Valve Removal, Air Horn Valve Installation, Air Horn Installation
INITIAL SETUP

Nut, lock (P/N MS51922-1) (3)
Head liners removed from cab (WP 0203 00)
Cab overhead storage compartment removed (WP
Tags, marker (Item 31, WP 0235 00) 0204 00)
AIR HORN REMOVAL

1. Remove two lock nuts (1), screws (2), and four washers (3) securing air horn (4) in place. Discard lock nuts.
2. Separate air horn (4) from cab floor (5) and bracket (6).
3. Remove air tube (7), elbow (8), and nipple (9) from air horn (4).
4. Remove lock nut (1), screw (10), two washers (11), and bracket (6) from plate (12). Discard lock nut.
5. If damaged, remove rivet (13) and plate (12) from cab floor (5).
1
3 5
7 6
1
3
11
12 2
13
11
4
10
0214 00-1
TM 9-2320-302-20
AIR HORN AND VALVE REPLACEMENT - CONTINUED 0214 00
AIR HORN VALVE REMOVAL
1. Release end of pull cord (14) from cab (15).

2. Remove screw (16) and loop clamp (17) from cab (15). Remove loop clamp from pull cord (14).
NOTE
Tag tubes to aid in installation
3. Disconnect three tubes (18) and remove tee (19) and elbow (20) from valve (21).
4. Remove two screws (22) and valve (21) from cab (15).
18
20
18 21 15
16
19 17 22
18
14
AIR HORN VALVE INSTALLATION
WARNINGS
1. Apply a light coat of pipe sealing compound to threads of elbow (20) and tee (19).
NOTE
Ensure valve is properly positioned to allow for mounting on cab.
0214 00-2
TM 9-2320-302-20
AIR HORN VALVE INSTALLATION - CONTINUED

2. Install tee (19) and elbow (20) on valve (21) and connect three tubes (18) to fittings.
3. Install valve (21) to cab (15) and secure with two screws (22).
4. Attach pull cord (14) with loop clamp (17) to valve (21) and secure loop clamp to cab (15) with screw (16).
AIR HORN INSTALLATION
1. If removed, install plate (12) to cab floor (5) with new rivet (13).
2. Install bracket (6) to plate (12) with two washers (11), screw (10) and new lock nut (1).
WARNINGS
3. Apply pipe sealing compound to nipple (9) and install elbow (8), nipple, and air tube (7) to air horn (4).
4. Position air horn (4) to bracket (6) and cab floor (5).
5. Secure air horn (4) in place with four washers (3), two screws (2) and new lock nuts (1).
1
3
1
3
11
12 2
13
11
4
10
6. Start vehicle and check for leaks in air system and operation of air horn.
7. Install cab head liners (WP 0203 00).
0214 00-3
TM 9-2320-302-20
AIR HORN INSTALLATION - CONTINUED

8. Install cab overhead storage compartment (WP 0204 00).
END OF WORK PACKAGE
0214 00-4
TM 9-2320-302-20
DATA AND INSTRUCTION PLATES REPLACEMENT 0215 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Rivet (4)
Drill, electric, portable (Item 11, WP 0236 00)
Drill set, twist (Item 12, WP 0236 00) References
Riveter, blind, hand (Item 28, WP 0236 00) TM 9-2320-302-10
NOTE
All data and instruction plates are replaced the same way.
REMOVAL
CAUTION
• If drilling in door panel, ensure that window is rolled up. Failure to do so could result in damage to win-
dow.
• If drilling in dashboard panel, ensure panel is removed from dashboard. Failure to do so could result in
damage to heating ducts.
Remove four rivets (1) and plate (2). Discard rivets.
1 2
1
1 2
INSTALLATION
NOTE
If installing plate on new panel, use illustration for location of drill holes.
Install plate (2) with four new rivets (1).
END OF WORK PACKAGE
0215 00-1
TM 9-2320-302-20
0215 00-2
TM 9-2320-302-20
M16 RIFLE MOUNTING BRACKET REPLACEMENT 0216 00
INITIAL SETUP

REMOVAL
1. Remove four nuts (1), two catch bracket assemblies (2), four cap screws (3), and washers (4) from rifle mounting
bracket (5).
2. Remove four caps crews (6), washers (7), eight washers (8), four nuts (9), and two rifle mounting supports (10) from
rifle mounting bracket (5).
3. Remove two nuts (11), four washers (12), two cap screws (13), and rifle mounting bracket (5).
4
2
3
1 2
6
7
5 8
6
7
8
13
12 10
8
11 9
0216 00-1
TM 9-2320-302-20
M16 RIFLE MOUNTING BRACKET REPLACEMENT - CONTINUED 0216 00
INSTALLATION
1. Install rifle mounting bracket (5) with four washers (12), two cap screws (13), and nuts (11).
2. Install two rifle mounting supports (10) on rifle mounting bracket (5) with eight washers (8), four washers (7), cap
screws (6), and nuts (9).
3. Install two catch bracket assemblies (2) on rifle mounting bracket (5) with four washers (4), cap screws (3), and nuts (1).
4
2
3
1 2
6
7
5 8
6
7
8
13
12 10
8
11 9
END OF WORK PACKAGE
0216 00-2
TM 9-2320-302-20
CUP HOLDER REPLACEMENT 0217 00
INITIAL SETUP
REMOVAL
1. Remove two screws (1), flat washers (2), and L/H cup holder (3) from dash (4).
2. Remove two screws (5), flat washers (6), and R/H cup holder (7) from swivel (8).
3. Remove swivel (8) from dash (4).
1,2 5,6,8
INSTALLATION
1. Install L/H cup holder (3) on dash (4) with two flat washers (2) and screws (1).
2. Install swivel (8) on dash (4).
3. Install R/H cup holder (7) on swivel (8) with two flat washers (6) and screws (5). Ensure R/H cup holder rotates freely.
END OF WORK PACKAGE
0217 00-1
TM 9-2320-302-20
0217 00-2
TM 9-2320-302-20
CAB ROOF AIR DEFLECTOR REPLACEMENT 0218 00
Air Deflector Removal, Mounting Hardware Removal, Mounting Hardware Installation, Air Deflector Installation
INITIAL SETUP

Materials/Parts Cab roof liner removed (WP 0202 00)
Nut, lock (P/N RUDAP691) (6)
Washer, lock (P/N RUDAP696) (8)
AIR DEFLECTOR REMOVAL

Remove eight nuts (1), lock washers (2), screws (3), and air deflector (4) from vehicle. Discard lock washers.
0218 00-1
TM 9-2320-302-20
CAB ROOF AIR DEFLECTOR REPLACEMENT - CONTINUED 0218 00
MOUNTING HARDWARE REMOVAL
NOTE
Perform steps 1 through 6 at each side of cab roof.
1. Remove lock nut (5), two washers (6), screw (7), and top pivot bracket (8) from strut (9). Discard lock nut.
9
8 6
5
6
7
2. Remove lock nut (10), two washers (11), screw (12), and strut (9) from channel (13). Discard lock nut.
3. Remove nut (14), washer (15) and screw (16) and channel (13) from support bracket (17).
4. Remove two nuts (18), reinforcing plate (19), gasket (20), two screws (21), and support bracket (17) from rear of cab
roof.
14
9 11 12
15
13
16 11
10
17
21
18
19
20
0218 00-2
TM 9-2320-302-20
MOUNTING HARDWARE REMOVAL - CONTINUED

5. Remove two nuts (22), screws (23), channel (13), swivel spacers (24), swivel plates (25), and rubber seals (26) from cab
roof.
23
13
24
25
26
22
6. Remove lock nut (27), two washers (28), screw (29), and bottom pivot bracket (30) from channel (13). Discard lock nut.
30
13 28 29
28
27
MOUNTING HARDWARE INSTALLATION
NOTE
Perform steps 1 through 6 at each side of cab roof.
1. Install bottom pivot bracket (30) on third hole from front of channel (13) with screw (29), two washers (28), and new
lock nut (27).
0218 00-3
TM 9-2320-302-20
MOUNTING HARDWARE INSTALLATION

2. Install two rubber seals (26), swivel plates (25), swivel spacers (24), and channel (13) on cab roof with two screws (23)
and nuts (22).
23
13
24
25
26
22
3. Install support bracket (17), gasket (20), and reinforcing plate (19) on rear of cab roof with two screws (21) and nuts
(18).
4. Install channel (13) on support bracket (17) with screw (16), washer (15), and nut (14).
14
9 11 12
15
13
16 11
10
17
21
18
19
20
0218 00-4
TM 9-2320-302-20
MOUNTING HARDWARE INSTALLATION - CONTINUED

5. Install strut (9) on rear hole of channel (13) with screw (12), two washers (11), and new lock nut (10).
6. Install top pivot bracket (8) on strut (9) with screw (7), two washers (6), and new lock nut (5).
9
8 6
5
6
7
AIR DEFLECTOR INSTALLATION

1. Install air deflector (4) on vehicle with eight screws (3), new lock washers (2) and nuts (1).
2. Install cab roof liner (WP 0202 00).
END OF WORK PACKAGE
0218 00-5
TM 9-2320-302-20
0218 00-6
TM 9-2320-302-20
HVAC AIR CYLINDER REPLACEMENT 0219 00
INITIAL SETUP

Materials/Parts
Nut, push (P/N BOA 702011 00)
Nut, push (P/N BOA 707014 00)
REMOVAL
1. Place heater/air conditioner slide lever in “DEF” position (TM 9-2320-302-10).
2. Remove screws (1) securing dash panel (2) in place.
1 2
0219 00-1
TM 9-2320-302-20
HVAC AIR CYLINDER REPLACEMENT - CONTINUED 0219 00
REMOVAL - CONTINUED
3. Push in on cover ring (3) and pull out on air line (4) to disconnect from air cylinder (5).
4. Remove push nuts (6 and 7) and air cylinder (5) from mounting rod (8) and flapper door rod (9). Discard push nuts.
INSTALLATION
1. Slide air cylinder (5) on mounting rod (8) and flapper door rod (9) and secure with new push nuts (6 and 7).
2. Install air line (4) by pushing air line into cover ring (3) as far as possible. Pull back carefully on air line to lock in place.
3. Operate vehicle and verify air cylinder (5) is functioning properly (TM 9-2320-302-10).
4. Install dash cover (2) with screws (1).
2
1
END OF WORK PACKAGE
0219 00-2
TM 9-2320-302-20
HVAC BLOWER MOTOR REPLACEMENT 0220 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Dash panel removed for access (WP 0219 00)
References
TM 9-2320-302-10
REMOVAL
1. Remove five screws (1) and blower motor cover (2).
2. Disconnect blower motor harness connector (3) from vehicle wiring harness receptacle (4).
4 2
0220 00-1
TM 9-2320-302-20
HVAC BLOWER MOTOR REPLACEMENT - CONTINUED 0220 00
REMOVAL - CONTINUED
3. Remove three screws (5) and blower motor (6) from housing (7).
5
7
INSTALLATION
1. Install blower motor (6) on housing (7) with three screws (5).
2. Connect blower motor harness connector (3) to vehicle wiring harness receptacle (4).
3. Operate vehicle and check blower operation (TM 9-2320-302-10).
4. Install blower motor cover (2) with five screws (1).
4 2
1
5. Install dash panel (WP 0219 00).
END OF WORK PACKAGE
0220 00-2
TM 9-2320-302-20
HVAC HEATER CORE REPLACEMENT 0221 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Rags, wiping (Item 28, WP 0235 00)
Gloves (Item 13, WP 0236 00) Tags, marker (Item 31, WP 0235 00)
Equipment Condition
Cooling system drained (WP 0041 00)
REMOVAL
1. Remove screws nine (1) and cover (2).
2. Remove three screws (3) and cover (4).
4 1
0221 00-1
TM 9-2320-302-20
HVAC HEATER CORE REPLACEMENT - CONTINUED 0221 00
REMOVAL - CONTINUED
5
6
4. Remove seven screws (7) and cover (8) from dash panel (9).
5. Open glove box door (10) and remove two screws (11) and top panel (12) from compartment (13).
6. Remove three nuts (14), spring washers (15) and compartment (13) from dash panel (9).
7. Disconnect and tag two flex hoses from ducts behind glove box.
8. Disconnect and tag air line from air cylinder behind glove box.
0221 00-2
TM 9-2320-302-20
REMOVAL - CONTINUED
11
12
9
13
10
14,15
9. Place rags on cab floor, loosen two hose clamps (16), and tag and disconnect heater core hoses (17).
10. Remove four screws (18) and heater core cover (19).
19
18
16
17
0221 00-3
TM 9-2320-302-20
REMOVAL - CONTINUED
WARNING
Failure to wear protective gloves could result in serious skin cuts from sharp edges and fins.
11. Wearing protective gloves, slide heater core (20) with seal up and out of housing (21).
20
21
INSTALLATION
WARNING
Failure to wear protective gloves could result in serious skin cuts from sharp edges and fins.
1. Wearing protective gloves, slide heater core (20) with seal into housing (21).
19
18
16
17
2. Install heater core cover (19) and secure with four screws (18).
3. Install heater core hoses (17) and tighten two clamps (16).
0221 00-4
TM 9-2320-302-20
4. Connect air line to cylinder behind glove box.
5. Connect two flex hoses to ducts behind glove box.
6. Insert compartment (13) into dash (9) and secure with three nuts (14) and spring washers (15).
7. Insert top panel (12) to compartment (13) and secure with two screws (11).
11
12
9
13
10
14,15
8. Position cover (8) on dash panel (9) and secure with seven screws (7).
0221 00-5
TM 9-2320-302-20
9. Position cover (6) on dash panel (9) and secure with two screws (5).
10. Position cover (4) on dash panel (9) and secure with three screws (3).
11. Position cover (2) on dash panel (9) and secure with nine screws (1).
4 1
5
2
6
END OF WORK PACKAGE
0221 00-6
TM 9-2320-302-20
AIR CONDITIONER RESISTER BLOCK REPLACEMENT 0222 00
INITIAL SETUP


Tags, marker (Item 31, WP 0235 00) Dash panel access covers removed (WP 0219 00)
REMOVAL
NOTE
1. Remove wiring harness connectors (1 and 2) from resistor block (3).
2. Remove two nuts (4) and resistor block (3).
3
4
2 1
INSTALLATION
1. Install resistor block (3) with two nuts (4).
2. Install wiring harness connectors (1 and 2) on resistor block (3).
3. Install dash panel access covers (WP 0219 00).
END OF WORK PACKAGE
0222 00-1
TM 9-2320-302-20
0222 00-2
TM 9-2320-302-20
AIR CONDITIONER THERMOSTATIC SWITCH REPLACEMENT 0223 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Dash panel access covers removed (WP 0219 00)
References
TM 9-2320-302-10
REMOVAL
1. Disconnect wiring harness connector (1) from thermostatic switch (2).
2. Remove four screws (3) and heater core cover (4).
NOTE
Mark thermostatic switch sensor tube at entry point in evaporator to aid in installation.
3. Remove two screws (5) and thermostatic switch (2) with sensor tube (6) attached.
4 6 5 5
1
2
INSTALLATION
1. Transfer measurement from old sensor tube (6) to new sensor tube, if installing a new thermostatic switch (2).
0223 00-1
TM 9-2320-302-20
AIR CONDITIONER THERMOSTATIC SWITCH REPLACEMENT - CONTINUED 0223 00
CAUTION
Use care when installing thermostatic switch sensor tube in evaporator. Using too much force will cause
tube to bend or kink.
2. Carefully insert sensor tube (6) into evaporator to a depth equal to mark on sensor tube.
NOTE
Sensor tube must be in contact with evaporator coil fin and be at least 4 in (10 cm) in evaporator.
3. Install thermostatic switch (2) with two screws (5).
4. Install heater core cover (4) with four screws (3).
5. Connect wiring harness connector (1) to thermostatic switch (2).
5 5
6
4
1
2
6. Install dash panel access covers (WP 0219 00).
END OF WORK PACKAGE
0223 00-2
TM 9-2320-302-20
AIR CONDITIONER BINARY SWITCH REPLACEMENT 0224 00
INITIAL SETUP

Tool kit, general mechanic’s (Item 36, WP 0236 00) Packing, preformed (P/N J200AR11)
Wrench, torque, 0-200 lb-in (Item 43, WP 0236 00) Oil, lubricating, refrigerant (Item 26, WP 0235 00)
References
TM 9-2320-302-10
REMOVAL
1. Disconnect harness connector (1) from binary switch (2).

2. Remove binary switch (2) and preformed packing (3) from receiver-drier (4). Discard preformed packing.
4
2,3
INSTALLATION
1. Lightly coat new preformed packing (3) with refrigerant lubricating oil. Install preformed packing on threads of
receiver-drier (4) coupling.
2. Install binary switch (2) and tighten to 108 lb-in (1220 Ncm).
3. Connect harness connector (1) to binary switch (2).
END OF WORK PACKAGE
0224 00-1
TM 9-2320-302-20
0224 00-2
TM 9-2320-302-20
AIR CONDITIONER LEAK TEST 0225 00
Inspection, Test
INITIAL SETUP

Leak detector, refrigerant (Item 22, WP 0236 00)
INSPECTION
WARNING
• Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Use 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 com-
pressed air. Combustible mixtures of air and R-134a may form, resulting in fire or explosion, which
could cause personal injury.
NOTE
• Refrigerant is odorless. As a result, all of it may leak away and not be noticed until system stops cool-
ing. All vehicle refrigerant systems lose some refrigerant depending on the condition of system. Higher
loss rates signal a need to locate and repair leaks.
• Leaks are most often found at the compressor hose connections and at various fittings and joints in sys-
tem. If unapproved replacement hoses are installed, refrigerant can be lost through hose permeation.
1. Visually inspect refrigerant system for air conditioning lubricant leakage and corrosion and damage to lines, hoses, and
other components.
2. Visually inspect lowest points of fittings, hoses, and lines for indication of lubricant leakage.
TEST
Use a leak detector in accordance with the manufacturer’s instruction manual and check for refrigerant leakage at hose
connections, fittings, and areas where leakage might occur. If leaks are indicated, notify Direct Support Maintenance of leak in
air conditioning system.
END OF WORK PACKAGE
0225 00-1
TM 9-2320-302-20
0225 00-2
TM 9-2320-302-20
AIR CONDITIONER COMPRESSOR MAGNETIC CLUTCH REPLACEMENT 0226 00
INITIAL SETUP

Holder, clutch (Item 17, WP 0236 00) Equipment Condition
Puller kit, universal (Item 27, WP 0236 00) Alternator belt removed (WP 0054 00)
REMOVAL
1. Using clutch holding tool to keep pulley from rotating, remove retaining bolt (1) and washer (2) from center of pulley
rotor assembly (3).
CAUTION
DO NOT try to remove pulley rotor assembly by prying or hammering. Failure to follow this caution could
result in equipment damage.
NOTE
Use a 5/8-11 bolt that is long enough to serve as clutch remover.
2. Install puller kit bolt in hub of pulley rotor assembly (3).
0226 00-1
TM 9-2320-302-20
AIR CONDITIONER COMPRESSOR MAGNETIC CLUTCH REPLACEMENT - CONTINUED 0226 00
REMOVAL - CONTINUED
3. Tighten puller kit bolt to remove pulley rotor assembly (3) from compressor shaft (4). Remove woodruff key (5) from
compressor shaft. Retain woodruff key for later use.
4. Remove field coil electrical lead (6).
5. Remove four bolts (7) and field coil assembly (8) from compressor (9).
5 9
6
7
2
4
1
8
INSTALLATION
1. Install field coil assembly (8) on compressor (9) with four bolts (7). Tighten bolts to 96 lb-in (1084 Ncm).
2. Install woodruff key (5) and pulley rotor assembly (3) on compressor shaft (4) taking care to properly align and seat
shaft and hub keyways.
3. Install washer (2) and retaining bolt (1) on pulley rotor assembly (3). Using clutch holding tool to keep pulley from
rotating, tighten retaining bolt to 20 lb-ft (27 Nm).
4. Turn pulley rotor assembly (3) by hand to ensure that assembly moves freely without interference with field coil assem-
bly (8).
5. Install field coil electrical lead (6).
6. Verify clutch engages when proper voltage is applied.
7. Install alternator belt (WP 0054 00).
END OF WORK PACKAGE
0226 00-2
TM 9-2320-302-20
M13 DECONTAMINATION KIT MOUNTING BRACKET REPLACEMENT 0227 00
INITIAL SETUP

TM 9-2320-302-10
Equipment Condition
Materials/Parts
Nut, self-locking (P/N MS51922-11) (2) Decontamination tank removed
REMOVAL
1. Open door of personal gear storage box (1).
2. Remove four self-locking nuts (2), eight washers (3), four cap screws (4), and M13 decontamination kit mounting
bracket (5) from side of personal gear storage box (1). Discard self-locking nuts.
3 1
4 5
INSTALLATION
1. Install M13 decontamination kit mounting bracket (5) on side of personal gear storage box (1) with four cap screws (4),
eight washers (3), and four new self-locking nuts (2).
2. Tighten four self-locking nuts (2) to 22 lb-ft (30 Nm).
3. Close door of personal gear storage box (1).
4. Install decontamination tank.
END OF WORK PACKAGE
0227 00-1
TM 9-2320-302-20
0227 00-2
TM 9-2320-302-20
GENERAL MAINTENANCE INSTRUCTIONS 0228 00
GENERAL
1. These general maintenance instructions contain general shop practices and specific methods you must be familiar with
to properly maintain the M915A3 Tractor Truck. You should read and understand these practices and methods before
performing any Unit Maintenance procedures.
2. Before beginning a task, find out how much repair, modification or replacement is needed to fix the equipment. Some-
times the reason for equipment failure can be seen right away and complete teardown is not necessary. Disassemble
equipment only as far as necessary to repair or replace damaged parts.
3. In some cases, a part may be damaged during removal. If the part appears to be good, and other parts behind it are not
defective, leave it in place and continue with the procedure. Here are a few simple rules:
a. Do not remove dowel pins or studs unless loose, bent, broken or otherwise damaged.
b. Do not remove bearings or bushings unless damaged. If you need to remove them to access parts behind, carefully
pull out bearings and bushings.
c. Replace all gaskets, lock washers, lock nuts, seals, cotter pins, and preformed packings.
4. All tags and forms attached to the equipment must be checked to learn the reason for removal of equipment from ser-
vice. Modification Work Orders (MWOs) and Technical Bulletins (TBs) must also be checked for equipment changes
and updates.
WORK SAFETY
1. Before beginning a procedure, think about the safety risks and hazards to yourself and to others. Wear protective gear
such as safety goggles or lenses, safety shoes, rubber apron or gloves.
2. Before beginning a procedure, ensure that the following conditions have been observed, unless otherwise specified:
a. Vehicle must be parked on level ground with parking brake applied and wheels blocked.
b. Transmission must be in N (Neutral).
c. Engine must be off.
d. Master battery switch must be in OFF position.
e. Components must be at operating temperature to be tested.
3. Immediately clean up spilled fluids to avoid slipping.
4. When lifting heavy parts, have someone help you. Ensure that lifting equipment or jack is working properly, that it
meets weight requirement of part being lifted, and that it is securely fastened to part.
5. Always use power tools carefully.
6. Observe all WARNINGs and CAUTIONS.
CLEANING INSTRUCTIONS
WARNING
Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and
damage equipment. To prevent this, refer to TM 9-247 for further instructions.
1. General. Cleaning instructions will be the same for the majority of parts and components which make up the truck. The
following applies to all cleaning operations:
a. Clean all parts before inspection, after repair, and before assembly.
b. Keep hands free of grease which can collect dust, dirt, and grit.
c. After cleaning, all parts should be covered or wrapped to protect them from dust and dirt. Parts that are subject to
rust should be lightly oiled after cleaning.
0228 00-1
TM 9-2320-302-20
GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED 0228 00
CLEANING INSTRUCTIONS - CONTINUED

2. Castings, Forgings, and Machined Metal Parts.
a. Clean inner and outer surfaces with detergent (Item 11, WP 0235 00) and dry with clean rags (Item 28, WP 0235
00).
b. Remove grease and accumulated deposits with a scrub brush.
WARNING
Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi
nel.
c. Clear all threaded holes with compressed air to remove dirt and cleaning fluids.
CAUTION
DO NOT wash oil seals, electrical cables, and flexible hoses with dry cleaning solvent or mineral spirits.
Serious damage or destruction of material will result.
3. Oil Seals, Electrical Cables, and Flexible Hoses. Wash oil seals, electrical cables, and flexible hoses with a solution of
detergent (Item 11, WP 0235 00) and water, and wipe dry with a clean rag (Item 28, WP 0235 00).
4. Bearings. Clean bearings in accordance with TM 9-214.
PRESERVATION OF PARTS
Unpainted metal parts that will not be installed immediately after cleaning may be covered with a thin coat of lubricat-
ing oil (Item 19, WP 0235 00).
PAINTING
1. On painted areas where paint has been removed, paint in accordance with procedures outlined in TM 43-0139 and TB
43-0209.
2. For camouflage painting instructions, refer to FM 5-20.
INSPECTION INSTRUCTIONS
NOTE
All damaged areas should be marked for repair or replacement.
1. All components and parts must be carefully checked to determine if they are serviceable for use, can be repaired or must
be scrapped.
2. Inspect drilled and tapped (threaded) holes for the following:
a. Wear, distortion, cracks, and any other damage in or around holes.
b. Threaded areas for wear distortion (stretching) and evidence of cross-threading.
3. Inspect metal lines, flexible lines or hoses, and metal fittings and connectors for the following:
a. Metal lines for sharp kinks, cracks, bad bends, and dents.
b. Flexible lines or hoses for fraying, evidence of leakage, and loose metal fittings or connectors.
c. Metal fittings and connectors for thread damage and worn or rounded hex heads.
0228 00-2
TM 9-2320-302-20
INSPECTION INSTRUCTIONS - CONTINUED
4. Inspect castings, forgings, and machined metal parts for the following:
a. Machined surfaces for nicks, burrs, raised metal wear, and other damage.
b. Inner and outer surfaces for breaks and cracks.
5. Inspect bearings in accordance with TM 9-214.
DISASSEMBLY AND ASSEMBLY INSTRUCTIONS
1. Keep major components together whenever possible and practical.

2. Tag hoses, electrical wires, cables, and harnesses to identify them and aid during installation.
3. Keep related parts together for identification purposes.

4. Temporarily install attaching hardware such as screws, bolts, washers, and nuts to prevent loss.
5. Only disassemble to the point of the problem.
6. Ensure that parts are clean and lubricated before assembly.
REPAIR INSTRUCTIONS
CAUTION
Before welding, the following components must be disconnected: DDEC ECU, Transmission ECU, ABS
ECU, CWS ECU, and batteries. If welding on a trailer, it must be uncoupled from tractor truck. Failure to
follow this caution may damage electronic components.
1. Repair castings, forgings, and machined parts using the following instructions:
a. Repair minor cracked castings or forgings in accordance with TM 9-237.
b. Repair minor damage to machined surfaces with an abrasive cloth dipped in detergent (Item 11, WP 0235 00).
c. Replace any deeply nicked machined surface that could affect the assembly operation.
d. Repair minor damage to threaded cap screw holes with thread tap of same size to prevent cutting oversize.
2. After repair, thoroughly clean all parts to prevent dirt, metal chips or other foreign material from entering any working
parts.
LUBRICATION INSTRUCTIONS
NOTE
Refer to TM 9-2320-302-10 and to Unit PMCS (WP 0021 00) for detailed, illustrated instructions on proper
lubrication. Some general practices to remember:
a. Use the correct lubricant.

b. Keep lubricants clean.
c. Clean all fittings prior to lubrication.
d. Lubricate clean disassembled and new parts to prevent rust.
0228 00-3
TM 9-2320-302-20
APPLICATION OF ADHESIVES AND SEALING COMPOUNDS
WARNING
1. General. Adhesives are recommended in some tasks to ensure and strengthen seals. Sealing compounds are used to seal
parts against moisture. The following information describes their correct use and application.
2. Adhesive. Adhesive provides a seal against leakage and a resistance to loosening when used in the assembly of
threaded, slip-fitted or press-fitting parts. Always use grade of adhesive specified and never use when other retaining
means are provided, such as lockwires, lock washers, lockplates, and fasteners.
3. Sealing Compound.
a. Anytime a seal is broken, the part must be thoroughly cleaned to remove any remaining sealing compound and
dirt.
b. Thoroughly clean surface before applying sealing compound.
c. When applying sealing compound, ensure that the area is completely covered. Press sealing compound into and
around parts as necessary.
d. Sealing compound will set in 15-30 minutes depending on temperature and humidity.
STANDARD TOOL REQUIREMENTS
1. The following are general practices regarding the use of tools:
a. Always use the proper tool kit and tools for the procedure being performed.
b. Ensure that tools are clean and lubricated to reduce wear and to prevent rust.
c. Keep track of tools. Do not be careless with them.
d. Return tools to toolbox when finished with repair or maintenance.
e. Return toolboxes and tools to tool storage when not in use.
f. Inventory tools before and after each use.
2. Some maintenance tasks may require special or fabricated tools. The “Initial Setup” of the procedure will specify any
special or fabricated tools needed to perform that procedure. Use these special tools only for the maintenance procedures
for which they are designed or called out. If you are unfamiliar with a required tool, see your supervisor.
TAGGING WIRES AND HOSES
1. Use marker tags (Item 31, WP 0235 00) to identify all electrical wires, fuel, oil, and coolant lines, and any other parts
which may be hard to identify or replace later. Fasten tags to parts during removal by wrapping wire fasteners around or
through parts and twisting ends together. Position tags to be out of the way during cleaning, inspection, and repair. Mark
tags with a pencil, pen or marker.
2. Whenever possible, identify electrical wires with the number of the terminal or wire to which it connects. If no markings
can be found, tag both wires or wire and terminal, and use the same identifying mark for both. If you cannot tag a wire
because it must fit through a small hole or you cannot reach it, write down the description of the wire and the point to
which it connects or draw a simple diagram on paper. Be sure to write down enough information so you will be able to
properly connect the wires during assembly. If you need to identify a loose wire, look for identifying number near end of
the wire, stamped on a permanent metal tag. Compare the number to wire numbers on the appropriate electrical sche-
matic.
0228 00-4
TM 9-2320-302-20
TAGGING WIRES AND HOSES - CONTINUED
3. Identify fuel, oil, and coolant lines when you are taking off more than one line at the same time. Mark tags with points to
which lines and hoses must be connected. If it is not obvious which end of a line goes where, tag each end of the line.
4. Identify and tag other parts as required by name and installed location.
SOLDERING
CAUTION
Use low wattage soldering gun when soldering electrical wires, connectors, terminal lugs, and receptacles.
High wattage soldering guns may damage parts by overheating.
1. Solder connection must be bright and clean before soldering. Remove dirt and grease with detergent (Item 11, WP 0235
00). Solder used must be of lead-tin alloy, rosin core (Item 29, WP 0235 00) with soldering flux (Item 12, WP 0235 00).
All wires, parts, and soldering gun (Item 30, WP 0236 00) must be tinned for good connection and maximum transfer of
heat.
2. To prevent overheating damage to electrical parts when soldering and unsoldering connections, hold bare wire, lead or
terminal lug close to soldering point with long roundnose pliers. Pliers act as heat sink and absorb excess heat.
3. Clean all solder joints with a scrub brush and electrical parts with detergent (Item 11, WP 0235 00) after soldering to get
a bright, clean surface.
HEAT SHRINKABLE TUBING
NOTE
Further information on shrink wrap usage and sources of supply can be found in WP 0119 00.
Use heat shrinkable tubing to insulate soldered and crimped electrical connections as follows:
a. Cut desired length of new heat shrinkable tubing twice the diameter of the connection to be covered.
b. Slide the heat shrinkable tubing onto the wire and out of the way before making electrical connection.
c. After making electrical connection, slide heat shrinkable tubing into place over electrical connection.
WARNING
DO NOT touch heat shrinkable tubing for at least 30 seconds after heating. Heat shrinkable tubing is hot and
will burn you.
d. Hold heat gun (Item 16, WP 0236 00) 4-5 in (10.2-12.7 cm) away from heat shrinkable tubing and apply heat for
approximately 30 seconds. Stop applying heat as soon as heat shrinkable tubing forms to the shape of the electrical
connection.
ELECTRICAL GROUND POINTS
Many electrical problems are the result of poor ground connections. You can ensure that ground connections are good
by performing the following steps:
0228 00-5
TM 9-2320-302-20
ELECTRICAL GROUND POINTS - CONTINUED
WARNING
Although master battery switch must be on and battery ground cable connected in order to test electrical cir-
cuit voltage, turn off master battery switch or disconnect battery ground cable before performing resistance
tests or replacing parts. This will prevent shock to personnel, and damage to parts and equipment.
a. Remove hardware connecting ground cable terminal lug to ground point.

b. Clean mounting hardware, ground cable terminal lugs, and ground point with detergent (Item 11, WP 0235 00) and
scrub brush.
c. Remove any rust with wire brush and crocus cloth.
d. Look for cracks, loose terminal lugs, and stripped threads. Replace any defective parts.
e. Install hardware connecting ground cable terminal lug to ground point. Ensure that all hardware is tight.
LINES AND PORTS
To keep dirt from contaminating fluid systems when removing and installing fuel, oil, and coolant lines, perform the fol-
lowing steps:
a. Clean fittings and surrounding area before disconnecting lines.
b. Cover, cap, plug or tape lines and ports after disconnecting lines. When these are not available, use hand-carved
wooden plugs, clean rags (Item 28, WP 0235 00), duct tape (Item 33, WP 0235 00) or other similar materials to pre-
vent dirt from entering system.
c. Ensure that new and used parts are clean before installing.
d. Wait to remove cover, cap, plug or tape from lines and ports until just before installing lines.
TUBES AND COMPRESSION FITTINGS
1. Tubes with inverted nuts and compression fittings are designed for one time assembly. Once assembled, they must be
replaced as a unit if any parts are found defective. Used parts may not seal properly when used with new ones.
2. Used tube assemblies in good condition can be installed to their original location without leaking.
3. Assemble new tubes, compression sleeves, and inverted nuts as follows:
a. Slide inverted nut onto end of tube.
b. Slide compression sleeve onto end of tube.
c. Repeat previous two steps for other end of tube as required.
COMPRESSION
TUBE SLEEVE
INVERTED
NUT
4. Install new tube assemblies as follows:

a. Insert end of tube as far as it will go into compression fitting to which tube is being installed.
0228 00-6
TM 9-2320-302-20
TUBES AND COMPRESSION FITTINGS - CONTINUED

b. Twist inverted nut into compression fitting and tighten inverted nut against compression sleeve with open-end
wrench. Compression sleeve will clamp down around tube and conform to internal surface of compression fitting
and inverted nut.
c. Repeat previous two steps for other end of tube as required.
COMPRESSION
SLEEVE
COMPRESSION
FITTING
INVERTED
NUT
TUBE
LOCKWIRE
1. Always use nonelectrical wire (Item 34, WP 0235 00).
2. Drilled head screws and bolts usually do not require lockwiring if they are installed with self-locking nuts or lock wash-
ers.
3. Three screws or bolts are the maximum number that may be lockwired in a series when they are spaced 4-6 in (10.2-15.2
cm) apart. The maximum number of closely spaced multiple groups of screws or bolts to be lockwired is limited to the
number of units that can be lockwired with a 24 in (61 cm) length of wire.
4. Do not secure screws, bolts or fittings which are spaced more than 6 in (15.2 cm) apart. Lockwire these fasteners to tie
points 6 in (15.2 cm) or less away.
5. Lockwire parts so that tension will be on lockwire when parts tend to loosen. Lockwire should be installed and twisted
tight so that loop around head stays down and does not come up over head of screw or bolt. This does not apply to cas-
tellated nuts when slot is close to top of nuts; wire is more secure when made to pass along the side of stud. Ensure that
lockwire is tight but not overstressed.
6. Make pigtail of 1/4-1/2 in (6.4-12.7 mm) at end of lockwire. Bend pigtail down so it will not become a snag.
7. When lockwiring castellated nuts, tighten castellated nut to low side of torque range, then continue tightening until slot
lines up with hole.
8. In blind, tapped hole application of bolts, castellated nuts or studs, lockwire as illustrated.
0228 00-7
TM 9-2320-302-20
LOCKWIRE - CONTINUED
SMALL SCREWS IN CLOSELY SPACED,

EXTERNAL RETAINER RING:
CLOSED GEOMETRICAL PATTERN: SINGLE FASTENER SINGLE WIRE METHOD
SINGLE WIRE METHOD APPLICATION:
DOUBLE TWIST METHOD
CASTELLATED NUTS ON UNDRILLED STUDS: MULTIPLE FASTENER APPLICATION:

DOUBLE TWIST METHOD DOUBLE TWIST METHOD
FLUID DISPOSAL
Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit.
MULTIMETER
1. General. The digital multimeter (Item 24, WP 0236 00) is used to troubleshoot the electrical system of the vehicle. The
multimeter’s ohms scale is used to test for continuity, shorts, and resistance and the voltmeter scale is used to test volt-
age levels at any point in the electrical system.
2. Continuity Tests. Continuity tests are performed to check for breaks in a circuit (such as a fuse, switch, light bulb or
electrical cable).
NOTE
If digital readout will not zero properly, replace batteries and repeat zeroing procedure. If digital readout will
not zero after batteries have been replaced, notify your supervisor.
a. Zero the Multimeter.
(1) Set multimeter ON/OFF switch (1) to ON position.
(2) Press OHMS FUNCTION switch (2).
(3) Press LOWEST VOLTAGE/OHMS selector switch (3).
(4) Touch black and red probes (4 and 5) together and check for a zero reading on digital readout (6).
0228 00-8
TM 9-2320-302-20
MULTIMETER - CONTINUED
6 2
1
3
5
4
CAUTION
Before performing a continuity test, always turn master battery switch to OFF position and disconnect cir-
cuit to be tested. Failure to follow this caution may damage multimeter.
b. Testing for Continuity.
(1) Zero multimeter.
(2) Connect black and red probes (4 and 5) to both terminals of circuit being tested.
(3) Read digital readout (6) and interpret results as follows:
(a) If digital readout (6) indicates 0 (zero), circuit has continuity.
(b) If digital readout (6) indicates resistance, circuit is open.
0228 00-9
TM 9-2320-302-20
TESTING AN ELECTRICAL CABLE

TESTING A BULB
TESTING A SWITCH
0228 00-10
TM 9-2320-302-20
CAUTION
c. Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be connected have metal-to-
metal contact with each other. A short also occurs when a circuit that should not touch ground has metal-to-metal
contact with ground.
RED BLACK
ORANGE
BLUE TESTING FOR SHORTS

(2) Connect black probe (4) to one circuit and red probe (5) to either a ground or another circuit.
(3) Read digital readout (6) and interpret results as follows:
(a) If digital readout (6) indicates 0 (zero), circuits are shorted or circuit is grounded if testing to ground.
(b) If digital readout (6) does not indicate 0 (zero), circuits are not shorted.
(c) If digital readout (6) jumps or flickers, circuits are shorted or grounded intermittently.
5
4
0228 00-11
TM 9-2320-302-20
CAUTION
d. Testing for Resistance. Allowable resistance readings depend on circuit being tested. Refer to the particular sec-
tion dealing with that circuit or component for allowable readings.
(2) Press OHMS FUNCTION switch (2).
(3) Press LOWEST VOLTAGE/OHMS selector switch (3). If test calls for ohms range other than RX1, set
RANGE SELECTOR switch (7) to required range.
(4) Connect black and red probes (4 and 5) across circuit to be tested.
(5) Read digital readout (6) and interpret results as circuit resistance.
3. Measuring DC Voltage.
a. Set multimeter ON/OFF switch (1) to ON position.
b. Press VOLTS FUNCTION switch (8).
c. Set AC/DC selector switch (9) to DC.
d. Select and press LOWEST VOLTAGE/OHMS selector switch (3) for voltage range higher than volts to be mea-
sured.
e. Connect red probe (5) to positive (+) side of circuit and black probe (4) to negative (-) side of circuit.
f. Read digital readout (6) and interpret results as DC voltage in circuit being tested.
2 9
8
6
5
4 3
0228 00-12
TM 9-2320-302-20
ELECTRICAL REPAIR
For complete instructions on the repair of standard military and commercial connectors and general information on
splicing, refer to WP 0119 00.
END OF WORK PACKAGE
0228 00-13
TM 9-2320-302-20
0228 00-14
TM 9-2320-302-20
ARCTIC HEATER REPLACEMENT (WEBASTO) 0229 00
Arctic Heater Removal, Arctic Heater Fuel Pump Removal, Arctic Heater Installation, Arctic Heater Fuel Pump Installa-
tion
INITIAL SETUP

Two
Equipment Condition
Materials/Parts
Tags, marker (Item 31, WP 0235 00) Cooling system drained (WP 0041 00)
ARCTIC HEATER REMOVAL
WARNING
1. At top of transmission, tag and disconnect two connectors (1 and 2) of arctic heater harness (3) from connectors of wir-
ing harness (4).
1
4
0229 00-1
TM 9-2320-302-20
ARCTIC HEATER REPLACEMENT (WEBASTO) - CONTINUED 0229 00
ARCTIC HEATER REMOVAL - CONTINUED

2. At left-rear of cab, loosen clamp and disconnect exhaust tube (5) from exhaust port (6) of arctic heater (7).
3. While supporting arctic heater (7), remove four nuts and screws holding arctic heater mounting bracket to cab floor.
4. Disconnect connector (8) of arctic heater (7) from connector of wiring harness (9).
NOTE
Have suitable container available to catch coolant draining from hoses.
5. Loosen clamp and disconnect coolant hose (10) from coolant pump (11) of arctic heater (7).
6. Loosen clamp and disconnect coolant hose (12) from coolant outlet port (13).
7. Loosen clamp and disconnect fuel supply hose from fuel inlet (14).
8. Remove arctic heater (7) assembly from vehicle.
7
9 8
12
13 14 11
10
0229 00-2
TM 9-2320-302-20
ARCTIC HEATER REMOVAL - CONTINUED

9. Remove six nuts (15), screws (16) and mounting bracket (17) from adapter bracket (18).
10. Remove three screws (19), washers (20), and adapter bracket (18) from arctic heater (7).
15
17
18 19
16 20
0229 00-3
TM 9-2320-302-20
ARCTIC HEATER FUEL PUMP REMOVAL
WARNING
1. Remove nut (21), washer (22), screw (23), and clamp (24) from arctic heater fuel pump (25).
2. Disconnect connector (26) of arctic heater fuel pump (25) from wiring harness (27).
NOTE
• Have a suitable container available to catch fuel draining from hoses.
• Note position of pump for installation.
• Perform step 3 at each end of arctic heater fuel pump.
3. Loosen clamp (28) and disconnect fuel hose (29) from arctic heater fuel pump (25).
4. Remove arctic heater fuel pump (25) from vehicle.
28 29
24
21,22,23
27
25
26
0229 00-4
TM 9-2320-302-20
ARCTIC HEATER INSTALLATION
WARNING
1. Install adapter bracket (18) to arctic heater (7) with three washers (20) and screws (19).
2. Install mounting bracket (17) to adapter bracket (18) with six screws (16) and nuts (15).
15
17
18 19
16 20
0229 00-5
TM 9-2320-302-20
ARCTIC HEATER INSTALLATION - CONTINUED

1. Position arctic heater (7) assembly to vehicle.
2. While supporting arctic heater (7), connect fuel supply hose to fuel inlet (14) and tighten clamp.
3. Connect coolant hose (12) to coolant outlet port (13) and tighten clamp.
4. Connect coolant hose (10) to coolant pump (11) of arctic heater (7) and tighten clamp.
5. Connect connector (8) of arctic heater (7) to connector of wiring harness (9).
6. Install mounting bracket of arctic heater to cab floor with four screws and nuts.
7. Install exhaust tube (5) to exhaust port (6) of arctic heater (7) and tighten clamp.
7
9 8
12
13 14 11 10
0229 00-6
TM 9-2320-302-20
ARCTIC HEATER INSTALLATION - CONTINUED

8. At top of transmission, connect two connectors (1 and 2) of arctic heater harness (3) to connectors of wiring harness (4).
4
3
0229 00-7
TM 9-2320-302-20
ARCTIC HEATER FUEL PUMP INSTALLATION
WARNING
1. Position arctic heater fuel pump (25) to vehicle.
NOTE
Perform step 2 at each end of arctic heater fuel pump.
2. Connect fuel hose (29) to arctic heater fuel pump (25). Tighten clamp (28).
3. Connect connector (26) of arctic heater fuel pump (25) to wiring harness (27).
4. Install arctic heater fuel pump (25) with clamp (24), screw (23), washer (22), and nut (21).
28 29
24
21,22,23
27
25
26
0229 00-8
TM 9-2320-302-20
ARCTIC HEATER FUEL PUMP INSTALLATION - CONTINUED

END OF WORK PACKAGE
0229 00-9
TM 9-2320-302-20
0229 00-10
TM 9-2320-302-20
ILLUSTRATED LIST OF MANUFACTURED ITEMS 0230 00
SCOPE
1. This work package includes complete instructions for making items authorized to be manufactured or fabricated at Unit
Maintenance.
2. A Part Number Index in alphanumeric order is provided in Table 1 for cross-referencing the part number of the item to
be manufactured to Table 2, which covers fabrication criteria.
3. All bulk materials needed for manufacture of an item are listed by part number or specification number.
PART NUMBER INDEX
Table 1. Part Number Index.
TABLE
PART NUMBER NAME NUMBER
FITC-02 Cable, Special Purpose 2
NT10010-BKX13 Tube, Nylon 2
PFT-4A Tubing, Nonmetellic 2
PFT-4A-BLK-100X13 Tube, Nylon 2
PFT-6B-BLK-100X6 Tube, Nylon 2
0230 00-1
TM 9-2320-302-20
Table 1. Part Number Index - Continued.
TABLE
P52-6738 Coupling, Assembly 2
04-9323-013 Pipe, Flex 2
05-09562-005 Hose, Neoprene 2
05-09562-006 Hose, Straight 2
05-09564-008 Hose, Neoprene 2
05-12538-036 Hose 2
05-12539-043 Hose, Straight 2
05-15224-004 Hose, Rubber 2
06-18131-000 Liner, Plywood 2
12-13366-040 Tube, Nylon 2
12-13367-045 Tube, Nylon 2
12-13367-060 Tube, Nylon 2
12-13367-105 Tube, Nylon 2
12-13367-142 Tube, Nylon 2
12-13367-200 Tube, Nylon 2
0230 00-2
TM 9-2320-302-20
TABLE
12-13370-037 Tube, Nylon 2
12-13371-037 Tube, Nylon 2
12-13374-006 Tube, Nylon 2
12-13472-019 Tube, Nylon 2
12-13473-040 Tube, Nylon 2
18-11197-001X10 Trim, Edging 2
22-21952-004 Hose 2
22-21952-018 Hose 2
22-21952-020 Hose 2
22-21952-048 Hose 2
22-21952-052 Hose 2
22-21952-063 Hose, Heater 2
22-28607-018 Hose, Heater 2
22-28607-061 Hose, Rubber 2
22-30167-030 Hose, Heater 2
22-30168-003 Hose, Heater 2
22-30168-034 Hose, Heater 2
22-35191-010 Seal 2
22-35281-016 Hose, Rubber 2
22-35281-030 Hose, Rubber 2
22-35282-025 Hose, Rubber 2
22-35282-090 Hose, Rubber 2
22-35282-135 Hose, Rubber 2
23323FX-48 Hose, Nonmetallic 2
350359X0.3 Hose, Coolant 2
4246-0410X5 Tubing, Nylon 2
47336AX Hose, Nonmetallic 2
47338AX Hose, Nonmetallic 2
48-00050-206X6 Tape, Foam 2
48-00081-038X24 Hose 2
48-00099-150X3 Hose 2
48-00100-010X5 Tubing, Nylon 2
48-00100-010X10 Tubing, Nylon 2
48-00100-010X15 Tubing, Nylon 2
0230 00-3
TM 9-2320-302-20
TABLE
48-00100-812X15 Tubing, Nylon 2
48-00100-812X18 Tubing, Nylon 2
48-00100-814X16 Tubing, Nylon 2
48-00100-815X15 Tubing, Nylon 2
48-00100-816X6 Tubing, Nylon 2
48-00100-816X18 Tubing, Nylon 2
48-00100-816X48 Tubing, Nylon 2
48-00100-829X12 Tubing, Nylon 2
48-00100-829X36 Tubing, Nylon 2
48-00100-829X56 Tubing, Nylon 2
48-00101-010X7 Tube, Nylon 2
48-00101-010X48 Hose 2
48-00101-010X72 Hose 2
48-00101-010X96 Hose 2
48-00101-010X144 Hose 2
48-00101-010X180 Hose 2
48-00101-010X264 Hose 2
48-00101-020X24 Hose, Nonmetallic 2
48-00101-022X1 Tube, Nylon 2
48-00101-030X10 Tube, Nylon 2
48-00121-016X30 Hose 2
48-00121-016X53 Hose 2
48-02014-008X48 Hose 2
48-02015-012X24 Hose, Rubber 2
48-02217-025X5 Conduit, Nonmetallic 2
48-02217-025X36 Tubing, Nonmetallic 2
48-02217-050X3 Conduit 2
48-02217-050X8 Conduit 2
48-02217-062X3 Conduit 2
48-02217-062X105 Conduit 2
48-02217-075X57.08 Conduit 2
48-02218-050X105 Conduit 2
48-02218-075X12 Conduit 2
0230 00-4
TM 9-2320-302-20
TABLE
48-02454-106X27 Tape, Foam 2
48-02454-206X12 Tape, Ureth Foam 2
48-02471-001X8 Seal, Door 2
48-02471-001X55 Seal 2
5156170 Hose 2
68240R-276 Conduit 2
77620-7.5 Hose 2
Table 2. Manufactured Items.
MANUFACTURED
PART NUMBER NAME FROM DESCRIPTION
FITC-02 CABLE, SPECIAL M83420/1-005 144 IN LONG

PURPOSE
NT10010-BKX13 TUBE, NYLON 3250-1010 40 IN LONG
PFT-4A TUBING, PFT-4A BLACKX1300 CUT TO FIT
NONMETALLIC
PFT-4A-BLK-100X13 TUBE, NYLON PFT-4A BLACKX1300 13 IN LONG
PFT-6B-BLK-100X6 TUBE, NYLON 3250-061 6 IN LONG
PVT-6B-BLK-100X15 TUBE, NYLON 3250-061 15 IN LONG
0230 00-5
TM 9-2320-302-20
Table 2. Manufactured Items - Continued.
MANUFACTURED

PFT-8B-BLK-100X1 TUBE, NYLON C608-100BLK 15 IN LONG
PFT-8B-BLK-100X36 HOSE, NONME. C608-100BLK 36 IN LONG
P52-6738 COUPLING ASSEMBLY 24032 CUT TO FIT
04-9323-013 PIPE, FLEX R342S5 25 13 IN LONG
05-09562-005 HOSE, NEOPRENE 24244 5 IN LONG
05-09562-006 HOSE, STRAIGHT 24240 6 IN LONG
0230 00-6
TM 9-2320-302-20
MANUFACTURED
05-09564-008 HOSE, NEOPRENE 24248 8 IN LONG

05-12538-036 HOSE, STRAIGHT 4230-0174 36 IN LONG
05-12539-043 HOSE, RUBBER 28430 43 IN LONG
05-15224-004 LINER, PLYWOOD 24228 4 IN LONG
06-18131-000 TUBE, NYLON CS122-56 GRADE CD 7X7.5 IN
INTERIOR TYPE
12-13366-040 TUBE, NYLON PFT-4A BLACKX1300 40 IN LONG
12-13367-045 TUBE, NYLON 3250-061 45 IN LONG
18-11197-001X10 TRIM, EDGING 48-02188-001 10 FT LONG
22-21952-004 HOSE 4230-0002 4 IN LONG
22-21952-018 HOSE 4230-0002 18 IN LONG
22-21952-020 HOSE 4230-0002 20 IN LONG
22-21952-048 HOSE 4230-0002 48 IN LONG
22-21952-052 HOSE 4230-0002 52 IN LONG
22-21952-063 HOSE, HEATER 4230-0002 63 IN LONG
22-28607-018 HOSE, HEATER 350357 18 IN LONG
22-28607-061 HOSE, RUBBER MS521301A203R 6 IN LONG
22-30167-030 HOSE, HEATER 4230NX-5/8 30 IN LONG
22-30168-003 HOSE, HEATER 4230NX-3/4 3 FT LONG
22-30168-034 HOSE, HEATER 4230NX-3/4 34 IN LONG
22-35191-010 SEAL 48-02412-525 CUT TO FIT
0230 00-7
TM 9-2320-302-20
MANUFACTURED

23323FX-48 HOSE, NONMETALLIC 3250-061 48 IN LONG
350359X0.3 HOSE, COOLANT 4230-0174 0.3 FT LONG
4246-0410X5 TUBING, NYLON PFT-4A BLACKX1300 5 FT LONG
47336AX HOSE, NONMETALLIC FC350-06 12 IN LONG
47338AX HOSE, NONMETALLIC FC350-10 19 IN LONG
48-00050-206X6 TAPE, FOAM V532X 3/4 INX200FT 6 FT LONG
48-00081-038X24 HOSE 28430 24 IN LONG
48-00099-150X3 HOSE 24224 3 IN LONG
48-00100-010X5 TUBING, NYLON PFT-4A BLACKX1300 5 FT LONG
48-00100-812X15 TUBING, NYLON C602 15 IN LONG
48-00100-829X36 TUBING, 4246-02277 36 IN LONG
NONMETALLIC
48-00101-010X7 TUBE, NYLON 3250-061 7 FT LONG
48-00101-010X48 HOSE PFT-6B-BLK-100 48 IN LONG
0230 00-8
TM 9-2320-302-20
MANUFACTURED

48-00101-020X24 HOSE, NONMETALLIC C608-100BLK 24 IN LONG
48-00101-020X96 NOSE, NONMETALLIC C608-100BLK 96 IN LONG
48-00101-022X1 TUBE, NYLON 48-00101-022 1 FT LONG
48-00101-030X10 TUBE, NYLON 3250-1010 10 FT LONG
48-00101-030X108 HOSE, NONMETALLIC 3250-1010 108 IN LONG
48-00121-016X30 HOSE 48-00121-016 30 IN LONG
48-00121-016X53 HOSE 48-00121-016 53. IN LONG
48-02014-008X48 HOSE 4251-0125 48 FT LONG
48-02015-012X24 HOSE, RUBBER 881-12 24 IN LONG
48-02217-025X5 CONDUIT, 64498R 5 FT LONG
NONMETALLIC
48-02217-025X36 TUBING, 64498R 36 IN LONG
NONMETALLIC
48-02217-050X3 CONDUIT 68237R 3 FT LONG
48-02217-050X8 CONDUIT 68237R 8 IN LONG
48-02217-062X3 CONDUIT 68237R 3 FT LONG
48-02217-062X105 CONDUIT 48-02218-050 105 IN LONG
48-02217-075X57.08 CONDUIT 68240R 57.08 IN LONG
48-02218-050X105 CONDUIT 48-02218-050 105 IN LONG
48-02218-075X12 CONDUIT 48-02218-075 12 IN LONG
48-02454-106X27 TAPE, FOAM 4516 5/8 in 27 IN LONG
48-02454-206X12 TAPE, URETH FOAM V4062 12 FT LONG
48-02471-001X8 SEAL, DOOR 48-02471-001 8 FT LONG
48-02471-001X55 SEAL 48-02471-001 5.5 FT LONG
5156170 HOSE MS521301A206R 2.5 IN LONG
68240R-276 CONDUIT 68240R 276 IN LONG
77620-7.5 HOSE 77551 7.5 IN LONG
0230 00-9
TM 9-2320-302-20

MANUFACTURED
AUTOMATIC SLACK
ADJUSTER
INSTALLATION
TEMPLATE
0230 00-10
TM 9-2320-302-20
TORQUE LIMITS 0231 00
SCOPE
This work package lists standard torque values and provides general information for applying torque. Special torque val-
ues and tightening sequences are indicated in the maintenance procedures for applicable components.
GENERAL
1. Always use torque values listed in Table 1 when a maintenance procedure does not give a specific torque value.
2. Unless otherwise indicated, standard torque tolerance shall be ±10%.
3. Torque values listed are based on clean, dry threads. Reduce torque by 10% when engine oil is used as a lubricant.
Reduce torque by 20% if new plated cap screws are used.
4. Cap screws threaded into aluminum may require reductions in torque of 30% or more of Grade 5 cap screw torque. Cap
crew threaded into aluminum must also attain two cap screw diameters of thread engagement.
5. If the maintenance procedures do not specify a tightening order, use the following guides:
a. Unless otherwise specified, lubricate threads of fasteners with oil (OE/HDO-10 or OEA).
b. When tightening fasteners above 30 lb-ft (41 Nm), use the torque pattern but only tighten to 70 percent of final
value (multiply final value by 0.7). Repeat pattern until final value is reached.
c. Tighten circular patterns using circular torque pattern. Tighten straight patterns using straight torque pattern.
CAUTION
If replacement cap screws are of higher grade than originally supplied, use torque specifications for the orig-
inal. This will prevent equipment damage due to overtorquing.
0231 00-1
TM 9-2320-302-20
Table 1. Torque Limits.
CURRENT USAGE MUCH USED MUCH USED USED AT TIMES USED AT TIMES
QUALITY OF INDETERMINATE MINIMUM MEDIUM BEST

MATERIAL COMMERCIAL COMMERCIAL COMMERCIAL
SAE Grade Number 1 or 2 5 6 or 7 8
Cap Screw Head

Markings
Manufacturer’s
marks may vary
These are all
SAE Grade 5
(3 line)
CAP SCREW BODY SIZE TORQUE TORQUE TORQUE TORQUE
INCHES - THREAD LB-FT (NM) LB-FT (NM) LB-FT (NM) LB-FT (NM)
1/4 20 5 (7) 8 (11) 10 (14) 12 (16)
28 6 (8) 10 (14) 14 (19)
5/16 18 11 (15) 17 (23) 19 (26) 24 (33)
24 13 (18) 19 (26) 27 (37)
3/8 16 18 (24) 31 (42) 34 (46) 44 (60)
24 20 (27) 35 (47) 49 (66)
7/16 14 28 (38) 49 (66) 55 (75) 70 (95)
20 30 (41) 55 (75) 78 (106)
1/2 13 39 (53) 75 (102) 85 (115) 105 (142)
20 41 (56) 85 (115) 120 (163)
9/16 12 51 (69) 110 (149) 120 (163) 155 (210)
18 55 (75) 120 (163) 170 (231)
5/8 11 83 (113) 150 (203) 167 (226) 210 (285)
18 95 (129) 170 (231) 240 (325)
3/4 10 105 (142) 270 (366) 280 (380) 375 (508)
16 115 (156) 295 (400) 420 (569)
7/8 9 160 (217) 395 (536) 440 (597) 605 (820)
14 175 (237) 435 (590) 675 (915)
1 8 235 (319) 590 (800) 660 (895) 910 (1234)
14 250 (339) 660 (895) 990 (1342)
0231 00-2
TM 9-2320-302-20
CHAPTER 4
SUPPORTING INFORMATION
TM 9-2320-302-20

TM 9-2320-302-20
REFERENCES 0232 00
SCOPE
This work package lists all forms, field manuals, technical bulletins, technical manuals, and other publications refer-
enced in this manual and which apply to Unit Maintenance of the M915A3 Line Haul Tractor Truck.
PUBLICATIONS INDEXES
The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to
material covered in this technical manual.
Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Pam 25-30
Functional User’s Manual for the Army Maintenance Management System . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Pam 738-750
U.S. Army Equipment Index of Modification Work Orders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Pam 750-10
FORMS
Refer to DA Pam 738-750, The Army Maintenance Management System (TAMMS), for instructions on the use of main-
tenance forms.
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404
Equipment Log Assembly (Records) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408
Maintenance Request Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407
Preventive Maintenance Schedule and Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 314
Processing and Deprocessing Record for Shipment, Storage and Issue of Vehicles and Spare Engines . . . . . . . DD Form 1397
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368
Recommended Changes to Equipment Technical Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2
Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
Report of Discrepancy (ROD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 364
FIELD MANUALS
Camouflage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-20
Operation and Maintenance of Ordnance Material in Extreme Cold Weather (0°F to -65°F) . . . . . . . . . . . . . . . . . . . .FM 9-207
TECHNICAL BULLETINS AND SUPPLY BULLETINS
Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment,

and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209
Corrosion Prevention and Control Including Rustproofing Procedures for Tactical Vehicles and Trailers . . . . . . . . TB 43-0213
Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB SIG 222
Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems. . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651
Warranty Bulletin for M915A3 Truck Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2320-302-15
0232 00-1
TM 9-2320-302-20
REFERENCES - CONTINUED 0232 00
TECHNICAL MANUALS
Administrative Storage of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 740-90-1
Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-254
Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214
Materials Used for Cleaning, Preserving, Abrading and Cementing Ordnance
Materiel and Related Materials, Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247
Operator’s and Organizational Maintenance Manual Including Repair
Parts and Special Tool List for Decontaminating Apparatus, Portable . . . . . . . . . . . . . . . . . . . TM 3-4230-214-12&P
Operator’s, Unit, Direct Support and General Maintenance Manual for
Care, Maintenance, Repair and Inspection of Pneumatic Tires and Inner Tubes . . . . . . . . . . . . . . . TM 9-2610-200-14
Operator’s, Organizational, Direct Support, and General Support Maintenance
Manual for Lead-acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14
Operator’s Manual for M915A3 Tractor Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-302-10
Operator’s Manual for Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237
Painting Instruction for Field Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139
Preservation, Packaging, and Packing of Military Supplies and Equipment . . . . . . . . . . . . . . . . TM 38-230-1 & TM 38-230-2
Procedures for Destruction of Tank-automotive Equipment to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-6
Repair Parts and Special Tools Lists for M915A3 Tractor Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-302-24P
Use of Antifreeze Solutions, Antifreeze Extender, Cleaning Compounds, and
Test Kit in Engine Cooling Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-651
OTHER PUBLICATIONS
Abbreviations for Use on Drawings and in Specifications, Standards, and
Technical Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-12D
Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100
Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items . . . . . . . . . . . . . . . . . . . . . .CTA 50-970
Fuels and Lubricants Standardization Policy for Equipment Design, Operation, and Logistic Support . . . . . . . . . . . .AR 70-12
Vehicle, Wheeled, Preparation for Shipment and Limited Storage of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MIL-V-62038D
0232 00-2
TM 9-2320-302-20
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION 0233 00
THE ARMY MAINTENANCE SYSTEM MAC
1. This introduction provides a general explanation of all maintenance and repair functions authorized at the various main-
tenance levels under the standard Army Maintenance System concept.
2. The MAC immediately following the introduction designates overall authority and responsibility for the performance of
maintenance functions on the identified end item or component. The application of the maintenance functions to the end
item or component shall be consistent with the capacities and capabilities of the designated maintenance levels, which
are shown in the MAC (WP 0234 00) in column (4) as:
Unit - includes two subcolumns, C (Operator/Crew) and O (Unit) Maintenance
Direct Support - includes an F subcolumn
General Support - includes an H subcolumn
Depot - includes a D subcolumn
3. The tools and test equipment requirements (immediately following the MAC) list the tools and test equipment (both spe-
cial tools and common tool sets) required for each maintenance function as referenced from the MAC.
4. The remarks (immediately following the tools and test equipment requirements) contain supplemental instructions and
explanatory notes for a particular maintenance function.
MAINTENANCE FUNCTIONS
Maintenance functions are limited to and defined as follows:

1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteris-
tics with established standards through examination (e.g., by sight, sound, or feel).
2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic or electrical characteristics of an item
and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift devices and
hydrostatic testing of pressure hoses.
3. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes decon-
taminate, when required), to preserve, to drain, to paint or to replenish fuel, lubricants, chemical fluids or gases.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating
characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring, and diag-
nostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certi-
fied standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.
7. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions.
Install may be the act of emplacing, seating or fixing into position a spare, repair part or module (component or assem-
bly) in a manner to allow the proper functioning of an equipment or system.
8. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. “Replace” is authorized by
the MAC and its assigned maintenance level is shown as the third position code of the Source, Maintenance and Recov-
erability (SMR) code.
9. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disas-
sembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by cor-
recting specific damage, fault, malfunction or failure in a part, subassembly, module (component or assembly), end item
or system.
0233 00-1
TM 9-2320-302-20
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED 0233 00
MAINTENANCE FUNCTIONS - CONTINUED
NOTE
The following definitions are applicable to the “repair” maintenance function:
• Services - Inspect, test, service, adjust, align, calibrate, and/or replace.

• Fault location/troubleshooting - The process of investigating and detecting the cause of equipment mal-
functioning; the act of isolating a fault within a system or Unit Under Test (UUT).
• Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded

item to the level of its least component, that is assigned an SMR code for the level of maintenance under
consideration (i.e., identified as maintenance significant).
• Actions - Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
10. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational
condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest
degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition.
11. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new con-
dition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance
applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours/
miles, etc.) considered in classifying Army equipment/components.
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1
1. Column (1) - Group Number. Column (1) lists FGC numbers, the purpose of which is to identify maintenance signifi-
cant components, assemblies, subassemblies, and modules with the Next Higher Assembly (NHA).
2. Column (2) - Component/Assembly. Column (2) contains the item names of components, assemblies, subassemblies,
and modules for which maintenance is authorized.
3. Column (3) - Maintenance Function. Column (3) lists the functions to be performed on the item listed in Column (2).
(For a detailed explanation of these functions refer to “Maintenance Functions” outlined above).
4. Column (4) - Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function
listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals) in the appro-
priate subcolumn. This work time figure represents the active time required to perform that maintenance function at the
indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at
different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure repre-
sents the average time required to restore an item (assembly, subassembly, component, module, end item or system) to a
serviceable condition under typical field operating conditions. This time includes preparation time (including any neces-
sary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time
required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol des-
ignations for the various maintenance levels are as follows:
C . . . . . Operator or Crew Maintenance
O . . . . . Unit Maintenance
F . . . . . Direct Support Maintenance
L . . . . . Specialized Repair Activity (SRA)
H . . . . . General Support Maintenance
D . . . . . Depot Maintenance
0233 00-2
TM 9-2320-302-20
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED 0233 00
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED
NOTE
The “L” maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance
are identified by a work time figure in the “H” column of column (4), and an associated reference code is
used in the REMARKS CODE column (6). This code is keyed to the remarks and the SRA complete repair
application is explained there.
5. Column (5) - Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not indi-
vidual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE, and
special support equipment required to perform the designated function. Codes are keyed to the entries in the tools and
test equipment table.
6. Column (6) - Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is
keyed to the remarks table entries (Table 3).
EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS, TABLE 2
1. Column (1) - Tool or Test Equipment Reference Code. The tool and test equipment reference code correlates with a
code used in column (5) of the MAC.
2. Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
3. Column (3) - Nomenclature. Name or identification of the tool or test equipment.
4. Column (4) - National Stock Number (NSN). The NSN of the tool or test equipment.
5. Column (5) - Tool Number. The manufacturer's part number, model number or type number.
EXPLANATION OF COLUMNS IN THE REMARKS, TABLE 3
1. Column (1) - Remarks Code. The code recorded in column (6) of the MAC.
2. Column (2) - Remarks. This column lists information pertinent to the maintenance function being performed as indi-
cated in the MAC.
0233 00-3
TM 9-2320-302-20
0233 00-4
TM 9-2320-302-20
MAINTENANCE ALLOCATION CHART (MAC) 0234 00
Table 1. MAC for the M915A3 Tractor Truck.
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
UNIT DS GS DEPOT TOOLS AND

GROUP COMPONENT/ MAINTENANCE EQUIPMENT REMARKS
NUMBER ASSEMBLY FUNCTION C O F H D REF CODE CODE
01 ENGINE
0100 Engine Assembly Inspect 0.3
Test 0.5 0.5 6,17,21,114
Service 2.0 102,120
Replace 17.0 100,100,120
Repair 18.0 100,120
Overhaul 30.0 100,101,120
Engine Mounts Replace 0.8 100,120
0101 Cylinder Head Replace 4.0 23,48,50,100,
Assembly 120
Repair 10.4 3,13,23,26,27,
28,50,67,69,87,
89,90,91,94,95,
101,120
Cylinder Block Inspect 1.0 100
Test 1.0 1,100,111,112,
120
Replace 6.0 100,120
Repair 12.0 1,3,11,12,13,39,
50,69,80,83,100,
101,111,112,120
0102 Vibration Damper Replace 1.0 100,120
Crankshaft Assembly Inspect 0.5 101
Replace 17.3 47,85,101,120
Main Seals Replace 1.0 45,88,100,120
0103 Flywheel Housing Replace 1.0 9,100,120
0104 Rod, Piston and Pin Inspect 0.5 101
Replace 18.0 25,31,34,35,
78,82,101,120
0105 Rocker Arm Inspect 0.4 100,120
Assemblies Replace 2.8 32,54,72,75,79,
100,107,120
Rocker Arm Cover Replace 0.5 100,120
Housing
Camshaft Assembly Inspect 0.4 100
Replace 3.0 74,77,100,107,
120
0234 00-1
TM 9-2320-302-20
Table 1. MAC for the M915A3 Tractor Truck - Continued.
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

Camshaft Drive Gear Inspect 0.2
Replace 1.0 44,100,120
0106 Oil Pan Replace 0.8 100,120
Repair 1.0 100,120
Oil Filter Replace 0.8 102
Oil Filter Adapter Replace 1.5 102,120
Oil Cooler Core Replace 3.0 102,120
Oil Pump Assembly Replace 1.0 100,120
Repair 3.0 100,120
Regulator Valve Replace 0.5 100,120
Assembly
0108 Exhaust Manifold Replace 1.4 36,100,120
Intake Manifold Replace 1.0 36,100,120
0109 Bull/Idler Gears Replace 1.5 7,9,10,76,81,
100,120
Accessory Drive Replace 1.0 22,97,100,120
0112 Engine Retarder Test 0.8 21,114
Assembly Adjust 0.5 100,120
Replace 0.5 100,120
Repair 4.3 100,120
0125 Gear Case and Front Replace 1.8 36,81,100,
Cover 120
03 FUEL SYSTEM
0301 Fuel Injector Assembly Replace 2.0 100,120
Repair 1.8 100,120
0302 Fuel Pump Replace 0.5 120
Hose Assembly Replace 1.0 120
0304 Air Cleaner Assembly Replace 0.3 120
Air Intake Assembly Replace 0.2 120
0305 Turbocharger Replace 0.8 5,99,100,120
Repair 3.0 100,120
0306 Fuel Tank Inspect 0.1
Replace 2.0 102,120
0309 Fuel Filter Elements Service 0.1
Replace 0.3 102
0311 Ether Starting Aid Replace 1.0 120
Repair 0.5 120
0234 00-2
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

0312 Electronic Throttle Replace 0.3 120
Assembly
04 EXHAUST SYSTEM
0401 Muffler Inspect 0.1
Replace 0.5 120
Exhaust Pipe Inspect 0.1
Replace 1.3 120
05 COOLING SYSTEM
0501 Radiator Assembly Service 0.3 102 A
Replace 0.7 102,120
Repair 0.5 101
0502 Fan Shroud Replace 1.0 120
0503 Thermostat Housing Replace 0.5 120
Repair 0.5 39,61,120
0504 Water Pump Replace 3.0 42,102,120
Repair 1.5 98,113,120
0505 Fan Drive Support Replace 0.6 100,120
Fan Clutch and Drive Replace 2.0 120
Repair 1.5 100,120
Fan Clutch Solenoid Replace 0.5 120
Fan Belt Adjust 0.5 102,120
Replace 0.5 120
Spindle and Housing Replace 1.5 100,120
Repair 3.0 120
0508 Water Filter Replace 0.3 102
06 ELECTRICAL
SYSTEM
0601 Alternator Test 0.3 0.5 21,101,103,114
Replace 0.3 120
Repair 2.0 101,119
Drive Belt Adjust 0.5 102,120
Replace 0.5 120
0602 Regulator Replace 0.5 120
Dual Voltage Control Test 0.3 102
Unit Replace 0.3 120
0603 Starter Replace 1.5 120
Repair 2.0 101,119
0605 Engine Electronic Test 0.3 21,114
Control Unit (ECU) Replace 0.3 120 B
0234 00-3
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

Engine Wiring Harness Test 0.2 103
Replace 1.0 120
Repair 0.3 103,120
0607 Instrument Panel Replace 0.3 120
Switches
0608 Fuse, Relay and Circuit Replace 0.1 120
Breaker
0609 Headlight Adjust 0.3 120
Repair 0.2 120
Taillight Replace 0.2 120
Repair 0.2 120
Blackout Lights Replace 0.3 120
Repair 0.2 120
Side Marker Lights Replace 0.3 120
Repair 0.2 120
0610 Air Pressure Warning Replace 0.5 120
Sensors
ABS, Electronic Control Test 0.3 4,18,114
Unit (ECU) Replace 0.3 120 B
ABS Sensors Replace 0.5 120
Engine Sensors Replace 0.2 120
0611 Electric Horn Replace 0.2 120
0612 Batteries Test 0.2 103 C
Replace 0.5 120
0613 Chassis Harness Test 0.2 103
Replace 2.0 120
Repair 0.3 103,120
Cab Harness Test 0.2 103
Replace 2.0 120
Repair 0.3 103,120
ABS, Electrical Replace 1.0 120
Harnesses Repair 0.3 103,120
Turn Signal Switch Replace 0.3 120
Assembly
07 TRANSMISSION
Shift Selector Replace 0.3 120
Electronic Control Unit Replace 0.5 120 B
Wiring Harness Replace 0.5 120
0234 00-4
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

Sensors Replace 0.3 120
Control Module Replace 1.0 120
Repair 1.0 100,120
0708 Torque Converter Replace 0.5 73,120
Repair 1.0 33,65,100,117,
120
0710 Fill/Check Tube Replace 0.3 120
Yoke Replace 0.3 120
Transmission Service 1.0 102,120
Assembly Test 0.3 0.5 20,114
Replace 8.0 10,14,15,100,
120
Repair 10.0 14,15,63,84,100,
120
Torque Converter Replace 0.5 100,120
Housing
Flex Plate and Ring Replace 8.0 75,100,120
Gear
Front Support and Oil Replace 0.5 24,53,55,56,
Pump Module 57,59,62,100,
120
Repair 0.5 24,53,55,56,
57,59,62,100,
120
Rear Cover Module Replace 0.5 57,66,84,92,100,
118,120,122
Repair 0.5 57,66,84,92,100,
118,120,122
Main Shaft Module Replace 0.5 100,120
0713 Rotating Clutch Replace 0.5 29,30,49,60,66,
Module 100,118,120
Repair 0.5 29,30,49,60,66,
100,118,120
C3/C4 and Main Replace 0.5 68,100,120
Bearing Module Repair 0.5 68,100,120
P1/P2 Planetary Replace 0.5 59,66,100,120
Module Repair 0.5 59,66,100,120
Control Valve Replace 0.5 93,100,103,120,
123
Repair 0.5 93,100,103,120,
123
0234 00-5
TM 9-2320-302-20

(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL

0721 Oil Cooler and Hoses Replace 0.5 103,120
09 DRIVELINES
0900 Propeller Shafts Inspect 0.2
Service 0.2 102
Replace 1.9 103,120
Repair 1.0 103,120
10 FRONT AXLE
1000 Axle Assembly Inspect 0.3
Service 0.1 102,120
Aline 1.0 102,120
Replace 4.5 100,120
Repair 4.0 100,120
1004 Tie Rod Knuckle Replace 0.8 120
Repair 1.0 102,120
11 REAR AXLE
1100 Forward-rear Axle Inspect 0.1
Service 0.2 102,106,120
Replace 4.5 100,120
Repair 8.0 102,120
Rear-rear Axle Inspect 0.1
Service 0.2 102,106,120
Replace 3.0 100,120
Repair 8.0 101,120
1102 Differential Replace 1.0 101,120
Repair 10.5 41,96,101,120
Output Shaft Assembly Replace 0.1 101,120
12 BRAKES
1202 Hanging Brake Replace 1.0 120
Assembly Repair 0.3 120
Front Brakes Inspect 0.7
Service 0.1 120
Adjust 0.5 120
Replace 2.0 102,120
Rear Brakes Inspect 0.7
Service 0.1 120
Adjust 0.5 120
Replace 2.0 102,120
Brake, Slack Adjusters Adjust 0.3 120
Replace 0.3 120
1208 Front Chamber Inspect 0.2
Assembly Replace 1.3 120
0234 00-6
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

Rear Chamber Inspect 0.2
Assembly Replace 1.3 120
Air Dryer Service 0.5 120
Replace 0.5 120
Repair 0.8 100,120
Foot Valve Replace 0.2 120
Repair 1.0 100,120
Air Valves Replace 0.3 120
Air Reservoir Replace 0.3 120
ABS Solenoid Valve Replace 0.8 120
1209 Air Compressor Replace 1.0 103,120
Repair 4.0 46,101,120
13 WHEELS
1311 Front Hub and Drum Replace 0.5 102,120
Assemblies Repair 0.1 42,101,120
Wheel Assembly Inspect 0.1 0.5
Replace 0.4 102,120
Rear Hub and Drum Replace 0.5 102,120
Repair 1.0 42,101,120
ABS Tone Ring Replace 0.5 51,120
1313 Tires Replace 0.1 102,120
Repair 0.5 102 D
14 STEERING
1401 Steering Wheel Replace 1.0 102,120
Tilt Steering Column Replace 1.0 120
Steering Universal Joint Replace 3.0 120
and Shaft Repair 1.0 120
1407 Steering Gear Replace 0.5 100,120
Repair 2.5 8,38,43,52,58,
101,108,120
1410 Power Steering Pump Test 0.3 116,120
Replace 0.7 100,120
Repair 1.5 100,120
1411 Power Steering Hoses Inspect 0.1
Replace 0.5 120
1413 Reservoir Assembly and Replace 1.0 120
Bracket Repair 1.0 103,120
0234 00-7
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

15 FRAME ASSEMBLY
1501 Frame Components Inspect 0.5 0.5
Replace 2.1 101,120
Ramp Assembly Inspect 0.1
Replace 0.3 101,120
1503 Pintle Hook Inspect 0.1 0.2
Service 0.1 102
Replace 0.5 120
Repair 0.5 120
1504 Spare Tire Carrier Replace 1.0 120
Repair 0.5 120
1506 Fifth Wheel Assembly Inspect 0.3
Service 0.3 102
Adjust 1.0 115,120
Replace 2.0 100,120
Repair 1.0 100,120
Wear Plate Replace 1.0 100,120
Repair 0.8 100,120
Slider Bracket Replace 0.5 100,120
Repair 1.3 100,104,120
16 SUSPENSION
1601 Front Suspension Inspect 0.1
Service 0.1 102
Replace 1.5 100,120
Repair 1.0 100,120
Shackle/Bracket Replace 0.5 100,120
Assembly
Front Spring Assembly Replace 2.0 100,120
Shock Absorbers Replace 0.5 120
Rear Suspension Inspect 0.1
Replace 6.0 100,120
Repair 12.0 100,120
Spring Pack Replace 1.0 100,120
Shock Absorbers Replace 0.5 120
1605 Torque Rods Replace 1.0 100,120
18 CAB
1801 Cab Assembly Inspect 0.1
Replace 4.0 105,120
Repair 3.0 101,120
0234 00-8
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

Doors Replace 0.4 120
Repair 0.7 120
Hood Adjust 0.3 120
Replace 0.5 103,120
Repair 2.0 100,120
1802 Windshield and Replace 1.5 100,120
Windows
Quarter Fender Replace 0.4 120
Assembly
1805 Floor Covers Replace 1.0 120
1806 Seat Belt Assembly Inspect 0.2
Replace 0.5 120
Seat Assembly Inspect 0.1 0.2
Replace 0.5 120
Repair 2.0 100,120
1808 Storage Boxes Replace 0.5 120
Repair 0.5 120
22 ACCESSORY ITEMS
2202 Heater Hoses Replace 1.5 120
Mirrors Replace 0.3 120
Windshield Washer and Replace 1.2 120
Motor
Vehicle Heater/Air Test 0.3 70
Conditioner Replace 2.0 86,120
Repair 1.0 100,120
Heater/Air Conditioner Replace 0.2 120
Controls
2210 Data Plates Replace 0.2 120
33 SPECIAL PURPOSE
KITS
3303 Arctic Personnel and Install 2.0 103,120
Engine Heater Kit Replace 1.0 103,120
Repair 2.0 103,120
34 ARMAMENT
MATERIAL
3401 Rifle Mounting Kit Replace 0.5 120
0234 00-9
TM 9-2320-302-20
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL

42 ELECTRICAL
EQUIPMENT
4209 Beacon Warning Light Install 0.1
Kit Replace 0.2 120
52 REFRIGERATION,
AIR CONDITIONER/
HEATER, AND AIR
CONDITIONING
COMPONENTS
5200 Air Conditioning Inspect 0.1 0.3 70
System Service 1.5 86
Compressor Replace 1.0 86,120
5201 Compressor Clutch Replace 0.8 40,120
Belt Adjust 0.2 103,120
Replace 1.0 120
5217 Valves and Lines Replace 0.5 86,120
5230 Condenser Replace 1.0 86,120
Receiver-drier Replace 1.0 86,120
68 WARNING,
SCANNING, AND
SIGNAL DEVICES,
AND
NAVIGATIONAL
INSTRUMENTS
6809 Collision Warning Inspect 0.1
System (CWS) Test 0.3 19,114
Replace 0.3 120 B
Repair 0.3 120
Harness, Collision Replace 1.0 120
Warning System Repair 0.3 103,120
91 CHEMICAL,
BIOLOGICAL, AND
RADIOLOGICAL
(CBR) EQUIPMENT
9120 M13 Decontamination Replace 0.5 120
Mounting Kit
0234 00-10
TM 9-2320-302-20
Table 2. Tools and Test Equipment Requirements for the M915A3 Tractor Truck.
(1) (2) (3) (4) (5)
TOOL OR TEST
EQUIPMENT
REFERENCE MAINTENANCE NATIONAL TOOL
CODE LEVEL NOMENCLATURE STOCK NUMBER NUMBER
1 H Adapter, Cylinder 4910-01-319-6971 J38768-A
2 O Adapter, Electrical (part of tool 5935-01-353-2532 J34812-1
number J38500-H)
3 H Adapter, Motor, Hoist 3950-01-319-6973 J35635-A
4 O Adapter, Test, ABS 4910-01-372-3128 446 300 3140
5 F Adapter, Torque Wrench 5120-00-215-8200 11663358-2
6 F Adapter Kit, Mechanical 4940-01-353-7038 J28593
7 F Adjuster, Lash, Cam-I 5120-01-322-8885 J35596
8 F Adjusting Tool, Worm 5120-01-371-7369 J37070
9 H Alignment Stud Set J43431
10 F Barring Tool, Engine 5120-01-322-3498 J36237
11 H Bolt, Eye 5306-01-294-3028 993-042
12 H Bolt, Eye, Cylinder Block Lift 5306-01-319-1987 J35595
Tool
13 H Bracket, Engine Mounting 2510-01-320-8905 J35636
14 F Bracket, Transmission J35926
Holding
15 F Bracket, Transmission J41445
Holding
16 O Cable Assembly, Special (part 6150-01-353-9708 J38500-2
of tool number J38500-H)
17 O Card, Software J38500-2300D
18 O Cartridge, ABS 4910-01-354-2767 J38500-404A
19 O Cartridge, CWS TBD TBD
20 O Cartridge, Test, Transmission 4940-01-367-6194 J38500-303
21 O Cartridge, Test Set, DDEC III/ 4940-01-367-4657 J38500-1500C
IV (part of tool number
J38500-H)
22 F Checker, Gear Lash 5120-01-353-2520 J38662
23 F Clamp, Material Lift 3940-01-324-4713 J35641-A
24 H Compressor, Main-Pressure J41462
Relief Spring
25 H Compressor, Piston Ring 5120-01-353-8567 J35598-A
26 H Compressor, Spring J8062-3
27 H Compressor, Spring 5120-01-353-2522 J24203-3
28 H Compressor, Spring J8062-1
0234 00-11
TM 9-2320-302-20
Table 2. Tools and Test Equipment Requirements for the M915A3 Tractor Truck - Continued.
(1) (2) (3) (4) (5)
TOOL OR TEST
EQUIPMENT
29 H Compressor, Spring, C2 (use J37030-1
with J37030-3)
30 H Compressor, Spring, C5 (use J37030-2
with J37030-3)
31 F Driver, Bushing 5120-01-353-2521 PT 4365-1
32 F Gage, Profile J42749
33 H Gage, Profile 5220-01-388-1460 J38548
34 H Gage, Profile J35884-A
35 H Gage, Profile J38689-A
36 F Guide Stud Set 5120-01-322-3505 J36107
37 H Guides, Connecting Rod J43661
38 H Handle, Drive 5120-00-677-2259 J8092
39 O Handle, Installer 5120-00-977-5578 J7079-2
40 O Holder, Clutch 5120-01-439-0305 99-499
41 F Holding Bar, Pinion 5120-01-455-0436 J3453-1
42 O Indicator, Dial 5210-00-402-9619 J7872
43 F Inserter, Bearing 5120-01-354-2943 J37071-A
44 H Inserter, Gear 5120-01-322-1132 J35949
45 F Inserter, Seal 5120-01-322-1129 J35686-B
46 F Inserter and Remover 5120-01-338-7182 J25447-B
47 H Inserter and Remover 5120-01-322-2360 J35642
48 F Inserter and Remover 5120-01-322-6222 J36310-A
49 H Inserter and Remover, Spring 5120-01-388-5623 J35923-2
50 H Inserter Set, Dowel 5120-01-322-3500 J36224
51 O Installation Tool, ABS Tone 107119
Ring
52 F Installation Tool, Seal 5120-01-354-0468 J37073
53 H Installer, Charging Pump J39954
Bushing
54 F Installer, Cup Plug 5120-01-333-4744 J36326
55 H Installer, Front Support Sleeve J37041
and PTO Bearing
56 H Installer, Output Bearing J37034
57 H Installer, Output Bearing Cup J37033
(use with J37034)
58 F Installer, Output Shaft 5120-01-054-4042 J-24202-1A
0234 00-12
TM 9-2320-302-20
(1) (2) (3) (4) (5)
TOOL OR TEST
EQUIPMENT
59 H Installer, P1 Carrier Bushing J37038
and Ground Sleeve Bearing,
Pump Body Bushing, and
Bearing Retainer Bushing
60 H Installer, Rotating Clutch J37040
Bushing
61 O Installer, Seal 5120-00-977-5579 J8550
62 F Installer, Seal, Input J37032
63 F Installer, Seal, Output J37031
64 H Installer, Valve Stem Seal J39109
65 H Installer, Torque Converter J39949
Cover Bushing
66 H Installer, Turbine Shaft J37036
Bushing/Output Bushing/P2
Carrier Bushing
67 H Installer, Valve Guide 5120-01-322-3501 J33191-A
68 H Installer, Wear Plate J39534
69 H Installer Set, Cup Plug 5120-01-322-2359 J35653
70 O Leak Detector, Refrigerant 4940-01-387-0948 16500
71 O Level, Digital J38460-A
72 F Lifter, Rocker Arm 5120-01-322-6116 J35996-A
73 F Lifting, Bracket, Flywheel 5120-01-116-6049 J-24365
74 F Pilot, Cam Gear 5120-01-322-3508 J35906
75 F Pin, Shoulder, Headless 5315-01-333-2771 J36235
76 H Plate, Indexing 3460-01-319-5533 J35651
77 F Plate, Retaining 3040-01-319-0848 J35652-B
78 H Pliers, Piston Ring 5120-01-142-2459 J22405-02
79 F Pliers, Retaining Ring 5120-01-322-6888 J36347
80 H Press, Cylinder Line 3449-01-319-5599 J35597-A
81 H Protector, Crankshaft 2815-01-321-9248 J35994
82 H Protector, Piston 5120-01-048-2156 J24210
83 H Puller, Mechanical 5120-01-322-1128 J35791
84 F Puller Kit, Universal 5180-01-048-2153 J24171-A
85 H Pump, Hydraulic Ram 4320-01-320-4618 J35951-175
86 F Reclaimer, Refrigerant, 4250-01-396-8928 EEEAC304A
R134A
0234 00-13
TM 9-2320-302-20
(1) (2) (3) (4) (5)
TOOL OR TEST
EQUIPMENT
87 H Reconditioning Set 5120-01-322-3507 J33880
88 F Remover, Seal 5120-01-322-1131 J35993
89 H Remover, Valve Guide 5120-01-322-3506 J34696-B
90 H Remover, Valve Seat 5120-00-494-1836 J23479-271
91 H Remover, Valve Seat 5120-01-322-8883 J23479-460-A
92 H Remover, Wheel Bearing Cup 5120-00-784-6482 J3940
93 H Remover/Installer, Main J35924
Pressure Spring
94 H Replacing Tool, Engine 5120-01-322-1133 J33190
95 H Replacing Tool, Engine 5120-01-322-2955 J34983
96 H Scale 4910-00-707-9178 J544-01
97 F Service Kit, Accessory Drive 5120-01-322-3499 J36024
98 F Service Kit, Water Pump 5120-01-322-6115 J35988-C
99 F Shield, Turbo Protect 4910-01-127-7959 J26554-A
100 F Shop Equipment, Automotive 4910-00-754-0707 SC 4910-95-A31
Maintenance and Repair: Field
Maintenance, Basic, Less
Power
101 F Shop Equipment, Automotive 4910-00-348-7696 SC 4910-95-A02
Maintenance and Repair: Field
Maintenance, Wheeled
Vehicles
102 O Shop Equipment, Automotive 4910-00-754-0654 SC 4910-95-A74
Maintenance and Repair:
Organizational Maintenance,
Common No. 1
103 O Shop Equipment, Automotive 4910-00-754-0650 SC 4910-95-A72
Maintenance and Repair:
Organizational Maintenance,
Common No. 2
104 F Slider, Spring Compression 4910-01-165-6015 TFTLN-2500
105 F Sling, Beam Type 3940-01-353-8561 J-39520
106 O Socket, Socket Wrench 5130-01-389-8450 BWD482
107 F Socket, Socket Wrench 5120-01-322-1123 J36003-A
108 F Spanner Attachment 5120-01-353-8490 J 37464
109 F Spreader, Sling 3940-01-354-9446 38841
0234 00-14
TM 9-2320-302-20
(1) (2) (3) (4) (5)
TOOLS OR TEST
EQUIPMENT
REFERENCE MAINTENANCE NATIONAL/NATO TOOL
110 H Test Block, Pressure Switch J33884
111 H Tester, Cylinder 4910-01-320-4638 J29006-5
112 H Tester, Cylinder 4910-01-319-6990 J36223-D
113 F Tester, Impeller 5120-01-322-2358 J35687
114 O Tester, Internal Combustion, J38500-H
DDEC Diagnostic Reader
115 O Tester, Kingpin Lock 4910-01-157-3571 TFTLN-1000
116 F Tester, Power Steering 4910-01-160-3618 J-26487-B
117 H Tool, Torque Converter Bolt J38564
118 H Tool Base, Spring Compressor, J37030-3
C1, C2, and C5
119 F Tool Kit, Automotive Fuel and 5180-00-754-0655 SC 5180-95-B08
Electrical System Repair
120 O Tool Kit, General Mechanic’s: 5180-00-177-7033 SC 5180-95-N26
Automotive
121 O Tool Kit, Internal Combustion 5180-01-358-5231 J35888-60
122 H Tool Set, Spanner Nut Torque J37035
123 H Tray Set, Valve Body Parts J33163
124 O Wiring Harness 6150-01-354-2604 J35751
125 O Wrench, Box 5120-01-322-1124 J35948
Table 3. Remarks for the M915A3 Tractor Truck.
(1) (2)
REMARKS CODE REMARKS

A Refer to TM 750-254 (cooling systems) for additional information.
B Do not discard failed ECU. Contact Contractor Logistic Support (CLS) for disposition instructions.
C Refer to TM 9-6140-200-14 (batteries) for additional information.
D Refer to TM 9-2610-200-14 (tires) for additional information.
0234 00-15
TM 9-2320-302-20
0234 00-16
TM 9-2320-302-20
EXPENDABLE AND DURABLE ITEMS LIST 0235 00
SCOPE
This work package lists expendable and durable items you will need to maintain the M915A3 Tractor Truck. This listing
is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970,
Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Depart-
ment Expendable/Durable Items.
EXPLANATION OF COLUMNS
1. Column (1) - Item Number. This number is assigned to the entry in the list and is referenced in the narrative instruc-
tions to identify the item [e.g., Use antifreeze (Item 4, WP 0235 00)].
2. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
O - Unit Maintenance
3. Column (3) - National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it.
4. Column (4) - Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number
(P/N). This provides the other information you need to identify the item.
5. Column (5) - Unit of Measure (U/M). This code shows the physical measurement or count of an item, such as gallon,
dozen, gross, etc.
0235 00-1
TM 9-2320-302-20
Table 1. Expendable and Durable Items List.

(1) (2) (3) (4) (5)
ITEM NATIONAL ITEM NAME, DESCRIPTION, CAGEC,

NUMBER LEVEL STOCK NUMBER AND PART NUMBER U/M
1 O ADHESIVE
(71984) RTV732-3OZTUBE
8040-00-877-9872 3 Ounce Tube OZ
2 O ADHESIVE: General Purpose, Type II
(18876) 9995460
8040-00-664-4318 1 Pint Can PT
3 O 8040-00-142-9823 ADHESIVE: Silicone Rubber KIT
(81349) MIL-A-46106
4 C ANTIFREEZE: Permanent,
Ethylene Glycol, Inhibited
(81349) MILA46153
6850-00-181-7929 1 Gallon Bottle GAL
6850-00-181-7933 5 Gallon Can GAL
6850-00-181-7940 55 Gallon Drum GAL
5 C ANTIFREEZE: Permanent,
Type: Arctic Grade
(81349) MIL-A-11755
6850-00-174-1806 55 Gallon Drum GAL
6 O COMPOUND: Antiseize, High Temperature
(73165) 51008
8030-00-597-5367 25 pound can LB
7 O COMPOUND: Caulking
(21106) MORTITE B-2
8030-01-241-9727 90 Foot Roll FT
8 C COMPOUND: Cleaning, Windshield
(81348) O-C-1901
6850-00-926-2275 16 Ounce Can OZ
9 O COMPOUND: Sealing:
Dissimilar Metal Protection
(71961) 6099
8030-01-392-3276 1 Gallon Can GAL
10 O COMPOUND: Sealing, Pipe
(05972) 079-21
8030-00-081-2286 50 CC Bottle CC
8030-00-081-2327 Box of 10 Bottles, 10 CC Each Bottle CC
11 C DETERGENT: General Purpose, Liquid
(81348) P-D-220
7930-00-282-9699 1 Gallon Can GAL
0235 00-2
TM 9-2320-302-20
Table 1. Expendable and Durable Items List - Continued.

(1) (2) (3) (4) (5)

12 O FLUX: Soldering
(58536) A-A-51145 TY1 FORM A
3439-00-255-9935 1 Pound Can LB
13 C FUEL: Diesel, DF-1 Grade, Winter
(81346) ASTM D 975
9140-00-286-5286 Bulk GAL
9140-00-286-5287 5 Gallon Can GAL
9140-00-286-5288 55 Gallon Drum, 16 Gage GAL
14 C FUEL: Diesel, DF-2 Grade
(81346) ASTM D 975
9140-00-286-5294 Bulk GAL
9140-00-286-5295 5 Gallon Can GAL
15 C GREASE: Automotive and Artillery, GAA
(81349) M-10924
9150-01-197-7693 14 Ounce Cartridge (M-10924-B) OZ
9150-01-197-7688 1-1/4 Ounce Tube (M-10924-A) OZ
9150-01-197-7690 2-1/4 Pound Can (M-10924-C) LB
9150-01-197-7692 35 Pound Can (M-10924-E) LB
9150-01-197-7691 120 Pound Drum (M10924-F) LB
16 O GREASE: Silicone
(53711) 5205453
9150-01-066-1823 Box of 12 tubes, 5.3 ounces each OZ
17 O GREASE: Molybdenum Disulfide
(39428) 1062K97
9150-01-326-5424 14 Ounce Cartridge OZ
18 C OIL: Lubricating, OEA, Arctic
(81349) MIL-L-46167
9150-00-402-4478 1 Quart Can QT
9150-00-402-2372 5 Gallon Can GAL
9150-00-491-7197 55 Gallon Drum GAL
19 C OIL: Lubricating, OE/HDO 10
(81349) MIL-L-2104
9150-00-189-6727 1 Quart Can QT
9150-00-186-6668 5 Gallon Can GAL
9150-00-191-2772 55 Gallon Drum, 18 Gage (MILL2104) GAL
0235 00-3
TM 9-2320-302-20

(1) (2) (3) (4) (5)

20 C OIL: Lubricating, OE/HDO 15/40
(81349) MIL-L-2104
9150-01-152-4117 1 Quart Can QT
9150-01-152-4118 5 Gallon Can GAL
9150-01-152-4119 55 Gallon Drum GAL
(81349) MIL-L-2104
9150-00-186-6681 1 Quart Can QT
9150-00-188-9858 5 Gallon Can GAL
9150-00-189-6729 55 Gallon Drum GAL
(81349) MILL2104
9150-00-189-6730 1 Quart Can QT
9150-00-188-9862 55 Gallon Drum GAL
23 C OIL: Lubricating, GO 75
(81349) MIL-PRF-2105
9150-01-035-5390 1 Quart Can QT
9150-01-035-5391 5 Gallon Can GAL
24 C OIL: Lubricating, GO 80/90
(81349) MIL-PRF-2105
9150-01-035-5392 1 Quart Can QT
9150-01-313-2191 1 Gallon Can GAL
9150-01-035-5395 5 Gallon Can GAL
9150-01-035-5394 55 Gallon Drum GAL
25 C OIL: Lubricating, GO 85/140
(81349) MIL-PRF-2105
9150-01-048-4591 1 Quart Can QT
9150-01-035-5395 5 Gallon Can GAL
9150-01-035-5396 55 Gallon Drum GAL
26 C OIL: Lubricating, Refrigerant Compressor,
Synthetic Ester
(59595) CAPELLA HFG-68NA
9150-01-410-8972 1 Quart Can QT
27 O PAINT: Heat Resisting, White
(87187) 1505
8010-01-141-3949 13 Ounce Can, Pressurized Spray OZ
28 C RAG: Wiping
(64067) 7920-00-205-1711
7920-00-205-1711 50 Pound Bale LB
0235 00-4
TM 9-2320-302-20

(1) (2) (3) (4) (5)

29 O SOLDER: Lead-tin Alloy, Rosin Core
(81348) QQ-S-571
3439-00-555-4629 1 Pound Spool LB
30 O STRAP: Tiedown, EA
Electrical Components
Box of 100
5975-00-984-6582 (96906) MS3367-1-0
6 Inch Length,
1.75 Inch Maximum Bundle, Black
5975-00-935-5946 (96906) MS3367-2-1
13.35 Inch Length,
4 Inch Maximum Bundle, Brown
5975-00-903-2284 (96906) MS3367-4-0
4 Inch Length, Black
31 O TAG: Marker
(64067) 9905-00-537-8954
9905-00-537-8954 Bundle of 50 EA
32 O TAPE: Double-sided
(7X678) 4970 YD
33 O TAPE: Duct, 2 Inches Wide
(39428) 1791K70
5640-00-103-2254 60 Yard Roll YD
34 O WIRE: Nonelectrical
(81346) ASTM A641
9505-00-596-0191 5 Pound Coil LB
0235 00-5
TM 9-2320-302-20
0235 00-6
TM 9-2320-302-20
TOOL IDENTIFICATION LIST 0236 00
SCOPE
This work package lists all common tools and supplements and special tools/fixtures needed to maintain the M915A3
Tractor Truck.
EXPLANATION OF COLUMNS IN THE TOOL IDENTIFICATION LIST
1. Column (1) - Item Number (No.). This number is assigned to the entry in the list and is referenced in the initial setup to
identify the item (e.g., Tool kit, general mechanic’s, Item 36, WP 0236 00).
2. Column (2) - Item Name. This column lists the item by noun nomenclature and other descriptive features (e.g., Car-
tridge, ABS).
3. Column (3) - National Stock Number. This is the National Stock Number (NSN) assigned to the item; use it to requi-
sition the item.
4. Column (4) - Part Number/CAGEC. Indicates the primary number used by the manufacturer (individual, company,
firm, corporation or Government activity) which controls the design and characteristics of the item by means of its engi-
neering drawings, specifications, standards, and inspection requirements to identify an item or range of items. The man-
ufacturer’s Commercial and Government Entity Code (CAGEC) is also included.
5. Column (5) - Reference. This column identifies the authorizing supply catalog or RPSTL for items listed in this work
package.
0236 00-1
TM 9-2320-302-20
TOOL IDENTIFICATION LIST - CONTINUED 0236 00
TOOL IDENTIFICATION LIST
Table 1. Tool Identification List.

(1) (2) (3) (4) (5)
ITEM NATIONAL PART NUMBER/

NO. ITEM NAME STOCK NUMBER CAGEC REFERENCE
1 Adapter, Electrical 5935-01-353-2532 J 34812-1 (33287) TM 9-2320-302-24P
2 Adapter, Test, ABS 4910-01-372-3128 446 300 3140 (78500) TM 9-2320-302-24P
3 Bar, Wrecking: 30 in length 5120-00-293-0665 55-130 (57068) SC 4910-95-A72
4 Cable Assembly, Special 6150-01-353-9708 J 38500-2 (33287) TM 9-2320-302-24P
5 Card, Software J38500-2300D (33287) TM 9-2320-302-24P
6 Cartridge, ABS 4910-01-354-2767 J38500-404A (33287) TM 9-2320-302-24P
7 Cartridge, CWS TBD TBD TBD
8 Cartridge, Test, Transmission 4940-01-367-6194 J38500-303 (33287) TM 9-2320-302-24P
9 Cartridge, Test Set, DDEC III/IV 4940-01-367-4657 J38500-1500C (33287) TM 9-2320-302-24P
10 Compressor Unit, Reciprocating 4310-00-752-9633 MIL-C-52980 (81349) SC 4910-95-A74
11 Drill, Electric, Portable: 3/8 in size 5130-00-935-7354 6635 (55111) SC 4910-95-A74
12 Drill Set, Twist 5133-00-293-0983 800434 (19203) SC 4910-95-A74
13 Gloves, Chemical and Oil Protective: 8415-00-641-4601 ZZ-G-381 (81348) SC 4910-95-A74
rubber
14 Goggles, Industrial 4240-00-052-3776 A-A-1110 (58536) SC 4910-95-A74
15 Handle, Installer 5120-00-977-5578 J7079-2 (33287) TM 9-2320-302-24P
16 Heat Gun 4940-00-561-1002 **6966C (78976) GSA Catalog
17 Holder, Clutch 5120-01-439-0305 99-499 (07BE6) TM 9-2320-302-24P
18 Indicator, Dial 5210-00-402-9619 J7872 (33287) TM 9-2320-302-24P
19 Installation Tool, ABS Tone Ring 107119 (4N501) TM 9-2320-302-24P
20 Installer, Seal 5120-00-977-5579 J8550 (33287) TM 9-2320-302-24P
21 Jack, Hydraulic, Hand: 12 ton capacity 5120-00-224-7330 67224 (07505) SC 4910-95-A74
22 Leak Detector, Refrigerant 4940-01-387-0948 16500 (07295) TM 9-2320-302-24P
23 Level, Digital J-44675 (33287)
24 Multimeter, Digital 6625-01-139-2512 T00377 (55026) SC 4910-95-A72
25 Pan, Drain: 4 gallon capacity 4910-00-387-9592 450 (05463) SC 4910-95-A74
26 Pliers, Retaining Ring: internal, 5120-00-293-0186 4200-3174865PC4 SC 4910-95-A72
0.120 in diameter, 3.15-6.5 in (80064)
ring diameter
27 Puller Kit, Universal 5180-00-313-9496 1178 (45225) SC 4910-95-A72
28 Riveter, Blind, Hand: 3/32 in, 1/8 in, 5120-00-017-2849 250K (10054) SC 4910-95-A74
5/32 in, and 3/16 in diameters
29 Socket, Socket Wrench 5130-01-389-8450 BWD482 (55719) TM 9-2320-302-24P
0236 00-2
TM 9-2320-302-20
Table 1. Tool Identification List - Continued.

(1) (2) (3) (4)
(5)
ITEM NATIONAL PART NUMBER/
NO. ITEM NAME STOCK NUMBER CAGEC REFERENCE
30 Soldering Gun 3439-00-618-6623 D550-3 (97049) SC 4910-95-A74
31 Tape, Measuring: 50 feet long 5210-00-554-7085 403 (37163) SC 4910-95-A72
32 Tensiometer, Dial Indicating 6635-01-093-3710 BT-33-73F (33287) SC 4910-95-A74
33 Tester, Internal Combustion, DDEC 4910-01-343-3508 J 38500-H (33287) TM 9-2320-302-24P
Diagnostic Reader
34 Tester, Kingpin Lock 4910-01-157-3571 TFTLN-1000 (74410) TM 9-2320-302-24P
35 Tool Kit, Electrical Connector Repair 5180-00-876-9336 7550526 (19204) SC 4910-95-A72
36 Tool Kit, General Mechanic’s: 5180-00-177-7033 SC5180-90-N26 SC 5180-95-N26
Automotive (50980)
37 Tool Kit, Internal Combustion 5180-01-358-5231 J 35888-60 (33287) TM 9-2320-302-24P
38 Trestle, Hoist, Portable: 7 ton capacity 3950-00-251-8013 306 (79805) SC 4910-95-A72
39 Vise, Machinist’s 5120-00-293-1439 504M2 (79416) SC 4910-95-A74
40 Wiring Harness 6150-01-354-2604 J 35751 (33287) TM 9-2320-302-24P
41 Wrench, Box 5120-01-322-1124 J35948 (33287) GSA Catalog
42 Wrench, Strap, Oil Filter 5120-00-020-2947 2432097 (10001) SC 4910-95-A74
43 Wrench, Torque: 3/8 in drive, 0-200 5120-00-853-4538 F200I (90947) SC 4910-95-A72
lb-in capacity
44 Wrench, Torque: 3/8 in drive, 0-300 5120-00-776-1841 2163993 (10001) SC 4910-95-A74
lb-in capacity
45 Wrench, Torque: 3/8 in drive, 15-75 5120-01-355-1734 QC2FR75 (55719) SC 4910-95-A74
lb-ft capacity
46 Wrench, Torque: 50-250 lb-ft capacity 5120-01-042-0982 VB-2503MFR (27464) SC 4910-95-A74
47 Wrench, Torque: 3/4 in drive, 100-600 5120-01-113-9564 7379 (45225) SC 4910-95-A72
lb-ft capacity
48 Wrench Set, Socket: 3/4 in drive 5120-00-204-1999 FEDSTD353 (06542) SC 4910-95-A72
49 Wrench Set, Socket Attachment: 5120-01-178-6342 J-29843 (33287) GSA Catalog
screwdriver, torx, 1/4 and 3/8 in drive
50 Pliers, Slip Joint 5120-00-537-3375 HCP48A
0236 00-3
TM 9-2320-302-20
0236 00-4
TM 9-2320-302-20
INDEX
Subject Work Package Page
Numerics
12V Power Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00 0068 00-1
A
Access Cover Replacement, Transmission Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00 0207 00-1
Adjustment
Air Compressor Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00 0028 00-1
Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00 0054 00-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00 0206 00-1
Fifth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00 0178 00-1
Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00 0082 00-1
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00 0187 00-1
Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00 0139 00-1
Air
Brake Chamber Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00 0141 00-1
Brake Chamber Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00 0142 00-1
Cleaner Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00 0036 00-1
Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00 0036 00-1
Cylinder Replacement, HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219 00 0219 00-1
Deflector Replacement, Cab Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00 0218 00-1
Dryer Canister Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00 0158 00-1
Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00 0157 00-1
Horn and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00 0214 00-1
Intake Duct Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00 0036 00-1
Intake Tubes and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00 0037 00-1
Pressure Sending Units (Primary/Secondary) Replacement . . . . . . . . . . . . . . 0105 00 0105 00-1
Recirculation Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00 0038 00-1
Solenoid Replacement
Front ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00 0162 00-1
Rear ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00 0163 00-1
Supply Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00 0146 00-1
Tank and Fittings Replacement, Primary I . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00 0143 00-1
Tank and Fittings Replacement, Primary II . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00 0144 00-1
Tank and Fittings Replacement, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00 0145 00-1
Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00 0101 00-1
Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00 0147 00-1
Air Compressor
Discharge Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00 0027 00-1
Governor Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00 0028 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00 0029 00-1
Index-1
TM 9-2320-302-20
INDEX - Continued
A - Continued
Air Conditioner
Binary Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00 0224 00-1
Compressor Magnetic Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0226 00 0226 00-1
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00 0225 00-1
Resister Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00 0222 00-1
Thermostatic Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223 00 0223 00-1
Air Conditioning Control Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00 0067 00-1
Air Conditioning System
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-9
Troubleshooting and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00 0017 00-1
Air System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00 0014 00-1
Alignment
Collision Warning System (CWS) Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00 0110 00-1
Front Axle Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00 0131 00-1
Alternator
Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00 0054 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00 0055 00-1
Antenna Alignment, Collision Warning System (CWS) . . . . . . . . . . . . . . . . . . . . . . 0110 00 0110 00-1
Antenna Assembly Replacement, Collision Warning System (CWS) . . . . . . . . . . . 0111 00 0111 00-1
Anti-lock Brake System (ABS)
Air Solenoid Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00 0162 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00 0163 00-1
Electronic Control Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00 0108 00-1
Sensor Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00 0106 00-1
Sensor Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00 0107 00-1
Tone Ring Replacement, Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00 0165 00-1
Tone Ring Replacement, Rear-rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00 0166 00-1
Troubleshooting and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00 0013 00-1
Arctic Heater Replacement (WABASTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00 0229 00-1
Automatic Ether Starting Aid
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00 0035 00-1
Wiring Harnesses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00 0117 00-1
Index-2
TM 9-2320-302-20
INDEX - Continued
B
Basic Issue Items (BII) Storage Box and Mounting Bracket Replacement . . . . . . . 0198 00 0198 00-1
Battery
Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00 0114 00-1
Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00 0115 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00 0113 00-1
Belt
Alternator, Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00 0054 00-1
Fan, Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00 0046 00-1
Seat, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00 0193 00-1
Blackout
Drive Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00 0084 00-1
Marker Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00 0084 00-1
Marker Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00 0086 00-1
Marker Replacement, Right Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0085 00 0085 00-1
Blower Motor Replacement, HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00 0220 00-1
Box Replacement, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00 0114 00-1
Bracket Replacement
Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00 0181 00-1
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00 0180 00-1
Brake Chamber Replacement
Air, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00 0141 00-1
Air, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00 0142 00-1
Brake Light/Trailer Brake Light Sending Unit Replacement . . . . . . . . . . . . . . . . . . 0109 00 0109 00-1
Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00 0134 00-1
Brake Spider and Brake Chamber Bracket Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00 0136 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00 0138 00-1
Brake System
Brakeshoe Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00 0135 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00 0137 00-1
Breather Replacement
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00 0133 00-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00 0128 00-1
Brush Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00 0184 00-1
Bumper Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00 0175 00-1
Index-3
TM 9-2320-302-20
INDEX - Continued
C
Cab
Air Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00 0149 00-1
Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00 0206 00-1
Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00 0202 00-1
Overhead Storage Compartment Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0204 00 0204 00-1
Roof Air Deflector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00 0218 00-1
Cables Replacement, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00 0115 00-1
Cab-to-Frame Ground Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0118 00 0118 00-1
Canister Replacement, Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00 0158 00-1
Center Gage Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00 0061 00-1
Central Processing Unit (CPU) Replacement, Collision Warning System (CWS) . 0111 00 0111 00-1
Characteristics, Capabilities, and Features, Equipment . . . . . . . . . . . . . . . . . . . . . 0002 00 0002 00-1
Charge Air Cooler and Air Recirculation Shield Replacement . . . . . . . . . . . . . . . . 0038 00 0038 00-1
Chassis and Fifth Wheel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00 0016 00-1
Check Engine Switch and Jumper Harness Replacement . . . . . . . . . . . . . . . . . . . 0070 00 0070 00-1
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00 0071 00-1
Clearance Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00 0089 00-1
Clutch and Drive Pulley Replacement, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00 0049 00-1
Clutch Solenoid Replacement, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00 0048 00-1
Collision Warning System (CWS)
Antenna Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00 0110 00-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00 0111 00-1
Column Cover Replacement, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00 0205 00-1
Compressor Replacement, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00 0029 00-1
Connectors Maintenance, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00 0119 00-1
Constant Air Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00 0148 00-1
Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00 0066 00-1
Control Module Replacement, Electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00 0075 00-1
Control Panel Replacement, Heater and Air Conditioning . . . . . . . . . . . . . . . . . . . 0067 00 0067 00-1
Coolant Hoses, Pipes, and Clamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00 0042 00-1
Cooler and Oil Filter Adapter Maintenance, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00 0025 00-1
Cooling System
Drain and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00 0041 00-1
Index-4
TM 9-2320-302-20
INDEX - Continued
C - Continued
Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Cup Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0217 00 0217 00-1
D
Dash Panel Replacement, Upper Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00 0063 00-1
Data and Instruction Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00 0215 00-1
Data, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00 0002 00-6
DDEC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00 0007 00-1
Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Dipstick, Tube, and Adapter Replacement, Oil Level . . . . . . . . . . . . . . . . . . . . . . . 0023 00 0023 00-1
Discharge Hose Replacement, Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00 0027 00-1
Drag Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00 0169 00-1
Drain and Fill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00 0041 00-1
Drive Train, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-1
Driveline
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00 0129 00-1
U-joints and Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00 0130 00-1
Driver Display Unit (DDU) Replacement, Collision Warning System (CWS) . . . . . 0111 00 0111 00-1
Dryer Replacement, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00 0157 00-1
Dual Voltage Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00 0058 00-1
E
Electric Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00 0112 00-1
Electrical Connectors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00 0119 00-1
Electrical System
Electronic
Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00 0075 00-1
Control Unit (ECU) Replacement, Anti-lock Brake System (ABS) . . . . . . . . . . 0108 00 0108 00-1
Control Unit (ECU) Replacement, Transmission . . . . . . . . . . . . . . . . . . . . . . . 0124 00 0124 00-1
Throttle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00 0074 00-1
Engine Hood Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00 0185 00-1
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00 0006 00-1
Equipment
Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00 0002 00-1
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00 0002 00-6
Index-5
TM 9-2320-302-20
INDEX - Continued
E - Continued
Ether Starting Aid Maintenance, Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00 0035 00-1
Exhaust System
Flex Pipe, Clamps, and Heat Shield Replacement . . . . . . . . . . . . . . . . . . . . . . 0040 00 0040 00-1
Muffler, Stack, and Heat Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00 0039 00-1
F
Fan
Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00 0046 00-1
Clutch and Drive Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00 0049 00-1
Clutch Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00 0048 00-1
Impeller and Shroud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00 0047 00-1
Fender Extension Maintenance, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00 0194 00-1
Fender Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00 0195 00-1
Fiber Optic Light Source Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00 0069 00-1
Fifth Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00 0178 00-1
Fill Tube Maintenance, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00 0022 00-1
Filter Adapter and Bracket Replacement, Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00 0051 00-1
Filter Adapters Replacement, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00 0032 00-1
Filter Element
Fuel Filter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00 0031 00-1
Fuel Strainer, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00 0031 00-1
Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00 0024 00-1
Water, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00 0050 00-1
Flex Pipe, Clamps, and Heat Shield Replacement, Exhaust System . . . . . . . . . . . 0040 00 0040 00-1
Floor Mats Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00 0201 00-1
Foot Brake Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00 0161 00-1
Front
Air Brake Chamber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00 0141 00-1
Brake Spider and Brake Chamber Bracket Replacement . . . . . . . . . . . . . . . . 0136 00 0136 00-1
Brakeshoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00 0135 00-1
Bumper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00 0175 00-1
Gladhands Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00 0153 00-1
Quick-release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00 0155 00-1
Service Brake Relay Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00 0152 00-1
Shock Absorber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00 0182 00-1
Index-6
TM 9-2320-302-20
INDEX - Continued
F - Continued
Front - Continued
Splash Guard and Fender Extension Maintenance . . . . . . . . . . . . . . . . . . . . . 0194 00 0194 00-1
Front Axle
Stop Cushion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00 0132 00-1
Toe-in Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00 0131 00-1
Fuel
Filter Adapters Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00 0032 00-1
Hoses and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00 0030 00-1
Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00 0092 00-1
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00 0034 00-1
Strainer and Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00 0031 00-1
Tank and Mounting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0033 00 0033 00-1
Fuel Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00 0094 00-1
Fuel System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-1
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00 0071 00-1
G
Gages and Lamps Replacement, Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00 0060 00-1
General Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00 0020 00-1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00 0228 00-1
Gladhand(s) Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00 0153 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00 0154 00-1
Governor Replacement and Adjustment, Air Compressor . . . . . . . . . . . . . . . . . . . 0028 00 0028 00-1
Ground Wire Replacement, Cab-to-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0118 00 0118 00-1
Guard Replacement, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00 0184 00-1
H
Hand Brake Replacement, Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00 0159 00-1
Head Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00 0203 00-1
Headlamp
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00 0082 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00 0083 00-1
Headlight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00 0083 00-1
Heater Control Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00 0067 00-1
Heater Core Replacement, HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221 00 0221 00-1
Index-7
TM 9-2320-302-20
INDEX - Continued
H - Continued
Heater Replacement, Arctic (WABASTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00 0229 00-1
Hoist Replacement, Spare Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00 0176 00-1
Hold-down Pin Replacement, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00 0113 00-1
Hood
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00 0187 00-1
Latch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00 0188 00-1
Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00 0189 00-1
Prop and Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00 0190 00-1
Hood Assembly
Replacement, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00 0185 00-1
Hook, Pintle, Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00 0179 00-1
Horn Replacement, Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00 0112 00-1
Hoses and Fittings Replacement, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00 0030 00-1
Hoses, Pipes, and Clamps Replacement, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00 0042 00-1
Housing Cover Replacement, Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043 00 0043 00-1
Hub, Drum, Wheel Bearings, and Seal Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00 0165 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00 0166 00-1
HVAC
Air Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219 00 0219 00-1
Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00 0220 00-1
Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221 00 0221 00-1
I
Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230 00 0230 00-1
Impeller and Shroud Replacement, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00 0047 00-1
Intake Tubes and Hoses Replacement, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00 0037 00-1
Interior Light Unit and Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00 0091 00-1
Introduction
Unit Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . 0020 00 0020 00-1
J
Junction Block Replacement
Cab Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00 0149 00-1
Constant Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00 0148 00-1
Index-8
TM 9-2320-302-20
INDEX - Continued
L
Lamps Replacement
Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00 0060 00-1
Right Gage Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00 0062 00-1
Latch Replacement
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00 0188 00-1
Storage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00 0199 00-1
Leak Test, Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00 0225 00-1
Left Hand Switch Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00 0064 00-1
Left Panel Gages and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00 0060 00-1
Left Side Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00 0173 00-1
Left Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00 0172 00-1
Light Maintenance, Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00 0090 00-1
Light Replacement
Blackout Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00 0084 00-1
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00 0089 00-1
Marker Light, Blackout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00 0084 00-1
Side Marker/Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00 0088 00-1
Light Source Replacement, Fiber Optic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00 0069 00-1
Light Unit and Bulb Replacement, Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00 0091 00-1
Liner(s) Replacement
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00 0202 00-1
Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00 0203 00-1
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00 0189 00-1
List
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-2
Nomenclature Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-2
Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00 0002 00-2
Lubrication
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1. 0020 00-4
Procedures, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00 0020 00-1
Lug Nut Installation, Front and Dual Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00 0164 00-1
M
M13 Decontamination Kit Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . 0227 00 0227 00-1
M16 Rifle Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216 00 0216 00-1
Magnetic Clutch Replacement, Air Conditioner Compressor . . . . . . . . . . . . . . . . . 0226 00 0226 00-1
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Index-9
TM 9-2320-302-20
INDEX - Continued
M - Continued
Maintenance Instructions, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00 0228 00-1
Major Components, Location and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00 0002 00-2
Manufactured Items, Illustrated List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230 00 0230 00-1
Master Battery Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00 0072 00-1
Mats Replacement, Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00 0201 00-1
Mirror Replacement
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00 0208 00-1
Spotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00 0209 00-1
Module Replacement
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00 0066 00-1
Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00 0080 00-1
Motor and Linkage Replacement, Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . 0210 00 0210 00-1
Mounting Bracket Replacement
M13 Decontamination Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0227 00 0227 00-1
M16 Rifle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216 00 0216 00-1
Vehicle Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0213 00 0213 00-1
Mud Flap Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00 0196 00-1
Muffler, Stack, and Heat Shield Replacement, Exhaust System . . . . . . . . . . . . . . . 0039 00 0039 00-1
N
Nomenclature Cross-reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-2
O
Oil
Cooler and Oil Filter Adapter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00 0025 00-1
Cooler Lines and Fittings Replacement, Transmission . . . . . . . . . . . . . . . . . . 0122 00 0122 00-1
Cooler Replacement, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00 0127 00-1
Fill Tube Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00 0022 00-1
Fill/Level Check Tube Replacement, Transmission . . . . . . . . . . . . . . . . . . . . . 0121 00 0121 00-1
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00 0024 00-1
Filter Elements Replacement, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00 0123 00-1
Level Dipstick, Tube, and Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . 0023 00 0023 00-1
Pressure Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00 0097 00-1
Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00 0095 00-1
Sample Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00 0026 00-1
Overhead Storage Compartment Replacement, Cab . . . . . . . . . . . . . . . . . . . . . . . 0204 00 0204 00-1
Ozone Depleting Substances (ODS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Index-10
TM 9-2320-302-20
INDEX - Continued
P
Parking Brake and Trailer Air Supply Valve Replacement . . . . . . . . . . . . . . . . . . . 0160 00 0160 00-1
Parking Brake Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00 0079 00-1
Pedal Replacement, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00 0134 00-1
Personal Gear Storage Box and Mounting Bracket Replacement . . . . . . . . . . . . . 0197 00 0197 00-1
Pintle Hook Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00 0179 00-1
Pitman Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00 0169 00-1
Plates Replacement, Data and Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00 0215 00-1
Platform Replacement
Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00 0173 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00 0200 00-1
PMCS Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00 0020 00-3
Power Steering Reservoir and Hose Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00 0170 00-1
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . 0020 00 0020 00-1
Preventive Maintenance Checks and Services (PMCS), Unit . . . . . . . . . . . . . . . . . 0021 00 0021 00-1
Primary I Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00 0143 00-1
Primary II Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00 0144 00-1
Probe Replacement, Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00 0081 00-1
Prop and Mount Replacement, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00 0190 00-1
Pump Maintenance, Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00 0052 00-1
Pump Replacement, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00 0034 00-1
R
Radiator
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 00 0045 00-1
Support Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00 0044 00-1
Rear
Air Brake Chamber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00 0142 00-1
Axle Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00 0133 00-1
Brake Spider and Brake Chamber Bracket Replacement . . . . . . . . . . . . . . . . 0138 00 0138 00-1
Brakeshoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00 0137 00-1
Fender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00 0195 00-1
Gladhand Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00 0154 00-1
Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00 0200 00-1
Quick-release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00 0156 00-1
Relay Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00 0151 00-1
Shock Absorber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00 0183 00-1
Index-11
TM 9-2320-302-20
INDEX - Continued
R - Continued
Rear - Continued
Suspension System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-8
Tie Down Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00 0177 00-1
View Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00 0208 00-1
Receptacle Replacement
12V Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00 0068 00-1
NATO Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00 0076 00-1
Trailer Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00 0078 00-1
Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00 0077 00-1
Regulator Replacement, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00 0057 00-1
Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00 0071 00-1
Relay Replacement, Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00 0059 00-1
Reporting Equipment Improvement Recommendations (EIRs) . . . . . . . . . . . . . . . 0001 00 0001 00-1
Reservoir and Hose Maintenance, Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 0170 00 0170 00-1
Reservoir, Windshield Washer, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00 0211 00-1
Resister Block Replacement, Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00 0222 00-1
Right Gage Panel and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00 0062 00-1
Right Hand Switch Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00 0065 00-1
Right Rear Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00 0174 00-1
Right Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00 0171 00-1
S
Sample Valves Replacement, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00 0026 00-1
Seat
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00 0193 00-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00 0192 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00 0191 00-1
Secondary Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00 0145 00-1
Selector Replacement, Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00 0120 00-1
Sending Unit Replacement
Brake Light/Trailer Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00 0109 00-1
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00 0094 00-1
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00 0097 00-1
Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00 0099 00-1
Air Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00 0101 00-1
Anti-lock Brake System (ABS), Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00 0106 00-1
Anti-lock Brake System (ABS), Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00 0107 00-1
Fan Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00 0100 00-1
Index-12
TM 9-2320-302-20
INDEX - Continued
S - Continued
Sensor Replacement - Continued
Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00 0092 00-1
Fuel Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00 0093 00-1
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00 0095 00-1
Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00 0096 00-1
Side, Collision Waring System (CWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00 0111 00-1
Synchronous Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00 0104 00-1
Timing Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00 0103 00-1
Transmission Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00 0126 00-1
Turbo Boost Sensor (TBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00 0102 00-1
Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00 0099 00-1
Water Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00 0098 00-1
Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00 0019 00-1
Shaft Replacement and Repair, Universal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00 0168 00-1
Shift
Selector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00 0120 00-1
Tower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00 0120 00-1
Shock Absorber Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00 0182 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00 0183 00-1
Side Sensor Display Replacement, Collision Warning System (CWS) . . . . . . . . . . 0111 00 0111 00-1
Slack Adjuster Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00 0139 00-1
Slack Adjuster and S-cam Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00 0140 00-1
Slave Receptacle Replacement, NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00 0076 00-1
Solenoid Replacement, Fan Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00 0048 00-1
Spare Wheel Hoist Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00 0176 00-1
Spindle and Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00 0053 00-1
Splash Guard Maintenance, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00 0194 00-1
Spotter Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00 0209 00-1
Starter
Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00 0059 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00 0056 00-1
Steering
Column Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00 0205 00-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00 0167 00-1
Steering System
Index-13
TM 9-2320-302-20
INDEX - Continued
S - Continued
Step Replacement
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00 0172 00-1
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00 0171 00-1
Right Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00 0174 00-1
Stop Cushion Replacement, Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00 0132 00-1
Stop/Tail/Backup Lights Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . 0116 00 0116 00-1
Storage Box
Basic Issue Items (BII) and Mounting Bracket, Replacement . . . . . . . . . . . . . 0198 00 0198 00-1
Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00 0199 00-1
Personal Gear and Mounting Bracket, Replacement . . . . . . . . . . . . . . . . . . . . 0197 00 0197 00-1
Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Strainer and Filter Element Replacement, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00 0031 00-1
Support Rod Replacement, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00 0044 00-1
Switch
Binary, Air Conditioner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00 0224 00-1
Check Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00 0070 00-1
Master Battery, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00 0072 00-1
Parking Brake Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00 0079 00-1
Thermostatic, Air Conditioner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0223 00 0223 00-1
Turn Signal, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00 0073 00-1
Switch Panel
Maintenance, Left Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00 0064 00-1
Replacement, Right Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00 0065 00-1
Symptom Index, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00 0005 00-1
Synchronous Reference Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00 0104 00-1
T
Taillight
Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00 0181 00-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00 0087 00-1
Tank and Fittings Replacement
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00 0146 00-1
Primary I Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00 0143 00-1
Primary II Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00 0144 00-1
Tank and Mounting Brackets Replacement, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 0033 00 0033 00-1
Theory of Operation
Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-9
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-5
Index-14
TM 9-2320-302-20
INDEX - Continued
T - Continued
Theory of Operation - Continued
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-5
Collision Warning System (CWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-10
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-3
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-3
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-1
Rear Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-8
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-7
Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-7
Thermostat and Thermostat Housing Cover Replacement . . . . . . . . . . . . . . . . . . . 0043 00 0043 00-1
Throttle Replacement, Electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00 0074 00-1
Tie Down Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00 0177 00-1
Timing Reference Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00 0103 00-1
Toe-in Alignment, Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00 0131 00-1
Tone Ring, ABS, Replacement
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00 0165 00-1
Rear-rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00 0166 00-1
Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231 00 0231 00-1
Tower Replacement, Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00 0120 00-1
Towing Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00 0180 00-1
Traction Control System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00 0003 00-7
Tractor Protective Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00 0150 00-1
Trailer Electrical Receptacles Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00 0078 00-1
Trailer Hand Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00 0159 00-1
Transmission
Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00 0128 00-1
Electronic Control Unit (ECU) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124 00 0124 00-1
Electronic Control Unit (ECU) Wiring Harness Replacement . . . . . . . . . . . . . . 0125 00 0125 00-1
Oil Cooler Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122 00 0122 00-1
Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00 0127 00-1
Oil Fill/Level Check Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00 0121 00-1
Oil Filter Elements Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00 0123 00-1
Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00 0126 00-1
Tunnel Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00 0207 00-1
Transmission and Driveline Systems Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 0011 00 0011 00-1
Troubleshooting
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00 0014 00-1
Index-15
TM 9-2320-302-20
INDEX - Continued
T - Continued
Troubleshooting - Continued
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00 0012 00-1
Chassis and Fifth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00 0016 00-1
Collision Warning System (CWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00 0018 00-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00 0009 00-1
DDEC Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00 0007 00-1
Driveline Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00 0011 00-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00 0010 00-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00 0006 00-1
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00 0008 00-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00 0004 00-1
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00 0015 00-1
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00 0005 00-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00 0011 00-1
Troubleshooting and Testing
Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00 0017 00-1
Anti-lock Brake System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00 0013 00-1
Tube Replacement, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00 0147 00-1
Turbo Boost Sensor (TBS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00 0102 00-1
Turn Signal
Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00 0088 00-1
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00 0073 00-1
U
U-joints and Bearings Replacement, Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00 0130 00-1
Unit
Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . 0021 00 0021 00-1
Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . 0020 00 0020 00-1
Universal Shaft Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00 0168 00-1
Upper Right Dash Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00 0063 00-1
Utility Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00 0090 00-1
Utility Power Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00 0077 00-1
V
Valve(s) Replacement
Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00 0214 00-1
Foot Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00 0161 00-1
Front Service Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00 0152 00-1
Index-16
TM 9-2320-302-20
INDEX - Continued
V - Continued
Valve(s) Replacement - Continued
Parking Brake and Trailer Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0160 00 0160 00-1
Quick-release, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00 0155 00-1
Quick-release, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00 0156 00-1
Rear Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00 0151 00-1
Tractor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00 0150 00-1
Vehicle Jack Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0213 00 0213 00-1
Voltage Control Replacement, Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00 0058 00-1
Voltage Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00 0057 00-1
W
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00 0001 00-1
Water
Filter Adapter and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00 0051 00-1
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00 0050 00-1
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00 0052 00-1
Water Level
Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00 0080 00-1
Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00 0081 00-1
Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00 0099 00-1
Wheel
Bearings and Seal Replacement, Front Hub, Drum . . . . . . . . . . . . . . . . . . . . . 0165 00 0165 00-1
Bearings and Seal Replacement, Rear Hub, Drum . . . . . . . . . . . . . . . . . . . . . 0166 00 0166 00-1
Lug Nut Installation, Front and Dual Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00 0164 00-1
Replacement, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00 0167 00-1
Windshield
Washer Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00 0211 00-1
Wiper and Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212 00 0212 00-1
Wiper Motor and Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00 0210 00-1
Wiper and Wiper Arm Replacement, Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . 0212 00 0212 00-1
Wiring Harness(es) Replacement
Automatic Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00 0117 00-1
Stop/Tail/Backup Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00 0116 00-1
Transmission Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00 0125 00-1
Index-17
TM 9-2320-302-20
Index-18
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
Official:
13902
DISTRIBUTION:
To be distributed in accordance with the initial distribution number (IDN) 381094, requirements for
TM 9-2320-302-20.
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 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles
Weights Cubic Measure
1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Pounds 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
Temperature
Liquid Measure
5/9 (°F - 32) = °C
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212° Fahrenheit is equivalent to 100° Celsius
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 90° Fahrenheit is equivalent to 32.2° Celsius
32° Fahrenheit is equivalent to 0° Celsius
9/5 C° +32 = F°
APPROXIMATE CONVERSION FACTORS
To Change To Multiply By To Change To Multiply By
Inches Centimeters 2.540 Centimeters Inches 0.394
Feet Meters 0.305 Meters Feet 3.280
Yards Meters 0.914 Meters Yards 1.094
Miles Kilometers 1.609 Kilometers Miles 0.621
Sq Inches Sq Centimeters 6.451 Sq Centimeters Sq Inches 0.155
Sq Feet Sq Meters 0.093 Sq Meters Sq Feet 10.764
Sq Yards Sq Meters 0.836 Sq Meters Sq Yards 1.196
Sq Miles Sq Kilometers 2.590 Sq Kilometers Sq Miles 0.386
Acres Sq Hectometers 0.405 Sq Hectometers Acres 2.471
Cubic Feet Cubic Meters 0.028 Cubic Meters Cubic Feet 35.315
Cubic Yards Cubic Meters 0.765 Cubic Meters Cubic Yards 1.308
Fluid Ounces Milliliters 29.573 Milliliters Fluid Ounces 0.034
Pints Liters 0.473 Liters Pints 2.113
Quarts Liters 0.946 Liters Quarts 1.057
Gallons Liters 3.785 Liters Gallons 0.264
Ounces Grams 28.349 Grams Ounces 0.035
Pounds Kilograms 0.454 Kilograms Pounds 2.205
Short Tons Metric Tons 0.907 Metric Tons Short Tons 1.102
Pound-Feet Newton-Meters 1.356 Newton-Meters Pound-Feet 0.738
Pounds per Sq Kilopascals 6.895 Kilopascals Pounds per Sq 0.145

Inch Inch
Miles per Gallon Kilometers per Liter 0.425 Kilometers per Liter Miles per Gallon 2.354
Miles per Hour Kilometers per Hour 1.609 Kilometers per Hour Miles per Hour 0.621
PIN: 078099-000

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TM 9-2320-302-20

UNIT MAINTENANCE MANUAL

TRUCK, TRACTOR, LINE HAUL:

Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

This page is blank.

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Dates of issue for original and change pages/work packages are:

Original 28 May 2001

Cover (Back Blank) 0

* Zero in this column indicates an original page or work package.

This Page Intentionally Left Blank.

FOR INFORMATION ON FIRST AID, REFER TO FM 21-11.

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

1. DO NOT operate truck engine in enclosed areas.

3. DO NOT drive truck with inspection plates or cover plates removed.

4. BE ALERT for exhaust poisoning symptoms. They are:

• Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:

• Remove person from area.

• Keep person warm.

• Do not permit physical exercise.

• Administer cardiopulmonary resuscitation (CPR), if necessary.

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

ADHESIVES AND SEALING COMPOUNDS

AIR LINES AND FITTINGS

DIESEL FUEL HANDLING

ETHER QUICK-START SYSTEM

HAZARDOUS WASTE DISPOSAL

To order this NBC decal use:

PRESSURIZED COOLING SYSTEM

TECHNICAL MANUAL HEADQUARTERS

UNIT MAINTENANCE MANUAL

TRUCK, TRACTOR, LINE HAUL:

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION

WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

CHAPTER 2 UNIT TROUBLESHOOTING PROCEDURES

WP 0004 00 Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

Table of Contents - Continued

WP 0014 00 Air System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1

CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS

WP 0019 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1

Table of Contents - Continued

WP 0060 00 Left Panel Gages and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1

Table of Contents - Continued

Table of Contents - Continued

WP 0155 00 Front Quick-release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1

Table of Contents - Continued

WP 0202 00 Cab Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1

CHAPTER 4 SUPPORTING INFORMATION

WP 0232 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0232 00-1

HOW TO USE THIS MANUAL

FEATURES OF THIS MANUAL:

• A Table of Contents is provided at the beginning of this manual.

FOLLOW THESE GUIDELINES WHEN YOU THIS MANUAL:

This Page Intentionally Left Blank.

This Page Intentionally Left Blank.

GENERAL INFORMATION 0001 00