W564 0111e PDF

Publication No.
W564-0111E
Service Manual
01
Retarder
Model R120S
TADANO LTD.
Forword
Forword
This service manual describes the assembly and

disassembly procedures for the models of retarders
below that are mounted to the Rough Terrain Crane.
Before starting the work, check the model number on
the nameplate.
Also, together with this manual, please read the
materials including the related parts catalog and
service manuals, and exercise proper handling.
1. Applicable Crane Model

The retarder models corresponding to the crane
model are listed in the table below.
Applicable Control method

Crane model Mounting method Retarder model
serial No. (Control unit)
TR-250M-7 Digiprop type Mid-mount retarder
--
GR-300N-1 (With coolant temperature sensor
and oil temperature sensor,
GR-250N-1 Up to FB4282 R120S F1
4-step switch)
GR-350N-1 Up to 506317
From FB4283 VERA type
From 506318
GR-500N-1 Up to 582802 Digiprop type Direct mount retarder
GR-600N-1 Up to FD5208 (With coolant temperature sensor
UN-500K-1 Up to UC5088 and oil temperature sensor,
4-step switch) R120S GA
From 582803 VERA type
From FD5209
From UC5089
TR-250M-6 Analog type Mid-mount retarder
TR-350M-3 (conventional control method)
-- 120S F1
(Coolant sensor only
5-step switch)
(Difference with the retarder control method (control unit))

Item Digiprop type VERA type
ISO interface L line With Without
Indication of past error by pilot lamp With Without
Deletion of past error L line and PC PC only
1. Vehicle stop 1. Vehicle stop
2. Hand lever in position 0 2. Hand lever in position 0
Service function starting steps
3. Ignition OFF/ON 3. Ignition OFF/ON
4. Hand lever from 4 to 0
Error code Refer to page 101. Refer to page 102.
Connector terminal arrangement Refer to pages 34, 35. Refer to page 44.
Please note that the contents may be changed due

to modification.
1 W564-0111E
Forword
2. Contents 2.2. Troubleshooting

(With Abnormality Code) ..........................32
Forword ............................................................ 1 2.2.1. Reading of Abnormality Memory by
Flashing Code of Retarder Pilot Lamp.....32
1. Applicable Crane Model ..................................... 1 2.2.2. Reading by Grounding of ISO Interface
2. Contents ............................................................. 2 L Line........................................................33
2.2.3. Deletion of Abnormality Code
Construction .................................................... 4 from Memory ............................................33
2.2.4. Reading of Abnormality Memory
1. Overview of Retarder.......................................... 4 from PC ....................................................33
1.1. Serial Number............................................ 4 2.2.5. Abnormality Code and Troubleshooting...34
1.2 Illustration of Main Body ............................ 5 2.3. Troubleshooting
1.3. Illustration of Control System..................... 7 (Without Abnormality Code) .....................41
1.4. Description of Retarder Operation............. 9
3. Troubleshooting (Control Unit: VERA Type) .....43
Functions........................................................ 11 3.1. Diagnosis (Self Diagnosis of Trouble)......43
3.2. Troubleshooting
1. Retarder System (Control Unit: Digiprop Type).11
(With Abnormality Code) ..........................43
1.1. Mid-Mount Retarder (TR-250M-7,
3.2.1. Calling of Abnormality Code.....................43
GR-300N-1, GR-250N-1, GR-350N-1) .....11
3.2.2. Deletion of Abnormality Code
1.2. Direct Mount Retarder (GR-500N-1,
from Memory ............................................43
GR-600N-1, UK-500K-1) ......................... 12
3.2.3. Abnormality Code and Troubleshooting...44
1.3. Error Code Checking Procedure
(Digiprop Type) ........................................ 13 4. Inspection..........................................................48
4.1. Adjustment pressure and pump
2. Retarder System (Control Unit: VERA Type).... 16
pressure check.........................................48
2.1. Mid-Mount Retarder (GR-250N-1,
4.1.1. Pump Pressure Checking Procedure.......49
GR-350N-1) ............................................. 16
4.2. Control System Check .............................51
2.2. Direct Mount Retarder (GR-500N-1,
4.2.1. Inspection of Supply Air Pressure Pv.......52
GR-600N-1, UN-500K-1) ......................... 17
4.2.2. Measuring Instrument Setup....................53
2.3. Error Code Checking Procedure
4.2.3. Inspection Procedure ...............................54
(VERA Type) ............................................ 18
4.3. Vehicle Stop Operation Check .................56
4.3.1. Inspection.................................................56
Maintenance ................................................... 21
1. Maintenance ..................................................... 21 Servicing ........................................................ 57

1.1. Oil amount check..................................... 21
1. Servicing of Retarder Main Body ......................57
1.1.1. Oil Amount Checking Procedure ............. 22
1.1. Servicing of Ventilator ..............................57
1.2. Oil replacement ....................................... 23
1.1.1. Disassembly.............................................58
1.2.1. Oil Replacement Procedure .................... 24
1.1.2. Inspection.................................................60
1.3. Cleaning the Air Filter .............................. 25
1.1.3. Assembly..................................................60
1.3.1. Air Filter Cleaning Procedure .................. 26
1.2. Servicing of Check Valve .........................61
1.3. Servicing of Oil Cooler .............................62
Troubleshooting............................................. 27
1.3.1. Preliminary Work ....................................63
1. Troubleshooting Flowchart ............................... 27 1.3.2. Removal ...................................................64
1.3.3. Inspection.................................................65
2. Troubleshooting (Control Unit: Digiprop Type) . 31
1.3.4. Mounting ..................................................66
2.1. Diagnosis (Self Diagnosis of Trouble) ..... 31
2 W564-0111E
Forword
1.4. Mounting/Dismounting of Lower Cover ... 67 1.10. Abnormality Code Table .........................101
1.5. Servicing of Breather Filter ...................... 68 1.10.1. Control Unit: Digiprop Type ....................101
1.6. Replacing the Output Side Shaft 1.10.2. Control Unit: VERA Type........................102
Oil Seal .................................................... 69
1.6.1. Working Procedure.................................. 70 Overview of Retarder
(Conventional Control Method).................. 103
2. Servicing of Mid-Mount Retarder Main Body.... 72
2.1. Mounting/Dismounting of Retarder.......... 72 1. Overview of Conventional Control Method
2.1.1. Removal Procedure................................. 73 Retarder ..........................................................103
2.2. Mounting/Dismounting of Input/ 1.1. Function .................................................103
Output Shaft Flange ................................ 75 1.2. Case with TR-250M-6 ............................104
2.2.1. Mounting .................................................. 77 1.3. Case with TR-350M-3 ............................105
2.3. Replacing the Input Side Shaft Oil Seal .. 78
2.3.1. Working Procedure.................................. 79
3. Servicing of Direct Mount Retarder Main

Body.................................................................. 81
3.1. Mounting/Dismounting of Output Shaft
Flange...................................................... 81
3.2. Mounting/Dismounting of Retarder
(Example of TADANO Rough Terrain
TR500M and 350M)................................. 83
3.2.2. Mounting .................................................. 85
3.3. Replacing the Input Side Shaft Oil Seal .. 86
Data ................................................................. 89
1. Data .................................................................. 89
1.1. Tightening Torque Table .......................... 89
1.2. Special Tool.............................................. 90
1.3. Specified Oil............................................. 91
1.4. Specified Coolant, Sealer, and
Lubricant .................................................. 92
1.4.1. Coolant .................................................... 92
1.4.2. Sealer and Lubricant ............................... 92
1.5. Retarder R120S Specification ................. 93
1.6. Connection Layout................................... 94
1.7. Mid-Mount Retarder Disassembly
Diagram ................................................... 95
1.8. Direct Mount Retarder Disassembly
Diagram ................................................... 97
1.9. Electrical Wiring Diagram ........................ 99
1.9.1. Control Unit: Digiprop Type ..................... 99
1.9.2. Control Unit: VERA Type ....................... 100
3 W564-0111E
Construction
Construction
1. Overview of Retarder
1.1. Serial Number
The serial number (8 digits) is stamped at the oil

cooler side of the retarder housing, the position
indicated by an arrow in the right figure. This
number consists of the 4-digit number, starting
with a letter W and indicating the retarder model,
and the 4-digit number indicating the
manufacturing order. Serial number
Example: W0260123
When making an inquiry or ordering repair parts,

please indicate this serial number.
4 W564-0111E
Construction
1.2 Illustration of Main Body
1. Retarder housing
2. Serial number
3. Rotor housing
4. Oil cooler
5. Refill level check plug (M30 × 1.5)
13. Coolant drain plug (M12 × 1.5)
14. Adjusting air connection port
16. Exhaust connection port
5 W564-0111E
Construction
1. Retarder housing
4. Oil cooler
7. Retarder oil drain plug (M22 × 1.5)
9. Oil cooler oil drain plug (M12 × 1.5)
11. Leaked oil drain plug (M10 × 1)
13. Coolant drain plug (M12 × 1.5)
6 W564-0111E
Construction
1.3. Illustration of Control System
20. Control unit

22. 24-V ignition power supply
24. Ground
27. Retarder hand lever switch
28. Retarder pilot lamp
29. Stop lamp relay
30. Coolant temperature sensor
35. Proportional solenoid valve
36. Adjusting air piping (A)
37. Supply air piping (P)
38. Quick exhaust piping (R)
81. Vehicle speed signal
290. Oil temperature sensor
291. ISO interface connector (diagnosis)
293. ABS signal
294. 24-V battery power supply or ignition power supply
295. Fuse (5 A)
7 W564-0111E
8
Construction
W564-0111E
4. Oil cooler 36. Adjustment air pressure 96. Outlet orifice
18. Leaked oil recovery gallery 37. Supply air pressure 97. Inlet orifice Oil sump Coolant
19. Oil feeding duct 38. Exhaust 144. Check valve
20. Control unit 60. Retarder main body 290. Oil temperature sensor Supply air pressure Pump pressure
22. Ignition power supply 61. Oil sump 291. Diagnosis connector
24. Ground 62. Stator 293. ABS signal
27. Hand lever switch 63. Rotor 294. Battery power supply Adjustment air pressure
28. Pilot lamp 67. Stator pin 295. Fuse (5 A)
29. Stop lamp relay 81. Vehicle speed signal
30. Coolant temperature sensor 82. Ventilator
35. Proportional solenoid valve 95. Pump pressure test plug
Construction
1.4. Description of Retarder Operation working chamber located between the rotor (63)
and stator (62).
Braking
By the operation of hand lever switch (27) having
the maximum of 4-step switching, the retarder
(60) is controlled.
When the hand lever switch is set in 1st position,

a constant speed driving is started. The speed of
that moment is stored in the memory, and the
retarder maintains the vehicle speed on a
downslope at a constant speed within the
maximum braking torque range.
When the retarder is set to OFF (position 0) or set

to the brake positions (2nd to 4th position), the
"constant speed" up to that moment will be Principle of hydrodynamics:
deleted from the memory. When another "constant a: Rotor
speed" operation is started, the new speed of that b: Stator
moment is stored in the memory. c: Oil flow
When the hand lever switch is set to positions The rotor (63) is joined with the propeller shaft,
from 1 to 4, the retarder operates in the steps and the stator (62) is fixed to the retarder housing.
from 1 to 4.
By the rotation of rotor (63), oil flow is generated,
The maximum braking torque can be obtained and the oil circulates between the rotor (63) and
when the hand lever switch is set to the highest stator (62).
position.
When the speed of oil flow is decreased in the
The control medium of retarder (60) is the stator, the rotor becomes decelerated, and the
compressed air. The compressed air can be brake is applied to the vehicle.
obtained from the air tank for auxiliary device of
the vehicle. While the brake is applied, the kinetic energy of
the decelerating vehicle is turned into heat. As a
When the hand lever switch (27) is activated, the result, the oil temperature becomes high. In order
input signal is sent to the control unit (20). By the to dissipate the heat, a portion of the circulating oil
input signal, the control unit (20) outputs the in working chamber is constantly fed to the oil
control current, and the control current is supplied cooler (4) and returned to the circulation flow. In
to the proportional solenoid valve (35). the oil cooler (4), the heat from the oil is
transferred to the vehicle coolant, and is
The proportional solenoid valve (35) sends the dissipated into the atmosphere from the vehicle
adjustment air pressure, which is proportional to radiator.
the amount of control current, to the oil sump (61).
The adjustment air pressure of oil sump (61)

feeds the amount of oil corresponding to the
operation condition (propeller shaft speed) to the
9 W564-0111E
Construction
proportional solenoid valve is decreased linearly.

Pulse lubrication
Consequently, the adjustment air pressure is
With the ignition turned ON, when the retarder is
restricted, and a restriction is also implemented to
not activated during travelling, the control unit (20)
the retarder braking torque. When the oil
generates a very short lubrication pulse with an
temperature exceeds the temperature upper limit
interval of approximately three minutes, and the
range, the braking torque will not be output.
lubrication is performed to the retarder bearing
and oil seal. At this time, no braking force is
Regardless of the oil temperature, if an
generated.
excessively sudden rise of oil temperature occurs,
Overheat protection the control unit restricts the braking torque.
The temperature sensor (30, 290) sends signals
relating to the coolant and oil temperatures to the When the restriction by overheat protection
control unit. exceeds a certain level, a notification is made to
the driver with a flashing of the pilot lamp.
The retarder braking torque is restricted so that
the coolant and oil temperatures do not exceed During the overheat protection restriction or when
the temperatures that are already set in the a retarder malfunction has occurred, the vehicle
control unit, thus protecting the vehicle cooling speed must be controlled by using the service
system and retarder. brake.
Ventilator (82)
The braking torque and its resulting heat are
When the retarder is activated, the oil is charged
reduced to a level at which a balance is achieved
to inside the working chamber. The amount of air
between the retarder braking energy and the heat
equal to the charged oil is discharged to outside
quantity dissipated by vehicle cooling system.
through the ventilator. As a result, the bubbling of
oil is reduced, allowing for the charging to be
With the retarder under braking state, when the
performed appropriately. When air is completely
coolant temperature rises to the upper limit range,
discharged from the working chamber, the float of
the control current supplied to the retarder
ventilator floats because of the buoyancy by oil,
proportional solenoid valve is decreased linearly
thereby closing the valve and preventing the oil
for the initial five seconds. Consequently, the
from leaking.
adjustment air pressure is restricted, and a
restriction is also implemented to the retarder Stator pin (67)
braking torque. Subsequently, the control system When the retarder is not active, some air is
works to maintain the coolant temperature at a present in the working chamber. A slight braking
constant level. For example, when the force is generated when a flow is generated to the
measurement temperature is lower than the air by the rotation of rotor (63). This results in a
maximum allowable temperature, the adjustment power loss. To minimize this loss, the stator pin
air pressure is gradually increased (up to the that works automatically is arranged on the outer
maximum point at which the correction function is face of the stator blade. A disk at the leading end
not activated). In a reverse case, the adjustment of stator pin disturbs the airflow that goes through
air pressure is gradually decreased (down to the the stator blade, and hampers the generation of
minimum of 0). effective braking force. When the working
chamber is filled with oil, the disk presses the
With the retarder under braking state, when the oil spring by the oil pressure and it is stored away at
temperature rises to the upper limit range, the the bottom. Therefore, the oil flow is not disrupted,
control current supplied to the retarder and the effective braking force is exerted.
10 W564-0111E
Functions
Functions
1. Retarder System (Control Unit: Digiprop Type)
1.1. Mid-Mount Retarder (TR-250M-7, GR-300N-1, GR-250N-1, GR-350N-1)

31. Retarder function Controller
[1] When the retarder hand lever is set to position 1 to 4 when the vehicle speed is at 1 km/h or more and when the accelerator is released, the output corresponding to
Retarder system
position (4 steps) is sent to the retarder ECU, operating the retarder. Power train, retarder cooling system
[2] Under a status when the retarder hand lever is OFF, the output to retarder ECU is turned OFF, not operating the retarder. Engine
[3] When the vehicle speed is less than 1 km/h or when the accelerator is being depressed, the retarder relay output is turned OFF to cut the output circuit to the retarder Relationship between input current from controller and Radiator
ECU, not operating the retarder. operating air pressure
[4] When the vehicle speed becomes to 63 km/h or more, the output is performed so that the retarder step 1 is operated regardless of the hand lever or accelerator status. Proportional control valve (Yellow for retarder) Torque
Transmission Retarder converter
[5] The retarder indicator is turned OFF when the hand lever is OFF, and lit when in positions 1 to 4. With the retarder under operation, when the down regulation input is SL80 Water
Propeller controller
Braking force step (Retarder control valve) pump
Idling received from the retarder ECU, the retarder indicator flashes. shaft
Air pressure
(Hand lever Current (mA) Operating air pressure
detection [6] With the vehicle speed less than 1 km/h, when the abnormality input from the retarder ECU is received, the retarder indicator flashes at high speed.
position) (MPa)
Position 1 with simultaneous input Position 2 Position 3 Position 4
Upper input status Lower input status Serial signal output Lower output status
status to upper
combination meter
(Main speed) (Accelerator sensor 1, 2) (Retarder 1) (Retarder 2) (Retarder 3) (Retarder 4) (Retarder lamp) (Retarder 1) (Retarder 2) (Retarder 3) (Retarder 4) (Retarder 5) (Retarder relay)
Retarder
Oil cooler for torque converter

Guaranteed performance
(Other positions are shown as reference.)
Current
Propeller shaft Rear axle
Characteristics diagram Front axle
Temperature sensor Retarder Temperature sensor
(Retarder oil temperature) (Retarder coolant temperature)
V=b - Down regulation (overheat protection function)
Combination of other than above Previous status retained Air filter
section [1] Torque adjustment by coolant temperature Plug for retarder DIAG (For retarder circuit)
Starting temperature: 95C; Stable control temperature: 105C; Maximum temperature: 110C (Not connected normally)
[2] Torque adjustment by oil temperature
Starting temperature: 180C; Maximum temperature: 210C
- Pulse lubrication
Interval: 3 minutes; Time: 0.1 second; Current value: 575 mA Retarder operation indication lamp (Based on MDT data table, serial signal output to Do17 combination meter)
Illumination: Retarder switch position 1 to 4
Flashing: During down regulation operation (0.8 second cycle)
Combination of other than above Previous status retained Retarder in operation OFF: At retarder switch "OFF"
Vs = a
section Combination meter
Sensor speed (M)
Combination of other than above

MDT (lower) Fuse
Vs indicates 1 is the transistor

From battery
1 indicates the level "H."
vehicle For Ai, adopt smaller 1 is the operation switch close (H). 0 indicates the level "L." 1 is the relay contact ON. ON.
speed. of Ai2 and Ai3. 0 is the operation switch open (L). 1/0 is 0.8 second cycle. 0 is the relay contact OFF. 0 is the transistor
(km/h) OFF.
MDT (upper) 12 V for main speed
1 is the ECU output ON (L).
0 is the ECU output OFF (H). Relay RA12
Abnormality signal Main speed input
Remarks
With 1/0, the ECU output ON/OFF is repeated at every 0.5 (Retarder)
Vehicle speed (km/h) seconds (1 Hz).
Combination meter serial output
When the change of "0 -> 1" or "1 -> 0" occurs twice or more in Main speed output
*1. The previous output status is kept for 3 seconds, and then it is set as "1/0" (0.4 second cycle). However, 1 second, the input status is set as 1/0. When 0 or 1 continues
when the power is ON, it shall be as "1" for 7 seconds. for 1 second or more, the input status is set as 0 or 1.
Note 1. In case of main speed abnormality (error 01), the V = b section shall be the main speed status. Upper and lower sections serial 1/1 main speed
From battery input
Note 2. When Ai2 < 50 bit or Ai2 > 972 bit: Ai shall be the value of Ai3. Upper and lower sections serial
When Ai3 < 50 bit or Ai3 > 972 bit: Ai shall be the value of Ai2. Fuse output
When Ai2, Ai3 < 50 bit or Ai2, Ai3 > 972 bit: Ai shall be the smaller of Ai2 and Ai3. For retarder DIAG (ISO-L line)
* At lubrication, the controller performs the output of 575 mA for 0.3 seconds once Retarder switch (hand lever)
every 3 minutes. However, the indication lamp does not light. * Do not screw in at inspection. Temperature sensor
Adjustment air piping port M22 x 1.5 Retarder 1 Retarder lamp (-) (Retarder coolant
Oil level (oil temperature of 60C or more)
Exhaust pipe connection port M22 x 1.5 Retarder 2 temperature)
Max - Min = 0.5 L Tightening torque: 66 Nm
Tightening torque: 66 Nm Check plug M30 x 1.5 Retarder 3 Sender, thermo
Retarder 4
Tightening torque: 150 Nm
Use prohibited Temperature sensor
(Retarder oi temperature)
From air compressor Sender, thermo

Retarder
Stator
Accelerator sensor 1
Proportional
5 V for accelerator 1 Valve, control valve
solenoid
Proportional control valve Accelerator sensor 1 input
Rotor (Retarder control valve) GND for accelerator 1
Shield * Caution is needed due to darkish nature even when turned OFF.
GND for shield
Air tank 5 V for accelerator 2

Upper and lower sections Retarder controller
Accelerator sensor 2 input
Rotating direction serial output
GND for accelerator 2 Upper and lower sections
Shield serial input
Transmission GND for shield
side Front axle Retarder
side * Refer to Di15 input signal in MDT data table.
Air filter Illumination: During retarder operation in position 1 to 4; At error

Main speed input occurrence; At 5 second after power "ON" (blown bulb
test)
OFF: During retarder non-operation
Output when "Hand lever ≥ Position 1" and "Control torque > 0"
Coolant inlet Fuse

side
(Front side) From battery
Fuse
From battery
Coolant outlet side

(Back side)
Oil cooler Retarder switch (Hand lever)
Relay RA13
Temperature sensor (retarder oil temperature) 2nd 3rd 4th Hand lever switch (Retarder stop lamp)
Coolant drain plug 1st
Oil sump M14 x 1.5
M12 x 1.5 Pressure switch
Tightening torque: 28 Nm (For stop lamp)
Temperature sensor (retarder coolant temperature)
M14 x 1.5
Oil drain plug
Tightening torque: 28 Nm (Oil cooler) M12 x 1.5
Oil drain plug
(Retarder) M22 x 1.5
Position limit Wiring No. Terminal No. 1st 2nd 3rd 4th Tail stop lamp Tail stop lamp
Tightening torque: 66 Nm Leaked oil drain plug pin
* When approximately 200 ml or more is accumulated, check again after driving for 1,000 km.
When a considerable amount is accumulated, a replacement of oil seal is needed.
11 W564-0111E 11
Functions
1.2. Direct Mount Retarder (GR-500N-1, GR-600N-1, UK-500K-1)

[1] When the retarder hand lever is set to position 1 to 4 when the vehicle speed is at 1 km/h or more and when the accelerator is released, the output corresponding to position (4 steps) is
sent to the retarder ECU, operating the retarder. Retarder system
Power train, retarder cooling system
[2] Under a status when the retarder hand lever is OFF, the output to retarder ECU is turned OFF, not operating the retarder.
[3] When the vehicle speed is less than 1 km/h or when the accelerator is being depressed, the retarder relay output is turned OFF to cut the output circuit to the retarder ECU, not Plug for retarder DIAG
- Down regulation (overheat protection function)
Air pressure (MPa)

operating the retarder. (Not connected normally)
[1] Torque adjustment by coolant temperature
[4] With the accelerator depressed, when the vehicle speed becomes to 60 km/h or more, regardless of the hand lever status, constant speed hill descend function is activated, and the Proportional control valve Retarder controller Radiator
Starting temperature: 95C Torque
vehicle speed is kept at 60 km/h or less. SL59 Engine
Stable control temperature: 105C Air filter converter
[5] When the vehicle speed is less than 60 km/h and the hand lever is OFF, the retarder indicator is turned OFF. When the vehicle speed is 60 km/h or more and the hand lever is OFF, the (Retarder control valve)
Maximum temperature: 110C Propeller (For retarder circuit)
constant speed hill descend function is activated, and the retarder indicator is lit. When the hand lever is in positions 1 to 4, the indicator is lit regardless of the retarder operating status. shaft
Also, with the retarder under operation, when the down regulation is input from the retarder ECU, the retarder indicator flashes.
Idling Starting temperature: 180C (Yellow for retarder)
[6] With the vehicle speed less than 1 km/h, when the abnormality input from the retarder ECU is received, the retarder indicator flashes at high speed. Transmission
detection Maximum temperature: 210C
Upper input status Lower input status Serial signal output status Lower output status - Pulse lubrication
to upper combination meter Interval: 3 minutes
(Main speed) (Accelerator sensor 1, 2) (Retarder 1) (Retarder 2) (Retarder 3) (Retarder 4) (Retarder lamp) (Retarder 1) (Retarder 2) (Retarder 3) (Retarder 4) (Retarder 5) (Retarder relay) Time: 0.1 second
Retarder
Current value: 575 mA
Current
Characteristics diagram
Relationship between input current from controller and operating air pressure
Oil cooler for torque

converter
Braking force step
(Hand lever position) Current (mA) Operating air pressure
V=b Combination of other than above Previous status retained (MPa) Retarder
section Temperature sensor
Temperature sensor Propeller shaft
Front axle (Retarder coolant temperature)
(Retarder oil temperature) Rear axle
Guaranteed performance Retarder operation indication lamp (Based on MDT data table, serial signal output to Do17 combination meter)
Combination meter Illumination: Retarder switch position 1 to 4
Retarder in operation Flashing: During down regulation operation (0.8 second cycle)
Combination of other than above Previous status retained Sensor speed (M)
OFF: At retarder switch "OFF"
MDT (lower)
Combination of other than above
Fuse
From battery
Vs indicates 1 indicates the level "H." 1 is the transistor
vehicle For Ai, adopt smaller of 1 is the operation switch close (H). 0 indicates the level "L." 1 is the relay contact ON. ON. MDT (upper)
speed. Ai2 and Ai3. 0 is the operation switch open (L). 1/0 is 0.8 second cycle. 0 is the relay contact OFF. 0 is the transistor
(km/h) OFF.
12 V for main speed
Abnormality signal 1 is the ECU output ON (L). Relay RA12
Remarks
0 is the ECU output OFF (H). Main speed input (Retarder)

Vehicle speed (km/h) With 1/0, the ECU output ON/OFF is repeated at every 0.5
seconds (1 Hz). Combination meter serial Main speed output
*1. The previous output status is kept for 3 seconds, and then it is set as "1/0" (0.4 second cycle). However, when the When the change of "0 -> 1" or "1 -> 0" occurs twice or more in output
power is ON, it shall be as "1" for 7 seconds. 1 second, the input status is set as 1/0. When 0 or 1 continues
Note 1. In case of main speed abnormality (error 01), the V = b section shall be the main speed status. for 1 second or more, the input status is set as 0 or 1. Upper and lower sections serial 1/1 main speed
Note 2. When Ai2 < 50 bit or Ai2 > 972 bit: Ai shall be the value of Ai3. From battery input
Upper and lower sections serial
When Ai3 < 50 bit or Ai3 > 972 bit: Ai shall be the value of Ai2. Fuse output
When Ai2, Ai3 < 50 bit or Ai2, Ai3 > 972 bit: Ai shall be the smaller of Ai2 and Ai3.
Retarder switch (hand lever) For retarder DIAG (ISO-L line)
* At lubrication, the controller performs the output of 575 mA for 0.3 seconds once every 3
minutes. However, the indication lamp does not light. * Do not screw in at inspection. Retarder 1 Retarder lamp (-) Temperature sensor
Oil level (oil temperature of 60C or more) Adjustment air piping port M22 x 1.5 (Retarder coolant
Tightening torque: 66 Nm Retarder 3 Sender, thermo
Injection and check plug M30 x 1.5
Tightening torque: 150 Nm Retarder 4
Temperature sensor
Use prohibited (Retarder oi temperature)

Retarder
Stator
5 V for accelerator 1 Valve, Proportional control valve
solenoid
Shield * Caution is needed due to darkish nature even when turned OFF.
GND for shield
Air tank 5 V for accelerator 2
Upper and lower sections Retarder controller
Rotating direction serial output
Shield
Transmission GND for shield serial input
side Front axle
side Air filter Retarder * Refer to Di15 input signal in MDT data table.
Illumination: During retarder operation in position 1 to 4; At error

Main speed input occurrence; At 5 second after power "ON" (blown bulb
test)
Coolant inlet Fuse

side From battery
(Front side)
Fuse Relay RA13
From battery (Retarder stop lamp)
Coolant outlet side

(Back side)
Temperature sensor (retarder oil temperature) TS7 2nd 3rd 4th
Coolant drain plug Pressure switch 1st Hand lever switch
Oil sump M14 x 1.5
M12 x 1.5 (For stop lamp)
Temperature sensor (retarder coolant temperature) TS6

M14 x 1.5 Oil drain plug
(Oil cooler) M12 x 1.5
Oil drain plug
Position limit Wiring No. Terminal No. 1st 2nd 3rd 4th
Tightening torque: 66 Nm Leaked oil drain plug
pin Tail stop lamp
Tightening torque: 13 Nm * When approximately 200 ml or more is accumulated, check again after driving for 1,000 km. Tail stop lamp
12 W564-0111E 12
Functions
1.3. Error Code Checking Procedure (Digiprop Type)
Calling condition
- Hand lever is OFF and vehicle is stopped (0 km/h).
Calling method by plug for retarder DIAG (ISO-L line)

1. Turn the ignition key ON.
2. Ground the plug for retarder DIAG (ISO-L line) for two seconds or more. (Plug connection)
3. The diagnosis lamp (yellow) displays the initial error code by flashing.
4. Repeat the operation in 1. to display the next error code.
Flashing display of error code

- The tenths place is shown by long lighting first...................... One 2-second lighting indicates 10.
- Then, the ones place shown by short lighting........................ One 0.5-second lighting indicates 1.
- Interval of each lighting .......................................................... 1 second
- If the pilot lamp is already lit before the calling (during error occurrence), the lamp remains lit
after indicating the flashing code.
- Before and after the flashing code indication, there are three-second intervals. During this interval, the lamp
is not lit.
Example: When with flashing code 23
ON
OFF
Note
- By the flashing signal of diagnosis lamp (yellow), the error contents can be checked.
- When two or more malfunctions are present, they are stored in the order of occurrence, and
indicated in the order starting with the oldest one.
- With one calling, only one error code is shown.
- After all the errors are indicated, the first error is shown again.
- When the error is not stored, the diagnosis lamp (yellow) remains OFF.
Deleting method of error memory

- Deletion condition
Deletion is possible only while vehicle is stopped (0 km/h).
- Deleting method by plug for retarder DIAG (ISO-L line)
1. Turn the ignition key OFF.
2. Connect the plug for retarder DIAG (ISO-L line) to the ground. (Plug connection)
3. Turn the ignition key ON.
4. After keeping for two seconds or more, separate from the ground (disconnect the plug). * Caution is
needed (memory is deleted).
13 W564-0111E
Functions
Error code table

Error Condition
Contents Severity Note
code State Time
1 Stop lamp relay grounded ON 1s Minor
5 Low voltage of ignition power supply < 17.5 V 60 s Major
6 Overvoltage of ignition power supply > 32.5 V 10 s Major
8 Coolant temperature sensor open circuit or Major/Minor Simultaneous failure
R > 2 K 1s
battery short circuit of temperature
9 Grounding of coolant temperature sensor R < 600  1s Major/Minor sensor and coolant
11 Oil temperature sensor open circuit or Major/Minor temperature sensor
R > 2 K 1s is judged as of
battery short circuit
12 Grounding of oil temperature sensor Major/Minor major severity.
Individual
R < 600  1s occurrence of either
of the failures is
judged as minor.
13 Hand lever switch status unknown 1s Major
14 Battery short circuit of hand lever Position 0 10 s Major
15 Grounding of hand lever 1s Major
16 Vehicle speed signal disconnection 2s Major
18 Vehicle speed signal battery short circuit or Major
2s
unknown signal
23 Proportional solenoid valve malfunction Major Refer to notes
Position 0 1s
No.1* below the table.
24 Proportional solenoid valve malfunction > Position Major Refer to notes
1s
No.2* 0 below the table.
25 Proportional solenoid valve malfunction > Position Major Refer to notes
60 s
No.3* 0 below the table.
27 Proportional solenoid valve malfunction Major Refer to notes
Position 0 2s
No.5* below the table.
28 Low voltage of battery power supply < 17.5 V 60 s Major
29 Control unit internal failure Major
180 ms
(Watchdog SIBA)
31 Coding abnormality 100 ms Major
32 Pilot lamp open circuit or ground ** Major Refer to notes
OFF 3s
below the table.
33 Pilot lamp battery short circuit ** Major Refer to notes
ON 3s
below the table.
34 Unknown engine speed signal 2s Minor
35 Control unit internal failure
ROM (CRC check) 123 s Major
EEPROM 500 ms Major
* Proportional solenoid valve malfunction No.1: - Battery short circuit of proportional valve
- Control unit malfunction
* Proportional solenoid valve malfunction No.2: - Short circuit of solenoid or cable

- Open circuit of solenoid or cable
- Grounding of proportional valve
* Proportional solenoid valve malfunction No.3: - Control unit malfunction
* Proportional solenoid valve malfunction No.5: - Control unit malfunction
** Pilot lamp malfunction: - Displaying of flashing code is possible after the malfunction is canceled.
14 W564-0111E
Functions
Processing at malfunction
Braking torque Pilot lamp

Minor Without reduction Illumination with all
malfunction (with exception) positions
Major 0 Illumination with all
malfunction positions
Oil temperature sensor = Malfunction, coolant temperature sensor = Normal → Minor malfunction
Oil temperature sensor = Normal, coolant temperature sensor = Malfunction → Minor malfunction,
however, braking torque = 50% reduction
Malfunction with both sensors → Major malfunction (braking torque = 0)
Even at major malfunction, the pulse lubrication signal is output.
Controller main body diagram
Terminal No. Terminal name
Hand lever switch input 3rd (braking force step 2)

Hand lever switch input 2nd (braking force step 1)
Hand lever switch input 1st (constant vehicle speed hill
descend) * Does not function
Power supply (ignition)
Hand lever switch input 5th (braking force step 4)
Hand lever switch input 4th (braking force step 3)
Hand lever switch output
Diagnosis connector (ISO-L)
(Not used)
Power supply (battery)
Ground
Proportional solenoid valve input

X1 connector X2 connector X3 connector Proportional solenoid valve output
Coolant temperature sensor input
Coolant temperature sensor output
Oil temperature sensor input

Oil temperature sensor output
Vehicle speed signal

(Not used)
Harness side connector part number (AMP)

X1 connector (18 pin)
Pilot lamp input (RKL)
Stop lamp relay output (BLR)
15 W564-0111E
Functions
2. Retarder System (Control Unit: VERA Type)
2.1. Mid-Mount Retarder (GR-250N-1, GR-350N-1)

[1] When the retarder hand lever is set to position 1 to 4 when the vehicle speed is at 1 km/h or more and when the accelerator is released, the output corresponding to position
Retarder system
(4 steps) is sent to the retarder ECU, operating the retarder. Power train, retarder cooling system
[2] Under a status when the retarder hand lever is OFF, the output to retarder ECU is turned OFF, not operating the retarder. Engine
[3] When the vehicle speed is less than 1 km/h or when the accelerator is being depressed, the retarder relay output is turned OFF to cut the output circuit to the retarder ECU, Relationship between input current from controller and Radiator
not operating the retarder. operating air pressure
[4] When the vehicle speed becomes to 63 km/h or more, the output is performed so that the retarder step 1 is operated regardless of the hand lever or accelerator status. Proportional control valve (Yellow for retarder) Torque
SL80 Transmission Retarder converter
[5] The retarder indicator is turned OFF when the hand lever is OFF, and lit when in positions 1 to 4. With the retarder under operation, when the down regulation input is received Propeller controller Water
Braking force step (Retarder control valve) pump
Idling from the retarder ECU, the retarder indicator flashes. shaft
Air pressure
detection [6] With the vehicle speed less than 1 km/h, when the abnormality input from the retarder ECU is received, the retarder indicator flashes at high speed.
(MPa)
Upper input status Lower input status Serial signal output status Lower output status
to upper combination
meter
Retarder
Oil cooler for torque converter

Guaranteed performance
Current
Propeller shaft Rear axle
Characteristics diagram Front axle
Temperature sensor Retarder Temperature sensor
(Retarder oil temperature) (Retarder coolant temperature)
V=b - Down regulation (overheat protection function)
section Combination of other than above Previous status retained Air filter
[1] Torque adjustment by coolant temperature Plug for retarder DIAG (For retarder circuit)
(Not connected normally)
Starting temperature: 95C; Stable control temperature: 105C; Maximum temperature: 110C
Starting temperature: 180C; Maximum temperature: 210C
- Pulse lubrication
Interval: 3 minutes; Time: 0.1 second; Current value: 575 mA Retarder operation indication lamp (Based on MDT data table, serial signal output to Do17 combination meter)

Previous status retained Retarder in operation
Combination of other than above OFF: At retarder switch "OFF"
Vs = a
section Combination meter
Sensor speed (M)
Combination of other than above Fuse

MDT (lower)
From battery
vehicle
speed. For Ai, adopt smaller 1 is the operation switch close (H). 0 indicates the level "L." 1 is the relay contact ON. ON.
(km/h) of Ai2 and Ai3. 0 is the operation switch open (L). 1/0 is 0.8 second cycle. 0 is the relay contact OFF. 0 is the transistor
OFF.
MDT (upper) 12 V for main speed
1 is the ECU output ON (L).
Abnormality signal 0 is the ECU output OFF (H). Relay RA12
Main speed input
Remarks
With 1/0, the ECU output ON/OFF is repeated at every 0.5 (Retarder)
Vehicle speed (km/h) seconds (1 Hz). Combination meter serial output
When the change of "0 -> 1" or "1 -> 0" occurs twice or more in Main speed output
*1. The previous output status is kept for 3 seconds, and then it is set as "1/0" (0.4 second cycle). However, 1 second, the input status is set as 1/0. When 0 or 1 continues
when the power is ON, it shall be as "1" for 7 seconds. for 1 second or more, the input status is set as 0 or 1. Upper and lower sections serial
Note 1. In case of main speed abnormality (error 01), the V = b section shall be the main speed status. 1/1 main speed
From battery input
output
When Ai3 < 50 bit or Ai3 > 972 bit: Ai shall be the value of Ai2. Fuse
When Ai2, Ai3 < 50 bit or Ai2, Ai3 > 972 bit: Ai shall be the smaller of Ai2 and Ai3. For retarder DIAG (connector)
* At lubrication, the controller performs the output of 575 mA for 0.3 seconds once Retarder switch (hand lever) Retarder operation (+)
every 3 minutes. However, the indication lamp does not light. * Do not screw in at inspection.
Retarder 1 Retarder lamp (-) Temperature sensor
Oil level (oil temperature of 60C or more) Adjustment air piping port M22 x 1.5
(Retarder coolant temperature)
Exhaust pipe connection port M22 x 1.5 Retarder 2
Tightening torque: 66 Nm Check plug M30 x 1.5 Retarder 3 Sender, thermo

Temperature sensor
Use prohibited
(Retarder oi temperature)

Retarder
Stator
5 V for accelerator 1 Valve, Proportional
solenoid control valve
Shield
GND for shield
5 V for accelerator 2 Retarder controller
Air tank Upper and lower sections
Accelerator sensor 2 input serial output * Caution is needed due to darkish nature even when turned OFF.
Rotating direction
Upper and lower sections
GND for accelerator 2
Shield serial input
Transmission GND for shield Retarder
side Front axle
side
Air filter * Refer to Di15 input signal in MDT data table.
Main speed input
occurrence; At 5 second after power "ON" (blown bulb
test)
Tightening torque: 285 Nm Output when "Hand lever ≥ Position 1" and "Control torque > 0"
Coolant inlet Fuse

side From battery
(Front side)
Relay RA13
Fuse (Retarder stop lamp)
From battery
Coolant outlet side

(Back side)
Oil cooler
Retarder switch (Hand lever)
Temperature sensor (retarder oil temperature) 3rd 4th
2nd Hand lever switch
Coolant drain plug M14 x 1.5 1st
Oil sump
M12 x 1.5
Pressure switch
Tightening torque: 25 Nm (For stop lamp)
Temperature sensor (retarder coolant temperature)

M14 x 1.5
Oil drain plug
Oil drain plug
Tail stop lamp Tail stop lamp
Tightening torque: 13 Nm * When approximately 200 ml or more is accumulated, check again after driving for 1,000 km.
16 W564-0111E 16
Functions
2.2. Direct Mount Retarder (GR-500N-1, GR-600N-1, UN-500K-1)

[1] When the retarder hand lever is set to position 1 to 4 when the vehicle speed is at 1 km/h or more and when the accelerator is released, the output corresponding to position (4 steps) is Retarder system
sent to the retarder ECU, operating the retarder. Power train, retarder cooling system
[2] Under a status when the retarder hand lever is OFF, the output to retarder ECU is turned OFF, not operating the retarder.
[3] When the vehicle speed is less than 1 km/h or when the accelerator is being depressed, the retarder relay output is turned OFF to cut the output circuit to the retarder ECU, not operating Plug for retarder DIAG
- Down regulation (overheat protection function)
Air pressure (MPa)

(Not connected normally)
the retarder. [1] Torque adjustment by coolant temperature
[4] With the accelerator depressed, when the vehicle speed becomes to 60 km/h or more, regardless of the hand lever status, constant speed hill descend function is activated, and the vehicle Proportional control valve Retarder controller Radiator
Starting temperature: 95C
SL59 Torque Engine
speed is kept at 60 km/h or less. Stable control temperature: 105C Propeller Air filter
(Retarder control valve) converter
[5] When the vehicle speed is less than 60 km/h and the hand lever is OFF, the retarder indicator is turned OFF. When the vehicle speed is 60 km/h or more and the hand lever is OFF, the Maximum temperature: 110C shaft (For retarder circuit)
constant speed hill descend function is activated, and the retarder indicator is lit. When the hand lever is in positions 1 to 4, the indicator is lit regardless of the retarder operating status. [2] Torque adjustment by oil temperature
Also, with the retarder under operation, when the down regulation is input from the retarder ECU, the retarder indicator flashes. Starting temperature: 180C
Idling (Yellow for retarder)
[6] With the vehicle speed less than 1 km/h, when the abnormality input from the retarder ECU is received, the retarder indicator flashes at high speed. Maximum temperature: 210C Transmission
detection
- Pulse lubrication
Upper input status Lower input status Serial signal output status to Lower output status
upper combination meter Interval: 3 minutes
Time: 0.1 second
Current value: 575 mA
Retarder
Current
Characteristics diagram
Relationship between input current from controller and operating air pressure
Oil cooler for torque

converter
Braking force step
V=b
section Combination of other than above Previous status retained (MPa) Retarder
Temperature sensor Propeller shaft
Front axle Temperature sensor (Retarder coolant temperature)
(Retarder oil temperature) Rear axle
Guaranteed performance Retarder operation indication lamp (Based on MDT data table, serial signal output to Do17 combination meter)
Combination meter
Retarder in operation
Combination of other than above Previous status retained Sensor speed (M)
OFF: At retarder switch "OFF"
Combination of other than above MDT (lower)

Fuse
From battery
vehicle For Ai, adopt smaller of 1 is the operation switch close (H). 0 indicates the level "L." 1 is the relay contact ON. ON. MDT (upper)
speed. Ai2 and Ai3. 0 is the operation switch open (L). 1/0 is 0.8 second cycle. 0 is the relay contact OFF. 0 is the transistor
(km/h) OFF.
12 V for main speed
1 is the ECU output ON (L). Relay RA12
Remarks
Abnormality signal 0 is the ECU output OFF (H). (Retarder)

With 1/0, the ECU output ON/OFF is repeated at every 0.5 seconds Main speed input
Vehicle speed (km/h) (1 Hz).
When the change of "0 -> 1" or "1 -> 0" occurs twice or more in 1 Combination meter serial
Main speed output
*1. The previous output status is kept for 3 seconds, and then it is set as "1/0" (0.4 second cycle). However, when the second, the input status is set as 1/0. When 0 or 1 continues for 1 output
power is ON, it shall be as "1" for 7 seconds. second or more, the input status is set as 0 or 1.
Note 1. In case of main speed abnormality (error 01), the V = b section shall be the main speed status. Upper and lower sections serial 1/1 main speed
From battery input
When Ai3 < 50 bit or Ai3 > 972 bit: Ai shall be the value of Ai2. output
Fuse
When Ai2, Ai3 < 50 bit or Ai2, Ai3 > 972 bit: Ai shall be the smaller of Ai2 and Ai3. Retarder switch (hand lever) For retarder DIAG (connector)
* At lubrication, the controller performs the output of 575 mA for 0.3 seconds once every 3 Retardar operation (+)
minutes. However, the indication lamp does not light. * Do not screw in at inspection.
Retarder 1 Retarder lamp (-) Temperature sensor
Oil level (oil temperature of 60C or more) Adjustment air piping port M22 x 1.5 (Retarder coolant
Tightening torque: 66 Nm Injection and check plug M30 x 1.5 Retarder 3 Sender, thermo

Temperature sensor
Use prohibited (Retarder oi temperature)

Retarder
Stator
5 V for accelerator 1 Valve, Proportional control valve
solenoid
Proportional control valve
Shield
GND for shield
Air tank Retarder controller
5 V for accelerator 2
Upper and lower sections
Accelerator sensor 2 input serial output * Caution is needed due to darkish nature even when turned OFF.
Rotating direction
Transmission Shield
Front axle GND for shield serial input
side
side Retarder
Air filter
* Refer to Di15 input signal in MDT data table.
Main speed input

occurrence; At 5 second after power "ON" (blown bulb
test)
Coolant inlet Fuse

side From battery
(Front side)
Fuse Relay RA13
(Retarder stop lamp)
From battery
Coolant outlet side

(Back side)
Temperature sensor (retarder oil temperature) TS7 2nd 3rd 4th Hand lever switch
Coolant drain plug M14 x 1.5 Pressure switch 1st
Oil sump M12 x 1.5 (For stop lamp)
Temperature sensor (retarder coolant temperature) TS6

M14 x 1.5
Oil drain plug
Oil drain plug
Tail stop lamp Tail stop lamp
* When approximately 200 ml or more is accumulated, check again after driving for 1,000 km.
17 W564-0111E 17
Functions
2.3. Error Code Checking Procedure (VERA Type)
Calling condition
- Hand lever is OFF and vehicle is stopped (0 km/h).
Calling method by connector for retarder DIAG (CN727)

1. With the ignition key turned ON, connect the male and female connectors of the connector for retarder
DIAG (CN727).
Then, disconnect the connectors.
2. The diagnosis lamp (yellow) displays the initial error code by flashing.
3. Repeat the operation in 1. to display the next error code.
Flashing display of error code

- The tenths place is shown by long lighting first........................One 2-second lighting indicates 10.
- Then, the ones place shown by short lighting..........................One 0.5-second lighting indicates 1.
- Interval of each lighting ............................................................1 second
- If the pilot lamp is already lit before the calling (during error occurrence), the lamp remains lit
after indicating the flashing code.
- Before and after the flashing code indication, there are three-second intervals. During this interval, the lamp
is not lit.
Example: When with flashing code 23
ON
OFF
Note
- By the flashing signal of diagnosis lamp (yellow), the error contents can be checked.
- When two or more malfunctions are present, they are stored in the order of occurrence, and
indicated in the order starting with the oldest one.
- With one calling, only one error code is shown.
- After all the errors are indicated, the first error is shown again.
- When the error is not stored, the diagnosis lamp (yellow) remains OFF.
Deletion of error memory

- The stored error (past error) can only be deleted with the dialog software (WinDia).
18 W564-0111E
Functions
Error code table

s:Evaluated as major. Braking torque is not present.
m: Evaluated as minor. Braking torque is present.
Error Evalu-
code
Contents Recognition time/Condition
ation
Control unit internal failure - Parameter Immediately after current application
Control unit internal failure - EEPROM Immediately after current application
Control unit internal failure - ROM Approximately 10 seconds after current application
Control unit internal failure - Safety concept 60 msec.

Proportional solenoid valve trouble, open circuit or 1 sec./ECU internal PWM signal/Status signal/AD signal value
grounding abnormality
1 sec./ECU internal PWM signal/Status signal/AD signal value
Proportional solenoid valve trouble, short to battery abnormality
Proportional solenoid valve trouble, ECU internal failure abnormality
Ignition power supply low voltage 60 sec./17.5 V limit, 0.5 V hysteresis
Ignition power supply overvoltage 10 sec./33 V limit, 0.5 V hysteresis
Hand lever switch status unknown 2 sec./Signal pattern/Connection order abnormality
Hand lever switch grounding 1 sec./Terminal voltage ≤ 0.3 x ECU internal power supply voltage
Hand lever switch shorted to battery 10 sec./Terminal voltage ≤ 0.7 x ECU internal power supply voltage
Simultaneous failure of coolant temperature sensor
and oil temperature sensor Abnormality of both temperature sensors
Coolant temperature sensor, open circuit or short to battery 1 sec./Sensor resistance > 1,540 
Coolant temperature sensor grounding 1 sec./Sensor resistance < 760 
Oil temperature sensor, open circuit or short to battery 1 sec./Sensor resistance > 2,000 
Oil temperature sensor grounding 1 sec./Sensor resistance < 760 
Vehicle speed signal open circuit 2 sec./Without pulse/2.5 V < Terminal voltage ≤ 4.8 V
Pilot lamp, open circuit or grounding 1 sec./Without output + Voltage V ≤ ECU internal voltage x 0.3
Pilot lamp shorted to battery 3 sec./With output + Voltage V ≥ ECU internal voltage x 0.7
ABS signal grounding 60 sec./Voltage V < Ignition power supply x 0.3

5sec./Ignition power supply x 0.3 < Voltage V < Ignition power
ABS signal level unknown supply x 0.7
Control unit trouble by ABS signal ECU internal signal value abnormality
Stop lamp relay grounding 1 sec./With output + Voltage V ≥ ECU internal voltage x 0.3
1
m : Coolant temperature sensor error = Braking torque 50%
m2: Oil temperature sensor error = Without braking torque reduction
19 W564-0111E
Functions
Processing at malfunction
Braking torque Pilot lamp

Minor Without reduction Illumination with all
malfunction (with exception) positions
Major 0 Illumination with all
malfunction positions
Oil temperature sensor = Malfunction, coolant temperature sensor = Normal → Minor malfunction
Oil temperature sensor = Normal, coolant temperature sensor = Malfunction → Minor malfunction,
however, braking torque = 50% reduction
Malfunction with both sensors → Major malfunction (braking torque = 0)
Even at major malfunction, the pulse lubrication signal is output.
Terminal No. Terminal name
Constant vehicle speed hill descend

Hand lever switch input 1 (braking torque 25%)
Power supply (ignition)
Hand lever switch (+)
DIAG (ISO-K) (Not used)
ABS (Not used)
Ground
Pilot lamp output
Stop lamp relay output
X1 connector X2 connector X3 connector
Coolant temperature sensor (-)

Coolant temperature sensor (+)
Proportional solenoid valve (+)
Proportional solenoid valve (-)
Oil temperature sensor (+)
Oil temperature sensor (-)
Harness side connector part number (AMP)
20 W564-0111E
Maintenance
Maintenance
1. Maintenance
1.1. Oil amount check
1. Retarder housing
5. Refill level check plug (M30 × 1.5)............................................ 150 Nm (1,530 kgf·cm)
6. Sealing washer (30 × 36).......................................................... Replace
21 W564-0111E
Maintenance
[NOTICE]
 The specified oil (refer to chapter 1.3. in Data) with an appropriate amount of 5 L (full amount: 5.5 L) must be
used.
1.1.1. Oil Amount Checking Procedure

1. Set the retarder oil temperature to 60C or more (temperature at driving).
2. Stop the vehicle on a flat location.
3. Set the hand lever switch to position 0.
4. Turn the ignition key switch ON and OFF once.
5. Set the hand lever switch to the highest position (position 4), then return to position 0. (This allows the
activation even during vehicle stop.)
6. Set the hand lever switch to the highest position, keep the status for approximately five seconds, then turn it
OFF. Repeat this step twice.
7. Turn OFF the retarder. Also, to cut the pulse lubrication, turn OFF the key switch. Wait for five minutes under
this status, and make sure to return the oil in working chamber to the sump and oil cooler.
8. Loosen the refill level check plug, and remove the

plug together with the sealing washer. Then, wipe
off the oil on the gauge.
Be careful with burns!

The refill level check plug is hot, being at the same
temperature as the oil temperature.
9. Insert the refill level check plug into the filler port.
Do not screw in!
10. Pull the check plug again, and check the oil level.
The appropriate level is at between Max and Min
of the gauge.
11. When the oil level is insufficient, fill the oil while
using a guide that the difference between Max
and Min of the gauge is 0.5 L.
22 W564-0111E
Maintenance
12. Replace the sealing washer with a new one, then

tighten the plug to 150 Nm (1,530 kgf·cm).
1.2. Oil replacement
1. Retarder housing
5. Refill level check plug (M30 × 1.5)............................................150 Nm (1,530 kgf·cm)
6. Sealing washer (30 × 36)..........................................................Replace
7. Retarder oil drain plug (M22 × 1.5) ...........................................66 Nm (670 kgf·cm)
8. Sealing washer (22 × 29)..........................................................Replace
9. Oil cooler oil drain plug (M12 × 1.5)..........................................25 Nm (260 kgf·cm)
10. Sealing washer (12 × 15.5).......................................................Replace
11. Leaked oil drain plug (M10 × 1) ................................................13 Nm (130 kgf·cm)
12. Sealing washer (10 × 13.5).......................................................Replace
23 W564-0111E
Maintenance
[NOTICE]
 The specified oil (refer to chapter 1.3. in Data) with an appropriate amount of 5 L (full amount: 5.5 L) must be
used.
When the oil is drained, the oil temperature must be at 60C or more (under driving state).
When replacing the oil, be sure to turn OFF the retarder and key switch so that the adjusting air does not
become activated by the retarder operation and pulse lubrication.
1.2.1. Oil Replacement Procedure
1. Place a drained oil catcher under the retarder.
2. Remove the retarder oil drain plug (7) and oil drain
plug (9), then drain the oil.
Be careful with burns!
3. Remove the leaked oil drain plug (11), and drain

the oil and, when present, others.
[NOTICE]
 When an oil leak from the shaft oil seal is present or when an intrusion of waste water occurs after high speed
car wash, the leaked oil is gathered in the tank.
When the leaked oil drain plug (11) is removed, if a considerable amount of leaked oil (approximately 200 mL
or more) comes out, check the leaked oil amount again after driving for approximately 1,000 km. If a
considerable amount of leaked oil is still present also at this time, both oil seals need to be replaced.
4. Replace the sealing washers (8, 10, 12) with new

ones, and tighten the drain plugs (7, 9, 11).
Retarder drain plug (7): 66 Nm (670 kgf·cm)
Oil cooler drain plug (9): 25 Nm (260 kgf·cm)
Leaked oil drain plug (11): 13 Nm (130 kgf·cm)
5. From the filler port, fill the specified oil precisely with
an appropriate amount of 5 L (full amount: 5.5 L).
6. Perform the oil amount check. (Refer to chapter 1.1.

in Maintenance.)
[NOTICE]
 The oil at refill puddles in the oil sump only, and it is
not fed to the oil cooler, so the oil level becomes high.
Be sure to perform the oil amount check according to
the procedure in chapter 1.1. of Maintenance.
24 W564-0111E
Maintenance
1.3. Cleaning the Air Filter
51. Filter housing

52. Retaining plate
53. Cover
54. O-ring .......................................................Replace. Apply grease when assembling.
55. Spring
56. Intermediate plate
57. Filter element
58. Spring
25 W564-0111E
Maintenance
[NOTICE]
 This air filter is made to properly supply air to the retarder even when the element is clogged. However, the air
is not cleaned when the element is clogged. Be sure to perform inspections periodically.
1.3.1. Air Filter Cleaning Procedure
1. Relieve the pressure in the supply air line to air filter.
Attention! Because the air pressure of auxiliary equipment system drops, use caution with the
suspension and others.
Attention! If the pressure in the supply air line is not relieved, the cover (53) or others pop out due to
pressure and danger is present.
2. Press the cover (53), and pull out the retaining

plate (52).
3. From the housing (51), pull out and remove the

cover (53), O-ring (54), spring (55), intermediate
plate (56), filter element (57), and spring (58).
4. Clean the element (57) by blowing air from

outside. Check the element (57) for damage, and
replace if necessary.
5. To the housing (51), insert the spring (58), filter

element (57), intermediate plate (56), and spring
(55) in order.
6. Grease the O-ring (54) lightly, then install it to the

cover (53).
7. Press the cover into the housing (51), then insert

the retaining plate (52).
[NOTICE]
 When the filter housing is removed and then
mounted again, set the filter housing to the proper
mounting position.
26 W564-0111E
Troubleshooting
Troubleshooting
1. Troubleshooting Flowchart
[NOTICE]
 Before the troubleshooting, check the retarder oil level, and set to the normal level.
(Refer to chapter 1.1. in Maintenance.)
In order for the retarder to sufficiently exert its performance, use the specified oil (refer to chapter 1.3. in Data).
Oil leak from

breather and
insufficient
retarder braking
force
Trouble for
Retarder pilot Input/output
R 120S
lamp shaft oil leak
27 W564-0111E
Troubleshooting
Main Troubleshooting: Group A
A
Oil leak from breather and
insufficient retarder braking
force
Is any leak to outside

present?
(Other than breather)
Repair the retarder.
No Yes
Check the
Check the retarder oil
adjustment air level.
pressure (Py).
OK NG Is water mixed in
oil
At the check, the (emulsification)?
retarder oil level
Pump pressure (Pdyn) must be normal! Yes No
and adjustment air Check the heat
pressure (Py) OK NG exchanger.
At the check, the

retarder oil level must Check the retarder
be normal! oil level.
In case of "braking
force shortage," OK NG Too low Too high
contact NRS.
In case of "oil leak
from breather," Correct the
proceed to "Check the retarder oil level
ventilator." to normal.
Pdyn
Check the ventilator.
NG
OK NG Py
NG
Check the check Replace the

valve of stainless ventilator.
steel heat
exchanger.
OK NG Check the proportional
current, wiring, and plug
connection. OK = Normal
NG = Abnormal
Check the Replace the check OK NG
proportional valve of the stainless
valve. steel heat exchanger. Check the supply
OK NG
air pressure.
OK NG
Check the Replace the Check the temperature
control unit. proportional Check the adjustment, temperature
valve. Mechanical trouble of
proportional valve, or compressed air sensor (oil/water),
leak due to bolt system of pressure sensor, and
tightening failure vehicle. lead.
OK NG OK NG
Clogging of Contact the Contact Replace the

compression air line automobile NRS. temperature
to proportional valve, manufacturer. sensor, wiring, or
or leak pressure sensor.
28 W564-0111E
Troubleshooting
Main Troubleshooting: Group B
B
Retarder
pilot lamp
Illuminates at
retarder OFF position Illumination does not Flashing
after lamp test. occur?
Read the abnormality Check the fuse. Temperature

code (page 15). adjustment!
Correct the abnormality, Is the ABS or Check the operating

and delete the accelerator switch status (if engine
abnormality memory. active? speed is increased
during retarder
operation).
OK NG
Check the pilot lamp,
and replace when Check the
necessary. temperature sensor Give instruction
(oil/water) and wiring. to driver!
OK NG
Check the vehicle Replace the

cooling system temperature
(coolant level, sensor or wiring.
thermostat, coolant
pump, fan, radiator
clogging).
29 W564-0111E
Troubleshooting
Main Troubleshooting: Group C
C
Input/output
shaft oil leak
Is water mixed in oil?

(Emulsification)
Yes No
Check the Check the oil seal of

heat input/output shaft, and
exchanger. replace when necessary.
When trouble recurs,

contact NRS.
33064e
30 W564-0111E
Troubleshooting
2. Troubleshooting - Reading from PC

(Control Unit: Digiprop Type) (For the hardware and software requirements,
refer to 2.2. "Troubleshooting (With Abnormality
2.1. Diagnosis (Self Diagnosis of Trouble) Code)" in Troubleshooting. For the relevant
working procedure, refer to "DigiDia User's
The digiprop control unit is equipped with the
Manual.")
diagnosis function, enabling the abnormality to be
automatically detected and notified.
When the control unit identifies an abnormality, a
corresponding abnormality code is stored in the
memory, and the retarder pilot lamp (shown by the
arrow) lights steadily. (High speed flashing signal)
- Minor abnormality:
The lamp lights from the position 0 to 4 of hand
lever switch, and the braking force is exerted to a
certain extent.
- Major abnormality:
The lamp lights from the position 0 to 4 of hand
lever switch, and the braking force is not exerted.
To prevent the retarder trouble, it is recommended
that the vehicle be driven at an appropriate speed
to the nearest repair site, and then the driving be
stopped.
[NOTICE]
 After the abnormality is corrected, when the ignition
is turned OFF and ON, the retarder starts to operate
again and the retarder pilot lamp goes out. However,
the abnormality code remains stored in the
abnormality memory.
When the abnormality is still present or occurs
again, the lamp becomes lit again with the hand
lever switch positions from 0 to 4.
 The abnormalities identified by the control unit are
described in 1.10.1. "Abnormality Code Table" of
Data. For repairs, refer to 2.2. "Troubleshooting
(With Abnormality Code)" in Troubleshooting.
 For the abnormalities that are not identified by the
control unit, refer to 2.3. "Troubleshooting (Without
Abnormality Code)" in Troubleshooting.
 There are two ways to read the abnormality
memory from the control unit.
- Reading by flashing code of retarder pilot lamp

(shown by the arrow)
(For the required working procedure, refer to 2.2.
"Troubleshooting (With Abnormality Code)" in
Troubleshooting.)
31 W564-0111E
Troubleshooting
2.2. Troubleshooting (With Abnormality Code)

Special tool
Commercially-available tool
Tester ········· Recommendation: Fluke 76 or 87
2.2.1. Reading of Abnormality Memory by Flashing Code of Retarder Pilot Lamp
[NOTICE]
 When two or more abnormalities are stored in the
memory, they are output in the order of occurrence.
However, only one abnormality is output by one
operation.
Exception:
"Coding abnormality" is not stored in the memory, but
output by the flashing code.
The flashing code can be read by grounding the ISO

interface L line.
32 W564-0111E
Troubleshooting
2.2.2. Reading by Grounding of ISO Interface L Line
Condition:
- Vehicle stop status
- Hand lever switch position 0
Steps:
1. Connect the L line of ISO interface to the ground for
2 seconds or more. In order to ground, connect
the PC interface (53.8206.12) or service cable
(53.8224.10) provided for this purpose to the
4-terminal connector, then press the push button
of the switch.
2. The flashing code of the initial abnormality is
output.
3. Repeat the step 1 to output the next abnormality
code.
Display example: Abnormality code 23
Meaning of flashing code: E: Retarder pilot lamp ON
- Long flashing signal (2 seconds): Tenths place A: Retarder pilot lamp OFF
- Short flashing signal (0.5 seconds): Ones place t: Time
2.2.3. Deletion of Abnormality Code from Memory
Steps:
1. Turn OFF the ignition switch.
2. Connect the L line of ISO interface to the ground. In
order to ground, connect the PC interface or
service cable provided for this purpose to the
4-terminal connector, then press the push button
of the switch.
3. Turn ON the ignition switch.
4. After two seconds or more elapse, disconnect the
L line from the ground.
2.2.4. Reading of Abnormality Memory from PC
Hardware requirements:
- IBM PC-AT meeting conditions below or compatible
machine
- Processor: 80386 - 33 MHz or above
- Memory (RAM): 500 KB or more for executable
program
- Hard disk (HDD): 2 MB of free memory location
- 3.5 inch floppy disk drive (FDD)
- Video card: VGA standard
33 W564-0111E
Troubleshooting
- Serial interface (interface):

- 9-pole IBM interface, or
- 25-pole RS232C interface
- PC keyboard: Standard 102 or AT compatible
- Monitor: VGA black & white, or color
- Mouse: Although supported, it may be absent.
- PC interface 53.8206.12
Software requirements:
- OS: PC-DOS, MS-DOS, or
DR-DOS version 5.0 or above
- "DigiDia" photo diagnosis program
2.2.5. Abnormality Code and Troubleshooting
Connector terminal assignment
With all connectors, the side to which the connector is inserted is shown. (i.e., Lead wires are located in behind.)
Connector X1 of control unit

1. Not used
2. Not used
3. Not used
4. Hand lever switch: Position 3 (Braking force step:
Step 2)
Step 1)
6. Hand lever switch: Position 1 (Hill descend at
constant vehicle speed)
7. Ignition power supply
Step 4)
Step 3)
10. Hand lever switch +
11. ISO interface, L line
12. ISO interface, K line
13. Battery power supply
14. Not used
15. Ground
16. 2 "HS2" (option)
17. 1 "LS1" (option)
18. 1 "HS1" (option)
34 W564-0111E
Troubleshooting

1. Cannot be used/For application
2. Proportional solenoid valve -
3. Proportional solenoid valve +
4. Coolant temperature sensor -
5. Coolant temperature sensor +
6. Cannot be used/Ground
7. Not used
8. Oil temperature sensor –
9. Oil temperature sensor +

1. "DIU 1" (option)
3. ABS signal
4. "DID 2" (option)
5. "DID 1" (option)
6. "DIU 2" (option)
7. "INA-U" (option)
9. "DID 3" (option)
10. "INA-I" (option)
11. Stop lamp relay
12. "DID 4" (option)
ISO interface connector

1. K line
2. L line
4. Ground
35 W564-0111E
Troubleshooting
Meaning of "Measurement" column in table below
Example:
X1 - + X3

15 11
No. 11 terminal of connector X3

Set the tester to ohm, and measure the resistance.
No. 15 terminal of connector X1
- +

Indicates the resistance measurement.
- V +
Indicates the voltage measurement.
X1
No. 15 terminal of connector X1 is the ground of control unit.
15
When no abnormality to peripherals, poor contact of connector, or abnormality to lead wire is found in the
"Cause/Remedy" column in the table below, replace the control unit.
Normal
Abnormality
code Abnormality contents Condition/Operation Measurement Reference Cause/Remedy
value
01 Stop lamp relay - Ignition OFF X1 X3 Relay Inspection on
shorted to ground - Disconnect connector 
Ω + resistance: lead wire,
15 11
X3 from control unit. 250 to 350  connector, and
relay
02 LS1 output shorted - Ignition OFF X1 X1 0V Inspection on
to battery - Disconnect connector  V + lead wire,
15 17
X1 from control unit. connector, and
- Disconnect the spare relay
connector (lamp,
relay, etc.).
- Ignition ON
03 HS1 output shorted - Ignition OFF X1 X1 Relay Inspection on
to ground - Disconnect connector 
15 18
relay
04 HS2 output shorted - Ignition OFF X1 X1 Relay Inspection on
to ground - Disconnect connector 
15 16
relay, or user
side factor
05 Ignition power supply - Ignition OFF X1 X1  17.5 V Inspection on
low voltage - Disconnect connector  V + lead wire,
15 7
- Ignition ON relay
36 W564-0111E
Troubleshooting
Normal
Abnormality
value
06 Overvoltage of - Ignition OFF X1 X1  32.5 V Inspection on
ignition power supply - Disconnect connector  V + vehicle electrical
15 7
X1 from control unit. system (Refer to
- Ignition ON manufacturer's
- Engine start (idling) manual.)
08 Coolant temperature - Ignition OFF X2 X2 20C±10C = Inspection on
sensor open/shorted - Disconnect connector 
Ω + 1,039 to lead wire and
4 5
to battery X2 from control unit. 1,117  sensor
09 Coolant temperature
sensor shorted to 60C±10C =
ground 1,099 to
1,271 
80C±10C =
1,271 to
1,347 
[NOTICE]:
 Shall be sufficient with a
normal measurement with a
single temperature range.
11 Oil temperature - Ignition OFF X2 X2 20C±10C = Inspection on
sensor open/shorted - Disconnect connector  lead wire and
9 1,039 to
+
8 Ω
to battery X2 from control unit. 1,117  sensor
12 Oil temperature
sensor shorted to 60C±10C =
ground 1,099 to
1,271 
80C±10C =
1,271 to
1,347 
[NOTICE]
 Shall be sufficient with a
normal measurement with a
single temperature range.
37 W564-0111E
Troubleshooting
Normal
Abnormality
value
13 Switch status - Ignition ON X1 X1  17.5 V Inspection on
(1) unknown with - Retarder lever switch:  V + lead wire,
15 10
retarder lever switch Position 5 connector, and
hand lever
switch
13 - Ignition ON X1 X1  17.5 V Inspection on
(2) - Retarder lever switch:  V + lead wire,
15 8
Position 5 connector, and
hand lever
switch
15 9
hand lever
switch
15 4
hand lever
switch
15 5
hand lever
switch
15 6
hand lever
switch
14 Hand lever switch - Ignition OFF X1 X1 0V Inspection on
shorted to battery - Disconnect connector  V + lead wire and
15 10
X1 from control unit. connector
- Ignition ON
- Retarder lever switch:
Position 0
15 Retarder lever switch - Ignition OFF X1 X1 Resistance Check each step
shorted to ground - Disconnect connector 
Ω + infinite of retarder for
15 10
X1 from control unit. short to ground.
- Retarder lever switch:
Position 5
16 Open circuit of - Ignition ON X1 X3 1V Inspection on
vehicle speed signal  V + lead wire and
15 2
speedometer
18 Vehicle speed signal - Ignition OFF X1 X3 9V Inspection on
shorted to battery or - Disconnect connector  V + lead wire and
15 2
signal unknown X3 from control unit. speedometer
- Ignition ON
19 ABS shorted to - Ignition ON X1 X3  3.5 V Inspection on
ground  V + lead wire, relay,
15 3
and ABS control
unit
38 W564-0111E
Troubleshooting
Normal
Abnormality
value
21 ABS signal - Ignition ON X1 X3  16.5 V Inspection on
Unknown  V + lead wire, relay,
15 3
and ABS control
unit
22 Control unit internal -- Replace the
abnormality by ABS control unit.
current
23 Proportional solenoid - Ignition OFF X1 X2  10 V Inspection on
valve abnormality - Disconnect connector  V + lead wire
15 3
No. 1: X2 from control unit.
Shorted to battery - Ignition ON
24 Proportional solenoid - Ignition ON X2 X2 18 to 25  Inspection on
(1) valve abnormality - Disconnect connector 
Ω + lead wire and
2 3
No. 2: X2 from control unit. proportional
- Proportional solenoid valve
solenoid valve (whole valve)
solenoid short
circuit
- Proportional
solenoid valve
lead wire short
circuit
- Proportional
solenoid valve
solenoid open
circuit
- Proportional
solenoid valve
lead wire open
circuit
- Short to ground
with proportional
solenoid valve
24 - Ignition OFF X1 X2 Resistance Inspection on
(2) - Disconnect connector 
Ω+ infinite lead wire and
15 3
X2 from control unit. proportional
solenoid valve
24 - Ignition OFF X1 X2 Resistance Inspection on
(3) - Disconnect connector 
Ω + infinite lead wire and
15 2
X2 from control unit. proportional
solenoid valve
25 Proportional solenoid Replace the
valve abnormality control unit.
No. 3:
Control unit
malfunction
27 Proportional solenoid Replace the
valve abnormality control unit.
No. 5:
Control unit
malfunction
28 Battery power supply - Ignition OFF X1 X1  17.5 V Inspection on
low voltage - Disconnect connector  V + lead wire,
15 13
- Ignition ON fuse
29 Control unit Replace the
abnormality control unit.
39 W564-0111E
Troubleshooting
Normal
Abnormality
value
31 Control unit: Coding Prepare new
abnormality parameter for
control unit.
32 Retarder pilot lamp - Ignition OFF X1 X3  17.5 V Inspection on
open/shorted to - Disconnect connector  V + lead wire,
15 8
ground X3 from control unit. retarder pilot
- Ignition ON lamp, and fuse
33 Retarder pilot lamp: - Ignition ON X1 X3 2V Inspection on
Shorted to battery - Retarder lever switch:  V + lead wire and
15 8
Position 1 retarder pilot
lamp
35 Control unit Replace the
malfunction control unit.
37 Pedal operation Inspection on
abnormality pedal switch and
lead wire
40 W564-0111E
Troubleshooting
2.3. Troubleshooting (Without Abnormality Code)
Check of retarder operating status by PC
By connecting the ISO service interface with PC, the

retarder operating status of during traveling and stop
can be checked. Refer to "2.2.4. Reading of
Abnormality Memory from PC" or "DigiDia User's
Manual." However, including English, only seven
European languages are supported.
Table 1. Absolutely no retarder braking force is present.
Reference
No. Cause Inspection/Check
page
1-1 Oil shortage Oil amount check 9
1-2 Blocking of supplied air Control system check 31
1-3 Proportional solenoid valve trouble Control system check 32
Table 2. Retarder braking force insufficiency
Reference
page
2-1 Oil shortage Oil amount check 9
Overheat protection adjustment by Perform downshift to increase
2-2 7
insufficient engine speed engine speed.
Overheat protection function failure
2-3 Control system check 32
or proportional solenoid valve failure
Missing orifice at oil cooler mating
2-4 Orifice check 41
surface
2-5 Retarder assembly internal failure Pump pressure check 27
Table 3. Instable retarder braking force
Reference
page
3-1 Water intrusion into retarder Oil cooler check 41
3-2 Proportional solenoid valve failure Control system check 32
41 W564-0111E
Troubleshooting
Table 4. Braking force generation with retarder OFF (position 0)
Reference
page
4-1 Excessive oil amount Oil amount check 9
4-2 Proportional solenoid valve failure Control system check 32
Table 5. Slow release after retarder OFF
Reference
page
5-1 Breather filter clogging Breather filter check 47
5-2 Ventilator clogging Ventilator check 36
Table 6. Oil leak from breather filter
Reference
page
6-1 Check valve failure Check valve check 40
6-2 Ventilator failure Ventilator check 36
6-4 Excessive oil amount Oil amount check 9
Table 7. Pilot lamp flashing
Reference
page
Increase engine speed to improve
Activation of overheat protection by
7-1 cooling performance (perform 7
insufficient engine speed
downshift).
7-2 Overheat protection failure Control system check 32
Table 8. Premature activation of overheat protection
Reference
page
Wiring connection failure with
32
8-1 coolant temperature sensor and oil Connector connection check
78
temperature sensor
8-2 Engine coolant system failure Vehicle cooling system check 7
8-3 Overheat protection failure Control system check 32
42 W564-0111E
Troubleshooting
3. Troubleshooting (Control Unit: VERA Type)
3.1. Diagnosis (Self Diagnosis of Trouble)
The retarder pilot lamp also has a function as an abnormality indicator.

- Minor abnormality
The lamp lights steadily with the retarder lever switch position from 0 to 4. The braking force is either
maintained or reduced to half.
- Major abnormality
The lamp lights steadily with the retarder lever switch position from 0 to 4. The braking force is not generated.
The retarder switch becomes OFF.
[NOTICE]
 When the ignition is turned OFF and ON to operate the retarder again, the retarder pilot lamp goes out after a
five-second lamp test. If the abnormality occurs again, the retarder pilot lamp continues to be lit with the
retarder lever switch positions from 0 to 4.
3.2. Troubleshooting (With Abnormality Code)
Indication of Abnormality Contents

While an abnormality is occurring with which the lamp continues to be lit in the retarder lever switch position 0,
the contents of abnormality can be indicated by the flashing signal of pilot lamp.
3.2.1. Calling of Abnormality Code 3.2.2. Deletion of Abnormality Code from

Condition: Memory
- The stored error (past error) can only be deleted
- Hand lever switch position 0
with the dialog software (WinDia).
Steps:
1. Set the ignition key to ON status. Connect the
male and female retarder DIAG connector
(CN727) for two seconds or more, then disconnect
the connectors.
2. The flashing code of the initial abnormality is
output.
3. Repeat the step 1 to output the next abnormality
code.
Meaning of flashing code:
- Long flashing signal (2 seconds): Tenths place
- Short flashing signal (0.5 seconds): Ones place
[NOTICE] Display example: Abnormality code 23

 While the male and female of retarder DIAG E: Retarder pilot lamp ON
connector (CN727) are connected as described in A: Retarder pilot lamp OFF
above step 1, the retarder operates when the t: Time
abnormality is minor.
43 W564-0111E
Troubleshooting
3.2.3. Abnormality Code and Troubleshooting
Connector terminal assignment
With all connectors, the side to which the connector is inserted is shown. (i.e., Lead wires are located in behind.)
X1 connector of control unit

1. Not used
2. Not used
3. Not used
4. Not used
5. Retarder switch: Position 1 (Hill descend at constant
vehicle speed)
6. Retarder switch: Position 2 (braking torque 25%)
= Hand lever switch position 1
9. Retarder switch: position 4 (braking torque 75%)
10. Retarder switch output (hand lever power supply)
12. ISO interface, K line
13. ABS signal
14. Ground
16. Stop lamp relay
17. Not used
X3 connector of control unit

1. Coolant temperature sensor +
2. Coolant temperature sensor -
3. Proportional solenoid valve +
4. Proportional solenoid valve -
5. Oil temperature sensor +c
6. Oil temperature sensor -
7. Not used
8. Not used
9. Not used
10. Not used
11. Not used
12. Not used
44 W564-0111E
Troubleshooting
Abnormality Code Table

The flashing code, contents, and inspection method of recognized abnormality are described in the table
below.
For the terminal arrangement of connector, refer to a separate sheet.
[NOTICE]
 "X3/3  × 3/4" in the "Measurement/Tester connection" column of the table indicates that the "measurement of
resistance between connector terminal X3/3 and X3/4 by using a tester." When V is noted instead of , it
indicates the measurement of voltage.
 X1/14 = Control unit/ground
 Only when no abnormality is found after a thorough check on relevant items, replace the control unit.
Abnormality Abnormality Abnormality Time until Measurement Measurement/ Reference Cause/

Flashing Inspection contents level abnormality preparation/ Tester value/ Remedy
code process recognition Operation connection Set value
1 1 Data batch Major Immediately Parameter input
abnormality after ignition failure, redo of
ON parameter input
2 1 EEPROM Major Immediately Replace the
abnormality after ignition control unit.
ON
3 1 ROM Major Approximately Replace the
abnormality 10 seconds control unit.
after ignition
ON
4 1 SIBA Major 60 Replace the
abnormality milliseconds control unit.
5 1 Proportional Major 1 second - Ignition: OFF X 3/3  X 3/4 18 to 25  Check the
valve is - X3 plug not proportional
shorted to connected valve and
ground or wiring.
open.
5 2 Major X 3/3  X 1/14 Resistance Check the
infinite proportional
valve and
wiring.
5 3 Major X 3/4  X 1/14 Resistance Check the
infinite proportional
valve and
wiring.
6 1 Proportional Major 1 second - Ignition: OFF X 3/3 V X 1/14  10 V Check the plug
valve is - Plugs X1 and and wiring.
shorted to X3 not
battery. connected
- Ignition ON
8 1 Internal failure Major 3 seconds Replace the
of control unit control unit.
relevant to
proportional
valve
9 1 Power supply Major 60 seconds - Ignition: OFF X 1/7 V X 1/14  17.5 V Check the
low voltage - Plug X1 not wiring,
connected connector, and
- Ignition ON fuse.
10 1 Power supply Major 10 seconds - Ignition: OFF X 1/7 V X 1/14  32.5 V Check the
overvoltage - Plugs X1 and vehicle
X3 not electrical
connected system (refer to
- Ignition ON specifications of
vehicle
manufacturer).
11 1 Switch status Major 2 seconds - Ignition ON X 1/10 V X 1/14  17.5 V Check the
unknown with - Retarder lever X 1/5 V X 1/14 0V wiring,
retarder lever switch: X 1/6 V X 1/14 0V connector, and
switch Position 0 X 1/8 V X 1/14 0V retarder lever
X 1/9 V X 1/14 0V switch.
X 1/18 V X 1/14 0V
45 W564-0111E
Troubleshooting

11 2 Major - Ignition ON X 1/5 V X 1/14  17.5 V Check the
- Retarder lever X 1/6 V X 1/14  17.5 V wiring,
switch: X 1/8 V X 1/14 0V connector,
Position 1 X 1/9 V X 1/14 0V and retarder
X 1/18 V X 1/14 0V lever switch.
switch: X 1/8 V X 1/14  17.5 V connector,
Position 2 X 1/9 V X 1/14 0V and retarder
Position 3 X 1/9 V X 1/14  17.5 V and retarder
Position 4 X 1/9 V X 1/14  17.5 V and retarder
X 1/18 V X 1/14  17.5 V lever switch.
12 1 Retarder lever Major 1 second - Ignition: OFF X 1/10  X 1/14 Resistance Check the
switch is - Plug X1 not infinite wiring,
shorted to connected connector,
ground. - Retarder lever and retarder
switch: lever switch.
Position 4
13 1 Retarder lever Major 10 seconds - Ignition: OFF X 1/10 V X 1/14 0 V Check the
switch is - Plug X1 not wiring,
shorted to connected connector,
battery. - Ignition ON and retarder
- Retarder lever lever switch.
switch:
Position 0
16 1 Simultaneous Major 1 second Refer to 17,
failure of 18, 19, and
coolant 20 below.
temperature
sensor and oil
temperature
sensor
17 1 Coolant Minor 1 second - Ignition: OFF X 3/1  X 3/2 20C±10C = Check the
temperature - Plug X3 not 1,039 - 1,117 wiring,
sensor open connected  connector,
circuit and sensor.
60C±10C =
1,194 - 1,271

80C±10C =
1,271 - 1,347

Note:
Normally, it is
sufficient with
a
measurement
with a single
temperature
range.
18 1 Coolant Minor 1 second - Ignition: OFF X 3/2  X 1/14 Resistance Check the
temperature - Plugs X1 and infinite wiring and
sensor is X3 not connector.
shorted to connected
ground.
46 W564-0111E
Troubleshooting

19 1 Oil Minor 1 second - Ignition: OFF X 3/5  X 3/6 20C±10C = Check the
temperature - Plug X3 not 1,039 - 1,117 wiring,
sensor open connected  connector,
circuit and sensor.
60C±10C =
1,194 - 1,271

80C±10C =
1,271 - 1,347

Note:
Normally, it is
sufficient with
a
measurement
with a single
temperature
range.
20 1 Oil Minor 1 second - Ignition: OFF X 3/5  X 1/14 Resistance Check the
temperature - Plugs X1 and infinite wiring and
sensor is X3 not connector.
shorted to connected
ground.
21 1 Vehicle speed Major 2 seconds - Ignition ON X 1/11 V X 1/14 1V Check the
signal open wiring and
circuit vehicle speed
signal.
23 1 Retarder pilot Major 1 second - Ignition: OFF X 1/15 V X 1/14  17.5 V Check the
lamp open - Plug X1 not wiring and
circuit or connected fuse.
shorted to - Ignition ON
ground
24 1 Retarder pilot Major 3 seconds - Ignition ON X 1/15 V X 1/14  2 V Check the
lamp open - Retarder stage wiring and
circuit or switch: retarder pilot
shorted to Position 1 lamp.
battery
29 1 ABS signal is Major 60 seconds - Ignition ON X 1/13 V X 1/14  3.5 V Check the
shorted to wiring, relay,
ground. and ABS
control unit.
30 1 ABS Major 5 seconds - Ignition ON X 1/13 V X 1/14  16.5 V Check the
undefined wiring, relay,
status and ABS
control unit.
31 1 Internal Major 1 second Replace the
deficiency of retarder
control unit control unit.
relevant to
ABS signal
34 1 Stop lamp Minor 1 second - Ignition: OFF X 1/16  X 1/14 Relay Check the
relay open - Plug X1 not installation wiring,
circuit or connected status: 250 to connector,
shorted to 350  and relay.
battery
47 W564-0111E
Troubleshooting
4. Inspection
4.1. Adjustment pressure and pump pressure check
1. Retarder housing
140. Plug (M12 × 1.5) ....................................25 Nm (260 kgf·cm)
141. Sealing washer ......................................Replace
Special tool
[NOTICE]
 By this pump pressure check, the stator status and rotor status as well as an abnormality inside the retarder
such as an internal leak can be identified.
48 W564-0111E
Troubleshooting
Preliminary check
- Battery voltage: 20.5 to 30 V
- Vehicle air pressure 500 to 1,100 kPa (5 to 11 kgf/cm2)
- The retarder oil level is proper.
- Retarder lever switch is in position 0.
4.1.1. Pump Pressure Checking Procedure

1. Remove the pump pressure test plug (140) of
retarder housing (1).
2. Mount the pressure gauge (156).
3. With the vehicle stopped, turn the ignition switch

from OFF to ON.
4. Set the hand lever switch to the highest position

(position 4), then return to position 0.
5. Set the hand lever switch to the highest position

(position 4), then read the pressure gauge.
6. Perform a comparison of pressure indicated by

pressure gauge with the value shown in the
adjustment air pressure of table below.
156: Pressure gauge 0 to 2.5 MPa

53.4788.10
[NOTICE]
 When the measured pressure differs from the adjustment air pressure in the table, it indicates a control system
trouble.
Refer to "4.2. Control System Check" in Troubleshooting.
7. Drive the vehicle, and set the speed at which the

propeller shaft revolution becomes as indicated
below.
R120S: 2,000 to 2,200 r/min
8. Under the traveling status above, activate the

retarder highest position (position 4), and read the
pump pressure on the pressure gauge.
9. Perform a comparison of the pressure gauge

pump pressure with the pressure shown in the
table below.
49 W564-0111E
Troubleshooting
Braking torque Control Adjustment air Pump pressure

setting current pressure R120S
Propeller
Stable value after shaft rotation
approx. 2,000 r/min
10 seconds [kPa]
[Nm] [mA] [kPa]
1,500 463 to 475 165 to 215 1,400 or more
1,750 483 to 495 195 to 245 1,600 or more
1 kg/cm2 = 100 kPa
[NOTICE]
 When the measured pump pressure at traveling is 500 kPa or higher than the value in the above table, it
indicates a trouble to the retarder or control system. Although the pump pressure is normal during stop, if the
pump pressure at traveling does not reach the value in the table, it indicates a rotor/stator trouble or an
internal leak.
50 W564-0111E
Troubleshooting
4.2. Control System Check
4. Oil cooler
20. Control unit
30. Coolant temperature sensor
32. Lead wire of coolant temperature sensor, two-line wire
33. Proportional solenoid valve connector
34. Air tank for auxiliary device
35. Proportional solenoid valve
36. Adjustment air pressure (A)
37. Supply air pressure (P)
38. Exhaust (R)
39. Air piping (from 4-way protection valve to air tank for auxiliary device)
290. Oil temperature sensor
296. Lead wire of oil temperature sensor, two-line wire
314. 4-way protection valve
315. Air piping (from pressure regulating valve to 4-way protection valve)
316. Air piping (braking system 1)
317. Air piping (braking system 2)
318. Air piping (parking brake)
51 W564-0111E
Troubleshooting
Preliminary check
- No abnormality is present to vehicle electrical system.
Special tool
Commercially-available tool
Tester ･････ Recommendation: Fluke 76 or 87
4.2.1. Inspection of Supply Air Pressure Pv
1. Connect the pressure gauge to the test connection

of compression air line (39) (4-way protection
valve - air tank for auxiliary equipment), and check
the supply air pressure Pv.
Minimum pressure: 0.5 MPa
Maximum pressure: 1.1 MPa
Pressure gauge 53.1403.10
[NOTICE]
 When the pressure is outside the specified range,
always perform a check on the vehicle compressed
air system by comparing with the manufacturer
data.
52 W564-0111E
Troubleshooting
4.2.2. Measuring Instrument Setup
1. Connect the temperature simulator (173) to the

temperature sensor plug (108) via the adaptor
cable (337).
173. Temperature simulator 53.8207.10

337. Adaptor cable 53.8279.10
[NOTICE]
 Check that the plug for water and oil is connected
properly.
2. Loosen the screw of refill level check plug (5), and

remove the sealing washer (6).
3. Connect the pressure gauge (158) to the retarder

housing (1).
158. Pressure gauge 53.1403.10
4. Connect the proportional current measurement

adaptor (172).
- Disconnect the connector from the proportional
solenoid valve (35), and connect it to the
proportional current measurement adaptor (172).
- Connect the plug of "proportional current"
measurement adaptor (172) to the proportional
solenoid valve (35).
- For the mA measurement, connect the tester (174).
- Set the "Propvalve" switch of proportional current
measurement adaptor (172) to "I."
172. Proportional current measurement adaptor

53.8198.10
53 W564-0111E
Troubleshooting
4.2.3. Inspection Procedure
1. Set the rotary switches of temperature simulator

(173) to coolant temperature of 95C and oil
temperature of 165C. Then, set the hand lever
switch to the highest position. The adjustment air
pressure Py and control current must reach the
values in 3.4. "Table of pump pressure inspection"
(page 29).
173. Temperature simulator 53.8207.10
[NOTICE]
 Even when the control current has reached the
specified value, if the adjustment air pressure has
not reached the specified value, replace the
proportional solenoid valve with the new one. When
both the control current and adjustment air pressure
do not reach the specified value, replace the control
unit.
2. Set the rotary switch of temperature simulator

(173) to the coolant temperature of 105C. The
adjustment air pressure Py must be 0.02 MPa or
more lower than the maximum set pressure.
Set the rotary switch of temperature simulator
(173) to the coolant temperature of 125C. The
pressure of adjustment air pressure Py must be 0.
Again, set the rotary switch of temperature
simulator to the coolant temperature of 95C.
3. Set the rotary switch of temperature simulator

(173) to the oil temperature of 185C.
The adjustment air pressure must be 0.01 MPa or
more lower than the maximum set pressure.
Set the rotary switch of temperature simulator to
the oil temperature of 225C.
The pressure of adjustment air pressure Py must
be 0.
[NOTICE]
 When the specified value cannot be obtained,
replace the control unit.
54 W564-0111E
Troubleshooting
4. Remove the pressure gauge.
5. Using a new sealing washer, securely tighten the

refill level check plug (5) to 150 Nm.
6. Perform connections of original coolant

temperature gauge and oil temperature gauge
again.
7. Remove the proportional current measurement

adaptor, then connect the connector to the
proportional solenoid valve.
55 W564-0111E
Troubleshooting
4.3. Vehicle Stop Operation Check
Requirements for inspection:

- The vehicle electrical system has been checked in
accordance with the user's manual, and the
requirements have been met.
- Compressed air: 0.5 to 1.1 MPa
- The retarder oil level is proper.
- Hand lever switch: Position 0
4.3.1. Inspection
1. Turn the ignition switch from OFF to ON.

A five-second pilot lamp bulb test is performed. It
is normal when the pilot lamp goes out after the
test.
If the lamp lights again, it indicates that the control
unit has recognized an abnormality.
Refer to 3.2. Troubleshooting (With Abnormality
Code).
2. Sequentially set the hand lever switch one position

higher.
It is normal when the pilot lamp is lit and air
shifting noise can be heard near the retarder main
body.
3. Sequentially set the hand lever switch one position

lower, and turn the switch OFF.
It is normal when a strong air noise of quick
exhaust is heard and the pilot lamp is turned OFF.
56 W564-0111E
Servicing
Servicing
1. Servicing of Retarder Main Body
1.1. Servicing of Ventilator
1. Retarder housing
72. Top cover
73. Hexagon bolt (M6 × 30) ................ 10 Nm (100 kgf·cm)
74. Washer
76. Float holder
77. Ventilator case
78. Float .............................................. Perform a check, and replace ventilator assembly (82) when necessary.
79. O-ring (55 × 3)............................... Replace. Apply grease and install.
80. Oil seal (22.6 × 34 × 5.5) .............. Perform a check, replace ventilator assembly (82) when necessary, and
apply grease.
82. Ventilator assembly
84. Strainer
195. Gasket
196. Hexagon socket head bolt (M6 × 12) ....8 Nm (80 kgf·cm)
197. Washer
198. Baffle plate
199. Spacer
57 W564-0111E
Servicing
Cleaning agent and lubricant

O-ring and oil seal ........................ Grease
Float.............................................. Denatured alcohol
Strainer ......................................... Gasoline
Special tool
1.1.1. Disassembly
1. Remove the hexagon bolt (73).
2. Remove the washer (74).
Tightening torque: 10 Nm (100 kgf·cm)
3. Remove the top cover (72).
4. Remove the gasket (195), then clean the retarder

housing (1) and top cover (72) sealing surface.
58 W564-0111E
Servicing
5． Remove the hexagon bolt (196) and washer

(197).
6． Remove the baffle plate (198).
7． Remove the spacer (199).
8． By using the ventilator extractor (200), pull out

and remove the ventilator case (77).
200. Ventilator extractor

PR91000001
9． Take out the float (78) and float holder (76).
10． Take out the strainer (84), and clean with

gasoline.
11． Remove the O-ring (79).
59 W564-0111E
Servicing
1.1.2. Inspection
1. Check the float (78) surface, especially the

sealing surface (shown by the arrow), for any
scratches.
2. Measurement of float weight

Weight: 11±1 g
If outside the range, replace the ventilator
assembly.
[NOTICE]
 The float may become heavier due to an oil
intrusion.
3. Sealability inspection
By using appropriate means, have the float (78)
stand vertically straight. Then, horizontally lay
the ventilator case (77) over the float. To the
concave area created to the upper section, pour
the denatured alcohol. When the fluid surface
does not become lowered for one minute, the
seal is in normal state.
If a sealing failure is present, replace the
ventilator assembly.
1.1.3. Assembly
1. Grease the O-ring (79), then install it to the

ventilator case (77).
2. In the reverse order of the disassembly, perform

the assembly.
60 W564-0111E
Servicing
1.2. Servicing of Check Valve
144. Check valve

145. Joint .......................................................Apply LOCKTITE L270, and tighten. 100 Nm (1,020 kgf·cm)
Check the valve seat, and replace if necessary.
146. Valve ......................................................Check the sealing surface, and replace if necessary.
147. Spring.....................................................Check for damage, and replace if necessary.
61 W564-0111E
Servicing
1.3. Servicing of Oil Cooler
1. Retarder housing
4. Oil cooler
7. Retarder oil drain plug (M22 × 1.5) .....................................66 Nm (670 kgf·cm)
8. Sealing washer (22 × 29) ......................................................Replace
9. Oil cooler oil drain plug (M12 × 1.5) ......................................25 Nm (260 kgf·cm)
10. Sealing washer (12 × 15.5)...................................................Replace
11. Leaked oil drain plug (M10 × 1) ............................................13 Nm (130 kgf·cm)
13. Coolant drain plug (M12 × 1.5) .............................................25 Nm (260 kgf·cm)
48. O-ring (82 × 4).......................................................................Replace when necessary
50. Blind lid
85. Self-locking hexagon nut (M8) ..............................................Replace. 26 Nm (270 kgf·cm)
86. Washer
87. Hexagon bolt (M8 × 40) ........................................................ 26 Nm (270 kgf·cm)
88. Washer
90. O-ring (45 × 4).......................................................................Replace. Apply grease.
91. O-ring (8 × 2).........................................................................Replace. Apply grease.
92. O-ring (36 × 4).......................................................................Replace. Apply grease.
93. Orifice plate (retarder outlet)
98. Orifice plate (retarder inlet)
99. Insert
290. Oil temperature sensor (M14 × 1.5)......................................28 Nm (290 kgf·cm)
327. Sealing washer (22 × 29)......................................................Replace
62 W564-0111E
Servicing
Data: Pressure test ............... 1.0 MPa (10 kgf/cm2)

Lubricant: O-ring ................... Grease
Special tool
1.3.1. Preliminary Work
1. Remove the oil temperature sensor (290) and

sealing washer (327).
2. Close the heater shutoff valve and others of

engine coolant.
3. Remove the coolant drain plug (13) of retarder,

and drain the coolant.
Remove the oil drain plug (7, 9, 11), and drain

the oil.
63 W564-0111E
Servicing
1.3.2. Removal
1. Loosen and remove four self-locking hexagon

nuts (85).
2. Loosen two hexagon bolts (87), and remove the

oil cooler (4).
3. Remove three O-rings (90, 91, 92) and orifice

(93).
[NOTICE]
 Do not remove the insert (99).
When the insert (99) and orifice (98) located behind

are removed, be sure to set to the correct mounting
direction at assembly. Set the orifice with its
chamfered side of outside surface facing back. Set
the insert with its three legs facing back, and
position the two of three legs at upper and lower
side of right side so that the oil gallery of housing
does not become blocked.
64 W564-0111E
Servicing
4. Check the blind lid (50) for oil leak.

When necessary, replace the O-ring (48).
Screw in the shock hammer (206) into the blind

lid to pull out and remove the blind lid using the
impact.
206. Shock hammer

53.7712.10
1.3.3. Inspection
1. Close the hole of oil temperature sensor by the

sealing washer and plug (M14 × 1.5).
2. Mount the pressure test plate (94) to the oil

cooler (4), and connect the air hose.
94. Pressure test plate
PR90800000
3. Fill the coolant side of the oil cooler with warm

water of approximately at 70C.
4. Gradually increase the air pressure from 0, and

pressurize up to 1 MPa (10 kgf/cm2).
If any bubbles come out from the warm water,
there is a leak from the oil cooler. In that case,
replace the oil cooler.
5. Remove the pressure test plate.
65 W564-0111E
Servicing
1.3.4. Mounting
[NOTICE]
 With a new oil cooler, both the coolant side and oil side are wet with storage oil. Therefore, drain the storage
oil before use, and flush the coolant side with warm water.
1. Apply grease lightly to the new O-rings (90, 91,

92), and stick them to the retarder housing.
2. Apply grease lightly to the orifice (93), and stick

it to the hole at the right side.
3. Mount the oil cooler (4) to the retarder housing.

Tighten with the bolt, washer, and new
self-locking nut.
4. As needed, mount to the vehicle.

(Refer to 5.4. or 6.4. Mounting/Dismounting of
Retarder.)
5. Replenish the engine coolant, and perform

bleeding.
Return the heater shutoff valve and others to the
original status.
6. When a leak is present with the oil cooler, it can

be suspected that water is still inside the
retarder. Therefore, be sure to perform flushing.
Refill with five liters of engine oil or flushing oil,
and operate the retarder a few times slowly at
position 2. Then, open the oil drain plug (7, 9) to
drain the oil.
Repeat this step for two to three times.
Replace the sealing washer with the new one,
and mount the drain plug.
Tightening torque:
Retarder oil drain plug (7): 66 Nm (670 kgf·cm)
Oil cooler oil drain plug (9): 25 Nm (260 kgf·cm)
[NOTICE]
 Always perform the retarder operation in the
position 1. If the retarder is operated suddenly
and strongly, foaming may occur due to immixing
of water and oil, resulting in a leak from breather.
7. After flushing, refill with an appropriate amount

of 5 L (full amount: 5.5 L).
66 W564-0111E
Servicing
1.4. Mounting/Dismounting of Lower Cover
Preliminary work: Oil draining
47. Hexagon socket head bolt (M6 × 20).....8 Nm (80 kgf·cm)

74. Washer
201. Gasket....................................................Replace
202. Lower cover
67 W564-0111E
Servicing
1.5. Servicing of Breather Filter
204. Breather filter .........................................Clean with gasoline, etc.

205. Circlip (JL30 × 1.2)
68 W564-0111E
Servicing
1.6. Replacing the Output Side Shaft Oil Seal
1. Retarder housing
115. Precoat hexagon bolt (M8 × 25) ............Replace. 30 Nm (310 kgf·cm). Retighten.
116. Labyrinth ring .........................................Apply Hylomar.
117. Oil seal (95 × 115 × 10) .........................Replace. Apply grease.
118. O-ring (122 × 2.5) ..................................Replace. Apply grease.
Sealer and lubricant

Labyrinth ring................................ Hylomar
Oil seal and O-ring........................ Grease
Special tool
69 W564-0111E
Servicing
1.6.1. Working Procedure
[NOTICE]
 Because the loosening prevention is implemented
to the bolt by LOCKTITE, the bolt may become
damaged if the impact wrench is used. Loosen
slowly by hand.
2. Screw in two hexagon bolts (M8 × 25) into the

pull-out screw hole of the labyrinth ring (116),
and pull out to remove the labyrinth ring.
3. Place the labyrinth ring on a suitable cylinder.
4. Through the two pull-out holes (shown by

arrows) of the labyrinth ring, punch through the
oil seal (117) by using the prick punch.
5. Shaft side inspection

With mid-mount retarder
Check for the wear or flaws to the lip contacting
surface of the oil seal of spacer ring (127).
Replace when necessary.
With direct mount retarder

Check for the wear or flaws to the lip contacting
surface of the oil seal of output shaft flange.
70 W564-0111E
Servicing
6． With the spacer ring replacement, mount the

extractor as shown in the figure, tighten the Tool
nut at the center to expand the inner diameter
of spacer ring. Then, route a hollow shaft from
the back, and lightly tap with a hammer grip or
others for extraction.
Special tool: Spacer ring extractor
PR91300000
7． On the oil seal press fit tool (114) bench, place

the labyrinth ring (116) as shown in the figure.
Grease the new oil seal (117) lightly, then
mount it to the retainer of the tool (114) as
shown in the figure. Then, using the hand
press, perform the press fit sufficiently with the
pressing force of 5,000 N (500 kgf) or less.
Keep pressing for 10 seconds to prevent the
lifting of oil seal.
Visually check that the oil seal is press fitted
correctly, and that no tilting or lifting is present.
114. Oil seal press fit tool 95D
PR91100000
8． Grease the O-ring (118) lightly, then install it to

the labyrinth ring (116).
9． Lightly apply Hylomar to around the leaked oil

recovery gallery hole (shown by the arrow)
shown in the labyrinth ring figure. Align so that
the leaked oil recovery gallery hole (shown by
the arrow) comes to the lower side and
matches with the retarder housing hole, then
mount the labyrinth ring.
10． Tighten the new precoat hexagon bolt (115).

71 W564-0111E
Servicing
2. Servicing of Mid-Mount Retarder Main Body

2.1. Mounting/Dismounting of Retarder
4. Oil cooler
13. Coolant drain plug (M12 × 1.5) .................................. 25 Nm (260 kgf·cm)
15. Sealing washer (12 × 15.5)........................................ Replace
36. Adjusting air piping
170. Hose band
171. Rubber hose
172. Hexagon bolt (M16 × 1.5 × 90)
173. Cap washer
174. Mount rubber
175. Spacer pipe
176. Self-locking hexagon nut (M16 × 1.5)........................ Replace. 210 Nm (2,140 kgf·cm)
177. Input side propeller shaft
178. Output side propeller shaft
179. Bolt
180. Spring washer............................................................ Replace
181. Nut
194. Proportional solenoid valve exhaust pipe
290. Oil temperature sensor .............................................. 28 Nm (290 kgf·cm)
327. Sealing washer (14 × 20)........................................... Replace
72 W564-0111E
Servicing
2.1.1. Removal Procedure

[NOTICE]
 Perform the mounting in the reverse order of the removal procedure.
1. Remove the oil temperature sensor (290) and

sealing washer (327).
[NOTICE]
 Replace the sealing washer (327), and tighten the
temperature sensor (290) to 28 Nm (290 kgf·cm).
2. Close the heater shutoff valve and others of

engine coolant.
3. Remove the coolant drain plug (13) of retarder,

and drain the coolant.
73 W564-0111E
Servicing
4． Loosen the hose band (170), and pull out and

remove the rubber hose (171) from the
retarder.
5． Remove the adjustment air pressure piping

(36) and proportional solenoid valve exhaust
pipe (194).
6． Remove the propeller shaft (177 and 178).
[NOTICE]
 With the universal joint of propeller shaft, be sure
to assemble with matching the flange mating
marks so that both the front and back are oriented
to the same direction (shown by arrows).
7． Remove the hexagon nut (176).
Tightening torque: 210 Nm (2,140 kgf·cm)
8． Remove the hexagon bolt (172) and cap

washer (173).
While supporting from below by placing a
transmission jack underneath the retarder,
remove the retarder.
9． Check the mount rubber (174), and replace

when necessary.
10． Replace the retarder with the new one, and

mount in a reverse order.
74 W564-0111E
Servicing
2.2. Mounting/Dismounting of Input/Output Shaft Flange
1. Retarder housing
100. Hexagon bolt (M22 × 160) .....................Replace. Apply LOCKTITE. 285 Nm (2,900 kgf·cm)
101. Output shaft flange
102. Splash ring
103. Splash ring
104. Input shaft flange
105. Hexagon nut (M22) ................................Replace. Not present depending on flange type.
106. Flange bolt .............................................Replace. Not present depending on flange type.
75 W564-0111E
Servicing
Bolt and nut type
Bolt type
76 W564-0111E
Servicing
Adhesive: Bolt ........................... LOCKTITE RC40
1. Loosen the bolt (100).
[NOTICE]
 Because the bolt loosening is prevented with
LOCKTITE, the loosening torque is approximately
at 600 Nm (approximately 60 kgf･m). With the bolt
type, ensure that the anti-rotation detention of
flange be implemented.
2. Pull out and remove the flange.
3. If the splash ring (103) is loose or damaged,

replace with the new one.
Splash ring assembly
Apply LOCKTITE RC40 to the flange engaging
section, then heat the splash ring to
approximately 200C to perform the shrink fit.
2.2.1. Mounting
1. Assemble the new flange bolt to the flange.
Attention! Align the mating mark (shown by the

arrow) of both flanges (101, 104) or the
hole pattern of flange bolt, then
assemble to the retarder housing (1).
2. Degrease the threaded section of new hexagon

bolt (100). Then, excluding the two threads at
the leading end, apply LOCKTITE RC40 to the
full circumference of next two to three threads.
77 W564-0111E
Servicing
2.3. Replacing the Input Side Shaft Oil Seal
3. Rotor housing
110. Precoat hexagon bolt (M8 × 30) ............Replace. 30 Nm (310 kgf·cm). Retighten.
111. Labyrinth ring .........................................Apply Hylomar.
Sealer and lubricant

Labyrinth ring................................ Hylomar
Oil seal and O-ring........................ Grease
Special tool
78 W564-0111E
Servicing

Tool
[NOTICE]
Because the loosening prevention is implemented to
the bolt by LOCKTITE, the bolt may become
damaged if the impact wrench is used. Loosen
slowly by hand.
2. Screw in two hexagon bolts (M8 × 30) into the

pull-out screw hole of the labyrinth ring (111),
and pull out to remove the labyrinth ring from the
rotor housing (3).
3. Place the labyrinth ring on a suitable cylinder.
4. Through the two through holes (shown by arrows)

of the labyrinth ring, punch through the oil seal
(112) by using the prick punch.
5. Check for the wear or flaws to the lip contacting

surface of the oil seal of the shaft side spacer
ring (125).
79 W564-0111E
Servicing
6． With the spacer ring replacement, use an

extractor. Tighten the nut at the center of the
extractor to expand the inner diameter of Tool
spacer ring. Then, route a hollow shaft from
the back, and tap with a hammer grip or
others for extraction.
Special tool: Spacer ring extractor
PR91300000
7． On the oil seal press fit tool (114) bench,

place the labyrinth ring (111) as shown in the
figure. To the new oil seal (112), apply grease
lightly, and mount it to the retainer of the tool
(114) as shown in the figure. Then, using the
hand press, perform the press fit sufficiently
with the pressing force of 5,000 N (500 kgf) or
less. Keep pressing for 10 seconds to prevent
the lifting of oil seal.
correctly, and that no tilting or lifting is
present.
114. Oil seal press fit tool 95D
PR91100000
8． Grease the O-ring (119) lightly, then install it to

the labyrinth ring (111).
9． Lightly apply Hylomar to around the leaked oil

recovery gallery hole (shown by the arrow)
shown in the labyrinth ring figure. Align so that
the leaked oil recovery gallery hole (shown by
the arrow) comes to the lower side and
matches with the retarder housing hole, then
mount the labyrinth ring.
10． Tighten the new hexagon bolt (110).

80 W564-0111E
Servicing
3. Servicing of Direct Mount Retarder Main Body

3.1. Mounting/Dismounting of Output Shaft Flange
1. Retarder housing
101. Output shaft flange
102. Splash ring
103. O-ring .....................................................Replace. Apply grease.
104. O-ring .....................................................Replace. Apply grease.
105. Hexagon nut ..........................................Replace
106. Flange bolt .............................................Replace
81 W564-0111E
Servicing
1. Remove the loosening prevention of the nut

(105).
2. Loosen the nut, and remove the O-ring (104).
3. Pull out the flange by using the puller.
4. If the splash ring (102) is damaged, replace with

the new one.
Splash ring assembly
Firstly, install the flange bolt (106). Apply
LOCKTITE RC40 to the flange engaging section.
Then, heat the splash ring to approximately
200C to perform the shrink fit.
5. Lightly apply grease to the new O-ring (103),

and install it to the flange.
6. Install the new flange bolt (106) to the flange.
7. Align the flange with the shaft spline, then mount

the flange. When the fitting is tight, heat the
flange to 100C to 150C, and then perform
mounting.
8. Lightly apply grease to the new O-ring (104),

and install it to the shaft. Then, tighten the new
nut (105). The tightening torque shall be in
accordance with the specification of vehicle
manufacturer.
9. Implement a loosening prevention to the nut

(105).
82 W564-0111E
Servicing
3.2. Mounting/Dismounting of Retarder (Example of TADANO Rough Terrain TR500M and 350M)
1. Retarder housing
210. Shim
211. Bolt
83 W564-0111E
Servicing
Special tool
Preliminary work Removal of propeller shaft flange. Refer to 6.1.

Removal of oil temperature sensor
Removal of two air piping
Removal of coolant hose
1. Remove the retarder mounting bolt (211). At this

time, remove the shims at four positions while
avoiding mixing of shims. Then, check the
thickness of each shim.
[NOTICE]
When mounting, the shim adjustment is needed.
2. Pull out the retarder main body from the shaft. If

it is too tight to pull out, use the special tool for
removal according to the procedure below.
3. Among the mounting bolts of labyrinth ring,

remove the four bolts indicated by the arrows.
4. Mount the retarder puller as shown in the figure,

then install the bolt [7] to 30 Nm (310 kgf·cm). [7]
5. Tighten the bolt [8], and pull out the retarder. [8]
Special tool: Retarder puller

7906100000
84 W564-0111E
Servicing
3.2.2. Mounting
1. When mounting a new retarder, the shim

adjustment is needed.
Shim thickness of original retarder = To
Marking of original retarder = So
Marking of new retarder = Sn
Shim thickness of new retarder
= Tn will be as follows:
Tn = To + So - Sn
Perform the above with each of four positions. Marking
[NOTICE]
 When mounting a completely new retarder or
when the shim thickness of original retarder is [1]
unknown, use the shim gauge to obtain the shim
thickness. Set the shim gauge [1] as shown in the
figure, and tighten the nut to 340 Nm (3,500
kgf·cm).
Measure the size Z. With the marking size Sn,
calculate the shim thickness Tn using the formula
below.
Tn = (Z - 10) - Sn
Perform the calculation with each of four
positions.
Special tool: Shim gauge
7906200000
2. Lightly apply Molybdenum Grease to the shaft,

then insert the retarder.
If too tight, perform according to the procedure
from 3. below. [2]
3. Cool the shaft by using dry ice, or heat the

retarder hole to 150C or less to achieve a
temperature difference between the shaft and
hole of 50C or more. Then, promptly mount the
retarder, and using the insertion tool [2] shown in
the right figure, tighten the nut to press in the
retarder.
Special tool: Retarder insertion tool
7906300000
4. Insert the shim, and tighten the bolt.

85 W564-0111E
Servicing
3.3. Replacing the Input Side Shaft Oil Seal
1. Retarder housing
3. Rotor housing
62. Stator
63. Rotor
64. Hexagon bolt (M8 × 90) .........................26 Nm (270 kgf·cm)
66. O-ring (8 × 2)..........................................Replace. Apply grease.
68. Washer
86 W564-0111E
Servicing
Lubricant: Oil seal and O-ring ....................... Grease
Special tool
Tool prepared on-site
Single-end stud M8 × 100
2. Pull out and remove the rotor housing (3).
3. Punch through the oil seal (136) by using the

prick punch.
87 W564-0111E
Servicing
4. To the new oil seal (136), apply grease lightly,

and using the press fit tool, press fit the seal with
the hand press. To prevent the lifting of oil seal,
keep pressing for 10 seconds.
Perform with the pressing force of 5,000 N (500
kgf) or less.
correctly, and that no tilting or lifting is present.
Special tool: Oil seal press fit tool 80D
PR90600000
5. Replace the O-ring (66 and 203) with the new

one. Lightly apply grease to the O-ring, and
install the O-ring. Stick the small O-ring (66) to
the concave section of rotor housing.
6. For a guide, plant the single-end stud (132), and

assemble the rotor housing (3).
At this time, align the leaked oil gallery hole, and
pay attention to the biting of seal ring (130).
7. Pull out the single-end stud (132), then install

the hexagon bolt (64) together with the washer
(68).
8. Tighten the hexagon bolts (64) in the order

shown in the figure.
88 W564-0111E
Data
Data
1. Data
1.1. Tightening Torque Table
Code Name Tightening torque Remarks
5 Refill level check plug M30 × 1.5 150 Nm (1,530 kgf·cm)
7 Retarder oil drain plug M22 × 1.5 66 Nm (670 kgf·cm)
9 Oil cooler oil drain plug M12 × 1.5 25 Nm (260 kgf·cm)
11 Leaked oil drain plug M10 × 1 13 Nm (130 kgf·cm)
13 Coolant drain plug M12 × 1.5 25 Nm (260 kgf·cm)
30 Temperature sensor M14 × 1.5 28 Nm (290 kgf·cm)
47 Lower cover hexagon socket head bolt M6 × 20 8 Nm (80 kgf·cm)
64 Rotor housing hexagon bolt M8 × 90 26 Nm (270 kgf·cm)
67 Stator pin 45 Nm (460 kgf·cm) LOCKTITE 640
73 Ventilator top cover hexagon bolt M6 × 30 10 Nm (100 kgf·cm)
85 Oil cooler mounting hexagon nut M8 26 Nm (270 kgf·cm) Self-locking nut
87 Oil cooler mounting hexagon bolt M8 × 40 26 Nm (270 kgf·cm)
100 Flange center hexagon bolt M22 285 Nm (2,900 kgf·cm)
110 Input side labyrinth ring hexagon bolt M8 × 30 30 Nm (310 kgf·cm) Precoat bolt
115 Output side labyrinth ring hexagon bolt M8 × 25 30 Nm (310 kgf·cm) Precoat bolt
Input side labyrinth ring hexagon socket head bolt
135 30 Nm (310 kgf·cm) Precoat bolt
M8 × 16
140 Pump pressure test plug M12 × 1.5 25 Nm (260 kgf·cm)
145 Check valve joint 100 Nm(1,020 kgf·cm)
196 Ventilator baffle plate M6 × 12 8 Nm (80 kgf·cm)
176 Rubber mount hexagon nut M16 × 1.5 210 Nm (2,140 kgf·cm) Self-locking nut
Air piping joint M22 × 1.5 66 Nm (670 kgf·cm)
Air piping joint M14 × 1.5 32 Nm (330 kgf·cm)

M14 × 1.5
Mount bracket mounting hexagon bolt 140 Nm (1,430 kgf·cm)
× 30
290 Temperature sensor M14 × 1.5 28 Nm (290 kgf·cm)
89 W564-0111E
Data
1.2. Special Tool
Special tool name Used in page(s) Part number

PC interface 16, 17, 25 53.8206.12
Service cable 16, 17, 25 53.8224.10
Adaptor cable 16, 17, 25 53.8255.11
Pressure gauge, 0 to 2.5 MPa (25 kgf/cm2) 27 53.4788.10
Pressure gauge, 0 to 600 kPa (6 kgf/cm2) 31, 32, 33 53.1403.10
Temperature simulator 31, 32, 33 53.8207.10
Temperature sensor adaptor cable 31, 32, 33 53.8279.10
Proportional valve current adaptor 31, 32, 33 53.8198.10
Ventilator puller 37, 38 PR91000001
Oil cooler pressure test tool 42, 44 PR90800000
Spacer ring puller 48, 50, 57, 59 PR91300000
Shaft oil seal press fit tool 95 48, 50, 57, 59 PR91100000
Shaft oil seal press fit tool 80 66, 67 PR90600000
Bearing press fit tool 53.7672.10
Press fit sleeve 53.7673.10
90 W564-0111E
Data
1.3. Specified Oil
Specified quality of oil
API service
Oil type Viscosity grade
classification
SAE 10W
Single grade SAE 20W-20 CC/SF or above

Engine oil
SAE 30
Multi grade All types CC/SF or above
Interval of periodical oil change
Use Travel distance 1)
Truck heavy use 2) Single grade 45,000 km
Truck normal use Single grade 90,000 km
Multi grade 90,000 km

Bus
Single grade 135,000 km
1) Even when the travel distance is not reached, the oil change is required in every 1,200 hours or 1 year.
2) The heavy use indicates severe uses such as described below.

- Construction vehicle, lumber carrier vehicle, heavy load tractor (6 × 4)
- Vehicles with smaller engine output compared with vehicle total weight (< 6 kW/t: Less than 6 kW per gross
weight ton)
- Frequent use on steep slope
If there are cases in which the oil degradation is accelerated by other than the above conditions, shorten the oil
change interval.
If uncertain, please contact us.
91 W564-0111E
Data
1.4. Specified Coolant, Sealer, and Lubricant
1.4.1. Coolant
Follow the instruction of the vehicle manufacturer.

When no instruction can be obtained, it shall be in
accordance with the instructions below.
Because the oil cooler of retarder is made of
aluminum, the antifreeze and anticorrosives are
restricted with ones that do not corrode the aluminum.
Water quality:
PH value 6.5 to 8.5 (20C)
Hardness 5 to 20 dH
Chloride ion 100 mg/l or less
Any suspended matters, especially ones containing
copper, must not be present.
Normally, drinking water satisfies the above

conditions.
Mixing ratio:
Water 49%
*
Antifreeze 50%
Anticorrosives 1%
*: Must be the product specified by vehicle
manufacturer.
1.4.2. Sealer and Lubricant
Because of the retarder operating temperature

reasons, only the sealer with permanent plasticity,
Hylomar, is allowed. Degrease the sealing surface,
then, according to the Hylomar instruction manual,
apply Hylomar lightly and evenly.
With all the O-rings and oil seals, use the

fluoro-rubber (NRS genuine part), and lightly apply
grease for installation. However, silicone grease must
not be used.
92 W564-0111E
Data
1.5. Retarder R120S Specification

The performance curve below indicates the GR-500N-1 class.
Final reduction ratio

Tire radius
Vehicle total mass
Propeller shaft maximum rotation speed: 4,200 rpm
Position 4
Braking torque T
Position 3
Position 2
Position 1
Propeller shaft rotation speed n
Vehicle speed v
93 W564-0111E
Data
1.6. Connection Layout
20. Control unit 37. Supply air piping

22. Ignition power supply 38. Exhaust
24. Ground 51. Air filter
27. Hand lever switch 81. Vehicle speed signal
28. Pilot lamp 290. Oil temperature sensor
29. Stop lamp relay 291. Diagnosis connector
30. Coolant temperature sensor 293. ABS signal
34. Air tank for auxiliary device (pv0.5 - 1.1 MPa) 294. Battery power supply
35. Proportional solenoid valve 295. Fuse (5 A)
94 W564-0111E
Data
1.7. Mid-Mount Retarder Disassembly Diagram
1. Retarder housing 125. Spacer ring

3. Rotor housing 126. O-ring (80 × 3)
5. Refill level check plug (M30 × 1.5) 127. Spacer ring
6. Sealing washer (30 × 36) 128. O-ring (80 × 3)
7. Retarder oil drain plug (M22 × 15) 134. Seal ring (Polypenco)
8. Sealing washer (22 × 29) 140. Plug (M12 × 1.5)
47. Hexagon socket head bolt (M6 × 20) 141. Sealing washer (12 × 15.5)
48. O-ring (82 × 4) 144. Check valve
50. Blind lid 145. Joint
62. Stator 146. Valve
63. Rotor 147. Spring
64. Hexagon bolt (M8 × 90) 195. Gasket
65. O-ring (8 × 2) 196. Hexagon socket head bolt (M6 × 12)
66. O-ring (8 × 2) 197. Washer (6.4)
67. Stator pin 198. Baffle plate
68. Washer (8.4) 199. Spacer
69. Rubber coat metal packing 201. Gasket
72. Top cover 202. Lower cover
73. Hexagon bolt (M6 × 30) 203. O-ring (270 × 2.5)
74. Washer (6.4) 204. Breather filter (30 × 4)
76. Float holder 205. Circlip (JL30 × 1.2)
77. Ventilator case
78. Float (L = 38 mm)
79. O-ring (55 × 3)
80. Oil seal (22.6 × 34 × 5.5)
84. Strainer
110. Precoat hexagon bolt (M8 × 30)
111. Labyrinth ring (input side)
112. Oil seal (95 × 115 × 10)
115. Precoat hexagon bolt (M8 × 25)
116. Labyrinth ring (output side)
117. Oil seal (95 × 115 × 10)
118. O-ring (125 × 2.5)
119. O-ring (125 × 2.5)
120. Bearing holder
121. O-ring (160 × 3)
122. Ball bearing (6017MC4S1)
123. Roller bearing (NU1017M1C3S1)
95 W564-0111E
Data
1.8. Direct Mount Retarder Disassembly Diagram
1. Retarder housing 140. Plug (M12 × 1.5)

3. Rotor housing 141. Sealing washer (12 × 15.5)
5. Refill level check plug (M30 × 1.5) 142. Roller bearing (NU1017M1C3S1)
6. Sealing washer (30 × 36) 144. Check valve
7. Retarder oil drain plug (M22 × 15) 145. Joint
8. Sealing washer (22 × 29) 146. Valve
47. Hexagon socket head bolt (M6 × 20) 147. Spring
48. O-ring (82 × 4) 195. Gasket
50. Blind lid 196. Hexagon socket head bolt (M6 × 12)
62. Stator 197. Washer (6.4)
63. Rotor 198. Baffle plate
64. Hexagon bolt (M8 × 90) 199. Spacer
65. O-ring (8 × 2) 201. Gasket
66. O-ring (8 × 2) 202. Lower cover
67. Stator pin 203. O-ring (270 × 2.5)
68. Washer (8.4) 204. Breather filter (30 × 4)
69. Rubber coat metal packing 205. Circlip (JL30 × 1.2)
72. Top cover
73. Hexagon bolt (M6 × 30)
74. Washer (6.4)
76. Float holder
77. Ventilator case
78. Float (L = 38 mm)
79. O-ring (55 × 3)
80. Oil seal (22.6 × 34 × 5.5)
84. Strainer
107. Centering cover (input side)
115. Precoat hexagon bolt
116. Labyrinth ring (output side)
118. O-ring (125 × 2.5)
134. Seal ring (Polypenco)
135. Precoat hexagon socket head bolt (M8 × 16)
136. Oil seal (80 × 110 × 10)
137. Oil seal (95 × 115 × 10)
138. O-ring (160 × 3)
97 W564-0111E
Data
96 W564-0111E
Data
98 W564-0111E
Data
1.9. Electrical Wiring Diagram
1.9.1. Control Unit: Digiprop Type
Hand lever switch position 1 Constant speed hill descend

Hand lever switch position 2 Braking force step 1 (weak)
Hand lever switch position 3 Braking force step 2
Hand lever switch position 4 Braking force step 3
Connector X1
Hand lever switch position 5 Braking force step 4 (strong)
Power supply
Ignition power supply
Diagnosis connector
Hand lever switch "+"

Ground
Power supply
HS1 (option) Battery or ignition power
Digiprop type control unit
LS1 (option) supply

HS2 (option)
Proportional solenoid valve "+"

Connector X2
Proportional solenoid valve "-"
Coolant temperature sensor "+"

Coolant temperature sensor "-"
Oil temperature sensor "+"
Oil temperature sensor "-"
ABS signal
DIU1 (option)
Connector X3
DIU2 (option)
Brake pedal position 1 (option) Braking force step 1
Pilot lamp
(Ignition power supply)
INA-U (option)
DID4 (option)
Stop lamp relay (BLR)
INA_I (option)
99 W564-0111E
Data
1.9.2. Control Unit: VERA Type
Ignition power supply
Ground
Hand lever switch

Diagnosis line
Stop lamp relay
ABS signal
Pilot lamp
Proportional solenoid valve
Coolant temperature sensor
Oil temperature sensor
100 W564-0111E
Data
1.10. Abnormality Code Table
1.10.1. Control Unit: Digiprop Type
Condition
Code Contents Severity Note
State Time
1 Stop lamp relay grounded ON 1s Minor
2 LS1 is shorted to battery. ON 400 ms Minor
3 HS1 is grounded. ON 1s Minor
4 HS2 is grounded. ON 1s Minor
5 Low voltage of ignition power supply < 17.5 V 60 s Major
6 Overvoltage of ignition power supply > 32.5 V 10 s Major
7 Switching valve is grounded. ON 1s Major
Coolant temperature sensor open circuit or battery Major/ Simultaneous
8 R > 2 K 1s
short circuit Minor failure of coolant
Major/ temperature
9 Coolant temperature sensor is grounded. R < 600  1s
sensor and oil
Minor
Oil temperature sensor open circuit or battery Major/ temperature
11 R > 2 K 1s sensor is major.
short circuit Minor
Occurrence of
Major/ single failure is
12 Oil temperature sensor is grounded. R < 600  1s
Minor
minor.
13 Switch status unknown with hand lever switch 1s Major
14 Battery short circuit of hand lever switch Position 0 10 s Major
15 Hand lever switch is grounded. 1s Major
16 Vehicle speed signal open circuit 2s Major
17 Switching valve open circuit or grounded OFF 1s Major R133-2 only
Vehicle speed signal battery short circuit or
18 2s Major
unknown signal
19 ABS signal grounded 60 s Major
Power supply >
21 ABS signal level unknown 1s Major
20.4 V
22 Control unit malfunction by ABS current 1s Major
23 Proportional valve malfunction No.1* Position 0 1s Major
> Position
24 Proportional valve malfunction No.2* 1s Major
0
Proportional valve malfunction No.3 (control unit > Position
25 60 s Major
malfunction) 0
Proportional valve malfunction No.5 (control unit
27 Position 0 2s Major
malfunction)
28 Battery power supply low voltage < 17.5 V 60 s Major
29 Control unit internal failure - Watchdog SIBA 180 ms Major
31 Coding abnormality 100 ms Major
32 Pilot lamp open circuit or grounded ** OFF 3s Major
33 Battery short circuit of pilot lamp ** ON 3s Major
Control unit internal failure - ROM 123 s Major
35
- EEPROM 500 ms Major
36 2/2 way valve malfunction Minor R133-2 only
37 Brake pedal signal unknown 100 ms/1 s Minor
* Proportional valve malfunction No.1: - Battery short circuit of proportional valve
- Control unit malfunction
Malfunction No.2: - Short circuit of solenoid or cable
- Open circuit of solenoid or cable
- Grounding of proportional valve wire
** Pilot lamp malfunction: Displaying of flashing code is possible after the malfunction is canceled.
101 W564-0111E
Data
1.10.2. Control Unit: VERA Type
s: Evaluated as major. Braking torque is not present.

m: Evaluated as minor. Braking torque is present.
Error Evalu-
code
Contents Recognition time/Condition
ation
Control unit internal failure - Parameter Immediately after current application
Control unit internal failure - EEPROM Immediately after current application
Control unit internal failure - ROM Approximately 10 seconds after current application
Control unit internal failure - Safety concept 60 msec.

Proportional solenoid valve trouble, open circuit or 1 sec./ECU internal PWM signal/Status signal/AD signal value
grounding abnormality
Proportional solenoid valve trouble, short to battery abnormality
Proportional solenoid valve trouble, ECU internal failure abnormality
Ignition power supply low voltage 60 sec./17.5 V limit, 0.5 V hysteresis
Ignition power supply overvoltage 10 sec./33 V limit, 0.5 V hysteresis
Hand lever switch status unknown 2 sec./Signal pattern/Connection order abnormality
Hand lever switch grounding 1 sec./Terminal voltage ≤ 0.3 x ECU internal power supply voltage
Hand lever switch shorted to battery 10 sec./Terminal voltage ≤ 0.7 x ECU internal power supply voltage
Simultaneous failure of coolant temperature sensor
and oil temperature sensor Abnormality of both temperature sensors
Coolant temperature sensor, open circuit or short to battery 1 sec./Sensor resistance > 1,540 
Coolant temperature sensor grounding 1 sec./Sensor resistance < 760 
Oil temperature sensor, open circuit or short to battery 1 sec./Sensor resistance > 2,000 
Oil temperature sensor grounding 1 sec./Sensor resistance < 760 
vehicle speed signal open circuit 2 sec./Without pulse/2.5 V < Terminal voltage ≤ 4.8 V
Pilot lamp, open circuit or grounding 1 sec./Without output + Voltage V ≤ ECU internal voltage x 0.3
Pilot lamp shorted to battery 3 sec./With output + Voltage V ≥ ECU internal voltage x 0.7
ABS signal grounding 60 sec./Voltage V < Ignition power supply x 0.3

5sec./Ignition power supply x 0.3 < Voltage V < Ignition power
ABS signal level unknown supply x 0.7
Control unit trouble by ABS signal ECU internal signal value abnormality
Stop lamp relay grounding 1 sec./With output + Voltage V ≥ ECU internal voltage x 0.3
1
m : Coolant temperature sensor error = Braking torque 50%
m2: Oil temperature sensor error = Without braking torque reduction
102 W564-0111E
Overview of Retarder (Conventional Control Method)
Overview of Retarder temperature is controlled (overheat protection).

(Conventional Control Method) This control is referred to as the down regulation.
1. Overview of Conventional Control For example, in case of the down regulation set
temperature T1 = 96C (TR-250M-5), when the
Method Retarder
retarder outlet coolant temperature becomes to
1.1. Function 96C or higher, the braking force is gradually and
linearly reduced according to the temperature. In
The retarder is mounted in between the the hand lever switch highest position (position 5),
transmission and front axle. It is a hydrodynamic the braking force becomes zero when the
brake that hydrokinetically generates the braking temperature becomes higher with an amount of
force and applies brake to the propeller shaft. 10C than T1, in other words, when the
When the hand lever switch (5 steps) is operated, temperature becomes at 106C.
the input signal corresponding to the switch As described above, the retarder braking force
position is sent to the retarder control unit, and the during the down regulation (retarder operation
control unit supplies the control current to the indication lamp is flashing) is lowered to a point at
solenoid control valve (proportional control valve). which a balance is achieved between the thermal
The solenoid control valve supplies the energy generated by braking force and the
adjustment air pressure P corresponding to the thermal energy dissipated by vehicle cooling
control current to the oil sump of retarder main system, and then the retarder braking force
body. becomes stable.
The adjustment air pressure P supplied to the oil Also, the retarder is not operated when the
sump feeds the amount of oil (engine oil) accelerator pedal is depressed, or when the
corresponding to the pressure and operating vehicle speed V is smaller than 1 km/h even if the
status (propeller shaft speed) to the working accelerator pedal is released.
chamber that is formed by the rotor and stator.
The rotor is joined with the propeller shaft, and the
stator is fixed to the retarder housing. By the
rotation of rotor, the velocity is given to the oil
inside the working chamber, and the oil is pushed
to the static stator side.
The oil flow is decelerated inside the stator,
consuming the kinetic energy and, at the same
time, decelerating the rotor, consequently braking
the propeller shaft.
On the other hand, the braking energy of retarder
is converted to heat. In order to dissipate the heat,
a part of the working chamber oil is put in
circulation to the oil cooler integrated in the
retarder main body by the rotor pump action.
The heat from the oil is transferred to the coolant
by the oil cooler, and then the heat is dissipated
into the atmosphere from the vehicle radiator.
To the return side coolant path from the retarder,
the temperature sensor is mounted. The sensor
detects the coolant temperature and sends
signals to the control unit, and the coolant
103 W564-0111E
1.2. Case with TR-250M-6
23. Retarder system * Because main SW is removed, input signal is not present.
Lower
Upper input status input status Upper serial Lower output status
signal
Retarder hand lever switch input Retarder hand lever switch output
output
status
V=b
section
Combination of other than above Previous status retained
V=a
section

Previous status retained
1 indicates the
V = Vehicle 1 is 24 V. level "H." 1 is the relay contact ON.
0 indicates the
speed 0 is 0 V. level "L." 0 is the relay contact OFF.
Remarks
Vehicle speed V (km/h)
OFF in case of abnormality

and position 0
Flashing signal when the temperature sensor is abnormal
Set value = 0
Retarder brake capacity select switch is abnormal.
Water thermo. sending unit is abnormal.
Illumination: Retarder under operation

Flashing: During down regulation, or oil
temperature sensor failure
Output is performed for 0.3 seconds and once in 3 minutes,

and retarder is operated in position 1 for a forced lubrication.
The retarder controller and multiplex data ROM have been
revised. The operation indication lamp does not light.
104 W564-0111E 104

1.3. Case with TR-350M-3
23. Retarder system * Because main SW is removed, input signal is not present.
Lower
Upper input status input status Upper serial Lower output status
signal
Retarder hand lever switch input Retarder hand lever switch output
output
status
V=b
section

V=a
section

Previous status retained
1 indicates the
V = Vehicle 1 is 24 V. level "H." 1 is the relay contact ON.
0 indicates the
speed 0 is 0 V. level "L." 0 is the relay contact OFF.
Remarks
Vehicle speed V (km/h)
OFF in case of abnormality

and position 0
Flashing signal when the temperature sensor is abnormal
Set value = 0
Retarder brake capacity select switch is abnormal.
Water thermo. sending unit is abnormal.
Illumination: Retarder under operation

Flashing: During down regulation, or oil
temperature sensor failure
Output is performed for 0.3 seconds and once in 3 minutes,

and retarder is operated in position 1 for a forced lubrication.
The retarder controller and multiplex data ROM have been
revised. The operation indication lamp does not light.
105 W564-0111E 105

Head Office Ko-34,Sinden-cho, Takamatsu, Japan
Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785
History of revision
1
2
3
4
5
ｃ2008
◯ TADANO LTD.
PRINTED IN JAPAN
0812 K

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Publication No.

This service manual describes the assembly and

1. Applicable Crane Model

Applicable Control method

(Difference with the retarder control method (control unit))

Please note that the contents may be changed due

2. Contents 2.2. Troubleshooting

1. Maintenance ..................................................... 21 Servicing ........................................................ 57

3. Servicing of Direct Mount Retarder Main

1.1. Serial Number

The serial number (8 digits) is stamped at the oil

When making an inquiry or ordering repair parts,

1.2 Illustration of Main Body

1.3. Illustration of Control System

20. Control unit

When the hand lever switch is set in 1st position,

When the retarder is set to OFF (position 0) or set

The adjustment air pressure of oil sump (61)

proportional solenoid valve is decreased linearly.

1.1. Mid-Mount Retarder (TR-250M-7, GR-300N-1, GR-250N-1, GR-350N-1)

Oil cooler for torque converter

Combination of other than above

Vs indicates 1 is the transistor

From air compressor Sender, thermo

Air tank 5 V for accelerator 2

Air filter Illumination: During retarder operation in position 1 to 4; At error

Coolant inlet Fuse

Coolant outlet side

1.2. Direct Mount Retarder (GR-500N-1, GR-600N-1, UK-500K-1)

Air pressure (MPa)

Oil cooler for torque

0 is the ECU output OFF (H). Main speed input (Retarder)

From air compressor Sender, thermo

Illumination: During retarder operation in position 1 to 4; At error

Coolant inlet Fuse

Coolant outlet side

Temperature sensor (retarder coolant temperature) TS6

1.3. Error Code Checking Procedure (Digiprop Type)

Calling method by plug for retarder DIAG (ISO-L line)

Flashing display of error code

Example: When with flashing code 23

Deleting method of error memory

Error code table

* Proportional solenoid valve malfunction No.2: - Short circuit of solenoid or cable

* Proportional solenoid valve malfunction No.3: - Control unit malfunction

* Proportional solenoid valve malfunction No.5: - Control unit malfunction

Braking torque Pilot lamp

Controller main body diagram

Terminal No. Terminal name

Hand lever switch input 3rd (braking force step 2)

Proportional solenoid valve input

Oil temperature sensor input

Vehicle speed signal

Harness side connector part number (AMP)

Stop lamp relay output (BLR)

2. Retarder System (Control Unit: VERA Type)

2.1. Mid-Mount Retarder (GR-250N-1, GR-350N-1)

31. Retarder function Controller

Oil cooler for torque converter

Illumination: Retarder switch position 1 to 4

Combination of other than above Fuse

Tightening torque: 150 Nm Retarder 4

From air compressor Sender, thermo