Usage:
D250E (5TN),
D300E (7FN),
D350E (9LR),
D400E (2YR) Articulated Trucks
Reference: Service Magazine, October 30, 1995, Page 14, "New ICM Transmission Control (Actual Gear Switch) Is Available".
Reference: Service Magazine, January 22, 1996, Page 6, "New Transmission Control (Actual Gear Switch) Now Used".
Reference: Service Magazine, March 18, 1996, Supplement to January 22, 1996 Article "New Transmission Control (Actual Gear Switch) Now Used".
Reference: Service Magazine, March 31, 1997, Page 25, "New Transmission Harness With Revised Grounding Now Used To Increase Service Life".
Reference: Service Magazine, June 22, 1998, Page 30, "Improved ICM Transmission Gear Position Sensor Available".
Reference: Service Manual Module, SENR9122, Systems Operation Testing & Adjusting, Electronic Programmable Transmission Control (EPTC II) For ICM Transmissions
Reference: Service Manual Module, SENR8656, Systems Operations Testing & Adjusting, Electronic Programmable Transmission Control (EPTC II) For Articulated Trucks.
The machines listed above are now equipped with a non-contacting Hall effect gear position sensor. The 139-9473, 131-5393, 127-4646, and 118-8471 Position Sensors have replaced the original mechanically contacting gear position switches. (See the referenced service magazine article.) The specific sensor installed depends on the machine. Both former and new sensors indicate the actual gear position. The service manual referenced above contains the testing and adjusting procedures for these sensors: In the Detected Faults section (faults with service codes), see "CID 0700 Transmission Gear Switch" in the Components Description Section and further back in the Testing and Adjusting Section. The following procedure is to be used as a supplement to the existing procedures, to identify problems with the gear position sensor.
1. Remove the cover plate on the transmission housing manifold that covers the gear position sensor.
2. Check wiring harness connections at the sensor and both sides of the bulkhead connector while monitoring the EPTC II for diagnostic codes. Perform a 10 pound pull test on each wire, to verify that connections are good.
3. Unplug the wiring harness connection at the gear position sensor. Inspect the contacts on the gear position sensor and in the harness connector for contamination. Plug the wiring harness connector into the gear position sensor connector.
NOTE: The 139-9473 and 131-5393 Position Sensors are encased in a black plastic housing. The black plastic housing prohibits the view of the magnet's position, therefore Steps 4-14 do not apply to these two sensors.
4. Perform a visual check of the sensor. The center of the magnet on the rotor should be directly under the raised protrusions on the switch housing for each switch position. The raised protrusions are on the same side of the housing as the raised part number. The round magnet is on the outer circumference of the black plastic rotor, and can easily be viewed through the clear plastic of the housing.
NOTE: The raised protrusions, or "timing marks", were added to the plastic housing of the 118-8471 Position Sensor effective with a date code of May 1, 1996. The marks appear on the face of the sensor which faces outward, as installed on the transmission. The raised protrusions were added to the housing of the 127-4646 Position Sensor effective with a date code of May 6, 1998. The date code of the sensor appears as raised letters on the plastic housing, in "NUMERALKOD" designation. The format uses letters to represent the date code. Starting on the left side of the "NUMERALKOD", the letter "N" represents "0", "U" represents "1", "M" represents "2" etc. Moving from left to right, each letter represents an incremental number, where the last letter "D" represents "9". The date code on the part is DDMMYY format. For example, date code "NLNADL" represents a date code of 06 MAY 96 (NL=06, NA=05th month, May, and DL=Year 96).
5. Remove the plug on the opposite side of the transmission case to access the rotary spool.
6. With the key switch in the ON position and the engine OFF, put the EPTC II in Mode 4 - Shift Monitor Mode. Monitor the transmission control to verify that the actual gear position sensor indicates "Neutral".
NOTE: Certain gear switch positions are not used on Articulated trucks. Refer to the transmission gear switch logic chart in the Service Manual for applicable switch positions for the machine being serviced.
7. Rotate the rotary selector spool by inserting a 1/4 inch socket drive into the end of the spool and turning it until the next detent is reached.
8. Verify that the EPTC II indicates the correct gears in order as the spool is rotated (simulating an upshift). The appropriate gear position pattern, dependent upon machine and transmission, can be found in the "Transmission Gear Switch Logic" table in the Service Manual referenced. As the spool is rotated for each position, visually inspect the actual gear position sensor to verify that the center of the magnet is under the corresponding raised protrusion position on the sensor housing. The magnet need not be in the center of the raised protrusion, but a portion of the magnet must be located under the protrusion for the system to function properly. If, after reaching the top gear of the transmission, each displayed transmission gear observed in the Shift Monitor Mode matched the corresponding gear sensor position, proceed to Step 13. If not, proceed to the next step.
Transmission Gear Switch
Transmission Gear Switch
9. Rotate the spool back to the Neutral position.
10. With the key switch in the "On" position and the engine off, put the EPTC II in Mode 2 - Shift Status Mode.
11. Check that the EPTC II indicates the correct five switch states (low signal or high signal) for each gear position as the spool is rotated. The switch states for each gear position are shown in the Transmission Gear Switch Logic chart in this article as well as the corresponding EPTC II Service Manual. Again, verify the magnet location for each switch position, as described in Step 8. If OK, proceed to the next step. If not, proceed to Step 14.
12. Repeat Step 11, but in reverse order. Rotate the spool in the opposite direction, simulating downshifting back to neutral. Proceed to Step 13.
13. Repeat Step 8, but in reverse order. Rotate the spool in the opposite direction, simulating downshifting back to neutral.
14. If the gear sensor magnet locations are acceptable during the previous steps, refer to CID 0700 on Page 55 of SENR9122-02, or Page 48 of SENR8656-01, for further electrical troubleshooting of the actual gear sensor and electrical wiring. The switch states observed in Step 11 may provide direction on where to proceed. If the magnet location was unacceptable, proceed to Step 15.
15. Check the shift linkage if linkage adjustment is suspect. Also check the flexible coupling which is keyed to the actual gear position sensor's rotor. Verify that the switch is properly bolted to the mounts.
16. An EPTC II diagnostic code of CID 0700 FMI 02 will likely be present if at least a portion of the magnet is not located under the raised protrusion on the switch housing for each switch position. If all steps above check out OK, including the procedures for CID 0700 in the service manual, replace the switch.